Rico EV-200LX User manual

EV -200LX Solid -State Control Systems
with On-Board Diagnostics
RICO Electric Vehicle Systems
RICO MANUFACTURING PART NUMBER
11980197
See section F Vehicle Controller for operation and troubleshooting information for
this controller

EV200LX SUPPLEMENT
General:
The EV100LX instructions and operating information is applicable to the EV200LX. The only
difference in the two control types is that the EV200 has a high current rating than the EV100LX,
a larger mounting foot print and different component parts.
Standard Outline Drawing:

EV200LX SUPPLEMENT
Component Locations:
ITEM# PART NUMBER DESCRIPTION QTY/EACH
5 158C3100BYP1 BASE 1
7 918D620G1 TRANSFORMER 1
8 157C8160G13 1REC ASM 1
9 171B3939G4 3REC ASM 1
10 44A727038-G01 2REC 1
11 171B3967P1L HEAT SINK 1
12 273A2523P11 THERMAL CONDUCTIVE 1
13 116C6961P1L HEAT SINK 1
14 273A2523P12 THERMAL CONDUCTIVE 1
15 259A9208PXCR RECTIFIER 1
16 171B3940G1 SNUBBER ASM 1
17 195B4039G1 SNUBBER MOUNT 1
19 116C6975G1 SPIDER ASM 1
20 273A2523P6 THERMAL CONDUCTIVE 1
21 273A2523P9 THERMAL CONDUCTIVE 1
22 171B3912G1 TERMINAL POST 2
23 259A9053P2 CAPACITOR 2
24 259A8733P1 CAPACITOR MOUNTING BRACKET 2
26 IC3645LXCD1** EV100LX CARDBOX ASM 1
28 171B3980G1 SHUNT ASM 1

EV200LX SUPPLEMENT
ITEM# PART NUMBER DESCRIPTION QTY/EACH
30 44A717068-001 RECTIFIER 1
31 44A727009-G06 THERMISTOR ASM 1
35 195B6250P2 FLEX BUS 4
36 195B6250P11 FLEX BUS 4
37 202B1621P3 CAPACITOR STRAPS 8
38 148B5620EPP3 BUS BAR 1
39 148B5620EPP1 BUS BAR 1
40 148B5620EPP2 BUS BAR 1
41 259A3290P1 INSULATING BUSHING 4

EV200LX SUPPLEMENT
Wiring Diagram:

EV200LX SUPPLEMENT
Current Limit Adjustments:
01005020 30 4010 70 80 9060
0
150
300
450
600
750
900
1050
1200
1350
1500
Percent On Time
Motor Amperes
PeakI
M
Maximum
PeakI
M
Minimum
AverageI
M
Maximum
AverageI
M
Minimum
Peak Motor C/L
@ Typical Motor Inductance
Min-Max @30% ONTIME 735/1170 Amps
Min-Max @50% ONTIME 560/990 Amps
Min-Max @70% ONTIME 390/810 Amps
Average Motor C/L
@ Typical Motor Inductance
Min-Max @30% ONTIME 615/960 Amps
Min-Max @50% ONTIME 480/870 Amps
Min-Max @70% ONTIME 347/750 Amps

1
INSTRUCTIONS
EV100 LX/LXT SCR
CONTROLS
GEH-5714
The information contained herein is intended to assist truck users and dealers in the servicing of SCR controls furnished
by the General Electric Company. It does not purport to cover all variations in equipment nor to provide for every possible
contingency to be met ith installation, operation or maintenance.
Should further information be desired or should particular problems arise hich are not covered sufficiently for the
purchaser's purpose, the matter should be referred to the truck manufacturer through his normal service channels, not directly
to the General Electric Company.
September 1993

2
EV100LX SCR CONTROL ORDERING INFORMATION
EXAMPLE-------------------------- IC3645EV 100 T1 TT 1
ARGUMENT NO. 01 02 03 04 05
ARGUMENT NO. 01 - BASIC CATALOG NUMBER
ARGUMENT NO. 02 - POWER BASE RATING
100 - EV100 POWER BASE ( APPLICATIONS LESS THAN 150 FLLR
200 - EV200 POWER BASE ( APPLICATIONS LESS THAN 200 FLLR
ARGUMENT NO. 03 - APPLICATION AND 1 REC OPTIONS
T1 - STANDARD CURRENT LIMIT TRACTION
T2 - HIGH PERFORMANCE CURRENT LIMIT TRACTION
P1 - STANDARD CURRENT LIMIT PUMP
P2 - HIGH PERFORMANCE CURRENT LIMIT PUMP
ARGUMENT NO. 04 - LOGIC CARD OPTIONS
MX - TRACTION DUAL MOTOR WITHOUT BDI
MT - TRACTION DUAL MOTOR WITH BDI
PX - PUMP CONTROL WITH TMM
TX - TRACTION WITHOUT BDI
TT - TRACTION WITH BDI
ARGUMENT NO. 0 - REVISION CODE
1 - ACTIVE

3
EV100LX COMPONENT LOCATIONS

4
EV100LX OUTLINE DRAWING

5
EV100LX WITH SPEED LIMIT AND FW

6
EV100LX WITH REGEN AND FW

7
EV100LX DUAL MOTOR CONTROL

8
EV100LX PUMP CONTROL

9
NO. PART-NUMBER DESCRIPTION QUANTITY
4 158C3100EEP1 BASE DETAIL ...........................................................01
11 171B3939G1 1REC ASSEMBLY LOW POWER ...........................01
11 171B3939G2 1REC ASSEMBLY HIGH POWER ..........................01
12 273A2523P9 THRM COND INSULATION ...................................01
14 171B3949G1 3 AND 4 REC. ASM. .................................................01
15 259A3290P1 INSULATING BUSHING ..........................................03
16 273A2523P8 THRM COND INSULATION ...................................01
18 44A717068-001 SCR, 2REC .................................................................01
19 44A717067-001 SCR, 5REC .................................................................01
20 44A723544-001 CAP. WARNING LABEL ......................................01
21 44A723543-001 EV-100 LOGO LABEL ..............................................01
22 158C3234G1 REACTOR ASSEMBLY ............................................01
24 259A9053P2 CAP MT FILM 150MF 25 .........................................01
26 IC3645LXCD1TX TRACTION WITHOUT BDI .....................................01
26 IC3645LXCD1TT TRACTION WITH BDI .............................................01
26 IC3645LXCD1MX DUAL MTR TRACTION WITHOUT BDI ...............01
26 IC3645LXCD1MT DUAL MTR TRACTION WITH BDI .......................01
26 IC3645LXCD1PX PUMP CONTROL......................................................01
28 171B3933G1 SPIDER AND WIRE ASM. .......................................01
29 44A727009-G01 THERMISTOR ASM .................................................01
30 171B3940G1 SNUBBER ASM.........................................................04
34 44A718897-001 CAPACITOR MTG. STRAP .....................................02
37 148B5620DPP1 BUS BAR ....................................................................01
38 148B5620DPP2 BUS BAR ....................................................................01
39 148B5620DPP4 BUS BAR ....................................................................01
40 148B5620DPP3 BUS BAR ....................................................................01
43 WH7138R36G1 WIRE HARNESS .......................................................01
48 L201P17B33 NUT, M8X1.25MM ....................................................02
49 L400P10B33 M8 FLAT WASHER ..................................................05
50 L401P27B33 M8 LOCK WASHER .................................................05
52 44A723274-001 M5X50MM T/R SCREW ...........................................04
53 44A723274-002 M5X26MM T/R SCREW ...........................................07
54 L14P17020B33 M8X1.25X20MM SCREW ........................................03
55 L10P14010B33 M5X0.8X10MM SCREW ..........................................05
56 L400P7B33 M5 NAR. FLAT WASHER ........................................05
57 L401P25B33 M5 SPRING LOCKWASHER ...................................05
58 44A723274-401 M3.5X12MM T/R SCREW........................................04
59 L10P11044B33 M3.5X0.6X44MM SCREW .......................................01
60 44A723274-204 M3.5X23MM T/R SCREW........................................08
61 L400P5B33 M3.5 NAR FLAT WASHER ......................................06
62 L401P23B33 M3.5 LOCK WASHER ..............................................06
63 L10P11008B33 M3.5X0.6X8MM SCREW .........................................06
64 L10P11016B33 METRIC PAN HD SCREW .......................................02
67 L14P15016B33 M6X1.0X16MM SCREW ..........................................01
69 L400P8B33 M6 FLAT WASHER ..................................................01
70 171B3954G1 SHUNT-WIRE ASM ..................................................01
73 N402P39B6 WASHER FLAT ST ...................................................03
EV100LX PART NUMBER IDENTIFICATION

10
EV100LX PART NUMBER IDENTIFICATION

11
TERMINAL CONNECTIONS FOR LX/LXT
LOGIC CARDS
TRACTION TRACTION TRACTION TRACTION
INPUT STANDARD SL/FW REGEN/FW DUAL MTR PUMP TB1 Accel Pot Input Accel Pot Input Accel Pot Input Accel Pot Input Accel Pot Input TB2 Start Switch Input Start Switch Input Start Switch Input Start Switch Input SL1 TB3 Seat Switch Input Seat Switch Input Seat Switch Input Seat Switch Input SL2 TB4 Key Switch Input Key Switch Input Key Switch Input Key Switch Input Key Switch Input TB5 Forward Switch Input Forward Switch Input Forward Switch Input Forward Switch Input SL3 TB6 Reverse Switch Input Reverse Switch Input Reverse Switch Input Reverse Switch Input SL4 PA1 Plug Signal Plug Signal Plug Signal PS Coil Driver Status Code 93 Input PA2 BDI Interrupt BDI Interrupt BDI Interrupt BDI Interrupt Status Code 93 Input PA3 Aux Hourmeter Input Aux Hourmeter Input Aux Hourmeter Input Aux Hourmeter Input Status Code 90 Input PA4 Not Used SL2 Sensor 2 Yellow Wire In-Board Mtr Rev Sw Status Code 94 Input PA5 Not Used SL3 Sensor 2 Green wire Right Mtr Dropout Sw Status Code 94 Input PA6 Not Used SL1 Mtr A2 Input Left Mtr Dropout Sw Status Code 91 Input PB1 FW Coil Driver FW Coil Driver FW Coil Driver F Rht Mtr Coil Driver Status Code 95 Input PB2 Not Used Not Used Regen Coil Driver F Lft Mtr Coil Driver Status Code 95 Input PB3 SP Coil Driver SP Coil Driver SP Coil Driver R Rht Mtr Coil Driver BDI Enable Signal Input PB4 F Coil Driver F Coil Driver F Coil Driver R Lft Mtr Coil Driver Pump (PMT Coil Driver PB5 R Coil Driver R Coil Driver R Coil Driver 1A coil Driver 1A Coil Driver PB6 1A Coil Driver 1A Coil Driver 1A Coil Driver D Coil Driver Status Code 92 Input PY1 Dash Display 4 Input Dash Display 4 Input Dash Display 4 Input Dash Display 4 Input Dash Display 4 Input PY2 Dash Display 3 Input Dash Display 3 Input Dash Display 3 Input Dash Display 3 Input Dash Display 3 Input PY3 Dash Display 1 Input Dash Display 1 Input Dash Display 1 Input Dash Display 1 Input Dash Display 1 Input PY4 Dash Display 2 Input Dash Display 2 Input Dash Display 2 Input Dash Display 2 Input Dash Display 2 Input PY5 Dash Display 5 Input Dash Display 5 Input Dash Display 5 Input Dash Display 5 Input Not Used PY6 Not Used Not Used Not Used Not Used Not Used PY7 Im Im Im Not Used Not Used PY8 TMMA-9 / Pump-PY12 TMMA-9 / Pump-PY12 TMMA-9 / Pump-PY12 TMMA-9 / Pump-PY12 Not Used PY9 TMMA-7 / Pump-PY11 TMMA-7 / Pump-PY11 TMMA-7 / Pump-PY11 TMMA-7 / Pump-PY11 Not Used PY10 TMMA-2 / Pump-PY10 TMMA-2 / Pump-PY10 TMMA-2 / Pump-PY10 TMMA-2 / Pump-PY10 Traction PY10 PY11 Not Used Not Used Not Used Not Used Traction PY9 PY12 Not Used Not Used Not Used Not Used Traction PY8 PY13 Not Used Not Used Not Used Not Used Not Used PY14 Not Used Not Used Not Used Not Used Not Used

12
Control Features
On-Board Diagnostics
Hourmeter
Stored Status Codes
Card Type Selection
Creep Speed
Current Limit
Plugging
Pedal Position Plug
Ramp Start
Full Power Transition
Controlled Acceleration
1A Timed Pick-Up
1A Thermal Hold-Off
1A Plugging Hold-Off
Delay to First Pulse
PMT (Fault Shut Down
Thermal Protection
Static Return to Off
IC364 LXCD1T
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Standard
Standard Enable/Disable
Features
Adjustable
2% to 15% On Time
Adjustable
See C/L Curves
Standard/High
Performance
Adjustable
200 to 930 Amps
Adjustable
100 to 930 amps
Can be Disabled
Standard
Standard with 1A Ctr
Adjustable
.1 to 22 seconds
Follows CA by .2 seconds
with Accel Volts is < .5V
or Accel Ohms is < 200
Standard at 90oC
cutback at 20% TON
Standard
Standard
Standard
Look Ahead and Reset two
count
Standard
90oC Cutback
Standard
2 Second Delay
IC364 LXCD1M
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Standard
Standard Enable/Disable
Features
Adjustable
2% to 15% On Time
Adjustable
See C/L Curves
Standard/High
Performance
Adjustable
200 to 930 Amps
Adjustable
100 to 930 amps
Can be Disabled
Standard
Standard with 1A Ctr
Adjustable
.1 to 22 seconds
Follows CA by .2 seconds
with Accel Volts is < .5V
or Accel Ohms is < 200
Standard at 90oC
cutback at 20% TON
Standard
Standard
Standard
Look Ahead and Reset two
count
Standard
90oC Cutback
Standard
2 Second Delay
IC364 LXCD1P
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Standard
Standard Enable/Disable
Features
Not Applicable
Adjustable
See C/L Curves
Standard/High
Performance
Not Applicable
Not Applicable
Not Applicable
Standard with 1A Ctr
Adjustable
.1 to 5.5 seconds
Follows CA by .2 seconds
with Accel Volts is < .5V
or Accel Ohms is < 200
Standard at 90oC
cutback at 20% TON
Not Applicable
Standard
Standard
Look Ahead and Reset two
count
Standard
90oC Cutback
Not Applicable
EV100LX Logic Card Specifications

13
Control Features
Voltage Range
Accelerator Input
Low Battery Operation
Reverse Battery Protection
Ambient Temperature
Approximate Weight
Coil Drivers
F/R or Line
1A
FW
Regen
D
PS
Shorted Driver Protection
Shorted 3 REC Protection
F/R and Speed Input
Switch Loading
1A switch
1A Current dropout
Dual Mtr Steering Logic
Dual Mtr Inside Wheel
Reversal
Regenerative Braking
Field Weakening
Speed Limit
Three Ranges
Creep to Full Speed
Steer pump Time Delay
IC364 LXCD1T IC364 LXCD1M IC364 LXCD1P
24-80 VDC
5000-0 Ohms
3.5-0 VDC
Standard
50% at 36-80 VDC
75% at 24 VDC
Standard
-30 to +50oC
5.5 Kg
On-Board
On-Board
On-Board
On-Board
Not Applicable
On-Board
Standard
Standard
Logic Current
Not Required
Adjustable
450 to 1260 Amps
Not Available
Not Available
Adjustable
Regen C/L - 75A to 630A
Regen Start - 15% to 96%
Adjustable
Pick-up - 52A - 466A
Drop-out - 65A to 895A
Standard
Adjustable
Input by Limit Switch
Seat - .5 to 63 sec
Neutral - .5 to 63 sec
24-80 VDC
5000-0 Ohms
3.5-0 VDC
Standard
50% at 36-80 VDC
75% at 24 VDC
Standard
-30 to +50oC
5.5 Kg
On-Board
On-Board
Not Applicable
Not Applicable
On-Board
On-Board
Standard
Standard
Logic Current
Not Required
Adjustable
450 to 1260 Amps
Standard
Standard
Not Applicable
Not Applicable
Standard
Adjustable
Two Speed Limits
Seat - .5 to 63 sec
Neutral - .5 to 63 sec
24-80 VDC
5000-0 Ohms
3.5-0 VDC
Standard
50% at 36-80 VDC
75% at 24 VDC
Standard
-30 to +50oC
5.5 Kg
On-Board
On-Board
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Standard
Standard
Logic Current
Not Required
Not Applicable
Not Available
Not Available
Not Applicable
Not Applicable
Standard
Adjustable
Input by Limit Switch
Not Applicable

14
Control Features
Accelerator Volts Lockout
Accel volts > 2.5V
Battery Volts Check
Battery Discharge Indica-
tion
Full Load Level Running
Mtr Current at 50% 1A
duty
Continuous Duty Mtr
Current with 0.3oC/Watt
Heatsink at 40oC Ambient
Plug Current Limit
Min-Max @ 1 Sec
Min-Max @ 3 Sec
Average Motor C/L with
Typical Mtr Inductance
Min-Max @ 30% TON
Min-Max @ 50% TON
Min-Max @ 70% TON
Min-Max @ 30% TON
Min-Max @ 50% TON
Min-Max @ 70% TON
IC364 LXCD1T
Standard
Standard
Optional
150 Amps Plus
103 Amps Plus
330/950 Amps
330/650 Amps
405/640 Amps (STD
320/565 Amps (STD
230/495 Amps (STD
475/690 Amps (H/P
455/685 Amps (H/P
435/680 Amps (H/P
IC364 LXCD1M
Standard
Standard
Optional
150 Amps Plus
103 Amps Plus
330/950 Amps
330/650 Amps
405/640 Amps (STD
320/565 Amps (STD
230/495 Amps (STD
475/690 Amps (H/P
455/685 Amps (H/P
435/680 Amps (H/P
IC364 LXCD1P
Standard
Standard
Optional
150 Amps Plus
103 Amps Plus
Not Applicable
405/640 Amps (STD
320/565 Amps (STD
230/495 Amps (STD
475/690 Amps (H/P
455/685 Amps (H/P
435/680 Amps (H/P
EV100LX Traction and Pump H/P Curve EV100LX Traction and Pump STD Curve