GEH-6334 GE Motors & Industrial Systems Instructions Unit Controller 2000 (UC2000) Operation and MaintenanceUnit Controller 2000 (UC2000) Operation and Maintenance GEH-6334 Issue Date: December 1995 ‘These instructions do not purport to cover all details or variations in equipment, not to provide for every possible contingency to be met during installation, operation, and maintenance. Should further information be desired or should ‘particular problems arise that are not covered sufficiently for the purchaser's purpose, the matter should be referred to GE Drive Systems & Turbine Controls. This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that customer in the installation, testing, and/or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written ‘approval of GE Drive Systems & Turbine Controls.©1995 by General Electric Company, USA. All rights reserved. Printed in the United States of America. ARCNET is a registered trademark of Datapoint Corporation. Ethemet is a trademark of Xerox Corporation. Genius is a trademark of GE Fanuc Automation North America, USA. IBM is a registered trademark of International Business Machines Corporation. PC and PC AT are registered trademarks of International Business Machines Corporation, PC/104 is a trademark of the PC/104 Consortium, ‘ThinWire is a trademark of Xerox Corporation. Windows is a trademark of the Microsoft Corporation. ‘Windows NT isa trademark of the Microsoft Corporation.init Controller 2000 (GEH-6334 SAFETY SYMBOL LEGEND ‘Commands attention to an operating procedure, practice, condition, or statement which, if not strictly observed, ‘could result in personal injury or death. CAUTION ‘Commands attention to an operating procedure, practice, condition, or statement which, if not strictly observed, could result in damage to or destruction of equipment. NOTE ‘Commands attention to an essential operating or maintenance procedure, condition, or statement that must be highlighted.GEH-6334 Unit Controller 2000, ‘This equipment contains a potential hazard of electric shock or burn. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate, or maintain this equipment. Isolation of test equipment from the equipment under test presents potential electrical hazards. Ifthe test equipment cannot be grounded to the equipment under test, the test equipment’s case must be shielded to prevent contact by personnel. ‘To minimize hazard of electrical shock or burn, approved grounding practices and procedures must be strictly followed. ‘To prevent personal injury or equipment damage caused by equipment malfunction, only adequately trained personnel should modify any programmable machine.Unit Controller 2000, GEH-6334 TABLE OF CONTENTS ‘Section/Subject Page Section/Subject Page CHAPTER 1. OVERVIEW CHAPTER 4. CONFIGURATION LL, Introduction ....s.0- 5 4-1, Introduction... secseesseeesee el 1-2. Hardware Summary - 4-1-1, Configurator Functions ....sccsssseeeseeeee 41 1 1H 1-3. Software Summary sessed 1-4. Communication Interfaces. veel 1-5. Scope of Manual 13 1-6. Related Documents 13 CHAPTER 2. RECEIVING, HANDLING, AND STORAGE 2-1. Introduction .. 22. Receiving and Hiding. 2:3, Storage... 2-4. Unpacking... 2-5, Time Limitations CHAPTER 3. INSTALLATION AND INITIAL ‘STARTUP 341, Introduction 3-2, Operating Environment .. 3-3. Mounting ....... 3-4. Cabling and Wiring... 3-4.1, Ac Power Requirements 3-4.2. Connections 3-4.3. Wiring Level Separations 3-4.4, Spacing. 3-4.5. Grounding 3-5. LAN Configurations. 3.5.1. DLAN+ Specifications 35.1.1. Hub Configuration 3.5.1.2. Hubless Configuration... 3.5.1.3. DLAN+ Cable and Connectors 3-5.2. Genius LAN... 3.5.2.1. Specifications 3-5.2.2. Controller Register Setings 35.2.3. Genius Cable and Connectors 3.5.3. Ethernet Specifications ... 3-6. Serial Interface Connections .. 3-7. Power-Off Check .... 3-7.1. Preliminary Checks 3-8, Startup .. 4-1.2. Configurator Requirements . CHAPTER 5. PRINTED WIRING BOARD AND 1/0 DESCRIPTIONS S-1, Introduction... 5 5-2. Board Identification .. Sel 53. Adjustable Hardware. see 5.3.1. Initial Hardware Settings. 252 53.1.1. Switches.. 52 53.1.2. Jumpers peso 52 5.3.2. Adjusting Replacement Boards sa 5-4. ‘Types of Connectors 52 5-4.1, Plug-in Connectors. 152 5-4.2. Terminal Board Connectors 52 5-4.3. Stab Connections (Stabs). 152 5-5. LEDs 52 5-6. Fuses... 54 5.7. Printed Wiring Boards Sd 57.1. Power Supply Board (UPSA) «....-scsse 54 5-711. Configurable Hardware... 54 5-7.1.2. LED. cevesneennenneee 54 5-713. Specifications... ceensee 254 5.7.2. Motherboard (UCIA)...... pesos oT 5-7.2.1. Hardware . ST 5-1.2.2. VO Connections... 57 5-7.3. CPU Board (UCPB) 5-10 5-1.3.1. Specifications... 5-10 5.7.3.2. Hardware Adjustments. 5-10 5-7.3.3. Connections 5-10 5-74. DLAN+/Ethernet 1/0 Board (AHAA) 5-75. Genius LAN Board twcenn. S-75.1. LEDs CHAPTER 6. FAULTS AND TROUBLESHOOTING 6-1, Introduction. 6-2. Bios and Runtime Faults. 62.1. Fault Indication.. 62.1.1. Controller Display... 62.1.2. LED DisplayGEH.6334 Unlt Controller 2000 TABLE OF CONTENTS — Continued Section/Subject Page Section/Subject CHAPTER 7. PARTS REPLACEMENT APPENDIX A. GLOSSARY OF TERMS. 7-1. Introduction sul 7.2. Replacing Boards om APPENDIX B. HARDWARE DRAWINGS 12.1. UPSA Board Replacement... 1 BL, IMMOGUCHON ..scesssseseesesseesee Ba - HGENI and UCPB Daughterboard Replacement... eeveeenses TD APPENDIX C. WARRANTY PARTS AND 7-23, UCIA/UCPB Board Replacement 12 SERVICE. 2.4. AAHA Board Replacement C1. Warranty Terms seeassane Cel 73. Replacing Fan C-2. Obtaining Parts and Service ‘Under Warranty... CHAPTER 8. SPARE AND RENEWAL PARTS |. Introduction. $2, Custom Renewal Parts Listing. 8-3. Ordering Renewal Parts. 8-4, Part Number Structure, 8-4.1, Component Part Numbers . 8-4.2, Board Part Numbers. LIST OF FIGURES Figure Page ‘Section/Subject Page 1-1, UC2000 Configuration Example ...-sccnee12 5.6. AAHA Board Layout. Sd 3-1. UC2000 Unit (Front and Right Side View)....3-2 5-7. GENI Board Layout. 5.16 3.2. Hub Configuration - DLAN+ 36 6-1. Binary Coded Hexadecimal LED Display... 6-2 3.3. Hubless Configuration - DLAN+. 37 B-l, UC2000 Elementary 3-4. Ethernet Configuration. 3.9 Drawing 336A3573 (Sheet 1 of 2) ....+.000-+.B-2 5-1. Sample Board Part Number, DS Series. . SL B-2, UC2000 Elementary 5-2, UC2000 Interconnections 253 Drawing 336A3573 (Sheet 2 of 2) ...-euo-0.B3 5-3. UPSA Board Layout ...... B.3. UC2000 Hardware 5-4. UCIA Board Layout. Drawing 336A3571 (Sheet 1 of 2) Ba 5-5. UCPB Board Layout B44. UC2000 Hardware Drawing 336A39/1 (Sheet 2 of 2) .Unit Controtier 2000 GEH-6334 LIST OF TABLES Table Page 3-1. Genius Controller Software Register Settings... eA 5. UPSA Ouput Power ... 55 . Connector 2PLA, 2PLB, and 2PLC, Power Supply From UPSA Boar o UCIA Board (QPL md 27LX) mt AAHA Board (QPL). : 5.6 5.3. FAPL Fan Connections 56 Sd. Connectors ACI, AC2, CCOM and CHAS! to UPSA Board... eerseeneeenes 56; 55, TICIA Rosrd Connections 58 5-6. ITB Connections to UCIA Board Connector Pt SR 5-7. 2B Connections to UCIA Board Connectors P3 and P4.. 59 5-8. 3TB Connections to UPSA Board - 59 5-9. UCPB Board Group Specifications.........+. 5-1 5-10, UCPB Reset Connection .-.-sesevieoreenees 512 S11, Battery Connector to UCPB Board 5.12 5-12. COMI and COM2 Serial Interface Connector seve SID Table 5-13, UCPB ARCNET Connection to "AHA Board Connector APL... 5-14. UCPB Ethernet Connections to AHAA Board Connector EPL.. 5-15. DLAN+ and Ethernet Connections t0 ‘AHA Board 5-16. Connector 2PL, Power Supply to ‘AHA Board from UPSA Roard 5-17, Connector APL, ARCNET 1/0 Between AAHIA Roard and UCPR Roard 5-18, Connector EPL, Ethernet I/O Between ‘AAHA Board and UCPB Board 5-19, wGENI Connector PL2. . 5.20. 5 V Signals on uGENI Connector PL1 5-21, 10 V Signals on uGENI Connector PL to Genius Bus... eee 6-1. UC2000 Startup Faults... 62. BIOS (hardware), Annunciated Fatal Faults 6-3. Runtime, Annunciated Non-fatal Faults 6-4, Runtime, Anmunciated Fatal Faults... 8-1, UC2000 Parts List sss. 68Unit Controller 2000 GEH-6334 CHAPTER 1 OVERVIEW 41-1, INTRODUCTION ‘This manval describes the Unit Controller 2000 (UC2000). The UC2000 is a master controller used to perform multiple duties over local area networks (LAN) such as DLAN+, Ethernet™ and Genius™. Features of the UC2000 include: © Scaleable platform and configurator architecture © Imerface to DLAN+, Ethernet, and Genius 1/0 © Local 1/0 support 1-2, HARDWARE SUMMARY The UC2000 is 2 single-unit controller. It contains two ‘microprocessor based printed wiring boards, a power supply board, and optional Genius and ARCNET expansion daughterboards as follows: + Motherboard (DS200UCIA) + CPU daughterboard (DS2000UCPB) ‘Power supply board (DS200UPSA) ‘Optional Genius deughterboard(s)(IC660ELB912) ‘Optional remote network OC2000s (Operator Console 2000) can be attached to the DLAN-+ to send messages to multiple UC2000s and receive feedbacks from rultple system components. Refer to GEH-6335, Operator Console 2600, Operation and Maintenance. 1-3. SOFTWARE SUMMARY Primary features of the runtime core software include: ‘© Maintain control blockware language and library + Modify software online Force /O points and internal Booleans ‘© Diagnostics for broken run/start permissives ‘© Application level alarm messages Non-volatile flash memory ‘© C2000 Configurator interface and support through Ethernet ‘The UC2000 is programmed for an application using a Windows™-based software package called the UC2000 Configurator. This program runs on an IBM” PC? type computer. Completed application data is downloaded to the UC2000 through Ethernet ‘The Configurator can also create logical functions for drive control. These functions can be assigned to an Operator Console (C2000) interface (keys and displays). Additionally, alphanumeric messages can be displayed on the OC2000 when certain conditions occur. For more information, refer to GEH-6335, Operator Console 2000, Operation and Maintenance and to GEH- 6333, GEDS Toolbox for UC2000 Configurator. To prevent personal injury or equipment damage caused by equipment malfunction, only trained persons should modify any programmable machine. 1-4. COMMUNICATIONS INTERFACES ‘The UC2000 provides the following connections for external communications (see Figure 1-1), * DLAN+ (DLAN using ARCNET) connection for interface to system components and remote operator panels ‘© Ethernet connection for configuration download ‘© RS-232C serial interface connection 1GEH-6334 Unit Controller 2000 Tener e013 szo00 wm Pe oun ] vezon vee OPERATOR INTERFACE PID CONTROLLER ocane0 ‘82000 T Teams TTeawe oct cio ewore oreRaTOR nenohe eeaaron Cone Tene Figure 1-1. UC2000 Configuration Example 12Unit Controller 2000 1-8. SCOPE OF MANUAL ‘This manual is intended to assist applications and ‘maintenance petsonnel in understanding the equipment hardware and software. The manual is organized as follows: Chapter 1 ~ Overview Briefly defines the UC2000, with an overview of the hardware and software design, Chapter 2 ~ Receiving, Handling, and Storage Provides guidelines for handling and storing the 12000 upon receipt Chapter 3 — Installation and Initial Startup Contains environmental, mounting, and electrical uidelines for installing the UC2000, including pre startup checks. Chapter 4 ~ Configurator Describes ihe configurator uility of de UC2000 including requirements and components. Chapter 5 - Printed Descriptions Describes the function and operation of boards in the UC2000, including descriptions of the adjustable hardware and defining I/O connector points, stabs, and LEDs. fring Board and VO GEH-6334 Chapter 6 ~ Faults and Troubleshooting Provides information to help detect and identify problems within the UC2000. Chapter 7 - Parts Replacement Providee instructions for replacing printed wiring ‘boards in the UC2000. Chapter 8 - Spare and Renewal Parts Contains uidering information for UC2000 pasts, including part numbers. Appendix A ~ Glossary of Terms Detines acronyms and terms used mn this manual Appendix B - Hardware Drawings Includes the hardware and elementary drawings provided in the back pane! of a UC2000. Appendix C -Warranty Parts and Service Explains procedures for obtaining warranty information and service. Refer to the Table of Contents for the organization of these chapters and appendices. 1-6, RELATED DOCUMENTS. GE provides system instruction manuals that include publications for the different components of that particular system. If additional publications are needed or for questions about the documentation, contact the nearest GE sales oftice ot authorized GE sales representative. 13Unit Controller 2000 GEH-6334 CHAPTER 2 RECEIVING, HANDLING, AND STORAGE 2-1, INTRODUCTION This chapter contains guidelines and precautions for handling and storing the UC2000 upon receipt. 2-2, RECEIVING AND HANDLING CAUTION To prevent possible damage to the equipment, immediately upon recelving the ‘UC2000, place it under adequate cover to protect ft from adverse conditions. Packing ‘cases are not suitable for outdoor or unprotected storage. ‘Shock caused by rough handling can damage electrical equipment. To prevent such damage when moving the equipment, be sure to observe normal precautions along with all hhandling instructions printed on the case. General Electric Company (GE) carefully inspects and ppacks all equipment before shipping it from the factory ‘A packing list, which itemizes the contents of each package, is attached to the side of each case of the equipment. GE provides handling guidelines to the carrier During, shipment, the equipment should not be exposed to excess ‘moismre or hnmidity, extreme temperatures, excess ‘temperature changes, or rough handling. Upon receipt, carefully examine the contents of each shipment, and check them with the packing list Immediately report any shortage, damage, or visual indication of rough handling to the cartier. Then notify both the transportation company and GE Drive Systems & Turbine Controls. Include the UC2000 requisition number and carton/case number (if available) when identifying the missing or damaged par. If assistance is needed, contact: Industrial Systems Drive Systems & Turbine Controls General Electric Company Product Service Engineering 1501 Roanoke Boulevard Salem, VA. 24153-6492 USA Phone 001-540-387-7595 Fax OU1-34U-387-80U6 2-3. STORAGE If the unit is not installed immediately upon receipt, it must be stored properly w prevent corrosion and deterioration. Since packing cases do not protect the ‘equipment for vutdoor storage, tie customer anust provide a clean, dry place free of extreme temperature ‘variations, high humidity, and dust Use the following guidelines when storing equipment: 1, Place the equipment under adequate cover with the following requirements: a. Keep the equipment clean and dry, protected {rom precipitation and flooding, . Use only breathable (canvas type) covering material — do not use plastic. Unpack the equipment as described in section 2-4, and label it. 3. Maintain the following environment in the storage enclosure: Ambient storage temperature limits from -40 °C (-40 °F) to 85 °C (185 °F). b. Surrounding air free of dust and corrosive elements, such a5 salt spray, or chemical and electrically conductive contaminants 2GEH-6334 Unit Controller 2000 c. Ambient relative humidity from 5 t0 95% with provisions to prevent corrosion 4. No rodents. e. Limit temperature variations that cause moisture condensation on the equipment. CAUTION Moisture on certain internal parts ean cause electrical failure. Condensation occurs with temperature drops of 15 °C (27°F) at 50% humidity over a 4-hour petiod, and with smaller temperature variations at higher humidity. If the storage room temperature varies in such a way, install a reliable heating system that keeps the equipment temperature slightly above that of the ambient air. This can include space heaters or panel space heaters (when supplied) inside each enclosure. A 100 W lamp can sometimes serve as a substitute source of heat. CAUTION To prevent fire hazard, remove all cartons and other such flammable materials packed inside units before energizing any heaters. 22 2-4. UNPACKING It is good practice to not completely unpack the equipment until it has been placed as near as possible to its permanent location. If the equipment has been exposed to low temperatures for an extended period of | time, do not unpack it until it has reached room temperature. ‘When unpacking, check the contents of each case against the packing list. Report any shortage to GE Drive Systems. Use standard unpacking tools, including a nail puller Carefully move the equipment from its container to avoid damaging or marring the part. Wipe off any particles of packing materials or foreign substances that ‘may be lodged in or between the parts ‘Small parts such as bols and screws) are packed in special containers to keep them together. However, they can become separated. Therefore, carefully inspect packing material for loose parts before discarding. 2-5. TIME LIMITATIONS The above specifications apply to shipping and storage durations of up to one year. Longer times may require additional treatment. For warranty information, refer to Appendix C.Unit Controller 2000 CHAPTER 3 INSTALLATION AND INITIAL STARTUP 3-1. INTRODUCTION 3-2. OPERATING ENVIRONMENT ‘This chapter contains environmental, mounting, and electrical guidelines for installing the UC2000. This information includes basic circuit checks needed after installation and before the UC2000 is started up, 1UC2000s are suited to most industrial environments. To ensure proper performance and normal operational life, the environment should be maintained as follows: Ambient temperature range: 0 °C (32 °F) t0 60 °C (140 °F) ‘The upper temperature limit degrades 2 °C per 1000 ft elevation (maximum elevation is 10,000 ft) Before starting installation, consult and study all furnished drawings. These should include arrangement drawings, connection diagrams, elementary diagrams, and a summary of the equipment. ‘This equipment contains a potential hazard of ‘electrical shock or burn. Only those who are adequately trained and thoroughly familiar Maximum operating temperature: 60 °C (140 °F) Maximum relative humidity: to 95% (non-condensing) ‘Temperature and humidity conditions, including relative rates of change should be controlled so that there is no ‘moisture condensation im or on the equipment. Equipment rating is based on ambient conditions as. with the equipment and (he instructions stated and must be derated for higher ambient should install, operate, or maintain this temperatures. equipment. Environments that include excessive amounts of any of NoTc lhe following elements reduce product performance aud life: Component and equipment reliabilities have improved dramatically over the past several © Dust, dirt, or foreign matter years, However, component and equipment failures can still occur. Electrical and © Electromagnetic radiation or noise introduced by: environmental conditions beyond the scope of the original design can be contributing - factors. Radio frequency signals, typically from portable transmisters used near the equipment or its wiring. Since failure modes cannot always be predicted or may depend on the application sind the environment, hest practices should be followed when dealing with 1/0 that is critical to process operation or personnel safety. Make sure that potential 1/0 failures are considered and appropriate lockouts or permissives are incorporated into the application. This is especially trae when dealing with processes that require human interaction. NOTE ‘The UC2000 can reliably operate in environment of § W radio transmitters at 27 ‘and 480 MHz with doors closed. = Stray high voltage or high frequency signals. typically produced by arc welders, unsuppressed relays, contactors, or brake coils operating near ‘the unit control circuits.Unit Controller 2000 (GEH-6334 + Vibration or shock + Moisture or vapors + Rapid temperature changes + Caustic fumes ‘© Power ine fluctuations 3-3, MOUNTING ‘The UC2000 is a base-mounted that can be mounted on a wall or other enclosure. ‘The mounting location is not restricted, except the door hinge of the unit must be able to open completely (see Figure 3-1). However, in selecting a location make sure the unit is protected from extreme heat and moisture. Do not mount the unit near equipment that generates large voltage spikes, EMI or RFI. 3-4, CABLING AND WIRING All installations should meet the requirements of both the National Electrical Code (NEC) and any applicable local codes. Use these codes to determine such factors as wire size, insulation type, conduit sizing, and enclosures. See section 3-5 for LAN configuration and Chapter 5 for UO connections. ‘To prevent electric shock or buen, make sure ‘that all input power is turned off before handling and connecting any power cables to the equipment. Then check voltage levels on the wiring to ensure that itis not carrying hazardous voltages. 3-4.1. Ac Power Requirements ‘The UC2000 is normally configured with the following power requirements: Voltage: 115/230 V ac, + 15% 115 V ac, low = 97.75 V ac and high = 132.25 V ac 230 V ac, low = 195.50 V ac and high = 264.50 V ac ‘Nominal line frequency: 50/60 Hz 3-4.2. Connections Cabing and wiring connec inde Incoming ene conesons 2 LAN cate comestion All terminal board connections 3-4.3, Wiring Level Separations To prevent signal interference caused by electrical noise, installation must consider the type of voltages on the wiring, These types must be separated and spaced as, described below. ‘There are four levels of wiring, which must be run in separate conduits or wireways: ‘© Low-level signals (Level L, see system level drawings w identify), which consist of analog signals up to +50 V de anc digital signals of 0 ough 15 V de ‘+ Modium-level signals (Level M), which consist of analog signals greater than 50 V de with less than 28, V ac ripple, and 28 V de light and awitching circuits ‘+ High level signals (Level H), which consist of de switching signals greater than 28 V, analog signals greater than $0 V de with greater than 28 V ac ripple, regulating signals of 50 V with less than 20 A-current, and ac feeders of up to 20 A © Power wiring (Level P), which consists af ae and de buses up to 800 V with currents of 20 - 800 A For more information on wiring level definitions and separation, refer to GEH-6011. Installation Guidance Service for DIRECTO-MATIC 2000 Equipment.GEH-6334 Unit Controlter 2000 3-4.4. Spacing ‘The following requirements ensure correct distance between cabling and wiring: © Signal wiring and power wiring may cross at right angles with a minimum J-inch separation, ‘© Avoid parallel runs between signal-level wires and power or control wires. If signal wires must be run parallel with power or control wires: ~ For distances up to 4 feet, maintain a minimum separation of 3 inches, ~ For distances over feet, add 1/4 inch of spacing for every foot of additional distance. + Within pultboxes and junction boxes, use grounded barriers to maintain the level separations. 3-4.5. Grounding Ifthe reference is supplied by a numerical control or by a process instrument with a grounded common, do not provide a separate ground for the unit common. ‘© If an isolation transformer is used and must be grounded, use a high resistance ground, unless local electrical codes direct otherwise. ‘For shielded and twisted shielded wire, ground the shields on one end only, preferably at the uait end. ‘+ Tie CCOM to a clean ground system. 3-5. LAN CONFIGURATIONS Tae UC2000 communicates over standard ARCNET LAN (DLAN+), Ethernet, and with Genius devices over the Genius network. The following sections provide installation specifications for connecting these networks to the UC2000. 34 3-5.1. DLAN+ Specifications Configuration: Daisychain or daisychain with active hubs Baud rate: 2.5 Mbits/sec Protocol: ‘Token passing Max. no. of nodes: 2-255 with active hubs 2-64 without active hubs Max. no. hubs: 3 Cable type: RG-62A/U coaxial Max. cable length: 1500 ft between active nodes 15000 ft between any end node and any other end node Connections: BNC connectors End terminations: BNC 93-chm terminator NOTE DLAN+ only supports the ARCNET active hub configurations. ARCNET passive hub configurations are not suited to the complexity of drive communication needs. ‘An active hub is a device that can create an ARCNET signal on multiple ports. It is used to add workstations t0 the network. A passive hub is a nonpowered device that splits an active hub channel into independent channels. To ensure data integrity, DLAN+ uses coaxial (coax) cable to connect clusters of drives, UC2000s, and MM2000 computers, (To prevent noise that can interfere ‘with communications, observe rules for power level separation as stated in the GE Installation Guidance Service Manual, GEH-6011.) Coax wire segments connect to an active hub’s multiple BNC ports in all but small systems. Each segment has a daisychain configuration connected to each node.Unit Controller 2000 Use the following general guidelines when installing DLAN+: * Do not reriove or power down nodes unless absolutely necessary. ‘© Maximum network size is limited by the amount of communication cable required and up to 255 nodes. Never create a loop with a network cable (for example, do not attach the same cable to the first and last hubs). ‘© Since coax cable is always connected to a BNC receptacle connector, a BNC plug connector must be installed at both ends of each cable length before it can be used. 3-5.1.1. HUB CONFIGURATION. Figure 3-2 shows a hub (star) configuration. Use the following guidelines when installing an active bub configuration: ‘= The number of devices (nodes and active hubs) from any end to any other end should not exceed 64. ‘© The total cable length between nodes should not exceed 1500 fi (457.9. m) ‘+ Active hnhs ean be daisychained for increased connectivity. The maximum cable length from any end to any other end should not exceed 15,000 ft (4572 m), ‘* A network should include no more than three active hubs. + Am active hub can use multiple BNC ports for directly connecting coaxial cable. ‘© Active hub ports do not require termination. 35.1.2. HUBLESS CONFIGURATION. Figure 3-3 shows a hubless daisychain configuration. Some systems use bus cards (printed wiring boards) for connecting ARCNET. Figure 3-3 shows a configuration using the DS200AAHA ARCNET LAN ‘Communications Board (AHA). GEH-6354 To get more than 1500 ft (457.2 m), use an active link to regenerate the signal and allow connection of a second segment. There is no limit to how many active links can be used, other than the 15,000 ft (4572 m) limitation NOTE Hub and hubless daisychain configurations can be mixed by attaching an active hub to the end of a bus segment instead of the terminator. 3-5.1.3. DLAN+ CABLE AND CONNECTORS. ‘This section provides equipment specification for DLAN+ cabling connections. © Cable: Coax RGS2A/U, 93.9, no. 22 AWG with Teflon insulation and jacker. Shield (bare copper) with insulated cover = Velocity of propagation: 84 t0 85% — Nominal capacitance: 13.5 pF per ft maximum — Nominal impedance: 93 0 maximum ~ Nominal diameter: .218 in, to .260 in. over- all = Temperature range: 40°F (5 °C) to 176 °F (80 °C) — Operating voltage: 700 V maximum * Connector, straight, for RG62A/U coax cable (10 connect DLAN+ to 112000, active hub, and other devices): use BNC coax connector with gold-plated pin, AMP #295395.9 or equivalent © BNC terminator for RG62A/U coax cable: 93 2. 1/2 W 5% resistor © Quick crimp tool (for crimping connectors on RG62A/U coax cable): AMP # 6947-1 or equivalent. ‘* BNC wire stripping tool: GC/GC Electronics #12- 458 or equivalent. 36GEH.6334 Unit Controller 2000 3-HUB MAX, 1,500 FT. MAX, END TERMINATION 4,500 FT. MAX, ee ian BETWEEN NODES BETWEEN NODES ENLARGED VIEW OF BETWEEN NODES TYPICAL HUB CONFIGURATION TYPICAL 255 NODE MAX. HUB CONFIGURATION NOTES: + Each hub counts as one node. +The total number of nodes from any end to sny other should not exceed 64, ‘+ The total cable length betwen nodes should net exceed 1500 ft ‘+ The total cable length fom any end to any other end should not exceed 15,000 ft. Figure 3-2. Hub Configuration — DLAN+Unit Controller 2000 GEH-6334 ance ont Ll | Ca Dezno8ais cna | DSROAAHA anor ons = tormevsrenenaris sooner. wax —— ‘TERMINATION. TERMOIATION {TYPICAL 6 NODE MAK. HUBLESS CONFIGURATION [A- GRIMPING TOOL FULL CYCLE RATCHET CRIMPING TOOL FOR RG-E2 AND [SELDEN ant WIRE AIM ELECTRONS (WADE TASMAN) CCOAKIAL STRIPPER FOR RG-62(GO=LECTRONGS, ROCKFORD, L [END -BNC CONNECTOR (AMPHENOL CORP.) CONNECTED TO REZ T-CONNECTOR 2784336076 (GEDS PART NO) -S$-OHM TERMINATOR 27BAISE0P9(GEDS PART NO), AMPHENOL RFX 4B0S059R0 ores: ‘+ Muiple users can be connected to an AG-62A coax backbone with an ARCNET bus board ‘+The backbone must be terminated st both ends with €9-ohm terminator. + End-o-and distance cannot exceed 1600 ft 1457.2 m) Figure 3-3. Hubless Configuration — DLAN+ 37GEH6334 3-5.2. Genius LAN The UC2000 communicates with Genius UO blocks over the Genius bus. The ICG6OELB912, (GEND board is a Genius 1/0 bus interface option. Its designed to be used a a daughterboard. Up to two boards can be connected to the UCIA board (motherboard) through a 50-pin connector (PLI) and a 10-pin connector (PL2) on the bottom side of the KGENI board, The board operates on 5 V de for logic power, +10% 4S V de to 5.5 V de). This section provides guidelines for connecting the Genius bus to the UC2000. 35.2.1. SPECIFICATIONS. Configuration: Daisychain using single twisted- pair, shielded Protocol: Peer-to-peer token passing Maximum no. drops: 32 Genius LAN reserves certain addresses for specific devices Drop (node) 0 is forthe hand-held ‘monitor; drops 01 through 30 are for 1/0 blocks; drop 31 is for a Genius controller. Addressing: Future UC2000 releases will serve multiple LAN controllers on a network. Therefore, when two controllers are on the same network, drops 30 and 31 are reserved for their use. NOTE Baud rate, cable length, cable type, and end termination specifications are interrelated. Before making any hardware or system selection for these, refer to the Genius 1/0 User’s Manual. Use the following general guidelines when installing Genius LAN: ‘+ Use daisychain (serial) connections; do not use tee ‘or hub connections. 38 Unit Controller 2000 ‘* Each drop has four bus terminals, Serial 1, Serial 2, Shield-in, and Shield-out ~ Wire Serial 1 on one drop to Serial 1 on the adjacent drops; wire Serial 2 to Serial 2 = Connect Shield-out on a drop to Shield-in on the next drop; however, leave unconnected the first node’s Shield-in and the last node’s Shield-out to prevent ground loops. Place Serial 1 and Serial 2 atthe electrical ends of the bus 36.2.2. CONTROLLER REGISTER SETTINGS. The Genius controller includes a software register that must bbe set for its address, the baud rate, and to enable ‘outputs. Table 3-1 defines the settings. Table 3-1. Genius Controller Software Register Setungs Position | Function (0-4 | Serial bus binary address Example: ont00111 j= Serial bus baud rate 00 ~ 153.6 extended (6-bit skip time) 10 ~ 38.4 (8 bit skip time) OF ~ 76.8 (8 bit skip time) 11 ~ 153.6 standard (8:bit skip time) 7 | Pos. 7> (0 - Outputs enabled 1 ~ Outputs disabled (default) “Rildevices ih the bus must be configured to run athe same baud rate. node ID = 7 (Pos. 4-0) 153.6 K baud (Pos. 5, 6} enabled (Pos. 7) 3-5.2.3, GENIUS CABLE AND CONNECTORS. This section provides equipment specifications for Genius cabling connections. Each wire is to be C.S.A listed and UL recognized (if applicable). This wire is NEC Article 275, UL classified, Class 2 circuits, and passes flame retardance ULSAV-1Unit Controller 2000 GEH-6334 For requirements for cabling between Genius blocks, refer tothe documentation supplied with that equipment. ‘The following cables and connectors are used between Genius blocks and the UC2000, or berween Genius blocks and a PC. ‘© Low capacitance twinaxial cable, 150 ohm, no. 22 AWG twisted-pair conductors, n0.22 AWG stranded tinned copper drain wire. Belden catalog no. 89182 or equivalent (For PVC, same as above but Belden catalog no. 9182 or equivalent) ‘Tinned copper conductors, no, 22 AWG (19 x 34), 14 ohms per 1000 ft (304.8 m) Tinned copper drain wire, no. 24 AWG stranded Foil shield 100% coverage, 18 ohms per 1000 ft (304.8 m) Wire insulation: Foamed FEP Teflon RePeRTER HU) aC Jacket insulation: FEP Teflon Nominal impedance: 150 ohms Nominal capacitance: 8.8 pF per ft Wire insulation thickness: 052 in - Colors: Jacket = black Wire white with white stripe Wire = white with yellow stripe Electrical properties: Belden catalog ‘no. 89269 or equivalent ‘Terminating resistor assembly (two per Genius chain): 150 ohm, 1/2 W 5% resistor for computer low capacitance twinaxial cable (GE part no, 44A713909P3) 3.5.3. Ethernet Specifications. Ethernet specifications are as follows (see Figure 3-4) Configuration: _—_—Daisychain, 10 Base 2 (ThinWire™) Baud rate: 10 Mbits/sec oo gtrini_o < e00 FEET oa Figure 3-4. Ethemet Configuration 39GEH-6334 Unit Controller 2000 Protocol CSMAJCD (cartier sense multiple access! with collision detect) ‘Max. no. of nodes: 38 per repeated segment (1000 total) Cable type: 2G-58U Coaxial Max. cable length: — ~600 ft (200 m) from repeater to terminator Connections: BNC “T” connectors End terminations: BNC 50 0 terminator ecommended minimum cable length: ~10 tt (3m) 3-6. SERIAL INTERFACE CONNECTIONS ‘The UC2000 contains an RS-232C serial interface connections. RS-232C Is located on the UCPE board as, connectors COMI and COM2, Refer to Table 5-12 for ius defiitions 3-6.1, COM1 Serial Cable COM is reserved for lower level configuration and diagnostics. This connector is a 9 pin d cubminiature (on ‘both ends) receptacle. Default serial specifications and pin assignments are ae follows: Baud rate: 9600 Data bits: 8 Parity: none Stop bits: 1 Pin Assignment C2000 Configurator 2 3 3 2 4 6 5 5 6 4 7 8 8 7 3-7. POWER-OFF CHECK All UC2000s are factory-tested and operable when shipped to the instalation site. Final checks should be ‘made after installation and before starting the UC2000 ‘use the steps listed in section 3-7.1. 3-7.1. Preliminary Checks ‘This equipment contains a potential hazard of electrical shock or burn. Extremely high voltages are present on some circuttry. To prevent accidental injury, do not touch any Circuitry without first ensuring dat It does not carry these voltages. 1. Ensure that all electrical terminal connections are tight NOTE To ensure that electrical connections remain tight, they should be ro-checked within three to six months after initial powerup, and annually thereafter, using serewdrivers and wrenches. 2. Ensure that all devices and boards are secure and hhave nat heen damaged during shipping and handling or installation, 3. Ensure that the incoming wiring conforms to approved wiring practices, described in section 3-4. 4, Ensure that no wiring has been damaged or frayed Garing installation. Replace if necessary. 3-8. STARTUP 1. Check that the correct line voltage is present on 3TB. (see Figure B-2) 2. Turn the unit power switch to the ON position. The green LED, DS2 on the UPSA board indicates that the power is on. “The UCPB board runs a seittest. Faults are indicated on the LEDS located on the UCIA board (see Chapter 6, Table 62). For software information, see GEH-6333, GEDS Toolbox for UC2000 Configurator.Unit Controller 2000 GEH-6334 CHAPTER 4 CONFIGURATOR 4-1. INTRODUCTION ‘The UC2000 is configured and its firmware upgraded using the UC2000 Configurator software package. This software is a Windows™-based program, which contains a collection of utilities. “The Configurator configures the UC2000's runtime actions, This utility specifies all aplication code configuration information and records it using a language called Peode. The Configurator downloads Peode to @ 'UC2000 into volatile or peemanent storage, The utility is used to monitor and alter parameters, and to make minor code changes online. In addition, the configurator ‘upgrades the latest product code firmware, such as block Uirais, scheduler, and such over the Ethernet. ‘The UC2000 basic 1/0 system (BIOS) and operating system are upgraded using the UC2000 loader. Instead of changing EPROMS, this low-level firmware is loaded into the flash memory of a UC2000 over a serial cable. The TCP/IP address of the UC2000 is also set with this utility, providing additional communication with the Configurator over Ethernet. 4-1.1. Configurator Functions ‘The major features of the Configurator include: ‘© Windows-based editor for configuring Pcode Gocluding drag and drop capabilities) ‘© Block macros and module library support ‘© Live data block flow diagrams ‘© Online code change ‘+ Online Help files + VO configuration and monitoring Signal management + Multiuser fle management + Report generation + Signal Trending + Batch mode operation Target firmware upgrades 4-1.2. Configurator Requirements The UC2000 Configurator runs on a Windows 95 or Windows NT™ platform. This software is intended to operate on an 80486, 33 MHz microprocessor (or higher). Other requirements include: ‘+16 MB RAM and 100 MB disk space to Toad the tools, configuration files, and libraries + 3.5 disk drive (for software installation) and cursor positioning device (CPD) such as a mouse ‘+ Ethernet port for interface to UC2000 platform (see section 3-5.3) © Serial cable, if low-level firmware upgrade capability is desired, atGEH-6334 Unit Controller 2000 Notes: 42Unit Controller 2000 GEB-6334 CHAPTER 5 PRINTED WIRING BOARD AND !/O DESCRIPTIONS 5-1. INTRODUCTION This chapter describes the printed wiring boards used in the UC2000 and their operation. It also lists and defines VO connector points including plug-in cable type, terminal board type, and stab terminals located on the printed wiring boards. The board layout figures in this chapter show the locations of these items on the boards. 5-2, BOARD IDENTIFICATION A printed wiring board is designated by an alphanumeric part (catalog) number. Two parts numbering series are commonly used for printed wiring boards at GE Drive Systems. ‘Some boards contained in the UC2000 are designated with part numbers beginning with the characters DS200. For example, the power supply board is idemtfied by part number DS200UPSAG#AAA. The characters in the part number provide information about the board, as shown in Figure 5-1. 200 PsA Ge Figure 5-1. Sample All digits are important when ordering or replacing any ‘board. Chapter 8 contains spare and renewal parts information, NOTE ‘The terms card and board both apply to printed wiring boards. In this manual, board the preferred term. However, card is used in some drawings and when it is part of a board's pre-established nomenclature. 6-3, ADJUSTABLE HARDWARE Some printed wiring boards used in the UC2000 include adjustable switches and jumpers for setting and fine ‘tuning functions. The board layout drawings in this chapter show their locations on the boards. The board adjustable hardware tables list and describe the adjustments, [A board revision (artwork change} thats backward compstibl, | Aboard revision unetional change) that is backward compatible, ‘Aboard revision ( Essentially anew c tional change] thet is not backward compatible. 9 number, A group, of variation, of a particular boars —— soar functional seronym, indicates thet the board isa base level board and ean contain firmware. [218 indicates the board is a higher level assembiy that cor contain firmware andlor other components added to the base level board, \Wentfies GE Drive Systems. Board Part Number, DS Series 5-4GEH-6334 Unit Controtier 2000 Potentially hazardous voltages are present in the unit circuits. Ensure that power is off before touching a board or any connected circuits. Use the external power switch to turn off power to the unit. ‘Ihe POWER ON switch on the UPSA board does not completely turn off all power to the unit, CAUTION Some boards contain static-sensit components. To prevent component damage caused by static electricity, use static-sensitive hhandling techniques with all boards. NOTE Board adjustable hardware may change with product upgrades and revisions, The information presented in this manual is current as of the issue date. 5.3.1. Initial Hardware Settings ‘The factory sets most adjustable hardware when ‘manufacturing and testing the unit. For adjustments that are not factory-set, refer to the tables in this chapter and the custom software, 53.1.1, SWITCHES. The UPSA board contains switches, which are defined in section 5-7.1.1 5-3.1.2. JUMPERS. The UC2000 uses Berg.type (manually moveable) jumpers for manufacturing tests. ‘Typically these jumpers are designated with a JP ‘nomenclarure NOTE Before moving any jumper, compare its actual position with the as shipped position shown on the hardware drawings located in the door pocket. 5.3.2, Adjusting Replacement Boards ‘When replacing a board, set the switches and jumpers on the new board to match the settings on the board being replaced. Chapter 7 provides instructions tor replacing, the boards. 6-4, TYPES OF CONNECTORS 5-4.1, Plugin Connectors ‘The type of connector, typically idenified by PL in its name, mates with a cable that plugs into it, The cable caries sigual and power WO widhin dhe wit aud externally to customer equipment. Plug-in connectors ‘provide Uee types of coanections. Internal board-to-board connections ~ Carry VO between boards in the UC2000. The connector typically has the esme name and pinout assignments ‘on each board. User connections - These connectors are located on ‘boards in the UC2000. They carry I/O between ‘these boards and user connections outside the unit. 5.4.2, Terminal Roard Connectors ‘This type of connector is identified hy a TB in its name It provides a connection point for individual wires that carry signals or power. This V/O can be between a board and components within the unit. The wires are secured in the terminal board by tightening screws at each connection. Refer to Tables 5-6 through 5-8 5-5. LEDs ‘The UC2000 includes light-emitting diodes (LEDs) as an indicator of a board or the unit condition. The indicators are located on /O paths, and turn on or off with the signal condition.Unit Controller 2000 [ARCNET TRANSCEIVER, THREE PORT HUB AND TERMINATION (2 BNCs) ARH ETHERNET TRANSCEIVER ‘AND TERMINATION (BNC) GrH.6554 opin 9PIN oconnctor || 0 CONNECTOR SERIAL PORT ‘SERIAL PORT 1 2 UPSA POWER SUPPLY 1181230 Vae +124Vee 50160 He 3148 de o ‘5Vde 125 Vie commen cea CONION PROCESSOR MODULE Porto Poros uciA ue2000 MOTHERBOARD conus ‘BOARD GEN cents BOARD UGE! GENIUS INTERFACE, TERMINAL Figure 6-2. UC2000 Interconnections 63GEH-6334 5-6, FUSES ‘Tne UC2000 contains five standard commercial fuses. Located on the UPSA board are fuses FU1, FU2, FU3, and FUS, For a description of each fuse, refer to Figure B.S. On the DS200UCPB is the fuse, F2 (see Figure B- 4). It provides power to the optional oppy disk. 5-7. PRINTED WIRING BOARDS This section describes the printed wiring boards used in the UC2000 (see Figure 5-2). These include: ‘© Power supply board, DS200UPSA (UPSA) Mout. avurd, DS200UCIA (UCIA) + Cental processing unit (CPU) daughterboard, DS200UCPB (UCPB) ‘+ DLAN+/Ethernet interface board, DS200AAHA (aamia) + Gonius LAN daughterboard(s), IC660ELBD12 (AGEND (optional) 5.7.1, Power Supply Board (UPSA) ‘The UPSA board is a two stage offline switching, 100 W power supply, which accepts an ac or de line inpor source and outputs cantral level voltages. Fignre 5- 3 shows the layout of the board, including the locations ff connector paints and configurable hardware. 5.7.1.1. CONFIGURABLE HARDWARE. The UPSA board contains the following configurable hardware (see Figure 5-3). The board has one potentiometer (pot), RVI. This pot is factory set and should only be adjusted if necessary. (For SV, set = .05 on +5 V test post, The UPSA contains two switches. SW1 is the power on switch and SW? is a reset switch (see section 5-7.1.3). ‘Use the external power switch to turn off power to the unit, The POWER ON switch on the UPSA board does not completely turn off all power to the unit. Unit Controtter 2000 5-7.1.2. LED. The board has one PS OK LED, DSI. This (green) LED indicates that the power supply is on. DSI stays on constantly except when there is no power or if NPSEN is a logical high. 5.7.1.3. SPECIFICATIONS. Line input voltage is applied to the ACI and AC2 terminal pounts and tused at 4 A by FUL. The supply converts the input voltage to +5 V, #24 V, and 219 V (output on three 9-pin connectors) as follows: +5 fused at 12 A by FU3 #424 fused at 3 A by FU4 and also supplies power to le +15 V Linear regulawr = -24 fused at 3 A by FU2 and also supplies power 19 the -15 V linear regulator This board also provides system and power on reset and control voltage under-voltage detection, NOTE The total power requirements of devices connected to these three connectors should not excood the fuse ratings or the 100 W supply rating. ‘The output pin, NPSEN is provided on each of the lonmpur connectors. This signal is used to reset on powerup or when an output under-voltage condition is detected. NPSEN normal state isa logic low. A logic high output (1) is detected in the following conditions + (G5) 0w46V=1 © (GFISV) 0013 V=1 © (15V) 0 wA3sV=t ‘+ Reset bution is pressed Input Power, 125 W with output loaded to 100 W: 90 ~ 250 V 2c, 50/60 Hz 90 - 250 V de ‘Typical line loss ride through: Line 115 V ac 60 Hz, load 100 W (approx. 40 ms) Lime 230 V ac 60 Hz, load 100 W (approx. 80 ms)Unit Controller 2000 GEH-6334 HEINE DS2O0UPSAGIA Pa s cr] ¢ me ~ mu & = oe i : 2 ew Oy 30 wo, Al O° Oo ‘RESET 3 Peg 5 rovancn z oo be Be) awe 5° iets OTB son] lig | i Figure 5-3. UPSA Board Layout Table 6-1. UPSA Output Power ‘Output Loading eer (Total should not exceed 100 W) +5, 42% 108 + 24, Unregulated 15a -24, Unregulated 1.5 A +15, 25% 150 mA “15, 45% 150 mA 55GEH-6334 Unit Controller 2000 Table 5-2, Connector 2PLA, 2PLB, and 2PLC, Power Supply From UPSA Board to UCIA Board (2P! and 2PIXI and ALHA Board (2PL) Pin No, | Nomenciatur 7 2 Deveription +24, unregulated ~24 V, unregulated Signal common +5.V, 12% Signal common +15 V, 25% Power supply enableireset Table &-3. FAPL Fan Connections com Noa Description Fan common 4+24.V fan power Table 5-4. Connectors ACI, AC2, CCOM and CHAS! to UPSA Board Pin ‘act acz ccom cHasi Description (Line) LINE IN 1 (Neutral JLINE IN 2 SYSTEM GROUND CHASSIS GROUNDUnit Controller 2000 §-7.2, Motherboard (UCIA) ‘The UCIA is the main printed wiring board in the UC2000. It contains connectors that provide mounting for additional boards such as: UCPB (host CPU daughterboard) via PC104 © Upto wo uGENI boards (controls data transfer between host and Genius bus) Refer to Figure 5-4 for the location of each connector and Table 5-5 for the connector descriptions. GEH-6334 5.7.2.1. HARDWARE, This section describes the ‘hardware found on the UCIA board. The board contains cone jumper, JPI, which is used for factory tests only DNI are LEDs defined by the process software. ‘Testpoints, TPI and TP2 are used for diagnostics when te process specifies. The fan connector (PI4) connects 5 V of power tothe fan on the UCPB board (optional) 5.7.2.2. JO CONNECTIONS. The UCIA contains power supply connectors 2PL and 2PLX. GENI and GEN? are Genius connectors to the ;GENI boards. ‘Terminal board connections are described in Table 5-6 through 5-8. hi | UL 7 (Monona a A =: C4: Cae ge f | : 2 ~~ Figure 6-4. UCIA Board Layout 57GEH-6334 Unit Controller 2000 Table 5-5. UCIA Board Connections Name Nomenclature | Description Pr ‘SER Ne ie ae lounting for power supply board, UI ee ad Mounting for ps ipoly board, UPSA P3 Gent Serial port connections to T82 Pa GEN2 ps PS & PIS = Mounting for wGENI boardis) P6&PIC ee s) Pe -PIa - Ne Pia FAN Fan connection (optional 1843 = Mounting for UCPB board/PC104 W2&J4 - Mounting for PC/104™ boardis) connectors Table 6-6. 178 Connections to UCIA Board Connector PI Name Deseript com’ [Toursaiccombus mmx Connection to SER ™* Connection to SER. SHO IN Shield in HD OUT Shield out 5-8Unit Controller 2000 GEH-6334 Table 6-7. 278 Connections to UCIA Board Connectors P3 and Pa Name Description SHD OUT Shield out SHD IN Shield in xit Connection to Genius 1 xot Connection to Genius 1 x12 Connection to Genius 2 x22 Connection to Genius 2 SHO IN Shield in SHD OUT Shield out Table 5-8. 2TB Connections to UPSA Board ‘Name Act ace Description | Tine Neutral 59GEB-6334 5-7.3. CPU Board (UCPB) ‘The UCPB is the central processing unit (CPU) daughterboard. The board has the following features: #80486 processor, DX4-100 MHz ‘© Single inline memory module (SIMM) socket ‘© 128K flash with ROM BIOS ‘+ 4MB I/O mapped flash memory © Two RS-232C serial ports © ARCNET and Ethernet controllers ‘Additional features such as LPT! (parallel printer port), FLOPPY (disk drive), IDE (bard disk drive), and KB (Keyboard) aze shown on the board layout in Figure 5-5, but are not used in this application. 5-7.3.1. SPECIFICATIONS. This section describes the hardware found on the UCPB board. The board operates ‘on 5 V de power (4.75 V to 5.25 V). 12 V (<100 mA) power supply erases or programs the flash devices, Including the BIOS. Both the 5 V and 12 V power is supplied to the board through an extended PC/104 bus connector. Unit Controller 2000 ‘The battery provides voltage for the RAM and real time clock. Battery voltage must be between 3.5 V and 5.5 V and is connected to the battery plug, if required (see Table 5-11 for pin connections). Fuse F2 is a2 A, 63 V, type F fuse, It supplies power to the floppy disk. 5-7.3.2. HARDWARE ADJUSTMENTS. The UCPB ‘board contains four jumper connections. JP1 and JP3 are used for factory tests only. JP2 and RESET are manually ‘movable jumpers. JP2 is the 486 local bus speed selection, installed for 25 MHz operation, This jumper is removed for 33 MHz operation (see Table 5-9). RESET, when connected, provides hard reset. CAUTION ‘This reset is an offline function. The operator should take special precaution to avoid harm to the process environment. 5-7.3.3, CONNECTIONS. This section defines ‘connection points for the UCPB board. The board contains communication connections, ARCNET, E> NET, and COMI and COM? (RS-232C). Figure 5-5 shows the connectors and hardware locations. Tables 5- 12 through 5-14 define the connections. ‘The UCPB also contains a SIMM socket (see connection SI in Figure 5-5). $1 can hold up to 16 MB of DRAM.Unit Controller 2000 (GEH-6334 ao fo | | JPi BATTERY RESET |. erocesson sa Fan | (OPTIONAL) pszooucpscsa | | & | Ler | | | | 2 coma H Ps CH KB. F2 | 1E [Joos 1 | 1 Figure 5-6. UCPB Board LayoutGEH-6334 Unit Controller 2000 Table 5-10. UCPB Reset Connection Pin Nomenclature | Description 1 ORESETIN Hard reset input 2 com ‘Signal return Table 5-11. Battery Connector to UCP Board Pin Nomenclature | Description 7 VaAT B5VI055V 2 - Not present. Band 4 GND Ground (signal return) Table 5-12. COM1 and COM2 Serial interface Connector Pin Nomenclature | Description 7 cD |CarerDeet SSS 2 AXD Received data 3 TxD Transmitted data a ore Data terminal ready tine 5 GND Ground (signal return} 6 psa Data set ready line 7 RTS Request to send line 8 crs Clear to send fine 8 RI Ring Indicator 10 Ne Not connectedUnit Controller 2000 Table 5-13, GEH-6334 UCP8 ARCNET Connections to AAHA Board Connector APL Description Not connected Ground (signal reture) Positive output Negative output Ground (signal return) Positive input Negative output Table 5-14, UCPB Ethernet Connections to AAHA Board Connector EPL Pin Nomenclature | Description 7 oD Carrier detectipositive input 2 cp Carrier detectinegative input 3 KD Receivedipostive input 4 RXD Receivedinegative output 5 1x0 ‘Transmitted/positive output 6 TxD Transmittedinegative outputGEH334 6-7.4, DLAN+ and Ethernet 1/0 Board (AAHA) ‘The AAHA board includes BNC connectors for attaching DLAN+ and Ethernet cables and connectors EPL, APL. and 2PL for I/O. Refer to Tables 5-15 through 5-18 for VO connection definitions and Figure 5-6 for the ‘connector locations. CAUTION Do not mix Ethernet and DLAN+ terminators. This can cause misoperation of hoth networks, Refer to Table 5-15. Unit Controller 2000 Table 5-16. DLAN+ and Ethernet Connections, to AAHA Board Connection | Description ARCBNC A | ARCNET BNC channel A connection (83 2 terminator) ARceNC_8 — | ARCNET BNC channel B connection (93 © terminator) BNC Ethernet BNC chant connection (50 © terminator) Table 5-16. Connector 2Pt, Power Supply 10 AAHA Board from UPSA Board Pin Nomenclature | Description 1 Doom Power supply return (signal return) 2 PS Power supply voltage anc ancance | ARCENC-A | m2 | ms = z oO EL a 2 jpcecceceds|| 838see|ls eo) DSZONAAHA Figure 5-6. AAHA Board Layout etaUnit Controller 2000 GEH-6334 Table 5-17. Connector APL, ARCNET YO Between ‘AHA Board and UCPB Board Pin Nomenclature | Description 7 TcLK Differential auxiliary connection, input non-inverting (NI) 2 clk Differential auxiliary connection, input inverting (I) 3 Ne Not connected 4 Ne Not connected 5 1 Differential ARCNET transmit pulse signal, input NI ‘ op Differential ARCNFT transmit pulse signal, innit | 7 Ne Not connected 8 ne Not connected 9 1TRK Differential ARCNET receive pulse, output NI 10 oTex Differential ARCNET receive pulse, output | Table 6-18. Connector EPL, Ethemet /O Between "AAHA Board and UCPB Board Pin Nomenclature | Description 7 Differential collision in, ourpux Nr 2 a Differontaleolision in, output | 3 cHass Connection to chassis £1 & E2 around 4 ole Differential data in, output NI 5 ok Differential data in, output | 6 cHass Connection to chassis £1 & €2 ground 7 Do+ Differential data out, input NI 8 Do- Differential data out input Connection ta chassis €1 & £2 groundGEH-6334 5-7.5. Genius LAN Board (uGENI) ‘The GENT board is a Genius 1/0 bus interface option. Up to two UGENT daughterboards can be connected to the UCIA motherboard. Connections to the UCIA are made through a 50-pin connector (PL1) and a 10-pin ‘connector (PL2) on the bottom side of the hGENI board, ‘The board operates on 5 V de for logic power, +10% 4.51055). Figure 5-7 shows the location of the connectors. Table 5- 19 through 5-21 define the signals on both connectors, Unit Controller 2000 NOTE All UGENT boards used in this unit must be revision G or later. 5:7.5.1, LEDS. Two LEDs on the uGENI board show the status of the board and its communications with the Genius bus. During proper operation, both LED1 (COMM) and LED2 (GEN1) will be on (solid). LED1 remains on when communications are good and flashes if communications are lost (fault). LED2 provides a selfiest on the board processor. Figure 5-7 shows the location of the LEDs. ° 7 sp COMM ° 50088 3 36 | * pla fo} ° Figure 5-7. wGENI Board LayoutUnit Controller 2000 GEH-6334 Table 5-19. uGENI Board Connector PL2 - Pin Nomenclature _| Description 1,3,8, 7, and 9 BV +8V 2, 4, 6, 8, and 10 ov Ground {signal return) Table 5-20. 5 V Signals on uGENI Board Connector PLT Pin Nomenclature] Description 13 ov Logic ground input 24 +5V 5 V, £ 10% power supply input 6-18 | ao-ar3 ‘Address lines that designate an address in shared RAM to be written or read 19-26 | PeI7)~ P610) | GEN! setup signals. 2 Ne Not connected, 28 Inst Reset initializes the uGENI board when held low. it must be held low during powerup and for 2 minimum of 20 ms after all power supplies are in tolerance. All uGENI output signals are held inactive during reset. 29 INT pen collector output that tells the UCIA an event occurred whenever it goes low (pulses low for 5.44 us). Provision must be made for the UCIA to remember that this, pulse occurred. Conditions that cause an interrupt can be selected and monitored ‘through the shared RAM interface. 30 IRD Read strobe line; the read input to the 1GENI is used during @ UCIA CPU read cycle. It enables data transfer from shared RAM to the UCIA interface bus. an WR Write strobe input indicating that data on D0 ~ D7 is valid and should be written from the UCIA interface bus to shared RAM. 32 IGENSEL GENI SELECT, used to request access to shared RAM. All output signals from uGENI are held inactive and data cannot be written into/read from shared RAM when this signal is high 33 IGENRDY Output to the UCIA, tolling it to complete its memory access cycle. This signal is used to introduce wait states, if necessary, during a uGENI shared RAM access. This signal falls ow, until the low to high transition of JRD or /WR. A high to low transition of this signal means that the UCIA can stop inserting wait states (ending its read or write cycle) 34 MONO Hand-held monitor (HHM) signal is high to the UCIA. (There are no provision to attach a HHM at this time.) 5.17GEH-6334 ‘Unit Controller 2000 Table 5-20. 5 V Signals on uGENI Board Connector PL1 — Continued Pia Nomenclature | Description Fight bi-divectinnal data lines used to transfer data to/from the HGENI board's shared RAM, These lines enter the high-impedance state when /RST is low or /GENSEL is high. 43 IGENIOK LED output. Low, when uGENI is running normally and high, when a hardware fault is detected. [nis line is internally current-limited to 5mA and can directly drive an LED fr can be used as a logic signal 44 ICOMMOK —_| LED output. Low, indicates no communications errors on the bus. It is current limited and can directly drive an LED or can be used as a loaie sianal. Table § 27. 10 V Signale on wGEN! Board Connector PLI to Goniue Bus in Nomenclature 45-48 | NC Not connected 49,50 | x1, x2 Differential signals that carry Genius bus data. They must be connected to a terminal connector on the host motherboard. 518Unit Controller 2000 GEH-6334 CHAPTER 6 FAULTS AND TROUBLESHOOTING 6-1. INTRODUCTION ‘The UC2000 includes fault detection software to aid in ‘troubleshooting. This chapter provides specific information to help identify problems in a startup and a download of Peode. 6-2. BIOS AND RUNTIME FAULTS Annunciated faults are announced and displayed faults, which occur during the startup of the hardware (BIOS) or during download of Pcode. These faults can indicate either a fatal fault condition or @ non-fatal fault condition as follows: Ina fatal fault condition, the controller does not run. The condition is shown in a hex format on an eight- segment bank of LEDS located on the UCIA board, Fault code and descriptions are additionally displayed in a decimal format in the Fault Log view of the Toolbox. ‘+ Ina non-fatal fault condition the controller continues to run and the fault code and descriptions are displayed in the Fault Log view of the Toolbox. ‘When the UC2000 completes the startup sequence and executes Peode, the bank of LEDs on the UCIA board display a walking ones pattern. This pattern is a single Tighted LED, which steps through all eight LEDs. Faults produced by the BIOS during startup of the 1UC2000 hardware produce a non-blinking code on the LEDs. The code represents hardware problems that require replacing the CPU board (UCPB). NOTE If the board is returned to GE Drive Systems for analysis, the fault code and description in Table 6-2 should be noted and reported. Ifa problem is detected after startup, a blinking fault code remains on the LEDs until the fault is corrected, and either the Pcode is downloaded again or the UC2000 is restarted. Refer to Table 6-4 for the corrective action. Faults produced at runtime occur during a download of Peode. These faults can be both fatal and non-fatal and display as described in Table 6-3 and 6-4. 6.2.1. Fault Indication ‘When the controller detects a fault it ousputs a fault code to indicate the problem. The fault codes display on both the Toolbex display window and on the UCIA board LEDs. Adsitionally, the controller can display these codes via an optional serial port (COMI). NOTE Fault code definitions may change with product upgrades and revisions. The fault codes presented in this chapter are current as of the issue date of this manual, 6-2.1.1. CONTROLLER DISPLAY. The Configurator displays the Device window, which contains the Fault Log View in the lower portion. This view shows fault messages (fault number and name), a log of faults encountered during Configuration functions. 6.2.1.2. LED DISPLAY. The LED bank on the UCIA board contains 10 segments (9-0). Segment 9 is software configurable and used to indicate a DLAN+ network fault (optional), Segment 8 turns on when any access is ‘made to the board, such as NVRAM or Genius 1/0. The remaining eight segments (7-0) display the software fault codes in binary-coded hexadecimal. Refer to Figure 6-1, to read the fault codes in hexadecimal. 61GEH-6334 Unit Controller 2000 DISPLAYS ANY access 70. oispuays. DispLays UGIRBOARD | HEXCODELEFT DIG HEX CODE RIGHT :GIT Ta eT BINARY VALUE a] fo] | revs = LED STATUS FOR FAULT CE, + Left four segments (LEDs 7 ~ 4) make up the fst digit 10) ‘ight four segments (LEDs 3 ~ 0} make up the second ait (8) Figure 6-1. Binary Coded Hexadecimal LED Display Table 6-1. UC2000 Startup Faults Non-blinking LED Code Description, Procedure (hex) 3 {UC2000 has started, but has not been given the TCP/IP address. Using the Configurator and the serial port of the UC2000, configure the TCP/IP address of the uc2000. 3D C2000 has started, has a valid TCP/P address and is waiting for a product code download. Using the Toolbox, download the product code via Ethernet. 3c UC2000 has started the product code, but is not executing any Pcode. Using the Configurator, download Pcode to RAM, or download Pcode to permanent storage and restart,Unit Controller 2000 GEH-6334 Teble 6-2. BIOS (Herdware], Annunicated Fetal Faults ‘Non-blinking ~_LED Code (hex) Description -D FB Fo 7 F6 FS Fa Ft F ee =D cy 9 e7 55 es oF op oe 07 05 os or cp ce ce cr ce att 343 Verity real mode Get CPU type Initialize system hardware Initialize chipset registers with intial POST values Set in POST flag Initialize CPU registers Initialize eache to intial POST values Initialize WO Initialize power management Load alternate registers with intial POST values Jump to UserPatcho Initialize keyboerd controler BIOS ROM checksum 8254 timer initialization 8237 DMA controller initialization Reset programmable interupt controller ‘Test DRAM refresh ‘Test 8742 keyboard controller Set ES segment register to 4.68 ‘Autosize DRAM Clear 512K base RAM Test 612K base address lines ‘Test 512K base memory ‘Test CPU bus-clock frequency Test CMOS RAM Reinitialize the chipset Shadow system BIOS ROM Rointiaize the cacheGEH-6334 Unit Controller 2000 Table 6-2. BIOS (Hardware), Annunicated Fatal Faults — Continued bp code tnex) 008 cs Tutosae cache ca Configure advanced chipset registers © Load alternate registers with CMOS valves oF Set Initial CPU speed 80 initialize interrupt vectors 3 Initialize 10S inert 9 Check ROM copyright notice 38 Initialize manager for PC option ROMS 87 Check video contiguration ageinst CMOS 86 Initialize PCI bus and devices 85 Initial vdeo adapter in ayatem 83 shadow video BIOS ROM a Display copyright notice AF Display CPU type and speed no Test keyboors as Set key cick, enabled a Enable keyboard ar 2:2:9-1 Test for unexpected interrupts as Display prompt, ress F2 to enter SETUP a3 Test RAM between £12 and 640 K oF Test extended memory 20 Test extended memory ade lines %8 Jump to UserPaicht 99 Configure advanced cache registers 37 Enable extemal and CPU caches 95 Display extemal cache sie 99 Display shadow message 91 Display nonaposable segments or Display faut messagesUnit Controller 2000 GEH-6334 Table 6-2. BIOS (Hardware), Annunicated Fatal Faults — Continued Nor-blinking = _LED Code (hex) Description 3 88 89 83 a1 7F 7 8 79 n 5 3 er 6E 60 68 69 67 65 63 6 5F 50 58 87 55 53 51 ar Check for configuration faults Test realtime clock CCheck for keyboard errs Set up hardware interrupt vectors Test coprocessor if present Disable onboard 1/0 ports Detect and install externsl RS-232C ports Detect and install external parallel ports Resinitaize onboard 1/0 ports Initialize BIOS data area Initialize Extended BIOS data area Initialize floppy controller Initialize hard-disk controller Initialize local-bus hard-disk controller Jump to UseePatch2 Disable A20 address line Clear huge ES segment register Search for option ROMS ‘Shadow option ROMs Set up power management Enable hardware interrupts Set time of day Check key lock Initiate typematic rate Erase F2 prompt Scan for F2 key stroke Enter SETUP Clear in-POST flag Check for faultsGEH-6334 Table 6-2, B10S (Hardware), Annunicated Fatal Faults — Continued Non-blinking Beeps Description LED Code (hex) sre " aD POST done - prepare to boot operating system 48 ‘One beep 49 ‘Check password (optional) 47 Clear globat descriptor table 43 Clear party checkers a Clear screen foptional) 40 Check virus and backup reminders oF Try te boot with INT 19 2F Interrupt handler fault 20 Unknown interupt fault 28 Pending interrupt fault 29 Initaize option ROM fault 27 Shutdown fault 25 Extended block move 23 Shutdown 10 fault 1D Initialize the chipset 1c Initialize refresh counter 1B ‘Check for forced Flash 1A ‘Check hardware status of ROM 19 B10 ROM is OK 18 Do a complete RAM test 7 Do OEM intiaization 16 Initiate interrupt controller 18 Read in the bootstrap code 14 initialized all vectors 13 Boot the Flash program 2 Initialize the boot device " Boot code was read OK 66Unit Controller 2000, GEH-6334 Table 6-3. Runtime, Annunicated Non-fatal Faults Fault Number decimay Name Description, Procedut (GENI_DOWN The Genius 1/0 interface card is down 1. Restart the UC2000 2. If still down, replace the interface card 2 GENI_SRI_EOF End of Genius shared RAM interface (SRI) 3 GENI_BAD_ARG Invalid values passed to the Genius driver 7 * a7 18 a9 20 21 GENI_BEYOND_sAI GENI_SEMAPHORE GENI_NO_INTERRUPT Lock_TIMEOUT RUFFFR_TO_SMal! Bus ERR DEV_ABSENT INVALID_POINTS INVALID-OPERATION INVALID_BLOCK_TYPE (GENI_UNINITIALIZED BLK_SBA_OUT_RANGE GENI_SRI_NOT_LOCKED UNKNOWN_OGRAM_COMMAND CMDBLK_SYNTAX_ERR ‘eMpDLK_TIMCOUT cMnalk_PROC_EAR DGRAM_TOO_LONG DGRAM_NUM PACKETS ‘MD _UNKNOWN Extending beyond the Genius SAI boundary A semaphore wae signaled, but the corresponding Genive ‘SRI event didn’t happen The Genius /O interface card has been incorrectly setup to not use interrupts ‘The Genius I/O interface card did not relinquish or accept ‘the SAI within the timeout period Not enough hiffer space for Genius driver ‘There is @ Gonius 1/0 serial bus problem Genius 0 block is not on the bus or not responding Invalid Gerius /0 point range Not one of GENIUS_OUTPUT/INPUT Not one of GENIUS_DIGITALJANALOG Genius 1/0 interface board network nome is unresolved Block number (serial bus address) is wal uf retige (0-81) ‘The Genius 1/0 interface card is not locked aut and unable to perform an unlock Unknown datagram command Invalid syntax tautt on datagram transmission Genius commend block statua ia IN_PROGREES for too long Fault processing Genius command Datagram is to0 long Number of packets has exceeded the maximum Command is not recognizedGEH-6334 Unit Controller 2000 Table 6-3, Runtime, Annunicated Non-fatal Faults ~ Continued Fault Number — i fdecima Namie Description, Procedure “24 BUFFER_BAD Destination buffer offset + 0 data len > shared memory, length 25 GENI_LOCK_NOT_READY Genius Inck is nat zer0; unavailable for lnckout eaquinst 26 SHMEM OPEN Unable to open Genius shared memory 27 ‘SHMEM_MMAP Unable to map to Genius shared memory 28 SEM_WAIT Unsuccessful semaphore wait call 29 thru 50 Spare Genius 1/0 errors 51 WNO_ID No target identification loaded 52 WNO_REV No revision record loaded a WNNU_VaR No var allocation record loaded 54 WFORCED Object ie foreod 55 WSIMULATED VO point is in simulation 56 WSIM_NOT_ENA Simulation is not enabled 87 WNV_FRC_REST NVRAM force list restoration problem 58 WNV_FRC_PROB NVRAM force list store or clear problem “82 WNOT_HEALTHY NO point not healthy Table 6-4. Runtime, Annunicated Fetal Faults Fault Number LED Code Name Fault Condition, Procedures (decimal) (hex) 5 33 EMEM INIT Fault configuring shared memory. Contact GE Drive Systems. 52 34 EDEV ‘The Peode file has not been configured for this device. 1. Verify that the device number in the Pcode is correct for this UC2000. Hf the device is correct, then download the Peode to permanent storage and restart to force 2 synchronization of device numbers. 53 35 EMsG_MEM Not enough memory to load the Peode file. ‘Add more physical memary to the UC2000 or move ‘functionality to another UC2000. o8Unit Controller 2000 GEH-6334 Table 6-4. Runtime, Annunicated Fatal Faults —Continued Fault Number ~LED Code Name Fault Condition, Procedures (decima)__thex) 54 36 EMSG_AD Fault reading message data. 55 37 ETYPE Invalid message type received from the tool.* 56 38 ESTYPE Invalid message subtype received from the tool.* 57 39° EFILE_OPN Fault opening the default Pcode file (UC2000 configuration wes not found) Download the Peode to permanent storage and restart if automatic startup is desired, 58 3A EFILEAD Fault reading the default Peode file. 1. Restart the UC2000. 2. Ifthe problem persists, download the Pcode to permanent storage and restart. 59 3B ECFG Invalid Peode file 1, Rebuild the Pcode with a compatible UC2000 tool and download. 2. If downloading online, verity that there is no major revision difference, 60. 3¢ ECG _LKD Configuration locked by another user. et 30 ENO_MEM (Out of system memory. Add more physical memory to the UC2000 ‘or mave functions to another UC2000. 62 SE ENO_SMEM (Out of shared memory. In the dialog box for modifying device parameters, select a larger ‘amount of system memory, rebuild, download Peode to permanent storage and restart the UC2000. 63 SF EREC_TYPE Unknown record type found in Pode file. 1. Verity that the UC2000 tool and runtime are compatible, 2 indicated by the two leftmost fields of their revisions being equal {tool vO1_15_03C is compatible with runtime vo1_15_02¢), 2. Rebuild and download. 4 40 ESYS_SEND Fault sending message to the system manager (sysi.* 65 41 EGEN_ERR General fault." 66 42 EBAD PTE Bad pointer received. * 67 43° EMEM_BLK Bad memory block encountered.* 68 44 ENO_TRUNC Not enough truncated memory. * "Contact GE Drive Systems & Turbine Controls 69GEH.6334 Unit Controller 2000 Table 6-4. Runtime, Annunicated Fatal Faults —Continued Fault Number LED Code Name Fault Condition, Procedures (decima _{hex) 68 45 ENO_ARRAY ‘Arrays not allowed in write command.” 70 48 EID_CHANGE Target device number change attempted by non-superuser. n 47 ESYS_CHANGE ‘System record change attempted by non-superuser 72 48 EPLOAD_REC Record not allowed in online download. Perform a full dawnload. Download cade to memory (restart code) 73 49 EFLOAD REC Record not allowed in full download. Download code to permanent storage and restart. a 48 EBAD_CONTXT Invalid context pointer received in multl-packer tool command.” ws 49 EFORCE_VAR Involid variable for forcing {non Boolean or invalid token).* 7 4c FI0_SPAWN Unable to spawn an 1/0 shared library. 1, Restart the UC2000. 2. Download product code and restart the UC2000. 7 4D E10_LOAD Fault loading UO record. 78 4E ESSMAP Fault creating Status_S (ss)map.* 19 4F — EBAD-DTYPE Invalid datatype.* 80 50 EDUP_REC Duplicate record found in load." 81 51 EDLPA_SPAWN Unable to spawn the Status_S VO driver (DLPAI. 1. Restart the UC2000. 2. Download product code end restart the UC2000. 82 52 FSSPAGE_CFG Unable to configure a Status_S page. 83 53 _EGENI_NETS Fault creating geni_nets.* co 84 —_EGENI_SPAWN Unable to spawn the Genius 1/0 driver {geni_drvt).. 1. Restart the UCZ000. 2. Download product code and restart the UC2000. 85 55 EFILE_WR, File waite fault." 86 56 ESS-REFSH Unable to configure a Status S refresh bit.* 87 57 ENO_GENI Missing Genius 1/0 hardware records.* 88 88 EBAD_GENI Bad Genius 1/0 bus inter fave card, *Contact GE Drive Systems & Turbine Controls G-10Unit Controller 2000 GEH-6334 Table 6-4. Runtime, Annunicated Fatal Faults Continued Are LED code Name ease (decimal) hex) a CO to eee Weta were psc athe madd. felt pete eter Download the code (including the appropriate product line library) and restart the UC2000, *Contact GE Drive Systems & Turbine Controls 611GEH-6334 Unit Controller 2000 Table 6-4. Runtime, Annunicated Fotal Faults —Continued Newnter LED Code Name Fault Condition, Procedures (decimal) sexy 10s 60 BADBLK Tava block sbeafies Dowload the code including the appropriate product line brary dnd restart the UC2000 110 8E__THREAD_ALIOG Ural fo lost enough marr forthe Moskva exciton treado.* m cr BPARAM Unable to rose a bok paramator.* 11270 MAXBO0L Too many Boaleans used.* 1137) MAXSHORT “Too many short integers used.* 11472 MAXLONG Too many long integers used.* 11873 MAXFLOAT Too many reas wsed.* 118 74 ~—-MAXDOUBLE-—=—Toormany doubles used. 778 MAXTINE Too many tine variables used.* 118-76 —BRANGE Boolean variables out of range.” 1877 onawoe hor integer veribl is out of ronge.* 17078 tRaNGE Long integer vaihin eat of rang * 12179 FRANGE Real vrable i out of range." 122 7A RANGE Double variable is out of renge.* 12378 TRANGE ‘Time vail is out of range. 126 7¢—_NoMoDs No modules were specified in the code Cina at Instone madule using the Toolbox 1257 CHART2INT Unable to attach tothe chart 2 inerupt handle.* 126 7E_—BGND_SPAWN Unable to spawn the background process (band. 1 nesta the UCz000. 2! Download product code and restart the UC2000. 1277 EXPIMMED Invalid datatype for parameter one of a rubber Hock.* 128 80 FIXUP Invalid bloc fp index. * 12981 BAD_MATH Invalid equation sting in matn engine Boek.” 120 62_—_Novane es apeiiad in code.* *Contact GE Drive Systems & Turbine ControlsUnit Controller 2000 GEH-6334 Table 6-4. Runtime, Annunicated Fatal Faults —Continued Meat ep coms Name ee (decimal) fren) fat es ano ]ors ec ard 139 8s amay rayne oof range. Rata teas ofthe any 198 67 BAD-BOOL inl emo sti Bolan enn Moo.* 136 Se BAD-ETRNG imate stg sin in cat to 137 68 BAD-CHOICE vad vetn on ack in i GA SS,SPAWN natin to pen tha Satu quting proce 2 8 BAD-PONT ——_ivald drape conversion scuid nan UO taneter oe i a oe iva are ld nd ockdetabae.* us a oe Iva vaib pci for tna Ms B4BADOLTVPE a0 toe acid 9 85 NOLSE.MAP Ula co atthe Stan, ap shared raery Verify that the topology of the system is correctly defined ‘and entered into the databace. Rebind, rebuild, and download the Peode. “Contact GE Drive Systems & Turbine Controls.77-6334 Unit Controtter 2000 Table 6-4, Runtime, Annunicated Fetal Faults —Continued Fault = Namibe LED code Nome Fault Condition, Procedures (decimal Shox 151 7 EVENT_ALLOG Unable to allocate enough memory for task events. 162 98 EVENT_CFIG Unable to configure an event.” 153 99 FGNO_TSK.MEM Exceeded the buffer space allocated for creating foreground threads.* 154 9A BGND_TSK MEM Exceeded the butfer space allocated for creating background threads.* 155 88 INIT_TSK_MEM Exceeded the buffer space allocated for creating initialization threads.* 156 ac OC_SRVR_SPAWN Unable to spawn the 062000 server process. 1, Restart the UC2000. 2. Download product code and restart the UC2000. 157 90 OC_SRVR_DIED Unexpected termination of the C2000 server process.* 158 9E (CLOCK INT Unable to attach to the clock interrupt.* 159 oF DYN_GAP_ATE Unable to resolve a device number into a Status_S drop number within a dynamic group block. Verify that the topology of the system is correctly defined and entered into the database. Rebind, rebuild, and download the Pcode, 160 AO NETTBL_ALLOC Unable to allocate the net table for diagnostics.” 161 ry NETLST_ALLOC Unable to allocate the net list for diagnostics.* 162 a2 ENO_ALARM_NET No Status_S network was designated as the default alarm network.” 163 AS INVALID_PTR Unable to resolve a variable pointer into a token. 164, Aa CHART_ONLINE Cannot create a new chert foreground process from an online download, Perform a full download. Download code to memory (restart code). 165 thru 255 Spare fault codes *Contact GE Drive Systems & Turbine ControlsUnit Controller 2000 (GEH-6334 CHAPTER 7 PARTS REPLACEMENT 7-1, INTRODUCTION This chapter provides instructions for replacing printed wiring boards in the UC2000. GE carefully tess all equipment before shipping, and does not expect equipment to fall under normal conditions. Most components never require repair or replacement. Disconnect all power supplies before performing any maintenanee, adjustments, servicing, parts replacements, or any other act requiring physical contact with electrical ‘working components or wiring of this equipment Circuit breakers, if supplied as part of the total system, may not disconnect all power to the equipment (see system elementary diagrams). Whether the ac voltage is. grounded or not, high voltage to ground may be present at many points. 7-2. REPLACING BOARDS, CAUTION To prevent component damage caused by static electricity, treat all boards with static sensitive handling techniques. Use a grounding strap when changing boards. Store boards in anti-static bags or boxes. Printed wiring boards may contain static-sensitive components, which must be considered when handling, and replacing a board. GE ships replacement boards in anti-static bags or hoxes. It is important that they be. stored and transported in these bags or boxes when not installed in the system. CAUTION ‘While power is applied to the unit, do not, remove or re-insert printed wiring boards or connections. This can damage the equipment. To replace a board: 1, Before replacing a board, ensure that the power is off. 2. Open the door of the UC2000 by loosening the top middle thumb screw on the outside of the door. NOTE Carefully disconnect all cables, as follows: For a ribbon cable, place one hand on each side of the cable connector that attaches to the board connector. Gently pull the cable connector with both hands. Do not pull by ribbon cable. For a cable with a pull tab, pull the ta For a screw terminal connector, loosen the screw at the top of each terminal and gently pull each wire free, On the replacement (new) board, set all jumpers, ‘POIs, and switches in the exact posirion as tose on the board being replaced. Ifa board revision has added or eliminated a voufiguiable component, of readjustment is needed, refer to the tables in Chapter 5, or the instructions provided with the replacement board NoTE Because of upgrades, boards of different revision levels may not contain identical hardware, However, GE Drive Systems & ‘Turbine Controls ensures compatibility of replacement hoards. aGEH-6334 7-2.1, UPSA Board Replacement To prevent electrical shock, turn off power to the unit and verify that there is no voltage between ACI and AC2. Replace the UPSA board as follows: 1. Open the door of the unit by loosening the top riddle thumb screw on the outside of the door. The UPSA board is attached to the door. 2. Disconnect connectors 2PLA, 2PLB, 2PLC, CCOM, FAPL, and ground wite ACI (ted) and AC2 (black). Refer to Figure 5-3. 3. Remove the six nuts that hold the board in place. 4, Install the new board, replace the nuts, and reconnect all cables, ensuring that they are properly seated at both ends. CAUTION To avoid damage to the board be sure the ground wires are reconnected correctly. ‘Connect the red wire into ACI and the black wire ito AC2. 7-2.2, WGENI and UCPB Daughterboard Replacement ‘The UCPB daughterboard is mounted on the UCIA motherboard. Therefore, itis recommended to replace the UCPB board as an assembly (UCIA/UCPB, part no. DS21SUCIAGAZZ0SA), described in section 7-2.3. However, if just the UCPB board needs replacing, use the following steps. Also, replace the HGENI — E TERS mam, FaARTSON] GREAT ESTATE cea00 FORT TW E oe ween] ON baseagsrs i TS sees E73 P| Figure 8-1. UC2000 Elementary Drawing 23642573 (Sheet 1 of 2) 82Unit Controller 2000 GEH-6334 WENBRANE SWITCH PANEL COPTIONAL> En al oul He fg— ro vers-coee eu GRITS ancl He me aul} to “ucia-2Pi Bra “vcimerix aye FAN wmf = oo em jeane PHY DSeO0UPSAGIA 2 {} BEE [a] Ge oe mo en wef} be dame : co vuresoer [fn FE es ilmecat= §) ac1[@ ner cuiner ceom se} foe — 3 8) ace] op—pxace cneurens lo 8 ; © TEATS, RRS] enn EERIE Ee ee] eens — Ma an SO T Sur ezono pext INO Figure 8-2. UC2000 Elementary Drawing 33643573 (Sheet 2 of 2)GEH-6334 Unit Controller 2000 DsenqunsaciAa (neTINNAl > - il o ° ° Le othr am UES oe ae le Po A Dse1Suerania se00ucrscaa FUSE naTa: Fe SCHURTER # OMF 63V TYPE F RATING; 2AMPS, 63V OR Eouty cpt ba 3 GENERA ELECTRIC [SEoagg ow BERT WO] ae a eee ae z d Figure B 9. UC2000 Hardware Drawing 39613671 (Shest 7 of 2) o4Unit Controller 2000 GEH-6334 Ds2ooursacia Ea FUSE DATA, Furs Fua, Fuay Fu3; BUSSMAN TYPE MDA~4 BUSSMAN TYPE AGC-3 BUSSMAN TYPE ABC-12 RATING; 4AMPS, 250V RATING) 3AKPS, 250 RATING; 120MPS, 250V SSC RATING; 200AMPS SSC RATING; I1D0AMPS SSC _RATING; 750AMPS OR EQUIV. OR EQUIV. OR EQUIV DS200nAHAGIA em] semen] paces EE) PT E Tai a we Figure 8-4. UC2000 Hardware Drawing 33643571 (Sheet 2 of 2)Unit Controller 2000 GEH-6334 APPENDIX C e WARRANTY PARTS AND SERVICE C-1, WARRANTY TERMS ‘The GE Drive Systems Terms and Conditions procure details product warranty information, including the warranty period and parts and service coverage. ‘The brochure is included with the customer documentation. It may also be obtained separately from the nearest GE Sales Office or authorized GE Sales Representative. C-2. OBTAINING PARTS AND SERVICE UNDER WARRANTY To obtain warranty replacement parts or service assistance contact the nearest GE Service Office. lease have the following information ready 10 exactly {identify the part and application: + GE requisition number located on the inside door cover of the UC2000 + Part number and description cATe: "a sre ry To oo @ Reader Comments Er ae The nea eve cee) a Salen, VA 24153-8682 USA We welcome comments and suggestions to make this publication more useful. fame “aephne ne Campa ane Fax lonber adios Sie Le ‘Se Region Ma Prbleaton a Isueison Date Tedevs Dae GENERAL COMMENTS Exeellent Good Fair Poor Contents ° ° ° ° Drgantation ° ° ° e Tecinical accuracy ° ° ° ° Carty ° ° ° ° Completeness ° ° ° ° Drawings, figures, and tables. =O ° ° ° Referencing and tables of contents ° ° ° Readsbiity ° ° ° ° SPECIFIC COMMENTS {Corectios, information that could be expanded, and soon) Page Number Comment (Other suagestions for improving this publication: ‘As compared to publications from other manufacturers of similar products, how woul you rate this document? © Superior (© Comparable (© Interior © Do not know Incicat the type ot userreadertunction that best describes your © System Integrator © oem © Installation © Programmer (© Maintenance © Operator Other (please specifysave FU er dls with Pice stamp are Industrial Systems— Drive Systems & Turbine Controls General Electric Company Technical Publications, Room 191 1501 Rosnoke Blvd. Salem, VA 24153-6492 USA vnennen HEME@ GE Industrial Control Systems Tesue Date: October 1997 General Electric Company (© 1997 by General Elecyic Company, USA. Industral Systems Allright reserved 1601 Roanoke Blvd. Solem VA 24153-6482 USA