Excitatriz AMIGE Cemento 2

GEH-5834
Instructions
AC/DC2000
Digital Adjustable
Speed Drive
Users Manual
Supplement 1
to GEH-5834
GE Drive Systems
AMBIENT CONDITION REQUIREMENTS
FOR MARINE AND OILWELL DRILLING DRIVES
AC/DC2000 DIGITAL ADJUSTABLE SPEED DRIVES
PURPOSE OF THIS SUPPLEMENT
This supplement contains ambient condition requirements specific to AC/DC2000 drives used in marine and
oilwell drilling applications.
WHEN TO USE THIS SUPPLEMENT
When the drive application is for marine or oilwell drilling, use this supplement to replace the ambient
condition guidelines provided in section 3-2 of instruction manual GEH-5834, AC/DC2000 Digital Adjustable
Speed Drive Users Manual.
AMBIENT CONDITION REQUIREMENTS
Ambient temperature range: 0 C - 50 C (32 F - 122 F)
Maximum relative humidity: 95 % non-condensing
Maximum ambient operating temperature: 50 C (122 F)
Temperature and humidity conditions, including relative rates of change, should be controlled so that there is
no moisture condensation in or on the equipment.
The ambient temperature in which the equipment is required to operate must be listed in the customer
specification.
Supplement 1 to GEH-5834 Ambient Condition Requirements for Marine and Oilwell Drilling Drives
Notes:
GE Drive Systems
General Electric Company
1501 Rcwnake Boulevard
Salem, Ilirginia 24 153
Issue Date: March 1995 @ 1995 by General Electric Company, US A.
All rights reserved
Printed in the United States of America.
GE Drive Systems
ERRATA
FOR INSTRUCTION MANUAL GEH-5834
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possibk contingency to be
met during installation, operation, and maintenance. Should firther information be desired or should particular problems arise that
are not covered suf&iently for the purchasers purpose, the matter should be referred to GE Drive Systems, Salem, Virginia U.S.A.
This sheet contains errata (errors) found in GEH-5834, the AC/DC2000 Digital Adjustable Speed Drive Users Manual
after the manual was published.
Please note these errors and mark the corrections in this copy of GEH-5834.
e
Page 4-5, paragraph 4-5.1.3. names the DC1 board. This board should instead be the MCP board, which is the
AC2000 drives power supply board.
0 Page 4-14, Figure 4-4, the title should identify this as DC2000 drive, not an AC2000 drive.
l Page 6-17, Table 6-21, the title should read I/O Between RTB Board and LTB. (The LCC board does not
have an OPTPL connector.)
(02/10/93)
Sheet 1 of 1
SUPPLEMENT2 to
GEH-5834
GE Motors &
Industrial Systems
These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met dur-
ing installation, operation, and maintenance. Iffurther information is desired or ifparticularproblems arise that are not covered suffi-
ciently for the purchasers purpose, the matter should be referred to GE Motors & Industrial Systems
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, operation, 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 Motors & Industrial Systems
1 Please replace Chapter 2 (Receiving, Handling and Storage) in its entirety with publication GE&100228
2 Please use the following table for acoustic information
ACOUSTIC NOISE LEVELS - C / CX FRAMES
SUPPLEMENT3 to
GEH-5834
GE Motors &
hdustrial Sys terns
These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met during
installation, operation, and maintenance Iffurther information is desired or tfparticular problems arise that are not covered sufficiently for
the purchasers purpose, the matter should be referred to GE Motors & Industrial Systems
This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that
whole or in part nor shall its contents be disclosed to any thirdparty without the written approval of GE Motors & Industrial Systems
1, Please use the following table for acoustic information*
86 dBP
fan
I I I
73 dBA 73 dBA
---_______
GEL1 00228
GE Motors &
Industrial Systems
RECEIVING AND STORAGE INSTRUCTIONS
FOR DIRECTO-MATIC@ 2000 EQUIPMENT
These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met dur-
ing installation, operation, and maintenance Iffurther information is desired or lfparticular problems arise that are not covered suffi-
ciently for the purchaser s purpose, the matter should be referred to GE Motors & Industrial Systems
This document contains proprietary information of General Electric Company, USA and isfurnished to its customer solely to assist that
whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Motors & Industrial Systems
CONTENTS
Safety Symbol Legend .................................................... 1
Overview .......................................................................... 1
Receiving Guidelines.. .................................................... .l
Handling Guidelines ....................................................... 2
Storage Guidelines ......................................................... .3
Warranty Parts and Service .......................................... 4
SAFETY SYMBOL LEGEND
Indicates a procedure, practice,
condition, or statement that, if
not strictly observed, could re-
sult in personal injury or death
Indicates a procedure, practice,
condition, or statement that, if
not strictly observed, could re-
sult in damage to or destruction
of equipment
NOTE Indicates an essential or important procedure,
practice, condition, or statement
OVERVIEW
This document contains guidelines and precautions for
handling and storing DIRECTO-MATIC@ 2000 equip-
ment upon receipt from a carrier This document also
contains information for obtaining warranty parts and
service.
Before handling or storing equipment, consult and study
all applicable drawings and instructions
For assistance, contact
Product Service .Engineering
150 1 Roanoke Blvd.
Salem, VA 24153-6492 USA
Phone 001-540-387-7595
Fax 001-540-387-8606
RECEIVING GUIDELINES
General Electric Company (GE) carefully inspects and
packs all equipment before shipping it from the factory
GE attaches a packing list, which itemizes the contents of
each package, to the side of each case of the equipment
GE provides handling guidelines to the carrier These
direct the carrier not to expose the shipment to excess
moisture or humidity, extreme temperatures, excess tem-
perature changes, or rough handling during transporta-
tion
GEI-100228 Receiving and Storage Instructions for DIRECTO-MATIC@ 2000 Equipment
Upon receiving a shipment, the customer should.
1 Conduct a visual inspection before or during the
offloading
2 Move the shipment to shelter
3 Conduct a thorough inspection of the shipment
Refer to Receiving Guidelines, Handling Guidelines, and
Storage Guidelines below
OFFLOADING
Immediately upon receipt of any equipment, conduct a
visual inspection for signs of rough handling or shipping
damage Conduct this initial inspection before the ship-
ment is offloaded. If damage is noted, immediately notify
the carrier before they leave the reception site
Notify the carrier that a thorough inspection was not con-
ducted upon the receipt of the shipment. A thorough in-
spection occurs after storage and unpacking
Refer to Moving and Lifting and Damage Notification
below.
SHELTERING
Potential for damage to equipment exists.
Packing cases are not suitable for outdoor
storage, even for short periods of time.
Immediately after the offloading visual inspection, place
the equipment under adequate cover to protect it from
adverse conditions
NOTE
Failure to protect equipment from adverse
conditions will void the equipment warranty.
Refer to Handling Guidelines and Storage Guidelines
below
INSPECTING
After moving the equipment to shelter, check the contents
of each package against the packing list Check for
.
Shortage
l Damage sustained while enroute
Refer to Receiving Guidelines, Handling Guidelines, and
Storage Guidelines below
If damage or rough handling is evident, notify the carrier
and GE immediately
The carrier or GE may require the following information
.
GE requisition number
.
Case number
.
Equipment serial number
.
Part (model) number
.
Damaged part (model) name and description
HANDLING GUIDELINES
Rough handling can damage electrical equip-
ment. To prevent such damage when moving
the equipment, be sure to observe normal
precautions along with all handling instruc-
tions printed on the case.
MOVING AND LIFTING
When handling equipment:
l Refer to equipment outline drawings for preferred
methods of lifting and moving equipment
l Observe the equipments center-of-gravity to ensure
that equipment does not fall
UNPACKING
Consider the following when unpacking a shipment
l If the equipment has been exposed to low tempera-
hu-es for an extended period, do not unpack it until it
has reached room temperature
2
Receiving and Storage Guidelines for DIRECTO-MATIC@ 2000 Equipment
GEI-100228
It is good practice not to completely unpack the
equipment until it has been placed near its permanent
location or its storage location
Use standard unpacking tools to carefully remove
equipment from its container
Use care when unpacking to prevent marring or dam-
aging parts
Label each item when it is unpacked
Check the contents of each case against the packing
list. Report shortages to GE
Wipe off particles of packing materials or foreign
substances that may be lodged in or between the
parts
Use caution to ensure that small parts (such as bolts
and screws) do not become separated
Carefully inspect packing material for loose parts
before discarding
STORAGE GUIDELINES
If the unit is not installed immediately upon receipt, it
must be stored properly to prevent corrosion and deterio-
ration Since packing cases do not protect the equipment
for outdoor storage, the customer must provide a clean,
dry place free of temperature variations, high humidity,
and dust.
SPECIFICATIONS
Use the following guidelines when storing equipment
. Place the equipment under adequate cover with the
following requirements
-
Keep the equipment clean and dry, protected
from precipitation and flooding
- Use only breathable (canvas type) covering ma-
terial - do not use plastic
Unpack the equipment as described in Unpacking
(page 4
l Maintain the following environment in the storage
enclosure-
-
Shipping and ambient storage temperature limits
are -25 C (-5 F) to 70 C (167 OF)
NOTE
These limits are guidelines to ensure a safe
storage environment for all equipment. How-
ever, some equipment can tolerate a wider
range. If the above temperature guidelines
cannot be met for your equipment, contact
GE to determine if different tolerances apply.
-
Surrounding air free of dust and corrosive ele-
ments, such as salt spray, or chemical and elec-
trically conductive contaminants.
-
Ambient relative humidity from 5 to 95% with
provisions to prevent corrosion
- No rodents
- Limit temperature variations that cause moisture
condensation on the equipment
CONDENSATION
Moisture on certain internal parts can cause
electrical failure.
Condensation occurs with temperature drops of
15 C (27 F) at 50% humidity over a 4-hour period
Condensation also occurs with smaller temperature varia-
tions at higher humidity
If the storage room temperature varies in such a way, in-
stall 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
To prevent fire hazard, remove all cartons
and other such flammable materials packed
inside units before energizing any heaters.
GEI-100228 Receiving and Storage Instructions for DIRECTO-MATICB 2000 Equipment
TIME LIMITATIONS
The above specifications apply to shipping and storage
durations of up to one year Longer times may require
additional treatment
WARRANTY PARTS AND SERVICE
WARRANTY TERMS
The GE Terms and Conditions brochure provides product
warranty information, including the warranty period and
parts and service coverage
The brochure is included with the customer documenta-
tion. It may also be obtained separately from the nearest
GE Sales Office or authorized GE Sales Representative
OBTAINING PARTS AND SERVICE
To obtain warranty replacement parts or service assis-
tance, contact the nearest GE Service Office
Please have the following information ready to exactly
identify the part and the application-
* GE requisition number
.
Equipment serial number and model number
.
Part number and description
GE Motors &
industrial Systems
Industrial Systems
1501 Roanoke Blvd.
Issue Date October 1996
Salem, VA 24153-6492 USA
AC/DC2000
Digital Adjustable Speed Drive
Users Manual
GEH-5834
Issue Date: January 1992
This document contains proprietary information of General Electric Company, USA and is furnished to its customers
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.
These instructions do not purport to cover all details or variations in equipment, nor 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 purchasers purpose, the matter should be
referred to GE Drive Systems & Turbine Controls.
01992 by General Electric Company, USA
All rights reserved.
Printed in the United States of America.
AC/DC2000 Digital Adjustable Speed Drive GEH-5834
SAFETY SYMBOL LEGEND
WARNING
c
Commands attention to an operating procedure, practice, condition or statement, which, if not strictly
observed, could result in personal injury or death.
I
CAUTION
I
I I
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-5834
AC/DC2000 Digital Adjustable Speed Drive
WARNING
c
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. If
the test equipment cannot be grounded to the equipment under test, the test equipments 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.
I WARNING c
To prevent personal injury or equipment damage caused by equipment malfunction, only
adequately trained presons should modify any programmable machine.
b
GEH-5834
TABLE OF CONTENTS
Section/Subiect
CHAPTER 1. GENERAL INFORMATION
Page
l-l. Definition and Scope ................ l-l
l-2. Equipment Overview ................ l- 1
1-2.1. Communications Interfaces ........... l-l
l-2.2. Software Design .................. 1-2
l-2.3. Hardware Design .................. l-2
CHAPTER 2. RECEIVING, HANDLING, AND
STORAGE
2-1. Introduction ....................... 2-l
2-2. Receiving and Handling .............. 2-l
2-3. Storage .......................... 2-l
2-4. Unpacking ........................ 2-2
2-5. Time Limitations ................... 2-2
CHAPTER 3. INSTALLATION AND INITIAL
STARTUP
3-1. Introduction ....................... 3-1
3-2. Operating Environment ............... 3-1
3-3. Mounting ........................ 3-l
3-4. Cabling and Wiring ................. 3-l
3-4.1. AC Power Requirements ............. 3-2
3-4.2. Connections ..................... 3-2
3-4.2.1. Power Connections ............... 3-2
3-4.2.2. Control Connections .............. 3-2
3-4.3. Wiring Level Separations ............ 3-2
3-4.4. Spacing ........................ 3-3
3-4.5. Grounding ...................... 3-3
3-4.6. Commons ....................... 3-3
3-4.7. Suppression ..................... 3-3
3-5. Service and Parts Instruction ........... 3-3
3-6. Power-off Check ................... 3-3
3-6.1. Wiring and Circuit Checks ........... 3-3
3-6.2. Motor and Device Checks ........... 3-4
3-7. Power Application and Startup .......... 3-4
CHAPTER 4. DESCRIPTION OF OPERATION
4-l. Introduction ..................... 4-l
4-2. Drive Software Structure ............ 4-l
4-2.1. Block System ................... 4-l
4-2.2. Building Block Architecture ......... 4-l
4-2.3. Diagnostics .................... 4-1
4-2.4. Configuring Blocks ............... 4-2
4-3. Drive Hardware Structure ............ 4-2
4-3.1. Control Section ................. 4-2
4-3.2. Power Converter ................. 4-3
SectlonlSubiect Page
4-4. Controller Operation ............... 4-3
4-4.1. AC2000 Control ................. 4-3
4-4.2. DC2000 Control ................. 4-3
4-5. Power Converter Operation .......... 4-4
4-5.1. AC2000 Power Conversion ......... 4-4
4-5.1.1. AC Line Fuses (FUl - FU3) ....... 4-4
4-5.1.2. Reactors ..................... 4-4
4-5.1.3. Control Power Transformer (CPT) ... 4-5
4-5.1.4. Rectifier Modules (DMl, DM2, DM3) 4-5
4-5.1.5. Filter Capacitors (lC, 2C), Discharge
Resistor (R2) .................. 4-5
4-5.1.6. Charge Control SCR Module (SMl),
Resistor (Rl) .................. 4-5
4-5.1.7. Inverter Transistor Modules (TRl-TR6) 4-5
4-5.1.8. Shunts ...................... 4-5
4-5.1.9. Dynamic Braking Transistor Module
(TM7), Resistor (R3) ............. 4-5
4-5.2. DC2000 Power Conversion ......... 4-5
4-5.2.1. AC Line Fuses (FUl - FU3) ....... 4-5
4-5.2.2. Ferrite Core Assembly (Reactors) .... 4-6
4-5.2.3. Main Contactor (MA or MD) ...... 4-6
4-5.2.4. DC Line Fuse (FU4) ............. 4-6
4-5.2.5. Control Power Transformer (CPT) ... 4-6
4-5.2.6. Shunt (SH) ................... 4-6
4-5.2.7. Current Transformer Assembly (CT) . 4-6
4-6. Drive System Connection Drawings .... 4-6
CHAPTER 5. PRINTED WIRING BOARD
DESCRIPTIONS
5-l. Introduction ..................... 5-l
5-2. Board Identification ................ 5-l
5-3. AC/DC2OfMl Boards ................ 5-l
5-3.1. Drive Control Card (531X3OlDCC) ... 5-2
5-3.1.1. Drive Control Processor (DCP) ...... 5-2
5-3.1.2. Motor Control Processor (MCP) .... 5-2
5-3.1.3. Co-Motor Processor (CMP) ........ 5-3
5-3.1.4. Reset Circuitry ................. 5-3
5-3.2. Drive Terminal Board (531X305NTB) . 5-3
5-3.2.1. Power Supplies ................ 5-3
5-3.2.2. Encoder Interface ............... 5-3
5-3.2.3. RS-232C Interface .............. 5-3
5-3.2.4. Special Purpose RS-422 Interface .... 5-3
5-3.2.5. Relay Outputs ................. 5-3
5-3.2.6. Analog Tach and Reference Coarse
Scaling ...................... 5-4
5-3.2.7. Low Level Analog Inputs and Outputs 5-4
5-3.2.8. Digital Control Inputs ............ 5-4
5-3.3. Signal Processor Card (531X309SPC) . . 5-4
i
GEH-5834
TABLE OF CONTENTS - Continued
SectionBubiect Page
5-3.3.1. Encoder #l ................... 5-4
5-3.3.2. Encoder ti ................... 5-4
5-3.3.3. Analog Channel #l, SPl .......... 5-4
5-3.3.4. Analog Channel #2, SP2 .......... 5-4
5-3.3.5. RS-422 Channel ................ 5-4
5-3.4. LAN Communication Card
(531X306LCC) .................. 5-4
5-3.5. LAN I/O Terminal Board
(531X307LTB) .................. 5-5
5-3.5.1. Input Circuit .................. 5-5
5-3.5.2. Current Regulator ............... 5-5
5-3.5.3. Optocoupled Interface ............ 5-5
5-3.5.4. Output Circuit ................. 5-5
5-3.6. Relay Terminal Board (531X191RTB) . 5-5
5-4. AC2000 Printed Wiring Boards ........ 5-6
5-4.1. Power Supply Board (531X303MCP) . . 5-6
5-4.1.1. Power Supplies ................ 5-6
5-4.1.2. Feedbacks ................... 5-7
5-4.1.3. Soft Start Control ............... 5-7
5-4.1.4. Dynamic Braking (DB) Control ..... 5-7
5-4.1.5. AC Line Monitor Circuit .......... 5-8
5-4.1.6. Inverter Transistor Firing Control .... 5-8
5-4.1.7. Faults ....................... 5-8
5-4.2. Base Drive Board (531X304IBD) ..... 5-8
5-4.2.1. Isolated Current Feedback ......... 5-9
5-4.2.2. Motor Terminal Voltage Isolation ... 5-9
5-4.2.3. Base Drive Circuits ............. 5-9
5-4.3. Dual Tach Isolator Board (531X31 1DTI) 5-10
5-5. DC2000 Printed Wiring Boards ........ 5-10
5-5.1. Power Supply Board (531X302DCI) ... 5-10
5-5.1.1. Power Supplies ................ 5-10
5-5.1.2. Field Power Circuitry and Current VCO 5-11
5-5.1.3. Armature Voltage VCO .......... 5-l 1
5-5.1.4. Armature Current VCO and
Discontinuous Current Detector ..... 5-11
5-5.1.5. AC Line Zero-crossing, Magnitude,
and Phase Sequence ............. 5-11
5-5.1.6. AC Line Current Instrumentation .... 5-11
5-5.1.7. MA Pilot Relay ................ 5-11
5-5.1.8. Firing Pulse Generator Circuits ..... 5-l 1
5-5.1.9. Delayed Firing Power ............ 5-11
5-5.2. Power Connect Board (531X308PCS
531X122PCN, 531X121PCR, and
531X123PCH) .................. 5-12
5-5.3. High Horsepower Snubber Board
(53 1X3 1OSND) ................. 5-12
Section/Subiect
CHAPTER 6. I/O DEFINITIONS
Page
6-1. Introduction ..................... 6-l
6-2. Types of Connectors ............... 6-l
6-2.1. Plug-in Connectors ............... 6-1
6-2.2. Terminal Board Connections ........ 6-l
6-2.3. Stab Connectors (Stabs) ............ 6-l
6-3. LED Indicators ................... 6-1
6-4. DCC Board I/O ................... 6-2
6-5. DC1 Board I/O ................... 6-9
6-6. DTI Board I/O ................... 6-13
6-7. IBD Board I/O ................... 6-14
6-8. LCC Board I/O ................... 6-17
6-9. LTB Board I/O ................... 6-21
6-10. MCP Board I/O .................. 6-23
6-11. NTB/3TB Board I/O .............. 6-26
6-12. PC- Board I/O .................. 6-31
6-13. RTB Board I/O .................. 6-38
6-14. SND Board I/O .................. 640
6-15. SPC Board I/O .................. 642
6-16. Top of Drive .................... 644
CHAPTER 7. OPERATING THE PROGRAMMER
7-l. Introduction ..................... 7-1
7-2. Keypad ........................ 7-l
7-3. Display ........................ 7-l
7-4. Operating Modes .................. 7-l
7-4.1. Operate Mode .................. 7-2
7-4.1.1. Red Key Functions .............. 7-2
7-4.1.2. Black/Green Key Functions ........ 7-3
7-4.2. Parameter Mode ................. 7-3
7-4.2.1. Entering Parameter Mode ......... 7-3
7-4.2.2. Examining Parameters ........... 7-4
7-4.2.3. Changing Parameters ............ 7-4
7-4.2.4. Exiting Parameter Mode .......... 7-5
7-4.3. Diagnostic Mode ................ 7-5
7-4.3.1. Entering Diagnostic Mode ......... 7-5
7-4.3.2. Exiting Diagnostic Mode .......... 7-6
7-5. Drive Diagnostics ................. 7-6
7-5.1. Running the Diagnostic Tests ........ 7-6
7-5.2. Diagnostic Test Descriptions ........ 7-7
7-5.2.1. Test 3 - DVM Mode ............ 7-7
7-5.2.2. Tests 4 thru 9 - ARM V, ARM I,
FIELD I, SPEED, TORQ, HP ...... 7-7
7-5.2.3. Test 10 - Software Revision ....... 7-7
7-5.2.4. Test 11, 31 - Diagnostic Variable
Display ...................... 7-7
ii
TABLE OF CONTENTS - Continued
Section/Subject Page
7-5.2.5. Test 12 - Cell Test . . . . . . . . . . . . . . 7-8
7-5.2.6. Test 13 - Board Test . . . . . . . . . . . , 7-8
7-5.2.7. Test 14 - Curtent Regulator Tuneup . . 7-8
7-5.2.8. Test 15 - Speed Regulator Tuneup . . . 7-8
7-5.2.9. Test 16 - Field Regulator Tuneup . . . . 7-8
7-5.2.10. RAM Test - Examine/Modify RAM
Location Value . . . . . . . . . . . . . . . . 7-8
7-5.3. Tests DACl, DAC2, METl, and MET2 7-14
CHAPTER 8. PARTS REPLACEMENT
8-1. Introduction . . . . . . . . . . . . . . . . . . . . . 8-l
8-2. Replacing Boards . . . . . . . . . . . . . . . . . 8-l
8-3. Transistor and SCR Module Repair/Replace-
ment - AC2000 P and Q Frames, DC2000
C and G Frames . . . . . . . . . . . . . . . . . . 8-2
8-4. SCR Stack Assembly Repair/Replacement -
DC2000 D Frame . . . . . . . . . . . . . . . . . 8-2
8-4.1. Removing Right-hand SCR Stack
Assembly . . . . . . . . . . . . . . . . . . . . . 8-2
8-4.2. SCR Replacement Procedure . . . . . . . . 8-3
8-4.3. Replacing Right-hand Stack Assembly . 8-3
8-4.4. Removing Left-hand SCR Assembly . . . 8-4
8-5. SCR Stack Assembly Repair/Replacement -
DC2000 E Frame . . . . . . . . . . . . . . . . . 8-4
8-5.1. SCR Replacement . . . . . . . . . . . . . . . . 8-5
Section/Subiect Page
CHAPTER 9. SPARE AND RENEWAL PARTS
9-1. Introduction . . . . . . . . . . . . . . . . . . . . . 9-1
9-2. Custom Renewal Parts Listing . . . . . . . . 9-l
9-3. Ordering Renewal Parts . . . . . . . . . . . . . 9-1
9-4. Part Number Structure . . . . . . . . . . . . . . 9-1
9-4.1. Order-specific Assembly Part Numbers . 9-1
9-4.2. Common Assembly Part Numbers . . . . 9-2
9-4.3. Component Part Numbers . . . . . . . . . . 9-2
9-4.4. Board Part Numbers . . . . . . . . . . . . . . 9-2
9-5. AC/DC2000 Drive Parts Lists . . . . . . . . . 9-3
APPENDIX A. GLOSSARY OF TERMS
APPENDIX B. RECOMMENDED POWER STUD
WIRING
B-l. Introduction . . . . . . . . . , . . . . . . . . . . . B-l
APPENDIX C. WARRANTY PARTS AND SERVICE
C-l. Warranty Terms . . . . . . . . . . . . . . . . . . . C-l
C-2. Obtaining Parts and Service Under
warranty . . . . . . . . . . . . . . . . . . . . . . . . C-l
. . .
111
GEH-5834 AC/DC2000 Digital Adjustable Speed Drive
LIST OF FIGURES
FIGURE Page
4-1. AC2000 Drive Connection Diagram -
Q Frame,75 100, and 125 KVA
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 4-8
Q Frame, 75, 100, and 125 KVA
(Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . 4-9
P Frame, Dynamic Braking, 15
and 30 KVA (Sheet 1 of 2) . . . . . . . . . . 4-10
P Frame, Dynamic Braking, 15
and30KVA(Sheet2of2) . . . . . . . . . . 4-11
P Frame, Dynamic Braking,
60 KVA (Sheet 1 of 2) . . . . . . . . . . . . . . 4-12
P Frame,Dynamic Braking,
60 KVA (Sheet 2 of 2) . . . . . . . . . . . . . 4-13
D Frame, Super Bridge . . . . . . . . . . . . . 4-14
4-5. DC2000 Drive Connection Diagram -
D Frame . . . . . . . . . . . . . . . . . . . . . . . 4-15
D Frame . . . . . . . . . . . . . . . . . . . . . . . 4-16
D Frame, Regenerative Controller . . . . . . 4-17
D Frame, Non-regenerative Controller . . . 4-18
E Frame, Power Conversion,
Single Bridge . . . . . . . . . . . . . . . . . . . . 4-19
E Frame . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-l 1. DC2000 Drive Connection Diagram -
E Frame, Power Conversion, High HP,
Full-wave Generation . . . . . . . . . . . . . . 4-21
4-12. DC2000 Drive Connection Diagram - G
& C Frames, Regenerative Controller . . 4-22
G & C Frames, Regenerative Controller,
Common Transformer Application . . . . . 4-23
FIGURE Page
G & CFrames, Non-regenerative
Controller ..................... 4-24
G & C Frames, Non-regenerative
Controller ..................... 4-25
5-l. AC/DC2000 Drive Board Location
Drawing ........................ 5-l
5-2. Board Connect Diagram for AC2000
Drive with LCC DLAN Connection .... 5-13
5-3. Board Connect Diagram for AC2000
Drive with LCC DLAN+ (ARCNET)
Connection ...................... 5-14
5-3. Board Connect Diagram for DC2000
Drive with LCC DLAN Connection .... 5-15
5-4. Board Connect Diagram for DC2000
Drive with LCC DLAN+ (ARCNET)
Connection ...................... 5-16
6-l. DCC Board I/O Connectors .......... 6-8
6-2. DC1 Board I/O Connectors ........... 6-12
6-3. DTI Board I/O Connectors ........... 6-14
6-4. IBD Board I/O Connectors ........... 6-16
6-5. LCC Board I/O Connectors - DLAN
Model ......................... 6-19
6-6. LCC Board I/O Connectors - DLAN+
(ARCNET) Model ................ 6-20
6-7. LTB Board I/O Connectors .......... 6-22
6-8. MCP Board I/O Connectors .......... 6-25
6-9. NTB Board I/O Connectors .......... 6-30
6-10. PCH Board I/O Connectors .......... 6-34
6-11. PCN Board I/O Connectors .......... 6-35
6-12. PCR Board I/O Connectors .......... 6-36
6-13. PCS Board I/O Connectors .......... 6-37
6-14. RTB Board I/O Connectors .......... 6-39
6- 15. SND Board I/O Connectors ......... 6-41
6-16. SPC Board I/O Connectors .......... 6-43
7-l. Changing Modes of Operation ........ 7-3
iv
LIST OF TABLES
TABLE Paae TABLE
4-l.
4-2.
4-3.
4-4.
5-l.
5-2.
6-l.
6-2.
6-3.
6-4.
6-5.
6-6.
6-7.
6-8.
6-9.
6-10.
6-11.
6-12.
6-13.
6-14.
6-15.
6-16.
6-17.
AC2000 Frame Size Specifications . . . . .
DC2000 Frame Size Specifications . . . . .
Transformers Per Controller Size . . . . . .
AC/DC2000 Drive Connection Diagrams .
RTB Board Ratings . . . . . . . . . . . . . . . .
DC2000 Drive Power Connect Boards . . ,
Connector lPL, I/O Between DCC Board
utd MCP Board (AC2000) . . . . . . . . . . .
Connector lPL, I/O Between DCC Board
md DC1 Board (DC2000) . . . . . . . . . . . .
Connector 2PL, I/O Between Power
Supply Board (MCP for AC2000,
DC1 for DC2000) And DCC and NTB
Boards . . . . . . . . . . . . . . . . . . . . . . . . .
Connector 3PL, DCC Board Output to LCC
Board (AC/DC2000) . . . . . . . . . . . . . . .
Connector 6PL, I/O Between DCC
Board and NTB Board (AC/DC2ooO) . . .
Connector 7PL, I/O Between DCC Board
and SPC Board (AC/DC2000) . . . . . . . .
and NTB Board (AC/DC2000) . . . . . . . .
and LCC Board (AC/DC2000) . . . . . . . .
LEDs on DCC Board . . . . . . . . . . . . . . .
Connector lCPL, Input to DC1 (DC2000)
Board from Current Transformer . . . . . .
Connector CPTPL, Input to Power Supply
Board (DC1 Board for DC2000, MCP
Board for AC2OOO) From Control
Power Transformer (CPT) . . . . . . . . . . .
Connectors CNPL, DRPL, FAPL, FCPL,
and FSPL, I/O Between DC1 Board
(DC2OCO) and Components . . . . . . . . . .
Connector 4PL, Output from DC1 Board
(DC2OCCl) or MCP Board (AC2000)
ToBoard . . . . . . . . . . . . . . . . . . . . . .
Connectors 5PL & SAPL, I/O Between
DC1 Board and PCH, PCN, PCR, or PCS
Boards (DC2000) . . . . . . . . . . . . . . . . .
Connector TB, I/O Between DTI Board
and External Connections (AC2000) . . .
Connectors APL, BPL, and CPL, I/O
Between IBD Board and Phase A , B,
and C Shunts, and Upper and Lower
Transistors (AC2000) . . . . . . . . . . . . . .
Connector BDCPL, I/O Between IBD
Board and MCP Board (AC2000) . . . . .
4-2
4-2
4-4
4-7
5-5
5-12
6-2
6-3
6-4
6-4
6-5
6-6
6-7
6-7
6-8
6-9
6-9
6-10
6-10
6-11
6-13
6-14
6-15
6-18.
6-19.
6-20.
6-21.
6-22.
6-23.
6-24.
6-25.
6-26.
6-27.
6-28.
6-29.
6-30.
6-31.
6-32.
6-33.
6-34.
6-35.
6-36.
6-37.
6-38.
Connector BDPPL, I/O Between IBD
Board and MCP Board (AC2OOO) . . . . .
Connector IOPL, I/O Between LCC
and LTB Boards (ACJDC2000) . . . . . . .
Connector LANPL, I/O Between LCC
Board and External Connections
(AWC2000) . . . . . . . . . . . . . . . . . . .
Connector OPTPL, I/O Between LCC
Board and LTB (AC/DC2000) . . . . . . . .
Connector ARCPL, I/O Between LCC
Board and DS200 ACNA (AGDC2000)
Connector KPPL, I/O Between LCC
Board and Keypad (AC/DC2OCO) . . . . .
Connector 2PL, I/O Between LCC Board
and Power Supply Board (AC/DC2000) .
Connector RPL, I/O Between LTB Board
and RTB Board (AC/DC2000) . . . . . . .
Connectors OTl thru OT7, LTB Board
Connection from Form C Relay Contacts
(AWC2000) . . . . . . . . . . . . . . . . . . .
Connectors IN1 thru IN8 Input to LTB
Board (AC/DC2000) . . . . . . . . . . . . . .
LEDs on LTB Board . . . . . . . . . . . . . .
Connectors 1FAPL and 2FAPL, Output
from MCP Board (AC2000) to Controller
Cooling Fans (If Used) . . . . . . . . . . . . .
Connector CCPL, Output from MCP
Board to Soft Start SCR (AC2000) . . . .
Connector DBPL, Output from MCP
Board to Dynamic Braking (DB)
Transistor (AC2000) . . . . . . . . . . . . . .
Connector CNTB, I/O Between MCP Boar
and External Connections via 2TB
(AC2000) . . . . . . . . . . . . . . . . . . . . . .
Stabs for MCP Board . . . . . . . . . . . . . .
LEDs on MCP Board . . . . . . . . . . . . . .
Connector COMPL, RS-232C I/O
Between NTB Board and User
Interface (AC/DC2000) . . . . . . . . . . . .
Connector 3TB, I/O Between NTB Board
and External Connections (ACYDC2000) .
Connectors 1FPL thru IRPL, I/O
Between PCN, PCR, or PCS Boards
and SCRs (DC20) . . . . . . . . . . . . . .
Connectors SFAPL & SFBPL, Output
from PCH Board (DC200) . . . . . . . . .
6-16
6-17
6-17
6-17
6-18
6-18
6-18
6-21
6-21
6-22
6-22
6-23
6-23
6-23
d
6-24
6-24
6-24
6-26
6-27
6-31
6-31
LIST OF TABLES - Continued
Table Pafle
6-39. Connectors SRAPL hz SRBPL, Output
from PCH Board (DC2000) . . . . . . . . . 6-31
6-40. Connectors FSAPL and FSBPL, Input
to PCH Board (DC2000) . . . . . . . . . . . 6-32
6-41. Connectors 1PL thru 6PL and 11PL thru
16PL, Output from PCH Board (TX2000) 6-32
6-42. PCH, PCN, PCR, PCS Board Stab . . . . . 6-32
6-43. Connection Options for PCR Board Stabs 6-33
6-44. Connection Options for PCS Board Stabs 6-33
6-45. PCN Board Stab Connection Options . . . 6-33
6-46, Connector RTB, I/O Between RTB and
External Connections (AC/DC2000) . . . . 6-38
6-47. LEDs on RTB Board . . . . . . . . . . . . . . 6-39
6-48. Connectors 1FSPL thru 6FSPL and
1RSPL thru 6RSPL, I/O Between SND
SND Board and SCRs (DC2000) . . . . . . 6-40
6-49. Stabs for SND Board . . . . . . . . . . . . . . 6-40
6-50. Connectors 16PL and lTB, I/O Between
SPC Board and External Connections
(AC/DC2000) . . . . . . . . . . . . . . . . . . . 6-42
6-5 1. Connector 2TB, Located on Top of Drive
(AUDC2000) . . . . . . . . . . . . . . . . . . . 6-44
7-l. Standard Diagnostic Test . . . . . . . . . . . . 7-7
7-2. RAM Addresses for Analog Signals . . . . 7-8
Table Page
7-3. Diagnostic Mode Analog Output Points . . 7-10
8-1. Transistor Module (AC2000) Mounting
and Connecting Torque Requirements . . . 8-2
8-2. SCR Module (AC2000) Mounting and
Connecting Torque Requirements . . . . . . 8-2
9-l. Printed Wiring Boards . . . . . . . . . . . . . . 9-3
9-2. Interconnection Cables . . . . . . . . . . . . . . 9-4
9-3. DC2000 Drive Subassemblies and
Components - C, D, E, and G Frames . . . 9-5
9-4. DC2000 Drive Horsepower-related
Components - C Frame, 230 V AC . . . . 9-6
Components - C Frame, 460 V AC . . . . 9-6
Components - G Frame, 230 V AC and
460VAC . . . . . . . . . . . . . . . . . . . . . . 9-7
Components - D Frame, 230 V AC and
460VAC . . . . . . . . . . . . . . . . . . . . . . 9-7
Components - D Frame, 575 V AC,
630 V DC and 700 V DC . . . . . . . . . . . 9-8
9-9. DC2000 Drive Leg Fuses - D Frame,
460V AC . . . . . . . . . . . . . . . . . . . . . . 9-8
vi
CHAPTER 1
GENERAL INFORMATION
l-l. DEFINITION AND SCOPE
This manual describes both the AC2000 and the DC2000
Digital Adjustable Speed Drives. These are micropro-
cessor-based power converters that produce controlled ac
output (AC2000) or dc output (DC2OOO) for customer
application.
This manual is intended to assist applications and mainte-
nance personnel in understanding the equipment hardware
and software. For adjustment, fault code, and troubleshoot-
ing information, refer to publications GEH-5835 (AC2000)
and GEH-5836 (DC2000).
This manual is organized as follows:
Chapter 1 - General Information
Briefly defines the AC/DC2000 drives with an
overview of the hardware and software design.
Chapter 2 - Receiving, Handling, and Storage
Provides guidelines for handling and storing the
AC/DC2000 drive upon receipt.
Chapter 3 - Installation and Initial Startup
Contains environmental, mounting, and electrical
guidelines for installing the AC/DC2000 drive,
including pre-startup checks.
Chapter 4 - Description of Operation
Describes the AC/DC2000 drive software and hard-
ware stmctnre, including overall drive operation.
Chapter 5 - Printed Wiring Board Descriptions
Describes the function and operation of boards within
the AC/DC2000 drive.
Chapter 6 - I/O Definitions
Lists and defines I/O connector points, stabs, and
LEDs for the AC/DC2000 drive.
Chapter 7 - Operating the Programmer
Describes how to use the Programmer, the
AC/DC2000 drive module included for making
software adjustments and for diagnostic testing.
Chapter 8 - Parts Replacement
Provides instructions for replacing printed wiring
boards, SCR modules, and transistor modules.
Chapter 9 - Spare and Renewal Parts
Contains ordering information for drive parts, includ-
ing part numbers.
Appendix A - Glossary of Terms
Defines acronyms and terms used in this manual.
Appendix B - Power Stud Wiring, Terminals, and
Crimping Tools
Lists tools and parts that GE recommends for instal-
ling and maintaining the AC/DC2000 drive.
Appendix C - Warranty Parts and Service
Explains procedures for obtaining warmnty informa-
tion and service.
Refer to the Table of Contents for the organization of
these chapters and appendices.
NOTE
The term AC/DC2000 is used to indicate
characteristics common to both the AC2000
and the DC2000 drives. If a characteristic
applies to only one type of drive, this manual
specifies either AC2000 or DC2000.
l-2. EQUIPMENT OVERVIEW
The AC/DC2000 drive uses a basic digital hardware
design with powerful application software capable of a
wide range of ac or dc output. The user interface consists
of a lo-character, alphanumeric display and a keypad for
simplified monitoring, diagnostics, and tuneup.
1-2.1. Communications Interfaces
The AC/DC2000 drive provides Local Area Network
(LAN) and RS-422 interfaces for external communication
options. RS-232C is used with the ST2000 Tools.
l-l
l-2.2. Software Design
The drive application program consists of functional
software modules (building blocks) combined to perform
to system requirements. Block definitions and configura-
tion parameters are stored in ROM (read-only memory),
while variables are stored in RAM (random-access
memory). Microcontrollers execute the code. See Chapter
4 for detail.
Tuneup and diagnostic software is transparent to the
user. A Programmer module with a digital display and
keypad allows an operator to request parameter values and
self-checks. See Chapter 7 for detail.
l-2.3. Hardware Design
The AC/DC2000 drive hardware consists of a control
section and a power converter section, described in
Chapter 4.
The controller includes printed wiring boards containing
programmable microprocessors with companion circuitry,
including EEPROM (electrically-erasable programmable
read-only memory). Additional boards provide optional
features.
The design varies only in the software used to process and
control output, and in the interface options. Chapter 5
describes the boards.
The drives power converter consists of bridge rectifiers,
resistor/capacitor configurations, and control circuitry. The
components and frame size vary for the ac and dc drives,
and for the power output required. Chapter 4 defines the
frame sizes.
1-2
CHAPTER 2
RECEIVING, HANDLING, AND STORAGE
2-1. INTRODUCTION
This chapter contains guidelines and precautions for
handling and storing the AC/DC2000 drive upon receipt
2-2. RECEIVING AND HANDLING
I
CAUTION
I I
Possible danger of damage to equipment.
Immediately upon receiving the drive, place it
under adequate cover to protect it from ad-
verse conditions. Packing cases are not suit-
able 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 ob-
serve normal precautions along with all han-
dling instructions printed on the case.
General Electric Company (GE) carefully inspects and
packs 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
moisture or humidity, extreme temperatures, excess
temperature changes, or rough handling.
Upon receipt, carefully examine the contents of each
shipment and check them with the packing list Immedi-
ately report any shortage, damage, or visual indication of
rough handling to the carrier Then notify both the
transportation company and GE Drive Systems Be sure to
include the serial number, part (model) number, drive
code, GE requisition number, and case number when
identifying the missing or damaged part.
If assistance is needed, contact
Industrial Systems-
Drive Systems & Turbine Controls
Product Service Engineering
1501 Roanoke Blvd
Salem, VA 241536492
Telephone 001-540-387-7595
Fax 001-540-387-8606
2-3. STORAGE
If the drive is not installed immediately upon receipt, it
must be stored properly to prevent corrosion and deteriori-
zation Since packing cases do not protect the equipment
for outdoor storage, the customer must store the equipment
in a suitable environment, per the following guidelines
1 Place the equipment under adequate cover with
the following requirements
a Keep the equipment clean and dry, protected
from precipitation and flooding.
b Use only breathable (canvas type) covering
material - do not use plastic.
2 Unpack the equipment as described in section 2-
4, and label it
3 Maintain the following environment in the stor-
age enclosure*
a Ambient storage temperature limits from -
20 C! (-4 F) to 55 C (131 F)
b Surrounding air free of dust and corrosive
elements, such as salt spray or chemical and
electrically conductive contaminants.
C Ambient relative humidity from 5 to 95%
with provisions to prevent condensation
d No rodents
2-l
e. Avoid temperature variations that cause
moisture condensation on the equipment
CAUTION
I
I J
Moisture on certain internal parts can cause
electrical failure.
Condensation occurs with temperature drops of 15 C (27
F) at 50% humidity over a 4-hour period, 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 watt lamp can
sometimes serve as a substitute source of heat
I I
1 CAUTION 1
I 1
To prevent fire hazard, remove all cartons
and other such flammable materials packed
inside units before energizing any heaters.
24. UNPACKING
It is good practice to not completely unpack the equipment
until it has been placed as near as possible to its perma-
nent 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 Sys-
tems.
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 bolts and screws) are packed in
special containers to keep them together However, they
may become separated For this reason, carefully inspect
packing material for loose parts before discarding it
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
2-2
GEH-5834
CHAPTER 3
INSTALLATION AND INITIAL STARTUP
3-1. INTRODUCTION
This chapter contains environmental, mounting, and
electrical guidelines for installing the AC/DC2000 drive.
It also includes basic circuit checks needed after instal-
lation and before the drive is started up.
Before starting installation, consult and study all furnished
drawings. These should include arrangement drawings,
connection diagrams, elementary diagrams, and a summary
of the equipment.
3-2. OPERATING ENVIRONMENT
AC/DC2000 drives are suited to most industrial environ-
ments. To ensure proper performance and normal opera-
tional life, the environment should be maintained as
follows:
Ambient temperature (acceptable): 0 C (32 OF) to
40 C (104 F)
Ambient temperature (preferred): 20 C (68 F) and
30 C (87 F)
NOTE
Higher ambient temperature decreases the life
expectancy of any electronic component.
Keeping ambient air in the preferred (cooler)
range should extend component life.
Relative humidity: Up to 90%
Environments that include excessive amounts of any of the
following elements reduce drive performance and life:
9 Dust, dirt, or foreign matter
. Vibration or shock
. Moisture or vapors
l Rapid temperature changes
. Caustic fumes
l Power line fluctuations
l Electromagnetic interference or noise intro-
duced by:
- Radio frequency signals, typically from
portable transmitters used near the equip-
ment or its wiring.
- Stray high voltage or high frequency signals,
typically produced by arc welders, unsup-
pressed relays, contactors, or brake coils
operating near drive control circuits.
3-3. MOUNTING
The system outline drawing (included with system docu-
mentation) contains the drive dimensions and mounting
diagrams.
Use the following mounting guidelines:
l Position an enclosed drive to permit heat radia-
tion from all surfaces.
l A wall-mounted drive may be mounted on any
firm, reasonably flat, vertical surface.
9 A wall-mounted enclosure may be placed side-
by-side with another enclosure.
l Provide front clearance of at least the width of
the enclosure door so that the door may be fully
opened for easy access.
3-4. CABLING AND WIRING
All installations should meet the requirements of both the
National Electrical Code and any applicable local codes.
Use these codes to determine such factors as wire size,
insulation type, conduit sizing, and enclosures.
3-l
Danger of electric shock or burn. Before
handling and connecting any power cables to
the equipment, make sure that all input power
is turned off. Then check voltage levels on the
wiring to ensure that it is not carrying haz-
ardous voltages.
3-4.1. AC Power Requirements
The AC/DC2000 drive is normally configured with the
following power requirements:
Voltage: 230 V ac or 460 V ac, +lO% and -5%
Phase: 3-phase
Nominal line frequency: 50 or 60 Hz with +2%
tolerance; (45 - 70 Hz are available)
Other input configurations are also available, but may
require special control and field power connections:
VoZtuge: 380 V ac and 575 V ac (DC2000 only),
+lO% V ac and -5% V ac; (special volts also avail-
able)
Nominal line frequency: 45 - 70 Hz
3-4.2. Connections
Cabling and wiring connections include:
l Incoming ac line connections
l Power connections to motor armature and motor
field
l All terminal board connections
When connecting any wiring/cabling, make sure that all
connections are tight.
Appendix B contains recommended power stud wiring,
terminals, and crimping tools.
3-4.2.1. POWER CONNECTIONS. (Refer to the elemen-
tary diagram.)
AC input power connects to:
9 The drive at Ll, L2, and L3 on the line side of
the ac fuses
l Or to the ac disconnect.
Motor connections are to:
l AC2000 drive terminals Tl, T2, and T3
l DC2000 drive terminals Al, A2, Fl, and F2
3-4.2.2. CONTROL CONNECTIONS. Control connec-
tions to the basic controller are made by wiring the Drive
Terminal Board (NTB/3TB). Chapter 6 defines the I/O
connections and includes figures to identify the connector.
For the LAN I/O Terminal Board (LTB), connect all I/O
to the LTBs screw terminals. The terminals are identified
by onboard labels (name and number).
The optional Relay Terminal Board (RTB) provides screw
terminal connections to the relays, as labelled on the
board.
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 three levels of wiring, which must be run in
separate conduits or wireways:
9 Signals (see system drawings to identify)
- Low level analog signals (commons, < 25 V
ac)
- Low level digital signals (< 25 V dc)
-
Speed and/or position sensor signals
- Power supplies and logic signals
l Control, ac or dc circuits (25 to 240 V)
GEH-5834
l Normal power output
- 2OOto6OOv
- Motor power leads, including fields
3-4.4. Spacing
The following requirements ensure correct distance
between cabling and wiring:
l Signal wiring and power wiring may cross at
right angles with a minimum l-inch separation.
. Avoid parallel runs between signal level wires
and power or control wires. If signal wires must
be run pamIle with control or power wires:
-
For distances up to 4 feet, maintain a mini-
mum separation of 3 inches.
- For distances over 4 feet, add l/4 inch of
additional spacing for every foot of addition-
al distance.
. Within pullboxes and junction boxes, use ground-
ed barriers to maintain the level separations.
3-4.5. Grounding
1. Ground the drive common (COM) at only one
point. If the reference is supplied by numerical
control or by a process instrument with a ground-
ed common, do not separately ground the drive
common.
2. If an isolation transformer is used and must be
grounded, use a high resistance ground.
3. For shielded and twisted shielded wire, ground
the shields on one end only, preferably at the
drive end. Provisions have been made to tie
shields to chassis ground at the drive I/O.
3-4.6. Commons
External commons, including reference and meter, can
only be connected at the NTB/3TB boards COM connec-
tion (3TB pin 66), unless otherwise indicated by the
system elementary diagrams.
3-4.7. Suppression
Electrical noise transients caused by control system relays,
solenoids, or brake coils can cause erratic drive behavior.
To prevent this, add a resistor/capacitor (RC) suppressor
in parallel with the 115 V ac coils of these devices. A
220 Q 2 W resistor in series with 0.5 pfd, 600 V capaci-
tor can be used.
3-5. SERVICE AND PARTS INSTRUCTION
Each drive contains instructions placed inside the door to
aid in connecting and troubleshooting the drive. These
instructions contain the following information:
l Board location
l Power module locations
l Fuse information and nomenclature
. Plug locations
. Incoming control connections at the NTB/3TB
board
l Power connections
3-6. POWER-OFF CHECK
All AC/DC2000 drive controllers are factory-tested and
operable when shipped to the installation site. However,
final checks should be made after installation before
starting the equipment.
Before initial powerup, check the drive using the steps
listed in sections 3-6.1. and 3-6.2.
3-6.1. Wiring and Circuit Checks
This equipment contains a potential hazard of
electrical shock or burn. Extremely high
voltages are present on some of the circuitry.
To prevent accidental injury from these volt-
ages, do not touch any circuitry without first
ensuring that it does not carry these voltages.
3-3
GEH-5834
1. Check that all incoming wiring agrees with the
elementary drawings supplied with the drive, and
is complete and correct.
2. Check that incoming power is the correct voltage
and frequency.
3. Make sure that the incoming wiring conforms to
approved wiring practices, as described previous-
ly (section 3-4).
4. Check that all electrical terminal connections are
tight.
5. Make sure that no wiring has been damaged or
frayed during installation. Replace if necessary.
6. If a current transformer circuit is not complete,
check that the shunt (used for shipping) is re-
moved.
7. With the drive disconnected from meggered
circuits, check for grounds in the armature or
field circuitry by meggering all terminals to
ground.
3-6.2. Motor and Device Checks
1. Check that the motor and options are correctly
installed and connected according to their device
instructions.
2. Check that the motor shaft is free to rotate.
3. Make sure that the motor and moving devices are
free to function.
4. Verify the motor and controller nameplate data.
a. Check that motor and controller voltages
match.
b. Check that motor current does not exceed
controller current.
C. Make sure that motor field current agrees
with data on the elementary diagram.
5. Check that all fuses are installed, are the right
size, and make firm contact in the fuse holder.
3-7. POWER APPLICATION AND STARTUP
After the previous power-off checks, complete the follow-
ing steps to check the drive with power on.
pi-,,,,,,,
Before any adjustments, servicing, or any
other act is performed requiring physical
contact with electrical working components or
wiring of this equipment, make sure all power
supplies are turned off. Then ground and
discharge the equipment.
1. Apply power to the drive.
2. If a 3-phase blower motor is used in the control-
ler and on the motor, check for correct rotation.
If incorrect:
a. Turn power off. Make sure that the circuit is
dead before touching it.
b. Interchange any two leads to the blower
motor.
C. Re-apply power and check for proper rota-
tion.
3. Check the display on the Programmer (described
in Chapter 7), for error indication:
a. If the controller starts up with no faults, the
Programmer indicates ready-to-run by dis-
playing M S 0% I % (Manual Mode) or A S
0% IO (Automatic Mode).
b. If a fault occurs at startup, the display blinks
and shows the fault name and number. (For
fault code definitions, see manual GEH-5835
for the AC2000 drive and GEH-5836 for the
DC2000 drive).
4. Using the elementary diagram, make sure that all
permissive, start, and stop circuits are functioning
correctly.
5. Call the assigned GE I&SE (Installation and
Service Engineering) office.
3-4
GEH-5834
NOTE
The complexity of the AC/DC2000 software
architecture requires that a trained specialist
conduct additional checks and startup using
the ST2000 Tools developed for that purpose.
3-5
3-6
CHAPTER 4
DESCRIPTION OF OPERATION
4-1. INTRODUCTION
This chapter descibes the AC/DC2000 drive software and
hardware structure, and overall operation. Chapter 5
describes printed wiring board operation in detail. When
reading these descriptions, refer to the drive connection
diagrams located at the end of this chapter.
4-2. DRIVE SOFTWARE STRUCTURE
The AC/DC2000 drive controllers store most configuration
data in EEPROM on the Drive Control Card (DCC). This
data is organized into 16-bit words, stored, and
checksummed. The DCCs Drive Control Processor (DCP)
controls memory access.
There are four major elements used in software configura-
tion:
. Generic interface to inner motor control loops
l Pointer-based selection of inputs to functional
modules
l Logical addressing of primary variables
l Use of functional building blocks for primary
regulator structures
4-2.1. Block System
The AC/DC2000 application software is a structure of
software modules that define data flow and function
execution. These modules are pre-defined blocks of code
that perform specific functions.
For example, there are simple blocks such as summing
junctions, and complex blocks such as speed regulators.
These functions are applied using the building block
architecture described below.
4-2.2. Bulldlng Block Architecture
The block programming scheme is an open architecture
programming method that combines pre-existing blocks of
code for a variety of applications. The drive is configured
from a library of functional blocks. They are then
connected by a mechanism that schedules and controls
their execution.
The AC/DC2000 drive stores programming data as
follows:
9 Block library (block definitions) in the Drive
Control Processor (DCP) ROM
. Block variables in RAM
l Block configuration parameters in EEPROM
The block is executed in a reserved portion of the DCP
foreground.
4-2.3. Diagnostics
The AC/DC2000 controller provides built-in diagnostics
for automatic selftest at powerup and for troubleshooting.
It tests circuitry down to the board level, generating
diagnostic messages. There are three ways to decode these
messages:
l Using the LED diagnostic readout on the DCC
(see publication GEH-5835 for the AC2000 drive,
GEH-5836 for the DC2000 drive)
l Using the Programmers alphanumeric readout
(see Chapter 7)
l Reading diagnostic messages over an optional
RS-232C communication link
An operator can examine and adjust operating parameters
stored in EEROM either of two ways: using the Program-
mer on the drives LCC board, or the ST2000 Toolkit (see
GEH-5860) on a serially-connected computer.
4-l
4-2.4. Configuring Blocks
A block source list is the program schedule. It defines
which blocks are to be executed and their rate and relative
order of execution. This list consists of a linear sequence
of source words stored in EEPROM.
The block compiler translates this source information into
a set of run lists. These lists point to run-time code and
data blocks. The block interpreter reads the run lists. It
uses a compact Next Block instruction sequence to thread
the execution of compiled blocks.
The ST2000 Toolkit displays the blocks as configured for
the particular application.
4-3. DRIVE HARDWARE STRUCTURE
The AC/DC2000 drive hardware consists of the control
section and the power converter section.
The control hardware is basically the same for the differ-
ent type drives (see section 4-3.1). The power conversion
hardware is defined by application requirements, and
therefore determines the drive frame size (see Tables 4-l
and 4-2).
4-3.1. Control Section
The control section (controller) is the drives brains.
It contains powerful programmable microprocessors with
companion circuitry, including EEPROM, to process the
application software.
Table 4- 1. AC2000 Frame Size Specifications
Frame
Size
P
Q
T
Typical Power Rating*
-icy-fF
60 I 460
300 460
l 150% current for 1 minute max., not to exceed rms hp
rating.
The controller includes the following printed wiring
boards:
Drive Control Card @CC), which contains
microprocessor circuitry
Drive I/O Terminal Board (NTB/3TB)
LAN/Communication Card (LCC), which in-
cludes the Programmer
Power Supply (MCP for AC2oo0, DC1 for
Dc2ooo)
Base Drive (IBD for AC2CKK9; Power Connect
(PC- for DC2000; see Table 5-2)
Dual Tach Interface (DTI, AC2000 - used
before DCC board revision AL.)
Optional boards include:
l Signal Processor Card (WC)
l Relay Terminal Board (RTB)
Sections 44.1 (AC2000) and 4-4.2 (DC2000) describe the
the drives overall control operation. Chapter 5 describes
the function and operation of the control sections printed
wiring boards.
Table 4-2. DC2000 Frame Size Specifications
Frame
Typical Power Rating*
4-2
4-3.2. Power Converter
The AC/DC2000 drives power converter includes bridge
rectifiers, resistor/capacitor designs, and control circuitry.
The components vary for the ac and dc drives, and for the
power output required.
Sections 4-5.1 (AC2000) and 4-5.2 (DC2CKKl) describe
these components and their operation.
4-4. CONTROLLER OPERATION
4-4.1. AC2000 Control
The AC2000 drive uses microprocessor regulation to
control output to 3-phase induction motors. It combines
programmable ac control, a full-wave diode bridge
rectifier, a pulse-width modulated transistor inverter, and
motor(s). Drive parameters are stored in an EEROM,
keeping them accurate and drift free.
Three-phase power is input through ac line fuses to a
full-wave diode bridge rectifier. Capacitors filter the dc
output.
A charge control circuit, located between the rectifier
bridge and filter capacitors, limits current inrush at
powerup. Power transistors, driven in a pulse-width
modulated (PWM) switching mode, invert the filtered dc
link voltage. This provides controlled 3-phase ac current
to the motor. The resulting output current is a sine wave
having a superimposed chopping frequency ripple.
The AC2000 controller uses a field angle control like the
field and armature control used with dc motors. Separate
interactive regulator loops provide speed, torque, flux, and
net motor current. The control senses voltage and current
feedback signals for all three phases. It digitizes and
integrates these signals to resolve both flux-producing and
torque-producing current vectors,
Torque, like armature current of a dc motor, is typically
regulated in response to the output of the speed regulator.
Flux magnitude is regulated according to the volts/Hz
rating of the motor. Like dc motor field current, flux may
be reduced to achieve the equivalent of field weakening
when operating above base speed.
Components of torque- and flux-producing current com-
mands are input to the current regulator. This determines
the net current vector needed to develop required torque.
In response to the current regulator output, the inverter
transistors base drive is modulated to produce the 3-phase
ac output needed to develop the net current vector.
4-4.2. DC2000 Control
The DC2000 drive provides microprocessor regulation for
dc motor control. It combines programmable dc drive
control with power circuitry. Drive parameters are stored
in EEROM, keeping them accurate and drift free.
Three-phase input power is fed through ac fuses, current
transformers, and the MA contactor (up to 300 hp). It
enters the power conversion SCR modules, which convert
it to adjustable dc voltage. The dc cnrrent is fed through
a shunt and a dc link fuse and an MD contactor (greater
than 300 hp) to the dc motor armature.
Motor field control (MFC) can be provided either of two
ways: by an internal 10 A maximum field supply, or by
optional external field supplies rated to 24 A or 72 A.
For the internal 10 A motor field control, the drives DC1
board contains field supply fuses (CFUl, CFU2, and
CFU3), metal oxide varistors (MOVs), a field current
feedback transformer (T3), and a line reactor (L4). The
field power module is mounted on the main controller
heatsink.
The external 24 A and 72 A motor field control includes
a separate heatsink with field supply fuses (CFUl-1,
CFUZ1, and CFU3-l), a line reactor (L4), a field power
module, and MFC suppression board containing the MOVs
and field current feedback transformer (Tl).
NOTE
The fuse and transformer designations are
different for the two MFC versions. Other
optional field controllers may be supplied.
Field power is supplied through fuses CFUl, CFU2, and
CFU3 (CFUl-1, CFUZ1, and CFU3-1 on the external
MFC). MOVs protect from line spikes and transients. The
power from the MFC is two-thirds wave rectified via
the field power module.
4-3
The SCR in the field power module controls field cur-
rent. The SCR fires when ac line Ll is high with respect
to L2 and L3. This passes current through the diode
between DX and DW to the motor field. The circuit is
completed through the SCR, and returns through the line
reactor to ac line L3.
When L2 becomes high, current flows through the diode
between DY and DW to the field. It returns through the
SCR and line reactor to L3.
When L3 becomes high, the SCR is reversed biased. The
energy stored in the field winding circulates current
through the diode between DZ and DW (acting as a
freewheeling diode) until Ll becomes high again and the
SCR is fired.
The current feedback transformer (Tl or T3 depending on
the MFC rating) senses field current. This current is fed
into the field gain select circuit on the DC1 Power Supply
Board and to the DCC Drive Control Card to control the
phase angle of the SCR firing.
Specialized field control packages may be supplied as
optional equipment.
The DC1 board provides output voltage through fuses
CPU4 and CFU to the control power transformer (CPT).
It connects to the CPT via terminals CPT Hl and CPT
H2. Onboard fuses CPU6 and CPU7 protect the internal
dc power supplies: CFIJ8 protects the internal 115 V ac
internal supply. These circuits are fed from the CPT
through DC1 I/O connector CPTPL.
The regenerative SCR power conversion bridge receives
3-phase power through ac line fuses PUl, FU2, and FU3.
Line-current transformers CT1 and CT3 provide a current
feedback signal for indicating commutation failure. The
MA contactor and reactors protect against ac line tran-
sients.
The Power Connect w-, see Table 5-2) board includes
RC snubber networks that protect the SCRs. The snubbers
connect across a forward/reverse SCR pair on regenerative
drives. The PC- board generates SCR firing pulses
through its onboard pulse transformers. They fire in the
order l-6-2-4-3-5 (positive phase sequence) for both
forward or reverse.
DC power is supplied to the armature through the shunt
and DAL It returns through DA2, which is fused for
standard drives. An RC network across Pl and DA2 aids
in latching the SCRs. The voltage feedback signal is
across the armature output; current feedback is derived
from the shunt. Some configurations include an optional
thermal switch mounted on the power semiconductor
heatsink(
4-5. POWER CONVERTER OPERATION
4-5.1. AC2000 Power Conversion
The paragraphs under this section (4-5.1.1 thru 4-5.1.9)
describe AC2ooO drive power converter circuitry.
4-5.1.1. AC LINE FUSES (FU1 - FU3). AC line fuses
protect the power semiconductors, internal wiring, and
output wiring from short circuits. Instantaneous and timed
overcurrent functions in control software also protect from
excess currents.
4-5.1.2. REACTORS. To limit short-circuit current at
the controller, the AC2000 drive may require series
reactors between the controller and its supply transformer.
These reactors should rate a series impedance of at least
2% of the base power unit impedance. The controller
requires a 3-phase reactor if the transformer feeding the
controller is larger than that listed in Table 4-3.
Table 4-3. Transformers Per Controller Size
Controller
Transformer
size (HP) Voltage Max. KVA
2to15 50
2oto30 100
40 to 60
460
200
75to 125 400
1 to 7.5 25
10to15 50
20to30
230
100
40 to 60 200
4-4
4-5.1.3. CONTROL POWER TRANSFORMER (CPT).
The CRT is energized through its primary fuses (CFU4
and CFU5) on the DC1 board. The secondary winding
provides two isolated voltages:
.
115 V ac to operate the RUN (Kl) relay, control-
ler cooling fans, and also some external control
devices
l 38 V ac (center-tapped) for the DC1 board to
generate the dc control voltages needed for
proper controller operation
4-5.1.4. RECTIFIER MODULES (DMl, DM2, DM3).
These three dual-diode modules make up a 3-phase, full-
wave bridge. This bridge rectifies the incoming ac supply
voltage to the dc link bus. These modules have electrical-
ly-isolated base plates and mount to the controllers
heatsink.
4-5.1 S. FILTER CAPACITORS (1 C, 2C), DISCHARGE
RESITOR (R2). These capacitors filter the dc link voltage
to provide a low impedance source for the fast-switching
inverter transistors. They also suppress ac supply line
transients.
They am electrolytic capacitors connected in a series/
parallel configuration to achieve the proper combination of
voltage rating and total capacitance. A single, center-
tapped resistor (R2) is used for series voltage matching
and capacitor discharge.
4-5.1.6. CHARGE CONTROL SCR MODULE (SMl),
RESISTOR (Rl). At powemp, the charge control resistor,
in series with the rectifier output to the dc link, limits the
charging current to the filter capacitors. After the capaci-
tors are initially charged, this SCR is gated and latched
on, providing a low impedance shunt around the resistor.
The SCR conducts until a dc link undervoltage occurs.
The DC1 board provides the SCR firing signal. The SCR
module has an electrically-isolated base plate that mounts
to the controllers heatsink.
4-5.1.7. INVERTER TRANSISTOR MODULES (TM1 -
TM6). The number of transistor modules used depends on
the drives current rating. Lower power drives use three
modules (TMl, TM2, and TM3), each with two transistors
and inverse connected power diodes. Higher power drives
require six modules (TM1 thm TM6), each with one
transistor and diode.
The transistors are the fast-switching type driven by the
Base Drive Board (IBD) to provide regulated pulse-width
modulated (PWM) control. The modules have electrically-
isolated base plates that mount to the controller heatsinks
common.
4-5.1.8. SHUNTS. Strip shunts in the controllers output
leads provide the motor current feedback signals to the
control circuits.
4-5.1.9. DYNAMIC BRAKING (DB) TRANSISTOR
MODULE (TM7), RESISTOR (R3). The optional DB
regeneration feature requires these transistors and an
externally-mounted resistor kit (R3). They dissipate the
energy that the motor regenerates to the dc link. Other
factors, such as a high ac line causing dc link voltage
pump up, may also cause the DB circuit to operate.
In applications where the DB Resistor Kit is
not rated for continuous operation, it is duty-
cycle rated per NEMA specifications. In those
applications, a continuously high ac input line
or a DB transistor failure that causes continu-
ous operation may damage equipment.
To prevent possible equipment damage caused by DB
failure with continuous operation, install a disconnect
device to the drive controller to deenergize the drive or
disconnect the DB resistor. An ac input starter or optional
DB contactor (DBC) may serve this function.
The DB transistor is driven in a pulse-width modulated
(PWM) mode with the ON and OFF times controlling the
regenerative discharge current through the DB resistor.
The transistor module has an electrically-isolated base
plate and mounts to the controllers heatsink.
4-5.2. DC2000 Power Conversion
The paragraphs under this section (4-5.2.1 thm 4-5.2.7)
describe AC2000 drive power converter circuitry.
4-5.2.1. AC LINE FUSES (FUl - FU3). AC line fuses
protect the power semiconductors, internal wiring, and
output wiring from short circuits. Instantaneous and timed
overcurrent functions in control software also protect from
excess current.
4-5
4-5.2.2. FERRITE CORE ASSEMBLY (REACTORS).
This reactor assembly is located on the ac power lines
between the ac line fuses and the SCRs. It protects the
SCRs from possible misoperation caused by transient
currents and voltages.
4-5.2.3. MAIN CONTACTOR (MA or MD). The MA
contactor (between the SCR and motor) provides a
controllable disconnect between the ac power line and the
power conversion bridge. The MD contactor provides a
disconnect in the dc armature circuit.
The contactor picks up when the running mode is
selected (see Programmer, Chapter 7) and no fault exists
in the drive. The contactor drops out under any of the
following conditions:
1. Coast Stop is initiated
2. STOP is selected and the motor slows to near
zero speed on regenerative drives
3. A fault condition occurs
4-5.2.4. DC LINE FUSE (FU4). This fuse is used in
regenerative drives only. It is located on the dc output line
to the motor armature, protects the SCRs and motor from
overcurrent sourced from the motor.
4-5.2.5. CONTROL POWER TRANSFORMER (CPT).
The CPT is energized through its primary fuses (CPU4
and CPU.5) on the DC1 board. The secondary winding
provides two isolated voltages:
.
115 V ac to operate the coil of the main (MA or
MD) contactor and controller cooling fan, if
required
l 38 V ac center-tapped for the DC1 board to
generate the dc control voltages necessary for
controller operation
4-5.2.6. SHUNT (SH). The shunt provides the armature
current feedback signal to the control circuit. A nominal
100 mV output signal is generated at the current rating
stamped on it.
4-5.2.7. CURRENT TRANSFORMER ASSEMBLY (CT).
The CT assembly provides ac line current feedback signals
used for circulating ac current fault detection.
4-6. DRIVE SYSTEM CONNECTION DRAWINGS
The remainder of this chapter contains drawings that show
connections for the AC/DC2000 drives listed in Table 4-4.
NOTE
Figures 4-1 thru 4-15 were produced from the
GE drawings referenced in Table 4-4, the GE
Drawing column.
4-6
Drive
AC2000
AC2000
AC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
DC2000
Frame
Q
P
P
D
D
D
D
D
E
E
E
G&C
G&C
G&C
G&C
Table 4-4. AC/DC2000 Drive Connection Drawings
Function/Application
75, 100, 125 WA
Dynamic braking, 15 & 30 kVA
Dynamic braking, 60 kVA
Super bridge
Regenerative controller
Non-regenerative controller
Power conversion, single bridge
High hp, full-wave generation,
power conversion
Regenerative controller
Regenerative controller,
common transformer application
Non-regenerative controller
Non-regenerative controller,
common transformer application
Figure GE Drawing
4-l 36C766741 AH
4-2 173C8433AC, sh 1
4-3 173C8433AC, sh. 2
4-4 36C766723CA
4-5 36C766724AD
4-6 36C766724AE
4-7 36C766724AF
4-8 36C766724AG
4-9 36C766623BA
4-10 36C766722AC
4-11 36C766723AA
4-12 36C766741AR, sh. 1
4-13 36C766741AR, sh. 2
4-14 36C766741AX, sh. 1
4-15 36C766741AX, sh. 2
NOTE
For board interconnections, see Figures 5-2 tbru 5-5.
4-7
GEH-5834
r
OPC -
II
KPPC
LCC CAR,
$Y
=-k
WL
7TE
DRIVE
SPC CN(D
/
I
I wrn
AC POWER
fl
SUPPLY CARD
FU6 A
I
I I\
I
AC BASE
DRIVER CARLl
I I I NVLA AD,
I
r
FU4
CLP3
-
FU5
P
e
lIcLP2
I I
CONTROL CAR0
.?PL l-y --y-l ZPL l-J OCLPI
A 1% ] IPL
ZFAPL
Em
OCPLZ
IFAPL OWL FUI
f
v
I
u I IRPL
IWL RPL 1
I TERMINAL BOARD RELAY CARD A
LAN TB CARD
OPTPL
A
OPTPL 1
000 00 000 no
, 1 ,d 1 ,d IIIq 1,
FANS
175HP ONLYI
NOTES
I CONNECTION NOMENCLATURE -
fl -STAtl ON 1 iLlI6 m -TERMINAL BOARD
2 COLOR COOEO WIRC -
CONTINUED ON
NEXT SHEET
R - RED. W - WHITE. R . BLUE. BLK - BLACK
3 SNUWER CARDS MOUNTED OVER
TRANSISTOR MOOULES
1 COMPONENTS MOVNltU ON UOOH
5 I33 REGEN. OPTION SHOWN DASHED IF DD
OPTION NOT FURNISHED. WlRE Cl
CONNECTED TO PI BUS
6 SEE 173C0433AB FOR OTHER CARDS
AN0 INTERCONNECTIONS A
Figure 4-1. AC2000 Drive Connection Diagram
- C! Frame, 75, 100, and 125 KVA
(Sheet 1 of 2)
4-8
TO AC SUPPLY TO AC MOTOR
, \ I \
3 PHE.E REACTOR
,IF RLOlREOl
1 I
IFOR I-50 HP OHLY,
L,- _ ~J .-. .-.---.
R4

I
L2~ CR COlTACTOR
P
-
/
--
l*
I
I
I
I
I
-I-
t
I
I
I
I
I
I
I
I
I
/
I
I
ZOTE
-
THSW -$-
c-7sy
2 I4
, I5
111
I7
15
19
-20
21
22
I.
\
Figure 4-l. AC2000 Drive Connection Diagram
- 0 Frame, 75, 100, and 125 KVA
(Sheet 2 of 2)
*CONTINUED FROM
PREVIOUS SHEET
4-9
GEH-5834
I - I
l-f-
I
-
1 1
m--d
I I l I I
I 1 I I
I I l I I
I
T
I 1 I I I
1 I
I
L-
Yr T!
3; L-31 t-3;
--I
I:, J
l!ik
I II
/
I
II
/
I
IU.
F&we 4-2. AC2000 Drive Connection Diagram - P Frame, Dynaniic Braking, 15 and 30 WA
(Sheet 7 of 2)
4-10
12
BPL
Bi
12
., .
CPL
:
I
Figure 4-2. AC2000 Drive Connection Diagram - P Frame, Dynamic Braking, 15 and 30 WA
(Sheet 2 of 2)
4-11
CEH-5834 AC/DC2000 Digital Adjustable Speed Drive
L3
L2
Ll
DB
lERliINAt
t!!TlOta
/
/
!I!!I!!I! irhi I
is---'
e--
TTJZJ
,----!
1-w .-
---_-___----
Fwm1lm jl*sN.
nimrEtAtnIbEb4
Fvl3Jvlin. jqrMdmlO.
mdmnstAbILBb4
----_----_--
Figure 4-3. AC2000 Drive Connection Diagram - P Frame, Dynamic Braking, 60 KVA
(Sheet 1 of 2)
4-12
E
tn
BPL
2
CPL
I
I
I. --
.I _--- ,
Figure 4-3. AC2000 Drive Connection Diagram - P-Frame, Dynamic Braking, 60 WA
(Sheet 2 of 2)
4-13
--- PLUG MTD
ON HEATSINK
TO PCCAR0
*
I
JT
i-
-
-
.
Ii
:73
-
-
-
-
-
-
-
-
KI KE K3
I
CURRENT
FETEOD%cK
RECTIFIER
ASSEMBLY
A-
SCRl2 SCRIS L6
FCL6 SCR3 SCR6
FCLS
/A- T
Ll3
=-xi!
Cl5
,OUF
SCRl6
FCLIS
L16
F&ure 4-4. AC2000 Drive Connection Diagram - D Frame, Super Bridge
4-14
CTI
LINE
FUSES
r,
TO BRANCH
CIRCUIT PROTECTION
L
L
L
--
PI
Id
Pi
I-
. ..-
I
r-
I..-
I
I
t--
I
I
r-
I
t-.-
I
I
:-
I
I
f
I
I
I
I
I
I
I
I
I
I
I
-gzJ
CT3
-a=iJ
R II
KI KZ K3
-8
______________ -------------------------------------,
TO POWER
4,
CoN~~C~,ARo-( f
-. ,.
TO SNUBBER
CAR0 AT PI
TO OAPL ON
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4-15
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- D Frame, Regenerative Controller
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4-19
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DC2000 Drive
Connection Diagram
- E Frame TO
4-20
GEH-5834
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F&e 4-11. DC2000 Drive Connection Diagram -
E Frame, Power Conversion, High HP, Full-wave Generation
4-21
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Figure 4- 14. DC2000 Drive
Connection Diagram - G and C Frames,
Non-regenerative Controller
4-24
Figure 4-15. DC2000 Drive
Connection Diagram - G and C Frames,
Non-regenerative Controller,
Common Transformer Application
I I
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4-26
AC/DC%KtO Digital Adjustable Speed Drive GEH-5834
CHAPTER 5
PRINTED WIRING BOARD DESCRIPTIONS
5-l. INTRODUCTION
This chapter describes the AC/DC2000 printed wiring
boards and their operation. Chapter 6 defines I/O connec-
tions for these boards, and provides layout diagrams
showing connector locations. Publications GEH-5834
(AC2OOO) and GEH-5835 (DC2000) contain jumper,
testpoint, and switch definitions.
Some boards are used in both the AC2000 and the
DC2000 drives; others are exclusive to either one or the
other. These categories are listed and defined below.
5-2. BOARD IDENTIFICATION
A printed wiring board is designated by an alphanumeric
part (catalog) number. For example, the Drive Control
Card is identified by part number 531X3OlDcCcrGl. The
531X301DCC portion is the base number that identifies a
printed wiring board, specifically the Drive Control Card.
The c digit can be A or B, depending on the configura-
tion; the r digit is an alphabetic character (for example, F
or G) that indicates the revision level.
All digits are important when ordering or replacing any
board. (See Chapter 9 for renewal parts information.)
NOTE
Card and board are both terms for printed
wiring boards. In this manual, board is the
preferred term. However, clud is used in some
drawings and when it is part of a boards pre-
established nomenclature - for example,
Drive Control Card @CC).
5-3. AC/DC2000 BOARDS
This section describes printed wiring boards used in both
the AC2000 and DC2000 drives. These include:
l Drive Control Card @CC)
l Drive Terminal Board (NTB/3TB)
l Signal Processor Card (WC) - Optional
l LAN Communications Card @CC)
. LAN I/O Terminal Board (LTB)
l Relay Terminal Board (RTB) - Optional
Figure 5-l shows board locations in the AC/DC2000
drive. Figures 5-2 thru 5-5, located at the end of this
chapter, are board interconnection diagrams.
IBD on AC2000; PC- (see Table 5-2) on DC2000
Power Supply - MCP on AC2000; DCI on DC2000
DCC
SPC
LCC
NTB/3TB*
LTB
RTB
*On some frame sizes, these boards
may be mounted side-by-side
Figure 5-7. AC/DC2000 Drive Board location Drawing
5-l
5-3.1. Drive Control Card (531X3DlDCC)
The Drive Control Card (DCC) contains the AC/DC2000
drives primary control circuitry. This includes 16-bit
microprocessors and associated circuits coupled via dual-
ported RAM.
NOTE
Dual-ported RAM (DPR) is RAM configured
as memory arrays that can be independently
and simultaneously accessed by two micropro-
cessors.
The DCC also contains general purpose interface circuitry
that connects with other boards to form various types of
ac and dc motor drives. This interface circuitry controls
and processes drive and motor signals, and customer I/O.
It also expands processing capability via external dual-
ported RAM.
The DCC includes three microprocessors:
186 . The Drive Control Processor (DCP), an 80C
microcontroller (Ul)
1% l The Motor Control Processor (MC?), an 80C
microcontroller (U21)
l The Co-motor Processor (CMP), a TMS32OClO
digital signal processor (U35)
The MCP communicates with the DCP and CMP through
dual-ported RAM. These processors are described below.
5-3.1.1. DRIVE CONTROL PROCESSOR (DCP). The
DCP is a 16-bit microcontroller with numerous built-in
peripheral functions, both digital and analog I/O. These
include address decoding for chip selects, wait-state
generators, an interrupt controller, timer/counters, and
direct memory access (DMA) controller. DCP software
consists of user interfaces, outer regulating loops (such as
speed and position), and system level functions.
Digital II0 Peripherals. On the DCP data bus, output
latches drive the 10 segment LEDs, six 24 V dc relay
drivers (for customer output), the loop contactor, three
general-purpose testpoints, the analog-to-digital (A/D)
converter, analog multiplexer, and an output to the SPC
board.
Input buffers bring in 12 general-purpose customer inputs
in the range of -24 to +24 V dc (biased to an inactive
state by the signal LBIAS from the NTB/3TB board).
Customer signals MSSY and TOIN provide direct general
purpose inputs to DCP internal interrupt and
timer/counter circuits. Timer/counter circuits are also
used to input the up/down pulse trains from encoder
interfaces on the Signal Processor Card (SPC) via 7PL.
Jumper adjustments can also direct the onboard MCP
encoder interface to the DCP.
Testpoint NMI is used to generate DCP nonmaskable
interrupt, which initiates an interactive board test. This
test performs internal selftests of DCP, MCP, and CMP,
strobes all board outputs, and displays all board inputs.
Analog Z/O Peripherals. The DCP circuitry provides four
&bit, digital-to-analog (D/A) outputs. These outputs range
from -10 to +lO V dc. Eight buffered analog inputs are
multiplexed into a lo-bit A/D converter.
Other circuits provide two high-resolution VCO inputs.
Each VCO circuit consists of a differential amplifier,
scaling potentiometer, biasing amplifier, and VCO. The
outputs of these VCOs go to two counter inputs. The
signal input to the feedback VCO is fed directly into DCP
interrupt or counter inputs to allow special applications,
such as digital tach feedback operation.
5-3.1.2. MOTOR CONTROL PROCESSOR (MCP). The
MCP is a &bit microcontroller with high-speed I/O,
conventional digital I/O, analog I/O, timer/counters, and a
watchdog timer. MCP software consists of inner loops
(such as current regulators), and motor/technology specific
functions (such as dc phase control, ac motion control, and
ac general purpose).
Memory. Writes to EPROM (U22 and U23) change the
active page. Each page contains the software required for
a particular ac or dc drive type. This enables this board to
be used with many drive applications without changing
EPROM.
Digifal IIO, High Speed IIO, and Analog Inputs. The
MCP contains several types of I/O, most buffered and
connected to 1PL for use in motor control. Included on
this connector are six lo-bit analog inputs, three high-
speed digital inputs, four high-speed outputs, ten general
purpose outputs, and one general purpose input.
Timer/Counters. Three timer/counter circuits provide nine
16-bit counters for MCP functions, primarily pulse train
generation.
Six of these counters receive clock inputs from the Power
Supply Board via connector 1PL. Of the six: two have
gate inputs and counter outputs available on 1PL; one can
5-2
GEH-5834
serve as a prescaler for a timer/counter input on the MCP,
two are used to count encoder up/down pulses; the final
two receives a fixed clock input and directs its output to
1PL.
5-3.1.3. CO-MOTOR PROCESSOR (CMP). The CMP
performs math-intensive functions to support motor control
algorithms beyond the MCPs capability. The board uses
this processor and its associated circuitry only when the
drive requires additional processing ability.
The CMP interfaces only to its EPROM and the
MCP/CMP dual-ported RAM. Onboard jumpers select
word blocks of program memory, allowing motor control
algorithms to be implemented with one EPROM.
5-3.1.4. RESET CIRCUITRY. The DCCs reset circuitry
consists of four logic invertem and their associated
circuitry, including a RESET pushbutton. A reset can be
generated four ways:
. By pressing the DCCs RESET button.
l By applying +5 to +24 V dc to the Drive Termi-
nal Boards (NTB/3TBs ) customer interface
point (6PL pin 30; 3TB pin 58).
l When the Power Supply Board produces an
HCMOS high level on the power supply monitor
pin (/PSEN, 2PL pin 9). This input ensures that
the DCC operates properly and protects the
EEROM during power-level fluctuations.
l The MCP generating a reset, one of two ways:
- Either by programmed software control
- Or by automatic internal hardware watchdog
protection, which pulls down its reset pin
(U21-16).
The DCC includes circuitry to prevent misoperation of the
MCP from holding the entire board in reset.
5-3.2. Drive Terminal Board (531X305NTB)
The Drive Terminal Board (NTB/3TB) contains the
customer connection terminals for most signal level I/O.
This board also includes most of the hardware customizing
jumpers and potentiometers required in the drive, along
with some passive interface circuitry.
The NT.B/3TB board connects to the DCC (Drive Control
Card) via 6PL and 8PL; to the Power Supply Board (DC1
for DC2000, MCP for AC2000) via 2PL and 4PL; and to
the customer/system via COMPL and terminal points.
The NTB/3TBs 3TB connector contains 90 terminal
board points in two rows of screw type terminals. They
are numbered sequentially, with odd numbers in the top
row and even numbers in the bottom row. These points
provide the following interfaces to the drive, primarily to
the DCC.
5-3.2.1. POWER SUPPLIES. The NTB/3TB provides
the following power output for external use:
l 300 mA each of regulated +5 V dc, +15 V dc,
-15 V dc
9 500 mA each of unregulated +24 V dc and -24 V
dc
9 Up to 0.5 A of 120 V ac
Baluns (line chokes) provide two noise-filtered power
supply outputs for driving digital encoders. Jumpers allow
distribution of the encoder loads among the +5 V dc and
515 V dc supplies to balance loading.
5-3.2.2. ENCODER INTERFACE. The NTB/3TB in-
cludes a differential A-quad-B encoder interface, including
a marker channel, that can be connected to the drive. This
circuit is optically isolated on the DCC. Jumpers on the
NTB/3TB select either 5 V or 15 V encoders.
5-3.2.3. RS-232C INTERFACE. Connector (COMPL)
provides an RS-232C serial link only for use with the
ST2000 Toolkit. (See GEH-5860 for information.)
5-3.2.4. SPECIAL PURPOSE RS-422 INTERFACE. This
board provides line termination resistors for a half-duplex,
RS-422 compatible, serial interface to the DCCs Motor
Control Processor.
5-3.2.5. RELAY OUTPUTS. This board provides the
following outputs from seven relays with a 120 V, 1 A
contact rating:
l Form C output from five relays controlled by the
DCC
l One form A output and one side of the coil from
a sixth relay controlled by the DCC
5-3
This enables the coil to be controlled by either
the DCC or a customer 24 V dc signal. It also
allows the DCC coil driver output to be accessed
directly by the customer for applications that
cannot tolerate the time delay associated with the
relay pickup.
. Two form C contacts and both sides of the coil
of a seventh relay, for general purpose use
A jumper allows this coil to be driven by either
24 V dc or 120 V ac
The NTB/3TB board also provides form C contacts from
the MA contactor pilot relay on the Power Supply Board.
These contacts are rated 120 V ac, 2 A.
5-3.2.6. ANALOG TACH AND REFERENCE COARSE
SCALING. The NTB/3TB includes switches that allow
coarse scaling of analog tach inputs (25 to 380 V) and of
analog references (9 to 29 V). The DCC board handles
fine scaling of these signals.
5-3.2.7. LOW LEVEL ANALOG I/O. The NTB/3TB
includes four potentiometers for scaling (5 to 50 V) lo-bit,
general purpose, medium resolution inputs to the DCC.
The NTB/3TB transfers two high resolution analog inputs
to the DCC, and receives four 8-bit, +lO volt analog
outputs from it. These outputs drive functions such as
other drives, analog meters, and diagnostics.
5-3.2.8. DIGITAL CONTROL INPUTS. Various control
inputs pass through the NTB/3TB to the DCC. These
include special purpose digital inputs, such as RESET and
CONTROL ON, and 12 general-purpose control inputs (up
to +24 V dc). Jumpers are included to bias unconnected
inputs to either +24 or -24 V, depending on whether
positive or negative interface logic is used.
5-3.3. Signal Processor Card (531X309SPC)
The optional Signal Processor Card (SPC) performs three
basic drive functions:
l Processing encoder feedback signals to the DCC
l Converting two additional current reference
signals to voltage reference signals, then trans-
mitting them to the DCC
l Receiving RS-422 serial commands and sending
them to the DCCs Motor Control Processor
(MCP)
The following paragraphs describe these I/O signals.
5-3.3.1. ENCODER #l. This circuit interfaces with 5 to
15 V incremental encoders or digital tachometers to supply
position or speed feedback, or reference instrumentation to
the drive. The interface provides an optically-isolated
differential input to the drive at 16PLl thru 16PL6.
Connector 3TB terminals 74 (ElVl) and 76 (ElV2)
provides 5 or 15 V power supply for the encoder. DIP
switches SWl-1 thru SWl-6 select the hardware interface
configuration.
5-3.3.2. ENCODER #2. This circuit is identical in
function to Encoder #l, except that it provides: differen-
tial input at either connector lTI3, terminals 1 thru 6, or
16PL pins 7 thru 12; 5 or 15 V power supply at 3TB
terminals 74 (ElVl) or 76 (ElV2); and DIP switches
SW2-1 thru SW2-6.
5-3.3.3. ANALOG CHANNEL #l, SPl. This circuit
contains a lo-bit A/D converter for 2 to 30 V, or for 1 to
5 mA, 4 to 20 mA, or 10 to 50 mA current-loop inputs. It
then provides digital output to the drive at either lTB,
terminals 7 and 8, or at 16PL, pins 13 and 14. Jumpers
JP5 thru JP7 and potentiometers Pl thru P3 are used to
adjust biasing, gain, and filtering of the signal.
5-3.3.4. ANALOG CHANNEL #2, SP2. This circuit is
identical in function to Analog Channel #l, except that it
uses: 1TB terminals 9 and 10; 16PL pins 15 and 16;
jumpers JP8 tbru JPlO; and potentiometers P4 thru P6.
5-3.3.5. RS-422 CHANNEL. This serial channel is a full-
duplex interface to the DCCs Motor Control Processor.
NOTE
A different serial channel is available on the
NTBMTB in half-duplex form. It is selected by
the DCCs jumper JP31.
5-3.4. LAN/Communication Card (531 X306LCC)
The LAN Communications Card (LCC) contains both
isolated and non-isolated circuits for communications
inputs to the drive. It also connects with the Programmer.
The board features the following components and their
associated functions:
l LAN Control Processor (LCP), an 8OC196
microcontroller (Ul)
l LCP 3-state output address latches (U2 and U3)
5-4
.
Dual-ported RAM, 1K x 8 (US); used for com-
munications between the DCCs Drive Control
Processor (DCP) and the LCP, and for parameter
passing between DCP and LCP via 3PL
. LCP EPROM, page-addressed 4 x 16K x 8 (US
and U7)
l LCP dedicated RAM, 8K x 8 (US and U9)
. Alphanumeric display controller (U18)
. 3-state octal buffers and 8-bit registers (U19,
U20, and U21; used for communications between
the LCP and the LAN I/O Terminal Board
(LTB). They process 16 digital inputs and 7
digital outputs via connector 1OPL.
Refer to Chapter 7 for information about the Programmer.
5-3.5. LAN I/O Terminal Board (531X307LTB)
The optional LAN Terminal Board (LTB) provides an
interface between the AC/DC2000 drives and external
devices, such as contactors, indicator lights, pushbuttons,
and interlocks. Drive control outputs consist of seven low
voltage, low current, form C relay contact connections and
pilot contact connections. They function to actuate the
Relay Terminal Boards (RTBs) seven high voltage, high
current relays.
When the RTB and LTB are used together, contacts from
both are available. The LTB relays may operate RTB
relays for amplification.
The LTB also includes eight dual-point inputs, which are
individually isolated and optically coupled to the drive.
Do not connect the input across an inductive
device. This may damage the circuit.
5-3.5.1. INPUT CIRCUIT. The input circuit provides a
series PET current regulator (wide voltage range) and an
optocoupler interface to the drive.
5-3.5.2. CURRENT REGULATOR. The current regulator
limits the series current through the two input terminals to
the following values:
A diode between the negative input terminal and the
regulator permits operation from an ac or dc source.
5-3.5.3. OPTOCOUPLED INTERFACE. A darlington
output optocoupler provides an interface between source
input and the drives +24 V dc input logic levels. A peak
detector capacitor tied to the darlington output maintains
a constant logic level with ac sources. Source input turns
on an indicator LED in series with the optocoupler input.
5-3.5.4. OUTPUT CIRCUIT. The output circuit consists
of seven relays with status indication LEDs. Each relay
has a set of form C contacts brought out to terminal board
points, and a form A contact to pilot the corresponding
RTB relay. 115 V ac can be connected to either the RTBs
or the LTBs OPTPL connector. A jumper must be added
if the OPTPL connector is not connected to 115 V ac.
5-3.6. Relay Terminal Board (531 Xl 91 RTB)
The RTB is an optional board that provides seven relays,
each with two form C contacts. These are driven either
directly from the LTB board relays or remotely by the
user. Table 5-l lists the board ratings:
Table 5-I. RTB Board Ratings
Board Contact Rating Coil
Group (Resistive) Voltage
1 QA, 220 V ac
Gl
lOA, 24 Vdc
115Vac,
4A, 1251250 V ac
50160 Hz
G3
4A, 30 V dc
2A, 125Vac
G4 24 V dc
2A, 30 V de
*The board etching severely restricts the current rating
to 2.4 A.
5-5
5-4. AC2000 PRINTED WIRING BOARDS
This section describes boards used only in the AC2000
drive. These include:
. Power Supply (MC?)
. Base Drive Board (IBD)
. Dual Tach Isolator Board (DTI)
54.1. Power Supply Board (531X303MCP)
The AC2000 Power Supply Board (MCP) provides logic
power and an interface between the high voltage power
circuitry and the DCC. It also includes the drive functions
described below.
The MCP board connects to the power supply, DB charge
control circuits, and 110 V ac. When power is on, poten-
tially lethal voltages exist on these circuits.
Potentially hazardous voltages are present in
this board. Make sure power is off before
touching the board or any connected circuits.
It is extremely important that power-on test-
ing be done only with low voltages, using the
safety procedures listed below.
Anyone testing with power on must strictly follow stan-
dard safety practices for working with hazardous voltages,
plus the following precautions:
l Make sure that power is completely off before
touching the Power Supply circuitry or connect-
ing any instruments to it.
l Use only insulated current probes and isolated
voltage sensing. These instruments must be put in
place without power on the system.
9 Never probe around on the board or the power
circuit with high voltage present.
l Use only instruments rated for the voltages
present.
9 Never float an oscilloscope.
5-6
The MCP board functions can be divided into several
major areas:
l Developing logic power for all the drives boards
l Acquiring feedbacks used to control the motor
l Controlling the soft-start function (charge control)
and dynamic braking (DB) circuit
l Controlling the MA and DB contactors
. Distribution of 115 V ac control power for the
fans or external logic
5-4.1 .l. POWER SUPPLIES. The MCP receives power
input from the drives main dc power supply (dc link) on
stab terminals DCPLFI (+) and DCPLF2 (COM). It
converts the input into the following voltages:
.
+24 V dc, fused at 0.5 A by FU4, and used to
power +15 V dc
.
-24 V dc, fused at 0.5 A by FU5, and used to
power -15 V dc
.
+5 V dc, fused at 3 A (5 A for board Rev. AF
and later) by FU3
.
17.7 V ac squarewave to power circuitry isolated
from high voltage. This includes the main inver-
ter transistor base drive circuits on the Base
Drive Board (IBD), gating circuitry for the soft
start SCRs, and the base drive circuit for the DB
transistor.
l The 110 V ac, fused at 0.5 A by FUI (for FXl)
An undervoltage sensing circuit monitors the status of the
+15, -15, and +5 V dc supplies. It generates a /PSEN
signal that controls the systems powerup reset. Under-
voltage inhibits all switch firings. The MCP boards 2PL
connector distributes the f24, f 15, +5 V dc, and /PSEN
signals to the DCC and NTB/3TB.
The MCP receives the control power transformers
(WIs) 115 V ac output via the CPTPL connector, and
distributes it to fan connectors 1FAPL and 2FAPL.
The 4PL connector provides both a fused 115 V ac (FXl
and X2) and a form C contact from the MA relay. (This
contact inhibits power driving the optocouplers for the
inverter and the DB transistors.)
Terminal block CNTB contains the fused 115 V ac. It also
provides a 115 V ac relay output (MAP) cycled with the
MA control to drive the DB (dynamic braking) contactor.
5-4.1.2. FEEDBACKS. The MCPreceives the following
motor control feedbacks:
l Inverter line-to-line output voltages V(C-A) and
V(B-A)
l Main dc link voltage (V dc)
. Current feedback pulses (/IA, /IB, and /IC)
Line-to-line voltage feedbacks are derived from the
IBDs attenuating resistors, which are referenced to the
inverter output. The voltages are amplified, summed,
biased to an offset, and input to a voltage-to-frequency
converter (VCO). The VCO outputs a 250 kHz frequency
at zero line-to-line voltage.
This output modulates up and down with application of
line-to-line volts. Nominally, the gain is 242.5 Hz/V line-
to-line with a normal full scale output near 50 kHz and
450 kI-Iz. Saturation occurs at 0 Hz and 500 kHz.
Main dc link power supply feedback is derived from
connections to stab terminals DCPLl (+) and DCPL2
(COM). Attenuating resistors isolate these terminals. A
differential amplifier measures the difference in potential
between the stab terminals, then sends this voltage to a
VCO. Since dc link voltage does not change sign, no
offset is present. The VCO gain is 578.3 Hz per link volt
(nominal).
The + 15 V dc supply powers the op-amp circuitry for
both the motor terminal and the dc link feedback voltages.
The VCO circuits use an independent +5 V dc supply
derived from the +15 V dc supply with a linear regulator
as logic power and as a reference.
The IBD uses a VCO circuit to create and isolate current
feedback pulses. The MCP only buffers these signals
before sending them to the DCC. (Buffers am Schmidt
trigger circuits powered from the +5 V dc supply.)
5-4.1.3. SOFT START CONTROL. The soft start control
receives a sync oscillator and gating command signal from
the DCC. It converts these signals into burst-fired gating
pulses for the charge control SCRs on connector CCPL.
The circuit runs at 25 kHz. At the gate drive command,
it provides a 10 psec gate pulse every oscillator period.
The following conditions inhibit gate drive:
9 Logic supply undervoltage
l Microprocessor hard reset (/RSTl, connector 1PL
pin 31)
l Hardware fault reset QFLTRST, 1PL pin 27)
9 DBHWOV trip (PAULTl, 1PL pin 30)
l Inverter base drive fault (FAULI2, 1PL pin 28)
A 5 V dc supply powers the burst-firing control circuit.
The gatiug circuitry derives power from an isolated
winding of a transformer powered by the 17.7 V ac
square-wave supply. The gating circuitry sits at high
voltage potential (with respect to the control circuit),
referenced to the SCRs that it drives. The gate drive
signals, from the burst-firing control to the gating circuits,
are optically isolated.
5-4.1.4. DYNAMIC BRAKING (DB) CONTROL. The DB
control receives feedback from the same isolation ampli-
fier that looks at the dc link for feedback. A comparator
circuit measures the link voltages absolute value and
controls the DB transistor. Putting the DB resistor across
the dc link when the voltage exceeds the set point. The
transistor turns off after the set hysteresis discharges the
link. If the DB fails to keep voltage down, an overvoltage
trip occurs. (Jumper JP3 adjusts trip points).
The DB transistor base drive operates like an inverter
base drive circuit, except it runs an isolated transistor
switch. The DB circuits power supplies are developed
from an isolated output winding of the transformer that
powers the soft start. These supplies are ultimately
referenced to the dc link common by connections on plug
DBPL (base and emitter terminals) and a stab on terminal
DBC (collector terminal).
The DB transistors drive command is optically isolated,
and delivers proportional base drive when the circuit is on.
Negative drive current turns off the transistor (current
selected by JP4 on Rev. AF and later).
Three conditions generate a DB base drive circuit fault:
l Transistor out of saturation
l Base drive circuit undervoltage
l Missing connection to the transistor collector
(stab on DBC)
5-7
When a fault occurs, a base-emitter voltage clamp (select-
ed by JPl) forms a current limit. A saturation detector on
the base drive then produces a fault output through an
optical isolator. The DCC receives the DB fault via the
same circuitry used to receive an overvoltage trip.
The drive uses the DBDlJN signal to monitor DB
operation. This signal indicates low voltage on the DB
transistors collector-emitter. DBDUTY is also used for
computing the average power dissipated in the DB
resistor. If dissipation exceeds the preset amount, the
power supply generates an annunciation and a fault.
If a DB transistor failure occurs, this circuitry can be used
to drive a DB contactor to mechanically disconnect the
DB resistor from the DB circuit.
The following conditions inhibit DB transistor control:
l Logic supply undervoltage
l Microprocessor hard reset (/RSTl, 1PL pin 3 1)
. Hardware fault reset (/FLTRST, 1PL pin 27)
l DBJ-IWOV trip (FAULTl, 1PL pin 30)
l Inverter base drive fault (FAULT2, 1PL pin 28)
l MA control not asserted
The microprocessor also uses the enable signal (ENDB)
and turn on signal (DBTST) to control the DB circuit.
5-4.1.5. AC LINE MONITOR CIRCUIT. This circuit
consists of four signals generated for the DCC:
. VMAG, an analog signal generated by a peak
detector on the positive sequence of the three
measured line-to-line voltages
l PHASELOSS, a digital signal generated when
any positive peak line-to-line voltage falls below
approximately 70% of the largest positive peak
value of the line-to-line voltages. (Actual phase-
loss trip is generated after a programmable
delay.)
l LINESYNC, a digital signal that changes state at
the zero-crossing of Ll-L2 voltages integral
. VSEQ, an analog signal that is the L3-Ll voltage
scaled and offset to 2.5 V
VSEQ used with LINESYNC determines the ac lines
direction of rotation. It is needed only if fan rotation is
important when cooling with a 3-phase blower. Addition-
ally, the DCC may use LINESYNC as a 60 Hz timebase.
6-4.1.6. INVERTER TRANSISTOR FIRING CONTROL.
This circuit converts the three groups of UP/DN and
ENABLE signals from the DCC into optical coupler drive
signals for the base drive circuits. The UP/DN signal turns
on a phases upper transistor if high, and lower transistor
if low (if the respective phase is enabled).
The following conditions prevent inverter transistors from
operating:
. Logic supply undervoltage
l Microprocessor hard reset (/RSTl, 1PL pin 31)
. Hardware fault reset (/FLTBST, 1PL pin 27)
l DB-HWOV trip (FAULTl, 1PL pin 30)
l Inverter base drive fault (FAULT2, 1PL pin 28)
l MA control not asserted
6-4.1.7. FAULTS. As stated previously, two hardware
fault conditions are sensed, latched, and reported to a
microprocessor:
.
DBJ-IWOV fault (FLTl), sets when either an
overvoltage or a DB circuit fault is sensed. This
turns off LEDl. (Microprocessor output
/FLTRST resets the fault.)
9 /FLTA, /FLTB, /FLTC faults (FLT2), transmitted
from the IBD board when a faulted base drive is
commanded to turn on. This turns off LED2. The
fault is reset by turning off all three enable
signals.
5-4.2. Base Drive Board (531X3041BD)
The Base Drive Board (IBD) provides three major drive
functions:
l Isolated current feedback
. Motor terminal voltage isolation
l Protected base drive for the power transistors
5-8
The IBD includes six independent fault latches that can
remember a base drive fault. A microprocessor checks
for this fault by individually addressing the six latch cir-
cuits.
Potentially hazardous voltages are present in
this boards circuits. Make sure power is off
before touching the board or any connected
circuits.
Any testing with power on must strictly follow
standard practices for working with hazardous
voltages, plus any additional precautions noted
in this chapter. Any testing that requires
board access must be done with only low
voltage present.
5-4.2.1. ISOLATED CURRENT FEEDBACK. There are
three isolated current feedback circuits. These amplify
voltage signals from shunts connected in series with the
motor terminals,
Each circuit has its own isolated power referenced to the
shunt. It amplifies the shunt signal, adds an offset, and
converts the result into frequency. An optocoupler isolates
the pulses and send them to the DCC board. This output
signal is offset to approximately 250 kHz, modulating
*200 kHz full scale with an input signal of +200 mV.
5-4.2.2. MOTOR TERMINAL VOLTAGE ISOLATION.
This circuit consists of three sets of three 47X, 0.1%
resistors per phase. They provide the (MCP) with inputs
for amplifiers that manufacture line-to-line voltage feed-
back. The inputs to the resistor sets connect to the motor
terminals via the common of the shunt isolator power
supply.
5-4.2.3. BASE DRIVE ClRCUlTS. The IBD board
contains six identical base drive circuits. They process
inputs from the MCP Board, producing isolated and
protected base drive for each output power transistor.
Before the optical isolators, the circuits include onboard
fault latches that disable faulted phase legs and control
LEDs that indicate transistor failure. They also provide a
readback capability in which the control can locate a fault
by individually addressing the fault latches.
The base drive circuitry optimizes transistor turn on delay,
storage time, and switching losses. It provides fault
protection that, combined with an overcurrent check by the
control, protects the power transistors. Each base drive
circuit executes the following functions:
Develops independent, isolated positive and
negative power supplies referenced to the driving
transistors emitter
processes an optically-isolated drive command
signal
Enforces a lockout to prevent shoothrough with
its opposing transistor during its storage time. It
does this using optical isolation to sense when its
p.artner is held solidly negatively biased.
Delivers proportional, positive base drive current
for transistor conduction. This reduces the power
needed to control the transistors. The scheme
uses collector-emitter voltage feedback to control
the base-emitter voltage.
provides a base-emitter clamp that forms a
current limit. It is adjusted by jumper for the
number of transistors in a darlington string (2, 3,
or 4). This limits both the current present during
a fault and the reverse recovery current of the
freewheeling diode during turn-on.
Senses when a transistor comes out of or fails to
go into saturation and profiles off the collector to
avoid overstressing the power transistor.
Delivers transient negative drive to turn off and
hold off the transistor. (Rev. AF and later in-
cludes a jumper to select negative drive current
values of 1, 2,4, or 8 A.)
Turns off the positive drive and holds a transistor
negative biased while its antiparallel freewheeling
diode is conducting. This prevents turn-on of the
parasitic inverse transistor from between the base
to collector region of the power transistor.
Uses optical isolation and external fault latches to
sense and indicate three fault conditions:
- Transistor out of saturation
- Base drive circuit undervoltage
-
No connection on the collector terminal
5-9
The IBD connects to the power semiconductors driving the
motor. When power to these semiconductors is on, all
IBD and shunt isolator circuits carry high level voltages.
Anyone testing with power on must strictly follow stan-
dard practices for working with hazardous voltages, plus
the following precautions:
l Use only insulated current probes and isolated
voltage sensing. These instruments must be put in
place without power on the system.
l Never probe around on the board or the power
circuit with high voltage present.
l Use only instruments rated for the voltages
present.
. Never float an oscilloscope.
54.3. Dual Tach Isolator Board (531X311DTI)
The Dual Tach Isolator Board (DTI) is used only with
DCC board revisions earlier than AL. It provides isolation
for two independent tachometers with signals A quad B.
It can be wired to isolate one channel of A quad B with
a marker (and one unused in/out).
The input circuitry consists of resistor networks that bias
the optical isolator input. Jumpers configure the circuitry
to accept encoders or tachometer inputs with output
signals transmitted from one of three common interfaces:
. Open collector differential output with internal
1K pullup resistors powered by +15 V
l Low impedance differential powered by +15 V
. Low impedance differential powered by +5 V
A +5 V signal powers the output circuitry. The circuit
produces a low impedance differential output that can be
used to source approximately 10 mA at 4 V output. This
output is compatible with the +5 V for the NTB/3TB
board or the optional SPC.
Inputs AO, /AO, BO, and /BO are output as isolated signals
EOA, lEOA, EOB, and /EOB; inputs A2, /A2, B2, and lB2
are output as E2A, /E2A, E2B, and /E2B (see Chapter 6).
The board includes additional 1K ohm pullup resistors,
controlled by jumpers if the correct encoder power is
wired to the terminal block.
5-10
On 30 kVA drives, the DTI mounts l-1/2 in. from the left
and l/2 in. from the bottom of the drive. On 15 and 60
kVA drives, the DTI mounts on a plate installed on the
right side of drive next to the RTB board space.
5-5. DC2000 PRINTED WIRING BOARDS
This section describes boards used only in the DC2000
drive. These include:
l Power Supply Board (DCI)
l Power Connect Boards (PC-, see Table 5-2).
l High Horsepower Snubber Board (SND)
5-5.1. Power Supply Board (531X302DCl)
The Dc Power Supply/Interface Board (DCI) contains the
following circuitry:
l Control-level power supplies (+5, &15, +24 V
dc)
9 Motor field power circuitry (except the SCR
module)
l Driver circuitry for the armature SCR gate pulse
generators
. Circuitry to instrument numerous ac line and dc
motor signals, including:
- Armature current and voltage
-
Field current
- AC line cut-tents
- AC line voltage magnitude and phase seq-
uence
5-5.1 .l . POWER SUPPLIES. The CPTs (control power
transformers) secondary center-tapped winding is full-
wave rectified and filtered. It provides unregulated +24
and -24 V dc voltages. These are fused at 3 A and 1 A
respectively. Onboard LEDs indicated blown fuses.
The DC1 generates f15 V dc supplies from the f24 V dc
supplies using linear voltage regulator integrated circuits.
These outputs are rated for 350 mA.
The DC1 generates the +5 V dc supply from the +24 V
dc supply using a switching regulator, transformer, and
power FET. This supply is rated for 3 A, with current
limiting sensed by resistors. The 2PL signal /PSEN goes
TTL low when the +5 V dc supply is in regulation; the
signal goes high when the +5 V dc supply is out of
regulation. This is useful as a microprocessor reset and
EEROM write protect during drive power-up and power-
down.
The board produces isolated +5 and f15 V dc supplies
(used to power the armature current feedback circuitry)
from auxiliary windings on the switching regulator
transformer. A zener diode regulates the isolated + 15 V
dc, a linear regulator controls the isolated +5 V dc. This
circuitry is at the motor armature potential since it con-
nects to the armature current sensing shunt.
5-5.1.2. FIELD POWER CIRCUITRY AND CURRENT
VCO. The field supply uses a 2/3 wave, single-quadrant
bridge. For fields up to 10 A, the DC1 contains all circuit-
ry, except for the SCR module (mounted on the heatsink).
Fuses protect the field circuitry, blowing when the external
MOVs absorb too much power. Onboard lights indicate
blown fuses. Optional field exciters may be supplied.
The field power circuitry includes snubbers, a current
transformer, and a line choke. Jumpers control current
transformer burdening, allowing the field current feedback
to be coarse scaled. Applications above 10 A require an
external field power circuit with feedback input on FCPL.
The feedback signal is rectified, filtered, scaled by P3, and
biased. Then it input to a VCO circuit that is output at the
DCIs testpoint FC.
5-5.1.3. ARMATURE VOLTAGE VCO. The motor
armature voltage is isolated by offboard resistors, then
brought in as differential input on 5PL. The DC1 then
transmits this signal to the DCC as both -5 to +5 V dc
analog representation and as a frequency representation by
a VCO circuit.
5-5.1.4. ARMATURE CURRENT VCO AND DISCONTIN-
UOUS CURRENT DETECTOR. A third VCO, which is at
armature bus potential, instruments motor current detected
from a shunt. An optocoupler passes this frequency down
to the signal level electronics referenced to the drive
common. The DC1 differentiates this current and compares
it and its derivative against low positive and negative
thresholds. The comparator outputs are logically ORed and
optically coupled to the DCC. This provides a discontinu-
ous/continuous current indicator for armature current.
5-5.1.5. AC LINE ZERO-CROSSING, MAGNITUDE, AND
PHASE SEQUENCE. A 3-phase filter and amplifier
circuit processes the ac line-to-line voltages. These are
logically ORed for use by the DCC board as a voltage
magnitude and phase loss function.
One of these signals is heavily filtered, processed by a
zero-crossing detector, and made TTL compatible for use
in synchronizing the drive to the ac line. The DC1 filters
and biases line 3-l. It then sends the signal to the DCC,
which uses it to determine phase sequence.
5-5.1.6. AC LINE CURRENT INSTRUMENTATION. The
drives 1 and 3 ac lines include current transformers. Their
current output is full-wave rectified and burdened as a
function of drive horsepower and voltage rating. The
board then buffers and biases the resulting ac voltages
across the two CTs, then transmits it to the DCC via 1PL.
The DCC uses these two signals to check for commutation
failure and ac instantaneous overcurrent.
5-5.1.7. MA PILOT RELAY. The K2 relay serves as a
pilot relay to the MA or MD contactor. The DCC drives
the coil. One form A contact supplies 120 V ac to the
contactor plug; a form C contact provides an auxiliary set
to the NTB/3TB board.
5-5.1.8. FIRING PULSE GENERATOR CIRCUITS.
Based on inputs from the DCC, microcontrollers steer
firing bursts to the appropriate SCR gate-pulse transformer
drivers. A 10% duty oscillator is logically ANDed with
the enables. This forms the firing bursts along with initial
pulse (IPU). The IPU is used to ensure that a firing pulse
is generated at the leading edge of the enable.
Rectangular waves envelope the period when the SCR
should be fired. An input signal indicates when the Cell
Test Mode is active. The board optically isolates the
armature power circuit from the control, primarily to
reduce noise coupling problems. It also provides darling-
ton drivers for the gate-pulse transformer.
5-5.1.9. DELAYED FIRING POWER. A transistor (con-
trolled by the DCC) supplies power to the gate-pulse
transformer. As a protection, it remains off until gating is
required. As an additional protection, a second transistor
removes power to the optocouplers.
5-11
5-5.2. Power Connect Boards (531X308PCS,
531 Xl 22PCN, 531X1 21 PCR, and 531 Xl 23PCH)
The Power Connect PC- board interfaces the drive control
circuitry to the SCR power bridge. The following factors
determine which PC- board the drive requires:
. Common or non-common isolation transformer
configuration
5-5.3. High Horsepower Snubber Board
(531X31OSND)
The SND boards are used only in the D frame drive. The
SND board replaces the PCS board in higher horsepower
drives. (The PCS board, which also contains snubbers, is
used to interface the control circuitry to the SCR power
bridge for low to medium horsepower controllers.)
There are two SND board types (groups):
l Regenerative or non-regenerative drive
.
Drives voltage
l Drives frame size
. Group 1 - AC line snubber board, replacing
531X308PCSG3 or -G4 boards.
9 Group 2 - Line/gate/de snubber board, replacing
531X308PCSG5 or -G6 boards.
Table 5-2 lists and describes the PC- boards.
The SND also contains a dc power source for driving a dc
contactor.
Table 5-2. DC2000 Drive Power Connect Boards
Description
1 quadrant, with snubbers
1 quadrant, without snubbers, D frame only
Used on drives with Common Isolation Transformer
1 quadrant, with snubbers, Low voltage applications
Used on drives with ( 500 V output
4 quadrant, without snubbers, E frame only
Used on drives with B 500 V output
Catalog Number
531 Xl 22PCNA-Gl
531 Xl 22PCNA-G2
531X121PCRA-Gl
531 Xl 21 PCRA-G2
531 X308PCSA-Gl
531 X308PCSA-G2
531 X308PCSA-G3
531 X308PCSA-G4
531X121PCRA-G4
531X123PCHA-Gl
531 Xl23PCHA-G2
5-12
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CHAPTER 6
I/O DEFINITIONS
6-1. INTRODUCTION
This chapter lists and defines I/O connector points and
LEDs for the AC/DC2000 drive. The connectors include
plug-in cable type, terminal board type, and stabs located
on the printed wiring boards.
This chapter is organized alphabetically by board name.
For example, section 6-4 covers the DCC, section 6-5 the
DCI, section 6-6 the DTI, and so forth. These sections
contain tables of I/O definitions for each connector, stab,
and LED on that board, and figures that show their
location.
6-2. TYPES OF CONNECTORS
6-2.1. Plug-in Connectors
This type of connector, identified by PL in its name,
mates with a cable that plugs into it. The cable carries
signal and power I/O within the drive and externally to
customer equipment. Plug-in connectors provide three
types of connections:
Internal board-to-board connections - Carry I/O between
boards in the drive. The connector has the same name
and same pinout assignments on each board.
Boardlcomponent connections - Carry I/O between
boards and components (for example, transformers or
SCRs) within the drive. These connectors are com-
monly 2-pin plugs.
User connections - These connectors are located on
boards in the drive. They carry I/O between these
boards and user connections outside the AC/DC2000
drive.
6-2.2. Terminal Board Connectors
This type of connector is identified by TB in its name. It
provides a connection point for individual wires that carry
signals or power. This I/O can be between a board and
components within or outside the drive. The wires are
secured in the terminal board by tightening screws at each
connection.
6-2.3. Stab Connectors (Stabs)
This type of onboard connector is a wide metal post that
secures one side of a removable wire jumper. It provides
options for configuring drive I/O, such as power require-
ments.
6-3. LED INDICATORS
The AC/DC2000 drive includes LEDs (light-emitting
diodes) on some boards as indicators of a board or drive
condition. The LEDs are located on I/O paths, and turn on
or off with the signal condition.
6-l
GEH-5834
6-4. DCC BOARD I/O
This section defines I/O points and LEDs for the DCC board. Figure 6-l shows connector locations.
Table 6- 1. Connector 1 PL,
I/O Between DCC Board and MCP Board (AC2000)
Pin
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32,33
34
36-37
38
39,40
Uomen-
:lature
._--
IBDUTY
HLOSS
.---
tiMAG
bSEQ
.---
IA
IB
IC
d( B-A)
V(C-A)
dDC
SYOSC
.---
J/DA
JIDB
J/DC
DBTST
ENA
ENB
ENC
ENDB
SSl
ss2
ss3
IFLTRST
FAULT2
LINESY
FAULT1
/FIST1
----
MAC
_---
DTYPE
----
Description
Not connected
DB transistor ON signal.
AC line phase loss signal.
Not connected.
AC line-to-line peak for magnitude detection.
AC line voltage for phase sequence detection.
Not connected
Phase A current feedback VCO output, 0 offset = 250 kHz.
Phase B current feedback VCO output; 0 offset = 250 kHz.
Phase C current feedback VCO output; 0 offset = 250 kHz.
Voltage feedback VCO output; 0 offset = 250 kHz.
Voltage feedback VCO output; 0 offset = 250 kHz.
DC link voltage feedback VCO output; 0 offset = 0 kHz.
25 kHz burst oscillator.
Not connected.
Phase A upper/lower base drive select
Phase B upper/lower base drive select.
Phase C upper/lower base drive select.
DB select.
Enable base drive A.
Enable base drive B.
Enable base drive C.
Enable DB transistor.
Soft-start SCR gate enable.
Same as SSl (pin 24).
Same as SSl (pin 24).
AC2000 Base Drive Board (IBD) fault reset
IOC trip signal from IBD board
AC line synchronizing signal.
DB overvoltage trip signal.
System reset.
Not connected.
MA pilot relay coil driver (active low).
Not connected.
4 5 V AC2000 drive type identifier.
Not connected.
6-2
GEH-5834
Pin
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36,37
38
39,40
Table 6-2. Connector lPL,
I/O Between DCC Board and DC/ Board (DC2000)
Nomen-
clature
IL3
IL1
VM
VG
VMAG
VSEQ
IDIS
IDC
IF
IM
----
250KHZ
VA
SYOSC
----
ENREV
ENFWD
IPU
FLDF
A14R
A25R
A36R
(ATP)
A14F
A25F
A36F
SCRTST
----
LINESYNC
IDIS
/RSTl
DFPC
(FW
MAC
_---
VFBB
DNPE
----
Description
O-5 V analog ac line current via CT; 0 offset = 2.5 V.
Same as IL3 (pin 1)
Not used.
Not used
0-5 V analog ac line voltage magnitude for phase loss circuit.
O-5 V analog ac line voltage for phase sequence detection
TTL output from discontinuous current sensor.
TTL VCO output from armature current shunt; 0 offset = 250 kHz
TTL VCO output from field current CT; 0 offset = 250 kHz.
Not used.
Not connected.
250 kHz TTL frequency reference used to measure IDIS duty
TTL VCO output from armature voltage sensor; 0 offset = 250 kHz
25 kHz burst oscillator for SCR gating.
Not connected.
Enable reverse bridge SCR firing.
Enable forward bridge SCR firing.
Initial SCR firing pulse.
Enable field SCR firing.
Reverse bridge SCR select line.
Same as pin 20.
Same as pin 20.
Armature interrupt routine timing flag.
Forward bridge SCR select line
Same as pin 24.
Same as pin 24
Short circuit SCR test mode select line
Not connected.
AC line synchronizing signal.
TTL output from discontinuous current sensor.
System reset
Delayed firing power control line.
Field and line synchronizing interrupt routines timing flag
MA pilot relay coil driver (active low).
Not connected.
Armature voltage feedback testpoint.
2 5 V drive type identifier signal.
Not connected.
6-3
Pin Nomen-
No. clature
1 +24VDC
2 -24VDC
3 COM
4 +5VDC
5 -5VDC
6 COM
7 +l SVDC
8 -15VDC
9 IPSEN
Table 6-3. Connector 2PL,
I/O Between Power Sum/v Board lMCP for AC2000. DCI for DC20001
And bkC and hT5/3T5 Boards
Description
Unfiltered positive 24 V dc power supply.
Unfiltered negative 24 V dc power supply.
Common return for all low level power supplies.
Positive 5 V dc regulated power supply for digital circuitry.
Negative 5 V dc regulated power supply for digital circuitry
Common return for all low level power supplies.
Positive 15 V dc regulated power supply for analog circuitry
Negative 15 V dc regulated power supply for analog circuitry.
Power supply within regulation tolerance (active low).
DCC Board Output to LCC Board (AC/DC2000)
Pin
No.
Nomen-
clature
Description
l-8 BDO-BD7
9 COM
10 +SVDC
11 lRST3
12 LINT
13 ILBSY
14 BALE
15 COM
16 /BCSL
17 /BRD
18 /BWR
19 BA8
20 BAQ
21 IBCSU
22 BAlO
23 BAl 1
24 COM
25 COM
26 +5VDC
27 - 34 BAO - BA7
Buffered, demultiplexed DCC Drive Control Processor (DCP) data bus lines 0 - 7.
Power supply return, common.
System reset signal (active low).
Interrupt from LCC/DCC microapplication chip to DCP.
Busy bus control handshake to DCP.
Buffered address latch enable from DCP.
LCC chip select.
Buffered read control line from DCP.
Buffered write control line from DCP.
Buffered, demultiplexed DCP address line 8.
Buffered, demultiplexed DCP address line 9.
DCC microapplication chip select.
Buffered, demultiplexed DCP address line 10
Buffered, demultiplexed DCP address line 11
Buffered, demultblexed DCP address lines 0 thru 7.
6-4
Pin NTB/3TB Nomen-
No. Term.# clature
1 42 CTLNl
2
3
4
5
6
7
8
9
10-14
15
16
17
18
19
20, 21
22
23
24
44
61
34
36
38
40
47
--
51
--
--
--
__
49
53
CTLN2
LBIAS
TOOUT
RUN
JOG
POL
XSTP
MSRF
ROl -R05
P3B
P4B
ASP0
----
----
PlB, P2B
____
DVM
DA1
25 54 DA2
26 55 MET1
27 56 MET2
28 57 MSSY
29 59 TOIN
30 58 RESET
31
--
TDB
32
__
RDB
33
--
CTSB
34
--
RTSB
35
_-
IRSTB
I/O Between DCC Board and NTB/3TB Board (AC/DC2000)
Description
CTLNl and CTLN2 form part of the circuit for picking up the MA contactor pilot relay
and must be connected together to allow the drive to run. They provide both a place
to connect external interlocks and provide a fail-safe (microprocessor independent)
means of stopping the drive.
See CTLNl .
k24 V dc bias for digital inputs from DTB (for +/- logic)
TTL output through 200 n from timer/counter 0 of DCCs Drive Control Processor.
General purpose digital input defaulted to, but not limited to, RUN function.
General purpose digital input defaulted to JOG function
General purpose digital input defaulted to the reference polarity function.
General purpose digital input defaulted to the XSTOP function (normally closed).
Relay #6 coil driver (Master Sync Reference output), open collector driver output.
NTB/3TB relay coil output driver lines 1 thru 5.
Scalable GP analog input from NTBI3TB.
Scalable GP analog input from NTBI3TB.
Medium resolution analog input with fixed scaling for +lO V dc maximum from
Not connected.
Not connected.
Scalable GP analog input from NTBI3TB
Not connected
Medium resolution analog input channel with fixed scaling for f25.5 V dc maximum.
DACl, DAC2, METl, and MET2 signals are outputs from 8-bit D/A converters and
can source + 10 V dc at no load or +18 V dc at 10 mA load (200 Q series impedence).
Any drive variable can be steered to these D/A outputs and can be scaled to set what
value corresponds to the 10 V dc output. (DA1 and DA2 are for diagnostics and
system applications; MET1 and MET2 are for meter driver functions.)
See DA1 (pin 24).
See DA1 (pin 24).
See DA1 (pin 24).
Input to internal interrupt (INTO) of DCP. Is biased to +24 V dc through 27K n and
must be pulled to COM (less than +1.5 V dc) to be recognized by DCP
Input to internal timer/counter 0 of Drive Control Processor (DCP, located on DCC). Is
biased to +24 V dc through 27K s1 and must be pulled to COM (less than +1.5 V dc)
to be recognized by DCP.
Hard reset input to the drive. Connecting RESET to +5 to +24 V dc causes all
processors in the drive to be reset. Leaving RESET open or connecting to COM
allows drive operation. The DCC provides a 20 ms noise filter on this input.
RS-232 channel transmitted from DCP.
RS-232 channel received by DCP.
RS-232 channel clear-to-send handshake
RS-232 channel clear-to-receive handshake.
System reset signal.
6-5
GEH-5834
Table 6-5. Connector 6PL - Continued
Pin
No.
NTBRTB Nomen-
Term.# clature
Description
36 -- ----
37 -- RFNB
38 -- RFPB
39 -- FBNB
40 -- FBPB
Not connected.
Differential analog input from NTB/3TB to reference VCO, negative line.
Same as 3TB point 37, but positive line.
Differential analog input from NTB13TB to feedback VCO, but negative line.
Same as 3TB point 39, but positive line 3.
I/O Between DCC Board and SPC Board (AC/DC2000)
Pin
No.
1
2
3
4
5
6
7
a
9
10
11
12
13
14
15
16
17
ia
19
20
Nomen-
clature
SPA1
SPA2
ElZ
E2Z
-15VDC
+15VDC
COM
SPRS
COM
+5VDC
ElUP
El DN
E2UP
E2DN
lRST7
COM
__-_
----
SPTX
SPRX
Description
f5 V dc SPC analog channel #l.
f5 V dc SPC analog channel #2.
Marker channel from encoder #l interface.
Marker channel from encoder #2 interface.
Negative 15 V dc power supply for analog circuitry on SPC.
Positive 15 V dc power supply for analog circuitry on SPC.
Power supply return.
Digital output from DCP to SPC.
Power supply return, common
Positive 5 V dc power supply for digital circuitry SPC
Up channel output from encoder #l interface.
Down channel output from encoder #l interface.
Up channel output from encoder #2 interface.
Down channel output from encoder #2 interface.
System reset (active low).
Not connected
Not connected.
5 V dc output from DCCs Motor Control Processor (MCP) UART.
VB5 V dc input to MCP UART.
6-6
Pin NTB/3TB Nomen-
No. Term.# clature
1 6 FA
2 8 FB
3 10 FCOM
4 12 EXSY
5
-- ----
6 1 EOAB
7 3 IEOAB
8 5 EOBB
9 7 /EOBB
10 9 EOMB
11 11 IEOMB
12
13
__
14
----
Cl1
14 16 Cl2
15 18 Cl3
16 20 Cl4
17 22 Cl5
18 24 Cl6
19 26 Cl7
20 28 Cl8
Pin Nomen-
No. clature
Description
1 +SVDC Positive 5 V dc power supply for digital circuitry on LCC.
2 -24VDC Negative 24 V dc power supply for programmer display on LCC.
3-6 COM Power supply return, common.
7 +24VDC Positive 24 V dc power supply for LTB board relay drivers.
8 +5VDC Positive 5 V dc power supply for digital circuitry on LCC.
*Connector 9PL used only on the LCC DLAN model, previous to the DLAN+ model (see Figures 5-2 and 5-4).
Description
Non-inverting RS-422 half duplex serial data line from the WCs Motor Control
Processor (MCP) UART.
Inverting W-422 half-duplex serial data line from MCP UART.
Signal return for EXSY (at COM potential).
External sync input to MCP.
Not connected.
Encoder interface Channel A non-inverted differential input.
Encoder interface Channel A inverted differential input. (Tie to COM for
single-ended encoders.)
Encoder interface Channel B non-inverted differential input
Encoder interface Channel B inverted differential input (Tie to COM for
single-ended encoders.)
Encoder interface marker pulse channel non-inverted differential input.
Encoder interface marker pulse channel inverted differential input. (Tie to COM
for single-ended encoders.)
Not connected.
Cl1 - Cl8 are general purpose control inputs, f24 V dc maximum with 27 m
input impedance
See Cl1 (pin 13).
See Cl1 (pin 13).
See Cl1 (pin 13).
See Cl1 (pin 13)
See Cl1 (pin 13).
See Cl1 (pin 13)
See Cl1 (pin 13)
Table 6-8. Connector 9PL*,
I/O Between DCC Board and LCC Board (AC/DC2000)
6-7
Table 6-9. LEDs on DCC Board
LED Name Indication
1 Bar Graph LED indicative of fault patterns showing whether the drive is healthy and stopped or running.
When the drive has a fault, the graph displays the fault code number. For a detailed description of fault
codes, see the troubleshooting manual, GEH-5835 (AC2000) or GEH-5636 (DC2000).
0
ln
P
6PL
IL.-l 21
WJ6
lo2
&
JP36
6PL
Figure 6-1. DCC Board I/O Connectors
6-8
GEH-5834
6-5. DCI BOARD I/O
This section defines I/O points for the DC1 board. Figure 6-2 shows connector locations.
For connectors 1PL and 2PL, see Tables 6-2 and 6-3.
Table 6-10 Connector ICPL,
Input to DCI (DC2000) Board from Current Transformer
Input from line phase 1 current transformer.
Table 6- 11. Connector CPTPL,
Input to Power Supply Board (DCI Board* for DC2000, MCP Board for AC2000)
From Control Power Transformer (CPT)
Pin
Board No
MCP 1
MCP 2
DCI 1
DCI 2
DCI 3
DCI 4
DCI 5&6
Nomen-
clature
Description
Xl
x2
115Vac.
-_-_
115 V ac (from CPT ground side).
38 V ac, center tapped for controller power supplies.
38 V ac output to CPT, center tapped for controller power supplies.
Center tap point for 38 V ac.
Not used.
115 V ac for controller cooling fan (if supplied).
* DCI connections to CPT secondary.
6-9
Connec- Pin Nomen-
tor No. clature
CNPL 1 MAP
CNPL 2 x2
DRPL Red IP
DRPL White IN
FAPL
FAPL
FCPL
FCPL
FSPL
FSPL
Xl
x2
ACOM
----
FLC Gate pulse transformer output to field power module SCR (red wire).
FLG Gate pulse transformer output to field power module SCR (white wire).
Table 6-12. Connectors CNPL, DRPL, FAPL, FCPL, and FSPL,
I/O Between DCI Board (DC2000) and Components
Description
MA contactor control output.
MA contactor control output.
Armature current feedback from shunt, O-l 00 mV. Positive when motoring with
the forward power circuit (red wire).
Armature current feedback from shunt. Negative when motoring with forward
power circuit (white wire)
115 V ac for controller cooling fan.
115 V ac for controller cooling fan.
Analog common
External field control feedback. Used only with external motor field control
assemblies.
* DCI connections:
- CNPL to MA relay coil
- DRPL to armature shunt
- FAPL to controller cooling fan(s) (if used)
- FCPL to external field current transformer (only used when field rating exceeds DCI capability (10 A)
- FSPL to motor field SCR gate
Table 6- 13. Connector 4PL,
Output from DCI Board (DC2000) or MCP Board (AC2000) To NTB/3TB Board
Pin NTB13TB Nomen-
No. Term. # clature
Description
1 77 MACM* Form C common contact* from MA pilot relay
2 79 MANO* Form C normally-open contact* from MA pilot relay.
3 81 MANC* Form C normally-closed contact* from MA pilot relay.
4 83 CFXl** 120 V ac, &15%, fused at 500 mA total including internal fans.
5 a5 x2** Return for CFXl 120 V ac loads.
*Auxiliary contacts from the relay used to pilot the MA contactor. Rated for 125 V ac, 2 A.
**Isolated from COM.
6-10
Table 6-14. Connectors 5PL and SAPL*,
I/O Between DCI Board and PCH, PCN, PCR, or PCS Boards (DC2000)
Pin
No.
Nomen-
clature
1 A6F
2 DFP
3 A5F
4 PCOM
5 A4F
6 DFP
7 A3F
6 PCOM
9 A2F
10 DFP
11 AlF
12 PCOM
13 AlR
14 DFP
15 A2R
16 PCOM
17 A3R
18 DFP
19 A4R
20 PCOM
21 A5R
22 DFP
23 A6R
24 PCOM
25 DCN
26 DCP
Description
Drives cell 6F gate pulse transformer.
Delayed firing power for A6F and A5F
Drives cell 5F gate pulse transformer
Shield wire.
Delayed firing power for A4F and A3F
Shield wire.
Delayed firing power for A2F and Al F.
Drives cell 1 F gate pulse transformer
Shield wire.
Drives cell 1 R gate pulse transformer
Delayed firing power for Al R and A2R.
Drives cell 2R gate pulse transformer
Shield wire.
Drives cell 3R gate pulse transformer.
Delayed firing power for A3R and A4R.
Shield wire.
Delayed firing power for A5R and A6R
Shield wire.
Resistance isolated armature voltage (negative)
Resistance isolated armature voltage (positive).
*Identical pin assignments on connectors 5PL and 5APL; 5APL exists only on the PCH, used for a slave
parallel bridge.
6-11
GEH-5834
= KF
l/R
u
2/w
1
FSPL
1
l-l
FCPL
II
DW
II
DY WJ2
d b 1
I
s
lCPL
= DX
II L2
= Mov2
=L3
WJl
d
= DZ
= AF
l/R 2/w
1
DRPL
t 3
y:
CNPL
I I MOVl
=cPTH1 Ll= CPTHP =
Figure 6-2. DCI Board I/O Connectors
6-12
6-6. DTI BOARD I/O
This section defines I/O points for the DTI board. Figure 6-3 shows connector locations.
Table 6-15. Connector TB,
I/O Between DTI Board and External Connections (AC2000)
Pin
No.
Nomen-
clature
1 A0
2 EOVl
3 IA0
4 EOA
5 BO
6 IEOA
7 /BO
8 EOB
9 SP
10 /EoB
11 SP
12 +5v
13 SP
14 COM
15 SP
16 ElVl
17 A2
18 E2A
19 IA2
20 lE2A
21 82
22 E2B
23 /B2
24 lE2B
Description
Non-inverting differential input for Encoder #0, channel A
Positive side of power supply for Encoder EOAIEOB.
Inverting differential input for Encoder #O, channel A.
Non-inverting differential input for Encoder #O, channel A.
Non-inverting differential input for Encoder #0, channel B
Inverting differential input for Encoder #O, channel A
Inverting differential input for Encoder #0, channel B.
Non-inverting differential input for Encoder #O, channel B.
Not used
Inverting differential input for Encoder #O, channel B.
Not used.
Power, +5 V.
Not used.
Power, common.
Not used.
Positive side of power supply for encoder El A/El B.
Non-invering differential input for Encoder #2, channel A.
Non-inverting differential input for Encoder #2, channel A.
Inverting differential input for Encoder #2, channel A.
Inverting differential input for Encoder #2, channel A
Inverting differential input for Encoder #2, channel B
Inverting differential input for Encoder #2, channel B.
6-13
GEH-5834
531 X311 DTI
8
B
Bi8?&%%&2. 0 0 2 2 . m JP8
1 I l-l I l-l I l-l I 1 23 ~UJP~
kilIlJP5
TB
c
m JP7
2 I I 1 24
Figure 6-3. DTI Board VO Connector
6-7. IBD BOARD I/O
This section defies I/O points for the IBD board. Figure 6-4 shows connector locations.
Table 6- 16. Connectors APL, BPL, and CPL,
I/O Between IBD Board and Phase A , B, and C Shunts, and Upper and Lower Transistors (AC2000)
Pin
No.
1
2
3
4
5
6
7
8
9
10
11
12
Nomen-
clature
B2-
E2-
-___
_-_-
C2/El-
El-*
Bl-
COM I-*
SHUNT_
_--_
_-__
cl-*
Description
Lower transistor base signal (transistor module**, phase -* shunt).
Lower transistor emitter signal (transistor module**, phase -* shunt).
Not used
Not used.
Lower transistor collector signal (transistor module**, phase -* shunt).
Upper transistor emitter signal (transistor module**, phase -* shunt).
Upper transistor base signal (transistor module**, phase -* shunt).
Shunt phase -* - motor side (white wire).
Shunt phase -* (red wire).
Not used.
Not used.
Upper transistor collector signal (transistor module**, phase -* shunt).
Use letter of phase. For example, nomenclature (signal) B2Afor phase A, B2Bfor phase B, and so on.
**Transistor module 1 for phase A; module 2 for phase B; module 3 for phase C.
6-14
Table 6- 17. Connector BDCPL,
I/O Between IBD Board and MCP Board (AC2000)
:i / :EEi 1 Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
VAISO
IFBA
P5VA
DCOMA
NFLTA
FLTRSTA
ENSA
AUFS
ALFS
----
CLK
----
_---
VBISO
IFBB
P5VB
DCOMB
NFLTB
P15V
N15V
BUFS
BLFS
----
FAN3
DTYPE
VCISO
IFBC
P5VC
DCOMC
NFLTC
FLTRSTC
ENSC
CUFS
CLFS
Phase A output voltage isolated by three 475K, .l% resistors.
Shunt current feedback for Phase A.
Logic +5 V power supply.
Logic common.
Phase A base drive fault logic output.
Reset for Phase A and B fault latches.
Enable signal for Phase A
Phase A upper transistor firing signal.
Phase A lower transistor firing signal.
Not connected.
1 MHz clock for LCAs.
Not connected.
Not connected.
Phase B output voltage isolated by three 475K, 1% resistors.
Shunt current feedback for Phase B.
Logic +5 V power supply
Logic common.
Phase B base drive fault logic output.
P15 V logic power supply.
N15 V logic power supply
Phase B upper transistor firing signal.
Phase B lower transistor firing signal
Not connected
Analog input
Voltage programmed by R226 that refers to drive type (4.5 V for AC2000)
Phase C output voltage isolated by three 475K, .l% resistors.
Shunt current feedback for Phase C.
Logic +5 V power supply.
Logic common.
Phase C basedrive fault logic output.
~ Reset for Phase C fault latch.
1 Enable signal for Phase C
Phase C upper transistor firing signal.
~ Phase C lower transistor firing signal.
6-15
GEH-5834
Table 6- 18. Connector BDPPL,
I/O Between IBD Board and MCP Board (AC2000)
Pin Nomen-
No. ciature
Description
1
m--s---
17.7 V ac twisted pair power supply to IBD.
2
_______
17.7 V ac twisted pair power supply to IBD.
-
1 BDCPL 33
BDPPL ,:
In
Figure 6-4. IBD Board I/O Connectors
6-16
6-8. LCC BOARD I/O
This section defines I/O points for the LCC board. Figure 6-5 shows connectors used with the DLAN model; Figure 6-6
shows connectors used with the DLAN+ model.
For connectors 3PL and 9PL, and see Tables 6-4 and 6-8.
Table 6- 19. Connector IOPL,
I/O Between LCC Board and LTB Board (AWDC2000)
Pin
No.
1
Nomen-
clature
-___
Description
+24 U de.
2-8 IN1 - IN8
9-16
----
17
-___
18 IN1
19-25 OUT0 - OUT6
26
--__
f24 U logic lines to the drive.
Not connected.
f24 U dc.
f24 U logic line to the drive.
Relay control lines 0 thru 6.
+24 U dc
Table 6-20. Connector LANPL,
I/O Between LCC Board and External Connections (AWDC2000)
Pin Nomen-
No. clature
Description
1 TX With /TX (LANTB pin 2) differential transmit signals (provides greater noise immunity).
2 /TX See TX (LANTRB pin 1).
3 SHLD Shield (must be grounded)
*Connector 9PL used only on the D-LAN model, previous to the DLAN+ (see Figures 5-2 and 5-4.)
Table 6-21. Connector OPTPL,
I/O Between LCC Board and LTB (AC/DC2000)
POescrlption
1 115 U ac Direct (unprocessed) connection to RPL-1.
2 Relay coil common. Same as RTB-50.
6-17
Table 6-22. Connector ARCPi*,
I/O Between LCC Board and DS200 ACNA (AC/DC2000)
Pin Nomen-
No. clature
Description
1 TXA- Transmitting and receiving signals, channel A.
TXA+
TXB-
TXB+
P5
DCOM
TXB
TXA
Transmitting and receiving signals, channel A.
Transmitting and receiving signals, channel B.
Transmitting and receiving signals, channel B.
Power +5 V dc.
Power digital common.
Transmitting signal selected by JP15 as isolated DLAN circuit or W-422.
Receiving signal selected by JP15 as isolated DLAN circuit or RS-422.
*Connector ARCPL is used only on the ARCNET model (see Figures 5-3 and 5-5).
Table 6-23 Connector KPPL,
I/O Between LCC Board and Keypad (AC/DC2000)
Pin Nomen-
No. clature
Description
l-9
------
Keypad connectors to processor; Output from Ul to pins 19-32 respectively.
10 LODIN Display; Input to Ul pin 38.
11 LDCLK Display; Input to Ul pin 39.
Table 6-24. Connector 2PL*,
I/O Between LCC Board and Power Supply Board (AC/DC2000)
Pin Nomen-
No. clature
Description
1 +24VDC Unfiltered positive 24 V dc power supply.
2 -24VDC Unfiltered negative 24 V dc power supply.
3 DCOM Common return for all low level power supplies.
4 +5 Positive 5 V dc regulated power supply for digital circuitry.
5 +5 Positive 5 V dc regulated power supply for digital circuitry.
6 DCOM Common return for all low level power supplies.
*Connector 2PL used only on the ARCNET model (see Figures 5-3 and 5-5)
6-18
GEH-5834
r-l
IANPL
Figure 6-5. LCC Board l/O Connectors - DLAN Model
6-19
1 KPPL ,o
JP17 JP19
unun
JP14 JP16 JP15 fi?O
en en en Jp16
Figure 6-6. LCC Board I/O Connectors - DLAN+ (ARCNET) Model
6-20
GEH-5834
6-9. LTB BOARD I/O
This section defines I/O points and LEDs for the LTB board. Figure 6-7 shows connector locations.
For connector lOPL, see Table 6-19.
Table 6-25. Connector RPL,
I/O Between LTB Board and RTB Board (AC/DC2000)
Pin
No.
Nomen-
clature
1
----
2
----
3 OUT1
4
____
5 OUT2
6
---_
7 OUT3
8
--__
9 OUT4
10
----
11 OUT5
12
---_
13 OUT6
14
_---
15 OUT7
16
----
Description
115 V ac RTB relay common.
Not connected.
RTB relay K6 pilot output 0.
Not connected.
Not connected.
Not connected.
Not connected.
Not connected.
RTB relay Kll pilot output 5.
Not connected.
Not connected.
Table 6-26 Connectors OTl thru OT7,
LTB Board Connection from Form C Relay Contacts (AC/DC2000)
Pin Nomen-
No. clature
Description
1 OTxCM* Relay common connection; contact rating (0.60 A , 125 V dc).
2 OTxNC* Relay normally-closed (NC) connection; contact rating (0.6A, 110 V dc).
3 OTxNO* Relay normally-open (NO) connection, contact rating (2.OA, 30 V dc).
* Number here (x) corresponds relay output circuit (OT) number
6-21
Table 6-27. Connectors IN1 thtv lN8,
Input to LTB Board (AC/DC2000)
1 INx Positive dc input; input voltage (25 - 250 v dc); series current (5 - 8 mA).
2
_I_
Not connected; input voltage (25 - 230 v dc); series current (5 - 10 mA peak).
3 INx* Neutral or negative dc input; input voltage (116 - 230 V dc); series current (5 - 10 mA peak).
*Number here (x) corresponds to input circuit (IN) number.
Table 6-28. LEDs on LTB Board
LED
Name
Indication
l-8 On when the source is applied to circuits IN1 thru IN8, respectively.
17 - 23 On when Relay RX1 thru RX8, respectively, is energized.
T 7 r
I 1
ITBl ITB2 IT63 IT64 IT85 IT66 ITB7 IT86 RXTBl RXTB2 RXTB3 RXTEM RXTB5 RXTEl6 RXTB7
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
i?
0 0 0 0 0 () ()
Figure 6-7. LTB Board 10 Connectors
6-22
6-10. MCP BOARD I/O
This section defines I/O points and LEDs for the MCP board. Figure 6-8 shows connector locations.
Previous tables define other MCP I/O: Table 6-l for connector 1PL; Table 6-3 for 2PL; Table 6-l 1 for CPTPL; Table 6-17
for BDCPL; and Table 6-18 for BDPPL.
Table 6-29. Connectors 1 FAPL and 2FAPL,
Output from MCP Board (AC2000) to Controller Cooling Fans (If Used)
Pin Connec- Nomen-
No. tor clature
Description
1 1FAPL Xl 115 V ac for controller cooling fan 1.
2 1FAPL X2 115 V ac for controller cooling fan 1 (ground side).
1 2FAPL Xl 115 V ac for controller cooling fan 2
2 2FAPL X2 115 V ac for controller cooling fan 1 (ground side).
Table 6-30. Connector CCPL,
Output from MCP Board to Soft Start SCR (AC2000)
Pin Nomen-
No. clature
1 K
2 G4
3 G3
4 G2
5 Gl
Description
Charge control SCR cathode signal.
Charge control SCR gate signal.
Charge control SCR2 gate signal (high horsepower only).
Charge control SCR3 gate signal (high horsepower only)
Not used.
Table 6-31. Connector DBPL,
Output from MCP Board to Dynamic Braking (0s) Transistor (AC2000)
Negative DB power supply source (for later use).
* Stab also (see Table 6-33).
6-23
Table 6-32. Connector CNTB,
I/O Between MCP Board and External Connections via 2TB (AC2000)
Pin Nomen-
No. clature
Description
1 MAP 115 V ac power switched by MA contactor for DB contactor.
2 x2 Grounded 115 V ac from control power transformer (CPT).
3 FXl Fused 115 V ac from CPT.
*See Table 6-51.
Table 6-33. Stabs for MCP Board
Stab
DBC
GND
DCPLl
DCPL2
DCPLFl
DCPLF2
ACLPl
ACLP2
ACLP3
Description
Collector of the dynamic brake transistor; normally connected to the negative side of the DB resistor
Ground.
Positive and negative instrumentation of the dc link voltage on the invertor side of the dc link fuse
Positive and negative instrumentation of the dc link voltage on the invertor side of the dc link fuse.
Positive and negative terminal of the dc link capacitor.
Positive and negative terminal of the dc link capacitor
Instrumentation from the drive side ac line fuses.
Instrumentation from the drive side ac line fuses
Instrumentation from the drive side ac line fuses
Table 6-34. LEDs on MCP Board
LED
Name
Indication
1 Normally on. Goes off with overvoltage of the dc link or a fault in the dynamic brake circuit. (The
fault is latched and shuts down the system; the fault can be reset by the microprocessor.)
2 Normally on Goes off with a fault in any of the six base drive circuits. (The fault is latched; the
microprocessor can indicate which base drive circuit faulted).
6-24
GEH-5834
&.Fl
ACG.3
ACE2
ACLPl
II
EO
II
DCPLl
DcG..F*
AC POWER SUPPLY CARD
531 X303MCP
DCOM
0
TP3
CPTPL
1
u
DEPL
1
q
1
DBC
II
4PL
1
5
1 FAPL
uu
PFA!L
1 1
,F%
Figure 6-8. MCP Board I/O Connectors
6-25
6-11. NTB/3TB BOARD l/O
This section defines I/O points for the NTB/3TB board. Figure 6-9 shows connector locations.
Previous tables define other NTB/3TB I/O: Table 6-3 for connector 2PL, Table 6-5 for 6PL; Table 6-7 for 8PL; and Table
6-13 for 4PL.
Table 6-35. Connector COMPL,
RS-232C I/O Between NTB/3TB Board and User Intetiace (AC/DC2000)
Pin
No.
Nomen-
clature
Description
1 - 25 ----
The drive includes an RS-232C connection only for use as a serial link with
the ST2000 Toolkit. The ST2000 Toolkit is a diagnostic and configuration
program used during installation, tuneup, and troubleshooting. GE does not
intend this communications link to be used for any other purpose
CAUTION
Do not connect Pin 25 directly to a PC (personal computer) unless
JP21 is in the 1-2 position, or damage may occur.
NOTE
Although the RS-232C interface should work correctly with all 25
pins of COMPL connected, using the minimum possible interface
avoids incompatibility and noise problems.
6-26
GEH-5834
3TB Nomen-
Term.# clature
1
2
EOA
EOVl
3 EOA
4 EOV2
5 EOB
6 FA
7 EOB
8 FB
9 EOM
10 FCOM
11 EOM
12 EXSY
13 RlC
14 Cl1
15 Rl NC
16 Cl2
17 Rl NO
18 Cl3
19 R2C
20 Cl4
21 R2NC
22 Cl5
23 R2NO
24 Cl6
25 R3C
26 Cl7
27 R3NC
24 Cl6
25 R3C
26 Cl7
27 R3NC
28 Cl8
29 R3NO
30 RF24(1)
Table 6-36. Connector 3TB,
I/O Between NTB/3TB Board and External Connections (AC/DC2000)
Description
Non-inverting differential input for Encoder #O, channel A
Positive side of power supply for Encoder EOAIEOB. Either +5 or +15 V dc as set by DTBs
jumper JP12.
Inverting differential input for Encoder #O, channel A.
Return for EOVl, basically at COM potential.
Non-inverting differential input for Encoder #0, channel B.
Non-inverting RS-422, half-duplex serial data line. Provides a serial channel into the DCCs
Motor Control Processor (as opposed to the RS-232C channel into the DCCs Drive Control
Processor). DTB jumpers JPl and JP2 are used to connect line termination resistors to FA and
FB (needed at each end of an RS-422 network).
Inverting differential input for Encoder #O, channel B.
Inverting RS-422 half-duplex, serial data line. (See FA, 3TB point 6.)
Encoder interface marker pulse channel non-inverted differential input.
Signal return for EXSY (at COM potential).
Encoder interface marker pulse channel, inverted differential input.
External sync input to DCCs Motor Control Processor.
Relay #l common contact.
Cl1 - Cl8 are general purpose control inputs&24 V dc maximum with 27 m input impedance.
Relay #l normally-closed contact.
See Cl1 (3TB point 14).
Relay #l normally-open contact.
See Cl1 (3TB point 14)
Relay #2 common contact.
Relay #2 normally-closed contact.
Relay #2 normally-open contact.
Relay #3 common contact
Voltage reference for digital control inputs. Defaulted to -24 V dc; changes to +24 V dc via
DTBs JPlO and JPll. Each digital control input is active when connected to RF24, inactive
when open. Total tit24 V dc load includes loading on RF24.
6-27
3TB
Term.#
31 R4C
32 RF24(2)
33 R4NC
34 RUN
35 R4NO
36 JOG
37 R5NO
38 POL
39 R5NC
40 XSTP
41 R5C
42 CTLN 1
43 R6NO
44 CTLN2
45 R6C
46 Pl
47 MSRF
48 P2
49 DVM
50 P3
51 ASP0
52 P4
53 DACl
54 MET1
55 DAC2
56 MET2
57 MSSY
58 RESET
Nomen-
clature
Table 6-36 - Continued.
Connector 3TB, I/O Between NTB/3TB Board and External Connections (AC/DC2000)
Description
Voltage reference for digital control inputs. (See RF24[1], 3TB point 30.)
Relay #4 normally-closed contact
General purpose input. Defaulted to, but not limited to, RUN function.
General purpose input, defaulted to JOG function.
General purpose input, defaulted to the reference polarity function.
General purpose input, defaulted to the XSTOP function (normally-closed).
Control on input 1. CTLNl and CTLN2 (3TB point 42) form part of the circuit that picks up the
MA contactor pilot relay. They must be connected together for the drive to run. Can also be
used to connect external interlocks, providing a fail-safe (microprocessor-independent) way to
stop the drive.
Control on input 2 (See CTLNl, TB#42.)
Pl thru P4 are medium resolution analog input channels for voltages from f5 V dc to f50 V
dc. Scaled via respective pots Pl thru P4 on the NTBI3TB. Input impedance 2 10 kQ.
Relay #6 coil driver (Master Sync Reference output), open collector driver output.
See Pl (3TB point 46).
Medium resolution analog input channel with fixed scaling for f25 5 V dc maximum. In
conjunction with drive test 03, provides a digital voltmeter function with > 0.5% accuracy for
diagnostic functions.
Medium resolution analog input channel with fixed scaling for fl0 V dc maximum
Output from 8-bit D/A converter. Can source f10 V dc at no load or f8 V dc at a 10 mA load
(200 R series impedance). Any drive variable sent to this output and can be scaled to set the
value corresponding to 10 V dc output. (For diagnostics and system applications.)
Output from 8-bit D/A converter. Can source f10 V dc at no load or f8 V dc at a 10 mA load
(200 Q series impedance) Any drive variable can be sent to this output and can be scaled to
set what value corresponds to 10 V dc output. (Provided for meter driver functions).
Same as MET1 (3TB point 54), except provided for diagnostics and system applications.
Same as MET1 (3TB point 54).
Input to internal interrupt INTO of DCP. Biased to +24 V dc through 27 kQ, must be pulled to
COM (< +1.5 V dc) to be recognized by DCCs Drive Control Processor (DCP).
Hard reset input to the drive. Connecting RESET to +5 to +24 V dc resets all processors in
the drive. Leaving RESET open or connecting to COM allows drive operation. The DCC
provides a 20 ms noise filter on this input.
6-28
3TB
Term.#
59 TOIN
60 +5VDC
61 TOOUT
62 +lSVDC
63 REFP
64 -15VDC
65 REFN
66 COM(l)
67 RSVD( 1)
68 COM (2)
69 FDBP
70 +24VDC
71 RSVD(2)
72 -24VDC
73 FDBN
74 ElVl
75 RSVD(3)
76 ElV2
77 MACM
78 RSVD(4)
79 MAN0
80 GRCl
81 MANC
82 GNCl
83 CFXl
84 GNOl GP
85 x2
86 GRC2
Connector 3TB, I/O Between NTB/3TB Board and External Connections (AC/DC2000)
Nomen-
clature
Description
Input to internal timer/counter 0 of DCCs DCP. Is biased to +24 V dc through 27 m and must
be pulled to COM (less than +1.5 V dc) to be recognized by DCP.
+5 V dc source, ltlO%, 300 mA (including load on ElVl).
TTL output through 200 Q from DCPs timer/counter 0 (on DCC).
+15 V dc source, flO%, 300 mA (including load on ElVl).
Non-inverting differential analog reference input (See REFN, 3TB point 65.)
-15 V dc source, flO%, 300 mA (including load on ElVl).
Inverting differential analog reference input. Maximum reference can be 9 - 29 V dc, coarsely
selected by DTBs switches 1 - 7. DCCs pot provides fine scaling. Input impedance 2 60 kC
with e 1 ms of filtering.
0 V common reference for all drive I/O
Not used. Provides voltage clearance between signal level points and points with potentials
above 50 V.
0 V common reference for all drive I/O, same as 3TB point 66.
Non-inverting differential analog tach input. (See REFN, 3TB point 73.)
+24 V dc source, rt25%, unregulated, 500 mA (including RF24 load).
above 50 V.
-24 V dc source, +25%, unregulated, 500 mA (including RF24 load).
Inverting differential analog tach input. Either AN or dc tachometers with a top speed voltage
from 25 to 390 V can be connected to these differential inputs DTBs switches 1 - 7 provide
coarse scaling; DCCs pot and jumper provide fine scaling and AN tach rectification. Input
impedance is r 300 kQ with c 1.5 ms of filtering.
Baluned power supply for encoders on SPC.
above 50 V.
Return for ElVl, basically at COM potential.
Form C common contact from MA pilot relay; auxiliary contact from the relay used to pilot the
MA contactor. Rated for 125 V ac, 2 A.
above 50 V.
Form C normally-open contact from MA pilot relay; auxiliary contact from the relay used to
pilot the MA contactor. Rated for 125 V ac, 2 A.
GP relay common contact of first form C.
Form C normally-closed contact from MA pilot relay; auxiliary contact from the relay used to
pilot the MA contactor Rated for 125 V ac, 2 A
GP relay normally-closed contact
120 V ac, f15%, fused at 500 mA total including internal fans (isolated from COM).
Relay normally-open contact.
Return for CFXl 120 V ac loads (isolated from COM).
GP relay common contact of second form C (rated 120 V ac, 1 A).
6-29
Connector 3TB, I/O Between NTBL3TB Board and External Connections (AC/DC2000)
3TB Nomen-
TermR clature
87 GR+
88 GNCP
89 GR-
90 GN02
Description
GR+ and GR- (3TB point 89) are coil inputs to a general purpose relay. This relay is not
internally connected to any drive circuitry and may be used as required for customer applica-
tions. (Coil may be driven by 24 V or 120 V ac or dc.)
GP relay normally-closed contact (rated 120 V ac, 1 A).
See GR+ (3TB point 87).
GP relay normally-open contact (rated 120 V ac, 1 A).
4PL
I
I k% 5
lllIlIITlllllIIlTlI1
3 :: 58
IA
s:
DA1 DA2
Figure 6-9. NTB/3TB Board I/O Connectors
6-30
6-12. PC- BOARD I/O
This section defines I/O points for the PCH, PCN, PCR, and PCS boards. (See Table 5-2 for board definitions.) Figures 6-10
thru 6-13 show board connectors.
For connectors 5PL and 5APL, and see Table 6-14.
Table 6-37. Connectors 1 FPL thru 1 RPL,
I/O Between PCN, PCR, or PCS Boards and SCRs (DC2000)
Nomen-
clature
Description
.~
*Not included on PCN board.
Table 6-38. Connectors SFAPL & SFBPL,
Output from PCH Board (DC2000)
SFAPL 5FBPL
Pin No. Pin No.
1, 2 1, 2
3, 4 3
5, 6 5
7, 6 7
9 9
10 10
Nomen-
clature
AlF
A2F
A3F
A4F
A5F
A6F
Description
Drives cell 1 F gate pulse transformer.
Table 6-39 Connectors SRAPL & SRBPL
SRAPL SRBPL
Pin No. Pin No.
1, 2 1,2
3 3, 4
5 5, 6
7 7, 6
9 9
10 10
I
Nomen-
clature
AlR
A2R
A3R
A4R
A5R
A6R
Description
Drives cell 1 R gate pulse transformer.
6-31
Stab
PlA, PlB
P2A
P2B
Pl
P2
P3 - P6
P7 - PlO
DCS
1-3AC
4-6AC
Table 6-40. Connectors FSAPL and FSBPL
Input to PCH Board (DC2000)
Connector Pins Description
FSAPL 1, 3, 5, 7, 9, 10 Forward firing sequence signals.
FSBPL 1, 3, 5, 7, 9, 10 Reverse firing sequence signals.
Table 6-41. Connectors 1PL thru 6PL and 11 PL thru 16PL,
Connector Pins Description
1 -6PL 1 Forward gate pulse to corresponding SCR (red wire).
1 -6PL 2 Forward gate pulse to corresponding SCR (white wire).
11 -16PL 1 Reverse gate pulse to corresponding SCR (red wire).
11 -16PL 2 Reverse gate pulse to corresponding SCR (white wire)
Board
PCS
PCR, PCS
PCS
All
All
All
PCH, PCR, PCS
PCS
PCN, PCR, PCS
PCR, PCS
Table 6-42. PCH, PCN, PCR, PCS Board Stabs
Description
Positive dc bus voltage feedback
Negative dc bus voltage feedback.
Negative dc bus voltage feedback
Positive dc bus
Negative dc bus.
Voltage feedback scaling resistor connections (see Tables 6-43 thru 6-45).
Voltage feedback scaling resistor connections (see Tables 6-43 and 6-44).
To dc snubber resistor.
Snubber resistor connections.
Snubber resistor connections
6-32
Table 6-43. Connection Options for PCR Board Stabs Table 6-44. Connection Options for PCS Board Stabs
Stab Connection
P3-P8, P6-P9
P3-P4, P5-P6
P7-P8, P9-PlO
P4 - P7, P5 - PlO
P3 - P7, P6 - PlO
P4 - P8, P5 - P9
None
Voltage (Stabs Pl - P2)
Gl, G4* G2* G3* Stab Connection
Gl, G3* G2, G4*
19ov
240 V
290 v
340 v
400 v
450 v
500 v
350 v
420 V
500 v
570 v
550 v
630 V
700 v
50 v
80 V
120 v
150v
170 v
210 v
240 V
P3 - P8, P6 - P9
P3 - P4, P5 - P6
P7-P8, P9-PlO
P4-P7, P5-PlO
P3-P7, P6-PlO
P4 - P8, P5 - P9
None
240 V
290 v
500 v
550 v
570 v
580 V
630 V
240 V
350 v
390 v
500 v
550 v
595 v
700 v
l PCR group number. See Table 5-2 *PCS group number. See Table 5-2.
Table 6-45. PCN Board Stab Connection Options
Stab Connection Gl* G2*
P3-P4, P5-P6 240 V 550 v
None 500 v 700 v
l PCN group number. See Table 5-2.
6-33
CZ3
Pl
n
II
6
mrd llPL
n;l2PL
nrd 14PL /---Jj; 15PL
CZZl
P5
lZ=, CZ3
P4 P6
531 X123PCH
CZZl
P6
25 1
BFIPL
E2 lOI ,,,2 26] r= l=r
PYO
Inn::
1PL
OIL
2PL
+24
=
PkOM c
DFP
= FPl
m ; 16PL 0;6PL
Figure 6- 10. PCH Board I/O Connectors
2Pol
tlln::
3PL
4PL
D3PL ,m
6-34
4FPL
Kl
1
5FPL 6FPL 1 FPL SFPL 3FPL
:m :m :nl :ul :cn
531 X122PCN
P2;;
Pl
n
II

1AC
CZ3
c5c-----Yp=4,
NOTE: REMOVE Wl AND W2 FOR 5OOV
DC DRIVES
2AC
EZZl
3AC
fi=3
Figure 6-11. PCN Board l/O Connectors
6-35
GEH-5834
4FPL
Kl
T) P2

Pl
EZ3
5RPL
XIII
5FPL
:m
Lb3
Y
1AC
CZZI
PRPL 3RPL
6RPL 1RPL
:m
531 x121 PCR
:nl I3 kl
2 2
POWER CONNECTCARD
6FPL
:m
n
II P7

2Ac
EZZl
;I P4

e
1
5PL 25
3AC
CZS
1FPL
:nl
llP6

rlP6

2FPL 3FPL
I5 ti
2 2
C = f 4AC C = a SAC c = a 6AC
Figure 6-12. PCR Board I/O Connectors
6-36
GEH-5834
4RPL
5RPL 6RPL
1 R_pL
I
PRIL SFl_pL
I
WP3
In El
4F;L 5EJL
F3
=
E
-
POWER CONNECTCARD
531 X3oaPCS
In
SF&
F3
22%
Pl
=
lzs
PZ \\ .___ ----- _ -GM
WP4
3zs
I I
1 FPL 3FPL
=
PS
DCS
=
4Es 5% 6%
Figure 6-13. PCS Board I/O Connectors
6-37
6-13. RTB BOARD I/O
This section defines I/O points and LEDs for the RTEI board. Figure 6-14 shows connector locations.
For connector RPL, see Table 6-25.
Table 6-46. Connector RTB,
l/O Between RTB and External Connections (AC/DC2000)
RTB
Term.#
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Nomen- RTB Nomen-
clature* Term.# clature*
K20A 18 K221 NC
K201 NO 19 K222NO
K201 CM27 20 K222CM
K201 NC 21 K222NC
K202NO 22 K23A
K202CM 23 K231 NO
K202NC 24 K231 CM
K21A 25 K231 NC
K211 NO 26 K232NO
K211CM 27 K232CM
K211 NC 28 K232NC
K212NO 29 K24A
K212CM 30 K241 NO
K212NC 31 K241 CM
K22A 32 K241 NC
K221 NO 33 K242NO
K221 CM 34 K242CM
RTB Nomen-
Term.# clature*
35 K242NC
36 K25A
37 K251 NO
38 K251 CM
39 K251 NC
40 K252NO
41 K252CM
42 K252NC
43 K26A
44 K26ANO
45 K261 NO
46 K261 NC
47 K262NO**
48 K262CM**
49 K262NC**
50 KCM**
51 115v**
l The RTB board contains seven relays, each with two form C contacts. Nomenclature for the terminal points indicate the contact
connection. For example, for K201NO: K= relay; 20 = which of seven relays (20 - 26); 7 = which of the two form C contacts;
and NO = normally open, as opposed to normally closed (NC) or common (CM).
** RTB terminal numbers 47 - 51 are for the AC2000 drive only
6-38
Table 6-47. LEDs on RTB Board
LED
Name
Indication
1 - 7 1 On when Relays K6 thru K12 (respectively) are energized.
RPL
1 7116
RTB TB OPTION CARD
531 X191 RTB
LED1
0
$JP
LED2
0
$lJW
3-
LED3
0
j!
LED4
0
iDJP4
3-
LED5
0
glJP5
LED6
0
gJP6
3
LED7
0
1,JP7
2
3
OPTPL
u
RTB RTE
KlBl RTB2 FIT@3 RW RTBL RTB6 RTB7 RTB6 RTB9 RTBIO RTEll RTB12 RTB13 RTB14 RTB15 RTB16 Rm
i3
s
2 si
>
M
?
2
1 10 20 30 40 51
I
Figure 6-14. RTB Board I/O Connectors
6-39
6-14. SND BOARD I/O
This section defines I/O points for the SND board. Figure 6-15 shows connector locations.
Table 6-48. Connectors 1FSPL thru GFSPL and 1RSPL thru GRSPL,
I/O Between SND Board and SCRs (DC2000)
Nomen-
clature
Description
Table 6-49. Stabs for SND Board
Stab Description
Pl Output to dc armature motor.
P2 Output to dc armature motor.
ACS 1 - 6 AC signals (snubber resistor connections).
DCS Resistor across feedback armature
M + 105 V dc to external.
A Internal tie point.
AA Internal tie point.
B Contactor control
CACl AC rectifier input from CPT in full-wave bridge.
CAC2 AC rectifier input from CPT in full-wave bridge.
6-40
GEH-5834
HIGH HORSEPOWER
SNUBBER CARD
531XBlOSND
1 FSPL 4RSPL PFSPL
rl 11 cl
SRSPL BFSPL 6RSPL
rl rl rl
4FSPL 1RSPL BFSPL PRSPL JRSPL
Figure 6-75. SND Board MO Connectors
6-41
6-15. SPC BOARD I/O
This section defines I/O points for the SPC board. Figure 6-16 shows connector locations.
For connector 7PL, see Table 6-6.
Table 6-50, Connectors 16PL and 1 TB,
I/O Between SPC Board and User interface (AUDC2000)
1TB
Term. #
--
--
--
--
--
--
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16PL
Pin #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Nomen-
clature
Description
ElAB Non-inverting input for Encoder #l, channel A
/ElAB Inverting input for Encoder #l, channel A.
ElBB Non-inverting input for Encoder #l, channel B
/El BB Inverting input for Encoder #l, channel B.
ElMB Non-inverting input for Encoder #l, marker channel.
/El MB Inverting input for Encoder #l, marker channel.
E2AB Non-inverting input for Encoder #2, channel A
lE2AB Inverting input for Encoder #2, channel A.
E2BB Non-inverting input for Encoder #2, channel B.
IE2BB Inverting input for Encoder #2, channel B.
E2MB Non-inverting input for Encoder #2, marker channel.
lE2MB Inverting input for Encoder #2, marker channel
PFl N Inverting input for analog channel SPl.
PFl P Non-inverting input for analog channel SPl.
PF2N Inverting input for analog channel SP2
PF2P Non-inverting input for analog channel SP2.
TXP Non-inverting RS-422 output from DCCs Motor Control Processor (MCP)
TXN Inverting RS-422 output from DCCs MCP.
RXN Inverting RS-422 input to DCCs MCP
RXP Non-inverting RS-422 input to DCCs MCP.
6-42
GEH-5834
SPlTPP
m r-1
; 7
u
a
N
f-7
: $
u
N
Figure 6- 16. SPC Board I/O Connector
6-43
6-16. TOP OF DRIVE
Table 6-51 defines I/O for connector 2TB, located on top of the drive.
2TB
Term.#.
1
2
3
4
5*
6*
7*
6
9
10
11
12
Nomen-
clature
es_-
----
KLIXON
KLIXON
CNTBl
CNTB2
CNTB3
CPTBP
XFMR
----
XFMR
CPTBl
Table 6-51. Connector 2TB,
Located on Top of Drive (AC/DC2000)
Description
Not used.
Not used.
Thermoswitch connection for heatsink thermal over-temperature protection.
Same as 2TB point 3.
115 V ac power switched by MA contactor for DB contactor MAP.
Grounded 115 V ac from control power transformer (CPT) X2
Fused 115 V ac from CPT FXl .
CPT primary connection.
Not used.
CPT primary connection
*Connect to MCP board connector CNTB (see Table 6-32)
6-44
CHAPTER 7
OPERATING THE PROGRAMMER
7-1. INTRODUCTION
NOTE
To avoid drive malfunction, only qualified
personnel should use the Programmer.
The AC/DC2000 drive includes an operator interface
module - the Programmer - for software adjustments
and diagnostic testing. The Programmer provides a digital
display for an alphanumeric readout of fault codes, status,
RAM values, and EEROM values. Its alpha-numeric
keypad enables the user to operate and adjust the drive.
The Programmer resides on the drives LCC board, which
mounts on the DCC board. It is accessed by opening the
cabinet door at the front of the drive.
Chapter 6 lists and defines the LCCs I/O connections.
NOTE
The Programmers parameter address, desig-
nated as EE1.O (CFGJPR), must contain a I
(an odd number) to enable it to function. A 0
in the address disables the Programmer. See
Parameter Mode (section 7-4.2) to change the
value, if needed.
7-2. KEYPAD
NOTE
This chapter indicates a Programmer key by
enclosing the key name in ( ) symbols. For
example, (STOP) symbolizes the key labelled
STOP.
The Programmer keypad enables an operator to control the
drive by:
l Examining drive parameters
. Inputing alphanumeric data
l Running diagnostics
l Initiating self-tuning programs
There are 20 keys. Most keys have more than one label,
each a different color. The color indicates the keys
function during the associated operating mode.
7-3. DISPLAY
NOTE
This chapter indicates a Programmer display
by using a different typestyle. For example, if
the Programmer displays the word RE-
VERSE, this chapter shows it as REVERSE.
The Programmers display presents an alphanumeric
readout for drive parameters, faults, and keypad inputs.
The fault code display provides an easier alternative to
the boards indicating LEDs, which must be decoded.
The display uses 6 (of 16) characters for the mnemonic,
where required. Decimal points indicate the operating
mode:
9 One decimal in the Operate Mode (for example,
OPE RATE MODE)
l Two decimals in the Parameter Mode (for exam-
ple, P.AR AMETR-M MODE)
9 Three decimals in the Diagnostic Mode (for
example, D LA GNOSTIC MODE)
7-4. OPERATING MODES
The Programmer operates in any of three modes:
. Operate Mode, the normal mode which the drive
automatically enters at powerup
l Parameter (EEROM or Mirror) Mode, selected by
an operator from Operate Mode
l Diagnostic Mode, selected by an operator from
Parameter Mode
7-l
GEH-5834
The Programmers operating mode determines the func-
tion of most keys. This is shown by the color (and
position) of the keys labels:
l Red labels (top of the key) apply during the
Operate Mode
. Blue labels (bottom) during Diagnostic Mode
l Black labels (middle of key) during Operate,
Diagnostic, and Parameter Modes
l Green labels (middle, right side of black label),
selected by holding down (SHIFT) while pressing
a key, during Operate, Diagnostic, and Parameter
Modes; (SHIFT) is also green
The following paragraphs describe the modes and key
functions.
pii-
Potential drive activation and inadvertent
equipment movement when testing. Through-
out the remainder of this section, do not use
DIAGNOSTIC RUN, SELF-TUNE (I-TUNE
or S-TUNE), or any Programmer RUN func-
tions on any drive (such as crane or elevator)
where motion may cause damage or injury.
7-4.1. Operate Mode
At powerup, the drive enters Operate Mode. This activates
the red and black/green keypad functions.
NOTE
Red key functions are dominant; black/green
key functions only work in Operate Mode
after (SET) has been pressed.
If a key is not activated, the Programmer briefly displays
FL41 L-KEYOFF.
The Operate Mode display is in the form M SO% I O%,
where M indicates Manual mode (alternatively an A
indicates Auto mode). X0% indicates percentage of rated
speed, and I 0% indicates percentage of rated current.
Note the one decimal point to indicate Operate Mode.
WARNING
1
Potential drive activation and inadvertent
equipment movement when testing. Use Oper-
ate Mode only as a diagnostic tool; motor will
rotate, ignoring safety circuits. Do not at-
tempt to use (RUN), (SLOW), (JOG), (Rl), (R2), or
(REV), WW
7-4.1.1. RED KEY FUNCTIONS. In the Operate mode,
the red key functions are used as follows:
(STOP) -
(DRV#) -
(SET) -
Controlled stop
Used as part of access code to Parameter
Mode
Used for entering Parameter Mode (section
7-4.2) and to adjust settings of various key-
pad functions; activated using the following
steps:
1. Press (SET)
2. Press either (RUN), (SLOW), (JOG),
(Rl), (R2), (REFR), or (DRV#)
3. Enter the desired setting in decimal
numbers (for example, for Drive 77,
enter 77 after pressing (DRV#)
4. Press (ENTER)
NOTE
The EEROM must be Write Enabled to make
these adjustments (see section 7-4.2.3).
(INC) - Press to increase or decrease the speed at
which the drive is running for any of the
RUN functions
(DEC) - Press to increase or decrease the speed at
which the drive is running for any of the
RUN functions
(REV) - Activates a commands reverse function:
1. Press (REV) and the Programmer dis-
plays REVERSE.
7-2
2. Press the desired function key: (RUN),
(SLOW), (JOG), (RI), (R2), or (REFR)
NOTE
If (REVXJOG) is pressed, the drive performs
the REVERSE JOG as long as the JOG key is
held. When {JOG) is released, the REVERSE
JOG function stops. However, the Program-
mer remains in the Reverse Operate mode,
and displays REVERSE to indicate that.
(RESET) - Resets the drive after fault or error messages
appear; produces a Software Reset
we -
Auto/manual operating mode; can toggle be-
tween Auto (A) and Manual (M) if proper
bit is set in EE.690
(RATIO) - Not used
7-4.1.2. BLACK/GREEN KEY FUNCTIONS. The black/
green key functions are used as follows:
Numerals - Black (0) thru (9); use (SHIFT) for green (A)
thru (F), decimal point, and hyphen
(PREV) - Displays previous (last) mnemonic entered
(NEXT) - Displays the next mnemonic
(ADDR) - Displays last address entered
(HEXIDEC) - Press to enter hexadecimal format; press
again to re-enter decimal format
(ENTER) - Press to enter a value
(CLEAR/MODE) - Used to clear a parameter
7-4.2. Parameter Mode
Parameter Mode allows the user to examine and change
any EEROM (E*) or EEROM mirror parameter ad-
dresses to customize the drive to an application.
There are two types of Parameter Modes:
.
Parameter EEROM Mode. Changes made to
parameters during this mode can be permanent -
changes are remembered even if power is re-
moved from the drive.
l Parameter Mirror Mode. Changes made to
parameters during this mode are overwritten by
the corresponding EEROM address during
powerup or a hard reset.
Parameter Mode activates the same black/green key
functions as the Operate mode. It also uses red keys
(STOP), (INC), and (DEC). See section 7-4.1 (Operate Mode)
for key definitions.
7-4.2.1. ENTERING PARAMETER MODE. Figure 7-l
depicts the Programmer operating modes and steps to
move between them. Note that Parameter Mirror Mode
can be entered from either from the Operate Mode or from
the Parameter EEROM Mode.
PRESS
POWER-UP
>
(SET)(DRIVE#)(~)
PARAMETER
(8)
h
PRESS
(CLEAR/MODE)
DIAGNOSTIC
c-7.
PRESS (PREV)
PARAMETER
MODE
' PRESS (CLEAR/MODE)
/MODE)
Figure 7-l Changing Modes of Operation
7-3
To enter Parameter Mode:
1. Check that the Programmer is in the Operate
Mode (display should read M S.O% I 0%)
2. Press (SET)
3. Press (DRW)
4. Press (7)
The next step selects either Parameter Mirror or
Parameter EEROM Mode.
5. a. To select Parameter EEROM Mode, press
(7)
The display shows PAR AMETR-E MODE.
b. To select Parameter Mirror Mode, press (8).
The display shows P.AR.AMETFi-M MODE.
Note that the Programmer uses two decimal points in
the display to indicate Parameter Mode.
6. Press (ENTER)
NOTE
Pressing (PREV) takes the display back one EE
address. This key also is used to change be-
tween Parameter Mirror Mode and Parameter
EEROM Mode.
To enter Parameter Mirror Mode from the Parameter
EEROM Mode:
1. Check that the Programmer displays
P.AR.AMETR-E MODE
2. Press (CLEAR/MODE)
The display should now show P AR.AMETR-M MODE.
To return to the Parameter EEROM mode from the Mirror
Mode, press (PREV).
7-4.2.2. EXAMINING PARAMETERS. To examine the
present value of any parameter:
1. Key in the 3- or 4-digit parameter address
2. Press (ENTER)
7-4
The Programmer immediately displays the address
name and present contents.
3. To examine the parameter in the next higher or
lower address, press the (NEXT) or (PREV) key
This allows an operator to easily view parameter in a
series of consecutive addresses.
To examine another parameter (not in a next address):
1. Press (CLEAR/MODE) to clear the present parameter
The display then shows PAR AMETR-E MODE (the -E
indicates Parameter EEROM Mode) or P.AR AMETR-M
MODE (the -it4 indicates Parameter Mirror Mode).
2. Key in the address number for the parameter
desired
3. Press (ENTER)
The address name and contents appears in the display.
NOTE
To enter or view in hexadecimal, press the
(HEWDEC) key. To re-enter decimal mode,
press (HEWDEC) again.
7-4.2.3. CHANGING PARAMETERS. To change param-
eters, two conditions must exist:
1. The DCCs EEROM (E2) jumper JPl must be in
position 2-3 for write ENABLE (position l-2 =
E2 write PROTECT).
2. Parameter address 2.0, designated as EE.2.0,
(DGNJP) must contain a 1 (odd value).
If a 0 (even value) is present, add a 1 and press (ENTER).
To change a parameter, use the steps in the following
example.
Example:
Examine and change the minimum delay time from
RUN/JOG commanded to reference enabled. Drive delay
time (EE.38, STRDLY) is already set at 0.25 seconds.
Change it to 0.15 seconds.
1. Make sure the DCCs E2 Enable jumper (JPl) is
in the ENABLE position (2-3), and that EE.2.0,
DGNJP contains a 1.
2. After examining EE.2.0, press:
(CLEAR/MODE)
then (3)
then (8)
then (ENTER)
The display shows S.TR.DLY 25, corresponding to a
0.25 second delay time.
3. Either press (DEC) until the display value de-
creases to 15, or press (1) then (5)
In either case the display shows S TRDLY. 15 (note
that the decimal point in this display indicates Param-
eter Mode).
4. Press (ENTER)
This places the new value into EEROM.
The display then shows P.ARAMETR-E MODE
6. To examine other addresses at this point, key in
the appropriate parameter address number fol-
lowed by (ENTER)
NOTE
This next step is extremely important to pre-
vent accidental reprogramming of the drive.
7. To seal the new parameter values, remove the I
from EE.2.0, DGNJP returning it to the as
shipped 0; return JPl to the write PROTECT
position (l-2).
7-4.2.4. EXITING PARAMETER MODE. The operator
exits Parameter Mode by pressing (CLEAR/MODE) two or
three times, as needed (refer to Figure 7-l):
l If in Parameter EEROM Mode, press
(CLEAR/MODE) three times
This moves first to Parameter Mirror Mode, next to
Diagnostic Mode, then finally to Operate Mode.
l If in Parameter Mirror Mode, press (CLEAR/MODE)
twice
This moves first to Diagnostic Mode, then to Operate
Mode.
7-4.3. Diagnostic Mode
The Diagnostic Mode is used for:
9 Providing internal digital displays
l Running diagnostic checks
l Initiating self-tuning procedures
This mode activates the blue and black keypad functions,
with the blue functions dominant, (INC) and (DEC).
Blue label functions include (DGS), (DGR), (DVM), (ARMV),
(ARMI), (FIELDI), (SPEED), (TORQ), (HP), (RAM), (DRV#), and
(TEST).
The black label functions are the same as in Operate
Mode (see section 7-4.1 for definitions), except for
(HEX/DEC), which does not function in Diagnostic Mode.
NOTE
The hexadecimal numeral option (shown on
the keys in green) is not available in Diagnos-
tic Mode.
7-4.3.1. ENTERING DIAGNOSTIC MODE. To enter the
Diagnostic Mode:
1. Make sure that drive is in Parameter Mirror
Mode (the display shows PAR AMETER-M MODE).
If not, see section 7-4.2.
The display immediately shows D.I.A.GNOSTIC MODE.
If a particular parameter is being displayed in the Parame-
ter Mode, enter the Diagnostic Mode as follows:
This displays P AR AMETR-M MODE
7-5
GEH-5834
This displays D I A.GNOSTIC MODE (note the three
decimal points in the display to indicate Diagnostic
Mode).
7-4.3.2. EXlTlNG DIAGNOSTIC MODE. To move from
the Diagnostic Mode to the Operate Mode, press
(CLEAR/MODE} once.
To return to the Parameter Mirror Mode from the Diag-
nostic Mode, press the (PREV) key.
7-5. DRIVE DIAGNOSTICS
Potential drive activation and equipment
movement when testing. Throughout the
remainder of this section, do not use DIAG-
NOSTIC RUN, SELF-TUNE (I-TUNE or
S-TUNE), or any Programmer RUN functions
on any (such as crane or elevator) where
movement may cause damage or injury.
The Programmer allows an operator to run resident
diagnostic tests on the drive. These tests aid in startup,
tuneup, and troubleshooting. To run diagnostic tests, the
drive must be in Diagnostic Mode, as described above.
This section describes the available diagnostic tests, which
are listed in Table 7-1. Note that some tests are only
available with certain hardware or software configurations.
7-5.1. Running the Diagnostic Tests
To run Tests 3 thru 9:
1. Enter Diagnostic Mode (described above)
2. Press the key for the selected test
To run diagnostic Tests 10 thru 16:
1. Press (TEST). This displays T E.S.T NO
2. Press X, where X is the number of the particular
test to be performed
3. Press (ENTER)
7-6
To cancel a Diagnostic Test, press (PREV) once.
To exit DIAGNOSTIC mode without displaying any
diagnostic variables, press (CLEAR/MODE} twice.
Table 7- 1. Standard Diagnostic Tests
Name
Test 1
Test 2
Test 3
Test 4
Test 5
Test 6
Test 7
Test 8
Test 9
Test 10
Test 31
Test 11
Test 12
Test 13
Test 14
Test 15
Test 16
RAM Test
DACl, -2
METl, -2
Description
(DGS), keypad selection. Do not use.
(DGR), keypad selection. Do not use.
(DVM), keypad selection. Displays digital
voltmeter
(ARM V), keypad selection. Displays arma-
ture voltage.
(ARM I), keypad selection. Displays arma-
ture current in amps.
(FIELD I), keypad selection Displays field
current in amps.
(RPM), keypad selection. Displays motor
speed (revolution per minute).
(TORQ), keypad selection. Displays motor
torque in 1 lb-ft.
(HP), keypad selection. Displays motor
horsepower.
Displays software revision of DCC and
LCC microprocessors.
Displays four diagnostic variables
(selectable) in decimal format.
Displays four diagnostic variables
(selectable) in hexadecimal format.
Invokes the cell (SCFUtransistor) test.
Invokes the board test function.
Current regulator tuneup function.
Speed regulator tuneup function.
Field regulator tuneup function.
Displays single diagnostic variable
(selectable).
Digital-to-analog converter outputs.
Digital-to-analog converter outputs.
GEH-5834
7-5.2. Diagnostic Test Descriptions
7-5.2.1. TEST 3 - DVM MODE. Test 3 uses the Pro-
grammer as a digital voltmeter (DVM) for checking
analog testpoints on the drive boards.
The test probe wire, supplied in the miscellaneous parts
packet shipped with the drive, connects from the testpoint
to be monitored to either the NTB/ 3TB boards testpoint
DVM or terminal 3TB-49. This DVM has fixed scaling,
and can measure dc voltage in the ~50 V range with a
LO.5 % accuracy.
7-5.2.2. TESTS 4 thru 9 - ARM V, ARM I, FIELD I,
SPEED, TORQ, HP. These tests display motor data:
armature voltage, armature current, field current, speed,
torque, and horsepower. Select the test in Diagnostic Mode
by entering its number. Note that the test number (black
label on key) and test name (blue label on key) corre-
spond.
To cancel the previous test and enter a new test, press the
appropriate key or (TEST) once.
7-5.2.3. TEST 10 - SOFTWARE REVISION. Test 10
displays the revision level of the DCC and LCC boards
microprocessors: Drive Control Processor (DCP), Motor
Control Processor (MCP), Co-Motor Processor (CMP),
and LAN Control Processor (LCP).
To run Test 10:
1. Press (TEST)
2. Press (i)(O)
3. Press (ENTER)
The Programmer displays D.=.O.O.OO M.= 0 0 00 for DCP
and MCP.
4. Press (INC)
The Programmer displays C =.O 0.00 L.=.O 0.00 for CMP
and LCP.
5. Press (INC)
The display shows D.= 0.0 00 for UCP.
To enter a new test, press (TEST).
To exit Test 10, press (PREV).
7-5.2.4. TEST 11, 31 - DIAGNOSTIC VARIABLE DIS
PLAY. Tests 11 and 3 1 display four drive variables for
diagnostic use. Test 11 provides hexadecimal values; Test
31 provides decimal values.
To run either test:
1. Enter the RAM addresses of the variables to be
monitored into E2 location 110 thru 113 for
DIAGl thru DIAG4, respectively. Refer to
Parameter Mode, section 7-4.2, for procedures,
and Table 7-2 for variable addresses.
2. Press (TEST)
3. For Test 11, press (l)(l)
For Test 3 1, press Q)(l)
4. Press (ENTER)
The test starts and displays 1.2. aaaaH yyyyH for Test 11
or 12. AAAAA BBBBB for Test 31. AAAA is the first
variables value; BBBB the second variables value.)
5. Press (DEC) or (INC)
The Programmer displays 3 4. CCCCH DDDDH or 3 4.
CCCCC DDDDD. (CCCC is the third variables value;
DDDD the fourth variables value).
NOTE
The value displays in 2s complement. Values
from 0000 to 7FFF are positive (0 to +32767);
values from FFFF to 8000 are negative (FFFF
= -1,SOOO = -32768).
Table 7-2. RAM Addresses* for Analog Signals
RAM Address Signal Description
100 Speed Feedback
103 Voltage Feedback
104 CFB
105 Field Current
112 CEMF
140 Speed REF Output
*These addresses contain a variable that represents an
analog signal.
7-7
7-5.2.5. TEST 12 - CELL TEST. Test 12 checks the
SCR/transistor (cell).
7-5.2.6. TEST 13 - BOARD TEST. Test 13 is the board
test function. Press any key during this test and the
Programmer displays the keys number.
To exit this test, press the DCC boards RESET button.
(To run Test 13, the proper bit in address EE.2 must be
set.)
NOTE
Although tuneup Tests 14, 15, and 16 can be
run from the Programmer, data retrieved
from these tests is stored in RAM and cannot
easily be saved. Therefore, tuneups should be
made with the ST2000 Toolkit (see GEH-
5860).
Tuneups should be run in the following order:
Test 16, Test 14, Test 15.
7-5.2.7. TEST 14 - CURRENT REGULATOR TUNEUP.
To enter this tuneup function:
1. Press (TEST)
2. Press (l)(4)
3. Press (ENTER)
The Programmer displays E N T R PAR 1 as a prompt to
enter a value for the first parameter (the three deci-
mats indicate Diagnostic Mode).
4. To set a new Parameter 1 value:
a. Key in the selected parameter value (motor
no.)
b. Press (ENTER)
5. To set Parameter 1 to the default value (0), press
(ENTER)
The display now shows E.N.T.R PAR 2 as a prompt to
enter a value for Parameter 2.
6. To set the Parameter 2 value:
a. Key in the selected parameter value (0 to
run test: 1 to do calculation only)
b. Press (ENTER)
5. To select the Parameter 2 default value (0),
press (ENTER)
The Current Regulator Tuneup now starts and the Pro-
grammer displays a tuneup message.
To abort the tuneup test in progress, press (STOP).
To return to the Diagnostic Mode, press (PREV).
To return to the Operate Mode, press (CLEAR/MODE).
7-5.2.8. TEST 15 - SPEED REGULATOR TUNEUP. To
enter this tuneup function:
1. Press (TEST)
2. Press (l)(5)
3. Repeat steps 3 thru 6 of tuneup Test 14
7-5.2.9. TEST 16 - FIELD REGULATOR TUNEUP. To
enter this regulator tuneup function:
1. Press (TEST)
2. Press (l)(6)
3. Repeat steps 3 thru 5 of tuneup Test 14
7-5.2.10. RAM TEST-EXAMINE/MODIFY RAM LOCA-
TION VALUE.
pii-
Use caution when altering RAM values. Any
change may also change the drive characteris-
tic, causing the system to misoperate.
The RAM Test allows users to examine and/or modify the
RAM location values. To enter this test:
1. Press (RAM)
The Programmer displays R A M EXAM/MODIFY.
2. Key in the desired RAM address
3. Press (ENTER)
7-8
GEH-5834
The display now reads D.- 1.04R 0
(XXXXXRYYYYY), where XXXXX = RAM address
and YYYYY = RAM value at that address. (The first
letter can be D, M, or L for DCP, MCP, or LCP.)
To alter the RAM value:
1. After the current RAM value is displayed (see
Step 3 above), key in the new value
2. Press (ENTER)
The display now shows the new RAM value, unless
the Modify RAM command is disabled. In that case,
the display shows M 0 D. RAM DISABLED.
To exit the RAM Test (either without changing or after
changing the RAM value):
1. Press (PREV) or (CLEAR/MODE)
The Programmer then displays D I A.GNOSTIC MODE.
2. Press (PREV) or (CLEAR/MODE) again
7-5.3. DACl, DAC2, METl, and MET2.
If the drive is already using the DACl, DACZ,
METl, and MET2 outputs, changing them
may cause the drive to misoperate. Before
entering this test, refer to the drives elemen-
tary diagrams and custom instructions or PC
software to determine this.
The DACl, DAC2, METl, and MET2 analog outputs are
available for test purposes. The four outputs function
identically, and are programmed similarly to Test 11.
Each output has two addresses (see Table 7-3):
l The @I address selects the variable to be output
(EElOO = DACl, EE102 = DAC2, EElO4 =
METl, and EE106 = MET2)
l The Mx address is the maximum input value
@El01 = DACl, EE103 = DAC2, EE105 =
METl, and EE107 = METZ)
For example, to bring up this function:
1. In Parameter Mode, call up EElOO-DAC&l and
EElOl-DAClMX (select EE.100)
2. Enter the signal to be monitored (from Table 7-2)
into EElOO
Putting that RAM Address in EEloO produces that
signal at the NTB/3TB boards DA1 testpoint and
DACl terminal (3TB-53).
DAC2, METl, and MET2 function like DACl. When a
signals RAM address is loaded into the DAC and MET
addresses, the signal is output on the NTB/3TB boards
testpoints and terminal points listed in Table 7-3.
Table 7-3. Diagnostic Mode Analog Output Points
EEl02-DAC@2 &
EEl03-DAC2MX
1 DA2 j DA2,3TB-55
EE104-MET@1 &
EEl m-MET1 MX
/ MET1 1 METl, 3TB-54
EEl06-MET@2 &
EEl07-MET2MX
1 MET2 / MET2, 3TB-56
7-9
GEH-5834
7-10
CHAPTER 8
PARTS REPLACEMENT
8-1. INTRODUCTION
This chapter provides instructions for replacing printed
wiring boards, SCR modules, and transistor modules.
GE carefully tests all equipment before shipping, and does
not expect equipment failure under normal conditions.
Most components never require repair or replacement.
WARNING
1
Disconnect all power supplies before perform-
ing any maintenance, adjustments, servicing,
parts replacements, or any other act requiring
physical contact with electrical working com-
ponents 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 dia-
grams). Whether the ac voltage is grounded
or not, high voltage to ground may be present
at many points.
CAUTION
While power is applied to the drive, do not
remove printed wiring boards or connections,
or re-insert them. This can damage the equip-
ment.
To replace a board:
1. Make sure that power to the drive is off.
2. Carefully disconnect all cables.
3. Release all hold-down tabs, then carefully pull
out board.
4. Set all jumpers on the replacement board in
exactly the same position as those jumpers on the
failed board.
5. Install the new board, making sure that all tabs
snap tightly into position.
6. Reconnect all cables, making sure that they are
properly seated in the connectors.
8-2. 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 compo-
nents, which must be considered when handling and
replacing a board. GE ships replacement boards in anti-
static bags or boxes. It is important that they be stored and
transported in these bags/boxes when not installed in the
system.
7. Set all potentiometers in the same physical
position as those on the board that was removed.
To fine tune, refer to Chapter 7, Operating the
Programmer.
8. If the DCC is changed, the EEROM (US) with
the correct software must be installed into the
new board.
a. If the EEROM from the failed board is
good, remove the chip using an EEROM
removal tool, and install the chip into the
new DCC.
b. If the EEROM from the failed board is
damaged, a new EEROM must be pro-
grammed to the custom parameter list.
8-l
8-3. TRANSISTOR AND SCR MODULE REPAIR/
REPLACEMENT - AC2000 P AND Q FRAMES,
DC2000 C AND G FRAMES
The AC2000 P and Q frame drives contain transistor
modules. The DC2000 C and G frame drives contain SCR
modules. Use the following procedures to replace both
types of modules.
NOTE
In addition to standard repair tools, this
instruction requires GL322 VERSILUBE@
Plus lubricant (part no. 104X214AB059).
1. Lower the card carriers to expose the rear of the
unit. where the module is located.
2. Disconnect the wires from the damaged module.
If needed, mark the wires so that they can be
connected correctly to the new module.
3. Remove the bus bar and mounting screws.
4. Clean old lubricant and dirt off the mounting
surface.
5. Apply a thin film of VERSILUBEB Plus lubri-
cant to both contacting surfaces.
Table 8-1. Transistor Module (AC2000)
Mounting & Connecting Torque Requirements
104X125DC014
thru -19
155inlb /Handtighten
P 104X17OCBOlO l Hand tighten
thru -15
104X1 25DC039 55 in lb Hand tighten
Q 104X1 25DCO40 55 in lb 60 in lb
104X170CB026, -31 *
t
104X125DC051, -52 55 in lb 60 in lb
T 104X1 7OCBO28 28 in lb Hand tighten
104X170CBO31, -32 l
t
Using a torque wrench, tighten opposite corners a small amount
at a time until a total of 25 inch-lbs (in lb) is reached
6. Install the new module, reconnecting the wires,
bus bar, and mounting screws. Tighten the screws
to the torque specifications listed in Table 8-l
(transistor module) or Table 8-2 (SCR module).
For mounting screws:
a. Tighten screws one at a time, progressing
counterclockwise on 4-screw mounting, until
all screws are snug.
b. Tighten to required torque in opposite order,
progressing clockwise on 4-screw mount-
ing, beginning with the last screw snugged.
8-4. SCR STACK ASSEMBLY REPAIR/REPLACE-
MENT - DC2000 D FRAME
8-4.1. Removing Right-hand Stack Assembly
1. Make sure that all power to the drive is discon-
nected.
2. Remove the SCR firing circuit plugs from the
snubber board for the right-hand SCR module.
(It is not necessary to remove the SCR firing
circuit plugs from the left-hand module.)
Table 8-2. SCR Module (DC2000)
Mounting & Connecting Torque Requirements
Frame SCR Module
Size Part Number
Torque Requirements
Heatsink Bus Bar
Mounting Screws Mounting Screws
16Oinlb
104X125DCO62 55 in lb Hand tighten
20 in lb then 1 turn
104X1 25DA152 (360,,) Same as heatsink
D, E
104X125DA153, 20 in lb then
-55 l-112 turns (54OO)
Same as heatsink
G
104X1 25DC054,
-55, -56, -60, -61
28 in Ib
Hand tighten
*To avoid excess torque on connected modules, support the bus bar
while tightening screws
8-2
3. Remove the ac wires (lAC_ -, 2AC- -, 3AC- J
from the snubber board.
4. Remove the six mounting nuts that hold the
snubber board in place.
5. Remove the harness retainers from their captive
positions.
6. Carefully roll the snubber board off the stack and
over onto the left-hand stack.
7. Remove the three ac line input bolts.
8. Remove the electrical connection (bus) at the
bottom of the stack.
9. Remove the four mounting bolts at the stacks
top and bottom.
10. Lift the stack assembly off the panel and place it
on a workbench for further disassembly, as
described below.
8-4.2. SCR Replacement Procedure
NOTE
In addition to standard maintenance tools,
this procedure requires SF1153 lubricant and
graphite spray.
1. Identify the defective SCR (from fault codes, see
GEH-5836) and its location.
2. To disassemble the section containing the defec-
tive SCR, place the stack assembly on its side
and alternately loosen and remove each nut. Place
each nut on a clean surface in the same orienta-
tion and order that they were removed.
3. Remove the defective cell.
4. Clean and lubricate the heatsinks as follows:
a. Place a few drops of SF1 153 lubricant in the
center of both heatsink mounting surfaces.
b. Using a lint-free cloth or tissue, thoroughly
polish the interface area until clean.
C. Place a few drops of SF1153 lubricant on
the heatsinks mating surfaces, using a
lint-free cloth or tissue to evenly spread the
lubricant.
d. Wipe off any excess lubricant.
5. Clean and lubricate the SCR cell by performing
all substeps of step 4 (above).
6. Coat the clamp mechanisms threads, nuts, and
washers with a small amount of graphite spray.
7. Replace the SCR cell carefully, making sure that
its orientation and polarity are correct.
a. Use care when placing the cell on the dowel
pin to prevent scratching the cell post sur-
face.
b. Rotate the cell back and forth a few times to
ensure proper seating.
8. Reassemble the SCR cell assembly, taking care
not to damage cell with the heatsink.
a. Tighten the clamp nuts only finger tight to
20 inch-pounds.
b. Make sure that the number of exposed
threads on each stud are approximately
equal.
9. Tighten each nut alternately as follows:
9
*Turn in l/4 turn increments from finger-tight starting
position.
8-4.3. Replacing Right-hand Stack Assembly
Replace the repaired stack assembly by following in
reverse the procedure outlined for removal (8-4.1).
8-3
8-4.4. Removing Left-hand Stack Assembly
To remove the drives left-hand stack assembly, follow the
same procedure as for right-hand stack, as described
above, with two exceptions:
. It is not necessary to remove the snubber board.
l Remove ac wires 4AC- -, 5AC- -, 6AC- _ from
the snubber board.
8-5. SCR STACK ASSEMBLY REPAWREPLACE-
MENT - DC2000 E FRAME
NOTE
In addition to standard maintenance tools,
this procedure requires SF1153 lubricant,
graphite spray, and Freon solvent spray or
low pressure dry air.
1. Make sure that all power is disconnected.
2. Remove the plastic baffles covering the stack(s)
to be removed.
3. Remove the leg fuses or bus straps connected on
the stack assemblys upper and lower sections.
4. Disconnect the SCR stack assembly from the
bridge and place it on a clean work table.
a. Note and record exactly where all hardware
and wires go.
b. If stack assembly is dirty, clean it using a
soft paintbrush, cleaning cloths, and low
pressure dry air or Freon solvent spray.
5. Check and record the reading of the spring bar
gauge on the side of the stack assembly con-
taining the defective cell.
NOTE
8-5.1. SCR Replacement Procedure
To replace the SCRs in this stack assembly, follow steps
1 thru 8(b) of section 8-4.2. Then tighten each nut as
follows:
1. Tighten each nut alternately to 12 inch-pounds
force to take up all slack in the assembly.
2. Tighten each nut alternately in l/4 turn incre-
ments for a total of l-3/8 turns on each nut.
3. Sight across both ends of the spring bar and
adjust the heatsink clamp pressure so that the
spring bar gauge reads the same value as its
original setting (step 5 above).
4. Replace the repaired stack assembly by following
in reverse order the removal steps outlined
above. Be sure to reconnect all wires and re-
place all hardware.
This reading is used to reset the spring bar
during re-assembly. To ensure that the read-
ing is accurate, sight across both ends of the
spring bar.
8-4
CHAPTER 9
SPARE AND RENEWAL PARTS
9-l. INTRODUCTION
This chapter contains information needed when ordering
spare and renewal (replacement) parts for the AC/DC2000
drive. This information consists of a parts listing with the
catalog (part) numbers. Both the part name and the
complete part number must be included when ordering.
GE recommends that the customer keep a set of spare
parts onhand to minimize system downtime if repair is
needed.
9-2. CUSTOM RENEWAL PARTS LISTING
In addition to the parts list in this manual, GE provides a
separate Renewal Parts List with the drives custom
instructions or PC software. As indicated, this custom list
applies specifically to the equipment furnished on a
customers particular application at the time of shipment.
If this Renewal Parts List is missing, contact the nearest
GE Sales Office or GE Sales Representative to obtain a
copy. Be sure to include the drive model and GE
requisition numbers.
9-3. ORDERING RENEWAL PARTS
Renewal parts should be ordered by contacting the nearest
Sales Office or an authorized GE Sales Representative. Be
sure to include:
. Drive model, located on its nameplate
9 Part name
l Complete part number, located on its nameplate
Parts still under warranty may be obtained directly from
the factory (designated on the elementary diagram), as
described in Appendix C.
9-4. PART NUMBER STRUCTURE
A GE part number is structured so that different portions
of that number identify the type of equipment and location
of manufacture. For ordering, a customer does not need
to understand this makeup - the equipments nameplate
provides the complete number. However, since that
information is used for some software applications, this
section defines the part number structuring.
A part falls into one of four categories:
Order-specific assemblies - Major assemblies or items
that make up a specific drive: made up of common
assemblies
Common Assemblies - subassemblies used in many GE
Drive Systems products, not just a particular drive
Components - individual parts that make up assemblies
Printed wiring boards
These categories and the makeup of their part numbers are
defined below.
9-4.1. Order-specific Assembly Part Numbers
Order-specific Assemblies make up the particular drive
provided. Other items obtained specifically for the order
may also use a similar part number structure.
For example, if 3VXYZ999CDOl is the part number for
an order-specific assembly:
3v = assembly provided by GE Drive Systems,
Salem, Virginia (7V = assembly provided by GE
Drive Products Operation, Erie, Pennsylvania
XYZ999 = original order identification number
CD = assembly type: CD for core drive; LU for
lineup; CA for case; PN for panel
01 = unit identification number
9-1
9-4.2. Common Assembly Part Numbers
Common Assemblies are subassemblies used as compo-
nents of order-specific assemblies. Common Assemblies
are not designed for a particular drive, but provide a
function used in other GE products.
A Common Assembly part number consists of the number
36 followed by an alpha character. It may contain up to 14
characters.
For example, 36C77345AAGO2 is the part number for a
DC2000 drives external Motor Field Control assembly.
9-4.3. Component Part Numbers
Components are the basic parts that make up assemblies.
They represent the lowest discrete level of a system.
Component part numbers consist of a combination of
alphanumeric characters that define the class and specific
item.
For example, if 104X109ADO38 is the part number, then:
104X = component
109 = component type (fuse)
ADO38 = specific item or rating (500 V, 3.2 A FNQ)
9-4.4. Board Part Numbers
Part numbers for printed wiring boards identify the
product class, board function, and revision levels. Boards
that contain software include a suffix M# where # is the
software number. The same board without that software
uses a G# suffix, indicating a group number.
For example, if 531X301DCCABMl is the part number,
then:
53 1X = printed wiring board for a GE Drive Systems
microprocessor-based drive (this is the product class)
3OlDCC = control board for AC/DC2000 drive
(board function)
ABM1 = revision level A& including MI, the soft-
ware version
NOTE
The factory may substitute later versions of
boards based on availability and design en-
hancements.
9-5. AC/DC2000 DRIVE PARTS LISTS
This section lists part numbers for boards, subassemblies,
and components used in AC/DC2000 drives. For a listing
of parts specific to a particular drive application, refer to
the Renewal Parts List (described above) provided with
the equipment.
9-2
Drive Type
AC/DC2000
AC2000
Table 9-l. Printed Wiring Boards
Board Name/Description
Relay Terminal Board (RTB)
Drive Control (DCC) Card with microprocessors
Drive Terminal Board (DTB)
LAN Control Card (LCC) for DLAN
LAN Control Card (LCC) for DLAN+ (ARCNET)
LAN Terminal Board (LTB)
Signal Processor Card @PC)
Power Supply Board (MCP)
Base Driver Board (IBD)
Dual Tach Isolator Board (DTI)
Power Supply Board (DCI) with 10 amp MFC
Power Supply Board (DCI) without MFC
Power Connect Board (PC):
1 quadrant, with snubbers, low voltage
applications
High HP Snubber board (SND), D frame only
* Used on drives with Common Isolation Transformer
** Used on drives with 5 500 V output.
l ** Used on drives with > 500 V output.
Part Number
53lX191RTBA-Gl
531X301 DCCA-M-
531 X305NTBA-Gl
531 X306LCCA-M-
531 X306LCCB-M-
531 X307LTBA-Gl
531 X309SPCA-Gl
531X303MCPA-Gl
531X3041BDA-Gl
531X31 1 DTIA-Gl
531 X302DCIA-Gl
531 X302DCIA-G2
531X121PCRA-Gl
531X121PCRA-G2
531 Xl 21 PCRA-G4*
531 Xl 22PCNA-Gl
531 Xl 22PCNA-G2
531X123PCHA_Gl**
531 Xl 23PCHA-G2***
531 X308PCSA-Gl l
531 X308PCSA-G2*
531 X308PCSA-G3*
531 X308PCSA-G4*
531X31OSNDA-Gl
9-3
Drive Type
AC2000
3PL 36C774524AAG36
7PL 36C774524AAG51
9PL 36C774524MG42
IOPL 36C774524AAG47
1PL 36C774524AAG48
2PL 36B605787AAG03
4PL 36C774524AAG49
6PL 36C774524AAG39
8PL 36C774524AAG41
1OPL 36C774524AAG43
BDCPL 36C774524AAG50
APL 36B605625BAGOl
BPL 36B605625BAG02
CPL 36B605625BAG03
DC2000 1PL 36C774524AAG35
2PL 36B605787AAG02
4PL 36C774524AAG45
5PL 36C774524AAG38
6PL 36C774524AAG46
8PL 36C774524AAG44
* Connectors used may vary with options provided.
Table 9-2. Interconnection Cables
Connector Part Number
9-4
Table 9-3. DC2000 Drive Subassemblies and Components - C, D, E, and G Frames
Subassembly/Component Description
Blower motor (230 V ac)
Blower motor (460 V ac)
Control power transformer (230 V ac, l-30 hp)
Control power transformer (230 V ac, 40-l 00 hp)
Control power transformer (460 V ac, 3-75 hp)
Control power transformer (460 V ac, loo-250 hp)
Control power transformer (230 V ac)
Control power transformer (460 V ac)
Current transformer assembly (460 V ac, 75 hp)
Current transformer assembly (460 V ac, 150 hp)
Current transf. assembly (460 V ac, 200/250 hp)
Fan (small, 4-l/2 in.)
Fan (large, 7 in.)
Fuses, Blower (16 A)
Fuses, control power:
3 A (CFUG)
1 A (CFU7)
0.5 A (CFU8)
3.2 A (CFU4 & -5)
15 A (CFUl, -2 & -3)
Fuses, MFC (30 A)
Motor field module
Motor field control module (external)
Remote mounting
Mounted on C frame
MOV assembly
Relays K6, K7, & K8
SCR armature supply with leads
Snubber assembly (dc)
Snubber capacitor (ac)
Snubber resistor circuit board
Suppressor
Thermoswitch (optional on C & G frames)
T
C 81 G Frames
36B605593AAG03
36B605593AAG04
36B605538AAGOl
36B605538ACGOl
36B605538AAG02
36B605538ACG02
Not used
Not used
36B05537AAGOl
36B05537ABGOl
36B05533AAGOl
104X21 5CA003
104X21 5CA004
Not used
104X109AD104
104X109AD103
104X1 09AD102
104X1 09AD038
104X1 09AD076
Not used
104X125DC062
36C774345AAGOl
36C774345ABGOl
36B605756ABGOl
104X1 66AAO77
See Tables 9-5 8 -6
Not used
Not used
Not used
Not used
104X1 52AC067
Part Number
D Frame
Same as C & G
Same as C & G
Not used
Not used
Not used
Not used
36B3605538AEGOl
36B605538AEG02
Not used
Not used
See Table 9-7
SameasC&G
Same as C & G
Not used
Same as C & G
Same as C & G
Same as C 8 G
Same as C & G
Not used
104X1 09AD084
Same as C & G
Not used
Not used
Not used
Not used
See Table 9-7
Not used
Not used
Not used
36A358207AAGOl
Same as C & G
E Frame
Not used
SameasC&G
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Not used
Same as C & G
Same as C & G
104X1 09AD083
Same as C & G
Same as C & G
SameasC&G
Same as C & G
Not used
Same as C & G
Same as C & G
Not used
Not used
Not used
Not used
36A353476ARGOl
36B3605224EAGOl
68A7184P15
DS3800NPCAl Al
Not used
Not used
9-5
Table 9-4. DC2000 Drive Horsepower-related Components - C Frame, 230 V AC
Part Number Suffix Per Horsepower
Part #
104x-
1 OQAG-
1 OQAG-
125DC
125DC-
202AA-
105CB-
105CA-
105CB-
105CA-
118BA-
60hp
Part Description
AC power fuse
DC power fuse
Arm SCR modules
Fused drives
Fuseless drives
Circuit breaker
MA contactor
MA contactor
MA aux interlock
MA aux interlock
MA aux interlock
5b
-
007
IOhD 15hp
007
007
026
020
015
003
___
007
---
20hp
011
009
026
020
009
005
___
007
___
__-
25hp
011
015
027
020
009
006
---
008
--_
30hp
011
015
027
020
009
006
_--
008
___
50hr, 75hp 1OOhp 7Shp
007
005
026
027
015
003
-_-
007
-__
020
021
_-_
013
_--
011
025
011
027
025
026
027
015
003
__-
007
_-_
026
027
015
003
___
007
_--
_-_
*Regenerative drives only
Fuseless drives have circuit breakers in place of the 3-phase ac line fuses
Table 9-5. DC2000 Drive Horsepower-related Components - C Frame, 460 V AC
T Part Number Suffix Per Horsepower
Part Description
Part #
104x-
30hF IOhp
-
007
013
3Ohp iOhp
011
013
011
014
Shl
-
015
015
026 027 027 027
020 020 020 020
015 009 009 009
005 005 006 012
___ -_- ___ --_
007 007 008 008
-_- --_ --- -__
__- --- __- -_-
-
OOhp 1 1 25hp 150hF I i
5hp
-
007
003
.5hp
007
003
026 026
026 026
015 015
003 003
-__ ___
007 007
_-- ---
_-_
-
_-_
15hp
-
007
007
026
027
015
003
---
007
---
___
-
IOhp
-
007
003
20hp
007
007
!5hp !OOhp !5Ohp
007 007
009 009
026
027
015
003
--*
007
---
---
021
015
020
020
---
013
069
-__
-__
011
021
015
020
021
_--
013
-_-
---
___
011
007
003
007
003
026 026
026 026
015 015
003 003
_-- _-_
007 007
___ ---
-__ ---
007
003
026
026
015
003
___
007
---
-_-
AC power fuse 1OQAG.
DC power fuse 1 OQAJ-
Arm SCR modules
Fused drives 125DC
Fuseless drives** 125DC
Circuit breaker 202AA-
MA contactor 105CB-
MA contactor 105CA-
MA aux interlock 105CB.
MA aux interlock 105CA-
MA aux interlock 118BA-
027
015
003
___
007
_-_
__-
**Fuseless drives have circuit breakers in place of the 3-phase ac line fuses
9-6
NOTE
Derating factors such as service factor, overloads, altitudes, and
ambients may affect power components. This would require a
different component, ordered with a different part number.
Table 9-6. DC2000 Drive Horsepower-related Components - G Frame, 230 V AC and 460 V AC
T
230 V AC:
Part No. Suffix Per HP
460 V AC:
Part No. S iUR fix Per HP
l-
Part
lumber
1 OSAG-
1 OSAJ-
125DC
125DC-
105&B-
105CB-
Part Description
r
AC power fuse
DC power fuse*
Armature SCR modules l *
2-l/4 in x l-314 in x l-314 in
4 in x 2-112 in x l-314 in
MA contactor
MA auxiliary
3hp
-
003
001
I
lOhp
003
003
031
022
003
007
2Ohp
006
007
!5hp
-
006
009
2b
003
001
5hp
-
003
005
Shf
-
006
005
IOhp
006
007
031
022
003
007
-
032
023
003
007
032
023
003
007
-
031
022
003
007
7
I
031
022
003
007
-
>l
I
032
023
003
007
-
032
023
003
007
**Some drives use different SCR modules, distinguished by the sizes listed and by the color (smaller size is ivory, larger size is black) Before
ordering, check which was used in the drive Then order the same type
Table 9-7. DC2000 Drive Horsepower-related Components - D Frame, 230 V AC and 460 V AC
230 V AC:
Part No. Suffix Per Horsepower
460 V AC:
uffix Per Horsepower Part No.
Part
Description
AC power fuse
DC power fuse
Armature SCRs
Without leads
With leads
DC contactor
DC contactor
Curr transfrm
assembly
!50hp IOOhp
027 027
021 025
030
026
5OOhp 600hp
032 032
025 025
123 123 137 089 089
GO2 GO2 GO2 GO1 GO1
008 009
---
007 008
--_ ---
GO1
___ ---
GO2 GO2 GO2 GO1 GO1
089 123 123 137
GO1 GO2 GO2 GO3
008 008 009 009
__- --- ___ ---
GO1 GO2 GO2 GO2
%OOhp 1 IOOhp 1 l25hp 1 l50hp : 2OOhp 250hp
030 030
030 032
L
300hp 12
032
032
!OOhp
027
019
OOhl
Part Number
104XlOSAG- 027 027 027
104X1 OSAG- 025 027 028
104X1 25DA- 089 089
36A353476AX- GO1 GO1
104X106MA- 008 008
104xl06MA-
___ -__
36A358216YA- GO1 GO1
089
GO1
008
__-
GO1
032 034
025 026
137 137
GO3 GO3
___ _--
GO1 GO1
GO2 GO2
*For regenerative drives only On regenerative drives with paralleled dc fuses, replace both fuses even if only one is blown
**Two per drive required
9-7
Table 9-8. DC2000 Drive Horsepower-related Components - D Frame, 575 V AC, 630 V DC, and 700 V DC
575 V AC, 630 V DC: 575 V AC, 700 V DC:
Part No. Suffix Per Horsepower Part No. Suffix Per Horsepower
Part Number
Part
Description
4OOhp !iOOhp 6OOhp 700hp 8OOhp 9OOhp 1OOOhp 4OOhp SOOhp 6OOhp 700hp 8OOhp 9OOhp 1OOOhp
104X109AR- 029 031 033 027 027* 029 029** 027 029 031 033 027 027 029
104X109AW-
0% 007 009 oop ()@j** 007 007 ___ ___ -__ _-- ___ ___ ---
104X125DA- 137 137 137 137 137 137 137 137
137 137 137 137 137 137
36A353476AX- GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3 GO3
104X106AE- 008 008 008 008 009 009 009 008 008 008 009 009 --- ---
AC power fuse
DC power fuse*
Armature SCRs
Without leads
With leads
DC contactor
For regenerative drives only On regenerative drives with paralleled dc fuses, replace both fuses even if only one is blown
**Two required per drive
Table 9-9. DC2000 Drive Leg Fuses - D Frame, 460 V AC
Part No. Suffix Per HP
Part Description Part Number
700hp 800hp 9OOhp lOOO-1500hp
9-8
APPENDIX A
GLOSSARY OF TERMS
lCPL, lFAPL, 2FAPL - I/O connectors. See Chapter 6.
1PL thru lOPL, 16PL - I/O connectors. See Chapter 6.
1TB thru 3TB - I/O connectors. See Chapter 6.
A/D - Analog-to-digital conversion.
APL - I/O connector. See Chapter 6.
application software - Job-specific software resident in
the drive, designed specifically for the customers
application.
ARCNET - See DLAN, DLAN+.
base speed - Maximum speed of a motor at rated arma-
ture volts and rated field amps.
BDCPL, BDPPL - I/O connectors. See Chapter 6.
board - Printed wiring board.
BPL - I/O connector. See Chapter 6.
building blocks (software) - Standard modules (blocks)
of microprocessor code that perform a specific
software function (for example, a speed regulator).
Blocks are configured into the application program.
card - Alternate term for printed wiring board.
CCPL - I/O connector. See Chapter 6.
C frame - Size of drive. See Table 4-3.
configure - To assign specific parameters to memory to
select applicable software blocks from the block
library, then schedule the running order.
CMP - Co-Motor Processor. The optional TMS32OClO
digital signal processor (U35) mounted on the DCC.
It performs math-intensive functions to support motor
control algorithms beyond the Motor Control
Processors (MCPs) capability.
CNPL, CNTB, COMPL, CPL - I/O connectors. See
Chapter 6.
CPT - Control power transformer.
CPTPL - I/O connector. See Chapter 6.
crossover point - See field weakening.
CT - Line current transformers.
D/A - Digital-to-analog conversion.
DB - Dynamic braking.
DBPL - I/O connector. See Chapter 6.
DCC - Drive Control Card, 531X3OlDCC. Main intelli-
gence board containing the drives primary control
circuitry, including three 16-bit microprocessors.
DC1 - DC Power Supply/Interface board, 531X302DCI.
Furnishes dc power to drive.
DCP - Drive Control Processor. The WC186 micro-
controller (Ul) mounted on the DCC. Its software
consists of user interfaces, outer regulating loops, and
system-level functions.
DFP - Delayed firing power, to armature SCRs.
D frame - Size of drive. See Table 4-2.
diagnostics - Software that checks drive hardware or soft-
ware, providing error indications that identify the type
or location of malfunction.
DLAN, DLAN+ - Communication links between drives
and controllers. There can be up to 32 drops on
DLAN and 255 drops on DLAN+ (ARCNET). See
Figures 6-4and 6-5.
DLAN PLUS - Same as DLAN+, also called ARCNET.
DPR - Dual-ported RAM. Used for communications
between two microprocessors, such as the DCP and
the LCP.
A-l
DMl, DM2, DM3 - Three dual-diode modules that make
up a 3-phase, full-wave rectifier bridge.
DRPL - I/O connector. See Chapter 6.
DTI - Dual Tach Isolator board, 531X311DTIA. This
board provides isolation for two independent tachome-
ters with signals A-quad-B. It also connects to the
power semiconductors driving the motor. Used only
when drives DCC board is revision L or earlier.
DVM - Digital voltmeter.
EE or E2 - See EEROM definition.
EE Enable Device - Device used to enable or protect
EEROM programming. A hardware jumper (JP13)
located on the DCC board.
EEROM - Electrically erasable read-only memory, also
called EE or E2 (E-squared). Contains the drive
parameters.
FAPL, FCPL - I/O connector. See Chapter 6.
field weakening - Lowering of field current at rated
armature volts to allow higher speeds. Actual arma-
ture voltage where field weakening begins is called
the crossover point.
frame size - Size of drive cabinet, determined by hard-
ware components required for power application. See
Chapter 4, Tables 4-l and 4-2, for specifications.
FSPL - I/O connector. See Chapter 6.
FUl thru FU3 - AC line fuses located on incoming 3-
phase power lines.
G frame - Size of drive. See Table 4-2.
hard (hardware) reset - Reset generated by a hardware
device instead of software input. Resets the drive
boards. Used to clear some faults and allow certain
parameter changes. Activated by pressing the DCCs
RESET button or by connecting NTB/3TB terminal
board point 3TB-69 to 3TB-66.
IBD - Base Drive board, 531X304IBD. Includes fault
latches used by the microprocessor to check faults,
isolated current feedback, motor terminal voltage
isolation, and protected base drive for power transis-
tors.
A-2
LAN - Local area network. A communications link that
enables attached device to talk to each other over a
limited geographical area. It allows dispersion of
various computers, files, print servers, terminals, and
such, over a limited geographic area.
LANTB - I/O connector. See Chapter 6.
LCC - LAN Communications Card, 531X306LCCA for
DLAN version, 531X306LCCB for DLAN+ model.
This board contains the Programmer.
LCP - LAN Control Processor. An 8OC196
microcontroller (Ul) located on the LCC board.
LED - Light emitting diode. Used as a visual indicator
for a board or drive function.
LTB - LAN I/O Terminal Board, 531X307LTB (option-
al). This board provides an interface between the
drive and external devices, such as contactors, lights,
pushbuttons, and interlocks.
MA - Main ac contactor.
MCP - (1) Motor Control Processor. The 8OC196 (U21)
microcontroller mounted on the DCC. Its software
consists of inner loops and motor/technology-specific
functions.
(2) The AC2000 drives Power Supply,
531X303MCP. This board provides logic power, an
interface between high voltage power circuitry and the
DCC, and undervoltage sensing.
MD - Main dc contactor.
MFC - Motor field control.
module - An electronic assembly of boards, components,
or a combination of these, that together perform a
specific function.
MOV - Metal oxide varistor (a voltage suppressor).
NTBMTB - Drive Terminal Board, 531X305NTBA. The
board containing the drives customer connection
terminals (3TB) for most signal-level I/O. It also
contains most of the hardware customizing jumpers
and potentiometers, plus passive interface circuitry.
P frame - Size of drive. See Table 4-l.
parameters - Adjustable software settings used to pro-
gram and tune the drive regulators.
PC- (PCHA, PCNA, PCRA, PCSA) - Power Connect
board, see Table 9-l for identifying part numbers.
This board connects the drive with the power circuit-
ry. The particular PC board used depends on the
drives frame size, voltage, and isolation transformer
configuration (common or non-common), and whether
the drive is regenerative or non-regenerative.
PL - Plug (may be plug or receptacle).
plug-in connector - A type of I/O connector, typically
containing more than one pin, and made so that a
connecting cable (with wires matching the connector
pin-out) plugs onto it as one unit.
Programmer (module) - An operator interface module
that includes a digital display and keypad, used for
software adjustment, diagnostic testing, and digital
readout of fault codes. Included on the LCC board.
Q frame - Size of drive. See Table 4-l.
RAM - Random access memory. Memory that can be
both read and written to.
RC - A resistor/capacitor configuration, which functions
as a suppressor.
regenerative - Ability to return power from the armature
to the ac line. Creates braking effect on motor.
RPL - I/O connector. See Chapter 6.
RS-232C - A serial link communications interface stan-
dard for interconnecting data terminal equipment
(DTE), such a printer, CRT, or computer, to data
communications equipment (DCE), such as a modem,
for transmission over a telephone line or network. RS-
232C is characterized by an unbalanced or single-
ended voltage interface. This connection is provided
on the AC/DC2000 drive only for interfacing with the
ST2000 Toolkit.
RS-422 - A serial link communications interface standard
that defines electrical interface characteristics. This
standard permits greater distances between equipment
and faster data transfer than RS-232C. RS-422 is
characterized by a balanced or differential voltage
interface.
RTB - Relay Terminal Board, 531X191RTB (optional).
This board contains seven relays with 110 V ac coils
that can be jumper-selected to operate from LTB
board signals or from external contacts. Each relay
contains two form C contacts.
SCR - Silicon-controlled rectifier (thyristor).
software (soft) reset - Reset initiated either by software
input, instead of by a hardware device. Activated by
pressing the Programmers RESET key or by serial
input.
SND - High Horsepower Snubber Board, 531X31OSPC.
This board is used only with the DC2000 D frame. It
replacesg the PCS board at higher horsepowers, and
functions to interface the drives control circuitry to
the SCR power bridge.
SPC - Signal Processor Card, 531X309SPC (optional).
This board processes inputs before sending them to
the DCC. It provides encoder feedback, converts
current reference signals to voltage reference signals,
and receives RS-422 inputs.
stab - A wide, raised metal post on a printed wiring
board I/O path used as a type of jumper connection to
configure various board options. Connection is made
using wire that plugs onto the stab.
ST2000 Toolkit - A software package used to configure
and perform diagnostics on the AC/DC2000 drive.
Publication GEH-5860 describes the Toolkit.
T frame - Size of drive. See Table 4-l.
terminal board connector - A type of I/O connector
made so that individual wires are inserted into a
connector point and fastened by turning a screw on
the connector.
testpoint - A hardware point, usually a metal ring or
post, located on a printed wiring path for testing a
signal or voltage on a board.
TB - I/O connector (terminal board). See Chapter 6.
TP - Testpoint. See definition above.
TRl thru TR6 - Inverter transistor modules. The number
used depends on the drives current rating.
VCO - Voltage controlled oscillator. Its frequency output
is proportional to the voltage applied to it.
A-3
A-4
APPENDIX B
POWER STUD WIRING, TERMINALS, & CRIMPING TOOLS
B-l. INTRODUCTION
This appendix lists power stud wiring, terminals, and
crimping tools that GE recommends for installing and
maintaining the AC/DC000 drive. See Chapter 3 for
installation guidelines for wiring and connections.
Table B-l lists crimping tools for particular wires and
terminal types. Tables B-2 and B-3 list the power stud
wiring, terminals, and tools according to the drive horse-
power and input voltage. Note that the last column
(Crimping Tool) of Tables B-2 and B-3 references the
Item column from Table B-l.
NOTE
All wiring must meet National Electrical Code
(NEC) standards, as well as any applicable
local codes.
Table B-7. Crimping Tools
AMP*
Item
Crimping Tool
Cat.#
Vi=
For Wire
Size
Terminal
Type
1 49592
2 49935
3 69062
Hand
Hand
Hand-hydraulic with
self-contained dies
14- 12 AWG
12- 10 AWG
8-2AWG
Solistrand*
Solistrand
Solistrand
AMP Electra-hydraulic Power
Unit 115 V AC (Cat. No.)
Crimp. Head
Tool Cat.#
Die Cat.#
4 69120-l 69065 46323-2 1-10AWG Solistrand
5 69120-l 69065 46323-2 2/O AWG Solistrand
6 69120-l 69065 46326-2 250 MCM AMPower
9 69120-l 69065 46327-2 300 MCM AMPower
* Trademark of AMP Incorporated.
B-l
Drive
HP
l-3
,
Stud Dia.*
AC DC Gty.*** AWG MCM
-25
5 .25
7.5 .25
10 .25
15 .25
20 .25
25 .25
30 .25
40 .38
50 .38
60 .38
75
100
38
.38
Table B-2. Power Stud Wiring, Terminals and Tools - 230 V AC, 240 V DC
.25
.25
.25
.25
.25
.25
.25
.25
.38
.38
.38
.38
.38
Power Wire
1 12 009 33458 .25
1 12 009 33458 .25
1 10 009 33458 .25
1 10 009 33458 .25
1 8 012 33461 .25
1 8 012 33461 .25
1 6 015 33465 .25
1 6 015 33465 .25
1 4 059 31811 .25
1 4 059 31811 .25
1 2 057 320383 .25
1 2 057 320383 25
1 l/O 067 36915 .25
1 l/O 067 36915 .25
1 l/O 067 36915 .25
1 l/O 067 36915 .25
1 2/o 023 36923 38
1 3/o 025 36927 .38
1 3/o 025 36927 .38
1 4/o 068 321878 .38
1 4/o 068 321878 .38
2 4/o 021 36917 .38
2 l/O 021 36917 .38
2 210 023 36923 .38
2 3/o 025 36927 .38
2 4/o 068 321878 .38
Terminal-AMP
GE Cat. # AMP Inc. Hole
104X161A Cat. # Dia.
Crimping Tool
(Table B-l)
Item 2
Item 2
Item 2
Item 2
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 4
Item 4
Item 3
Item 3
Item 5
Item 6
Item 6
Item 7
Item 7
Item 4
Item 4
Item 5
Item 6
Item 7
*An ac stud is not used for wiring on drives that have circuit breakers.
**Wire size from National Electrical Code (NEC) Table 31 O-l 6. Copper wire rated 60 C for s 100 A and 75 C for > 100 A,
in 30 C ambient and 1.25 drive rated amps. These are minimum wire sizes. Consult and conform to all local and national
electrical codes.
***Quantity of wires and terminals in parallel per stud.
B-2
Drive
HP
l-3
5
7.5
10
15
20
25
30
40
50
60
75
100
125
150
200
250
Table B-3. Power Stud Wiring, Terminals and Tools - 230 V AC, 240 V DC
Stud Dia.*
AC DC
.25
.25
.25
.25
25
.25
.25
.25
.38
.38
.38
.38
.38
.38
.38
.38
.38
.25
.25
.25
.25
.25
.25
.25
25
.38
.38
.38
38
.38
38
.38
.38
.38
Power Wire*
Gty.* AWG MCM
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
12 009
12 009
12 009
12 009
12 009
12 009
10 009
10 009
a 012
a 012
6 015
6 015
6 015
6 015
6 059
4 059
4 057
2 057
2 067
1 067
1 067
1 067
1 067
l/O 075
2/o 025
3/o 068
4/o 068
4/o 021
l/O 021
l/O 023
3/o 025
410 068
4/o 068
300
Terminal-AMP
GE Cat. # AMP Inc. Hole
104X161A Cat. # Dia.
33458 .25
33458 .25
33458 .25
33458 .25
33458 .25
33458 .25
33458 .25
33458 .25
33461 .25
33461 25
33465 .25
33465 .25
33465 .25
33465 .25
31811 .25
31811 .25
320383 .25
320383 .25
36915 .25
36915 .25
36915 .25
36915 .25
36915 .25
36921 .25
36927 .38
321878 .38
321878 .38
36917 .38
36917 .38
36923 .38
36927 .38
321878 .38
321878 .38
325803 6.38
Crimping Tool
(Table B-l)
Item 2
Item 2
Item 2
Item 2
Item 2
Item 2
Item 2
Item 2
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 3
Item 4
Item 4
Item 4
Item 4
Item 4
Item 5
Item 6
Item 7
Item 7
Item 4
Item 4
Item 5
Item 6
Item 7
Item 7
Item 9
*, **, *** See reference definitions on previous page.
B-3
B-4
APPENDIX C
WARRANTY PARTS AND SERVICE
C-l. WARRANTY TERMS C-2. OBTAINING PARTS AND SERVICE lJNDER
WARRANTY
The GE Drive Systems Terms and Conditions brochure
details product warranty, which includes the warranty
period and parts and service coverage.
To obtain warranty replacement parts or service assistance,
contact the nearest GE I&SE Service Office.
The brochure is included with customer documentation. It
may also be obtained separately from the nearest GE Sales
Office or authorized GE Sales Representative.
Please have the following information ready to exactly
identify the part and application:
. GE requisition number
l Drive serial number & model number
l Part number & description
C-l
GEH-5834
c-2
*(,QGXVWULDO
&RQWURO6\VWHPV
*HQHUDO(OHFWULF&RPSDQ\
1b01 carcIc IvJ.
3aIcm, VA 241b3 U3A

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