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GEH-5834

Instructions

AC/DC2000 Digital Adjustable Speed Drive

User’s 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 User’s 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 purchaser’s 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 User’s 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 drive’s 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 during installation, operation, and maintenance. Iffurther information is desired or ifparticularproblems arise that are not covered sufficiently 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 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 purchaser’s 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 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 during installation, operation, and maintenance Iffurther information is desired or lfparticular problems arise that are not covered sufficiently 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 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

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 result in personal injury or death

Indicates a procedure, practice, condition, or statement that, if not strictly observed, could result 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 equipment 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

General Electric Company 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 temperature changes, or rough handling during transportation

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 shipment 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 inspection 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 equipment. To prevent such damage when moving the equipment, be sure to observe normal precautions along with all handling instructions 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 equipment’s 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 damaging 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 material - 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 elements, such as salt spray, or chemical and electrically 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 variations at higher humidity

If the storage room temperature varies in such a way, install a reliable heating system that keeps the equipment temperature slightly above that of the ambient air This can include space heaters or panel space heaters (when supplied) inside each enclosure. A 100 W lamp can sometimes serve as a substitute source of heat

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 documentation. 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 assistance, 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

General Electric Company Industrial Systems 1501 Roanoke Blvd.

Issue Date October 1996 Salem, VA 24153-6492 USA


User’s 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 purchaser’s 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 equipment’s case must be shielded to prevent contact by personnel.

To minimize hazard of electrical shock or burn, approved grounding practices and procedures must be strictly followed.

I WARNING c

To prevent personal injury or equipment damage caused by equipment malfunction, only adequately trained presons should modify any programmable machine.

b


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


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


LIST OF FIGURES

FIGURE Page

4-1. AC2000 Drive Connection Diagram - Q Frame,75 100, and 125 KVA (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . 4-8

4-1. AC2000 Drive Connection Diagram - Q Frame, 75, 100, and 125 KVA (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . 4-9

4-2. AC2000 Drive Connection Diagram - P Frame, Dynamic Braking, 15 and 30 KVA (Sheet 1 of 2) . . . . . . . . . . 4-10

4-2. AC2000 Drive Connection Diagram - P Frame, Dynamic Braking, 15 and30KVA(Sheet2of2) . . . . . . . . . . 4-11

4-3. AC2000 Drive Connection Diagram - P Frame, Dynamic Braking,

60 KVA (Sheet 1 of 2) . . . . . . . . . . . . . . 4-12 4-3. AC2000 Drive Connection Diagram -

P Frame,Dynamic Braking, 60 KVA (Sheet 2 of 2) . . . . . . . . . . . . . 4-13

4-4. AC2000 Drive Connection Diagram - D Frame, Super Bridge . . . . . . . . . . . . . 4-14

4-5. DC2000 Drive Connection Diagram - D Frame . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-6. DC2000 Drive Connection Diagram - D Frame . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-7. DC2000 Drive Connection Diagram - D Frame, Regenerative Controller . . . . . . 4-17

4-8. DC2000 Drive Connection Diagram - D Frame, Non-regenerative Controller . . . 4-18

4-9. DC2000 Drive Connection Diagram - E Frame, Power Conversion, Single Bridge . . . . . . . . . . . . . . . . . . . . 4-19

4-10. DC2000 Drive Connection Diagram - 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

4-13. DC2000 Drive Connection Diagram - G & C Frames, Regenerative Controller, Common Transformer Application . . . . . 4-23

FIGURE Page

4-14. DC2000 Drive Connection Diagram - G & CFrames, Non-regenerative Controller ..................... 4-24

4-15. DC2000 Drive Connection Diagram - 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) . . . . . . . . Connector 8PL, I/O Between DCC Board and NTB Board (AC/DC2000) . . . . . . . . Connector 9PL, I/O Between DCC Board 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 (AG’DC2000) 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 h’z 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 9-5. DC2000 Drive Horsepower-related

Components - C Frame, 460 V AC . . . . 9-6 9-6. DC2000 Drive Horsepower-related

Components - G Frame, 230 V AC and 460VAC . . . . . . . . . . . . . . . . . . . . . . 9-7

9-7. DC2000 Drive Horsepower-related Components - D Frame, 230 V AC and 460VAC . . . . . . . . . . . . . . . . . . . . . . 9-7

9-8. DC2000 Drive Horsepower-related 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 microprocessor-based power converters that produce controlled ac output (AC2000) or dc output (DC2OOO) for customer application.

This manual is intended to assist applications and maintenance personnel in understanding the equipment hardware and software. For adjustment, fault code, and troubleshooting 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 hardware 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, including 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 installing and maintaining the AC/DC2000 drive.

Appendix C - Warranty Parts and Service Explains procedures for obtaining warmnty information 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 configuration 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 drive’s 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 adverse conditions. Packing cases are not suitable for outdoor or unprotected storage.

Shock caused by rough handling can damage electrical equipment. To prevent such damage when moving the equipment, be sure to observe normal precautions along with all handling 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 General Electric Company 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 storage 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 permanent location. If the equipment has been exposed to low temperatures for an extended period of time, do not unpack it until it has reached room temperature

When unpacking, check the contents of each case against the packing list Report any shortage to GE Drive 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


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 installation 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 environments. 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 equipment 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 documentation) 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 hazardous 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 available)

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 elementary 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 connections 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 LTB’s 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)


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 minimum separation of 3 inches.

- For distances over 4 feet, add l/4 inch of additional spacing for every foot of additional distance.

. Within pullboxes and junction boxes, use grounded 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 grounded 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 board’s COM connection (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 capacitor 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 voltages, do not touch any circuitry without first ensuring that it does not carry these voltages.

3-3


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 previously (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 removed.

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 following 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 controller 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 rotation.

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 displaying 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


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 DCC’s Drive Control Processor (DCP) controls memory access.

There are four major elements used in software configuration:

. 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 Programmer’s 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 drive’s 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 different 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 drive’s “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 includes 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 drive’s overall control operation. Chapter 5 describes the function and operation of the control section’s printed wiring boards.

Table 4-2. DC2000 Frame Size Specifications

Frame Typical Power Rating*

4-2


4-3.2. Power Converter

The AC/DC2000 drive’s 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 commands 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 transistor’s 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 drive’s 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 current. 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 transients.

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, controller 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 electrically-isolated base plates and mount to the controller’s 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 capacitors 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 controller’s heatsink.

4-5.1.7. INVERTER TRANSISTOR MODULES (TM1 - TM6). The number of transistor modules used depends on the drive’s 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 heatsink’s common.

4-5.1.8. SHUNTS. Strip shunts in the controller’s 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 continuous 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 controller’s 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


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 i’LlI6 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 RLO”lREOl 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


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 PC”CAR0

* 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 POWER SUPPLY

CARD

TO SHUBBEA CAR0 AT -?Z’

FIELD AMMETER IOPTIONAL,

h UOYE JUMPER TO OASHEO POSlTlON FOR INTERWM. VOLTAGE FEEDBACK

Ib3,M”LT,-COHTACTOR OPTION1

-IL-

-v--

1

EXTERNAL ;ipTOTR FIELO

-XL

----- E ?E!FL

INTERLOCKS -----

I I I

:... I

II iI II /I II II

.----- I FOR

ANNUNCIATION/ SH”TOOWN

TO TO F HOY SHUNT SCRS SCRS

‘22 PI pz I-61FI I-6lRI

hYTB ________ ___. -_ _-__ ---_- -- -----------------J

I

I --- I4 i I I ------ J

Figure 4-5. DC2000 Drive Connection Diagram - D Frame

4-15


I I I CT3

-.

CAR0 AT -PC?’

-- - E

Figure 4-6. DC2000 Drive Connection Diagram - D Frame

FROM TO SHUNT s% SCRS

1 ii I ‘&Y

PI ,6TG pz I-61FI I-61RI q ;I

I II III LO!

____ -_ --_-- __-_ _ ----- ----- --------------- J

POWER SUPPLY CAR0 d

i&, TO GRAIICH

C,RC”,T PROTECTION

A MOVE JUMPER TO DASHED POSlTlON FOR INTERNAL VOLTAGE FEEDBACK

MC?:OR Q I

I &.. -------! -I

.JZ-

i

EXTERNAL yMOpTupTA F I E LO

.JA-

_----- TO EXTERNAL PlLOT RELAY

_-----

------,., 105 “DC TO EXTERNAL

------,-) COHTACTOR CWfTROL

-----

-----

FOR ANHUNCIATION,

SHUTDOWN

4-16


r------J

I I

L---------- I

Figure 4-7. DC2000 Drive Connection Diagram - D Frame, Regenerative Controller

------

------

--m---

-___

___/

C-\

~----

------

------

------

------

------

------

------

------

------

- \ .*’

TO

AC

LIN

E I

TO

CPT

----T

2

------

~----

------

------

------

------

---

-- IO

PTIO

NAL

1

SCR5

F L’

m

r, W

H RE

D I

(2, A

,1

\ 5FSP

L

7

I ---

- -

SCR6

F I m

r, W

H RE

D I

It.40

.---_

------

------

------

------

------

-----

1 ----------Olb3

pT,O

NAL

BUS1

SHUN

T

TO

DRPL

An

- SC

RZF ! 1 WH

RED

aa JR

CS

L----

-----d

RO

CS

; -5

-c c

- c

73x

2:;

- - i<

-’ i

L----

-----J


-- PLUG UT0 ON HEATSINK

L , TO PC dAAD

TYP. SCR COHN.

TO TM

- FEEDBACK ,x VOLTAGE

TO jEl6

YI K2 K3

THSW

J--f-A, I 21 TO TB6

c7

Figure 4-9. DC2000 Drive Connection Diagram - E Frame, Power Conversion, Single Bridge

4-19


BLOWER MOTOR c.0V-3PH-60HZ-IHP __--_--_

CTI -.

R 1

BF

f- I I I I I I I I I

I I I

I I

I I I I I I I I I I I I I I I I I I I I I I I I I I I I I

I I I I I I

I I I I I I I I I I I I I I I I I I I I

I

L

r‘ 8 I I

I I I I I I I

i.

A REUOVE JUMPERS FOR EXTERNAL VOLTAGE FEEOBACK

F-------j i .----2Z-~

TO POWER SUPPLY CARD

.-iv-

I

EXT UOTOR FIELD INPUT

4 CPTFU FOR NON-STANDAft ..^. -,..r

FAULT INTERLOCKS

----

.----

wx IDS” POWER _--- SKETCH “A”

CONNECTION FOR 67 W,T”OUT

8 AEL*Y

FOR ANNUNCIATION OR

SHUTDOWN

POWER SUPPLY cm0

I _I NOTE: -

LO,” “OLTAOE IZ3O”ICI COHHECTIOHS FOR CPTA Figure 4-10.

DC2000 Drive Connection Diagram - E Frame TO

4-20


-.A.- -FOR FUSELESS OPERATION. REPLACE FUSES WITH BUS STRAPS

tr

. CT1 :

I

F”I SCRIF

SCR3F FCLB

Ai- C6

F”13

piiJ fiizJ

K! KZ K3

I CURRENT FEE$A;CK

RECTIFIER 15SEMBLY

SCR4f F”4

SCRlZR FUl5

- SCRDF

FCLS CS I! A-

XII-I 5CR13R ‘OYF

TO TBS FEEDBACK * VOLTAGE 10

REV THSW lzv

TO it36 C7

.

F&e 4-11. DC2000 Drive Connection Diagram - E Frame, Power Conversion, High HP, Full-wave Generation

4-21

LI

P

I I IF

1

,&’

‘I-

I--- _

------

---_

R6

R cz

=d

I I I R8

R

I RL

C NE

TWO

RY

------

---

-----I

IO

PTIO

N~CI

I J

I.3

P

- .

/

I” I

I i J


(,I-:

c

r

r E

J

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

\ I

\


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 connections 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 configuration; 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 board’s 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 drive’s 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 microprocessors.

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

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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 MCP’s 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 DCC’s 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 DCC’s RESET button.

l By applying +5 to +24 V dc to the Drive Termi- nal Board’s (NTB/3TB’s ) 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/3TB’s 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 includes 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 DCC’s 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

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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 transmitting them to the DCC

l Receiving RS-422 serial commands and sending them to the DCC’s 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: differential 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 DCC’s Motor Control Processor.

NOTE

A different serial channel is available on the NTBMTB in half-duplex form. It is selected by the DCC’s 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)

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. Dual-ported RAM, 1K x 8 (US); used for communications between the DCC’s 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 Board’s (RTB’s) 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 drive’s +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 RTB’s or the LTB’s 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.

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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, potentially 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 testing be done only with low voltages, using the safety procedures listed below.

Anyone testing with power on must strictly follow standard 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 connecting 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.

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The MCP board functions can be divided into several major areas:

l Developing logic power for all the drive’s 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 drive’s 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 inverter 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 system’s powerup reset. Under- voltage inhibits all switch firings. The MCP board’s 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 transformer’s (WI’s) 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 IBD’s 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 (FAUL’I2, 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 amplifier that looks at the dc link for feedback. A comparator circuit measures the link voltage’s 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 circuit’s 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 transistor’s 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)

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When a fault occurs, a base-emitter voltage clamp (selected 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 transistor’s 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 phaseloss trip is generated after a programmable delay.)

l LINESYNC, a digital signal that changes state at the zero-crossing of Ll-L2 voltage’s 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 line’s 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 phase’s 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 circuits.

Potentially hazardous voltages are present in this board’s 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 feedback. 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 transistor’s 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 includes 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 standard 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 sequence

5-5.1 .l . POWER SUPPLIES. The CPT’s (control power transformer’s) 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 connects 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 circuitry, 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 DCI’s 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 discontinuous/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 drive’s 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 darlington drivers for the gate-pulse transformer.

5-5.1.9. DELAYED FIRING POWER. A transistor (controlled 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

. Drive’s voltage

l Drive’s 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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tion


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 requirements.

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


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


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).

Table 6-4. Connector 3PL, 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.

Power supply return, common.

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

Table 6-5. Connector 6PL, 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 DCC’s 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


Table 6-5. Connector 6PL - Continued I/O Between DCC Board and NTB/3TB Board (AC/DC2000)

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.

Table 6-6. Connector 7PL, 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 DCC’s 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).

Table 6-7. Connector 6PL, I/O Between DCC Board and NTB/3TB Board (AC/DC2000)

Description

Non-inverting RS-422 half duplex serial data line from the WC’s 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


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


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. Drives cell 4F gate pulse transformer. Delayed firing power for A4F and A3F Drives cell 3F gate pulse transformer. Shield wire. Drives cell 2F gate pulse transformer. 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. Drives cell 4R gate pulse transformer. Shield wire. Drives cell 5R gate pulse transformer. Delayed firing power for A5R and A6R Drives cell 6R gate pulse transformer. 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


= 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 Non-inverting differential input for Encoder #2, channel B Non-inverting differential input for Encoder #2, channel B Inverting differential input for Encoder #2, channel B Inverting differential input for Encoder #2, channel B.

6-13


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


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)


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)


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)


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)


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


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


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. RTB relay K7 pilot output 1. Not connected. RTB relay K8 pilot output 2. Not connected. RTB relay K9 pilot output 3. Not connected. RTB relay K10 pilot output 4. Not connected. RTB relay Kll pilot output 5. Not connected. RTB relay K12 pilot output 6. Not connected.

Table 6-26 Connectors OTl thru OT7, LTB Board Connection from Form C Relay Contacts (AC/DC2000)


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)


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


&.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.


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


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 DTB’s 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 DCC’s Motor Control Processor (as opposed to the RS-232C channel into the DCC’s 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 DCC’s 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. See Cl1 (3TB point 14). Relay #2 normally-closed contact. See Cl1 (3TB point 14). Relay #2 normally-open contact. See Cl1 (3TB point 14). Relay #3 common contact. See Cl1 (3TB point 14). Relay #3 normally-closed contact. See Cl1 (3TB point 14). Relay #3 common contact See Cl1 (3TB point 14). Relay #3 normally-closed contact. See Cl1 (3TB point 14). Relay #3 normally-open contact. Voltage reference for digital control inputs. Defaulted to -24 V dc; changes to +24 V dc via DTB’s 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

Relay #4 common contact. 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. Relay #4 normally-open contact. General purpose input, defaulted to JOG function. Relay #5 normally-open contact. General purpose input, defaulted to the reference polarity function. Relay #5 normally-closed contact. General purpose input, defaulted to the XSTOP function (normally-closed). Relay #5 common contact. 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.

Relay #6 normally-open contact. Control on input 2 (See CTLNl, TB#42.) Relay #6 common contact. 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.

See Pl (3TB point 46). Medium resolution analog input channel with fixed scaling for fl0 V dc maximum See Pl (3TB point 46). 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 DCC’s 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

Table 6-36 - Continued. Connector 3TB, I/O Between NTB/3TB Board and External Connections (AC/DC2000)


Input to internal timer/counter 0 of DCC’s 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 DCP’s 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 DTB’s switches 1 - 7. DCC’s 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). Not used. Provides voltage clearance between signal level points and points with potentials 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 DTB’s switches 1 - 7 provide coarse scaling; DCC’s 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. Not used. Provides voltage clearance between signal level points and points with potentials 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. Not used. Provides voltage clearance between signal level points and points with potentials 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


Table 6-36 - Continued. 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 applications. (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)


.~

*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. Drives cell 2F gate pulse transformer. Drives cell 3F gate pulse transformer. Drives cell 4F gate pulse transformer. Drives cell 5F gate pulse transformer. Drives cell 6F gate pulse transformer.

Table 6-39 Connectors SRAPL & SRBPL Output from PCH Board (DC2000)

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.

Drives cell 2R gate pulse transformer. Drives cell 3R gate pulse transformer. Drives cell 4R gate pulse transformer. Drives cell 5R gate pulse transformer. Drives cell 6R 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, Output from PCH Board (DC2000)

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

mr”d llPL

n;l2PL

nr”d 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


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


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)


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


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


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 DCC’s Motor Control Processor (MCP)

TXN Inverting RS-422 output from DCC’s MCP.

RXN Inverting RS-422 input to DCC’s MCP

RXP Non-inverting RS-422 input to DCC’s MCP.

6-42


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 drive’s 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 LCC’s I/O connections.

NOTE

The Programmer’s parameter address, designated 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 key’s 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 Programmer’s display presents an alphanumeric readout for drive parameters, faults, and keypad inputs. The fault code display provides an easier alternative to the board’s 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 example, 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


The Programmer’s operating mode determines the function 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 functions 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), W’W

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 keypad 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 command’s reverse function:

1. Press (REV) and the Programmer displays 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 between 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 addresses 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 removed 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 between 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 parameters, two conditions must exist:

1. The DCC’s 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 DCC’s 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 decreases 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 followed by (ENTER)

NOTE

This next step is extremely important to prevent 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



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 armature voltage.

(ARM I), keypad selection. Displays armature 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.


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 board’s 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 variable’s value; BBBB the second variable’s value.)

5. Press (DEC) or (INC)

The Programmer displays 3 4. CCCCH DDDDH or 3 4. CCCCC DDDDD. (CCCC is the third variable’s value; DDDD the fourth variable’s value).

NOTE

The value displays in 2’s 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 key’s 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 characteristic, 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


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 drive’s elementary 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 board’s DA1 testpoint and DACl terminal (3TB-53).

DAC2, METl, and MET2 function like DACl. When a signal’s RAM address is loaded into the DAC and MET addresses, the signal is output on the NTB/3TB board’s 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


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 performing any maintenance, adjustments, servicing, parts replacements, or any other act requiring physical contact with electrical working components or wiring of this equipment.

Circuit breakers, if supplied as part of the total system, may not disconnect all power to the equipment (see system elementary diagrams). Whether the ac voltage is grounded or not, high voltage to ground may be present at many points.

CAUTION

While power is applied to the drive, do not remove printed wiring boards or connections, or re-insert them. This can damage the equipment.

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 components, 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 programmed 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 lubricant 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 mounting, 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 disconnected.

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 stack’s 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 defective 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 orientation 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 heatsink’s 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 mechanism’s 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 surface.

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 drive’s 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 assembly’s 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 containing 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 increments 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 replace all hardware.

This reading is used to reset the spring bar during re-assembly. To ensure that the reading 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 drive’s custom instructions or PC software. As indicated, this custom list applies specifically to the equipment furnished on a customer’s 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 it’s 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 equipment’s 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 components 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 drive’s 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 software 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-

*Regenerative drives only

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

*Regenerative drives only **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 customer’s application.

ARCNET - See DLAN, DLAN+.

base speed - Maximum speed of a motor at rated armature 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 Processor’s (MCP’s) 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 drive’s 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 microcontroller (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 software, 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 tachometers with signals A-quad-B. It also connects to the power semiconductors driving the motor. Used only when drive’s 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 armature voltage where field weakening begins is called the crossover point.

frame size - Size of drive cabinet, determined by hardware 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 DCC’s 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 transistors.

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 (optional). 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 drive’s 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 drive’s 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 program 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 circuitry. The particular PC board used depends on the drive’s 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 standard 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 Programmer’s 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 drive’s current rating.

VCO - Voltage controlled oscillator. It’s 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 horsepower 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 46324-2 3/O AWG Solistrand 7 69120-l 69065 46325-2 4/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


c-2

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Documents

ge drive systems errata

drive application

instruction manual geh

acdc2000 drives

ambient condition guidelines

copy of geh

ge motors industrial

oilwell drilling drives