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BI006008

Bucyrus
All Rights Reserved

BUCYRUS
R

Technical Manual

BI006008

DANGER:
THIS MANUAL IS INTENDED TO PROVIDE INFORMATION AND DATA FOR
MAl ~TENANCE AND OPERATION ON THIS MACHINE. THE ELECTRICAL
ECUIPMENT INVOLVED SHOULD BE SERVICED ONLY BY QUALIFIED
INDIVIPUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH
VOLTJ GE SYSTEMS AND WARD-LEONARD LOOP DC DRIVES. FAILURE TO
COMPLY WOULD RESULT IN PERSONAL INJURY OR DEATH.
,

_-0

DANGER:

DO NO ATTEMPT ANY MAINTENANCE, MECHANICAL OR ELECTRICAL, ON


THIS InACHINE WITHOUT FULL UNDERSTANDING OF THE COMPONENT
OPERA ION AND INTERNAL PARTS. COMPONENTS UTILIZING ELECTRICAL;
POWEF, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR . ,.
TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND
ISOLATED PRIOR TO DISASSEMBLY.

The FEEDE ~ CABLE must contain a provision for a ground connection, especially where
2300 volts end above are used. The power line end must attach (see the paragraph on
ground circ its) to a suitable permanent ground. The machine end must securely attach
through a b Ited connection to ground the machine frame. This provides a constant
ground for t lie machine and electrical equipment. Failure to provide this adequate
ground endi ngers employees and equipment.

POWER LINE. GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZEl . Without a good grounding system, high voltage exists between the
machine and the ground. The portable cable and power lines supplying the machine
must have a ~round wire, ample in capacity, running parallel to the main wires over the
entire distanc e from the transformer to the machine. A suitable grounding system must
be used at th ~ transformer. Consult the local electric supplier for details.

DANGER:
DUE TO INHERENT DANGERS IN THE OPERATION OF ANY HIGH VOLTAGE
ELECTRICJl L EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE
GROU ~D CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING
RESIS' OR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND
CcDNTINUITv CHECK SYSTEM IS ALSO RECOMMENDED.

BI006008

BI006008

Marion

182M Mining Shovel

ELECTRICAL SERVICE MANUAL No. 2243


-SN: 23367, 23368

Table of Contents -

This man al is divided into several sections covering various systems and their electrical components of the
1 2M Mining Shovel. Refer to book 2 of this manual for vendor instructions and publications.

Book 1:
Int oduction
Sect on

1 - SYSTEM OVERVIEW

Sectipn

2 - SYSTEM COMPONENTS and OPERATION

Secti pn

3 - STANDARDS for ELECTRICAL INSTALLATION

Secti< n 4

- CABLE PULLING SCHEDULE

Part No. 140G1 Rev. C


Part No. 211945-5 Rev. A

Sectic n

5 -ELECTRicAL SETTINGS

Secticn

6 - EXCAVATOR THEORY

Sectior

7 - DC 2000 DRIVE SYSTEM and INSTRUCTION MANUALS

Sectio)

8 - FIELD EXCITER INSTRUCTIONS

Sectio

9 - BRAKE INSTRUCTIONS

Sectior

10 - MOTOR CONTROL CENTER

Part No. 211946-3

Part No. 212656-7

Book 2:
Introd~ction

Section 11 - ELECTRICAL SCHEMATICS OVERVIEW


Section 12 - ELECTRICAL SCHEMATICS
SN: 23367

Part No. 211944-7 Rev. C

SN: 23368

Part No. 212781-4 Rev. C

VENDOR PUBLICATIONS:
Rota ing Equipment
Con 01
Supr ort Devices
IMPORTANT NOTE
The infonnation and documer ation enclosed were developed and assembled by The 1\larion Power Shovel Company ("l\'farion")~ a subsidiary ofGJobal Industrial
Technologies, Inc., for the lim ted purpose of relating necessary technological material to our customers. The contents herein were developed and produced at
substantial expense and are v lued by Manon at a proprietary level. Therefore, this information and docurnenk'1tion is being furnished solely for use with the
subject machine and is not to e used, reproduced or disclosed in any way, in whole or in part, without the prior express written permission of Marion.

1997

The Marion Power Shovel Company

2243-I.M61

BI006008

BI006008

Introduction
-

GENERA INFORMATION

Table of Contents _
Page

..................................................
SAFETY LERT SYMBOLS

ii

"

SAFETY P ECAUTIONS.................................................... iii


FIRE PRE ENT/ON

"

TRAINING

vi

WARRANT

vii

2243-1.1V161

BI006008

BI006008

Introduction
GENERAL INFORMATION
This man
of this rna
personnel
maintena
used for t

al is designed to assist the owner in the operation and preventive maintenance


hine. Following easy to understand step-by-step procedures, maintenance
can perform these tasks in a safe manner. When a systematic and thorough
ce/service procedure (a responsibility of the maintenance superintendent) is
is machine, minimum unplanned downtime and reliable operation will result.

THIS MA UAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A
separate, etailed parts book has been supplied. Please carefully read the instructions in
it. All parts re listed by group and/or product code numbers with item/part numbers for
THIS SPE IFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and
returned, a e subject to a rehandling charge. RIGHT HAND and LEFT HAND parts on the
upper fram correspond to the operator's hands at the controls; as seated when
operating t e machine. Please state the correct machine SERIAL NUMBER (located on a
plate in the perator's cab) when corresponding or contacting factory service or parts
department . Records on each machine are filed by serial number and when given this
number, yo r machine's specific design and original equipment is accessed quickly by
the Marion arts representative.
itions or revisions may be made to this manual. These will be mailed direct to
you from th factory. Shpuld you require additional information or factory service
assistance c ntact your regional service representative or
ustomer Service Department
T e Marion Power Shovel Company
6 7 West Center Street
P. .Box 505
M rion,OH 43301-0505

- or Telephone (614) 383-5211


Fax: (614) 382-2052

It is Marion's
licy to improve its products whenever possible and practical to do so. The
company rese ves the right to make changes or add improvements at any time without
incurring any bligation JO install such changes on machines sold previously.
tinuous program of product research and development some procedures,
nd parts may be altered in a constant effort to improve machines.

BI006008

SAFETY ALERT SYMBOLS

This safety alert symbol is used here and throughout this manual to call
your attention to instructions concerning your personal safety. Carefully
read and follow these instructions and observe all SAFElY, DANGER, and
CAUTION graphics mounted on various areas of the machine.

Be certain anyone servicing this machine is aware of these SAFElY SYMBOLS and their
definition. In the event you question your ability to safely perform any of the enclosed
maintenance and operational procedures contact your regional Marion service
representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the
safety alert signal is used.

ADANGER:

Denotes extreme intrinsic hazard which exists and could result


in high probability of death or irreparable injury if proper
precautions are ignored.

ACAUTION:

Denotes a reminder of safety practices or directs attention to


unsafe practices which could result in personal injury if proper
precautions are ignored.

An example of a safety alert symbol and special instructions is shown below.

ADANGER:

Inherent danger exists in the operation of any high voltage


electrical equipment. A safe grounding system includes
ground conductors in the power cable, a neutral grounding
resistor, and related relays and switch-gear. A ground
continuity check system is required by law in many parts of the
world.

Operating, maintaining or servicing this machine is dangerous unless performed


properly. Each person must satisfy himself and his employer thathe is alert, has the
necessary skill, knowledge, proper tools and equipment, and that all the methods used
are safe and correct. Factory service representatives and specialists are available to
provide additional information or technical assistance.
The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or
medications that might effect his eyesight, hearing or reactions.
Safety must always be the most important concern. Consult your supervisor when safety
is in doubt.

ii

BI006008

SAFE

PRECAUTIONS

- The 0 ner and/or operator must replace any and all safety and warning product
graphi s if they are defaced or removed from the machine.
- Before doing any work on the machine, a qualified electrician must lock out or remove
the ele tric power supply from the machine and tag it so personnel are aware that
someo e is working on the machine.
- Do not tart an engine indoors unless adequate exhaust ventilators are provided. Once
an engi e is running, move the machine outdoors as soon as possible.
ds, feet, and clothing away from rotating parts.
- Do not ove or operate the machine without knowing the location and purpose of all
personn I, plus test or support equipment, in or near the machine.
ore you act. Carelessness is one luxury the service man cannot afford.
ar rings, wrist watches or loose fitting clothing when working on machinery.
They co Id catch on moving parts causing serious injury. Never adjust and/or service a
machine 'n bare feet, sandals or sneakers.
ar safety glasses when using a hammer, chisel or other tools that may cause

- Excessiv or repeated skin contact with sealants or solvents may cause skin irritation.
In case of skin contact, remove sealant or solvent promptly by washing with soap and
water.
- Never utili e the machine air or hydraulic systems for support when working on the
machine. eactivate and isolate the system prior to performing maintenance.
- Equipmen should be parked on level ground at all times during machine servicing and
periods of dleness.
- Cranes an hoists must be of sufficient capacity to lift the heavier components
(gearcases dipper/bucket, boom, etc.) and have an ample safety margin.
- Be sure he vy items are properly supported from cranes or hoists before removing
supporting embers from machine.
- Have suffici nt service personnel available when removing or installing large heavy
items to mal tain control at all times.
- Always use afety stands in conjunction with hydraulic jacks or hoists. Do not rely on
the jack or h ist to carry the load, they could fail.
- Use safety c tch on all hoist hooks. Do not take a chance, the load could slip off of the
hook.
iii

BI006008

- If a heavy item begins to fall, let it fall, don't try to catch it.
- When disassembling machine, be sure to use safety stands and adequate cribbing to
prevent tipping or rollover of components.
- Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and
parts off of the ground. Eliminate the possibility of a fall which could result in serious
injury.
- Floors, walkways and stairways must be clean and dry. After draining operations be
sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous
combination.
- Check all wire ropes for telltale signs of early wear or failure. Look for and secure any
loose bolts or locking devices.
- Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless qualified. Check limit
switches for proper operation.
- When using an acetylene torch, always wear welding goggles and gloves. Keep a
"charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are
separated by a metal shield and are chained to the cart. Do not weld or heat areas near
transformers or electrical cabinets and utilize proper shielding around lubrication lines.
- Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when
applicable. Use hammers, punches and chisels only when absolutely necessary. Then,
be sure to wear safety glasses.
- Be careful when using compressed air to dry parts. Use approved air blow guns, do
not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding
to protect everyone in the work area.
- Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or
servicing the machine.
- After servicing, be sure all tools, parts or servicing equipment are removed from the
machine, or secured in an appropriate storage area.
- Protective eye goggles should be worn at all times when working on the air
conditioning system. Work on the air conditioning system only in a well ventilated area.
- Wipe away excess lubricants around bearings and gears. Never lubricate parts in
motion.
- Operate machine on level ground and be constantly aware of swing clearance. Never
hold a load longer than needed in the dump cycle. Use swing brakes only when
machine is stopped.

iv

BI006008

FIRE PF EVENTION
-

Alway~

have a "charged" fire extinguisher on hand and know how to use it. Inspect and
servicE the extinguisher as indicated on its instruction plate.

- DO NC T smoke while handling flammables or when near batteries.


- lnspec all lines, tubes, and hoses carefully. Tighten all connections to the
recomr~ended torque. See the Visual Inspection Schedule for the walk around
inspect on procedure.
- Loose c r damaged lines, tubes, and hoses, which leak, can cause a fire.
- Make CE rtain that all clamps, guards, and shields are replaced correctly so as to
prevent yibration and the rubbing of one part against another which might result in
heat bui d-up during operation.
- DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
- DO NOT over-bend or strike pressurized hose lines. DO NOT install bent or damaged
lines, tul:es, or hoses. Replace them with new immediately.
- DO NOT start the machine or move any of the controls if a warning tag is attached to
the contr >Is or the start panel.
- Keep all c leaning rags properly stored. DO NOT discard them into a pile on board.
- Keep all s ructural frame compartments, walkways, and work areas clean and free of
lubricant residue.

- NEVER

WE

d, burn, or perform service on the machine alone.


,

- If a motor >r other component is running hot, shutdown the machine until it has cooled
and/or the cause eliminated.

BI006008

TRAINING
Qualified maintenance personnel using a scheduled maintenance program are the best
way to minimize machine downtime and maximize productivity of equipment.
Marion offers factory and mine site maintenance seminars and special familiarization
programs for mechanics, oilers, electricians and operators on a fee basis.
These programs are presented by qualified factory specialists and service technicians.
Special customized training programs can also be developed to meet specific mine
requirements.
Objectives of training and training materials are to provide the means for developing and
maintaining on-site service repair capability.
For further information about Marion service training capabilities and programs contact:
Customer Service Department
The Marion Power Shovel Company
617 West Center St.
P.O.Box 505
Marion, OH 43301-0505

vi

BI006008

R PAIR/SPARE PARTS WARRANTY


The Marion ower Shovel Company ("Marion"), a subsidiary of Global Industrial Technologies,
Inc., warran s that its products, when shipped, for a period of six (6) months from the date of
delivery, F. .B. point of shipment, will meet applicable, agreed specifications, if any with
respect ther to, and will be free from defects in material and workmanship, provided that the
Marion prod cts sold are properly stored, assembled, used and maintained. Products not
manufactur d by Marion shall be subject only to such warranty as may be made by the
manufactur thereof. All claims under this warranty must be made in writing immediately
upon discov ry. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
WHATSOE R, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT
L1MITATIO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.
Should any f i1ure of the Marion products to conform to this warranty appear within the limited
time period s t forth above, Marion shall, upon Buyer's submission of a claim as provided
above, either 1) repair or replace, F.O.B. point of shipment, any nonconforming part or parts of
Marion's pro ucts which hc;we been returned to it for examination, transportation prepaid, or
otherwise ex mined by Marion, and which examination discloses the nonconformity to
Marion's satis action; or 2) refund an equitable portion of the purchase price.
THE FOREG ING IS MARION'S ONLY OBLIGATION AND BUYER'S EXCLUSIVELY
REMEDY FO BREACH OF WARRANTIES AND, EXCEPT FOR GROSS NEGLIGENCE,
WILLFUL MI CONDUCT, OR REMEDIES PERMITTED UNDER THE PERFORMANCE,
INSPECTION, AND ACCEPTANCE CLAUSE OF MARION'S TERMS AND CONDITIONS, THE
FOREGOING S BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR ALL CLAIMS
ARISING WIT RESPECT TO MARION PRODUCTS OR RELATING THERETO, WHETHER
SUCH CLAIM ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING
NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. BUYER'S FAILURE TO
SUBMIT A CL 1M AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR
DAMAGES 0 OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON
LATENT DEFE TS.
IN NO EVENT INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED
WARRANTIES NO REMEDIES) SHALL BUYER BE ENTITLED TO ANY INDIRECT,
SPECIAL, INCI ENTAL OR CONSEQUENTIAL DAMAGES, WHETHER ARISING FROM
LATE PERFOR ANCE OR A FAILURE TO PERFORM, DEFICIENCIES OR NEGLIGENCE
IN THE DESIG ,MANUFACTURE, SALE DELIVERY OR ASSEMBLY OF MARION
PRODUCTS 0 FAILUREOF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER
AND WHETHE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE
AND STRICT LI BILlTY) OR OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH
RESPECT TO ARION PRODUCTS OR RELATING THERETO MUST BE COMMENCED
WITH ONE (1) EAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE
BARRED.
'---------l---------~--~-~-------------.----.~----.---.-----~.-.--.------~~

REV. 12/6/95

warranty. m60

vii

BI006008

---------------------------

--~---------------------

-----------------

------------------------------------------------

--------- --------

---------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - -

viii

BI006008

Book #1
Section

System Overview
-

Table of Contents _
Page
"

1.1

ELECTRIC L SYSTEM OUTLINE

"

1.2

KEY INTER OCK SYSTEM -SN: 23367

"

1.3

KEY INTER OCK SYSTEM -SN: 23368

"

1.4

ONE-LINE E ECTR/CAL DIAGRAMS

"

1.5

SCRIPTION

Schematic

COMPRESSED AIR SYSTEM

SChematic -

UTO LUBE

SChematic -

UTO LUBE CONTROL

Machine Spe ifications -English


Machine Spe ifications -Metric

2243-1.M61

1.9
"

1.10
1.11

" 1.12
1.13

BI006008

BI006008

Section

System Overview
SYSTEM DESCRIPTION
This mach'ne is equipped with a totally static, variable voltage, digital D.C. control system
that can ccnvert and invert A.C. power to control D.C. motors. The control system consists
of the hoi~ t drag/propel and swing motions. The propel motion shares the drag electrical
system. TI" e swing function remains fully active during propel.
When motipn drive power is required, controlled gating of thyristors converts A.C. voltage
into variablE voltage D.C. This controlled D.C. controls the speed of and limits the current to
the drive m :::>tors.
When motipn plugging occurs, the D.C. drive motors act as generators. During these
periods, the mechanical energy is converted into electrical energy, which is inverted back
to A.C. by tt e thyristor bridge networks, and returned to the power network.
Refer to the ~ne-Line Diagrams of this electrical system starting on page 1.5 in this section
of the manu I. These will assist in understanding the system.

------t----.--

-.------.-.- -- - - - - - - - - - - -

----~-------~.----.-----.----.-----

------\----------_._--------------------------------

-------+-----------_._------

--------~._---------------------

._--- - - - - - . _ - - - - - - - - - - _ . - - - - - . - . - - - - - - - - - - - - - - - - - -

------(-----------_._---~---

1.1

BI006008

BI006008

ELECTRICAL SYSTEM OUTLINE

..;

6.6 KV, 3-Phase, 50 Hertz Supply Voltage -Maximum Voltage Fluctuation + 10%/-20%.

..;

41E Volt AC Auxiliary Voltage, 55/110 Volt Secondary.

..;

150 KVA Dry Auxiliary Transformer.

..;

Vac~um

..;

War~-Leonard Power Conversion .

..;

Stat c DC Generator Field Exciters with Digital Control.

..;

Stati~

..;

Joys ick Control via Expander Boards.

..;

Elec ro-Mechanical Auto Lube Control.

..;

Auxil flry Collector Rings placed on the Machinery Deck for Maintenance Ease.

Contactor Control of M.G. Set Drive Motor with Reduced Voltage Starting.

Motor Field Exciters with Digital Cotrol.

-----+-----------~--~-----~--------------------------------

1.2

BI006008

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REEL

n' ClM1ronAL. WORMlnc. MIl tS n EXQJlSIVE Pfl:OPERTY


Il MI) HAS BEBC DEB..OPlD I.T S\e$TMmAL 0P0tSt.
ITS ~ AR TO 8 \10, ~ 011 DtSClO5O I.
DPflDSO) Ifl'ITTEIf P9lIIsstOlilOf ... NIJ mrs MAlt'UC NG
TO II 01 tDWD,-

IMPORTANT NOTE

OHIO

COLLECTOR RINGS

BOTTOM OF UPPER FRAME

MARION DIVISION OF
IMORESCO INC. MARION.

TRAIL CABLE
J. BOX

E
BOLT EXTENDED
W BOL T WITHDRAWN I .
L.O. LOCKED OPEN
L.C. LOCKED CLOSED
DENOTES DOORS MECHANICALLY
INTERLOCKED WITH LOCAL ISOLATOR

CABLE,

LOWER FRAME
DISCONNECT

DOOR

SN: 23367

DOOR

KEY INTERLOCK
SYSTEM

.1

DOOR

1944-7

L.C.

~ll~

AUXIL IARY
TRANSFORMER

FUTURE USE
(IF REQD.1

HIGH VOLTAGE CONTACTOR CABINET

DO~

H.V. FUSE CABINET

BI006008

BI006008

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L.O.

IMPORTANT NOTE

AU. (:::()110 Of If StUU BE II{JUIbO TO .. C*

tJJwn

=:l.~;r1'l~~A=-"f'tl~I~T~~~O~~,*~
~,f&t~~~

OHIO

COLLECTOR RINGS

BOTTOM OF UPPER FRAME

WARION DIVISION OF
IMORESCO INC. MARION.

E
BOLT EXTENDED I
W
SOL T W I T H D R A W N '
L.O. LOCKED OPEN
L.C. LOCKED CLOSED
DENOTES DOORS MECHANICALLY
INTERLOCKED WITH LOCAL ISOLATOR

CABLE
REEL

TRAIL CABLE
. J. BOX

-ntts flttlmlG rtO'fCD'n PROPfUfTNn JIf:) COtf'ltomt. tWOOMWOlf .1M) IS 1l o:a..l1SI~ PflCW'OlTY
Of MUrK* DfVlSI(lI Of ~ 1JK:..041 tJ HJ.S I'Io(D t(\{].MD AT SlSr~nlrt. D7OCS[.

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DISCONNECT

DOOR

SYSTFM

SN: 23368

DOOR

KEY INTERLOCK

E
.1

DOOR

FUTURE USE
tIF REQD.!

21?7R1- A

l.C.

~II~

AUXILIARY
TRANSFORMER

M.G. SET
DRIVE MOTOR

HIGH VOLTAGE CONTACTOR CABINET

Do~1

H.V. FUSE CABINET

BI006008

BI006008

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IMPORTANT NOTE

CABLE REEL

o
E
F
G

L
M

AUX XFMR

150 KVA

NOTES

liMit

IN

fH~~R~f >1

"(

FUSEO:~:_I ":li~ ""

MARION DIVISION OF

(BOIK)

DISCONNECT
3-P

,I l

'THi$ ORA-WING REPRESENTS Pf!OPRIETAR'f AWo COI4FIOHHllll INFORMATION PoND 15 THE EXCLUSIVE PfiOPUHY
OF MARION OlV1SJON Of INORESCO INC.(l.lll AND HAS 601 DVElOPED AT Sl)8STAN.TlAL OPENS,

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6600 V

TRAIL
CABLE
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1500Vl

1)

FAUL T

GROUNO
IA TRIP

MODULE

[C23A)

(C26A]

(C25C)

:L...Q __ ~

a=:1llr

Z30V

7.5 KVA

r.2::
""''"

LTG

[003R) BUS

: o-1l1H-[0030)
L __ ~

l--~

415 TO 55-0-55V

AUX.XFMR

3 KVA

H-----------

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

II

10

09

08

07

06

05

04

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[C22G]

125 VOC
CONTROL
BUS

c
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K
M

M-RUN
VACUUM
CONTACTOR

MARION DIVISION Of
INORESCO INC. MARION. OHIO

'OTES

... rUSE SPEC IAL


MARION DIY.
PIC 384340-8

[A28G]

NEUTRAL
STARTING
REACTOR

SGR

[C22K]

TR

-2

[c 13F]

GENERATOR

~11---

SWING

SGFE

SSCR

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GENERATOR

CROWD

CGFE

r[c'On
CSCR

~PC:H L~CI~ COC,~w

$ $_2 -\ ~

HOC

00

LHOIST
GENERATOR

HGFE

CR

r[C07FJ
P

01

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

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09

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05

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ep

(A20V]--Q--UVR

IMPORTANT NOTE

or Wlote DlVISIOIII OF' ItClRSCO 1lC.00J III> HAS BEDI OC'lUJ


lll!llU0flE. IEITlfIJlM IIlAIl'" IlOfl ITS COIIlOOS MIf. ro
JIHOl Oft IN PMT wrlMGUT lIE PRtoIl: DPRESSED IRITTEJ(
AlL COf'e Of IT 3lLIU. BE ll[MJO ro II OIl _ . '

'"lN1! mAI1tC REJ'RESEMTS r'lWPl(l'MY 1M) a.:wltOtl .... Itl

I?

1%

'~

[A22V] --{-SHUNT
TRIP

WELD

ITE~R

F
G

AIR
CONDITIONER

POWER

INCOMING

415 V. AUX.

ANTI-COND.
HEATERS

1
--'V-

OHIO

SHUNT
TRIP

--;'..--0 MFT

.OTES

DC MOTOR
ZL
-<~[B25H] FIELD
EXCITERS
IX
I
I

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MARION DIVISION OF
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SUPPLIES

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26

25

24

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09

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21

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.75 NOM. 1.0,

,50 NOM, 1.0.

AUXlUARY
COlLECTOR
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BI006008

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Air Hose.
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1.11

BI006008

BI006008

The Marion Power Shovel Company


Machine Specifications -English
Model: 182M MINI G SHOVEL
Description: Stand rd Range - Motor Generator Set

Specification: 182M-HR-17
No.633032387
182mhr17.w61

J~~-~~--J

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BOOM HANDLE DIPPE

UPPER FRAME

Boom Length
40'-2"
Boom Sheave Diameter - Pi ch Diameter
54"
Boom Foot Pin to Shipper S aft
16'-9"
Dipper Handle Length
27'-0"
Dipper Capacity, CU.Yds. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13

S - Clearance Radius - Rear End . ,


,,
,
, , , . 24'-6"
T - Clearance Under Frame
,,,.,
,.,
,
5'-7"
U - Clearance Height - Gantry .. ",,' .. ,
,,'
29'-9"
V - Clearance Height - Filter House .,.,
" ,.,,,,
25'-3"
W - Eye Level - Operator's Cab, Standard ,
,
25'-2"
,
,
20'-5"
X - Clearance Width - Machinery House
Hoist Drum - Pitch Diameter
,,
, , , . , , , , , " 40"
Hoist Rope Diameter (Double Line) .", .. ,., ..... ". 2"
Boom Support Rope Diameter (Twin Dual) , , . , , . , , . . .. 2"

WORKING RANGES

Without Limits
A - Boom Angle
45
B - Dumping Height - Maxim
26'-6"
C - Dumping Radius @ Maxi um Height
47'-1"
D - Dumping Height @ Maxi
m Radius
18'-0"
E- Dumping Radius - Maximu
48'-10"
F - Cutting Height - Maximum
42'-9"
G - Cutting Radius @ Maximu Height
50'-10"
H - Cutting Height @ Maximu Radius
22'-9"
J - Cutting Radius - Maximum
56'-9"
K - Radius of Clean-up
,
, , . , , , 36'-5"
L - Clearance Radius - Outside Boom Point Sheave , .. , . 39'-2"
M - Clearance Height - Over B om Point Sheave ... ,.,. 41 '-1 "

ELECTRICAL EQUIPMENT
Cont.
Peak
Hoist Motor, 640 hp @ 475 V, Total hp " .. ,." 640
924
Swing Motors, Two, 130 hp @475 V, Total hp ... 260
378
Propel Motors, Two, 195 hp @ 475 V, Total hp ., 390
560
Crowd Motors, 130 hp @ 475 V, Total hp
130
189
Induction Driving Motor, Total hp . , . ,
,
,
800
Swing Speed, rpm
,,,,
,.,,
, , , , . , , . , , , . , 2,9
Travel Speed, mph, ""
,.,
,
", .. ".,. 1.0
Complies with the Indian Electricity Rules 1956 as amended,

WEIGHTS
Std.
Opt.
29'-9" . , , .. 29'-9"
N - Crawler Length
,,,,,
,,
0- Crawler Width .. ,
,.,,.,,,.,
22'-6" , , , , , 24'-1"
P - Belt Width ..,.,.......... , . . . , . . , , ., 39".,...., 59"
Bearing Pressure, Lbs,per S . In, .,.... 36.4
24.3
Q - Clearance Under Lower Fra e .. ,
2'-0" .. , . , , 2'-0"
R - Clearance Under Crawler Ge rcase .. , . " 19" ... , ... 19"
Patent Pending
Printed in U.S.A.

Shipping Weight, Lbs. ..,.,


"
,.""
660,000
Working Weight, Lbs
, , , , . , .. , , , , , , .. , , ,
780,000
Ballast (Furnished by Purchaser), Lbs. . ",
"",,120,000
Minimum Weight of Ballast, Lbs,/Cu,Ft. ... , ,
, , , ..... 250
Range and Weights Subject to Variation Due to Options Selected
by Purchaser,

The Comp y reserves the right to improve or change the design of its products and specifications thereof and the
Company sh II incur no liability thereby or any obligations to install such improvements on products previously sold,

1.12

BI006008

BI006008

The Marion Power Shovel Company


Machine Specifications -Metric

Specification: 182M-HR-17
NO.633032387

Model: 182M MINI G SHOVEL


Description: Stand rd Range - Motor Generator Set

182mhr17.w61

1--------

-~~---'=-J
1

G
-.---- L

Meters

Boom Length. . . . . . . . . .
.
Boom Sheave Diameter - Pi ch Diameter
Boom Foot Pin to Shipper haft
Dipper Handle Length
Dipper Capacity, CU.Meters

12.24
1.37
5.10
8.23
10

WORKING RANGES
Without
A - Boom Angle
B - Dumping Height - Maxim m
C - Dumping Radius @ Maxi um Height
D - Dumping Height @ Maxi um Radius
E - Dumping Radius - Maxim m
F - Cutting Height - Maximum
Height
G - Cutting Radius @ Maxim
H - Cutting Height @ Maximu Radius
J - Cutting Radius - Maximum
K - Radius of Clean-up . . . .. .
L - Clearance Radius - Outsid Boom Point Sheave
M - Clearance Height Over B om Point Sheave

Limits
45
8.08
14.35
5.49
14.90
13.04
15.51
6.93
17.30
11.10
11.94
12.52

UPPER FRAME
S - Clearance Radius Rear End
T - Clearance Under Frame
U - Clearance Height - Gantry
V - Clearance Height - Filter House
,
,
W - Eye Level - Operator's Cab, Standard
X - Clearance Width - Machinery House
Hoist Drum - Pitch Diameter
Hoist Rope Diameter (Double Line), mm
Boom Support Rope Diameter (Twin Dual), mm

7.47
1.70
9.07
7.69
7.67
6.22
1.02
51.0
51.0

ELECTRICAL EQUIPMENT
Hoist Motor, 477 kw, Total kw
Swing Motors, Two, 97 kw, Total hp
Propel Motors, Two, 145 kw, Total kw . . . . . . . ..
Crowd Motors, 97 kw, Total kw . ,
Induction Driving Motor, Total kw . ,
Swing Speed, rpm
Travel Speed, kph
,

Cont.
477
194
290
, 97

Peak
689
282
418
141
" 597
2.9
1.61

Complies with the Indian Electricity Rules 1956 as amended.

WEIGHTS
CRAWLER AND LOWER FR
N - Crawler Length. . . . . . . ..
0- Crawler Width
,
P - Belt Width
Bearing Pressure, Kgs.per S . Cm. .
Q - Clearance Under Lower Fra e
R - Clearance Under Crawler G arcase . . . ..
Patent Pending
Printed in U.S.A.

Std.
9.07
6.86
1.00
2.56
0.61
0.48

Opt.
9.07
7.34
1.50
,. 1.71
0.61
0.48

Shipping Weight, Kgs. .


Working Weight, Kgs
Ballast (Furnished by Purchaser), Kgs
Minimum Weight of Ballast, Kgs./Cu.Meter

299,400
353,800
54,400
4,005

Range and Weights Subject to Variation Due to Options Selected


by Purchaser.

The Comp ny reserves the right to improve or change the design of its products and specifications thereof and the
Company s all incur no liability thereby or any obligations to install such improvements on products previously sold.

1.13

BI006008

BI006008

Book #1
Section

System Components and Operation


-

Table of ContentsPage

2.1 LOW R FRAME


2.1.1
LOWE FRAME and CRAWLERS -Plan View. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.1.1
WIRIN -LOWER FRAME
2.1.2
WIR NG DISTRIBUTION -LOWER FRAME
2.1.4
2.1.5
LO ER FRAME DISCONNECT SWITCH BOX
" 2.1.6
LO ER FRAME CONTROL JUNCTION BOX
PR PEL BRAKE MAGNET VALVES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.1.7
PR
EL MOTOR JUNCTION BOXES
2.1.8
CRA LER LUBE PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.1.9
PRO ELBRAKES
2.1.10
ROPEL BRAKE PRESSURE SWITCHES
2.1.10
2.2.1
2.2 ROTAT NG FRAME
182M D CK PLAN
2.2.1
POW R FACTOR CAPACITOR HWT (insert)
2.2.3
2.2.5
I STRUCTIONS -HWT CAPACITORS GEH-2711 D (insert)
MAIN CO LECTOR RINGS (HV.)
2.2.7
AUXILIA Y COLLECTOR RING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.2.8
AUXI IARY COLLECTOR RING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .. 2.2.9
COLL CTOR RING INSPECTION and ADJUSTMENT
2.2.10
E CLOSURE INSPECTION
2.2.12
F EQUENCY of INSPECTIONS
2.2.13
BUSH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.2.13
CABINET on the LEFT WING
2.2.15
DIG/P OPEL CONTACTOR CABINET
2.2.16
Sc ematic -DIG / PROPEL CONTACTOR
2.2.17
HIGH OLTAGE CABINET
2.2.18
LO TRAK MODULE
2.2.20
HI H VOLTAGE CABINET ELECTRICAL DIAGRAM
2.2.21
DC CO TROL CABINET
2.2.24
GENE ATOR FIELD EXCITER TRANSFORMERS
2.2.27
CABINETS on the RIGHT WING
2.2.28
GROU D FAULT CONTROL CABINET
2.2.29
Sch matic -GROUND FAULT CONTROL. . . . . . . . . . . . . . . . . . . . . . . .. 2.2.30
HIGH V LTAGE FUSE CABINET
2.2.31
MOTO CONTROL CENTER
2.2.32

BI006008

Page
AUTO LUBE CONTROL
182M AUTO LUBE CONTROL CENTER
WIRING -AUTO LUBE CONTROL PANELS
AUTO LUBE -ROTATING FRAME and OPEN GEARS
AUTO LUBE CONTROL PANEL
AUTO LUBE ELECTRIC CONTROL PANEL
CONTROL PANEL ELECTRICAL DIAGRAMS
AUTO LUBE LOWER FRAME
AUTO LUBE CONTROL PANEL
ELECTRIC CONTROL PANEL
CONTROL PANEL ELECTRICAL DIAGRAMS
BOOM JACKING LIMIT
BOOM JACKING LIMIT SWITCH
HOUSE AIR FILTRATION SYSTEM
MAINTENANCE
182M DYNAVANE AIR FILTERS
FILTER FAN START-UP PROCEDURES
FILTER FAN HOOK-UP CHART
BOARDING STAIRS
DIPPER TRIP

2.2.34
2.2.34
2.2.35
2.2.36
2.2.36
2.2.37
2.2.39
2.2.40
2.2.40
2.2.41
2.2.42
2.2.44
2.2.45
2.2.46
2.2.46
2.2.47
2.2.47
2.2.47
2.2.48
2.2.49

2.3 OPERATOR'S CONTROLS


2.3.1
2.3.1
182M OPERATOR'S CAB (Plan View)
OPERATOR'S SEAT
2.3.2
OPERATOR'S SEAT ADJUSTMENT
2.3.3
BOARDING STAIRS
2.3.3
OPERATING CONTROLS
2.3.5
PRIMARY CONTROLLERS
2.3.6
Left Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.6
Right Controller
2.3.6
182M JOYSTICK MACHINERY MOTIONS
2.3.7
MASTERSWITCHES (JOYSTICKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.8
MASTERSWITCH REMOVAL
2.3.8
MASTERSWITCH CALIBRATION
2.3.8
MASTERSWITCH (JOYSTICK) CONTROLLER SYSTEM. . . . . . . . . . . . . . . . . . . .. 2.3.8
INTRODUCTION
2.3.8
ELECTRICAL TESTS
2.3.8
FUNCTIONAL DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.8
Masterswitches (Joystick Operator Controls)
2.3.8
INTERFACE FOR JOYSTICKS (MASTER SWITCHES)
2.3.9
CALIBRATION PROCEDURE
2.3.10
INTEGRATED CIRCUIT (IC) PIN LAYOUT
2.3.15
MASTERSWITCH (JOYSTICK) CONTROL PANEL
2.3.16
MASTERSWITCH EXPANDER BOARD
2.3.17
SUMMARYDATASHEET
2.3.19
SECONDARY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.20
LEFT CONSOLE
2.3.20
RIGHT CONSOLE
2.3.21
ALARMS
2.3.23
AIR PANEL
2.3.24

BI006008

Page
2.4.1
2.4 OPE AriON
GENE AL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.1
182M OMENCLATURE
2.4.1
182M PERATOR'S CAB (Plan View)
2.4.2
PRE-S ART INSPECTION
2.4.3
MACHI E START-UP & SHUTDOWN
2.4.5
ST RT-UP PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.5
2.4.7
RANSFER FROM DIG TO PROPEL
RANSFER FROM PROPEL TO DIG
2.4.7
PA TIAL SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.8
CO PLETE SHUTDOWN
2.4.9
GROU
PREPARATION
2.4.10
MACHI E OPERATION
2.4.11
GE ERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.11
DIG ING....................................................... 2.4.11
2.4.12
182M OPERATOR CONTROLS -DIGGING
MO ON LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.13
PRO EL
2.4.14
2.4.14
1 2M OPERATOR CONTROLS -PROPEL
STE RING
2.4.16
PRO UCTION EFFICIENCY
. . . . . . . . . . . . . . .. 2.4.17
CAB E REEL OPERATION
2.4.18
2.5 BOOM IRING
Schemati ,BOOM W!RING
BOOM W RING PLAN ViEWS
CROWD IMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
SPEE REDUCER OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ELEC RICAL RATINGS
CAM ETTING
OPER TION and ADJUSTMENT of CAMS
VE NIER ADJUSTMENT
CRO D LIMIT SWITCH MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
HOIST LI ITS

2243-2.Me1

2.5.1
2.5.1
2.5.2
2.5.3
2.5.3
2.5.5
2.5.5
2.5.6
2.5.6
2.5.6
2.5.7

BI006008

BI006008

Section

System Components and Operation


2.1 LOW R FRAME

Propel Motor
Junction Box

Lube Piping

Motor Blower
Disconnect Switch

Cable Reel

Front

See

Vi ew-X-+~:::"_:::::;;;;;:;;;;;:=-----t

----,

-------

\_--_ . ~
------

Propel Motor
Junction Box

Left Crawler

If

Rotation

Lube Piping

Left Propel
Motor
Ifpe1847.Wpg

LOWER FRAME and CRAWLERS -Plan View

2.1.1

BI006008

Lower Frame
Disconnect
Switch Box

View

SeaView
For Connections

.. Front of Machine

From Collector Rings-Aux


Ref

View J

View

Typ Wire Connection

K-K
wlfa1847.wpg

WIRING -LOWER FRAME

2.1.2

BI006008

To Ground
Collector

----4

To HV
Collectors

IFR

Lower Frame
Structure

ViewZ-Z

Collectors,
Main

IDouble Connection
8 Places

Top Of
Lower Frame

View-X
- Typical 8 Places

2.1.3

BI006008

Collector Ring
Assembly

.
e1

Lower Frame
'--_""" Disconnect
Cable ,Switch
Reel I

Trail
Cable

Lower Frame
Control
Junction Box

L.H. Crawler
Auto Lube
Pressure
Switch

Propel
..... Motor
Blower

L.H. Propel
Brake
Pressure
Switch

J
L.H. propelj
Brake
Magnet I
Valve,

R.H. Propel
Brake
Magnet
Valve

R.H. Propel
Brake
Pressure
Switch

R.H. Crawler
Auto Lube
Pressure
Switch

Propel
Motor
Blower

R.H.

L.H.
Propel
Motor

oJ

Propel
Motor
wdlf1847.wpg

WIRING DISTRIBUTION -LOWER FRAME

2.1.4

BI006008

p
Inspection
Window ---~

~D;sconnect Switch

B ....

Disconnect Switch

.,,.
,
,

-.

Box~

=lli"~ "-~

~"--(J'EJ/
_ooo~o,

',~._~-

..,
,

u/::

I~

.~.~/

fl ~

~'Disconnect Switch
Handle

'l'/

~Close

~DisconnectSwitch

D~~

Open

-0

~_~~~ __ ~~

~~~ __ ~"=~

Front View Of Cabinet

Grounding Cable

------~

-~-

-------------/~"""'...__.....,.._..._lh_~~H

isconn ct Switch

~~....
------------'~~~~

Groundin

Surge Arrestors
3 Places

Cable

Cut-Away Front View Showing


Components Inside
Ifds1847,wpg

LOWER FRAME DISCONNECT SWITCH BOX

2.1.5

BI006008

LOWER FRAME CONTROL JUNCTION BOX

The Lower Frame Control Junction Box provides access to all of the lower frame control
circuits. It is mounted on the rear of the lower frame structure. The circuits include:
.j Right and Left Propel Brake Pressure Switches.
.j Right and Left Propel Auto Lube Pressure Switches.
.j Right and Left Propel Brake Magnet Valves.
.j Right and Left Propel Motor Over-Temp Thermo-switches .
.j Right and Left Propel Motor Anti-Condensation Heaters.
.j Ground Check Door Interlock on the High Voltage Disconnect Box.

To Auto-Lube
Pressure Switch

~~====:==jF;::;;;;;;;;~1===f~~~~~51

---===-....l:=c=fl~=~

To Collector Ring JB

View AA
Ifjb1847,wpg

The Lower Frame Disconnect Switch Box is mounted on the rear of the lower frame,
between the propel motors.

2.1.6

BI006008

The front door of the disconnect switch box is fitted with a micro-switch that is wired into the
ground Cleck protection circuit. If this door is opened, and power is on to the machine, then
the substption will trip out ~provided the ground check protection circuit is operable. This
is an adc ed safety device. This door is equipped with a hasp for padlocking. (A tool is
required 0 open it.)

AD~N GER:

ADt

NGER:

NEVER OPEN THE DISCONNECT SWITCH BOX WHILE THE


MACHINE IS OPERATING. Always shut down the machine and
interrupt the power supply at the substation BEFORE opening
this box.

HIGH VOLTAGE EXISTS WITHIN THE DISCONNECT


SWITCH BOX. Always exercise extreme caution when servicing
it or working around it.

PROPEL E RAKE MAGNET VALVES


The Propel Brake Pressure Switches and Magnet Valves are mounted on the rear of the
lower frame structure. Gage ports are provided to aid in the proper setting of the pressure
switches. Refer to the Air Schematic for this machine for the pressure switch setting.

---_.

----~---,----_

..

_-~-_

..

__

._----~--_

2.1.7

_~~~-_.

...

_.----,-~----.-.-_._---_._-_

..

_---.----_.,--~--_.,-

BI006008

PROPEL MOTOR JUNCTION BOXES

ii
One Propel Motor Junction Box is
mounted on each Propel Motor.
Each junction box joins the
circuits shown at right:

A1 - Motor Armature Wires.


J A2 - Motor Armature Wires.
J F1 - Motor Field Wires.
I F2 - Motor Field Wires.
J P1 & P2 - Motor Over-Temp. Thermo-Switches.
II H1 & H2 - Motor Anti-Condensation Heaters.
iL_~~!?~'~~e~!~otor Blower.

View 5-5
Typ Both Motor J.B.'s

Front of Machine

1X11

Front of Machine

5-5

See View
For Internal
Connection

View L

5-5

See View
For Internal
Connection

ViewM

Typ 80th Motor J.B.'s

Typ Both Motor J.B.'s


pmjb1847.Wpg

PROPEL MOTOR JUNCTION BOXES

2.1.8

BI006008

"

Front
Of Machine

Front ~
Of Machine

Auto lube Cr wIer-Left


Auto Lube Crawler-Right

Notes:

Set Increasing Pressure (Contacts Open) At 2500 PS.1.


Set Decreasing Pressure (Contacts Closed)At 1900 P.S.1.
Clps1847,wpg

CRAWLER LUBE PRESSURE SWITCHES

2.1.9

BI006008

PROPEL BRAKES
Top Of Lower
Frame Structure

_----/ For Pressure Switch Settings,


Refer To The Air Schematic

~----;/~
~

~~

Set Decreasing Pressure At 10 P.S.1.


Set Increasing Pressure At 95 P.S.1.

Solenoid (Magnet)
Valve

Air Supply Line From


Center Journal Area

To Left
Propel Brake

To Right
Propel Brake

Propel Brake Pressure Switches


pbpS1847.wpg

PROPEL BRAKE PRESSURE SWITCHES

2.1.10

BI006008

r"

Control Console, Right

<t

Machine

Ground Fault
Control
Cabinet
Auxiliary
/
Transformer

Boom Foot

~-l
1

j/I"H'~

1J

. ~
/"
~-=

/~,-

INc!2 SW"i-n-g-'-~'/

No.1 Swing
Gearcase

I Gearcase

Auxiliary

Fuse
Cabinet/ /

. _--,-_ . Lube Catch

I------f~'C'b;":~:I~~:O'rSj~~l ("I".~.~'~ ~ :'I


,~

t'rITrl'IAmhn'\'\!
High
Voltage

II

L-,_~&U~=IJ=~IJ~~Ut
I

d_ ,I
Hoist Rope

RFePlaCle~[
'j
-I' - ~~ -. .-//r-.
I'

HOist I I,
- - -~ Machinery
~
,Assembly I

~~

__!I

Alr--

I -(~
l)
\

_~~Ttessor/--n

I!

System /-n
, L o w Air\ OGL
' I Pressure'<..lL.1

Reeving
JJWinch

_Switch

/Dig-Propel

IL)--1)--JI

II

'---_ _---I

Cabinet

Gantry
..~
Backleg / -

(~~

MG

Auto' Lube
Control
Center
Telephone
Station

LJ

--r;--~-

1 M.G. Set
, Drive Motor
~-T----~

deck1847wpg

182M DECK PLAN

2.2.1

BI006008

2.2.2

ljtNtHAl~

ELECTRIC

r-::,,=EV-----+-----.-TI-TL-E------------l
NO.

CONT ON SHEETBI006008 SH NO.

2.

OUTLINE
IN :B/f/lCKETS
T R S.

J)IMENS/OA/,
/1 R E 11/ L LI

OUTDOOR)
SOLDERLESS
CONN. FOR A

H WT

FIRST MADE FOR

CONT ON SHEET

[xxx]

#10 SOLID TOA


#4 STR'D. CONN.

.2.50-2.0 G RD.

[6J

34 . 00

[864J

+
,n.

I I

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.......

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[/3 X 16J
(2..)_500 X. ~ 2. 5
SLOTS

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........

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25.08 [c637J

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APPROX.WT

LBS

CAT. 36F29c;3G8 SR. NO.


OF;VAA
/27.3
VOU.0000
HZ So
PH. 3 .CJJHH. .DE L T /i
CONIC. DIAG.
CAIfIIl' l1ue N1:fUtIlC It "(lUII' ICU

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I

_C!!~~!-~O!_~~~~ __OI~E~
HUOS ON FA lLS

LOCATION

.'.

PRINTS TO

36 F2903 G 8
CONT ON SHEET

SH NO.

2-

weE 'GElH N

Ff803WF (282-/01-1)
PRINTED IN USA

2.2.3

BI006008

2.2.4

BI006008 GEH-2711D

INSTRUCTIONS

TYPE HWT CAPACITORS

REFER TO CAP CITOR UNIT INSTRUCTION


GEH-2743 INCLU ED WITH THIS EQUIPMENT
BEFORE PERFO MING ANY WORK ON THE
EQUIPMENT.

GENER L INSTALLATION
Check the capaci or nameplate to make certain
that the capacitor v ltage rating is the same as the
applied voltage. Th equipment should be located
so as to minimize t e transfer of heat from other
equipment or from t e sun into the capacitors. The
preferred mounting osition is with the capacitors
vertical (terminal b x on top) for greater protection
from the weather.
e sure that air can circulate
freely about the cap citors. Incoming leads should
be arranged or supp rted so as not to place a strain
on the fuses or bushi gs inside the terminal box.

ASSEMBLY
ONNECTIONS

TABLE I
Capacitor Capacitor
Voltage Unit Sizes
(Kvar)
(Volts)
2400
2400
2400
4160
4160
4800

25,50,75
100,125,150
200
25,50,75
100,125,150
200
25,50

Fuse
Voltage
Rating
(Volts)

Fuse Current
Rating
(Amperes)

4300
4300
4300
5500
5500

35
75
100
18
50

5500

18

INDOOR EQUIPMENTS
The standard design of equipments is for indoor
dustproof application and terminal boxes are supplied
with knockouts for the customer's incoming conduit
connections. Standard methods of terminating conduit should be followed.

OUTDOOR EQUIPMENTS
All standard Type HWT capacitors use two fuses
per 3-phase capacito unit. These are assembled
to the capacitor unit st d by means of adapter blocks.
To remove a fuse, unscrew the locking setscrew
in adapter block usin a 1/4-inchAllen wrench. The
fuse will then pull or crew out of adapter block.

Designs for outdoor applications are supplied


with special entrance hubs and knockouts are replaced with gasketed cover plates.

CLEARANCES
Recommended electrical clearances, enclosed
space, are as shown in Table II:

Refer to the equip ent outline drawing (included


with the eqUipment) fo provision for customer's incoming conductors.
Current limiting fu es with blown fuse indicators
are used in all Type H T capacitors. Table I indicates fuse sizes norm ly used wi th the various individual capacitor units eluded in HWT capacitors.

TABLE II
Volts

Line-to-Line

2400
4160

2-1/2 inches
3-1/2 inches

Line-to-Ground
2 inches
3 inches

. These. instrv<:lions do not P';'


rt to coyer 011 detoil. or Yoriotions in equipme<lt nor to proyide for eyery pouible contingency to be mel in conne<:tion with
IOsiollol,on, operol/on or maIO nonce. Should further information be desired or should particular problems arise which ore not COyered wffide<ltly for the
purchaser's purpose,. the matt r should be referred to the Generol Ele<:Iric Company.

GENERAL El CTRIC COMPANY, CAPACITOR PRODUCTS DEPARTMENT, HUDSON fAllS, N. Y. 12839


7/34

(l~)

2,2.5

BI006008

2.2.6

BI006008

MAIN C LLECTOR RINGS (H.V.)

Bottom Plate of the


Rotating Frame Structure

Insulator
Mounting Bar ~""""-

21.50
(546 mm)

Mounting Bar
Mounting Pad ------....~::.:---4'--t--+--~
Top Plate of the
Lower Frame Structure
(-----~

Rotating Frame Structure

Center Journal Pin

Lower Frame Structure

crmn1847.wpg

ADAN ER:

HIGH-VOLTAGE AREA! DISCONNECT, ISOLATE AND LOCK


OUT MINE SUBSTATION POWER SUPPLY TO THE MACHINE
BEFORE ENTERING OR WORKING IN THE MAIN COLLECTOR
RING AREA. NEVER TOUCH THE COLLECTOR RINGS UNLESS
THEY HAVE BEEN PROPERLY EARTHED (GROUNDED) BY A
QUALIFIED ELECTRICIAN.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD
RESULT IN PERMANENT SERIOUS INJURY OR DEATH.

The MAIN CO LECTOR RINGS are the electrical conductor which transfer high voltage from
the lower fram to the upper rotating frame. These conductors are located inside the roller
circle in the ar a between the lower and upper frames. The collector rings are mounted on
ceramic insula ors which are bolted to the bottom of the rotating frame. Four concentric ring
assemblies ar provided. Eight collector assemblies with two brushes each are mounted on
the lower fram top plate with insulators and mounting bars.

2.2.7

BI006008

AUXILIARY COLLECTOR RING ASSEMBLY with ROTO SEAL

c;.
Rotation
Hoist Rope
Guard

Front of
Machine

.l-

Drive Pin Location

Hoist Drum

~ Co~~~ction

Lube ~
Connecti on

r--.z=f=-r:__~'~'

Dual Rctoseal
DC and Auxiliary
Collector Ring Assembly
Top of Center Journal Nut
Raised for Thrust
Washer Replacement
Top of Center Journal

10.75 in.= 273mm


8.08 in.= 205mm

---l
Rotating
Frame

Bottom Plate in
Upper Frame
Rotoseal Assembly

Lower Frame

lube Connection
Air Connection

Center Journal

Bottom Plate in
lower Frame

Wiring Enclosure
Rtsl1845.wpg

The combined Collector Rings and Roto Seal Assembly is mounted above the center journal
on the deck of the rotating frame. The 22 collector rings provide for ground check, auxiliary
control, propel motor shunt field and armature circuits.
Two sides of the collector rings have inspection windows with protective steel door covers
that are mounted on bolt-on access doors.

2.2.8

BI006008

Y COLLECTOR RING MAINTENANCE


/

i~~~~~:~

22

:_-

Cover

with Bearing

r----lL-i---'~=-----"

Removable

End
Assembly

Ground Check Ckt

Flange Block
Assembly
(inside)

Shielded able, #14 AWG, 600 V.


Ground Shield to Center Pipe
Ne to Collector Ring
211------+20f----_f_

~nd

1 10,

AC Control Ckt

J #12 AWG/Ring

19f----_+__
181-----+-

30, AC MTR Ckt


#12 AWG/Ring

Collector
Rings

171-----+Removable

161-----+} 10, AC Heater Ckt


151-----+#12 AWG/Ring

/Panel

141------+} 10, AC Control Ckt


13
#12 AWG/Ring

Access
Panel
with
Window

121------+
111------1
101------1

c===s~~~::::r---

D.C. Control Ckt.


#12 AWG/RING

Collector
Ring
Housing
Bearing
Assembly

~ } D.C. Shunt Field


~

~@

#6AWG

D.C. Shunt Field


#6AWG
Shaft

D.C. MTA. Armature


350MCM

~
o4j)--

D.C. MTR. Armature


350 MCM

Assembly

crch1847.wpg

.; Check the tightness of all electrical and mechanical


connectio s. Tighten as required.
,; Check tha the housing panels are properly closed and all
gaskets ar in position.
ANNUAL CHE

.;

colrg22p.wpg

ightness of all electrical and mechanical

COLLECTOR RING ASSEMBLY

.; Regularly c ean the inside of the slip ring assembly using a dry cloth -NEVER USE WATER OR
OTHER LI UIDS.
.; The rings s ould be clean and dry at all times .

.;
NOTE:

rts should be replaced immediately.


arings are sealed and do not require further grease.

2.2.9

BI006008

COLLECTOR RING INSPECTION and ADJUSTMENT

A.

Brush Rigging.

1.

Brush studs are supported between 2 outboard bearings. The brush studs extend
through the outboard bearings and they are secured by a setscrew in the
outboard bearing. The setscrews prevent rotation of the brush stud. The
setscrews should be checked for tightness. Some collector ring assemblies are
furnished with additional brush stud anti-rotation devices. These devices are
located on the outboard side of the outboard bearings. They incorporate an
additional setscrew to prevent brush stud rotation. The additional setscrew must
also be checked for tightness.

2.

The spacing between the outboard bearings is critical to assure the free rotation
of the brush rigging. The brush stud insulator sleeves are cut to length in order to
provide the proper spacing. The outboard bearings should be located snugly
against the insulator sleeve without any deformation of the materials. Hand tighten
the outboard jam nuts and then secure the brush stud with the setscrews referred
to above.

CAUTION:

DO NOT OVER-TIGHTEN THE OUTBOARD JAM NUTS. Overtightening can preload the bearings and cause excessive
friction.

A final check should be made to assure no binding of outboard brush rigging or


binding of brushes with insulator barriers.

B.

Brush Holders.

1.

Inspect the brush holders for proper alignment. Brush holders should be located
so that the entire brush contact surface rides squarely on the ring with the brush
moving freely in the brush box. The top of the brush should be parallel with the
top of the brush box.

2.

Brush holder clamps should be checked for tightness. Clamp bolts should be set
at a maximum of 75 in-Ibs. Loose clamps will allow the brush holder to rotate,
causing the brush to lift from the surface of the ring. Brush lift will cause arcing
and excessive heat concentration.

3.

Brush terminations at the holder should be inspected to assure that no external


force is imposed on the holder that would cause rotation of the holder on the stud.
Flexible or soft wire leads are recommended for these terminations. External
clamps should be used to support the entire weight of the leads.

4.

A final check should be made to assure that the brush studs can not rotate. Refer
to BRUSH RIGGING above.

2.2.10

BI006008

C.

Bru hes.
1.

Inspect for wear. If the distance from the top of the brush to the top of the brush
box is over half the depth of the brush box, the brush should be replaced.

2.

Inspect brush contact surface by removing the brush and checking the brush
s!Jrface for dirt, oxidation, pitting or other contaminants. Remove any large
particles and follow seating instructions in the following paragraph.

3.

Check brush contact surface for proper seating. If the seating is not proper, the
contact surface will be tracked differently in different areas. To reseat the brushes,
ay a piece of sandpaper between the ring and the brush. Install the brush in the
rush holder in proper alignment and rotate the core while applying pressure on
he brush. If the core cannot be rotated, the sandpaper must be pulled across the
rush surface. Wrap sandpaper at least 1800 around the ring to prevent rounding
f the brush edges. Recheck the brush contact surface and repeat the sanding
rocess if necessary until the entire contact surface appears uniform and without
its.

A
D.

AUTION:

DO NOT USE EMERY PAPER OR CLOTH TO SEAT THE


BRUSHES - EMERY WILL BECOME EMBEDDED IN THE
BRUSH AND CONTINUE THE ABRASIVE ACTION AGAINST
THE RING AND BRUSH. Emery and many other abrasives are
conductive and must not be used.

Brush

1.

spect and test springs


f r proper tension. The
bush tension springs
s ould be set at 1.5-3.0
Ib . per spring and as
u iform as possible.
U iform settings for each
br sh prevent selective
a ion by which certain
br shes carry more or
Ie s than their share of
th load. Insufficient
br sh pressure can
ca se loss of contact
an over-tension can
ca se excessive brush
an ring wear.

t
OJ

Lift scale until the spring


just lifts off the brush
surface, and read the
scale.

WIRE lOOP

Brush
Holder

Brush
~t---RJNG

cola1828. wpg

2.2.11

BI006008

2.

E.

F.

The spring tension should be periodically tested on all brushes to assure


uniform brush tension. Test for tension as shown in the figure. For spring
tension adjustment refer to REMOVING AND REPLACING BRUSHES AND
SPRING TENSION SCREWS later in this section.

Rings.
1.

Inspect the ring surface for dirt, oxidation or other contaminants. A properly
operating ring will have a film that appears burnished in color where the brushes
track with a darker surrounding color. If this condition does not exist, cleaning will
be necessary.

2.

The ring should be cleaned with a non-conductive abrasive such as Ideal


Industries' Flexible Abrasive for collector rings. Hold the abrasive against the ring
with a medium amount of pressure while turning the core. If the core cannot be
turned, the abrasive must be rubbed over the ring. Continue this process until the
ring surface is polished without any dirt or contaminants left on the surface. To
prevent abrasive from being lodged in the brushes, they should be lifted off the
ring.

3.

Inspect rings for pitting. Pitting of the ring must be corrected since pits will
produce arcing, leading to the development of larger and more pits. Small pits
can be removed by hand stoning of the area. If large pits and/or a considerable
amount of pits are present on the surface, the surface must be machined.
Machining is also necessary if concentricity of the surface is questionable. When
stoning or machining rings, remove only enough material to eradicate the pits.
Again, the brushes should be lifted from the surface when stoning or machining.
Finish the ring surface to a 16-32 micro-finish as described in step 2 above.

Electrical Connections.
Inspect all electrical connections for corrosion and tightness. Clean corroded parts with
a wire brush and/or muriatic acid. Loose and/or corroded terminations will cause a
concentration of excessive heat.

ENCLOSURE INSPECTION
A.

Moisture is a major cause of collector ring deterioration. Corrosion of parts and


insulation breakdown can be attributed to the presence of water. Dust and dirt present
within the enclosure will affect the proper operation of the assembly. Most dusts cause
excessive brush and collector ring wear and conductive dusts, if allowed to
accumulate, will form a path for short circuiting.

2.2.12

BI006008

B.

A P perly designed enclosure will be dust tight and watertight; however, condensation
ma still form on the walls of the enclosure. In some environments, condensation can
be Iiminated with the addition of a breather and drain. Other environments, particularly
dus y ones, require a thermostatically controlled heater to eliminate condensation.

C.

An spection should be periodically performed by removing the enclosure and


che king for condensation, water and dust collection. If contaminants are found, the
end sure and the assembly should be wiped down with a lint free cloth. If the problem
app ars persistent, steps should be taken to remedy the leakage or condensation
prob em.

FREQUE CY of INSPECTIONS

The first i spection should be made shortly after installation and before operation.
Continuin inspections should be made on a regular basis after every 200-400 hours of
operation nder normal conditions.

olders with non-adjustable spring tension.

A.
1.

R fer to the figure below. Pull spring free end (It.#B) out of brush holder recess
a d slide spring off of fixed hub (It.#A).

2.

U screw binder screw (It.#C) and take off brush shunt connector (It.#D) and
re ove brush (It.#E).

3.

In tall a new brush, reversing the above procedure.

cola2828.wpg

2.2.13

BI006008

B.

Brush Holders with adjustable spring tension.


1.

Refer to the figure on the following page. Release the spring tension on the brush
spring by holding the spring tension screw with a screwdriver at slot (1t.#A) and
loosening spring tension nut on opposite side. Do not completely remove the nut,
just loosen. The screws can be adjusted with a 9/32 wrench without removing
from the stud.

2.

Pull spring (1t.#B) up and out of the way and unscrew binder screw (1t.#C). Take
off brush shunt connector (1t.#D) and remove brush (1t.#E).

3.

Install a new brush, reversing the above procedure.

4.

Tension is applied on the brush spring by holding the nut with a wrench and
turning the screw with the screw driven clockwise until the inner coils are tight.
Back off 1/4 turn, then tighten the nut. The spring should have a minimum of 1
pound pull at the brush. See COLLECTOR RING INSPECTION AND ADJUSTMENT
- BRUSH SPRINGS.

5.

To replace brush spring tension screw (1t.#A), simply take the spring tension
screw nut off and pull the screw and spring out of the holes in brush holder
(1t.#F). Use the above steps in reverse order to replace the spring tension screw.

CLAMP BOLT

.r----

BRUSH STUD

E
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BI006008

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DIG/PROPEL CONTACTOR CABINET

2.2.16

BI006008

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Schematic -DIG / PROPEL CONTACTOR

2.2.17

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BI006008

HIGH VOLTAGE CABINET

The cabinet includes:


.j Startup Panel
.j Main Disconnect Switch
.j Vacuum Contactor Cabinet

1.

POWER FACTOR METER - indicates


the MG set drive motor power factor.

2.

HOUR METER - an elapsed time


meter that shows total machine
operating hours with excitation (L.E.)
On.

3.

~~~~
_,r.

AMMETER - (0-200 Amp Range) Indicates the drive motor current in


amperes.

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4.

HIGH VOLTAGE CABINET - VOLT


METER (0-8250 Volt Range) - an A.C.
voltmeter that indicates the voltage
on the incoming trail cable.

_ _ Starting Panel

IV

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9~~~
8
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OAOUMD IroIOl<t6~

Sfl RESET

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Vacuum Contactor
Cabinet

/
Main Disconnect Switch

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HIGH VOLTAGE CABINET (Front view)

2.2.18

BI006008

5.

LOr TRAK IV PROTECTIVE RELAY MODULE - Monitors the dive motor to protect
aga nst over current, overload, phase unbalance and ground fault.

6.

GRC UND MONITOR TRIP - A red pushbutton used by qualified electrical maintenance
per~ onnel to check the ground trip circuit in the mine substation and power supply.
Pressing this button will cause the power supply to the machine to be turned off (deene gized). It must be reset and re-energized at the mine substation.

7.

SLO NN FUSE INDICATOR (SFI) -Indicates a blown fuse on the secondary of the high
switch.

volta~e disconnect

ALWAYS OPEN THE DISCONNECT SWITCH BEFORE


REPLACING A FUSE.
8.

SFI, F ESET - A black pushbutton used to reset the visual blown fuse indicator after
repla~ement/correction. Press this button once to verify a fuse fault before notifying
elect ical maintenance personnel.

9.

M.G. SET START - A green illuminated pushbutton for starting the M.G. Set. When
startin~ M.G. Set, press and hold this button until M.G. Set is up to its normal operating
speec. The green light in this button being on indicates the M.G. Set is running.

10

M.G. ~ ET STOP - A red pushbutton that, when pressed, de-energizes (shuts down) the
M.G. ~ et induction drive motor. The M.G. Set will coast to a stop.

ACAJTION:

STARTING THE M.G. SET REPEATEDLY OVER 3 OR 4 TIMES IN


ONE HOUR COULD CAUSE PERMANENT DAMAGE.

11. M.G. SET MOTOR DISCONNECT SWITCH - Disconnects power to the M.G. set drive
motor.
ACAlTION:

DO NOT OPEN THE M.G. SET MOTOR DISCONNECT SWITCH


UNDER LOAD. PRESS THE M.G. SET STOP BUnON (#10)
BEFORE MOVING THE DISCONNECT SWITCH TO THE OFF
POSITION.

------+--------------,~-----,----,-----,-----,---------

---------+----~~
------,----,--~---,-------,--,---------------,-,----,--,----,--,--

2.2.19

BI006008

LODTRAK MODULE

The Control section of the cabinet


contains a Power Factor meter, Hour
meter, Ammeter, Voltmeter,
LODTRAK IV module, Blown Fuse
indicator and pushbutton, Start / Stop
pushbutton, Ground Monitor Trip
pushbutton, Transformer and Relays.

LCD

1~~SE$~lr~~~~4tiln(:~:~ent A Control Power Transformer is used


to isolate and step down the primary
high voltage for the AC Voltmeter and
power Factor meter on the Control
Cabinet door and for the control
devices.
The 3 current transformers [1 CT, 2CT
and 3CT] are used to drive the AC
Ammeter, Power Factor meter and the
Primary Instantaneous Overcurrent
Function, which is part of the
LODTRAK IV mounted on the Control
Cabinet door.
The Ground Current Transformer [GCT] provides ground check input to the LODTRAK IV
module. Circled numbers near devices are symbols used to identify parts in the parts book.
For further wiring and component information, refer to the L1MITAMP section from General
Electric.

2.2.20

BI006008

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HIGH VOLTAGE CABINET ELECTRICAL DIAGRAM -Sht. 1

2.2.21

BI006008

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HIGH VOLTAGE CABINET ELECTRICAL DIAGRAM -Sht. 2

2.2.22

BI006008

IHI LV DOOR - STD AJR OR VACUUM

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H.IGH VOLTAGE CABINET ELECTRICAL DIAGRAM -Sht. 3

2.2.23

BI006008

DC CONTROL CABINET
NOTE:

For DC Control Drive


layouts refer to the
schematic in Section 12,
Sheet Codes 29A,
298 and 29C.

Icr... Voltmeter

Propel Motor
Field Fault

Q-15QVDC

Drive Fault

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Drive Fault
Reset

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Hoist Crowd & Propel Panel

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Fault Indicators on the DC Control Cabinet:


PROPEL MOTOR FIELD FAUL T - A red light which indicates a problem with one or both of

the propel motor fields. An alarm will be set off when the light comes on. To eliminate the
alarm, stop the machine and push LE STOP. The light will remain on until the problem is
corrected.
DRIVE FAULT - A red light which indicates a malfunction in one of the systems controlled by

the CPU. Refer to the OIU screen to determine the problem.


DRIVE FAULT RESET - A black pushbutton. Push and release several times until the drive

fault light goes out. If it does not go out, call for service.

2.2.24

BI006008

------+-----------------~------------~--------------------------------

------t-------------------------------------------------------

-------+----------------------------------------------------------

2.2.25

BI006008

2.2.26

BI006008

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Swing
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Crowd

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Generator Field Excitation


Transformer - 3 Places

-----._--

TO (f Machine
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GENERATOR FJELD EXCITER TRANSFORMERS

2.2.27

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Front Of
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High Voltage
Fuse Cabinet

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Front Of Machine

89Q9

Auxiliary
Transformer

Surge
Arrestors

Ground
Fault
Control
I

I--- fi!. Rotation

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Motor Control Center

r----~-I

Top Of
Ri9htWing

h
Plug Is For Power
Lead From Welding
Machine.

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:

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O.G.L.
Panel

Pressure
Switch

1I1 ~ox

11

L.F.

MPG
Panel

U.F.

MPG
Panel

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Air Compressor
With Control
Pressure SWitch

--------------:

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BI006008

BI006008

FAULT CONTROL CABINET

~~~

The Gro nd Fault Control


cabinet ntains a door
mounted ground fault monitor
for the a iliary bus. It has
power an fault indicating lights
along wit test and reset
pushbutt ns. When a ground
fault of 1 mpere or more
occurs, t e ground fault relay
operates nd the shunt trip of
CB-AB tri s the auxiliary bus
circuit bre ker off line.

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Door

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Monitor Panel

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Circuit Breaker
Operating
Handle

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TEST

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View Showing
Components
on Door

Panel

Fuses

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t.

Circuit Breaker,
15Amp
3-Pole

Control
Transformer

Terminal

R-GFA

Ground Fault

------~:~~~--------~._j

2.2.29

Adjustable
Resistor

View with
Door
Removed

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Legend:

1 ) - - - Single Conductor
2 ) ~ Diagram To Indicate Multiple Conductors
3) GFMP-A Ground Fault Monitor Panel-(For Aux. Bus)
4) GFR-A
Ground Fault Monitor Panel-(For Aux. Bus)
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Settings:

Actual Ampere Trip Level Depends


On The Number Of Times Sensed
Conductor Is Passed Thru C.T.
ie.-The Final Current Ratio -See
Schematic For Details.

Note:

1) R-GFA To 4000 Ohms


2) GFR-A 2A .2 Sec

BI006008

BI006008

Panel

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Fuse Holder

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Fuse
3 Places

1 .... ::J

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Front View With Door Removed

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HIG H VOLTAGE FUSE CABINET

2.2.31

BI006008

MOTOR CONTROL CENTER


Items on the Motor Control Center:
1.

OPERATOR'S CAB AIR CONDITIONER

2.

WELD RECEPTACLE

3.

HOIST GENERATOR FIELD EXCITER


TRANSFORMER

4.

CROWD GENERATOR FIELD EXCITER


TRANSFORMER

5.

SWING GENERATOR FIELD EXCITER


TRANSFORMER

~Moti~~~=~nt.r
c::::J

PHASE SEQUENCE - This panel


includes a red light which indicates an
error in the power supply when
illuminated. Electrical interlocks will
prevent machine start-up if phase
reversal exists.

c::J

ON

STAAT
STOP

Typicel

E. Pan.

OFF

c:::J
ON

r:::::::::3J]

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OFF

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OFF

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ON

OFF

10

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ON

FILTER FAN #1 -Includes a green light


which indicates the fans are
operating plus start-stop push buttons.

rn

AUXILIARY BUS MAIN BREAKER CB-AB

FILTER FAN #2 - Includes a green light


which indicates the fans are
operating plus start-stop pushbuttons.

OFF

12

c:::J
ON

ON

G~

off
AUTO

2.2.32

OFF

OFF

10. HOIST MOTOR BLOWER - This panel


includes START and STOP pushbutton
for operating the air cooling fan on the
DC drive motor. The green indicating
light above the pushbuttons indicates
that the hoist blower circuit is energized.

c:::J

ON

OFF

ON

G~

OFF

16

11

c::J
Off
AUTO

c::::J

15

GLJ ~

OFF

ON

OFF

c:::J

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ONc=3J) OFF

c:::J

c:::J
ON

'&
9.

-1l

ON

B,.ok.,
Swlt<h

ONc=3J) OFF

8.

14

ONc=3J) OFF

A voltmeter and a 4-position switch to


check the voltage across each phase:
OFF, L1-L2, L2-L3 and L1-L3.
7.

c:::J

G[]] ~

ONc=3J) Off

6.

c:::J

13

ON c::::3JI OFF

c:::J

17

ON

U~

OFF

BI006008

11. AIR OMPRESSOR - This panel includes a two position selector switch which controls
the peration of the air compressor. The AUTO position lets the compressor cycle on
and off automatically a dictated by its pressure switch. The OFF position makes air
co pressor is running. The compressor will not operate if phase in incoming power
sup Iy is reversed.
12. ANT -CONDENSATION HEATERS - This panel includes a two position selector switch
whic controls the operation of the space heaters in the motor control center, the DC
Cab net, the dig-propel cabinet, all the DC drive motors, and the M.G. Set. AUTO
posi on automatically energizes the heaters whenever the M.G. Set is shut down. OFF
posi ion turns the heaters off. The green light above the selector switch will be
iIIuml ated whenever the heater are energized. These heaters are not thermostatically
contr lied. Once energized, they operate continuously until shut off or the M.G. Set is
start d. These heaters should be used only during periods of high humidity or low
temp ratures.
13.
14. HOIS CABLE WINCH
15. CPE RANSFORMER - Control Power Excitation Transformer breaker.
16. CRO D & SWING MOTOR BLOWERS - This panel contains a green indicating light
that i dicates the crowd and swing motor blowers circuits are both energized.
17.

L MOTOR BLOWERS - This panel includes a green indicating light that indicates
pel motor blowers circuit is energized. These blowers operate only when the
e drive is in the propel mode.

NOTE:

T,

e following breakers on the Motor Control Center must be closed for machine

s rt-up and operation:


Sequence.,
ing Line.
ans Nos. 1 and 2.
,; Hoist, Crowd & Swing, and Propel Motor Blowers.
,; Hoist, Crowd, and Swing Generator Field Excitor Transformers.
,; Air C mpressor.
,; Regul tor Power Supply.

2.2.33

BI006008

AUTO LUBE CONTROL

To Auto Lube
OGL Hoist
Auto Lube
Electric
Control Panel
-3 Places

Front of

Machine

~===:::::====::::::;:-;::========;-;:======::::=4'I
Hoist,
Boom

Rotating
Frame

Lower
Frame

OGL

MPG

MPG

00000

0000@

-----)

Air Pressure
Regulator
-3 Places

Auto Lube
Control Panel
-3 Places

System
Low Air
Pressure
Switch

~""""-+-r-Air

Lube Drum,
120 Lb., 16 Gal.
-3 Places

,,

OGL'

MPG'

To Auto Lube /
MPG Rotating Frame

Pump
-3 Places

'MPG

To Auto Lube
MPG Lower Frame
actr1847,wpg

182M AUTO LUBE CONTROL CENTER

2.2.34

BI006008

A.C. Auxiliary Cabinet

Lighting Panel

Open Gear

Contro'

Pan., OGL

Horn

-!r

Upper Frame
Contor Panel MPG

...

Horn -~-+-----.I

Hom

I
,

-Lower Frame
Control Panel MPG I

1
I

Air
Solenoid
Valve

Pressu Switch
Open Ge r Control
-~-

Air
Solenoid
Valve

Pressure Switch
Upper Frame Control
.__-D---.

Pressure Switches
Lower Frame Control
.--4--.,
I

?,G,tl

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WIRING -AUTO LUBE CONTROL PANELS

2.2.35

BI006008

AUTO LUBE -ROTATING FRAME and OPEN GEARS

These 2 systems use identical but separate control panels. Both systems are timed to cycle
at 15 minute intervals. The OGL system lubricates 26 lube points, the Rotating Frame MPG
system lubricates 35 lube points.

ACAUTION:

Inadequate lubricant to machine components can result in serious


damage and costly repairs.

Auto Lube Electric


;Control Panel

14-_ _+--r-Alarm Horn


Pump Operating (Amber)
Power On (Green)

Failure (Red)

Manual Start Pushbutton


(Activates the System
for One Cycle)

Alarm Reset Pushbutton

Electrical Conduit
Air Regulator and Gauge
Solenoid Valve, 3-Way-r--_ _....,;:::j-iJ-I

Pressure Gauge

~....... "'<.-Glbbe

Additional Lube to
Circuit, Used on
OGL Only

Valve

Air Supply Inlet

Safety Un loader
Lube Return to Drum

Lube from Pump


Air to Pump

aprf1847.wpg

AUTO LUBE CONTROL PANEL


Rotating Frame and Open Gears

2.2.36

BI006008

2-Pole Relay

CR-1

CR-2

4-Pole Relay

rr==:::::::::;;:::====::U....J 2- Pole Relay


o

CR-3

Time Delay Relay

o
eprff1847.Wpg

AUTO LUBE ELECTRIC CONTROL PANEL


(Shown with door open)

This electric control panel: is designed to provide adjustable control of the auto lube system.
The followin items are in the panel:
DOOR SW/~ H - A 2-position switch which ensures that the panel door is closed while the
system is 0 erating, and provides an override for servicing the panel.
POWER ON NOIGATOR - A green light indicating that the system is operational.
PUMP OPE

TlONAL - An amber light indicating that the lube pump is operating.

FAILURE - A ed light and horn that indicate a system malfunction caused by one or more
of the followi g:

- E pty reservoir.
- B oken lube line.
- BI cked lube line.
- In ufficient air pressure.
- Pr ssure switch failure.
- C ntrol panel failure.

2.2.37

BI006008

ALARM RESET - Shuts off the alarm and resets the control panel for continued automatic
operation.

TIMER - The timer determines and starts the lube cycle.


Two rows of pins are located on the timer dial. The inner row trips a switch to start
the lube cycle, and the outer row resets the relays after the cycle has been
completed. The space between the pin holes represents 37.5 seconds. So, to
provide a 5 minute cycle, it is necessary to have 8 spaces between the inner pins.
The spacing between the inner and outer pins is determined by the time delay
relay. The time between cycle start and reset must always be greater than the time
delay relay setting.

TIME DELAY RELAY - Terminates the lube cycle and activates the alarm system, if the system
fails to cycle within the time set on the relay. (Each setting on the relay timer represents 30
seconds.)
NOTE:
The pressure switch located in each lube system normally terminates the lube
cycle when the operating pressure is reached. The switch must be activated
before the time delay relay "times out" or a malfunction will be indicated. Normal
operating pressure is 2500 PSI (+ 1000/-650 PSI). The pressure will vary with
conditions. Since the lube cycle time will vary with lubricant viscosity, temperature,
pump capacity and air pressure, cycle the system manually several times and
record the normal cycle time. Set the relay timer to the longest cycle, plus 30
seconds, then adjust the outer row of pins on the timer dial to provide a time
interval between the inner and outer pins that is greater than the time delay relay
setting.

EXAMPLE:
If the time delay relay is set for 120 seconds, then the spaces between the inner
start pin and the following outer pin must be 4 spaces.

2.2.38

BI006008

L2-~f-------------------j

NOTES:

OnIon
on t
inte
is 3

The oor switch actuator pin must


be p lied out for any open door
testi 9 of the control panel.

ime of the timer must be a


er interval than the alarm time
e Time Delay Relay. The
al between each dial pin hole
.5 seconds.

}---{>-------04:

Alarm
Reset

IJ.

,-

Failure

,~

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CR-2

r--.---0----<:>-<lr I; > - - - O - - - - - - { 2 l ,#

..,,:l

CR-)

1 - - - - - - - - - - 0 . . ; . - - - i : )-_ _

CR-3

J-Io/"-:1~/f
I

CR3

External Alarm Circuit in the Operator's Cab.


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ELEMENTARY DIAGRAM

scrfi182.wpg

INTE CONNECTION DIAGRAM

ROTATING FRAME and OPEN GEARS AUTO LUBE


CONTROL PANEL ELECTRICAL DIAGRAMS

2.2.39

BI006008

AUTO LUBE LOWER FRAME


This system supplies lubricant to 24 points on the crawlers. The lubricant flows to the Lower
Frame through the rotoseal in the center journal and on to each crawler. This system uses
a dual cycle timer with 2 settings: one setting at 10 minute intervals during diggings, and one
setting at 2.5 minute intervals during propel.

ACAUTION:

Inadequate lubricant to machine components can result in serious


damage and costly repairs.

o
Auto Lube Electric
Control Panel

Alarm Horn

Failure (Red)

Fast Cycle (Green)

Pump Operating (Amber)

Power On (Green)

Manual Start Pushbutton


(Activates the System
for One Cycle)

Alarm Reset Pushbutton

Electrical Conduit
Air Regulator and Gauge
Solenoid Valve, 3-Way-r--_ _--:l--::iH

Pressure Gauge

~-----"""GlobeValve

Air Supply Inlet

Safety Unloader
Lube Return to Drum

Lube from Pump


Air to Pump

aplf1847.wpg

AUTO LUBE CONTROL PANEL


Lower Frame

2.2.40

BI006008

Timer
Fast
Cycle
Timer

Time
Delay
Relay

pnelf182.wpg

ELECTRIC CONTROL PANEL


(Shown with door open)

This eJectri control panel is designed to provide adjustable control of the auto lube system.
This panel operates the same as the Open Gears and Rotating Frame panels, with the
exception t at it has an additional timer. When the machine is digging, the lower frame is
lubed at 1 minute intervals. During propel, the additional (No.2) timer changes the lube
cycle to 2.5 minutes. (4 pin spaces on the inner row of pins.)
Set the spa e between the inner and outer pins the same as on the 15 minute timer dial. An
additional g en light (fast cycle) indicates that the system is operating in the propel mode.

- - - - - - + - - -------------- ------------------ --_.,----- - - - - - - + - - - - - - - - - - - - - - - - - - - - - _ . _ - - - -----------------------------------

2.2.41

BI006008

LOWER FRAME AUTO LUBE CONTROL PANEL ELECTRICAL DIAGRAMS

'.I.

Failure

pump

Opr.

,1

,.
11

Power

.J

On
CR.2

9 Pump Solenoid

r:C-1

Fast
Cycle

} -_ _--'K

J'f>f'-1l-1?llr
,

External Alarm Circuit in the Operator's Cab


sclfe182.wpg

ELEMENTARY DIAGRAM
NOTES:

On-Time of the timer must be a longer interval than the alarm time on the Time Delay
Relay. The interval between each dial pin hole is 37.5 seconds.
The door switch actuator pin must be pUlled out for any open door testing of the control
panel.

2.2.42

BI006008

CloCk
Fast Cycle NO.2

Clock
Slow Cycle NO.1

I
I

~'HJ

SOL

LE Ckl

Alarrn
Horn

'-l~J
Propel
Ckt

sclfi182.wpg

INTERCONNECTION DIAGRAM

------1-------.-----.----------------.-.--.

.._------------._- ------ _.----_._-- _._-------

-------+---_._------~_._-------

2.2.43

BI006008

BOOM JACKING LIMIT

The BOOM JACKING LIMIT is an electrical switch located on the front inside wall of the
machinery house just left of center. The purpose of the boom jacking limit is to control the
amount of boom jacking. This is a situation where, the boom is raised beyond its normal 45
degree operating angle because too much crowd force is being applied at the face.
Effects of boom jacking can be serious damage to boom foot lugs and boom support ropes.
The boom jacking limit is activated by the closing of the switch when the cable attached to
the top of the boom goes slack due to a condition of boom jacking.
When the spring loaded, plunger type switch is activated, crowd out control reference is
removed and an audible bell will sound in the operators cab. Crowd reference is regained
by retracting handle from face.
Adjustment of the switch consists of maintaining the distance between the plunger face and
switch contact. This is done by adjusting nuts on the front and rear of the plunger rod.
Correct adjustment is .75 inch(19mm) distance between face of front adjusting nuts and front
of guide assembly. (See illustration for location of adjusting nuts.)

2.2.44

BI006008

Maximum Stroke Inch (6 mm)


Capscrew, .38 Gr.5

~--.25

.5 Inch (12.7 mm)


Front House Wall

Plunger Plate Face,


Plunger Plate
Guide Rod for
Plunger Plate

~witch Brack~t

'd

---r------Umit Switch

[$

'~:=J-L-C:==_~~~:8 ~
------------~
-

lunger Adjusting
Nuts "B"
(Front)

Support
Bracket
Plunger Adjusting
Nuts "C"
(Rear)
1.75 (44 mm)

[ - - ' l -_____

.75 (19 mm)

<t

9.50
Boom
(241.3 mm) , ,.

.Y~)

/)H?~"jY/

~/---------'I--'

\~

. /<::
~,

"108.84

~(2764.5 mm)
''',

'~

~\

\\

'"''~"

Switch Actuator
Cable

",,~

'\./
~,

~~

"

Switch Ope ating Characteristics: ~~


Pre-Travel
.050/ .046 inch
Differential ravel _ _ .027/ .046 inch
Recommen ed Travel
.15 inch
Total Travel
.260/ .240 inch
Force req'd
Trip
2.8 Lbs.
Force @.25 nch Stroke
7.3 Lbs.

Front
House
Wall

Boom Assembly

'\

'~

~
~

\,,~\'\,

~ ~

""

~ ~
"

"'" ~

~,,\
""

''''

' ' " -

- 45

blmt1847.wpg

BOOM JACKING LIMIT SWITCH

i /

' "\
' \

, , \

'J
.
--,--l._
_~
l---I

''\

_J~~~V)
t Boom~

Adjust the lunger Nuts "C" and Position the Switch as


Foot
Shown so t e Plunger Face Will Not Force the Switch to Over-Travel.

2.2.45

Dec k

"'~

-''"-

NOTES:
To Avoid D mage to the Switch, Position
the Plunge Adjustment Nuts "B" as Shown to
Contact Su face "A" Before the Limit Switch Bottoms Out.

" '\

Rotating
Frame
Structure

BI006008

HOUSE AIR FILTRATION SYSTEM


The HOUSE AIR FIL TAA nON SYSTEM uses filter fans to create
a slight pressure above the outside air to reverse any possible
IN-FLOW through rope and other openings. Thus, all air
entering the house is filtered. NOTE: An open access door or
cover will defeat this system, allowing dust and dirt to enter.
Filtered air circulation reduces dust accumulation and related
maintenance.
CONCEPT: Dirty air enters the filter house and inlet end of the
wedge shaped filter cells. Most air (about 90%) changes
direction quickly and passes through the narrow side
passages. Dirt particles, with greater mass, tend to continue
straight into the bleed air duct; thus, dirt particles and bleed
air return outside.

ifJ

Clean Air
to the Machinery House

MAINTENANCE:

HOUSE AIR FILTER


SYSTEM

,;

Periodically check that bleed air ducts are open and


clear.

,;

Keep inlet passages free of paper, leaves, wiping cloths, or any debris that would
obstruct air flow.

,;

Look for deposit build-up on filter blades. A light coat of dust is normal, but a heavier
coating requires cleaning.

,;

Brush surface ancrremove dust with compressed air. If necessary, wash heavy build-up
with water or suitable solvent.

ADANGER!

ANOTE:

THE MACHINERY HOUSE ROOF MAY BE SLIPPERY. Use the hand


rails as well as extreme caution during any maintenance or service
on the roof.
Mine conditions will dictate the maintenance frequency of the filters.
Monitor the filters closely and establish a schedule to suit conditions.

2.2.46

BI006008

Fan Section -2 Places


Filter Section -2 Places
Plenum

Air

---

Air

---

Flow

Flow

Filter Fan No.2

Filter Fan No.1

dv2d1847.wpg

182M DYNAVANE AIR FILTERS


( Viewed from the Rear of the Machine)

FILTER F N START-UP PROCEDURES

1.

Verify
directi
house
corre

2.

Check the voltage at each motor terminal.


Make ure it is within +/-3% of the auxiliary
bus n minal. If not, the auxiliary bus
transf mer tap may need adjustment.

Filter Fan Junction Box

hat all fans rotate in the proper


n to push air into the machinery
If not, change the phasing to
the rotation.

3.

ith an amprobe to see that the


curren is balanced among all 3 phases of
the mo or within +/-5%. If not, check for
loose c nnections between the motor
control center cubicle and the motor, at all
junctio points between the two.

RED

: FB1T1

BLK

: FB 1 T2

--------r-----____<o

0-

"_.

Filter

O~(~)\ Fan
.~

o-BL~~~o/ j
~

GRN

:
\

GND

Motor
No.2

ffsc1847.wpg

FILTER FAN HOOK-UP CHART

-----r------~----------.------.-.

2.2.47

BI006008

)
~
" Counterweights
NOTE: Angle must be
Removed to Remove
Ladder from Track

~~"

- Counterweight
Enclosure

Track~

Walkway. Left
\

Machinery House
Assembly

Signal Chord (2)


One On Each Side
Of Ballast Box.
Used To Signal
Operator From
Ground

Limit Switch

Crawler
Assembly

Ground

BOARDING STAIRS

2.2.48

BI006008

Drum Guard

Lube Fittings
D.C. Motor

Capscr
.5 Inch Gr.5
- 4 Places

Drum

Dipper Trip
Mounting~

Base

'"

.C::;:;::::===~~~

View-A
DTRP1847,wpg

DIPPER TRIP

NOTE:

T e Dipper Trip Assembly is mounted on the right-front Gantry leg. Refer to G.E.
anual GEH-3967M in Book #2 of this manual for the D.C. Motor instructions.

- - - - - - - + - - - - - - - - - - - - - - - _ . _ - - - - - _..

2.2.49

BI006008

2.2.50

BI006008

2.30P

ATOR'S CONTROLS

OPERAT R'S CAB

Front
of
Machine
Control
Console,
Left

Joystick Controller,
Hoist / Swing / Horn
Control
Console,
Right

Joystick Control
Panel in the
Cab Base

Operator's Seat
----------------

-~~-I-I----I

I
I
I
I
I

I
1

I
I

.l...J_.

lli"

I
,1

A;,
Control
Panel
Stand

Door

182M OPERATOR'S CAB (Plan View)

2.3.1

BI006008

OPERATOR'S SEAT
The operator's seat has adjustments for positioning it in the best location to suit individual
operators. It swivels into and out of operating position to provide easier entry/exit for the
operator. Lift the spring loaded T-handle lock beside the seat pivot to swing it into and out
of operating position. To raise or lower the seat, turn the hand wheel under it, clockwise
(CW) to raise and counterclockwise (CCW) to lower. An adjustable foot rest is provided for
operator comfort. Refer to the following page for more information on seat adjustment.
The operator should always adjust the seat to suit before taking over the controls.
Do not attempt to operate this machine unless you understand all
the machine controls. Never leave the operator's seat without first
setting all motion brakes and "dropping out" (de-energizing) line
excitation (LE) by pushing the EXCITATION STOP pushbutton.

ADANGER:

I,
I,
---l~~~

I,
I
I,
I

I,

opst1847.Wpg

2.3.2

BI006008

OPERAT R'S SEAT ADJUSTMENT


The oper tor's seat was selected to give operators of all sizes the ability to position and
adjust th seat to their preferred arrangement. Since the operator must sit for extended
periods 0 time, it is worthwhile to adjust the seat to his most comfortable position.
A.

WEI HT COMPENSATOR - knob adjusts support coils tension to suit the weight of
occu ant. Use the knob to dial the weight of the operator (110 to 290 Lbs.) on the visual
indic tor next to it.

B.

HEIG T - Vertical adjustment handle. Lift up to release.

C.

FOR ND AFT - Lift the lever bar at the front of the seat and move the seat forward or
rearw rd as desired, releasing the lever at the desired location.

D.

BACK EST TILT - angle of the backrest is adjustable from vertical by lifting the lever up
on th left side to release the backrest.

E.

CUNATION ~ angle of inclination adjustment handle. Lift up to release. The front


eat can be varied to tip up or down.

F.

R - adjust for back comfort using the knob.

BOARDIN

STAIRS

The boardi g stairs are located on the left side of the machine at the rear of the walkway.
The stairs re counter weighted to remain in the up position when the machine is in
operation 0 down where boarding the machine. When the stairs are pulled down 3 to 4
inches a lim t switch will trip and drop out line Excitation (LE) which will stop the machine.
Refer to the igure on the following page.
To board wh n the machine is in operation:
1.

Pull one of the two signal chords at the rear of the ballast bar and wait for the operator
to bring the machine to a halt.

2.

Lower t e stairway.

AWAR ING:

3.

DO NOT ATTEMPT TO LOWER THE STAIRS WITHOUT


SIGNALING THE OPERATOR FIRST. When the ladder is pulled
down 3 to 4 inches, all brakes will set on the machine. FAILURE
TO HEED THIS WARNING COULD RESULT IN DAMAGE TO THE
MACHINE AND/OR RESULT IN PERSONAL INJURY.

After bo rding the machine, raise the stairs to their full UP position. The machine will
not be 0 erable until the stairs are completely in the UP position.

2.3.3

BI006008

Counterweight
Enclosure

Machinery House
Assembly

Signal Chord (2)


One On Each Side
Of Ballast Box.
Used To Signal
Operator From
Ground

1_-

Frontof~~
--Machine

Crawler
Assembly

Ground

\
BOARDING STAIRS

2.3.4

BI006008

OPERAT NG CONTROLS

This secl'on provides the operator with the location and an explanation of the controls,
instructio lS for machine;operation.
The oper:iting controls for this mining shovel are all clustered on the operator's control
stands ar d the air panel stand to the left of the operator's seat. The machine start-up
controls a e located inside the machinery house.
The machine's operating motions - HOIST, CROWD, SWING, and PROPEL - are initiated by
the opera pr using the two joystick controllers. These are the primary controls.
The secor dary controls are mounted in the control stands on either side of the operator.
They are t e necessary lights, switches, and pushbuttons to support the primary controls.
Air pressu e gauges and a crowd clutch regulator are located in the air panel stand. Also
located hel~ are buzzers and lights that signal the operator and announce faults in selected
systems 0 -board.
The mach ne controls have been positioned in the cab to provide the operator with
comfortabl ~ operation of all the primary controls and easy access to all the secondary
controls. Tt-e cab has been positioned and designed to give the operator a clear view of the
digging an j dumping area and the front end.
The cab has a phone system connected to receivers near the entrance doors on the right
and left win ~s inside the machinery house. This system provides communication between
the house end the cab during testing or maintenance periods.

------+-----------~-------------------~-----------~-----------~----

------+------------------------~--~--------------

---------------------------------

-------'r---------------------~----------

2.3.5

BI006008

PRIMARY CONTROLLERS
The primary operating
controls are the two joystick
controllers mounted on the
right & left consoles at each
side of the operator's seat.

Joystick Controller, RIGHT

Left Controller

Joystick
Controller, LEFT

The control on the left


controls the CROWD
machinery to move the
dipper handle in (retract) or
out (CROWD) when the
machine drive is in the DIG
mode. If the machine drive
is in the PROPEL mode,
then this controller controls
the PROPEL machinery on
the left crawler.

Control
Console,
RIGHT

The pushbutton on the left


controller operates the
dipper trip machinery to
open the dipper door.

ocld1847.Wpg

Right Controller
The controller on the right controls the HOIST machinery to raise or lower the dipper and the
swing machinery to rotate the machine either right or left when the machine drive is in the
DIG mode. If the machine drive is in the PROPEL mode, this controller controls the PROPEL
machinery on the right crawler and the swing machinery.
Both the hoist and the right propel drives are speed controlled. This means that the further
the controller is moved in either direction from its neutral position, the faster the drive will go.
The swing drive is torque controlled. This means that the further the controller is moved left
or right from its neutral position, the more torque the swing drive will develop.
The pushbutton on the right controller operates the signal whistle on the outside of the
machinery house. Push the button with your thumb sounds the air operated whistle. This
pushbutton will activate the whistle whether LE is on or not.

2.3.6

BI006008

LEFT JOYSTICK

RIGHT JOYSTICK

Propel FORWARD,)
(
Left Crawler

Propel FO. RWARD,)


( Right Crawler

Hoist LOWER

Crowd EXTEND
Dipper Trip
P hbutton

Swing
RIGHT

--r'

X Axis
Signal
Pushbutton

..

Crowd RETRACT

Hoist RAISE

Propel REARWARD,)
(
Left Crawler

Propel REARWARD,)
(
Right C?rawler

YAxis~

Y Axis ......:

Y-Axis

Crowd Motion

Hoist Motion
Right

x - Axis

NO MOTION

+~~-i(-l
Left

Swing Motion

Pushbutto
Dipper Trip

Signal Whistle

Y -Axis in
PROPEL
Mode

~===H=j Sprocket

-Indicated

by ( )

Propel Motion
jyst1847.wpg

182M JOYSTICK MACHINERY MOTIONS

2.3.7

BI006008

MASTERSWITCHES (JOYSTICKS)
MASTERSWITCH REMOVAL
The Masterswitches can be removed for servicing by removing 4 masterswitch mounting
screws and opening the console. As the masterswitch is removed, feed the control wires into
the masterswitch mounting bracket.
NOTE:

When replacing the masterswitch, make sure that the Y ("_") axis (cast into the
mounting flange) faces forward. Refer to the Electrical Schematics 10r wiring
diagrams.

MASTERSWITCH CALIBRATION
The master switches must be calibrated when a new switch is installed. To allow 10r wear in
the master switch components, they should be recalibrated at 500 hour intervals.

MASTERSWITCH (JOYSTICK) CONTROLLER SYSTEM

INTRODUCTION
The master switches are inductively coupled, non-contacting units 10r long 1i1e. These are
spring return to center joysticks.
A joystick control panel, consisting of (2) expander boards and (14) relays, interface the
joystick output to the motion regulator equipment, since the regulator equipment is not
compatible with the joystick output. The panel is located in the cab base.

ELECTRICAL TESTS
Electrical Schematic Diagrams are provided in the Schematics Section 01 this Manual.
When performing these tests, refer to the Functional Description provided in 4.3 and con1irm
that the system operates as described.

FUNCTIONAL DESCRIPTION
Masterswitches (Joystick Operator Controls)
The expander boards receive directional and neutral position in1ormation 1rom the master
switches and, the output operates the hoist, swing, and crowd master switch relays, which
enable each motion regulator and motor field controls.

2.3.8

BI006008

S-H and HMS-N will operate when:

OIST master switch axis is moved off neutral in the hoist direction.
S-L and HMS-N will operate when:

OIST master switch axis is moved off neutral in the lower direction.
-L and SMS-N will operate when:

WING master switch axis is moved off neutral in the swing left direction.
Relays SM -R and SMS-N will operate when:

- The SING master switch axis is moved off neutral in the swing right direction.
Relays CM -C and CMS-N will operate when:

- The C OWD master switch axis is in the crowd position.


Relays CM -R and CMS-N will operate when:

OWD master switch axis Is in the retract position.

ir horn) will operate when:


1ST master switch thumb P.B. is depressed
ipper trip auxiliary) will operate when:

OWD master switch thumb P.B. is depressed.


, SMSF. CMSF are fault relays for their respective master switch axes. They

- The ref rence signal from the axis is not within bounds; e.g., its amplifier saturates or
puts 0 t no signal.
- The el ctronic "Neutral" signal does not agree with the joystick neutral limit switch.

INTERFACE FOR JOYSTICKS (MASTER SWITCHES)

The PC boa d assembly is shipped factory preset according to this procedure. When
connecting to the joystick controller, it should only be necessary to check and slightly adjust
the input null per calibration procedure step 6 and 10.

2.3.9

BI006008

Test equipment and documentation requirements:


- Digital voltmeter with auto polarity or oscilloscope with high impedance input.
- Schematic diagrams.
- Master switch expander board illustration 2.3.w, 2.3.x, 2.3.y.& 2.3z
- Trimpost adjust screwdriver.
I

ADANGER:

THIS BOARD IS AN ELECTRICAL SHOCK HAZARD AND DEATH


OR SERIOUS INJURY MAY RESULT IF IMPROPERLY HANDLED.
115VAC is present on the PIC board. DO NOT TOUCH THE
AREA NEAR TRANSFORMER WHEN HANDLING, CONNECTING,
OR WORKING. Remove the power connection.

CALIBRATION PROCEDURE
1. Connect a 115VAC power cord to power input terminals 115VAC (HI) and 115VAC (LO).
DO NOT apply power or plug into power source at this time.
2.

Connect a joystick with "X" and "Y" axis outputs connected per the schematics. It is
important that the shovel handle not be moved until step 10 is completed.

3.

Connect a digital voltmeter, which Is set to its 20 volt scale, to the circuit by hooking
negative (black) lead to signal common (See drawing sheet 24 following in this section.)
The voltmeter negative lead need not be moved throughout this procedure.

4. Apply 115VAC to PIC board through power cord connected in Step 1. Observe voltage
on voltmeter. It should read approximately 15.0 volts. Check the negative 15VDC supply.

5. Adjust input signal null.


A.

Connect voltmeter positive lead to "X" axis input. Put the joystick handle in neutral
position and do not disturb until step 9 is completed.

B. Connect positive lead of voltmeter to pin 14 of IC 109. Test pin "A". Refer to page
2.3.17 - MASTERSWITCH EXPANDER BOARD -SHT. #1 following in this section as
a guide.
C. Set voltmeter on the 2.0 volt scale.
D. Adjust RV 101 potentiometer until voltmeter reads 0.0 volts. This nulls "S" axis input
signal to zero when joystick is in neutral. Reduce scale on voltmeter to 200 millivolts
and repeat until voltmeter reads 0.00 volts.
E. Connect positive lead of voltmeter to pin 1 of IC 209. Test pin "b".

2.3.10

BI006008

F. A just RV 201 potentiometer until voltmeter reads 0.000 volts. This nulls "Y" axis
in ut signal.
G. AI other adjustments must be checked after this procedure is complete. THIS
o TPUT IS FUNDAMENTAL TO THE ACCURACY OF THE OTHER OUTPUTS.

6. Adjust ense positive direction output.


A. M

e positive lead to voltmeter to pin 2 of IC 108. Test pin "c.

B. Ad] st RV 109 until voltage reads 140 millivolts on meter.


C. Mo e positive lead of voltmeter to pin 13 of IC 208. Test pin "d".
D. Adj st RV 209 until voltage reads 140 millivolts on meter.

7. Adjust ense negative direction output.


A. Mo e positive lead of voltmeter to pin 10 of IC 107. Test pin "e".
B. Adj st RV 110 until voltage reads 140 millivolts on meter.
C. Con ect positive lead of voltmeter to pin 5 of IC 207. Test pin "I".
D. Adju t RV 210 until voltage reads 140 millivolts.

8. Adjust n utral sense signal.

A. Con ect positive lead to pin 5 of IC1 07. Test pin "g".
B. Adju t RV 111 until meter reads 135 millivolts.
C. Conn ct positive lead to pin of IC 201. Test pin "h".
D. Adjus RV 211 until meter reads 135 millivolts.

9. Adjust de dband set point.

A. This a justment must be made after steps 1 through 8 have been completed.

2.3.11

BI006008

B. Deadband is adjustable between 0% and 20% of joystick output signal. When the
amount of deadband has been determined, multiply amount times the maximum
output signal from the joystick (1.5 volts) to determine set point.
Example: Factory Setting
1. 10% deadband is desired.
2. Deadband % x 1.5 = set point.
3. Therefore: .1 x 1.5 = .15 volts.
C. Move positive lead of voltmeter (Scale set to 2.0 volts) to pin 2 of IC 110. Test pin "I".
D. Adjust RV 106 until voltmeter reads a voltage equal to calculated deadband voltage.
Example was determined to be .15 volts, except change to .12 volts (.08 x 1.5). This
will set "X" axis deadband.
E. Move positive lead of voltmeter to pin 13 of IC 210 (Scale set to 2.0 volts). Test pin
"j",
F. Adjust RV 206 to determine set point of "Y" axis deadband.
G. Remember the deadband set point since it will be used to calibrate the positive and
negative offset adjustments.
H. Due to the light spring return action of the joystick, the handle may not return to true
neutral from each direction in an axis. Before proceeding to step 10, it is therefore
necessary to also null the signal in the following manner for each axis.
1.

Connect voltmeter per step 5.

2.

Push lightly on joystick each way in the axis until a recognizable "off-center"
resistance is felt and observe the voltmeter readings as the handle is moved. A
minimum + voltage should be observed as the handle passes through neutral. If
not, adjust signal null so that this minimum occurs when the handle is judged to
be in the true vertical position.

3.

Again push lightly on the joystick handle as above except allow the handle to
spring return to neutral and observe the null voltage. When allowing spring return
to neutral from either direction in this fashion, the reSUlting voltage measured
should not exceed 50 millivolts. If it exceeds 75 millivolts, the masterswitch is
faulty and should be returned for repair.

10. Positive and negative signal offset adjustment.


A. The positive and negative signal offset adjustment are used in the circuit to insure
that output signal voltages will be equal to zero when the joystick has been moved
to the end of the deadband or beginning of control signal output.

2.3.12

BI006008

B. M ve positive lead of voltmeter to pin 1 of IC 110. Test pin "k". Adjust command pot
u til voltmeter switches from negative 15 volts to a positive 15V +/-1 Volt. Make
a 'ustment carefully as the switch over point is very sensitive.
C. M ve positive lead to pin 7 of IC 110. Test pin "I". Reduce scale to 200 millivolts.
Ad ust RV 103 until voltmeter reads zero.
D. M e positive lead of voltmeter to pin 7 of IC 109. Test pin "m". Adjust RV 105 until
vol meter reads zero.
E. Mo e positive lead of voltmeter to pin 8 of IC 210. Test pin "n". Adjust RV 203 until
vol meter reads zero.
F. Mo e positive lead of voltmeter to pin 8 of IC 209. Test pin "0". Adjust RV 205 until
volt eter reads zero.

11. Output ignal amplitude adjustment


A. The noninverting output signal will be positive when the joystick is moved in a

posi ive direction and negative when moved in the negative direction. The inverting
out ut will be opposite to the noninverting outputs. Factory output signal level set
at + -10.0 volts. However, change to +/-8.0 volts.
B. Mov positive lead of voltmeter to "X" axis, noninverting output. Set scale at 20 volts

on

C.

eter.
command pot to maximum negative direction and adjust RV 104 until meter
-8.0 volts.

D. Lowe command pot towards neutral (slowly). Meter reading should swing to zero
smo thly. If meter reading switches to zero too soon, repeat 10 and 11 as
inter tions occur between these adjustments.

E. Swin command, pot to maximum positive direction and adjust RV 102 until meter
reads +8.0.

F.
G.

ositive lead of voltmeter to "Y" axis, noninverting output.

H. Swing ommand pot to maximum negative direction. Adjust RV 204 until meter reads
-8.0 v Its.

I.

J.

ommand pot to maximum positive direction and adjust RV 202 until meter
8.0 volts.

2.3.13

BI006008

K. Repeat step D.
NOTE:

Repeat steps 10 and 11 until exact outputs are achieved. One adjustment
affects the other and repetition may be necessary.

12. Adjust 1% to 5% maximum signal set point.


A. Move the position lead of the voltmeter to pin 13 of IC 107. Test pin "p". Set range
to 200 millivolts.
B. Determine percentage of maximum signal (factory set at 2.5%) desired and multiply
times max signal output to determine set point.
Example: Range - 2.5%
Max signal = 8.0 volts
Set point = .025 x 8 = 200 millivolts
C. Adjust RV 107 until meter reads 200 millivolts.
D. Connect voltmeter to pin 2 of IC 207. Test pin "q".
E. Adjust RV 207 until meter reads 200 millivolts.
F. Move joystick and observe operation of the Light Emitting Diodes (LED).

13. Adjust 110% signal detect circuit.


A. Set voltmeter to 20 volt range.
B. Connect positive lead of voltmeter to pin 2 of IC 107. Test pin "r".
C. Determine set point:
Set point = 1.1 (Max signal)
Factory setup: 1.1 x 8.0 = 8.8 volts
D. Adjust RV 108 until meter reads 8.8 volts.
E. Connect positive lead of voltmeter to pin 13 of IC 207. Test pin "s".
F. Adjust RV 208 until meter reads 8.8 volts.
G. Move joystick and observe operation of LED.

2.3.14

BI006008

14. The calibration procedure is completed. Use summary data sheets to record voltage
settin ~s for future calibration activities.

"r=~~=====-,

~~13

102

12 11 10 9

345 6

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Ol

INTEGRATED CIRCUIT (IC) PIN LAYOUT (Typical)

-----j------------------------------------------

2.3.15

BI006008

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2.3.16

BI006008

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2.3.17

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6. DEADBAHD SETPOfNT

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V IC 207. PIN '10

5. NEUTRAL SENSE OUTPUT

V IC 107, PIN '/0


v IC 207, PIN 5

MV

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4. SENSE NEGATIVE DIRECTION OUTPUT

v IC 108, PIN. 2
V IC 20B, PIN .13

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3. SE NSE POS ITiVE DIRECT ION OUTPUT

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2. INPUT SIGNAL NULL

t. POWER SUPPL Y

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8D VOL TS FOR BOTH "X" AND -y" AXIS MAX 1-)

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RECOMMENDED SETTING rOR ITEM 8.

v IC 107, PIN. 2
V IC 207, PIN '13

10.110% SIGNAL SETPOINT

V IC 207, PIN 2

V IC 107, PIN '13

9. 1-5% SIGNAL SETPalNT

X-AXIS MAX (-j


X-AXIS MAX I-I
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B. OUTPUT SIGNAL AMPLITUDES

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7. POSITIVE AND NEGATIVE SIGNAL OFFSET

CAL /BRATION PROCEDURE

INTERFACE FOR JOYSTICKS

BI006008

BI006008

SECONDARY CONTROLS
These are located on the consoles on either side of the operator. They consist of the
necessary lights, switches, and push buttons to support the primary controls. Warning
signals and lights that inform the operator of potential machine problems or get his attention
from other personnel are also mounted in the consoles.

EMERGENCY
STOP

PROPEL MOTOR
BLOWER

10

()2

LEFT CONSOLE:
1.

6 O

motion brakes, removes power to the machine drives, and opens


the on-board high voltage vacuum breaker. this control should
only be used in situations where personal injury or machine
damage is imminent.

ROPEL

BAAK

PROPEL

DIG

~?J8,A

PROPEL

40q04

EMERGENCY STOP - a red mushroom pushbutton that sets all

ACAUTION:

2.

DO NOT USE EMERGENCY STOP TO


ROUTINELY SHUT DOWN THE MACHINE.
This control causes the machine to stop
very abruptly, which can over-stress
components and result in their premature
failure.

PROPEL MOTOR BLOWER - a green light which indicates the

propel motor blowers are operating when in the propel mode.


3.

PROPEL BRAKE - A red light to indicate the propel brakes are set

and a green light to indicate the propel brakes are released. These
are activated only when L.E. is energized and the control is in the
PROPEL mode.
4. DIG, PROPEL - green lights that indicate machine operating mode.
@@
cnsl1847.wpg

@@

5. PROPEL MOTOR FIELD - A red light which indicates a problem


with one or both of the propel motor fields. An alarm will be set off
when the light comes on. To eliminate the alarm, stop the machine
and push the LE STOP button. The light will remain on until the
problem is corrected.

6. CONTROL TRANSFER - a selector switch with three positions: DIG, BRAKES SET and
PROPEL. It is used to transfer between machine operating modes.
DIG - activates the hoist, crowd, and swing drives; deactivates the propel drive; and

automatically sets the propel brakes.


BRAKES SET - all brakes set regardless of the position of each brake control switch. The

master controllers Goysticks) are deactivated; thus the hoist, crowd, swing, and propel
drive functions are inoperable.
PROPEL - activates the propel and swing drives; deactivates the hoist and crowd

drives; automatically sets the hoist and crowd brakes if not already set with the manual
control switches; starts propel warning signal which is continuous while in propel.

2.3.20

BI006008

AOpa

EMERGENCY

STOP

MOTOR

BLOWER

10 ({:J)2
36RopaB

PROP

40004
6
,..-EXITATI
START

7({:J)
SWING

BRAKE

~T~~SE
@

SE (! ~;SE

modes. The recommended procedure is to have the swing


brakes released when propelling for a clearer view of the
area around the machine.
7. EXCITATION - These two push buttons control the application of

power (line excitation) to the machine's operating drives. The


START pushbutton, when pressed, energizes the control circuits.
It is illuminated green when L.E. is on. The STOP pushbutton,
when pressed, de-energizes the control circuits, indicated by the
green light in the START pushbutton going out. This control
permits the operator to temporarily remove power to the
machine drives without shutting down the machine. THE STOP
BUTTON SHOULD BE PRESSED, DROPPING OUT L.E.,
BEFORE THE OPERATOR LEAVES THE SEAT FOR ANY
REASON.

BRAKE

CROWD

1~W1iASE
@ @

NOTE: The swing drive is operable in both the DIG and PROPEL

@ @

ACAUTION:

To avoid excessive motion brakes wear,


all machine drives should be stopped and
not moving before "dropping out"
(de-energizing) Line Excitation. It is proper
operator procedure to stop all motions
and then set the brakes before pressing
the EXCITATION STOP pushbutton.

cnsll847.wpg

8. SWING

AKE - A 2-position selector switch to SET or RELEASE the two swing brakes.
AKE - A 2-position selector switch to SET or RELEASE the hoist brake.

10.
11.

BRAKE - A 2-position selector switch to SET or RELEASE the crowd brake.

AULT RESET - A black pushbutton. Push and release several times until the
es out. If it does not go out call for service.

12. HOIST, CROWD, SWING AND PROPEL MOTOR OVER-TEMPERATURE - Red lights
which i dicate a motor problem. An alarm will be set off when any of the 4 lights come
on. To Iiminate the alarm, stop the machine and push the LE stop button. The Iight(s)
will rem in on until the problem is corrected.
13. DC GR UNO LOOP - A red light which indicates an armature circuit ground in the hoist,
crowd, r swing motors. An alarm will be set off when the light comes on, to eliminate
the afar ,stop the machine and push the LE stop button. The Iight(s) will remain on
until the problem is corrected.

2.3.21

BI006008

14. MASTER SWITCH FAULT - A red light which indicates a @


problem with either or both masterswitches. An alarm will be
set off when the light comes on, to eliminate the alarm, stop
the machine and push the LE stop button. The light(s) will
remain on until the problem is corrected.
15. MOTOR BLOWERS - Indicates one or more of the blowers on
the D.C. drive motors for the hoist, swing or crowd machinery
has malfunctioned. The blower(s) at fault will have to be
determined.

HOiST
MOTOR
O'TEMP

CROWD

PROPEL
MOTOR
OTEMP

DC
MASTER
LOOP
SWITCH
GROUND
FAULT

~TOR

O'TEMP

SWING
MOTOR
Q'TEMP

@@@
@@@
@@@

MOTOR
BLOWERS

FILTER
FANS

AUTO
WBE

__. _ - - - - - -

._--_.

16. FILTER FANS -Indicates a malfunction in one or both of the


house air intake filter fans located on the house roof. The fan
at fault will have to be determined.

@~A1R

NOTE:

All fault warning lights are all of the "push to test" type.
To test that the light in each is functional, push it. The
light should come on. If not, replace the lamp. The light
will go out when manual pressure is removed. In order
to test these lights, the M.G.Set must be running. In
addition, the drive control must be in the propel mode
and line excitation (LE) activated (its green light
illuminated), to test the Propel Motor Temp light. These
lights should be tested at the beginning of each shift.

ACAUTION:

18
17. AUTO LUBE - Indicates a malfunction in one or more auto
lube systems. Stop the machine and check the lube control
panels in the Right Hand Wing. DO NOT operate the machine
without correcting the problem.

CONDITIONER

HE~T
(\\\0':: VE"'CooL

VENT

~
s~~

O~~L~~
@

CAB UGHTS

~1
cnsr1847.wpg

In the event an announced fault is experienced in any of the


fault lights, THE MACHINE MUST BE SHUT DOWN
IMMEDIATELY, the fault investigated, and the problem
eliminated BEFORE continuing to operate. Continued operation
after a fault is announced could result in damage to the
machine.

18. AIR CONDITIONER - A 4-position switch which controls the air conditioner operating
modes.
19. VENT - A 2-position switch to control the vent blower. The blower supplies filtered fresh
air through the air conditioner when in the heat, vent or cool mode.
20.

FAN SPEED - A 2-position switch to control the fan speed.

21. CAB LIGHTS - A 2-position switch to turn the cab lights on and off.

2.3.22

BI006008

ALARM

The alar s are located on the front of the right hand console. They include:
RM - Rounds off in a fast pulse in conjunction with a fault Iight(s) the alarm can
d by stopping the machine and pushing the LE button.
BOARDIN ALARM - A continuous alarm when activated by one of the pull chords at the rear
of the ma hine. The alarm is de-activated with release of the pull chord.
CROWD
limits.

OTION LIMIT - A chime indicating the dipper handle is into the crowd or retract

BOARDIN ALARM - A continuous alarm when activated by one of the pUll chords at the rear
of the ma hine. the alarm is de-activated with the release of the pUll chord.
CROWD
limits.

OTION LIMIT - A chime indicating the dipper handle is into the crowd or retract

Hoist. Crowd and Swing


Generator Field Excitation
Transformers in the '
Cab Base
" ......:

~~operator's Seat
,
,
,
,
J

Joystick Control Panel


( In th e ~b

~a_s~ l

Air

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cab21847.wpg

OPERATOR'S CAB -Plan View

2.3.23

BI006008

AIR PANEL
Crowd Clutch
Adjustment Regulator

1. The upper air pressure gauge indicates the


air system operating pressure of 120 PSI
(689 Kpa).

CAUTION: IF THE SYSTEM PRESSURE


IS BELOW 100 PSI, OR
ABOVE 120PSI, SHUT THE
MACHINE DOWN AND
CORRECT THE PROBLEM.
Failure to heed this caution
could result in machine
damage.

Gauge Port,
Crowd Clutch Pressure
(Plugged)

System
Air Pressure
Crowd Clutch
Air Pressure

2. Crowd Clutch Regulator - The crowd


machinery is fitted with a clutch which will slip
and protect the machinery from impact loads
that may occur when digging.

o
Air Panel Stand

3. Adjust the air regulator to obtain an air


pressure of 80 PSI in the lower gauge.
Further adjustment may be required due to
digging conditions and friction material.
Once set, no additional adjustment is required.

Air Supply
apnl1847.wpg

View

A-A

IMPORTANT NOTE:

The air supply line at the crowd clutch is equipped with a check valve that permits air
flow into the clutch but not out. This check valve is there to prevent inadvertent loss of
clutch action by accidentally eXhausting air and possibly letting the dipper handle
move in the boom yoke blocks without motor or brake control. This check valve is
located inside the guard over the clutch. To exhaust air from the crowd clutch, the air
supply line must be closed, the clutch guard removed and the air line to the clutch
loosened to reduce the air pressure.
DANGER: RELEASE THE AIR LINE PRESSURE BEFORE REDUCING AIR
PRESSURE TO THE CLUTCH. DO NOT ATTEMPT TO REMOVE
ANY FITTINGS UNTIL THE AIR PRESSURE HAS COMPLETELY
BLED OFF. FAILURE TO USE CAUTION COULD RESULT IN
PERSONAL INJURY.

----c

2.3.24

BI006008

2.4 OPE ATION

GENERA INFORMATION
This secti n of the manual is designed to assist the owner in the operation of this machine.
It provide the operator with the location and explanation of the controls, instructions for
machine peration, and certain maneuvering techniques.
Througho t this section, the use of the terms "LEFT', "RIGHT', "FRONT" and "REAR" refer to
machine I cations as viewed by the operator sitting in the operator's seat in the cab.

Heater / Air Conditioner


Operator's Cab
Dipper Trip Assembly

Dipper Pitch
Brace
Main Rotating

Gear~~~~~~~~~~.~.b;~~~~~~~
IP

O. . .

06 0

Crawler Belt
Lower Frame and Crawlers Assembly

Crawler Drive Sprocket


18247 _lIlIl. wpg

182M NOMENCLATURE

2.4.1

BI006008

OPERATOR'S CAB

Front
of

Machine
Joystick Controller,
--Hoist / Swing / Horn

Control
Console,
Left

Console,
Right

Joystick Control
Panel in the
Cab Base

-,-\

-,

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Operator's Seat

Air
Panel
Stand

182M OPERATOR'S CAB (Plan View)

2.4.2

BI006008

PRE-ST RT INSPECTION
Before st rting or operating the machine, know the emergency stop and proper operating
procedu es. Become familiar with all the controls and sound the signal horn to alert
coworker in the pit area of the intent to operate or move the machine,
arding, and before entering the operator's cab, inspect the areas listed below:
Dipper:
..; Rope
..; Teet
..; Adap
..; Dipp
..; Trip
..; Dipp
..; Lubri

& Equalizer Sheave


& Pins
ers
r & Bail Structures for Cracks
echanism & Snubber
r Latch Bar
ation Fittings

Front End
..; Condi ion of Boom
..; Hoist heaves
..; Crow Machinery
..; Handl /yoke Block Clearance
..; Lube overage
..; Hoist opes for Wear or Damage
..; Boom upport Pendants
..; Air & L be Lines & Connections
..; Loose ins or Retainers
..; Walkw ys & Railings

..; Trail C ble & Cable Reel Condition


..; Swing ear & Pinions for Lube & Damage
..; Guardi g
..; Cracks 'n Structure
..; Roller ircle Condition
..; Lube C verage
..; Air & L be Lines & Connections
ADAN ER:

HIGH VOLTAGE. DO NOT contact the high voltage areas of


the trail cable or collector rings. NEVER perform electrical or
mechanical repairs or maintenance in these areas without
disconnecting the trail cable power supply. Failure to
disconnect trail cable power supply could result in severe bodily
injury or death.

2.4,3

BI006008

Crawlers:

J Belt Tension
J Missing Shoe Pins or Retaining Bolts
J Idlers, Load Rollers & Sprockets for Damage
J Lube Lines, Fittings & Guards for Condition
J Lube Coverage
J Structures for Cracks
J Propel Machinery
J Tension Rod Nuts for Tightness

Rotating Frame & Machinery House:

J Structure Condition
J Air Compressor Crankcase Oil Level, Drive Belt & Operation
J Auto Lube Systems: Lube Supply Adequate & Operation
J Air & Lube Lines & Connections
J Lube Coverage
J De-leer Reservoir Level
J Drain Moisture/Condensation from Air Line Filter & Air Tank
J Blower Motors Operational
J Filter Fans Operational
J Swing Machinery
J Hoist Machinery
J Open Gears for Condition
J Hoist Ropes for Condition
J Electrical Cabinets for Security & Door Position
J Fire Extinguishers or System for Charge & Condition
J Walkways, Rails & Ladders for Access & Condition
J Gantry Structure & Backlegs for Cracks
J Gantry Foot Pins & Retainers
J Equipment Structure Base Bolts
J Guards Condition
J House Panels Condition

Operator's Cab:

J Controls for Operation


J Warning Indicators & Alarm
J All Brakes for Function
J Support Systems for Function
ACAUTION:

Notify maintenance personnel at once if pre-start inspection


routine identifies any defects.

2.4.4

BI006008

MACHIN

START-UP & SHUTDOWN

START- P PROCEDURE
Typical st rt-up from a completely shut down condition is accomplished as follows.

Do no start this machine unless you are completely familiar with the various controls.
Always perform the Pre-start Inspection given at the beginning of this section before the
actual tart-up.
1. Make s re power is ON and the applicable main circuit breakers closed by observing that
the vol meters on the front of the motor control center and the high voltage cabinet are
indicati g voltage. If a meter is not showing voltage, then close the affected breakers. If
that is ot the problem, then notify the electrical maintenance personnel for assistance.
2. At the otor Control Center, check the Phase Sequence light. If not lit, push it to test its
red la p. If alright, turn the Air Compressor switch to the AUTO position. Shut
compre or down immediately if any unusual sounds are heard. The green indicator light
will co e on when the compressor is running.

3. Next, p sh the Filter Fan NO.1 start pushbutton. Let it come up to operating speed and
then pu h the Filter Fan NO.2 start pushbutton. The green lights will come on when the
filter fan are running. Push their stop push buttons if any unusual sounds are heard.

4. Start the motor blowers by pressing the start pushbutton on the Hoist Motor Blower panel.
This will also start the motor blowers on the crowd and swing motors and permit the
propel
otor blowers to startup when switching to the propel mode.
NOTE: If the propel motor blower indicator light does not come on, when in propel mode,

c eck that the manual on each propel motor blower is closed before calling for
s rvice.
The sou d of the fans and their green indicating lights coming on will let you know that
they are perating. Hold the start button down until the green indicating lights for the hoist
and the c owd and swing blowers are illuminated. The propel motors blowers indicating
light will ome on only if the machine drive is in the propel mode. Shut blowers down
immedia Iy if any unusual sounds are heard.
Always let the system being started come up to normal operating
speed before starting the next system.
5. At the Hig Voltage Cabinet, momentarily press the M.G. Set start pushbutton. The M.G
Set will g through a reduced voltage starting sequence automatically (approximately 15
seconds ill be required) The green light in the start button will illuminate when the set
has reac ed full speed. Be prepared to push the M.G. Set stop button if any unusual
noises ar heard. If the starting sequence takes too long the M.G. Set will shut down
automatic lIy. If this happens call for service.

2.4.5

BI006008

6. Check that power is on the Auto Lube Control Panels. The green indicator lights on the
front of each panel should be illuminated. If not, check that the circuit breaker in the
Lighting Panel by the left house door that is labeled Auto Lube is on. If the green indicator
lights do not come on when the auto lube breaker is closed, do not operate the machine,
call for service.
7. When all systems are operating satisfactorily, leave the machinery house and go to the
operator's cab.
8. Note the air system pressure on the Air Panel Stand. It must be 115 PSI (793 kPa) or
above before Line Excitation (LE) can be energized. If it is above 120 PSI (827 kPa), report
this condition to the proper maintenance personnel for adjustment/correction.
9. Set in the operator's seat and swing into the operating position. Adjust the seat as
required.
10. Observe the fault warning lights on the Operator Control Console. If any are illuminated
investigate the reason and correct the problems found before proceeding. Push each
fault light to test its lamp. Note any burned out.
11. Set the Hoist, Swing, and Crowd Brakes.
12. Position the Control Transfer switch to BRAKE. SET.
13. Check that the primary controllers are in their NEUTRAL (center) positions.
14. Press the Excitation Start pushbutton on the Operator Control Console to activate the
drive systems.

NOTE:

Line Excitation (LE) CANNOT be activated unless:

a. The M.G.Set is running.


b. Hoist, Crowd, and Swing joysticks are in NEUTRAL (centered).
c. Hoist, swing, and crowd DC motor blowers are running.
d. Pressure in the air system exceeds 100 PSI (690 kPa) to 115 PSI (793 kPa).
e. Retractable boarding stair is fUlly up into its machine operating position.

Observe that the LE green indicator light comes ON. When this light is on, the motion
controllers are energized.
15. Move the Control Transfer switch to the DIG position and move the Hoist, Swing, and
Crowd Brake switches to their RELEASE positions. The machine is now operational in
the dig mode as indicated by the Control Mode lights on the Operator Control Console.

2.4.6

BI006008

TO TRAN FER FROM DIG TO PROPEL MODE:

Return both primary controllers to the neutral position. This initiates a 5 second delay in
the tra sfer circuits.
Move t e hoist and crowd brake selector switches to the SET position.

AC

UTION:

THE MOTION BRAKES ARE INTENDED FOR PARKING AND


EMERGENCY STOPS. FOR MINIMUM BRAKE LINING WEAR,
BRING ALL MOTIONS TO A COMPLETE STOP BEFORE
SETTING THE BRAKES.

Move t e control transfer switch to the BRAKE SET position. Motor control is removed
and all rakes are set-regardless of the other brake switch positions.
Move t e transfer switch to the PROPEL position and allow 3 seconds for the transfer to
propel. Check that the propel motor blower, propel brake released and propel mode
green I ghts have turned on, indicating that transfer to the propel mode has been
com pie ed.
'
The m chine is ready to propel and the swing function is fully operable to assist the
operato in maneuvering.

TO TRANS ER FROM PROPEL TO DIG MODE:

Return oth primary controllers to neutral position. This initiates a 5 second delay in the
transfer ircuits.
Move th control transfer switch to BRAKE SET. Motor control is removed and all brakes
are set. heck the propel brake set red light is on and propel blower green light is off.
control transfer switch to the DIG position and allow 3 seconds for the transfer
to dig m de. Check that the green dig mode light has turned on to indicate that transfer
to the di mode has been completed.
hoist and crowd brake selector switches to RELEASE position.
The mac ine is ready to dig.

.._-..

----+---------~--~-~~~--_

~-_

..

_-_.~_._-_

-----+----~-_._--------------_._-------

2.4,7

. _-

~- --~--

--._---~._----~

..- -_.-- .-----------

BI006008

NOTE:

The propel brake indicator lights are controlled by pressure switches located close
to each brake. When the switches OPEN, the brakes will be set. The dig and
propel mode indicator lights are controlled by the control transfer switch.

ADANGER:

UNAUTHORIZED CHANGES TO THE BRAKE PRESSURE


SWITCHES COULD RESULT IN EQUIPMENT DAMAGE AND
PERSONAL INJURY.

Pres. Sw. CLOSES


Hoist Brake
1g.P.~I (!.f>~ .
Swing & Crowd Brakes
95 PSI (655 kPa)
Propel Brakes 95..PSj(655kPa)..

1.

k.P.<:lL

Pres. Sw. OPENS

.!g.p.~! . (~.s.~ ..k.P.~L


55 PSI (379 kPa)

{3PS\(90'kPa)..

PARTIAL SHUTDOWN
To shut down the machine in order to leave the operator's seat temporarily, for break or for
shift change, only the primary controls need be deactivated. If it is the end of the shift, rotate
the machine one full revolution to change the position of the rollers in the roller circle for
even wear. Sound the whistle before swinging the machine.
Lower the dipper to the ground and set all brakes after machine motion has stopped. Move
the Control Transfer switch to BRAKE. SET position.
Finally, fully press and release the Excitation Stop pushbutton to de-energize Line Excitation
(LE). The green indicator light in the Excitation Start pushbutton should go out.
The machine is now inoperable and is partially shut down.

2.4.8

BI006008

COMPL TE SHUTDOWN
1. Park t e machine on a level area that is out of the way of rock slides or falling rocks and
that is not prone to flooding. The surface of the area should be firm so the machine
canno sink into it.
2. When he machine is safely located, follow the procedure described in the preceding
seetio "Partial Shutdown".
3. Leave he Operator's Cab and go to the High Voltage Cabinet inside the Machinery
House.
4. De-ene gize the M.G. Set induction drive motor by pressing the M.G .Set stop pushbutton
on the front of the High Voltage Cabinet. The green indicator in the M.G. Set start
pushbu on will go out when the vacuum breaker opens the circuit feeding the motor. The
M.G. S t will coast to a stop.
5. Go to t e Motor Control Center. Fully press, then release the STOP push buttons for the
followin systems to shut them down:
Hoist Motor Blower (this shuts down all motor blowers).
Filter Fan No.2.
Filter Fan NO.1.
The r spective green indicator lights should go out.

Move t e Air Compressor selector switch to its OFF position.

7. If it is humid or cool, turn the Anti-Condensation Heater selector switch to AUTO, if the
machine has this system. This will protect the electrical equipment while the machine is
shut do n and the power is on.
e is now shut down to a point where inspection, maintenance, etc., can be
urn off all lights not needed.

ADA

HIGH VOLTAGE. High voltage and incoming electric power


is ON to the transformers, disconnects, electrical cabinets, and
collector rings. NEVER PERFORM MAINTENANCE OR
REPAIRS IN THESE AREAS WITHOUT DISCONNECTING THE
POWER SUPPLY (TRAIL CABLE) FROM THE MACHINE. Failure
to do so could result In personal Injury or death.

2.4.9

BI006008

GROUND PREPARATION
Ground preparation is very important. The mining shovel requires a properly prepared
ground base for operation. The crawler shoes must have full contact with the ground when
the machine is digging. With the machine weight distributed ,over the crawler shoes
minimum ground bearing pressure is obtained and the machine components are less
stressed.
For optimum operation, the ground supporting a mining shovel must be as near level as
possible and firm. Sharp rocks and boulders cause point loading which will damage the
propel machinery and crawler structures and should be removed if possible. Where this is
impractical, cover the working area with fill dirt to a sufficient depth that will eliminate the
effects of the rocks.
The mining shovel design incorporates a calculated balance between boom length, boom
angle, allowable dipper load, machine weight, and ballast used. During normal digging
cycles, the center of gravity shifts from the front to the rear within a specific distance. If, for
any reason, the digging radius or load increases to cause the center of gravity to extend
beyond this specific distance the machine will become unstable.

CAUTION:

OPERATION OF AN UNSTABLE MACHINE COULD RESULT


IN DAMAGE TO THE SHOVEL, TRUCKS OR SUPPORT
EQUIPMENT.

2.4.10

BI006008

GENER L
Each mot on of this machine is controlled by distinct joystick actions. The operator transfers
joystick m vements into the desired machine action - CROWD, HOIST SWING, PROPEL - to
result in
mbined smooth, safe, and productive machine operation.
Short, fast and erratic movement of the joysticks results in uncoordinated machine motions.
This will r duce productivity, consume excess energy, risk personal safety, and shorten
machine I fe.
This mac
optimize
operation
hauling e

inery develops inertia when put into motion. If that motion is not controlled to
ach second of machine operation, costs of operation will increase. Careless
an result in serious personal injury and severe damage to a machine or even to
uipment. Always use careful judgement when in the operator's seat.

Machine h ist and crowd controls are designed to give the operator maximum power or bail
pull no ma er what speed is selected by movement of the joysticks. Therefore, if you feel like
you are f eling fatigued because of "control jockeying" you are most likely operating
incorrectly

DIGGING
The digging cycle consists of positioning the machine dipper into
the bank, p netrating the material to load the dipper through the
hoist and owd motion, retracting the dipper out of the bank
swinging t the dump point, dumping into the hauler and
returning th dipper to the bank ..
Ie the CROWD motion is most important in achieving
an optimum ipper fill. For best results the operator must "shave"
the material off the face of the bank (refer to the figure) with the
dipper lip. his is best accomplished by matching available
machine bail pull with depth of "bite" into the bank that penetrates
the material ithout stalling the HOIST motor.
Balancing C OWD/HOIST motions with the material's resistance
to being sh ed off the bank face in a smooth, efficient filling of
the dipper is he mark of a professional machine operator.

2.4.11

dgcy1845.wpg

DIGGING CYCLE

BI006008

For digging, machine


control is in DIG mode,
Line Excitation activated,
and the hoist, swing, and
crowd brakes released.
Begin the dig cycle by
moving the dipper into the
toe of the bank. Push the
RIGHT joystick forward to
lower the dipper to this
position. Move the LEFT
joystick forward engage the
CROWD motion.
Control
Console.
RIGHT

NOTE:

Counteract any
tendency of the
machine to drift
by slight
engagement of
the swing
machinery in the
direction
opposite the drift.
Do this by
moving the
RIGHT joystick to
the left or right.

octd1847.wpg

182M OPERATOR CONTROLS -DIGGING


Continue the dig cycle by pulling back the RIGHT joystick to hoist and pushing forward on
the LEFT joystick to crowd. Control the amount of crowd force into the face so as to keep the
dipper filling.
ACAUTION:

NOTE:

Avoid overcrowding into the bank until the HOIST motion stalls.
This poor operating technique will reduce cycle efficiency and
machine production.

Limits designed into the CROWD motion neutralize overcrowding or hoist stall
conditions by automatically commanding zero speed to the CROWD function. This
feature eliminates accelerated wear to electric drive and clutch components and
minimizes possibility of boom jacking caused by the operator commanding
excessive crowd force.

2.4.12

BI006008

When th dipper is full, pull the LEFT joystick to the rear to retract the dipper from the bank.
Continu to hoist the dipper to its dump height. Stop the hoist by returning the RIGHT
joystick t neutral and moving this joystick left or right for the direction of swing desired.
NGER:

When swinging, the dipper must be raised to clear all


obstructions. Always be aware of the necessary swing
clearance at the rear of the machine. Do not start the swing
until the dipper clears the bank.

Start swin ing slowly to avoid excessive side thrust on the boom and dipper handle. As you
approach the dump point, change the RIGHT joystick either left or right in the opposite
direction f swing travel to slow and stop swing motion. Use swing motion as needed to
keep dipp r over haul truck and steady to dump.
Open the ipper door by using the pushbutton on top of the LEFT joystick. Hold the switch
down Ion enough to release the latch bar, which opens door.
To return t the face for the next dig cycle, move the RIGHT joystick forward and either left
or right to ave the machine toward the face. This will lower the dipper to the toe of the bank
as it swing. Use CROWD motion as required to position the dipper out from the boom.

ACA

TION:

Stop the swing motion before beginning to dig into the bank. DO
NOT USE THE DIPPER TO STOP the SWING MOTION.

MOTION L MITS
There are otion limits built into this mining shovel to protect the machinery against over
travel or ave use. These limits and the procedure used to get out of each is explained here.
The Boom
the crowd
limit, revers
support rap

cking Limit is activated when the boom is raised out of its normal position by
otion. This .results in a loss of crowd out effort and motion. To get out of this
the LEFT joystick to RETRACT. This will permit boom to settle down onto its
s and the crowd out drive will be restored.

Crowd Exten /Retract Limits can be activated by either crowding the dipper handle out too

far or retracti g it in too m'uch. Getting into either limit results in the loss of effort and motion
to the dipper andIe in whatever direction it was moving. To get out of either limit condition,
move the L T joystick in
the reverse direction from that in which the dipper handle was
I
operating. Th s will activate the drive in the opposite direction and move the dipper handle
out of the vi ated limit.
Limit is activated when the dipper handle is raised too high and is near the

sheaves at th
the hoist brak
the EXCITATI
brake, then I

boom point. This results in a loss of hoist and lower effort and motion and in
setting. To get out of this limit, return the RIGHT joystick to NEUTRAL. Press
N START pushbutton on the operator's left control stand to release the hoist
wer the dipper handle out of the limit with the hoist joystick.

2.4.13

BI006008

NOTE:

Anytime one of these motion limits is violated, the Limit bell on the front of the
operator's right control console will sound.

ACAUTION:

These motion limits are safety devices built into the machine to protect it
against operator error. THESE ARE NOT OPERATING LIMITS AND ARE
NOT TO BE USED DURING NORMAL OPERATION. REPEATED
ACTIVATION OF ANY LIMIT WILL RESULT IN DAMAGE TO MACHINE
COMPONENTS and require downtime for repair. This causes production
costs to increase. An accomplished operator will seldom, if ever, get into
any of these limits while running the machine.

PROPEL

Moving the machine


around the bank
work area and from
one bench to another
or anyWhere in the pit
requires careful
operator
concentration and
co-ordination with the
ground crew.

Right
Crawler
Forward
Dipper Trip Pushbutton

I
Swing
Left

Joystick
Controller, LEFT

Control
Console,
RIGHT

Oclp1847.wpg

182M OPERATOR CONTROLS -PROPEL


Park the dipper handle in its carry position before transferring control from DIG to PROPEL
mode. Carry the dipper with the dipper handle lower than its horizontal position when
propelling, so the dipper weight is supported with the shipper shaft too. This position
minimizes shock loads on the hoist drum shaft and bearings when propelling the machine.

2.4.14

BI006008

For prop ~lIing, machine control is in PROPEL mode, Line Excitation activated, and propel
brakes r~leased (green light ON). The swing drive is activated in this mode also. It is
recommE nded standard procedure to have the swing brakes released while propelling
steering f ~r better travel area obseNation and machine control. The propel warning Klaxons
or buzzer will sound all the time the machine is in the propel mode and LE is energized.

NOTE:

When transferring from DIG to PROPEL mode, the hoist and crowd brakes
automatically SET to prevent the dipper from falling. It is proper operator
procedure, regardless, to set these brakes with their manual control switches
before transferring modes.

Moving th RIGHT joystick controls the propel machinery on the RIGHT crawler. Moving the
LEFT joys ick controls the propel machinery on the LEFT crawler.
Forward rnovement from "neutral" of either joystick results in the respective crawler belt
moving fcrward; rearward movement of either results in the respective crawler moving in
reverse.

IMPORTArliT:
Forw rd movement of the crawlers is toward the front idlers. The operator should be
aware of the crawl~rs position with respect to the rotating frame before attempting to
move the machine.
The forwa d/rearward movement of either joystick controls the speed of the propelling
motion in Jroportion to the amount the lever is moved away from its neutral (centered)
position.
ACAJTION:

Make sure the propel brakes are released (green indicating


light ON) before moving either master controller off neutral.
MOVING A CRAWLER BELT BEFORE ITS BRAKE IS
RELEASED WILL RESULT IN PREMATURE BRAKE WEAR and
expensive machine downtime to repair.

ACAlTION:

After placing machine control in the propel mode, carefully


push each joystick forward to confirm the direction of crawler
travel. WHEN THE OPERATOR CAB DOES NOT ALIGN WITH
THE FRONT IDLERS ON THE LOWER FRAME, MACHINE
MOVEMENT COULD BE DIFFERENT THAN EXPECTED.

-----+--_._._---

-~ ---~'-'~--~-'~---.--'--~-.~--------~--------'-'-~-----------~

-----+~._-----

-~-.

--.~--~------

... -.-------_.-

2.4.15

_.- _.. _

_.~----.

__

._------~

BI006008

STEERING
Each crawler belt, being able to move independently, gives
three ways to steer.
1. DIFFERENTIAL - both crawlers moving in the same
direction but at different speeds

"PIVOT STEER"

( Right / Left)

2. PIVOT - crawlers moving in opposite directions

3. SKID - one crawler moving, the other stationary

Straight propel motion forward is the best direction to travel


when making long distance moves.

"DIFFERENTIAL STEER"
NOTE:

( Right / Left )

Do not propel the machine in reverse direction over


extended distances or up or down long inclines.

Turning the machine left or right requires the operator to


select the direction of turn.
ACAUTION:

Visually-check the trail cable


location, the machine ground
clearance, and the pit area for
personnel and equipment. Also
check the machine's location
relative to the face/bank. Sound the
signal whistle prior to moving or
steering the machine.

S
T

p
~

"SKID STEER"

( Right / Left)
steer3WY.wpg

STEERING the MACHINE

With the dipper in front of the crawler front idlers, the propel will perform as follows:
Move both joysticks equally forward to propel the machine straight forward. Likewise,
moving both joysticks equally rearward propels the machine il'"' straight reverse. Returning
both joysticks to neutral stops propel effort.
Steer LEFT by moving the RIGHT joystick forward and the LEFT joystick rearward, moving
both the amount needed to achieve a smooth pivot turn.
Steer RIGHT by moving the LEFT joystick forward and the RIGHT joystick rearward,
moving both the amount needed to achieve a smooth pivot turn.
To propel in a straight line, move both joysticks in the same direction the same distance from
neutral.
The difference in the direction and/or distance the joysticks are from neutral determines the
machine's turning arc.

2.4.16

BI006008

When pr pelling long distances (over 500 feet/150 meters), extra lubrication is needed for
the craw er side frame components. Make sure the fast cycle in the auto lube system is
working roperly.
When sto ping the machine for any interval during the move, place the control in BRAKES
SET mo e. Once the machine has been positioned at the bank or has reached its
destinati n, return machine control to DIG mode to resume operation.

AD

NGER:

When transferring from PROPEL to DIG mode, pause in BRAKES


SET position until the red PROPEL BRAKE SET indicating light
comes ON. Then move the control transfer switch to DIG. This
will insure the propel brakes are set and the crawler belts locked
in position to prevent machine movement.

PRODUC ION EFFICIENCY


Electric sh
the contro
productio
swing spe
factors su
shifts, an
machine p

vels are only as efficient as the operator at


. The operator therefore controls machine
within the variables of dipper capacity,
d, bail pull, and material density. Other
h as machine availability time, number of
fragmentation of material also effect
oduction efficiency.

Many oper ors lose much of their productive efficiency


in their ina ility to contr9' the pit face/floor conditions
or the prop r spotting ot'the haul units.
To maintai maximum output, the optimum swing
angle for s ovels is an arc of 30-90 between the
digging fac and the dump point.

swarcshwpg

SWING ARC

Swing arcs reater than 90 require the machine to spend more time in the swing cycle
between 10 ding and dumping. This decreases production.

-------+---_.__.------- --. ------ ----- --------- ----- -- -- --- -- -

------+---_._._--- ._- -- ----- - -- - - -- -- -- ---- ---. --

- - - - - - - + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -....- .. _-----_ ..--"-------------------------

2.4.17

BI006008

The operator should spot the haul units. Do this by suspending the dipper above the spot
where you want to dump. Each haul unit driver can then position his truck body in the center
of this target area.

ACAUTfON:

Set the hoist brake to hold the loaded dipper in position if


spotting time will exceed 30 seconds.

The working face often has difficult areas where blasting failed to fragmentize the rock or
material. Avoid these areas while loading the truck. Loosen and break out the difficult/tight
material while waiting on haul trucks to return.

Haul truck spotting can also be


done quickly by keeping the pit
area immediately within the radius
of the boom point clear of rocks
and debris. This housekeeping
practice can also reduce the cost
of shovel crawler maintenance
and haul truck tire expense.
18247trk.wpg

SPOTTING the HAUL TRUCK

CAUTION:

Do not sweep rocks or blocks of material on the floor of the pit


with the dipper. This practice will accelerate wear and cause
serious machine damage.

CABLE REEL OPERATION


This unit is mounted at the rear of the lower frame assembly. Its function is to handle the trail
cable, that supplies electric power to the machine, during machine relocation. It is a
self-contained unit that is powered by an air operated motor. Refer to the equipment manual
from the manufacturer of this unit for more detail.

ADANGER:

HIGH VOLTAGE DO NOT REMOVE THE GUARDS OR


OPEN ANY ENCLOSURES ON THIS CABLE REEL UNTIL
POWER IN THE TRAIL CABLE HAS BEEN SHUT OFF AND ITS
CONTROL BREAKER AT THE MINE SUB-STATION LOCKED
OUT IN ITS TRIPPED POSITION. Only qualified personnel are
permitted to work on this cable reel assembly. Accidental
contact with energized electrical compol,1ents will cause death.

Compressed air is supplied to the cable reel by the compressor on board the machine. The
manual control valve for the reel is mounted on the rear of the unit on a swing out boom.
This boom arrangement permits the reel operator to be in view of the machine operator
during operation.

2.4.18

BI006008

When th machine is operating (compressed air is in the supply lines), the cable reel can be
operated in its constant tension condition and will perform its function unattended. To put
the cable reel in its constant tension condition, move the lever on the manual control valve
to its re I in position. The valve is detented and the control lever will stay where it is
positione at either of three settings.
With the ntrol valve set at reel in, the trail cable will automatically wind onto the cable reel
when the achine is propelled in reverse direction toward the trail cable. When machine is
propelled orward away from trail cable, the trail cable will be pulled off cable reel. Anytime
machine i stopped, cable will cease winding onto or from reel.
The tensi n imparted to the trail cable by the reel in this constant tension operation is
adjustable by a pressure regulator on the right side of the cable reel. It is correct when there
is sufficie t pUll on the trail cable to wind onto the reel, but not so great as to put
unnecess ry strain on the cable. Report any problems with cable reel operation to the
maintena ce crew so they can adjust the tension during the next preventive maintenance
period.
The unwin position of the manual control valve is used to remove trail cable from the reel.
It need on y be used to' remove cable from reel for change out or repair/maintenance if
constant t nsion operation is utilized for normal machine operation.
I

When the anual control 'valve is in its neutral or centered position, the reel will not unwind
or reel in. It is locked in position by the valve.
IMPORTAN NOTE:
aving the cable come of the reel anytime the machine is completely shut down
(air com ressor off)" place the cable reel's manual control valve lever at its neutral
) position before leaving the machine.

ACA

ION:

Do not operate the machine with over two wraps of trail cable
wound onto reel's drum, unless provision has been made for
more by the manufacturer.

2.4.19

BI006008

~---------------

--------------

----------------------------------------

2.4.20

BI006008

2.5 BO M WIRING

FINAL CROWD

.--+--

SK15B

FINAL RETRACT

-----SK42E

SK42H
SK42E

INITIAL CROWD

I
..r:

SK15B

INITIAL RETRACT

SK39E

SK39H
SK39E

GND

i,--+__

GND

---

.,_~

CROWD LIMIT SWITCH

--I'"

, .

eMA'
tMAl

Fl

fic~aM

FZ

,5C25""

p,
p;:

CROWD MOT OR

jo(,)

TO BOOM
JUNCTION
BOX

u.

5MO't

IZAHtJ

Ii'

.,
.,

"I _
"z.

H~

lZA~

IU

GHO

,,
-.!
Gil

~~3:
I

<>.J.

0-':~31"~
" __ :!J

is"

UPPER FRAME LUBE


PRESSURE SWITCH
-----~,---,z.~-l

~'z.n3~

11
IZrux{"t".-----

r'-./'.~
~.

-----

GIIlL--.J I

-_._---~

CROWD BLOWER MOTOR

G O
___
,,:....-_-

-::-

HOIST LIMIT SWITCH


bmws1847.wpg

Schematic, BOOM WIRING

2.5.1

BI006008

MMr'------f,)
I. I--ft~',

-HG----.-.
tIiJi'-;"-1

". ,

l L.. _.~
: .t,j WI

(1
I

Hoist Limit
Switch

'I
I

,j

Upper Frame
Lube Pressure
Switch

Open Gear
Lube PS
Open Gear Lube
Pressure Switch
Upper Frame
Lube PS

/ ~\\
< Intmd.
Crowd Shaft
Ref

Crowd
Blower
Motor

J
.,

Crowd
Motor

Crowd Brake
Magnet Valve

----fHHI-+

r-.

U.F. Boom Junction Box

---L.

BOOM WIRING PLAN VIEWS

2.5.2

-,

BI006008

CROWD LIMIT SWITCH


/

* Use Loctite 271-31 on Keys and

//"//////

Lubricate with MPG


at Assembly

Set Screws at Assembly

Crowd Limit Switch


( Cams 1.2,3 & 4 )

.38 Capscrew
Gr.5,
4 Places

+- - - \ , ( - + - -

~~

.'-+-00

_..J1J'

Shim as
Required for
Coupling
Alignment.
Support Bracket
.5 Capscrew
Gr. 5 - 6 Places
Clsc1847.wpg

NOTE:

e speed reducer requires % pint of the listed oil. Check the oil level every 200
urs and change it at 2500 hours.

SPEED REDUCER OIL

R-ec-o-m-m-e-n-de-d-O-i-'_.
(Or equivalent)

~s-C;;iY--I-'-----------

Range BUS
@ 100"

Lubricant

180 - -

Viscosity
Grade No.

The CROWD (MIT SWITCH, located on a bracket on the right side of the boom in-line with
the intermedi te pinion shaft, is a rotating-cam type electrical-mechanical unit designed for
continuous ration in either the clockwise or counterclockwise direction. Electrical contacts
in the switch re provided for controlling four circuits.
Each set of c ntacts is actuated by cams which are supported on a separate disk welded
to the main sh ft of the switch. As the shaft rotates, the cams open and close. The sequence
of operation 0 the contacts depends on the position of the various cams with respect to the
shaft.
Torque requir ments of the switch are a maximum of 12 inch-pounds to open a contact. The
contacts are fo ced open'by direct cam action and are spring closed. This design provides
a failsafe condi ion so opening of the circuit is not dependent on springs or other parts that
could fail.

2.5.3

BI006008

A cross section view of the switch shows the contact unit (1t.#1) in the open position. Switch
in normal operation (within limits) is in the closed position. In the open position, the camshaft
(1t.#2) has been rotated so that the contact arm roller (1t.#3) is shown riding on the high
portion of the cam (1t.#4) and has depressed the plunger of the contact unit opening the
contacts. As the cam continues to rotate, the arm roller will drop down to the lower portion
of the cam allowing the spring loaded plunger to return to its normal (open) position.

ACAUTION:

NEW SPEED REDUCERS DO NOT CONTAIN OIL

.j The speed reducer has a 50: ratio


.j The limit switch must be reset after maintenance which requires removal of anyone of the

following (dipper handle, shipper shaft, intermediate crowd shaft and limit switch).

1.
2.
3.
4.
5.
6.
7.

Contact unit
Camshaft
Contact-arm roller
Operating cam
Switch-unit plunger
Contact arm
Vernier-adjustment locking
screw
8. Vernier plate
9. Cam-follower bracket
1O.Filler strips

c1SW1845.wpg

When installing a replacement limit switch, carefully align the switch with the intermediate
crowd shaft using shims. This will prevent excessive wear on switch bearings and provide
long mechanical service life. The switch is equipped with self-aligning sealed ball bearings
which prevent entry of dust and dirt minimizing level of torque to drive the shaft.

2.5.4

BI006008

ELECTR CAL RATINGS


Carry Co 1tinuously .. 15Am ps.
A.C."Mal~ e"Value ... 75 Amp s.

D.C. Inductive

A.C.lnte rrupting
Volts

Amperes

Volts

Amperes

110
220
440
550

75
50
18
14

125
250
600

1.8
0.7*
0.24

CAMSE:T ING

SCORED ( 'AM
The dis cl ne-up on the cam shaft, to which the cams are
attached , t ave indicated marks at 15 intervals. The keyway
slots in t he ends of the shaft co incide with the zero point.
After de ter illining the number of degrees that the contacts
should beo pened, select the p roper cam section from Table
1.
Use two car 1S of the same secti on number to obtain the desired range of settings given in
the table for each circuit. The Ieft hand column of Table 1 indicates what cam sections are
to be bra ke 1 off to obtain a particular cam number.

TABLE 1: OP ERATION and ADJUSTMENT of CAMS

Break Off
Cam Section
No.
Full Cam
No.1
No.1,2
No.1,2,3
No.1,2,3,4
No.1,2,3,4,5

Closed Range
(In Degrees)

Open Range
(In Degrees)

Min.

Max.

Min.

Max.

10
175
255
285
315
325

175
255
295
315
325
335

185
105
65
45
35
25

350
185
105
65
45
35

2.5.5

BI006008

OPERATION and ADJUSTMENT of CAMS


For ease in snapping off the cam portions at the scored points it is recommended that an
adjustable wrench be used. Extra care should be used when snapping off cam portion No.4
(leaving portions NO.5 and 6) to avoid breaking off cam portion NO.5. It is recommended
that a second adjustable wrench be used.
Place the two scored cams on each cam holder and align the cams to give the approximate
desired contact opening and closing. When placing the cams on the shaft, be sure that the
cams are placed back-to-back with the markings of each cam facing outward. This will
prevent an interrupted cam surface and also prevent the roller from striking a broken cam
surface. Secure the cams to the cam holder at 1800 intervals with the two bolts and lock
washers furnished. Before tightening the bolts, finer cam adjustment can be made, if
required, by lining up the start of the cam rise with respect to the cam holder indicating
marks at the desired points of contact opening and closing.

VERNIER ADJUSTMENT
The vernier-adjustment mechanism fulfills two purposes. It provides vernier or fine
incremental adjustment of the switch open and closed contact positions, and allows for
adjustment while the switch is actually rotating. The vernier-adjustment locking screw (11.#7)
varies the relative position of the cam-follower roller with the operating cam. To adjust a
specific circuit for desired open or closed contact position, loosen the vernier adjustment
locking screw (1t.#7) and slide it up or down to open or close contact sooner or later as
desired.
The markings on the vernier plate (1t.#8) represent two-degree increments of adjustment.
It should be noted that the vernier adjustment affects the opening and closing of the contact
unit by the same amount. It is not possible to get individual incremental adjustment of the
opening and closing position on anyone circuit If this is required, then the closing position
must be set on another circuit. The two contact units involved can then be electrically tied
together. After final settings are established, securely tighten the adjusting screw to prevent
any accidental movement.

CROWD LIMIT SWITCH MAINTENANCE


No further lubrication beyond that provided at the factory is required on the limit switch. The
contact unit is a completely self-contained device which may be replaced by removing two
metal screws and inserting a new unit. The silver contacts require no attention but must be
replaced before all the silver is worn away. Filing or otherwise dressing the contacts results
only in loss of silver and reduction of the normal contact life.
Inspection of the cam-follower roller assembly can be made by removing the two forward
bolts holding the cam-follower bracket, then swinging the entire bracket assembly back to
provide access to the cam-follower parts.
The following procedures should be followed when replacing bearings or camshaft or
reversing the camshaft extension.

2.5.6

BI006008

Remove he cast cover. Remove both seal plates, the cam follower bracket, and the four
bolts whi h secure the internal switch to the cast box. Remove the internal switch from the
box.
Remove tree bolts holding flange on shaft extension side of switch. After removing the filler
strips, 10 sen the thrust collars on each end of the shaft and slide them inward along the
shaft. Lift ntire cam shaft assembly up and out of the switch frame.
After repla ing parts as required, reassemble the filler strips and the three bolts holding the
flange.
Reinstall t e internal switch into the cast box with the shaft extension protruding from the
desired s de and tighten the four mounting bolts which secure the switch to the box.
Reinstall t e seal plates.
Visually c ter the shaft in the seal plate hole and tighten the internal flange. Reassemble
and tight n the cam follower bracket. Measure for proper shaft-extension length and
position, a d tighten the thrust collars.
The final s ep in the reassembly procedure is to reset the desired contact sequence by
adjusting t e cam and vernier adjustment.
Note:
Mounting bracket shown in median
position. Adjust switch location as required
to meet particular mine operating conditions,
but do not allow bail equilizer sheave to
contact the boom point sheave rims.

Actuating
Lever

Dipner Handle

Hoist Limit
Switch
Shipper Sharr

Tapped
Block
800m

Centerline of
Boom

Side

01 Boom

VIEW A-A
hlmt1847.wpg

HOIST LIMITS

2.5.7

BI006008

2.5.8

BI006008

Book #1
Section

Standards for Electrical Installation


Part No. 140G1 Rev.C

2243-I.M61

BI006008

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DC. NO

The erection contractor shall personally, or through an


authorized and competent representative, constantly supervise
the work from beginning to completion and final acceptance.
So far as practical, he shall keep the same Foreman and workmen
throughou~ the project.

Erection contractors are expected to use competent electricians


and sufficient supervision tv insure adequate performance of
the work. All work shall be subject to the inspection and
approval of the D.n. erection advisor whose judgment shall
be considered Final. Work which, in his ~pinion, does no~
meet these standards and the intent of the drawings, shall be
brought into conformity by the erection contractor without
additional compensation.

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In addition to ~eing properly Functional from both an electrical


and mechanical standpoint, proper attention is to be given to
the appearance of the installation.

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ANGLES

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0.000
0.0000

OTHERwtSE SPf;OFIEO THtS SHEET ONLY

lJ\..EFUNCS UNLESS +

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The ~.n.erection advisor has the authority to call for extra


fastenings where he deems it desirable. All departures from
drawings m~st be ap~roved by him prior to actual performance
of the work.

Graphical representation of conduit a~d cable routes and


fastening methods is to be regarded as illustrative and
typIcal. Where function or appearance may be improved by
additional Fastenings or modified routes, such departure
from the drawings is permissible. Extra lnst~l latlon hardware has been included in the material 3uppl ied for this purpose. B'ds and e~timates should be based on the assumption
that all the material 1 isted will be used

All conduit and cable shall be securely Fastened to the


sc!pporting structure. The maximum distance between supports
shall not exceed four feet.

Installation of Conduit and Armored Coble

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n~o

Welds shall be neat in appearance and of adequate strength


for the purpose. The electrical erection contractor shall
secure permission from the ~.r1. erection advisor before
welding structural load bearing surfaces. (In certain c&ses
~ field welding is permitted on load ca,'rying boom members).

cut in structural and mechanical members are to


be done in the manner specified on the drawings or in
the absence of specific information on the drawings, in
the manner directed by the D.n. erection advisor.
Holes shall be nO larger than necessary for the purpose
and cut in a neat manner. Edges shall be ground smooth
to minimize stress concentration inload bearing parts
and to improve appearance in oth~r locations.
'

H~:es

The intent of the drawings and these standards is to


describe a complete a~d worka~le electrical system.
All item~ which are not speciFically mentioned in these
standards or noted in the dr .
.
.
essary to ma e a complete and working installation,shal
be included.
Cuttinq and Patching

These standards supplement the graphical presentation in


the drawings. They describe, in particular, the qual ity
desired in the installation. The work of the electrical
erection organi~ation is expected to conForm to both the
drawings and these standards. It is recoGnized th~t th~
ielll erection organization whether this be the ultimate owner or a contractor or subcontractor is normally
not in the direct employ of D.M.
The work of electrical
erection contractors, subcontractors and/or employees of
the ultimate owner dF the excavator must meet
standards as interpreted by the D.M.
erection advisor
on the site. Failure to comply shall be cause For voiding
the machine warranty.
era ftmansh i p

The wiring and electrical equipment is to be installed in


a manner consistent with the best excavator wiring practice.
Electrical systems installed aboard an excavator are subject
to more severe operating conditions than the usual installation
in II Fixed industrial structure or building. Continued and intense mechanical vibration and shock require special attention
to support and mechanical security.

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Complete System Inferred

STANDARDS FOR ELECTRICAL INSTALLATION

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Covers shall be replaced on all junction boxes promptly


after work is completed to exclude water and dirt.

All splices and connections in conductors shall be lugged


an.i bolted, or use two-way connectors, except where wire
nuts are specified.

Conductors and cables shall be identified with suitable


leq bands at both ends of each run. Karkings on terminal
strips shall be vith indelible aarker, yellow point, or
siailar substance resistant to oil and water.

Unless specifically called for otherwise on the drawings,


cables shall be run parallel or perpendicular to the
surfaces on which they are mounted. All cables in a bank
shall be parallel without unnecessary cross overs. Bends
shall be of a radius consistent with the cable size and
shall not over-stress ar.or or insulation.

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All suppl ies and ~terials necessary for the electrical work
which are expenda~'le and which are not a part of the finished
excavator are to be supplied by the electrical erection contractor.

.N.

All materials to be used in the construction of the machine and


which will remain in place on the machi,.e after completion are
to be supplied by
In the event of shorta~e, said shortage shall be reported to the D.N. erection adVIsor who will
determine if shortage should be remedied by local procurement
or shipment from D.N. factory.

ihe electrical erection contractor is ex~ected to provide and


maintain such tools as are necessary to the efficient conduct
of this work.

The electrical erection contractor shall ~operate with the


other contractors and install at the ~irection of the Harion
erect,on advisor, such temporary wiring as may be requ:red
for lighting and power during the erection period. He shall
remove same at the end of the job anG from time to time mo~ify
his original installation at the direction of the D.N.
erection advisor.

The electrical erection contractor shall be responsible for


the proper storage and protection of all electrical equipment .
as it arrives at the job site. He shall provide such temporary
wiring and temporary heat as may be required to protect the
equipment from water damage and condensation.

The electrical erection contractor shal I clean up after his


work and assist in keeping the premises neat, clean and orderly.

The electrical erection contractor shall be responsible for


the ~afety of his crew and shall conduct his work in such a
manner as not to endanger others. He shall cooperate in
safety programs and regulations for the project as a whole.

The electrical erection contractor is expected to cooperate


in all respects with the other erection contractors at the
site and coordinate his wcrk with the work of others.
In
cases of confl ict, the D.M.
erection ~dvi~or ~. t~ ,
sna! I resolve such conTTTCt tOr the good of the job as a
whole and so advise the parties. His decision shall be final.

Armored cable, where installed exposed to the w~ather,


shall be jacketed to insure shedding water.
Proper
attention sh~ll be given to drip loops. At terminations,
~
a proper connector shall be used to prevent the e~trance ~

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Conduct of the Work

Installation of Conduit and ;\Onored Cable

STANDARDS FOR ELECTRICAL INSTALLATION

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NUMP,'E.:RS A.Rt=."TO
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WHEN NECESSARY , 0 AVOID

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tie wrap at leaH ev~ry /,,,

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securely and terminate


Leg band wir~ and c.. ble identifiCation

STANDARDS FOR ELECTRICAL !NSTALLATION

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BI006008

BI006008

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Cut with stripping tool

Pencil with knife

TlIke ~re not to nick conductor

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IN PLATE

WHERE. POSSIBLE

I '-TERMINATE

(ONNECTU" TO HAVE IHSULATE:.D


THMAr lJ~ BU5HIHb Tt>
rROTCT WIRES.
P~epllre us inl) CA) (8)
T~pe if requIred

PLACE CLAMP IMMEDIATELY


NEXT TO CONNECTOR WHEN
CONNECTOR IS NOT TERMINATED
IN PLATE OR THREADED OPEN IN G

WHERE ~
PRACT I CAL

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STANDARDS FOR ELECTRICAL INSTALLATION

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MARK>N POW'ER SHOVEL DIVISION

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2SKV

ISKV

8KV

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T(Ft\IINAl LUG 8 A A R E L n
O'l nPOSED CONOUCTOA

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B I

00 NOT USE

.
SKV

VOL TAGE

using ~brasjye

"REDUCED DIMENSION"

*The minimum A oimension, A (min.),may be used


in a clean, dry location only, such as an
enclosed terminal box where reduced tracking
protection is acceptable.

25
2SKV

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ISKV

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115

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"CONVENT IaNAL" Y.I T


Val TAGE I A I 06+

TABLE I.

CABLE PREPARATION DIMENSIONS (in.)

SKV
I

PROCEDURES

L Train cable into position and cut to proper length.


2. Thoroughly clean cable jacket thre-e inches beyond dimension
cloth 'rom "SCOTCH" Brand Cabl. Proparalion Kit.

A. PREPARE CABLE

TERMIN~TION

FOR ELECTRICAL INSTALLATION

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c.oa ... a..u.. ...

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iiiiLW-- JAlt_5 1990

C)

type terminations

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s an exact instruction procedure to be


nHalling 3M-K Tape Termination Kits
gh vol tage cables.
Instruct ions appear
the "conventional" and "reduced dimen-

type terminations require additional tape and should


be reserved for those situations where insufficient
space makes it oesirable to use them. Note that the
dimension chan (Table I) reflects both the "conventional" and "reduced dimension" rorms.
Table 2 lists
the additional tape required to convert a "convention"'" kit to a "reduced dimension" kit for a given
type and size cable.

sion"

The following
followed when
on shielded. h
below for both

INSTALLATION TECHNIQUES FOR HIGH VOLTAGE TERMINATIONS

STANDARDS

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Wrao around stUD around cable shieldi"a and burl uo aQainst th~ "doe of the iacket.
Inst'rt the tongue into the slOl and snug up like a belt. Bend the longue back and cut
011 excen. lSee Fig. 31

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Rrmove c.>ble ~mi<onductive mat.,.;"I. tuY;ng 1/4" upow<! ~ond mrtaJlic


shielding. DO NOT CUT INTO CABLE INSULATION. THOROUGHLY CLEAN
ALL EXPOSED INSULATION WITH CLEAN ABRASIVE CLOTH.
2. Remove cable in",lation from end of conductor for 1 n" plus depth of t~rminal lug
barrel or lengt!>
ex~ conductor requ;red. DO NOT NICK CONDUCTOR.
(~ Fig. 41
1.

C. REMOVE SEMI-CONDUCTIVE MATERIAL AND CABLE INSULATION

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1. RrrTlOW ablr jackrl and non-mOl. Hie 'ill.,. l.p< (if p~ll
minimum dtst.ncr
01 ~ pI", ~lh of lrrmin.1 J~ bar",1 or I~h Of uposood conduclor rrQUl
cr.. ld drlrrmi~l. CAUTION; DO NOT CUT INTO METALLIC SHIELDING.
2. T.~ ablr jackel smoolhly 'or 1/4 inch. (~ Fig. 2) Smooth ~ with a~ive
dOlh.
J. RrmoYe cable" mptallic shirlding Iraving 1" .. posood ~ond cable jacket. 00 NOT
NICK SEMICONDUCTIVE MATERIAL (II wire shirlding is u~."" instruclions
below in Fig. 2A.I

'M

STANDARDS FOR ELECTRICAL INSTALLATION

B. REMOVE JACKET METALLIC SHIELD AND APPLY GROUND STRAP

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scutPi

-:-"" ._ ..-.--" .... ----~---------. - _... -~

=::'=:-:::::'::::-=-:'-=::,="IIU.-:=:'-:=""-:-:

_NOTE

FIG. ,

_..

'

.. _..

lItton lor

dlsta~

3.

2.

1.

~St::zJtPI ST"~S

COHTIIO'..

T"~(

0Yft"
COr>-

.-

.3TDS FO ~ FIL D F. CT

""'-

procede to the appropriate steps below in


accordance with the type termination being made.

%220

~I

-------...

[--81.....,.7DTIO

~ .1

T
--/AOGI

Ofl).

Wrap one half.'.pped layer of No. 23 Tape for 2" along the ~ble j8Ck .... starting n
point where ground nrap is attached to cable metallic shielding. Wrap Dn1! ~If
lapped layer of No. 23 Tape 2" along grounding wi,.. bend wire back .Iong j.ck'"
for 1", then bend away from cable. l~ Fill- 8)

TAPING HINT: Highly elon9"te the No.?3 Tape to form a moistul?-ti9ht ...1.

Ti9htly halflap "SCOTCHH Brand 110. 23 Hi9h Voltage Splicing T.pe @


Hpencil H ar>d oemi-condueting tape. lnClending onto termiNlI I~ or ~xpolled
ductor se.'... nd build up to 1eY'ef of c.bIe insu!.!"1ion.

FIG. 7

~~

the tape b.>ck on itself. endin1at the gtound strzp.

G. APPLY OUTER JACKET

.-

~ond No. 13 Tape. (~ Fig. 7) Lef'e an ..",n (ront edge and continue to half.lap

1. Storting at the edge of the ground st"'P. app;y "SCOTCH" Brand No. :'220 Str=
Control Tape OS liner side 10ward cable. remO'Ying liner as ta~ is applied. Stre-te"

.----.,=.tc=-.-----.-==~-=-~----:-

TAPING HINT: Highly elongate the


13 Tape throughout tl>e entire dinance.
CAUTION: DO NOT WRAP NO. 13 TAPE MORE THAN 1/4" ONTO T~E
CABLE INSULATION.
2. 'f term ina' lug ;, u~. fill any indenu on lug wilh small pieces 01 No. 13 Tape.
L""el wind No. 13 Tape from 1/16" on edge of "pencil" onto lug to lorm smooth
concentric buildup as shown. (~ FiO. 6) II no terminal lug is used. halllap one
tayer 01 No. 13 Tape from 1/16" on edge of "pencil" onto conductor seal.

CD

:;;;':::;0"::'~====-=::.":'==.:.

two

half.tapped layers of "SCOTCH" Brand No. 13 SemiConducting Tape


1/." ~ond t"'e cable semi-eonductive material. (~ Fill- 6) Begin and end
taping at front edge of gr""nd nr Jp. L-ave an ""en Iront edge.

1. Wrap

E. APPLY SEMI-eONDUCTING TAPE

~..... ~AN - 5199u-

c::.

"'"

;r: ...

t.

.j,

-t>

C
~ ~

~I

~:I

.J

.. - 1
'. If J

Pencil insulation :or distance ~ . (Sre Fig. SI Burt t3~t with a cle,:,n abrasive cloth
from SCOTCH' Cable Prep;;:a"tion Kit SO no voids will remain .. fler terminat;o' is
insulated.
'0 conductor end or attach c1vsed m~haniut lug. Use crimptynt lug wirh
lhc!"moplastic insula:Pd ca~les. Follow cc..nnecror manufacrurers rlirt'CrinrlS. U~
.Hili-oxidant pastt for aluminum concktctors.. If solder sW'tated lug is used. prote-ct
ca~:e insulation with lemporary wraps of conon lape. CAUTIOI':: BE SURE TO
REMOVE ALL AI"TIOXIDANT PASTE FROM LUG AREA AFTER CRIMPmG
ALUMINUM LUGS. DO f..:OT USE ACID CORE SOLDER OR ACID FLUX.
Clean enlire area of pre"arec ca~le insulation t-y wiping with a Y.llvenlsaturared
cloth from "SCOTCH" Cable p,.paration Kit. After solvent is u>ed on insulation.
area must be absolulely dry and free or ail solvent res;due.

~~~

3.

1.

F. APPLY STRESS CONTROL TAPE

FOR ELECTRICAL INSTALLATION

D. PE:\:CI:" INSULATION. SEAL CONDUC,OR EI'\D AND CLEAN pnEPARED CABLE

STANDARDS

BI006008

BI006008

--

'"
()

I)

())

'1

(~

\
0_~.

~_z'J

SKV to 'SKY
"REDUCED DIMENSION"

tL...sJ99D

----~

.-.~---.

_..

---_

---....,-

.....
--..-.-..-..
_-...-.-.......-:-------....... ......
-.---..
--..
....
.,...._
......... -.- .......

~---.-.-.-.

_OCT!

_ooeo

----

_..
roo'

.__ o.-,--:---:.:.,.~
..,.:

DAeSI2R INIDUS'TM:S. INC.

MARION POWER 8HOYEL DMSK>H

WC3P one hall.lapped byer of '"SCOTCH" Brand No. 33+ Vinly Plaotic Electrical
Tape @ over splicing tape, extending jllSt onto th. cable jock.t and onto the conduelor lug or exposed conductor seal. (See Fig. 8)

2.

Build up No. 23 Tape to I thickness of 3116" be?nning two inC~ on cable jacket
~t;re termination overlapping onto No. 23

as shown IFig. 81 and continuing over


Tape in pencil area.

OUTER JACKET COMPLETION

.....

,.

.......
........
.........
.... --

H.

t".

ex~ conductor

2. Wrap Ot>e ~fll~ IWYef" of '"SCOTCH" BC3nd No. 33' Vinyl P1xtic Electrical
Tlpe @ ~r sp!;cing tape. exttnding from 1" onto cable jocketto termi.... log or

I Build up No. 23 Tope to I thickness of 3116", beginning two inches onto cable
jocket. IS sh<>wn. and ending one inch beyond streu tape on cable insulatiotL

OUTER JACKET COMPLETION

Fig. 8

H.

&

"CONVENTIONAL"

SKV to 2SKV

'

::-."

--

(!) _ _ ,;,

K TAPE TERMINA-

~~
I

,.

ro~

_----'

FILD V.ECT
.-".,......,---~
... '--~--~'

ST.D5

FIG. ,

06. . . . . ......

~~SCutdJ in

~-. . . . . . .

-.

...

I>~...-... : . : . : ..~. . . . . .

.....

I'

~.

~l("

~.~,--... _-~---~,_.

BI_... 8oFIO

--J~OGI

TAPING HINT: Apply No. 70 Tape with mode...te tension. For upright tenn;tations. begin at cable jocket and end It lug. For inverted tenninations. end taping It
cabl. jacket.

final overwrap of Silicone Tape during installation.


2. Overwrap end "'al with at leM! four layers of '"SCOTCH" Brand No. 70 Silicone
Rubber Tape.
NOTE: INNER LAYERS MAY BE HIGHLY STRETCHED.
3. Overwrap ENTI RE termination with ant ~dition.1 "alf.lappe<! layer of No. 70
Tlpe. CAUTION: BE SURE TO COVER EXPOSED VINYL TAPE COMPLETELY.
(See Fig. 9)

1. If possible. conMf'Cl tennination to final position. If not, take care not to dam"9'!

APPLY TRACKING PROTECTION (An REDUCED DIMENSION


TIONS MUST be overwrapped with trd resist..,t No. 70 bpe.)

,:",.. r~.~
~ ..

I.

_'u

".
n~.
t:_-3~~

TAPING HINT: Apply No. 70 Tape with modorato tension. For upright termi""1
tions,. begin It cable jacket Ind end at lug. For inverted terminations. end taping It
uble Jacket.

Tape. CAUTION: BE SURE TO COVER EXPOSED VINYL TAPE COMPLETELY.


(See Fig. 9)

3. Overwrap ENTI RE termination with one additional half.lappe<! ".Yer of No. 70

2. Ovorwnp ond ..al with at loast four I.yer. of "S::OTCH" Brand No. 70 Silicone
Rubber Ta~ (6) . NOTE: INNER LAYERS MAY BE H

final overwrap of Silicone Tape during installation.

1. If poS1ib1e. eonne-ct termination to finar position. If not. tak~ care not to damage

I. FOR TRACKING PROTECTION

STANDARDS FOR ELECTRICAL INSTALLATION

BI006008

BI006008

I
2

I
1
I

1
1
1

~.;,.-

t)

.... ,

::...-;:-...::-:.-::;-~

1720MILSI
INSULATION
THICKNESS

CABLE

XLP, POLY
EPR
INSULATED

KV
UNG

15

'7~;;-

- .-.

, -

1"1

2
2

'j

,
2

., - ".

.......

- - -------- MARK)N
POWER SHOVEl. DfYISK)H
.''f!i~I....
,.;-: c:; ! -:-=~-:.::.::-~--.:.::;.=.::--=
_.......-... ...--.a..... :lAI!SSI!lUIDUSTRES, INC.
~~. ~Jitt._ 5 1990
..--. -:--..--~ "---'-'-"'U' _.-'

'000

C)

7SO

tIM'IiON.OMO

6SO
7
0 0 '1

500
SSO
600

OSO

400

350

~:;

2 .
7

1
'_

'(I';""

--1.

2/0
liP

70

Scot~~

iii

~.-..

ScotFli 23

I.LO

~.

CONDUCTOR SIZE

1000

aoo

7!>O

600
650
700

,
1
I
I
1

COO
450
500

2
, X L P , POLY
2
EPR
2
INSULATED
2
CABLE
2
(175 MILSI
,INSULATION
2
THICKNESS

~""oo:>n

5702

5701

15
KV
GRD

r-

,.

Sc:ot!=.t! 70

JSO

r--

,-

)00

j-

0/0

3To---

800

.......

THICKNESS

CABLE
11SO .. ILSI
INSULATION

XLP, POLY
EPR
INSULATED

UNG

8
KV
GRD
&

KIT NUMBER

I
57p2

210--

900

tl'

I
I

5701

2----

-0-0-0-

Sc:ot~.h 23

I/O

I
I
I
1

"'~M

REOUIRED (ROLLS)

ADDlTlONAL MATERIALS

I
I

Anu un.

CONDUCTOR SIZE

AOOITIONAL MAT'L. REdD. FOR

')IMENSION"'KIT

TAB LE 2.

~5~

S'

";W

tJt.11

.r'

~1;

'~J

.~

'.' ~

.-

XLP, POl.Y
EPI;
INSULATED
CABLE
190MILSI
INSULATION
THICKNESS

UNG

&

KV
GRD

KIT NUMBER

"K" TAPE

"RcL>UCED

FOR fIELD fJ~cr

'0')0

800

.7SO

700

000
OSO
500
SSO
600
650

JSO

3aO

3/G
0/0
250

210

---

2
2

1
1
1

1
1

1
1

"7

BJ..-rttIICI

,J

10
OF

11..-

.,. -- ~ ......-----.

...

I~ .1

--r . . OGI

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
7

1
I

1
1

Scot;.li 70

Sc:ot!=li 23
I

lLO

2
2
2
2
2
2

CONDUCTOR SIZE

1
1

1
1
1

2
2

2
I
I

2
2

2
2
2
2
2
7

Seot.eli 70

1
I
I
1
I

1
1

Seot.eli 23

900
1000

800

70
7SO

6so

050
500
.SSO
600

JSO
400

300

25;)

-'/0

3/0

210

1
I/O

CONDUCTOR SIZE

,-==""--=~.,.__ .--:-._~:----

.jTJ)S

5702

KIT NUMBER

5702

I
5701

KIT NUMBER

STANDARDS FOR ELECTRICAL INSTALLATION

BI006008

BI006008

2SKV

115704

to 750MCM

1000MC~

~........

;::=.:.
.':=
....

f2AWG to 10COMCM

8HOVB.. DrVISk)N

8CCMCM to 1.000MCM

2~OMC/'1

1S0MCM to

"BAWG to ',4/0

Wire Size

:-,-:-..=::=.::.::-._ ...-..- _IIU~

==~_::=::._:_..E?_
..-u. _..

~ ONO

- ~--:._- ~:C -

DfESl2RIllDUmU!S,INC.

~I~

.-- /i.?;g~\~;.,;::~ i~~;;-- ._--~~_.~-~~--="""===....._--

I sr1JS FOR FIELD f/?CT

-I--------=====-------r--------------r.:=---------------,=:---------------T.:::;-:=----,=:-;--:--:-:---1
.. _ _ "':::::::=: _
MARION POWER
-of..
--

fi)

ISKV

ISKV

8KV

SKY

15KV

SKV

SKY

Vol-tage
Ra t i"g

Cable Type and Range

Usc this table to determine the proper


kit appl iealion.

115703

RS702

#S701

Kit
No.

TABLE 3.

~--=:-~}~~-::5_199D_." _. ._ .. ,"'====.. ,- --

.;,:~
:' ~

:;

, '"

i: ~~

~.!

."

I~

II

i
i

STANDARDS FOR ELECTRICAL INSTALLATION

BI006008

BI006008

BI006008

Book #1
Section

Cable PUlling Schedule


Part No. 211945-5 Rev.A

2243-I.M61

BI006008

R.L.

u:

,jj
-'

;!
~

CD

DATE

~ mflrU~N

moo s- APi; s.4. / -

2'1

DESCRIPTION OF REVISIONS, ADDITIONS AND CANCELLATIONS

1119-97 ADD 6[.

DRAWN

OWZ

D.C. NO.

500 Z6

tiS

.:

-rhls drawing rep-asents proprietary


and confldentlallnforma1fon and Is the
eXduslve propeny of THE MARION
POWER SHOVEL COMPANY (MPS)
and has been developed at substantial
expense. Therefore, neither the drawing
nor Its contents are 10 be used,
reproduced, or dlsdosed, In whole or In
part, wl1hout the prior, expressed wrlt1en
permission of MPS, and this drawing
and all cop/esollt shall be re1umed
to MPS on Its demand"

IMPORTANT NOTE

c?

I.
rl?Q ISHE~TNo ~
ELB

?11QL1I:;-1;

BARLOW

I CHECK BY

PULLING SCHEDULE

IDRWNO

I DRAWN BY

~IIIID;w45G

DATE DRAWN

DESCRIPTIONCABLE

Marion, Ohio

The Marion Power Shovel Company

::J

CABLE PULLING SCHEDULE


182M MINING SHOVEL
KEY 18247-48
OAL INDIA

BI006008

BI006008

THIS COLUMN LISTS THE TOTAL NUMBER OF INDIVIDUAL CONDUCTORS INVOLVED IN THE SUBJECT CABLE RUN.

THIS COLUMN LISTS THE SIZE OF THE WIRE TO BE USED BASED ON THE STANDARD AWG (AMERICAN WIRE GAUGE) SIZE.

THIS COLUMN LISTS THE TYPE OF CABLE TO BE USED. REFER TO THE LEGEND FOR AN EXPLANATION OF THE SYMBOLS USED. THE CABLE
JACKET AND CONDUCTOR INSULATION TYPES ARE BASED ON MPSD STANDARDS. NO SUBSTITUTES ARE TO BE USED WITHOUT WRITTEN PERMISSION FROM MPSD ENGINEERING.

THIS COLUMN LISTS THE VOLTAGE


BEFORE INSTALLATION.

THESE COLUMNS LIST THE INDIVIDUAL CONDUCTOR DESIGNATIONS, SINGLE THRU TRIPLE ARE USED. UP TO NINETYNINE(99) DESIGNATIONS
MAY BE LISTED PER CABLE IN ROWS OF SIX(6) , SEPARATED BY A SPACE. ALL SPARES ARE INDICATED BY THE WORD "SPARE". SOME
DESIGNATIONS WILL APPEAR WITH THE SYMBOLS "$", ">", OR "<,, WHICH INDICATE SPECIAL TERMINATION INSTRUCTIONS EXPLAINED IN
114BA14Z*
(F1)
THE LEGEND. MANY CONDUCTORS APPEAR WITH THE TRIPLE DESIGNATIONS, E.G. 11:2AB27G OR 5J15HA. THE TOP IDENTIFICATION ALWAYS
110TA37Q*
(F2)
INDICATES THE TERMINAL NOMENCLATURE FOUND AT THE "FROM" DESIGNATION DEVICE(IE. 114BA14Z* AND (F1. THE BOTTOM IDENTIFICATION REPRESENTS THE TERMINAL NOMENCLATURE AT THE "TO" DESIGNATION DEVICE(IE. 110TA37Q* AND (F2. THE DESIGNATION THAT
APPEARS SURROUNDED BY BRACKETS OR FOLLOWED BY AN ASTERISK(*), AS 110TA37Q*,
(F1), AND
(F2)
IN THE ABOVE EXAMPLES,
REPRESENTS CONNECTION INFORMATION ONLY. THE MIDDLE NUMBER REPRESENTS THE CONDUCTOR IDENTIFICATION, AND IS TO BE USED TO
LABEL THE WIRE AT EACH END. WHEN A DOUBLE DESIGNATION IS USED, THEN THE IDENTIFIED CONDUCTOR IS WITHOUT THE BRACKETS
OR ASTERISK AND IS USED IN LABELING. ALL CABLES AND CONDUCTORS ARE TO BE PROPERLY IDENTIFIED AND ALL CONNECTIONS VERIFIED
AT ASSEMBLY. CONDUCTOR IDENTIFICATION FOLLOWED BY A # INDICATES FORMER WIRE LABEL. (EX. - 14BC13C#)

10
THRU
15

The Marion Power Shovel Co.

RWNO

?11 QAJ:_I:

SHOULD BE CONFIRMED AT ASSEMBLY

THIS COLUMN LISTS THE TOTAL LENGTH OF WIRE OR CABLE REQUIRED FOR THE SUBJECT CABLE RUN. THIS NUMBER IS FOR ESTIMATING
PURPOSES ONLY, AND SHOULD NOT BE USED TO DETERMINE PRE-CUT CABLE LENGTHS AT INSTALLATION. EXACT CABLE LENGTHS USED AT
INSTALLATION SHOULD BE DETERMINED AT ASSEMBLY.

THESE RATINGS

THESE COLUMNS LIST THE "FROM" AND "TO" DESTINATIONS FOR CABLE ROUTING.

3, 4

INSULATION USED.

THE SECOND COLUMN LISTS A NUMBER THAT REFERS TO SPECIAL INSTRUCTION NOTES WHICH APPLY TO THE SUBJECT CABLE. ALL NOTES
ARE PRINTED IN NUMERICAL ORDER ON THE LAST SHEET(S) OF THIS DOCUMENT.
NOTE: ONLY THOSE NOTES WHICH APPLY TO THE
SUBJECT MACHINE ARE PRINTED.

:2

RATING OF THE CONDUCTOR

THE FIRST COLUMN IDENTIFIES THE CABLE OR CONDUIT NUMBER OR DESIGNATION. THE SYMBOLS USED TO MAKE-UP THESE ALPHANUMERIC
[SEE THE LEGEND FOR AN EXPLANATION OF THE ALPHA
NUMBERS INDICATE DRIVE NUMBER AND THE TYPE OR DEVICE BEING SERVED.
SYMBOLS USED.] THE FIRST SET OF NUMERIC DIGITS RELATE THE CABLE TO A PARTICULAR DRIVE NUMBER. MAJOR DRIVES ARE SEPARATED
BY HEADINGS WHICH RELATE TO MAJOR AREAS SERVED. THE INSTALLER SHALL APPROPRIATELY MARK ALL CABLES USING THESE
DESIGNATIONS.

EXPLANATION

18247-48
COAL INDIA

COLUMN

CUSTOMER:

MACHINE KEY:

THIS DOCUMENT CONTAINS ALL INFORMATION NECESSARY TO COMPLETE MACHINE CABLE AND CONDUIT
ROUTINGS AND TERMINATIONS FOR THE SUBJECT MACHINE. THIS SCHEDULE IS UNIQUE TO THE MACHINE
LISTED ON THE COVER SHEET AND REFERENCED IN THE UPPER RIGHT-HAND CORNER OF EACH GROUP SHEET.
THE COVER SHEET ALSO REFERENCES THE MAJOR WIRING GROUP, OR KEY, SUPPORTED BY THIS SCHEDULE.
EXPLANATION OF EACH COLUMN OF THE ATTACHED SCHEDULE FOLT.nw9

INS T R U C T ION S

CABLE PULLING SCHEDULE

WHE~NO

BI006008

BI006008

CUSTOMER:

MACHINE KEY:

18247-48
COAL INDIA

ARMATURE AND SERIES FIELD

CURRENT FEED BACK

MOTOR OR GENERATOR SHUNT FIELD

FEEDER

HEATER

LIGHTING

LIMIT SWITCH

METERING AND TEST PANEL

MASTER SWITCH

PANEL TO PANEL

PRESSURE SWITCH

RESISTOR. RHEOSTAT OR POTENTIOMETER

SPARE

TELEPHONE SYSTEM

VOLTAGE FEEDBACK

SPECIAL OR MISCELLANEOUS

SOLENOID OR MAGNET VALUE

CF

FR

LS

MS

PS

TS

VF

CABLE NUMBER NOMENCLATURE

I.

SYMBOL

TYPE MC SINGLE AND MULTI-CONDUCTOR ARMORED CABLE.

RWNO

~11 QLl:_J:

NEC TYPE XHHW WIRE. SINGLE CONDUCTOR. STRANDED. INSULATED WITH CROSSLINKED
SYNTHETIC POLYMER.

XHW

The Marion Power Shovel Co.

TWISTED. SHIELDED AND JACKETED LOW VOLTAGE MULTI-CONDUCTOR CABLE.


NEC TYPE THWN SINGLE CONDUCTOR. STRANDED. HEAT AND MOISTURE RESISTANT
THERMOPLASTIC INSULATION WIRE WITH NYLON JACKET.

TWN

NEC TYPE THW SINGLE CONDUCTOR. STRANDED. HEAT AND MOISTURE RESISTANT
THERMOPLASTIC INSULATION WIRE.

UL & CSA LISTED SINGLE CONDUCTOR TYPE AWM-TEW 105 -C VINYL PLASTIC
INSULATION. FLEXIBLE STRANDING

SHIELDED AND JACKETED LOW VOLTAGE MULTI-CONDUCTOR CABLE.

MULTI-CONDUCTOR SHIELDED. ARMORED & PVC JACKETED CABLE.

NEC TYPE SA SINGLE CONDUCTOR SILICONE RUBBER INSULATED HIGH TEMP. WIRE

NON-SHIELDED SINGLE CONDUCTOR HIGH-VOLTAGE INSULATED WIRE.

MACHINE TOOL WIRE.

NEC TYPE MC SINGLE AND MULTI-CONDUCTOR PVC JACKETED. ARMORED CABLE.

NEC

TSH

THW

TEW

SH

SAJ

SA

MV

MTW

AJ

CABLE JACKET AND CONDUCTOR INSULATION TYPES

A CONDUCTOR DESIGNATION(S) FOLLOWED BY THIS SYMBOL INDICATES THE INFORMATION


OR INSTRUCTIONS GIVEN IN THE "NOTE" LISTED FOR THE SUBJECT CABLE APPLY ONLY
TO THESE CONDUCTORS.

>

III.

A CONDUCTOR DESIGNATION FOLLOWED BY THIS SYMBOL INDICATES THE CONDUCTOR IS


TO BE CONNECTED TO A NORMALLY OPEN (N.O.) CONTACT

A CONDUCTOR DESIGNATION FOLLOWED BY THIS SYMBOL INDICATES THE CONDUCTOR IS


TO BE CONNECTED TO A NORMALLY CLOSED (N.C.) CONTACT

CONDUCTOR DESIGNATIONS

DESCRIPTION

<

II.

::JIMJ:lvL

A BRIEF DESCRIPTION OF THE SYMBOLES AND ABBREVIATIONS USED THROUGHOUT THIS DOCUMENT ARE LISTED BELOW. THE CABLE JACKET AND
CONDUCTOR DESCRIPTIONS LISTED ARE BASED ON NEC TERMINOLOGY TO AID THE INSTALLER IN IDENTIFYING THE CORRECT WIRE OR CABLE. FOR
EXACT CABLE OR WIRE SPECIFICATIONS REFER TO THE APPROPRIATE ITEM ON THE MATERIAL LIST SHEET OF THE REFERENCE GROUP.

LEG END

CABLE PULLING SCHEDULE

II

SHE:'NO

BI006008

BI006008

TITLE

TITLE

26 - DIG-PROPEL CABINET

The Marion Power Shovel Co.

28 - LIGHTING

10 - HV COLLECTOR RINGS

28

D.C. CABINET

16 - HOIST MOTOR

HOIST GENERATOR

15 - CROWD GENERATOR

8 - BOOM WIRING
14

22 - HOIST CABLE WINCH

BOOM J.B.

RWNO

211945-~

18 - SWING MOTOR #2

17 - SWING MOTOR #1

14 - SWING GENERATOR

28 - RESISTORS

OPERATORS CAB

19

22

12

12 - AUXILIARY TRANSFORMER

H.V. CABINET

27 - MOTOR CONTROL CENTER

9 AUTO-LUBE
13 - GROUND FAULT CNTRL PANEL

13 . M.G. SET DRIVE MOTOR

TITLE

10 - AUX COLLECTOR RINGS

BXC. & P.S. TRANSFORMERS

5 - LOWER FRAME

SHEET
NO.

COAL INDIA

18247-48

24 . MISC.

:.ll

17 - DIPPER TRIP MOTOR

SHEET
NO.

CUSTOMER:

MACHINE KEY:

20 . FILTER FANS

20 AIR COMPRESSOR

24

SHEET
NO.

I N D E X

CABLE PULLING SCHEDULE

WHE~NO

BI006008

BI006008

DESTINATION
FROM

COLLECTOR RING
J.B.

H.V. COLLECTORS
(L.H. )

R.H. PROP. MTR.


(#2)

L.F. DISCONNECT
SWITCH

H.V. COLLECTORS
L.H.

L.H. PROP. MTR.


(#1) BLWR MTR.

R.H. PROP. MTR.


(#2) BLWR MTR.

1F2

1FR1

1FR2

1FRll

1FR21

#12

#12

#1

#1

#6

#6

AJ

AJ

MV

MV

AJ

AJ

T1*
12E37X
R*
T1*
12E45X
R*

600V

1*
HL1
l*R

A*
HL1
l*BK

F2*
PM2F2
PM1F1*R

F2*
PMFP
5*R

600V

8KV

8KV

600V

600V

A2*
PM2A2
4*BK

A1*
PM2A1
3*BK

600V

600V

A2*
PM1A2
2*BK

A1*
PM1A1
l*BK

600V

600V

T2*
12E47X
BK*

T2*
12E39X
BK*

2*
HL2
2*BK

B*
HL2
2*BK

F1*
PMFN
6*BL

F1*
PM1F1
PM2F2*BL

T3*
12E49X
BL*

T3*
12E41X
BL*

3*
HL3
3*BL

c*
HL3
3*BK

SPARE
BK

18247-48
COAL INDIA

IDRWNO

#12
BARE
GND

#12
BARE
GND

GRN
GND

2X#6

#8
BARE
SPARE

#8
BARE
SPARE

211 Ql1.l:;_1;

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE
BK

CON D U C TOR

The Marion Power Shovel Co.

R.H. PROP. MTR.


(#2) BLWR. SW.

L.H. PROP. MTR.


(#1) BLWR. SW.

H.V. COLLECTORS
R.H.

COLLECTOR RING
J.B.

L.H. PROP. MTR.


(#1)

AJ

1F1

350
MCM

COLLECTOR RING
J.B.

R.H. PROP. MTR.


(#2)

1A22

AJ

AJ

AJ

350
MCM

COLLECTOR RING
J.B.

R.H. PROP. MTR.


(#2)

1A21

350
MCM

COLLECTOR RING
J.B.

L.H. PROP. MTR.


(#1)

1A12

!Iel~

350

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

DESTINATION
TO

COLLECTOR RING
J.B.

L.H. PROP. MTR.


(#1)

LOWER FRAME

SEE
NOTES

1All

CABLE
NUMBER

CABLE PULLING SCHEDULE

ITSHE::,NO

BI006008

BI006008

FRAME GND

FRAME GND

FRAME GND

LH PROPEL MTR
#1 BLOWER SW

R H PROPEL MTR
#2 BLOWER SW

L H PROPEL
MOTOR #1

R H PROPEL
MOTOR #2

L.F. CONTROL
J.B.

COLLECTOR RING
J.B.

L H PROPEL
MOTOR #1

R H PROPEL
MOTOR #2

L H PROPEL MTR
#1 BLOWER MTR

R H PROPEL MTR
#2 BLOWER MTR

L H PROPEL MTR
#1 BLOWER SW

R H PROPEL MTR
#2 BLOWER SW

L.F. DISC. SW.


BOX

1G3

1G4

1GS

1G6

1G7

1GB

1G9

1GC1

#12

#12

#12

#12

#12

#1

#1

#1

#1

#1

AJ

THW

THW

THW

THW

THW

THW

THW

THW

THW

600V

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE
GND

SPARE
*R

GND
GRN

GND
GRN

GND
GRN

GND
GRN

GND
GRN

GND
GRN

GND
GRN*

GND
GRN*

GRb!*

GC2
*BK

GND
GRN

GND
GRN

GND
GRN*

COAL INDIA

18247-48

RWNO

#12
BARE
SPARE

?11 011 I: r=

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE
*BL

CON D U C TOR

The Marion Power Shovel Co.

FRAME GND

H.V. COLLECTORS
R.H.

1G2

DESTINATION
TO
FRAME GND

DESTINATION
FROM

H.V. COLLECTORS
L.H.

SEE
NOTES

1G1

CABLE
NUMBER

CABLE PULLING SCHEDULE

IISHE~NO

BI006008

BI006008

L.H. AUTO LUBE


P.S.

R.H. PROPEL
BRK P.S.

R.H. AUTOLUBE
P.S.

L.H. PROP. MTR.


(1Il)&BLWR SW.

L.F. CONTROL
J.B.

1PS12

1PS21

1PS22

1X11

1X12

DESTINATION
FROM

L.H. PROPEL
BRK. P.S.

SEE
NOTES

1PS11

CABLE
NUMBER

12

12

#12

1112

#12

#12

#12

#12

AJ

AJ

AJ

AJ

AJ

AJ

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

H2*
12AS7U
lS*BL/BK

H1*
12ASSU
16*R/BK

SL18E
9*BL/BK

SPARE
*R/BK
1112
BARE

SPARE
*BK

SL22E
10*R

1112
BARE

12E39N
18*BK

14B30N
BK*

SL18J
BK*

14B30N
BK*

SL18J
BK*

12E37N
17*R

14B30L
R*

SPARE
R*

14B30L
R*

SPARE
R*

14B30N
14*OR/BK

SK04P
12*BL

P1*
SL37E
11 *OR/BK

12E41N
19*BL

SPARE
BL*

SK04P
BL*

SPARE
BL*

ElL"

RWNO

GC2
22*Y/BK

14B30L
13*OR

P2*
SL37J
Y/BK*

12ES1C
20*OR

#12
BARE
GND

#12
BARE
GND

#12
BARE
GND

#12
BARE
GND

t=

SPARE
BK/R

SPARE
*BR

SPARE
BK/R*

?11 0" r:

SPARE
*BR/BK

SPARE
*y

SPARE
BR/BK*

12W69F
*BR

SPARE
*y

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SL18E

CON D U C TOR

The Marion Power Shovel Co.

COLLECTOR RING
J.B.

COLLECTOR RING
J.B.

L.F. CONTROL
J.B.

L.F. CONTROL
J.B.

L.F. CONTROL
J.B.

L.F. CONTROL
J.B.

DESTINATION
TO

CABLE PULLING SCHEDULE

IISHE~NO

BI006008

BI006008

CROWD BLWR
MOTOR

CROWD MOTOR

CROWD MOTOR

2G1

2G2

CROWD MOTOR

2F1

2FR1

CROWD MOTOR

2A1

R.H. PROP. BRK.


M.V.

1Z21

BOOM WIRING

L.H. PROP. BRK.


M.V.

1Z11

DESTINATION
FROM

R.H. PROP. MTR.


(#2)&BLWR SW.

SEE
NOTES

1X21

CABLE
NUMBER

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

12

#1

#1

#12

#12

4/0

#12

#12

#12

THW

THW

TWN

THW

THW

AJ

AJ

AJ

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
VOLT
OF WIRE
FT. COND SIZE TYPE AGE

GND
GN/Y*

GND
GN/Y*

T1*
12FllX
BK*

F2*
8C2SM
BK*

A1*
CMA1
BK*

SL22E
R*

SL22E
R*

T2*
12F13X
BK*

F1*
8C38M
BK*

A2*
CMA2
BK*

SPARE
BK*

SPARE
BK*

H2*
12AA41U
lS*BL/BK

H1*
12AA39U
16*R/BK
#12
BARE

12E39N
lQ*BK

12E37N
, 7*R

T3*
12F1SX
BK*

SK04P
BL*

SK04P
BL*

IDRWNO

#12
BARE
GND

#12
BARE
GND

P1*
SL37J
Y/BK*

*aR

P2*
SK04P
12*OR/BK

12E69F

12E41N

1)11 OA

SPARE
BR/BK*

12E69J
21*OR

r= r=

SPARE
BK/R*

*y

SPARE

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

l!l'BL

CON D U C TOR

The Marion Power Shovel Co.

L.F. CONTROL
J.B.

L.F. CONTROL
J.B.

COLLECTOR RING
J.B.

DESTINATION
TO

CABLE PULLING SCHEDULE

nsHE~NO

BI006008

BI006008

CROWD BRAKE
P.S.

OPEN GEAR
LUBE P.S.

UPPER FRAME
LUBE PRESS SW

CROWD MOTOR

CROWD BRAKE
M.V.

2PS1

2PS2

2PS3

2X1

2Z1

AUTOLUBE J.B.

AUTOLUBE J.B.

3FR1

3FR2

AUTO-LUBE

HOIST LIMIT
SWITCH

2LS2

DESTINATION
FROM

CROWD LIMIT
SWITCH

SEE
NOTES

2LS1

CABLE
NUMBER

D-P PANEL

3S

3S

#12

#12

#12

#12

#12

#12

#12

#12

#12

TWN

TWN

TWN

TWN

TWN

TWN

TWN

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE
SK04A

14B41F
R*

SL1
R*

SK26K
BK*

P1*
SK04A
BK*

14A31L
BK*

14C31L
BK*

SK24G
BK*

SK04A
BK*

BK*

14B47F
BK*

SL2
BK*

SK04P
BK*

P2*
SM06E
BK*

14A31M
BK*

14C31M
BK*

SK24H
BK*

SK48F
BK*

SK39E
BK

#12
BARE
GND

#12
BARE
GND

H1*
12ASSU
BK*

18247-48
COAL INDIA

DRWNO

H2*
12AS7U
BK*

SK42E
BK*

" ... ... nAt=' ,..

SK4?H
BK*

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SK39H
BK*

CON D U C TOR

The Marion Power Shovel Co.

DISTRIBUTION
PANEL #1

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

DESTINATION
TO

CABLE PULLING SCHEDULE

USHEETNO

BI006008

BI006008

AUTOLUBE
JUNC BOX

3PS3

AUX COLLECTOR
(BRUSH HOLDERS)

20

20

40

50

70

55

2/0

#1

#1

#1

#12

#12

#12

#12

SA

THW

MV

MV

AJ

AJ

600V

600V

8KV

8KV

600V

600V

600V

600V

LG. NUMB
VOLT
IN
OF WIRE
FT. COND SIZE TYPE AGE

1"
PM1A1
BK"
4"
PM2A2
BK"
4"
PM2A2
BK"

GRN"
GND

2"BK
HL12

2"
PM1A2
BK"

3"BK
HL13

3"BK
HL13

SPARE
BL

14 ..
14B30N
BK

2"BK
HL12

14C31L
"BL

BL"
SPARE

BL"
7G51R

IDRWNO

2"
PM1A2
BK"

2X#6
GRN
GND

2X#6
GRN
GND

#12
BARE
SPARE

14C31M
"OR

#12
BARE
GND

OR"
7G52R

3"
PM2A1
BK"

#12
BARE
SPARE

7r.<;LlR

?11 011 t:_1:.

3"
PM2A1
BK"

.. y

SPARE

Y"
SPARE

BR"

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

14A31M
"BK

1"
PM1A1
BK"

GRN"
GND

l"BK
HL11

l"BK
HL11

13"
14B30L
R

14A31L
"R

BK"
5L57K

#12
BARE
GND

R/BK"
7G55R

R"
5K15B

BK"
7G48R

R"
7G47R

CON D U C TOR

The Marion Power Shovel Co.

AUX COLLECTOR
RING J.B.

HV COLLECTOR
RINGS

5G1

6All

FRAME GND

HV COLLECTOR
RINGS (RH)

5FR2

AUX COLLECTOR RINGS

HV FUSE CBNT

HV COLLECTOR
RINGS (LH)
HI-VOLT CBNT

AUX COLLECTOR
RINGS

BOOM JUNC BOX

OPER. CAB J.B.

D.C. CABINET

DESTINATION
TO

5FR1

818

UPPER FRAME
LUBE JB

3PS1

HV COLLECTOR RINGS

AUTOLUBE J.B.

3P2

DESTINATION
FROM

AUTOLUBE J.B.

SEE
NOTES

3P1

CABLE
NUMBER

CABLE PULLING SCHEDULE

IISHE.ET~O

BI006008

BI006008

AUX COLLECTOR
RING J.B.

AUX COLLECTOR
RING J.B.

AUX COLLECTOR
RING J.B.

AUX COLLECTOR
RING J.B.

AUX COLLECTOR
ENCLOSURE

AUX COLLECTOR
RING J.B.

6A13

6A21

6A22

6F1

6G1

6X1

DESTINATION
FROM

AUX COLLECTOR
RING J.B.

SEE
NOTES

6A12

CABLE
NUMBER

MCC

FRAME GND

35

10

40

45

12

45

35

30

#12

#4

#6

350
MCM

350
MCM

350
MCM

350
MCM

AJ

THW

AJ

AJ

AJ

AJ

AJ

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

15*
12A55U
BL/BK*

16*
12A57U
R/BK*
#12
BARE
GND

18*
12E39N
BK*

GND
GRN*

6*
PMFN
*BL

17*
12E37N
R*

GND
GRN*

5*
PMFP
*R

PM2A2
*BK

PM2A1
HMA1*BK

PM1A2
*BK

PM1A1
CM"'*l'lll'

SPARE
OR/BK

19*
12E41N
BL*

IDRWNO

SPARE
Y/BK

SPARE
OR*

#8
BARE
GND

SPARE
BK/R*

?11 0,1 J:_J:

SPARE
BR/BK*

SPARE
y*

21*BR
12E69J

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE
*BK

CON D U C TOR

The Marion Power Shovel Co.

D.C. CABINET

DIG-PROPEL
CBNT

HOIST MOTOR

DIG-PROPEL
CBNT

BOOM J.B.

DESTINATION
TO

CABLE PULLING SCHEDULE

WHE:T~O

BI006008

BI006008

H.V. CABINET

H.V. CABINET

BP2

BP3

AUX. XFMR PRI

AUX. XFMR SEC

9FR1

9G1

DESTINATION
TO

OPER. CAB J.B.

D.C. CABINET

MCC

H.V. CABINET

D.C. CABINET

GROUND TRRU
GFACT

10

35

25

50

40

30

12

12

#16

#1

#12

#12

#12

#14

#12

TRW

MV

SAJ

AJ

600V

BKV

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

H2,o
HL52
BK,o
XO,o
XO
GND-GRN

XO,o
XO
GND-GRN

5K04B
BL,o

H1,o
HL51
BK,o

36*
2C49F
R,o

5K07E
R,o

SPARE
BK,o

BL/BK,o
SPARE

R/BK,o
12A69N
1112
BARE
SPARE

,oBK
SPARE

35,oR,o
2C49B

22*
GC2
30Q,o
SPARE

SPARE
,oBL/BK

SPARE
,oR/BK
#12
BARE
GND

10*
5L22E
,oBK

9*
5L1BE
R,o

H3,o
HL53
BK,o

13*
2C05B
BK,o

#12
BARE
SPARE

OR/BK,o
SPARE

,oBL
SPARE

SPARE

SPARE
,ooR/BK

IORWNO

2X#6
GRN
GND

M12,o
2C05C
OR,o

Y/BK,o
SPARE

,oOR
SPARE

SPARE

SPARE
,oy/BK

leUR

12*
5K04P

#12
BARE
SPARE

BK/R,o
SPARE

46Q,oBR,o
12A69F

SPARE
,oBR/BK

211 Q4;_t:

SPARE
y,o

BR/BK,o
SPARE

,oy
SPARE

BARE
SHLD
GND

SPARE
,oBR/BK

SPARE
,oy

20*
12E5 1 C
,oBR

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

11*
5L37E
,oBL

CON D U C TOR

The Marion Power Shovel Co.

H.V. FUSE CBNT

AUXILIARY TRANSFORMER

H.V. CABINET

BP1

H.V. CABINET

AUX COLLECTOR
RING J.B.

B19

6X3

DESTINATION
FROM

AUX COLLECTOR
RING J.B.

SEE
NOTES

6X2

CABLE
NUMBER

CABLE PULLING SCHEDULE

,..

[SHEET NO

BI006008

BI006008

MCC MAIN CB

AUX. XFMR SEC

G.F. CNTL PNL

M.G. SET MOTOR

M.G. SET MOTOR

llFR1

llFR2

40

20

10

#1

#1

#12

#12

#14

#8

#8

#6

MV

MV

MTW

MTW

TSH

THW

THW

THW

8KV

8KV

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

T1*
2B01T
BK*

GRN
GND

2X#6

T1*
2B01T
T1*BK

10*BK*
2D8F
C*

Xl
X1*BK

M*
2D8Q
11*

A
BK*

T2*
2B05T
BK*

T2*
2B05T
T2*BK

9*BK*
2D10Q
GF4*

X3
X3*BK

T*
2D9M
12*

B
BK*

X2*

X2
BK*

X1*

GND
GRN*

Xl
BK*

GND
GRN*

T3*
2B09T
BK*

T3*
2B09T
T3*BK

RWNO

GRN
GND

2X#6

T10*
2BK21
T10*BK

SPARE

211 g4~-~

T11*
2BK22
T11*BK

SHLD
GND

T12*
2BK23
T12*BK

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

3*BK*
2D7E

c*
2D8F
2*

C
BK*

X3
BK*

X3*

CON D U C TOR

The Marion Power Shovel Co.

P.F. CORRECTION
CAPACITOR

H.V. CABINET

M.G. SET DRIVE MOTOR

G.F. CNTL PNL

10X1

GFACT

G.F. CNTL PNL


CB-GF

819

10FR1

10CF1

SURGE ARRESTER

SURGE ARRESTER
FUSES FU-SA

9X2

GROUND FAULT CNTRL PANEL

SURGE ARRESTER
FUSES FU-SA

AUX. XFMR SEC

GROUND

DESTINATION
TO

9X1

DESTINATION
FROM

SURGE ARRESTER

SEE
NOTES

9G2

CABLE
NUMBER

CABLE PULLING SCHEDULE

WH:E~O

BI006008

BI006008

SWING GENERATOR

SWING GENERATOR

13CF1

13F1

15A1

HOIST GENERATOR

HOIST GENERATOR

SWING GENERATOR

SWING GENERATOR

13A4

13VF1

SWING GENERATOR

13A3

SWING GENERATOR

SWING GENERATOR

13A2

13H1

SWING GENERATOR

M.G. SET MOTOR

DESTINATION
FROM

SWING GENERATOR

SEE
NOTES

13A1

11H1

CABLE
NUMBER

HOIST MOTOR

20

25

15

25

25

15

15

15

15

20

500
MCM

#12

#12

#8

#14

250
MCM

250
MCM

250
MCM

250
MCM

#12

MTW

XHW

TSH

MTW

600V

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
VOLT
OF WIRE
FT. COND SIZE TYPE AGE

HGA2*
HMA1
BK*

SGA1
BK*

H1*
12A53U
R*

F4*
9A48R
BK*

SlR1
BK*

SGA3*
SM2A2
BK*

SGA4*
SM2A1
BK*

SGA1*
SM1A2
BK*

SGA2*
SM1A1
BK*

Ulnv

H1*
12A53U

SGA2
BK*

H2*
12A55U
BK*

F1
9A56R
BK*

SlR2
BR*

H2*
12A55U

#12
BARE
GND

18247-48
COAL INDIA

IDRWNO

SPARE
OR*

?11 QLlJ:;_J:

#14
SHLD
GND

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE
R*

CON D U C TOR

The Marion Power Shovel Co.

L.H. WING J.B.

R.H. REAR ROT.


FRAME COMPo

L.H. WING J.B.

L.H. WING J.B.

R.H. REAR ROT.


FRAME COMPo

R.H. REAR ROT.


FRAME COMPo

R.H. REAR ROT.


FRAME COMPo

R.H. REAR ROT.


FRAME COMPo

CROWD GENERATOR

DESTINATION
TO

CABLE PULLING SCHEDULE

.. '"

[SHEET NO

BI006008

BI006008

16A1

HOIST GENERATOR

lSVF1

CROWD GENERATOR

CROWD GENERATOR

HOIST GENERATOR

lSH1

HOIST GENERATOR

HOIST GENERATOR

lSCF1

L.H. REAR ROT.


FRAME COMPo

HOIST GENERATOR

lSA6

lSF1

L.H. REAR ROT.


FRAME COMPo

HOIST GENERATOR

lSAS

15

15

15

15

15

15

15

15

20

20

350
MCM

#12

#12

#8

#14

500
MCM

500
MCM

500
MCM

500
MCM

500
MCM

AJ

MTW

MTW

XHW

TSH

600V

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

CGA2*
CMA1
BK*

HGA1
BK*

H1*
12AS3U
H1*BK

F1*
7A48R
BK*

H1R1

HGA1
BK*

HGA1
BK*

HGA1
BK*

HGA2*
HMA1
BK*

HGA2*
HMA1
BK*

HGA2
BK*

H2*
12ASSU
H2*BK

F4*
7AS6R
BK*

H1R2

18247-48
COAL INDIA

IDRWN~

SPARE

211~4~-t;

#14
SHLD
GND

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE

CON D U C TOR

The Marion Power Shovel Co.

L.H. REAR ROT.


FRAME COMPo

L.H. WING
J.B.

SWING GENERATOR

L.H. WING
J.B.

L.H. WING
J.B.

L.H. REAR ROT.


FRAME COMPo

HOIST GENERATOR

lSA4

105

HOIST MOTOR

HOIST GENERATOR

lSA3

DESTINATION
TO
HOIST MOTOR

DESTINATION
FROM

HOIST GENERATOR

SEE
NOTES

lSA2

CABLE
NUMBER

CABLE PULLING SCHEDULE

04,..

[SHEET NO

BI006008

BI006008

HOIST MOTOR
BLOWER

DIG-PROPEL
CABINET

30

35

20

20

20

15

15

15

15

15

#12

#8

500
MCM

500
MCM

500
MCM

#12

#12

#8

#14

350
MCM

AJ

MTW

MTW

XHW

TSH

600V

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OP WIRE
VOLT
PT. COND SIZE TYPE AGE

T1
12EllU
R

Fl
7C25M
R

HMA2
BR

HMA2
BR

HMA2
BR

CGA1
BR

HI
12A37U
H1BR

Fl
8A48R
BR

CIR1

BX.

CGA1

T2
12E13U
BR

SPARE
BK

CGA2
BR

H2
12A39U
H2BR

F4
8A56R
BR

C1R2

T3
12E15U
BL

F2
7C38M
BL

DRWNO

#12
BARE
GND

#10
BARE
SPARE

SPARE

~11alll:'

#14
SHLD
GND

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE

CON D U C TOR

The Marion Power Shovel Co.

MCC

HOIST MOTOR

18F1

18FR1

D.C. CABINET

HOIST MOTOR

18A3

HOIST MOTOR

18A2

DIG-PROPEL
CABINET

HOIST MOTOR

DIG-PROPEL
CABINET

L.H. WING J.B.

HOIST GENERATOR

L.H. WING J.B.

L.H. WING J.B.

L.H. REAR ROT.


FRAME COMPo

DESTINATION
TO

18A1

HOIST MOTOR

CROWD GENERATOR

16VF1

CROWD GENERATOR

CROWD GENERATOR

16H1

16F1

CROWD GENERATOR

105

16CF1

DESTINATION
PROM

CROWD GENERATOR

SEE
NOTES

16A2

CABLE
NUMBER

CABLE PULLING SCHEDULE

[SHEET NO

BI006008

BI006008

D.C. CABINET

BOOM J.B.

SWING MOTOR #1
(LH)

SWING MOTOR #1
BLOWER

20F1

20FR1

15

30

35

35

65

30

30

30

#12

#10

250
MCM

250
MCM

#8

#12

#12

#12

#12

MTW

AJ

AJ

AJ

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

T1
12F19X
BK

Fl
9C25M
R

SM1A2
BK

SM1A1
BK

A2&F1
L1 (+)
R

5K19K
R

Pl
5K04A
R

T2
12F21X
BK

TIE PT.
9C38M
BK

DTR1
BK

S2

5K04P
BK

P2
5M04E
BK

5K17H
BK

ilK

5K17G
R

H2
12A57U

H1
12A55U

T3
12F23X
BK

SPARE
BL

F2
DTR7
BL

y(-)
BL

#12
BARE
SPARE

SPARE
BL

DRWNO

#12
GRN
GND

#12
BARE
SPARE

#10
BARE
GND

#12
BARE
GND

#12
BARE
GND

l)iinA~

,..

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

#12
BARE
SPAR",

CON 0 U C TOR

The Marion Power Shovel Co.

R.H. REAR ROT.


FRAME COMPo

SWING MOTOR #1

20A2

R.H. REAR ROT.


FRAME COMPo

D.C. CABINET

SWING MOTOR #1

SWING MOTOR #1

DIPPER TRIP
MOTOR

20A1

19A1

HOIST BRAKE
M.V.

18Z1

DIPPER TRIP MOTOR

D.C. CABINET

HOIST MOTOR

18X1

D.C. CABINET

D.C. CABINET

HOIST BRAKE
P.S.

R.H. REAR ROT.


FRAME COMPo

DESTINATION
TO

18PS1

DESTINATION
FROM

HOIST MOTOR

SEE
NOTES

18H1

CABLE
NUMBER

CABLE PULLING SCHEDULE

II

SHEET NO

BI006008

BI006008

SWING BRAKE
P.S. #1

SWING MOTOR #1

SWING BRAKE
M.V.

20PS2

20X1

20Z1

SWING MOTOR #2

SWING MOTOR #2

SWING MOTOR #2
(RH)

SWING MOTOR #2
BLOWER

SWING MOTOR #2

21A1

21A2

21F1

21FR1

21H1

SWING MOTOR #2

SWING BRAKE
PRESS. SWS.

20PS1

DESTINATION
FROM

SWING MOTOR 111

SEE
NOTES

20H1

CABLE
NUMBER

15

30

30

40

25

40

30

#12

#12

#10

250
MCM

250
MCM

#12

#12

#12

#12

1112

MTW

MTW

MTW

AJ

MTW

AJ

600V

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

H1*
12A55U
H1*BK

T1*BK
12F29X

F1*
9C32R
F2*R

SM2A2
BK*

SM2A1
BK*

5K31G
R*

P1*
5K04A
R*

5K31K
BK*

5K31J
R*

H1*
12A55U
R*

H2*
12A57U
H2*BK

T2*BK
12F31X

F2*
9C38M
R*

5K04P
BK*

*TIE PT
5M08E
BK*

5K31M
BK*

H2*
12A57U
IlK*

1112
BARE
SPARE

T3*BK
12F33X

SPARE
BL*

#12
BARE
GND

SPARE
BL*

IORWNO

#12
GRN
GND

#12
BARE
GND

#12
BARE
GND

1) ......

nAr-

,..

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARt:

#12
BARE

CON D U C TOR

The Marion Power Shovel Co.

SWING MOTOR #1

BOOM J.B.

SWING MOTOR #1
(LH)

R.H. REAR ROT.


FRAME COMPo

R.H. REAR ROT.


FRAME COMPo

OPERATORS CAB
J.B.

D.C. CABINET

SWING BRAKE
P.S. #2

OPERATORS CAB
J.B.

HOIST MOTOR

DESTINATION
TO

CABLE PULLING SCHEDULE

"SHEET NO

BI006008

BI006008

SWING MOTOR 112

DESTINATION
FROM

DIG-PROPEL
CABINET

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

BOOM J.B.

22A3

22F1

22FR1

22H1

22LS1
BOOM L.S.

15

15

30

35

35

30

12

1112

1112

1112

1110

250
MCM

350
MCM

1112

MTW

MTW

AJ

MTW

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. CONO SIZE TYPE AGE

5K39H
BK*

12A55U
H1*R

5K39K
BK*

12A57U
H2*BK

12F29X
BL/BK*

12F23X
R/BK*
1112
BARE
GND

12F13X
BK*

12FllX
R*

8C25M
R*

CMA2
BK*

8C38M
BK*

ASK

E'2*BK

CMA1
BK*

P2*
5M08E

P1*
5M08D

1112
GRN
GND

12F31X
OR/BK*

12F15X
BL*

SPARE
BL*

DRWNO

12F33X
Y/BK*

12F19X
OR*

2XII12
BARE
GND

"of of

SPARE
BK/R*

nA,.. ,.

SPARE
BR/BK*

SPARE
y*

12F21X
BR*

COAL INDIA

1824748

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

1112
BARE
SPARE

CON 0 U C TOR

The Marion Power Shovel Co.

SWING MOTOR 112

MCC UNIT FB4

D.C. CABINET

L.H. REAR ROT.


FRAME COMPo

SWING MOTOR III

DESTINATION
TO

BOOM J.B.

BOOM J.B.

SEE
NOTES

22A1

21X1

CABLE
NUMBER

CABLE PULLING SCHEDULE

II

SHEET NO

BI006008

BI006008

411

23FR2

24FRI

23FR3

411

23FRI

AIR COMPo MTR.

AIR COMPRESSOR

FILTER FAN J.B.

FILTER FAN #2

FILTER FAN #1

FILTER FANS

MCC

MCC UNITS
FBI & FB2

20

25

40

30

12

12

#12

#14

#14

#14

#12

#12

AJ

THW

THW

THW

AJ

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

12GllU
R*

2X#14
GRN
GND

12DllU
BK*

Tl*
12D37U
BK*

Tl*
12DllU
BK*

12G13U
BK*

12D13U
BK*

T2*
12D39U
BK*

T2*
12D13U
BK*

5K42E
BL/BK*

5K15B
R/BK*
#12
BARE

5K24H
BK*

5K24G
R*

#12
BARE
SPARE

5K39K
BL/BK*

5K39H
R/BK*

12G15U
BL*

12D15U
BK*

T3*
12D41U
BK*

T3*
12D15U
BK*

5K48F
OR/BK*

SPARE
BL*

5K42H
OR/BK*

5K26K

BL*

5K24H
BK'

DRWNO

#12
BARE
GND

12D37U
BK*

#14
GRN
GND

#14
GRN
GND

SPARE
Y/BK*

5K04A
OR*

SPARE

5M06E
OR*

SPl;Il.E

I)-t ..

,..

12D41U
BK*

SPARE
BK/R*

5K39E
BR*

SPARE

n .. ,..

12D39U
BK*

SPARE
BR/BK*

SPARE
y*

SPARE

y*

BR*

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

5K24G
,,*

CON D U C TOR

The Marion Power Shovel Co.

FILTER FAN J.B.

FILTER FAN J.B.

OPERATORS CAB
J.B.

BOOM J.B,

22Xl

DESTINATION
TO
D.C. CABINET

DESTINATION
FROM

BOOM J.B.

SEE
NOTES

22Pl

CABLE
NUMBER

CABLE PULLING SCHEDULE

II SHEET NO

BI006008

BI006008

CROWD EXC. XFMR


PRI "CGT"

CROWD EXC. XFMR

25FR3

25FR4

MCC

D.C. CABINET

DRIVE CVT T-PS

DRIVE CVT T-PS

25FR7

25FR8

15

35

20

40

13

40

15

40

20

20

#12

#12

#6

#6

#6

#6

#6

#6

#12

#12

AJ

AJ

600V

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

X4
5A25C

H5
5A17B
R*

Xl
5A38Q
R*

H1
5A21Q
*R

Xl
5A38L
R*

H1
5A21L
R*

Xl
5A38G
R*

H1
5A21G
R*

R*
5K04G

12G27K

X5
5A28D

H1
5A19B
BK*

X2
5A38R
BK*

H2
5A21R
T2*BK

X2
5A38M
BK*

H2
5A21M
BK*

X2
5A38H
BK*

H2
5A21H
BK*

BK*
5K04F

BK*

12G27N

#12

#12
BARE
GND

#12
BARE
GND

IDRWNO

#8
BARE
GND

#8
BARE
GND

H3
5A21S
T3*BL
X3
5A38S
BL*

#8
BARE
GND

#8
BARE
GND

#8
BARE
GND

#8
BARE
GND

#12
BARE
GND

GND

BlIRE

X3
5A38N
BL*

H3
5A21N
BL*

X3
5A38J
BL*

H3
5A21J
BL*

BL*
SPARE

1\04 04 nil r-

...

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE
BL*

CON D U C TOR

The Marion Power Shovel Co.

D.C. CABINET

SWING EXC. XFMR


SEC "SGT"

25FR6

MCC

SWING EXC. XFMR


PRI "SGT
II

D.C. CABINET

25FR5

SEC "CGT II

D.C. CABINET

HOIST EXC. XFMR


SEC "HGT"

25FR2

MCC

MCC

HOIST EKC. XFMR


PRI "HGT"

25FR1

EKC. & P.S. TRANSFORMERS

MCC TB

AIR SYSTEM P.S.

24PS2

TO

DESTIt~ATION

MCC

DESTINATION
FROM

AIR COMPo P.S.

SEE
NOTES

24PS1

CABLE
NUMBER

CABLE PULLING SCHEDULE

II

SHEET NO

BI006008

BI006008

OPER. CAB
J.B.

HMS - JOYSTICK
CONTROL PANEL

819

819

819

33FR2

33MS1

33MS2

33MS3

SMS - JOYSTICK
CONTROL PANEL

CMS - JOYSTICK
CONTROL PANEL

OPER. CAB
J.B.

33FR1

55

50

45

25

50

1116

#16

1116

#10

1110

1112

#12

#12

#12

SH

SH

SH

THW

AJ

AJ

600V

600V

600V

600V

600V

600V

600V

600V

600V

9D33C

8D33C

7D33C

12B09F
RA

SPARE

SPARE

SPARE

12BllF
BKA

BKA
12BllF

BKA
12G53J

RA
12G47C

RA
12B09F

BKA
12G39U

X2
5J16M
BKA

13K"

H2
12B35F

RA
12G37U

Xl
5J16G
RA

H1
12B33F
n.

9D35C

8D35C

7D35C

12B13F
BLA

BLA
12B13F

BLA
12G55J

18247-48
COAL INDIA

DRWNO

1116
SHLD
GND

1116
SHLD
GND

1116
SHLD
GND

GND
BAREA

1112
BARE
GND

#12
BARE
GND

1')1inJlr'r-'

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

BLA
12G41U

#12
BARE
GND

#12
BARE
GND

CON D U C TOR

The Marion Power Shovel Co.

D.C. CABINET

D.C. CABINET

D.C. CABINET

AIR CONDo
POWER

MCC

35

MCC

HOIST CABLE
P.B. STATION

26X1

OPERATORS CAB

20

MCC

HOIST CABLE
WINCH

15

35

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

26FR1

HOIST CABLE WINCH

D.C. CABINET

CPE TRANSFORMER

25FR10

DESTINATION
TO

MCC

DESTINATION
FROM

CPE TRANSFORMER

SEE
NOTES

25FR9

CABLE
NUMBER

CABLE PULLING SCHEDULE

115HEETNO

BI006008

BI006008

OPER. CAB J.B.

OPER. CAB J.B.

OPER. CAB J.B.

33P3

33P7

33P8

DESTINATION
PROM

OPER. CAB J.B.

SEE
NOTES

33P2

CABLE
NUMBER

30

12

#12

600V

AJ

#12

16

600V

600V

AJ

#12

12

600V

AJ

AJ

#12

16

SPARE
BL/BK*

5JA42G
R/BK*

#12
BARE
SPARE

5L22D
BL/BK*

5K46D
R/BK*

5K18P
OR/BK*

5M48G
BL*

5M16E
OR/R*
5L22E
BL/R*

5M32H
BK*

5M18E
Y/R*

5K36D
BL/BK*

5K48F
R/BK*

5M22E
R*

5LI0E
OR/BK*

5K31G
BK*

5K31M
BL*

SPARE
OR/BK*

5JA16E
BL*

5K24K
Y/R*

5K31C
R*

#12
BARE
SPARE

5JA13E
BK*

5K17L
OR/R*

5K17H
BL/R*

5JAIIE
R*

5K24E
BL/BK*

SPARE
R/BK*

COAL INDIA

18247-48

RWNO

SPARE
Y/BK*

5M24E
OR*

5M20E
BR/R*

5Ll2E
Y/BK*

5K15B
OR*

SPARE
Y/BK*

5JA28E
OR*

SPARE
BK/R*

5L16E
BR/BK*

8F40C
BK/R*
7F40C
BR/BK*

211 Ql1.J:;_J::

5K39E
BR*
5K25P
y*

#12
BARE
SPARE

5K42E
BR*

SPARE
BK/R*

SPARE
y*

SPARE
BR/BK*

SPARE
y*

5JA40G
BR*

5K17G
BK/R*

5K17E
BR/BK*

5K17C
Y/BK*

#12
BARE
SPARE

5K24C
BR*

SPARE
y*

OR

X(+)

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE
OR/BK*

Z(

BL

5K04P
BX*

5K04A
R*

CON D U C TOR

The Marion Power Shovel Co.

D.C. CABINET

30

40

DIG-PROPEL
CABINET

D.C. CABINET

30

LG. NUMB
VOLT
IN
OF WIRE
FT. CONO SIZE TYPE AGE

D.C. CABINET

DESTINATION
TO

CABLE PULLING SCHEDULE

USH:~O

BI006008

BI006008

OPER.CAB J.B.

OPER.CAB J.B.

33X1

33X2

819

OPER. CAB J.B.

33P12

35CF1

OPER. CAB J.B.

33P11

L.H. WING J.B.

MISC.

OPER. CAB J.B.

33P10

DESTINATION
FROM

OPER. CAB J.B.

SEE
NOTES

33P9

~lt.,TMBER

CABLE

25

70

45

30

25

50

50

16

#14

#12

#12

#12

#14

#12

#12

SAJ

AJ

AJ

MTW

AJ

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
OF WIRE
VOLT
IN
FT. COND SIZE TYPE AGE

12E51T
Y/B*

12E61N
OR*

H1R1
BK*

5K15B
R*

5K15B
R*

5L29E

938
RD*

900
RD*

H1R2
BR*

5M44G
BK*

5M44G
BK*

5M55G

910
RD*

902-

SPARE

SPARE

900-

5M24E
BK*

5M32H
,,*

SPARE
R*

SPARE
BL*

SPARE
BL*

7F28C

913
RD*

2C49D
BR*

SPARE

RWNO

SPARE
OR*

#12
BARE
SPARE

#12
BARE
GND

#12
BARE
SPARE

920
RD*

SPARE

5K04F
OR*

935
RD*

SPARE
BK/RD*

BR*

~11 QL1;_:

#14
SHLD
GND

932
RD*

#12
BARE
GND

SPARE
BR/BK*

SPARE
Y*

SP-.RE

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

5M26G
BL

CON D U C TOR

The Marion Power Shovel Co.

D.C. CABINET

R.H. BOARDING
SIGNAL SW.

L.H. BOARDING
SIGNAL SW.

D.C. CABINET

AIR CONDo
CONTROL

MCC

MCC

TO

DESTINAT!O~1

CABLE PULLING SCHEDULE

WH:T;O

BI006008

BI006008

L.H. WING J.B.

L.H. WING J.B.

WELD RECEPT

LADDER LIMIT
SWITCH

L.H. WING J.B.

D.C. CABINET

35F3

35FR1

35LS1

35VF1

35Xl

L.R. WING J.B.

35F2

819

35CF3

L.R. WING J.B.

L.H. WING J.B.

819

35CF2

DESTINATION
FROM

35F1

SEE
NOTES

CABLE
NUMBER

20

25

35

#12

#12

#12

#6

20

15

#8

#8

AJ

SA

#8

SAJ

#14

SAJ

#14

20

20

25

25

600V

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
I.N
VOLT
OF WIRE
FT. COND SIZE TYPE AGE

15AllB
BK*

#12
BARE
SPARE
SGA2
R/BK*

15A07B
R*

HGA2
BK*

5K07F
BK*

12B23F
BK*

9A56R
BK*

8A56R
BK*

7A56R
BK*

SlR2
BR*

C1R2
SR'

HGA1
R*

5K07E
R*

12B21F
R*

9A48R
R*

8A48R
R*

7A48R
R*

SlR1
BK*

BK*

CIR1

#12
BARE
GND

CGA1
BL*

SPARE
BL*

12B25F
BL*

SPARE
BL*

SPARE
BL*

SPARE
BL*

SPARE
R*

R*

IDRWNO

CGA2
OR*

#12
BARE
GND

#10
BARE
SPARE

#10
BARE
SPARE

#10
BARE
SPARE

SPARE
OR*

SPARE
OR*

#14

?11 011 r. r

SPARE
Y*

#14
SHLD
GND

GND

SHI.D

SGA1
BR*

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SPARE

CON 0 U C TOR

The Marion Power Shovel Co.

L. PROPEL ALARM

D.C. CABINET

D.C. CABINET

MCC UNIT FA4

D.C. CABINET

D.C. CABINET

D.C. CABINET

D.C. CABINET

D.C. CABINET

DESTINATION
TO

CABLE PULLING SCHEDULE

IISH~T~O

BI006008

BI006008

DIG-PROPEL
CABINET

DIG-PROPEL
CABINET

DIG-PROPEL
CABINET

DIG-PROPEL
CABINET

819

820

37A2

37A3

37A4

37CFl

37Hl

DIG-PROPEL
CABINET TB

DIG-PROPEL
CABINET

37Al

DIG-PROPEL CABINET

AIR HORN M.V.

3SZ1

DESTINATION
PROM

L. PROPEL ALARM

SEE
NOTES

3SX2

CABLE
NUMBER

20

15

15

15

15

20

20

#12

#14

350
MCM

500
MCM

500
MCM

500
MCM

#12

#12

SA

SAJ

AJ

600V

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OP WIRE
VOLT
PT. COND SIZE TYPE AGE

12As3U
BK

SH2*
2PIRI
BK*

CGAI
BK*

HGAI
BK*

HGAI
BK*

HGAI
BK*

IsK04P
R*

IsA07B
R*

12As7U
BK

SH2*
2PIR2
BR

IDRWNO

SHl*
IPIR2
OR*

1)110.11 r

#14
SHLD
GND

t::

COAL INDIA

18247-48

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SHl*
IPIRI
R*

#12
BARE
GND

GND

DJl

sMI0E
BK*

#12
BARE

IsAllB

CON D U C TOR

The Marion Power Shovel Co.

DIG-PROPEL CBNT
SPACE HEATERS

D.C. CABINET

L.H. REAR ROT.


FRAME COMPo

L.H. REAR ROT.


FRAME COMPo

L.H. REAR ROT.


FRAME COMPo

L.H. REAR ROT.


FRAME COMPo

OPER. CAB J.B.

R. PROPEL ALARM

DESTINATION
TO

CABLE PULLING SCHEDULE

nsH~T~O

BI006008

BI006008

DESTINATION
TO

DIG-PROPEL
CABINET

D.C. CABINET

GROUND

MCC HORIZONTAL
GND BUS

MCC UNIT FA2

MCC UNIT

MCC

38G1

38R1

38P1

38FR1

40

40

30

10

20

20

12

16

#4

#12

#12

#4

2S0
MCM

#18
RED

#12

AJ

THW

THW

TEW

AJ

600V

600V

600V

600V

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

SPARE

R/BK*
SM38F

R*
SN44A

BK*
SN44B

BL*
SN44C

SPARE
OR/BK*

SK1SB
BL/BK*
12AS7U
#12
BARE
GND

SK04G
BL*

12AS7U
BL*

X3
X3*BK

SK14G
BK*

12ASSU
BK*

GND
GRN*

X2
X2*BK

PC2AUC*
SM38F
TB1*

SPARE

SL04D
OR/BK*

Z( )
BL*

DRWNO

#8
BARE
GND

12ES1C
Y/BK*

SK04M
OR*

SM28E
BK/R*

12AS3U
BR*

12AS7U
BK/R*

BR*

"' ..... ,...-

12ES7E
BR/BK*

SPARE
y*

#12
BARE
SPARE
SPARE

#12
BARE
GND

12AS3U
BR/BK*

SPARE
y*

SPARE
Y/BK*

SJAlloJ
OR*

SJA13J

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

SK04A
R*

12AS3U
R*

GND
GRN*

Xl
X1*R

PC1AUX*
SM38C
PC2AUX*

SLSOG
B/BK*

X(+)

TB-1*
SK1SB
PC1AUX*

SJA06G
SR*

SK04A

CON D U C TOR

The Marion Power Shovel Co.

D.C. CABINET

D.C. CABINET

R.H. REAR ROT.


FRAME COMPo

AUX. XFMR SEC.

MCC UNIT FA6

38FR1

MOTOR CONTROL CENTER

DIG-PROPEL
CABINET

37P2

DESTINATION
FROM

DIG-PROPEL
CABINET

SEE
NOTES

37P1

CABLE
NUMBER

CABLE PULLING SCHEDULE

II SHEET NO

BI006008

BI006008

DESTINATION
FROM

LTG. PANEL

D.C. CABINET
T.B.

D.C. CABINET
PS-PRA

SOFRS

SOX1

LIGHTING

DIPPER TRIP
RESISTORS

RESISTORS

D.C. CABINET

D.C. CABINET

SEE
NOTES

SOFR4

47R17

39P1

CABLE
NUMBER

10

10

30

35

80

1112

1112

1112

118

1118
RED

MTW

MTW

SA

TEW

BK*
lSA07B

BK*
lSA03C

600V

600V

R*
SL1
lSA01C*

BK*
lSAllB

BK*
SL2

BK*
SL2

DTR10
BK*

CRLYS*
SK04A
SRLYS*

HRLYS*
SK04A
CRLYS*

DTR3
BK*

HRLY2*
SK04A
HTB-1*

SL29E
LTB-1*

HRyr2*

BL*
SPARE

DTR1
BK*

HRLY2*
SK04A
HRLYS*

DRWNO

1112
BARE
SPARE

DTR7
BK*

PMOTX*
SM38F
HTB-4*

?11 OA 1:_1:

HRYLS*
SMSSG
LTB-1*

CRYLS*
SMSSG
SRLYS*

18247-48
COAL INDIA

DES I G NAT ION

CUSTOMER:

MACHINE KEY:

PMOTX'
SM32H
HTB-1*

CON D U C TOR

600V

600V

600V

LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE

The Marion Power Shovel Co.

D.C. CABINET
T.B.

D.C. CABINET
PS-PRA

D.C. CABINET

D.C. CABINET

D.C. CABINET

DESTINATION
TO

CABLE PULLING SCHEDULE

WH:~O

BI006008

BI006008

105

411

818

819

820

The Marion Power Shovel Co.

RWNO

18247-48
COAL INDIA

~11 QLlc;_J:

CUSTOMER:

MACHINE KEY:

RECONNECT SPACE HEATERS FROM PARALLEL TO SERIES [REMOVE PLUG & CORD CONNECTION FOR SHIPPING].

GROUND SHIELD AT "DESTINATION TO" END ONLY.

COLOR CODE GROUND CONDUCTOR WITH GREEN SLEEVING.

CABLE SUPPLIED IN ASSOCIATED ASSEMBLY GROUP.

SHIELD MUST BE GROUNDED AT ONLY ONE END

CONNECT FIELDS IN SERIES

CONNECT F2 TO F3.

NOTES

CABLE PULLING SCHEDULE

WH:T,:O

BI006008

BI006008

BI006008

Book #1
Section

Electrical Settings
Part No. 211946-3

2243-I.M61

BI006008

,
..,.

<'"1

CLASS: MIN ING SHOVEL

Iso:

ING:

800HP!MODEL: 5K831064FI\RPM: 1480\ CYCLE: 501 V: 3150/6300

NO LOAD VOL TS: LOWER. RETRACT. SWING RIGHT

14.

15.

MOTOR FIELD AMPS - NEUTRAL:

ADJUST FOR EMPTY DIPPER MAXIMUM LOWERING SPEED' 1200 RPM.

20.

21.

SWING

19.0

19.0

27.8

PROPEL WEAK FIELD TO PICK UP AT S7SV GEN.

TAKE UP:

TRIPPING:

POUNDS

DIPPER TR IP MOTOR:

RESISTANCE NO.
ARM. V

ARM. A

A 6-4-96 CHG PROPEL AMP SETTINGS, DEL HOIST WEAK FIELD - SEE DC

FLO. V

I
I

THiRD A~'GLE

~8

DATE:

DATE:

TESTED BY:
INSPECTOR:

DATE:

READING BY:

I 50028
OWZ 149410

owz

FLO. A

..;SFECIFI:n -

00-000

0.000

0.00

0.0

THIS SHE.ET ONLY

QT~'ERWISE

TCLERANCES UNLESS

THE MARION POWER SHOVEL CO.


MARION. OHIO

DROP OUT AT 47SV GEN. SWING WEAK FIELD PICK UP AT 5S0V GEN, DROP OUT AT 4S0V GEN.

PLUGGING TO BE FIELD ADJUSTED.

23.

26.

350/350
600/600
600/600

VOLTAGE LIMIT LINE TO INTERSECT THE CURRENT LINE AT 550 VOLTS AND 225 AMPERES.

1235 AMPERES FOR HOIST: 260 AMPERES FOR CROWD: AND 21S AMPERES FOR SWING.

24.

25.

2-808
SWING

GENERATOR VOLT-AMPERE SETTINGS: CURRENT LINE TO INTERSECT THE 600V LINE AT

SAME AS HOIST AND CROWD MOTIONS.

9.5

11.8

13.B

MOTOR FIELD AMPS - LOWERING/WEAKENED

22.

9.5

35.3
11.8

4 I .3
24.8

MOTOR FIELD AMPS: FORCED

13.9

600

18.

590

590

495

2340

660
600

HOIST

CROWD

1-818

2-810

19.

17.

SEPERATE FIELD AMPERES: AT NO LOAD VOL TS

NO LOAD VOL TS: HOIST, CROWD. SWING LEFT

13.

16.

GENERATOR AND MOTOR SETTINGS


STALL AMPERES: BOTH DIRECT IONS

12.

II.
PR OPEL

RELAY DPTR: ADJUST TIME DELAY ITDADI TO 2.5 SECONDS.

9.

10.

RESISTOR R-GFA: ADJUST TO 4000 OHMS.

B.

1-808

RELAY GFRA: SET IDIALI PICK UP AT 2 AMPS. SET IDIALI TIME DELAY ON INSTANTANEOUS

IADJUST UPWARD IF REQUIRED!.

LODTRAK IV SETTINGS: SEE TABLE LABELED LODTRAK IV SETTINGS.

6.

7.

RELAY STDR: ADJUST TIME DELAY ITOAEI EQUAL TO THE RTDR SETTING PLUS 2 SECONDS.

4.

SET TO REACH FULL SPEED IESTIMATE 15 SECONDS!.

5.

3.

RELAY RTDR: ADJUST TIME DELAY iTDAEI EQUAL TO THE TIME REQUIRED FOR THE MG

HA

CONNECT MG SET DRIVE MOTOR FOR 6300 VOL TS.

L>~

NO:

J.

n'DDeD

I MACHINE

2.

,n

BOOM LENGTH: 12.24M 140'-2'"11 HANDLE LENGTH: 8.23M 127"-""

B 110-7-97 ADD DISPLAY & UNIT INFORMATION, LODTRAK SETTINGS

u.:
-..,.

....J

'"u,

--

<D

TYPE: 182M HR 17

SOL 0 TO: COAL INDIA LIMITED "GLOBAL TENDER"

WINDING RTDS ARE USED

23

BEARING RTDS ARE USED


CT SEC FULL LOAD AMPS
LRC CURRENT TIMES FLC

29
3B
39

PHASE UNBALANCE ALM % OF FLC


46

Jt

A~n

~TD

IMP ORTANT NOTE

I liNG::;

50

MANUAL

NO

NO

NO

0.10

100

YES

40

YES

YES

20

YES

IS

YES

170

110

IS

YES

10

6.1

3.3

NO

NO RTD

NO

TODF

TODF

100

17

VALUE/UNITS
( ON HV CAB
ES1 MI0A 1

"ZE

l)WG

! 'I

GWG eDDE

DWG NO

IE. WATSON; BARLOW

10-19-95

JCHECK 2Y

oy

Rt;;:r

II<PPRCVED

)"':..TER. . . L

ELEC SETTING SPEC SHEET


i~RI;W~ 51"

IPi,ON

:~1T :,,:..\'.~

:~sc<;

TO 32

I
I

"~,,

, H[A T 1F:EA TME~T

i"'10' "

MARION. OHIO

50 OR 60

MANUAL! AUTO

NO OR YES

NO DR YES

NO OR YES

0.05 TO 1.00

10 TO 100

NO OR YES

5 TO 69

NO OR YES

NO OR YES

10 TO 30

NO OR YES

5 TO 29

NO OR YES

6 TO 37
85 TO 125
80 TO 170

NO OR YES

2.00 TO 5.00
3.0 TO 12.0
1 TO 90

NO OR YES

NO RTD OR RTD

NO OR YES

TODF /TRIPI ALM

TDDF OR NTDF

50 TO 9000

UNiTS

I CO", WT

THE MARION POWER SHOVEL CO.

RESET OF TEMP TRIP


FREDUENCY IS

64
65

LOAD JAM USED

61

UNDERCURRENT TRIP USED

UNDERCURRENT IS

57
58

GND FAULT DELAY SEC

=
USED =

GND FAULT TRIP % OF 1 AMP


54

53

GND FAULT ALM % OF 1 AMP


51

GROUND FAULT TRIP

GROUND FAULT IS

50

52

PHASE REVERSAL TRIP

49

PHASE UNBALANCE TRIP % OF FLC


48

=
USED =

PHASE UNBALANCE TRIP

47

=
CALC OVERLOAD ALM DEG.
PHASE UN8ALANCE ALM

43
44

UL TIMATE TRIP IS 1 OF FLC

42

45

INST. OVERCURRENT TIMES FLC

INS T. OVERCURRENT IS USED

41

STALL TIME SEC

=
=
=

40

OVERLOAD TYPE

26

RELAY STATE

TRIP RELAY STATE


AU~

IB

=
=

CT PRIMARY TO 5 AMP

CONTRAST

DISPLRY

!\

REFER TO INSTRUCTIONS
#GEH 5500

r. n~~

19

17

FUNCTlON/
SET POINT

BI006008

,
~

<D
N

r-

BI006008

BI006008

Book #1
Section

Excavator Theory
-Table of Contents Page
6.1 EXC VATOR DRIVE THEORY
, 6.1.1
INTRa UCTION..................................................... 6.1.1
M CHANICAL PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.1.2
La OS and TORQUES
6.1.7
SP ED CONTROLLED DRIVES
6.1.8
TO QUE CONTROLLED DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.1.10
6.2 ELE

RICAL SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.2.1

R TRIP CONTROL
TRIP FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
TRIP OPERATION
ELECT ICAL EQUIPMENT
AD USTMENTS
TR UBLESHOOTING

6.3.1
6.3.1
6.3.1
6.3.3
6.3.4
6.3.6

6.4 M.G. ET MOTOR


MOTa SELECTION
MOTa TyPE
MOTa VOLTAGE RATINGS
MOTa STARTING

6.4.1
6.4.1
6.4.1
6.4.1
6.4.2

6.5 ADJU TMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..


DYNAM C TESTS
. . . . . . . . . . . . . . . . . . . . . . . . ..
EX AVATaR APPLICATION DATA
,
Fa RTH QUADRANT DYNAMIC LIMITS

6.5.1
6.5.1
6.5.3
6.5.4

2243.e.M61

BI006008

BI006008

Section

Excavator Theory

manufactured by Marion Power Shovel and equipped with drives by the General
Electric C mpany are powered by DC motors supplied by DC generators in a Ward-Leonard
system. his Instruction Manual shall apply to such systems incorporating full-reversing
thyristor ield exciters for the generators and controlled by operational amplifier type
regulator.
These ins ructions are generally applicable to crawler mounted, mining size machines used
in loadin trucks or other surface transport. The contents of this section of the manual are
intended t apply to conventional mining shovels, special purpose draglines, and the Marion
Superfro configuration.
The fund
from the e
material;
Cycle" of t

ental purpose of all the aforementioned excavators is to win the desired material
rth; elevate it to the required height; turn to the unloading position; deposit the
d return to a fresh position. This process is repetitive and constitutes the "Digging
e subject excavator types.

nal mining shovel wins the desired material using the cutting force provided by
the hoist otion with the cutting position adjusted by the crowd motion. The hoist is also
used to e evate the load while the crowd extends or retracts to the correct position for
unloading The swing drive for all three types of excavators provides the rotational motion
to transp rt the load from the digging position to the dumping position and return. Then,
both the h ist and crowd motions must be used to reposition the dipper to the new digging
face.
The Mario
significant
system h
in increas
pitch angl
The swing

Superfront shovel can be described as having a similar duty cycle but with two
dvantages over the conventional mechanical arrangement. First, a mechanical
been devised where the hoist and crowd efforts are complementary, resulting
d cutting and loading force. Second, a pantograph linkage pius control of the
allows the dipper to make a flat pass with the cutting force virtually horizontal.
otion rotates the excavator in the same fashion as the conventional shovel.

Crawler mo nted draglines, included here as they are equipped with similar control, use the
drag motio to provide the necessary cutting and loading forces. The hoist motion serves
to elevate he load and return the empty bucket to a new digging position. The hoist and
drag motio s must be worked in combination to achieve a particUlar bucket position and to
accomplis a desired trajectory of the bucket.

6.1.1

BI006008

Depending on the management of the particular mine and the application of the particular
excavator, the digging cycle for the sUbject machine types may vary from 20 to 40 seconds.
The digging cycle for a particular operation is fairly repetitive. In order to achieve a smooth,
productive digging cycle; the capacity of the individual motions in terms of speed and torque
must be coordinated. This is done by the excavator manufacturer using time tested formulae
when the drive horsepower, gear ratios hitch quantity, drum diameter, etc. are selected.
The necessity for the hoist and swing motions to be coordinated is the easiest to illustrate.
At the completion of the digging portion of the pass, the load is ready to be elevated and
swung to the dumping position. The hoist motion should have the capacity to elevate the
load to the desired position in about the same time required as the swing motion takes to
rotate the loaded inertia thru the desired angle. Similarly, the hoist motion-lowering speed
must be sufficient to arrive at the new digging position simultaneous with the completion of
the swing return. Further, such co-ordination must be convenient to the operator such that
the optimum digging cycle can be repeated time after time.
The digging cycle of the excavator is the sum of the individual contributions made by each
of the motions. As the digging cycle is fairly repetitive for a given excavator application, the
dUty cycle of a given excavator motion is also fairly repetitive. The maximum expected duty
cycle of each motion is taken into account as the excavator drive is designed.
The examination of the duty cycles, expressed as speed and torque, illustrates that each
excavator drive requires rotation in both directions (positive and negative speed) as well as
torque in both directions (motoring and braking). Thus, the DC motor is ideally suited to
power an excavator drive as it is capable of acting as either a motor or a brake and can be
easily reversed.

MECHANICAL PARAMETERS

To arrive at a thorough understanding of excavator drive requirements, the conditions of


positive and negative speed pius motoring and braking torque must be considered. The
hoist motion of a shovel or drag line provides the most obvious example. Figure 1 is a
simplified illustration of a hoist drive. A motor mounted pinion engages a large gear rigidly
connected to the hoist cable drum. The cable passes out of the shovel house and around
the boom point sheave to attach to the dipper bail.

6.1.2

BI006008

Crawler

Figure 1

exta1847.wpg

As this te is not concerned with selecting gear ratios, cable lengths, etc.; the drive can be
readily si plified to the system shown in Figure 2. The cable drum can be shown directly
installed 0 a motor shaft. The drum is equipped with cable supporting a load which can be
raised an lowered.

o
Drum

0
Motor

Figure 2
Certain b
motor rotati
(lowering) i
cable) ten
Motor torq

extb1847.wpg

ic assumptions must be made with regard to Figure 2. First, it is assumed that


n in a direction to raise the load (hoisting) is positive and that negative rotation
assigned to the opposite condition. Similarly, torque on the drum (or pull in the
ing to raise the load from rest is assumed to be positive or motoring torque.
e tending to reduce the tension in the cable is assumed to be negative.

6.1.3

BI006008

Two directions of rotation and two conditions of torque result in a total of four possible
operating conditions. The drive illustrated in Figure 2 is capable of operating in all four
possible combinations of speed and torque as follows:

I.

Positive speed and positive torque constitute a mode where the drum is rotating in the
direction to raise the load and the motor torque is at least sufficient to overcome gravity.

II.

Positive speed and negative torque mode occurs with the drum rotating in the direction
to raise the load but with motor torque in a direction to reduce the speed. (Braking) The
tension in the cable can be reduced to zero in this mode.

III. Negative speed and negative torque occur with the drum rotating in a direction to lower
the load and with the motor torque in a direction to increase lowering speed. Again, the
tension in the cable can be zero.

IV. Negative speed and positive torque result when the drum rotates in the lowering
direction but the motor is supplying hoisting torque. Tension exists in the cable.
The above four conditions of operation are logically related It is common practice to describe
the four operating modes as "Quadrants" and to assemble them into a single representation.

Brake Torque

Motor Torque

tr
Spetld

"...

I:)

0..

en

:;-

Speed

3
Speed

"...~

..
en

Figure 3

extc1847.wpg

Now, referring to both Figure 2 and Figure 3, an operating cycle can be established.
Assuming that the motor speed and the direction of rotation can be controlled, the following
"cycle" is described:
- With the system at rest, the command for positive speed will require hoisting torque
and an increase in cable tension. Quadrant I.
- A command for reduced hoist speed will require a reversal of motor torque to
decelerate the inertia and cable tension will be reduced to zero. Quadrant II.

6.1.4

BI006008

- A' hoisting speed is reduced to zero and then begins to lower, motor torque is the
sc me direction as before. Quadrant 1/1.
-

A~

a steady lowering speed is reached, motor torque must reverse to offset the effect
of gravity on the load. Quadrant IV.

Note that the drive cycle discussed may move about freely from one quadrant to another as
comman ~ed by a request for a change in motor speed. Further, note that al/ the possible
operatinf conditions for the drive configuration are included.
The ope ration of the simplified hoist motion drive described concerns only the
character stics of a drive occupied with overcoming gravity and the relatively low inertia of
the drive pomponents.
The swin~ motion is a different type drive in that the effect of gravity has little impact on the
operating characteristics. In fact, the swing motion of a perfectly level excavator would not
see any lead as a result of gravity. The swing drive, therefore, can be considered to simply
provide th~ torque for the acceleration and deceleration of the inertia of the excavator upper
frame assembly.
Inertia is tre characteristic, in this case, of a rotating body to continue to rotate or of a body
at rest to r ~main at rest. When referring to a rotating body, this characteristic is termed the
moment 0 inertia. The amount of inertia of any rotating body is proportional to the mass of
the body end the square of the effective radius of rotation.
Of course the entire upper frame of an excavator represents a rather complex mass and
significant ;lortions of the mass are located at some distance from the center of rotation. The
moment 01: inertia for an excavator swing motion is much larger than that of any other
excavator (notion.
Representing the large inertia of the upper frame as a large diameter circle and the swing
motor as a small diameter circle, the swing motion can be illustrated.

6.1.5

BI006008

Braking

Motoring

2
3

(+)

Torque

Motoring

Braking

Figure 4

extd1847.wpg

The operation of the excavator through a complete swing cycle can be described as follows:
- Quadrant I - A command to the motor for a swing to the left from rest results in
motoring torque and a gradual increase in speed to the left.
- Quadrant II - To decelerate, the motor is commanded to reverse the direction of
torque while the speed is still in the left direction and will bring the drive to a stop.
- Quadrant III - The continued application of motor torque in the same direction as
Quadrant II now begins to produce rotation to the right. Acceleration will continue
until motor torque is removed.
- Quadrant IV - As the upper frame rotates to the right, the motor may be commanded
to apply left or braking torque to reduce the swing speed.
Relating the above to the excavator duty cycle, the filling of the dipper would signal the need
to swing left through Quadrant I and brake to a stop with the dipper above the truck through
Quadrant II. The dipper would be emptied over the truck and then the motor would be
commanded to swing right through Quadrant III. The operator must anticipate when to apply
braking torque to decelerate through Quadrant IV to arrive at the new digging position as the
rotation stops.

6.1.6

BI006008

LOADS nd TORQUES
simplified descriptions have not detailed either the inertia or torque

When ref rring to drive inertia, this includes the inertia of the motor armature, gearing, and
other ro ating parts such as the hoist cable drum. There are also inertia components
associat d with-load on the motor shaft which do not rotate. This includes the pay load in
the buck t or dipper. It also includes the dead load of cables, fittings, chains, and the bucket
or dippe itself. The inertia of these parts must be included and are converted to the
equivale t rotational inertia.
The com onent torques associated with a given excavator drive are more complex in that
they are n t always applied in the same direction and must be summed algebraically. From
the previ us illustrations, it can be seen that motoring torque occurs when the direction of
the effort i the same as the direction of rotation while braking torque occurs when effort is
opposite otation.
Typical to
the dipp
cables ar
to gravity
to hinder
is that su

ques include load torque which might result from the gravity effect on the load in
r. Another is torque as a result of friction. Others such as that required to bend
nd drums and sheaves are usually neglected. It can be seen that the torque due
s always exerted in the same direction. friction torque, on the other hand, tends
cceleration of the drive but helps brake. Of course, the important driving torque
plied by the motor.

braic summation of all the component torques mentioned results in describing


f the drive. That is, whether it is at rest, accelerating, or decelerating. The result
of such
summation is commonly called the accelerating torque even though it may
sometime be in a direction to decelerate the drive. By convention, positive accelerating
torque re ults in a speed INCREASE and negative accelerating torque results in a speed
DECREAS . Also, when the accelerating torque is zero, the drive is either running at a
constant seed or is at rest.
As a simpli ied example, let us assume a drive has a load torque due to gravity applied to a
motor sha . If motor torque is made exactly equal to load torque, the motor will remain at
rest. If mo or torque is made greater than the load torque, acceleration will occur in the
direction t increase the speed. Similarly, if the motor torque is reduced below that of the
load gravit will cause th.e load to accelerate downward.
It now be omes convenient to insert inertia into the drive concept. Any change in drive
speed, wh ther occurring from zero speed or from a constant speed, requires that the
acceleratin torque act on the total inertia. The rate at which the drive speed changes is a
function of the amount of accelerating torque in relation to the amount of inertia to be
overcome. For example, an excavator swing motion has high inertia relative to the
acceleratin torque available. ThUS, a relatively long accelerating time is required for a swing
motion co pared to that of a hoist or drag drive.

6.1.7

BI006008

The requirements for a change in drive speed can be illustrated by using the four quadrant
plot of speed and torque. The following figure illustrates two drives, the left including a
gravity load torque like a hoist motion and the right illustration without gravity load like a
swing motion.
(+)

1(+) S

Effect of Grav ity

HT

(-)T

(+)

'---"" 0

Figure 5

exte1847.wpg

Both the above figures illustrate a drive at rest at point A.


A command for the motor to accelerate causes an excursion as shown from A to B where
accelerating torque produces a change in speed from zero to positive speed at B. If the
accelerating torque is removed as shown, the drive will continue to run at the speed shown
at point B.
Similarly, a command for negative speed while running at point B results in a decelerating
torque to zero speed at point C and a smooth acceleration on to negative speed at point D.
Excursions of speed and torque occur on an excavator each time the operator calls for or
commands a change in motor torque.

SPEED CONTROLLED DRIVES


Thus far, the discussion of speed and torque related to an excavator drive has been
concerned with the action of the motor in response to "command". The command to which
the motor responds is a result of the control method selected for the particular motion. The
best control method for a particular motion is that which permits optimum control by the
operator.
Speed controlled drives have been proven appropriate for hoist, crowd, drag and propel
motions. Note that, as shown in Figure 6, a limit on the available torque is necessary to
prevent excessive acceleration and excessive strain on equipment.

6.1.8

BI006008

lOOI

%Speed
50 -r------~

lO-t---------,.

-+--------\---r--\-Torque

ax.

Figure 6

extf1847.wpg

Note that he above representation in Quadrant I of a speed controlled drive is somewhat


idealized f r clarity. Three controller positions are illustrated which represent commands for
10%, 50%, and 100% speed condition. The selection of a 10% controller position would thus
request th drive to accelerate within the torque limit to reach 10% speed.
The cone pt of speed control can be illustrated further by expanding the characteristic to
include b th Quadrants I and II.

%Speed
00
(4-

-~

l--s-Effect of Gravity Load


C

--

~
\
\-Q..

10

-)Torque

(+) Torque

Figure 7

6.1.9

Max

extg1847.wpg

BI006008

Note that the speed-torque characteristic illustrated in Quadrant II does not include a torque
limit in that exact control is usually unnecessary. Figure 7 also illustrates the effect of a
gravity load on the particular excavator motion as if this were a hoist system. Assuming the
drive is running at 10% positive speed, the controller can be moved to the 50% position to
accelerate the drive. The torque increases on command from point A out to the torque limit
and the speed increases based on the value of available accelerating torque. As the drive
speed approaches the desired 50% value, accelerating torque is no longer required and the
drive runs at 50% speed, point B.
Similarly, moving the controller from 50% to 100% causes an excursion of torque to the right
from point B to C.
The opposite controller movement from 100% to 50% Produces the leftward excursion from
point C into Quadrant II and the speed reduction back to point B.

TORQUE CONTROLLED DRIVES


Torque control is applied only to excavator swing motions. As the name implies, the
controller is used to select a desired torque rather than speed. To prevent overspeed, the
torque controlled drive also requires speed limit.
The following illustration displays idealized characteristics of speed and torque utilizing
torque control. Quadrants I and II are shown. Note that Quadrant II does not include torque
limits. It is desirable to have braking torque fairly constant and this can be accomplished
without torque limit control.

%Speed
100
(-~

t
I
~

l-)Torque

'" -- --

t
A

./'

~Figure 8

6.1.10

-----

(+)Torque
exth1847.wpg

BI006008

Also she wn in Figure 8 is the speed-torque characteristic resulting from controller


commards. Starting from rest at Point A, the controller may be moved full "on" calling for
100% tor<~ue. The excursion proceeds out to the 100% torque line and speed increases as
a result 0 this accelerating torque to point C. Note that swinging the excavator at full speed
in the leftl,~ard direction requires some torque to overcome friction and other similar losses.
For this r ason, point C does not occur at zero torque.
The secor d characteristic shown in Figure 8 shows a speed-torque excursion resulting from
placing t 1e controller in the half "on" position. Beginning from rest at point A, speed
increases ~lightly until the 50% torque line has been reached and then accelerates within the
limit to pc int B. Returning the masterswitch to neutral after point B has been reached will
allow the ~ wing to FREE WHEEL with the speed decreasing only as a function of the braking
action of tj1e friction torque and similar losses. However, if the controller is actually placed
in the "SVI ing right" direction, electrical braking will occur causing the excursion into the
Quadrant I and a reduction in speed back to rest at point A.

-----+----------------~~------~---~----~-

6.1.11

BI006008

----------------~-

6.1.12

BI006008

6.2 ELE~TRICAL SYSTEM DESCRIPTION


The prev ous discussion centered on the requirements for a successful excavator drive. It
then bec mes pertinent to examine those requirements of the electrical drives which supply
the force ~d motion. The output device for supplying force and motion is a special design
DC motol with rugged mechanical features and low inertia armature for fast drive response.
A genera lor, electrically matched to the motor requirements and designed for operation in
the exca\ ator environment, serves as the adjustable voltage motor armature supply.
The discI ssion of excavator drives illustrated the application of torque to produce speed
change. he combination of speed and torque can then be expressed as horsepower. To
produce orque electrically, the motor must have shunt field flux and armature current.
Changes 'n speed as a result of elect torque are reflected in armature voltage. By making
basic ass Jmptions as to the use of constant motor field strength, voltage and current can
broadly bE compared to speed and torque Likewise, the product of voltage and current, or
watts, is analogous to the product of speed and torque, or horsepower.
Power is b ought aboard the excavator as constant voltage AC, subject to some droop under
load and spme rise under regenerating conditions. The motor generator set, with a generator
for each el~ctrical motion, converts the constant voltage AC to adjustable voltage DC. Finally,
the DC metor converts the adjustable voltage DC power to the torque and speed for driving
the indivic ualloads.
The namelblate rating information on the DC rotating machines is an indication of how they
are applied to the electrical drive system. The DC motor shows a nameplate rating of
horsepower, speed, and voltage from which rated torque can be calculated. The generator
nameplate specifies the kilowatts, ampere, and voltage ratings. In both cases, the voltages
are includE d to indicate similar capabilities.
DC excavctor motor ratings are expressed as amperes rather than torque. Amperes, by
definition, i re the units by which thermal capacity is measured.
Therefore, 1"e nameplate rating or continuous load rating of a DC generator and a DC motor
can be rep esented pictorially.

-----+-------------------~-----~---------------~

6.2.1

BI006008

MOTOR

GENERATOR

----

- - -1f(

OJ
0'

I
"Cl

I'd

-+J

>

OJ

Q)

0-

t/)

I
Amperes

Amperes
Figure 9

exti1847.wpg

This representation illustrates that a DC rotating machine can be operated continuously


within a specified envelope. The thermal capacity is related to the armature current.
Continuous operation at current levels above the rating cause a decrease in insulation life.
Simply due to the inherent physical manufacture of DC machines, a generator is capable of
operating satisfactorily at higher than rated voltage and a motor is capable at operating at
higher than rated speed. Excavator generators are rated at 475 volts but can be operated
up to 600 volts. (Some generators are specially constructed for "double voltage" service,
rated at 950 volts.) Excavator motors are rated to run at a particular speed with a 72 volt
shunt field rating. (144 volts for some applications.) As with the generator, the motor may be
operated under "overspeed" conditions with a weakened shunt field.
DC rotating machines also have the inherent capability of being operated under overload
conditions. The rated value of armature current can be exceeded without thermal harm,
providing that the excursion is offset by equal duty below the rating.
Taking into account the overvoltage, overspeed, and overcurrent capabilities. of DC
machines; the total capacity can be represented as follows:

6.2.2

BI006008

GENERATOR

Rate

MOTOR

Rate

-i

1
I
1'0

I
/]

r~

'0

l~

OJ
OJ

0.

CI)

Amperes

Amperes
Figure 10

extj1847.wpg

The envel pes portrayed describe the DC rotating machines in terms of thermal and
commutatl g capacity. The thermal capacity may not be exceeded on a continuous basis
and the c mmutating limits may not be exceeded in operation.
To exami e the concept of commutating limits, a fundamental understanding of
commutat; n itself is necessary. Successful commutation is simply the achievement of
acceptable commutator and brush life. When commutation is unsuccessful, the wear of both
is acceler ted precipitously. Note that the actual life can vary by a broad range due to
difference in environment, duty, etc. and still be termed acceptable.
It is gener Iy accepted that successful commutation results from an electro-chemical film
which exis s on the commutator surface. This film has two properties which promote
successful ommutation. The film has low electrical resistance and has a low co-efficient of
friction.
, a DC machine tends to deposit this film under certain conditions of speed,
load current, while it tends to remove this film under other conditions of speed,
voltage, an current. Obviously, the electrical equipment must be operated under conditions
where the fil condition ip promoted. The commutation limits are simply the expression of
an operatin area conducive to the production of the proper film.
In the sele tion of the electrical drive components to power an excavator motion, the
expected d ty cycle must be examined. The motor horsepower and consequently the
thermal cap city of the drive must be at least equivalent to the root mean square (RMS)
value of the I ad cycle. The peak values of speed and torque required of the drive are then
considered t assure that they fall within the commutation limits. Note that this is all a matter
of motor hor epower selection as the generator is preselected to match the motor.

6.2.3

BI006008

Throughout the discussion of excavator drive theory, it was emphasized that the torques to
be considered included load torque and accelerating torque. The electric motor to power
a particular excavator drive must have sufficient overload capacity to supply the sum of these
two types of torque. Similarly, the generator must have sufficient overload capacity to power
the motor for overload conditions. Figure 11 shows the electrical and mechanical equivalents
of the requirement by the electrical drive to accelerate the excavator motion. Note that this
figure shows a value of continuous gravity load such as might be seen by a hoist, drag, or
crowd motion.
GravitY

~ "X"
-r---t-_ ---s-

-- ,I __

Load-

z...

..........
I----~

>.::- ...... ~

rtj

I1l
I1l
til

--to" -

Amperes

I
I
I

,
,

~--

Torque
Figure 11

extk1847.wpg

The illustration can be expanded to provide further information. The area included in
an-accelerating excursion pius the introduction of a time factor represents energy.

6.2.4

BI006008

S__---Gravity

Load-----...z~

_.~I

"Cl
OJ
Q)

tJ)

Amperes
Figure 12

extl1847.wpg

The elect ical envelope, shown cross-hatched, represents the electrical energy or
kilowatt-se onds necessary to Produce the excursion. Similarly, the cross-hatched area in
the right h nd envelope represents horsepower-seconds of physical energy applicable to
the load.
Electrical oad on the generator is reflected in shaft load on the drive motor of the
motor-gen rator set. All excavator motions are generally powered from the same AC drive
motor and their loads must also be included. It is generally conceded that the peak
requireme t for the AC motor occurs when the hoist and swing motions peak
simultaneo sly. The MG set drive motor horsepower is selected to accommodate
simultaneo s hoist and swing peak demands. Of course, the maximum generator kilowatt
requiremen occurs at the "corner" of the volt-ampere envelope. See point "X" on Figure 12.
It has been I arned by many years of experience that, if the motor is selected with sufficient
pull-out torq e capacity to supply hoist plus swing peaks, the thermal or steady load rating
of the motor will not be exceeded. This "rule of thumb" applies to motors with 250% pull-out
torque rati g. AC motor overall duty cycle loading is usually only about 90% of the
nameplate orsepower rating.

6.2.5

BI006008

6.2.6

BI006008

6.3 DIP ER TRIP CONTROL

DIPPER RIP FUNCTION


Shovel e cavators of the types covered by this instruction are equipped with a dipper trip
function t unload the dipper. In some cases, this function will be accomplished with an air
or hydrau ically powered operator,
The shov I dipper is equipped with a door hinged to swing open and this door has 2 latching
bar, sprin loaded to the latched position. To trip the dipper, a wire rope is connected to the
latch bar nd reeved to a trip mechanism, usually mounted on the gantry platform.
The dippe trip mechanism consists of a trip motor geared to a small drum on which the trip
rope is w und.
When the dipper is loaded and positioned, the operator may depress the crowd master
switch thu b latch which initiates pull on the latch bar and allows the load weight to push
open the oor.
es during the excavator duty cycle, the rope is maintained in a taut condition to
from interfering with the digging operation. This is the take-up mode.
The dipper door closes and latches by gravity as the dipper is returned for the succeeding
pass.

DIPPER T IP OPERATION
To accom Iish the dipper trip function, a DC motor with suitable armature and shunt field
resistance is continuously connected to the main 125 volt DC bus. In the take-up mode,
significant r sistance is connected in the armature circuit for supplying the small amount of
torque for r ducing the slack rope. In the tripping mode, a contactor shorts out most of the
armature r sistance to achieve high torque for a short time.
To furnish
placed in s
at less than
to operate i

measure of protection against excessive trip time, a thermal overload relay is


ies with the entire circuit. This relay is equipped with an overload heater rated
10% of the rated tripping current. The thermal overload relay is thus expected
the crowd master switch thumb latch is held down for an abnormal interval.

6.3.1

BI006008

L2(-)

Ll(+)

r - -MOTOR
------i

Com

Ser

Shunt
L...-

x(+) RhumbLatch

O~--:lJ~r~D::..:T~O:;;:;L:....-------------.

c&1(-)
DT

(CMS)

Figure 13

extm1847.wpg

From a practical standpoint, it should be understood that the dipper trip motor does not
need to actually pull on the latch bar to accomplish the tripping. When the trip contactor (DT)
is energized, the motor first accelerates the roped drum and removes any slack left in the
rope. As the rope becomes completely taut, the inertia of the drum, gears, and motor rotor
serve to "jerk" the latch open. Typically, the tripping operation can be illustrated as follows:

.... i'

-......
... ---.-r---

-,~

--

50

----' -=
=- - - - ..

: . - f:' ::: ~

1 0 0 ' - 1-r:- - - . :~ - .

....-:::._- - - - I -

=--= --......;.u--I-_:-_-I-:~:

, ,

'-i;;--~-i- --'

~7 :.=. - --~_.-.I----I-.- -_ .. - - ._._-

~:

: ::f--:'-..

::MOLUL. ;..I'U...l.lJ':'Va L...:;)

..,.... . - .. ,

..

.-

_- --. - .-- .-.- .. _-~:.::= .:..:..:: :-.=


- - - .. -;. ~'- _.. .~-

~ : :. 4~ _ _ .:::.:"

--

t-

o D.-':-... I-----U
---,., . . .,. _.. -I' --,..,
-v

,_.j

._--

._.,

......

"---:-1'-~
..0'8
.
"--:-T~ 6"
- ./-.
.,-:-=:-t::=:'''i"me :In~ S"econa : .:.~:'==.: =.-=- :-:..
100%
-.. #'. -_...
1 -'" .. - --'.

-:___....,..1------. .....
or ~ .rnr
J\itlPS\~ .I'-=- - _ - -----, ,. I' _s::50% .-.-.. -'1/..'" - -.:.,,- '-- 1
-~
0%

:~~

.=

.-

:.::

- .-

~ ~~-:::T~::' ~~~~ ::~


Figure 14

extn1847.wpg

Note that the characteristics shown in Figure 14 are for illustrative purposes only.
Considerable deviation can exist from one shovel to another or even from one set of trip
equipment to another due to differences in friction, adjustments, inertia, etc.
In Figure 14, the first 0.4 seconds represents the, acceleration of the motor, gearing, and
drum as the rope becomes taut. the succeeding 0.2 seconds is the effect of the actual jerk
on the latch bar reflected to the motor.

6.3.2

BI006008

ELECTRI~AL EQUIPMENT

The dipp ~r trip motor supplied for shovel excavators is 2 compound wound shunt motor,
totally er closed non-ventilated, with a shaft suitable for a direct mounted pinion, The
following ~ulation shows the typical DC motor ratings and data for powering the dipper trip
function:
Torque Rating (Ft.Lbs,)
100

150

200

CD219AT
153PA801
1,5
850
260

CD2110AT
154-SA808
2,0
850
280

CD259AT
164RA800
3.0
850
400

10,3
88
1,79
47,8
0,966

14.3
124
2.46
34,8
0,677

22,5
145
1,15
74,2
0,587

111 'fltings:

Frame Size
Model No,
Horsepower
Rated Speed-rpm
Approx, Weight-Ibs,

~ta:

Max. Take-up Amps


Max. Trip Amps
Shunt Field Amps-rated
hunt Field Ohms @ 25C
P rm. Circuit Ollms @ 25C

The armat~re and field circuit resistance provided are connected in the circuit in the
following falshion:

L2(-

17 DT

Ra 1

Rl

R3

R4

R2~
RS

--~

Figure 15

6,3,3

exto1847. wpg

BI006008

The actual resistance values supplied for the three types of dipper trip motors used are listed
as follows:
Resistor Amps (Ohms)
Resistor Position

100#ft.

150#ft.

200#ft.

Ra
F1
R2
R3
R4
R5

32 (1.2)
17.8 (2.2)
11.5 (5.4)
11.5 (5.4)
11.5 (5.4)
Not Req'd.

50 (0.5)
9.2 (8.5)
9.2 (8.5)
9.2 (8.5)
9.2 (8.5)
Not Req'd.

50 (0.5)
12.7 (4.5)
12.7 (4.5)
12.7 (4.5)
10.3 (6.8)
10.3 (6.8)

The specific catalog numbers for the resistors used are tabulated as follows for ready
reference.
*Cat. No. IC9033-

Cont. Amps

Ohms Each

*Cat. No. IC9033-

C5B50JK
C5C12JK
B5C22JK
B5C45JK
B5C54JK
B5C68JK
B5C85JK

50
32
17.8
12.7
11.5
10.3
9.2

0.5
1.2
2.2
4.5
5.4
6.8
8.5

C5D6
C5E1
B5G6
B5G9
B5H1
B5H2
B5H3

* The catalog numbers in the left hand column have been superceded by those in the
right hand column.

ADJUSTMENTS
The current ratings of the motor armature, the motor field, and the resistor design must be
taken into account when adjustments are made for either of the two operating modes. As
constructed, tentative settings have been provided if the resistors are connected as shown
on the drawings provided for the particular excavator. Refinement of these settings is almost
always necessary to adapt both the take-up and the tripping modes to accommodate the
particular frictions and mechanical conditions for a particular excavator.
Generally, the procedure would be to adjust the shunt field current first, the take-up armature
current second, and the trip armature current last. In all cases, care should be taken that the
adjustments are made with the main DC exciter set at 125 volts.

6.3.4

BI006008

DT

R3

L2(-)
R1

R2

R4
(1)

RS

Figure 16

(2 )

extp1847.wpg

In most c es, the initial adjustments of the dipper trip function are made with the dipper trip
motor at 0 near outdoor ambient temperature. It will usually be necessary to re-tune the trip
and take- p functions after the shovel has begun to operate and the dipper trip motor is at
its normal operating tem'perature.
Adjustme
to the shunt,field of the dipper trip motor should initially be made at a value of
current gr ater than normal expecting the circuit copper to warm up with temperature. The
shunt fiel current should be checked with the resistor tap at the value shown in the
excavator rawings. Generally, the shunt field current should be about 2.0 amperes for the
100 poun foot motor, 2.7 amps for the 150 pound foot motor, or 1.3 amperes for the 200
pound foo motor. If the measured value is near the quoted-value, leave as is and proceed.
If necessa y to adjust, move the shunt field tap (1) shown in Figure 16
Next, the t eup armature current should be adjusted. In this case, the copper temperature
does not ave significant impact due to the relatively large amount of external resistance
utilized. Wi h the resistor tap (2) in Figure 16 connected as shown in the excavator drawings,
observe th trip rope slack and operate the shovel. The trip rope should be sufficiently taut
to be kep out of the operating area. If too much tension exists, the dipper may trip
inadverten Iy as it is hoisted away.
If the shunt field adjustment is correct, the takeup armature current will range from about 5
to 10 amp res for all three sizes of dipper trip, motors.
Should th condition occur where the resistor tap (2) is moved all the way toward the
overload re ay end of the circuit (all resistance inserted) and takeup torque is still excessive;
a reductio in shunt field current is necessary. referring to Figure 16, tap (1) should
be-moved away from tap (2). Try a 20% reduction in shunt field current and observe the
operation. f takeup is still excessive, reduce another 20%.
To adjust t e trip current, resistor tap (3) shown in Figure 16 must be used. It is suggested
that all of re istor Ra be inserted initially. If a satisfactory trip operation is obtainable with all
of resistor a inserted, optimum motor, gear, and rope life can be expected. However, if
insufficient ripping torque occurs, tap (3) may be moved toward the motor end of the circuit
to increase torque.

6.3.5

BI006008

TROUBLESHOOTI NG

The dipper trip function is a relatively simple electrical circuit which is fairly easy to adjust
and troubleshoot. however, the dipper trip total function can result in significant excavator
downtime. Often, problems reported are mechanical in nature and ~hould be recognized as
such.
Some of the common symptoms, causes and corrective actions are tabulated as follows:
PROBLEM: The takeup function does not appear to be functioning at all. The trip rope
droops into the operating area. The actual tripping function mayor may not
be operative.

Possible Causes

Corrective Action

1. Open Circuit in the electrical


system.

Make a visual inspection for broken wires, poor


wire terminal connection, loose terminal screws or
bolts, open resistor, failed overload relay, or open
overload heater. If visual inspection fails to locate
trouble, perform electrical continuity checks either
by voltage or by resistance measurement.

2. Dipper Trip Motor does not


produce takeup torque.

Inspect the dipper trip motor visually and with


instruments, if necessary. Look for burned brush
shunts, brushes stuck in holder, broken brush
springs, and commutator condition. Check
-continuity of armature and shunt field circuit for
broken wires internal to the motor. Check shunt
poles for possible open circuit internal to the coil.
Check motor for grounds. Perform AC drop test on
the shunt field circuit, if suspect. Check
comnutating series fields for possible open circuit.
Finally, check armature for open turns by
bar-to-bar continuity or by other means.

3.

Check trip motor and mechanical parts. Examine


motor and drum assembly for broken shaft or a
shaft key which is sheared or missing. Check
motor pinion and drum gear for missing or
damaged gear teeth. Check motor and drum for
frozen or locked bearings.~

Mechanical failure of trip


mechanism.

6.3.6

BI006008

PROBLE*: The trip function does not operate. The take-up function mayor may not be
operable.
Possible Causes

Corrective Action

1. Fault ~xists in the electrical


systern

Check for a possible open circuit or grounds in


the power wiring including broken wire, poor
wire termination, loose terminal screws or bolts,
open resistor Ra, failed overload relay, open
overload heater.
Examine the DT contactor for worn out contact
tips or an open circuit in the contactor blowout
coil.
Check for a possible open circuit in the DT
control including wires, terminations, DT
contactor operating coil, overload relay, and
master switch thumb latch. Examine the state of
the thermal overload relay. If tripped, determine
the cause and correct by repair of electrics,
electrical readjustments, lubrication of latch bar,
or repair of a mechanical failure.

2. Dipper Trip Motor at fault.

Inspect the dipper trip motor visually or with


instruments if necessary. Look for burned brush
shunts, short brushes,brushes stuck in holder,
broken brush springs and commutator condition.
Check continuity of armature circuit wiring and
for open circuits internal to the commutating
fields and series fields. Test armature for open
burns by bar-to-bar continuity or other means, if
suspect. Check for grounds.

3. Mechar ical failure of trip


mechar ism.

Check trip motor and mechanical parts. Examine


motor and drum assembly for broken shaft or a
shaft key which is sheared or missing. Examine
motor pinion drum gear for missing or damage
gear teeth. Check motor and drum for frozen or
locked bearings.

6.3.7

BI006008

PROBLEM: Insufficient takeup torque allowing the rope to slacken into the operating
area. Typically, the slack may eventually be taken up but problem will recur.

Possible Causes

Corrective Actions

1. Electrical adjustments are not


correct.

Refer to adjustment instructions in this section.


Increase the amount resistance shorted out at
adjustment (2) making sure that the motor
continuous rating is not exceeded. Also, if
necessary, the shunt field current may be
increased by moving adjustment (1) toward (2).

2. Electrical fault may exist.

Test for possible ground in the armature and


shunt field circuits. Examine motor commutator
and brush condition. Check armature circuit for
shorted or open turns and the shunt field circuit
for shorted turns. Use AC drop test, if indicated.
Measure main DC exciter for possible low bus
voltage. Look for high resistance connection in
the wiring.

3.

A bearing may be failed or failing in either the


motor, the drum assembly or hte trip rope
deflecting sheave. Check the lubrication of the
gearing between the motor and drum. Poor
lubrication increases torque required.

Mechanical problem may exist.

PROBLEM: Insufficient torque results when the trip is initiated.

Possible Causes

Corrective Action

1. Electrical re-adjustment required.

Refer to the adjustment procedures described in


this section. An increase in tripping current may
be made by changing adjustment (3). Exercise
judgement before readjusting a trip function
which has been operating properly. The problem
may be mechanical.

6.3.8

BI006008

2. Mech nical re-adjustment or


repai may be required.

Check for failed or failing bearing at the motor,


trip rope drum or deflecting sheave. Ensure that
the latch bar assembly is lubricated per the
shovel manufacturers recommendations.
Examine the latch assembly for foreign material.
Check for damaged or worn latch bar, latch way,
latch socket in dipper. Check gearing at motor
and drum for damage or excessive wear.

: Excessive torque occurs in the takeup mode of operation.


ause
Electrical eadjustment required.

Corrective Action
Refer to the adjustment procedures contained in
this section. A reduction in takeup armature
current may be performed at (2). If necessary,
shunt field strength may be reduced at (1). If
suspect, check main DC exciter bus to ensure
that the voltage is at 125. Excessive voltage may
increase takeup current.

Excessive torque occurs in the tripping mode of operation.


Corrective Action
adjustment required.

NOTE:

Refer to the adjustment procedures contained in


this section. A reduction in tripping armature
current may performed at (3). If suspect, check
main DC exciter bus to ensure that voltage is at
125. Excessive voltage tripping current.

or additionaldetails on operation, maintenance, and troubleshooting of the


ipper trip motor, contactor, overload relaY,-etc.; refer to the specific G.E.
i struction publications covering the specific electrical parts.

6.3.9

BI006008

6.3.10

BI006008

6.4 M.G. SET MOTOR

MOTOR
The hor
manufac
industrial
requirem

power rating of the main MG set drive motor is selected by the excavator
rer based on the expected excavator drive motion loading. Contrary to most
practice, the horsepower rating is selected on the basis of the peak torque
nt rather than the long term thermal load.

The maxi um expected instantaneous torque required at the drive motor shaft occurs when
the hoist motion and the suing motion simultaneously achieve their peak DC load. This
''worst cas torque condition occurs when hoisting a full dipper at the same time the swing
loading
ses through it's peak. When this occurs, the crowd (or drag) is at negligible
loading.
II

The simu taneous peak DC kilowatts, added together, can be converted to peak torque
required t the MG set motor shaft. This value of peak horsepower divided by the motor
rated pea torque (pull-out torque) in per unit results in the nameplate horsepower.
For exam Ie, if the calc.ulated peak horsepower is 2500 and the motor pull-out torque is
n the motor nameplate should be 2500/2.5, or 1000 HP.
Main MG et drive motors selected by this method generally experience thermal or long term
loading in the order of 85% to 90% of the nameplate horsepower.

MOTOR
The majori
motors fo
100% torq
normally
operating

PE
of the excav~tors of the size under discussion are equipped with induction drive
the main MG set. These motors are of a modified NEMA design B with about
e at zero speed with full rated voltage applied. These induction type motors are
50% pull-out torque rated at full voltage, although there are some excavators
ith 300%.

Some ex avator designs are made with synchronous MG set drive motors to permit
operation n marginal mine power systems. Again, these synchronous motors may appear
in both 25 % and 300% pUll-out torque ratings.

MOTOR

OLTAGE RATINGS

Ihe excav tor electrical design is based on full excavator production with a maximum
incoming I ne voltage range from 95% to 110% of the nominal value. The nominal value of
voltage will, of course, vary based on the availability of local power. It is necessary to select
the name late voltage rating of the MG set drive motor properly to provide the correct
pull-out to que ca~city over the incoming voltage range,

6.4.1

BI006008

Excavators destined for domestic service are usually applied on systems with a nominal
incoming line rating of 2300, 4000, or 6900 volts. The permissible range of the 95% to 110%
range would be applied to these values.
To insure that the full pUll-out torque is available even under minimum voltage conditions,
the motor nameplate voltages selected at a lower value than that of the system nominal
voltage. For example, motor nameplate voltages of 2200, 3810, or 6600 would be applied
to systems with a nominal voltage rating of 2300,4000, and 6900 volts.
A similar policy is followed for excavators destined for export. Nominal system voltages of
3300 or 6600 volts would be equipped with motors having a nameplate rating of 3150 or
6300 volts.

MOTOR STARTING
The starting of the main MG set motor is the most severe duty experienced by the mine
power system. Where a single excavator is served from single transformer by the trailing
cable; the mine power system can be designed to allow the voltage to drop significantly at
the motor terminals without disturbing nearby loads. Multiple excavators utilizing a single
transformer source must take nearby loads into consideration.
The starting in-rush current for induction motors are usually in the order of 650% to 750%.
For synchronous motors, the older designs were around 450% but now range between
550% and 630%.
On starting, the voltage may be allowed to drop significantly providing sufficient voltage is
available to provide break away torque at zero speed. Most MG sets require approximately
20% of motor nameplate torque to break away. Since the starting torque varies in proportion
to the square of the applied voltage, the voltage drop at the terminals of the motor should
not exceed 30%. (i.e.: not less than 70% of nominal.)
Since the voltage drop in the transformer and trailing cable is normally rather high, the
application of reduced voltage starting is not recommended. The normal mine power system
is, in itself, a reduced voltage starting condition. The application of either the
auto-transformer or series reactor type of reduce voltage starting serves to greatly increase
the time required to start the MG set, reSUlting in unnecessary thermal stress in the rotor, etc.
Generally, where reduced voltage starting appears to be a necessity, the system should be
closely investigated as there may be insufficient power to dig with the excavator.
The normally calculated time for starting a typical MG set inertia is about 5 seconds,
assuming that full nameplate rated voltage was available at the motor terminals. When
started on a typical mine power system, the time to start varies from about 9 to 12 seconds.
--~c=========---

6.4.2

BI006008

Now that
finished t
work is
pertorma

the shovel has had its static tests completed and the mechanical people have
eir work, the machine is ready to move. The true test of the proficiency of your
t hand. Operational or dynamic tests are the true measure of a machine's
ceo

When run
system,
motion u
voltage,

ing dynamic tests for the first time or after you've made changes to the electrical
ever assume that everything is okay. Start off slow and gradually increase the
to its full capacity. It's far better to realize there is a problem at a low value of
rrent or speed than at full capacity.

The easi st and possibly the best method of checking the dynamic performance of the
excavato is by utilizing an X-V recorder. Because the current, voltage and speed are
constantl changing it is difficult to get the total shape of the volt-amp curve without a
recording device. It is possible to get good results with an oscillograph, Brush or similar
recorder, ut translating the results into the shape of the volt-amp curve or the dynamic limit
in the reg nerative quadrant can be time consuming. One advantage of the oscillograph is
that a tim record is made, but where possiblE! it is recommended an X-V recorder be used
because of the instant results. Currently the most widely used X-V recorders are the
HewlettP kard models 7034A and 7035B, but other types have also been used with some

When m ing X-V recordings of dynamic tests it is extremely important that proper limits are
shown on he chart paper. The maximum settings that the rotating equipment can tolerate
from a co mutation standpoint are shown on Figure 17. However, in order to protect their
gears or echanical system, Marion may elect to have the specific machine settings inside
these m imum limits. Th'e MPS recommended electrical setting sheet is official. Consult it.
in the motoring quadrants (1 st and 3rd quadrants) are set by the MPS
ded setting stleet values.
The dyn
ic limits for the regeneration quadrants (2nd and 4th) are the same for each MD
motor siz ,regardless of the excavator on which it is used. The dynamic limit is based on
percent f rated stall current vs. percent of rated motor speed. The actual limits for an
individual otor can be obtained by finding the percentages on the dynamic limit line and
multiplyin the ratings times the percentages. Figure 18 shows these limits converted to rpm
for the M 816 thru MD824 respectively. These limits are shown in motor rpm because on
the hoist d drag motions the motor speed in the 4th quadrant is the limiting commutation
factor at hi h motor speeds. All excavators should be initially set up for the speed vs. current
to assure hat during plugging (regenerative braking) the machine does not exceed these
limits, but so to check that it makes use of all the allowable area under the curve. Dynamic
tests shou d always be made under staged conditions. The hoist motion motoring quadrant
(1st) is ch cked by hoisting an empty dipper at full masterswitch with the bucket under the
boom poi t.

BI006008

This approximates the open circuit voltage condition. Hoisting the bucket through the bank
in a normal operating mode should check the slope of the current limit line. Having the
operator momentarily stall the bucket in the bank checks the stall current setting.
Accelerating a full bucket from rest to full speed (in the hoist direction only) approximates
the peak power point.
The 4th quadrant test for the hoist motion is always performed with an empty bucket. The test
is run with the bucket at the boom point for hoist. The motion is then lowered at top speed
and plugged to both neutral and hoist. On new machines or after changes have been made
plugging tests should begin at half speed and checked progressively in several steps until
maximum speed is reached.
The crowd motion is tested in a manner similar to that procedure used on the hoist.
The swing tests can be staged by accelerating to top speed by a maximum throw of the
master switch from a creep speed, then throwing the switch to the maximum opposite
direction once top speed has been reached. The procedure is then repeated to fill out the
rest of the 4 quadrants.
To accomplish these tests and obtain the significant data you desire, the operator must
understand what you want. Make certain that he knows exactly what you want AND does it.
Otherwise he could adversely affect the outcome of the tests and your conclusions on the
machine's performance.

----._-------- --------------------

6.5.2

BI006008

EXCAVATOR APPLICATION DATA


EXCAVATOR EQUIPMENT -COMMUTATION LIMITS
For MD Motors and CDS Generators
ARl1A.TURE AMPS X 1000

200

400

600

80
::E
0-

a:
a:

100

120b

1400

16C a

'--_I.--~

......
j!..;..:...:...I:'...._.'_'

...r._
...

1670

Q30

835

818

2130

820

1065

820

2700

800

1350

822

3600

740

1760

824

4500

700

2200

...,I'......_ , ,
_

Figure 17

6.5.3

extq1847.wpg

BI006008

FOURTH QUADRANT DYNAMIC LIMITS


ARMATURE AMPS vs. MOTOR RPM
--S9-S-V-o-lts---------------,
a r------/~---===/='-=-=-=7::;-:~==-\
V':)LT:.GE LIMIT

58%

a j-----

72% \
\

OYN:.MIC LIMIT

(STt.TIC-+-25%)

STATIC LIMIT

'\
\

\
\

01-----

rr
=L,==='-'=-~--=irL=-=-=-=-~I=-=- -IJ
\

01------

-==ili==-=--::':20

o~

:;

;:lERCENT

5rB;;:-<:

~:-.1OTOR

40

60

80

100

120

I
/

25

CONOITION FRCM ~
OP~RATIONAL ST:'NDPOINT

c:::: :::::

R~IS CURRS~!T eN :'NY ~PLlC.loTION


MUST NOT EXCEO ,<ATEa M:TOR
~::2--CURR::NT - RESPONSIBILITY FOR
8'"
'""HICH SHCULD BE RECOGNI ZED
~ ~
':'ND ACCEPTED BY EXCAVATOR
c::::
SUILOER.

>

..... :::l

CROSS-HATCHSO AREA
BEING A OYN~IC

R~TED STALL CI.J'RNT


OR GENE.Cl.:.TORl

o ,...
,...

110% STALL S::TTING


FOR SCR CONTROLLED
EQUIPMENT BASED ON

I
/
I
$T~LL

__

~P!R!5

..,~

~o

~':'t
c..~

a f-----

/
/

I
/

51-----/
/

~T('R

R""

llO4

200

1420

806
tC8
810
812

JOO

12C5
1125

650
850

814

1250

'15

167:1

Sf 8

120

!20
822

2120
2700

3600

a24[

.~~

740
700

45)

1075
IC25

"5

930

sec

LIM ITS
F" I ELD

~CR WE~K

01-----

sL..-

/
/..

Use Dynamic limit

---''--..J-

---'

Figure 18

6.5.4

extr1847.wpg

BI006008

Section

DC 2000 Drive System


and Instruction Manuals
-

Table of Contents -

7.1

GF 20000 Generator Field Exciter Operation and Maintenance Instructions for


Directo-Ma ic 2000 Equipment
" GEH-6148

7.2
AC/DC 200
AC/DC 200
DCFB Pow
SDCC Driv
DSCO
Configurabl
Configurabl
Configurabl
DS200
DS200FS
Receiving a

2243-I.M61

Wiring Board Instructions

Drive Terminal board 531X305 NTB AA-AH G1


GEI-100020
Drive Lan I/O Terminal Board 531X307LTB AA-AC G1
GEI-100022
r Supply Board DS200DCBG1AA Through G1AEB
GEI-100028
Control Card DS200SDCCG1AA - G1ABA,
DCCG2AAA-G2ABA
GEI-100029
Hardware for PCCA Power Connect Card
GEI-100161
Hardware for DC200SLCC Land Communications Card . GEI-100162
Hardware for RTBA Relay Terminal Board
TBAG1AAA-G1ADB
GEI-100167
Single-Phase Field Supply Amplifier board
GEI-100186
d Storage Instructions for Directo-Matic 2000 Equipment . GEI-100228

BI006008

BI006008

GEH-6148

Instructions

GF2000
Dc Generator Field Exciter

Operation and Maintenance

BI006008

BI006008

Supplement To
GEH-6148

GE Motors & Industrial System

The values listed in Table 4-1 of GEH-6148 have been updated.


In GEH-6148, lease replace Table 4-1 on page 4-3 with the updat ed Table 4-1 below.

Table 4-1. GF2000Frame Size Specifications

Ac Input
Voltage
(Vac)

Maxi mum Dc
Output Voltage
(V de)

Maximum De
Output Current

230
460
575

3 00
6 00
8 00

259
259
259

C Extension (CX)

230
460
575

3 00
6 00
8 00

490
490
490

230
460
575

3 00
6 00
8 00

127
127

Frame Size

(A)

99

BI006008

GEH-6148

Supplement to GEH-6148

Notes:

GE Motors & Industrial Systems

---------------------------

;ue date: May 1996

OE Industrial Systems
1501 Roanoke Boulevard
Salem, VA 241536492 USA

SUPPLEMENT3
GEH-61,

BI006008

GEMotors&
Industrial System~

---------+---------------------------

These instructions 0 not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met dUT
ing installation, op ration, and maintenance, Iffurther information is desired or ifparticular problems arise that are not covered sufficientlyfor the purc ser's purpose. the matter should be referred to GE Motors & Industrial Systems.
This document cont ins proprietary information ofGeneral Electn'c Company, USA and is furnished to its customer solely to assist that
customer in the ins llation, testing. operation. and/or maintenance ofthe equipment described. This document shall not be reproduced iJ
whole or in part no shall its contents be disclosed to any third party without the wn'tten approval ofGE Motors & Industrial Systems.

1.
2.

Chapter 2 (Receiving, Handling and Storage) in its entirety with publication GEI-I00228.
Please use th following table for acoustic information:

ACOUSTIC NOISE LEVELS - C / CX FRAMES

blower
~

74dBA

_ -

77dBA
;

fan

62 dBA

84dBA
;

65 dBA

o-

74 dBA

BI006008

SUPPLEMENT4

BI006008

GEH-61

GEMotors&
Industrial System~
-------+-----------------------These instructions not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met durin,
installation, operati n, and maintenance. Iffurther information is desired or ifparticular problems arise that are not covered sufficiently fi
the purchaser's pur ose, the matter should be referred to GE Motors & Industrial Systems.
This document cont ins proprietary information ofGeneral Electric Company, USA and is furnished to its customer solely to assist that
customer in the inst llation, testing, operation, and/or maintenance ofthe 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 ofGE Motors & Industrial Systems.

1.

Please use th following table for acoustic information:

fan

62dBA

65 elBA

74dBA

fan

67dBA

69 elBA

74dBA

fan

73 dBA

73 elBA

BI006008

BI006008

GEI-10022

BE Motors &
Industrial System.

----------+--------------------------RECEIVING AND STORAGE INSTRUCTIONS


FOR DIRECTO-MA TIC 2000 EQUIPMENT
I These instructions

0 not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met durop ration, and maintenance. Iffurther information is desired or Ifparticular problems arise that are not covered sufficientlyfor the purc aser,s purpose, the matter should be referred to GE Motors & Industrial Systems.

I ing installation,

This document cont ins proprietary information ofGeneral Electric Company, USA and is furnished to its customer solely to assist that
customer in the inst llation,testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproduced in
whole or in part no shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems.

CONTENTS
Safety Symbol Le end
Overview
Receiving Guideli es
Handling GuidelilJ es
Storage Guideline
Warranty Parts ar d Service

OVERVIEW
1
1
1
2
3
.4

SAFET(SYMBOLLEGEND
WARNING

CAUTION

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, con dition, or statement.

This document contains guidelines and precautions for


handling and storing DIRECTO-MA TIC~ 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
1501 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.

BI006008

1-100228

Receiving and Storage Instructions for DIRECTO-MATIC 2000 Equipment

pon receiving a shipment, the customer should:


Conduct a visual inspection before or during the
offloading.
Move the shipment to shelter.
Conduct a thorough inspection of the shipment.
.efer to Receiving Guidelines, Handling Guidelines, and
torage Guidelines below.

Shortage

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

)FFLOADING

mmediately upon receipt of any equipment, conduct a


'isual inspection for signs of rough handling or shipping
lamage. Conduct this initial inspection before the shipnent is offloaded. If damage is noted, immediately notify
he carrier before they leave the reception site. ..
\lotify the carrier that a thorough inspection was not confucted upon the receipt of the shipment. A thorough in;pection occurs after storage and unpacking.

HANDLING GUIDELINES

R.efer to Moving and Lifting and Damage Notification


Delow.

CAUTION

SHELTERING

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.

CAUTION
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

MOVING AND LIFTING

When handling equipment:

Refer to equipment outline drawings for preferred


methods oflifting and moving equipment.

Observe the equipment's center-of-gravity to ensure


that equipment does not fall.

Failure to protect equipment from adverse


conditions will void the equipment warranty.
Refer to Handling Guidelines and Storage Guidelines
below.

UNPACKING

Consider the following when unpacking a shipment:


INSPECTING

After moving the equipment to shelter, check the contents


of each package against the packing list. Check for:

If the equipment has been exposed to low temperatures for an extended period, do not unpack it until it
has reached room temperature.

BI006008

Receiving and

GEI-I002~

orage Guidelines for DIRECTO-MATIC 2000 Equipment

It is good pr ctice not to completely unpack the


equipment u til it has been placed near its permanent
location or i storage location.

Use standar unpacking tools to carefully remGve


equipment fr m its container.

Shipping and ambient storage temperature limit


are: -25C (-5 OF) to 70C (167 OF).
NOTE

Use care wh n unpacking to prevent marring or damaging parts.

Label each it m when it is unpacked.

Check the co tents of each case against the packing


list. Report s ortages to GE.

Wipe offpart cles'ofpacking materials or foreign


substances th t may be lodged in or between the
parts.

Use caution t ensure that small parts (such as bolts


and screws) d not become separated.

Carefully ins ect packing material for loose parts


before discar ing.

These limits are guidelines to ensure a safe


storage environment for all equipment. However, 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

GE GUIDELINES
If the unit is not in tailed immediately upon receipt, it
must be stored pro erly to prevent corrosion and deterioration. Since pack' g cases do not protect the equipment
for outdoor storag , the customer must provide a clean,
dry'place free ofte perature variations, high humidity,
and dust.

Use the following uidelines when storing equipment:


ent under adequate cover with the
ements:
Keep the e uipment clean and dry, protected
from preci itation and flooding.
Use only b eathable (canvas type) covering material- do ot use plastic.
Unpack the eq 'pment as described in Unpacking
(page 2).

Moisture on certain internal parts can cause


electrical failure.
Condensation occurs with temperature drops of
15C (27 OF) at 50% humidity over a 4-hour period.
Condensation also occurs with smaller temperature variations at higher humidity.

SPECIFICATION

CAUTION

Maintain the fo lowing environment in the storage


enclosure:

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

CAUTION
To prevent fire hazard, remove all cartons
and other such flammable materials packed
inside units before energizing any heaters.

BI006008

EI-I00228

Receiving and Storage Instructions for DIRECTO-MATIC 2000 Equipment

ME LIMITATIONS

OBTAINING PARTS AND SERVICE

le above specifications apply to shipping and storage


lrations of up to one year. Longer times may require
lditional treatment.

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:

WARRANTY PARTS AND SERVICE


fARRANTY TERMS

he GE Terms and Conditions brochure provides product


arranty information, including the warranty period and
arts and service coverage.

GE requisition number

Equipment serial number and model number

Part number and description

he brochure is included with the customer documentaon. It may also be obtained separately from the nearest
E Sales Office or authorized GE Sales Representative.

GEMotors&
Industrial Systems

-------------------------------------

e Date: October 1996

6110llrlll Eillctric Complloy

Industrial Systems
1501 Roanoke Blvd.
Salem, VA 241536492 USA

BI006008

GF2000
Dc Generator Field Exciter

Operation and Maintenance


GEH-6148
Issue Date: June 1995

These instructio do not purport to cover all details or variations in equipment, not to provide for every possible
contingency to b met during installation, operation, and maintenance. Should further information be desired or
should particula problems arise that are not covered sufficiently for the purchaser's purpose, the matter should be
referred to GE D 've Systems and Turbine Controls.
This document c ntains proprietary information of General Electric Company, USA and is furnished to its customer
solely to assist th 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 if GE Drive Systems & Turbine Controls.

BI006008

1995 by General Electric Company, U.S.A.


Ail rights reserved.
Printed in the United States of America.

ARCNET is a registered trademark of Datapoint Corporation.


IBM, IBM PC, and PC AT are registered trademarks of International Business Machines Corporation.
LynxOS is a registered trademark of Lynx Real-Time Systems, Incorporated.
MS-DOS is a registered trademark of Microsoft Corporation.
Muffm and Tarzan are registered trademarks of COMAIR ROTRON, a KLI Company.
DIRECTO-MATIC and VERSILUBE are registered trademarks of General Electric Company, U.S.A.

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

Safety Symbol Legend

WARNING

Commands ttention to an operating procedure, practice, condition, or statement which, if not strictly observed, coul result in personal injury or death.

CAUTION
Commands a ention to an operating procedure, practice, condition, or statement which, if not strictly observed, coul result in damage to or destruction of equipment.

NOTE

Commands a ention to an essential operating or maintenance procedure, condition, or statement that must be
highlighted.

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter

WARNING

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.

WARNING

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

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

TABLE OF CONTENTS

Section/Subject
CHAPTER 1.

VERVIEW

1-1. DefInition d Scope


1-2. Equipment Overview
1-2. 1. Comm cations Interfaces
1-2.2. Software Design
1-2.3. Hardwar Design
1-3. Related D uments

1-1
1-2
1-2
1-2
1-2
1-2

CHAPTER 2. R CEIVING, HANDLING, AND


STORAGE

2-1.
2-2.
2-3.
2-4.
2-5.

Introductio
Receiving d Handling
Storage
Unpacking
Time Limi tions

2-1
2-1
2-1
2-2
2-2

CHAPTER 3. IN TALLATION AND INITIAL


STARTUP

3-1. Introduction
3-2. Operating E vironment
3-3. Mounting
3-4. Cabling and iring
3-4.1. Ac Power equirements
3-4.2. Connectio
3-4.2.1. Power C nnections
3-4.2.2. Control onnections
3-4.3. Wiring Le el Separations
3-4.4. Spacing
3-4.5. Grounding
3-4.6. Commons
3-4.7. Suppressio
3-5. Service and arts Instruction
3-6. Power-off C eck
3-6.1. Wiring and Circuit Checks
3-6.2. Generator d Device Checks
3-7. Power Appli tion and Startup

3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-2
3-2
3-3
3-3
3-3
3-3
3-3
3-3
3-4
3-4
3-4

CHAPTER 4. FU CTIONAL DESCRIPTION

4-1. Introduction. .
4-2. Exciter Softw e Structure
4-2.1. Block Syste
4-2.2. Building BI k Architecture
4-2.3. Diagnostics
4-2.4. ConfIguring Blocks
4-3. Exciter Hard are Structure
4-3.1. Control Sec 'on
4-3.2. Power Con rter

.4-1
.4-1
4-1
.4-1
4-2
.4-2
.4-2
4-2
4-2

4-4. Controller Operation


4-5. Power Converter Operation
4-5.1. Ac Line Fuses (FUl - FU3)
4-5.2. Ac Reactors
4-5.3. Loop Contactor (MDA)
4-5.4. Control Power Transformer (CPT)
4-5-5. Shunt
4-5.6. Field Exciter Output Module
4-6. Exciter Connection Drawings

4-2
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-4

CHAPTER 5. PRINTED WIRING BOARD


DESCRIPTIONS

5-1. Introduction
5-2. Board IdentifIcation
5-3. Adjustable Hardware
5-3.1. Initial Hardware Settings
5-3.1.1. Potentiometers
5-3.1.2. Switches
5-3.1.3. Jumpers
5-3.2. Adjusting Replacement Boards
5-4. Printed Wiring Boards
5-4.1. Power Supply Board (DS200DCFB)
5-4.1.1. Power Supplies
5-4.1.2. Voltage and Current Feedback VCO
Circuits
,
,
5-4.1.3. Motor Voltage Attenuation Circuit
5-4.1.4. Ac Line Magnitude and Zero Crossing
5-4.1.5. Ac Line Current Transformer
Interface
5-4.1.6. Contactor Drive Circuits
5-4.1.7. Field/Armature SCR Firing Control
Circuits
5-4.1.8. ConfIgurable Hardware
5-4.2. Field Exciter Crowbar Board
(DS200FECB)
5-4.2.1. ConfIgurable Hardware
5-4.3. LAN 1/0 Terminal Board
(531X307LTB)
5-4.3.1. LTB Board SpecifIcations
5-4.4. Drive Terminal Board (531X305NTB)
5-4.4.1. Power Supplies
5-4.4.2. Encoder Interface
5-4.4.3. RS-232C Interface
5-4.4.4. Special Purpose RS-422 Interface
5-4.4.5. Relay Outputs
5-4.4.6. Analog Tach and Reference Coarse
Scaling
5-4.4.7. Low-level Analog I/O
5-4.4.8. Digital Control Inputs

5-1
5-1
5-1
5-2
5-2
5-2
5-2
5-2
5-2
5-3
5-3
5-3
5-3
5-4
5-4
5-4
5-4
5-4
5-8
5-8
5-9
5-9
5-10
5-10
5-10
5-10
5-10
5-10
5-11
5-11
5-11

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

TABLE OF CONTENTS - Continued

Section/Subject

Section/Subject
5-4.4.9. Configurable Hardware
5-11
5-4.5. Power Connect Card (DS200PCCA)
5-15
5-4.6. Relay Terminal Board (DS200RTBA)
5-18
5-4.7. Drive Control Card (DS215SDCC)
5-20
5-4.7.1. Reset Circuits
5-20
5-4.7.2. Configurable Hardware
5-20
5-4.7.3. Replacing/Inserting Software
5-20
5-4.8. LAN Communications Card
(DS215SLCC)
5-23
5-4.8.1. Configurable Hardware
5-23
5-4.8.2. Replacing/Inserting Software
5-23
5-4.9. Signal Processor Card (531X309SPC)
5-26
5-4.9.1. Configurable Hardware
5-26
5-4.10. Voltage Attenuator Board (DS200SVAA) 5-31
5-4.11. Shunt Isolator Board (DS200SVIA)
5-33
5-4.11.1. Input Stage
5-33
5-4.11.2. Isolation Stage
5-34
5-4.11.3. Output Stage
5-34
5-4.11.4. Adjustment Procedures
5-34
5-4.11.5. Voltage Isolation Function
5-34
5-4.11.6. Current Signal Converter
5-35
5-4.11. 7. Configurable Hardware
5-35
CHAPTER 6. I/O DEFINITIONS

6-1. Introduction
6-2. Types of Connectors
6-2.1. Plug-in Connectors
6-2.2. Terminal Board Connectors
6-2.3. Stab Connections (Stabs)
6-3. LED and Neon Indicators
6-4. DCFB Board 1/0
6-5. FECB Board I/O
6-6. LTB Board I/O
6-7. NTB/3TB Board I/O
6-8. PCCA Card I/O
6-9. RTBA Board I/O
6-10. SDCC Card 1/0
6-11. SLCC Card I/O
6-12. SPC Card I/O
6-13. SVAABoardI/O
6-14. SVIA Board I/O

ii

6-1
6-1
6-1
6-1
6-1
6-1
6-2
6-7
6-8
6-11
6-17
6-18
6-20
6-22
6-23
6-24
6-25

CHAPTER 7. FUSES AND TESTPOINTS

7-1. Line Fuses


7-2. DCFB Onboard Fuses
7-3. Testpoints
7-3.1. DCFB Board Testpoints
7-3.2. NTB/3TB Board Testpoints
7-3.3. SDCC Card Testpoints
7-3.4. SPC Card Testpoints
7-3.5. SVIA Board Testpoints

7-1
7-1
7-3
7-3
7-3
7-4
7-6
7-7

CHAPTER 8. SOFTWARE ADJUSTMENTS

8-1. Introduction
8-2. ST2000 Toolkit
8-2.1. Equipment Requirements
8-2.2. Using the ST2000 Toolkit.
8-3. Drive Configurator, LynxOS Version
8-3.1. Equipment Requirements
8-3.2. Using the Drive Configurator
8-4 Programmer Module
8-4.1. Keypad
8-4.2. Display
8-4.3. Operating Modes
8-4.3.1. Operate Mode
8-4.3.2. Parameter Mode
8-4.3.3. Diagnostic Mode
8-4.4. Drive Diagnostics
8-4.4.1. Running the Diagnostic Tests
8-4.4.2. Diagnostic Test Definitions
8-4.4.3. DACl, DAC2, METl, and MET2

8-1
8-1
8-1
8-1
8-2
8-2
8-2
8-2
8-3
8-3
8-3
8-3
8-5
8-7
8-7
8-7
8-8
8-10

CHAPTER 9. TUNEUP PROCEDURE

9-1. Introduction
9-1
9-2. Required Equipment.
9-1
9-3. Setup
9-1
9-3.1. DAC Variable Selection
9-2
9-3.2. Diagnostic Use
9-3
9-3.3. Setting EEPROM Values in EDITIOOO
9-3
9-3.4. Entering Terminal Mode
9-3
9-3.5. Test 31 - Display Diagnostic Variables
9-3
9-3.6. Setting Regulation Modes
9-3
9-4. Step 1 - Preliminary Calculations
9-3
9-4.1. VCO Feedback Scaling
9-4
9-4.2. Bridge Overcurrent Protection
9-4
9-5. Step 2 - Generator Field Time Constant.
9-4
9-6. Step 3 - Proportional Field Current Regulator
Response
9-6
9-7. Step 4 - Proportional Plus Integral
Regulator
9-7

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

TABLE OF CONTENTS - Continued

Section/Subject
9-8. Step 5 - F eld Current Converter
Linearizaf n
9-9. Step 6 nerator Saturation Curve
9-10. Step 7 dy Current Lag Time Constant
Determin tion
9-11. Step 8 ature Voltage Regulator
9-12. Step 9 ature Current Feedback
Scaling d Overcurrent Setting
9-13 . Step 10 ature Time Constant
Determin tion
9-14. Step 11 mature Current Regulator.
9-15. Step 12 ature Current Rate and
Filter
9-16. Step 13 - peed Regulator Feedback
Scaling an Polarity Verification
9-17. Step 14 - roportional Speed Regulator
9-18. Step 15 - roportional Plus Integral Speed
Regulator. .
CHAPTER 10.

9-8
9-9
9-10
9-11
9-12
9-13
9-14
9-16
9-16
9-17
9-18

ROUBlESHOOTING

10-1. Introductio
10-1
10-2. Tools and
truments
10-1
10-3. General T ubleshooting
10-1
10-4. Stability P blem Troubleshooting........... 10-6
10-4.1. Cyclical tability Problems
10-6
10-4.2. Mechani al Oscillation Problems
10-7
10-4.3. Erratic 0 eration Problems
10-7
10-4.4. Troubles ooting Procedures
10-7
10-4.4.1. Initial hecks
'" 10-7
10-4.4.2. Proble Determination
10-7
10-4.5. Ac Line hase Problems
10-7
10-5. Specific Fa t Troubleshooting
10-9
10-5.1. Fault Indi ation
10-9
10-5.1.1. Progr
er Display
10-9
10-5.1.2. LED D' play
10-9
10-5.2. Types of aults
10-9
10-5.3. Clearing e Fault.
10-10
CHAPTER 11. D

GNOSTIC LISTS

11-1. Introduction
11-2. MCP Diagn stic Circular List..
11-2.1. Circular L st Content........................
11-2.2. Circular L st Operation
11-2.3. Circular L st Display
11-3. DCP Circul List Blocks
11-3.1. CLST BI ks
11-3.1.1. CLSTl ( asic) Block

11-1
11-1
11-1
11-1
11-1
11-2
11-2
11-2

11-3.1.2. CLST2 (Intermediate) Block


11-3.1.3. CLST3 (Advanced) Block
11-3.2. Circular List Display
11-4. LCP History Buffer

11-2
11-3
11-3
11-4

CHAPTER 12. PARTS REPLACEMENT

12-1. Introduction
12-2. Replacing Boards
12-3. SCR Module Repair/Replacement..

12-1
12-1
12-2

CHAPTER 13. SPARE AND RENEWAL PARTS

13-1. Introduction
13-1
13-2. Custom Renewal Parts Listing
13-1
13-3. Ordering Renewal Parts
13-1
13-4. Part Number Structure
13-1
13-4.1. Order-specific Assembly Part Numbers .. 13-1
13-4.2. Common Assembly Part Numbers
13-2
13-4.3. Component Part Numbers
13-2
13-4.4. Board Part Numbers
13-2
13-5. GF2000 Dc Generator Field Exciter
Parts Lists
13-2
APPENDIX A. GLOSSARY OF TERMS
APPENDIX B. HARDWARE DRAWINGS

B-1. Introduction

B-1

APPENDIX C. ELEMENTARY DIAGRAM, C AND


C EXTENSION FRAME EXCITERS

C-l. Introduction

C-l

APPENDIX D. ELEMENTARY DIAGRAM, G


FRAME EXCITERS

D-l. Introduction

D-l

APPENDIX E. PERIODIC MAINTENANCE

E-l. Introduction
E-2. Preventive Maintenance
E-3. Cooling Fans

E-l
E-l
E-2

APPENDIX F. WARRANTY PARTS AND


SERVICE

F-l. Warranty Terms


F-l
F-2. Obtaining Parts and Service Under Warranty F-l

iii

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

LIST OF FIGURES

5-1. Pot Set at Default Position


5-2. DCFB Board Layout.
5-3. FECB Board Layout
5-4. LTB Board Layout
5-5. NTB/3TB Board Layout.
5-6. PCCA Card Layout
5-7. RTBA Board Layout..
5-8. SDCC Card Layout
5-9. SLCC Card Layout
5-10. SPC Card Layout
5-11. SVAA Attenuation Circuit
5-12. SVAA Board Layout
5-13. SVIA Simplified Elementary Diagram
5-14. SVIA Board Layout
7-1. DCFB Board Layout..
7-2. NTB/3TB Board Layout..
7-3. SDCC Card Layout
7-4. SPC Card Layout.
7-5. SVIA Board Layout..
8-1. Changing Modes of Operation
9-1. GF2000 Regulators and Control Loops
9-2. Generator Saturated Field Time Constant
Determination
9-3. Proportional Generator Field Current
Regulator.
'"
9-4. Proportional Field Current Regulator
Response Plot

iv

5-2
5-4
5-8
5-10
5-11
5-16
5-18
5-21
5-24
5-26
5-31
5-32
5-33
5-35
7-2
7-3
7-5
7-6
7-8
8-5
9-2
9-5
9-6
9-7

9-5. Proportional Plus Integral Generator Field


Current Regulator
9-6. Converter Linearization
9-7. Deadtime (Ifg = 0) Determination Plot
9-8. Typical Generator Saturation Curve
9-9. Armature Voltage Regulator With Eddy
Current Lead and Lag Time Constants
9-10. Armature Voltage Regulator Response
Plot
9-11. Armature Time Constant Determination
Response Plot...................................
9-12. Generator Armature Current Regulator.. ...
9-13. Generator Armature Current Regulator
Response
'"
9-14. Speed Regulator Block Diagram.............
9-15. Proportional Speed Regulator Response
10-1. BCD-coded LED Display
10-2. Binary-coded LED Display
B-1. GF2000 Dc Generator Field Exciter
Hardware Drawing 336A3511
C-l. Sample Elementary Diagram, GF2000
C Frame Exciter.
D-1. Sample Elementary Diagram, GF2000
G Frame Exciter.

9-7
9-8
9-9
9-10
9-11
9-12
9-14
9-15
9-16
9-18
9-18
10-9
10-9
B-2
C-2
D-3

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

LIST OF TABLES

4-1.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.

GF2000 F ame Size Specifications


.4-3
DCFB Bo d Adjustable Hardware
5-5
NTB/3TB oard Adjustable Hardware
5-11
PCCA C d Uses
5-15
PCCA C d Adjustable Hardware
5-16
RTBA Bo d Adjustable Hardware
5-18
SDCC C
Adjustable Hardware
5-21
SLCC Car Adjustable Hardware
5-25
SPC Card djustable Hardware
5-27
SVAA Bo d Attenuation Jumper
Placement
5-32
5-10. DCFB DI Switches SW4 and SW5 Settings
With SV
Board Attenuation of 0.442
5-32
5-11. SVIA Inp t Gain
5-33
5-12. SVIA Bo d Adjustable Hardware
5-36
6-1. Connector PL, I/O Between DCFB Board
and SDCC Card
6-2
6-2. Connector PL, I/O Between DCFB Board
and NTB/3 B, SDCC, and SLCC Boards ..... 6-3
6-3. Connector PL, I/O Between DCFB Board
and NTB/3 B Board
6-3
6-4. Connector PL, I/O Between DCFB Board
and PCCA ard
6-4
6-5. Connectors NPL, CPTPL, and FAPL,
I/O Betwee DCFB Board and Components .. 6-5
6-6. Connectors
IPL, IA2PL, IFIPL, and
IF2PL, I/O Between DCFB Board and
Shunts
6-5
6-7. Connector ACPL, I/O Between DCFB
Board and ontactor Driver Circuits
6-5
6-8. DCFB Boar Stab Terminal Connections
6-6
6-9. Neon Lamp and LEDs on DCFB Board
6-6
6-10. FECB Bo d Stab Terminal Connections
6-7
6-11. Connector PL, I/O Between LTB,
NTB/3TB, d SDCC Boards
6-8
6-12. Connectors INI Through IN8, Inputs to
LTB Board
6-9
6-13. Connector PL, I/O Between LTB Board
and SLCC ard
6-9
6-14. Connector PTPL, I/O Between LTB Board
and NTB/3 B Board
6-9
6-15. Connectors T1 Through 0T7, LTB Board
Connectio from Form C Relay Contacts. 6-10
6-16. Connector
L, I/O Between LTB Board
and RTBA oard
6-10
6-17. LEDs on L B Board
6-10
6-18. Connector 3 B, I/O Between NTB/3TB
Board and ternal Connections
6-11

6-19. Connector 6PL, I/O Between NTB/3TB


Board and SDCC Card
6-15
6-20. Connector COMPL, RS-232C I/O Between
NTB/3TB Board and User Interface
6-16
6-21. Connectors IFPL Through 6FPL and
lRPL Through 6RPL, Output from PCCA
Card to SCR Bridge
,
'"
6-17
6-22. PCCA Card Stab Terminal Connections
6-17
6-23. Connector RTBA, I/O Between RTBA
Board and External Connections
6-18
6-24. Connectors CPIPL Through CP5PL and
Y9PL Through Y35PL, RTBA Pluggable
Circuits
6-19
6-25. LEDs on RTBA Board
6-19
6-26. Connector 3PL, SDCC Card Output to
6-20
SLCC Card
6-27. Connector 7PL, I/O Between SDCC Card
and SPC Card
6-21
6-28. Connector IIPL, SDCC Output to Meters. 6-21
6-29. LEDs on SDCC Card
6-21
6-30. Connector ARCPL, I/O Between SLCC
Card and DLAN or ARCNET
6-22
6-31. Connector KPPL, I/O Between SLCC Card
and Keypad
" .,
6-22
6-32. Connectors 16PL and 1TB, I/O Between
SPC Card and External Connections
6-23
6-33. SVAA Board Terminal Connections
6-24
6-34. SVIA Board Terminal Board Connections .. 6-25
6-35. LED on SVIA Board
6-25
7-1. GF2000 Dc Generator Field Exciter Line
Fuse Values
7-1
7-2. DCFB Board Fuses
7-2
7-3. DCFB Board Testpoints
7-3
7-4. NTB/3TB Board Testpoints
7-3
7-5. SDCC Card Testpoints
7-4
7-6. SPC Card Testpoints
7-6
7-7. SVIA Board Testpoints
7-7
8-1. Standard Diagnostic Tests
8-8
8-2. RAM Addresses for Analog Signals
8-9
8-3. Diagnostic Mode Analog Output Points .,
8-10
9-1. GF2000 Variable Addresses
9-2
9-2. GF2000 Regulation Modes
9-5
9-3. Open Loop Firing Mode EEPROM Values
9-4
9-4. Generator Proportional Command and
Feedback Gain EEPROM Values
9-6
9-5. Proportional Plus Integral Regulator
EEPROM Values
9-8
9-6. Field Current Linearization EEPROM
Values
9-9

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

LIST OF TABLES - Continued

9-7. Armature Voltage Regulator EEPROM


Values
9-8. Armature Current Regulator Gain
EEPROM Values
'"
9-9. Proportional Speed Regulator EEPROM
Values
10-1. Troubleshooting Quick Reference Guide
10-2. General Troubleshooting Chart
10-3. Stability Troubleshooting
10-4. Summary of Fault Types
10-5. Specific Fault Troubleshooting Using
Fault Numbers
11-1. MCP Circular List Software Jumpers
EE.6282 (MDGNJP)

vi

9-12
9-15
9-17
10-2
10-3
10-8
10-10
10-11
11-5

11-2. DCP Circular List Software Jumpers


11-3. LCP History Buffer Software Jumpers
12-1. SCR Module Mounting and Connecting
Torque Requirements
13-1. GF2000 C and CX Frame Exciter Parts
List
13-2. GF2000 G Frame Exciter Parts List
C-1. GF2000 C and CX Frame Elementary
Diagram Sheet Summary
D-l. GF2000 G Frame Elementary Diagram
Sheet Summary
D-2. Terminal Board 2TB Connections, GF2000
G Frame Exciter

11-7
11-9
12-2
13-3
13-6
C-l
D-l
D-2

BI006008

GF2000 Dc G

GEH-6148

erator Field Exciter

CHAPTER 1
OVERVIEW

1-1 . DEFINITI N AND SCOPE

This manual des ribes the GF2000 Dc Generator Field


Exciter. The G 000 exciter is a microprocessorbased power co erter that provides a controlled dc
output to excite e field of a dc generator used in a
motor-generator control system.
This manual is . tended to assist applications and
maintenance per onnel in understanding the equipment
hardware and so are.

Chapter 1 - Ov
Briefly defm s the GF2000 exciter, with an overview of the
dware and software design.
Chapter 2 - Rec iving, Handling, and Storage
Provides gui elines for handling and storing the
GF2000 exci r upon receipt.
Chapter 3 - In lation and Initial Startup
Contains en . onmental, mounting, and electrical
guidelines for installing the GF2000 exciter, including pre-st
p checks and tuneup procedures.
ional Description
Describes the F2000 exciter software and hardware structur , including overall operation.
Chapter 5 - Print d Wiring Board Descriptions
Describes the
ction and operation of boards
within the exc er, including descriptions of the
adjustable bar ware included on each board.
Chapter 6 - I/O ermitions
Lists and defm s I/O connector points, stabs, and
LEDs for the F2000 exciter.
Chapter 7 - Fuses and Testpoints
Lists and defm s the fuses and signal testpoints
available in the exciter and on some boards.

Chapter 8 - Software Adjustments


Defmes the adjustable software used to customize
and fme-tune the GF2000 exciter. Includes information on operating the Programmer, the module
used to make software adjustments and to perform
diagnostic testing.
Chapter 9 - Tuneup Procedure
Provides a procedure to optimize the time constants and gain values of all the regulators in the
control loops used in the GF2000 exciter control
software.
Chapter 10 - Troubleshooting
Provides information to detect and correct problems with the GF2000 exciter, including general
problems, stability problems, and problems indicated by diagnostic test error codes.
Chapter 11 - Diagnostic Circular List
Describes the GF2000 exciter's Diagnostic Circular List and how to use it for troubleshooting.
Chapter 12 - Parts Replacement
Provides instructions for replacing printed wiring
boards and silicon-controlled rectifiers (SCRs)
used in the GF2000 exciter.
Chapter 13 - Spare and Renewal Parts
Contains ordering information for GF2000 exciter
parts, including part numbers.
Appendix A - Glossary of Terms
Defmes acronyms and terms used in this manual.
Appendix B - Hardware Drawings
Includes the hardware drawings provided in the
door pocket of a GF2000 exciter.
Appendix C - Sample Elementary Diagram, C and
C Extension Frame Exciters
Provides a sample elementary diagram for C and
C Extension frame GF2000 exciters.

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GEH-6148
Appendix D - Sample Elementary Diagram, G
Frame Exciters
Provides a sample elementary diagram for a G
frame GF2000 exciter.
Appendix E - Periodic Maintenance
Provides recommended periodic maintenance for
the equipment.
Appendix F - Warranty Parts and Service
Explains procedures for obtaining warranty information and service.
Refer to the Table of Contents for the organization of
these chapters and appendices.

GF2000 Dc Generator Field Exciter


1-2.3. Hardware Design

A GF2000 exciter consists of a control section and a


power converter section, described in Chapter 4.
The control section, or controller, includes printed
wiring boards containing microprocessors with companion circuits, including EEPROM (electrically erasable programmable read-Only memory). Additional
boards provide optional features. Chapter 5 describes
the boards.
The power converter section consists of an SCR
bridge rectifier and control circuitry. The components
and frame size vary for the dc output required. Chapter 4 defmes the frame sizes available for the GF2000
exciter.

1-2. EQUIPMENT OVERVIEW


1-3. RELATED DOCUMENTS

The GF2000 Dc Generator Field Exciter uses a basic


digital hardware design with powerful application
software. The user interface consists of a IO-character
alphanumeric display and a keypad for simplified
monitoring, diagnostics and tuneup.

The following documents also apply to the GF2000


exciter, and may assist in installation and troubleshooting:

1-2.1. Communications Interfaces

Hardware summary - located in the exciter door


pocket, includes drawings showing the locations
of terminal board points, printed wiring
boards, connectors, plugs, and power fuses
within the exciter (see Appendix B for examples)

The GF2000 exciter provides local area network


(LAN) and RS-422 interfaces for external communications. An RS-232C interface is also provided for use
with the ST2000 Toolkit or Drive Configurator,
LynxOS@ Version.

GEH-5860 - ST2000 Toolkit User's Manual


GEH-6203 - Drive Configurator, LynxOS Version,
User's Manual

1-2.2. Software Design

Custom software (if applicable)

The application program consists of functional software modules (building blocks), which combine to
perform to system requirements. Block definitions and
configuration parameters are stored in ROM (readonly memory), while variables are stored in RAM
(random-access memory). Microcontrollers execute
the code. See Chapter 4 for details.

GEH-6011 - Installation Guidance Service for


DIRECTO-MATIC 2000 Equipment

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 8 for details.

1-2

GE Drive Systems supplies the applicable documents


to customers as needed to support the equipment.

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

CHAPTER 2
RECEIVING, HANDLING, AND STORAGE

2-1. INTROD CTION

If assistance is needed, contact:

This chapter co tains guidelines and precautions for


handling and st ring the GF2000 Dc Generator Field
Exciter upon re eipt.

Industrial SystemsDrive Systems & Turbine Controls


General Electric Company
Product Service Engineering
1501 Roanoke Boulevard
Salem, VA 24153-6429 USA
Telephone 001-540-387-7595
Fax
001-540-387-8606

2-2. RECEIVI G AND HANDLING

CAUTION
2-3. STORAGE

Possible d ger of damage to equipment.


Immediatel upon receiving the GF2000
exciter, pIa e it under adequate cover to
protect it f: m adverse conditions. Packing
cases are n suitable for outdoor or unprotected stora e.
Shock cans
age electric
damage wh
sure to obse
with all han
the case.

by rough handling can damequipment. To prevent such


moving the equipment, be
e normal precautions along
ing instructions printed on

If the exciter is not installed immediately upon receipt,


it must be stored properly to prevent corrosion and
deterioration. 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.

Use the following guidelines when storing equipment:


1.

General Electric ompany (GE) carefully inspects and


packs all equipm t before shipping it from the factory. A packing l' t, which itemizes the contents of
each package, is ttached to the side of each case of
the equipment.
GE provides han
shipment, the equ
cess moisture or
cess temperature

ing guidelines to the carrier. During


ment should not be exposed to exmidity, extreme temperatures, exanges, or rough handling.

Upon receipt, car fully examine the contents of each


shipment, and che k them with the packing list. Immediately report y shortage, damage, or visual indication of rough h dling to the carrier. Then notify
both the transport ion company and GE Drive Systems. Include the rial number, part (model) number,
drive code, GE re uisition number, and case number
when identifying e missing or damaged part.

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


-20C (-4 OF) to 55C (131F).

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 corrosion.

No rodents.

2-1

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GF2000 Dc Generator Field Exciter

GEH-6148
e.

Temperature variations that cause moisture


condensation on the equipment.

CAUTION
Moisture on certain internal parts can
cause electrical failure.
Condensation occurs with temperature drops of 15C
(27 OF) 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 100W lamp can sometimes serve as a substitute source of
heat.

2-4. UNPACKING
It is good practice to not completely unpack the
equipment until it has been placed as near as possible
to its permanent location. If the equipment has been
exposed to low temperatures for an extended period of
time, do not unpack it until it has reached room temperature.
When unpacking, check the contents of each case
against the packing list. Report any shortage to GE
Drive Systems.
Use standard unpacking tools, including a nail puller.
Carefully move the equipment from its container to
avoid damaging or marring the part. Wipe off any
particles of packing materials or foreign substances
that may be lodged in or between the parts.
Small parts (such as bolts and screws) are packed in
special containers to keep them together. However,
they may become separated. Therefore, carefully inspect packing material for loose parts before discarding.

CAUTION
2-5. TIME LIMITATIONS
To prevent fire hazard, remove all cartons
and other such flammable materials packed
inside units before energizing any heaters.

2-2

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 F.

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GF2000 Dc G nerator Field Exciter

GEH-6148

CHAPTER 3
INSTALLATION AND INITIAL STARTUP

This chapter co tains environmental, mounting, and


electrical guidel es for installing the GF2000 Dc
Generator Field xciter. The information presented
includes basic ci cuit checks needed after installation
and before the e citer is started up.

Caustic fumes

Power line fluctuations

Electromagnetic radiation or "noise" introduced


by:
Radio frequency signals, typically from portable transmitters used near the equipment or
its wiring.

Before starting' stallation, consult and study all furnished drawings. These should include arrangement
drawings, conne tion diagrams, elementary diagrams,
and a summary f the equipment.

Stray high voltage or high frequency signals,


typically produced by arc welders, unsuppressed relays, contactors, or brake coils operating near exciter control circuits.

G ENVIRONMENT

GF2000 exciters e suited to most industrial environments. To ensure proper performance and normal operationallife, the environment should be maintained as
follows:

Ambient tempen
40C (104

re (acceptable): 0 C (32 OF) to

Ambient tempen

re (preferred): 20C (68 OF) to

3-3. MOUNTING
The system outline drawing (included with the system
documentation) contains the exciter dimensions and
mounting diagrams.
Use the following mounting guidelines:

30 C (87 OF

Position an enclosed exciter to permit heat radiation from all surfaces.

A wall-mounted exciter may be mounted on any


fIrm, reasonably flat, vertical surface.

A wall-mounted enclosure may be placed side-byside with another enclosure.

Provide front clearance of at least the width of the


enclosure door so that the door may be fully
opened for easy access.

NOTE

Higher ambi nt temperature decreases the


life expectan of any electronic component. Keepin ambient air in the preferred
(cooler) rang should extend component
life.

Relative humidity: Up to 95% (non-condensing)


Environments that clude excessive amounts of any of
the following elem nts reduce exciter performance and
life:

3-4. CABLING AND WIRING

Dust, dirt, or

Vibration or s

All installations should meet the requirements of both


the National Electrical Code (NEC) and any applicable
local codes. Use these codes to determine such factors
as wire size, insulation type, conduit sizing, and enclosures.

Rapid tempera

e changes

3-1

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GF2000 Dc Generator Field Exciter

GEH-6148

WARNING

NOTE

Danger of electric shock or burn. Before


handling and connecting any power cables
to the equipment, ensure 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 GF2000 exciter is normally configured with the


following power requirements:

Voltage: 230,460, or 575 Vac,

+ 10%

and -5%

Phase: 3-phase
Nominal line frequency: 50 or 60 Hz, 2%
Input power to the control power transformer (CPT),
which provides 115 V ac and 40 V ac to the power
supply board, may be supplied by the ac input, or by
an external control power source. The requirements
for externally fed control power are:

Elementary diagrams may change with


product upgrades and revision. The elementary diagrams presented in Appendices
C and D are current as of the issue date of
this manual.
Ac input power connects to either a breaker or disconnect switch, which is connected to L1, L2, and L3 on
the line side of fuses FU1, FU2, and FU3.
Control power may be fed from the ac input, or may
be supplied externally by connection to fuses CPTFU1
and CPTFU2.
Generator connections are to output terminals PI and
P2.
3-4.2.2. CONTROL CONNECTIONS. Control connections to the GF2000 exciter are made by wiring the
Drive Terminal Board (NTB/3TB). Chapter 5 describes this board and includes a layout drawing to
identify the connectors on the board. Chapter 6 defmes
the I/O connections.

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).

Voltage: 230, 460 or 575, +10% and -5%

Phase: 3-phase

The optional Relay Terminal Board (RTBA) provides


screw terminal connections to the relays, as labeled.

Nominal line frequency: 50 or 60 Hz, 2 %


3-4.3. Wiring level Separations
3-4.2. Connections

Cabling and wiring connections include:

Incoming ac line connections

Power connections to the generator and motor


armatures and fields

All terminal board connections

To prevent signal interference caused by electrical


noise, installation must consider the type of voltages
on the wiring. These types must be separated and
spaced as described below.
There are four levels of wiring, which must be run in
separate conduits or wireways:

Low-level signals (Level L, see system level


drawings to identify), which consist of analog signals up to SO V dc and digital signals of 0
through 15 V dc

Medium-level signals (Level M), which consist of


analog signals greater than 50 V dc with less than
28 V ac ripple, and 28 V dc light and switching
circuits

When connecting any wiring/cabling, ensure that all


connections are tight.

3-4.2.1. POWER CONNECTIONS. Refer to the system

elementary diagram provided with the exciter. Sample


elementary diagrams for the C and G frame exciters
are provided in Appendices C and D.

3-2

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GEH-6148

GF2000 Dc G nerator Field Exciter

High-level
switching
greater th
ripple, re
A current,

signals (Level H), which consist of dc


.gnals greater than 28 V, analog signals
50 V dc with greater than 28 V ac
ating signals of 50 V with less than 20
d ac feeders of up to 20 A

3-4.6. Commons

External commons, including reference and meter, can


only be connected at the COM connector on the
NTB/3TB board, unless otherwise specifIed by the
system elementary diagrams.

g (Level P), which consists of ac and


to 800 V with currents of 20 - 800 A
3-4.7. Suppression

For additional ormation on wiring level defInitions


and separation, efer to GEH-6011, Installation Guidance Service fo DIRECTO-MATIC 2000 Equipment.

3-4.4. Spacin

The following r quirements ensure correct distance


between cabling and wiring:

Signal wir g and power wiring may cross at


right angles with a minimum I-inch separation.

Avoid paral 1 runs between signal-level wires and


power or co trol wires. If signal wires must be
run parallel ith power or control wires:
For dist ces up to 4 feet, maintain a minimum se aration of 3 inches.
ces over 4 feet, add 1/4 inch of
or every foot of additional distance.

1.

Within pullb xes and junction boxes, use


grounded biers to maintain the level separations.

Ground the e citer common (COM) at only one


point. If the ference is supplied by a numerical
control or by a process instrument with a
grounded co
on, do not provide a separate
ground for th exciter common.

2.

transformer is used and must be


a high resistance ground, unless 10odes direct otherwise.

3.

For shielded d twisted shielded wire, ground the


shields on on end only, preferably at the exciter
end. Provisio have been made to tie shields to
chassis groun at the exciter I/O.

Electrical noise transients caused by control system


relays, solenoids, or brake coils can cause erratic exciter behavior. To prevent this, add a series resistor/capacitor (Re) suppressor in parallel with the 115
V ac coils of these devices. A 220 n, 2 W resistor in
series with a 0.5 IJ-F, 600 V capacitor can typically be
used.

3-5. SERVICE AND PARTS INSTRUCTION

Each GF2000 exciter contains instructions placed inside the door to aid in connecting and troubleshooting
the exciter. These instructions contain the following
information:

Board locations

Power module locations

Fuse information and nomenclature

Plug locations

Incoming control connections at the NTB/3TB


board

Power connections

3-6. POWER-OFF CHECK

All GF2000 exciters are factory-tested and operable


when shipped to the installation site. However, it is
not uncommon for connections to loosen during shipping and handling. Therefore, fInal checks should be
made after installation before starting the equipment.
Before initial powerup, check the exciter using the
steps listed in sections 3-6.1 and 3-6.2.

3-3

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GEH-6148

GF2000 Dc Generator Field Exciter

3-6.1 . Wiring and Circuit Checks

WARNING

3-6.2. Generator and Device Checks

This equipment contains a potential hazard


of electrical shock or burn. Extremely high
voltages are present on some circuitry. To
prevent accidental injury, do not touch any
circuitry without fIrst ensuring that it does
not carry these voltages.
1.

1.

Check that the generator options are correctly


installed and connected per their device instructions.

2.

Ensure that the generator shaft is free to rotate,


and that the generator and moving devices are free
to function.

3.

Verify the generator and controller nameplate


data, such as generator maximum field current,
rated field voltage, and maximum field voltage.

Ensure that all electrical terminal connections are


tight.

a.

Check that the generator and controller voltages match.

b.

Check that the generator field current does


not exceed controller current.

NOTE

To ensure that electrical connections remain tight, they should be re-checked


within three to six months after initial
powerup, and annually thereafter, using
screwdrivers and wrenches or an infrared
survey.

4.

Check that all fuses are installed, are the right


size, and make firm contact in the fuseholder.

3-7. POWER APPLICATION AND STARTUP

2.

Ensure that all devices, modules, and boards are


secure and have not been damaged during shipping and handling or installation. Boards may be
held in place by plastic snaps (holders) or mounted
on standoffs. Check that all holders are snapped
into position and all standoffs are securely tightened.

3.

Check that all incoming wiring agrees with the


elementary drawings supplied with the exciter,
and is complete and correct.

4.

Ensure that the incoming wiring conforms to approved wiring practices, as described previously
(section 3-4).

5.

Ensure 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.

3-4

With the exciter disconnected from meggered


circuits, check for grounds in the generator, motor, or leads by meggering all terminals to
ground.

After the previous power-off checks, complete the


following steps to check the exciter with the power on.

WARNING

Before any adjustments, servicing, or any


other act is performed requiring physical
contact with electrical working components
or wiring of this equipment, ensure all
power supplies are turned off. Then
ground and discharge the equipment.

1.

Check that incoming power is the correct voltage


and frequency.

2.

Apply power to the exciter.

3.

Check for correct rotation of the 3-phase blower


in the exciter (if used). If incorrect:
a.

Turn power off. Ensure 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.

BI006008

GF2000 Dc G nerator Field Exciter


4.

Check the 'splay on the Programmer (described


in Chapter 8) for error indication:
a.

b.

5.

6.

If the xciter powers up with no faults, the


Progr
er indicates ready-to-run by displayin M S 0% 10% (Manual Mode) or AS
0% I % (Automatic Mode).
t occurs at powerup, the display
d shows the fault name and number.
t code deftnitions, see Chapter 9.)

Using the s stem elementary diagram, ensure that


all permiss' e, start, and stop circuits are functioning pro erly.

GEH-6148
7.

Check the direction of rotation and rpm of the


prime mover.

8.

Call the assigned GE Service Offtce for additional


checks and startup.
NOTE

The GF2000 exciter software architecture


requires that a trained specialist conduct
additional checks and startup using the
ST2000 Toolkit or Drive Configurator,
LynxOS Version, developed for that purpose.

e motor-generator set running interhen the generator is turning at its

m.

3-5

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GF2000 Dc Generator Field Exciter

GEH-6148

Notes:

3-6

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

CHAPTER 4
FUNCTIONAL DESCRIPTION

4-1.INTROD CTION

4-2.1. Block System

This chapter de ribes the GF2000 Dc Generator Field


Exciter softwar and hardware structure, and overall
operation of the xciter. Refer to the sample elementary diagrams c ntained in Appendices C and D.
Chapter 5 cont . s descriptions of the printed wiring
boards containe in the exciter.

The GF2000 exciter application software is a structure


of software modules that defme data flow and function
execution. These modules are pre-defmed blocks of
code that perform specific functions.

The GF2000 exc ter provides a controlled dc output to


excite the field 0 a dc generator used in a motorgenerator contro system. In this type control system,
the armature 100 consists of a dc generator and a dc
motor. The GF2
exciter receives both voltage and
current feedbac from the generator, and regulates
both of these var abIes to drive the dc motor.

The software includes 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. Building Block Architecture

Appendices C an
grams for the G
diagram shows th
including the mot

D provide sample elementary dia000 exciter. Sheet 0 lBB of each


dc power circuit for the exciter,
r-generator power system.

The block programming scheme is an open architecture programming method that combines pre-existing
blocks of code for a variety of applications. The exciter software is configured from a library of functional blocks. The blocks are then connected by a
mechanism that schedules and controls their execution.

4-2. EXCITER

OFTWARE STRUCTURE

The GF2000 exciter stores programming data as follows:

The GF2000 exci r stores most configuration and


adjustment data' EEPROM on the Drive Control
Card (SDCC).
s data is organized into 16-bit
words, and is stor d and checksummed. The SDCC's
Drive Control Pro essor (DCP) controls memory access.

Block library (block defmitions) in the Drive


Control Processor (DCP) ROM

Block variables in RAM

Block configuration parameters in EEPROM

Four major eleme ts of the software configuration are:

An operator can examine and adjust parameters stored


in EEPROM in one of three ways: using the Programmer on the LAN Communications Card (SLCC),
or using the ST2000 Toolkit (see GEH-5860) or Drive
Configurator, LynxOS Version (see GEH-6203), on a
serially connected computer.

Generic inter; ce to inner generator control loops

Pointer-based election of inputs to functional


modules

Logical addres ing of primary variables

Use of functio
regulator struc

building blocks for primary


es

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GF2000 Dc Generator Field Exciter

GEH-6148
4-2.3. Diagnostics

The GF2000 exciter 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:

Using the LED diagnostic readout on the SDCC


(see Chapter 9)

Using the Programmer's alphanumeric readout


(see Chapter 8)

Reading diagnostic messages over an optional RS232C communication link.

Drive Control Card (SDCC), which contains microprocessor circuitry

Drive Terminal Board (NTB/3TB)

LAN Communications Card (SLCC), which includes the Programmer

Power Supply Board (DCFB)

Power Connect Card (PCCA)

Optional boards include:

Signal Processor Card (SPC)

LAN I/O Terminal Board (LTB)

4-2.4. Configuring Blocks

Relay Terminal Board (RTBA)

A block source list is the program schedule. It defmes


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.

Section 4-4 describes the exciter's overall control operation. Chapter 5 describes the function and operation
of the control section's printed wiring boards.

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.

4-3.2. Power Converter

The ST2000 Toolkit and Drive Configurator, LynxOS


Version, display the blocks as configured for the particular application.

The GF2000 exciter's power converter section includes SCR bridge rectifiers, snubber circuits, and
control circuitry. The components vary for the power
output required. Section 4-5 describes these components and their operation.

4-4. CONTROLLER OPERATION


4-3. EXCITER HARDWARE STRUCTURE

The GF2000 hardware consists of the control section


and the power converter section.
The power conversion hardware is defmed by the application requirements, and therefore determines the
exciter's frame size (see Table 4-1). The control section is basically the same for the different frame sizes.

4-3.1. Control Section

The control section, or controller, contains powerful


programmable microprocessors with companion circuitry, including EEPROM, to process the application
software. The controller includes the following printed
wiring boards:

4-2

The GF2000 exciter provides microprocessor regulation to provide a controlled dc output to excite the field
of a dc generator in a motor-generator control system.
The exciter combines programmable dc drive control
with power circuitry. Exciter parameters are stored in
EEPROM, keeping them accurate and drift free.
Three-phase ac input power to the GF2000 must be
supplied by a single transformer. The ac input power
is fed to the SCR bridge through rectifier fuses, which
protect the bridge against internal and converter faults.
If the GF2000 is used to gate a single-phase motor
field exciter, the motor field exciter must be powered
by a separate single-phase transformer; it cannot be
powered by a secondary winding of the transformer
that supplies the GF2000 exciter. Multiple GF2000
exciters should be powered from a combination of
delta-delta and delta-wye transformers.

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GF2000 Dc G

GEH-6148

erator Field Exciter


Table 4-1. GF2000 Frame Size Specifications
Ae Input
Voltage
(Vael

Maximum Dc
Output Voltage
(V del

Maximum Dc
Output Current
(AI

230
460
575

300
600
800

280
280
280

C Extension

230
460
575

300
600
800

500
500
500

230
460
575

300
600
800

125
125
125

Frame Size

The SCR bridge converts the incoming ac power to an


adjustable dc vo age. The dc current is fed to the generator field thro gh a shunt, which is used to provide
output current fe dback.

The SCR converter also includes snubber circuits


across each set of SCRs. A separate RC network
serves as a dc fIlter across the output of the SCR
bridge.

Ac reactors limi the rate of change of line current


when the curren commutates from one output leg to
another.

The PCCA card provides an interface between the


GF2000 control circuitry and the SCR bridge. The
PCCA provides gating to the SCRs in the bridge. For
low-to-medium horsepower applications, the PCCA
also includes snubber circuits. For higher horsepower
applications, the snubbers are omitted from the PCCA,
and are located elsewhere in the system.

A field exciter 0 tput module protects the SCR bridge


against high volt ges generated when the dc generator
field current is d -energized and the exciter no longer
controls the field voltage. The module includes a
crowbar circuit at provides a path for field current to
flow if the gener tor field voltage exceeds a preset
limit. A load resi tor absorbs the residual field current
during bridge re rsals.
Current and vol
erator and motor
(voltage-controlle
the analog signals

e feedback signals from the dc gene fed to the DCFB board. VCOs
oscillators) on the DCFB convert
into variable frequency signals.

The DCFB recei


control power tr
logic power to th
enclosure fans. F
fan is also power

s 115 and 38 V ac power from the


former (CPT). The DCFB provides
exciter and 115 V ac to the card
r C frame exciters, the SCR bridge
by the DCFB 115 V ac source.

The GF2000 excit r features a full-reversing SCR


converter, which eceives 3-phase power through
fuses FU1, FU2, d FU3. (The SCR converter is
shown in the elem ntary diagrams contained in Appendices C and D . The SCR converter includes 12
SCRs that make u the SCR bridge: SCRs IF through
6F make up the fo ard portion of the bridge; SCRs
IR through 6R m e up the reverse portion of the
bridge.

The dc power is supplied to the generator field


through a shunt. No dc fuse is required. The shunt
provides current feedback to the DCFB. The DCFB
also receives voltage feedback from across the dc
output.
A thermal sensor is mounted on the SCR heatsink. If
the temperature of the heat sink exceeds 190 OF (87.8
0c), the thermal sensor opens a switch which can be
used to shut down the SCR bridge.

4-5. POWER CONVERTER OPERATION

The following sections describe the power converter


circuitry associated with the GF2000 exciter.

4-5.1. Ac line Fuses (FU1 - FU3)

Ac line fuses protect the power SCRs, internal wiring,


and output wiring from short circuits. Instantaneous
and timed overcurrent functions in the control software
also protect against excess current.

4-3

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GF2000 Dc Generator Field Exciter

GEH-6148
4-5.2. Ac Reactors

4-5.6. Field Exciter Output Module

Ac reactors are included on the ac power lines between the ac line fuses and the SCR bridge. The reactors limit the rate of change in line current when the
bridge current commutates from one leg to another.

The field exciter output module connects across the


output buses of the GF2000 exciter. This module performs load resistance, dc filtering, and protective
crowbar functions for the exciter.

4-5.3. Loop Contactor (MDA)

The MDA loop contactor, located in the armature


loop, provides a controllable disconnect between the
dc generator and the motor. The contactor picks up
when the run mode is selected (see Programmer description in Chapter 8) and no fault exists in the exciter. The contactor drops out if Normal Stop (Coast
Stop) is initiated, or if a fault condition occurs.

4-5.4. Control Power Transformer (CPT)

The CPT is energized either from the ac input lines, or


from an external control power source. The secondary
winding provides two isolated voltages:

115 V ac to operate the enclosure cooling fans and


SCR bridge cooling fan (if used)

38 V ac center-tapped for the DCFB board to

generate the dc control voltages necessary for


controller operation

4-5.5. Shunt

The generator field shunt provides the SCR bridge


current feedback signal to the DCFB board. The shunt
generates a nominal 100 mV output signal at the current rating stamped on it.

The output module includes two 450 n, 1 A wirewound power resistors connected in series across the
GF2000 exciter output buses. (Note that this type of
resistor is typically specified according to resistance
and current rating, rather than wattage.) These resistors provide a load resistance for the GF2000 exciter.
The resistors are selected based on the maximum output voltage (Edo) with a 575 V ac input. The load resistors provide a path for the small amount of current
that remains when all of the SCRs are momentarily
turned off during reversal of the bridge.
The dc filter consists of a 140 n, 1.75 A wire-wound
power resistor connected in series with a 0.5 ~F, 2000
V dc capacitor. The dc fllter and load resistors help
the SCR bridge build the generator field current from
zero to the holding current of the SCRs.
The crowbar circuit protects the SCR bridge against
the high voltages generated by the dc generator field
when the field current is reduced. The crowbar circuit
includes a dual in-line SCR module. Each SCR in the
module is connected to a Field Exciter Crowbar Board
(FECB). If the voltage across the dc generator field
exceeds a preset limit in either direction, the corresponding FECB board gates its SCR to provide a path
for the field current to flow. Hardware jumpers on the
FECB board are used to select a generator field voltage limit of 700 or 1400 V. An externally mounted
series resistor (RCB) may be included to decrease the
time the field current takes to decay to zero.
The FECB board is described in Chapter 5.

NOTE

To increase the range of the generator field


current regulator, the rated generator field
current should not exceed 75% of the current rating of the shunt. This results in a
maximum field current forcing ratio of
1.67 per unit.

4-6. EXCITER CONNECTION DRAWINGS

Appendices C and D contain sample elementary diagrams for C frame and G frame GF2000 exciters, respectively.
NOTE

Elementary diagrams may change with


product upgrades and revisions. The information presented in this manual is current as of the issue date.

4-4

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GF2000 Dc G nerator Field Exciter

GEH-6148

CHAPTER 5
PRINTED WIRING BOARD DESCRIPTIONS

This chapter de cribes the printed wiring boards used


in the GF2000 c Generator Field Exciter and their
operation. Chap er 6 defmes the I/O connections for
these boards. C apter 7 lists and defmes the fuses and
testpoints cont . ed on some of these boards.

5-2. BOARD I ENTIFICATION


A printed wirin
meric part (cat
series are corom
GE Drive Syste

board is designated by an alphanuog) number. Two parts numbering


nly used for printed wiring boards at
s.

Most boards con ained in the GF2000 exciter are designated with part numbers beginning with the characters DS200. For xample, the Power Supply Board is
identified by part number DS200DCFBG#ruu. The
DS200DCFB po ion is the base number that identifies
the printed wirin board, in this case, the Power Supply Board. The r d u digits are alphabetic characters
that indicate the r vision level of the printed wiring
board. The r digi reflects a functional change that is
not downward co patible. It is essentially a new
catalog number.
e u digits represent revision levels
that are downwar compatible to the r revision level.
The G# identifies group, which is a variation of a
particular board.

the configuration; the r digit is an alphabetic character


that indicates the revision level of the printed wiring
board. The G# identifies a group, which is a variation
of a particular board.
All digits are important when ordering or replacing
any board. Chapter 13 contains spare and renewal
parts information.

NOTE

The terms card and board both apply to


printed wiring boards. In this manual,
board is the preferred term. However, card
is used in some drawings and when it is
part of a board's pre-established nomenclature - for example, the Drive Control
Card (SDCC).

5-3. ADJUSTABLE HARDWARE

Some printed wiring boards used in the GF2000 exciter include adjustable potentiometers (pots),
switches, and jumpers for setting and fme-tuning
functions. The board layout drawings in this chapter
show their locations on the boards. The board adjustable hardware tables list and describe the adjustments.

WARNING
include onboard software stored in
ction in the exciter. For one of
memory chips to
these boards, the art number begins with the characters DS200 if the oard does not include the memory
chips, and DS215 f the board does include the memory chips. For ex pIe, a Drive Control Card without
onboard software' identified by the part number
DS200SDCC; aD ive Control Card with onboard
software is identifi d by the part number
DS215SDCC.
Other boards cont
designated with p
acters 531X. For e
is identified by p
531X305NrB porti
the printed wiring
minal Board. The

ed in the GF2000 exciter are


numbers beginning with the charample, the Drive Terminal Board
number 531X305NTBcrG#. The
n is the base number that identifies
oard, in this case, the Drive Terdigit can be A or B, depending on

Potentially hazardous voltages are present


in the exciter circuits. Ensure that power is
off before touching a board or any connected circuits.

CAUTION
Some boards contain static-sensitive components. To prevent component damage
caused by static electricity, use staticsensitive handling techniques with all
boards.

5-1

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GF2000 Dc Generator Field Exciter

GEH-6148
NOTE

The jumpers are defmed in the board adjustable hardware tables contained in this chapter.

Board adjustable hardware may change


with product upgrades and revisions. The
information presented in this manual is
current as of the issue date. The ST2000
Toolkit or Drive Configurator, if purchased with the exciter, contains information current as of the date the equipment
was manufactured.

NOTE

Before moving any jumper, compare its actual position with the "as shipped" position
shown on the hardware drawings located in
the exciter door pocket.

5-3.1. Initial Hardware Settings

5-3.2. Adjusting Replacement Boards

The factory sets most adjustable hardware when manufacturing and testing the exciter. For adjustments that
are not factory-set, refer to the tables in this chapter
and the exciter's Custom Software.

When replacing a board, set the pots, switches, and


jumpers on the new board to match the settings on the
board being replaced. Chapter 12 provides instructions
for replacing a board.

5-3.1.1. POTENTIOMETERS. Potentiometers (pots)


may be adjusted during startup to optimize exciter performance. The initial (default) setting is the straight-up
position (see Figure 5-1). These pots are defmed in the
board adjustable hardware tables contained in this
chapter.

5-4. PRINTED WIRING BOARDS

This section describes the printed wiring boards used


in the GF2000 exciter. These include:

Power Supply Board (DCFB)

Field Exciter Crowbar Board (FECB)

LAN I/O Terminal Board (LTB) - Optional

Drive Terminal Board (NTB/3TB)

Power Connect Card (PCCA)

Relay Terminal Board (RTBA) - Optional

Drive Control Card (SDCC)

LAN Communications Card (SLCC) - Optional

Signal Processor Card (SPC) - Optional

Voltage Attenuator Board (SVAA)

Shunt Isolator Board (SVIA)

NOTE

Use only high-impedance digital voltmeters


or the optional onboard DVM to make indicated adjustments.

Figure 5-1. Pot Set at Default Position

5-3.1.2. SWITCHES. Some boards contain DIP


switches for configuring I/O options. Switch settings
are defmed in the board adjustable hardware tables
contained in this chapter.
5-3.1.3. JUMPERS. The exciter uses Berg-type
(manually moveable) jumpers for both manufacturing
test and customer options. Typically these jumpers are
designated with a IP nomenclature.
The exciter uses hard-wired jumpers to configure
boards for component substitutions or upgrades. Typically these jumpers are designated with a WI nomenclature.

5-2

The hardware drawings included in Appendix B show


the locations of these boards in the GF2000 exciter.
The sample elementary diagrams included in Appendices C and D include board interconnection information
for the exciter.

BI006008

GF2000 Dc G nerator Field Exciter


5-4.1. Power Supply Board (DS200DCFB)

The DS200DC B Power Supply Board (DCFB) receives 38 and I 5 V ac input power from the control
power transfo er (CPT), and provides control-level
power to the ex iter and lIS V ac to the enclosure
fans. The DCF board includes the following circuits:

Control-lev I power supplies (+S, 15, and 24


V dc)

Motor or g nerator field power circuits (except


the SCR m dule)

Driver circ 'ts for the generator field SCR gate


pulse gener tors

Circuits to' trument numerous ac line and dc


motor or ge erator signals, including:
Arma e current(s) and voltage(s)
Generat r and motor field currents
Ac line urrent
Ac line oltage magnitude and phase sequence

Section 6-4 defi s I/O points for the DCFB board.


Section 7-2 defm s DCFB onboard fuses and section
7-3.1 defmes D B testpoints.
5-4.1.1. POWER SUPPLIES. The DCFB board receives 38 Vac ( 10%) from the CPT. This voltage is
full-wave rectifie and f1ltered to produce the unregulated 24 V dc tputs. The + 24 V dc output is rated
at 3 A; the -24 V dc output is rated at I A.
Regulators on the DCFB derive 15 V dc from the
24 V dc suppli . The IS V dc outputs are each
rated at 0.8 A, of which 0.25 A is available for externalloading.
The DCFB also g nerates a +5 V dc, 4 A output from
the + 24 V dc sup ly. The IPSEN signal on 2PL goes
to a TTL low stat when the +S V dc supply is in
regulation; the si al goes high if the supply goes out
of regulation. Wh n high, IPSEN generates a microprocessor reset on the Drive Control Card (SDCC).
The DCFB provid s isolated +5 and IS V dc supplies to power the
ature current feedback circuits.
The power supply
circuits by fuses F
emitting diodes (L
blown fuse indicaf

utputs are protected against short


2 and FU3 (7 A 2AG). LightDs) CRSI and CR5S provide
ns for these fuses.

5-4.1.2. VOLTAG AND CURRENT FEEDBACK VCO


CIRCUITS. The D FB includes voltage-controlled
oscillator (VCO) c cuits that convert input voltages to

GEH-6148
frequency signals. Each VCO has a nominal output
frequency of 250 kHz. The output frequency varies
from 0 to SOO kHz, depending upon the input voltage.
VCO outputs are sent to the SDCC through connector
IPL to provide feedback of the following:

SCR bridge ac input voltage

Output bridge voltage (generator field voltage)

Motor or generator voltage

Millivolt signals from field shunts

Millivolt signals from armature shunts

The SCR bridge VCO circuit provides feedback to the


SDCC through connector IPL, pin 13 (lPL-13). DIP
switch SW4 is used to scale the voltage applied to the
circuit. A frequency-to-voltage reconstruction circuit
provides a diagnostic signal for testpoint TP37 on the
SDCC through IPL-37. The diagnostic bridge voltage
signal can be viewed using an ac-coupled oscilloscope.
The second VCO provides feedback of the motor or
generator voltage to the SDCe through IPL-39. DIP
switch SWS is used to scale the voltage applied to the
circuit. In the GF2000 exciter, this VCO provides
feedback of the voltage across the generator armature.
Two other VCO circuits provide feedback of the input
voltage from a field shunt. The VCO output frequency
signals are sent to the SDCe through connector IPL.
In the GF2000 exciter, these VCOs provide feedback
of the voltages across the motor field shunt (IPL-9)
and generator field shunt (IPL-40).
The DCFB also includes two motor armature VCO
circuits. The frequency output signals from these
veos are sent to the SDCC through IPL-8 and
IPL-IO. These VCOs are at the potential of the armature bus, and are fed by an isolator. In the GF2000
exciter, one of these VCOs is used to provide feedback
of the generator armature current. Generator armature
current, detected across a shunt, is sent to the DCFB
through the SVIA board.
5-4.1.3. MOTOR VOLTAGE ATTENUATION CIRCUIT.
The DCFB includes a motor voltage attenuation circuit
that provides an analog representation of the motor
voltage. This signal is sent to the SDCC through IPL6. The attenuation circuit is biased at 2.S V, and can
vary from 0 to S V depending on the motor voltage.
DIP switch SW6 is used to scale the motor voltage
feedback. In the GF2000 exciter, the motor armature
voltage is sent to the DCFB through the SVAA board,
which is mounted on a remote panel.

5-3

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GF2000 Dc Generator Field Exciter

GEH-6148

connector IPL. The gate array is programmed at powernp by a serial PROM.

5-4.1.4. AC LINE MAGNITUDE AND ZERO


CROSSING. The DCFB contains amplifier circuits that

process the ac line-to-line voltages. The voltage signals


are sent to the SDCC through IPL-ll, IPL-12, and
IPL-29. These signals are used to detect power bridge
SCR failures and may also be used to derive the synchronization signal for the firing of the SCRs. DIP
switches SWl, SW2, and SW3 are used to scale the ac
line voltage feedback.

The 5 V outputs of the gate array are converted by


gate pulse amplifier circuits into the power level required to feed the forward and reverse gate pulse
transformers on the PCCA card. These signals are sent
to the PCCA through 5PL. To prevent spurious firing
signals, the firing power is removed from the gating
circuits until the gate array is programmed and the 5 V
power is being regulated.

5-4.1.5. AC LINE CURRENT TRANSFORMER


INTERFACE. The GF2000 exciter does not include ac

current transformers; therefore this function (and DIP


switch SW7) of the DCFB is not used.

5-4.1.8. CONFIGURABLE HARDWARE. The DCFB


board includes Berg-type jumpers and DIP switches,
used for customer options. Figure 5-2 shows the layout
of the DCFB board, including the locations of the
jumpers and switches. Table 5-1 lists and defmes these
items.

5-4.1.6. CONTACTOR DRIVE CIRCUITS. The DCFB


includes relay K2, which serves as a pilot relay to the
MD contactor. The SDCC drives the coil of this relay
through IPL-34, IPL-35, and IPL-36. Connector
MACPL provides 24 V de FET output to the MD
contactor driver.

NOTE

In Table 5-1, unless otherwise specified, the


GF2000 exciter uses the same DCFB board
jumper settings as those called out for a
DC2000 drive.

5-4.1.7. FIELD/ARMATURE SCR FIRING CONTROL


CIRCUITS. The DCFB contains a gate array circuit

that controls the firing of the SCRs in the bridge based


upon control signals received from the SDCC through
IA1PL

Vl

V2

V3

P1A

P2A

VM1A

VM1B

VM2A

\I

II

II

II

II

II

II

II

II

2. ~ ~
,;-;:---; I'; ,r-; 3

'==

onnC
Uu

Rn W
1A2PL

e.-c.... c.... c....

VM23A RnW ~

'-'-

IF ~

c.....c....w"'C
-:J""O-~

L:,

IF2PL

o'ddb~

t:::=\

::>:.-

~nw

OJ:.oc-

111111113

R ;---]W

lU

'-

I-ZOI.
EJ-

1 c::J

~J3

EJ~

!~~I

3
PPL

SW6

NPL

20, tj,

ICPL

JPl

DB
JP2

LT1

c::J ~ ]

123
CR51

FU2

~
~
FU3

L:J

CNPL

O~
+'"

JCOM

~!L
-2J,['
1FPc

lOll

~I

2FPL

[~

I'

::ll
25 I

5PL

r1 N

~
rU1

P5
2PL

DS20CDCFBG1B

Figure 5-2. DCFB Board Layout

5-4

P15

F1

5PL

[C

:,

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Table 5-1. DCFB Board Adjustable Hardware
Revision

Description

All

JPl

Select source of ac line sync signal passed to the SDCC


Proper synchronization to the ac line is critical to the operation of the drive, and 1.2 is the only valid
setting of this jumper for DC2000s.
1.2 Generated by DCFB using line voltage 2-3 (DC2000 applications)
2.3 Generated by the TCCB card (EX2000 applications)

All

JP2

Decrease ac contactor drop-out time


Not used on GF2000 exciters.

All

JP3

Configuration of armature shunt #1 input circuit


Jumpers JP3 through JP7 must be set together for proper operation of the voltage controlled oscillator
(VCO) which converts the shunt current to a frequency signal which is then read by the SDCC.

Application
G, C or D frame DC2000
M, J of K frame DC2000/EX2000
GF2000 or ME2000 with SVIA card
M frame CB2000
J frame CB2000 with SHVI card

JP3. JP4
1.2
1.2
2.3
1 .2
1.2

JP5-JPZ
1.2
2.3
1.2
1.2
2.3

When JP3 & 4 are in position 1.2, no attenuation affects the IA 1 PL input signal which may come from
either a 100 mV (1 pu) shunt or a an external VCO. The local VCO will produce 0 Hz at -5 pu and 500 kHz
at + 5 pu from a shunt signal. A frequency input signal from an external VCO must be bypassed around the
local VCO (See JP5 and JP6). Putting JP3 and JP4 in position 2.3 rescales the input to receive an analog
isolator (SVIA) signal such that the local VCO produces a frequency output of 12 kHz with -5.0 V input
and 488 kHz with +5.0 V input (lV = 1 pu).
Jumpers JP5-7 select and enable the local (DCFB) VCO when in position 1.2. When in position 2.3 the
local VCO is disabled and bypassed to allow use of an up stream VCO circuit.
1.2 Direct input of shunt or external VCO signal
2.3 Input rescaled for analog isolator signal
All

JP4

Configuration of armature shunt #1 input circuit (see JP3)


1.2 Direct input of shunt or external VCO signal
2.3 Input rescaled for analog isolator signal

All

JP5

Configuration of armature shunt #1 VCO circuit (see JP3)


1.2 Local VCO circuit selected
2.3 Local VCO circuit bypassed

All

JP6

Configuration of armature shunt #1 VCO circuit (see JP3)


1.2 Local VCO circuit selected
2.3 Local VCO circuit bypassed

All

JP7

Configuration of armature shunt #1 VCO circuit (see JP3)


1.2 Local VCO circuit enabled
2.3 Local VCO circuit disabled

All

JP8

Configuration of armature shunt #2 input circuit


Jumpers JP8 through JP12 must be set together for proper operation of the voltage controlled oscillator
(VCO) which converts the shunt current to a frequency signal which is then read by the SDCC.

Application
G, C or D frame DC2000
M, J of K frame DC2000JEX2000
GF2000 or ME2000 with SVIA card
M frame CB2000
J frame CB2000 with SHVI card

JPB, JP9
1.2
1.2
2,3
1.2
1.2

JP1Q-JP12
1,2
2,3
1.2
1.2
2.3

When JP8 & 9 are in position 1.2, no attenuation affects the IA2PL input signal which may come from
either a 100 mV (1 pu) shunt or a an external VCO. The local VCO will produce 0 Hz at -5 pu and 500 kHz
at + 5 pu from a shunt signal. A frequency input signal from an external VCO must be bypassed around the
local VCO (See JPl 0 and JPll). Putting JP8 and JP9 in position 2.3 rescales the input to receive an analog isolator (SVIA) signal such that the local VCO produces a frequency output of 12 kHz with -5.0 V input
and 488 kHz with + 5.0 V input (1 V = 1 pu).
Jumpers JPl 0-12 select and enable the local (DCFB) VCO when in position 1.2. When in position 2.3 the
local VCO is disabled and bypassed to allow use of an up stream VCO circuit.
1.2 Direct input of shunt or external VCO signal
2.3 Input rescaled for analog isolator signal
All

JP9

Configuration of armature shunt #2 input circuit (see JP8)


1.2 Direct input of shunt or external VCO signal
2.3 Input rescaled for analog isolator signal

5-5

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GEH-6148

GF2000 Dc Generator Field Exciter


Table 5-1. DCFB Board Adjustable Hardware - Continued

Revision

Name

Description

All

JP10

Configuration of armature shunt #2 VCO circuit (see JP8)


1.2 Local VCO circuit selected
2.3 Local VCO circuit bypassed

All

JP11

Configuration of armature shunt #2 VCO circuit (see JP8)


1.2 Local VCO circuit selected
2.3 Local VCO circuit bypassed

All

JP12

Configuration of armature shunt #2 VCO circuit (see JP8)


1.2 Local VCO circuit enabled
2.3 Local VCO circuit disabled

All

SW1

Select the ac line voltage applied to the line voltage 1-2 circuit
SW1 and SW3 scale the V1-2 and V1-3 line voltage feedbacks into VCOs used to provide the SDCC with
a frequency signal proportional to instantaneous line voltages. These are used for phase loss and sequence
detection, and for line sync via the bi-phase PLL. SW2 scales the V2-3 voltage applied to the circuit used
to generate the ac line synchronization and frequency measurement signal via the zero-crossing detector.
Scaling of SW1-SW3 is in conjunction with the SHVI/M card voltage attenuators, if used.
The maximum nominal V ac is the maximum ac input voltage which may be 15% high without saturating
the instrumentation circuitry.
For DC2000/EX2000 applications, switches SW1, 2, 3, 4, 5, and 6 must all be set to the same position.
Above 617 V ac, SHVI/M attenuators must be used (refer to SHVI JP9 through JP17). For
GF2000/ME2000 applications, switches SW1 through SW4 must be set to the same position; switches
SW5 and SW6 may be set to different positions than SW1-SW4, depending upon the application.
For the DC2000, the settings of these switches affect the scaling of VAR.1 08 (ACLINMAGL which affects
the phase loss protective fault (see EE.582). For each of the max nominal rms line-line voltage selections,
if the input is at the max nominal, VAR.1 08 will be approximately 25700 counts. For the EX2000, these
switches have a similar effect on the phase loss function provided by EE.576, PUATHR. For both drive
types, a scale factor, EE.VLL SF allows these voltages to be scaled to a 1 pu = 20000 basis prior to being
applied to the phase loss function.
o (All off)
308 max nominal V ac (762 V ac using SHVI attenuators)
8
(4 on)
364 max nominal V ac (901 V ac using SHVI attenuators)
1
(1 on)
488 max nominal V ac (1214 V ac using SHVI attenuators)
9
(1 & 4 on)
545 max nominal V ac (1353 V ac using SHVI attenuators)
617 max nominal V ac (1535 V ac using SHVI attenuators)
2
(2 on)

All

SW2

Select the ac line voltage applied to the line


o (All off)
308 max nominal V
8
(4 on)
364 max nominal V
1
(1 on)
488 max nominal V
9
(1 & 4 on)
545 max nominal V
2
(2 on)
617 max nominal V

All

SW3

Select the ac line voltage applied to the line voltage 1-3 circuit (see SW 1)
(All off)
308 max nominal V ac (762 V ac using SHVI attenuators)
8 (4 on)
364 max nominal V ac (901 V ac using SHVI attenuators)
1 (1 on)
488 max nominal V ac (1 214 V ac using SHVI attenuators)
9 (1 & 4 on) 545 max nominal V ac (1353 V ac using SHVI attenuators)
2 (2 on)
617 max nominal V ac (1535 V ac using SHVI attenuators)

All

SW4

Select the voltage applied to the dc bridge voltage feedback VCO circuit
SW4 scales the voltage applied to the circuit used to generate the frequency representation of dc bridge
voltage (P1 to P2) feedback passed to the SDCC. SW5 scales the voltage applied to the circuit used to
generate the frequency representation of dc motor voltage feedback passed to the SDCC. SW6 scales the
voltage applied to the circuit used to generate the analog representation of dc motor voltage feedback
passed to the SDCC. Scaling of SW4 through SW6 is in conjunction with the SHVI/M card voltage
attenuators, if used.
The voltages listed in the selection table are maximum nominal V ac and nominal V dc. The maximum
nominal V ac is the maximum ac input voltage which may be 15% high without saturating the VCO
channel instrumentation circuitry. For the dc VCO channels, nominal V dc is the dc voltage which results in
20,000 counts raw voltage feedback (VFBRAW) before scaling by EE.1503 (VFBSFn).
For DC2000/EX2000 applications, switches SW1, 2, 3, 4, and 5 should be set to the same position.
Above 617 V ac, SHVI/M attenuators must be used (refer to SHVI JP9 through JP17). For
GF2000/ME2000 applications switches SW1 through SW4 should be set to the same position; switches
SW5 and SW6 may be set to different positions than SW1-SW4, depending upon the application.
o (All off)
308 V ac, 341 V dc (762 V ac, 843 V dc using SHVI/M attenuators)
8
(4 on)
364 V ac, 403 V dc (901 V ac, 996 V dc using SHVI/M attenuators)
1
(1 on)
488 V ac, 541 V dc (1214 V ac, 1342 V dc using SHVI/M attenuators)
9
(1 & 4 on)
545 V ac, 602 V dc (1353 V ac, 1496 V dc using SHVI/M attenuators)
2
(2 on)
617 V ac, 683 V dc (1535 Vac, 1698 V dc using SHVI/M attenuators)

5-6

sync circuit (see SW1)


ac (762 V ac using SHVI attenuators)
ac (901 V ac using SHVI attenuators)
ac (1214 V ac using SHVI attenuators)
ac (1353 V ac using SHVI attenuators)
ac (1535 V ac using SHVI attenuators)

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Table 5-1. DCFB Board Adjustable Hardware - Continued
Revision

Na e

Description

All

SW

Select the voltage applied to the de motor voltage feedback VCO circuit
Note that for GF2000 and ME2000 exciters, the applied armature voltage may be different than the voltage applied to the SCR bridge.
o (All off)
308 V ae, 341 V de (762 V ac, 843 V dc using SHVI/M attenuators)
364 V ac, 403 V dc (901 V ac, 996 V dc using SHVI/M attenuators)
8
(4 on)
(1 on)
488 V ac, 541 V dc (1214 V ac, 1342 V de using SHVI/M attenuators)
1
(1 & 4 on)
545 V ac, 602 V dc (1353 Vac, 1496 V de using SHVI/M attenuators)
9
617 V ac, 683 V dc (1535 Vac, 1698 V de using SHVI/M attenuators)
2
(2 on)

All

SW

Select the voltage applied to the analog dc motor voltage feedback circuit
Note that for GF2000 and ME2000 exciters, the applied armature voltage may be different than the voltage applied to the SCR bridge.
SW6 is an analog instrumentation channel. The channel feeds a an AID converter on the SDCC card. A 2.5
V bias added on the DCFB card allows the unipolar AID converter to "read" bipolar instrumentation signals.
A change of 1 pu for a dc voltage results in a 1.7 V swing about the + 2.5 V bias. A 1 pu change
for an ac voltage results in a 1.535 V swing about the + 2.5 V bias.
o (All off)
154 V ae, 171 V dc (380 V ac, 422 V de using SHVI/M attenuators)
(1 on)
244 V ae, 270 V dc (605 V ac, 671 V dc using SHVIIM attenuators)
1
308 V ac, 341 V dc (766 V ac, 849 V dc using SHVI/M attenuators)
2
(2 on)
385 V ac, 427 V dc (959 V ac, 1062 V de using SHVI/M attenuators)
4
(3 on)
11 (1,2,4 on)
426 V ac, 472 V dc (1061 V ac, 1175 V de using SHVI/M attenuators)
(1,3 on)
475 V ae, 526 V dc (1184 V ac, 1312 V de using SHVI/M attenuators)
5
540 V ac, 598 V dc (1345 Vac, 1489 V de using SHVI/M attenuators)
6
(2,3 on)
(1,2,3 on)
630 V ac, 697 V dc (1570 V ac, 1739 V de using SHVI/M attenuators)
7

All

SW

Select ac line CT burdens as a function of rated drive hp and voltage


These switch settings scale the ac line current transformers as a function of dc amps. Correct scaling is
essential for proper operation of the ac lac protective feature. These CTs are mounted on lines 1 and 3 of
the power converter, and are wired through plug 1CPL to a common burden resistor. Select the proper
setting as a function of drive current and CT turns ratio. The CT ratio can be determined from its part
number and the following table.

Paa Number
104X157AB 023
104X157AB 025
104X157AB 020
104X157AB 013
104X157AB024
104X157AB 026

Turns Ratio
1000:1
2000:1
4000:1
5000:1
5000:1
8000:1

When set properly, the current magnitude read in VAR.1 019 (CTCFB) should be scaled within 15% of the
current magnitude in VAR.1 04 (CFB). Above 144 mA ACCT secondary current, the CTs are routed through
a set of 10: 1 step down CTs on the SHVI/SHVM card, using JP1 through JP8 on the SHVI/SHVM card.
The enumerations listed are in terms of the mA input to the DCFB card IACCT secondary milliamps
attenuated by 10: 1 SHVI/SHVM attenuation if selected}. At present, the SHVI/SHVM cards are used on M,
J, K, and L frames only, and then 10: 1 CTs are used only if the ACCT secondary current is > 144 mAo
The CT secondary current (in mil/iamps) is approximated by:

1 pu rated current x 1000


let, mA

=
Combined CT turns ratio

(All off)
1
(1 on)
2
(2 on)
3
(1,2 on)
4
(3 on)
5
(1,3 on)
6
(2,3 on)
(1,2,3 on)
7
8
(4 on)
(1,4 on)
9
10 (2,4 on)
11 (1,2,4 on)
12 (3,4 on}
13 (1,3Aon)
14 (2,3,4 on)
15 (All on)

0.0 < = Ict, mA < 6.0


6.0 < = Ict, mA < 13.4
13.4 < = Ict, mA < 21.1
21.1 < = Ict, mA < 28.4
28.4 < = Ict, mA < 39.3
39.3 < = Ict, mA < 46.7
46.7 <
Ict, mA < 54.4
54.4 < = let, mA < 61.8
61.8 < = Ict, mA < 88.7
88.7 < = Ict, mA < 96.0
96.0 < = Ict, mA < 103
103 < = Ict, mA < 111
111 < = Ict, mA < 122
122 < = Ict, mA < 129
129 < = Ict, mA < 137
137 <= Ict, mA < 144

5-7

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter

5-4.2. Field Exciter Crowbar Board


(DS200FECB)

5-4.2.1. CONFIGURABLE HARDWARE. The FECB


board includes two Berg-type hardware jumpers, designated Bll and BJ2. These jumpers are used to select
the field voltage at which the FECB gates the SCR to
provide a path for the field current to flow.

The DS200FECB Field Exciter Crowbar Board


(FECB) is used to monitor the voltage across a generator or motor field. If the voltage exceeds a preset
limit, determined by hardware jumpers Bll and B12,
the FECB gates a crowbar SCR to provide a path for
the field current to flow.

When pins 1 and 2 of Bll and BJ2 are connected, the


field voltage limit is 1400 V. When pins 2 and 3 are
connected, the field voltage limit is 700 V. Figure 5-3
shows the layout of the FECB board, including the
locations of jumpers Bll and BJ2.

In the GF2000 exciter, two FECB boards are contained in the field exciter output module. Each is connected to one of the SCRs in a dual in-line SCR module. The FECB board/SCR pairs protect the GF2000
SCR bridge against the high voltages generated by the
de generator field when the field current is reduced in
either direction.

NOTE

For the FECB board to operate properly,


jumpers BJI and BJ2 must be in the same
position.

Section 6-5 defmes I/O points for the FECB board.

E32

E33

fT1

-I>-!
N'

E31

fT1

fT1

(Jl

OJ

(Jl

'--

I!
;;<)

CD

'--

I
A

C)

c::=J !
--'
~

I
~

=:J
~

DS200FECBG1A
Figure 5-3. FECB Board Layout

5-8

!~

BI006008

GF2000 Dc G nerator Field Exciter


5-4.3. LAN 10 Terminal Board (531X307LTB)

GEH-6148

Input Specifications. The input specifications for the


LTB are as follows:

The 531X307 B LAN I/O Terminal Board (LTB)


provides an int rface between control devices (such as
exciters or dri es) and external devices, such as contactors, indicat r lights, pushbuttons, and interlocks.

Nominal Voltage Range

The LTB contr I outputs consist of seven low-voltage,


low-current, fo m C relay contact connections. The
LTB also provi es pilot contact connections that function to actuate p to seven high-voltage, high-current
relays, such as ose on the DS200RTBA Relay Terminal Board ( BA). When the LTB and RTBA are
used together, ontacts from both are available.

CAUTION

24 - 230 V ac, 60 Hz

4 - 10 rnA peak

115 - 230 V ac, 50 Hz

4 - 10 rnA peak

24 - 250 V dc

4 - 8 rnA
NOTE

For revision 531X307LTBAGGl boards


and above, devices connected in series with
an input that has a dc leakage current
greater than 1.0 rnA or ac peak leakage
current greater than 4.0 rnA can cause the
input to be continuously in the ON state.

The LTB is av . able in two group numbers: Gland


G2. The G1 ve sion contains eight 24 V dc input
plugs, designat d CIlPL through CI8PL, which are
configurable co trol inputs (see Figure 5-4). These
inputs connect t 8PL, which connects to terminal
board points an to the SDCC.
The G2 version omits control inputs CIlPL through
CI8PL and co ector 8PL, and can only be used with
dc inputs.

Current Range

For all other revision boards, devices connected in series with an input that has an
ac/dc leakage current greater than 0.05 mA
can cause the input to be continuously in
the ON state.

Output Specifications. The output specifications for


the LTB board are as follows:

Relay Outputs - Form C contacts (non-fused):


0.6 A at 125 V ac

Do not con ect the input across an inductive


device, as t . can damage the circuit.

0.6 A at 110 V dc
Figure 5-4 sho the layout of the LTB board, including the locations of connector points and LEDs contained on the bo d.

2.0 A at 30 V dc

RTBA Pilot Outputs - Form A contacts

I/O Terminal Wire - Size must be 28 - 14


AWG. The maximum length of a 26-conductor
interconnection ribbon cable is 20 feet. The
maximum lengths of input and output wiring depends upon the application.

Section 6-6 defi es I/O points for the LTB board.


5-4.3.1. LTB BARD SPECIFICATIONS. This section
contains input d output specifications for the LTB
board.

NOTE

Do not route I/O ribbon cables with power


cables. In ac applications, capacitive coupling of connection wires can cause I/O input (lNl through INX) leakage.

5-9

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

CI'h

:'ll
rl~

~J

l~~

~ ~;-

U
"L_
Q]

Ei
r

Z~20

10PL

:~c=:::Ji~

8PL

Hl~119

LJl

oprPL

r"\

1'--

LED23

LEOZ2

LEOZ'

LE020

r"\

r"'.,

I'""">,

........,

'-./

"'-/

'J

!;:

CD

()
LEO' 9

LEO'S

LEDP

"""

'J

"""

'J

'J

I RPL

I/o

531 X307LTB
~

:.:

E;

'"

()

TERMINAL BOARD

()

:::;

()

"""

D~

~~
r-~~J

rr=n

LJ~~
Cl7PL

~r]

RX7

RX6

RXS

RX4

RX3

OTB6

OTBS

OT84

OTB3

RX2

RX'
l

IT86

IT85

lT84

I
I

IT83

IT82

IT81

ir--i=r1i
_L-J_,
==:Jb===od_'~
'

Cl8PL

Figure 5-4. LTB Board Layout

5-4.4. Drive Terminal Board (531X305NTB)

The 531X305NTB Drive Terminal Board (NTB/3TB)


contains customer connection terminals for most signal-level I/O. This board also includes most of the
hardware customizing jumpers and pots required in the
GF2000 exciter, along with some passive interface
circuits.
The NTB/3TB board connects to the SDCC via 6PL
and 8PL; to the DCFB via 2PL and 4PL; and to the
customer/system via COMPL and terminal points.
The NTB/3TB board's 3TB connector contains 90
terminal board points in two rows or screw-type terminals. The terminals 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 exciter, primarily to the SDCC.
Section 6-7 defmes I/O points for the NTB/3TB board.
Section 7-3.2 defmes NTB/3TB onboard testpoints.
5-4.4.1. POWER SUPPLIES. The NTB/3TB board
provides the following power outputs for external use:

Hardware jumpers allow distribution of the encoder


loads among the +5 and 15 V dc supplies to balance
loading.
5-4.4.2. ENCODER INTERFACE. The NTB/3TB board
includes a differential A-quad-B encoder interface,
including a marker channel, that can be connected to
the exciter. This circuit is optically isolated on the
SDCC. Jumpers on the NTB/3TB are used to configure the interface for 5 Vor 15 V encoders.
5-4.4.3. RS-232C INTERFACE. Connector COMPL
included on the NTB/3TB board provides an RS-232C
serial link for use with the ST2000 Toolkit (see GEH5860) or Drive Configurator, LynxOS Version (see
GEH-6203).
5-4.4.4. SPECIAL PURPOSE RS-422 INTERFACE.

The NTB/3TB board provides line termination resistors for a half-duplex, RS-422 compatible, serial interface to the Motor Control Processor (MCP) on the
SDCC.
5-4.4.5. RELAY OUTPUTS. The NTB/3TB board
provides the following outputs from seven relays with
a 120 V, 0.5 A contact rating:

Regulated +5 V dc and 15 V dc, each with a


current capacity of 300 rnA

Form C output from five relays controlled by the


SDCC

Unregulated 24 V dc, with a current capacity of


500 rnA.

One form A output and one side of the coil from a


sixth relay controlled by the SDCC. This enables
the coil to be controlled by the SDCC or a customer 24 V dc signal. It also allows the SDCC
coil driver output to be accessed by the customer

5-10

120 V ac, with a current capacity of 0.4 A

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


for applica ions that cannot tolerate the time delay
associated ~ith the relay pickup.

Two form ~ contacts and both sides of the coil of


a seventh r lay for general purpose use. A hardware jumPl r is used to select whether this coil is
driven by 2~ V dc or 120 V ac.

The NTB/3TB ,~so provides form C contacts from the


MA contactor p ot relay on the power supply board.
These contacts a e rated at 120 V ac, 2.0 A.
5-4.4.6. ANALC G TACH AND REFERENCE COARSE
SCALING. The 1 TB/3TB board includes DIP switches
that allow coarse scaling of analog tach (25 to 380 V)
and analog refer nce (9 to 29 V) inputs. The SDCC
card provides fIr e scaling of these signals.
5-4.4.7. LOW-L1 VEL ANALOG 1/0. The NTB/3TB
includes four pot to scale (5 to 50 V) lO-bit, generalpurpose, medium-resolution inputs to the SDCC. The
NTB/3TB transf s two high-resolution analog inputs

to the SDCC, and receives four 8-bit, 10 V analog


outputs from the SDCC. The outputs drive functions
such as other drives or exciters, analog meters, and
diagnostics.
5-4.4.8. DIGITAL CONTROL INPUTS. Various control
inputs pass through the NTB/3TB to the SDCC. These
inputs include special-purpose digital inputs, such as
RESET and CONTROL ON, and 12 general-purpose
control inputs (up to 24 V de). Jumpers are used to
bias unconnected inputs to +24 or -24 V dc, depending upon whether positive or negative logic is used.
5-4.4.9. CONFIGURABLE HARDWARE. The
NTB/3TB includes Berg-type jumpers; DIP switches,
identified by an SW nomenclature; and pots, identifIed
by a P nomenclature. Figure 5-5 shows the layout of
the NTB/3TB, including the locations of the jumpers,
DIP switches, and pots. Table 5-2 lists and defmes
these items.

Figure 5-5. NTB/3TB Board Layout

Table 5-2. NTB/3TB Board Adjustable Hardware


Revision

Name

Description

All

JPl

Termination resistors for the MCP RS-422 interface (see also JP2)
RS-422 termination resistors should only be installed at the physical first and last drops (ends of the cable
runs).
1.2 Not installed
2.3 Installed (Must also put JP2 2.3)

All

JP2

Termination resistors for the MCP RS-422 interface (See also JP1)
1.2 Not installed
2.3 Installed (Must also put JP1 2.3)

All

JP4

Swap RS232C RxD and TxD data lines, COMPL pins 2 and 3 (see also JP5)
Note many PCs can be jumpered to either the DCE or DTE configuration, and many cables are wired with
pins 2 and 3 interchanged. If communication is not established with JP4 and JP5 in the default position,
the alternate position may be necessary.
1.2 DCE mode for PC/term interface. Drive transmits on pin 3.
1.3 DTE mode for modem interface. Drive transmits on pin 2.

5-11

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 5-2. NTB/3TB Board Adjustable Hardware - Continued


Revision

Name

Description

All

JP5

Swap RS232C RxD and TxD data lines, COMPL pins 2 and 3 (see also JP4)
3.4 DCE mode for PC/term interface. Drive transmits on pin 3.
2.4 DTE mode for modem interface. Drive transmits on pin 2.

All

JP6

RS232C
3.7
3.4
2.4
2.6

All

JP7

RS232C RTS (COMPL-4)/CTS (-5) handshake line options (see also JP6)
The default position bypasses handshaking, generally allowing satisfactory serial communication
independent of whether COMPL pins 4 and 5 are connected to a DTE or DCE port, or not connected at all.
1.5 DCE or DTE forced true handshaking
1.2 DCE mode full handshaking
1.3 DTE mode full handshaking

All

JP8

RS232C DSR (COMPL-6l and DTR (COMPL-20) handshake options (see JP9)
The default position bypasses handshaking, generally allowing satisfactory serial communication,
independent of whether COMPL pins 6 and 20 are connected to a DTE or DeE port, or not connected at
all.
1.2 DSR and DTR both tied to + 15 V de (forced true)
1.3 DSR connected to DTR (Ioopback)

All

JP9

RS232C DSR (COMPL-6l and DTR (COMPL-20) handshake options (see JP8)
3.4 DSR and DTR both tied to + 15 V dc (forced true)
2.4 DSR connected to DTR (Ioopback)

AD-Pres

JP10

RF24 polarity for digital control inputs (see also JPll)


Note on early prototypes of this card JP10 and JP11 were identified as JP3A and JP3B.
1.2 RF24 = -24 V (negative logic)
1.3 RF24 = +24 V (positive logic)

AD-Pres

JPll

RF24 polarity for digital control inputs (see also JPl 0)


3.4 RF24 = -24 V (negative logic)
2.4 RF24 = + 24 V (positive logic)

All

JP12

Voltage to encoder supply (EOV1, EOV2)


1.2 EOVl
+15Vdc
2.3 EOVl
+5 V dc

RTS (COMPL-4)/CTS (-5) handshake line options (see also JP7)


DCE mode forced true handshaking
DCE mode full handshaking
DTE mode full handshaking
DTE mode forced true handshaking

All

JP13

Voltage to encoder supply (E1V1, E1V2)


1.2 El Vl = EOVl per JP12
2.3 E1Vl = -15 V dc

AL-Pres

JP14,
JP15

Coarse voltage range select for VCO #3, V3VCO


JP14 & JPl 5 settings determine the gain of the first stage of the analog interface circuitry for the (VC3P,
VC3Nl analog inputs to the V3VCO channel, per the following table.
Maximum
Nominal
JP14 JP15
Input Voltage
Input Voltage
2.3
2.3
16.9
10.0
1.2
2.3
23.3
13.8
2.3
1.2
34.9
20.6
1.2
1.2
41 .3
24.4
Maximum and Nominal values represent differential input voltages at the 3TB inputs with the following
significances:
Second Max: Max voltage for which the first stage will provide linear transfer function independent of the
V3SCLE setting.
Nominal: Voltage which will produce 20000 counts in V3VCOVAR (VAR.184) with the EE. V3SCLE
(EE.484) programmed to 10000. This is the optimum "rated reference" voltage, allowing 25 % overrange.
Note that VCO #3 is only available on drives having SDCC control cards, not DCC control cards.
2.3 10.0 V Nom (with JP15 2.3); or 20.6 V Nom (JP15 1.2)
1.2 13.8 V Nom (with JP15 2.3); or 24.4 V Nom (JP15 1.2)

5-12

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 5-2. NTB/3TB Board Adjustable Hardware - Continued


Revision

Description

All

JP1

Encoder 0 optically isolated receiver voltage drive level (EOA)


1.215Vdc
2.3 5 V dc

All

JP18

Encoder 0 optically isolated receiver voltage drive level (EOB)


1.2 15 V dc
2.3 5 V dc

All

JP19

Encoder 0 optically isolated receiver voltage drive level (EOM)


1.2 15 V dc
2.3 5 V dc

All

JP20

Voltage level of external drive for general purpose relay (GR + and GR-)
1.2 120 volts
2.3 24 volts

All

JP21

Supply -24 volts on COMPL-25


1.2 COMPL-25 is open
2.3 COMPL-25 is connected to -24 V dc

AL-Pres

JP22,
JP23

Coarse voltage range select for VCO #4, V4VCO


JP22 & JP23 settings determine the gain of the first stage of the analog interface circuitry for the (VC4P,
VC4N) analog inputs to the V4VCO channel, per the following table.
Maximum
Nominal
JP22 JP23 Input Voltage Input Voltage
2.3 2.3
16.9
10.0
1.2 2.3
23.3
13.8
2.3 1.2
34.9
20.6
1.2 1.2
41 .3
24.4
Maximum and Nominal values represent differential input voltages at the 3TB inputs with the following
significances:
Second Max: Max voltage for which the first stage will provide linear transfer function independent of the
V4SCLE setting.
Nominal: Voltage which will produce 20000 counts in V4VCOVAR (VAR.185) with the EE.V4SCLE
(EE.488) programmed to 10000. This is the optimum "rated reference" voltage, allowing 25% overrange.
Note that VCO #4 is only available on drives having SDCC control cards, not DCC cards.
2.3 10.0 V Nom (with JP23 2.3); or 20.6 V Nom (JP22 1.2)
1.2 13.8 V Nom (with JP23 2.3); or 24.4 V Nom (JP22 1.2)

AL-Pres

JP24

Enable 4-20 mA current loop input to the feedback VCO (FDBP, FDBN)
When the current loop mode is enabled (2.3), a 500-ohm burden resistor is inserted, yielding 10 volts at
20 mAo
1.2 Voltage input mode, scaled via SW1-5
2.3 Current loop input mode, SW1-5 should be open

AA-AC

JP3A

RF24 polarity for digital control inputs (see also JP3B)


Note JP3A and JP3B were renamed JP1 0 and JP11 on subsequent revisions.
1.2 RF24 = -24V (negative logic)
1.3 RF24 = +24V (positive logic)

AA-AC

JP3B

RF24 polarity for digital control inputs. (See also JP3A).


3.4 RF24 = -24V (negative logic)
2.4 RF24 = +24V (positive logic)

All

SW1-5

Feedback VCO Channel/Analog Tach Feedback (FDBP, FDBN) Voltage Range Select
These switch settings determine the gain of the first stage of the analog interface circuitry for the (FDBP,
FDBN) analog inputs to the FBVCO channel. Maxima and Nominal values represent differential input
voltages at the 3TB inputs with the following significances:
First Max: Voltage for which the VCO stage will saturate with the FBSCL (DCC P6, if present) scaling
potentiometer set to the maximum gain (full CCW) position.
Second Max: Max voltage for which the first stage will provide linear transfer function independent of the
FBSCL setting.

5-13

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 5-2. NTB/3TB Board Adjustable Hardware - Continued

Revision

Name

Description

Nominal: Voltage which will produce 20000 counts in FBVCOVAR (VAR.183) with the FBSCL scaling pot
set to maximum gain (full CCW) and the EE.FVSCL# (EE.1386m) programmed to 10000. This is the
optimum "rated feedback" voltage, allowing 25% overrange.
Note that the software scaling function on the VCO channels is only available on DCP Rev 1.24 & later.
ALSO NOTE: When JP7 on the DCC/SDCC card is in the 2.3 position, each voltage range in the chart
should be divided by 6. For use with 4-20 mA current inputs, set all switches off and see JP24 (REV AL
and later).
o (All off) 25-33 Volts Max, 20.0 Volts Nom or 4-20 mA
1 (1 on)
32-42 Volts Max, 25.1 Volts Nominal
2
(2 on)
39-52 Volts Max, 30.9 Volts Nominal
3 (1,2 on) 45-60 Volts Max, 35.9 Volts Nominal
4
(3 on)
55-74 Volts Max, 44.0 Volts Nominal
6 (2,3 on) 69-92 Volts Max, 54.9 Volts Nominal
8
(4 on)
89-119 Volts Max, 70.5 Volts Nominal
12 (3,4 on) 118-159 Volts Max, 94.5 Volts Nominal
14 (2-4 on) 132-177 Volts Max, 105 Volts Nominal
16 (5 on)
175-236 Volts Max, 140 Volts Nominal
20 (3,5 on) 205-276 Volts Max, 164 Volts Nominal
24 (4,5 on) 239-321 Volts Max, 191 Volts Nominal
28 (3-5 on) 268-362 Volts Max, 215 Volts Nominal
31 (All on)
300-390 Volts Max, 231 Volts Nominal
All

SW6-7

Reference VCO Channel/Analog Reference (REFP, REFN) Voltage Range Select


These switch settings determine the gain of the first stage of the analog interface circuitry for the (REFP,
REFN) analog inputs to the RFVCO channel. Maxima and Nominal values represent differential input
voltages at the 3TB inputs with the following significances:
First Max: Voltage for which the VCO stage will saturate with the RFSCL (DCC P5, if present) scaling
potentiometer set to the maximum gain (full CW) position.
Second Max: Max voltage for which the first stage will provide linear transfer function independent of the
RFSCL setting.
Nominal: Voltage which will produce 20000 counts in RFVCOVAR (VAR. 182) with the RFSCL scaling pot
set to maximum gain (full CW) and the EE.RVSCL# (EE.1281 m) programmed to 10000. This is the
optimum "rated reference" voltage, allowing 25% overrange.
Note that the software scaling function on the VCO channels is only available on DCP Rev 1.24 & later.
o (All off) 12.5-16.9 Volts Max, 10.0 Volts Nominal
17.3-23.3 Volts Max, 13.8 Volts Nominal
2 (7 on)
25.8-34.9 Volts Max, 20.6 Volts Nominal
1 (6 on)
3 (All on) 30.6-41.3 Volts Max, 24.4 Volts Nominal

All

P1

Provides scaling of analog input P1 from 8 volts to 50 volts maximum.

All

P2

Provides scaling of analog input P2 from 8 volts to 50 volts maximum.

All

P3

Provides scaling of analog input P3 from 8 volts to 50 volts maximum.

All

P4

Provides scaling of analog input P4 from 8 volts to 50 volts maximum.

5-14

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


5-4.5. Power Connect Card (DS200PCCA)

Table 5-3 summarizes the uses of the various PCCA


group numbers.

The DS200PC( A Power Connect Card (PCCA) provides an interfa e between the GF2000 exciter's control circuitry aIl~ the SCR power bridge. The PCCA
uses pulse trans ormers to provide gate drive to the
SCR bridge. Fc low to medium horsepower controllers, the PCCA also includes snubber circuits to control spikes aero s the ac lines, de bus, and gate drivers. For higher llorsepower controllers, some or all of
the snubber eirePits are omitted from the PCCA, and
are located else here in the system.

Section 6-8 defmes I/O points for the PCCA card.


The PCCA has four wire jumpers, designated JPl,
JP2. WP3, and WP4. Jumpers JPI and JP2 must be
connected to the appropriate stab terminals P3 through
PlO, as determined by the card group number and
system voltage. Jumpers WP3 and WP4 are used to
connect stab terminals P2A to P2B, and PIA to PIB,
respectively. These jumpers are used to select whether
the PCCA snubber capacitors are connected to the
same point on the power bridge as the voltage feedback channel.

The PCCA has en group numbers. The group number


used in a system is determined by the system voltage,
frame size, and fVhether the system uses regenerative
or non-regenera 've power conversion.

Figure 5-6 shows the layout of the PCCA card, including the locations of the stab terminals. Table 5-4 lists
and defmes the placement of the wire jumpers for
various PCCA group numbers and system voltages.

The armature vo tage scaling depends on which group


number is used:

Gl, G3, G7, G~ - Regenerative, 240 - 630 volts


G2, G4, G8, G 0 - Non-regenerative, 240 - 700 volts

Table 5-3. PCCA Card Uses


Group

G1, G2

G3,G4

G5,G6

G7,G8

G9, G10

Snubbers

Ac & dc

Dc only

None & no
attenuation string

Ac & dc

Dc only

Frames

e,G

Not used

J, K, L, M

e,G

D, J, M

Ac Volts

;5;600 V rms

N/A

;5;1500 V rms

;5;600 V rms

;5;600 V rms

Fuses

Line

N/A

Leg

Line

Leg

Reactors

Line

N/A

Leg

Line

Leg

Bus Trans ormer

Separate or
common

N/A

Separate or
common

Separate or
common

Separate or
common

5-15

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

2RPl..

IRPL
4RPL

[]

6RPL

5RPL

[]

5PL

o
5FPL

P3
P2

P23

o
6FP~

o o

2F?L

1FPL

3FP c

P7

P4

r-----""
"

DS200PCCAG1A

WP3

P9

'

P5

P8

PIO

P6

P2A

WP2
DCS

PI

lACS

PIA

2ACS

3ACS

4ACS

5ACS

Figure 5-6. PCCA Card Layout

Table 5-4. PCCA Card Adjustable Hardware


Revision

Name

Description

All

JP1

Groups 1, 3, 7 only 3.8 240 V dc;


3.4 290 V dc;
7.8 500 V dc;
4.7 550 V dc;
3.7 370 V dc;
4.8 580 V dc;
o 630 V dc;

Selects dc armature voltage range


Also connect JP2 P6-P9
Also connect JP2 P5-P6
Also connect JP2 P9-P10
Also connect JP2 P5-P10
Also connect JP2 P6-P10
Also connect JP2 P5-P9
Leave all P3-P10 open

All

JP2

Groups 1,3, 7 only 6.9 240 V dc;


5.6 290 V dc;
10.9 500 V dc;
10.5 550 V dc;
10.6 370 V dc;
5.9 580 V dc;
o 630 V dc;

Selects dc armature voltage range (see JP1, Groups 1,3,7)


Also connect JP1 P3-PB
Also connect JP1 P3-P4
Also connect JP1 P7-P8
Also connect JP1 P4-P7
Also connect JP1 P3-P7
Also connect JP1 P4-PB
Leave all P3-P10 open

All

JP1

Groups 2, 4, 8 only 3.8 240 V dc;


3.4 350 V dc;
7.8 390 V dc;
4.7 500 V dc;
3.7 550 V dc;
4.8 595 V dc;
o
700 V dc;

Selects dc armature voltage range


Also connect JP2 P6-P9
Also connect JP2 P5-P6
Also connect JP2 P9-P10
Also connect JP2 P5-P10
Also connect JP2 P6-P1 0
Also connect JP2 P5-P9
Leave all P3-P1 0 open

5-16

SACS

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Table 5-4. PCCA Card Adjustable Hardware - Continued
Revision

Nane

Description

All

JP

Groups 2, 4, 8 only 6.9 240 V dc;


5.6
350 V dc;
10.9 390 V dc;
10.5 500 V dc;
10.6 550 V dc;
5.9
595 V dc;
700 V dc;

AAA-AAZ

JP1

Selects dc armature voltage range (see JP1 , Groups 2, 4, 8)


Also connect JP1 P3-P8
Also connect JP1 P3-P4
Also connect JP1 P7-P8
Also connect JP1 P4-P7
Also connect JP1 P3-P7
Also connect JP1 P4-P8
Leave all P3-P1 0 open

Group 5 only - Selects dc armature voltage range


3.8 240 V dc; Also connect JP2 P6-P9
3.4 290 V dc; Also connect JP2 P5-P6
7.8
500 V dc; Also connect JP2 P9-P10
4.7
550 V dc; Also connect JP2 P5-P10
3.7
370 V dc; Also connect JP2 P6-P10
4.8
580 V dc; Also connect JP2 P5-P9
630 V dc; Leave all P3-P10 open

AAA-AAZ

JP2

Group 5 only - Selects dc armature voltage range (see JP1, Group 5)


6.9 240 V dc; Also connect JP1 P3-P8
5.6
290 V dc; Also connect JP1 P3-P4
10.9 500 V dc; Also connect JP1 P7-P8
10.5 550 V dc; Also connect JP1 P4-P7
10.6 370 V dc; Also connect JP1 P3-P7
5.9
580 V dc; Also connect JP1 P4-P8
630 V dc; Leave all P3-P10 open

ABA-Pres

JP1, JP2

Group 5 only - Voltage attenuator string and jumpers no longer on Group 5.

AAA-AAZ

JP1

Group 6 only - Selects dc armature voltage range


3.8 240 V dc; Also connect JP2 P6-P9
3.4 350 V dc; Also connect JP2 P5-P6
7.8
390 V dc; Also connect JP2 P9-P10
4.7
500 V dc; Also connect JP2 P5-P10
3.7 550 V dc; Also connect JP2 P6-P10
4.8 595 V dc; Also connect JP2 P5-P9
700 V dc; Leave all P3-P10 open

AAA-AAZ

JP2

Group 6 only - Selects dc armature voltage range (see JP1, Group 6)


6.9 240 V dc; Also connect JP1 P3-P8
5.6
350 V dc; Also connect JP1 P3-P4
10.9 390 V dc; Also connect JP1 P7-P8
10.5 500 V dc; Also connect JP1 P4-P7
10.6 550 V dc; Also connect JP1 P3-P7
5.9
595 V dc; Also connect JP1 P4-P8
700 V dc; Leave all P3-P10 open

ABA-Pres

JPl, J='2

Group 6 only - Voltage attenuator strings and jumpers no longer on Group 6

All

WP3

Groups 1-4, 7-10 only - Separateltie card snubbers and VFBK to sameldifferent point(s)
WP3 and WP4 are wire jumpers on the PCCA card which are connected between stab terminals P2AP2B and P1A-P1 B, respectively. If these jumpers are present the card snubber capacitors are attached
to the same point on the bridge as the voltage feedback channel. WP3 & WP4 may be removed if the
card snubbers and voltage feedback channel need to be connected to different bridge points.
1.2 Jumper IN - Connect snubbers & voltage feedback channel to same point
Jumper OUT - Separate snubbers & voltage feedback channel

All

WP4

Groups 1-4, 7-10 only - Separateltie card snubbers and VFBK to sameldifferent point(s)
1.2 Jumper IN - Connect snubbers & voltage feedback channel to same point
Jumper OUT - Separate snubbers & voltage feedback channel

5-17

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

5-4.6. Relay Terminal Board (DS200RTBA)


The DS200RTBA Relay Terminal Board (RTBA) is an
optional board that is sometimes referred to as a Relay
Card. The RTBA provides ten relays, seven of which
have two form C contacts, the other three have four
form C contacts. These relays are relays are driven
directly from the relays on the LTB board, or remotely by the user.

,1
~Tac

, ,HS"

The RTBA relays are available with three coil voltages, depending on the group number of the board.
The coil voltages available are 110 V dc (RTBAG1);
24 V dc (RTBAG2); and 115 V ac, 50/60 Hz
(RTBAG3).
Section 6-9 defmes I/O points for the RTBA board.
The RTBA board includes Berg-type jumpers. Figure
5-7 shows the RTBA board layout, including the locations of these jumpers. Table 5-5 lists and defmes the
jumpers.

!'

I<:T81 (

C-=:-f-;=.;-'--;;;;c--+::;;::;-I

Figure 5-7. RTBA Board Layout

Table 5-5. RTBA Board Adjustable Hardware


Revision

Name

Description

All

JP1

Relay #20 coil voltage source


Each RTBA relay may be picked-up by either an internal control voltage source supplied through plug RPL
from LTB or an external voltage source connected on the terminal board between KnA (n = 20-26) and
KCM. (Note that additional options are available for K20-K22 via JP8 and JP9).
1.2 Use external power source (RTBA.TB.K20A)
2.3 Use power source from LTB through plug RPL

All

JP2

Relay #21 coil voltage source


1.2 Use external power source (RTBA.TB.K21Al
2.3 Use power source from LTB through plug RPL

All

JP3

Relay #22 coil voltage source


1.2 Use external power source (RTBA.TB.K22Al
2.3 Use power source from LTB through plug RPL

All

JP4

Relay #23 coil voltage source


1.2 Use external power source (RTBA.TB.K23Al
2.3 Use power source from LTB through plug RPL

All

JP5

Relay #24 coil voltage source


1.2 Use external power source (RTBA.TB.K24AI
2.3 Use power source from LTB through plug RPL

All

JP6

Relay #25 coil voltage source


1.2 Use external power source (RTBA.TB.K25Al
2.3 Use power source from LTB through plug RPL

All

JP7

Relay #26 coil voltage source


1.2 Use external power source (RTBA.TB.K26Al
2.3 Use power source from LTB through plug RPL

5-18

BI006008

GF2000 Dc

Ge~erator

Field Exciter

GEH-6148

Table 5-5. RTBA Board Adjustable Hardware - Continued


Revision

Nam~

Description

All

JP8

K20-22 coil neutral source


In the 1.2 position, the coil neutrals of K20-K26 are all tied to RTB.50 (KeM). In the 2.3 position, the coil
neutrals of K20-K22 are isolated from RTB.50; JP9 must be set to position 2.3 to connect the coil neutrals
to RPL.1 and LTB.
1.2 K20-K22 coil neutrals connected to RTB.50, KeM
2.3 K20-K22 coil neutrals isolated from RTB.50

All

JP9

RPL. 1 connection
1.2 Ties RPL.1 to RTB.51 & OPTPL.2
2.3 Ties RPL.1 to K20-K22 coil neutrals

All

JP1 C

Select whether pluggable circuit Y25PL-Y28PL is powered from ePH


1.2 Pluggable circuit using Y25PL-Y28PL, not connected to ePH
2.3 Pluggable circuit using Y25PL-Y28PL powered from ePH

All

JP11

Select whether pluggable circuit Y25PLY28PL is powered from ePN


1.2 Pluggable circuit using Y25PL-Y28PL, not connected to ePN
2.3 Pluggable circuit using Y25PL-Y28PL powered from ePN

All

JP12

Select whether pluggable circuit Y31 PLY34PL is powered from ePH


1.2 Pluggable circuit using Y31 PL-Y34PL, not connected to ePH
2.3 Pluggable circuit using Y31 PL-Y34PL powered from ePH

All

JP13

Select whether pluggable circuit Y31 PL-Y34PL is powered from ePN


1.2 Pluggable circuit using Y31 PL-Y34PL, not connected to ePN
2.3 Pluggable circuit using Y31 PL-Y34PL powered from ePN

All

JP14

Select whether pluggable circuit Y19PL-Y22PL is powered from ePH


1.2 Pluggable circuit using Y19PL-Y22PL, not connected to ePH
2.3 Pluggable circuit using Y19PL-Y22PL powered from ePH

All

JP15

Select whether pluggable circuit Y19PL-Y22PL is powered from ePN


1.2 Pluggable circuit using Y19PL-Y22PL, not connected to ePN
2.3 Pluggable circuit using Y19PL-Y22PL powered from ePN

5-19

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter

5-4.7. Drive Control Card (DS215SDCC)

The DS215SDCC Drive Control Card (SDCC) contains the exciter's primary control circuits and software. The SDCC also contains general-purpose interface circuits that connect with other boards to form
various types of ac and dc motor drives and exciters.
The interface circuits control and process exciter and
motor signals, and customer I/O.
The SDCC contains three microprocessors: the Drive
Control Processor (DCP) at location Ul, the Motor
Control Processor (MCP) at location U21, and the Comotor Processor (CMP) at location U35.

5-4.7.2. CONFIGURABLE HARDWARE. The SDCC


contains Berg-type hardware jumpers, identified with a
IP nomenclature, and hard-wired jumpers, identified
with a WI nomenclature. Figure 5-8 shows the locations of these jumpers on the SDCC card. Table 5-6
lists and defmes these jumpers.
5-4.7.3. REPLACING/INSERTING SOFTWARE. The
SDCC must include the onboard software stored in
EPROMs Ull, U12. U22, and U23, and in EEPROM
U9 to function in the exciter. When replacing an
SDCC, transfer the onboard software from the old
card to the new as follows:

CAUTION

The SDCC card uses onboard software stored in five


memory chips: four EPROMs (Ull, Ul2, U22, and
U23), which contain configuration data programmed at
the factory; and one EEPROM (U9), which contains
field-adjustable parameters. These memory chips are
contained in sockets on the SDCC.

To prevent component damage caused by


static electricity, treat all boards with static
sensitive handling techniques. Use a
grounding strap when handling boards or
components. Store boards in anti-static
bags or boxes.

NOTE

The DS200SDCC card does not include the


five memory chips mentioned above (the
sockets are empty). To order a replacement
card including the five memory chips,
specify a DS215SDCC card.

To prevent damage to components, use the


proper chip extraction/insertion tool when
performing the following procedure.
1.

Section 6-10 defmes I/O points for the SDCC card.


Section 7-3.3 defmes SDCC onboard testpoints.
5-4.7.1. RESET CIRCUITS. The SDCC includes four
reset circuits, including a RESET pushbutton.

CAUTION
To prevent damage to memory chips, ensure that chips are properly oriented when
inserting them into sockets.

CAUTION
The system trips when a hard reset is initiated; do not reset when running.
A reset can be generated in four ways:

By pressing the RESET pushbutton on the SDCC.

By applying +5 to +24 V dc to customer interface point 3TB pin 58 on the NTB/3TB board.

The board generating a reset by programmed


software control.

The board generating a reset by automatic internal


hardware watchdog protection.

520

Carefully remove one of the EPROM chips (Ull,


U12, U22, or U23) from the old card and insert it
into the same socket on the new card.

2.

Repeat the previous step one chip at a time for


each of the remaining EPROM chips.

3.

Remove the EEPROM chip (U9) from the old


card and insert it into the correct socket on the
new card.

4.

If the same failure symptoms still exist, install the


new (blank) EEPROM shipped with the new card.
Program the new EEPROM per the customer
software adjustment values using the ST2000
Toolkit (see GEH-5860) or Drive Configurator,
LynxOS Version (see GEH-6203).

BI006008

GF2000 Dc GE ~erator Field Exciter

GEH-6148
==---==~ 3Pl

~r=

JP

' @
R
H
cps

CCM

cax

-iP12

! FSR

,FSX
: ClX

1-10lR

1:0
L

81C

o
o

r-I------

c=J:J

OClKC

~~

J1::

II

:; ~

N',5 P15 TP4 TP5 TP6

XF

U3S

00000

~GaR

"~

D u~

0
I

'"

6
DAGS

~O

-, I

"'6

U9

TP12

EEROM

:;r

c:=J:J JPl

"'6

NMI

"TPNT

JP8

J;)23

c=J:J
JPJ

c=J:J c=J:J
P16
C=L~J
LJ 1

FClK

" ====--====--~
40
0

fC=-'

IL

BP

lPl

d
39

DS215SDCCG1A

0
0

TP37

TP29

TP8

2P
L _ __

I ['~===-"",===-=4~0
i
~
6PL
'!~,
l1Pl ,19'0

_L_.:.J1 16
1

II.,

!~lr~1

Figure 5-8. SDCC Card Layout

Table 5-6. SDCC Card Adjustable Hardware

Revision

Name

Description

All

JP1

EEPROM parameter write protect


1.2 Writes inhibited, safe mode
2.3 Writes enabled (required to modify EEPROM)

All

JP7

Enable 6:1 gain increase for feedback VCO circuitry


1.2 Normal gain
2.3 Increase gain 6: 1 (see NTB SW1)

All

JP8

Enable absolute value circuit for feedback VCO circuitry


Note that, due to the 1O-volt maximum voltage available on the STBA card, the FB VCO is not normally
suitable for analog tachs unless the NTB/3TB board is used.
1.2 Bipolar mode, for DC tachometers
2.3 Absolute mode, for analog AC AN tachometers

AFD-Pres

JP12

DCP PROM high page enable


This jumper provides for future access to the full address space of 4 Mbit DCP program memory. It is currently not used and should be left in the 1.2 position.
1.2 U12 and U11 are EPROM or FLASH memories up to 2 Mbit
2.3 Reserved for 4 Mbit FLASH memory (29F040) applications

AFD-Pres

JP14

MCP PROM high page enable


This jumper provides for future access to the full address space of 4 Mbit MCP program memory. It is currently not used and should be left in the 1.2 position.
1.2 U22/U23 are EPROM or FLASH memories up to 2 Mbit
2.3 Reserved for 4 Mbit FLASH memory (29F040) applications

5-21

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 5-6. SDCC Card Adjustable Hardware - Continued


Revision

Name

Description

O-ACZ

JP15

Enable for DCP crystal


1.2 Enabled (required for normal operation)
o Manufacturing test only

ADS-Pres

JP16

Enables FLASH electrically erasable program memory erase/reprogram mode


JP16 is required to be in the 2.3 position only for in-house reprogramming of 12 V FLASH memory such as
the AM28F020. JP16 applies + 12 V dc to the VPP pin of the DCP and MCP program memory. EPROM
memory and 5 V FLASH memory (such as the 29F040) do not require + 12 V dc, so for these types of
U12, U11, U22, and U23 memory, JP16 should be left in the default 1.2 position.
1.2 Normal mode for EPROM or FLASH memory read only
2.3 Reserved for FLASH memory reprogramming mode

All

JP22

Enable for MCP crystal


1.2 Enabled (required for normal operation)
o Manufacturing test only

All

JP23

Signal source into DCP's external DMA channel, used for time tagged inputs
1.2 From NTS/3TB analog feedback input (for AC AN tach interfaces)
2.3 From the NTS/3TS encoder marker track input, EOM.

O-ACZ

JP33

Enable for CMP crystal


1.2 Enabled (required for normal operation)
o Manufacturing test only

ADS-Pres

WJ1

Remap MET3 D/A to DAC1 output for SDCCG3


SDCCG3 omits the 12-bit D/A converter used for DAC1 and DAC2, and instead drives DAC1 and DAC2
outputs with the 8-bit D-A used to drive MET3 and MET4 on SDCCG1. MET3 and MET4 are not available
on SDCCG3. If this jumper is erroneously present on an SDCCG1 card, the D/A outputs will be corrupted;
if this jumper is missing on an SDCCG3 card, the DAC1 /DAC2 output will not function.
o SDCCG 1, jumper omitted
1.2 SDCCG3, jumper installed

ADS-Pres

WJ2

Remap MET4 D/A to DAC2 output for SDCCG3


o SDCCG 1, jumper omitted
1.2 SDCCG3, jumper installed

ADS-Pres

WJ3

Provide 1O-volt full scale reference for D/A outputs on SDCCG3


If this jumper is incorrectly set for the SDCC group number, the D/A converters will operate improperly.
o SDCCG1, uses internal reference from 12-bit D/A
1.2 SDCCG3, develops reference from + 5 V dc power supply

ADS-Pres

WJ4

Identify card group number to firmware


The firmware uses this jumper to identify whether the card contains G1 or G3 components. Incorrect setting of this jumper will cause malfunction of the DCP, including the inability of the processor to power up
and configure card logic cell arrays, and possible loss of EEPROM drive configuration memory.
o Omit jumper, identifies card as group G1
1.2 Install jumper. identifies card as group G3

ADS-Pres

WJ5

Configure card for logic cell array size


Incorrect setting of this jumper may damage or cause unreliable operation of LCA U32.
o Jumper omitted on SDCC G3 (LCA is 3042 device)
1.2 Jumper installed on SDCC G1 (LCA is 3064 device)

ADS-Pres

WJ7

Configure card for EEPROM size


In all present drive applications, WJ7 and WJ9 must be omitted and WJ8 and WJ1 0 must be installed. The
alternate setting allows for future expansion of EEPROM size from 32K to 64K. Incorrect setting of these
jumpers will result in incorrect reading and configuration of the drive EEPROM.
o SDCCG1 and G3, jumper omitted
1.2 Reserved for future expansion

ADS-Pres

WJ8

Configure card for EEPROM size


o Reserved for future expansion
1.2 SDCCG1 and G3, jumper installed

ADS-Pres

WJ9

Configure card for EEPROM size


o SDCCG1 and G3, jumper omitted
1.2 Reserved for future expansion

ADS-Pres

WJ10

Configure card for EEPROM size


o Reserved for future expansion
1.2 SDCCG1 and G3, jumper installed

5-22

BI006008

GEH-6148

erator Field Exciter


5-4.8. LAN C mmunications Card
{DS215SLCC

The DS2l5SL C LAN Communications Card (SLCC)


provides isolate and non-isolated input circuits for
communicatio to the exciter. The SLCC connects to
the NTB/3TB, DCC, and DCFB boards via 2PL; to
the SDCC card ia 3PL; and to the optional LTB
board via IOPL The SLCC also connects to the Programmer.
The SLCC fea es an alphanumeric display controller
that connects to the Programmer. Refer to Chapter 8
for information bout the Programmer.
The SLCC also . eludes onboard software contained in
two EPROMs, esignated U6 and U7.
NOTE

EPROMs
empty). To
cluding th
DS215SLC

LCC card does not include


6 and U7 (the sockets are
order a replacement board ine two memory chips, specify a
card.

The SLCC has ee group numbers. The 01 version


of the SLCC inc udes circuits used to connect the exciter to DLAN ( ive local area network) or DLAN +
(ARCNET) ne orks; the G2 version includes only
the DLAN inter ce circuits; and the G4 version ineludes neither th DLAN nor the ARCNET circuits.

5-4.8.1. CONFIGURABLE HARDWARE. The SLCC


includes Berg-type jumpers and hard-wired jumpers.
Figure 5-9 shows the locations of the SLCC card
jumpers. Table 5-7 lists and defmes these items.
5-4.8.2. REPLACINGIINSERTING SOFTWARE. The
SLCC must inelude the onboard software stored in
EPROMs U6 and U7 to function in the exciter. When
replacing the SLCC card, the onboard software must
be transferred from the old card to the new. Carefully
remove each of the two EPROM chips from the old
card and insert it into the same socket on the new
card.

CAUTION
To prevent component damage caused by
static electricity, treat all boards with static
sensitive handling techniques. Use a
grounding strap when handling boards or
components. Store boards in anti-static
bags or boxes.
To prevent damage to components, use the
proper chip extraction/insertion tool when
performing the following procedure.
To prevent damage to memory chips, ensure that chips are properly oriented when
inserting them into sockets.

es I/O points for the SLCC card.

5-23

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

DS215SLCCG1A

DEVICE

-+

TDWARD THIS

-+

END

10PL

[~
"M

"i':

D%
----l'"""L- ----l'"""LU6

U7

I
I

Lo

0--0
0--0

WJ4

2PL

WJ5

WJ2

0--0
WJi

0--0

"M "M

~d~ j~

n
M

_d~

ARCPL

WJ30--0

Figure 5-9. SLCC Card Layout

5-24

BI006008

GF2000 Dc GE nerator Field Exciter

GEH-6148

Table 5-7. SLCC Card Adjustable Hardware


Revision

Nan e

Description

Jumpers JP14 tt rough JP1 8 are not present on DS215SLCCG4 cards.


All

JP1

Groups 1 and 2 only - This jumper selects the RS-422 DLAN drivers or the isolated DLAN circuit
1.2 Isolated DLAN circuit
2.3 RS422 drivers and receivers

All

JP1

Groups 1 and 2 only - This jumper selects the RS-422 DLAN drivers or the isolated DLAN circuit
1.2 Isolated DLAN circuit
2.3 RS-422 drivers and receivers

All

JP16

Groups 1 and 2 only - This jumper selects the RS-422 DLAN drivers or the isolated DLAN circuit
1.2 Isolated DLAN circuit
2.3 RS422 drivers and receivers

All

JP1

Groups 1 and 2 only - This jumper puts the DLAN termination resistors in the DLAN circuit
The termination jumpers should be added to the drives located at the end of a daisy-chain 422 LAN. Never
exceed 5 sets of termination resistors in a 422 DLAN circuit.
1.2 Termination resistors in
2.3 Termination resistors out

All

JP1

Groups 1 and 2 only - This jumper puts the DLAN termination resistors in the DLAN circuit
The termination jumpers should be added to the drives located at the end of a daisy-chain 422 LAN. Never
exceed 5 sets of termination resistors in a 422 DLAN circuit.
1.2 Termination resistors in
2.3 Termination resistors out

All

JP1

Groups 1, 2, and 4 - This jumper connects the crystal to the processor


This jumper should be in place except during manufacturing testing.
1.2 Normal running condition
2.3 Manufacturing testing

All

JP2(

Groups 1,2, and 4 - This jumper sets up the EPROM sockets for either EPROMs or Flash PROMs
1.2 EPROM setting
2.3 Flash PROM setting

All

WJ1

Groups 1,2, and 4 - This jumper redirects the Ready Line when there is no ARCNET module
This jumper should be in place when there is no ARCNET module.
1.2 No ARCNET module (DS215SLCCG2, G4)
o ARCNET module present (DS215SLCCG 1)

ACC-Pres

WJ2

Groups 1, 2, and 4 - This jumper connects the LRX signal to ground through a 470-ohm resistor
This jumper should be in place for G4 only.
o LRX signal is not connected to ground (DS215SLCCG1, G2)
1.2 LRX signal is connected to ground (DS215SLCCG4)

ACC-Pres

WJ3

Groups 1,2, and 4 - This jumper connects the T2CLK signal to ground through a 470-ohm resistor
This jumper should be in place for G4 only.
o T2CLK signal is not connected to ground (DS215SLCCG1, G2)
1.2 T2CLK signal is connected to ground (DS215SLCCG4)

ACC-Pres

WJ4

Groups 1,2, and 4 - This jumper connects the input signal to ground through a 470-ohm resistor
This jumper should be in place for G4 only.
o Input signal is not connected to ground (DS215SLCCGl, G2)
1.2 Input signal is connected to ground (DS215SLCCG4)

ACC-Pres

WJ5

Groups 1,2, and 4 - This jumper connects the input signal to ground through a 470-ohm resistor
This jumper should be in place for G4 only.
o Input signal is not connected to ground (DS215SLCCG 1, G2)
1.2 Input signal is connected to ground (DS215SLCCG4)

5-25

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

5-4.9.1. CONFIGURABLE HARDWARE. The SPC card


includes Berg-type jumpers; a DIP switch (earlier revisions of the SPC card included two DIP switches);
and six pots, designated PI through P6. The jumpers
are used for manufacturing test or customer options.
Figure 5-10 shows the SPC card layout, including the
locations of the jumpers, DIP switch, and pots. Table
5-8 lists and defmes these items.

5-4.9. Signal Processor Card (531X309SPC)

The optional 531X309SPC Signal Processor Card


(SPC) processes I/O for the SDCC card. The SPC
includes two identical encoder interface circuits: Encoder #1 and Encoder #2. Each encoder interface circuit interface with 5 to 15 V incremental encoders or
digital tachometers to supply position or speed feedback, or reference instrumentation to the exciter.
Section 6-12 defmes 1/0 points for the SPC card. Section 7-3.4 defmes SPC onboard testpoints.

531X309SPC

SIGNAL PROCESS

TPZUP

o
o

:::=! EZA8

i IEZA8
'I

=~

I
!

EZ88

\:

IEz88

a::

~8~1

>

II

'-----'

JP7 r

::~:

::~
RXP

TPl UP

:::J 0
C

lo

-:

TP1DN

JP10

3
i 1
, I

2 I==:J== 4

TPl Z
III

SPlTPl

.
JP9

TP27

JP4

:;;
Du
TX RX
I

,C l,

2I==:J==4

SPZTPZ

DDDDDD
P6
ZRESP

P5
ZSCALE

P4
ZZERO

P3
1RESP

Figure 5-10. SPC Card Layout

5-26

_CD

PFZP
TXP

JP8

, ,

I==:J - -

PZ
1SCALE

L-==

ZI==:J==4

,
PF1N

1 Z

JPl

I==:J

I~~~

=~
c::::JCJ\'
c::J .....,';

SWl

EZM8
I IEZM8

TPZDN

Pl
1ZERO

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Table 5-8. SPC Card Adjustable Hardware
Revision

Description

All

JP1

Encoder #1 clock inhibit, this is used for test purposes only.


1.2 Enables encoder #1 logic array (normal operation)
o Inhibits clock to PAL (manufacturing test only)

All

JP2

Encoder #1 marker channel enable to be used for absolute position.


1.2 Inhibit marker, for incremental position or speed only
2.3 Enable marker, for absolute position instrumentation

All

JP3

Encoder #2 clock inhibit, this is used for test purposes only.


1.2 Enables encoder #2 logic array (normal operation)
o Inhibits clock to PAL (manufacturing test only)

All

JP4

Encoder #2 marker channel enable to be used for absolute position.


1.2 Inhibit marker, for incremental position or speed only
2.3 Enable marker, for absolute position instrumentation

AA-AF

JP5

Select biasing of input PF1 N for the analog channel SPA 1 (VAR.256)
Jumpers JP5 - JP7 and pots P1 - P3 on the SPC card control hardware options for the process follower
analog channel SPA 1 (VAR.256), input from PF1 P and PF1 Non 1TB. This circuit is a general purpose amplifier which can accept either current loop or voltage inputs. JP5, JP7, and P1 (1ZERO) control the offset
added to the input; P2 (1 SCALE) controls the gain of the amplifier, CCW = more gain; P3 (1 RESP) controls
the response of the low pass filter of the amplifier, CCW = more filtering; and JP6 controls input burdening when this circuit is used for current loop inputs. JP5 and JP7 allow several options for the 1ZERO offset pot. The most common configurations are as follows:
JP5 JP7 MODE
1.2 1.2 No offset trimming, 1ZERO is disabled
1.2 1.3 Positive trimming, CCW = more offset
1.2 1.4 Negative trimming, CCW = more offset
For example, to set-up a 4-20 rnA current loop, assuming PF1 P positive with respect to PF1 N, set JP5 1.2,
JP6 1.3, and JP7 1.4. Apply a 4 mA input, and adjust P1 until VAR.256 is O. Then apply a 20 rnA input,
and adjust P2 to give the desired full scale (the amplifier saturates at a maximum value of + 511 counts).
Note that currents less than 4 rnA will produce negative values down to -512 counts at VAR.256. If this
is undesirable, feed VAR.256 into a limit block before using it in the drive.
1.2 Bias to common
1.3 Add negative bias, 0 to -8 V dc
1.4 Add positive bias, 0 to + 8 V dc
1.5 Add no bias

AG-Pres

JP5

Select gain of amplifier for the analog channel SPA 1 (VAR.256)


Jumpers JP5 - JP7 and pots P1 - P3 on the SPC card control hardware options for the process follower analog
channel SPA1 (VAR.256l, input from PF1 P and PF1 N on HB. This circuit is a general purpose amplifier which
can accept either current loop or voltage inputs. JP7 and P1 (1 ZERO) control the offset added to the input;
JP5 and P2 (1 SCALE) control the gain of the amplifier, CW = more gain; P3 (1 RESP) controls the response of
the low pass filter of the amplifier, CCW = more filtering; and JP6 controls input burdening when this circuit is
used for current loop inputs. The most common configurations are as follows:
PF1 P/PF1 N
MODE
JP5 JP6 JP7
1-5 rnA 1.2 1.3 1.3
4-20 mA 1.2 1.3 1.3
10-50 rnA 1.2 1.4 1.3
0-30 V
1.2 1.2 1.3
For example, to set-up a 4-20 rnA current loop, assuming PF1 P positive with respect to PF1 N:
- Set JP5 1.2 and JP6 1.3. Temporarily set JP7 to 1.2.
- Apply a 20 rnA input, and adjust P2 until Test point SPHP2 is 6.25 V.
- Set JP7 to 1.3.
- Adjust P1 until SPHP2 is 5.0 V and VAR.256 is +500 counts.
- Apply a 4 rnA input, and verify that SP1 TP2 and VAR.256 are both O.
If the ratio between the maximum and minimum inputs is not 5, the voltage at SP1 TP2 for the second step
should be adjusted to (5 x max)/(max - min) V instead of 6.25 V. Note that VAR.256 saturates at a maximum
value of + 511 counts when SP1 TP2 exceeds 5 V. Also note that currents less than 4 rnA produce negative
values down to -512 counts at VAR.256. If this is undesirable, feed VAR.256 into a limit block before using it
in the drive.
1.2 Normal gain
2.3 10:1 gain boost for max input < 5 mA or < 2 V

5-27

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 5-8. SPC Card Adjustable Hardware - Continued


Revision

Name

Description

AA-AF

JP6

Select input burdening for PF1 P/PF1 N of the analog channel SPA1 (see JP5)
1.2 No burden, for 2-30 V dc input signals
1.3 Burden for 4-20 mA current loop input
1.4 Burden for 10-50 mA current loop input

AG-Pres

JP6

Select input burdening for PF1 P/PF1 N of the analog channel SPA1 (see JP5)
1.2 No burden, for 2-30 V dc input signals
1.3 Burden for 1-5 or 4-20 mA current loop input
1.4 Burden for 10-50 mA current loop input

AA-AF

JP7

Select biasing
1.2 Bias
1.3 Add
1.4 Add
1.5 Add

AG-Pres

JP7

Select zero offset for the analog channel SPA1 (see JP5). Use P1 for fine trim.
1.2 No offset
1.3 Negative offset
1.4 Positive offset

AA-AF

JP8

Select biasing of input PF2N for the analog channel SPA2 (VAR.257)
Jumpers JP8 - JP1 0 and pots P4 - P6 on the SPC card control hardware options for the process follower analog channel SPA2 (VAR.257), input from PF2P and PF2N on HB. This circuit is a general purpose amplifier
which can accept either current loop or voltage inputs. JP8, JP10, and P4 (2ZERO) control the offset added to
the input; P5 (2SCALE) controls the gain of the amplifier, CCW = more gain; P6 (2RESP) controls the response of the low pass filter of the amplifier, CCW = more filtering; and JP9 controls input burdening when
this circuit is used for current loop inputs. JP8 and JP10 allow several options for the 2ZERO offset pot. The
most common configurations are as follows:
JP8 JP10 MODE
1.2 1.2
No offset trimming, 2ZERO is disabled
Positive trimming, CCW = more offset
1.2 1.3
Negative trimming, CCW = more offset
1.2 1 .4
For example, to set up a 4-20 mA current loop, assuming PF2P positive with respect to PF2N, set JP8 1.2,
JP9 1.3, and JP1 0 1.4. Apply a 4 mA input, and adjust P4 until VAR.257 is O. Then apply a 20 mA input, and
adjust P5 to give the desired full scale (the amplifier saturates at a maximum value of + 511 counts). Note
that currents less than 4 mA will produce negative values down to -512 counts at VAR.257. If this is undesirable, feed VAR.257 into a limit block before using it in the drive.
1.2 Bias to common
1.3 Add negative bias, 0 to -8 V dc
1.4 Add positive bias, 0 to + 8 V dc
1.5 Add no bias

AG-Pres

JP8

Select gain of amplifier for the analog channel SPA2


Jumpers JP8 - JP1 0 and pots P4 - P6 on the SPC card control hardware options for the process follower analog channel SPA2 (VAR.257J, input from PF2P and PF2N on HB. This circuit is a general purpose amplifier
which can accept either current loop or voltage inputs. JP1 0 and P4 (2ZERO) control the offset added to the
input; JP8 and P5 (2SCALE) control the gain of the amplifier, CW = more gain; P6 (2RESP) controls the response of the low pass filter of the amplifier, CCW = more filtering; and JP9 controls input burdening when
this circuit is used for current loop inputs. The most common configurations are as follows:
PF2P/PF2N
MODE
JP8 JP9 JP10
1-5 mA 1.2 1.3 1.3
4-20 mA 1.2 1.3 1.3
10-50 mA 1.2 1.4 1.3
0-30 V
1.2 1.2 1.3
For example, to set up a 1-5 mA current loop, assuming PF2P positive with respect to PF2N:
- Set JP8 to 1.2 and JP9 to 1.3. Temporarily set JP1 0 to 1.2.
- Apply a 5 mA input, and adjust P5 until testpoint SP2TP2 is 6.25 V.
- Set JP1 0 to 1.3.
- Adjust P4 until SP2TP2 is 5.0 V, and VAR.257 is +500 counts.
- Apply a 1 mA input, and verify that SP2TP2 and VAR.257 are both O.
If the ratio between the maximum and minimum inputs is not 5, the voltage at SP2TP2 for the second step
should be adjusted to 5 x max / (max - min) V instead of 6.25 V. Note that VAR.257 saturates at a maximum
value of + 511 counts when SP2TP2 exceeds 5 V. Also note that currents less than 1 mA produce negative
values down to -512 counts at VAR.257. If this is undesirable, feed VAR.257 into a limit block before using it
in the drive.
1.2 Normal gain
2.3 10:1 gain boost for max input < 5 mA or < 2 V

5-28

of input PF1 P for the analog channel SPA 1 (see JP5)


to common
positive bias, 0 to + 8 V dc
negative bias, 0 to -8 V dc
no bias

BI006008

GF2000 Dc G nerator Field Exciter

GEH-6148

Table 5-8. SPC Card Adjustable Hardware - Continued


Revision

Description

AA-AF

JP9

Select input burdening for PF2P/PF2N of the analog channel SPA2 (see JP8)
1.2 No burden, for 2-30 V dc input signals
1.3 Burden for 4-20 mA current loop input
1.4 Burden for 10-50 mA current loop input

AG-Pres

JP9

Select input burdening for PF2P/PF2N of the analog channel SPA2 (see JP8)
1.2 No burden, for 2-30 V dc input signals
1.3 Burden for 1-5 or 4-20 mA current loop input
1.4 Burden for 10-50 mA current loop input

AA-AF

JP10

Select biasing
1.2 Bias
1.3 Add
1.4 Add
1.5 Add

AG-Pres

JP10

Select biasing of input PF2P for the analog channel SPA2 (see JP8). Use P1 for fine trim.
1.2 No offset
1.3 Negative offset
1.4 Positive offset

AA-AF

SW1- ,
SW1-

Selects input attenuation resistors for channel A of encoder #1


Input attenuation resistors for channel A of encoder #1 can be selected as follows
o (All off) 15 volt encoder interface
5 volt encoder interface
1 (1 on)
5 volt encoder (alternate setting)
2 (2 on)
3 (1 ,2 on) External attenuation

AG-Pres

SW1-1

Selects input attenuation resistors for channel A of encoder #1


Input attenuation resistors for channel A of encoder #1 can be selected as follows
o (Off) 15 volt encoder interface
1 (On) 5 volt encoder interface

AG-Pres

SW1-2

Selects input attenuation resistors for channel B of encoder #1


Input attenuation resistors for channel B of encoder #1 can be selected as follows
o (Off) 15 volt encoder interface
1 (On) 5 volt encoder interface

AA-AF

SW1-3
SW1-4

Selects input attenuation resistors for channel B of encoder #1


Input attenuation resistors for channel B of encoder #1 can be selected as follows:
o (All off) 15 volt encoder interface
5 volt encoder interface
1 (3 on)
2 (4 on)
5 volt encoder (alternate setting)
3 (3,4 on) External attenuation

AG-Pres

SW1-3

Selects input attenuation resistors for marker channel of encoder #1


Input attenuation resistors for marker channel of encoder #1 can be selected as follows
o (Off) 15 volt encoder interface
1 (On) 5 volt encoder interface

AG-Pres

SW1-4

Selects input attenuation resistors for channel A of encoder #2


Input attenuation resistors for channel A of encoder #2 can be selected as follows
o (Off) 15 volt encoder interface
1 (On) 5 volt encoder interface

AA-AF

SW1-5,
SW1-6

Selects input attenuation resistors for marker channel of encoder #1


Input attenuation resistors for marker channel of encoder #1 can be selected as follows
o (All off) 15 volt encoder interface
1 (5 on)
5 volt encoder interface
2 (6 on)
5 volt encoder (alternate setting)
3 (5,6 on) External attenuation

AG-Pres

SW1-5

Selects input attenuation resistors for channel B of encoder #2


Input attenuation resistors for channel B of encoder #2 can be selected as follows
o (Off) 15 volt encoder interface
1 (On)
5 volt encoder interface

of input PF2P for the analog channel SPA2 (see JP8)


to common
positive bias, 0 to + 8 V dc
negative bias, 0 to -8 V dc
no bias

5-29

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 5-8. SPC Card Adjustable Hardware - Continued

Revision

Name

Description

AG-Pres

SW1-6

Selects input attenuation resistors for marker channel of encoder #2


Input attenuation resistors for marker channel of encoder #2 can be selected as follows
o (Off) 15 volt encoder interface
1 (On) 5 volt encoder interface

AG-Pres

SW1-7

Selects input attenuation resistor for serial channel RXP/RXN (1 TB-13)


RXP and RXN (1 TB-13, 14) may be used either as the input from a BEl serial absolute encoder. or as the
receiver input of a full-duplex RS-422 serial channel to the motor control processor.
o (Off) 15 volt input (Serial encoder interface)
1 (On) 5 volt input (RS-422 serial communication)

AA-AF

SW2-1,
SW2-2

Selects input attenuation resistors for channel A of encoder #2


Input attenuation resistors for channel A of encoder #2 can be selected as follows
o (All off) 15 volt encoder interface
5 volt encoder interface
1 (1 on)
2 (2 on)
5 volt encoder (alternate setting)
3 (1 ,2 on) External attenuation

AA-AF

SW2-3.
SW2-4

Selects input attenuation resistors for channel B of encoder #2


Input attenuation resistors for channel B of encoder #2 can be selected as follows
o (All off) 15 volt encoder interface
1 (3 on)
5 volt encoder interface
2 (4 on)
5 volt encoder (alternate setting)
3 (3,4 on) External attenuation

AA-AF

SW2-5.
SW2-6

Selects input attenuation resistors for marker channel of encoder #2


Input attenuation resistors for marker channel of encoder #2 can be selected as follows
o (All off) 15 volt encoder interface
5 volt encoder interface
1 (5 on)
2 (6 on)
5 volt encoder (alternate setting)
3 (5,6 on) External attenuation

All

P1
(1ZERO)

Full CCW

All

P2
(1SCALE)

Full CCW = 0700. Provides gain adjust of SPA 1 (see JP5).

All

P3
(1 RESP)

Full CCW = 0700. Adjusts response of SPA 1, from 1 to 1000 msec.


Response #1 (P3) adjusts the response of analog channel #1 (SPA1). The response can be adjusted from 1 to
1000 msec.

All

P4
(2ZERO)

Full CCW = 0700. Provides zero adjust of SPA2 (see JPB).

All

P5
(2SCALE)

Full CCW = 0700. Provides gain adjust of SPA2 (see JPB).

All

P6
(2RESP)

Full CCW = 0700. Adjusts response of SPA2. from 1 to 1000 msec.


Response #2 (P6) adjusts the response of analog channel #2 (SPA2). The response can be adjusted from 1 to
1000 msec.

5-30

= 0700. Provides zero adjust of SPA1

(see JP5).

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


5-4.10. Volt ge Attenuator Board
(DS200SVA )

NOTE

Wire jumpers WJl through WJ4 should be


placed in similar positions for each SVAA
input line. For example, if WJl is connected between stab terminals PTll and
PT13 (across resistor Rll), WJ2 should
connect PT17 and PT19, WJ3 should connect PT31 and PT33, and WJ4 should connect PT37 and PT 39.

The DS200SV A Voltage Attenuator Board (SVAA)


attenuates the ltage of a generator, bridge, or motor
from its rated I vel to 600 V dc or less. The SV AA is
used for syste s with voltages of 600 to 1500 V dc to
reduce the feed ack voltage to a level that is within the
input specificat ons of the DCFB board.
The SVAA bo d is connected between the generator,
bridge, or mot and terminal board 2TB to reduce the
voltage present t 2TB. The DCFB isolates the voltages at 2TB fro the other control boards.
The SVAA con ains two identical attenuation circuits.
Figure 5-11 sho s one of the attenuation circuits.
Each attenuatio circuit includes six 100 ill resistors,
three in series ith each input line, and four 475 ill,
1 % resistors ac oss the output lines. The output resistors are confi ed such that they make up two pairs
of parallel resis rs connected in series.
Each attenuatio circuit provides a default attenuation
of 0.442 (the ou ut voltage is 0.442 x the input voltage). For other ttenuation values, the SVAA includes
stab terminals at each end of the 100 ill input resistors. The stab te minals can be connected using wire
ugh WJ4 to select the amount of
jumpers WJl
attenuation appli d to the input voltage. Table 5-9
shows the attenu tion values available.
NOTE

pm

9
i

NOTE

Adjust EE.1503 (VFBSFO) and CFBSFO


(EE.1504) such that 20,000 counts equals 1
pu armature voltage feedback and 1 pu
CEMF feedback, respectively.
Two other wire jumpers, WJ5 and WJ6, are used to
connect the center points of the attenuation circuits to
ground, if desired. These jumpers are also not supplied with the SV AA board, and must be ordered
separately if required by the application. Figure 5-12
shows the layout of the SVAA, including the locations
of the stab terminals.
Section 6-13 defmes I/O points for the SV AA board.

Wire jump rs WJl through WJ4 are not


supplied wi h the SVAA board, and must
be ordered eparately if the application requires an a enuation setting other than the
default valu of 0.442.

0911
lOOK .17-

On the DCFB board, DIP switches SW4 and SW5


select the voltage applied to the dc bridge (generator
for the GF2000 exciter) voltage feedback and dc motor
voltage feedback circuits, respectively. Table 5-10
shows typical settings for the individual switches in
SW4 and 5 when the DCFB is used with SVAA board
attenuation of 0.442 (default setting).

PTl4

Ri2
lOOK .17-

Rig I
47SKi
.17-U

I
PT17

PTl8

c--,

i2:1 SC2

PTl9

0914
lOOK .17-

9
1

R:1
lOOK .17.

SCs

PTl6

PT20

R'S
100, .17-

:=J

PT21
R16

100K .17-

c:::J

C]SC4

Figure 5-11. SVAA Attenuation Circuit

5-31

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 5-9. SVAA Board Attenuation Jumper Placement


Attenuation

WJ1

WJ2

WJ3

WJ4

0.442

Not present.

Not present.

Not present.

Not present.

0.547

PTll-PT13

PT17-PT19 (Rev ACB-Pres)


PT15-PT17 (Rev AAA-ABA)

PT31-PT33 (Rev ACB-Pres)


PT21-PT23 (Rev AAA-ABA)

PT37-PT39 (Rev ACB-Pres)


PT25-PT27 (Rev AAA-ABA)

0.704

PTll-PT14

PT17-PT20 (Rev ACB-Pres)


PT15-PT18 (Rev AAA-ABA)

PT31-PT34 (Rev ACB-Pres)


PT21-PT24 (Rev AAA-ABA)

PT37-PT40 (Rev ACB-Pres)


PT25-PT28 (Rev AAA-ABAI

1.00

PT11-PT15
(Rev ACB-Pres)

PT17-PT21 (Rev ACB-Pres)

PT31-PT35 (Rev ACB-Pres)

PT37-PT41 (Rev ACB-Pres)

Table 5-10. DCFB DIP Switches SW4 and SW5 Settings


With SVAA Board Attenuation of 0.442
Voltage
IV dc)

DIP Switch SW4 and SW5 Settings

Circuit
Gain

Approximate
Voltage at 2TB

650

Off

Off

Off

Off

0.0038698

253

700 - 900

Off

Off

Off

On

0.0032778

272-350

1000

On

Off

Off

Off

0.0024411

389

1250

Off

On

Off

Off

0.0019317

486

1500

Off

Off

On

Off

0.0015449

583

PT,S

SC3

1--1
I

I
L_,_~

PT11

PT14

1--1

UU

PTn

0
1I1

'---_,_---l

PT12

0
0
1I1

SCl

<
;po
;po

;po
PT20

SC4

1--1
I

,
L

__
,

PT18

1LJ

r.

PT19

I'

I! : - - 1

LJ

PT'? '--- _ _
I

---l

SC2

PT21

PT3S

SC?

1--1
I

'--- __ ---l

1--1

PT::54

PT36

00

'---_,_---l
SC5

PT32 PB,

PT33

n
LJ

PT39

SCB

1--1
I

L __ ---l
I

PT41

11

lJ

PT40

PBS

0 00

1--1

PT3?

L_,_---l
SC6

Figure 5-12. SVAA Board Layout

5-32

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GEH-6148

GF2000 Dc G nerator Field Exciter


5-4.11. Shu

Table 5-11. SVIA Input Gain

Isolator Board (DS200SVIA)

The DS200SV Shunt Isolator Board (SVIA) provides isolation f shunt current signals. The mV signal
from a shunt is amplified by the input stage of the
SVIA, and is i lated from the common mode voltage
that exists in th power circuit. Several standard input
resistors are pr vided on the SVIA to amplify 100
mV to 475 m shunt signals to 7.5 V outputs.

Input
Terminal

Input Resistor (0)

Gain

TB1-1

User selected

7500/R11

TB1-3

7500

Unity

TB1-5

475

16

TB1-6

221

34

The SVIA requ res an unregulated supply of +24 V


dc, 25%, 80
input power.

TB1-7

100

75

puts (TBI-3, TBI-5, TBI-6, and TBI-7) feature fixed


input resistors, for the gain values in Table 5-11.

The SVIA cons sts of three stages: the high-gain input


stage, the unity gain isolation stage, and the variable
gain and offset djust output stage. Figure 5-13 is a
simplified elem ntary diagram of the SVIA, showing
each of these st ges.

The fifth input (TB 1-1) is connected to a set of saddle


clamps that enable the user to install the required input
resistor, designated RH, for the desired gain. Resistor
Rll can be determined as follows:

Section 6-14 de mes 110 points for the SVIA board.


Section 7-3.5 d fmes SVIA onboard testpoints.

R11 =

5-4.11.1. INP T STAGE. The input stage includes a


differential am lifier with a 7.5 len feedback resistor.
Five input co ections enable the user to select the
gain required y the application. Four of the five inSOURC

The output of the SVIA board is typically connected to


a DS200DCFB Power Supply Board (DCFB). In these
applications, the desired output voltage is 1 V.
P15V

T61-7

:B1-5

475
JI

CAP OUT

7.5K

'"

VIN
W,

T61-1

lao

ACJM

SUPPLY

NI51S
TP6

II

J*-O

475K

MAX

~75K
I' C:'~20K
CCW

NEG
6US T62-1
VOUT
'P9

'10K

~
:

r----,----,--LJ..........I ~

'----;

6US T62-2

o
~

TP 8

MAX
pas

ACOM

nn
I

16M

vors
UNITY GAIN
ISOLATION STAGE

~~""-+----i~ I ~g~ EO
~

CW

N~

ACOMIS

OUTPUT STAGE

OFFSET

6.4V

"

mV

SHUNT
INPUT
T61-2

6AV

VINI
TP7

221

1J

~:=J--~R:-,

INPUT STAGE

161-3

T61-5

Shunt Voltage (ml') xl pu Current (A) x 7500 0


1000 m V x Shunt Current (A) x Desired Output Voltage

100

.001
ACOM

P15V

ACOM
TPIO

N15V

II,

!'IlJ

N15V

_ ,

TPI2

mv
TP11

P28
TP~
y

5. V

5AV

'" ,:;,,,,

lo-,t/-IOV
200 mV

+-1l:~>---t*-~'.32Kt/,3

TEST

I lOOK

P24/28V

POWER
ON

200K

CW
TEST
TP3

PCOM
TPI4

TB2-7

Figure 5-13. SVIA Simplified Elementary Diagram

5-33

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GF2000 Dc Generator Field Exciter

GEH-6148
If necessary, adjust EE.1505 (CFBSFO) to produce
5000 counts at 1 pu when the 1 pu current does not
correspond to the drive or exciter's shunt rating, or
when the closest available resistor is not the exact
value found in the above equation. This adjustment is
made using the ST2000 Toolkit (see GEH-5860) or
Drive Configurator, LynxOS Version (see
GEH-6203).

Terminal board point TBl-2 provides the other input


to the input stage differential amplifier. To invert the
polarity of the SVIA output, connect the positive input
to TBl-2, and the negative input to the terminal selected above for the desired input gain.
The input stage voltage can be observed by measuring
between testpoints TP7 (VINI) and TP2 (ACOMIS).
Chapter 7 lists and defmes the SVIA board testpoints.
The input stage features a 2 IlF, 100 V fIlter capacitor
for the TB1-1 input. Jumper 11 is used to select
whether the fIlter capacitor is connected to the input
circuit. The capacitor should be connected for low
impedance input voltages, such as shunt mV signals,
which have a high common mode voltage to ground.
The input stage also features a test circuit used to calibrate the SVIA. Berg-type jumper J2 is used to set the
range of pot R3 (TEST) to either 200 mV or 1O V.
R3 adjusts the dc test voltage output at TBl-4 to the
voltage required by the application. The test voltage
can be observed by connecting a measuring device
between TP3 (TEST) and TP2 (ACOMIS).

stage provides 2500 V rms (continuous) and 3500 V


peak (continuous) common-mode isolation between
any two ports.
5-4.11.3. OUTPUT STAGE. The output stage provides
variable gain and offset for the SVIA. Pots R2 and R1
provide gain and offset adjustment, respectively, for
the output stage. For best performance, configure the
SVIA such that most of the required amplification is
achieved at the input stage; use R2 as a vernier adjustment. Pot RI provides a 20 mV variation in the
output voltage when R2 is fully counterclockwise.

The range of the output voltage is 1O V at 4 rnA


maximum. The SVIA outputs are at terminal board
points TB2-4 and TB2-3.
5-4.11.4. ADJUSTMENT PROCEDURES. For optimal
performance, set the offset and gain of the SVIA as
follows:

1.

Disconnect the input wires and connect TB 1-4 to


the desired input pin of TB 1. Set jumper J2 to the
desired range (1O V or 200 mY). Set 11 to the
OUT position to remove the 2 !IF capacitor from
the input circuit.

2.

Adjust pot R3 (TEST) for 0 V at TBl-4 or TP3


(TEST).

3.

Adjust pot R1 (OFFSET) for 0 V at TP9


(VOUT).

4.

Adjust pot R3 for the desired input voltage and


adjust pot R2 (GAIN) for the desired output voltage.

5.

Set jumper 11 to the IN position if the SVIA is


used as a shunt signal isolator.

5-4.11.2. ISOLATION STAGE. The isolation stage is

powered by an isolated 15 V dc power supply. Input


power to the SVIA can be provided by the most convenient unregulated +24 V dc, 25%, 80 rnA source.
The + 24 V dc input is connected to a + 15 V regulator, used to power the isolated power supply. The
POWER ON LED lights when + 15 V dc is available
at the regulator output. The isolated power supply uses
the + 15 V regulator output to produce separate unregulated 15 V dc, 5 rnA power for the input and
output stages.
Normally open contacts of relay K1 provide an interlock between terminal board points TB2-7 and TB2-8
to indicate a loss of power to the SVIA. The contacts
open when power is lost.
The isolation stage is configured for unity gain to
provide the best common mode rejection and temperature performance, least phase shift, and most stable
gain-versus-frequency characteristics. The isolation
5-34

5-4.11.5. VOLTAGE ISOLATION FUNCTION. Using


input connections TB1-1 and TBI-2, the SVIA can be
used to perform voltage isolation. Armature-level voltages can be further attenuated by connecting an SVAA
board between the shunt and the SVIA. Input TB 1-1
should be used with R11 selected per the following
equation; jumper 11 should be in the OUT position to
remove the fIlter capacitor from the input circuit. Select Rll as shown:

R11

=[

( VIN x 7.5kQ) - 600k0.] x 475kQ.


VOUT

475k0. +600k0.

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


where V/N is e input voltage to the SVAA, VOUT is
the output volt e of the SVIA, and the SVAA attenuation is set for the default value of 0.442.

J2 to the 10 position to select the 1O V range. This


provides a -2.0 V bias at TBl-3. This configuration
results in an output voltage at TB2-4 of 0-8 V with pot
R2 fully counterclockwise. Adjust R2 to suit the application.

5-4.11.6. CUR ENT SIGNAL CONVERTER. The


SVIA can also e used to convert a 4-20 rnA current
signal into a 0- 0 V dc signal. In this application, connect a 500 n re istor across TBI-I and TBl-2, and
connect the inp t to these points. Connect TBl-4 to
TB 1-3. Insert a 7.5 kQ resistor in R11 and set jumper

5-4.11.7. CONFIGURABLE HARDWARE. Figure 5-14


shows the layout of the SVIA, including the locations
of the jumpers and pots described above. Table 5-12
lists and defmes these items.

'.J

SC1

1--1
_1_

-.l'

::

1-'-1
I

L __

VIN

I
I',--

... ""

'" '"

r,'

c=Jz
T'::ST

[====
-;

I~

rl

[=1

R3
TEST

SOURC'::

'"00

I
U

Lr

SIS

~S
N'SIS

====

VINI
c=J7

PCOM

==:J
DS200SVIAG1 A

P28

13

14

P~

c=Js

P1SP

14

ACOMIS

c=J3

I
-.J

DS

15

c=J1

====

"'0

00

z:l':
,..,

'"

+(\

\0

0"

ACOM
[::=::J1

GAIN

i
~
co

'.J

'" '"

::

TBZ

P15V

ln

[::=::J 11
N1SV

c=J1

... ""

OFFSET

Figure 5-14. SVIA Board Layout

5-35

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 5-12. SVIA Board Adjustable Hardware


Revision

Name

Description

All

J1

Connects or disconnects input capacitor


Inserts a 2 l!F shunting capacitor across the input terminals. Used for dc voltages less than 100 V dc from
low impedance sources, such as shunt mV signals, across TS1-1 to TS1-2.
IN
Capacitor in for TB1-1 to TB1-2 for signals such as shunt mV signals
OUT Capacitor out for TB1-1 to TS1-2 for voltage signal isolation

All

J2

Range select for test voltage output on TB 1-4


Changes the range of the test output voltage to TB 1-4 and TP3. This test voltage output is adjusted via
pot R3.
200 200 mV range on R3 (TEST)
10 10 volt range on R3 (TEST)

All

R1

Offset potentiometer
R1 is used to adjust the dc offset of the isolator module to zero. With zero volts in on the TB1 input, adjust
R1 for 0.0 volts dc on the output, TB2-4 or TP9.

All

R2

Gain potentiometer
R2 is the gain adjust to obtain the correct dc scaling on the isolator output, TP9 and TB2-4. Typically, R2
is adjusted to give 1 V on the output with 1 per unit current flowing through the instrumented shunt.

All

R3

Test voltage output (TB 1-4l adjust


R3 is used to adjust the dc test voltage output (TB1 -4) to the voltage required by the application. Typically,
the test voltage output will be set the same as the millivolts output of the armature shunt connected to the
input with 1 per unit current flowing.

5-36

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

CHAPTER 6

1/0 DEFINITIONS

This chapter lis


LEDs for the G
The connectors
board type, and
wiring boards.

and defmes I/O connector points and


2000 Dc Generator Field Exciter.
clude plug-in cable type, terminal
tab terminals located on the printed

User connections - These connectors are located on


boards in the exciter. They carry I/O between
these boards and user connections outside the
GF2000 exciter.

6-2.2. Terminal Board Connectors

This chapter is rganized alphabetically by board


name: section 6 covers the DCFB; section 6-5, the
LTB; section 6- , the NTB/3TB; and so on. Each section contains tab es of I/O defmitions for each connector, stab termin ,and LED on that board. The board
layout figures in Chapter 5 show the locations of these
items on the bo ds.

This type of connector is identified by a 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
exciter. The wires are secured in the terminal board by
tightening screws at each connection.

6-2.3. Stab Connections (Stabs)


CONNECTORS
6-2.1. Plug-in

onnectors

The type of conn


name, mates wi
carries signal an
externally to cust
provide three typ

ctor, typically identified by PL in its


a cable that plugs into it. The cable
power I/O within the exciter and
mer equipment. Plug-in connectors
s of connections:

Internal board-to
tween boards
cally has the
on each boar

board connections - Carry I/O bein the exciter. The connector typiame name and pinout assignments
.

Board-to-compon
boards and c
ers or semico
connectors ar

nt connections - Carry I/O between


ponents (for example, transformductors) within the exciter. These
commonly 2-pin plugs.

This type of connector is a wide metal post that secures one side of a removable wire jumper. It provides
options for configuring exciter I/O, such as power
requirements.

6-3. LED AND NEON INDICATORS

The GF2000 exciter includes LEDs (light-emitting


diodes) and/or neon lamps on some boards as indicators of a board or exciter condition. The indicators are
located on I/O paths, and turn on or off with the signal
condition.

6-1

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

6-4. DCFB BOARD I/O


This section defmes I/O points, LEDs, and neon lamps for the DCFB board. Figure 5-2 shows connector, LED, and
neon lamp locations on the board.
Table 6-1. Connector 1PL,
I/O Between DCFB Board and SDCC Card

Pin No.

Nomenclature

Description

FANO

ACCT current.

2 - 5

Not connected.

FAN5

Motor voltage #2 - analog output.

FIG5

FIN5 counter control.

FINO

Dc armature shunt #1 VCO output.

FIN1

Motor field current shunt #1 VCO output.

10

FIN2

Dc armature shunt #2 VCO output.

11

FIN4

V1-V2 ac line voltage feedback.

12

FIN5

Vl-V3 ac line voltage feedback.

13

FIN6

14
15

FIG4

FIN4 counter control.

16

IENREV

Enable reverse armature SCRs.

17

IENFWD

Enable forward armature SCRs.

18

IFF2

Field #2 SCR firing.

19

IFF1

Field #1 SCR firing.

20

A14R

A 14R cell decode signal.

21

A25R

A25R cell decode signal.

22

A36R

A36R cell decode signal.

23

Not connected.

24

A14F

A 14F cell decode signal.

25

A25F

A25F cell decode signal.

26

A36F

A36F cell decode signal.

27

SCRTST

Short circuit SCR test mode select line.

28

XIL

XILINX programmed (0

29

SYNC

Ac line synchronization signal.

30

Yes; 1

= No).

Not connected.

31

IRST1

System reset.

32

FLD1 CTRL

Field #1 control enable.

33

FLD2CTRL

Field #2 control enable.

34

MAC1

MA contactor drive.

35

MAC2

MD contactor #1 drive.

36

MAC3

MD contactor #2 drive.

37

VFBB

Dc voltage feedback testpoint.

38

DTYPE

Drive type (1.8 - 2.2 V dc for GF2000 exciter).

39

FIN7

Generator armature voltage feedback VCO output.

FIN8

Generator field shunt #2 VCO output.

40

6-2

Dc bridge voltage feedback.


Not connected.

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Table 6-2. Connector 2PL,
I/O Between DCFB Board and NTB/3TB, SDCC, and SLCC Boards

Nomenclature

Description

IPSEN

Power supply enable (active lowl.

-15V

-15 V dc, 5%, to the NTB/3TB, SDCC, and SLCC boards.

+15V

+ 15 V dc, 5%, to the NTB/3TB, SDCC, and SLCC boards.

DCOM

Drive common to the NTB/3TB, SDCC, and SLCC boards.

5, 6

+5V

+ 5 V dc, 5%, to the NTB/3TB, SDCC, and SLCC boards.

DCOM

Drive common to the NTB/3TB, SDCC, and SLCC boards.

-24V

-24 V dc, 20%, to the NTB/3TB, SDCC, and SLCC boards.

+24V

+ 24 V dc, 20%, to the NTB/3TB, SDCC, and SLCC boards.

Pill No.

Table 6-3. Connector 4PL,


I/O Between DCFB Board and NTB/3TB Board

Pin No.

NTB/3TB
Terminal

Nomenclature

Description

85

X2

115 V ac output (unfused side).

83

FX1

115 V ac output (fused side).

81

MANC

Form C normally closed contact from the MA pilot relay (K2).

79

MANO

Form C normally open contact from the MA pilot relay (K2).

77

MACM

Form C common contact from the MA pilot relay (K2).

6-3

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 6-4. Connector 5PL,
I/O Between DCFB Board and PCCA Card
Pin No.

6-4

Nomenclature

Description

A6F

Drives cell 6F gate pulse transformer.

P24

+ 24 volt output.

A5F

Drives cell 5F gate pulse transformer.

P24

+ 24 volt

A4F

Drives cell 4F gate pulse transformer.

P24

+ 24 volt output.

A3F

Drives cell 3F gate pulse transformer.

P24

+ 24 volt output.

A2F

Drives cell 2F gate pulse transformer.

10

P24

+ 24 volt

11

A1 F

Drives cell 1F gate pulse transformer.

12

P24

+ 24 volt

13

A1R

Drives cell 1R gate pulse transformer.

14

P24

+ 24 volt output.

15

A2R

Drives cell 2R gate pulse transformer.

16

P24

+ 24 volt output.

17

A3R

Drives cell 3R gate pulse transformer.

18

P24

+ 24 volt output.

19

A4R

Drives cell 4R gate pulse transformer.

20

P24

+ 24 volt output.

21

A5R

Drives cell 5R gate pulse transformer.

22

P24

+ 24 volt

23

A6R

Drives cell 6R gate pulse transformer.

24

P24

+ 24 volt output.

output.

output.

output.

output.

25

Test attenuation.

26

Test attenuation.

BI006008

GEH-6148

GF2000 Dc GE nerator Field Exciter


Table 6-5. Connectors CNPL, CPTPL, and FAPL,
I/O Between DCFB Board and Components
~onnector

Nomenclature

Description

X1

MA contactor control output.

----

MA contactor control output.

X2

115 V ac output (unfused side).

Pin No.

rNPL

wPTPL

X1

115 V ac output (fused side).

----

Not connected.

DeOM

Common connection.

-------

38 V ac output.

X2

115 V ac output for controller cooling fan.

X1

115 V ac output for controller cooling fan.

APL

38 V ac output.

Table 6-6. Connectors IA 1PL, IA2PL, IF1 PL, and IF2PL,


I/O Between DCFB Board and Shunts
Con ~ector

Pin No.

IA1 L

1
2

IA2 L

1
2

IF1FL

1
2

IF2F L

1
2

Nomenclature

Description

-------------

Generator armature current shunt input (+), red.

-------------

Generator armature current shunt input (-), white.


Motor #2 armature current (+), red.
Motor #2 armature current (-), white.
Motor field current shunt input (+), red.
Motor field current shunt input (-), white.
Generator field current shunt input (+), red.
Generator field current shunt input (-), white.

Table 6-7. Connector MA CPL,


I/O Between DCFB Board and Contactor Driver Circuits
Nomenclature

Description

----

MD #1 contactor control common output.

----

MD #1 contactor control 24 V dc output.

----

MD #2 contactor control common output.

----

MD #2 contactor control 24 V dc output.

Pin No.

6-5

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 6-8. DCFB Board Stab Terminal Connections


Stab

Description

V1

Phase A ac line voltage.

V2

Phase B ac line voltage.

V3

Phase C ac line voltage.

P1A

Dc bridge voltage (+).

P2A

Dc bridge voltage (-).

VM1A

Generator armature voltage ( + ).

VM1B

Generator armature voltage (-).

VM2A

Motor armature voltage (+).

VM2B

Motor armature voltage (-).

Table 6-9. Neon Lamps and LEDs on DCFB Board

6-6

Name

Indication

CR51

(LED) When lit (red), indicates that fuse FU2 in the + 24 V dc line
to the + 15 V dc regulator is blown.

CR55

(LED) When lit (red), indicates that fuse FU3 in the -24 V dc line
to the -15 V dc regulator is blown.

LT1

(Neon lamp) When lit, indicates that fuse FU1 in the 115 V ac
line to CNPL-1, CPTPL-2 and FAPL-2 is blown.

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

6-5. FEeB B

This section d mes I/O points for the FECB board. Figure 5-3 shows connector locations on the board.

Table 6-10. FEeB Board Stab Terminal Connections


Stab

Nomenclature

Description

Ell

Connects to SCR anode.

E3l - E33

Not connected.

E42

Connects to SCR cathode.

E5l

CFIRE

Connects to SCR gate.

E52

CATCOM

Connects to SCR cathode.

6-7

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
6-6. LTB BOARD I/O

This section defmes 110 points and LEDs for the LTB board. Figure 5-4 shows connector and LED locations on the
board.

Table 6-11. Connector BPL,


I/O Between LTB, NTB/3TB, and SDCC Boards
Pin No.

NTB/3TB
Terminal

Nomenclature

Description

FA

Non-inverting RS-422 half-duplex serial data line from the SDCC's Motor
Control Processor (MCP) UART.

FB

Inverting RS-422 half-duplex serial data line from MCP UART.

10

DCOM

Signal return for EXSY (at COM potential).

12

EXSY

External sync input to MCP.

--

----

Not connected.

EOAB

Encoder interface Channel A non-inverted differential input.

IEOAB

Encoder interface Channel A inverted differential input. (Tie to COM for


single-ended encoders.)

EOBB

Encoder interface Channel B non-inverted differential input.

IEOBB

Encoder interface Channel B inverted differential input. (Tie to COM for


single-ended encoders.)

10

EOMB

Encoder interface marker channel non-inverted differential input.

11

11

IEOB

Encoder interface marker channel inverted differential input. (Tie to COM


for single-ended encoders.)

12

--

----

Not connected.

13

14

Cll

Cll - CI8 are general-purpose control inputs, 24 V dc maximum with 27


kO input impedance.

14

16

CI2

See Cll (pin 13).

15

18

CI3

See Cll (pin 13).

16

20

CI4

See Cll (pin 13).

17

22

CI5

See Cll (pin 13).

18

24

CI6

See Cll (pin 13).

19

26

CI7

See Cll (pin 13).

20

28

CI8

See Cll (pin 13).

6-8

BI006008

GEH-6148

GF2000 Dc Gl nerator Field Exciter


Table 6-12. Connectors IN1 Through IN8,
Inputs to LTB Board

Pin No.

Non enclature

Description

INx-~

24 - 240 V ac or dc input logic signal is brought in on INx + and INx- where + is for
the high or hot side and - is for the low or ground side. Each input draws 6 mA maximum. The signal is converted to a 24 V dc logic signal for the SDCC.
Not connected.

INx

24 - 240 V ac or dc input logic signal is brought in on INx + and INx- where + is for
the high or hot side and - is for the low or ground side. Each input draws 6 mA maximum. The signal is converted to a 24 V dc logic signal for the SDCC.

Number here (x) corresponds to input circuit (IN) number.

Table 6-13. Connector 10PL,


I/O Between L TB Board and SL CC Card

Pin No.

Nomenclature

Description

P24

+24 V dc.

112 - 118

24 V logic lines to the exciter.

----

Not connected.

17

N24

-24 V dc.

18

111

24 V logic line to the exciter.

101-107

Relay control lines 0 through 6.

P24

+24 V dc.

1
2-8
9 - 16

19 - 25
26

Table 6-14. Connector OPTPL,


I/O Between L TB Board and NTB/3TB Board

Pin No.

Nomen lature

Description

X2

Return for CFXl 120 V ac loads (isolated from COM). Same as NTB/3TB pin 85.

CFXl

120 V ac, 15%, from NTB/3TB board, fused at 500 rnA, including internal fans
(isolated from COM). Same as NTB/3TB pin 83.

6-9

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 6-15. Connectors 071 Through OT7,


LTB Board Connections from Form C Relay Contacts
Nomenclature

Description

OTxCM*

Relay common connection; contact rating is 0.6 A @ 125 V ac, 0.6 A @


110 V dc, 2.0 A @ 30 V dc.

OTxNC*

Relay normally closed (NC) connection; contact rating is 0.6 A @ 125 V


ac, 0.6 A @ 110 V dc, 2.0 A @ 30 V dc.

OTxNO*

Relay normally open (NO) connection; contact rating is 0.6 A @ 125 Vac,
0.6 A @ 110 V dc, 2.0 A @ 30 V dc.

Pin No.

Number here (x) corresponds to relay output circuit (aT) number.

Table 6-16. Connector RPL,


I/O Between LTB Board and RTBA Board
Pin No.

Nomenclature

Description

X2

Return for CFX 1 120 V ac loads (isolated from COM). Same as OPTPL-1 .

2
3

Not connected.
RX1

4
5

Not connected.
RX2

RX3

RX4

10
11

RX5

RTBA relay RX5 pilot output.


Not connected.

RX6

14
15

RTBA relay RX4 pilot output.


Not connected.

12
13

RTBA relay RX3 pilot output.


Not connected.

RTBA relay RX2 pilot output.


Not connected.

6
7

RTBA relay RX 1 pilot output.

RTBA relay RX6 pilot output.


Not connected.

RX7

16

RTBA relay RX7 pilot output.


Not connected.

Table 6-17. LEDs on LTB Board


LED Name
1 - B

17 - 23

6-10

Indication
On when the source is applied to circuits IN 1 through INB, respectively.
On when Relay RX1 through RX7, respectively, is energized.

BI006008

GF2000 Dc G nerator Field Exciter

GEH-6148

6-7. NTB/3TE BOARD I/O

This section de mes I/O points for the NTB/3TB board. Figure 5-5 shows connector locations on the board.
Previous tables defme other NTB/3TB I/O: Table 6-2 for connector 2PL; Table 6-3 for 4PL; Table 6-11 for 8PL, and
Table 6-14 for )PTPL.

Table 6-18. Connector 3 TB,


I/O Between NTB/3TB and External Connections
3TB
Terminal

No ~enclature

Description

EO..

Non-inverting differential input for Encoder #0, channel A.

EO\ 1

Positive side of power supply with balun choke for Encoder EOA/EOB. Either + 5 or
+ 15 V dc as set by NTB/3TB jumper JP12.

lEO

EO\i 2

Return for EOV1, basically at COM potential.

EOB

Non-inverting differential input for Encoder #0, channel B.

FA

Non-inverting RS-422 half-duplex serial data line. Provides a serial channel into the
SDCC's MCP (as opposed to the RS-232C channel into the SDCC's DCP). Jumpers
JPl and JP2 are used to connect line termination resistors to FA and FB (needed at
each end of an RS-422 network).

/EOE

Inverting differential input for Encoder #0, channel B.

FB

Inverting RS-422 half-duplex serial data line (see FA, 3TB point 6).

EOM

Encoder interface marker pulse channel non-inverted differential input.

10

FCO VI

Signal return for EXSY (at COM potentia/).

11

/EOIV

Encoder interface marker pulse channel inverted differential input.

12

EXS

External sync input to SDCC's Motor Control Processor.

13

R1C

Relay #1 common contact.

14

Cll

Cll - CI8 are general-purpose control inputs, 24 V dc maximum with 27 kn input


impedance.

15

R1NC

Relay #1 normally closed contact.

16

CI2

See Cll (3TB point 14).

17

R1NC

Relay #1 normally open contact.

18

CI3

See Cll (3TB point 14).

19

R2C

Relay #2 common contact.

20

CI4

See Cll (3TB point 14).

21

R2NC

Relay #2 normally closed contact.

22

CI5

See Cll (3TB point 14).

23

R2NO

Relay #2 normally open contact.

24

CI6

See Cll (3TB point 14).

25

R3C

Relay #3 common contact.

26

CI7

See Cll (3TB point 14).

27

R3NC

Relay #3 normally closed contact.

28

CI8

See Cll (3TB point 14).

29

R3NO

Relay #3 normally open contact.

Inverting differential input for Encoder #0, channel A.

6-11

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 6-18. Connector 3TB - Continued,


I/O Between NTB/3TB and External Connections
3TB
Terminal

Nomenclature

Description

30

RF24(1 )

Voltage reference for digital control inputs. Defaulted to -24 V dc; changes to + 24 V
dc via NTB/3TB's jumpers JP1 0 and JP11. Each digital control input is active when
connected to RF24, inactive when open. Total 24 V dc load includes loading on
RF24.

31

R4C

Relay #4 common contact.

32

RF24(2)

Voltage reference for digital control inputs (see RF24[1], 3TB point 30).

33

R4NC

Relay #4 normally closed contact.

34

RUN

General-purpose input. Defaulted to, but not limited to, RUN function.

35

R4NO

Relay #4 normally open contact.

36

JOG

General-purpose input. Defaulted to JOG function.

37

R5NO

Relay #5 normally open contact.

38

POL

General-purpose input. Defaulted to the reference polarity function.

39

R5NC

Relay #5 normally closed contact.

40

XSTP

General-purpose input. Defaulted to the XSTOP function (normally closed).

41

R5C

Relay #5 common contact.

42

CTLN1

Control on input 1. CTLN1 and CTLN2 (3TB point 44) form part of the circuit that
picks up the MA contactor pilot relay. They must be connected together for the exciter to run. Can also be used to connect external interlocks, providing a fail-safe
(microprocessor independent) way to stop the exciter.

43

R6NO

Relay #6 normally open contact.

44

CTLN2

Control on input 2 (see CTLN 1, 3TB point 42).

45

R6C

Relay #6 common contact.

46

P1

P1 through P4 are medium-resolution analog input channels for voltages from 5 V dc


to 50 V dc. Scaled via respective pots P1 through P4 on the NTB/3TB. Input impedance ~ 10 kn.

47

MSRF

Relay #6 coil driver (Master Sync Reference output), open collector output. When
inactive, MSRF is pulled up to + 24 V dc through 1400 n maximum. When active,
MSRF is pulled down to 1.5 V dc maximum through 200 n, not including a maximum
drop of 3.4 V across the 200 n due to the relay #6 coil load. If internal control of
this relay is not required, relay #6 may be picked up by an external driver capable of
pulling MSRF down to 1.5 V dc maximum sinking 17 mAo

48

P2

See P1 (3TB point 46).

49

DVM

Medium resolution analog input channels, with fixed scaling for 51.0 V dc max
(25.5 on early DCC cards). Input impedance and filtering is 511 kn and 100 ms. In
conjunction with exciter test 03, provides a digital voltmeter function with at least
0.5% accuracy for diagnostic functions.

50

P3

See P1 (3TB point 46).

51

ASPO

Medium-resolution analog input channel with fixed scaling for 5 V dc maximum.


Input impedance and filtering is 10 kn and 1 ms.

52

P4

See P1 (3TB point 46).

53

DAC1

Output from 8-bit (DCC and SDCCG3) or 12-bit (SDCCG1) D/A converter. Can source
10 V dc at no load or 8 V dc at a 10 mA load (200 n series impedance). Any exciter variable can be sent to this output and can be scaled to set the value corresponding to 10 V dc output. If the variable attains a magnitude greater than this
value, the output is clamped to 1 0 V, rather than rolling over. (For diagnostics and
system applications.)

6-12

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Tab/e 6-18. Connector 3TB - Continued,
//0 Between NTB/3TB and Externa/ Connections
3TB
Terminal

Nc menclature

Description

54

M T1

Output from 8-bit D/A converter. Can source 1 0 V dc at no load or 8 V dc at a 10


mA load (200 n series impedance). Any exciter variable can be sent to this output
and can be scaled to set the value corresponding to 10 V dc output. If the variable
attains a magnitude greater than this value, the output is clamped to 1 0 V, rather
than rolling over. (Provided for meter driver functions.)

55

DA C2

Same as DACl (see 3TB point 53).

56

MET2

Same as METl (see 3TB point 54).

57

M~SY

Input to internal interrupt INTO of the SDCC's Drive Control Processor (DCP). Biased
to + 24 V dc though 27 kn, must be pulled to COM (less than + 1.5 V dc) to be recognized by the DCP.

58

RE ET

Hard reset input to the exciter. Connecting RESET to + 5 to + 24 V dc resets all


processors in the exciter. Leaving RESET open or connecting to COM allows exciter
operation. The SDCC provides a 20 ms noise filter on this input.

59

TOIN

Input to internal timer/counter 0 of the SDCC's Drive Control Processor (DCP). Biased
to + 24 V dc through 27 kn, and must be pulled to COM (less than + 1.5 V dc) to be
recognized by the DCP.

60

+5 VDC

+ 5 V dc source, 1 0%, 300 mA (including load on EOV1 and El Vl).

61

TOe UT

TTL output through 200 n from DCP's timer/counter 0 (on SDCC).

62

+1 VDC

+ 15 V dc source, 1 0%, 300 mA (including load on EOVl and El Vl).

63

REFP

Non-inverting differential analog reference input. Maximum reference can be 9 to 29


V dc, coarsely selected by NTB/3TB's switches SW1 through SW7. Fine scaling provided by EE.1281 (RVSCLn). This circuit uses a VCO similar to the one used by FDBP
and FDBN. Input impedance is at least 60 kn with less than 1 ms of filtering. If this
circuit is not needed for the exciter speed reference, the digitalization of this input is
available for other functions requiring high resolution.

64

-15\ DC

-15 V dc source, 1 0%, 300 mA (including load on El Vl).

65

REF

Inverting differential analog reference input, with REFP, 3TB point 63.

66

cor-.

(1)

o V common reference for all exciter I/O. COM should be

used for signal level returns

only.
67

RSV ~(1 )

Not used. Provides voltage clearance between signal-level points and points with potentials above 50 V.

68

co M(2}

oV

69

FDBF

Non inverting differential analog tach input (with 3TB point 73). Either ac AN or dc
tachometers with a top speed voltage from 25 to 390 V (6 to 65 V if jumper JP7 on
the SDCC card is in the 2-3 position) can be connected to these differential inputs.
NTB/3TB's DIP switches SWl through SW7 provide coarse scaling. SDCC's jumper
JP8 and EE.1386 (FVSCLn) provide fine scaling and analog ac AN tach rectification.
Input impedance of this circuit is at least 300 kn, with less than 1.5 ms of filtering.
If this circuit is not needed for the exciter speed feedback, the digitalization of this
input is a available for other functions requiring high resolution.

common reference for all exciter I/O, same as 3TB point 66.

70

+24 DC

+24 V dc source, 25%, unregulated, 500 mA (including load on RF24).

71

RSVC(2)

Not used. Provides voltage clearance between signal-level points and points with potentials above 50 V.

72

-24V[ C

-24 V dc source, 25%, unregulated, 500 mA (including load on RF24).

73

FDBN

Inverting differential analog tach input (with 3TB point 69).

74

E1Vl

Power supply with balun line choke for encoders on SPC card. Either -15V dc or
same voltage as EOVl (+ 5 or + 15 V dc) as selected using NTB/3TB jumper JP13.

6-13

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 6-18. Connector 3TB - Continued,


I/O Between NTB/3TB and External Connections
3TB
Terminal

Nomenclature

Description

75

RSVD(3)

Not used. Provides voltage clearance between signal-level points and points with potentials above 50 V.

76

E1V2

Return for E1 V1, basically at COM potential.

77

MACM

Form C common contact from MA pilot relay; auxiliary contact from the relay used to
pilot the MA contactor. Rated for 125 V ac, 2A.

78

RSVD(4)

Not used. Provides voltage clearance between signal-level points and points with potentials above 50 V.

79

MANO

Form C normally open contact from the MA pilot relay; auxiliary contact from the
relay used to pilot the MA contactor. Rated for 125 V ac, 2A.

80

GRC1

General-purpose relay common contact of first form C. Rated for 120 V ac, 0.5 A.

81

MANC

Form C normally closed contact from the MA pilot relay; auxiliary contact from the
relay used to pilot the MA contactor. Rated for 125 V ac, 2A.

82

GNC1

General-purpose normally closed contact.

83

CFX1

120 V ac source from drive, 1 5%, fused at 500 mA (isolated from COM).

84

GN01

General-purpose relay normally open contact.

85

X2

Return for CFX1 120 V ac loads (CFX1 and X2 isolated from COM).

86

GRC2

General-purpose relay common contact of second from C. Rated 120 V ac, 0.5 A).

87

GR+

GR + and GR- (3TB point 89) are coil inputs to a general purpose relay. This relay is
not internally connected to any exciter circuitry, and may be used as required for customer applications. The coil may be driven by 24 V or 120 V, either ac or dc, as selected using jumper JP20.

88

GNC2

General-purpose relay normally closed contact. Rated 120 V ac, 0.5 A.

89

GR-

See GR + (3TB point 87).

90

GN02

General-purpose relay normally open contact. Rated 120 V ac, 0.5 A.

91

VC3N

Inverting differential analog input for auxiliary VCO #3. The top reference voltage
may be 9 to 29 V de. Jumpers JP14 and JP1 5 provide coarse scaling of the inputs.
This circuit uses a VCO similar to the one used by REFP and REFN. Input impedance
is at least 60 kO with less than 1 ms of filtering. The digitalization of this input is
available at VAR.184 for functions requiring a high-resolution analog input by using
BLK.263 (V3VCO). (An SDCC card is required to support VCO #3; it is not available
on the DCC card.)

92

VC4N

Inverting differential analog input for auxiliary VCO #4. The top reference voltage
may be 9 to 29 V de. Jumpers JP22 and JP23 provide coarse scaling of the inputs.
This circuit uses a VCO similar to the one used by REFP and REFN. Input impedance
is at least 60 kO with less than 1 ms of filtering. The digitalization of this input is
available at VAR.185 for functions requiring a high-resolution analog input by using
BLK.264 (V4VCO). (An SDCC card is required to support VCO #4, it is not available
on the DCC card.)

93

VC3P

Non-inverting differential analog input for auxiliary VCO #3.

94

VC4P

Non-inverting differential analog input for auxiliary VCO #4.

95

MET3

10 V dc analog output from an 8-bit D/A converter (see 3TB point 54).

6-14

BI006008

GEH-6148

GF2000 Dc Geperator Field Exciter


Table 6-19. Connector 6PL,
I/O Between NTB/3TB Board and SDCC Card
Pin No.

NTf 13TB
Ter ninal

Nomenclature

Description

CTLN1

Control on input 1. CTLNl and CTLN2 (3TB point 44) form part of the
circuit that picks up the MA contactor pilot relay. They must be connected together for the exciter to run. Can also be used to connect external interlocks, providing a fail-safe (microprocessor independent) way
to stop the exciter.

CTLN2

See CTLN2 (pin 1).

LBIAS

24 V de bias for digital inputs from NTB/3TB (for + or - logic).

~4

:;1

TOOUT

TTL output through 200 n from DCP's timer/counter 0 (on SDCC).

64

RUN

General-purpose input. Defaulted to, but not limited to, RUN function.

1S6

JOG

General-purpose input. Defaulted to JOG function.

POL

General-purpose input. Defaulted to the reference polarity function.

XSTP

General-purpose input. Defaulted to XSTP function (normally closed).

MSRF

Relay #6 coil driver (Master Sync Reference output), open collector output.

10- 14

R01 - R05

NTB/3TB relay coil output driver lines 1 through 5.

15

P3B

Scalable general-purpose analog input from NTB/3TB.

16

P4B

Scalable general-purpose analog input from NTB/3TB.

17

! 1

ASPO

Medium-resolution analog input channel with fixed scaling for 5 V dc


maximum. Input impedance and filtering is 10 kO and 1 ms.

18

VC3NB

Inverting differential analog input to SDCC auxiliary VCO #3.

VC3PB

Non-inverting differential analog input to SDCC auxiliary VCO #3.

P1A, P1 B

Scalable general-purpose analog inputs from NTB/3TB.

22

----

Not connected.

23

4\9

DVM

Medium resolution analog input channels, with fixed scaling for 51 .0 V


dc max (25.5 on early DCC cards). Input impedance and filtering is 511
kn and 100 ms. In conjunction with exciter test 03, provides a digital
voltmeter function with at least 0.5% accuracy for diagnostic functions.

24

53

DA1

Output from 8-bit (DCC and SDCCG3) or 12-bit (SDCCG1) D/A converter. Can source 1 0 V dc at no load or 8 V dc at a 10 mA load (200
n series impedance). Any exciter variable can be sent to this output and
can be scaled to set the value corresponding to 10 V dc output. If the
variable attains a magnitude greater than this value, the output is
clamped to 10 V, rather than rolling over. (For diagnostics and system
applications.)

19
20, 21

25

50

DA2

Same as DA 1 (pin 24).

26

MET1

Output from 8-bit D/A converter. Can source 1 0 V dc at no load or 8


V dc at a 10 mA load (200 n series impedance). Any exciter variable can
be sent to this output and can be scaled to set the value corresponding
to 10 V dc output. If the variable attains a magnitude greater than this
value, the output is clamped to 1 0 V, rather than rolling over. (Provided
for meter driver functions.)

27

5E

MET2

Same as MET1 (pin 26).

28

MSSY

Input to internal interrupt INTO of the SDCC's Drive Control Processor


(DCP). Biased to +24 V dc though 27 kO, must be pulled to COM (less
than + 1.5 V dc) to be recognized by the DCP.

6-15

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Tab/e 6-19. Connector 6PL - Continued,


//0 Between NTB/3TB Board and SDCC Card
Pin No.

NTB/3TB
Terminal

Nomenclature

Description

29

59

TOIN

Input to internal timer/counter 0 of the SDCC's Drive Control Processor


(DCP). Biased to + 24 V dc through 27 kn, and must be pulled to COM
(less than + 1.5 V dc) to be recognized by the DCP.

30

58

RESET

Hard reset input to the exciter. Connecting RESET to + 5 to + 24 V dc


resets all processors in the exciter. Leaving RESET open or connecting to
COM allows exciter operation. The SDCC provides a 20 ms noise filter
on this input.

31

----------

TDB

RS-232C channel transmitted from DCP.

RDB

RS-232C channel received by the DCP.

CTSB

RS-232C channel clear-to-send handshake.

RTSB

RS-232C channel c1ear-to-receive handshake.

VC4NB

Inverting differential analog input for SDCC auxiliary VCO #4.

VC4PB

Non-inverting differential analog input for SDCC auxiliary VCO #4.

RFNB

Differential analog input from NTB/3TB to reference VCO, negative line.

RFPB

Same as pin 37, but positive line.

FBNB

Differential analog input NTB/3TB to feedback VCO, negative line.

FBPB

Same as pin 39, but negative line.

32
33
34
35
36
37
38
39
40

Tab/e 6-20. Connector COMPL,


RS-232C //0 Between NTB/3TB Board and User Interface
Pin No.
1 - 25

Nomenclature

Description
The exciter includes an RS-232C connection only for use as a serial link with the
ST2000 Toolkit or Drive Configurator, LynxOS Version. These software packages are
diagnostic and configuration programs 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 of COMPL directly to a PC (personal computer) unless jumper 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.

6-16

BI006008

GEH-6148

GF2000 Dc Ge nerator Field Exciter


6-8. PCCA CJ RD I/O

This section de mes I/O points for the PCCA card. Figure 5-6 shows connector locations.
For connector 51PL, see Table 6-4.

Table 6-21. Connectors 1FPL Through 6FPL and 1RPL Through 6RPL,
Output from PCCA Card to SCR Bridge
onnector

Pin No.

Description
Forward gate pulse to corresponding SCR (red wire).

FPL - 6FPL
2
RPL - 6RPL

Forward gate pulse to corresponding SCR (white wire).


Reverse gate pulse to corresponding SCR (red wire).

Reverse gate pulse to corresponding SCR (white wire).

Table 6-22. PCCA Card Stab Terminal Connections


Stab

Card Group No.

Description

Pl

Gl - 4, 7 - 10

Positive dc bus.

Pl A, Pl B

Gl - 4,7 - 10

Positive dc bus voltage feedback. When wire jumper WJ3 is connected between these terminals, the card snubber capacitors are connected to the
same point on the bridge as the voltage feedback channel (see Table 5-4).

P2

Gl - 4, 7 - 10

Negative dc bus.

P2A, P2B

Gl-4,7-10

Positive dc bus voltage feedback. When wire jumper WJ4 is connected between these terminals, the card snubber capacitors are connected to the
same point on the bridge as the voltage feedback channel (see Table 5-4).

P3 - Pl0

Gl - 4,7 - 10

Voltage feedback scaling resistor connections (see Table 5-4).

DCS

Gl - 4, 7 - 10

To dc snubber circuit.

lACS - 6ACS

Gl,2,7,8

To ac snubber circuits.

6-17

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
6-9. RTBA BOARD 1/0

This section defmes I/O points and LEDs for the RTBA board. Figure 5-7 shows connector and LED locations.
For connector RPL, see Table 6-16.

Table 6-23. Connector RTBA,


I/O Between RTBA Board and External Connections
RTBA
Terminal

RTBA
Terminal

Nomenclature *

RTBA
Terminal

Nomenclature *

K20A

18

K221 NC

35

K242NC

K201NO

19

K222NO

36

K25A

K201CM

20

K222CM

37

K251NO

K201NC

21

K222NC

38

K251CM

K202NO

22

K23A

39

K251NC

K202CM

23

K231NO

40

K252NO

K202NC

24

K231CM

41

K252CM

K21A

25

K231NC

42

K252NC

K211NO

26

K232NO

43

K26A

10

K211 CM

27

K232CM

44

K261 NO

11

K211NC

28

K232NC

45

K261CM

12

K212NO

29

K24A

46

K261 NC

13

K212CM

30

K241 NO

47

K262NO

14

K212NC

31

K241CM

48

K262CM

15

K22A

32

K241 NC

49

K262NC

16

K221NO

33

K242NO

50

KCM

17

K221CM

34

K242CM

51

115V

6-18

Nomenclature*

The RTBA board contains seven relays that have two form C contacts. Nomenclature for the
terminal board points indicates the contact connection. For example, the terminal board point
K201NO: K = relay; 20 = which of the seven relays (20 - 26); 1 = which of the two form
C contacts; and NO = normally open, as opposed to normally closed (NC) or common (CM).

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


Table 6-24. Connectors CP1 PL Through CP5PL and Y9PL Through Y35PL,
RTBA Pluggable Circuits
Connectpr

Description

CP1 PL - CP5PL, pin 1

Pluggable circuit control power, positive (hot) side (CPH).

CP1 PL - CP5PL, pin 2

Pluggable circuit control power, negative side (CPN).

Y9PL-1

CPH.

Y9PL-2

Connected to Y1 OPL-1 . Y9PL and Y1 OPL form a powered pluggable circuit.

Y10PL-1

Connected to Y9PL-2.

Y10PL-2

CPN.

Y11PL-1

CPH.

Y11 PL - Y14PL

Two-position plugs forming a series string to coil of relay K27.

Y15PL

Jumpers Y18PL-2 to CPN.

Y16PL

Relay K27 normally open contacts.

Y17PL

Relays K27 and K28 dry contacts in series.

Y18PL

Relays K28 and K29 coil leads.

Y1 9PL - Y22PL

Pluggable control circuit with K28 interlock.

Y23PL,

'< 24PL

Y25PL - ~28PL
Y29PL,

'< 30PL

Dry circuit with K29 contact.


Pluggable control circuit with K29 interlock.
Dry circuit with K29 contact.

Y31 PL - Y34PL

Pluggable control circuit with K29 interlock.

Y35PL - rt'37PL

Pluggable control circuit.

Table 6-25. LEDs on Relays of RTBA Board

LED on
Relay's Name
K20 - K29

Indication
On when relays K20 though K29 (respectively) are energized.

6-19

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
6-10. SDCC CARD I/O

This section defines I/O points and LEOs for the SOCC card. Figure 5-8 shows connector and LEO locations.
Previous tables defme other SOCC I/O: Table 6-1 for connector IPL; Table 6-2 for 2PL; Table 6-19 for 6PL; and
Table 6-11 for 8PL.

Table 6-26. Connector 3PL,


SDCC Card Output to SLCC Card

Pin No.

Nomenclature

Description

BDO - BD7

Buffered, multiplexed SDCC Drive Control Processor (DCP) data bus lines 0 - 7.

DCOM

Power supply return, common.

10

P5

+5

11

IRST3

System reset signal (active low).

12

LINT

Interrupt from SLCC/SDCC microapplication chip to DCP.

13

ILBSY

Busy bus control handshake to DCP.

14

BA12

Buffered address latch enable from DCP.

15

DCOM

Power supply return, common.

16

IBCSL

SLCC chip select.

17

IBRD

Buffered read control line from DCP.

18

IBWR

Buffered write control line from DCP.

19

BA8

Buffered, demultiplexed DCP address line 8.

20

BA9

Buffered, demultiplexed DCP address line 9.

21

IBCSU

SDCC microapplication chip select.

22

BA10

Buffered, demultiplexed OCP address line 10.

23

BA11

Buffered, demultiplexed OCP address line 11.

DCOM

Power supply return, common.

P5

+5 V

BAO - BA7

Buffered, demultiplexed OCP address lines 0 through 7.

1 - 8

24, 25
26
27 - 34

6-20

V dc regulated power supply for digital circuits.

dc regulated power supply for digital circuits.

BI006008

GEH-6148

GF2000 Dc GE nerator Field Exciter


Table 6-27. Connector 7PL,
I/O Between SDCC Card and SPC Card

Nomenclature

Description

SPA1

5 V dc SPC analog channel #1.

SPA2

5 V dc SPC analog channel #2.

Pin No

E1Z

Marker channel from encoder #1 interface.

E2Z

Marker channel from encoder #2 interface.

N15

-15 V dc power supply for analog circuits on SPC card.

P15

+ 15 V

dc power supply for analog circuits on SPC card.

DCOM

Power supply return, common.

SPRS

Digital output from DCP to SPC card.

DCOM

Power supply return, common.

10

P5

+5 V

11

E1UP

Up channel output from encoder #1 interface.

12

E1DN

Down channel output from encoder #1 interface.

13

E2UP

Up channel output from encoder #2 interface.

14

E2DN

Down channel output from encoder #2 interface.

15

ORST7

System reset (active low).

16

DCOM

Power supply return, common.

17,18

----

Not connected.

19

SPTX

20

SPRX

+5 V
+5 V

dc power supply for digital circuits on SPC card.

dc output from SDCC's Motor Control Processor (MCP) UART.


dc input to MCP UART.

Table 6-28. Connector 11 PL,


SDCC Output to Meters

Pin No.

Nomerclature

Description

DCOI'J

Drive common connection.

MTR1

MTR1 through MTR4 are outputs from an 8-bit D/A converter and can source 1 0 V
dc at no load or 8 V dc at 10 rnA load (200 n series impedance), Any exciter variable
can be steered to these D/A outputs and can be scaled to set what value corresponds
to the 10 V dc output. These outputs are for meter driver functions.

MTR2

See MTR1 (pin 4).

MTR3

See MTR1 (pin 4).

MTR4

See MTR1 (pin 4).

DCOM

Drive common connection.

1,2

Not connected.

9,10

Not connected.

Table 6-29. LEDs on SDCC Card

LED Name

Indi ation
Bar raph LED indicating fault patterns showing whether the exciter is healthy, and stopped or running When the exciter has a fault, the graph displays the fault code number. For a detailed description of fault codes, see Chapter 10.

6-21

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
6-11 . SLCC CARD I/O

This section defmes I/O points for the SLCC card. Figure 5-9 shows connector locations.
Previous tables defme other SLCC I/O: Table 6-2 for connector 2PL; Table 6-13 for IOPL; and Table 6-26 for 3PL.

Table 6-30. Connector ARCPL,


I/O Between SLCC Card and DLAN or ARCNET
Nomenclature

Description

TXA-

Transmitting and receiving signals, channel A.

TXA+

Transmitting and receiving signals, channel A.

TXB-

Transmitting and receiving signals, channel B.

TXB+

Transmitting and receiving signals, channel B.

P5

+ 5 V dc power.

DCOM

Power digital common.

TXB

Transmitting signal selected by JP1 5 as isolated DLAN circuit or RS-422.

TXA

Receiving signal selected by JP1 5 as isolated DLAN circuit or RS-422.

Pin No.

Table 6-31. Connector KPPL,


I/O Between SLCC Card and Keypad
Pin No.

Nomenclature

1 - 9

6-22

Description
Keypad connectors to processor; Output from U1 to pins 19 - 32, respectively.

10

LODIN

Display; Input to U1 pin 38.

11

LDCLK

Display; Input to U1 pin 39.

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter


6-12. SPC CARD 1/0

This section defi~es I/O points for the SPC card. Figure 5-10 shows connector locations.
For connector T. 'L, see Table 6-27.

Table 6-32. Connectors 16PL and 1TB,


I/O Between SPC Card and External Connections

16PL
Pin No.
1
2
3
4
5
6

HS
Term nal

-------

Nomenclature

Description

E1AB

Non-inverting input for encoder #1 channel A

IE1AB

Inverting input for encoder #1 channel A.

E1BB

Non-inverting input for encoder #1 channel B.

IEl BB

Inverting input for encoder #1 channel B.

E1MB

Non-inverting input for encoder #1 marker channel.

IE1MB

Inverting input for encoder #1 marker channel.

E2AB

Non-inverting input for encoder #2 channel A.

IE2AB

Inverting input for encoder #2 channel A.

E2BB

Non-inverting input for encoder #2 channel B.

10

IE2BB

Inverting input for encoder #2 channel B.

11

E2MB

Non-inverting input for encoder #2 marker channel.

12

IE2MB

Inverting input for encoder #2 marker channel.

13

PFl N

Inverting input for analog channel SPA 1 (VAR.256).

14

PF1P

Non-inverting input for analog channel SPA 1 (VAR.256).

15

PF2N

Inverting input for analog channel SPA2 (VAR.257l.

16

10

PF2P

Non-inverting input for analog channel SPA2 (VAR.257).

17

11

TXP

Non-inverting RS-422 output from SDCC's Motor Control Processor


(MCP).

18

12

TXN

Inverting RS-422 output from MCP.

19

13

RXN

Inverting RS-422 input to MCP.

20

14

RXP

Non-inverting RS-422 input to MCP.

6-23

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter

6-13. SVAA BOARD I/O

This section defmes I/O points for the SVAA board. Figure 5-12 shows connector locations.

Table 6-33. SVAA Board Terminal Connections

Terminal

6-24

Description

SC1

Attenuator voltage input #1 (+).

SC2

Attenuator voltage input #1

SC3

Attenuator voltage output #1 (+).

SC4

Attenuator voltage output #1

SC5

Attenuator voltage input #2 {+ j.

sca

Attenuator voltage input #2

SC7

Attenuator voltage output #2 (+).

SCB

Attenuator voltage output #2

(-j.

{oj.

(oj.

(-j.

BI006008

GEH-6148

GF2000 Dc Ge ~erator Field Exciter


6-14. SVIA BC~ARD I/O

This section def Illes I/O points and the POWER ON LED for the SVIA board. Figure 5-14 shows connector and LED
locations.
Table 6-34. SVIA Board Terminal Board Connections
Connector

T rminal

Nomenclature

Primary positive input, using custom gain resistor R11. Input TB1-1 is
normally connected to the positive side of the shunt terminal. This input goes into resistor R11, the gain select resistor connected to the
saddle clamp terminals (see section 5-4-10 for instructions on selecting
the value for resistor R11).

TB1

ACOM

Negative input. This input is typically connected to the negative side of


the shunt terminal.

----

Alternate unity preamp gain (7.5 kO) input.

VTEST

Output connection for a test voltage source. Typically used to set the
scaling of the SVIA isolator. Refer to Table 5-11 for information on
using J2 for range selection and R3 for voltage adjustment.

Alternate input with preamp gain of 16 (475 OJ.

----------

NMAX

Most negative output. This signal represents the SVIA output through a
diode such that if multiple SVIAs are connected together via this signal,
the interconnection point represents the most negative of all the SVIAs
connected.

PMAX

Most positive output. This signal represents the SVIA output through a
diode such that if multiple SVIAs are connected together via this signal,
the interconnection point represents the most positive of all the SVIAs
connected.

ACOM

Output common. This terminal is the overall output signal common.


When the SVIA is connected to a differential receiver or VCO, this signal is connected to the low side of the receiver.

TB2

Description

Alternate input with preamp gain of 34 (221 OJ.


Alternate input with preamp gain of 75 (1000).

Output signal. This terminal is the overall output signal. Typically the
output voltage is 1 V = 1 per unit armature current. The SVIA is capable of 1 OV at 4 mA maximum.

P28

+ 24 V dc input. Connected to the high side of an external + 24 V dc


power supply which powers the SVIA.

PCOM

+ 24 V dc common. Connected to the low side of an external


dc power supply which powers the SVIA.

+ 24

Power OK form A contact. Terminal to connect the power supply monitor relay contact to an external device. Typically trips the exciter if this
contact opens.
Power OK form A contact.

Table 6-35. LED on SVIA Board


LED Name

De cription

POWER ON

Th ~ LED is lit when the + 15 V dc supply from the regulator is present. If the POWER ON LED is
no lit, check that + 24 V dc is present between TB2-5 (+) and TB2-6 (-). Note if the + 24 V dc
inpJt is present, relay K1 should close the contacts between TB2-7 and TB2-8.

6-25

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Notes:

6-26

BI006008

GEH-6148

GF2000 Dc GE nerator Field Exciter

CHAPTER 7
FUSES AND TESTPOINTS

7-1. LINE FU~ ES

7-2. DCFB ONBOARD FUSES

All GF2000 Dc Generator Field Exciters include protective fuses on the ac power lines and control power
lines. C frame exciters also include fuses on the
blower motor p wer lines. The ac power line fuses are
typically design ted FUI through FU3; the control
power line fuse, CPTFUI through CPTFU3; and the
blower motor pc wer line fuses, BFl through BF3.

The DCFB contains fuses FU1 through FU3, defmed


in Table 7-2. Neon light LTllights if FUI is blown;
LED CR5l lights if FU2 is blown and control power
is applied to the exciter; and LED CR55 lights if FU3
is blown and control power is applied. Figure 7-1
shows DCFB fuse, neon light, and LED locations.

Table 7-1 lists ~ 'Pical values for these fuses. Chapter


13 contains part lists for GF2000 C and G frame exciters. These PaJ~s lists identify the part number for
each fuse.

WARNING

The hardware dI~wings in the exciter door pocket


show the locatio s of these fuses. Appendix B contains
sample hardwarf drawings for the GF2000 exciter.

Dangerous voltages exist on the DCFB


when power is on. Turn off exciter power
and stop generator. Allow internal capacitors to discharge before touching or moving
the board, or when attaching or removing
meters.

Table 7-1. GF2000 Dc Generator Field Exciter Line Fuse Values


Fuse Locat on in Circuit

Fuse Designation

Fuse Value

Type

Ac input p( wer lines, C frame:


230 V ae, 108-260 A output
230 V ae, 261-525 A output

FU 1 - FU3

300 A, 500 V
500 A, 500 V

Semiconductor

460 V ae, 128-260 A output


460 V ae, 261-505 A output

300 A, 500 V
500 A, 500 V

600 V ae 107-183 A output


600 V ae 184-421 A output

200 A, 700 V
400 A, 700 V

Ac input power lines, G frame:


230 V ac 1-55 A output
230 V ac 56-74 A output
230 V ac 75-107 A output

FU1 - FU3

60 A, 500 V
100 A, 500 V
175 A, 500 V

460 V ac 1-53 A output


460 V ac 54-69 A output
460 V ac 70-1 27 A output

60 A, 500 V
100 A, 500 V
175 A, 500 V

600 V ac 1-58 A output


600 V ac 59-106 A output

60 A, 700 V
100 A, 700 V

Control po .... er lines, C and G frames:


230 V ac input
460 V ac nput
575 V ac nput

All input IIpltages


Blower mot( r lines, C frame only:
230 V ac, 50 Hz
230 V ac, 60 Hz

Semiconductor

CPTFU 1, CPTFU2

8.0 A, 600 V
4.0 A, 600 V
3.2 A, 600 V

FNQ-R, time delay

CPTFU3

5.0 A, 600 V

FNQ-R, time delay

SF1 - BF3

3.2 A
4.0A

FRS-R, dual-element time delay

460 V ac, 50 Hz
460 V ac, 60 Hz

1.8 A
2.0A

575 V ac, 50 Hz
575 V ac, 60 Hz

1.25 A
1.8 A

7-1

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
Table 7-2. DCFB Board Fuses
Fuse

Function

FU 1

Fuse for the 115 V ac po wer supply brought to 3TB; 1/2 A, 2A G fast acting. FU 1 protects the 11 5 V ac
power supplied for customer use. Check for wiring errors or overload if this fuse blows. When the fuse is
blown and load is connected, neon light LT1 on the DCFB board will be lit.

FU2

Fuse for signal-level power supplies + 24, + 15, and + 5 V dc; 7 A, 2AG fast acting. When FU2 is blown,
the exciter is unable to generate fault messages, but LED CR51 will be lit when control power is applied to
the exciter. The usual cause of this fuse blowing is an accidental short of + 24 V dc, either while probing
or due to a wiring error at the terminal board. If FU2 continues to blow when 1PL, 2PL, and 5PL are disconnected from the DCFB board, the board should be replaced.

FU3

Fuse for signal-level power supplies -24 and -15 V dc; 7 A, 2AG fast acting. When FU3 is blown, the Programmer is unable to display fault messages, but LED CR55 on the DCFB board will be lit when control
power is applied to the exciter. The usual cause of this fuse blowing is an accidental short of -24 V dc,
either while probing or due to a wiring error at the terminal board. If FU3 continues to blow when 1PL,
2PL, and 5PL are disconnected from the DCFB board, the board should be replaced.

Rn W

IF1 Pi

IA2PL

VI

V2

V3

PIA

P2A

VMIA

VM18

VM2A

II

II

II

II

II

II

II

II

PPL
W

~-I-jW
C::::=

NPc
R

2n
2~1I,
~'
~I

ICP c

r==='T

SW7

-'

L-J

JP1

3~

~riT'
TCPL

08

SQPL

~D

~Jl':k=':::c-.r======::L-A~~::J'1

JP2

C:=:J

D,'PL
FU2

~
FU3

CR51

DC Oa
+'"

DCOM

rc
"

5PL

lOilrc~

cdJl'
1 FPL

~I

2FPL

Irz-=

I',

5PL

~I

!'

c:=J
P5
2PL

NI5

pH:;

0I

DS200DCFBG1B

Figure 7-1. DCFB Board Layout

7-2

1 2 3

CNPL

D
'. "
FI

GSA]
FUI

BI006008

GEH-6148

GF2000 Dc Gl nerator Field Exciter


7-3. TESTPO NTS

7-3.1. DCFB Board Testpoints

The GF2000 eJi citer includes onboard testpoints for


use in troubleslooting. Testpoints are metal posts located on specifif' signal paths. The signal can then be
measured or vii wed by connecting an oscilloscope or
other measurint instrument to that testpoint.

Table 7-3 lists and defmes the testpoints contained on


the DCFB board. Figure 7-1 shows the locations of
these testpoints on the board.

7-3.2. NTB/3TB Board Testpoints

Tables 7-3 thro gh 7-7 list the testpoints contained on


boards used in tie GF2000 exciter. Boards containing
testpoints are p esented here in alphabetical order by
board name (D( FB, NTB/3TB, and so on) to assist
the reader in re ~rencing this material.

Table 7-4 lists and defmes the testpoints contained on


the NTB/3TB board. Figure 7-2 shows the locations of
these testpoints on the board.

NOTE

In Tables i 3 through 7-7, if a board revision is not isted for a testpoint, that testpoint is inc uded on all board revisions.
Table 7-3. DCFB Board Testpoints
Name

Description

P5

Testpoint for regulated

DCOM

o V common reference point for test signals.

Revision

+5

V de (5%) power supply.

+ 15

P15

Testpoint for regulated

N15

Testpoint for regulated -15 V de (5%) power supply.

ACCT

Testpoint for ACCT signal from DCFB to SDCC (not applicable to GF2000).

V de (5%) power supply.

Table 7-4. NTB/3TB Board Testpoints


Name

Descri tion

DA1

10 V de analog output from a-bit (SDCCG3) or 12-bit (SDCCG1) D/A converter, same as
3TB pi, 53.

DA2

10 V de analog output from a-bit (SDCCG3) or 12-bit (SDCCG1) D/A converter, same as
3TB pi~ 55.

MET1

10 V ::Ie analog output from a-bit D/A converter, same as 3TB pin 54.

MET2

10 V ::Ie analog output from a-bit D/A converter, same as 3TB pin 56.

DVM

Digital

COM

o V co Inmon reference point for test signals, same as

~oltmeter

Revision

(Test 03) input, range 50 V dc, same as 3TB pin 49.


3TB pin 66.

,I
r

~I

O~

Ii I!I
iii

11 !lllll
i I

IIIi I

Figure 7-2. NTB/3TB Board Layout

7-3

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
7-3.3. SDCC Card Testpoints

Table 7-5 lists and defmes the testpoints contained on the SDCC card. Figure 7-3 shows the locations of these testpoints on the card.

Table 7-5. SDCC Card Testpoints


Name

Description

DCOM1
DCOM2

o V common reference point for test signals, same as DCOM2.


o V common reference point for test signals, same as DCOM 1.

P5

Testpoint for regulated + 5 volt (5 %) power supply.

TP4

Drive Control Processor (DCP) foreground timing flag (720 Hz).

TP5

DCP blockware timing flag (720 Hz).

TP6

DCP slow background timing flag (90 Hz).

RTS

Unused. General-purpose testpoint output from DCP.

TP8

Analog representation of the generator armature current (via the primary shunt IA 1 of this
bridge only), with a nominal dc offset of about +2 V. A deviation of 0.5 V represents
approximately 1 pu shunt current. In DCFB applications which use dual shunts, TP8 does
NOT represent any of the current in shunt IA2 nor does it represent any current from
shunts in other bridges of a multibridge drive.

FCLK

"I'm alive" 8 MHz oscillator output from Motor Control Processor (MCP).

PWM

General-purpose firmware timing testpoint for MCP (development engineering use only).

NMI

Initiates board test (Test 13) when momentarily tied to + 5 V dc. For card test only, not
recommended for use in a drive environment.

MTPNT

General-purpose firmware timing testpoint for MCP (development engineering use only).

DACS

Diagnostic D/A converter daughterboard select; used with auxiliary diagnostic hardware in
conjunction with EE.600.

N15

Testpoint for regulated -1 5 volt (5 %) power supply.

P15

Testpoint for regulated + 15 volt (5%) power supply.

CDR

CDX

TMS320 serial data receive


The testpoints in the upper left corner of the SDCC (CDR, CDX, CLX, CLR, FSX, CLKC,
CP5, and CCM) are reserved for diagnostic purposes for the TMS320C25 processor, via a
D/A daughterboard which allows serial diagnostic D/A converters to be added for development/test purposes only.
TMS320 serial data transmit.

CLX

TMS320 serial transmit clock input.

CLR

TMS320 serial receive clock input.

FSX

TMS320 serial frame sync pulse for transmit.

FSR

TMS320 serial frame sync pulse for receive.

CLKC

TMS320 clock oscillator output.

Revision

AFD-Pres

CP5

+ 5 V dc power supply to TMS320 diagnostic D/A daughterboard.

CCM

Common power supply return for TMS320 diagnostic D/A daughterboard.

BIO

CMP control line from MCP for processor synchronization.

AFD-Pres
AFD-Pres

XF

CMP handshake line to MCP for processor synchronization.

TP29

Testpoint for input line frequency.

TP37

Testpoint for de voltage.

7-4

BI006008

GEH-6148

GF2000Dc Gl nerator Field Exciter


3PL

=(1,3 4

'if'
,IL

=,1

JP 3

&

I'CLKC
P
BC 5
I ceM
I
CDX
:IFSR
FSX
RCLX
CLR
DCDR

U35

~[

7?lJl~:

::L

"[

LEJ
I

il

JP12

c::::::J:J
8]0

03

XF

N15 P-:5 TP4 T,D5 TD O

0 0 0 0 0
'":<

~
DACS

sr
s~

I
!

~T
0

U9

~~

MTPNT

JP14

3:

JP22

9 P L co

c::::::J:J JPl

c::::::J

;;

or

3:6

60

DCP

JP8

Ul

c::::::J:J
JP7

JP23

c::::::J:J c::::J :J

f-o

=..

MC'

P16

3:
c..

c:::=J =~

'21

o
DCOM2

RESET

8 L

'Jt"

'(;l

I~J~~~~~J~~I ,~

FCLK
2

:[.

:0;0

I 0 NMI

R"S

i
EEROtJ.

:<'"

TP12

c::::::J:J

3:

D~co

"'::
9

r,

'0

IL....,

1PL

39

DTP3?

] o

,P29

o TPS

2?L

DS215SDCCG', A

,i [

'0

6PL

J ~L:J;ol
39

Figure 7-3. SDCC Card Layout

7-5

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
7-3.4. SPC Card Testpoints

Table 7-6 lists and defmes the testpoints contained on the SPC card. Figure 7-4 shows the locations of these testpoints
on the card.

Table 7-6. SPC Card Testpoints


Revision

Name

Description

TP1UP

Encoder #1 up counter output.

TP1DN

Encoder #1 down counter output.

TP1Z

Encoder #1 marker channel output (if enabled).

TP2UP

Encoder #2 up counter output.

TP2DN

Encoder #2 down counter output.

TP2Z

Encoder #2 marker channel output (if enabled).

RX

RS-422 receiver input.

TX

RS-422 transmitter output.

SP1TP1

SPA 1 differential amplifier output, ahead of pot P1/P2 offset & scaling.

SP1TP2

Final output of SPA 1 analog input channel, analog version of VAR.256. An analog voltage
of 5 V dc converts to 511 counts at VAR.256.

SP2TP1

SPA2 differential amplifier output, ahead of pot P4/P5 offset & scaling.

TP2TP2

Final output of SPA2 analog input channel, analog version of VAR.257. An analog voltage
of 5 V dc converts to 511 counts at VAR.257.

531X309SPC

SIGNAL PROCESS

TP2UP

17
I

E2AB
/E2AB ,

:::;

TP2DN

I'

CD

E2BB
/E2BB

_>

/E2MB '
PF1 N
PF1P

f-O-----I

...

c:::J
-

JP7

TP27

123

1 2

c:::::- JP4

c::rJP2

TP1UP

D D

[]

CD

TP1DN

PF2N

SPHPI

DO

TX RX

o
SP2TP2

2c:::J::::4

J
D ~D'
N

P6
2RESP

~I

P5
2SCALE

Figure 7-4. SPC Card Layout

7-6

-IClD-

~ ~J

P4
2ZERO

P3
1 RESP

~I

P2
1SCALE

P1
1ZERO

-..J

-c
r-

3
1

2c:::J::::4

...

c:::J - ~
JPB

PF2P

JP9

_N
In

JP10 r

TP1Z

:: H

2c:::J::::4

()

TXP

JP5

r ,
I

c:r

JP1

E2MB

iJN
10

'<.0

O;g

N
:::;
-0

BI006008

GEH-6148

GF2000 Dc Ge ~erator Field Exciter


7-3.5. SVIA Board Testpoints

Table 7-7 lists apd defmes the testpoints on the SVIA board. Figure 7-5 shows the locations of these testpoints on the
board.

WARNING

Dangerous voltages exist on the input stage of the SVIA board when power is on. Exercise care when attaching or emoving test probes.
Table 7-7. SVIA Board Testpoints

Revision

Name

De~ cription

VIN

Mo itors the voltage on input terminal TB1-1, typically the positive terminal on a shunt.

ACOMIS

Mo itors the voltage on input terminal TB1-2. Also is the common input to the SVIA.
Typ cally the negative terminal on a shunt.

TEST

Mo itors the test voltage output, used to adjust the gain of the isolator card. See description of R3 in Table 5-11 for test voltage adjustment. This signal is also available at TB14.

SOURCE

Mor itors the voltage on TB1-3, the unity gain voltage source inputs.

P151S

Mor itors the isolated

N151S

Mor itors the isolated -15 V dc power supply for the isolator input stage.

VINI

Mor itors the output of the preamplifier which preconditions signals before the isolation
stage.

VOIS

Mor itors the isolation stage output before the final stage amplifier.

VOUT

Monitors the overall output of the SVIA after the final stage amplifier.

ACOM

Monitors the output stage amplifier common.

P15V

Mor tors the

N15V

Mon tors the -1 5 V dc power for the output stage amplifier.

P24

Mon tors the 24 V dc power supply input - positive side.

PCOM

Mon tors the 24 V dc power supply input - negative side.

P15P

Mon tors the + 15 V dc power input to the internal isolated power supply.

+ 15

+ 15

V dc power supply for the isolator input stage.

V dc power for the output stage amplifier.

7-7

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

ACOMIS

[=:J 2

1-'-"1
I

TEST

[=:J

L __ ~

ZJS

SOJRCE

14

P',5IS

[=:J 5
N151S

[=:J 6

Pi5P
15

c==J

VI"I

17

PCOM

14

=::J

13

==:J

P28

DS200SVIAG 1A

VOIS

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VOUT

19
ACOM

11

GAIN

T82

~r-,---+~---+----+,- - - 1

c;

b_,

OFFSET

Figure 7-5. SVIA Board Layout

7-8

Pi5V

[=:J11
N15V
I

11

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter

CHAPTER 8
SOFTWARE ADJUSTMENTS

8-2.1. Equipment Requirements


The GF2000 D
processor-base
rameters. Thes
once controlled
ware combinati

Generator Field Exciter uses microsoftware that includes adjustable paparameters perform many functions
ough adjustable hardware and softns.

The parameters
to the specific h
enable field and
exciter for opti

e modified to customize the exciter


dware and application. They also
maintenance personnel to fme-tune the
al performance.

The ST2000 Toolkit requires an RS-232C link to


communicate with the exciter. It is designed to operate
on an mM PC AT@or compatible computer (80286,
80386, or 80486 processor).
The minimum computer requirements are as follows:

000 Toolkit or Drive Configurator,


LynxOS Versio and Programmer are used to make
these software a ~ustments.

8-2. ST2000

Hard disk drive, 40 MB minimum (15 MB of this


is required to load the ST2000 Toolkit)

MS-DOS@ 3.0 (or equivalent DOS) or later

640 K RAM minimum

5-1/4 inch or 3-112 inch disk drive (for software


installation)

CGA graphics

Monochrome monitor (multiple shades of gray)

RS-232C serial port

Parallel printer port, Centronics compatible

OOlKIT

The DOS-based T2000 Toolkit is a set of software


tools used to co 19ure, maintain, and fme-tune the
exciter. The too .t consists of a collection of programs (tools)
. g under a command shell on an
IBM PC@ compa ible computer (see section 8-2.1 for
requirements) .
The toolkit inclu es an extensive database of GF2000
definitions, acces ed and manipulated using menudriven selections. Additionally, the STIOOO program
can graphically d splay the exciter's program logic on
the computer scr en. By viewing the logic flow, the
user can better
erstand and manipulate the exciter's
adjustable values.
The ST2000 Too
configure and test
site, the toolkit e
trained personnel
tain the installed
real-time display
tions data.

't is used at the factory to originally


the exciter system. At the customer
bles GE field engineers and other
0 reconfigure, fme-tune, and mainciter. Optional modules provide
f control variables and communica-

Chapter 9 provide a procedure for performing a


tuneup of the GF2
exciter using the ST2000
Toolkit.

Recommended enhancements include:

80286 or higher microprocessor, running at 16


MHz or faster

2 MB to 4 MB RAM

Disk cache software

EGA or VGA color graphics with color monitor

80 MB hard disk drive

8-2.2. Using the ST2000 Toolkit


Publication GEH-5860 provides instructional information about the ST2000 Toolkit.

8-1

BI006008

GEH-6148
8-3. DRIVE CONFIGURATOR, LYNXOS
VERSION

The LynxOS-based Drive Configurator is also a set of


software tools used to configure, maintain, and fmetune the exciter. The Drive Configurator is a collection of programs (tools) designed to run on an IBM
PC-compatible computer equipped with the LynxOS
operating system (see section 8-3.1 for requirements).
The Drive Configurator is used to originally configure
and test an exciter system, and to fme-tune and maintain that system in the field. It uses a database to generate the configuration for the exciter during manufacture, and to allow GE field engineers and other trained
personnel to adjust the exciter configuration for optimal performance. Optional modules provide real-time
display of control variables and communications data.
The database is used to maintain configuration data for
one or more control systems. The product is usually
installed on a central database server. On smaller installations, the database may reside on the same PC as
the Drive Configurator.

GF2000 Dc Generator Field Exciter


8-3.2. Using the Drive Configurator

Publication GEH-6203 provides instructional information about the Drive Configurator.

8-4. PROGRAMMER MODULE


NOTE

To avoid exciter malfunction, only qualified


personnel should use the Programmer.
The GF2000 exciter includes a Programmer module
with a 16-character digital display and an alphanumeric keypad. It functions as an operator interface for
performing software adjustments and diagnostic testing
when the ST2000 Toolkit or Drive Configurator is
not available.
The Programmer provides a digital display for an alphanumeric readout of fault codes, status, RAM values, and EEPROM values. The alphanumeric keypad
enables the user to operate and adjust the exciter.
NOTE

8-3.1. Equipment Requirements

The Drive Configurator is designed to operate on an


mM PC AT or compatible computer with the following minimum requirements:

LynxOS operating system, version 2.1 or later

80386 microprocessor

8 MBRAM

150 MB hard disk drive

VGA graphic card and monitor

RS-232C serial port

Permanent changes made using the Programmer module must also be made in the
ST2000 Toolkit or Drive Configurator to
keep the tools compatible with the exciter's
software configuration.
The Programmer resides on the SLCC card, which
mounts on the SDCC card. The Programmer is accessed by opening the cabinet door at the front of the
exciter.
Chapter 6 lists and defmes the SLCC's I/O connections.
NOTE

The following enhancements are recommended:

80486 microprocessor, running at 33 MHz or


faster

12 to 16 MB RAM

Color monitor

8-2

The Programmer's parameter address,


designated as EEl.O (CFGJPR), must contain a 1 (an odd number) to enable it to
function. A 0 in the address disables the
Programmer. See Parameter Mode (section
8-4.3.2) to change the value, if needed.

BI006008

GEH-6148

GF2000 Dc G nerator Field Exciter


8-4.3. Operating Modes

8-4.1. Keypa
NOTE

This chap er indicates a Programmer key


by enclos' g the key name in () symbols.
For exam Ie, (STOP) symbolizes the key labeled Sr,
The Programm r keypad enables an operator to control the exciter y:

The Programmer operates in any of three modes:

Operate Mode, the normal mode which the exciter


automatically enters at powerup

Parameter (EEPROM or Mirror) Mode, selected


by an operator from Operate Mode

Diagnostic Mode, selected by an operator from


Parameter Mode

The Programmer's operating mode determines the


function of most keys. This is shown by the color
(and position) of the keys' labels:

The keypad co ains 20 keys. Most have more than


one label, each different color. The color indicates
the key's functi n during the associated operating
mode.

8-4.2. Displa
NOTE

This chapt
play by us'
ample, if t
word RE

r indicates a Programmer disg a different typestyle. For exe Programmer displays the
'RSE, this chapter shows it as

REVERSE.

The display uses 6 (of 16) characters for the mnemonic, where re uired. The number of decimal points
in the mnemoni indicates the operating mode:
indicates Operate Mode (for examTE MODE)

Blue labels (bottom of key) during Diagnostic


Mode

Black labels (middle of key) during Operate, Diagnostic, and Parameter Modes

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.

Potential exciter activation and inadvertent


equipment movement when testing.
Through the remainder of this section, do
not use DIAGNOSTIC RUN, SELF-TUNE
(I-TUNE or S-TUNE), or any Programmer
RUN function on any application (such as
crane or elevator) where motion may cause
injury.
8-4.3.1. OPERATE MODE. At powerup, the exciter

enters Operate Mode. This activates the red and


black/green keypad functions.

s indicate Parameter Mode (for ex.AMETR_M MODE)

Red labels (top of key) during Operate Mode

WARNING

The Programme's display presents an alphanumeric


readout for exci r parameters, faults, and keypad inputs. The fault de display provides an easier alternative to the SD C card's indicating LEDs, which
must be decode .

Initiating s If-tuning programs

Three dec'
s indicate Diagnostic Mode (for
example, D..A.GNOSTIC MODE)

NOTE

Red key functions are dominant; black/


green key functions only work in Operate
Mode after (SHIFT) has been pressed.
8-3

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
If a key is not activated, the Programmer briefly displays FL41 L_KEYOFF.

The Operate Mode display is in the form M S.O% I


0%, where M indicates Manual mode (alternatively an
A indicates Auto mode), S.O% indicates percentage of
rated speed, and I 0% indicates percentage of rated
current. Note that one decimal point is used to indicate
Operate Mode.

WARNING

(DEC)

Press to decrease the speed at which the


exciter is running for any of the RUN
functions.

(REV)

Activates a command's reverse function:

1.

2.

Press (REV) and the Programmer


displays REVERSE.
Press the desired function key:
(RUN), (SLOW), (JOG), (Rl), (R2),
or (REFR).

NOTE

Potential exciter activation and inadvertent


equipment movement when testing. Use
Operate Mode only as a diagnostic tool;
motor will rotate, ignoring safety circuits.
Do not attempt to use (RUN), (SLOW),
(JOG), (R1), (R2), or (REV), (A/M).

Red Key Functions. In the Operate Mode, the red key


function are used a follows:
(SLOW)

Controlled stop

(DRV#)

Used as part of the access code to Parameter Mode

(SET)

Used to enter Parameter Mode (section


8-4.3.2) and to adjust settings of various
keypad functions; activated using the
following steps:

1.

Press (SET).

2.

Press either (RUN), (SLOW), (JOG),


(R 1), (R2), (REFR), or (DRV#).

3.

4.

Resets the exciter after fault or error


messages appear; produces a Software
Reset

(A/M)

Auto/manual operating mode; can toggle


between Auto (A) and Manual (M) if the
proper bit is set in EE.690

(RATIO)

Not used

Black/Green Key Functions. The black/green key


functions are used as follows:
Black (0) through (9); use (SHIFT) for
green (A) through (F), decimal point, and
hyphen

Enter the desired setting in decimal


numbers (for example, for Drive 77,
enter 77 after pressing (DRV#.

(PREV)

Displays the previous (last) mnemonic


entered

Press (ENTER).

(N EXT)

Displays the next mnemonic

(ADDR)

Displays the last address entered

(HEX/DEC)

Press to enter hexadecimal format; press


again to return to decimal format

(ENTER)

Press to enter a value

(CLEAR/
MODE)

Used to clear a parameter

The EEPROM must be Write Enabled to


make these adjustments (see the instructions on changing parameters in section
8-4.3.2).

8-4

(RESET)

Numerals

NOTE

(INC)

If (REV)(JOG) is pressed, the exciter performs the REVERSE JOG as long as the
(JOG) key is pressed. When (JOG) is released, the REVERSE JOG function stops.
However, the Programmer remains in the
Reverse Operate mode, and displays
REVERSE to so indicate.

Press to increase the speed at which the


exciter is running for any of the RUN
functions.

BI006008

GEH-6148

GF2000 Dc Ge tlerator Field Exciter


8-4.3.2. PARA'I"IETER MODE. Parameter Mode allows
2
the user to exau ine and change any EEPROM (E ) or
EEPROM "mir or" parameter addresses to customize the exciter t an application.

3.

Press (DRV#).

4.

Press (7).

There are two t; 'Pes of Parameter Modes:

The next step selects either the Parameter Mirror or


Parameter EEPROM Mode.

5.

Parameter E;EPROM Mode. Changes made to


parameters ~uring this mode can be permanent changes are remembered even if power is removed fron the exciter.

a.

To select Parameter EEPROM Mode, press


(7).

The display shows P.AR.AMETR_E MODE.

Parameter ~irror Mode. Changes made to parameters du ing this mode are overwritten by the
correspondi.i g EEPROM address during powerup
or a hard re et.

b.

To select Parameter Mirror Mode, press (8).


The display shows P.AR.AMETR_M MODE.

Note that the Programmer uses two decimal points in


the display to indicate Parameter Mode.

Parameter Mode activates the same black/green key


functions as the Operate Mode. It also uses red keys
(STOP), (INC), a~d (DEC). See section 8-4.3.1
(Operate Mode) or key defInitions.

6.

Press (ENTER).
NOTE

Entering Param~ter Mode. Figure 8-1 depicts the


Programmer ope ating modes and steps to move between them. Not that Parameter Mirror Mode can be
entered either fre m the Operate Mode or from the
Parameter EEPRpM Mode.

Pressing (ENTER) takes the display back


one EE address. This key also is used to
change between Parameter Mirror Mode
and Parameter EEPROM Mode.

To enter Paramet r Mode:


1.

To enter Parameter Mirror Mode from the Parameter


EEPROM Mode:

Check that tb~ Programmer is in the Operate


Mode (displa should read M S.O% I 0%).

1.

Check that the Programmer displays


P.AR.AMETR E MODE.

2.

Press (SET).

POWE UP

OPERATE
MODE

PRESS
(SET)(DRV#)(7)
. . - - - - - - - , (7)

~
PRESS
(CLEAR/MODE)

(8)

PRESS (PREV)

DIAGNOSTIC
MODE
~

-J

PRESS (CLEAR/MODE)

PARAMETER
EEPROM
MODE
A

PRESS
(PREV)

PRESS
(CLEAR/MODE)

PARAMETER
MIRROR
MODE
L..-.

---J

Figure 8-1. Changing Modes of Operation

8-5

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
2.

Press (CLEAR/MODE).

To change a parameter, use the steps in the following


example.

The display now displays P.AR.AMETR_M MODE.


To return to the Parameter EEPROM Mode from the
Parameter Mirror Mode, press (PREV).

Examining Parameters. To examine the present value


of any parameter:
1.

Enter the 3- or 4-digit parameter address.

2.

Press (ENTER).

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.
Ensure that the SDCC's E Enable jumper (JPI) is
in the ENABLE position (2-3), and that EE.2.0,
DGNJP contains a 1.

2.

After examining EE.2.0, enter the following keystrokes:

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.

1.

(CLEAR/MODE)(3)(8)(ENTER)

The display shows S.TR.DLY.


0.25 second delay time.

25, corresponding to a

This allows the operator to easily view parameters in a


series of consecutive addresses.

3.

To examine another parameter (not in a next address):

In either case, the display shows S.TR.DLY. 15 (note


that the decimal point in this display indicates Parameter Mode).

1.

Press (CLEAR/MODE) to clear the present address.

The display then shows P.AR.AMETR_E MODE (the_E


characters indicate Parameter EEPROM Mode) or
P.AR.AMETR_M MODE (the _M characters indicate
Parameter Mirror Mode).

4.

Enter the 3- or 4-digit parameter address.

3.

Press (ENTER).

Press (ENTER).

This places the new value into EEPROM.


5.

2.

Either press (DEC) until the display value decreases to 15, or press (1), then (1).

Press (CLEAR/MODE).

The display the shows P.AR.AMETR_E MODE.


6.
The address name and contents appear in the display.

NOTE

NOTE

The next step is extremely important to


prevent accidental reprogramming of the
exciter.

To enter or view in hexadecimal format,


press (HEX/DEC). To return to decimal
mode, press (HEX/DEC) again.
Changing Parameters. To change parameters, two
conditions must exist:

The SDCC's EEPROM (E2) jumper IPI must be


in position 2-3 for write ENABLE (position 1-2 =
2
E write PROTECT).
Parameter address 2.0, designated as EE.2.0
(DGNIP), must contain a 1 (odd value). If a 0
(even value) is present, add a 1 and press
(ENTER).

8-6

To examine other addresses at this point, enter the


desired parameter address, and press (ENTER).

7.

To seal the new parameter values, remove the 1


from EE.2.0, DGNJP, returning to the "as
shipped" 0; return SDCC jumper JPl to the write
PROTECT position (1-2).

Exiting Parameter Mode. To exit Parameter Mode,


press (CLEAR/MODE) two or three times, as needed
(see Figure 8-1):

If in Parameter EEPROM Mode, press


(CLEAR/MODE) three times.

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter


This moves fIrs to Parameter Mirror Mode, then to
Diagnostic Mod, and fmally to Operate Mode.

If in Param ter Mirror Mode, press


(CLEAR/M DE) two times.

This moves fIrst to Diagnostic Mode, then to Operate


Mode.

The displays shows D.I.A.GNOSTIC MODE.

Exiting 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 Diagnostic Mode, press the (PREV) key.

8-4.3.3. DIAGN STIC MODE. The Diagnostic Mode

8-4.4. Drive Diagnostics

is used to:

Provide inte al digital displays

WARNING

Potential exciter activation and inadvertent


equipment movement when testing.
Through the remainder of this section, do
not use DIAGNOSTIC RUN, SELF-TUNE
(I-TUNE or S-TUNE), or any Programmer
RUN functions on any application (such as
crane or elevator) where motion may cause
damage or injury.

Initiate self-

This mode activa es the blue and black keypad functions, with blue
ctions dominant, (INC) and (DEC).
Blue keypad fun tions include (DGS), (DGR), (DVM),
(ARMV), (ARM I), (FIELDI), (SPEED), (TORQ), (HP),
(RAM), (DRV#),
d (TEST).

NOTE

The Programmer allows an operator to run resident


diagnostic tests on the exciter. These tests aid in
startup, tuneup, and troubleshooting. To run diagnostic
tests, the exciter must be in Diagnostic Mode, as described above.

The hexadec' al numeral option (shown on


the keys in g een) is not available in Diagnostic Mode.

This section describes the available tests, listed in Table 8-1. Note that some tests are only available with
certain hardware or software confIgurations.

Black keypad fu ctions are the same as in Operate


Mode (see section 8-4.3.1), except for (HEX/DEC),
which does not
ction in Diagnostic Mode.

Entering Diagnos 'c Mode. To enter Diagnostic


Mode:

diagnostic Tests 3 through 9:

1.

1.

Enter Diagnostic Mode as described above.

2.

Press the key for the selected test.

Ensure that th exciter is in Parameter Mirror


Mode (the dis lay shows P.AR.AMETR_M MODE)
If not, see sect on 8-4.3.2.

8-4.4.1. RUNNING THE DIAGNOSTIC TESTS. To run

2.

To run diagnostic Tests 10 through 15:

The display immed ately shows D.I.A.GNOSTIC


ee decimal points in the display
used to indicate Di ostic Mode).

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.

If a particular par eter is being displayed in the Parameter Mode, ente the Diagnostic Mode as follows:

3.

Press (ENTER).

MODE (note the t

To cancel a Diagnostic Test, press (PREV) once.


To exit Diagnostic Mode without displaying any diagnostic variables, press (CLEAR/MODE) twice.

8-7

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
Table 8-1. Standard Diagnostic Tests

DVM has fIxed scaling, and can measure de voltage in


the 50 V range with a 0.5% accuracy.

Name

Description

Test 1

(DGS), keypad selection. Do not use.

Test 2

(DGR), keypad selection. Do not use.

Test 3

(DVM), keypad selection. Displays


digital voltmeter.

Test 4

(ARM V), keypad selection. Displays


armature voltage.

Test 5

(ARM I), keypad selection. Displays


armature current in amps.

Test 6

(FIELD I), keypad selection. Displays


field current in amps.

Test 7

(RPM), keypad selection. Displays


motor speed (revolutions per minute!.

Test 8

(TORQ), keypad selection. Displays


motor torque in 1 Ib-ft.

Test 10 - Software Revision. Test 10 displays the revision level of the SDCC and SLCC cards' microprocessors: Drive Control Processor (DCP), Motor Control Processor (MCP), Co-motor Processor (CMP),
and LAN Control Processor (LCP).

Test 9

(HP), keypad selection. Displays motor horsepower.

To run Test 10;

Test 10

Displays software revision of SDCC


and SLCC microprocessors.

1.

Press (TEST).

Test 31

Displays four diagnostic variables


(selectable! in decimal format.

2.

Press (1 XO).

Test 11

Displays four diagnostic variables


(selectable! in hexadecimal format.

3.

Press (ENTER).

Test 12

Invokes the cell (SCR! test.

Test 13

Invokes the board test function.

Test 15

Speed regulator tuneup function.

4.

Test 25

Same as Test 15, but test results


and calculated parameters are saved
in EEPROM, rather than RAM.

The Programmer displays C. = .0.0.00 L. = .0.0.00 for


CMP and LCP, respectively.

RAM Test

Displays single diagnostic variable


(selectable!.

5.

DAC1, -2

Digital-to-analog converter outputs.

The Programmer displays D. = .0.0.00 for UCP.

MET1, -2

Digital-to-analog converter outputs.

Tests 4 through 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) correspond.
To cancel the previous test and enter a new test, press
the appropriate key or (TEST) once.

The Programmer displays D. = .0.0.00 M. = .0.0.00


for DCP and MCP, respectively.
Press (INC).

Press (INC).

To enter a new test, press (TEST).


To exit Test 10 press (PREV).

8-4.4.2. DIAGNOSTIC TEST DEFINITIONS. This section provides descriptions of the available diagnostic
tests (listed in Table 8-1).

Test 3 - DVM Mode. Test 3 uses the Programmer as a


digital voltmeter (DVM) to check analog testpoints on
the exciter boards.

Tests 11, 31 - Diagnostic Variable Display. Tests 11


and 31 display four exciter variables for diagnostic
use. Test 11 provides hexadecimal values; Test 31
provides decimal values.
To run either test:
1.

The test probe wire, supplied in the miscellaneous


parts packet shipped with the exciter, connects from
the testpoint to be monitored to either the NTB/3TB
board's testpoint DVM or to terminal 3TB-49. The

8-8

Enter the RAM addresses of the variables to be


2
monitored into E locations 110 through 113 for
DIAG1 through DIAG4, respectively. Refer to
Parameter Mode, section 8-4.3.2 for procedures,
and Table 8-2 for variable addresses.

BI006008

GF2000 Dc Ge ~erator Field Exciter


2.
3.

GEH-6148

Press (TES ).

NOTE

For Test 11 press (1X1); For Test 31, press

Although tuneup Test 15 can be run from


the Programmer, data retrieved from the
test is stored in RAM and cannot easily be
saved. Therefore, tuneups should be made
with the ST2000 Toolkit (see GEH-5860) or
Drive Configurator (see GEH-6203), or by
running Test 25, which stores test results in
EEPROM.

(3)(1 ).

4.

Press (ENTI R).

The test starts 31 d displays 1.2. aaaaH yyyyH for Test


11 or 1.2. AAA A BBBBB for Test 31. (AAAA is the
value of the first variable; BBBB is the value of the
second variable.
5.

Test 15 or 25 - Speed Regulator Tuneup. To enter


this tuneup function:

Press (DEC) or (INC).

The Programme displays 3.4. CCCCH DDDDH or


3.4. CCCCC DDpDD. (CCCC is the value of the third
variable; DDDD is the value of the fourth variable.)

1.

Press (TEST).

2.

Press (1 )(5) or (2)(5).

NOTE

3.

Press (ENTER).

The value dfsplays are in 2's complement.


Values from oo to 7FFF are positive (0 to
+32767); v~ ues from FFFF to 8000 are
negative (Fl1FF = -1, 8000 = -32768).

The Programmer displays E.N.T.R PAR 1 as a prompt


to enter a value for the first parameter (the three
decimals indicate Diagnostic Mode).
4.

Test 12 - Cell

TE~t.

To set a new Parameter 1 value:

Test 12 checks the SCR (cell).


a.

Enter the selected parameter value (motor


number).

b.

Press (ENTER).

Test 13 - Board rest. Test 13 is the board test function. Press any kf y during this test and the Program-

mer displays the ey's number.


To exit this test, ress the SDCC card's RESET button. (To run Test 13, the proper bit in address EE.2
must be set.)

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.

Enter the selected parameter value (0 to run


test; 1 to perform calculation only).

b.

Press (ENTER).

Table 8-2. RA V1 Addresses * for Analog Signals


RAM Add ess

Signal Description

100

Speed feedback

103

Voltage feedback

104

CFB

105

Field current

112

CEMF

140

Speed REF output

These addresl es contain a variable that represents an analc g signal.

7.

To set Parameter 2 to the default value (0), press


(ENTER).

The Speed Regulator Tuneup now starts and the Programmer 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 (CLEARI
MODE).

8-9

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

RAM Test - Examine/Modify RAM Location Value.


The RAM Test allows users to examine and/or modify
the RAM locations values.

WARNING

Use caution when altering RAM values.


Any change may also change the exciter
characteristic, causing the system to misoperate.
To enter this test:
1.

2.

Enter the desired RAM address.

3.

Press (ENTER).

The display now reads D. . .1.~R_O


(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:

2.

If the exciter is already using the DAC1,


DAC2, :MET!, and :METI outputs, changing them may cause the exciter to misoperate. Before entering this test, refer to the
exciter's elementary diagrams and custom
instructions or PC software to determine
this.

Each output has two addresses (see Table 8-3).

The @I address selects the variable to be output


(EE.100 = DAC1, EE.102 = DAC2, EEI04 =
MET.l, and EE.106 = MET2).

The MX address is the maximum input value


(EE.101 = DAC1, EE.103 = DAC2, EE.105
MET!, and EE.107 = MET2).

Press (RAM).

The Programmer displays RAM. EXAM/MODIFY.

1.

CAUTION

After the current RAM value is displayed (see


step 3 above), enter the new value.
Press (ENTER).

The display now shows the new RAM value, unless


the Modify RAM command is disabled. In that case,
the display shows M.O.D. RAM DISABLED.
To exit the RAM Test (either without changing or
after changing the RAM value):

For example, to enter this function:


1.

In Parameter Mode, call up EE.100-DAC@1 and


EE.101-DAC1MX (select E.l00).

2.

Enter the signal to be monitored (from Table 8-2)


into EE.100. Putting that RAM address in EE.100
produces that signal at the NTB/3TB board's DA1
testpoint and DACI terminal (3TB-53).

DAC2, MET!, and MET2 function like DAC1. 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 terminals points listed in Table
8-3.

Tab/e 8-3. Diagnostic Mode Analog Output Points

Loaded Into
Address

NTB/3TB
Testpoint

Terminal
Board Point

DA'

DA', 3TB-53

DA2

DA2, 3TB-55

Press (TEST) or (CLEAR/MODE) again.

EE.' OO-DAC@' &


EE.10'-DAC1MX
EE.'02-DAC@2 &
EE.' 03-DAC2MX
EE.1 04-MET@' &
EE.' 05-MET' MX

MET'

MET', 3TB-54

8-4.4.3. DAC1, DAC2, MEn, AND MET2. The

EE.'06-MET@2 &
EE. , 07-MET2MX

MET2

MET2, 3TB-56

1.

Press (PREV) or (CLEAR/MODE).

The Programmer then displays D.I.A.GNOSTIC


MODE.

2.

DAC1, DAC2, MET!, and MET2 analog outputs are


available for test purposes. The four outputs function
identically, and are programmed similarly to Test 11.

8-10

BI006008

GF2000 Dc G

GEH-6148

erator Field Exciter

CHAPTER 9
TUNEUP PROCEDURE

Step 15 - Proportional plus integral speed regulator


response
The tuneup pro edure is used to optimize the time
constants and g' values of all the regulators in the
control loops us d in the GF2000 Dc Generator Field
Exciter control oftware. An overview of the control
software, inclu g the regulators and control loops, is
shown in Figure 9-1.
The basic tuneu
trolloops, and c
loop is evaluate
loop can then be
erator field, the
eddy current eff;
the regulator's f
are as follows:

method is to tune the innermost conntinue to the outermost loops. Each


and tuned so that the next outermost
tuned. The time constants of the genenerator armature, and that due to
cts must be determined in order to set
e constant values. The tuneup steps

These steps are covered in sections 9-4 through 9-18.

9-2. REQUIRED EQUIPMENT


The following equipment is required to perform this
tuneup procedure:

IBM PC AT or compatible computer equipped


with ST2000 Toolkit (refer to GEH-5860)

RS-232C cable to connect the computer to the


GF2000 exciter

Dual-channel oscilloscope with 100: 1 probes

Four-channel chart recorder with digital memory


option (HIOKI or Gould Windowgraph, or
equivalent)

Digital voltmeter (DVM)

Step 1 - Prer . ary calculations and settings


Step 2 - Generat r field time constant determination
Step 3 - Proport onal field current regulator response
nal plus integral regulator response
ent converter linearization

Step 6 - Generat r saturation curve characterization


Step 7 - Eddy cent time constant determination
voltage regulator response
eous armature overcurrent protection

e time constant determination

9-3. SETUP
Connect the computer's available serial communications port to connector COMPL (RS-232C port) on the
GF2000 exciter's NTB/3TB board (the computer must
be equipped with the ST2000 Toolkit as described
above). Run the ST2000 Toolkit, ensuring proper initialization and communications between the computer
and the exciter. Refer to GEH-5860 for instruction on
the proper use of the ST2000 Toolkit.
Ensure that other equipment listed above is available
for use during the tuneup procedure.

e current regulator response


e current rate and fJ.lter

Step 13 - Speed fi edback scaling and polarity verification


Step 14 - Proport onal speed regulator response

Isolator modules or digital-to-analog converters


(DACs) can be used to monitor field voltage and current. Two 12-bit DAC outputs, labeled DAC1 and
DAC2, are available on the NTB/3TB board to display
analog signals. Four 8-bit, 1O V DAC outputs, designated METl through MET4 are also available on the
NTB/3TB board. These outputs are used to drive

9-1

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

LOAO
TORQUE

IASTEP

FLUX

'5000 COUNTS/1 PU
IAGEN

VCEMF

VCO

wCCr.'J50rIS
ARMATURE
CURRENT
FEEDBACK
IAGEN

5000 COUNTS/' PU
VCO

Wcvr ... 150 rls

ARMATURE
VOLTAGE
FEEDBACK

VOFBI

20000 COUNTSI1 PU

J
VAGEN

VCO

Figure 9-1. GF2000 Regulators and Control Loops

meters. The following section provides instructions for


selecting the variables present on the DAC outputs.

The help information for EE.IOI and EE.I03 included


in the ST2000 Toolkit contains instructions on setting
the variable scaling. Table 9-1 lists useful variable
addresses for the GF2000 exciter.

9-3.1. DAC Variable Selection

NOTE

To select the variables present on the DAC outputs:


1.

From the ST2000 Toolkit function header, select


the EDIT2000 Menu (Parameter Editor).

2.

Press (F2) or (Alt F6) (Search for Item).

3.

Enter EE.DAC1 or EE.1 00 and press (F1) (Enter/


Select).

Press (F1) (Change Value) to select a RAM variable.


To enter a variable address for the DAC, press (F1)
and enter the numeric address. Set the DAC scaling by
entering the maximum count number for the variable
to be displayed. Addresses EE.lOO (DACI@I) and
EE.101 (DACIMX) set the variable address and scaling factor, respectively, for DACI; addresses EE.I02
(DAC2@I) and EE.103 (DAC2MX) set the variable
address and scaling factor, respectively, for DAC2.
NOTE

The scaling factor should be greater than


256, which enables the 16-bit DAC to read
the memory location as a word.

A similar procedure is used for the MET1


through MET4 outputs by assigning variables to EE.104 through EE.107.
To display RAM variables located in the Co-motor
Processor (CMP):
1.

Search for EE.554 (CPNTRI), as described in


steps 2 and 3 above.

Table 9-1. GF2000 Variable Addresses


Address

Mnemonic

Description

VAR.1092

IBRIDGE

Bridge current or generator


field current feedback

VAR.1024

VBRIDGE

RAM variable representing


field voltage

VAR.1000

FIRCMD

Firing command signal

VAR.1002

ILOPOUT

High performance current


regulator output

C335H
(RAM)

ALPHAPRIME

Firing angle delay signal*

9-2

RAM variable in the Co-motor Processor (CMP).

BI006008

GEH-6148
2.

3.

NOTE

Set EE.554 CPNTRl) to the numerical address of


the CMP
variable to be displayed. The
CMP RAM variable pointed to by EE.554 will be
available on variable VAR.292 (CDIAGl).

Exercise care when using the Terminal


Mode. In this mode, writes are made directly to the GF2000 exciter without any
required confirmation or entry tracking.
The terminal mode should be used primarily for entering reference step signals and
performing diagnostic tests, such as Test 31
(see section 9-3.5).

Load the D C located at EE.l00 or EE.102 with


VAR.292.
NOTE

EE.555 (C
) is a pointer that can be
used with v iable V AR.293 (CDIAG2) in
er as described above for
the same m
EE.554 and V AR.292.

9-3.2. Diagnos ic Use

For diagnostic poses, set EE.ll0 (DIAGl) and


EE.lll (DIAG2) to variables VAR.292 and
VAR.293. These variables can then be displayed on
the computer scr en by running Test 31 as described
in section 9-3.5. r can be assigned to a DAC output.

9-3.5. Test 31 - Display Diagnostic Variables

When in Terminal Mode, entering ]31 displays four


diagnostic variables pointed to by EE.ll0 (DIAG1).
EE.lll (DIAG2). EE.112 (DIAG3). and EE.I13
(DIAG4). The diagnostic variables are displayed in
columns on the ST2000 Toolkit computer screen. In
diagnostic mode, the variables can also be displayed.
two at a time. on the alphanumeric display on the exciter's Programmer.

9-3.6. Setting Regulation Modes


9-3.3. Setting

EPROM Values in EDIT2000

alues using the EDIT2000 screen:


1.

Press (F2) or (Alt F6) (Search for Item), and enter


EE.XXXX (were XXXX is the EE address to be
changed).

2.

After the EE ariable is found. press the Change


Value softke and enter the desired value for the
variable. Pre s the Accept Change softkey and
enter your ini ials when prompted.

Table 9-2 shows the regulation modes of the GF2000


exciter. These modes are controlled by the signals
passed through functional block 555 (GFXFR). the
generator exciter transfer (DCP-to-MCP) block.

9-4. STEP 1 - PRELIMINARY CALCULATIONS

3.

Press the Se to Drive softkey. This sends the


value just ent red into the database to the
EEPROM in e GF2000 exciter.

To enter Terminal Mode from the SUOOO Toolkit


main menu. move the cursor to EE2000 and press
(F1). When the E 2000 tool is displayed, press (F6)
(Terminal Mode).
en prompted for a password.
enter OMNI.

Before setting the generator field current feedback


scaling. ensure that the drive type, EE.550
(DRVTYP). is set to 85 to enable the GF2000 exciter
software. A hard reset is required after setting the
drive type.
The generator field current feedback scaling should be
set to give 5000 counts for rated generator field current. The following parameters must be known to calculate the proper scaling factors:

Rated field current (Ifg) in amperes

Rated field resistance (Rfg) in ohms

Field shunt millivolt rating and current rating in


amperes

9-3

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
Table 9-2. GF2000 Regulation Modes
Block 555
GFXFER
Input Pointer

Points to Variable

Generator Field
Regulator Tuneup
Mode

Armature Voltage
Regulation Mode

Armature Voltage
Regulation Mode
IContactor M Closed)

Armature Current
Regulation Mode

EE.5816 (GF@VRE)

VAR.1417 (VARON)

EE.5817 (GF@IRE)

VAR.1418 (IARON)

EE.5818IGF@IVS)

VAR.1419 (IASEL)

EE.5819 (GF@MST)

VAR.1420 (MSTAT)

9-4.1. VCO Feedback Scaling

For the GF2000, the field shunt should be selected to


give 75 mV at rated field current. A voltage controlled
oscillator (VCO) on the DCFB board converts the
voltage across the shunt (mV) into a number of counts
to be used by the exciter control software. To scale the
generator field current feedback to 5000 counts for
rated field current, set EE.1523 (FL2SFO) as follows:
FL2SFO

= 0.75 x 16,384 x shunt rating (A) / Jfg

9-5. STEP 2 - GENERATOR FIELD TIME


CONSTANT

The generator field time constant is determined by


stepping the generator field converter voltage and observing the time response of the generator field current. Set up the regulator for direct firing control using
the ST2000 Toolkit in the following manner:

1.

To avoid problems caused by sudden changes in


gain values while performing step 2, set the reference signal, RAM address C346H (IREGSTP), to
zero. Using the ST2000 Terminal Mode, type
C346H = 0 and press (Enter). (The' character is
located in the top left comer of the keyboard.)

2.

Using the ST2000 Toolkit, set the EEPROM locations listed in Table 9-3 to the values shown to
convert the enhanced current regulator to an open
loop firing mode (refer to section 9-3.3 for instructions on setting EEPROM values).

3.

Using the ST2000 Terminal Mode, increase the


field current regulator reference step signal,
C346H (IREGSTP), until the shunt voltage is 25 %
of its rated value. Type . C346H = XXXX, where
XXXX represents the number of counts for the desired step amplitude.

For example, if the rated field current Ifg is 50 A and


the 100 millivolt shunt is rated at 75 A , the generator
field current scale factor is given by:
FL2SFO

= 0.75 x 16,384 x 75/50 = 18,432

9-4.2 Bridge Overcurrent Protection

The generator field and converter bridge are protected


by an instantaneous overcurrent (IOC) function. To
activate this function, set EE.1507 (IOCTRO) to the
desired trip level. A typical setting is:
JOCTRO = 5000 counts x 1.6 = 8000 counts

The generator field and converter bridge can also be


protected by an Ixt overcurrent function. To invoke
this function, set EE.25 (TOC@IN) equal to
VAR.1092 (IBRIDGE), and set EE.1494 (TOCLVO),
EE.1495 (TOCATO), and EE1496 (TOCTTO) to set up
the Ixt overcurrent function. Typical values are:
TOCLVO

= 110%

NOTE

In the open loop configuration, address


C346H is the generator field voltage reference signal (16384 = Edo).

4.

TOCATO = 1500 %-sec - If the field current exceeds the preset value of 110% for 1500%-sec,
fault 32 (TOC_ANUN) will occur.

JBRIDGE

5.
TOCTTO = 2000 %-sec - If the field current exceeds the preset value of 110% for 2000%-sec,
fault 8 (TOC_TRIP) will occur.
9-4

Calibrate VAR.1092 (lBRIDGE), the bridge current feedback. This value should be equal to:

= % rated current x 5000

It may be necessary to trim the bridge voltage


feedback, VBRGFB, using EE.1503 (VFBFSO),
the voltage feedback scale factor. Set EE.1503
until VBRGFB equals 20,000 at the rated bridge
voltage.

BI006008

GEH-6148

GF2000 Dc Gel erator Field Exciter


Table 9-3. Open Loop Firing Mode EEPROM Values
Address

Mner onic

Value

Description

EE.1590

HIRK 0

Sets generator field feedback to zero

EE.1591

HIRK fylO

Sets generator field integral gain to zero

EE.1581

ILiMC 0

Sets generator integral limits to zero

EE.1589

HIRK 0

32

Sets proportional regulator path gain to one

EE.1523

FL2S 0

Calculated
in section 9-4

Sets the generator field current feedback scale factor such that 5000 counts = 1 per
unit generator field current

Adjust EE.l
(lBRlDGE)
current. Not
proportional
VAR.1092.

23 (FL2SFO) to scale VAR.1092


uch that 5000 counts gives 1 per unit
that EE.1523 and VAR.1092 are
an increase in EE.1523 will increase

Also check t e polarity of VAR.1092 (IBRIDGE)


by entering i positive reference step using address
C346H (IRE~STP) and observing VAR.1092.
VAR.l092 s ould change in a positive direction
with a positi e reference command. This can be
done as follolNs:

5.

a.

Assign (lne of the DAC channels to display


VAR.1O~2 (lBRIDGE), and observe this signal whill stepping the regulator.

b.

Step the egulator by typing' C346H =


XXXX, 1 here XXX)( represents the desired
count va ue to determine the step amplitude.

Using the fOl -channel chart recorder, measure


and record tiJjne constants for the generator field
with the field unsaturated and saturated. The
unsaturated t' me constant is found by stepping the
field current Tom approximately 0.20 per unit to
0.15 per unit. Negative going steps are used to
maximize the linear range of the test. The step
sizes should tie adjusted as necessary to

avoid field voltage saturation. The resulting field


current waveform is used to measure the time
constant at 63 % of the steady state current value
(see Figure 9-2 for a typical response plot). The
saturated time constant is found in a similar manner by stepping the field current from approximately 1.0 per unit to 0.90 per unit. The unsaturated time constant, Tfg, is used in section 9-6 to
calculate the regulator gains. The field resistance
is calculated from the field voltage and current at
full field. The time constant is found as follows:
a.

Connect one channel of the chart recorder to


an isolator for the field current signal, and
another channel to an isolator for the field
voltage signal. DAC outputs can also be used
to display these signals if isolators are not
available (see section 9-3.1 for instructions on
setting up the DAC outputs).

b.

Step the generator field voltage to generate


0.20 per unit to 0.15 per unit field current
while observing the field voltage and current
signals. Measure the time constant at 63 % of
the steady state value of the resultant current
signal. When checking the saturated time
constant at full field, measure the field voltage and current then calculate the field resistance from the ratio of Vr/Ir.

63~

,
i

It,
--+---' SAT.

1-0
.1
.
..

Figure 9-2. Generator Saturated Field Time Constant Determination

9-5

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 9-4. Generator Proportional Command and


Feedback Gain EEPROM Values

9-6. STEP 3 - PROPORTIONAL FIELD


CURRENT REGULATOR RESPONSE
This section includes procedures for calculating proportional feedback gain, entering the resulting value
into the regulator software, and checking the regulator
response. Two gains, EE.1589 (HIRKCO) and
EE.1590 (HIRKFO), are adjusted for the proportional
regulator response (see Table 9-4). Section 9-7 adds an
integrator to improve steady state performance. The
proportional and integral regulator gains are adjusted
separately to minimize the number of simultaneous
variables. Figure 9-3 is a block diagram of the proportional field current regulator.
1.

Address

Mnemonic

Description

EE.1589

HIRKCO

Current regulator proportional


gain in the feedforward path

EE.1590

HIRKFO

Current regulator proportional


gain in the feedback path

3.

Using the EDIT2000 screen, set EE.1589


(HIRKCO) and EE.1590 (HIRKFO) to 1/3 of the
values calculated in step 1, and then simultaneously increase each value for a 80 radian/second
response at weak field. The full field response will
be faster by a ratio of the full field time constant
divided by the weak field time constant.

4.

Observe the field voltage on the oscilloscope while


increasing C346H incrementally using the ST2000
Terminal Mode. Note and record the numerical
value that causes the field voltage signal to go
from a discontinuous to a continuous waveform.
This value, Ifg, will be used in section 9-8 to calculate EE.1583 (ICNTCO).

5.

Using the ST2000 Terminal Mode, check the response of the regulator by stepping the regulator
and estimating the time response of the current
output signal. This should be done using two different step sizes: one in the range of 0.20 to 0.15
per unit; the other in the range of 1.0 to 0.90 per
unit. Figure 9-4 shows a typical response plot.

Calculate the gain value, EE.1589 (HIRKFO), and


enter it into the exciter using the ST2000
EDIT2000 screen. The following formula can be
used to calculate the gain:

HIRKFO

Wef x rfg x 1024 x 16384 x Rfg x Ifrated


Edo x 5000 x 32

where Wcf is the crossover frequency of the field


current regulator in rad/sec, and Edo is equal to
1.35 times the line-to-line input voltage.
Assume Tfg is equal to the unsaturated generator
field time constant. Then assume EE.1590
(HIRKCO) is equal to EE.1589 (HIRKFO).
To obtain the generator's field current regulator
response, close the field current loop and step the
regulator while observing the time response of the
resulting current waveform.
2.

Using the ST2000 Terminal Mode, reduce the


reference signal to zero by typing 'C346H = 0
and pressing (Enter) to avoid a sudden change in
the firing command during the following step.

PROPORTIONAl
COMMAND GAIN

FIELD
EXCITER

ILOPII32
ILOPOUT

ILOPREF
HIRKCO

32

PROPORTIONAl
FEEDBACK GAIN

Ilg
Edo

1024

--16384

FIELD CURRENT
CF8
5000IPU

FEEDBACK
5000

HIRKFO
Ifrated

Figure 9-3. Proportional Generator Field Current Regulator

9-6

GENERATOR
FIELD

1/Rfg
1 + sTlg

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter

63%

,
!
I

Figure 9-4. Proportional Field Current Regulator Response Plot

9-7. STEP 4 - PROPORTIONAL PLUS

T1

INTEGRAL RE GULATOR

This section set~ up and tests the proportional plus


integral regulatc . The integral gain is calculated and
set to provide thp. regulator with increased steady state
accuracy. Figur 9-5 shows a block diagram of the
proportional plu integral field current regulator.

Tfg (weak field)


5

HIRWIO

1.

The integral gai of the regulator, EE.1591


(HlRWIO), can be calculated from the following equations:

Tlx 1440

Using the EDIT2000 screen, set the EEPROM


listed in Table 9-5 to set up the proportional plus
integral regulator as follows:
a.

Set EE.1591 (HIRWIO) to the calculated


value and EE.1581 (lLIMCO) to 16384, as
shown in Table 9-5.

INTEGRAL
cc f,lMAND GAIN

HIRKFOx 32
=----

GAIN

FIELD

GENERATOR

EXCITER

FIELD

ILOPOUT
ILOPREF

+$T3
+sT1

HIRWIO(HsTI)

I-128(s)

-1024

Ifg
Edo

---

I/Rfg

I---

16384

1 +sTfg

"-..-

FIELD CURRENT
FEEDBACK GAIN
CFB
l+sT2
1+sT1

5000/PU

FEEDBACK

5000
Ifrated

Figure 9-5. Proportional Plus Integral Generator Field Current Regulator

9-7

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
Table 9-5. Proportional Plus Integral Regulator
EEPROM Values
Address

Mnemonic

Value

Description

EE.1591

HIRWIO

Calculate

Current regulator
integral gain

EE.1581

ILiMeD

16384

Voltage range limit


for current regulator integrator

b.

2.

Increase the integral gain, EE.1591


(HlRWIO), until the desired slope is obtained.
Note that EE.1591 can often be increased by
as much as a factor of 10 before overshoot
occurs.

Check the regulator's response by stepping the


regulator and estimating the time response of the
current output signal. Using the ST2000 Terminal
Mode, type 'C346H = XXXX, where XXXX represents the count for the desired step size. C346H
(IREGSTP) is the hex address of the step input to
the field current regulator.
Use two different step sizes, one in the range of
0.20 to 0.15 per unit, the other in the range of 1
to 0.90 per unit. The step sizes should be adjusted
if necessary to avoid field voltage saturation. Use
care to ensure a critically damped response. The
response plot should be similar to that shown in
Figure 9-4.

9-8. STEP 5 - FIELD CURRENT CONVERTER


LINEARIZATION

This section details the generator field current converter linearization procedure. Use the four-channel
chart recorder to display the firing angle signal, RAM
address 28893 (ALPHA); the firing command signal,
VAR.l000 (FIRCMD); the field current signal; and
the field voltage signal. Table 9-1 contains a list of
useful variable addresses. The GF2000 is given positive and negative reference signals to produce a current reversal. The "dead time" between the positive
and negative current signals is measured. For a reversing bridge, the "dead time" should be between 3 and
10 milliseconds for a 10% step in the field current
regulator. Figure 9-6 shows a block diagram of the
converter linearization.
1.

Measure the number of field current feedback


counts, VAR.1092 (IBRIDGE), required to reach
continuous current. This value is typically close to
100.

2.

Calculate and set the EEPROM values listed in


Table 9-6 using the EDITIOOO screen.

3.

Configure the DAC outputs to display useful variables on the four-channel chart recorder. Field
voltage and field current are the two most important variables for this step. Use voltage and

FIELD CURRENT REFERENCE

OISCONTINOUS CURRENT

LOW PASS FILTER

lLOPREF

FEED-FORWARD COMPENSATION

VlCNT

~--+--_.

.j----l'--_-J
TASHI

GENERATOR.

ALPHA

FJELD
PUSH

PROPORTIONAL

CURRENT

GAlN

REF

ILOPl/32

CONVERTER
PHASEOELAY

ILOPREF

ALPHA

.----,

CFe

5CIOOIPU

Figure 9-6. Converter Linearization

9-8

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter


Table 9-6. Field Current Linearization EEPROM Values
Address

Mne ,",onic

Description

Formula

EE.1582

DCG VCO

Voltage gain for open loop current regulator

296 x (V rated 1 V line-to-linel

EE.1583

ICNT ~O

Continuous current scaling factor

0.6 x Ifg continuous counts (typically close to 60)

EE.1584

WCR pLO

Open loop current reference filter

Wc (weak field) x (65536/360) = 80 x (65536/360)

EE.1587

GVR I,CO

Voltage gain for reversal request comparison

621 x (V rated 1 V line-to-line)

EE.1588

RTL~ CO

Retard limit current scaling factor

3 x (If rated x % reactance x V line-to-line) 1 KVA rating


(Use a default of 5% reactance.)

current isol tors, if available, to display the analog field vo tage and current signals. If isolators
are not ava able, DACl and DAC2 can be used
to display t ese signals (refer to section 9-3.1 for
instructions on selecting DAC variables). If isolators are use ~ for the field voltage and current signals, DAC and DAC2 can be configured to output other u eful variables such as the firing angle
signal, RA~ address 28893 (ALPHA), and the
fIring COIrn and signal, VAR.l000 (FIRCMD).
Then, usin the ST2000 Terminal Mode, step the
GF2000 fo Iward and backwards while observing
the signals t>f interest on the chart recorder. The
GF2000 is tepped by typing:

4.

Measure the "dead time" for Ifg (generator field


current) from the chart recorder plot. The "dead
time" is defmed as the time between the forward
and reverse firing signals when the field current is
zero, as shown in Figure 9-7. The "dead time"
should be between 3 and 10 milliseconds.

9-9. STEP 6 - GENERATOR SATURATION


CURVE

= 1l00, which sets the forward field current regwator reference signal,

Before continuing with this section, disable the voltage and current regulators by ensuring that GF@VRE,
GF@IRE, GF@IVS are pointing at zero. This is typically accomplished by inhibiting the MG set running
interlock and opening the M contactor, as shown in
Table 9-2.

= 500, which sets the reverse field current regwator reference signal.

With the MG set running, incrementally increase


C346H (IREGSTP) while observing the change in

, C346H

'C346H

_--t

i-I
...

DEADTIME

WNVVV\fVI!I!IfVU
CI11 A1VW/VI!V'NV
V
IjVf\NV Ii V
fg

Vy

Figure 9-7. Deadtime (ffg = 0) Determination Plot

9-9

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
the generator armature voltage versus the generator
voltage feedback, VAR.I093 (VMA1_Yeo). Adjust
EE.1503 (VFBSFO) so that 1 per unit generator voltage results in a count of 2oo on VAR.I093
(VMA1_Yeo). ConfIrm proper polarity of the feedback signal by assuring that a positive armature voltage results from a positive reference signal. The armature voltage feedback can be nulled using EE.569
(VARMOF) when the drive is stopped.
This section determines the saturation curve of the dc
generator. Use the field current regulator to vary the
field current from zero to rated field current and record the value of the corresponding generator armature
voltage. Figure 9-8 shows a typical generator saturation curve, produced by plotting the armature voltage
versus the fIeld current on a graph.
The generator field time constant varies as the slope of
the generator saturation curve. A highly non-linear
saturation curve would suggest that the time constant
of the field varies by a factor of 2 or more as a function of field current.

The eddy current time constant is the delay in the


change in armature voltage with respect to a change in
generator field current. Generators with solid magnet
frame constructions exhibit eddy current lag time constants between 0.02 and 0.10 seconds. For laminated
magnet frame generators, the eddy current lag time
constant is negligible.
A step signal input is entered into the regulator using
the STIOOO Terminal Mode, while the generator fIeld
voltage, generator field current, and generator armature voltage are recorded with the chart recorder. Figure 9-9 shows a block diagram of the voltage regulator
including the generator eddy current lead and lag time
constants.
Using the ST2000 Terminal Mode, enter a step signal
into the regulator by typing' C346H = XXXX, where
XXXX represents the count for the desired step amplitude. Start the count at 1000, then step it to 2000 to
capture the eddy current lag time constant at weak
fIeld. e346H (IREGSTP) is the hex address for the
field current regulator reference signal. The step amplitudes should be chosen to step the field at weak field
and also near full field (4500 to 4750).

9-10. STEP 7 - EDDY CURRENT LAG TIME


CONSTANT DETERMINATION

This section is used to determine the eddy current time


constant. The time constant is then used to calculate
the appropriate armature voltage regulator gains.

o
o

>

;::

.8

- - - - -

o .6

,
,

I
I

I
I

I
I

~-----~------~------~-----

_I -

E
0.4

..!. - _ _ _ _ _

I
I

I
I

- - - - -

<:
Q)

0.2

o \.-'
o

------------~-----

- - - - - 1 - - - - - -

I
I

I
I

I
I

I
I

I
I

I
'

'

'- - - - - - 1

'

'

I
I

I
I

I
I

I
I

I
I

I
I

I
I

I ' ,
I
I

~'

--~------:------f------~------:------f------~-----

~
I
I

j
I
I

l
I
I

I
I

I
I

I
-..l.-

I
-..l.-

0.2

0.3

0.4

0.5

0.6

. L -_ _- - - '

O. i

. L -_ _---'-

pee '",nit

l
I
I

Field Cueeent

~ __ ---J

I
I
I

L - -_ _--'--

0.7

Figure 9-8. Typical Generator Saturation Curve

9-10

------:------{---

0..

,
,

:::0

The eddy current time constant is the time to 63 % of


the steady state value of the armature voltage feedback, VAR.1093 (VMA1_VeO). Record the measured time constants for use in later calculations.

0.8

--l.-_ _- - - '

0.9

BI006008

GEH-6148

GF2000 Dc Ge ~erator Field Exciter


GENERATOR
GEN.FIELO

EDDY

GENERATOR ARMATURE

CURRENT

CURRENT

VOLTAGE REGULATOR

REGULATOR

LAGIl.EAD

VA

VAREF

_~+\!:;:)_
f?\ _

HVAWlO14<40{1 Tl)

GVAREG

20000IPU

IF

115000

Kvg(1 Tld)

1+sTfr

ARMATURE

1-1PU

1+sTlg

Wcvr-150 rJs

VOLTAGE
FEEDBACK
VARMFB
20000IPU
20000

Fi~

ure 9-9. Armature Voltage Regulator With Eddy Current Lead and Lag Time Constants

9-11. STEP 8
REGULATOR

ARMATURE VOLTAGE

The regulator lead time constant (Tl) used to cancel


the eddy current lag constant (Tlg) is given by:
Tl

NOTE

Ensure that the motor-generator set is


running befpre performing the following
procedure. Refer to Table 9-2 for Armature
Voltage Re~~.dation Mode.
The armature vo age regulator is used to zero the residual de generatDr armature voltage. In this section,
gains for the arm~ture voltage regulator are calculated
and entered usin! the ST2000 EDIT2000 screen. The
armature voltage feedback scaling is calculated and
set, and the step esponse of the regulator is checked.
The open-loop ga~ of the proportional plus integral
generator armatu e voltage regulator is given by (the
minimum eddy c ~ent time constant found should be
used for the calCl: ations):
GH

HVA WlO x 1 40 x 20000 x Kvg


(1 +sTl}(1 +s17d)
x -7:-=-'.-::::----::~
64 x 4096 x 5000
s(l +sTfr)(1 +sTIg)

Solve for the arm~ture voltage integral gain, EE.5338


(HVAWIO), usin1 the following equation:
HVAWlO

Wcvr x 64 x 4096 x 5000


Kvg x 1440 x 20000

where Wcvr is th crossover requency of the armature


voltage regulator In rad/sec, and Kvg is the maximum
slope of the gener tor saturation curve.

HVAKFO x 64
HVAWI0 x 1440

Setting the regulator lead time constant (Tl) equal to


the minimum eddy current lead time constant and
solving the equation for the proportional gain EE.5337
(HVAKFO) results in:

HVAKFO

TIg x HVAWIO x 1440

64
where Tlg is the eddy current lag time constant. Set
EE.5336 (HVAKCO) equal to EE.5337 (HVAKFO).
NOTE

The proportional and integral gains are related and cannot be independently adjusted.
The relationship between these gain values
must be considered when adjusting them.
With EE.573.5 (OVERV_MB source) set to 1, adjust
the instantaneous overvoltage level, EE.606
(OVLTMB) as desired for the particular application
per the following equation:
OVLTMB

= 20000 + (200 x Required Overvoltage %)

When closing the armature voltage or current loops for


the fIrst time, restrict the generator fIeld current reference limit, EE.5339 (GIFLMO), to 2000 counts or
40 % of the rated generator field current. Thereafter,
set EE.5339 (GIFLMO), for the particular application.
Typical values are 1.67 pu (8333) for reversing hot

9-11

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 9-7. Armature Voltage Regulator


EEPROM Values

mill applications and 1.25 pu (6250) for cold mill applications and drives that accelerate at a relatively slow
rate of 20 % of rated speed per second.
1.

2.

Configure the exciter for Armature Voltage


Regulation Mode per Table 9-2. Set up the chart
recorder to display armature voltage feedback,
armature current, field voltage, and field current.
Using the ST2000 EDIT2000 menu, set the parameters in Table 9-7 to their calculated values.
Using the ST2000 Terminal Mode, step the armature voltage regulator and verify correct regulator
response in the following manner:
a.

b.

Type' C340H = XXXX, where XXXX is 10%


of the desired armature voltage step amplitude. C340H (VASTP) is the hex address for
the armature voltage reference signal. Increase EE.5338 (HVAWIO), the integral gain
of the dc generator armature voltage, until the
desired regulator response is obtained. Figure
9-10 shows a typical response plot.

Address

Mnemonic

Value

Description

EE.5336

HVAKCO

Calculate

Armature voltage
command gain

EE.5337

HVAKFO

Calculate

Armature voltage
feedback gain

EE.5338

HVAWIO

Calculate

Armature voltage
integral gain

EE.5339

GIFLMO

Calculate

Generator field
current reference
limit

EE.579

IOVTHR

Calculate

Instantaneous
overvoltage trip
level

9-12. STEP 9 - ARMATURE CURRENT


FEEDBACK SCALING AND OVERCURRENT
SETTING

CAUTION

Adjust the proportional gains EE.5336


(HVAKCO) and EE.5337 (HVAKFO) to obtain the correct shape. The lead time constant
(Tlead) formed by the ratio of the proportional gain over the total integral gain should
be proportional to the eddy current time constant of the dc generator:
Tlead

The following test is normally performed in


Voltage Regulation Mode with the main
contactor closed. Because armature current
may be present if a contactor is not used or
if a contactor is used and is closed on
power-up, set EE.573.14 and EE.573.15 to
1 to disable the auto-null function.

HVAKFO
HVA WIO x 1440

This section checks the polarity and scaling of the current feedback signal. The instantaneous overcurrent
level is then set, and the protection circuit is tested for
proper operation.

Observe the field current, field voltage, and


armature voltage for proper response.

JJW~VJV~(VJV\M\WWMV\\NV~V~,\N\
Va
I
I

-I

63%
,
I
I

rlAVR

~jV\\n\~rl\01\l\i~rV\
,\

'n
,lfllff{\NYlrI{1
0/\A
A{I!\,fi II !\fl/\ ~
~ yvV\,'
~V\I'VrvVI/' \N
I

Figure 9-10. Armature Voltage Regulator Response Plot

9-12

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter


NOTE

For this t
there must
ent. The m
to reduce i
must be in
section 9-3.

3.

,the rotor must be locked and


e no motor field current prestor field leads may be shorted
duced voltages. The exciter
oltage Regulation Mode (see
).

Check the IOC operation by shorting the output of


the dc generator and varying the input of the dc
generator armature voltage regulator. Short-circuit
armature current circulates until it reaches the
IOC trip level.
NOTE

All electromechanical safety devices should


also be dynamically checked for proper operation and trip level.

NOTE

Small volta e reference steps of 2 - 5% are


sufficient f testing in this section.
1.

2.

Check the p larity and scaling of the current feedback signal y entering a voltage step signal at
C340H (VA TP), and observing the magnitude
and polarity f the current feedback signal,
VAR.l005 ( AIFB). The step signal is input using
the ST2000 erminal Mode while VAR.l005 is
observed for a proportional change as follows:
a.

Confi e one of the DAC outputs to display


VAR.l 5 (IAIFB), the current feedback
signal (s e section 9-3.1). Using the chart recorder, bserve the polarity of this signal with
respect t the step input. (VAR.l005 can also
be assi ed to a diagnostic output and displayed u ing Test 31 (see section 9-3.5).)

b.

Using th ST2000 Terminal Mode, enter


C340H XXXX, where XXXX is the desired
step ma 'tude count, while observing the
VAR.1 5 (lAIFB) signal. Adjust the magnitude of e armature current feedback using
EE.1505 the current feedback trim factor.

ture IOC setpoint, EE.1525


(lOCARO), b multiplying the per unit count
(5000) by the desired overcurrent percentage. For
example, for 260% overcurrent level setting, the
proper setting for the IOC setpoint is given by:

IOCARO = 5000 x 2.60 = 13000


See the ST2
help for this variable for additional inform ion.

CAUTION
To avoid pass ble damage to the commutator due to hig sustained levels of armature
current, m' . ize the duration of the high
armature cur ent tests.

9-13. STEP 10 - ARMATURE TIME CONSTANT


DETERMINATION

This section is used to determine the armature time


constant. This time constant value is used to calculate
control parameters for the armature current regulator.
1.

Using the ST2000 Terminal Mode, step the armature voltage regulator while measuring the armature time constant from the resulting armature
current signal. As shown in Figure 9-11, the time
constant is the time required for the armature current to reach 63% of its steady state value. To
step the regulator, type . C340H = XXXX, where
XXXX is the count representing the voltage step
amplitude. C340H (VASTEP) is the hex address
for the armature voltage reference signal.

2.

Note the time constant, which is used to calculate


the appropriate regulator parameters. Enter the
calculated values into the GF2000 exciter using
the ST2000 EDIT2000 screen. The integral gain
of the generator armature current regulator.
EE.5330 (RIAWIO), is given by:
BIA WIO

Weer x 64 x 4096 x Ra
Kvg x 1440

where Wcvr is the crossover frequency of the armature current regulator (50 to 150 rad/sec) and
Ra is the per unit armature resistance. Note that
(Ra x Ia rated)/Va rated = 0.05 for typical dc
motors and generator loops. Kvg is typically
unity, the generator voltage constant.
The lead time constant (TI) of the generator armature current regulator is equal to:

Tl

BlAKFO x 64
= BIA
WIO x 1440

9-13

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Ia

Va
Figure 9-11. Armature Time Constant Determination Response Plot

Tl is used to cancel the larger of the eddy current lag


(Tlg) or the armature current lag time constant (Ta).
The armature current regulator feedback gain,
EE.5329 (HIAKFO), is therefore given by:
HIAKFO = Tlg (or Ta) x HIA WIO x 1440
64

The proportional feedback and command gains are


equal: EE.5329 (HIAKFO) = EE.5328 (HIAKCO).
The lead-lag fllter time constants should be preset to
the following values:

Lead time constant (1'2)

= Td = 1/50 sec

Lag time constant (T3)

= Tg = 11400 sec

This gives the following values for the lead and lag
compensation coefficients EE.5331 (GLLCO),
EE.5332 (GLLC1), and EE.5333 (GLLD1):

GUCO = 2Td + T x 1024 = 7318


2Tg +T
GLLC1 = -2Td + T x 1024 = - 7068
2Tg + T

GLW1

2Tg - T x 1024
2Tg +T

= 774

where T, the sample time of the 12-bit DAC outputs,


is equal to 1/720 sec.
NOTE

The lead and lag time constants can have a


large effect on the regulator response and
should be adjusted with extreme discretion.
If T2 and T3 must be adjusted, the exciter
must be stopped. The ratio of the lead to
lag time constants should be less than 10.

9-14. STEP 11 - ARMATURE CURRENT


REGULATOR
NOTE

The exciter must be in Armature Current


Regulation Mode before continuing (see
Table 9-2). Closing the main contactor
makes VAR.1419 (IASEL) equal to 1 and
VAR.1417 (VARON) equal to 0, then
makes VAR.1418 (IARON) equal to 1 to
regulate armature current.
Set EE.S73.14, EE.S73.1S, and EE.6283.3
equal to 1 to inhibit auto-nulling at powerup. Refer to the help for these variables
for more information.

9-14

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter

Table 9-8. Armature Current Regulator


Gain EEPROM Values

To be properly ~sted, the current regulator. must be


separated from revious control blocks. Usmg the
ST2000 BLKEI T screen, fmd and select the core
block. Press the Block Info softkey (F1) and replace
the speed regula or output VAR.140 (SREGOUT) at
core block input COR@IC with an unused, generalpurpose register such as EE.REG75. The value of
EE.REG75 mus be set to zero when the armature
current regulatol is tested in this section. EE.REG75 is
then the variable used to input a step signal into the
fIltered reference regulator in section 9-14. The dc
generator armanlre current regulator must be ttmed
fast enough to eI f"orce the dc armature current of the
motor. A value f~r Wc between 100 and 150 rad/sec
provides a prope response with minimum overshoot.

Address

Mnemonic

Value

Description

EE.5328

HIAKCO

Calculate

Armature current
regulator gain

EE.5329

HIAKFO

Calculate

Armature current
regulator feedback gain

EE.5330

HIAWIO

Calculate

Armature current
regulator integral
gain

NOTE

Gain parameters EE.5328 (IDAKCO),


EE.5329 (IDAKFO), and EE.5330
(IDAWIO) are related. These parameters
and must be adjusted carefully while considering their relationships.

A block diagram of the armature current regulator is


shown in Figure 1:>-12. This section uses the ST2000
Terminal Mode t step the armature current regulator
while the step rellPonse of the regulator is observed.
NOTE

2.

Using the ST2000 Terminal Mode, step the armature current regulator by typing' C341 H =
XXXX, where XXXX represents the count for the
desired current reference step signal. C341H
(IAREF) is the hex address for the armature current reference step signal. Use a 20% step in the
armature current reference to prevent saturating
the field exciter.

3.

Check the armature current response for proper


regulator operation. See Figure 9-13 for a typical
response plot. If the response is too slow, increase
the integral gain HlAKWO and the proportional
gains HlAKFO and HIAKCO in the same proportions.

The JOC set(>oint should be set to a safe


value to pro ect against accidental overcurrent. The se point is adjusted by setting
EE.1507 (lOCTRO) in the STIOOO
EDIT2000 sc~een. Refer to the help for
EE.1507 (ana EE.1525 and EE.1527) for
more inform~tion.
1.

Using the ST 000 EDIT2000 screen, set the armature current r gulator gain values listed in Table

9-8.

ARMATURE
CURRENT
REGULATOR
IAREF
5000IPU

EDDY
CURRENT
COMP

HIAWIOl440*{1 +sT1}
644096 Isl

GIAREG
5000
-1 PU

1 +sT2
1 +sT3

EDDY
CURRENT
LAG/LEAD

GEN FIELD
CURRENT
REGULATOR
IFGREF
5000
-1 PU

1
5000(1 +sTfr)

IF
1-1 PU

ARMATURE
CIRCUIT
VA

, -, PU

Kvg(l +sTld)

l/Ra

IA
1-1 PU

I--1 +sTlg

, +sTa

Weer. 150 rls


ARMATURE
CURRENT
FEEDBACK
IARMFB
5OOO/PU

5000

Figure 9-12. Generator Armature Current Regulator

9-15

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

LOPREF

63%

'-,-=--- t ACR

Figure 9-13. Generator Armature Current Regu/ator Response

9-15. STEP 12 - ARMATURE CURRENT RATE


AND FILTER

The armature current rate limit block includes a lowpass filter to remove the tachometer ripple disturbance
from the output of the speed regulator. This section
tests the filtered current regulator response. An unused, general purpose register (such as EE.REG75) is
used as the input to the low-pass filter (COR@IC).

WCGIAO

100 x 65536
1440

= 4551

lRATLMO = 100 x 20 = 2000

9-16. STEP 13 - SPEED REGULATOR FEEDBACK SCALING AND POLARITY VERIFICATION


NOTE

1.

2.

Using the ST2000 EDIT2000 screen, set


EE.REG75 to the desired count for the proper
step amplitude.
Set the low-pass filter frequency, EE.5326
(WCGIAO), and current rate limit, EE.1526
(IRATLMO), to the values found using the following equations while observing the small and large
signal responses.
WCGIAO

Filter Frequency (rad / sec) x 65536


1440

lRATLMO = 100 x Per unit current / sec

Typically the filter frequency is 100 rad/sec and


the current rate limit is 20 pu current/sec. Therefore, the typical values for EE.5326 (WCGIAO)
and EE.1526 (IRATLMO) are found by:

9-16

Apply full field current and unlock the rotor before proceeding.
This section checks the speed regulator feedback scaling and polarity. Before proceeding, the speed regulator must be reconnected to the core block using the
ST2000 BLKEDIT screen. The general-purpose register used as a step input in the previous sections must
be replaced with the speed regulator output VAR.140
(SREGOUT) at core block input COR@IC.
The armature voltage regulator may be used to perform this test. To activate the armature voltage regulator, increment the armature voltage reference signal,
RAM address C340H (VASTP), while observing the
speed feedback for proper scaling and polarity. The
speed feedback count should be scaled such that 2oo

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter


is the maximum
age reference st
speed feedback
that gives 1/2 P
speed feedback

count value obtained. A positive voltp signal should produce a positive


ignal. A voltage reference step signal
armature volts should produce a
ount of:

1000 x (base speed/max speed)

9-17. STEP 1 - PROPORTIONAL SPEED


REGULATOR
NOTE

The diagno tic Speed Regulator Tuneup test


(Test 15 or 5) may be used here (see Chapter 8 for a escription of this test). Some
industries ay use other methods of tuning
the speed r gulators. The procedure in this
section is in ended to be used in the absence
of a pre-est blished method.
Figure 9-14 is a lock diagram of the speed regulator.
When the integr gain and limits are zeroed, the speed
regulator can be
ed in the proportional gain mode.
This mode is use to fmd the mechanical time constant
of the system an to set EE.1408 (SRJO), the speed
regulator inertial compensation gain.

1.

2.

Using the S
EEPROM v
shown. The
found with
set to 0 and

000 EDIT2000 screen, set the


ues listed in Table 9-9 to the values
roportional speed regulator gains are
e integral gain, EE.141O (SRWIO),
e proportional gains, EE.1406
(SRKCMO) d EE.1407 (SRKFBO), set to 4096.
The inner 10 p gain, EE.1409 (SRWO), is calculated accor . g to the desired crossover frequency
of the loop:

Table 9-9. Proportional Speed Regulator


EEPROM Values
Address

Mnemonic

Value

Description

EE.1410

SRWIO

Sets integral gain


to zero

EE.1406

SRKCMO

4096

Proportional speed
command gain

EE.1407

SRKFO

4096

Proportional speed
feedback gain

EE.1411

SRWF

Set to zero

EE.1409

SRWO

Calculate

Inner loop gain

EE.1408

SRJO

Determine

Inertial compensation gain

EE.1412

SRLMP

Calculate

Positive speed
regulator limit

EE.1413

SRLMN

Calculate

Negative speed
regulator limit

If the mechanical time constant or the per unit inertia value of the system is known, the value of
EE.1408 (SRJO) can be calculated as follows:

SRJO=64 x (top speed/base speed) x J (per unit)


The positive and negative speed regulator limits,
EE.1412 (SRLMP) and EE.1413 (SRLMN), are
given by:

SRLMP

= 5000 x Per unit armature current limit

SRLMN
3.

= 5000 x Per unit armature current

Using an unused general-purpose register, such as


EE.REG75, input a speed reference command
step signal. Check for proper response while
stepping the proportional regulator. The response
plot should look similar to Figure 9-15.
NOTE

Increase the' ertial compensation gain, EE.1408


(SRJO), incre entally from unity to the value that
gives the des' ed response.

There are two ways to limit the armature


current reference: in the speed regulator t
and in the core block with EE.SOS
(CORELMM) and EE.S06 (CORELMG).

9-17

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
SPEEO
REGULATOR

PROPORTIONAL
GAIN

TOTAL
INERTIA

TORQUE
CONTROL
SREGOUT ~_ _~

SRCM

OlWmax

,n=lI'T

,.,1/5000

TMOT
PU

WMOT
PU

- -__
+ fl--,~I----<.~-~

l='=-

TLOAO

-.v-1

,-----+

INTEGRAL
GAIN
SRWI*720

S'65536

~i

SPEEO
FEEOBACK

SRFB
20oo0IWmax

L-

---<~_ _-

---

_!

20000

LJ'
,

Wmax ,
'--------'

Figure 9-14. Speed Regulator Block Diagram

~ ,

63%
I

t SR

Ia

Figure 9-15. Proportional Speed Regulator Response

9-18, STEP 15 - PROPORTIONAL PLUS


INTEGRAL SPEED REGULATOR

SRKCMO

The proportional plus integral speed reference regulator is set up and tested in this fInal tuneup section. Its
function is to regulate the correct speed despite load
disturbances that come from the process.

SRWIO

1.

Calculate EE.1406 (SRKFBO), EE.1407


(SRKCMO), and EE.1410 (SRWIO) using the following equations. Set these values using the
ST2000 EDITIOOO screen.
SRKFBO = (Kd

9-18

+ 1) x

4096
Kd

= 4096

= 91

Wcs

Kd

where Kd, a damping factor, is between 1 and 3,


and Wcs is the crossover frequency of the speed
regulator in rad/sec.
2.

Step the regulator using the ST2OO0 Terminal


Mode and a general-purpose register for the step
input signal. Check the regulator response for
proper operation. The response curve should be
similar to the one in Figure 9-15.

BI006008

GF2000 Dc GE nerator Field Exciter

GEH-6148

CHAPTER 10
TROUBLESHOOTING

10-1. INTRO[ UCTION


This chapter pr vides specific information to help detect and correct problems with the GF2000 DC Generator Field Exc iter. This chapter is organized into
three primary Sl ctions:
General Troub eshooting. This section covers problems that h ve no associated fault or error indication, or tha cannot be fixed using the standard
fault systetr .
Stability ProblE m Troubleshooting. This section defmes three ypes of stability problems: cyclical
stability pre blems; mechanical oscillation problems; and e ifatic operation problems.
Specific Fault '1 roubleshooting. This section defmes
exciter fault detected by exciter diagnostics and
indicated as error codes. Table 10-5 at the end of
this chapter ~efmes these error codes.

WARNING
This equipn ent contains a potential hazard
of electric s ~ock or burn. Only adequately
trained per onnel who are thoroughly familiar with he equipment and the instructions should maintain this equipment.

10-2. TOOLS

NO INSTRUMENTS

These troubleshooting instructions require the standard


tools used when working with electrical equipment.
Additionally, the following instruments and references
should be available:

Oscilloscope

Megger

Renewal Parts Listing

Hardware Summary

Elementary diagrams

WARNING

To prevent electric shock, ensure that all


power supplies to this equipment are
turned off. Then ground and discharge the
equipment before performing any adjustment, servicing, or other act requiring
physical contact with the electrical components or wiring.

10-3. GENERAL TROUBLESHOOTING


Table 10-1 outlines the general problems that may
occur with the GF2000 exciter. Table 10-2 contains
the possible solutions for each problem listed in Table
10-1.

NOTE

All tools aD( instruments used to touch


electrical co nponents should be insulated
and ground d to meet National Electrical
Code (NEe) standards.

10-1

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-1. Troubleshooting Quick Reference Guide


Type of Problem

Problem Reference in Table 10-2

Exciter faults, LED indication

1. All diagnostic LEDs off


2. All diagnostic LEDs on
3. Fault messages displayed (repetitive)
4. Fault messages displayed (non-repetitive, random)

Programmer problems

5. Programmer display off


6. Error messages displayed
7. Programmer ineffective, no errors displayed
8. Parameter changes ineffective
9. Diagnostics do not perform

Fuse blowing, MOV failures, and board failures

10. Fuse blowing (ac power fuses)


11. Power supply fuses blowing
12. MOV failures
13. Repetitive board failures
14. Line voltage problems

Operational problems

15. 24 V logic not operating properly


16. Motor does not run
17. Motor runs in the wrong direction
18. Motor does not reverse
19. Motor speed is incorrect
20. Serial link does not function properly
21. Erratic operation
22. Stability problems
23. Signal-level detector chatter
24. Too much coast time on deceleration (regenerative
drives)

Motor problems

25. Motor runs hot


26. Motor audible noise
27. Motor vibration

Improper EEROM/EEPROM rewrites at


powerup or reset

28. EEROM/EEPROM rewrites

Noise, wiring, power supplies, and similar problems

29. Noise or random nuisance faults


30. Wiring procedures
31. Checking power supplies

10-2

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 10-2. General Troubleshooting Chart
Problem

Correction Procedures

1. All diagnostic EDs off

1. Check Programmer display for exciter fault (if used).


2. Check for 3-phase ac input.
3. Check for open ac line fuses (FU1 through FU3) or breaker.
4. Check for open fuses on DCFB board.
5. Ribbon cable(s) disconnected, open, loose, or intermittent.

6. Power supplies loaded down or failed - refer to Problem 31 (Checking power


supplies).
7. Use Programmer to attempt to enter the Parameter Mode (see Chapter 8). Refer
to Table 10-5 if any fault codes are detected. A hard reset should clear this
lockup condition.
8. Replace SLCC card firmware.

9. Replace SDCC card firmware.


2. All diagnostic LEDs on

1 . Drive faulted - check fault code list (Table 10-5).


2. NTB/3TB board's RESET point (3TB-58) connected to +5 or +24 V de.
3. Replace SLCC card firmware.
4. Replace SDCC card firmware.

3. Fault messages displayed (repetitive)

4. Fault messages displayed (nonrepetitive, rand m)


5. Programmer dis playoff

1. See Table 10-5, Specific Fault Troubleshooting, for troubleshooting procedures


related to specific exciter fault number.
1. See Problem 29 (Noise or random faults).
2. See Problem 30 (Wiring procedures).

1. Check that all plugs are connected properly.


2. Check power supplies - see Problem 31 (Checking power supplies).
3. Replace SLCC card firmware.

6. Error messages ~isplayed


7. Programmer ine fective, no errors
displayed

1. See Table 10-5, Specific Fault Troubleshooting, for troubleshooting procedures


related to specific error message.
1. Check that all plugs are connected properly.
2. Check jumpers on SLCC card for proper position.
3. Check that the exciter is in Auto mode. This mode inhibits certain mode references.
4. Replace SLCC card firmware.

8. Parameter

chan~

es ineffective

1. Check SDCC card's Write Protect jumper, JP1. JP1 must be in the 2-3 or ENABLE
position for programming.
2. Check setting in EE.2.0, DGNJP) - must contain a #1 # to allow reprogramming.
3. If the exciter uses multi-motor operation for different gear ranges, spindle orient,
and so on, verify that the proper motor parameters are being adjusted. Check by
setting to 10 the IOC trip setpoint of the motor parameters being adjusted.
Starting the exciter causes and IOC fault if the proper motor parameters have
been adjusted.
4. Check Problem 7 (Programmer ineffective, no errors displayed).
5. Replace SLCC card firmware.

6. Replace SDCC card firmware.


9. Diagnostics do n t perform

1. Check that the particular function is available - refer to the Custom Software,
software jumper descriptions.
2. Check the SDCC card's jumper JP1. JP1 must be in position 2-3 for some diagnostic tests to work. Refer to Programmer information in Chapter 8.
3. Check the NTB/3TB board's POL point (3TB-38) for reverse signal.

4. Refer to Problem 7, (Programmer ineffective, no errors displayed).

10-3

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-2. General Troubleshooting Chart - Continued


Problem
10. Fuse blowing (ac power fuses)

Correction Procedures
1. Compare the fuse size with the Renewal Parts List.
2. Check for out-of-tolerance or sagging ac line voltage on regenerative exciters refer to Problem 14 (Line voltage problems) and Problem 29 (Noise or random
nuisance faults).
3. Using a megger, check for a ground in motor circuit or blower circuit. (Observe
applicable WARNINGs and CAUTIONs.)
4. Check to see if exciter is being forced into current limit by an overhauling load.

11. Power supply fuses blowing

1. Check that the fuses are the correct size.


2. Check for any shorted or overloaded power supplies. Refer to Problem 31.
3. Replace the DCFB board.

12. MOV failures

1. Refer to Problem 14 (Line voltage problems).


2. Generator fault causes ac fuses to open during regeneration. Check for grounded
armature, field, or wiring.

13. Repetitive board failures

1. Check all connections at all terminal boards.


2. Check that all ribbon cables and plugs are connected properly (for example, not
offset by one row or pin).
3. Check the stab terminal connections on the DCFB and PCCA boards.
4. Check that all voltages (incoming ac and internal dc) are correct.
5. Check for moisture.
6. Check for damage caused by airborne chemical contamination.

14. Line voltage problems

1. Check that the line voltage is within exciter specifications, -5 to

+ 10%.

2. Check that the ac line voltage is balanced line-to-line and line-to-ground.


3. Check for ac line notches or spikes.
4. Check that the ac line frequency is within 1 Hz of rated.
5. When the ac line is supplied by a diesel-driven alternator, check for changes in
line frequency during exciter acceleration or regeneration.
6. Check for more than 1-1/2 cycles of ringing following commutation notches in
the ac line caused by the exciter. Amplitude should be :> 200 V.
7. Check for an ungrounded secondary on the power system transformer directly in
front of the exciter, if used. (The transformers are generally a delta/wye type with
the neutral of the wye grounded through a high resistance or directly to ground.
15. 24 V logic not operating properly

1. Check the 24 V dc power supplies.


2. Check the logic polarity control jumpers per the Custom Software.
3. Check control logic connections at the NTB/3TB board.
4. Check for proper polarity and common circuit if the 24 V dc supply is from a
source other than the exciter.
5. Check that the exciter is in the proper mode (0, 1, 2, or 3) for the particular generator or function being operated.

16. Motor does not run

1. Fuses open (or optional circuit breaker open).


2. Fuses open on DCFB board.
3. Check all hardware and software jumpers per the Custom Software.
4. Check control logic voltage and state, and power supply voltage levels at the
NTB/3TB board.
5. Check that the exciter is in the proper operate mode (Auto, Manual, etc.).
6. The motor may be stalled in current limit.
7. The motor-generator set running interlock is open.

17. Motor runs in the wrong direction

1 . Check for the logic signal at the NTB/3TB board's POL point (3TB-3B).
2. Armature connections are reversed (correct armature and tach leads) ..
3. Check all software and logic polarity control jumpers per the Custom Software.
4. Check the reference polarity.
5. Check the Custom Software to verify that the reverse function is enabled when
operating from the serial link.

10-4

BI006008

GF2000 Dc

Ge~erator

GEH-6148

Field Exciter
Table 10-2. General Troubleshooting Chart - Continued

Problem
18. Motor does ot reverse

Correction Procedures
1. Check that the exciter is regenerative.
2. Switch any two output leads.
3. Check the reference polarity.
4. Check control logic to the NTB/3TB board's POL point (3TB-38), if used for reversing.
5. Check the logic polarity control jumpers per the Custom Sohware.
6. Check the Custom Software to verify that the function is enabled when operating
from the serial link.

19. Motor speed is incorrect

1. Check that the motor design is suitable for the application.


2. Check that the proper reference is enabled per the Custom Software.
3. Check for proper reference scaling.
4. Check for noisy tach signal. Refer to Problem 30 (Wiring procedures).
5. Check that the motor is not in current limit.
6. Check that the motor or exciter is not in voltage limit.
7. Check that the tach scaling parameters are set correctly.

20. Serial link do s not function properly

1. Check that all required jumpers to enable function are set properly.
2. Check the exciter's baud rate compared to serial link device (a hard reset is required following a change in baud rate).
3. Check serial link connections at the NTB/3TB board.
4. If RS-422 is used, verify that the handshaking lines are properly connected.
Check that the sending device is responding to the exciter's DTR signal (low
level) when the device transmits to the exciter.
5. Replace the SLCC card.

21. Erratic operat on

1. Check power supplies for magnitude and ripple - refer to Problem 31 (Checking
power supplies).
2. Check connections on all ribbon cables.
3. Tighten all connections on terminal boards and all power connections.
4. Confirm correct hardware jumper settings per the Custom Sohware.
5. Check all parameters per the software test data sheets in the exciter door or Custom Software.
6. Check for noisy ground connection - refer to Problem 30 (Wiring procedures).

22. Stability probl ms

1. Check settings of all parameters per the software test data sheets in the exciter
door pocket.
2. Check that all contacts on the MA contactor are closing.
3. Refer to section 10-4 (Stability Problem Troubleshooting).

23. Signal-level de ector chatter

1. Is signal-level detector looking at a noisy signal (for example, tach feedback)?


2. Is enough hysteresis programmed into the appropriate parameter address?

24. Too much coa t time on deceleration


25. Motor runs ho

1. Check settings in the Custom Software and confirm that regeneration is enabled.
1. Motor may be overloaded; check for mechanical problems.
2. Check the motor winding temperature. If the motor has Class F insulation and the
winding temperature is less than 130C (260 of). this is normal.
3. Check the rotation of the motor blowers.
4. If the motor runs hot at very low speeds, check the motor application guide for
full-torque speed range.

26. Motor audible oise

1. Unstable regulator - check Problem 22 (Stability problems).

27. Motor vibratior

1. Coast Stop Exciter - if the vibration is electrically induced, the vibration disappears. If it does not disappear, check for mechanical causes.
2. Refer to Problem 22 (Stability problems).
3. The motor is not mounted level.
4. The motor base is vibrating.

10-5

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-2. General Troubleshooting Chart - Continued


Problem

Correction Procedures

28. EEROM/EEPROM rewrites

1. The SDCC card's jumper JP1 must be in the 1-2 position during powerup or hard
reset.

29. Noise or random nuisance faults

1. Check that the + 5 V dc supply is not used externally.


2. Check for suppression on all relays, contactors, and starters.
3. Check all power supplies - refer to Problem 31 (Checking power supplies).
4. Refer to Problem 30 (Wiring procedures).

30. Wiring procedures

1. Check the wire sizes on the ac power connections.


2. Check that the control wires (24 V dc, 115 V ac) do not run in the same conduit
or run parallel closer than 4 inches to the power wires, causing noise pickup.
3. Check that all signal wires (such as tach, encoder, reference, load cell, or RS232C/RS-422) are twisted-pair, shielded and that shields are grounded at the exciter end only.
4. Check that signal wires are not grounded at more than one end or other than the
exciter end only.
5. Check that the signal wires do not run in the same conduit, parallel, or closer than
4 inches to the power wires.
6. Check that there is only one system ground.
7. Check that the ground bus is large enough to prevent voltage drops or noise
pickup.

31. Checking power supplies

1. Check the + 15 V testpoint for + 15 V dc, 5 %. Verify with an oscilloscope that


there is less than or equal to 100 mV of ripple.
2. Check the -15 V testpoint for -15 V dc, 5%. Verify with an oscilloscope that
there is less than or equal to 100 mV of ripple.
3. Check the +5 V testpoint for +5 V dc, 5%. Verify with an oscilloscope that
there is less than or equal to 100 mV of ripple.

10-4. STABILITY PROBLEM TROUBLESHOOTING

Because of their similar behavior, this manual classifies three broad categories of exciter problems as
stability problems:

Cyclical stability problems

Mechanical oscillation problems

Erratic operation problems

Technically, the last two of these are not "true" stability problems. They are included in this section as
stability problems because they share the characteristics of oscillations or fluctuations in the exciter.
This section also discusses troubleshooting of stability
and other problems caused by phase differences between the ac line power brought to the DCFB board
and that brought to the field and/or armature bridge.
Problems caused by such phase differences can be
resolved by setting parameters contained in the SDCC
EEPROM.
10-6

10-4.1 . Cyclical Stability Problems

This category includes "hunting", oscillations in speed


or current, and similar problems. Generally, these are
characterized by cyclical, well-defmed sinusoidal oscillation periods.
Usually, cyclical stability problems are electrically
induced. They can be corrected with proportional and
integral gain adjustments.
Most GF2000 exciters have at least three regulating
loops:

Current regulator, continuous current

Current regulator, discontinuous current

Speed regulator

If any of these are mistuned, stability problems can


occur under the right conditions.

BI006008

GF2000 Dc G nerator Field Exciter

GEH-6148

NOTE

GF2000 exciters are almost always stable.

Various ~ rms of position regulators are


also avail Ie. Because of their variety, this
section ca ot address them.

Most stability problems, but not all, are corrected


by adjusting speed loop parameters.

In general, when troubleshooting cascading or


series regulating loops, the correct procedure is
to stabilize the regulators in the following order:

10-4.2. Mec anical Oscillation Problems

These are mec anical deficiencies that, under certain


conditions, can be aggravated or excited by electrical
frequencies. Fo example, such problem include vibration, audib e noise, and gear chatter.

Operation Problems

These are inter 'ttent speed or current fluctuations,


mechanical "b ping", or other non-sinusoidal or
non-periodic d turbances. Such problems can be
induced by inte 'ttent grounds, noise, or mechanical
problems.

eshooting Procedures
NOTE

ter checks and adjustments required in t . section require use of the


Programm r.
10-4.4.1. INITI L CHECKS. Before troubleshooting
the exciter for s bility problems using Table 10-3,
check the folIo ing conditions:
1.

2.
3.

4.

1.

Inner regulator

2.

Current regulator

3.

Speed regulator

4.

Position regulator (if furnished)


NOTE

If any of these steps stabilize the exciter,


record any parameter changes and do not
continue with the remaining steps.

10-4.5. Ac Line Phase Problems

For the exciter to operate properly, the ac line inputs


to the armature bridge must be in phase with the ac
line sync signal to the DCFB board, or phase differences must be compensated for using parameters
stored in the SDCC EEPROM. Problems caused by
phase differences between these inputs include:

Armature SCR failures

SCR test failures (opens or shorts)

All softwar jumpers match the exciter parameter


list (see Ch pter 8).

Loss of stability (speed, current, or field regulation problems)

jumpers match the jumper selection


hapter 5).

Advance limit too low (cannot achieve rated armature voltage)

All softwar parameters match the parameter list


(see Chapte 8).

Retard limit too high (cannot regulate zero


speed/volts)

All wiring i correct and agrees with the exciter


elementary iagrams.

Fault 22 (PHASELOS) when EE.187 has a value


of zero

10-4.4.2. PROS EM DETERMINATION. Use Table 103 to determine e type of problem, keeping the following pointers' mind:

10-7

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
EEPROM parameter EE.558 (ASYADJ) adds a fIxed
angle offset to the armature fIring circuit to compensate for phase differences between the ac line sync
input to the DCFB board and the ac line input to the
armature bridge. The default value of ASYADJ is O.
The range of possible values is -12000 to 12000,
where 16384 corresponds to 180 degrees. A positive
value is used if the armature phasing lags the line sync
phasing; a negative value is used if the armature
phasing leads the line sync phasing.

For example, assume that the Ll, L2, and L3 inputs to


the DCFB board for the line sync PLL are connected
to phases A, B, and C, respectively. If the Ll, L2,
and L3 inputs to the armature bridge are connected to
C, A, and B, respectively (lagging the line sync phasing by 120 degrees), set ASYADJ to 10922 (120/180 x
16384). If the armature bridge inputs are connected to
B, C, and A, respectively (leading the line sync phasing by 120 degrees), set ASYADJ to -10922.

Table 10-3. Stability Troubleshooting


Symptoms

Procedures

1. Unstable when unloaded, but stable


when loaded; exciter is stable but indicates gearbox or motor noise, or runs
erratically

1.

2. Speed instability below base speed

Adjust auto-tune parameters then re-run auto-tune.

2. If instability still exists, return adjusted parameters to their


original settings and skip to Symptom 4.
1. See Custom Software for gain changes in speed loop.
2. If no improvement, return the adjusted parameters to their original settings.
3. If there is some improvement, but instability still exists, document changes and skip to Symptom 4.

3. Speed instability above base speed

1. See Custom Software for gain changes in stability parameters.


2. If no improvement, return the adjusted parameters to their original settings.
3. If there is some improvement, but instability still exists, document changes and skip to Symptom 4.

4. Drive is unstable:
over a small part of the speed
range,
- or when loaded but stable when
unloaded,
- or such that oscillating frequency
is proportional to speed

1. Check that the problem is not tach related. Correct the tach
feedback problem (misaligned or loose coupling, belt slippage,
wiring, or excessive ripple).
2. With an oscilloscope, check that the power supplies are clean
(refer to Problem in Table 10-2).
3. Run the exciter to top speed and push the SDCC's RESET button. The exciter then coast stops. Mechanically induced problems will still be present as the motor slows down. If the problem disappears, continue to next step.
4. Determine resonant frequency Fr in Hz with an oscilloscope, if
possible. Convert to radians per second as follows:
Wr = 6.28 x Fr
5. If no improvement, return the parameters to their original settings and skip to Symptom 6.

5. Unidirectional stability problems

1. Inspect the load to ensure that nothing is wrong mechanically.

6. Additional procedures - if these procedures are required, contact GE Drive


Systems, Product Service Engineering,
(703) 387-7595.

If the above procedures do not stabilize operation, additional steps


may be required, including:

1. Checking out the current loop.


2. Running the field regulator open loop to verify stability.

10-8

BI006008

GF2000 Dc G nerator Field Exciter

GEH-6148

10-5. SPECIF C FAULT TROUBLESHOOTING

10-5.1. Fault Indication

The GF2000 e
nostics to aid'
detects a fault,
cate the proble

iter software includes selftest diagtroubleshooting. When the exciter


t outputs error (fault) codes to indi. Table 10-5 defmes these fault codes.

Faults 400 to 1023


faster blink rate
binary pattern (left-most LED is 2 9 [or 512],
8
second-most LED is 2 [or 256J, and so on;
see Figure 10-2)

Diagnostic LEOs

NOTE

Fault code dermitions may change with


product u
ades and revisions. The fault
codes pres nted in Table 10-5 are current
as of the is ue date of this manual. The
ST2000 T lkit or Drive Configurator, if
purchased ith the exciter, contains current fault c de definitions as of the date the
equipment as manufactured.
The exciter disp ays the fault codes on both the Programmer and th SDCC card's LEDs. Although the
Programmer's d splay is easier to read, the LEDs
provide a backu ,if needed. Additionally, the drive
can broadcast th se codes via an optional serial data
link.
10-5.1 .1. PROG AMMER DISPLAY. The Programmer
includes a digital display that shows a fault message
(fault number an name). Table 10-5, located at the
end of this chapt r, defmes these faults by number.
10-5.1.2. LED 0 SPLAY. Diagnostic LEDs display

I L

2 (or 256)

2 9 (or 512l

Figure 10-2. Binary-coded LED Display

No fault or exciter not running


sequential blinking, two at a time
blinking from outer positions inward to center, and back

These same LEDs can be set by software jumper to


also coarsely display exciter variables when running.
(For example, displayed in an absolute or signed bar
graph mode). However, this setting does not inhibit
the LED fault display.

10-5.2. Types of Faults

codes either BC (binary coded decimal) or binary,


depending on the fault number. They indicate the
faults in a bI' . mode, as follows:

Table 10-5 lists and describes the GF2000 exciter


faults. There are nine types of faults with the following characteristics (see Table 10-4):

1.

Trip faults. Trip faults are internal protective


conditions. When detected, they immediately
shut down a running exciter. The exciter cannot
be restarted until externally reset, via either a
hardware (hard) reset or a software (soft) reset, as
described in section 10-5.3.

2.

Filtered faults. Filtered (pending) Faults are the


same as Trip Faults with one exception: they must
continue for a time period before the exciter
shuts down. These faults are used to minimize
nuisance trips caused by momentary noise glitches
when a shutdown can be slightly delayed without
hazard.

3.

Non-latched Annunciated Faults. These faults


report conditions that should be noted, but that
do not need to shut down the exciter. However,
until corrected, these faults inhibit an exciter from

Faults 1 to 3
slow bI'
BCD pa
hundred
most, th

9
rate
em (left-most two LEDs encode the
digit; next four, the tens digit; rightunits digit; see Figure 10-1)

Diagnostic LEOs

DO 0000000
hundreds
digit

Figure 1

tens
digit

units
digit

1. BCD-coded LED Display

10-9

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter

starting. If the fault condition disappears, these


faults generally clear automatically without requiring a hard or soft reset.
4.

Latched Annunciated Faults. These are the same


as Non-latched Annunciated Faults, except that a
hard or soft reset is required to clear them.

5.

Brief Faults. To the user, these are the same as


Non-latched Annunciated Faults. The difference is
internal to the computer.

6.

Locked Faults. Locked Faults are Trip Faults of


a serious nature and cannot be cleared by a soft
reset. To clear the fault, the condition must be
fIxed, then a hard reset performed.

7.

Trip States. Trip States are similar to Trip


Faults, except that they report on conditions external, rather than internal, to the exciter.

8.

Filtered States. Filtered States are similar to Filtered Faults, except they report on conditions external, rather than internal, to the exciter.

9.

NOTE

The type of fault determines how it is


cleared.

10-5.3. Clearing the Fault

There are several ways to reset the exciter controller


to clear a fault. A software (soft) reset can be executed from the Programmer, or by serial command
from a device connected to the serial link. A hardware (hard) reset can be executed by pressing the
RESET pushbutton on the SDCC card, or by momentarily interrupting incoming power to the exciter.
Table 10-4 shows the types of resets that clear the
GF2000 exciter faults. A soft reset adequately clears
most latched faults. However, some types of faults
should be cleared by a hard reset.

NOTE

A soft reset displays all faults in the fault


stack, and should be performed instead of
a hard reset, whenever possible. If a soft
reset does not seem to restore the exciter to
normal operation, use a hard reset.

Non-latched States. These are similar to Nonlatched Annunciated Faults, except that they report on conditions external, rather than internal,
to the exciter.

Table 10-4. Summary of Fault Types


Drive Shutdown
Fault Type

Internal

Reset to Clear Fault

External

No

Immediate

Delayed

Hard

Soft

Automatic

Trip fault

./

./

./

./

Filtered Fault

./

./

./

./

Non-latched
Annunciated Fault
and Brief Fault

./

./

./

Latched
Annunciated Fault

./

./

./

./

Locked Fault

./

./

./

Trip State

./

./

./

./

Filtered State

./

./

./

./

Non-latched State

./

./

./

10-10

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers


No.

Name

Fault Condition, Causes

Type Fault

CLEAR

Clear

IOC TRIP

Instantaneous over-current
The armature current sampled by the dc shunt has exceeded the limit set by EE.1507,
IOCTRO. The armature current can be monitored by test point TP8 (if present) on the
DCC/SDCC Drive Control Card. Possible causes:
- IOC set too low. Check IOCTRO (EE.1507/1907/2307/2707).
- CFBSFn (EE.1505) set too low, causing saturation of the hardware.
- SCR misfiring. Check wiring for crosstalk, misconnections.
- Current regulator mistuned. Run test 14.
- Armature connections loose or brushes not seated properly.
- Mechanical load problems -- shaft bind, brake, gear box, etc.
- Current feedback isolator failure. Check 1PL and DRPL on DCI/DCFB.
- Shunt feedback not scaled properly.
- SCR failure. Run test 12.
- For multibridge, EE.608 or 610 set improperly in master drives.

Trip fault

OVER SPD

Tach overspeed
The magnitude of SFB (VAR.l 00) has exceeded the overspeed threshold (EE.20). Possible
causes:
- SFB blocks (BLK.320, SFBK; BLK.301, SREG; etc.) improperly set.
- Speed overshoot due to speed regulator tuning underdamped.
- Loss of field current.

Filtered fault

FIELD LOS

Field loss
The field current has fallen below the limit set by EE-1562, FLDLSO. Possible causes:
- Blown field fuse. Check for blown MOVs.
- Field connections loose or incorrect.
- FLDLSn set too high. Set at least 25% below FLDMNn, EE-1566.
- FLDECn set too low.
- Field reference blocks set incorrectly (BLK.259 or 300).
- Field gain jumpers set incorrectly on DCI.
- Field regulator gain too low. Run field tuneup.
- Incorrect field mode (2/3, NRP, or NRX) selected via EE.573.2.
- For SDCC, U31 date codes ~ 9420 may require DCP revision~ 5.10.
This fault can be inhibited by setting EE.1562 to 0 (for motor #0).
Beginning with revision 6.31, IFLDAFB (VAR.l090) (or FLDFB, VAR.l05 if Field #A is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568EE.1575. However, FIELDLOS uses UN-normalized field feedback to detect a fault and can
be compared to the field loss limit (FLDLSOl by viewing IFl FB, VAR.l 028.

Filtered fault

SFB_POL

SFBlTach polarity reversed


Filtered state
The polarity of SFB does not agree with the polarity of motor voltage or frequency. This fault
is generated when the magnitude of CEMF (VAR.112) is greater than 20% and the polarity
of SFB is not the same as the polarity of CEMF. Possible causes:
- Reversed tach connections
- SFB blocks (BLK.320, SFBK; BLK.327, ENCP1; etc.) improperly set
- On DC2000, Reversed VFB connections (Pl/P2 wired incorrectly)
- For analog tachs, failure of ribbon cable 6PL (pins 39 or 40)
- See also FLT.20.

RESETRUN

Run command asserted during reset


Possible causes:
- Drive powered up or reset with 3TB or STBA RUN or JOG closed (on STBA board, these
signals are brought to one of the configurable inputs).
- Incorrect 3TB or STBA logic polarity (see NTB JPl 0 or STBA JPl 0 and JPll, EE.l.4).
- Auto-start inhibited (EE.5Al.
- Momentary loss of incoming power while running.

Trip state

TOC_TRIP

Timed overcurrent
Possible causes:
- Motor mechanically overloaded due to load or wear.
- Field current less than 85% of rated.
- TOC settings too low (EE.1490-1496l.
- Armature winding failure.
- DB contactor failure (if used).
- TOC@IN (EE.25) if used, is not pointed at bridge or motor current.

Trip fault

= No Faults present

10-11

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued

No.

Name

Fault Condition, Causes

Type Fault

SERLTRIP

Trip generated by serial or LAN command 3Fh


Possible causes:
- "?" command accidentally entered from serial link keyboard.
- Received command 3F from LAN.

Trip state

10

NO CTS

13

EECKSMO

Bad page 0 EE checksum, EE.O - EE.255


Latched
The actual EEROM checksum in the given range does not agree with the stored checksum.
annunciated
Possible causes:
fault
- Block load of EEROM attempted with DCC/SDCC JP1 open or in 1.2 position.
- Drive reset or lost power while EEROM was being updated.
- DCC/SDCC JP1 was changed during update or touched with static charge.
- ST2000 or LAN download aborted or failed while in progress, or communication failure
(Rev 1.70 and earlier).
In the first case, the actual EEROM is not affected, and it is safe to reset the fault, enable
the jumper, and perform the block load again. In all other cases, effort should be made to
find the faulty settings and correct them. Set EE.2.1 and perform two hard resets to force a
correction to the checksums.

14

IREG SAT

CFB too low at fully advanced firing


The current loop has fired 60 fully advanced {as controlled by EE.1 544, ADVLMn or
EE.1592, HADLMnl firings in a row and armature current remained less than 10%. Detection of this condition can be inhibited by setting EE-571.1, MFLTJP.
Possible causes:
- EE.565-EE.568 not set, causing current loop autotune to incorrectly compute
settings for EE.1 544 and EE.1 592.
- EE.1544, EE.1592, or EE.1581 (IL1McO) set too low.
- Main contactor not picking up, or picking up too slowly. Increasing EE.39 (MAPDLY) will
correct for slow magnetics.
- Open connections or contactors in the motor armature circuit.
- Dc fuse open.
- Inspect 5PL, DRPL, and SCR gate lead connectors. Run test 12.

Serial link lost transmit capability due to CTS handshake


Trip fault
The serial link has data to transmit (such as a fault codel, but is unable to send it due to the
Clear-To-Send RS232 handshake line. Possible causes:
- Improper configuration of COMPL.4 and COMPL.5.
- Improper configuration of NTB.JP.6 and JP.7
- Failure of connector 6PL or SDCC or STBA board.

Filtered fault

Note in applications using the enhanced current regulator (EE.570.1), EE.1581 may be set
so low that the current regulator does not have enough authority to advance to CEMF limit
IEE.1 592). In this case, FLT .14 logic is not able to detect an open loop/firing circuit. Raising
EE.1581 (typically by 25%) allows this protection to function with little impact on performance. Beginning with revision 5.00 (DRVTYP=85), FLT.222 gives enhanced detection of
this fault detection.
15

VFB LOSS

VFB too low for given firing angle


Filtered fault
The drive has failed to measure at least 1 % armature voltage when the firing angle is within
75 degrees of full advance and current is at least 5 %. The analog VFB signal can be monitored for a circuit failure at control card test point TP37. Detection of this condition can be
inhibited by setting EE.571.6, MFLTJP. Possible causes:
- Voltage select jumpers and power connections on the PCCA Power Connect
Card are incorrect.
- 5PL failure. Check 5PL-25 and -26 (right-most pair of wires in cable).
- Failure of VFB circuitry on the SDCI/DCFB. Check VFB at TP37.
- Possible blown dc fuse.
- For DCFB, VM 1A/B voltage feedback not connected (see EE.570.11).

16

NORMOPEN

Normally open interlock is closed


Possible causes:
- Improperly selected source of NORMOPEN (EE.292, EE.4.14)
- External interlock closed or improperly connected

10-12

Filtered state

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

17

XSTOP

XSTOPCMD, VAR.679, hardware XSTP input is open


Possible causes:
- Improperly selected source of XSTOP input (EE.253)
- External input open or intermittent
- Failure of ribbon cable 6PL
- Improper choice of XSTOP mode (EE.6.4)

Trip state

Note that prior to revision 2.31, this was a filtered fault, and XSTOPCMD could be TRUE
briefly, causing a stop but not a fault.
18

STALL_OC

Timed overcurrent at stalled rotor


Possible causes:
- Mechanical failure (failed brake, frozen bearing, etc.)
Field current less than 85% of rated
SOC settings too low (EE.1490-1496)
Armature winding failure
DB contactor failure (if used)
If motor was rotating, speed threshold too high (EE.1492 or EE.21) or problem in
speed feedback measurement (BLK.320).
SOC@IN (EE.30) if used, is not pointed at bridge or motor current

19

OVERVOLT

Instantaneous overvoltage
Filtered fault
The armature voltage has exceeded the limit set by EE.579, IOVTHR. The analog VFB signal
can be monitored for a circuit failure at DCC/SDCC testpoint TP37.
Possible causes:
- Advance limit set too high (EE.1544 or EE.1592).
- Crossover set too high (EE.1567).
- Drive unstable. Run tests 14 and 16 to check arm/field regulators.
VFB circuit failure. Check DCC/SDCC TP37.
- For DCFB, VM1A/B voltage feedback not connected (see EE.570.11).

20

SFB_LOSS

SFBlTach feedback loss


The magnitude of SFB does not agree with the magnitude of motor voltage or frequency.
This fault is generated when the magnitude of CEMF (VAR.112) is greater than 20% (4000
counts) and the magnitude of SFB (VAR.1 00) is less than 2%. Possible causes:
- Tach leads broken
- Tach hardware scaled improperly (Analog: NTB.SW.1)
- For analog tachs, failure of ribbon cable 6PL (pins 39 or 40)
- Encoder connected improperly (STBA/SDCC jumpers, EE. 7, BLK.326, etc.)
- Encoder jumpers set for 15 volt encoder when 5 volt encoder used
- Encoder "Z" channel polarity holding counters in reset.
- SFB blocks (BLK.320, SFBK; BLK.301, SREG; etc.) improperly set
- Loss of field current
- Open dc fuse or armature loop
- Bug during reset in revision 1.10-1.50 when using CEMF as SFB
For debug purposes only, this fault may be inhibited by FLTJPR.7.

Filtered fault

21

NORMCLSD

Normally closed interlock is open


Possible causes:
- Improperly selected source of NORMCLSD (EE.291, EE.4.14)
- External interlock open or improperly connected

Filtered state

22

PHASELOS

Ac line dip or imbalance


Possible causes:
- EE.582 or 583 setting is too sensitive.
- Low ac line or phase imbalance.
- Blown fuse in ac line or on SDCI/DCFB card.
- Loose ac power connections.
- Failure in 15 volt power supplies.
For EX2000 see EE.576.
Beginning with revision 5.36, for DC2000 only, this fault requires a hard reset to clear. For
revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.
Beginning with revision 5.41, field and armature SCR firings are inhibited when this fault
occurs.

Trip fault

Trip fault

10-13

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

23

FIELDTOC

Field timed overcurrent


The field current has exceeded the reference by an amp-seconds rating defined by EE.1563,
FTOCGO. Possible causes:
- Field SCR shorted.
- Field regulator unstable or running in voltage-regulated mode.
- FTOCGn set too sensitive.
- Excessive field forcing through BLK.259 or 300 (VAR.165).
Incorrect field mode (2/3, NRP, or NRX) selected via EE.573.2.
- For SDCC, U31 date codes ~ 9420 may require DCP revision <: 5.10.
Field SCR firings are inhibited when this fault occurs.
Beginning with revision 6.31, IFLDAFB (VAR.l090) (or FLDFB, VAR.l05 if Field #A is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568-EE.1575.
However, FIELDTOC uses UN-normalized field feedback to detect a fault which is typically
equivalent to IFl FB, VAR.l 028.

Trip fault

25

COM FAIL

Commutation failure
The drive has shut down because it detected an imminent SCR commutation failure.
Possible causes:
- Open or intermittent connection on pins 1 or 2 of ribbon cable 1PL.
- Shorted or open SCRs.
- Insufficient commutation voltage margin due to ac line dips or CEMF limit or crossover
set too high.
- Improper CT burden selection settings on SDCI/DCFB. Set for higher horsepower rating.
- Commutation failure threshold set too low (EE.581, CFLTHR).
- Dc current in ac line saturating CTs due to high loads and multiple bridge reversals at a
rapid rate (faster than 60 Hz).
- Nuisance trips due to hardware/software sensitivities prior to 302DCIANGl /AJG2,
301 DCCAMG1, and 1.60 (AG) revisions. Increase EE.581.
- Leads swapped in CT connector, ICPL, on SDCI/DCFB card. Compare VAR.l 04 and
V AR. 101 9 for same polarity and magnitude. Use burden switches for coarse
adjustment, EE.1520 for fine.
- Bug in MPG3 revisions 2.15 - 2.20 when SDCC and DCFB are used. FLT.25 must be
inhibited in these revisions.
Inhibit this fault by setting EE.581 to 32767. When this fault is detected, armature SCR firings are immediately inhibited (no phase-back occurs).

Trip fault

26

AC IOCUR

Ac instantaneous overcurrent
Current as instrumented by the ac line current transformers has exceeded the limit set by
EE.580, ACIOCT. Possible causes:
- Improper CT burden selection on the SDCI/DCFB. Verify settings and that the scaling of
CTCFB (VAR.l 019) roughly matches CFB (VAR.1 04) using test 31.
ACIOCT set too low. Set to 32767 to inhibit this fault.
- Current regulator overshoot. Run current loop tune-up.
- Open or intermittent connection on pin 1 or 2 of ribbon cable 1PL.
- Commutation failure or ac shoot-through. Run cell test.
- Refer to additional items under FLT.25 (COM FAIL).
For early revisions, see note under EE.587 and increase EE.580.
- During cell test, a shorted cell exists and firing angle used during test is too advanced.
Temporarily defeat FLT.26 using EE.580 or reduce the firing angle using EE.1580.
As of revision 2.11, armature SCR firings are immediately inhibited when this fault is detected.

Trip fault

27

NO LSYNC

Indeterminate line sync input


Locked fault
The drive is not receiving a suitable ac line synchronization signal from the SDCI/DCFB. Test
point TP29 on the DCC/SDCC (not on early DCC revisions) should show a 5-volt square wave
of the line frequency. Possible causes:
- Fuses blown or missing on the DCI/DCFB/SDCI interface card. (Note: if fuses are
blown, check for MOV failures).
- Excessive ac line phase imbalance or notching.
- Failure of 1PL cable (pin 29) or DCI/DCFB/SDCI card.
- For multibridge, failure of LAN power supply or SPCS card, misconfiguration of master
or follower drive (EE.572).
Field and armature SCR firings are inhibited when this fault occurs.
For revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by
invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.

10-14

BI006008

GF2000 Dc G nerator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


Fault Condition, Causes

Type Fault

28

/llegal Run mode commanded


Not used in the AC/DC2000 (replaced by more descriptive faults such as FLT.360).

Trip state

29

Control-on loop open


Possible causes:
- Open circuit or noise between 3TB.42 and 3TB.44 on NTB.
- Intermittent connection in 6PL pins 1 or 2.
- Open circuit on STBA K28+ and K28- (STB.64 and STB.66). See also STBA JP29
and JP30.
- STBA RLY 3 dropped out or RLY 3 contact not bypassed from control-on circuit.
See STBA JP31, JP32, and JP39.
The control-on loop should not be used as the normal stopping mode for the drive. It is
intended for real emergency use only or as a safety lockout when the drive is already
stopped.

Trip state

No.

Name

31

NO PHSE

Indeterminate phase sequence input


The drive is not receiving a suitable ac line signal for determining the phase sequence or line
sync. Test point TP29 on the 301 DCC/SDCC card (not on early revisions) should show a 5
volt TTL level square wave of line frequency. Possible causes:
- Line or power supply card fuses blown.
- Excessive ac line phase imbalance, noise, or notching.
- Failure of 1PL cable (pin 29 or 6) or DCI/DCFB/SDCI card.
- 15 volt power supplies outside 10% limit.
- (Multibridge) Failure of LAN power supply or SPCB card, misconfiguration of master or
follower drive (EE.572).
For revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by
invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.

Locked fault

32

TOC ANU

Timed overcurrent alarm

Non-latched
annunciated
fault

33

NEGPHSEQ

Negative phase sequence not allowed


This fault can only occur if a negative sequence ac line source has been detected and
EE.570.1 is set to inhibit negative sequence operation. If the SDCC and DCFB cards are
being used and the bi-phase PLL is enabled (see EE.570.3 for MP group 3), only positive
sequence operation is allowed, independent of EE.570.1.
- Reverse any 2 ac input lines and recheck.
- Check items listed for FLT.31.
Field and armature SCR firings are inhibited when this fault is detected. Note some applications using the DCFB board do not allow drive operation with reverse phase sequence.

Trip state

34

PLLTRACK

Ac line synchronization PLL error too high


Either noise or a frequency change on the ac line instrumentation has caused the PLL error
to exceed the acceptable limit. The response of the PLL circuit may be changed by EE.575,
PLL_GN. Possible causes:
- Excessively noisy, notched, or unbalanced ac line.
- Fuses blown or missing on DCI/SDCI/DCFB.
- PLL_GN set too low (especially variable frequency ac lines).
- Failure of 15 V dc power supplies.
- Bi-phase PLL enabled (EE.570.4) but 3-phase L1/L2/L3 not connected to DCFB.
- Bi-phase PLL enabled (EE.570.4) but gains not set (EE.576, 577).

Non-latched
annunciated
fault

35

Run while rotating, flying restart inhibited


Motor rotating when RUN or JOG commanded. Possible causes:
RUN commanded while motor coasting or externally driven.
- ZSPEED (EE.21) set too low.
- Too much noise or offset (Analog: check EE.49) in tach feedback.
- Need to enable flying restart mode (EE.5.3).

Non-latched
state

Annunciates bad serial message


Possible causes:
- Incorrect Baud rate (EE.120).
- Noise on serial link wiring.
- Bad message checksum in protocol mode.
- Invalid message (too many characters).

Non-latched
annunciated
fault

36

SPEED

10-15

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

38

EELOCKED

EE writes disabled
EEROM cannot be modified via the serial link, LAN, or Programmer unless EE.2.0 is set.

Non-latched
state

39

EEWRFAIL

EE write verify fail. Possible causes:


- SDCC JP1 in disabled position.
- Exceeded maximum changes to EEROM 110,000 changes per 256 word page}.
- EEROM IU9) has failed.

Non-latched
annunciated
fault

40

SPEEDLIM

Speed reference outside limits. Possible causes:


- BLK.255, RUNRF output exceeds EE.356
- BLK.256, JOGRF output exceeds EE.376
- BLK.301, SREG command exceeds EE.1418
- EE.290, RFLM@I pointing to a TRUE value
The speed regulator can impose both maximum and minimum limits. The other sources
impose only an absolute maximum limit.

Non-latched
state

41

KEY OFF

The key pushed is presently disabled (see EE.690).


KPDJP1 (EE690) has been programmed to disable this function.
- Check the loading of KPD JP1 IEE.690}.

Non-latched
annunciated
fault

42

XSTPOPEN

XSTOP input open when RUN or JOG requested. On STBA board, these signals are connected to configurable inputs. Possible causes:
- EE.253, XSTP@I not pointed to correct source of the XSTOP input.
- XSTOP input open or intermittent.
- Failure in NTB/3TB, STBA, or SDCC board, or connector 6PL.

Non-latched
state

45

SPDTRACK

Speed tracking fault. Possible causes:


- Speed tracking improperly set up IEE.26-28).
- Drive unstable or unable to hold speed.
- Speed regulator blocks improperly set up.
This fault can be inhibited by setting EE.27 to O.

Trip fault

46

CFB OFST

CFB VCO zero offset too high


Non-latched
While the drive is stopped ( no current flowing in the shunt), it has measured more than 5% annunciated
current, indicating an excessive zero offset in the current feedback isolator on the
fault
DCI/SDCI/DCFB card. Detection of this condition can be overridden by EE.571.4.
Possible causes:
- DRPL connected incorrectly at shunt or plug on DCI/SDCI/DCFB.
- Twisted-pair wires from shunt picking up noise. Route away from power leads and
twist pair tighter.
- Failure in the current feedback isolator on the DCI/SDCI/DCFB.

52

NCLSDANN

Normally closed interlock is open

Non-latched
annunciated
fault

57

NOPENANN

Normally open interlock is closed

Non-latched
annunciated
fault

65

A1F_OPEN

Cell test open circuit detected in A 1F


Inadequate current was detected in the SCR during the open circuit SCR test. Possible
causes:
- SCR or leg fuse failure.
- The open circuit firing angle may need to be tailored for the motor under test using
EE.1577, CTSTVO.
- 5PL or SCR gate lead cable/connection failure.

Trip fault

66

A2F OPEN

Cell test open circuit detected in A2F

Trip fault

67

A3F OPEN

Cell test open circuit detected in A3F

Trip fault

68

A4F OPEN

Cell test open circuit detected in A4F

Trip fault

10-16

BI006008

GF2000 Dc G nerator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

69

A5F OPE

Cell test open circuit detected in A5F

Trip fault

70

A6F OPE

Cell test open circuit detected in A6F

Trip fault

Cell test detected no forward current


Inadequate current was detected in the SCRs during the open circuit SCR test in multiple cells.
The fault code indicates whether the problem affects all SCRs, only forward or reverse, or
some other combination. Listen for current in the motor during the test to isolate firing versus
feedback problems. Possible causes:
- SCR or fuse failures.
- The open circuit test firing angle may need to be tailored for the motor under test using
EE.1577, CTSTVO.
- 5Pl or SCR gate lead cable/connection failure.
- Shunt feedback wiring damaged or not connected.
- Current feedback isolator failure on SOCI or OCFB.
- Armature loop open or motor not connected.
Inadequate time allowed for contactor to close (EE.39 MAPOlV).
Regeneration enabled on non-regenerative drive (EE. 1500.1, 1900.1)
Simulator mode enabled (EE.570.0).
Firing power failure. Check for + 24 volts on gate pulse primary during drive test 12.

Trip fault

71

72

ARM OPEN

Open circuit test detected no armature loop


More than 5% voltage was detected at the beginning of the second pass of cell test, but VFB
was ok at the beginning of the first pass. This would normally happen if the short circuit test
fired into an open circuit, so the VFB senses snubber voltage due to lack of a discharge path.
Possible causes:
- Blown dc fuse.
- Open circuit in armature, dc contactor, or wiring.
- Insufficient time allowed for dc contactor to close -- increase EE.39.
- Failure in VFB sensor (OCFB) or connections (5Pl).
- P1 or P2 connection to armature (for snubbers and VFB) is open.
This fault can be overridden by setting EE.571.11.

Trip fault

73

A1R OPEN

Cell test open circuit detected in A 1R

Trip fault

74

A2R OPEN

Cell test open circuit detected in A2R

Trip fault

75

A3R OPEN

Cell test open circuit detected in A3R

Trip fault

76

A4R OPEN

Cell test open circuit detected in A4R

Trip fault

77

A5R_OPEN

Cell test open circuit detected in A5R

Trip fault

78

A6R OPEN

Cell test open circuit detected in A6R

Trip fault

79

REV OPEN

Cell test revealed no reverse current (see FlT. 71)

Trip fault

80

SHRTFAll

Short circuit cell test failed


When cell test detects a short on the first pass, cell test runs the test again, testing cells in
the same order. If the second pass detects a different shorted cell than on the first pass, FlT80 is reported. Possible causes:
- The short circuit test thresholds for voltage and current need to be increased for the
motor under test. See EE.1578 and 1579.
- SCR misfiring due to dv/dt.
- SCR misgating due to noise coupling or misconnection of gate leads.
- Noise in the CFB and VFB sensor hardware.

Trip fault

10-17

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

81

A 1 SHORT

Cell test short circuit detected in A 1


Motor current or voltage was detected in the SCR during the short circuit SCR test. Possible
causes:
- SCR shorted.
- SCR misfiring due to dv/dt.
SCR misgating due to noise coupling or misconnection of gate leads.
- The short circuit test thresholds for voltage may need to be tailored for the motor
under test. See EE.1578 and 1579.
Prior to revision 1.84. open armature or VFB not 0 when cell test invoked. especially if
fault reported is A6_SHORT. Check dc fuse. motor not at standstill. or bad VFB sensor
circuitry.
Note that for K frame (multibridge) drives. if a cell is shorted, the master drive will report
which leg (A1 - A6). If the short is in a follower bridge. that follower drive will report a
FLT.232. MBRGSHRT, to pinpoint the location of the shorted cell.

Trip fault

82

A2 SHORT

Cell test short circuit detected in A2 (see FLT .81 )

Trip fault

83

A3 SHORT

Cell test short circuit detected in A3 (see FLT.81)

Trip fault

84

A4 SHORT

Cell test short circuit detected in A4 (see FLT.81)

Trip fault

85

A5 SHORT

Cell test short circuit detected in A5 (see FLT.81)

Trip fault

86

A6 SHORT

Cell test short circuit detected in A6 (see FLT.81)

Trip fault

97

OPENFAIL

Open circuit cell test failed


When cell test detects a failure on the first pass. cell test runs the test again. If the second
pass detects a different set of cells open than on the first pass. FLT .97 is reported (revision
1.84 to present). Possible causes:
- The open circuit test firing angle needs to be increased (EE.1577).
- Intermittent connection in 5PL ribbon cable or power wiring.
- See also FLT. 71.

Trip fault

98

MULTOPEN

Cell test detected multiple opens (see FLT.71)

Trip fault

99

ALL OPEN

Cell test detected no forward or reverse current (see FLT. 71)

Trip fault

129

DRIVETYP

Programmed drive type doesn't match hardware configuration


Possible causes:
- Software installed at U22/U23 does not match EE.550, DRVTYP
Hardware installed at 1PL does not match EE.556. HDWTYP
DRIVE TYPE EE.550 EE.556 INTERFACE CARD VOLTS AT 1PL-38
DC2000
5
5 or 0
DCI (531 X302DCI)
2.3 - 2.7
DC2000
85
5
DCI or SDCI
2.3 - 2.7
Note: EE.556 is invalid for EE.580=85.
DC2000
5 or 85
4
DCFB (DS200DCFB)
1.8 - 2.2
- Failure of ribbon cable 1PL pin 38
- Failure of DCC/SDCC card.
The actual voltage being read by the DCC/SDCC card at 1PL-38 is displayed under the heading "DTYP" of drive test 13 (J13) using an RS232 terminal connected to COMPL.

Trip fault

130

MCPBDREV

Invalid MCP software revision (SDCC sockets U22/U23)


The revision of the MCP software, in SDCC sockets U22 and U23, is not recent enough to
support features selected by the EEROM configuration, or the MCP software is not compatible
with the other EPROMS on the SDCC card. Possible causes:
- EEROM not configured per application requirements
Software revision (per PROM labels and per drive test 10) older than specified in
MCPREV (EE.66)
- SDCC only: MCP revision less than 4.34 when DCP is greater than 4.33. This is a
locked fault which can be corrected only by installing a compatible EPROM set for
U12/U11 and U22/U23.

Trip fault

10-18

BI006008

GF2000 Dc G erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

131

MCP_FAI

SDCC motor control processor U21 (MCP), selftest failed


MCP has failed its power-up selftest. Pass/fail status of MCP is also displayed on an RS232
terminal running test 13 (J13). Possible causes:
- Socketed ICs on the SDCC control card not properly seated
- Failure of U21 on SDCC card. Replace card.

Trip fault

MCP EPROM (SDCC U22/U23) checksum error


The MCP EPROMs have been improperly programmed or have failed. Possible causes:
- U22 or U23 on SDCC card not properly seated.
- Failure of U21, U22, U23 or SDCC card.
- U21 is an 80c196KC chip instead of an 80c196KB. Prior to revision 1.90 (AK), U21 must
be an 80c196KB microcontroller.

Trip fault

Trip fault

132

133

DPRMFAIL

DCP/MCP Dual port RAM (DCC/SDCC U8) selftest failed


MCP has detected a failure in the U8 dual-port RAM during its power-up selftest. Pass/fail
status is also displayed on an RS232 terminal running test 13 (J13). Possible causes:
- Socketed IC on the DCC/SDCC control card not properly seated.
- Failure of DCC/SDCC card.

134

DCPB DO

Trip fault
Timeout, MCP watchdog of DCP background
The MCP has detected an execution rate failure of the background software in the DCP. DCP
background monitors a byte (DPRM_DCPB_MCPB_WDOG) 11 times a second, and if it is
negative, DCP resets it to O. MCP background decrements the byte 22 times a second, and
generates fault 134 if it ever gets down to -100 counts. (See related fault 377). Possible
causes:
- Socketed ICs on the SDCC control card not properly seated or bent pins
- Failure of SDCC card
- Noise disturbing SDCC control card due to improper wiring practices
- EEROM configuration has overloaded processor
- Card connected to 1PL or 3PL installed or operating incorrectly.
- Intermittent, noisy, or out of spec low level power supply.

135

DCPF DOG

Timeout, MCP watchdog of DCP foreground


The MCP has detected an execution rate failure of the foreground software in the DCP. MCP
background increments a byte (DPRM_DCPF_WDOG) approximately 22 times a second. DCP
background also increments this byte, about 11 times a second. DCP foreground resets this
byte to zero about 90 times a second. If MCP ever sees this byte larger than 100, then it
generates fault 135. See related fault 375. Refer to FLT.134 for possible causes.

Trip fault

136

MCPF DOG

Timeout, MCP watchdog of MCP foreground


The MCP has detected an execution rate failure of its foreground software. MCP background
increments a byte (DPRM_MCPF_WDOG) about 22 times a second. DCP background also
increments this byte, about 11 times a second. MCP foreground resets this byte to zero
about 360 times a second. If MCP background ever sees this byte larger than 100, then it
generates fault 136. See related fault 378. Refer to FLT.134 for possible causes.
For the DC2000, this fault can be caused by the loss of the line sync input (1 PL-29). Beginning with revision 5.31, field and armature SCR firings are inhibited when this fault occurs.
For revision 6.31 and later (DC2000 only), if EE.6283.6 is set, invoking a soft reset will reinitialize MCP with out requiring a hard reset (a firm reset is performed). See EE.6283.6 for
details.
NOTE - Multiple soft resets may be required.

Trip fault

137

MCPEXRA

80c196 processor external RAM U97 powerup test fail


External RAM device U97 (8K bytes) on the SDCC control card failed the powerup test for
one or more memory locations. Possible causes:
- Defective SDCC card.
- Socketed device on SDCC not inserted fully or pin bent under.

Trip fault

10-19

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued

No.

Name

Fault Condition, Causes

Type Fault

138

CMPSHRAM

80C196/TMS320c25 shared RAM U36/37 powerup test fail


Shared RAM devices U36 and U37 (32K words) on the SDCC control card failed the powerup test for one or more memory locations. During powerup, this RAM, which is accessible
by both the MCP (U21) and CMP {U35j, is tested by MCP, once with CMP halted, and once
with CMP running. If the RAM test fails with the CMP halted, FLT.138 is reported. If the
RAM test fails with the CMP running, FLT.145, DPRCFAIL, is reported. Possible causes:
- Defective SDCC card.
- Socketed device on SDCC card not inserted fully, or pin bent under.

Trip fault

139

CMPBDTYP

Co-motor processor (CMP) drive type mismatch


The CMP software, in SDCC sockets U36 and U37, is not appropriate for the selected drive
type (see EE.550 and EE.551, DRVTYP and ALGTYP) and the available control card hardware.
Supported types:
EE.DRVTYP = 5, EE.ALGTYP = 0
EE.DRVTYP = 5, EE.ALGTYP = 0, 100, 300
Verify EE settings, and revision and insertion of CMP PROMs U36 and U37.

Trip fault

140

CMPBDREV

Invalid CMP (U36,U37) software revision


Trip fault
The revision of the CMP software, in DCC sockets U36 and U37, is not recent enough to
support features selected by the EEROM configuration or the CMP software is not compatible
with other EPROMs on the SDCC card. Verify the EEROM is configured properly and software revision (per PROM labels and per drive test 10) is at least as high as specified revision
in MCPREV (EE.66).

141

CMP FAIL

CMP (SDCC U35) selftest failed


CMP has failed its power-up selftest. Pass/fail status of CMP is also displayed on an RS232
terminal running test 13 (] 13). Carefully check that all socketed ICs on the SDCC control
card are properly seated. The SDCC control card should be replaced if this does not correct
the fault.

Trip fault

142

CMPROMCK

CMP EPROM (SDCC U36,U37) checksum error


The CMP EPROMs are improperly programmed or have failed, and must be replaced. Ensure
they are properly seated in their sockets.

Trip fault

143

CMPBDACK

CMP bad acknowledge


The co-motor processor (CMP, U35) is not properly responding to the motor control processor (MCP). Possible causes:
- Check seating of socketed components on the control card
- Check that the software revisions in U22/U23 and U36/U37 (DCC only) are compatible
with each other
- Excessive CPU load on the MCP or CMP processor. Check EE configuration to ensure
unneeded functions are not enabled.
- Failure of DCC or SDCC control card.

Trip fault

144

CMPNOACK

CMP no acknowledge
CMP (U35) is not responding to MCP (U21). Check items listed for FLT .141, or replace the
control card.

Trip fault

145

DPRCFAIL

MCP/CMP Dual port RAM or shared RAM selftest failed


MCP has detected a failure in the U33 dual-port RAM (DCC card) or U36/U37 shared RAM
(SDCC card) during its powerup test. Pass/fail status is also displayed on an RS232 terminal
running test 13 (] 13). Possible causes:
Seating of socketed ICs on SDCC card.
- Wrong revision of PAL in socket U91 on SDCC card--must be AB or later.
- Defective DCC or SDCC card.

Trip fault

146

CMP WDOG

MCP/CMP watchdog fault


The MCP processor has detected an execution rate failure of the CMP software. Possible
causes:
- Seating of socketed ICs on SDCC card.
- Noise disturbing SDCC card due to improper wiring practices.
- JP33 not in 1-2 position.

Trip fault

10-20

BI006008

GF2000 Dc G

erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Fault Condition, Causes

Type Fault

147

MCP Diagnostic Circular List latch annunciation


Indicates that the MCP Diagnostic Circular List has latched to the frozen state. The information preserved in the buffer may be interrogated via the drive serial link (see EE.600).

Non-latched
annunciated
fault

148

Trip fault
Serial absolute encoder communications watchdog
The absolute encoder function via the serial interface on the SPC card is enabled by
MCNFIG.12 (EE.570), but no serial communications have been received for 150 milliseconds. Possible causes:
- Hardware not setup properly: DCP JP31 2-3; SPC.SW.1.7 off
Encoder connected to + 15 volts, common, 1TB.13 and 1TB.14
- Encoder failure, not sending serial information
- Failure in SPC card or ribbon cable 7PL pins 19 or 20
For the BEl serial encoder with the D 17 interface, hook-up is as follows:
BEl terminal
Drive terminal
1TB-13 RXN (SDCC card)
A
TXD
1TB- 14 RXP (DCC card)
ITXD
HB- 13 RXN (DCC card)
1TB-14 RXP (SDCC card)
B
I
CKT GRND
3TB-66 COM
+ 15 V dc
3TB-62 + 15
P
J
CHASSIS
Note that connections to 1TB depend on which drive control card is installed, either DCC
or SDCC. Connect U to V to set the Baud rate to 2400. Connect L to I get increasing
counts for CCW rotation, or connect L to P to get increasing counts for CW rotation.
Other Baud rates (not currently supported by the drive) are: Q-R, 19200; S-R, 9600; and TU,4800. See also FLT.149.

149

Serial absolute encoder communications error


The absolute encoder function via the serial interface on the SPC card is communicating
with the drive, but the character or message error rate is excessive (more than 1 bad message for every 10). Possible causes:
- Baud rate set incorrectly on encoder--should be 2400
- Wrong polarity on RXP/RXN (1 TB.14113)--for DCC card, need RXP mostly plus write
RXN; for SDCC card, RXN should be mostly plus (see FLT. 148)
- Excessive noise pickup due to routing of RXP/RXN twisted pair or power.
See also FLT.148.

Non-latched
annunciated
fault

Field #B current feedback loss


The field current has fallen below the limit set by EE.1 564, FLBLSO.
Possible causes:
Field #B enabled (EE.570.9), but not installed
Blown field fuse.
Field connections loose or incorrect.
FLBLSn set too high. Set at least 25% below FLDMNn, EE.1 566.
FLBECn set too low.
Field reference blocks set incorrectly (BLK.259 or 300).
Field feedback gain set incorrectly.
Field #B regulator gains too low.
This fault can be inhibited by setting EE.1 564 to 0, or inhibiting field #B via EE.570.9.
Beginning with revision 6.31, IFLDBFB (VAR.1 091) (or FLDFB, VAR.1 05 if Field #A is disabled and Field #B is enabled via EE.5300.0) is normalized by the flux saturation curve
defined by EE.1568-EE.1575. However, FLOB LOS uses UN-normalized field feedback to
detect a fault and can compared to the field loss limit (FLBLSO) by viewing IF2FB,
VAR.1029.

Trip fault

Field #B timed overcurrent


The field current has exceeded the reference by an amp-seconds rating defined by
EE.1565, FBTOCO.
Possible causes:
Field SCR(s) shorted.
Field regulator unstable or running in voltage regulated mode.
FTOCGn set too sensitive.
Excessive field forcing through BLK.259 or 300 (VAR.165).
Field SCR firings are inhibited when this fault occurs.
Beginning with revision 6.31, IFLDAFB (VAR.1 090) (or FLDFB, VAR.1 05 if Field #A is disabled and Field #B is enabled via EE.5300.0J is normalized by the flux saturation curve
defined by EE.1568-EE.1575. However, FLDB_TOC uses UN-normalized field feedback to
detect a fault which is typically equivalent to IF2FB, VAR.1 029.

Trip fault

165

166

Name

FLOB LOS

10-21

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

167

Fault Condition, Causes

Type Fault

Field #B undercurrent tracking


The field current has remained below the field command by at least 15% of rated for more
than 5 seconds.
Possible causes:
Field #B enabled (EE.570.9), but not installed
Hot field. Unable to achieve commanded current.
Field regulator unstable. Check tuneup.
See also FLT.165, FLDB_LOS.
Set EE.571.0 to inhibit field tracking for both field #A and #B.
Beginning with revision 6.31, IFLDBFB (VAR.1 091) (or FLDFB, VAR.1 05 if Field #A is disabled and Field #B is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568-EE.1575. FLDB_TRK uses this normalized field feedback to detect a fault.

Filtered fault

Non-latched
annunciated
fault

168

IA2 OFST

DCFB card IA2 shunt VCO zero offset too high


While the drive is stopped (no current flowing in the shunt!. it has measured more than 5%
current, indicating an excessive zero offset in the current feedback isolator IA2 on the
DCFB. Detection of this condition can be overridden by EE.571.4, MFLTJP.
Possible causes:
- IA2 connected incorrectly at shunt or plug on DCFB.
- Second shunt enabled via EE.1501.2, but not connected.
- Twisted pair from shunt picking up noise. Route away from power leads and twist pair
tighter.
- Failure in the current feedback isolator on the DCFB.

169

VM1 OFST

DCFB armature voltage (VM 1) feedback VCO zero offset too high
Non-latched
During power-up, or while the drive has stopped if EE.570.5, MCNFIG, is set, a zero offset
annunciated
greater than 5 % has been detected in the VM 1ANM 1B armature voltage sensor circuitry on fault
the DCFB. Possible causes:
- EE.569 is set beyond its range (SDCC/DCFB combination only).
- EE.569 is set to improper value. Run test 14 to set automatically.
- EE.570.5 is set and drive can be externally rotated while stopped.
- Failure of DCFB.
- Wiring error in connection of armature signals (VM 1AlB) to feedback interface card.
Detection of this condition can be overridden by EE.571.5, MFLTJP.

187

CFB POL

Dc (armature) shunt polarity reversed


The drive has measured a 20% reverse current while firing the forward bridge or a 20%
forward current while firing the reverse bridge. Possible causes and solutions:
- Run cell test (12) to confirm fault (revision 1.50 AF or later). Note in DCFB dual shunt
applications, cell test reports this fault regardless of whether shunt IA1 or IA2 is
backwards, so both shunts should be checked.
- DPRL wired backward at shunt or plugged in backward on SDCI/DCFB.
- Gate lead plugs connected to wrong SCRs.
- Twisted pair from shunt picking up noise. Route away from power leads and twist
pair tighter.
- Failure in the current feedback isolator on the SDCI/DCFB.
- During cell test on multibridge drives, if a cell is shorted, it is possible for reverse current
to flow in a shunt. Inhibit this fault and run cell test again to locate the shorted SCR.
Detection of this condition can be overridden by EE.571.3, MFLTJP.

Filtered state

188

FLO OFST

Field current feedback VCO zero offset too high


During power-up, a zero offset greater than 5% has been detected in the field current sensor circuitry on the SDCIIDCFB. Field firing is inhibited and the drive makes additional offset
measurements. If the excessive offset was actually due to a decaying field current, when
the current decays, the fault will automatically clear if the offset returns to normal. Reporting of an excessive offset and the concurrent field firing shutdown can be inhibited by
EE.571.4, MFLTJP. The maximum erroneous offset due to a decaying field under these
conditions is 5% of rated. Possible causes:
- Drive came out of a hard reset before field decayed. Hold reset button closed for ten
seconds before releasing and see if fault clears.
- JP1, JP2, or P3 on DCI not set correctly.
- Failure of SDCI/DCFB.
- For SDCC, U31 date codes ~ 9420 may require DCP revision ~ 5.10.

Non-latched
annunciated
fault

10-22

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

189

VFB OFS

Bridge or armature voltage feedback VCO zero offset too high


During power-up, or while the drive is stopped if EE.570.5, MCNFIG, is set, a zero offset
greater than 5 % has been detected in the bridge (P1/P2) voltage sensor circuitry on the
DCIIDCFB/SDCI. Possible causes:
- EE.574 is set beyond its range.
- EE.574 is set to improper value. Run test 14 to set automatically.
- EE.570.5 is set and the drive can be externally rotated while stopped.
- Failure of the DCI/DCFB/SDCI.
- Open or intermittent connection on pins 25 or 26 of ribbon cable 5PL.
- Wiring error in connection of armature signals (P1/P2) to feedback interface card.
Detection of this condition can be overridden by EE.5711.5, MFLTJP.

Non-latched
annunciated
fault

190

IDISC FL

Discontinuous current sensor failure, stuck discontinuous


The discontinuous current sensor is not detecting any armature current when CFB is actually greater than 1 pu. On the DCI card, this sensor is a hardware circuit which looks at
CFB, and is only used with the DCC control card standard current regulator and only prior
to revision 2.20. On the DCFB, or when a DCI is used with the SDCC, or when the enhanced current regulator is used (EE.570.2L or after revision 2.17, discontinuous current is
determined using the VFB signal. Possible causes of this fault:
- Circuit failure on DCI/DCFB.
- Routing, twisting, or installation of shunt to DRPL wiring.
- Failure or low scaling of VFB circuit (revision 2.20 or later).
Detection of this fault can be inhibited by setting EE.571.2. It is recommended that
EE.571.1 be set if the enhanced current regulator is enabled and the MP firmware revision
is less than 2.20.

Filtered fault

191

ICONT FL

Discontinuous current sensor failure, stuck continuous


When the drive is stopped, the discontinuous current sensor is reporting armature current.
Possible causes:
- Dc shunt installed incorrectly or connections loose.
- Routing of twisted pair from the shunt to DRPL on the DCI. Twist the pair tighter and
route away from noisy wiring.
- DRPL plugged in incorrectly or loose.
- Current feedback isolator failure on the DCI.
- Failure or high scaling of VFB circuit (revision 2.20 or later).
Detection of this fault can be inhibited by setting EE.571.2. Please refer to additional help
at FLT.190.

Filtered fault

192

DIMETRIC

Diametric (dc bus shoot-through) fault


The drive has shutdown because it detected an SCR bridge diametric fault. During the first
45 degrees after each firing, the average dc voltage is sampled over three intervals of approximately 15 degrees each. If the sum of these voltage magnitudes is less than
EE.DIMTRC, and the average dc current (VAR.CFB) is greater than 15 percent, then fault
192, DIMETRIC, is reported. Possible causes:
- Shorted SCR. Run cell test (test 12).
- EE.588, DIMTRC, setting is too high.
- A commutation failure occurred but was not detected. Check EE.581.
When this fault is detected, armature and field SCR firings are immediately inhibited (no
phase-back occurs first).

Trip fault

10-23

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued

No.

Name

Fault Condition, Causes

Type Fault

193

VARMTRCK

Mismatch of bridge and armature voltage feedback signals from DCFB


Voltage feedback variables VARM and VBRIDGE from the DCFB have differed by more than
20% for 360 firings while the MD contactor is supposed to be closed.
Possible causes:
- VM1A/B on DCFB not connected to motor armature.
- P1 AlB on DCFB not connected to SCR bridge output.
- DIP switches scaling for P1 A/P2A (SW4) and VM1 AlB (SW5) on the DCFB not set to
same voltage range.
- MD contactor not closing when it should.
- Impedance added between the bridge and the armature is dropping more than 20%
voltage. If this is ok, inhibit FLT.193 via EE.571.14.
- Failure of VCOs on the DCFB or VCO counters on the SDCC.
- VCO counters not loaded in LCA logic due to invalid value in EE.1 .5.
- Revision of DCP is less than 2.32.
Detection of this condition can be overridden by EE.571.14, MFLTJP. Also see EE.570.11.

Trip fault

194

HDWRTYPE

Mismatch of firmware settings and drive hardware detected


The drive has detected a discrepancy between firmware configuration jumpers and actual
hardware installed. Possible causes:
- DCFB detected at 1PL, but SDCI selected via EE.573.0.
- Field #B enabled (EE.570.9) without DCFB or with field #A in the 2/3 wave mode
(EE.5 73.2).
- Multibridge enabled (EE.607.0) without DCFB or while not in simulatormode.

Trip fault

195

DCFBFAIL

DCFB logic cell array failure


The feedback signal from the DCFB to the SDCC indicates that the programmable logic
device on the DCFB has failed to configure itself on power-up. Possible causes:
- Configuration PROM or LCA on DCFB missing, failed, or not fully seated.
- Failure of 1PL ribbon cable (pin 28 should go low after initialization).
Failure of the DCFB.
Inhibit this fault by setting EE.571.12 (weight 4096).

Trip fault

196

LEG_LOSS

Ac leg current low or imbalanced


Possible causes:
- EE.584 or 585 set too sensitive.
- Blown leg fuse or open SCR or gate lead. Run cell test.
- Ac line phase imbalance.
- Erroneously reported by software revisions prior to 1.51.
- Logic current limit (EE.1508) set near or below current limit.
A setting of 0 in EE.585, LEGSEN, inhibits FLT.196.

Trip fault

197

OVERV MB

Instantaneous overvoltage for motor #B


The armature voltage connected to DCFB (only) analog voltage input VM2A has exceeded
the limit set by EE.606, MBOVLT. This voltage could be either the GF2000 motor voltage,
or motor #B in a dual-motor (parallel) application. Possible causes:
- VM2A not connected to a valid voltage feedback.
- VM2A not scaled properly via EE.1 524. VM2SFO.
- Fault input connected to VMA1 instead of VMA2, per EE.573.5.
- See help for FLT .19 for additional causes.

Filtered fault

10-24

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

198

FIELDTRK

Field undercurrent tracking


The field current has remained below the field command by at least 15% of rated for more
than 5 seconds. Possible causes:
- Hot field. Unable to achieve commanded current.
- Field regulator unstable. Check tuneup.
- See FLT.4, FIELDLOS.
Wrong field mode (2/3, NRP, or NRX) selected via EE.573.2.
- For SDCC, U31 date codes ~ 9420 may require DCP revision ~ 5.10.
Set EE.571.0 to inhibit field tracking.
Beginning with revision 6.31, IFLDAFB (VAR.1090) (or FLDFB, VAR.105 if Field #A is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568EE.1575. FIELDTRK uses this normalized field feedback to detect a fault.

Filtered fault

199

lac RVRS

Reverse bridge instantaneous overcurrent


The bridge current in the reverse direction as sampled by the dc shunt has exceeded the
limit set by EE.1527, 10CRVO. Possible causes:
lac set too low. Check 10CRVO (EE.1527).
- See other causes listed for FLT.1.

Trip fault

200

lac MTRB

Armature instantaneous overcurrent for motor #B (DCFB only)


Trip fault
The armature current as sampled by the dc shunt IA2 (DCFB only) has exceeded the limit set
by EE.1529, 10CMBO. Possible causes:
- lac set too low. Check 10CMBO (EE.1529).
- Shunt IA2 not connected to a valid current feedback signal.
- Shunt IA2 not scaled properly (EE.1521, CF2SFn).
- CF2SFn (EE.1521) set too low, causing saturation of the hardware.
- See other causes listed for FLT.1.

201

lac ARM

Armature instantaneous overcurrent


The armature current as sampled by the dc shunt has exceeded the limit set by EE.1525,
10CARO. Possible causes:
- lac set too low. Check 10CARO (EE.1525).
- See other causes listed for FLT. 1.

Trip fault

202

SYINLOSS

Loss of ac line sync input


The SYNC signal on the DCI/SDCI/DCFB is not tracking an appropriate ac line frequency.
Possible causes:
- Bridge power which connects to power supply card not turned on. Check L 1/L2/L3 inputs
to card; for DCFB also DIP switch settings.
- Line or power supply card fuses are blown or missing. (Check MOVs).
- Failure of SDCI/DCI or 1PL (pin 29). Verify line frequency TTL signal at TP29 on
DCC/SDCC.
- Misconfiguration of PLL configuration. Ccheck EE.570.3 and EE.572.4, 6, & .10
all normally O. Verify EE.570.4.
- Excessively noisy, notched, or unbalanced ac line.
- Failure of 15 volt power supplies.
- Failure of LAN power supply or SPCB, misconfiguration of multibridge master or follower
drive (EE.572).
- On revision 1.40 and earlier, this fault is erroneously reported and should be inhibited via
EE.571.7.
Presence of ac line sync is essential for proper field and armature operation, even in the
simulator mode, as the PLL and field regulator do not operate in the absence of this input.
Beginning with revision 5.31, field and armature SCR firings are inhibited when this fault
occurs.
Beginning with revision 5.36, for DC2000 only, this fault requires a hard reset to clear. For
revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.

Trip fault

203

NO BURST

SYOSC (synchronized firing burst generator) failed


The pulse train from the oscillator used to form the SCR firing bursts is missing. This signal
should appear on 1PL-14 as a 20% duty cycle, 25 kHz, TTL waveform. Possible causes:
- Failure of U61 or U27 on the SDCC. Replace SDCC.
Failure of ribbon cable 1PL.
- Misoperation of control card due to noise or intermittent connection on control card.
Check installation of socketed components.

Trip fault

10-25

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

204

La ACFRQ

Low ac line frequency, less than 45 Hz (or phase loss)


Filtered fault
The drive is not receiving a suitable ac line sync signal from the DCI/DCFB or its frequency is
outside acceptable range. Possible causes:
- Alternator power supply (if used) not maintaining line frequency.
- Fuses blown on the interface card. Check MOVs.
- Excessive ac line phase imbalance or notching.
Nuisance fault due to software error prior to revision 1.20.
See additional items under FLT.202.1.
This fault can be overridden by EE.571.1 O. Beginning with revision 5.31, field and armature
SCR firings are inhibited when this fault occurs.

205

HI_ACFRQ

High ac line frequency, greater than 70 Hz (or phase loss)

Filtered fault

206

AC GT DC

Ac current exceeds dc current trip


The magnitude of ac current transformer current, VAR.1 019, CTCFB, has exceeded the
magnitude of dc shunt current, VAR.1 04, CFB, by the trip threshold, EE.1519, ACGDCn.
Possible causes:
- Improper CT burden selection on the DCI/DCFB.
Improper scaling of CTCFB via EE.1520, CTTRMn.
- ACGDCn, EE.1519, set too low.
- Too much circulating ac current or bridge fault.
This fault may be inhibited by setting EE.1519 to O.

Trip fault

207

CT OFSET

High ac current transformer offset read when current should be 0


A reading of over 250% current has been read on one of the current transformers when the
drive is not firing SCRs. Possible causes:
Open or intermittent connection on pins 1 or 2 of ribbon cable 1PL.
- Failure of CT interface circuitry on the DCI/DCFB.
- Failure of DCC/SDCC.
This fault may be inhibited by setting EE.581 to 32767.

Trip fault

208

IL1 LOSS

Ac current transformer IL1 too low at given CFB level


Possible causes:
ICPL on DCI/DCFB not connected.
CTs not burdened correctly.
- (Non-regenerative only) Fault must be inhibited via EE.587.
- EE.587 set too low.
- Leads swapped in CT connector, ICPL, on SDCI/DCFB card. Compare VAR.1 04 and
VAR.1 019 for same polarity and magnitude. Use burden switches for coarse adjustment,
EE.1520 for fine.
- For early revisions, see note under EE.587 and increase EE.587.
This fault may be inhibited by setting EE.587 to O.

Trip fault

209

IL3 LOSS

Ac current transformer IL3 too low at given CFB level

Trip fault

210

CT POLAR

Ac current transformer IL1 or IL3 polarity reversed


Possible causes:
- Leads swapped in CT connector, ICPL, on SDCI/DCFB card. Compare VAR.1 04 and
VAR.1 019 for same polarity and magnitude. Use burden switches for coarse adjustment,
EE.1520 for fine.
- CTs improperly burdened on DCI/DCFB.
Gate leads connected to wrong SCRs.
- Hardware too sensitive prior to 531 XDCIANG1/AJG2 revision.
- For early revisions, see note under EE.587 and set EE.571.8.
Once CTs are known to be wired correctly, this fault may be inhibited by setting EE.571.8.

Trip fault

211

CFB LOSS

CFB too low at given ac current transformer level


Possible causes:
- CTs not burdened correctly. Set burdening to a higher horsepower.
- EE.586 set too low.
- Leads swapped in CT connector, ICPL, on SDCI/DCFB card. Compare VAR.1 04 and
VAR.1019 for same polarity and magnitude. Use burden switches for coarse adjustment,
EE.1520 for fine.
- Nuisance trips due to hardware/software sensitivities prior to 302DCIANG1/AJG2,
302DCCAMG1, and 1.60 lAG) revisions. Increase EE.586 by up to 2:1 to
desensitize (see note under EE.587).
This fault may be inhibited by setting EE.586 to O.

Trip fault

10-26

Type Fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

212

HSO OVF

Internal armature firing circuit failed


Fault 212 indicates an internal software overflow in the high speed output buffer.
Possible causes:
Software malfunction due to noise or intermittent connection on 301 DCC. Check
external signal wiring practices, installation of socketed components, ribbon
cables, and low voltage power supplies.
Armature current regulator bandwidth set higher than software is able to achieve.
Try reducing bandwidth.
For K/L frame (multibridge) follower drives, the master drive was hard reset, causing
the follower to lose synchronization.
- Inappropriate PLL selection (EE.570.4) or gain (EE.575-577).
- Loss of sync signal, see FLT.202 (SYINLOSS) possible causes.
This fault may be inhibited via EE.571.9. Field and armature SCR firings are inhibited when
this fault occurs.
For revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by
invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.

Locked fault

213

CTSTFAIL

Cell test failed to determine the state of the SCRs due to setup
Cell test detected a short during one pass and an open circuit during the other pass, and
thus was not able to reliably determine the bridge health. Possible causes:
- The cell test configuration parameters (EE.1577 - EE.1579) are all set too low for
adequate signal-to-noise margins, and must be raised.
- Failure of the CFB and/or VFB sensing circuitry (DCI/DCFB).
- Excessive noise in CFB and VFB due to poor wiring or loose connections.

Trip fault

214

CTST_VFB

Cell test detected too much armature voltage at startup


At the beginning of the short circuit test, VFB was greater than 5% and the SCRs cannot
be reliably tested. Possible causes:
- The motor was rotating when cell test was invoked.
- Dc contactor not closing, or longer MAPDLY time needed (EE.39).
- Excessive offset in the VFB circuitry (See EE.574).
- Failure in the VFB sensor or connections (DCI/DCFB).
- Excessive leakage in the bridge snubbers or SCRs, coupled with an open armature
loop (especially if dc contactor is used).
This fault may be overridden by setting EE.571.11.

Trip fault

215

VFB FAIL

Cell test detected a low or reverse armature voltage


During the open circuit test, VFB magnitude or polarity was incorrect. Possible causes:
- Reversed or open connections of armature to power connect card.
- Open connections in ribbon cable 5PL pins 25 or 26.
- Open circuit test firing angle too low -- increase EE.1577.
- Failure in VFB circuitry on control card or power supply card.
- Revision 1.90 only: Erroneously reported during cell test in simulator.
This fault can be overridden by setting EE.571.11.

Trip fault

V12 or V13 feedback VCO zero offset too high


The DC offset in DCFB signals V12 and V13 are continuously computed. FLT.221 is generated if a zero-offset greater than 3% has been detected in one or both of these signals.
Possible causes:
- Failure of DCFB card or ribbon cable 1PL.
- Wiring error in connection of signals (V11V2N3) on DCFB card
- Excessive coupling of common mode noise into floating commons of DCFB card via
feedback connections due to poor cable routing.
Detection of this condition can be overridden by EE.1500.15, MJPROO. Effective revision
4.35.

Non-latched
annunciated
fault

221

10-27

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

222

liNT SAT

Enhanced current integrator saturated (DRVTYP = 85)


The enhanced current regulator integrator has remained saturated (reached the limit,
ILiMcO EE.1581) for 60 firings in a row. Detection of this condition is enabled by setting
EE.6283.2 (MCFGJP). Possible causes:
Voltage feedback is scaled incorrectly. Check EE.1503 (VFBSFO) and hardware jumpers on the DCI/OCFB card for correct scaling.
Ac voltage input is NOT actually within the nominal range indicated by the data used
to calculate the integrator limit (ILiMcO, EE.1581).
EE.1581 (ILiMcO) is still set too low even though the above two conditions are OK.
Voltage feedforward gain tuned too low, check EE.1585 (WVFBcOl, EE.1586
(GVFFcOl, and EE.1594 (HIRCPO).
(Simulator only) EE.ARMRES, ARM_TC. or EE.IOCTRn set too low.

Non-latched
annunciated
fault

223

ILP OPEN

Enhanced current integrator saturated at CFB less than 5 % (DRVTYP = 85)


The enhanced current regulator integrator has remained saturated (reached the limit,
ILiMcO EE.1581) for 60 firings in a row and armature current has remained less than 5%.
Detection of this condition is enabled by setting EE.6283.0 (MCFGJP). By setting
EE.6283.1, this fault can be changed from an brief annunciated fault (does not stop the
drive) to a trip fault. Possible causes: [4.41]
Voltage feedback is scaled incorrectly. Check EE.1503 (VFBSFO) and hardware
jumpers on the DCI/DCFB card for correct scaling.
EE.1581 (ILiMcO) is set too low.
Voltage feedforward gain tuned too low, check EE.1585 (WVFBcOl, EE.1586
(GVFFcOl, and EE.1594 (HIRCPO).
Open connections or contactors in the motor armature circuit.
Open connections in 5PL, DRPL. or SCR gate leads.
DC fuse open.
(Simulator only) EE.ARMRES, ARM_TC, or EE.lOCTRn set too low.

Non-latched
annunciated
fault

Armature instantaneous over-current for motor #A


The armature current as sampled by the de shunt IA1 has exceeded the limit set by
EE.6302, IOCMAO. Possible causes:
- IOC set too low. Check IOCMAO (EE.6302).
- Shunt IA1 not scaled properly (EE.1505, CFBSFn).
CFBSFn (EE.1505) set too low, causing saturation of the hardware.
- See other causes listed for FLT. 1.

Trip fault

Motor B IA2 shunt polarity reversed (DCFB only)


Used primarily in 2-motor applications with seperate motor loops. The drive has measured
a 20% reverse IA2 shunt (DCFB only) current while firing the forward bridge or a 20%
forward IA2 shunt current while firing the reverse bridge. Possible causes and solutions:
Run Cell test (1 2) to confirm fault.
IA2 wired backwards at shunt or plugged in backwards on DCFB.
Gate lead plugs connected to wrong SCRs.
Twisted pair from shunt picking up noise. Route away from power leads and twist
pair tighter.
Failure in the current feedback isolator on the DCFB card.
During cell test on multibridge drives, if a cell is shorted it is possible for reverse current to flow in a shunt. Inhibit this fault and run cell test again to locate the shorted
SCR.
Detection of this condition can be overridden by EE.571.3, MFLTJP.

Fi Itered state

225

226

10-28

CFBB POL

BI006008

GF2000 Dc G erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

230

MBLCON G

Multibridge EE configuration error


An invalid EE configuration for multibridge exists. Probable causes:
- MBLTTL IEE.61 0) set to less than 2 drops
- MBLCFG (EE.608) A + B total drops doesn't equal MBLTTL total drops
- Cell test or torque proving activated on revisions which do not contain these features.
The configuration must be corrected and all bridges hard reset.

Non-latched
annunciated
fault

231

CTACSH T

Indeterminate shorted cell detected during SCR test


During the short circuit cell test, current was detected in either the shunt or CT, but the
voltage produced across the armature was insufficient to determined which cell was
shorted, perhaps because the EE.1578 voltage detection threshold was set too high, the
EE.1579 current detection threshold was set too low, or the EE.1580 firing angle was set
too low. Review these adjustments and repeat the cell test.

Trip fault

232

MBRGSH T

A multibridge follower detected a short in its bridge


During a cell test of the multibridge, a follower detected CT or shunt current during a
period when none of that follower's cells were being gated, indicating a shorted cell.
Normally, under such a condition, the master bridge will detect which leg (A 1 - A6) is
shorted and report a FLT.81 - 86, and the follower bridge containing the short will report
a FLT.232 to pinpoint the shorted cell.

Trip fault

233

MBBALA C

K/L frame multibridge master/follower current out of balance


A drive's current has stayed in error from the master current reference by over 50% for
over 2 seconds and the master current reference is greater than 50%. As of revision
4.35, if this fault condition persists for over 5 seconds, the fault changes from brief annunciated to trip. Possible causes:
- The drive has been stopped by a local stop command.
- The drive is not generating any current due to blown fuse, open contactor or
connection. or failure in the firing circuit hardware.
- Failure in the drive current feedback circuitry.
- For follower bridges, balance regulator gain (EE.612) set too low.
- EE.MBLTTL or MBLCFG set incorrectly in master drive(s).
Detection of this fault may be inhibited by setting EE.607.5.

Non-latched
annunciated
fault

234

MBLSCHE

K/L frame multibridge follower feedback checksum error on fiber optics


The master drive received an invalid message from a follower drive over the fiber optic
link. Possible causes:
- Two followers have the same drop number IEE.609, MBLDRP).
- Loose or bad coupling in the fiber optics, or cable crimped.
- Stray light entering fiber optics through unused MBHA connector.

Non-latched
annunciated
fault

10-29

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

235

MBLSLVRN

K/L frame multibridge follower running when master bridge is stopped


Follower drives cannot run unless the master drive is running. Possible cause:
- Follower commanded to run from Programmer or other local source when master
drive is not running.

Non-latched
annunciated
fault

236

MBLMNOEC

K/L frame master bridge did not hear its own message on the fiber optic
The master drive listens to the commands it sends to the followers on the fiber optic cable. This fault is reported if the master drive did not hear these messages. (If it hears
these messages, but they are garbled, FLT .237 is reported.) Possible causes:
- Loose or bad coupling in the fiber optics, or cable crimped.
- EE.572.3 not set.
- Failure of the MBHA fiber hub card or its power supply.
- Failure of the SPCB daughter card.

Non-latched
annunciated
fault

237

MBLMBDEC

K/L frame master bridge received a garbled echo of its own message
The master bridge cannot hear its own fiber optic transmissions correctly.
Possible causes:
- Multiple bridges programmed to be the master (EE.609, MBLDRP).
- Crimp or sharp bend in fiber optic cable.
- Stray light entering fiber optics through unused MBHA connector.

Non-latched
annunciated
fault

238

MBLMCHEX

K/L frame follower drive received a garbled message from the master
The follower bridge cannot hear fiber optic transmissions from the master correctly. Possible causes:
- Multiple bridges programmed to be the master (EE.609, MBLDRP).
- Crimp or sharp bend in fiber optic cable.
- Stray light entering fiber optics through unused MBHA connector.

Non-latched
annunciated
fault

239

MBLMLATE

K/L frame follower drive failed to receive command from master when expected
The follower drive did not hear the command from the master bridge in time, or not at all.
Possible causes:
- Follower drive not using master line sync signal (EE.572.4).
- Loose or bad coupling in the fiber optics, or cable crimped.
- EE.572.3 not set.
- Failure of the MBHA fiber hub card or its power supply.
- Failure of the SPCB daughter card.
- Master drive not powered or in reset.
Since revision 3.36, MBLMLATE will automatically clear when the master is restored if
the follower was not running when the fault occurred, provided the follower is using its
own line sync rather than the master's.

Non-latched
annunciated
fault

330

DCP FAIL

DCP selftest failed


U1 on SDCC card failed.

Trip fault

331

DCPROMCK

DCP EPROM checksum error


U11 or U12 failure.

Trip fault

10-30

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

332

Fault Condition, Causes

Type Fault

Logic cell array U32 powerup test fail


The programmable logic cell array (LCA) device U32 has failed to program correctly. Pin
55 of this device indicates programming status. After a powerup or reset, this pin should
be low. After U32 is programmed by U1, the pin should be high. FLT.332 is reported if U1
detects this pin in the wrong state either before of after programming. Possible causes:
- Defective SDCC.
- Socketed device on SDCC not inserted fully, or pin bent under.

Trip fault

333

MLCAPR G

Logic cell array U31 power-up test fail


Trip fault
The programmable logic cell array (LCA) device U31 has failed to program correctly. Pin
55 of this device indicates programming status. After a power-up or reset, this pin should
be low. Programming of this LCA is done daisy-chained with LCA U32. U32 is programmed first, then it passes programming data from U1 through it to U31. After U31 is
thus programmed by U1, the pin should be high. FLT.333 is reported if U1 detects this pin
in the wrong state either before of after programming. Possible causes:
- Defective SDCC.
- Socketed device on SDCC not inserted fully, or pin bent under.

335

DPRLFAIL

Dual port RAM between DCP and LCP on the SLCC card failed initialization test
Possible causes:
- Improper SLCC installation, including 3PL and 9PL (if used)
- Failure of SLCC card or 3PL.
(S)LCC enabled via CFGJPR (EE.1.0), but card not installed.

Trip fault

336

DPRMFAI

Dual port RAM between DCP and MCP on the SDCC card failed initialization test
Possible causes:
- Improper seating of U8, or bent IC pins
- Failure of SDCC card.

Trip fault

337

DPRUFAIL

Dual port RAM between DCP and UCP on the UCC card failed initialization test
The EX2000 uses a TCCS microapplication card connected via 3PL. This fault indicates a
failure in the SDCC card test of TCCS memory. Possible causes:'
- Improper TCCS installation.
- Failure of TCCS card or 3PL ribbon cable.
- TCCS UCC card enabled via CFGJPR (EE.1.8), but card not installed.

Trip fault

338

TRC_ANU

Timed overcurrent alarm

Non-latched
annunciated
fault

339

TRC TRIP

Timed overcurrent
Possible causes:
Motor mechanically overloaded due to load or wear.
Field current less than 85% of rated.
TRC settings too low (EE.1489, 1493, 1497).
CFGJPO.8 IEE.1498.8) is set.
Armature winding failure.
DS contactor failure (if used).
TRC@IN IEE.25) if used, is not pointed at bridge or motor current.

Trip fault

340

NOLCPDP

LCC or SLCC DPRAM not detected


LAN card not detected or not responding, or LCC detected when SLCC is required. Possible causes:
- LAN card (LCC) enabled by EE.1.0, but not installed.
- LAN card (SLCC) enabled by EE.1.1, but LCC installed instead. (Valid only if SDCC is
present).
- LCC/SLCC installed incorrectly. Check all LCC/SLCC connectors and socketed ICs.
- Failure of 3PL, LCC/SLCC card, or DCC/SDCC card.

Trip fault

341

NOUCPDP

UCC DPRAM not detected


Microapplication card not detected or not responding. Possible causes:
- Microapplication card enabled by EE.1.8 but not installed.

Trip fault

10-31

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

342

MOTOR OT

Motor Thermal Switch Fault


The input pointer MOTA@I (EE.3604l is typically pointed at the local drive liD which is
monitoring the Motor Thermal Switch. For FLTJP1.3 = 0, the sense of fault is 1 =
Faulted, 0 = No Fault. For FLTJP1.3 = 1, the sense of fault is 0 = Faulted, 1 = No Fault.
The enumerations at FLTJP1.0 select the behavior of the fault. If the fault input pointer is
not used (pointed at zero) the fault is disabled.
Possible Causes:
- MOTA@I (EE.3604) Pointed Incorrectly
- Improper sense selected by FLTJP1.3 (EE.3612.3)
- Motor is overheating

343

XFMR OT

Transformer Thermal Switch Fault


The input pointer XOT@IN (EE.3605) is typically pointed at the local drive liD which is
monitoring the Transformer Thermal Switch. For FLTJP1. 7 = 0, the sense of fault is 1
Faulted, 0 = No Fault. For FLTJP1. 7 = 1, the sense of fault is 0 = Faulted, 1 = No Fault.
The enumerations at FLTJP1 .4 select the behavior of the fault. If the fault input pointer is
not used (pointed at zero) the fault is disabled.
Possible Causes:
- XOT@IN (EE.3605l Pointed Incorrectly
- Improper sense selected by FLTJP1. 7 (EE.3612.7)
- Transformer is overheating

344

BRK_SPLY

Brake Power Supply Fault


The drive sequencing sets RLSEBRAK (VAR.814), which is sent to the brake supply, to
release the brake. The brake supply provides a feedback boolean that is wired into the
local drive 1/0 and is set when the brake supply is trying to release the brake. There is
typically a delayed comparison between RLSEBRAK and the brake supply feedback in order
to determine if the brake is responding. The input pointer BPSA@I (EE.3606) is typically
pointed at the result of this comparison for the purpose of determining a fault condition.
For FLTJP1 .11 = 0, the sense of fault is 1 = Faulted, 0 = No Fault. For FLTJP1 .11 = 1,
the sense of fault is 0 = Faulted, 1 = No Fault. The enumerations at FLTJP1 .8 select the
behavior of the fault. If the fault input pointer is not used (pointed at zero) the fault is disabled.
Possible Causes:
- BPSA@I (EE.3606) Pointed Incorrectly
- Improper sense selected by FLTJP1 .11 (EE.3612. 11)
- Brake Supply is operating improperly

345

UNKNOWNL

LCC/SLCC fault outside its valid range. Possible causes:


- Communication failure between DCC/SDCC and LCC/SLCC (noise?).
- Failure of LCP processor on LCC/SLCC card, or 3PLl9PL.

Latched
annunciated
fault

346

UNKNOWNM

MCP fault outside its valid range. Possible causes:


- Communication failure between DCP and MCP on DCC/SDCC card (noise?).
- Failure of MCP processor on DCC/SDCC card. Check seating of U21.
- Failure of U8 on DCC/SDCC card. Check seating of socketed parts.

Latched
annunciated
fault

347

UNKNOWNU

UCC fault outside its valid range


Not used yet.

Latched
annunciated
fault

348

LPROTMON

Line Protection Monitor Fault


The input pointer LPMA@I (EE.3607) is typically pointed at the local drive liD which is
monitoring the Fuse Blown indication from the LPPA/B module (LPPA E4 & E5). For more
information, see LPPA. For FLTJP1.15 = 0, the sense of fault is 1 = Faulted, 0 = No
Fault. For FLTJP1 .1 5 = 1, the sense of fault is 0 = Faulted, 1 = No Fault. The enumerations at FLTJP1.12 select the behavior of the fault. If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- LPMA@I (EE.3607) Pointed Incorrectly
- Improper sense selected by FLTJP1.15 (EE.3612.15)
- LPPA/B giving fuse blown indication

10-32

Type Fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

Bridge Thermal Switch Fault


The input pointer OTMW@I (EE.361 O)is typically pointed at the local drive I/O which is
0, the sense of fault is 1
monitoring the Bridge Warning Thermal Switch. For FLTJP2.5
= Faulted, 0 = No Fault. For FLTJP2.5 = 1, the sense of fault is 0 = Faulted, 1 = No
Fault. The enumerations at FLTJP2.3 select the behavior of the fault. If the fault input
pointer is not used (pointed at zero) the fault is disabled. Possible Causes:
- OTMW@I (EE.3610) Pointed Incorrectly
- Improper sense selected by FLTJP2.5 (EE.3613.5)
- Bridge Warning Thermal Switch failure or wrong sense
- Bridge is becoming overheated

349

350

BLOCKER

Block Compiler Error


An error in the block source list, EE.800-1022, was detected during compilation. A brief
explanatory message appears on the serial link when the compile command ("Z") is issued.

Trip fault

352

MINREVN

Software revision too low for EEROM configuration


The required revisions indicated by EE.65-66 are newer than the actual revisions reported
by test 10. Possible causes:
- OCP or MCP software revision too old for level requested in EEROM
- LCP software revision too old for level requested in EEROM (DP 0-1.87 only)
- EE.65-66 calling for wrong software revisions
- EE.67 calling for wrong software revision (OP revs 0-1.87 only)
- EE.67 must be set to 0 when OCP 1.60 is used with LCP 5.00 or higher
- Prior to revision 1.70, may indicate bad MCP (try setting EE.66 = 0)
- Hardware failure: DCC/SOCC or LCC/SLCC control cards or 3PL. Check seating of
socketed components and ribbon cables.

Trip fault

353

LCPREVNO

LCP software revision too low for EEROM configuration


The required LCP revision indicated by EE.67 is newer than the actual revision reported by
test 10. Possible causes:
- LCP software revision too old for level requested in EEROM.
EE.67 calling for wrong software revision.
- Hardware failure: DCC/SDCC or LCC/SLCC control cards or 3PL. Check seating of
socketed components and ribbon cables.

Trip fault

354

UCPREVNO

UCP software revision too low for EEROM configuration (trip)


This fault code is not presently used in the drive firmware.

Trip fault

355

THA ANUN

Motor A Thermal Model Alarm (Annunciation)


This fault occurs when the temperature state of BLK.THRMA reaches or exceeds the
square of the value set in THAALM [3568]. Possible Causes;
- Motor is too hot. Reduce motor loading before trip occurs.
- THAALM [3568] set too low.
- THATau [3567] (motor time constant) set incorrectly.
- THA@IN [3566] pointed at incorrect address.
- THA@SP [3570] pointed at incorrect address.
- THA@GS [3571] pointed at incorrect address.

Non-latched
annunciated
fault

356

THA TRIP

Motor A Thermal Model Trip


This fault occurs when the temperature state of BLK.THRMA reaches or exceeds the
square of the value set in THATRP [3569]. Possible Causes:
- Motor is too hot. Reduce motor loading.
- THATRP [3569] set too low.
- THATau [3567] (motor time constant) set incorrectly.
THA@IN [3566] pointed at incorrect address.
- THA@SP [3570J pointed at incorrect address.
- THA@GS [3571] pointed at incorrect address.

Trip fault

10-33

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

357

THB_ANUN

Motor B Thermal Model Alarm


This fault occurs when the temperature state of BLK.THRMB reaches or exceeds the
square of the value set in THBALM [3579). Possible Causes:
- Motor is too hot. Reduce motor loading before trip occurs.
- THBALM [3579] set too low.
- THBTau [3578) (motor time constant) set incorrectly.
- THB@IN [3577] pointed at incorrect address.
- THB@SP (3581) pointed at incorrect address.
- THB@GS [3582) pointed at incorrect address.

Non-latched
annunciated
fault

358

THB_TRIP

Motor B Thermal Model Trip


This fault occurs when the temperature state of BLK.THRMB reaches or exceeds the
square of the value set in THBTRP (3580). Possible Causes:
- Motor is too hot. Reduce motor loading.
- THBTRP[3580) set too low.
- THBTau (3578) (motor time constant) set incorrectly.
- THB@IN [3577) pointed at incorrect address.
- THB@SP (3581) pointed at incorrect address.
- THB@GS [3582) pointed at incorrect address.

Trip fault

Link Presence Fault


Some drives are implemented such that an 105 is the master of the drives functions. The
drive may want to take corrective action through the fault mechanism if the Master 105
drops off line. Auxcmd's can provide a Link Present bit from the Master lOS and L1NK@1
(EE.3611) would typically be pointed at the appropriate Auxcmd. For more information.
see EE.AUXCMA,B.C,D.
For FLTJP2.9 = O. the sense of fault is 1 = Faulted. 0 = No Fault.
For FLTJP2.9 = 1. the sense of fault is 0 = Faulted, 1 = No Fault.
The enumerations at FLTJP2.6 select the behavior of the fault.
If the fault input pointer is not used (pointed at zero) the fault is disabled.
Possible Causes:
- L1NK@1 (EE.3611) Pointed Incorrectly
- Improper sense selected by FLTJP2.9 (EE.3613.9)
- Link Presence detection indicates fault
- Data link communication to lOS lost
360

TESTWRUN

361

362

363

10-34

CTST TIM

Tests 12-19 commanded while drive is already running


Drive must be stopped before a tuneup. cell test, or board test can be initiated from any
source.

Non-latched
state

Cell test inhibited (See EE.2.4)


The cell test or torque proving operations have been invoked although cell test has been
disabled by EE.2.4. Some applications, such as elevators, may require special external
control sequences before cell test should be allowed.

Trip state

Cell test response timeout


The start/stop sequencer timed out waiting for the motor control processor to complete a
cell test/torque proving cycle. Possible causes:
- Failure of DCC/SDCC MCP processor due to noise or intermittent card or IC socket
connection--check U22/U23, etc.
- (DC2000) Line sync power removed then reapplied without a hard reset

Trip fault

No process response to enable request


Blockware or motor control processor has not responded to a request by the start/stop
sequencer. Possible causes:
- CORE block not programmed correctly.
- Other MCP faults exist but are inhibited by EE.4.1 O.

Trip fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

364

PROC_TR

No process response to a regulate torque request (see FLT.363)

Trip fault

365

SS LOGIC

Illegal start/stop sequencer logic state.


This fault indicates the drive's sequencing logic has reached an undefined state, due to a
failure in the DCC/SDCC card firmware.

Trip state

366

MCONOPE

M contactor reporting open/closed when it should be open/closed


Trip state
For DCC, the drive has been commanded to start, and has requested that the main contactor close, but ten seconds have elapsed and the feedback variable, MACLOSFB
IVAR.823), which indicates the status of the contactor, indicates it has not closed. Note:
From revision 1 .82 to 1.91. this fault did not trip the drive.
For SDCC, revision 2.22 to present, the commanded main contactor states (MDACLOSD.
VAR.823 and MDBCLOSD, VAR.766) do not agree with the actual states (MACLOSFB,
VAR.823 and MDBCLSFB, VAR.765) or simulated contactor states. See EE.1498.4 and
VAR.761.
Possible causes:
- MACLOSFB not pointed to contactor input via EE.295, MCLS@1.
- Failure in contactor, wiring, or pilot relay.
- For SDCC, MDBCLSFB not pointed to contactor input via EE.244, MBCL@1.
- For SDCC. MAPDLY, EE.39 set too short.
This fault can be inhibited by FLTJPR.4 IEE.4) beginning with revision 2.31.

367

FAN LOSS

Normally closed "loss of fan" interlock is open


Possible causes:
- Failure of cooling fan(s}, blower fuses, etc.
- Improperly selected source of FAN LOSS (EE.296).
- External interlock from fan open or-improperly connected.
This fault can be changed from an alarm to a trip via FLTJPR.2 (EE.4).
Beginning on revision 4.35, this fault is affected by the fault power-up timer. See EE.36
FUPDLY and VAR.819 FTPUPTIM.

Filtered state

368

OVERTEMP

Normally closed "overtemperature" interlock is open


Possible causes:
- Overheating due to loss of blower, clogged air filters, etc.
- Improperly selected source of OVERTEMP (EE.297).
- External interlock from thermal sensor open or improperly connected.
This fault can be changed from an alarm to a trip via FLTJPR.3 (EE.4).
Beginning on revision 4.35, this fault is affected by the fault power-up timer. See EE.36
FUPDLY and VAR.819 FTPUPTIM.

Filtered state

369

MCONALR

Main contactor feedback alarm


This fault occurs when the contactor feedback status while running does not agree with
the commanded contactor state. Possible causes:
- EE.295. MCLS@I, or EE.244 not pointed at valid contactor status.
- EE.39, MAPDLY, set too short for actual contactor timing.
- EE.45, AUXDLY, set too short for contactor debouncing.
- Failure in contactor coil driver wiring or circuitry.
- Failure in contactor auxiliary contact feedback wiring.
After revision 2.30, this fault can be inhibited by FLTJPR.4 (EE.4).

Non-latched
annunciated
fault

370

REVSPEED

Speed feedback reports reverse speed


This fault is generated when the value of the boolean pointed to by REVS@I IEE.298) is
TRUE. Possible causes:
- Improper address in EE.298.
- SFB shows rotation opposite to that of the speed command.

Trip fault

371

MOPENRUN

RUN request received before main contactor has been closed


This fault occurs when EE.MCRQ@I is not pointed at zero (indicating that the con-tactor
is being controlled externally). EE.SEQJPR.4 is set (indicating that RUN requests should
not be accepted if the contactor has not been closed), VAR.MACLOSED is false
(indicating the contactor is not closed), and a RUN request is received.
Possible causes:
- External start logic sequencing is incorrect.
- EE.SEQJPR.4 is set incorrectly.

Non-latched
state

10-35

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


Fault Condition, Causes

Type Fault

DCP general execution fault


Indicates that execution of the foreground module is overflowing the basic execution period
and is doing so to such an extent as to severely limit execution of the background module.
Detection of this condition trips the drive and resets the block interpreter, so that recompilation (or hard reset) is required in order to re-activate the functional block structure.
This fault indicates that the scheduled functions severely stress the execution capabilities
of the DCP CPU, so that adjustment of the source list is almost certainly required.

Trip fault

DCP foreground execution fault


Indicates that execution of the foreground module is overflowing the basic execution period
at a moderate rate. This fault indicates that the scheduled functions somewhat stress the
execution capabilities of the DCP CPU, so that adjustment of the source list may be required. This fault can be inhibited by FLTJPR.5 (EE.4).

Non-latched
annunciated
fault

374

DCP background execution fault


Indicates that average execution rates of the background modules are falling below acceptable levels. See VAR.514-516 for algorithm details. Possible causes:
- Too much foreground loading (block sourcelist loading)
- Too much background loading (winder, serial link, etc.)
This fault can be inhibited by FLTJPR.5 (EE.41.

Non-latched
annunciated
fault

375

Internal DCP watchdog time-out (annunciated). The DCP processor has detected an execution rate failure of the foreground software in the DCP. DCP background increments a byte
(DPRM_DCPF_WDOG) approximately 11 times per second. MCP background also increments this byte, about 22 times per second. DCP foreground resets this byte to zero about
90 times per second. If DCP background ever sees this byte larger than 50, it generates
fault 375. See related FLT.135. Refer to FLT.134 for possible causes.

Latched
annunciated
fault

No.

Name

372

373

DCP FRGD

376

LCP WDOG

DCP/LCC watchdog time out


Trip fault
Failure of watchdog between the drive control processor (DCP) and the LAN control processor (LCP). If LCP is enabled (CFGJPR.O), DCP monitors a byte from LCP every 89 milliseconds. If it is equal to 165, DCP resets a counter, otherwise DCP increments the counter.
Fault 376 is generated by DCP if the counter ever reaches 10. DCP sets the byte to 85 to
allow LCP to verify that DCP is functioning. Possible causes:
- Failure in 3PL or 9PL cable.
- Failure of LCC/SLCC card.
- Failure of DCC/SDCC card.
This fault can be inhibited by FLTJPR.9 (EE.4).

377

MCP WDOG

DCP/MCP watchdog time out


The DCP has detected an execution rate failure of the background software in the MCP.
MCP background monitors a byte (DPRM_DCPB_MCPB_WDOG) 22 times per second, and if
it is positive, MCP resets it to O. DCP background increments the byte 11 times per second, and generates fault 377 if it ever gets up to 100 counts. See related fault 134.
Possible causes;
- U22/U23 installed incorrectly (interchanged, backwards, bent pins).
- JP22 on DCC/SDCC card (near crystal X1) not installed.
- U21 failed.
- Failure of DCC/SDCC card
- U22/U23 defective.
- U21, U22, U23, U8 or other socketed parts not fully seated.
- Excessive noise on DCOM bus interfering with DCC/SDCC card.
This fault can be inhibited by FLTJPR.11 (EE.4).

10-36

Trip fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

378

MCPFWD G

MCP foreground watchdog time out


The DCP has detected an execution rate failure of the MCP foreground software. DCP
background increments a byte (DPRM_MCPF_WDOG) about 11 times per second. MCP
background also increments this byte. about 22 times per second. MCP foreground resets
this byte to zero about 360 times per second. If DCP background ever sees this byte larger
than 100, it generates fault 378. See related fault 136. Refer to FLT.134 for possible
causes. This fault can be inhibited by FLTJPR.11 (EE.41.

Trip fault

379

UCP WD

DCP/UCC watchdog time out

Trip fault

380

BAD HEX

Bad records in hex download file from LAN or serial link


During a hex ASCII download to EEROM, a record with a bad length, address, record type,
or checksum was received, possibly due to noise corruption. Only record types 0 (data
record) and 1 (end of file record) are allowed. Possible causes:
- Bad hex file
- More than 5 seconds elapsed between successive download records
- Time-out waiting for end of file record (revision 1.71 to present)
Noise. Try again with drive stopped, or use isolated serial hook-up.

Latched
annunciated
fault

381

EECKSM1

Bad page 1 EE checksum (EE.256 - EE.511)


See FLT.13.

Latched
annunciated
fault

382

EECKSM2

Bad page 2 EE checksum (EE.512 - EE.767)

Latched
annunciated
fault

383

EECKSM3

Bad page 3 EE checksum (EE.768 - EE.1 023)

Latched
annunciated
fault

384

EECKSM4

Bad page 4 EE checksum (EE.1 024 - EE.1279)

Latched
annunciated
fault

385

EECKSM5

Bad page 5 EE checksum (EE.1280 - EE.15351

Latched
annunciated
fault

386

EECKSM6

Bad page 6 EE checksum (EE.1536 - EE.1791)

Latched
annunciated
fault

387

EECKSM7

Bad page 7 EE checksum (EE.1792 - EE.2047)

Latched
annunciated
fault

388

EECKSM8

Bad page 8 EE checksum (EE.2048 - EE.2303)

Latched
annunciated
fault

389

EECKSM9

8ad page 9 EE checksum (EE.2304 - EE.2559)

Latched
annunciated
fault

390

EECKSM1

Bad page 10 EE checksum (EE.2560 - EE.2815l

Latched
annunciated
fault

391

EECKSM11

Bad page 11 EE checksum (EE.2816 - EE.3071)

Latched
annunciated
fault

10-37

BI006008

GEH-6148

GF2000 Dc Generator Field Exciter


Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued

No.

Name

Fault Condition. Causes

Type Fault

392

EECKSM12

Bad page 12 EE checksum (EE.3072 - EE.3327)

Latched
annunciated
fault

393

EECKSM13

Bad page 13 EE checksum (EE.3328 - EE.35831

Latched
annunciated
fault

394

EECKSM14

Bad page 14 EE checksum IEE.3584 - EE.38391

Latched
annunciated
fault

395

EECKSM15

Bad page 15 EE checksum IEE.3840 - EE.40151

Latched
annunciated
fault

396

EEBADSIZ

EEROM U9 is the wrong size part for SDCC


The SDCC requires a larger EEROM (28c2561 than was used on the DCC 128c641. The
drive has detected the wrong part in socket U9 of the SDCC. Possible causes:
- The wrong part is installed in U9.
- The first and second EEROM pages of a valid U9 contains identical data. Change any
EEROM location. then hard reset to see if this corrects the fault.

Locked fault

To replace a DCC with an SDCC and keep the DCC configuration, either use ST2000 to
load your configuration into the new SDCC EEROM or use the following commands using a
PC with a program which can communicate serially with the drive via COMPL. and which
can upload and download files.
1. With the desired configuration EEROM installed, upload its configuration to a file in
the PC by sending the following command to the drive:
A x O-4095 < Enter>
Note: You can use either the DCC or SDCC to do this, provided EE.3.4 is set.
2. With the new EEROM installed in the SDCC. download the file to the drive.
Note: If the EEROM is totally blank (no programming label attached). the
Programmer must first be used to set EE.2 and EE.3 to 21 before completing step 2.
397

399

10-38

10SEECHK

10S]LT

105 portion of the drive EEROM has a bad checksum


The drive has detected an incorrect checksum in the 105 portion of the drive EEROM.
Possible causes and solutions:
- 105 EEROM not being used. but does not contain all zeroes. Prior to revision 2.41.
this EEROM was not checked by the firmware. To zero the 105 EEROM. send the
three-character string ":FF" to the drive using RS232 terminal mode.
- If 105 (including command language blocks) is not being used. inhibit the 105 and
this fault by setting EE.5500.0.
- Invalid download of 105 EEROM. Repeat the download.
- Bad EEROM U9 on SDCC.
The 105 checksum may be recalculated without erasing the 105 pattern by setting EE.2.1
temporarily and doing a hard reset. Alternately. the serial hex command" :00FFFF01 01"
will force a calculation of the 105 checksum.

Latched
annunciated
fault

Drive 105 code stack or timing overflow


The 105 portion of the drive firmware has run too long or has corrupted the stack. The
drive trips under this condition. Possible causes:
- The 105 blocks are timed incorrectly. Try using a different pattern of blocks 410-413.

Trip fault

105 portion of drive is faulted


The drive has detected a fault in the 105 portion of the drive firmware.
Possible causes:
- 105 block enabled (BLK.41 O. etc.) but SLCC not installed.
- SLCC not enabled via EE.1.1 (CFGJPRI.
- The 105 has tried to log an out-of-range fault to the fault stack. Fault numbers from
105 must be 800 or greater.
105 blocks include BLK.41 0-BLK.418 (I0Sn. CLNGn. etc.).

Trip fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

400

Fault Condition, Causes

Type Fault

The internal stack has filled the second-to-Iast byte in the stack area
Possible causes:
- LCC/SLCC is defective. Replace the LCC/SLCC.
- LCP programming error. Replace the LCP software with a previous release.

Trip fault

401

L ECKSU

During initialization, a program code checksum error was found


Possible causes:
- LCC/SLCC EPROMs are defective. Replace the EPROMs.
- LCC/SLCC is defective. Replace the LCC/SLCC.

Trip fault

402

L INTRAM

During initialization, the internal 80C196 RAM failed


Possible causes:
- LCP is defective. Replace the LCP (80C196).
- LCC/SLCC is defective. Replace the LCC/SLCC.

Trip fault

403

L EXTRA

During initialization, the external 80C196 RAM failed


Possible causes:
- The external RAM is defective.
- LCC/SLCC is defective. Replace the LCC/SLCC.

Trip fault

404

L_INTMRS

During initialization, the internal 80C196 timers failed


Possible causes:
- LCP is defective. Replace the LCP (80C196).
- LCC/SLCC is defective. Replace the LCC/SLCC.

Trip fault

405

L_DPRAM

During initialization, the DUAL_PORT_RAM failed


Possible causes:
- The dual-port RAM is defective.
- LCC/SLCC is defective. Replace the LCC/SLCC.

Trip fault

406

L KPDSHT

During initialization, the keypad was shorted


Possible causes:
- The keypad has a row shorted to a column. Replace the keypad.
- A key was pushed during initialization. Remove any pressure that might be on the
face of the keypad during initialization.

Trip fault

407

L STKRA

During initialization, the stack RAM (a portion of the external RAM) failed
Possible causes:
The external RAM is defective.
- LCC/SLCC is defective. Replace the LCC/SLCC.

Trip fault

410

L LANFLT

The BIU is unable to properly receive the data it is transmitting


The BIU has not heard the last 128 bytes sent out on its serial port.
Possible causes:
Jumpers J13, 14, 15, 16, 17, and 18 not set correctly. Check for proper settings.
- The serial lines are shorted. Check for proper wiring connections.
- The SLCC is configured for an isolated DLAN but there is no DLAN power supply
connected to the SLCC. Check for proper wiring connections and power supply if
needed.
- There are too many termination resistors in the DLAN circuit. Check the DLAN
termination resistors (no more than five sets should be on the LAN).
- There is another drop on the DLAN with the same drop number as this drop. Ensure
that all drops have a unique drop number.
All drops are not programmed with the same link size. Ensure that all drops have
the same number programmed for the total number of drops on the LAN.
Hardware driver or receiver, or serial port is defective. Replace the LCC/SLCC.

Latched
annunciated fault

411

L FRZMSK

The Freeze Mask contains more than six variables to be transmitted


Possible causes:
- The Freeze Mask (EE622) contains more than six variables to be transmitted. Adjust
the FREEZE_MASK (EE622) to send no more than six variables.

Latched
annunciated fault

10-39

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

412

L BIUMSG

The received message does not contain the correct number of bytes
Possible causes:
The receiving hardware is defective.
The serial port of this device is defective. Replace the LCC/SLCC on this drop.
There are too many termination resistors in the circuit. Check the DLAN termination
resistors (no more than five sets should be on the LAN).
The serial link lines were temporarily shorted. Check the DLAN for possible shorts.
Defective driver hardware on the transmitting drop. Replace the sender's DLAN card.
An invalid message was sent on the LAN. If the sender is a user's program, then
check the messages being for proper length.

Latched
annunciated
fault

413

L LANMIS

The DLAN contains drops with EXPECTED_ACK enabled and disabled


This drop has EXPECTED_ACK disabled while another drop (or drops) on the DLAN has
EXPECTED_ACK enabled, or there is more than one drop with the same drop number.
Possible causes:
- Some other drop has EXPECTED_ACK and WEIGHTED_ZERO active while this drop
does not. Ensure that the EXPECTED_ACK and WEIGHTED_ZERO are consistent
between all drops on the LAN.
- Duplicate drop numbers being used on the LAN. Ensure that all drops have a unique
drop number. Ensure that all drops have the same number programmed for the total
number of drops on the LAN.

Trip fault

DCP did not update the DCP watchdog in 240 milliseconds


Possible causes:
- DCP failure. Replace DCC/SDCC.
- Dual Port RAM failure. Replace LCC/SLCC.
- Bad 9PL cable. Replace 9PL cable.

Trip fault

414

416

LARCMSGF

This ARCNET node did not receive an ACK after a transmitted message
This node did not receive an ACK for a message that was transmitted five times.
Possible causes:
- The destination node is not present on the ARCNET LAN. Ensure that the destination
node is present.
- The ARCNET cable is open or shorted. Ensure that the ARCNET cable is not open or
shorted between nodes.

Latched
annunciated
fault

417

LARCTAFL

The destination node does not have any free receiver buffers
This node is unable to send a message because the destination node does not have any
receiver buffers available, or because the ARCNET LAN is constantly being reconfigured.
Possible causes:
- Too many messages are being sent to the destination node. Limit the messages
being sent to a drive (1 OO/sec).
- The ARCNET cable is open or shorted. Ensure that the ARCNET cable is not open or
shorted between nodes.
- The ARCNET module is malfunctioning causing constant reconfigurations. Replace
the malfunctioning ARCNET module, if possible.
- The destination node is malfunctioning. Replace the destination node LCC/SLCC.

Latched
annunciated
fault

418

LARCRECO

This node is experiencing ARCNET LAN reconfigurations


This node has experienced at least one reconfiguration every 1.28 seconds for a period of
80 seconds. A soft reset will clear the fault only if a 1.28 second time period has elapsed
without a reconfiguration occurring. Possible causes:
- No other ARCNET nodes visible from this node. Ensure that there are other ARCNET
nodes active on the LAN.
- The ARCNET cable is open or shorted. Ensure that the ARCNET cable is not open or
shorted between nodes.
- The ARCNET module for this node has defective drivers or receivers. Replace
ARCNET module.
- An ARCNET module is malfunctioning, causing constant reconfigurations. Replace
defective ARCNET module, if possible.
- There is a 'T' connector in the circuit with an open cable connected to one end.
Remove or terminate the end of the open cable with a 100-ohm resistor.

Latched
annunciated
fault

10-40

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

419

LARCRSE

This node's ARCNET module unexpectedly experienced a RESET


Possible causes:
- Loose or poor connections to the LCC/SLCC connectors (power, digital, LAN).
Secure or replace all cables connected to the LCC/SLCC.
- Circulating currents due to separated grounds between boards or ARCNET nodes.
- Defective ARCNET module. Replace, if possible.
- Defective LCC/SLCC. Replace.

Latched
annunciated
fault

There is an error in the format of a received ARCNET message


Possible cause:
- The sender produced an invalid message. Correct the message at the source.

Latched
annunciated
fault

420

421

LARCXRA

During initialization, the ARCNET external RAM failed


Possible causes:
- The ARCNET module or external RAM is defective. Replace ARCNET module, if
possible.
- LCC/SLCC is defective. Replace.

Latched
annunciated
fault

422

LARCFBIN

The format of a received STATUS_SJEEDBACK message is incorrect


Possible causes:
An ARCNET cable is open or shorted. Check ARCNET cables for opens and shorts.
- An ARCNET repeater of node is working incorrectly. Check the ARCNET nodes and
repeaters for passing messages.
- The source of the STATUS_S_FEEDBACK message formed the message incorrectly.
Check the source code for proper STATUS_S_FEEDBACK format.

Latched
annunciated
fault

423

LARCRBFL

This ARCNET node's receive buffer has overflowed and a message is lost
Possible cause:
- Some other ARCNET node or nodes are sending messages to this node faster than
this node can accept the messages. Limit communications to this node. Do not
exceed 100 messages per second to this node.

Latched
annunciated
fault

425

LDLANMSG

DCP has passed an erroneous message to LCP to transmit on DLAN


Possible causes:
- DCP has misloaded the outgoing message. Replace evaluation PROMs with released
PROMs (DCP PROMs).
- Hardware fault. Check the 3PL ribbon cable and connectors.

Latched
annunciated
fault

426

LARCOUTM

DCP has passed an erroneous message to LCP to transmit on DLAN PLUS


Possible causes:
DCP has misloaded the outgoing message. Replace evaluation PROMs with released
PROMs (DCP PROMs).
- Hardware fault. Check the 3PL ribbon cable and connectors.

Latched
annunciated
fault

427

LCLKSYNC

This ARCNET node's clock has been resynchronized with the master clock because there
was more than 64 msec of error between the two clocks. FLT.427 is not a fault; it is a
momentary condition. Possible cause:
- Turning the master clock on and off. Ensure that the master clock is not turned off.

Latched
annunciated
fault

428

LARCRBFF

This ARCNET node's receive buffer has overflowed and a message has been lost.
Possible cause:
- Some other ARCNET node or nodes are sending messages to this node faster than
this node can accept the messages. Limit communications to this node. Do not
exceed 1 message per 22 msec to this node.

Latched
annunciated
fault

10-41

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

429

LACCAPFL

The ac drive's dc bus programmed capacitance is too large


Latched
This fault may show up in a PARENT (the dc bus regulator) or a CHILD (an ac drive tied to annunciated
the dc bus). For the CHILD, this fault means the programmed bus capacitance (EE.587,
fault
CAPVDC) is larger than 32767, and the value will not be sent to the PARENT. For the
PARENT, this fault declares that:
1) A CHILD has sent a capacitance value greater than 32766 and the value has been
discarded.
2) Drop 0 has sent a capacitance value. (there should not be a drop 0 on ARCNET).
3) A capacitor message (PROT 11 h) has been received with an invalid length of message (there should be two bytes to define the cap value).
4) The TOTAL DC BUS CAPACITANCE has exceeded 65535, and has been clamped to
65535. The TOTAL value is passed to DCP through DPRAM DCP VAR.1440.
Possible causes and solutions:
CHILD - EE.587 is larger than 32766. Limit EE.587 to 0 - 32766.
PARENT - A CHILD has sent a capacitor value larger than 32766. The drive firmware
doesn't allow the drives to send a value larger than 32766. Check the senders of the
common dc bus capacitor message (ARCNET protocol 11 h) and limit the value to 0 32766.
PARENT - Drop 0 sent a common dc bus capacitor value. Find which ARCNET drop
has been programmed to be drop 0 and program the correct drop number. There
should not be a drop O.
PARENT - A drop has sent more/less than 2 bytes for the cap value. Find which
ARCNET drop is sending the invalid message and correct the message. (If a drop
sends an invalid message, then that drop's value will not get loaded into the
CAP_TABLE.)
PARENT - The TOTAL DC BUS CAPACITANCE has exceeded 65535. Modify the
CHILDREN capacitance so that the TOTAL does not exceed 65535.
To help debug the Common Bus Capacitor TOTAL, you can (through ST2000 Toolkit,
Drive Configurator, or some other RS232 terminal) examine the capacitor table and TOTAL
value by typing in ALB8DOH <cr> or AL47312 < cr>.
The first two words are the TOTAL calculated capacitance (LSWORD first).
The next word is a mirror of the TOTAL CAP in DPRAM (DCP VAR.1440). This word will
be clamped to 65535 if the accumulated capacitance exceeds 65535. The double word of
TOTAL calc cap does not get clamped.
The next 255 words contain each ARCNET drop's (1-255) capacitor value, or 65535 if no
capacitor value has been received, or the capacitor value received plus 32768 if the
"CHILD" is not in Link Presence. Only the entries with their msbit cleared are added up to
make the TOTAL cap. (See EE.706.4, EE. 706.5{ARCJP1), EE.719(CBREGU), EE.587
(CAPVDC)).

550

10-42

EECKSM16

Bad page 16 EE checksum (EE.4096 - EE.4351)

Latched
annunciated
fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

551

EECKSM1

Bad page 17 EE checksum (EE.4352 - EE.4607)

Latched
annunciated
fault

552

EECKSMl

Bad page 18 EE checksum IEE.4608 - EE.4863)

Latched
annunciated
fault

553

EECKSMl

Bad page 19 EE checksum IEE,4864 - EE.5119)

Latched
annunciated
fault

554

EECKSM2

Bad page 20 EE checksum (EE.5120 - EE.5375)

Latched
annunciated
fault

555

EECKSM21

Bad page 21 EE checksum (EE.5376 - EE.5631)

Latched
annunciated
fault

556

EECKSM22

Bad page 22 EE checksum IEE.5632 - EE.5887)

Latched
annunciated
fault

557

EECKSM23

Bad page 23 EE checksum IEE.5888 - EE.6143)

Latched
annunciated
fault

558

EECKSM24

Bad page 24 EE checksum (EE.6144 - EE.6399)

Latched
annunciated
fault

559

EECKSM25

Bad page 25 EE checksum (EE.6400 - EE.6655)

Latched
annunciated
fault

560

EECKSM26

Bad page 26 EE checksum (EE.6656 - EE.6911)

Latched
annunciated
fault

561

EECKSM27

Bad page 27 EE checksum IEE.6912 - EE.7167)

Latched
annunciated
fault

562

EECKSM28

Bad page 28 EE checksum IEE.7168 - EE.7423)

Latched
annunciated
fault

563

EECKSM29

Bad page 29 EE checksum (EE.7424 - EE.7679)

Latched
annunciated
fault

564

EECKSM30

Bad page 30 EE checksum IEE.7680 - EE.7935)

Latched
annunciated
fault

565

EECKSM31

Bad page 31 EE checksum IEE.7936 - EE.8175)

Latched
annunciated
fault

10-43

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

567

GND_ANUN

Excess Ground Current Fault Annunciated


A ground current signal is brought into local drive analog lID, conditioned in blockware,
and sent to a SLD which produces an excess-ground-current boolean. The input pointer
GNDA@I IEE.3608) is typically pointed at this boolean to provide an Excess Ground Current fault. For FLTJP2.2 = 0, the sense of fault is 1 = Faulted, 0 = No Fault.
For FLTJP2.2 = 1, the sense of fault is 0 = Faulted, 1 = No Fault. The enumerations at
FLTJP2.0 select the behavior of the fault. If the fault input pointer is not used (pointed at
zero) the fault is disabled.
Possible Causes:
- GNDA@I IEE.3608) Pointed Incorrectly
- Improper sense selected by FLTJP2.2 (EE.3613.2l
- SLD compare level set incorrectly
- Excess Ground Current exceeds annunciate level

Non-latched
annunciated
fault

568

GND_TRIP

Excess Ground Current Fault Trip


Trip fault
A ground current signal is brought into local drive analog lID, conditioned in blockware,
and sent to a SLD which produces an excess-ground-current boolean. The input pointer
GNDT@I (EE.3609) is typically pointed at this boolean to provide an Excess Ground Current Trip fault. The enumerations at FLTJP2.15 select the sense of the fault. For
FLTJP2.1 5 = 0, the sense of fault is 1 = Faulted, 0 = No Fault. For FLTJP2. 15 = 1, the
sense of fault is 0 = Faulted, 1 = No Fault. If the fault input pointer is not used (pointed
at zero) the fault is disabled.
Possible Causes:
- GNDT@I (EE.3609) Pointed Incorrectly
- Improper sense selected by FLTJP2.15 (EE.3613.15)
- SLD compare level set incorrectly
- Excess Ground Current exceeds trip level

570

MBD01TRP

Multibridge follower LAN drop #1 is tripped


This fault is displayed at the master drive of a multibridge when a follower drive is
tripped. Check the follower drive fault code to determine the cause.

Trip fault

571

MBD02TRP

Multibridge follower LAN drop #2 is tripped

Trip fault

572

MBD03TRP

Multibridge follower LAN drop #3 is tripped

Trip fault

573

MBD04TRP

Multibridge follower LAN drop #4 is tripped

Trip fault

577

MBD08TRP

Multibridge B group master LAN drop #8 is tripped

Trip fault

578

MBD09TRP

Multibridge B group master LAN drop #9 is tripped

Trip fault

579

MBD10TRP

Multibridge B group master LAN drop #10 is tripped

Trip fault

580

MBD11TRP

Multibridge B group master LAN drop #11 is tripped

Trip fault

581

MBD12TRP

Multibridge B group master LAN drop #12 is tripped

Trip fault

601

MBD01ALM

Multibridge follower LAN drop #1 has a fault


This fault is displayed at the master drive of a multibridge when a follower drive has an
annunciated (not a trip) fault. Check the follower drive fault code to determine the cause.
Note it is possible that the follower fault code was a "brief" annunciated fault, such as
FLT.34 (PLLTRACK), which may no longer be present, giving the appearance that the
master is reporting a follower fault when none exists on the follower's Programmer display. If ST2000 is connected to the master drive in terminal mode when the fault occurs,
the follower fault code and its alphanumeric will be displayed on the screen.
This fault can also be generated by the master when the master is running and has commanded the follower drives to run, but a follower drive reports back that it is not running
(perhaps because the follower was locally commanded to stop). This latter condition may
or may not trip the master drive, depending on EE.607.3.

Non-latched
annunciated
fault

602

MBD02ALM

Multibridge follower LAN drop #2 has a fault

Non-latched
annunciated
fault

10-44

BI006008

GF2000 Dc Ge rator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

603

MBD03AL

Multibridge follower LAN drop #3 has a fault

Non-latched
annunciated
fault

604

MBD04AL

Multibridge follower LAN drop #4 has a fault

Non-latched
annunciated
fault

608

MBD08AL

Multibridge B group master LAN drop #8 has a fault

Non-latched
annunciated
fault

609

MBD09AL

Multibridge B group follower LAN drop #9 has a fault

Non-latched
annunciated
fault

610

MBD10AL

Multibridge B group follower LAN drop #10 has a fault

Non-latched
annunciated
fault

611

MBD11AL

Multibridge B group follower LAN drop #11 has a fault

Non-latched
annunciated
fault

612

MBD12AL

Multibridge B group follower LAN drop #12 has a fault

Non-latched
annunciated
fault

Multibridge follower LAN drop #1 is not responding


This fault is displayed at the master of a multibridge drive when a follower drive is not
communicating with the master drive. For additional diagnosis, check for fault codes at
follower drives to see if follower is able to hear master. Possible causes:
- Follower drive not powered-up or not enabled via EE.607.0.
- Defective, loose, or dirty fiber-optic connection.
- EE.610, MBLTTL, not set correctly to total number of drops.
- Follower drop numbers, EE.609, not assigned sequentially or uniquely.
- MCPs of all bridges not at same firmware revision.
- MBHA card failure or not powered up (check followers for faults).
- SPCB card failure (check SPRS, RX, and TX test points).
- For 12-pulse systems, failure of simplex cable from MBHA C1 MODE to respective
master SPCB MODE.

Non-latched
annunciated
fault

632

633

MBD02NAK

Multibridge follower LAN drop #2 is not responding

Non-latched
annunciated
fault

634

MBD03NAK

Multibridge follower LAN drop #3 is not responding

Non-latched
annunciated
fault

635

MBD04NAK

Multibridge follower LAN drop #4 is not responding

Non-latched
annunciated
fault

639

MBD08NAK

Multibridge B group master LAN drop #8 is not responding

Non-latched
annunciated
fault

640

MBD09NAK

Multibridge B group follower LAN drop #9 is not responding

Non-latched
annunciated
fault

641

MBD10NAK

Multibridge B group follower LAN drop #10 is not responding

Non-latched
annunciated
fault

10-45

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

642

MBD11 NAK

Multibridge B group follower LAN drop #11 is not responding

Non-latched
annunciated
fault

643

MBD 12NAK

Multibridge B group follower LAN drop #12 is not responding

Non-latched
annunciated
fault

662

HI VOLTS

LNMON Block - High Line Voltage Detected


The LNMON block takes line voltage (VAR.1 08) and scales it by 20000/LMVSCL. If the
result is greater than LMHIVT for LMCTIM milliseconds then VAR.1 088 is set and a fault
occurs.
Possible Causes:
- LMHIVT [3590] set too low
- LMVSCL [3588] set incorrectly
- LMCTIM [3589] set too low
- Line voltage is too high
- See also LNMON BLK.344 and VAR.1 08 ACLINMAG.

663

LO_VOLTS

LNMON Block - Low Line Voltage Detected


The LNMON block takes line voltage (VAR.1 08) and scales it by 20000/LMVSCL. If the
result is less than LMLOVT for LMCTIM milliseconds then VAR.1 089 is set and a fault
occurs.
Possible Causes:
- LMLOVT [3591] set too high
- LMVSCL [3588] set incorrectly
- LMCTIM [3589] set too low
- Line voltage is too low
- See also LNMON BLK.344 and VAR.1 08 ACLINMAG.

664

HI FREQ

LNMON Block - High Line Frequency Detected


The LNMON block takes line frequency (VAR.1 09) and compares it against LMHIFQ
EE.3592. If the result is greater than LMHIFQ for LMCTIM milliseconds then VAR.1148 is
set and a fault occurs.
Possible Causes:
- LMHIFQ [3592] set too low
- LMCTIM [3589] set too low
- Line frequency is too high
- See also LNMON BLK.344 and VAR.1 09 ACLlNFRQ.

665

LOfREQ

LNMON Block - Low Line Frequency Detected


The LNMON block takes line frequency (VAR.1 09) and compares it against LMLOFQ
EE.3593. If the result is less than LMHIFQ for LMCTIM milliseconds then VAR.1149 is set
and a fault occurs.
Possible Causes:
- LMLOFQ [3593] set too high
- LMCTIM [3589] set too low
- Line frequency is too low
- See also LNMON BLK.344 and VAR.1 09 ACLlNFRQ.

10-46

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

666

AUX_FLT1

Aux Fault 1 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP1 . If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF1@1
- Wrong sense of input determined by AXFJP1.3
- Faulted condition at AXF1 @I

667

AUX_FLT2

Aux Fault 2 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP1 . If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
Improperly selected source pointer AXF2@1
- Wrong sense of input determined by AXFJP1 .3
- Faulted condition at AXF2@1

668

AUX_FLT3

Aux Fault 3 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1 . The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable. and is configured with a jumper bit ofAXFJP1. If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF3@1
- Wrong sense of input determined by AXFJP1 .11
- Faulted condition at AXF3@1

669

AUXfLT4

Aux Fault 4 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1 . The input pointer AXF#@I. when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable. and is configured with a jumper bit ofAXFJP1 . If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF4@1
- Wrong sense of input determined by AXFJP1 .15
- Faulted condition at AXF4@1

670

AUXfLT5

Aux Fault 5 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP2. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP2. If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF5@1
- Wrong sense of input determined by AXFJP2.3
- Faulted condition at AXF5@1

671

AUX_FLT6

Aux Fault 6 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP2. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP2. If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF6@1
- Wrong sense of input determined by AXFJP2.7
- Faulted condition at AXF6@1

Type Fault

10-47

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

672

AUX_FLT7

Aux Fault 7 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper
enumeration of AXFJP2. The input pointer AXF#@I, when used, points to the boolean
value that signals the fault condition. The sense of the input boolean may be either highenable or low-enable, and is configured with a jumper bit of AXFJP2. If the fault input
pointer is not used (pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF7@1
- Wrong sense of input determined by AXFJP2.11
- Faulted condition at AXF7@1

673

AUX FLT8

Aux Fault 8 - Generic Pointable Fault


Aux faults are generic pointable faults whose behavior is configurable with a jumper
enumeration of AXFJP2. The input pointer AXF#@I, when used, points to the boolean
value that signals the fault condition. The sense of the input boolean may be either highenable or low-enable, and is configured with a jumper bit of AXFJP2. If the fault input
pointer is not used (pointed at zero) the fault is disabled. Possible Causes:
- Improperly selected source pointer AXF8@1
- Wrong sense of input determined by AXFJP2.1 5
- Faulted condition at AXF8@1

808

DPROMCKS

Main CPU EPROM checksum failure at U11 or U12 (105 page)


Main processor PROM checksum failure detected in 105 code section.

Latched
annunciated
fault

810

DEVERIFY

Value to EEROM, main CPU not verified


The last value loaded to EEROM on the main processor did not verify.

Latched
annunciated
fault

811

SERLCKSM

Checksum of transmitted message does not agree with data received

Latched
annunciated
fault

812

MLDCKSUM

Checksum of transmitted message does not agree with the data in memory

Latched
annunciated
fault

815

EE CKSUM

Main CPU EEROM checksum error detected in 105 section

Latched
annunciated
fault

816

EEID_FLT

Main CPU EEROM identification failure in 105 section


Main processor 105 EEROM identification failure detected.

Latched
annunciated
fault

826

ENGSTALL

105 LAN message buffer full. Permissive engines temporary stop


A LAN message buffer is full and permissive engine processing has been temporarily suspended.

Latched
annunciated
fault

827

LUP WDOG

105 watchdog timer between LAN CPU and main CPU timeout
The watchdog timer between the LAN processor and the main processor has timed out.

Latched
annunciated
fault

831

L RWTOUT

LAN memory read/write sent but drop did not answer


A LAN memory read or write request was sent to a network drop but the drop did not
answer.

Latched
annunciated
fault

832

WVAR MSG

LAN message buffer full. Math engines temporary stop.


A LAN message buffer is full and math engine processing has been temporarily suspended.

Latched
annunciated
fault

10-48

Type Fault

BI006008

GF2000 Dc Ge erator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition. Causes

Type Fault

835

E2_CKSU

Main CPU EEROM checksum error in 105 section


Main processor 105 EEROM checksum error detected.

Latched
annunciated
fault

836

E21D FLT

Main CPU identification failure detected in 105 section


Main processor 105 EEROM identification failure detected.

Latched
annunciated
fault

837

EEMCKSU

Main CPU 105 EEROM RAM mirror checksum error


Main processor 105 EEROM RAM mirror checksum error detected.

Latched
annunciated
fault

838

E2MCKSU

Main CPU 105 EEROM RAM mirror checksum error


Main processor 105 EEROM RAM mirror checksum error detected.

Latched
annunciated
fault

839

STAKOVFL

105 scheduler had a task stack overflow


Main processor RTOS operating system task stack overflow.

Latched
annunciated
fault

841

SENGSTAL

LAN message buffer full. Sequence engines temporary stop


A LAN message buffer is full and sequence engine processing has been temporarily suspended.

Latched
annunciated
fault

842

DIAGCOLL

Diagnostic data collection fault


An error has been detected in collecting the data for a diagnostic message.

Latched
annunciated
fault

844

NO_lOS

10S-in-a-Drive is not available


The 10S-in-a-Drive functionality is not available either because it has been disabled or an
EEPROM image has not been downloaded from the 105 configurator. Other causes of this
fault include:
- An invalid or NO EEPROM image was detected by the 10S-in-a-Drive firmware and the
105 EEPROM configuration was required. Either download the correct 105 configuration
or inhibit the fault by clearing 10SJPR (EE.5500.1).
A configuration was downloaded into an 105 with features that are not supported by
the firmware. Either update the firmware or use the correct version of the 105
compiler (upward compatibility error).

Latched
annunciated
fault

845

BRIDGFLT

Primary network bridge fault


The primary network bridge for a network (FO) message was not in link presence. The
message was rerouted through the backup bridge drop.

Latched
annunciated
fault

846

10SINIT

105 portion of 10S-in-a-Drive did not initialize correctly


This error is caused by an invalid EEPROM image or by an EEPROM image that exceeds
the size constraints of RAM or EEPROM.

Latched
annunciated
fault

847

LCP_SYNC

The LCP/IOS initialization had an error


The initialization protocol between the LCP and 105 ended either because the LCP did not
respond within 1 second. or the LCP returned an unexpected initialization state to the
lOS's initialization request.

Latched
annunciated
fault

848

REFRESH

The 105 is sending out too many refresh bits


There are certain control bits on the drive and 105 that must be refreshed every 1.28
seconds after they have been set. The 105 is limited to four such signals active at any
given time. The refresh fault is issued when this limit has been exceeded.

Latched
annunciated
fault

849

ACTR CFG

105 actor/tracker configuration error


The actor/tracker subsystem did not initialize correctly. The tracking system has not been
enabled.

Latched
annunciated
fault

10-49

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued


No.

Name

Fault Condition, Causes

Type Fault

850

105 BUSY

The 10S-in-a-Orive background tasks are not executing


The 105 portion of the 10S-in-a-Orive is not being given enough time in the drive block
scheduling to complete its background scans. This is caused when the scan time of the
105 exceeds ten seconds. More time must be allocated to the IDS in the drive patterns
by using the IOS1, 1052, 1054, and IOS8 drive blocks if this error occurs.

Latched
annunciated
fault

851

GENI ERR

Error detected on Genius Controller


Geni card controller fault. An error was detected on the GENI controller card. This fault
should never occur on an 10S-in-a-Drive, because there is no Genius I/O support available.

Latched
annunciated
fault

852

BAD MSG

A message was received on ARCNET that had an invalid format


A message was received that could not be successfully decoded by the IDS. The message was ignored and flushed from the message queue.

Latched
annunciated
fault

853

TRKR MSG

An actor/tracker message could not be processed correctly


An actor/tracker message was received that could not be successfully decoded or processed by the tracking subsystem. This includes problems with internal actor event
queues overflowing. The message was ignored and flushed from the message queue.

Latched
annunciated
fault

854

MSG OVFL

The message object could not transmit a message


The LAN message buffer is full so the message block cannot transmit any more messages until buffer space becomes available.

Latched
annunciated
fault

855

ODE FLT

Order of execution recursion fault


A call has been made to an order of execution (ODE) sequence that is currently active.
Check the ODE logic to ensure that there is not a recursive call to an ODE.

Latched
annunciated
fault

856

OBJ FLT

Order of execution calls an unknown object


A request has been made within an ODE to execute an object type that is not yet supported by the firmware. Verify that you have the current versions of 105 firmware and
compiler.

Latched
annunciated
fault

857

105 U857

Latched
Undefined 105 error
A new 105 fault has been generated that is not yet supported by the ST2000 data base
annunciated
files. Please alert PO of the problem. This fault corresponds to fault 157 on a stand alone fault
105.

858

105 U858

Latched
Undefined 105 error
annunciated
A new 105 fault has been generated that is not yet supported by the ST2000 data base
files. Please alert PD of the problem. This fault corresponds to fault 158 on a stand alone fault
105.

859

CLMSGBAO

CLMSG used while 105 enabled


The CLMSG block was called when the 10Sx blocks were also allowed to generate messages. The CLMSG block can only be used when 10SJPR lEE 5500) bits 0, 1, and 2 are
reset, which will disable the 10S-in-a-Drive functionality. Either set 10SJPR to the appropriate value or replace the CLMSG block with an 1051 block to get rid of the fault.
105 Prom Revision Mismatch
The 10SB firmware revision level is less that the level requested by the 10SB EEPROM
configuration. Either update the PROM set to the appropriate level, or recompile the configuration file using the revision level of the 10SB firmware.

860

1023

10-50

Latched
annunciated
fault

RESET

DCC/SDCC is in a hard reset condition


If all ten LEOs on the DCC/SDCC are lit continuously, and no fault code is being displayed via the RS232 link, Programmer, or LAN connection, the control card is probably
being held in reset. Possible causes:
- External reset input, 3TB-58 or STBA-38, is closed, holding reset high.
- Failure in + 5 V dc or 15 V dc control power supplies to the control card.
- EPROMs U22/U23 on the control card not inserted correctly.
- Failure of DCC/SDCC control card.

Trip fault

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter

CHAPTER 11
DIAGNOSTIC LISTS

11-1. INTROD CTION

The GF2000 ex iter software includes the following


three diagnostic eatures that send selected data to
memory:

Motor Cont 01 Processor (MCP) Diagnostic Circular List

Drive Contr 1 Processor (DCP) Circular List


Blocks

LAN Contr 1 Processor (LCP) History Buffer

These features e able variable data to be captured


while the exciter is in operation, and to be read by the
user as an aid in oubleshooting.
The MCP and D
connected comp
(see GEH-5860)
sion (see GEH-6
tended to be acc
2000 (MM2ooo)
Publication GEH
GEH-62l3 provi

P lists are accessed via a serially


er using either the ST2000 Toolkit
r Drive Configurator, LynxOS Ver03). The LCP History Buffer is insed by a Man-Machine Interface
ia the exciter's DLAN + connection.
6212 describes the MM2ooo;
es configuration information.

Tables 11-1 thro gh 11-3, located at the end of this


chapter, defme
EEPROM addresses for each of the
exciter's diagnos c functions.

A set of four pointers determine the MCP variable for


display in the first four columns. These pointers are
EE.6OO (MDAIIN), EE.603 (MDA2IN), EE.552
(MPNTR1), and EE.553 (MPNTR2) for the four columns, respectively, left to right.
The user selects an MCP variable to display in the fIrst
four columns of the list by entering the variable's address (see the description of EE.6282 bit 0 in Table
11-1) into the associated pointer.
The remaining columns display the bridge current, the
fIring angle, the cell pair select counter, and asynchronous current regulator fIring data.

11-2.2. MCP Diagnostic Circular List Operation

Software jumper MDGNJP (addresses EE.6282.0


through EE.6282.4) controls the operation of the MCP
Diagnostic Circular List (see Table 11-1).

11-2.3. Circular List Display

The MCP Diagnostic Circular List can be viewed using the ST2000 Toolkit (see GEH-5860) or Drive
Configurator, LynxOS Version (see GEH-6203). To
display the circular list:
1.

Using the Programmer, ST2000 Toolkit, or Drive


Configurator, select the circular list freeze options
by setting software jumper MDGNJP.

2.

Select an MCP variable to display by entering its


address into one of the four pointers. To do this:

NOSTIC CIRCULAR LIST

While the GF2


exciter is running, selected MCP
data is continuou y sent to memory, providing a circular list of MC variable data. When a stop command, trip, fault, or trigger from the DCP disables the
exciter, the data i latched (frozen) in memory. This
data provides a pi ture of motor control events that
occurred just bef< re the exciter stopped.

11-2.1. Circula List Content

The MCP Diagno tic Circular List resides as a page


in RAM, 8 col
wide by 128 rows deep. Each
column is 1 word wide.

a.

Refer to Table 11-1 to fmd the available variables and their addresses (or use the ST2000
Toolkit or Drive ConfIgurator to read them at
address EE.6282.0). Select up to four variables for anyone Circular List display.

b.

Use the Programmer keypad, ST2000 Toolkit


(EDITIOOO menu item), or Drive Conflgurator to enter this address into a pointer.

11-1

BI006008

GF2000 Dc Generator Field Exciter

GEH-6148
3.

Using the terminal emulation mode of the ST2000


Toolkit or Drive Configurator, enter either of two
RAM dump commands:
A

m 60000 Displays the most recent 22 lines in

the list is determined by the number and size of the


channels used. For example, a circular list consisting
of four 16-bit (two-byte) channels, will be 2048 samples long. If more channels are used, the length of the
list is reduced accordingly.

unsigned format
A

m60000-- Displays the most recent 22 lines in


signed ( +/-) format
m 58288-60336-- Displays all 128 lines in
signed (+/-) format

The output is a nine-column page of data arranged as


follows:
Column 1
Columns 2 - 5
Column 6
Column 7
Column 8

Column 9
Lines 1 - 21
Line 22

Data flow

RAM location (address)


Circular list data, selected MCP
variables
Bridge current, VAR.1092
(IBRIDGE) , 5000 = 1 pu
Firing angle, 0 = full advance,
16383 = 180-degree retard
Cell pair select counter, range 250255 or 0-12 (1000 added if firing reverse bridge; 1oo added if armature firing is enabled)
Asynchronous current regulator firing data
Circular list data
First seven columns: 0oo value =
frozen, valid data; oo1 or 65535
= not frozen, therefore invalid data.
Last column: address of the line corresponding to when the trigger occurred (if displayed in signed format,
add 65536 to obtain the trigger address)
oldest data = top line; newest data
= bottom line

11-3.1. CLST Blocks

Three CLST blocks are available, each corresponding


to a different functional level: CLSTI (basic level),
CLST2 (intermediate level), and CLST3 (advanced
level). Each succeeding functional level builds upon
the functionality of the proceeding level. These levels
are defmed in the following sections.
EEPROM addresses EE.5868 through EE.5881 control
the operation of the CLST block. Variable VAR.1453
contains status information for the block. Table 11-2
defmes these EEPROM and variable addresses, including the CLST block(s) to which each address applies.
11-3.1.1. CLST1 (BASIC) BLOCK. CLSTl requires
the least amount of processor execution time. This list
consists of four 16-bit (two-byte) channels that are
recorded at the block's scheduled rate (defmed in the
block source list described in Chapter 4). Data is recorded while the variable selected by pointer EE.5868
(CL@RUN) is high. Recording stops when the
CL@RUN variable goes low.

Data recording can also be toggled on and off by an *


(asterisk) command via the drive serial link.
11-3.1.2. CLST2 (INTERMEDIATE) BLOCK. In addition to the functions in the CLSTl block, CLST2 includes the following features:

Selectable data recording rate

Post-trigger data capture delay

List overwrite lock

RUN command inverter

NOTE

Typically at least four lines are displayed after


the trigger.

11-3. DCP CIRCULAR LIST BLOCKS

The DCP Diagnostic Circular List (CLST) blocks


capture up to eight user-selected DCP variables, with
each variable assigned to a channel. The total memory
space used by the circular list is 16 kB; the length of

11-2

The data recording rate is selected using EE.5879


(CL_RAT), as defmed in Table 11-2. This enables the
user to collect data at a rate different from (slower
than) the block execution rate. The data recording
rate, entered as milliseconds, is converted to an integer number of scheduled block executions. The actual
collection rate is reported in the status line (header)
when the circular list is read.

BI006008

GEH-6148

GF2000 Dc Ge erator Field Exciter


The post-trigger data capture delay enables the circular
list to capture a umber of samples, defIned by
EE.5880 (CL_ LY), after the CL@RUN variable
goes low. This ature allows the user to sample data
surrounding a tr gger event.

LD

Returns the status of the circular list when the


list is collecting. When the list is stopped, this
command dumps the contents of the circular
list in ASCII form.
NOTE

The list overwri e lock prevents data surrounding a


trigger event fr
being overwritten by subsequent
restarting of the block. When the variable selected by
pointer EE.587 (CL@LCK) goes high, the circular
list is allowed t start and stop only once.
of the CL@RUN command can be
.5881.0 (CL_JPR).
11-3.1.3. CLST (ADVANCED) BLOCK. In addition to
the functions in e CLSTl and CLST2 blocks,
CLST3 includes the following features:

Eight data c llection channels (rather than four)

g on channels 3 through 6

The first line of a data dump contains the


following "header" information, based upon
which circular list block (CLSTl, CLST2, or
CLST3) is enabled.
For a CLSTl block, the fIrst line of the data
dump contains the following information:

a a

BlockRate

00000 00000

00000 00000

Collection data in bytes (8 bits), words (16


bits), or do ble words (32 bits)

The eight data c


EE.5877 (CL_T
data as bytes, w
through 6 may c
be confIgured to
intervals; and C
bytes.

llection channels are confIgured using


P). Channels 1 and 2 may collect
rds, or double words; Channels 3
llect data as bytes or words, and may
average data over their collection
annels 7 and 8 collect data only as

As in CLST2, e data recording rate is selected using


EE.5879 (CL_ T). When averaging is selected for a
channel, data s pIes are accumulated at the block
execution rate.
e samples are then averaged and
stored as a data oint at the rate defmed by CL_RAT.

11-3.2. Circul r List Display

The contents an lor status of the DCP Circular List


can be viewed ing the ST2()()() Toolkit (see GEH5860) or Drive onfIgurator, LynxOS Version (see
GEH-6203). Us' g the terminal emulation mode of the
ST2000 Toolkit r Drive ConfIgurator, enter any of
the following se ial commands:
L

The LD command can be used with the


terminal emulation mode capture or log
function to save the circular list contents to
a file. The me can then be used for off-line
analysis of the data.

Returns the status of the circular list.

where BlockRate, the scheduled rate of the


circular list block, is equal to 1 (nO/sec), 2
(360/sec), 4 (l80/sec), or 8 (90/sec).
For a CLST2 or CLST3 block, the fIrst line
of the data dump contains the following information:
StopDelay TimeRate BlockRate CollectRate
StpReqTmO StpSamplTm2,1 ,0
where:
StopDelay is equal to EE.5880 (CL_DLY),