GEH-6680LCI Faults

GE Energy
LS2100 Static Starter Control

Reference and Troubleshooting Guide
GEH-6680B
g
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Indicates a procedure, condition, or statement that should be

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Note Indicates an essential or important procedure, condition, or statement.

This equipment contains a potential hazard of electric shock
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thoroughly familiar with the equipment and the instructions
should install, operate, or maintain this equipment.
Isolation of test equipment from the equipment under test

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cannot be grounded to the equipment under test, the test
equipment’s case must be shielded to prevent contact by
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Contents
Chapter 1 Overview 1-1

Introduction ............................................................................................................................1-1
Using Toolbox Help for Reference and Troubleshooting.......................................................1-3
Equipment/Material Needed ...................................................................................................1-4
Safety Equipment .....................................................................................................1-4
Typical Maintenance Tools.......................................................................................1-4
How to Get Help.....................................................................................................................1-5
Related Documents.................................................................................................................1-5
Document Distribution .............................................................................................1-5
Chapter 2 Preventive Maintenance 2-1

Introduction ............................................................................................................................2-1
Maintenance Schedule ............................................................................................................2-2
Maintenance Record ...............................................................................................................2-2
Maintenance Procedures .........................................................................................................2-2
Before Beginning .....................................................................................................2-2
Procedure List...........................................................................................................2-3
Fan Replacement Intervals .......................................................................................2-3
Dust Removal ...........................................................................................................2-4
Cleaning Up Oil or Similar Fluids............................................................................2-5
Loose Connections ...................................................................................................2-5
Damaged Insulation..................................................................................................2-6
Contactors and Relays ..............................................................................................2-6
Printed Wiring Boards/Modules...............................................................................2-6
Short-Circuit Damage .............................................................................................................2-7
Chapter 3 Parts Replacement 3-1

Introduction ............................................................................................................................3-1
Safety Precautions and Replacement Guidelines....................................................................3-2
Control Cabinet.......................................................................................................................3-3
Pump Cabinet .........................................................................................................................3-6
Routine Maintenance................................................................................................3-8
Removal and Replacement Procedures ....................................................................3-9
Power Conversion Cabinet ...................................................................................................3-15
De-energizing Procedure for the LS2100 Lineup...................................................3-16
Power Conversion Module (PCM) .........................................................................3-17
AC Line Filters.......................................................................................................3-23
®
VersaMax Micro PLC for Pump Panel I/O ........................................................................3-24
Downloading the requisition software....................................................................3-26
Standard LS2100 configuration file .......................................................................3-26
®
Using VersaPro to store the VersaMax Micro PLC configuration.......................3-27
LS2100 Reference and Troubleshooting Guide GEH-6680B Contents • i

Chapter 4 Troubleshooting 4-1
Introduction ............................................................................................................................4-1
General Troubleshooting ........................................................................................................4-2
Specific Fault Troubleshooting.............................................................................................4-10
Types of Faults .......................................................................................................4-10
Fault Indications .....................................................................................................4-10
Viewing and Resetting Faults on the Keypad/DDI ................................................4-11
Glossary of Terms G-1
Index I-1
ii • Contents LS2100 Reference and Troubleshooting Guide GEH-6680B

Chapter 1 Overview
Introduction
Refer to Figure 1-1 and 1-2. This document provides recommended preventive maintenance, component
replacement, and general troubleshooting procedures for the LS2100 Static Starter
Control (LS2100).
Chapter 1 provides an overview of this document.
Section Page
Using Toolbox Help for Reference and Troubleshooting.........................................1-4

Equipment/Material Needed.....................................................................................1-5
Safety Equipment .......................................................................................1-5
Typical Maintenance Tools.........................................................................1-5
How to Get Help.......................................................................................................1-6
Related Documents...................................................................................................1-6
Document Distribution...............................................................................1-6
Chapter 2, Preventive Maintenance The procedures help to prevent, detect, and

correct conditions that could cause equipment malfunction. This includes inspections
for damage and wear, tests, and cleaning of equipment at regular intervals.
Chapter 3, Parts Replacement Replaceable parts of the LS2100 are located in the
control, pump, and power conversion cabinets. Certain parts in the pump cabinet are
replaceable online (energized). There are no online replaceable parts in the control or
power conversion cabinets.
Chapter 4, General Troubleshooting General troubleshooting of the LS2100
centers around the alarms and trips generated by fault conditions. These are
displayed on the keypad and can be verified through the keypad or a connected pc
with the Control System Toolbox (toolbox) software loaded. Alarm level settings can
also be viewed through the keypad or a connected pc.
Glossary provides definitions of terms and acronyms used within this document.
Index provides an alphabetical term and subject reference.
LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 1 Overview • 1-1

Figure 1-1. LS2100 Static Starter Control Lineup
Figure 1-2. 8.5 MVA LS2100 Static Starter Control Power Conversion Cabinet
1-2 • Chapter 1 Overview LS2100 Reference and Troubleshooting Guide GEH-6680B

Figure 1-3. 14 MVA LS2100 Static Starter Control Lineup
Source Bridge Load Bridge
Figure 1-4. 14 MVA LS2100 Static Starter Control Power Conversion Cabinet

Using Toolbox Help for Reference and Troubleshooting
GEH-6415 describes LS2100 The GE Control System Toolbox is an optionally purchased configuration program
toolbox features and use. used to tune and commission the static starter as needed for each application. The
toolbox provides Microsoft® Windows®-based menus, block diagrams, dialog
boxes, and wizards on a pc-based interface.
When you select Help on the toolbox main menu bar, a drop-down menu provides
several options for finding information.
Organized Help topics, a Help Index

Help
tab, and Find tab for searching the
Contents
Help database
Using Help
How to find information in Help and
how to customize the toolbox Help Release Notes > Additional information about the
features toolbox and GE contacts (requires
Send Problem Report
access to the GE intranet)
Information about the exciter and Goto Toolbox Web Site
toolbox version, installation notes Tip of the Day
Identifies toolbox release, version,
(compatibilities), and requirements About . . . . and platform information
From the Help menu (above), select Contents to access online help files, which
contain fault, function, and wizard information also provided in this manual.
Static-started firmware and

associated reference files may
change with product upgrades
and revisions. The information
provided in this document,
GEH-6680, is current at the
time of its issue. However, the
toolbox Help files provided with
your static starter may be a
more current representation of
your configuration.

Equipment/Material Needed
The equipment and material in the following checklist should be available for the
procedures in this document.
Safety Equipment
Site-specific safety/confined space manual
Personal safety gear (for example; safety boots, safety glasses, hard-hat, high-
voltage gloves, face shield, safety jacket)
High voltage ac/dc detector (with an insulated pole of appropriate length)
Locks and tags, danger and caution tape
Protective grounding cables and grounding stick
Static-charge wrist straps
Typical Maintenance Tools

High-quality tools, including screwdrivers and pliers, designed specifically for
working with electrical wiring systems
Socket set (metric and standard)
Hex wrench set (metric and standard)
1-inch adjustable wrench
5/32" Allen Head Socket Attachment or Allen Wrench
Torque wrench
Electrical tape
Fine file
Clean dry cloth
Heatsink Spreader Tool (GE part 246B9953BPG1)
Novagard Versilube silicone lubricating grease (GE part G322L)
Swing jaw hose clamp (GE part PDMH1020HOSECLP)
Soft-bristled brush (such as a paintbrush)
Mild solution of distilled water and laboratory detergent (Axarel MicroCare
2200 recommended) (Refer to section, Printed Wiring Boards.)
Isopropyl alcohol and citrus based cleaner
Digital meter
High-voltage detector (such as a tic tracer using an insulated pole of appropriate
length)
One megger tester (capable of dc testing from 500 V up to 5 kV)
Source of dry, low-pressure compressed air
Vacuum cleaner with non-metallic nozzle and finely woven, high-efficiency
filter
Fuse puller

How to Get Help
If technical assistance is required beyond the instructions provided in the LS2100
documentation, contact GE as follows:
GE Energy
Post Sales Service
1501 Roanoke Blvd.
“+” indicates the Salem, VA 24153-6492 USA
international access code Phone: 1 800 533 5885, United States.
required when calling from + 1 540 378 3280 (International)
outside the USA.
Fax: + 1 540 387 8606 (All)
Note Please have the GE requisition or shop order number and the equipment serial
or model number available to exactly identify the equipment when calling. Serial
number is on the rating nameplate located on the inside of the control cabinet door.
Related Documents
For more information, refer to the LS2100 documents in Table 1-1, as applicable.
Printed wiring boards in the static starter are located in the control, and power
conversion cabinets. Refer to Table 1-2 for board locations, catalog numbers, and
individual board documents.
Note For specific information or instructions on auxiliary equipment such as

transformers, protective relays, and dc output contactors, refer to the documents
supplied with those products.
Document Distribution
GE Energy supplies product documents to its customers to support the equipment
provided for each requisition. The contract documents define the terms of the
document distribution.
If provided (per contract), the following documents contain requisition information
about the LS2100.
Requisition drawings, including outlines, layouts, and elementary diagrams
Renewal Parts listing
Note If differences exist between the general product documentation and the
requisition documentation, the requisition documentation should be considered the
more exact representation of your equipment or system configuration. Refer to the
section, How to Get Help for information on contacting GE to obtain any required
documentation.

Table 1-1. LS2100 Static Starter Control Documents
Subject Document Content

LS2100 Installation and GEH-6678 Functional description, technical data, customer I/O connections,
Startup Guide keypad (DDI) overview, initial startup procedures
LS2100 User’s Guide GEH-6679 Operational description, full keypad (DDI) information, printed wiring
board overview, other information to help the user operate the
LS2100
Control System toolbox for GEH-6415 How to use the toolbox and options for configuring an LS2100
Configuring an LS2100
Static Starter Control
LS2100 Static Starter GEI-100539 Procedures, precautions, and environmental requirements for
Product Description receiving the static starter from the shipper and storing it before
installation
Printed wiring boards See Table 1-2 Table of printed wiring boards used in the LS2100, their location, part
number, and document number (for complete information)
Trend Recorder GEH-6408 How to use the Trend Recorder feature of the toolbox, including how
to record graphical views of signals
Table 1-2. LS2100 Excitation Control Printed Wiring Boards
Catalog (Part)
Number Board/Module Cabinet Location Document
DS200ADMA Analog to Digital Daughter board Control GEI-100218
DS200DDTB Auxiliary I/O Terminal board Control GEI-100219
DS200DSPC Digital Signal Processor board Control GEI-100220
DS200FCGD Gate Distribution and Status board Control GEI-100221
DS200FCSA Current Sensor Interface board Power Conversion GEI-100222
DS200FGPA Static starter Gate Pulse Amplifier board Power Conversion GEI-100223
DS200FHVA High Voltage Gate Interface board (14 MVA) Power Conversion GEI-100224
IS200FHVB High Voltage Gate Interface board (8.5 MVA) Power Conversion GEI-100530
DS200NATO Voltage Feedback Scaling board Power Conversion GEI-100225
IS215UCVEH2 Unit Controller board Control GEH-6421
DS200VBPL Static Starter backplane Control GEI-100227

Notes

Chapter 2 Preventive Maintenance
Introduction
Preventive maintenance helps to detect and correct conditions that could cause
equipment malfunction. This includes inspections for damage and wear, tests, and
cleaning of equipment at regular intervals. This chapter provides guidelines for
preventive maintenance and is organized as follows:
Section Page
Maintenance Schedule..............................................................................................2-2
Maintenance Record.................................................................................................2-2
Maintenance Procedures...........................................................................................2-2
Before Beginning .......................................................................................2-2
Procedure List ............................................................................................2-3
Fan Replacement Intervals .........................................................................2-3
Dust Removal.............................................................................................2-4
Cleaning Up Oil or Similar Fluids .............................................................2-5
Loose Connections .....................................................................................2-5
Damaged Insulation ...................................................................................2-6
Contactors and Relays................................................................................2-6
Printed Wiring Boards/Modules.................................................................2-6
Short-Circuit Damage...............................................................................................2-7

or burn. Only adequately trained persons who are
should maintain this equipment.
To prevent electric shock while servicing the equipment,
personnel must understand and follow all safety
requirements for working around dangerous voltages.
LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 2 Preventive Maintenance • 2-1
Maintenance Schedule
For maximum benefit, preventive maintenance needs to be performed at scheduled
intervals by a qualified technician. The required frequency for each procedure
depends on:
• How much the equipment is used
Refer to GEH-6679, LS2100 • Ambient environmental conditions
User’s Guide for
environmental specifications. It is recommended that preventive maintenance be performed at least once every two
months in environments that do not meet specifications and on normally scheduled
shutdowns in environments that do meet the environmental specifications. The
schedule should include an inspection of wiring and components before re-applying
power.
Maintenance Record
GE recommends keeping a detailed record of maintenance (such as a log book) for
every static starter. This record serves two purposes:
• Verifies that all equipment is routinely checked
• Aids troubleshooting and prevention of equipment failure by providing a history
of equipment maintenance and problems
Maintenance Procedures
These procedures involve cleaning the equipment and checking for wear and damage
through visual inspection and functional tests.
Before Beginning
To prevent electric shock make sure all power supplies to
the static starter cabinets are turned off. Ground and
discharge equipment before performing any adjustments,
servicing, or other acts requiring physical contact with the
electrical components or wiring.
Before performing any procedures in this section, the static starter must be de-
energized. Do not deviate from the stated de-energizing procedures. If safety
requirements cannot be met completely, or if you do not understand them, do not
work on the equipment.
2-2 • Chapter 2 Preventive Maintenance LS2100 Reference and Troubleshooting Guide GEH-6680B
Procedure List
The following procedures should be performed at appropriate intervals determined
by the environment. Refer to subsequent sections in this chapter for detailed
procedures.
1. Remove dust and dirt from cabinets and electrical components.
2. Check all screw and bolt connections.
3. Inspect wiring for abrasive wear, burns, or melted wire insulation.
4. Inspect all boards: plugs, connectors, wiring, fiber-optic connections.
5. Inspect pumps and the muffin fans for correct operation and rotation.
6. Inspect dc output contactors.
7. Verify integrity and the proper operation of the space heaters (located in control
pump, and power conversion cabinets).
When inspections have been completed, energize the control system and verify its
correct operation. Use a pc or the keypad to communicate to the control and correct
all reported alarms and faults.
Fan Replacement Intervals

The muffin fans on the power supply rack and control board rack should be replaced
at least every seven years. If the control cabinet ambient exceeds 40°C (104°F), fans
should be replaced every four years.
Dust Removal
Build up of dust on electrical components and wiring can

damage components and cause mis-operation.
Tracking involves a build-up Build-up of dust on components can increase operating temperature, thus reducing
of electrical charge along the their normal life. On standoff insulators, it can collect enough moisture to produce a
wire surface, which can cause current path from bus bars to chassis ground. Dust (especially metallic dust) on wire
intermittent problems that are surfaces can cause tracking between connector pins.
hard to find.
¾ To remove dust from the static starter components
1. Clean bus bars and standoff insulators with a clean dry cloth – do not use any
solvents.
2. Using a fine-filtered vacuum cleaner with a non-metallic nozzle, remove dust
and dirt from wiring and electrical components.
3. Inspect cabinet air filters, if equipped. Shake or vacuum filters clean, or replace,
as required.
Note Dust is best removed by vacuuming with a grounded vacuum nozzle/brush. A

less desirable method is blowing with a low-pressure air source that is filtered and
has a water/oil separator.
Do not use high-pressure compressed air, which may

damage components.
If a blow nozzle with a tube extension is used, tape the area
around the tip of the tube to prevent damage to insulation.
When blowing some areas, contamination in other areas
may become worse. Cover areas such as the bridge
assemblies, printed wiring boards, and transformers to
prevent increased contamination.
After cleaning, examine the parts for pitting or other signs of metal deposits on
insulation or insulated parts. If parts are pitted, do not reuse.
Cleaning Up Oil or Similar Fluids
Wear gloves and eye protection when using cleaning fluids

and use them only in a well-ventilated area.
If oil or other similar fluids have accumulated inside the cabinets (such as from a
power device failure), clean them. Use a cleaner strong enough to remove
contaminates, but one that does not harm the components or leave a residue.
Other good products are • A recommended product is Axarel MicroCare 2200 (best for printed wiring
citrus-based solvents. boards and other delicate devices).
• After cleaning, examine the parts for pitting or other signs of metal deposits on
insulation or insulated parts. If parts are pitted, do not reuse.
• Contaminated Nomex insulation should not be reused.
Note Normal household cleaners (such as 409) may leave a salt residue behind, so
must not be used.
Loose Connections
Vibration during equipment operation can loosen mechanical and electrical
connections and cause intermittent equipment failure. Additionally, dust and
moisture in loose connections can cause loss of low-level signals at terminal boards
and also thermal runaway at bus connections.
¾ To check connections
1. Check all hardware and electrical connections by attempting to move the
device/wire, and tighten if needed.
2. Tighten or replace any loosened crimp-style lugs.
3. Tighten or replace all loose or missing hardware.
4. Inspect printed wiring boards for correct seating, and verify that any plugs,
wiring, and bus connectors are tight.
To prevent component damage caused by static electricity,

treat all boards and devices with static-sensitive handling
techniques. Wear a wrist grounding strap when handling
boards or components, but only after boards or components
have been removed from potentially energized equipment
and are at a normally grounded workstation.
To prevent equipment damage, do not remove, insert, or
adjust board connections while power is applied to the
equipment.
Damaged Insulation
Wires and cables with damaged insulation are dangerous when carrying electricity.
They can also intermittently short, causing equipment and functional failure.
¾ To check wires and cables

1. Check all wires and cables for fraying, chipping, nicks, wear, or rodent damage.
2. Check all wires and cables for signs of overheating or carbonization.
3. Repair minor low-voltage insulation damage with a good grade of electrical
tape. If a damaged cable carries high voltages, replace the cable.
4. Replace any cables or wires that have more than mild damage.
Contactors and Relays

¾ To check contactors and relays
1. If possible, manually trip the device to ensure that it works properly.
2. Inspect contacts on open (as opposed to sealed) contactors and relays.
Discoloration and rough contact surfaces are normal.
3. If beads have formed because of severe arcing:
a. Dress the contact faces with a fine file. Do not use emery cloth or
sandpaper.
b. Identify and correct the cause of arcing.
c. Refer to the component’s document for instructions on maintenance, repair,
and replacement procedures.
Printed Wiring Boards/Modules

¾ To clean printed wiring boards/modules
1. Vacuum to remove dust from around the board connections before and after
unplugging.
2. Remove the boards per the instructions in Chapter 3 or the individual board
document (see Table 1-2). Be sure to observe the personal and equipment safety
instructions.
3. Vacuum to remove dust from the board and connections. A soft-bristled brush
may be used to loosen dirt.
4. If excessively dirty, boards may need to be washed, as follows:
a. Use a soft-bristled brush to scrub the board in a lukewarm (37.7°C, 100°F),
mild solution of distilled water and household or laboratory detergent.
(Harsh chemicals and solutions will damage the board. Do not use solvents
containing ammonia, aldehydes, alkalis, aromatic hydrocarbons, or
ketones.)
b. Rinse thoroughly by dipping the board several times in fresh, lukewarm,
distilled water. Do not soak the board.
c. Dry the board by shaking off excess water, immersing and agitating the
board in isopropyl alcohol, then air dry for a few hours.
Short-Circuit Damage
If a short-circuit occurs, overcurrent protective devices on the circuit should cut off
power to the equipment. This normally prevents electrical damage, except at the
point of the short. However, the heat produced by an electrical arc can carbonize
some organic insulating materials, which then lose insulating qualities.
After repairing the cause of the short-circuit and before re-energizing the static
starter:
• Inspect the system thoroughly for damage to conductors, insulation, or
equipment. Replace, if found (refer to section, Damaged Insulation).
• Check insulation resistance.
• Inspect the overcurrent protection devices for damage to insulation and contacts
(refer to section, Contactors and Relays). Replace or repair, as needed.
• Check and replace any open fuses.
Notes
Chapter 3 Parts Replacement
Introduction
Replaceable parts of the LS2100 are located in the control, pump, and power
conversion cabinets. Some parts in the control cabinet are replaceable online
(energized). There are no online replaceable parts in the control or power conversion
cabinets. The information is organized as follows:
Section Page
Safety Precautions and Replacement Guidelines......................................................3-2

Control Cabinet ........................................................................................................3-3
Pump Cabinet ...........................................................................................................3-6
Routine Maintenance .................................................................................3-8
Removal and Replacement Procedures ......................................................3-9
Power Conversion Cabinet .....................................................................................3-15
De-energizing Procedure for the LS2100 Lineup ....................................3-18
Power Conversion Module (PCM)...........................................................3-19
AC Line Filters.........................................................................................3-25
®
VersaMax Micro PLC for Pump Panel I/O ..........................................................3-26
Downloading the requisition software .....................................................3-28
Standard LS2100 configuration file .........................................................3-28
®
Using VersaPro to store the VersaMax Micro PLC configuration ........3-29
LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 3 Parts Replacement • 3-1
Safety Precautions and Replacement Guidelines
With power applied, this equipment contains a potential
hazard of electric shock or burn. Only adequately trained
persons who are thoroughly familiar with the equipment and
the instructions should maintain this equipment.
personnel must understand and follow all safety requirements
for working around dangerous voltages. Make sure that all
power sources to the equipment are turned off, then ground
and discharge the equipment before performing any
adjustments, servicing, or other acts requiring physical
contact with the electrical components or wiring.
Before starting any replacement procedures, make sure that shutting down the
equipment does not interfere with plant operations.
Note It may be necessary to clean the static starter before beginning replacement
procedures. Clean the static starter per the sections, Dust Removal and Cleaning Up
Oil or Similar Fluids in Chapter 2.
Refer to section, The following are guidelines for performing any parts replacement procedure:
Equipment/Material Needed, • Strictly follow all safety precautions and lock-out/tag-out procedures.
in Chapter 1 for tools and
equipment needed to perform • Always install wiring in the routing as when it was removed. The wiring should
replacement procedures. be labeled before being disconnected so that it can be connected in the same
location. Wire routing is important due to interference and partial discharge
control.
• Follow the recommended torque requirements as in Table 3-1.
• Carefully terminate all fiber-optic cables and observe the minimum bend radius
of 2 in (52 mm) for all cables. (Refer to GEH-6678, LS2100 Installation and
Startup Guide, for complete fiber-optic cable recommendations.)
• Always reinstall any baffles, covers, or other items removed to gain access to
parts being replaced.
Table 3-1. Torque Requirements for General Hardware
Electrical Connections Mechanical Connections

Hardware Size Torquing the Bolt Torquing the Nut Torquing the Bolt Torquing the Nut
in-lbf (n-m) in-lbf (n-m) in-lbf (n-m) in-lbf (n-m)
10-32 30 (3.4) 25 (2.8) 30 (3.4) 25 (2.8)
1/4-20 or M6 58 (6.6) 48 (5.4) 101 (11.4) 84 (9.5)
5/16-18 or M8 115 (13) 96 (10.8) 230 (26) 192 (21.7)
3/8-16 202 (22.8) 168 (19) 360 (40.7) 300 (34)
1/2-13 504 (57) 420 (47.5) 1037 (117) 840 (95)
5/8-11 1008 (114) 840 (95) 2088 (236) 1740 (196.6)
3-2 • Chapter 3 Parts Replacement LS2100 Reference and Troubleshooting Guide GEH-6680B
Control Cabinet
All boards and components must be replaced only when the LS2100 is de-energized.
See section De-energizing Procedure for the LS2100 Lineup.
Control power
circuit breakers
Control power
transformer and
power supply
Panel mounted
relays
VME card rack
VersaMax I/O
modules
Auxiliary I/O
Terminal
Board
Customer
terminal boards
Figure 3-1. Control Cabinet Components
Note For detailed control cabinet component layout information, refer to the device
nomenclature sticker, 151X1212CA01NP01, located on the back of the control
cabinet door.
¾ To change the keypad
1. Disconnect all cables from the keypad.
2. Remove the keypad mounting screws and remove the keypad.
3. Orient new keypad in the same position as the one removed, and mount it with
the screws removed in step 2.
4. Tighten hardware per Table 3-1.
5. Reconnect all cables disconnected in Step 1.
6. Perform any necessary hardware verifications and tests. Refer to GEH-6678,
LS2100 Installation and Startup Guide.

power sources to the equipment are turned off (main power
supply and control power supply), then ground the main ac
power cables in the power conversion cabinet before
performing any adjustments, servicing, or other acts
requiring physical contact with the electrical components or
wiring.
¾ To replace boards
1. Replace the board per the replacement instructions in the applicable individual
board document (refer to Table 1-2 for document listing).
Note It is not safe to download the code to flash memory on the static starter while it
is in operation. At the end of the process, the system is reset and the static starter will
trip.
¾ To replace the control rack fan
1. Verify that the connector to the fan is correctly labeled, then disconnect it (see
Figure 3-2).
2. Remove the fan mounting hardware, then remove the fan. (Do not drop anything
into the control).
3. Orient the new fan in the same position as the one removed and set it into place.
4. Secure the new fan with the mounting hardware removed in step 2. Tighten per
Table 3-1.
5. Reconnect the connector that was disconnected in step 1.
Single muffin
fan
Figure 3-2. Control Rack Fan
Pump Cabinet
The drive uses a liquid cooling system to transfer heat from heat producing devices
(such as Silicon Controlled Recifiers (SCR) and high wattage resistors) to a heat
exchanger.
The liquid cooling system is a closed-loop system with a covered reservoir for
makeup coolant (see Figure 3-3). Coolant circulates from the pump discharge, to the
heat exchanger, to the power conversion bridges, and returns to the pump. A portion
of the coolant bypasses to a deionizer system to maintain the coolant resistivity.
The liquid cooling system has the following features:
• Self-venting, closed-loop cooling system that uses a water and propylene glycol
mixture
• Full-capacity coolant circulation pump
• Redundant circulation pumps with automatic changeover and isolation valves
for maintenance
• Full capacity heat exchanger, either remote liquid-to-liquid or liquid-to-air with
cooling blower and optional redundant heat exchanger blowers with automatic
changeover
• Purity alarm monitor with digital resistance and temperature display and
contacts for alarm and trip
• Translucent coolant storage reservoir with cover and contacts for overflow
alarm, low-level alarm and low-level trip
• Deionizer system with isolation valve for maintenance
• Gauge pressure switch
• Pressure gauge
• Drain valves
• Temperature-regulating valve

persons who are thoroughly familiar with the equipment
and the instructions should maintain this equipment.
requirements for working around dangerous voltages. Make
sure that all power sources to the equipment are turned off,
then ground and discharge the equipment before
wiring.
CLF2: PUMP HIGH LEVEL FAULT
CAP VENT
(FILL
HERE)
MOTOR STARTERS-
M1-M4. M3 & M4 ARE
OPTIONAL WITH
COOLANT WATER TO AIR HEAT
RESERVOIR EXCHANGER
M1 M4
CLFA: PUMP LOW

LEVEL ALARM
CLF1: PUMP
LOW LEVEL
FAULT
CTRS:
INLET
RESISTIVITY/
TEMPERATURE
OUTLET SENSOR
CWP1 PUMP1
DEIONIZER
FILTER
INLET
PRESSURE CHARCOAL
SWITCH FILTER
PRESSURE
GAUGE
CWP2 PUMP2
FLOW
FROM STRAINER
BRIDGE
3-WAY
DIVERTER
FLOW TO VALVE
BRIDGE
DRAIN FLOW FROM FLOW TO HEAT TEMPERATURE

VALVE HEAT EXCHANGER EXCHANGER REGULATING VALVE
Figure 3-3. Liquid Cooling System for LS2100
Routine Maintenance
Check the following items monthly to make sure the liquid cooling system is
properly maintained:
• Check the propylene glycol concentration and replenish the coolant, as
necessary.
• Keep the cooling system free from contamination.
• Keep the reservoir covered.
• Clean the strainers.
• Check the coolant resistivity. The life of the carbon filter and deionizer depends
upon the operating temperatures and quality of makeup coolant. If possible, they
should be replaced before the coolant reaches the 1-megohm/centimeter alarm
level.
The deionizer tank should be refurbished by an authorized

service center or replaced with the recommended spare part.
Severe damage to the equipment can result.
• Check all hose connections for leaks. Repair any coolant leaks promptly. To
repair a leak in the 3/8-inch blue coolant hose, re-terminate the hose using two
stepless ear clamps of the type originally supplied with the drive (see Table 3-2).
Cut off the portion of the hose under the old clamps before making a new
connection. The hose itself may be replaced with the hose listed in Table 3-2.
Note Do not use an adjustable, radiator-type clamp on the 3/8-inch bridge hose. This
type of clamp is sharp and not perfectly round.
• Check the radiator on liquid-to-air heat exchangers. Remove any paper or debris
blocking the radiator.
• Check bridge clamp pressure (source bridge and load bridge).
Table 3-2. Recommended Spare Parts
Description Part Number Quantity

Blue Hose 278A2175PUP1 50*
Black Hose Clamp 278A2175RYP1 12
Clear Hose Clamp 305A6482P4 8
Blue Hose Clamp 305A6482P5 24
Filter Wrench 278A2175VNP4 1
Pincer Hose Clamp Tool 305A6482P2 1
*1 = 1 foot (50 = 50 feet)
Removal and Replacement Procedures
Carbon Filter and Deionizer Cartridge Replacement
Note Replace the carbon filter and deionizer cartridge as a pair.
¾ To replace the deionizer cartridge

1. Close ball valve on supply 3/8-inch supply line to the deionizer cartridge and
carbon filter pair.
2. Detach input and output 3/8-inch lines from the low spillage couplings (see
Figure 3-3). These couplings are hand-operated, and mounted in a position to
prevent the reversal of the input and output lines.
3. Remove the 3/8-inch nuts on the clamp, then remove the clamp.
4. Lift out the expended deionizer cartridge.
5. Put in the new deionizer cartridge.
Note All deionizers, regardless of the external cartridge configuration, use the same
mixed bed resin: Ionic NM-60/SG manufactured by Sybron Chemicals Inc.,
Birmingham, NJ 08011, USA. You may contact a local supplier for a new or
refurbished deionizer or purchase from GE Energy or the following supplier: (GE
part number 323A2419)
Water Chemistry Inc.
3404 Aerial Way Drive
Roanoke, VA 24018
Phone: (540) 989-0400
6. Attach input and output 3/8-inch lines to the couplings.

7. Replace the clamp, and the 3/8-inch nuts that hold it in place.
8. Replace the activated charcoal filter.
Filter Replacement
¾ To replace the filter
1. Replace the deionizer cartridge.
2. Unscrew the filter housing (see Figure 3-4).
3. Replace expended filter element with new AMETEK EPM-10 cartridge by
contacting:
AMETEK
Plymouth Products Inc.
502 Indiana Avenue, PO Box 1047
Sheboygan, WI 53082-1047
www.plymouthwater.com
Phone: 1 (800) 222-7558
Fax: (920) 457-6652
4. Open the ball valve on 3/8-inch supply line to the deionizer cartridge and filter
pair.
Figure 3-4. Typical Deionizer Cartridge Flow and Filter
Strainer Cleaning
Open the drain valve on the strainer unit to flush debris from the strainer (see Figure
3-5).
Strainer
Drains
Figure 3-5. Strainer
Coolant Pump Replacement
or burn. Only adequately trained persons who are
should install or maintain this equipment.
¾ To remove coolant pump (two persons are required)

1. Turn off and lock out the startup switch that supplies 460 V ac power to the
subject pump.
2. Remove cover plate at rear of pump motor (see Figure 3-6).
3. Check power at pump to verify that it is off.
4. Disconnect all wires.
5. Turn off supply and discharge valves for pump.
6. Remove the supply and discharge hoses.
7. While the second person holds the failed pump and motor assembly, unfasten
the 1/2-inch hex head bolts that secure the bracket to the cabinet. (The bolt
attaches to weld nuts on the other side of the cabinet wall.)
Discharge
Supply valve valve
Remove
cover plate
½" bolts
Figure 3-6. Pump and Motor Assembly
¾ To install new coolant pump (two persons are required)

1. While the second person holds the replacement pump and motor assembly in
place, fasten the ½-inch hex head bolts that secure the bracket to the cabinet.
2. Attach the hoses.
3. Turn on all valves nearest pump.
4. Reconnect all wires at the rear of the pump motor.
5. Turn on the 460 V ac supply power.
6. Check all connections for leaks.
Temperature-regulating Valve Replacement
Note This procedure will result in the loss of coolant. Replenish coolant per the
directions described previously in this manual.
¾ To replace the temperature-regulating valve

1. Turn motor starters M1 and M2 to the OFF position.
2. Turn all valves to the OFF position, including any valves between the LS2100
and heat exchanger.
3. Turn three-way diverter valve to the MANUAL position.
4. Disconnect the union from incoming pipes at all three ports of the failed valve
(see Figure 3-7). Be prepared to catch any draining coolant.
5. Remove valve from manifold assembly and unscrew unions. Clean any
hardened thread sealant from union threads and from the threads on incoming
pipes.
6. Replace failed valve with FPE part number B1530P080 by contacting:
Fluid Power Energy, Inc.
W229 N591 Foster Court
Waukesha, Wisconsin 53186
http://www.fpevalves.com
Phone: (262) 548-6220
Fax: (262) 548-6239
7. Apply thread sealant (Loctite 565, for example) to threads of each union and
screw into each port of the new valve. Allow sealant to dry as indicated by
sealant manufacturer.
8. Apply thread sealant to incoming pipe threads and install new valve in manifold
assembly by tightening nut on unions to threads of incoming pipes at all three
ports of the valve. Allow sealant to dry as indicated by sealant manufacturer.
9. Replace lost coolant per the instructions given previously in this manual.
10. Verify the water to propylene glycol mixture.
11. Return all valves to the ON position, including any valves between the LS2100
and heat exchanger.
12. Return the three-way diverter valve to AUTOMATIC position as in Figure 3-7.
13. Return motor starters M1 and M2 to the AUTO position.
14. Check connections to temperature regulating valve for leaks.
Unions
Orient to
manual
position
Temperature
regulating
valve
Figure 3-7. Temperature Regulating Valve Replacement
Power Conversion Cabinet
The power conversion cabinet(s) contains the Power Conversion Module (PCM), the
Gate Pulse Amplifier (FGPA) boards, current feedback (FCSA) boards, voltage
feedback (NATO) boards, source bridge line filter, and/or load bridge line filter.
Any parts replacement and troubleshooting inside the power conversion cabinet can
be done only if the LS2100 is de-energized and lock-out/tag-out procedures are
followed.
Source Line
Filter
Power Conversion
Module
Source Source
Bridge A Bridge B
Load
Bridge
Load Line
Filter
Figure 3-8. 8.5 MVA Power Conversion Cabinet, Front View
Source Line Filter
Power Conversion
Module
Source Bridge A
Source Bridge B
Figure 3-8A 14 MVA Power Conversion Cabinet, Front view – Source Bridge
Load Line Filter
Load Bridge B
Figure 3-8B 14 MVA Power Conversion Cabinet, Front view – Load Bridge

persons who are thoroughly familiar with the equipment
and the instructions should maintain this equipment.
requirements for working around dangerous voltages. Make
sure that all power sources to the equipment are turned off,
then ground and discharge the equipment before
wiring.
De-energizing Procedure for the LS2100 Lineup
Use the following procedure to de-energize the LS2100 before attempting to replace
a part inside the power conversion cabinet.
¾ To de-energize the LS2100 lineup
1. Follow all local established procedures for lock-out/tag-out.
2. Shut down all power supplies to the LS2100, including control, main ac input
and output. This typically includes opening the control power breaker (CB1),
generator disconnect switch (89SS), and isolation transformer switch (52SS).
3. Wait at least two minutes after the main ac power supply is turned OFF for all
capacitors in the circuits to discharge.
4. Verify that there is no voltage on any incoming terminals using a suitable
voltmeter.
5. Ground all six phases of the source input and all three phases of the load output
power supply in the power conversion cabinet(s). The cables must be connected
to the PE GND bus located at the bottom, rear section of the power conversion
cabinet(s).
Pump Cabinet
Source Power Load Power
Conversion Conversion
Cabinet Cabinet
Control Cabinet
Figure 3-9. Top view of 14 MVA System
Pump Cabinet
Power Conversion
Cabinet
Control Cabinet
Figure 3-10. Top View of 8.5 MVA System
Table 3-3. Device Nomenclature Sticker Part Numbers
LS2100 Rating Part Numbers

8.5 MVA 151X1212BA01NP01, 151X1212BA01NP02,
151X1212FA01NP01
14 MVA 151X1212TA01NP01, 151X1212TA01NP02,
151X1212TA01NP03
Power Conversion Module (PCM)

As in Figure 3-10, the 8.5 MVA LS2100 contains both source bridges and the load
bridge in a single PCM. The 14MVA LS2100 comprises two separate PCMs, one for
the source and another for the load (See figure 3-9).
Bridge Structure Overview

An insulating I-beam supports the SCR stack’s liquid-cooled heatsinks in the vertical
and horizontal position (see Figures 3-11 and 3-12). The heatsinks in the 14 MVA
LS2100 are tin or nickel-plated copper. The heatsinks in the 8.5 MVA LS2100 are
tin or nickel-plated aluminum with copper tubing. They are bolted to the I-beam with
a spring, which allows a lateral sliding motion.
A glass-reinforced plastic SCR support holds the SCRs in place. This support
registers on an insulating heatsink support bolted to the heatsinks with a set of spring
washers. The heatsink support holds the weight of the SCRs while the stack is
unclamped.
The SCR stack is clamped at 47,500 Newtons (10,800 pounds) so that the total load
on the two parallel stacks is 95,000 Newtons (21,600 pounds).
Note The clamp assembly is supported from the side frames of the bridge
independently of the SCR stacks.
This structure allows the clamp force to be completely removed with all components
intact. The heatsinks can then be moved laterally and the SCRs replaced like books
on a shelf.
The insulators and wire supports are positioned by roll pins in the bus bars and the
clamp pivot. In some cases, there are slots that permit removal when clamp force is
removed by sliding the component past the roll pin.
.......
Heatsinks SCR SCR

Support
Insulator
Connection
for Liquid-
Coolant Hose
Clamp
Heatsink Head
Support
Clamp
Torque
Nut
Teflon
Insulator
Clamp Gap
3.2 mm (0.125")
Jam Nut Spring Nut
Spring
Washers
47,500 N
(10,800lbs.)
44,000 Newtons
(10,000 Pounds) Detail of Clamp Pivot
Figure 3-11. Two SCRs and Typical Support, Front View
Liquid–Coolant
Hose to Heatsink
Heatsink
SCR
Capacitor
Assembly
I-Beam
Hose in Front of
SCR Support Heatsink Support
Capacitor Assembly
Figure 3-12. View of Bridge Showing Heatsink Array
SCR Replacement
Note For the 8.5 MVA LS2100, always replace SCRs as a matched pair. Purchase a
matched pair SCR parts kit from GE Energy (GE part number
151X1212BZ02SA01).
¾ To replace an SCR
1. Open the bridge module doors, left-hand door first, and support them in a full-
open position. Take care not to stress wire and fiber-optic cables at the hinge
and not to damage electronic components. (Refer to Figures 3-11 and 3-12).
2. Loosen the two clamp torque nuts to remove load from the SCR stack.
3. Remove the SCR as follows:
a. Unplug the gate and cathode leads at the FHVA/FHVB board.
b. Insert the heatsink spreader tool (GE part number 246B9953BPG1) on
opposite sides of the SCR (see Figure 3-13), then use it to remove pressure
from the SCR.
c. Grasp the SCR support and slide the SCR from the stack.
d. If the SCR sticks to the heatsink, rotate it to free it.
* Long & Short

Heatsinks
SCR
Heatsink *
Spreader
Tool
Heatsink
Support
* Points of Tool
On Opposite SCR Support
Sides of SCR
I-Beam
Figure 3-13. Heatsink Spreader Tool Placement, Side View
4. Clean the heatsink surface with fine abrasive paper, then wipe thoroughly with a
clean cloth. Hard cleaning may expose bare copper or aluminum, but this does
not impair performance.
5. For the 14 MVA LS2100: Remove the plastic SCR support from the old SCR
and install on the replacement SCR.
For the 8.5 MVA LS2100: Match the replacement SCR provided to the
replacement SCR support as follows:
246B9953ALP3 Eupec 4.25” diameter
246B9953ALP4 ABB 4.1” diameter
246B9953ALP5 Dynex 3.5” diameter
246B9953ALP6 ABB 3.3” diameter
Install the matching replacement SCR support on the replacement SCR.
6. Clean the replacement SCR mounting surface with fine abrasive paper to
remove oxides and wipe thoroughly with a clean cloth.
7. Lightly coat the surfaces with Novagard Versilube silicone lubricating grease
(GE part G322L).
8. Install the replacement SCR and position by snapping the SCR support onto the
heatsink support.
9. Connect the gate and cathode leads to the FHVA/FHVB board.
10. Remove the heatsink spreader tool.
11. Verify that all SCRs, insulators, and wire supports are in alignment within 2.2
mm (.09 in). The wire supports must be aligned vertically.
12. Tighten the torque clamp nuts until the clamp gap is 3.2 mm (.125 in).
13. The jam nuts are used to secure the Teflon™ rod insulator. Tighten against the
Teflon insulator one turn beyond hand tight.
Heatsink and Capacitor Assembly Replacement

In the event of a reistor failure or leaking heatsink, the bridge and filter heatsink
assemblies may be replaced. Refer to Figures 3-11 and 3-12, if needed, during the
following procedures.
¾ To remove a heatsink and capacitor assembly
1. Verify that power to the pump panel has been turned off.
2. Open the bridge module doors, left-hand door first, and support them in a full-
open position. Take care not to stress wire and fiber-optic cables at the hinge
and not to damage electronic components.
3. Loosen the two clamp torque nuts to remove load from the SCR stack.
4. Disconnect all wires from the heatsink assembly and adjacent capacitor
assembly, labeling them for proper retermination to the replacement heatsink
assembly.
5. Block off both the inlet and outlet hoses of the heatsink to be removed and all
hoses in front of the adjacent capacitor assembly using swing jaw clamp
PDMH1020HOSECLP.
6. Disconnect the inlet and outlet hoses of the heatsink to be removed and all hoses
in front of the adjacent capacitor assembly by removing the blue hose clamps.
Use caution when removing the blue hose clamps. Any

damaged hose must be replaced to prevent leaks.
7. If replacing one of the large, bridge heatsinks, remove the SCRs adjacent to the
heatsink, as described in the SCR replacement procedures.
8. If replacing one of the filter heatsinks, all SCRs may remain in place.
9. Remove the adjacent capacitor assembly.
10. Remove the locknuts and washers mounting the heatsink to the heatsink support.
11. Remove the stainless steel cap screw, spring, spacer and washers holding the
heatsink assembly to the I-beam using a 5/32” Allen wrench. Keep all hardware
for re-installation.
12. Remove the heatsink.
¾ To install the heatsink
1. Replace the heatsink, and secure as follows:
a. Mount the heatsink to the I-beam by installing the stainless steel cap screw,
spring, spacer and washers as in Figure 3-14. Torque to 25 in-lbs.
b. Secure to the heatsink support by installing the flat washer first, followed by
the spring washer’s concave face against the flat washer.
c. Tighten the locknut against the spring washer, and then back off 1/2 turn.
2. Replace the capacitor assembly and snubber wires.
3. Replace the SCR as described in the SCR replacement procedure above.
4. Reconnect all hoses and remove hand clamps.
5. Reconnect all wires to the heatsink and capacitor assemblies.
6. Verify that all SCRs, insulators, and wire supports are in alignment within 2.2
mm (.09 in). The wire supports must be aligned vertically.
7. Tighten the torque clamp nuts until the clamp gap is 3.2 mm (.125 in).
8. The jam nuts are used to secure the Teflon rod insulator. Tighten against the
Teflon insulator one turn beyond hand tight.
9. Check for leaks after power to the pump panel is restored.
Figure 3-14. Heatsink Mounting Hardware
AC Line Filters
The 8.5 MVA LS2100 contains both source and load AC line filters in a single
power conversion cabinet. In the 14MVA LS2100, the load and source filters are in
separate cabinets (see Figure 3-9).
¾ To replace a fuse
1. Verify that the static starter has been properly de-energized per the section, De-
energizing Procedure for Power Conversion Cabinet.
2. Remove any lexan covers as needed to access the fuse to be replaced.
3. Remove the pin that holds the blown fuse indicator switch in place and pull the
end of the switch from the fuse.
4. Pull the fuse out of the fuse holder.
Note Replacement fuse must be of the same voltage and current parameters as the
fuse removed. Refer to the renewal parts list for the correct part number fuse.
5. Orient the new fuse in the same position as the one removed and set it into the
fuse holder.
6. Reconnect the blown fuse indicator switch to the new fuse.
7. Reset the red indicator tab of the blown fuse indicator switch.
8. Re-install any lexan covers removed in step 2.
All Lexan pieces in LS2100 are functionally important and

must be in place during operation. If removed for
maintenance access they must be re-installed before the
static starter is energized again
¾ To replace a capacitor or MOV

1. Verify that the static starter has been properly de-energized per the section, De-
energizing Procedure for Power Conversion Cabinet.
2. Remove any lexan covers as needed to access the component to be replaced.
3. Disconnect any wires to the failed component, labeling them for proper
retermination to the new component. Replace all damaged wires as necessary.
4. Remove all mounting hardware and failed component.
5. Install the new component in the same orientation as the old one using the
mounting hardware removed in step 4.
6. Reconnect all wires disconnected in step 3.
7. Re-install any lexan covers removed in step 2.
VersaMax® Micro PLC for Pump Panel I/O
The VersaMax Micro programmable logic control (PLC) processes the LS2100
pump panel inputs and outputs. It has input provisions for hard-wired run commands
from the MK6 when requested by the customer. The status of the input devices is
transmitted through Modbus serial communication to the UCVE. The UCVE then
sends the status information to the DSPC where the pump panel control program is
executed.
Figure 3-15. LS2100 Pump Panel Inputs and Outputs
The PLC receives control commands to energize the outputs from the UCVE control
program through serial Modbus communication. All the control logic, driving the
PLC control outputs, is executed in the UCVE controller.
Figure 3-16. Output Devices Driven by the Versamax Micro PLC
Downloading the requisition software
The hardware and software configuration is standard for both crossover and non-
crossover LS2100 units. The configuration is stored in the PLC during the final test
in the Salem factory.
Use the following instructions to store the VersaMax Micro PLC configuration
software in the event of a PLC replacement or if instructed by Salem’s Static Starter
Engineering.
Requirements:
VersaPro 2.01 Software IC641VPP700 (Professional) or
IC641VPS002 (Standard)
GE Fanuc Part number:
The professional package could be used
for both LM90/30 and Versamax Micro.
The standard can be used only for
VersaMax Micro.
Connecting Cable between the GE Fanuc IC 200 CBL500
Laptop and VersaMax Micro PCL
Comm1
Standard LS2100 configuration file

The standard LS2100 Versamax PLC backup file is part of the LS2100 runtime
release and can be found in the following directory in the HMI or installation pc:
C:\Program Files\GE Control System Solutions\Static

Starter Control\LS2100\V01.01.05C\vmplc
The file name is: ls2100_Vmax01.flb
Using VersaPro® to store the VersaMax Micro PLC
configuration
¾ To store VersaMax Micro PLC configuration software
1. Open the VersaPro program. The Work Area screen displays.
2. From the Main menu, select Folder, then click Restore. The Restore
Folder dialog box displays.
3. Click the Source File Path and Name browse icon to find the
Ls2100_Vmax01.flb file.
4. Select the vmplc directory.
5. Select the Ls2100_Vmax01.flb file, then click Open.
6. Click the Destination Path browse icon to find the directory and restore the
PLC configuration software.
7. Select a directory in which you want to restore the PLC configuration (example:
c:\site\master\ls2100).
8. Click OK. The PLC configuration is restored in the directory indicated.
9. Connect the GE Fanuc IC200CBL500 cable from the pc Comm Port 1 or 2 to
the PLC Comm Port 1.
10. Create a communication device to establish the serial communication between
the configuring pc and the PLC.
a. From the Main menu select Tools, then Communications Setup.
b. From the Communications Setup window, select the Ports tab and
check that the COM1 and COM2 port settings display.
c. In the configuration pc, verify that the used COM port settings match those
in the indicated screen.
d. Verify that the selected device has the used COM port (i.e., the
®
Cimplicity ControlSerial device uses COM1).
11. From the Main menu, select PLC, then click Connect .
12. From the Connect window, select one of the serial communication devices
(i.e., CimplicityControlSerial). Click Connect to establish communication.
13. Once the connection is established, the Versamax PLC status information
displays.
14. From the Main menu, select PLC, then click Store…
If the PLC is not in the RUN mode, the following message displays.
15. Click the Stop PLC icon to place the PLC in STOP mode.
16. From the Main menu, select PLC, then click Store…
17. The Store Folder to PLC window displays. Select all three options, then click
OK.
18. To view the log information, click the General tab.
Disregard the four warnings that generate when the storing process ends.
19. Place the PLC in the RUN mode. Click RUN.
The PLC is now back in RUN mode.
Notes
Chapter 4 Troubleshooting
Introduction
Troubleshooting the LS2100 includes:
General troubleshooting, which has no specific fault code or indication
Specific troubleshooting, which displays a specific fault number/name on the keypad
The information is organized as follows:
Section Page
Introduction ............................................................................................................................4-1
General Troubleshooting ........................................................................................................4-2
Specific Fault Troubleshooting...............................................................................................4-8
Types of Faults .........................................................................................................4-8
Fault Indications .......................................................................................................4-8
Viewing and Resetting Faults on the Keypad/DDI ..................................................4-9
LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 4 Troubleshooting • 4-1

General Troubleshooting
persons who are thoroughly familiar with the equipment and
the instructions should maintain this equipment.
power sources to the equipment are turned off, then ground
and discharge the equipment before performing any
adjustments, servicing, or other acts requiring physical
contact with the electrical components or wiring.
The following table, which provides a quick reference guide to general

troubleshooting, contains problem numbers that are referenced in the subsequent
tables.
4-2 • Chapter 4 Troubleshooting LS2100 Reference and Troubleshooting Guide GEH-6680B

Troubleshooting Quick Reference Guide
Type of Problem Problem Number Reference
Static Starter faults, LED indication on DSPC 1. For DSPC, see section Specific Fault Troubleshooting
board
Keypad/DDI problems 2. Keypad/DDI display off
3. Error messages displayed
4. Keypad/DDI ineffective - no errors displayed
5. Parameter changes ineffective
6. Diagnostics do not perform
Board failures, power supply failures, fan failures 7. Power supply fuses blowing
8. MOV failures
9. Repetitive board failures
10. Fan or fan power supply failures
Operational problems 11. Ac or dc input breakers opening

12. Serial link does not function properly
13. Erratic operation
14. Stability problems
15. MOV failures
Noise, wiring, power supplies, and similar 16. Noise or random nuisance faults
problem 17. Wiring procedures

General Troubleshooting Guide
Problem Correction Procedures
1) Keypad/DDI display off 1. Are plugs connected correctly?

2. Check power supplies – refer to problem 17.
3. Check DSPC board for proper operation.
4. Replace DSPC board or keypad/DDI.
2) Keypad/DDI ineffective, 1. Are plugs inserted properly?

no errors displayed 2. Check DSPC board for proper operation.
3) Parameter changes 1. Check DSPC board for proper operation.

ineffective 2. Replace DSPC board or keypad/DDI.
4) Diagnostics do not 1. Check that the particular function is available (refer to the Custom Software
perform Descriptions).
2. Check DSPC board for proper operation.
5) Power supply fuses 1. Check that the fuses are correct size.
blowing 2. Check for any shorted or overloaded power supplies - refer to problem 16.
6) MOV failures 1. Check waveforms of ac inputs.
7) Repetitive board failures 1. Check for damage caused by airborne chemical contamination or foreign objects.
2. Check all connections at all terminal boards.
3. Check that all boards are properly inserted into the backplane.
4. Check the power supply.
5. Check that all voltages are correct.
6. Check for moisture.
8) Serial link does not 1. Check that correct serial link cable is being used.
function properly 2. Check the Static Starter's baud rate compared to serial link device (hard reset must
be performed afterward if baud rate is changed).
3. Check serial link connections at terminal board.
4. Check/replace the DSPC.

Table 4-2. General Troubleshooting Guide — Continued
Problem Correction Procedures
9) Erratic operation 1. Check power supplies for magnitude and ripple – refer to problem 16.
2. Check connections on all cables and boards.
3. Tighten all connections on terminal boards and all power connections.
4. Confirm correct hardware jumper settings per the Custom Software.
5. Check all parameters per the software test data sheet or Custom Software.
6. Check for noisy ground connections.
10) Stability problems 1. Check settings of all parameters.

2. Contact GE Energy.
11) Noise/random nuisance 1. Check that any dc supply voltages are not used externally.
faults 2. Check for suppression on all relays, contactors, and starters.
3. Check all power supplies.
12) Wiring procedures 1. Check the wire sizes on the ac and dc 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 are twisted-pair, shielded and that shields are grounded
at the Static Starter end only.
4. Check that signal wires are not grounded at more than one end or other than the
Static Starter 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.
13) Checking power Check the LEDs on the power supply module for proper voltage indications.
supplies

Table 4-3. General Control Cabinet Troubleshooting
Type of Fault Behavior Detection Action
UCVE board not responding Lost communication to the Board LEDs are dark Possible problem with
DSPC board not responding board power supply of the board
Keypad screen blank Impossible to communicate Verify power supply and
to the board from the keypad the backplane
UCVE board does not Communication problems When PC hooked up to the Check integrity of the
communicate with the PC with the controller controller it is not possible to ENET cable
and the keypad read or change of any of the
parameters
UCVE board is working but DSPC LEDs are dark Board LEDs do not indicate Check power supply to the
DSPC does not indicate that Processor LED does not any communication between board (verify backplane)
it is responding indicate that the card is DSPC and UCVE boards
active
When communicating to the When using a trend recorder Lack of feedback values Verify NATO and FCSA
Static Starter with the there are no feedback boards
toolbox there are no values from the static starter Verify DSPC and UCVE
feedback values for current boards
and volts
Sync Trip Flt When static starter A problem with ac power Check incoming ac
commanded to RUN it trips supply to the bridge amplitude on all three
on PLL_Loss phases
No communication from the Controller is not responding It is not possible to send a Replace the keypad
keypad to the controller to the commands from the command to the controller Replace the cable from the
keypad from the keypad keypad to the backplane
PLC Heart beat fault UCVE does not Trip - VersaMax PLC Check for 5Vdc at pins 5
communicate with PLC heartbeat & 7 on VersaMax PLC
Alarm coolant Temp alarm Port-2. If 5 V is not
present, the PLC needs
Alarm pump resistivity replacement or factory
alarm repair.
Trip resistivity Trip
Trip pump high level trip

Table 4-4. General Pump Cabinet Troubleshooting
Source/load line filter Rise in coolant temperature Dis -colorisation of line filter Check for proper coolant flow in
resistors gets over resistors the heat sink of the filter
heated Smoke from filter cabinet resistors.
Check for proper coolant circuit
connection to the line filters
resistors heat sink.
Check for proper operation of
temperature regulating valve.
Check for the proper flow of
external cooling water (under
customer scope) in heat
exchanger (W-W)
High-level of harmonic High level of harmonic noise Verify the ac input voltage Verify ac line filter fuses
disturbances at the ac detected by other users waveform using the scope Verify ac line filter resistors and
incoming line There is no indication that capacitors
ac line filter is actively
working in the circuit – no
heat generated by the
resistors
Ac line filter resistor When static starter under Use meter to verify integrity Replace capacitor if shorted
problem load, there is an intensive of the line filter capacitors
heat generated by the ac
line filter unit
Table 4-5. General Power Conversion Cabinet Troubleshooting
FGPA board is not All yellow LEDs are not lit Check gating LEDs on ESEL Replace FGPA board
generating gate pulses Bridge does not work – no Check fibre-optic cables
output current; from FCGD board
Use oscilloscope to verify
bridge proper gating
SCR is not conducting SCR is not conducting but is Verify the 10 – 20 Ohm Replace gate leads or
not shorted resistance between Gate SCR
and Cathode

Specific Fault Troubleshooting
Additionally, the static starter The LS2100 Static Starter software includes self-test diagnostics to aid in
can broadcast these codes troubleshooting. When the static starter detects a fault it displays the fault code on
through an optional serial the keypad.
data link.
Types of Faults
There are currently two types of fault conditions:
• Alarm faults indicate conditions that you should note, but that are not serious
enough to automatically shut down or trip the static starter. If the condition goes
away, some alarm faults clear themselves and the display then identifies the
alarm as brief. Otherwise, you must stop the static starter to clear this type of
fault.
• Trip faults indicate a more serious condition that needs to be corrected.
Therefore, it trips the static starter. The static starter should not be restarted until
the condition is corrected.
You can clear most faults by selecting Clear Faults on the static starter’s keypad or
in the (optional) toolbox program.
Fault Indications
The DSPC board is the The static starter indicates a fault condition on the keypad, toolbox display, and on
DS200DSPC Digital Signal the DSPC board.
Processor, located in the
On the keypad, a fault icon appears in the right side of the display: The operator can
static starter control rack.
then use the keypad to access the fault/alarm description (see Figure 4-1) and to clear
the fault.
Abbreviated Description
Fault No.
ACTIVE FAULT DISPLAY
Fault Icon:
50 Trip HtSink temp low, B
108 DC bus voltage low Flashing = fault
12 Trip Gnd flt, Not flashing (on steady) = alarm
113 Trip Invalid board set
--- RESET FAULTS NOW ---
Fault Behavior
Figure 4-1. Sample Fault Display Screen on Keypad
The toolbox uses a Windows-based pc display. When a fault occurs, the word
Alarm or Trip appears in the lower right corner of the screen. You can view a
description and clear the fault using the toolbox functions. Refer to GEH-6414.
The DSPC Fault LED displays at the front of the static starter’s control rack. This
red indicator is on solid for a fault and flashes for an alarm. A fault is identified by
an assigned number and abbreviated description. Both of these are displayed when
an operator examines a fault using the keypad or the toolbox.

Viewing and Resetting Faults on the Keypad/DDI
When the keypad/DDI indicates either a Trip or an Alarm fault, you can view
information and reset (clear) current faults, as follows:
1. From the Main menu, select Fault List, and then select Display Active
Faults. The following screen displays.
Faults are displayed in order
of occurrence with the most
recent fault at the top.
2. To view detail on a particular fault, select that fault (listed on the Active Fault
Display screen) by pressing Enter. The following screen displays.
3. Reset the faults either of two ways:

• Select Reset Faults Now in the Fault Display screen.
• Click the Reset Faults button.
¾ To view the static starter’s fault history (a list of previously cleared

faults and fault resets)
This display list may be • From the Main menu, select Fault List, and then select Display Fault
multiple screens long. History.

Notes

Glossary of Terms
block
Instruction blocks contain basic control functions, which are connected together
during configuration to form the required machine or process control. Blocks can
perform math computations, sequencing, or regulator (continuous) control.
board
Printed wiring board or card.
bus
Upper bar for power transfer, also an electrical path for transmitting and receiving
data.
DDI/keypad
Diagnostic Display/Interface that is also referred to as the keypad that provides
exciter status icons and displays fault information. It can also be used to check
firmware and hardware versions, run the exciter, set parameters, reset the exciter,
and provide other control functions.
device
A configurable component of a control system.
fault code
A message from the controller to the HMI indicating a system warning or failure.
firmware
The set of executable software that is stored in memory chips that hold their content
without electrical power, such as EEPROM or Flash.
LS2100 Reference and Troubleshooting Guide GEH-6680B Glossary of Terms • G-1

flash
A non-volatile programmable memory device.
gating
Controlling the conduction of the power SCRs with an input pulse train (or a
voltage).
HMI
Human Machine Interface, usually a PC running Windows NT and CIMPLICITY
HMI software.
I/O
Input/output interfaces that allow the flow of data into and out of a device.
line filter
Filter networks across the three-phase input lines to the static starter to minimize the
voltage spikes that result from the abrupt decay of current during SCR
commutations.
Modbus
A serial communication protocol developed by Modicon for use between PLCs and
other computers.
redundant
A system consisting of duplicated components (boards or modules), which can
transfer functionality from a failed component to one of the duplicate components
without loss of the entire system’s functionality.
signal
The basic unit for variable information in the controller.
toolbox
A Windows NT -based software package used to configure the EX2100 and Mark VI
turbine controller.
V/Hz
V/Hz is the ratio of generator voltage to the frequency; this is limited to prevent
overfluxing the generator.
G-2 • Glossay of Terms LS2100 Reference and Troubleshooting Guide GEH-6680B

E
equipment
maintenance tools 1-4
safety 1-4
Index F
fan replacement intervals 2-3
faults
indications 4-10
trip 4-10
types 4-10
viewing and resetting 4-11
A H
AC line filters 3-23, 4-8 heatsink
alarm faults 4-10, 4-11 installing 3-22
help
B how to get 1-5
Boards
Digital Signal Processor 1-6 K
Gate Pulse Amplifier 1-6 keypad
printed wiring 1-6, 2-5, 2-6 changing 3-4
UCVE 3-24, 4-7 viewing and resetting faults 4-11
bridge
assemblies 2-4
L
Power Conversion 3-6
structure overview 3-17 loose connections 2-5
LS2100
C catalog numbers 1-5, 1-6
de-energize lineup 3-3, 3-16
cabinet printed wiring boards 1-6, 2-6
control 2-3, 3-3, 3-16 standard configuration file 3-26
pump 1-1, 2-3, 3-1
cleaning
M
strainer 3-11
communication motor starters
serial 3-24, 3-30, 3-31 M1 3-13
contactors and relays 2-6, 2-7 M2 3-13
control maintenance
cabinet 2-3, 3-3, 3-16 cleaning boards 2-5
power circuit breakers 3-3 cleaning up oil 2-5
controller 3-25, 4-7 contactors and relays 2-6
Control System Toolbox 1-3, 1-6 dust removal 2-4
fan replacement 2-3
D loose connections 2-5
procedures 2-2
damage pump cabinet 3-8
insulation 2-6 record 2-2
short-circuit 2-7 schedule 2-2
documents
distribution 1-5
related 1-5
dust removal 2-4, 3-2
LS2100 Reference and Troubleshooting Guide GEH-6680B Index • I-1

P
Power Conversion
cabinet 1-1, 2-3, 3-15
module 3-15, 3-17
procedure list 2-3
R
reference 1-1, 1-3, 4-3
related documents 1-5
document distribution 1-5
replacement
boards 3-4
carbon filter 3-8, 3-9
control rack fan 3-5
coolant pump 3-12
deionizer cartridge 3-9
filter 3-10
heatsink and capacitor assembly 3-21
parts 3-1
SCR 3-20, 3-21
temperature-regulating valve 3-13
S
safety
equipment 1-4
guidelines 3-2
silicon controlled rectifiers (SCR) 3-6, 3-17, 3-20
software
downloading 3-26
spare parts
description 3-8
number 3-8
static starter 1-1, 2-2, 4-10
T
Toolbox
help 1-3
troubleshooting
general 4-2
quick reference guide 4-3
specific fault 4-10
typical maintenance tools 1-4
V
VersaMax 3-24, 3-26
I-2 • Index LS2100 Reference and Troubleshooting Guide GEH-6680B

g GE Energy
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1 540 387 7000

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LS2100 Static Starter Control

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Indicates a procedure, condition, or statement that, if not

Indicates a procedure, condition, or statement that, if not

Indicates a procedure, condition, or statement that should be

Note Indicates an essential or important procedure, condition, or statement.

Isolation of test equipment from the equipment under test

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.......................................................................................... Fold here first ........................................................................................................

Chapter 1 Overview 1-1

Chapter 2 Preventive Maintenance 2-1

Chapter 3 Parts Replacement 3-1

LS2100 Reference and Troubleshooting Guide GEH-6680B Contents • i

Glossary of Terms G-1

ii • Contents LS2100 Reference and Troubleshooting Guide GEH-6680B

Using Toolbox Help for Reference and Troubleshooting.........................................1-4

Chapter 2, Preventive Maintenance The procedures help to prevent, detect, and

LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 1 Overview • 1-1

1-2 • Chapter 1 Overview LS2100 Reference and Troubleshooting Guide GEH-6680B

Source Bridge Load Bridge

LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 1 Overview • 1-3

Organized Help topics, a Help Index

Static-started firmware and

1-4 • Chapter 1 Overview LS2100 Reference and Troubleshooting Guide GEH-6680B

Typical Maintenance Tools

LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 1 Overview • 1-5

Note For specific information or instructions on auxiliary equipment such as

1-6 • Chapter 1 Overview LS2100 Reference and Troubleshooting Guide GEH-6680B

Subject Document Content

Table 1-2. LS2100 Excitation Control Printed Wiring Boards

LS2100 Reference and Troubleshooting Guide GEH-6680B Chapter 1 Overview • 1-7

1-8 • Chapter 1 Overview LS2100 Reference and Troubleshooting Guide GEH-6680B

This equipment contains a potential hazard of electric shock

Fan Replacement Intervals

Build up of dust on electrical components and wiring can

Note Dust is best removed by vacuuming with a grounded vacuum nozzle/brush. A

Do not use high-pressure compressed air, which may

Wear gloves and eye protection when using cleaning fluids

To prevent component damage caused by static electricity,

¾ To check wires and cables

Contactors and Relays

Printed Wiring Boards/Modules

Safety Precautions and Replacement Guidelines......................................................3-2

Table 3-1. Torque Requirements for General Hardware

Electrical Connections Mechanical Connections

VME card rack

Figure 3-1. Control Cabinet Components

To prevent electric shock while servicing the equipment,

Figure 3-2. Control Rack Fan

With power applied, this equipment contains a potential

CLFA: PUMP LOW

DRAIN FLOW FROM FLOW TO HEAT TEMPERATURE

Figure 3-3. Liquid Cooling System for LS2100

The deionizer tank should be refurbished by an authorized

Table 3-2. Recommended Spare Parts