9449900990

Basler ECS2100
Excitation System
Publication 9449300990
® Revision -
Excitation Control Equipment

Instruction Book
NCPA
Lodi Energy Center
System P/N: 9449300100
® Basler Electric
12570 State Route 143
Highland IL 62249-1074 USA
www.basler.com, info@basler.com
Phone +1 618-654-2341 Fax +1 618-654-2351
Manual P/N: 9449300990
ECS2100 EXCITATION SYSTEM INSTRUCTION MANUAL

Description Publication Tab
ECS2100 Overall System IL6D34314 1
Handling, Installation, and Maintenance 9410100990 2
Single- or Dual-Channel Installation IL6D34315 3
Controller Configuration Tool (ccTool) ILECSM009 4
PanelMate Display User’s Guide 01-00394-00 5
PanelMate Screens IL195C492 6
Remote PanelMate Installation (Multi Drop Adapter) ILECSM008 7
Time Overcurrent Relay (BE1-51) 9137200997 8
Ground Detector (64) IL195C308 9
Type SG Auxiliary Relay (94E) 41-751N 10
Communication Converter (CONV) Data Sheet 11
Exciter Control Module (E1M, E1R) IL8651C66 12
Firing Control Interface Module (F1M, F1R) IL8651C67 13
Sensor Input Module (S1M, S1R) IL8651C65 14
Analog I/O Module (A1M, A1R, A2M, A2R) IL8651C69 15
Digital I/O Module (D1M, D1R, D2M, D2R) IL8651C68 16
Bridge Control Module (BCM) IL8651C70 17
Power Bridge (PWR DWR) IL4D01737 18
De-Excitation/Crowbar Module (DX) IL8526C34 19
ECS2100 Isolation Card (PTCT) IL25A4501 20
Isolation Transducer (ALXDM, ALXDR, DCXDM, DCXDR) IL8651C64 21
Field Breaker (41A) IB2C12060H05 22
Power Supply (PS1, PS2) Data Sheet 23
Power Supply (PS4A, PS4B) Data Sheet 24
Power Supply (PS6, PS7) Data Sheet 25
Shaft Suppression Capacitor (CD1, CD2) Data Sheet 26
Shaft Suppression Resistor (RD1, RD2) Data Sheet 27
AC Surge Suppressor (VT) Data Sheet 28
Thermostat (TH) 95C-10686-3 29
I
Description Publication Tab
Installation Guidelines for Seismic Applications 2190A88 30
Layout Drawings, Unit 1 9449300400 31
Outline Drawings, Unit 1 9449300920 32
Wiring Diagrams, Unit 1 9449300950 33
Interconnection Diagrams, Unit 1 9449300960 34
Schematic Diagrams, Unit 1 9449300910 35
Layout Drawings, Unit 2 9449300401 36
Outline Drawings, Unit 2 9449300921 37
Wiring Diagrams, Unit 2 9449300951 38
Interconnection Diagrams, Unit 2 9449300961 39
Schematic Diagrams, Unit 2 9449300911 40
ROUTE 143, BOX 269

HIGHLAND, IL 62249 USA
http://www.basler.com, info@basler.com
PHONE +1 618-654-2341 FAX +1 618-654-2351
II
FOR
ECS2100 EXCITATION CONTROL SYSTEM
OVERALL DESCRIPTION
PURPOSE AND APPLICATION

The voltage regulator and excitation system control the output of an ac generator by controlling the power
delivered to the generator field. Typically, field power is delivered through thyristor (SCR) power amplifiers.
Operating Power
Operating power for the regulator and excitation system depends upon the type of system and can be supplied by
any of the following sources:
• An appropriate step-down power potential transformer (PPT) connected to the output terminals of the ac
generator
• A shaft-driven permanent magnet generator (PMG), usually an integral part of a brushless excitation system
• A separate motor-generator set
• A reliable station source, usually 480 Vac or higher
Excitation System Types

Excitation systems can be classified as either static exciters or voltage regulators. A static exciter operates
directly on the field of an ac generator. A voltage regulator usually controls the field of an auxiliary machine
(exciter) whose output is either rectified or connected directly to the ac generator. Voltage regulators can be
further classified by the following exciter types.
Brushless Exciter
A brushless exciter derives its operating power from a shaft-mounted PMG (usually operating at 420 Hz). The
output of the regulator controls the dc power applied to the stator field of an alternator, whose ac rotor windings
are rectified by shaft mounted diodes. This rectified output is fed directly to the ac generator field.
Single Field DC Exciter
A single field dc exciter is controlled by a regulator whose dc output usually powers the single main field of the dc
machine.
Buck-Boost DC Exciter
A buck-boost dc exciter is controlled by a combination of a "base" dc level in a main shunt field and two auxiliary
"buck" and "boost" fields. The dc level in the main field is usually set by a power rheostat. The buck and boost
fields regulate by adding to or subtracting from the base excitation level.
Alternator-Rectifier Exciter
An alternator-rectifier exciter is controlled by a regulator whose output controls the field of an ac alternator. The ac
output is rectified and applied to the main machine field through brushes.
Excitation System Control Modes

An excitation system can be controlled in either manual or automatic mode.
Manual Mode
In manual mode, the dc field voltage or current is controlled in response to a dc error detector. Normally, the
regulator will default automatically to this mode if the PT signals are lost, for example, due to an open PT fuse
Automatic Mode
In automatic mode, the field current is controlled through an ac voltage error detector that responds to changes in
the generator ac terminal voltage. When operating in automatic mode, either reactive current (var) or power factor
(PF) control mode can be selected.
Var control mode regulates the ac generator reactive current flow. The calculated var level is compared to a var
reference value and the ac voltage setpoint is raised or lowered to achieve the desired var flow.
Publication Revision First Printing: Copyright

IL6D34314 D Revised: 01/08 2008
PF control mode adjusts the generator power factor by detecting the phase relationship of the generator voltage
and current. The calculated power factor is compared to a PF reference and the ac voltage setpoint is raised or
lowered accordingly.
HARDWARE
The excitation control system is an integrated unit composed of sections of low-voltage, metal-enclosed
switchgear along with the generator field and any rotating exciter. (As an option, the low-voltage sections may be
attached to a high-voltage cubicle containing the excitation power transformer.) The system has three major
sections: incoming line, power amplifier, and control.
Incoming Line Section

The incoming line section contains terminal blocks for connection to the exciter or main generator field, the
incoming ac power, and the excitation ac supply circuit breaker (41A). It is also the location for any excitation
power transformer protective relays and generator relays such as overcurrent relays.
Power Amplifier Section

The power amplifier section consists of one or more cubicles. In some configurations, each cubicle contains from
one to four power amplifier draw-out drawers, main and reserve cooling fans (if utilized), and the fan control
circuits (if required). Another configuration for the power cubicles consists of fixed, mounted SCR bridges which
may be either convection- or fan-cooled. The field flashing, nonlinear resistor, and other field-related power
devices are typically located in this section and/or the incoming line section.
Control Section
The control cubicle typically contains a set of a set of SIM, ECM, and FCIM modules for each channel and the
control relays required to operate the system. Auxiliary control transformers for the system are also located within
the control cubicle.
With the exception of the control cubicle, most of the ECS2100 system is similar to previous analog or digital
excitation equipment produced by Basler Electric.
EXCITATION CONTROL FUNCTIONS AND CIRCUITS

The principal excitation control functions and circuits are described in the following paragraphs. For a more
detailed description of a specific module, consult that module's instruction manual.
Exciter Control Module

Virtually all of the functions that traditionally have been provided by individual analog modules are included in
software modules or "blocks" in the ECM card. Some of these functions are optional and must be specifically
provided in the job-specific, flash EEPROM contained in the ECM.
Manual Mixer
This function replaces the dc error detector and a portion of the signal mixer in previous analog systems. It is
used for closed-loop regulation of field current (or in a few instances, field voltage). The feedback signal from a
field current/voltage transducer is sent to the manual mixer function which compares it to a reference value
(manual adjuster reference) and then multiplies the resultant signal by a gain constant. This signal is then
compared to any enabled limiter signals and the resultant error value is sent to the regulator mode select function.
In most systems, this function is automatically the default mode of control when the PT signal fails.
Auto Regulator
This function replaces the ac error detector and a portion of the signal mixer in previous analog systems. It is
derived from the regulator PTs. It can optionally be derived from metering PTs, in the event the digital system
detects a failure of the regulator PTs. The feedback signal, proportional to the generator terminal voltage, is
compared to a reference value (ac adjuster/follower) and then summed with any enabled generator ac current
compensation signals. The resultant error is multiplied by a gain and sent to the auto mixer function.
Several types of generator current compensation can be provided as auxiliary signals to the auto regulator
function. Reactive droop and line drop compensations use a processed CT input to modify the reference setpoint
(ac digital adjuster) value, based upon the magnitude of the reactive portion of the line current. Cross-current
compensation uses an additional CT input from another generator to provide for reactive current sharing of
paralleled units.
Page First Printing: Revision Publication
2 Revised: 01/08 D IL6D34314
Auto Mixer
This function replaces a portion of the signal mixer in previous analog systems. It is used for the closed-loop
regulation of the generator terminal voltage. The mixer enables one of three possible input error signals: ac
voltage, power factor, or var error. The resultant signal may be then summed with any enabled PSS and/or
generator current limiter signal. This signal is then compared with any other enabled limiter signals and the
resultant error value is sent to the regulator selection function.
Var Regulator/Control
The var regulator error function compares the calculated var level of the machine output to an internal reverence
(var adjuster) value. The resultant error is multiplied by a gain and sent to either the ac adjuster/follower of the
var/PF mixer. In the first option, called var control, when the var error signal is outside an error window for more
than a preset time delay, a signal is sent to raise or lower the internal ac adjuster which provides the reference for
the ac error detector. The var controller thus serves to supervise or control the voltage regulator to keep the vars
near the set value. For a condition when the var error may be outside the error window but before the preset timer
has timed out (such as, during transients), the system in var control continues to behave like a voltage regulator
during system disturbances.
A second option, called var regulation, is sometimes utilized for industrial applications where the generator is
used to provide local power factor correction in addition to real power (watts). In this case, the var error
substitutes for the ac voltage error. Proper adjustment of parameters is critical for stable operation.
Power Factor Regulator/Control
The power factor regulator error function compares the calculated machine power factor value to an internal
reference (PF adjuster). The resultant error is multiplied by a gain and sent to either the ac adjuster/follower or the
auto mixer. In the first option, called power factor control, the PF controller operates in a similar manner to a var
controller. In the second option, called PF regulation, the PF regulator operates in a similar manner to a var
regulator.
PF regulation, like var regulation, is sometimes utilized for industrial applications where the generator is used to
provide local power factor correction in addition to real power (watts). In this case, the PF error substitutes for the
ac voltage error. Proper adjustment of parameters is critical for stable operation. Note also that the PF error
is not nearly as sensitive to var output as the var error at unity power factor. At unity power factor, a 1%
bandwidth in power factor (0.99 lag to 0.99 lead) corresponds to a var bandwidth of 14% (±0.14 per unit of
generator rating). The power factor to var relationship is also highly nonlinear. For this reason, PF regulation is
not normally a recommended mode of operation.
AC Voltage (Auto) Adjuster/Follower
This function provides the means for varying generator terminal voltage (or var/PF output under var/PF control) by
varying the internal reference applied to the ac regulator error function. It also has a follower function that
provides the means to raise or lower the output based upon a manual error signal input that remains outside an
error tolerance for a preset time delay.
Manual Adjuster/Follower
This function provides the means for varying the machine excitation level (current or voltage) by varying the
internal reference applied to the manual mixer function. It also has a follower function that provides the means to
raise or lower the output based upon an ac auto error signal input that remains outside an error tolerance for a
preset time delay.
Var and Power Factor Adjusters
These functions provide the means for varying the generator var output or power factor by varying the internal
references applied to the digital var and PF regulator error functions.
Excitation System Stabilizer ("Damping")
Damping compensates for the inherent, long time delay associated with the response of the generator and exciter
fields of brushless or rotating exciter systems. The excitation control system is stabilized by applying a negative
feedback to the ac error and limiter functions. This feedback signal is derived from either the generator or exciter
field current (or voltage) rate of change and scaled by a gain factor.
Transient Gain Reduction (TGR)
TGR is usually only applied to static excitation control systems. It is normally used for improving the stability of the
excitation system by providing separately defined time constants for the various limiters and error detectors.
Publication Revision First Printing: Page

IL6D34314 D Revised: 01/08 3
Minimum Excitation Limiter (MEL)
The MEL maintains machine excitation above a predetermined MVA characteristic and thus prevents the machine
from reaching underexcited conditions that could endanger synchronism with the power system. The inputs to this
limiter are taken from the CT and PT signals, and the resultant operating point is compared to an approximated
steady-state stability limit curve. The MEL function sends an output that is proportional to the distance from the
limiter curve and the operating point. The MEL sends an output that is proportional to the distance from the limiter
curve and the operating point. The MEL output is auctioneered against the ac error signal to prevent excitation
from decreasing below the desired level. This function operates in the same manner as the traditional analog
systems in that the limiter curve is based upon assuming it is a steady-state stability limit, and as such, is
recalibrated based upon the square of the system voltage.
Underexcitation Limiter (UEL)
The UEL is nearly identical to the MEL (minimum excitation limiter). However, it is capable of recalibration of the
limit curve based upon the stator temperature or the hydrogen cooling gas pressure. Thus, it is used for limiting of
underexcited conditions based upon the generator capability. The inputs to this limiter also are taken from the CT
and PT signals. The resultant operating point is compared to the limit curve.
Overexcitation Limiter (OEL, Previously MXL)
In previous analog excitation control systems, this function was referred to as the maximum excitation limiter. This
function limits the magnitude and duration of excessive current and voltage applied to the exciter or machine field.
The limiter returns excitation to a preset level after an adjustable time delay. The limiter operates on an inverse
time characteristic, permitting lower values of overexcitation for longer time periods and cutting off higher values
of overexcitation in shorter time intervals. The OEL function also has cool-down modeling that provides a
"memory" of the heating effects of excessive overcurrent.
Instantaneous Overcurrent Limiter (iOEL)
In previous analog systems this function was referred to as the instantaneous maximum excitation limiter (iMXL).
This limiter prevents to the excitation system from producing high output currents in excess of any useful level,
such as could occur if a turn-to-turn short appears in the field. As the name implies, there is essentially no time
delay in actuation of this limiting function.
Bridge Current Limiter (BCL)
The ECM can also provide an addition limiter referred to as a bridge control limiter. This is a software function that
limits the maximum dc current permitted through each three-phase, six-SCR bridge based on RTD temperature
information sent from each BCM via the FCIM back to the ECM.
Volts per Hertz Limiter (HXL)
This limiter prevents the generator from providing excessive volts per hertz operating conditions. This could result
from system frequency dropping below normal or from system conditions causing overvoltage at nominal
frequency. Excessive volts per hertz can cause overheating of the machine and unit transformer. This limiter has
an inverse time characteristic when online and instantaneous operation when offline to prevent excessive voltage
per hertz during coast-down of a unit for circumstances where the excitation system remains energized.
Overvoltage Limiter (OVL)
The overvoltage limiter protects the machine from sustained high levels of generator terminal voltage. High
terminal voltage can occur due to either full-load rejection on a large hydro unit or a failure within the excitation
system.
Regulator Mode Select (PID Controller)
This function provides the means to utilize proportional, integral, and derivative closed-loop control of the
generator terminal voltage.
Adjuster Followers
The adjuster follower functions provide for a bumpless transfer of the digital regulator from ac voltage regulation
to dc field regulation and vice versa. In the dc field regulation mode, the follower in the ac adjuster is enabled. It
senses the ac error signal and changes the setpoint of the ac error signal and changes the setpoint of the ac
adjuster to keep the error with a preset bandwidth. In the ac voltage regulation mode, the follower in the digital dc
adjuster is enabled. It senses the dc error signal and changes the setpoint of the digital dc adjuster to keep the
error with a preset bandwidth.

4 Revised: 01/08 D IL6D34314
Balance Meter Driver
The balance meter driver is a sub-function of the regulator mode select (PID controller). It provides a signal to
drive a balance meter. This function accepts the output of the ac mixer error and subtracts it from the manual
mixer error. It serves to help ensure that a bumpless transfer will occur when the ECS2100 system switches from
the auto regulator to the manual (dc)regulator or should the operator desire to switch from auto to manual.
Power System Stabilizer (PSS)
The PSS is an optional feature that provides damping of oscillations that may occur on certain power systems due
to voltage regulators swinging against the balance of the system. The PSS function may be configured to
incorporate the IEEE dual-input model, which can accommodate both an instantaneous electrical power signal
and either a frequency or speed input signal.
Protection Functions
The digital regulator module can be programmed to utilize the following protective functions:
• Overvoltage (OVP)
• Volts per Hertz (HXP)
• Overexcitation (OXP)
• Loss of Field of Underexcitation (LOF)
• Loss of Sensing (LOS)
The digital protection pickup settings must be coordinated with the pickup settings of both the respective digital
limiters and any additional external system backup protective relays that may be utilized.
Field Temperature Monitor
The exciter and/or generator field temperature can be accurately calculated and displayed by means of this
function. The temperature is calculated based upon the known field resistance at a known temperature (usually
25°C). The measured resistance is obtained from dividing the measured field voltage by the measured field
current. The temperature is then determined based upon the temperature coefficient of the winding material
(usually copper).
Transient Event Recorder and Data Logger
The digital excitation control system can be programmed to capture a single event of up to eight channels of
signals to a data base. Each channel can contain up to 9,600 points of data in intervals as short as 1 millisecond.
In addition, the system can record a time/date stamped list of events to a data logger function. Up to 1,000 events
can be recorded. An event may include:
• Pickup and/or operation of any limiter
• Pickup and/or operation of any protective feature
• Excursion of PT and CT signals outside of a preset range
• Field temperature
• Field resistance to ground
• Power supply failure on any card
DIGITAL FIRING CONTROL

The firing circuits provide properly timed pulses to fire the solid-state thyristor (SCR) power amplifiers
(converters). The magnitude of the dc level of the power amplifier is determined by synchronized pulses that are
time delayed in the digital firing control. The amount of time delay is a function of the control voltage.
The pulses move over a 180° nominal range (actual range about 160° due to finite end stops) in response to the
input signal. The more advance the firing pulse becomes, the higher the average output voltage from the thyristor
bridge(s).
ECS2100 systems may employ redundant channels including digital firing to provide enhanced reliability for the
excitation control system.
The ECM sends a bridge voltage command to the FCIM. It also sends the required number of bridges for
operation to the FCIM. The FCIM uses the power potential transformer (PPT) voltage measured by an IT module
to compute the necessary timing reference for firing the SCRs. This PLL (phase-locked loop) generated timing
reference is based upon the entire line voltage waveform rather than merely the "zero crossings". The PLL locks
within approximately 20 milliseconds under rated conditions. Under some fault or startup conditions, the FCIM
card may provide a continuous stream of firing pulses to all SCRs so they act as rectifier diode bridges. This is
IL6D34314 D Revised: 01/08 5
called "force firing" and is done in the absence of usable phase reference. This feature can be disabled by user
settings.
The FCIM card sends all of the necessary signals to the BCM card to control it while the digital firing system is
powered. These signals include the firing messages, Start, Stop, and Trip commands. The firing messages are
acted upon directly by BCM firing.
POWER AMPLIFIERS (THYRISTOR CONVERTERS)

The power amplifier usually consists of six thyristors (SCRs) arrange in a three-phase full-wave bridge. The
bridge may be either a panel-mounted assembly or a draw-out, drawer assembly. The six-device, full-wave
configuration permits both positive and negative forcing voltages to be applied to the field. In a rotating exciter or
brushless system, negative forcing can occur only in the exciter field. Therefore, there is no negative forcing in the
main generator field.
In some previous analog excitation control systems, the power amplifier may have employed a semi-converter
configuration. This arrangement used three thyristors and three diodes in a three-phase bridge. For this type of
power amplifier, a "free-wheeling" or commutating diode was used across the field. A semi-converter permitted
only positive forcing voltage. When field voltage was reduced to a minimum, the field current decayed naturally
(set by the field time constant) through the "free-wheeling" diode.
In addition to the thyristors, the power amplifier assembly usually contains RC snubber circuits, heat sinks,
current-limiting fuses, fans, thermal sensors, and thyristor firing pulse transformers.
ISOLATION TRANSDUCERS (DC-DC FIELD TRANSDUCERS)

The isolation transducer cards isolate and amplify the millivolts-level signal from the field current shunts to rated
field current for rated kVA and rated terminal voltage. The field voltage transducer (when furnished) provides
isolation and attenuation of the dc signal from the generator or exciter field. The output of the IT card is a fiber-
optic light signal with a frequency proportional to the input dc voltage level.
SENSOR INPUT MODULE (AC ISOLATION TRANSDUCER)

The sensor input module provides the means to isolate the ac generator PT and CT signals from the digital
electronics. The PT and CT secondary inputs are sampled simultaneously every 400 microseconds by stereo
sigma delta analog-to-digital converters with 16-bit resolution. Six of these high-speed, high-resolution ADCs are
used in parallel to provide 12 input channels. Fiber-optic cable connections for digital input/output (DIO) and
analog input/output (AIO) boards are also located on the SIM card.
Serial communication for these cards is routed through the serial I/O link FPGA. This FPGA is used to link all
analog and digital inputs and outputs, including the PTs and CTs, to the ECM.
FAN CONTROL CIRCUIT

For brushless or rotating exciters, and for specific types of thyristor bridges, the following discussion may not
apply. Most static excitation systems require forced-air cooling to get the maximum current from the thyristor
power amplifiers. The standard static system contains two cooling fans: a main and a redundant fan. The fan
control circuit will energize both fans when the excitation system is first turned on. Once air flow is established ,
the non-selected fan will drop off line. Fan motor circuits are fed by two 2 kVA transformers that are protected on
both the primary and secondary windings by fuses. In addition, the motors are protected with bimetallic overload
relays. Loss of fan protection is provided by airflow switches and a circuit that detects dropout of the selected fan
contactor. If both fans fail while the unit is online, an excitation trip signal is normally initiated. The fan control
circuit function normally resides in firmware in the BCM (bridge control module) card.
CAUTION
Generator startup and shutdown procedures must allow for the loss of fan motor
torque and higher motor current at reduces voltage. The cooling fans are single-
phase and have a starting switch that is speed operated. When the frequency
decreases, the fan speed decreases and the starting switch will cut back in,
resulting in motor overload.

6 Revised: 01/08 D IL6D34314
FIELD FLASHING
Because a static exciter receives all of its power from the machine terminals (and the terminal voltage is at zero
during a black startup), it may be necessary to flash the generator field. Flashing power is supplied by the station
battery or, in some cases, by a dc rectifier circuit fed from an auxiliary ac source. Flashing the field raises the
machine terminal voltage to a sufficient value to enable the static excitation system to continue building the
machine terminal voltage to the desired nominal level. To minimize the field flashing load on the station battery, a
forced firing function is sometimes used. This results in the power amplifier output remaining at its maximum level
until the machine terminal voltage is about 60 to 70% of nominal. Then, the field flashing and forced firing feature
is disabled.
Field flashing is performed in either of two modes. The standard mode, referred to as auto field flash, results in an
immediate field flash after the 41A device is closed (no field flashing switch is needed). The second mode,
referred to as manual flash, requires an operator to hold a field flash switch in the flash position during the entire
flashing procedure.
CONTROL RELAYS
Some control interface relays operate from 125 Vdc. This power is usually provided from two sources: the station
battery and the excitation source (41A device), rectified to 125 Vdc. These sources are auctioneered with diodes
to permit the higher of the two sources to supply the control circuit. Once the unit is online, any loss of the station
battery will enable the unit to remain online.
The station battery is typically disconnected by a two-pole circuit breaker. If the station battery voltage is 250 Vdc,
a dc-to-dc converter is furnished to supply 125 Vdc for interface relay control power.
SETTINGS
Verifying the suitability of the excitation control equipment settings is the sole responsibility of the user. The
following discussion is intended only as a guide in helping to determine the settings. The settings must be
configured so that the excitation system will operate as an integrated pat of the user's specific power system and
be consistent with the user's operating methods. User-specific schematic diagrams should be reviewed to identify
the settings that apply to a particular application.
The relay control software contains time delayed relays whose delay times require setting. One such timer is the
41ATD relay, whose time delay prevents undesirable operation during the transient that follows the closing of the
41A device. Typically, this time delay is set for five seconds. Another timer is used by the 31TD relay, which
serves to automatically stop a field flash sequence. The amount of time required to flash the generator field will
depend on both the parameters of the generator field and the power available from the station battery (or other
source). Some fields can be flashed in less than five seconds, while others may require more than 15 seconds to
flash. The 31TD is typically set at 10 seconds, although the factory test setting is normally five seconds.
NOTE
The 31TD is not provided in excitation systems where there is no field flashing
circuit.
The time delayed 86ETD relay allows the field current to decay before the 41A device is opened during a unit
shutdown. The amount of time required to de-excite the generator field will depend on the type of excitation power
amplifier converter, ceiling voltage, and generator field time constant. Typically, the 86ETD delay is set at five
seconds, while the factory test setting is three seconds.
When the 41A device is open, the various adjusters go to a preset (pre-position) level. Typically, this level is set
so that when the 41A is first closed, the generator voltage (at no load) goes to about 80 to 90% of rated and the
balance meter is at zero. The second preset on the dc adjuster is sometimes set so that when the overexcitation
protection trips the regulator back to the manual or dc mode, the field current goes to about 80% of the rated, full-
load value.
DIGITAL SETTINGS
All settings for regulation and limiter gains, limiting and protection pickups, and time delays are normally set to
typical values at the factory. These settings are programmed into the FLASH memory of the ECS2100 system.

IL6D34314 D Revised: 01/08 7
All of the gain factors utilized in the ECS2100 system functions are based upon a per unit convention rather than
an absolute volts per volt convention (utilized in analog systems). However, the equivalent analog gain can be
determined from the digital gain by assuming the following:
• For functions using a field transducer input (voltage or current), 1 per unit equals 5.00 Vdc
• For functions using PT signals, 1 per unit equals 120 Vac
During the startup of a specific excitation control system, the typical ECS2100 settings, loaded into the FLASH
memory, may require some fine tuning. Examples of these settings include ac or dc error gain, or ESS (damping),
or TGR time constants. Some of those settings, knows as adjustable parameters, may be adjusted either by use
of the PanelMate HMI or a PC operating ccTool software.
SAFETY
WARNING!
Bodily injury could result if contact is made with components in this apparatus
which carry either line voltage or are subject to abnormally high voltages. The
circuit diagrams, provided as part of a system’s documentation package, will
disclose hazardous areas.
As with all electrical equipment, appropriate safety measures should be taken whenever dealing with the
excitation equipment. High voltage is present within the excitation cubicles; their magnitudes depend upon the
particular system. Opening the sources, e.g., disconnecting device 41, does not completely disconnect the high
voltages. As long as the machine is still physically connected to the system, there is a possibility that a safety
hazard exists.
Every precaution must be taken when working at the excitation control switchgear to ensure that all high voltages
are isolated and avoided by test personnel. In addition to the machine terminal voltage (460 Vac or greater) at the
excitation transformer, there may be other sources of power entering the cubicles. These sources may include the
user-supplied 125/250 Vdc and/or 120/240 Vac used to feed certain devices. A good rule to follow is to assume
that all connections are live and dangerous until proven otherwise and to completely avoid all body contact with
any of these voltages.
One other cautionary note concerns the generator field ground detector. Because the ground detector input
supply is usually 120 Vac, both the ac bus and dc (100 Vdc) might be back-fed from this device. Therefore, it too
must be disconnected when servicing the excitation control equipment.
MAINTENANCE
No maintenance of the equipment is required other than the periodic inspection and removal of accumulated dust.
SPARE PARTS
A reasonable stock of spare parts will minimize downtime in the event of a equipment malfunction. When ordering
spare parts, specify the equipment part number (listed on the equipment nameplate) and the individual part
numbers (listed in the equipment subassembly documentation).
GLOSSARY
Terms commonly used in ECS2100 documentation are defined in the following paragraphs.
BCM. Bridge Control Module. Up to 16 BCMs can be controlled by one FCIM.
Bridge. A configuration of thyristors (SCRs) that convert ac current into dc current.
ccTool. Controller Configuration Tool. A Windows (2000, XP, or Vista) based application that connects to an
ECM, FCIM, or BCM card for user-programming of the card functions. Presents table or block diagram
representations of the controller program and operation.
CM. Conduction Monitor card. Provides current level information on each SCR or bridge.
ECM. Exciter Control Module. Contains the excitation control, limiting, protection, and communication software
(but is not considered a part of the DFC.

8 Revised: 01/08 D IL6D34314
FCIM. Firing Control Interface Module. Processes the ac source waveforms and firing angle command from the
ECM and determines when to fire each SCR.
FLASH. A type of random access memory (RAM) that retains memory contents without power and not relying on
a battery.
FO. Fan Out card. Provides transceiver capability beyond the three built into the FCIM as standard.
FPGA. Field Programmable Gate Array. An integrated circuit that implements complex logic functions within a
single package.
IT. Isolation Transducer card. Isolates two analog signals for digital input to FCIM or BCM and other modules.
PLL. Phase Locked Loop. A closed-loop control scheme to automatically lock the frequency and phase of an
oscillator so that it produces a precise firing angle necessary to maintain the desired level of a converter output
under control. It is also used in the ECS2100 to determine the magnitude, phase angle and frequency of the
generator terminal voltage and current.
RS-232. A standard physical link protocol for serial communication. Almost every PC has a communication
connection of this type.
SCR. Silicon Controlled Rectifier. A variable-conduction rectifier with delayed forward turn-on gating. Also called a
thyristor.
VCO. Voltage Controlled Oscillator. A circuit that provides a variable frequency output proportional to a voltage
input.

IL6D34314 D Revised: 01/08 9
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10 Revised: 01/08 D IL6D34314
INSTRUCTION MANUAL
FOR
HANDLING, INSTALLING, AND MAINTAINING
EXCITATION CONTROL EQUIPMENT
Publication: 9410100990
Revision: — 06/07
INTRODUCTION
This manual provides information concerning the handling, installation, and maintenance of generator and
motor excitation control equipment manufactured by Basler Electric. This publication (9410400990)
supersedes publication 99-1484.
• General Information
• Equipment Handling
• Installation
• Maintenance
• Maintenance Schedule
WARNING!
To avoid personal injury or equipment damage, only qualified personnel should
perform the procedures in this manual.
9410100990 Rev - Introduction i

First Printing: June 2007
Printed in USA
© 2007 Basler Electric, Highland Illinois 62249 USA
All Rights Reserved
CONFIDENTIAL INFORMATION
of Basler Electric, Highland Illinois, USA. It is loaned for confidential use, subject
to return on request, and with the mutual understanding that it will not be used in
any manner detrimental to the interest of Basler Electric.
It is not the intention of this manual to cover all details and variations in equipment, nor does this manual
provide data for every possible contingency regarding installation or operation. The availability and design
of all features and options are subject to modification without notice. Should further information be
required, contact Basler Electric.
BASLER ELECTRIC
ROUTE 143, BOX 269
HIGHLAND IL 62249 USA
PHONE +1 618.654.2341 FAX +1 618.654.2351
ii Introduction 9410100990 Rev -
CONTENTS
SECTION 1 • GENERAL INFORMATION................................................................................................. 1-1
SECTION 2 • EQUIPMENT HANDLING ................................................................................................... 2-1
SECTION 3 • INSTALLATION................................................................................................................... 3-1
SECTION 4 • MAINTENANCE .................................................................................................................. 4-1
SECTION 5 • MAINTENANCE SCHEDULE ............................................................................................. 5-1
9410100990 Rev - Introduction iii

iv Introduction 9410100990 Rev -

SECTION 1 • GENERAL INFORMATION
INTRODUCTION
This publication serves as a general guide for the handling, storage, installation, and maintenance of
generator and motor excitation control equipment manufactured by Basler Electric. The objective of this
guide is to furnish general guidelines that will promote and enhance a reliable installation.
SYSTEM IDENTIFICATION
Each excitation control system manufactured by Basler Electric is assigned a model, part, and serial
number. The system part number must accompany any correspondence concerning the excitation
system. When ordering parts from Basler Electric, be sure to specify the Basler part number, quantity,
description, and system part number. The system part number can be found in the instruction manual as
well as on the front panel of the system enclosure. An identification nameplate is affixed to the front of
each enclosure.
INSTRUCTION MANUAL
An instruction manual is supplied with every excitation system and should be referred to for information
relating to the individual system requirements. The instruction manual contains important information and
should be kept in a safe place for future reference. Typical instruction manual content includes:
• System specifications
• A functional description
• General operating instructions
• A list of system components
• System drawings
• Publications relevant to devices installed in the system.
SAFETY
WARNING!
Some components of the excitation system carry voltage at hazardous levels.
Contact with these voltages can result in personal injury or death.
Only personnel who are thoroughly trained and who understand the hazards
associated with working on excitation systems should carry out inspection and
maintenance procedures. Plant personnel should become familiar with the
schematic diagrams, wiring diagrams, and instruction manual associated with
this equipment.
Care must be exercised to comply with safety practices as well as local, state,
and federal regulations for this class of equipment.
CAUTION
Failure to inspect, clean, and maintain the excitation control system can reduce
the life expectancy of the equipment or impair its operation.
As with all electrical equipment, appropriate safety measures should be taken whenever dealing with the
excitation equipment. High voltage is present within the excitation cubicles; the magnitude of the voltage
depends upon the particular system. Removing the voltage sources does not completely disconnect the
high voltages. As long as the machine is still physically connected to the system, there is a possibility that
a safety hazard exists.
Every precaution must be taken when working with the excitation control equipment to ensure that all high
voltages are isolated and avoided by personnel. In addition to the three-phase ac excitation source
9410100990 Rev - General Information 1-1
voltage, there may be other sources of power entering the cubicles. These sources can include 125/250
Vdc control power, 120/240 Vac station power, and 480 Vac used to supply certain devices. The field
voltage is also present at the field ground detector. Due to capacitors in the shaft suppression network,
there may be voltage present even when the field circuit breaker is open. A good rule to follow is to
assume that all connections are live and dangerous until proven otherwise.
Before performing maintenance on the current transformer (CT) circuits, place a short-circuit across the
secondary connections of the CT at the shorting-type terminal block.
On some DECS and ECS2100 systems, the ground detector (ground fault relay) is powered by a
separate source. Both the ac power bus and dc field bus might be backfed from this device with 120 Vdc.
Therefore, it too must be disconnected when the excitation control equipment is serviced.
1-2 General Information 9410100990 Rev -

SECTION 2 • EQUIPMENT HANDLING
RECEIVING
Basler excitation control equipment is carefully inspected and packed before leaving the factory. Upon
receipt, the equipment should be examined for evidence of shipping damage. If damage is evident, the
carrier (transportation company) and Basler Electric should be notified.
Only authorized personnel should be permitted to handle the equipment. Ensure that the equipment used
to move the system components has sufficient lifting capacity.
STORAGE
Equipment that will not be installed immediately should be stored according to the following guidelines.
Recommended Storage Procedures
NOTE
Outdoor storage of the equipment is unacceptable. Do not leave the equipment
outdoors exposed to the weather. All equipment should be protected from
damage and vandalism.
Guidelines for moving the equipment into and out of storage is provided in the
paragraphs under Moving Equipment Sections.
All equipment should be stored in an environmentally controlled building or shelter. The environment’s
relative humidity must be below 40%.
If flooding is a concern, all equipment should be elevated on blocks or supports to prevent damage from
water. To determine a safe elevation (height), the purchaser must rely on past experience and site
conditions.
Following an initial inspection, prepare the equipment for storage by taking the following precautions:
• Restore all protective packing
• Identify, label, and secure any shipped-loose components
• Cover all openings to prevent the ingress of dust and insects
• Store all cartons/crates containing draw-out equipment flat to prevent strain and distortion of the
assemblies
Alternate Storage Procedures

If the equipment must be stored in a structure without the necessary heating and ventilation, you must
protect the equipment from condensation. The interior temperature of each cubicle must be maintained at
5°C (41°F) above the ambient temperature and air circulation (in at the bottom and out at the top) must be
maintained.
If the cubicles are equipped with heaters, these circuits should be energized during storage. If the
cubicles are not equipped with heaters, temporary heaters should be used. Heater recommendations are:
• A 250 watt heater is recommended for a typical cubicle/compartment
• A 100 watt heater is recommended for each crate/carton containing draw-out equipment
CAUTION
Use care when applying heat near cardboard and packing material. Keep heaters
far enough away so that these materials do not become overheated.
Spontaneous combustion (fire) could result from continued heat buildup.
9410100990 Rev - Equipment Handling 2-1

Limits of Warranty
The product warranty does not cover equipment damage related to the failure to observe the storage
guidelines presented in this publication.
MOVING EQUIPMENT SECTIONS

The method of moving the equipment sections depends on the handling equipment available at the
installation site. Check the shipping weight of the excitation equipment and verify that the lifting capacity
of the handling equipment is adequate. Use care when moving the equipment. Do not drop or bump the
equipment—delicate meters and instruments may be damaged. Protect door-mounted components and
the enclosure finish at all times. Keep equipment sections upright during transit. If it becomes necessary
to lie the equipment sections down for any reason, contact Basler Electric for any specific precautions to
be taken.
If possible, equipment sections should remain secured to their shipping skid while being moved. The skid
base adds extra rigidity to the frame and helps prevent distortion of the enclosure during moving. The skid
also permits the use of a forklift or hydraulic pallet truck for moving. Always carefully balance and steady
the load. To prevent injuries and damage, only trained personnel should attempt moving the equipment.
The top of each equipment section is equipped with provisions for lifting the section. Overhead hoisting
may be used when available. Observe all safety rules and follow proper rigging guidelines when using
sling rigging. The use of safety hooks or shackles connected directly to the lifting points (eyes) is
recommended. Do not pass ropes or cables through the lifting eyes. The use of spreader or spanner bars
will help prevent crushing or distorting the frame and paint finish.
2-2 Equipment Handling 9410100990 Rev -

SECTION 3 • INSTALLATION
INSTALLING MOUNTING CHANNELS
Mounting channels may be installed to the bottom of the excitation equipment for final installation and
ease of handling. It is necessary to lift the section enough to safely bolt the mounting channels to the
holes provided in the bottom of the enclosure. Often, the mounting channel is installed in the floor and the
enclosure is lowered onto it. Be sure that the mounting channel is level. This is especially important if the
equipment sections are long or if multiple sections must bolt together to form a common lineup.
SETTING THE EQUIPMENT SECTIONS IN PLACE

First, remove the bolts securing the section to the skit. Lift the sections from the skit base using hoists,
jacks, or other appropriate lifting devices. Carefully move the section into place over the mounting studs.
When moving the section, be sure to leave enough clearance above the conduit stubs and the projecting
mounting studs in the floor. Carefully lower the section onto the mounting studs or bolt inserts in the floor.
Be sure that all holes and studs line up properly.
When multiple equipment sections are supplied, refer to the installation plans and drawings for the proper
arrangement of sections.
Ensure that all equipment sections are level and plumb.
WIRE AND CABLE INSTALLATION

All external control wiring and cable connections are shown on the system connection diagrams. Remote
devices, such as control switches, transformers, and alarm and status systems are shown generically. If a
point-to-point, site-specific interconnection diagram is available, it should be used when making
connections. Be sure to use only final, “as-built” drawings. Preliminary or “approval” type drawings should
be destroyed. If no site-specific interconnection drawing is available, it is necessary to interpret the control
functions required and locate the remote devices that perform the functions. Each of the remote system
interconnection diagrams will be required to properly identify the terminal point connections that are to be
wired to the primary excitation system enclosure. It is recommended that a final “as installed” point-to-
point interconnection diagram be created and retained for future reference.
When making connections, use standard copper wire for all interface wiring. Run control wiring in conduit
separate from the power cables.
Wire and Cable Sizing

The installing contractor is responsible for selecting the wire size required for interconnecting the various
pieces of equipment in the system. Ampere and voltage level requirements are indicated on the drawings
supplied with the system. A minimum of 14 AWG wire is recommended for all control circuits. The current
and voltage levels and the distance that the wire is run must be considered in all cases. Shielded or
twisted wire must be used where specified on the system drawings.
Conduit Openings
Holes or conduit knockouts are not supplied on standard systems. The installing contractor has the
convenience of locating the conduit openings as required during installation. Holes may be punched or
cut as the conditions at the jobsite dictate. Use adequately sized tools to cut or punch holes.
Testing Power Cables

Installing power cables in conduit, cable troughs, and ceiling-suspended hangers often requires
considerable force. The pulling of cables can damage insulation and stretch or break conductor strands.
For this reason, after the cables are pulled into position and before they are connected, they should be
tested to verify that they are not defective or have been damaged during installation. Perform a complete
dielectric strength test in accordance with IEEE 421.3 or other standard approved by the authority having
jurisdiction at the jobsite. Do not megger or hipot the voltage regulating units.
After the power cables have been tested, connect them to the appropriate terminals in the control
sections. Make sure that the lugs are suitable for use with the cables being installed. Use care when
stripping insulation from cables to avoid nicking or “ringing” the conductor. Tighten the cable lugs to the
torque values recommended by the lug manufacturer.
9410100990 Rev - Installation 3-1
Proper Phase Rotation
Observe correct phase rotation (sequence) when connecting the power and sensing circuits. The
excitation system is designed for ABC rotation. The system will not function properly if the incorrect phase
rotation is connected. Consult Basler Electric if necessary to alter the phase rotation.
Current Transformers
The standard practice for installing current transformers is to be sure the side of a toroid type CT marked
with a dot or “H1” is facing toward the source. Bar-type current transformers have a polarity mark (dot or
H1). Secondary circuits also have polarity marks such as lead markings “X1”, “X2”, etc. Pay close
attention to the polarity indications on the drawings and CTs when installing them. Also, ensure that the
CT is installed on the correct phase as indicated on the interconnection diagram. Be sure to remove all
jumpers or shorting bars on the CTs before operating the system. Never open-circuit a CT while current is
flowing in the circuit. To perform maintenance on a live CT circuit, always short the CT secondary before
disconnecting any circuit wires. A shorting type terminal board may be provided for this purpose.
Otherwise, use a jumper wire. Bar type CTs are usually provided with a shorting “link” mounted on the CT
terminals.
Control Power
Control power should be connected as shown on the system drawings. Note the current and voltage
requirements listed on the drawings. Batteries should be tested frequently and properly maintained. One
of the most frequently reported causes of system failures and malfunctions is poorly or improperly
maintained control system batteries. Follow all of the battery manufacturer’s recommended maintenance
practices. It is recommended that circuit overcurrent devices be installed as closely as possible to the
supply source. Disconnect devices are also recommended on the control sources to the system.
Terminals and Lugs

It is recommended that all control wiring have terminal lugs of the solderless ring tongue, fork lock or
similar type installed. Use properly sized lugs and crimping tools when installing the lugs. It is good
practice to limit each terminal to not more than two wires per connection. Spare terminals are provided for
convenience of installation. Ensure that all connections are tightened securely.
Grounding
Make sure that all secondary wiring is connected to the system ground bus as indicated on the drawings.
The ground bus should be connected to the system ground with as direct a connection as possible and
should not be run in metal conduit unless the conduit is adequately bonded to the circuit. The grounding
conductor should be sized to carry the maximum short-circuit current available. A permanent low-
resistance ground is essential for adequate safety and protection.
Protective Relays and Devices

Protective relays and devices have been tested at the factory for correct connections and operation.
Factory settings are noted on the system drawings but are not to be considered the final or recommended
settings. Factory settings are used only during functional testing of the equipment prior to delivery. All
protective relay and device settings should be made and verified by qualified personnel before placing the
equipment into service. The instruction manual for each device should be consulted when making
settings and a settings record should be maintained for each device. Periodic equipment testing is
recommended to verify device function and settings.
DOCUMENTATION
The importance of good recordkeeping cannot be overstressed. Installation details should be recorded
and securely filed for future used. The following list gives some examples of useful information that may
be recorded or filed during equipment installation.
• Record the dielectric test results and insulation resistances.
• Create a detailed point-to-point installation interconnection diagram.
• Retain all instruction manuals and equipment drawings.
• Record all pertinent system variables obtained during startup and testing. These system variables
can include current, voltage, kilowatt, power factor, and temperature readings.
• Post all normal operating and emergency operating procedures.
3-2 Installation 9410100990 Rev -

• Record all switch positions used during normal operation.
• Create a logbook to be used at shift breaks for recording system readings and switch positions.
• Create a log of maintenance procedures for each system device.
• Create a directory of telephone numbers for emergency and technical assistance.
The preceding list of suggestions should help establish a good recordkeeping procedure and operational
history for the system.
9410100990 Rev - Installation 3-3

3-4 Installation 9410100990 Rev -

SECTION 4 • MAINTENANCE
INTRODUCTION
Preventive maintenance requires equipment knowledge, equipment records, and careful planning.
Each excitation system is comprised of separate devices interconnected to form an integrated control
system. Equipment knowledge is obtained from the instruction manuals provided with the equipment.
Each device has an instruction manual describing the important operating features and adjustment
guidelines pertinent to that device.
Good recordkeeping is essential in developing an operational history of the equipment. Refer to Section
3, Installation, Documentation for recordkeeping guidelines.
Careful planning will ensure a successful maintenance program. Equipment repair almost always costs
more than maintenance, and the loss of revenue due to equipment downtime can be severe.
MAINTENANCE GUIDELINES
Observing the following maintenance fundamentals and following the maintenance schedule of Section 5
will promote equipment reliability and longevity.
Keep It Clean
Dirt, dust, and corrosives are prime enemies of electrical equipment. Excessive dust buildup hinders
system cooling and causes higher operating temperatures. If possible, prevent dust and dirt from
accumulating on the equipment. Otherwise, frequent cleaning will need to be performed. During regularly
scheduled shutdown for maintenance, the system should be vacuumed thoroughly (except for printed
circuit boards). Do not use compressed air to clean electrical equipment. All filters should be inspected
and replaced/cleaned according to the maintenance schedule as required by the conditions in the plant
environment.
Keep It Cool
Another prime enemy of electrical equipment is excessive heat. Do not allow vent openings to be blocked
or restricted. Ensure that the ambient temperature of the cubicles is less than 40°C (104°F) unless
otherwise indicated on system drawings. If equipped, check the heater and air conditioner power source
and operation. Check for clogged air filters and proper cooling fan operation. Maintain proper blower
motor lubrication.
Keep It Dry
Moisture can cause equipment failure or erroneous operation. Dripping pipes, condensation, and other
moisture sources should be eliminated. Anti-condensation heaters should be checked often and may be
added if not originally equipped.
Eliminate Vibration
Vibration tends to move or loosen electrical connections. Determine the cause of vibration and eliminate
as much vibration as possible. Keep cubicle doors securely fastened and tighten any loose mounting
hardware. Be alert to changing conditions; changing vibration patterns are usually the advance warning of
an impending failure.
Keep Connections Clean and Tight

Schedule inspections of electrical connections and clean or replace any corroded parts. When cleaning
connections, use the appropriate cleaning fluid or solvent. Never use compressed air to clean electrical
equipment.
Keep Up With the Changes

Document any revisions, modifications, or additions made to the system. Keep all records safe and
secure. The manufacturer’s drawings are seldom revised after shipment, so any field changes are the
responsibility of the user to document and file. Provide up-to-date drawings for any service personnel who
are contracted to work on the system and insist on revised, detailed drawings from them if changes are
made.
9410100990 Rev - Maintenance 4-1

Corrosion and Condensation
Inspect the equipment for corrosion and condensation semiannually.
Clean the exterior of the closures and touch up any scratches and abrasions using touch-up paint.
If there is condensation inside the equipment enclosures, check the heater circuit. The heater thermostat
should be set above the ambient dew point temperature.
If excessive condensation is found inside the control or transformer cubicles, check for leaks or openings.
INSPECTION AND MAINTENANCE NOTES

The following notes are organized according to the inspection and maintenance needs of the excitation
system components.
Printed Circuit Boards

Remove accumulated dust from all circuit boards. Excessively dirty circuit boards should be removed
from the equipment and cleaned with compressed air from a spray can of the type used for computer
hardware cleaning. No contact should be made with the circuit board by a vacuum cleaner type of device
as static electricity could damage the circuit board components.
Test and calibrate printed circuit boards according to the procedures listed in the associated instruction
manuals.
Bus, Cable, and Terminations

Check the general condition of connectors, terminations, and other current carrying parts. Inspect the bus
connections and cable terminations for signs of thermal stress. Note any discoloration which would
indicate excessive heating due to loose hardware, high current, or low contact force.
Inspect insulators and supports for breaks, cracks and burns. Clean the insulators and supports where
abnormal conditions such as salt deposits, coal dust, cement dust, sand, or construction dirt prevail. This
is necessary to avoid flashover. The insulators and supports should never be cleaned with an oily or dirty
rag. Oil holds dirt particles which may cause arcing across the surface of insulators.
Contactor
Inspect and maintain the contactor according to the contactor instruction manual. Observe the following
maintenance notes.
Before the contactor is placed in service or following maintenance, operate the contactor slowly, by hand
two or three times without power to check operation and alignment of the moving parts. If the contactor
operates satisfactorily, then close and open it two or three additional times using the operator magnet, but
with the main power circuit de-energized.
NOTE
Do not exceed operation frequencies indicated in contactor instruction manual.
If the contactor has been operated under heavy fault conditions, it should be inspected at the first
opportunity after it has been de-energized.
Inspect and maintain the contacts according to the contactor instruction manual. Badly pitted, burned, or
worn contacts should be replaced.
Examine the arc horns and arc chute walls for excessive arc erosion. Check the arc chute walls and grid
plates for excessive metal deposits and cracks. Clean dust and other foreign mater from the arc chute
chamber.
Check the general condition of connectors, shunts, and other current carrying parts. Inspect and clean the
insulators and supports.
Fuses
Inspect the fuses, fuse holders, and fuse contact surfaces for signs of overheating, as evidenced by
distorted and discolored metal. There may be discoloration of copper and copper alloy surfaces. This is
the result of oxidation and does not indicate overheating.
4-2 Maintenance 9410100990 Rev -

Check the main current carrying contacts for galling and surface imperfections. Minor imperfections can
be burnished out.
Check the fuse holders for proper latching.
De-Excitation/Crowbar (DXCB) Module (ECS2100 Systems Only)

The DXCB module should be inspected and its operation verified periodically. During verification of DXCB
module operation, the ±24 Vdc power supply voltage must be applied.
Inspection and Cleaning
Completely remove accumulated dust from the assembly and the printed circuit boards. If the circuit
boards appear dirty, they must be removed and cleaned. Verify that the module is free of rodent litter.
Offline and Online LED Operation
When excitation is off, either offline or online, LEDs (D1 and D2) are off. D1 and D2 should light only
when current is flowing through the DXCB module SCR (as is the case during a normal or immediate
shutdown).
DXCB Output Operation
With the generator shut down, press Test switch SW2 and verify that the CSRD output energizes the
external relay. The MGR and M300 signals should change state. This test verifies that when the DXCB
module has a current signal, it will output correctly.
Operation During Normal Shutdown
During normal shutdown, observe that the DXCB module SCR fires and conducts. When the 41 ac
breaker is opened and the DXCB module is fired, current that was flowing in the field will be conducted
through the DXCB module. If the current is present for sufficient time, the DXCB module will provide a
signal to the ECS2100 indicating that current was sensed.
Break-Over Diode Operation
Verification of the break-over diode voltage firing level should be performed at startup and at the
scheduled maintenance intervals for both the de-excitation module and the crowbar. This test verifies that
the DXCB module will conduct at excessive field voltage levels but not conduct at normal field voltage
levels. The crowbar module protects the rectifier chassis and generator field from the excessive voltage
that develops during pole slip and certain fault conditions. The crowbar relies solely on the break-over
diode firing. Therefore, it is important to verify break-over diode function.
WARNING!
Expected trigger voltages are between 750 and 4,250 Vdc, depending on the
DXCB module settings.
With both leads of the DXCB module disconnected from the field circuit, apply a dc voltage across the
module. Start at a low value of voltage and increase the voltage to within 100 Vdc of the expected trigger
voltage. Then, slowly increase the voltage until the trigger is reached and record the trigger level,
verifying that the trigger value is within the expected tolerance. When the DXCB module is triggered, it will
apply a short-circuit across the applied dc voltage. Ideally, a power source with at least 50 Adc short-
circuit output would provide the required current to turn on the conduction monitor and cause LED D2 to
light.
Cooling Fans
Cooling fan maintenance includes inspection and cleaning of the motor, fan blades, fan shutter, and fan
shutter switch.
Motors and Motor Control Equipment
Inspect the fan motor for excessive vibration and noise. Excessive vibration can be caused by loose
mounting hardware, improper shaft alignment, or a bent shaft. Excessive noise can be caused by worn
bearings or a binding rotor.
Keep the motor and motor control equipment clean. In dirty operating environments, clean out dirt
quarterly or semiannually, depending on site conditions. Check operation of the contactors and relays.
Moving parts should operate without excessive friction. Look for loose pins, bolts, and bearings. A dirty
control should be wiped or blown clean. Check contacts for pitting and signs of overheating (such as
discoloration of metal or charred insulation). Make sure contact pressure is adequate (consult the
manufacturer’s specifications) and is the same on all poles. Inspect, clean, and check overload relays for
proper setting. In general, maintenance requirements for these relays include checking that:
• The rating or trip setting takes into account ambient temperature as well as the higher inrush currents
of modern, energy-efficient motors
• Contacts are clean and free from oxidation
• The relay will operate dependably when needed
To ensure reliable operation, test and calibrate the relays every three years.
Fan Blades
Ensure that the fan motor power supply is disconnected and padlocked prior to working on the fan blade
assembly.
Inspect the fan blade assembly for excessive vibration. If excessive vibration is observed, check for loose
mounting hardware, improper shaft alignment, or a bent shaft.
The fan blades should be inspected and cleaned annually.
Fan Shutter Switch
Verify that the switch functions when the fan is operating.
Check for vane damage and cracks.
The fan shutter switch should be cleaned annually.
Fiber Optic and Ribbon Cable

All fiber optic and ribbon cable connections should be clean and tight. Inspect the fiber optic and ribbon
cables for damage.
Ground Detector Module/Relay

Test the ground detector module/relay annually according to the device instruction manual. Check the
ground detector power supply semiannually.
Line Filter
Check all line filter fuses. If open fuses are found, check for a short-circuit and replace capacitors. Check
the line filter capacitors for leaks or bulging cases. Contact Basler Electric if leaking or bulging capacitors
are discovered.
If dirty, clean all line filter resistors. Check the resistors for damage from overheating.
Inspect all line filter wires and terminations for damage due to overheating.
Metal-Oxide Varistors (MOVs)

Check all MOV fuses. If open fuses are found, check for a short-circuit and replace the MOV. Check all
MOV wiring and terminations for damage due to overheating.
Protective Relays
Protective relays should be tested annually. Inspect, maintain, and calibrate each relay according to the
device instruction manual.
PanelMate (ECS2100 Systems Only)

Use a clean, damp, nonabrasive cloth and any commercially-available window cleaner to clean the
screen. The cleaning solution should be applied to the cloth rather than the screen surface.
Regular maintenance checks should be performed to ensure that the operator interface is functioning
properly.
Circuit Breaker
The circuit breaker should be periodically cleaned using a vacuum cleaner and/or lint-free cloth. Unless
otherwise indicated, never use compressed air since dirt or foreign objects can be driven into undesired
areas. Never use a wire brush to clean any part of the circuit breaker.

Refer to the circuit breaker instruction manual for specific inspection and maintenance recommendations.
Rectifier Chassis (Power Drawer)

Remove all accumulated dust from the rectifier chassis. (Draw-out rectifier chassis can be removed from
the compartment for cleaning access.) accumulated dust should be removed from the heat sinks, SCRs,
and circuit boards. On draw-out rectifier chassis, the contact fingers should be checked for cleanliness
and mechanical integrity.
Inspect all snubber capacitors for leaks and bulges. Leaking or bulging capacitors must be replaced.
Verify that the snubber resistors and wiring are in good condition.
Air-core reactors (if equipped) should be inspected to verify that they are not bent (due to excessive fault
current). If the reactors are significantly bent, contact Basler Electric.
Remove accumulated dust from printed circuit boards per Printed Circuit Boards earlier in this section.
Power Supplies
If equipped, verify power supply cooling fan operation.
Check for short-circuits if power supply fuses are blown.
Shaft Suppression Module

Inspect the capacitors for leaks. Leaking capacitors should be replaced.
Inspect the shaft suppression resistor for a broken element or signs of overheating.
Inspect all wiring for signs of damage or deterioration. Verify that the ground connection is sound.
Heaters
Check operation of the thermostat and heater circuits. Inspect the surface areas around the heaters for
evidence of overheating.
Voltraps (Where Equipped)

Check all Voltraps for cracks and burn marks.
Control Relays
Visually inspect the control relays for burn marks and check the control relays for proper operation.
Equipment Enclosure
Inspect the equipment enclosures for openings into the interior. Seal all openings with the appropriate
material/weather stripping. Check the cable and bus entry areas, the enclosure roof, and access panels
(doors). Check the rain flashing on top of any air conditioner duct openings.
Inspect the enclosure for signs of corrosion. Clean the exterior of the enclosures and touch up scratches
and abrasions using primer and touchup paint.
Inspect and replace vent filters as required. in a dusty environment, filters should be inspected several
times during the year to ensure sufficient ventilation for the equipment.
Lubricate the door locks and hinges.
Air Conditioning Units

Inspect and clean the air conditioner according to the guidelines listed in the equipment instruction
manual. Replace or clean filters periodically or as site conditions dictate. For corrosive or coastal
environments, frequent washing of the air conditioner cabinet, fan blades, and coil with fresh water is
recommended.
WARNING!
Disconnect all power to the air conditioner before starting maintenance.
Check the rain flashing on top of any air conditioner duct openings.

Exciter Transformer
Inspect and clean the transformer semiannually. Refer to the transformer manufacturer’s instruction
manual for maintenance recommendations. Supports, taps, terminal blocks, bushings, and other
insulating surfaces should be cleaned with a dry cloth. Inspect bushings for cracks. If rust, corrosion, or
paint deterioration is observed, it should be corrected.
Dry-Type Transformer
Clean the transformer with a vacuum cleaner and compressed, dry air. Clean the windings with a vacuum
cleaner as the first step followed by the use of compressed air. The compressed air should be clean and
dry and applied at a pressure not to exceed 25 psi.
If moisture is noted, it should be removed by drying with heated air from a blower. The temperature of the
applied air should not exceed 110°C (230°F).
Inspect all insulators, bushings, and terminals for corona discharge (tracking), breaks, cracks, burns, and
tightness of hardware.
Liquid-Filled Transformer
Verify that the oil level is satisfactory. Check the temperature gauge, liquid level gauge, pressure gauge,
and other indicators. Record the readings quarterly. Check the temperature gauge drag pointer for
evidence of excessive loading.
Check the pressure relief device. Check the sudden pressure relay circuit for proper operation and power
supply.
Conduct a megger or power factor check of the insulation for comparison with previous observations.
Record the findings semiannually.
Field Flashing Circuit

Check the condition of the flashing contactor and arc chute.
Verify the condition of the contacts by referring to the appropriate instruction manual. Typically, the arc
chute must be removed to examine the contacts. The contactor should be replaced if it has excessively
worn contacts.
Examine the arc chute. If it appears excessively black and has a lot of carbon buildup from interruption of
flashing current, then the exciter should be checked for proper startup sequencing. The flashing contactor
is required only to break dc current when voltage buildup does not occur and because the DXCB module
has fired on an aborted flash. Therefore, the arc chute should not have to absorb much energy. The
contactor should be replaced if arc chute damage is evident.
For systems having AC field-flashing, the condition of the flashing isolation transformer and contactor
should also be checked.

SECTION 5 • MAINTENANCE SCHEDULE
This section provides a recommended inspection schedule for the excitation system equipment. Each
user’s own experience, along with the conditions at the equipment site should determine the frequency of
inspection. In the maintenance schedule of Table 5-1, inspection and maintenance operations are
abbreviated as follows:
C – Change of Component
D – Check for Dirt/Debris and Clean
F – Check for Open Fuse
I – Inspect Component/Equipment
O – Torque Bus and Cable Connections
R – Refurbish at Factory
T – Test and/or Calibrate Component
V – Verify Operation
Table 5-1. Maintenance Schedule

Routine Length of Service in Years
Semiannually
Quarterly
Annually
Startup
12.5
17.5
27.5
2.5
7.5
10
15
20
22
25
5
Maintenance Item
AC Isolation Transducers T D T T T T T T T T T T T
Air Conditioner T I D Inspect and maintain according to instruction manual.
Air Filters I/C/D
Analog I/O Circuit Boards T D T T T T T T T T T T T
Bridge Control Module (BCM) T D T T T T T T T T T T T
Bridge Isolation Transducers T D T T T T T T T T T T T
Bus Connections I/O I I I I I I
Cable Terminations I/O I I I I I I
Circuit Breaker T I/D Inspect and maintain according to instruction manual.
Conduction Monitors V V V V V V V V V V V V
Contactor, AC T I/D C
Contactor, DC T I/D C
Control Fuses I/F I/F
Control Relays V V V V V V V V V V V V
Corrosion/Condensation I I
Crowbar Module T T T T T T T T T T T T
DC Isolation Transducers T D T T T T T T T T T T T
De-Excitation Module T T T T T T T T T T T T
Digital Controller (DECS) T D Inspect and maintain according to instruction manual.
Digital I/O Circuit Boards T D T T T T T T T T T T T
Dustiness I I D
Exciter Control Module (ECM) T D T T T T T T T T T T T
Fan/Blower Motors T T C C
Fan Blade Assemblies I I
Fan Shutter Switch I I C C
Fiber Optic Connections I I
Field Flashing Contactor T I
Field Flashing Circuit T I
Firing Control Module (FCIM) T D T T T T T T T T T T T
Firing Module (IFM) T D Inspect and maintain according to instruction manual.
Ground Detector Module T T C C
9410100990 Rev - Maintenance Schedule 5-1

Routine Length of Service in Years
Semiannually
Quarterly
Annually
Startup
12.5
17.5
27.5
2.5
7.5
10
15
20
22
25
5
Maintenance Item
Insulators and Supports I/D I/D
Line Filter Capacitors I I C C
Line Filter Fuses I/F I/F
Line Filter Resistors I I
MOV Fuses I/F I/F
MOVs I I C C C C C C C C C C C
PanelMate T C C
Power Converter (Drawer) T/I/D D R R R R R
Power Converter (Fixed) T/I/D D R R R R R
Power Supplies T C C C
Protective Relays T T Inspect and maintain according to instruction manual.
Ribbon Cable Connections I I
Sensor Input Module (SIM) T D T T T T T T T T T T T
Shaft Suppression Capacitors I I C C
Shaft Suppression Resistor I I
Space Heater Circuit T D T T T T T T T T T T T
Temperature, Ambient I I
Voltraps I I
Wiring I I
Wiring Connections I I
5-2 Maintenance Schedule 9410100990 Rev -

ROUTE 143, BOX 269
PHONE +1 618-654-2341 FAX +1 618-654-2351
I.L. 6D34315E
ECS2100 Single or Dual Channel System Installation
INSTRUCTION LEAFLET
specific schematics.) Tests described in this IL for
DRAWINGS options not supplied on the unit should be
skipped.
The following order specific drawings are
referenced within this document.
• System One Line Diagram
SAFETY
• Control System Software
• System Interface DANGER:
• 125Vdc Relay Logic BODILY INJURY OR POSSIBLE DEATH
COULD RESULT IF CONTACT IS MADE
• Auxiliary Interface WITH THE COMPONENTS IN THIS
• List of Apparatus APPARATUS WHICH CARRY EITHER
• Conduit List LINE VOLTAGE, OR GENERATOR FIELD
VOLTAGE OR ARE SUBJECT TO
ABNORMALLY HIGH VOLTAGES.
REFERENCES TO THE CIRCUIT
PURPOSE
DIAGRAMS, NOTABLY WITHIN OTHER
DOCUMENTATION WILL DISCLOSE
The purpose of these instructions is to serve as a
HAZARDOUS AREAS.
guide in placing a single channel and/or single
cubicle type ECS2100 unit into service for the
first time. All wiring connections between the
As with all electrical equipment, appropriate
excitation switchgear and both the machine and
safety measures should be taken whenever dealing
the customer's control station should be checked
with the excitation equipment. High voltage is
for continuity and proper polarity.
present within the excitation cubicles; their
magnitudes depend upon the particular system.
This document contains a general description of
Opening the sources (e.g., disconnect device 41)
how a variety of systems (i.e. Static, Brushless,
does not completely disconnect the high voltages.
rotating exciter) with a variety of options that may
As long as the machine is still physically
be put into service. The references are generic and
connected to the system, there is a possibility that
some options in them will not apply at any one
particular site. Before attempting an installation it
is essential that the site-specific schematics are
Every precaution must be taken when working at
obtained and used as a guide. (Note: the last three
the excitation control switchgear to ensure that all
characters beside the generic drawing number
high voltages are isolated and avoided by test
above typically refer to the last three characters of
personnel. In addition to the machine terminal
the site specific schematics. The “x” is a wild card
voltage (460 VAC or greater) at the excitation
that may be replaced with any letter on the site-
transformer, there may be other sources of power
Revised 11-09-06 1
INSTRUCTIONS FOR SINGLE OR DUAL CHANNEL INSTALLATION I.L. 6D34315E
entering the cubicles, such as the customer 1- D-C 0-200 Millivolt Source (to accurately
125/250 VDC and/or 120/240 VAC used to feed set the transducers this should be accurate
certain devices. The field voltage is also present at to within 0.1%)
the ground detector power source. A good rule to 1- D-C 0- to approx 500Vdc @1 amp (to
follow is to assume that all connections are live accurately set the transducers this should
and dangerous until proven otherwise and to avoid be accurate to within 0.1%) (Voltage out-
completely all body contact with any of these put should be higher than the excitation
voltages. system ceiling voltage, i.e. more than 1.25
times rated RMS voltage to the bridge,
One other cautionary note refers to the Generator from a PMG or a station service
Field Ground Detector. Because the Ground transformer.)
Detector input supply is usually a separate 110
VAC, both the AC power bus and DC field bus [An excitation or relay test box may be substituted
might be backfed from this device with 120 VDC. for the above 4 items.]
Therefore it too must be disconnected when
servicing the excitation control equipment. 1- 0-200 ohm, 1W Variable Resistor
1- 0-1 Mega ohm, 2W Variable Resistor
1- 1 kilo ohm, ¼ W Resistor
TEST EQUIPMENT REQUIRED
1- 3 Phase Power Source of adequate OPTIONAL TEST EQUIPMENT

capacity, proper voltage and frequency to 1- Phase-Sequence Meter (Not absolutely
energize the converter bridge required, but highly recommended)
Typically 15 kVA is suggested, however 1- Chart Recorder, two element (Brush MO-
as little as 3 kVA may be sufficient. 200 Series) or equivalent
1- Suitable load for the converter bridge. (It 1- Voltage balancing unit for use with chart
is highly recommended that that the load recorder
be inductive.)
1- Oscilloscope (2 Channel preferred with
isolated inputs or an isolation amplifier)
1- Current Probe for oscilloscope to measure
thyristor gate current NOTE THAT MOST OSCILLOSCOPES
1- Differential voltage Probe for oscilloscope HAVE A COMMON CONNECTION FOR
if inputs are not isolated ALL INPUTS (THE CASE OF THE SCOPE).
1- Volt-ohmmeter 20,000 Ohms/Volt or WHEN MAKING MULTIPLE
better CONNECTION TO A SCOPE, BE SURE
1- Phase-Angle Meter (Oscilloscope may be THERE IS NO SHORT CIRCUIT ON THE
used as substitute.) COMMON CONNECTION. ISOLATION
1- 120 V, 1 Amp, 3-Phase source (to TRANSFORMERS MAY BE REQUIRED.
accurately set the transducers this should WHEN THE CASE IS ISOLATED FROM
be accurate to within 0.1%) GROUND, THE POTENTIAL ON THE CASE
1- 20 V, 7.5 Amps , 3-Phase source whose MAY CAUSE SHOCKS IF CASE IS
phase angle can be set independent of the TOUCHED.
above voltage source (to accurately set the
transducers this should be accurate to
within 0.1%)
Revised 11-09-06 2
GLOSSARY DEVICE NUMBER FUNCTIONS
AIOM Analog Input / Output Module. Several components in an ECS2100 Unit are
Provides the interface for analog identified by device function numbers defined by
signals into and out of the system. ANSI/IEEE C37.2-1979.
31 = separate excitation device, a device that
DIOM Digital Input / Output Module. connects a circuit to a source of separate
Provides the interface for 125 VDC excitation during the starting sequence; or one that
control signals into and out of the energizes the excitation and ignition circuits of a
power rectifier.
system.
41 = field circuit breaker or contractor, a
device that functions to apply or remove the field
BCM Bridge Control Module generates excitation of a machine. In the following sections
the thyristor firing pulses this device is referred to as 41A because it is
utilized on the AC power input of the regulator or
ECM Exciter Control Module contains static exciter.
the excitation control, limiting, 43 = manual transfer or selector device, a
protection, and communication manually operated device that transfers the control
software. circuits in order to modify the plan of operation of
the switching equipment or of some of the
devices.
FCIM Firing Circuit Interface Module
determines when the firing pulses 86 = lockout relay, a hand or electrically reset
auxiliary relay that is operated upon the
should occur. Provides the occurrence of abnormal conditions to maintain
interface from ac line and dc field associated equipment or devices inoperative until
signals from the IT cards to the it is reset.
ECM. 90 = regulating device, a device that functions to
regulate a quantity, or quantities, such as voltage,
current, power, speed, frequency, temperature, and
SIM Sensor Input Module. Provides the load, at a certain value or between limits for
interface from PT and CT signals machines, tie lines, or other apparatus.
and the AIOM and DIOM signals
to and from the ECM.
Revised 11-09-06 3
OUTLINE OF GENERAL PROCEDURE

Machine not running A. Verify external wiring to be per job schematic Ref. Job Schematics &Job Conduit List.
B. Verify auxiliary power circuits Ref. Job Schematics
C. If an excitation transformer is used, verify Ref. Job Schematics
excitation transformer phasing. If a PMG
Iis used check phase rotation on turning
gear. Ref. Job Schematics
D. Energize circuit boards and verify application
software is the proper revision. Ref. Individual Module IL's
E. Check scale and offset of all transducers
using simulated intelligence sources. Ref. Table 1,2,3 (at end of this IL)
Ref. Job Schematics
F. Verify the operation of all relays, breakers,
and control switches.
Ref. Job Schematics
G. Check exciter firing control and converter
bridge(s). Ref. IL xxx
Ref. Job Schematics
H. Check adjusters, followers, regulators and
controllers using simulated intelligence
sources. Ref. Job Schematics
I. Check operation of all limiting and protection Ref. Job Schematics

functions using simulated intelligence
sources. Verify pickups and time delays to Ref. Job Schematics
be per customer’s request.
J. Test monitoring functions using simulated
intelligence sources.
K. Reconnect to original power potential
transformer or PMG. (If original source
was not used to check convertor bridges.)
Machine Running L. If a PMG is used, verify PMG voltage

at rated speed, magnitude and phase rotation.
line circuit breaker open
M. Check excitation system control offline.
N. Check stability offline. (Bump test.)
Machine running O. Check polarity and phase angle of machine
at rated speed, current signals to be correct.
line circuit breaker closed
P. If VAR or PF control is used, check system Ref. See contract Instruction Book Leaflets for
with controller on. individual modules
Q. Check for stable operation and correct
setting of various limiters using actual
machine signals. Test settings or software
injected test offsets may be used if
necessary.
R. If a Power System Stabilizer used, check,
setup and test the with the Power System
Stabilizer turned on.
S. Check final operation of machine in
conjunction with electrical system.
NOTES:
Steps D, E, I, J, Q, and R Settings (steps H, I, J, N, P, Q, R, and S) are the
responsibility of the customer or his hired consultant
To be done by or supervised by a Service Engineer using ccTool software
Revised 11-09-06 4
CHECKOUT PROCEDURE in exact agreement with the excitation and control

schematics. Equipment mis-operation and/or
Preliminary damage can occur if this is not done.
It is recommended that the service people
familiarize themselves with all job instructions
and associated equipment before performing any Checkout of Auxiliary Power Circuits (B)
installation tests All lights, receptacles, thermostats and space
It is also suggested that a copy be made of all job heaters should be verified as working properly per
schematics and conduit lists, to provide a physical the job schematic.
reminder of the circuits as they are checked. As
specific circuits are tested they should be crossed Checkout Power Source Phasing
off. Some jobs may contain circuits not described i.e. Excitation Transformer (If used) or PMG
in here. They must also be tested and crossed off. (If used) (C)
For dual channel systems, the calibration 1. Thoroughly check the excitation transformer
procedures in the following sections must be and it’s internal and external connections and
performed on both the Main and Redundant polarities to be per its instruction book and
channels. The values obtained in each channel contract schematic.
should be as close to each other as possible. It is
strongly recommended that each procedure be 2. Check phase sequence of the primary
carried out at the same time on both channels connections to the excitation transformer to
using the "Tile" capability in the Window tab insure that the voltages come up positive in
when a laptop computer is connected to both phase sequence. The following chart shows
Channels using ccTool. the positive in phase sequence rotation, with
typical notation.
To avoid undesired trips, it is advisable to disable
the trip commands leaving the excitation system
before performing the offline testing. These A B C
circuits should be enabled prior to rolling the Transformer Primary T1 T2 T3
generator.
Transformer Secondary X1 X2 X3
For personnel safety it is also advisable to disable
the ground detector, and remove power from Bridge Input PS1 PS2 PS3
cubicle heaters while working in the unit. The
leads to the field should also be lifted when
connected to a dummy load. The leads to a PMG Actual nomenclature may vary depending on
or excitation transformer should be lifted when site-specific conventions. The key item is that
feeding the bridge from a test power source. The after the 41 device is closed the phase
connection between the shunt and field current sequence of the three-phase supply to the ac
transducer should be lifted when a test mv source isolation transducers and bridge is positive. If
is used. These circuits should all be reconnected the machine phase sequence is different from
prior to rolling the generator. that shown on the excitation schematic, the
cause must be determined and corrected
Checkout of External Wiring (A) before the equipment is energized.
Service personnel should make a point-to-point

check of all wiring connections, both to and from
the excitation switchgear, for continuity and
proper polarity. Improper wiring and/or phasing FAILURE TO CHECK THOROUGHLY THE
can cause miss-operation of the regulator limiter EXCITATION TRANSFORMER, ITS
and/or protection functions. For example, the INTERNAL AND EXTERNAL
compensators and some limiters in the regulator CONNECTIONS, THE POLARITY OF ITS
circuits require machine voltage and current WINDINGS AND THE PHASE SEQUENCE
intelligence with the proper phase sequence and a OF ALL OF THE VOLTAGES MENTIONED
particular relationship between the current and WILL CAUSE MALFUNCTION AND
voltage. It is essential that the external wiring be
Revised 11-09-06 5
POSSIBLE SERIOUS DAMAGE TO THE 4. Connect to the metering pt switches a three-

POWER COMPONENTS OF THE STATIC phase ac voltage with a magnitude and phase
EXCITER sequence equal to the pt secondary voltage
Energize circuit boards and Check software when the generator output is at its rated value.
revisions (D) Check the “LINETRN02_MAGNITUDE”
output of the “LINETRN#02” block is
1. Check that the output of the blackstart (fed 1.000(+0.0009). If not use the appropriate
from 125 Vdc) power supply is 24 (±3) Vdc. “SIG_IN” block “SIGIN_CH**_SCALE”
2. With a PC, using ccTool software, connect to constants to make the output of the
each ECM, FCIM, and BCM card. If needed, “LINETRN#02” block equal to1.000
run a validation of the application software (±0.0009). Set all three “SIG_IN” block input
(rhx) in each card. Check that the revision is constants, “SIGIN_CH**_SCALE”, to the
per the unit specific schematics. same value for a three-phase input.
3. Check that the revision of the PanelMate 5. Run transfer curve with input voltage set to
executive firmware is also per the unit specific simulate 90, 110, 130 percent of generator line
schematics. voltage. The expected results should be linear.
Check scale and offset of all transducers (E) 6. Connect to each CT switch an ac current equal
in magnitude and polarity to the CT secondary
It is strongly recommended that each step in current when the generator output is at its
the following procedure be performed on both rated value. Check that the
channels in a dual channel system before “LINETRN**_MAGNITUDE” output of the
continuing to the next step in order to obtain appropriate “LINETRN” block output
the closest results possible in Main and (typically “LINETRN00_MAGNITUDE”) is
Redundant channels for the same input values 1.000(±0.005). If not, use the appropriate
of currents and voltages. “SIG_IN” block “SIGIN_CH**_SCALE”
(typically SIGIN_CH04_SCALE,
When setting up the input transducers SIGIN_CH05_SCALE, and
establish communication with the ECM using a SIGIN_CH06_SCALE) constants to obtain the
PC, running ccTool software. appropriate “LINETRN00_MAGNITUDE”
1. Set the PT and CT inputs to zero by shorting output at 1.000(±0.005). Set all three
the inputs at their respective input switches. appropriate “SIGIN_CH**_SCALE”
Check at the associated outputs of the constants be the same for a three-phase input.
“SIG_IN” block that the each PT and CT 7. Run a transfer curve with the CT input current
signal is close to zero (±0.0009). If not use the set to 1, 2, 3, and 4 amps. The expected results
appropriate “offset” constant to make the should be linear.
output of each input close to zero. Remove 8. Set PT and CT inputs to simulate the generator
any shorts being at rated conditions. Using ccTool,
2. Connect to the regulator PT switches a three- capture an event recording the instantaneous
phase ac voltage with a magnitude and phase voltage and current inputs. Verify phasing is
sequence equal to the pt secondary voltage correct. Check on PanelMate display that line
when the generator output is at its rated value. voltage, line current, MW, Mvar, and power
Check the “LINETRN01_MAGNITUDE” factor read correctly on all screens. In order to
output of the “LINETRN#01” block is do so, check the general pages in the
1.000(±0.0009). If not use the appropriate PanelMate, and all the specific pages
“SIG_IN” block “SIGIN_CH**_SCALE” dedicated to only the Main or Redundant
constants to make the output of the Channels.
“LINETRN#01” block equal to 1.000
(±0.0009). Set all three “SIG_IN” block input
constants, “SIGIN_CH**_SCALE”, to the Note: for IT transducers, pin 19 is positive with
same value for a three-phase input. respect to 20, and pin 21 is positive with
respect to 22.
3. Run transfer curve with input voltage set to
simulate 90, 110, 130 percent of generator line 9. Pull the appropriate fuse, and short the
voltage. The expected results should be linear. connections to the phase AB line transducer
Revised 11-09-06 6
(ALXD). Check in the FCIM card that the 15. Check on PanelMate display that field voltage
output “FVAB_OUTPUT” of the reads correctly on all screens.
“F_TO_VAB” block is 0(±40) counts. If not
adjust the “FVAB_OFFSET” so that the 16. Lift the leads from the output current shunt
output “FVAB_OUTPUT” is 0(±40) counts. and connect a millivolt source to the wires
Set the ac line transducer input (Pins J19, J20) going to the field current transducer (DCXD).
to a DC voltage equal to the RMS value of the Set the dc input equal to the shunt millivolt
line-to-line voltage applied to the converter level corresponding to the field current at ten
bridge(s). Check that “FVAB_OUTPUT” is per cent full load. Check in the ECM that the
1100(±80) counts. If not adjust the constant FCIM_INP block's output
input “CONST1_IN1 in the "CONST1" block “FCIN_GEN_FLD_CUR” is 0.100(±0.0009).
until the “FVAB_OUTPUT” of the If not, adjust the “FCIN_IG_OFFSET” so that
"F_TO_VAB" block is 1100(±80) counts. the output “FCIN_GEN_FLD_CUR” is at
0.100(±0.0009).
10. Pull the appropriate fuse, and short the
connections to the phase BC line transducer 17. Set the dc input equal to the shunt millivolts
(ALXD). Check in the FCIM card that the when the field current is at full load. Check
output “FVBC_OUTPUT” of the that the output of the FCIM_INP block
“F_TO_VBC” block is 0(±40) counts. If not “FCIN_GEN_FLD_CUR” is 1.000(±0.0009).
adjust the “FVBC_OFFSET” so that the If not adjust “FCIN_IG_SCALE” so that the
output “FVBC_OUTPUT” is 0(±40) counts. output “FCIN_GEN_FLD_CUR” is
Set the ac line transducer input (Pins J21, J22) 1.000(±0.001). Recheck at ten percent and
to a DC voltage equal to the RMS value of the repeat as needed.
line-to-line voltage going to the converter 18. Run transfer curve with input millivolts set to
bridge(s). Check that “FVBC_OUTPUT” of simulate 50, 100, and 200 percent of full load
the "F_TO_VBC block is 1100(±80) counts. If field current. The expected results should be
not adjust the constant input “CONST1_IN1 linear.
in the "CONST1" block and re-check step 10.
19. Check on PanelMate display that the field
11. Ensure all connection are re-established and current reads correctly on all screens.
replace all fuses removed.
20. Ensure all connection are re-established and
12. With the appropriate fuse pulled short the replace all fuses removed.
connection to the field voltage transducer
(Pins J21, J22 of DCXD). Check in the ECM 21. If analog inputs are used, check that load
that the FCIM_INP block’s output resistors are present if a 4-20 ma source is
“FCIN_GEN_FLD_VLT” is 0.000(±0.0009). used. Check in the “ALOGDIG” block that
If not, adjust “FCIN_VG_OFFSET” so that AD_OFFSET_3”, “AD_GAIN_3” are
the output “FCIN_GEN_FLD_VLT” is properly set for channel 1, per the order
0.000(±0.0009). drawings and customers transducer. (If a
ground detector is used, Channel 3 typically
13. Set the dc input equal to the field voltage at measures leakage to ground, and can be set up
full load. (Typically, full load field current later with the ground detector. Check in the
times field resistance at 75 deg. C). Check that “ALOGDIG” block that "AD_OFFSET_4",
the output of the FCIM_INP block “AD_GAIN_4” are properly set for channel 2,
“FCIN_GEN_FLD_VLT” is at per the order drawings and customers
1.000(±0.0009). If not, adjust the value of transducer.
“FCIN_VG_SCALE” so that the output
“FCIN_GEN_FLD_VLT” is 1.000(±0.0009). 22. If RTD inputs are used, check in the
“ALOGDIG” block that “AD_OFFSET_1”,
14. Run transfer curve with input voltage set to “AD_GAIN_1”, “AD_OFFSET_2”,
simulate 50, 100, 150 percent of full load field “AD_GAIN_2”, “AD_RTD_KSCALE”,
voltage (if possible). The expected results “AD_RTD_RZ”, and “AD_RTD_RZ” are
should be linear. properly set. Connect test resistance in place
of RTD. For a 100 ohm input, the output of
“ALOGDIG” should read 0.0 degrees Celsius.
For a 110 ohm input, the output of
“ALOGDIG” should read 25.9 degrees
Revised 11-09-06 7
Celsius. If output goes to a remote meter, secondary voltage when the generator output
inject signals and check for correct operation is at its rated value. Connect to the metering
of remote meter PT switches a three-phase ac voltage with the
23. If analog outputs are used, check in the same magnitude and phase sequence as the PT
“DIGALOG” block that offsets and scales are secondary voltage when the generator output
properly set, per the order drawings. If output is at its rated value. Check that the unit can be
goes to a remote meter, inject signals and transferred between automatic and manual.
check for correct operation of remote meter Check “AUTO” and “MAN” lights.
5. Check Loss of sensing. Check that the unit
transfers from ‘AUTO’ to ‘MANUAL’ when
Checkout of relays, breakers, and control the regulator and (if used) metering PT’s
switches (F) voltage falls below a selectable value.
Normally the unit is started up in the ‘AUTO’
1. Check the operation of all relays, contactors, mode. Since the PT voltage is initially low, the
cooling fans, circuit breakers, adjusters and controls are defaulted by the loss of sensing
the various control switches located both at function to the “MANUAL’ mode. When the
the excitation switchgear and at the station PT voltage crosses the selectable level in a
operator’s control board. Operation of all these predetermined time the unit transfers back to
devices must be in complete agreement with the ‘AUTO’ mode.
the job contract schematic. The check should
first be made using the local PanelMate, then If metering PT’s are used the unit transfers
control room switches, and then distributed from one set of PT’s to the other when only
control system screens. For dual channel one set of PT’s is low. Transfer to manual
systems, this portion of the procedure should occurs when both sets of PT inputs go low.
be performed first with the Main Channel in This can be simulated (tested) in two ways:
control, and then with Redundant Channel in
control, repeating all the steps. The following The first test simulates a blown fuse by
are checks for the more typically used disconnecting a single PT input. The second
components. simulates a high resistance fuse/connection by
lowering the PT inputs.
2. Check operation of “LOCAL/REMOTE”
transfer. With “LOCAL/REMOTE” in 6. Check correct operation of field flash circuitry
“LOCAL”, the controls in the PanelMate while disconnected from field. Set 31TD per
mounted on the excitation switchgear are customer’s requirements (typically 10
active. With “LOCAL/REMOTE” in seconds). Check 31, 31X contacts in alarm
“REMOTE”, the switches mounted in the and annunciator circuits. Check that field flash
control room are active and the PanelMate is turned off when field current builds up, or
screen switches on the logic cubicle are when regulator pt voltage is applied.
inactive. Steps 3 to 9 should be done in 7. Check operation of the automatic adjuster.
“LOCAL” and then repeated in “REMOTE”. Verify travel range and preposition meet
Check any local and remote lights. customer’s operational practices. With the
3. Check 41A-CS CLOSE command, 41A 41A device tripped, the adjuster output is at
device, 41AX relays and interlocks. When the the ACVLTADJ block preposition value
local 41CS is switched to TRIP position, the (“ACADJ_PP_1”), and cannot be moved
86 device operates immediately, initiating under normal operation. With the 41A device
phase back. The 41A device trips about 5 closed, the adjuster output can be moved.
seconds later (after software timer times out). The range can be easily verified. With the
Upon customer emergency trip, the 41A adjuster at minimum apply a PT signal until
device operates immediately. Check red and the ac error signal reads zero. (Balance meter
green lights. Check alarm and annunciate can be used if dc error is kept at zero.) This is
contacts associated with 41A, 41AX, and 86. the minimum setting of the adjuster.
4. Check mode select. Connect to the regulator Alternately with the adjuster at maximum
PT switches a three-phase ac voltage with the apply a PT signal until again the ac error
same magnitude and phase sequence as the PT signal reads zero. Both of these settings
(“ACADJ_MAX”, “ACADJ_MIN”) are
Revised 11-09-06 8
selectable with the ccTool software. The travel Converter Bridges with Generator Not
time is settable using “ACADJ_SLEW” Running (G)
8. Check operation of the manual adjuster. 1. In the following steps, the bridge operation
Verify travel range and preposition meets under control of the “SLC2_BASE” signal in
customer’s operational practices. With the the “REG_SLCT2” block will be checked.
41A device tripped, the adjuster output is at Three-phase, 60 Hz power for this test may be
the MANADJ block preposition value taken from the excitation transformer
(“MANADJ_PP_1”), and cannot be moved secondary if the transformer can be energized
under normal operation. With the 41A device with its rated primary voltage at the time the
closed, the adjuster output can be moved. main unit transformer is being tested. If a
The range can be easily verified. With the separate supply source must be used, it should
adjuster at minimum, vary a simulated shunt be sized to provide sufficient static exciter
mV signal until dc error reads zero. (Balance load to give the exciter a reasonable
meter can be used if ac error is kept at zero.) operational test. The test supply can be either a
This is the minimum setting of the adjuster. closed three-phase delta or a three-phase wye.
Alternately with the adjuster at maximum Do not use an open-delta three-phase supply
apply a simulated shunt mV signal until again for this test. Check phase sequence of the
the dc error signal reads zero. Both of these supply voltage used to be in agreement with
settings (“MANADJ_MAX”, the contract schematic. The three-phase test
“MANADJ_MIN”) are selectable with the voltage should be connected at the input to the
ccTool software. The travel time is settable 41A device.
using “MANADJ_SLEW”.
9. Check operation of the var control adjuster.
Verify travel range and preposition meet
customer operational practices. With the 41A
device tripped, the adjuster output is at the IF THE EXCITATION TRANSFORMER IS
VARCONTR block preposition value NOT USED AND A SEPARATE SOURCE IS
(“VRC_PP_1”), and cannot be moved under CONNECTED TO THE 41A DEVICE, THE
normal operation. With the 41A device closed, EXCITATION TRANSFORMER SEC-
the adjuster output can be moved. The range ONDARY CONNECTIONS TO THE 41A
can be easily verified. With the adjuster at DEVICE MUST BE DISCONNECTED AND
minimum, apply PT and CT signals and adjust TAGGED AND TAPED. DO NOT
simulated vars until the var balance signal ENERGIZE THE EXCITATION
reads zero. This is the minimum setting of the TRANSFORMER SECONDARY WITH THE
adjuster. Alternately with the adjuster at SEPARATE TEST SOURCE. STARTING
maximum apply PT and CT signals and adjust RESISTORS ALONE MAY BE USED AS A
simulated vars until again the var balance LOAD FOR THIS TEST. IT IS
signal reads zero. Both of these settings PREFERABLE THAT A HIGHER
(“VRC_MAX”, “VRC_MIN”) are selectable CURRENT LOAD (PREFERABLY
with the ccTool software. The travel time is INDUCTIVE) BE USED.
settable using “VRC_SLEW”.
10. If used, check operation of 64-switch and field
ground fault detector. Check that ground fault
detector is disabled during field flash.
IF THE ROTOR FIELD IS TO BE USED AS
11. If used, check operation of cooling fans and PART OF THE LOAD, AN ADDITIONAL
associated controls. LOAD RESISTOR SHOULD BE ADDED IN
12. Repeat steps 3 through 11 above for SERIES WITH THE GENERATOR OR
“REMOTE”. EXCITER FIELD. THIS RESISTOR MUST
13. Check any other control features per job BE SIZED TO PREVENT ANY DAMAGE TO
schematic. THE EXCITER OR GENERATOR ROTOR
AND PREVENT OVERLOADING THE
Check Exciter Power firing Control and TEST POWER SUPPLY WHEN THE UNIT
IS NOT ROTATING, SINCE CURRENTS
Revised 11-09-06 9
LESS THAN NO LOAD FIELD CURRENT WHEN MAKING MULTIPLE

CAN CAUSE DAMAGE TO THE CONNECTIONS TO THE SCOPE, BE VERY
GENERATOR OR BRUSHES. CHECK CAREFUL TO AVOID SHORT CIRCUITS
WITH CUSTOMER TO DETERMINE SAFE AT THE SCOPE COMMON CONNECTION.
LEVEL OF CURRENT WHEN UNIT IS ISOLATION TRANSFORMERS MAY BE
STATIONARY. REQUIRED.
Oscilloscope Note: In order to have the pulses
properly displayed, the oscilloscope must be
synchronized to the firing circuit supply voltage.
If the ac line isolation transducer receives its
ANYTIME THE EXCITER BRIDGE FEEDS voltage from the same 60 Hz test supply then the
A FIELD AT STANDSTILL, CLOSE scope can be set to LINE SYNC. If the excitation
SUPERVISION MUST BE MAINTAINED TO transformer is used for the test supply, and the
PREVENT THERMAL DAMAGE SINCE oscilloscope are connected to the customer’s 60
THE MACHINE COOLING IS NOT Hz system, a separate sync. signal should be
EFFECTIVE AT STANDSTILL. DAMAGE supplied to the external sync. terminal of the
MAY ALSO OCCUR TO BRUSHES AT scope and the scope should be set for
STANDSTILL. EXTERNAL SYNC. It is highly recommended
that a current probe be used to measure the firing
pulses.
2. This step will simulate an open loop
condition, and enable control of the bridge 5. Check that each firing pulse is made up of a
output by setting “SLC2_BASE”. With the number of individual pickets, typically four
EC2100 regulator out of service (41A open), pickets for each firing pulse.
set the “SLC2_KIA”, “SLC2_MAXA”, 6. Vary the “SLC2_BASE”setting and observe
SLC2_MINA” variables to zero. Set the that the firing pulses move from right to left
“SLC2_BASE” variable to 1.0 in both on the oscilloscope screen (earlier in time) as
channels. the “SLC2_BASE”setting increases (RAISE
3. If the system has only one bridge, proceed to direction of the base adjuster). Large values of
the following step. For systems with more “SLC2_BASE”cause the unit to go to ceiling.
than one bridge, leave only one enabled by Values of “SLC2_BASE” near zero cause
setting the others in the Maintenance Mode output voltage to approach zero. (Actual low-
using the Maintenance block provided in the end voltage depends on whether or not the
FCIM. It is crucial that the FCIM being simulated load is inductive.) Also note that the
accessed corresponds to the channel that is in negative output voltage, seen when the exciter
control. power amplifier is phased back in the
neighborhood of 90°-180° delay, is a
4. With a suitable dummy load connected, and an momentary transient that appears only with an
oscilloscope connected to view the firing inductive load.
pulses at the power amplifier modules, close
device 41A, and observe that the power
amplifier output voltage is near the no-load NOTE: DO NOT DWELL AT CEILING
field voltage. Observe the exciter output VOLTAGE LEVELS ANY LONGER THAN
waveform to be similar to waveforms shown 60 SECONDS UNLESS LOAD IS SIZED TO
in Figure 1 for a full converter. Note that six HANDLE CONTINUOUS CEILING
SCR firings per cycle are present by the six VOLTAGE. LOAD RESISTORS POSSIBLY
bumps per cycle in the output waveform. WILL BECOME EXCESSIVELY HOT IF
CEILING VOLTAGE LEVELS ARE
APPLIED CONTINUOUSLY. ALLOW
SUFFICIENT COOLING TIME (60
SECONDS) BEFORE SUBJECTING TO
CEILING LEVELS AGAIN.
MOST OSCILLOSCOPES HAVE A
COMMON CONNECTION FOR ALL
INPUTS (THE CASE OF THE SCOPE).
Revised 11-09-06 10
exciter test load resistor in series with the

machine field and the test power supply ready
for combination tests with the regulator logic
later.
Check the adjusters, followers, regulators, and
controllers using Simulated Intelligence with
Generator Not Running (H)
DO NOT USE THE SAME 60-HERTZ TEST

SOURCE FOR A SOURCE OF TEST
VOLTAGE TO THE LOGIC MODULES
AND THE POWER MODULES AT THE
SAME TIME BECAUSE TEST SOURCE
REGULATION MAY CAUSE UNSTABLE
OPERATION.
The following are the more commonly used
regulators, adjusters, and controllers and a typical
method for checking each. For dual channel
systems, the following checks should be
performed first with the Main Channel in control,
and then each step repeated with the Redundant
Fig. 1 Typical Output Waveforms for Full Channel in control.
Converter
1. Check the setup of the automatic adjuster
7. The exciter output, in response to the control (software block “ACVLTADJ”). With
“SLC2_BASE”setting control, must be 41A closed use the operator control to move
smooth and with an inductive load adjuster output from maximum to minimum.
approximately linear between the start of Look at “ACADJ_TRAVEL” for the percent
conduction of the thyristors and near travel from 0 to 100. Check that maximum
saturation voltage (near exciter ceiling (ACADJ_REF), minimum, and travel time are
voltage) where Ceiling Volts = 1.25 x Test proper to meet this sites operational
Supply Voltage. (Note: with a resistive load requirements. Open 41A and check that output
only the upper portion of the curve will be returns to preposition 1. Check that this is
linear. Voltage will not go to zero with zero proper to meet site startup requirements. If
input.) used, check for correct operation of adjuster
8. Check polarity of field voltmeter in control position meter, or maximum/minimum
room. position lights or indications.
9. Set the bridge just tested into the Maintenance 2. Check setup of the manual adjuster control
Mode, and "Return from Maintenance" one (software block “MANADJ”). Look at
the bridges that had been set in Maintenance “MANADJ_TRAVEL” for the percent travel
Mode previously, using the PanelMate. from 0 to 100. With 41A closed use the
Repeat steps 4 through 8. operators control to move the adjuster from
maximum (MANADJ_REF) to minimum.
10. For dual channel systems: when all the bridges Check that maximum, minimum, and travel
have been tested, switch the system to time are proper to meet this sites operational
Redundant Channel in Control, and repeat requirements. Open 41A and check that output
steps 4 through 9. returns to preposition 1. Check that this is
This completes the tests of the power proper to meet site startup requirements. If
components of the static exciter and the base used, check for correct operation of adjuster
adjuster circuitry (manual control of position meter, or maximum/minimum
excitation). After completion of these tests, the position lights or indications.
logic circuitry should be tested. Leave the
Revised 11-09-06 11
3. Check balance meter. With 41A open, disable signals to simulate 0 pf overexcited (generator
followers. Disable any var or power factor lagging vars). For droop compensation,
controller. Set “RCOMP_XC” and ACREG_V2 should become more negative by
“RCOMP_RC” to zero in “REAC_COMP” the amount of droop compensation. For rise
block. Set “LDR_XC” and “LDR_RC” to zero compensation, ACREG_V2 should become
in “LINEDROP” block if used. Set simulated more positive by the amount of droop
PT intelligence and CT intelligence to compensation.
correspond to rated values, and simulated field 8. If used, check setup of var controls (software
current to represent full load field current. block “VARCONTR”). With var control off,
Check output of “POWERTRN#00” block set PT and CT signals to simulate rated load
reads correct MW and MVARS. Close 41A. unity power factor. Use var control raise/lower
Set auto and manual adjuster outputs to 1.0. switches to set “VRC_V2” to zero. Turn on
Check that output of “AUTO_MXR” as seen var control. Reduce PT signal to below
at the “REG_SLCT2” (SLC2_ACR) and VRC_VMIN. Check adjuster position. Change
“MAN_MXR” (SLC2_DCR) both read zero. CT signal to simulate generator overexcited
Check that balance meter reads zero. Raise (approximately 0.8 lagging power factor).
auto adjuster and check that balance meter Verify ac adjuster output remains unchanged.
goes negative. Raise manual adjuster and Return PT signal to rated voltage. Verify that
check that balance meter returns to zero. output of ac adjuster decreases. Change CT
4. Check manual adjuster followers. With unit in signal to simulate generator overexcited
auto, and followers disabled, lower PT (approximately 0.8 lagging power factor).
intelligence to 98 percent of rated. Enable Verify that output of ac adjuster increases.
followers. Check that the manual adjuster 9. If used, check setup of power factor controls
(MANADJ_REF) output increases and the (software block “PFCONTR”). With pf
balance meter heads toward zero. Adjuster control off, set PT and CT signals to simulate
output stops moving when minimum is rated load unity power factor. Use pf control
reached or when balance meter gets near zero raise/lower switches to set “PFC_V2” to zero.
(within bandwidth of manual follower). Turn on PF control. Reduce pt signal to below
5. Check automatic adjuster followers. With unit VRC_VMIN. Check adjuster position. Change
in manual, and followers disabled, return PT CT signal to simulate generator overexcited
intelligence to 100 percent of rated. Use auto (approximately 0.8 lagging power factor).
adjuster switch to return balance meter to zero. Verify ac adjuster output remains unchanged.
Set simulated field current to 90 percent of full Return PT signal to rated voltage. Verify that
load. Enable followers. Check that the output of ac adjuster decreases. Change CT
automatic adjuster output (ACADJ_REF) signal to simulate generator overexcited
increases and the balance meter heads toward (approximately 0.8 lagging power factor).
zero (may cross over and go positive). Verify that output of ac adjuster increases.
Adjuster output stops moving when minimum 10. For dual channel systems, set simulated PT
is reached or when balance meter gets near and CT intelligence to correspond to rated
zero (within bandwidth of automatic values, and simulated field current to represent
follower). full load. With the Main Channel in control,
6. Return “RCOMP_XC” and “RCOMP_RC” to verify that the Trackers are enabled in the
original value in “REAC_COMP” block. Set PanelMate page dedicated to the transfer of
PT and CT signals to simulate 0 pf channel control. Also verify in the same page
overexcited (generator lagging vars). For that the Tracker window reads 0 + 0.1. If this
droop compensation ACREG_V2 should value is not within limits, recalibrate the
become more negative by the amount of droop analog output dedicated to pass the firing
compensation. For rise compensation signal from one channel to the other (usually
ACREG_V2 should become more positive by AD01). Check that the Redundant Tracker in
the amount of droop compensation. the page dedicated to the Redundant channel
7. If line-drop compensation is used, return reads the same value as the Tracker in the
“LDR_XCL” and “LDR_RCL” to original general control page. The Main Tracker in the
value in “LINEDROP” block. Set PT and CT page dedicated to the Main channel usually
will read a different value.
Revised 11-09-06 12
11. Disable the Trackers in the PanelMate page pickup. Turn off mV input; wait for inverse
for transfer control. Go to the "Output timer to time down. Suddenly apply mV
Control" page for the Main channel and raise source and measure time until OEL times out
the adjuster reference. Observe that the and record. Check that this timing is consistent
with the A, B, and C settings and timing is
Tracker reading goes negative. Enable the coordinated with generator thermal capability
Tracker and verify the Tracker value returns to (ANSI C57.xx). “OEL00_F2” turns true after
near zero. inverse timer times out. Remove mV source.
12. Switch to Redundant Channel in Control and 5. Set mV source to be 30 percent over limiter
repeat the above step but raise the adjuster pickup. Turn off mV input; wait for inverse
reference in the Redundant channel page. timer to time down. Suddenly apply mV
source and measure time until limiter and
Checkout of Limiters and Protective Functions protective functions time out and record.
(I) Check that this timing is consistent with the A,
The following are the more commonly used B, and C settings and the timing is coordinated
limiter and protective features and a typical with generator thermal capability.
method for checking each. The event recorder 6. Check correct operation of flags to transfer
feature in ccTool may be used to check short time channels, disable followers, and generate unit
delays in the following section as needed. For dual trip per site specific requirements.
channel systems, it is advisable to perform the 7. If used, check Temperature Recalibration.
calibration of each block at the same time with
both channels to obtain the closest possible 8. If used, check Pressure Recalibration.
results. 9. "INST_CUR" block. Check Instantaneous
Note: If desired, after each pickup point has been Limiter. Check any relays, lights, or
verified, the operation of each limiter can be seen annunciators associated with
by looking at the bridge output voltage. The firing INSTANTANEOUS Current Limiter.
circuit must be brought to a reasonable level (100) 10. Set system to simulate 52 breaker open. Raise
prior to the implementation of the above pickup mV input until Inst. Limiter “INS_F1” picks
signal test. The firing signal can be adjusted with up, and record this as off-line limiter pickup.
the auto/man adjusters. The tracking circuit 11. Raise mV input until Inst. Limiter “INS_F3”
(adjuster followers) should be disabled to prevent picks up, and record this as off-line protection
them from interfering with the operation of the pickup. Remove mV source.
limiters during the test.
12. Set mV source to be 4 percent over off-line
1. "OEL_P" block. Check Overexcitation protection pickup "INS_SP4". Suddenly apply
(Maximum) Excitation Limiter (OEL {MXL} mV source and measure time until INST_CUR
Time Delay). Check any relays, lights, or timers time out and record.
annunciator associated with the OEL (MXL). 13. Set system to simulate 52 breaker closed.
Raise mV input until Inst. Limiter “INS_F1”
Note: When the step change is done any picks up, and record this as on-line limiter
instability of the signal source will cause pickup.
false operation of the pickup point and vary
the timing. The signal can be monitored 14. Raise mV input until Inst. Limiter “INS_F3”
with the data logging function. picks up, and record this as on-line protection
pickup. Remove mV source.
2. Check that the recal inputs are not effecting
the output. Raise mV input until OEL picks up 15. Set mV source to be 4 percent over the on-line
“OEL00_F1”, and record this as limiter protection pickup “INS_SP3”. Suddenly apply
pickup. OEL output remains at “OEL00_OFF” mV source and measure time until all Inst_cur
while OEL is timing. timers time out and record. Check that this is
coordinated with generator thermal capability.
3. Raise mV input until OEL picks up
“OEL00_F3”, and record this as protection 16. "HXL_P" block. Check Volts/Hertz Limiter
pickup. (HXL). Check any relays, lights, or
annunciators associated with the HXL.
4. Set mV source to be 4 percent over limiter
Revised 11-09-06 13
17. Raise PT intelligence until "HXL_F1" picks 27. "UEL_P" block. Check Under Excitation
up and record this as limiter pickup. Raise PT (Capability curve) Limiter (UEL). Check any
intelligence until "HXL_F3" picks up and relays, lights, or annunciators associated with
record this as protection pickup. the UEL.
18. Reduce PT intelligence fifteen percent. Sud-
denly increase PT signal to 4 percent over 28. Check that the recal inputs are not affecting
limiter pickup. Measure time until HXL times the output. Set PT intelligence at rated value,
out. Check that this timing is consistent per set balance meter to zero, and CT intelligence
settings and timing is coordinated with to 0.5 amp at zero power factor lead. Simulate
generator volts/thermal capability (ANSI 52 breaker closed. UEL output should be
C37.xx). “HXL_F2” turns true after inverse negative and equal to “UEL_OFF”. Raise CT
timer times out. signal until UEL picks up and record. Increase
CT signal until "UEL_F2" picks up and
19. Reduce PT intelligence ten percent. Suddenly record.
increase PT signal to 10 percent over limiter
pickup. Measure time until HXL times out. 29. Reduce CT signal to 0.5 amp. Increase CT
Check that this timing is consistent per signal to five percent above "MEL_F2" pick
settings and timing is coordinated with up and measure time until "UEL_P" timers
generator volts/thermal capability. “HXL_F2” time out and record.
turns true after inverse timer times out. 30. Shift phase angle 60 degrees to simulate 26
20. "OVL_P" block. Check Overvoltage Limiter degrees (.9 pf.) under excited. Raise CT signal
(OVL). Check any relays, lights, or until UEL picks up again and record.
annunciators associated with the OVL. Typically this will be more than CT signal at
full load unity p.f. Check that this is
21. Raise PT intelligence until "OVL_F1" picks coordinated with any loss of field protection.
up and record and record this as limiter
pickup. Raise PT intelligence until "OVL_F3" 31. If used, check Temperature Recalibration.
picks up and record this as protection pickup. 32. If used, check Pressure Recalibration.
22. Reduce PT intelligence ten percent. Suddenly 33. Check Loss of Sensing. Check all relays plus
increase pt signal to 4 percent over limiter any lights and annunciators associated with
pickup. Measure time until OVL times out. L.O.S. Disconnect one phase to simulate failed
Check that this timing is consistent per fuse.
settings and timing is coordinated with
generator voltage capability. 34. Check any other limiter and protective
features.
23. "MEL_P" block. Check Minimum
Excitation Limiter (MEL). Check any relays, 35. Make all limiter and protective equipment
lights, or annunciators associated with the settings per customer specified values (settings
MEL. are customer’s responsibility).
24. Set PT intelligence at rated value, set balance
meter to zero and CT intelligence to 0.5 amp
at zero power factor lead. Simulate 52 breaker Test Monitoring Functions (J)
closed. MEL output should be negative and
equal to “MEL_OFF”. Raise CT signal until Test the operation of all protective circuits, using
MEL picks up and record value. Increase CT simulated intelligence where required. Refer to
signal until "MEL_F2" picks up and record. contract schematic diagrams.
25. Reduce CT signal to 0.5 amp. Increase CT 1. Check generator ground detectors and all
signal to five percent above "MEL_F2" pick associated relays, lights and annunciators.
up and measure time until MEL_P timers Typical setup is as follows (using ccTool to access
times out and record. FLDGND block in ECM):
26. Shift phase angle 60 degrees to simulate 26
degrees (.9 pf.) under excited. Raise CT signal a. Disconnect pin 5 from the field.
until MEL picks up again and record value. b. Apply 120 volts AC, 60 Hz to pins 6 and
Typically this will be more than CT signal at 7. Leave resistor off of the pin 10 and 12.
full load unity p.f. Check that this is Check that there is no voltage across pins
coordinated with any loss of field protection. 1 and 2. Verify that output "AD00_IN_A"
Revised 11-09-06 14
is at least +0.01 (this offset voltage has to

be always positive). Adjust parameter Reconnection to Original 60 Hertz Source (K)
AD00_OFFSET_3 to make it so.
The entire ECS2100 Regulator has now been
c. Force appropriate relay ON to apply 120 checked and the system can be reconnected to the
volts AC across pins 8 and 9. Plug 1M machine in preparation for start-up. All test
resistor (RT) into pins 10 and 12. Measure voltage and simulated intelligence sources should
voltage output across RT (120 + 20 volts be removed and all parts of the regulator and static
DC). Verify that parameter exciter should be placed in the “normal IN-
FLDGND_SOURCEVOLTS equals that SERVICE condition”. All test jumpers should be
voltage. Disconnect RT from pins 10 and removed. All protective relay functions should be
11. re-enabled, and all lifted leads re-landed.
d. Connect a 1K resistor between “-125 volt”
output (pin 5) and ground. Measure the
voltage across the resistor. Measure the
voltage across pin 1 and 2. Verify that
output AD00_IN_A is the same as voltage ALL OF THE OPEN LOOP TESTING WITH
across pins 1 and 2 (+ 0.001). THE MACHINE NOT RUNNING HAS BEEN
e. If not set AD00_RTDGAIN_3 to make it COMPLETED. BE SURE THAT ALL
so. Check that output EXTERNAL CONNECTIONS AND
FLDGND_GROUNDCURRENT equals SETTINGS ARE CORRECT. ALL OF THE
the voltage across the 1 K resistor. If not, CIRCUITS LISTED BELOW SHOULD BE
set FLDGND_ITSCALE to make it so. RE-ENABLED.
f. With the 1K resistor still connected across 1. Enable the following circuits
pins 4 and 5, FLDGND_RMIN should a. Minimum excitation limiter
equal 1K + 0.3K. If not, then adjust b. Volts/hertz limiter
FLDGND_SOURCEOHMS to make it so.
Check that field ground alarm indications c. Maximum excitation limiter
and contacts signify that a field ground has d. Instantaneous limiter
occurred.
e. Unit trip
g. Check that FLDGND_VFSCALE equals
the field voltage that was used to set the 2. Before start-up of the generator
transducers. a. Check that limiter and protective
h. Remove the 1K resistor from across pins 4 equipment settings have been made.
and 5. Plug 1M resistor (RT) into pins 10 (Settings are customer’s responsibility.)
and 12. Check that FLDGND_RMIN b. Check that the generator unit output circuit
equals to 1000K + 300K. Check that field breaker 52, device 41A, and if used, field
ground alarm indications and contacts flashing contactor 31 are open.
have cleared.
c. Check that the manual adjuster
2. If used, check output field overtemperature (MANADJ_PP1) is set to give 70 percent
alarms and all associated relays, lights and no-load field current.
annunciators.
d. “Auto” mode is selected and var or power
a. With field voltage and current intelligence factor control disabled.
set at 1.0 per unit, check that
FCIN_RBASE equals base load resistance, e. Check that followers are disabled.
and FCIN_TBASE equals the field f. Check that all droop or rise compensators
temperature at which the base load are disabled.
resistance was calculated. Check metering g. Close the three-pole potential switch for
outputs. the regulator PTs , and the CT input
b. Reduce simulated field current to 10 switch. If used, close the three-pole
percent. Check alarms. potential switch for the metering PTs.
Revised 11-09-06 15
h. Check that connections to generator field

have been reconnected.
i. Check that connections to excitation IMMEDIATELY CHECK THAT THE
transformer or pmg have been GENERATOR FIELD CURRENT
reconnected. CORRESPONDS TO THE VALUE SET BY
j. Check that space heaters have been PP#1 IN “MANADJ” BLOCK IF THE UNIT
reconnected. REMAINS IN MANUAL. IF UNIT IS IN
AUTO CHECK THAT THE GENERATOR
k. Check that connections to field ground TERMINAL VOLTAGE CORRESPONDS TO
detector have been reconnected. THE VALUE SET BY PP#1 IN “AUTOADJ”
l. Check that connections to unit trip circuit BLOCK. TRIP DEVICE 41A IF THE
have been reconnected. TERMINAL VOLTAGE IS EXCESSIVE OR
IF THE FIELD CURRENT MEASURED IS
m. Check that connections between the shunt RADICALLY HIGHER THAN THE
and transducer have been remade. MACHINE FIELD DATA SPECIFICATION.
3. With ccTool, set up an Event Recorder block 2. If unit is in manual, use manual adjuster to
in the ECM to measure terminal voltage, firing make terminal voltage equal to 1.0 per unit. (If
command, field current, 41A close feedback, field current instantaneous limiter prevents
41A close command, and 41A trip command raising voltage, increase off-line trip setting
(both instantaneous and time delayed) when first and then the off-line limiter setting.
the breaker is closed the first time. Set event to Enable adjusters and verify that balance meter
be triggered by the 41A close command. If goes to near zero. Transfer unit to auto.
field flash is used, the close 31 command Terminal voltage bump should be small.
should also be recorded. Other inputs may be
recorded as desired.
4. Check that the correct phase sequence exists at

both the input terminals of device 41A and the DO NOT EXCEED THE MACHINE
regulator input panel terminals. On systems VOLTAGE RATING DURING ANY OF
where excitation power is derived from the THESE TESTS. EXCEEDING VOLTAGE
machine terminals, this can be done using an RATINGS MAY RESULT IN DAMAGE TO
oscilloscope looking at residual voltage of the EQUIPMENT AND INJURY TO
generator. PERSONNEL.
5. If a pmg is used, before closing the 41A

device check the magnitude of the pmg 3. If unit is in auto, use auto adjuster to make
voltage is per the contract schematic. terminal voltage equal to 1.0 per unit. (If field
current instantaneous limiter prevents raising
Check Excitation Control Off-Line Circuit (M) voltage, increase off-line trip setting first and
then the off-line limiter setting. Enable
1 With the generator at rated speed, close device adjuster followers and verify that balance
41A. Close the field flashing contactor 31, meter goes to near zero. Transfer unit to
applying field flashing energy from either the manual, and then back to auto. Terminal
station battery or a rectified AC source. voltage bump should be small.
Review the event to verify correct operation of 4. If the output field temperature monitor is
the equipment during the start. being used and before the field has a chance to
Note: If MANUAL adjuster is too low the unit warm up, check that FCIN_FIELDTEMP
will not transfer into AUTO. Raise MANUAL equals the temperature of the cold rotor field.
adjuster to enable transfer to AUTO. If not change FCIN_TBASE to make it so.
Revised 11-09-06 16
5. Holding the machine at rated speed and rated that the Tracker value is close to zero (+0.1).
no-load voltage on its terminals, check the Transfer to Redundant channel and repeat
three-phase intelligence voltage at the steps 8 through 11. At customer request, the
regulator input panel terminals 7-8-9 to be unit can be switched to Redundant channel in
approximately 120 volts line-to-line and to control with 41A device open, and the
have phase sequence 7-8-9. Actual value generator field flashed again and the steps in
should agree with regulator PT ratio on site this section repeated.
specific schematics. If they disagree determine
reason before proceeding. Check Excitation Control Off-Line (N)
6. Check that the output of the terminal voltage Note: The off-line instantaneous limiter has to be
transducers reads 1.00, (in both channels for a set high enough not to impact the bump test,
dual channel system). If not adjust scale i.e., to the on-line value for a rotating
factors in the “SIGIN” block in each channel exciter. The reason is that positive voltage
to make it so. bumps with a rotating exciter can cause the
limiter to effectively reduce the generator
7. Check that “SLC2_V4” reads between 1.0 and ceiling voltage and make the response look
1.15. (A precise value should be based on the like that of an over or critically dampened
generator saturation curve and be equal the regulator. See figure #5.
actual field current at no load divide by the
airgap field current at rated voltage read from The Preliminary Setup should be as follows:
the saturation curve.) If not, adjust 1. Stability and damping adjustments of the
SLC2_KFC to make it so. For a dual channel regulating system are usually made with the
system, change SLC2_KFC in the Redundant synchronous machine off line (except for
channel to the adjusted value. synchronous condensers that must be
8. Verify the operability of the Manual regulator connected to the system to operate). If settings
(unit is in AUTO) in both the RAISE and the have been determined by stability studies,
LOWER direction by moving the Manual those values should be set before doing the
voltage adjuster to cause the regulator balance bump test.
meter to indicate on first one side of meter 2. With ccTool, set up an Event Recorder block
zero and then the other side of zero. This in the ECM to measure the bump input signal,
action of the voltage adjuster should not affect terminal voltage, firing command, and field
the machine terminal voltage. current during the off line bump tests. Set
9. Move the voltage adjuster in the LOWER event to trigger on input of the bump signal.
direction. This action should reduce the Other inputs may be recorded as desired.
machine terminal voltage. The balance meter 3. With the generator operating at rated speed
should return to near zero. Move the voltage and off line, adjust the terminal voltage to the
adjuster in the RAISE direction, causing the rated value by means of the auto adjuster.
machine terminal voltage to return to normal.
Adjust “ACADJ_SLEW” as needed for 4. Connect a low voltage variable DC source to
smooth voltage control by the operator. an analog input point of an AIO card. (A
source can be made by connecting a 5W or
10. Transfer unit to manual and move the manual more potentiometer, 1k to 10K, across the
adjuster in the LOWER direction. This action +24 to -24 volt power supply to the BCM in a
should reduce the machine terminal voltage. manner suitable to feed a plus or minus test
The balance meter should return to near zero. voltage signal into the analog input.) The
Move the voltage adjuster in the RAISE analog input should be scaled so that 1.00 volt
direction, causing the machine terminal in yields 0.0100 change in the appropriate
voltage to return to normal. Adjust ALOGDIG output. Thus a DC voltage of
“MANADJ_SLEW” as needed for smooth approximately one volt will simulate a
voltage control by the operator. machine voltage change of 1%. Make a rapid
11. Return unit to auto. change in the machine voltage setting by
changing this test voltage signal (starting with
12. For a dual channel system, verify the Tracker 1% change in terminal voltage in the direction
and the Transfer Possible is enabled. Check to reduce voltage). Gradually increase bumps
Revised 11-09-06 17
to 5% voltage change first in the LOWER the power grid. Load unit to about 10 percent
direction and then in the RAISE direction for rated MW load (higher if required by turbine
various damping adjustments. By observing conditions).
the response action on the recorder charts, 2. With the generator connected to the power
optimum damping adjustments may be made. system (line breaker 52 closed) and the
See Figure 5 for suggested optimum response machine at unity power factor, check that the
conditions. Care should be taken that the unit phase angle between the current and voltage
is not under damped when off line so as to intelligence using the event recorder. At unity
avoid oscillations when the unit is on line. power factor the Phase B line current should
lag the phase AB line-to-line voltage by
approximately 150 degrees. If needed, adjust
“POWERTRAN#00_PHASE” (in both
channels for a dual channel system) to make
THE INSTALLATION ENGINEER SHOULD “PTRAN_MVAR” read 0.00 at unity power
BE VERY CAREFUL IN RUNNING THESE factor. (This compensates for phase shifts
TESTS TO AVOID SUBJECTING THE between the regulator PTs and CTs from the
MACHINE TO TERMINAL VOLTAGES ideal 150 degrees phase shift.)
GREATER THAN ITS RATING.
3. Re-enable all reactive compensation functions.
Check with the customer to be sure of the
required setting. For satisfactory parallel
operation of the regulator-controlled machine
with the system, there should be a 4% to 6%
reactance between the machine terminals and
the system. This reactance can be in the unit
transformer, or the regulator can be biased by
the droop compensator, set for 4% to 6%
reactive droop to accomplish the same effect.
4. Using auto control, raise excitation slightly;
i.e.; set the generator to supply vars to the
system. Verify that for droop compensation
the adjuster reference moves slightly more
than the terminal voltage increase. Verify that
for rise compensation the adjuster reference
moves slightly less than the terminal voltage
increase.
5. After checking the regulator balance meter is
near zero, transfer from the auto to manual
regulator control. Carefully operate the manual
regulator adjuster slightly in both the LOWER
direction and the RAISE direction, and
observe that the machine reactive loading is
Fig. 5 Generator Output Responses decreased in response to lowering the adjuster,
and is increased in response to raising the
Check polarity and phase angle of Machine CT manual regulator. Transfer unit back to
and PT signals to be correct (O) automatic.
1. The unit is now ready to be synchronized with 6. For a dual channel system, verify Tracker is
the power grid. Before closing the generator reading close to zero and transfer from Main
(52) breaker, set up an Event Recorder block channel control to Redundant channel control.
in the ECM, using ccTool, to measure The oscillations in voltage should be very
regulator PT inputs, CT inputs and terminal small. Repeat previous step. Transfer unit
voltage. If metering PTs are used they should back to Main channel in control.
also be recorded. Synchronize the unit with
Revised 11-09-06 18
7. Unit MW load can be increased as needed to

meet power system needs. Check, setup and tune power system stabilizer
(R)
8. If desired (or required) by the customer, an on-
line bump test should be performed at this 1. If required by the customer, the power system
time. In performing an on-line bump, great stabilizer should be setup and tested by a
care should be taken to avoid excessive var qualified expert.
swings. Use the adjuster to determine how
much voltage change corresponds to a 10%
var change. Typically the magnitude of the Check Final Operation of Machine in
bump should cause no more than a 10% var Conjunction with System (S)
change. Check with customer to determine a
desired or expectable value. The event A final check should be made at this time with the
recording for an on-line bump should include machine connected to the system. Make final
terminal voltage, firing command, field check of ground detector.
current, unit MVAR and unit MW.
9. If possible the unit load should be raised to
rated MW at rated power factor. The scaling
for the field current transducers should be
checked at full load. At Full load the field
current transducer should read 1.00. Caution:
if field current transducer scale is changed, the
off line settings must also be changed.
IF ANY OF THESE RAISE OR LOWER

OPERATIONS APPARENTLY CAUSE
MAJOR DISTURBANCES IN THE
CONNECTED SYSTEM, QUICKLY
TRANSFER CONTROL FROM THE AUTO
TO MANUAL REGULATOR.
If VAR or PF control is used, check system
with controller on (P)
1. The unit is now ready to be put in var/pf
control mode. Check that var controller error
is near to zero. Put unit in var mode. Raise and
lower vars using the var controls. Adjust
“VRC_SLEW” or “PFC_SLEW” (in either the
VARCONTR or PFCONTR block) as needed
for smooth control by the operator.
Check for stable operation of limiters (Q)

1. If desired (or required) by the customer, each
limiter should be tested to take control of the
excitation system on-line. An offset may be
put into the limiter set point to recalibrate the
pickup to occur in a safe region of operation.
Revised 11-09-06 19
MAINTENANCE SPECIFICATIONS AND PERFORMANCE
This equipment contains solid state components Burden

that require little maintenance. The removal of The nominal burden of the ground detector source
accumulated dust occasionally will be sufficient. is about 20 VA at 120 V, 60Hz.
Maintenance for non-solid-state components is
required only as specifically defined. Environment
Ambient temperature range of -20°C to 50°C
SPARE PARTS Relative humidity of 0 to 95% non-condensing
A reasonable stock of spare parts will minimize

downtime, in the event of a malfunction in this
equipment. When ordering spare parts, care
should be taken to specify the style numbers (or
other identification) which are printed on the
nameplate, located on this apparatus.
The following is a list of recommended spare

parts, and is intended only as a guide for
customers. Consult the Asheville ECE Marketing
Department for any questions.
1 - ECM Circuit Card

1 - SIM Circuit Card
1 - FCIM Circuit Card
1 - IT Circuit Card
1 - AIO Circuit Card
1 - DIO Circuit Card
1 - BCM Circuit Card (Optional if no redundant
bridges)
Various assorted fuses
Revised 11-09-06 20
Note: To "find" software blocks, inputs, or outputs in ccTool, use the hotkey F3
SUMMARY OF PT AND CT INPUT TRANSDUCER SETUP

(SIM Card)
Page INPUT INPUT BLOCK SET TO MAKE
No. CONNECTION VALUE (in ECM) INPUT PARAMETER OUTPUT READ
6 REGULATOR PT ZERO (Short PT switches) SIGIN SIGIN_CH01_OFFSET SIGIN_CHAN01 = 0.000+.0009

Steps SWITCHES SIGIN_CH02_OFFSET SIGIN_CHAN02 = 0.000+.0009
1,2 SIGIN_CH03_OFFSET SIGIN_CHAN03 = 0.000+.0009
6 3-PHASE AC Voltage equal to SIGIN_CH01_SCALE (in LINETRN#01 Block)

PT Secondary when generator at SIGIN_CH02_SCALE LINETRN01_MAGNITUDE
Steps RATED VOLTS SIGIN_CH03_SCALE = 1.000 +.0009
3,4 (Set ALL 3 the same)
6 METERING PT ZERO (Short PT switches) SIGIN SIGIN_CH07_OFFSET SIGIN_CHAN07 = 0.000+.0009

SWITCHES SIGIN_CH08_OFFSET SIGIN_CHAN08 = 0.000+.0009
Steps SIGIN_CH09_OFFSET SIGIN_CHAN09 = 0.000+.0009
1,2
6 3-PHASE AC Voltage equal to SIGIN_CH07_SCALE (in LINETRN#02 Block)
PT Secondary when generator at SIGIN_CH08_SCALE LINETRN02_MAGNITUDE
Steps RATED VOLTS SIGIN_CH09_SCALE = 1.000 +.0009
6 CT SWITCHES ZERO (Short CT switches) SIGIN SIGIN_CH04_OFFSET SIGIN_CHAN04 = 0.000+.0009

3 PHASE SIGIN_CH05_OFFSET SIGIN_CHAN05 = 0.000+.0009
Steps SIGIN_CH06_ OFFSET SIGIN_CHAN06 = 0.000+.0009
1,2
6 3-PHASE AC Current equal to SIGIN_CH04_SCALE (in LINETRN#00 Block)
CT Secondary when generator at SIGIN_CH05_SCALE LINETRN00_MAGNITUDE
Steps RATED VOLTS, MVA, and PF SIGIN_CH06_SCALE = 1.000 +.0009
or
6 CT SWITCH ZERO (Short CT switch) SIGIN SIGIN_CH05_OFFSET SIGIN_CHAN05=0.000+.0009
1 PHASE
Steps
1,2
6 1-PHASE AC Current equal to SIGIN_CH05_SCALE (in LINETRN#00 Block)
CT Secondary when generator at LINETRN00_MAGNITUDE
Steps RATED VOLTS, MVA, and PF = 1.000 +.0009
7,8
6 BOTH PT & CT Set for UNITY PF when POWERTN#00 POWERTRN00_SHIFT POWERTN00_MVAR

INPUTS generator at RATED VOLTS and (Phase B only: ~150 degrees) = 0.00+.009 and
Steps MVA POWERTRN00_MVA
3,4 = 1.00+.009
TABLE 1
Revised 11-09-06 21
SUMMARY OF PPT OR PMG TRANSDUCER SETUP

(IT Card - ALXD)
No. CONNECTION VALUE INPUT PARAMETER OUTPUT READ
6 J19 to J20 ZERO (Short) F_TO_VAB FVAB_OFFSET FVAB_OUTPUT = 0+40

(in FCIM)
Step DC Voltage equal to PPT (in CONST1 Block) FVAB_OUTPUT = 1100+80
10 Secondary RMS CONST1_IN1
6 J21 to J22 ZERO (Short) F_TO_VBC FVBC _ OFFSET FVBC_OUTPUT = 0+40

(in FCIM)
Step DC Voltage equal to PPT (in CONST1 Block) FVBC_OUTPUT = 1100+80
11 Secondary RMS CONST1_IN1
J19 to J20 ZERO (Short) FCIM_INP FCIN_PPT_OFFSETA FCIN_PPT_PTA = 0.00+.009

(Only with 60 Hz (in ECM)
version of FCIM DC Voltage equal to PPT FCIN_PPT_SCALEA FCIN_PPT_PTA = 1.00+.009
software) Secondary RMS
J21 to J22 ZERO (Short) FCIM_INP FCIN_PPT_OFFSETB FCIN_PPT_PTB = 0.00+.009
(Only with 60 Hz (in ECM)
version of FCIM DC Voltage equal to PPT FCIN_PPT_SCALEB FCIN_PPT_PTB = 1.00+.009
software) Secondary RMS
TABLE 2
SUMMARY OF FIELD CURRENT AND VOLTAGE TRANSDUCER SETUP

(IT Card - DCXD)
No. CONNECTION VALUE (in ECM) INPUT PARAMETER OUTPUT READ
7 J21 to J22 ZERO (Short) FCIM_INP FCIN_VG_OFFSET FCJN_GEN_FLD_VLT

= 0.000+.0009
Steps
13-16 DC Volts = 100% of RATED FCJN_VG_SCALE FCIN_GEN_FLD_VLT
FULL LOAD at 75 DEG. C = 1.000+.0009
7 J19 to J20 DC mV = 10% of RATED FCIM_INP FCIN_IG_OFFSET FCIN_GEN_FLD_CUR

FULL LOAD = 0.100+.0009
Steps
17-20 DC mV = 100% of RATED FCIN_IG_SCALE FCIN_GEN_FLD_CUR
FULL LOAD = 1.000+.0009
TABLE 3
Revised 11-09-06 22
IL ECSM009B
ccTool Configuration Software Help

Instruction Leaflet
This document is a compilation of the material available through the Help menu of the ccTool configuration
software. When working in the ccTool application, this same information can be accessed by clicking Help,
Tool Help.
What is ccTool? Page 1 of 1
What is ccTool?
The Controller Configuration Tool (ccTool) is a sophisticated tool for configuring, monitoring, maintaining,
and debugging a programmable controller. Typically, ccTool is used at installation to configure the controller
and, thereafter, is used to monitor operations and, as needed, fine tune input values.
ccTool provides a full range of options for viewing, editing, and saving configuration information, and
includes security levels to ensure that only authorized users can change the configuration information.
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Model for Programming a Controller Page 1 of 1
The ccTool Model for Programming a Controller
The ccTool model for programming a controller provides an easy-to-use application program on a PC to
define configuration information for the blocks of code within the controller. The ccTool application is first
used to define all configuration information in a file on the PC. Once the controller is in a Resolved state,
ccTool is used to download the information to the Random Access Memory (RAM) of the controller. You then
use ccTool to fine tune configuration values as needed within RAM. Because information in RAM is lost in
the event of a power cycle, you save the configuration information from RAM to permanent Flash memory
after you have tested and are satisfied with the configuration. At power-up, the configuration comes from
Flash and overwrites the RAM values.
This overall model of operation is illustrated below.
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Blocks and Block Connections Page 1 of 1
Blocks and Block Connections
The controller contains blocks of code that control specific functions. A block can have any number of inputs
and outputs. An input can be a constant or a connection to another block.
For example, the following illustration shows the ACVLTADJ and AUTO_REG blocks of the ECM as they
might be displayed in the ccTool Diagram window. Some of the inputs, such as the K1 through KC inputs of
the AUTO_REG block, are constants. The REF output of the ACVLTADJ block provides the input for the
ACADJ_REF input of the AUTO_REG block, and the connection line is shown. (Connection lines can be
made invisible in the Diagram window, in which case the output name is shown outside the input line as
illustrated below for AUTO_REG block inputs such as PSS2_OUT and TEST. See Diagram Window
Contents for more information on the contents of the Diagram window).
The controller defines the blocks and their inputs. Using ccTool, you define:
l The assignment of each input as either a constant or a connection to another block.

l The timing of the signals between blocks, called the execution strategy.
There are two types of blocks:
l Interrupt blocks have an execution strategy. Some interrupt blocks have a fixed execution strategy,
meaning that the controller assigns the strategy and you cannot change it.
l Mainline blocks either execute or do not execute. They do not have an execution strategy. Some
mainline blocks are fixed, meaning you cannot turn off the execution. Some controllers do not have
mainline blocks.
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Execution Strategy Page 1 of 1
Execution Strategy
The execution strategy defines when a block executes in relation to all other blocks, the time slots in which
the execution takes place, and the the executions per cycle.
See the Execution Strategy Window for more information.
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File, RAM, and Flash Configurations Page 1 of 1
File, RAM, and Flash Configurations
Configuration information resides in three places:
l Configuration File - You use the configuration file to define new configurations before putting them in
operation. When you are ready to put the configuration into operation, you download from the
configuration file to the RAM of the controller. If the controller is not in the Resolved state when you try
to download, ccTool asks if you want to set the state to Resolved. Your security level is also checked
at the time of download. Any level user can edit the configuration file, but only users with the
appropriate security level can download the information to RAM.
l RAM - This is the configuration information that will be executed. After you download from the
configuration file, the controller state will be Resolved. You set the state to Execute Blocks to begin
executing the new RAM values. You then monitor and fine tune the configuration as needed.
l Flash memory - Flash memory is the permanent memory of the controller. Unlike RAM, Flash memory
is not lost if the power goes off. Therefore, you save from RAM to Flash in order to retain information
in the event of a power outage or re-cycle. At power-up, the Flash configuration replaces the RAM
configuration. You cannot directly edit any information in Flash memory.
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Controller States Page 1 of 1
Controller States
The following table describes the controller states that are tracked within ccTool.
State Description
Unknown This state indicates there is no response from the controller or the response
cannot be understood. It can result from losing the connection to the controller
or an error in the controller. You cannot set this state. Once in this state, the
problem with the controller or the connection must be fixed before operation
can continue.
Boot Use this state only when you need to download new firmware into the
controller. You can set this state, or ccTool goes into this state automatically if it
gets a response from the controller saying that it is in boot state.
Unresolved This state indicates an user error in the configuration information. To change
the state, you must correct the configuration error.
Resolved This state indicates that the configuration information is valid and ready to
execute but is not executing yet. You can set this state to have ccTool re-check
the resolution.
Initialized This state sets block outputs and internal states of the block sto known values.
Executing This state indicates that the blocks are executing in RAM. After ccTool shows
Blocks the state as Resolved, you can set this state.
Executing This state is set by the controller and cannot be set within ccTool. You can
Application change parameter values while in this state but you cannot change the state.
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Security Page 1 of 1
Security
ccTool security levels apply to the RAM configuration. You can edit any information in the File Configuration
regardless of your security level. Your security level is checked when you download from the File
Configuration to RAM, or when you directly edit RAM.
The security levels are:
l View Only allows you to view all information in RAM but not save any changes.
l Tune Configuration allows changing input assignments.
l Change Configuration allows adding and removing blocks, purchasing blocks, and changing the
type of input.
The View Only level does not require a password. All other security levels are password protected.
You are logged into ccTool as a View Only user. If you know the associated password, you can change your
security level after you connect to a controller. The Connect command allows you to change your level after
the connection is made, and you can later use the Set Security Level command as needed. Users at a
higher level can change the password for their security level or a lower level. If you forget your password,
call Cutler-Hammer and give them the Controller ID. They can then give you a new password.
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Running ccTool Page 1 of 1
Running ccTool
1. Click the Start menu, and then point to Programs, Cutler-Hammer, ccTool. Click on ccTool.
2. Type your initials, and then click OK.
You are logged in as a View Only user. If authorized, you can choose Set Security Level from the File menu
to change your security level.
The ccTool window appears. You can now use the Connect command to connect to a controller.
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The ccTool Windows Page 1 of 1
The ccTool Windows
When you start ccTool, the main ccTool window contains pull down menus and a gray working area in which
other windows are displayed after you connect to a controller. Depending upon how the window was setup
when you lasted used ccTool, it may also contain:
l A toolbar along the top of the window

l A window, called the connection bar, that lists the controllers you are connected to and the windows
displayed for each contoller
l A status bar in the bottom border of the window. The status bar displays reference information such
as the current contoller state and your security level. It also displays a brief description of the block,
input, or output as you work with objects in a window.
You can toggle the display of the toolbar, connection bar, and status bar using commands in the View menu.
After you connect to a controller, you can display one or more of the following windows in the working area of
the main window:
l The Diagram window displays and allows you to manipulate a graphical representation of a
configuration.
l The Application Configuration window displays the configuration information in a table.
l The Execution Strategy window displays the execution strategy in a table.
l The Mainline Execution window displays a table showing whether or not each mainline block will
execute.
You may also have custom monitor windows setup for you by Cutler-Hammer.
The window in which you are currently working is referred to as the active window. The active window has a
blue header.
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Menu and Command Button Layout Page 1 of 1
Menu and Command Button Layout
You have access to commands in ccTool through:
l Pull-down menus that include all commands related to the active window
l A toolbar that includes icons for the most frequently used commands
l Pop-up menus that appear over an object when you right-click on the object. These menus are called
shortcut menus. They include the most frequently used commands for that type of object.
When you start ccTool, the menu bar and tool bar appear as follows:
After you connect to a controller, additional menus appear and the tool bar icons related to working with a
controller become active.
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Toolbar Icons Page 1 of 1
Toolbar Icons
The icons in the ccTool toolbar are:
Connect: Connects ccTool to a controller.
Open: Opens a configuration file.
Save: Saves the configuration file in the active window.
Close: Closes the connection to the controller or, if you are working in offline mode, closes the
configuration file.
Preferences: Defines your personal settings for how certain features of ccTool operate.
Add Block: Adds a block.
Remove Block: Removes a block.
Set State: Sets the state of the controller.
Reload: Reloads the RAM Configuration from the controller.
Toggle Connection Bar: Displays or removes a window that lists your current connections.
Alarms: Displays the Alarms window. The icon flashes with a red border, as shown here, if there are
active unacknowledged alarms. The icon flashes with a yellow border if there are one or more active alarms
that have been acknowledged but not cleared. The icon does not flash and has no color if there are no active
alarms.
Configuration Differences: Displays a list of all differences between the configurations. A flashing
icon indicates at least one difference has been detected. However, some differences will not be detected
until the command has been invoked.
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Getting Help Page 1 of 1
Getting Help
ccTool provides a variety of types of help:
l Tool Help - Choose Tool Help from the Help menu to display the Help you are now using. This Help
explains how ccTool works.
l Block Help - Choose Block Help from the Help menu to display Help on the blocks within each
controller. This Help describes and provides a diagram of each block. From a block diagram, it also
allows you to find the block in ccTool.
l Context Sensitive Help - Most dialogs contain a Help button. Click the Help button to go directly to
the Help topic for that command.
l Status Bar - The status bar at the bottom of the ccTool window displays a brief description of the
block, input, or output as you work with objects in windows.
l Tool Tips - Position the cursor over a toolbar icon to display the command name.
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Connecting to a Controller Page 1 of 1
Connecting to a Controller
The topics in this section are designed to teach you the basics of connnecting.
The topics are:
l Setting the Windows to Open

l Connecting Through a COM Port
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Set Connection Preferences Page 1 of 1
Setting the Windows to Open
You can set the windows that appear when you connect to a controller.
To do so:
1. Click the Preferences icon in the toolbar, or choose Preferences from the File menu.
2. Under Initial Windows, check the windows you want to display when you connect to a controller.
3. Click OK.
Your preferences are set.
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Connect Page 1 of 1
Connecting through a COM Port
The Connect command establishes the connection to a controller.
To connect to a controller directly through a COM port:
1. Click the Connect icon in the toolbar , or choose Connect from the File menu.
Note: If you are already connected to a controller, the Connect menu item changes to Connect Using.
Choose Connect Using, and then choose COM Port Connect.
2. Enter the Port, Baud Rate, and Address, and then click OK. If the address is not in the list, you can
type it.
A status dialog displays while the connection is established.
The command ends and the windows you checked in the Preferences dialog appear.
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Assigning Blocks in the Diagram Window Page 1 of 1
Assigning Blocks in the Diagram Window
The topics in this section are designed to teach you the basics of adding a block and defining input
assignments. Before performing these tasks, look at the Block Help for the block you plan to add. These
topics use the example of adding the DA1 block to the FCIM file configuration.
These topics also focus on using the Diagram window. Note that you also can add blocks and assign inputs
in the Application Configuration window. The Diagram window is used here because it provides a more
visual interface than the Application Configuration window.
The topics are:
l Setting Up the Diagram Window

l Adding a Block
l Displaying and Positioning a Block
l Drawing a Connection Line
l Entering Assignment Values
For general information on using the Diagram window, see Using the Diagram Window.
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Setting Up the Diagram Window Page 1 of 1
Setting Up the Diagram Window
At this point, you want to set up the Diagram window to display the File Configuration and allow editing. You
want to display the File Configuration because you always add and configure a block in the File
Configuration rather than RAM. This allows you to define the configuration before putting it into operation. In
order to allow editing in the Diagram window, you must turn on Dynamic Edit Mode.
To set up the Diagram window:
1. If the Diagram window is not displayed, choose it from the Window, New Window menu.
2. If the current configuration is not File Configuration, choose File Configuration from the drop-down
list in the toolbar.
3. Click the Toggle Dynamic Edit icon to enable Dynamic Edit Mode.
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Adding a block Page 1 of 3
Adding a Block
Now that you have the Diagram window setup, you want to add a block. You use the Add Block command to
add a block and, optionally, define the execution strategy and inputs. The steps below illustrate adding the
DA1 block of the FCIM controller, defining its execution strategy, and assigning all of its inputs.
To add a block:
1. Choose Add Block from the Configurations menu.
2. In the Add Block dialog, select the block to add, check the Configure the Added Blocks option, and
then click Next.
3. In the Configure Blocks dialog, leave both Execution Strategy and Input Assignments checked.
Click Next. (Note that Execution Strategy will be gray if the block is fixed. In that case, skip the next
step.)
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4. In the Execution Strategy dialog, define the execution strategy as follows:

¡ If the Max Executions are more than one, you can change the Executions per cycle by
selecting the number from the drop-down list.
¡ If the executions per cycle are less than 16, you can have the block execute in different time
slices by clicking a cell of the table.
¡ Click Next when you are done defining the strategy.
The Input Assignment dialog appears for the first block input. The default assignment type
(From Output or Constant) for this input is selected. In the example below, the first input for the
DA1 is DA1_IN1, and the default assignment type is From Output.
5. In the Input Assignment dialog:

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¡ To change the assignment type, click the Constant or From Output radio button.
¡ For a Constant value, type a value and click the radio button that identifies the type of value as
Decimal, Hexadecimal, etc.
¡ For a From Output value, select the block and output from the drop-down lists.
¡ Click Next when you are done.
For the DA1_IN1 input shown in the example above, you want to change the assignment type
to Constant and enter a value. (You will later draw a connection in the Diagram window to
change the type back to From Output).
If there are any potential problems with this assignment, a confirmation dialog asks you to
verify making the assignment. Click Yes to continue, or No to return to the Input Assignment
dialog.
6. The Input Assignment dialog repeats for each input. Assign each input a value as explained in the
previous step. For DA1, assign all remaining inputs constant values.
After you have assigned all inputs, the Configure Blocks dialog is again displayed.
7. In this Configure Blocks example, all block inputs have been assigned and so you can click Finish to
end the command. If all inputs had not been assigned, the unassigned block(s) would be listed in the
dialog and you could either make the assignments or end the command without making assignments.
The block is added. The new block is not displayed in the Diagram window automatically. You display it in
the Diagram window as described in the next topic.
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Displaying and Positioning a Block Page 1 of 1
Displaying and Positioning a Block
Now that you have added a block, you want to display it in the Diagram window. You use the Block List to
display the block. The Block List is a window that lists all blocks in the configuration and indicates whether
they are currently displayed (visible) or not displayed (invisible). You use the Block List to control which
blocks are displayed in the Diagram window.
1. In the toolbar of the Diagram window, click the Toggle Block List icon to display the Block List.
2. In the Diagram window, pan to the area where you want to display the block you added. You can use
the scroll bars to do this or the Pan or Zoom commands.
3. In the Block List, first click any visible blocks that you want to make invisible. Then, click the block you
added to make it visible.
The block is placed in the center of the Diagram window, and is blinking.
4. To move the block, position the cursor over the block, and then hold down the left button and drag the
block to the desired location. Release the mouse button when the block is at the desired location.
For example, you could place the DA1 block close to the F_TO_VAB block because the IN1 input of DA1 will
connect to the F_V_TAB output.
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Drawing a Connection Line Page 1 of 2
Drawing a Connection Line
Now that you have displayed the block you added in the Diagram window, you want to change some of its
input assignments. You can change input assignments (or assign unassigned inputs) in the Diagram window
by either drawing a connection line or entering the assignment values in a dialog box. In the steps below,
you will draw a connection line and make it orthogonal. In the next topic, you will enter assignment values.
To draw a connection line:
1. Position the cursor over the input line for which you want to draw a connection. The input can be
unassigned, a constant that you want to change to a connection, or a connection that you want to
change to a different output. The cursor must be positioned exactly over the input line. The cursor
changes to when it is correctly positioned.
2. Hold down the left button and drag to draw a line representing the connection. The cursor changes to
.
3. Release the button over the output to which you want to connect. The output line is highlighted.
verify making the assignment. Click Yes to make the assignment, or No to cancel it.
The connection line is drawn. For example, you could change the IN1 input of DA1 from a constant to a
connection by drawing a connection line between the IN1 input of DA1 and OUTPUT of F_V_VAB as follows:
To add points to a connection line and re-shape it:
1. If you want to add one point, position the cursor over the line at the place you want to add the point. If
you want to add multiple evenly spaced points, position the cursor anywhere over the line.
2. Click the right mouse button to display the shortcut menu.
3. Choose Add Point(s), and then choose the number of points from the submenu.
If you chose to add 1 point, it is added at the location you clicked. If you choose to enter multiple
points, they are evenly placed along the line (or along the line segment if you previously added points
and re-shaped the line to have multiple segments).
4. To re-shape the line, hold down the left mouse button over a point, and then drag.
5. You can repeat these steps as needed to continue to add points and re-shape the line.
For example, you could re-shape the connection line you drew above as follows:
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Drawing a Connection Line Page 2 of 2
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Entering Assignment Values Page 1 of 1
Entering Assignment Values
In addition to assigning input in the Diagram window by drawing connection lines, you can assign input by
entering the values in a dialog box. You can use this method to assign inputs that are constants or
connections.
To enter assignment values:
1. Position the cursor over the input to assign or edit, click the right mouse button, and then choose
Assignment from the shortcut menu.
2. Enter the values as follows:

¡ To change the assignment type, click the Constant or From Output radio button.
¡ For a Constant value, type a value and click the radio button that identifies the type of value as
Decimal, Hexadecimal, etc.
¡ For a From Output value, select the block and output from the drop-down lists.
3. Click OK.
verify making the assignment. Click Yes to continue, or No to return to the Assign Block Input
dialog.
The input is assigned the type and value you specified.
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To download to RAM Page 1 of 1
Downloading to RAM
After you define your new File Configuration, you download it to RAM. Downloading to RAM sends the whole
configuration to the controller and overwrites all values now in RAM. Be sure you want to do this before
proceeding. Some notes about downloading:
l If you added or removed a block in the File Configuration, or changed the type of an input, you must
have a security level of Change Configurations to download to RAM. If you only changed input values
in the File Configuration, you only need to have the Tune Configuration security level to download to
RAM.
l All blocks in the File Configuration must be completely configured before downloading. If one or more
blocks are not completely configured, the Download To RAM command allows you to configure them
as this point.
l The controller must be in the Resolved state. If it is not, the Download To RAM command asks if you
want to change the state to Resolve.
l The configuration you download is not automatically put into execution. After downloading, you
change the state from Resolved to Executing Blocks as part of verifying the RAM configuration.
To download to RAM:
1. Choose Download to RAM from the Configurations menu.
2. If one or more blocks in the File Configuration are not completely configured, a dialog asks if you want
to configure the blocks. Click Yes to have operation proceed as described for Add a Block. Click No to
cancel the download.
3. If the controller state is not Resolved, a dialog asks if you want to change the state to Resolved. Click
Yes to change the state to Resolved, or No to cancel the download.
4. A dialog warns you that the current values in RAM will be overwritten and asks if you want to
continue. Click Yes to proceed, or No to cancel the download.
The File Configuration values are downloaded to RAM.
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Verfiying the RAM Configuration Page 1 of 1
Verifying the RAM Configuration
After downloading to RAM, you put the new RAM values into execution, and then monitor and fine tune the
values as needed to verify that they are correct.
1. Click the Set State icon in the Diagram window toolbar, or choose Set State from the
Configurations menu.
2. Click the Executing Blocks radio button, and then click OK.
The RAM configuration is put into execution.
3. In the Diagram window toolbar, select RAM Configuration from the drop-down list.
4. Click the Show/Hide RAM Values icon in the Diagram window toolbar to display the actual RAM
values.
5. Monitor the RAM values to ensure that they are correct. If necessary, you can change an input value
but cannot change the input type.
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Saving to Flash and File Page 1 of 1
Saving to Flash and File
When you are done fine-tuning your RAM Configuration, you save it to Flash. To create a backup copy of the
fine-tuned configuration, you then upload RAM or Flash to the File Configuration.
l To save the RAM Configuration to Flash, choose Save RAM to Flash from the Configurations menu. A
dialog asks you to confirm that you want to overwrite everything in Flash.
l To upload to the File Configuration, choose Upload RAM to File or Upload Flash to File from the
Configurations menu. A dialog asks you to confirm that you want to overwrite everything in the File
Configuration. After you upload, use Save or Save As to save the file configuration to disk.
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Diagram Window - overview Page 1 of 1
Using the Diagram Window
The topics in this section describe the content and features of the Diagram window.
The topics are:
l Window Content
l Diagram Toolbar Commands
l Selecting and Moving Blocks
l Moving Connection Points and Line Segments
l Shortcut Menus
l Navigating in the Diagram
For examples of specific tasks you perform in the Diagram window, see Assigning Blocks in the Diagram
Window.
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Diagram Window - content Page 1 of 2
Window Content
The Diagram window displays and allows you to manipulate a graphical representation of a configuration. It
is particularly useful for viewing and fine tuning assignments. In addition to providing a full range of menu
commands for assigning blocks, you can manipulate the graphical representation to:
l Draw connections graphically

l Monitor runtime values when the RAM configuration is displayed
l Right-click on an input, output, connection, or block to display a menu of commands specific to that
type of object
l Display or hide connections and blocks to view only the information of interest
l View the Configuration File, RAM, or Flash configuration
l Navigate around the drawing by panning, following connections, or finding specific blocks, inputs, or
outputs
l Change the magnification and area displayed using zoom commands
For example, you could display only the following portion of a configuration in the window:
Block information is shown in the Diagram window (except when you are displaying the actual RAM values)
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Diagram Window - content Page 2 of 2
as follows:
l Inputs are shown on the left of the block and outputs on the right of the block. The input and output
names (or abbreviated names) are shown inside the block.
l Constant values are shown within brackets, such as for the K1 through KC inputs of the AUTO_REG
block.
l Connections can be made visible or invisible. When visible, the connection line is shown as illustrated
above for the connection between the REF output of the ACVLTADJ block and the ACADJ_REF input
of the AUTO_REG block. When invisible, the output name appears next to the input line, as illustrated
above for AUTO_REG inputs such as PSS2_OUT.
l When an output has multiple connections, the number of connections is shown on the output line.
l Pink lines in the diagram indicate that the line is not orthogonal. You can add points to make the line
orthogonal.
To edit any information in the Diagram window, you must use the toolbar to enable Dynamic Edit.
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Diagram Window - toolbar Page 1 of 2
Diagram Toolbar Commands
The Diagram window extends the toolbar along the top of the ccTool window to include the following
Diagram toolbar.
Each Diagram toolbar command is described below.
Toggle Dynamic Edit

Enables or disables Dynamic Edit. You must enable Dynamic Edit in order to edit the drawing and
configuration information.
Pan Mode and Rectangle Select Mode
The Diagram window has two viewing modes: Pan Mode and Rectangle Select Mode. The shape of the
cursor when it is not positioned over a block or connection line indicates the current mode: indicates Pan
Mode, indicates Rectangle Select Mode.
When Dynamic Edit is off, Pan Mode is always in effect. Dragging the cursor anywhere in the diagram (either
on an object or outside an object) pans the diagram.
When Dynamic Edit is on, you can use either Pan Mode or Rectangle Select Mode. In Pan Mode, dragging
the cursor when not on a block or connection line pans the diagram. In Rectangle Select Mode, dragging the
cursor when not on a block or connection line draws a rectangle and selects the objects in the rectangle.
Note that connection points are not selected unless the entire connection is within the box.
Zoom to Fit
Zooms out until the diagram fits into the current window. If the diagram is too large or the window is too
small, the diagram is zoomed to the smallest possible setting for the window size.
Zoom to Box
Zooms in to an area that you specify by drawing a rectangle.
Zoom to Base View

Zooms the diagram to a one-to-one ratio. After you click the icon, the cursor changes to the cursor shown in
this icon. Position the cursor at the location that you want to be the center of the new zoomed area, and then
click.
Zoom In and Zoom Out

Zooms in or out incrementally.
Toggle Block List

Turns on or off display of the Block List. The Block List is a window that lists all blocks in the configuration
and indicates whether they are currently displayed (visible) or not displayed (invisible). When Dynamic Edit is
enabled, you can use the Block List to make blocks visible or invisible. Particularly if you have a lot of blocks
and block connections, it is useful to make some blocks invisible as you work with other blocks. See
Displaying and Positioning a Block for an example of using the Block List.
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Diagram Window - toolbar Page 2 of 2
Toggle RAM Values

In the RAM Configuration when the controller is executing, you can use this command to view or hide RAM
values. See Verifying the RAM Configuration for an example of using this command.
Description Display Setting

Sets the description display. The descriptions provide additional information about a block, input or output.
Shows the current configuration. In offline mode, only the File Configuration is available. When connected to
a controller, you can choose either File, RAM or Flash configurations.
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Diagram Window - Moving Blocks Page 1 of 1
Selecting and Moving Blocks
When Dynamic Edit is on, you can select and move blocks.
In either Pan Mode or Rectangle Select Mode, you can select and move blocks as follows:
l To move a single block, drag the block.
l To move multiple blocks, hold down the Ctrl Key and select each block, and then downclick within the
extents of the selected blocks and drag to move them.
In Rectangle Select Mode, you can also select and move blocks as follows:
1. Position the cursor outside of the blocks and drag to draw a selection box around the blocks.
2. Downclick within the extents of the selection box and drag to move the selected blocks.
Any connection lines to the blocks are automatically adjusted as you move the blocks. You do not need to
select the connection lines.
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Diagram Window - Moving Connection Page 1 of 1
Moving Connection Points and Line Segments
You can draw connection lines and add points to the lines as described in Drawing a Connection.
After you add points to a line, you can dynamically re-shape the line by dragging points or line segments.
You can only drag line segments that are vertical or horizontal, and are not the starting or ending line
segment. The shape of the cursor indicates the type of movement allowed:
Cursor Meaning
You are over a connection point or a segment of the connection
line that cannot be moved.
You are over a connection point that can be moved
You are over a horizontal segment of the connection that cannot
be moved
You are over a vertical segment of the connection that cannot be
moved.
You are over a horizontal segment that can be moved.
Movement will be restricted to the perpendicular direction of the
segment.
You are over a vertical segment that can be moved. Movement
will be restricted to the perpendicular direction of the segment.
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Diagram Window - Shortcut Page 1 of 2
Shortcut Menus
Different shortcut menus are displayed depending on where you right-click in the Diagram window. The
shortcut menus are illustrated below. For information on the commands in these menus, see the Command
Reference.
l Right-click in a blank area of the diagram to display the following menu.
l Right-click inside a block to display the following menu.
l Right-click on an input line to display the following menu. (You must click on the line, not the input
value or connection line).
l Right-click on an output line to display the following menu. (You must click on the line, not the input
value or connection line).
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Diagram Window - Shortcut Page 2 of 2
l When Dynamic Edit is enabled, right-click on a connection line to display the following menu. (When
Dynamic Edit is not enabled, the first menu shown above is displayed when you right-click on a
connection line).
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Diagram Window - Navigate Page 1 of 1
Navigating in the Diagram
You can dynamically navigate through the diagram using the scroll bars, or by dragging the cursor when
in Pan Mode.
You can pan to specific information in the diagram using the following commands:
l Use the Find command in the View menu or shortcut menu to scroll to a specific block, input, or
output.
l For inputs or outputs that are connections, use Pan to Connection in the shortcut menu to pan to the
connecting input or output. Pan to Connection is only available if the connection line is displayed. Use
Display Connections in the shortcut menu to display connection lines.
You can also use the Find in Window command in the block, input, or output shortcut menu to locate a block,
input, or output in another window.
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Using the Application Configuration Window Page 1 of 1
Using the Application Configuration Window
The topics in this section describe the content and features of the Application Configuration window.
The topics are:
l Window Content
l Mouse Interaction
l Setting Up the Table
l Navigating in the Table
l Edit Mode
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Application Window Content Page 1 of 1
Window Content
The Application Configuration window displays the configuration information in a table. It is particularly useful
when you want to compare File, RAM, and Flash values. You can manipulate the table to:
l View the File, RAM, and/or Flash configurations

l Set File, RAM, or Flash as a reference column in order to highlight differences in the values between
the three configurations
l Edit File or RAM assignments in the table
l View or hide columns, including columns that track who last changed the data
l Collapse the table to show summary information for a block or expand it to show all inputs and
outputs
l Search through the table to find differences in the values for the File, RAM, and Flash configurations
The following Application Configuration window illustration shows all block inputs and outputs for the DA1
and F_TO_VAB blocks, and only the block name for other blocks. It also includes only some of the available
columns of information.
In the table:
l In the Type column, inputs are shown in the standard font and outputs are shown in Italics.
l A white background in a cell indicates that you can edit that value. You cannot edit values in gray
cells.
l Red values indicate a difference from the corresponding value in the column you established as the
reference column. In this example, the File Input is the reference column.
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Application Window Mouse Interaction Page 1 of 2
Mouse Interaction
Selection (Left-click)
Selection in the Application Configuration window is used to identify the RAM values for the Refresh
Selected RAM Values command and the Update Selected RAM Values preference.
l To select a single RAM value, left-click or use the arrow keys to move the cursor to the row of a RAM
value.
The RAM value is displayed in green to indicate that it is selected.
l To select or de-select multiple RAM values, hold down the Ctrl key while you left-click.
Note: Unless you hold down the Ctrl key, the previously selected RAM value is de-selected
and will not be updated when you move the cursor to another row in the table.
Double-click left button
l Double-click a block name or block type in the first or second column of the table to expand or
collapse the block input information.
l Double-click an input value in the RAM Input or File Input column to display the Assign Block Input
dialog.
l Double-click the RAM Input column header to display a dialog that allows you to change the name
assigned to the RAM file. By default, the RAM file is assigned the name of the configuration file when
you download the File Configuration to RAM.
Right-Click
Different shortcut menus are displayed depending on where you right-click in the Application Configuration
table. The shortcut menus are illustrated below. For information on the commands in these menus, see the
Command Reference.
Note: When you first display the Application Configuration Window, or any ccTool window that contains a
table of information, you must left-click in a cell of the table before you can right-click to display the shortcut
menu.
l Right-click in the row of a block name to display the following menu.
l Right-click in the row of an input to display the following menu.
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Application Window Mouse Interaction Page 2 of 2
l Right-click in the row of an output to display the following menu.
l Right-click in a column header to display the following list of column names. Check an item in this list
to display the column, or uncheck an item to hide the column.
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Application - Setting up the Table Page 1 of 1
Setting Up the Table
This section summarizes the View menu commands you can use to set up the display of the Application
Configuration table. For more information on one of the commands, click the corresponding link.
l Use Set Properties to turn on or off the display of columns in the table. You also can access the
command by double-clicking a column header.
l Use Set Reference Column when you want to highlight any differences in values between the File,
RAM, and Flash configurations. This command sets the reference column to be either the File Input,
RAM Input, or Flash Input column. After the reference column is set, values in the other columns that
differ from the reference value are displayed in red.
l Use Expand All to display the block inputs for all blocks, or Collapse All to display only the block
names. (To expand or collapse an individual block, double-click the block name or block type in the
first or second column of the table.)
l Use Display Engineering Units to display input values in the unit of measure defined for the value.
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Application - Navigating the Table Page 1 of 1
Navigating in the Table
You can scroll through the Application Configuration table using the scroll bars, or using the keyboard
scrolling keys such as the arrow keys and paging keys.
You can scroll to specific information in the table using the following commands.
l Use the Find in the View menu command to scroll to a specific block, input, or output.
l Use the Find Config Differences and Find Next Difference commands to scroll through the table,
looking at each row in which there is a difference between the File, RAM, and/or Flash data. Choose
the Find Config Differences command from the View to establish the start point for the search. You
can then press F7 (or choose Find Next Difference from the Edit menu) to scroll to the next difference.
Continue to press F7 to scroll to each difference. After you have scrolled through all differences from
the start point you established, a dialog informs you that the search is complete.
Tip You only need to use the Find Config Differences command if you want a dialog to display
after you have viewed all differences. You can press F7 without having used Find Config
Differences to scroll through the differences without being notified when you have viewed all
differences.
l For inputs or outputs that are connections, use Pan to Connection to scroll to the connection, or to
any other instance of that output value in the table. Choose the command from the shortcut menu
after you right-click anywhere in the row of a block output that is a connection, or after you right-click
over the output value in the File Input, Flash Input, or RAM Input cell of a block input row.
In addition to using the commands above to locate information in this window, you can use the Find in
Window command to locate a block, input, or output in another ccTool window.
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Application - Edit Mode Page 1 of 1
Edit Mode
Edit Mode provides a quick way of editing RAM Configuration constant values in the Application
Configuration window.
Note: Use of Edit Mode is not recommended for most situations because Edit Mode does not update RAM
values and other windows dynamically. Always exit Edit Mode before going to other windows. The other
windows and RAM values are updated when you exit Edit Mode.
To use Edit Mode:
1. To turn on Edit Mode, check it in the Edit menu or the shortcut menu.
The cells of all constant values in the RAM Input column turn yellow.
2. You can now edit any of the RAM constant values by clicking the value, and then typing a new value.
3. To exit Edit Mode, uncheck it in the Edit menu or the shortcut menu.
Tip After you click a RAM Input value to initially position the cursor, you can use the up and down arrow keys
to move the cursor to other RAM Input values and edit them.
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Execution Strategy Window Page 1 of 1
Using the Execution Strategy Window
The Execution Strategy Window presents a matrix. The time slots of the cycles are listed along the top of the
matrix. The blocks are listed down the side, followed by the time it takes each block to execute. The cells
within the matrix represent the time slots in which each block will execute. A number in a cell indicates the
percentage of the total time.
You can:
l View the File, RAM, or Flash execution strategy

l Set File, RAM, or Flash as a reference. When you display a configuration that is not the reference,
values that differ from those in the reference configuration are shown in red.
l Click a cell that has a dash (-) to have the block execute in that time slot.
l Doubleclick a cell to change the executions per cycle.
l Choose Reorder from the Configurations menu (or left click, then right click in a Block Name cell) to
change the order in which the blocks execute.
If all cells for a block are blank, nothing has been assigned. You can doubleclick a cell to assign the
executions per cycle.
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Mainline Execution Window Page 1 of 1
Mainline Execution Window
The Mainline Execution window displays a table showing whether or not each mainline block will execute.
You can:
l View the File, RAM, and/or Flash execution assignments

l Set File, RAM, or Flash as a reference column in order to highlight differences in the values between
the three configurations
l In the File Configuration, turn on or off execution of blocks that are not fixed. You can only change the
execution assignment in the File Configuration. You cannot change it in RAM or Flash.
The following illustration shows an example Mainline Execution window.
In the table:
l An X indicates that the block will execute. A dash indicates it will not.
l A white background in a cell indicates that you can edit that value. You cannot edit values in gray
cells. If all cells for a block are gray, the block is fixed and you cannot change the execution status.
l Red values indicate a difference from the reference column.
To turn on or off execution of a block in the File Configuration:
l Click in a white cell with an X to turn off execution of the block. A dialog asks you to confirm that you
want to clear the execution.
l Click in a white cell with a dash (-) to turn on execution of the block.
To hide or show one of the columns in the table, uncheck or check File Assignments, Flash Assignments, or
RAM Assignments in the View menu.
To set a reference column, use the Reference Column command in the View menu.
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Setting Up Security Page 1 of 1
Setting Up Security
This topics in this section describe:
l Setting Up Your Security Level

l Setting Up Security Passwords
For general information on ccTool security, see Security.
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Setting Your Security Level Page 1 of 1
Setting Your Security Level
Use the Set Security Level command to change your current security level. You must enter the associated
password to change to a security level that is higher than your current level.
1. Choose Set Security Level from the Controller menu.
Your current security level is selected.
2. Select a security level and, if the level is higher than your current level, enter the associated
password. The security levels are:
¡ View Only allows you to view all information in RAM but not save any changes.
¡ Tune Configuration allows changing input assignments.
¡ Change Configuration allows adding and removing blocks, purchasing blocks, and changing
the type of input.
3. Click OK.
ccTool changes your security level.
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Changing Passwords Page 1 of 2
Setting Security Passwords
Use the Set Security Passwords command to change the password of one or more security levels for any or
all connected controllers. You can change the password of your current security level or a lower security
level. You can also set the Exciter Name for the selected controllers. Controllers with the same Exciter Name
and passwords do not require you to enter the password each time you connect.
Note: Be careful when changing passwords because the old password cannot be recovered after you set a
new one. Also, passwords are not user-specific. The same password applies to all users of the security level:
To set security passwords:
1. Choose Set Security Passwords from the Controller menu.
Your current security level is selected in the list.
2. Select the controllers to change their passwords.

3. Enter an Exciter Name or uncheck this option to keep the current name.
4. To change a lower security level, select it from the list.
5. Type the new password for the selected security level.
6. Click Set. A confirmation dialog tells you the password is saved.
7. To change the password for another level, repeat Steps 2-6.
8. When you are done changing passwords, click Close.
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Setting Up Printing Page 1 of 1
Setting up Printing
You can print the contents of any of the ccTool windows. ccTool uses the standard Windows Print, Print
Preview, and Printer Setup commands. It also includes a Page Setup command that allows you to define the
page layout and scale for printing and, in case of the Diagram window, the size of the diagram.
This section explains how to use Page Setup command. The topics covered are:
l Setting Up Pages in the Diagram Window

l Setting Up Pages in the Non-Diagram Windows
After using Page Setup, use the Print Preview command before actually printing. Print Preview allows you to
verify that the print results will be as you expect.
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Setting Up Pages in Diagram Page 1 of 1
Setting up Pages in the Diagram Window
Use the Page Setup command in the Diagram window to define any of the following:
l The diagram size. You may need to change the diagram size even if you do not plan on printing the
diagram. For example, when you make more blocks in a diagram visible, you may need to increase
the diagram size in order to have more space to place the blocks.
l The page size and orientation. You can also turn on the display of page breaks in the Diagram
window.
l The scale factor for printing.
To use the Page Setup command in the Diagram window:
1. If you want to change the diagram size, display either the RAM or File configuration. The diagram size
is defined and saved by configuration type and cannot be directly edited for the Flash configuration.
(You can download to Flash to update the Flash diagram size).
2. If Dynamic Edit Mode is not on, click to turn it on.
3. Choose Page Setup from the File menu.
4. Click the tab of an option, and then define the settings:

¡ Page Size (the default tab)
¡ Diagram Size
¡ Print Scale
5. Repeat the previous step as needed.
6. When you are done setting options, click OK.
Any changes you made to the Page Size, Diagram Size, or Print Scale settings are put into effect:
Notes:
l If you will be printing the diagram, it is typically most effective to use the Page Size option to define
the page size and turn on page breaks, and use the Diagram Size option to define the size as a
number of pages. This allows you to see how the diagram will be printed as you work with it.
l Depending on your printer, the page margins on the printed diagram may be slightly different than
page margins shown in ccTool. Do a print preview before printing to verify the page margins that will
be used on the printed pages.
l When you print, the entire diagram size is printed unless you set a print range in the Print dialog. If the
diagram size is much larger than the actual space used, blank pages will be printed. To avoid this,
you can use the Autosize or Minimum Size option in the Diagram Size tab.
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Page Size Page 1 of 1
Page Size
This option assists in the layout of the diagram. Use it to define the size and orientation of the pages in the
diagram, and to turn on the display of page breaks in the Diagram window. The page size you define here is
used by the Pages option of the Diagram Size tab. It is not necessarily the page size that will be used by the
printer.
Changes you made to the Page Size settings apply to all configurations (File, RAM, and Flash). They remain
in effect for this ccTool session and, if you use the Save command, are saved for all configurations.
Define the settings as follows:
l To define the page size, choose a standard engineering drawing size from the drop-down list, or type
the Width and Height.
l To change the orientation of the page, select Portrait or Landscape.
l To display the page breaks in the Diagram window, check Show Page Breaks.
After you define the page size, you can click Diagram Size or Print Scale to change those settings, or can
click OK to end the Page Setup command.
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Diagram Size Page 1 of 1
Diagram Size
Use this option to change the size of the diagram for the RAM or File configuration. You can set the size to
be a number of pages or a defined height and width. Changing the diagram size does not change the
physical location of blocks on the diagram. Blocks remain in the same position relative to the upper left
corner of the diagram.
When you change the diagram size, the new size applies only to the current RAM or File configuration. The
new size is automatically saved when you change the RAM configuration. It is saved for the File
configuration if you save the configuration.
l Select the Pages option to define the diagram size as a number of pages. This option uses the page
size defined in the Page Size tab. You can type the number of pages across and down, or click
Autosize to set the size to the minimum number of pages required to accommodate all of the blocks
currently visible in the diagram.
l Select the Custom Size option to define the size by height and width. You can choose a standard
engineering drawing size from the drop-down list, type the size, or click Minimum Size to set the size
to the minimum size required to accommodate all of the blocks currently visible in the diagram.
After you define the diagram size, you can click Page Size or Print Scale to change those settings, or can
click OK to end the Page Setup command.
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Print Scale Page 1 of 1
Print Scale
Use the Print Scale option when you want to change the scale of the diagram for printing or print previewing.
The scale is changed only for printing; the actual document scale remains the same.
Changes you make to the Print Scale settings apply only to the active window. They remain in effect for the
window only during this session of ccTool.
l To scale the document up or down to fit on a certain number of printed pages, check Fit to Pages and
type the number of pages to print across and high. When Fit to Pages is checked, it uses the Scale
Percentage shown in the dialog as the maximum scale allowed. Therefore, if you are using Fit to
Pages to scale down the diagram, you can leave the Scale Percentage at 100% because scaling
down will result in a Scale Percentage of less than 100%. If you are using Fit to Pages to scale up a
document, you must increase the Scale Percentage shown in the dialog because Fit to Pages will
scale the document up to the highest possible scale for the number of pages without exceeding the
Scale Percentage shown in the dialog. For example, if you define the Scale Percentage as 200%, Fit
to Pages will scale the document up as high as possible to fit on the number of pages specified
without exceeding 200%.
l To scale a diagram up or down without specifying the number of printed pages, define a Scale
percentage and do not check Fit to Pages.
After you define the scale, you can click Page Size or Diagram Size to change those settings, or can click
OK to end the Page Setup command.
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Setting Up Pages in Grid Based Windows Page 1 of 2
Setting up Pages in the Non-Diagram Windows
Use the Page Setup command in any of the following ccTool windows to define the page layout and scale for
printing: Application Configuration, Execution Strategy, Mainline Execution, Memory, and Execution Time.
The Page Setup command is the same in all of these windows.
Changes you make to the default Page Setup settings apply only to the active window. The changes remain
in effect for the window only during this session of ccTool.
To use Page Setup in any of the windows listed above:
1. Choose Page Setup from the File menu.
2. In the Header and Footer lists, you can define the header and footer that appear on each printed
page. You type text and/or formatting codes to define the content of the header and footer.
3. In the Margins panel, you can change the current page margins and the placement of the header and
footer.
4. In the Print Options panel, you can check the Black & White option to have the grid and text print in
black on a white background rather than printing in the colors shown in the window. None of the other
options are used. Grid lines are always printed even if not checked here, and columns and rows are
printed as they appear in the window.
5. In the Page Order panel, select one of the following options:
l Top to Bottom (the default) prints all pages for the first set of columns that fit across a
page, then all pages for the next set of columns, etc.
l Left to Right prints all pages for the first set of rows that fit across a page, then all pages
for the next set of rows, etc.
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Setting Up Pages in Grid Based Windows Page 2 of 2
6. In the Center panel, you can select one or both of the following options to center the document on the
page when the document does not extend to the full width or length of the page as defined by the
page margins:
l Center Horizontally is useful when the column breaks in the grid result in the document
not extending to the full-page width. It centers the document horizontally so that the left
and right margins increase to be equal size.
l Center Vertically is useful when the document is less than one full page length. It
centers the document vertically so that the top and bottom margins are equal size.
7. In the Scale panel, you can change the scale of the document for printing as follows:
l To scale the document up or down to fit on a certain number of printed pages, check Fit
to Pages and type the number of pages to print across and high. When Fit to Pages is
checked, it uses the Scale Percentage shown in the dialog as the maximum scale
allowed. Therefore, if you are using Fit to Pages to scale down the diagram, you can
leave the Scale Percentage at 100% because scaling down will result in a Scale
Percentage of less than 100%. If you are using Fit to Pages to scale up a document, you
must increase the Scale Percentage shown in the dialog because Fit to Pages will scale
the document up to the highest possible scale for the number of pages without
exceeding the Scale Percentage shown in the dialog. For example, if you define the
Scale Percentage as 200%, Fit to Pages will scale the document up as high as possible
to fit on the number of pages specified without exceeding 200%.
l To scale a document up or down without specifying the number of printed pages, define
a Scale percentage and do not check Fit to Pages.
8. When you are done defining the page setup, click OK.
Printing now uses the page setup you defined. Use Print Preview before printing to verify that the page
layout is as you expected.
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Specifying Headers and Footers Page 1 of 1
Specifying Headers and Footers
You specify the header and footer in the Page Setup dialog by typing text and formatting codes. You can
enter the codes in upper or lower case.
The general formatting codes are as follows:
Format Code Description

&L Left-aligns the characters that follow
&C Centers the characters that follow
&R Right-aligns the characters that follow
&A Prints the sheet name, which is always Sheet1.
&D Prints the current date
&T Prints the current time
&P Prints the page number
&P+number Prints the page number plus number
&P-number Prints the page number minus number
&& Prints an ampersand
&N Prints the total number of pages in the document
The special font codes are as follows:
Format Code Description

&B Use a bold font
&I Use an italic font
&U Underline the header
&S Strike-out the header
&"fontname" Use the specified font
&nn Use the specified 2 digit font size
Headers and footers are centered unless you specify &L or &R, and are in Courier font unless you specify a
different font name with the &"fontname" code. Some examples follow.
This example for Header... Would print the header ...

&L&"TimesRoman"&12 The text "Application Configuration
Application Configuration Report Report", left justified in 12 point Times
Roman font
&L&D The date left-justified and the page

&RPage &P of &N number right-justified with the total
number of pages, such as "Page 1 of
8"
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Using the Connection Bar Page 1 of 2
Using the Connection Bar
The Connection Bar is particularly useful when you are connected to multiple controllers. With a user
interface that is similar to the Windows Explorer, it presents a hierarchy of the controllers to which you are
connected, files you have open for offline editing, and the windows open for each controller and file. You can
use it to easily navigate between windows when you are connected to multiple controllers and/or have
multiple files open. The Connection Bar is updated automatically as you open or close controller
connections, files, or windows.
When you access ccTool, the Connection Bar appears automatically if it was displayed the last time you
used ccTool. The bar appears in the same place as last displayed.
To use the Connection Bar:
1. If the Connection Bar is not displayed, click the Toggle Connection Bar icon in the toolbar .
The Connection Bar is displayed. For example, the content is as illustrated below if you
connected to the ECM and FICM controllers, bridge connected through FICM to Bridge 0, and
opened a configuration file named FV4YST16.ccf. The windows open for each connection and
file are listed under the connection or file. The active window is highlighted in the list.
2. You can:
l Click a window in the list to make it the active window.

l Click the minus sign (-) in front of an item to collapse the hierarchy under that item. The
list collapses only if the active window is not in the hierarchy under this item.
l Click the plus sign (+) in front of an item to expand the hierarchy under that item.
3. To turn off display of the Connection Bar, click the Toggle Connection Bar icon in the toolbar .
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Using the Connection Bar Page 2 of 2
You can also move or re-size the Connection Bar as described in the next topic.
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Moving and Re-sizing the Connection Bar Page 1 of 1
Moving and Re-Sizing the Connection Bar
The first time you display the Connection Bar, it appears docked to the left side of the main ccTool window.
Docked means that the window holds a fixed position on the left or right side of the main ccTool window.
You can undock and manipulate the Connection Bar as follows:
1. Double-click the header of the Connection Bar to undock it. The window header turns blue to indicate
that the window is undocked.
2. You can now move or re-size the window as you would any other window. Specifically, to move the
window, position the cursor in the window header, and then hold down the left mouse button and drag
the window. To re-size the window, position the cursor over one of the window edges until the cursor
changes to a double-sided arrow, and then hold down the left mouse button and drag the window
edge.
3. To re-dock the window to the same side of the main ccTool window as it was previously docked,
double-click the window header. To dock it to the opposite side of the main ccTool window, move the
window until it is flush against that edge of the ccTool window.
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Working with Alarms Page 1 of 1
Working with Alarms
The controller activates an alarm to alert you to a condition that requires your attention.
The topics in this section describe how to work with alarms. The topics are:
l Setting the Auto-Refresh Preference

l Acknowledging Alarms
l Clearing and Removing Alarms
l Other Commands in the Alarms Window
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Setting the Auto-Refresh Preference Page 1 of 1
Setting the Auto-Refresh Preference
The Auto-Refresh preference for Alarms controls how often the controller checks for alarms in order to
refresh the Alarms icon and Alarms window. When the controller finds that an alarm has been activated
since the last auto-refresh interval, it refreshes the Alarms icon to show the flashing red border . If the
Alarms window is displayed, it also adds the alarm to the window.
The default auto-refresh interval for alarms is 5 seconds. To change the auto-refresh interval:
2. Click the Auto Refresh tab.
3. For Alarms, type the auto-refresh interval as the number of seconds.
Note: Only uncheck Alarms for temporary situations such as communications being very slow
when you are using a remote connection. When Alarms is unchecked, you are not notified of
any new alarms.
4. Click OK.
Your preferences are set.
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Acknowleding Alarms Page 1 of 2
Acknowledging Alarms
When an alarm goes off, the Alarms icon in the toolbar flashes with a red border . You then use the
Alarms command to acknowledge the alarm. Acknowledging an alarm just indicates that you have viewed
the message. The alarm continues to be listed in the Alarms window until it is cleared and removed.
After you acknowledge all alarms in the Alarms window, the Alarms icon border changes from flashing red to
flashing yellow . Flashing yellow indicates that all alarms have been acknowledged but are not yet
cleared and removed. If another alarm goes off, the icon border again flashes in red.
To acknowledge alarms:
1. In the toolbar, click the Alarms icon when it is flashes with a red border .
The Alarms window lists the alarms. The text "Alarm" in the column next to the alarm
description indicates that the alarm has not yet been acknowledged. For example, the following
window contains alarms that are activated if the FCIM loses communication with Bridge 0.
2. You can acknowledge one or multiple alarms:
l To acknowledge a single alarm, double-click the alarm.
l If the alarms are grouped into categories by type, as in the illustration above, you can
acknowledge all alarms of one type. To do so, right-click on the row of one of the alarms
of the type, and then choose Acknowledge All Alarms of this Type from the shortcut
menu.
l To acknowledge all alarms, click the Acknowledge All Alarms button.
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Acknowleding Alarms Page 2 of 2
When you acknowledge an alarm, the text "Acknowledged" replaces the text "Alarm" in the
column next to the Alarm description.
3. When you are done acknowledging alarms, you can do one of the following:
l Click Close to close the Alarms window

l Clear and/or remove alarms
l Use other commands in the Alarms window
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Clearing and Removing Alarms Page 1 of 1
Clearing and Removing Alarms
After you acknowledge alarms in the Alarms window, you can clear or remove them from the Alarms window
as follows.
Clearing Alarms
Alarms are normally cleared automatically by the controller when the condition that caused the
alarm no longer exists. There may be alarms, however, that require that you clear the alarm.
You can manually clear a single alarm or all alarms of the same type:
l To clear a single alarm, right-click on the row of the alarm, and then choose Clear
Alarm from the shortcut menu. A dialog asks you to confirm clearing the alarm.
l If the alarms are grouped into categories by type, you can clear all alarms of one type.
To do so, right-click on the row of one of the alarms of the type, and then choose Clear
All Alarms of this Type from the shortcut menu. A dialog asks you to confirm clearing
the group of alarms.
When you clear an alarm, the text "Cleared" appears in the column next to the Acknowledged
column.
Removing Alarms
Alarms must be acknowledged and cleared before you can remove them from the Alarms
window. To remove them, click the Remove All Cleared, Acknowledged Alarms button. The
alarms are removed from the window.
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Other Commands in the Alarms Window Page 1 of 1
Other Commands in the Alarms Window
In addition to the commands used to acknowledge alarms, and clear and remove them, the Alarms window
contains the following commands.
Refresh
Click the Refresh button in the Alarms window to update the window with all alarms that have
been activated since the last auto-refresh.
Alarm History Commands
The controller writes a log of all alarms. This is particularly useful because there may be alarms
that go off and are cleared so quickly that ccTool never detects the alarm. To view the alarm
history, click the Upload to Database button in the Alarms window. If you previously uploaded
the history, the command uploads only the new information to ensure that there are no
duplicates in the database.
The Clear History command clears the controller log; it does not clear the database if you
uploaded the log to a database. Be sure to upload the history to a database before using this
command to ensure that the information is not lost.
Show All Alarms
You can list the description of all alarms for the controller in the Alarms window. To do so,
check Show All Alarms. Uncheck Show All Alarms to return to the standard Alarms window
display.
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Working with Events and Data Loggers Page 1 of 1
Working with Data Loggers and Event Recorders
The topics in this section describe how to work with Data Loggers and Event Recorders.
The topics are:
l What are Data Loggers and Event Recorders?

l Setting Default Graph Display Preferences
l Uploading the Data
l Using the Graph Window
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What are Data Loggers and Event Recorders? Page 1 of 1
What are Data Loggers and Event Recorders?
You setup a Data Logger when you need to monitor specific outputs. A Data Logger is a special function
block that takes samples of data. You specify the inputs to this block as the outputs from other blocks that
you want to monitor. You also specify the time interval at which you want the Data Logger to sample the
data. Once a Data Logger is setup and put into execution, it is always recording data. You choose when to
upload and view the data.
Note: The Data Logger writes the sampled data to a buffer. When the buffer is full, the Data
Logger begins to overwrite the existing data from the top of the buffer. You can look at the
Total Size and Data Size columns in the View Events and Data Loggers command to
determine whether the buffer is full. To clear the buffer, you can set the state from Executing to
Resolved, and then back to Executing. The buffer is cleared when the state changes to
Executing or when you change an input while in the Executing state. Before clearing the buffer,
use the Events and Data Loggers command to upload the data to the PC.
You setup an Event Recorder when you want to capture the data related to a single event. An Event
Recorder is a special function block that records the output values related to an event. You specify the inputs
to this block as the trigger that sets off the event and the outputs that you want to record. You enable the
Event Recorder when you want the controller to start monitoring for an occurrence of the trigger. When the
trigger occurs, the Event Recorder records the event and automatically displays a dialog in ccTool to allow
you to upload and view the data at that point. (The Event Recorder does not have any of the buffer overwrite
concerns that were noted above for the Data Logger).
There are two types of triggers: LOGIC and FLOAT. For the LOGIC type, you define whether a TRUE or
FALSE value for a specific output triggers the event. For the FLOAT type, the event is triggered if the value
of a specific output falls outside a minimum and maximum value that you define. The Event Recorder saves
both pre-trigger and post-trigger data. You specify a time interval for sampling the data and how many
samples you want taken at each interval for pre-trigger and total samples.
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Positioning Channels Page 1 of 2
Setting Graph Display Preferences
You view Data Loggers and Event Recorders in a Graph window. You can set the default display
characteristics for this window using the Preferences command. The Preferences command also includes a
feature named Changes in graph window are saved in preferences. This feature is an efficient way to set
preferences when you are not yet familiar with all of the graph display options, or want to refine settings in
the Graph window before saving them as your preferences. When this feature is checked, the last graph
display settings you define in a Graph window before closing it are saved as your preferences.
Note: Changes you make in Preferences apply only to subsequent Graph windows that you open. Choose
the command before opening any Graph windows if you want changes to apply to those windows.
To define your preferences:
2. Click the Default Graph Display tab.
3. For all of the options except Default Wave Height and Default Vertical Scale:
l Change the default settings shown in the dialog as needed. For an explanation of each
option, see Setting Graph Display Options.
l Check Changes in graph window are saved in preferences to update your
preferences automatically with changes to the settings that you make using the related
commands in the Graph window.
4. Change the Default Wave Height and Default Vertical Scale as needed:
The Default Wave Height defines the default height for the waves in the channels, in pixels. It is used
by the Default Vertical Scale settings to determine how to display the channels by default. The two
options for setting vertical scale are:
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Positioning Channels Page 2 of 2
¡ Set to one of the default values

Choose this option when you want all channels to have the same vertical scale and different
wave heights by default. It has ccTool calculate a default vertical scale for all channels that
best matches the range of data while also coming as close as possible to the default wave
height.
¡ Set to default wave height
Choose this option when you want all channels to have the same wave height and different
vertical scales by default. It sets all channels to have the default wave height.
These preferences do not have direct command equivalents in the Graph window. You set the
defaults in the Preferences command for all channels. In the Graph window, you adjust the default
vertical scale as needed for individual channels.
5. When you are done setting preferences, click OK.
Your preferences are set. They will be used the next time you open a Graph window.
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Uploading the Data Page 1 of 2
Uploading the Data
You upload the data recorded by an Event Recorder or a Data Logger in order to view the data or save it in a
file.
To upload the data:
1. For an Event Recorder, the View Events and Data Loggers dialog displays automatically when the
event occurs. For a Data Logger or a previously recorded (and not yet reset) Event Recorder, choose
Events and Data Loggers from the View menu to display the dialog.
The dialog displays the following information for each Event Recorder or Data Logger:
For Data Logger ... For Event Recorder ...

Time Records the time that the last Records the time that the trigger
sample was written to the buffer occurred
Status Valid Data means the data is ready Valid Data means the data is ready
and you can proceed with this and you can proceed with this
command. command.
Getting Data means the controller Getting Data means the controller
is in the process of collecting data. is in the process of collecting data.
You must cancel from this You must cancel from this command
command and wait until the data is and wait until the data is collected
collected before proceeding. before proceeding.
Not Initialized means the Data

Logger block is not ready, typically
because you have not assigned it
yet.
Buffer Erased means the buffer

was cleared and nothing has been
written to it since it was cleared.
Total Size and Data Total Size is the total size of the Total Size and Data Size are always
Size buffer in bytes. Data size indicates the same.
how much of the buffer is filled.
(The Data Size is approximate
because this dialog is not updated
automatically as data is written to
the buffer).
If the Data Size equals the Total

Size, it indicates the buffer is full
and is being overwritten.
2. Select the Data Logger or Event Recorder for which you want to upload data, and then click Get Data.
The following illustration assumes you selected the DATA_LOGGER block. The options in the
dialog are the same for all Data Loggers and Event Recorders.
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Uploading the Data Page 2 of 2
3. Select one of the following options, and then click OK.
l View Data displays the data in the Graph Window.

l Save Data displays the standard Save dialog, allowing you to save the data as a
standard Event Recorder (.evt) or Data Logger (.dlg) binary file. Use Save rather than
Export if you want to later display the file in the Graph window. The saved binary file will
contain all controller and setup information as well as the event data.
l Export Data displays the standard Save As dialog, allowing you to save the data as a
text file. Use Export when you want to view the file outside of ccTool. The text file will
contain all of the event data but will be missing some of the controller and setup
information.
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Using the Graph Window Page 1 of 1
Using the Graph Window
The Graph window is displayed after you choose the view option in the View Events and Data Loggers
command, and after you open a previously saved file using the Open Event Graph or Import Graph Data
command. The topics in this section describe how to use the window.
The topics are:
l Window Basics
l Setting and Moving the Cursors
l Setting Channel Properties
l Managing the Display
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Window Basics Page 1 of 3
Window Basics
The Graph window is modeled on an oscilloscope. It presents a graph of the data recorded by a Data Logger
or Event Recorder and allows you to compare and analyze the data as you would on a physical oscilloscope.
The window is the same for a Data Logger or Event Recorder, except that a few additional options are
available for an Event Recorder.
The sections of the window are illustrated and described below.
Graph Area of Window
The graph charts the recorded data as a function of time, where the x-axis represents time and the y-axis
represents the data values. Each output being monitored appears as a channel on the graph. You set and
move two graph cursors to view and compare values.
You can display the name of each channel or, as illustrated above, only the number of the channel. An arrow
along the left of the graph shows the zero point of each channel. If the zero point is not currently displayed,
the arrow points up or down towards the zero point.
You can dynamically set and move the graph cursors and channels, as well as control the graph display
using commands in the window and in the menus.
Note: This documentation uses the term graph cursor to refer to the cursors you set in the graph, and the
term mouse cursor to refer to the cursor you move on the screen as you move the mouse.
Overview Area of Window
Above the graph is a dashed line that represents an overview of the data. The dashed line represents all of
the data in the graph, and the symbols on it represent the position of the Graph window, graph cursors, and
(for the Event Recorder) the trigger point within all of the data. You cannot interact in the Overview.
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Cursors Panel
The top right section of the window displays the Cursors panel.
You can set the graph cursors by selecting the channels from these drop-down lists. You can set the channel
properties by clicking the button next to the drop-down list. As you set and move the graph cursors, the
X, Y, dX, and dY values are displayed here.
Vertical Scale, Position, and Horizontal Scale Controls
The middle right section of the window contains the following controls:
You can set the vertical scale and/or position of a channel, or the horizontal scale of all channels.
Channel List
The lower right section of the window lists the channels and their current vertical scale. A checkmark next to
a channel indicates that the channel is currently displayed in the graph.
Page 76 of 90
In this list, you can:
l Uncheck a channel to turn off its display in the graph, or check it to turn on its display.
l Click a channel to select it. You select a channel in order to set its vertical scale or position. You can
only select a channel that has a checkmark.
l Double-click a channel to set its properties.
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Setting and Moving the Cursors Page 1 of 1
Setting and Moving the Cursors
When the Graph window is first displayed, the two graph cursors are not displayed. You set the channels for
the graph cursors to initially position them. You can then move the cursors along the same channels or move
them to different channels as needed to view and compare data.
Before setting or moving the graph cursors, check Snap to Data Points in the Cursors menu if you want the
cursors to snap to the closest data point as you set and move them.
To initially set the channel for a graph cursor or later set a different channel, you can either:
l Select the channel from the CURSOR 1 or CURSOR 2 Channel drop-down list in the top right of the
window.
If the graph cursor was not previously set, it is placed at the zero point location of the channel
you selected. If the graph cursor was previously set on a different channel, it is moved to the
selected channel at the same X-axis location.
l Use the shortcut menu to define the channel and location for the graph cursor. To do this:
1. Position the mouse cursor on the channel at the location you want to place the graph
cursor.
2. When the mouse cursor changes to , right-click to display the shortcut menu.
3. Choose the Set Cursor 1 or Set Cursor 2 command.
The graph cursor is set on the channel, and positioned at the location you right-clicked.
Note: The shortcut menu only contains the Set Cursor commands if you right-click while the
mouse cursor is the cursor. A right-click while the mouse cursor is still the cursor
displays the shortcut menu but the menu does not contain the Set Cursors command.
After you initially set the channel for a graph cursor, you also can dynamically move the cursor to a different
channel. To do this, position the mouse cursor directly over the of the graph cursor, and then drag the to
the desired channel. x x
To move a graph cursor to a different position on the current channel, you can:
l Dynamically move the graph cursor along the channel. To do this, position the mouse cursor
anywhere along the vertical line that runs though the graph cursor, and then drag the vertical line.
l Use the shortcut menu to define a new position on the channel. To do this, right-click at the location
you want to position the graph cursor (you do not have to right-click directly over the channel), and
then choose Position Cursor 1 or Position Cursor 2 from the shortcut menu.
l Position the graph cursor at the center of the window. To do this, choose Position Cursor 1 or Position
Cursor 2 from the Cursors menu.
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Setting Channel Properties Page 1 of 1
Setting Channel Properties
As you work with channels in the graph, you may want to change their vertical scale, re-position them, make
some channels invisible, or change the color or name of the channel. A channel's vertical scale, position,
visibility, color, and name are called the channel properties. There are a number of ways you can change the
channel properties:
l You can dynamically change the position of a channel in the graph by dragging the channel in the
graph.
l You can check or uncheck the first column in the Channel List to set a channel's visibility.
l You can use the Channel Properties command to change any of the properties of a channel.
l You can select a channel, and then change its position or scale.
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Using the Channel Properties Command Page 1 of 1
Using the Channel Properties Command
You use the Channel Properties command to change a channel's color, visibility, scale, and/or position
To change a channel's properties:
1. Choose the Channel Properties command in one of the following ways:
l Double-click the channel in the Channel List.

l Right-click a channel in the graph, and then choose Properties from the shortcut menu.
l Click the button next to the channel name in the top right section of the Graph
window.
2. You can change any of the following:
l The Channel Name controls the name shown in the Channel List and graph. The
default channel name is the name of the output. To change the channel name, type a
new name.
l Color controls the color of the channel in the graph and Channel List. To change the
channel color, click the color button and then choose a new color.
l Visibility controls whether the channel is displayed in the graph. Check this option to
display the channel in the graph, or uncheck it to turn off display of the channel in the
graph.
l Vertical Scale is the number of counts per grid division. The default scale is determined
by your preferences. To change the vertical scale, select or type a new scale in the
drop-down list. If you type a scale that is out of range for the sample of data, an error
dialog displays the valid range.
l Vertical Position is the distance from the top of the graph, in pixels, of the zero point of
the channel. To change the position of the channel in the graph, type a new distance in
pixels.
3. When you are done setting properties, click OK.
The Graph window is updated to show the changes you made to the channel properties.
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Changing the Scale or Position of the Selected Channel Page 1 of 1
Changing the Scale or Position of the Selected Channel
You can select a channel and then change its vertical scale and/or position in the graph. This method of
changing a channel's position is particularly useful when you want to align the zero points of two channels.
Rather than dynamically aligning the two channels in the graph, you can select and then type the same zero
point location for each channel.
To select a channel and change its vertical scale and/or position:
1. Click the channel in the Channel List or graph to select it.
The current vertical scale and position of the selected channel appear in the Selected Channel
area of the window.
The vertical scale is the number of counts per grid division. The position is the distance from
the top of the graph, in pixels, of the zero point of the selected channel.
2. To change the vertical scale, select or type a new scale in the drop-down list. If you type a scale that
is out of range for the sample of data, an error dialog displays the valid range.
3. To change the position, type a new value in the Position box to move the zero point to that position, or
click the arrows next to the box to move the channel up or down one pixel at a time.
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Managing the Display Page 1 of 1
Managing the Display
The topics in this section describe how to manage the display in the Graph window.
The topics are:
l Scrolling the Graph

l Setting the Horizontal Scale
l Setting Display Options
l Setting the Graph Height
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Scrolling the Graph Page 1 of 1
Scrolling the Graph
You can scroll the graph dynamically using the scroll bars, or you can use the following commands:
l Go to Cursor 1 scrolls the graph to display graph cursor 1 in the center of the window.
l Go to Cursor 2 scrolls the graph to display graph cursor 2 in the center of the window.
l (For Event Recorders only) Go to Trigger Pt scrolls the graph to display the trigger point in the center
of the window.
You can choose these commands from the Cursors menu or the shortcut menu.
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Setting Horizontal Scale Page 1 of 1
Setting the Horizontal Scale
The horizontal scale of the graph is the time interval per grid division. You use the controls in the middle right
area of the Graph window to change the horizontal scale.
You can select a new horizontal scale value from the drop-down list, or you can click AutoFit to set the
horizontal scale so that the entire width of the drawing is displayed in the window.
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Setting Display Options Page 1 of 2
Setting Graph Display Options
You can set general graph display options using commands in the View, Cursors, and Grid menus. The
options you can set are described below. You set the defaults for these options using the Preferences
command. The options are listed here in the order that they appear in the Preferences command, in order to
allow you to reference this section as you use the Preferences command to define the defaults for these
options.
Note: Of the display options described here, only TINT time is saved with the file. If you
change any other settings, the change applies only to the current window.
The graph display options that you can set in the View, Cursors, and Grid menus are:
Display Channel Names (View Menu)

Check this option to display the channel names at the left of the graph. Uncheck it to display the channel
numbers at the left of the graph. The channel numbers are the numbers that appear in the Channel List.
Snap Cursor to Data Points (Cursors Menu)

Check this option to snap the graph cursors to the channel data points as you set or move the graph cursors.
Snapping to the data points displays the actual data sample values (rather than interpolated values) as the X
and Y values. Data points do not have to be displayed for snapping to work.
Display Data Points (View Menu)

Check this option to display the data points in all channels in the graph. Uncheck it to turn off the display of
data points.
Highlight Selected Channel (View Menu)

Check this option to display the selected channel in the graph in a slightly larger line weight than other
channels. This setting only controls selection highlighting in the graph. The selected channel is always
highlighted in the Channel List.
Channel Colors in List (View Menu)

Check this option to display each channel in the Channel List in its channel color. Uncheck it to display the
Channel List in black and white.
Hide Grid (View Menu)

Check this option to turn off the display of the grid. Uncheck it to turn on the display of the grid.
Connecting Lines (View Menu)

This command controls how connecting lines in the channels are displayed. The options are:
l None displays only the data points (and automatically checks the Display Data Points option):
l Stepped displays the connections as a series of steps:
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l Interpolated smoothes the connecting lines:
TINT time (Grid Menu)

This option applies only to Event Recorders, and you only need to change it as instructed by Cutler-Hammer.
TINT time is a multiplier that corrects for the fact that the controller's time is not exactly 1 millisecond. Cutler-
Hammer will provide you with the correct multiplier.
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Changing the Graph Height Page 1 of 1
Changing the Graph Height
You may need to increase or decrease the height of the graph as you change the vertical scale of channels,
make them visible or invisible, and/or move them around on the graph. For example, if you increase the
wave height of channels by changing their vertical scale, the channels may overlap. You may need to
increase the graph size in order to have enough room to re-position the channels so that they no longer
overlap.
The Grid Height determines the height of the graph. Space is added or removed from the bottom of the
graph as you increase or decrease the grid height. The height is defined in pixels.
To change the grid/graph height:
1. Choose Set Grid Size from the Grid menu.
The dialog shows the current grid/graph height.
2. Type a height for the grid in pixels, and then choose OK.
The height of the grid/graph is adjusted to add or remove space from the bottom of the graph.
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Assign Block Input Page 1 of 2
Assign Block Input
You can assign or change the input values of block inputs that are displayed in the Diagram or Application
Configuration window. In the File Configuration, you can assign unassigned values, change existing values,
and/or change the assignment type. In the RAM configuration, you can change existing values but not
change the assignment type unless the Controller is in the Resolve State or a lower state.
To assign a block input:
1. Display the input you want to assign in the Diagram or Application Configuration window.
2. Choose the Assign Block Input command as follows:
l In the Diagram Window, right-click the input in the diagram, and then choose
Assignment from the shortcut menu.
l In the Application Configuration window, double-click the input in the table. You can also
right-click the input, and then choose either File Assignment or RAM Assignment from
the shortcut menu.
The Assign Block Input dialog appears for the input you specified. For example, the following
illustration assumes you specified the DA1_PAGE input of the DA1 block in the File
Configuration.
In this dialog:
l The From Output and Constant radio buttons are only active if you are editing the File
Configuration. In the File Configuration, you can use these buttons to change the
assignment type. In the RAM Configuration, you cannot change the assignment type
unless the Controller is in the Resolve State or a lower state.
l For a Constant value, the Eng Units radio button is only active if Engineering Units are
defined for this input.
l The Update RAM Values checkbox is only active if you are editing the RAM
Configuration in the Executing State. When Update RAM Values is checked, all RAM
values are read in order to update any changes that may propagated through the
system. When Update RAM Values is unchecked, the input you edit is updated
immediately but any affected values are not updated until the next auto-refresh interval.
You are given the choice of whether or not to update values immediately because
updating them immediately may take some time if you have a large configuration and/or
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Assign Block Input Page 2 of 2
a slow connection.
3. Enter the input assignment as follows:
l To change the assignment type in the File Configuration, click the Constant or From
Output radio button.
l For a Constant value, type a value and click the radio button that identifies the type of
value as Decimal, Hexadecimal, etc.
l For a From Output value, select the block and output from the drop-down lists.
4. If you are editing the RAM Configuration in the Executing State and want to update all affected RAM
values immediately, check Update RAM Values.
5. Click OK.
verify making the assignment. Click Yes to continue, or No to return to the Assign Block Input
dialog.
The input is assigned the value you specified.
Tip In the Diagram window, you can also assign input by drawing a connection.
Related Topics:
l Configure Block
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Open Configuration Page 1 of 1
Open Configuration
You can open an existing configuration file for offline editing.
To do so:
1. Choose Open Configuration in any of the following ways:
l Click the Open icon in the toolbar.

l Press Ctrl-O.
l Choose Open Configuration from the File menu.
l Double-click the Files item in the Connection Bar.
ccTool displays the standard Open dialog. The Look In folder is set to the folder you defined
for Configuration Files in your Directory Preferences. Files of Types is set to Configuration
Files (ccf).
2. If necessary, change the setting for Look In folder or Files of Types.

3. Select the file to open, and then click Open.
ccTool opens the selected configuration file and displays it in the windows you defined as your Initial
Windows in your General Preferences.
Tips
l To open a file that you have used recently, choose the filename from the list at the bottom of the File
menu.
l You also can use this command to open Event Recorder or Data Logger files. To do so, change the
Look In folder to the folder than contains the file, and change the Files of Type to either Event
Recorder Files or Data Logger Files. The Event Recorder or Data Logger file will be opened in the
Graph window.
Related Topics:
l Open Event Graph

l Save
l Save As
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PanelMate Power Series
Online Operation
User’s Guide
&XWOHU+DPPHU
173 Heatherdown Drive
Westerville, OH 43086-6166
The information contained in this manual is the property of Cutler-Hammer, Inc. Information in this
manual is subject to change without notice and does not represent a commitment on the part of
Cutler-Hammer, Inc.
Any Cutler-Hammer software described in this manual is furnished under a license agreement. The
software may be used or copied only in accordance with the terms of the agreement. It is against the
law to copy the software on any medium except as specifically allowed in the agreement. No part of
this manual may be reproduced or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise, without prior written permission of Cutler-Hammer, Inc.
RESTRICTED RIGHTS LEGEND

Use, duplication, or disclosure by the Government is subject to restrictions set forth in paragraph
(b)(3)(B) of the Rights in Technical Data and Computer Software clause of DAR 7-104.9(a).
Contractor/Manufacturer is Cutler-Hammer, P.O. Box 6166, Westerville, OH 43086-6166.
TRADEMARKS
AcceleratI/On is a trademark of Cutler-Hammer, Inc.
TouchPanel is a trademark of Cutler-Hammer, Inc.
PowerBlink is a trademark of Cutler-Hammer, Inc.
PowerAnimation is a trademark of Cutler-Hammer, Inc.
PowerGraphics is a trademark of Cutler-Hammer, Inc.
PanelMate is a registered trademark of Cutler-Hammer, Inc.
Microsoft and Windows are registered trademarks of Microsoft Corporation.
Modbus is a trademark of Schneider Automation Inc.
Remote I/O, DH-485, Data Highway, and Data Highway Plus are trademarks of Allen-Bradley
Company, Inc.
GEnius I/O is a trademark of GE Fanuc Automation North America, Inc.
DCS-NET is a trademark of Reliance Electric Company.
Commercial names of products from other manufacturers or developers that appear in this manual are
registered or unregistered trademarks of those respective manufacturers or developers, which have
expressed neither approval nor disapproval of Cutler-Hammer products.
Copyright Cutler-Hammer, Inc. 1998. All rights reserved.
P/N 01-00394-00
Table of Contents i
Table of Contents
Preface ..............................................................................................................................................I
About This Manual.....................................................................................................................II
Purpose ...................................................................................................................................II
What’s Inside..........................................................................................................................II
Support Services....................................................................................................................... III
Chapter 1: Power-Up Sequence ...................................................................................................... 1
Power-Up Sequence.................................................................................................................... 2
Execute Normal Power-Up Diagnostics ................................................................................... 2
Determine if the Unit Should Enter the Transfer Mode ........................................................... 3
Check for Executive Firmware ................................................................................................ 3
Check User Configuration Compatibility with Executive Firmware ......................................... 3
Check for Presence of Installed Drivers ................................................................................... 4
Determine Power-Up Mode ..................................................................................................... 4
Run Mode Operation............................................................................................................... 6
Chapter 2: Online Page Layout ...................................................................................................... 7
Online Page Layout .................................................................................................................... 8
Page Number and Page Title ................................................................................................... 9
Pages In Alarm ....................................................................................................................... 9
Alarm Window ....................................................................................................................... 9
Refresh Graphics ........................................................................................................................ 9
Conditional Visibility ............................................................................................................... 10
Default Control Buttons............................................................................................................ 11
Get Page ............................................................................................................................... 13
PLC Page Selection ............................................................................................................... 13
Host Display Window............................................................................................................ 13
Directory............................................................................................................................... 14
Chapter 3: Operator Input............................................................................................................ 15
Operator Input .......................................................................................................................... 16
One-Touch Selection of Variable-Sized Templates ................................................................ 16
Two-Touch Selection of Variable-Sized Templates................................................................ 16
Selecting a Template............................................................................................................. 16
Control Button Operation...................................................................................................... 16
Chapter 4: Alarms......................................................................................................................... 19
Alarms ..................................................................................................................................... 20
Alarm Summary Page ........................................................................................................... 21
View or Acknowledge Alarms............................................................................................... 21
Chapter 5: Password Protection.................................................................................................... 23
Password Protection.................................................................................................................. 24
Lost Password Recovery........................................................................................................ 25
ii Online Operation User’s Guide
Chapter 6: Setup Page....................................................................................................................27

Setup Page.................................................................................................................................28
Change Password A or Change Password B ...........................................................................28
Log-in Password A and Log-in Password B............................................................................28
Set Date and Time .................................................................................................................28
Log-out Password A and Log-out Password B ........................................................................29
Display System/Configuration Information ............................................................................29
Enter Offline Mode ................................................................................................................29
Cleaning Mode ......................................................................................................................29
Calibrate Touchscreen............................................................................................................29
Adjust Contrast ......................................................................................................................29
Switch to Two Column Keypad or Switch to Three Column Keypad ......................................29
Chapter 7: Fault Relay...................................................................................................................31
Fault Relay................................................................................................................................32
Fault Relay and Online System Errors....................................................................................32
Fault Relay and Communication Errors .................................................................................32
Fault Relay and Alarms..........................................................................................................33
Fault Relay and Loss of Power ...............................................................................................33
Chapter 8: Maintenance Template ................................................................................................35
Maintenance Template ..............................................................................................................36
Start Monitor .........................................................................................................................36
Deactivate..............................................................................................................................36
Change Value ........................................................................................................................37
Modify Template....................................................................................................................37
Change PLC Name ................................................................................................................37
Change PLC Ref ....................................................................................................................38
Data Format...........................................................................................................................40
Chapter 9: Errors...........................................................................................................................41
Remote I/O Errors .....................................................................................................................42
Errors During Run Mode...........................................................................................................42
Communication Errors ..............................................................................................................42
Local Errors...........................................................................................................................43
Remote Errors........................................................................................................................44
System Errors............................................................................................................................45
Error Codes...............................................................................................................................46
Interface Card Errors.................................................................................................................53
Appendix A: Online Operation Problems......................................................................................55
Online Operation Problems .......................................................................................................56
Appendix B: Momentary Pushbutton Operation ..........................................................................57
Momentary Pushbutton Operation .............................................................................................58
Preface I
Preface
Welcome to Cutler-Hammer’s Online Operation User’s Guide. This chapter describes the contents of
this manual and provides information on Support Services.
II Online Operation User’s Guide
About This Manual
Purpose
This manual focuses on describing the features of the PanelMate Power Series unit when in Run
Mode.
What’s Inside
This manual is organized in the following way:
Preface
Chapter 1: Power-Up Sequence
Chapter 2: Online Page Layout
Chapter 3: Operator Input
Chapter 4: Alarms
Chapter 5: Password Protection
Chapter 6: Setup Page
Chapter 7: Fault Relay
Chapter 8: Maintenance Template
Chapter 9: Errors
Appendix A: Online Problems
Appendix B: Momentary Pushbutton Operation
Preface III
Support Services
It is Cutler-Hammer’s goal to ensure your greatest possible satisfaction with the operation of our
products. We are dedicated to providing fast, friendly, and accurate assistance. That is why we offer
you so many ways to get the support you need. Whether it’s by phone, fax, modem, or mail, you can
access Cutler-Hammer support information 24 hours a day, seven days a week. Our wide range of
services include:
Technical Support 1-800-809-2772

If you are in the U.S. or Canada, you can take advantage of our toll-free line for technical assistance
with hardware and software product selection, system design and installation, and system debugging
and diagnostics. Technical support engineers are available for calls during regular business hours
(8 am - 5:30 pm EST) by calling 1-800-809-2772. International calls can be made to either the Tech
Line at 1-800-809-2772 (toll call) or the Cutler-Hammer main business line at 614-882-3282.
Emergency Technical Support 1-800-809-2772

Because machines do not run on a nine-to-five schedule, we offer emergency after-hours technical
support. A technical support engineer can be paged for emergencies involving plant down situations
or safety issues. Emergency support calls are automatically routed directly to our answering service
after-hours (5:30 pm - 8 am EST) and weekends. For emergency technical support, call
1-800-809-2772.
Note that the Emergency Technical Support phone number does not currently support product repairs
or shipping outside normal business hours.
Technical Support Fax 614-882-0417

You can also contact our technical support engineers by faxing your support requests directly to the
Advanced Product Support Center (APSC) located in Westerville, Ohio at 614-882-0417.
Information Fax-Back Service 614-899-5323

The latest Cutler-Hammer product information, specifications, technical notes and company news is
available to you via fax through our direct document request service at 614-899-5323. Using a touch-
tone phone, you can select any of the info faxes from our automated product literature and technical
document library, punch in a fax number and receive the information immediately.
Website and E-mail Address http://www.cutlerhammer.eaton.com/automation

chatechsupport@ch.etn.com
If you have Internet capabilities, you also have access to technical support via our website at
http://www.cutler-hammer.eaton.com/automation. The website includes technical notes, frequently
asked questions, release notes, and other technical documentation. This direct technical support
connection also offers you the ability to request assistance and exchange software files electronically.
Technical support messages and files can be sent to chatechsupport@ch.etn.com.
IV Online Operation User’s Guide
Bulletin Board Service 614-899-5209

Parameters: 8 data bits, 1 stop bit, parity none, 9600-28.8K baud
If you have modem access, you can dial in directly to our electronic bulletin board service for the
latest product and company information. File sharing, product software downloads and our user
message service are just a few of the things you will find online at 614-899-5209.
Software Update Service 1-800-809-2772

FAX 614-899-4141
We also offer you the opportunity to take advantage of software upgrades, advanced software notices,
and special software promotions through our Software Update Service. When you register your
software, you will receive one-year of free or reduced-price upgrades along with all the other benefits
of membership, including 48-hour shipping of software upgrades. Contact the Software Update
Service at 1-800-809-2772 or fax 614-899-4141.
Repair and Upgrade Service 614-882-3282 ext. 7601

FAX 614-882-3414
Our well-equipped Customer Service department is ready to assist you with repairs, upgrades, and
spare parts services. If a situation arises where one of these services is needed, just call 614-882-3282
x7601 or fax 614-882-3414.
Product Ordering Service 614-882-3282

FAX 614-882-6532
Authorized Cutler-Hammer distributors may place product orders directly with our Order Processing
department by calling 614-882-3282 x406 or faxing 614-882-6532. For information on your local
distributor, call the Cutler-Hammer Tech Line.
Customer Support Center 1-800-356-1243

Authorized Cutler-Hammer distributors and Cutler-Hammer sales offices can get assistance for
Cutler-Hammer standard and component product lines through the Customer Support Center. Call
the Customer Support Center for the following assistance:
1. Stock availability, proof of shipment, or to place an order.
2. Expedite an existing order.
3. Product assistance and product price information.
4. Product returns other than warranty returns.
For information on your local distributor or sales office, call the Cutler-Hammer Tech Line at
1-800-809-2772.
Correspondence Address Cutler-Hammer

P.O. Box 6166
Westerville, OH 43086-6166
Shipping Address Cutler-Hammer

173 Heatherdown Drive
Westerville, OH 43081
Chapter 1: Power-Up Sequence 1
Power-Up Sequence
1
In this chapter, you will learn:
• The sequence of events during power-up
2 Online Operation User’s Guide
Power-Up Sequence
On power-up, the PanelMate unit performs the following sequence of operations:
• Execute normal power-up diagnostics
• Determine if the unit should enter the Transfer Mode
• Check for Executive Firmware
• Check User Configuration compatibility with Executive Firmware
• Check for presence of installed drivers
• Determine Power-up Mode
Execute Normal Power-Up Diagnostics

Normal system power-up diagnostics include test of:
• Video Frame Buffer
• Character Cell RAM
• Watchdog
• DRAM
• Real-Time Clock Battery
• Real-Time Clock
• Serial Ports 1 and 2
Each test will be displayed on screen with a PASSED or FAILED message. If the Video Frame Buffer
or Character Cell RAM fail it may not be possible to display a failure message. In the event this type
of failure, an alarm tone pattern will be generated which will indicate the actual failure. Refer to the
Troubleshooting Guide for the PanelMate Power Series System chapter in the PanelMate Power
Series Hardware Installation Guide for additional information.
The diagnostics will be performed in approximately 20 to 30 seconds.
If there are failures, you may be able to continue if they are not fatal errors. You may receive the
message:
Non-Fatal Self Test Diagnostic Failure Occurred.
Press CANCEL key to continue.
As soon as you press the CANCEL key, the unit will continue with the system boot-up.
If there is a fatal error, you will receive the following message:
FATAL Self Test Diagnostic Failures Occurred.
VCP Unit System HALTED.
The system will be completely halted. The only way to reset the system is to cycle power. If this
occurs, contact your local distributor.
Determine if the Unit Should Enter the Transfer Mode

The unit will check an internal setup register to determine if it is required to enter the Transfer Mode.
It will also test for the presence of the selection keypad. If the keypad is not connected, the PanelMate
unit assumes it is not installed in a panel and should go into the transfer mode and prepare for
communication with a personal computer. Refer to the Transfer Mode topic or the Transfer Utility
User’s Guide for more information.
Check for Executive Firmware

The unit will run a self-test for the completeness and integrity of the Executive Firmware. If healthy,
the power-up sequence continues.
If there is a failure, the following message is displayed:
Executive Firmware is not completely loaded.
Download of new Executive Firmware is required.
Press CANCEL key to enter the Offline Mode.
You must download new Executive Firmware to continue.
Note that if the Executive Firmware gets corrupted, the PanelMate unit will power up to the Recovery
Mode. Refer to the Recovery Mode topic for more information.
Recovery Mode
In the unlikely event of the Executive Firmware getting corrupted in the PanelMate unit, the
PanelMate unit will power up to the Recovery Mode.
Recovery Mode is indicated by the Recover Mode prompt located in the lower right corner of the
screen. During normal operation, the Recovery Mode prompt is replaced by the Serial Mode prompt
or the Network Mode prompt.
You must re-download your executive firmware to resume operating.
Check User Configuration Compatibility with Executive Firmware

The unit checks that a complete User Configuration is stored in the unit. The compatibility of User
Configuration with the Executive Firmware is then verified. If they match, the power-up sequence
continues.
If they are incompatible, the following error message is displayed:
Incompatible Executive Firmware and Configuration versions.
Download of new Executive Firmware or new Configuration is
required.
Press CANCEL key to enter Offline mode.
Check for Presence of Installed Drivers

The Executive Firmware checks to ensure the correct drivers are installed. The Executive Firmware
will not permit the installation of an incompatible version of a driver. If the Executive Firmware
detects an incompatible version, the following error message is displayed:
User configuration indicates missing downloadable driver.
Download of new configuration or missing. Downloadable Driver
is required.
Press CANCEL key to enter Offline Mode.
Determine Power-Up Mode

The unit will determine which mode to select: Offline Mode or Run Mode. The unit will return to
the operating mode it was in before power was removed. When power is applied, it will attempt to
return to that mode.
Note that if the Executive Firmware gets corrupted, the PanelMate unit will power up to the Recovery
Mode. Refer to the Recovery Mode topic for more information.
Also note that if you accidentally enter the Alternate Mode, cycle power on the PanelMate unit to
return to the operating mode the unit was in before it entered the Alternate Mode. Refer to the
Alternate Mode topic for more information.
Alternate Mode
Alternate Mode is feature that allows you to load two small configurations in the PanelMate unit and
toggle between the two configurations. If you enter Alternate Mode, a banner will appear on the
screen to state that you are in Alternate Mode and then the Alternate Offline Mode screen will be
displayed. Once in Alternate Mode, the PanelMate unit will stay in Alternate Mode until power is
cycled. Once power is cycled, the PanelMate unit will return to the operating mode it was in before
the unit entered the Alternate Mode.
Offline Mode
Initialization to the Offline Mode will display a screen which allows the following selections: Execute
Diagnostics, Enter Serial Transfer Mode, Enter Network Transfer Mode, Display
System/Configuration Information, Enter Run Mode, and Calibrate Touchscreen. The diagnostic tests
and calibration are explained in the Execute Diagnostics section in the PanelMate Power Series
Hardware Installation Guide. Refer to the PanelMate Transfer topic for more information on serial
transfer and network transfer modes.
Run Mode
The following message will be displayed:
Please wait .... entering Run Mode
At this point in the initialization, the integrity of the Executive Firmware and integrity of the User
Configuration have been verified. The proper driver is also known to be installed. The PanelMate unit
will display the Loading Status Screen while performing the initialization procedure outlined below.
The time to complete the initialization depends upon the complexity of the configuration. The
complexity of the user configuration is determined by the density of the pages, number of alarm
conditions, and the number of control bits which must be initialized in the PLC(s).
The Loading Status Screen displays the name, date, and time of the configuration being loaded, the
component that is currently being loaded, the percentage of the configuration that has been loaded,
and the percentage of the usable free memory remaining (based on the largest contiguous block).
The following steps outline the run mode initialization procedure:

1. Load System Parameters
2. Load PLC Name and Port Table
3. Load Message Library
4. Load Page Passwords/Titles
5. Load System Online Labels
6. Load Symbol Library
7. Load Normal Character Font
8. Load Graphic Character Font
9. Load Double-High Character Font
10. Load Configuration Pages
11. Create the Run Mode data base from Page Component files and verify all expressions and PLC
references
12. Allocate DRAM memory
13. Load Quad Character Font
14. Create Block Reads
15. Begin PLC communications and energize the Fault Relay

16. Control bit resets; every control bit reference in a PLC is written to zero. Also send remote bits
(Enable Fault Relay, Passwords, etc..) to PLC(s)
Note that if PLC communications are not valid, the communication retry process could be
lengthy.
To users of Generic Protocol, at this step, the PanelMate unit will prepare messages with task
code 67 for each PLC bit reference in the system configuration. At this time, the host computer
should be prepared to request the information from the PanelMate unit.
17. Send the status of the Hardware Selection (Security) Keyswitch
18. Update the Startup Page information and display
If the Startup Page is password protected, the protection will be ignored during startup.
Subsequent selections of that page will be password protected.
19. Remote send of Startup Page information to PLC
Note that if a configuration is too large to fit in the PanelMate unit, the PanelMate unit will
attempt to go online indefinitely, displaying the Loading Status screen. The Loading Status
screen states each portion of the configuration as it is being loaded. It is suggested that the
Configuration Verifier (accessed by the Verify selection in the File Menu) be executed on every
configuration before downloading to a PanelMate unit for online operation.
Run Mode Operation

The online system performs three basic tasks: Screen Updating, Alarming, and Remote Operations.
Screen Updating refers to the updating of the currently displayed page based on changes to reference
values. Alarming refers to the determination of alarm conditions and whether to display the alarms on
screen or send the alarms to a printer. Remote Operations refers to receiving or sending remote bits
such as Silence Alarm Horn or Automatic Page Change to or from the PLC. For more information on
screen updating, refer to the Refresh Graphics topic or the Conditional Visibility topic.
During the Run Mode, up to four separate scans may be occurring. All can be scanned at a user-
specified rate. The scans are Screen Scan, Alarm Scan, Message Scan, and Trend Scan.
The Screen Scan scans only for the references on the currently displayed page to provide current
status. The Alarm Scan scans for all alarm and System Parameter references, regardless of which
page is currently being scanned. The Message Scan scans for references in the Message Library and
global messages. The Trend Scan sets the time delay between updates from the PLC of all register
references defined in the trend templates while in Run Mode.
Proper Run Mode operations will only occur if a programmable controller or other intelligent device
is properly communicating with the PanelMate unit. If errors occur, see the Errors During Run
Mode topic. In Run Mode, a variety of operations will take place; some are related to the display
functions of the PanelMate unit, and some are related to the operator input functions.
Chapter 2: Online Page Layout 7
Online Page Layout
2
• About the online page layout
• How to refresh graphics
• What is conditional visibility
• The different default control buttons
Online Page Layout

The online page layout for touchscreen units is flexible. The Configuration Editor allows you to
determine the online page layout for touchscreen units when in Run Mode. When the Flexible Page
Layout field is selected in the System Parameters - General Tab dialog box, it enables you to select
or deselect the Page Status Banner, Default Buttons, Alarm Table, or Cancel Key items in the New
Configuration Page dialog box and in the Page Properties dialog box. When the Flexible Page
Layout items are selected, the items will appear on the page in Run Mode. When the Flexible Page
Layout items are deselected, the items will be removed on the page in Run Mode. Note that for each
configuration page, you may determine to keep or remove the Flexible Page Layout items.
Note the following Flexible Page Layout items:
• When the Flexible Page Layout feature is enabled and templates with button controls are selected,
the control buttons will appear on the right side of the PanelMate unit unless the selected
template is located in this area. If the selected template resides in the standard control button
area, the control buttons will appear in an area not occupied by the selected template. Be aware
that you can select the control button group and move it to a more desirable location.
• When the Flexible Page Layout feature is enabled and templates with numeric control are
selected, the numeric entry keypad will appear on the right side of the PanelMate unit unless the
selected template is located in this area. If the selected template resides in the standard numeric
entry keypad area, the numeric entry keypad will appear in an area not occupied by the selected
template. Be aware that you can select the numeric entry keypad and move it to a more desirable
location.
The online page layout for keypad units is not flexible. Keypad units will always display the Page
Status Banner, Alarm Table, Cancel Key, and Default Buttons.
The online page layout is described below.
Page Number and Page Title

The top line displays the page number and the page title of the currently displayed page. It also
displays the time of day in 24 hour format. (Note that the time will be displayed in the CANCEL key
on the touchscreen units.) Additionally, the status of the Hardware Security Keyswitch, Password A,
and Password B are displayed on the line by the letters K, A, and B respectively. The letter will be
displayed if the password is valid for operator entry.
Pages In Alarm
The second line will show only the pages in alarm. The PanelMate unit will use the First-In-First-Out
(FIFO) method to show only the most recent 10 pages in alarm. If no pages are in alarm, then no
page numbers will be displayed.
Alarm Window
This area will show the alarms you have received. The Alarm Window will display 4 alarms. If there
are more than 4 alarms, the PanelMate unit will use the First-In-First-Out (FIFO) method to show
only the latest alarms received. If there are no alarms, then the Alarm Window will be blank.
Note that if you have a touchscreen unit, control buttons will be displayed as boxes instead of arrows.
Refresh Graphics
To refresh templates, variable-sized templates, and graphics that appear on the online PanelMate unit
screen, the Refresh Affected Graphics Online field must be selected for the item you are configuring.
When the Refresh Affected Graphics Online field is selected, templates, variable-sized templates, and
graphics that lie within the area of the item being updated will be refreshed to properly reflect the
layering of objects on the page when the item is updated.
For example, the following template and object are displayed on the online PanelMate unit screen.
If the Readout Template is updated and the Refresh Affected Graphic Online field is not selected, the
screen will appear as shown below.
If the Readout Template is updated and the Refresh Affected Graphic Online field is selected, the
screen will appear as shown below.
Conditional Visibility
All templates, variable-sized templates, symbols, and text objects can be visible at all times or only
visible based on a condition. When creating a template, variable-sized template, symbol, or text
object, you have the following options:
• If the Enable Conditional Visibility field is not selected for the template, variable-sized template,
symbol, or text object you are configuring, the item will be visible at all times and all updating of
the item will be activated when in Run Mode.
• If the Enable Conditional Visibility field is selected and the Visibility Expression evaluates to be
true for the template, variable-sized template, symbol, or text object you are configuring, the item
will be displayed and all updating of the item will be activated when in Run Mode.
• If the Enable Conditional Visibility field is selected and the Visibility Expression evaluates to be
false for the template, variable-sized template, symbol, or text object you are configuring, the
item will not be displayed and all updating of the item will be deactivated when in Run Mode.
When templates, variable-sized templates, symbols, or text objects are activated or deactivated as a
result of the Visibility Expression changing, the item is drawn or erased accordingly. If you want the
layering of objects to be maintained, you must select the Refresh Affected Graphics Online field for
the item you are configuring. Refer to the Refresh Graphics topic for more information.
Note the following Conditional Visibility items:
• It is not recommended to use the Conditional Visibility feature on a Variable-Sized Control
Button on a PanelMate touchpanel unit.
• It is not recommended to use the Conditional Visibility feature on a Variable-Sized Control
Button on a PanelMate touchscreen unit or PanelMate PC unit that does not have the Direct
Select field enabled on the System Parameters – General Tab dialog box.
Default Control Buttons

The default control button labels will appear when the system powers up in Run Mode, when the
CANCEL button is pressed, when operator input is completed, or when the automatic cancel feature
takes effect.
The Silence Alarm Horn control button will always appear even if there are not any alarms.
Refer to the Fault Relay topic for more information about the fault relay. Note that the Enable Fault
Relay control button only appears for communications errors and alarms.
Refer to the View or Acknowledge Alarms topic for more information about viewing or
acknowledging alarms.
Refer to the Get Page topic for more information about getting a page.
Note that the default control buttons displayed on a PanelMate Power Series 1500 unit are Reset PLC
Comm, View or Acknowledge Alarms, and Get Page control buttons. The Enable Fault Relay control
button will be replaced by the Reset PLC Comm control button because the PanelMate Power Series
1500 does not support an external Fault Relay.
When you press the Get Page control button on a touchpanel unit, the following control buttons will
appear.
Refer to the Alarm Summary Page topic for more information about the getting the alarm page.
Refer to the Directory topic for more information about the directory.
When you press the Get Page control button on a touchscreen unit, one of the following touchscreen
keypads will appear to allow numeric entries.
Press the Switch to Two Column Keypad template or the Switch to Three Column Keypad
template on the Setup Page to switch between keypads. Refer to the Switch to Two Column Keypad or
Switch to Three Column Keypad section in the Setup Page topic for more information.
Press the More Buttons control button and the following control buttons will appear.
Refer to the Maintenance Template topic for more information about the Maintenance Template.
Note that the Maintenance Template control button only appears if a Maintenance Template is
allowed on the page.
Refer to the Change Online Labels topic for more information about the System Online Labels. Note
that the Change Online Labels control button only appears if any of the system online labels have
been changed and the user can toggle between the standard and user-defined labels.
Refer to the Host Display Window topic for more information about the Host Display Window. Note
that the Host Display Window control button only appears if selected in the System Parameters -
General Tab dialog box.
Refer to the Setup Page topic for more information about the Setup Page.
Get Page
The first page to appear when entering Run Mode will be Page 0, unless you have defined a different
start-up page when editing the Startup Page Number field in the Systems Parameters - General Tab
dialog box. From the default control button selections, select any other page by performing the
following tasks:
1. Press the Get Page control button. The control button labels will change. Press the Directory
control button to access a page title directory.
2. On the numeric keypad, press the number of the page you wish to select. (Note that if you are
entering a single-digit page number, the number must be preceded by a zero, e.g., 01.) The new
page will appear immediately. If you press the number for the page you are already on, the page
is not re-drawn. Press the CANCEL key to remain on the current page and return the control
buttons to their default labels.
PLC Page Selection

The PanelMate unit has the capability to monitor a register in the PLC and change the page shown on
the screen automatically.
The Page Change Register field (described in the Systems Parameters - Remote Tab dialog box
topic in the Configuration Editor User’s Guide) holds the register number in the PLC which is
monitored by the PanelMate unit. When a valid page number is placed in this register via PLC logic,
if a control variable-sized template or control template is not selected in the current page, that page
will be recalled to the screen.
Once control is relinquished, the page referenced in the register will be recalled.
Note that if the Allow Immediate Page Change field in the Systems Parameters - General Tab
dialog box is enabled, the page will change immediately regardless if control is selected.
Host Display Window

When using the Generic Protocol, it is possible for a host computer to send data to the PanelMate unit
for display in an extra page called the Host Display Window. Refer to the Generic Protocol Driver
Manual for further information about this feature. If the host has sent data to the Host Display
Window, the left end of the Page Banner will be blinking.
Directory
A directory of the page titles is automatically created by the PanelMate unit as you configure your
system. If you need to refer to this list of page titles while in Run Mode, press the Get Page control
button from the default control button selections. The control button labels will immediately change.
Press Directory control button to view the directory.
To exit from the directory, press any page number or the CANCEL key.
Some online units may have up to 100 pages available for configuration.
Chapter 3: Operator Input 15
Operator Input
3
• The options for operator input
Operator Input
Operator input may be one-touch (optional) or two-touch depending upon your equipment and your
configuration.
One-Touch Selection of Variable-Sized Templates

One-touch selection is available only when:
• You are operating a touchscreen unit
• You have selected Direct Select on the System Parameters - General Tab dialog box.
With one-touch selection, a template is selected immediately when you touch it. If the template
requires control button input, the corresponding control button labels appear when the template is
selected. If no selection is wanted, press the CANCEL key.
Two-Touch Selection of Variable-Sized Templates

Two-touch selection is required for TouchPanel units, or for touchscreen units when Direct Select is
not checked on the Systems Parameters - General Tab dialog box. Two-touch operation requires at
least two keystrokes. Any template or variable-sized template that displays a small arrow in the lower
left-hand corner of the template can be controlled by the operator.
Selecting a Template
Before any change can be made to a template, that template must be selected. To select a template,
press the TouchPanel to move the white box cursor to the location of the template on the screen.
If the template requires control button input, the corresponding control button labels appear when the
template is selected. Press the appropriate control button.
If the wrong template is selected before the control button is pressed, simply use the selection keypad
to make the right choice. If no selection is wanted, press the CANCEL key.
Control Button Operation

The PanelMate unit’s control buttons provide the following functions.
• Normally Open, Momentary - PLC bit is set to 1 when the control button is pressed, then 0 when
the control button is released.
• Normally Open, Maintained - PLC bit is set to 1 when the control button is pressed.
• Normally Close, Momentary - PLC bit is set to 0 when the control button is pressed, then 1 when
the control button is released.
• Normally Close, Maintained - PLC bit is set to 0 when the control button is pressed.
• Toggle - PLC bit is set to the inverse of it’s last state when the control button is pressed.
• Page Change - A new page is presented when the control button is pressed.
Chapter 3: Operator Input 17
When the control button is pressed, the PanelMate unit sends the appropriate command to the PLC or
changes the page.
If a template requires numeric keypad input, the Change Value control button will appear when the
template is selected. The control button labels will immediately change to read Clear and Enter New
Value. Use the numeric keys to write the value onto the screen, then press the Enter New Value
control button to transmit the value to the PLC. If the wrong number is written before the control
button is pressed, simply press the Clear control button and try again. If no selection is wanted, press
the CANCEL key.
When variable-sized templates or graphics are used, a given template cell area may contain more than
one control point. When the membrane is initially touched, the first control point that lies within the
indicated template cell area is selected, and is identified by its flashing control indicator. If this is not
the desired control point, a subsequent pressing of the same membrane will step to the next variable-
sized template in a top-to-bottom, left-to-right search pattern within the cell area. The selection
process will cycle and recycle through all the variable-sized templates with controls lying within the
selected cell area.
Chapter 4: Alarms 19
Alarms
4
In this chapter you will learn:
• The features of an alarm
• About the Alarm Summary Page
• How to view or acknowledge alarms
Alarms
The alarm conditions that you designate in the PanelMate unit’s template editors are constantly
monitored. When an alarm condition occurs, an alarm message is automatically configured by the
PanelMate unit and printed in the 4-line alarm window. The same message will also go to a printer if
you have configured a printer in the PLC Name and Port Table dialog box.
Alarm conditions can be selected for audible alarming. The Alarm Horn can be silenced two different
ways. The Alarm Horn can be silenced by pressing the Silence Alarm Horn control button from the
default control button selection. The Alarm Horn can also be silenced remotely by setting a bit in the
PLC. See Systems Parameters - Remote Tab topic in the Configuration Editor’s User Guide for
more information on configuring the Remote Silence Alarm Bit. The PanelMate unit can also set a bit
in the PLC when the Silence Alarm Horn control button is pressed. This can allow one operator to
silence all Alarm Horns on all the PanelMate units on a network.
The alarm message always includes:
• the device name or alarm device name
• the nature of the alarm (high alarm, low alarm, or the alarm condition label)
• the time of the event being reported
• the page the device is displayed on in the PanelMate unit
Additionally, the following attributes also apply to alarm messages, depending on the condition being
reported:
New alarms If you have a grayscale PanelMate unit, the alarms are displayed as
no intensity text on high intensity background. If you have a color
PanelMate unit, the alarms are displayed as white text on a red
background.
Acknowledged If you have a grayscale PanelMate unit, the alarms are displayed as
no intensity text on a medium intensity background. If you have a
color PanelMate unit, the alarms are displayed as yellow text on a
black background. The abbreviation “Ackd” will appear in the
message in front of the time.
Cleared, not acknowledged If you have a grayscale PanelMate unit, the alarms are displayed as
high intensity text on a no intensity background. If you have a color
PanelMate unit, the alarms are displayed as red text on a white
background. The abbreviation “Clrd” will appear in the message in
front of the time.
Cleared and Acknowledged The message will disappear from the screen. The message that gets
sent to the printer will include the abbreviation “Clrd” in front of the
time.
The four most recent alarm messages appear in the alarm window of the current page.
Chapter 4: Alarms 21
Alarm Summary Page

The Alarm Summary Page is automatically created by the PanelMate unit as alarm conditions occur.
In the PanelMate unit, the 100 most current alarm messages can be viewed on the Alarm Summary
Page at any time. As new alarms occur, the oldest alarms will be removed. For example, if 100 alarms
have occurred and then one more occurs, the oldest alarm will be removed and the new alarm will be
added to the beginning of the Alarm Summary Page. The page indicator for the page which contains
the removed alarm will still blink until the alarm condition has been cleared.
To get to the Alarm Summary Page, press the Get Alarm Page control button from the default
control button selections. The Alarm Summary Page will appear immediately, displaying the most
current 26 alarm messages. If there are no alarm messages to display, the page will be blank.
To view the alarms beyond the most current 26, use the Scroll Up and Scroll Down control buttons.
These buttons move a small, white block cursor that marks the start of a specific alarm message.
When the block cursor is scrolled down past the last message on the screen, the messages beyond 26
appear. This block cursor is also used to mark individual alarm messages for acknowledgment.
To return to any other page in the system, press the Get Page control button and enter the page
number using the numeric keypad.
View or Acknowledge Alarms

To acknowledge alarms in the alarm window located on each page, press the View or Acknowledge
Alarms control button from the default control button selections. The control buttons will
immediately change and a small, white block cursor will mark the most current alarm, located at the
top of the alarm window.
To acknowledge alarms in the Alarm Summary Page, press the View or Acknowledge Alarms
control button. The control buttons will immediately change and a small, white block cursor will
mark the most current alarm, located at the top of the page.
These control button labels will appear:
Chapter 5: Password Protection 23
Password Protection
5
• About password protection
Password Protection
Passwords can be used to restrict access to certain functionality when the PanelMate unit is in the
Run Mode. The PanelMate unit supports multiple levels of password protection. A great deal of
flexibility is provided so it is important to define an implementation scheme before configuring your
passwords. There are three levels of protection: Password A, Password B, and the Keyswitch.
Passwords A and B are configured in the System Parameters - Password Tab dialog box.
(Passwords can be enabled or disabled to permit or prohibit change during online operation.) A
security keyswitch can be attached to a removable terminal block to provide another level of
protection.
Although you may enter a password of up to 8 characters in the System Parameters – Password Tab
dialog box, the allowable range for passwords in Run Mode is 0 to 65535.
PanelMate Power Series 1500 does not support the security keyswitch.
Note that leading zeroes are not supported when configuring Password A and Password B in the
System Parameters - Password Tab dialog box.
Passwords can be used in the following areas in the Run Mode and must be enabled for entry each
time they are selected.
Templates with Numeric Entry selected:
Readout Template
Variable-Sized Readout Template
Bar Template
Variable-Sized Bar Template
Table Template
Enter Offline Mode
Maintenance Template
Set Date and Time
The following combinations of Password Protection are available:
• None
• Keyswitch Only
• Keyswitch and Password A
• Keyswitch and Password B
• Keyswitch and Password A or B
• Password A Only
• Password B Only
• Password A or B
Password protection can also be invoked to protect access on a Page-by-Page basis. Once a Page
Password is logged-in, then access to a page remains active until it is logged-out. While logged-in,
the operator can change pages and return to this page until logged-out. Password A and B can be
logged-out manually or a user-defined time period can expire which will log-out all passwords. If the
time-out occurs, the operator retains access to the current page.
Chapter 5: Password Protection 25
Page Passwords are accessed in the Setup Page. This page is accessed from the default page by
selecting the Get Page, More Buttons and Setup Page control buttons. The letters K, A, and B will
appear to the left of the time of day clock on the top line of each page to indicate when the Keyswitch,
Password A, and Password B are enabled for entry. The status of the passwords and security
keyswitch, when used as Page Passwords, may be transmitted to a PLC by setting the appropriate
address in the System Parameters - Password Tab dialog box. This feature can be useful when
implementing the Page Protection concept when a Page Change is sent from a PLC.
The security keyswitch is an option which may be ordered as a spare part from the Cutler-Hammer
Customer Service Department. The terminals on the PanelMate unit require contact closure to enable
entry. Multiple key switches, PLC relay contact outputs, and hard contact outputs from other devices,
such a magnetic strip badge readers, may be used in combination to create the contact closure signal.
Note that a security keyswitch cannot be connected to the PanelMate Power Series 1500.
Passwords A and B are downloaded within the User Configuration to the PanelMate unit. These
values may be used at system start-up or they may be defined to overwrite current passwords which
reside in the system.
Password Protection can be implemented in many ways. Examples of usage are defined below:
• Offline Mode protected with Keyswitch and Password A
• Set Date and Time protected with Keyswitch and Password B
• Page 9, the machine parameter page, protected with Keyswitch
• Reset Part Counter Readout Template protected with Password A
• Operating Temperature Setpoint Readout Template protected with Password B
Lost Password Recovery

It is not possible to determine the passwords in an online unit, however, it is possible to recover if a
password is lost. There are two techniques which may be used.
If the User Configuration had the Overwrite Password fields selected, you can simply use the Transfer
Utility to upload the configuration from the PanelMate unit to a personal computer and then
download it to the PanelMate unit. This will cause the system to revert to the original passwords
which were set in the configuration. If the Offline Mode selection is password protected, you must
remove the Electronics Module Assembly from the front panel to automatically invoke the transfer
mode.
If the User Configuration does not have the Overwrite Password fields selected, you must use the
Configuration Software to upload the configuration. Next, modify the configuration and select the
Overwrite Password fields and enter the new passwords. Finally, download the new configuration to
the PanelMate unit.
Chapter 6: Setup Page 27
Setup Page
6
• The features available on the setup page
Setup Page
The Setup Page is accessed from the default control buttons. The Setup Page provides selection of the
following features while the online unit remains in the Run Mode.
To access a feature, select a template then press the Execute control button.
Note that if you have a PanelMate Power Series 1500, the Setup Page will display a Reset PLC
Comm control button instead of an Enable Fault Relay control button. The Reset PLC Comm
control button will reset communication errors if the reason for the error no longer exists.
Change Password A or Change Password B

This selection permits you to change a software password. You will be prompted to Enter the Old
Password, Enter the New Password, then Re-enter the New Password. If the ability to change the
passwords in the online mode is not desired, do not enable the Allow Password A Change field or the
Allow Password B Change field in the System Parameters - Password Tab dialog box.
Log-in Password A and Log-in Password B

These selections permit you to Log-in a valid page password. The password remains enabled until you
Log-out or the Page Password Time-out period expires.
Refer to the Password A and Password B sections in the Systems Parameters - Password Tab dialog
box topic for information on configuring passwords.
Set Date and Time

This selection permits you to enter the Set Date or Set Time field. Use the numeric keypad to enter
the appropriate value. Use the minus key to separate numeric values. Note that the time is entered in
24-hour (military) format. This selection can be password protected.
Chapter 6: Setup Page 29
Log-out Password A and Log-out Password B

These selections permit you to Log-out of a page password by pressing the Execute control button.
The Log-out Password A template or Log-out Password B template will only appear on the Setup
Page if you have logged-in password A or password B.
Display System/Configuration Information

This selection will display the current User Configuration, Executive Firmware, and Installed
Drivers.
Enter Offline Mode

This selection will remove the online unit from the Run Mode and place it in the Offline Mode. The
Offline Mode permits access to the following: Execute Diagnostics, Enter Transfer Mode, Display
System/Configuration Information, or Enter Run Mode. This entry may be password protected.
Cleaning Mode
This selection will allow you to clean your touchscreen.
The Cleaning Mode template will only appear in the Setup Page if you have a touchscreen unit.
Calibrate Touchscreen
This selection will allow you to calibrate your touchscreen.
The Calibrate Touchscreen template will only appear in the Setup Page if you have a touchscreen
unit.
Adjust Contrast
This selection will allow you to adjust the contrast.
The Adjust Contrast template will only appear in the Setup Page if you have a dual-scan or grayscale
LCD display.
Switch to Two Column Keypad or Switch to Three Column Keypad

This selection switches between the two-column and three column numeric entry keypads.
The Switch to Two Column Keypad template or Switch to Three Column Keypad template will only
appear in the Setup Page if you have a touchscreen unit.
For more information about the two column or three column keypads, refer to the Default Control
Buttons topic.
Chapter 7: Fault Relay 31
Fault Relay
7
• About the fault relay
Fault Relay
The fault relay is a relay contact output with normally open and normally closed contacts. At power
up, the PanelMate unit performs system diagnostics. If diagnostics are passed, the fault relay is
energized (enabled). The unit begins communications to PLCs. Four events can cause the fault relay
to de-energize: online system error, communication error, alarm (if this feature is selected), and loss
of power.
Note that the PanelMate Power Series 1500 does not support an external Fault Relay.
Fault Relay and Online System Errors

Proper operation of the system is monitored to ensure that all internal processes are active and
functioning normally. If a system error is detected, the fault relay is de-energized, the system is halted
and an error message is displayed at the bottom of the screen. Refer to the Errors During Run Mode
topic for more details.
Fault Relay and Communication Errors

Integrity of the communication link to the PLC (or Host Computer) is monitored by ensuring that
proper responses are received for each transmission that the PanelMate unit makes. If a
communication attempt fails, the PanelMate unit will re-transmit a request several times before
reporting a communication error. When a communication error is detected, the fault relay is de-
energized and an error message is displayed at the bottom of the screen. Communications with
operational PLCs will continue.
When a communication error exists, the continual re-transmission of messages may begin to slow
system response. Every PLC write transmission is sent, then re-tried and then discarded. The
frequency of the re-transmission gradually decreases to five minutes if requests continue to fail over a
prolonged period of time. This feature effectively prevents failing requests from slowing network
communications. If the operator inputs control buttons faster than the transmission rate of the
network during communication errors, the PanelMate unit will buffer PLC writes in order to ensure
that all control commands are processed. When the communication error clears, the buffered control
button writes will be sent in rapid succession.
Warning
If blank templates appear on the screen, a communication error has occurred. The operator should not
attempt to perform control with blank templates as this may cause control buttons to be buffered in
the PanelMate unit. Buffered control buttons may be sent in rapid succession when the
communication error clears and may result in undesirable control system operation.
The System Parameters – Communications Tab dialog box permits the selection of setting all
referenced control button bits to zero (or one for Variable-Sized Control Buttons configured as
Normally Closed, Momentary) when the Enable Fault Relay control button is pressed or when a
Remote Enable Fault Relay Bit reference is triggered by the PLC. To reset all control button bits, the
Bit Zero After Comm Fault field in the System Parameters – Communication Tab dialog box must
be selected. To configure a Remote Enable Fault Relay Bit, the Remote Enable Fault Relay Bit field
must be configured in the System Parameters – Remote Tab dialog box. Refer to the System
Parameters – Communications Tab dialog box or the System Parameters – Remote Tab dialog
box in the Configuration Editor User’s Guide for more information.
Chapter 7: Fault Relay 33
The data at the time of a communication failure will remain on the current page. All data from other
PLCs which are communicating correctly will be displayed as usual. If the communication error
continues to exist and you select a different page, then no data from the PLC with errors will be
shown on the newly selected page. For example, if the page contains a readout template, no numerical
data from the PLC with the communication errors will be shown. Once the communication problem is
corrected and the Enable Fault Relay control button is pressed or the Remote Enable Fault Relay Bit
reference is triggered by the PLC, the fault relay will be energized and the page will be re-drawn. Any
references to a PLC which are not communicating will not be re-drawn until valid communications
have resumed. If the communication error still exists, the fault relay will be de-energized and a
communication error message will be displayed on the bottom line of the screen.
Note that pressing the Enable Fault Relay control button or triggering the Remote Enable Fault
Relay Bit reference may still cause invalid information to be displayed. For example, if an expression
for a bar template value contains a reference to a PLC which is communicating and also to a PLC
which is not communicating, the bar will be updated on the screen even though invalid data may
appear on the screen.
When communications have been re-established, the relay remains de-energized until the operator
presses the Enable Fault Relay control button or a Remote Enable Fault Relay Bit reference is
triggered by a PLC.
Fault Relay and Alarms

The Fault Relay De-energize on Alarm field in the Systems Parameters – Communications Tab
dialog box allows the Fault Relay to de-energize when an alarm occurs. If the Fault Relay De-
energize on Alarm field is selected, the fault relay will be de-energized when an alarm condition is
detected. If the Fault Relay De-energize on Alarm field is not selected, the fault relay will not be
associated with alarming. Refer to the System Parameters – Communications Tab dialog box in the
Configuration Editor User’s Guide for more information.
Fault Relay and Loss of Power

A loss of power will cause the fault relay to de-energize. If the online system was in the Run Mode
before the loss of power and power is restored, it will return to the Run Mode.
Chapter 8: Maintenance Template 35
8
• About the Maintenance Template
In order to use the Maintenance Template online, you must configure the Allow on Page selection in
the New Configuration Page dialog box or in the Page Properties dialog box within the
Configuration Editor.
It is important to note that when in Run Mode, do not place Maintenance Templates in an area of the
screen where invisible templates are located. If an invisible template becomes visible, it will draw on
top of the Maintenance Template. The Maintenance Template will not be able to be selected for de-
activation until the object obscuring that template becomes invisible. It is recommended that on pages
which use the template visibility and allow Maintenance Template selection, an area of the page be
reserved for placement of the Maintenance Template.
To access the Maintenance Template online, you must press the Get Page control button from the
default control buttons online, press the More Buttons control button (More on a touchscreen unit),
and then press the Maintenance Template control button. The Maintenance Template selection
cursor will appear in the upper left corner. You can place the Maintenance Template on any cell
including cells already occupied by a fixed template or another Maintenance Template. You cannot
place a Maintenance Template on top of a variable-sized template.
Note that the Maintenance Template will not appear on your page until you press the Activate control
button. (The default PLC Name will appear in the Maintenance Template.) If you press the
Deactivate control button, the Maintenance Template will be removed from your page.
Once the Maintenance Template is activated, press the CANCEL key and re-select the Maintenance
Template. The Deactivate and Modify Template control buttons will appear.
Note that when selecting a template cell to place a Maintenance Template, static values will be
displayed in the template’s value fields if the PanelMate unit is not communicating to the PLC.
Start Monitor
This control button label will toggle between Start Monitor and Stop Monitor. With this control
button, it is possible to freeze a value for prolonged observation.
When you press the Start Monitor control button and the Enable Writes field in the New
Configuration Page dialog box is configured on the page and the Maintenance Template is
configured with a valid reference, the Change Value control button will also appear.
Note that if the double high font is redefined, the Maintenance Template will be blank for numeric
and hex display formats unless the characters have been redefined. If the characters have been
redefined, then the redefined characters will be displayed.
Deactivate
This control button will delete the Maintenance Template from the page.
Change Value
This control button will be displayed only if the Enable Writes field in the New Configuration dialog
box or the Page Properties dialog box was configured for the page. This control button will change
the display and open a data entry field to permit the operator to enter a value. If Password Protection
has been configured in the New Configuration dialog box or the Page Properties dialog box for the
pages that contain Maintenance Templates, the operator will be prompted before data entry is
permitted.
Modify Template
This control button is used to change the configuration of the Maintenance Template. This control
button will change the display and call three control buttons. The control buttons are Change PLC
Name, Change PLC Ref, and Data Format. The operator may change one or all of the three entry
variables (name, reference, format). When the Maintenance Template is configured with a valid
reference, the Start Monitor control button will appear. Once you are satisfied with the changes, you
must press the Start Monitor control button. This will advise the PanelMate unit to check the name,
reference, and format to determine if they are valid, and if valid, begin to read that information.
If the reference is invalid, an error will be displayed on the error line on the bottom of the page and
the reference will be cleared.
Change PLC Name

The online selection of the PLC Name occurs in the Change PLC Name control button. The default
PLC Name will be displayed in the data entry field. Use the Previous or Next control buttons to scroll
through the list of names entered in the PLC Name and Port Table dialog box.
Once you press the Change PLC Name control buttons, three buttons will appear labeled Previous,
Next, and Accept.
Change PLC Ref

The online selection of the PLC Register Reference occurs in the reference field of the template. The
operator must know the correct alpha and numeric characters to enter to access the memory of the
PLC to which it is communicating. See your Communications Driver Manual for more information. If
the PLC brand uses numbers only, the numeric keypad may be used to enter the address. If the PLC
brand requires characters other than numeric, then the Previous, Next, and Clear buttons will serve a
special purpose. The Previous and Next button are used to determine the operation of the Clear
button which becomes a “Hot Key” . The functionality of the Hot Key can be changed by using the
buttons labeled Previous and Next. The Hot Key can assume the following functionality:
Keypad Touchscreen
Hot Keys Hot Keys Description
Cursor Right >> Move the entry cursor one character right.
Cursor Left << Move the entry cursor one character left.
Delete DEL Delete the character at the current cursor position.
Space SPACE Place a blank space at the current cursor position.
Clear CLEAR Clear the entire entry field.
Select SEL Enters the mode to select alpha character strings.
Upon entering the Change PLC Reference mode, the Hot Key labeled “Clear” will be displayed.
Selecting the Previous button will change the Hot Key to Space, while selecting the Next button will
change the Hot Key to Select.
Upon entering the Select mode, the first of a list of alpha characters for the currently selected PLC
Name will be displayed in the data entry field. Selecting the Next button will move deeper into the
alpha character list while selecting Previous button would take you back to Clear. Once in the Select
mode, the Previous and Next keys will scroll through the alpha character strings that are required to
address the PLC brand associated with the PLC Name currently selected. Once the correct character
string is displayed, you may press the Select Hot Key to lock in that character. Alternately, you may
press a numeric key which will lock in the alpha key and enter a number. Pressing the numeric key
will reduce the number of keystrokes and permit faster entry. Do not press the Accept button until the
entire address is entered or an error may occur.
The operator uses a combination of Hot Key entry and numeric entry to enter the address for the PLC.
The Hot Key may also be used to edit an existing address without requiring complete re-entry of the
address. Refer to the Maintenance Template Examples for more information.
Maintenance Template Examples

Example 1: Entering a new address.
To enter the Allen-Bradley Reference N7:10
Select the Maintenance Template.
Press the Modify Template control button.
Press the Change PLC Ref control button.
Press the Next button. This will place the Hot Key in the Select mode.
Press the Next button until an N appears in the entry field.
Press <7>. Use the numeric keypad.
Press the Next button until the colon, : , appears in the entry field.
Press <1>, then press <0> to enter 10. Use the numeric keyboard.
Press the Accept button to enter the address.
As a final step, press the top Start Monitor control button to begin reading that address.
Example 2: Editing an existing field.

To change the Allen-Bradley Reference N7:10 to N7:20
Select the Maintenance Template
Press the Modify Template control button.
Press the Change PLC Ref control button. The cursor will appear at the far right of the
entry field.
Press the Previous button. This will place the Hot Key in the Space mode.
Press the Previous button. This will place the Hot Key in the Delete mode.
Press the Previous button. This will place the Hot Key in the Cursor Left mode.
Press the Cursor Left Hot Key. The Hot Key moves the cursor from the far right onto the 0.
Press the Cursor Left Hot Key. The Hot Key moves the cursor from the 0 onto the 1.
Press <2>. Use the numeric keypad. The overstrike replaces the 1. The value now reads
N7:20.
Press the Accept button to enter the address.
As a final step, press the top Start Monitor control button to begin reading that address.
Data Format
The register can be formatted to display in one of the following selections: NUM, BITS, or HEX.
• If NUM is selected, the data will display in a numeric format. The PanelMate unit will
automatically type cast information based upon the memory area of the PLC which is read. This
means it will manage integer, BCD, and binary data types and display them as numbers. Numeric
entries will be converted to the correct data type and sent to the PLC if the Enable Writes field is
configured in the New Configuration Page dialog box or in the Page Properties dialog box.
• If BITS is selected, the data is entered and will be displayed in a binary bit pattern for the register
selected. If the PLC word contains 16 bits, then the display will show two 8 bit bytes. The
sequence is high byte above low byte and high bit to the left, low bit to the right. The bit values
will not be manipulated to any data format. The operator accepts responsibility for entering a
legal bit combination. (For example, writing 1111 to a BCD digit is an illegal value.)
• If HEX is selected, the data is entered and will be displayed in hexadecimal format (0-9 and A-F)
of the bit pattern for the register selected.
Sixteen bit values are displayed in four-digit HEX representation.
Example: 0023 HEX is written to the PLC as 0000 0000 0010 0011.
It is not converted to 35 decimal or 0000 0000 0100 0101 in binary.
Only NUM types are converted to the numeric value based upon the memory areas of the PLC
referenced.
The figure below shows an example of a 16-bit word in a Maintenance Template with the Bits format
selected.
The Maintenance Template does not support 32-bit registers (i.e., #S32, #U32, #BIN6, #BIN8,
#BCD8, #BCD6, and #FP).
The Maintenance Template does not support unsoliciteds.
Chapter 9: Errors 41
Errors
9
• About Remote I/O errors
• About errors during Run Mode
• About communication errors
• About system errors
• About error codes
Remote I/O Errors

Warning
If communication errors occur on the remote I/O link, control bit write information entered in the
PanelMate unit may cause control bits to be sent to the AcceleratI/On board memory and not
transmitted to the PLC. When the Remote I/O link is re-established all of the new control bit
information is sent to the PLC. Buffered control bit information will be sent when the communication
error clears and may result in undesirable control system operation.
Errors during Run Mode

During Run Mode operation three basic conditions are checked:
• proper communications with PLC or host computer
• proper operation of the microprocessor
• proper operation of the Executive Firmware
If there is a PLC or host computer problem, the error is classified as a Communication Error. The two
types of Communication Errors are local errors and remote errors.
If there is a microprocessor or Executive Firmware problem, the error is classified as a System Error.
Refer to the Error Codes topic for a list of error codes and their descriptions.
Note that you can also receive remote I/O errors.
Communication Errors
The PanelMate unit can interface with a single PLC or with multiple PLCs. It provides predictable
fault responses with the occurrence of communication errors which indicate a breakdown in
communication between the PanelMate unit and a PLC. It is the Control System Designer’s
responsibility to define how the operator should respond to an error.
The PanelMate unit provides two indications when a communication error occurs: an error message is
written to the bottom of the screen and the fault relay is de-energized. The fault relay is provided for
both local annunciation to an operator and to send hardwired feedback to a PLC.
Once a communication error occurs, the operator should first note the page status. The data is a
snapshot in time of the last valid communication. The next action is to try to clear the error by
pressing the Enable Fault Relay control button or triggering the Remote Enable Fault Relay Bit
reference. This energizes the fault relay and attempts to restart communications. If the condition
causing the error no longer exists, the screen is updated with dynamic information. If the error
remains, the fault relay is de-energized again and the communication error message is written to the
screen. If values could not be read due to the lack of communications, then templates will be
displayed as blank.
Warning
If blank templates appear on the screen, it means that communications have not been re-established.
The operator should not attempt to perform control with blank templates because the actual state of
the machine or process cannot be determined. If the operator continues to press control buttons, data
may be sent faster than the communication link which is in error can handle them. The PanelMate
unit will buffer the control requests until communications have re-established. This may result in
control bits being sent to a PLC in rapid succession which may cause undesirable operation of the
control system.
Communication errors can be cleared by pressing the Enable Fault Relay control button, triggering
the Remote Enable Fault Relay Bit reference, or changing pages, provided the reason for the error no
longer exists. Integrity of the communication link to the PLC (or host) is monitored by ensuring that
proper responses are received for each transmission that the PanelMate unit makes, according to the
specific protocol in use.
Communication problems can include:
• Broken or incorrect cabling to the PLC
• PLC or interface card failure
• Incorrect setting of PLC interface card switches
• Removal of a PLC from the active network
• Attempt to access a non-existent PLC address
• Attempt to write to a protected PLC address
• Too much traffic on a PLC network
The PanelMate unit will try to re-transmit a request several times before reporting that a
communications error has occurred. Unlike Systems Errors, Communication Errors do not halt the
system. The PanelMate unit continues to re-transmit requests indefinitely, even after an error has
been reported.
The frequency of the re-transmission gradually decreases to five minutes if requests continue to fail
over a prolonged period of time. This feature effectively prevents failing requests from conflicting
with other communications.
Local Errors
Local errors are reported on the bottom of the screen as follows:
where
X is an internally generated communication error code which indicates the nature of
the problem. Refer to the Error Codes topic for a list of error codes and their
descriptions.
N is the PLC name in the PLC Name and Port Table
P is the port
O is the operation being performed
R is the reference
Remote Errors
Remote errors are reported on the bottom of the screen as follows:
where
X is a generated communication error code from a remote device. Refer to your PLC
user manual for more information on this error code.
N is the PLC name in the PLC Name and Port Table
P is the port
R is the reference
If you are using Allen-Bradley PLCs for Data Highway or Data Highway Plus, a complete set of error
codes can be found in the Allen-Bradley Publication 1770-6.5.16, November 1991. Take note of the
hexadecimal error code and consult the Allen-Bradley publication. If the remote error code is F0XX
(hex), then the XX represents the Allen-Bradley EXT STS (extended status) error code. The EXT
STS codes are found in the EXT STS Codes for Command Code 0F (hex) table. Other remote error
codes are found in the Remote STS Error Codes table.
When a communication error is reported, the fault relay is de-energized, but the system continues to
operate. Other PLC transmissions will be attempted and processed. Transmissions which have failed
will be re-attempted until normal communication is re-established. Each time the error is detected,
the message will be reprinted at the bottom of the screen (and the relay will be de-energized). The
data at the time of a communication failure will remain on the current page. If a different page is
selected, no data from the PLC with errors will be shown. For example, if the page contains a readout
template, no numerical data from the PLC with the communication errors will be shown. The
numerical area will be blank. All data from other PLCs which are operating correctly, will be
displayed as usual. Once the communications problem is corrected and the Enable Fault Relay
control button is pressed or the Remote Enable Fault Relay Bit reference is triggered by the PLC, the
page will be re-drawn. Any templates or Variable-Sized Templates which reference a PLC which is
not communicating will not be re-drawn until valid communications has resumed.
When the error is corrected, the relay remains de-energized until the operator presses the Enable
Fault Relay control button or the Remote Enable Fault Relay Bit reference is triggered by the PLC,
which appears on the default selections when a communications error occurs. This also clears the
message from the bottom of the screen. (The button label disappears once the button has been
pressed.)
Note that invalid information may still be displayed. For example, if an expression for a Variable-
Sized Bar Template value contains a reference to PLC which is communicating and also contains a
reference to a PLC which is not communicating, the Variable-Sized Bar Template will be updated on
the screen, even though invalid data may be in the data base.
System Errors
During Run Mode operation, two basic conditions are checked in the PanelMate unit: proper
operation of the CPU and proper operation of the system software.
Proper operation of the microprocessor is monitored by a Watchdog Timer. If a microprocessor error
is detected, the fault relay is de-energized, the screen will display “Watchdog Time-out. Press Cancel
Key to Continue” , and the system is halted.
One possible reason for the Watchdog Time-out error could be related to the power. Check to make
sure that the PanelMate unit is properly installed. If problems still occur, call your local distributor for
more information.
Proper operation of system software is monitored to ensure that all internal processes are active and
functioning normally. If a system software error is detected, the fault relay is de-energized, and the
system is halted.
An error message is displayed at the bottom of the screen:
where
X a system error code which indicates the nature of the problem. Refer to the Error
Codes topic for a list of the error codes and their descriptions.
P is an internal error code. This error code may appear more than one time.
Note that if these error messages appear, please call your local distributor.
Error Codes
Error
Number Description Possible Cause
0 Undefined error.
1 Software module not found or
corrupted.
2 Out of memory.
201 Bad or missing communication card.
244-246 Read/write error. Cabling wrong.
RS232/RS422 converter bad or missing.
Excessive noise on communication line.
253 Acknowledge not received from the No communication.
remote device or remote device did PLC busy.
not reply to request in allotted Invalid network ID.
amount of time. Wrong communication parameter.
PanelMate unit may be receiving too many
unsolicited messages.
1000 Internal system error code. Invalid configuration.
Bad PLC Name and Port Table.
1001 Serial port buffer overrun. PLC locked in transmit mode.
PLC transmitting too much data.
1002 Error on input. Wrong communication parameters.
Intermittent hardware failure.
1003 Error on output. Wrong communication parameters.
Intermittent hardware failure.
1100 Device descriptor cannot be Out of memory.
generated.
Module not found.
1101 Device cannot be opened. Missing module.
Serial controller or I/O board bad.
Missing or bad hardware.
Interface board not installed.
1102 Expected data was not received. Communication established. The PanelMate
unit started reading data but timed out.
Error 1102 is usually followed by a 1202 or
1702 error.
Error
1103 Support process cannot start. Out of memory.

Module corrupted.
Module not found.
1104 Device cannot be opened. Missing module.
Serial controller or I/O board bad.
Missing or bad hardware.
Interface board not installed.
1125 Framing error. Wrong communication parameters.
1126 Parity error. Wrong parity.
1127 Overrun error. Wrong communication parameters, no
communication.
1128 Hardware break. Grounding, shield, or termination problem.
1150 Data Highway, Data Highway Plus,
and AcceleratI/On error - the
AcceleratI/On card has detected an
error during its memory diagnostics.
1151 Data Highway, Data Highway Plus,
AcceleratI/On card would not restart.
1151 DH-485 - destination buffer not big
enough to receive message
1152 DH-485 - message too big to
transmit.
1153 Data Highway, Data Highway Plus, AcceleratI/On card receiving unsolicited data
and AcceleratI/On error - the (MSG’s) too fast.
AcceleratI/On card has no transmit
buffers available.
1153 DH-485 - received NAK from Normally received if destination has too many
destination. outstanding requests.
1154 Data Highway, Data Highway Plus, AcceleratI/On card hardware failure.
AcceleratI/On card would not
respond to the interface software’s
command.
1154 DH-485 - time-out no response from Invalid ID or PLC type.
destination after 3 retries.
1155 DH-485 - duplicate node detected. Two devices on highway have same network
ID (node #).
Error
1156 DH-485 - data link is not active (link Missing or bad cable
time-out) PanelMate unit is not Noise on communication line.
passing token.
1157 DH-485 - application time-out
(destination active but not
responding).
1158 DH-485 - The PanelMate unit has Network communications disrupted. The
not received token from previous cable was disconnected from the PanelMate
node. unit or the previous node has dropped off the
network.
Error 1158 is usually followed by an 1156
error.
1200 Communication active but remote Noise on communication line.
device responded with negative Wrong parity.
acknowledge (NAK).
1201 Communication active but remote Noise on communication line.
device responded with negative Wrong parity.
acknowledge (NAK).
remote device or remote device did PLC is busy.
The PanelMate unit may be receiving too
many unsolicited messages.
This error is driver dependent.
1203 PanelMate unit cannot set privilege Communication error while trying to set
level in GE PLC (SNP). privilege.
Other device has set privilege.
1250 Could not establish link with Square
D PLC.
1250 Could not synchronize with
Westinghouse PLC.
1250 Reliance AutoMate Gateway not No communication.
configured. PLC is busy.
Invalid network ID.
The PanelMate unit unsuccessfully trying to
reconfigure Reliance gateway module.
Dipswitches configured wrong.
Power loss to gateway module.
Intermittent error.
1250 Channel prematurely closed by GE The PanelMate unit too busy to close channel.
CCM.
Error
1250 Communication to GE with SNP out The PanelMate unit too busy to accept reply.
of sync. Noise or cable problems
1251 Open Channel request was refused GE CCM card is too busy to open channel.
by GE CCM. Noise on communication line to GE.
Wrong parity.
1251 Reliance AutoMate processor not
found in destination slot.
1251 PanelMate unit cannot set privilege Communication error while trying to set
level in GE PLC (SNP). privilege.
Other device has set privilege.
1252 More than one Reliance AutoMate
processor in the rack.
1700 Communications out of sync. Duplicate token, noise, or busy device causes
PanelMate unit to time-out and PLC responds
to previous request.
1701 A reply was received for which there Scan delays too large.
was no request issued.
remote device or remote device did PLC busy.
The PanelMate unit may be receiving too
many unsolicited messages.
This error is driver dependent.
If using unsolicited messages over Data
Highway or Data Highway Plus, check the
part number of the EPROM on your Allen-
Bradley AcceleratI/O board. The EPROM
needs to be upgraded to revision 06
(P/N 85-00285-06).
1703 Internal system error code.
1705 This interface does not support any
unsolicited requests from a remote
device.
1706 Received an unsolicited command
that is not supported.
1707 The remote device memory type is
not supported.
1708 Cannot write to read only reference.
1750 Siemens follow-on telegrams are not PLC sending too much data.
supported.
Error
1750 Block transfer not detected on

remote I/O.
1750 Data Highway and Data Highway
Plus - does not support PLC-3
address format.
1750 Generic Protocol octal register
reference invalid.
1750 DH-485 - I/O word number out of
range.
1751 Too much data in Generic Protocol. More than 60 words in data transfer.
Plus - symbolic word and addressing
mode is not supported.
1751 Remote I/O - rack is not active or
configured.
1752 Remote I/O - PLC is in test or
program mode.
Plus - symbolic file and addressing
mode is not supported.
1753 Remote I/O - remote rack is in a
faulted condition.
1754 Remote I/O - communications not On a PLC-3 if communications do not
active. recover on the PanelMate unit check the
revision of the EPROM on the AcceleratI/On
card.
The revision must be 05 or greater
(P/N 85-00285-05 or 85-00307-05).
1755 Remote I/O - block transfer count is
too small.
1761 Allen-Bradley error code 01 - remote Not enough memory in an older PLC 5/15
device could not take message. and/or 5/250.
Too much traffic on device.
1762 Allen-Bradley error code 02 - remote The PanelMate unit is communicating
device does not acknowledge. properly on the highway but the remote
device cannot be found (Wrong network ID).
Remote device is bad or missing.
1763 Allen-Bradley error code 03 - Duplicate token holder detected.
unrecognized response from remote General network error.
device.
Error
1764 Allen-Bradley error code 04 - local Not passing token.

port is disconnected (Data Highway The PanelMate unit is disconnected from
Plus only). highway or improperly connected.
Noise on communication line.
1766 Allen-Bradley error code 06 - Two devices with the same network ID
duplicate node detected. (node #).
1767 Allen-Bradley error code 07 - station
is off-line.
1768 Allen-Bradley error code 08 -
hardware fault.
1774 Allen-Bradley error code 0E - Communications out of sync.
PanelMate unit received duplicate
transaction number.
2000- Internal system error code. Driver corrupted (Re-download driver).
2002
2100 Internal system error code. Configuration and driver may be
incompatible.
2101 Invalid reference. Cannot parse. Invalid PLC reference syntax.
2102 Invalid reference. Cannot parse. Invalid PLC reference syntax.
2103 All PLC references in current block Check all references to same memory area.
are invalid.
2105 Could not update database via block Possible hardware problem.
read.
Internal data structure corrupted.
2106 Could not update database via PLC sending unsoliciteds to PanelMate unit
unsolicited request. memory area that does not exist.
2107 Remote interface supports only one
block read.
2108 Block read size <num> is invalid Reply packet mismatch. Read out of range.
and should be <correct size>.
2120 Invalid bit write register. GE CCM or TI Host Link bit write registers
invalid.
2200 Unsolicited request failed. PLC is sending unsolicited data before
Connection not established with PanelMate unit is ready to receive it.
remote device yet.
2201 Inconsistent local address. Network ID does not match interface board
ID.
2500 Invalid separator. Check PLC references.
2501 Invalid reference. Cannot parse. Invalid character in PLC reference.
Error
2502 Invalid reference. Cannot parse. Not enough characters in network address or
PLC reference.
2503 Invalid reference. Cannot parse. Too many characters in network address or
PLC reference.
2525 Network address component out of Configured Network ID or PLC ID out of
range. range.
3000- Internal system error code. Driver corrupted.
3005 Download new executive firmware/ drivers.
3006 Cannot write to unsolicited driver. A reference associated with a name in the
unsolicited device field is being used in a
control button or numeric entry field.
3025 Network address (PLC ID field) is
invalid or out of range.
3050- Internal system error code. Data Baud rate too slow.
3055 buffer corrupted.
4100 Invalid network ID.
4102 Not enough network ID levels
specified.
4103 Too many network ID levels
specified.
Interface Card Errors

The error codes shown below are associated with interface cards.
Error
Number Description Possible Cause Possible Solution
101 Internal system error. Out of environment space. Add shell command to
The mode argument is config.sys and increase
invalid. environment size.
Increase the amount of
RAM available or do not run
TSRs, other programs, or
device drivers.
102 Interface card software KT software not properly Install Allen-Bradley
missing or bad path. installed. KT software Standard Driver Software
directory not in the path. (Cat No 6001-FIE) as shown
in the Allen-Bradley
Software User manual.
Add the KT software
directory to path command
in autoexec.bat and reboot
system.
102 Interface card software Configuration software not Reinstall configuration
missing or bad path. properly installed or is software.
corrupt.
103 Interface card software KT software is corrupt. Reinstall Allen-Bradley
bad. Standard Driver Software
(Cat No 6001-F1E) as
shown in the Allen-Bradley
Standard Driver Software
User Manual.
103 Interface card software Configuration software is Reinstall configuration
bad. corrupt. software
104 Not enough memory is Out of low memory (lower Increase the amount of
available to initialize 640K of RAM). RAM available or do not run
interface card. TSRs other programs or
device drivers.
Refer to the DOS manual to
optimize memory usage.
Error
Number Description Possible Cause Possible Solution
105 KT card could not be KT card could not be Exit configuration software
initialized. initialized for unknown and run startkt.exe
reasons. command as shown in the
Allen-Bradley Standard
Driver Software User
Manual.
If the card initializes
correctly, the problem is a
shortage of memory.
Increase the amount of
RAM available or do not run
TSRs other programs or
device drivers.
Refer to the DOS manual to
optimize memory usage.
If the card fails to initialize
an error message displays.
See Error Codes in the
Allen-Bradley Standard
Driver Software User
Manual.
106 SD card program error. Configuration software not Reinstall configuration
properly installed or is software.
corrupt.
107 SD card bad port and/or Port address does not match Ensure the dip switch
memory address. the switch settings on settings on interface card
interface card. Port address match the port address
in conflict with other selected.
memory in computer.
Select a different port
address.
108 SD card memory error. SD card memory in conflict Select a different memory
with other memory in setting. Replace and test
computer. SD card may be with a known good interface
defective. card.
109 SD card processor SD card may be defective. Replace and test with a
failure. known good interface card.
10A SD card error. SD card may be defective. Replace and test with a
known good interface card.
10B SD card software Configuration software not Reinstall configuration
module not found. properly installed or is software.
corrupt.
Appendix A: Online Operation Problems 55
Online Operation Problems
A
• Common online problems and solutions
Online Operation Problems

Some common online operation problems and solutions are listed below.
Note: For information on configuration editor or transfer problems, refer to the PanelMate Power
Series Configuration Editor User’s Guide or the Transfer Utility User’s Guide.
Problem Possible Cause Corrective Action

When going online, the Configuration does not have a Configure PLC Name and
following error message driver defined in the PLC Port Table, save, export, and
appears: Name and Port Table dialog transfer corrected
box. configuration.
“User configuration indicates
missing downloadable driver.
Download of new
configuration or missing
downloadable driver is
required”.
Line Trend Templates displays 1. Sampled values for one or 1. Expand the trend range for
blank data between trended more pens is outside the the affected pens.
points. maximum or minimum trend
limits set in the configuration
editor for that part of the
template.
2. Due to overall PanelMate 2. Reduce the sample rate by
loading or PLC network increasing the sample interval
loading, the data could not be expression; or reduce the
read from the PLC in the background PanelMate polling
configured time interval. by adjusting the alarm scan
(NOTE: This is more likely to delay and message scan delay
occur on the PanelMate Power (possibly even the page scan
Series 1500 due to its lower delay) in the System
performance processor board.) Parameters - Communication
Tab dialog box; or reduce PLC
network loading by reducing or
eliminating other PLC network
traffic.
Appendix B: Momentary Pushbutton Operation 57
Momentary Pushbutton Operation
B
• About momentary pushbutton precautions
Momentary Pushbutton Operation

The PanelMate online units have several built-in safety features that represent unique benefits for use
in real-time machine control. Understanding how to apply these safety features can significantly
enhance the intrinsic safety of the overall control system. These safety features involve the use of the
fault relay that is built into the PanelMate Power Series 1700, 2000, 3000, 4000 and 5000 online
units and the Control Bit Zero feature built into the PanelMate configuration software of all
PanelMate online units. In order to understand the use of these features, a quick review of basic PLC
safety practices is covered below.
Whenever operator input is used for starting or stopping a piece of process machinery like a motor, a
stamping press, or a conveyor, momentary inputs are used and the outputs that govern the action are
latched in by PLC logic. Momentary pushbuttons (either normally open or normally closed) are used
whether the button is a physical pushbutton or a pushbutton representation on a Video Control Panel
to simplify the ladder logic so as to insure that operator requests to start or stop are always carried out
on the process machinery. Regardless of whether a physical or video pushbutton is used, the inherent
safety of the PLC logic is compromised if the start or stop pushbutton becomes “stuck” in the
depressed state. If the pushbutton that requests the machinery to start is stuck in the “on” state and
the momentary pushbutton to request the machine to stop is pressed, the PLC logic will process the
stop request in one scan of the logic then immediately re-start the machine in the next scan of logic
due to the stuck start request. This is obviously a dangerous situation that must be prevented.
Since a PanelMate unit communicates to a PLC using either a serial or PLC LAN communications
mechanism, there are two ways in which a video pushbutton can become “stuck”.
• When power is lost to the PanelMate unit while pressing a momentary pushbutton. Since only the
press of the pushbutton is communicated to the PLC and the release is never sensed, the control
bit is left in the “request on” state.
• When a communication error occurs on the release of the pushbutton and the release action is
never properly sent to the PLC. This will also result in the control bit being left in the “request
on” state.
The following options can be performed to prevent a PanelMate unit from becoming “stuck”.
1. The PLC ladder logic that processes each momentary control request can clear the request after
latching the control output. This, however, cannot be used for jog functions.
2. Wire the PanelMate unit’s fault relay (available on all PanelMate models except the PanelMate
Power Series 1500 and PanelMate PC) as an input to the PLC. The fault relay drops out (it can be
wired normally open or closed) whenever power is lost to the PanelMate or when a
communications fault occurs. The fault relay input can then be used in ladder logic to trigger the
clearing of all control bits in the PLC. This is actually the best technical solution since the
response is immediate once the problem is sensed.
Appendix B: Momentary Pushbutton Operation 59
3. PanelMate also has a built-in feature designed to correct this potential situation that doesn’t
require any PLC logic. At system boot-up and after a communications fault is reset by the
operator (or remotely by the PLC), the PanelMate can be made to write all momentary control
bits to their normal state. This means that every Normally Open, Momentary control button will
have a zero written to the associated PLC control bit and every Normally Closed, Momentary
control button will have a one written to the associated PLC control bit. This solution is less
desirable than using the fault relay because it requires either a complete restart of the PanelMate
unit after power loss or an operator action before the potential “stuck button” is reset. Also, it is
possible that a cable could become disconnected or severed and this reset would not occur. This
function is enabled by checking the box labeled “Bit Zero After Com Fault” in the System
Parameters–Communications Tab dialog box. This box is left unchecked by default when a
new configuration is created and must be checked by the developer to enable this feature.
Depending on the number of momentary pushbuttons created in the PanelMate configuration, the
resetting of all control bits could noticeably increase the boot-up and communications reset time.
PanelMate offers several features to help increase the intrinsic safety of the control system, but it is up
to the control system developer to determine the best solution to a potential “stuck pushbutton”.
Index 61
Index
A E
About This Manual, II Emergency Technical Support, III
Purpose, II Enter Offline Mode, 29
What’s Inside, II Errors During Run Mode, 42
Adjust Contrast, 29 Execute Normal Power-Up Diagnostics, 2
Alarm Summary Page, 21
Alarm Window, 9 F
Alarms, 20
Alternate Mode, 4 Fault Relay, 32
Fault Relay and Alarms, 33
Fault Relay and Communication Errors,
B 32
Bulletin Board Service, IV Fault Relay and Loss of Power, 33
Fault Relay and Online System Errors, 32
C
Calibrate Touchscreen, 29
G
Change Password A or Change Password Get Page, 13
B, 28
Change PLC Name (Maintenance H
Template), 37
Change PLC Ref (Maintenance Host Display Window, 13
Template), 38
Change Value (Maintenance Template), I
37
Check for Executive Firmware, 3 Information Fax-Back Service, III
Check for Presence of Installed Drivers, 4 Interface Card Errors, 53
Check User Configuration Compatibility
with Executive Firmware, 3 L
Cleaning Mode, 29
Communication Errors, 42 Local Errors, 43
Conditional Visibility, 10 Log-in Password A and Log-in Password
Control Button Operation, 16 B, 28
Correspondence Address, IV Log-out Password A and Log-out
Password B, 29
Lost Password Recovery, 25
D
Data Format (Maintenance Template), 40 M
Deactivate (Maintenance Template), 36
Default Control Buttons, 11 Maintenance Template Examples, 39
Determine if the Unit Should Enter the Maintenance Template, 36
Transfer Mode, 3 Modify Template (Maintenance
Determine Power Up Mode, 4 Template), 37
Directory, 14 Momentary Pushbutton Operation, 58
Display System/Configuration
Information, 29
62 Runtime Operation User’s Guide
O
Offline Mode, 4
One-Touch Selection of Variable-Sized
Templates, 16
Online Page Layout, 8
Online Problems, 56
Operator Input, 16
P
Page Number and Page Title, 9
Pages In Alarm, 9
Password Protection, 24
PLC Page Selection, 13
Power Up Sequence, 2
Preface, I
Problems, Online, 56
Product Ordering Service, IV
R
Recovery Mode, 3
Refresh Graphics, 9
Remote Errors, 44
Remote I/O Errors, 42
Run Mode Operation, 6
Run Mode, 5
S
Selecting a Template, 16
Set Date and Time, 28
Setup Page, 28
Software Update Service, IV
Start Monitor (Maintenance Template),
36
Support Services, III
Switch to Two Column Keypad or Switch
to Three Column Keypad, 29
System Errors, 45
T
Technical Support Fax, III
Technical Support, III
Troubleshooting the Online Operation, 56
Two-Touch Selection of Variable-Sized
Templates, 16
V
View or Acknowledge Alarms, 21
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I.L. 195C492C
ECS2100 PanelMate Screen
INSTRUCTION LEAFLET
This document describes the control of a 2-channel ECS2100 excitation system using the PanelMate operator control
interface. The PanelMate Power Series 1700 is described here with additional information being available in PanelMate
Power Series Online Operation User’s Guide, IL#P/N-01-00394-00.
A 1-channel or 3-channel system would have the same general pages described below. The difference being a 2 or 3
channel system will contain pages giving channel specific data.
Modbus 4.6 RTU protocol is used to implement communication between the PanelMate and the controller that resides in
the ECM. The software in the ECM card has dedicated blocks that direct information sent to or received from the
PanelMate. These blocks are called PMIN for input from the PanelMate and PMOUT for output information directed to
the PanelMate.
PAGE 0
Page 0 is the page that will be visible when the PanelMate is initially
powered. Page 0 is shown in Figure 1. Identified is the address of
each control board that may be addressed via Modbus or by the
ccTool programming software.
To navigate from this point the “Index” button will open the Index
page.
Figure 1
Index
The Index page contains navigation buttons to open pages of the

PanelMate program. There are also navigation pages on other
pages. When a navigation button is pressed, the white outline on
the button moves from the top and left side of the button to the
bottom and right side of the button. Once a selection is made, the
“Execute” button appears on the right side of the screen. Pressing
the “Execute” button will open the page selected.
The operator may also navigate to other pages by pressing the “Get
Page” arrow on the right edge of the screen. When that button is
pressed, a keypad will appear on the right side of the screen. To
view a page directory, press the ‘DIR’ selection on the keypad. The
operator may open any page that is not password protected by
entering the page number on the keypad. The “Get Page” feature is
available on all PanelMate pages. For more information concerning
the “Get Page” function, refer to PanelMate Power Series Online Figure 2
Operation User’s Guide, IL#P/N-01-00394-00, page 7-14.
Page 1 of 16 November 13, 2006

Alarms
The Alarm page is simply an LED matrix. A

red light in one of the white outline boxes indicates an
alarm. There are indications for the Main Channel (M)
and Redundant Channel (R) indications.
As long as the alarm is active, the light will
remain red on the Alarm page and the alarm on the
Alarm Banner (Figure 4) will remain red text on white
background. The time of the alarm and the page
number of the alarm would be displayed on the end of
the alarm banner.
When the condition clears, the red ‘LED’
would go out and the alarm on the banner would
switch to red text on a white background with the
letters “CLRD” beside the time. The time displayed
after the alarm is cleared, is changed to the time the
alarm is cleared. Figure 3
Navigation to the Index, Bridge Status, and
Transfer Control pages are available at the bottom of
the page. If a bridge alarm is annunciated, the details
of that bridge alarm may be found on the bridge
status page(s).
There may be more or fewer alarms on any
individual system.
The alarm banner (Figure 4) is visible at

all times and does not change with page
changes. In this example, ‘Coolant Pump Failed’
and ‘Oil Pressure Low’ alarms are still active. The
time on the right is the time the alarm became Figure 4
active and the notation of ‘P00’ indicates the
page number the alarm can be found.
The examples shown are generic in nature and do not represent actual excitation system alarms. The examples of
‘Reduction Furnace Overtemp’ and ‘Inbound Hopper Overweight’ have been cleared by the inputs no longer being
active.
Most alarms must be acknowledged in order to remove them from the alarm page. This is done by pressing the
‘View or Acknowledge Alarms’ on the right of the PanelMate screen. At that time an option to scroll up or down the last
100 alarms allows the operator to acknowledge all alarms or alarms that the operator selects. When alarms are
acknowledged the background of those alarms becomes black and the text becomes yellow with a notation of ACKN in
front of the time stamp.
To view the entire Alarms page, use the ‘Get Page’ feature. When the keypad appears on the right side of the
screen, press ‘Alarms’. The Alarms page will then open displaying the last 100 alarms.
For more information about PanelMate alarm features, refer to PanelMate Power Series Online Operation User’s
Guide, IL#P/N-01-00394-00, page 19.

Limiters & Trips
The Limiters & Trips page is similar to
the Alarms page in that it is a page with an LED
matrix. An illuminated ‘LED’ (red) indicates that
the condition is detected.
This page indicates which limiters have
taken control as well as transfer to manual,
transfer to redundant channel, and trip actions.
Individual system requirements may alter this
page.
An LED under the Trips label would give
an indication of the trip condition. Note that once
the trip has occurred if the condition has cleared,
the LED will no longer be red. However, the
alarm banner at the top of the page will be
displayed with the time and reason for the trip.
A lack of the white squares on any of
these ‘LED’ matrix pages, or yellow boxes
indicates the loss of Modbus
communication.
Figure 5
Output Control
The Output Control page has five meters and

seven status reports. The meters display the field
voltage, field current, generator (line) voltage, a
balance meter, and the firing command percentage.
The meter outputs are the outputs of the channel
in control. If one channel were out of service, then
an operator would have to use the Output Control
page of the channel that was operational.
The Output Control page also displays
system status indicators. These indications are:
System Status- Indicates that both channels
are ready, neither channel is ready, or one of the
channels is not ready.
Remote/Local- Indicates the control of each
channel. Under properly functioning operations, both
channels should be in local control or both should be
in remote control.
Channel Control- Indicates which of the
channels is in control. Figure 6
70-CS Manual- Indications allow operator to
raise or lower balance or manual reference. When
this indication is pressed, the right side of the screen
will show two selections to raise and lower the voltage
in Manual Mode.
90-CS Auto- Indication is similar to 70-CS
Manual. To raise or lower voltage while in the Auto Mode, an operator should press the 90-CS indication. Two
selections will then appear on the right side of the screen, ‘Lower Voltage’ and ‘Raise Voltage’. The operator can then
change the voltage by pressing either of these two selections.
Mode Select- Indication of Manual or Auto mode. Pressing this indicator will display two
selections on right side of screen. The two selections will allow operator to choose Auto Mode or Manual Mode.
AC Breaker- Indicates the opened or closed status of the AC field breaker.

Many meters displayed on the PanelMate are like the Line Voltage meter (Figure
7). The large number (shown as 123.45) is the actual line voltage reading. The smaller
number in the white block is the per unit value (P.U.). This value is the actual reading
divided by the rated value. For instance, if the generator rated voltage is 18kV and the
actual reading were 17100V, then the figure in the white box would be 0.95.
Figure 7
Indication icons, such as the one shown in Figure 8 give an indication or status of
the regulator system. Any indicator with the arrow in the bottom left corner is also a
control switch. Pressing the AC Breaker indicator, the operator will be given two
command selections which can close or open the AC field breaker
To close the 41A breaker, the operator should press the ‘AC Breaker’ indicator
that is available on either the Output Control page or the Generator Monitor page. When
that is pressed, two selections will appear on the right side of the PanelMate screen.
These control selections are shown in Figure 9. When the operator selects “Close 41A’,
the breaker will close and the field will flash automatically for a pre-determined amount of
time, or until the field is self-sustaining.
Figure 8
Once the breaker has closed and the field has flashed, the ECS2100 will return to
the mode
(Auto or Manual) it was operating in when the 41A was open.
Opens AC Field Breaker.
Closes 41A Field Breaker.
Figure 9

An indicator without the arrow in the bottom right corner would only be an
indicator and not have any control functions attached to it. An example of an
indication with no control feature is pictured in Figure 10.
Figure 10
Generator Monitor
The Generator Monitor is the page that an

operator would use most often. There are five
meters not present on the Output Control page.
These meters display the generator voltage,
current, megawatts, megavars, and power factor.
The control indicators at the bottom of the
page are the same controls available on the
Output Control page (Figure 6).
Figure 11
Transfer Control
The Transfer Control page would be used
to transfer control of the ECS2100 from one
channel to another.
To transfer channel control, the
PanelMate being used must be in control. It also
must be known if the PanelMate being used is the
‘Local’ or ‘Remote’ PanelMate. The Local/Remote
indicator informs the operator. If the PanelMate
being used is not in control, that function is
available on Remote/Local Control page shown in
Figure 13.
Note that the PanelMate on the door of the
ECS2100 is considered the ‘Local’ PanelMate. Any
other control location is considered ‘Remote’.
Once the PanelMate being used is in
control, the PanelMate Enable Trans control must
indicate “PanelMate Enabled”. That would be
accomplished by pressing the “PanelMate Enable Figure 12
Trans” indicator and selecting “Enable PanelMate
Transfer”. Then press the “Transfer Using PanelMate”
indicator and select the channel to be in control.

Remote/Local Control
Remote/Local Control page indicates the
location controlling each channel. Under normal
operations, all channels should be controlled from
the same location. To change the control location,
press the Local/Remote indicator and select the
desired control location.
When the ECS2100 is initially powered up
the remote location should be in control.
In a typical set-up, the local PanelMate can
give control to the remote or can take control from
the remote. The remote PanelMate can give control
to the local, but cannot take control from the local.
Figure 13
Fan Control / Bridge Temp Monitor
Toggle switches on the right allow the

operator to override the fan circuit and select the
backup fan to run or to select all fans to run.
Indications let the operator which fan is
running. Heatsink and Ambient air temperature
table indicate the temperature level of each RTD.
Fan Control pages will vary according to
the type of converter bridge used in the system.
Due to the extensive amount of data being
transmitted to this page it is advised not to leave
this page displayed for extended periods of time.
Figure 14

Bridge Status
The Bridge Status page is another LED matrix
page. A red ‘LED’ will indicate an alarm condition. The first
six indications on the left side are the conduction monitors.
A red ‘LED’ in one of these would indicate a no current
flow in that portion of the circuit. The most likely cause of a
conduction monitor failure is a blown fuse in the bridge.
The next seven indicators are overtemp alarms in each leg
of the converter circuit.
The indicators on the right side of the screen
monitor the condition of the RTD’s which are supplying the
signals indicated on the left side of the screen. As with the
other ‘LED’ matrix screens, if the white boxes are not
visible, there has been a loss of Modbus communication.
If a bridge has been removed from service for
any reason, the ‘Return Bridge to Service’ button must be
pressed once the bridge is ready to return to service.
Figure 15
The Bridge Status page(s) will vary according to
the type of bridge used in the system. Systems with more
than 3 bridges would have more than one Bridge Status
page.
For programming purposes, indications on this
page are not shown on the alarm banner or alarm page.
Due to the extensive amount of data being
transmitted to this page it is advised not to leave this page
displayed for extended periods of time.
PSS
The PSS screen will be available only on systems
that have PSS on the ECS2100 regulator. PSS is enabled
and disabled with the PSS ON/OFF control switch and
indicator on the right side of the screen. The output
indications are along the left of the page are channel specific
PSS output. The indications along center are the normal
operating mode indications.
Figure 16

Field Ground Monitor
The Field Ground and Field Temp Monitor page
displays field to ground resistance and a calculated field
temperature. Feedback from each channel is displayed along
with indication of which channel is in control.
There are no control functions on this page, only field
indications and meters. If the field ground resistance is
detected less than the FLDGND_RMIN then an alarm
condition exists and will be displayed in the FLDGND MAIN
indicator.
Figure 17
VAR
The VAR screen will be available only on systems
that have VAR control on the ECS2100 regulator. The gray
button is a toggle button which will turn VAR on and off. The
control indicators along the bottom of the page are the same
control switches available on the Generator Monitor page
(Figure 11) and the Output Control page (Figure 6).
Figure 18

Channel Index
The Channel Index page is used to navigate to
channel specific pages for the main or redundant
channels. Main Channel and Redundant Channel pages
are primarily used in maintenance situations to view
feedback from the different channels.
If the system has three channels there will be
additional selections for Supervisory Channel pages. If
the system has only one channel, neither this page nor
any of the following pages will be present.
IF ONE CHANNEL IS NOT WORKING, THEN
THE OPERATOR WILL HAVE TO USE PAGES FROM
THE WORKING CHANNEL INSTEAD OF THE
GENERAL PAGES ALREADY SHOWN IN THIS
INSTRUCTION LEAFLET.
Figure 19
Channel Specific Pages

The channel specific pages for Output Control, Generator Monitor, Channel Tracking, and VAR control would
look like Figures 6, 11, 12, and 18 respectively. The meters on the channel specific pages would display the values being
read by that channel, whether or not that channel is in control.
Meter Panel
The meter panel page is the only page that is
found only in the channel specific pages. There are no
control functions, only position indicating meters. All
meters are shown in P.U. (per unit) values.
Figure 20
For additional information such as setting date and time, uploading and downloading programs, alarms,
and passwords refer to PanelMate Power Series Online Operation User’s Guide, IL#P/N-01-00394-00. On rare
occasions a red alarm appears on the bottom of the PanelMate screen referring to alarm #00065. Due to
receiving information from 4 different controllers (ECM/ECR/FCIM/FCIR) there can be some timing issues if
unshielded cables are used for the Modbus communication. If this becomes a problem the cables from the ECM
and ECR to the PanelMate should be exchanged with shielded cables.

TASK GUIDE
Operations Page Required Steps

Close AC Field Breaker (41A) Either Output Control 1. Press ‘AC BREAKER’ indicator
Or Generator Monitor at bottom of screen.
2. On right of screen select ‘Close
41A’.
Flash Field none Done automatically by closing AC

Field Breaker.
Place regulator in Auto/Manual Either Output Control 1. Press “MODE SELECT’

Or Generator Monitor indicator at bottom of screen.
2. On right of screen select mode
desired.
Note: The regulator will
automatically transfer from manual
to auto mode upon expiration of
timers and acceptable terminal
voltage signals providing the
regulator was in auto mode during
the previous shutdown.
Raise/Lower Voltage Either Output Control 1. If regulator is in Manual Mode

Or Generator Monitor press ‘70-CS MANUAL’.
2. If regulator is in Auto Mode,
press ‘90-CS AUTO’.
3. On right of screen select to
raise or lower voltage.
Change Channel in Control Transfer Control 1. Press ‘Transfer Status’ indicator

at top of screen.
2. On right side of screen select
‘Enable Transfer’.
3. Press ‘PanelMate Enable Tranf’
in bottom left corner of screen.
4. On right side of screen select
‘Enable PanelMate Transfer’.
5. Press ‘Transfer using PM’
indicator also in the lower left
corner of screen.
6. On right side of screen, select
channel desired.
Note: The PanelMate being used
must be in control of the system.
See Change Local/Remote control.

Change Remote/Local Control Remote/Local Control (password 1. Press ‘Remote/Local’ indicator
protected) at the top of the screen.
2. On the right of the screen,
select Remote or Local.
Note: The Local PanelMate can
give control to the Remote
PanelMate or it can take control
from the Remote PanelMate. The
Remote PanelMate can only give
control to the Local PanelMate. It
cannot take control from the Local
PanelMate.
View the Alarm Page Any 1. Select ‘Get Page’ on the right of
the screen.
2. On the keypad, press ‘Alarm’
Acknowledge Alarms Alarm Page or Alarm banner that This can be done either on the
is always visible Alarm page or on the Alarm banner.
1. On the right side of the screen,
select ‘View or Acknowledge
Alarms’.
2. To acknowledge all alarms,
select ‘Acknowledge All
Alarms’.
3. To acknowledge selected
alarms, move the cursor up or
down by pressing ‘Scroll Up’ or
‘Scroll Down’.
4. When the cursor is on the
desired alarm, select
‘Acknowledge Alarm’.
Open Field Breaker (41A) Either Output Control 3. Press ‘AC BREAKER’ indicator
Or Generator Monitor at bottom of screen.
4. On right of screen select ‘Trip
41A’.

ALARM MESSAGES
ALARM PAGE CONDITION CHECK / ACTION
41A failed to close (M) / (R) Alarm Status A signal to close the 41A 1. Mechanical operation of
device was sent, but 41A device.
confirmation of 41A closure 2. 41A feedback signal to
was not received. DIGIN1_C609.
3. Press ‘Trip 41A’ to reset.
Bridge Alarm (M) / (R) Alarm Status A bridge has an alarm. Refer to Bridge Status
page(s) for details of the
alarm.
DXCB operated (M) / (R) Alarm Status DX module operated due to Investigate. Check AC line
a voltage spike on the field. snubbers or AC voltraps.
This can be a typical
occurrence on some
systems during a normal
shutdown.
Field Flash Failed (M) / (R) Alarm Status 41A device closed but 1. 31 devices.
neither field current nor 2. Field flash voltage
terminal voltage reached supply.
required threshold levels. 3. Some systems require to
be reset after this alarm.
If so, press ‘Trip 41A’.
FLD Current xdcr fail (M) / (R) Alarm Status Channel specified has lost 4. DCXDM(R)
the signal from DCXDM or 5. Power supply
DCXDR. connections to
DCXDM(R).
6. Fuses DCOFU(R)
7. Fiber optic connections
IFG, VFG, IEXFR,
VEXFR.
FLD Voltage xdcr fail (M) / (R) Alarm Status The channel specified has 1. ALXDM(R).
lost signals from ALXDM(R). 2. Fuses ACLFU(R).
3. FIM(R) input from
ALXDM(R).
4. Fiber optic connections
between ALXDM (R)
and FIM (R)
HXL limiting (M) / (R) Limiters & Trips Volts per Hertz limiter is in 1. Check terminal voltage.
control of regulator. 2. Adjust voltage.
HXL timing (M) / (R) Limiters & Trips Volts per Hertz ratio has 1. Check terminal voltage.
exceeded the protection 2. Adjust voltage.
setting and is now in the
timing.
HXL timed out (M) / (R) Limiters & Trips Volts per Hertz ratio has 1. Check terminal voltage.
exceeded the protection 2. Adjust voltage.
setting and has now timed
out. The HXL limiter should
now take control.
HXL trip (M) / (R) Limiters & Trips The HXL Limiter failed to Investigate terminal voltage
reduce the volts per hertz levels previous to trip.
ratio The HXL protection
has tripped the regulator via
the 94E relay.
HXL xfer to Redundant (M) / (R) Limiter & Trips HXL limiter has transferred Terminal voltage.
the system to the redundant
channel in an attempt to
avoid a trip.
INST limiting (M) / (R) Limiters & Trips INST Limiter is in control of 1. Check field current.
the regulator. 2. Adjust voltage.
INST trip (M) / (R) Limiters & Trips The INST Limiter failed to Investigate field current
reduce the field current. The levels previous to trip.
INST protection has tripped
the regulator via the 94E
relay.
INST xfer to Redundant (M) / (R) Limiter & Trips INST limiter has transferred Field current.
avoid a trip.
LBF trip (M) / (R) Limiters & Trips Both fans in the power 1. 88MPFU and 88RPFU
cubicle have failed and the fuses.
regulator has tripped via the 2. T10 and T11
94E relay. transformers.
3. Fan motors.
LOS transfer to manual (M) / (R ) Limiters & Trips Loss of sensing has 1. PT
detected less than 89% 2. Feedback from PT to PT
terminal voltage and thus SIM card.
has transferred the system
to manual control.
LOS transfer to Redundant (M) / (R ) Limiters & Trips Loss of sensing has 1. PT
detected less than 89% 2. Feedback from PT to PT
terminal voltage and thus SIM card.
has transferred the system
to the redundant channel.
Main Local/Red Remote Local / Remote Two channels under control Follow instruction is TASK
of separate locations. GUIDE for Change
Remote/Local Control.
Main not Ready Transfer Main Channel not ready for 1. PT signal to main
Control service. channel (SIM J1 or J4)
2. Power supply for
channel (PS1 or PS4)
MEL limiting (M) / (R) Limiters & Trips MEL Limiter is in control of Check MW and MVAR
the regulator. operating point.
MEL trip (M) / (R) Limiters & Trips The MEL Limiter failed to Investigate MW and MVAR
correct the under excitation levels previous to trip.
condition. The MEL
protection has tripped the
regulator via the 94E relay.
MEL xfer to Redundant (M) / (R) Limiters & Trips MEL limiter has transferred Check MW and MVAR
the system to the redundant operating point.
avoid a trip.
Met PT fail (M) / (R) Alarm Status The channel specified has 1. Metering PT.
detected a loss of signal 2. Switch SW2.
from the metering PT. 3. Transformers AUPT4-6.
4. SIM(R) input J4.
OEL limiting (M) / (R) Limiters & Trips OEL Limiter is in control of 1. Check field current.
the regulator. 2. Adjust reference point.
OEL timed out (M) / (R) Limiters & Trips Field Current remained 1. Check field current.
above the timing threshold 2. Adjust reference point
and the OEL will now begin
limiting.
OEL timing (M) / (R) Limiters & Trips Field Current has reached 1. Check field current.
the timing threshold. The 2. Adjust reference point
OEL timer will delay the
limiting for a predetermined
number of seconds.
OEL xfer to Redundant (M) / (R) Limiters & Trips OEL limiter has transferred Field current.
avoid a trip.
OEL trip (M) / (R) Limiters & Trips The OEL Limiter failed to Investigate field current
correct the over excitation levels previous to trip.
condition. The OEL
OTT trip (M) / (R) Limiters & Trips The regulator has tripped via Excitation transformer
the 94E relay due to an temperature.
overtemperature condition of
the excitation transformer.
Outside trip (M) / (R) Limiters & Trips Regulator has been tripped 1. PPT overcurrent relay.
from outside sources such 2. Other sources.
as PPT overcurrent relay or
immediate trip signal to the
86 relay.
OVL limiting (M) / (R) Limiters & Trips OVL Limiter is in control of 1. Check terminal voltage.
the regulator. 2. Adjust voltage.
OVL trip (M) / (R) Limiters & Trips The OVL Limiter failed to Investigate generator
reduce the generator voltage before trip.
voltage. The OVL protection
has tripped the regulator via
the 94E relay.
Phase Lock Loop (M) / (R) Alarm Status VAB and VBC are not 1. Fuses ACLFU,
locking on the input AC ACLFUR.
frequency. 2. Fiber optic connections,
V-AB, V-BC, V-ABR, V-
BCR.
PPT Hi-Temp (M) / (R) Alarm Status The channel specified has Excitation transformer
received a hi-temp alarm temperature.
from the excitation
transformer.
PPT Hi-Hi-Temp (M) / (R) Alarm Status The channel specified has Excitation transformer
received a hi-hi-temp alarm temperature.
from the excitation
transformer.
Power Supply 1 (2) (M) / (R) Alarm Status Failure of primary power 1. Power supply 1 (PS1)
supply for channel. for main channel loss.
2. Power supply 2 (PS2)
for redundant channel
loss.
3. Fuses SACFU or
MACFU.
4. Transformer T3.

PS4 (M) / (R) Alarm Status Failure of backup power 1. Power supplies 4A and
supply for channel. 4B.
2. Fuses 1TFU
3. Circuit breaker AUCB.
Red Local/Main Remote Local / Remote Two channels under control Follow instruction is TASK
of separate locations. GUIDE for Change
Remote/Local Control.
Redundant in Control Transfer 1. Main Channel has 1. Manual redundant

Control transferred control to the override switch in logic
redundant channel, or cubicle.
2. An operator has 2. Limiters.
manually transferred
control to the redundant
channel either through
PanelMate selection or
the hardwired switch in
the logic cubicle.
Redundant not Ready Transfer Redundant Channel not 1. PT signal to redundant
Control ready to accept transfer. channel (SIR J1 or J4)
2. Power supply for
channel (PS2 or PS4)
Reg. PT fail (M) / (R) Alarm Status The channel specified has 1. Regulator PT.
detected a loss of signal 2. Switch SW1.
from the metering PT. The 3. Transformers AUPT1-3.
regulator will now use the 4. SIM(R) input J1.
metering PT signal if one is
available.
Tracker Disabled Transfer Tracker has been disabled. Regulator should not be
Control The tracker allows the operated without the tracker.
redundant channel to ‘track’ Open the ‘Transfer Control’
the outputs of the main page. Press Tracker Status
channel. and select ENABLE
TRACKER.
Transfer Disabled Transfer The ability to transfer Open the ‘Transfer Control’
Control channels has been disabled. page. Press Transfer Status
and select ENABLE
TRANSFER.
Transformer Trip (M) / (R) Limiter & Trips Contacts on PPT overtemp 1. PPT temperature.
trip device have closed. 2. Digital input from PPT
contacts.
Two Channels not Ready Transfer Neither Main Channel nor See Main not Ready and
Control Redundant Channel are Redundant not ready.
ready for service.
UEL limiting (M) / (R) Limiters & Trips UEL Limiter is in control of Check MW and MVAR
the regulator. operating point.
UEL trip (M) / (R) Limiters & Trips The UEL Limiter failed to Investigate MW and MVAR
correct the under excitation operating levels previous to
condition. The UEL trip.

UEL xfer to Redundant (M) / (R) Limiters & Trips UEL limiter has transferred Check MW and MVAR
the system to the redundant operating point.
avoid a trip.
VAB xducer fail (M) / (R) Alarm Status Loss of VAB transducer Fiber optic connections
signal. between ALXDM (R) and
FIM (R)
VBC xducer fail (M) / (R) Alarm Status Loss of VBC transducer Fiber optic connections
signal. between ALXDM (R) and
FIM (R)

ILECSM008B
ECS2100 MULTI DROP ADAPTER (MDA) 4A36840G01

INSTRUCTION LEAFLET
Purpose
The MDA is used to connect multiple exciter control modules (ECMs) to a single PanelMate or Modbus™ PLC. Only
one PanelMate or PLC can be connected to the MDA, as it would be the master for the Modbus communication. Up to
three ECMs can be connected to the MDA; the ECMs are Modbus slaves.
Application
For local PanelMate connection, up to three ECMs can be connected at jacks J2, J3, and J4 with standard Ethernet
cable (RJ-45 terminals 568A category 5 patch cord). The circuit card of the 4A36840G01 MDA takes care of the
conversion from two-wire communication of the ECM to the four-wire communication to the PanelMate. Next, connect
J1 to the local PanelMate with standard Cat-5 Ethernet patch cable.
For a remote PanelMate or Modbus PLC, connect the remote MDA to three ECMs with the Cat-5 Ethernet cable. This
MDA will be mounted in the exciter cubicle. To connect the remote Modbus device, use J5 with twisted, shielded
cable. Pin 1 is positive, pin 2 is negative, and pin 3 is used for the shield connection. In the control room, a second
MDA will be required to land the twisted pair at J5. Then use J1 to connect the remote PanelMate to the network with
a standard Ethernet patch cord.
Drawings
INSTRUCTION MANUAL
FOR
TIME OVERCURRENT RELAY
BE1-51
NEUTRAL DEFEAT PHASE - TAP

PHASE E F E F
ON D G D G
TAP INST INST
CAL 1 2 C H C H
B I B I
A J A J
OFF CAL
INST TAP TAP
1
A B C
TIME DIAL TIMING TIME DIAL

TIMING
NEUTRAL
BE1-51
OVERCURRENT RELAY
R
Style No. V3E Z1P B2C1F POWER
Serial No. H12345678 R U
A B C N TIME INST INST

1 2
PUSH TO
ENERGIZE
OUTPUT
1
2 ELEMENT FUNCTION
TAP A B C D E F G H I J
T HIGH 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00
LOW 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00
P0048-48
Publication: 9137200997
Revision: D 08/07
INTRODUCTION
This instruction manual provides information about the operation and installation of the BE1-51 Time
Overcurrent Relay. To accomplish this, the following information is provided:
• General Information and Specifications

• Controls and Indicators
• Functional Description
• Installation
• Tests and Adjustments
WARNING!
To avoid personal injury or equipment damage, only qualified personnel should
perform the procedures in this manual.
NOTE
Be sure that the relay is hard-wired to earth ground with no smaller than 12 AWG
copper wire attached to the ground terminal on the rear of the unit case. When
the relay is configured in a system with other devices, it is recommended to use a
separate lead to the ground bus from each unit.
9137200997 Rev D BE1-51 Introduction i

First Printing: July 1992
Printed in USA
© 1992-1993, 1998, 2007 Basler Electric, Highland Illinois 62249 USA
All Rights Reserved
August 2007
CONFIDENTIAL INFORMATION
of Basler Electric, Highland Illinois, USA. It is loaned for confidential use, subject
to return on request, and with the mutual understanding that it will not be used in
any manner detrimental to the interest of Basler Electric.
It is not the intention of this manual to cover all details and variations in equipment, nor does this manual
provide data for every possible contingency regarding installation or operation. The availability and design
of all features and options are subject to modification without notice. Should further information be
required, contact Basler Electric.
BASLER ELECTRIC
ROUTE 143, BOX 269
HIGHLAND IL 62249 USA
PHONE +1 618.654.2341 FAX +1 618.654.2351
ii BE1-51 Introduction 9137200997 Rev D
REVISION HISTORY
The following information provides a historical summary of the changes made to the BE1-51 instruction
manual (9137200997). Revisions are listed in reverse chronological order.
Manual
Revision and Date Change
D, 08/07 • Updated Output Contacts ratings in Section 1.
• Moved content of Section 6, Maintenance to Section 4.
• Updated front panel illustrations to show laser graphics.
• Moved content of Section 7, Manual Change Information to manual
introduction.
• Added manual part number and revision to all footers.
• Updated cover drawings.
• Moved Time Overcurrent Characteristic Curves from Section 1 to new
Appendix A.
• Updated power supply burden data in Section 1.
• Updated Target Indicator description in Section 3.
C, 01/98 • Changed paragraph styles to new manual design.
• Added Note 3 to Figure 1-1.
• Corrected inductive output specification from 0.1 to 0.3 A.
• Changed TOC specification.
• Added instantaneous response time with graph 1-1.
• Deleted specification reference to field selectable switch in Type S
power supply.
• Corrected weight in kilograms for all case styles.
• Replaced Figure 1-49 with correct curve.
• Corrected Figure 1-51.
• Added multiturn potentiometer description to controls in Table 2-1.
• Corrected Range 9 entries in Table 2-2.
• Changed “Element D” in Table 2-4 to “Element N”.
• Deleted Figure 3-1.
• Revised the power supply functional description to accommodate new
wide range power supplies.
• Corrected Figures 4-2, 4-3, and 4-4.
• Deleted Figure 4-5.
B, 09/93 • Added Figures 4-4 and 4-6 through 4-9.
• Restructured Section 5, Operational Test.
• Corrected minor typographical errors.
A, 02/93 • Added characteristic curves for integrating algorithm, Figures 1-39
through 1-70.
• Changed Figure 1-2.
• Corrected minor discrepancies.
—, 07/92 • Initial release
9137200997 Rev D BE1-51 Introduction iii

iv BE1-51 Introduction 9137200997 Rev D

CONTENTS
SECTION 1 • GENERAL INFORMATION ................................................................................................ 1-1
SECTION 2 • CONTROLS AND INDICATORS ........................................................................................ 2-1
SECTION 3 • FUNCTIONAL DESCRIPTION ........................................................................................... 3-1
SECTION 4 • INSTALLATION .................................................................................................................. 4-1
SECTION 5 • TESTS AND ADJUSTMENTS ............................................................................................ 5-1
APPENDIX A • TIME OVERCURRENT CHARACTERISTIC CURVES ................................................... A-1
9137200997 Rev D BE1-51 Introduction v

vi BE1-51 Introduction 9137200997 Rev D

TABLE OF CONTENTS
SECTION 1 • GENERAL INFORMATION ................................................................................................ 1-1
DESCRIPTION....................................................................................................................................... 1-1
STANDARD FEATURES ....................................................................................................................... 1-1
Time Overcurrent Functions............................................................................................................... 1-1
Non-Integrating Timing....................................................................................................................... 1-2
Integrating Timing............................................................................................................................... 1-2
Built-In Test ........................................................................................................................................ 1-2
OPTIONS ............................................................................................................................................... 1-2
Timing................................................................................................................................................. 1-2
Neutral Defeat .................................................................................................................................... 1-2
Sensing Input Type ............................................................................................................................ 1-2
Sensing Input Range.......................................................................................................................... 1-2
Power Supply ..................................................................................................................................... 1-3
Targets ............................................................................................................................................... 1-3
Outputs ............................................................................................................................................... 1-3
Instantaneous Outputs ....................................................................................................................... 1-3
Packaging........................................................................................................................................... 1-3
MODEL AND STYLE NUMBER DESCRIPTION................................................................................... 1-3
SPECIFICATIONS ................................................................................................................................. 1-5
Sensing Input Burden......................................................................................................................... 1-5
Sensing Input Rating .......................................................................................................................... 1-5
Time Overcurrent Pickup Selection Range ........................................................................................ 1-5
Time Overcurrent Measuring Accuracy.............................................................................................. 1-5
Time Overcurrent Dropout Ratio ........................................................................................................ 1-5
Instantaneous Overcurrent Pickup Range ......................................................................................... 1-5
Instantaneous Overcurrent Measuring Accuracy ............................................................................... 1-5
Instantaneous Overcurrent Dropout Ratio ......................................................................................... 1-5
Instantaneous Response.................................................................................................................... 1-5
Time Delay Accuracy ......................................................................................................................... 1-6
Output Circuits.................................................................................................................................... 1-6
Target Indicators ................................................................................................................................ 1-6
Power Supply ..................................................................................................................................... 1-6
Radio Frequency Interference (RFI) .................................................................................................. 1-6
Isolation .............................................................................................................................................. 1-6
Surge Withstand Capability ................................................................................................................ 1-7
UL Recognized ................................................................................................................................... 1-7
GOST-R.............................................................................................................................................. 1-7
Operating Temperature ...................................................................................................................... 1-7
Storage Temperature ......................................................................................................................... 1-7
Shock.................................................................................................................................................. 1-7
Vibration ............................................................................................................................................. 1-7
Weight ................................................................................................................................................ 1-7
Case Size ........................................................................................................................................... 1-7
Figures
Figure 1-1. Style Number Identification Chart ........................................................................................... 1-4
Figure 1-2. Typical Instantaneous Response Time................................................................................... 1-5
Tables
Table 1-1. Power Supply Specifications.................................................................................................... 1-6
9137200997 Rev D BE1-51 General Information i

ii BE1-51 General Information 9137200997 Rev D

DESCRIPTION
BE1-51 Time Overcurrent Relays are microprocessor-based devices that monitor the magnitude of single-
phase, two-phase-and-neutral, or three-phase-and-neutral ac current to provide accurate time overcurrent
and instantaneous overcurrent protection for 50 hertz or 60 hertz power systems.
STANDARD FEATURES
Time Overcurrent Functions
Time overcurrent elements pick up over a range of 0.1 to 0.8 amperes, 0.3 to 2.4 amperes, 0.5 to 4.0
amperes, 1.5 to 12.0 amperes, 0.1 to 2.4 amperes, or 0.5 to 12.0 amperes and provide an adjustable time
delay that is proportional to the overcurrent. Time delay is initiated when the sensed current exceeds the
pickup point. When the current drops below the pickup point, the timing circuit is reset immediately. At
reset, the output contacts, if operated, are restored to normal.
Adjustment of the overcurrent pickup point is provided by controls on the relay front panel. Time delay is a
function of the characteristic curve that has been selected. Time delay is settable from 00 to 99 on the
TIME DIAL thumbwheel switch located on the front panel. Curve type is selected either as an option or, in
some models, is switch selectable.
Sixty-nine characteristic curves and three timing options are available. They are:
Characteristic curves:
• Seven inverse time
• Nine I2t
• Seven inverse time with extended timing range
• Nine I2t with extended timing range
• Five British Standard 142 (E curves)
• Seven integrating inverse time
• Nine integrating I2t
• Seven integrating inverse time with extended timing range
• Nine integrating I2t with extended timing range
Timing option Z1 (switch selectable - 16 position) B and C curves:
• Nine I2t
Timing option Z1 with option 2-D or 2-E (switch selectable - 16 position) B and C curves:
• Nine I2t with extended timing range
Timing option Z2 (switch selectable - 16 position) B and E (British Standard 142) curves:
• One I2t
• Five British Standard (BS) 142 (E curves)
Timing option Z2 with option 2-D or 2-E (switch selectable - 16 position) B and E (BS142) curves:
• One I2t with extended timing range
• Five British Standard 142 (E curves)
Timing option Z3 (switch selectable - 16 position) integrating B and C curves:
• Seven integrating inverse time
• Nine integrating I2t
Timing option Z3 with option 2-D or 2-E (switch selectable - 16 position) integrating extended B and C
curves:
• Seven integrating inverse time with extended timing range
• Nine integrating I2t with extended timing range
9137200997 Rev D BE1-51 General Information 1-1

Characteristic curves are shown by the graphs in Appendix A, Time Overcurrent Characteristic Curves.
Note that each graph (i.e. function) consists of a set of representative curves. Each curve (as well as any
between-curve interpolation) is selectable by the front panel TIME DIAL using a two-digit destination from
00 to 99. Because of space limitations, each graph shows only 14 of the 100 possible selections.
Non-Integrating Timing
Timing options Z1 and Z2 and the characteristic curves available with those options use non-integrating
timing. Non-integrating timing is accomplished by timing at a gate that is not solely dependent on the
magnitude of the applied multiple of pickup current. The time-out value is calculated based on the type of
time curve characteristic selected, time dial setting, and the magnitude of the applied multiple of pickup
current. The time-out value is continuously updated during the timing cycle. When pickup is exceeded, a
timer is initiated. When the timer elapsed time exceeds the calculated time-out value, a time trip output
signal is generated.
This type of non-integrating time delay characteristic exhibits a dynamic characteristic that is immediately
responsive to changes of the applied multiple of pickup current.
Integrating Timing
Timing option Z3 and the characteristic curves available for that option uses integrating timing. Integrating
timing is accomplished by summing time increments that are based on the magnitude of the applied
multiple of pickup current, the time curve characteristic selected, and the time dial value. These time
increments are summed until a predetermined value is exceeded, then a time trip output signal is
generated.
This type of integrating time delay characteristic simulates the operating characteristics of an
electromechanical overcurrent relay.
Built-In Test
A built-in test (BIT) switch mounted on the Logic Board provides diagnostic troubleshooting and
calibration.
OPTIONS
Timing
An extended timing option multiplies by approximately 5.7, the standard time delays. The resulting curves
are shown following the standard curves in Appendix A - e.g., Figure A-1 is timing type B1 and Figure A-2
is the timing type B1 with extended timing range.
When timing option Z1, Z2, or Z3 is specified, a printed circuit board mounted selector switch allows a
choice of up to sixteen different time overcurrent functions. Timing option Z1 or Z3 may be further
specified as standard or extended time, depending upon option 2 selection.
Neutral Defeat
When neutral defeat is specified, a front panel switch allows neutral current sensing to be disabled. This
function permits the user to energize desired circuits and not trip because of imbalanced current in the
neutral circuit. After the circuits are balanced, the neutral defeat function can be switched off and neutral
current sensing protection is provided.
Sensing Input Type

When single-phase, two-phase-and-neutral, three-phase, or three-phase-and-neutral sensing has been
specified, the front panel TAP selector and the front panel TAP CAL control set the pickup point for all
phases. An independent front panel TAP (NEUTRAL) selector and front panel CAL (NEUTRAL) control
set the neutral pickup point. In addition, for three-phase-and-neutral sensing units, one of the seven
sensing input range combinations must be specified.
Sensing Input Range

For three-phase-and-neutral sensing units, input ranges are:
• 0.5 to 4.0 amperes (phase and neutral)
• 1.5 to 12 amperes (phase) and 0.5 to 4.0 amperes (neutral)
1-2 BE1-51 General Information 9137200997 Rev D

• 0.5 to 4 amperes (phase) and 1.5 to 12 amperes (neutral)
• 1.5 to 12 amperes (phase and neutral)
• 0.3 to 2.4 amperes (phase) and 0.1 to 0.8 amperes (neutral)
For all other units, two ranges are available. They are 0.5 to 12 amperes and 0.1 to 2.4 amperes.
Power Supply
Five power supply options are available. They are:
• 24 Vdc
• 48 Vdc
• 125 Vdc and 100/125 Vac
• 48 Vdc or 125 Vdc and 100/125 Vac
• 250 Vdc and 240 Vac
Targets
Single-phase relays have two function targets that indicate when the time delay or instantaneous
element(s) have operated. On multiple phase relays, additional targets indicate which phase or neutral
element(s) operated.
Function targets may be specified as either internally operated or current operated by a minimum of 0.2
amperes through the output trip circuit. When current operated, the output circuit must be limited to 30
amperes for 0.2 seconds, 7 amperes for 2 minutes, and 3 amperes continuously.
Outputs
Optional normally opened, normally closed, or SPDT auxiliary output contacts may be selected. Contacts
actuate when the output relay is energized. Internally operated front panel mounted targets, and front
panel targets operated by the dc current in the output circuit are available for the time overcurrent and
instantaneous overcurrent functions. Optional front panel mounted PUSH-TO-ENERGIZE-OUTPUT
pushbuttons allow direct actuation of each output relay for external circuit testing.
Instantaneous Outputs
One or two instantaneous overcurrent outputs are optionally available. Each is adjustable up to 40 times
the time overcurrent pickup point. When the sensed current exceeds the instantaneous overcurrent
pickup point, an output relay is energized. An independent front panel control (INST 1 or INST 2) adjusts
the pickup point for each optional output. If more than one phase is applied to the relay, the instantaneous
pickup point will be the same for all phases. If neutral current is sensed, a front panel INST 1 (NEUTRAL)
provides adjustment of the neutral pickup point. Instantaneous overcurrent elements are not voltage
controlled.
Packaging
Each relay is mounted in a drawout cradle and enclosed in a standard utility style case with either semi-
flush or projection mounting (depending upon case style selected). Circuit components are accessed by
removing the individual printed circuit boards from the relay cradle. Use an extender card (Basler Electric
part number: 9165500199) to test and troubleshoot the relay. An available test plug (Basler Electric part
number: 10095 or G.E. part number 12XLA12A1) allows the relay to be tested in place without disturbing
external control circuit wiring.
MODEL AND STYLE NUMBER DESCRIPTION

Electrical characteristics and operational features included in a particular style of the BE1-51 Time
Overcurrent Relay are defined by a combination of letters and numbers that make up its style number.
The model number, together with the style number, describes the options included in a specific device,
and appears on the front panel, drawout cradle, and inside the case assembly. Upon receipt of a relay, be
sure to check the style number against the requisition and the packing list to ensure that they agree.

Style Number Identification Chart (Figure 1-1) illustrates the manner in which the relay style number is
determined. For example, if the style number were H3E-Z1P-B2C1F, the device would have the following
characteristics:
H - Three-Phase-and-Neutral sensing
3 - Sensing input range of 1.5 to 12.0 amperes for phase and 0.5 to 4.0 amperes for neutral
E - Normally open outputs
Z1 - Switch selectable time curves
P - Operating power derived from 125 Vdc or 120 Vac
B - Current operated targets
2 - Two instantaneous elements
C - Push-to-energize outputs
1 - Normally open auxiliary timed output relay
F - Semi-flush mounting
Figure 1-1. Style Number Identification Chart

SPECIFICATIONS
BE1-51 Time Overcurrent Relays electrical and physical specifications are as follows:
Sensing Input Burden

Less than 0.1 ohms per phase or neutral.
Sensing Input Rating

The maximum continuous rating is 20 A, 1 second current rating is 50X (times) the maximum tap current
selected, or 500 A, whichever is less. For ratings other than those specified by the time curves, the rating
is calculated as follows:
50 x tap or 500 A (whichever is less)
I=
T
where I = Maximum current
T = Time that current flows (in seconds)
Time Overcurrent Pickup Selection Range

Continuously adjustable over the current sensing input ranges specified in the Style Chart (Figure 1-1).
Time Overcurrent Measuring Accuracy

±2% of pickup setting.
When the TAP CAL control is fully CW, the actual pickup will be within ±5% of the front panel TAP
selector setting.
Time Overcurrent Dropout Ratio

Better than 92 of pickup level.
Instantaneous Overcurrent Pickup Range

Continuously adjustable over the range of 1 to 40 times the time overcurrent pickup setting.
Instantaneous Overcurrent Measuring Accuracy

±2% of pickup setting.
Instantaneous Overcurrent Dropout Ratio

Better than 98% of pickup level.
Instantaneous Response
Figure 1-2 shows the typical response for the instantaneous pickup element.
Figure 1-2. Typical Instantaneous Response Time

Time Delay Accuracy
±5% of the characteristic curve (Figures A-1 through A-37) for any combination of the front panel TIME
DIAL setting and the front panel TAP/TAP CAL overcurrent pickup setting.
Repeatability is within ±2% of setting at 25°C.
Output Circuits
Resistive Ratings
120 Vac: Make, break, and carry 7 Aac continuously
250 Vdc: Make and carry 30 Adc for 0.2 s, carry 7 Adc continuously, and break 0.3 Adc
500 Vdc: Make and carry 15 Adc for 0.2 s, carry 7 Adc continuously, and break 0.3 Adc
Inductive Ratings
120 Vac, 125 Vdc, 250 Vdc: Break 0.3 A (L/R = 0.04)
Target Indicators
Function targets may be specified as either internally operated or current operated by a minimum of 0.2
amperes through the output trip circuit. When current operated, the output circuit must be limited to 30
amperes for 0.2 seconds, 7 amperes for 2 minutes, and 3 amperes continuously.
Power Supply
Power for the internal circuitry may be derived from a variety of ac or dc external power sources as
indicated in Table 1-1.
Table 1-1. Power Supply Specifications
Input Voltage
Type Burden at Nominal
Nominal Range
O (mid range) 48 Vdc 24 to 150 Vdc 1.6 W
125 Vdc 24 to 150 Vdc 1.9 W

P (mid range)
120 Vac 90 to 132 Vac 8.9 VA
R (low range) 24 Vdc 12 to 32 Vdc ∗ 1.7 W
48 Vdc 24 to 150 Vdc 1.6 W

S (mid range)
125 Vdc 24 to 150 Vdc 1.9 W
250 Vdc 68 to 280 Vdc 2.1 W

T (high range)
240 Vac 90 to 270 Vac 14.2 VA
∗ Type R power supply may require 14 Vdc to begin operation. Once operating, the voltage may be
reduced to 12 Vdc.
Radio Frequency Interference (RFI)

Field-tested using a five-watt, hand-held transceiver operating at random frequencies centered around
144 MHz and 440 MHz, with the antenna located six inches from the relay in both horizontal and vertical
planes.
Isolation
In accordance with IEC 255-5 and ANSI/IEEE C37.90, one-minute dielectric (high potential) tests as
follows:
All circuits to ground: 2,121 Vdc
Input to output circuits: 1,500 Vac or 2,121 Vdc

Surge Withstand Capability
Qualified to ANSI/IEEE C37.90.1-1989, Standard Surge Withstand Capability (SWC) Tests for Protective
Relays and Relay Systems.
UL Recognized
UL recognized per Standard 508, UL File No. E97033. Note: Output contacts are not UL recognized for
voltages greater than 250 volts and input power supply voltages greater than 150 volts.
GOST-R
Gost-R certified No. POCC US.ME05.B03391; complies with the relevant standards of Gosstandart of
Russia. Issued by accredited certification body POCC RU.0001.11ME05.
Operating Temperature
The operating temperature range is from -40°C (-40°F) to +70°C (+158°F).
Storage Temperature
The storage temperature range is from -65°C (-85°F) to +100°C (+212°F).
Shock
In standard tests, the relay has withstood 15 g in each of three mutually perpendicular planes without
structural damage or degradation of performance.
Vibration
In standard tests, the relay has withstood 2 g in each of three mutually perpendicular planes, swept over
the range of 10 to 500 Hz for six sweeps, 15 minutes each sweep without structural damage or
degradation of performance.
Weight
Single-Phase: 13.0 lbs. (5.90 kg)
Two-Phase and Neutral: 14.0 lbs. (6.35 kg)
Three-Phase: 14.0 lbs. (6.35 kg)
Three-Phase and Neutral: 14.4 lbs. (6.53 kg)
Case Size
S1 (Refer to Section 4 for case dimensions.)


SECTION 2 • CONTROLS AND INDICATORS
TABLE OF CONTENTS
SECTION 2 • CONTROLS AND INDICATORS ........................................................................................ 2-1
INTRODUCTION.................................................................................................................................... 2-1
Figures
Figure 2-1. Location of Controls and Indicators ........................................................................................ 2-1
Tables
Table 2-1. Controls and Indicators ............................................................................................................ 2-2
Table 2-2. Sensing Input Ranges .............................................................................................................. 2-3
Table 2-3. Target Installation Configurations ............................................................................................ 2-4
9137200997 Rev D BE1-51 Controls and Indicators i

ii BE1-51 Controls and Indicators 9137200997 Rev D

SECTION 2 • CONTROLS AND INDICATORS
INTRODUCTION
BE1-51 controls and indicators are located on the front panel and front interior. The controls and
indicators are shown in Figure 2-1 and described in Table 2-1. Your relay may not have all of the controls
and indicators shown and described here.
O P Q R S
NEUTRAL DEFEAT PHASE - TAP

PHASE E F E F
ON D G D G
TAP INST INST
CAL 1 2 C H C H
B I B I
OFF
A J A J B
INST TAP CAL TAP
1
N A B C C
TIME DIAL TIME DIAL
TIMING TIMING D
NEUTRAL
M BE1-51 E
OVERCURRENT RELAY
Style No. V3E Z1P B2C1F POWER
F
R
Serial No. H12345678 R U
A B C N TIME INST INST

1 2
L PUSH TO
ENERGIZE
G
OUTPUT
1
2 ELEMENT FUNCTION H
TAP A B C D E F G H I J
HIGH 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00
K T
LOW 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00
I
P0048-49
Figure 2-1. Location of Controls and Indicators
9137200997 Rev D BE1-51 Controls and Indicators 2-1

Table 2-1. Controls and Indicators
Call-
Control or Indicator Function
Out
A TAP NEUTRAL Selector Provides selection of the Neutral Overcurrent Pickup Point in
conjunction with the front panel NEUTRAL CAL control.
B PHASE-TAP Selector Provides the selection of the Overcurrent Pickup Point in
conjunction with the front panel TAP CAL control.
C CAL NEUTRAL Control (On A single turn potentiometer provides adjustment of the Neutral
Relays with Phase-and- Overcurrent Pickup Point between the selected tap setting and
Neutral Sensing Only) the next lower tap setting.
Not TAP RANGE Plate Plate position indicates the terminal connections (high or low)
Shown High/Low used to select the current sensing input range. Refer to Table
2-2 for sensing input ranges.
D TIME DIAL NEUTRAL (If Determines the time delay between sensing of the overcurrent
present) condition and the closing of the output relay. Refer to
Appendix A and Table A-2 for curve selection information.
E TIMING NEUTRAL (If LED illuminates when the neutral pre-set Overcurrent Pickup
present) Point is reached and exceeded.
F Time Current Characteristic Provides selection of the time current characteristic curves.
Curve Selector (Z1, Z2, and Refer to Appendix A and Table A-2 for curve selection
Z3 Timing Options Only) information. Cutaway view shows switch behind the front
panel.
G POWER Indicator LED illuminates to indicate that the Relay Power Supply is
functioning.
H Target Reset Switch Manually resets all targets (both element and function type).
I FUNCTION Targets - TIME, Front panel FUNCTION targets light when the corresponding
INST1, INST2 output relay is energized by an overcurrent condition. Refer to
Table 2-3 for target installation configurations.
J ELEMENT Targets∗ Front panel ELEMENT targets light when an output relay is
energized by an overcurrent condition. Refer to Table 2-3 for
target installation configurations.
K PUSH-TO-ENERGIZE Actuation of this function is by a thin non-conducting rod (do
OUTPUT Pushbutton not use a screwdriver) through a hole in the front panel. This
allows the Output Relays to be manually energized for testing
of the external trip circuit(s).
ELEMENT Targets, where supplied, are not operated by this
control.
L TIMING Indicator LEDs light when the preset Overcurrent Pickup Point is
reached and exceeded.
M TIME DIAL Selector Determines the time delay between sensing of the overcurrent
condition and the closing of the output relay. Refer to
Appendix A and Table A-2 for curve selection information.
N TAP CAL Control A single turn potentiometer provides adjustment of the Phase
Overcurrent Pickup Point between the selected tap setting and
the next lower tap setting.
O INST 1 Control (Options 1-1 A four-turn potentiometer provides adjustment of the front
and 1-2 Only)† panel INST 1 trip setting over the range of 1 to 40 times the
selected phase time overcurrent pickup (TAP) value.
2-2 BE1-51 Controls and Indicators 9137200997 Rev D

Call-
Control or Indicator Function
Out
P INST 2 Control (Option 1-2 A four-turn potentiometer provides adjustment of the front
Only)† panel INST 2 trip setting of the range of 1 to 40 times the
selected phase time overcurrent pickup (TAP) value.
Q NEUTRAL DEFEAT LED LED lights when neutral defeat function is enabled.
R NEUTRAL DEFEAT Switch When ON, neutral defeat function is enabled.
S INST 1 NEUTRAL Control A four-turn potentiometer provides adjustment of the front
(Options 1-1 and 1-2 Only)† panel INST 1 NEUTRAL trip setting over the range of 1 to 40
times the selected neutral time overcurrent pickup (TAP)
value.
Not N/T (Normal/Test) Switch This switch is mounted internally on the Logic Board. Switch
Shown S1 S1 provides stored built-in-test (BIT) programs to validate the
calibration of the relay.
∗ The number of phases and neutral sensed by the relay is defined by the sensing input type (see the
Style Identification Chart, Figure 1-1).
† This instantaneous overcurrent sensing circuit detects levels that are multiples of the level selected
for the time overcurrent sensing circuit. Any change of the tap selector or calibration (CAL) controls
will cause a directly proportional change of the instantaneous overcurrent levels.
Table 2-2. Sensing Input Ranges

TAP Current Sensing
TAP Selector
Range Terminals
Plate or
Pickup A B C D E F G H I J ØA ØB ØC N
Sensing Input Range 1, Single-Phase ∗

HIGH 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00 8,7 — — —
LOW 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00 9,7 — — —
Sensing Input Range 1, Three-Phase ∗

HIGH 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00 8,7 14,15 17,18 —
LOW 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00 9,7 13,15 16,18 —
Sensing Input Range 1, Two-Phase-and-Neutral ∗

HIGH 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00 8,7 — 14,15 17,18
LOW 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00 9,7 — 13,15 16,18
Sensing Input Range 2, Three-Phase-and-Neutral

Phase or
0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00 8,9 13,14 15,16 17,18
Neutral

Phase 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00 8,9 13,14 15,16 —
Neutral 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00 — — — 17,18

Phase 0.75 1.00 1.50 1.75 2.25 2.50 3.00 3.25 3.75 4.00 8,9 13,14 15,16 —
Neutral 2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00 — — — 17,18
9137200997 Rev D BE1-51 Controls and Indicators 2-3

TAP Current Sensing
TAP Selector
Range Terminals
Plate or
Pickup A B C D E F G H I J ØA ØB ØC N

Phase or
2.25 3.00 4.50 5.25 6.75 7.50 9.00 9.75 11.25 12.00 8,9 13,14 15,16 17,18
Neutral

Phase or
0.15 0.20 0.30 0.35 0.45 0.50 0.60 0.65 0.75 0.80 8,9 13,14 15,16 17,18
Neutral

Phase 0.45 0.60 0.90 1.05 1.35 1.50 1.80 1.95 2.25 2.40 8,9 13,14 15,16 —
Neutral 0.15 0.20 0.30 0.35 0.45 0.50 0.60 0.65 0.75 0.80 — — — 17,18

Phase or
0.45 0.60 0.90 1.05 1.35 1.50 1.80 1.95 2.25 2.40 8,9 13,14 15,16 17,18
Neutral
Sensing Input Range 9 (All Other Sensing Types) ∗

HIGH 0.45 0.60 0.90 1.05 1.35 1.50 1.80 1.95 2.25 2.40 Same as Range 1
LOW 0.15 0.20 0.30 0.35 0.45 0.50 0.60 0.65 0.75 0.80 Same as Range 1
∗ For relays with sensing input ranges 1 or 9, connect the system wiring to the current sensing
terminals for the desired range (HIGH or LOW).
Table 2-3. Target Installation Configurations

Number of Instantaneous Elements Targets Installed (Types A and B)
Sensing
Input Type Element Function
None One Two
A B C N TIME INST 1 INST 2
X X
K X X X
X X X X
X X X X
G X X X X X X
X X X X X X X
X X X X X
H X X X X X X X
X X X X X X X X
X X X X X
X X X X X X X
X X X X X X X
2-4 BE1-51 Controls and Indicators 9137200997 Rev D

SECTION 3 • FUNCTIONAL DESCRIPTION
TABLE OF CONTENTS
GENERAL .............................................................................................................................................. 3-1
BLOCK DIAGRAM ANALYSIS .............................................................................................................. 3-1
Power Supply ..................................................................................................................................... 3-2
Current Sensing ................................................................................................................................. 3-2
Tap Select and Tap Cal...................................................................................................................... 3-2
Neutral Defeat .................................................................................................................................... 3-2
Multiplexor .......................................................................................................................................... 3-2
Analog-To-Digital Converter and Level Detector ............................................................................... 3-2
Time Trip Comparator and Scaler ...................................................................................................... 3-2
Microprocessor (Not Shown).............................................................................................................. 3-2
Instantaneous Overcurrent (Options 1-1 and 1-2) ............................................................................. 3-3
Timed and Instantaneous Outputs ..................................................................................................... 3-3
Auxiliary Outputs ................................................................................................................................ 3-3
Push-to-Energize Pushbuttons........................................................................................................... 3-3
Power Supply Status Output (Option 3-6).......................................................................................... 3-3
Target Indicators ................................................................................................................................ 3-3
Figures
Figure 3-1. Functional Block Diagram ....................................................................................................... 3-1
9137200997 Rev D BE1-51 Functional Description i

ii BE1-51 Functional Description 9137200997 Rev D

SECTION 3 • FUNCTIONAL DESCRIPTION
GENERAL
BE1-51 Time Overcurrent Relays are microprocessor-based devices that provide protection for the phase
or phase and neutral time and instantaneous overcurrent functions.
BLOCK DIAGRAM ANALYSIS

The following block diagram analysis is referenced to Figure 3-1. A microprocessor (not illustrated in
Figure 3-1) processes signals, performs logic functions, and all of the time overcurrent computations.
Figure 3-1. Functional Block Diagram
9137200997 Rev D BE1-51 Functional Description 3-1

Power Supply
Operating power for the relay circuitry is supplied by a wide range, electrically isolated, low-burden power
supply. Power supply operating power is not polarity sensitive. The front panel power LED and power
supply status output indicate when the power supply is operating. Power supply specifications are listed
in Table 1-1.
Current Sensing
All relay models (except three-phase-and-neutral units) have two sensing ranges for each phase. Each
high/low sensing range has its own set of input terminal connections.
• Five ampere CTs have: LOW (0.5 A to 4.0 A) and HIGH (1.5 A to 12.0 A).
• One ampere CTs have: LOW (0.1 A to 0.8 A) and HIGH (0.3 A to 2.4 A).
Three-phase-and-neutral sensing units, however, have one of four possible combinations of input sensing
ranges with one range for neutral and one range for the phases.
• Five ampere CTs have: 0.5 A to 4.0 A and 1.5 A to 12.0 A.
• One ampere CTs have: 0.1 A to 0.8 A and 0.3 A to 2.4 A.
Tap Select and Tap Cal

Front panel TAP selectors and TAP CAL controls are provided for selection and precise adjustment of
the phase and neutral (if provided) time overcurrent pickup points. The front panel TAP selectors, ten-
position BCD weighted rotary switches, select the desired current sensing pickup point, while the front
panel TAP CAL controls provide precise adjustment between the selected setting and the next lower
setting.
Neutral Defeat
Front panel mounted switch allows neutral current sensing to be disabled. When the switch is set to ON,
a current imbalance in the neutral circuit will not trip the output contacts.
Multiplexor
The multiplexor sequentially switches a voltage representing each of the sensed input currents to the
analog-to-digital converter and level detector.
Analog-To-Digital Converter and Level Detector

Analog dc voltages representing the sensed currents from the multiplexor are converted to binary
numbers (successive approximation) and applied to the time trip comparator and scaler circuits.
Time Trip Comparator and Scaler

This circuit accepts both the binary number representing the detected current level and the desired time
delay characteristic selected by the front panel TIME DIAL, then computes the required time delay before
the timed output relay will be energized. Time delay characteristics are shown in the curves located in
Appendix A. If extended timing range options 2-D or 2-E is present, the time delay characteristic curves
are modified so that the time delay is approximately 5.7 times the derived value.
Time delay computations are updated continuously so that changes in the overcurrent condition are
monitored and result in a corresponding change in the time delay. A software counter begins counting
when the initial binary number is received from the analog-to-digital converter and level detector. The
counter measures the elapsed time of the overcurrent condition, and resets if the current decreases
below the pickup point. This continuously increasing binary number is then passed to the comparator.
Microprocessor (Not Shown)

Some of the circuitry already discussed is part of the microprocessor and no definite lines are drawn to
separate the functions. The microprocessor compares the desired time delay (from the time trip
comparator and scaler) with the actual elapsed time from the counter. When the elapsed time reaches the
intended delay, the timed output relay is energized. During the time delay period, the front panel TIMING
indicator (i.e. pickup) associated with the detected phase is illuminated.
If targets are present, the front panel TIME FUNCTION target will be tripped, and the A, B, C, or N
ELEMENT target associated with the detected phase will be tripped. See Table 2-3 for the types of
targets that are present (depending upon relay configuration).
3-2 BE1-51 Functional Description 9137200997 Rev D
If option 3 is present, an auxiliary output relay (with either N.O., N.C., or SPDT contacts) is also actuated
when the timed output relay energizes.
Instantaneous Overcurrent (Options 1-1 and 1-2)

Input current levels applied to the time overcurrent circuitry are also passed to the instantaneous
overcurrent circuitry. These levels are compared to the setting of the front panel INST 1 adjust and the
front panel INST 1 (NEUTRAL) adjust (if present). If the input current level is above the setting, the output
driver energizes the instantaneous 1 output relay. If the instantaneous 2 option is present, the input level
is also compared with the setting of the front panel INST 2 adjust to energize the instantaneous 2 output
relay. Not that the current level settings for the instantaneous overcurrent element will always be from 1 to
40 times above the front panel TAP and TAP (NEUTRAL) settings of the time overcurrent element.
If target type A or B is present, the front panel INST 1 target and the front panel INST 2 targets are
tripped when their respective output relay is energized, along with the front panel A, B, C or N ELEMENT
targets (if present) associated with the detected phases. (See Section 2, Controls and Indicators, for the
types of targets that can be present depending upon the relay configuration.)
Timed and Instantaneous Outputs

Each output signal (representing either time overcurrent or instantaneous overcurrent) from each
monitored phase (or neutral) is applied to the respective output driver. Each output driver supplies
operating current to energize the associated output relay. Either normally open (output type E) or
normally closed (output type G) contacts may be specified. (The contact configurations of all output relays
for a given model will be the same.)
Auxiliary Outputs
In addition to the output relays, an auxiliary relay, having the same or a different contact configuration,
may be specified. Both the output and the auxiliary relays will remain energized for the duration of the
overcurrent condition.
Push-to-Energize Pushbuttons
If either option 2-C or 2-E is present, each individual output relay can be directly energized for test
purposes by the actuation of a front panel PUSH-TO-ENERGIZE OUTPUT pushbutton. The pushbutton is
actuated by the insertion of a thin, non-conducting rod through an access hole in the front panel.
Power Supply Status Output (Option 3-6)

Power supply status output relays have a set of normally closed contacts that are energized open during
power-up. If either or both power supply output legs (+12 Vdc or -12 Vdc) fails, the power supply status
output relay is de-energized and the output contacts close. Shorting bars across the output contacts are
held open by the installed connection plug. When the relay is removed from service by removing the
connection plug, the shorting bars are closed.
Target Indicators
Target indicators are optional components selected when a relay is ordered. The electronically latched
and reset targets consist of red LED indicators located on the relay front panel. A latched target is reset
by operating the target reset switch on the front panel. If relay operating power is lost, any illuminated
(latched) targets are extinguished. When relay operating power is restored, the previously latched targets
are restored to their latched state.
A relay can be equipped with either internally operated targets or current operated targets.
Internally Operated Targets
The relay trip outputs are directly applied to drive the appropriate target indicator. Each indicator is
illuminated regardless of the current level in the trip circuit.
Current Operated Targets
A current operated target is triggered by closure of the corresponding output contact and the presence of
at least 200 milliamperes of current flowing in the trip circuit.
Note that the front panel function targets (TIMED, INST 1, etc.) may be either internally or current
operated. Phase and neutral indicators are current operated only if the instantaneous options are not
included and if current operated targets are specified.
9137200997 Rev D BE1-51 Functional Description 3-3
NOTE
Prior to August 2007, BE1-51 target indicators consisted of magnetically latched,
disc indicators. These mechanically latched target indicators have been replaced
by the electronically latched LED targets in use today.
3-4 BE1-51 Functional Description 9137200997 Rev D

TABLE OF CONTENTS
SECTION 4 • INSTALLATION .................................................................................................................. 4-1
INTRODUCTION.................................................................................................................................... 4-1
RELAY OPERATING GUIDELINES AND PRECAUTIONS .................................................................. 4-1
MOUNTING............................................................................................................................................ 4-1
CONNECTIONS .................................................................................................................................... 4-7
MAINTENANCE ................................................................................................................................... 4-14
STORAGE............................................................................................................................................ 4-14
Figures
Figure 4-1. Outline Dimensions, Side View, Semi-Flush Mounted, Double-Ended Case......................... 4-2
Figure 4-2. Outline Dimensions, Side View, Projection Mounted, Double-Ended Case ........................... 4-3
Figure 4-3. Outline Dimensions, Front View, Case Cover ........................................................................ 4-4
Figure 4-4. Panel Cutting and Drilling Dimensions, Semi-Flush Mounting, Double-Ended Case............. 4-5
Figure 4-5. Panel Drilling Dimensions, Projection Mounting, Double-Ended Case .................................. 4-6
Figure 4-6. Typical External Connections, Current Operated Targets, DC Powered ............................... 4-7
Figure 4-7. Typical Sensing External Connections, Sensing Input Type G or K....................................... 4-8
Figure 4-8. Typical Sensing External Connections, Sensing Input Type I or X ........................................ 4-8
Figure 4-9. Typical Sensing External Connections, Sensing Input Type H or V....................................... 4-9
Figure 4-10. Typical Internal Diagram, Sensing Input Type K ................................................................ 4-10
Figure 4-11. Typical Internal Diagram, Sensing Input Type I or X .......................................................... 4-11
Figure 4-12. Typical Internal Diagram, Sensing Input Type G ................................................................ 4-12
Figure 4-13. Typical Internal Diagram, Sensing Input Type H or V......................................................... 4-13
9137200997 Rev D BE1-51 Installation i

ii BE1-51 Installation 9137200997 Rev D

INTRODUCTION
BE1-51 relays are shipped in sturdy cartons to prevent damage during transit. Upon receipt of a relay,
check the model and style number against the requisition and packing list to see that they agree. Inspect
the relay for shipping damage. If there is evidence of damage, file a claim with the carrier, and notify your
sales representative or Basler Electric.
If the relay will not be installed immediately, store it in its original shipping carton in a moisture- and dust-
free environment. Before placing the relay in service, it is recommended that the test procedures of
Section 5, Tests and Adjustments be performed.
RELAY OPERATING GUIDELINES AND PRECAUTIONS

Before installing or operating the relay, not the following guidelines and precautions.
• For proper current operated target operation, a minimum current of 200 milliamperes must flow
through the output trip circuit.
• If a wiring insulation test is required, remove the connection plugs and withdraw the relay from its
case.
CAUTION
When the connection plugs are removed, the relay is disconnected from the
operating circuit and will not provide system protection. Always be sure that
external operating (monitored) conditions are stable before removing a relay for
inspection, test, or service.
NOTE
Be sure that the relay is hard-wired to earth ground with no smaller than 12 AWG
copper wire attached to the ground terminal on the rear of the case. When the
relay is configured in a system with other devices, it is recommended to use a
separate lead to the ground bus from each device.
MOUNTING
Because the relay is of solid-state design, it does not have to be mounted vertically. Any convenient
mounting angle may be chosen. Refer to Figures 4-1 through 4-5 for relay outline dimensions and panel
drilling diagrams.
9137200997 Rev D BE1-51 Installation 4-1

D2853-22
06-15-99
Figure 4-1. Outline Dimensions, Side View, Semi-Flush Mounted, Double-Ended Case
4-2 BE1-51 Installation 9137200997 Rev D

Figure 4-2. Outline Dimensions, Side View, Projection Mounted, Double-Ended Case

Figure 4-3. Outline Dimensions, Front View, Case Cover

Figure 4-4. Panel Cutting and Drilling Dimensions, Semi-Flush Mounting, Double-Ended Case

Figure 4-5. Panel Drilling Dimensions, Projection Mounting, Double-Ended Case

CONNECTIONS
Be sure to check the model and style number of a relay before connecting and energizing the relay.
Incorrect wiring may result in damage to the relay. Except where noted, connections should be made with
wire no smaller than 14 AWG.
Typical external connections are shown in Figures 4-6 through 4-9. Internal connections are shown in
Figures 4-10 though 4-13.
To prevent an inductive overload of the relay contacts, it is necessary to break the trip circuit externally
through the 52a contacts.
Relay circuitry is connected to the case terminals by removable connection plugs (1 plug for 10-terminal
cases and 2 plugs for 20-terminal cases). Removal of the connection plug(s) opens the normally open trip
contact circuits and shorts the normally closed trip circuits before opening the power and sensing circuits.
Figure 4-6. Typical External Connections, Current Operated Targets, DC Powered

Figure 4-7. Typical Sensing External Connections, Sensing Input Type G or K
Figure 4-8. Typical Sensing External Connections, Sensing Input Type I or X

Figure 4-9. Typical Sensing External Connections, Sensing Input Type H or V

Figure 4-10. Typical Internal Diagram, Sensing Input Type K

Figure 4-11. Typical Internal Diagram, Sensing Input Type I or X

Figure 4-12. Typical Internal Diagram, Sensing Input Type G

Figure 4-13. Typical Internal Diagram, Sensing Input Type H or V

MAINTENANCE
BE1-51 relays require no preventative maintenance other than a periodic operational check. If the relay
fails to function properly, contact Technical Sales Support at Basler Electric to coordinate repairs.
STORAGE
This protective relay contains aluminum electrolytic capacitors which generally have a life expectancy in
excess of 10 years at storage temperatures less than 40°C (104°F). Typically, the life expectancy of a
capacitor is cut in half for every 10°C rise in temperature. Storage life can be extended if, at one year
intervals, power is applied to the relay for a period of 30 minutes.

SECTION 5 • TESTS AND ADJUSTMENTS
TABLE OF CONTENTS
SECTION 5 • TESTS AND ADJUSTMENTS ............................................................................................ 5-1
GENERAL .............................................................................................................................................. 5-1
REQUIRED TEST EQUIPMENT ........................................................................................................... 5-1
OPERATIONAL TEST ........................................................................................................................... 5-1
Preliminary Instructions ...................................................................................................................... 5-1
Time Overcurrent Pickup Test............................................................................................................ 5-3
Neutral Defeat Test ............................................................................................................................ 5-5
Timed Output Test.............................................................................................................................. 5-5
Instantaneous Overcurrent Pickup Test............................................................................................. 5-7
ADJUSTMENTS OF CONTROLS FOR RELAY OPERATION ............................................................. 5-8
TAP and TAP (NEUTRAL) Selector Setting....................................................................................... 5-8
Time Overcurrent Curve Selection (Timing Type Z1, Z2, and Z3 Only) ............................................ 5-9
Time Delay Selection ....................................................................................................................... 5-10
Neutral Time Delay Selection........................................................................................................... 5-10
INST 1 Control Setting ..................................................................................................................... 5-10
INST 2 Control Setting ..................................................................................................................... 5-11
Figures
Figure 5-1. Test Setup for Sensing Input Type K (Single-Phase Sensing) ............................................... 5-2
Figure 5-2. Test Setup for Sensing Input Type G (Three-Phase Sensing) ............................................... 5-2
Figure 5-3. Test Setup for Sensing Input Type H or V (Three-Phase with Neutral Sensing).................... 5-3
Figure 5-4. Test Setup for Sensing Input Type I or X (Two-Phase with Neutral Sensing)........................ 5-3
9137200997 Rev D BE1-51 Tests and Adjustments i

ii BE1-51 Tests and Adjustments 9137200997 Rev D

SECTION 5 • TESTS AND ADJUSTMENTS
GENERAL
Procedures in this section are for use in testing and adjusting a relay for the desired operation in a
protective scheme. If a relay fails an operational test, or if an adjustment discloses a faulty relay, refer to
Section 4, Installation, Maintenance.
REQUIRED TEST EQUIPMENT

Minimum test equipment required for relay testing and adjustment is listed below. Refer to Figures 5-1
through 5-4 for test setups.
• Appropriate ac or dc power source for relay operation.
• Appropriate ac source (50 or 60 hertz as appropriate) for current testing.
• Dc external power source for output relay(s) test setup and timer input.
• Relay test set capable of delivering 40 amperes. A higher capability is needed for instantaneous
settings above 40 amperes.
• Timer.
• One shunt resistor for providing minimum target load.
OPERATIONAL TEST
Preliminary Instructions
Perform the following steps before going on to any testing.
Step 1. Connect the relay test setup in accordance with Figures 5-1 through 5-4, depending upon the
sensing input type for your relay (see Figure 1-1, Style Number Identification Chart).
(a) Sensing Input Type K (Single-Phase Sensing). Refer to Figure 5-1.
NOTE
For relays having the above sensing, only the front panel LOW range current
sense terminal(s) should be connected for a complete check of the relay.
Ensure that timed output terminals 1 and 10 are connected.
(b) Sensing Input Type G (Three-Phase Sensing). Refer to Figure 5-2.
NOTE
For relays having the above sensing, only the from panel LOW range current
sense terminal(s) should be connected for a complete check of the relay.
For all three-phase relays, the test signals must connect to both the current and
voltage terminals for the same phase.
Ensure that timed output terminals 1 and 10 are connected.
(c) Sensing Input Type H or V (Three-Phase with Neutral Sensing). Refer to Figure 5-3.
Ensure that the timed output terminals 1 and 10 are connected. Also, verify that either A,
B, or C current sense terminals are connected initially (N terminals will be connected later
in the test).
9137200997 Rev D BE1-51 Tests and Adjustments 5-1

(d) Sensing Input Type I or X (Two-Phase with Neutral Sensing). Refer to Figure 5-4.
Ensure that the timed output terminals 1 and 10 are connected. Also, verify that either A,
B, or C current sense terminals are connected initially (N terminals will be connected later
in the test).
Step 2. Remove the relay front cover.

Step 3. Set the front panel TIME DIAL selector and, if present, the front panel TIME DIAL (NEUTRAL)
selector to 99.
Step 4. Adjust the front panel INST 1 and INST 2 controls, if present, fully clockwise (CW).
Step 5. Adjust the front panel TAP CAL control, and if present, the front panel TAP (NEUTRAL) control
fully CW.
Step 6. Ensure that the relay front panel TARGETS, if present, are reset.
Figure 5-1. Test Setup for Sensing Input Type K (Single-Phase Sensing)
Figure 5-2. Test Setup for Sensing Input Type G (Three-Phase Sensing)
5-2 BE1-51 Tests and Adjustments 9137200997 Rev D

Figure 5-3. Test Setup for Sensing Input Type H or V (Three-Phase with Neutral Sensing)
Figure 5-4. Test Setup for Sensing Input Type I or X (Two-Phase with Neutral Sensing)
Time Overcurrent Pickup Test

This test checks the minimum and maximum overcurrent pickup points of the time overcurrent element.
NOTE
During this test, disregard any indication on the test setup timer.
Step 1. Perform the preliminary instructions.

Step 2. Set the front panel TAP selector to A.
Step 3. Adjust the test set, for an overcurrent threshold having one of the following values:
(a) 0.5 for relays with Sensing Input Range 1, 2, or 4.
(b) 1.5 A for relays with Sensing Input Range 3 or 5.

Step 4. Slowly adjust the front panel TAP CAL control CCW until the front panel TIMING indicator
illuminates.
RESULT: For the phase minimum overcurrent pickup point of 0.5 A (Step 3a, above) or 1.5 A
(Step 3b, above) the front panel TAP CAL control should be near its maximum CCW limit.
Step 5. Adjust the front panel TAP CAL control fully CW to allow measurement of the actual
overcurrent pickup point at the A setting of the front panel TAP selector. Note that the front
panel TIMING indicator will extinguish. Do not disturb this setting.
Step 6. Slowly increase the current toward the value of the front panel TAP selector A setting until the
front panel TIMING indicator illuminates. Do not disturb this setting.
Step 7. Record the current reading and remove input current.
RESULT: The recorded value should be within ±5% of the front panel TAP selector A setting
for the phase minimum overcurrent pickup point for the time overcurrent.
Step 8. Set the front panel TAP selector to J.
Step 9. Slowly adjust the test set, increasing the overcurrent threshold toward the value of the front
panel TAP selector J setting until the front panel TIMING indicator just illuminates. Do not
disturb this setting.
RESULT: The recorded value should be within ±5% of the front panel TAP selector J setting for
the phase maximum overcurrent pickup point for the time overcurrent element.
Step 11. Perform the following steps as appropriate for the correct sensing input types.
(a) Sensing Input Type K (Single-Phase Sensing). This concludes the time overcurrent test.
Proceed to the timed output test.
(b) Sensing Input Type I or X (Two-Phase and Neutral Sensing). Remove the power and
reconnect the input sensing to the remaining phases as shown in Figure 5-4, each time
repeating Steps 1 through 10. For neutral testing, continue with Step 12.
(c) Sensing Input Type G (Three-Phase Sensing). Remove the power and reconnect the
input sensing to each of the remaining phases as shown in Figure 5-2, each time
repeating Steps 1 through 10.
(d) Sensing Input Type H or V (Three-Phase with Neutral Sensing). Remove the power and
reconnect the input sensing to each of the remaining phases as shown in Figure 5-3,
each time repeating Steps 1 through 10. For neutral testing, continue with Step 12.
For the neutral sensing (terminals 17 and 18), connect the relay as shown in Figures 5-3 and 5-
4, then perform the following steps (Steps 13 through 21).
Step 13. Set the front panel TAP (NEUTRAL) selector to A.
Step 14. Adjust the test set for an overcurrent threshold having one of the following values:
(a) 0.5 A for relays with Sensing Input Range 2 or 3.
(b) 1.5 A for relays with Sensing Input Range 4 or 5.
Step 15. Slowly adjust the front panel CAL (NEUTRAL) control CCW until the front panel TIMING
indicator illuminates.
RESULT: For the neutral minimum overcurrent pickup point of 0.5 A (Step 16a, above) or 1.5 A
(Step 16b, above) the front panel CAL (NEUTRAL) control should be near its maximum CCW
limit.
Step 16. Adjust the front panel CAL (NEUTRAL) control fully CW to allow measurement of the actual
overcurrent pickup point at the A setting of the front panel TAP (NEUTRAL) selector. Note that
the front panel TIMING (NEUTRAL) indicator will extinguish. Do not disturb this setting.
Step 17. Slowly increase the current toward the value of the front panel TAP (NEUTRAL) selector A
setting until the front panel TIMING (NEUTRAL) indicator illuminates. Do not disturb this
setting.
RESULT: The recorded value should be within ±5% of the front panel TAP (NEUTRAL)
selector A setting for the neutral minimum overcurrent pickup point for the time overcurrent.
Step 19. Set the front panel TAP (NEUTRAL) selector to J.
panel TAP (NEUTRAL) selector J setting until the front panel TIMING (NEUTRAL) indicator
just illuminates. Do not disturb this setting.
RESULT: The recorded value should be within ±5% of the front panel TAP (NEUTRAL)
selector J setting for the neutral maximum overcurrent pickup point for the time overcurrent
element.
Neutral Defeat Test

Step 2. Set the front panel NEUTRAL TAP selector to A.
Step 3. Set the front panel NEUTRAL TIME DIAL selector to 00.
Step 4. Apply two times (200%) input current of tap A to neutral terminals and allow relay to time out
(trip).
Step 5. Set the front panel NEUTRAL DEFEAT switch to ON (up).
RESULT: (1) NEUTRAL DEFEAT LED illuminates.
(2) NEUTRAL TIMING LED extinguishes.
(3) Output relay opens (closes if NC).
Step 6. Set the front panel NEUTRAL DEFEAT switch to OFF (down).
RESULT: (1) NEUTRAL DEFEAT LED extinguishes.
(2) NEUTRAL TIMING LED illuminates.
(3) Output relay closes (opens if NC) after appropriate time delay.
Step 7. Remove input current.
Timed Output Test

This test checks the accuracy of the time overcurrent characteristic delay.
NOTE
For relays having three-phase sensing (Sensing Input Type G or V), only a single
input phase needs to be connected, since this is sufficient for a complete test of
the Time Delay. For relays that include neutral sensing (Sensing Input Type H, I,
V, or X) this test includes reconnecting the Test Output to the Neutral Sensing
terminals for testing the Timed Output during neutral sensing.
Step 1. Verify that the preliminary instructions have been performed.

Step 2. (Timing type Z1, Z2, or Z3 only.) Select the desired time current characteristic curve.
Step 3. Set the front panel TAP selector to B.
Step 4. Adjust the front panel TIME DIAL to 20.
Step 5. Adjust the test set for an overcurrent threshold of precisely 5 times the front panel TAP selector
B setting.
Step 6. Apply input current to the relay and initiate the test setup timer.
Step 7. Observe that the appropriate front panel TIMING indicator illuminates and when the time delay
ends that the timed output relay is energized.
RESULTS: (1) The appropriate front panel TIMING indicator extinguishes.
(2) The test setup timer stops. (Record count for use in Step 9.)
(3) If target type A or B is present:
(a) The front panel FUNCTION-TIME target (if present) trips.

(b) The appropriate front panel ELEMENT target A, B, or C (if present)
trips.
Step 8. Remove input current and (if present) reset the relay front panel targets.
NOTE
Due to delays inherent in the test equipment, the time delay for the following test
may appear to exceed these limits.
Step 9. On the appropriate time overcurrent curve chart (Figures A-1 through A-69), locate the line
representing 5 times the tap value (from Step 5) where it intersects the particular curve
representing the front panel TIME DIAL setting of 20 (from Step 4). The resulting time delay
value in seconds should be within ±5% of the timer reading [from Step 7(2)].
Step 10. Adjust the front panel TIME DIAL to 40, 60, and 99, each time repeating Steps 6 through 9.
NOTE
For relays having two-phase-and-neutral, three-phase, or three-phase-and-
neutral sensing (Sensing Input Types G, H, I, V, or X) it is not necessary to
repeat this test for the remaining phases.
For relays having two-phase-and-neutral, or three-phase-and-neutral sensing
(Sensing Input Types H, I, V, or X) perform Steps 11 through 20.
For relays having single-phase or three-phase sensing (Sensing Input Types G
or K) with instantaneous overcurrent option 1-1 or 1-2, proceed to the
instantaneous overcurrent test.
Step 11. Remove the power and reconnect the test output to the neutral current sensing input of the
relay as shown in Figures 5-3 and 5-4 (terminals 17 and 18).
Step 12. Set the front panel TAP (NEUTRAL) selector to B.
Step 13. Rotate the front panel CAL (NEUTRAL) control fully CW.
Step 14. Rotate the front panel TIME DIAL (NEUTRAL) to 20.
Step 15. Ensure that all relay targets have been reset.
Step 16. Adjust the test set for an overcurrent threshold of precisely 5 times the front panel TAP
(NEUTRAL) selector B setting as measured by the ammeter.
Step 17. Apply input current to the relay and initiate the test setup timer.
RESULTS: Observe that the appropriate front panel TIMING (NEUTRAL) indicator illuminates.
Step 18. When the time delay ends, the timed output relay is energized.
RESULTS: (1) The front panel TIMING (NEUTRAL) indicator extinguishes.
(2) The test setup timer stops. (Record count for use in Step 20.)
(3) If target Type A or B is present:
(a) Front panel FUNCTION-TIME target (if present) trips.
(b) Appropriate front panel ELEMENT target A, B, or C (if present) trips.
Step 19. Remove input current and (if present) reset the relay front panel targets.
Step 20. On the appropriate time overcurrent curve chart (Figures A-1 through A-69), locate the line
representing 5 times the tap value (from Step 5) where it intersects the particular curve
representing the front panel TIME DIAL (NEUTRAL) setting of 20 (from Step 14). The resulting
time delay value in seconds should be within ±5% of the timer reading [from step 18(2)].

NOTE
Due to delays inherent in the test equipment, the time delay may appear to
exceed these limits. This concludes the timed output test.
Relays having instantaneous overcurrent option 1-1 or 1-2 only proceed to the
Instantaneous Overcurrent Pickup Test.
Instantaneous Overcurrent Pickup Test

This test checks the minimum overcurrent pickup points for Instantaneous 1 and (if present)
Instantaneous 2 outputs.
NOTE
For relays having three-phase sensing (Sensing Input Types G or V), only a
single input phase is connected since this is sufficient for a complete test of the
instantaneous overcurrent sensing and output.
For relays that include neutral sensing (Sensing Input Types H, I, V, or X), this
test includes reconnecting the test output to the neutral sensing terminals for
testing the instantaneous 1 output during neutral sensing.

Step 2. Reconnect the test setup to the INST 1 output terminals 2 and 10 as shown in Figures 5-1
through 5-4. Note that the timer may be removed from the test setup at this time.
Step 3. Set the TAP selector to A.
Step 4. Turn the front panel INST 1 control fully CCW to establish a pickup point of 1 times the TAP
selector A setting.
panel TAP selector A setting until the Instantaneous 1 output relay energizes.
RESULT: If target Type A or B is present:
(a) The front panel FUNCTION-INST 1 target (if present) will trip.
(b) The appropriate front panel ELEMENT target A, B, or C (if present) will trip.
Step 6. Remove input current. Record the test set current setting.
RESULT: The recorded value should be equal to or less than the front panel TAP selector A
setting for the minimum overcurrent pickup point for the instantaneous 1 overcurrent element.
Step 7. Reset the relay front panel targets (if present).
Step 8. Turn the front panel INST 1 control fully CW to establish a pickup point of 40 times the front
panel TAP selector A setting.
Step 9. Adjust the test set to approximately 35 times the front panel TAP selector A setting.
Step 10. Slowly adjust the test set further toward an overcurrent threshold of 40 times the front panel
TAP selector A setting until the instantaneous 1 output relay energizes. Do not disturb this
setting.
RESULT: If target Type A or B is present:
(a) The front panel FUNCTION-INST 1 target (if present) will trip.
(b) The appropriate front panel ELEMENT target A, B, or C (if present) will trip.
Step 11. Record the current reading. Remove input current (the front panel TIMING indicator should
extinguish).
RESULT: The recorded value should be greater than 40 times the front panel TAP selector A
setting for the maximum overcurrent pickup point for the instantaneous 1 overcurrent element.

NOTE
For relays having neutral sensing (Sensing Input Types H, I, V, or X) perform
Step 12. For relays with option 1-2 (INST 2 elements), perform Step 13.
Otherwise, the test ends here.
Step 12. For the neutral sensing, connect the relay as shown in Figures 5-3 and 5-4, then repeat Steps 2
through 11, substituting the following:
(a) The front panel TAP (NEUTRAL) selector instead of the front panel TAP selector (Step 3).
(b) The front panel INST 1 (NEUTRAL) control instead of the front panel INST 1 control
(Step 4).
Step 13. Reconnect the test setup to the INST 2 output terminals (11 and 12) as shown in Figure 5-1,
then repeat Steps 4 through 11, substituting the following:
(a) Front panel INST 2 control instead of the front panel INST 1 control (Step 3).
(b) Front panel FUNCTION-INST 2 target instead of the front panel INST 1 target (Step 4).
(c) Instantaneous 2 output relay instead of the instantaneous 1 output relay (Step 2).
ADJUSTMENTS OF CONTROLS FOR RELAY OPERATION

The following procedures set up the relay for use in a protective scheme. The procedures are arranged in
a logical sequence that prevents upsetting previous control settings. For relays not having certain options,
skip the corresponding adjustment paragraph. These paragraphs are identified by their headings.
TAP and TAP (NEUTRAL) Selector Setting
NOTE
Selection of one of the specific overcurrent pickup points provided by the front
panel TAP selector (and with the front panel TAP CAL control fully CW) will
permit a pickup point within ±5% of the selector value without having to connect
the relay to a test setup to verify the setting. If present, the front panel TAP
(NEUTRAL) selector and the front panel CAL (NEUTRAL) control provide this
function for the neutral overcurrent pickup point
However, if the desired pickup point falls between these front panel TAP selector
settings, or if the instantaneous overcurrent option 1-1 or 1-2 is present, the relay
should be connected to a test setup for a precise setting, then the following steps
should be performed.
Step 1. Connect the test setup to the relay according to the sensing input type present in the relay as
follows:
(a) Sensing Input Type K: Refer to Figure 5-1. Because the relay front panel TIMING indicator
provides the needed pickup indication, do not connect the test setup to the output
terminals. The current sense terminals for the desired range (HIGH or LOW), however,
should be connected to the relay.
(b) Sensing Input Types I or X: Refer to Figure 5-4. Because the relay front panel TIMING
indicator provides the needed pickup indication, do not connect the test setup to the output
terminals. The front panel TAP selector is ganged and the adjustment of one input phase
automatically aligns the other, thus, only one set of current sense terminals need be
connected. For adjustment of the front panel TAP (NEUTRAL) selector, the relay is
reconnected for neutral sensing by this procedure.
(c) Sensing Input Type G: Refer to Figure 5-2. Because the relay front panel TIMING indicator
provides the needed pickup indication, do not connect the test setup to the output
terminals. The desired range terminals (HIGH or LOW), however, should be connected to
the relay. The front panel TAP selector is ganged and the adjustment of one input phase
automatically aligns the others, thus, only one set of current sense terminals need be
connected.

(d) Sensing Input Types H or V: Refer to Figure 5-3. Because the relay front panel TIMING
indicator provides the needed pickup indication, do not connect the test setup to the output
terminals. The front panel TAP selector is ganged and the adjustment of one input phase
automatically aligns the others, thus, only one set of current sense terminals need be
connected. For adjustment of the front panel TAP (NEUTRAL) selector, the relay is
reconnected for neutral sensing by this procedure.
Step 2. Remove the relay front cover.
Step 3. Sensing Input Types G, I, K, or X. Verify that the front panel TAP RANGE plate is installed and
the correct range (HIGH or LOW) is visible.
Step 4. Adjust the test current to the desired time overcurrent pickup point for the relay.
Step 5. Set the front panel TAP selector to the closest setting above the desired pickup point.
Step 6. Adjust the front panel TAP CAL control fully CW.
Step 7. Apply current to the relay.
Step 8. Slowly adjust the front panel TAP CAL control CCW until the front panel TIMING indicator just
illuminates which indicates the desired time overcurrent pickup point for phase sensing. For
relays with two-phase-and-neutral, three-phase, or three-phase-and-neutral sensing, this
pickup point will be the same for all the phases.
NOTE
For relays with two-phase-and-neutral or three-phase-and-neutral sensing
(Sensing Input Types I or V), perform Steps 10 through 15. Otherwise, the time
overcurrent pickup point calibration ends here (unless instantaneous 1 or 2
overcurrent calibration is to be performed later in these procedures).
Step 10. Reconnect the test set output to the neutral sense terminals. See Figures 5-3 or 5-4.
Step 11. Adjust the current to the desired time overcurrent pickup point for the relay.
Step 12. Set the front panel TAP (NEUTRAL) selector to the closest setting above the desired pickup
point.
Step 13. Rotate the front panel CAL (NEUTRAL) control fully CW.
Step 14. Slowly adjust the front panel CAL (NEUTRAL) control CCW until the front panel TIMING
(NEUTRAL) indicator just illuminates to establish the desired time overcurrent pickup point for
neutral sensing.
NOTE
Pickup point calibration ends here.
Time Overcurrent Curve Selection (Timing Type Z1, Z2, and Z3 Only)
Step 1. Remove the relay cradle front cover to gain access to the logic board time overcurrent
characteristic curve selector.
Step 2. Remove the Phillips screws from both sides of the unit and remove the front panel. See Figure
2-1 for the location of the logic board and curve selector.
Step 3. Select the desired curve. See Table A-2 for the desired curve and selector position.
Step 4. Re-install the front panel and the front cover.

Time Delay Selection
NOTE
If Timing Type Z1, Z2, or Z3 is installed, refer to time overcurrent curve selection
to obtain the desired set of time overcurrent curves (see Figures A-1 through A-
69). Then proceed to Step 1, following.
If Timing Type Z1, Z2, or Z3 is not installed, determine the timing type from the
model and style number for a specific relay. Then select the appropriate timing
curve (see Figures A-1 through A-69). Proceed to the following, Step 1.
Step 1. Referring to the appropriate time overcurrent characteristic curve, select the desired time delay
on the front panel TIME DIAL for the anticipated input overcurrent difference (multiples-of-
pickup current) from the selected time overcurrent pickup point as follows:
(Selected Pickup Point) - (Anticipated Input Overcurrent) = Overcurrent Difference from Pickup
Step 2. Set the front panel TIME DIAL as follows:
(a) On the appropriate curve, plot upward from the multiples-of-pickup-current value until the
horizontal line opposite the desired time delay (time-in-seconds) is reached. The setting
curve nearest the plot point should then be entered on the front panel TIME DIAL.
(b) Using Figure 1-6 as an example, if the overcurrent is expected to be 4 times the pickup
point value and time delay of 4 seconds is desired, plot upward from the point 4 on the
multiples-of-pickup-current axis until the point 4 from the time-in-seconds axis is
crossed. The curve for a setting of 52 crosses the plot point and should be entered on the
front panel TIME DIAL.
(c) For a lesser overcurrent difference from the pickup point, the time delay will be greater, so
that for a multiple of 3 times the pickup current, the time delay for the previous front panel
setting of 52 will be 5.8 seconds.
Neutral Time Delay Selection

Step 1. Use the same characteristic curve used in the previous paragraph (Time Delay Selection).
However, the multiples-of-pickup current, time-in-seconds, and the resulting front panel
NEUTRAL TIME DIAL setting can differ.
Step 2. Set the front panel NEUTRAL TIME DELAY as follows:
(a) On the appropriate curve, plot upward from the multiples-of-pickup-current value until the
horizontal line opposite the desired time delay (time-in-seconds) is reached. The setting
curve nearest the plot point should then be entered on the front panel NEUTRAL TIME
DELAY.
(b) Using Figure 1-6 as an example, if the overcurrent is expected to be 4 times the pickup
point value and time delay of 4 seconds is desired, plot upward from the point 4 on the
multiples-of-pickup-current axis until the point 4 from the time-in-seconds axis is
crossed. The curve for a setting of 52 crosses the plot point and should be entered on the
front panel NEUTRAL TIME DIAL.
(c) For a lesser overcurrent difference from the pickup point, the time delay will be greater, so
that for a multiple of 3 times the pickup current, the time delay for the previous front panel
setting of 52 will be 5.8 seconds.
INST 1 Control Setting
NOTE
Because the lower limit for this pickup is determined by the front panel TAP
selector setting and the front panel TAP (CAL) control position, ensure that these
adjustments have been performed as in the paragraph TAP and TAP
(NEUTRAL) Selector Setting.

Step 1. Verify that the test setup is as described in TAP and TAP (NEUTRAL) Selector Setting, Steps 1
through 6.
Step 2. Connect the test setup to the instantaneous 1 element output terminals (2 and 10) as shown in
Figures 5-1 through 5-4. The timer should not be connected.
CAUTION
Steps 3 through 8 provide the application of overcurrent for short periods to allow
adjustment while avoiding overheating of the input sensing transformers. To
avoid damaging the relay, do not attempt to apply a constant high level of input
current for adjustment of the front panel INST 1, INST 1 (NEUTRAL), or INST 2
controls.
Step 3. Set the front panel INST 1 control to a position approximating the desired instantaneous 1
overcurrent pickup point for the relay.
Step 5. Rapidly increase the overcurrent input to the relay until the instantaneous output relay just
energizes. Note the overcurrent threshold reading on the ammeter.
Step 7. Reset the INST TARGET (if present).
Step 8. If the overcurrent threshold reading from Step 5 was too high or low, adjust the front panel
INST 1 control CCW to lower (or CW to raise) the instantaneous 1 overcurrent pickup point.
Repeat Steps 4 through 8. If the overcurrent threshold reading from Step 5 was NOT too high
or low, proceed to Step 9.
NOTE
For relays with two-phase-and-neutral or three-phase-and-neutral sensing
(Sensing Input Types I or X), perform Steps 9 through 14.
Step 9. Reconnect the output to the neutral current sense terminals. See Figures 5-3 or 5-4.
Step 10. Set the front panel INST 1 (NEUTRAL) control to a position approximating the desired neutral
instantaneous 1 overcurrent pickup point for the relay.
Step 12. Rapidly increase the overcurrent input to the relay until the instantaneous output relay just
energizes. Note the test set overcurrent threshold reading on the ammeter.
Step 13. Remove the input current.
Step 14. Reset the INST TARGET (if present).
Step 15. If the overcurrent threshold reading from Step 13 was too high or low, adjust the front panel
INST 1 (NEUTRAL) control CCW to lower (or CW to raise) the Neutral Instantaneous 1
Overcurrent Pickup Point. Repeat Steps 9 through 14. If NOT, proceed to the next test.
INST 2 Control Setting

For this adjustment, repeat INST 1 Control Setting, but substitute instantaneous 2 output terminals (11
and 12) and the front panel INST 2 controls. Because neutral sensing does not apply to this pickup point,
ignore Steps 9 through 15.


APPENDIX A • TIME OVERCURRENT
CHARACTERISTIC CURVES
TABLE OF CONTENTS
APPENDIX A • TIME OVERCURRENT CHARACTERISTIC CURVES ...................................................A-1
EXPLANATION OF CURVES................................................................................................................A-1
Figures
Figure A-1. Timing Type B1, Short Inverse ...............................................................................................A-3
Figure A-2. Timing Type B1, Short Inverse with Extended Timing Range................................................A-3
Figure A-3. Timing Type B2, Long Inverse................................................................................................A-4
Figure A-4. Timing Type B2, Long Inverse with Extended Timing Range ................................................A-4
Figure A-5. Timing Type B3, Definite Time ...............................................................................................A-5
Figure A-6. Timing Type B3, Definite Time with Extended Timing Range ................................................A-5
Figure A-7. Timing Type B4, Moderately Inverse......................................................................................A-6
Figure A-8. Timing Type B4, Moderately Inverse with Extended Timing Range ......................................A-6
Figure A-9. Timing Type B5, Inverse.........................................................................................................A-7
Figure A-10. Timing Type B5, Inverse with Extended Timing Range .......................................................A-7
Figure A-11. Timing Type B6, Very Inverse ..............................................................................................A-8
Figure A-12. Timing Type B6, Very Inverse with Extended Timing Range ...............................................A-8
Figure A-13. Timing Type B7, Extremely Inverse......................................................................................A-9
Figure A-14. Timing Type B7, Extremely Inverse with Extended Timing Range ......................................A-9
Figure A-15. Timing Type B8, I2t .............................................................................................................A-10
Figure A-16. Timing Type B8, I2t with Extended Timing Range ..............................................................A-10
Figure A-17. Timing Type C1, I2t with Limit #1 ........................................................................................A-11
Figure A-18. Timing Type C1, I2t with Limit #1 and Extended Timing Range .........................................A-11
Figure A-33. Timing Type E2, BS 142 Long Inverse...............................................................................A-19
Figure A-34. Timing Type E4, BS 142 Inverse (1.3 Sec) ........................................................................A-19
Figure A-35. Timing Type E5, BS 142 Inverse (2.9 Sec) ........................................................................A-20
Figure A-36. Timing Type E6, BS 142 Very Inverse ...............................................................................A-20
Figure A-37. Timing Type E7, BS 142 Extremely Inverse.......................................................................A-21
Figure A-38. Timing Type B1, Short Inverse with Integrated Algorithm ..................................................A-22
Figure A-39. Timing Type B1, Short Inverse with Integrated Algorithm and Extended Timing...............A-22
Figure A-40. Timing Type B2, Long Inverse with Integrated Algorithm...................................................A-23
Figure A-41. Timing Type B2, Long Inverse with Integrated Algorithm and Extended Timing ...............A-23
Figure A-42. Timing Type B3, Definite Time with Integrated Algorithm ..................................................A-24
Figure A-43. Timing Type B3, Definite Time with Integrated Algorithm and Extended Timing ...............A-24
Figure A-44. Timing Type B4, Moderately Inverse with Integrated Algorithm.........................................A-25
Figure A-45. Timing Type B4, Moderately Inverse with Integrated Algorithm and Extended Timing .....A-25
Figure A-46. Timing Type B5, Inverse with Integrated Algorithm............................................................A-26
Figure A-47. Timing Type B5, Inverse with Integrated Algorithm and Extended Timing ........................A-26
Figure A-48. Timing Type B6, Very Inverse with Integrated Algorithm ...................................................A-27
Figure A-49. Timing Type B6, Very Inverse with Integrated Algorithm and Extended Timing ................A-27
9137200997 Rev D BE1-51 Time Overcurrent Characteristic Curves i
Figure A-50. Timing Type B7, Extremely Inverse with Integrated Algorithm...........................................A-28
Figure A-51. Timing Type B7, Extremely Inverse with Integrated Algorithm and Extended Timing .......A-28
Figure A-52. Timing Type B8, I2t with Integrated Algorithm ....................................................................A-29
Figure A-53. Timing Type B8, I2t with Integrated Algorithm and Extended Timing .................................A-29
Figure A-54. Timing Type C1, I2t Limit #1 with Integrated Algorithm ......................................................A-30
Figure A-57. Timing Type C2, I2t Limit #2 with Integrated Algorithm and Extended Timing ...................A-31
Tables
Table A-1. Timing Choices with Available Curves.....................................................................................A-1
Table A-2. Timing Curve Selection Table..................................................................................................A-2
ii BE1-51 Time Overcurrent Characteristic Curves 9137200997 Rev D

APPENDIX A • TIME OVERCURRENT
CHARACTERISTIC CURVES
EXPLANATION OF CURVES
Graphs on the following pages illustrate sample characteristic curves for all of the time overcurrent
functions individually as options, or selectable by switch (if the Z1, Z2, or Z3 timing option is specified). Z1
option can select any of the timing types designated as B1 through B8, and C1 through C8. Z2 option can
select any of the timing types designated as B1 through B8, and the British Standard timing types: E2,
E4, E5, E6, and E7. Z3 option can select the integrating algorithm for any of the timing types designated
as B1 through B8, and C1 through C8.
Note that there are two versions of each timing type: standard and extended timing. Both types are
located on the same page. The exception to this is the British Standard curves, which do not have an
extended timing version. For any given relay, either the standard or the extended range version will apply,
never both.
Table A-1 lists timing choices with available curves. Table A-2 lists the positions of the timing curve
selector switch. (See Figure 2-1 for switch location).
Table A-1. Timing Choices with Available Curves

Timing Choices Z1 Z2 Z3 (Integrating)
Short Inverse Short Inverse Short Inverse
Long Inverse Long Inverse Long Inverse
Definite Time Definite Time Definite Time
Moderately Inverse Moderately Inverse Moderately Inverse
Inverse Time Inverse Time Inverse Time
Very Inverse Very Inverse Very Inverse
Extremely Inverse Extremely Inverse Extremely Inverse
2
It BS 142 Long Inverse I2t
Available Curves
I2t with Limit 1 BS142 Inverse (1.3 sec) I2t with Limit 1
I2t with Limit 2 BS142 Inverse (2.9 sec) I2t with Limit 2
I2t with Limit 3 BS142 Very Inverse I2t with Limit 3
I2t with Limit 4 BS142 Extremely Inverse I2t with Limit 4
I2t with Limit 5 N/A I2t with Limit 5
9137200997 Rev D BE1-51 Time Overcurrent Characteristic Curves A-1

Table A-2. Timing Curve Selection Table
Standard Extended Standard Extended
Selector Selector
Curves Curves Curves Curves
Timing Type Position Position
Z1, Z2 Z1, Z2 Z3 Z3
∗ †
Fig. No. Fig. No. Fig. No. Fig. No.
B1 - Short Inverse 3 3 A-1 A-2 A-38 A-39
B2 - Long Inverse 1 1 A-3 A-4 A-40 A-41
B3 - Definite Time 5 5 A-5 A-6 A-42 A-43
B4 - Moderately Inverse 2 2 A-7 A-8 A-44 A-45
B5 - Inverse 4 4 A-9 A-10 A-46 A-47
B6 - Very Inverse 6 6 A-11 A-12 A-48 A-49
B7 - Extremely Inverse 7 7 A-13 A-14 A-50 A-51
2
B8 - I t 0 0 A-15 A-16 A-52 A-53
C1 - I2t with Limit #1 8 — A-17 A-18 A-54 A-55
C2 - I2t with Limit #2 9 — A-19 A-20 A-56 A-57
2
C3 - I t with Limit #3 A — A-21 A-22 A-58 A-59
2
C4 - I t with Limit #4 B — A-23 A-24 A-60 A-61
C5 - I2t with Limit #5 C — A-25 A-26 A-62 A-63
C6 - I2t with Limit #6 D — A-27 A-28 A-64 A-65
2
C7 - I t with Limit #7 E — A-29 A-30 A-66 A-67
2
C8 - I t with Limit #8 F — A-31 A-32 A-68 A-69
E2 - Long Inverse — 8 A-33 — — —
E4 - Inverse (1.3 Sec.) — 9 A-34 — — —
E5 - Inverse (3.0 Sec.) — A A-35 — — —
E6 - Very Inverse — B A-36 — — —
E7 - Extremely Inverse — C,D,E,F A-37 — — —
∗ Timing option Z1 and Z3.
† Timing option Z2 only.
A-2 BE1-51 Time Overcurrent Characteristic Curves 9137200997 Rev D

P0049-03
P0049-02
1.5 1.5
Figure A-1. Timing Type B1, Short Inverse Figure A-2. Timing Type B1, Short Inverse
with Extended Timing Range

P0049-04
P0049-05
Figure A-3. Timing Type B2, Long Inverse Figure A-4. Timing Type B2, Long Inverse

P0049-07
P0049-06
Figure A-5. Timing Type B3, Definite Time Figure A-6. Timing Type B3, Definite Time

P0049-08
P0049-09
Figure A-7. Timing Type B4, Moderately Inverse Figure A-8. Timing Type B4, Moderately Inverse

P0049-10
P0049-11
Figure A-9. Timing Type B5, Inverse Figure A-10. Timing Type B5, Inverse

P0049-13
P0049-12
Figure A-11. Timing Type B6, Very Inverse Figure A-12. Timing Type B6, Very Inverse with
Extended Timing Range

P0049-15
P0049-14
Figure A-13. Timing Type B7, Extremely Inverse Figure A-14. Timing Type B7, Extremely Inverse

P0049-17
P0049-16
Figure A-15. Timing Type B8, I2t Figure A-16. Timing Type B8, I2t

P0049-19
P0049-18
Figure A-17. Timing Type C1, I2t with Limit #1 Figure A-18. Timing Type C1, I2t with Limit #1
and Extended Timing Range

P0049-21
P0049-20

P0049-22
P0049-23

P0049-25
P0049-24

P0049-27
P0049-26

P0049-29
P0049-28

P0049-31
P0049-30

P0049-32
P0049-33

P0049-35
P0049-34
Figure A-33. Timing Type E2, BS 142 Figure A-34. Timing Type E4,
Long Inverse BS 142 Inverse (1.3 Sec)

P0049-37
P0049-36
Figure A-35. Timing Type E5, Figure A-36. Timing Type E6,
BS 142 Inverse (2.9 Sec) BS 142 Very Inverse

P0049-38
Figure A-37. Timing Type E7,

BS 142 Extremely Inverse

P0049-40
P0049-39
Figure A-38. Timing Type B1, Short Inverse Figure A-39. Timing Type B1, Short Inverse with
with Integrated Algorithm Integrated Algorithm and Extended Timing

P0049-41
P0049-42
Figure A-40. Timing Type B2, Long Inverse Figure A-41. Timing Type B2, Long Inverse with

P0049-44
P0049-43
Figure A-42. Timing Type B3, Definite Time Figure A-43. Timing Type B3, Definite Time with

P0049-46
P0049-45
Figure A-44. Timing Type B4, Moderately Figure A-45. Timing Type B4, Moderately
Inverse with Integrated Algorithm. Inverse with Integrated Algorithm
and Extended Timing

P0049-48
P0049-47
Figure A-46. Timing Type B5, Inverse with Figure A-47. Timing Type B5, Inverse with
Integrated Algorithm Integrated Algorithm and Extended Timing

P0049-50
P0049-49
Figure A-48. Timing Type B6, Very Inverse Figure A-49. Timing Type B6, Very Inverse with

P0049-52
P0049-51
Figure A-50. Timing Type B7, Extremely Inverse Figure A-51. Timing Type B7, Extremely Inverse
with Integrated Algorithm with Integrated Algorithm
and Extended Timing

P0049-53
P0049-54
Figure A-52. Timing Type B8, I2t Figure A-53. Timing Type B8, I2t with Integrated
with Integrated Algorithm Algorithm and Extended Timing

P0049-56
P0049-55
Figure A-54. Timing Type C1, I2t Limit #1 Figure A-55. Timing Type C1, I2t Limit #1
with Integrated Algorithm with Integrated Algorithm

P0049-58
P0049-57
Figure A-56. Timing Type C2, I2t Limit #2 Figure A-57. Timing Type C2, I2t Limit #2 with

P0049-60
P0049-59

P0049-61
P0049-62

P0049-64
P0049-63

P0049-66
P0049-65

P0049-68
P0049-67

P0049-70
P0049-69


ROUTE 143, BOX 269
PHONE +1 618-654-2341 FAX +1 618-654-2351
I.L. 195C308C
Revised 11/13/06
ECS2100 Field Ground Detector
INSTRUCTION LEAFLET
All user settings and the firmware are stored in
DRAWINGS non-volatile flash memory and may be easily
The following drawings are referenced within this upgraded in the field using a laptop computer and
document. the proprietary ccTool software.
Ground Detector Source Schematic...195C308
Ground Detector Block Schematic ....195A308 This document contains a description of the
functions of the Ground Detector, along with a
PURPOSE description of inputs and outputs. There is also a
The function of the field ground detector is to brief description of the installation of the Ground
detect a ground current flowing from the machine Detector. Maintenance and warranty information
d-c field winding to the grounded machine shaft. is provided as well.
The ground detector continuously monitors the
machine field, and detects ground currents SAFETY
typically ranging from 0.1 ma to 30 ma.
DANGER:
The ground detector consists of a ground detection BODILY INJURY COULD RESULT IF
source along with pc cards and software in the CONTACT IS MADE WITH COMPONENTS
ECS2100. Relay contacts from a Digital output IN THIS APPARATUS WHICH CARRY
module (DIOM) provide remote alarm indication EITHER LINE VOLTAGE, OR
whenever a ground is detected. The actual leakage GENERATOR FIELD VOLTAGE OR ARE
current and equivalent resistance to ground may SUBJECT TO ABNORMALLY HIGH
be monitored via either the local or remote VOLTAGES. REFERENCES TO THE
operator interface device. The ground detector CIRCUIT DIAGRAMS, NOTABLY WITHIN
source may be either of two styles. The first is OTHER DOCUMENTATION WILL
intended to be applied to either brushless or brush DISCLOSE HAZARDOUS AREAS.
excitation systems with rated generator field
voltages ceilings of up to 800 V d-c. For this style
provision is made for checking the operation and As with all electrical equipment, appropriate
scaling of the ground current sensing circuitry by safety measures should be taken whenever dealing
applying a “simulated ground” to the ground with the excitation equipment. High voltage is
detector source. A second source is available for present within the excitation cubicles; their
static excitation systems with rated generator field magnitudes depend upon the particular system.
voltages ceilings of up to 1250 V d-c. At these Opening the sources (e.g., disconnect device 41)
voltages a separate isolation module is typically does not completely disconnect the high voltages.
used to provide electrical isolation between the As long as the machine is still physically
ground detector source and the analog input card. connected to the system, there is a possibility that
Effective Date 11/13/06 Supersedes 195C308B Page 1 of 6

INSTRUCTIONS FOR FIELD GROUND DETECTOR I.L. 195C308C
Every precaution must be taken when working at OPERATION/APPLICATION

the excitation control switchgear to ensure that all The Ground Detector is an integrated subsystem
high voltages are isolated and avoided by test within an ECS2100 excitation system. It consists
personnel. In addition to the machine terminal of a Ground Detector Source four control modules
voltage (460 Vac or greater) at the excitation Analog Input Output Module (AIOM), Sensor
transformer, there may be other sources of power Input Module (SIM), Exciter Control Module
entering the cubicles, such as the customer (ECM), Digital Input Output Module (DIOM), a
125/250 Vdc and/or 120/240 Vac used to feed user interface display, fuses and control relay
certain devices. The field voltage is also present at contacts. (A voltage isolation module between the
the ground detector power source. A good rule to Ground Detector Source and the Analog Input
follow is to assume that all connections are live Output Module (AIOM) may be used in higher
and dangerous until proven otherwise and to avoid voltage applications.) The Ground Detector
completely all body contact with any of these Source supplies approximately -125 vdc to the
voltages. positive side of a machine field (Field positive bus
is held negative with respect to ground.). This
One other cautionary note refers to the Generator source then measures the leakage current to
Field Ground Detector. Because the Ground ground. A voltage proportional to the leakage
Detector input supply is usually 120 Vac, both the current is sent to one of the inputs of an Analog
AC bus and DC (100 Vdc) might be backfed from Input Output Module. This voltage is digitized in
this device. Therefore it too must be disconnected the AIOM and sent serially via fiberoptic cables to
when servicing the excitation control equipment. the, Sensor Input Module. In the SIM the serial
information is converted to a digital word and sent
to the Exciter Control Module. This value of
GLOSSARY leakage current then appears as on output of the
ALOG_DIG software block. This ALOG_DIG
AIOM Analog Input / Output Module. software block is connected to the FLDGND
Provides the interface for analog software block.
signals into and out of the system.
Within the FLDGND software block, an
DIOM Digital Input / Output Module. equivalent resistance to ground is computed.
Provides the interface for 125 Vdc Typically, this computed resistance is sent to a
control signals into and out of the user interface, such as a Panelmate 1700, via the
system. PMOUT software block. The FLDGND software
block also generates a “Low Field Ground
ECM Exciter Control Module. Contains Resistance” alarm. Via the PMOUT software
the excitation control, limiting, block, this computed resistance is sent to a user
protection, and communication interface. Alternatively, via a DIGROUT software
software. block, this alarm can be used to pick up a relay in
the Digital Input Output Module. In some
SIM Sensor Input Module. Provides the applications, this is used to provide a dry relay
interface from PT and CT signals contact for a remote alarm.
and the AIOM and DIOM signals
to and from the ECM. Note: this ground detection scheme assumes that
the field is isolated form ground everywhere
except for the one point where the field ground
source references the “+” bus to be approximately

–125 vdc to ground. If there are other sources or Note: The 125 above is used as a nominal figure
loads connected to the field circuit, they will cause for ground detector source output voltage. The 30
misoperation of the ground detector. Care must be above is used as a nominal figure for current
taken to remove any other ground detectors from limiting resistance in the ground detector source.
the field circuit. Actual voltage and for current limiting resistance
can be set in FLDGND software block.
This field ground detection scheme can be used
with either a rotating exciter field or a generator For the min. resistance calculation, it is assumed
field. For brushless excitation systems where the ground occurs at the (+) terminal of the
grounding brushes are connected to the field machine field, and the voltage is supplied solely
occasionally, other discrete relay controls can be from the 125 V d-c supply of the ground detector
added to the control software and additional source. For the maximum resistance calculation, it
contacts from a DIOM can be used to lower the is assumed the ground occurs at the (-) terminal of
grounding brushes at the desired interval. Note: the machine field, and the voltage is supplied
this system does not contain a brush contact from the 125 V ground detector source supply in
verifier feature as in some other ground detection series with the D-C voltage applied across the
schemes. entire machine field. The possibility for a ground
to occur at a point in the excitation system where
The ground detector is continuously monitoring the machine field voltage to ground can nullify the
the leakage current to ground and computing an 125 V d-c from the ground detector source does
equivalent ground resistance range. (It acts much not exist. This is because the ground detector’s
like having a 125 vdc meggar continuously source voltage is always adds to any machine field
connected to the field) The magnitude of the voltage to ground.
ground current is dependent upon both the ohmic
value of the ground resistance and where the The ground detector scheme monitors the leakage
ground occurs in the excitation system. Depending current to ground by measuring the voltage drop
on where the ground occurs, the amount of across an internal shunt resistor. In the lower
leakage current will vary with the field voltage. voltage ground detector source a 500 ohm resistor
Therefore the actual ground resistance will fall is used. So an output voltage of 1 volt dc between
within a defined range for any particular value of pins 1 & 2 of the ground detector source would
leakage current. The following equations may be correspond to 2 milliamps of leakage current to
employed to determine the minimum and ground. In the higher voltage ground detector
maximum resistance values that can be expected source a 200 ohm resistor id used. So an output
for a given leakage current. voltage of 1 volt dc between pins 1 & 2 of the
ground detector source would correspond to 5
Min. resistance (kΩ) = (125 / IG) -30 milliamps of leakage current to ground.
Max. resistance (kΩ) = ((VF+ 125)/ IG) -30 EXAMPLE: FOR A MACHINE OPERATING
WITH A FIELD VOLTAGE OF 325 V D-C
Where (VF), WITH A MEASURED LEAKAGE
CURRENT OF 2.5 MA (lG), THE
VF = DC voltage across machine field. (volts) FOLLOWING RESISTANCE VALUES ARE
OBTAINED:
IG = Measured leakage ground current.(ma)

the current limiting resistors R1, R2, R3, through

Min. resistance = 125 - 30 = 20 K ohms the sensing resistor R4 and out terminal TB-4
2.5 which is also connected to station ground. For the
higher voltage ground detector source (G02),
325 + 125 - 30 Resistor R0 serves to limit the voltage across the
Max. resistance = 2.5 = 180Kohms
diode bridge if “high” voltages are applied across
the outputs.
This means that the ground resistance could be
anywhere between 20 K ohms to 180 K ohms. The enable relay 64G is energized when a 120 V,
50-60 Hz supply is connected to pins TB-8 and
The ground detector does not calculate a precise TB-9. This A-C power is typically removed
single value of field ground resistance. Rather it during field flashing by a 31X contact to prevent
calculates a resistance range, with the actual reading a ground through the station battery. A
resistance to ground being somewhere between 41AX contact may be used to remove the 125Vdc
the minimum resistance and maximum resistance. from the field when the exciter disconnect is open.
Note: If a ground occurs near the (-) terminal of The resistors R6, R7, zener diode Z1, and
the machine field, and the field voltage is high capacitor C1 serve to provide protection of the
enough to cause the leakage current to exceed Analog Input Output Module against voltage
4.17 ma, the calculated min. resistance will be transients coming in from the machine field
negative. connection.
Ground Detector Source Hardware For the lower voltage ground detector source
(G01), a resistor RT is supplied which may be
The ground detector source operates from a 1 used to check the setup of the ground detector.
phase, 120 V, 50-60 Hz supply. The diode bridge Normally this resistor is disconnected from the
DB1 rectifies A-C power from T1. The nominally output of the ground detector source. Before using
125 V d-c rectified signal is supplied to the output RT, the field needs to be disconnected from the
pins through current limiting resistors R1, R2,R3, ground detector source by opening 64FU. After 64
and sensing resistor R4 when relay 64G is FU has been opened, RT is unplugged from TB-
energized. For the lower voltage ground detector 13, 14,15 and then plugged into TB-10, 11,12.
source (G01) the output pins are TB-4 and TB-5 , The display should then read approximately one
where TB-4 is connected to ground and TB-5 is megaohm. After taking the reading RT should be
connected to the field “+” bus. For the higher replaced in TB-13, 14,15 before closing 64FU.
voltage ground detector source (G02) the output
pins are TB-4 and TB-6 , where TB4 is connected INSTALLATION
to ground and TB-6 is connected to the field “+” When shipped, the equipment will have its
bus. Current limiting resistors R1, R2, and, R3 Ground Detector Source physically installed and
serve to limit the current to about 4.2 ma if the connected. If replacement is necessary, open
output terminals are shorted together. Sensing GDFU (EXFU), and 64FU before removing the
resistor R4 serves to develop a voltage Ground Detector Source. Carefully label and
proportional to leakage current. That voltage, document each of the connections to the Ground
representing leakage current, is sent to an Analog Detector Source in order to properly reconnect to
Input Output Module. Should a ground develop, a a new board.
ground current will flow from the grounded
machine shaft through the field winding, through

Connection of ccTool For the higher voltage ground detector source

In order to perform a setup, the user must connect (G02)
a personal computer running the Windows™ 1. With the machine field disconnected from the
application program ccTool to the ECM via ground (64FU open) and RT removed,
connector J22. Use a standard through wired measure 120 V a-c between pins 6 and 7 and 8
RS232 cable with DB 9 pin on the end connecting
and 9 on the Ground Detector source. If
to the ECM and DB 9 or 25 pin at the other end to voltage is not present, check fuses GDFU (or
match the RS232 port on the PC. After assuring EXFU) feeding the ground detector source for
the communication source jumper is properly a possible open fuse.
installed and the ECM is energized, invoke
ccTool. Use software blocks ALOG_DIG and 2. Measure 125 V d-c between TB-5 (-) and TB-
FLDGND to setup the ground detector. 4 (+). Measure 125 V d-c between TB-5 (-)
and ground bus.
3. Connect a 100 Kilo-ohm resistor between
DETAILED TEST INSTRUCTION TB-13, and TB-15. Measure 0.2 volts d-c
These instructions are required only if the between TB-1 (-) and TB-2 (+). Display
apparatus does not function in accordance with should read approximately 100 Kilo-ohm.
the description and operation previously Remove resistor from TB-13, and TB-15.
described above or in the instruction leaflet for
the system of which this apparatus is a part. 4. Close 64FU. Measure voltage from the “+”
bus to ground on both sides of the fuse 64FU
For the lower voltage ground detector source to be the same. ( The voltage should be
(G01) approximately –125vdc with ground on meter
common.)
1. With the machine field disconnected from
the ground (64FU open) and RT removed,
measure 120 V a-c between pins 6 and 7 and 8
and 9 on the Ground Detector source. If MAINTENANCE
voltage is not present, check fuses GDFU (or
EXFU) feeding the ground detector source for This equipment contains solid state components
a possible open fuse. which require little maintenance. The removal of
accumulated dust occasionally will be sufficient.
2. Measure 125 V d-c between TB-5 (-) and Maintenance for non-solid-state components is
TB-4 (+). Measure 125 V d-c between TB-5 (- required only as specifically defined.
) and ground bus.
3. Plug RT into TB-10, 11,12. Measure 0.062
d-c between TB-1 (-) and TB-2 (+). Display SPARE PARTS
should read 1000 kilo-ohm. Return RT to TB-
13, 14,15. A reasonable stock of spare parts will minimize
down-time, in the event of a malfunction in this
4. Close 64FU. Measure voltage from the “+” equipment. When ordering spare parts, care
bus to ground on both sides of the fuse 64FU
to be the same. ( The voltage should be
approximately –125vdc with ground on meter
common.)
For the ECM, it is recommended that the user
stock at least one ECM board.

SPECIFICATIONS AND PERFORMANCE Environment

Burden
The nominal burden of the ground detector source Relative humidity of 0 to 95% non-condensing
is about 20 VA at 120 V, 60Hz.

Highland, Illinois USA (618) 654-2341

ABB Automation Inc. Instruction Leaflet
Substation Automation and Protection Division
Coral Springs, FL 33065 41-751N
Effective: September 1995 Type SG

Supersedes I.L. 41-751M, Dated August 1980 Auxiliary Relay
( ) Denotes Change Since Previous Issue
6, 12, 24, 48, 125 and 250 volts dc

! CAUTION 115 and 230 volts - 25 hertz
115, 230, 440 and 575 volts - 50 or 60 hertz
Before putting protective relays into service,
remove all blocking which may have been By using a series resistor, each of the different volt-
inserted for the purpose of securing the parts age relays may be used on higher voltage systems
during shipment, make sure that all moving parts provided the proper dielectric and safety consider-
operate freely, inspect the contacts to see that ations are observed.
they are clean and close properly, and operate
the relay to check the settings and electrical con- 2.0 CONSTRUCTION & OPERATION
nections
The SG relays are clapper-type devices designed to
1.0 APPLICATION operate over a wide range of ac and dc voltages.
When their coils are energized at or above pickup rat-
The relay is intended for use in the applications ing, the moving contacts on the armature assembly,
requiring: close and/or open with the two stationary contacts to
activate the electrically independent contact circuits.
(1) Increased current-carrying or interrupting
capability in a contact (low current con- Closed types are supplied with two make and two
tact energizes the SG coil to close the break contacts. Open types (front connected) can be
high current contact). supplied with two make and two break contacts, or
with only the two make contacts which can be
(2) Circuit isolation.
reversed to provide one make, one break, or two
(3) Contact conversion (for example, from a break contact circuits. Contact gap and follow should
normally open to normally closed condi- be readjusted per Table 1 after contacts have been
tion), or reversed. Adjustment is accomplished by bending the
stationary contacts.
(4) Contact multiplication (from one contact
input to two contact output).
Small coil springs on the moving contact arms pro-
vide adequate contact pressure to assure positive
The SG relay is available with 2 N.O. (normally-open)
contact action between the moving and stationary
and 2 N.C. (normally-closed) contacts. They change
contacts.
condition when the coil is energized at a voltage level
above pickup. The contacts are arranged in a 3-lead
DC types have a bronze pin on the core which serves
configuration with a “common” connected to a N.C.
as a stop pin for the armature, and prevents magnetic
and a N.O. contact.
seal-in of the armature due to residual magnetism. Ac
types have a non-magnetic washer at the base of the
The relay can be supplied with suitable coils for use
core assembly to prevent the armature from sticking
on the following voltages:
All possible contingencies which may arise during installation, operation or maintenance, and all
details and variations of this equipment do not purport to be covered by these instructions. If further
information is desired by purchaser regarding this particular installation, operation or maintenance
of this equipment, the local ABB Power T&D Company Inc. representative should be contacted.
Printed in U.S.A .
41-751N Type SG Auxiliary Relay
in the closed-gap position. Copper shading rings are 1 Second

also provided on the core face of the ac types to pre- Rating Resistance: Rating:
vent chattering of the armature. amps Volts Ohms amps
1 - 2.5 35
3.0 CHARACTERISTICS 2 - 0.7 55
3 - 0.33 85
All relays will pick up at 80% of the nameplate volt- 4 - 0.2 110
age rating or less. No adjustments are provided for 5 - 0.1 185
- 5 12 -
varying the pickup. The armature will open at 30% or - 12 48 -
less on direct current and at 60% or less on alternat- - 24 185 -
ing current. - 32 294 -
- 48 725 -
- 62.5 1152 -
4.0 INSTALLATION - 125 4650 -
- 250 17000 -
Mount the relay with the base against a vertical plane
and with the contacts at the top.
Table 1:
CONTACT GAP AND FOLLOW ADJUSTMENT
When the sheet metal cabinets are ordered for open-
type relays, the relays and cabinets are shipped sep- Contact Contact Make-Contact
arately. The relays can be assembled on the tapped Arrange Gap Follow
mounting holes in the bottom of the case by means 2M 5/32” 3/64”
of the mounting screws which are provided. The cab- 2B 5/32” -
inets have knockouts for conduit connections on top, SPDT 5/32” 3/64”
bottom and sides. DPDT 1/8-9/64” 3/64”
Break Contact Follow
(1) (2)
5.0 BURDEN 2M - -
The closed gap volt-ampere burden at rated voltage 2B 1/32-3/64” 0.020-0.031”
SPDT 3/64” 0.031”
(60 hertz) is 10, at a power factor of approximately DPDT 3/64” 0.031”
50%. The open gap volt-ampere burden at rated volt-
age (60 hertz) is 16, at the same power factor. The
watt consumption at rated dc voltage is 3.5. 7.0 MAINTENANCE
All contacts should be cleaned periodically. A contact
6.0 CONTACTS burnisher style 182A836H01 is recommended for this
purpose. The use of abrasive material for cleaning
each contact will carry 12 amperes continuous and contacts is not recommended, because of the danger
30 amperes for one minute. of embedding small particles in the face of the soft
silver and thus impairing the contact.
The contact interrupting ratings are as follows: All
values are non-inductive currents.
8.0 REPAIR AND RENEWAL PARTS
INTERRUPTING RATING IN AMPERES
Major repairs can be most satisfactorily done at the
factory or ABB Service Shops. However, for custom-
dc 2 Contacts ac
Volts
1 Contact in Series 1 Contact ers equipped to do their own work, parts may be fur-
nished on order. In ordering any part or requesting
24 15 50 50 any information, always give entire nameplate data.
48 8 35 45
115 2.4 20 30
Relays for use on ac are assembled with a thin
230 0.75 2.5 20
550 0.25 0.5 10 bronze washer between the yoke and core. A brass
screw holds the yoke and core together. This washer
helps to reduce the residual magnetism after the
OPERATING TIME
relay is de-energized. In case t he relay should be
Pickup: .033 - .05 sec. at dc rating dismantled, it is important that this washer be
.016 - .033 sec. at ac rating
replaced when re-assembling it.
Dropout: less than .016 sec on dc or ac
2
Type SG Auxiliary Relay 41-751N
Sub 4 Sub 5
629A337 1D2102
Figure 1: Internal Schematic for Type SG Relay in Front Figure 2: Internal Connections for Closed Type SG
Connected Case. Relay.
NOTE: R.H. CONTACT IS OMITTED ON 2 MAKE, 1 BREAK RELAYS
Sub 4 Sub 5
57D390 57D389
Figure 3: Internal Connections for 2-Make and 2-Break Figure 4: Internal Connections for Open Type SG Relay
contact Open Type SG Relay. with Reversible Contacts.
3
Sub 5
182A904
Figure 5: Outline and Drilling plan for t he Closed Type SG Auxiliary Relay with 5/8 inch terminal studs.
Sub 3
182A903
Figure 6: Outline and Drilling plan for the Semi-Flush Case for the Type SG Relay with 5/8 inch terminal studs.
4
Sub 12
31D890
Figure 7: Outline and Drilling plan for the Open Type SG Auxiliary Relay with Reversible Contacts.
Sub 5
18D5332
Figure 8: Outline and Drilling plan for the 2-Make and 2-Break Contact Open Type SG Relay.
5
THIS SPACE RESERVED FOR NOTES
6
THIS SPACE RESERVED FOR NOTES
7
*Sub 3
629A331
Figure 9: Outline and Drilling Plan for t he Type SG Relay in Front Connected with dust cover.
ABB Automation Inc.

4300 Coral Ridge Drive
Coral Springs Florida 33065
TEL: 954-752-6700
Printed in U.S.A. visit our website at www.abbus.com/papd FAX: 954-345-5329
MORE INFORMATION:
link to schematics
link to photos
link to scope shots
link to accessories
link to quick reference guide
link to RS485 wire
Model IRSFC24 Rev. C AUG 2007
RS232<=>3KV ISOLATED RS485 Automatic Converter

with Terminal Strip, RJ12/RJ11 connectors, LED Indicators, for Industrial Applications
General Description: Features:

The IRSFC24 has fast automatic transmit-enable timing for easy Temperature Range: -40C to +85C
RS232<=>RS485 conversion, in 2-wire half-duplex applications, at 3KV Isolated for Industrial Applications
data rates up to 115.2Kbps. LED indicators for Power, TXD, RXD, Fast Automatic Transmit Enable
with jumper selectable bias and termination. TI 1/4 unit load LED Indicators for RS232 & RS485
SN65LBC184 Transceiver IC with built-in protection, and onboard Terminal Strip or RJ12s for RS485
transient protection. A loop-back jumper allows for easy self-testing
of the unit.
Physical Properties:
RS232: 3-wire interface to RJ11/12 Connector (TXD, RXD, Common), DTE/DCE Jumpers
RS485: Wago terminal strip (TXD/RXD-, TXD/RXD+, Common) and dual RJ12/RJ11 connectors
Power: 2.1mm center positive "Barrel" connector, Terminals, (9-35Vdc), switching regulator
LEDs: For RS232 & RS485: Power (Yellow), TXD (Red), RXD (Green)
Bias: 910 / 2.2K Ohm pull-up and pull-down resistors (jumper selectable)
Termination: 120 Ohm (jumper selectable)
Special: Robust transient protection and isolation, Loop-back test jumper
Specifications:
Temp./Humidity: -40C to +85C (-40F to +185F) operating temp., 10-90% relative humidity, non-condensing
Isolation Voltage 3KV for 1-Sec. peak for opto-isolators and onboard DC-DC converter
Input Voltage Range: 9-35Vdc (Switching regulator)
Power: Under 1/2 Watt (typical) + external load
Physical Size: PCB size: 3.25" X 3.00" X 0.9" with connectors: 3.50" X 3.25 X 0.9" (built-in #6 standoffs)
RS485 Distance: 4000ft. (1250 meters) minimum, with up to 32 unit loads
Speed/Format: Up to 115.2Kbps data rate, with any combination of bits (start, data, parity, stop, etc.)
Operation: 2-wire, half-duplex, RS485 data, using twisted 24AWG wire (100-120 Ohm impedance)
Options and Ordering Information:

IRSFC24: $99.00ea. (Fully tested & operational, Circuit board only, no accessories)
Enclosure: $10.00ea. P/N Enclosure-M (medium)
RS232 Cable: $7.50ea. P/N DB9F-7 (RJ11/12 to DB9F adapter with 7ft. cable)
Power Supply: $8.50ea. P/N 12VDC-SPS (12Vdc @ 0.45A Switching Power Supply)
IRSFC24-B9FSPS: $125.00ea. IRSFC24 Converter with all options (Qty. 1-9)
NOTE: Industrial/robust applications, can be used with outdoor wiring (signs, camera PTZ, etc.)
I.L. 8651C66C
Revised 11/13/2006
ECS2100 Exciter Control Module
INSTRUCTION LEAFLET
SAFETY
DRAWINGS
DANGER:
The following drawings are referenced within this BODILY INJURY COULD RESULT IF
document. CONTACT IS MADE WITH COMPONENTS
ECM Card Assembly .........................8651C66 IN THIS APPARATUS WHICH CARRY
EITHER LINE VOLTAGE OR ARE
SUBJECT TO ABNORMALLY HIGH
PURPOSE VOLTAGES. REFERENCES TO THE
CIRCUIT DIAGRAMS, NOTABLY WITHIN
The purpose of the Exciter Control Module OTHER DOCUMENTATION WILL
(ECM) is to serve as the primary control board for DISCLOSE HAZARDOUS AREAS.
the ECS2100 excitation system. The ECM
contains a 32-bit digital signal processor that As with all electrical equipment, appropriate
implements all of the regulator, limiter, safety measures should be taken whenever dealing
protection, and system control functions. The with the excitation equipment. High voltage is
ECM also utilizes a 32-bit microcontroller that present within the excitation cubicles; their
supervises communication with other boards in magnitudes depend upon the particular system.
the system as well as with the user over several Opening the sources (e.g., disconnect device 41)
different communication media (RS-232, RS-485, does not completely disconnect the high voltages.
Ethernet 10baseT, Ethernet AUI, modem). All As long as the machine is still physically
user settings and the firmware are stored in non- connected to the system, there is a possibility that
volatile flash memory and may be easily upgraded a safety hazard exists.
in the field using a laptop computer and the
proprietary ccTool software. Up to 3 ECMs may Every precaution must be taken when working at
be installed in a system to provide fully redundant the excitation control switchgear to ensure that all
control with supervision. high voltages are isolated and avoided by test
personnel. In addition to the machine terminal
This document contains a description of the voltage (460 Vac or greater) at the excitation
functions of the ECM, along with a description of transformer, there may be other sources of power
inputs and outputs. There is also a brief entering the cubicles, such as the customer
description of the installation of the ECM. 125/250 Vdc and/or 120/240 Vac used to feed
Maintenance and warranty information is certain devices. A good rule to follow is to assume
provided as well. that all connections are live and dangerous until
proven otherwise and to avoid completely all body
contact with any of these voltages.
Effective Date 11/13/06 Supersedes 8651C66C Page 1 of 6

INSTRUCTIONS FOR Exciter Control Module I.L. 8651C66C
One other cautionary note refers to the Generator status of the ECM; normally blinks in a
Field Ground Detector. Because the Ground regular counting pattern at a one second
Detector input supply is usually 120 Vac, both the rate.
AC bus and DC (100 Vdc) might be backfed from 1 RS232 Port, DB9 port (J22) used for
this device. Therefore it too must be disconnected interface to ccTool via Modbus RTU.
when servicing the excitation control equipment. 1 Internal 33.6 kbaud Modem RJ11 jack
(J15) used for remote interface to ccTool
via Modbus RTU.
GLOSSARY
2 RS485 Port, RJ45 port (J17, J18) used for
ECM Exciter Control Module. Contains interface to Panelmate, other operator
the excitation control, limiting, interface devices, distributed control or
protection, and communication SCADA systems via Modbus RTU.
software (but is not considered a 1 RS485 Port RJ45 ganged ports (J19, J20)
part of the Digital Firing Control). used for connection between multiple
ECMs in two or three channel system.
1 Ethernet Port RJ45 port (J16) pused for
OPERATION/APPLICATION interface to distributed control or SCADA
systems; either 10baseT or AUI port (J21)
The Exciter Control Module is a dual processor port may be used to interface with any
controller card that serves as the primary control Ethernet media.
board for the ECS2100 excitation system. The 6 Ethernet Status LEDs used to indicate
ECM contains a 32-bit digital signal processor communication status on the Ethernet
that implements all of the regulator, limiter, port; Collision, Link, Transmit, Receive,
protection, and system control functions. The Jabber, and Polarity indications are
ECM also utilizes a 32-bit microcontroller that provided.
supervises communication with other boards in 1 Serial Interface to SIM used to gather CT
the system as well as with the user over several and PT data from the SIM card as well as
different communication media (RS-232, RS-485, to interface with the DIOM and AIOM
Ethernet 10baseT, Ethernet AUI, modem). All boards via the SIM FPGA.
user settings and the firmware are stored in non-
volatile flash memory and may be easily upgraded 1 Serial Interface to FCIM used for bi-
in the field using a laptop computer and the directional communication with the FCIM
proprietary ccTool software. Up to 3 ECMs may and the BCM via the FCIM of various
be installed in a system to provide fully redundant firing control data.
control with supervision. 2 24Vdc power supply inputs. Either or
both supplies will provide the power,
ECM I/O and Hardware implementing the redundant power supply
philosophy of the ECS2100 system.
The following list of hardware resources and
inputs and outputs of the ECM is included as an
aid in understanding its functionality. INSTALLATION
When shipped the equipment will have its

# of ECM Hardware Resource ECM(s) physically installed and connected. If
8 Status LEDs used to indicate operational replacement is necessary, carefully label and

document each of the connections to the ECM(s) Connection of ccTool

in order to properly reconnect to a new board. In order to perform a setup, the user must connect
a personal computer running the Windows™
Refer to the ECM Block Diagram (8651C66) for application program ccTool to the ECM via
the location of connectors and LED indicators. connector J22. Use a standard through wired
RS232 cable with DCE 9 pin on the end
connecting to the ECM and DTE 9 or 25 pin at the
ECM Setup other end to match the RS232 port on the PC.
Much of the initial setup will have been done at After assuring the communication source jumper
the factory or by the field installation engineer. is properly installed and the ECM is energized,
However, some adjustment or verification of invoke ccTool.
setup may be necessary. ECM setup consists of
verification or adjustment of:
PROGRAMMING
• Jumper configuration
• Installation or updating of the user program Program Modifications Onsite
• Adjustment of block parameters. Using the ccTool, modifications of flash stored
• Observation/Monitoring of proper operation code can be made at the customer’s facility or
remotely (ccTool supports modem connection) to
Jumpers the site. This capability permits the firmware as
For jumper placement refer to the Block Diagram well as the startup, running, and shutdown
8651C66. Jumpers are placed for two functions on sequence logic to be changed on site. Three
the ECM, for RS-232 mode (modem or DSUB specific classes of stored data can be changed:
connection) and for Flash memory configuration.
• Download/Upload BOOT firmware
Communication Jumpers • Download/Upload CODE firmware
Jumpers J6, J10, and J13 are used to establish • Download/Upload Application (Tables)
whether RS232 communication comes through
J22 or from the 33.6kbaud modem via J15. ECM These functions will be useful during initial
startup will typically proceed with the startup as well as in later maintenance situations.
communication connection directly to J22.
BOOT Firmware
Flash Memory Jumpers The BOOT firmware is code that controls the
The FLASH memory jumper seldom needs to be ECM power-up, communications, and
changed. The primary occasion requiring a upload/download process. Since the BOOT bank
FLASH jumper change is for downloading a new of FLASH memory controls the download
firmware BOOT program. When new BOOT code process, downloading new BOOT code requires
is downloaded, the jumpers must be moved to re- the use of the existing BOOT code with a
locate the new code at the memory location, subsequent interchanging of the location of the old
which is executed at power-up. CODE and BOOT banks (with the power off). It
will be necessary to invoke the new BOOT bank
The location of banks of flash memory may be at the next power-on of the ECM. This is an
changed with jumper J14. For the most part, the infrequent event, as BOOT code is relatively
default jumper location will suffice. For more simple and not likely to change.
information consult the ccTool User’s Manual.

Refer to the distribution medium discussion under The user application consists of invoking and
CODE Firmware. For more information of the interconnecting blocks. The interconnections are
upload/download process refer to the ccTool implemented through software patching within the
User’s Manual. firmware and governed by table entries within the
USER FLASH RAM
CODE Firmware
Using ccTool, the user may upload or download
the operating firmware which creates all the NORMAL ECM OPERATION
features and functions of the ECM. The ECM is
shipped with the latest operating firmware at the The ECM will operate independently of any user
time of production. New firmware will be intervention. However, aspects of operation may
distributed on computer medium, principally a 3- be observed, monitored, or controlled through the
1/2 inch floppy disk or on a Compact Disk CD- use of the ccTool program, visually through the 8
ROM. The file containing the released code will ECM LEDs, or through information
have the extension, .RHX. communicated with the ECM and displayed either
on a local Panelmate™ , located at the excitation
Application/User Program control cubicles, or on the control room display.
. Each system is designed by Customer Order
Engineering (COE), based on an adaptation of a Creating or Adjusting User Programs
standard base design to best serve the customer's Programs are created, modified, and adjusted
job requirements. using the ccTool program. The function of many
of the blocks within the user’s program are
The COE personnel install customized software governed by constant inputs. The constants may
according to the specific requirements of the be modified dynamically during on-line operation.
order. A series of standardized and pre-tested Thus gains, scale factors, and time constants may
application programs are initially used by COE. be adjusted to improve operation.
Adjustments then are made to satisfy individual
site-specific customer requirements. The software Providing Over-riding Control
is installed in the ECM module during production Using the ccTool program, a user may force
assembly and test. The program is also provided values or states within his Block Diagram
on computer data media that is shipped along with program. This is generally done for the sake of
the other documentation of the system. debugging or to temporarily compensate for
operational problems.
The application block diagram program is loaded
into the ECM through the Windows™ application Monitoring Alarms
program, ccTool. The ccTool also allows copying Using the ccTool program, the user may monitor
and/or modification of the provided program and respond to alarms, trips, and other system
stored within the ECM in its Flash RAM. exceptions. The ALARM descriptions are stored
within the ECM as part of the operating firmware.
Modification of the original user application Thus, when a new exception type is added, its
program likely will be the most frequent description is immediately available for display by
upload/download event over the life of the ECM the ccTool while the user is monitoring.
and the associated excitation equipment. Changes
may be as simple as gain adjustments or more
involved changes in the block structure.

Examining LEDs for Visual • Download/Upload code firmware

Operational Indications • Download/Upload new boot firmware
The 8 LEDs (LED1-LED8) are used to indicate • ccTool Communication Test
various potential operational problems or normal
system operation. Normal operation is indicated Field Testability
with a regular binary counting pattern that repeats No testing will be done in the field except those
approximately once per second. Any other display built into the hardware or firmware and those
pattern should be reported to the factory for inferred by examination of the operation. Integrity
troubleshooting assistance. The LEDs are of the operation is provided by checksums, a
mounted on the ECM board. Refer to the Block “watchdog” timer in the processor hardware, other
Diagram 8651C66. built-in software checks, and tests performed by
the ccTool.
Monitoring Operation of Blocks
Using the ccTool, the user may see the logical and Checksum
analog states of all the data used by and generated A checksum of the operating firmware is
by the block diagram. calculated whenever the ECM is powered on. If
the checksum is incorrect, the application
DIAGNOSTICS firmware is not executed, and the ECM remains
within BOOT mode, executing the separate
Diagnostic functions are available within the “BOOT CODE” in the BOOT FLASH memory.
ECM and within the ccTool. These diagnostics
may aid in determining whether the ECM is at Watchdog Timer
fault, eliminating some unnecessary replacements. The watchdog timer is a hardware function within
Further, if a problem is not in the ECM, the the module processor which will reset the system
diagnostics should help localize the source of the if software doesn’t periodically send a signal into
problem. the timer. If the watchdog timer resets the system,
the fact will be known by the system and an alarm
Proper operation of the ECM may be verified by will occur. Timing delays within the hardware
connecting to the unit using ccTool and viewing will show up as alarms by this function, even if
the Alarm screen. If the board is operating the system still appears to be operating.
properly, there should be no system alarms
present. Depending on the status of various inputs, LIMITS OF WARRANTY
there may be valid block alarms. Contact the
factory for assistance in troubleshooting any The warranty of this apparatus may be
system alarms. invalidated, unless the following described
procedures are followed. Apparatus which
For module replacement, refer to the malfunctions should be replaced with new
INSTALLATION section. units obtained from the factory.
Malfunctioning items should be returned to the
Potential maintenance actions include: factory for repair after authorization is
• Access LEDs for visual operational received from the local sales and service office
indications or the factory. This is particularly true of
• Modify jumpers electronic printed circuit boards which require
• Monitor operation of blocks with ccTool careful handling by skilled personnel and for
• Adjust parameters of blocks which field repair or modifications should not
• Download/Upload application be attempted.


This is a limited warranty, covering repair or should be taken to specify the style numbers (or
replacement only. No consequential damages other identification) which are printed on the
resulting from failure of this module are nameplate, located on this apparatus.
covered.
For the ECM, it is recommended that the user
stock at least one ECM board.
MAINTENANCE
This equipment contains solid state components SPECIFICATIONS AND PERFORMANCE

which require little maintenance. The removal of
accumulated dust occasionally will be sufficient. Power Supply Requirements
Maintenance for non-solid-state components is +24Vdc ±10%, with nominal current of 0.43
required only as specifically defined. ADC.
Environment
SPARE PARTS Ambient temperature range of -20°C to 50°C
A reasonable stock of spare parts will minimize Relative humidity of 0 to 95% non-condensing

I.L. 8651C67C
Revised 11/13/06
ECS2100 Firing Control Interface Module
INSTRUCTION LEAFLET
DRAWINGS SAFETY
The following drawings are referenced within this DANGER:

document: BODILY INJURY COULD RESULT IF
FCIM Card Assembly ........................8651C67 CONTACT IS MADE WITH COMPONENTS
IN THIS APPARATUS WHICH CARRY
EITHER LINE VOLTAGE OR ARE SUBJECT
PURPOSE TO ABNORMALLY HIGH VOLTAGES.
The primary purpose of the Firing Control Interface REFERENCES TO THE CIRCUIT
Module (FCIM) is to control the firing of Silicon DIAGRAMS, NOTABLY WITHIN OTHER
Controlled Rectifiers (SCRs) in the Excitation DOCUMENTATION, WILL DISCLOSE
Control Bridge(s). The output of the bridge is HAZARDOUS AREAS.
connected to the field winding of a generator or an
interposing exciter. A Converter Bridge consists of As with all electrical equipment, appropriate safety
six SCRs connected in a three-phase, full-wave measures should be taken whenever dealing with the
converter bridge configuration. This configuration excitation equipment. High voltage is present within
permits both positive and negative forcing voltage the excitation cubicles; their magnitudes depend
to be applied to the field winding. Negative output upon the particular system. Opening the sources
voltage only occurs transiently as the bridge (e.g., disconnect device 41) does not completely
removes stored energy in the field winding. The disconnect the high voltages. As long as the
field current, however, cannot be reversed. machine is still physically connected to the system,
Converter bridges are paralleled to increase the there is a possibility that a safety hazard exists.
current rating and to provide redundancy.
Every precaution must be taken when working at the
Each converter bridge is provided with gate firing excitation control switchgear to ensure that all high
pulses that are generated by a Bridge Control voltages are isolated and avoided by test personnel.
Module (BCM). The FCIM can control up to sixteen In addition to the machine terminal voltage (460
(16) paralleled BCMs and converter bridges. VAC or greater) at the excitation transformer, there
may be other sources of power entering the cubicles,
The Excitation Control Module (ECM) sends a such as the customer 125/250 VDC and/or 120/240
signal to the FCIM that sets the level of the output VAC used to feed certain devices. A good rule to
voltage of the Converter Bridge(s). follow is to assume that all connections are live and
dangerous until proven otherwise and to avoid
This document contains a description of the completely all body contact with any of these
functional characteristics of the FCIM along with a voltages.
description of inputs and outputs. Maintenance and
warranty information is provided as well.
Page 1 of 8
INSTRUCTIONS FOR Firing Control Interface Module I.L. 8651C67C
One other cautionary note refers to the Generator and firing angle command from the
Field Ground Detector. Because the Ground ECM and determines when to fire
Detector input supply is usually 120 VAC, both the each SCR.
AC bus and DC (100 VDC) might be backfed from Flash A type of Random Access Memory
this device. Therefore it too must be disconnected (RAM) that retains memory contents
when servicing the excitation control equipment. without power, and not relying on a
battery.
GLOSSARY FO Fan Out card. Provides transceiver
BCM Bridge Control Module. Up to 16 capability beyond the three built into
BCMs can be controlled by one the FCIM as Standard.
FCIM. FPGA Field Programmable Gate Array. An
Bridge A configuration of thyristors that integrated circuit that implements
convert AC current to DC current. complex logic functions within a
ccTool Controller Configuration Tool, a PC single package.
based Windows (95, 98, or NT) IT Isolation Transducer card. Isolates
application program which connects two analog signals for digital input
to an ECM, FCIM, or BCM card for to FCIM or BCM and other
user programming of the card modules.
functions. Presents Table or Block PLL Phase Locked Loop. A closed-loop
Diagram representations of the circuit scheme to automatically lock
controller program and operation. the frequency and phase of an
CM Conduction Monitor card. Provides oscillator, so that it produces a
current level information on each precise firing angle necessary to
SCR or bridge. maintain the desired level of a
COE Customer Order Engineering, converter output parameter under
provides all the engineering control.
information for a customer job- QSPI Queued Serial Peripheral Interface,
specific design, including the provides a high speed means to
application firmware required to communicate with the ECM. The
operate the FCIM. QSPI is built into the architecture of
DCE Data Communications Equipment the FCIM controller (MC68HC16).
(part of the RS232 standard). The RS232 A standard physical link protocol for
FCIM is DCE configured. serial communication. Almost every
DFC Digital Firing Control (subset of the PC provides a port using this
digital excitation control system). communication connection.
DTE Data Terminal Equipment (part of SCR Silicon Controlled Rectifier. A
the RS232 standard). The PC variable-conduction rectifier with
running ccTool is DTE configured. delayed forward turn-on gating. Also
ECM Exciter Control Module. Contains referred to in the industry as a
the excitation control, limiting, thyristor.
protection, and communication VCO Voltage Controlled Oscillator. A
software (but is not considered a part circuit that provides a variable
of the Digital Firing Control). frequency output proportional to a
FCIM Firing Control Interface Module. voltage input.
Processes the AC source waveforms
Page 2 of 8
OPERATION/APPLICATION (ccTool), which may be connected to the FCIM

through an RS232 port. The ccTool program display
The FCIM is an MC68HC16 microprocessor-based is very user oriented (not just lists of numbers or
controller card containing Code FLASH RAM, Boot codes), for instance, showing alarms as they occur
FLASH RAM, and User FLASH RAM memory. with textual descriptions and explanations.
The FCIM is provided the operational set point data The software implemented control scheme is also
to operate as an excitation control system by the viewable as a block diagram or as tables using the
Exciter Control Module (ECM) via the high-speed ccTool.
QSPI interface built into the architecture of the
68HC16 processor within the FCIM. FCIM I/O and Hardware
The following list of hardware resources and inputs
Using isolated VAB and VBC power line input signals and outputs of the FCIM is included as an aid in
(obtained from an IT module), a software understanding its functionality.
implemented Phase Locked Loop (PLL) within the
FCIM processor creates an internal timing signal # of FCIM Hardware Resource
which is used to establish SCR firing signals. These 2 10 bit A/D converters based upon built-in
are time and pattern synchronized correctly to the 68HC16 processor converters. The input is
source AC line. Firing signals, interspersed with scaled for -10V to +10V, unadjusted.
data signals, are transmitted to up to 16 paralleled 4 12 bit D/A outputs based upon MP7680.
bridges, each controlled by a BCM. This The output is scaled for –10VDC to
information is sent over fiber-optic cables, using a +10VDC unadjusted.
custom logical and physical communication
protocol implemented by a Field Programmable 4 DC Logical Inputs. For each of the four
Gate Array (FPGA). inputs from universal AC/DC inputs from
DIOM, TRUE if the input is high.
The FCIM, BCM, and ECM replaces previous 6 VCO counter inputs. These are optical
designs which used various control relays and cable inputs driving 16 bit counters within
timers to control the excitation system. To the a custom FPGA. An external IT card
maximum extent possible discrete relays, timers, provides a variable frequency input
and associated wiring are eliminated, and their proportional to a scaled and measured
function is implemented in the software of the voltage. These inputs are processed by the
FCIM, BCM, and ECM. Discrete relays are used custom FPGA and sent to the processor at
when the power requirements of the devices being fixed intervals, representing an isolated
operated (e.g., the 41A device) necessitate them or digitization of the signals being measured.
when an application requires dry contacts. 12 Status LEDs, consisting of 4 RED, 4
AMBER, and 4 GREEN. The LEDs are
Data communication is bi-directional between the accessed via the DR” Block Function.
FCIM and the BCM(s), and between the FCIM and 4 Relay Control output contacts (For
the ECM. The ECM receives all significant example, power cubicle fans ON/OFF)
operating data of the FCIM and the BCM(s).
1 RS232 Port based upon the SCI interface
built into the 68HC16.
The FCIM consolidates alarm and other information
from all the bridges and provides it to a Windows™
application program, Controller Configuration Tool
Page 3 of 8
2 24VDC power supply inputs. Either or both

supplies will provide the power, Optical connections are made by inserting the fiber
implementing the redundant power supply optic cables and connectors provided into the
philosophy of the ECS2100 system. receptacles at the bottom edge of the board. U35,
2 Fused status lines, used for the "State U36; U37, U38; and U39, U40 are fiber optic
Control Select", controlling redundant transceiver pairs that provide bi-directional
operations of the BCMs. communication to BCM0, BCM1, and BCM2,
3 Optical Transmit Interface to fiber respectively. Dual fiber cable assemblies are
communication channel to BCMs. provided for these connections in various lengths,
depending on the specific design. U41 through U46
1 Drive for external Fiber Interface. A single are fiber optic receivers which use single fiber optic
external optical output to the Fan Out cable assemblies to receive the signals from up to
Module for driving BCMs 3 thru 15. six Isolation Transducers. These signals typically
3 Optical Receive Interface from fiber represent Vfg, Ifg, Vfe, Ife, VAB, and VBC power
communication channels from BCMs. signals.
13 Inputs from external Fiber Channel
interface (Fan Out Module) Communication to BCM3 through BCM15 is
1 Inter-Processor Interface based upon the provided through the Fan Out connector, J17, with
high-speed QSPI interface of the 68HC16 the external board power supplied from that
processor. This interface handles connector, protected by fuse F4 (1/4 Amp).
communications between the FCIM and the
ECM. Digital and analog electrical inputs and outputs are
provided as shown in the Block Diagram drawing.
In general, it is difficult to establish within this
document the precise use of each of the digital and
INSTALLATION
When shipped the equipment will have its FCIM(s) analog I/O points. Refer to the drawings for each
physically installed and connected. If replacement job-specific system, supplied as physical drawings
is necessary, carefully label and document each of and as part of the HTML, dynamic on-line, HELP.
the connections to the FCIM, in order to properly But, above all, careful documentation of the original
reconnect to a new board. Even for the original connections is essential any time the FCIM is
startup (as well as when replacing the FCIM), the removed.
user will be required to interface with the FCIM for
the purpose of monitoring and adjusting for the FCIM Setup
specific job application. Refer to the FCIM Block Much of the initial setup will have been done at the
Diagram (8651C67) for the location of connectors, factory or by the field installation engineer.
fuses, and jumpers. However, some adjustment or verification of setup
may be necessary. FCIM setup consists of
verification or adjustment of:
FCIM Board Connections
Power and signal connections must be provided to
the FCIM. Signals are both optical and electrical. • Jumper configuration
Refer to Block Diagram 8651C67 and the job- • Installation or updating of the user program
specific schematics. For testing purposes, electrical • Adjustment of block parameters.
power to the FCIM may be provided through the • Observation/Monitoring of proper operation
redundant +24VDC connectors, J4 and J5. (Power is
provided normally via J8 from the ECM).
Page 4 of 8
Jumpers PROGRAMMING
For jumper placement refer to the Block Diagram
Program Modifications Onsite
8651C67. Jumpers are placed for two functions on Using the ccTool, modifications of FLASH stored
the FCIM, for RS-232 mode (ECM or ccTool code can be made at the customer’s facility or
connection) and for F memory configuration. remotely (ccTool supports modem connection) to
the site. This capability permits the firmware as well
Communication Jumpers as the startup, running, and shutdown sequence
Jumpers JMP10, JMP11 are used to establish
logic to be changed on site. Three specific classes of
whether RS232 communication comes through J20 stored data can be changed:
or from the ECM to which the FCIM is connected.
FCIM startup will typically proceed with the
• Download/Upload BOOT firmware
communication connection directly to the FCIM.
• Download/Upload CODE firmware
• Download/Upload Application (Tables)
Flash Memory Jumpers
The FLASH memory jumpers seldom need to be
These functions will be useful during initial startup
changed. The primary occasion requiring a FLASH
as well as in later maintenance situations.
jumper change is for downloading a new firmware
BOOT program. When new BOOT code is
downloaded, the jumpers must be moved to re- BOOT Firmware
The BOOT firmware is code that controls the FCIM
locate the new code at the memory location which is
power-up, communications, and upload/download
executed at power-up.
process. Since the BOOT bank of FLASH memory
controls the download process, downloading new
The location of banks of BOOT, CODE, and
BOOT code requires the use of the existing BOOT
TABLES FLASH RAM memory may be changed
code with a subsequent interchanging of the location
with jumpers, JMP1 through JMP9. For the most
of the old CODE and BOOT banks (with the power
part, the default jumper location will suffice. For
off). It will be necessary to invoke the new BOOT
more information consult the ccTool User’s
bank at the next power-on of the FCIM. This is an
Manual.
infrequent event, as BOOT code is relatively simple
and not likely to change.
Connection of ccTool
In order to perform a setup, the user must connect a
Refer to the distribution medium discussion under
personal computer running the Windows™
CODE Firmware. For more information of the
application program ccTool to the FCIM via
upload/download process refer to the ccTool User’s
connector J20. Use a standard through wired RS232
Manual.
cable with DCE 9 pin on the end connecting to the
FCIM and DTE 9 or 25 pin at the other end to
match the RS232 port on the PC. After assuring the CODE Firmware
communication source jumper is properly installed Using ccTool, the user may upload or download the
and the FCIM is energized, invoke ccTool. operating firmware which creates all the features
and functions of the FCIM. The FCIM is shipped
with the latest operating firmware at the time of
production. New firmware will be distributed on
computer medium, principally a 3-1/2 inch floppy
disk or on a Compact Disk CD-ROM. The file
containing the released code will have the
extension, .RHX.
Page 5 of 8
Application/User Program Panelmate™ , located at the excitation control

. Each system is designed by Customer Order cubicles, or on the control room display.
Engineering (COE), based on an adaptation of a
standard base design to best serve the customer's job Creating or Adjusting User Programs
requirements. Programs are created, modified, and adjusted using
the ccTool program. The function of many of the
The COE personnel install customized software blocks within the user’s program are governed by
according to the specific requirements of the order. constant inputs. The constants may be modified
A series of standardized and pre-tested application dynamically during on-line operation. Thus gains,
programs are initially used by COE. Adjustments scale factors, and time constants may be adjusted to
then are made to satisfy individual site-specific improve operation.
customer requirements. The software is installed in
the FCIM module during production assembly and Providing Over-riding Control
test. The program is also provided on computer data Using the ccTool program, a user may force values
media that is shipped along with the other or states within his Block Diagram program. This is
documentation of the system. generally done for the sake of debugging or to
temporarily compensate for operational problems.
The application block diagram program is loaded
into the FCIM through the Windows™ application Monitoring Alarms
program, ccTool. The ccTool also allows copying Using the ccTool program, the user may monitor
and/or modification of the provided program stored and respond to alarms, trips, and other system
within the FCIM in its Flash RAM. exceptions. The ALARM descriptions are stored
within the FCIM as part of the operating firmware.
Modification of the original user application Thus, when a new exception type is added, its
program likely will be the most frequent description is immediately availabel for display by
upload/download event over the life of the FCIM the ccTool while the user is monitoring.
and the associated excitation equipment. Changes
may be as simple as gain adjustments or more Examining LEDs for Visual Operational
involved changes in the block structure. Indications
The “DR” block, within the FCIM, controls the state
The user application consists of invoking and of 12 LEDs, 4 Red, 4 Green, and 4 Amber. The
interconnecting blocks. The interconnections are LEDs are mounted on the FCIM board. Refer to the
implemented through software patching within the Block Diagram 8651C67.
firmware and governed by table entries within the
USER FLASH RAM The customer’s application makes use of these
LEDs to convey the state of the operating program
by visible indication. Use the ccTool program to
NORMAL FCIM OPERATION view the Block Diagram representation of the User
Program in order to determine the meaning of the
The FCIM will operate independently of any user LED displays.
intervention. However, aspects of operation may be
observed, monitored, or controlled through the use Monitoring Operation of Blocks
of the ccTool program, visually through the 12 Using the ccTool, the user may see the logical and
FCIM LEDs, or through information communicated analog states of all the data used by and generated
with the ECM and displayed either on a local by the block diagram.
Page 6 of 8
DIAGNOSTICS fact will be known by the system and an alarm will

Diagnostic functions are available within the FCIM occur. Timing delays within the hardware will show
and within the ccTool. These diagnostics may aid in up as alarms by this function, even if the system still
determining whether the FCIM is at fault, appears to be operating.
eliminating some unnecessary replacements.
Further, if a problem is not in the FCIM, the Communication Tests with ccTool
diagnostics should help localize the source of the The ccTool provides communication test functions.
problem. Repetitive test write followed by read actions are
carried out to either the FCIM or through the FCIM
For module replacement, refer to the to the BCMs. By invoking the communication tests,
INSTALLATION section. operation of several subsystems can be verified,
including processors and fiber optic channels.
Potential maintenance actions include:
• Access LEDs for visual operational indications Replacing the Fuses
• Replace fuses For fuse replacement refer to the Block Diagram
• Modify jumpers drawing. Fuses are replaceable for the two State
• Monitor operation of blocks with ccTool Select lines and for the bridge fiber optic
• Adjust parameters of blocks communication Fan-Out power. Each of these three
• Download/Upload application fuses is a 250 ma. Littelfuse type 273-250.
• Download/Upload code firmware
• Download/Upload new boot firmware
LIMITS OF WARRANTY
• ccTool Communication Test
The warranty of this apparatus may be
invalidated, unless the following described
Field Testability
procedures are followed. Apparatus which
No testing will be done in the field except those
malfunctions should be replaced with new units
built into the hardware or firmware and those
obtained from the factory. Malfunctioning items
inferred by examination of the operation. Integrity
should be returned to the factory for repair after
of the operation is provided by checksums, a
authorization is received from the local sales and
“watchdog” timer in the processor hardware, other
service office or the factory. This is particularly
built-in software checks, and tests performed by the
true of electronic printed circuit boards which
ccTool.
require careful handling by skilled personnel
and for which field repair or modifications
Checksum
should not be attempted.
A checksum of the operating firmware is calculated
whenever the FCIM is powered on. If the checksum
This is a limited warranty, covering repair or
is incorrect, the application firmware is not
replacement only. No consequential damages
executed, and the FCIM remains within BOOT
resulting from failure of this module are covered.
mode, executing the separate “BOOT CODE” in the
BOOT FLASH memory.
Watchdog Timer
The watchdog timer is a hardware function within
the module processor which will reset the system if
software doesn’t periodically send a signal into the
timer. If the watchdog timer resets the system, the
Page 7 of 8
MAINTENANCE QSPI
This equipment contains solid state components High-speed communication with the ECM module
which require little maintenance. The removal of is by means of the Queued Serial Peripheral
accumulated dust occasionally will be sufficient. Interface (QSPI) which is an integral part of the
Maintenance for non-solid-state components is FCIM processor. Bi-directional data interchanges
required only as specifically defined. occur at intervals of 1.024 milliseconds. The ECM
initiates a QSPI interchange every millisecond, and
it will consequently never miss a sample.
SPARE PARTS
A reasonable stock of spare parts will minimize PLL Firing Control
down-time, in the event of a malfunction in this The PLL, Phase Locked Loop, (with ranges of 15
equipment. When ordering spare parts, care should Hz to 90 Hz for static systems, and 60 to 480 Hz for
be taken to specify the style numbers (or other brushless and rotating exciters) requires two phases
identification) which are printed on the nameplate, of three-phase voltage power input signals. These
located on this apparatus. are provided by an IT Card via fiber optic links to
connectors U41, U42.
For the FCIM, it is recommended that the user stock
at least one FCIM board, fuses, and plastic-housed Active Current Balance
0.010-inch jumpers. Active current balancing algorithms (so-called
“Skip Firing “) may be provided on each BCM. The
FCIM will enable, freeze or disable each BCM’s
SPECIFICATIONS AND PERFORMANCE implementation of the balance. BCM’s will report
Power Supply Requirements back their “fair share” current to the FCIM. The
+24VDC ±10%, with nominal current of 0.14 ADC FCIM then makes this information available to the
ECM.
External Serial Communication
The RS232 communication occurs at a fixed rate of Redundancy
38.4 KBaud through J20, a 9-pin sub-miniature “D” A State Select line is available on FCIMs for the
connector, configured as DCE. Since PCs are purpose of controlling which one of two FCIM
typically configured as DTE, a standard “through” redundant fiber networks is to be used to control the
RS232 cable may be used. All parameters for this BCMs. A third FCIM (termed the “supervisory”
communication are fixed by the FCIM firmware, FCIM) monitors the operation of the two redundant
requiring no user setup or intervention. Some choice FCIMs, detecting the failure conditions that require
is provided by the ccTool for the logical protocol, a switch over to the second FCIM, using the State
but the physical protocol is fixed. Select Line.
Bridge Communication Environment

The bridge communication to the Bridge Control Ambient temperature range of -20°C to 50°C
Modules is performed over a fiber optic link. Three
fiber optic channels are built into the FCIM. An Relative humidity of 0 to 95% non-condensing
electrical connector is provided to interface with a
Fan Out Card, providing 13 additional full duplex
fiber channels.
Page 8 of 8
I.L. 8651C65C
Revised 11/13/06
ECS2100 Sensor Input Module
INSTRUCTION LEAFLET
As long as the machine is still physically
DRAWINGS connected to the system, there is a possibility that
The following drawings are referenced within this a safety hazard exists.
document.
SIM Card Assembly...........................8651C65 Every precaution must be taken when working at
the excitation control switchgear to ensure that all
high voltages are isolated and avoided by test
PURPOSE personnel. In addition to the machine terminal
The purpose of the Sensor Input Module (SIM) is voltage (460 Vac or greater) at the excitation
to provide the means to interface the AC generator transformer, there may be other sources of power
metering and regulator PT and CT signals to the entering the cubicles, such as the customer
digital excitation control system. Each SIM has 125/250 Vdc and/or 120/240 Vac used to feed
the capability to sense twelve analog inputs (24 certain devices. A good rule to follow is to assume
Vac nominal, 40Vdc peak). Utilizing the ccTool that all connections are live and dangerous until
software, the analog input data can be connected proven otherwise and to avoid completely all body
to any control software block input in the ECM. contact with any of these voltages.
One other cautionary note refers to the Generator

SAFETY Field Ground Detector. Because the Ground
Detector input supply is usually 120 Vac, both the
DANGER: AC bus and DC (100 Vdc) might be backfed from
BODILY INJURY COULD RESULT IF this device. Therefore it too must be disconnected
CONTACT IS MADE WITH COMPONENTS when servicing the excitation control equipment.
SUBJECT TO ABNORMALLY HIGH GLOSSARY
VOLTAGES. REFERENCES TO THE
CIRCUIT DIAGRAMS, NOTABLY WITHIN AIOM Analog Input / Output Module. Up
OTHER DOCUMENTATION, WILL to 4 AIOMs can be connected to
DISCLOSE HAZARDOUS AREAS. one ECM.
DIOM Digital Input / Output Module. Up
As with all electrical equipment, appropriate to 4 DIOMs can be connected to
safety measures should be taken whenever dealing one ECM.
with the excitation equipment. High voltage is ECM Exciter Control Module. Contains
present within the excitation cubicles; their the excitation control, limiting,
magnitudes depend upon the particular system. protection, and communication
Opening the sources (e.g., disconnect device 41) software (but is not considered a
does not completely disconnect the high voltages. part of the Digital Firing Control).
Revised 11/13/06 Page 1 of 3

INSTRUCTIONS FOR Sensor Input Module I.L. 8651C65C
FPGA Field Programmable Gate Array. the location of connectors and LED indicators.
An integrated circuit that
implements complex logic
functions within a single package. VERIFICATION OF CALIBRATION
SIM Sensor Input Module. Provides the There are no user adjustments on the SIM Card. If
interface from PT and CT signals necessary, adjustments may be made digitally
and the AIOM and DIOM to the within the user's program. Each of the modules
ECM. that use the SIM for input operates on the basis of
a user program viewable as a block diagram using
OPERATION/APPLICATION the ccTool program. The ccTool provides
The Sensor Input Module provides the means to individual adjustment of gain and offset for each
isolate the AC generator metering and regulator input. Using a precision voltage source,
PT and CT signals from the digital electronics. multimeter, and ccTool, the user may verify the
The PT and CT secondary inputs (24 Vac accuracy of the inputs across the full range by
nominal, 40Vdc peak) are sampled simultaneously plotting the analog input versus the digital values
every 400 microseconds by stereo sigma delta displayed in ccTool.
analog-to-digital converters with 16-bit resolution.
Six of these high-speed, high-resolution A-to-Ds
are used in parallel to provide 12 input channels. LIMITS OF WARRANTY
Fiber optic cable connections for Digital Input / The warranty of this apparatus may be
Output Modules (DIOM) and Analog Input / invalidated, unless the following described
Output Modules (AIOM) are also located on the procedures are followed. Apparatus which
SIM. Serial communications to these cards are malfunctions should be replaced with new
routed through the SIM FPGA. This FPGA is used units obtained from the factory.
to link all analog and digital inputs and outputs, Malfunctioning items should be returned to the
including the PTs and CTs, to the ECM. factory for repair after authorization is
received from the local sales and service office
Utilizing the ccTool software, the analog input or the factory. This is particularly true of
data can be connected to any control software electronic printed circuit boards which require
block input in the ECM. These inputs are typically careful handling by skilled personnel and for
connected to phase locked loops or system test which field repair or modifications should not
inputs. be attempted.

INSTALLATION replacement only. No consequential damages
When shipped the equipment will have its SIM(s) resulting from failure of this module are
physically installed and connected. If replacement covered.
is necessary, carefully label and document each of
the connections to the SIM(s) in order to properly
reconnect to a new board. Verify that all pins of MAINTENANCE
J10 and J11 are properly aligned with
corresponding connectors on ECM and make sure This equipment contains solid-state components
that these connectors are fully inserted in the which require little maintenance. The removal of
mating connectors. accumulated dust occasionally will be sufficient.
Refer to the SIM Block Diagram (8651C65) for required only as specifically defined.

INSTRUCTIONS FOR Sensor Input Module I.L. 8651C65C
SPARE PARTS SPECIFICATIONS AND PERFORMANCE
A reasonable stock of spare parts will minimize Power Supply Requirements

down-time, in the event of a malfunction in this +24Vdc ±10%, with nominal current of 0.25
equipment. When ordering spare parts, care ADC.
other identification) that are printed on the Environment
nameplate, located on this apparatus. Ambient temperature range of -20°C to 50°C
For the SIM, it is recommended that the user stock Relative humidity of 0 to 95% non-condensing
at least one SIM board.

I.L. 8651C69C
Revised 11/13/06
ECS2100 Analog Input / Output Module
INSTRUCTION LEAFLET
DRAWINGS CIRCUIT DIAGRAMS, NOTABLY WITHIN
OTHER DOCUMENTATION, WILL
The following drawings are referenced within this DISCLOSE HAZARDOUS AREAS.
document.
AIOM Card Assembly .......................8651C69 As with all electrical equipment, appropriate
PURPOSE present within the excitation cubicles; their
The purpose of the Analog Input / Output Module Opening the sources (e.g., disconnect device 41)
(AIOM) is to provide a means to interface the does not completely disconnect the high voltages.
ECS2100 excitation control system with external As long as the machine is still physically
devices such as meters, resistance temperature connected to the system, there is a possibility that
detectors (RTD), transducers, chart recorders, a safety hazard exists.
distributed control systems (DCS), and
programmable logic controllers (PLC). Each Every precaution must be taken when working at
AIOM has the capability to sense two analog the excitation control switchgear to ensure that all
inputs (±10 Vdc) and one 100 ohm Platinum high voltages are isolated and avoided by test
RTD. Four individually configurable (±10 Vdc / personnel. In addition to the machine terminal
4-20 mAdc) analog outputs are provided on each voltage (460 Vac or greater) at the excitation
module. Each ECS2100 control channel may be transformer, there may be other sources of power
equipped with a maximum of four AIOMs that are entering the cubicles, such as the customer
connected in daisy chain fashion using an isolated 125/250 Vdc and/or 120/240 Vac used to feed
bi-directional fiber optic communication link. certain devices. A good rule to follow is to assume
Utilizing the ccTool software, the analog input that all connections are live and dangerous until
and output data can be connected to any control proven otherwise and to avoid completely all body
software block input or output in the ECM. contact with any of these voltages.
One other cautionary note refers to the Generator

SAFETY Field Ground Detector. Because the Ground
Detector input supply is usually 120 Vac, both the
DANGER: AC bus and DC (100 Vdc) might be backfed from
BODILY INJURY COULD RESULT IF this device. Therefore it too must be disconnected
CONTACT IS MADE WITH COMPONENTS when servicing the excitation control equipment.
Effective Date 11/13/06 Supersedes8651C69B Page 1 of 3

INSTRUCTIONS FOR Analog Input / Output Module I.L. 8651C69C
GLOSSARY Digital data is transmitted to and received from

the AIOM simultaneously over a 5 megabit per
AIOM Analog Input / Output Module. Up second serial fiber optic link for isolation of the
to 4 AIOMs can be connected to AIOM cards and reduction of noise. The ECM is
one ECM. the master and the AIOM(s) are the slave devices.
ECM Exciter Control Module. Contains An FPGA on each AIOM builds a serial bit stream
the excitation control, limiting, including the digital data of each analog input on
protection, and communication that AIOM as well as the input data received from
software. all downstream AIOMs. Simultaneously, the
FPGA Field Programmable Gate Array. FPGA extracts the digital data for its analog
An integrated circuit that outputs and passes the remaining output data from
implements complex logic the ECM to the next AIOM downstream.
functions within a single package.
A maximum of four AIOMs can be connected to
each control channel. These may be included in
OPERATION/APPLICATION the original system or may be added by the
customer in the field as the need for additional I/O
The Analog Input / Output Module has the arises. If multiple AIOMs are used, the boards are
capability to sense two analog inputs (±10 Vdc) connected in a daisy chain fashion using a bi-
and one 100 ohm Platinum RTD. These inputs are directional fiber optic link. Because the fiber optic
sampled simultaneously by stereo sigma delta link is immune to electrical noise, the boards may
analog-to-digital converters with 16-bit resolution. be mounted in close proximity or up to 22 meters
The RTD may be connected in either two wire or from the cubicle. This results in reduced wiring to
three wire configuration. These inputs are sampled the excitation cubicle.
by the ECM every 8 milliseconds. Utilizing the
ccTool software, the analog input data can be
connected to any control software block input in INSTALLATION
the ECM. These inputs are commonly used to
provide temperature and hydrogen gas pressure When shipped the equipment will have its
feedback to the system for use in the recalibration AIOM(s) physically installed and connected. If
/ generator optimization functions. replacement is necessary, carefully label and
document each of the connections to the AIOM(s)
Four individually configurable analog outputs are in order to properly reconnect to a new board.
provided on each module. The analog outputs can
be configured to output either ±10 Vdc or 4-20mA Refer to the AIOM Block Diagram (8651C69) for
current loop with a 16-bit resolution. The voltage the location of connectors, fuses, and LED
mode of operation must see a load larger than 1K indicators.
ohms. The current loop must maintain a receiver
resistance of less than 1K ohms. The ECM
updates the outputs at an 8 millisecond rate. VERIFICATION OF CALIBRATION
Utilizing the ccTool software, the analog output
data can be connected to any control software There are no user adjustments on the AIOM Card.
block output in the ECM. These outputs are If necessary, adjustments may be made digitally
commonly used to drive existing panel meters or within the user's program. Each of the modules
to interface with DCS systems or chart recorders. that use the AIOM for input or output operates on
the basis of a user program viewable as a block

INSTRUCTIONS FOR Analog Input / Output Module I.L. 8651C69C
diagram using the ccTool program. The ccTool

provides individual adjustment of gain and offset
for each input and output. Using a precision MAINTENANCE
voltage source, multimeter, and ccTool, the user
may verify the accuracy of the inputs across the This equipment contains solid state components
full range by plotting the analog input versus the which require little maintenance. The removal of
digital values displayed in ccTool. Likewise, the accumulated dust occasionally will be sufficient.
user may verify the accuracy of the outputs by Maintenance for non-solid-state components is
plotting the digital output value shown in ccTool required only as specifically defined.
versus the measured analog output. The RTD
input may be verified by connecting a variable
resistor to the input and plotting the measured SPARE PARTS
resistance to the digital temperature (or resistance)
value displayed in ccTool. A reasonable stock of spare parts will minimize
LIMITS OF WARRANTY should be taken to specify the style numbers (or
The warranty of this apparatus may be nameplate, located on this apparatus.
procedures are followed. Apparatus which For the AIOM, it is recommended that the user
malfunctions should be replaced with new stock at least one AIOM board. In addition, the
units obtained from the factory. user should stock replacement fuses (Littelfuse
Malfunctioning items should be returned to the 273.250 or equivalent).
factory for repair after authorization is
received from the local sales and service office
or the factory. This is particularly true of SPECIFICATIONS AND PERFORMANCE
electronic printed circuit boards which require
careful handling by skilled personnel and for Power Supply Requirements
which field repair or modifications should not +24Vdc ±10%, with nominal current of 0.22 ADC
be attempted.
Environment
This is a limited warranty, covering repair or Ambient temperature range of -20°C to 50°C
resulting from failure of this module are Relative humidity of 0 to 95% non-condensing
covered.

I.L. 8651C68C
Revised 11/13/06
ECS2100 Digital Input / Output Module
INSTRUCTION LEAFLET
DRAWINGS CIRCUIT DIAGRAMS, NOTABLY WITHIN
The following drawings are referenced within this DISCLOSE HAZARDOUS AREAS.
document.
DIOM Card Assembly .......................8651C68 As with all electrical equipment, appropriate
PURPOSE present within the excitation cubicles; their
The purpose of the Digital Input / Output Module Opening the sources (e.g., disconnect device 41)
(DIOM) is to provide a means to interface the does not completely disconnect the high voltages.
ECS2100 excitation control system with external As long as the machine is still physically
devices such as pushbuttons, switches, indicator connected to the system, there is a possibility that
lights, control relays, distributed control systems a safety hazard exists.
(DCS), and programmable logic controllers
(PLC). Each DIOM has the capability to sense Every precaution must be taken when working at
twelve digital inputs (±24 - 125Vdc or 120Vac). the excitation control switchgear to ensure that all
Eight digital form C relay outputs are also high voltages are isolated and avoided by test
provided on each module. Each ECS2100 control personnel. In addition to the machine terminal
channel may be equipped with a maximum of four voltage (460 Vac or greater) at the excitation
DIOMs that are connected in daisy chain fashion transformer, there may be other sources of power
using an isolated bi-directional fiber optic entering the cubicles, such as the customer
communication link. Utilizing the ccTool 125/250 Vdc and/or 120/240 Vac used to feed
software, the digital input and output data can be certain devices. A good rule to follow is to assume
connected to any control software block input or that all connections are live and dangerous until
output in the ECM. proven otherwise and to avoid completely all body
SAFETY One other cautionary note refers to the Generator

Field Ground Detector. Because the Ground
DANGER: Detector input supply is usually 120 Vac, both the
BODILY INJURY COULD RESULT IF AC bus and DC (100 Vdc) might be backfed from
CONTACT IS MADE WITH COMPONENTS this device. Therefore it too must be disconnected
IN THIS APPARATUS WHICH CARRY when servicing the excitation control equipment.

INSTRUCTIONS FOR Digital Input / Output Module I.L. 8651C68C
GLOSSARY including the digital data of each input on that

DIOM as well as the input data received from all
DIOM Digital Input / Output Module. Up downstream DIOMs. Simultaneously, the FPGA
to 4 DIOMs can be connected to extracts the digital data for its outputs and passes
one ECM. the remaining output data from the ECM to the
ECM Exciter Control Module. Contains next DIOM downstream.
the excitation control, limiting,
protection, and communication A maximum of four DIOMs can be connected to
software (but is not considered a each control channel. These may be included in
part of the Digital Firing Control). the original system or may be added by the
FPGA Field Programmable Gate Array. customer in the field as the need for additional I/O
An integrated circuit that arises. If multiple DIOMs are used, the boards are
implements complex logic connected in a daisy chain fashion using a bi-
functions within a single package. directional fiber optic link. Because the fiber optic
link is immune to electrical noise, the boards may
be mounted in close proximity or up to 22 meters
OPERATION/APPLICATION from the cubicle. This results in reduced wiring to
the excitation cubicle.
The Digital Input / Output Module has the
capability to sense twelve digital inputs (±24 -
125Vdc or 120Vac). These inputs are sampled by INSTALLATION
the ECM every 8 milliseconds. Utilizing the
ccTool software, the digital input data can be When shipped the equipment will have its
connected to any control software block input in DIOM(s) physically installed and connected. If
the ECM. These inputs are commonly used to replacement is necessary, carefully label and
provide an interface to the excitation control document each of the connections to the DIOM(s)
system from pushbuttons, control switches, and in order to properly reconnect to a new board.
relay auxiliary contacts.
Refer to the DIOM Block Diagram (8651C68) for
Eight individually configurable digital outputs are the location of connectors and LED indicators.
provided on each module. The digital outputs are
each connected to form C relays with ratings of
10A, 120Vac or 10A, 30Vdc. The ECM updates VERIFICATION OF DIOM
the outputs at an 8-millisecond rate. Utilizing the
ccTool software, the digital output data can be There are no user adjustments on the DIOM Card.
connected to any control software block output in Using a voltage source and ccTool, the user may
the ECM. These outputs are commonly used to verify the operation of the digital inputs by
drive external relays and indicator lights, or to applying voltage (24 – 125 Vdc or 120Vac) to
interface with DCS systems. each input and monitoring the corresponding
digital value displayed in ccTool. A logical “True”
Digital data is transmitted to and received from indicates that voltage is present on the input.
the DIOM simultaneously over a 5 megabit per Similarly, operation of the digital outputs may be
second serial fiber optic link for isolation of the verified by toggling each output from “False” to
DIOM cards and reduction of noise. The ECM is “True” using ccTool and monitoring the status of
the master and the DIOM(s) are the slave devices. each form C relay output using a digital
An FPGA on each DIOM builds a serial bit stream multimeter.

INSTRUCTIONS FOR Digital Input / Output Module I.L. 8651C68C
LIMITS OF WARRANTY Maintenance for non-solid-state components is

required only as specifically defined.
procedures are followed. Apparatus which SPARE PARTS
malfunctions should be replaced with new
units obtained from the factory. A reasonable stock of spare parts will minimize
Malfunctioning items should be returned to the down-time, in the event of a malfunction in this
factory for repair after authorization is equipment. When ordering spare parts, care
received from the local sales and service office should be taken to specify the style numbers (or
or the factory. This is particularly true of other identification) which are printed on the
electronic printed circuit boards which require nameplate, located on this apparatus.
careful handling by skilled personnel and for
which field repair or modifications should not For the DIOM, it is recommended that the user
be attempted. stock at least one DIOM board.

replacement only. No consequential damages SPECIFICATIONS AND PERFORMANCE
resulting from failure of this module are
covered. Power Supply Requirements
+24Vdc ±10%, with nominal current of 0.14 ADC
MAINTENANCE Environment
This equipment contains solid state components
which require little maintenance. The removal of Relative humidity of 0 to 95% non-condensing

I.L. 8651C70C
Revised 11/13/06
ECS2100 Bridge Control Module
INSTRUCTION LEAFLET
DRAWINGS SAFETY
The following drawings are referenced within this DANGER:

document: BODILY INJURY COULD RESULT IF
BCM Card Assembly.........................8651C70 CONTACT IS MADE WITH COMPONENTS
EITHER LINE VOLTAGE OR ARE SUBJECT
PURPOSE TO ABNORMALLY HIGH VOLTAGES.
The primary purpose of the Bridge Control Module REFERENCES TO THE CIRCUIT
(BCM) is to generate the picket-fence train of firing DIAGRAMS, NOTABLY WITHIN OTHER
pulses for six Silicon Controlled Rectifiers (SCRs) DOCUMENTATION, WILL DISCLOSE
in a three-phase, full-wave AC-to-DC converter HAZARDOUS AREAS.
bridge configuration. The output of the bridge is
connected to the field winding of a generator or an As with all electrical equipment, appropriate safety
interposing exciter. A full-wave bridge measures should be taken whenever dealing with the
configuration permits both positive and negative excitation equipment. High voltage is present within
forcing voltage to be applied to the field winding. the excitation cubicles; their magnitudes depend
Negative output voltage only occurs transiently as upon the particular system. Opening the sources
the bridge removes stored energy in the field (e.g., disconnect device 41) does not completely
winding. The field current, however, cannot be disconnect the high voltages. As long as the
reversed. machine is still physically connected to the system,
there is a possibility that a safety hazard exists.
Converter bridges are paralleled to increase the
current rating and to provide redundancy. A Firing Every precaution must be taken when working at the
Control Interface Module (FCIM) determines the excitation control switchgear to ensure that all high
precise instant in time when to fire each of the six voltages are isolated and avoided by test personnel.
SCRs in a bridge. The FCIM can control up to In addition to the machine terminal voltage (460
sixteen (16) paralleled BCMs and converter bridges. Vac or greater) at the excitation transformer, there
may be other sources of power entering the cubicles,
Each individual BCM controls the actions of a such as the customer 125/250 Vdc and/or 120/240
single thyristor bridge. Vac used to feed certain devices. A good rule to
follow is to assume that all connections are live and
This Document contains a description of the dangerous until proven otherwise and to avoid
functions of the BCM, along with a description of completely all body contact with any of these
inputs and outputs. There is also a brief description voltages.
of the installation of the BCM. Maintenance and
warranty information is provided as well.
Effective Date 11/13/06 Supersedes IL8651C70B Page 1 of 9

INSTRUCTIONS FOR Bridge Control Module I.L. 8651C70C
One other cautionary note refers to the Generator FCIM Firing Control Interface Module.
Field Ground Detector. Because the Ground Processes the AC source waveforms
Detector input supply is usually 120 Vac, both the and firing angle command from the
AC bus and DC (100 Vdc) might be backfed from ECM and determines when to fire
this device. Therefore it too must be disconnected each SCR.
when servicing the excitation control equipment. Flash A type of Random Access Memory
(RAM) that retains memory contents
without power, and not relying on a
GLOSSARY battery.
FO Fan Out card. Provides transceiver
BCM Bridge Control Module. Up to 16 capability beyond the three built into
BCMs can be controlled by one the FCIM as Standard.
FCIM. FPGA Field Programmable Gate Array. An
Bridge A configuration of thyristors that integrated circuit that implements
convert AC current to DC current. complex logic functions within a
ccTool Controller Configuration Tool, a PC single package.
based Windows (95, 98, or NT) IT Isolation Transducer card. Isolates
application program which connects two analog signals for digital input
to an ECM, FCIM, or BCM card for to FCIM or BCM and other
user programming of the card modules.
functions. Presents Table or Block PLL Phase Locked Loop. A closed-loop
Diagram representations of the circuit scheme to automatically lock
controller program and operation. the frequency and phase of an
CM Conduction Monitor card. Provides oscillator, so that it produces a
current level information on each precise firing angle necessary to
SCR or bridge. maintain the desired level of a
COE Customer Order Engineering, converter output parameter under
provides all the engineering control.
information for a customer job- QSPI Queued Serial Peripheral Interface,
specific design, including the provides a high speed means to
application firmware required to communicate with the ECM. The
operate the FCIM. QSPI is built into the architecture of
DCE Data Communications Equipment the FCIM controller (MC68HC16).
(part of the RS232 standard). The RS232 A standard physical link protocol for
FCIM is DCE configured. serial communication. Almost every
DFC Digital Firing Control (subset of the PC provides a port using this
digital excitation control system). communication connection.
DTE Data Terminal Equipment (part of SCR Silicon Controlled Rectifier. A
the RS232 standard). The PC variable-conduction rectifier with
running ccTool is DTE configured. delayed forward turn-on gating. Also
ECM Exciter Control Module. Contains referred to as a thyristor.
the excitation control, limiting, VCO Voltage Controlled Oscillator. A
protection, and communication circuit that provides a variable
software (but is not considered a part frequency output proportional to a
of the Digital Firing Control). voltage input.
Page 2 of 9
OPERATION/APPLICATION The software implemented control scheme is

The BCM and FCIM combination is the programmable and viewable as a block diagram or
replacement for previous designs that have used as tables using the Windows™ application
analog means to fire the SCRs in a bridge. To the program ccTool.
maximum extent possible discrete relays, timers,
and associated wiring are eliminated, and their BCM I/O and Hardware
functions are implemented in the software of the The following list of hardware resources and inputs
FCIM, BCM, and ECM. Discrete relays are used and outputs of the BCM is included as an aid in
when the power requirements of the devices being understanding its functionality.
operated (e.g., the 41A device) necessitate them or
when an application requires dry contacts. # of BCM Hardware Resource
2 10 bit A/D convertors based upon built-in
The BCM fires an SCR bridge based upon 68HC16 processor converters. The input is
commands received through a fiber optic cable from scaled for –10V to +10V, unadjusted.
an FCIM, which in turn receives its control 4 12 bit D/A outputs based upon MP7680.
information from an ECM. The FCIM performs the The output is scaled for -10Vdc to +10Vdc
necessary AC power line synchronizing using a unadjusted.
software-calculated phase locked loop (PLL) based
on isolated, sampled three phase voltage signals 2 DC Logical Inputs. For each of the two
from an IT module. inputs from universal AC/DC inputs from
DIOM, TRUE if the input is high.
The BCM is a 68HC16 microprocessor-based 2 State Select Inputs. For each of the two
controller card containing Code FLASH RAM, Boot inputs, a +24Vdc is considered TRUE if the
FLASH RAM, and User FLASH RAM memory. input is high. These inputs are isolated
through optical couplers.
Firing signals interspersed with data signals are 4 VCO counter inputs. These are optical
transmitted to up to 16 paralleled BCMs, over fiber cable inputs driving 16 bit counters within a
optic cables using a custom logical and physical custom FPGA. An external IT card
communication protocol implemented by an FPGA provides a variable frequency input
(Field Programmable Gate Array). proportional to a scaled and measured
voltage. These inputs are processed by the
Data communication is bi-directional between the custom FPGA and sent to the processor at
BCM(s) and the FCIM. All significant alarm and fixed intervals, representing an isolated
other operating data from the BCM are passed to the digitization of the signals being measured.
FCIM, and from there to the ECM. 12 Status LEDs, 4 RED, 4 AMBER, and 4
GREEN.
The BCM receives timed firing commands from the 4 Relay Control output contacts.
FCIM and provides the gate signals to the six SCRs.
It also receives and interprets the inputs from
interface devices; conduction monitors, ± DC 1 RS232 Port based upon the SCI interface
current shunt signals, and SCR and ambient RTD built into the 68HC16.
temperature sensors. The BCM monitors and
controls the starting and stopping of the bridge
through activation and deactivation of local
breakers/contactors.
Page 3 of 9
2 + 24Vdc power supply inputs. Either or the purpose of monitoring and adjusting for the
both supplies will provide the power, specific job application. Refer to the BCM Block
implementing the redundant power supply Diagram (8651C70) for the location of connectors
philosophy of the ECS2100 system. The and jumpers.
digital logic as well as the SCR firing pulse
circuits use the positive supply voltage. BCM Board Connection
2 -24Vdc power supply inputs. Either or both Power and signal connections must be provided to
supplies will provide the power, the BCM. Signals are both optical and electrical.
implementing the redundant power supply Refer to Block Diagram 8651C70 and the job-
philosophy of the ECS2100 system. The specific schematics. All electrical power to the
negative supply voltage is used only by the BCM is provided through the redundant ±24Vdc
SCR firing pulse circuits. connectors, J3 and J4.
2 Optical Transmit Interface from fiber
communication channels with the FCIMs. Optical connections are made by inserting the fiber
The second input allows for redundancy of cables and connectors provided into the main optical
FCIMs. channel receptacles, U41, U42, at the bottom edge
of the board. For redundant (two-channel) systems,
2 Optical Receive Interface to fiber a second optical channel is provided through U43,
communication channels to FCIMs. The U44. Dual fiber cable assemblies are provided for
second output allows for redundancy of the these connections in various lengths, depending on
FCIMs. the specific design.
6 High Energy "Picket Fence" SCR pulse
circuits. Signals received via fiber optic U45 through U48 are four fiber optic receivers that
cable from the FCIM results in the use single fiber cable assemblies to receive signals
appropriate pattern of picket pulses to SCR from two Isolation Transducer modules (2 channels
gates. per module). One of the modules typically obtains
6 Bi-Polar Conduction Sensor inputs. Enable the I+ and I- bridge currents from the two bridge
the assessment of actual firing pattern of shunts.
SCRs for fault detection and metering of
the total and individual device currents. Digital and analog electrical inputs and outputs are
Conduction signals also used for detection provided as shown in the Block Diagram 8651C70A
of failed devices. drawing. In general, it is difficult to establish within
1 4 position dip switch to set the Bridges’ this document the precise use of each of the digital
address, 0 – 15. and analog I/O points. Refer to the drawings for
7 RTD (Resistance Temperature Device) each job-specific system, supplied as physical
drawings and as part of the HTML, dynamic on-
inputs, for measuring the ambient and the
line, HELP. But, above all, carefully document of
six heat sink temperatures..
the original connections is essential any time the
BCM is removed.
INSTALLATION
When shipped the equipment will have its BCM(s) RTDs
physically installed and connected. If replacement is The temperature of each of the SCRs and the
necessary, carefully label and document each of the ambient temperature are measuerd using Resistance
connections to the BCM, in order to properly Temperature Devices. No calibration is required.
reconnect to a new board. Even for the original The device cables plug into J10, J12, J13, J16, J18,
startup (as well as when replacing the BCM), the J20, and J22.
user will be required to interface with the BCM for
Page 4 of 9
Conduction Monitoring BOOT program. When new BOOT code is

In addition to current and voltage sensing, the BCM downloaded, the jumpers must be moved to re-
implements conductivity sensing for each of the six locate the new code at the memory location which is
current control devices (SCRs) of the bridge. By use executed at power-up.
of a gapped core with a Hall effect magnetic flux
sensor, current above ±30 amps in any leg will The location of banks of BOOT, CODE, and
trigger the sensor associated with each of the six TABLES FLASH RAM memory may be changed
SCRs. through the use of jumpers, JMP9 through JMP16.
Jumpers are of the 0.1-inch plastic housed style.
The Conduction Monitor sensors are used to
reference the accurate DC shunt-measured summed For the most part, the default jumper location will
current to the particular devices actually carrying the suffice. Consult the ccTool User’s Manual for
current during any interval of time. By selecting more information.
samples of current at particular times within the
conduction intervals of each SCR, the accuracy of State Select Jumper Setting
current estimates are improved by avoiding The default setting is for NOT REDUNDANT
commutation overlap intervals. operation (Single Channel). If redundant operation
is required, change JMP4 and JMP6 per Table 1 in
BCM Setup Block Diagram 8651C70.
Much of the initial setup will have been done at the
factory or by the field installation engineer. SCR Jumper Setting
However, some adjustment or verification of setup Jumper functionality is provided on the BCM to
may be necessary. BCM setup consists of enable/disable SCR pulse gating operation and to
verification or adjustment of: establish the energy or current level of the SCR
gating pulses. Although the number and duration of
• Jumper configuration the SCR "picket fence" gating pulses is controlled
• Installation or updating of the user program within the BCM, the requirement is established and
• Adjustment of block parameters. communicated from the FCIM through the fiber
• Observation/Monitoring of proper operation optic network.
Jumpers Enable firing jumpers J5, 1-2, and J6, 1-2,

For jumper placement refer to the Block Diagram connections provide ±24Vdc to the SCR firing
8651C70. Jumpers are placed for several external circuit. Remove the jumpers in order to disable SCR
functions on the BCM and for FLASH memory firing.
configuration.
Jumper settings are available for establishing the
No Communication Jumpers SCR gating current level. Jumpers provide from 1 to
There are no jumper configurable RS232 5 parallel current paths, providing 20% increments
communication features for the BCM. Some in current. The order of the jumpers is not
protocol aspects of the communication are significant, only the number of jumpers.
established via software using the CCTool.
Up to four jumpers are placed on the headers near
Flash Memory Jumpers the SCR driver pulse transformers on the BCM.
The FLASH memory jumpers seldom need to be Each jumper added increases the SCR drive current
changed. The primary occasion requiring a FLASH by 20%. No jumpers installed provides 20% of full
jumper change is for downloading a new firmware available current.
Page 5 of 9
Bridge Address Switch controls the download process, downloading new

A four position DIP switch, S1, mounted on the boot code requires the use of the existing BOOT
BCM is used to set the BCM's address, from 0 to code with a subsequent interchanging of the location
15. See the Block Diagram 8651C70 for the location of the old CODE and BOOT banks (with the power
of the switch. Table 4 on that drawing shows the off). It will be necessary to invoke the new BOOT
switch settings for the range of addresses. bank at the next power-on of the BCM. This is an
infrequent event, as BOOT code is relatively simple
State Select Jumper setting. and not likely to change.
For a single channel system, the default setting is
appropriate. See the Block Diagram 8651C70, Table Refer to the distribution medium discussion under
1, for the setting of the jumpers for redundant (two CODE Firmware. For more information of the
and three channel) systems. upload/download process refer to the ccTool User’s
Manual.
Connection of ccTool
In order to perform a setup, the user must connect a CODE Firmware
personal computer running the Windows™ Using ccTool, the user may upload or download the
application program ccTool to the BCM via operating firmware which creates all the features
connector J27. Use a standard through wired RS232 and functions of the BCM. The BCM is shipped
cable with DCE 9 pin on the end connecting to J27 with the latest operating firmware at the time of
on the BCM and DTE 9 or 25 pin at the other end to production. New firmware will be distributed on
match the RS232 port being used on the users PC. computer medium, principally a 3-1/2 inch floppy
After assuring the BCM is energized, invoke ccTool disk or on a Compact Disk CD-ROM. The file
by following the instructions in the ccTool User’s containing the released code will have the
Manual. extension, .RHX.
PROGRAMMING Application/User Program

Program Modifications Onsite The User Program is implemented in the same
Using the ccTool, modifications of FLASH stored fashion for the BCM as for the FCIM. However the
code can be made at the customer’s facility or program much simpler for the BCM.
remotely (ccTool supports modem connection) to
the site. This capability permits the firmware as well Each system is designed by Customer Order
as the startup, running, and shutdown sequence Engineering (COE), based on an adaptation of a
logic to be changed on site. Three specific classes standard base design to best serve the customer's job
of stored data can be changed: requirements.
• Download/Upload BOOT firmware The COE personnel install customized software

• Download/Upload CODE firmware according to the specific requirements of the order.
• Download/Upload Application (Tables) COE initially uses a series of standardized and pre-
tested application programs. Adjustments then are
These functions will be useful during initial startup made to satisfy individual site-specific customer
as well as in later maintenance situations. requirements. The software is installed in the BCM
module during production assembly and test. The
BOOT firmware program is also provided on computer data media
The BOOT firmware is code that controls the BCM that is shipped along with the other documentation
power-up, communications, and the up/download of the system.
process. Since the BOOT bank of FLASH memory
Page 6 of 9
The application block diagram program is loaded Monitoring Alarms

into the BCM through the Windows™ application Using the ccTool program, the user may monitor
program, ccTool. The ccTool also allows copying and respond to alarms, trips, and other system
and/or modification of the provided program stored exceptions. The ALARM descriptions are stored
within the FCIM in its Flash RAM. within the BCM as part of the operating firmware.
Thus, when a new exception type is added, its
Modification of the original user application description is immediately available for display by
program likely will be the most frequent the ccTool while the user is monitoring.
upload/download event over the life of the BCM
and the associated excitation equipment. Changes Examining LEDs for Visual Operational
may be as simple as gain adjustments or more Indications
involved changes in the block structure. The “DR” block, within the BCM, controls the state
of 12 LEDs, 4 Red, 4 Green, and 4 Amber. The
The user application consists of invoking and LEDs are mounted on the BCM board. Refer to the
interconnecting blocks. The interconnections are Block Diagram 8651C70.
implemented through software patching within the
firmware and governed by table entries within the The customer’s application makes use of these
USER FLASH RAM LEDs to convey the state of the operating program
by visible indication. Use the ccTool program to
NORMAL BCM OPERATION view the Block Diagram representation of the User
The BCM will operate independently of any user Program in order to determine the meaning of the
intervention. However, aspects of operation may be LED displays.
observed, monitored, or controlled through the use
of the ccTool program, visually through the 12 Monitoring Operation of Blocks
BCM LEDs, or through information communicated Using the ccTool, the user may see the logical and
with the ECM and displayed either on a local analog states of all the data used by and generated
Panelmate™ , located at the excitation control by the block diagram.
cubicles, or on the control room display.
Creating or Adjusting User Programs DIAGNOSTICS

Programs are created, modified, and adjusted using
the ccTool program. The function of many of the Diagnostic functions are available within the BCM
blocks within the user’s program are governed by and within the ccTool. These diagnostics may aid in
constant inputs. The constants may be modified determining whether the BCM is at fault,
dynamically during on-line operation. Thus gains, eliminating some unnecessary replacements.
scale factors, and time constants can be adjusted to Further, if a problem is not in the BCM, the
improve operation. diagnostics should help localize the source of the
problem.
Providing over-riding control
Using the ccTool program, a user may force values For module replacement, refer to the
or states within his Block Diagram program. This is INSTALLATION section.
generally done for the sake of debugging or to
temporarily compensate for operational problems. Potential maintenance actions include:
• Access LEDs for visual operational indications
• Modify Jumpers
• Monitor operation of blocks with ccTool
Page 7 of 9
• Adjust parameters of blocks invalidated, unless the following described

• Download/Upload application procedures are followed. Apparatus which
• Download/Upload code firmware malfunctions should be replaced with new units
• Download/Upload new boot firmware obtained from the factory. Malfunctioning items
• ccTool Communication Test should be returned to the factory for repair after
authorization is received from the local sales and
Field Testability service office or the factory. This is particularly
No testing will be done in the field except those true of electronic printed circuit boards which
built into the hardware or firmware and those require careful handling by skilled personnel
inferred by examination of the operation. Integrity and for which field repair or modifications
of operation is provided by checksums, a should not be attempted.
“watchdog” timer in the processor hardware, other
built-in software checks, and tests performed by the This is a limited warranty, covering repair or
ccTool. replacement only. No consequential damages
resulting from failure of this module are covered.
Checksum
A checksum of the operating firmware is calculated
whenever the BCM is powered on. If the checksum MAINTENANCE
is incorrect, the application firmware is not This equipment contains solid state components
executed, and the BCM remains within BOOT which require little maintenance. The removal of
mode, executing the separate “BOOT CODE” in the accumulated dust occasionally will be sufficient.
BOOT FLASH memory. Maintenance for non-solid-state components is
Watchdog Timer
The watchdog timer is a hardware function within
the module processor which will reset the system if SPARE PARTS
software doesn’t periodically send a signal into the A reasonable stock of spare parts will minimize
timer. If the watchdog timer resets the system, the down-time, in the event of a malfunction in this
fact will be known by the system and an alarm will equipment. When ordering spare parts, care should
occur. Timing delays within the hardware will show be taken to specify the style numbers (or other
up as alarms by this function, even if the system still identification) which are printed on the nameplate,
appears to be operating. located on this apparatus.
Communication Tests with the ccTool For the BCM, it is recommended that the user stock
The ccTool provides communication test functions. at least one BCM board and plastic-housed 0.010-
Repetitive test write followed by read actions are inch jumpers.
carried out through the FCIM to each of the BCMs,
or directly to a BCM. By invoking the
communication tests, operation of several SPECIFICATIONS AND PERFORMANCE
subsystems can be verified, including processors
and fiber optic channels. Power Supply Requirements
+24Vdc ±10%, with nominal current of 0.25 ADC
LIMITS OF WARRANTY RTD

The RDT temperature range is 0 to 100 °C ± 1°
Page 8 of 9
External Serial Communication

RS-232 communication occurs at a fixed rate of
38.4 KBaud through a 9 pin sub-miniature “D”
connector, J27, configured as DCE. Since PCs are
typically configured as DTE, a standard “through”
RS232 cable may be used. All parameters for this
communication are fixed by the BCM firmware,
requiring no user setup or intervention. Some choice
is provided by the ccTool for the logical protocol,
but the physical protocol is fixed.
Bridge Communication
The bridge communication to the Bridge Control
Modules is performed over a fiber optic link. Three
fiber optic channels are built into the FCIM. An
electrical connector is provided to interface with a
Fan Out Card, providing 13 additional full duplex
fiber channels.
Active Current Balance

Active current balancing algorithms (so-called
“Skip Firing “) may be provided on each BCM. The
FCIM will enable, freeze or disable each BCM’s
implementation of the balance. BCM’s will report
back their “fair share” current to the FCIM. The
FCIM then makes this information available to the
ECM.
Redundancy
A State Select line is available on FCIMs for the
purpose of controlling which one of two FCIM
redundant fiber networks is to be used to control the
BCMs. A third FCIM (termed the “supervisory”
FCIM) monitors the operation of the two redundant
FCIMs, detecting the failure conditions that require
a switch over to the second FCIM, using the State
Select Line. Each BCM has a State Select input
connector J9.
Environment
Ambient temperature range of -20° to 50°C
Relative humidity of 0 to 95% non-condensing
Page 9 of 9
I.L. 4D01737B
Instructions for ECS2100 Three Phase Power Drawer - Draw Out Design
Full Converter (Inverter) Power Amplifier Drawer
The apparatus described herein is part of a system. A necessary complement to this amplifier is the circuit
The specific system is described in a separate that provides the firing pulses to the thyristors.
instruction leaflet located near the front of this Operation of the firing circuits is explained in the
instruction book. The system instructions should be Digital Firing Control Instruction Leaflet. The phase
thoroughly read and understood before proceeding lock loop used to create the firing reference is
with this leaflet. All "DANGER" and "CAUTION" generated on the FCIM and the firing signals are sent
notes included in the instructions for the system will to the BCM. On the BCM, gate pulse amplifiers apply
apply to the apparatus herein described. a picket fence signal to the Thyristor gates. The picket
fence signal is adjustable on the BCM by software
DRAWINGS settings appropriate for the application. In order to get
Typical Schematic (1100A) 4D01737A. the maximum range of output voltage, the gate circuits
Output Waveforms Inverter 662A221. of the thyristors must be pulsed at the proper time and
Mechanical Layout Power Drawer 4D01727A. in the proper sequence. During flashing, all of the
Mechanical Layout Power Drawer 4D01727D. bridges may be fired in unison and at a very high rate
Rear View of Power Drawer 4D01747C to cause the thyristor control bridge to act like a diode
bridge.
FULL CONVERTER (Inverter)
The ECS2100 power converter is a switching type AC
to DC converter that uses silicon-controlled rectifiers During normal operation, the pulses must be 120
(thyristors) as the control element. It is used to supply electrical degrees apart between each thyristor in the
the excitation to the field of an electric machine. It is positive legs and 120 degrees apart between those in
an inverting type bridge and has thyristors in all legs the negative legs. In addition, the pulses between the
of the three-phase full wave bridge and thus is capable positive and negative legs must be 180 degrees apart.
of driving the output voltage both positive and Since there is a 180-degree shift between the positive
negative. Although voltage can reverse, the amplifier and negative thyristor pulses and a 120-degree shift
can only output positive current as the current can between each pulse in the positive or negative legs,
never reverse through a thyristor. See the typical there is no pulse occurring in a negative leg when a
electrical drawing 4D01737A. positive leg is pulsed. This would mean that there
would be no return path for the current. To provide the
The amplifier is constructed as a draw out drawer necessary return path, each thyristor is pulsed twice
assembly with contacts at the rear for both power and per cycle. The first pulse is the main pulse and
control disconnects. Many drawers may be paralleled determines what point in the cycle the thyristor will
to handle higher currents. The input voltage rating of conduct. The second pulse occurs 60 degrees later and
the drawer is typically limited to 600 Vac or less and is used to give a return path for the current when the
is based on creepage and clearance and the PIV of the amplifier is first turned on. To vary the output voltage
thyristors. The application environment must be from maximum positive to maximum negative, the
considered in both the voltage and current the rating. pulses must be varied 180 degrees (160 degrees
The rating chart is used as a guideline including margin).
DESCRIPTION AND OPERATION The inverter power amplifier has the capability of
reversing the load voltage while maintaining
Phase rotation and actual phasing of the three phase conventional current flow. This characteristic is useful
supply to the power disconnects must be AC1, AC2, in forcing the circuit current to zero by transferring the
AC3 as marked. This is necessary to insure that the magnetic energy from the load to the line.
gate pulses that fire the SCRs will be timed correctly.
Page 1 of 4
Instruction for Power Drawer I.L. 4D01737B
Note that if the gates are pulsed at zero delay with in the BCM on reception of the firing signal. Jumpers
respect to positive voltage on the anodes of the on the BCM select the required gate current and as
thyristors, current will flow when the supply voltage is stated earlier, each thyristor is fired twice per cycle.
positive and power will flow to the field. If the gates The rise time and duration of the pulses is very fast
are pulsed at 90 degrees delay, current will flow and a current probe and fast oscilloscope should be
during half the time the supply voltage is positive and used for accurate representation of the current
during half the time the supply voltage is negative. waveform.
The net result is zero average load voltage and zero
average power flow to the field. If the gates are pulsed A BCM, IT, and Power Supply are mounted on the
at more than 90 degrees delay, current will flow when front of each Power Drawer (see drawings 4D01737A
the supply voltage is negative longer than when it is and 4D01737D). The IT is used to measure the
positive and there will be power flow from the field to positive and negative shunt current. Software in the
the supply. A delay of 90 degrees to 180 degrees is a BCM uses the firing signal received from the FCIM,
transient condition and power will flow only until the the Conduction Monitor inputs and the IT to develop
field current is zero. measurements of the average peak current in each
thyristor. These currents, as well as the average shunt
Refer to drawing 662A221 showing output currents can be are gathered by the FCIM and are
waveforms. Note that these waveforms are drawn available via Modbus. They can also be viewed at the
assuming perfect sine waves at the input to the output of the CSL block in the BCM.
amplifier and do not show commutation effects. In
actual practice, the firing of the thyristors into a load CONDUCTION MONITORS
distorts the supply sine wave hence the output
waveforms will be distorted since they are made up of The Conduction Monitors are used to verify that each
parts of the supply sine wave. The following shows thyristor is conducting. The conduction monitors
typical field voltage: detect 30 amps or greater in both directions and are
placed in the ac input to the bridge (see the back view
of the bridge drawing 4D01747C). The conduction
monitor software (CSL block) in the BCM reads the
status of the conduction monitors and will detect when
a thyristor is not conducting. A thyristor may not be
conducting if the gate lead is open, or if a fuse is
blown. The following shows the output of a single
bridge into an inductive load with a missing pulse:
Since the output of the power drawers is connected to

the field of a machine, the current in the circuit cannot
change instantaneously but must follow the time
constant of the field. This time constant is very long
compared to the power supply frequency and hence
the field current will be essentially constant for one
cycle of the power frequency. Since the output current
is constant, the current flowing in the a-c supply leads
will be square waves. If a resistive load is connected
for test, then the current will follow the voltage and no Note that the conduction monitor software can be
longer be constant for one cycle of the power turned on or off conditionally in the software so that
frequency. This should be noted if there are current alarms are not generated when the current is less than
transducers in the field circuit that normally measure a 30 amps (see the CSL software block in the BCM).
pure d-c current. Consider that it may be of benefit to check conduction
when the bridge is off, verifying that all the
BCM - Pulse Transformers conduction monitors are indicating there is no current.
This condition can be viewed in the Alarm window in
The number of picket fence pulses and the duration of the FCIM and is shown below for two bridges that are
each pulse is set in the software block BRGCNFG in not conducting current.
the FCIM. The firing commands are sent by fiber
optics from the FCIM to the BCM to initiate firing.
The electrical pulses to fire the thyristors are created
Page 2 of 4
If both the positive and negative thyristor in one phase will display this number. Use ccTool to verify this
are open, or when there is a blown fuse, the number.
conduction monitor software in the BCM will detect
the condition. The Alarm log in the FCIM should be REMOVING THE DRAWOUT UNIT
read, and from the information presented one can
deduce if a fuse is blown, or if thyristors are not The unit may be removed while the machine is under
conducting. load. Determine that the remaining drawers have
sufficient capacity to carry the load before removing a
drawer.
1. Remove front panel and unplug fiber optics.

Removing the fiber connection stops the firing pulses.
2. Insert a 3/8 inch square drive crank and crank out

the drawer until the crank turns free (2 inches). As
soon as the drawer is withdrawn approximately 1/2
inch, the control connections to the multiple pin plug
will be broken and power to the gate pulse
transformers is disconnected..
2. Slide the drawer out to the end of the rails till the
stops hit.
3. Turn the stops out of the way and remove the

drawer. Use a mechanical lift to remove the drawer; it
weighs more than 500 pounds.
4. If the drawer is to be left out for a long period of

time, a temporary cover should be placed over the
opening to maintain sufficient air flow in remaining
units.
FAN CONTROL
5. To install a drawer, reverse steps 1 to 4.
Each of the power drawers selects either main fan or
backup fan control. The fans can be configured to turn INITIAL SETTINGS AND TESTS
on when the heat sinks or inlet air exceeds a threshold
temperature, or they can be configured to turn on when Each power amplifier drawer has been tested and
the exciter is turned on. In addition, either fan can be adjusted at the factory. However, before replacing a
selected to be the "primary" fan and appropriate power drawer with a new one from the factory, verify
alarms for failed conditions can be viewed in the that the firmware (rhx file) and the software (ccf file)
Alarm screen. for the new drawer are the same. If they are not the
same, consult with Basler Electric. In addition to the
Since each bridge selects the main fan or backup fan, firmware and software the dip switch, S1, on the front
the bridges can be removed, or turned off, without of the BCM for the new drawer must be set the same
shutting off the cooling to the bridges that are still in as the dip switch on the drawer that is removed. Note
service. that the dip switch selects the drawer number, and that
these numbers must be unique. Also, in order to verify
BRIDGE NUMBERING the rhx and ccf files, the BCM must be powered and
ccTool must be used.
Each Power Drawer occupies a position in the exciter
assembly cubicle. These positions are numbered, using In order to verify the rhx and ccf files, the 24 volt
hexadecimal, starting at 0 and ending with F. The power supplies on the front of the Power Drawer must
maximum number of bridges that each FCIM can be energized. This energizes the BCM so that ccTool
control is 16. The BCM determines the bridge number can communicate with it. Apply 120 Vac, or 125 Vdc
by reading the position of the switch S1. In the to PSP and PSN as shown on drawing 4D01737A.
software, the output of FM_OUT block in the BCM Observe polarity.
Page 3 of 4
Inspect each drawer for loose nuts, bolts, wires, etc.

Verify that the fuses are not open, and verify that the Spare or replacement parts can be ordered by
thyristors are not shorted: description and reference to the drawer style number
on the nameplate. Place spare part orders with Basler
• Check all thyristors, and fuses with an ohmmeter Electric.
to determine if any have failed. Thyristors should
read a high resistance in both directions. A fuse SAFETY
should be a short circuit. When taking ohmmeter BODILY INJURY COULD RESULT IF
readings, be sure to allow for any parallel paths CONTACT IS MADE WITH COMPONENTS IN
around the device being tested. THIS APPARATUS THAT CARRY EITHER LINE
VOLTAGE OR ARE SUBJECT TO
• If a thyristor is failed, contact Basler Electric for a ABNORMALLY HIGH VOLTAGES.
replacement Heatsink assembly. REFERENCES TO THE CIRCUIT DIAGRAMS,
NOTABLY WITHIN OTHER DOCUMENTATION,
(It is recommended that rated PPT voltage, use 30 WILL DISCLOSE HAZARDOUS AREAS.
amp fuses, be applied to the AC1, AC2 and AC3
before inserting the Power Drawer back into the As with all electrical equipment, appropriate safety
exciter.) measures should be taken whenever dealing with the
excitation equipment. High voltage is present within
SPARE PARTS the excitation cubicles; their magnitudes depend upon
the particular system. Opening the sources (e.g.,
This equipment contains solid state components which disconnect device 41) does not completely disconnect
require very little maintenance, however coal dust and the high voltages. As long as the machine is still
other air borne contaminates can degrade the isolation physically connected to the system, there is a
required for proper operation and can lead to failure. possibility that a safety hazard exists.
When the drawers are dirty (they will appear slightly
blackened) they should be cleaned. The drawers Every precaution must be taken when working at the
should be sent to Basler Electric for proper cleaning. excitation control switchgear to ensure that all high
voltages are isolated and avoided by test personnel. In
A reasonable stock of spare parts will minimize addition to the machine terminal voltage (460 Vac or
downtime, in the event of a malfunction in this greater) at the excitation transformer, there may be
equipment. When ordering spare parts, care should be other sources of power entering the cubicles, such as
taken to specify the style numbers (or other the customer 125/250 Vdc and/or 120/240 Vac used to
identification) that is printed on the nameplate, located feed certain devices. A good rule to follow is to
on this apparatus. Make sure that scrs in replacement assume that all connections are live and dangerous
drawers have the same Basler Electric part number, or until proven otherwise and to avoid completely all
equivalent. Also, be sure to record the firmware body contact with any of these voltages.
revision and save a copy of the software configuration
file (ccf).
Page 4 of 4
FOR
DE-EXCITATION/CROWBAR (DXCB) MODULE
STYLE 2D80367 G01, G02, G03, G12, G13, G23

The DXCB module, illustrated in outline drawing 2D80367920, consists of a current sensor circuit board (PC1), a
control circuit board (PC2), and a thyristor.
The DXCB module protects the generator field and exciter circuits by providing a low impedance path for currents
that would otherwise cause excessively high transient voltage or damaging arcs. A DXCB module can be used in
one of two modes: de-excitation (DX) mode or crowbar (CB) mode.
In DX mode, the DXCB module provides a path for the generator field current when its field breaker is opening or
when the “normal” path is not available.
In CB mode, the DXCB module provides a low-resistance path to large positive voltages that appear across the
generator field and exciter bridge. Generator pole-slip voltage is one source of high voltage.
DXCB Module Styles

Table 1 lists the six available styles of DXCB module.
Table 1. DXCB Module Styles
DXCB Field Maximum Field
Module Style Voltage Current
G01 480 Vdc 1,000 Adc
G02 480 Vdc 2,000 Adc
G03 480 Vdc 5,000 Adc
G12 600 Vdc 2,000 Adc
G13 600 Vdc 5,000 Adc
G23 1,200 Vdc 5,000 Adc
Drawings
The following drawings are provided with this publication:
 Outline drawing, 2D80367920
 Block diagram, 2D80367001
 Connection diagram, 2D80371
Typical DXCB Module Application

Figure 1 illustrates a typical excitation system using two DXCB modules. One module is being used in de-
excitation (DX) mode and one module is being used in crowbar (CB) mode.
The normal path for current is through the power potential transformer (PPT), ac breaker (41AC), exciter bridge,
field breaker (41DC), and the generator field. If this current path is interrupted, such as when the field breaker
opens, the generator field (being a large inductor) will develop the necessary voltage to keep the field current (Ifg)
from changing. The de-excitation circuit then provides the path for this current.
A resistor, Rd, may be provided to absorb energy from the generator field. This reduces the time it takes to de-
excite the generator when a dc interrupt device is used.
The crowbar circuit provides a low resistance path to large, positive voltages. When the crowbar conducts, a logic
level feedback is provided to the excitation system to phase back the excitation power bridge. A resistor, Rc, limits
the “bridge current” when the crowbar is conducting.
In crowbar operation, the control circuit board provides a phase back signal to either the MGR or M300 type
exciters. These outputs are labeled MGR and M300 respectively.
Publication Revision First Printing: Copyright

IL8526C34 E Revised: 12/08 2008
Figure 1. Typical DXCB Module Application
CURRENT SENSOR BOARD FUNCTIONAL DESCRIPTION

The current sensor board detects current flow when the flux density in the air gap exceeds the pickup threshold of
the Hall-effect switch. LEDs D1 and D2 light to indicate current flow. The current sensor turns off (does not
indicate current flow) when the flux density decreases below the dropout threshold of the Hall-effect switch. The
Hall-effect switch has a pickup threshold of approximately 30 amperes and a dropout threshold of approximately 5
amperes. (These pickup and dropout values are approximate due to possible variances in the air gap.)
Operating Power
Operating power for the current sensor board circuitry is received via the control circuit board. Components on the
current sensor board reduce the 24 Vdc applied to the control circuit board down to an appropriate level.
LED D9
LED D9, located on the control circuit board, lights to confirm that the current sensor board is connected to the
control circuit board via the ribbon cable.
CONTROL CIRCUIT BOARD FUNCTIONAL DESCRIPTION

As shown in connection drawing 2D80371, control circuit board PC2 on the DXCB module provides the control
interface with the excitation system to fire the thyristor.
Thyristor Firing
Two optically-isolated logic inputs are available to control firing of the thyristor. Logic input J2 accepts a 24 Vdc
firing input at terminals FP24 (+) and FN24 (–). Logic input J1 accepts a 125 Vdc firing input at terminals FP125
(+) and FN125 (–). When thyristor firing is initiated by logic input J1 or J2, a train of pulses fire the thyristor for as
long as the logic commands firing. The initial high intensity of the firing pulse train decreases after approximately
200 milliseconds. If a power supply failure occurs, capacitors provide enough energy to fire the thyristors for 500
milliseconds. A gate pulse transformer isolates the control firing circuitry from the thyristor gate.
Thyristor Current Flow Indication

The control circuit board detects current flow through the thyristor by monitoring the current sensor board. When
thyristor current is detected, the control circuit board provides a relay driver signal, CRSD, via J9. CRSD Active
LED D36 lights when the relay driver is energized. The CRSD output has an adjustable time delay of 50
milliseconds to 1.05 seconds that is controlled by jumpers JTD1 and JTD2 and potentiometer R51. To obtain the
desired CRSD output time delay, observe the following guidelines:
 For a 50 millisecond time delay, set JTD1 at D (disable) and JTD2 at D (disable).
 For a 350 millisecond time delay, set JTD1 at E (enable) and JTD2 at D (disable).
 To add up to one second of delay time, set JTD2 at E (enable) and adjust R51 for the desired time delay.

2 Revised: 12/08 E IL8526C34
Break-Over Diodes
The break-over diodes (BODs) fire the thyristor based on “high voltage”. Depending on the system requirements,
as many as five 800 volt BODs are connected in series with appropriate current limiting resistors and stabs for
selecting firing voltages. Stabs JB1 through JB5 select the appropriate current limiting resistance. Stabs JB6
through JB11 select the appropriate firing voltage:
 For 800 volts, jumper JB10 to JB6. Connect the anode jumper of the thyristor to JB5.
 For 1,600 volts, jumper JB9 to JB6. Connect the anode jumper of the thyristor to JB4.
 For 4,000 volts, remove the jumper. Connect the anode jumper of the thyristor to JB1.
BOD Firing Voltage Setting Considerations for De-Excitation Mode
The BOD firing voltage level should be set to protect the generator field as recommended by IEEE C37.18 (1979),
Standard Enclosed Field Discharge Circuit Breakers for Rotating Machinery, page 21, Table 4 (see Table 2 of this
publication). The BOD firing voltage level should be:
 Set lower than the contact voltage rating of the 41DC breaker or contacts. When the 41DC is opened under
load, the voltage that develops across its contacts should be greater than the break-over voltage so that the
de-excitation thyristor will be fired.
 Coordinated with surge protection.
 Set higher than the maximum negative output of the exciter bridge plus a “safety factor” to prevent inadvertent
de-excitation operation.
When 41AC is used, BOD firing cannot be relied upon to fire the de-excitation circuitry. The voltage developed by
the contacts of an ac breaker attempting to interrupt dc current will likely be insufficient.
BOD Firing Voltage Setting Considerations for Crowbar Mode
The BOD firing voltage level should be set to protect the generator field as recommended by IEEE C37.18 (1979),
Standard Enclosed Field Discharge Circuit Breakers for Rotating Machinery, page 21, Table 4 (see Table 2 of this
publication). The BOD firing voltage level should be:
 Set less than the PRV of the exciter bridge thyristors.
 Higher than the maximum positive output of the exciter bridge, including the communication voltage.
Table 2. Recommended Permissible Transient Crest Voltages Based on Machine Field Circuit Insulation
(For use in selection of field discharge resistors.)
Recommended
Standard Manufacturer Permissible
Nominal Field Machine Field—60 Hz Transient Crest
Circuit Voltage Dielectric Test (Volts rms) Voltage
250 2500 1770
375 3750 2650
500 5000 3530
750 5500 3890
1000 6000 4240
Pushbutton Controls
The control circuit board has two pushbutton controls: Test and Reset.
The Test pushbutton is used to simulate current flow through the thyristor. Jumper J7 must be in the E (enable)
position to allow this test.
The Reset pushbutton resets the CSRD signal when the control circuit board is in Manual Reset mode. Manual
Reset mode is enabled by placing jumper J6 in the M (manual) position.
Operating Power
The control circuit board accepts 24 Vdc operating power at terminals P24 (+), N24 (–), and COM at J4. These
terminals are protected by diodes against reverse polarity. Components on the control circuit board reduce the

IL8526C34 E Revised: 12/08 3
24 Vdc operating power down to an appropriate level. LED D17 lights to indicate the presence of +24 Vdc and
LED D25 lights to indicate the presence of –24 Vdc.
Jumper J5
Jumper J5 is used to make the gate to cathode connection on the thyristor.
PARALLELING
Logic firing and BOD firing are paralleled so that either or both can fire the thyristor required. (BOD firing alone or
logic firing alone may be utilized in some applications.)
As shown in Figure 2, control circuit boards can be paralleled using ribbon cable connections to J10 and J11.
(Wire to the primary unit and connect to the followers with ribbon cable.) This feature is provided for redundancy
and to increase the rating for certain types of operation.
Parallel operation should be broken up into two categories: control firing and self firing.
Control Firing
Parallel operation via control firing is not a concern since the firing pulses are synchronized.
Self Firing
For de-excitation or crowbar applications, a resistor is required when DXCB modules are paralleled, either Rc or
Rd.
NOTE
For de-excitation operation via self firing, the excitation system must have a
breaker that will support the required voltage. For parallel operation without
separate discharge resistors in series with each thyristor, the voltage across the
parallel thyristor may disappear before self firing occurs.
Figure 2. Parallel DXCB Operation with Resistor
SPECIFICATIONS
Thyristor/Heat Sink Assembly Rating

53 mm: 2,000 field amperes
75 mm: 5,000 field amperes

4 Revised: 12/08 E IL8526C34
DXCB Module Ratings
Continuous Rating
100 Adc at 55C (131F) for 50 mm or 75 mm thyristors.
One Second Rating
Six operations at maximum rating is considered the life of the device.
75 mm Thyristor: 6,000 Adc
50 mm Thyristor: 2,000 Adc
Non-Repeatable (Fuse Type) Operation
Withstands 20,000 Adc for 1 second in applications where the bus bar and thyristor are sized appropriately. The
thyristor may be shorted after operation and require replacement before subsequent operation of the exciter.
VDRM and VRRM Rating
VDRM (repetitive peak off-state voltage) and VRRM (repetitive peak reverse voltage) for cells will be 4,200 volts.
Power Connections
For DXCB module terminals CX and CB, use cables or bus bars from the generator field circuit. These terminals
are 0.375-16 UNC. Terminal CB is current in—anode side of the thyristor. Terminal DX is current out—cathode
side of the thyristor.
Logic Power
125 Vdc logic power is applied to pins 1 (+) and 3 (–) of connector DXTBP. The mating plug is Phoenix
MSTB2.5-ST-S.08.
Control Firing
Thyristor firing can be externally initiated through the application of either a 125 Vdc or 24 Vdc control firing input.
125 Vdc Control Firing
A 125 Vdc control firing input is applied to terminals FP125 (+) and FN125 (–) of connector J1. The mating plug is
Phoenix MSTB2.5-ST-5.08.
24 Vdc Control Firing
A 24 Vdc control firing input is applied to terminals FP24 (+) and FN24 (–) of connector J2. The mating plug is
Phoenix MSTB2.5-ST-5.08.
High Voltage Firing (JB1 Through JB11)

Jumpers on the control card select the level of high voltage firing. No connections are required external to the
module to initiate high voltage firing. Logic power is not required to initiate high voltage firing. However, there is no
indication of current (from the current sensor) without logic power.
Phase Back and CSRD Circuit Connections

Connector J9 carries the phase back signals to an MGR or M300 and a current sensing relay driver. The mating
plug is Phoenix MSTB2.5-ST-5.08.
Physical Ratings
Dimensions: See drawing 2D80367920
Weight: 21.4 kg (47.2 lb)
Maximum Temperature: 55C (131F) at full rating
Humidity: 0 to 95% relative humidity, non-condensing
MAINTENANCE
The DXCB module requires no maintenance other than periodic inspection and removal of accumulated dust.

IL8526C34 E Revised: 12/08 5

6 Revised: 12/08 E IL8526C34
This page left intentionally blank.
© 2011 Siemens Energy. Inc. – Letter

© 2011 Siemens Energy. Inc. – Ledger



IL 25A4501A
ECS2100 Isolation Card (CTPT)

Instruction Leaflet
The ECS transformer card provides signal-level isolation and voltage levels required for input to the Signal
Input Module (SIM) as required by the ECS2100. Figure 1 shows the simplified PT circuit and Figure 2
shows the CT circuit.
There are three transformers (T1, T2, and T3) that attenuate the PT signals from 120 Vac to 20 Vac. Jumpers
J7, J8, J10 (on the primary side), J4, J5, J6 (on the secondary side) are used to make a delta-delta
configuration. Each of the transformers can be used in a single-phase sensing configuration by removing the
appropriate primary and secondary jumpers. The 120 Vac PT signals are connected into the board at J19 and
the 20 Vac output signals connect at J1, J2, and J3. In a typical application, a one-to-one cable is used to
connect:
• From J1 of this card to the main channel SIM
• From J2 of this card to the redundant channel SIM
• From J3 of this card to the supervisor channel SIM
Transformers T4, T5, and T6 are used for current sensing. The primary side (J16) of the transformers is
typically connected across a 0.3 ohm precision sensing resistor. The sensing resistor is in series with the CT
secondary and rated currents are typically 4 Aac, rms. When using three CTs, jumpers J14 and J15 are used
to configure the secondary in a wye configuration. Three-phase sensing, single-phase sensing, and sensing
any two CT currents is supported.
Using a separate transformer card for the main, redundant, and supervisor channels will eliminate single
point failure in the transformer card.
Figure 1. PT Connections
INSTRUCTIONS FOR ECS2100 ISOLATION CARD IL25A4501A
Figure 2. CT Connections
I.L. 8651C64C
Revised 11/13/06
ECS2100 Isolation Transducer
INSTRUCTION LEAFLET
DRAWINGS As with all electrical equipment, appropriate
The following drawings are referenced within this safety measures should be taken whenever dealing
document. with the excitation equipment. High voltage is
IT Card Assembly ..............................8651C64 present within the excitation cubicles; their
FCIM Card Assembly ........................8651C67 magnitudes depend upon the particular system.
Opening the sources (e.g., disconnect device 41)
does not completely disconnect the high voltages.
PURPOSE As long as the machine is still physically
The purpose of the Isolation Transducer (IT) is to connected to the system, there is a possibility that
provide a highly isolated version of the input a safety hazard exists.
signal in a form convenient for reception by the
module using the signal. The output of the Every precaution must be taken when working at
Isolation Transducer is a pulsed fiber optic light the excitation control switchgear to ensure that all
signal with a frequency proportional to the input high voltages are isolated and avoided by test
voltage. The Isolation Transducer has two isolated personnel. In addition to the machine terminal
sections, each electrically isolated from the other voltage (460 Vac or greater) at the excitation
and with the output electrically isolated from the transformer, there may be other sources of power
input. The Isolation Transducer is specifically entering the cubicles, such as the customer
targeted at pairs of signals associated with the 125/250 Vdc and/or 120/240 Vac used to feed
power portions of a generator or exciter system. certain devices. A good rule to follow is to assume
The FCIM and BCM are ECS2100 modules that all connections are live and dangerous until
capable of using the IT for highly isolated input. proven otherwise and to avoid completely all body
SAFETY One other cautionary note refers to the Generator

Field Ground Detector. Because the Ground
DANGER: Detector input supply is usually 120 Vac, both the
BODILY INJURY COULD RESULT IF AC bus and DC (100 Vdc) might be backfed from
CONTACT IS MADE WITH COMPONENTS this device. Therefore it too must be disconnected
IN THIS APPARATUS WHICH CARRY when servicing the excitation control equipment.
CIRCUIT DIAGRAMS, NOTABLY WITHIN

DISCLOSE HAZARDOUS AREAS.
Revised 11/13/06
Page 1 of 5
INSTRUCTIONS FOR Isolation Transducer I.L. 8651C64C
GLOSSARY
The accuracy of the transducer frequency is
BCM Bridge Control Module. Up to 16 ±4KHz = ±1.6% of Full Scale. No adjustment is
BCMs can be controlled by one provided within the Isolation Transducer. If
FCIM. necessary, adjustments may be made digitally
DFC Digital Firing Control (subset of within the user's program. Each of the modules
the digital excitation control which use the IT for input operates on the basis of
system). a user program viewable as a block diagram using
the ccTool program. The ccTool provides user
ECM Exciter Control Module. Contains adjustment for each specific input.
the excitation control, limiting,
protection, and communication The reception is based upon functions built into
software (but is not considered a the fiber optic FPGA. Due to the free running
part of the Digital Firing Control). characteristic of the VCOs, the average accuracy
FCIM Firing Control Interface Module. of the digital data is very good. The incoming
Processes the AC source frequency is counted over a known fixed time
waveforms and firing angle interval. Since the VCO is free-running, any pulse
command from the ECM and which is missed during one interval will still fall
determines when to fire each SCR. within the next interval. Thus quantization errors
FO Fan Out card. Provides transceiver are averaged out.
capability beyond the three built
into the FCIM as Standard. The advantage of a VCO translation is that the
FPGA Field Programmable Gate Array. isolation is provided by non-conducting optical
An integrated circuit that fiber.
implements complex logic
functions within a single package.
IT Isolation Transducer card. Isolates INSTALLATION
two analog signals for digital input
to FCIM or BCM and other When shipped the equipment will have its IT(s)
modules. physically installed and connected. If replacement
VCO Voltage Controlled Oscillator. A is necessary, carefully label and document each of
circuit that provides a variable the connections to the IT(s) in order to properly
frequency output proportional to a reconnect to a new board.
voltage input.
Refer to the IT Block Diagram (8651C64) for the
location of connectors, fuses, and jumpers.
OPERATION/APPLICATION
The Isolation Transducer has an input voltage
range of 100mV to 2000V. VERIFICATION OF CALIBRATION
The Isolation Transducer has two isolated Voltage
Controlled Oscillator (VCO) channels. Each There are no user adjustments on the IT Card.
channel creates an output frequency, which is However, the IT card may be tested for three
proportional to the input voltage for that channel. different voltage input ranges as a verification of
The transfer function for each channel is: accuracy. The factory verifies calibration for three
range conditions:
Fout= 750KHz +250KHz * Vin/Vrange
Revised 11/13/06
Page 2 of 5
Max input @ 100 mV

Max input @ 200 V SPARE PARTS
Max input @ 500 V
The input range is established by means of A reasonable stock of spare parts will minimize
jumpers on each of the two IT sections. Refer to down-time, in the event of a malfunction in this
the IT Calibration Chart for jumper configurations equipment. When ordering spare parts, care
for the three input voltage ranges. In all cases, the should be taken to specify the style numbers (or
full range output is 750KHz ± 250KHz. other identification) which are printed on the
Regardless of the selected range, with 0.0 volts
input, the output should be 750KHz. For the BCM, it is recommended that the user
Output should be ±1.6% (+4kHz). stock at least one BCM board, fuses, and plastic-
housed 0.010-inch jumpers.
LIMITS OF WARRANTY
SPECIFICATIONS AND PERFORMANCE
invalidated, unless the following described Power Supply Requirements
procedures are followed. Apparatus which +24Vdc ±10%, with nominal current of 0.25 ADC
malfunctions should be replaced with new
units obtained from the factory. Environment
Malfunctioning items should be returned to the Ambient temperature range of -20°C to 50°C
factory for repair after authorization is
received from the local sales and service office Relative humidity of 0 to 95% non-condensing
or the factory. This is particularly true of
electronic printed circuit boards which require
careful handling by skilled personnel and for
which field repair or modifications should not
be attempted.

resulting from failure of this module are
covered.
MAINTENANCE
This equipment contains solid state components

which require little maintenance. The removal of
Revised 11/13/06
Page 3 of 5
IT Calibration
Verification
Chart
Input Voltage Jumper Output Freq.
Configuration (KHz)
Max Input *200Mv
PLUS MINUS CH. 1 CH. 2 PLUS MINUS
23mV 23mV J15-J3& J17-J5& 778 720
J16-J4 J18-J6
45mV 45mV " " 800 692
68mV 68mV " " 834.8 664
90mV 90mV " " 860 636
112mV 112mV " " 890 608
135mV 135mV " " 920 580
151mV 151mV " " 950 552
186mV 186mV " " 974 523
200mV 200mV " " 1000 500
Max Input 200V
50V 50V J15-J7& J17-J9& 778 725
J16-J8 J18-J10
100V 100V " " 800 700
200V 200V " " 850 650
300V 300V " " 900 600
400V 400V " " 950 550
500V 500V " " 1000 500
Max Input 500V
200V 200V J15-J11 J17-J13 800 700
&J16-J2 &J18-J1
400V 400V " " 850 650
600V 600V " " 900 600
800V 800V " " 950 550
1000V 1000V " " 1000 500
• 100Mv or 200Mv scales selected by J27-28, J29-30 for the chart divide the input in mV by 2 for
100Mv scale.
Revised 11/13/06
Page 4 of 5
INSTRUCTIONS FOR Isolation Transducer I.L.8651C64
Jumper Settings for IT Cards
Transducer side 1 (Inputs on terminals J21 and J22)

Full Scale Jumpers
Range
100 mv peak J23 to J5 along with J24 to J6 plus J29 and
J30
200 mv peak J23 to J5 along with J24 to J6
250 volt peak J17 to J5 along with J18 to J6
750 volt peak J23 to J17 and J9 to J5 along with J24 to J18 and
J10 to J6
2000 volt peak No Jumper
Transducer side 2 (Inputs on terminals J19 and J20)

Full Scale Jumpers
Range
100 mv peak J25 to J3 along with J26 to J4 plus J27 and
J28
200 mv peak J25 to J3 along with J26 to J4
750 volt peak J25 to J15 and J7 to J3 along with J26 to J16
and J8 to J4
2000 volt peak No Jumper
•
Revised 11/13/06
Page 5 of 5
Cutler-Hammer I.B. 2C12060H05
Instructions for Installation, Operation and Maintenance of

Magnum DS Low Voltage Power Circuit Breakers
Double-wide Fixed
Narrow Frame Fixed
Standard Frame Fixed
Effective July 2002, Supersedes I.B. 2C12060H04 dated May 2002

I.B. 2C12060H05 Page iii
PURPOSE For application information, consult Cutler-Hammer or

see applicable Product Guides, Technical Documents,
This instruction manual is expressly intended to cover Application Publications and/or Industry Standards.
the installation, operation and maintenance of Magnum
DS Power Circuit Breakers. These circuit breakers may
be supplied as part of complete switchboard assemblies SAFETY
or as separate components. This manual applies only to
the circuit breaker and (if drawout) it’s mating cassette. All safety codes, safety standards and/or regulations
Magnum DS circuit breakers may also be supplied as must be strictly observed in the installation, operation
fixed mounted devices. In the case of fixed versions of and maintenance of this equipment.
Magnum DS circuit breakers, certain sections of this
manual, referring to such items as position interlocks
and the drawout mechanism, will not apply.
Trip units associated with Magnum DS Power Circuit

! WARNING
Breakers will be addressed in a general manner in this THE WARNINGS AND CAUTIONS INCLUDED AS
manual. Specific trip unit details and time-current char- PART OF THE PROCEDURAL STEPS IN THIS MAN-
acteristic curves are covered in separate documents UAL ARE FOR PERSONNEL SAFETY AND PROTEC-
specific to the trip units. TION OF EQUIPMENT FROM DAMAGE. AN EXAM-
PLE OF A TYPICAL WARNING LABEL HEADING IS
Magnum DS circuit breaker accessory items are dis- SHOWN ABOVE TO FAMILIARIZE PERSONNEL
cussed briefly in this manual. Field installation instruc- WITH THE STYLE OF PRESENTATION. THIS WILL
tions for such items, however, are covered in individual HELP TO INSURE THAT PERSONNEL ARE ALERT
instruction leaflets specific to the accessory. This infor- TO WARNINGS. IN ADDITION, CAUTIONS ARE ALL
mation is also available from the Cutler-Hammer web- UPPER CASE AND BOLDFACE.
site at www.cutler-hammer.com
All possible contingencies which may arise during installation operation or maintenance, and all details and variations
of this equipment do not purport to be covered by these instructions. If further information is desired by purchaser
regarding his particular installation, operation or maintenance of particular equipment, contact the local Cutler-
Hammer Inc. representative.
Effective 7/02
Page iv I.B. 2C12060H05
TABLE OF CONTENTS
SECTION 1: INTRODUCTION PAGE
1-1 General Information.............................................................................................................................................1

1-2 Safety Features ...................................................................................................................................................2
1-3 Safety Practices ..................................................................................................................................................2
1-4 Qualified Personnel .............................................................................................................................................3
1-5 Other Publications and Documentation...............................................................................................................3
SECTION 2: RECEIVING, HANDLING AND INSTALLATION
2-1 General Information.............................................................................................................................................4

2-2 Suggested Tools .................................................................................................................................................4
2-3 Unpacking Circuit Breaker...................................................................................................................................4
2-3.1 Storing Circuit Breaker ...........................................................................................................................4
2-4 Lifting Circuit Breaker ..........................................................................................................................................5
2-5 Circuit Breaker Inspection ...................................................................................................................................6
2-6 Installing Drawout Circuit Breaker .......................................................................................................................6
2-6.1 Rejection Interlocks ................................................................................................................................6
2-6.2 Circuit Breaker Positioning .....................................................................................................................7
2-6.3 Levering Circuit Breaker .........................................................................................................................9
2-7 Fixed Circuit Breaker.........................................................................................................................................10
2-8 Circuit Breaker Operation..................................................................................................................................10
SECTION 3: CIRCUIT BREAKER DESCRIPTION AND OPERATION
3-1 Introduction........................................................................................................................................................11
3-2 Basic Circuit Breaker Assembly ........................................................................................................................15
3-3 Pole Units ..........................................................................................................................................................15
3-3.1 Primary Moving Contacts .....................................................................................................................15
3-3.2 Primary Stationary Contacts.................................................................................................................16
3-4 Operating Mechanism .......................................................................................................................................17
3-4.1 Manual Operation .................................................................................................................................17
3-4.2 Electrical Operation ..............................................................................................................................18
3-4.3 Anti-Pump Feature ...............................................................................................................................18
3-5 Arc Chambers ...................................................................................................................................................18
3-5.1 Arc Chute .............................................................................................................................................18
3-6 Electronic Tripping System................................................................................................................................19
3-6.1 Microprocessor-based Trip Unit ...........................................................................................................19
3-6.2 Rating Plug ...........................................................................................................................................21
3-6.3 Current Sensors ...................................................................................................................................21
3-6.4 Trip Actuator .........................................................................................................................................22
3-6.5 Mechanical Trip Flag ............................................................................................................................22
3-6.6 Making Current Release.......................................................................................................................22
3-6.7 High Instantaneous Trip Option............................................................................................................22
3-6.8 Voltage Taps ........................................................................................................................................22
3-7 Secondary Contacts and Connection Diagrams ...............................................................................................23
3-7.1 Connection Diagrams ...........................................................................................................................24
Effective7/02
I.B. 2C12060H05 Page v
PAGE
3-8 Accessory Devices ............................................................................................................................................31

3-8.1 Through-the-Window Electrical Accessories ........................................................................................31
3-8.2 Internal Electrical Accessories .............................................................................................................33
3-8.3 Mechanical Accessories .......................................................................................................................35
SECTION 4: DRAWOUT CIRCUIT BREAKER AND CASSETTE
4-1 General .............................................................................................................................................................38

4-1.1 Drawout Cassette .................................................................................................................................38
4-2 Drawout Circuit Breaker Dimensions ................................................................................................................38
4-3 Drawout Cassette Dimensions ..........................................................................................................................38
SECTION 5: FIXED CIRCUIT BREAKER
5-1 General .............................................................................................................................................................42

5-2 Fixed Circuit Breaker Dimensions .....................................................................................................................42
SECTION 6: INSPECTION AND MAINTENANCE
6-1 General .............................................................................................................................................................43

6-2 General Cleaning Recommendations ...............................................................................................................43
6-3 When to Inspect ................................................................................................................................................43
6-4 What to Inspect .................................................................................................................................................44
6-4.1 Functional Field Testing .......................................................................................................................44
6-4.2 Arc Chute Inspection ............................................................................................................................45
6-4.3 Primary Contact Inspection ..................................................................................................................46
6-5 Circuit Breaker Modifications and Changes ......................................................................................................47
6-5.1 Rating Plug Replacement.....................................................................................................................47
6-5.2 Current Sensor Replacement ...............................................................................................................48
SECTION 7: TROUBLESHOOTING
7-1 Introduction........................................................................................................................................................49
SECTION 8: RENEWAL PARTS
8-1 General .............................................................................................................................................................52
Effective 7/02
Page vi I.B. 2C12060H05
FIGURES
Figure Title Page
1-1 Magnum DS Family of Low Voltage Power Fixed and Drawout Circuit Breakers (800-5000 Amperes) ..1
1-2 Typical Magnum Nameplate ....................................................................................................................2
1-3 Sample Designation Example ..................................................................................................................3
2-1 Shipping Clamps for Drawout Circuit Breaker ..........................................................................................4

2-2 Magnum DS Circuit Breaker with Lifting Yoke Attached ..........................................................................5
2-3 Rear View Showing Current Sensor Rating Through Viewing Window ....................................................6
2-4 One Side of Drawout Circuit Breaker Properly Seated on Extension Rail ................................................6
2-5 Cassette Rejection Interlock Pin Positioning/Installation ..........................................................................7
2-6 Remove Position ......................................................................................................................................8
2-7 Disconnect Position ..................................................................................................................................8
2-8 Test Position ............................................................................................................................................8
2-9 Connect Position ......................................................................................................................................8
2-10 Cassette Label Showing Disconnected, Test and Connected Position of Recessed Cover ....................9
2-11 Levering Position Indication ....................................................................................................................10
2-12 Typical Fixed Magnum Circuit Breaker ..................................................................................................10
3-1 Typical Drawout Circuit Breaker Features (Front and Rear Views) ........................................................11
3-2 Typical Fixed Circuit Breaker Features (Front and Rear Views) ............................................................12
3-3 Typical Double-wide Standard Frame Circuit Breaker Features (Front and Rear Views) ......................13
3-4 Typical Magnum DS Drawout Circuit Breaker Front Cover ....................................................................14
3-5 Typical Magnum Construction (Right Side View)....................................................................................15
3-6 Features of Magnum Moving Conductor Assembly ................................................................................15
3-7 Narrow Frame (8-finger) Moving Conductor Assembly ..........................................................................16
3-8 Standard Frame (12-finger) Moving Conductor Assembly......................................................................16
3-9 Parital Cross-Sectional View (Shown in Closed Position) ......................................................................16
3-10 Electrically Operated Drawout Circuit Breaker with Front Cover Removed ............................................17
3-11 Circuit Breaker Closing Springs Being Manually Charged......................................................................18
3-12 Electrical Motor Operator to Charge Closing Spring ..............................................................................18
3-13 Cross Section of Conductor and Arc Control System ............................................................................19
3-14 Integral Arc Runner as Viewed From Top of Arc Chamber
(Arc Chute Removed and Circuit Breaker Closed) ................................................................................19
3-15 Magnum Arc Plate Assembly ..................................................................................................................19
3-16 Pictorial Diagram of Typical Current Sensing, Processing and Tripping System....................................20
3-17 Digitrip RMS 1150 Programmable Trip Unit Installed in Magnum DS Circuit Breaker............................21
3-18 Hand Held Tester ....................................................................................................................................21
3-19 Replaceable Current Sensors Shown with Bottom Adapters and Cover Plate Removed ......................22
3-20 Line Side Voltage Tap for 1150 Trip Unit ................................................................................................23
3-21 Top View Secondary Connectors............................................................................................................23
3-22 Secondary Connector Protective Hood ..................................................................................................23
3-23 Cassette Mounted Secondary Wiring ......................................................................................................24
3-24 AMP Secondary Wiring Removal Tool.....................................................................................................24
3-25 Digitrip Connection Diagrams .................................................................................................................25
thru
3-30 Digitrip Connection Diagrams .................................................................................................................30
3-31 Through-the-Window Electrical Accessories ...........................................................................................31
3-32 Shunt Trip with Cutoff Switch...................................................................................................................31
3-33 Shunt Trip Switch Installed ......................................................................................................................31
3-34 Spring Release with Optional Latch Check Switch ..................................................................................32
3-35 Undervoltage Release Device .................................................................................................................32
Effective7/02
I.B. 2C12060H05 Page vii
Figure Title Page
3-36 Shunt Trip, Spring Release and Undervoltage Release Installed............................................................32

3-37 Auxiliary Switch (2A/2B)...........................................................................................................................33
3-38 Mechanical Trip Indicator with Associated Overcurrent Trip Switch ........................................................33
3-39 Motor Operator Kit ...................................................................................................................................34
3-40 Motor Operator Installed in Narrow Frame Circuit Breaker......................................................................34
3-41 Cover Mounted Key Lock and Operations Counter................................................................................. 35
3-42 Cassette Mounted Key Lock ....................................................................................................................35
3-43 ON-OFF Pushbutton Lockable Cover Plate.............................................................................................35
3-44 Safety Shutters in Closed Position...........................................................................................................36
3-45 Safety Shutters in Open Position .............................................................................................................36
3-46 Cell Switch (Drawout Position Indicator) Unmounted ..............................................................................36
3-47 Cell Switches Mounted on Cassette ........................................................................................................36
3-48 Door Escutcheon and Gasket ..................................................................................................................36
3-49 IP54 Waterproof Cover ............................................................................................................................37
3-50 Cassette-Mounted 2-Way Cablr Interlock ................................................................................................37
4-1 Drawout Circuit Breaker in Cassette .......................................................................................................38

4-2 Drawout Circuit Breaker with Automatic Primary Disconnects ................................................................38
4-3 Drawout Cassette Features .....................................................................................................................39
4-4 Narrow Frame Cassette (Horizontal Terminals) ......................................................................................40
4-5 Standard Cassette (Vertical Terminals) ..................................................................................................40
4-6 Basic Cassette (Without Stabs) ...............................................................................................................41
4-7 Universal Cassette, 4-Pole (Flat Terminal Pads).....................................................................................41
5-1 Fixed Circuit Breaker with Available Vertical Adaptor..............................................................................42
6-1 Top Rear View of Circuit Breaker with One Arc Chute Removed............................................................45
6-2 Bottom View of Arc Chute........................................................................................................................45
6-3 Primary Contacts with Circuit Breaker Open (Not Used for Contact Wear Inspection) ...........................46
6-4 Contact Inspection Area with Circuit Breaker Open.................................................................................46
6-5 Use of Contact Wear Indicator with Circuit Breaker Closed ....................................................................47
6-6 Trip Unit Rating Plug Location .................................................................................................................47
6-7 Current Sensor Cover in Place Over Sensors .........................................................................................48
6-8 One Current Sensor Shown Removed and Disconnected.......................................................................48
Effective 7/02
Page viii I.B. 2C12060H05
TABLES
Table Title Page
1.1 Magnum DS Ratings at 240, 480, 600 volts ..............................................................................................2
2.1 Circuit Breaker Weights .............................................................................................................................5

2.2 Rejection Interlock Pin Locations...............................................................................................................7
3.1 Magnum Digitrip Trip Units ......................................................................................................................20

3.2 Magnum DS Current Sensors and Matching Rating Plugs......................................................................22
3.3 Shunt Trip and Spring Release Voltage Ratings .....................................................................................31
3.4 Spring Release Ratings ...........................................................................................................................32
3.5 Undervoltage Release .............................................................................................................................33
3.6 Auxiliary Switch, Overcurrent Trip Switch and Cell Switch Contact Ratings............................................33
3.7 Motor Operator.........................................................................................................................................34
6.1 Inspection Frequency...............................................................................................................................43
7.1 Circuit Breaker Troubleshooting Guide....................................................................................................49
Effective7/02
I.B. 2C12060H05 Page 1
SECTION 1: INTRODUCTION NECT) and one position out of its compartment on

extension rails (REMOVE). The operating mechanism
1-1 GENERAL INFORMATION is a two-step stored energy mechanism, either manually
or electrically operated.
The Magnum DS Power Circuit Breaker is a fixed or dra-
wout air circuit breaker design utilizing an electronic trip- When withdrawn on captive compartment cassette
ping system. It is designed for use in both switchboard extension rails, Magnum DS circuit breakers can be
and metal-enclosed switchgear assemblies having maxi- inspected, accessory items added, and minor mainte-
mum voltages of 635 volts ac. Magnum DS circuit break- nance performed. The inside of the compartment can
ers are available in three physical frame sizes with con- also be inspected with the circuit breaker on its exten-
tinuous current ratings from 800 through 6000 A. and sion rails.
interrupting capacities from 42 kA to 150 kA. The three
physical frame sizes have common height and depth NOTICE
dimensions, differing only in width (Figure 1-1). The cir-
cuit breaker nameplate provides complete rating informa-
tion. All Magnum DS circuit breakers are 100 percent Please read and understand these instructions
rated, UL listed, and are built and tested in an ISO 9002 before attempting to unpack, install, operate or
certified facility to applicable NEMA, ANSI, IEEE and UL maintain this equipment. Study the breaker and its
standards (Table 1.1, Figures 1-2 and 1-3). mechanism carefully before attempting to operate it
on an energized circuit.
Magnum DS circuit breakers use a rigid frame housing
of engineered thermoset composite resins which has
high strength structural properties, excellent dielectric
characteristics and arc tracking resistance.
! WARNING
The drawout Magnum DS circuit breaker is a through- MAGNUM DS CIRCUIT BREAKERS SHOULD NOT
the-door design having three breaker positions with the UNDER ANY CIRCUMSTANCES BE APPLIED OUT-
compartment door closed (CONNECT, TEST, DISCON- SIDE THEIR NAMEPLATE RATINGS. OPERATION
OUTSIDE OF THESE RATINGS COULD RESULT IN
DEATH, BODILY INJURY OR PROPERTY DAMAGE.
Double-wide Fixed
Standard Frame Drawout
Narrow Frame Fixed
Figure 1-1 Family of Magnum Low Voltage Power Fixed and Drawout Circuit Breakers (800-5000 Amperes)
Effective 7/02
Page 2 I.B. 2C12060H05
1-2 SAFETY FEATURES
Magnum DS circuit breakers and associated draw-out

A
equipment are manufactured with built-in interlocks and B
safety related features. They are provided to reduce
hazards to operating personnel and provide proper C
operating sequences.
Table 1.1 Magnum DS Ratings at 240, 480, 600 volts
Maximum Breaker Interrupting Short Time D
Amperes Designation Rating Rating
800 MDN-408 42 kA 42 kA
MDN-508 50 kA 50 kA
E
MDN-608 65 kA 65 kA
MDS-408 42 kA 42 kA
MDS-508 50 kA 50 kA
MDS-608 65 kA 65 kA
MDS-808 85 kA 85 kA
MDS-C08 100 kA 85 kA
1200 MDN-412 42 kA 42 kA
MDN-512 50 kA 50 kA
MDN-612 65 kA 65 kA
MDS-412 42 kA 42 kA
MDS-512 50 kA 50 kA
MDS-612 65 kA 65 kA
MDS-812 85 kA 85 kA
A Low voltage power circuit breaker family name
B Breaker family designation number
1600 MDN-416 42 kA 42 kA
MDN-516 50 kA 50 kA C Breaker frame size in amperes
MDN-616 65 kA 65 kA
MDS-416 42 kA 42 kA D Interrupting capacity rating
MDS-516 50 kA 50 kA
E Factory Equipped Accessories
MDS-616 65 kA 65 kA
MDS-816 85 kA 85 kA
2000 MDS-520 50 kA 50 kA Figure 1-2 Typical Magnum Nameplate
MDS-620 65 kA 65 kA
MDS-820 85 kA 85 kA
2500 MDS-525
MDS-625
50 kA
65 kA
50 kA
65 kA
! WARNING
MDS-825 85 kA 85 kA
MDS-C25 100 kA 85 kA TYPE MAGNUM DS CIRCUIT BREAKERS ARE
3000 MDS-630 65 kA 65 kA ROBUST AND ARE PROVIDED WITH SAFETY FEA-
MDS-830 85 kA 85 kA TURES. NEVERTHELESS, THE VOLTAGES, CUR-
MDS-C30 100 kA 85 kA RENTS AND POWER LEVELS AVAILABLE IN AND
3200 MDS-632 65 kA 65 kA AROUND THIS EQUIPMENT WHEN IT IS IN OPERA-
MDS-832 85 kA 85 kA TION ARE EXTREMELY DANGEROUS AND COULD
MDS-C32 100 kA 85 kA BE FATAL. UNDER NO CIRCUMSTANCES SHOULD
4000 MDS-840, 84N 85 kA 85 kA INTERLOCKS AND OTHER SAFETY FEATURES BE
MDS-C40, C4N 100 kA 100 kA MADE INOPERATIVE, AS THIS MAY RESULT IN
MDS-E40, E4N 150 kA 100 kA DEATH, BODILY INJURY OR PROPERTY DAMAGE.
5000 MDS-850, 85N 85 kA 85 kA
MDS-C50, C5N 100 kA 100 kA
MDS-E50, E5N 150 kA 100 kA 1-3 SAFETY PRACTICES
6000 MDS-860, 86N 85 kA 85 kA
MDS-C60, C6N 100 kA 100 kA
To protect personnel associated with the installation,
MDS-E60, E6N 150 kA 100 kA operation and maintenance of this equipment, the fol-
lowing practices must be followed:
Effective7/02
I.B. 2C12060H05 Page 3
1. Only qualified electrical personnel familiar with the

equipment, its operation and the associated hazards
should be permitted to work on the equipment.
M D S C32
Additionally, only qualified personnel should be per-
mitted to install or operate the equipment. Circuit Breaker Interrupting Frame
Type Capacity Size
MDS - Standard and 4 - 42,000 08 - 800 Amps
2. Always be certain that the primary and secondary cir- Double Wide Frames 5 - 50,000 12 - 1200 Amps
cuits are de-energized or the circuit breaker is 6 - 65,000 16 - 1600 Amps
removed to a safe work location before attempting MDN - Narrow Frame 8 - 85,000 20 - 2000 Amps
C - 100,000 25 - 2500 Amps
any maintenance. E - 150,000 30 - 3000 Amps
32 - 3200 Amps
3. For maximum safety, only insert a completely assem- 40 - 4000 Amps
50 - 5000 Amps
bled breaker into an energized cell.
Figure 1-3 Magnum Designation Example
4. Always ensure that drawout circuit breakers are in
one of their designed cell positions, such as Connect,
Test, Disconnect or Remove. A circuit breaker per-
mitted to remain in an intermediate position could
result in control circuits being improperly connected
resulting in electrical failures.
1-4 QUALIFIED PERSONNEL
For the purpose of operating and maintaining low volt-

age power circuit breakers, a person should not be con-
sidered qualified if the individual is not thoroughly
trained in the operation of the circuit breaker and how it
interfaces with the assembly in which it is used. In addi-
tion, the individual should have knowledge of the con-
nected loads.
For the purpose of installing and inspecting circuit

breakers and their associated assembly, a qualified per-
son should also be trained with respect to the hazards
inherent to working with electricity and the proper way to
perform such work. The individual should be able to de-
energize, clear and tag circuits in accordance with
established safety practices.
1-5 OTHER PUBLICATIONS AND

DOCUMENTATION
In addition to this instruction manual, other printed infor-

mation and documentation is available and supplied as
appropriate. This additional information can include, but
not necessarily be limited to, an instruction manual for a
specific electronic trip unit, instruction leaflets for acces-
sory items, renewal parts information, necessary dimen-
sional drawings and a Product (application) Guide.
Specific reference documents associated with Magnum
DS circuit breakers are listed in a separate document
entitled Engineering Data 2C12062H01.
Effective 7/02
Page 4 I.B. 2C12060H05
SECTION 2: RECEIVING, HANDLING AND On drawout circuit breakers shipped without a cassette,
INSTALLATION two shipping clamps hook into the breaker side plates
and are held to the pallet with 4 lag screws (Figure 2-1).
2-1 GENERAL INFORMATION Remove the lag screws and clamps. Save the screws
and clamps for future shipment of the breaker. On
Magnum DS Power Circuit Breakers, when supplied as empty cassettes, remove the 4 or 5 lag screws and/or
part of an assembly, may be shipped already installed in machine screws which pass through the floorpan of the
their respective breaker compartments. Receiving and cassette holding it to the wooden pallet. On drawout
handling of this equipment is addressed in an assembly breakers shipped in a cassette, first remove the breaker
instruction manual supplied with the assembled equip- from the cassette using the levering mechanism and
ment. This instruction manual applies to only the circuit drawout rails. After the breaker is removed the machine
breakers.
screws passing through the floorpan can be removed.
2-2 SUGGESTED TOOLS
A large number of different tools are not required to

properly install and maintain Magnum DS circuit break-
ers. The following tools are, however, suggested:
• Flat blade screwdriver

• Phillips head screwdriver
• 3/8” socket (rachet) wrench
• 10 mm socket
• 17 mm socket
• Secondary wiring removal tool
2-3 UNPACKING CIRCUIT BREAKER Shipping Clamp

Before beginning to unpack new Magnum DS circuit
breakers, read and understand these directions.
Following the directions will ensure that no damage is
caused. Figure 2-1 Shipping Clamps for Drawout Circuit Breaker
Shipping containers should be inspected for obvious On fixed breakers, remove the lag screws passing
signs of rough handling and/or external damage through the mounting feet which hold the breaker to the
incurred during the transportation phase. Record any pallet.
observed damage for reporting to the transportation car-
rier and Cutler-Hammer, once the inspection is complet- Circuit breakers are designed to be easily lifted from
ed. All reports and claims should be as specific as pos- the wooden pallet using an appropriate lifting yoke and
sible and include the order number and other applicable
overhead or portable lifting device (Figure 2-2).
nameplate information.
Every effort is made to ensure that Magnum DS circuit 2-3.1 STORING CIRCUIT BREAKER
breakers arrive at their destination undamaged and
ready for installation. Care should be exercised, howev- If it is necessary to store a circuit breaker before instal-
er, to protect the breakers from impact at all times. Do lation, do so in its original shipping container. Keep the
not remove protective packaging until the breakers are circuit breaker in a clean dry place. Ensure there is
ready for inspection, testing and/or installation. ample air circulation and heat, if necessary, to prevent
condensation. It is very important that the circuit break-
When ready to inspect and install the Magnum DS cir- er not be exposed to dirt or moisture.
cuit breaker, carefully remove the banding straps and lift
off the cardboard box. Remove any additional packing NOTICE
material and internally packed documentation. The cir-
cuit breaker and/or cassette are mounted to a wooden A circuit breaker that has been stored for any
shipping pallet. length of time should be operated a minimum of
five times before it is placed in service.
Effective 7/02
I.B. 2C12060H05 Page 5
If the circuit breaker is to be lifted onto compartment

extension rails, follow the instructions in paragraph 2-6
entitled “Installing Drawout Circuit Breaker.”
Table 2.1 Basic Circuit Breaker Weights

Breaker Weights (lbs)
Model Fixed Drawout Universal Cassette
3P 4P 3P 4P 3P 4P
MDN-408 95 120 107 136 61 70
MDN-508
MDN-608
MDN-412
MDN-512
MDN-612
MDN-416
MDN-516
MDN-616
MDS-408 114 141 130 161 117 123
MDS-508 118 146 138 172 117 123
MDS-608
MDS-412
MDS-512
MDS-612
MDS-416
MDS-516
MDS-616
MDS-520 128 160 155 194 117 123
MDS-620
MDS-808
MDS-812
Figure 2-2 Magnum DS Circuit Breaker with Lifting MDS-816
Yoke Attached MDS-820
MDS-C08
2-4 LIFTING CIRCUIT BREAKER MDS-C12
MDS-C16
MDS-C20
! CAUTION MDS-525
MDS-625
150 190 189 240 123 150
DO NOT ATTEMPT TO LIFT CIRCUIT BREAKERS MDS-630

MDS-632
WITH ORDINARY CRANE HOOKS, ROPES, CHAINS MDS-825
OR OTHER SUCH DEVICES. FAILURE TO FOLLOW MDS-830
THIS CAUTION COULD RESULT IN DAMAGE TO MDS-832
VITAL PARTS SUCH AS ARC CHUTES, BARRIERS MDS-C25
AND WIRING OR THE ENTIRE CIRCUIT BREAKER. MDS-C30
MDS-C32
To closely examine, install or just become more familiar MDS-840, 84N 237 319 303 366 199 250
with the circuit breaker, carefully lift and place the circuit MDS-C40, C4N
breaker on a solid work surface capable of handling the MDS-E40, E4N
circuit breaker’s weight (Table 2.1) or on the captive MDS-850, 85N 276 360 343 441 212 266
drawout extension rails of the breaker compartment MDS-860, 86N
(Figure 2-2). This is accomplished by using the appro- MDS-C50, C5N
priate lifting yoke and lifter. The lifting yoke consists of MDS-C60, C6N
two steel hooks specially shaped to hook under the inte- MDS-E50, E5N
MDS-E60, E6N
gral molded lifting handles on both sides of the circuit
breaker (Figure 3-1). Every effort should be made dur-
ing lifting to minimize circuit breaker swing and tilt.
Effective 7/02
Page 6 I.B. 2C12060H05
2-5 CIRCUIT BREAKER INSPECTION NOT PROPERLY SEATED ON THE EXTENSION

RAILS, IT COULD FALL FROM THE RAILS CAUSING
All circuit breakers, once removed from their shipping EQUIPMENT DAMAGE AND/OR BODILY INJURY.
containers, should be visually inspected for any obvious
damage. Carefully lower the circuit breaker down onto the exten-
sion rails. Be certain that the circuit breaker’s four mold-
The current rating of the rating plug installed in the trip ed drawout rail supports are fully seated in the exten-
unit should match the current rating of the sensors sion rail cutouts on both sides (Figure 2-4). Do not
mounted on the lower primary stabs of the circuit break remove the lifting yoke from the circuit breaker until
er. Check to make sure that this match exists. The rat- it is properly seated on the rails.
ing plug rating can be viewed from the front of the circuit
breaker (Figure 3-4). The sensor rating can be viewed Once the circuit breaker is on the extension rails and the
through the viewing windows at the rear of the circuit lifting yoke is removed, proceed with the rest of the cir-
breaker (Figure 2-3). Sensors and rating plugs can be cuit breaker installation.
easily changed as described in Section 6.
2-6.1 REJECTION INTERLOCKS
2-6 INSTALLING DRAWOUT CIRCUIT BREAKER
Within any one physical frame size Magnum drawout
In structures equipped for drawout circuit breakers, a circuit breakers come in a variety of continuous current
bolted-in cassette with movable extension rails supports and interruption ratings, some of which are incompati-
the circuit breaker (Figures 2-2 and 2-4). The extension ble with others. Double wide circuit breakers also come
rails must first be pulled all the way out. Once the rails with several phase sequence options which are also
are fully extended, the circuit breaker can be carefully incompatible. To prevent the insertion of circuit break-
placed on the extension rails. ers with (1) inadequate interrupting capability, (2) with
physically incompatible primary disconnects or (3) with
an incompatible phase sequence, rejection interlock
! CAUTION key plates are provided on both the circuit breaker and
cassette. The key plate on the circuit breaker is pre-
IT IS IMPORTANT TO TAKE GREAT CARE WHEN assembled at the factory; but the cassette-side rejec-
PLACING A DRAWOUT CIRCUIT BREAKER ON ITS tion plate and key pattern must be assembled and
EXTENSION RAILS. IF THE CIRCUIT BREAKER IS installed by the switchboard builder.
Molded Rail
Supports
Extension Rail
Cutout
Figure 2-3 Rear View Showing Current Sensor Rating Figure 2-4 One Side of Drawout Circuit Breaker
Through Viewing Window Properly Seated on Extension Rail
Effective 7/02
I.B. 2C12060H05 Page 7
Table 2.2 Rejection Interlock Pin Locations
! CAUTION
Cell For:
Pin Locations
1 2 3 4 5 6 7 8
MDN-408, 412, 416 X X
DO NOT DISABLE REJECTION INTERLOCKS. X
MDN-508, 512, 516 X X
DOING SO AND USING A LOWER CAPACITY CIR-
MDN-608, 612, 616 X X X X
CUIT BREAKER IN AN INCOMPATIBLE CASSETTE
COULD RESULT IN AN ELECTRICAL FAULT WHICH MDS-408, 412, 416 X X
COULD RESULT IN DEATH, BODILY INJURY MDS-508, 512, 516, 520 X X X

AND/OR EQUIPMENT DAMAGE. MDS-608, 612, 616, 620 X X X X
MDS-808, 812, 816, 820 X X X X X
The rejection interlocks are steel pins in the floor of the MDS-C08, C12, C16, C20 X X X X X X
circuit breaker cassette. As the circuit breaker is
MDS-525 X X X
pushed into the structure, the mating pins on the bottom
MDS-625, 630, 632 X X X X
of the circuit breaker move past a set of corresponding
pins in the cassette, if the circuit breaker and cassette MDS-825, 830, 832 X X X X X
are compatible. If the circuit breaker and the cassette MDS-C25, C30, C32 X X X X X X
are mismatched, the rejection pins will block the inser- MDS-840 X X X
tion of the circuit breaker into the cassette before the MDS-84N X X X
levering-in mechanism is engaged. MDS-C40 X X X X
MDS-C4N X X X X
Before attempting to push the circuit breaker into the
MDS-E40 X X X X X
DISCONNECT position, compare the positioning of
rejection interlock pins in the cassette in keeping with MDS-E4N X X X X X
Table 2.2 and Figure 2-5 and the information supplied MDS-850, 860 X X X
on the circuit breaker’s nameplate. Proceed if the circuit MDS-85N, 86N X X X
breaker and cassette are compatible. MDS-C50, C60 X X X X
MDS-C5N, C6N X X X X
2-6.2 CIRCUIT BREAKER POSITIONING
MDS-E50, E60 X X X X X
The Magnum DS drawout circuit breaker has four nor- MDS-E5N, E6N X X X X X
mal positions: The REMOVE position is a position outside the com-
partment on the cassette’s drawout rails where the cir-
• REMOVE (Withdrawn) (Figure 2-6) cuit breaker is not engaged with the levering mecha-
• DISCONNECT (Figure 2-7) nism. The DISCONNECT, TEST, and CONNECT, posi-
• TEST (Figure 2-8) tions are reached by means of the levering mechanism.
• CONNECT (Figure 2-9)
With the breaker solidly positioned on the cassette’s
From Table 2.2, make a pin location comparison. extension rails and the levering-in mechanism in the
Stop nuts should be torqued to 8-10 Ft.-Lb. DISCONNECT position, carefully and firmly push the
circuit breaker into the compartment as far as it will go.
The outer (recessed) portion of the circuit breaker face
plate should align with the GREEN target line (labelled
DISC) on the inside top left wall of the cassette (Figure
2-10).
5
1
6
2
7
3
! CAUTION
4
8 MAKE CERTAIN THAT THE CIRCUIT BREAKER IS
FULLY INSERTED INTO ITS COMPARTMENT
BEFORE ANY ATTEMPT IS MADE TO LEVER THE
CIRCUIT BREAKER. ATTEMPTING TO LEVER THE
CIRCUIT BREAKER IN BEFORE IT IS FULLY POSI-
TIONED INSIDE ITS COMPARTMENT CAN RESULT
Figure 2-5 Cassette Rejection Interlock Pin IN DAMAGE TO BOTH THE CIRCUIT BREAKER AND
Positioning/Installation THE COMPARTMENT.
Effective 7/02
Page 8 I.B. 2C12060H05
Compartment Secondary
Front Door Connection Not Made Rear of
Compartment
Circuit
Breaker Primary
Side View Connections
Not Made
Circuit Breaker
Out of Compartment
On Extension Rails ■ No Electrical Connections Made
■ Breaker On Extension Rails
■ Remove or Inspection Position
Figure 2-6 Remove Position
Secondary
Connection
Not Made
Rear of
Compartment
Compartment
Front Door
Circuit
Breaker Primary
Not Made
■ Only Ground Connection Made

■ Breaker Still Behind Door
■ Typical Storage Position
Figure 2-7 Disconnect Position

Secondary
Connection Made
Rear of
Compartment
Compartment
Front Door
Circuit
Breaker Primary
Not Made
■ Breaker and Trip Unit Testing

■ Primary Connection Not Made
■ Secondary and Ground Connections Made
Figure 2-8 Test Position
Effective 7/02
I.B. 2C12060H05 Page 9
Secondary
Connection Made
Rear of
Compartment
Compartment
Front Door
Circuit
Breaker Primary
Made
■ Full Breaker Operation

■ Primary, Secondary and Ground Connections Made
■ Fully Racked into Cassette (Compartment)
Figure 2-9 Connect Position
2-6.3 LEVERING CIRCUIT BREAKER
The circuit breaker is now ready to be levered. With the

circuit breaker OPEN, the levering device access door
can be raised. The levering device is hand operated
using a standard 3/8” square drive and ratchet, which is
not provided (Figure 2-11). As long as the access door
is raised, the circuit breaker is held trip free. Begin by
rotating the levering-in screw to the full counterclock-
wise (DISCONNECT) position.
Close the compartment door and begin levering the

breaker into its different positions using a clockwise
ratcheting motion. When the circuit breaker is levered
fully to the DISCONNECT or CONNECT position the
levering shaft hits a hard stop; do not exceed 25 ft.lb. of
torque or the levering mechanism may be damaged.
The circuit breaker can be levered with the compart-
ment door open or closed, but it is advisable to
close the door prior to levering. The position of the
circuit breaker within its compartment is indicated by
color coded position indicators (Red = Connect, Yellow
= Test, Green = Disconnect) (Figures 2-11 and 3-4). To
Figure 2-10 Cassette Label Showing Disconnected, remove the circuit breaker from its compartment, follow
Test and Connected Position of Recessed Cover the procedure just described using a counterclockwise
ratcheting motion.
Effective 7/02
Page 10 I.B. 2C12060H05
CONNECT
TEST
DISCONNECT
Mounting
Foot
Figure 2-11 Levering Position Indication
Figure 2-12 Typical Fixed Magnum Circuit Breaker
The fixed circuit breaker frame has two mounting feet,

NOTICE one on each side, to permit the fixed circuit breaker to
be securely mounted. Each mounting foot has two slot-
The circuit breaker mechanism is interlocked such ted mounting holes which are used to bolt the circuit
that charged closing springs are automatically dis- breaker securely in place. Use either M10 or 3/8” bolts
charged if the circuit breaker is levered into or out for this purpose. Refer to the dimensional drawings
of the cell. Discharge takes place between the DIS- referred to in Section 5 (Fixed Circuit Breakers) for cir-
CONNECT and TEST position. cuit breaker and bus stab dimensions.
NOTICE
2-7 FIXED CIRCUIT BREAKER
The Magnum DS fixed type circuit breaker differs from Refer to the circuit breaker weights in Table 2.1 to
the drawout version in that it has no levering device, pri- ensure that the panel on which a fixed circuit break-
mary disconnects and secondary disconnects (Figure 2- er is to be mounted is capable of supporting the
12). In addition, a fixed circuit breaker does not have a weight.
standard feature to hold the breaker in a trip-free posi-
tion. To ensure the proper sequence of operation 2-8 CIRCUIT BREAKER OPERATION
between two or more circuit breakers, an optional key
interlock is mounted through the front panel (Figure 3-4). Circuit breakers should be operated manually and/or
electrically before they are put into service. This can be
Circuit breaker terminals have holes for making bolted done during the installation process or some later date
horizontal primary bus connections. Adapters are avail- prior to start-up. To check circuit breaker operation, fol-
able for making vertical primary bus connections. low the operational procedures outlined in Section 3 for
Secondary connections can be made through standard both manually operated and electrically operated circuit
terminal blocks or a special connector compatible with breakers.
the drawout circuit breaker’s type secondary connector.
Both secondary connection devices are mounted at the
top front of the circuit breaker.
Effective 7/02
I.B. 2C12060H05 Page 11
SECTION 3: CIRCUIT BREAKER mon for the two frame sizes that cover all continuous
DESCRIPTION AND OPERATION current ratings through 5000 amperes.
Double Wide frame circuit breakers utilize six (or eight)

3-1 INTRODUCTION
sets of rear primary connections; these circuit breakers
are available from the factory with several different
Magnum DS circuit breakers are available in both
phase sequences, distinguishable by the sixth character
drawout and fixed mounting configurations (Figures 3-1
in the model number. The phase sequence is also
and 3-2). A majority of features are common to both
labeled on the rear of the circuit breaker (Figure 3-3).
configurations, and will be discussed in this section.
For drawout breakers, phase sequence labels are also
The mounting features unique to the drawout and fixed
supplied with the cassette and must be applied by the
configurations will be covered individually in Sections 4
switchgear builder. Circuit brakers with different phase
and 5 respectively.
sequences are not interchangeable. Drawout breakers
with differing phase sequence are prevented from inser-
Controls and indicators for both drawout and fixed circuit
tion into the cassette by properly assembled rejection
breakers are functionally grouped on the front of the cir-
key plates (see section 2-6.2).
cuit breaker. The front escutcheon (faceplate) is com-
6 Primary Disconnect Finger Cluster

1
7 Arc Chamber
8 Primary Vertical Adapter

5
9 Sensor Rating Viewing Window
10 Levering Device Bearing Plate
11 Padlockable Levering Device Access Door

4 12 Circuit Breaker Nameplate
3 2 1
12 10
11
5
7
1 Baffled Arc Chute Cover

4
2 Secondary Disconnects (Contacts) 6
3 Faceplate (Front Cover) 9
4 Drawout Rail Supports
5 Integral Lifting Handle 8
6
10
Figure 3-1 Typical Drawout Circuit Breaker Features (Front and Rear Views)
Effective 7/02
Page 12 I.B. 2C12060H05
1
6 Fixed Primary Terminal (with optional Vertical Adapter)
7 Arc Chamber
4 8 Sensor Rating Viewing Window
9 Mounting Foot
10 Circuit Breaker Nameplate
2
3 1
10
9
4
1 Baffled Arc Chute Cover

6
2 Secondary Disconnect
5
3 Faceplate (Front Cover)
4 Integral Lifting Handle
8
5 Fixed Horizontal Primary Terminal
Figure 3-2 Typical Fixed Circuit Breaker Features (Front and Rear Views)
Effective 7/02
I.B. 2C12060H05 Page 13
5 Fixed Vertical Primary Terminals

1 Baffled Arc Chute Cover with Optional Vertical Adaptor
2 Secondary Contact Connector 6 Arc Chamber
3 Faceplate (Front Cover) 7 Mounting Foot
4 Integral Lifting Handle 8 Circuit Breaker Nameplate

9 Phase Identification Labels
2
1
9 4
9
6
Figure 3-3 Typical Double-wide Standard Frame Fixed Circuit Breaker Features (Front and Rear Views)
Effective 7/02
Page 14 I.B. 2C12060H05
1 2
CLOSED (Red)
5
(Green)
OPEN
(Yellow)
6
CHARGED
3 (White)
DISCHARGED
4
8
PUSH ON (Green)
14
9 PUSH OFF
7 (Red)
15 10
CONNECT
13 11 TEST
DISCONNECT
12
Red = Connect
Yellow = Test
Green = Disconnect
1 Trip Flag (Pop Out Indicator) 7 Manual “OFF” Button (Push) 12 Color Coded-Breaker
Position Indicator
2 Three Accessory Windows 8 Manual “ON” Button (Push)
13 Nameplate
3 Trip Unit 9 Manual Charge Handle
14 Trip Unit Test Port
4 Rating Plug 10 Optional Operation Counter
15 Trip Unit Cover with Two
5 Contact Status (Open-Close) 11 Padlockable Levering Device Access
Mounting Screws (Mounting
Door for Drawout Breaker
6 Spring Status (Charged-Discharged) Screws will Accept Customer
Supplied Lead Security Meter
Seals
Figure 3-4 Typical Magnum DS Drawout Circuit Breaker Front Cover
Effective 7/02
I.B. 2C12060H05 Page 15
3-2 BASIC CIRCUIT BREAKER ASSEMBLY provide for pole unit isolation and insulation from one
another. Each pole unit has one primary contact
Magnum DS circuit breakers use a rigid frame housing assembly, which consists of a moving portion and a
construction of engineered thermoset composite resins. fixed portion. The exact design configuration depends
This construction provides high strength structural prop- upon the breaker’s frame size. Circuit breakers with
erties, excellent dielectric characteristics and resistance frame sizes of 4000 amperes and higher use two pole
to arc tracking. units and arc chute assemblies connected mechanically
and electrically in parallel to form one phase.
The 3-piece construction approach provides support
while isolating and insulating power conductors (Figure 3-3.1 PRIMARY MOVING CONTACTS
3-5):
Depending upon the frame size, each primary moving
(1)
1 A 2-piece engineered thermoset composite resin contact assembly is comprised of multiple individual
case encloses current paths and arc chambers. The copper contact fingers connected to the load conductor
chambers act to channel arc gases up and out of the cir- through flexible braided connectors (Figure 3-6). Two
cuit breaker during interruption. flexible connectors are used to connect each finger to
the load conductor. The number of fingers used
(2)
2 The operating mechanism sits on the front of the depends upon the circuit breaker’s continuous and
case and is electrically isolated and insulated from cur- short-circuit current ratings (Figures 3-7 and 3-8). On
rent contact structures. It is covered by an insulating some ratings fingers are removed and replaced with
front cover. spacers.
3-3 POLE UNITS The single contact finger performs both the main and
arcing contact functions on different parts of the same
A current carrying pole unit is individually enclosed and finger (Figure 3-6). A highly conductive alloy pad is part
rigidly supported by the case. The individual chambers of the contact finger and functions as the moving main
contact, and is called the “Heel.” The tip of the same
contact finger functions as the moving arcing contact,
and is called the “Toe.”
2 (Front Cover) 1 (Case)

Single Contact Moving
Finger Arcing
Pivot
Contact
Point
Area
(Toe)
Moving Main Contact

Conductive Pad
(Heel)
Dual
Flexible
Connections
Figure 3-5 Typical Magnum Construction (Right Side Figure 3-6 Features of Magnum Moving Conductor
View) Assembly
Effective 7/02
Page 16 I.B. 2C12060H05
“Toe”
(Arcing Contact)
“Heel”
(Main Contact)
“Toe”
(Arcing Contact)
“Heel”
(Main Contact)
Figure 3-7 Narrow Frame (8-finger) Moving Conductor Figure 3-8 Standard Frame (12-finger) Moving
Assembly Conductor Assembly
yyyy
ÀÀÀÀ

@@@@
,,,,
3-3.2 PRIMARY STATIONARY CONTACTS
Breaker
,,,
yyy
,,
yy ,
y
yyyyy
,,,,,
The primary stationary contact is a combination of two
items (Figure 3-9). One is a conductive pad mounted Front
on the line conductor which functions as the stationary
,,,
yyy
,,y
yy,y
,
main contact. The other is an arc runner, also connect-
ed to the line conductor. The integral arc runner serves Arc Chute
yyy
,,,
,,
yy ,
y,
y
a dual purpose:
Integral
Arc Runner
• Fixed arcing contact
,,,
yyy
,,
yy yy
,,
,
y
Moving Contact Arcing
• Part of the arc chute Fingers Contact (Toe)
Line
,,,,
yyyy,,
yy
Conductor
Current
Flow
,,,,
yyyy,,
yy
Moving Contact
Springs Stationary
Main Contact
Moving Main
,,,,
yyyy
,
y
xxxxxxxx Contact (Heel)
x x
x x
xxxxxxxx
,,,,
yyyy
y,
Current
Flow
xxxxxxxx
x x
x x
xxxxxxxx
Breaker
Bottom
Figure 3-9 Partial Cross-Sectional View (Shown in

Closed Position)
Effective 7/02
I.B. 2C12060H05 Page 17
3-4 OPERATING MECHANISM “OFF” buttons respectively located on the front of the cir-
cuit breaker (Figure 3-4). Performing either operation is
The Magnum DS operating mechanism is based on the accomplished by pressing and releasing the appropriate
proven cam and spring design of the DSII power circuit button. Access to these pushbuttons can be limited by
breaker. It is easily accessed by removing four cover the use of an optional, padlockable cover. In addition,
screws and the front cover (Figure 3-10). The mecha- complete access to the “ON” button can be prevented
nism is a two-step stored energy mechanism. Potential with an optional prevent close cover. The status of the
energy is stored to close the circuit breaker. Sufficient springs and the primary contacts are always indicated in
energy to open the circuit breaker remains available an indicator window just above the pushbuttons.
after a closing operation.
Electrically operated optional devices are available to
3-4.1 MANUAL OPERATION automatically close or trip a manually operated circuit
breaker. An electrical spring release is available to close
On manually operated circuit breakers, the closing spring a manually operated circuit breaker. Two optional
can only be charged manually. To manually charge the devices, a shunt trip and an undervoltage release, are
spring, insert one finger in the recess behind the charging available to automatically trip (open) a manually operated
handle and pull out. This permits a gloved hand to grasp circuit breaker. All of these UL listed optional devices can
the handle and begin charging (Figure 3-11). It takes be installed easily in the field. For more details on these
from 5 to 7 downward strokes on the charging handle to devices, refer to paragraph 3-8 in this manual.
complete the manual charging process. It is possible to
manually recharge the spring immediately after closing An electrical operator which is used to charge the closing
the circuit breaker and before it has been tripped open. spring automatically can be added to a manually operat-
ed circuit breaker in the field (Figure 3-12). Manually
Standard manually operated circuit breakers are closed operated circuit breakers are pre-wired to accept this
and opened by hand using the Manual “ON” and Manual addition.
1
1 Secondary Wiring Points
2
2 Field Installable Accessories
(3 maximum)
3 Trip Unit
4 Electric Charging Motor

3
5 Manual Charge Handle 5
6 Operations Counter (optional)
7 Padlockable Levering Device 6

Access Door
8 Breaker Position Indicator

4
Figure 3-10 Electrically Operated Drawout Circuit Breaker with Front Cover Removed
Effective 7/02
Page 18 I.B. 2C12060H05
Electrical Motor
Operator
Figure 3-11 Circuit Breaker Closing Springs Being Figure 3-12 Electrical Motor Operator to Charge
Manually Charged Closing Spring
3-4.2 ELECTRICAL OPERATION closing, a Latch Check Switch (LCS) option is available
(see paragraph 3-8.1) which will block the application of
For electrically operated circuit breakers, the springs are the electrical close command until the breaker is ready
normally charged through the use of an electrical operator to close.
(Figure 3-12). The springs can, however, be charged
manually as just described in the previous paragraph 3-5 ARC CHAMBERS
(Figure 3-11).
The Magnum DS circuit breaker utilizes arc chambers to
Like the manually operated circuit breaker in the previous insulate and isolate individual poles from one another,
paragraph, electrically operated circuit breakers can also from the rest of the circuit breaker, and from operating
be manually closed and opened through the use of the personnel (Figure 3-1). Arc chambers are molded and
front mounted Manual “ON” and Manual “OFF” buttons. integral parts of the circuit breaker frame. Enclosed
within each arc chamber is an arc chute which mounts
An electrically operated circuit breaker from the factory is over each set of primary contacts.
also equipped as standard with a spring release to close
the circuit breaker electrically. An optional shunt trip and After the main contacts part, any remaining current is
undervoltage release are also available to trip (open) an driven to the arcing contacts (Figure 3-13). Magnetic
electrically operated circuit breaker. Refer to paragraph action draws the arc to the arc chute. As the arcing
3-8 for more details on both standard and optional contacts separate, the moving arcing contacts discharge
devices. into the arc chute plates while the integral arc runner
also helps to draw the arc into the arc chute (Figure 3-
3-4.3 ANTI-PUMP FEATURE 14).
The Magnum circuit breaker has both mechanical and 3-5.1 ARC CHUTE
electrical anti-pump features. If the circuit breaker is
closed on a fault condition (and trips open while the The Magnum DS arc chute mounts down over the arc-
CLOSE signal is maintained), using either the mechani- ing contact. Alternating V-shaped arc chute plates
cal pushbutton or the electrical close coil, it will not attract the arc and interrupt it. The top arc plate, which
make subsequent attempt to close until the close com- is a part of the arc chute itself, also helps to attract the
mand is removed and reapplied. Note that if the close arc away from the moving arcing contact and up into the
signal is applied prematurely (before the breaker is com- arc chute’s V-shaped plates (Figure 3-15).
pletely charged and latched), the close command will be Arc chute components are assembled in an insulating
ignored until it is removed and reapplied. For electrical
Effective 7/02
I.B. 2C12060H05 Page 19
jacket which is removable from the top of the circuit Top

breaker, as previously described in paragraph 2-4.
Each arc chute has a baffled top cover.
3-6 ELECTRONIC TRIPPING SYSTEM
The Magnum DS circuit breaker utilizes a three part trip-

ping system (Figure 3-16):
• Microprocessor-based trip unit

• Current Sensors
• Trip Actuator
“V” Shaped
All three parts of the tripping system are discussed here,
except that the trip unit itself is not discussed in detail. Plates
For detailed information pertaining to the different trip
unit models available with Magnum DS circuit breakers,
refer to the specific instruction leaflet dedicated to the
trip units (I.L. 70C1036 and I.L. 70C1037 ).
3-6.1 MICROPROCESSOR-BASED TRIP UNIT
Magnum circuit breakers use any one of a family of

Digitrip RMS trip units whose main features are summa-
rized in Table 3.1 (Figure 3-17). Note, however, that the “V” Shaped
1150 trip unit is not available in the narrow frame circuit Plates
breaker.
Models 220 and 520 are plug compatible and inter- Top Plate for
,,
yy
yyy
,,, ,
y
changeable in the field. Circuit breakers with these trip Arcing Contact
units can be upgraded to Models 520M and/or 520MC in
Figure 3-15 Magnum Arc Plate Assembly
,,
yy
,,,
yyy
,,
yy
,,,
yyyy
,
yy
,,,
y
,
y
Top Arc
Plate
,,
yy ,,
yy
Integral
Arc Runner Integral
Arc Runner
,,,,
yyyy
,
yy,
Current
Flow
,,,,
yyyy
xxxxxxxx
x x
x x
xxxxxxxx
,,,,
yyyy
,y
Current
Flow
Figure 3-13 Cross Section of Conductor and Arc Figure 3-14 Integral Arc Runner Viewed From Top of Arc
Control System Chamber (Arc Chute Removed, Circuit Breaker Closed)
Effective 7/02
Page 20 I.B. 2C12060H05
Cutler-Hammer
Rating
Toroidal Plug
Current
Sensor
Trip
Trip Unit Actuator
A 01 02 03 Typical Magnum DS
B
Circuit Breaker
C
N A B C Sensors
G
Note: Alternate ground locations

N
may be required to meet
installation requirements
Figure 3-16 Pictorial Diagram of Typical Current Sensing, Processing and Tripping System
the field; however additional wiring (for power supply
and communications) may be required to take full
advantage of the additional features. Contact Cutler- Table 3.1 Magnum Digitrip Trip Units
Hammer for upgrading to Model 1150.
Functions 220 520 520M➄ 520MC➄ 1150➄
The electronic trip units are self-powered. When the cir- LSIG Protection Yes ➀ Yes Yes Yes Yes
cuit breaker is closed, no external power is required to
operate their protective systems. Current signal levels Disable (I) No Yes Yes Yes Yes
and the control power are derived from the current sen- GF Protection No Yes Yes Yes Yes
sors integrally mounted in the circuit breaker. GF Alarm No No Yes Yes Yes
Display No No Yes ➁ Yes ➁ Yes ➂
A functional local test of a major portion of the trip unit’s
electronic circuitry and the circuit breaker’s mechanical Programmable No No No No Yes
tripping action can be verified through the trip unit’s test Metering No No Yes ➃ Yes ➃ Yes
receptacle (Figure 3-17). This is accomplished using a Power and
Digitrip (DS Type) Test Kit which provides a secondary Energy Values No No No No Yes
injection test that simulates the current sensors. A Power Quality No No No No Yes
small hand held Magnum functional Test Kit can also be
used to check circuitry and mechanical tripping func- Communication No No No Yes Yes
tions (Figure 3-18). ➀ Long and Instantaneous only.
➁ One-line, (four characters per line) LCD display.
When the circuit breaker is shipped from the factory, the
➂ Three-line, (eight characters per line) LED display.
trip unit’s protective functions are normally set at mini-
➃ Phase, neutral, ground, and high load current only.
mum values. For specific overload tripping characteris-
tics and time/current curves to coordinate with a load or ➄ Available control voltages are 24/48Vdc, 120Vac and 240Vac
system, refer to the trip unit instruction book.
Effective 7/02
I.B. 2C12060H05 Page 21
3-6.2 RATING PLUG Pop Out

Trip Flag
All Magnum DS circuit breaker trip units use a fixed type
rating plug. The current rating of the rating plug must
match the current rating of the integrally mounted cur-
rent sensors (Figure 2-4, 3-17 and Table 3.3). The rat- Auxiliary Power
ing plug performs several functions: Module Port
1) It tells the trip unit what the rating is of the current

sensors. A label on the front of the rating plug clearly
indicates that the rating plug and sensors must have the
same rating. Rating
Plug
2) It determines the maximum instantaneous setting
which is a function of the current sensor rating.
3) The National Electrical Code (NEC) requires that the

maximum ground fault pickup value not exceed 1200
amperes. A properly matched rating plug accomplishes
this requirement for higher ampere sensors by incorpo-
rating circuitry to identify that level by sensor rating.
Test
If the rating plug is removed from the trip unit, the circuit Receptacle
breaker will trip if it is carrying current. Make certain the
rating plug is secured in position with its retaining screw.
Do not torque the retaining screw beyond 15 In-Oz.
Refer to Table 3.2 for a tabulation of the available rating

plugs. Figure 3-17 Digitrip RMS 1150 Programmable Trip Unit
Installed in Magnum DS Circuit Breaker
3-6.3 CURRENT SENSORS
Three toroidally wound current sensors are installed at

the rear of the circuit breaker on the lower terminals
(Figure 3-19). The sensors produce an output current
proportional to the load current. Under preselected con-
ditions of current magnitude and time, the sensors fur-
nish the trip unit with a signal and the energy required to
trip the circuit breaker.
Neutral current sensors are available for customer

installation. The additional sensor is not supplied with
the circuit breaker and must be ordered separately.
They are wired to the trip unit through the secondary
contacts of the circuit breaker.
Refer to Table 3.3 for a tabulation of the available cur-

rent sensor ratings.
Figure 3-18 Hand Held Tester
Effective 7/02
Page 22 I.B. 2C12060H05
3-6.5 MECHANICAL TRIP FLAG
A red, pop out mechanical trip indicator is an optional

Magnum DS feature. It is located above the trip unit on
the breaker’s front faceplate (Figure 3-17). It operates
by releasing and popping out any time the circuit break-
er trips due to to an overcurrent condition. Note that the
mechanical trip indicator will not prevent the breaker
from being reclosed. The indicator is reset manually by
pushing it back in. If the indicator is not reset the circuit
breaker will operate normally, but future mechanical trip
indication will be lost.
An optional overcurrent trip switch (bell alarm) that oper-

ates off the position of the mechanical trip indicator is
also available. The switch is reset when the trip indicator
is reset.
Toroidal On optional Digitrip models with LED cause-of-trip indi-

Sensor cators, these indicators should also be reset (by pushing
momentarily) after the cause of the fault has been diag-
nosed; this will preserve the internal battery. On trip
Figure 3-19 Replaceable Current Sensors Shown with units equipped for communication the LED reset func-
Bottom Adapters and Cover Plate Removed tion can be performed remotely using INCOM com-
mands.
3-6.6 MAKING CURRENT RELEASE

Table 3.2 Magnum DS Current Sensors and Matching
Rating Plugs All Magnum DS circuit breaker trip units have a making
current release function. This safety feature prevents
Current Rating in Amperes the circuit breaker from being closed and latched on a
faulted circuit. The non-adjustable release is preset at a
200 800 2500 peak instantaneous current of 25 x In; this corresponds
to an rms current of 11 x In with maximum asymmetry.
250 1000 3000
The making current release is enabled only for the first 2
300 1200 3200 cycles following a circuit breaker closing operation. The
making current release will trip the circuit breaker
400 1600 4000 instantaneously, release the mechanical (pop-out) indi-
cator and flash the instantaneous LED trip indicator, if
600 2000 5000 so equipped.
3-6.7 HIGH INSTANTANEOUS TRIP OPTION
The high instantaneous trip option is installed in 800 to

3-6.4 TRIP ACTUATOR 3200 ampere Magnum DS circuit breakers with a 100
kA interrupting capacity. In general, the high instanta-
The trip actuator is a small cylindrically shaped electro- neous trip is comprised of three small air core sensors,
magnetic device which acts mechanically to trip the cir- one in each phase, which produce a signal and transmit
cuit breaker (Figure 3-16). In general, it is comprised of it back to the trip unit when the 85 kA withstand rating of
a permanent magnet, a spring loaded rod to produce the circuit breaker is exceeded. The result is an instan-
the mechanical tripping, and a lever for resetting the taneous trip by the circuit breaker. This high instanta-
actuator after tripping occurs. The electronic trip unit neous trip option permits the 800-3200 ampere Magnum
provides a pulse which counteracts the effect of the per- DS circuit breakers to be applied where a 100 kA fault is
manent magnet, allowing the spring loaded rod to act possible, while selectivity up to 85 kA is maintained.
mechanically. The device is reset when the circuit
breaker opens.
Effective 7/02
I.B. 2C12060H05 Page 23
3-6.8 VOLTAGE TAPS (Figure 3-21). The wiring points are finger safe with
no more than two wires per terminal.
On circuit breakers with Digitrip 1150 trip units potential
taps are required to monitor the three phase voltages. Up to two secondary contact plug-in connectors (AMP),
Voltage taps may be placed on either the line (top) or each with 30 secondary points, are mounted on the top
load (bottom) terminals of the breaker at the factory. rear portion of the circuit breaker . The plug-in connec-
Figure 3-20 illustrates line-side voltage taps. tors are protected by a molded hood (Figure 3-22).
How many connectors are mounted depends upon a
3-7 SECONDARY CONTACTS AND CONNECTION number of considerations, such as whether the circuit
DIAGRAMS breaker is electrically or manually operated and how
many features are required. When the front cover of the
A maximum of sixty secondary wiring connection points circuit breaker is removed, the top of each plug-in con-
are available on the standard frame circuit breaker (48 nector is exposed. A label on each connector identifies
on narrow frame), each dedicated to a specific function the wiring points.
Protective Hood
Figure 3-22 Secondary Connector Protective Hood
Figure 3-20 Line-Side Voltage Tap for 1150 Trip Unit
Secondary Connector Labels Labels Legend

OTS Overcurrent Trip Switch
UVR Undervoltage Release
ATR Automatic Trip Relay
(520M and 1150 Trip
Units Only)
INCOM PowerNet
Communications Network
A BUS (Future Use)
A/S Auxiliary Contacts
NEUTRAL Neutral Sensor Input
GF SGND Source Ground Input
ZONE Zone Interlocking
ST Shunt Trip
SR Spring Release
MOTOR Charging Motor
LCS Latch Check Switch
Figure 3-21 Top View Secondary Connectors
Effective 7/02
Page 24 I.B. 2C12060H05
Drawout type circuit breakers: Compatible secondary Closed Hinged Covers Terminal Blocks
plug-in connectors are mounted on the top front portion with Testing Holes
of the drawout cassette (Figure 3-23). These connec-
tors match and plug into the circuit breaker mounted
connectors. Contact points are wired from the cas-
sette’s plug-in connectors to cassette mounted terminal
blocks. The terminal blocks are also mounted on the
top front portion of the cassette. The secondary termi-
nals have finger-proof hinged covers with small holes for
probe testing.
Fixed type circuit breakers: There are two secondary Plug-in

connection options: Connectors
(1) Without Terminal Block
(2) With Terminal Block
1. Without Terminal Block - If a terminal block for

customer use is not required, the circuit breaker is
supplied with both plug-in connectors (male and
female) just described in the two previous para-
graphs. The plug-in connectors are joined and
attached to the top portion of the circuit breaker. Figure 3-23 Cassette Mounted Secondary Wiring
The customer can plug secondary wiring with crimp-
on connectors into back of the plug-in connectors;
subsequently the connections to the circuit breaker
can be quickly joined or separated as required.
2. With Terminal Block - For those customers pre-

ferring to wire to a terminal block, terminal blocks
with finger-proof hinged covers are added to the
secondary configuration just described for a fixed
circuit breaker “without a terminal block.” The termi-
nal blocks are wired to the plug-in connectors and
also permanently attached to the upper rear portion
of the circuit breaker (Figures 3-2 and 3-3).
A standard tool is available from the plug-in connector

manufacturer (AMP) to facilitate the removal of sec- Figure 3-24 AMP Secondary Wiring Removal Tool
ondary wiring from a plug-in connector, or contact
Cutler-Hammer for assistance (Figure 3-24). The con-
nector halves must be separated to use this tool.
3-7.1 CONNECTION DIAGRAMS
The connection diagrams for all Magnum DS circuit

breakers using Digitrip RMS trip units are shown in
Figures 3-25 through 3-30.
Effective 7/02
Effective 7/02
I.B. 2C12060H05
SEE NOTE 13
NOTES: 6. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NON-
1. 4 WIRE CRIMP CONNECTION ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.
2. 3 WIRE CRIMP IF HIGH INST TRIP MODULE IS SUPPLIED. 7. ON THREE POLE BREAKERS ONLY, HAVING GROUND FAULT FUNCTIONALITY, A JUMPER INSTALLED FROM B-6 TO B-7
3. WIRE CONNECTION USED WITH DIGITRIP 520M/520MC GROUND ALARM POWER SUPPLY MODULE WILL “HANG UNCON- WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL GROUND FAULT SENSING. INPUTS B-4 AND B-5
Figure 3-25 Connection Diagram for Narrow and Standard Frame with Digitrip 220/520/520M/520MC
NECTED” IF DIGITRIP 220 OR 520 IS SUPPLIED. WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS.
4. ALL AUX SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP UNIT 8. THIS LEAD SUPPLIED ON G62 STYLE HIGH INSTANTANEOUS TRIP MODULE ONLY.
IN “NON-TRIPPED” STATE (OTS SWITCHES). 9. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.
5. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT BOARD PRO- 10. ON 4-POLE BREAKERS, THE NEUTRAL CURRENT SENSOR IS THE SAME STYLE AND WIRED THE SAME AS THE PHASE
VIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR SENSORS AND IS LOCATED WITHIN THE BREAKER FRAME. THE SECONDARY CONTACTS B-4, B-5, ARE NOT WIRED OUT.
SUBSEQUENT OPERATION. 11. SECOND SHUNT TRIP MAY BE INSTALLED (USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT
AVAILABLE WITH SECOND SHUNT TRIP.
AN OPTIONAL LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) 12. ONLY ONE LATCH CHECK SWITCH MAY BE INSTALLED. USE OF CUSTOMER ACCESSIBLE LATCH CHECK SWITCH (B-29,
LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND B-30) IN SERIES WITH SPRING RELEASE DEFEATS ANTI-PUMP FUNCTION AND IS NOT RECOMMENDED. SEE NOTE 3 FOR
RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING RELEASE SPRING RELEASE LATCH CHECK SWITCH.
PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN 13. THIS AUX. SWITCH ASSEMBLY NOT AVAILABLE IN NARROW FRAME. MAXIMUM OF TWO AUX SWITCHES (4A/4B)
THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND REAPPLIED TO THE SPRING INSTALLED IN NARROW FRAME.
RELEASE FOR SUBSEQUENT OPERATION.
Page 25
Page 26
Figure 3-26 Connection Diagram for Standard Frame with Digitrip 1150
5. ON THREE POLE BREAKERS ONLY, HAVING GROUND FAULT FUNCTIONALITY, A JUMPER INSTALLED FROM B-6 TO B-7
NOTES: WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL GROUND FAULT SENSING. INPUTS B-4 AND
1. 3 WIRE CRIMP IF HIGH INST TRIP MODULE IS SUPPLIED. B-5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS.
2. ALL AUX SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP UNIT 6. NORMALLY OPENED CONTACT PROGRAMMED AS RELAY A. VIA DIGITRIP FRONT PANEL. (ALARM CONTACT).
IN “NON-TRIPPED” STATE (OTS SWITCHES). 7. NORMALLY CLOSED CONTACT PROGRAMMED AS RELAY B. VIA DIGITRIP FRONT PANEL. (BLOCK CLOSE CONTACT)
3. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT BOARD PRO- 8. NORMALLY OPEN CONTACT PROGRAMMED AS RELAY C. VIA DIGITRIP FRONT PANEL. (LATCHING CONTACT)
VIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR 9. THIS LEAD SUPPLIED ON G62 STYLE HIGH INSTANTANEOUS TRIP MODULE ONLY.
SUBSEQUENT OPERATION. 10. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.
11. ON 4-POLE BREAKERS, THE NEUTRAL CURRENT SENSOR IS THE SAME STYLE AND WIRED THE SAME AS THE
AN OPTIONAL LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) PHASE SENSORS AND IS LOCATED WITHIN THE BREAKER FRAME. THE SECONDARY CONTACTS B-4, B-5, ARE NOT
LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND WIRED OUT.
RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING RELEASE 12. FOUR POINT SOCKET USED HERE.
PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN 13. SECOND SHUNT TRIP MAY BE INSTALLED (USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT
THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND REAPPLIED TO THE SPRING AVAILABLE WITH SECOND SHUNT TRIP.
RELEASE FOR SUBSEQUENT OPERATION. 14. ONLY ONE LATCH CHECK SWITCH MAY BE INSTALLED. USE OF CUSTOMER ACCESSIBLE LATCH CHECK SWITCH (B-
4. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NON- 29, B-30) IN SERIES WITH SPRING RELEASE DEFEATS ANTI-PUMP FUNCTION AND IS NOT RECOMMENDED. SEE NOTE 3
ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED. FOR SPRING RELEASE LATCH CHECK SWITCH.
Effective 7/02
I.B. 2C12060H05
Effective 7/02
I.B. 2C12060H05
NOTES:
1. 4 WIRE CRIMP CONNECTION
2. 3 WIRE CRIMP IF HIGH INST TRIP MODULE IS SUPPLIED. 6. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NON-
3. WIRE CONNECTION USED WITH DIGITRIP 520M/520MC GROUND ALARM POWER SUPPLY MODULE WILL “HANG UNCON- ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.
NECTED” IF DIGITRIP 220 OR 520 IS SUPPLIED. 7. ON THREE POLE BREAKERS ONLY, HAVING GROUND FAULT FUNCTIONALITY, A JUMPER INSTALLED FROM B-6 TO B-7
4. ALL AUX SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP UNIT WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL GROUND FAULT SENSING. INPUTS B-4 AND B-
IN “NON-TRIPPED” STATE (OTS SWITCHES). 5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS.
5. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT BOARD PRO- 8. THIS LEAD SUPPLIED ON G62 STYLE HIGH INSTANTANEOUS TRIP MODULE ONLY.
VIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR 9. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.
SUBSEQUENT OPERATION. 10. ON 4-POLE BREAKERS, THE NEUTRAL CURRENT SENSOR IS THE SAME STYLE AND WIRED THE SAME AS THE PHASE
SENSORS AND IS LOCATED WITHIN THE BREAKER FRAME. THE SECONDARY CONTACTS B-4, B-5, ARE NOT WIRED OUT.
AN OPTIONAL LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) 11. SECOND SHUNT TRIP MAY BE INSTALLED (USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT
LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND AVAILABLE WITH SECOND SHUNT TRIP.
RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING RELEASE 12. ONLY ONE LATCH CHECK SWITCH MAY BE INSTALLED. USE OF CUSTOMER ACCESSIBLE LATCH CHECK SWITCH (B-
PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN 29, B-30) IN SERIES WITH SPRING RELEASE DEFEATS ANTI-PUMP FUNCTION AND IS NOT RECOMMENDED. SEE NOTE 3
THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND REAPPLIED TO THE SPRING FOR SPRING RELEASE LATCH CHECK SWITCH.
Figure 3-27 Connection Diagram for Double-wide Frame with Digitrip 520/520M/520MC with ABCABC Configuration
Page 27
LINE N1 N2 LA1 LA2 LB1 LB2 LC1 LC2
Page 28
NOTES: 6. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NON-
1. 4 WIRE CRIMP CONNECTION ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.
2. 3 WIRE CRIMP IF HIGH INST TRIP MODULE IS SUPPLIED. 7. ON THREE POLE BREAKERS ONLY, HAVING GROUND FAULT FUNCTIONALITY, A JUMPER INSTALLED FROM B-6 TO B-
3. WIRE CONNECTION USED WITH DIGITRIP 520M/520MC GROUND ALARM POWER SUPPLY MODULE WILL “HANG 7 WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL GROUND FAULT SENSING. INPUTS B-4
UNCONNECTED” IF DIGITRIP 220 OR 520 IS SUPPLIED. AND B-5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS.
4. ALL AUX SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP 8. THIS LEAD SUPPLIED ON G62 STYLE HIGH INSTANTANEOUS TRIP MODULE ONLY.
UNIT IN “NON-TRIPPED” STATE (OTS SWITCHES). 9. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.
5. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT BOARD 10. ON 4-POLE BREAKERS, THE NEUTRAL CURRENT SENSOR IS THE SAME STYLE AND WIRED THE SAME AS THE
PROVIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED PHASE SENSORS AND IS LOCATED WITHIN THE BREAKER FRAME. THE SECONDARY CONTACTS B-4, B-5, ARE NOT
FOR SUBSEQUENT OPERATION. WIRED OUT.
11. SECOND SHUNT TRIP MAY BE INSTALLED (USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT
AN OPTIONAL LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) AVAILABLE WITH SECOND SHUNT TRIP.
LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND 12. ONLY ONE LATCH CHECK SWITCH MAY BE INSTALLED. USE OF CUSTOMER ACCESSIBLE LATCH CHECK SWITCH (B-
RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING RELEASE 29, B-30) IN SERIES WITH SPRING RELEASE DEFEATS ANTI-PUMP FUNCTION AND IS NOT RECOMMENDED. SEE NOTE 3
PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN FOR SPRING RELEASE LATCH CHECK SWITCH.
THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND REAPPLIED TO THE SPRING
Figure 3-28 Connection Diagram for Double-wide Frame with Digitrip 520/520M/520MC with AABBCC Configuration
Effective 7/02
I.B. 2C12060H05
Effective 7/02
I.B. 2C12060H05
NOTES 4. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NON-
1. ON THREE POLE BREAKERS ONLY (NOT EIGHT PHYSICAL POLES), HAVING GROUND FAULT FUNCTIONALITY, A ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.
JUMPER INSTALLED FROM B-6 TO B-7 WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL 5. 3 WIRE CRIMP IF HIGH INST TRIP MODULE IS SUPPLIED.
GROUND FAULT SENSING. INPUTS B-4 AND B-5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS. 6. NORMALLY OPENED CONTACT PROGRAMMED AS RELAY A. VIA DIGITRIP FRONT PANEL. (ALARM CONTACT).
2. ALL AUX SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP 7. NORMALLY CLOSED CONTACT PROGRAMMED AS RELAY B. VIA DIGITRIP FRONT PANEL. (BLOCK CLOSE CONTACT)
UNIT IN “NON-TRIPPED” STATE (OTS SWITCHES). 8. NORMALLY OPEN CONTACT PROGRAMMED AS RELAY C. VIA DIGITRIP FRONT PANEL. (LATCHING CONTACT)
Figure 3-29 Connection Diagram for Double-wide Frame with Digitrip 1150 with ABCABC Configuration
3. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT BOARD PRO- 9. ON 4-POLE BREAKERS (ACTUALLY 8 PHYSICAL POLES), THE NEUTRAL CURRENT SENSOR IS THE SAME STYLE AND
VIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR WIRED THE SAME AS THE PHASE SENSORS AND IS LOCATED WITHIN THE BREAKER FRAME. THE SECONDARY CON-
SUBSEQUENT OPERATION. TACTS B-4, B-5, ARE NOT WIRED OUT.
10. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.
AN OPTIONAL LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) 11. FOUR POINT SOCKET USED HERE.
LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND 12. SECOND SHUNT TRIP MAY BE INSTALLED (USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT
RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING RELEASE AVAILABLE WITH SECOND SHUNT TRIP.
PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN 13. ONLY ONE LATCH CHECK SWITCH MAY BE INSTALLED. USE OF CUSTOMER ACCESSIBLE LATCH CHECK SWITCH (B-
THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND REAPPLIED TO THE SPRING 29, B-30) IN SERIES WITH SPRING RELEASE DEFEATS ANTI-PUMP FUNCTION AND IS NOT RECOMMENDED. SEE NOTE 3
RELEASE FOR SUBSEQUENT OPERATION. FOR SPRING RELEASE LATCH CHECK SWITCH.
Page 29
LINE N1 N2 LA1 LA2 LB1 LB2 LC1 LC2
Page 30
NOTES 4. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NON-
1. ON THREE POLE BREAKERS ONLY (NOT EIGHT PHYSICAL POLES), HAVING GROUND FAULT FUNCTIONALITY, A ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.
JUMPER INSTALLED FROM B-6 TO B-7 WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL 5. 3 WIRE CRIMP IF HIGH INST TRIP MODULE IS SUPPLIED.
GROUND FAULT SENSING. INPUTS B-4 AND B-5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS. 6. NORMALLY OPENED CONTACT PROGRAMMED AS RELAY A. VIA DIGITRIP FRONT PANEL. (ALARM CONTACT).
2. ALL AUX SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP 7. NORMALLY CLOSED CONTACT PROGRAMMED AS RELAY B. VIA DIGITRIP FRONT PANEL. (BLOCK CLOSE CONTACT)
UNIT IN “NON-TRIPPED” STATE (OTS SWITCHES). 8. NORMALLY OPEN CONTACT PROGRAMMED AS RELAY C. VIA DIGITRIP FRONT PANEL. (LATCHING CONTACT)
Figure 3-30 Connection Diagram for Double-wide Frame with Digitrip 1150 with AABBCC Configuration
3. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT BOARD PRO- 9. ON 4-POLE BREAKERS (ACTUALLY 8 PHYSICAL POLES), THE NEUTRAL CURRENT SENSOR IS THE SAME STYLE AND
VIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR WIRED THE SAME AS THE PHASE SENSORS AND IS LOCATED WITHIN THE BREAKER FRAME. THE SECONDARY CON-
SUBSEQUENT OPERATION. TACTS B-4, B-5, ARE NOT WIRED OUT.
10. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.
AN OPTIONAL LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) 11. FOUR POINT SOCKET USED HERE.
LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND 12. SECOND SHUNT TRIP MAY BE INSTALLED (USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT
RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING RELEASE AVAILABLE WITH SECOND SHUNT TRIP.
PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN 13. ONLY ONE LATCH CHECK SWITCH MAY BE INSTALLED. USE OF CUSTOMER ACCESSIBLE LATCH CHECK SWITCH (B-
THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND REAPPLIED TO THE SPRING 29, B-30) IN SERIES WITH SPRING RELEASE DEFEATS ANTI-PUMP FUNCTION AND IS NOT RECOMMENDED. SEE NOTE 3
RELEASE FOR SUBSEQUENT OPERATION. FOR SPRING RELEASE LATCH CHECK SWITCH.
Effective 7/02
I.B. 2C12060H05
I.B. 2C12060H05 Page 31
3-8 ACCESSORY DEVICES Accessory Viewing Windows

A variety of accessory devices are available for use with
Magnum DS circuit breakers. Unless otherwise stated,
they are all considered optional devices in the sense
that they are not provided as standard on a manually
operated circuit breaker. Available accessories are
identified here and discussed in general terms. For
more detailed information and/or installation instructions,
refer to individual instruction leaflets dedicated to the
accessories.
Magnum DS circuit breaker accessories are designed to

fit all frame sizes. The accessories fall into one of three
categories:
Figure 3-31 Through-the-Window Electrical Accessories
• Plug-in electrical
• Internal electrical
• Mechanical
3-8.1 PLUG-IN ELECTRICAL ACCESSORIES
There are four Magnum DS Plug-In electrical acces-

sories. Three can be viewed for identification by name
and rating through viewing windows located in the right
front of the circuit breaker (Figure 3-31). All four are
plug-in type and can be factory installed or field installed
using a UL listed kit.
The four Plug-In accessories are:
• Shunt Trip (ST)

• Spring Release (SR)
• Undervoltage Release (UVR)
• Auxiliary Switch
Shunt Trip - The shunt trip is an optional device on cir- Figure 3-32 Shunt Trip with Cutoff Switch
cuit breakers (Figures 3-32 and 3-33). It opens the cir-
cuit breaker instantaneously when its coil is energized
by a voltage input (Table 3.3). A total of two shunt trips
can be mounted on a Magnum DS circuit breaker.
Table 3.3 Shunt Trip Ratings

Operational ① Opening
Control Voltage Range Inrush Power Time
Voltages 70-110% Consumption (ms)
24 Vdc 17-26 Vdc 250 W 35
48 Vdc 34-53 Vdc 250 W 35
110-125 Vdc 77-138 Vdc 450 W 35
220-250 Vdc 154-275 Vdc 450 W 35
110-127 Vac 77-140 Vac 450 VA 35
208-240 Vac 146-264 Vac 450 VA 35
① Required for less than 35 ms Figure 3-33 Shunt Trip Switch Installed
Effective 7/02
Page 32 I.B. 2C12060H05
Spring Release - The spring release is an optional Undervoltage Release - The undervoltage release is
device (Figure 3-34). It remotely closes the circuit an optional device on both manually and electrically
breaker when the coil is energized by a voltage input operated circuit breakers (Figure 3-35). It opens the cir-
(Table 3.4). The closing spring must be fully charged cuit breaker when its supply voltage falls to between 35-
and the trip latch reset (not held in the tripped position) 60% of rated voltage. If the release is not energized to
for the SR to operate. If these two conditions are not 85% of its supply voltage, the circuit breaker cannot be
met the close signal will be ignored until it is removed closed electrically or manually (Table 3.5).
and re-applied.
Auxiliary Switch - An auxiliary switch is an optional
An optional Latch Check Switch (LCS) can also be device providing remote electrical indication if the circuit
installed to delay application of power to the Spring breaker is open or closed (Figure 3-37). Up to 3 auxil-
Release coil until the circuit breaker is “ready to close”. iary switches can be mounted in the circuit breaker.
The LCS will not permit energization of the Spring Each switch has 2 normally open (“a”) and 2 normally
Release until the breaker is fully charged and the trip closed (“b”) contacts for a total of 12 available contacts
latch is reset. Two versions of the LCS are available. (Table 3.6).
One version is wired internally to the Shunt Trip coil
control circuit. On the other version the LCS switch
contacts are brought out through the secondary con-
tacts for integration into external control schemes. Note
that placing the (externally accessible) LCS directly in
series with the ST coil is not recommended as this will
override the “anti-pump” feature of the electrical charg-
ing/closing system.
Figure 3-35 Undervoltage Release
Figure 3-34 Spring Release with Optional Latch Switch
Table 3.4 Spring Release Ratings

Operational ① Closing
Control Voltage Range Inrush Power Time
Voltages 70-110% Consumption (ms)
24 Vdc 17-26 Vdc 250 W 40
48 Vdc 34-53 Vdc 250 W 40
110-125 Vdc 77-138 Vdc 450 W 40
220-250 Vdc 154-275 Vdc 450 W 40
110-127 Vac 77-140 Vac 450 VA 40
208-240 Vac 146-264 Vac 450 VA 40
① Required for less than 200 ms
Figure 3-36 Shunt Trip, Spring Release and
Undervoltage Release Installed
Effective 7/02
I.B. 2C12060H05 Page 33
Mechanical
Figure 3-37 Auxiliary Switch (2A/2B) Trip Indicator
Figure 3-38 Mechanical Trip Indicator with Associated

Overcurrent Trip Switch
3-8.2 INTERNAL ELECTRICAL ACCESSORIES
Table 3.6 Auxiliary Switch, Other electrical accessories are mounted inside the cir-
Overcurrent Trip Switch and cuit breaker. They can be factory or site installed.
Cell Switch Contact Ratings There are two different internally mounted accessories:
Control Contact Rating
Voltages Inductive Load • Overcurrent Trip Switch (Bell Alarm)
(amperes) • Motor Operator
250 Vac 10
Overcurrent Trip Switch (Bell Alarm) - An overcurrent
125 Vdc 0.5 trip switch (bell alarm) is an optional device (Figure 3-38).
250 Vdc 0.25 It provides an electrical indication when a circuit
Table 3.5 Undervoltage Release

Operational Dropout ①➁ Opening
Control Voltage Range Volts Inrush/Continuous Time
Voltages 85-110% 30-60% Power Consumption (ms)
24 Vdc ① 20-26 Vdc 7-14 Vdc 250 W/18 W 70
32 Vdc ① 27-35 Vdc 10-19 Vdc 275 W/15 W 70
48 Vdc ① 41-53 Vdc 14-29 Vdc 275 W/18 W 70
110-125 Vdc ① 94-138 Vdc 33-75 Vdc 450 W/10 W 70
220-250 Vdc ① 187-275 Vdc 66-150 Vdc 450 W/10 W 70
110-127 Vac ➁ 94-140 Vac 33-76 Vac 450 VA/10 VA 70
208-240 Vac ➁ 177-264 Vac 62-144 Vac 400 VA/10 VA 70
380-415 Vac ➁ 323-457 Vac 114-249 Vac 480 VA/10 VA 70
480 Vac ➁ 408-528 Vac 144-288 Vac 400 VA/10 VA 70
600 Vac ➁ 510-660 Vac 180-360 Vac 400 VA/10 VA 70
① Required for 200 ms
➁ Required for 400 ms
Effective 7/02
Page 34 I.B. 2C12060H05
breaker trips as a result of the trip unit reacting to an

overcurrent condition. Opening as a result of a circuit
breaker’s manual open button, shunt trip or undervoltage
release does not cause the overcurrent trip switch to oper-
ate. The overcurrent trip switch has (2a 2b) Form C con-
tacts (Table 3.6).
The status of the contacts changes when the trip indica-

tor pops out. This permits the switch to be used as an
alarm or in conjunction with a spring release to block a
subsequent remote electrical closing signal.
Motor Operator - A Motor operator is an electric motor
assembly internally mounted in the circuit breaker
(Figures 3-39 and 3-40). It charges the closing springs
electrically for remote or local operation. The motor
operator can be factory or site installed (Table 3.7).
Figure 3-39 Motor Operator Kit
To convert a manually operated circuit breaker to an
electrically operated circuit breaker, a UL listed motor
operator kit is available.
Figure 3-40 Motor Operator Installed in Narrow Frame

Table 3.7 Motor Operator Circuit Breaker
Control ① Operational Running Typical Power Maximum
Voltage Range Current Inrush Consumption Charging Time
Voltages 85-110 % (A. avg.) Current (watts or VA) (seconds)
24 Vdc 20-26 12.0 300% of Running 300 5
48 Vdc 41-53 5.0 500% of Running 250 5
110-125 Vdc 94-138 2.0 600% of Running 250 5
220-250 Vdc 187-225 1.0 600% of Running 250 5
110-127 Vac 94-140 2.0 600% of Running 250 5
208-240 Vac 177-264 1.0 600% of Running 250 5
① AC voltages are 50/60Hz
Effective 7/02
I.B. 2C12060H05 Page 35
Operations
Counter
“OFF”
Key Lock
Figure 3-41 Cover Mounted Key Lock and Operations Figure 3-42 Cassette Mounted Key Lock
Counter
3-8.3 MECHANICAL ACCESSORIES Cassette Lock - A cassette mounted lock can be used
in conjunction with different interlocking schemes (such
There are eight optional mechanical type accessories: as main-tie-main) (Figure 3-42). The lock holds the cir-
cuit breaker trip-free in the conected position, preventing
• Operations Counter it from being closed.
• Off Key Lock Up to three lock cylinders can be installed on one cas-
• Cassette Lock sette. Cutler-Hammer supplies the lock provisions only.
• Pushbutton Cover The customer is responsible for the locks, which can be
• Prevent Close Cover Kirk or Castell.
• Cassette Safety Shutters
• Cassette Cell Switch
Pushbutton Cover - A padlockable cover is available to
• Door Escutcheon
limit access to the “ON” and “OFF” pushbuttons (Figure
• Waterproof Cover
3-43). It can be installed with either or both pushbutton
• Mechanical Interlock
covers in place.
Operations Counter - The operations counter is a
mechanical device used to provide a record of the num-
ber of circuit operations. It is mounted in the lower right
portion of the circuit breaker and can be viewed through
the front cover (Figure 3-41).
Off Key Lock - The off key lock secures the circuit
breaker in the “OFF” position. It is mounted in the lower
right portion of the circuit breaker and can be viewed
through the front cover (Figure 3-41). The customer
supplies the key lock. The provisions available are for
Kirk, Castell or Ronis.
Figure 3-43 ON-OFF Pushbutton Lockable Cover Plate
Effective 7/02
Page 36 I.B. 2C12060H05
Prevent Close Cover - Complete access to the “ON” Door Escutcheon - The door escutcheon is a molded
pushbutton can be prevented by adding the prevent frame used to seal the space between the circuit break-
close cover to the pushbutton cover. er and the compartment door cutout. It is supplied with
a mounting gasket (Figure 3-48).
Cassette Safety Shutters - Automatically operated
insulating type safety shutters are available for use with
the drawout cassette. When the drawout circuit breaker
is levered from the CONNECT position, the shutters
automatically close to cover the fixed primary contacts
(Figure 3-44). When the circuit breaker is levered into
the cassette, the shutters automatically open permitting
primary connections to be made (Figure 3-45).
Figure 3-46 Cell Switch (Drawout Position Indicator)

Unmounted
Figure 3-44 Safety Shutters in Closed Position
Figure 3-47 Cell Switches Mounted on Cassette
Figure 3-45 Safety Shutters in Open Position
Cassette Cell Switch - The cassette cell switch is a

compartment position switch for drawout circuit break-
ers. It is available in a 2a2b or 4a4b contact configura-
tion, and mounts on the right side of the cassette
(Figure 3-46 and 3-47). Refer to the Ratings Table 3.6
for cell switch contact information. The cell switch
changes status between the TEST and CONNECT
positions.
Figure 3-48 Door Escutcheon and Gasket
Effective 7/02
I.B. 2C12060H05 Page 37
Figure 3-49 IP54 Waterproof Cover

IP54 Waterproof Cover - A hinged dome shaped
waterproof cover attaches to the metal compartment
door to provide waterproof protection for the circuit
breaker (Figure 3-49).
Mechanical Interlock - A family of mechanical inter-
locks are available to interlock the closing of two or
three Magnum circuit breakers. The mechanical inter-
lock holds one or more circuit breakers tripped (prevents
closure) when others are closed. A lever assembly is
mounted on each breaker which interfaces with the pole
shaft and the tripper bar. The lever assemblies are
interconnected with either cables or rods, depending
upon the relative orientation of the breakers. Rods can
be used only when the circuit breakers to be interlocked
are vertically stacked. Cables can be used for any ori-
entation of the breakers. Mechanical interlocks are
available for both fixed and drawout circuit breakers and
in both 2-way and 3-way versions. An illustration of a 2-
way cable interlock mounted on two drawout circuit
breakers is shown in Figure 3-50.
Figure 3-50 Cassette-Mounted 2-Way Cable Interlock
Effective 7/02
Page38 I.B. 2C12060H05
SECTION 4: DRAWOUT CIRCUIT supplies vertical stab/terminals only (Figure 4-5). The
BREAKER AND CASSETTE basic cassette omits the copper stab/terminals so that
these pieces can be integrated with vertical bus bars
4-1 GENERAL provided by the switchgear builder (Figure 4-6). The
universal cassette provides a set of flat pad terminals on
Section 3 discussed topics and features common to all the rear of the cassette that can be adapted to vertical,
Magnum DS circuit breakers, no matter what the mount- horizontal or front connection (Figures 4-7). Mounting
ing configuration. In this section, features unique to the locations for cell (TOC) switches, safety shutters,
drawout configuration not covered elsewhere, including mechanical interlocks and key interlocks are provided
the drawout cassette, are covered. Drawings and on the cassette. Note that the narrow frame cassette
dimensions associated with all circuit breakers, drawout uses the IEC cell switches and shutter assemblies.
cassettes and any appropriate primary bus connections
can be found in a separate document entitled
Engineering Data 2C12062H01. The installation and 4-2 DRAWOUT CIRCUIT BREAKER DIMENSIONS
levering of a drawout circuit breaker were discussed in
Section 2. If necessary, review that information, since it The Magnum DS drawout circuit breaker connects to the
will not be repeated here. fixed primary stabs of the drawout cassette through the pri-
mary finger clusters attached to the rear of the circuit
4-1.1 DRAWOUT CASSETTE breaker. Two different frame sizes cover all Magnum DS
circuit breakers from an overall dimensional standpoint.
A drawout circuit breaker is used in combination with a Circuit breaker drawings can be found in Engineering
fixed drawout cassette (Figures 4-1 and 4-3); the dra- Data 2C12062H01.
wout circuit breaker is equipped with automatic primary
disconnects (Figure 4-2). The cassette provides all of 4-3 DRAWOUT CASSETTE DIMENSIONS
the necessary interfaces to the drawout circuit breaker
including automatic primary and secondary connections. Cassette drawings provide all the dimensional informa-
For the narrow frame circuit breaker a single cassette tion required for all mounting configurations and can
style using horizontal stabs and horizontal customer bus also be found in Engineering Data 2C12062H01.
bar terminals is available (Figure 4-4). For the standard Review carefully for a specific installation.
and double-wide circuit breakers three cassette styles,
all with vertical stabs, are available: basic, standard, and
universal. The standard cassette
Figure 4-2 Drawout Circuit Breaker with Automatic

Figure 4-1 Drawout Circuit Breaker in Cassette Primary Disconnects
Effective 7/02
I.B. 2C12060H05 Page 39
4 5
1 2
1 Extension Rails 5 Arc Hood

2 Extension Rail Cutout 6 Optional Cell (TOC) Switch Mounting
3 Secondary Plug-in Connectors 7 Optional Key Interlock Mounting Location
4 Secondary Terminal Blocks 8 Grounding Bar
Figure 4-3 Drawout Cassette Features
Effective 7/02
Page 40 I.B. 2C12060H05
Figure 4-4 Narrow Frame Cassette (Horizontal Terminals)
Figure 4-5 Standard Cassette (Vertical Terminals)
Effective 7/02
I.B. 2C12060H05 Page 41
Figure 4-6 Basic Cassette (Without Stabs)
Figure 4-7 Universal Cassette, 4-Pole (Flat Terminal Pads)
Effective 7/02
Page 42 I.B. 2C12060H05
SECTION 5: FIXED CIRCUIT BREAKER
5-1 GENERAL
Section 3 discussed topics and features common to all Optional

Magnum DS circuit breakers, no matter what the mount- Vertical
ing configuration. In this section, features unique to the Horizontal Adaptor
fixed configuration not covered elsewhere are covered. Connection
Drawings and dimensions associated with all fixed cir-
cuit breakers and any appropriate primary bus connec-
tions can be found in a separate document entitled
Engineering Data 2C12062H01. The installation of a
fixed circuit breaker was discussed in Section 2. If nec-
essary, review that information, since it will not be
repeated here.
5-2 FIXED CIRCUIT BREAKER DIMENSIONS
The standard fixed circuit breaker is supplied with hori-

zontally mounted primary connections (Figure 5-1).
Optional vertical primary adaptors are available for dif-
ferent bus configurations. Refer to Engineering Data
2C12062H01 for fixed circuit breaker dimensions, verti- Figure 5-1 Fixed Circuit Breaker with Available Vertical
cal adaptor dimensions and vertical adaptor assembly Adaptor
details.
Effective 7/02
I.B. 2C12060H05 Page 43
SECTION 6: INSPECTION AND It is recommended that maintenance record sheets be

MAINTENANCE completed for the equipment. Careful and accurate doc-
umentation of all maintenance activities provides a valu-
able historical reference on equipment condition over
6-1 GENERAL
time.
6-2 GENERAL CLEANING RECOMMENDATIONS

! WARNING
Circuit breaker cleaning activities should be a part of an
overall activity that includes the assembly in which the
FAILURE TO INSPECT, CLEAN AND MAINTAIN CIR-
circuit breaker is installed. Loose dust and dirt can be
CUIT BREAKERS CAN REDUCE EQUIPMENT LIFE
removed from external surfaces using an industrial qual-
OR CAUSE THE EQUIPMENT NOT TO OPERATE
ity vacuum cleaner and/or lint free cloth. Unless other-
PROPERLY UNDER FAULT CONDITIONS. THIS
wise indicated, never use high pressure blowing air,
COULD RESULT IN EQUIPMENT DAMAGE, BODILY
since dirt or foreign objects can be driven into areas,
INJURY OR EVEN DEATH.
such as the breaker mechanism, where additional fric-
tion sources could create problems. Never use a wire
brush to clean any part of the circuit breaker.
! CAUTION
6-3 WHEN TO INSPECT
INSPECTION AND MAINTENANCE PROCEDURES
Do not wait for specific scheduled periods to visually
SHOULD BE CARRIED OUT ONLY BY PERSONNEL
inspect the equipment, if there are earlier opportunities.
FAMILIAR WITH THE HAZARDS ASSOCIATED WITH
If possible, make a visual inspection each time a circuit
WORKING ON POWER CIRCUIT BREAKERS. ADDI-
breaker compartment door is opened, and especially
TIONALLY, THEY SHOULD BECOME FAMILIAR
when a circuit breaker is withdrawn on its compartment
WITH THE SPECIFICS ASSOCIATED WITH TYPE
extension rails. This preventive measure could help to
MAGNUM DS CIRCUIT BREAKERS AS PRESENTED
avoid future problems.
IN THIS INSTRUCTION BOOK.
Industry standards for this type of equipment recom-
Magnum Circuit Breakers are “Top of the Line” equip-
mend a general inspection and lubrication after the
ment. This means they are manufactured under a high
number of operations listed in Table 6.1 of this section.
degree of quality control, with the best available materi-
This should also be conducted at the end of the first six
als and with a high degree of tooling for accuracy and
months of service, if the number of operations has not
parts interchangeability. Design tests and actual installa-
been reached.
tion experience show them to have durability well
beyond minimum standards requirements. However,
because of the variability of application conditions and
the great dependence placed upon these circuit break-
ers for protection and the assurance of service continu-
ity, inspection and maintenance activities should take
place on a regularly scheduled basis.
Since maintenance of these circuit breakers consists

mainly of keeping them clean, the frequency of sched- Table 6.1 Inspection Frequency
uled inspection and maintenance depends to some
degree on the cleanliness of the surroundings. Cleaning
and preventive measures are a part of any good mainte- Breaker Frame Size Interval➀
nance program. Plant operating and local conditions can (Breaker Cycles)
vary to such an extent that the actual schedule should
be tailored to the conditions. When the equipment is 800 amperes and below 1750
subject to a clean and dry environment, cleaning is not
required as frequently as when the environment is Between 800 and 3000 amperes 500
humid with a significant amount of dust and other for-
eign matter. 3000 amperes and above 250
➀ Breaker Cycle = one no load open/close operation
Effective 7/02
Page44 I.B. 2C12060H05
After the first inspection, inspect at least once a year. If Eaton Cutler-Hammer recommends that the following
these recommended inspections show no maintenance functional tests be performed on Magnum circuit break-
requirements, the period may be extended to a more ers as part of any maintenance procedure. The circuit
economical point. Conversely, if the recommended breaker should be removed from service and Cutler-
inspection shows, for instance, a heavy accumulation of Hammer notified if the circuit breaker fails to perform any
dirt or other foreign matter that might cause mechanical, of these tests successfully. Please be prepared to pro-
insulation or other electrical damage, the inspection and vide the number of operations the circuit breaker has to
maintenance interval should be decreased. date as well as the following nameplate information:
❶ G.O.#: It: Seq: ❸ Code:
6-4 WHAT TO INSPECT ❷ Cust. P.O.: ❹ Date of Manufacture
➎ Cat#:
What to inspect and to what extent is dictated by the
nature of the maintenance function. Routine inspec-
tions require one type of observation. Inspections fol-
lowing a known high level fault require more detailed
inspections.
A drawout type circuit breaker should first be withdraw

from its compartment onto the compatment’s extension
rails. When the inspection is complete, the circuit
breaker can be levered to the TEST position to check
the electrical operations of the circuit breaker. During
the levering out and levering in of the circuit breaker, be
aware for any signs that would indicate that this process
is not working properly.
During the inspection of fixed type circuit breakers, bus

systems supplying the fixed circuit breakers should be ❶
de-energized for convenience and safety.
For functional testing of the trip unit, refer to the sepa-

rate detailed instruction book dedicated to the trip unit.
❷
❸
❹
➎
{
Once the circuit breaker has been cleaned as described
in paragraph 6-2, visually inspect it for any signs of
damage, missing or loose parts and unusual wear. Be Manual Operation Functional Test
especially alert for foreign matter that must be removed.
On drawout circuit breakers, inspect the primary discon- Charge the breaker mechanism springs either using the
nect finger clusters for signs of wear and erosion. Make charging handle or the motor operator. Press the ON
appropriate corrections to anything found out of order. pushbutton to close the breaker manually and verify
closing by noting the state of the indicating flag. Charge
6-4.1 FUNCTIONAL FIELD TESTING the breaker mechanism springs either using the charg-
ing handle or the motor operator. If using the motor
operator, disconnect power to it to prevent automatic
NOTICE recharging. Press the OFF pushbutton to manually
open the breaker. Press the ON pushbutton to manually
Before doing any work on drawout type circuit close the breaker. Is the breaker closed? Press the
breakers, make sure the breaker is levered out to OFF pushbutton to manually open the breaker. Is the
the TEST or DISCONNECT position. During the lev- breaker open? Repeat this entire described test proce-
ering out and levering in of the circuit breaker, be dure three times.
aware of any signs that would indicate that the lev-
ering process is not working properly. If working Electrical Operation Functional Test
on a fixed circuit breaker, bus systems should be
de-energized for convenience and safety. The cir- This test procedure is based on the assumption that the
cuit breaker should be switched to the OFF position breaker is equipped with optional shunt trip and spring
and the mechanism springs discharged. release accessories. If one accessory is missing, substi-
tute the manual button to replace the accessory’s func-
tion.
Effective 7/02
I.B. 2C12060H05 Page 45
Charge the breaker mechanism springs either using the Since the arc chutes are removed, this is an ideal time
charging handle or the motor operator. Close the break- to inspect primary contacts for wear using the circuit
er by applying rated voltage to the spring release acces- breaker’s contact wear indicators. The details associat-
sory and verify closing by noting the state of the indicated with primary contact inspection are presented in the
ing flag. Charge the breaker mechanism springs either next paragraph.
using the charging handle or the motor operator. If
using the motor operator, disconnect power to it to pre-
vent automatic recharging. Open the breaker by apply-
Arc Chute Baffled
ing rated voltage to the shunt trip accessory. Close the
breaker using the spring release accessory. Is the Removed Cover
breaker closed? Open the breaker using the shunt trip
accessory. Is the breaker open? Repeat this entire
described test procedure three times.
Arc Chamber
Trip Unit Overload Functional Test
This test uses the Digitrip 1150 self test function, the
Digitrip Test Kit or the handheld Magnum Functional
Test Kit. Review test kit instructions for the trip unit.
Instruction leaflet 5720B55, section 1.2 or 1.3 applies for
instantaneous test procedures or paragragraph 5.2.1
“1150 Self Testing, Trip Mode” in the trip unit instruction
leaflet 70C1036.
Charge the breaker mechanism springs either using the

charging handle or the motor operator. Press the ON
pushbutton to close the breaker manually and verify
closing by noting the state of the indicating flag. Charge
the breaker mechanism springs either using the charg-
ing handle or the motor operator. If using the motor
operator, disconnect power to it to prevent automatic
recharging. Trip the breaker with a trip unit test. Verify Figure 6-1 Top Rear View of Circuit Breaker with One
that the trip indicator pop out button (if so equipped) is Arc Chute Removed
“out” and then reset it. Press the ON pushbutton to
manually close the breaker. Is the breaker closed? Trip
the breaker with a trip unit test. Verify that the trip indi-
cator pop out button (if so equipped) is “out” and then
reset it. Repeat this entire described test procedure
three times. Reset the blinking red cause of trip LED on
the trip unit by pressing the Reset/Battery Test pushbut-
ton.
6-4.2 ARC CHUTE INSPECTION
When a circuit breaker experiences a high level fault or

during regularly scheduled maintenance periods, the cir-
cuit breaker’s arc chutes and arc chambers should be
inspected for any kind of damage or dirt. Be especially Alternating
alert for signs of significant erosion of the V-shaped “V” Shaped
plates inside the arc chute. Plates
Arc chutes fit inside the arc chambers and down over a
the primary contacts. Each arc chute is held in place by
one top inserted screw (Figure 6-1). Begin by removing
the arc chute screws and all three arc chutes. Turn
each arc chute upside down to visually inspect the
inside (Figure 6-2). Figure 6-2 Bottom View of Arc Chute
Effective 7/02
yy

,,
z
Page 46 I.B. 2C12060H05

|
{{
Arcing Integral
Contact Arc
(Toe) Runner
Stationary
Main Contact
Moving Main
Contact
(Side View)
Figure 6-3 Primary Contacts with Circuit Breaker Open Figure 6-4 Contact Inspection Area with Circuit Breaker
(Not Used for Contact Wear Inspection) Open
NOTICE
When making a contact wear inspection, always
! WARNING make the inspection by looking straight down into

the arc chamber for the proper perspective.
Viewing the contact wear area from an angle could
ARC CHUTES MUST ALWAYS BE SECURED PROP- distort the view.
ERLY IN PLACE BEFORE A CIRCUIT BREAKER IS
INSTALLED IN A CIRCUIT BREAKER COMPART- The contact wear indicator is the relative position of the
MENT. FAILURE TO DO THIS COULD RESULTS IN individual contact fingers to a narrow, side-to-side ledge
EQUIPMENT DAMAGE, BODILY INJURY OR EVEN inside the arc chamber. The ledge is actually part of the
DEATH. arc chamber. When the circuit breaker is closed and
the contacts are in good condition, the narrow ledge is
When the inspections are complete, position each arc covered by the back end of the contacts (Figure 6-5). If
chute down over its respective set of primary contacts, the back end of the contacts do not totally cover the
and secure in place with the screw removed earlier. ledge, the contacts should be replaced.
Torque the arc chute screws to 35 to 45 in-lb.
6-4.3 PRIMARY CONTACT INSPECTION
With the arc chutes removed, visually inspect each pri- ! WARNING
mary contact structure for signs of wear and/or damage.
The primary contacts with the circuit breaker open can ARC CHUTES MUST ALWAYS BE SECURED PROP-
be viewed by looking directly down into the arc chamber ERLY IN PLACE BEFORE A CIRCUIT BREAKER IS
(Figure 6-3 and 6-4). INSTALLED IN A CIRCUIT BREAKER COMPART-
MENT. FAILURE TO DO THIS COULD RESULTS IN
A contact wear indicator is provided for each primary EQUIPMENT DAMAGE, BODILY INJURY OR EVEN
contact and indicates whether or not the contact should DEATH.
be replaced. Inspection of the contacts using the con-
tact wear indicators is conducted only with the circuit Once the inspection is complete, be sure the arc chutes
breaker closed (Figures 6-5). are properly replaced as previously described in para-
graph 6-4.1.
Effective 7/02
I.B. 2C12060H05 Page 47
Side-to-Side Side-to-Side
Ledge Ledge
Contact Wear
Contact Wear Inspection Area
Inspection Area (Ledge Now Becoming
(Ledge Not Visible Visible Under
Under Contacts) Contacts)
Contact Wear Indicator - Contacts Contact Wear Indicator - Contacts

Closed and in Good Condition Closed and Wear is Indicated
Figure 6-5 Use of Contact Wear Indicator with Circuit Breaker Closed
6-5 CIRCUIT BREAKER MODIFICATIONS AND To remove the rating plug from the trip unit, open the
CHANGES small rating plug door located on the right side of the trip
unit (Figure 6-6). The trip unit’s battery cavity is also
The topics discussed here will relate to those actions located behind this door. Use a 1/8” wide screwdriver to
that can be taken in the field to change, update, main- remove the M4 screw holding the rating plug in position.
tain or repair a Magnum DS circuit breaker. This infor- Pull the door to release the rating plug from the trip unit.
mation does not, however, include most accessory
devices. Their installation is covered by separate
instruction leaflets dedicated to the individual devices.
The tasks described here do not, under ordinary circum-
stances, require any assistance beyond the appropriate
instructional material. If further assistance is required,
however, contact your Cutler-Hammer representative.
6-5.1 RATING PLUG REPLACEMENT

Rating
Plug
NOTICE
If a rating plug is not installed in the trip unit, the
trip unit will trip when energized. Also remember
that the trip unit’s rating plug and the circuit break-
er’s current sensors must have matching ratings.
Figure 6-6 Trip Unit Rating Plug Location
Effective 7/02
Page 48 I.B. 2C12060H05
To install a new rating plug, insert the rating plug into f the circuit breaker is a drawout configuration, the lower
the cavity where the other rating plug was removed. primary disconnect finger clusters and the vertical adap-
Make sure the three pins on the rating plug are aligned tors must first be removed from frame sizes up to
with the sockets in the cavity. The rating plug should fit 3000/3200A. On the 3000/3200A frame, both the upper
with a slight insertion force. and lower primary disconnects and vertical adaptors
must be removed. Each primary disconnect finger clus-
ter is removed by loosening the two hex-head bolts with
! CAUTION a 10 mm wrench. These bolts do not have to be com-
pletely removed to slide the primary disconnects off of
the terminals. Remove the vertical adaptors next from
TO PREVENT DAMAGE TO THE RATING PLUG, DO the circuit breaker terminals by removing the two or
NOT FORCE IT INTO THE MOUNTING CAVITY. three 10 mm bolts holding them in place (Figure 6-8).
Use the same 1/8” screwdriver to tighten the M4 screw The current sensors are removed by pulling them off of
and secure the rating plug in the trip unit. The maxi- the terminals and unplugging the wiring plugs from the
mum torque on the mounting screw is 15 in-oz. Close sensors (Figure 6-8).
the rating plug door.
Install new current sensors by connecting the wiring
6-5.2 CURRENT SENSOR REPLACEMENT plugs to the sensors and sliding the sensors over the
terminals. Reinstall the cover over the sensors and
secure in place with the screws previously removed.
NOTICE
Reinstall the previously removed vertical adaptors to the
terminals using the removed hardware and 40 ft-lb of
Remember that the trip unit’s rating plug and the tightening torque. Make sure the vertical adaptors are
circuit breaker’s current sensors must have match- square to the rear housing. Slip the primary discon-
ing ratings. nects on to the vertical adaptors. Make sure the primary
disconnects are fully inserted on to the vertical adaptors.
The three current sensors are installed at the rear of the Tighten the two retention bolts to 40 in-oz of torque.
circuit breaker on the lower terminals. A cover with sen- Properly engaged and secured retention bolts should
sor rating viewing windows covers the sensors and is engage the slots or holes in the vertical adaptors.
held in place with screws (Figure 6-7). Remove the
cover by removing the screws.
Vertical
Adaptor
Current Sensor Current

Cover Sensor
Wiring Plug
Figure 6-7 Current Sensor Cover in Place Over Figure 6-8 One Current Sensor Shown Removed and
Sensors Disconnected
Effective 7/02
I.B. 2C12060H05 Page 49
SECTION 7: TROUBLESHOOTING
7-1 INTRODUCTION
Table 7.1 will help to determine the probable causes of

simple circuit breaker problems and possible corrective
actions. Possible problems associated with the elec-
tronic trip unit are covered in a companion publication,
I.L. 70C10337H01. If the problem cannot be resolved
with the aid of one or both of these guides, contact the
Cutler-Hammer service center for more in-depth assis-
tance.
Table 7.1 Circuit Breaker Troubleshooting Guide (continued on next page)
Symptom Probable Cause Corrective Actions

The circuit breaker trips open Rating plug not installed Install rating plug that
(red fault trip indicator button and load current through corresponds to current sensors
is out and/or fault indicator LED the breaker
is lighted) when closed on a
load current Repeated closing on Wait for circuit breaker (and
transient (in-rush) current loads) to cool before re-closing
with thermal memory active
An overload or fault current Use status and fault

condition indicators to help locate and
remove overload or fault
condition
Circuit breaker opens Undervoltage release Check and correct the UVR
(fault trip indicator button operates; voltage too low supply voltage (85-110% rated
is not out) or zero voltage)
Shunt trip operates Check control signal(s) to

shunt trip; correct if necessary
Trip latch is defective Inspect latch condition and

engagement before closing;
consult Cutler-Hammer service
center
Effective 7/02
Page 50 I.B. 2C12060H05
Table 7.1 Circuit Breaker Troubleshooting Guide (continued from previous page)

Circuit breaker cannot Shunt trip control signal Check supply voltage exceeds
be opened remotely, but absent or too low 70% of rated voltage when
can be opened locally signal is applied to shunt trip
Shunt trip is faulty or Remove front cover; check

improperly installed voltage supplied to shunt
trip; make sure shunt trip is
seated and retainer snapped
into place. Check for shunt
trip motion; replace shunt
trip if faulty
Secondary contact wiring Make sure electrical pin and

problem socket connectors are properly
seated in molded plug. Verify
proper wiring
Circuit breaker cannot OPEN pushbutton locked Remove lock

be opened locally
Faulty mechanism or main Contact Cutler-Hammer
contacts welded service center
Circuit breaker makes Closing spring not fully Charge spring manually; check
no attempt to close with charged (check SPRING voltage to electrical operator;
either local (manual) or CHARGED indicator) replace electrical operator if
remote controls; springs faulty
do not discharge
If equipped with undervoltage Unplug undervoltage release
release, undervoltage release from mounting deck and retry
is not energized or is faulty closing operation; if OK, check
voltage supply to undervoltage
release (>85%); replace under-
voltage release if faulty
Circuit breaker locked in Check reason for lock

OPEN position
Drawout position interlock Make sure that circuit breaker is

is operating; levering screw at a position that permits closure;
door is open check that shutter
(door) over the levering screw
is fully closed
Circuit breaker interlocked Check for presence of an

with another circuit breaker interlocking scheme (cable
or device interlock or key interlock);
check to see if interlocked
circuit breaker is CLOSED
Effective 7/02
I.B. 2C12060H05 Page 51
Table 7.1 Circuit Breaker Troubleshooting Guide (continued from previous page)
Circuit breaker cannot Spring release (closing) coil Check power supply voltage;
be closed remotely (can supply voltage low or spring replace spring release if faulty
be closed locally) release faulty
Secondary contact wiring Make sure electrical pin and

problem socket connectors are properly
seated in molded plug. Verify
proper wiring
Spring release closing coil Clear Digitrip 1150 relay contact

signal blocked
Circuit breaker cannot Opening and/or closing Check reason for lock
be closed locally (but pushbuttons locked
can be closed remotely)
Circuit breaker does not Charging motor supply voltage Check charging motor electrical
recharge electrically but absent or too low (<85%) circuit voltage (check under
will recharge manually load)
Charging motor faulty Replace charging motor assembly
Drawout circuit breaker Circuit breaker will not fully Circuit breaker ratings do not
will not lever-in enter cell (cell rejection correspond to the cassette
code plate) requirements
Levering-in screw not in Rotate levering-in screw

fully DISCONNECT counterclockwise to
position at insertion DISCONNECT position, then
insert breaker fully into cassette
Levering-in screw in Push circuit breaker in as far

DISCONNECT position it will go, cover should be flush
but not pushed in far enough with front of cassette side plate
Protective boots covering Remove boots

stationary disconnects
Shutter jammed or locked Clear problem
Effective 7/02
Page 52 I.B. 2C12060H05
SECTION 8: RENEWAL PARTS
8-1 GENERAL
All renewal parts and/or spare parts recommendations

for Type Magnum DS Circuit Breakers are supplied in
separate Renewal Parts Documentation, not this
instruction manual. Refer to the most recent version of
this documentation for specific assistance.
When ordering parts, always specify, if known, the part

name and style number. If the style number is not
known, it would help to refer to a pictorial and/or graphic
reference. Also include the circuit breaker type, General
Order number and other information as shown on the
nameplate on the front cover of the circuit breaker
(Figures 1-2 and 3-4).
Some detailed parts shown in the figures in this manual

may only be available as a part of a sub-assembly.
Certain parts may not be available at all for field installa-
tion. Some parts in the figures are illustrated just to
show their function and location in the assembly. The
Renewal Parts Documentation indicates which parts are
available and in what form. For additional information,
visit the Cutler-Hammer website at
www.cutler-hammer.com
Effective 7/02
I.B. 2C12060H05
This instruction booklet is published solely for informa-

tion purposes and should not be considered all inclu-
sive. If further information is required, you should con-
sult Cutler-Hammer.
Sale of product shown in this literature is subject to

terms and conditions outlined in appropriate Cutler-
Hammer selling policies or other contractual agreement
between the parties. This literature is not intended to
and does not enlarge or add to any such contract. The
sole source governing the rights and remedies of any
purchaser of this equipment is the contract between the
purchaser and Cutler-Hammer.
NO WARRANTIES, EXPRESSED OR IMPLIED,

INCLUDING WARRANTIES OF FITNESS FOR A PAR-
TICULAR PURPOSE OR MERCHANTABILITY, OR
WARRANTIES ARISING FROM COURSE OF DEAL-
ING OR USAGE OF TRADE, ARE MADE REGARDING
THE INFORMATION, RECOMMENDATIONS AND
DESCRIPTIONS CONTAINED HEREIN. In no event
will Cutler-Hammer be responsible to the purchaser or
user in contract, in tort (including negligence), strict lia-
bility or otherwise for any special, indirect, incidental or
consequential damage or loss whatsoever, including but
not limited to damage or loss of use of equipment, plant
or power system, cost of capital, loss of power, addition-
al expenses in the use of existing power facilities, or
claims against the purchaser or user by its customers
resulting from the use of the information, recommenda-
tions and description contained herein.
Cutler-Hammer
Pittsburgh, Pennsylvania U.S.A.
Effective 7/02(ISI)
Style 2C12060H05
Printed in U.S.A.
150 W S in g le O150W�Single�Output�Switching�Power�Supply
u tput Switching Power Sup pl y aSs--115500 sseer irei es s
��
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SPECIFICATION
MODEL AS150-5
S-150-5 AS150-7.5
S-150-7.5 AS150-9
S-150-9 AS150-12
S-150-12 AS150-13.5
S-150-13.5 AS150-15
S-150-15 AS150-24
S-150-24 AS150-27
S-150-27 AS150-48
S-150-48
DC�VOLTAGE 5V 7.5V 9V 12V 13.5V 15V 24V 27V 48V
RATED�CURRENT 30A 20A 16.7A 12.5A 11.2A 10A 6.5A 5.6A 3.2A
CURRENT�RANGE 0�~�30A 0�~�20A 0�~�16.7A 0�~�12.5A 0�~�11.2A 0�~�10A 0�~�6.5A 0�~�5.6A 0�~�3.2A
RATED�POWER 150W 150W 150.3W 150W 151.2W 150W 156W 151.2W 153.6W
RIPPLE�&�NOISE�(max.) Note.2 150mVp-p 150mVp-p 180mVp-p 180mVp-p 180mVp-p 180mVp-p 240mVp-p 240mVp-p 240mVp-p
OUTPUT VOLTAGE ADJ.�RANGE 4.5�~�5.5V 6�~�8.3V 8�~�10.4V 10.6�~�13.2V 12�~�15V 13.5�~�16.5V 21�~�28V 24�~�30V 43�~�53V
VOLTAGE�TOLERANCE Note.3 2.0% 1.0% 1.0% 1.0% 1.0% 1.0% 1.0% 1.0% 1.0%
LINE�REGULATION 0.5% 0.5% 0.3% 0.3% 0.3% 0.3% 0.2% 0.2% 0.2%
LOAD�REGULATION 0.5% 0.5% 0.3% 0.3% 0.3% 0.3% 0.2% 0.2% 0.2%
SETUP,�RISE�TIME 100ms,�50ms�at�full�load
HOLD�TIME (Typ.) 28ms�at�full�load
VOLTAGE�RANGE 88�~�132VAC/176�~�264VAC�selected�by�switch��248�~�370VDC
FREQUENCY RANGE 47�~�63Hz
EFFICIENCY (Typ.) 78% 80% 80% 82% 83% 84% 85% 86% 87%
INPUT
AC�CURRENT (Typ.) 3.2A/115VAC��1.6A/230VAC
INRUSH�CURRENT (Typ.) COLD�START 35A
LEAKAGE�CURRENT <3.5mA /�240VAC
105�~�150% rated�output�power
OVER�LOAD
Protection�type�:�Shut�down�o/p�voltage,�re-power�on�to�recover
PROTECTION
5.75�~�6.75V 8.63�~�10.13V 10.35�~�12.2V 13.8�~�16.2V 15.53�~�18.2V 17.25�~�20.3V 30�~�34.8V 31.1�~�36.45V 55.2�~�64.8V
OVER�VOLTAGE
Protection�type�:�Shut�down�o/p�voltage,�re-power�on�to�recover
WORKING�TEMP. -10�~�+60 (Refer�to�output�load�derating�curve)
WORKING�HUMIDITY 20�~�90%�RH�non-condensing
ENVIRONMENT STORAGE�TEMP.,�HUMIDITY -20�~�+85 ,�10�~�95%�RH
TEMP.�COEFFICIENT 0.03%/ (0�~�50
VIBRATION 10�~�500Hz,�2G�10min./1cycle,�60min.�each�along�X, Y,�Z�axes
SAFETY STANDARDS UL1012,�UL60950-1, TUV�EN60950-1 Approved
WITHSTAND�VOLTAGE I/P-O/P:3KVAC��I/P-FG:1.5KVAC��O/P-FG:0.5KVAC
SAFETY & ISOLATION�RESISTANCE I/P-O/P,�I/P-FG,�O/P-FG:100M�Ohms/500VDC
EMC EMI�CONDUCTION�&�RADIATION Compliance�to��EN55022�(CISPR22)�Class�B
(Note�4) Compliance�to EN61000-3-2,-3
HARMONIC�CURRENT
EMS�IMMUNITY Compliance�to�EN61000-4-2,3,4,5,6,8,11;�ENV50204,�EN55024,�Light�industry�level,��criteria A
MTBF 286.7K�hrs�min.��MIL-HDBK-217F�(25 )
OTHERS DIMENSION 199*110*50mm�(L*W*H)
PACKING 0.8Kg;�16pcs/13.8Kg/0.95CUFT
��
NOTE
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File�Name:S-150-SPEC��2005-09-13
300 Myles Standish Blvd., Taunton, MA 02780
WWW.ASTRODYNE.COM Ph: 1-800-823-8082 Fax: 508-823-8181
150 W S in g le O150W�Single�Output�Switching�Power�Supply
u tput Switching Power Sup pl y aSs--115500 sseer irei es s
Mechanical�Specification Case�No.�906��Unit:mm
192
5 172
100
6
12
3.5
1
2
9.5
4
110
97
5
8.2
6
5-M3
7
37
199
6 190.5
6.5
12
16.5
3.5
24.5
3.5
20
50
25
3-
M3
20 159
Terminal�Pin.�No Assignment
Pin�No. Assignment Pin�No. Assignment
1 AC/L 4,5 DC�OUTPUT -V
2 AC/N 6,7 DC�OUTPUT +V
3 FG
Derating�Curve Static�Characteristics�(24V)
Ta=25
32 350
100
OUTPUT�RIPPLE�(mVp-p)
2 28 300
OUTPUT�VOLTAGE�(V)
80
24 250
1
1 S-150-5~12�CONVECTION
60 2 S-150-15~48�CONVECTION 20 200
S-150-5~12�FORCED AIR
LOAD�(%)
16 150
40
12 100
20
8 50
-10 0 10 20 30 40 50 60 (VERTICAL) 80 85 90 95 100 105 110 115 120 125 130

-10 0 45 55 (HORIZONTAL) 160 170 180 190 200 210 220 230 240 250 260
AMBIENT�TEMPERATURE�( ) INPUT�VOLTAGE�(V)�60Hz
File�Name:S-150-SPEC��2005-09-13
300 Myles Standish Blvd., Taunton, MA 02780
WWW.ASTRODYNE.COM Ph: 1-800-823-8082 Fax: 508-823-8181
PFC500/PDC500 Series Data Sheet
Features
• RoHS lead solder exemption compliant
• Power Factor Correction meets EN61000-3-2 (AC input
versions)
• Fully-regulated outputs
• Remote sense
• Logic level Inhibit
• Current Share, Power Fail, and Power Good Signals
• Overtemperature, overvoltage, and overcurrent protected
• Available with metric or SAE mountings
• Input transient & ESD compliance to
EN61000-4-2/-3/-4/-5
• Fan output voltage and optional fan
• Optional isolation diodes for parallel or redundant
operation
• DC input versions (36-75VDC)
Description
The PFC500/PDC500 products of the PerFormanCe Power Series combine high performance midrange power with
high power density (4.4 watts/in3) and high reliability to meet the requirements of communications, commercial, and
industrial systems.
Providing tightly regulated DC power, the PFC500/PDC500 delivers full output performance with only 300 Linear Feet
per Minute (LFM) forced-air cooling (factory-installed fan optional). Main channel current sharing is provided for
redundant applications, and AC input units can be paralleled with DC input versions. Units are available with SAE
mountings or optional metric mountings.
The PFC500/PDC500 product line is approved to the latest international regulatory standards, and displays the CE
Mark.
Single-Output Model Selection

MODEL OUTPUT ADJUSTMENT MAXIMUM OUTPUT LINE LOAD RIPPLE & NOISE INITIAL SETTING
VOLTAGE RANGE CURRENT (NOTE 3) REGULATION REGULATION (NOTE 4) %p-p (NOTE 5) ACCURACY
PFC500-1024/PDC500-1024D 24V 21.6V to 26.4V 21A 0.5% 0.2% 1% 23.88V to 24.12V
(NOTE 1)
PFC500-1028 (NOTE 2) 28V 25.2V to 30.8V 17.9A 0.5% 0.2% 1% 27.86V to 28.14V
PFC500-1048 (NOTE 2) 48V 46.0V to 56.0V 10.4A 0.5% 0.5% 1% 47.52V to 48.48V
NOTES: 1) For AC input, use PFC500 prefix; use PDC500 prefix for DC input versions.
2) Consult factory for availability of 28V and 48V units with DC input.
3) Output currents ratings are expressed with 300 LFM forced air.
4) Remote sense connected. See Application Note #P1 for load regulation when using the D option for 24V units.
5) Maximum peak to peak noise expressed as a percentage of output voltage, 20 MHz bandwidth.
For ripple/noise on “D” option models, see options data on page 3.
PFC500 Input Specifications

PARAMETER CONDITIONS/DESCRIPTION MIN NOM MAX UNITS
Input Voltage - AC Continuous input range. 85 264 VAC
Input Frequency AC Input. 47 63 Hz
Brown Out Protection Lowest AC input voltage that regulation is maintained with full rated loads. 85 VAC
Hold-Up Time Over full AC input voltage range at full rated load. 20 ms
Input Current 85 VAC at full rated load. 7.8 ARMS
Input Protection Non-user serviceable internally located AC input line fuse, F10A, 250V.
Inrush Surge Current Internally limited by thermistor, one cycle, 25°C. 110 VAC 35
APK
220 VAC 65
Power Factor Per EN61000-3-2. 0.98 W/VA
Operating Frequency Switching frequency of main transformer. 100 kHz
AUG 01, 2003 revised to JUL 13, 2006 Page 1 of 4 www.power-one.com

PDC500 Input Specifications

Input Voltage - DC Continuous input range. Full power at 42-75 VDC. 36 75 VDC
Derate linearly from 40 VDC to 36 VDC, 400W.
Low Voltage Protection Lowest DC input voltage. 34 VDC
Hold-up Time At full load over DC input range. 17 ms
Input Current 48 VDC at full rated load. 14 ADC
Input Protection Non-user serviceable internally located fuse.
Inrush Surge Current Vin = 75 VDC, cold thermistor. TBD APK
Output Specifications (PFC500 and PDC500)

Efficiency Full rated load, 110 VAC (PFC500)/ 48VDC (PDC500). 75 %
Minimum loads PFC/PDC500-1024 0.6
PFC500-1028 0.6 Amps
PFC500-1048 1.2
Ripple and Noise Full load, 20 MHz bandwidth. See Model Selection Charts
Output Power 300 LFM forced air cooling required for operation. See optional fan. 500 Watts
Continuous power, multiple output models. PDC500 requires derating below
42 VDC; see PDC500 input specifications.
Overshoot / Undershoot Output voltage overshoot/undershoot at turn-on. 0 V
Regulation Without connection of remote sense. PFC/PDC500-1024 0.8
PFC500-1028 0.7 %
PFC500-1048 1.0
Transient Response Recovery time, to within 1% of initial set point due to a 50-100% load change,
1 ms
3% max. deviation.
Turn-on Delay Time required for initial output voltage stabilization. 1 Sec
Turn-on Rise Time Time required for output voltage to rise from 10% to 90%. 10 ms
Interface Signals and Internal Protection (PFC500 and PDC500)

Overvoltage Protection PFC/PDC500-1024 27.0 30.7
PFC500-1028 32.0 35.0 V
PFC500-1048 60.0 70.0
Overload Protection Fully protected against output overload and short circuit. Automatic recovery upon removal of overload condition.
Overtemperature Protection System shutdown due to excessive internal temperature, automatic reset.
Remote Sense Total voltage compensation for cable losses with respect to the main output. 250 mV
Current Share Accuracy of shared current with up to 6 parallel units. 10 %
Inhibit TTL compatible logic signal will inhibit outputs by the application of a logic low signal.
An open circuit or external TTL high signal allows normal operation.
Input Power TTL compatible logic signal. Time before regulation dropout due to 4 ms
Fail Warning loss of input power at 110 VAC.
Power Good TTL compatible signal. Signal is low if main output is greater PFC/PDC500-1024 22.08 27.36
or less than 10% of nominal. For models without the PFC500-1028 25.20 30.80 V
“D” option, internal pull-up resistor is 1k For “D” option, PFC500-1048 44.20 54.72
pull-up resistor is 475. See Apps Note #P1 for details.
Fan Voltage Provides 170mA current to user supplied fan if fan option is not selected. 12 V

Safety, Regulatory, and EMI Specifications

Agency Approvals UL1950. UL 60950 / CSA60950-00 (cULus Mark)
Approved
EN60950 (TÜV). PDC500 (Pending).
Dielectric Withstand Meets reinforced insulation of IEC60950.
Electromagnetic Interference FCC CFR title 47 Part 15 Sub-Part B - Conducted. B
Class
EN55022 / CISPR 22 Conducted. B
ESD Susceptibility Per EN61000-4-2, level 4. 8 kV
Radiated Susceptibility Per EN61000-4-3, level 3. 10 V/M
EFT/Burst (PFC500) Per EN61000-4-4, level 4. ±4 kV
EFT/Burst (PDC500) Per EN61000-4-4, level 4. TBD kV
Input Transient Protection PFC500 Per EN61000-4-5 class 3. PDC500 (class 2) Line to Line (PFC500) 1
Line to Ground (PFC500) 2
Line to Line (PDC500) 0.5 kV
Line to Ground (PDC500) 0.5
Insulation Resistance Input to output. 10 M
Leakage Current (PFC500) Per EN60950, 264 VAC. 2.0 mA
Environmental Specifications
Altitude Operating. 10k ASL Ft.
Non-Operating. 40k ASL Ft.
Operating Temperature At 100% load 0 50 °C
Derate linearly above 50°C by 2.5% per °C. At 50% load 0 70 °C
Storage Temperature -55 85 °C
Forced Air Cooling Forced air cooling of 300 LFM (400 LFM for PDC500) is required if the internal
fan is not specified Cooling air velocity is measured at the output exiting window
(2.5” x 5”). Airflow direction is from the input section to the output section.
Temperature Coefficient 0°C to 70°C (after 15 minute warm-up). ±0.02 ±0.05 %/°C
Relative Humidity Non-Condensing. 5 95 %RH
Shock Operating: 10±3mSec, 3 axis, Half Sine. 20 G
Non-operating: 10±3mSec, 3 axis, Half Sine. 40
Vibration Operating: 5-32Hz 0.02 in (DA)
32-2000Hz Sinusoidal 1 GPK
Non-operating: 6.15 GRMS
Options
DESCRIPTION NOTES SIZE IMPACT
Isolation Diodes Add “D” as a suffix to the model number to order factory installed isolation diodes N/A
for parallel or redundant operation. For 24V models with the “D” option, external caps
are required to meet the 1% noise/ripple spec. Power Good has a pull-up
resistor of 475 on the 24V models. See Application Note #P1 for details.
Fan Add “F” as a suffix to the model number to order integral fan. 10.50" x 5.00" x 2.50"
Fan provides the required 300 LFM (400 LFM for PDC500) of forced air cooling, (266.7mm x 127.0mm x 63.5mm)
or otherwise provided by the end user.
Metric Mounting Add “M” as a suffix to the model number to order chassis with
N/A
M4 x 0.7 mounting inserts.

Overall Size: 9.00" x 5.00" x 2.50" (228.6mm x 127.0mm x 63.5mm)

Overall Length With Fan: 10.50" (266.7mm)
Weight: 4.3 lb (1.95 kg)
SUGGESTED AIRFLOW *
DC+ or
DC- or
Input and Output Connections: 6-32 Screw Terminal on 0.375" (9.5mm) centers
Chassis: 0.090" (2.3mm) Aluminum Alloy, With Clear Finish
* Airflow should be measured at the exiting window (5” x 2.5”).
NUCLEAR AND MEDICAL APPLICATIONS - Power-One products are not designed, intended for use in, or authorized for use as critical
components in life support systems, equipment used in hazardous environments, or nuclear control systems without the express written consent of
the respective divisional president of Power-One, Inc.
TECHNICAL REVISIONS - The appearance of products, including safety agency certifications pictured on labels, may change depending on the
date manufactured. Specifications are subject to change without notice.

GLC50 Commercial/GLM50 Medical
50 WATT GLOBAL PERFORMANCE SWITCHERS
GLOBAL PERFORMANCE SWITCHERS
Features:
DC Power Supplies
• Cost-effective power source
• Universal input 90-264 Vac
• 2-year warranty
• Compact (4.25” x 2.50” x 1.25”; meets
1U applications)
• Overload and overvoltage protection
• Conducted EMI exceeds FCC Class B and
CISPR 22 Class B (Commercial models) and
CISPR 11 Class B (Medical models)
• Commercial UL/CSA/IEC60950-1, EN60950 approvals
• Medical UL/EN/IEC60601-1, CSA22.2 No. 601,
• RoHS compliant models available (G suffix)
• marked to LVD
SPECIFICATIONS
Ac Input Temperature Coefficient
90-264 Vac, 47-63 Hz single phase.. 0.03%/°C typical on all outputs.
Input Current Output Noise
Maximum input current at 120 Vac, 60 Hz with full rated output load: 1.5 A 0.5% rms, 1% pk-pk, 20 MHz bandwidth, differential mode. Measured with noise
probe directly across output terminals of the power supply.
Hold-Up Time
15 ms minimum from loss of ac input at full load, nominal line (115 Vac). Transient Response
500 μs typical response time for return to within 0.5% of final value for a 50% load
Output Power
step change. ∆i/∆t<0.2 A/μs. Maximum voltage deviation is 3.5%. Startup/shut-
50 W continuous, 60 W peak. Peak ratings are for 60 s maximum duration,
down overshoot less than 3%.
10% duty cycle. During peak load condition, output regulation may exceed
total regulation limits. Voltage Adjustment
Built-in potentiometer adjusts V1 ±5%.
Output Regulation
To maintain specified regulation on multi-output models, output #1 load EMI/EMC Compliance
power must be at least 1/5th of, and not greater than 5 times output #2 load All models include built-in EMI filtering to meet the following emissions require-
power. ments:
Overload Protection EMI SPECIFICATIONS COMPLIANCE LEVEL
Fully protected against short circuit and output overload. Short circuit pro-
tection is cycling type power limit on outputs 1 & 2; foldback type on output Conducted Emissions GLC EN55022 Class B; FCC Class B
3. Recovery after fault is automatic. See output ratings chart for additional Conducted Emissions GLM EN55011 Class B; FCC Class B
notes or conditions. Static Discharge EN61000-4-2, 6 kV contact, 8 kV air
Efficiency RF Field Susceptibility EN61000-4-3, 3 V/meter
70-85% at full rated load, nominal input voltage, depending on model and Fast Transients/Bursts EN61000-4-4, 2 kV, 5 kHz
load distribution. Surge Susceptibility EN61000-4-5, 1 kV diff., 2 kV com.
Minimum Load Commercial Leakage Current
Operating without minimum load will not degrade reliability, but regula- 160 μA 254 Vac @ 60 Hz input (with no deviations).
tion may be affected. Multiple output models require 20% minimum load
on V1 for proper regulation. Single models require 5% minimum load when Commercial Safety
a transient load greater than 30% is applied or removed, but will operate All GLC models are approved to UL1950, CSA22.2 No.
without load. 234 Level 3, IEC950 and EN60950.
Input Protection Medical Leakage Current

Internal ac fuse provided. Designed to blow only if a catastrophic failure oc- 100 μA 264 Vac @ 60 Hz input (normal conditions).
curs in the unit—fuse does not blow on overload or short circuit.
Medical Safety
Inrush is limited by internal thermistors. Inrush at 240 Vac, All GLM50 models are approved to UL/EN/IEC60601-1, CSA22.2 No. 601.
averaged over the first ac half-cycle under cold start
conditions will not exceed 37 A.
All specifications are typical at nominal input, full load at 25OC unless otherwise stated
Commercial Medical Minimum Total
Model Model Output No. Output Current Load (B) OVP Setpoint Noise P-P Regulation (A)
GLC50A GLM50A 1 +5.05 V 4A 0.8 A 6.2 ± 0.6 V 50 mV 2%
2 +12 V 2.5 A 120 mV +10%,-5%
3 -12 V 0.2 A 120 mV 3%
GLC50B GLM50B 1 +5.05 V 4A 0.8 A 6.2 ± 0.6 V 50 mV 2%
2 +15 V 2.5 A 150 mV +10%,-5%
3 -15 V 0.2 A 150 mV 3%
GLC50D GLM50 D 1 +5.05 V 4A 0.8 A 6.2 ± 0.6 V 50 mV 2%
2 +24 V 1.5 A 240 mV +10%,-5%
3 -12 V 0.2 A 120 mV 3%
GLC50G GLM50G 1 +3.3 V 4A 0.8 A 4.2 ± 0.6 V 33 mV 2%
2 +12 V 2.5 A 120 mV +10%-5%
3 -12 V 0.2 A 120 mV 3%
GLC50-3.3 GLM50-3.3 1 3.3 V 8A 0.2 4.2 ± 0.6 V 66 mV 2%
GLC50-5 GLM50-5 1 5.1 V 8A 0.4 6.2 ± 0.6 V 75 mV 2%
GLC50-12 GLM50-12 1 12 V 4.2 A 0.2 14 ± 1.1 V 120 mV 2%
GLC50-15 GLM50-15 1 15 V 3.3 A 0.16 18.5 ± 1.5 V 150 mV 2%
GLC50-24 GLM50-24 1 24 V 2.1 A 0.1 28 ± 2.5 V 240 mV 2%
GLC50-28 GLM50-28 1 28 V 1.8 A 0.09 34.5 ± 2.8 V 280 mV 2%
GLC50-48 GLM50-48 1 48 V 1.1 A 0.05 54 ± 3.0 V 480 mV 2%
Notes:
A. Total regulation is defined as the maximum deviation from the nominal voltage for all steady-state conditions of initial voltage setting, input line voltage and output load.
B. To maintain specified regulation on multi-output models, output #1 load power must be at least 1/5th of, and not greater than 5 times output #2 load power.
C. Add “G” suffix to model number for RoHS compliant model.
GLC50 MECHANICAL SPECIFICATIONS
ENVIRONMENTAL SPECIFICATIONS OPERATING NON-OPERATING

Temperature (A) 0 TO 50°C -40 to +85°C A. Units should be allowed to warm up/operate under non-condensing condi-
Humidity (A) 0 to 95% RH 0 to 95% RH tions before application of power. derate output current and total output
power by 2.5% per °C above 50°C.
Shock (B) 20 gpk 40 gpk
B. Shock testing—half-sinusoidal, 10 ± 3 ms duration, ± direction, 3 orthogonal
Altitude -500 to 10,000 ft -500 to 40,000 ft axes, total 6 shocks.
C. Random vibration—10 to 2000Hz, 6dB/octave roll-off from 350 to 2000Hz, 3
Vibration (C) 1.5 g rms’ 0.003 g /Hz
2
5 g rms’ 0.026 g2/Hz
orthogonal axes. Tested for 10 min./axis operating and 1 hr./axis non-operating.
SL Power Electronics Corp, 6050 King Drive, Bldg. A, Ventura, CA 93003, USA. Phone:(805) 486 4565 Fax:(805) 487 8911 www.slpower.com. Rev. 1/07.
Data Sheet © 2007 SL Power Electronics Corp. The information and specifications contained in this data sheet are believed to be correct at time of publication.
However, Condor accepts no responsibility for consequences arising from reproduction errors or inaccuracies. Specifications are subject to change without notice.
TYPE CMP HIGH VOLTAGE FILTER CAPACITORS
GENERAL DESCRIPTION
TYPE CMP CAPACITORS offer superior electrical

characteristics coupled with small size. They are
designed to meet or exceed the requirements of MIL-C-
19978/3E.
TYPE CMP CAPACITORS are designed for wide

range of uses including filter, spark suppression,
bypass, coupling applications (in the low audio
frequency range), energy storage, laser discharge,
power factor correction, etc. The CQ72-style case and
internal construction permit operation in any position.
Glazed ceramic bushings are used, and the threaded
stud terminal is supplied with a nut, lockwasher and/or
solder lug. The entire assembly is hermetical sealed.
SPECIFICATIONS
TEMPERATURE RANGE: -55 TO + 85 °C.
CAPACITANCE: 0.001 uF. to 100 uF.
RATED VOLTAGE: 600 VDC to 50,000 VDC
TOLERANCE: ±10% standard.
IMPREGNATION: Type CMP capacitors are impregnated and filled with silicone oil and hermetically sealed.
CASE: Tern Plate Steel.
FINISH: Military Gray Synthetic Enamel.
TERMINAL: All metallized hermetic terminals are used to insure perfect seals. Terminals meet L5
requirements of MIL-I-10 specifications. For voltages > 30kV, a single bushing with a
threaded ground stud is employed to assure safety and stability.
DIELECTRIC: Polyester Resin film and the finest grade Kraft Paper impregnated with silicone oil.
BRACKETS: Footed Mounting Brackets are available and are not included with the capacitor.
MOUNTING POSITION: All type CMP capacitors will operate satisfactorily mounted in any position.
TEST VOLTAGE: For capacitors rated ≤20kV, 200% rated voltage applied terminal-to-terminal for one minute
at room temperature. For rated voltages between 20 kV and 50 kV, 150% rated voltage for
two minutes at room temperature. For terminal to case, rating is same above plus 1 kV. Test
voltage shall be applied and discharged through a resistance of at least 1 Ω/rated volt to
maximum of 5 kΩ.
FLASHOVER: For rated voltages ≤5kV, capacitor terminal will with stand 125 %rated voltage at a pressure
of 12 kPa, (1.7 psia or 0.12 bar), equivalent to 50,000 feet altitude. For rated voltage of ≥6
kV, terminals will with stand 125% rated voltage at a pressure of 68kPa (10 psia), equivalent
to 10,000 feet altitude.
6455 N. Avondale Avenue Chicago, Illinois 60631

PHONE: 773-774-6666 FAX: 773-774-6690
www.capacitorindustries.com E-mail: CCC @ capacitorindustries.com
APPLICATION NOTES
SIZE: The case sizes listed below are not necessarily the smallest possible for a given capacitor. If a
custom size and shape are required by your application, CCC will be pleased to work with you to
optimize to your needs. CCC stocks a wide range of can sizes in several styles. If the revised design
employs a stock can, no cost penalty should be incurred. If a custom can is required, cost depends
heavily on quantity.
IMPREGNANT: CMP capacitors are premium products impregnated with silicone dielectric fluid, which is about ten
times more expensive than high grade mineral oil. The use of mineral oil in CMP designs results in
substantial cost reductions, at the expense of operating temperature range and flammability. Should
your design allow the use of mineral oil impregnated, CCC will be pleased to quote on mineral oil
impregnated design.
CONTAINER: At the highest voltages, the large ceramic terminals required become a substantial portion of material
costs. Capacitor cost can be reduced by either specifying only one terminal (with the other grounded
to the case) or one terminal rated for the full voltage with the other rated for a much lower voltage
(for example, when one terminal will be connected to neutral). While CMP capacitors can be
fabricated to any voltage level, above 50kV, CCC’s BAM capacitors tend to be much more cost
effective. These capacitors are fabricated in an insulating tubular container with the terminal at each
end. The case, therefore, becomes the insulation between the terminals. For further detail, see
CCC’s BAM catalog.
WINDING DESIGN: Capacitors can be constructed in a range of winding designs (e.g., extended foil, tab constructions,
etc.) and can be fabricated from a wide range of dielectric materials including polypropylene,
polyester (“Mylar”), polycarbonate, etc. with varying layers and configurations of paper. Each
combination of construction and material has its advantages and disadvantages. Your successful
application of any high technology capacitor depends on matching the capacitor design to your
requirements. Using its computerized design programs, CCC will work with you to determine your
requirements and customize the design gives the greatest current carrying capability and lowest ESR
at the expense of a somewhat higher inductance than can be achieved with tab design. The
inductance and ESR in tab designs depends on the number of tabs. Increasing the number of tabs in
a winding increases the time required in manufacture, and, therefore, the cost to the customer. Mylar
is a good general-purpose dielectric with a relatively high dielectric constant which results in a
smaller capacitor than polypropylene; however, polypropylene has much better high frequency
characteristics. The proper use of fluid-impregnated paper layers is important in capacitors which
see frequent and wide swings in voltage (ac, pulse discharge, etc.), as it provides a medium with
greater tolerance to electron injection in highly stressed regions of the capacitor.
Chicago Condenser Corporation Manufactures a wide variety of impregnated plastic film and paper dielectric
capacitors in many styles, including metal cans, non-conducting cases, “wrap-and-fill” with axial leads, and capacitor bypass
feedthroughs. Some MIL Spec product lines (e.g., CP53 “bathtubs” and CQ72) are available. During our sixty years in
business, we count many of the world’s largest corporations among our customers in the fields of lasers, military electronics,
scientific apparatus, etc. While CCC has standard product line, such as that represented in this catalog, it manufactures
essentially all products to order, typically with eight to ten weeks delivery. As a result of this semi-custom manufacture,
product characteristics can be customized through alterations in winding type, winding materials, etc. to optimize the product
for the user’s application. For this reason, CCC maintains expert engineering staff ready to help customers determine their
needs. The brief applications information on the next page introduces some of the relevant criteria.

PHONE: 773-774-6666 FAX: 773-774-6690
Part Number Volt uF W T L

CMP-104-3M 3,000 0.1 1.75 1 2.13
CMP-254-3M 3,000 0.25 2.5 1.19 2.5
CMP-504-3M 3,000 0.5 1.75 1 3.25
CMP-105-3M 3,000 1 1.75 1 4.75
CMP-205-3M 3,000 2 3.75 1.25 4.25
CMP-405-3M 3,0003 4 3.75 2.25 4.25
CMP-605-3M ,000 6 3.75 1.75 4.75
CMP-805-3M 3,000 8 437 3.75 4.75
CMP-106-3M 3,000 10 4.57 3.75 5
CMP-126-3M 3,000 12 3.75 3.19 6.75
CMP-156-3M 3,000 15 4.57 3.75 6
CMP-206-3M 3,000 20 4.57 3.75 10
CMP-256-3M 3,000 25 8 4 9.25
CMP-306-3M 3,000 30 8 4 9.25
Inches CMP-503-4M 4,000 0.05 1.75 1 2.13

CMP-104-4M 4,000 0.1 1.75 1 2.13
CMP-254-4M 4,000 0.25 1.75 1 2.25
CMP-504-4M 4,000 0.5 1.75 1 4
Part Number Volt uF W T L CMP-105-4M 4,000 1 2.5 1.19 4
CMP-104-6C 600 0.1 1.75 1 2.13 CMP-205-4M 4,000 2 3.75 1.25 4.75
CMP-254-6C 600 0.25 1.75 1 2.13 CMP-405-4M 4,000 4 3.75 2.25 4.75
CMP-504-6C 600 0.5 1.75 1 2.13 CMP-605-4M 4,000 6 3.75 2.25 6.5
CMP-105-6C 600 1 1.75 1 2.13 CMP-805-4M 4,000 8 3.75 3.19 6
CMP-205-6C 600 2 1.75 1 3.25 CMP-106-4M 4,000 10 4.57 3.75 5.5
CMP-405-6C 600 4 1.75 1 4.75 CMP-126-4M 4,000 12 4.57 3.75 6.5
CMP-605-6C 600 6 2.5 1.19 4.5 CMP-156-4M 4,000 15 4.57 3.75 8.5
CMP-805-6C 600 8 2.5 1.19 5.5 CMP-206-4M 4,000 20 4.57 3.75 10.5
CMP-106-6C 600 10 3.75 1.25 4.5 CMP-256-4M 4,000 25 8 4 11
CMP-126-6C 600 12 3.75 1.25 4.75 CMP-306-4M 4,000 30 13.5 4.13 7
CMP-156-6C 600 15 3.75 1.25 4.75
CMP-206-6C 600 20 3.75 1.75 4.75 CMP-503-5M 5,000 0.05 1.75 1 2.13
CMP-256-6C 600 25 3.75 2.25 5.75 CMP-l04-5M 5,000 0.1 1.75 1 2.13
CMP-306-6C 600 30 3.75 3.19 4.75 CMP-254-5M 5,000 0.25 1.75 1 3
CMP-504-5M 5,000 0.5 1.75 1 4.75
CMP-104-1M 1,000 0.1 1.75 1 2.13 CMP-105-5M 5,000 1 2.5 1.19 4.75
CMP-254-1M 1,000 0.25 1.75 1 2.13 CMP-205-5M 5,000 2 3.75 2.25 4.75
CMP-504-1M 1,000 0.5 1.75 1 2.13 CMP-405-5M 5,000 4 4.57 3.75 3.75
CMP-105-lM 1,000 1 1.75 1 2.13 CMP-60-5M 5,000 6 4.57 3.75 4.75
CMP-205-1M 1,000 2 1.75 1 3.5 CMP-805-5M 5,000 8 4.57 3.75 6.25
CMP-405-1M 1,000 4 2.5 1.19 3.75 CMP-106-5M 5,000 10 4.57 3.75 7.5
CMP-605-1M 1,000 6 2.5 1.19 4.75 CMP-126-5M 5,000 12 4.57 3.75 9.5
CMP-805-1M 1,000 8 2.5 1.19 4.75 CMP-156-5M 5,000 15 8 4 9.25
CMP-106-1M 1,000 10 3.75 1.25 4.5 CMP-206-5M 5,000 20 8 4 11
CMP-126-1M 1,000 12 3.75 1.75 4.75 CMP-256-5M 5,000 25 13.5 4.13 9.25
CMP-156-lM 1,000 15 3.75 1.75 4.75 CMP-306-5M 5,000 30 13.5 4.13 9.25
CMP-206-1M 1,000 20 3.75 2.25 4.75
CMP-256-1M 1,000 25 3.75 2.25 6.25 CMP-104-6M 6,000 0.1 3.75 1.25 2.25
CMP-306-1M 1,000 30 4.57 3.75 4 CMP-254-6M 6,000 0.25 3.75 1.25 2.5
CMP-504-6M 6,000 0.5 3.75 1.25 3.75
CMP-104-2M 2,000 0.1 1.75 1 2.13 CMP-105-6M 6,000 1 3.75 1.75 4.5
CMP-254-2M 2,000 0.25 1.75 1 2.13 CMP-205-6M 6,000 2 3.75 2.25 5.75
CMP-504-2M 2,000 0.5 1.75 1 2.13 CMP-405-6M 6,000 4 4.57 3.75 6
CMP-105-2M 2,000 1 2.5 1.19 3.5 CMP-605-6M 6,000 6 4.57 3.75 8.25
CMP-205-2M 2,000 2 2.5 1.19 3.5 CMP-805-6M 6,000 8 4.57 3.75 10.25
CMP-405-2M 2,000 4 2.5 1.19 4.75 CMP-106-6M 6,000 10 8 4 9.25
CMP-605-2M 2,000 6 3.75 1.25 4.75 CMP-126-6M 6,000 12 8 4 11
CMP-805-2M 2,000 8 3.75 1.75 4.75 CMP-156-6M 6,000 15 13.5 4.13 7
CMP-106-2M 2,000 10 3.75 2.5 5.25 CMP-206-6M 6,000 20 13.5 4.13 9.25
CMP-126-2M 2,000 12 3.75 2.25 4.75 CMP-256-6M 6,000 25 13.5 4.13 11
CMP-156-2M 2,000 15 3.75 2.25 6 CMP-306-6M 6,000 30 13.5 5 12.875
CMP-206-2M 2,000 20 3.75 3.19 5.75
CMP-256-2M 2,000 25 4.57 3.75 5.5 CMP-104-8M 8,000 0.1 2.5 1.19 3
CMP-306-2M 2,000 30 4.57 3.75 5.75 CMP-254-8M 8,000 0.25 2.5 1.19 4.75
Part Number Volt uF W T L Part Number Volt uF W T L

CMP-504-8M 8,000 0.5 3.75 2.25 4 CMP-503-15M 15,000 0.05 3.75 1.75 3.5
CMP-105-8M 8,000 1 3.75 2.25 4.75 CMP-104-15M 15,000 0.1 3.75 1.75 3.75
CMP-205-8M 8,000 2 3.75 3.19 6.875 CMP-254-15M 15,000 015 3.75 3.19 5
CMP-405-8M 8,000 4 4.57 3.75 9 CMP-504-15M 15,000 0.5 3.75 3.19 6.5
CMP-605-8M 8,000 6 8 4 11 CMP-105-15M 15,000 1 4.57 3.75 8
CMP-805-8M 8,000 8 13.5 4.13 9 CMP-205-15M 15,000 2 8 4 11
CMP-l06-8M 8,000 10 13.5 4.13 9.25 CMP-405-15M 15,000 4 13.5 4.13 11
CMP-126-8M 8,000 12 13.5 4.13 9.25
CMP-156-8M 8,000 15 13.5 4.13 13.13 CMP-103-20M 20,000 0.01 3.75 2.25 3.25
CMP-206-8M 8,000 20 13.5 5.13 12.875 CMP-203-20M 20,000 0.02 3.75 215 315
CMP-503-20M 20,000 0.05 3.75 215 3.75
CMP-104-10M 10,000 0.1 3.75 1.75 3.25 CMP-104-20M 20,000 0.1 3.75 2.25 3.75
CMP-254-10M 10,000 0.25 3.75 1.75 4 CMP-254-20M 20,000 015 3.75 3.19 6
CMP-504-10M 10,000 0.5 3.75 1.75 4.75 CMP-504-20M 20,000 0.5 4.57 3.75 6
CMP-105-10M 10,000 1 3.75 2.25 7.25 CMP-105-20M 20,000 1 8 4 815
CMP-205-10M 10,000 2 4.57 3.75 6.5 CMP-205-20M 20,000 2 13.5 4.13 9.5
CMP-405-10M 10,000 4 8 4 9.25
CMP-605-10M 10,000 6 13.5 4.13 7 CMP-103-25M* 25,000 0.01 3.75 3.19 3.5
CMP-805-10M 10,000 8 13.5 4.13 9.25 CMP-203-25M* 25,000 0.02 3.75 3.19 3.5
CMP-106-10M 10,000 10 13.5 4.13 11 CMP-503-25M* 25,000 0.05 3.75 3.19 4
CMP-126-10M 10,000 12 13.5 4.13 13.13 CMP-104-25M* 25,000 0.1 3.75 3.19 4.75
CMP-156-10M 10,000 15 13.5 5.13 12.875 CMP-254-25M* 25,000 0.25 4.57 3.75 6.5
CMP-504-25M* 25,000 0.5 4.57 3.75 10.5
CMP-503-12.5M 12.500 0.05 3.75 1.75 3 CMP-105-25M 25,000 1 8 4 8
CMP-104-12.5M 12.500 0.1 3.75 1.75 3.625
CMP-254-12.5M 12.500 0.25 3.75 1.75 4.75 CMP-103-30M* 30,000 0.01 3.75 3.19 2.5
CMP-504-12.5M 12.500 0.5 3.75 3.19 4.625 CMP-203-30M* 30,000 0.02 3.75 3.19 2.5
CMP-105-12.5M 12.500 1 4.57 3.75 5.5 CMP-503-30M* 30,000 0.05 3.75 3.19 4.5
CMP-205-12.5M 12.500 2 4.57 3.75 10 CMP-104-30M* 30,000 0.1 4.57 3.75 4
CMP-405-12.5M 12.500 4 13.5 4.13 9.25 CMP-254-30M* 30,000 0.25 4.57 3.75 7.5
CMP-605-12.5M 12.500 6 13.5 4.13 11 CMP-504-30M 30,000 0.5 13.5 4.13 7
CMP-805-12.5M 12.500 8 13.5 5.13 12.875 CMP-105-30M 30,000 1 13.5 4.13 13.13
CMP-106-12.5M 12.500 10 13.5 5.13 13.75
CMP-502-40M* 40,000 0.005 4.57 3.75 5
CMP-103-15M 15,000 .01 3.75 1.75 3.25 CMP-103-40M* 40,000 0.01 4.57 3.75 5
CMP-203-15M 15,000 0.02 3.75 1.75 31 CMP-203-40M* 40,000 0.02 4.57 3.75 5
CMP-503-40M* 40,000 0.05 4.57 3.75 5.5
CMP-104-40M* 40,000 0.1 4.57 3-.75 9
CMP-254-40M 40,000 0.25 13.5 4.13 9.25
CMP-504-40M 40,000 0.5 13.5 5.13 12.875
CMP-203-50M* 50,000 0.02 4.57 3.75 7.5

CMP-503-50M* 50,000 0.05 4.57 3.75 9.5
CMP-104-50M 50,000 0.1 8 4 9.25
CMP-254-50M 50,000 0.25 13.5 4.13 13.75
CMP-504-50M 50,000 0.5 13.5 5.13
WARNING: HIGH VOLTAGE
Many of the products in this catalog can store lethal voltages and energies. Utmost care should be exercised in the use of
these products to assure that voltage or power source is disconnected and that the capacitor is discharged, grounded, and
shorted before servicing equipment into which a capacitor has been installed. Installation should comply with all federal,
state, and local electrical code requirements.

PHONE: 773-774-6666 FAX: 773-774-6690
Smoothwound Resistors
• DESCRIPTION
Post Glover Smoothwound Resistors are designed and built to meet the most demanding mechanical and electrical requirements in the
industry. They are constructed of a ni-chrome or stainless steel wire alloy wound on a porcelain tube.The element is then covered with a
refractory cement coating either with or without a silica sand additive. The coating aids in dissipating heat, elevating the permissible watt
rating.
• FEATURES
Post Glover Smoothwound resistors are available in through-bolt or flat bar
mounting arrangements. This makes Post Glover Smoothwound Resistors directly
interchangeable with most major brands. Individual coils can be manufactured
with either fixed or adjustable taps.
• APPLICATION
Our Smoothwound Resistor is the best you can buy for applications where high
resistance and low currents are the main criteria. This resistor is especially well
suited for use in;
• Dynamic braking with low duty cycle or small motors,
• Low voltage neutral grounding,
• Elevator controls.
PART NUMBER: CSW___-____

OHM VALUE = Specified to no more than one decimal place
SIZE = 2 through 6
TYPICAL RANGE * DIMENSIONS IN INCHES
SIZE AMPERAGE RESISTANCE L OD ID

2 1–20 A 0.5 - 225 Ω 6 2 1 1/4
3 1–20 A 1 - 450 Ω 9 2 1 1/4
4 1–20 A 1.25 - 550 Ω 12 2 1 1/4
5 1–20 A 1.5 - 850 Ω 15 2 1 1/4
6 1–20 A 2 - 1000 Ω 18 2 1 1/4
L ID
OD
* These are typical ratings only. Other ratings are possible for special case, including using a 1.5” diameter core.
Please contact the factory for additional assistance.
4750 Olympic Blvd • Erlanger, Kentucky 41018 • USA

Toll free 800-537-6144 • Facsimile (859) 283-2978
www.postglover.com
PGR Document #007-05
T498A,B
Electric Heat Thermostats
PRODUCT DATA
FEATURES
• CSA Performance Certifled at 16A.
• CSA Certified, Underwriters Laboratories Inc. Listed

up to 5 kW at 277 Vac.
• Long life, industrial-grade Micro Switch™ mechanism.
• Rugged, engineering plastic mounting base with

captive mounting screws.
• Replaces any standard wall-mounted electric heat

thermostat.
• Classic beige styling.
• Range: 40°F to 80°F (5°C to 25°C).
• Locking cover and range stops are optional.
• Energy efficient and economical.
GENERAL
The T498A,B Electric Heat Thermostats provide line voltage
control of electric heating equipment. A snap action switch
makes heating circuit on temperature fall.
Contents
General ............................................................................... 1
Features .............................................................................. 1
Specifications ...................................................................... 2
Ordering Information ........................................................... 2
Installation ........................................................................... 3
Setting and Checkout .......................................................... 4
Security Features ................................................................ 4
Calibration ........................................................................... 5
Copyright © 1996 Honeywell Inc. • • All Rights Reserved X-XX UL

95C-10686-3
T498A,B ELECTRIC HEAT THERMOSTATS
CSA Performance Certification:

SPECIFICATIONS 16A at 208/240 Vac.
IMPORTANT Setpoint Adjustment:
The Specifications given in this publication do not Control knob on face of thermostat.
include normal manufacturing tolerances. Therefore,
this unit may not exactly match the listed Sensing Element:
specifications. Also, this product is tested and Flat bimetallic blade.
calibrated under closely controlled conditions, and
some minor differences in performance can be Differential:
expected if those conditions are changed. For exact Approximately 3°F (2°C) nonadjustable.
engineering specifications, contact your Honeywell
sales representative. Dimensions:
See Fig. 1 for nominal dimensions.
Models:
T498A: Makes heating circuit on temperature fall. With Thermometer:
setting knob on extreme counterclockwise position, Optional coil bimetal 50°F to 90°F (10°C to 30°C).
provides single line break—spst (see Fig. 2).
T498B: Makes heating circuit on temperature fall. With Mounting Means:
setting knob at OFF position, provides double line Direct mounting on NEMA standard vertical 2 x 4 inch
break for fuse protected 240V heating circuits (see (50 mm x 100 mm) switch box, or 4 x 4 inch (100 mm x
Fig. 3). Remakes circuit no higher than -31°F (-35°C) in 100 mm) box with mud ring adapter (not provided) using
OFF position. Both models available with a 6-32 slotted Robertson™ screws.
thermometer located in the cover to indicate the actual
room temperature. Approval:
Underwriters Laboratories Listed: File No. E47434, Guide
Setting Range: No. XAPX.
40°F to 80°F, markings every 5°F. CSA: File No. LR1322
Type of Switching: Accesories (Not Included):
Fully enclosed snap acting Micro Switch™. 272804A Range Stop and Locking Screws Assembly:
T498A: Single line break (spst). Includes locking cover screws, Tinnerman clips,
T498B: Spst with double line break (dpst in OFF position). wrench, and range stops—two plastic pins to insert
inside cover for field-selection of minimum and
Wiring Connections: maximum temperature settings.
Six inch (150 mm) stranded copper leadwires suitable for 272805H Replacement Cover Assembly: For T498B
connecting to aluminum wiring if approved special service Fahrenheit beige models (manufactured after
CO/ALR connectors are used. Color-coded Black to Ll November, 1993—date coded after 9345).
(T498A,B); Red to L2 (T498B only).
Electrical Rating (Noninductive (resistive) rating):

22A noninductive at 120/208/240 Vac.
19A noninductive at 277 Vac.
ORDERING INFORMATION
When purchasing replacement and modernization products from your TRADELINE® wholesaler or distributor, refer to the
TRADELINE® Catalog or price sheets for complete ordering number, or specify:
1. Order Number. 3. Accessories, if desired.
2. Switching. 4. Order additional system components and system accessories
separately.
If you have additional questions, need further information, or would like to comment on our products or services, please write or
phone:
1. Your local Home and Building Control Sales Office (check white pages of your phone directory).
2. Home and Building Control Customer Logistics
Honeywell Inc., 1885 Douglas Drive North
Minneapolis, Minnesota 55422-4386 (612) 951-1000
In Canada—Honeywell Limited/Honeywell Limitée, 155 Gordon Baker Road, North York, Ontario M2H 2C9.
International Sales and Service Offices in all principal cities of the world. Manufacturing in Australia, Canada, Finland, France,
Germany, Japan, Mexico, Netherlands, Spain, Taiwan, United Kingdom, U.S.A.
95C-10686—3 2
1-1/4 1 Leave the cover on the thermostat while making

(33)
connections.
1-1/32
(26)
2 Push the leadwires into the outlet box and insert the
thermostat into the box for mounting by pushing against
5/8 (16) the cover.
50
60
70 3 Remove the thermostat cover by grasping the top and
bottom edges and pulling outward.
80 4 Turn the dial so that the setpoint indicator is at the
40
OFF 3-9/32
(83)
12 o’clock position. This will prevent accidental damage
to the dial stop during mounting.
4-17/32
2-3/32
(53) 5 Using a screwdriver, secure the thermostat to the outlet
(116) box by tightening the two mounting screws. Handle the
thermostat with care; excessive pressure can damage
the control knob or sensing element.
1/2 (13)
CAUTION
15/16
2-29/32 (72)
(24)
1. Disconnect power supply before making wiring
M6089A
connections to prevent electrical shock or
Fig. 1. Nominal dimensions in in. (mm). equipment damage.
2. All wiring must comply with applicable codes and
RECYCLING NOTICE 3
ordinances.
Thermostats are designed to be used with a
If this control is replacing a control that contains separate limit control in the appliance.
mercury in a sealed tube, do not place your old
control in the trash. 6 Using wire connectors approved for No. 12 wires, make
line voltage wiring connections directly to the leadwires
Contact your local waste management authority for installed on the thermostat.
instructions regarding recycling and the proper
disposal of any control containing mercury in a
sealed tube. CAUTION
If connecting with aluminum conductors, use
If you have any questions, call Honeywell Inc. at approved CO/ALR solderless wire connectors to avoid
1-800-468-1502. fire hazard.
INSTALLATION L2
T498A 2
WARNING 1 3
HIGH VOLTAGE CONTROL. L1 L1

(HOT)
ELECTRICAL SHOCK HAZARD.
This thermostat is a line voltage (120 to 277 volt)
control. Do not install this thermostat if you are not T1
completely familiar and competent with electrical
wiring. If improperly handled, there can be risk of 120
to 277 volt electric shock hazard that can cause
serious injury or death. 4
Location ELECTRIC
HEATER
Install a vertical outlet box that is used to mount the T498, four
to five feet (1.5m) above the floor on an inside wall where the 1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
thermostat will be subjected to average room temperature. PROTECTION AS REQUIRED.
2 USE SPECIAL SERVICE CO/ALR SOLDERLESS CONNECTORS

Mount the thermostat away from concealed warm or cold water WHEN CONNECTING ALUMINUM CONDUCTORS OR A FIRE
HAZARD MAY RESULT.
pipes, warm air ducts, light switches and dimmers, refrigerators
or drafts from hallways, fireplaces, stairways or fans. 3 BREAKS AND REMAKES BELOW -31°F(-35°C); NORMALLY
THERMALLY ACTIVATED. BREAKS ON A TEMPERATURE RISE;
MAKES ON A TEMPERATURE FALL.
Mounting and Wiring 4 USE A SEPARATE LIMIT CONTROL IN THE HEATING APPLIANCE.
When replacing an old line voltage electric heating M6091A
thermostat, remove the old thermostat carefully to avoid

damaging the insulation on the wiring. Fig. 2. Typical hookup for T498A Thermostat.
Check the old insulation for cracks, nicks, or fraying and apply
approved electrical tape where necessary to achieve adequate
insulation, or replace the wires using approved methods.
3 95C-10686—3
L2 2
T498B
1 3 6
L1 L1 L2
(HOT) RED WIRE
5
T1 T2
50 60
4
70
40
ELECTRIC
HEATER OFF
80
1 POWER SUPPLY. PROVIDE DISCONNECT MEANS AND OVERLOAD
PROTECTION AS REQUIRED.
2 USE SPECIAL SERVICE CO/ALR SOLDERLESS CONNECTORS

WHEN CONNECTING ALUMINUM CONDUCTORS OR A FIRE
HAZARD MAY RESULT.
°F
3 BREAKS AND REMAKES BELOW -31°F(-35°C); NORMALLY

50
THERMALLY ACTIVATED. BREAKS ON A TEMPERATURE RISE; 60
MAKES ON A TEMPERATURE FALL. 70
80
90
4 USE A SEPARATE LIMIT CONTROL IN THE HEATING APPLIANCE.
5 BREAKS AT POSITIVE OFF ONLY; NOT THERMALLY ACTIVATED.
6 DO NOT CONNECT GROUNDED CONDUCTORS (NEUTRAL) ON

120V OR 277V CIRCUITS. INSULATE AND TAPE, OR CUT OFF
RED WIRES IF UNUSED. M6092A
Fig. 3. Typical hookup for T498B Thermostat. M7236
Fig. 4. Locking cover installation.

SETTING AND CHECKOUT
IMPORTANT Range Stops
Make sure all wiring connections are tight. 1 Set the thermostat to the desired setpoint. Remove the
cover.
After the thermostat has been installed and wired, simulate 2 Install the plastic dowels (included) into the minimum
normal operation as follows. and/or maximum range stop holes on the inside back of
1 Turn the setting dial completely clockwise. The electric the cover. See Fig. 5.
heater should start to heat. 3 Replace the cover. Check the operation of the range
2 Turn the dial completely counterclockwise. The power stops.
circuit should be broken and the electric heater should
start to cool.
3 To determine the final setting, move the dial indicator to
the 70°F (21°C) position on the scale. If the setting is
not satisfactory after a minimum of two hours of
thermostat operation, turn the dial indicator to raise or
lower the temperature. Move the indicator only a few
degrees each time an adjustment is necessary.
RANGE STOP
SECURITY FEATURES HOLES
Locking Cover
1 Remove cover by swinging up from the bottom edge of
the thermostat.
2 Insert the Tinnerman Speed Nut® (included) into the
slot on the lower back of thermostat base. See Fig. 4.
3 Insert the Allen screw into the Speed Nut until the
screw head is flush with the lower edge of the
thermostat base.
4 Replace the thermostat cover and lock by removing the M7238
Allen screw until screw body protrudes through the
cover hole.
5 To unlock the cover, insert the Allen screw into the
thermostat base until the screw body clears the cover. Fig. 5. Range stop installation.
95C-10686—3 4
CALIBRATION
The T498 Thermostats are calibrated at the factory using
precise instruments under closely controlled conditions.
Recalibration should not be necessary. Allow the thermostat
to operate for several hours before checking calibration. 50 60
Temperature deviations of 2°F (1°C) are normal. If the
70
40
thermostat is mounted in a suitable location and still appears
out of calibration, check calibration using the procedures that OFF
follow.
80
Check Calibration
1 Remove the thermostat cover and set it aside for
°F
several minutes. Radiant heat from your hands will
affect the thermometer reading.
50
2 Turn the setting dial clockwise until the switch makes 60
70
(clicking sound) and the heating equipment and fan 80
90
start.
3 No recalibration is necessary if the thermostat switch
makes with the thermostat setting at the same
temperature as indicated on the thermostat cover
thermometer.
4 If the thermostat setting differs from the thermometer, APPLY NEW INSERT DECAL
record the temperature difference and recalibrate as M7237
instructed in the Recalibration Procedure section.
Recalibration Procedure Fig. 6. Thermostat recalibration.

1 Note the temperature difference between the
thermostat setting and the thermometer.
2 Turn the setting dial clockwise until the switch makes
(clicking sound).
3 Remove the adhesive backing of the indicator decal
provided.
4 Carefully align the indicator mark on the decal with the
correct temperature setting number on the cover. See
Fig. 6.
5 Using finger pressure, secure the realigned decal on
the center of the knob.
6 Wait five minutes and recheck the calibration.
5 95C-10686—3






















































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Basler ECS2100

Excitation Control Equipment

ECS2100 EXCITATION SYSTEM INSTRUCTION MANUAL

ROUTE 143, BOX 269

PURPOSE AND APPLICATION

Excitation System Types

Excitation System Control Modes

Publication Revision First Printing: Copyright

Incoming Line Section

Power Amplifier Section

EXCITATION CONTROL FUNCTIONS AND CIRCUITS

Exciter Control Module

Publication Revision First Printing: Page

Page First Printing: Revision Publication

DIGITAL FIRING CONTROL

POWER AMPLIFIERS (THYRISTOR CONVERTERS)

ISOLATION TRANSDUCERS (DC-DC FIELD TRANSDUCERS)

SENSOR INPUT MODULE (AC ISOLATION TRANSDUCER)

FAN CONTROL CIRCUIT

Page First Printing: Revision Publication

Publication Revision First Printing: Page

Page First Printing: Revision Publication

Publication Revision First Printing: Page

Page First Printing: Revision Publication

9410100990 Rev - Introduction i

© 2007 Basler Electric, Highland Illinois 62249 USA

All Rights Reserved

SECTION 2 • EQUIPMENT HANDLING ................................................................................................... 2-1

SECTION 3 • INSTALLATION................................................................................................................... 3-1

SECTION 4 • MAINTENANCE .................................................................................................................. 4-1

SECTION 5 • MAINTENANCE SCHEDULE ............................................................................................. 5-1

9410100990 Rev - Introduction iii

iv Introduction 9410100990 Rev -

1-2 General Information 9410100990 Rev -

Recommended Storage Procedures

Alternate Storage Procedures

9410100990 Rev - Equipment Handling 2-1

MOVING EQUIPMENT SECTIONS

2-2 Equipment Handling 9410100990 Rev -

SETTING THE EQUIPMENT SECTIONS IN PLACE

WIRE AND CABLE INSTALLATION

Wire and Cable Sizing

Testing Power Cables

Terminals and Lugs

Protective Relays and Devices

3-2 Installation 9410100990 Rev -

9410100990 Rev - Installation 3-3

3-4 Installation 9410100990 Rev -

Keep Connections Clean and Tight

Keep Up With the Changes

9410100990 Rev - Maintenance 4-1

INSPECTION AND MAINTENANCE NOTES

Printed Circuit Boards

Bus, Cable, and Terminations

4-2 Maintenance 9410100990 Rev -

De-Excitation/Crowbar (DXCB) Module (ECS2100 Systems Only)

Fiber Optic and Ribbon Cable

Ground Detector Module/Relay

Metal-Oxide Varistors (MOVs)

PanelMate (ECS2100 Systems Only)

4-4 Maintenance 9410100990 Rev -

Rectifier Chassis (Power Drawer)

Shaft Suppression Module

Voltraps (Where Equipped)