Bi006008 00 01 - Body PDF

BI006008
Bucyrus
All Rights Reserved
BUCYRUS
R
Technical Manual
BI006008
DANGER:
THIS MANUAL IS INTENDED TO PROVIDE INFORMATION AND DATA FOR
MAl ~TENANCE AND OPERATION ON THIS MACHINE. THE ELECTRICAL
ECUIPMENT INVOLVED SHOULD BE SERVICED ONLY BY QUALIFIED
INDIVIPUALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH
VOLTJ GE SYSTEMS AND WARD-LEONARD LOOP DC DRIVES. FAILURE TO
COMPLY WOULD RESULT IN PERSONAL INJURY OR DEATH.
,
_-0
DANGER:
DO NO ATTEMPT ANY MAINTENANCE, MECHANICAL OR ELECTRICAL, ON

THIS InACHINE WITHOUT FULL UNDERSTANDING OF THE COMPONENT
OPERA ION AND INTERNAL PARTS. COMPONENTS UTILIZING ELECTRICAL;
POWEF, AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR . ,.
TENSION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND
ISOLATED PRIOR TO DISASSEMBLY.
The FEEDE ~ CABLE must contain a provision for a ground connection, especially where
2300 volts end above are used. The power line end must attach (see the paragraph on
ground circ its) to a suitable permanent ground. The machine end must securely attach
through a b Ited connection to ground the machine frame. This provides a constant
ground for t lie machine and electrical equipment. Failure to provide this adequate
ground endi ngers employees and equipment.
POWER LINE. GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZEl . Without a good grounding system, high voltage exists between the
machine and the ground. The portable cable and power lines supplying the machine
must have a ~round wire, ample in capacity, running parallel to the main wires over the
entire distanc e from the transformer to the machine. A suitable grounding system must
be used at th ~ transformer. Consult the local electric supplier for details.
DANGER:
DUE TO INHERENT DANGERS IN THE OPERATION OF ANY HIGH VOLTAGE
ELECTRICJl L EQUIPMENT, A SAFE GROUNDING SYSTEM SHOULD INCLUDE
GROU ~D CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING
RESIS' OR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND
CcDNTINUITv CHECK SYSTEM IS ALSO RECOMMENDED.
BI006008
BI006008
Marion
182M Mining Shovel
ELECTRICAL SERVICE MANUAL No. 2243

-SN: 23367, 23368
Table of Contents -
This man al is divided into several sections covering various systems and their electrical components of the
1 2M Mining Shovel. Refer to book 2 of this manual for vendor instructions and publications.
Book 1:
Int oduction
Sect on
1 - SYSTEM OVERVIEW
Sectipn
2 - SYSTEM COMPONENTS and OPERATION
Secti pn
3 - STANDARDS for ELECTRICAL INSTALLATION
Secti< n 4
- CABLE PULLING SCHEDULE
Part No. 140G1 Rev. C

Part No. 211945-5 Rev. A
Sectic n
5 -ELECTRicAL SETTINGS
Secticn
6 - EXCAVATOR THEORY
Sectior
7 - DC 2000 DRIVE SYSTEM and INSTRUCTION MANUALS
Sectio)
8 - FIELD EXCITER INSTRUCTIONS
Sectio
9 - BRAKE INSTRUCTIONS
Sectior
10 - MOTOR CONTROL CENTER
Part No. 211946-3
Part No. 212656-7
Book 2:
Introd~ction
Section 11 - ELECTRICAL SCHEMATICS OVERVIEW

Section 12 - ELECTRICAL SCHEMATICS
SN: 23367
Part No. 211944-7 Rev. C
SN: 23368
VENDOR PUBLICATIONS:
Rota ing Equipment
Con 01
Supr ort Devices
IMPORTANT NOTE
The infonnation and documer ation enclosed were developed and assembled by The 1\larion Power Shovel Company ("l\'farion")~ a subsidiary ofGJobal Industrial
Technologies, Inc., for the lim ted purpose of relating necessary technological material to our customers. The contents herein were developed and produced at
substantial expense and are v lued by Manon at a proprietary level. Therefore, this information and docurnenk'1tion is being furnished solely for use with the
subject machine and is not to e used, reproduced or disclosed in any way, in whole or in part, without the prior express written permission of Marion.
1997
The Marion Power Shovel Company
2243-I.M61
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BI006008
Introduction
-
GENERA INFORMATION
Table of Contents _
Page
..................................................
SAFETY LERT SYMBOLS
ii
"
SAFETY P ECAUTIONS.................................................... iii

FIRE PRE ENT/ON
"
TRAINING
vi
WARRANT
vii
2243-1.1V161
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Introduction
GENERAL INFORMATION
This man
of this rna
personnel
maintena
used for t
al is designed to assist the owner in the operation and preventive maintenance

hine. Following easy to understand step-by-step procedures, maintenance
can perform these tasks in a safe manner. When a systematic and thorough
ce/service procedure (a responsibility of the maintenance superintendent) is
is machine, minimum unplanned downtime and reliable operation will result.
THIS MA UAL IS NOT THE PARTS BOOK, and cannot be used to order parts. A
separate, etailed parts book has been supplied. Please carefully read the instructions in
it. All parts re listed by group and/or product code numbers with item/part numbers for
THIS SPE IFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and
returned, a e subject to a rehandling charge. RIGHT HAND and LEFT HAND parts on the
upper fram correspond to the operator's hands at the controls; as seated when
operating t e machine. Please state the correct machine SERIAL NUMBER (located on a
plate in the perator's cab) when corresponding or contacting factory service or parts
department . Records on each machine are filed by serial number and when given this
number, yo r machine's specific design and original equipment is accessed quickly by
the Marion arts representative.
itions or revisions may be made to this manual. These will be mailed direct to
you from th factory. Shpuld you require additional information or factory service
assistance c ntact your regional service representative or
ustomer Service Department
T e Marion Power Shovel Company
6 7 West Center Street
P. .Box 505
M rion,OH 43301-0505
- or Telephone (614) 383-5211

Fax: (614) 382-2052
It is Marion's
licy to improve its products whenever possible and practical to do so. The
company rese ves the right to make changes or add improvements at any time without
incurring any bligation JO install such changes on machines sold previously.
tinuous program of product research and development some procedures,
nd parts may be altered in a constant effort to improve machines.
BI006008
SAFETY ALERT SYMBOLS
This safety alert symbol is used here and throughout this manual to call
your attention to instructions concerning your personal safety. Carefully
read and follow these instructions and observe all SAFElY, DANGER, and
CAUTION graphics mounted on various areas of the machine.
Be certain anyone servicing this machine is aware of these SAFElY SYMBOLS and their
definition. In the event you question your ability to safely perform any of the enclosed
maintenance and operational procedures contact your regional Marion service
representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the
safety alert signal is used.
ADANGER:
Denotes extreme intrinsic hazard which exists and could result

in high probability of death or irreparable injury if proper
precautions are ignored.
ACAUTION:
Denotes a reminder of safety practices or directs attention to

unsafe practices which could result in personal injury if proper
An example of a safety alert symbol and special instructions is shown below.
ADANGER:
Inherent danger exists in the operation of any high voltage

electrical equipment. A safe grounding system includes
ground conductors in the power cable, a neutral grounding
resistor, and related relays and switch-gear. A ground
continuity check system is required by law in many parts of the
world.
Operating, maintaining or servicing this machine is dangerous unless performed

properly. Each person must satisfy himself and his employer thathe is alert, has the
necessary skill, knowledge, proper tools and equipment, and that all the methods used
are safe and correct. Factory service representatives and specialists are available to
provide additional information or technical assistance.
The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or
medications that might effect his eyesight, hearing or reactions.
Safety must always be the most important concern. Consult your supervisor when safety
is in doubt.
ii
BI006008
SAFE
PRECAUTIONS
- The 0 ner and/or operator must replace any and all safety and warning product
graphi s if they are defaced or removed from the machine.
- Before doing any work on the machine, a qualified electrician must lock out or remove
the ele tric power supply from the machine and tag it so personnel are aware that
someo e is working on the machine.
- Do not tart an engine indoors unless adequate exhaust ventilators are provided. Once
an engi e is running, move the machine outdoors as soon as possible.
ds, feet, and clothing away from rotating parts.
- Do not ove or operate the machine without knowing the location and purpose of all
personn I, plus test or support equipment, in or near the machine.
ore you act. Carelessness is one luxury the service man cannot afford.
ar rings, wrist watches or loose fitting clothing when working on machinery.
They co Id catch on moving parts causing serious injury. Never adjust and/or service a
machine 'n bare feet, sandals or sneakers.
ar safety glasses when using a hammer, chisel or other tools that may cause
- Excessiv or repeated skin contact with sealants or solvents may cause skin irritation.
In case of skin contact, remove sealant or solvent promptly by washing with soap and
water.
- Never utili e the machine air or hydraulic systems for support when working on the
machine. eactivate and isolate the system prior to performing maintenance.
- Equipmen should be parked on level ground at all times during machine servicing and
periods of dleness.
- Cranes an hoists must be of sufficient capacity to lift the heavier components
(gearcases dipper/bucket, boom, etc.) and have an ample safety margin.
- Be sure he vy items are properly supported from cranes or hoists before removing
supporting embers from machine.
- Have suffici nt service personnel available when removing or installing large heavy
items to mal tain control at all times.
- Always use afety stands in conjunction with hydraulic jacks or hoists. Do not rely on
the jack or h ist to carry the load, they could fail.
- Use safety c tch on all hoist hooks. Do not take a chance, the load could slip off of the
hook.
iii
BI006008
- If a heavy item begins to fall, let it fall, don't try to catch it.
- When disassembling machine, be sure to use safety stands and adequate cribbing to
prevent tipping or rollover of components.
- Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and
parts off of the ground. Eliminate the possibility of a fall which could result in serious
injury.
- Floors, walkways and stairways must be clean and dry. After draining operations be
sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous
combination.
- Check all wire ropes for telltale signs of early wear or failure. Look for and secure any
loose bolts or locking devices.
- Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless qualified. Check limit
switches for proper operation.
- When using an acetylene torch, always wear welding goggles and gloves. Keep a
"charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are
separated by a metal shield and are chained to the cart. Do not weld or heat areas near
transformers or electrical cabinets and utilize proper shielding around lubrication lines.
- Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when
applicable. Use hammers, punches and chisels only when absolutely necessary. Then,
be sure to wear safety glasses.
- Be careful when using compressed air to dry parts. Use approved air blow guns, do
not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding
to protect everyone in the work area.
- Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or
servicing the machine.
- After servicing, be sure all tools, parts or servicing equipment are removed from the
machine, or secured in an appropriate storage area.
- Protective eye goggles should be worn at all times when working on the air
conditioning system. Work on the air conditioning system only in a well ventilated area.
- Wipe away excess lubricants around bearings and gears. Never lubricate parts in
motion.
- Operate machine on level ground and be constantly aware of swing clearance. Never
hold a load longer than needed in the dump cycle. Use swing brakes only when
machine is stopped.
iv
BI006008
FIRE PF EVENTION
-
Alway~
have a "charged" fire extinguisher on hand and know how to use it. Inspect and
servicE the extinguisher as indicated on its instruction plate.
- DO NC T smoke while handling flammables or when near batteries.

- lnspec all lines, tubes, and hoses carefully. Tighten all connections to the
recomr~ended torque. See the Visual Inspection Schedule for the walk around
inspect on procedure.
- Loose c r damaged lines, tubes, and hoses, which leak, can cause a fire.
- Make CE rtain that all clamps, guards, and shields are replaced correctly so as to
prevent yibration and the rubbing of one part against another which might result in
heat bui d-up during operation.
- DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
- DO NOT over-bend or strike pressurized hose lines. DO NOT install bent or damaged
lines, tul:es, or hoses. Replace them with new immediately.
- DO NOT start the machine or move any of the controls if a warning tag is attached to
the contr >Is or the start panel.
- Keep all c leaning rags properly stored. DO NOT discard them into a pile on board.
- Keep all s ructural frame compartments, walkways, and work areas clean and free of
lubricant residue.
- NEVER
WE
d, burn, or perform service on the machine alone.

,
- If a motor >r other component is running hot, shutdown the machine until it has cooled
and/or the cause eliminated.
BI006008
TRAINING
Qualified maintenance personnel using a scheduled maintenance program are the best
way to minimize machine downtime and maximize productivity of equipment.
Marion offers factory and mine site maintenance seminars and special familiarization
programs for mechanics, oilers, electricians and operators on a fee basis.
These programs are presented by qualified factory specialists and service technicians.
Special customized training programs can also be developed to meet specific mine
requirements.
Objectives of training and training materials are to provide the means for developing and
maintaining on-site service repair capability.
For further information about Marion service training capabilities and programs contact:
Customer Service Department
617 West Center St.
P.O.Box 505
Marion, OH 43301-0505
vi
BI006008
R PAIR/SPARE PARTS WARRANTY

The Marion ower Shovel Company ("Marion"), a subsidiary of Global Industrial Technologies,
Inc., warran s that its products, when shipped, for a period of six (6) months from the date of
delivery, F. .B. point of shipment, will meet applicable, agreed specifications, if any with
respect ther to, and will be free from defects in material and workmanship, provided that the
Marion prod cts sold are properly stored, assembled, used and maintained. Products not
manufactur d by Marion shall be subject only to such warranty as may be made by the
manufactur thereof. All claims under this warranty must be made in writing immediately
upon discov ry. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
WHATSOE R, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT
L1MITATIO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.
Should any f i1ure of the Marion products to conform to this warranty appear within the limited
time period s t forth above, Marion shall, upon Buyer's submission of a claim as provided
above, either 1) repair or replace, F.O.B. point of shipment, any nonconforming part or parts of
Marion's pro ucts which hc;we been returned to it for examination, transportation prepaid, or
otherwise ex mined by Marion, and which examination discloses the nonconformity to
Marion's satis action; or 2) refund an equitable portion of the purchase price.
THE FOREG ING IS MARION'S ONLY OBLIGATION AND BUYER'S EXCLUSIVELY
REMEDY FO BREACH OF WARRANTIES AND, EXCEPT FOR GROSS NEGLIGENCE,
WILLFUL MI CONDUCT, OR REMEDIES PERMITTED UNDER THE PERFORMANCE,
INSPECTION, AND ACCEPTANCE CLAUSE OF MARION'S TERMS AND CONDITIONS, THE
FOREGOING S BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR ALL CLAIMS
ARISING WIT RESPECT TO MARION PRODUCTS OR RELATING THERETO, WHETHER
SUCH CLAIM ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING
NEGLIGENCE AND STRICT LIABILITY) OR OTHER THEORIES. BUYER'S FAILURE TO
SUBMIT A CL 1M AS PROVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR
DAMAGES 0 OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON
LATENT DEFE TS.
IN NO EVENT INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED
WARRANTIES NO REMEDIES) SHALL BUYER BE ENTITLED TO ANY INDIRECT,
SPECIAL, INCI ENTAL OR CONSEQUENTIAL DAMAGES, WHETHER ARISING FROM
LATE PERFOR ANCE OR A FAILURE TO PERFORM, DEFICIENCIES OR NEGLIGENCE
IN THE DESIG ,MANUFACTURE, SALE DELIVERY OR ASSEMBLY OF MARION
PRODUCTS 0 FAILUREOF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER
AND WHETHE BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE
AND STRICT LI BILlTY) OR OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH
RESPECT TO ARION PRODUCTS OR RELATING THERETO MUST BE COMMENCED
WITH ONE (1) EAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE
BARRED.
'---------l---------~--~-~-------------.----.~----.---.-----~.-.--.------~~
REV. 12/6/95
warranty. m60
vii
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---------------------------
--~---------------------
-----------------
------------------------------------------------
--------- --------
---------------- - - - - - - - - - - - - - - - - - - - - - - - - - - - -
viii
BI006008
Book #1
Section
System Overview
-
Table of Contents _
Page
"
1.1
ELECTRIC L SYSTEM OUTLINE
"
1.2
KEY INTER OCK SYSTEM -SN: 23367
"
1.3
KEY INTER OCK SYSTEM -SN: 23368
"
1.4
ONE-LINE E ECTR/CAL DIAGRAMS
"
1.5
SCRIPTION
Schematic
COMPRESSED AIR SYSTEM
SChematic -
UTO LUBE
SChematic -
UTO LUBE CONTROL
Machine Spe ifications -English

Machine Spe ifications -Metric
2243-1.M61
1.9
"
1.10
1.11
" 1.12
1.13
BI006008
BI006008
Section
System Overview
SYSTEM DESCRIPTION
This mach'ne is equipped with a totally static, variable voltage, digital D.C. control system
that can ccnvert and invert A.C. power to control D.C. motors. The control system consists
of the hoi~ t drag/propel and swing motions. The propel motion shares the drag electrical
system. TI" e swing function remains fully active during propel.
When motipn drive power is required, controlled gating of thyristors converts A.C. voltage
into variablE voltage D.C. This controlled D.C. controls the speed of and limits the current to
the drive m :::>tors.
When motipn plugging occurs, the D.C. drive motors act as generators. During these
periods, the mechanical energy is converted into electrical energy, which is inverted back
to A.C. by tt e thyristor bridge networks, and returned to the power network.
Refer to the ~ne-Line Diagrams of this electrical system starting on page 1.5 in this section
of the manu I. These will assist in understanding the system.
------t----.--
-.------.-.- -- - - - - - - - - - - -
----~-------~.----.-----.----.-----
------\----------_._--------------------------------
-------+-----------_._------
--------~._---------------------
._--- - - - - - . _ - - - - - - - - - - _ . - - - - - . - . - - - - - - - - - - - - - - - - - -
------(-----------_._---~---
1.1
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ELECTRICAL SYSTEM OUTLINE
..;
6.6 KV, 3-Phase, 50 Hertz Supply Voltage -Maximum Voltage Fluctuation + 10%/-20%.
..;
41E Volt AC Auxiliary Voltage, 55/110 Volt Secondary.
..;
150 KVA Dry Auxiliary Transformer.
..;
Vac~um
..;
War~-Leonard Power Conversion .
..;
Stat c DC Generator Field Exciters with Digital Control.
..;
Stati~
..;
Joys ick Control via Expander Boards.
..;
Elec ro-Mechanical Auto Lube Control.
..;
Auxil flry Collector Rings placed on the Machinery Deck for Maintenance Ease.
Contactor Control of M.G. Set Drive Motor with Reduced Voltage Starting.
Motor Field Exciters with Digital Cotrol.
-----+-----------~--~-----~--------------------------------
1.2
BI006008
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Il MI) HAS BEBC DEB..OPlD I.T S\e$TMmAL 0P0tSt.
ITS ~ AR TO 8 \10, ~ 011 DtSClO5O I.
DPflDSO) Ifl'ITTEIf P9lIIsstOlilOf ... NIJ mrs MAlt'UC NG
TO II 01 tDWD,-
IMPORTANT NOTE
OHIO
COLLECTOR RINGS
BOTTOM OF UPPER FRAME
MARION DIVISION OF
IMORESCO INC. MARION.
TRAIL CABLE
J. BOX
E
BOLT EXTENDED
W BOL T WITHDRAWN I .
L.O. LOCKED OPEN
L.C. LOCKED CLOSED
DENOTES DOORS MECHANICALLY
INTERLOCKED WITH LOCAL ISOLATOR
CABLE,
LOWER FRAME
DISCONNECT
DOOR
SN: 23367
DOOR
KEY INTERLOCK
SYSTEM
.1
DOOR
1944-7
L.C.
~ll~
AUXIL IARY
TRANSFORMER
FUTURE USE
(IF REQD.1
HIGH VOLTAGE CONTACTOR CABINET
DO~
H.V. FUSE CABINET
BI006008
BI006008
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IMPORTANT NOTE
AU. (:::()110 Of If StUU BE II{JUIbO TO .. C*
tJJwn
=:l.~;r1'l~~A=-"f'tl~I~T~~~O~~,*~
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OHIO
COLLECTOR RINGS
WARION DIVISION OF
IMORESCO INC. MARION.
E
BOLT EXTENDED I
W
SOL T W I T H D R A W N '
L.O. LOCKED OPEN
L.C. LOCKED CLOSED
DENOTES DOORS MECHANICALLY
CABLE
REEL
TRAIL CABLE
. J. BOX
-ntts flttlmlG rtO'fCD'n PROPfUfTNn JIf:) COtf'ltomt. tWOOMWOlf .1M) IS 1l o:a..l1SI~ PflCW'OlTY
Of MUrK* DfVlSI(lI Of ~ 1JK:..041 tJ HJ.S I'Io(D t(\{].MD AT SlSr~nlrt. D7OCS[.
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DOOR
SYSTFM
SN: 23368
DOOR
KEY INTERLOCK
E
.1
DOOR
FUTURE USE
tIF REQD.!
21?7R1- A
l.C.
~II~
AUXILIARY
TRANSFORMER
M.G. SET
DRIVE MOTOR
HIGH VOLTAGE CONTACTOR CABINET
Do~1
H.V. FUSE CABINET
BI006008
BI006008
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IMPORTANT NOTE
CABLE REEL
o
E
F
G
L
M
AUX XFMR
150 KVA
NOTES
liMit
IN
fH~~R~f >1
"(
FUSEO:~:_I ":li~ ""
MARION DIVISION OF
(BOIK)
DISCONNECT
3-P
,I l
'THi$ ORA-WING REPRESENTS Pf!OPRIETAR'f AWo COI4FIOHHllll INFORMATION PoND 15 THE EXCLUSIVE PfiOPUHY
OF MARION OlV1SJON Of INORESCO INC.(l.lll AND HAS 601 DVElOPED AT Sl)8STAN.TlAL OPENS,
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6600 V
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FAUL T
GROUNO
IA TRIP
MODULE
[C23A)
(C26A]
(C25C)
:L...Q __ ~
a=:1llr
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7.5 KVA
r.2::
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LTG
[003R) BUS
: o-1l1H-[0030)
L __ ~
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415 TO 55-0-55V
AUX.XFMR
3 KVA
H-----------
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
II
10
09
08
07
06
05
04
03
02
01
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[C22G]
125 VOC
CONTROL
BUS
c
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K
M
M-RUN
VACUUM
CONTACTOR
MARION DIVISION Of
INORESCO INC. MARION. OHIO
'OTES
... rUSE SPEC IAL

MARION DIY.
PIC 384340-8
[A28G]
NEUTRAL
STARTING
REACTOR
SGR
[C22K]
TR
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[c 13F]
GENERATOR
~11---
SWING
SGFE
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GENERATOR
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LHOIST
GENERATOR
HGFE
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P
01
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
II
10
09
08
07
OS
05
04
03
02
BI006008
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.....
ep
(A20V]--Q--UVR
IMPORTANT NOTE
or Wlote DlVISIOIII OF' ItClRSCO 1lC.00J III> HAS BEDI OC'lUJ

lll!llU0flE. IEITlfIJlM IIlAIl'" IlOfl ITS COIIlOOS MIf. ro
JIHOl Oft IN PMT wrlMGUT lIE PRtoIl: DPRESSED IRITTEJ(
AlL COf'e Of IT 3lLIU. BE ll[MJO ro II OIl _ . '
'"lN1! mAI1tC REJ'RESEMTS r'lWPl(l'MY 1M) a.:wltOtl .... Itl
I?
1%
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[A22V] --{-SHUNT
TRIP
WELD
ITE~R
F
G
AIR
CONDITIONER
POWER
INCOMING
415 V. AUX.
ANTI-COND.
HEATERS
1
--'V-
OHIO
SHUNT
TRIP
--;'..--0 MFT
.OTES
DC MOTOR
ZL
-<~[B25H] FIELD
EXCITERS
IX
I
I
IX
- < ~ f---o'Xr>-
2J
2G
'- _~rv ~ _ -J'7SIAIR
-<~~~COMPRESSOR
IX
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IX
MARION DIVISION OF
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30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
II
10
09
08
07
06
05
04
03
02
BI006008
BI006008
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24
23
22
21
20
19
18
17
16
15
14
13
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10
09
08
07
06
05
04
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MARION. OHIO
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WARION DIVISION OF
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SET DECREASING PRESSURE

AT 70 PSI (463 KPAj AND
SET INCREASING PRESSURE
AT "0 PSI (158 KPA)
.75 NOM. 1.0,
,50 NOM, 1.0.
AUXlUARY
COlLECTOR
RINGS
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REGULATOR SET
AT 120 PSI (627 KPA)
,50 NOM. 1.0.
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AT 100 PSI (689 KPAJ AND
AT 115 PSI (7113 KPAJ~
AT 70 PSI {463 KPAj :

(3 PlCS.)
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UPPER FRAME
GREASE PUMP
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SET DECREASING PRESSURE AT

10 PSI leg KPI\).\ND
SET INCREASING PRESSURE AT
95 PSI I6SS KPI\)
(li SWITCHES)
lOWER FRAME
BI006008
BI006008
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Auto Lube Crawler - Right
I
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Rotating Frame Grease
tiEA"
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Lube Hose.
Air Hose.
Drip Point.
0 - - - Bushing, Bearing.
- - - - Pipe, Steel Tube.
- - - - - Boundary of Drwg. Groul;
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MPG
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1
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L. & R. Crawler Lube Points - ,

10.12: Sprocket Bearing.
I
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1 - 9: Load Rollers.
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Auto Lube Control Center

GEA/IS
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.--NOTES:
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J. __ - - - - - - -----rI
Lube Crawler - Left
I
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Open Gears Swing
ROLLeR CtRClC
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BI006008
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1.11
BI006008
BI006008

Machine Specifications -English
Model: 182M MINI G SHOVEL
Description: Stand rd Range - Motor Generator Set
Specification: 182M-HR-17
No.633032387
182mhr17.w61
J~~-~~--J
----- G -------1------ L
----1
I
lJLl\-.I_._
~~
-..L-.I_._~_f'_==:::===~~l:==~+--.L---Li
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00
U
BOOM HANDLE DIPPE
UPPER FRAME
Boom Length
40'-2"
Boom Sheave Diameter - Pi ch Diameter
54"
Boom Foot Pin to Shipper S aft
16'-9"
Dipper Handle Length
27'-0"
Dipper Capacity, CU.Yds. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
S - Clearance Radius - Rear End . ,

,,
,
, , , . 24'-6"
T - Clearance Under Frame
,,,.,
,.,
,
5'-7"
U - Clearance Height - Gantry .. ",,' .. ,
,,'
29'-9"
V - Clearance Height - Filter House .,.,
" ,.,,,,
25'-3"
W - Eye Level - Operator's Cab, Standard ,
,
25'-2"
,
,
20'-5"
X - Clearance Width - Machinery House
Hoist Drum - Pitch Diameter
,,
, , , . , , , , , " 40"
Hoist Rope Diameter (Double Line) .", .. ,., ..... ". 2"
Boom Support Rope Diameter (Twin Dual) , , . , , . , , . . .. 2"
WORKING RANGES
Without Limits
A - Boom Angle
45
B - Dumping Height - Maxim
26'-6"
C - Dumping Radius @ Maxi um Height
47'-1"
D - Dumping Height @ Maxi
m Radius
18'-0"
E- Dumping Radius - Maximu
48'-10"
F - Cutting Height - Maximum
42'-9"
G - Cutting Radius @ Maximu Height
50'-10"
H - Cutting Height @ Maximu Radius
22'-9"
J - Cutting Radius - Maximum
56'-9"
K - Radius of Clean-up
,
, , . , , , 36'-5"
L - Clearance Radius - Outside Boom Point Sheave , .. , . 39'-2"
M - Clearance Height - Over B om Point Sheave ... ,.,. 41 '-1 "
ELECTRICAL EQUIPMENT
Cont.
Peak
Hoist Motor, 640 hp @ 475 V, Total hp " .. ,." 640
924
Swing Motors, Two, 130 hp @475 V, Total hp ... 260
378
Propel Motors, Two, 195 hp @ 475 V, Total hp ., 390
560
Crowd Motors, 130 hp @ 475 V, Total hp
130
189
Induction Driving Motor, Total hp . , . ,
,
,
800
Swing Speed, rpm
,,,,
,.,,
, , , , . , , . , , , . , 2,9
Travel Speed, mph, ""
,.,
,
", .. ".,. 1.0
Complies with the Indian Electricity Rules 1956 as amended,
WEIGHTS
Std.
Opt.
29'-9" . , , .. 29'-9"
N - Crawler Length
,,,,,
,,
0- Crawler Width .. ,
,.,,.,,,.,
22'-6" , , , , , 24'-1"
P - Belt Width ..,.,.......... , . . . , . . , , ., 39".,...., 59"
Bearing Pressure, Lbs,per S . In, .,.... 36.4
24.3
Q - Clearance Under Lower Fra e .. ,
2'-0" .. , . , , 2'-0"
R - Clearance Under Crawler Ge rcase .. , . " 19" ... , ... 19"
Patent Pending
Printed in U.S.A.
Shipping Weight, Lbs. ..,.,

"
,.""
660,000
Working Weight, Lbs
, , , , . , .. , , , , , , .. , , ,
780,000
Ballast (Furnished by Purchaser), Lbs. . ",
"",,120,000
Minimum Weight of Ballast, Lbs,/Cu,Ft. ... , ,
, , , ..... 250
Range and Weights Subject to Variation Due to Options Selected
by Purchaser,
The Comp y reserves the right to improve or change the design of its products and specifications thereof and the
Company sh II incur no liability thereby or any obligations to install such improvements on products previously sold,
1.12
BI006008
BI006008

Machine Specifications -Metric
Specification: 182M-HR-17
NO.633032387
Model: 182M MINI G SHOVEL

Description: Stand rd Range - Motor Generator Set
182mhr17.w61
1--------
-~~---'=-J
1
G
-.---- L
Meters
Boom Length. . . . . . . . . .
.
Boom Sheave Diameter - Pi ch Diameter
Boom Foot Pin to Shipper haft
Dipper Handle Length
Dipper Capacity, CU.Meters
12.24
1.37
5.10
8.23
10
WORKING RANGES
Without
A - Boom Angle
B - Dumping Height - Maxim m
C - Dumping Radius @ Maxi um Height
D - Dumping Height @ Maxi um Radius
E - Dumping Radius - Maxim m
F - Cutting Height - Maximum
Height
G - Cutting Radius @ Maxim
H - Cutting Height @ Maximu Radius
J - Cutting Radius - Maximum
K - Radius of Clean-up . . . .. .
L - Clearance Radius - Outsid Boom Point Sheave
M - Clearance Height Over B om Point Sheave
Limits
45
8.08
14.35
5.49
14.90
13.04
15.51
6.93
17.30
11.10
11.94
12.52
UPPER FRAME
S - Clearance Radius Rear End
T - Clearance Under Frame
U - Clearance Height - Gantry
V - Clearance Height - Filter House
,
,
W - Eye Level - Operator's Cab, Standard
X - Clearance Width - Machinery House
Hoist Drum - Pitch Diameter
Hoist Rope Diameter (Double Line), mm
Boom Support Rope Diameter (Twin Dual), mm
7.47
1.70
9.07
7.69
7.67
6.22
1.02
51.0
51.0
Hoist Motor, 477 kw, Total kw
Swing Motors, Two, 97 kw, Total hp
Propel Motors, Two, 145 kw, Total kw . . . . . . . ..
Crowd Motors, 97 kw, Total kw . ,
Induction Driving Motor, Total kw . ,
Swing Speed, rpm
Travel Speed, kph
,
Cont.
477
194
290
, 97
Peak
689
282
418
141
" 597
2.9
1.61
Complies with the Indian Electricity Rules 1956 as amended.
WEIGHTS
CRAWLER AND LOWER FR
N - Crawler Length. . . . . . . ..
0- Crawler Width
,
P - Belt Width
Bearing Pressure, Kgs.per S . Cm. .
Q - Clearance Under Lower Fra e
R - Clearance Under Crawler G arcase . . . ..
Patent Pending
Printed in U.S.A.
Std.
9.07
6.86
1.00
2.56
0.61
0.48
Opt.
9.07
7.34
1.50
,. 1.71
0.61
0.48
Shipping Weight, Kgs. .

Working Weight, Kgs
Ballast (Furnished by Purchaser), Kgs
Minimum Weight of Ballast, Kgs./Cu.Meter
299,400
353,800
54,400
4,005
Range and Weights Subject to Variation Due to Options Selected

by Purchaser.
The Comp ny reserves the right to improve or change the design of its products and specifications thereof and the
Company s all incur no liability thereby or any obligations to install such improvements on products previously sold.
1.13
BI006008
BI006008
Book #1
Section
System Components and Operation

-
Table of ContentsPage
2.1 LOW R FRAME

2.1.1
LOWE FRAME and CRAWLERS -Plan View. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.1.1
WIRIN -LOWER FRAME
2.1.2
WIR NG DISTRIBUTION -LOWER FRAME
2.1.4
2.1.5
LO ER FRAME DISCONNECT SWITCH BOX
" 2.1.6
LO ER FRAME CONTROL JUNCTION BOX
PR PEL BRAKE MAGNET VALVES .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.1.7
PR
EL MOTOR JUNCTION BOXES
2.1.8
CRA LER LUBE PRESSURE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.1.9
PRO ELBRAKES
2.1.10
ROPEL BRAKE PRESSURE SWITCHES
2.1.10
2.2.1
2.2 ROTAT NG FRAME
182M D CK PLAN
2.2.1
POW R FACTOR CAPACITOR HWT (insert)
2.2.3
2.2.5
I STRUCTIONS -HWT CAPACITORS GEH-2711 D (insert)
MAIN CO LECTOR RINGS (HV.)
2.2.7
AUXILIA Y COLLECTOR RING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.2.8
AUXI IARY COLLECTOR RING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . .. 2.2.9
COLL CTOR RING INSPECTION and ADJUSTMENT
2.2.10
E CLOSURE INSPECTION
2.2.12
F EQUENCY of INSPECTIONS
2.2.13
BUSH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.2.13
CABINET on the LEFT WING
2.2.15
DIG/P OPEL CONTACTOR CABINET
2.2.16
Sc ematic -DIG / PROPEL CONTACTOR
2.2.17
HIGH OLTAGE CABINET
2.2.18
LO TRAK MODULE
2.2.20
HI H VOLTAGE CABINET ELECTRICAL DIAGRAM
2.2.21
DC CO TROL CABINET
2.2.24
GENE ATOR FIELD EXCITER TRANSFORMERS
2.2.27
CABINETS on the RIGHT WING
2.2.28
GROU D FAULT CONTROL CABINET
2.2.29
Sch matic -GROUND FAULT CONTROL. . . . . . . . . . . . . . . . . . . . . . . .. 2.2.30
HIGH V LTAGE FUSE CABINET
2.2.31
MOTO CONTROL CENTER
2.2.32
BI006008
Page
AUTO LUBE CONTROL
182M AUTO LUBE CONTROL CENTER
WIRING -AUTO LUBE CONTROL PANELS
AUTO LUBE -ROTATING FRAME and OPEN GEARS
AUTO LUBE CONTROL PANEL
AUTO LUBE ELECTRIC CONTROL PANEL
CONTROL PANEL ELECTRICAL DIAGRAMS
AUTO LUBE LOWER FRAME
ELECTRIC CONTROL PANEL
BOOM JACKING LIMIT
BOOM JACKING LIMIT SWITCH
HOUSE AIR FILTRATION SYSTEM
MAINTENANCE
182M DYNAVANE AIR FILTERS
FILTER FAN START-UP PROCEDURES
FILTER FAN HOOK-UP CHART
BOARDING STAIRS
DIPPER TRIP
2.2.34
2.2.34
2.2.35
2.2.36
2.2.36
2.2.37
2.2.39
2.2.40
2.2.40
2.2.41
2.2.42
2.2.44
2.2.45
2.2.46
2.2.46
2.2.47
2.2.47
2.2.47
2.2.48
2.2.49
2.3 OPERATOR'S CONTROLS

2.3.1
2.3.1
182M OPERATOR'S CAB (Plan View)
OPERATOR'S SEAT
2.3.2
OPERATOR'S SEAT ADJUSTMENT
2.3.3
BOARDING STAIRS
2.3.3
OPERATING CONTROLS
2.3.5
PRIMARY CONTROLLERS
2.3.6
Left Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.6
Right Controller
2.3.6
182M JOYSTICK MACHINERY MOTIONS
2.3.7
MASTERSWITCHES (JOYSTICKS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.8
MASTERSWITCH REMOVAL
2.3.8
MASTERSWITCH CALIBRATION
2.3.8
MASTERSWITCH (JOYSTICK) CONTROLLER SYSTEM. . . . . . . . . . . . . . . . . . . .. 2.3.8
INTRODUCTION
2.3.8
ELECTRICAL TESTS
2.3.8
FUNCTIONAL DESCRIPTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.8
Masterswitches (Joystick Operator Controls)
2.3.8
INTERFACE FOR JOYSTICKS (MASTER SWITCHES)
2.3.9
CALIBRATION PROCEDURE
2.3.10
INTEGRATED CIRCUIT (IC) PIN LAYOUT
2.3.15
MASTERSWITCH (JOYSTICK) CONTROL PANEL
2.3.16
MASTERSWITCH EXPANDER BOARD
2.3.17
SUMMARYDATASHEET
2.3.19
SECONDARY CONTROLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.3.20
LEFT CONSOLE
2.3.20
RIGHT CONSOLE
2.3.21
ALARMS
2.3.23
AIR PANEL
2.3.24
BI006008
Page
2.4.1
2.4 OPE AriON
GENE AL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.1
182M OMENCLATURE
2.4.1
182M PERATOR'S CAB (Plan View)
2.4.2
PRE-S ART INSPECTION
2.4.3
MACHI E START-UP & SHUTDOWN
2.4.5
ST RT-UP PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.5
2.4.7
RANSFER FROM DIG TO PROPEL
RANSFER FROM PROPEL TO DIG
2.4.7
PA TIAL SHUTDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.8
CO PLETE SHUTDOWN
2.4.9
GROU
PREPARATION
2.4.10
MACHI E OPERATION
2.4.11
GE ERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.11
DIG ING....................................................... 2.4.11
2.4.12
182M OPERATOR CONTROLS -DIGGING
MO ON LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.4.13
PRO EL
2.4.14
2.4.14
1 2M OPERATOR CONTROLS -PROPEL
STE RING
2.4.16
PRO UCTION EFFICIENCY
. . . . . . . . . . . . . . .. 2.4.17
CAB E REEL OPERATION
2.4.18
2.5 BOOM IRING
Schemati ,BOOM W!RING
BOOM W RING PLAN ViEWS
CROWD IMIT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
SPEE REDUCER OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
ELEC RICAL RATINGS
CAM ETTING
OPER TION and ADJUSTMENT of CAMS
VE NIER ADJUSTMENT
CRO D LIMIT SWITCH MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
HOIST LI ITS
2243-2.Me1
2.5.1
2.5.1
2.5.2
2.5.3
2.5.3
2.5.5
2.5.5
2.5.6
2.5.6
2.5.6
2.5.7
BI006008
BI006008
Section
System Components and Operation

2.1 LOW R FRAME
Propel Motor
Junction Box
Lube Piping
Motor Blower
Disconnect Switch
Cable Reel
Front
See
Vi ew-X-+~:::"_:::::;;;;;:;;;;;:=-----t
----,
-------
\_--_ . ~
------
Propel Motor
Junction Box
Left Crawler
If
Rotation
Lube Piping
Left Propel
Motor
Ifpe1847.Wpg
LOWER FRAME and CRAWLERS -Plan View
2.1.1
BI006008
Lower Frame
Disconnect
Switch Box
View
SeaView
For Connections
.. Front of Machine
From Collector Rings-Aux

Ref
View J
View
Typ Wire Connection
K-K
wlfa1847.wpg
WIRING -LOWER FRAME
2.1.2
BI006008
To Ground
Collector
----4
To HV
Collectors
IFR
Lower Frame
Structure
ViewZ-Z
Collectors,
Main
IDouble Connection
8 Places
Top Of
Lower Frame
View-X
- Typical 8 Places
2.1.3
BI006008
Collector Ring
Assembly
.
e1
Lower Frame
'--_""" Disconnect
Cable ,Switch
Reel I
Trail
Cable
Lower Frame
Control
Junction Box
L.H. Crawler
Auto Lube
Pressure
Switch
Propel
..... Motor
Blower
L.H. Propel
Brake
Pressure
Switch
J
L.H. propelj
Brake
Magnet I
Valve,
R.H. Propel
Brake
Magnet
Valve
R.H. Propel
Brake
Pressure
Switch
R.H. Crawler
Auto Lube
Pressure
Switch
Propel
Motor
Blower
R.H.
L.H.
Propel
Motor
oJ
Propel
Motor
wdlf1847.wpg
WIRING DISTRIBUTION -LOWER FRAME
2.1.4
BI006008
p
Inspection
Window ---~
~D;sconnect Switch
B ....
Disconnect Switch
.,,.
,
,
-.
Box~
=lli"~ "-~
~"--(J'EJ/
_ooo~o,
',~._~-
..,
,
u/::
I~
.~.~/
fl ~
~'Disconnect Switch
Handle
'l'/
~Close
~DisconnectSwitch
D~~
Open
-0
~_~~~ __ ~~
~~~ __ ~"=~
Front View Of Cabinet
Grounding Cable
------~
-~-
-------------/~"""'...__.....,.._..._lh_~~H
isconn ct Switch
~~....
------------'~~~~
Groundin
Surge Arrestors
3 Places
Cable
Cut-Away Front View Showing

Components Inside
Ifds1847,wpg
LOWER FRAME DISCONNECT SWITCH BOX
2.1.5
BI006008
LOWER FRAME CONTROL JUNCTION BOX
The Lower Frame Control Junction Box provides access to all of the lower frame control
circuits. It is mounted on the rear of the lower frame structure. The circuits include:
.j Right and Left Propel Brake Pressure Switches.
.j Right and Left Propel Auto Lube Pressure Switches.
.j Right and Left Propel Brake Magnet Valves.
.j Right and Left Propel Motor Over-Temp Thermo-switches .
.j Right and Left Propel Motor Anti-Condensation Heaters.
.j Ground Check Door Interlock on the High Voltage Disconnect Box.
To Auto-Lube
Pressure Switch
~~====:==jF;::;;;;;;;;~1===f~~~~~51
---===-....l:=c=fl~=~
To Collector Ring JB
View AA
Ifjb1847,wpg
The Lower Frame Disconnect Switch Box is mounted on the rear of the lower frame,
between the propel motors.
2.1.6
BI006008
The front door of the disconnect switch box is fitted with a micro-switch that is wired into the
ground Cleck protection circuit. If this door is opened, and power is on to the machine, then
the substption will trip out ~provided the ground check protection circuit is operable. This
is an adc ed safety device. This door is equipped with a hasp for padlocking. (A tool is
required 0 open it.)
AD~N GER:
ADt
NGER:
NEVER OPEN THE DISCONNECT SWITCH BOX WHILE THE

MACHINE IS OPERATING. Always shut down the machine and
interrupt the power supply at the substation BEFORE opening
this box.
HIGH VOLTAGE EXISTS WITHIN THE DISCONNECT

SWITCH BOX. Always exercise extreme caution when servicing
it or working around it.
PROPEL E RAKE MAGNET VALVES

The Propel Brake Pressure Switches and Magnet Valves are mounted on the rear of the
lower frame structure. Gage ports are provided to aid in the proper setting of the pressure
switches. Refer to the Air Schematic for this machine for the pressure switch setting.
---_.
----~---,----_
..
_-~-_
..
__
._----~--_
2.1.7
_~~~-_.
...
_.----,-~----.-.-_._---_._-_
..
_---.----_.,--~--_.,-
BI006008
PROPEL MOTOR JUNCTION BOXES
ii
One Propel Motor Junction Box is
mounted on each Propel Motor.
Each junction box joins the
circuits shown at right:
A1 - Motor Armature Wires.

J A2 - Motor Armature Wires.
J F1 - Motor Field Wires.
I F2 - Motor Field Wires.
J P1 & P2 - Motor Over-Temp. Thermo-Switches.
II H1 & H2 - Motor Anti-Condensation Heaters.
iL_~~!?~'~~e~!~otor Blower.
View 5-5
Typ Both Motor J.B.'s
Front of Machine
1X11
Front of Machine
5-5
See View
For Internal
Connection
View L
5-5
See View
For Internal
Connection
ViewM
Typ 80th Motor J.B.'s
Typ Both Motor J.B.'s

pmjb1847.Wpg
PROPEL MOTOR JUNCTION BOXES
2.1.8
BI006008
"
Front
Of Machine
Front ~
Of Machine
Auto lube Cr wIer-Left

Auto Lube Crawler-Right
Notes:
Set Increasing Pressure (Contacts Open) At 2500 PS.1.

Set Decreasing Pressure (Contacts Closed)At 1900 P.S.1.
Clps1847,wpg
CRAWLER LUBE PRESSURE SWITCHES
2.1.9
BI006008
PROPEL BRAKES
Top Of Lower
Frame Structure
_----/ For Pressure Switch Settings,

Refer To The Air Schematic
~----;/~
~
~~
Set Decreasing Pressure At 10 P.S.1.

Set Increasing Pressure At 95 P.S.1.
Solenoid (Magnet)
Valve
Air Supply Line From

Center Journal Area
To Left
Propel Brake
To Right
Propel Brake
Propel Brake Pressure Switches

pbpS1847.wpg
PROPEL BRAKE PRESSURE SWITCHES
2.1.10
BI006008
r"
Control Console, Right
<t
Machine
Ground Fault
Control
Cabinet
Auxiliary
/
Transformer
Boom Foot
~-l
1
j/I"H'~
1J
. ~
/"
~-=
/~,-
INc!2 SW"i-n-g-'-~'/
No.1 Swing
Gearcase
I Gearcase
Auxiliary
Fuse
Cabinet/ /
. _--,-_ . Lube Catch
I------f~'C'b;":~:I~~:O'rSj~~l ("I".~.~'~ ~ :'I

,~
t'rITrl'IAmhn'\'\!
High
Voltage
II
L-,_~&U~=IJ=~IJ~~Ut
I
d_ ,I
Hoist Rope
RFePlaCle~[
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-I' - ~~ -. .-//r-.
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HOist I I,
- - -~ Machinery
~
,Assembly I
~~
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\
_~~Ttessor/--n
I!
System /-n
, L o w Air\ OGL
' I Pressure'<..lL.1
Reeving
JJWinch
_Switch
/Dig-Propel
IL)--1)--JI
II
'---_ _---I
Cabinet
Gantry
..~
Backleg / -
(~~
MG
Auto' Lube
Control
Center
Telephone
Station
LJ
--r;--~-
1 M.G. Set
, Drive Motor
~-T----~
deck1847wpg
182M DECK PLAN
2.2.1
BI006008
2.2.2
ljtNtHAl~
ELECTRIC
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FIRST MADE FOR
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Ff803WF (282-/01-1)
PRINTED IN USA
2.2.3
BI006008
2.2.4
BI006008 GEH-2711D
INSTRUCTIONS
TYPE HWT CAPACITORS
REFER TO CAP CITOR UNIT INSTRUCTION

GEH-2743 INCLU ED WITH THIS EQUIPMENT
BEFORE PERFO MING ANY WORK ON THE
EQUIPMENT.
GENER L INSTALLATION
Check the capaci or nameplate to make certain
that the capacitor v ltage rating is the same as the
applied voltage. Th equipment should be located
so as to minimize t e transfer of heat from other
equipment or from t e sun into the capacitors. The
preferred mounting osition is with the capacitors
vertical (terminal b x on top) for greater protection
from the weather.
e sure that air can circulate
freely about the cap citors. Incoming leads should
be arranged or supp rted so as not to place a strain
on the fuses or bushi gs inside the terminal box.
ASSEMBLY
ONNECTIONS
TABLE I
Capacitor Capacitor
Voltage Unit Sizes
(Kvar)
(Volts)
2400
2400
2400
4160
4160
4800
25,50,75
100,125,150
200
25,50,75
100,125,150
200
25,50
Fuse
Voltage
Rating
(Volts)
Fuse Current
Rating
(Amperes)
4300
4300
4300
5500
5500
35
75
100
18
50
5500
18
INDOOR EQUIPMENTS
The standard design of equipments is for indoor
dustproof application and terminal boxes are supplied
with knockouts for the customer's incoming conduit
connections. Standard methods of terminating conduit should be followed.
OUTDOOR EQUIPMENTS
All standard Type HWT capacitors use two fuses
per 3-phase capacito unit. These are assembled
to the capacitor unit st d by means of adapter blocks.
To remove a fuse, unscrew the locking setscrew
in adapter block usin a 1/4-inchAllen wrench. The
fuse will then pull or crew out of adapter block.
Designs for outdoor applications are supplied

with special entrance hubs and knockouts are replaced with gasketed cover plates.
CLEARANCES
Recommended electrical clearances, enclosed
space, are as shown in Table II:
Refer to the equip ent outline drawing (included

with the eqUipment) fo provision for customer's incoming conductors.
Current limiting fu es with blown fuse indicators
are used in all Type H T capacitors. Table I indicates fuse sizes norm ly used wi th the various individual capacitor units eluded in HWT capacitors.
TABLE II
Volts
Line-to-Line
2400
4160
2-1/2 inches
3-1/2 inches
Line-to-Ground
2 inches
3 inches
. These. instrv<:lions do not P';'

rt to coyer 011 detoil. or Yoriotions in equipme<lt nor to proyide for eyery pouible contingency to be mel in conne<:tion with
IOsiollol,on, operol/on or maIO nonce. Should further information be desired or should particular problems arise which ore not COyered wffide<ltly for the
purchaser's purpose,. the matt r should be referred to the Generol Ele<:Iric Company.
GENERAL El CTRIC COMPANY, CAPACITOR PRODUCTS DEPARTMENT, HUDSON fAllS, N. Y. 12839

7/34
(l~)
2,2.5
BI006008
2.2.6
BI006008
MAIN C LLECTOR RINGS (H.V.)
Bottom Plate of the

Rotating Frame Structure
Insulator
Mounting Bar ~""""-
21.50
(546 mm)
Mounting Bar
Mounting Pad ------....~::.:---4'--t--+--~
Top Plate of the
Lower Frame Structure
(-----~
Rotating Frame Structure
Center Journal Pin
Lower Frame Structure
crmn1847.wpg
ADAN ER:
HIGH-VOLTAGE AREA! DISCONNECT, ISOLATE AND LOCK

OUT MINE SUBSTATION POWER SUPPLY TO THE MACHINE
BEFORE ENTERING OR WORKING IN THE MAIN COLLECTOR
RING AREA. NEVER TOUCH THE COLLECTOR RINGS UNLESS
THEY HAVE BEEN PROPERLY EARTHED (GROUNDED) BY A
QUALIFIED ELECTRICIAN.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS COULD
RESULT IN PERMANENT SERIOUS INJURY OR DEATH.
The MAIN CO LECTOR RINGS are the electrical conductor which transfer high voltage from
the lower fram to the upper rotating frame. These conductors are located inside the roller
circle in the ar a between the lower and upper frames. The collector rings are mounted on
ceramic insula ors which are bolted to the bottom of the rotating frame. Four concentric ring
assemblies ar provided. Eight collector assemblies with two brushes each are mounted on
the lower fram top plate with insulators and mounting bars.
2.2.7
BI006008
AUXILIARY COLLECTOR RING ASSEMBLY with ROTO SEAL
c;.
Rotation
Hoist Rope
Guard
Front of
Machine
.l-
Drive Pin Location
Hoist Drum
~ Co~~~ction
Lube ~
Connecti on
r--.z=f=-r:__~'~'
Dual Rctoseal
DC and Auxiliary
Collector Ring Assembly
Top of Center Journal Nut
Raised for Thrust
Washer Replacement
Top of Center Journal
10.75 in.= 273mm

8.08 in.= 205mm
---l
Rotating
Frame
Bottom Plate in
Upper Frame
Rotoseal Assembly
Lower Frame
lube Connection
Air Connection
Center Journal
Bottom Plate in
lower Frame
Wiring Enclosure
Rtsl1845.wpg
The combined Collector Rings and Roto Seal Assembly is mounted above the center journal
on the deck of the rotating frame. The 22 collector rings provide for ground check, auxiliary
control, propel motor shunt field and armature circuits.
Two sides of the collector rings have inspection windows with protective steel door covers
that are mounted on bolt-on access doors.
2.2.8
BI006008
Y COLLECTOR RING MAINTENANCE

/
i~~~~~:~
22
:_-
Cover
with Bearing
r----lL-i---'~=-----"
Removable
End
Assembly
Ground Check Ckt
Flange Block
Assembly
(inside)
Shielded able, #14 AWG, 600 V.

Ground Shield to Center Pipe
Ne to Collector Ring
211------+20f----_f_
~nd
1 10,
AC Control Ckt
J #12 AWG/Ring
19f----_+__
181-----+-
30, AC MTR Ckt

#12 AWG/Ring
Collector
Rings
171-----+Removable
161-----+} 10, AC Heater Ckt

151-----+#12 AWG/Ring
/Panel
141------+} 10, AC Control Ckt

13
#12 AWG/Ring
Access
Panel
with
Window
121------+
111------1
101------1
c===s~~~::::r---
D.C. Control Ckt.

#12 AWG/RING
Collector
Ring
Housing
Bearing
Assembly
~ } D.C. Shunt Field

~
~@
#6AWG
D.C. Shunt Field

#6AWG
Shaft
D.C. MTA. Armature

350MCM
~
o4j)--
D.C. MTR. Armature

350 MCM
Assembly
crch1847.wpg
.; Check the tightness of all electrical and mechanical

connectio s. Tighten as required.
,; Check tha the housing panels are properly closed and all
gaskets ar in position.
ANNUAL CHE
.;
colrg22p.wpg
ightness of all electrical and mechanical
COLLECTOR RING ASSEMBLY
.; Regularly c ean the inside of the slip ring assembly using a dry cloth -NEVER USE WATER OR
OTHER LI UIDS.
.; The rings s ould be clean and dry at all times .
.;
NOTE:
rts should be replaced immediately.

arings are sealed and do not require further grease.
2.2.9
BI006008
COLLECTOR RING INSPECTION and ADJUSTMENT
A.
Brush Rigging.
1.
Brush studs are supported between 2 outboard bearings. The brush studs extend
through the outboard bearings and they are secured by a setscrew in the
outboard bearing. The setscrews prevent rotation of the brush stud. The
setscrews should be checked for tightness. Some collector ring assemblies are
furnished with additional brush stud anti-rotation devices. These devices are
located on the outboard side of the outboard bearings. They incorporate an
additional setscrew to prevent brush stud rotation. The additional setscrew must
also be checked for tightness.
2.
The spacing between the outboard bearings is critical to assure the free rotation
of the brush rigging. The brush stud insulator sleeves are cut to length in order to
provide the proper spacing. The outboard bearings should be located snugly
against the insulator sleeve without any deformation of the materials. Hand tighten
the outboard jam nuts and then secure the brush stud with the setscrews referred
to above.
CAUTION:
DO NOT OVER-TIGHTEN THE OUTBOARD JAM NUTS. Overtightening can preload the bearings and cause excessive
friction.
A final check should be made to assure no binding of outboard brush rigging or

binding of brushes with insulator barriers.
B.
Brush Holders.
1.
Inspect the brush holders for proper alignment. Brush holders should be located
so that the entire brush contact surface rides squarely on the ring with the brush
moving freely in the brush box. The top of the brush should be parallel with the
top of the brush box.
2.
Brush holder clamps should be checked for tightness. Clamp bolts should be set
at a maximum of 75 in-Ibs. Loose clamps will allow the brush holder to rotate,
causing the brush to lift from the surface of the ring. Brush lift will cause arcing
and excessive heat concentration.
3.
Brush terminations at the holder should be inspected to assure that no external

force is imposed on the holder that would cause rotation of the holder on the stud.
Flexible or soft wire leads are recommended for these terminations. External
clamps should be used to support the entire weight of the leads.
4.
A final check should be made to assure that the brush studs can not rotate. Refer
to BRUSH RIGGING above.
2.2.10
BI006008
C.
Bru hes.
1.
Inspect for wear. If the distance from the top of the brush to the top of the brush
box is over half the depth of the brush box, the brush should be replaced.
2.
Inspect brush contact surface by removing the brush and checking the brush
s!Jrface for dirt, oxidation, pitting or other contaminants. Remove any large
particles and follow seating instructions in the following paragraph.
3.
Check brush contact surface for proper seating. If the seating is not proper, the
contact surface will be tracked differently in different areas. To reseat the brushes,
ay a piece of sandpaper between the ring and the brush. Install the brush in the
rush holder in proper alignment and rotate the core while applying pressure on
he brush. If the core cannot be rotated, the sandpaper must be pulled across the
rush surface. Wrap sandpaper at least 1800 around the ring to prevent rounding
f the brush edges. Recheck the brush contact surface and repeat the sanding
rocess if necessary until the entire contact surface appears uniform and without
its.
A
D.
AUTION:
DO NOT USE EMERY PAPER OR CLOTH TO SEAT THE

BRUSHES - EMERY WILL BECOME EMBEDDED IN THE
BRUSH AND CONTINUE THE ABRASIVE ACTION AGAINST
THE RING AND BRUSH. Emery and many other abrasives are
conductive and must not be used.
Brush
1.
spect and test springs

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

just lifts off the brush
surface, and read the
scale.
WIRE lOOP
Brush
Holder
Brush
~t---RJNG
cola1828. wpg
2.2.11
BI006008
2.
E.
F.
The spring tension should be periodically tested on all brushes to assure

uniform brush tension. Test for tension as shown in the figure. For spring
tension adjustment refer to REMOVING AND REPLACING BRUSHES AND
SPRING TENSION SCREWS later in this section.
Rings.
1.
Inspect the ring surface for dirt, oxidation or other contaminants. A properly
operating ring will have a film that appears burnished in color where the brushes
track with a darker surrounding color. If this condition does not exist, cleaning will
be necessary.
2.
The ring should be cleaned with a non-conductive abrasive such as Ideal

Industries' Flexible Abrasive for collector rings. Hold the abrasive against the ring
with a medium amount of pressure while turning the core. If the core cannot be
turned, the abrasive must be rubbed over the ring. Continue this process until the
ring surface is polished without any dirt or contaminants left on the surface. To
prevent abrasive from being lodged in the brushes, they should be lifted off the
ring.
3.
Inspect rings for pitting. Pitting of the ring must be corrected since pits will
produce arcing, leading to the development of larger and more pits. Small pits
can be removed by hand stoning of the area. If large pits and/or a considerable
amount of pits are present on the surface, the surface must be machined.
Machining is also necessary if concentricity of the surface is questionable. When
stoning or machining rings, remove only enough material to eradicate the pits.
Again, the brushes should be lifted from the surface when stoning or machining.
Finish the ring surface to a 16-32 micro-finish as described in step 2 above.
Electrical Connections.
Inspect all electrical connections for corrosion and tightness. Clean corroded parts with
a wire brush and/or muriatic acid. Loose and/or corroded terminations will cause a
concentration of excessive heat.
ENCLOSURE INSPECTION
A.
Moisture is a major cause of collector ring deterioration. Corrosion of parts and

insulation breakdown can be attributed to the presence of water. Dust and dirt present
within the enclosure will affect the proper operation of the assembly. Most dusts cause
excessive brush and collector ring wear and conductive dusts, if allowed to
accumulate, will form a path for short circuiting.
2.2.12
BI006008
B.
A P perly designed enclosure will be dust tight and watertight; however, condensation
ma still form on the walls of the enclosure. In some environments, condensation can
be Iiminated with the addition of a breather and drain. Other environments, particularly
dus y ones, require a thermostatically controlled heater to eliminate condensation.
C.
An spection should be periodically performed by removing the enclosure and

che king for condensation, water and dust collection. If contaminants are found, the
end sure and the assembly should be wiped down with a lint free cloth. If the problem
app ars persistent, steps should be taken to remedy the leakage or condensation
prob em.
FREQUE CY of INSPECTIONS
The first i spection should be made shortly after installation and before operation.
Continuin inspections should be made on a regular basis after every 200-400 hours of
operation nder normal conditions.
olders with non-adjustable spring tension.
A.
1.
R fer to the figure below. Pull spring free end (It.#B) out of brush holder recess
a d slide spring off of fixed hub (It.#A).
2.
U screw binder screw (It.#C) and take off brush shunt connector (It.#D) and
re ove brush (It.#E).
3.
In tall a new brush, reversing the above procedure.
cola2828.wpg
2.2.13
BI006008
B.
Brush Holders with adjustable spring tension.

1.
Refer to the figure on the following page. Release the spring tension on the brush
spring by holding the spring tension screw with a screwdriver at slot (1t.#A) and
loosening spring tension nut on opposite side. Do not completely remove the nut,
just loosen. The screws can be adjusted with a 9/32 wrench without removing
from the stud.
2.
Pull spring (1t.#B) up and out of the way and unscrew binder screw (1t.#C). Take
off brush shunt connector (1t.#D) and remove brush (1t.#E).
3.
Install a new brush, reversing the above procedure.
4.
Tension is applied on the brush spring by holding the nut with a wrench and
turning the screw with the screw driven clockwise until the inner coils are tight.
Back off 1/4 turn, then tighten the nut. The spring should have a minimum of 1
pound pull at the brush. See COLLECTOR RING INSPECTION AND ADJUSTMENT
- BRUSH SPRINGS.
5.
To replace brush spring tension screw (1t.#A), simply take the spring tension
screw nut off and pull the screw and spring out of the holes in brush holder
(1t.#F). Use the above steps in reverse order to replace the spring tension screw.
CLAMP BOLT
.r----
BRUSH STUD
E
cola3828.wpg
2.2.14
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Wireway
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High
Voltage
Cabinet
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CPEX
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Drive Control
AC Power
pply
BI006008
BI006008
ell
10
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DIG/PROPEL CONTACTOR CABINET
2.2.16
BI006008
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Schematic -DIG / PROPEL CONTACTOR
2.2.17
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BI006008
HIGH VOLTAGE CABINET
The cabinet includes:

.j Startup Panel
.j Main Disconnect Switch
.j Vacuum Contactor Cabinet
1.
POWER FACTOR METER - indicates

the MG set drive motor power factor.
2.
HOUR METER - an elapsed time

meter that shows total machine
operating hours with excitation (L.E.)
On.
3.
~~~~
_,r.
AMMETER - (0-200 Amp Range) Indicates the drive motor current in

amperes.
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.....
va. T
alEE" .. UEIlI
.---~~t_
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4.
HIGH VOLTAGE CABINET - VOLT

METER (0-8250 Volt Range) - an A.C.
voltmeter that indicates the voltage
on the incoming trail cable.
_ _ Starting Panel
IV
"0---7
9~~~
8
"""SET
OAOUMD IroIOl<t6~
Sfl RESET
10
i
I
11
I--
~~ '"'-
Vacuum Contactor
Cabinet
/
Main Disconnect Switch
hvcF1847.wpg
HIGH VOLTAGE CABINET (Front view)
2.2.18
BI006008
5.
LOr TRAK IV PROTECTIVE RELAY MODULE - Monitors the dive motor to protect
aga nst over current, overload, phase unbalance and ground fault.
6.
GRC UND MONITOR TRIP - A red pushbutton used by qualified electrical maintenance
per~ onnel to check the ground trip circuit in the mine substation and power supply.
Pressing this button will cause the power supply to the machine to be turned off (deene gized). It must be reset and re-energized at the mine substation.
7.
SLO NN FUSE INDICATOR (SFI) -Indicates a blown fuse on the secondary of the high
switch.
volta~e disconnect
ALWAYS OPEN THE DISCONNECT SWITCH BEFORE

REPLACING A FUSE.
8.
SFI, F ESET - A black pushbutton used to reset the visual blown fuse indicator after
repla~ement/correction. Press this button once to verify a fuse fault before notifying
elect ical maintenance personnel.
9.
M.G. SET START - A green illuminated pushbutton for starting the M.G. Set. When
startin~ M.G. Set, press and hold this button until M.G. Set is up to its normal operating
speec. The green light in this button being on indicates the M.G. Set is running.
10
M.G. ~ ET STOP - A red pushbutton that, when pressed, de-energizes (shuts down) the
M.G. ~ et induction drive motor. The M.G. Set will coast to a stop.
ACAJTION:
STARTING THE M.G. SET REPEATEDLY OVER 3 OR 4 TIMES IN

ONE HOUR COULD CAUSE PERMANENT DAMAGE.
11. M.G. SET MOTOR DISCONNECT SWITCH - Disconnects power to the M.G. set drive
motor.
ACAlTION:
DO NOT OPEN THE M.G. SET MOTOR DISCONNECT SWITCH

UNDER LOAD. PRESS THE M.G. SET STOP BUnON (#10)
BEFORE MOVING THE DISCONNECT SWITCH TO THE OFF
POSITION.
------+--------------,~-----,----,-----,-----,---------
---------+----~~
------,----,--~---,-------,--,---------------,-,----,--,----,--,--
2.2.19
BI006008
LODTRAK MODULE
The Control section of the cabinet

contains a Power Factor meter, Hour
meter, Ammeter, Voltmeter,
LODTRAK IV module, Blown Fuse
indicator and pushbutton, Start / Stop
pushbutton, Ground Monitor Trip
pushbutton, Transformer and Relays.
LCD
1~~SE$~lr~~~~4tiln(:~:~ent A Control Power Transformer is used

to isolate and step down the primary
high voltage for the AC Voltmeter and
power Factor meter on the Control
Cabinet door and for the control
devices.
The 3 current transformers [1 CT, 2CT
and 3CT] are used to drive the AC
Ammeter, Power Factor meter and the
Primary Instantaneous Overcurrent
Function, which is part of the
LODTRAK IV mounted on the Control
Cabinet door.
The Ground Current Transformer [GCT] provides ground check input to the LODTRAK IV
module. Circled numbers near devices are symbols used to identify parts in the parts book.
For further wiring and component information, refer to the L1MITAMP section from General
Electric.
2.2.20
BI006008
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HIGH VOLTAGE CABINET ELECTRICAL DIAGRAM -Sht. 1
2.2.21
BI006008
,-----------------------------,
011111
IN
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HIGH VOLTAGE CABINET ELECTRICAL DIAGRAM -Sht. 2
2.2.22
BI006008
IHI LV DOOR - STD AJR OR VACUUM
)ij~
BACK vlE;;
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II" SCfllL[
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H.IGH VOLTAGE CABINET ELECTRICAL DIAGRAM -Sht. 3
2.2.23
BI006008
DC CONTROL CABINET
NOTE:
For DC Control Drive

layouts refer to the
schematic in Section 12,
Sheet Codes 29A,
298 and 29C.
Icr... Voltmeter
Propel Motor
Field Fault
Q-15QVDC
Drive Fault
lr~~
II
Drive Fault
Reset
II
L~
Hoist Crowd & Propel Panel
dccc1847. wpg
Fault Indicators on the DC Control Cabinet:

PROPEL MOTOR FIELD FAUL T - A red light which indicates a problem with one or both of
the propel motor fields. An alarm will be set off when the light comes on. To eliminate the
alarm, stop the machine and push LE STOP. The light will remain on until the problem is
corrected.
DRIVE FAULT - A red light which indicates a malfunction in one of the systems controlled by
the CPU. Refer to the OIU screen to determine the problem.

DRIVE FAULT RESET - A black pushbutton. Push and release several times until the drive
fault light goes out. If it does not go out, call for service.
2.2.24
BI006008
------+-----------------~------------~--------------------------------
------t-------------------------------------------------------
-------+----------------------------------------------------------
2.2.25
BI006008
2.2.26
BI006008
I/- - - - - - - - - - II -'
I
I
I
II
II
I F--'~-'iT=r~===--"=~=~=~=,,-,-
Hoist
I
I
---=:-----9
I
I
"--""'-----,=-r~J
Swing
Elevated Cab Base
Crowd
I
I
,Ir=========i
,
I'-~~--~_--J
ii
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Generator Field Excitation

Transformer - 3 Places
-----._--
TO (f Machine
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GENERATOR FJELD EXCITER TRANSFORMERS
2.2.27
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....
Front Of
Right Wing
III~
_..... ._.
_._}
...__........ _._-_..
High Voltage
Fuse Cabinet
_r"
Front Of Machine
89Q9
Auxiliary
Transformer
Surge
Arrestors
Ground
Fault
Control
I
I--- fi!. Rotation
JI
Motor Control Center
r----~-I
Top Of
Ri9htWing
h
Plug Is For Power
Lead From Welding
Machine.
,I
:
:
I~J.--=
O.G.L.
Panel
Pressure
Switch
1I1 ~ox
11
L.F.
MPG
Panel
U.F.
MPG
Panel
~~~
<lksy~~m n~~i~
- - - - - __ 1
Air Compressor
With Control
Pressure SWitch
--------------:
J
I
BI006008
BI006008
FAULT CONTROL CABINET
~~~
The Gro nd Fault Control

cabinet ntains a door
mounted ground fault monitor
for the a iliary bus. It has
power an fault indicating lights
along wit test and reset
pushbutt ns. When a ground
fault of 1 mpere or more
occurs, t e ground fault relay
operates nd the shunt trip of
CB-AB tri s the auxiliary bus
circuit bre ker off line.
o
Door
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Ground Fault
Monitor Panel
""
Circuit Breaker
Operating
Handle
09.0:
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OEST
TEST
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:l_=:=_::=--=::===:==._:=::=::::=======::=::::::::::::::::~j
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View Showing
Components
on Door
Panel
Fuses
\
t.
Circuit Breaker,
15Amp
3-Pole
Control
Transformer
Terminal
R-GFA
Ground Fault
------~:~~~--------~._j
2.2.29
Adjustable
Resistor
View with
Door
Removed
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Legend:
1 ) - - - Single Conductor
2 ) ~ Diagram To Indicate Multiple Conductors
3) GFMP-A Ground Fault Monitor Panel-(For Aux. Bus)
4) GFR-A
Ground Fault Monitor Panel-(For Aux. Bus)
",r-
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"
",,,-,,
Settings:
Actual Ampere Trip Level Depends

On The Number Of Times Sensed
Conductor Is Passed Thru C.T.
ie.-The Final Current Ratio -See
Schematic For Details.
Note:
1) R-GFA To 4000 Ohms

2) GFR-A 2A .2 Sec
BI006008
BI006008
Panel
oj
.~
+
Fuse Holder
Door
~/
I--
- -
-~~=
~
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'/
...
3~""~
--
,... V
.-..
Fuse
3 Places
1 .... ::J
.......
-~ ....-{
~
~~
.... ~I
...1
Front View With Door Removed
hvfc1847.wpg
HIG H VOLTAGE FUSE CABINET
2.2.31
BI006008
MOTOR CONTROL CENTER

Items on the Motor Control Center:
1.
OPERATOR'S CAB AIR CONDITIONER
2.
WELD RECEPTACLE
3.
HOIST GENERATOR FIELD EXCITER

TRANSFORMER
4.
CROWD GENERATOR FIELD EXCITER

TRANSFORMER
5.
SWING GENERATOR FIELD EXCITER

TRANSFORMER
~Moti~~~=~nt.r
c::::J
PHASE SEQUENCE - This panel

includes a red light which indicates an
error in the power supply when
illuminated. Electrical interlocks will
prevent machine start-up if phase
reversal exists.
c::J
ON
STAAT
STOP
Typicel
E. Pan.
OFF
c:::J
ON
r:::::::::3J]
c::J
OFF
c:::J
rn
OFF
c::J
ON
OFF
10
c:::J
ON
FILTER FAN #1 -Includes a green light

which indicates the fans are
operating plus start-stop push buttons.
rn
AUXILIARY BUS MAIN BREAKER CB-AB
FILTER FAN #2 - Includes a green light

which indicates the fans are
operating plus start-stop pushbuttons.
OFF
12
c:::J
ON
ON
G~
off
AUTO
2.2.32
OFF
OFF
10. HOIST MOTOR BLOWER - This panel

includes START and STOP pushbutton
for operating the air cooling fan on the
DC drive motor. The green indicating
light above the pushbuttons indicates
that the hoist blower circuit is energized.
c:::J
ON
OFF
ON
G~
OFF
16
11
c::J
Off
AUTO
c::::J
15
GLJ ~
OFF
ON
OFF
c:::J
[]] ~
ONc=3J) OFF
c:::J
c:::J
ON
'&
9.
-1l
ON
B,.ok.,
Swlt<h
ONc=3J) OFF
8.
14
ONc=3J) OFF
A voltmeter and a 4-position switch to

check the voltage across each phase:
OFF, L1-L2, L2-L3 and L1-L3.
7.
c:::J
G[]] ~
ONc=3J) Off
6.
c:::J
13
ON c::::3JI OFF
c:::J
17
ON
U~
OFF
BI006008
11. AIR OMPRESSOR - This panel includes a two position selector switch which controls
the peration of the air compressor. The AUTO position lets the compressor cycle on
and off automatically a dictated by its pressure switch. The OFF position makes air
co pressor is running. The compressor will not operate if phase in incoming power
sup Iy is reversed.
12. ANT -CONDENSATION HEATERS - This panel includes a two position selector switch
whic controls the operation of the space heaters in the motor control center, the DC
Cab net, the dig-propel cabinet, all the DC drive motors, and the M.G. Set. AUTO
posi on automatically energizes the heaters whenever the M.G. Set is shut down. OFF
posi ion turns the heaters off. The green light above the selector switch will be
iIIuml ated whenever the heater are energized. These heaters are not thermostatically
contr lied. Once energized, they operate continuously until shut off or the M.G. Set is
start d. These heaters should be used only during periods of high humidity or low
temp ratures.
13.
14. HOIS CABLE WINCH
15. CPE RANSFORMER - Control Power Excitation Transformer breaker.
16. CRO D & SWING MOTOR BLOWERS - This panel contains a green indicating light
that i dicates the crowd and swing motor blowers circuits are both energized.
17.
L MOTOR BLOWERS - This panel includes a green indicating light that indicates
pel motor blowers circuit is energized. These blowers operate only when the
e drive is in the propel mode.
NOTE:
T,
e following breakers on the Motor Control Center must be closed for machine
s rt-up and operation:

Sequence.,
ing Line.
ans Nos. 1 and 2.
,; Hoist, Crowd & Swing, and Propel Motor Blowers.
,; Hoist, Crowd, and Swing Generator Field Excitor Transformers.
,; Air C mpressor.
,; Regul tor Power Supply.
2.2.33
BI006008
AUTO LUBE CONTROL
To Auto Lube
OGL Hoist
Auto Lube
Electric
Control Panel
-3 Places
Front of
Machine
~===:::::====::::::;:-;::========;-;:======::::=4'I
Hoist,
Boom
Rotating
Frame
Lower
Frame
OGL
MPG
MPG
00000
0000@
-----)
Air Pressure
Regulator
-3 Places
Auto Lube
Control Panel
-3 Places
System
Low Air
Pressure
Switch
~""""-+-r-Air
Lube Drum,
120 Lb., 16 Gal.
-3 Places
,,
OGL'
MPG'
To Auto Lube /
MPG Rotating Frame
Pump
-3 Places
'MPG
To Auto Lube
MPG Lower Frame
actr1847,wpg
182M AUTO LUBE CONTROL CENTER
2.2.34
BI006008
A.C. Auxiliary Cabinet
Lighting Panel
Open Gear
Contro'
Pan., OGL
Horn
-!r
Upper Frame
Contor Panel MPG
...
Horn -~-+-----.I
Hom
I
,
-Lower Frame
Control Panel MPG I
1
I
Air
Solenoid
Valve
Pressu Switch
Open Ge r Control
-~-
Air
Solenoid
Valve
Pressure Switch
Upper Frame Control
.__-D---.
Pressure Switches
Lower Frame Control
.--4--.,
I
?,G,tl
wgal1847.wpg
WIRING -AUTO LUBE CONTROL PANELS
2.2.35
BI006008
AUTO LUBE -ROTATING FRAME and OPEN GEARS
These 2 systems use identical but separate control panels. Both systems are timed to cycle
at 15 minute intervals. The OGL system lubricates 26 lube points, the Rotating Frame MPG
system lubricates 35 lube points.
ACAUTION:
Inadequate lubricant to machine components can result in serious

damage and costly repairs.
Auto Lube Electric

;Control Panel
14-_ _+--r-Alarm Horn

Pump Operating (Amber)
Power On (Green)
Failure (Red)
Manual Start Pushbutton

(Activates the System
for One Cycle)
Alarm Reset Pushbutton
Electrical Conduit
Air Regulator and Gauge
Solenoid Valve, 3-Way-r--_ _....,;:::j-iJ-I
Pressure Gauge
~....... "'<.-Glbbe
Additional Lube to
Circuit, Used on
OGL Only
Valve
Air Supply Inlet
Safety Un loader
Lube Return to Drum
Lube from Pump

Air to Pump
aprf1847.wpg

Rotating Frame and Open Gears
2.2.36
BI006008
2-Pole Relay
CR-1
CR-2
4-Pole Relay
rr==:::::::::;;:::====::U....J 2- Pole Relay

o
CR-3
Time Delay Relay
o
eprff1847.Wpg
AUTO LUBE ELECTRIC CONTROL PANEL

(Shown with door open)
This electric control panel: is designed to provide adjustable control of the auto lube system.
The followin items are in the panel:
DOOR SW/~ H - A 2-position switch which ensures that the panel door is closed while the
system is 0 erating, and provides an override for servicing the panel.
POWER ON NOIGATOR - A green light indicating that the system is operational.
PUMP OPE
TlONAL - An amber light indicating that the lube pump is operating.
FAILURE - A ed light and horn that indicate a system malfunction caused by one or more
of the followi g:
- E pty reservoir.
- B oken lube line.
- BI cked lube line.
- In ufficient air pressure.
- Pr ssure switch failure.
- C ntrol panel failure.
2.2.37
BI006008
ALARM RESET - Shuts off the alarm and resets the control panel for continued automatic
operation.
TIMER - The timer determines and starts the lube cycle.

Two rows of pins are located on the timer dial. The inner row trips a switch to start
the lube cycle, and the outer row resets the relays after the cycle has been
completed. The space between the pin holes represents 37.5 seconds. So, to
provide a 5 minute cycle, it is necessary to have 8 spaces between the inner pins.
The spacing between the inner and outer pins is determined by the time delay
relay. The time between cycle start and reset must always be greater than the time
delay relay setting.
TIME DELAY RELAY - Terminates the lube cycle and activates the alarm system, if the system
fails to cycle within the time set on the relay. (Each setting on the relay timer represents 30
seconds.)
NOTE:
The pressure switch located in each lube system normally terminates the lube
cycle when the operating pressure is reached. The switch must be activated
before the time delay relay "times out" or a malfunction will be indicated. Normal
operating pressure is 2500 PSI (+ 1000/-650 PSI). The pressure will vary with
conditions. Since the lube cycle time will vary with lubricant viscosity, temperature,
pump capacity and air pressure, cycle the system manually several times and
record the normal cycle time. Set the relay timer to the longest cycle, plus 30
seconds, then adjust the outer row of pins on the timer dial to provide a time
interval between the inner and outer pins that is greater than the time delay relay
setting.
EXAMPLE:
If the time delay relay is set for 120 seconds, then the spaces between the inner
start pin and the following outer pin must be 4 spaces.
2.2.38
BI006008
L2-~f-------------------j
NOTES:
OnIon
on t
inte
is 3
The oor switch actuator pin must

be p lied out for any open door
testi 9 of the control panel.
ime of the timer must be a

er interval than the alarm time
e Time Delay Relay. The
al between each dial pin hole
.5 seconds.
}---{>-------04:
Alarm
Reset
IJ.
,-
Failure
,~
'Ao
CR-2
r--.---0----<:>-<lr I; > - - - O - - - - - - { 2 l ,#
..,,:l
CR-)
1 - - - - - - - - - - 0 . . ; . - - - i : )-_ _
CR-3
J-Io/"-:1~/f
I
CR3
External Alarm Circuit in the Operator's Cab.

scrfe182.wpg
ELEMENTARY DIAGRAM
scrfi182.wpg
INTE CONNECTION DIAGRAM
ROTATING FRAME and OPEN GEARS AUTO LUBE

2.2.39
BI006008
AUTO LUBE LOWER FRAME

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

damage and costly repairs.
o
Auto Lube Electric
Control Panel
Alarm Horn
Failure (Red)
Fast Cycle (Green)
Pump Operating (Amber)
Power On (Green)
Manual Start Pushbutton

(Activates the System
for One Cycle)
Alarm Reset Pushbutton
Electrical Conduit
Air Regulator and Gauge
Solenoid Valve, 3-Way-r--_ _--:l--::iH
Pressure Gauge
~-----"""GlobeValve
Air Supply Inlet
Safety Unloader
Lube Return to Drum
Lube from Pump

Air to Pump
aplf1847.wpg

Lower Frame
2.2.40
BI006008
Timer
Fast
Cycle
Timer
Time
Delay
Relay
pnelf182.wpg
ELECTRIC CONTROL PANEL

(Shown with door open)
This eJectri control panel is designed to provide adjustable control of the auto lube system.
This panel operates the same as the Open Gears and Rotating Frame panels, with the
exception t at it has an additional timer. When the machine is digging, the lower frame is
lubed at 1 minute intervals. During propel, the additional (No.2) timer changes the lube
cycle to 2.5 minutes. (4 pin spaces on the inner row of pins.)
Set the spa e between the inner and outer pins the same as on the 15 minute timer dial. An
additional g en light (fast cycle) indicates that the system is operating in the propel mode.
- - - - - - + - - -------------- ------------------ --_.,----- - - - - - - + - - - - - - - - - - - - - - - - - - - - - _ . _ - - - -----------------------------------
2.2.41
BI006008
LOWER FRAME AUTO LUBE CONTROL PANEL ELECTRICAL DIAGRAMS
'.I.
Failure
pump
Opr.
,1
,.
11
Power
.J
On
CR.2
9 Pump Solenoid
r:C-1
Fast
Cycle
} -_ _--'K
J'f>f'-1l-1?llr
,
External Alarm Circuit in the Operator's Cab

sclfe182.wpg
ELEMENTARY DIAGRAM
NOTES:
On-Time of the timer must be a longer interval than the alarm time on the Time Delay
Relay. The interval between each dial pin hole is 37.5 seconds.
The door switch actuator pin must be pUlled out for any open door testing of the control
panel.
2.2.42
BI006008
CloCk
Fast Cycle NO.2
Clock
Slow Cycle NO.1
I
I
~'HJ
SOL
LE Ckl
Alarrn
Horn
'-l~J
Propel
Ckt
sclfi182.wpg
INTERCONNECTION DIAGRAM
------1-------.-----.----------------.-.--.
.._------------._- ------ _.----_._-- _._-------
-------+---_._------~_._-------
2.2.43
BI006008
BOOM JACKING LIMIT
The BOOM JACKING LIMIT is an electrical switch located on the front inside wall of the
machinery house just left of center. The purpose of the boom jacking limit is to control the
amount of boom jacking. This is a situation where, the boom is raised beyond its normal 45
degree operating angle because too much crowd force is being applied at the face.
Effects of boom jacking can be serious damage to boom foot lugs and boom support ropes.
The boom jacking limit is activated by the closing of the switch when the cable attached to
the top of the boom goes slack due to a condition of boom jacking.
When the spring loaded, plunger type switch is activated, crowd out control reference is
removed and an audible bell will sound in the operators cab. Crowd reference is regained
by retracting handle from face.
Adjustment of the switch consists of maintaining the distance between the plunger face and
switch contact. This is done by adjusting nuts on the front and rear of the plunger rod.
Correct adjustment is .75 inch(19mm) distance between face of front adjusting nuts and front
of guide assembly. (See illustration for location of adjusting nuts.)
2.2.44
BI006008
Maximum Stroke Inch (6 mm)

Capscrew, .38 Gr.5
~--.25
.5 Inch (12.7 mm)

Front House Wall
Plunger Plate Face,

Plunger Plate
Guide Rod for
Plunger Plate
~witch Brack~t
'd
---r------Umit Switch
[$
'~:=J-L-C:==_~~~:8 ~
------------~
-
lunger Adjusting
Nuts "B"
(Front)
Support
Bracket
Plunger Adjusting
Nuts "C"
(Rear)
1.75 (44 mm)
[ - - ' l -_____
.75 (19 mm)
<t
9.50
Boom
(241.3 mm) , ,.
.Y~)
/)H?~"jY/
~/---------'I--'
\~
. /<::
~,
"108.84
~(2764.5 mm)
''',
'~
~\
\\
'"''~"
Switch Actuator
Cable
",,~
'\./
~,
~~
"
Switch Ope ating Characteristics: ~~

Pre-Travel
.050/ .046 inch
Differential ravel _ _ .027/ .046 inch
Recommen ed Travel
.15 inch
Total Travel
.260/ .240 inch
Force req'd
Trip
2.8 Lbs.
Force @.25 nch Stroke
7.3 Lbs.
Front
House
Wall
Boom Assembly
'\
'~
~
~
\,,~\'\,
~ ~
""
~ ~
"
"'" ~
~,,\
""
''''
' ' " -
- 45
blmt1847.wpg
BOOM JACKING LIMIT SWITCH
i /
' "\
' \
, , \
'J
.
--,--l._
_~
l---I
''\
_J~~~V)
t Boom~
Adjust the lunger Nuts "C" and Position the Switch as

Foot
Shown so t e Plunger Face Will Not Force the Switch to Over-Travel.
2.2.45
Dec k
"'~
-''"-
NOTES:
To Avoid D mage to the Switch, Position
the Plunge Adjustment Nuts "B" as Shown to
Contact Su face "A" Before the Limit Switch Bottoms Out.
" '\
Rotating
Frame
Structure
BI006008
HOUSE AIR FILTRATION SYSTEM

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

SYSTEM
,;
Periodically check that bleed air ducts are open and

clear.
,;
Keep inlet passages free of paper, leaves, wiping cloths, or any debris that would
obstruct air flow.
,;
Look for deposit build-up on filter blades. A light coat of dust is normal, but a heavier
coating requires cleaning.
,;
Brush surface ancrremove dust with compressed air. If necessary, wash heavy build-up
with water or suitable solvent.
ADANGER!
ANOTE:
THE MACHINERY HOUSE ROOF MAY BE SLIPPERY. Use the hand

rails as well as extreme caution during any maintenance or service
on the roof.
Mine conditions will dictate the maintenance frequency of the filters.
Monitor the filters closely and establish a schedule to suit conditions.
2.2.46
BI006008
Fan Section -2 Places

Filter Section -2 Places
Plenum
Air
---
Air
---
Flow
Flow
Filter Fan No.2
Filter Fan No.1
dv2d1847.wpg
182M DYNAVANE AIR FILTERS

( Viewed from the Rear of the Machine)
FILTER F N START-UP PROCEDURES
1.
Verify
directi
house
corre
2.
Check the voltage at each motor terminal.

Make ure it is within +/-3% of the auxiliary
bus n minal. If not, the auxiliary bus
transf mer tap may need adjustment.
Filter Fan Junction Box
hat all fans rotate in the proper

n to push air into the machinery
If not, change the phasing to
the rotation.
3.
ith an amprobe to see that the

curren is balanced among all 3 phases of
the mo or within +/-5%. If not, check for
loose c nnections between the motor
control center cubicle and the motor, at all
junctio points between the two.
RED
: FB1T1
BLK
: FB 1 T2
--------r-----____<o
0-
"_.
Filter
O~(~)\ Fan
.~
o-BL~~~o/ j
~
GRN
:
\
GND
Motor
No.2
ffsc1847.wpg
FILTER FAN HOOK-UP CHART
-----r------~----------.------.-.
2.2.47
BI006008
)
~
" Counterweights
NOTE: Angle must be
Removed to Remove
Ladder from Track
~~"
- Counterweight
Enclosure
Track~
Walkway. Left
\
Machinery House
Assembly
Signal Chord (2)

One On Each Side
Of Ballast Box.
Used To Signal
Operator From
Ground
Limit Switch
Crawler
Assembly
Ground
BOARDING STAIRS
2.2.48
BI006008
Drum Guard
Lube Fittings
D.C. Motor
Capscr
.5 Inch Gr.5
- 4 Places
Drum
Dipper Trip
Mounting~
Base
'"
.C::;:;::::===~~~
View-A
DTRP1847,wpg
DIPPER TRIP
NOTE:
T e Dipper Trip Assembly is mounted on the right-front Gantry leg. Refer to G.E.
anual GEH-3967M in Book #2 of this manual for the D.C. Motor instructions.
- - - - - - - + - - - - - - - - - - - - - - - _ . _ - - - - - _..
2.2.49
BI006008
2.2.50
BI006008
2.30P
ATOR'S CONTROLS
OPERAT R'S CAB
Front
of
Machine
Control
Console,
Left
Joystick Controller,
Hoist / Swing / Horn
Control
Console,
Right
Joystick Control
Panel in the
Cab Base
Operator's Seat
----------------
-~~-I-I----I
I
I
I
I
I
I
1
I
I
.l...J_.
lli"
I
,1
A;,
Control
Panel
Stand
Door
2.3.1
BI006008
OPERATOR'S SEAT
The operator's seat has adjustments for positioning it in the best location to suit individual
operators. It swivels into and out of operating position to provide easier entry/exit for the
operator. Lift the spring loaded T-handle lock beside the seat pivot to swing it into and out
of operating position. To raise or lower the seat, turn the hand wheel under it, clockwise
(CW) to raise and counterclockwise (CCW) to lower. An adjustable foot rest is provided for
operator comfort. Refer to the following page for more information on seat adjustment.
The operator should always adjust the seat to suit before taking over the controls.
Do not attempt to operate this machine unless you understand all
the machine controls. Never leave the operator's seat without first
setting all motion brakes and "dropping out" (de-energizing) line
excitation (LE) by pushing the EXCITATION STOP pushbutton.
ADANGER:
I,
I,
---l~~~
I,
I
I,
I
I,
opst1847.Wpg
2.3.2
BI006008
OPERAT R'S SEAT ADJUSTMENT

The oper tor's seat was selected to give operators of all sizes the ability to position and
adjust th seat to their preferred arrangement. Since the operator must sit for extended
periods 0 time, it is worthwhile to adjust the seat to his most comfortable position.
A.
WEI HT COMPENSATOR - knob adjusts support coils tension to suit the weight of
occu ant. Use the knob to dial the weight of the operator (110 to 290 Lbs.) on the visual
indic tor next to it.
B.
HEIG T - Vertical adjustment handle. Lift up to release.
C.
FOR ND AFT - Lift the lever bar at the front of the seat and move the seat forward or
rearw rd as desired, releasing the lever at the desired location.
D.
BACK EST TILT - angle of the backrest is adjustable from vertical by lifting the lever up
on th left side to release the backrest.
E.
CUNATION ~ angle of inclination adjustment handle. Lift up to release. The front

eat can be varied to tip up or down.
F.
R - adjust for back comfort using the knob.
BOARDIN
STAIRS
The boardi g stairs are located on the left side of the machine at the rear of the walkway.
The stairs re counter weighted to remain in the up position when the machine is in
operation 0 down where boarding the machine. When the stairs are pulled down 3 to 4
inches a lim t switch will trip and drop out line Excitation (LE) which will stop the machine.
Refer to the igure on the following page.
To board wh n the machine is in operation:
1.
Pull one of the two signal chords at the rear of the ballast bar and wait for the operator
to bring the machine to a halt.
2.
Lower t e stairway.
AWAR ING:
3.
DO NOT ATTEMPT TO LOWER THE STAIRS WITHOUT

SIGNALING THE OPERATOR FIRST. When the ladder is pulled
down 3 to 4 inches, all brakes will set on the machine. FAILURE
TO HEED THIS WARNING COULD RESULT IN DAMAGE TO THE
MACHINE AND/OR RESULT IN PERSONAL INJURY.
After bo rding the machine, raise the stairs to their full UP position. The machine will
not be 0 erable until the stairs are completely in the UP position.
2.3.3
BI006008
Counterweight
Enclosure
Machinery House
Assembly
Signal Chord (2)

One On Each Side
Of Ballast Box.
Used To Signal
Operator From
Ground
1_-
Frontof~~
--Machine
Crawler
Assembly
Ground
\
BOARDING STAIRS
2.3.4
BI006008
OPERAT NG CONTROLS
This secl'on provides the operator with the location and an explanation of the controls,
instructio lS for machine;operation.
The oper:iting controls for this mining shovel are all clustered on the operator's control
stands ar d the air panel stand to the left of the operator's seat. The machine start-up
controls a e located inside the machinery house.
The machine's operating motions - HOIST, CROWD, SWING, and PROPEL - are initiated by
the opera pr using the two joystick controllers. These are the primary controls.
The secor dary controls are mounted in the control stands on either side of the operator.
They are t e necessary lights, switches, and pushbuttons to support the primary controls.
Air pressu e gauges and a crowd clutch regulator are located in the air panel stand. Also
located hel~ are buzzers and lights that signal the operator and announce faults in selected
systems 0 -board.
The mach ne controls have been positioned in the cab to provide the operator with
comfortabl ~ operation of all the primary controls and easy access to all the secondary
controls. Tt-e cab has been positioned and designed to give the operator a clear view of the
digging an j dumping area and the front end.
The cab has a phone system connected to receivers near the entrance doors on the right
and left win ~s inside the machinery house. This system provides communication between
the house end the cab during testing or maintenance periods.
------+-----------~-------------------~-----------~-----------~----
------+------------------------~--~--------------
---------------------------------
-------'r---------------------~----------
2.3.5
BI006008
PRIMARY CONTROLLERS
The primary operating
controls are the two joystick
controllers mounted on the
right & left consoles at each
side of the operator's seat.
Joystick Controller, RIGHT
Left Controller
Joystick
Controller, LEFT
The control on the left

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

controller operates the
dipper trip machinery to
open the dipper door.
ocld1847.Wpg
Right Controller
The controller on the right controls the HOIST machinery to raise or lower the dipper and the
swing machinery to rotate the machine either right or left when the machine drive is in the
DIG mode. If the machine drive is in the PROPEL mode, this controller controls the PROPEL
machinery on the right crawler and the swing machinery.
Both the hoist and the right propel drives are speed controlled. This means that the further
the controller is moved in either direction from its neutral position, the faster the drive will go.
The swing drive is torque controlled. This means that the further the controller is moved left
or right from its neutral position, the more torque the swing drive will develop.
The pushbutton on the right controller operates the signal whistle on the outside of the
machinery house. Push the button with your thumb sounds the air operated whistle. This
pushbutton will activate the whistle whether LE is on or not.
2.3.6
BI006008
LEFT JOYSTICK
RIGHT JOYSTICK
Propel FORWARD,)
(
Left Crawler
Propel FO. RWARD,)

( Right Crawler
Hoist LOWER
Crowd EXTEND
Dipper Trip
P hbutton
Swing
RIGHT
--r'
X Axis
Signal
Pushbutton
..
Crowd RETRACT
Hoist RAISE
Propel REARWARD,)
(
Left Crawler
Propel REARWARD,)
(
Right C?rawler
YAxis~
Y Axis ......:
Y-Axis
Crowd Motion
Hoist Motion
Right
x - Axis
NO MOTION
+~~-i(-l
Left
Swing Motion
Pushbutto
Dipper Trip
Signal Whistle
Y -Axis in
PROPEL
Mode
~===H=j Sprocket
-Indicated
by ( )
Propel Motion
jyst1847.wpg
182M JOYSTICK MACHINERY MOTIONS
2.3.7
BI006008
MASTERSWITCHES (JOYSTICKS)
MASTERSWITCH REMOVAL
The Masterswitches can be removed for servicing by removing 4 masterswitch mounting
screws and opening the console. As the masterswitch is removed, feed the control wires into
the masterswitch mounting bracket.
NOTE:
When replacing the masterswitch, make sure that the Y ("_") axis (cast into the
mounting flange) faces forward. Refer to the Electrical Schematics 10r wiring
diagrams.
MASTERSWITCH CALIBRATION
The master switches must be calibrated when a new switch is installed. To allow 10r wear in
the master switch components, they should be recalibrated at 500 hour intervals.
MASTERSWITCH (JOYSTICK) CONTROLLER SYSTEM
INTRODUCTION
The master switches are inductively coupled, non-contacting units 10r long 1i1e. These are
spring return to center joysticks.
A joystick control panel, consisting of (2) expander boards and (14) relays, interface the
joystick output to the motion regulator equipment, since the regulator equipment is not
compatible with the joystick output. The panel is located in the cab base.
ELECTRICAL TESTS
Electrical Schematic Diagrams are provided in the Schematics Section 01 this Manual.
When performing these tests, refer to the Functional Description provided in 4.3 and con1irm
that the system operates as described.
Masterswitches (Joystick Operator Controls)
The expander boards receive directional and neutral position in1ormation 1rom the master
switches and, the output operates the hoist, swing, and crowd master switch relays, which
enable each motion regulator and motor field controls.
2.3.8
BI006008
S-H and HMS-N will operate when:
OIST master switch axis is moved off neutral in the hoist direction.
S-L and HMS-N will operate when:
OIST master switch axis is moved off neutral in the lower direction.
-L and SMS-N will operate when:
WING master switch axis is moved off neutral in the swing left direction.
Relays SM -R and SMS-N will operate when:
- The SING master switch axis is moved off neutral in the swing right direction.
Relays CM -C and CMS-N will operate when:
- The C OWD master switch axis is in the crowd position.

Relays CM -R and CMS-N will operate when:
OWD master switch axis Is in the retract position.
ir horn) will operate when:

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

, SMSF. CMSF are fault relays for their respective master switch axes. They
- The ref rence signal from the axis is not within bounds; e.g., its amplifier saturates or
puts 0 t no signal.
- The el ctronic "Neutral" signal does not agree with the joystick neutral limit switch.
INTERFACE FOR JOYSTICKS (MASTER SWITCHES)
The PC boa d assembly is shipped factory preset according to this procedure. When
connecting to the joystick controller, it should only be necessary to check and slightly adjust
the input null per calibration procedure step 6 and 10.
2.3.9
BI006008
Test equipment and documentation requirements:

- Digital voltmeter with auto polarity or oscilloscope with high impedance input.
- Schematic diagrams.
- Master switch expander board illustration 2.3.w, 2.3.x, 2.3.y.& 2.3z
- Trimpost adjust screwdriver.
I
ADANGER:
THIS BOARD IS AN ELECTRICAL SHOCK HAZARD AND DEATH

OR SERIOUS INJURY MAY RESULT IF IMPROPERLY HANDLED.
115VAC is present on the PIC board. DO NOT TOUCH THE
AREA NEAR TRANSFORMER WHEN HANDLING, CONNECTING,
OR WORKING. Remove the power connection.
CALIBRATION PROCEDURE
1. Connect a 115VAC power cord to power input terminals 115VAC (HI) and 115VAC (LO).
DO NOT apply power or plug into power source at this time.
2.
Connect a joystick with "X" and "Y" axis outputs connected per the schematics. It is
important that the shovel handle not be moved until step 10 is completed.
3.
Connect a digital voltmeter, which Is set to its 20 volt scale, to the circuit by hooking
negative (black) lead to signal common (See drawing sheet 24 following in this section.)
The voltmeter negative lead need not be moved throughout this procedure.
4. Apply 115VAC to PIC board through power cord connected in Step 1. Observe voltage
on voltmeter. It should read approximately 15.0 volts. Check the negative 15VDC supply.
5. Adjust input signal null.

A.
Connect voltmeter positive lead to "X" axis input. Put the joystick handle in neutral
position and do not disturb until step 9 is completed.
B. Connect positive lead of voltmeter to pin 14 of IC 109. Test pin "A". Refer to page
2.3.17 - MASTERSWITCH EXPANDER BOARD -SHT. #1 following in this section as
a guide.
C. Set voltmeter on the 2.0 volt scale.
D. Adjust RV 101 potentiometer until voltmeter reads 0.0 volts. This nulls "S" axis input
signal to zero when joystick is in neutral. Reduce scale on voltmeter to 200 millivolts
and repeat until voltmeter reads 0.00 volts.
E. Connect positive lead of voltmeter to pin 1 of IC 209. Test pin "b".
2.3.10
BI006008
F. A just RV 201 potentiometer until voltmeter reads 0.000 volts. This nulls "Y" axis
in ut signal.
G. AI other adjustments must be checked after this procedure is complete. THIS
o TPUT IS FUNDAMENTAL TO THE ACCURACY OF THE OTHER OUTPUTS.
6. Adjust ense positive direction output.

A. M
e positive lead to voltmeter to pin 2 of IC 108. Test pin "c.
B. Ad] st RV 109 until voltage reads 140 millivolts on meter.

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

A. Mo e positive lead of voltmeter to pin 10 of IC 107. Test pin "e".
B. Adj st RV 110 until voltage reads 140 millivolts on meter.
C. Con ect positive lead of voltmeter to pin 5 of IC 207. Test pin "I".
D. Adju t RV 210 until voltage reads 140 millivolts.
8. Adjust n utral sense signal.
A. Con ect positive lead to pin 5 of IC1 07. Test pin "g".
B. Adju t RV 111 until meter reads 135 millivolts.
C. Conn ct positive lead to pin of IC 201. Test pin "h".
D. Adjus RV 211 until meter reads 135 millivolts.
9. Adjust de dband set point.
A. This a justment must be made after steps 1 through 8 have been completed.
2.3.11
BI006008
B. Deadband is adjustable between 0% and 20% of joystick output signal. When the
amount of deadband has been determined, multiply amount times the maximum
output signal from the joystick (1.5 volts) to determine set point.
Example: Factory Setting
1. 10% deadband is desired.
2. Deadband % x 1.5 = set point.
3. Therefore: .1 x 1.5 = .15 volts.
C. Move positive lead of voltmeter (Scale set to 2.0 volts) to pin 2 of IC 110. Test pin "I".
D. Adjust RV 106 until voltmeter reads a voltage equal to calculated deadband voltage.
Example was determined to be .15 volts, except change to .12 volts (.08 x 1.5). This
will set "X" axis deadband.
E. Move positive lead of voltmeter to pin 13 of IC 210 (Scale set to 2.0 volts). Test pin
"j",
F. Adjust RV 206 to determine set point of "Y" axis deadband.
G. Remember the deadband set point since it will be used to calibrate the positive and
negative offset adjustments.
H. Due to the light spring return action of the joystick, the handle may not return to true
neutral from each direction in an axis. Before proceeding to step 10, it is therefore
necessary to also null the signal in the following manner for each axis.
1.
Connect voltmeter per step 5.
2.
Push lightly on joystick each way in the axis until a recognizable "off-center"
resistance is felt and observe the voltmeter readings as the handle is moved. A
minimum + voltage should be observed as the handle passes through neutral. If
not, adjust signal null so that this minimum occurs when the handle is judged to
be in the true vertical position.
3.
Again push lightly on the joystick handle as above except allow the handle to
spring return to neutral and observe the null voltage. When allowing spring return
to neutral from either direction in this fashion, the reSUlting voltage measured
should not exceed 50 millivolts. If it exceeds 75 millivolts, the masterswitch is
faulty and should be returned for repair.
10. Positive and negative signal offset adjustment.

A. The positive and negative signal offset adjustment are used in the circuit to insure
that output signal voltages will be equal to zero when the joystick has been moved
to the end of the deadband or beginning of control signal output.
2.3.12
BI006008
B. M ve positive lead of voltmeter to pin 1 of IC 110. Test pin "k". Adjust command pot
u til voltmeter switches from negative 15 volts to a positive 15V +/-1 Volt. Make
a 'ustment carefully as the switch over point is very sensitive.
C. M ve positive lead to pin 7 of IC 110. Test pin "I". Reduce scale to 200 millivolts.
Ad ust RV 103 until voltmeter reads zero.
D. M e positive lead of voltmeter to pin 7 of IC 109. Test pin "m". Adjust RV 105 until
vol meter reads zero.
E. Mo e positive lead of voltmeter to pin 8 of IC 210. Test pin "n". Adjust RV 203 until
vol meter reads zero.
F. Mo e positive lead of voltmeter to pin 8 of IC 209. Test pin "0". Adjust RV 205 until
volt eter reads zero.
11. Output ignal amplitude adjustment

A. The noninverting output signal will be positive when the joystick is moved in a
posi ive direction and negative when moved in the negative direction. The inverting
out ut will be opposite to the noninverting outputs. Factory output signal level set
at + -10.0 volts. However, change to +/-8.0 volts.
B. Mov positive lead of voltmeter to "X" axis, noninverting output. Set scale at 20 volts
on
C.
eter.
command pot to maximum negative direction and adjust RV 104 until meter
-8.0 volts.
D. Lowe command pot towards neutral (slowly). Meter reading should swing to zero
smo thly. If meter reading switches to zero too soon, repeat 10 and 11 as
inter tions occur between these adjustments.
E. Swin command, pot to maximum positive direction and adjust RV 102 until meter
reads +8.0.
F.
G.
ositive lead of voltmeter to "Y" axis, noninverting output.
H. Swing ommand pot to maximum negative direction. Adjust RV 204 until meter reads
-8.0 v Its.
I.
J.
ommand pot to maximum positive direction and adjust RV 202 until meter
8.0 volts.
2.3.13
BI006008
K. Repeat step D.
NOTE:
Repeat steps 10 and 11 until exact outputs are achieved. One adjustment
affects the other and repetition may be necessary.
12. Adjust 1% to 5% maximum signal set point.

A. Move the position lead of the voltmeter to pin 13 of IC 107. Test pin "p". Set range
to 200 millivolts.
B. Determine percentage of maximum signal (factory set at 2.5%) desired and multiply
times max signal output to determine set point.
Example: Range - 2.5%
Max signal = 8.0 volts
Set point = .025 x 8 = 200 millivolts
C. Adjust RV 107 until meter reads 200 millivolts.
D. Connect voltmeter to pin 2 of IC 207. Test pin "q".
E. Adjust RV 207 until meter reads 200 millivolts.
F. Move joystick and observe operation of the Light Emitting Diodes (LED).
13. Adjust 110% signal detect circuit.

A. Set voltmeter to 20 volt range.
B. Connect positive lead of voltmeter to pin 2 of IC 107. Test pin "r".
C. Determine set point:
Set point = 1.1 (Max signal)
Factory setup: 1.1 x 8.0 = 8.8 volts
D. Adjust RV 108 until meter reads 8.8 volts.
E. Connect positive lead of voltmeter to pin 13 of IC 207. Test pin "s".
F. Adjust RV 208 until meter reads 8.8 volts.
G. Move joystick and observe operation of LED.
2.3.14
BI006008
14. The calibration procedure is completed. Use summary data sheets to record voltage
settin ~s for future calibration activities.
"r=~~=====-,
~~13
102
12 11 10 9
345 6
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INTEGRATED CIRCUIT (IC) PIN LAYOUT (Typical)
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2.3.15
BI006008
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BI006008
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5. NEUTRAL SENSE OUTPUT
V IC 107, PIN '/0

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4. SENSE NEGATIVE DIRECTION OUTPUT
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RECOMMENDED SETTING rOR ITEM 8.
v IC 107, PIN. 2
V IC 207, PIN '13
10.110% SIGNAL SETPOINT
V IC 207, PIN 2
V IC 107, PIN '13
9. 1-5% SIGNAL SETPalNT
X-AXIS MAX (-j

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B. OUTPUT SIGNAL AMPLITUDES
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7. POSITIVE AND NEGATIVE SIGNAL OFFSET
CAL /BRATION PROCEDURE
INTERFACE FOR JOYSTICKS
BI006008
BI006008
SECONDARY CONTROLS
These are located on the consoles on either side of the operator. They consist of the
necessary lights, switches, and push buttons to support the primary controls. Warning
signals and lights that inform the operator of potential machine problems or get his attention
from other personnel are also mounted in the consoles.
EMERGENCY
STOP
PROPEL MOTOR
BLOWER
10
()2
LEFT CONSOLE:
1.
6 O
motion brakes, removes power to the machine drives, and opens

the on-board high voltage vacuum breaker. this control should
only be used in situations where personal injury or machine
damage is imminent.
ROPEL
BAAK
PROPEL
DIG
~?J8,A
PROPEL
40q04
EMERGENCY STOP - a red mushroom pushbutton that sets all
ACAUTION:
2.
DO NOT USE EMERGENCY STOP TO

ROUTINELY SHUT DOWN THE MACHINE.
This control causes the machine to stop
very abruptly, which can over-stress
components and result in their premature
failure.
PROPEL MOTOR BLOWER - a green light which indicates the
propel motor blowers are operating when in the propel mode.

3.
PROPEL BRAKE - A red light to indicate the propel brakes are set
and a green light to indicate the propel brakes are released. These
are activated only when L.E. is energized and the control is in the
PROPEL mode.
4. DIG, PROPEL - green lights that indicate machine operating mode.
@@
cnsl1847.wpg
@@
5. PROPEL MOTOR FIELD - A red light which indicates a problem

with one or both of the propel motor fields. An alarm will be set off
when the light comes on. To eliminate the alarm, stop the machine
and push the LE STOP button. The light will remain on until the
problem is corrected.
6. CONTROL TRANSFER - a selector switch with three positions: DIG, BRAKES SET and
PROPEL. It is used to transfer between machine operating modes.
DIG - activates the hoist, crowd, and swing drives; deactivates the propel drive; and
automatically sets the propel brakes.

BRAKES SET - all brakes set regardless of the position of each brake control switch. The
master controllers Goysticks) are deactivated; thus the hoist, crowd, swing, and propel
drive functions are inoperable.
PROPEL - activates the propel and swing drives; deactivates the hoist and crowd
drives; automatically sets the hoist and crowd brakes if not already set with the manual
control switches; starts propel warning signal which is continuous while in propel.
2.3.20
BI006008
AOpa
EMERGENCY
STOP
MOTOR
BLOWER
10 ({:J)2
36RopaB
PROP
40004
6
,..-EXITATI
START
7({:J)
SWING
BRAKE
~T~~SE
@
SE (! ~;SE
modes. The recommended procedure is to have the swing

brakes released when propelling for a clearer view of the
area around the machine.
7. EXCITATION - These two push buttons control the application of
power (line excitation) to the machine's operating drives. The

START pushbutton, when pressed, energizes the control circuits.
It is illuminated green when L.E. is on. The STOP pushbutton,
when pressed, de-energizes the control circuits, indicated by the
green light in the START pushbutton going out. This control
permits the operator to temporarily remove power to the
machine drives without shutting down the machine. THE STOP
BUTTON SHOULD BE PRESSED, DROPPING OUT L.E.,
BEFORE THE OPERATOR LEAVES THE SEAT FOR ANY
REASON.
BRAKE
CROWD
1~W1iASE
@ @
NOTE: The swing drive is operable in both the DIG and PROPEL
@ @
ACAUTION:
To avoid excessive motion brakes wear,

all machine drives should be stopped and
not moving before "dropping out"
(de-energizing) Line Excitation. It is proper
operator procedure to stop all motions
and then set the brakes before pressing
the EXCITATION STOP pushbutton.
cnsll847.wpg
8. SWING
AKE - A 2-position selector switch to SET or RELEASE the two swing brakes.
AKE - A 2-position selector switch to SET or RELEASE the hoist brake.
10.
11.
BRAKE - A 2-position selector switch to SET or RELEASE the crowd brake.
AULT RESET - A black pushbutton. Push and release several times until the
es out. If it does not go out call for service.
12. HOIST, CROWD, SWING AND PROPEL MOTOR OVER-TEMPERATURE - Red lights
which i dicate a motor problem. An alarm will be set off when any of the 4 lights come
on. To Iiminate the alarm, stop the machine and push the LE stop button. The Iight(s)
will rem in on until the problem is corrected.
13. DC GR UNO LOOP - A red light which indicates an armature circuit ground in the hoist,
crowd, r swing motors. An alarm will be set off when the light comes on, to eliminate
the afar ,stop the machine and push the LE stop button. The Iight(s) will remain on
until the problem is corrected.
2.3.21
BI006008
14. MASTER SWITCH FAULT - A red light which indicates a @

problem with either or both masterswitches. An alarm will be
set off when the light comes on, to eliminate the alarm, stop
the machine and push the LE stop button. The light(s) will
remain on until the problem is corrected.
15. MOTOR BLOWERS - Indicates one or more of the blowers on
the D.C. drive motors for the hoist, swing or crowd machinery
has malfunctioned. The blower(s) at fault will have to be
determined.
HOiST
MOTOR
O'TEMP
CROWD
PROPEL
MOTOR
OTEMP
DC
MASTER
LOOP
SWITCH
GROUND
FAULT
~TOR
O'TEMP
SWING
MOTOR
Q'TEMP
@@@
@@@
@@@
MOTOR
BLOWERS
FILTER
FANS
AUTO
WBE
__. _ - - - - - -
._--_.
16. FILTER FANS -Indicates a malfunction in one or both of the

house air intake filter fans located on the house roof. The fan
at fault will have to be determined.
@~A1R
NOTE:
All fault warning lights are all of the "push to test" type.
To test that the light in each is functional, push it. The
light should come on. If not, replace the lamp. The light
will go out when manual pressure is removed. In order
to test these lights, the M.G.Set must be running. In
addition, the drive control must be in the propel mode
and line excitation (LE) activated (its green light
illuminated), to test the Propel Motor Temp light. These
lights should be tested at the beginning of each shift.
ACAUTION:
18
17. AUTO LUBE - Indicates a malfunction in one or more auto
lube systems. Stop the machine and check the lube control
panels in the Right Hand Wing. DO NOT operate the machine
without correcting the problem.
CONDITIONER
HE~T
(\\\0':: VE"'CooL
VENT
~
s~~
O~~L~~
@
CAB UGHTS
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cnsr1847.wpg
In the event an announced fault is experienced in any of the

fault lights, THE MACHINE MUST BE SHUT DOWN
IMMEDIATELY, the fault investigated, and the problem
eliminated BEFORE continuing to operate. Continued operation
after a fault is announced could result in damage to the
machine.
18. AIR CONDITIONER - A 4-position switch which controls the air conditioner operating
modes.
19. VENT - A 2-position switch to control the vent blower. The blower supplies filtered fresh
air through the air conditioner when in the heat, vent or cool mode.
20.
FAN SPEED - A 2-position switch to control the fan speed.
21. CAB LIGHTS - A 2-position switch to turn the cab lights on and off.
2.3.22
BI006008
ALARM
The alar s are located on the front of the right hand console. They include:
RM - Rounds off in a fast pulse in conjunction with a fault Iight(s) the alarm can
d by stopping the machine and pushing the LE button.
BOARDIN ALARM - A continuous alarm when activated by one of the pull chords at the rear
of the ma hine. The alarm is de-activated with release of the pull chord.
CROWD
limits.
OTION LIMIT - A chime indicating the dipper handle is into the crowd or retract
BOARDIN ALARM - A continuous alarm when activated by one of the pUll chords at the rear
of the ma hine. the alarm is de-activated with the release of the pUll chord.
CROWD
limits.
OTION LIMIT - A chime indicating the dipper handle is into the crowd or retract
Hoist. Crowd and Swing

Generator Field Excitation
Transformers in the '
Cab Base
" ......:
~~operator's Seat
,
,
,
,
J
Joystick Control Panel

( In th e ~b
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OPERATOR'S CAB -Plan View
2.3.23
BI006008
AIR PANEL
Crowd Clutch
Adjustment Regulator
1. The upper air pressure gauge indicates the

air system operating pressure of 120 PSI
(689 Kpa).
CAUTION: IF THE SYSTEM PRESSURE

IS BELOW 100 PSI, OR
ABOVE 120PSI, SHUT THE
MACHINE DOWN AND
CORRECT THE PROBLEM.
Failure to heed this caution
could result in machine
damage.
Gauge Port,
Crowd Clutch Pressure
(Plugged)
System
Air Pressure
Crowd Clutch
Air Pressure
2. Crowd Clutch Regulator - The crowd

machinery is fitted with a clutch which will slip
and protect the machinery from impact loads
that may occur when digging.
o
Air Panel Stand
3. Adjust the air regulator to obtain an air

pressure of 80 PSI in the lower gauge.
Further adjustment may be required due to
digging conditions and friction material.
Once set, no additional adjustment is required.
Air Supply
apnl1847.wpg
View
A-A
IMPORTANT NOTE:
The air supply line at the crowd clutch is equipped with a check valve that permits air
flow into the clutch but not out. This check valve is there to prevent inadvertent loss of
clutch action by accidentally eXhausting air and possibly letting the dipper handle
move in the boom yoke blocks without motor or brake control. This check valve is
located inside the guard over the clutch. To exhaust air from the crowd clutch, the air
supply line must be closed, the clutch guard removed and the air line to the clutch
loosened to reduce the air pressure.
DANGER: RELEASE THE AIR LINE PRESSURE BEFORE REDUCING AIR
PRESSURE TO THE CLUTCH. DO NOT ATTEMPT TO REMOVE
ANY FITTINGS UNTIL THE AIR PRESSURE HAS COMPLETELY
BLED OFF. FAILURE TO USE CAUTION COULD RESULT IN
PERSONAL INJURY.
----c
2.3.24
BI006008
2.4 OPE ATION
GENERA INFORMATION
This secti n of the manual is designed to assist the owner in the operation of this machine.
It provide the operator with the location and explanation of the controls, instructions for
machine peration, and certain maneuvering techniques.
Througho t this section, the use of the terms "LEFT', "RIGHT', "FRONT" and "REAR" refer to
machine I cations as viewed by the operator sitting in the operator's seat in the cab.
Heater / Air Conditioner

Operator's Cab
Dipper Trip Assembly
Dipper Pitch
Brace
Main Rotating
Gear~~~~~~~~~~.~.b;~~~~~~~
IP
O. . .
06 0
Crawler Belt
Lower Frame and Crawlers Assembly
Crawler Drive Sprocket

18247 _lIlIl. wpg
182M NOMENCLATURE
2.4.1
BI006008
OPERATOR'S CAB
Front
of
Machine
Joystick Controller,
--Hoist / Swing / Horn
Control
Console,
Left
Console,
Right
Joystick Control
Panel in the
Cab Base
-,-\
-,
I
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Operator's Seat
Air
Panel
Stand
2.4.2
BI006008
PRE-ST RT INSPECTION
Before st rting or operating the machine, know the emergency stop and proper operating
procedu es. Become familiar with all the controls and sound the signal horn to alert
coworker in the pit area of the intent to operate or move the machine,
arding, and before entering the operator's cab, inspect the areas listed below:
Dipper:
..; Rope
..; Teet
..; Adap
..; Dipp
..; Trip
..; Dipp
..; Lubri
& Equalizer Sheave

& Pins
ers
r & Bail Structures for Cracks
echanism & Snubber
r Latch Bar
ation Fittings
Front End
..; Condi ion of Boom
..; Hoist heaves
..; Crow Machinery
..; Handl /yoke Block Clearance
..; Lube overage
..; Hoist opes for Wear or Damage
..; Boom upport Pendants
..; Air & L be Lines & Connections
..; Loose ins or Retainers
..; Walkw ys & Railings
..; Trail C ble & Cable Reel Condition

..; Swing ear & Pinions for Lube & Damage
..; Guardi g
..; Cracks 'n Structure
..; Roller ircle Condition
..; Lube C verage
..; Air & L be Lines & Connections
ADAN ER:
HIGH VOLTAGE. DO NOT contact the high voltage areas of

the trail cable or collector rings. NEVER perform electrical or
mechanical repairs or maintenance in these areas without
disconnecting the trail cable power supply. Failure to
disconnect trail cable power supply could result in severe bodily
injury or death.
2.4,3
BI006008
Crawlers:
J Belt Tension
J Missing Shoe Pins or Retaining Bolts
J Idlers, Load Rollers & Sprockets for Damage
J Lube Lines, Fittings & Guards for Condition
J Lube Coverage
J Structures for Cracks
J Propel Machinery
J Tension Rod Nuts for Tightness
Rotating Frame & Machinery House:
J Structure Condition
J Air Compressor Crankcase Oil Level, Drive Belt & Operation
J Auto Lube Systems: Lube Supply Adequate & Operation
J Air & Lube Lines & Connections
J Lube Coverage
J De-leer Reservoir Level
J Drain Moisture/Condensation from Air Line Filter & Air Tank
J Blower Motors Operational
J Filter Fans Operational
J Swing Machinery
J Hoist Machinery
J Open Gears for Condition
J Hoist Ropes for Condition
J Electrical Cabinets for Security & Door Position
J Fire Extinguishers or System for Charge & Condition
J Walkways, Rails & Ladders for Access & Condition
J Gantry Structure & Backlegs for Cracks
J Gantry Foot Pins & Retainers
J Equipment Structure Base Bolts
J Guards Condition
J House Panels Condition
Operator's Cab:
J Controls for Operation

J Warning Indicators & Alarm
J All Brakes for Function
J Support Systems for Function
ACAUTION:
Notify maintenance personnel at once if pre-start inspection

routine identifies any defects.
2.4.4
BI006008
MACHIN
START-UP & SHUTDOWN
START- P PROCEDURE
Typical st rt-up from a completely shut down condition is accomplished as follows.
Do no start this machine unless you are completely familiar with the various controls.
Always perform the Pre-start Inspection given at the beginning of this section before the
actual tart-up.
1. Make s re power is ON and the applicable main circuit breakers closed by observing that
the vol meters on the front of the motor control center and the high voltage cabinet are
indicati g voltage. If a meter is not showing voltage, then close the affected breakers. If
that is ot the problem, then notify the electrical maintenance personnel for assistance.
2. At the otor Control Center, check the Phase Sequence light. If not lit, push it to test its
red la p. If alright, turn the Air Compressor switch to the AUTO position. Shut
compre or down immediately if any unusual sounds are heard. The green indicator light
will co e on when the compressor is running.
3. Next, p sh the Filter Fan NO.1 start pushbutton. Let it come up to operating speed and
then pu h the Filter Fan NO.2 start pushbutton. The green lights will come on when the
filter fan are running. Push their stop push buttons if any unusual sounds are heard.
4. Start the motor blowers by pressing the start pushbutton on the Hoist Motor Blower panel.
This will also start the motor blowers on the crowd and swing motors and permit the
propel
otor blowers to startup when switching to the propel mode.
NOTE: If the propel motor blower indicator light does not come on, when in propel mode,
c eck that the manual on each propel motor blower is closed before calling for
s rvice.
The sou d of the fans and their green indicating lights coming on will let you know that
they are perating. Hold the start button down until the green indicating lights for the hoist
and the c owd and swing blowers are illuminated. The propel motors blowers indicating
light will ome on only if the machine drive is in the propel mode. Shut blowers down
immedia Iy if any unusual sounds are heard.
Always let the system being started come up to normal operating
speed before starting the next system.
5. At the Hig Voltage Cabinet, momentarily press the M.G. Set start pushbutton. The M.G
Set will g through a reduced voltage starting sequence automatically (approximately 15
seconds ill be required) The green light in the start button will illuminate when the set
has reac ed full speed. Be prepared to push the M.G. Set stop button if any unusual
noises ar heard. If the starting sequence takes too long the M.G. Set will shut down
automatic lIy. If this happens call for service.
2.4.5
BI006008
6. Check that power is on the Auto Lube Control Panels. The green indicator lights on the
front of each panel should be illuminated. If not, check that the circuit breaker in the
Lighting Panel by the left house door that is labeled Auto Lube is on. If the green indicator
lights do not come on when the auto lube breaker is closed, do not operate the machine,
call for service.
7. When all systems are operating satisfactorily, leave the machinery house and go to the
operator's cab.
8. Note the air system pressure on the Air Panel Stand. It must be 115 PSI (793 kPa) or
above before Line Excitation (LE) can be energized. If it is above 120 PSI (827 kPa), report
this condition to the proper maintenance personnel for adjustment/correction.
9. Set in the operator's seat and swing into the operating position. Adjust the seat as
required.
10. Observe the fault warning lights on the Operator Control Console. If any are illuminated
investigate the reason and correct the problems found before proceeding. Push each
fault light to test its lamp. Note any burned out.
11. Set the Hoist, Swing, and Crowd Brakes.
12. Position the Control Transfer switch to BRAKE. SET.
13. Check that the primary controllers are in their NEUTRAL (center) positions.
14. Press the Excitation Start pushbutton on the Operator Control Console to activate the
drive systems.
NOTE:
Line Excitation (LE) CANNOT be activated unless:
a. The M.G.Set is running.

b. Hoist, Crowd, and Swing joysticks are in NEUTRAL (centered).
c. Hoist, swing, and crowd DC motor blowers are running.
d. Pressure in the air system exceeds 100 PSI (690 kPa) to 115 PSI (793 kPa).
e. Retractable boarding stair is fUlly up into its machine operating position.
Observe that the LE green indicator light comes ON. When this light is on, the motion
controllers are energized.
15. Move the Control Transfer switch to the DIG position and move the Hoist, Swing, and
Crowd Brake switches to their RELEASE positions. The machine is now operational in
the dig mode as indicated by the Control Mode lights on the Operator Control Console.
2.4.6
BI006008
TO TRAN FER FROM DIG TO PROPEL MODE:
Return both primary controllers to the neutral position. This initiates a 5 second delay in
the tra sfer circuits.
Move t e hoist and crowd brake selector switches to the SET position.
AC
UTION:
THE MOTION BRAKES ARE INTENDED FOR PARKING AND

EMERGENCY STOPS. FOR MINIMUM BRAKE LINING WEAR,
BRING ALL MOTIONS TO A COMPLETE STOP BEFORE
SETTING THE BRAKES.
Move t e control transfer switch to the BRAKE SET position. Motor control is removed
and all rakes are set-regardless of the other brake switch positions.
Move t e transfer switch to the PROPEL position and allow 3 seconds for the transfer to
propel. Check that the propel motor blower, propel brake released and propel mode
green I ghts have turned on, indicating that transfer to the propel mode has been
com pie ed.
'
The m chine is ready to propel and the swing function is fully operable to assist the
operato in maneuvering.
TO TRANS ER FROM PROPEL TO DIG MODE:
Return oth primary controllers to neutral position. This initiates a 5 second delay in the
transfer ircuits.
Move th control transfer switch to BRAKE SET. Motor control is removed and all brakes
are set. heck the propel brake set red light is on and propel blower green light is off.
control transfer switch to the DIG position and allow 3 seconds for the transfer
to dig m de. Check that the green dig mode light has turned on to indicate that transfer
to the di mode has been completed.
hoist and crowd brake selector switches to RELEASE position.
The mac ine is ready to dig.
.._-..
----+---------~--~-~~~--_
~-_
..
_-_.~_._-_
-----+----~-_._--------------_._-------
2.4,7
. _-
~- --~--
--._---~._----~
..- -_.-- .-----------
BI006008
NOTE:
The propel brake indicator lights are controlled by pressure switches located close
to each brake. When the switches OPEN, the brakes will be set. The dig and
propel mode indicator lights are controlled by the control transfer switch.
ADANGER:
UNAUTHORIZED CHANGES TO THE BRAKE PRESSURE

SWITCHES COULD RESULT IN EQUIPMENT DAMAGE AND
PERSONAL INJURY.
Pres. Sw. CLOSES

Hoist Brake
1g.P.~I (!.f>~ .
Swing & Crowd Brakes
95 PSI (655 kPa)
Propel Brakes 95..PSj(655kPa)..
1.
k.P.<:lL
Pres. Sw. OPENS
.!g.p.~! . (~.s.~ ..k.P.~L

55 PSI (379 kPa)
{3PS\(90'kPa)..
PARTIAL SHUTDOWN
To shut down the machine in order to leave the operator's seat temporarily, for break or for
shift change, only the primary controls need be deactivated. If it is the end of the shift, rotate
the machine one full revolution to change the position of the rollers in the roller circle for
even wear. Sound the whistle before swinging the machine.
Lower the dipper to the ground and set all brakes after machine motion has stopped. Move
the Control Transfer switch to BRAKE. SET position.
Finally, fully press and release the Excitation Stop pushbutton to de-energize Line Excitation
(LE). The green indicator light in the Excitation Start pushbutton should go out.
The machine is now inoperable and is partially shut down.
2.4.8
BI006008
COMPL TE SHUTDOWN
1. Park t e machine on a level area that is out of the way of rock slides or falling rocks and
that is not prone to flooding. The surface of the area should be firm so the machine
canno sink into it.
2. When he machine is safely located, follow the procedure described in the preceding
seetio "Partial Shutdown".
3. Leave he Operator's Cab and go to the High Voltage Cabinet inside the Machinery
House.
4. De-ene gize the M.G. Set induction drive motor by pressing the M.G .Set stop pushbutton
on the front of the High Voltage Cabinet. The green indicator in the M.G. Set start
pushbu on will go out when the vacuum breaker opens the circuit feeding the motor. The
M.G. S t will coast to a stop.
5. Go to t e Motor Control Center. Fully press, then release the STOP push buttons for the
followin systems to shut them down:
Hoist Motor Blower (this shuts down all motor blowers).
Filter Fan No.2.
Filter Fan NO.1.
The r spective green indicator lights should go out.
Move t e Air Compressor selector switch to its OFF position.
7. If it is humid or cool, turn the Anti-Condensation Heater selector switch to AUTO, if the
machine has this system. This will protect the electrical equipment while the machine is
shut do n and the power is on.
e is now shut down to a point where inspection, maintenance, etc., can be
urn off all lights not needed.
ADA
HIGH VOLTAGE. High voltage and incoming electric power

is ON to the transformers, disconnects, electrical cabinets, and
collector rings. NEVER PERFORM MAINTENANCE OR
REPAIRS IN THESE AREAS WITHOUT DISCONNECTING THE
POWER SUPPLY (TRAIL CABLE) FROM THE MACHINE. Failure
to do so could result In personal Injury or death.
2.4.9
BI006008
GROUND PREPARATION
Ground preparation is very important. The mining shovel requires a properly prepared
ground base for operation. The crawler shoes must have full contact with the ground when
the machine is digging. With the machine weight distributed ,over the crawler shoes
minimum ground bearing pressure is obtained and the machine components are less
stressed.
For optimum operation, the ground supporting a mining shovel must be as near level as
possible and firm. Sharp rocks and boulders cause point loading which will damage the
propel machinery and crawler structures and should be removed if possible. Where this is
impractical, cover the working area with fill dirt to a sufficient depth that will eliminate the
effects of the rocks.
The mining shovel design incorporates a calculated balance between boom length, boom
angle, allowable dipper load, machine weight, and ballast used. During normal digging
cycles, the center of gravity shifts from the front to the rear within a specific distance. If, for
any reason, the digging radius or load increases to cause the center of gravity to extend
beyond this specific distance the machine will become unstable.
CAUTION:
OPERATION OF AN UNSTABLE MACHINE COULD RESULT

IN DAMAGE TO THE SHOVEL, TRUCKS OR SUPPORT
EQUIPMENT.
2.4.10
BI006008
GENER L
Each mot on of this machine is controlled by distinct joystick actions. The operator transfers
joystick m vements into the desired machine action - CROWD, HOIST SWING, PROPEL - to
result in
mbined smooth, safe, and productive machine operation.
Short, fast and erratic movement of the joysticks results in uncoordinated machine motions.
This will r duce productivity, consume excess energy, risk personal safety, and shorten
machine I fe.
This mac
optimize
operation
hauling e
inery develops inertia when put into motion. If that motion is not controlled to
ach second of machine operation, costs of operation will increase. Careless
an result in serious personal injury and severe damage to a machine or even to
uipment. Always use careful judgement when in the operator's seat.
Machine h ist and crowd controls are designed to give the operator maximum power or bail
pull no ma er what speed is selected by movement of the joysticks. Therefore, if you feel like
you are f eling fatigued because of "control jockeying" you are most likely operating
incorrectly
DIGGING
The digging cycle consists of positioning the machine dipper into
the bank, p netrating the material to load the dipper through the
hoist and owd motion, retracting the dipper out of the bank
swinging t the dump point, dumping into the hauler and
returning th dipper to the bank ..
Ie the CROWD motion is most important in achieving
an optimum ipper fill. For best results the operator must "shave"
the material off the face of the bank (refer to the figure) with the
dipper lip. his is best accomplished by matching available
machine bail pull with depth of "bite" into the bank that penetrates
the material ithout stalling the HOIST motor.
Balancing C OWD/HOIST motions with the material's resistance
to being sh ed off the bank face in a smooth, efficient filling of
the dipper is he mark of a professional machine operator.
2.4.11
dgcy1845.wpg
DIGGING CYCLE
BI006008
For digging, machine

control is in DIG mode,
Line Excitation activated,
and the hoist, swing, and
crowd brakes released.
Begin the dig cycle by
moving the dipper into the
toe of the bank. Push the
RIGHT joystick forward to
lower the dipper to this
position. Move the LEFT
joystick forward engage the
CROWD motion.
Control
Console.
RIGHT
NOTE:
Counteract any
tendency of the
machine to drift
by slight
engagement of
the swing
machinery in the
direction
opposite the drift.
Do this by
moving the
RIGHT joystick to
the left or right.
octd1847.wpg
182M OPERATOR CONTROLS -DIGGING

Continue the dig cycle by pulling back the RIGHT joystick to hoist and pushing forward on
the LEFT joystick to crowd. Control the amount of crowd force into the face so as to keep the
dipper filling.
ACAUTION:
NOTE:
Avoid overcrowding into the bank until the HOIST motion stalls.
This poor operating technique will reduce cycle efficiency and
machine production.
Limits designed into the CROWD motion neutralize overcrowding or hoist stall
conditions by automatically commanding zero speed to the CROWD function. This
feature eliminates accelerated wear to electric drive and clutch components and
minimizes possibility of boom jacking caused by the operator commanding
excessive crowd force.
2.4.12
BI006008
When th dipper is full, pull the LEFT joystick to the rear to retract the dipper from the bank.
Continu to hoist the dipper to its dump height. Stop the hoist by returning the RIGHT
joystick t neutral and moving this joystick left or right for the direction of swing desired.
NGER:
When swinging, the dipper must be raised to clear all

obstructions. Always be aware of the necessary swing
clearance at the rear of the machine. Do not start the swing
until the dipper clears the bank.
Start swin ing slowly to avoid excessive side thrust on the boom and dipper handle. As you
approach the dump point, change the RIGHT joystick either left or right in the opposite
direction f swing travel to slow and stop swing motion. Use swing motion as needed to
keep dipp r over haul truck and steady to dump.
Open the ipper door by using the pushbutton on top of the LEFT joystick. Hold the switch
down Ion enough to release the latch bar, which opens door.
To return t the face for the next dig cycle, move the RIGHT joystick forward and either left
or right to ave the machine toward the face. This will lower the dipper to the toe of the bank
as it swing. Use CROWD motion as required to position the dipper out from the boom.
ACA
TION:
Stop the swing motion before beginning to dig into the bank. DO
NOT USE THE DIPPER TO STOP the SWING MOTION.
MOTION L MITS
There are otion limits built into this mining shovel to protect the machinery against over
travel or ave use. These limits and the procedure used to get out of each is explained here.
The Boom
the crowd
limit, revers
support rap
cking Limit is activated when the boom is raised out of its normal position by
otion. This .results in a loss of crowd out effort and motion. To get out of this
the LEFT joystick to RETRACT. This will permit boom to settle down onto its
s and the crowd out drive will be restored.
Crowd Exten /Retract Limits can be activated by either crowding the dipper handle out too
far or retracti g it in too m'uch. Getting into either limit results in the loss of effort and motion
to the dipper andIe in whatever direction it was moving. To get out of either limit condition,
move the L T joystick in
the reverse direction from that in which the dipper handle was
I
operating. Th s will activate the drive in the opposite direction and move the dipper handle
out of the vi ated limit.
Limit is activated when the dipper handle is raised too high and is near the
sheaves at th
the hoist brak
the EXCITATI
brake, then I
boom point. This results in a loss of hoist and lower effort and motion and in
setting. To get out of this limit, return the RIGHT joystick to NEUTRAL. Press
N START pushbutton on the operator's left control stand to release the hoist
wer the dipper handle out of the limit with the hoist joystick.
2.4.13
BI006008
NOTE:
Anytime one of these motion limits is violated, the Limit bell on the front of the
operator's right control console will sound.
ACAUTION:
These motion limits are safety devices built into the machine to protect it
against operator error. THESE ARE NOT OPERATING LIMITS AND ARE
NOT TO BE USED DURING NORMAL OPERATION. REPEATED
ACTIVATION OF ANY LIMIT WILL RESULT IN DAMAGE TO MACHINE
COMPONENTS and require downtime for repair. This causes production
costs to increase. An accomplished operator will seldom, if ever, get into
any of these limits while running the machine.
PROPEL
Moving the machine

around the bank
work area and from
one bench to another
or anyWhere in the pit
requires careful
operator
concentration and
co-ordination with the
ground crew.
Right
Crawler
Forward
Dipper Trip Pushbutton
I
Swing
Left
Joystick
Controller, LEFT
Control
Console,
RIGHT
Oclp1847.wpg
182M OPERATOR CONTROLS -PROPEL

Park the dipper handle in its carry position before transferring control from DIG to PROPEL
mode. Carry the dipper with the dipper handle lower than its horizontal position when
propelling, so the dipper weight is supported with the shipper shaft too. This position
minimizes shock loads on the hoist drum shaft and bearings when propelling the machine.
2.4.14
BI006008
For prop ~lIing, machine control is in PROPEL mode, Line Excitation activated, and propel
brakes r~leased (green light ON). The swing drive is activated in this mode also. It is
recommE nded standard procedure to have the swing brakes released while propelling
steering f ~r better travel area obseNation and machine control. The propel warning Klaxons
or buzzer will sound all the time the machine is in the propel mode and LE is energized.
NOTE:
When transferring from DIG to PROPEL mode, the hoist and crowd brakes
automatically SET to prevent the dipper from falling. It is proper operator
procedure, regardless, to set these brakes with their manual control switches
before transferring modes.
Moving th RIGHT joystick controls the propel machinery on the RIGHT crawler. Moving the
LEFT joys ick controls the propel machinery on the LEFT crawler.
Forward rnovement from "neutral" of either joystick results in the respective crawler belt
moving fcrward; rearward movement of either results in the respective crawler moving in
reverse.
IMPORTArliT:
Forw rd movement of the crawlers is toward the front idlers. The operator should be
aware of the crawl~rs position with respect to the rotating frame before attempting to
move the machine.
The forwa d/rearward movement of either joystick controls the speed of the propelling
motion in Jroportion to the amount the lever is moved away from its neutral (centered)
position.
ACAJTION:
Make sure the propel brakes are released (green indicating

light ON) before moving either master controller off neutral.
MOVING A CRAWLER BELT BEFORE ITS BRAKE IS
RELEASED WILL RESULT IN PREMATURE BRAKE WEAR and
expensive machine downtime to repair.
ACAlTION:
After placing machine control in the propel mode, carefully

push each joystick forward to confirm the direction of crawler
travel. WHEN THE OPERATOR CAB DOES NOT ALIGN WITH
THE FRONT IDLERS ON THE LOWER FRAME, MACHINE
MOVEMENT COULD BE DIFFERENT THAN EXPECTED.
-----+--_._._---
-~ ---~'-'~--~-'~---.--'--~-.~--------~--------'-'-~-----------~
-----+~._-----
-~-.
--.~--~------
... -.-------_.-
2.4.15
_.- _.. _
_.~----.
__
._------~
BI006008
STEERING
Each crawler belt, being able to move independently, gives
three ways to steer.
1. DIFFERENTIAL - both crawlers moving in the same
direction but at different speeds
"PIVOT STEER"
( Right / Left)
2. PIVOT - crawlers moving in opposite directions
3. SKID - one crawler moving, the other stationary
Straight propel motion forward is the best direction to travel

when making long distance moves.
"DIFFERENTIAL STEER"
NOTE:
( Right / Left )
Do not propel the machine in reverse direction over

extended distances or up or down long inclines.
Turning the machine left or right requires the operator to

select the direction of turn.
ACAUTION:
Visually-check the trail cable

location, the machine ground
clearance, and the pit area for
personnel and equipment. Also
check the machine's location
relative to the face/bank. Sound the
signal whistle prior to moving or
steering the machine.
S
T
p
~
"SKID STEER"
( Right / Left)
steer3WY.wpg
STEERING the MACHINE
With the dipper in front of the crawler front idlers, the propel will perform as follows:
Move both joysticks equally forward to propel the machine straight forward. Likewise,
moving both joysticks equally rearward propels the machine il'"' straight reverse. Returning
both joysticks to neutral stops propel effort.
Steer LEFT by moving the RIGHT joystick forward and the LEFT joystick rearward, moving
both the amount needed to achieve a smooth pivot turn.
Steer RIGHT by moving the LEFT joystick forward and the RIGHT joystick rearward,
moving both the amount needed to achieve a smooth pivot turn.
To propel in a straight line, move both joysticks in the same direction the same distance from
neutral.
The difference in the direction and/or distance the joysticks are from neutral determines the
machine's turning arc.
2.4.16
BI006008
When pr pelling long distances (over 500 feet/150 meters), extra lubrication is needed for
the craw er side frame components. Make sure the fast cycle in the auto lube system is
working roperly.
When sto ping the machine for any interval during the move, place the control in BRAKES
SET mo e. Once the machine has been positioned at the bank or has reached its
destinati n, return machine control to DIG mode to resume operation.
AD
NGER:
When transferring from PROPEL to DIG mode, pause in BRAKES

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

Electric sh
the contro
productio
swing spe
factors su
shifts, an
machine p
vels are only as efficient as the operator at

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

in their ina ility to contr9' the pit face/floor conditions
or the prop r spotting ot'the haul units.
To maintai maximum output, the optimum swing
angle for s ovels is an arc of 30-90 between the
digging fac and the dump point.
swarcshwpg
SWING ARC
Swing arcs reater than 90 require the machine to spend more time in the swing cycle
between 10 ding and dumping. This decreases production.
-------+---_.__.------- --. ------ ----- --------- ----- -- -- --- -- -
------+---_._._--- ._- -- ----- - -- - - -- -- -- ---- ---. --
- - - - - - - + - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -....- .. _-----_ ..--"-------------------------
2.4.17
BI006008
The operator should spot the haul units. Do this by suspending the dipper above the spot
where you want to dump. Each haul unit driver can then position his truck body in the center
of this target area.
ACAUTfON:
Set the hoist brake to hold the loaded dipper in position if

spotting time will exceed 30 seconds.
The working face often has difficult areas where blasting failed to fragmentize the rock or
material. Avoid these areas while loading the truck. Loosen and break out the difficult/tight
material while waiting on haul trucks to return.
Haul truck spotting can also be

done quickly by keeping the pit
area immediately within the radius
of the boom point clear of rocks
and debris. This housekeeping
practice can also reduce the cost
of shovel crawler maintenance
and haul truck tire expense.
18247trk.wpg
SPOTTING the HAUL TRUCK
CAUTION:
Do not sweep rocks or blocks of material on the floor of the pit

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

This unit is mounted at the rear of the lower frame assembly. Its function is to handle the trail
cable, that supplies electric power to the machine, during machine relocation. It is a
self-contained unit that is powered by an air operated motor. Refer to the equipment manual
from the manufacturer of this unit for more detail.
ADANGER:
HIGH VOLTAGE DO NOT REMOVE THE GUARDS OR

OPEN ANY ENCLOSURES ON THIS CABLE REEL UNTIL
POWER IN THE TRAIL CABLE HAS BEEN SHUT OFF AND ITS
CONTROL BREAKER AT THE MINE SUB-STATION LOCKED
OUT IN ITS TRIPPED POSITION. Only qualified personnel are
permitted to work on this cable reel assembly. Accidental
contact with energized electrical compol,1ents will cause death.
Compressed air is supplied to the cable reel by the compressor on board the machine. The
manual control valve for the reel is mounted on the rear of the unit on a swing out boom.
This boom arrangement permits the reel operator to be in view of the machine operator
during operation.
2.4.18
BI006008
When th machine is operating (compressed air is in the supply lines), the cable reel can be
operated in its constant tension condition and will perform its function unattended. To put
the cable reel in its constant tension condition, move the lever on the manual control valve
to its re I in position. The valve is detented and the control lever will stay where it is
positione at either of three settings.
With the ntrol valve set at reel in, the trail cable will automatically wind onto the cable reel
when the achine is propelled in reverse direction toward the trail cable. When machine is
propelled orward away from trail cable, the trail cable will be pulled off cable reel. Anytime
machine i stopped, cable will cease winding onto or from reel.
The tensi n imparted to the trail cable by the reel in this constant tension operation is
adjustable by a pressure regulator on the right side of the cable reel. It is correct when there
is sufficie t pUll on the trail cable to wind onto the reel, but not so great as to put
unnecess ry strain on the cable. Report any problems with cable reel operation to the
maintena ce crew so they can adjust the tension during the next preventive maintenance
period.
The unwin position of the manual control valve is used to remove trail cable from the reel.
It need on y be used to' remove cable from reel for change out or repair/maintenance if
constant t nsion operation is utilized for normal machine operation.
I
When the anual control 'valve is in its neutral or centered position, the reel will not unwind
or reel in. It is locked in position by the valve.
IMPORTAN NOTE:
aving the cable come of the reel anytime the machine is completely shut down
(air com ressor off)" place the cable reel's manual control valve lever at its neutral
) position before leaving the machine.
ACA
ION:
Do not operate the machine with over two wraps of trail cable
wound onto reel's drum, unless provision has been made for
more by the manufacturer.
2.4.19
BI006008
~---------------
--------------
----------------------------------------
2.4.20
BI006008
2.5 BO M WIRING
FINAL CROWD
.--+--
SK15B
FINAL RETRACT
-----SK42E
SK42H
SK42E
INITIAL CROWD
I
..r:
SK15B
INITIAL RETRACT
SK39E
SK39H
SK39E
GND
i,--+__
GND
---
.,_~
CROWD LIMIT SWITCH
--I'"
, .
eMA'
tMAl
Fl
fic~aM
FZ
,5C25""
p,
p;:
CROWD MOT OR
jo(,)
TO BOOM
JUNCTION
BOX
u.
5MO't
IZAHtJ
Ii'
.,
.,
"I _
"z.
H~
lZA~
IU
GHO
,,
-.!
Gil
~~3:
I
<>.J.
0-':~31"~
" __ :!J
is"
UPPER FRAME LUBE

PRESSURE SWITCH
-----~,---,z.~-l
~'z.n3~
11
IZrux{"t".-----
r'-./'.~
~.
-----
GIIlL--.J I
-_._---~
CROWD BLOWER MOTOR
G O
___
,,:....-_-
-::-
HOIST LIMIT SWITCH

bmws1847.wpg
Schematic, BOOM WIRING
2.5.1
BI006008
MMr'------f,)
I. I--ft~',
-HG----.-.
tIiJi'-;"-1
". ,
l L.. _.~
: .t,j WI
(1
I
Hoist Limit
Switch
'I
I
,j
Upper Frame
Lube Pressure
Switch
Open Gear
Lube PS
Open Gear Lube
Pressure Switch
Upper Frame
Lube PS
/ ~\\
< Intmd.
Crowd Shaft
Ref
Crowd
Blower
Motor
J
.,
Crowd
Motor
Crowd Brake
Magnet Valve
----fHHI-+
r-.
U.F. Boom Junction Box
---L.
BOOM WIRING PLAN VIEWS
2.5.2
-,
BI006008
CROWD LIMIT SWITCH

/
* Use Loctite 271-31 on Keys and
//"//////
Lubricate with MPG

at Assembly
Set Screws at Assembly
Crowd Limit Switch

( Cams 1.2,3 & 4 )
.38 Capscrew
Gr.5,
4 Places
+- - - \ , ( - + - -
~~
.'-+-00
_..J1J'
Shim as
Required for
Coupling
Alignment.
Support Bracket
.5 Capscrew
Gr. 5 - 6 Places
Clsc1847.wpg
NOTE:
e speed reducer requires % pint of the listed oil. Check the oil level every 200
urs and change it at 2500 hours.
SPEED REDUCER OIL
R-ec-o-m-m-e-n-de-d-O-i-'_.
(Or equivalent)
~s-C;;iY--I-'-----------
Range BUS
@ 100"
Lubricant
180 - -
Viscosity
Grade No.
The CROWD (MIT SWITCH, located on a bracket on the right side of the boom in-line with
the intermedi te pinion shaft, is a rotating-cam type electrical-mechanical unit designed for
continuous ration in either the clockwise or counterclockwise direction. Electrical contacts
in the switch re provided for controlling four circuits.
Each set of c ntacts is actuated by cams which are supported on a separate disk welded
to the main sh ft of the switch. As the shaft rotates, the cams open and close. The sequence
of operation 0 the contacts depends on the position of the various cams with respect to the
shaft.
Torque requir ments of the switch are a maximum of 12 inch-pounds to open a contact. The
contacts are fo ced open'by direct cam action and are spring closed. This design provides
a failsafe condi ion so opening of the circuit is not dependent on springs or other parts that
could fail.
2.5.3
BI006008
A cross section view of the switch shows the contact unit (1t.#1) in the open position. Switch
in normal operation (within limits) is in the closed position. In the open position, the camshaft
(1t.#2) has been rotated so that the contact arm roller (1t.#3) is shown riding on the high
portion of the cam (1t.#4) and has depressed the plunger of the contact unit opening the
contacts. As the cam continues to rotate, the arm roller will drop down to the lower portion
of the cam allowing the spring loaded plunger to return to its normal (open) position.
ACAUTION:
NEW SPEED REDUCERS DO NOT CONTAIN OIL
.j The speed reducer has a 50: ratio

.j The limit switch must be reset after maintenance which requires removal of anyone of the
following (dipper handle, shipper shaft, intermediate crowd shaft and limit switch).
1.
2.
3.
4.
5.
6.
7.
Contact unit
Camshaft
Contact-arm roller
Operating cam
Switch-unit plunger
Contact arm
Vernier-adjustment locking
screw
8. Vernier plate
9. Cam-follower bracket
1O.Filler strips
c1SW1845.wpg
When installing a replacement limit switch, carefully align the switch with the intermediate
crowd shaft using shims. This will prevent excessive wear on switch bearings and provide
long mechanical service life. The switch is equipped with self-aligning sealed ball bearings
which prevent entry of dust and dirt minimizing level of torque to drive the shaft.
2.5.4
BI006008
ELECTR CAL RATINGS

Carry Co 1tinuously .. 15Am ps.
A.C."Mal~ e"Value ... 75 Amp s.
D.C. Inductive
A.C.lnte rrupting
Volts
Amperes
Volts
Amperes
110
220
440
550
75
50
18
14
125
250
600
1.8
0.7*
0.24
CAMSE:T ING
SCORED ( 'AM
The dis cl ne-up on the cam shaft, to which the cams are
attached , t ave indicated marks at 15 intervals. The keyway
slots in t he ends of the shaft co incide with the zero point.
After de ter illining the number of degrees that the contacts
should beo pened, select the p roper cam section from Table
1.
Use two car 1S of the same secti on number to obtain the desired range of settings given in
the table for each circuit. The Ieft hand column of Table 1 indicates what cam sections are
to be bra ke 1 off to obtain a particular cam number.
TABLE 1: OP ERATION and ADJUSTMENT of CAMS
Break Off
Cam Section
No.
Full Cam
No.1
No.1,2
No.1,2,3
No.1,2,3,4
No.1,2,3,4,5
Closed Range
(In Degrees)
Open Range
(In Degrees)
Min.
Max.
Min.
Max.
10
175
255
285
315
325
175
255
295
315
325
335
185
105
65
45
35
25
350
185
105
65
45
35
2.5.5
BI006008
OPERATION and ADJUSTMENT of CAMS

For ease in snapping off the cam portions at the scored points it is recommended that an
adjustable wrench be used. Extra care should be used when snapping off cam portion No.4
(leaving portions NO.5 and 6) to avoid breaking off cam portion NO.5. It is recommended
that a second adjustable wrench be used.
Place the two scored cams on each cam holder and align the cams to give the approximate
desired contact opening and closing. When placing the cams on the shaft, be sure that the
cams are placed back-to-back with the markings of each cam facing outward. This will
prevent an interrupted cam surface and also prevent the roller from striking a broken cam
surface. Secure the cams to the cam holder at 1800 intervals with the two bolts and lock
washers furnished. Before tightening the bolts, finer cam adjustment can be made, if
required, by lining up the start of the cam rise with respect to the cam holder indicating
marks at the desired points of contact opening and closing.
VERNIER ADJUSTMENT
The vernier-adjustment mechanism fulfills two purposes. It provides vernier or fine
incremental adjustment of the switch open and closed contact positions, and allows for
adjustment while the switch is actually rotating. The vernier-adjustment locking screw (11.#7)
varies the relative position of the cam-follower roller with the operating cam. To adjust a
specific circuit for desired open or closed contact position, loosen the vernier adjustment
locking screw (1t.#7) and slide it up or down to open or close contact sooner or later as
desired.
The markings on the vernier plate (1t.#8) represent two-degree increments of adjustment.
It should be noted that the vernier adjustment affects the opening and closing of the contact
unit by the same amount. It is not possible to get individual incremental adjustment of the
opening and closing position on anyone circuit If this is required, then the closing position
must be set on another circuit. The two contact units involved can then be electrically tied
together. After final settings are established, securely tighten the adjusting screw to prevent
any accidental movement.
CROWD LIMIT SWITCH MAINTENANCE

No further lubrication beyond that provided at the factory is required on the limit switch. The
contact unit is a completely self-contained device which may be replaced by removing two
metal screws and inserting a new unit. The silver contacts require no attention but must be
replaced before all the silver is worn away. Filing or otherwise dressing the contacts results
only in loss of silver and reduction of the normal contact life.
Inspection of the cam-follower roller assembly can be made by removing the two forward
bolts holding the cam-follower bracket, then swinging the entire bracket assembly back to
provide access to the cam-follower parts.
The following procedures should be followed when replacing bearings or camshaft or
reversing the camshaft extension.
2.5.6
BI006008
Remove he cast cover. Remove both seal plates, the cam follower bracket, and the four
bolts whi h secure the internal switch to the cast box. Remove the internal switch from the
box.
Remove tree bolts holding flange on shaft extension side of switch. After removing the filler
strips, 10 sen the thrust collars on each end of the shaft and slide them inward along the
shaft. Lift ntire cam shaft assembly up and out of the switch frame.
After repla ing parts as required, reassemble the filler strips and the three bolts holding the
flange.
Reinstall t e internal switch into the cast box with the shaft extension protruding from the
desired s de and tighten the four mounting bolts which secure the switch to the box.
Reinstall t e seal plates.
Visually c ter the shaft in the seal plate hole and tighten the internal flange. Reassemble
and tight n the cam follower bracket. Measure for proper shaft-extension length and
position, a d tighten the thrust collars.
The final s ep in the reassembly procedure is to reset the desired contact sequence by
adjusting t e cam and vernier adjustment.
Note:
Mounting bracket shown in median
position. Adjust switch location as required
to meet particular mine operating conditions,
but do not allow bail equilizer sheave to
contact the boom point sheave rims.
Actuating
Lever
Dipner Handle
Hoist Limit
Switch
Shipper Sharr
Tapped
Block
800m
Centerline of
Boom
Side
01 Boom
VIEW A-A
hlmt1847.wpg
HOIST LIMITS
2.5.7
BI006008
2.5.8
BI006008
Book #1
Section
Standards for Electrical Installation

Part No. 140G1 Rev.C
2243-I.M61
BI006008
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DC. NO
The erection contractor shall personally, or through an

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

and sufficient supervision tv insure adequate performance of
the work. All work shall be subject to the inspection and
approval of the D.n. erection advisor whose judgment shall
be considered Final. Work which, in his ~pinion, does no~
meet these standards and the intent of the drawings, shall be
brought into conformity by the erection contractor without
additional compensation.
1I IZ;/ot'
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In addition to ~eing properly Functional from both an electrical

and mechanical standpoint, proper attention is to be given to
the appearance of the installation.
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ANGLES
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ANGLE
0.0
0.00
0.000
0.0000
OTHERwtSE SPf;OFIEO THtS SHEET ONLY
lJ\..EFUNCS UNLESS +
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The ~.n.erection advisor has the authority to call for extra

fastenings where he deems it desirable. All departures from
drawings m~st be ap~roved by him prior to actual performance
of the work.
Graphical representation of conduit a~d cable routes and

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

sc!pporting structure. The maximum distance between supports
shall not exceed four feet.
Installation of Conduit and Armored Coble
,,"~~t: ~) ),>~'.,
n~o
Welds shall be neat in appearance and of adequate strength

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

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

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

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

a manner consistent with the best excavator wiring practice.
Electrical systems installed aboard an excavator are subject
to more severe operating conditions than the usual installation
in II Fixed industrial structure or building. Continued and intense mechanical vibration and shock require special attention
to support and mechanical security.
il~11
{I
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Complete System Inferred
STANDARDS FOR ELECTRICAL INSTALLATION
BI006008
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Covers shall be replaced on all junction boxes promptly

after work is completed to exclude water and dirt.
All splices and connections in conductors shall be lugged

an.i bolted, or use two-way connectors, except where wire
nuts are specified.
Conductors and cables shall be identified with suitable

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

cables shall be run parallel or perpendicular to the
surfaces on which they are mounted. All cables in a bank
shall be parallel without unnecessary cross overs. Bends
shall be of a radius consistent with the cable size and
shall not over-stress ar.or or insulation.
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All suppl ies and ~terials necessary for the electrical work
which are expenda~'le and which are not a part of the finished
excavator are to be supplied by the electrical erection contractor.
.N.
All materials to be used in the construction of the machine and

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

maintain such tools as are necessary to the efficient conduct
of this work.
The electrical erection contractor shall ~operate with the

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

the proper storage and protection of all electrical equipment .
as it arrives at the job site. He shall provide such temporary
wiring and temporary heat as may be required to protect the
equipment from water damage and condensation.
The electrical erection contractor shal I clean up after his

work and assist in keeping the premises neat, clean and orderly.
The electrical erection contractor shall be responsible for

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

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

shall be jacketed to insure shedding water.
Proper
attention sh~ll be given to drip loops. At terminations,
~
a proper connector shall be used to prevent the e~trance ~
n~
Conduct of the Work
Installation of Conduit and ;\Onored Cable
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OR LUGS) W\RCS
TO BE:\\\.lG C.Lt\M'?E.L:> DOWM.
,
armor and filler
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C.DNNE.C.TOR~
IN
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MARION POYlER SHOVEL DIVISION
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CLA.M P
Coil u~ ~nou9h pi9tail

to make complete resistor adjuHm~nt.
terminal
indel ;ble in" "",r"er
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WHE.R'C.. UN\SiRU"i IS
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DRESSER INDUSTRIES, tHe.
'n ....- . . _ .. w_ ..... _ ....__ . . C'_, .........., ...
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JUL
CROWDING
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NUMP,'E.:RS A.Rt=."TO
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\J~I"lG 'TWO LIN E. os AS SHOWN
WHEN NECESSARY , 0 AVOID
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Trc1 in 'Wi re ne .... t 1y on rod and

tie wrap at leaH ev~ry /,,,
Cra~
securely and terminate

Leg band wir~ and c.. ble identifiCation
STANDARDS FOR ELECTRICAL !NSTALLATION
.. r'
BI006008
BI006008
C>
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Cut with stripping tool
Pencil with knife
TlIke ~re not to nick conductor
~'.
IN PLATE
WHERE. POSSIBLE
I '-TERMINATE
(ONNECTU" TO HAVE IHSULATE:.D

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

NEXT TO CONNECTOR WHEN
CONNECTOR IS NOT TERMINATED
IN PLATE OR THREADED OPEN IN G
WHERE ~
PRACT I CAL
~ C~E."''''
I 5 / -CUT E"'t:>~ ~Q,UIao..RE.
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DAP.SSal1ilOUS'mlB, INC.
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MARK>N POW'ER SHOVEL DIVISION
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2SKV
ISKV
8KV
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FIG. 1
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S rDS FOR
....
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T(Ft\IINAl LUG 8 A A R E L n
O'l nPOSED CONOUCTOA
C
B I
00 NOT USE
.
SKV
VOL TAGE
using ~brasjye
"REDUCED DIMENSION"
*The minimum A oimension, A (min.),may be used

in a clean, dry location only, such as an
enclosed terminal box where reduced tracking
protection is acceptable.
25
2SKV
3/1,
9~
20
ISKV
I 3/1, I
8~
115
8KV
P2-,3lf1 7l
MI~
"CONVENT IaNAL" Y.I T

Val TAGE I A I 06+
TABLE I.
CABLE PREPARATION DIMENSIONS (in.)
SKV
I
PROCEDURES
L Train cable into position and cut to proper length.

2. Thoroughly clean cable jacket thre-e inches beyond dimension
cloth 'rom "SCOTCH" Brand Cabl. Proparalion Kit.
A. PREPARE CABLE
TERMIN~TION
FOR ELECTRICAL INSTALLATION
~---.~-b----,,..
c.oa ... a..u.. ...
~~....---..-.-.._-_
iiiiLW-- JAlt_5 1990
C)
type terminations
- - - - _ .... __ - . ....
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t( ..
s an exact instruction procedure to be

nHalling 3M-K Tape Termination Kits
gh vol tage cables.
Instruct ions appear
the "conventional" and "reduced dimen-
type terminations require additional tape and should

be reserved for those situations where insufficient
space makes it oesirable to use them. Note that the
dimension chan (Table I) reflects both the "conventional" and "reduced dimension" rorms.
Table 2 lists
the additional tape required to convert a "convention"'" kit to a "reduced dimension" kit for a given
type and size cable.
sion"
The following
followed when
on shielded. h
below for both
INSTALLATION TECHNIQUES FOR HIGH VOLTAGE TERMINATIONS
STANDARDS
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10 CVT "11fT 01 TM(
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FIG. 2
1 C.lIIIl' ~-..."f"""""",,,,,,,,,-,,,,,,"'-SCOTCH-'"
WIRE SHIELD l'RoctDURE
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Wrao around stUD around cable shieldi"a and burl uo aQainst th~ "doe of the iacket.
Inst'rt the tongue into the slOl and snug up like a belt. Bend the longue back and cut
011 excen. lSee Fig. 31
_._- .--
FIG. 4
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LUG B&ROILn
E _ O COOCOUCTOOI
TrltV'N&l.
(lOt
Rrmove c.>ble ~mi<onductive mat.,.;"I. tuY;ng 1/4" upow<! ~ond mrtaJlic

shielding. DO NOT CUT INTO CABLE INSULATION. THOROUGHLY CLEAN
ALL EXPOSED INSULATION WITH CLEAN ABRASIVE CLOTH.
2. Remove cable in",lation from end of conductor for 1 n" plus depth of t~rminal lug
barrel or lengt!>
ex~ conductor requ;red. DO NOT NICK CONDUCTOR.
(~ Fig. 41
1.
C. REMOVE SEMI-CONDUCTIVE MATERIAL AND CABLE INSULATION
...
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IIARK)N POWER atOYEL DrVISION -of.
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TMtINAL LUC
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1. RrrTlOW ablr jackrl and non-mOl. Hie 'ill.,. l.p< (if p~ll
minimum dtst.ncr
01 ~ pI", ~lh of lrrmin.1 J~ bar",1 or I~h Of uposood conduclor rrQUl
cr.. ld drlrrmi~l. CAUTION; DO NOT CUT INTO METALLIC SHIELDING.
2. T.~ ablr jackel smoolhly 'or 1/4 inch. (~ Fig. 2) Smooth ~ with a~ive
dOlh.
J. RrmoYe cable" mptallic shirlding Iraving 1" .. posood ~ond cable jacket. 00 NOT
NICK SEMICONDUCTIVE MATERIAL (II wire shirlding is u~."" instruclions
below in Fig. 2A.I
'M
B. REMOVE JACKET METALLIC SHIELD AND APPLY GROUND STRAP
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DIleSSSIINDUSTRIES, INC.
MARION POWER SHOVEl. DIVISION
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FIG. ,
_..
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.. _..
lItton lor
dlsta~
3.
2.
1.
~St::zJtPI ST"~S
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T"~(
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.3TDS FO ~ FIL D F. CT
""'-
procede to the appropriate steps below in

accordance with the type termination being made.
%220
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[--81.....,.7DTIO
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--/AOGI
Ofl).
Wrap one half.'.pped layer of No. 23 Tape for 2" along the ~ble j8Ck .... starting n
point where ground nrap is attached to cable metallic shielding. Wrap Dn1! ~If
lapped layer of No. 23 Tape 2" along grounding wi,.. bend wire back .Iong j.ck'"
for 1", then bend away from cable. l~ Fill- 8)
TAPING HINT: Highly elon9"te the No.?3 Tape to form a moistul?-ti9ht ...1.
Ti9htly halflap "SCOTCHH Brand 110. 23 Hi9h Voltage Splicing T.pe @

Hpencil H ar>d oemi-condueting tape. lnClending onto termiNlI I~ or ~xpolled
ductor se.'... nd build up to 1eY'ef of c.bIe insu!.!"1ion.
FIG. 7
~~
the tape b.>ck on itself. endin1at the gtound strzp.
G. APPLY OUTER JACKET
.-
~ond No. 13 Tape. (~ Fig. 7) Lef'e an ..",n (ront edge and continue to half.lap
1. Storting at the edge of the ground st"'P. app;y "SCOTCH" Brand No. :'220 Str=
Control Tape OS liner side 10ward cable. remO'Ying liner as ta~ is applied. Stre-te"
.----.,=.tc=-.-----.-==~-=-~----:-
TAPING HINT: Highly elongate the

13 Tape throughout tl>e entire dinance.
CAUTION: DO NOT WRAP NO. 13 TAPE MORE THAN 1/4" ONTO T~E
CABLE INSULATION.
2. 'f term ina' lug ;, u~. fill any indenu on lug wilh small pieces 01 No. 13 Tape.
L""el wind No. 13 Tape from 1/16" on edge of "pencil" onto lug to lorm smooth
concentric buildup as shown. (~ FiO. 6) II no terminal lug is used. halllap one
tayer 01 No. 13 Tape from 1/16" on edge of "pencil" onto conductor seal.
CD
:;;;':::;0"::'~====-=::.":'==.:.
two
half.tapped layers of "SCOTCH" Brand No. 13 SemiConducting Tape

1/." ~ond t"'e cable semi-eonductive material. (~ Fill- 6) Begin and end
taping at front edge of gr""nd nr Jp. L-ave an ""en Iront edge.
1. Wrap
E. APPLY SEMI-eONDUCTING TAPE
~..... ~AN - 5199u-
c::.
"'"
;r: ...
t.
.j,
-t>
C
~ ~
~I
~:I
.J
.. - 1
'. If J
Pencil insulation :or distance ~ . (Sre Fig. SI Burt t3~t with a cle,:,n abrasive cloth
from SCOTCH' Cable Prep;;:a"tion Kit SO no voids will remain .. fler terminat;o' is
insulated.
'0 conductor end or attach c1vsed m~haniut lug. Use crimptynt lug wirh
lhc!"moplastic insula:Pd ca~les. Follow cc..nnecror manufacrurers rlirt'CrinrlS. U~
.Hili-oxidant pastt for aluminum concktctors.. If solder sW'tated lug is used. prote-ct
ca~:e insulation with lemporary wraps of conon lape. CAUTIOI':: BE SURE TO
REMOVE ALL AI"TIOXIDANT PASTE FROM LUG AREA AFTER CRIMPmG
ALUMINUM LUGS. DO f..:OT USE ACID CORE SOLDER OR ACID FLUX.
Clean enlire area of pre"arec ca~le insulation t-y wiping with a Y.llvenlsaturared
cloth from "SCOTCH" Cable p,.paration Kit. After solvent is u>ed on insulation.
area must be absolulely dry and free or ail solvent res;due.
~~~
3.
1.
F. APPLY STRESS CONTROL TAPE
FOR ELECTRICAL INSTALLATION
D. PE:\:CI:" INSULATION. SEAL CONDUC,OR EI'\D AND CLEAN pnEPARED CABLE
STANDARDS
BI006008
BI006008
--
'"
()
I)
())
'1
(~
\
0_~.
~_z'J
SKV to 'SKY
"REDUCED DIMENSION"
tL...sJ99D
----~
.-.~---.
_..
---_
---....,-
.....
--..-.-..-..
_-...-.-.......-:-------....... ......
-.---..
--..
....
.,...._
......... -.- .......
~---.-.-.-.
_OCT!
_ooeo
----
_..
roo'
.__ o.-,--:---:.:.,.~
..,.:
DAeSI2R INIDUS'TM:S. INC.
MARION POWER 8HOYEL DMSK>H
WC3P one hall.lapped byer of '"SCOTCH" Brand No. 33+ Vinly Plaotic Electrical
Tape @ over splicing tape, extending jllSt onto th. cable jock.t and onto the conduelor lug or exposed conductor seal. (See Fig. 8)
2.
Build up No. 23 Tape to I thickness of 3116" be?nning two inC~ on cable jacket
~t;re termination overlapping onto No. 23
as shown IFig. 81 and continuing over

Tape in pencil area.
OUTER JACKET COMPLETION
.....
,.
.......
........
.........
.... --
H.
t".
ex~ conductor
2. Wrap Ot>e ~fll~ IWYef" of '"SCOTCH" BC3nd No. 33' Vinyl P1xtic Electrical
Tlpe @ ~r sp!;cing tape. exttnding from 1" onto cable jocketto termi.... log or
I Build up No. 23 Tope to I thickness of 3116", beginning two inches onto cable
jocket. IS sh<>wn. and ending one inch beyond streu tape on cable insulatiotL
OUTER JACKET COMPLETION
Fig. 8
H.
&
"CONVENTIONAL"
SKV to 2SKV
'
::-."
--
(!) _ _ ,;,
K TAPE TERMINA-
~~
I
,.
ro~
_----'
FILD V.ECT
.-".,......,---~
... '--~--~'
ST.D5
FIG. ,
06. . . . . ......
~~SCutdJ in
~-. . . . . . .
-.
...
I>~...-... : . : . : ..~. . . . . .
.....
I'
~.
~l("
~.~,--... _-~---~,_.
BI_... 8oFIO
--J~OGI
TAPING HINT: Apply No. 70 Tape with mode...te tension. For upright tenn;tations. begin at cable jocket and end It lug. For inverted tenninations. end taping It
cabl. jacket.
final overwrap of Silicone Tape during installation.

2. Overwrap end "'al with at leM! four layers of '"SCOTCH" Brand No. 70 Silicone
Rubber Tape.
NOTE: INNER LAYERS MAY BE HIGHLY STRETCHED.
3. Overwrap ENTI RE termination with ant ~dition.1 "alf.lappe<! layer of No. 70
Tlpe. CAUTION: BE SURE TO COVER EXPOSED VINYL TAPE COMPLETELY.
(See Fig. 9)
1. If possible. conMf'Cl tennination to final position. If not, take care not to dam"9'!
APPLY TRACKING PROTECTION (An REDUCED DIMENSION

TIONS MUST be overwrapped with trd resist..,t No. 70 bpe.)
,:",.. r~.~
~ ..
I.
_'u
".
n~.
t:_-3~~
TAPING HINT: Apply No. 70 Tape with modorato tension. For upright termi""1
tions,. begin It cable jacket Ind end at lug. For inverted terminations. end taping It
uble Jacket.
Tape. CAUTION: BE SURE TO COVER EXPOSED VINYL TAPE COMPLETELY.

(See Fig. 9)
3. Overwrap ENTI RE termination with one additional half.lappe<! ".Yer of No. 70
2. Ovorwnp ond ..al with at loast four I.yer. of "S::OTCH" Brand No. 70 Silicone
Rubber Ta~ (6) . NOTE: INNER LAYERS MAY BE H
final overwrap of Silicone Tape during installation.
1. If poS1ib1e. eonne-ct termination to finar position. If not. tak~ care not to damage
I. FOR TRACKING PROTECTION
BI006008
BI006008
I
2
I
1
I
1
1
1
~.;,.-
t)
.... ,
::...-;:-...::-:.-::;-~
1720MILSI
INSULATION
THICKNESS
CABLE
XLP, POLY
EPR
INSULATED
KV
UNG
15
'7~;;-
- .-.
, -
1"1
2
2
'j
,
2
., - ".
.......
- - -------- MARK)N
POWER SHOVEl. DfYISK)H
.''f!i~I....
,.;-: c:; ! -:-=~-:.::.::-~--.:.::;.=.::--=
_.......-... ...--.a..... :lAI!SSI!lUIDUSTRES, INC.
~~. ~Jitt._ 5 1990
..--. -:--..--~ "---'-'-"'U' _.-'
'000
C)
7SO
tIM'IiON.OMO
6SO
7
0 0 '1
500
SSO
600
OSO
400
350
~:;
2 .
7
1
'_
'(I';""
--1.
2/0
liP
70
Scot~~
iii
~.-..
ScotFli 23
I.LO
~.
CONDUCTOR SIZE
1000
aoo
7!>O
600
650
700
,
1
I
I
1
COO
450
500
2
, X L P , POLY
2
EPR
2
INSULATED
2
CABLE
2
(175 MILSI
,INSULATION
2
THICKNESS
~""oo:>n
5702
5701
15
KV
GRD
r-
,.
Sc:ot!=.t! 70
JSO
r--
,-
)00
j-
0/0
3To---
800
.......
THICKNESS
CABLE
11SO .. ILSI
INSULATION
XLP, POLY
EPR
INSULATED
UNG
8
KV
GRD
&
KIT NUMBER
I
57p2
210--
900
tl'
I
I
5701
2----
-0-0-0-
Sc:ot~.h 23
I/O
I
I
I
1
"'~M
REOUIRED (ROLLS)
ADDlTlONAL MATERIALS
I
I
Anu un.
CONDUCTOR SIZE
AOOITIONAL MAT'L. REdD. FOR
')IMENSION"'KIT
TAB LE 2.
~5~
S'
";W
tJt.11
.r'
~1;
'~J
.~
'.' ~
.-
XLP, POl.Y
EPI;
INSULATED
CABLE
190MILSI
INSULATION
THICKNESS
UNG
&
KV
GRD
KIT NUMBER
"K" TAPE
"RcL>UCED
FOR fIELD fJ~cr
'0')0
800
.7SO
700
000
OSO
500
SSO
600
650
JSO
3aO
3/G
0/0
250
210
---
2
2
1
1
1
1
1
1
1
"7
BJ..-rttIICI
,J
10
OF
11..-
.,. -- ~ ......-----.
...
I~ .1
--r . . OGI
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
7
1
I
1
1
Scot;.li 70
Sc:ot!=li 23
I
lLO
2
2
2
2
2
2
CONDUCTOR SIZE
1
1
1
1
1
2
2
2
I
I
2
2
2
2
2
2
2
7
Seot.eli 70
1
I
I
1
I
1
1
Seot.eli 23
900
1000
800
70
7SO
6so
050
500
.SSO
600
JSO
400
300
25;)
-'/0
3/0
210
1
I/O
CONDUCTOR SIZE
,-==""--=~.,.__ .--:-._~:----
.jTJ)S
5702
KIT NUMBER
5702
I
5701
KIT NUMBER
BI006008
BI006008
2SKV
115704
to 750MCM
1000MC~
~........
;::=.:.
.':=
....
f2AWG to 10COMCM
8HOVB.. DrVISk)N
8CCMCM to 1.000MCM
2~OMC/'1
1S0MCM to
"BAWG to ',4/0
Wire Size
:-,-:-..=::=.::.::-._ ...-..- _IIU~
==~_::=::._:_..E?_
..-u. _..
~ ONO
- ~--:._- ~:C -
DfESl2RIllDUmU!S,INC.
~I~
.-- /i.?;g~\~;.,;::~ i~~;;-- ._--~~_.~-~~--="""===....._--
I sr1JS FOR FIELD f/?CT
-I--------=====-------r--------------r.:=---------------,=:---------------T.:::;-:=----,=:-;--:--:-:---1
.. _ _ "':::::::=: _
MARION POWER
-of..
--
fi)
ISKV
ISKV
8KV
SKY
15KV
SKV
SKY
Vol-tage
Ra t i"g
Cable Type and Range
Usc this table to determine the proper

kit appl iealion.
115703
RS702
#S701
Kit
No.
TABLE 3.
~--=:-~}~~-::5_199D_." _. ._ .. ,"'====.. ,- --
.;,:~
:' ~
:;
, '"
i: ~~
~.!
."
I~
II
i
i
BI006008
BI006008
BI006008
Book #1
Section
Cable PUlling Schedule

Part No. 211945-5 Rev.A
2243-I.M61
BI006008
R.L.
u:
,jj
-'
;!
~
CD
DATE
~ mflrU~N
moo s- APi; s.4. / -
2'1
DESCRIPTION OF REVISIONS, ADDITIONS AND CANCELLATIONS
1119-97 ADD 6[.
DRAWN
OWZ
D.C. NO.
500 Z6
tiS
.:
-rhls drawing rep-asents proprietary

and confldentlallnforma1fon and Is the
eXduslve propeny of THE MARION
POWER SHOVEL COMPANY (MPS)
and has been developed at substantial
expense. Therefore, neither the drawing
nor Its contents are 10 be used,
reproduced, or dlsdosed, In whole or In
part, wl1hout the prior, expressed wrlt1en
permission of MPS, and this drawing
and all cop/esollt shall be re1umed
to MPS on Its demand"
IMPORTANT NOTE
c?
I.
rl?Q ISHE~TNo ~
ELB
?11QL1I:;-1;
BARLOW
I CHECK BY
PULLING SCHEDULE
IDRWNO
I DRAWN BY
~IIIID;w45G
DATE DRAWN
DESCRIPTIONCABLE
Marion, Ohio
::J
CABLE PULLING SCHEDULE

182M MINING SHOVEL
KEY 18247-48
OAL INDIA
BI006008
BI006008
THIS COLUMN LISTS THE TOTAL NUMBER OF INDIVIDUAL CONDUCTORS INVOLVED IN THE SUBJECT CABLE RUN.
THIS COLUMN LISTS THE SIZE OF THE WIRE TO BE USED BASED ON THE STANDARD AWG (AMERICAN WIRE GAUGE) SIZE.
THIS COLUMN LISTS THE TYPE OF CABLE TO BE USED. REFER TO THE LEGEND FOR AN EXPLANATION OF THE SYMBOLS USED. THE CABLE
JACKET AND CONDUCTOR INSULATION TYPES ARE BASED ON MPSD STANDARDS. NO SUBSTITUTES ARE TO BE USED WITHOUT WRITTEN PERMISSION FROM MPSD ENGINEERING.
THIS COLUMN LISTS THE VOLTAGE

BEFORE INSTALLATION.
THESE COLUMNS LIST THE INDIVIDUAL CONDUCTOR DESIGNATIONS, SINGLE THRU TRIPLE ARE USED. UP TO NINETYNINE(99) DESIGNATIONS
MAY BE LISTED PER CABLE IN ROWS OF SIX(6) , SEPARATED BY A SPACE. ALL SPARES ARE INDICATED BY THE WORD "SPARE". SOME
DESIGNATIONS WILL APPEAR WITH THE SYMBOLS "$", ">", OR "<,, WHICH INDICATE SPECIAL TERMINATION INSTRUCTIONS EXPLAINED IN
114BA14Z*
(F1)
THE LEGEND. MANY CONDUCTORS APPEAR WITH THE TRIPLE DESIGNATIONS, E.G. 11:2AB27G OR 5J15HA. THE TOP IDENTIFICATION ALWAYS
110TA37Q*
(F2)
INDICATES THE TERMINAL NOMENCLATURE FOUND AT THE "FROM" DESIGNATION DEVICE(IE. 114BA14Z* AND (F1. THE BOTTOM IDENTIFICATION REPRESENTS THE TERMINAL NOMENCLATURE AT THE "TO" DESIGNATION DEVICE(IE. 110TA37Q* AND (F2. THE DESIGNATION THAT
APPEARS SURROUNDED BY BRACKETS OR FOLLOWED BY AN ASTERISK(*), AS 110TA37Q*,
(F1), AND
(F2)
IN THE ABOVE EXAMPLES,
REPRESENTS CONNECTION INFORMATION ONLY. THE MIDDLE NUMBER REPRESENTS THE CONDUCTOR IDENTIFICATION, AND IS TO BE USED TO
LABEL THE WIRE AT EACH END. WHEN A DOUBLE DESIGNATION IS USED, THEN THE IDENTIFIED CONDUCTOR IS WITHOUT THE BRACKETS
OR ASTERISK AND IS USED IN LABELING. ALL CABLES AND CONDUCTORS ARE TO BE PROPERLY IDENTIFIED AND ALL CONNECTIONS VERIFIED
AT ASSEMBLY. CONDUCTOR IDENTIFICATION FOLLOWED BY A # INDICATES FORMER WIRE LABEL. (EX. - 14BC13C#)
10
THRU
15
The Marion Power Shovel Co.
RWNO
?11 QAJ:_I:
SHOULD BE CONFIRMED AT ASSEMBLY
THIS COLUMN LISTS THE TOTAL LENGTH OF WIRE OR CABLE REQUIRED FOR THE SUBJECT CABLE RUN. THIS NUMBER IS FOR ESTIMATING
PURPOSES ONLY, AND SHOULD NOT BE USED TO DETERMINE PRE-CUT CABLE LENGTHS AT INSTALLATION. EXACT CABLE LENGTHS USED AT
INSTALLATION SHOULD BE DETERMINED AT ASSEMBLY.
THESE RATINGS
THESE COLUMNS LIST THE "FROM" AND "TO" DESTINATIONS FOR CABLE ROUTING.
3, 4
INSULATION USED.
THE SECOND COLUMN LISTS A NUMBER THAT REFERS TO SPECIAL INSTRUCTION NOTES WHICH APPLY TO THE SUBJECT CABLE. ALL NOTES
ARE PRINTED IN NUMERICAL ORDER ON THE LAST SHEET(S) OF THIS DOCUMENT.
NOTE: ONLY THOSE NOTES WHICH APPLY TO THE
SUBJECT MACHINE ARE PRINTED.
:2
RATING OF THE CONDUCTOR
THE FIRST COLUMN IDENTIFIES THE CABLE OR CONDUIT NUMBER OR DESIGNATION. THE SYMBOLS USED TO MAKE-UP THESE ALPHANUMERIC
[SEE THE LEGEND FOR AN EXPLANATION OF THE ALPHA
NUMBERS INDICATE DRIVE NUMBER AND THE TYPE OR DEVICE BEING SERVED.
SYMBOLS USED.] THE FIRST SET OF NUMERIC DIGITS RELATE THE CABLE TO A PARTICULAR DRIVE NUMBER. MAJOR DRIVES ARE SEPARATED
BY HEADINGS WHICH RELATE TO MAJOR AREAS SERVED. THE INSTALLER SHALL APPROPRIATELY MARK ALL CABLES USING THESE
DESIGNATIONS.
EXPLANATION
18247-48
COAL INDIA
COLUMN
CUSTOMER:
MACHINE KEY:
THIS DOCUMENT CONTAINS ALL INFORMATION NECESSARY TO COMPLETE MACHINE CABLE AND CONDUIT
ROUTINGS AND TERMINATIONS FOR THE SUBJECT MACHINE. THIS SCHEDULE IS UNIQUE TO THE MACHINE
LISTED ON THE COVER SHEET AND REFERENCED IN THE UPPER RIGHT-HAND CORNER OF EACH GROUP SHEET.
THE COVER SHEET ALSO REFERENCES THE MAJOR WIRING GROUP, OR KEY, SUPPORTED BY THIS SCHEDULE.
EXPLANATION OF EACH COLUMN OF THE ATTACHED SCHEDULE FOLT.nw9
INS T R U C T ION S
WHE~NO
BI006008
BI006008
CUSTOMER:
MACHINE KEY:
18247-48
COAL INDIA
ARMATURE AND SERIES FIELD
CURRENT FEED BACK
MOTOR OR GENERATOR SHUNT FIELD
FEEDER
HEATER
LIGHTING
LIMIT SWITCH
METERING AND TEST PANEL
MASTER SWITCH
PANEL TO PANEL
PRESSURE SWITCH
RESISTOR. RHEOSTAT OR POTENTIOMETER
SPARE
TELEPHONE SYSTEM
VOLTAGE FEEDBACK
SPECIAL OR MISCELLANEOUS
SOLENOID OR MAGNET VALUE
CF
FR
LS
MS
PS
TS
VF
CABLE NUMBER NOMENCLATURE
I.
SYMBOL
TYPE MC SINGLE AND MULTI-CONDUCTOR ARMORED CABLE.
RWNO
~11 QLl:_J:
NEC TYPE XHHW WIRE. SINGLE CONDUCTOR. STRANDED. INSULATED WITH CROSSLINKED
SYNTHETIC POLYMER.
XHW
TWISTED. SHIELDED AND JACKETED LOW VOLTAGE MULTI-CONDUCTOR CABLE.

NEC TYPE THWN SINGLE CONDUCTOR. STRANDED. HEAT AND MOISTURE RESISTANT
THERMOPLASTIC INSULATION WIRE WITH NYLON JACKET.
TWN
NEC TYPE THW SINGLE CONDUCTOR. STRANDED. HEAT AND MOISTURE RESISTANT
THERMOPLASTIC INSULATION WIRE.
UL & CSA LISTED SINGLE CONDUCTOR TYPE AWM-TEW 105 -C VINYL PLASTIC
INSULATION. FLEXIBLE STRANDING
SHIELDED AND JACKETED LOW VOLTAGE MULTI-CONDUCTOR CABLE.
MULTI-CONDUCTOR SHIELDED. ARMORED & PVC JACKETED CABLE.
NEC TYPE SA SINGLE CONDUCTOR SILICONE RUBBER INSULATED HIGH TEMP. WIRE
NON-SHIELDED SINGLE CONDUCTOR HIGH-VOLTAGE INSULATED WIRE.
MACHINE TOOL WIRE.
NEC TYPE MC SINGLE AND MULTI-CONDUCTOR PVC JACKETED. ARMORED CABLE.
NEC
TSH
THW
TEW
SH
SAJ
SA
MV
MTW
AJ
CABLE JACKET AND CONDUCTOR INSULATION TYPES
A CONDUCTOR DESIGNATION(S) FOLLOWED BY THIS SYMBOL INDICATES THE INFORMATION

OR INSTRUCTIONS GIVEN IN THE "NOTE" LISTED FOR THE SUBJECT CABLE APPLY ONLY
TO THESE CONDUCTORS.
>
III.
A CONDUCTOR DESIGNATION FOLLOWED BY THIS SYMBOL INDICATES THE CONDUCTOR IS

TO BE CONNECTED TO A NORMALLY OPEN (N.O.) CONTACT
A CONDUCTOR DESIGNATION FOLLOWED BY THIS SYMBOL INDICATES THE CONDUCTOR IS

TO BE CONNECTED TO A NORMALLY CLOSED (N.C.) CONTACT
CONDUCTOR DESIGNATIONS
DESCRIPTION
<
II.
::JIMJ:lvL
A BRIEF DESCRIPTION OF THE SYMBOLES AND ABBREVIATIONS USED THROUGHOUT THIS DOCUMENT ARE LISTED BELOW. THE CABLE JACKET AND
CONDUCTOR DESCRIPTIONS LISTED ARE BASED ON NEC TERMINOLOGY TO AID THE INSTALLER IN IDENTIFYING THE CORRECT WIRE OR CABLE. FOR
EXACT CABLE OR WIRE SPECIFICATIONS REFER TO THE APPROPRIATE ITEM ON THE MATERIAL LIST SHEET OF THE REFERENCE GROUP.
LEG END
II
SHE:'NO
BI006008
BI006008
TITLE
TITLE
26 - DIG-PROPEL CABINET
28 - LIGHTING
10 - HV COLLECTOR RINGS
28
D.C. CABINET
16 - HOIST MOTOR
HOIST GENERATOR
15 - CROWD GENERATOR
8 - BOOM WIRING
14
22 - HOIST CABLE WINCH
BOOM J.B.
RWNO
211945-~
18 - SWING MOTOR #2
17 - SWING MOTOR #1
14 - SWING GENERATOR
28 - RESISTORS
OPERATORS CAB
19
22
12
12 - AUXILIARY TRANSFORMER
H.V. CABINET
9 AUTO-LUBE
13 - GROUND FAULT CNTRL PANEL
13 . M.G. SET DRIVE MOTOR
TITLE
10 - AUX COLLECTOR RINGS
BXC. & P.S. TRANSFORMERS
5 - LOWER FRAME
SHEET
NO.
COAL INDIA
18247-48
24 . MISC.
:.ll
17 - DIPPER TRIP MOTOR
SHEET
NO.
CUSTOMER:
MACHINE KEY:
20 . FILTER FANS
20 AIR COMPRESSOR
24
SHEET
NO.
I N D E X
WHE~NO
BI006008
BI006008
DESTINATION
FROM
COLLECTOR RING
J.B.
H.V. COLLECTORS
(L.H. )
R.H. PROP. MTR.

(#2)
L.F. DISCONNECT
SWITCH
H.V. COLLECTORS
L.H.
L.H. PROP. MTR.

(#1) BLWR MTR.
R.H. PROP. MTR.

(#2) BLWR MTR.
1F2
1FR1
1FR2
1FRll
1FR21
#12
#12
#1
#1
#6
#6
AJ
AJ
MV
MV
AJ
AJ
T1*
12E37X
R*
T1*
12E45X
R*
600V
1*
HL1
l*R
A*
HL1
l*BK
F2*
PM2F2
PM1F1*R
F2*
PMFP
5*R
600V
8KV
8KV
600V
600V
A2*
PM2A2
4*BK
A1*
PM2A1
3*BK
600V
600V
A2*
PM1A2
2*BK
A1*
PM1A1
l*BK
600V
600V
T2*
12E47X
BK*
T2*
12E39X
BK*
2*
HL2
2*BK
B*
HL2
2*BK
F1*
PMFN
6*BL
F1*
PM1F1
PM2F2*BL
T3*
12E49X
BL*
T3*
12E41X
BL*
3*
HL3
3*BL
c*
HL3
3*BK
SPARE
BK
18247-48
COAL INDIA
IDRWNO
#12
BARE
GND
#12
BARE
GND
GRN
GND
2X#6
#8
BARE
SPARE
#8
BARE
SPARE
211 Ql1.l:;_1;
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
BK
CON D U C TOR
R.H. PROP. MTR.

(#2) BLWR. SW.
L.H. PROP. MTR.

(#1) BLWR. SW.
H.V. COLLECTORS
R.H.
COLLECTOR RING
J.B.
L.H. PROP. MTR.

(#1)
AJ
1F1
350
MCM
COLLECTOR RING
J.B.
R.H. PROP. MTR.

(#2)
1A22
AJ
AJ
AJ
350
MCM
COLLECTOR RING
J.B.
R.H. PROP. MTR.

(#2)
1A21
350
MCM
COLLECTOR RING
J.B.
L.H. PROP. MTR.

(#1)
1A12
!Iel~
350
LG. NUMB
IN
OF WIRE
VOLT
FT. COND SIZE TYPE AGE
DESTINATION
TO
COLLECTOR RING
J.B.
L.H. PROP. MTR.

(#1)
LOWER FRAME
SEE
NOTES
1All
CABLE
NUMBER
ITSHE::,NO
BI006008
BI006008
FRAME GND
FRAME GND
FRAME GND
LH PROPEL MTR
#1 BLOWER SW
R H PROPEL MTR
#2 BLOWER SW
L H PROPEL
MOTOR #1
R H PROPEL
MOTOR #2
L.F. CONTROL
J.B.
COLLECTOR RING
J.B.
L H PROPEL
MOTOR #1
R H PROPEL
MOTOR #2
L H PROPEL MTR
#1 BLOWER MTR
R H PROPEL MTR
#2 BLOWER MTR
L H PROPEL MTR
#1 BLOWER SW
R H PROPEL MTR
#2 BLOWER SW
L.F. DISC. SW.

BOX
1G3
1G4
1GS
1G6
1G7
1GB
1G9
1GC1
#12
#12
#12
#12
#12
#1
#1
#1
#1
#1
AJ
THW
THW
THW
THW
THW
THW
THW
THW
THW
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
GND
SPARE
*R
GND
GRN
GND
GRN
GND
GRN
GND
GRN
GND
GRN
GND
GRN
GND
GRN*
GND
GRN*
GRb!*
GC2
*BK
GND
GRN
GND
GRN
GND
GRN*
COAL INDIA
18247-48
RWNO
#12
BARE
SPARE
?11 011 I: r=
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
*BL
CON D U C TOR
FRAME GND
H.V. COLLECTORS
R.H.
1G2
DESTINATION
TO
FRAME GND
DESTINATION
FROM
H.V. COLLECTORS
L.H.
SEE
NOTES
1G1
CABLE
NUMBER
IISHE~NO
BI006008
BI006008
L.H. AUTO LUBE

P.S.
R.H. PROPEL
BRK P.S.
R.H. AUTOLUBE
P.S.
L.H. PROP. MTR.

(1Il)&BLWR SW.
L.F. CONTROL
J.B.
1PS12
1PS21
1PS22
1X11
1X12
DESTINATION
FROM
L.H. PROPEL
BRK. P.S.
SEE
NOTES
1PS11
CABLE
NUMBER
12
12
#12
1112
#12
#12
#12
#12
AJ
AJ
AJ
AJ
AJ
AJ
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
H2*
12AS7U
lS*BL/BK
H1*
12ASSU
16*R/BK
SL18E
9*BL/BK
SPARE
*R/BK
1112
BARE
SPARE
*BK
SL22E
10*R
1112
BARE
12E39N
18*BK
14B30N
BK*
SL18J
BK*
14B30N
BK*
SL18J
BK*
12E37N
17*R
14B30L
R*
SPARE
R*
14B30L
R*
SPARE
R*
14B30N
14*OR/BK
SK04P
12*BL
P1*
SL37E
11 *OR/BK
12E41N
19*BL
SPARE
BL*
SK04P
BL*
SPARE
BL*
ElL"
RWNO
GC2
22*Y/BK
14B30L
13*OR
P2*
SL37J
Y/BK*
12ES1C
20*OR
#12
BARE
GND
#12
BARE
GND
#12
BARE
GND
#12
BARE
GND
t=
SPARE
BK/R
SPARE
*BR
SPARE
BK/R*
?11 0" r:
SPARE
*BR/BK
SPARE
*y
SPARE
BR/BK*
12W69F
*BR
SPARE
*y
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SL18E
CON D U C TOR
COLLECTOR RING
J.B.
COLLECTOR RING
J.B.
L.F. CONTROL
J.B.
L.F. CONTROL
J.B.
L.F. CONTROL
J.B.
L.F. CONTROL
J.B.
DESTINATION
TO
IISHE~NO
BI006008
BI006008
CROWD BLWR
MOTOR
CROWD MOTOR
CROWD MOTOR
2G1
2G2
CROWD MOTOR
2F1
2FR1
CROWD MOTOR
2A1
R.H. PROP. BRK.

M.V.
1Z21
BOOM WIRING
L.H. PROP. BRK.

M.V.
1Z11
DESTINATION
FROM
R.H. PROP. MTR.

(#2)&BLWR SW.
SEE
NOTES
1X21
CABLE
NUMBER
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
12
#1
#1
#12
#12
4/0
#12
#12
#12
THW
THW
TWN
THW
THW
AJ
AJ
AJ
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
VOLT
OF WIRE
GND
GN/Y*
GND
GN/Y*
T1*
12FllX
BK*
F2*
8C2SM
BK*
A1*
CMA1
BK*
SL22E
R*
SL22E
R*
T2*
12F13X
BK*
F1*
8C38M
BK*
A2*
CMA2
BK*
SPARE
BK*
SPARE
BK*
H2*
12AA41U
lS*BL/BK
H1*
12AA39U
16*R/BK
#12
BARE
12E39N
lQ*BK
12E37N
, 7*R
T3*
12F1SX
BK*
SK04P
BL*
SK04P
BL*
IDRWNO
#12
BARE
GND
#12
BARE
GND
P1*
SL37J
Y/BK*
*aR
P2*
SK04P
12*OR/BK
12E69F
12E41N
1)11 OA
SPARE
BR/BK*
12E69J
21*OR
r= r=
SPARE
BK/R*
*y
SPARE
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
l!l'BL
CON D U C TOR
L.F. CONTROL
J.B.
L.F. CONTROL
J.B.
COLLECTOR RING
J.B.
DESTINATION
TO
nsHE~NO
BI006008
BI006008
CROWD BRAKE
P.S.
OPEN GEAR
LUBE P.S.
UPPER FRAME
LUBE PRESS SW
CROWD MOTOR
CROWD BRAKE
M.V.
2PS1
2PS2
2PS3
2X1
2Z1
AUTOLUBE J.B.
AUTOLUBE J.B.
3FR1
3FR2
AUTO-LUBE
HOIST LIMIT
SWITCH
2LS2
DESTINATION
FROM
CROWD LIMIT
SWITCH
SEE
NOTES
2LS1
CABLE
NUMBER
D-P PANEL
3S
3S
#12
#12
#12
#12
#12
#12
#12
#12
#12
TWN
TWN
TWN
TWN
TWN
TWN
TWN
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
SK04A
14B41F
R*
SL1
R*
SK26K
BK*
P1*
SK04A
BK*
14A31L
BK*
14C31L
BK*
SK24G
BK*
SK04A
BK*
BK*
14B47F
BK*
SL2
BK*
SK04P
BK*
P2*
SM06E
BK*
14A31M
BK*
14C31M
BK*
SK24H
BK*
SK48F
BK*
SK39E
BK
#12
BARE
GND
#12
BARE
GND
H1*
12ASSU
BK*
18247-48
COAL INDIA
DRWNO
H2*
12AS7U
BK*
SK42E
BK*
" ... ... nAt=' ,..
SK4?H
BK*
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SK39H
BK*
CON D U C TOR
DISTRIBUTION
PANEL #1
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
DESTINATION
TO
USHEETNO
BI006008
BI006008
AUTOLUBE
JUNC BOX
3PS3
AUX COLLECTOR
(BRUSH HOLDERS)
20
20
40
50
70
55
2/0
#1
#1
#1
#12
#12
#12
#12
SA
THW
MV
MV
AJ
AJ
600V
600V
8KV
8KV
600V
600V
600V
600V
LG. NUMB
VOLT
IN
OF WIRE
1"
PM1A1
BK"
4"
PM2A2
BK"
4"
PM2A2
BK"
GRN"
GND
2"BK
HL12
2"
PM1A2
BK"
3"BK
HL13
3"BK
HL13
SPARE
BL
14 ..
14B30N
BK
2"BK
HL12
14C31L
"BL
BL"
SPARE
BL"
7G51R
IDRWNO
2"
PM1A2
BK"
2X#6
GRN
GND
2X#6
GRN
GND
#12
BARE
SPARE
14C31M
"OR
#12
BARE
GND
OR"
7G52R
3"
PM2A1
BK"
#12
BARE
SPARE
7r.<;LlR
?11 011 t:_1:.
3"
PM2A1
BK"
.. y
SPARE
Y"
SPARE
BR"
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
14A31M
"BK
1"
PM1A1
BK"
GRN"
GND
l"BK
HL11
l"BK
HL11
13"
14B30L
R
14A31L
"R
BK"
5L57K
#12
BARE
GND
R/BK"
7G55R
R"
5K15B
BK"
7G48R
R"
7G47R
CON D U C TOR
AUX COLLECTOR
RING J.B.
HV COLLECTOR
RINGS
5G1
6All
FRAME GND
HV COLLECTOR
RINGS (RH)
5FR2
AUX COLLECTOR RINGS
HV FUSE CBNT
HV COLLECTOR
RINGS (LH)
HI-VOLT CBNT
AUX COLLECTOR
RINGS
BOOM JUNC BOX
OPER. CAB J.B.
D.C. CABINET
DESTINATION
TO
5FR1
818
UPPER FRAME
LUBE JB
3PS1
HV COLLECTOR RINGS
AUTOLUBE J.B.
3P2
DESTINATION
FROM
AUTOLUBE J.B.
SEE
NOTES
3P1
CABLE
NUMBER
IISHE.ET~O
BI006008
BI006008
AUX COLLECTOR
RING J.B.
AUX COLLECTOR
RING J.B.
AUX COLLECTOR
RING J.B.
AUX COLLECTOR
RING J.B.
AUX COLLECTOR
ENCLOSURE
AUX COLLECTOR
RING J.B.
6A13
6A21
6A22
6F1
6G1
6X1
DESTINATION
FROM
AUX COLLECTOR
RING J.B.
SEE
NOTES
6A12
CABLE
NUMBER
MCC
FRAME GND
35
10
40
45
12
45
35
30
#12
#4
#6
350
MCM
350
MCM
350
MCM
350
MCM
AJ
THW
AJ
AJ
AJ
AJ
AJ
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
15*
12A55U
BL/BK*
16*
12A57U
R/BK*
#12
BARE
GND
18*
12E39N
BK*
GND
GRN*
6*
PMFN
*BL
17*
12E37N
R*
GND
GRN*
5*
PMFP
*R
PM2A2
*BK
PM2A1
HMA1*BK
PM1A2
*BK
PM1A1
CM"'*l'lll'
SPARE
OR/BK
19*
12E41N
BL*
IDRWNO
SPARE
Y/BK
SPARE
OR*
#8
BARE
GND
SPARE
BK/R*
?11 0,1 J:_J:
SPARE
BR/BK*
SPARE
y*
21*BR
12E69J
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
*BK
CON D U C TOR
D.C. CABINET
DIG-PROPEL
CBNT
HOIST MOTOR
DIG-PROPEL
CBNT
BOOM J.B.
DESTINATION
TO
WHE:T~O
BI006008
BI006008
H.V. CABINET
H.V. CABINET
BP2
BP3
AUX. XFMR PRI
AUX. XFMR SEC
9FR1
9G1
DESTINATION
TO
OPER. CAB J.B.
D.C. CABINET
MCC
H.V. CABINET
D.C. CABINET
GROUND TRRU
GFACT
10
35
25
50
40
30
12
12
#16
#1
#12
#12
#12
#14
#12
TRW
MV
SAJ
AJ
600V
BKV
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
H2,o
HL52
BK,o
XO,o
XO
GND-GRN
XO,o
XO
GND-GRN
5K04B
BL,o
H1,o
HL51
BK,o
36*
2C49F
R,o
5K07E
R,o
SPARE
BK,o
BL/BK,o
SPARE
R/BK,o
12A69N
1112
BARE
SPARE
,oBK
SPARE
35,oR,o
2C49B
22*
GC2
30Q,o
SPARE
SPARE
,oBL/BK
SPARE
,oR/BK
#12
BARE
GND
10*
5L22E
,oBK
9*
5L1BE
R,o
H3,o
HL53
BK,o
13*
2C05B
BK,o
#12
BARE
SPARE
OR/BK,o
SPARE
,oBL
SPARE
SPARE
SPARE
,ooR/BK
IORWNO
2X#6
GRN
GND
M12,o
2C05C
OR,o
Y/BK,o
SPARE
,oOR
SPARE
SPARE
SPARE
,oy/BK
leUR
12*
5K04P
#12
BARE
SPARE
BK/R,o
SPARE
46Q,oBR,o
12A69F
SPARE
,oBR/BK
211 Q4;_t:
SPARE
y,o
BR/BK,o
SPARE
,oy
SPARE
BARE
SHLD
GND
SPARE
,oBR/BK
SPARE
,oy
20*
12E5 1 C
,oBR
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
11*
5L37E
,oBL
CON D U C TOR
H.V. FUSE CBNT
AUXILIARY TRANSFORMER
H.V. CABINET
BP1
H.V. CABINET
AUX COLLECTOR
RING J.B.
B19
6X3
DESTINATION
FROM
AUX COLLECTOR
RING J.B.
SEE
NOTES
6X2
CABLE
NUMBER
,..
[SHEET NO
BI006008
BI006008
MCC MAIN CB
AUX. XFMR SEC
G.F. CNTL PNL
M.G. SET MOTOR
M.G. SET MOTOR
llFR1
llFR2
40
20
10
#1
#1
#12
#12
#14
#8
#8
#6
MV
MV
MTW
MTW
TSH
THW
THW
THW
8KV
8KV
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
T1*
2B01T
BK*
GRN
GND
2X#6
T1*
2B01T
T1*BK
10*BK*
2D8F
C*
Xl
X1*BK
M*
2D8Q
11*
A
BK*
T2*
2B05T
BK*
T2*
2B05T
T2*BK
9*BK*
2D10Q
GF4*
X3
X3*BK
T*
2D9M
12*
B
BK*
X2*
X2
BK*
X1*
GND
GRN*
Xl
BK*
GND
GRN*
T3*
2B09T
BK*
T3*
2B09T
T3*BK
RWNO
GRN
GND
2X#6
T10*
2BK21
T10*BK
SPARE
211 g4~-~
T11*
2BK22
T11*BK
SHLD
GND
T12*
2BK23
T12*BK
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
3*BK*
2D7E
c*
2D8F
2*
C
BK*
X3
BK*
X3*
CON D U C TOR
P.F. CORRECTION
CAPACITOR
H.V. CABINET
M.G. SET DRIVE MOTOR
G.F. CNTL PNL
10X1
GFACT
G.F. CNTL PNL

CB-GF
819
10FR1
10CF1
SURGE ARRESTER
SURGE ARRESTER
FUSES FU-SA
9X2
GROUND FAULT CNTRL PANEL
SURGE ARRESTER
FUSES FU-SA
AUX. XFMR SEC
GROUND
DESTINATION
TO
9X1
DESTINATION
FROM
SURGE ARRESTER
SEE
NOTES
9G2
CABLE
NUMBER
WH:E~O
BI006008
BI006008
SWING GENERATOR
SWING GENERATOR
13CF1
13F1
15A1
HOIST GENERATOR
HOIST GENERATOR
SWING GENERATOR
SWING GENERATOR
13A4
13VF1
SWING GENERATOR
13A3
SWING GENERATOR
SWING GENERATOR
13A2
13H1
SWING GENERATOR
M.G. SET MOTOR
DESTINATION
FROM
SWING GENERATOR
SEE
NOTES
13A1
11H1
CABLE
NUMBER
HOIST MOTOR
20
25
15
25
25
15
15
15
15
20
500
MCM
#12
#12
#8
#14
250
MCM
250
MCM
250
MCM
250
MCM
#12
MTW
XHW
TSH
MTW
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
VOLT
OF WIRE
HGA2*
HMA1
BK*
SGA1
BK*
H1*
12A53U
R*
F4*
9A48R
BK*
SlR1
BK*
SGA3*
SM2A2
BK*
SGA4*
SM2A1
BK*
SGA1*
SM1A2
BK*
SGA2*
SM1A1
BK*
Ulnv
H1*
12A53U
SGA2
BK*
H2*
12A55U
BK*
F1
9A56R
BK*
SlR2
BR*
H2*
12A55U
#12
BARE
GND
18247-48
COAL INDIA
IDRWNO
SPARE
OR*
?11 QLlJ:;_J:
#14
SHLD
GND
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
R*
CON D U C TOR
L.H. WING J.B.
R.H. REAR ROT.

FRAME COMPo
L.H. WING J.B.
L.H. WING J.B.
R.H. REAR ROT.

FRAME COMPo
R.H. REAR ROT.

FRAME COMPo
R.H. REAR ROT.

FRAME COMPo
R.H. REAR ROT.

FRAME COMPo
CROWD GENERATOR
DESTINATION
TO
.. '"
[SHEET NO
BI006008
BI006008
16A1
HOIST GENERATOR
lSVF1
CROWD GENERATOR
CROWD GENERATOR
HOIST GENERATOR
lSH1
HOIST GENERATOR
HOIST GENERATOR
lSCF1
L.H. REAR ROT.

FRAME COMPo
HOIST GENERATOR
lSA6
lSF1
L.H. REAR ROT.

FRAME COMPo
HOIST GENERATOR
lSAS
15
15
15
15
15
15
15
15
20
20
350
MCM
#12
#12
#8
#14
500
MCM
500
MCM
500
MCM
500
MCM
500
MCM
AJ
MTW
MTW
XHW
TSH
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
CGA2*
CMA1
BK*
HGA1
BK*
H1*
12AS3U
H1*BK
F1*
7A48R
BK*
H1R1
HGA1
BK*
HGA1
BK*
HGA1
BK*
HGA2*
HMA1
BK*
HGA2*
HMA1
BK*
HGA2
BK*
H2*
12ASSU
H2*BK
F4*
7AS6R
BK*
H1R2
18247-48
COAL INDIA
IDRWN~
SPARE
211~4~-t;
#14
SHLD
GND
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
CON D U C TOR
L.H. REAR ROT.

FRAME COMPo
L.H. WING
J.B.
SWING GENERATOR
L.H. WING
J.B.
L.H. WING
J.B.
L.H. REAR ROT.

FRAME COMPo
HOIST GENERATOR
lSA4
105
HOIST MOTOR
HOIST GENERATOR
lSA3
DESTINATION
TO
HOIST MOTOR
DESTINATION
FROM
HOIST GENERATOR
SEE
NOTES
lSA2
CABLE
NUMBER
04,..
[SHEET NO
BI006008
BI006008
HOIST MOTOR
BLOWER
DIG-PROPEL
CABINET
30
35
20
20
20
15
15
15
15
15
#12
#8
500
MCM
500
MCM
500
MCM
#12
#12
#8
#14
350
MCM
AJ
MTW
MTW
XHW
TSH
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OP WIRE
VOLT
PT. COND SIZE TYPE AGE
T1
12EllU
R
Fl
7C25M
R
HMA2
BR
HMA2
BR
HMA2
BR
CGA1
BR
HI
12A37U
H1BR
Fl
8A48R
BR
CIR1
BX.
CGA1
T2
12E13U
BR
SPARE
BK
CGA2
BR
H2
12A39U
H2BR
F4
8A56R
BR
C1R2
T3
12E15U
BL
F2
7C38M
BL
DRWNO
#12
BARE
GND
#10
BARE
SPARE
SPARE
~11alll:'
#14
SHLD
GND
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
CON D U C TOR
MCC
HOIST MOTOR
18F1
18FR1
D.C. CABINET
HOIST MOTOR
18A3
HOIST MOTOR
18A2
DIG-PROPEL
CABINET
HOIST MOTOR
DIG-PROPEL
CABINET
L.H. WING J.B.
HOIST GENERATOR
L.H. WING J.B.
L.H. WING J.B.
L.H. REAR ROT.

FRAME COMPo
DESTINATION
TO
18A1
HOIST MOTOR
CROWD GENERATOR
16VF1
CROWD GENERATOR
CROWD GENERATOR
16H1
16F1
CROWD GENERATOR
105
16CF1
DESTINATION
PROM
CROWD GENERATOR
SEE
NOTES
16A2
CABLE
NUMBER
[SHEET NO
BI006008
BI006008
D.C. CABINET
BOOM J.B.
SWING MOTOR #1
(LH)
SWING MOTOR #1
BLOWER
20F1
20FR1
15
30
35
35
65
30
30
30
#12
#10
250
MCM
250
MCM
#8
#12
#12
#12
#12
MTW
AJ
AJ
AJ
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
T1
12F19X
BK
Fl
9C25M
R
SM1A2
BK
SM1A1
BK
A2&F1
L1 (+)
R
5K19K
R
Pl
5K04A
R
T2
12F21X
BK
TIE PT.
9C38M
BK
DTR1
BK
S2
5K04P
BK
P2
5M04E
BK
5K17H
BK
ilK
5K17G
R
H2
12A57U
H1
12A55U
T3
12F23X
BK
SPARE
BL
F2
DTR7
BL
y(-)
BL
#12
BARE
SPARE
SPARE
BL
DRWNO
#12
GRN
GND
#12
BARE
SPARE
#10
BARE
GND
#12
BARE
GND
#12
BARE
GND
l)iinA~
,..
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
#12
BARE
SPAR",
CON 0 U C TOR
R.H. REAR ROT.

FRAME COMPo
SWING MOTOR #1
20A2
R.H. REAR ROT.

FRAME COMPo
D.C. CABINET
SWING MOTOR #1
SWING MOTOR #1
DIPPER TRIP
MOTOR
20A1
19A1
HOIST BRAKE
M.V.
18Z1
DIPPER TRIP MOTOR
D.C. CABINET
HOIST MOTOR
18X1
D.C. CABINET
D.C. CABINET
HOIST BRAKE
P.S.
R.H. REAR ROT.

FRAME COMPo
DESTINATION
TO
18PS1
DESTINATION
FROM
HOIST MOTOR
SEE
NOTES
18H1
CABLE
NUMBER
II
SHEET NO
BI006008
BI006008
SWING BRAKE
P.S. #1
SWING MOTOR #1
SWING BRAKE
M.V.
20PS2
20X1
20Z1
SWING MOTOR #2
SWING MOTOR #2
SWING MOTOR #2
(RH)
SWING MOTOR #2
BLOWER
SWING MOTOR #2
21A1
21A2
21F1
21FR1
21H1
SWING MOTOR #2
SWING BRAKE
PRESS. SWS.
20PS1
DESTINATION
FROM
SWING MOTOR 111
SEE
NOTES
20H1
CABLE
NUMBER
15
30
30
40
25
40
30
#12
#12
#10
250
MCM
250
MCM
#12
#12
#12
#12
1112
MTW
MTW
MTW
AJ
MTW
AJ
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
H1*
12A55U
H1*BK
T1*BK
12F29X
F1*
9C32R
F2*R
SM2A2
BK*
SM2A1
BK*
5K31G
R*
P1*
5K04A
R*
5K31K
BK*
5K31J
R*
H1*
12A55U
R*
H2*
12A57U
H2*BK
T2*BK
12F31X
F2*
9C38M
R*
5K04P
BK*
*TIE PT
5M08E
BK*
5K31M
BK*
H2*
12A57U
IlK*
1112
BARE
SPARE
T3*BK
12F33X
SPARE
BL*
#12
BARE
GND
SPARE
BL*
IORWNO
#12
GRN
GND
#12
BARE
GND
#12
BARE
GND
1) ......
nAr-
,..
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARt:
#12
BARE
CON D U C TOR
SWING MOTOR #1
BOOM J.B.
SWING MOTOR #1
(LH)
R.H. REAR ROT.

FRAME COMPo
R.H. REAR ROT.

FRAME COMPo
OPERATORS CAB
J.B.
D.C. CABINET
SWING BRAKE
P.S. #2
OPERATORS CAB
J.B.
HOIST MOTOR
DESTINATION
TO
"SHEET NO
BI006008
BI006008
SWING MOTOR 112
DESTINATION
FROM
DIG-PROPEL
CABINET
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
BOOM J.B.
22A3
22F1
22FR1
22H1
22LS1
BOOM L.S.
15
15
30
35
35
30
12
1112
1112
1112
1110
250
MCM
350
MCM
1112
MTW
MTW
AJ
MTW
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
FT. CONO SIZE TYPE AGE
5K39H
BK*
12A55U
H1*R
5K39K
BK*
12A57U
H2*BK
12F29X
BL/BK*
12F23X
R/BK*
1112
BARE
GND
12F13X
BK*
12FllX
R*
8C25M
R*
CMA2
BK*
8C38M
BK*
ASK
E'2*BK
CMA1
BK*
P2*
5M08E
P1*
5M08D
1112
GRN
GND
12F31X
OR/BK*
12F15X
BL*
SPARE
BL*
DRWNO
12F33X
Y/BK*
12F19X
OR*
2XII12
BARE
GND
"of of
SPARE
BK/R*
nA,.. ,.
SPARE
BR/BK*
SPARE
y*
12F21X
BR*
COAL INDIA
1824748
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
1112
BARE
SPARE
CON 0 U C TOR
SWING MOTOR 112
MCC UNIT FB4
D.C. CABINET
L.H. REAR ROT.

FRAME COMPo
SWING MOTOR III
DESTINATION
TO
BOOM J.B.
BOOM J.B.
SEE
NOTES
22A1
21X1
CABLE
NUMBER
II
SHEET NO
BI006008
BI006008
411
23FR2
24FRI
23FR3
411
23FRI
AIR COMPo MTR.
AIR COMPRESSOR
FILTER FAN J.B.
FILTER FAN #2
FILTER FAN #1
FILTER FANS
MCC
MCC UNITS
FBI & FB2
20
25
40
30
12
12
#12
#14
#14
#14
#12
#12
AJ
THW
THW
THW
AJ
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
12GllU
R*
2X#14
GRN
GND
12DllU
BK*
Tl*
12D37U
BK*
Tl*
12DllU
BK*
12G13U
BK*
12D13U
BK*
T2*
12D39U
BK*
T2*
12D13U
BK*
5K42E
BL/BK*
5K15B
R/BK*
#12
BARE
5K24H
BK*
5K24G
R*
#12
BARE
SPARE
5K39K
BL/BK*
5K39H
R/BK*
12G15U
BL*
12D15U
BK*
T3*
12D41U
BK*
T3*
12D15U
BK*
5K48F
OR/BK*
SPARE
BL*
5K42H
OR/BK*
5K26K
BL*
5K24H
BK'
DRWNO
#12
BARE
GND
12D37U
BK*
#14
GRN
GND
#14
GRN
GND
SPARE
Y/BK*
5K04A
OR*
SPARE
5M06E
OR*
SPl;Il.E
I)-t ..
,..
12D41U
BK*
SPARE
BK/R*
5K39E
BR*
SPARE
n .. ,..
12D39U
BK*
SPARE
BR/BK*
SPARE
y*
SPARE
y*
BR*
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
5K24G
,,*
CON D U C TOR
FILTER FAN J.B.
FILTER FAN J.B.
OPERATORS CAB
J.B.
BOOM J.B,
22Xl
DESTINATION
TO
D.C. CABINET
DESTINATION
FROM
BOOM J.B.
SEE
NOTES
22Pl
CABLE
NUMBER
II SHEET NO
BI006008
BI006008
CROWD EXC. XFMR

PRI "CGT"
CROWD EXC. XFMR
25FR3
25FR4
MCC
D.C. CABINET
DRIVE CVT T-PS
DRIVE CVT T-PS
25FR7
25FR8
15
35
20
40
13
40
15
40
20
20
#12
#12
#6
#6
#6
#6
#6
#6
#12
#12
AJ
AJ
600V
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
X4
5A25C
H5
5A17B
R*
Xl
5A38Q
R*
H1
5A21Q
*R
Xl
5A38L
R*
H1
5A21L
R*
Xl
5A38G
R*
H1
5A21G
R*
R*
5K04G
12G27K
X5
5A28D
H1
5A19B
BK*
X2
5A38R
BK*
H2
5A21R
T2*BK
X2
5A38M
BK*
H2
5A21M
BK*
X2
5A38H
BK*
H2
5A21H
BK*
BK*
5K04F
BK*
12G27N
#12
#12
BARE
GND
#12
BARE
GND
IDRWNO
#8
BARE
GND
#8
BARE
GND
H3
5A21S
T3*BL
X3
5A38S
BL*
#8
BARE
GND
#8
BARE
GND
#8
BARE
GND
#8
BARE
GND
#12
BARE
GND
GND
BlIRE
X3
5A38N
BL*
H3
5A21N
BL*
X3
5A38J
BL*
H3
5A21J
BL*
BL*
SPARE
1\04 04 nil r-
...
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
BL*
CON D U C TOR
D.C. CABINET
SWING EXC. XFMR

SEC "SGT"
25FR6
MCC
SWING EXC. XFMR

PRI "SGT
II
D.C. CABINET
25FR5
SEC "CGT II
D.C. CABINET
HOIST EXC. XFMR

SEC "HGT"
25FR2
MCC
MCC
HOIST EKC. XFMR

PRI "HGT"
25FR1
EKC. & P.S. TRANSFORMERS
MCC TB
AIR SYSTEM P.S.
24PS2
TO
DESTIt~ATION
MCC
DESTINATION
FROM
AIR COMPo P.S.
SEE
NOTES
24PS1
CABLE
NUMBER
II
SHEET NO
BI006008
BI006008
OPER. CAB
J.B.
HMS - JOYSTICK
CONTROL PANEL
819
819
819
33FR2
33MS1
33MS2
33MS3
SMS - JOYSTICK
CONTROL PANEL
CMS - JOYSTICK
CONTROL PANEL
OPER. CAB
J.B.
33FR1
55
50
45
25
50
1116
#16
1116
#10
1110
1112
#12
#12
#12
SH
SH
SH
THW
AJ
AJ
600V
600V
600V
600V
600V
600V
600V
600V
600V
9D33C
8D33C
7D33C
12B09F
RA
SPARE
SPARE
SPARE
12BllF
BKA
BKA
12BllF
BKA
12G53J
RA
12G47C
RA
12B09F
BKA
12G39U
X2
5J16M
BKA
13K"
H2
12B35F
RA
12G37U
Xl
5J16G
RA
H1
12B33F
n.
9D35C
8D35C
7D35C
12B13F
BLA
BLA
12B13F
BLA
12G55J
18247-48
COAL INDIA
DRWNO
1116
SHLD
GND
1116
SHLD
GND
1116
SHLD
GND
GND
BAREA
1112
BARE
GND
#12
BARE
GND
1')1inJlr'r-'
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
BLA
12G41U
#12
BARE
GND
#12
BARE
GND
CON D U C TOR
D.C. CABINET
D.C. CABINET
D.C. CABINET
AIR CONDo
POWER
MCC
35
MCC
HOIST CABLE
P.B. STATION
26X1
OPERATORS CAB
20
MCC
HOIST CABLE
WINCH
15
35
LG. NUMB
IN
OF WIRE
VOLT
26FR1
HOIST CABLE WINCH
D.C. CABINET
CPE TRANSFORMER
25FR10
DESTINATION
TO
MCC
DESTINATION
FROM
CPE TRANSFORMER
SEE
NOTES
25FR9
CABLE
NUMBER
115HEETNO
BI006008
BI006008
OPER. CAB J.B.
OPER. CAB J.B.
OPER. CAB J.B.
33P3
33P7
33P8
DESTINATION
PROM
OPER. CAB J.B.
SEE
NOTES
33P2
CABLE
NUMBER
30
12
#12
600V
AJ
#12
16
600V
600V
AJ
#12
12
600V
AJ
AJ
#12
16
SPARE
BL/BK*
5JA42G
R/BK*
#12
BARE
SPARE
5L22D
BL/BK*
5K46D
R/BK*
5K18P
OR/BK*
5M48G
BL*
5M16E
OR/R*
5L22E
BL/R*
5M32H
BK*
5M18E
Y/R*
5K36D
BL/BK*
5K48F
R/BK*
5M22E
R*
5LI0E
OR/BK*
5K31G
BK*
5K31M
BL*
SPARE
OR/BK*
5JA16E
BL*
5K24K
Y/R*
5K31C
R*
#12
BARE
SPARE
5JA13E
BK*
5K17L
OR/R*
5K17H
BL/R*
5JAIIE
R*
5K24E
BL/BK*
SPARE
R/BK*
COAL INDIA
18247-48
RWNO
SPARE
Y/BK*
5M24E
OR*
5M20E
BR/R*
5Ll2E
Y/BK*
5K15B
OR*
SPARE
Y/BK*
5JA28E
OR*
SPARE
BK/R*
5L16E
BR/BK*
8F40C
BK/R*
7F40C
BR/BK*
211 Ql1.J:;_J::
5K39E
BR*
5K25P
y*
#12
BARE
SPARE
5K42E
BR*
SPARE
BK/R*
SPARE
y*
SPARE
BR/BK*
SPARE
y*
5JA40G
BR*
5K17G
BK/R*
5K17E
BR/BK*
5K17C
Y/BK*
#12
BARE
SPARE
5K24C
BR*
SPARE
y*
OR
X(+)
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
OR/BK*
Z(
BL
5K04P
BX*
5K04A
R*
CON D U C TOR
D.C. CABINET
30
40
DIG-PROPEL
CABINET
D.C. CABINET
30
LG. NUMB
VOLT
IN
OF WIRE
FT. CONO SIZE TYPE AGE
D.C. CABINET
DESTINATION
TO
USH:~O
BI006008
BI006008
OPER.CAB J.B.
OPER.CAB J.B.
33X1
33X2
819
OPER. CAB J.B.
33P12
35CF1
OPER. CAB J.B.
33P11
L.H. WING J.B.
MISC.
OPER. CAB J.B.
33P10
DESTINATION
FROM
OPER. CAB J.B.
SEE
NOTES
33P9
~lt.,TMBER
CABLE
25
70
45
30
25
50
50
16
#14
#12
#12
#12
#14
#12
#12
SAJ
AJ
AJ
MTW
AJ
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
OF WIRE
VOLT
IN
12E51T
Y/B*
12E61N
OR*
H1R1
BK*
5K15B
R*
5K15B
R*
5L29E
938
RD*
900
RD*
H1R2
BR*
5M44G
BK*
5M44G
BK*
5M55G
910
RD*
902-
SPARE
SPARE
900-
5M24E
BK*
5M32H
,,*
SPARE
R*
SPARE
BL*
SPARE
BL*
7F28C
913
RD*
2C49D
BR*
SPARE
RWNO
SPARE
OR*
#12
BARE
SPARE
#12
BARE
GND
#12
BARE
SPARE
920
RD*
SPARE
5K04F
OR*
935
RD*
SPARE
BK/RD*
BR*
~11 QL1;_:
#14
SHLD
GND
932
RD*
#12
BARE
GND
SPARE
BR/BK*
SPARE
Y*
SP-.RE
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
5M26G
BL
CON D U C TOR
D.C. CABINET
R.H. BOARDING
SIGNAL SW.
L.H. BOARDING
SIGNAL SW.
D.C. CABINET
AIR CONDo
CONTROL
MCC
MCC
TO
DESTINAT!O~1
WH:T;O
BI006008
BI006008
L.H. WING J.B.
L.H. WING J.B.
WELD RECEPT
LADDER LIMIT
SWITCH
L.H. WING J.B.
D.C. CABINET
35F3
35FR1
35LS1
35VF1
35Xl
L.R. WING J.B.
35F2
819
35CF3
L.R. WING J.B.
L.H. WING J.B.
819
35CF2
DESTINATION
FROM
35F1
SEE
NOTES
CABLE
NUMBER
20
25
35
#12
#12
#12
#6
20
15
#8
#8
AJ
SA
#8
SAJ
#14
SAJ
#14
20
20
25
25
600V
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
I.N
VOLT
OF WIRE
15AllB
BK*
#12
BARE
SPARE
SGA2
R/BK*
15A07B
R*
HGA2
BK*
5K07F
BK*
12B23F
BK*
9A56R
BK*
8A56R
BK*
7A56R
BK*
SlR2
BR*
C1R2
SR'
HGA1
R*
5K07E
R*
12B21F
R*
9A48R
R*
8A48R
R*
7A48R
R*
SlR1
BK*
BK*
CIR1
#12
BARE
GND
CGA1
BL*
SPARE
BL*
12B25F
BL*
SPARE
BL*
SPARE
BL*
SPARE
BL*
SPARE
R*
R*
IDRWNO
CGA2
OR*
#12
BARE
GND
#10
BARE
SPARE
#10
BARE
SPARE
#10
BARE
SPARE
SPARE
OR*
SPARE
OR*
#14
?11 011 r. r
SPARE
Y*
#14
SHLD
GND
GND
SHI.D
SGA1
BR*
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SPARE
CON 0 U C TOR
L. PROPEL ALARM
D.C. CABINET
D.C. CABINET
MCC UNIT FA4
D.C. CABINET
D.C. CABINET
D.C. CABINET
D.C. CABINET
D.C. CABINET
DESTINATION
TO
IISH~T~O
BI006008
BI006008
DIG-PROPEL
CABINET
DIG-PROPEL
CABINET
DIG-PROPEL
CABINET
DIG-PROPEL
CABINET
819
820
37A2
37A3
37A4
37CFl
37Hl
DIG-PROPEL
CABINET TB
DIG-PROPEL
CABINET
37Al
DIG-PROPEL CABINET
AIR HORN M.V.
3SZ1
DESTINATION
PROM
L. PROPEL ALARM
SEE
NOTES
3SX2
CABLE
NUMBER
20
15
15
15
15
20
20
#12
#14
350
MCM
500
MCM
500
MCM
500
MCM
#12
#12
SA
SAJ
AJ
600V
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OP WIRE
VOLT
PT. COND SIZE TYPE AGE
12As3U
BK
SH2*
2PIRI
BK*
CGAI
BK*
HGAI
BK*
HGAI
BK*
HGAI
BK*
IsK04P
R*
IsA07B
R*
12As7U
BK
SH2*
2PIR2
BR
IDRWNO
SHl*
IPIR2
OR*
1)110.11 r
#14
SHLD
GND
t::
COAL INDIA
18247-48
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SHl*
IPIRI
R*
#12
BARE
GND
GND
DJl
sMI0E
BK*
#12
BARE
IsAllB
CON D U C TOR
DIG-PROPEL CBNT
SPACE HEATERS
D.C. CABINET
L.H. REAR ROT.

FRAME COMPo
L.H. REAR ROT.

FRAME COMPo
L.H. REAR ROT.

FRAME COMPo
L.H. REAR ROT.

FRAME COMPo
OPER. CAB J.B.
R. PROPEL ALARM
DESTINATION
TO
nsH~T~O
BI006008
BI006008
DESTINATION
TO
DIG-PROPEL
CABINET
D.C. CABINET
GROUND
MCC HORIZONTAL
GND BUS
MCC UNIT FA2
MCC UNIT
MCC
38G1
38R1
38P1
38FR1
40
40
30
10
20
20
12
16
#4
#12
#12
#4
2S0
MCM
#18
RED
#12
AJ
THW
THW
TEW
AJ
600V
600V
600V
600V
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
SPARE
R/BK*
SM38F
R*
SN44A
BK*
SN44B
BL*
SN44C
SPARE
OR/BK*
SK1SB
BL/BK*
12AS7U
#12
BARE
GND
SK04G
BL*
12AS7U
BL*
X3
X3*BK
SK14G
BK*
12ASSU
BK*
GND
GRN*
X2
X2*BK
PC2AUC*
SM38F
TB1*
SPARE
SL04D
OR/BK*
Z( )
BL*
DRWNO
#8
BARE
GND
12ES1C
Y/BK*
SK04M
OR*
SM28E
BK/R*
12AS3U
BR*
12AS7U
BK/R*
BR*
"' ..... ,...-
12ES7E
BR/BK*
SPARE
y*
#12
BARE
SPARE
SPARE
#12
BARE
GND
12AS3U
BR/BK*
SPARE
y*
SPARE
Y/BK*
SJAlloJ
OR*
SJA13J
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
SK04A
R*
12AS3U
R*
GND
GRN*
Xl
X1*R
PC1AUX*
SM38C
PC2AUX*
SLSOG
B/BK*
X(+)
TB-1*
SK1SB
PC1AUX*
SJA06G
SR*
SK04A
CON D U C TOR
D.C. CABINET
D.C. CABINET
R.H. REAR ROT.

FRAME COMPo
AUX. XFMR SEC.
MCC UNIT FA6
38FR1
DIG-PROPEL
CABINET
37P2
DESTINATION
FROM
DIG-PROPEL
CABINET
SEE
NOTES
37P1
CABLE
NUMBER
II SHEET NO
BI006008
BI006008
DESTINATION
FROM
LTG. PANEL
D.C. CABINET
T.B.
D.C. CABINET
PS-PRA
SOFRS
SOX1
LIGHTING
DIPPER TRIP
RESISTORS
RESISTORS
D.C. CABINET
D.C. CABINET
SEE
NOTES
SOFR4
47R17
39P1
CABLE
NUMBER
10
10
30
35
80
1112
1112
1112
118
1118
RED
MTW
MTW
SA
TEW
BK*
lSA07B
BK*
lSA03C
600V
600V
R*
SL1
lSA01C*
BK*
lSAllB
BK*
SL2
BK*
SL2
DTR10
BK*
CRLYS*
SK04A
SRLYS*
HRLYS*
SK04A
CRLYS*
DTR3
BK*
HRLY2*
SK04A
HTB-1*
SL29E
LTB-1*
HRyr2*
BL*
SPARE
DTR1
BK*
HRLY2*
SK04A
HRLYS*
DRWNO
1112
BARE
SPARE
DTR7
BK*
PMOTX*
SM38F
HTB-4*
?11 OA 1:_1:
HRYLS*
SMSSG
LTB-1*
CRYLS*
SMSSG
SRLYS*
18247-48
COAL INDIA
DES I G NAT ION
CUSTOMER:
MACHINE KEY:
PMOTX'
SM32H
HTB-1*
CON D U C TOR
600V
600V
600V
LG. NUMB
IN
OF WIRE
VOLT
D.C. CABINET
T.B.
D.C. CABINET
PS-PRA
D.C. CABINET
D.C. CABINET
D.C. CABINET
DESTINATION
TO
WH:~O
BI006008
BI006008
105
411
818
819
820
RWNO
18247-48
COAL INDIA
~11 QLlc;_J:
CUSTOMER:
MACHINE KEY:
RECONNECT SPACE HEATERS FROM PARALLEL TO SERIES [REMOVE PLUG & CORD CONNECTION FOR SHIPPING].
GROUND SHIELD AT "DESTINATION TO" END ONLY.
COLOR CODE GROUND CONDUCTOR WITH GREEN SLEEVING.
CABLE SUPPLIED IN ASSOCIATED ASSEMBLY GROUP.
SHIELD MUST BE GROUNDED AT ONLY ONE END
CONNECT FIELDS IN SERIES
CONNECT F2 TO F3.
NOTES
WH:T,:O
BI006008
BI006008
BI006008
Book #1
Section
Electrical Settings
Part No. 211946-3
2243-I.M61
BI006008
,
..,.
<'"1
CLASS: MIN ING SHOVEL
Iso:
ING:
800HP!MODEL: 5K831064FI\RPM: 1480\ CYCLE: 501 V: 3150/6300
NO LOAD VOL TS: LOWER. RETRACT. SWING RIGHT
14.
15.
MOTOR FIELD AMPS - NEUTRAL:
ADJUST FOR EMPTY DIPPER MAXIMUM LOWERING SPEED' 1200 RPM.
20.
21.
SWING
19.0
19.0
27.8
PROPEL WEAK FIELD TO PICK UP AT S7SV GEN.
TAKE UP:
TRIPPING:
POUNDS
DIPPER TR IP MOTOR:
RESISTANCE NO.
ARM. V
ARM. A
A 6-4-96 CHG PROPEL AMP SETTINGS, DEL HOIST WEAK FIELD - SEE DC
FLO. V
I
I
THiRD A~'GLE
~8
DATE:
DATE:
TESTED BY:
INSPECTOR:
DATE:
READING BY:
I 50028
OWZ 149410
owz
FLO. A
..;SFECIFI:n -
00-000
0.000
0.00
0.0
THIS SHE.ET ONLY
QT~'ERWISE
TCLERANCES UNLESS
THE MARION POWER SHOVEL CO.

MARION. OHIO
DROP OUT AT 47SV GEN. SWING WEAK FIELD PICK UP AT 5S0V GEN, DROP OUT AT 4S0V GEN.
PLUGGING TO BE FIELD ADJUSTED.
23.
26.
350/350
600/600
600/600
VOLTAGE LIMIT LINE TO INTERSECT THE CURRENT LINE AT 550 VOLTS AND 225 AMPERES.
1235 AMPERES FOR HOIST: 260 AMPERES FOR CROWD: AND 21S AMPERES FOR SWING.
24.
25.
2-808
SWING
GENERATOR VOLT-AMPERE SETTINGS: CURRENT LINE TO INTERSECT THE 600V LINE AT
SAME AS HOIST AND CROWD MOTIONS.
9.5
11.8
13.B
MOTOR FIELD AMPS - LOWERING/WEAKENED
22.
9.5
35.3
11.8
4 I .3
24.8
MOTOR FIELD AMPS: FORCED
13.9
600
18.
590
590
495
2340
660
600
HOIST
CROWD
1-818
2-810
19.
17.
SEPERATE FIELD AMPERES: AT NO LOAD VOL TS
NO LOAD VOL TS: HOIST, CROWD. SWING LEFT
13.
16.
GENERATOR AND MOTOR SETTINGS

STALL AMPERES: BOTH DIRECT IONS
12.
II.
PR OPEL
RELAY DPTR: ADJUST TIME DELAY ITDADI TO 2.5 SECONDS.
9.
10.
RESISTOR R-GFA: ADJUST TO 4000 OHMS.
B.
1-808
RELAY GFRA: SET IDIALI PICK UP AT 2 AMPS. SET IDIALI TIME DELAY ON INSTANTANEOUS
IADJUST UPWARD IF REQUIRED!.
LODTRAK IV SETTINGS: SEE TABLE LABELED LODTRAK IV SETTINGS.
6.
7.
RELAY STDR: ADJUST TIME DELAY ITOAEI EQUAL TO THE RTDR SETTING PLUS 2 SECONDS.
4.
SET TO REACH FULL SPEED IESTIMATE 15 SECONDS!.
5.
3.
RELAY RTDR: ADJUST TIME DELAY iTDAEI EQUAL TO THE TIME REQUIRED FOR THE MG
HA
CONNECT MG SET DRIVE MOTOR FOR 6300 VOL TS.
L>~
NO:
J.
n'DDeD
I MACHINE
2.
,n
BOOM LENGTH: 12.24M 140'-2'"11 HANDLE LENGTH: 8.23M 127"-""
B 110-7-97 ADD DISPLAY & UNIT INFORMATION, LODTRAK SETTINGS
u.:
-..,.
....J
'"u,
--
<D
TYPE: 182M HR 17
SOL 0 TO: COAL INDIA LIMITED "GLOBAL TENDER"
WINDING RTDS ARE USED
23
BEARING RTDS ARE USED

CT SEC FULL LOAD AMPS
LRC CURRENT TIMES FLC
29
3B
39
PHASE UNBALANCE ALM % OF FLC

46
Jt
A~n
~TD
IMP ORTANT NOTE
I liNG::;
50
MANUAL
NO
NO
NO
0.10
100
YES
40
YES
YES
20
YES
IS
YES
170
110
IS
YES
10
6.1
3.3
NO
NO RTD
NO
TODF
TODF
100
17
VALUE/UNITS
( ON HV CAB
ES1 MI0A 1
"ZE
l)WG
! 'I
GWG eDDE
DWG NO
IE. WATSON; BARLOW
10-19-95
JCHECK 2Y
oy
Rt;;:r
II<PPRCVED
)"':..TER. . . L
ELEC SETTING SPEC SHEET

i~RI;W~ 51"
IPi,ON
:~1T :,,:..\'.~
:~sc<;
TO 32
I
I
"~,,
, H[A T 1F:EA TME~T
i"'10' "
MARION. OHIO
50 OR 60
MANUAL! AUTO
NO OR YES
NO DR YES
NO OR YES
0.05 TO 1.00
10 TO 100
NO OR YES
5 TO 69
NO OR YES
NO OR YES
10 TO 30
NO OR YES
5 TO 29
NO OR YES
6 TO 37
85 TO 125
80 TO 170
NO OR YES
2.00 TO 5.00
3.0 TO 12.0
1 TO 90
NO OR YES
NO RTD OR RTD
NO OR YES
TODF /TRIPI ALM
TDDF OR NTDF
50 TO 9000
UNiTS
I CO", WT
THE MARION POWER SHOVEL CO.
RESET OF TEMP TRIP

FREDUENCY IS
64
65
LOAD JAM USED
61
UNDERCURRENT TRIP USED
UNDERCURRENT IS
57
58
GND FAULT DELAY SEC
=
USED =
GND FAULT TRIP % OF 1 AMP

54
53
GND FAULT ALM % OF 1 AMP

51
GROUND FAULT TRIP
GROUND FAULT IS
50
52
PHASE REVERSAL TRIP
49
PHASE UNBALANCE TRIP % OF FLC

48
=
USED =
PHASE UNBALANCE TRIP
47
=
CALC OVERLOAD ALM DEG.
PHASE UN8ALANCE ALM
43
44
UL TIMATE TRIP IS 1 OF FLC
42
45
INST. OVERCURRENT TIMES FLC
INS T. OVERCURRENT IS USED
41
STALL TIME SEC
=
=
=
40
OVERLOAD TYPE
26
RELAY STATE
TRIP RELAY STATE

AU~
IB
=
=
CT PRIMARY TO 5 AMP
CONTRAST
DISPLRY
!\
REFER TO INSTRUCTIONS
#GEH 5500
r. n~~
19
17
FUNCTlON/
SET POINT
BI006008
,
~
<D
N
r-
BI006008
BI006008
Book #1
Section
Excavator Theory
-Table of Contents Page
6.1 EXC VATOR DRIVE THEORY
, 6.1.1
INTRa UCTION..................................................... 6.1.1
M CHANICAL PARAMETERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.1.2
La OS and TORQUES
6.1.7
SP ED CONTROLLED DRIVES
6.1.8
TO QUE CONTROLLED DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.1.10
6.2 ELE
RICAL SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.2.1
R TRIP CONTROL
TRIP FUNCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
TRIP OPERATION
ELECT ICAL EQUIPMENT
AD USTMENTS
TR UBLESHOOTING
6.3.1
6.3.1
6.3.1
6.3.3
6.3.4
6.3.6
6.4 M.G. ET MOTOR

MOTa SELECTION
MOTa TyPE
MOTa VOLTAGE RATINGS
MOTa STARTING
6.4.1
6.4.1
6.4.1
6.4.1
6.4.2
6.5 ADJU TMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..

DYNAM C TESTS
. . . . . . . . . . . . . . . . . . . . . . . . ..
EX AVATaR APPLICATION DATA
,
Fa RTH QUADRANT DYNAMIC LIMITS
6.5.1
6.5.1
6.5.3
6.5.4
2243.e.M61
BI006008
BI006008
Section
Excavator Theory
manufactured by Marion Power Shovel and equipped with drives by the General
Electric C mpany are powered by DC motors supplied by DC generators in a Ward-Leonard
system. his Instruction Manual shall apply to such systems incorporating full-reversing
thyristor ield exciters for the generators and controlled by operational amplifier type
regulator.
These ins ructions are generally applicable to crawler mounted, mining size machines used
in loadin trucks or other surface transport. The contents of this section of the manual are
intended t apply to conventional mining shovels, special purpose draglines, and the Marion
Superfro configuration.
The fund
from the e
material;
Cycle" of t
ental purpose of all the aforementioned excavators is to win the desired material
rth; elevate it to the required height; turn to the unloading position; deposit the
d return to a fresh position. This process is repetitive and constitutes the "Digging
e subject excavator types.
nal mining shovel wins the desired material using the cutting force provided by
the hoist otion with the cutting position adjusted by the crowd motion. The hoist is also
used to e evate the load while the crowd extends or retracts to the correct position for
unloading The swing drive for all three types of excavators provides the rotational motion
to transp rt the load from the digging position to the dumping position and return. Then,
both the h ist and crowd motions must be used to reposition the dipper to the new digging
face.
The Mario
significant
system h
in increas
pitch angl
The swing
Superfront shovel can be described as having a similar duty cycle but with two
dvantages over the conventional mechanical arrangement. First, a mechanical
been devised where the hoist and crowd efforts are complementary, resulting
d cutting and loading force. Second, a pantograph linkage pius control of the
allows the dipper to make a flat pass with the cutting force virtually horizontal.
otion rotates the excavator in the same fashion as the conventional shovel.
Crawler mo nted draglines, included here as they are equipped with similar control, use the
drag motio to provide the necessary cutting and loading forces. The hoist motion serves
to elevate he load and return the empty bucket to a new digging position. The hoist and
drag motio s must be worked in combination to achieve a particUlar bucket position and to
accomplis a desired trajectory of the bucket.
6.1.1
BI006008
Depending on the management of the particular mine and the application of the particular
excavator, the digging cycle for the sUbject machine types may vary from 20 to 40 seconds.
The digging cycle for a particular operation is fairly repetitive. In order to achieve a smooth,
productive digging cycle; the capacity of the individual motions in terms of speed and torque
must be coordinated. This is done by the excavator manufacturer using time tested formulae
when the drive horsepower, gear ratios hitch quantity, drum diameter, etc. are selected.
The necessity for the hoist and swing motions to be coordinated is the easiest to illustrate.
At the completion of the digging portion of the pass, the load is ready to be elevated and
swung to the dumping position. The hoist motion should have the capacity to elevate the
load to the desired position in about the same time required as the swing motion takes to
rotate the loaded inertia thru the desired angle. Similarly, the hoist motion-lowering speed
must be sufficient to arrive at the new digging position simultaneous with the completion of
the swing return. Further, such co-ordination must be convenient to the operator such that
the optimum digging cycle can be repeated time after time.
The digging cycle of the excavator is the sum of the individual contributions made by each
of the motions. As the digging cycle is fairly repetitive for a given excavator application, the
dUty cycle of a given excavator motion is also fairly repetitive. The maximum expected duty
cycle of each motion is taken into account as the excavator drive is designed.
The examination of the duty cycles, expressed as speed and torque, illustrates that each
excavator drive requires rotation in both directions (positive and negative speed) as well as
torque in both directions (motoring and braking). Thus, the DC motor is ideally suited to
power an excavator drive as it is capable of acting as either a motor or a brake and can be
easily reversed.
MECHANICAL PARAMETERS
To arrive at a thorough understanding of excavator drive requirements, the conditions of

positive and negative speed pius motoring and braking torque must be considered. The
hoist motion of a shovel or drag line provides the most obvious example. Figure 1 is a
simplified illustration of a hoist drive. A motor mounted pinion engages a large gear rigidly
connected to the hoist cable drum. The cable passes out of the shovel house and around
the boom point sheave to attach to the dipper bail.
6.1.2
BI006008
Crawler
Figure 1
exta1847.wpg
As this te is not concerned with selecting gear ratios, cable lengths, etc.; the drive can be
readily si plified to the system shown in Figure 2. The cable drum can be shown directly
installed 0 a motor shaft. The drum is equipped with cable supporting a load which can be
raised an lowered.
o
Drum
0
Motor
Figure 2
Certain b
motor rotati
(lowering) i
cable) ten
Motor torq
extb1847.wpg
ic assumptions must be made with regard to Figure 2. First, it is assumed that

n in a direction to raise the load (hoisting) is positive and that negative rotation
assigned to the opposite condition. Similarly, torque on the drum (or pull in the
ing to raise the load from rest is assumed to be positive or motoring torque.
e tending to reduce the tension in the cable is assumed to be negative.
6.1.3
BI006008
Two directions of rotation and two conditions of torque result in a total of four possible
operating conditions. The drive illustrated in Figure 2 is capable of operating in all four
possible combinations of speed and torque as follows:
I.
Positive speed and positive torque constitute a mode where the drum is rotating in the
direction to raise the load and the motor torque is at least sufficient to overcome gravity.
II.
Positive speed and negative torque mode occurs with the drum rotating in the direction
to raise the load but with motor torque in a direction to reduce the speed. (Braking) The
tension in the cable can be reduced to zero in this mode.
III. Negative speed and negative torque occur with the drum rotating in a direction to lower
the load and with the motor torque in a direction to increase lowering speed. Again, the
tension in the cable can be zero.
IV. Negative speed and positive torque result when the drum rotates in the lowering
direction but the motor is supplying hoisting torque. Tension exists in the cable.
The above four conditions of operation are logically related It is common practice to describe
the four operating modes as "Quadrants" and to assemble them into a single representation.
Brake Torque
Motor Torque
tr
Spetld
"...
I:)
0..
en
:;-
Speed
3
Speed
"...~
..
en
Figure 3
extc1847.wpg
Now, referring to both Figure 2 and Figure 3, an operating cycle can be established.
Assuming that the motor speed and the direction of rotation can be controlled, the following
"cycle" is described:
- With the system at rest, the command for positive speed will require hoisting torque
and an increase in cable tension. Quadrant I.
- A command for reduced hoist speed will require a reversal of motor torque to
decelerate the inertia and cable tension will be reduced to zero. Quadrant II.
6.1.4
BI006008
- A' hoisting speed is reduced to zero and then begins to lower, motor torque is the
sc me direction as before. Quadrant 1/1.
-
A~
a steady lowering speed is reached, motor torque must reverse to offset the effect
of gravity on the load. Quadrant IV.
Note that the drive cycle discussed may move about freely from one quadrant to another as
comman ~ed by a request for a change in motor speed. Further, note that al/ the possible
operatinf conditions for the drive configuration are included.
The ope ration of the simplified hoist motion drive described concerns only the
character stics of a drive occupied with overcoming gravity and the relatively low inertia of
the drive pomponents.
The swin~ motion is a different type drive in that the effect of gravity has little impact on the
operating characteristics. In fact, the swing motion of a perfectly level excavator would not
see any lead as a result of gravity. The swing drive, therefore, can be considered to simply
provide th~ torque for the acceleration and deceleration of the inertia of the excavator upper
frame assembly.
Inertia is tre characteristic, in this case, of a rotating body to continue to rotate or of a body
at rest to r ~main at rest. When referring to a rotating body, this characteristic is termed the
moment 0 inertia. The amount of inertia of any rotating body is proportional to the mass of
the body end the square of the effective radius of rotation.
Of course the entire upper frame of an excavator represents a rather complex mass and
significant ;lortions of the mass are located at some distance from the center of rotation. The
moment 01: inertia for an excavator swing motion is much larger than that of any other
excavator (notion.
Representing the large inertia of the upper frame as a large diameter circle and the swing
motor as a small diameter circle, the swing motion can be illustrated.
6.1.5
BI006008
Braking
Motoring
2
3
(+)
Torque
Motoring
Braking
Figure 4
extd1847.wpg
The operation of the excavator through a complete swing cycle can be described as follows:
- Quadrant I - A command to the motor for a swing to the left from rest results in
motoring torque and a gradual increase in speed to the left.
- Quadrant II - To decelerate, the motor is commanded to reverse the direction of
torque while the speed is still in the left direction and will bring the drive to a stop.
- Quadrant III - The continued application of motor torque in the same direction as
Quadrant II now begins to produce rotation to the right. Acceleration will continue
until motor torque is removed.
- Quadrant IV - As the upper frame rotates to the right, the motor may be commanded
to apply left or braking torque to reduce the swing speed.
Relating the above to the excavator duty cycle, the filling of the dipper would signal the need
to swing left through Quadrant I and brake to a stop with the dipper above the truck through
Quadrant II. The dipper would be emptied over the truck and then the motor would be
commanded to swing right through Quadrant III. The operator must anticipate when to apply
braking torque to decelerate through Quadrant IV to arrive at the new digging position as the
rotation stops.
6.1.6
BI006008
LOADS nd TORQUES
simplified descriptions have not detailed either the inertia or torque
When ref rring to drive inertia, this includes the inertia of the motor armature, gearing, and
other ro ating parts such as the hoist cable drum. There are also inertia components
associat d with-load on the motor shaft which do not rotate. This includes the pay load in
the buck t or dipper. It also includes the dead load of cables, fittings, chains, and the bucket
or dippe itself. The inertia of these parts must be included and are converted to the
equivale t rotational inertia.
The com onent torques associated with a given excavator drive are more complex in that
they are n t always applied in the same direction and must be summed algebraically. From
the previ us illustrations, it can be seen that motoring torque occurs when the direction of
the effort i the same as the direction of rotation while braking torque occurs when effort is
opposite otation.
Typical to
the dipp
cables ar
to gravity
to hinder
is that su
ques include load torque which might result from the gravity effect on the load in
r. Another is torque as a result of friction. Others such as that required to bend
nd drums and sheaves are usually neglected. It can be seen that the torque due
s always exerted in the same direction. friction torque, on the other hand, tends
cceleration of the drive but helps brake. Of course, the important driving torque
plied by the motor.
braic summation of all the component torques mentioned results in describing

f the drive. That is, whether it is at rest, accelerating, or decelerating. The result
of such
summation is commonly called the accelerating torque even though it may
sometime be in a direction to decelerate the drive. By convention, positive accelerating
torque re ults in a speed INCREASE and negative accelerating torque results in a speed
DECREAS . Also, when the accelerating torque is zero, the drive is either running at a
constant seed or is at rest.
As a simpli ied example, let us assume a drive has a load torque due to gravity applied to a
motor sha . If motor torque is made exactly equal to load torque, the motor will remain at
rest. If mo or torque is made greater than the load torque, acceleration will occur in the
direction t increase the speed. Similarly, if the motor torque is reduced below that of the
load gravit will cause th.e load to accelerate downward.
It now be omes convenient to insert inertia into the drive concept. Any change in drive
speed, wh ther occurring from zero speed or from a constant speed, requires that the
acceleratin torque act on the total inertia. The rate at which the drive speed changes is a
function of the amount of accelerating torque in relation to the amount of inertia to be
overcome. For example, an excavator swing motion has high inertia relative to the
acceleratin torque available. ThUS, a relatively long accelerating time is required for a swing
motion co pared to that of a hoist or drag drive.
6.1.7
BI006008
The requirements for a change in drive speed can be illustrated by using the four quadrant
plot of speed and torque. The following figure illustrates two drives, the left including a
gravity load torque like a hoist motion and the right illustration without gravity load like a
swing motion.
(+)
1(+) S
Effect of Grav ity
HT
(-)T
(+)
'---"" 0
Figure 5
exte1847.wpg
Both the above figures illustrate a drive at rest at point A.

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

Thus far, the discussion of speed and torque related to an excavator drive has been
concerned with the action of the motor in response to "command". The command to which
the motor responds is a result of the control method selected for the particular motion. The
best control method for a particular motion is that which permits optimum control by the
operator.
Speed controlled drives have been proven appropriate for hoist, crowd, drag and propel
motions. Note that, as shown in Figure 6, a limit on the available torque is necessary to
prevent excessive acceleration and excessive strain on equipment.
6.1.8
BI006008
lOOI
%Speed
50 -r------~
lO-t---------,.
-+--------\---r--\-Torque
ax.
Figure 6
extf1847.wpg
Note that he above representation in Quadrant I of a speed controlled drive is somewhat

idealized f r clarity. Three controller positions are illustrated which represent commands for
10%, 50%, and 100% speed condition. The selection of a 10% controller position would thus
request th drive to accelerate within the torque limit to reach 10% speed.
The cone pt of speed control can be illustrated further by expanding the characteristic to
include b th Quadrants I and II.
%Speed
00
(4-
-~
l--s-Effect of Gravity Load

C
--
~
\
\-Q..
10
-)Torque
(+) Torque
Figure 7
6.1.9
Max
extg1847.wpg
BI006008
Note that the speed-torque characteristic illustrated in Quadrant II does not include a torque
limit in that exact control is usually unnecessary. Figure 7 also illustrates the effect of a
gravity load on the particular excavator motion as if this were a hoist system. Assuming the
drive is running at 10% positive speed, the controller can be moved to the 50% position to
accelerate the drive. The torque increases on command from point A out to the torque limit
and the speed increases based on the value of available accelerating torque. As the drive
speed approaches the desired 50% value, accelerating torque is no longer required and the
drive runs at 50% speed, point B.
Similarly, moving the controller from 50% to 100% causes an excursion of torque to the right
from point B to C.
The opposite controller movement from 100% to 50% Produces the leftward excursion from
point C into Quadrant II and the speed reduction back to point B.
TORQUE CONTROLLED DRIVES

Torque control is applied only to excavator swing motions. As the name implies, the
controller is used to select a desired torque rather than speed. To prevent overspeed, the
torque controlled drive also requires speed limit.
The following illustration displays idealized characteristics of speed and torque utilizing
torque control. Quadrants I and II are shown. Note that Quadrant II does not include torque
limits. It is desirable to have braking torque fairly constant and this can be accomplished
without torque limit control.
%Speed
100
(-~
t
I
~
l-)Torque
'" -- --
t
A
./'
~Figure 8
6.1.10
-----
(+)Torque
exth1847.wpg
BI006008
Also she wn in Figure 8 is the speed-torque characteristic resulting from controller

commards. Starting from rest at Point A, the controller may be moved full "on" calling for
100% tor<~ue. The excursion proceeds out to the 100% torque line and speed increases as
a result 0 this accelerating torque to point C. Note that swinging the excavator at full speed
in the leftl,~ard direction requires some torque to overcome friction and other similar losses.
For this r ason, point C does not occur at zero torque.
The secor d characteristic shown in Figure 8 shows a speed-torque excursion resulting from
placing t 1e controller in the half "on" position. Beginning from rest at point A, speed
increases ~lightly until the 50% torque line has been reached and then accelerates within the
limit to pc int B. Returning the masterswitch to neutral after point B has been reached will
allow the ~ wing to FREE WHEEL with the speed decreasing only as a function of the braking
action of tj1e friction torque and similar losses. However, if the controller is actually placed
in the "SVI ing right" direction, electrical braking will occur causing the excursion into the
Quadrant I and a reduction in speed back to rest at point A.
-----+----------------~~------~---~----~-
6.1.11
BI006008
----------------~-
6.1.12
BI006008
6.2 ELE~TRICAL SYSTEM DESCRIPTION

The prev ous discussion centered on the requirements for a successful excavator drive. It
then bec mes pertinent to examine those requirements of the electrical drives which supply
the force ~d motion. The output device for supplying force and motion is a special design
DC motol with rugged mechanical features and low inertia armature for fast drive response.
A genera lor, electrically matched to the motor requirements and designed for operation in
the exca\ ator environment, serves as the adjustable voltage motor armature supply.
The discI ssion of excavator drives illustrated the application of torque to produce speed
change. he combination of speed and torque can then be expressed as horsepower. To
produce orque electrically, the motor must have shunt field flux and armature current.
Changes 'n speed as a result of elect torque are reflected in armature voltage. By making
basic ass Jmptions as to the use of constant motor field strength, voltage and current can
broadly bE compared to speed and torque Likewise, the product of voltage and current, or
watts, is analogous to the product of speed and torque, or horsepower.
Power is b ought aboard the excavator as constant voltage AC, subject to some droop under
load and spme rise under regenerating conditions. The motor generator set, with a generator
for each el~ctrical motion, converts the constant voltage AC to adjustable voltage DC. Finally,
the DC metor converts the adjustable voltage DC power to the torque and speed for driving
the indivic ualloads.
The namelblate rating information on the DC rotating machines is an indication of how they
are applied to the electrical drive system. The DC motor shows a nameplate rating of
horsepower, speed, and voltage from which rated torque can be calculated. The generator
nameplate specifies the kilowatts, ampere, and voltage ratings. In both cases, the voltages
are includE d to indicate similar capabilities.
DC excavctor motor ratings are expressed as amperes rather than torque. Amperes, by
definition, i re the units by which thermal capacity is measured.
Therefore, 1"e nameplate rating or continuous load rating of a DC generator and a DC motor
can be rep esented pictorially.
-----+-------------------~-----~---------------~
6.2.1
BI006008
MOTOR
GENERATOR
----
- - -1f(
OJ
0'
I
"Cl
I'd
-+J
>
OJ
Q)
0-
t/)
I
Amperes
Amperes
Figure 9
exti1847.wpg
This representation illustrates that a DC rotating machine can be operated continuously

within a specified envelope. The thermal capacity is related to the armature current.
Continuous operation at current levels above the rating cause a decrease in insulation life.
Simply due to the inherent physical manufacture of DC machines, a generator is capable of
operating satisfactorily at higher than rated voltage and a motor is capable at operating at
higher than rated speed. Excavator generators are rated at 475 volts but can be operated
up to 600 volts. (Some generators are specially constructed for "double voltage" service,
rated at 950 volts.) Excavator motors are rated to run at a particular speed with a 72 volt
shunt field rating. (144 volts for some applications.) As with the generator, the motor may be
operated under "overspeed" conditions with a weakened shunt field.
DC rotating machines also have the inherent capability of being operated under overload
conditions. The rated value of armature current can be exceeded without thermal harm,
providing that the excursion is offset by equal duty below the rating.
Taking into account the overvoltage, overspeed, and overcurrent capabilities. of DC
machines; the total capacity can be represented as follows:
6.2.2
BI006008
GENERATOR
Rate
MOTOR
Rate
-i
1
I
1'0
I
/]
r~
'0
l~
OJ
OJ
0.
CI)
Amperes
Amperes
Figure 10
extj1847.wpg
The envel pes portrayed describe the DC rotating machines in terms of thermal and
commutatl g capacity. The thermal capacity may not be exceeded on a continuous basis
and the c mmutating limits may not be exceeded in operation.
To exami e the concept of commutating limits, a fundamental understanding of
commutat; n itself is necessary. Successful commutation is simply the achievement of
acceptable commutator and brush life. When commutation is unsuccessful, the wear of both
is acceler ted precipitously. Note that the actual life can vary by a broad range due to
difference in environment, duty, etc. and still be termed acceptable.
It is gener Iy accepted that successful commutation results from an electro-chemical film
which exis s on the commutator surface. This film has two properties which promote
successful ommutation. The film has low electrical resistance and has a low co-efficient of
friction.
, a DC machine tends to deposit this film under certain conditions of speed,
load current, while it tends to remove this film under other conditions of speed,
voltage, an current. Obviously, the electrical equipment must be operated under conditions
where the fil condition ip promoted. The commutation limits are simply the expression of
an operatin area conducive to the production of the proper film.
In the sele tion of the electrical drive components to power an excavator motion, the
expected d ty cycle must be examined. The motor horsepower and consequently the
thermal cap city of the drive must be at least equivalent to the root mean square (RMS)
value of the I ad cycle. The peak values of speed and torque required of the drive are then
considered t assure that they fall within the commutation limits. Note that this is all a matter
of motor hor epower selection as the generator is preselected to match the motor.
6.2.3
BI006008
Throughout the discussion of excavator drive theory, it was emphasized that the torques to
be considered included load torque and accelerating torque. The electric motor to power
a particular excavator drive must have sufficient overload capacity to supply the sum of these
two types of torque. Similarly, the generator must have sufficient overload capacity to power
the motor for overload conditions. Figure 11 shows the electrical and mechanical equivalents
of the requirement by the electrical drive to accelerate the excavator motion. Note that this
figure shows a value of continuous gravity load such as might be seen by a hoist, drag, or
crowd motion.
GravitY
~ "X"
-r---t-_ ---s-
-- ,I __
Load-
z...
..........
I----~
>.::- ...... ~
rtj
I1l
I1l
til
--to" -
Amperes
I
I
I
,
,
~--
Torque
Figure 11
extk1847.wpg
The illustration can be expanded to provide further information. The area included in
an-accelerating excursion pius the introduction of a time factor represents energy.
6.2.4
BI006008
S__---Gravity
Load-----...z~
_.~I
"Cl
OJ
Q)
tJ)
Amperes
Figure 12
extl1847.wpg
The elect ical envelope, shown cross-hatched, represents the electrical energy or
kilowatt-se onds necessary to Produce the excursion. Similarly, the cross-hatched area in
the right h nd envelope represents horsepower-seconds of physical energy applicable to
the load.
Electrical oad on the generator is reflected in shaft load on the drive motor of the
motor-gen rator set. All excavator motions are generally powered from the same AC drive
motor and their loads must also be included. It is generally conceded that the peak
requireme t for the AC motor occurs when the hoist and swing motions peak
simultaneo sly. The MG set drive motor horsepower is selected to accommodate
simultaneo s hoist and swing peak demands. Of course, the maximum generator kilowatt
requiremen occurs at the "corner" of the volt-ampere envelope. See point "X" on Figure 12.
It has been I arned by many years of experience that, if the motor is selected with sufficient
pull-out torq e capacity to supply hoist plus swing peaks, the thermal or steady load rating
of the motor will not be exceeded. This "rule of thumb" applies to motors with 250% pull-out
torque rati g. AC motor overall duty cycle loading is usually only about 90% of the
nameplate orsepower rating.
6.2.5
BI006008
6.2.6
BI006008
6.3 DIP ER TRIP CONTROL
DIPPER RIP FUNCTION

Shovel e cavators of the types covered by this instruction are equipped with a dipper trip
function t unload the dipper. In some cases, this function will be accomplished with an air
or hydrau ically powered operator,
The shov I dipper is equipped with a door hinged to swing open and this door has 2 latching
bar, sprin loaded to the latched position. To trip the dipper, a wire rope is connected to the
latch bar nd reeved to a trip mechanism, usually mounted on the gantry platform.
The dippe trip mechanism consists of a trip motor geared to a small drum on which the trip
rope is w und.
When the dipper is loaded and positioned, the operator may depress the crowd master
switch thu b latch which initiates pull on the latch bar and allows the load weight to push
open the oor.
es during the excavator duty cycle, the rope is maintained in a taut condition to
from interfering with the digging operation. This is the take-up mode.
The dipper door closes and latches by gravity as the dipper is returned for the succeeding
pass.
DIPPER T IP OPERATION
To accom Iish the dipper trip function, a DC motor with suitable armature and shunt field
resistance is continuously connected to the main 125 volt DC bus. In the take-up mode,
significant r sistance is connected in the armature circuit for supplying the small amount of
torque for r ducing the slack rope. In the tripping mode, a contactor shorts out most of the
armature r sistance to achieve high torque for a short time.
To furnish
placed in s
at less than
to operate i
measure of protection against excessive trip time, a thermal overload relay is

ies with the entire circuit. This relay is equipped with an overload heater rated
10% of the rated tripping current. The thermal overload relay is thus expected
the crowd master switch thumb latch is held down for an abnormal interval.
6.3.1
BI006008
L2(-)
Ll(+)
r - -MOTOR
------i
Com
Ser
Shunt
L...-
x(+) RhumbLatch
O~--:lJ~r~D::..:T~O:;;:;L:....-------------.
c&1(-)
DT
(CMS)
Figure 13
extm1847.wpg
From a practical standpoint, it should be understood that the dipper trip motor does not
need to actually pull on the latch bar to accomplish the tripping. When the trip contactor (DT)
is energized, the motor first accelerates the roped drum and removes any slack left in the
rope. As the rope becomes completely taut, the inertia of the drum, gears, and motor rotor
serve to "jerk" the latch open. Typically, the tripping operation can be illustrated as follows:
.... i'
-......
... ---.-r---
-,~
--
50
----' -=
=- - - - ..
: . - f:' ::: ~
1 0 0 ' - 1-r:- - - . :~ - .
....-:::._- - - - I -
=--= --......;.u--I-_:-_-I-:~:
, ,
'-i;;--~-i- --'
~7 :.=. - --~_.-.I----I-.- -_ .. - - ._._-
~:
: ::f--:'-..
::MOLUL. ;..I'U...l.lJ':'Va L...:;)
..,.... . - .. ,
..
.-
_- --. - .-- .-.- .. _-~:.::= .:..:..:: :-.=

- - - .. -;. ~'- _.. .~-
~ : :. 4~ _ _ .:::.:"
--
t-
o D.-':-... I-----U
---,., . . .,. _.. -I' --,..,
-v
,_.j
._--
._.,
......
"---:-1'-~
..0'8
.
"--:-T~ 6"
- ./-.
.,-:-=:-t::=:'''i"me :In~ S"econa : .:.~:'==.: =.-=- :-:..
100%
-.. #'. -_...
1 -'" .. - --'.
-:___....,..1------. .....
or ~ .rnr
J\itlPS\~ .I'-=- - _ - -----, ,. I' _s::50% .-.-.. -'1/..'" - -.:.,,- '-- 1
-~
0%
:~~
.=
.-
:.::
- .-
~ ~~-:::T~::' ~~~~ ::~

Figure 14
extn1847.wpg
Note that the characteristics shown in Figure 14 are for illustrative purposes only.
Considerable deviation can exist from one shovel to another or even from one set of trip
equipment to another due to differences in friction, adjustments, inertia, etc.
In Figure 14, the first 0.4 seconds represents the, acceleration of the motor, gearing, and
drum as the rope becomes taut. the succeeding 0.2 seconds is the effect of the actual jerk
on the latch bar reflected to the motor.
6.3.2
BI006008
ELECTRI~AL EQUIPMENT
The dipp ~r trip motor supplied for shovel excavators is 2 compound wound shunt motor,
totally er closed non-ventilated, with a shaft suitable for a direct mounted pinion, The
following ~ulation shows the typical DC motor ratings and data for powering the dipper trip
function:
Torque Rating (Ft.Lbs,)
100
150
200
CD219AT
153PA801
1,5
850
260
CD2110AT
154-SA808
2,0
850
280
CD259AT
164RA800
3.0
850
400
10,3
88
1,79
47,8
0,966
14.3
124
2.46
34,8
0,677
22,5
145
1,15
74,2
0,587
111 'fltings:
Frame Size
Model No,
Horsepower
Rated Speed-rpm
Approx, Weight-Ibs,
~ta:
Max. Take-up Amps

Max. Trip Amps
Shunt Field Amps-rated
hunt Field Ohms @ 25C
P rm. Circuit Ollms @ 25C
The armat~re and field circuit resistance provided are connected in the circuit in the
following falshion:
L2(-
17 DT
Ra 1
Rl
R3
R4
R2~
RS
--~
Figure 15
6,3,3
exto1847. wpg
BI006008
The actual resistance values supplied for the three types of dipper trip motors used are listed
as follows:
Resistor Amps (Ohms)
Resistor Position
100#ft.
150#ft.
200#ft.
Ra
F1
R2
R3
R4
R5
32 (1.2)
17.8 (2.2)
11.5 (5.4)
11.5 (5.4)
11.5 (5.4)
Not Req'd.
50 (0.5)
9.2 (8.5)
9.2 (8.5)
9.2 (8.5)
9.2 (8.5)
Not Req'd.
50 (0.5)
12.7 (4.5)
12.7 (4.5)
12.7 (4.5)
10.3 (6.8)
10.3 (6.8)
The specific catalog numbers for the resistors used are tabulated as follows for ready
reference.
*Cat. No. IC9033-
Cont. Amps
Ohms Each
*Cat. No. IC9033-
C5B50JK
C5C12JK
B5C22JK
B5C45JK
B5C54JK
B5C68JK
B5C85JK
50
32
17.8
12.7
11.5
10.3
9.2
0.5
1.2
2.2
4.5
5.4
6.8
8.5
C5D6
C5E1
B5G6
B5G9
B5H1
B5H2
B5H3
* The catalog numbers in the left hand column have been superceded by those in the
right hand column.
ADJUSTMENTS
The current ratings of the motor armature, the motor field, and the resistor design must be
taken into account when adjustments are made for either of the two operating modes. As
constructed, tentative settings have been provided if the resistors are connected as shown
on the drawings provided for the particular excavator. Refinement of these settings is almost
always necessary to adapt both the take-up and the tripping modes to accommodate the
particular frictions and mechanical conditions for a particular excavator.
Generally, the procedure would be to adjust the shunt field current first, the take-up armature
current second, and the trip armature current last. In all cases, care should be taken that the
adjustments are made with the main DC exciter set at 125 volts.
6.3.4
BI006008
DT
R3
L2(-)
R1
R2
R4
(1)
RS
Figure 16
(2 )
extp1847.wpg
In most c es, the initial adjustments of the dipper trip function are made with the dipper trip
motor at 0 near outdoor ambient temperature. It will usually be necessary to re-tune the trip
and take- p functions after the shovel has begun to operate and the dipper trip motor is at
its normal operating tem'perature.
Adjustme
to the shunt,field of the dipper trip motor should initially be made at a value of
current gr ater than normal expecting the circuit copper to warm up with temperature. The
shunt fiel current should be checked with the resistor tap at the value shown in the
excavator rawings. Generally, the shunt field current should be about 2.0 amperes for the
100 poun foot motor, 2.7 amps for the 150 pound foot motor, or 1.3 amperes for the 200
pound foo motor. If the measured value is near the quoted-value, leave as is and proceed.
If necessa y to adjust, move the shunt field tap (1) shown in Figure 16
Next, the t eup armature current should be adjusted. In this case, the copper temperature
does not ave significant impact due to the relatively large amount of external resistance
utilized. Wi h the resistor tap (2) in Figure 16 connected as shown in the excavator drawings,
observe th trip rope slack and operate the shovel. The trip rope should be sufficiently taut
to be kep out of the operating area. If too much tension exists, the dipper may trip
inadverten Iy as it is hoisted away.
If the shunt field adjustment is correct, the takeup armature current will range from about 5
to 10 amp res for all three sizes of dipper trip, motors.
Should th condition occur where the resistor tap (2) is moved all the way toward the
overload re ay end of the circuit (all resistance inserted) and takeup torque is still excessive;
a reductio in shunt field current is necessary. referring to Figure 16, tap (1) should
be-moved away from tap (2). Try a 20% reduction in shunt field current and observe the
operation. f takeup is still excessive, reduce another 20%.
To adjust t e trip current, resistor tap (3) shown in Figure 16 must be used. It is suggested
that all of re istor Ra be inserted initially. If a satisfactory trip operation is obtainable with all
of resistor a inserted, optimum motor, gear, and rope life can be expected. However, if
insufficient ripping torque occurs, tap (3) may be moved toward the motor end of the circuit
to increase torque.
6.3.5
BI006008
TROUBLESHOOTI NG
The dipper trip function is a relatively simple electrical circuit which is fairly easy to adjust
and troubleshoot. however, the dipper trip total function can result in significant excavator
downtime. Often, problems reported are mechanical in nature and ~hould be recognized as
such.
Some of the common symptoms, causes and corrective actions are tabulated as follows:
PROBLEM: The takeup function does not appear to be functioning at all. The trip rope
droops into the operating area. The actual tripping function mayor may not
be operative.
Possible Causes
Corrective Action
1. Open Circuit in the electrical

system.
Make a visual inspection for broken wires, poor

wire terminal connection, loose terminal screws or
bolts, open resistor, failed overload relay, or open
overload heater. If visual inspection fails to locate
trouble, perform electrical continuity checks either
by voltage or by resistance measurement.
2. Dipper Trip Motor does not

produce takeup torque.
Inspect the dipper trip motor visually and with

instruments, if necessary. Look for burned brush
shunts, brushes stuck in holder, broken brush
springs, and commutator condition. Check
-continuity of armature and shunt field circuit for
broken wires internal to the motor. Check shunt
poles for possible open circuit internal to the coil.
Check motor for grounds. Perform AC drop test on
the shunt field circuit, if suspect. Check
comnutating series fields for possible open circuit.
Finally, check armature for open turns by
bar-to-bar continuity or by other means.
3.
Check trip motor and mechanical parts. Examine

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

mechanism.
6.3.6
BI006008
PROBLE*: The trip function does not operate. The take-up function mayor may not be
operable.
Possible Causes
Corrective Action
1. Fault ~xists in the electrical

systern
Check for a possible open circuit or grounds in

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

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

mechar ism.
Check trip motor and mechanical parts. Examine

motor and drum assembly for broken shaft or a
shaft key which is sheared or missing. Examine
motor pinion drum gear for missing or damage
gear teeth. Check motor and drum for frozen or
locked bearings.
6.3.7
BI006008
PROBLEM: Insufficient takeup torque allowing the rope to slacken into the operating
area. Typically, the slack may eventually be taken up but problem will recur.
Possible Causes
Corrective Actions
1. Electrical adjustments are not

correct.
Refer to adjustment instructions in this section.

Increase the amount resistance shorted out at
adjustment (2) making sure that the motor
continuous rating is not exceeded. Also, if
necessary, the shunt field current may be
increased by moving adjustment (1) toward (2).
2. Electrical fault may exist.
Test for possible ground in the armature and

shunt field circuits. Examine motor commutator
and brush condition. Check armature circuit for
shorted or open turns and the shunt field circuit
for shorted turns. Use AC drop test, if indicated.
Measure main DC exciter for possible low bus
voltage. Look for high resistance connection in
the wiring.
3.
A bearing may be failed or failing in either the

motor, the drum assembly or hte trip rope
deflecting sheave. Check the lubrication of the
gearing between the motor and drum. Poor
lubrication increases torque required.
Mechanical problem may exist.
PROBLEM: Insufficient torque results when the trip is initiated.
Possible Causes
Corrective Action
1. Electrical re-adjustment required.
Refer to the adjustment procedures described in

this section. An increase in tripping current may
be made by changing adjustment (3). Exercise
judgement before readjusting a trip function
which has been operating properly. The problem
may be mechanical.
6.3.8
BI006008
2. Mech nical re-adjustment or

repai may be required.
Check for failed or failing bearing at the motor,

trip rope drum or deflecting sheave. Ensure that
the latch bar assembly is lubricated per the
shovel manufacturers recommendations.
Examine the latch assembly for foreign material.
Check for damaged or worn latch bar, latch way,
latch socket in dipper. Check gearing at motor
and drum for damage or excessive wear.
: Excessive torque occurs in the takeup mode of operation.

ause
Electrical eadjustment required.
Corrective Action
Refer to the adjustment procedures contained in
this section. A reduction in takeup armature
current may be performed at (2). If necessary,
shunt field strength may be reduced at (1). If
suspect, check main DC exciter bus to ensure
that the voltage is at 125. Excessive voltage may
increase takeup current.
Excessive torque occurs in the tripping mode of operation.

Corrective Action
adjustment required.
NOTE:
Refer to the adjustment procedures contained in

this section. A reduction in tripping armature
current may performed at (3). If suspect, check
main DC exciter bus to ensure that voltage is at
125. Excessive voltage tripping current.
or additionaldetails on operation, maintenance, and troubleshooting of the

ipper trip motor, contactor, overload relaY,-etc.; refer to the specific G.E.
i struction publications covering the specific electrical parts.
6.3.9
BI006008
6.3.10
BI006008
6.4 M.G. SET MOTOR
MOTOR
The hor
manufac
industrial
requirem
power rating of the main MG set drive motor is selected by the excavator
rer based on the expected excavator drive motion loading. Contrary to most
practice, the horsepower rating is selected on the basis of the peak torque
nt rather than the long term thermal load.
The maxi um expected instantaneous torque required at the drive motor shaft occurs when
the hoist motion and the suing motion simultaneously achieve their peak DC load. This
''worst cas torque condition occurs when hoisting a full dipper at the same time the swing
loading
ses through it's peak. When this occurs, the crowd (or drag) is at negligible
loading.
II
The simu taneous peak DC kilowatts, added together, can be converted to peak torque
required t the MG set motor shaft. This value of peak horsepower divided by the motor
rated pea torque (pull-out torque) in per unit results in the nameplate horsepower.
For exam Ie, if the calc.ulated peak horsepower is 2500 and the motor pull-out torque is
n the motor nameplate should be 2500/2.5, or 1000 HP.
Main MG et drive motors selected by this method generally experience thermal or long term
loading in the order of 85% to 90% of the nameplate horsepower.
MOTOR
The majori
motors fo
100% torq
normally
operating
PE
of the excav~tors of the size under discussion are equipped with induction drive
the main MG set. These motors are of a modified NEMA design B with about
e at zero speed with full rated voltage applied. These induction type motors are
50% pull-out torque rated at full voltage, although there are some excavators
ith 300%.
Some ex avator designs are made with synchronous MG set drive motors to permit
operation n marginal mine power systems. Again, these synchronous motors may appear
in both 25 % and 300% pUll-out torque ratings.
MOTOR
OLTAGE RATINGS
Ihe excav tor electrical design is based on full excavator production with a maximum
incoming I ne voltage range from 95% to 110% of the nominal value. The nominal value of
voltage will, of course, vary based on the availability of local power. It is necessary to select
the name late voltage rating of the MG set drive motor properly to provide the correct
pull-out to que ca~city over the incoming voltage range,
6.4.1
BI006008
Excavators destined for domestic service are usually applied on systems with a nominal
incoming line rating of 2300, 4000, or 6900 volts. The permissible range of the 95% to 110%
range would be applied to these values.
To insure that the full pUll-out torque is available even under minimum voltage conditions,
the motor nameplate voltages selected at a lower value than that of the system nominal
voltage. For example, motor nameplate voltages of 2200, 3810, or 6600 would be applied
to systems with a nominal voltage rating of 2300,4000, and 6900 volts.
A similar policy is followed for excavators destined for export. Nominal system voltages of
3300 or 6600 volts would be equipped with motors having a nameplate rating of 3150 or
6300 volts.
MOTOR STARTING
The starting of the main MG set motor is the most severe duty experienced by the mine
power system. Where a single excavator is served from single transformer by the trailing
cable; the mine power system can be designed to allow the voltage to drop significantly at
the motor terminals without disturbing nearby loads. Multiple excavators utilizing a single
transformer source must take nearby loads into consideration.
The starting in-rush current for induction motors are usually in the order of 650% to 750%.
For synchronous motors, the older designs were around 450% but now range between
550% and 630%.
On starting, the voltage may be allowed to drop significantly providing sufficient voltage is
available to provide break away torque at zero speed. Most MG sets require approximately
20% of motor nameplate torque to break away. Since the starting torque varies in proportion
to the square of the applied voltage, the voltage drop at the terminals of the motor should
not exceed 30%. (i.e.: not less than 70% of nominal.)
Since the voltage drop in the transformer and trailing cable is normally rather high, the
application of reduced voltage starting is not recommended. The normal mine power system
is, in itself, a reduced voltage starting condition. The application of either the
auto-transformer or series reactor type of reduce voltage starting serves to greatly increase
the time required to start the MG set, reSUlting in unnecessary thermal stress in the rotor, etc.
Generally, where reduced voltage starting appears to be a necessity, the system should be
closely investigated as there may be insufficient power to dig with the excavator.
The normally calculated time for starting a typical MG set inertia is about 5 seconds,
assuming that full nameplate rated voltage was available at the motor terminals. When
started on a typical mine power system, the time to start varies from about 9 to 12 seconds.
--~c=========---
6.4.2
BI006008
Now that
finished t
work is
pertorma
the shovel has had its static tests completed and the mechanical people have
eir work, the machine is ready to move. The true test of the proficiency of your
t hand. Operational or dynamic tests are the true measure of a machine's
ceo
When run
system,
motion u
voltage,
ing dynamic tests for the first time or after you've made changes to the electrical
ever assume that everything is okay. Start off slow and gradually increase the
to its full capacity. It's far better to realize there is a problem at a low value of
rrent or speed than at full capacity.
The easi st and possibly the best method of checking the dynamic performance of the
excavato is by utilizing an X-V recorder. Because the current, voltage and speed are
constantl changing it is difficult to get the total shape of the volt-amp curve without a
recording device. It is possible to get good results with an oscillograph, Brush or similar
recorder, ut translating the results into the shape of the volt-amp curve or the dynamic limit
in the reg nerative quadrant can be time consuming. One advantage of the oscillograph is
that a tim record is made, but where possiblE! it is recommended an X-V recorder be used
because of the instant results. Currently the most widely used X-V recorders are the
HewlettP kard models 7034A and 7035B, but other types have also been used with some
When m ing X-V recordings of dynamic tests it is extremely important that proper limits are
shown on he chart paper. The maximum settings that the rotating equipment can tolerate
from a co mutation standpoint are shown on Figure 17. However, in order to protect their
gears or echanical system, Marion may elect to have the specific machine settings inside
these m imum limits. Th'e MPS recommended electrical setting sheet is official. Consult it.
in the motoring quadrants (1 st and 3rd quadrants) are set by the MPS
ded setting stleet values.
The dyn
ic limits for the regeneration quadrants (2nd and 4th) are the same for each MD
motor siz ,regardless of the excavator on which it is used. The dynamic limit is based on
percent f rated stall current vs. percent of rated motor speed. The actual limits for an
individual otor can be obtained by finding the percentages on the dynamic limit line and
multiplyin the ratings times the percentages. Figure 18 shows these limits converted to rpm
for the M 816 thru MD824 respectively. These limits are shown in motor rpm because on
the hoist d drag motions the motor speed in the 4th quadrant is the limiting commutation
factor at hi h motor speeds. All excavators should be initially set up for the speed vs. current
to assure hat during plugging (regenerative braking) the machine does not exceed these
limits, but so to check that it makes use of all the allowable area under the curve. Dynamic
tests shou d always be made under staged conditions. The hoist motion motoring quadrant
(1st) is ch cked by hoisting an empty dipper at full masterswitch with the bucket under the
boom poi t.
BI006008
This approximates the open circuit voltage condition. Hoisting the bucket through the bank
in a normal operating mode should check the slope of the current limit line. Having the
operator momentarily stall the bucket in the bank checks the stall current setting.
Accelerating a full bucket from rest to full speed (in the hoist direction only) approximates
the peak power point.
The 4th quadrant test for the hoist motion is always performed with an empty bucket. The test
is run with the bucket at the boom point for hoist. The motion is then lowered at top speed
and plugged to both neutral and hoist. On new machines or after changes have been made
plugging tests should begin at half speed and checked progressively in several steps until
maximum speed is reached.
The crowd motion is tested in a manner similar to that procedure used on the hoist.
The swing tests can be staged by accelerating to top speed by a maximum throw of the
master switch from a creep speed, then throwing the switch to the maximum opposite
direction once top speed has been reached. The procedure is then repeated to fill out the
rest of the 4 quadrants.
To accomplish these tests and obtain the significant data you desire, the operator must
understand what you want. Make certain that he knows exactly what you want AND does it.
Otherwise he could adversely affect the outcome of the tests and your conclusions on the
machine's performance.
----._-------- --------------------
6.5.2
BI006008
EXCAVATOR APPLICATION DATA

EXCAVATOR EQUIPMENT -COMMUTATION LIMITS
For MD Motors and CDS Generators
ARl1A.TURE AMPS X 1000
200
400
600
80
::E
0-
a:
a:
100
120b
1400
16C a
'--_I.--~
......
j!..;..:...:...I:'...._.'_'
...r._
...
1670
Q30
835
818
2130
820
1065
820
2700
800
1350
822
3600
740
1760
824
4500
700
2200
...,I'......_ , ,
_
Figure 17
6.5.3
extq1847.wpg
BI006008
FOURTH QUADRANT DYNAMIC LIMITS

ARMATURE AMPS vs. MOTOR RPM
--S9-S-V-o-lts---------------,
a r------/~---===/='-=-=-=7::;-:~==-\
V':)LT:.GE LIMIT
58%
a j-----
72% \
\
OYN:.MIC LIMIT
(STt.TIC-+-25%)
STATIC LIMIT
'\
\
\
\
01-----
rr
=L,==='-'=-~--=irL=-=-=-=-~I=-=- -IJ
\
01------
-==ili==-=--::':20
o~
:;
;:lERCENT
5rB;;:-<:
~:-.1OTOR
40
60
80
100
120
I
/
25
CONOITION FRCM ~
OP~RATIONAL ST:'NDPOINT
c:::: :::::
R~IS CURRS~!T eN :'NY ~PLlC.loTION

MUST NOT EXCEO ,<ATEa M:TOR
~::2--CURR::NT - RESPONSIBILITY FOR
8'"
'""HICH SHCULD BE RECOGNI ZED
~ ~
':'ND ACCEPTED BY EXCAVATOR
c::::
SUILOER.
>
..... :::l
CROSS-HATCHSO AREA
BEING A OYN~IC
R~TED STALL CI.J'RNT

OR GENE.Cl.:.TORl
o ,...
,...
110% STALL S::TTING

FOR SCR CONTROLLED
EQUIPMENT BASED ON
I
/
I
$T~LL
__
~P!R!5
..,~
~o
~':'t
c..~
a f-----
/
/
I
/
51-----/
/
~T('R
R""
llO4
200
1420
806
tC8
810
812
JOO
12C5
1125
650
850
814
1250
'15
167:1
Sf 8
120
!20
822
2120
2700
3600
a24[
.~~
740
700
45)
1075
IC25
"5
930
sec
LIM ITS
F" I ELD
~CR WE~K
01-----
sL..-
/
/..
Use Dynamic limit
---''--..J-
---'
Figure 18
6.5.4
extr1847.wpg
BI006008
Section
DC 2000 Drive System

and Instruction Manuals
-
Table of Contents -
7.1
GF 20000 Generator Field Exciter Operation and Maintenance Instructions for

Directo-Ma ic 2000 Equipment
" GEH-6148
7.2
AC/DC 200
AC/DC 200
DCFB Pow
SDCC Driv
DSCO
Configurabl
Configurabl
Configurabl
DS200
DS200FS
Receiving a
2243-I.M61
Wiring Board Instructions
Drive Terminal board 531X305 NTB AA-AH G1

GEI-100020
Drive Lan I/O Terminal Board 531X307LTB AA-AC G1
GEI-100022
r Supply Board DS200DCBG1AA Through G1AEB
GEI-100028
Control Card DS200SDCCG1AA - G1ABA,
DCCG2AAA-G2ABA
GEI-100029
Hardware for PCCA Power Connect Card
GEI-100161
Hardware for DC200SLCC Land Communications Card . GEI-100162
Hardware for RTBA Relay Terminal Board
TBAG1AAA-G1ADB
GEI-100167
Single-Phase Field Supply Amplifier board
GEI-100186
d Storage Instructions for Directo-Matic 2000 Equipment . GEI-100228
BI006008
BI006008
GEH-6148
Instructions
GF2000
Dc Generator Field Exciter
Operation and Maintenance
BI006008
BI006008
Supplement To
GEH-6148
GE Motors & Industrial System
The values listed in Table 4-1 of GEH-6148 have been updated.

In GEH-6148, lease replace Table 4-1 on page 4-3 with the updat ed Table 4-1 below.
Table 4-1. GF2000Frame Size Specifications
Ac Input
Voltage
(Vac)
Maxi mum Dc
Output Voltage
(V de)
Maximum De
Output Current
230
460
575
3 00
6 00
8 00
259
259
259
C Extension (CX)
230
460
575
3 00
6 00
8 00
490
490
490
230
460
575
3 00
6 00
8 00
127
127
Frame Size
(A)
99
BI006008
GEH-6148
Supplement to GEH-6148
Notes:
GE Motors & Industrial Systems
---------------------------
;ue date: May 1996
OE Industrial Systems
1501 Roanoke Boulevard
Salem, VA 241536492 USA
SUPPLEMENT3
GEH-61,
BI006008
GEMotors&
Industrial System~
---------+---------------------------
These instructions 0 not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met dUT
ing installation, op ration, and maintenance, Iffurther information is desired or ifparticular problems arise that are not covered sufficientlyfor the purc ser's purpose. the matter should be referred to GE Motors & Industrial Systems.
This document cont ins proprietary information ofGeneral Electn'c Company, USA and is furnished to its customer solely to assist that
customer in the ins llation, testing. operation. and/or maintenance ofthe equipment described. This document shall not be reproduced iJ
whole or in part no shall its contents be disclosed to any third party without the wn'tten approval ofGE Motors & Industrial Systems.
1.
2.
Chapter 2 (Receiving, Handling and Storage) in its entirety with publication GEI-I00228.
Please use th following table for acoustic information:
ACOUSTIC NOISE LEVELS - C / CX FRAMES
blower
~
74dBA
_ -
77dBA
;
fan
62 dBA
84dBA
;
65 dBA
o-
74 dBA
BI006008
SUPPLEMENT4
BI006008
GEH-61
GEMotors&
Industrial System~
-------+-----------------------These instructions not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met durin,
installation, operati n, and maintenance. Iffurther information is desired or ifparticular problems arise that are not covered sufficiently fi
the purchaser's pur ose, the matter should be referred to GE Motors & Industrial Systems.
This document cont ins proprietary information ofGeneral Electric Company, USA and is furnished to its customer solely to assist that
customer in the inst llation, testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproduced in
whole or in part nor shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems.
1.
Please use th following table for acoustic information:
fan
62dBA
65 elBA
74dBA
fan
67dBA
69 elBA
74dBA
fan
73 dBA
73 elBA
BI006008
BI006008
GEI-10022
BE Motors &
Industrial System.
----------+--------------------------RECEIVING AND STORAGE INSTRUCTIONS

FOR DIRECTO-MA TIC 2000 EQUIPMENT
I These instructions
0 not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met durop ration, and maintenance. Iffurther information is desired or Ifparticular problems arise that are not covered sufficientlyfor the purc aser,s purpose, the matter should be referred to GE Motors & Industrial Systems.
I ing installation,
customer in the inst llation,testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproduced in
whole or in part no shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems.
CONTENTS
Safety Symbol Le end
Overview
Receiving Guideli es
Handling GuidelilJ es
Storage Guideline
Warranty Parts ar d Service
OVERVIEW
1
1
1
2
3
.4
SAFET(SYMBOLLEGEND
WARNING
CAUTION
Indicates a procedure, practice,

condition, or statement that, if
not strictly observed, could result in personal injury or death.
not strictly observed, could result in damage to or destruction
of equipment.
NOTE Indicates an essential or important procedure,

practice, con dition, or statement.
This document contains guidelines and precautions for

handling and storing DIRECTO-MA TIC~ 2000 equipment upon receipt from a carrier. This document also
contains information for obtaining warranty parts and
service.
Before handling or storing equipment, consult and study
all applicable drawings and instructions.
For assistance, contact:
General Electric Company
Product Service Engineering
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
Phone: 001-540-387-7595
Fax: 001-540-387-8606
RECEIVING GUIDELINES
General Electric Company (GE) carefully inspects and
packs all equipment before shipping it from the factory.
GE attaches a packing list, which itemizes the contents of
each package, to the side of each case of the equipment.
GE provides handling guidelines to the carrier. These
direct the carrier not to expose the shipment to excess
moisture or humidity, extreme temperatures, excess temperature changes, or rough handling during transportation.
BI006008
1-100228
Receiving and Storage Instructions for DIRECTO-MATIC 2000 Equipment
pon receiving a shipment, the customer should:

Conduct a visual inspection before or during the
offloading.
Move the shipment to shelter.
Conduct a thorough inspection of the shipment.
.efer to Receiving Guidelines, Handling Guidelines, and
torage Guidelines below.
Shortage
Damage sustained while enroute
Refer to Receiving Guidelines, Handling Guidelines, and

Storage Guidelines below.
If damage or rough handling is evident, notify the carrier
and GE immediately.
The carrier or GE may require the following information:
GE requisition number
Case number
Equipment serial number
Part (model) number
Damaged part (model) name and description
)FFLOADING
mmediately upon receipt of any equipment, conduct a

'isual inspection for signs of rough handling or shipping
lamage. Conduct this initial inspection before the shipnent is offloaded. If damage is noted, immediately notify
he carrier before they leave the reception site. ..
\lotify the carrier that a thorough inspection was not confucted upon the receipt of the shipment. A thorough in;pection occurs after storage and unpacking.
HANDLING GUIDELINES
R.efer to Moving and Lifting and Damage Notification

Delow.
CAUTION
SHELTERING
Rough handling can damage electrical equipment. To prevent such damage when moving
the equipment, be sure to observe normal
precautions along with all handling instructions printed on the case.
CAUTION
Potential for damage to equipment exists.
Packing cases are not suitable for outdoor
storage, even for short periods of time.
Immediately after the offloading visual inspection, place
the equipment under adequate cover to protect it from
adverse conditions.
NOTE
MOVING AND LIFTING
When handling equipment:
Refer to equipment outline drawings for preferred

methods oflifting and moving equipment.
Observe the equipment's center-of-gravity to ensure

that equipment does not fall.
Failure to protect equipment from adverse

conditions will void the equipment warranty.
Refer to Handling Guidelines and Storage Guidelines
below.
UNPACKING
Consider the following when unpacking a shipment:

INSPECTING
After moving the equipment to shelter, check the contents

of each package against the packing list. Check for:
If the equipment has been exposed to low temperatures for an extended period, do not unpack it until it
has reached room temperature.
BI006008
Receiving and
GEI-I002~
orage Guidelines for DIRECTO-MATIC 2000 Equipment
It is good pr ctice not to completely unpack the

equipment u til it has been placed near its permanent
location or i storage location.
Use standar unpacking tools to carefully remGve

equipment fr m its container.
Shipping and ambient storage temperature limit

are: -25C (-5 OF) to 70C (167 OF).
NOTE
Use care wh n unpacking to prevent marring or damaging parts.
Label each it m when it is unpacked.
Check the co tents of each case against the packing

list. Report s ortages to GE.
Wipe offpart cles'ofpacking materials or foreign

substances th t may be lodged in or between the
parts.
Use caution t ensure that small parts (such as bolts

and screws) d not become separated.
Carefully ins ect packing material for loose parts

before discar ing.
These limits are guidelines to ensure a safe

storage environment for all equipment. However, some equipment can tolerate a wider
range. If the above temperature guidelines
cannot be met for your equipment, contact
GE to determine if different tolerances apply.
Surrounding air free of dust and corrosive elements, such as salt spray, or chemical and electrically conductive contaminants.
Ambient relative humidity from 5 to 95% with
provisions to prevent corrosion.
No rodents.
Limit temperature variations that cause moisture
condensation on the equipment.
CONDENSATION
GE GUIDELINES
If the unit is not in tailed immediately upon receipt, it
must be stored pro erly to prevent corrosion and deterioration. Since pack' g cases do not protect the equipment
for outdoor storag , the customer must provide a clean,
dry'place free ofte perature variations, high humidity,
and dust.
Use the following uidelines when storing equipment:

ent under adequate cover with the
ements:
Keep the e uipment clean and dry, protected
from preci itation and flooding.
Use only b eathable (canvas type) covering material- do ot use plastic.
Unpack the eq 'pment as described in Unpacking
(page 2).
Moisture on certain internal parts can cause

electrical failure.
Condensation occurs with temperature drops of
15C (27 OF) at 50% humidity over a 4-hour period.
Condensation also occurs with smaller temperature variations at higher humidity.
SPECIFICATION
CAUTION
Maintain the fo lowing environment in the storage

enclosure:
If the storage room temperature varies in such a way, install a reliable heating system that keeps the equipment
temperature slightly above that of the ambient air. This
can include space heaters or panel space heaters (when
supplied) inside each enclosure. A 100 W lamp can
sometimes serve as a substitute source of heat.
CAUTION
To prevent fire hazard, remove all cartons
and other such flammable materials packed
inside units before energizing any heaters.
BI006008
EI-I00228
Receiving and Storage Instructions for DIRECTO-MATIC 2000 Equipment
ME LIMITATIONS
OBTAINING PARTS AND SERVICE
le above specifications apply to shipping and storage

lrations of up to one year. Longer times may require
lditional treatment.
To obtain warranty replacement parts or service assistance, contact the nearest GE Service Office.
Please have the following information ready to exactly
identify the part and the application:
WARRANTY PARTS AND SERVICE

fARRANTY TERMS
he GE Terms and Conditions brochure provides product

arranty information, including the warranty period and
arts and service coverage.
Equipment serial number and model number
Part number and description
he brochure is included with the customer documentaon. It may also be obtained separately from the nearest
E Sales Office or authorized GE Sales Representative.
GEMotors&
Industrial Systems
-------------------------------------
e Date: October 1996
6110llrlll Eillctric Complloy
Industrial Systems
1501 Roanoke Blvd.
BI006008
GF2000
Dc Generator Field Exciter
Operation and Maintenance

GEH-6148
Issue Date: June 1995
These instructio do not purport to cover all details or variations in equipment, not to provide for every possible
contingency to b met during installation, operation, and maintenance. Should further information be desired or
should particula problems arise that are not covered sufficiently for the purchaser's purpose, the matter should be
referred to GE D 've Systems and Turbine Controls.
This document c ntains proprietary information of General Electric Company, USA and is furnished to its customer
solely to assist th customer in the installation, testing, and/or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the
written approval if GE Drive Systems & Turbine Controls.
BI006008
1995 by General Electric Company, U.S.A.

Ail rights reserved.
Printed in the United States of America.
ARCNET is a registered trademark of Datapoint Corporation.

IBM, IBM PC, and PC AT are registered trademarks of International Business Machines Corporation.
LynxOS is a registered trademark of Lynx Real-Time Systems, Incorporated.
MS-DOS is a registered trademark of Microsoft Corporation.
Muffm and Tarzan are registered trademarks of COMAIR ROTRON, a KLI Company.
DIRECTO-MATIC and VERSILUBE are registered trademarks of General Electric Company, U.S.A.
BI006008
GEH-6148
GF2000 Dc G nerator Field Exciter
Safety Symbol Legend
WARNING
Commands ttention to an operating procedure, practice, condition, or statement which, if not strictly observed, coul result in personal injury or death.
CAUTION
Commands a ention to an operating procedure, practice, condition, or statement which, if not strictly observed, coul result in damage to or destruction of equipment.
NOTE
Commands a ention to an essential operating or maintenance procedure, condition, or statement that must be
highlighted.
BI006008
GEH-6148
GF2000 Dc Generator Field Exciter
WARNING
This equipment contains a potential hazard of electric shock or burn. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate,
or maintain this equipment.
Isolation of test equipment from the equipment under test presents potential electrical hazards. If the
test equipment cannot be grounded to the equipment under test, the test equipment's case must be
shielded to prevent contact by personnel.
To minimize hazard of electrical shock or burn, approved grounding practices and procedures must be
strictly followed.
WARNING
To prevent personal injury or equipment damage caused by equipment malfunction, only adequately
trained personnel should modify any programmable machine.
BI006008
GF2000 Dc Ge erator Field Exciter
GEH-6148
TABLE OF CONTENTS
Section/Subject
CHAPTER 1.
VERVIEW
1-1. DefInition d Scope

1-2. Equipment Overview
1-2. 1. Comm cations Interfaces
1-2.2. Software Design
1-2.3. Hardwar Design
1-3. Related D uments
1-1
1-2
1-2
1-2
1-2
1-2
CHAPTER 2. R CEIVING, HANDLING, AND

STORAGE
2-1.
2-2.
2-3.
2-4.
2-5.
Introductio
Receiving d Handling
Storage
Unpacking
Time Limi tions
2-1
2-1
2-1
2-2
2-2
CHAPTER 3. IN TALLATION AND INITIAL

STARTUP
3-1. Introduction
3-2. Operating E vironment
3-3. Mounting
3-4. Cabling and iring
3-4.1. Ac Power equirements
3-4.2. Connectio
3-4.2.1. Power C nnections
3-4.2.2. Control onnections
3-4.3. Wiring Le el Separations
3-4.4. Spacing
3-4.5. Grounding
3-4.6. Commons
3-4.7. Suppressio
3-5. Service and arts Instruction
3-6. Power-off C eck
3-6.1. Wiring and Circuit Checks
3-6.2. Generator d Device Checks
3-7. Power Appli tion and Startup
3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-2
3-2
3-3
3-3
3-3
3-3
3-3
3-3
3-4
3-4
3-4
CHAPTER 4. FU CTIONAL DESCRIPTION
4-1. Introduction. .
4-2. Exciter Softw e Structure
4-2.1. Block Syste
4-2.2. Building BI k Architecture
4-2.3. Diagnostics
4-2.4. ConfIguring Blocks
4-3. Exciter Hard are Structure
4-3.1. Control Sec 'on
4-3.2. Power Con rter
.4-1
.4-1
4-1
.4-1
4-2
.4-2
.4-2
4-2
4-2
4-4. Controller Operation

4-5. Power Converter Operation
4-5.1. Ac Line Fuses (FUl - FU3)
4-5.2. Ac Reactors
4-5.3. Loop Contactor (MDA)
4-5.4. Control Power Transformer (CPT)
4-5-5. Shunt
4-5.6. Field Exciter Output Module
4-6. Exciter Connection Drawings
4-2
4-3
4-3
4-4
4-4
4-4
4-4
4-4
4-4
CHAPTER 5. PRINTED WIRING BOARD

DESCRIPTIONS
5-1. Introduction
5-2. Board IdentifIcation
5-3. Adjustable Hardware
5-3.1. Initial Hardware Settings
5-3.1.1. Potentiometers
5-3.1.2. Switches
5-3.1.3. Jumpers
5-3.2. Adjusting Replacement Boards
5-4. Printed Wiring Boards
5-4.1. Power Supply Board (DS200DCFB)
5-4.1.1. Power Supplies
5-4.1.2. Voltage and Current Feedback VCO
Circuits
,
,
5-4.1.3. Motor Voltage Attenuation Circuit
5-4.1.4. Ac Line Magnitude and Zero Crossing
5-4.1.5. Ac Line Current Transformer
Interface
5-4.1.6. Contactor Drive Circuits
5-4.1.7. Field/Armature SCR Firing Control
Circuits
5-4.1.8. ConfIgurable Hardware
5-4.2. Field Exciter Crowbar Board
(DS200FECB)
5-4.2.1. ConfIgurable Hardware
5-4.3. LAN 1/0 Terminal Board
(531X307LTB)
5-4.3.1. LTB Board SpecifIcations
5-4.4. Drive Terminal Board (531X305NTB)
5-4.4.1. Power Supplies
5-4.4.2. Encoder Interface
5-4.4.3. RS-232C Interface
5-4.4.4. Special Purpose RS-422 Interface
5-4.4.5. Relay Outputs
5-4.4.6. Analog Tach and Reference Coarse
Scaling
5-4.4.7. Low-level Analog I/O
5-4.4.8. Digital Control Inputs
5-1
5-1
5-1
5-2
5-2
5-2
5-2
5-2
5-2
5-3
5-3
5-3
5-3
5-4
5-4
5-4
5-4
5-4
5-8
5-8
5-9
5-9
5-10
5-10
5-10
5-10
5-10
5-10
5-11
5-11
5-11
BI006008
GEH-6148
TABLE OF CONTENTS - Continued
Section/Subject
Section/Subject
5-4.4.9. Configurable Hardware
5-11
5-4.5. Power Connect Card (DS200PCCA)
5-15
5-4.6. Relay Terminal Board (DS200RTBA)
5-18
5-4.7. Drive Control Card (DS215SDCC)
5-20
5-4.7.1. Reset Circuits
5-20
5-20
5-4.7.3. Replacing/Inserting Software
5-20
5-4.8. LAN Communications Card
(DS215SLCC)
5-23
5-23
5-4.8.2. Replacing/Inserting Software
5-23
5-4.9. Signal Processor Card (531X309SPC)
5-26
5-26
5-4.10. Voltage Attenuator Board (DS200SVAA) 5-31
5-4.11. Shunt Isolator Board (DS200SVIA)
5-33
5-4.11.1. Input Stage
5-33
5-4.11.2. Isolation Stage
5-34
5-4.11.3. Output Stage
5-34
5-4.11.4. Adjustment Procedures
5-34
5-4.11.5. Voltage Isolation Function
5-34
5-4.11.6. Current Signal Converter
5-35
5-4.11. 7. Configurable Hardware
5-35
CHAPTER 6. I/O DEFINITIONS
6-1. Introduction
6-2. Types of Connectors
6-2.1. Plug-in Connectors
6-2.2. Terminal Board Connectors
6-2.3. Stab Connections (Stabs)
6-3. LED and Neon Indicators
6-4. DCFB Board 1/0
6-5. FECB Board I/O
6-6. LTB Board I/O
6-7. NTB/3TB Board I/O
6-8. PCCA Card I/O
6-9. RTBA Board I/O
6-10. SDCC Card 1/0
6-11. SLCC Card I/O
6-12. SPC Card I/O
6-13. SVAABoardI/O
6-14. SVIA Board I/O
ii
6-1
6-1
6-1
6-1
6-1
6-1
6-2
6-7
6-8
6-11
6-17
6-18
6-20
6-22
6-23
6-24
6-25
CHAPTER 7. FUSES AND TESTPOINTS
7-1. Line Fuses

7-2. DCFB Onboard Fuses
7-3. Testpoints
7-3.1. DCFB Board Testpoints
7-3.2. NTB/3TB Board Testpoints
7-3.3. SDCC Card Testpoints
7-3.4. SPC Card Testpoints
7-3.5. SVIA Board Testpoints
7-1
7-1
7-3
7-3
7-3
7-4
7-6
7-7
CHAPTER 8. SOFTWARE ADJUSTMENTS
8-1. Introduction
8-2. ST2000 Toolkit
8-2.1. Equipment Requirements
8-2.2. Using the ST2000 Toolkit.
8-3. Drive Configurator, LynxOS Version
8-3.2. Using the Drive Configurator
8-4 Programmer Module
8-4.1. Keypad
8-4.2. Display
8-4.3. Operating Modes
8-4.3.1. Operate Mode
8-4.3.2. Parameter Mode
8-4.3.3. Diagnostic Mode
8-4.4. Drive Diagnostics
8-4.4.1. Running the Diagnostic Tests
8-4.4.2. Diagnostic Test Definitions
8-4.4.3. DACl, DAC2, METl, and MET2
8-1
8-1
8-1
8-1
8-2
8-2
8-2
8-2
8-3
8-3
8-3
8-3
8-5
8-7
8-7
8-7
8-8
8-10
CHAPTER 9. TUNEUP PROCEDURE
9-1. Introduction
9-1
9-2. Required Equipment.
9-1
9-3. Setup
9-1
9-3.1. DAC Variable Selection
9-2
9-3.2. Diagnostic Use
9-3
9-3.3. Setting EEPROM Values in EDITIOOO
9-3
9-3.4. Entering Terminal Mode
9-3
9-3.5. Test 31 - Display Diagnostic Variables
9-3
9-3.6. Setting Regulation Modes
9-3
9-4. Step 1 - Preliminary Calculations
9-3
9-4.1. VCO Feedback Scaling
9-4
9-4.2. Bridge Overcurrent Protection
9-4
9-5. Step 2 - Generator Field Time Constant.
9-4
9-6. Step 3 - Proportional Field Current Regulator
Response
9-6
9-7. Step 4 - Proportional Plus Integral
Regulator
9-7
BI006008
GEH-6148
TABLE OF CONTENTS - Continued
Section/Subject
9-8. Step 5 - F eld Current Converter
Linearizaf n
9-9. Step 6 nerator Saturation Curve
9-10. Step 7 dy Current Lag Time Constant
Determin tion
9-11. Step 8 ature Voltage Regulator
9-12. Step 9 ature Current Feedback
Scaling d Overcurrent Setting
9-13 . Step 10 ature Time Constant
Determin tion
9-14. Step 11 mature Current Regulator.
9-15. Step 12 ature Current Rate and
Filter
9-16. Step 13 - peed Regulator Feedback
Scaling an Polarity Verification
9-17. Step 14 - roportional Speed Regulator
9-18. Step 15 - roportional Plus Integral Speed
Regulator. .
CHAPTER 10.
9-8
9-9
9-10
9-11
9-12
9-13
9-14
9-16
9-16
9-17
9-18
ROUBlESHOOTING
10-1. Introductio
10-1
10-2. Tools and
truments
10-1
10-3. General T ubleshooting
10-1
10-4. Stability P blem Troubleshooting........... 10-6
10-4.1. Cyclical tability Problems
10-6
10-4.2. Mechani al Oscillation Problems
10-7
10-4.3. Erratic 0 eration Problems
10-7
10-4.4. Troubles ooting Procedures
10-7
10-4.4.1. Initial hecks
'" 10-7
10-4.4.2. Proble Determination
10-7
10-4.5. Ac Line hase Problems
10-7
10-5. Specific Fa t Troubleshooting
10-9
10-5.1. Fault Indi ation
10-9
10-5.1.1. Progr
er Display
10-9
10-5.1.2. LED D' play
10-9
10-5.2. Types of aults
10-9
10-5.3. Clearing e Fault.
10-10
CHAPTER 11. D
GNOSTIC LISTS
11-1. Introduction
11-2. MCP Diagn stic Circular List..
11-2.1. Circular L st Content........................
11-2.2. Circular L st Operation
11-2.3. Circular L st Display
11-3. DCP Circul List Blocks
11-3.1. CLST BI ks
11-3.1.1. CLSTl ( asic) Block
11-1
11-1
11-1
11-1
11-1
11-2
11-2
11-2
11-3.1.2. CLST2 (Intermediate) Block

11-3.1.3. CLST3 (Advanced) Block
11-3.2. Circular List Display
11-4. LCP History Buffer
11-2
11-3
11-3
11-4
CHAPTER 12. PARTS REPLACEMENT
12-1. Introduction
12-2. Replacing Boards
12-3. SCR Module Repair/Replacement..
12-1
12-1
12-2
CHAPTER 13. SPARE AND RENEWAL PARTS
13-1. Introduction
13-1
13-2. Custom Renewal Parts Listing
13-1
13-3. Ordering Renewal Parts
13-1
13-4. Part Number Structure
13-1
13-4.1. Order-specific Assembly Part Numbers .. 13-1
13-4.2. Common Assembly Part Numbers
13-2
13-4.3. Component Part Numbers
13-2
13-4.4. Board Part Numbers
13-2
13-5. GF2000 Dc Generator Field Exciter
Parts Lists
13-2
APPENDIX A. GLOSSARY OF TERMS
APPENDIX B. HARDWARE DRAWINGS
B-1. Introduction
B-1
APPENDIX C. ELEMENTARY DIAGRAM, C AND

C EXTENSION FRAME EXCITERS
C-l. Introduction
C-l
APPENDIX D. ELEMENTARY DIAGRAM, G

FRAME EXCITERS
D-l. Introduction
D-l
APPENDIX E. PERIODIC MAINTENANCE
E-l. Introduction
E-2. Preventive Maintenance
E-3. Cooling Fans
E-l
E-l
E-2
APPENDIX F. WARRANTY PARTS AND

SERVICE
F-l. Warranty Terms

F-l
F-2. Obtaining Parts and Service Under Warranty F-l
iii
BI006008
GEH-6148
LIST OF FIGURES
5-1. Pot Set at Default Position

5-2. DCFB Board Layout.
5-3. FECB Board Layout
5-4. LTB Board Layout
5-5. NTB/3TB Board Layout.
5-6. PCCA Card Layout
5-7. RTBA Board Layout..
5-8. SDCC Card Layout
5-9. SLCC Card Layout
5-10. SPC Card Layout
5-11. SVAA Attenuation Circuit
5-12. SVAA Board Layout
5-13. SVIA Simplified Elementary Diagram
5-14. SVIA Board Layout
7-1. DCFB Board Layout..
7-2. NTB/3TB Board Layout..
7-3. SDCC Card Layout
7-4. SPC Card Layout.
7-5. SVIA Board Layout..
8-1. Changing Modes of Operation
9-1. GF2000 Regulators and Control Loops
9-2. Generator Saturated Field Time Constant
Determination
9-3. Proportional Generator Field Current
Regulator.
'"
9-4. Proportional Field Current Regulator
Response Plot
iv
5-2
5-4
5-8
5-10
5-11
5-16
5-18
5-21
5-24
5-26
5-31
5-32
5-33
5-35
7-2
7-3
7-5
7-6
7-8
8-5
9-2
9-5
9-6
9-7
9-5. Proportional Plus Integral Generator Field

Current Regulator
9-6. Converter Linearization
9-7. Deadtime (Ifg = 0) Determination Plot
9-8. Typical Generator Saturation Curve
9-9. Armature Voltage Regulator With Eddy
Current Lead and Lag Time Constants
9-10. Armature Voltage Regulator Response
Plot
9-11. Armature Time Constant Determination
Response Plot...................................
9-12. Generator Armature Current Regulator.. ...
9-13. Generator Armature Current Regulator
Response
'"
9-14. Speed Regulator Block Diagram.............
9-15. Proportional Speed Regulator Response
10-1. BCD-coded LED Display
10-2. Binary-coded LED Display
B-1. GF2000 Dc Generator Field Exciter
Hardware Drawing 336A3511
C-l. Sample Elementary Diagram, GF2000
C Frame Exciter.
D-1. Sample Elementary Diagram, GF2000
G Frame Exciter.
9-7
9-8
9-9
9-10
9-11
9-12
9-14
9-15
9-16
9-18
9-18
10-9
10-9
B-2
C-2
D-3
BI006008
GEH-6148
LIST OF TABLES
4-1.
5-1.
5-2.
5-3.
5-4.
5-5.
5-6.
5-7.
5-8.
5-9.
GF2000 F ame Size Specifications

.4-3
DCFB Bo d Adjustable Hardware
5-5
NTB/3TB oard Adjustable Hardware
5-11
PCCA C d Uses
5-15
PCCA C d Adjustable Hardware
5-16
RTBA Bo d Adjustable Hardware
5-18
SDCC C
Adjustable Hardware
5-21
SLCC Car Adjustable Hardware
5-25
SPC Card djustable Hardware
5-27
SVAA Bo d Attenuation Jumper
Placement
5-32
5-10. DCFB DI Switches SW4 and SW5 Settings
With SV
Board Attenuation of 0.442
5-32
5-11. SVIA Inp t Gain
5-33
5-12. SVIA Bo d Adjustable Hardware
5-36
6-1. Connector PL, I/O Between DCFB Board
and SDCC Card
6-2
and NTB/3 B, SDCC, and SLCC Boards ..... 6-3
and NTB/3 B Board
6-3
and PCCA ard
6-4
6-5. Connectors NPL, CPTPL, and FAPL,
I/O Betwee DCFB Board and Components .. 6-5
6-6. Connectors
IPL, IA2PL, IFIPL, and
IF2PL, I/O Between DCFB Board and
Shunts
6-5
6-7. Connector ACPL, I/O Between DCFB
Board and ontactor Driver Circuits
6-5
6-8. DCFB Boar Stab Terminal Connections
6-6
6-9. Neon Lamp and LEDs on DCFB Board
6-6
6-10. FECB Bo d Stab Terminal Connections
6-7
6-11. Connector PL, I/O Between LTB,
NTB/3TB, d SDCC Boards
6-8
6-12. Connectors INI Through IN8, Inputs to
LTB Board
6-9
6-13. Connector PL, I/O Between LTB Board
and SLCC ard
6-9
6-14. Connector PTPL, I/O Between LTB Board
and NTB/3 B Board
6-9
6-15. Connectors T1 Through 0T7, LTB Board
Connectio from Form C Relay Contacts. 6-10
6-16. Connector
L, I/O Between LTB Board
and RTBA oard
6-10
6-17. LEDs on L B Board
6-10
6-18. Connector 3 B, I/O Between NTB/3TB
Board and ternal Connections
6-11
6-19. Connector 6PL, I/O Between NTB/3TB

Board and SDCC Card
6-15
6-20. Connector COMPL, RS-232C I/O Between
NTB/3TB Board and User Interface
6-16
6-21. Connectors IFPL Through 6FPL and
lRPL Through 6RPL, Output from PCCA
Card to SCR Bridge
,
'"
6-17
6-22. PCCA Card Stab Terminal Connections
6-17
6-23. Connector RTBA, I/O Between RTBA
Board and External Connections
6-18
6-24. Connectors CPIPL Through CP5PL and
Y9PL Through Y35PL, RTBA Pluggable
Circuits
6-19
6-25. LEDs on RTBA Board
6-19
6-26. Connector 3PL, SDCC Card Output to
6-20
SLCC Card
6-27. Connector 7PL, I/O Between SDCC Card
and SPC Card
6-21
6-28. Connector IIPL, SDCC Output to Meters. 6-21
6-29. LEDs on SDCC Card
6-21
6-30. Connector ARCPL, I/O Between SLCC
Card and DLAN or ARCNET
6-22
6-31. Connector KPPL, I/O Between SLCC Card
and Keypad
" .,
6-22
6-32. Connectors 16PL and 1TB, I/O Between
SPC Card and External Connections
6-23
6-33. SVAA Board Terminal Connections
6-24
6-34. SVIA Board Terminal Board Connections .. 6-25
6-35. LED on SVIA Board
6-25
7-1. GF2000 Dc Generator Field Exciter Line
Fuse Values
7-1
7-2. DCFB Board Fuses
7-2
7-3. DCFB Board Testpoints
7-3
7-4. NTB/3TB Board Testpoints
7-3
7-5. SDCC Card Testpoints
7-4
7-6. SPC Card Testpoints
7-6
7-7. SVIA Board Testpoints
7-7
8-1. Standard Diagnostic Tests
8-8
8-2. RAM Addresses for Analog Signals
8-9
8-3. Diagnostic Mode Analog Output Points .,
8-10
9-1. GF2000 Variable Addresses
9-2
9-2. GF2000 Regulation Modes
9-5
9-3. Open Loop Firing Mode EEPROM Values
9-4
9-4. Generator Proportional Command and
Feedback Gain EEPROM Values
9-6
9-5. Proportional Plus Integral Regulator
EEPROM Values
9-8
9-6. Field Current Linearization EEPROM
Values
9-9
BI006008
GEH-6148
LIST OF TABLES - Continued
9-7. Armature Voltage Regulator EEPROM

Values
9-8. Armature Current Regulator Gain
EEPROM Values
'"
9-9. Proportional Speed Regulator EEPROM
Values
10-1. Troubleshooting Quick Reference Guide
10-2. General Troubleshooting Chart
10-3. Stability Troubleshooting
10-4. Summary of Fault Types
10-5. Specific Fault Troubleshooting Using
Fault Numbers
11-1. MCP Circular List Software Jumpers
EE.6282 (MDGNJP)
vi
9-12
9-15
9-17
10-2
10-3
10-8
10-10
10-11
11-5
11-2. DCP Circular List Software Jumpers

11-3. LCP History Buffer Software Jumpers
12-1. SCR Module Mounting and Connecting
Torque Requirements
13-1. GF2000 C and CX Frame Exciter Parts
List
13-2. GF2000 G Frame Exciter Parts List
C-1. GF2000 C and CX Frame Elementary
Diagram Sheet Summary
D-l. GF2000 G Frame Elementary Diagram
Sheet Summary
D-2. Terminal Board 2TB Connections, GF2000
G Frame Exciter
11-7
11-9
12-2
13-3
13-6
C-l
D-l
D-2
BI006008
GF2000 Dc G
GEH-6148
erator Field Exciter
CHAPTER 1
OVERVIEW
1-1 . DEFINITI N AND SCOPE
This manual des ribes the GF2000 Dc Generator Field

Exciter. The G 000 exciter is a microprocessorbased power co erter that provides a controlled dc
output to excite e field of a dc generator used in a
motor-generator control system.
This manual is . tended to assist applications and
maintenance per onnel in understanding the equipment
hardware and so are.
Chapter 1 - Ov
Briefly defm s the GF2000 exciter, with an overview of the
dware and software design.
Chapter 2 - Rec iving, Handling, and Storage
Provides gui elines for handling and storing the
GF2000 exci r upon receipt.
Chapter 3 - In lation and Initial Startup
Contains en . onmental, mounting, and electrical
guidelines for installing the GF2000 exciter, including pre-st
p checks and tuneup procedures.
ional Description
Describes the F2000 exciter software and hardware structur , including overall operation.
Chapter 5 - Print d Wiring Board Descriptions
Describes the
ction and operation of boards
within the exc er, including descriptions of the
adjustable bar ware included on each board.
Chapter 6 - I/O ermitions
Lists and defm s I/O connector points, stabs, and
LEDs for the F2000 exciter.
Chapter 7 - Fuses and Testpoints
Lists and defm s the fuses and signal testpoints
available in the exciter and on some boards.
Chapter 8 - Software Adjustments

Defmes the adjustable software used to customize
and fme-tune the GF2000 exciter. Includes information on operating the Programmer, the module
used to make software adjustments and to perform
diagnostic testing.
Chapter 9 - Tuneup Procedure
Provides a procedure to optimize the time constants and gain values of all the regulators in the
control loops used in the GF2000 exciter control
software.
Chapter 10 - Troubleshooting
Provides information to detect and correct problems with the GF2000 exciter, including general
problems, stability problems, and problems indicated by diagnostic test error codes.
Chapter 11 - Diagnostic Circular List
Describes the GF2000 exciter's Diagnostic Circular List and how to use it for troubleshooting.
Chapter 12 - Parts Replacement
Provides instructions for replacing printed wiring
boards and silicon-controlled rectifiers (SCRs)
used in the GF2000 exciter.
Chapter 13 - Spare and Renewal Parts
Contains ordering information for GF2000 exciter
parts, including part numbers.
Appendix A - Glossary of Terms
Defmes acronyms and terms used in this manual.
Appendix B - Hardware Drawings
Includes the hardware drawings provided in the
door pocket of a GF2000 exciter.
Appendix C - Sample Elementary Diagram, C and
C Extension Frame Exciters
Provides a sample elementary diagram for C and
C Extension frame GF2000 exciters.
1-1
BI006008
GEH-6148
Appendix D - Sample Elementary Diagram, G
Frame Exciters
Provides a sample elementary diagram for a G
frame GF2000 exciter.
Appendix E - Periodic Maintenance
Provides recommended periodic maintenance for
the equipment.
Appendix F - Warranty Parts and Service
Explains procedures for obtaining warranty information and service.
Refer to the Table of Contents for the organization of
these chapters and appendices.

1-2.3. Hardware Design
A GF2000 exciter consists of a control section and a

power converter section, described in Chapter 4.
The control section, or controller, includes printed
wiring boards containing microprocessors with companion circuits, including EEPROM (electrically erasable programmable read-Only memory). Additional
boards provide optional features. Chapter 5 describes
the boards.
The power converter section consists of an SCR
bridge rectifier and control circuitry. The components
and frame size vary for the dc output required. Chapter 4 defmes the frame sizes available for the GF2000
exciter.
1-2. EQUIPMENT OVERVIEW

1-3. RELATED DOCUMENTS
The GF2000 Dc Generator Field Exciter uses a basic

digital hardware design with powerful application
software. The user interface consists of a IO-character
alphanumeric display and a keypad for simplified
monitoring, diagnostics and tuneup.
The following documents also apply to the GF2000

exciter, and may assist in installation and troubleshooting:
1-2.1. Communications Interfaces
Hardware summary - located in the exciter door

pocket, includes drawings showing the locations
of terminal board points, printed wiring
boards, connectors, plugs, and power fuses
within the exciter (see Appendix B for examples)
The GF2000 exciter provides local area network

(LAN) and RS-422 interfaces for external communications. An RS-232C interface is also provided for use
with the ST2000 Toolkit or Drive Configurator,
LynxOS@ Version.
GEH-5860 - ST2000 Toolkit User's Manual

GEH-6203 - Drive Configurator, LynxOS Version,
User's Manual
1-2.2. Software Design
Custom software (if applicable)
The application program consists of functional software modules (building blocks), which combine to
perform to system requirements. Block definitions and
configuration parameters are stored in ROM (readonly memory), while variables are stored in RAM
(random-access memory). Microcontrollers execute
the code. See Chapter 4 for details.
GEH-6011 - Installation Guidance Service for

DIRECTO-MATIC 2000 Equipment
Tuneup and diagnostic software is transparent to the

user. A Programmer module with a digital display and
keypad allows an operator to request parameter values
and self-checks. See Chapter 8 for details.
1-2
GE Drive Systems supplies the applicable documents

to customers as needed to support the equipment.
BI006008
GEH-6148
CHAPTER 2
RECEIVING, HANDLING, AND STORAGE
2-1. INTROD CTION
If assistance is needed, contact:
This chapter co tains guidelines and precautions for

handling and st ring the GF2000 Dc Generator Field
Exciter upon re eipt.
Industrial SystemsDrive Systems & Turbine Controls

Telephone 001-540-387-7595
Fax
001-540-387-8606
2-2. RECEIVI G AND HANDLING
CAUTION
2-3. STORAGE
Possible d ger of damage to equipment.

Immediatel upon receiving the GF2000
exciter, pIa e it under adequate cover to
protect it f: m adverse conditions. Packing
cases are n suitable for outdoor or unprotected stora e.
Shock cans
age electric
damage wh
sure to obse
with all han
the case.
by rough handling can damequipment. To prevent such

moving the equipment, be
e normal precautions along
ing instructions printed on
If the exciter is not installed immediately upon receipt,

it must be stored properly to prevent corrosion and
deterioration. Since packing cases do not protect the
equipment for outdoor storage, the customer must
provide a clean, dry place free of temperature variations, high humidity, and dust.
Use the following guidelines when storing equipment:

1.
General Electric ompany (GE) carefully inspects and

packs all equipm t before shipping it from the factory. A packing l' t, which itemizes the contents of
each package, is ttached to the side of each case of
the equipment.
GE provides han
shipment, the equ
cess moisture or
cess temperature
ing guidelines to the carrier. During

ment should not be exposed to exmidity, extreme temperatures, exanges, or rough handling.
Upon receipt, car fully examine the contents of each

shipment, and che k them with the packing list. Immediately report y shortage, damage, or visual indication of rough h dling to the carrier. Then notify
both the transport ion company and GE Drive Systems. Include the rial number, part (model) number,
drive code, GE re uisition number, and case number
when identifying e missing or damaged part.
Place the equipment under adequate cover with

the following requirements:
a.
Keep the equipment clean and dry, protected

from precipitation and flooding.
b.
Use only breathable (canvas type) covering

material - do not use plastic.
2.
Unpack the equipment as described in section 2-4,

and label it.
3.
Maintain the following environment in the storage

enclosure:
a.
Ambient storage temperature limits from

-20C (-4 OF) to 55C (131F).
b.
Surrounding air free of dust and corrosive

elements, such as salt spray, or chemical and
electrically conductive contaminants.
c.
Ambient relative humidity from 5 to 95%

with provisions to prevent corrosion.
No rodents.
2-1
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GEH-6148
e.
Temperature variations that cause moisture

CAUTION
Moisture on certain internal parts can
cause electrical failure.
Condensation occurs with temperature drops of 15C
(27 OF) at 50% humidity over a 4-hour period, and
with smaller temperature variations at higher humidity.
If the storage room temperature varies in such a way,
install a reliable heating system that keeps the equipment temperature slightly above that of the ambient
air. This can include space heaters or panel space
heaters (when supplied) inside each enclosure. A 100W lamp can sometimes serve as a substitute source of
heat.
2-4. UNPACKING
It is good practice to not completely unpack the
equipment until it has been placed as near as possible
to its permanent location. If the equipment has been
exposed to low temperatures for an extended period of
time, do not unpack it until it has reached room temperature.
When unpacking, check the contents of each case
against the packing list. Report any shortage to GE
Drive Systems.
Use standard unpacking tools, including a nail puller.
Carefully move the equipment from its container to
avoid damaging or marring the part. Wipe off any
particles of packing materials or foreign substances
that may be lodged in or between the parts.
Small parts (such as bolts and screws) are packed in
special containers to keep them together. However,
they may become separated. Therefore, carefully inspect packing material for loose parts before discarding.
CAUTION
2-5. TIME LIMITATIONS
2-2
The above specifications apply to shipping and storage

durations of up to one year. Longer times may require
additional treatment. For warranty information, refer
to Appendix F.
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GEH-6148
CHAPTER 3
INSTALLATION AND INITIAL STARTUP
This chapter co tains environmental, mounting, and

electrical guidel es for installing the GF2000 Dc
Generator Field xciter. The information presented
includes basic ci cuit checks needed after installation
and before the e citer is started up.
Caustic fumes
Power line fluctuations
Electromagnetic radiation or "noise" introduced

by:
Radio frequency signals, typically from portable transmitters used near the equipment or
its wiring.
Before starting' stallation, consult and study all furnished drawings. These should include arrangement
drawings, conne tion diagrams, elementary diagrams,
and a summary f the equipment.
Stray high voltage or high frequency signals,

typically produced by arc welders, unsuppressed relays, contactors, or brake coils operating near exciter control circuits.
G ENVIRONMENT
GF2000 exciters e suited to most industrial environments. To ensure proper performance and normal operationallife, the environment should be maintained as
follows:
Ambient tempen
40C (104
re (acceptable): 0 C (32 OF) to
Ambient tempen
re (preferred): 20C (68 OF) to
3-3. MOUNTING
The system outline drawing (included with the system
documentation) contains the exciter dimensions and
mounting diagrams.
Use the following mounting guidelines:
30 C (87 OF
Position an enclosed exciter to permit heat radiation from all surfaces.
A wall-mounted exciter may be mounted on any

fIrm, reasonably flat, vertical surface.
A wall-mounted enclosure may be placed side-byside with another enclosure.
Provide front clearance of at least the width of the

enclosure door so that the door may be fully
opened for easy access.
NOTE
Higher ambi nt temperature decreases the

life expectan of any electronic component. Keepin ambient air in the preferred
(cooler) rang should extend component
life.
Relative humidity: Up to 95% (non-condensing)

Environments that clude excessive amounts of any of
the following elem nts reduce exciter performance and
life:
3-4. CABLING AND WIRING
Dust, dirt, or
Vibration or s
All installations should meet the requirements of both

the National Electrical Code (NEC) and any applicable
local codes. Use these codes to determine such factors
as wire size, insulation type, conduit sizing, and enclosures.
Rapid tempera
e changes
3-1
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GEH-6148
WARNING
NOTE
Danger of electric shock or burn. Before

handling and connecting any power cables
to the equipment, ensure that all input
power is turned off. Then check voltage
levels on the wiring to ensure that it is not
carrying hazardous voltages.
3-4.1. Ac Power Requirements
The GF2000 exciter is normally configured with the

following power requirements:
Voltage: 230,460, or 575 Vac,
+ 10%
and -5%
Phase: 3-phase
Nominal line frequency: 50 or 60 Hz, 2%
Input power to the control power transformer (CPT),
which provides 115 V ac and 40 V ac to the power
supply board, may be supplied by the ac input, or by
an external control power source. The requirements
for externally fed control power are:
Elementary diagrams may change with

product upgrades and revision. The elementary diagrams presented in Appendices
C and D are current as of the issue date of
this manual.
Ac input power connects to either a breaker or disconnect switch, which is connected to L1, L2, and L3 on
the line side of fuses FU1, FU2, and FU3.
Control power may be fed from the ac input, or may
be supplied externally by connection to fuses CPTFU1
and CPTFU2.
Generator connections are to output terminals PI and
P2.
3-4.2.2. CONTROL CONNECTIONS. Control connections to the GF2000 exciter are made by wiring the
Drive Terminal Board (NTB/3TB). Chapter 5 describes this board and includes a layout drawing to
identify the connectors on the board. Chapter 6 defmes
the I/O connections.
For the LAN I/O Terminal Board (LTB), connect all

I/O to the LTB's screw terminals. The terminals are
identified by onboard labels (name and number).
Voltage: 230, 460 or 575, +10% and -5%
Phase: 3-phase
The optional Relay Terminal Board (RTBA) provides

screw terminal connections to the relays, as labeled.
Nominal line frequency: 50 or 60 Hz, 2 %

3-4.3. Wiring level Separations
3-4.2. Connections
Cabling and wiring connections include:
Incoming ac line connections
Power connections to the generator and motor

armatures and fields
All terminal board connections
To prevent signal interference caused by electrical

noise, installation must consider the type of voltages
on the wiring. These types must be separated and
spaced as described below.
There are four levels of wiring, which must be run in
separate conduits or wireways:
Low-level signals (Level L, see system level

drawings to identify), which consist of analog signals up to SO V dc and digital signals of 0
through 15 V dc
Medium-level signals (Level M), which consist of

analog signals greater than 50 V dc with less than
28 V ac ripple, and 28 V dc light and switching
circuits
When connecting any wiring/cabling, ensure that all

connections are tight.
3-4.2.1. POWER CONNECTIONS. Refer to the system
elementary diagram provided with the exciter. Sample

elementary diagrams for the C and G frame exciters
are provided in Appendices C and D.
3-2
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GEH-6148
High-level
switching
greater th
ripple, re
A current,
signals (Level H), which consist of dc

.gnals greater than 28 V, analog signals
50 V dc with greater than 28 V ac
ating signals of 50 V with less than 20
d ac feeders of up to 20 A
3-4.6. Commons
External commons, including reference and meter, can

only be connected at the COM connector on the
NTB/3TB board, unless otherwise specifIed by the
system elementary diagrams.
g (Level P), which consists of ac and

to 800 V with currents of 20 - 800 A
3-4.7. Suppression
For additional ormation on wiring level defInitions

and separation, efer to GEH-6011, Installation Guidance Service fo DIRECTO-MATIC 2000 Equipment.
3-4.4. Spacin
The following r quirements ensure correct distance

between cabling and wiring:
Signal wir g and power wiring may cross at

right angles with a minimum I-inch separation.
Avoid paral 1 runs between signal-level wires and

power or co trol wires. If signal wires must be
run parallel ith power or control wires:
For dist ces up to 4 feet, maintain a minimum se aration of 3 inches.
ces over 4 feet, add 1/4 inch of
or every foot of additional distance.
1.
Within pullb xes and junction boxes, use

grounded biers to maintain the level separations.
Ground the e citer common (COM) at only one

point. If the ference is supplied by a numerical
control or by a process instrument with a
grounded co
on, do not provide a separate
ground for th exciter common.
2.
transformer is used and must be

a high resistance ground, unless 10odes direct otherwise.
3.
For shielded d twisted shielded wire, ground the

shields on on end only, preferably at the exciter
end. Provisio have been made to tie shields to
chassis groun at the exciter I/O.
Electrical noise transients caused by control system

relays, solenoids, or brake coils can cause erratic exciter behavior. To prevent this, add a series resistor/capacitor (Re) suppressor in parallel with the 115
V ac coils of these devices. A 220 n, 2 W resistor in
series with a 0.5 IJ-F, 600 V capacitor can typically be
used.
3-5. SERVICE AND PARTS INSTRUCTION
Each GF2000 exciter contains instructions placed inside the door to aid in connecting and troubleshooting
the exciter. These instructions contain the following
information:
Board locations
Power module locations
Fuse information and nomenclature
Plug locations
Incoming control connections at the NTB/3TB

board
Power connections
3-6. POWER-OFF CHECK
All GF2000 exciters are factory-tested and operable

when shipped to the installation site. However, it is
not uncommon for connections to loosen during shipping and handling. Therefore, fInal checks should be
made after installation before starting the equipment.
Before initial powerup, check the exciter using the
steps listed in sections 3-6.1 and 3-6.2.
3-3
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GEH-6148
3-6.1 . Wiring and Circuit Checks
WARNING
3-6.2. Generator and Device Checks
This equipment contains a potential hazard

of electrical shock or burn. Extremely high
voltages are present on some circuitry. To
prevent accidental injury, do not touch any
circuitry without fIrst ensuring that it does
not carry these voltages.
1.
1.
Check that the generator options are correctly

installed and connected per their device instructions.
2.
Ensure that the generator shaft is free to rotate,

and that the generator and moving devices are free
to function.
3.
Verify the generator and controller nameplate

data, such as generator maximum field current,
rated field voltage, and maximum field voltage.
Ensure that all electrical terminal connections are

tight.
a.
Check that the generator and controller voltages match.
b.
Check that the generator field current does

not exceed controller current.
NOTE
To ensure that electrical connections remain tight, they should be re-checked

within three to six months after initial
powerup, and annually thereafter, using
screwdrivers and wrenches or an infrared
survey.
4.
Check that all fuses are installed, are the right

size, and make firm contact in the fuseholder.
3-7. POWER APPLICATION AND STARTUP
2.
Ensure that all devices, modules, and boards are

secure and have not been damaged during shipping and handling or installation. Boards may be
held in place by plastic snaps (holders) or mounted
on standoffs. Check that all holders are snapped
into position and all standoffs are securely tightened.
3.
Check that all incoming wiring agrees with the

elementary drawings supplied with the exciter,
and is complete and correct.
4.
Ensure that the incoming wiring conforms to approved wiring practices, as described previously
(section 3-4).
5.
Ensure that no wiring has been damaged or frayed

during installation. Replace if necessary.
6.
If a current transformer circuit is not complete,

check that the shunt (used for shipping) is removed.
7.
3-4
With the exciter disconnected from meggered

circuits, check for grounds in the generator, motor, or leads by meggering all terminals to
ground.
After the previous power-off checks, complete the

following steps to check the exciter with the power on.
WARNING
Before any adjustments, servicing, or any

other act is performed requiring physical
contact with electrical working components
or wiring of this equipment, ensure all
power supplies are turned off. Then
ground and discharge the equipment.
1.
Check that incoming power is the correct voltage

and frequency.
2.
Apply power to the exciter.
3.
Check for correct rotation of the 3-phase blower

in the exciter (if used). If incorrect:
a.
Turn power off. Ensure that the circuit is

dead before touching it.
b.
Interchange any two leads to the blower motor.
c.
Re-apply power and check for proper rotation.
BI006008

4.
Check the 'splay on the Programmer (described

in Chapter 8) for error indication:
a.
b.
5.
6.
If the xciter powers up with no faults, the

Progr
er indicates ready-to-run by displayin M S 0% 10% (Manual Mode) or AS
0% I % (Automatic Mode).
t occurs at powerup, the display
d shows the fault name and number.
t code deftnitions, see Chapter 9.)
Using the s stem elementary diagram, ensure that

all permiss' e, start, and stop circuits are functioning pro erly.
GEH-6148
7.
Check the direction of rotation and rpm of the

prime mover.
8.
Call the assigned GE Service Offtce for additional

checks and startup.
NOTE
The GF2000 exciter software architecture

requires that a trained specialist conduct
additional checks and startup using the
ST2000 Toolkit or Drive Configurator,
LynxOS Version, developed for that purpose.
e motor-generator set running interhen the generator is turning at its
m.
3-5
BI006008
GEH-6148
Notes:
3-6
BI006008
GEH-6148
CHAPTER 4
4-1.INTROD CTION
4-2.1. Block System
This chapter de ribes the GF2000 Dc Generator Field

Exciter softwar and hardware structure, and overall
operation of the xciter. Refer to the sample elementary diagrams c ntained in Appendices C and D.
Chapter 5 cont . s descriptions of the printed wiring
boards containe in the exciter.
The GF2000 exciter application software is a structure

of software modules that defme data flow and function
execution. These modules are pre-defmed blocks of
code that perform specific functions.
The GF2000 exc ter provides a controlled dc output to

excite the field 0 a dc generator used in a motorgenerator contro system. In this type control system,
the armature 100 consists of a dc generator and a dc
motor. The GF2
exciter receives both voltage and
current feedbac from the generator, and regulates
both of these var abIes to drive the dc motor.
The software includes simple blocks, such as summing

junctions, and complex blocks, such as speed regulators. These functions are applied using the building
block architecture described below.
4-2.2. Building Block Architecture
Appendices C an
grams for the G
diagram shows th
including the mot
D provide sample elementary dia000 exciter. Sheet 0 lBB of each

dc power circuit for the exciter,
r-generator power system.
The block programming scheme is an open architecture programming method that combines pre-existing
blocks of code for a variety of applications. The exciter software is configured from a library of functional blocks. The blocks are then connected by a
mechanism that schedules and controls their execution.
4-2. EXCITER
OFTWARE STRUCTURE
The GF2000 exciter stores programming data as follows:
The GF2000 exci r stores most configuration and

adjustment data' EEPROM on the Drive Control
Card (SDCC).
s data is organized into 16-bit
words, and is stor d and checksummed. The SDCC's
Drive Control Pro essor (DCP) controls memory access.
Block library (block defmitions) in the Drive

Control Processor (DCP) ROM
Block variables in RAM
Block configuration parameters in EEPROM
Four major eleme ts of the software configuration are:
An operator can examine and adjust parameters stored

in EEPROM in one of three ways: using the Programmer on the LAN Communications Card (SLCC),
or using the ST2000 Toolkit (see GEH-5860) or Drive
Configurator, LynxOS Version (see GEH-6203), on a
serially connected computer.
Generic inter; ce to inner generator control loops
Pointer-based election of inputs to functional

modules
Logical addres ing of primary variables
Use of functio
regulator struc
building blocks for primary

es
4-1
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GEH-6148
4-2.3. Diagnostics
The GF2000 exciter provides built-in diagnostics for

automatic selftest at powerup and for troubleshooting.
It tests circuitry down to the board level, generating
diagnostic messages, There are three ways to decode
these messages:
Using the LED diagnostic readout on the SDCC

(see Chapter 9)
Using the Programmer's alphanumeric readout

(see Chapter 8)
Reading diagnostic messages over an optional RS232C communication link.
Drive Control Card (SDCC), which contains microprocessor circuitry
Drive Terminal Board (NTB/3TB)
LAN Communications Card (SLCC), which includes the Programmer
Power Supply Board (DCFB)
Power Connect Card (PCCA)
Optional boards include:
Signal Processor Card (SPC)
LAN I/O Terminal Board (LTB)
4-2.4. Configuring Blocks
Relay Terminal Board (RTBA)
A block source list is the program schedule. It defmes

which blocks are to be executed and their rate and
relative order of execution. This list consists of a linear sequence of source words stored in EEPROM.
Section 4-4 describes the exciter's overall control operation. Chapter 5 describes the function and operation
of the control section's printed wiring boards.
The block compiler translates this source information

into a set of run lists. These lists point to run-time
code and data blocks. The block interpreter reads the
run lists. It uses a compact Next Block instruction sequence to thread the execution of compiled blocks.
4-3.2. Power Converter
The ST2000 Toolkit and Drive Configurator, LynxOS

Version, display the blocks as configured for the particular application.
The GF2000 exciter's power converter section includes SCR bridge rectifiers, snubber circuits, and
control circuitry. The components vary for the power
output required. Section 4-5 describes these components and their operation.
4-4. CONTROLLER OPERATION

4-3. EXCITER HARDWARE STRUCTURE
The GF2000 hardware consists of the control section

and the power converter section.
The power conversion hardware is defmed by the application requirements, and therefore determines the
exciter's frame size (see Table 4-1). The control section is basically the same for the different frame sizes.
4-3.1. Control Section
The control section, or controller, contains powerful

programmable microprocessors with companion circuitry, including EEPROM, to process the application
software. The controller includes the following printed
wiring boards:
4-2
The GF2000 exciter provides microprocessor regulation to provide a controlled dc output to excite the field
of a dc generator in a motor-generator control system.
The exciter combines programmable dc drive control
with power circuitry. Exciter parameters are stored in
EEPROM, keeping them accurate and drift free.
Three-phase ac input power to the GF2000 must be
supplied by a single transformer. The ac input power
is fed to the SCR bridge through rectifier fuses, which
protect the bridge against internal and converter faults.
If the GF2000 is used to gate a single-phase motor
field exciter, the motor field exciter must be powered
by a separate single-phase transformer; it cannot be
powered by a secondary winding of the transformer
that supplies the GF2000 exciter. Multiple GF2000
exciters should be powered from a combination of
delta-delta and delta-wye transformers.
BI006008
GF2000 Dc G
GEH-6148

Table 4-1. GF2000 Frame Size Specifications
Ae Input
Voltage
(Vael
Maximum Dc
Output Voltage
(V del
Maximum Dc
Output Current
(AI
230
460
575
300
600
800
280
280
280
C Extension
230
460
575
300
600
800
500
500
500
230
460
575
300
600
800
125
125
125
Frame Size
The SCR bridge converts the incoming ac power to an

adjustable dc vo age. The dc current is fed to the generator field thro gh a shunt, which is used to provide
output current fe dback.
The SCR converter also includes snubber circuits

across each set of SCRs. A separate RC network
serves as a dc fIlter across the output of the SCR
bridge.
Ac reactors limi the rate of change of line current

when the curren commutates from one output leg to
another.
The PCCA card provides an interface between the

GF2000 control circuitry and the SCR bridge. The
PCCA provides gating to the SCRs in the bridge. For
low-to-medium horsepower applications, the PCCA
also includes snubber circuits. For higher horsepower
applications, the snubbers are omitted from the PCCA,
and are located elsewhere in the system.
A field exciter 0 tput module protects the SCR bridge

against high volt ges generated when the dc generator
field current is d -energized and the exciter no longer
controls the field voltage. The module includes a
crowbar circuit at provides a path for field current to
flow if the gener tor field voltage exceeds a preset
limit. A load resi tor absorbs the residual field current
during bridge re rsals.
Current and vol
erator and motor
(voltage-controlle
the analog signals
e feedback signals from the dc gene fed to the DCFB board. VCOs
oscillators) on the DCFB convert
into variable frequency signals.
The DCFB recei

control power tr
logic power to th
enclosure fans. F
fan is also power
s 115 and 38 V ac power from the

former (CPT). The DCFB provides
exciter and 115 V ac to the card
r C frame exciters, the SCR bridge
by the DCFB 115 V ac source.
The GF2000 excit r features a full-reversing SCR

converter, which eceives 3-phase power through
fuses FU1, FU2, d FU3. (The SCR converter is
shown in the elem ntary diagrams contained in Appendices C and D . The SCR converter includes 12
SCRs that make u the SCR bridge: SCRs IF through
6F make up the fo ard portion of the bridge; SCRs
IR through 6R m e up the reverse portion of the
bridge.
The dc power is supplied to the generator field

through a shunt. No dc fuse is required. The shunt
provides current feedback to the DCFB. The DCFB
also receives voltage feedback from across the dc
output.
A thermal sensor is mounted on the SCR heatsink. If
the temperature of the heat sink exceeds 190 OF (87.8
0c), the thermal sensor opens a switch which can be
used to shut down the SCR bridge.
4-5. POWER CONVERTER OPERATION
The following sections describe the power converter

circuitry associated with the GF2000 exciter.
4-5.1. Ac line Fuses (FU1 - FU3)
Ac line fuses protect the power SCRs, internal wiring,

and output wiring from short circuits. Instantaneous
and timed overcurrent functions in the control software
also protect against excess current.
4-3
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GEH-6148
4-5.2. Ac Reactors
4-5.6. Field Exciter Output Module
Ac reactors are included on the ac power lines between the ac line fuses and the SCR bridge. The reactors limit the rate of change in line current when the
bridge current commutates from one leg to another.
The field exciter output module connects across the

output buses of the GF2000 exciter. This module performs load resistance, dc filtering, and protective
crowbar functions for the exciter.
4-5.3. Loop Contactor (MDA)
The MDA loop contactor, located in the armature

loop, provides a controllable disconnect between the
dc generator and the motor. The contactor picks up
when the run mode is selected (see Programmer description in Chapter 8) and no fault exists in the exciter. The contactor drops out if Normal Stop (Coast
Stop) is initiated, or if a fault condition occurs.
4-5.4. Control Power Transformer (CPT)
The CPT is energized either from the ac input lines, or

from an external control power source. The secondary
winding provides two isolated voltages:
115 V ac to operate the enclosure cooling fans and

SCR bridge cooling fan (if used)
38 V ac center-tapped for the DCFB board to
generate the dc control voltages necessary for

controller operation
4-5.5. Shunt
The generator field shunt provides the SCR bridge

current feedback signal to the DCFB board. The shunt
generates a nominal 100 mV output signal at the current rating stamped on it.
The output module includes two 450 n, 1 A wirewound power resistors connected in series across the
GF2000 exciter output buses. (Note that this type of
resistor is typically specified according to resistance
and current rating, rather than wattage.) These resistors provide a load resistance for the GF2000 exciter.
The resistors are selected based on the maximum output voltage (Edo) with a 575 V ac input. The load resistors provide a path for the small amount of current
that remains when all of the SCRs are momentarily
turned off during reversal of the bridge.
The dc filter consists of a 140 n, 1.75 A wire-wound
power resistor connected in series with a 0.5 ~F, 2000
V dc capacitor. The dc fllter and load resistors help
the SCR bridge build the generator field current from
zero to the holding current of the SCRs.
The crowbar circuit protects the SCR bridge against
the high voltages generated by the dc generator field
when the field current is reduced. The crowbar circuit
includes a dual in-line SCR module. Each SCR in the
module is connected to a Field Exciter Crowbar Board
(FECB). If the voltage across the dc generator field
exceeds a preset limit in either direction, the corresponding FECB board gates its SCR to provide a path
for the field current to flow. Hardware jumpers on the
FECB board are used to select a generator field voltage limit of 700 or 1400 V. An externally mounted
series resistor (RCB) may be included to decrease the
time the field current takes to decay to zero.
The FECB board is described in Chapter 5.
NOTE
To increase the range of the generator field

current regulator, the rated generator field
current should not exceed 75% of the current rating of the shunt. This results in a
maximum field current forcing ratio of
1.67 per unit.
4-6. EXCITER CONNECTION DRAWINGS
Appendices C and D contain sample elementary diagrams for C frame and G frame GF2000 exciters, respectively.
NOTE
Elementary diagrams may change with

product upgrades and revisions. The information presented in this manual is current as of the issue date.
4-4
BI006008
GEH-6148
CHAPTER 5
PRINTED WIRING BOARD DESCRIPTIONS
This chapter de cribes the printed wiring boards used

in the GF2000 c Generator Field Exciter and their
operation. Chap er 6 defmes the I/O connections for
these boards. C apter 7 lists and defmes the fuses and
testpoints cont . ed on some of these boards.
5-2. BOARD I ENTIFICATION

A printed wirin
meric part (cat
series are corom
GE Drive Syste
board is designated by an alphanuog) number. Two parts numbering

nly used for printed wiring boards at
s.
Most boards con ained in the GF2000 exciter are designated with part numbers beginning with the characters DS200. For xample, the Power Supply Board is
identified by part number DS200DCFBG#ruu. The
DS200DCFB po ion is the base number that identifies
the printed wirin board, in this case, the Power Supply Board. The r d u digits are alphabetic characters
that indicate the r vision level of the printed wiring
board. The r digi reflects a functional change that is
not downward co patible. It is essentially a new
catalog number.
e u digits represent revision levels
that are downwar compatible to the r revision level.
The G# identifies group, which is a variation of a
particular board.
the configuration; the r digit is an alphabetic character

that indicates the revision level of the printed wiring
board. The G# identifies a group, which is a variation
of a particular board.
All digits are important when ordering or replacing
any board. Chapter 13 contains spare and renewal
parts information.
NOTE
The terms card and board both apply to

printed wiring boards. In this manual,
board is the preferred term. However, card
is used in some drawings and when it is
part of a board's pre-established nomenclature - for example, the Drive Control
Card (SDCC).
5-3. ADJUSTABLE HARDWARE
Some printed wiring boards used in the GF2000 exciter include adjustable potentiometers (pots),
switches, and jumpers for setting and fme-tuning
functions. The board layout drawings in this chapter
show their locations on the boards. The board adjustable hardware tables list and describe the adjustments.
WARNING
include onboard software stored in
ction in the exciter. For one of
memory chips to
these boards, the art number begins with the characters DS200 if the oard does not include the memory
chips, and DS215 f the board does include the memory chips. For ex pIe, a Drive Control Card without
onboard software' identified by the part number
DS200SDCC; aD ive Control Card with onboard
software is identifi d by the part number
DS215SDCC.
Other boards cont
designated with p
acters 531X. For e
is identified by p
531X305NrB porti
the printed wiring
minal Board. The
ed in the GF2000 exciter are

numbers beginning with the charample, the Drive Terminal Board
number 531X305NTBcrG#. The
n is the base number that identifies
oard, in this case, the Drive Terdigit can be A or B, depending on
Potentially hazardous voltages are present

in the exciter circuits. Ensure that power is
off before touching a board or any connected circuits.
CAUTION
Some boards contain static-sensitive components. To prevent component damage
caused by static electricity, use staticsensitive handling techniques with all
boards.
5-1
BI006008
GEH-6148
NOTE
The jumpers are defmed in the board adjustable hardware tables contained in this chapter.
Board adjustable hardware may change

with product upgrades and revisions. The
information presented in this manual is
current as of the issue date. The ST2000
Toolkit or Drive Configurator, if purchased with the exciter, contains information current as of the date the equipment
was manufactured.
NOTE
Before moving any jumper, compare its actual position with the "as shipped" position
shown on the hardware drawings located in
the exciter door pocket.
5-3.1. Initial Hardware Settings
5-3.2. Adjusting Replacement Boards
The factory sets most adjustable hardware when manufacturing and testing the exciter. For adjustments that
are not factory-set, refer to the tables in this chapter
and the exciter's Custom Software.
When replacing a board, set the pots, switches, and

jumpers on the new board to match the settings on the
board being replaced. Chapter 12 provides instructions
for replacing a board.
5-3.1.1. POTENTIOMETERS. Potentiometers (pots)

may be adjusted during startup to optimize exciter performance. The initial (default) setting is the straight-up
position (see Figure 5-1). These pots are defmed in the
board adjustable hardware tables contained in this
chapter.
5-4. PRINTED WIRING BOARDS
This section describes the printed wiring boards used

in the GF2000 exciter. These include:
Field Exciter Crowbar Board (FECB)
LAN I/O Terminal Board (LTB) - Optional
Relay Terminal Board (RTBA) - Optional
Drive Control Card (SDCC)
LAN Communications Card (SLCC) - Optional
Signal Processor Card (SPC) - Optional
Voltage Attenuator Board (SVAA)
Shunt Isolator Board (SVIA)
NOTE
Use only high-impedance digital voltmeters

or the optional onboard DVM to make indicated adjustments.
Figure 5-1. Pot Set at Default Position
5-3.1.2. SWITCHES. Some boards contain DIP

switches for configuring I/O options. Switch settings
are defmed in the board adjustable hardware tables
contained in this chapter.
5-3.1.3. JUMPERS. The exciter uses Berg-type
(manually moveable) jumpers for both manufacturing
test and customer options. Typically these jumpers are
designated with a IP nomenclature.
The exciter uses hard-wired jumpers to configure
boards for component substitutions or upgrades. Typically these jumpers are designated with a WI nomenclature.
5-2
The hardware drawings included in Appendix B show

the locations of these boards in the GF2000 exciter.
The sample elementary diagrams included in Appendices C and D include board interconnection information
for the exciter.
BI006008

5-4.1. Power Supply Board (DS200DCFB)
The DS200DC B Power Supply Board (DCFB) receives 38 and I 5 V ac input power from the control
power transfo er (CPT), and provides control-level
power to the ex iter and lIS V ac to the enclosure
fans. The DCF board includes the following circuits:
Control-lev I power supplies (+S, 15, and 24

V dc)
Motor or g nerator field power circuits (except

the SCR m dule)
Driver circ 'ts for the generator field SCR gate

pulse gener tors
Circuits to' trument numerous ac line and dc

motor or ge erator signals, including:
Arma e current(s) and voltage(s)
Generat r and motor field currents
Ac line urrent
Ac line oltage magnitude and phase sequence
Section 6-4 defi s I/O points for the DCFB board.

Section 7-2 defm s DCFB onboard fuses and section
7-3.1 defmes D B testpoints.
5-4.1.1. POWER SUPPLIES. The DCFB board receives 38 Vac ( 10%) from the CPT. This voltage is
full-wave rectifie and f1ltered to produce the unregulated 24 V dc tputs. The + 24 V dc output is rated
at 3 A; the -24 V dc output is rated at I A.
Regulators on the DCFB derive 15 V dc from the
24 V dc suppli . The IS V dc outputs are each
rated at 0.8 A, of which 0.25 A is available for externalloading.
The DCFB also g nerates a +5 V dc, 4 A output from
the + 24 V dc sup ly. The IPSEN signal on 2PL goes
to a TTL low stat when the +S V dc supply is in
regulation; the si al goes high if the supply goes out
of regulation. Wh n high, IPSEN generates a microprocessor reset on the Drive Control Card (SDCC).
The DCFB provid s isolated +5 and IS V dc supplies to power the
ature current feedback circuits.
The power supply
circuits by fuses F
emitting diodes (L
blown fuse indicaf
utputs are protected against short

2 and FU3 (7 A 2AG). LightDs) CRSI and CR5S provide
ns for these fuses.
5-4.1.2. VOLTAG AND CURRENT FEEDBACK VCO

CIRCUITS. The D FB includes voltage-controlled
oscillator (VCO) c cuits that convert input voltages to
GEH-6148
frequency signals. Each VCO has a nominal output
frequency of 250 kHz. The output frequency varies
from 0 to SOO kHz, depending upon the input voltage.
VCO outputs are sent to the SDCC through connector
IPL to provide feedback of the following:
SCR bridge ac input voltage
Output bridge voltage (generator field voltage)
Motor or generator voltage
Millivolt signals from field shunts
Millivolt signals from armature shunts
The SCR bridge VCO circuit provides feedback to the

SDCC through connector IPL, pin 13 (lPL-13). DIP
switch SW4 is used to scale the voltage applied to the
circuit. A frequency-to-voltage reconstruction circuit
provides a diagnostic signal for testpoint TP37 on the
SDCC through IPL-37. The diagnostic bridge voltage
signal can be viewed using an ac-coupled oscilloscope.
The second VCO provides feedback of the motor or
generator voltage to the SDCe through IPL-39. DIP
switch SWS is used to scale the voltage applied to the
circuit. In the GF2000 exciter, this VCO provides
feedback of the voltage across the generator armature.
Two other VCO circuits provide feedback of the input
voltage from a field shunt. The VCO output frequency
signals are sent to the SDCe through connector IPL.
In the GF2000 exciter, these VCOs provide feedback
of the voltages across the motor field shunt (IPL-9)
and generator field shunt (IPL-40).
The DCFB also includes two motor armature VCO
circuits. The frequency output signals from these
veos are sent to the SDCC through IPL-8 and
IPL-IO. These VCOs are at the potential of the armature bus, and are fed by an isolator. In the GF2000
exciter, one of these VCOs is used to provide feedback
of the generator armature current. Generator armature
current, detected across a shunt, is sent to the DCFB
through the SVIA board.
5-4.1.3. MOTOR VOLTAGE ATTENUATION CIRCUIT.
The DCFB includes a motor voltage attenuation circuit
that provides an analog representation of the motor
voltage. This signal is sent to the SDCC through IPL6. The attenuation circuit is biased at 2.S V, and can
vary from 0 to S V depending on the motor voltage.
DIP switch SW6 is used to scale the motor voltage
feedback. In the GF2000 exciter, the motor armature
voltage is sent to the DCFB through the SVAA board,
which is mounted on a remote panel.
5-3
BI006008
GEH-6148
connector IPL. The gate array is programmed at powernp by a serial PROM.
5-4.1.4. AC LINE MAGNITUDE AND ZERO

CROSSING. The DCFB contains amplifier circuits that
process the ac line-to-line voltages. The voltage signals

are sent to the SDCC through IPL-ll, IPL-12, and
IPL-29. These signals are used to detect power bridge
SCR failures and may also be used to derive the synchronization signal for the firing of the SCRs. DIP
switches SWl, SW2, and SW3 are used to scale the ac
line voltage feedback.
The 5 V outputs of the gate array are converted by

gate pulse amplifier circuits into the power level required to feed the forward and reverse gate pulse
transformers on the PCCA card. These signals are sent
to the PCCA through 5PL. To prevent spurious firing
signals, the firing power is removed from the gating
circuits until the gate array is programmed and the 5 V
power is being regulated.
5-4.1.5. AC LINE CURRENT TRANSFORMER

INTERFACE. The GF2000 exciter does not include ac
current transformers; therefore this function (and DIP

switch SW7) of the DCFB is not used.
5-4.1.8. CONFIGURABLE HARDWARE. The DCFB

board includes Berg-type jumpers and DIP switches,
used for customer options. Figure 5-2 shows the layout
of the DCFB board, including the locations of the
jumpers and switches. Table 5-1 lists and defmes these
items.
5-4.1.6. CONTACTOR DRIVE CIRCUITS. The DCFB

includes relay K2, which serves as a pilot relay to the
MD contactor. The SDCC drives the coil of this relay
through IPL-34, IPL-35, and IPL-36. Connector
MACPL provides 24 V de FET output to the MD
contactor driver.
NOTE
In Table 5-1, unless otherwise specified, the

GF2000 exciter uses the same DCFB board
jumper settings as those called out for a
DC2000 drive.
5-4.1.7. FIELD/ARMATURE SCR FIRING CONTROL

CIRCUITS. The DCFB contains a gate array circuit
that controls the firing of the SCRs in the bridge based

upon control signals received from the SDCC through
IA1PL
Vl
V2
V3
P1A
P2A
VM1A
VM1B
VM2A
\I
II
II
II
II
II
II
II
II
2. ~ ~
,;-;:---; I'; ,r-; 3
'==
onnC
Uu
Rn W
1A2PL
e.-c.... c.... c....
VM23A RnW ~
'-'-
IF ~
c.....c....w"'C
-:J""O-~
L:,
IF2PL
o'ddb~
t:::=\
::>:.-
~nw
OJ:.oc-
111111113
R ;---]W
lU
'-
I-ZOI.
EJ-
1 c::J
~J3
EJ~
!~~I
3
PPL
SW6
NPL
20, tj,
ICPL
JPl
DB
JP2
LT1
c::J ~ ]
123
CR51
FU2
~
~
FU3
L:J
CNPL
O~
+'"
JCOM
~!L
-2J,['
1FPc
lOll
~I
2FPL
[~
I'
::ll
25 I
5PL
r1 N
~
rU1
P5
2PL
DS20CDCFBG1B
Figure 5-2. DCFB Board Layout
5-4
P15
F1
5PL
[C
:,
BI006008
GEH-6148

Table 5-1. DCFB Board Adjustable Hardware
Revision
Description
All
JPl
Select source of ac line sync signal passed to the SDCC

Proper synchronization to the ac line is critical to the operation of the drive, and 1.2 is the only valid
setting of this jumper for DC2000s.
1.2 Generated by DCFB using line voltage 2-3 (DC2000 applications)
2.3 Generated by the TCCB card (EX2000 applications)
All
JP2
Decrease ac contactor drop-out time

Not used on GF2000 exciters.
All
JP3
Configuration of armature shunt #1 input circuit

Jumpers JP3 through JP7 must be set together for proper operation of the voltage controlled oscillator
(VCO) which converts the shunt current to a frequency signal which is then read by the SDCC.
Application
G, C or D frame DC2000
M, J of K frame DC2000/EX2000
GF2000 or ME2000 with SVIA card
M frame CB2000
J frame CB2000 with SHVI card
JP3. JP4
1.2
1.2
2.3
1 .2
1.2
JP5-JPZ
1.2
2.3
1.2
1.2
2.3
When JP3 & 4 are in position 1.2, no attenuation affects the IA 1 PL input signal which may come from
either a 100 mV (1 pu) shunt or a an external VCO. The local VCO will produce 0 Hz at -5 pu and 500 kHz
at + 5 pu from a shunt signal. A frequency input signal from an external VCO must be bypassed around the
local VCO (See JP5 and JP6). Putting JP3 and JP4 in position 2.3 rescales the input to receive an analog
isolator (SVIA) signal such that the local VCO produces a frequency output of 12 kHz with -5.0 V input
and 488 kHz with +5.0 V input (lV = 1 pu).
Jumpers JP5-7 select and enable the local (DCFB) VCO when in position 1.2. When in position 2.3 the
local VCO is disabled and bypassed to allow use of an up stream VCO circuit.
1.2 Direct input of shunt or external VCO signal
2.3 Input rescaled for analog isolator signal
All
JP4
Configuration of armature shunt #1 input circuit (see JP3)

All
JP5
Configuration of armature shunt #1 VCO circuit (see JP3)

1.2 Local VCO circuit selected
2.3 Local VCO circuit bypassed
All
JP6

All
JP7

1.2 Local VCO circuit enabled
2.3 Local VCO circuit disabled
All
JP8
Configuration of armature shunt #2 input circuit

Jumpers JP8 through JP12 must be set together for proper operation of the voltage controlled oscillator
(VCO) which converts the shunt current to a frequency signal which is then read by the SDCC.
Application
G, C or D frame DC2000
M, J of K frame DC2000JEX2000
GF2000 or ME2000 with SVIA card
M frame CB2000
J frame CB2000 with SHVI card
JPB, JP9
1.2
1.2
2,3
1.2
1.2
JP1Q-JP12
1,2
2,3
1.2
1.2
2.3
When JP8 & 9 are in position 1.2, no attenuation affects the IA2PL input signal which may come from
either a 100 mV (1 pu) shunt or a an external VCO. The local VCO will produce 0 Hz at -5 pu and 500 kHz
at + 5 pu from a shunt signal. A frequency input signal from an external VCO must be bypassed around the
local VCO (See JPl 0 and JPll). Putting JP8 and JP9 in position 2.3 rescales the input to receive an analog isolator (SVIA) signal such that the local VCO produces a frequency output of 12 kHz with -5.0 V input
and 488 kHz with + 5.0 V input (1 V = 1 pu).
Jumpers JPl 0-12 select and enable the local (DCFB) VCO when in position 1.2. When in position 2.3 the
local VCO is disabled and bypassed to allow use of an up stream VCO circuit.
All
JP9
Configuration of armature shunt #2 input circuit (see JP8)

5-5
BI006008
GEH-6148

Table 5-1. DCFB Board Adjustable Hardware - Continued
Revision
Name
Description
All
JP10

All
JP11

All
JP12

1.2 Local VCO circuit enabled
2.3 Local VCO circuit disabled
All
SW1
Select the ac line voltage applied to the line voltage 1-2 circuit
SW1 and SW3 scale the V1-2 and V1-3 line voltage feedbacks into VCOs used to provide the SDCC with
a frequency signal proportional to instantaneous line voltages. These are used for phase loss and sequence
detection, and for line sync via the bi-phase PLL. SW2 scales the V2-3 voltage applied to the circuit used
to generate the ac line synchronization and frequency measurement signal via the zero-crossing detector.
Scaling of SW1-SW3 is in conjunction with the SHVI/M card voltage attenuators, if used.
The maximum nominal V ac is the maximum ac input voltage which may be 15% high without saturating
the instrumentation circuitry.
For DC2000/EX2000 applications, switches SW1, 2, 3, 4, 5, and 6 must all be set to the same position.
Above 617 V ac, SHVI/M attenuators must be used (refer to SHVI JP9 through JP17). For
GF2000/ME2000 applications, switches SW1 through SW4 must be set to the same position; switches
SW5 and SW6 may be set to different positions than SW1-SW4, depending upon the application.
For the DC2000, the settings of these switches affect the scaling of VAR.1 08 (ACLINMAGL which affects
the phase loss protective fault (see EE.582). For each of the max nominal rms line-line voltage selections,
if the input is at the max nominal, VAR.1 08 will be approximately 25700 counts. For the EX2000, these
switches have a similar effect on the phase loss function provided by EE.576, PUATHR. For both drive
types, a scale factor, EE.VLL SF allows these voltages to be scaled to a 1 pu = 20000 basis prior to being
applied to the phase loss function.
o (All off)
308 max nominal V ac (762 V ac using SHVI attenuators)
8
(4 on)
1
(1 on)
9
(1 & 4 on)
2
(2 on)
All
SW2
Select the ac line voltage applied to the line

o (All off)
308 max nominal V
8
(4 on)
364 max nominal V
1
(1 on)
488 max nominal V
9
(1 & 4 on)
545 max nominal V
2
(2 on)
617 max nominal V
All
SW3
Select the ac line voltage applied to the line voltage 1-3 circuit (see SW 1)
(All off)
8 (4 on)
1 (1 on)
488 max nominal V ac (1 214 V ac using SHVI attenuators)
9 (1 & 4 on) 545 max nominal V ac (1353 V ac using SHVI attenuators)
2 (2 on)
All
SW4
Select the voltage applied to the dc bridge voltage feedback VCO circuit
SW4 scales the voltage applied to the circuit used to generate the frequency representation of dc bridge
voltage (P1 to P2) feedback passed to the SDCC. SW5 scales the voltage applied to the circuit used to
generate the frequency representation of dc motor voltage feedback passed to the SDCC. SW6 scales the
voltage applied to the circuit used to generate the analog representation of dc motor voltage feedback
passed to the SDCC. Scaling of SW4 through SW6 is in conjunction with the SHVI/M card voltage
attenuators, if used.
The voltages listed in the selection table are maximum nominal V ac and nominal V dc. The maximum
nominal V ac is the maximum ac input voltage which may be 15% high without saturating the VCO
channel instrumentation circuitry. For the dc VCO channels, nominal V dc is the dc voltage which results in
20,000 counts raw voltage feedback (VFBRAW) before scaling by EE.1503 (VFBSFn).
For DC2000/EX2000 applications, switches SW1, 2, 3, 4, and 5 should be set to the same position.
Above 617 V ac, SHVI/M attenuators must be used (refer to SHVI JP9 through JP17). For
GF2000/ME2000 applications switches SW1 through SW4 should be set to the same position; switches
SW5 and SW6 may be set to different positions than SW1-SW4, depending upon the application.
o (All off)
308 V ac, 341 V dc (762 V ac, 843 V dc using SHVI/M attenuators)
8
(4 on)
1
(1 on)
9
(1 & 4 on)
2
(2 on)
617 V ac, 683 V dc (1535 Vac, 1698 V dc using SHVI/M attenuators)
5-6
sync circuit (see SW1)

ac (762 V ac using SHVI attenuators)
BI006008
GEH-6148

Table 5-1. DCFB Board Adjustable Hardware - Continued
Revision
Na e
Description
All
SW
Select the voltage applied to the de motor voltage feedback VCO circuit
Note that for GF2000 and ME2000 exciters, the applied armature voltage may be different than the voltage applied to the SCR bridge.
o (All off)
308 V ae, 341 V de (762 V ac, 843 V dc using SHVI/M attenuators)
8
(4 on)
(1 on)
488 V ac, 541 V dc (1214 V ac, 1342 V de using SHVI/M attenuators)
1
(1 & 4 on)
545 V ac, 602 V dc (1353 Vac, 1496 V de using SHVI/M attenuators)
9
2
(2 on)
All
SW
Select the voltage applied to the analog dc motor voltage feedback circuit
Note that for GF2000 and ME2000 exciters, the applied armature voltage may be different than the voltage applied to the SCR bridge.
SW6 is an analog instrumentation channel. The channel feeds a an AID converter on the SDCC card. A 2.5
V bias added on the DCFB card allows the unipolar AID converter to "read" bipolar instrumentation signals.
A change of 1 pu for a dc voltage results in a 1.7 V swing about the + 2.5 V bias. A 1 pu change
for an ac voltage results in a 1.535 V swing about the + 2.5 V bias.
o (All off)
154 V ae, 171 V dc (380 V ac, 422 V de using SHVI/M attenuators)
(1 on)
244 V ae, 270 V dc (605 V ac, 671 V dc using SHVIIM attenuators)
1
2
(2 on)
4
(3 on)
11 (1,2,4 on)
(1,3 on)
475 V ae, 526 V dc (1184 V ac, 1312 V de using SHVI/M attenuators)
5
6
(2,3 on)
(1,2,3 on)
7
All
SW
Select ac line CT burdens as a function of rated drive hp and voltage

These switch settings scale the ac line current transformers as a function of dc amps. Correct scaling is
essential for proper operation of the ac lac protective feature. These CTs are mounted on lines 1 and 3 of
the power converter, and are wired through plug 1CPL to a common burden resistor. Select the proper
setting as a function of drive current and CT turns ratio. The CT ratio can be determined from its part
number and the following table.
Paa Number
104X157AB 023
104X157AB 025
104X157AB 020
104X157AB 013
104X157AB024
104X157AB 026
Turns Ratio
1000:1
2000:1
4000:1
5000:1
5000:1
8000:1
When set properly, the current magnitude read in VAR.1 019 (CTCFB) should be scaled within 15% of the
current magnitude in VAR.1 04 (CFB). Above 144 mA ACCT secondary current, the CTs are routed through
a set of 10: 1 step down CTs on the SHVI/SHVM card, using JP1 through JP8 on the SHVI/SHVM card.
The enumerations listed are in terms of the mA input to the DCFB card IACCT secondary milliamps
attenuated by 10: 1 SHVI/SHVM attenuation if selected}. At present, the SHVI/SHVM cards are used on M,
J, K, and L frames only, and then 10: 1 CTs are used only if the ACCT secondary current is > 144 mAo
The CT secondary current (in mil/iamps) is approximated by:
1 pu rated current x 1000

let, mA
=
Combined CT turns ratio
(All off)
1
(1 on)
2
(2 on)
3
(1,2 on)
4
(3 on)
5
(1,3 on)
6
(2,3 on)
(1,2,3 on)
7
8
(4 on)
(1,4 on)
9
10 (2,4 on)
11 (1,2,4 on)
12 (3,4 on}
13 (1,3Aon)
14 (2,3,4 on)
15 (All on)
0.0 < = Ict, mA < 6.0

6.0 < = Ict, mA < 13.4
13.4 < = Ict, mA < 21.1
21.1 < = Ict, mA < 28.4
28.4 < = Ict, mA < 39.3
39.3 < = Ict, mA < 46.7
46.7 <
Ict, mA < 54.4
54.4 < = let, mA < 61.8
61.8 < = Ict, mA < 88.7
88.7 < = Ict, mA < 96.0
96.0 < = Ict, mA < 103
103 < = Ict, mA < 111
111 < = Ict, mA < 122
122 < = Ict, mA < 129
129 < = Ict, mA < 137
137 <= Ict, mA < 144
5-7
BI006008
GEH-6148
5-4.2. Field Exciter Crowbar Board

(DS200FECB)
5-4.2.1. CONFIGURABLE HARDWARE. The FECB

board includes two Berg-type hardware jumpers, designated Bll and BJ2. These jumpers are used to select
the field voltage at which the FECB gates the SCR to
provide a path for the field current to flow.
The DS200FECB Field Exciter Crowbar Board

(FECB) is used to monitor the voltage across a generator or motor field. If the voltage exceeds a preset
limit, determined by hardware jumpers Bll and B12,
the FECB gates a crowbar SCR to provide a path for
the field current to flow.
When pins 1 and 2 of Bll and BJ2 are connected, the

field voltage limit is 1400 V. When pins 2 and 3 are
connected, the field voltage limit is 700 V. Figure 5-3
shows the layout of the FECB board, including the
locations of jumpers Bll and BJ2.
In the GF2000 exciter, two FECB boards are contained in the field exciter output module. Each is connected to one of the SCRs in a dual in-line SCR module. The FECB board/SCR pairs protect the GF2000
SCR bridge against the high voltages generated by the
de generator field when the field current is reduced in
either direction.
NOTE
For the FECB board to operate properly,

jumpers BJI and BJ2 must be in the same
position.
Section 6-5 defmes I/O points for the FECB board.
E32
E33
fT1
-I>-!
N'
E31
fT1
fT1
(Jl
OJ
(Jl
'--
I!
;;<)
CD
'--
I
A
C)
c::=J !
--'
~
I
~
=:J
~
DS200FECBG1A
Figure 5-3. FECB Board Layout
5-8
!~
BI006008

5-4.3. LAN 10 Terminal Board (531X307LTB)
GEH-6148
Input Specifications. The input specifications for the

LTB are as follows:
The 531X307 B LAN I/O Terminal Board (LTB)

provides an int rface between control devices (such as
exciters or dri es) and external devices, such as contactors, indicat r lights, pushbuttons, and interlocks.
Nominal Voltage Range
The LTB contr I outputs consist of seven low-voltage,

low-current, fo m C relay contact connections. The
LTB also provi es pilot contact connections that function to actuate p to seven high-voltage, high-current
relays, such as ose on the DS200RTBA Relay Terminal Board ( BA). When the LTB and RTBA are
used together, ontacts from both are available.
CAUTION
24 - 230 V ac, 60 Hz
4 - 10 rnA peak
115 - 230 V ac, 50 Hz
4 - 10 rnA peak
24 - 250 V dc
4 - 8 rnA
NOTE
For revision 531X307LTBAGGl boards

and above, devices connected in series with
an input that has a dc leakage current
greater than 1.0 rnA or ac peak leakage
current greater than 4.0 rnA can cause the
input to be continuously in the ON state.
The LTB is av . able in two group numbers: Gland

G2. The G1 ve sion contains eight 24 V dc input
plugs, designat d CIlPL through CI8PL, which are
configurable co trol inputs (see Figure 5-4). These
inputs connect t 8PL, which connects to terminal
board points an to the SDCC.
The G2 version omits control inputs CIlPL through
CI8PL and co ector 8PL, and can only be used with
dc inputs.
Current Range
For all other revision boards, devices connected in series with an input that has an
ac/dc leakage current greater than 0.05 mA
can cause the input to be continuously in
the ON state.
Output Specifications. The output specifications for

the LTB board are as follows:
Relay Outputs - Form C contacts (non-fused):

0.6 A at 125 V ac
Do not con ect the input across an inductive

device, as t . can damage the circuit.
0.6 A at 110 V dc
Figure 5-4 sho the layout of the LTB board, including the locations of connector points and LEDs contained on the bo d.
2.0 A at 30 V dc
RTBA Pilot Outputs - Form A contacts
I/O Terminal Wire - Size must be 28 - 14

AWG. The maximum length of a 26-conductor
interconnection ribbon cable is 20 feet. The
maximum lengths of input and output wiring depends upon the application.
Section 6-6 defi es I/O points for the LTB board.

5-4.3.1. LTB BARD SPECIFICATIONS. This section
contains input d output specifications for the LTB
board.
NOTE
Do not route I/O ribbon cables with power

cables. In ac applications, capacitive coupling of connection wires can cause I/O input (lNl through INX) leakage.
5-9
BI006008
GEH-6148
CI'h
:'ll
rl~
~J
l~~
~ ~;-
U
"L_
Q]
Ei
r
Z~20
10PL
:~c=:::Ji~
8PL
Hl~119
LJl
oprPL
r"\
1'--
LED23
LEOZ2
LEOZ'
LE020
r"\
r"'.,
I'""">,
........,
'-./
"'-/
'J
!;:
CD
()
LEO' 9
LEO'S
LEDP
"""
'J
"""
'J
'J
I RPL
I/o
531 X307LTB
~
:.:
E;
'"
()
TERMINAL BOARD
()
:::;
()
"""
D~
~~
r-~~J
rr=n
LJ~~
Cl7PL
~r]
RX7
RX6
RXS
RX4
RX3
OTB6
OTBS
OT84
OTB3
RX2
RX'
l
IT86
IT85
lT84
I
I
IT83
IT82
IT81
ir--i=r1i
_L-J_,
==:Jb===od_'~
'
Cl8PL
Figure 5-4. LTB Board Layout
5-4.4. Drive Terminal Board (531X305NTB)
The 531X305NTB Drive Terminal Board (NTB/3TB)

contains customer connection terminals for most signal-level I/O. This board also includes most of the
hardware customizing jumpers and pots required in the
GF2000 exciter, along with some passive interface
circuits.
The NTB/3TB board connects to the SDCC via 6PL
and 8PL; to the DCFB via 2PL and 4PL; and to the
customer/system via COMPL and terminal points.
The NTB/3TB board's 3TB connector contains 90
terminal board points in two rows or screw-type terminals. The terminals are numbered sequentially, with
odd numbers in the top row and even numbers in the
bottom row. These points provide the following interfaces to the exciter, primarily to the SDCC.
Section 6-7 defmes I/O points for the NTB/3TB board.
Section 7-3.2 defmes NTB/3TB onboard testpoints.
5-4.4.1. POWER SUPPLIES. The NTB/3TB board
provides the following power outputs for external use:
Hardware jumpers allow distribution of the encoder

loads among the +5 and 15 V dc supplies to balance
loading.
5-4.4.2. ENCODER INTERFACE. The NTB/3TB board
includes a differential A-quad-B encoder interface,
including a marker channel, that can be connected to
the exciter. This circuit is optically isolated on the
SDCC. Jumpers on the NTB/3TB are used to configure the interface for 5 Vor 15 V encoders.
5-4.4.3. RS-232C INTERFACE. Connector COMPL
included on the NTB/3TB board provides an RS-232C
serial link for use with the ST2000 Toolkit (see GEH5860) or Drive Configurator, LynxOS Version (see
GEH-6203).
5-4.4.4. SPECIAL PURPOSE RS-422 INTERFACE.
The NTB/3TB board provides line termination resistors for a half-duplex, RS-422 compatible, serial interface to the Motor Control Processor (MCP) on the
SDCC.
5-4.4.5. RELAY OUTPUTS. The NTB/3TB board
provides the following outputs from seven relays with
a 120 V, 0.5 A contact rating:
Regulated +5 V dc and 15 V dc, each with a

current capacity of 300 rnA
Form C output from five relays controlled by the

SDCC
Unregulated 24 V dc, with a current capacity of

500 rnA.
One form A output and one side of the coil from a

sixth relay controlled by the SDCC. This enables
the coil to be controlled by the SDCC or a customer 24 V dc signal. It also allows the SDCC
coil driver output to be accessed by the customer
5-10
120 V ac, with a current capacity of 0.4 A
BI006008
GEH-6148

for applica ions that cannot tolerate the time delay
associated ~ith the relay pickup.
Two form ~ contacts and both sides of the coil of

a seventh r lay for general purpose use. A hardware jumPl r is used to select whether this coil is
driven by 2~ V dc or 120 V ac.
The NTB/3TB ,~so provides form C contacts from the

MA contactor p ot relay on the power supply board.
These contacts a e rated at 120 V ac, 2.0 A.
5-4.4.6. ANALC G TACH AND REFERENCE COARSE
SCALING. The 1 TB/3TB board includes DIP switches
that allow coarse scaling of analog tach (25 to 380 V)
and analog refer nce (9 to 29 V) inputs. The SDCC
card provides fIr e scaling of these signals.
5-4.4.7. LOW-L1 VEL ANALOG 1/0. The NTB/3TB
includes four pot to scale (5 to 50 V) lO-bit, generalpurpose, medium-resolution inputs to the SDCC. The
NTB/3TB transf s two high-resolution analog inputs
to the SDCC, and receives four 8-bit, 10 V analog

outputs from the SDCC. The outputs drive functions
such as other drives or exciters, analog meters, and
diagnostics.
5-4.4.8. DIGITAL CONTROL INPUTS. Various control
inputs pass through the NTB/3TB to the SDCC. These
inputs include special-purpose digital inputs, such as
RESET and CONTROL ON, and 12 general-purpose
control inputs (up to 24 V de). Jumpers are used to
bias unconnected inputs to +24 or -24 V dc, depending upon whether positive or negative logic is used.
5-4.4.9. CONFIGURABLE HARDWARE. The
NTB/3TB includes Berg-type jumpers; DIP switches,
identified by an SW nomenclature; and pots, identifIed
by a P nomenclature. Figure 5-5 shows the layout of
the NTB/3TB, including the locations of the jumpers,
DIP switches, and pots. Table 5-2 lists and defmes
these items.
Figure 5-5. NTB/3TB Board Layout
Table 5-2. NTB/3TB Board Adjustable Hardware

Revision
Name
Description
All
JPl
Termination resistors for the MCP RS-422 interface (see also JP2)
RS-422 termination resistors should only be installed at the physical first and last drops (ends of the cable
runs).
1.2 Not installed
2.3 Installed (Must also put JP2 2.3)
All
JP2
Termination resistors for the MCP RS-422 interface (See also JP1)
1.2 Not installed
All
JP4
Swap RS232C RxD and TxD data lines, COMPL pins 2 and 3 (see also JP5)
Note many PCs can be jumpered to either the DCE or DTE configuration, and many cables are wired with
pins 2 and 3 interchanged. If communication is not established with JP4 and JP5 in the default position,
the alternate position may be necessary.
1.2 DCE mode for PC/term interface. Drive transmits on pin 3.
1.3 DTE mode for modem interface. Drive transmits on pin 2.
5-11
BI006008
GEH-6148
Table 5-2. NTB/3TB Board Adjustable Hardware - Continued

Revision
Name
Description
All
JP5
Swap RS232C RxD and TxD data lines, COMPL pins 2 and 3 (see also JP4)
3.4 DCE mode for PC/term interface. Drive transmits on pin 3.
2.4 DTE mode for modem interface. Drive transmits on pin 2.
All
JP6
RS232C
3.7
3.4
2.4
2.6
All
JP7
RS232C RTS (COMPL-4)/CTS (-5) handshake line options (see also JP6)
The default position bypasses handshaking, generally allowing satisfactory serial communication
independent of whether COMPL pins 4 and 5 are connected to a DTE or DCE port, or not connected at all.
1.5 DCE or DTE forced true handshaking
1.2 DCE mode full handshaking
1.3 DTE mode full handshaking
All
JP8
RS232C DSR (COMPL-6l and DTR (COMPL-20) handshake options (see JP9)
The default position bypasses handshaking, generally allowing satisfactory serial communication,
independent of whether COMPL pins 6 and 20 are connected to a DTE or DeE port, or not connected at
all.
1.2 DSR and DTR both tied to + 15 V de (forced true)
1.3 DSR connected to DTR (Ioopback)
All
JP9
RS232C DSR (COMPL-6l and DTR (COMPL-20) handshake options (see JP8)
3.4 DSR and DTR both tied to + 15 V dc (forced true)
2.4 DSR connected to DTR (Ioopback)
AD-Pres
JP10
RF24 polarity for digital control inputs (see also JPll)

Note on early prototypes of this card JP10 and JP11 were identified as JP3A and JP3B.
1.2 RF24 = -24 V (negative logic)
1.3 RF24 = +24 V (positive logic)
AD-Pres
JPll
RF24 polarity for digital control inputs (see also JPl 0)

2.4 RF24 = + 24 V (positive logic)
All
JP12
Voltage to encoder supply (EOV1, EOV2)

1.2 EOVl
+15Vdc
2.3 EOVl
+5 V dc
RTS (COMPL-4)/CTS (-5) handshake line options (see also JP7)

DCE mode forced true handshaking
DCE mode full handshaking
DTE mode full handshaking
DTE mode forced true handshaking
All
JP13
Voltage to encoder supply (E1V1, E1V2)

1.2 El Vl = EOVl per JP12
2.3 E1Vl = -15 V dc
AL-Pres
JP14,
JP15
Coarse voltage range select for VCO #3, V3VCO

JP14 & JPl 5 settings determine the gain of the first stage of the analog interface circuitry for the (VC3P,
VC3Nl analog inputs to the V3VCO channel, per the following table.
Maximum
Nominal
JP14 JP15
Input Voltage
Input Voltage
2.3
2.3
16.9
10.0
1.2
2.3
23.3
13.8
2.3
1.2
34.9
20.6
1.2
1.2
41 .3
24.4
Maximum and Nominal values represent differential input voltages at the 3TB inputs with the following
significances:
Second Max: Max voltage for which the first stage will provide linear transfer function independent of the
V3SCLE setting.
Nominal: Voltage which will produce 20000 counts in V3VCOVAR (VAR.184) with the EE. V3SCLE
(EE.484) programmed to 10000. This is the optimum "rated reference" voltage, allowing 25 % overrange.
Note that VCO #3 is only available on drives having SDCC control cards, not DCC control cards.
2.3 10.0 V Nom (with JP15 2.3); or 20.6 V Nom (JP15 1.2)
5-12
BI006008
GEH-6148

Revision
Description
All
JP1
Encoder 0 optically isolated receiver voltage drive level (EOA)

1.215Vdc
2.3 5 V dc
All
JP18
Encoder 0 optically isolated receiver voltage drive level (EOB)

1.2 15 V dc
2.3 5 V dc
All
JP19
Encoder 0 optically isolated receiver voltage drive level (EOM)

1.2 15 V dc
2.3 5 V dc
All
JP20
Voltage level of external drive for general purpose relay (GR + and GR-)
1.2 120 volts
2.3 24 volts
All
JP21
Supply -24 volts on COMPL-25

1.2 COMPL-25 is open
2.3 COMPL-25 is connected to -24 V dc
AL-Pres
JP22,
JP23

JP22 & JP23 settings determine the gain of the first stage of the analog interface circuitry for the (VC4P,
VC4N) analog inputs to the V4VCO channel, per the following table.
Maximum
Nominal
JP22 JP23 Input Voltage Input Voltage
2.3 2.3
16.9
10.0
1.2 2.3
23.3
13.8
2.3 1.2
34.9
20.6
1.2 1.2
41 .3
24.4
Maximum and Nominal values represent differential input voltages at the 3TB inputs with the following
significances:
V4SCLE setting.
Nominal: Voltage which will produce 20000 counts in V4VCOVAR (VAR.185) with the EE.V4SCLE
(EE.488) programmed to 10000. This is the optimum "rated reference" voltage, allowing 25% overrange.
Note that VCO #4 is only available on drives having SDCC control cards, not DCC cards.
AL-Pres
JP24
Enable 4-20 mA current loop input to the feedback VCO (FDBP, FDBN)
When the current loop mode is enabled (2.3), a 500-ohm burden resistor is inserted, yielding 10 volts at
20 mAo
1.2 Voltage input mode, scaled via SW1-5
2.3 Current loop input mode, SW1-5 should be open
AA-AC
JP3A
RF24 polarity for digital control inputs (see also JP3B)

Note JP3A and JP3B were renamed JP1 0 and JP11 on subsequent revisions.
1.2 RF24 = -24V (negative logic)
1.3 RF24 = +24V (positive logic)
AA-AC
JP3B
RF24 polarity for digital control inputs. (See also JP3A).

All
SW1-5
Feedback VCO Channel/Analog Tach Feedback (FDBP, FDBN) Voltage Range Select
These switch settings determine the gain of the first stage of the analog interface circuitry for the (FDBP,
FDBN) analog inputs to the FBVCO channel. Maxima and Nominal values represent differential input
voltages at the 3TB inputs with the following significances:
First Max: Voltage for which the VCO stage will saturate with the FBSCL (DCC P6, if present) scaling
potentiometer set to the maximum gain (full CCW) position.
FBSCL setting.
5-13
BI006008
GEH-6148

Revision
Name
Description
Nominal: Voltage which will produce 20000 counts in FBVCOVAR (VAR.183) with the FBSCL scaling pot
set to maximum gain (full CCW) and the EE.FVSCL# (EE.1386m) programmed to 10000. This is the
optimum "rated feedback" voltage, allowing 25% overrange.
Note that the software scaling function on the VCO channels is only available on DCP Rev 1.24 & later.
ALSO NOTE: When JP7 on the DCC/SDCC card is in the 2.3 position, each voltage range in the chart
should be divided by 6. For use with 4-20 mA current inputs, set all switches off and see JP24 (REV AL
and later).
o (All off) 25-33 Volts Max, 20.0 Volts Nom or 4-20 mA
1 (1 on)
32-42 Volts Max, 25.1 Volts Nominal
2
(2 on)
3 (1,2 on) 45-60 Volts Max, 35.9 Volts Nominal
4
(3 on)
8
(4 on)
14 (2-4 on) 132-177 Volts Max, 105 Volts Nominal
16 (5 on)
175-236 Volts Max, 140 Volts Nominal
20 (3,5 on) 205-276 Volts Max, 164 Volts Nominal
24 (4,5 on) 239-321 Volts Max, 191 Volts Nominal
28 (3-5 on) 268-362 Volts Max, 215 Volts Nominal
31 (All on)
300-390 Volts Max, 231 Volts Nominal
All
SW6-7
Reference VCO Channel/Analog Reference (REFP, REFN) Voltage Range Select

These switch settings determine the gain of the first stage of the analog interface circuitry for the (REFP,
REFN) analog inputs to the RFVCO channel. Maxima and Nominal values represent differential input
voltages at the 3TB inputs with the following significances:
First Max: Voltage for which the VCO stage will saturate with the RFSCL (DCC P5, if present) scaling
potentiometer set to the maximum gain (full CW) position.
RFSCL setting.
Nominal: Voltage which will produce 20000 counts in RFVCOVAR (VAR. 182) with the RFSCL scaling pot
set to maximum gain (full CW) and the EE.RVSCL# (EE.1281 m) programmed to 10000. This is the
optimum "rated reference" voltage, allowing 25% overrange.
Note that the software scaling function on the VCO channels is only available on DCP Rev 1.24 & later.
o (All off) 12.5-16.9 Volts Max, 10.0 Volts Nominal
17.3-23.3 Volts Max, 13.8 Volts Nominal
2 (7 on)
25.8-34.9 Volts Max, 20.6 Volts Nominal
1 (6 on)
3 (All on) 30.6-41.3 Volts Max, 24.4 Volts Nominal
All
P1
Provides scaling of analog input P1 from 8 volts to 50 volts maximum.
All
P2
All
P3
All
P4
5-14
BI006008
GEH-6148

5-4.5. Power Connect Card (DS200PCCA)
Table 5-3 summarizes the uses of the various PCCA

group numbers.
The DS200PC( A Power Connect Card (PCCA) provides an interfa e between the GF2000 exciter's control circuitry aIl~ the SCR power bridge. The PCCA
uses pulse trans ormers to provide gate drive to the
SCR bridge. Fc low to medium horsepower controllers, the PCCA also includes snubber circuits to control spikes aero s the ac lines, de bus, and gate drivers. For higher llorsepower controllers, some or all of
the snubber eirePits are omitted from the PCCA, and
are located else here in the system.
Section 6-8 defmes I/O points for the PCCA card.

The PCCA has four wire jumpers, designated JPl,
JP2. WP3, and WP4. Jumpers JPI and JP2 must be
connected to the appropriate stab terminals P3 through
PlO, as determined by the card group number and
system voltage. Jumpers WP3 and WP4 are used to
connect stab terminals P2A to P2B, and PIA to PIB,
respectively. These jumpers are used to select whether
the PCCA snubber capacitors are connected to the
same point on the power bridge as the voltage feedback channel.
The PCCA has en group numbers. The group number

used in a system is determined by the system voltage,
frame size, and fVhether the system uses regenerative
or non-regenera 've power conversion.
Figure 5-6 shows the layout of the PCCA card, including the locations of the stab terminals. Table 5-4 lists
and defmes the placement of the wire jumpers for
various PCCA group numbers and system voltages.
The armature vo tage scaling depends on which group

number is used:
Gl, G3, G7, G~ - Regenerative, 240 - 630 volts

G2, G4, G8, G 0 - Non-regenerative, 240 - 700 volts
Table 5-3. PCCA Card Uses

Group
G1, G2
G3,G4
G5,G6
G7,G8
G9, G10
Snubbers
Ac & dc
Dc only
None & no
attenuation string
Ac & dc
Dc only
Frames
e,G
Not used
J, K, L, M
e,G
D, J, M
Ac Volts
;5;600 V rms
N/A
;5;1500 V rms
;5;600 V rms
;5;600 V rms
Fuses
Line
N/A
Leg
Line
Leg
Reactors
Line
N/A
Leg
Line
Leg
Bus Trans ormer
Separate or
common
N/A
Separate or
common
Separate or
common
Separate or
common
5-15
BI006008
GEH-6148
2RPl..
IRPL
4RPL
[]
6RPL
5RPL
[]
5PL
o
5FPL
P3
P2
P23
o
6FP~
o o
2F?L
1FPL
3FP c
P7
P4
r-----""
"
DS200PCCAG1A
WP3
P9
'
P5
P8
PIO
P6
P2A
WP2
DCS
PI
lACS
PIA
2ACS
3ACS
4ACS
5ACS
Figure 5-6. PCCA Card Layout
Table 5-4. PCCA Card Adjustable Hardware

Revision
Name
Description
All
JP1
Groups 1, 3, 7 only 3.8 240 V dc;

3.4 290 V dc;
7.8 500 V dc;
4.7 550 V dc;
3.7 370 V dc;
4.8 580 V dc;
o 630 V dc;
Selects dc armature voltage range

Also connect JP2 P6-P9
Leave all P3-P10 open
All
JP2
Groups 1,3, 7 only 6.9 240 V dc;

5.6 290 V dc;
10.9 500 V dc;
10.5 550 V dc;
10.6 370 V dc;
5.9 580 V dc;
o 630 V dc;
Selects dc armature voltage range (see JP1, Groups 1,3,7)

Also connect JP1 P3-PB
Also connect JP1 P4-PB
All
JP1
Groups 2, 4, 8 only 3.8 240 V dc;

3.4 350 V dc;
7.8 390 V dc;
4.7 500 V dc;
3.7 550 V dc;
4.8 595 V dc;
o
700 V dc;
Selects dc armature voltage range

Also connect JP2 P6-P1 0
Leave all P3-P1 0 open
5-16
SACS
BI006008
GEH-6148

Table 5-4. PCCA Card Adjustable Hardware - Continued
Revision
Nane
Description
All
JP
Groups 2, 4, 8 only 6.9 240 V dc;

5.6
350 V dc;
10.9 390 V dc;
10.5 500 V dc;
10.6 550 V dc;
5.9
595 V dc;
700 V dc;
AAA-AAZ
JP1
Selects dc armature voltage range (see JP1 , Groups 2, 4, 8)

Group 5 only - Selects dc armature voltage range

3.8 240 V dc; Also connect JP2 P6-P9
7.8
500 V dc; Also connect JP2 P9-P10
4.7
3.7
4.8
630 V dc; Leave all P3-P10 open
AAA-AAZ
JP2
Group 5 only - Selects dc armature voltage range (see JP1, Group 5)

5.6
5.9
ABA-Pres
JP1, JP2
Group 5 only - Voltage attenuator string and jumpers no longer on Group 5.
AAA-AAZ
JP1
Group 6 only - Selects dc armature voltage range

7.8
4.7
AAA-AAZ
JP2
Group 6 only - Selects dc armature voltage range (see JP1, Group 6)

5.6
5.9
ABA-Pres
JPl, J='2
Group 6 only - Voltage attenuator strings and jumpers no longer on Group 6
All
WP3
Groups 1-4, 7-10 only - Separateltie card snubbers and VFBK to sameldifferent point(s)
WP3 and WP4 are wire jumpers on the PCCA card which are connected between stab terminals P2AP2B and P1A-P1 B, respectively. If these jumpers are present the card snubber capacitors are attached
to the same point on the bridge as the voltage feedback channel. WP3 & WP4 may be removed if the
card snubbers and voltage feedback channel need to be connected to different bridge points.
1.2 Jumper IN - Connect snubbers & voltage feedback channel to same point
Jumper OUT - Separate snubbers & voltage feedback channel
All
WP4
Groups 1-4, 7-10 only - Separateltie card snubbers and VFBK to sameldifferent point(s)
1.2 Jumper IN - Connect snubbers & voltage feedback channel to same point
5-17
BI006008
GEH-6148
5-4.6. Relay Terminal Board (DS200RTBA)

The DS200RTBA Relay Terminal Board (RTBA) is an
optional board that is sometimes referred to as a Relay
Card. The RTBA provides ten relays, seven of which
have two form C contacts, the other three have four
form C contacts. These relays are relays are driven
directly from the relays on the LTB board, or remotely by the user.
,1
~Tac
, ,HS"
The RTBA relays are available with three coil voltages, depending on the group number of the board.
The coil voltages available are 110 V dc (RTBAG1);
24 V dc (RTBAG2); and 115 V ac, 50/60 Hz
(RTBAG3).
Section 6-9 defmes I/O points for the RTBA board.
The RTBA board includes Berg-type jumpers. Figure
5-7 shows the RTBA board layout, including the locations of these jumpers. Table 5-5 lists and defmes the
jumpers.
!'
I<:T81 (
C-=:-f-;=.;-'--;;;;c--+::;;::;-I
Figure 5-7. RTBA Board Layout
Table 5-5. RTBA Board Adjustable Hardware

Revision
Name
Description
All
JP1
Relay #20 coil voltage source

Each RTBA relay may be picked-up by either an internal control voltage source supplied through plug RPL
from LTB or an external voltage source connected on the terminal board between KnA (n = 20-26) and
KCM. (Note that additional options are available for K20-K22 via JP8 and JP9).
1.2 Use external power source (RTBA.TB.K20A)
2.3 Use power source from LTB through plug RPL
All
JP2

1.2 Use external power source (RTBA.TB.K21Al
All
JP3

All
JP4

All
JP5

1.2 Use external power source (RTBA.TB.K24AI
All
JP6

All
JP7

5-18
BI006008
GF2000 Dc
Ge~erator
Field Exciter
GEH-6148
Table 5-5. RTBA Board Adjustable Hardware - Continued

Revision
Nam~
Description
All
JP8
K20-22 coil neutral source

In the 1.2 position, the coil neutrals of K20-K26 are all tied to RTB.50 (KeM). In the 2.3 position, the coil
neutrals of K20-K22 are isolated from RTB.50; JP9 must be set to position 2.3 to connect the coil neutrals
to RPL.1 and LTB.
1.2 K20-K22 coil neutrals connected to RTB.50, KeM
2.3 K20-K22 coil neutrals isolated from RTB.50
All
JP9
RPL. 1 connection
1.2 Ties RPL.1 to RTB.51 & OPTPL.2
2.3 Ties RPL.1 to K20-K22 coil neutrals
All
JP1 C
Select whether pluggable circuit Y25PL-Y28PL is powered from ePH

1.2 Pluggable circuit using Y25PL-Y28PL, not connected to ePH
2.3 Pluggable circuit using Y25PL-Y28PL powered from ePH
All
JP11
Select whether pluggable circuit Y25PLY28PL is powered from ePN

1.2 Pluggable circuit using Y25PL-Y28PL, not connected to ePN
2.3 Pluggable circuit using Y25PL-Y28PL powered from ePN
All
JP12
Select whether pluggable circuit Y31 PLY34PL is powered from ePH

1.2 Pluggable circuit using Y31 PL-Y34PL, not connected to ePH
2.3 Pluggable circuit using Y31 PL-Y34PL powered from ePH
All
JP13
Select whether pluggable circuit Y31 PL-Y34PL is powered from ePN

1.2 Pluggable circuit using Y31 PL-Y34PL, not connected to ePN
2.3 Pluggable circuit using Y31 PL-Y34PL powered from ePN
All
JP14
Select whether pluggable circuit Y19PL-Y22PL is powered from ePH

1.2 Pluggable circuit using Y19PL-Y22PL, not connected to ePH
2.3 Pluggable circuit using Y19PL-Y22PL powered from ePH
All
JP15
Select whether pluggable circuit Y19PL-Y22PL is powered from ePN

1.2 Pluggable circuit using Y19PL-Y22PL, not connected to ePN
2.3 Pluggable circuit using Y19PL-Y22PL powered from ePN
5-19
BI006008
GEH-6148
5-4.7. Drive Control Card (DS215SDCC)
The DS215SDCC Drive Control Card (SDCC) contains the exciter's primary control circuits and software. The SDCC also contains general-purpose interface circuits that connect with other boards to form
various types of ac and dc motor drives and exciters.
The interface circuits control and process exciter and
motor signals, and customer I/O.
The SDCC contains three microprocessors: the Drive
Control Processor (DCP) at location Ul, the Motor
Control Processor (MCP) at location U21, and the Comotor Processor (CMP) at location U35.
5-4.7.2. CONFIGURABLE HARDWARE. The SDCC

contains Berg-type hardware jumpers, identified with a
IP nomenclature, and hard-wired jumpers, identified
with a WI nomenclature. Figure 5-8 shows the locations of these jumpers on the SDCC card. Table 5-6
lists and defmes these jumpers.
5-4.7.3. REPLACING/INSERTING SOFTWARE. The
SDCC must include the onboard software stored in
EPROMs Ull, U12. U22, and U23, and in EEPROM
U9 to function in the exciter. When replacing an
SDCC, transfer the onboard software from the old
card to the new as follows:
CAUTION
The SDCC card uses onboard software stored in five

memory chips: four EPROMs (Ull, Ul2, U22, and
U23), which contain configuration data programmed at
the factory; and one EEPROM (U9), which contains
field-adjustable parameters. These memory chips are
contained in sockets on the SDCC.
To prevent component damage caused by

static electricity, treat all boards with static
sensitive handling techniques. Use a
grounding strap when handling boards or
components. Store boards in anti-static
bags or boxes.
NOTE
The DS200SDCC card does not include the

five memory chips mentioned above (the
sockets are empty). To order a replacement
card including the five memory chips,
specify a DS215SDCC card.
To prevent damage to components, use the

proper chip extraction/insertion tool when
performing the following procedure.
1.
Section 6-10 defmes I/O points for the SDCC card.

Section 7-3.3 defmes SDCC onboard testpoints.
5-4.7.1. RESET CIRCUITS. The SDCC includes four
reset circuits, including a RESET pushbutton.
CAUTION
To prevent damage to memory chips, ensure that chips are properly oriented when
inserting them into sockets.
CAUTION
The system trips when a hard reset is initiated; do not reset when running.
A reset can be generated in four ways:
By pressing the RESET pushbutton on the SDCC.
By applying +5 to +24 V dc to customer interface point 3TB pin 58 on the NTB/3TB board.
The board generating a reset by programmed

software control.
The board generating a reset by automatic internal

hardware watchdog protection.
520
Carefully remove one of the EPROM chips (Ull,

U12, U22, or U23) from the old card and insert it
into the same socket on the new card.
2.
Repeat the previous step one chip at a time for

each of the remaining EPROM chips.
3.
Remove the EEPROM chip (U9) from the old

card and insert it into the correct socket on the
new card.
4.
If the same failure symptoms still exist, install the

new (blank) EEPROM shipped with the new card.
Program the new EEPROM per the customer
software adjustment values using the ST2000
Toolkit (see GEH-5860) or Drive Configurator,
LynxOS Version (see GEH-6203).
BI006008
GF2000 Dc GE ~erator Field Exciter
GEH-6148
==---==~ 3Pl
~r=
JP
' @
R
H
cps
CCM
cax
-iP12
! FSR
,FSX
: ClX
1-10lR
1:0
L
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o
o
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c=J:J
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~~
J1::
II
:; ~
N',5 P15 TP4 TP5 TP6
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00000
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0
I
'"
6
DAGS
~O
-, I
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U9
TP12
EEROM
:;r
c:=J:J JPl
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NMI
"TPNT
JP8
J;)23
c=J:J
JPJ
c=J:J c=J:J
P16
C=L~J
LJ 1
FClK
" ====--====--~
40
0
fC=-'
IL
BP
lPl
d
39
DS215SDCCG1A
0
0
TP37
TP29
TP8
2P
L _ __
I ['~===-"",===-=4~0
i
~
6PL
'!~,
l1Pl ,19'0
_L_.:.J1 16
1
II.,
!~lr~1
Figure 5-8. SDCC Card Layout
Table 5-6. SDCC Card Adjustable Hardware
Revision
Name
Description
All
JP1
EEPROM parameter write protect

1.2 Writes inhibited, safe mode
2.3 Writes enabled (required to modify EEPROM)
All
JP7
Enable 6:1 gain increase for feedback VCO circuitry

1.2 Normal gain
2.3 Increase gain 6: 1 (see NTB SW1)
All
JP8
Enable absolute value circuit for feedback VCO circuitry

Note that, due to the 1O-volt maximum voltage available on the STBA card, the FB VCO is not normally
suitable for analog tachs unless the NTB/3TB board is used.
1.2 Bipolar mode, for DC tachometers
2.3 Absolute mode, for analog AC AN tachometers
AFD-Pres
JP12
DCP PROM high page enable

This jumper provides for future access to the full address space of 4 Mbit DCP program memory. It is currently not used and should be left in the 1.2 position.
1.2 U12 and U11 are EPROM or FLASH memories up to 2 Mbit
2.3 Reserved for 4 Mbit FLASH memory (29F040) applications
AFD-Pres
JP14
MCP PROM high page enable

This jumper provides for future access to the full address space of 4 Mbit MCP program memory. It is currently not used and should be left in the 1.2 position.
1.2 U22/U23 are EPROM or FLASH memories up to 2 Mbit
2.3 Reserved for 4 Mbit FLASH memory (29F040) applications
5-21
BI006008
GEH-6148
Table 5-6. SDCC Card Adjustable Hardware - Continued

Revision
Name
Description
O-ACZ
JP15
Enable for DCP crystal

1.2 Enabled (required for normal operation)
o Manufacturing test only
ADS-Pres
JP16
Enables FLASH electrically erasable program memory erase/reprogram mode

JP16 is required to be in the 2.3 position only for in-house reprogramming of 12 V FLASH memory such as
the AM28F020. JP16 applies + 12 V dc to the VPP pin of the DCP and MCP program memory. EPROM
memory and 5 V FLASH memory (such as the 29F040) do not require + 12 V dc, so for these types of
U12, U11, U22, and U23 memory, JP16 should be left in the default 1.2 position.
1.2 Normal mode for EPROM or FLASH memory read only
2.3 Reserved for FLASH memory reprogramming mode
All
JP22
Enable for MCP crystal

All
JP23
Signal source into DCP's external DMA channel, used for time tagged inputs
1.2 From NTS/3TB analog feedback input (for AC AN tach interfaces)
2.3 From the NTS/3TS encoder marker track input, EOM.
O-ACZ
JP33
Enable for CMP crystal

ADS-Pres
WJ1
Remap MET3 D/A to DAC1 output for SDCCG3

SDCCG3 omits the 12-bit D/A converter used for DAC1 and DAC2, and instead drives DAC1 and DAC2
outputs with the 8-bit D-A used to drive MET3 and MET4 on SDCCG1. MET3 and MET4 are not available
on SDCCG3. If this jumper is erroneously present on an SDCCG1 card, the D/A outputs will be corrupted;
if this jumper is missing on an SDCCG3 card, the DAC1 /DAC2 output will not function.
o SDCCG 1, jumper omitted
1.2 SDCCG3, jumper installed
ADS-Pres
WJ2

o SDCCG 1, jumper omitted
1.2 SDCCG3, jumper installed
ADS-Pres
WJ3
Provide 1O-volt full scale reference for D/A outputs on SDCCG3

If this jumper is incorrectly set for the SDCC group number, the D/A converters will operate improperly.
o SDCCG1, uses internal reference from 12-bit D/A
1.2 SDCCG3, develops reference from + 5 V dc power supply
ADS-Pres
WJ4
Identify card group number to firmware

The firmware uses this jumper to identify whether the card contains G1 or G3 components. Incorrect setting of this jumper will cause malfunction of the DCP, including the inability of the processor to power up
and configure card logic cell arrays, and possible loss of EEPROM drive configuration memory.
o Omit jumper, identifies card as group G1
1.2 Install jumper. identifies card as group G3
ADS-Pres
WJ5
Configure card for logic cell array size

Incorrect setting of this jumper may damage or cause unreliable operation of LCA U32.
o Jumper omitted on SDCC G3 (LCA is 3042 device)
1.2 Jumper installed on SDCC G1 (LCA is 3064 device)
ADS-Pres
WJ7
Configure card for EEPROM size

In all present drive applications, WJ7 and WJ9 must be omitted and WJ8 and WJ1 0 must be installed. The
alternate setting allows for future expansion of EEPROM size from 32K to 64K. Incorrect setting of these
jumpers will result in incorrect reading and configuration of the drive EEPROM.
o SDCCG1 and G3, jumper omitted
1.2 Reserved for future expansion
ADS-Pres
WJ8

o Reserved for future expansion
1.2 SDCCG1 and G3, jumper installed
ADS-Pres
WJ9

o SDCCG1 and G3, jumper omitted
1.2 Reserved for future expansion
ADS-Pres
WJ10

o Reserved for future expansion
1.2 SDCCG1 and G3, jumper installed
5-22
BI006008
GEH-6148

5-4.8. LAN C mmunications Card
{DS215SLCC
The DS2l5SL C LAN Communications Card (SLCC)

provides isolate and non-isolated input circuits for
communicatio to the exciter. The SLCC connects to
the NTB/3TB, DCC, and DCFB boards via 2PL; to
the SDCC card ia 3PL; and to the optional LTB
board via IOPL The SLCC also connects to the Programmer.
The SLCC fea es an alphanumeric display controller
that connects to the Programmer. Refer to Chapter 8
for information bout the Programmer.
The SLCC also . eludes onboard software contained in
two EPROMs, esignated U6 and U7.
NOTE
EPROMs
empty). To
cluding th
DS215SLC
LCC card does not include

6 and U7 (the sockets are
order a replacement board ine two memory chips, specify a
card.
The SLCC has ee group numbers. The 01 version

of the SLCC inc udes circuits used to connect the exciter to DLAN ( ive local area network) or DLAN +
(ARCNET) ne orks; the G2 version includes only
the DLAN inter ce circuits; and the G4 version ineludes neither th DLAN nor the ARCNET circuits.
5-4.8.1. CONFIGURABLE HARDWARE. The SLCC

includes Berg-type jumpers and hard-wired jumpers.
Figure 5-9 shows the locations of the SLCC card
jumpers. Table 5-7 lists and defmes these items.
5-4.8.2. REPLACINGIINSERTING SOFTWARE. The
SLCC must inelude the onboard software stored in
EPROMs U6 and U7 to function in the exciter. When
replacing the SLCC card, the onboard software must
be transferred from the old card to the new. Carefully
remove each of the two EPROM chips from the old
card and insert it into the same socket on the new
card.
CAUTION
To prevent component damage caused by
static electricity, treat all boards with static
sensitive handling techniques. Use a
grounding strap when handling boards or
components. Store boards in anti-static
bags or boxes.
proper chip extraction/insertion tool when
performing the following procedure.
To prevent damage to memory chips, ensure that chips are properly oriented when
inserting them into sockets.
es I/O points for the SLCC card.
5-23
BI006008
GEH-6148
DS215SLCCG1A
DEVICE
-+
TDWARD THIS
-+
END
10PL
[~
"M
"i':
D%
----l'"""L- ----l'"""LU6
U7
I
I
Lo
0--0
0--0
WJ4
2PL
WJ5
WJ2
0--0
WJi
0--0
"M "M
~d~ j~
n
M
_d~
ARCPL
WJ30--0
Figure 5-9. SLCC Card Layout
5-24
BI006008
GF2000 Dc GE nerator Field Exciter
GEH-6148
Table 5-7. SLCC Card Adjustable Hardware

Revision
Nan e
Description
Jumpers JP14 tt rough JP1 8 are not present on DS215SLCCG4 cards.

All
JP1
Groups 1 and 2 only - This jumper selects the RS-422 DLAN drivers or the isolated DLAN circuit
1.2 Isolated DLAN circuit
2.3 RS422 drivers and receivers
All
JP1
2.3 RS-422 drivers and receivers
All
JP16
2.3 RS422 drivers and receivers
All
JP1
Groups 1 and 2 only - This jumper puts the DLAN termination resistors in the DLAN circuit
The termination jumpers should be added to the drives located at the end of a daisy-chain 422 LAN. Never
exceed 5 sets of termination resistors in a 422 DLAN circuit.
1.2 Termination resistors in
2.3 Termination resistors out
All
JP1
Groups 1 and 2 only - This jumper puts the DLAN termination resistors in the DLAN circuit
The termination jumpers should be added to the drives located at the end of a daisy-chain 422 LAN. Never
exceed 5 sets of termination resistors in a 422 DLAN circuit.
1.2 Termination resistors in
2.3 Termination resistors out
All
JP1
Groups 1, 2, and 4 - This jumper connects the crystal to the processor

This jumper should be in place except during manufacturing testing.
1.2 Normal running condition
2.3 Manufacturing testing
All
JP2(
Groups 1,2, and 4 - This jumper sets up the EPROM sockets for either EPROMs or Flash PROMs
1.2 EPROM setting
2.3 Flash PROM setting
All
WJ1
Groups 1,2, and 4 - This jumper redirects the Ready Line when there is no ARCNET module
This jumper should be in place when there is no ARCNET module.
1.2 No ARCNET module (DS215SLCCG2, G4)
o ARCNET module present (DS215SLCCG 1)
ACC-Pres
WJ2
Groups 1, 2, and 4 - This jumper connects the LRX signal to ground through a 470-ohm resistor
This jumper should be in place for G4 only.
o LRX signal is not connected to ground (DS215SLCCG1, G2)
1.2 LRX signal is connected to ground (DS215SLCCG4)
ACC-Pres
WJ3
Groups 1,2, and 4 - This jumper connects the T2CLK signal to ground through a 470-ohm resistor
o T2CLK signal is not connected to ground (DS215SLCCG1, G2)
1.2 T2CLK signal is connected to ground (DS215SLCCG4)
ACC-Pres
WJ4
Groups 1,2, and 4 - This jumper connects the input signal to ground through a 470-ohm resistor
o Input signal is not connected to ground (DS215SLCCGl, G2)
1.2 Input signal is connected to ground (DS215SLCCG4)
ACC-Pres
WJ5
Groups 1,2, and 4 - This jumper connects the input signal to ground through a 470-ohm resistor
o Input signal is not connected to ground (DS215SLCCG 1, G2)
1.2 Input signal is connected to ground (DS215SLCCG4)
5-25
BI006008
GEH-6148
5-4.9.1. CONFIGURABLE HARDWARE. The SPC card

includes Berg-type jumpers; a DIP switch (earlier revisions of the SPC card included two DIP switches);
and six pots, designated PI through P6. The jumpers
are used for manufacturing test or customer options.
Figure 5-10 shows the SPC card layout, including the
locations of the jumpers, DIP switch, and pots. Table
5-8 lists and defmes these items.
5-4.9. Signal Processor Card (531X309SPC)
The optional 531X309SPC Signal Processor Card

(SPC) processes I/O for the SDCC card. The SPC
includes two identical encoder interface circuits: Encoder #1 and Encoder #2. Each encoder interface circuit interface with 5 to 15 V incremental encoders or
digital tachometers to supply position or speed feedback, or reference instrumentation to the exciter.
Section 6-12 defmes 1/0 points for the SPC card. Section 7-3.4 defmes SPC onboard testpoints.
531X309SPC
SIGNAL PROCESS
TPZUP
o
o
:::=! EZA8
i IEZA8
'I
=~
I
!
EZ88
\:
IEz88
a::
~8~1
>
II
'-----'
JP7 r
::~:
::~
RXP
TPl UP
:::J 0
C
lo
-:
TP1DN
JP10
3
i 1
, I
2 I==:J== 4
TPl Z
III
SPlTPl
.
JP9
TP27
JP4
:;;
Du
TX RX
I
,C l,
2I==:J==4
SPZTPZ
DDDDDD
P6
ZRESP
P5
ZSCALE
P4
ZZERO
P3
1RESP
Figure 5-10. SPC Card Layout
5-26
_CD
PFZP
TXP
JP8
, ,
I==:J - -
PZ
1SCALE
L-==
ZI==:J==4
,
PF1N
1 Z
JPl
I==:J
I~~~
=~
c::::JCJ\'
c::J .....,';
SWl
EZM8
I IEZM8
TPZDN
Pl
1ZERO
BI006008
GEH-6148

Table 5-8. SPC Card Adjustable Hardware
Revision
Description
All
JP1
Encoder #1 clock inhibit, this is used for test purposes only.

1.2 Enables encoder #1 logic array (normal operation)
o Inhibits clock to PAL (manufacturing test only)
All
JP2
Encoder #1 marker channel enable to be used for absolute position.

1.2 Inhibit marker, for incremental position or speed only
2.3 Enable marker, for absolute position instrumentation
All
JP3
Encoder #2 clock inhibit, this is used for test purposes only.

1.2 Enables encoder #2 logic array (normal operation)
o Inhibits clock to PAL (manufacturing test only)
All
JP4
Encoder #2 marker channel enable to be used for absolute position.

1.2 Inhibit marker, for incremental position or speed only
2.3 Enable marker, for absolute position instrumentation
AA-AF
JP5
Select biasing of input PF1 N for the analog channel SPA 1 (VAR.256)
Jumpers JP5 - JP7 and pots P1 - P3 on the SPC card control hardware options for the process follower
analog channel SPA 1 (VAR.256), input from PF1 P and PF1 Non 1TB. This circuit is a general purpose amplifier which can accept either current loop or voltage inputs. JP5, JP7, and P1 (1ZERO) control the offset
added to the input; P2 (1 SCALE) controls the gain of the amplifier, CCW = more gain; P3 (1 RESP) controls
the response of the low pass filter of the amplifier, CCW = more filtering; and JP6 controls input burdening when this circuit is used for current loop inputs. JP5 and JP7 allow several options for the 1ZERO offset pot. The most common configurations are as follows:
JP5 JP7 MODE
1.2 1.2 No offset trimming, 1ZERO is disabled
1.2 1.3 Positive trimming, CCW = more offset
1.2 1.4 Negative trimming, CCW = more offset
For example, to set-up a 4-20 rnA current loop, assuming PF1 P positive with respect to PF1 N, set JP5 1.2,
JP6 1.3, and JP7 1.4. Apply a 4 mA input, and adjust P1 until VAR.256 is O. Then apply a 20 rnA input,
and adjust P2 to give the desired full scale (the amplifier saturates at a maximum value of + 511 counts).
Note that currents less than 4 rnA will produce negative values down to -512 counts at VAR.256. If this
is undesirable, feed VAR.256 into a limit block before using it in the drive.
1.2 Bias to common
1.3 Add negative bias, 0 to -8 V dc
1.4 Add positive bias, 0 to + 8 V dc
1.5 Add no bias
AG-Pres
JP5
Select gain of amplifier for the analog channel SPA 1 (VAR.256)

Jumpers JP5 - JP7 and pots P1 - P3 on the SPC card control hardware options for the process follower analog
channel SPA1 (VAR.256l, input from PF1 P and PF1 N on HB. This circuit is a general purpose amplifier which
can accept either current loop or voltage inputs. JP7 and P1 (1 ZERO) control the offset added to the input;
JP5 and P2 (1 SCALE) control the gain of the amplifier, CW = more gain; P3 (1 RESP) controls the response of
the low pass filter of the amplifier, CCW = more filtering; and JP6 controls input burdening when this circuit is
used for current loop inputs. The most common configurations are as follows:
PF1 P/PF1 N
MODE
JP5 JP6 JP7
1-5 rnA 1.2 1.3 1.3
4-20 mA 1.2 1.3 1.3
10-50 rnA 1.2 1.4 1.3
0-30 V
1.2 1.2 1.3
For example, to set-up a 4-20 rnA current loop, assuming PF1 P positive with respect to PF1 N:
- Set JP5 1.2 and JP6 1.3. Temporarily set JP7 to 1.2.
- Apply a 20 rnA input, and adjust P2 until Test point SPHP2 is 6.25 V.
- Set JP7 to 1.3.
- Adjust P1 until SPHP2 is 5.0 V and VAR.256 is +500 counts.
- Apply a 4 rnA input, and verify that SP1 TP2 and VAR.256 are both O.
If the ratio between the maximum and minimum inputs is not 5, the voltage at SP1 TP2 for the second step
should be adjusted to (5 x max)/(max - min) V instead of 6.25 V. Note that VAR.256 saturates at a maximum
value of + 511 counts when SP1 TP2 exceeds 5 V. Also note that currents less than 4 rnA produce negative
values down to -512 counts at VAR.256. If this is undesirable, feed VAR.256 into a limit block before using it
in the drive.
1.2 Normal gain
2.3 10:1 gain boost for max input < 5 mA or < 2 V
5-27
BI006008
GEH-6148
Table 5-8. SPC Card Adjustable Hardware - Continued

Revision
Name
Description
AA-AF
JP6
Select input burdening for PF1 P/PF1 N of the analog channel SPA1 (see JP5)
1.2 No burden, for 2-30 V dc input signals
1.3 Burden for 4-20 mA current loop input
AG-Pres
JP6
Select input burdening for PF1 P/PF1 N of the analog channel SPA1 (see JP5)
1.3 Burden for 1-5 or 4-20 mA current loop input
AA-AF
JP7
Select biasing
1.2 Bias
1.3 Add
1.4 Add
1.5 Add
AG-Pres
JP7
Select zero offset for the analog channel SPA1 (see JP5). Use P1 for fine trim.
1.2 No offset
1.3 Negative offset
1.4 Positive offset
AA-AF
JP8
Select biasing of input PF2N for the analog channel SPA2 (VAR.257)
Jumpers JP8 - JP1 0 and pots P4 - P6 on the SPC card control hardware options for the process follower analog channel SPA2 (VAR.257), input from PF2P and PF2N on HB. This circuit is a general purpose amplifier
which can accept either current loop or voltage inputs. JP8, JP10, and P4 (2ZERO) control the offset added to
the input; P5 (2SCALE) controls the gain of the amplifier, CCW = more gain; P6 (2RESP) controls the response of the low pass filter of the amplifier, CCW = more filtering; and JP9 controls input burdening when
this circuit is used for current loop inputs. JP8 and JP10 allow several options for the 2ZERO offset pot. The
most common configurations are as follows:
JP8 JP10 MODE
1.2 1.2
No offset trimming, 2ZERO is disabled
Positive trimming, CCW = more offset
1.2 1.3
Negative trimming, CCW = more offset
1.2 1 .4
For example, to set up a 4-20 mA current loop, assuming PF2P positive with respect to PF2N, set JP8 1.2,
JP9 1.3, and JP1 0 1.4. Apply a 4 mA input, and adjust P4 until VAR.257 is O. Then apply a 20 mA input, and
adjust P5 to give the desired full scale (the amplifier saturates at a maximum value of + 511 counts). Note
that currents less than 4 mA will produce negative values down to -512 counts at VAR.257. If this is undesirable, feed VAR.257 into a limit block before using it in the drive.
1.2 Bias to common
1.3 Add negative bias, 0 to -8 V dc
1.4 Add positive bias, 0 to + 8 V dc
1.5 Add no bias
AG-Pres
JP8
Select gain of amplifier for the analog channel SPA2

Jumpers JP8 - JP1 0 and pots P4 - P6 on the SPC card control hardware options for the process follower analog channel SPA2 (VAR.257J, input from PF2P and PF2N on HB. This circuit is a general purpose amplifier
which can accept either current loop or voltage inputs. JP1 0 and P4 (2ZERO) control the offset added to the
input; JP8 and P5 (2SCALE) control the gain of the amplifier, CW = more gain; P6 (2RESP) controls the response of the low pass filter of the amplifier, CCW = more filtering; and JP9 controls input burdening when
this circuit is used for current loop inputs. The most common configurations are as follows:
PF2P/PF2N
MODE
JP8 JP9 JP10
1-5 mA 1.2 1.3 1.3
4-20 mA 1.2 1.3 1.3
10-50 mA 1.2 1.4 1.3
0-30 V
1.2 1.2 1.3
For example, to set up a 1-5 mA current loop, assuming PF2P positive with respect to PF2N:
- Set JP8 to 1.2 and JP9 to 1.3. Temporarily set JP1 0 to 1.2.
- Apply a 5 mA input, and adjust P5 until testpoint SP2TP2 is 6.25 V.
- Set JP1 0 to 1.3.
- Adjust P4 until SP2TP2 is 5.0 V, and VAR.257 is +500 counts.
- Apply a 1 mA input, and verify that SP2TP2 and VAR.257 are both O.
If the ratio between the maximum and minimum inputs is not 5, the voltage at SP2TP2 for the second step
should be adjusted to 5 x max / (max - min) V instead of 6.25 V. Note that VAR.257 saturates at a maximum
value of + 511 counts when SP2TP2 exceeds 5 V. Also note that currents less than 1 mA produce negative
values down to -512 counts at VAR.257. If this is undesirable, feed VAR.257 into a limit block before using it
in the drive.
1.2 Normal gain
2.3 10:1 gain boost for max input < 5 mA or < 2 V
5-28
of input PF1 P for the analog channel SPA 1 (see JP5)

to common
positive bias, 0 to + 8 V dc
negative bias, 0 to -8 V dc
no bias
BI006008
GEH-6148

Revision
Description
AA-AF
JP9
Select input burdening for PF2P/PF2N of the analog channel SPA2 (see JP8)
AG-Pres
JP9
Select input burdening for PF2P/PF2N of the analog channel SPA2 (see JP8)
1.3 Burden for 1-5 or 4-20 mA current loop input
AA-AF
JP10
Select biasing
1.2 Bias
1.3 Add
1.4 Add
1.5 Add
AG-Pres
JP10
Select biasing of input PF2P for the analog channel SPA2 (see JP8). Use P1 for fine trim.
1.2 No offset
1.3 Negative offset
1.4 Positive offset
AA-AF
SW1- ,
SW1-
Selects input attenuation resistors for channel A of encoder #1

Input attenuation resistors for channel A of encoder #1 can be selected as follows
o (All off) 15 volt encoder interface
5 volt encoder interface
1 (1 on)
5 volt encoder (alternate setting)
2 (2 on)
3 (1 ,2 on) External attenuation
AG-Pres
SW1-1

o (Off) 15 volt encoder interface
1 (On) 5 volt encoder interface
AG-Pres
SW1-2
Selects input attenuation resistors for channel B of encoder #1

Input attenuation resistors for channel B of encoder #1 can be selected as follows
AA-AF
SW1-3
SW1-4

Input attenuation resistors for channel B of encoder #1 can be selected as follows:
1 (3 on)
2 (4 on)
3 (3,4 on) External attenuation
AG-Pres
SW1-3
Selects input attenuation resistors for marker channel of encoder #1

Input attenuation resistors for marker channel of encoder #1 can be selected as follows
AG-Pres
SW1-4

AA-AF
SW1-5,
SW1-6

1 (5 on)
2 (6 on)
AG-Pres
SW1-5

1 (On)
of input PF2P for the analog channel SPA2 (see JP8)

to common
positive bias, 0 to + 8 V dc
negative bias, 0 to -8 V dc
no bias
5-29
BI006008
GEH-6148

Revision
Name
Description
AG-Pres
SW1-6

AG-Pres
SW1-7
Selects input attenuation resistor for serial channel RXP/RXN (1 TB-13)

RXP and RXN (1 TB-13, 14) may be used either as the input from a BEl serial absolute encoder. or as the
receiver input of a full-duplex RS-422 serial channel to the motor control processor.
o (Off) 15 volt input (Serial encoder interface)
1 (On) 5 volt input (RS-422 serial communication)
AA-AF
SW2-1,
SW2-2

1 (1 on)
2 (2 on)
3 (1 ,2 on) External attenuation
AA-AF
SW2-3.
SW2-4

1 (3 on)
2 (4 on)
AA-AF
SW2-5.
SW2-6

1 (5 on)
2 (6 on)
All
P1
(1ZERO)
Full CCW
All
P2
(1SCALE)
Full CCW = 0700. Provides gain adjust of SPA 1 (see JP5).
All
P3
(1 RESP)
Full CCW = 0700. Adjusts response of SPA 1, from 1 to 1000 msec.

Response #1 (P3) adjusts the response of analog channel #1 (SPA1). The response can be adjusted from 1 to
1000 msec.
All
P4
(2ZERO)
Full CCW = 0700. Provides zero adjust of SPA2 (see JPB).
All
P5
(2SCALE)
Full CCW = 0700. Provides gain adjust of SPA2 (see JPB).
All
P6
(2RESP)
Full CCW = 0700. Adjusts response of SPA2. from 1 to 1000 msec.

Response #2 (P6) adjusts the response of analog channel #2 (SPA2). The response can be adjusted from 1 to
1000 msec.
5-30
= 0700. Provides zero adjust of SPA1
(see JP5).
BI006008
GEH-6148

5-4.10. Volt ge Attenuator Board
(DS200SVA )
NOTE
Wire jumpers WJl through WJ4 should be

placed in similar positions for each SVAA
input line. For example, if WJl is connected between stab terminals PTll and
PT13 (across resistor Rll), WJ2 should
connect PT17 and PT19, WJ3 should connect PT31 and PT33, and WJ4 should connect PT37 and PT 39.
The DS200SV A Voltage Attenuator Board (SVAA)

attenuates the ltage of a generator, bridge, or motor
from its rated I vel to 600 V dc or less. The SV AA is
used for syste s with voltages of 600 to 1500 V dc to
reduce the feed ack voltage to a level that is within the
input specificat ons of the DCFB board.
The SVAA bo d is connected between the generator,
bridge, or mot and terminal board 2TB to reduce the
voltage present t 2TB. The DCFB isolates the voltages at 2TB fro the other control boards.
The SVAA con ains two identical attenuation circuits.
Figure 5-11 sho s one of the attenuation circuits.
Each attenuatio circuit includes six 100 ill resistors,
three in series ith each input line, and four 475 ill,
1 % resistors ac oss the output lines. The output resistors are confi ed such that they make up two pairs
of parallel resis rs connected in series.
Each attenuatio circuit provides a default attenuation
of 0.442 (the ou ut voltage is 0.442 x the input voltage). For other ttenuation values, the SVAA includes
stab terminals at each end of the 100 ill input resistors. The stab te minals can be connected using wire
ugh WJ4 to select the amount of
jumpers WJl
attenuation appli d to the input voltage. Table 5-9
shows the attenu tion values available.
NOTE
pm
9
i
NOTE
Adjust EE.1503 (VFBSFO) and CFBSFO

(EE.1504) such that 20,000 counts equals 1
pu armature voltage feedback and 1 pu
CEMF feedback, respectively.
Two other wire jumpers, WJ5 and WJ6, are used to
connect the center points of the attenuation circuits to
ground, if desired. These jumpers are also not supplied with the SV AA board, and must be ordered
separately if required by the application. Figure 5-12
shows the layout of the SVAA, including the locations
of the stab terminals.
Section 6-13 defmes I/O points for the SV AA board.
Wire jump rs WJl through WJ4 are not

supplied wi h the SVAA board, and must
be ordered eparately if the application requires an a enuation setting other than the
default valu of 0.442.
0911
lOOK .17-
On the DCFB board, DIP switches SW4 and SW5

select the voltage applied to the dc bridge (generator
for the GF2000 exciter) voltage feedback and dc motor
voltage feedback circuits, respectively. Table 5-10
shows typical settings for the individual switches in
SW4 and 5 when the DCFB is used with SVAA board
attenuation of 0.442 (default setting).
PTl4
Ri2
lOOK .17-
Rig I
47SKi
.17-U
I
PT17
PTl8
c--,
i2:1 SC2
PTl9
0914
lOOK .17-
9
1
R:1
lOOK .17.
SCs
PTl6
PT20
R'S
100, .17-
:=J
PT21
R16
100K .17-
c:::J
C]SC4
Figure 5-11. SVAA Attenuation Circuit
5-31
BI006008
GEH-6148
Table 5-9. SVAA Board Attenuation Jumper Placement

Attenuation
WJ1
WJ2
WJ3
WJ4
0.442
Not present.
Not present.
Not present.
Not present.
0.547
PTll-PT13
PT17-PT19 (Rev ACB-Pres)

PT15-PT17 (Rev AAA-ABA)


0.704
PTll-PT14



PT25-PT28 (Rev AAA-ABAI
1.00
PT11-PT15
(Rev ACB-Pres)
Table 5-10. DCFB DIP Switches SW4 and SW5 Settings

With SVAA Board Attenuation of 0.442
Voltage
IV dc)
DIP Switch SW4 and SW5 Settings
Circuit
Gain
Approximate
Voltage at 2TB
650
Off
Off
Off
Off
0.0038698
253
700 - 900
Off
Off
Off
On
0.0032778
272-350
1000
On
Off
Off
Off
0.0024411
389
1250
Off
On
Off
Off
0.0019317
486
1500
Off
Off
On
Off
0.0015449
583
PT,S
SC3
1--1
I
I
L_,_~
PT11
PT14
1--1
UU
PTn
0
1I1
'---_,_---l
PT12
0
0
1I1
SCl
<
;po
;po
;po
PT20
SC4
1--1
I
,
L
__
,
PT18
1LJ
r.
PT19
I'
I! : - - 1
LJ
PT'? '--- _ _
I
---l
SC2
PT21
PT3S
SC?
1--1
I
'--- __ ---l
1--1
PT::54
PT36
00
'---_,_---l
SC5
PT32 PB,
PT33
n
LJ
PT39
SCB
1--1
I
L __ ---l
I
PT41
11
lJ
PT40
PBS
0 00
1--1
PT3?
L_,_---l
SC6
Figure 5-12. SVAA Board Layout
5-32
BI006008
GEH-6148

5-4.11. Shu
Table 5-11. SVIA Input Gain
Isolator Board (DS200SVIA)
The DS200SV Shunt Isolator Board (SVIA) provides isolation f shunt current signals. The mV signal
from a shunt is amplified by the input stage of the
SVIA, and is i lated from the common mode voltage
that exists in th power circuit. Several standard input
resistors are pr vided on the SVIA to amplify 100
mV to 475 m shunt signals to 7.5 V outputs.
Input
Terminal
Input Resistor (0)
Gain
TB1-1
User selected
7500/R11
TB1-3
7500
Unity
TB1-5
475
16
TB1-6
221
34
The SVIA requ res an unregulated supply of +24 V

dc, 25%, 80
input power.
TB1-7
100
75
puts (TBI-3, TBI-5, TBI-6, and TBI-7) feature fixed

input resistors, for the gain values in Table 5-11.
The SVIA cons sts of three stages: the high-gain input

stage, the unity gain isolation stage, and the variable
gain and offset djust output stage. Figure 5-13 is a
simplified elem ntary diagram of the SVIA, showing
each of these st ges.
The fifth input (TB 1-1) is connected to a set of saddle

clamps that enable the user to install the required input
resistor, designated RH, for the desired gain. Resistor
Rll can be determined as follows:
Section 6-14 de mes 110 points for the SVIA board.

Section 7-3.5 d fmes SVIA onboard testpoints.
R11 =
5-4.11.1. INP T STAGE. The input stage includes a

differential am lifier with a 7.5 len feedback resistor.
Five input co ections enable the user to select the
gain required y the application. Four of the five inSOURC
The output of the SVIA board is typically connected to

a DS200DCFB Power Supply Board (DCFB). In these
applications, the desired output voltage is 1 V.
P15V
T61-7
:B1-5
475
JI
CAP OUT
7.5K
'"
VIN
W,
T61-1
lao
ACJM
SUPPLY
NI51S
TP6
II
J*-O
475K
MAX
~75K
I' C:'~20K
CCW
NEG
6US T62-1
VOUT
'P9
'10K
~
:
r----,----,--LJ..........I ~
'----;
6US T62-2
o
~
TP 8
MAX
pas
ACOM
nn
I
16M
vors
UNITY GAIN
ISOLATION STAGE
~~""-+----i~ I ~g~ EO
~
CW
N~
ACOMIS
OUTPUT STAGE
OFFSET
6.4V
"
mV
SHUNT
INPUT
T61-2
6AV
VINI
TP7
221
1J
~:=J--~R:-,
INPUT STAGE
161-3
T61-5
Shunt Voltage (ml') xl pu Current (A) x 7500 0

1000 m V x Shunt Current (A) x Desired Output Voltage
100
.001
ACOM
P15V
ACOM
TPIO
N15V
II,
!'IlJ
N15V
_ ,
TPI2
mv
TP11
P28
TP~
y
5. V
5AV
'" ,:;,,,,
lo-,t/-IOV
200 mV
+-1l:~>---t*-~'.32Kt/,3
TEST
I lOOK
P24/28V
POWER
ON
200K
CW
TEST
TP3
PCOM
TPI4
TB2-7
Figure 5-13. SVIA Simplified Elementary Diagram
5-33
BI006008
GEH-6148
If necessary, adjust EE.1505 (CFBSFO) to produce
5000 counts at 1 pu when the 1 pu current does not
correspond to the drive or exciter's shunt rating, or
when the closest available resistor is not the exact
value found in the above equation. This adjustment is
made using the ST2000 Toolkit (see GEH-5860) or
Drive Configurator, LynxOS Version (see
GEH-6203).
Terminal board point TBl-2 provides the other input

to the input stage differential amplifier. To invert the
polarity of the SVIA output, connect the positive input
to TBl-2, and the negative input to the terminal selected above for the desired input gain.
The input stage voltage can be observed by measuring
between testpoints TP7 (VINI) and TP2 (ACOMIS).
Chapter 7 lists and defmes the SVIA board testpoints.
The input stage features a 2 IlF, 100 V fIlter capacitor
for the TB1-1 input. Jumper 11 is used to select
whether the fIlter capacitor is connected to the input
circuit. The capacitor should be connected for low
impedance input voltages, such as shunt mV signals,
which have a high common mode voltage to ground.
The input stage also features a test circuit used to calibrate the SVIA. Berg-type jumper J2 is used to set the
range of pot R3 (TEST) to either 200 mV or 1O V.
R3 adjusts the dc test voltage output at TBl-4 to the
voltage required by the application. The test voltage
can be observed by connecting a measuring device
between TP3 (TEST) and TP2 (ACOMIS).
stage provides 2500 V rms (continuous) and 3500 V

peak (continuous) common-mode isolation between
any two ports.
5-4.11.3. OUTPUT STAGE. The output stage provides
variable gain and offset for the SVIA. Pots R2 and R1
provide gain and offset adjustment, respectively, for
the output stage. For best performance, configure the
SVIA such that most of the required amplification is
achieved at the input stage; use R2 as a vernier adjustment. Pot RI provides a 20 mV variation in the
output voltage when R2 is fully counterclockwise.
The range of the output voltage is 1O V at 4 rnA

maximum. The SVIA outputs are at terminal board
points TB2-4 and TB2-3.
5-4.11.4. ADJUSTMENT PROCEDURES. For optimal
performance, set the offset and gain of the SVIA as
follows:
1.
Disconnect the input wires and connect TB 1-4 to

the desired input pin of TB 1. Set jumper J2 to the
desired range (1O V or 200 mY). Set 11 to the
OUT position to remove the 2 !IF capacitor from
the input circuit.
2.
Adjust pot R3 (TEST) for 0 V at TBl-4 or TP3

(TEST).
3.
Adjust pot R1 (OFFSET) for 0 V at TP9

(VOUT).
4.
Adjust pot R3 for the desired input voltage and

adjust pot R2 (GAIN) for the desired output voltage.
5.
Set jumper 11 to the IN position if the SVIA is

used as a shunt signal isolator.
5-4.11.2. ISOLATION STAGE. The isolation stage is
powered by an isolated 15 V dc power supply. Input

power to the SVIA can be provided by the most convenient unregulated +24 V dc, 25%, 80 rnA source.
The + 24 V dc input is connected to a + 15 V regulator, used to power the isolated power supply. The
POWER ON LED lights when + 15 V dc is available
at the regulator output. The isolated power supply uses
the + 15 V regulator output to produce separate unregulated 15 V dc, 5 rnA power for the input and
output stages.
Normally open contacts of relay K1 provide an interlock between terminal board points TB2-7 and TB2-8
to indicate a loss of power to the SVIA. The contacts
open when power is lost.
The isolation stage is configured for unity gain to
provide the best common mode rejection and temperature performance, least phase shift, and most stable
gain-versus-frequency characteristics. The isolation
5-34
5-4.11.5. VOLTAGE ISOLATION FUNCTION. Using

input connections TB1-1 and TBI-2, the SVIA can be
used to perform voltage isolation. Armature-level voltages can be further attenuated by connecting an SVAA
board between the shunt and the SVIA. Input TB 1-1
should be used with R11 selected per the following
equation; jumper 11 should be in the OUT position to
remove the fIlter capacitor from the input circuit. Select Rll as shown:
R11
=[
( VIN x 7.5kQ) - 600k0.] x 475kQ.

VOUT
475k0. +600k0.
BI006008
GEH-6148

where V/N is e input voltage to the SVAA, VOUT is
the output volt e of the SVIA, and the SVAA attenuation is set for the default value of 0.442.
J2 to the 10 position to select the 1O V range. This

provides a -2.0 V bias at TBl-3. This configuration
results in an output voltage at TB2-4 of 0-8 V with pot
R2 fully counterclockwise. Adjust R2 to suit the application.
5-4.11.6. CUR ENT SIGNAL CONVERTER. The

SVIA can also e used to convert a 4-20 rnA current
signal into a 0- 0 V dc signal. In this application, connect a 500 n re istor across TBI-I and TBl-2, and
connect the inp t to these points. Connect TBl-4 to
TB 1-3. Insert a 7.5 kQ resistor in R11 and set jumper
5-4.11.7. CONFIGURABLE HARDWARE. Figure 5-14

shows the layout of the SVIA, including the locations
of the jumpers and pots described above. Table 5-12
lists and defmes these items.
'.J
SC1
1--1
_1_
-.l'
::
1-'-1
I
L __
VIN
I
I',--
... ""
'" '"
r,'
c=Jz
T'::ST
[====
-;
I~
rl
[=1
R3
TEST
SOURC'::
'"00
I
U
Lr
SIS
~S
N'SIS
====
VINI
c=J7
PCOM
==:J
DS200SVIAG1 A
P28
13
14
P~
c=Js
P1SP
14
ACOMIS
c=J3
I
-.J
DS
15
c=J1
====
"'0
00
z:l':
,..,
'"
+(\
\0
0"
ACOM
[::=::J1
GAIN
i
~
co
'.J
'" '"
::
TBZ
P15V
ln
[::=::J 11
N1SV
c=J1
... ""
OFFSET
Figure 5-14. SVIA Board Layout
5-35
BI006008
GEH-6148
Table 5-12. SVIA Board Adjustable Hardware

Revision
Name
Description
All
J1
Connects or disconnects input capacitor

Inserts a 2 l!F shunting capacitor across the input terminals. Used for dc voltages less than 100 V dc from
low impedance sources, such as shunt mV signals, across TS1-1 to TS1-2.
IN
Capacitor in for TB1-1 to TB1-2 for signals such as shunt mV signals
OUT Capacitor out for TB1-1 to TS1-2 for voltage signal isolation
All
J2
Range select for test voltage output on TB 1-4

Changes the range of the test output voltage to TB 1-4 and TP3. This test voltage output is adjusted via
pot R3.
200 200 mV range on R3 (TEST)
10 10 volt range on R3 (TEST)
All
R1
Offset potentiometer
R1 is used to adjust the dc offset of the isolator module to zero. With zero volts in on the TB1 input, adjust
R1 for 0.0 volts dc on the output, TB2-4 or TP9.
All
R2
Gain potentiometer
R2 is the gain adjust to obtain the correct dc scaling on the isolator output, TP9 and TB2-4. Typically, R2
is adjusted to give 1 V on the output with 1 per unit current flowing through the instrumented shunt.
All
R3
Test voltage output (TB 1-4l adjust

R3 is used to adjust the dc test voltage output (TB1 -4) to the voltage required by the application. Typically,
the test voltage output will be set the same as the millivolts output of the armature shunt connected to the
input with 1 per unit current flowing.
5-36
BI006008
GEH-6148
CHAPTER 6
1/0 DEFINITIONS
This chapter lis

LEDs for the G
The connectors
board type, and
wiring boards.
and defmes I/O connector points and

2000 Dc Generator Field Exciter.
clude plug-in cable type, terminal
tab terminals located on the printed
User connections - These connectors are located on

boards in the exciter. They carry I/O between
these boards and user connections outside the
GF2000 exciter.
6-2.2. Terminal Board Connectors
This chapter is rganized alphabetically by board

name: section 6 covers the DCFB; section 6-5, the
LTB; section 6- , the NTB/3TB; and so on. Each section contains tab es of I/O defmitions for each connector, stab termin ,and LED on that board. The board
layout figures in Chapter 5 show the locations of these
items on the bo ds.
This type of connector is identified by a TB in its

name. It provides a connection point for individual
wires that carry signals or power. This I/O can be
between a board and components within or outside the
exciter. The wires are secured in the terminal board by
tightening screws at each connection.
6-2.3. Stab Connections (Stabs)

CONNECTORS
6-2.1. Plug-in
onnectors
The type of conn

name, mates wi
carries signal an
externally to cust
provide three typ
ctor, typically identified by PL in its

a cable that plugs into it. The cable
power I/O within the exciter and
mer equipment. Plug-in connectors
s of connections:
Internal board-to
tween boards
cally has the
on each boar
board connections - Carry I/O bein the exciter. The connector typiame name and pinout assignments
.
Board-to-compon
boards and c
ers or semico
connectors ar
nt connections - Carry I/O between

ponents (for example, transformductors) within the exciter. These
commonly 2-pin plugs.
This type of connector is a wide metal post that secures one side of a removable wire jumper. It provides
options for configuring exciter I/O, such as power
requirements.
6-3. LED AND NEON INDICATORS
The GF2000 exciter includes LEDs (light-emitting

diodes) and/or neon lamps on some boards as indicators of a board or exciter condition. The indicators are
located on I/O paths, and turn on or off with the signal
condition.
6-1
BI006008
GEH-6148
6-4. DCFB BOARD I/O

This section defmes I/O points, LEDs, and neon lamps for the DCFB board. Figure 5-2 shows connector, LED, and
neon lamp locations on the board.
Table 6-1. Connector 1PL,
I/O Between DCFB Board and SDCC Card
Pin No.
Nomenclature
Description
FANO
ACCT current.
2 - 5
Not connected.
FAN5
Motor voltage #2 - analog output.
FIG5
FIN5 counter control.
FINO
Dc armature shunt #1 VCO output.
FIN1
Motor field current shunt #1 VCO output.
10
FIN2
Dc armature shunt #2 VCO output.
11
FIN4
V1-V2 ac line voltage feedback.
12
FIN5
Vl-V3 ac line voltage feedback.
13
FIN6
14
15
FIG4
FIN4 counter control.
16
IENREV
Enable reverse armature SCRs.
17
IENFWD
Enable forward armature SCRs.
18
IFF2
Field #2 SCR firing.
19
IFF1
Field #1 SCR firing.
20
A14R
A 14R cell decode signal.
21
A25R
A25R cell decode signal.
22
A36R
A36R cell decode signal.
23
Not connected.
24
A14F
A 14F cell decode signal.
25
A25F
A25F cell decode signal.
26
A36F
A36F cell decode signal.
27
SCRTST
Short circuit SCR test mode select line.
28
XIL
XILINX programmed (0
29
SYNC
Ac line synchronization signal.
30
Yes; 1
= No).
Not connected.
31
IRST1
System reset.
32
FLD1 CTRL
Field #1 control enable.
33
FLD2CTRL
Field #2 control enable.
34
MAC1
MA contactor drive.
35
MAC2
MD contactor #1 drive.
36
MAC3
MD contactor #2 drive.
37
VFBB
Dc voltage feedback testpoint.
38
DTYPE
Drive type (1.8 - 2.2 V dc for GF2000 exciter).
39
FIN7
Generator armature voltage feedback VCO output.
FIN8
Generator field shunt #2 VCO output.
40
6-2
Dc bridge voltage feedback.

Not connected.
BI006008
GEH-6148

I/O Between DCFB Board and NTB/3TB, SDCC, and SLCC Boards
Nomenclature
Description
IPSEN
Power supply enable (active lowl.
-15V
-15 V dc, 5%, to the NTB/3TB, SDCC, and SLCC boards.
+15V
+ 15 V dc, 5%, to the NTB/3TB, SDCC, and SLCC boards.
DCOM
Drive common to the NTB/3TB, SDCC, and SLCC boards.
5, 6
+5V
DCOM
Drive common to the NTB/3TB, SDCC, and SLCC boards.
-24V
-24 V dc, 20%, to the NTB/3TB, SDCC, and SLCC boards.
+24V
Pill No.

I/O Between DCFB Board and NTB/3TB Board
Pin No.
NTB/3TB
Terminal
Nomenclature
Description
85
X2
115 V ac output (unfused side).
83
FX1
115 V ac output (fused side).
81
MANC
Form C normally closed contact from the MA pilot relay (K2).
79
MANO
Form C normally open contact from the MA pilot relay (K2).
77
MACM
Form C common contact from the MA pilot relay (K2).
6-3
BI006008
GEH-6148

I/O Between DCFB Board and PCCA Card
Pin No.
6-4
Nomenclature
Description
A6F
Drives cell 6F gate pulse transformer.
P24
+ 24 volt output.
A5F
P24
+ 24 volt
A4F
P24
+ 24 volt output.
A3F
P24
+ 24 volt output.
A2F
10
P24
+ 24 volt
11
A1 F
12
P24
+ 24 volt
13
A1R
Drives cell 1R gate pulse transformer.
14
P24
+ 24 volt output.
15
A2R
16
P24
+ 24 volt output.
17
A3R
18
P24
+ 24 volt output.
19
A4R
20
P24
+ 24 volt output.
21
A5R
22
P24
+ 24 volt
23
A6R
24
P24
+ 24 volt output.
output.
output.
output.
output.
25
Test attenuation.
26
Test attenuation.
BI006008
GEH-6148

Table 6-5. Connectors CNPL, CPTPL, and FAPL,
I/O Between DCFB Board and Components
~onnector
Nomenclature
Description
X1
MA contactor control output.
----
MA contactor control output.
X2
Pin No.
rNPL
wPTPL
X1
----
Not connected.
DeOM
Common connection.
-------
38 V ac output.
X2
115 V ac output for controller cooling fan.
X1
115 V ac output for controller cooling fan.
APL
38 V ac output.
Table 6-6. Connectors IA 1PL, IA2PL, IF1 PL, and IF2PL,

I/O Between DCFB Board and Shunts
Con ~ector
Pin No.
IA1 L
1
2
IA2 L
1
2
IF1FL
1
2
IF2F L
1
2
Nomenclature
Description
-------------
Generator armature current shunt input (+), red.
-------------
Generator armature current shunt input (-), white.

Motor #2 armature current (+), red.
Motor #2 armature current (-), white.
Motor field current shunt input (+), red.
Motor field current shunt input (-), white.
Generator field current shunt input (+), red.
Generator field current shunt input (-), white.
Table 6-7. Connector MA CPL,

I/O Between DCFB Board and Contactor Driver Circuits
Nomenclature
Description
----
MD #1 contactor control common output.
----
MD #1 contactor control 24 V dc output.
----
MD #2 contactor control common output.
----
MD #2 contactor control 24 V dc output.
Pin No.
6-5
BI006008
GEH-6148
Table 6-8. DCFB Board Stab Terminal Connections

Stab
Description
V1
Phase A ac line voltage.
V2
Phase B ac line voltage.
V3
Phase C ac line voltage.
P1A
Dc bridge voltage (+).
P2A
Dc bridge voltage (-).
VM1A
Generator armature voltage ( + ).
VM1B
Generator armature voltage (-).
VM2A
Motor armature voltage (+).
VM2B
Motor armature voltage (-).
Table 6-9. Neon Lamps and LEDs on DCFB Board
6-6
Name
Indication
CR51
(LED) When lit (red), indicates that fuse FU2 in the + 24 V dc line
to the + 15 V dc regulator is blown.
CR55
(LED) When lit (red), indicates that fuse FU3 in the -24 V dc line
to the -15 V dc regulator is blown.
LT1
(Neon lamp) When lit, indicates that fuse FU1 in the 115 V ac
line to CNPL-1, CPTPL-2 and FAPL-2 is blown.
BI006008
GEH-6148
6-5. FEeB B
This section d mes I/O points for the FECB board. Figure 5-3 shows connector locations on the board.
Table 6-10. FEeB Board Stab Terminal Connections

Stab
Nomenclature
Description
Ell
Connects to SCR anode.
E3l - E33
Not connected.
E42
Connects to SCR cathode.
E5l
CFIRE
Connects to SCR gate.
E52
CATCOM
Connects to SCR cathode.
6-7
BI006008
GEH-6148
6-6. LTB BOARD I/O
This section defmes 110 points and LEDs for the LTB board. Figure 5-4 shows connector and LED locations on the
board.
Table 6-11. Connector BPL,

I/O Between LTB, NTB/3TB, and SDCC Boards
Pin No.
NTB/3TB
Terminal
Nomenclature
Description
FA
Non-inverting RS-422 half-duplex serial data line from the SDCC's Motor
Control Processor (MCP) UART.
FB
Inverting RS-422 half-duplex serial data line from MCP UART.
10
DCOM
Signal return for EXSY (at COM potential).
12
EXSY
External sync input to MCP.
--
----
Not connected.
EOAB
Encoder interface Channel A non-inverted differential input.
IEOAB
Encoder interface Channel A inverted differential input. (Tie to COM for

single-ended encoders.)
EOBB
Encoder interface Channel B non-inverted differential input.
IEOBB
Encoder interface Channel B inverted differential input. (Tie to COM for

single-ended encoders.)
10
EOMB
Encoder interface marker channel non-inverted differential input.
11
11
IEOB
Encoder interface marker channel inverted differential input. (Tie to COM

for single-ended encoders.)
12
--
----
Not connected.
13
14
Cll
Cll - CI8 are general-purpose control inputs, 24 V dc maximum with 27

kO input impedance.
14
16
CI2
See Cll (pin 13).
15
18
CI3
See Cll (pin 13).
16
20
CI4
See Cll (pin 13).
17
22
CI5
See Cll (pin 13).
18
24
CI6
See Cll (pin 13).
19
26
CI7
See Cll (pin 13).
20
28
CI8
See Cll (pin 13).
6-8
BI006008
GEH-6148
GF2000 Dc Gl nerator Field Exciter

Table 6-12. Connectors IN1 Through IN8,
Inputs to LTB Board
Pin No.
Non enclature
Description
INx-~
24 - 240 V ac or dc input logic signal is brought in on INx + and INx- where + is for
the high or hot side and - is for the low or ground side. Each input draws 6 mA maximum. The signal is converted to a 24 V dc logic signal for the SDCC.
Not connected.
INx
24 - 240 V ac or dc input logic signal is brought in on INx + and INx- where + is for
the high or hot side and - is for the low or ground side. Each input draws 6 mA maximum. The signal is converted to a 24 V dc logic signal for the SDCC.
Number here (x) corresponds to input circuit (IN) number.

I/O Between L TB Board and SL CC Card
Pin No.
Nomenclature
Description
P24
+24 V dc.
112 - 118
24 V logic lines to the exciter.
----
Not connected.
17
N24
-24 V dc.
18
111
24 V logic line to the exciter.
101-107
Relay control lines 0 through 6.
P24
+24 V dc.
1
2-8
9 - 16
19 - 25
26
Table 6-14. Connector OPTPL,

I/O Between L TB Board and NTB/3TB Board
Pin No.
Nomen lature
Description
X2
Return for CFXl 120 V ac loads (isolated from COM). Same as NTB/3TB pin 85.
CFXl
120 V ac, 15%, from NTB/3TB board, fused at 500 rnA, including internal fans
(isolated from COM). Same as NTB/3TB pin 83.
6-9
BI006008
GEH-6148
Table 6-15. Connectors 071 Through OT7,

LTB Board Connections from Form C Relay Contacts
Nomenclature
Description
OTxCM*
Relay common connection; contact rating is 0.6 A @ 125 V ac, 0.6 A @

110 V dc, 2.0 A @ 30 V dc.
OTxNC*
Relay normally closed (NC) connection; contact rating is 0.6 A @ 125 V

ac, 0.6 A @ 110 V dc, 2.0 A @ 30 V dc.
OTxNO*
Relay normally open (NO) connection; contact rating is 0.6 A @ 125 Vac,
0.6 A @ 110 V dc, 2.0 A @ 30 V dc.
Pin No.
Number here (x) corresponds to relay output circuit (aT) number.
Table 6-16. Connector RPL,

I/O Between LTB Board and RTBA Board
Pin No.
Nomenclature
Description
X2
Return for CFX 1 120 V ac loads (isolated from COM). Same as OPTPL-1 .
2
3
Not connected.
RX1
4
5
Not connected.
RX2
RX3
RX4
10
11
RX5
RTBA relay RX5 pilot output.

Not connected.
RX6
14
15

Not connected.
12
13

Not connected.

Not connected.
6
7
RTBA relay RX 1 pilot output.

Not connected.
RX7
16

Not connected.
Table 6-17. LEDs on LTB Board

LED Name
1 - B
17 - 23
6-10
Indication
On when the source is applied to circuits IN 1 through INB, respectively.
On when Relay RX1 through RX7, respectively, is energized.
BI006008
GEH-6148
6-7. NTB/3TE BOARD I/O
This section de mes I/O points for the NTB/3TB board. Figure 5-5 shows connector locations on the board.
Previous tables defme other NTB/3TB I/O: Table 6-2 for connector 2PL; Table 6-3 for 4PL; Table 6-11 for 8PL, and
Table 6-14 for )PTPL.
Table 6-18. Connector 3 TB,

I/O Between NTB/3TB and External Connections
3TB
Terminal
No ~enclature
Description
EO..
Non-inverting differential input for Encoder #0, channel A.
EO\ 1
Positive side of power supply with balun choke for Encoder EOA/EOB. Either + 5 or
+ 15 V dc as set by NTB/3TB jumper JP12.
lEO
EO\i 2
Return for EOV1, basically at COM potential.
EOB
Non-inverting differential input for Encoder #0, channel B.
FA
Non-inverting RS-422 half-duplex serial data line. Provides a serial channel into the
SDCC's MCP (as opposed to the RS-232C channel into the SDCC's DCP). Jumpers
JPl and JP2 are used to connect line termination resistors to FA and FB (needed at
each end of an RS-422 network).
/EOE
Inverting differential input for Encoder #0, channel B.
FB
Inverting RS-422 half-duplex serial data line (see FA, 3TB point 6).
EOM
Encoder interface marker pulse channel non-inverted differential input.
10
FCO VI
Signal return for EXSY (at COM potentia/).
11
/EOIV
Encoder interface marker pulse channel inverted differential input.
12
EXS
External sync input to SDCC's Motor Control Processor.
13
R1C
Relay #1 common contact.
14
Cll
Cll - CI8 are general-purpose control inputs, 24 V dc maximum with 27 kn input

impedance.
15
R1NC
Relay #1 normally closed contact.
16
CI2
See Cll (3TB point 14).
17
R1NC
Relay #1 normally open contact.
18
CI3
19
R2C
20
CI4
21
R2NC
22
CI5
23
R2NO
24
CI6
25
R3C
26
CI7
27
R3NC
28
CI8
29
R3NO
Inverting differential input for Encoder #0, channel A.
6-11
BI006008
GEH-6148
Table 6-18. Connector 3TB - Continued,

3TB
Terminal
Nomenclature
Description
30
RF24(1 )
Voltage reference for digital control inputs. Defaulted to -24 V dc; changes to + 24 V
dc via NTB/3TB's jumpers JP1 0 and JP11. Each digital control input is active when
connected to RF24, inactive when open. Total 24 V dc load includes loading on
RF24.
31
R4C
32
RF24(2)
Voltage reference for digital control inputs (see RF24[1], 3TB point 30).
33
R4NC
34
RUN
General-purpose input. Defaulted to, but not limited to, RUN function.
35
R4NO
36
JOG
General-purpose input. Defaulted to JOG function.
37
R5NO
38
POL
General-purpose input. Defaulted to the reference polarity function.
39
R5NC
40
XSTP
General-purpose input. Defaulted to the XSTOP function (normally closed).
41
R5C
42
CTLN1
Control on input 1. CTLN1 and CTLN2 (3TB point 44) form part of the circuit that
picks up the MA contactor pilot relay. They must be connected together for the exciter to run. Can also be used to connect external interlocks, providing a fail-safe
(microprocessor independent) way to stop the exciter.
43
R6NO
44
CTLN2
Control on input 2 (see CTLN 1, 3TB point 42).
45
R6C
46
P1
P1 through P4 are medium-resolution analog input channels for voltages from 5 V dc

to 50 V dc. Scaled via respective pots P1 through P4 on the NTB/3TB. Input impedance ~ 10 kn.
47
MSRF
Relay #6 coil driver (Master Sync Reference output), open collector output. When
inactive, MSRF is pulled up to + 24 V dc through 1400 n maximum. When active,
MSRF is pulled down to 1.5 V dc maximum through 200 n, not including a maximum
drop of 3.4 V across the 200 n due to the relay #6 coil load. If internal control of
this relay is not required, relay #6 may be picked up by an external driver capable of
pulling MSRF down to 1.5 V dc maximum sinking 17 mAo
48
P2
See P1 (3TB point 46).
49
DVM
Medium resolution analog input channels, with fixed scaling for 51.0 V dc max
(25.5 on early DCC cards). Input impedance and filtering is 511 kn and 100 ms. In
conjunction with exciter test 03, provides a digital voltmeter function with at least
0.5% accuracy for diagnostic functions.
50
P3
51
ASPO
Medium-resolution analog input channel with fixed scaling for 5 V dc maximum.

Input impedance and filtering is 10 kn and 1 ms.
52
P4
53
DAC1
Output from 8-bit (DCC and SDCCG3) or 12-bit (SDCCG1) D/A converter. Can source
10 V dc at no load or 8 V dc at a 10 mA load (200 n series impedance). Any exciter variable can be sent to this output and can be scaled to set the value corresponding to 10 V dc output. If the variable attains a magnitude greater than this
value, the output is clamped to 1 0 V, rather than rolling over. (For diagnostics and
system applications.)
6-12
BI006008
GEH-6148

Tab/e 6-18. Connector 3TB - Continued,
//0 Between NTB/3TB and Externa/ Connections
3TB
Terminal
Nc menclature
Description
54
M T1
Output from 8-bit D/A converter. Can source 1 0 V dc at no load or 8 V dc at a 10

mA load (200 n series impedance). Any exciter variable can be sent to this output
and can be scaled to set the value corresponding to 10 V dc output. If the variable
attains a magnitude greater than this value, the output is clamped to 1 0 V, rather
than rolling over. (Provided for meter driver functions.)
55
DA C2
Same as DACl (see 3TB point 53).
56
MET2
Same as METl (see 3TB point 54).
57
M~SY
Input to internal interrupt INTO of the SDCC's Drive Control Processor (DCP). Biased
to + 24 V dc though 27 kn, must be pulled to COM (less than + 1.5 V dc) to be recognized by the DCP.
58
RE ET
Hard reset input to the exciter. Connecting RESET to + 5 to + 24 V dc resets all

processors in the exciter. Leaving RESET open or connecting to COM allows exciter
operation. The SDCC provides a 20 ms noise filter on this input.
59
TOIN
Input to internal timer/counter 0 of the SDCC's Drive Control Processor (DCP). Biased
to + 24 V dc through 27 kn, and must be pulled to COM (less than + 1.5 V dc) to be
recognized by the DCP.
60
+5 VDC
+ 5 V dc source, 1 0%, 300 mA (including load on EOV1 and El Vl).
61
TOe UT
TTL output through 200 n from DCP's timer/counter 0 (on SDCC).
62
+1 VDC
+ 15 V dc source, 1 0%, 300 mA (including load on EOVl and El Vl).
63
REFP
Non-inverting differential analog reference input. Maximum reference can be 9 to 29

V dc, coarsely selected by NTB/3TB's switches SW1 through SW7. Fine scaling provided by EE.1281 (RVSCLn). This circuit uses a VCO similar to the one used by FDBP
and FDBN. Input impedance is at least 60 kn with less than 1 ms of filtering. If this
circuit is not needed for the exciter speed reference, the digitalization of this input is
available for other functions requiring high resolution.
64
-15\ DC
-15 V dc source, 1 0%, 300 mA (including load on El Vl).
65
REF
Inverting differential analog reference input, with REFP, 3TB point 63.
66
cor-.
(1)
o V common reference for all exciter I/O. COM should be
used for signal level returns
only.
67
RSV ~(1 )
Not used. Provides voltage clearance between signal-level points and points with potentials above 50 V.
68
co M(2}
oV
69
FDBF
Non inverting differential analog tach input (with 3TB point 73). Either ac AN or dc
tachometers with a top speed voltage from 25 to 390 V (6 to 65 V if jumper JP7 on
the SDCC card is in the 2-3 position) can be connected to these differential inputs.
NTB/3TB's DIP switches SWl through SW7 provide coarse scaling. SDCC's jumper
JP8 and EE.1386 (FVSCLn) provide fine scaling and analog ac AN tach rectification.
Input impedance of this circuit is at least 300 kn, with less than 1.5 ms of filtering.
If this circuit is not needed for the exciter speed feedback, the digitalization of this
input is a available for other functions requiring high resolution.
common reference for all exciter I/O, same as 3TB point 66.
70
+24 DC
+24 V dc source, 25%, unregulated, 500 mA (including load on RF24).
71
RSVC(2)
72
-24V[ C
-24 V dc source, 25%, unregulated, 500 mA (including load on RF24).
73
FDBN
Inverting differential analog tach input (with 3TB point 69).
74
E1Vl
Power supply with balun line choke for encoders on SPC card. Either -15V dc or
same voltage as EOVl (+ 5 or + 15 V dc) as selected using NTB/3TB jumper JP13.
6-13
BI006008
GEH-6148
Table 6-18. Connector 3TB - Continued,

3TB
Terminal
Nomenclature
Description
75
RSVD(3)
76
E1V2
Return for E1 V1, basically at COM potential.
77
MACM
Form C common contact from MA pilot relay; auxiliary contact from the relay used to
pilot the MA contactor. Rated for 125 V ac, 2A.
78
RSVD(4)
79
MANO
Form C normally open contact from the MA pilot relay; auxiliary contact from the
relay used to pilot the MA contactor. Rated for 125 V ac, 2A.
80
GRC1
General-purpose relay common contact of first form C. Rated for 120 V ac, 0.5 A.
81
MANC
Form C normally closed contact from the MA pilot relay; auxiliary contact from the
relay used to pilot the MA contactor. Rated for 125 V ac, 2A.
82
GNC1
General-purpose normally closed contact.
83
CFX1
120 V ac source from drive, 1 5%, fused at 500 mA (isolated from COM).
84
GN01
General-purpose relay normally open contact.
85
X2
Return for CFX1 120 V ac loads (CFX1 and X2 isolated from COM).
86
GRC2
General-purpose relay common contact of second from C. Rated 120 V ac, 0.5 A).
87
GR+
GR + and GR- (3TB point 89) are coil inputs to a general purpose relay. This relay is
not internally connected to any exciter circuitry, and may be used as required for customer applications. The coil may be driven by 24 V or 120 V, either ac or dc, as selected using jumper JP20.
88
GNC2
General-purpose relay normally closed contact. Rated 120 V ac, 0.5 A.
89
GR-
See GR + (3TB point 87).
90
GN02
General-purpose relay normally open contact. Rated 120 V ac, 0.5 A.
91
VC3N
Inverting differential analog input for auxiliary VCO #3. The top reference voltage
may be 9 to 29 V de. Jumpers JP14 and JP1 5 provide coarse scaling of the inputs.
This circuit uses a VCO similar to the one used by REFP and REFN. Input impedance
is at least 60 kO with less than 1 ms of filtering. The digitalization of this input is
available at VAR.184 for functions requiring a high-resolution analog input by using
BLK.263 (V3VCO). (An SDCC card is required to support VCO #3; it is not available
on the DCC card.)
92
VC4N
Inverting differential analog input for auxiliary VCO #4. The top reference voltage
may be 9 to 29 V de. Jumpers JP22 and JP23 provide coarse scaling of the inputs.
This circuit uses a VCO similar to the one used by REFP and REFN. Input impedance
is at least 60 kO with less than 1 ms of filtering. The digitalization of this input is
available at VAR.185 for functions requiring a high-resolution analog input by using
BLK.264 (V4VCO). (An SDCC card is required to support VCO #4, it is not available
on the DCC card.)
93
VC3P
Non-inverting differential analog input for auxiliary VCO #3.
94
VC4P
95
MET3
10 V dc analog output from an 8-bit D/A converter (see 3TB point 54).
6-14
BI006008
GEH-6148
GF2000 Dc Geperator Field Exciter

I/O Between NTB/3TB Board and SDCC Card
Pin No.
NTf 13TB
Ter ninal
Nomenclature
Description
CTLN1
Control on input 1. CTLNl and CTLN2 (3TB point 44) form part of the
circuit that picks up the MA contactor pilot relay. They must be connected together for the exciter to run. Can also be used to connect external interlocks, providing a fail-safe (microprocessor independent) way
to stop the exciter.
CTLN2
See CTLN2 (pin 1).
LBIAS
24 V de bias for digital inputs from NTB/3TB (for + or - logic).
~4
:;1
TOOUT
TTL output through 200 n from DCP's timer/counter 0 (on SDCC).
64
RUN
1S6
JOG
POL
XSTP
General-purpose input. Defaulted to XSTP function (normally closed).
MSRF
Relay #6 coil driver (Master Sync Reference output), open collector output.
10- 14
R01 - R05
NTB/3TB relay coil output driver lines 1 through 5.
15
P3B
Scalable general-purpose analog input from NTB/3TB.
16
P4B
Scalable general-purpose analog input from NTB/3TB.
17
! 1
ASPO
Medium-resolution analog input channel with fixed scaling for 5 V dc

maximum. Input impedance and filtering is 10 kO and 1 ms.
18
VC3NB
Inverting differential analog input to SDCC auxiliary VCO #3.
VC3PB
Non-inverting differential analog input to SDCC auxiliary VCO #3.
P1A, P1 B
Scalable general-purpose analog inputs from NTB/3TB.
22
----
Not connected.
23
4\9
DVM
Medium resolution analog input channels, with fixed scaling for 51 .0 V

dc max (25.5 on early DCC cards). Input impedance and filtering is 511
kn and 100 ms. In conjunction with exciter test 03, provides a digital
voltmeter function with at least 0.5% accuracy for diagnostic functions.
24
53
DA1
Output from 8-bit (DCC and SDCCG3) or 12-bit (SDCCG1) D/A converter. Can source 1 0 V dc at no load or 8 V dc at a 10 mA load (200
n series impedance). Any exciter variable can be sent to this output and
can be scaled to set the value corresponding to 10 V dc output. If the
variable attains a magnitude greater than this value, the output is
clamped to 10 V, rather than rolling over. (For diagnostics and system
applications.)
19
20, 21
25
50
DA2
Same as DA 1 (pin 24).
26
MET1
Output from 8-bit D/A converter. Can source 1 0 V dc at no load or 8

V dc at a 10 mA load (200 n series impedance). Any exciter variable can
be sent to this output and can be scaled to set the value corresponding
to 10 V dc output. If the variable attains a magnitude greater than this
value, the output is clamped to 1 0 V, rather than rolling over. (Provided
for meter driver functions.)
27
5E
MET2
Same as MET1 (pin 26).
28
MSSY
Input to internal interrupt INTO of the SDCC's Drive Control Processor

(DCP). Biased to +24 V dc though 27 kO, must be pulled to COM (less
than + 1.5 V dc) to be recognized by the DCP.
6-15
BI006008
GEH-6148
Tab/e 6-19. Connector 6PL - Continued,

//0 Between NTB/3TB Board and SDCC Card
Pin No.
NTB/3TB
Terminal
Nomenclature
Description
29
59
TOIN
Input to internal timer/counter 0 of the SDCC's Drive Control Processor

(DCP). Biased to + 24 V dc through 27 kn, and must be pulled to COM
(less than + 1.5 V dc) to be recognized by the DCP.
30
58
RESET
Hard reset input to the exciter. Connecting RESET to + 5 to + 24 V dc

resets all processors in the exciter. Leaving RESET open or connecting to
COM allows exciter operation. The SDCC provides a 20 ms noise filter
on this input.
31
----------
TDB
RS-232C channel transmitted from DCP.
RDB
RS-232C channel received by the DCP.
CTSB
RS-232C channel clear-to-send handshake.
RTSB
RS-232C channel c1ear-to-receive handshake.
VC4NB
Inverting differential analog input for SDCC auxiliary VCO #4.
VC4PB
Non-inverting differential analog input for SDCC auxiliary VCO #4.
RFNB
Differential analog input from NTB/3TB to reference VCO, negative line.
RFPB
Same as pin 37, but positive line.
FBNB
Differential analog input NTB/3TB to feedback VCO, negative line.
FBPB
Same as pin 39, but negative line.
32
33
34
35
36
37
38
39
40
Tab/e 6-20. Connector COMPL,

RS-232C //0 Between NTB/3TB Board and User Interface
Pin No.
1 - 25
Nomenclature
Description
The exciter includes an RS-232C connection only for use as a serial link with the
ST2000 Toolkit or Drive Configurator, LynxOS Version. These software packages are
diagnostic and configuration programs used during installation, tuneup, and troubleshooting. GE does not intend this communications link to be used for any other purpose.
CAUTION
Do not connect pin 25 of COMPL directly to a PC (personal computer) unless jumper JP21 is in the 1-2
position, or damage may occur.
NOTE
Although the RS-232C interface should work correctly with all 25 pins of COMPL connected, using the
minimum possible interface avoids incompatibility and noise problems.
6-16
BI006008
GEH-6148
GF2000 Dc Ge nerator Field Exciter

6-8. PCCA CJ RD I/O
This section de mes I/O points for the PCCA card. Figure 5-6 shows connector locations.
For connector 51PL, see Table 6-4.
Table 6-21. Connectors 1FPL Through 6FPL and 1RPL Through 6RPL,
Output from PCCA Card to SCR Bridge
onnector
Pin No.
Description
Forward gate pulse to corresponding SCR (red wire).
FPL - 6FPL
2
RPL - 6RPL
Forward gate pulse to corresponding SCR (white wire).

Reverse gate pulse to corresponding SCR (red wire).
Reverse gate pulse to corresponding SCR (white wire).
Table 6-22. PCCA Card Stab Terminal Connections

Stab
Card Group No.
Description
Pl
Gl - 4, 7 - 10
Positive dc bus.
Pl A, Pl B
Gl - 4,7 - 10
Positive dc bus voltage feedback. When wire jumper WJ3 is connected between these terminals, the card snubber capacitors are connected to the
same point on the bridge as the voltage feedback channel (see Table 5-4).
P2
Gl - 4, 7 - 10
Negative dc bus.
P2A, P2B
Gl-4,7-10
Positive dc bus voltage feedback. When wire jumper WJ4 is connected between these terminals, the card snubber capacitors are connected to the
same point on the bridge as the voltage feedback channel (see Table 5-4).
P3 - Pl0
Gl - 4,7 - 10
Voltage feedback scaling resistor connections (see Table 5-4).
DCS
Gl - 4, 7 - 10
To dc snubber circuit.
lACS - 6ACS
Gl,2,7,8
To ac snubber circuits.
6-17
BI006008
GEH-6148
6-9. RTBA BOARD 1/0
This section defmes I/O points and LEDs for the RTBA board. Figure 5-7 shows connector and LED locations.
For connector RPL, see Table 6-16.
Table 6-23. Connector RTBA,

I/O Between RTBA Board and External Connections
RTBA
Terminal
RTBA
Terminal
Nomenclature *
RTBA
Terminal
Nomenclature *
K20A
18
K221 NC
35
K242NC
K201NO
19
K222NO
36
K25A
K201CM
20
K222CM
37
K251NO
K201NC
21
K222NC
38
K251CM
K202NO
22
K23A
39
K251NC
K202CM
23
K231NO
40
K252NO
K202NC
24
K231CM
41
K252CM
K21A
25
K231NC
42
K252NC
K211NO
26
K232NO
43
K26A
10
K211 CM
27
K232CM
44
K261 NO
11
K211NC
28
K232NC
45
K261CM
12
K212NO
29
K24A
46
K261 NC
13
K212CM
30
K241 NO
47
K262NO
14
K212NC
31
K241CM
48
K262CM
15
K22A
32
K241 NC
49
K262NC
16
K221NO
33
K242NO
50
KCM
17
K221CM
34
K242CM
51
115V
6-18
Nomenclature*
The RTBA board contains seven relays that have two form C contacts. Nomenclature for the
terminal board points indicates the contact connection. For example, the terminal board point
K201NO: K = relay; 20 = which of the seven relays (20 - 26); 1 = which of the two form
C contacts; and NO = normally open, as opposed to normally closed (NC) or common (CM).
BI006008
GEH-6148

Table 6-24. Connectors CP1 PL Through CP5PL and Y9PL Through Y35PL,
RTBA Pluggable Circuits
Connectpr
Description
CP1 PL - CP5PL, pin 1
Pluggable circuit control power, positive (hot) side (CPH).
CP1 PL - CP5PL, pin 2
Pluggable circuit control power, negative side (CPN).
Y9PL-1
CPH.
Y9PL-2
Connected to Y1 OPL-1 . Y9PL and Y1 OPL form a powered pluggable circuit.
Y10PL-1
Connected to Y9PL-2.
Y10PL-2
CPN.
Y11PL-1
CPH.
Y11 PL - Y14PL
Two-position plugs forming a series string to coil of relay K27.
Y15PL
Jumpers Y18PL-2 to CPN.
Y16PL
Relay K27 normally open contacts.
Y17PL
Relays K27 and K28 dry contacts in series.
Y18PL
Relays K28 and K29 coil leads.
Y1 9PL - Y22PL
Pluggable control circuit with K28 interlock.
Y23PL,
'< 24PL
Y25PL - ~28PL
Y29PL,
'< 30PL
Dry circuit with K29 contact.

Dry circuit with K29 contact.
Y31 PL - Y34PL
Y35PL - rt'37PL
Pluggable control circuit.
Table 6-25. LEDs on Relays of RTBA Board
LED on
Relay's Name
K20 - K29
Indication
On when relays K20 though K29 (respectively) are energized.
6-19
BI006008
GEH-6148
6-10. SDCC CARD I/O
This section defines I/O points and LEOs for the SOCC card. Figure 5-8 shows connector and LEO locations.
Previous tables defme other SOCC I/O: Table 6-1 for connector IPL; Table 6-2 for 2PL; Table 6-19 for 6PL; and
Table 6-11 for 8PL.

SDCC Card Output to SLCC Card
Pin No.
Nomenclature
Description
BDO - BD7
Buffered, multiplexed SDCC Drive Control Processor (DCP) data bus lines 0 - 7.
DCOM
Power supply return, common.
10
P5
+5
11
IRST3
System reset signal (active low).
12
LINT
Interrupt from SLCC/SDCC microapplication chip to DCP.
13
ILBSY
Busy bus control handshake to DCP.
14
BA12
Buffered address latch enable from DCP.
15
DCOM
16
IBCSL
SLCC chip select.
17
IBRD
Buffered read control line from DCP.
18
IBWR
Buffered write control line from DCP.
19
BA8
Buffered, demultiplexed DCP address line 8.
20
BA9
Buffered, demultiplexed DCP address line 9.
21
IBCSU
SDCC microapplication chip select.
22
BA10
Buffered, demultiplexed OCP address line 10.
23
BA11
Buffered, demultiplexed OCP address line 11.
DCOM
P5
+5 V
BAO - BA7
Buffered, demultiplexed OCP address lines 0 through 7.
1 - 8
24, 25
26
27 - 34
6-20
V dc regulated power supply for digital circuits.
dc regulated power supply for digital circuits.
BI006008
GEH-6148

I/O Between SDCC Card and SPC Card
Nomenclature
Description
SPA1
5 V dc SPC analog channel #1.
SPA2
5 V dc SPC analog channel #2.
Pin No
E1Z
Marker channel from encoder #1 interface.
E2Z
Marker channel from encoder #2 interface.
N15
-15 V dc power supply for analog circuits on SPC card.
P15
+ 15 V
dc power supply for analog circuits on SPC card.
DCOM
SPRS
Digital output from DCP to SPC card.
DCOM
10
P5
+5 V
11
E1UP
Up channel output from encoder #1 interface.
12
E1DN
Down channel output from encoder #1 interface.
13
E2UP
Up channel output from encoder #2 interface.
14
E2DN
Down channel output from encoder #2 interface.
15
ORST7
System reset (active low).
16
DCOM
17,18
----
Not connected.
19
SPTX
20
SPRX
+5 V
+5 V
dc power supply for digital circuits on SPC card.
dc output from SDCC's Motor Control Processor (MCP) UART.

dc input to MCP UART.
Table 6-28. Connector 11 PL,

SDCC Output to Meters
Pin No.
Nomerclature
Description
DCOI'J
Drive common connection.
MTR1
MTR1 through MTR4 are outputs from an 8-bit D/A converter and can source 1 0 V
dc at no load or 8 V dc at 10 rnA load (200 n series impedance), Any exciter variable
can be steered to these D/A outputs and can be scaled to set what value corresponds
to the 10 V dc output. These outputs are for meter driver functions.
MTR2
See MTR1 (pin 4).
MTR3
See MTR1 (pin 4).
MTR4
See MTR1 (pin 4).
DCOM
Drive common connection.
1,2
Not connected.
9,10
Not connected.
Table 6-29. LEDs on SDCC Card
LED Name
Indi ation
Bar raph LED indicating fault patterns showing whether the exciter is healthy, and stopped or running When the exciter has a fault, the graph displays the fault code number. For a detailed description of fault codes, see Chapter 10.
6-21
BI006008
GEH-6148
6-11 . SLCC CARD I/O
This section defmes I/O points for the SLCC card. Figure 5-9 shows connector locations.
Previous tables defme other SLCC I/O: Table 6-2 for connector 2PL; Table 6-13 for IOPL; and Table 6-26 for 3PL.
Table 6-30. Connector ARCPL,

I/O Between SLCC Card and DLAN or ARCNET
Nomenclature
Description
TXA-
Transmitting and receiving signals, channel A.
TXA+
TXB-
Transmitting and receiving signals, channel B.
TXB+
P5
+ 5 V dc power.
DCOM
Power digital common.
TXB
Transmitting signal selected by JP1 5 as isolated DLAN circuit or RS-422.
TXA
Receiving signal selected by JP1 5 as isolated DLAN circuit or RS-422.
Pin No.
Table 6-31. Connector KPPL,

I/O Between SLCC Card and Keypad
Pin No.
Nomenclature
1 - 9
6-22
Description
Keypad connectors to processor; Output from U1 to pins 19 - 32, respectively.
10
LODIN
Display; Input to U1 pin 38.
11
LDCLK
Display; Input to U1 pin 39.
BI006008
GEH-6148

6-12. SPC CARD 1/0
This section defi~es I/O points for the SPC card. Figure 5-10 shows connector locations.
For connector T. 'L, see Table 6-27.
Table 6-32. Connectors 16PL and 1TB,

I/O Between SPC Card and External Connections
16PL
Pin No.
1
2
3
4
5
6
HS
Term nal
-------
Nomenclature
Description
E1AB
Non-inverting input for encoder #1 channel A
IE1AB
Inverting input for encoder #1 channel A.
E1BB
Non-inverting input for encoder #1 channel B.
IEl BB
Inverting input for encoder #1 channel B.
E1MB
Non-inverting input for encoder #1 marker channel.
IE1MB
Inverting input for encoder #1 marker channel.
E2AB
Non-inverting input for encoder #2 channel A.
IE2AB
Inverting input for encoder #2 channel A.
E2BB
Non-inverting input for encoder #2 channel B.
10
IE2BB
Inverting input for encoder #2 channel B.
11
E2MB
Non-inverting input for encoder #2 marker channel.
12
IE2MB
Inverting input for encoder #2 marker channel.
13
PFl N
Inverting input for analog channel SPA 1 (VAR.256).
14
PF1P
Non-inverting input for analog channel SPA 1 (VAR.256).
15
PF2N
Inverting input for analog channel SPA2 (VAR.257l.
16
10
PF2P
Non-inverting input for analog channel SPA2 (VAR.257).
17
11
TXP
Non-inverting RS-422 output from SDCC's Motor Control Processor

(MCP).
18
12
TXN
Inverting RS-422 output from MCP.
19
13
RXN
Inverting RS-422 input to MCP.
20
14
RXP
Non-inverting RS-422 input to MCP.
6-23
BI006008
GEH-6148
6-13. SVAA BOARD I/O
This section defmes I/O points for the SVAA board. Figure 5-12 shows connector locations.
Table 6-33. SVAA Board Terminal Connections
Terminal
6-24
Description
SC1
Attenuator voltage input #1 (+).
SC2
Attenuator voltage input #1
SC3
Attenuator voltage output #1 (+).
SC4
Attenuator voltage output #1
SC5
Attenuator voltage input #2 {+ j.
sca
Attenuator voltage input #2
SC7
Attenuator voltage output #2 (+).
SCB
Attenuator voltage output #2
(-j.
{oj.
(oj.
(-j.
BI006008
GEH-6148
GF2000 Dc Ge ~erator Field Exciter

6-14. SVIA BC~ARD I/O
This section def Illes I/O points and the POWER ON LED for the SVIA board. Figure 5-14 shows connector and LED
locations.
Table 6-34. SVIA Board Terminal Board Connections
Connector
T rminal
Nomenclature
Primary positive input, using custom gain resistor R11. Input TB1-1 is
normally connected to the positive side of the shunt terminal. This input goes into resistor R11, the gain select resistor connected to the
saddle clamp terminals (see section 5-4-10 for instructions on selecting
the value for resistor R11).
TB1
ACOM
Negative input. This input is typically connected to the negative side of

the shunt terminal.
----
Alternate unity preamp gain (7.5 kO) input.
VTEST
Output connection for a test voltage source. Typically used to set the
scaling of the SVIA isolator. Refer to Table 5-11 for information on
using J2 for range selection and R3 for voltage adjustment.
Alternate input with preamp gain of 16 (475 OJ.
----------
NMAX
Most negative output. This signal represents the SVIA output through a
diode such that if multiple SVIAs are connected together via this signal,
the interconnection point represents the most negative of all the SVIAs
connected.
PMAX
Most positive output. This signal represents the SVIA output through a
diode such that if multiple SVIAs are connected together via this signal,
the interconnection point represents the most positive of all the SVIAs
connected.
ACOM
Output common. This terminal is the overall output signal common.

When the SVIA is connected to a differential receiver or VCO, this signal is connected to the low side of the receiver.
TB2
Description
Alternate input with preamp gain of 34 (221 OJ.

Alternate input with preamp gain of 75 (1000).
Output signal. This terminal is the overall output signal. Typically the
output voltage is 1 V = 1 per unit armature current. The SVIA is capable of 1 OV at 4 mA maximum.
P28
+ 24 V dc input. Connected to the high side of an external + 24 V dc

power supply which powers the SVIA.
PCOM
+ 24 V dc common. Connected to the low side of an external

dc power supply which powers the SVIA.
+ 24
Power OK form A contact. Terminal to connect the power supply monitor relay contact to an external device. Typically trips the exciter if this
contact opens.
Power OK form A contact.
Table 6-35. LED on SVIA Board

LED Name
De cription
POWER ON
Th ~ LED is lit when the + 15 V dc supply from the regulator is present. If the POWER ON LED is
no lit, check that + 24 V dc is present between TB2-5 (+) and TB2-6 (-). Note if the + 24 V dc
inpJt is present, relay K1 should close the contacts between TB2-7 and TB2-8.
6-25
BI006008
GEH-6148
Notes:
6-26
BI006008
GEH-6148
CHAPTER 7
FUSES AND TESTPOINTS
7-1. LINE FU~ ES
7-2. DCFB ONBOARD FUSES
All GF2000 Dc Generator Field Exciters include protective fuses on the ac power lines and control power
lines. C frame exciters also include fuses on the
blower motor p wer lines. The ac power line fuses are
typically design ted FUI through FU3; the control
power line fuse, CPTFUI through CPTFU3; and the
blower motor pc wer line fuses, BFl through BF3.
The DCFB contains fuses FU1 through FU3, defmed

in Table 7-2. Neon light LTllights if FUI is blown;
LED CR5l lights if FU2 is blown and control power
is applied to the exciter; and LED CR55 lights if FU3
is blown and control power is applied. Figure 7-1
shows DCFB fuse, neon light, and LED locations.
Table 7-1 lists ~ 'Pical values for these fuses. Chapter

13 contains part lists for GF2000 C and G frame exciters. These PaJ~s lists identify the part number for
each fuse.
WARNING
The hardware dI~wings in the exciter door pocket

show the locatio s of these fuses. Appendix B contains
sample hardwarf drawings for the GF2000 exciter.
Dangerous voltages exist on the DCFB

when power is on. Turn off exciter power
and stop generator. Allow internal capacitors to discharge before touching or moving
the board, or when attaching or removing
meters.
Table 7-1. GF2000 Dc Generator Field Exciter Line Fuse Values

Fuse Locat on in Circuit
Fuse Designation
Fuse Value
Type
Ac input p( wer lines, C frame:

230 V ae, 108-260 A output
230 V ae, 261-525 A output
FU 1 - FU3
300 A, 500 V
500 A, 500 V
Semiconductor
460 V ae, 128-260 A output

460 V ae, 261-505 A output
300 A, 500 V
500 A, 500 V
600 V ae 107-183 A output

600 V ae 184-421 A output
200 A, 700 V
400 A, 700 V
Ac input power lines, G frame:

230 V ac 1-55 A output
FU1 - FU3
60 A, 500 V
100 A, 500 V
175 A, 500 V

460 V ac 70-1 27 A output
60 A, 500 V
100 A, 500 V
175 A, 500 V

60 A, 700 V
100 A, 700 V
Control po .... er lines, C and G frames:

230 V ac input
460 V ac nput
575 V ac nput
All input IIpltages

Blower mot( r lines, C frame only:
230 V ac, 50 Hz
230 V ac, 60 Hz
Semiconductor
CPTFU 1, CPTFU2
8.0 A, 600 V
4.0 A, 600 V
3.2 A, 600 V
FNQ-R, time delay
CPTFU3
5.0 A, 600 V
FNQ-R, time delay
SF1 - BF3
3.2 A
4.0A
FRS-R, dual-element time delay
460 V ac, 50 Hz
460 V ac, 60 Hz
1.8 A
2.0A
575 V ac, 50 Hz
575 V ac, 60 Hz
1.25 A
1.8 A
7-1
BI006008
GEH-6148
Table 7-2. DCFB Board Fuses
Fuse
Function
FU 1
Fuse for the 115 V ac po wer supply brought to 3TB; 1/2 A, 2A G fast acting. FU 1 protects the 11 5 V ac
power supplied for customer use. Check for wiring errors or overload if this fuse blows. When the fuse is
blown and load is connected, neon light LT1 on the DCFB board will be lit.
FU2
Fuse for signal-level power supplies + 24, + 15, and + 5 V dc; 7 A, 2AG fast acting. When FU2 is blown,
the exciter is unable to generate fault messages, but LED CR51 will be lit when control power is applied to
the exciter. The usual cause of this fuse blowing is an accidental short of + 24 V dc, either while probing
or due to a wiring error at the terminal board. If FU2 continues to blow when 1PL, 2PL, and 5PL are disconnected from the DCFB board, the board should be replaced.
FU3
Fuse for signal-level power supplies -24 and -15 V dc; 7 A, 2AG fast acting. When FU3 is blown, the Programmer is unable to display fault messages, but LED CR55 on the DCFB board will be lit when control
power is applied to the exciter. The usual cause of this fuse blowing is an accidental short of -24 V dc,
either while probing or due to a wiring error at the terminal board. If FU3 continues to blow when 1PL,
2PL, and 5PL are disconnected from the DCFB board, the board should be replaced.
Rn W
IF1 Pi
IA2PL
VI
V2
V3
PIA
P2A
VMIA
VM18
VM2A
II
II
II
II
II
II
II
II
PPL
W
~-I-jW
C::::=
NPc
R
2n
2~1I,
~'
~I
ICP c
r==='T
SW7
-'
L-J
JP1
3~
~riT'
TCPL
08
SQPL
~D
~Jl':k=':::c-.r======::L-A~~::J'1
JP2
C:=:J
D,'PL
FU2
~
FU3
CR51
DC Oa
+'"
DCOM
rc
"
5PL
lOilrc~
cdJl'
1 FPL
~I
2FPL
Irz-=
I',
5PL
~I
!'
c:=J
P5
2PL
NI5
pH:;
0I
DS200DCFBG1B
Figure 7-1. DCFB Board Layout
7-2
1 2 3
CNPL
D
'. "
FI
GSA]
FUI
BI006008
GEH-6148
GF2000 Dc Gl nerator Field Exciter

7-3. TESTPO NTS
7-3.1. DCFB Board Testpoints
The GF2000 eJi citer includes onboard testpoints for

use in troubleslooting. Testpoints are metal posts located on specifif' signal paths. The signal can then be
measured or vii wed by connecting an oscilloscope or
other measurint instrument to that testpoint.
Table 7-3 lists and defmes the testpoints contained on

the DCFB board. Figure 7-1 shows the locations of
these testpoints on the board.
7-3.2. NTB/3TB Board Testpoints
Tables 7-3 thro gh 7-7 list the testpoints contained on

boards used in tie GF2000 exciter. Boards containing
testpoints are p esented here in alphabetical order by
board name (D( FB, NTB/3TB, and so on) to assist
the reader in re ~rencing this material.
Table 7-4 lists and defmes the testpoints contained on

the NTB/3TB board. Figure 7-2 shows the locations of
these testpoints on the board.
NOTE
In Tables i 3 through 7-7, if a board revision is not isted for a testpoint, that testpoint is inc uded on all board revisions.
Table 7-3. DCFB Board Testpoints
Name
Description
P5
Testpoint for regulated
DCOM
o V common reference point for test signals.
Revision
+5
V de (5%) power supply.
+ 15
P15
Testpoint for regulated
N15
Testpoint for regulated -15 V de (5%) power supply.
ACCT
Testpoint for ACCT signal from DCFB to SDCC (not applicable to GF2000).
V de (5%) power supply.
Table 7-4. NTB/3TB Board Testpoints

Name
Descri tion
DA1
10 V de analog output from a-bit (SDCCG3) or 12-bit (SDCCG1) D/A converter, same as
3TB pi, 53.
DA2
10 V de analog output from a-bit (SDCCG3) or 12-bit (SDCCG1) D/A converter, same as
3TB pi~ 55.
MET1
10 V ::Ie analog output from a-bit D/A converter, same as 3TB pin 54.
MET2
10 V ::Ie analog output from a-bit D/A converter, same as 3TB pin 56.
DVM
Digital
COM
o V co Inmon reference point for test signals, same as
~oltmeter
Revision
(Test 03) input, range 50 V dc, same as 3TB pin 49.

3TB pin 66.
,I
r
~I
O~
Ii I!I
iii
11 !lllll
i I
IIIi I
Figure 7-2. NTB/3TB Board Layout
7-3
BI006008
GEH-6148
7-3.3. SDCC Card Testpoints
Table 7-5 lists and defmes the testpoints contained on the SDCC card. Figure 7-3 shows the locations of these testpoints on the card.
Table 7-5. SDCC Card Testpoints

Name
Description
DCOM1
DCOM2
o V common reference point for test signals, same as DCOM2.

o V common reference point for test signals, same as DCOM 1.
P5
Testpoint for regulated + 5 volt (5 %) power supply.
TP4
Drive Control Processor (DCP) foreground timing flag (720 Hz).
TP5
DCP blockware timing flag (720 Hz).
TP6
DCP slow background timing flag (90 Hz).
RTS
Unused. General-purpose testpoint output from DCP.
TP8
Analog representation of the generator armature current (via the primary shunt IA 1 of this
bridge only), with a nominal dc offset of about +2 V. A deviation of 0.5 V represents
approximately 1 pu shunt current. In DCFB applications which use dual shunts, TP8 does
NOT represent any of the current in shunt IA2 nor does it represent any current from
shunts in other bridges of a multibridge drive.
FCLK
"I'm alive" 8 MHz oscillator output from Motor Control Processor (MCP).
PWM
General-purpose firmware timing testpoint for MCP (development engineering use only).
NMI
Initiates board test (Test 13) when momentarily tied to + 5 V dc. For card test only, not
recommended for use in a drive environment.
MTPNT
General-purpose firmware timing testpoint for MCP (development engineering use only).
DACS
Diagnostic D/A converter daughterboard select; used with auxiliary diagnostic hardware in
conjunction with EE.600.
N15
Testpoint for regulated -1 5 volt (5 %) power supply.
P15
Testpoint for regulated + 15 volt (5%) power supply.
CDR
CDX
TMS320 serial data receive

The testpoints in the upper left corner of the SDCC (CDR, CDX, CLX, CLR, FSX, CLKC,
CP5, and CCM) are reserved for diagnostic purposes for the TMS320C25 processor, via a
D/A daughterboard which allows serial diagnostic D/A converters to be added for development/test purposes only.
TMS320 serial data transmit.
CLX
TMS320 serial transmit clock input.
CLR
TMS320 serial receive clock input.
FSX
TMS320 serial frame sync pulse for transmit.
FSR
TMS320 serial frame sync pulse for receive.
CLKC
TMS320 clock oscillator output.
Revision
AFD-Pres
CP5
+ 5 V dc power supply to TMS320 diagnostic D/A daughterboard.
CCM
Common power supply return for TMS320 diagnostic D/A daughterboard.
BIO
CMP control line from MCP for processor synchronization.
AFD-Pres
AFD-Pres
XF
CMP handshake line to MCP for processor synchronization.
TP29
Testpoint for input line frequency.
TP37
Testpoint for de voltage.
7-4
BI006008
GEH-6148
GF2000Dc Gl nerator Field Exciter

3PL
=(1,3 4
'if'
,IL
=,1
JP 3
&
I'CLKC
P
BC 5
I ceM
I
CDX
:IFSR
FSX
RCLX
CLR
DCDR
U35
~[
7?lJl~:
::L
"[
LEJ
I
il
JP12
c::::::J:J
8]0
03
XF
N15 P-:5 TP4 T,D5 TD O
0 0 0 0 0
'":<
~
DACS
sr
s~
I
!
~T
0
U9
~~
MTPNT
JP14
3:
JP22
9 P L co
c::::::J:J JPl
c::::::J
;;
or
3:6
60
DCP
JP8
Ul
c::::::J:J
JP7
JP23
c::::::J:J c::::J :J
f-o
=..
MC'
P16
3:
c..
c:::=J =~
'21
o
DCOM2
RESET
8 L
'Jt"
'(;l
I~J~~~~~J~~I ,~
FCLK
2
:[.
:0;0
I 0 NMI
R"S
i
EEROtJ.
:<'"
TP12
c::::::J:J
3:
D~co
"'::
9
r,
'0
IL....,
1PL
39
DTP3?
] o
,P29
o TPS
2?L
DS215SDCCG', A
,i [
'0
6PL
J ~L:J;ol
39
Figure 7-3. SDCC Card Layout
7-5
BI006008
GEH-6148
7-3.4. SPC Card Testpoints
Table 7-6 lists and defmes the testpoints contained on the SPC card. Figure 7-4 shows the locations of these testpoints
on the card.
Table 7-6. SPC Card Testpoints

Revision
Name
Description
TP1UP
Encoder #1 up counter output.
TP1DN
Encoder #1 down counter output.
TP1Z
Encoder #1 marker channel output (if enabled).
TP2UP
Encoder #2 up counter output.
TP2DN
Encoder #2 down counter output.
TP2Z
Encoder #2 marker channel output (if enabled).
RX
RS-422 receiver input.
TX
RS-422 transmitter output.
SP1TP1
SPA 1 differential amplifier output, ahead of pot P1/P2 offset & scaling.
SP1TP2
Final output of SPA 1 analog input channel, analog version of VAR.256. An analog voltage
of 5 V dc converts to 511 counts at VAR.256.
SP2TP1
SPA2 differential amplifier output, ahead of pot P4/P5 offset & scaling.
TP2TP2
Final output of SPA2 analog input channel, analog version of VAR.257. An analog voltage
of 5 V dc converts to 511 counts at VAR.257.
531X309SPC
SIGNAL PROCESS
TP2UP
17
I
E2AB
/E2AB ,
:::;
TP2DN
I'
CD
E2BB
/E2BB
_>
/E2MB '
PF1 N
PF1P
f-O-----I
...
c:::J
-
JP7
TP27
123
1 2
c:::::- JP4
c::rJP2
TP1UP
D D
[]
CD
TP1DN
PF2N
SPHPI
DO
TX RX
o
SP2TP2
2c:::J::::4
J
D ~D'
N
P6
2RESP
~I
P5
2SCALE
Figure 7-4. SPC Card Layout
7-6
-IClD-
~ ~J
P4
2ZERO
P3
1 RESP
~I
P2
1SCALE
P1
1ZERO
-..J
-c
r-
3
1
2c:::J::::4
...
c:::J - ~
JPB
PF2P
JP9
_N
In
JP10 r
TP1Z
:: H
2c:::J::::4
()
TXP
JP5
r ,
I
c:r
JP1
E2MB
iJN
10
'<.0
O;g
N
:::;
-0
BI006008
GEH-6148

7-3.5. SVIA Board Testpoints
Table 7-7 lists apd defmes the testpoints on the SVIA board. Figure 7-5 shows the locations of these testpoints on the
board.
WARNING
Dangerous voltages exist on the input stage of the SVIA board when power is on. Exercise care when attaching or emoving test probes.
Table 7-7. SVIA Board Testpoints
Revision
Name
De~ cription
VIN
Mo itors the voltage on input terminal TB1-1, typically the positive terminal on a shunt.
ACOMIS
Mo itors the voltage on input terminal TB1-2. Also is the common input to the SVIA.
Typ cally the negative terminal on a shunt.
TEST
Mo itors the test voltage output, used to adjust the gain of the isolator card. See description of R3 in Table 5-11 for test voltage adjustment. This signal is also available at TB14.
SOURCE
Mor itors the voltage on TB1-3, the unity gain voltage source inputs.
P151S
Mor itors the isolated
N151S
Mor itors the isolated -15 V dc power supply for the isolator input stage.
VINI
Mor itors the output of the preamplifier which preconditions signals before the isolation
stage.
VOIS
Mor itors the isolation stage output before the final stage amplifier.
VOUT
Monitors the overall output of the SVIA after the final stage amplifier.
ACOM
Monitors the output stage amplifier common.
P15V
Mor tors the
N15V
Mon tors the -1 5 V dc power for the output stage amplifier.
P24
Mon tors the 24 V dc power supply input - positive side.
PCOM
Mon tors the 24 V dc power supply input - negative side.
P15P
Mon tors the + 15 V dc power input to the internal isolated power supply.
+ 15
+ 15
V dc power supply for the isolator input stage.
V dc power for the output stage amplifier.
7-7
BI006008
GEH-6148
ACOMIS
[=:J 2
1-'-"1
I
TEST
[=:J
L __ ~
ZJS
SOJRCE
14
P',5IS
[=:J 5
N151S
[=:J 6
Pi5P
15
c==J
VI"I
17
PCOM
14
=::J
13
==:J
P28
DS200SVIAG 1A
VOIS
[=:J 8
VOUT
19
ACOM
11
GAIN
T82
~r-,---+~---+----+,- - - 1
c;
b_,
OFFSET
Figure 7-5. SVIA Board Layout
7-8
Pi5V
[=:J11
N15V
I
11
BI006008
GEH-6148
CHAPTER 8
SOFTWARE ADJUSTMENTS

The GF2000 D
processor-base
rameters. Thes
once controlled
ware combinati
Generator Field Exciter uses microsoftware that includes adjustable paparameters perform many functions
ough adjustable hardware and softns.
The parameters
to the specific h
enable field and
exciter for opti
e modified to customize the exciter

dware and application. They also
maintenance personnel to fme-tune the
al performance.
The ST2000 Toolkit requires an RS-232C link to

communicate with the exciter. It is designed to operate
on an mM PC AT@or compatible computer (80286,
80386, or 80486 processor).
The minimum computer requirements are as follows:
000 Toolkit or Drive Configurator,

LynxOS Versio and Programmer are used to make
these software a ~ustments.
8-2. ST2000
Hard disk drive, 40 MB minimum (15 MB of this

is required to load the ST2000 Toolkit)
MS-DOS@ 3.0 (or equivalent DOS) or later
640 K RAM minimum
5-1/4 inch or 3-112 inch disk drive (for software

installation)
CGA graphics
Monochrome monitor (multiple shades of gray)
RS-232C serial port
Parallel printer port, Centronics compatible
OOlKIT
The DOS-based T2000 Toolkit is a set of software

tools used to co 19ure, maintain, and fme-tune the
exciter. The too .t consists of a collection of programs (tools)
. g under a command shell on an
IBM PC@ compa ible computer (see section 8-2.1 for
requirements) .
The toolkit inclu es an extensive database of GF2000
definitions, acces ed and manipulated using menudriven selections. Additionally, the STIOOO program
can graphically d splay the exciter's program logic on
the computer scr en. By viewing the logic flow, the
user can better
erstand and manipulate the exciter's
adjustable values.
The ST2000 Too
configure and test
site, the toolkit e
trained personnel
tain the installed
real-time display
tions data.
't is used at the factory to originally

the exciter system. At the customer
bles GE field engineers and other
0 reconfigure, fme-tune, and mainciter. Optional modules provide
f control variables and communica-
Chapter 9 provide a procedure for performing a

tuneup of the GF2
exciter using the ST2000
Toolkit.
Recommended enhancements include:
80286 or higher microprocessor, running at 16

MHz or faster
2 MB to 4 MB RAM
Disk cache software
EGA or VGA color graphics with color monitor
80 MB hard disk drive
8-2.2. Using the ST2000 Toolkit

Publication GEH-5860 provides instructional information about the ST2000 Toolkit.
8-1
BI006008
GEH-6148
8-3. DRIVE CONFIGURATOR, LYNXOS
VERSION
The LynxOS-based Drive Configurator is also a set of

software tools used to configure, maintain, and fmetune the exciter. The Drive Configurator is a collection of programs (tools) designed to run on an IBM
PC-compatible computer equipped with the LynxOS
operating system (see section 8-3.1 for requirements).
The Drive Configurator is used to originally configure
and test an exciter system, and to fme-tune and maintain that system in the field. It uses a database to generate the configuration for the exciter during manufacture, and to allow GE field engineers and other trained
personnel to adjust the exciter configuration for optimal performance. Optional modules provide real-time
display of control variables and communications data.
The database is used to maintain configuration data for
one or more control systems. The product is usually
installed on a central database server. On smaller installations, the database may reside on the same PC as
the Drive Configurator.

8-3.2. Using the Drive Configurator
Publication GEH-6203 provides instructional information about the Drive Configurator.
8-4. PROGRAMMER MODULE

NOTE
To avoid exciter malfunction, only qualified

personnel should use the Programmer.
The GF2000 exciter includes a Programmer module
with a 16-character digital display and an alphanumeric keypad. It functions as an operator interface for
performing software adjustments and diagnostic testing
when the ST2000 Toolkit or Drive Configurator is
not available.
The Programmer provides a digital display for an alphanumeric readout of fault codes, status, RAM values, and EEPROM values. The alphanumeric keypad
enables the user to operate and adjust the exciter.
NOTE
The Drive Configurator is designed to operate on an

mM PC AT or compatible computer with the following minimum requirements:
LynxOS operating system, version 2.1 or later
80386 microprocessor
8 MBRAM
150 MB hard disk drive
VGA graphic card and monitor
RS-232C serial port
Permanent changes made using the Programmer module must also be made in the
ST2000 Toolkit or Drive Configurator to
keep the tools compatible with the exciter's
software configuration.
The Programmer resides on the SLCC card, which
mounts on the SDCC card. The Programmer is accessed by opening the cabinet door at the front of the
exciter.
Chapter 6 lists and defmes the SLCC's I/O connections.
NOTE
The following enhancements are recommended:
80486 microprocessor, running at 33 MHz or

faster
12 to 16 MB RAM
Color monitor
8-2
The Programmer's parameter address,

designated as EEl.O (CFGJPR), must contain a 1 (an odd number) to enable it to
function. A 0 in the address disables the
Programmer. See Parameter Mode (section
8-4.3.2) to change the value, if needed.
BI006008
GEH-6148

8-4.3. Operating Modes
8-4.1. Keypa
NOTE
This chap er indicates a Programmer key

by enclos' g the key name in () symbols.
For exam Ie, (STOP) symbolizes the key labeled Sr,
The Programm r keypad enables an operator to control the exciter y:
The Programmer operates in any of three modes:
Operate Mode, the normal mode which the exciter

automatically enters at powerup
Parameter (EEPROM or Mirror) Mode, selected

by an operator from Operate Mode
Diagnostic Mode, selected by an operator from

Parameter Mode
The Programmer's operating mode determines the

function of most keys. This is shown by the color
(and position) of the keys' labels:
The keypad co ains 20 keys. Most have more than

one label, each different color. The color indicates
the key's functi n during the associated operating
mode.
8-4.2. Displa
NOTE
This chapt
play by us'
ample, if t
word RE
r indicates a Programmer disg a different typestyle. For exe Programmer displays the
'RSE, this chapter shows it as
REVERSE.
The display uses 6 (of 16) characters for the mnemonic, where re uired. The number of decimal points
in the mnemoni indicates the operating mode:
indicates Operate Mode (for examTE MODE)
Blue labels (bottom of key) during Diagnostic

Mode
Black labels (middle of key) during Operate, Diagnostic, and Parameter Modes
Green labels (middle, right side of black label),

selected by holding down (SHIFT) while pressing a
key, during Operate, Diagnostic, and Parameter
Modes; (SHIFT) is also green
The following paragraphs describe the modes and key

functions.
Potential exciter activation and inadvertent

equipment movement when testing.
Through the remainder of this section, do
not use DIAGNOSTIC RUN, SELF-TUNE
(I-TUNE or S-TUNE), or any Programmer
RUN function on any application (such as
crane or elevator) where motion may cause
injury.
8-4.3.1. OPERATE MODE. At powerup, the exciter
enters Operate Mode. This activates the red and

black/green keypad functions.
s indicate Parameter Mode (for ex.AMETR_M MODE)
Red labels (top of key) during Operate Mode
WARNING
The Programme's display presents an alphanumeric

readout for exci r parameters, faults, and keypad inputs. The fault de display provides an easier alternative to the SD C card's indicating LEDs, which
must be decode .
Initiating s If-tuning programs
Three dec'
s indicate Diagnostic Mode (for
example, D..A.GNOSTIC MODE)
NOTE
Red key functions are dominant; black/

green key functions only work in Operate
Mode after (SHIFT) has been pressed.
8-3
BI006008
GEH-6148
If a key is not activated, the Programmer briefly displays FL41 L_KEYOFF.
The Operate Mode display is in the form M S.O% I

0%, where M indicates Manual mode (alternatively an
A indicates Auto mode), S.O% indicates percentage of
rated speed, and I 0% indicates percentage of rated
current. Note that one decimal point is used to indicate
Operate Mode.
WARNING
(DEC)
Press to decrease the speed at which the

exciter is running for any of the RUN
functions.
(REV)
Activates a command's reverse function:
1.
2.
Press (REV) and the Programmer

displays REVERSE.
Press the desired function key:
(RUN), (SLOW), (JOG), (Rl), (R2),
or (REFR).
NOTE

equipment movement when testing. Use
Operate Mode only as a diagnostic tool;
motor will rotate, ignoring safety circuits.
Do not attempt to use (RUN), (SLOW),
(JOG), (R1), (R2), or (REV), (A/M).
Red Key Functions. In the Operate Mode, the red key

function are used a follows:
(SLOW)
Controlled stop
(DRV#)
Used as part of the access code to Parameter Mode
(SET)
Used to enter Parameter Mode (section

8-4.3.2) and to adjust settings of various
keypad functions; activated using the
following steps:
1.
Press (SET).
2.
Press either (RUN), (SLOW), (JOG),

(R 1), (R2), (REFR), or (DRV#).
3.
4.
Resets the exciter after fault or error

messages appear; produces a Software
Reset
(A/M)
Auto/manual operating mode; can toggle

between Auto (A) and Manual (M) if the
proper bit is set in EE.690
(RATIO)
Not used
Black/Green Key Functions. The black/green key

functions are used as follows:
Black (0) through (9); use (SHIFT) for
green (A) through (F), decimal point, and
hyphen
Enter the desired setting in decimal

numbers (for example, for Drive 77,
enter 77 after pressing (DRV#.
(PREV)
Displays the previous (last) mnemonic

entered
Press (ENTER).
(N EXT)
Displays the next mnemonic
(ADDR)
Displays the last address entered
(HEX/DEC)
Press to enter hexadecimal format; press

again to return to decimal format
(ENTER)
Press to enter a value
(CLEAR/
MODE)
Used to clear a parameter
The EEPROM must be Write Enabled to

make these adjustments (see the instructions on changing parameters in section
8-4.3.2).
8-4
(RESET)
Numerals
NOTE
(INC)
If (REV)(JOG) is pressed, the exciter performs the REVERSE JOG as long as the
(JOG) key is pressed. When (JOG) is released, the REVERSE JOG function stops.
However, the Programmer remains in the
Reverse Operate mode, and displays
REVERSE to so indicate.
Press to increase the speed at which the

exciter is running for any of the RUN
functions.
BI006008
GEH-6148
GF2000 Dc Ge tlerator Field Exciter

8-4.3.2. PARA'I"IETER MODE. Parameter Mode allows
2
the user to exau ine and change any EEPROM (E ) or
EEPROM "mir or" parameter addresses to customize the exciter t an application.
3.
Press (DRV#).
4.
Press (7).
There are two t; 'Pes of Parameter Modes:
The next step selects either the Parameter Mirror or

Parameter EEPROM Mode.
5.
Parameter E;EPROM Mode. Changes made to

parameters ~uring this mode can be permanent changes are remembered even if power is removed fron the exciter.
a.
To select Parameter EEPROM Mode, press

(7).
The display shows P.AR.AMETR_E MODE.
Parameter ~irror Mode. Changes made to parameters du ing this mode are overwritten by the
correspondi.i g EEPROM address during powerup
or a hard re et.
b.
To select Parameter Mirror Mode, press (8).

The display shows P.AR.AMETR_M MODE.
Note that the Programmer uses two decimal points in

the display to indicate Parameter Mode.
Parameter Mode activates the same black/green key

functions as the Operate Mode. It also uses red keys
(STOP), (INC), a~d (DEC). See section 8-4.3.1
(Operate Mode) or key defInitions.
6.
Press (ENTER).
NOTE
Entering Param~ter Mode. Figure 8-1 depicts the

Programmer ope ating modes and steps to move between them. Not that Parameter Mirror Mode can be
entered either fre m the Operate Mode or from the
Parameter EEPRpM Mode.
Pressing (ENTER) takes the display back

one EE address. This key also is used to
change between Parameter Mirror Mode
and Parameter EEPROM Mode.
To enter Paramet r Mode:

1.
To enter Parameter Mirror Mode from the Parameter

EEPROM Mode:
Check that tb~ Programmer is in the Operate

Mode (displa should read M S.O% I 0%).
1.
Check that the Programmer displays

P.AR.AMETR E MODE.
2.
Press (SET).
POWE UP
OPERATE
MODE
PRESS
(SET)(DRV#)(7)
. . - - - - - - - , (7)
~
PRESS
(CLEAR/MODE)
(8)
PRESS (PREV)
DIAGNOSTIC
MODE
~
-J
PRESS (CLEAR/MODE)
PARAMETER
EEPROM
MODE
A
PRESS
(PREV)
PRESS
(CLEAR/MODE)
PARAMETER
MIRROR
MODE
L..-.
---J
Figure 8-1. Changing Modes of Operation
8-5
BI006008
GEH-6148
2.
Press (CLEAR/MODE).
To change a parameter, use the steps in the following

example.
The display now displays P.AR.AMETR_M MODE.

To return to the Parameter EEPROM Mode from the
Parameter Mirror Mode, press (PREV).
Examining Parameters. To examine the present value

of any parameter:
1.
Enter the 3- or 4-digit parameter address.
2.
Press (ENTER).
Example: Examine and change the minimum delay

time from RUN/JOG commanded to reference enabled. Drive delay time (EE.38, STRDLY) is already
set at 0.25 seconds. Change it to 0.15 seconds.
Ensure that the SDCC's E Enable jumper (JPI) is
in the ENABLE position (2-3), and that EE.2.0,
DGNJP contains a 1.
2.
After examining EE.2.0, enter the following keystrokes:
The Programmer immediately displays the address

name and present contents.
3.
To examine the parameter in the next higher or

lower address, press the (NEXT) or (PREV) key.
1.
(CLEAR/MODE)(3)(8)(ENTER)
The display shows S.TR.DLY.

0.25 second delay time.
25, corresponding to a
This allows the operator to easily view parameters in a

series of consecutive addresses.
3.
To examine another parameter (not in a next address):
In either case, the display shows S.TR.DLY. 15 (note

that the decimal point in this display indicates Parameter Mode).
1.
Press (CLEAR/MODE) to clear the present address.
The display then shows P.AR.AMETR_E MODE (the_E

characters indicate Parameter EEPROM Mode) or
P.AR.AMETR_M MODE (the _M characters indicate
Parameter Mirror Mode).
4.
Enter the 3- or 4-digit parameter address.
3.
Press (ENTER).
Press (ENTER).
This places the new value into EEPROM.

5.
2.
Either press (DEC) until the display value decreases to 15, or press (1), then (1).
Press (CLEAR/MODE).
The display the shows P.AR.AMETR_E MODE.

6.
The address name and contents appear in the display.
NOTE
NOTE
The next step is extremely important to

prevent accidental reprogramming of the
exciter.
To enter or view in hexadecimal format,

press (HEX/DEC). To return to decimal
mode, press (HEX/DEC) again.
Changing Parameters. To change parameters, two
conditions must exist:
The SDCC's EEPROM (E2) jumper IPI must be

in position 2-3 for write ENABLE (position 1-2 =
2
E write PROTECT).
Parameter address 2.0, designated as EE.2.0
(DGNIP), must contain a 1 (odd value). If a 0
(even value) is present, add a 1 and press
(ENTER).
8-6
To examine other addresses at this point, enter the

desired parameter address, and press (ENTER).
7.
To seal the new parameter values, remove the 1

from EE.2.0, DGNJP, returning to the "as
shipped" 0; return SDCC jumper JPl to the write
PROTECT position (1-2).
Exiting Parameter Mode. To exit Parameter Mode,

press (CLEAR/MODE) two or three times, as needed
(see Figure 8-1):
If in Parameter EEPROM Mode, press

(CLEAR/MODE) three times.
BI006008
GEH-6148

This moves fIrs to Parameter Mirror Mode, then to
Diagnostic Mod, and fmally to Operate Mode.
If in Param ter Mirror Mode, press

(CLEAR/M DE) two times.
This moves fIrst to Diagnostic Mode, then to Operate

Mode.
The displays shows D.I.A.GNOSTIC MODE.
Exiting Diagnostic Mode. To move from the Diagnostic Mode to the Operate Mode, press
(CLEAR/MODE) once.
To return to the Parameter Mirror Mode from the Diagnostic Mode, press the (PREV) key.
8-4.3.3. DIAGN STIC MODE. The Diagnostic Mode
8-4.4. Drive Diagnostics
is used to:
Provide inte al digital displays
WARNING

equipment movement when testing.
Through the remainder of this section, do
not use DIAGNOSTIC RUN, SELF-TUNE
(I-TUNE or S-TUNE), or any Programmer
RUN functions on any application (such as
crane or elevator) where motion may cause
damage or injury.
Initiate self-
This mode activa es the blue and black keypad functions, with blue
ctions dominant, (INC) and (DEC).
Blue keypad fun tions include (DGS), (DGR), (DVM),
(ARMV), (ARM I), (FIELDI), (SPEED), (TORQ), (HP),
(RAM), (DRV#),
d (TEST).
NOTE
The Programmer allows an operator to run resident

diagnostic tests on the exciter. These tests aid in
startup, tuneup, and troubleshooting. To run diagnostic
tests, the exciter must be in Diagnostic Mode, as described above.
The hexadec' al numeral option (shown on

the keys in g een) is not available in Diagnostic Mode.
This section describes the available tests, listed in Table 8-1. Note that some tests are only available with
certain hardware or software confIgurations.
Black keypad fu ctions are the same as in Operate

Mode (see section 8-4.3.1), except for (HEX/DEC),
which does not
ction in Diagnostic Mode.
Entering Diagnos 'c Mode. To enter Diagnostic

Mode:
diagnostic Tests 3 through 9:
1.
1.
Enter Diagnostic Mode as described above.
2.
Press the key for the selected test.
Ensure that th exciter is in Parameter Mirror

Mode (the dis lay shows P.AR.AMETR_M MODE)
If not, see sect on 8-4.3.2.
8-4.4.1. RUNNING THE DIAGNOSTIC TESTS. To run
2.
To run diagnostic Tests 10 through 15:
The display immed ately shows D.I.A.GNOSTIC

ee decimal points in the display
used to indicate Di ostic Mode).
1.
Press (TEST). This displays T.E.S.T NO.
2.
Press X, where X is the number of the particular

test to be performed.
If a particular par eter is being displayed in the Parameter Mode, ente the Diagnostic Mode as follows:
3.
Press (ENTER).
MODE (note the t
To cancel a Diagnostic Test, press (PREV) once.

To exit Diagnostic Mode without displaying any diagnostic variables, press (CLEAR/MODE) twice.
8-7
BI006008
GEH-6148
Table 8-1. Standard Diagnostic Tests
DVM has fIxed scaling, and can measure de voltage in

the 50 V range with a 0.5% accuracy.
Name
Description
Test 1
(DGS), keypad selection. Do not use.
Test 2
(DGR), keypad selection. Do not use.
Test 3
(DVM), keypad selection. Displays

digital voltmeter.
Test 4
(ARM V), keypad selection. Displays

armature voltage.
Test 5
(ARM I), keypad selection. Displays

armature current in amps.
Test 6
(FIELD I), keypad selection. Displays

field current in amps.
Test 7
(RPM), keypad selection. Displays

motor speed (revolutions per minute!.
Test 8
(TORQ), keypad selection. Displays

motor torque in 1 Ib-ft.
Test 10 - Software Revision. Test 10 displays the revision level of the SDCC and SLCC cards' microprocessors: Drive Control Processor (DCP), Motor Control Processor (MCP), Co-motor Processor (CMP),
and LAN Control Processor (LCP).
Test 9
(HP), keypad selection. Displays motor horsepower.
To run Test 10;
Test 10
Displays software revision of SDCC

and SLCC microprocessors.
1.
Press (TEST).
Test 31
Displays four diagnostic variables

(selectable! in decimal format.
2.
Press (1 XO).
Test 11
Displays four diagnostic variables

(selectable! in hexadecimal format.
3.
Press (ENTER).
Test 12
Invokes the cell (SCR! test.
Test 13
Invokes the board test function.
Test 15
Speed regulator tuneup function.
4.
Test 25
Same as Test 15, but test results

and calculated parameters are saved
in EEPROM, rather than RAM.
The Programmer displays C. = .0.0.00 L. = .0.0.00 for

CMP and LCP, respectively.
RAM Test
Displays single diagnostic variable

(selectable!.
5.
DAC1, -2
Digital-to-analog converter outputs.
The Programmer displays D. = .0.0.00 for UCP.
MET1, -2
Digital-to-analog converter outputs.
Tests 4 through 9 - ARM V, ARM I, FIELD I,

SPEED, TORQ, HP. These tests display motor data:
armature voltage, armature current, field current,
speed, torque, and horsepower. Select the test in Diagnostic Mode by entering its number. Note that the
test number (black label on key) and test name (blue
label) correspond.
To cancel the previous test and enter a new test, press
the appropriate key or (TEST) once.
The Programmer displays D. = .0.0.00 M. = .0.0.00

for DCP and MCP, respectively.
Press (INC).
Press (INC).
To enter a new test, press (TEST).

To exit Test 10 press (PREV).
8-4.4.2. DIAGNOSTIC TEST DEFINITIONS. This section provides descriptions of the available diagnostic
tests (listed in Table 8-1).
Test 3 - DVM Mode. Test 3 uses the Programmer as a

digital voltmeter (DVM) to check analog testpoints on
the exciter boards.
Tests 11, 31 - Diagnostic Variable Display. Tests 11

and 31 display four exciter variables for diagnostic
use. Test 11 provides hexadecimal values; Test 31
provides decimal values.
To run either test:
1.
The test probe wire, supplied in the miscellaneous

parts packet shipped with the exciter, connects from
the testpoint to be monitored to either the NTB/3TB
board's testpoint DVM or to terminal 3TB-49. The
8-8
Enter the RAM addresses of the variables to be

2
monitored into E locations 110 through 113 for
DIAG1 through DIAG4, respectively. Refer to
Parameter Mode, section 8-4.3.2 for procedures,
and Table 8-2 for variable addresses.
BI006008

2.
3.
GEH-6148
Press (TES ).
NOTE
For Test 11 press (1X1); For Test 31, press
Although tuneup Test 15 can be run from

the Programmer, data retrieved from the
test is stored in RAM and cannot easily be
saved. Therefore, tuneups should be made
with the ST2000 Toolkit (see GEH-5860) or
Drive Configurator (see GEH-6203), or by
running Test 25, which stores test results in
EEPROM.
(3)(1 ).
4.
Press (ENTI R).
The test starts 31 d displays 1.2. aaaaH yyyyH for Test

11 or 1.2. AAA A BBBBB for Test 31. (AAAA is the
value of the first variable; BBBB is the value of the
second variable.
5.
Test 15 or 25 - Speed Regulator Tuneup. To enter

this tuneup function:
Press (DEC) or (INC).
The Programme displays 3.4. CCCCH DDDDH or

3.4. CCCCC DDpDD. (CCCC is the value of the third
variable; DDDD is the value of the fourth variable.)
1.
Press (TEST).
2.
Press (1 )(5) or (2)(5).
NOTE
3.
Press (ENTER).
The value dfsplays are in 2's complement.

Values from oo to 7FFF are positive (0 to
+32767); v~ ues from FFFF to 8000 are
negative (Fl1FF = -1, 8000 = -32768).
The Programmer displays E.N.T.R PAR 1 as a prompt

to enter a value for the first parameter (the three
decimals indicate Diagnostic Mode).
4.
Test 12 - Cell
TE~t.
To set a new Parameter 1 value:
Test 12 checks the SCR (cell).

a.
Enter the selected parameter value (motor

number).
b.
Press (ENTER).
Test 13 - Board rest. Test 13 is the board test function. Press any kf y during this test and the Program-
mer displays the ey's number.

To exit this test, ress the SDCC card's RESET button. (To run Test 13, the proper bit in address EE.2
must be set.)
5.
To set Parameter 1 to the default value (0), press

(ENTER).
The display now shows E.N.T.R PAR 2 as a prompt to

enter a value for Parameter 2.
6.
To set the Parameter 2 value:

a.
Enter the selected parameter value (0 to run

test; 1 to perform calculation only).
b.
Press (ENTER).
Table 8-2. RA V1 Addresses * for Analog Signals

RAM Add ess
Signal Description
100
Speed feedback
103
Voltage feedback
104
CFB
105
Field current
112
CEMF
140
Speed REF output
These addresl es contain a variable that represents an analc g signal.
7.
To set Parameter 2 to the default value (0), press

(ENTER).
The Speed Regulator Tuneup now starts and the Programmer displays a tuneup message.
To abort the tuneup test in progress, press (STOP).
To return to the Diagnostic Mode, press (PREV).
To return to the Operate Mode, press (CLEARI
MODE).
8-9
BI006008
GEH-6148
RAM Test - Examine/Modify RAM Location Value.

The RAM Test allows users to examine and/or modify
the RAM locations values.
WARNING
Use caution when altering RAM values.

Any change may also change the exciter
characteristic, causing the system to misoperate.
To enter this test:
1.
2.
Enter the desired RAM address.
3.
Press (ENTER).
The display now reads D. . .1.~R_O

(XXXXXRYYYYY), where XXXXX = RAM address
and YYYYY = RAM value at that address. (The fIrst
letter can be D, M, or L for DCP, MCP, or LCP.)
To alter the RAM value:
2.
If the exciter is already using the DAC1,

DAC2, :MET!, and :METI outputs, changing them may cause the exciter to misoperate. Before entering this test, refer to the
exciter's elementary diagrams and custom
instructions or PC software to determine
this.
Each output has two addresses (see Table 8-3).
The @I address selects the variable to be output

(EE.100 = DAC1, EE.102 = DAC2, EEI04 =
MET.l, and EE.106 = MET2).
The MX address is the maximum input value

(EE.101 = DAC1, EE.103 = DAC2, EE.105
MET!, and EE.107 = MET2).
Press (RAM).
The Programmer displays RAM. EXAM/MODIFY.
1.
CAUTION
After the current RAM value is displayed (see

step 3 above), enter the new value.
Press (ENTER).
The display now shows the new RAM value, unless

the Modify RAM command is disabled. In that case,
the display shows M.O.D. RAM DISABLED.
To exit the RAM Test (either without changing or
after changing the RAM value):
For example, to enter this function:

1.
In Parameter Mode, call up EE.100-DAC@1 and

EE.101-DAC1MX (select E.l00).
2.
Enter the signal to be monitored (from Table 8-2)

into EE.100. Putting that RAM address in EE.100
produces that signal at the NTB/3TB board's DA1
testpoint and DACI terminal (3TB-53).
DAC2, MET!, and MET2 function like DAC1. When

a signal's RAM address is loaded into the DAC and
MET addresses, the signal is output on the NTB/3TB
board's testpoints and terminals points listed in Table
8-3.
Tab/e 8-3. Diagnostic Mode Analog Output Points
Loaded Into
Address
NTB/3TB
Testpoint
Terminal
Board Point
DA'
DA', 3TB-53
DA2
DA2, 3TB-55
Press (TEST) or (CLEAR/MODE) again.
EE.' OO-DAC@' &

EE.10'-DAC1MX
EE.'02-DAC@2 &
EE.' 03-DAC2MX
EE.1 04-MET@' &
EE.' 05-MET' MX
MET'
MET', 3TB-54
8-4.4.3. DAC1, DAC2, MEn, AND MET2. The
EE.'06-MET@2 &
EE. , 07-MET2MX
MET2
MET2, 3TB-56
1.
Press (PREV) or (CLEAR/MODE).
The Programmer then displays D.I.A.GNOSTIC

MODE.
2.
DAC1, DAC2, MET!, and MET2 analog outputs are

available for test purposes. The four outputs function
identically, and are programmed similarly to Test 11.
8-10
BI006008
GF2000 Dc G
GEH-6148
CHAPTER 9
TUNEUP PROCEDURE
Step 15 - Proportional plus integral speed regulator

response
The tuneup pro edure is used to optimize the time
constants and g' values of all the regulators in the
control loops us d in the GF2000 Dc Generator Field
Exciter control oftware. An overview of the control
software, inclu g the regulators and control loops, is
shown in Figure 9-1.
The basic tuneu
trolloops, and c
loop is evaluate
loop can then be
erator field, the
eddy current eff;
the regulator's f
are as follows:
method is to tune the innermost conntinue to the outermost loops. Each

and tuned so that the next outermost
tuned. The time constants of the genenerator armature, and that due to
cts must be determined in order to set
e constant values. The tuneup steps
These steps are covered in sections 9-4 through 9-18.
9-2. REQUIRED EQUIPMENT

The following equipment is required to perform this
tuneup procedure:
IBM PC AT or compatible computer equipped

with ST2000 Toolkit (refer to GEH-5860)
RS-232C cable to connect the computer to the

GF2000 exciter
Dual-channel oscilloscope with 100: 1 probes
Four-channel chart recorder with digital memory

option (HIOKI or Gould Windowgraph, or
equivalent)
Digital voltmeter (DVM)
Step 1 - Prer . ary calculations and settings

Step 2 - Generat r field time constant determination
Step 3 - Proport onal field current regulator response
nal plus integral regulator response
ent converter linearization
Step 6 - Generat r saturation curve characterization

Step 7 - Eddy cent time constant determination
voltage regulator response
eous armature overcurrent protection
e time constant determination
9-3. SETUP
Connect the computer's available serial communications port to connector COMPL (RS-232C port) on the
GF2000 exciter's NTB/3TB board (the computer must
be equipped with the ST2000 Toolkit as described
above). Run the ST2000 Toolkit, ensuring proper initialization and communications between the computer
and the exciter. Refer to GEH-5860 for instruction on
the proper use of the ST2000 Toolkit.
Ensure that other equipment listed above is available
for use during the tuneup procedure.
e current regulator response

e current rate and fJ.lter
Step 13 - Speed fi edback scaling and polarity verification

Step 14 - Proport onal speed regulator response
Isolator modules or digital-to-analog converters

(DACs) can be used to monitor field voltage and current. Two 12-bit DAC outputs, labeled DAC1 and
DAC2, are available on the NTB/3TB board to display
analog signals. Four 8-bit, 1O V DAC outputs, designated METl through MET4 are also available on the
NTB/3TB board. These outputs are used to drive
9-1
BI006008
GEH-6148
LOAO
TORQUE
IASTEP
FLUX
'5000 COUNTS/1 PU
IAGEN
VCEMF
VCO
wCCr.'J50rIS
ARMATURE
CURRENT
FEEDBACK
IAGEN
5000 COUNTS/' PU
VCO
Wcvr ... 150 rls
ARMATURE
VOLTAGE
FEEDBACK
VOFBI
20000 COUNTSI1 PU
J
VAGEN
VCO
Figure 9-1. GF2000 Regulators and Control Loops
meters. The following section provides instructions for

selecting the variables present on the DAC outputs.
The help information for EE.IOI and EE.I03 included

in the ST2000 Toolkit contains instructions on setting
the variable scaling. Table 9-1 lists useful variable
addresses for the GF2000 exciter.
9-3.1. DAC Variable Selection
NOTE
To select the variables present on the DAC outputs:

1.
From the ST2000 Toolkit function header, select

the EDIT2000 Menu (Parameter Editor).
2.
Press (F2) or (Alt F6) (Search for Item).
3.
Enter EE.DAC1 or EE.1 00 and press (F1) (Enter/

Select).
Press (F1) (Change Value) to select a RAM variable.

To enter a variable address for the DAC, press (F1)
and enter the numeric address. Set the DAC scaling by
entering the maximum count number for the variable
to be displayed. Addresses EE.lOO (DACI@I) and
EE.101 (DACIMX) set the variable address and scaling factor, respectively, for DACI; addresses EE.I02
(DAC2@I) and EE.103 (DAC2MX) set the variable
address and scaling factor, respectively, for DAC2.
NOTE
The scaling factor should be greater than

256, which enables the 16-bit DAC to read
the memory location as a word.
A similar procedure is used for the MET1

through MET4 outputs by assigning variables to EE.104 through EE.107.
To display RAM variables located in the Co-motor
Processor (CMP):
1.
Search for EE.554 (CPNTRI), as described in

steps 2 and 3 above.
Table 9-1. GF2000 Variable Addresses

Address
Mnemonic
Description
VAR.1092
IBRIDGE
Bridge current or generator

field current feedback
VAR.1024
VBRIDGE
RAM variable representing

field voltage
VAR.1000
FIRCMD
Firing command signal
VAR.1002
ILOPOUT
High performance current

regulator output
C335H
(RAM)
ALPHAPRIME
Firing angle delay signal*
9-2
RAM variable in the Co-motor Processor (CMP).
BI006008
GEH-6148
2.
3.
NOTE
Set EE.554 CPNTRl) to the numerical address of

the CMP
variable to be displayed. The
CMP RAM variable pointed to by EE.554 will be
available on variable VAR.292 (CDIAGl).
Exercise care when using the Terminal

Mode. In this mode, writes are made directly to the GF2000 exciter without any
required confirmation or entry tracking.
The terminal mode should be used primarily for entering reference step signals and
performing diagnostic tests, such as Test 31
(see section 9-3.5).
Load the D C located at EE.l00 or EE.102 with

VAR.292.
NOTE
EE.555 (C
) is a pointer that can be
used with v iable V AR.293 (CDIAG2) in
er as described above for
the same m
EE.554 and V AR.292.
9-3.2. Diagnos ic Use
For diagnostic poses, set EE.ll0 (DIAGl) and

EE.lll (DIAG2) to variables VAR.292 and
VAR.293. These variables can then be displayed on
the computer scr en by running Test 31 as described
in section 9-3.5. r can be assigned to a DAC output.
9-3.5. Test 31 - Display Diagnostic Variables
When in Terminal Mode, entering ]31 displays four

diagnostic variables pointed to by EE.ll0 (DIAG1).
EE.lll (DIAG2). EE.112 (DIAG3). and EE.I13
(DIAG4). The diagnostic variables are displayed in
columns on the ST2000 Toolkit computer screen. In
diagnostic mode, the variables can also be displayed.
two at a time. on the alphanumeric display on the exciter's Programmer.
9-3.6. Setting Regulation Modes

9-3.3. Setting
EPROM Values in EDIT2000
alues using the EDIT2000 screen:

1.
Press (F2) or (Alt F6) (Search for Item), and enter

EE.XXXX (were XXXX is the EE address to be
changed).
2.
After the EE ariable is found. press the Change

Value softke and enter the desired value for the
variable. Pre s the Accept Change softkey and
enter your ini ials when prompted.
Table 9-2 shows the regulation modes of the GF2000

exciter. These modes are controlled by the signals
passed through functional block 555 (GFXFR). the
generator exciter transfer (DCP-to-MCP) block.
9-4. STEP 1 - PRELIMINARY CALCULATIONS
3.
Press the Se to Drive softkey. This sends the

value just ent red into the database to the
EEPROM in e GF2000 exciter.
To enter Terminal Mode from the SUOOO Toolkit

main menu. move the cursor to EE2000 and press
(F1). When the E 2000 tool is displayed, press (F6)
(Terminal Mode).
en prompted for a password.
enter OMNI.
Before setting the generator field current feedback

scaling. ensure that the drive type, EE.550
(DRVTYP). is set to 85 to enable the GF2000 exciter
software. A hard reset is required after setting the
drive type.
The generator field current feedback scaling should be
set to give 5000 counts for rated generator field current. The following parameters must be known to calculate the proper scaling factors:
Rated field current (Ifg) in amperes
Rated field resistance (Rfg) in ohms
Field shunt millivolt rating and current rating in

amperes
9-3
BI006008
GEH-6148
Table 9-2. GF2000 Regulation Modes
Block 555
GFXFER
Input Pointer
Points to Variable
Generator Field
Regulator Tuneup
Mode
Armature Voltage
Regulation Mode
Armature Voltage
Regulation Mode
IContactor M Closed)
Armature Current
Regulation Mode
EE.5816 (GF@VRE)
VAR.1417 (VARON)
EE.5817 (GF@IRE)
VAR.1418 (IARON)
EE.5818IGF@IVS)
VAR.1419 (IASEL)
EE.5819 (GF@MST)
VAR.1420 (MSTAT)
9-4.1. VCO Feedback Scaling
For the GF2000, the field shunt should be selected to

give 75 mV at rated field current. A voltage controlled
oscillator (VCO) on the DCFB board converts the
voltage across the shunt (mV) into a number of counts
to be used by the exciter control software. To scale the
generator field current feedback to 5000 counts for
rated field current, set EE.1523 (FL2SFO) as follows:
FL2SFO
= 0.75 x 16,384 x shunt rating (A) / Jfg
9-5. STEP 2 - GENERATOR FIELD TIME

CONSTANT
The generator field time constant is determined by

stepping the generator field converter voltage and observing the time response of the generator field current. Set up the regulator for direct firing control using
the ST2000 Toolkit in the following manner:
1.
To avoid problems caused by sudden changes in

gain values while performing step 2, set the reference signal, RAM address C346H (IREGSTP), to
zero. Using the ST2000 Terminal Mode, type
C346H = 0 and press (Enter). (The' character is
located in the top left comer of the keyboard.)
2.
Using the ST2000 Toolkit, set the EEPROM locations listed in Table 9-3 to the values shown to
convert the enhanced current regulator to an open
loop firing mode (refer to section 9-3.3 for instructions on setting EEPROM values).
3.
Using the ST2000 Terminal Mode, increase the

field current regulator reference step signal,
C346H (IREGSTP), until the shunt voltage is 25 %
of its rated value. Type . C346H = XXXX, where
XXXX represents the number of counts for the desired step amplitude.
For example, if the rated field current Ifg is 50 A and

the 100 millivolt shunt is rated at 75 A , the generator
field current scale factor is given by:
FL2SFO
= 0.75 x 16,384 x 75/50 = 18,432
9-4.2 Bridge Overcurrent Protection
The generator field and converter bridge are protected

by an instantaneous overcurrent (IOC) function. To
activate this function, set EE.1507 (IOCTRO) to the
desired trip level. A typical setting is:
JOCTRO = 5000 counts x 1.6 = 8000 counts
The generator field and converter bridge can also be

protected by an Ixt overcurrent function. To invoke
this function, set EE.25 (TOC@IN) equal to
VAR.1092 (IBRIDGE), and set EE.1494 (TOCLVO),
EE.1495 (TOCATO), and EE1496 (TOCTTO) to set up
the Ixt overcurrent function. Typical values are:
TOCLVO
= 110%
NOTE
In the open loop configuration, address

C346H is the generator field voltage reference signal (16384 = Edo).
4.
TOCATO = 1500 %-sec - If the field current exceeds the preset value of 110% for 1500%-sec,
fault 32 (TOC_ANUN) will occur.
JBRIDGE
5.
TOCTTO = 2000 %-sec - If the field current exceeds the preset value of 110% for 2000%-sec,
fault 8 (TOC_TRIP) will occur.
9-4
Calibrate VAR.1092 (lBRIDGE), the bridge current feedback. This value should be equal to:
= % rated current x 5000
It may be necessary to trim the bridge voltage

feedback, VBRGFB, using EE.1503 (VFBFSO),
the voltage feedback scale factor. Set EE.1503
until VBRGFB equals 20,000 at the rated bridge
voltage.
BI006008
GEH-6148
GF2000 Dc Gel erator Field Exciter

Table 9-3. Open Loop Firing Mode EEPROM Values
Address
Mner onic
Value
Description
EE.1590
HIRK 0
Sets generator field feedback to zero
EE.1591
HIRK fylO
Sets generator field integral gain to zero
EE.1581
ILiMC 0
Sets generator integral limits to zero
EE.1589
HIRK 0
32
Sets proportional regulator path gain to one
EE.1523
FL2S 0
Calculated
in section 9-4
Sets the generator field current feedback scale factor such that 5000 counts = 1 per
unit generator field current
Adjust EE.l
(lBRlDGE)
current. Not
proportional
VAR.1092.
23 (FL2SFO) to scale VAR.1092

uch that 5000 counts gives 1 per unit
that EE.1523 and VAR.1092 are
an increase in EE.1523 will increase
Also check t e polarity of VAR.1092 (IBRIDGE)

by entering i positive reference step using address
C346H (IRE~STP) and observing VAR.1092.
VAR.l092 s ould change in a positive direction
with a positi e reference command. This can be
done as follolNs:
5.
a.
Assign (lne of the DAC channels to display

VAR.1O~2 (lBRIDGE), and observe this signal whill stepping the regulator.
b.
Step the egulator by typing' C346H =

XXXX, 1 here XXX)( represents the desired
count va ue to determine the step amplitude.
Using the fOl -channel chart recorder, measure

and record tiJjne constants for the generator field
with the field unsaturated and saturated. The
unsaturated t' me constant is found by stepping the
field current Tom approximately 0.20 per unit to
0.15 per unit. Negative going steps are used to
maximize the linear range of the test. The step
sizes should tie adjusted as necessary to
avoid field voltage saturation. The resulting field

current waveform is used to measure the time
constant at 63 % of the steady state current value
(see Figure 9-2 for a typical response plot). The
saturated time constant is found in a similar manner by stepping the field current from approximately 1.0 per unit to 0.90 per unit. The unsaturated time constant, Tfg, is used in section 9-6 to
calculate the regulator gains. The field resistance
is calculated from the field voltage and current at
full field. The time constant is found as follows:
a.
Connect one channel of the chart recorder to

an isolator for the field current signal, and
another channel to an isolator for the field
voltage signal. DAC outputs can also be used
to display these signals if isolators are not
available (see section 9-3.1 for instructions on
setting up the DAC outputs).
b.
Step the generator field voltage to generate

0.20 per unit to 0.15 per unit field current
while observing the field voltage and current
signals. Measure the time constant at 63 % of
the steady state value of the resultant current
signal. When checking the saturated time
constant at full field, measure the field voltage and current then calculate the field resistance from the ratio of Vr/Ir.
63~
,
i
It,
--+---' SAT.
1-0
.1
.
..
Figure 9-2. Generator Saturated Field Time Constant Determination
9-5
BI006008
GEH-6148
Table 9-4. Generator Proportional Command and

Feedback Gain EEPROM Values
9-6. STEP 3 - PROPORTIONAL FIELD

CURRENT REGULATOR RESPONSE
This section includes procedures for calculating proportional feedback gain, entering the resulting value
into the regulator software, and checking the regulator
response. Two gains, EE.1589 (HIRKCO) and
EE.1590 (HIRKFO), are adjusted for the proportional
regulator response (see Table 9-4). Section 9-7 adds an
integrator to improve steady state performance. The
proportional and integral regulator gains are adjusted
separately to minimize the number of simultaneous
variables. Figure 9-3 is a block diagram of the proportional field current regulator.
1.
Address
Mnemonic
Description
EE.1589
HIRKCO
Current regulator proportional

gain in the feedforward path
EE.1590
HIRKFO
Current regulator proportional

gain in the feedback path
3.
Using the EDIT2000 screen, set EE.1589

(HIRKCO) and EE.1590 (HIRKFO) to 1/3 of the
values calculated in step 1, and then simultaneously increase each value for a 80 radian/second
response at weak field. The full field response will
be faster by a ratio of the full field time constant
divided by the weak field time constant.
4.
Observe the field voltage on the oscilloscope while

increasing C346H incrementally using the ST2000
Terminal Mode. Note and record the numerical
value that causes the field voltage signal to go
from a discontinuous to a continuous waveform.
This value, Ifg, will be used in section 9-8 to calculate EE.1583 (ICNTCO).
5.
Using the ST2000 Terminal Mode, check the response of the regulator by stepping the regulator
and estimating the time response of the current
output signal. This should be done using two different step sizes: one in the range of 0.20 to 0.15
per unit; the other in the range of 1.0 to 0.90 per
unit. Figure 9-4 shows a typical response plot.
Calculate the gain value, EE.1589 (HIRKFO), and

enter it into the exciter using the ST2000
EDIT2000 screen. The following formula can be
used to calculate the gain:
HIRKFO
Wef x rfg x 1024 x 16384 x Rfg x Ifrated

Edo x 5000 x 32
where Wcf is the crossover frequency of the field

current regulator in rad/sec, and Edo is equal to
1.35 times the line-to-line input voltage.
Assume Tfg is equal to the unsaturated generator
field time constant. Then assume EE.1590
(HIRKCO) is equal to EE.1589 (HIRKFO).
To obtain the generator's field current regulator
response, close the field current loop and step the
regulator while observing the time response of the
resulting current waveform.
2.
Using the ST2000 Terminal Mode, reduce the

reference signal to zero by typing 'C346H = 0
and pressing (Enter) to avoid a sudden change in
the firing command during the following step.
PROPORTIONAl
COMMAND GAIN
FIELD
EXCITER
ILOPII32
ILOPOUT
ILOPREF
HIRKCO
32
PROPORTIONAl
FEEDBACK GAIN
Ilg
Edo
1024
--16384
FIELD CURRENT
CF8
5000IPU
FEEDBACK
5000
HIRKFO
Ifrated
Figure 9-3. Proportional Generator Field Current Regulator
9-6
GENERATOR
FIELD
1/Rfg
1 + sTlg
BI006008
GEH-6148
63%
,
!
I
Figure 9-4. Proportional Field Current Regulator Response Plot
9-7. STEP 4 - PROPORTIONAL PLUS
T1
INTEGRAL RE GULATOR
This section set~ up and tests the proportional plus

integral regulatc . The integral gain is calculated and
set to provide thp. regulator with increased steady state
accuracy. Figur 9-5 shows a block diagram of the
proportional plu integral field current regulator.
Tfg (weak field)

5
HIRWIO
1.
The integral gai of the regulator, EE.1591

(HlRWIO), can be calculated from the following equations:
Tlx 1440
Using the EDIT2000 screen, set the EEPROM

listed in Table 9-5 to set up the proportional plus
integral regulator as follows:
a.
Set EE.1591 (HIRWIO) to the calculated

value and EE.1581 (lLIMCO) to 16384, as
shown in Table 9-5.
INTEGRAL
cc f,lMAND GAIN
HIRKFOx 32
=----
GAIN
FIELD
GENERATOR
EXCITER
FIELD
ILOPOUT
ILOPREF
+$T3
+sT1
HIRWIO(HsTI)
I-128(s)
-1024
Ifg
Edo
---
I/Rfg
I---
16384
1 +sTfg
"-..-
FIELD CURRENT
FEEDBACK GAIN
CFB
l+sT2
1+sT1
5000/PU
FEEDBACK
5000
Ifrated
Figure 9-5. Proportional Plus Integral Generator Field Current Regulator
9-7
BI006008
GEH-6148
Table 9-5. Proportional Plus Integral Regulator
EEPROM Values
Address
Mnemonic
Value
Description
EE.1591
HIRWIO
Calculate
Current regulator
integral gain
EE.1581
ILiMeD
16384
Voltage range limit

for current regulator integrator
b.
2.
Increase the integral gain, EE.1591

(HlRWIO), until the desired slope is obtained.
Note that EE.1591 can often be increased by
as much as a factor of 10 before overshoot
occurs.
Check the regulator's response by stepping the

regulator and estimating the time response of the
current output signal. Using the ST2000 Terminal
Mode, type 'C346H = XXXX, where XXXX represents the count for the desired step size. C346H
(IREGSTP) is the hex address of the step input to
the field current regulator.
Use two different step sizes, one in the range of
0.20 to 0.15 per unit, the other in the range of 1
to 0.90 per unit. The step sizes should be adjusted
if necessary to avoid field voltage saturation. Use
care to ensure a critically damped response. The
response plot should be similar to that shown in
Figure 9-4.
9-8. STEP 5 - FIELD CURRENT CONVERTER

LINEARIZATION
This section details the generator field current converter linearization procedure. Use the four-channel
chart recorder to display the firing angle signal, RAM
address 28893 (ALPHA); the firing command signal,
VAR.l000 (FIRCMD); the field current signal; and
the field voltage signal. Table 9-1 contains a list of
useful variable addresses. The GF2000 is given positive and negative reference signals to produce a current reversal. The "dead time" between the positive
and negative current signals is measured. For a reversing bridge, the "dead time" should be between 3 and
10 milliseconds for a 10% step in the field current
regulator. Figure 9-6 shows a block diagram of the
converter linearization.
1.
Measure the number of field current feedback

counts, VAR.1092 (IBRIDGE), required to reach
continuous current. This value is typically close to
100.
2.
Calculate and set the EEPROM values listed in

Table 9-6 using the EDITIOOO screen.
3.
Configure the DAC outputs to display useful variables on the four-channel chart recorder. Field
voltage and field current are the two most important variables for this step. Use voltage and
FIELD CURRENT REFERENCE
OISCONTINOUS CURRENT
LOW PASS FILTER
lLOPREF
FEED-FORWARD COMPENSATION
VlCNT
~--+--_.
.j----l'--_-J
TASHI
GENERATOR.
ALPHA
FJELD
PUSH
PROPORTIONAL
CURRENT
GAlN
REF
ILOPl/32
CONVERTER
PHASEOELAY
ILOPREF
ALPHA
.----,
CFe
5CIOOIPU
Figure 9-6. Converter Linearization
9-8
BI006008
GEH-6148

Table 9-6. Field Current Linearization EEPROM Values
Address
Mne ,",onic
Description
Formula
EE.1582
DCG VCO
Voltage gain for open loop current regulator
296 x (V rated 1 V line-to-linel
EE.1583
ICNT ~O
Continuous current scaling factor
0.6 x Ifg continuous counts (typically close to 60)
EE.1584
WCR pLO
Open loop current reference filter
Wc (weak field) x (65536/360) = 80 x (65536/360)
EE.1587
GVR I,CO
Voltage gain for reversal request comparison
621 x (V rated 1 V line-to-line)
EE.1588
RTL~ CO
Retard limit current scaling factor
3 x (If rated x % reactance x V line-to-line) 1 KVA rating

(Use a default of 5% reactance.)
current isol tors, if available, to display the analog field vo tage and current signals. If isolators
are not ava able, DACl and DAC2 can be used
to display t ese signals (refer to section 9-3.1 for
instructions on selecting DAC variables). If isolators are use ~ for the field voltage and current signals, DAC and DAC2 can be configured to output other u eful variables such as the firing angle
signal, RA~ address 28893 (ALPHA), and the
fIring COIrn and signal, VAR.l000 (FIRCMD).
Then, usin the ST2000 Terminal Mode, step the
GF2000 fo Iward and backwards while observing
the signals t>f interest on the chart recorder. The
GF2000 is tepped by typing:
4.
Measure the "dead time" for Ifg (generator field

current) from the chart recorder plot. The "dead
time" is defmed as the time between the forward
and reverse firing signals when the field current is
zero, as shown in Figure 9-7. The "dead time"
should be between 3 and 10 milliseconds.
9-9. STEP 6 - GENERATOR SATURATION

CURVE
= 1l00, which sets the forward field current regwator reference signal,
Before continuing with this section, disable the voltage and current regulators by ensuring that GF@VRE,
GF@IRE, GF@IVS are pointing at zero. This is typically accomplished by inhibiting the MG set running
interlock and opening the M contactor, as shown in
Table 9-2.
= 500, which sets the reverse field current regwator reference signal.
With the MG set running, incrementally increase

C346H (IREGSTP) while observing the change in
, C346H
'C346H
_--t
i-I
...
DEADTIME
WNVVV\fVI!I!IfVU
CI11 A1VW/VI!V'NV
V
IjVf\NV Ii V
fg
Vy
Figure 9-7. Deadtime (ffg = 0) Determination Plot
9-9
BI006008
GEH-6148
the generator armature voltage versus the generator
voltage feedback, VAR.I093 (VMA1_Yeo). Adjust
EE.1503 (VFBSFO) so that 1 per unit generator voltage results in a count of 2oo on VAR.I093
(VMA1_Yeo). ConfIrm proper polarity of the feedback signal by assuring that a positive armature voltage results from a positive reference signal. The armature voltage feedback can be nulled using EE.569
(VARMOF) when the drive is stopped.
This section determines the saturation curve of the dc
generator. Use the field current regulator to vary the
field current from zero to rated field current and record the value of the corresponding generator armature
voltage. Figure 9-8 shows a typical generator saturation curve, produced by plotting the armature voltage
versus the fIeld current on a graph.
The generator field time constant varies as the slope of
the generator saturation curve. A highly non-linear
saturation curve would suggest that the time constant
of the field varies by a factor of 2 or more as a function of field current.
The eddy current time constant is the delay in the

change in armature voltage with respect to a change in
generator field current. Generators with solid magnet
frame constructions exhibit eddy current lag time constants between 0.02 and 0.10 seconds. For laminated
magnet frame generators, the eddy current lag time
constant is negligible.
A step signal input is entered into the regulator using
the STIOOO Terminal Mode, while the generator fIeld
voltage, generator field current, and generator armature voltage are recorded with the chart recorder. Figure 9-9 shows a block diagram of the voltage regulator
including the generator eddy current lead and lag time
constants.
Using the ST2000 Terminal Mode, enter a step signal
into the regulator by typing' C346H = XXXX, where
XXXX represents the count for the desired step amplitude. Start the count at 1000, then step it to 2000 to
capture the eddy current lag time constant at weak
fIeld. e346H (IREGSTP) is the hex address for the
field current regulator reference signal. The step amplitudes should be chosen to step the field at weak field
and also near full field (4500 to 4750).
9-10. STEP 7 - EDDY CURRENT LAG TIME

CONSTANT DETERMINATION
This section is used to determine the eddy current time

constant. The time constant is then used to calculate
the appropriate armature voltage regulator gains.
o
o
>
;::
.8
- - - - -
o .6
,
,
I
I
I
I
I
I
~-----~------~------~-----
_I -
E
0.4
..!. - _ _ _ _ _
I
I
I
I
- - - - -
<:
Q)
0.2
o \.-'
o
------------~-----
- - - - - 1 - - - - - -
I
I
I
I
I
I
I
I
I
I
I
'
'
'- - - - - - 1
'
'
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I ' ,
I
I
~'
--~------:------f------~------:------f------~-----
~
I
I
j
I
I
l
I
I
I
I
I
I
I
-..l.-
I
-..l.-
0.2
0.3
0.4
0.5
0.6
. L -_ _- - - '
O. i
. L -_ _---'-
pee '",nit
l
I
I
Field Cueeent
~ __ ---J
I
I
I
L - -_ _--'--
0.7
Figure 9-8. Typical Generator Saturation Curve
9-10
------:------{---
0..
,
,
:::0
The eddy current time constant is the time to 63 % of

the steady state value of the armature voltage feedback, VAR.1093 (VMA1_VeO). Record the measured time constants for use in later calculations.
0.8
--l.-_ _- - - '
0.9
BI006008
GEH-6148

GENERATOR
GEN.FIELO
EDDY
GENERATOR ARMATURE
CURRENT
CURRENT
VOLTAGE REGULATOR
REGULATOR
LAGIl.EAD
VA
VAREF
_~+\!:;:)_
f?\ _
HVAWlO14<40{1 Tl)
GVAREG
20000IPU
IF
115000
Kvg(1 Tld)
1+sTfr
ARMATURE
1-1PU
1+sTlg
Wcvr-150 rJs
VOLTAGE
FEEDBACK
VARMFB
20000IPU
20000
Fi~
ure 9-9. Armature Voltage Regulator With Eddy Current Lead and Lag Time Constants
9-11. STEP 8
REGULATOR
ARMATURE VOLTAGE
The regulator lead time constant (Tl) used to cancel

the eddy current lag constant (Tlg) is given by:
Tl
NOTE
Ensure that the motor-generator set is

running befpre performing the following
procedure. Refer to Table 9-2 for Armature
Voltage Re~~.dation Mode.
The armature vo age regulator is used to zero the residual de generatDr armature voltage. In this section,
gains for the arm~ture voltage regulator are calculated
and entered usin! the ST2000 EDIT2000 screen. The
armature voltage feedback scaling is calculated and
set, and the step esponse of the regulator is checked.
The open-loop ga~ of the proportional plus integral
generator armatu e voltage regulator is given by (the
minimum eddy c ~ent time constant found should be
used for the calCl: ations):
GH
HVA WlO x 1 40 x 20000 x Kvg

(1 +sTl}(1 +s17d)
x -7:-=-'.-::::----::~
64 x 4096 x 5000
s(l +sTfr)(1 +sTIg)
Solve for the arm~ture voltage integral gain, EE.5338

(HVAWIO), usin1 the following equation:
HVAWlO
Wcvr x 64 x 4096 x 5000

Kvg x 1440 x 20000
where Wcvr is th crossover requency of the armature

voltage regulator In rad/sec, and Kvg is the maximum
slope of the gener tor saturation curve.
HVAKFO x 64
HVAWI0 x 1440
Setting the regulator lead time constant (Tl) equal to

the minimum eddy current lead time constant and
solving the equation for the proportional gain EE.5337
(HVAKFO) results in:
HVAKFO
TIg x HVAWIO x 1440
64
where Tlg is the eddy current lag time constant. Set
EE.5336 (HVAKCO) equal to EE.5337 (HVAKFO).
NOTE
The proportional and integral gains are related and cannot be independently adjusted.
The relationship between these gain values
must be considered when adjusting them.
With EE.573.5 (OVERV_MB source) set to 1, adjust
the instantaneous overvoltage level, EE.606
(OVLTMB) as desired for the particular application
per the following equation:
OVLTMB
= 20000 + (200 x Required Overvoltage %)
When closing the armature voltage or current loops for

the fIrst time, restrict the generator fIeld current reference limit, EE.5339 (GIFLMO), to 2000 counts or
40 % of the rated generator field current. Thereafter,
set EE.5339 (GIFLMO), for the particular application.
Typical values are 1.67 pu (8333) for reversing hot
9-11
BI006008
GEH-6148
Table 9-7. Armature Voltage Regulator

EEPROM Values
mill applications and 1.25 pu (6250) for cold mill applications and drives that accelerate at a relatively slow
rate of 20 % of rated speed per second.
1.
2.
Configure the exciter for Armature Voltage

Regulation Mode per Table 9-2. Set up the chart
recorder to display armature voltage feedback,
armature current, field voltage, and field current.
Using the ST2000 EDIT2000 menu, set the parameters in Table 9-7 to their calculated values.
Using the ST2000 Terminal Mode, step the armature voltage regulator and verify correct regulator
response in the following manner:
a.
b.
Type' C340H = XXXX, where XXXX is 10%

of the desired armature voltage step amplitude. C340H (VASTP) is the hex address for
the armature voltage reference signal. Increase EE.5338 (HVAWIO), the integral gain
of the dc generator armature voltage, until the
desired regulator response is obtained. Figure
9-10 shows a typical response plot.
Address
Mnemonic
Value
Description
EE.5336
HVAKCO
Calculate
Armature voltage
command gain
EE.5337
HVAKFO
Calculate
Armature voltage
feedback gain
EE.5338
HVAWIO
Calculate
Armature voltage
integral gain
EE.5339
GIFLMO
Calculate
Generator field
current reference
limit
EE.579
IOVTHR
Calculate
Instantaneous
overvoltage trip
level
9-12. STEP 9 - ARMATURE CURRENT

FEEDBACK SCALING AND OVERCURRENT
SETTING
CAUTION
Adjust the proportional gains EE.5336

(HVAKCO) and EE.5337 (HVAKFO) to obtain the correct shape. The lead time constant
(Tlead) formed by the ratio of the proportional gain over the total integral gain should
be proportional to the eddy current time constant of the dc generator:
Tlead
The following test is normally performed in

Voltage Regulation Mode with the main
contactor closed. Because armature current
may be present if a contactor is not used or
if a contactor is used and is closed on
power-up, set EE.573.14 and EE.573.15 to
1 to disable the auto-null function.
HVAKFO
HVA WIO x 1440
This section checks the polarity and scaling of the current feedback signal. The instantaneous overcurrent
level is then set, and the protection circuit is tested for
proper operation.
Observe the field current, field voltage, and

armature voltage for proper response.
JJW~VJV~(VJV\M\WWMV\\NV~V~,\N\
Va
I
I
-I
63%
,
I
I
rlAVR
~jV\\n\~rl\01\l\i~rV\
,\
'n
,lfllff{\NYlrI{1
0/\A
A{I!\,fi II !\fl/\ ~
~ yvV\,'
~V\I'VrvVI/' \N
I
Figure 9-10. Armature Voltage Regulator Response Plot
9-12
BI006008
GEH-6148

NOTE
For this t
there must
ent. The m
to reduce i
must be in
section 9-3.
3.
,the rotor must be locked and

e no motor field current prestor field leads may be shorted
duced voltages. The exciter
oltage Regulation Mode (see
).
Check the IOC operation by shorting the output of

the dc generator and varying the input of the dc
generator armature voltage regulator. Short-circuit
armature current circulates until it reaches the
IOC trip level.
NOTE
All electromechanical safety devices should

also be dynamically checked for proper operation and trip level.
NOTE
Small volta e reference steps of 2 - 5% are

sufficient f testing in this section.
1.
2.
Check the p larity and scaling of the current feedback signal y entering a voltage step signal at
C340H (VA TP), and observing the magnitude
and polarity f the current feedback signal,
VAR.l005 ( AIFB). The step signal is input using
the ST2000 erminal Mode while VAR.l005 is
observed for a proportional change as follows:
a.
Confi e one of the DAC outputs to display

VAR.l 5 (IAIFB), the current feedback
signal (s e section 9-3.1). Using the chart recorder, bserve the polarity of this signal with
respect t the step input. (VAR.l005 can also
be assi ed to a diagnostic output and displayed u ing Test 31 (see section 9-3.5).)
b.
Using th ST2000 Terminal Mode, enter

C340H XXXX, where XXXX is the desired
step ma 'tude count, while observing the
VAR.1 5 (lAIFB) signal. Adjust the magnitude of e armature current feedback using
EE.1505 the current feedback trim factor.
ture IOC setpoint, EE.1525

(lOCARO), b multiplying the per unit count
(5000) by the desired overcurrent percentage. For
example, for 260% overcurrent level setting, the
proper setting for the IOC setpoint is given by:
IOCARO = 5000 x 2.60 = 13000

See the ST2
help for this variable for additional inform ion.
CAUTION
To avoid pass ble damage to the commutator due to hig sustained levels of armature
current, m' . ize the duration of the high
armature cur ent tests.
9-13. STEP 10 - ARMATURE TIME CONSTANT

DETERMINATION
This section is used to determine the armature time

constant. This time constant value is used to calculate
control parameters for the armature current regulator.
1.
Using the ST2000 Terminal Mode, step the armature voltage regulator while measuring the armature time constant from the resulting armature
current signal. As shown in Figure 9-11, the time
constant is the time required for the armature current to reach 63% of its steady state value. To
step the regulator, type . C340H = XXXX, where
XXXX is the count representing the voltage step
amplitude. C340H (VASTEP) is the hex address
for the armature voltage reference signal.
2.
Note the time constant, which is used to calculate

the appropriate regulator parameters. Enter the
calculated values into the GF2000 exciter using
the ST2000 EDIT2000 screen. The integral gain
of the generator armature current regulator.
EE.5330 (RIAWIO), is given by:
BIA WIO
Weer x 64 x 4096 x Ra
Kvg x 1440
where Wcvr is the crossover frequency of the armature current regulator (50 to 150 rad/sec) and
Ra is the per unit armature resistance. Note that
(Ra x Ia rated)/Va rated = 0.05 for typical dc
motors and generator loops. Kvg is typically
unity, the generator voltage constant.
The lead time constant (TI) of the generator armature current regulator is equal to:
Tl
BlAKFO x 64
= BIA
WIO x 1440
9-13
BI006008
GEH-6148
Ia
Va
Figure 9-11. Armature Time Constant Determination Response Plot
Tl is used to cancel the larger of the eddy current lag

(Tlg) or the armature current lag time constant (Ta).
The armature current regulator feedback gain,
EE.5329 (HIAKFO), is therefore given by:
HIAKFO = Tlg (or Ta) x HIA WIO x 1440
64
The proportional feedback and command gains are

equal: EE.5329 (HIAKFO) = EE.5328 (HIAKCO).
The lead-lag fllter time constants should be preset to
the following values:
Lead time constant (1'2)
= Td = 1/50 sec
Lag time constant (T3)
= Tg = 11400 sec
This gives the following values for the lead and lag
compensation coefficients EE.5331 (GLLCO),
EE.5332 (GLLC1), and EE.5333 (GLLD1):
GUCO = 2Td + T x 1024 = 7318

2Tg +T
GLLC1 = -2Td + T x 1024 = - 7068
2Tg + T
GLW1
2Tg - T x 1024
2Tg +T
= 774
where T, the sample time of the 12-bit DAC outputs,

is equal to 1/720 sec.
NOTE
The lead and lag time constants can have a

large effect on the regulator response and
should be adjusted with extreme discretion.
If T2 and T3 must be adjusted, the exciter
must be stopped. The ratio of the lead to
lag time constants should be less than 10.
9-14. STEP 11 - ARMATURE CURRENT

REGULATOR
NOTE
The exciter must be in Armature Current

Regulation Mode before continuing (see
Table 9-2). Closing the main contactor
makes VAR.1419 (IASEL) equal to 1 and
VAR.1417 (VARON) equal to 0, then
makes VAR.1418 (IARON) equal to 1 to
regulate armature current.
Set EE.S73.14, EE.S73.1S, and EE.6283.3
equal to 1 to inhibit auto-nulling at powerup. Refer to the help for these variables
for more information.
9-14
BI006008
GEH-6148
Table 9-8. Armature Current Regulator

Gain EEPROM Values
To be properly ~sted, the current regulator. must be

separated from revious control blocks. Usmg the
ST2000 BLKEI T screen, fmd and select the core
block. Press the Block Info softkey (F1) and replace
the speed regula or output VAR.140 (SREGOUT) at
core block input COR@IC with an unused, generalpurpose register such as EE.REG75. The value of
EE.REG75 mus be set to zero when the armature
current regulatol is tested in this section. EE.REG75 is
then the variable used to input a step signal into the
fIltered reference regulator in section 9-14. The dc
generator armanlre current regulator must be ttmed
fast enough to eI f"orce the dc armature current of the
motor. A value f~r Wc between 100 and 150 rad/sec
provides a prope response with minimum overshoot.
Address
Mnemonic
Value
Description
EE.5328
HIAKCO
Calculate
Armature current
regulator gain
EE.5329
HIAKFO
Calculate
Armature current
regulator feedback gain
EE.5330
HIAWIO
Calculate
Armature current
regulator integral
gain
NOTE
Gain parameters EE.5328 (IDAKCO),

EE.5329 (IDAKFO), and EE.5330
(IDAWIO) are related. These parameters
and must be adjusted carefully while considering their relationships.
A block diagram of the armature current regulator is

shown in Figure 1:>-12. This section uses the ST2000
Terminal Mode t step the armature current regulator
while the step rellPonse of the regulator is observed.
NOTE
2.
Using the ST2000 Terminal Mode, step the armature current regulator by typing' C341 H =
XXXX, where XXXX represents the count for the
desired current reference step signal. C341H
(IAREF) is the hex address for the armature current reference step signal. Use a 20% step in the
armature current reference to prevent saturating
the field exciter.
3.
Check the armature current response for proper

regulator operation. See Figure 9-13 for a typical
response plot. If the response is too slow, increase
the integral gain HlAKWO and the proportional
gains HlAKFO and HIAKCO in the same proportions.
The JOC set(>oint should be set to a safe

value to pro ect against accidental overcurrent. The se point is adjusted by setting
EE.1507 (lOCTRO) in the STIOOO
EDIT2000 sc~een. Refer to the help for
EE.1507 (ana EE.1525 and EE.1527) for
more inform~tion.
1.
Using the ST 000 EDIT2000 screen, set the armature current r gulator gain values listed in Table
9-8.
ARMATURE
CURRENT
REGULATOR
IAREF
5000IPU
EDDY
CURRENT
COMP
HIAWIOl440*{1 +sT1}
644096 Isl
GIAREG
5000
-1 PU
1 +sT2
1 +sT3
EDDY
CURRENT
LAG/LEAD
GEN FIELD
CURRENT
REGULATOR
IFGREF
5000
-1 PU
1
5000(1 +sTfr)
IF
1-1 PU
ARMATURE
CIRCUIT
VA
, -, PU
Kvg(l +sTld)
l/Ra
IA
1-1 PU
I--1 +sTlg
, +sTa
Weer. 150 rls

ARMATURE
CURRENT
FEEDBACK
IARMFB
5OOO/PU
5000
Figure 9-12. Generator Armature Current Regulator
9-15
BI006008
GEH-6148
LOPREF
63%
'-,-=--- t ACR
Figure 9-13. Generator Armature Current Regu/ator Response
9-15. STEP 12 - ARMATURE CURRENT RATE

AND FILTER
The armature current rate limit block includes a lowpass filter to remove the tachometer ripple disturbance
from the output of the speed regulator. This section
tests the filtered current regulator response. An unused, general purpose register (such as EE.REG75) is
used as the input to the low-pass filter (COR@IC).
WCGIAO
100 x 65536
1440
= 4551
lRATLMO = 100 x 20 = 2000
9-16. STEP 13 - SPEED REGULATOR FEEDBACK SCALING AND POLARITY VERIFICATION

NOTE
1.
2.
Using the ST2000 EDIT2000 screen, set

EE.REG75 to the desired count for the proper
step amplitude.
Set the low-pass filter frequency, EE.5326
(WCGIAO), and current rate limit, EE.1526
(IRATLMO), to the values found using the following equations while observing the small and large
signal responses.
WCGIAO
Filter Frequency (rad / sec) x 65536

1440
lRATLMO = 100 x Per unit current / sec
Typically the filter frequency is 100 rad/sec and

the current rate limit is 20 pu current/sec. Therefore, the typical values for EE.5326 (WCGIAO)
and EE.1526 (IRATLMO) are found by:
9-16
Apply full field current and unlock the rotor before proceeding.
This section checks the speed regulator feedback scaling and polarity. Before proceeding, the speed regulator must be reconnected to the core block using the
ST2000 BLKEDIT screen. The general-purpose register used as a step input in the previous sections must
be replaced with the speed regulator output VAR.140
(SREGOUT) at core block input COR@IC.
The armature voltage regulator may be used to perform this test. To activate the armature voltage regulator, increment the armature voltage reference signal,
RAM address C340H (VASTP), while observing the
speed feedback for proper scaling and polarity. The
speed feedback count should be scaled such that 2oo
BI006008
GEH-6148

is the maximum
age reference st
speed feedback
that gives 1/2 P
speed feedback
count value obtained. A positive voltp signal should produce a positive

ignal. A voltage reference step signal
armature volts should produce a
ount of:
1000 x (base speed/max speed)
9-17. STEP 1 - PROPORTIONAL SPEED

REGULATOR
NOTE
The diagno tic Speed Regulator Tuneup test

(Test 15 or 5) may be used here (see Chapter 8 for a escription of this test). Some
industries ay use other methods of tuning
the speed r gulators. The procedure in this
section is in ended to be used in the absence
of a pre-est blished method.
Figure 9-14 is a lock diagram of the speed regulator.
When the integr gain and limits are zeroed, the speed
regulator can be
ed in the proportional gain mode.
This mode is use to fmd the mechanical time constant
of the system an to set EE.1408 (SRJO), the speed
regulator inertial compensation gain.
1.
2.
Using the S
EEPROM v
shown. The
found with
set to 0 and
000 EDIT2000 screen, set the

ues listed in Table 9-9 to the values
roportional speed regulator gains are
e integral gain, EE.141O (SRWIO),
e proportional gains, EE.1406
(SRKCMO) d EE.1407 (SRKFBO), set to 4096.
The inner 10 p gain, EE.1409 (SRWO), is calculated accor . g to the desired crossover frequency
of the loop:
Table 9-9. Proportional Speed Regulator

EEPROM Values
Address
Mnemonic
Value
Description
EE.1410
SRWIO
Sets integral gain

to zero
EE.1406
SRKCMO
4096
Proportional speed
command gain
EE.1407
SRKFO
4096
Proportional speed
feedback gain
EE.1411
SRWF
Set to zero
EE.1409
SRWO
Calculate
Inner loop gain
EE.1408
SRJO
Determine
Inertial compensation gain
EE.1412
SRLMP
Calculate
Positive speed
regulator limit
EE.1413
SRLMN
Calculate
Negative speed
regulator limit
If the mechanical time constant or the per unit inertia value of the system is known, the value of
EE.1408 (SRJO) can be calculated as follows:
SRJO=64 x (top speed/base speed) x J (per unit)

The positive and negative speed regulator limits,
EE.1412 (SRLMP) and EE.1413 (SRLMN), are
given by:
SRLMP
= 5000 x Per unit armature current limit
SRLMN
3.
= 5000 x Per unit armature current
Using an unused general-purpose register, such as

EE.REG75, input a speed reference command
step signal. Check for proper response while
stepping the proportional regulator. The response
plot should look similar to Figure 9-15.
NOTE
Increase the' ertial compensation gain, EE.1408

(SRJO), incre entally from unity to the value that
gives the des' ed response.
There are two ways to limit the armature

current reference: in the speed regulator t
and in the core block with EE.SOS
(CORELMM) and EE.S06 (CORELMG).
9-17
BI006008
GEH-6148
SPEEO
REGULATOR
PROPORTIONAL
GAIN
TOTAL
INERTIA
TORQUE
CONTROL
SREGOUT ~_ _~
SRCM
OlWmax
,n=lI'T
,.,1/5000
TMOT
PU
WMOT
PU
- -__
+ fl--,~I----<.~-~
l='=-
TLOAO
-.v-1
,-----+
INTEGRAL
GAIN
SRWI*720
S'65536
~i
SPEEO
FEEOBACK
SRFB
20oo0IWmax
L-
---<~_ _-
---
_!
20000
LJ'
,
Wmax ,
'--------'
Figure 9-14. Speed Regulator Block Diagram
~ ,
63%
I
t SR
Ia
Figure 9-15. Proportional Speed Regulator Response
9-18, STEP 15 - PROPORTIONAL PLUS

INTEGRAL SPEED REGULATOR
SRKCMO
The proportional plus integral speed reference regulator is set up and tested in this fInal tuneup section. Its
function is to regulate the correct speed despite load
disturbances that come from the process.
SRWIO
1.
Calculate EE.1406 (SRKFBO), EE.1407

(SRKCMO), and EE.1410 (SRWIO) using the following equations. Set these values using the
ST2000 EDITIOOO screen.
SRKFBO = (Kd
9-18
+ 1) x
4096
Kd
= 4096
= 91
Wcs
Kd
where Kd, a damping factor, is between 1 and 3,

and Wcs is the crossover frequency of the speed
regulator in rad/sec.
2.
Step the regulator using the ST2OO0 Terminal

Mode and a general-purpose register for the step
input signal. Check the regulator response for
proper operation. The response curve should be
similar to the one in Figure 9-15.
BI006008
GEH-6148
CHAPTER 10
TROUBLESHOOTING
10-1. INTRO[ UCTION

This chapter pr vides specific information to help detect and correct problems with the GF2000 DC Generator Field Exc iter. This chapter is organized into
three primary Sl ctions:
General Troub eshooting. This section covers problems that h ve no associated fault or error indication, or tha cannot be fixed using the standard
fault systetr .
Stability ProblE m Troubleshooting. This section defmes three ypes of stability problems: cyclical
stability pre blems; mechanical oscillation problems; and e ifatic operation problems.
Specific Fault '1 roubleshooting. This section defmes
exciter fault detected by exciter diagnostics and
indicated as error codes. Table 10-5 at the end of
this chapter ~efmes these error codes.
WARNING
This equipn ent contains a potential hazard
of electric s ~ock or burn. Only adequately
trained per onnel who are thoroughly familiar with he equipment and the instructions should maintain this equipment.
10-2. TOOLS
NO INSTRUMENTS
These troubleshooting instructions require the standard

tools used when working with electrical equipment.
Additionally, the following instruments and references
should be available:
Oscilloscope
Megger
Renewal Parts Listing
Hardware Summary
Elementary diagrams
WARNING
To prevent electric shock, ensure that all

power supplies to this equipment are
turned off. Then ground and discharge the
equipment before performing any adjustment, servicing, or other act requiring
physical contact with the electrical components or wiring.
10-3. GENERAL TROUBLESHOOTING

Table 10-1 outlines the general problems that may
occur with the GF2000 exciter. Table 10-2 contains
the possible solutions for each problem listed in Table
10-1.
NOTE
All tools aD( instruments used to touch

electrical co nponents should be insulated
and ground d to meet National Electrical
Code (NEe) standards.
10-1
BI006008
GEH-6148
Table 10-1. Troubleshooting Quick Reference Guide

Type of Problem
Problem Reference in Table 10-2
Exciter faults, LED indication
1. All diagnostic LEDs off

2. All diagnostic LEDs on
3. Fault messages displayed (repetitive)
4. Fault messages displayed (non-repetitive, random)
Programmer problems
5. Programmer display off

6. Error messages displayed
7. Programmer ineffective, no errors displayed
8. Parameter changes ineffective
9. Diagnostics do not perform
Fuse blowing, MOV failures, and board failures
10. Fuse blowing (ac power fuses)

11. Power supply fuses blowing
12. MOV failures
13. Repetitive board failures
14. Line voltage problems
Operational problems
15. 24 V logic not operating properly

16. Motor does not run
17. Motor runs in the wrong direction
18. Motor does not reverse
19. Motor speed is incorrect
20. Serial link does not function properly
21. Erratic operation
22. Stability problems
23. Signal-level detector chatter
24. Too much coast time on deceleration (regenerative
drives)
Motor problems
25. Motor runs hot

26. Motor audible noise
27. Motor vibration
Improper EEROM/EEPROM rewrites at

powerup or reset
28. EEROM/EEPROM rewrites
Noise, wiring, power supplies, and similar problems
29. Noise or random nuisance faults

30. Wiring procedures
31. Checking power supplies
10-2
BI006008
GEH-6148

Table 10-2. General Troubleshooting Chart
Problem
Correction Procedures
1. All diagnostic EDs off
1. Check Programmer display for exciter fault (if used).

2. Check for 3-phase ac input.
3. Check for open ac line fuses (FU1 through FU3) or breaker.
4. Check for open fuses on DCFB board.
5. Ribbon cable(s) disconnected, open, loose, or intermittent.
6. Power supplies loaded down or failed - refer to Problem 31 (Checking power

supplies).
7. Use Programmer to attempt to enter the Parameter Mode (see Chapter 8). Refer
to Table 10-5 if any fault codes are detected. A hard reset should clear this
lockup condition.
8. Replace SLCC card firmware.
9. Replace SDCC card firmware.

2. All diagnostic LEDs on
1 . Drive faulted - check fault code list (Table 10-5).

2. NTB/3TB board's RESET point (3TB-58) connected to +5 or +24 V de.
3. Fault messages displayed (repetitive)
4. Fault messages displayed (nonrepetitive, rand m)

5. Programmer dis playoff
1. See Table 10-5, Specific Fault Troubleshooting, for troubleshooting procedures

related to specific exciter fault number.
1. See Problem 29 (Noise or random faults).
2. See Problem 30 (Wiring procedures).
1. Check that all plugs are connected properly.

2. Check power supplies - see Problem 31 (Checking power supplies).
6. Error messages ~isplayed

7. Programmer ine fective, no errors
displayed
1. See Table 10-5, Specific Fault Troubleshooting, for troubleshooting procedures

related to specific error message.
1. Check that all plugs are connected properly.
2. Check jumpers on SLCC card for proper position.
3. Check that the exciter is in Auto mode. This mode inhibits certain mode references.
8. Parameter
chan~
es ineffective
1. Check SDCC card's Write Protect jumper, JP1. JP1 must be in the 2-3 or ENABLE
position for programming.
2. Check setting in EE.2.0, DGNJP) - must contain a #1 # to allow reprogramming.
3. If the exciter uses multi-motor operation for different gear ranges, spindle orient,
and so on, verify that the proper motor parameters are being adjusted. Check by
setting to 10 the IOC trip setpoint of the motor parameters being adjusted.
Starting the exciter causes and IOC fault if the proper motor parameters have
been adjusted.
4. Check Problem 7 (Programmer ineffective, no errors displayed).

9. Diagnostics do n t perform
1. Check that the particular function is available - refer to the Custom Software,
software jumper descriptions.
2. Check the SDCC card's jumper JP1. JP1 must be in position 2-3 for some diagnostic tests to work. Refer to Programmer information in Chapter 8.
3. Check the NTB/3TB board's POL point (3TB-38) for reverse signal.
4. Refer to Problem 7, (Programmer ineffective, no errors displayed).
10-3
BI006008
GEH-6148
Table 10-2. General Troubleshooting Chart - Continued

Problem
10. Fuse blowing (ac power fuses)
1. Compare the fuse size with the Renewal Parts List.
2. Check for out-of-tolerance or sagging ac line voltage on regenerative exciters refer to Problem 14 (Line voltage problems) and Problem 29 (Noise or random
nuisance faults).
3. Using a megger, check for a ground in motor circuit or blower circuit. (Observe
applicable WARNINGs and CAUTIONs.)
4. Check to see if exciter is being forced into current limit by an overhauling load.
11. Power supply fuses blowing
1. Check that the fuses are the correct size.

2. Check for any shorted or overloaded power supplies. Refer to Problem 31.
3. Replace the DCFB board.
12. MOV failures
1. Refer to Problem 14 (Line voltage problems).

2. Generator fault causes ac fuses to open during regeneration. Check for grounded
armature, field, or wiring.
13. Repetitive board failures
1. Check all connections at all terminal boards.

2. Check that all ribbon cables and plugs are connected properly (for example, not
offset by one row or pin).
3. Check the stab terminal connections on the DCFB and PCCA boards.
4. Check that all voltages (incoming ac and internal dc) are correct.
5. Check for moisture.
6. Check for damage caused by airborne chemical contamination.
14. Line voltage problems
1. Check that the line voltage is within exciter specifications, -5 to
+ 10%.
2. Check that the ac line voltage is balanced line-to-line and line-to-ground.

3. Check for ac line notches or spikes.
4. Check that the ac line frequency is within 1 Hz of rated.
5. When the ac line is supplied by a diesel-driven alternator, check for changes in
line frequency during exciter acceleration or regeneration.
6. Check for more than 1-1/2 cycles of ringing following commutation notches in
the ac line caused by the exciter. Amplitude should be :> 200 V.
7. Check for an ungrounded secondary on the power system transformer directly in
front of the exciter, if used. (The transformers are generally a delta/wye type with
the neutral of the wye grounded through a high resistance or directly to ground.
15. 24 V logic not operating properly
1. Check the 24 V dc power supplies.

2. Check the logic polarity control jumpers per the Custom Software.
3. Check control logic connections at the NTB/3TB board.
4. Check for proper polarity and common circuit if the 24 V dc supply is from a
source other than the exciter.
5. Check that the exciter is in the proper mode (0, 1, 2, or 3) for the particular generator or function being operated.
16. Motor does not run
1. Fuses open (or optional circuit breaker open).

2. Fuses open on DCFB board.
3. Check all hardware and software jumpers per the Custom Software.
4. Check control logic voltage and state, and power supply voltage levels at the
NTB/3TB board.
5. Check that the exciter is in the proper operate mode (Auto, Manual, etc.).
6. The motor may be stalled in current limit.
7. The motor-generator set running interlock is open.
17. Motor runs in the wrong direction
1 . Check for the logic signal at the NTB/3TB board's POL point (3TB-3B).
2. Armature connections are reversed (correct armature and tach leads) ..
3. Check all software and logic polarity control jumpers per the Custom Software.
4. Check the reference polarity.
5. Check the Custom Software to verify that the reverse function is enabled when
operating from the serial link.
10-4
BI006008
GF2000 Dc
Ge~erator
GEH-6148
Field Exciter
Problem
18. Motor does ot reverse
1. Check that the exciter is regenerative.
2. Switch any two output leads.
3. Check the reference polarity.
4. Check control logic to the NTB/3TB board's POL point (3TB-38), if used for reversing.
5. Check the logic polarity control jumpers per the Custom Sohware.
6. Check the Custom Software to verify that the function is enabled when operating
from the serial link.
19. Motor speed is incorrect
1. Check that the motor design is suitable for the application.

2. Check that the proper reference is enabled per the Custom Software.
3. Check for proper reference scaling.
4. Check for noisy tach signal. Refer to Problem 30 (Wiring procedures).
5. Check that the motor is not in current limit.
6. Check that the motor or exciter is not in voltage limit.
7. Check that the tach scaling parameters are set correctly.
20. Serial link do s not function properly
1. Check that all required jumpers to enable function are set properly.
2. Check the exciter's baud rate compared to serial link device (a hard reset is required following a change in baud rate).
3. Check serial link connections at the NTB/3TB board.
4. If RS-422 is used, verify that the handshaking lines are properly connected.
Check that the sending device is responding to the exciter's DTR signal (low
level) when the device transmits to the exciter.
5. Replace the SLCC card.
21. Erratic operat on
1. Check power supplies for magnitude and ripple - refer to Problem 31 (Checking
power supplies).
2. Check connections on all ribbon cables.
3. Tighten all connections on terminal boards and all power connections.
4. Confirm correct hardware jumper settings per the Custom Sohware.
5. Check all parameters per the software test data sheets in the exciter door or Custom Software.
6. Check for noisy ground connection - refer to Problem 30 (Wiring procedures).
22. Stability probl ms
1. Check settings of all parameters per the software test data sheets in the exciter
door pocket.
2. Check that all contacts on the MA contactor are closing.
3. Refer to section 10-4 (Stability Problem Troubleshooting).
23. Signal-level de ector chatter
1. Is signal-level detector looking at a noisy signal (for example, tach feedback)?

2. Is enough hysteresis programmed into the appropriate parameter address?
24. Too much coa t time on deceleration

25. Motor runs ho
1. Check settings in the Custom Software and confirm that regeneration is enabled.
1. Motor may be overloaded; check for mechanical problems.
2. Check the motor winding temperature. If the motor has Class F insulation and the
winding temperature is less than 130C (260 of). this is normal.
3. Check the rotation of the motor blowers.
4. If the motor runs hot at very low speeds, check the motor application guide for
full-torque speed range.
26. Motor audible oise
1. Unstable regulator - check Problem 22 (Stability problems).
27. Motor vibratior
1. Coast Stop Exciter - if the vibration is electrically induced, the vibration disappears. If it does not disappear, check for mechanical causes.
2. Refer to Problem 22 (Stability problems).
3. The motor is not mounted level.
4. The motor base is vibrating.
10-5
BI006008
GEH-6148

Problem
28. EEROM/EEPROM rewrites
1. The SDCC card's jumper JP1 must be in the 1-2 position during powerup or hard
reset.
29. Noise or random nuisance faults
1. Check that the + 5 V dc supply is not used externally.

2. Check for suppression on all relays, contactors, and starters.
3. Check all power supplies - refer to Problem 31 (Checking power supplies).
4. Refer to Problem 30 (Wiring procedures).
30. Wiring procedures
1. Check the wire sizes on the ac power connections.

2. Check that the control wires (24 V dc, 115 V ac) do not run in the same conduit
or run parallel closer than 4 inches to the power wires, causing noise pickup.
3. Check that all signal wires (such as tach, encoder, reference, load cell, or RS232C/RS-422) are twisted-pair, shielded and that shields are grounded at the exciter end only.
4. Check that signal wires are not grounded at more than one end or other than the
exciter end only.
5. Check that the signal wires do not run in the same conduit, parallel, or closer than
4 inches to the power wires.
6. Check that there is only one system ground.
7. Check that the ground bus is large enough to prevent voltage drops or noise
pickup.
31. Checking power supplies
1. Check the + 15 V testpoint for + 15 V dc, 5 %. Verify with an oscilloscope that

there is less than or equal to 100 mV of ripple.
2. Check the -15 V testpoint for -15 V dc, 5%. Verify with an oscilloscope that
3. Check the +5 V testpoint for +5 V dc, 5%. Verify with an oscilloscope that
10-4. STABILITY PROBLEM TROUBLESHOOTING
Because of their similar behavior, this manual classifies three broad categories of exciter problems as
stability problems:
Cyclical stability problems
Mechanical oscillation problems
Erratic operation problems
Technically, the last two of these are not "true" stability problems. They are included in this section as
stability problems because they share the characteristics of oscillations or fluctuations in the exciter.
This section also discusses troubleshooting of stability
and other problems caused by phase differences between the ac line power brought to the DCFB board
and that brought to the field and/or armature bridge.
Problems caused by such phase differences can be
resolved by setting parameters contained in the SDCC
EEPROM.
10-6
10-4.1 . Cyclical Stability Problems
This category includes "hunting", oscillations in speed

or current, and similar problems. Generally, these are
characterized by cyclical, well-defmed sinusoidal oscillation periods.
Usually, cyclical stability problems are electrically
induced. They can be corrected with proportional and
integral gain adjustments.
Most GF2000 exciters have at least three regulating
loops:
Current regulator, continuous current
Current regulator, discontinuous current
Speed regulator
If any of these are mistuned, stability problems can

occur under the right conditions.
BI006008
GEH-6148
NOTE
GF2000 exciters are almost always stable.
Various ~ rms of position regulators are

also avail Ie. Because of their variety, this
section ca ot address them.
Most stability problems, but not all, are corrected

by adjusting speed loop parameters.
In general, when troubleshooting cascading or

series regulating loops, the correct procedure is
to stabilize the regulators in the following order:
10-4.2. Mec anical Oscillation Problems
These are mec anical deficiencies that, under certain

conditions, can be aggravated or excited by electrical
frequencies. Fo example, such problem include vibration, audib e noise, and gear chatter.
Operation Problems
These are inter 'ttent speed or current fluctuations,

mechanical "b ping", or other non-sinusoidal or
non-periodic d turbances. Such problems can be
induced by inte 'ttent grounds, noise, or mechanical
problems.
eshooting Procedures
NOTE
ter checks and adjustments required in t . section require use of the

Programm r.
10-4.4.1. INITI L CHECKS. Before troubleshooting
the exciter for s bility problems using Table 10-3,
check the folIo ing conditions:
1.
2.
3.
4.
1.
Inner regulator
2.
Current regulator
3.
Speed regulator
4.
Position regulator (if furnished)

NOTE
If any of these steps stabilize the exciter,

record any parameter changes and do not
continue with the remaining steps.
10-4.5. Ac Line Phase Problems
For the exciter to operate properly, the ac line inputs

to the armature bridge must be in phase with the ac
line sync signal to the DCFB board, or phase differences must be compensated for using parameters
stored in the SDCC EEPROM. Problems caused by
phase differences between these inputs include:
Armature SCR failures
SCR test failures (opens or shorts)
All softwar jumpers match the exciter parameter

list (see Ch pter 8).
Loss of stability (speed, current, or field regulation problems)
jumpers match the jumper selection

hapter 5).
Advance limit too low (cannot achieve rated armature voltage)
All softwar parameters match the parameter list

(see Chapte 8).
Retard limit too high (cannot regulate zero

speed/volts)
All wiring i correct and agrees with the exciter

elementary iagrams.
Fault 22 (PHASELOS) when EE.187 has a value

of zero
10-4.4.2. PROS EM DETERMINATION. Use Table 103 to determine e type of problem, keeping the following pointers' mind:
10-7
BI006008
GEH-6148
EEPROM parameter EE.558 (ASYADJ) adds a fIxed
angle offset to the armature fIring circuit to compensate for phase differences between the ac line sync
input to the DCFB board and the ac line input to the
armature bridge. The default value of ASYADJ is O.
The range of possible values is -12000 to 12000,
where 16384 corresponds to 180 degrees. A positive
value is used if the armature phasing lags the line sync
phasing; a negative value is used if the armature
phasing leads the line sync phasing.
For example, assume that the Ll, L2, and L3 inputs to

the DCFB board for the line sync PLL are connected
to phases A, B, and C, respectively. If the Ll, L2,
and L3 inputs to the armature bridge are connected to
C, A, and B, respectively (lagging the line sync phasing by 120 degrees), set ASYADJ to 10922 (120/180 x
16384). If the armature bridge inputs are connected to
B, C, and A, respectively (leading the line sync phasing by 120 degrees), set ASYADJ to -10922.
Table 10-3. Stability Troubleshooting

Symptoms
Procedures
1. Unstable when unloaded, but stable

when loaded; exciter is stable but indicates gearbox or motor noise, or runs
erratically
1.
2. Speed instability below base speed
Adjust auto-tune parameters then re-run auto-tune.
2. If instability still exists, return adjusted parameters to their

original settings and skip to Symptom 4.
1. See Custom Software for gain changes in speed loop.
2. If no improvement, return the adjusted parameters to their original settings.
3. If there is some improvement, but instability still exists, document changes and skip to Symptom 4.
3. Speed instability above base speed
1. See Custom Software for gain changes in stability parameters.

2. If no improvement, return the adjusted parameters to their original settings.
3. If there is some improvement, but instability still exists, document changes and skip to Symptom 4.
4. Drive is unstable:
over a small part of the speed
range,
- or when loaded but stable when
unloaded,
- or such that oscillating frequency
is proportional to speed
1. Check that the problem is not tach related. Correct the tach
feedback problem (misaligned or loose coupling, belt slippage,
wiring, or excessive ripple).
2. With an oscilloscope, check that the power supplies are clean
(refer to Problem in Table 10-2).
3. Run the exciter to top speed and push the SDCC's RESET button. The exciter then coast stops. Mechanically induced problems will still be present as the motor slows down. If the problem disappears, continue to next step.
4. Determine resonant frequency Fr in Hz with an oscilloscope, if
possible. Convert to radians per second as follows:
Wr = 6.28 x Fr
5. If no improvement, return the parameters to their original settings and skip to Symptom 6.
5. Unidirectional stability problems
1. Inspect the load to ensure that nothing is wrong mechanically.
6. Additional procedures - if these procedures are required, contact GE Drive

Systems, Product Service Engineering,
(703) 387-7595.
If the above procedures do not stabilize operation, additional steps

may be required, including:
1. Checking out the current loop.

2. Running the field regulator open loop to verify stability.
10-8
BI006008
GEH-6148
10-5. SPECIF C FAULT TROUBLESHOOTING
10-5.1. Fault Indication
The GF2000 e
nostics to aid'
detects a fault,
cate the proble
iter software includes selftest diagtroubleshooting. When the exciter

t outputs error (fault) codes to indi. Table 10-5 defmes these fault codes.
Faults 400 to 1023

faster blink rate
binary pattern (left-most LED is 2 9 [or 512],
8
second-most LED is 2 [or 256J, and so on;
see Figure 10-2)
Diagnostic LEOs
NOTE
Fault code dermitions may change with

product u
ades and revisions. The fault
codes pres nted in Table 10-5 are current
as of the is ue date of this manual. The
ST2000 T lkit or Drive Configurator, if
purchased ith the exciter, contains current fault c de definitions as of the date the
equipment as manufactured.
The exciter disp ays the fault codes on both the Programmer and th SDCC card's LEDs. Although the
Programmer's d splay is easier to read, the LEDs
provide a backu ,if needed. Additionally, the drive
can broadcast th se codes via an optional serial data
link.
10-5.1 .1. PROG AMMER DISPLAY. The Programmer
includes a digital display that shows a fault message
(fault number an name). Table 10-5, located at the
end of this chapt r, defmes these faults by number.
10-5.1.2. LED 0 SPLAY. Diagnostic LEDs display
I L
2 (or 256)
2 9 (or 512l
Figure 10-2. Binary-coded LED Display
No fault or exciter not running

sequential blinking, two at a time
blinking from outer positions inward to center, and back
These same LEDs can be set by software jumper to

also coarsely display exciter variables when running.
(For example, displayed in an absolute or signed bar
graph mode). However, this setting does not inhibit
the LED fault display.
10-5.2. Types of Faults
codes either BC (binary coded decimal) or binary,

depending on the fault number. They indicate the
faults in a bI' . mode, as follows:
Table 10-5 lists and describes the GF2000 exciter

faults. There are nine types of faults with the following characteristics (see Table 10-4):
1.
Trip faults. Trip faults are internal protective

conditions. When detected, they immediately
shut down a running exciter. The exciter cannot
be restarted until externally reset, via either a
hardware (hard) reset or a software (soft) reset, as
described in section 10-5.3.
2.
Filtered faults. Filtered (pending) Faults are the

same as Trip Faults with one exception: they must
continue for a time period before the exciter
shuts down. These faults are used to minimize
nuisance trips caused by momentary noise glitches
when a shutdown can be slightly delayed without
hazard.
3.
Non-latched Annunciated Faults. These faults

report conditions that should be noted, but that
do not need to shut down the exciter. However,
until corrected, these faults inhibit an exciter from
Faults 1 to 3
slow bI'
BCD pa
hundred
most, th
9
rate
em (left-most two LEDs encode the
digit; next four, the tens digit; rightunits digit; see Figure 10-1)
Diagnostic LEOs
DO 0000000
hundreds
digit
Figure 1
tens
digit
units
digit
1. BCD-coded LED Display
10-9
BI006008
GEH-6148
starting. If the fault condition disappears, these

faults generally clear automatically without requiring a hard or soft reset.
4.
Latched Annunciated Faults. These are the same

as Non-latched Annunciated Faults, except that a
hard or soft reset is required to clear them.
5.
Brief Faults. To the user, these are the same as

Non-latched Annunciated Faults. The difference is
internal to the computer.
6.
Locked Faults. Locked Faults are Trip Faults of

a serious nature and cannot be cleared by a soft
reset. To clear the fault, the condition must be
fIxed, then a hard reset performed.
7.
Trip States. Trip States are similar to Trip

Faults, except that they report on conditions external, rather than internal, to the exciter.
8.
Filtered States. Filtered States are similar to Filtered Faults, except they report on conditions external, rather than internal, to the exciter.
9.
NOTE
The type of fault determines how it is

cleared.
10-5.3. Clearing the Fault
There are several ways to reset the exciter controller

to clear a fault. A software (soft) reset can be executed from the Programmer, or by serial command
from a device connected to the serial link. A hardware (hard) reset can be executed by pressing the
RESET pushbutton on the SDCC card, or by momentarily interrupting incoming power to the exciter.
Table 10-4 shows the types of resets that clear the
GF2000 exciter faults. A soft reset adequately clears
most latched faults. However, some types of faults
should be cleared by a hard reset.
NOTE
A soft reset displays all faults in the fault

stack, and should be performed instead of
a hard reset, whenever possible. If a soft
reset does not seem to restore the exciter to
normal operation, use a hard reset.
Non-latched States. These are similar to Nonlatched Annunciated Faults, except that they report on conditions external, rather than internal,
to the exciter.
Table 10-4. Summary of Fault Types

Drive Shutdown
Fault Type
Internal
Reset to Clear Fault
External
No
Immediate
Delayed
Hard
Soft
Automatic
Trip fault
./
./
./
./
Filtered Fault
./
./
./
./
Non-latched
Annunciated Fault
and Brief Fault
./
./
./
Latched
Annunciated Fault
./
./
./
./
Locked Fault
./
./
./
Trip State
./
./
./
./
Filtered State
./
./
./
./
Non-latched State
./
./
./
10-10
BI006008
GEH-6148
Table 10-5. Specific Fault Troubleshooting Using Fault Numbers

No.
Name
Fault Condition, Causes
Type Fault
CLEAR
Clear
IOC TRIP
Instantaneous over-current
The armature current sampled by the dc shunt has exceeded the limit set by EE.1507,
IOCTRO. The armature current can be monitored by test point TP8 (if present) on the
DCC/SDCC Drive Control Card. Possible causes:
- IOC set too low. Check IOCTRO (EE.1507/1907/2307/2707).
- CFBSFn (EE.1505) set too low, causing saturation of the hardware.
- SCR misfiring. Check wiring for crosstalk, misconnections.
- Current regulator mistuned. Run test 14.
- Armature connections loose or brushes not seated properly.
- Mechanical load problems -- shaft bind, brake, gear box, etc.
- Current feedback isolator failure. Check 1PL and DRPL on DCI/DCFB.
- Shunt feedback not scaled properly.
- SCR failure. Run test 12.
- For multibridge, EE.608 or 610 set improperly in master drives.
Trip fault
OVER SPD
Tach overspeed
The magnitude of SFB (VAR.l 00) has exceeded the overspeed threshold (EE.20). Possible
causes:
- SFB blocks (BLK.320, SFBK; BLK.301, SREG; etc.) improperly set.
- Speed overshoot due to speed regulator tuning underdamped.
- Loss of field current.
Filtered fault
FIELD LOS
Field loss
The field current has fallen below the limit set by EE-1562, FLDLSO. Possible causes:
- Blown field fuse. Check for blown MOVs.
- Field connections loose or incorrect.
- FLDLSn set too high. Set at least 25% below FLDMNn, EE-1566.
- FLDECn set too low.
- Field reference blocks set incorrectly (BLK.259 or 300).
- Field gain jumpers set incorrectly on DCI.
- Field regulator gain too low. Run field tuneup.
- Incorrect field mode (2/3, NRP, or NRX) selected via EE.573.2.
- For SDCC, U31 date codes ~ 9420 may require DCP revision~ 5.10.
This fault can be inhibited by setting EE.1562 to 0 (for motor #0).
Beginning with revision 6.31, IFLDAFB (VAR.l090) (or FLDFB, VAR.l05 if Field #A is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568EE.1575. However, FIELDLOS uses UN-normalized field feedback to detect a fault and can
be compared to the field loss limit (FLDLSOl by viewing IFl FB, VAR.l 028.
Filtered fault
SFB_POL
SFBlTach polarity reversed

Filtered state
The polarity of SFB does not agree with the polarity of motor voltage or frequency. This fault
is generated when the magnitude of CEMF (VAR.112) is greater than 20% and the polarity
of SFB is not the same as the polarity of CEMF. Possible causes:
- Reversed tach connections
- SFB blocks (BLK.320, SFBK; BLK.327, ENCP1; etc.) improperly set
- On DC2000, Reversed VFB connections (Pl/P2 wired incorrectly)
- For analog tachs, failure of ribbon cable 6PL (pins 39 or 40)
- See also FLT.20.
RESETRUN
Run command asserted during reset

Possible causes:
- Drive powered up or reset with 3TB or STBA RUN or JOG closed (on STBA board, these
signals are brought to one of the configurable inputs).
- Incorrect 3TB or STBA logic polarity (see NTB JPl 0 or STBA JPl 0 and JPll, EE.l.4).
- Auto-start inhibited (EE.5Al.
- Momentary loss of incoming power while running.
Trip state
TOC_TRIP
Timed overcurrent
Possible causes:
- Motor mechanically overloaded due to load or wear.
- Field current less than 85% of rated.
- TOC settings too low (EE.1490-1496l.
- Armature winding failure.
- DB contactor failure (if used).
- TOC@IN (EE.25) if used, is not pointed at bridge or motor current.
Trip fault
= No Faults present
10-11
BI006008
GEH-6148

Table 10-5. Specific Fault Troubleshooting Using Fault Numbers - Continued
No.
Name
Type Fault
SERLTRIP
Trip generated by serial or LAN command 3Fh

Possible causes:
- "?" command accidentally entered from serial link keyboard.
- Received command 3F from LAN.
Trip state
10
NO CTS
13
EECKSMO
Bad page 0 EE checksum, EE.O - EE.255

Latched
The actual EEROM checksum in the given range does not agree with the stored checksum.
annunciated
Possible causes:
fault
- Block load of EEROM attempted with DCC/SDCC JP1 open or in 1.2 position.
- Drive reset or lost power while EEROM was being updated.
- DCC/SDCC JP1 was changed during update or touched with static charge.
- ST2000 or LAN download aborted or failed while in progress, or communication failure
(Rev 1.70 and earlier).
In the first case, the actual EEROM is not affected, and it is safe to reset the fault, enable
the jumper, and perform the block load again. In all other cases, effort should be made to
find the faulty settings and correct them. Set EE.2.1 and perform two hard resets to force a
correction to the checksums.
14
IREG SAT
CFB too low at fully advanced firing

The current loop has fired 60 fully advanced {as controlled by EE.1 544, ADVLMn or
EE.1592, HADLMnl firings in a row and armature current remained less than 10%. Detection of this condition can be inhibited by setting EE-571.1, MFLTJP.
Possible causes:
- EE.565-EE.568 not set, causing current loop autotune to incorrectly compute
settings for EE.1 544 and EE.1 592.
- EE.1544, EE.1592, or EE.1581 (IL1McO) set too low.
- Main contactor not picking up, or picking up too slowly. Increasing EE.39 (MAPDLY) will
correct for slow magnetics.
- Open connections or contactors in the motor armature circuit.
- Dc fuse open.
- Inspect 5PL, DRPL, and SCR gate lead connectors. Run test 12.
Serial link lost transmit capability due to CTS handshake

Trip fault
The serial link has data to transmit (such as a fault codel, but is unable to send it due to the
Clear-To-Send RS232 handshake line. Possible causes:
- Improper configuration of COMPL.4 and COMPL.5.
- Improper configuration of NTB.JP.6 and JP.7
- Failure of connector 6PL or SDCC or STBA board.
Filtered fault
Note in applications using the enhanced current regulator (EE.570.1), EE.1581 may be set
so low that the current regulator does not have enough authority to advance to CEMF limit
IEE.1 592). In this case, FLT .14 logic is not able to detect an open loop/firing circuit. Raising
EE.1581 (typically by 25%) allows this protection to function with little impact on performance. Beginning with revision 5.00 (DRVTYP=85), FLT.222 gives enhanced detection of
this fault detection.
15
VFB LOSS
VFB too low for given firing angle

Filtered fault
The drive has failed to measure at least 1 % armature voltage when the firing angle is within
75 degrees of full advance and current is at least 5 %. The analog VFB signal can be monitored for a circuit failure at control card test point TP37. Detection of this condition can be
inhibited by setting EE.571.6, MFLTJP. Possible causes:
- Voltage select jumpers and power connections on the PCCA Power Connect
Card are incorrect.
- 5PL failure. Check 5PL-25 and -26 (right-most pair of wires in cable).
- Failure of VFB circuitry on the SDCI/DCFB. Check VFB at TP37.
- Possible blown dc fuse.
- For DCFB, VM 1A/B voltage feedback not connected (see EE.570.11).
16
NORMOPEN
Normally open interlock is closed

Possible causes:
- Improperly selected source of NORMOPEN (EE.292, EE.4.14)
- External interlock closed or improperly connected
10-12
Filtered state
BI006008
GEH-6148

No.
Name
Type Fault
17
XSTOP
XSTOPCMD, VAR.679, hardware XSTP input is open

Possible causes:
- Improperly selected source of XSTOP input (EE.253)
- External input open or intermittent
- Failure of ribbon cable 6PL
- Improper choice of XSTOP mode (EE.6.4)
Trip state
Note that prior to revision 2.31, this was a filtered fault, and XSTOPCMD could be TRUE
briefly, causing a stop but not a fault.
18
STALL_OC
Timed overcurrent at stalled rotor

Possible causes:
- Mechanical failure (failed brake, frozen bearing, etc.)
Field current less than 85% of rated
SOC settings too low (EE.1490-1496)
Armature winding failure
DB contactor failure (if used)
If motor was rotating, speed threshold too high (EE.1492 or EE.21) or problem in
speed feedback measurement (BLK.320).
SOC@IN (EE.30) if used, is not pointed at bridge or motor current
19
OVERVOLT
Instantaneous overvoltage
Filtered fault
The armature voltage has exceeded the limit set by EE.579, IOVTHR. The analog VFB signal
can be monitored for a circuit failure at DCC/SDCC testpoint TP37.
Possible causes:
- Advance limit set too high (EE.1544 or EE.1592).
- Crossover set too high (EE.1567).
- Drive unstable. Run tests 14 and 16 to check arm/field regulators.
VFB circuit failure. Check DCC/SDCC TP37.
- For DCFB, VM1A/B voltage feedback not connected (see EE.570.11).
20
SFB_LOSS
SFBlTach feedback loss

The magnitude of SFB does not agree with the magnitude of motor voltage or frequency.
This fault is generated when the magnitude of CEMF (VAR.112) is greater than 20% (4000
counts) and the magnitude of SFB (VAR.1 00) is less than 2%. Possible causes:
- Tach leads broken
- Tach hardware scaled improperly (Analog: NTB.SW.1)
- For analog tachs, failure of ribbon cable 6PL (pins 39 or 40)
- Encoder connected improperly (STBA/SDCC jumpers, EE. 7, BLK.326, etc.)
- Encoder jumpers set for 15 volt encoder when 5 volt encoder used
- Encoder "Z" channel polarity holding counters in reset.
- SFB blocks (BLK.320, SFBK; BLK.301, SREG; etc.) improperly set
- Loss of field current
- Open dc fuse or armature loop
- Bug during reset in revision 1.10-1.50 when using CEMF as SFB
For debug purposes only, this fault may be inhibited by FLTJPR.7.
Filtered fault
21
NORMCLSD
Normally closed interlock is open

Possible causes:
- Improperly selected source of NORMCLSD (EE.291, EE.4.14)
- External interlock open or improperly connected
Filtered state
22
PHASELOS
Ac line dip or imbalance

Possible causes:
- EE.582 or 583 setting is too sensitive.
- Low ac line or phase imbalance.
- Blown fuse in ac line or on SDCI/DCFB card.
- Loose ac power connections.
- Failure in 15 volt power supplies.
For EX2000 see EE.576.
Beginning with revision 5.36, for DC2000 only, this fault requires a hard reset to clear. For
revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.
Beginning with revision 5.41, field and armature SCR firings are inhibited when this fault
occurs.
Trip fault
Trip fault
10-13
BI006008
GEH-6148

No.
Name
Type Fault
23
FIELDTOC
Field timed overcurrent

The field current has exceeded the reference by an amp-seconds rating defined by EE.1563,
FTOCGO. Possible causes:
- Field SCR shorted.
- Field regulator unstable or running in voltage-regulated mode.
- FTOCGn set too sensitive.
- Excessive field forcing through BLK.259 or 300 (VAR.165).
Incorrect field mode (2/3, NRP, or NRX) selected via EE.573.2.
- For SDCC, U31 date codes ~ 9420 may require DCP revision <: 5.10.
Field SCR firings are inhibited when this fault occurs.
Beginning with revision 6.31, IFLDAFB (VAR.l090) (or FLDFB, VAR.l05 if Field #A is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568-EE.1575.
However, FIELDTOC uses UN-normalized field feedback to detect a fault which is typically
equivalent to IFl FB, VAR.l 028.
Trip fault
25
COM FAIL
Commutation failure
The drive has shut down because it detected an imminent SCR commutation failure.
Possible causes:
- Open or intermittent connection on pins 1 or 2 of ribbon cable 1PL.
- Shorted or open SCRs.
- Insufficient commutation voltage margin due to ac line dips or CEMF limit or crossover
set too high.
- Improper CT burden selection settings on SDCI/DCFB. Set for higher horsepower rating.
- Commutation failure threshold set too low (EE.581, CFLTHR).
- Dc current in ac line saturating CTs due to high loads and multiple bridge reversals at a
rapid rate (faster than 60 Hz).
- Nuisance trips due to hardware/software sensitivities prior to 302DCIANGl /AJG2,
301 DCCAMG1, and 1.60 (AG) revisions. Increase EE.581.
- Leads swapped in CT connector, ICPL, on SDCI/DCFB card. Compare VAR.l 04 and
V AR. 101 9 for same polarity and magnitude. Use burden switches for coarse
adjustment, EE.1520 for fine.
- Bug in MPG3 revisions 2.15 - 2.20 when SDCC and DCFB are used. FLT.25 must be
inhibited in these revisions.
Inhibit this fault by setting EE.581 to 32767. When this fault is detected, armature SCR firings are immediately inhibited (no phase-back occurs).
Trip fault
26
AC IOCUR
Ac instantaneous overcurrent
Current as instrumented by the ac line current transformers has exceeded the limit set by
EE.580, ACIOCT. Possible causes:
- Improper CT burden selection on the SDCI/DCFB. Verify settings and that the scaling of
CTCFB (VAR.l 019) roughly matches CFB (VAR.1 04) using test 31.
ACIOCT set too low. Set to 32767 to inhibit this fault.
- Current regulator overshoot. Run current loop tune-up.
- Open or intermittent connection on pin 1 or 2 of ribbon cable 1PL.
- Commutation failure or ac shoot-through. Run cell test.
- Refer to additional items under FLT.25 (COM FAIL).
For early revisions, see note under EE.587 and increase EE.580.
- During cell test, a shorted cell exists and firing angle used during test is too advanced.
Temporarily defeat FLT.26 using EE.580 or reduce the firing angle using EE.1580.
As of revision 2.11, armature SCR firings are immediately inhibited when this fault is detected.
Trip fault
27
NO LSYNC
Indeterminate line sync input

Locked fault
The drive is not receiving a suitable ac line synchronization signal from the SDCI/DCFB. Test
point TP29 on the DCC/SDCC (not on early DCC revisions) should show a 5-volt square wave
of the line frequency. Possible causes:
- Fuses blown or missing on the DCI/DCFB/SDCI interface card. (Note: if fuses are
blown, check for MOV failures).
- Excessive ac line phase imbalance or notching.
- Failure of 1PL cable (pin 29) or DCI/DCFB/SDCI card.
- For multibridge, failure of LAN power supply or SPCS card, misconfiguration of master
or follower drive (EE.572).
Field and armature SCR firings are inhibited when this fault occurs.
For revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by
invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.
10-14
BI006008
GEH-6148

Type Fault
28
/llegal Run mode commanded

Not used in the AC/DC2000 (replaced by more descriptive faults such as FLT.360).
Trip state
29
Control-on loop open

Possible causes:
- Open circuit or noise between 3TB.42 and 3TB.44 on NTB.
- Intermittent connection in 6PL pins 1 or 2.
- Open circuit on STBA K28+ and K28- (STB.64 and STB.66). See also STBA JP29
and JP30.
- STBA RLY 3 dropped out or RLY 3 contact not bypassed from control-on circuit.
See STBA JP31, JP32, and JP39.
The control-on loop should not be used as the normal stopping mode for the drive. It is
intended for real emergency use only or as a safety lockout when the drive is already
stopped.
Trip state
No.
Name
31
NO PHSE
Indeterminate phase sequence input

The drive is not receiving a suitable ac line signal for determining the phase sequence or line
sync. Test point TP29 on the 301 DCC/SDCC card (not on early revisions) should show a 5
volt TTL level square wave of line frequency. Possible causes:
- Line or power supply card fuses blown.
- Excessive ac line phase imbalance, noise, or notching.
- Failure of 1PL cable (pin 29 or 6) or DCI/DCFB/SDCI card.
- 15 volt power supplies outside 10% limit.
- (Multibridge) Failure of LAN power supply or SPCB card, misconfiguration of master or
follower drive (EE.572).
Locked fault
32
TOC ANU
Timed overcurrent alarm
Non-latched
annunciated
fault
33
NEGPHSEQ
Negative phase sequence not allowed

This fault can only occur if a negative sequence ac line source has been detected and
EE.570.1 is set to inhibit negative sequence operation. If the SDCC and DCFB cards are
being used and the bi-phase PLL is enabled (see EE.570.3 for MP group 3), only positive
sequence operation is allowed, independent of EE.570.1.
- Reverse any 2 ac input lines and recheck.
- Check items listed for FLT.31.
Field and armature SCR firings are inhibited when this fault is detected. Note some applications using the DCFB board do not allow drive operation with reverse phase sequence.
Trip state
34
PLLTRACK
Ac line synchronization PLL error too high

Either noise or a frequency change on the ac line instrumentation has caused the PLL error
to exceed the acceptable limit. The response of the PLL circuit may be changed by EE.575,
PLL_GN. Possible causes:
- Excessively noisy, notched, or unbalanced ac line.
- Fuses blown or missing on DCI/SDCI/DCFB.
- PLL_GN set too low (especially variable frequency ac lines).
- Failure of 15 V dc power supplies.
- Bi-phase PLL enabled (EE.570.4) but 3-phase L1/L2/L3 not connected to DCFB.
- Bi-phase PLL enabled (EE.570.4) but gains not set (EE.576, 577).
Non-latched
annunciated
fault
35
Run while rotating, flying restart inhibited

Motor rotating when RUN or JOG commanded. Possible causes:
RUN commanded while motor coasting or externally driven.
- ZSPEED (EE.21) set too low.
- Too much noise or offset (Analog: check EE.49) in tach feedback.
- Need to enable flying restart mode (EE.5.3).
Non-latched
state
Annunciates bad serial message

Possible causes:
- Incorrect Baud rate (EE.120).
- Noise on serial link wiring.
- Bad message checksum in protocol mode.
- Invalid message (too many characters).
Non-latched
annunciated
fault
36
SPEED
10-15
BI006008
GEH-6148

No.
Name
Type Fault
38
EELOCKED
EE writes disabled
EEROM cannot be modified via the serial link, LAN, or Programmer unless EE.2.0 is set.
Non-latched
state
39
EEWRFAIL
EE write verify fail. Possible causes:

- SDCC JP1 in disabled position.
- Exceeded maximum changes to EEROM 110,000 changes per 256 word page}.
- EEROM IU9) has failed.
Non-latched
annunciated
fault
40
SPEEDLIM
Speed reference outside limits. Possible causes:

- BLK.255, RUNRF output exceeds EE.356
- BLK.256, JOGRF output exceeds EE.376
- BLK.301, SREG command exceeds EE.1418
- EE.290, RFLM@I pointing to a TRUE value
The speed regulator can impose both maximum and minimum limits. The other sources
impose only an absolute maximum limit.
Non-latched
state
41
KEY OFF
The key pushed is presently disabled (see EE.690).

KPDJP1 (EE690) has been programmed to disable this function.
- Check the loading of KPD JP1 IEE.690}.
Non-latched
annunciated
fault
42
XSTPOPEN
XSTOP input open when RUN or JOG requested. On STBA board, these signals are connected to configurable inputs. Possible causes:
- EE.253, XSTP@I not pointed to correct source of the XSTOP input.
- XSTOP input open or intermittent.
- Failure in NTB/3TB, STBA, or SDCC board, or connector 6PL.
Non-latched
state
45
SPDTRACK
Speed tracking fault. Possible causes:

- Speed tracking improperly set up IEE.26-28).
- Drive unstable or unable to hold speed.
- Speed regulator blocks improperly set up.
This fault can be inhibited by setting EE.27 to O.
Trip fault
46
CFB OFST
CFB VCO zero offset too high

Non-latched
While the drive is stopped ( no current flowing in the shunt), it has measured more than 5% annunciated
current, indicating an excessive zero offset in the current feedback isolator on the
fault
DCI/SDCI/DCFB card. Detection of this condition can be overridden by EE.571.4.
Possible causes:
- DRPL connected incorrectly at shunt or plug on DCI/SDCI/DCFB.
- Twisted-pair wires from shunt picking up noise. Route away from power leads and
twist pair tighter.
- Failure in the current feedback isolator on the DCI/SDCI/DCFB.
52
NCLSDANN
Normally closed interlock is open
Non-latched
annunciated
fault
57
NOPENANN
Normally open interlock is closed
Non-latched
annunciated
fault
65
A1F_OPEN
Cell test open circuit detected in A 1F

Inadequate current was detected in the SCR during the open circuit SCR test. Possible
causes:
- SCR or leg fuse failure.
- The open circuit firing angle may need to be tailored for the motor under test using
EE.1577, CTSTVO.
- 5PL or SCR gate lead cable/connection failure.
Trip fault
66
A2F OPEN
Cell test open circuit detected in A2F
Trip fault
67
A3F OPEN
Trip fault
68
A4F OPEN
Trip fault
10-16
BI006008
GEH-6148

No.
Name
Type Fault
69
A5F OPE
Trip fault
70
A6F OPE
Trip fault
Cell test detected no forward current

Inadequate current was detected in the SCRs during the open circuit SCR test in multiple cells.
The fault code indicates whether the problem affects all SCRs, only forward or reverse, or
some other combination. Listen for current in the motor during the test to isolate firing versus
feedback problems. Possible causes:
- SCR or fuse failures.
- The open circuit test firing angle may need to be tailored for the motor under test using
EE.1577, CTSTVO.
- 5Pl or SCR gate lead cable/connection failure.
- Shunt feedback wiring damaged or not connected.
- Current feedback isolator failure on SOCI or OCFB.
- Armature loop open or motor not connected.
Inadequate time allowed for contactor to close (EE.39 MAPOlV).
Regeneration enabled on non-regenerative drive (EE. 1500.1, 1900.1)
Simulator mode enabled (EE.570.0).
Firing power failure. Check for + 24 volts on gate pulse primary during drive test 12.
Trip fault
71
72
ARM OPEN
Open circuit test detected no armature loop

More than 5% voltage was detected at the beginning of the second pass of cell test, but VFB
was ok at the beginning of the first pass. This would normally happen if the short circuit test
fired into an open circuit, so the VFB senses snubber voltage due to lack of a discharge path.
Possible causes:
- Blown dc fuse.
- Open circuit in armature, dc contactor, or wiring.
- Insufficient time allowed for dc contactor to close -- increase EE.39.
- Failure in VFB sensor (OCFB) or connections (5Pl).
- P1 or P2 connection to armature (for snubbers and VFB) is open.
This fault can be overridden by setting EE.571.11.
Trip fault
73
A1R OPEN
Cell test open circuit detected in A 1R
Trip fault
74
A2R OPEN
Cell test open circuit detected in A2R
Trip fault
75
A3R OPEN
Trip fault
76
A4R OPEN
Trip fault
77
A5R_OPEN
Trip fault
78
A6R OPEN
Trip fault
79
REV OPEN
Cell test revealed no reverse current (see FlT. 71)
Trip fault
80
SHRTFAll
Short circuit cell test failed

When cell test detects a short on the first pass, cell test runs the test again, testing cells in
the same order. If the second pass detects a different shorted cell than on the first pass, FlT80 is reported. Possible causes:
- The short circuit test thresholds for voltage and current need to be increased for the
motor under test. See EE.1578 and 1579.
- SCR misfiring due to dv/dt.
- SCR misgating due to noise coupling or misconnection of gate leads.
- Noise in the CFB and VFB sensor hardware.
Trip fault
10-17
BI006008
GEH-6148

No.
Name
Fault Condition. Causes
Type Fault
81
A 1 SHORT
Cell test short circuit detected in A 1

Motor current or voltage was detected in the SCR during the short circuit SCR test. Possible
causes:
- SCR shorted.
- SCR misfiring due to dv/dt.
SCR misgating due to noise coupling or misconnection of gate leads.
- The short circuit test thresholds for voltage may need to be tailored for the motor
under test. See EE.1578 and 1579.
Prior to revision 1.84. open armature or VFB not 0 when cell test invoked. especially if
fault reported is A6_SHORT. Check dc fuse. motor not at standstill. or bad VFB sensor
circuitry.
Note that for K frame (multibridge) drives. if a cell is shorted, the master drive will report
which leg (A1 - A6). If the short is in a follower bridge. that follower drive will report a
FLT.232. MBRGSHRT, to pinpoint the location of the shorted cell.
Trip fault
82
A2 SHORT
Cell test short circuit detected in A2 (see FLT .81 )
Trip fault
83
A3 SHORT
Cell test short circuit detected in A3 (see FLT.81)
Trip fault
84
A4 SHORT
Trip fault
85
A5 SHORT
Trip fault
86
A6 SHORT
Trip fault
97
OPENFAIL
Open circuit cell test failed

When cell test detects a failure on the first pass. cell test runs the test again. If the second
pass detects a different set of cells open than on the first pass. FLT .97 is reported (revision
1.84 to present). Possible causes:
- The open circuit test firing angle needs to be increased (EE.1577).
- Intermittent connection in 5PL ribbon cable or power wiring.
- See also FLT. 71.
Trip fault
98
MULTOPEN
Cell test detected multiple opens (see FLT.71)
Trip fault
99
ALL OPEN
Cell test detected no forward or reverse current (see FLT. 71)
Trip fault
129
DRIVETYP
Programmed drive type doesn't match hardware configuration

Possible causes:
- Software installed at U22/U23 does not match EE.550, DRVTYP
Hardware installed at 1PL does not match EE.556. HDWTYP
DRIVE TYPE EE.550 EE.556 INTERFACE CARD VOLTS AT 1PL-38
DC2000
5
5 or 0
DCI (531 X302DCI)
2.3 - 2.7
DC2000
85
5
DCI or SDCI
2.3 - 2.7
Note: EE.556 is invalid for EE.580=85.
DC2000
5 or 85
4
DCFB (DS200DCFB)
1.8 - 2.2
- Failure of ribbon cable 1PL pin 38
- Failure of DCC/SDCC card.
The actual voltage being read by the DCC/SDCC card at 1PL-38 is displayed under the heading "DTYP" of drive test 13 (J13) using an RS232 terminal connected to COMPL.
Trip fault
130
MCPBDREV
Invalid MCP software revision (SDCC sockets U22/U23)

The revision of the MCP software, in SDCC sockets U22 and U23, is not recent enough to
support features selected by the EEROM configuration, or the MCP software is not compatible
with the other EPROMS on the SDCC card. Possible causes:
- EEROM not configured per application requirements
Software revision (per PROM labels and per drive test 10) older than specified in
MCPREV (EE.66)
- SDCC only: MCP revision less than 4.34 when DCP is greater than 4.33. This is a
locked fault which can be corrected only by installing a compatible EPROM set for
U12/U11 and U22/U23.
Trip fault
10-18
BI006008
GF2000 Dc G erator Field Exciter
GEH-6148

No.
Name
Type Fault
131
MCP_FAI
SDCC motor control processor U21 (MCP), selftest failed

MCP has failed its power-up selftest. Pass/fail status of MCP is also displayed on an RS232
terminal running test 13 (J13). Possible causes:
- Socketed ICs on the SDCC control card not properly seated
- Failure of U21 on SDCC card. Replace card.
Trip fault
MCP EPROM (SDCC U22/U23) checksum error

The MCP EPROMs have been improperly programmed or have failed. Possible causes:
- U22 or U23 on SDCC card not properly seated.
- Failure of U21, U22, U23 or SDCC card.
- U21 is an 80c196KC chip instead of an 80c196KB. Prior to revision 1.90 (AK), U21 must
be an 80c196KB microcontroller.
Trip fault
Trip fault
132
133
DPRMFAIL
DCP/MCP Dual port RAM (DCC/SDCC U8) selftest failed

MCP has detected a failure in the U8 dual-port RAM during its power-up selftest. Pass/fail
status is also displayed on an RS232 terminal running test 13 (J13). Possible causes:
- Socketed IC on the DCC/SDCC control card not properly seated.
134
DCPB DO
Trip fault
Timeout, MCP watchdog of DCP background
The MCP has detected an execution rate failure of the background software in the DCP. DCP
background monitors a byte (DPRM_DCPB_MCPB_WDOG) 11 times a second, and if it is
negative, DCP resets it to O. MCP background decrements the byte 22 times a second, and
generates fault 134 if it ever gets down to -100 counts. (See related fault 377). Possible
causes:
- Socketed ICs on the SDCC control card not properly seated or bent pins
- Failure of SDCC card
- Noise disturbing SDCC control card due to improper wiring practices
- EEROM configuration has overloaded processor
- Card connected to 1PL or 3PL installed or operating incorrectly.
- Intermittent, noisy, or out of spec low level power supply.
135
DCPF DOG
Timeout, MCP watchdog of DCP foreground

The MCP has detected an execution rate failure of the foreground software in the DCP. MCP
background increments a byte (DPRM_DCPF_WDOG) approximately 22 times a second. DCP
background also increments this byte, about 11 times a second. DCP foreground resets this
byte to zero about 90 times a second. If MCP ever sees this byte larger than 100, then it
generates fault 135. See related fault 375. Refer to FLT.134 for possible causes.
Trip fault
136
MCPF DOG
Timeout, MCP watchdog of MCP foreground

The MCP has detected an execution rate failure of its foreground software. MCP background
increments a byte (DPRM_MCPF_WDOG) about 22 times a second. DCP background also
increments this byte, about 11 times a second. MCP foreground resets this byte to zero
about 360 times a second. If MCP background ever sees this byte larger than 100, then it
generates fault 136. See related fault 378. Refer to FLT.134 for possible causes.
For the DC2000, this fault can be caused by the loss of the line sync input (1 PL-29). Beginning with revision 5.31, field and armature SCR firings are inhibited when this fault occurs.
For revision 6.31 and later (DC2000 only), if EE.6283.6 is set, invoking a soft reset will reinitialize MCP with out requiring a hard reset (a firm reset is performed). See EE.6283.6 for
details.
NOTE - Multiple soft resets may be required.
Trip fault
137
MCPEXRA
80c196 processor external RAM U97 powerup test fail

External RAM device U97 (8K bytes) on the SDCC control card failed the powerup test for
one or more memory locations. Possible causes:
- Defective SDCC card.
- Socketed device on SDCC not inserted fully or pin bent under.
Trip fault
10-19
BI006008
GEH-6148

No.
Name
Type Fault
138
CMPSHRAM
80C196/TMS320c25 shared RAM U36/37 powerup test fail

Shared RAM devices U36 and U37 (32K words) on the SDCC control card failed the powerup test for one or more memory locations. During powerup, this RAM, which is accessible
by both the MCP (U21) and CMP {U35j, is tested by MCP, once with CMP halted, and once
with CMP running. If the RAM test fails with the CMP halted, FLT.138 is reported. If the
RAM test fails with the CMP running, FLT.145, DPRCFAIL, is reported. Possible causes:
- Defective SDCC card.
- Socketed device on SDCC card not inserted fully, or pin bent under.
Trip fault
139
CMPBDTYP
Co-motor processor (CMP) drive type mismatch

The CMP software, in SDCC sockets U36 and U37, is not appropriate for the selected drive
type (see EE.550 and EE.551, DRVTYP and ALGTYP) and the available control card hardware.
Supported types:
EE.DRVTYP = 5, EE.ALGTYP = 0
EE.DRVTYP = 5, EE.ALGTYP = 0, 100, 300
Verify EE settings, and revision and insertion of CMP PROMs U36 and U37.
Trip fault
140
CMPBDREV
Invalid CMP (U36,U37) software revision

Trip fault
The revision of the CMP software, in DCC sockets U36 and U37, is not recent enough to
support features selected by the EEROM configuration or the CMP software is not compatible
with other EPROMs on the SDCC card. Verify the EEROM is configured properly and software revision (per PROM labels and per drive test 10) is at least as high as specified revision
in MCPREV (EE.66).
141
CMP FAIL
CMP (SDCC U35) selftest failed

CMP has failed its power-up selftest. Pass/fail status of CMP is also displayed on an RS232
terminal running test 13 (] 13). Carefully check that all socketed ICs on the SDCC control
card are properly seated. The SDCC control card should be replaced if this does not correct
the fault.
Trip fault
142
CMPROMCK
CMP EPROM (SDCC U36,U37) checksum error

The CMP EPROMs are improperly programmed or have failed, and must be replaced. Ensure
they are properly seated in their sockets.
Trip fault
143
CMPBDACK
CMP bad acknowledge

The co-motor processor (CMP, U35) is not properly responding to the motor control processor (MCP). Possible causes:
- Check seating of socketed components on the control card
- Check that the software revisions in U22/U23 and U36/U37 (DCC only) are compatible
with each other
- Excessive CPU load on the MCP or CMP processor. Check EE configuration to ensure
unneeded functions are not enabled.
- Failure of DCC or SDCC control card.
Trip fault
144
CMPNOACK
CMP no acknowledge
CMP (U35) is not responding to MCP (U21). Check items listed for FLT .141, or replace the
control card.
Trip fault
145
DPRCFAIL
MCP/CMP Dual port RAM or shared RAM selftest failed

MCP has detected a failure in the U33 dual-port RAM (DCC card) or U36/U37 shared RAM
(SDCC card) during its powerup test. Pass/fail status is also displayed on an RS232 terminal
running test 13 (] 13). Possible causes:
Seating of socketed ICs on SDCC card.
- Wrong revision of PAL in socket U91 on SDCC card--must be AB or later.
- Defective DCC or SDCC card.
Trip fault
146
CMP WDOG
MCP/CMP watchdog fault

The MCP processor has detected an execution rate failure of the CMP software. Possible
causes:
- Seating of socketed ICs on SDCC card.
- Noise disturbing SDCC card due to improper wiring practices.
- JP33 not in 1-2 position.
Trip fault
10-20
BI006008
GF2000 Dc G
GEH-6148

No.
Type Fault
147
MCP Diagnostic Circular List latch annunciation

Indicates that the MCP Diagnostic Circular List has latched to the frozen state. The information preserved in the buffer may be interrogated via the drive serial link (see EE.600).
Non-latched
annunciated
fault
148
Trip fault
Serial absolute encoder communications watchdog
The absolute encoder function via the serial interface on the SPC card is enabled by
MCNFIG.12 (EE.570), but no serial communications have been received for 150 milliseconds. Possible causes:
- Hardware not setup properly: DCP JP31 2-3; SPC.SW.1.7 off
Encoder connected to + 15 volts, common, 1TB.13 and 1TB.14
- Encoder failure, not sending serial information
- Failure in SPC card or ribbon cable 7PL pins 19 or 20
For the BEl serial encoder with the D 17 interface, hook-up is as follows:
BEl terminal
Drive terminal
1TB-13 RXN (SDCC card)
A
TXD
1TB- 14 RXP (DCC card)
ITXD
HB- 13 RXN (DCC card)
1TB-14 RXP (SDCC card)
B
I
CKT GRND
3TB-66 COM
+ 15 V dc
3TB-62 + 15
P
J
CHASSIS
Note that connections to 1TB depend on which drive control card is installed, either DCC
or SDCC. Connect U to V to set the Baud rate to 2400. Connect L to I get increasing
counts for CCW rotation, or connect L to P to get increasing counts for CW rotation.
Other Baud rates (not currently supported by the drive) are: Q-R, 19200; S-R, 9600; and TU,4800. See also FLT.149.
149
Serial absolute encoder communications error

The absolute encoder function via the serial interface on the SPC card is communicating
with the drive, but the character or message error rate is excessive (more than 1 bad message for every 10). Possible causes:
- Baud rate set incorrectly on encoder--should be 2400
- Wrong polarity on RXP/RXN (1 TB.14113)--for DCC card, need RXP mostly plus write
RXN; for SDCC card, RXN should be mostly plus (see FLT. 148)
- Excessive noise pickup due to routing of RXP/RXN twisted pair or power.
See also FLT.148.
Non-latched
annunciated
fault
Field #B current feedback loss

The field current has fallen below the limit set by EE.1 564, FLBLSO.
Possible causes:
Field #B enabled (EE.570.9), but not installed
Blown field fuse.
Field connections loose or incorrect.
FLBLSn set too high. Set at least 25% below FLDMNn, EE.1 566.
FLBECn set too low.
Field reference blocks set incorrectly (BLK.259 or 300).
Field feedback gain set incorrectly.
Field #B regulator gains too low.
This fault can be inhibited by setting EE.1 564 to 0, or inhibiting field #B via EE.570.9.
Beginning with revision 6.31, IFLDBFB (VAR.1 091) (or FLDFB, VAR.1 05 if Field #A is disabled and Field #B is enabled via EE.5300.0) is normalized by the flux saturation curve
defined by EE.1568-EE.1575. However, FLOB LOS uses UN-normalized field feedback to
detect a fault and can compared to the field loss limit (FLBLSO) by viewing IF2FB,
VAR.1029.
Trip fault
Field #B timed overcurrent

The field current has exceeded the reference by an amp-seconds rating defined by
EE.1565, FBTOCO.
Possible causes:
Field SCR(s) shorted.
Field regulator unstable or running in voltage regulated mode.
FTOCGn set too sensitive.
Excessive field forcing through BLK.259 or 300 (VAR.165).
Field SCR firings are inhibited when this fault occurs.
Beginning with revision 6.31, IFLDAFB (VAR.1 090) (or FLDFB, VAR.1 05 if Field #A is disabled and Field #B is enabled via EE.5300.0J is normalized by the flux saturation curve
defined by EE.1568-EE.1575. However, FLDB_TOC uses UN-normalized field feedback to
detect a fault which is typically equivalent to IF2FB, VAR.1 029.
Trip fault
165
166
Name
FLOB LOS
10-21
BI006008
GEH-6148

No.
Name
167
Type Fault
Field #B undercurrent tracking

The field current has remained below the field command by at least 15% of rated for more
than 5 seconds.
Possible causes:
Field #B enabled (EE.570.9), but not installed
Hot field. Unable to achieve commanded current.
Field regulator unstable. Check tuneup.
See also FLT.165, FLDB_LOS.
Set EE.571.0 to inhibit field tracking for both field #A and #B.
Beginning with revision 6.31, IFLDBFB (VAR.1 091) (or FLDFB, VAR.1 05 if Field #A is disabled and Field #B is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568-EE.1575. FLDB_TRK uses this normalized field feedback to detect a fault.
Filtered fault
Non-latched
annunciated
fault
168
IA2 OFST
DCFB card IA2 shunt VCO zero offset too high

While the drive is stopped (no current flowing in the shunt!. it has measured more than 5%
current, indicating an excessive zero offset in the current feedback isolator IA2 on the
DCFB. Detection of this condition can be overridden by EE.571.4, MFLTJP.
Possible causes:
- IA2 connected incorrectly at shunt or plug on DCFB.
- Second shunt enabled via EE.1501.2, but not connected.
- Twisted pair from shunt picking up noise. Route away from power leads and twist pair
tighter.
- Failure in the current feedback isolator on the DCFB.
169
VM1 OFST
DCFB armature voltage (VM 1) feedback VCO zero offset too high
Non-latched
During power-up, or while the drive has stopped if EE.570.5, MCNFIG, is set, a zero offset
annunciated
greater than 5 % has been detected in the VM 1ANM 1B armature voltage sensor circuitry on fault
the DCFB. Possible causes:
- EE.569 is set beyond its range (SDCC/DCFB combination only).
- EE.569 is set to improper value. Run test 14 to set automatically.
- EE.570.5 is set and drive can be externally rotated while stopped.
- Failure of DCFB.
- Wiring error in connection of armature signals (VM 1AlB) to feedback interface card.
Detection of this condition can be overridden by EE.571.5, MFLTJP.
187
CFB POL
Dc (armature) shunt polarity reversed

The drive has measured a 20% reverse current while firing the forward bridge or a 20%
forward current while firing the reverse bridge. Possible causes and solutions:
- Run cell test (12) to confirm fault (revision 1.50 AF or later). Note in DCFB dual shunt
applications, cell test reports this fault regardless of whether shunt IA1 or IA2 is
backwards, so both shunts should be checked.
- DPRL wired backward at shunt or plugged in backward on SDCI/DCFB.
- Gate lead plugs connected to wrong SCRs.
- Twisted pair from shunt picking up noise. Route away from power leads and twist
pair tighter.
- Failure in the current feedback isolator on the SDCI/DCFB.
- During cell test on multibridge drives, if a cell is shorted, it is possible for reverse current
to flow in a shunt. Inhibit this fault and run cell test again to locate the shorted SCR.
Filtered state
188
FLO OFST
Field current feedback VCO zero offset too high

During power-up, a zero offset greater than 5% has been detected in the field current sensor circuitry on the SDCIIDCFB. Field firing is inhibited and the drive makes additional offset
measurements. If the excessive offset was actually due to a decaying field current, when
the current decays, the fault will automatically clear if the offset returns to normal. Reporting of an excessive offset and the concurrent field firing shutdown can be inhibited by
EE.571.4, MFLTJP. The maximum erroneous offset due to a decaying field under these
conditions is 5% of rated. Possible causes:
- Drive came out of a hard reset before field decayed. Hold reset button closed for ten
seconds before releasing and see if fault clears.
- JP1, JP2, or P3 on DCI not set correctly.
- Failure of SDCI/DCFB.
- For SDCC, U31 date codes ~ 9420 may require DCP revision ~ 5.10.
Non-latched
annunciated
fault
10-22
BI006008
GEH-6148

No.
Name
Type Fault
189
VFB OFS
Bridge or armature voltage feedback VCO zero offset too high

During power-up, or while the drive is stopped if EE.570.5, MCNFIG, is set, a zero offset
greater than 5 % has been detected in the bridge (P1/P2) voltage sensor circuitry on the
DCIIDCFB/SDCI. Possible causes:
- EE.574 is set beyond its range.
- EE.574 is set to improper value. Run test 14 to set automatically.
- EE.570.5 is set and the drive can be externally rotated while stopped.
- Failure of the DCI/DCFB/SDCI.
- Open or intermittent connection on pins 25 or 26 of ribbon cable 5PL.
- Wiring error in connection of armature signals (P1/P2) to feedback interface card.
Non-latched
annunciated
fault
190
IDISC FL
Discontinuous current sensor failure, stuck discontinuous

The discontinuous current sensor is not detecting any armature current when CFB is actually greater than 1 pu. On the DCI card, this sensor is a hardware circuit which looks at
CFB, and is only used with the DCC control card standard current regulator and only prior
to revision 2.20. On the DCFB, or when a DCI is used with the SDCC, or when the enhanced current regulator is used (EE.570.2L or after revision 2.17, discontinuous current is
determined using the VFB signal. Possible causes of this fault:
- Circuit failure on DCI/DCFB.
- Routing, twisting, or installation of shunt to DRPL wiring.
- Failure or low scaling of VFB circuit (revision 2.20 or later).
Detection of this fault can be inhibited by setting EE.571.2. It is recommended that
EE.571.1 be set if the enhanced current regulator is enabled and the MP firmware revision
is less than 2.20.
Filtered fault
191
ICONT FL
Discontinuous current sensor failure, stuck continuous

When the drive is stopped, the discontinuous current sensor is reporting armature current.
Possible causes:
- Dc shunt installed incorrectly or connections loose.
- Routing of twisted pair from the shunt to DRPL on the DCI. Twist the pair tighter and
route away from noisy wiring.
- DRPL plugged in incorrectly or loose.
- Current feedback isolator failure on the DCI.
- Failure or high scaling of VFB circuit (revision 2.20 or later).
Detection of this fault can be inhibited by setting EE.571.2. Please refer to additional help
at FLT.190.
Filtered fault
192
DIMETRIC
Diametric (dc bus shoot-through) fault

The drive has shutdown because it detected an SCR bridge diametric fault. During the first
45 degrees after each firing, the average dc voltage is sampled over three intervals of approximately 15 degrees each. If the sum of these voltage magnitudes is less than
EE.DIMTRC, and the average dc current (VAR.CFB) is greater than 15 percent, then fault
192, DIMETRIC, is reported. Possible causes:
- Shorted SCR. Run cell test (test 12).
- EE.588, DIMTRC, setting is too high.
- A commutation failure occurred but was not detected. Check EE.581.
When this fault is detected, armature and field SCR firings are immediately inhibited (no
phase-back occurs first).
Trip fault
10-23
BI006008
GEH-6148

No.
Name
Type Fault
193
VARMTRCK
Mismatch of bridge and armature voltage feedback signals from DCFB

Voltage feedback variables VARM and VBRIDGE from the DCFB have differed by more than
20% for 360 firings while the MD contactor is supposed to be closed.
Possible causes:
- VM1A/B on DCFB not connected to motor armature.
- P1 AlB on DCFB not connected to SCR bridge output.
- DIP switches scaling for P1 A/P2A (SW4) and VM1 AlB (SW5) on the DCFB not set to
same voltage range.
- MD contactor not closing when it should.
- Impedance added between the bridge and the armature is dropping more than 20%
voltage. If this is ok, inhibit FLT.193 via EE.571.14.
- Failure of VCOs on the DCFB or VCO counters on the SDCC.
- VCO counters not loaded in LCA logic due to invalid value in EE.1 .5.
- Revision of DCP is less than 2.32.
Detection of this condition can be overridden by EE.571.14, MFLTJP. Also see EE.570.11.
Trip fault
194
HDWRTYPE
Mismatch of firmware settings and drive hardware detected

The drive has detected a discrepancy between firmware configuration jumpers and actual
hardware installed. Possible causes:
- DCFB detected at 1PL, but SDCI selected via EE.573.0.
- Field #B enabled (EE.570.9) without DCFB or with field #A in the 2/3 wave mode
(EE.5 73.2).
- Multibridge enabled (EE.607.0) without DCFB or while not in simulatormode.
Trip fault
195
DCFBFAIL
DCFB logic cell array failure

The feedback signal from the DCFB to the SDCC indicates that the programmable logic
device on the DCFB has failed to configure itself on power-up. Possible causes:
- Configuration PROM or LCA on DCFB missing, failed, or not fully seated.
- Failure of 1PL ribbon cable (pin 28 should go low after initialization).
Failure of the DCFB.
Inhibit this fault by setting EE.571.12 (weight 4096).
Trip fault
196
LEG_LOSS
Ac leg current low or imbalanced

Possible causes:
- EE.584 or 585 set too sensitive.
- Blown leg fuse or open SCR or gate lead. Run cell test.
- Ac line phase imbalance.
- Erroneously reported by software revisions prior to 1.51.
- Logic current limit (EE.1508) set near or below current limit.
A setting of 0 in EE.585, LEGSEN, inhibits FLT.196.
Trip fault
197
OVERV MB
Instantaneous overvoltage for motor #B

The armature voltage connected to DCFB (only) analog voltage input VM2A has exceeded
the limit set by EE.606, MBOVLT. This voltage could be either the GF2000 motor voltage,
or motor #B in a dual-motor (parallel) application. Possible causes:
- VM2A not connected to a valid voltage feedback.
- VM2A not scaled properly via EE.1 524. VM2SFO.
- Fault input connected to VMA1 instead of VMA2, per EE.573.5.
- See help for FLT .19 for additional causes.
Filtered fault
10-24
BI006008
GEH-6148

No.
Name
Type Fault
198
FIELDTRK
Field undercurrent tracking

The field current has remained below the field command by at least 15% of rated for more
than 5 seconds. Possible causes:
- Hot field. Unable to achieve commanded current.
- Field regulator unstable. Check tuneup.
- See FLT.4, FIELDLOS.
Wrong field mode (2/3, NRP, or NRX) selected via EE.573.2.
- For SDCC, U31 date codes ~ 9420 may require DCP revision ~ 5.10.
Set EE.571.0 to inhibit field tracking.
Beginning with revision 6.31, IFLDAFB (VAR.1090) (or FLDFB, VAR.105 if Field #A is enabled via EE.5300.0) is normalized by the flux saturation curve defined by EE.1568EE.1575. FIELDTRK uses this normalized field feedback to detect a fault.
Filtered fault
199
lac RVRS
Reverse bridge instantaneous overcurrent

The bridge current in the reverse direction as sampled by the dc shunt has exceeded the
limit set by EE.1527, 10CRVO. Possible causes:
lac set too low. Check 10CRVO (EE.1527).
- See other causes listed for FLT.1.
Trip fault
200
lac MTRB
Armature instantaneous overcurrent for motor #B (DCFB only)

Trip fault
The armature current as sampled by the dc shunt IA2 (DCFB only) has exceeded the limit set
by EE.1529, 10CMBO. Possible causes:
- lac set too low. Check 10CMBO (EE.1529).
- Shunt IA2 not connected to a valid current feedback signal.
- Shunt IA2 not scaled properly (EE.1521, CF2SFn).
- CF2SFn (EE.1521) set too low, causing saturation of the hardware.
- See other causes listed for FLT.1.
201
lac ARM
Armature instantaneous overcurrent

The armature current as sampled by the dc shunt has exceeded the limit set by EE.1525,
10CARO. Possible causes:
- lac set too low. Check 10CARO (EE.1525).
- See other causes listed for FLT. 1.
Trip fault
202
SYINLOSS
Loss of ac line sync input

The SYNC signal on the DCI/SDCI/DCFB is not tracking an appropriate ac line frequency.
Possible causes:
- Bridge power which connects to power supply card not turned on. Check L 1/L2/L3 inputs
to card; for DCFB also DIP switch settings.
- Line or power supply card fuses are blown or missing. (Check MOVs).
- Failure of SDCI/DCI or 1PL (pin 29). Verify line frequency TTL signal at TP29 on
DCC/SDCC.
- Misconfiguration of PLL configuration. Ccheck EE.570.3 and EE.572.4, 6, & .10
all normally O. Verify EE.570.4.
- Excessively noisy, notched, or unbalanced ac line.
- Failure of 15 volt power supplies.
- Failure of LAN power supply or SPCB, misconfiguration of multibridge master or follower
drive (EE.572).
- On revision 1.40 and earlier, this fault is erroneously reported and should be inhibited via
EE.571.7.
Presence of ac line sync is essential for proper field and armature operation, even in the
simulator mode, as the PLL and field regulator do not operate in the absence of this input.
Beginning with revision 5.31, field and armature SCR firings are inhibited when this fault
occurs.
Beginning with revision 5.36, for DC2000 only, this fault requires a hard reset to clear. For
revision 6.31 and later (DC2000 only), if EE.6283.6 is set, this fault can be cleared by invoking a soft reset (a firm reset is performed). See EE.6283.6 for details.
Trip fault
203
NO BURST
SYOSC (synchronized firing burst generator) failed

The pulse train from the oscillator used to form the SCR firing bursts is missing. This signal
should appear on 1PL-14 as a 20% duty cycle, 25 kHz, TTL waveform. Possible causes:
- Failure of U61 or U27 on the SDCC. Replace SDCC.
Failure of ribbon cable 1PL.
- Misoperation of control card due to noise or intermittent connection on control card.
Check installation of socketed components.
Trip fault
10-25
BI006008
GEH-6148

No.
Name
204
La ACFRQ
Low ac line frequency, less than 45 Hz (or phase loss)

Filtered fault
The drive is not receiving a suitable ac line sync signal from the DCI/DCFB or its frequency is
outside acceptable range. Possible causes:
- Alternator power supply (if used) not maintaining line frequency.
- Fuses blown on the interface card. Check MOVs.
- Excessive ac line phase imbalance or notching.
Nuisance fault due to software error prior to revision 1.20.
See additional items under FLT.202.1.
This fault can be overridden by EE.571.1 O. Beginning with revision 5.31, field and armature
SCR firings are inhibited when this fault occurs.
205
HI_ACFRQ
High ac line frequency, greater than 70 Hz (or phase loss)
Filtered fault
206
AC GT DC
Ac current exceeds dc current trip

The magnitude of ac current transformer current, VAR.1 019, CTCFB, has exceeded the
magnitude of dc shunt current, VAR.1 04, CFB, by the trip threshold, EE.1519, ACGDCn.
Possible causes:
- Improper CT burden selection on the DCI/DCFB.
Improper scaling of CTCFB via EE.1520, CTTRMn.
- ACGDCn, EE.1519, set too low.
- Too much circulating ac current or bridge fault.
This fault may be inhibited by setting EE.1519 to O.
Trip fault
207
CT OFSET
High ac current transformer offset read when current should be 0

A reading of over 250% current has been read on one of the current transformers when the
drive is not firing SCRs. Possible causes:
Open or intermittent connection on pins 1 or 2 of ribbon cable 1PL.
- Failure of CT interface circuitry on the DCI/DCFB.
- Failure of DCC/SDCC.
This fault may be inhibited by setting EE.581 to 32767.
Trip fault
208
IL1 LOSS
Ac current transformer IL1 too low at given CFB level

Possible causes:
ICPL on DCI/DCFB not connected.
CTs not burdened correctly.
- (Non-regenerative only) Fault must be inhibited via EE.587.
- EE.587 set too low.
- Leads swapped in CT connector, ICPL, on SDCI/DCFB card. Compare VAR.1 04 and
VAR.1 019 for same polarity and magnitude. Use burden switches for coarse adjustment,
EE.1520 for fine.
- For early revisions, see note under EE.587 and increase EE.587.
Trip fault
209
IL3 LOSS
Ac current transformer IL3 too low at given CFB level
Trip fault
210
CT POLAR
Ac current transformer IL1 or IL3 polarity reversed

Possible causes:
VAR.1 019 for same polarity and magnitude. Use burden switches for coarse adjustment,
EE.1520 for fine.
- CTs improperly burdened on DCI/DCFB.
Gate leads connected to wrong SCRs.
- Hardware too sensitive prior to 531 XDCIANG1/AJG2 revision.
- For early revisions, see note under EE.587 and set EE.571.8.
Once CTs are known to be wired correctly, this fault may be inhibited by setting EE.571.8.
Trip fault
211
CFB LOSS
CFB too low at given ac current transformer level

Possible causes:
- CTs not burdened correctly. Set burdening to a higher horsepower.
- EE.586 set too low.
VAR.1019 for same polarity and magnitude. Use burden switches for coarse adjustment,
EE.1520 for fine.
- Nuisance trips due to hardware/software sensitivities prior to 302DCIANG1/AJG2,
302DCCAMG1, and 1.60 lAG) revisions. Increase EE.586 by up to 2:1 to
desensitize (see note under EE.587).
Trip fault
10-26
Type Fault
BI006008
GEH-6148

No.
Name
Type Fault
212
HSO OVF
Internal armature firing circuit failed

Fault 212 indicates an internal software overflow in the high speed output buffer.
Possible causes:
Software malfunction due to noise or intermittent connection on 301 DCC. Check
external signal wiring practices, installation of socketed components, ribbon
cables, and low voltage power supplies.
Armature current regulator bandwidth set higher than software is able to achieve.
Try reducing bandwidth.
For K/L frame (multibridge) follower drives, the master drive was hard reset, causing
the follower to lose synchronization.
- Inappropriate PLL selection (EE.570.4) or gain (EE.575-577).
- Loss of sync signal, see FLT.202 (SYINLOSS) possible causes.
This fault may be inhibited via EE.571.9. Field and armature SCR firings are inhibited when
this fault occurs.
Locked fault
213
CTSTFAIL
Cell test failed to determine the state of the SCRs due to setup
Cell test detected a short during one pass and an open circuit during the other pass, and
thus was not able to reliably determine the bridge health. Possible causes:
- The cell test configuration parameters (EE.1577 - EE.1579) are all set too low for
adequate signal-to-noise margins, and must be raised.
- Failure of the CFB and/or VFB sensing circuitry (DCI/DCFB).
- Excessive noise in CFB and VFB due to poor wiring or loose connections.
Trip fault
214
CTST_VFB
Cell test detected too much armature voltage at startup

At the beginning of the short circuit test, VFB was greater than 5% and the SCRs cannot
be reliably tested. Possible causes:
- The motor was rotating when cell test was invoked.
- Dc contactor not closing, or longer MAPDLY time needed (EE.39).
- Excessive offset in the VFB circuitry (See EE.574).
- Failure in the VFB sensor or connections (DCI/DCFB).
- Excessive leakage in the bridge snubbers or SCRs, coupled with an open armature
loop (especially if dc contactor is used).
This fault may be overridden by setting EE.571.11.
Trip fault
215
VFB FAIL
Cell test detected a low or reverse armature voltage

During the open circuit test, VFB magnitude or polarity was incorrect. Possible causes:
- Reversed or open connections of armature to power connect card.
- Open connections in ribbon cable 5PL pins 25 or 26.
- Open circuit test firing angle too low -- increase EE.1577.
- Failure in VFB circuitry on control card or power supply card.
- Revision 1.90 only: Erroneously reported during cell test in simulator.
This fault can be overridden by setting EE.571.11.
Trip fault
V12 or V13 feedback VCO zero offset too high

The DC offset in DCFB signals V12 and V13 are continuously computed. FLT.221 is generated if a zero-offset greater than 3% has been detected in one or both of these signals.
Possible causes:
- Failure of DCFB card or ribbon cable 1PL.
- Wiring error in connection of signals (V11V2N3) on DCFB card
- Excessive coupling of common mode noise into floating commons of DCFB card via
feedback connections due to poor cable routing.
Detection of this condition can be overridden by EE.1500.15, MJPROO. Effective revision
4.35.
Non-latched
annunciated
fault
221
10-27
BI006008
GEH-6148

No.
Name
Type Fault
222
liNT SAT
Enhanced current integrator saturated (DRVTYP = 85)

The enhanced current regulator integrator has remained saturated (reached the limit,
ILiMcO EE.1581) for 60 firings in a row. Detection of this condition is enabled by setting
EE.6283.2 (MCFGJP). Possible causes:
Voltage feedback is scaled incorrectly. Check EE.1503 (VFBSFO) and hardware jumpers on the DCI/OCFB card for correct scaling.
Ac voltage input is NOT actually within the nominal range indicated by the data used
to calculate the integrator limit (ILiMcO, EE.1581).
EE.1581 (ILiMcO) is still set too low even though the above two conditions are OK.
Voltage feedforward gain tuned too low, check EE.1585 (WVFBcOl, EE.1586
(GVFFcOl, and EE.1594 (HIRCPO).
(Simulator only) EE.ARMRES, ARM_TC. or EE.IOCTRn set too low.
Non-latched
annunciated
fault
223
ILP OPEN
Enhanced current integrator saturated at CFB less than 5 % (DRVTYP = 85)

The enhanced current regulator integrator has remained saturated (reached the limit,
ILiMcO EE.1581) for 60 firings in a row and armature current has remained less than 5%.
Detection of this condition is enabled by setting EE.6283.0 (MCFGJP). By setting
EE.6283.1, this fault can be changed from an brief annunciated fault (does not stop the
drive) to a trip fault. Possible causes: [4.41]
Voltage feedback is scaled incorrectly. Check EE.1503 (VFBSFO) and hardware
jumpers on the DCI/DCFB card for correct scaling.
EE.1581 (ILiMcO) is set too low.
Voltage feedforward gain tuned too low, check EE.1585 (WVFBcOl, EE.1586
(GVFFcOl, and EE.1594 (HIRCPO).
Open connections or contactors in the motor armature circuit.
Open connections in 5PL, DRPL. or SCR gate leads.
DC fuse open.
(Simulator only) EE.ARMRES, ARM_TC, or EE.lOCTRn set too low.
Non-latched
annunciated
fault
Armature instantaneous over-current for motor #A

The armature current as sampled by the de shunt IA1 has exceeded the limit set by
EE.6302, IOCMAO. Possible causes:
- IOC set too low. Check IOCMAO (EE.6302).
- Shunt IA1 not scaled properly (EE.1505, CFBSFn).
CFBSFn (EE.1505) set too low, causing saturation of the hardware.
- See other causes listed for FLT. 1.
Trip fault
Motor B IA2 shunt polarity reversed (DCFB only)

Used primarily in 2-motor applications with seperate motor loops. The drive has measured
a 20% reverse IA2 shunt (DCFB only) current while firing the forward bridge or a 20%
forward IA2 shunt current while firing the reverse bridge. Possible causes and solutions:
Run Cell test (1 2) to confirm fault.
IA2 wired backwards at shunt or plugged in backwards on DCFB.
Gate lead plugs connected to wrong SCRs.
Twisted pair from shunt picking up noise. Route away from power leads and twist
pair tighter.
Failure in the current feedback isolator on the DCFB card.
During cell test on multibridge drives, if a cell is shorted it is possible for reverse current to flow in a shunt. Inhibit this fault and run cell test again to locate the shorted
SCR.
Fi Itered state
225
226
10-28
CFBB POL
BI006008
GF2000 Dc G erator Field Exciter
GEH-6148

No.
Name
Type Fault
230
MBLCON G
Multibridge EE configuration error

An invalid EE configuration for multibridge exists. Probable causes:
- MBLTTL IEE.61 0) set to less than 2 drops
- MBLCFG (EE.608) A + B total drops doesn't equal MBLTTL total drops
- Cell test or torque proving activated on revisions which do not contain these features.
The configuration must be corrected and all bridges hard reset.
Non-latched
annunciated
fault
231
CTACSH T
Indeterminate shorted cell detected during SCR test

During the short circuit cell test, current was detected in either the shunt or CT, but the
voltage produced across the armature was insufficient to determined which cell was
shorted, perhaps because the EE.1578 voltage detection threshold was set too high, the
EE.1579 current detection threshold was set too low, or the EE.1580 firing angle was set
too low. Review these adjustments and repeat the cell test.
Trip fault
232
MBRGSH T
A multibridge follower detected a short in its bridge

During a cell test of the multibridge, a follower detected CT or shunt current during a
period when none of that follower's cells were being gated, indicating a shorted cell.
Normally, under such a condition, the master bridge will detect which leg (A 1 - A6) is
shorted and report a FLT.81 - 86, and the follower bridge containing the short will report
a FLT.232 to pinpoint the shorted cell.
Trip fault
233
MBBALA C
K/L frame multibridge master/follower current out of balance

A drive's current has stayed in error from the master current reference by over 50% for
over 2 seconds and the master current reference is greater than 50%. As of revision
4.35, if this fault condition persists for over 5 seconds, the fault changes from brief annunciated to trip. Possible causes:
- The drive has been stopped by a local stop command.
- The drive is not generating any current due to blown fuse, open contactor or
connection. or failure in the firing circuit hardware.
- Failure in the drive current feedback circuitry.
- For follower bridges, balance regulator gain (EE.612) set too low.
- EE.MBLTTL or MBLCFG set incorrectly in master drive(s).
Detection of this fault may be inhibited by setting EE.607.5.
Non-latched
annunciated
fault
234
MBLSCHE
K/L frame multibridge follower feedback checksum error on fiber optics

The master drive received an invalid message from a follower drive over the fiber optic
link. Possible causes:
- Two followers have the same drop number IEE.609, MBLDRP).
- Loose or bad coupling in the fiber optics, or cable crimped.
- Stray light entering fiber optics through unused MBHA connector.
Non-latched
annunciated
fault
10-29
BI006008
GEH-6148

No.
Name
Type Fault
235
MBLSLVRN
K/L frame multibridge follower running when master bridge is stopped

Follower drives cannot run unless the master drive is running. Possible cause:
- Follower commanded to run from Programmer or other local source when master
drive is not running.
Non-latched
annunciated
fault
236
MBLMNOEC
K/L frame master bridge did not hear its own message on the fiber optic
The master drive listens to the commands it sends to the followers on the fiber optic cable. This fault is reported if the master drive did not hear these messages. (If it hears
these messages, but they are garbled, FLT .237 is reported.) Possible causes:
- EE.572.3 not set.
- Failure of the MBHA fiber hub card or its power supply.
- Failure of the SPCB daughter card.
Non-latched
annunciated
fault
237
MBLMBDEC
K/L frame master bridge received a garbled echo of its own message
The master bridge cannot hear its own fiber optic transmissions correctly.
Possible causes:
- Multiple bridges programmed to be the master (EE.609, MBLDRP).
- Crimp or sharp bend in fiber optic cable.
Non-latched
annunciated
fault
238
MBLMCHEX
K/L frame follower drive received a garbled message from the master
The follower bridge cannot hear fiber optic transmissions from the master correctly. Possible causes:
- Multiple bridges programmed to be the master (EE.609, MBLDRP).
- Crimp or sharp bend in fiber optic cable.
Non-latched
annunciated
fault
239
MBLMLATE
K/L frame follower drive failed to receive command from master when expected
The follower drive did not hear the command from the master bridge in time, or not at all.
Possible causes:
- Follower drive not using master line sync signal (EE.572.4).
- EE.572.3 not set.
- Failure of the MBHA fiber hub card or its power supply.
- Failure of the SPCB daughter card.
- Master drive not powered or in reset.
Since revision 3.36, MBLMLATE will automatically clear when the master is restored if
the follower was not running when the fault occurred, provided the follower is using its
own line sync rather than the master's.
Non-latched
annunciated
fault
330
DCP FAIL
DCP selftest failed

U1 on SDCC card failed.
Trip fault
331
DCPROMCK
DCP EPROM checksum error

U11 or U12 failure.
Trip fault
10-30
BI006008
GEH-6148

No.
Name
332
Type Fault
Logic cell array U32 powerup test fail

The programmable logic cell array (LCA) device U32 has failed to program correctly. Pin
55 of this device indicates programming status. After a powerup or reset, this pin should
be low. After U32 is programmed by U1, the pin should be high. FLT.332 is reported if U1
detects this pin in the wrong state either before of after programming. Possible causes:
- Defective SDCC.
- Socketed device on SDCC not inserted fully, or pin bent under.
Trip fault
333
MLCAPR G
Logic cell array U31 power-up test fail

Trip fault
The programmable logic cell array (LCA) device U31 has failed to program correctly. Pin
55 of this device indicates programming status. After a power-up or reset, this pin should
be low. Programming of this LCA is done daisy-chained with LCA U32. U32 is programmed first, then it passes programming data from U1 through it to U31. After U31 is
thus programmed by U1, the pin should be high. FLT.333 is reported if U1 detects this pin
in the wrong state either before of after programming. Possible causes:
- Defective SDCC.
- Socketed device on SDCC not inserted fully, or pin bent under.
335
DPRLFAIL
Dual port RAM between DCP and LCP on the SLCC card failed initialization test
Possible causes:
- Improper SLCC installation, including 3PL and 9PL (if used)
- Failure of SLCC card or 3PL.
(S)LCC enabled via CFGJPR (EE.1.0), but card not installed.
Trip fault
336
DPRMFAI
Dual port RAM between DCP and MCP on the SDCC card failed initialization test
Possible causes:
- Improper seating of U8, or bent IC pins
- Failure of SDCC card.
Trip fault
337
DPRUFAIL
Dual port RAM between DCP and UCP on the UCC card failed initialization test
The EX2000 uses a TCCS microapplication card connected via 3PL. This fault indicates a
failure in the SDCC card test of TCCS memory. Possible causes:'
- Improper TCCS installation.
- Failure of TCCS card or 3PL ribbon cable.
- TCCS UCC card enabled via CFGJPR (EE.1.8), but card not installed.
Trip fault
338
TRC_ANU
Timed overcurrent alarm
Non-latched
annunciated
fault
339
TRC TRIP
Timed overcurrent
Possible causes:
Motor mechanically overloaded due to load or wear.
Field current less than 85% of rated.
TRC settings too low (EE.1489, 1493, 1497).
CFGJPO.8 IEE.1498.8) is set.
Armature winding failure.
DS contactor failure (if used).
TRC@IN IEE.25) if used, is not pointed at bridge or motor current.
Trip fault
340
NOLCPDP
LCC or SLCC DPRAM not detected

LAN card not detected or not responding, or LCC detected when SLCC is required. Possible causes:
- LAN card (LCC) enabled by EE.1.0, but not installed.
- LAN card (SLCC) enabled by EE.1.1, but LCC installed instead. (Valid only if SDCC is
present).
- LCC/SLCC installed incorrectly. Check all LCC/SLCC connectors and socketed ICs.
- Failure of 3PL, LCC/SLCC card, or DCC/SDCC card.
Trip fault
341
NOUCPDP
UCC DPRAM not detected

Microapplication card not detected or not responding. Possible causes:
- Microapplication card enabled by EE.1.8 but not installed.
Trip fault
10-31
BI006008
GEH-6148

No.
Name
342
MOTOR OT
Motor Thermal Switch Fault

The input pointer MOTA@I (EE.3604l is typically pointed at the local drive liD which is
monitoring the Motor Thermal Switch. For FLTJP1.3 = 0, the sense of fault is 1 =
Faulted, 0 = No Fault. For FLTJP1.3 = 1, the sense of fault is 0 = Faulted, 1 = No Fault.
The enumerations at FLTJP1.0 select the behavior of the fault. If the fault input pointer is
not used (pointed at zero) the fault is disabled.
Possible Causes:
- MOTA@I (EE.3604) Pointed Incorrectly
- Improper sense selected by FLTJP1.3 (EE.3612.3)
- Motor is overheating
343
XFMR OT
Transformer Thermal Switch Fault

The input pointer XOT@IN (EE.3605) is typically pointed at the local drive liD which is
monitoring the Transformer Thermal Switch. For FLTJP1. 7 = 0, the sense of fault is 1
Faulted, 0 = No Fault. For FLTJP1. 7 = 1, the sense of fault is 0 = Faulted, 1 = No Fault.
The enumerations at FLTJP1 .4 select the behavior of the fault. If the fault input pointer is
not used (pointed at zero) the fault is disabled.
Possible Causes:
- XOT@IN (EE.3605l Pointed Incorrectly
- Improper sense selected by FLTJP1. 7 (EE.3612.7)
- Transformer is overheating
344
BRK_SPLY
Brake Power Supply Fault

The drive sequencing sets RLSEBRAK (VAR.814), which is sent to the brake supply, to
release the brake. The brake supply provides a feedback boolean that is wired into the
local drive 1/0 and is set when the brake supply is trying to release the brake. There is
typically a delayed comparison between RLSEBRAK and the brake supply feedback in order
to determine if the brake is responding. The input pointer BPSA@I (EE.3606) is typically
pointed at the result of this comparison for the purpose of determining a fault condition.
For FLTJP1 .11 = 0, the sense of fault is 1 = Faulted, 0 = No Fault. For FLTJP1 .11 = 1,
the sense of fault is 0 = Faulted, 1 = No Fault. The enumerations at FLTJP1 .8 select the
behavior of the fault. If the fault input pointer is not used (pointed at zero) the fault is disabled.
Possible Causes:
- BPSA@I (EE.3606) Pointed Incorrectly
- Improper sense selected by FLTJP1 .11 (EE.3612. 11)
- Brake Supply is operating improperly
345
UNKNOWNL
LCC/SLCC fault outside its valid range. Possible causes:

- Communication failure between DCC/SDCC and LCC/SLCC (noise?).
- Failure of LCP processor on LCC/SLCC card, or 3PLl9PL.
Latched
annunciated
fault
346
UNKNOWNM
MCP fault outside its valid range. Possible causes:

- Communication failure between DCP and MCP on DCC/SDCC card (noise?).
- Failure of MCP processor on DCC/SDCC card. Check seating of U21.
- Failure of U8 on DCC/SDCC card. Check seating of socketed parts.
Latched
annunciated
fault
347
UNKNOWNU
UCC fault outside its valid range

Not used yet.
Latched
annunciated
fault
348
LPROTMON
Line Protection Monitor Fault

The input pointer LPMA@I (EE.3607) is typically pointed at the local drive liD which is
monitoring the Fuse Blown indication from the LPPA/B module (LPPA E4 & E5). For more
information, see LPPA. For FLTJP1.15 = 0, the sense of fault is 1 = Faulted, 0 = No
Fault. For FLTJP1 .1 5 = 1, the sense of fault is 0 = Faulted, 1 = No Fault. The enumerations at FLTJP1.12 select the behavior of the fault. If the fault input pointer is not used
(pointed at zero) the fault is disabled. Possible Causes:
- LPMA@I (EE.3607) Pointed Incorrectly
- LPPA/B giving fuse blown indication
10-32
Type Fault
BI006008
GEH-6148

No.
Name
Type Fault
Bridge Thermal Switch Fault

The input pointer OTMW@I (EE.361 O)is typically pointed at the local drive I/O which is
0, the sense of fault is 1
monitoring the Bridge Warning Thermal Switch. For FLTJP2.5
= Faulted, 0 = No Fault. For FLTJP2.5 = 1, the sense of fault is 0 = Faulted, 1 = No
Fault. The enumerations at FLTJP2.3 select the behavior of the fault. If the fault input
pointer is not used (pointed at zero) the fault is disabled. Possible Causes:
- OTMW@I (EE.3610) Pointed Incorrectly
- Bridge Warning Thermal Switch failure or wrong sense
- Bridge is becoming overheated
349
350
BLOCKER
Block Compiler Error

An error in the block source list, EE.800-1022, was detected during compilation. A brief
explanatory message appears on the serial link when the compile command ("Z") is issued.
Trip fault
352
MINREVN
Software revision too low for EEROM configuration

The required revisions indicated by EE.65-66 are newer than the actual revisions reported
by test 10. Possible causes:
- OCP or MCP software revision too old for level requested in EEROM
- LCP software revision too old for level requested in EEROM (DP 0-1.87 only)
- EE.65-66 calling for wrong software revisions
- EE.67 calling for wrong software revision (OP revs 0-1.87 only)
- EE.67 must be set to 0 when OCP 1.60 is used with LCP 5.00 or higher
- Prior to revision 1.70, may indicate bad MCP (try setting EE.66 = 0)
- Hardware failure: DCC/SOCC or LCC/SLCC control cards or 3PL. Check seating of
socketed components and ribbon cables.
Trip fault
353
LCPREVNO
LCP software revision too low for EEROM configuration

The required LCP revision indicated by EE.67 is newer than the actual revision reported by
test 10. Possible causes:
- LCP software revision too old for level requested in EEROM.
EE.67 calling for wrong software revision.
- Hardware failure: DCC/SDCC or LCC/SLCC control cards or 3PL. Check seating of
socketed components and ribbon cables.
Trip fault
354
UCPREVNO
UCP software revision too low for EEROM configuration (trip)

This fault code is not presently used in the drive firmware.
Trip fault
355
THA ANUN
Motor A Thermal Model Alarm (Annunciation)

This fault occurs when the temperature state of BLK.THRMA reaches or exceeds the
square of the value set in THAALM [3568]. Possible Causes;
- Motor is too hot. Reduce motor loading before trip occurs.
- THAALM [3568] set too low.
- THATau [3567] (motor time constant) set incorrectly.
- THA@IN [3566] pointed at incorrect address.
- THA@SP [3570] pointed at incorrect address.
- THA@GS [3571] pointed at incorrect address.
Non-latched
annunciated
fault
356
THA TRIP
Motor A Thermal Model Trip

This fault occurs when the temperature state of BLK.THRMA reaches or exceeds the
square of the value set in THATRP [3569]. Possible Causes:
- Motor is too hot. Reduce motor loading.
- THATRP [3569] set too low.
- THATau [3567] (motor time constant) set incorrectly.
THA@IN [3566] pointed at incorrect address.
- THA@SP [3570J pointed at incorrect address.
- THA@GS [3571] pointed at incorrect address.
Trip fault
10-33
BI006008
GEH-6148

No.
Name
Type Fault
357
THB_ANUN
Motor B Thermal Model Alarm

This fault occurs when the temperature state of BLK.THRMB reaches or exceeds the
square of the value set in THBALM [3579). Possible Causes:
- Motor is too hot. Reduce motor loading before trip occurs.
- THBALM [3579] set too low.
- THBTau [3578) (motor time constant) set incorrectly.
- THB@IN [3577] pointed at incorrect address.
- THB@SP (3581) pointed at incorrect address.
- THB@GS [3582) pointed at incorrect address.
Non-latched
annunciated
fault
358
THB_TRIP
Motor B Thermal Model Trip

This fault occurs when the temperature state of BLK.THRMB reaches or exceeds the
square of the value set in THBTRP (3580). Possible Causes:
- Motor is too hot. Reduce motor loading.
- THBTRP[3580) set too low.
- THBTau (3578) (motor time constant) set incorrectly.
- THB@IN [3577) pointed at incorrect address.
- THB@SP (3581) pointed at incorrect address.
- THB@GS [3582) pointed at incorrect address.
Trip fault
Link Presence Fault

Some drives are implemented such that an 105 is the master of the drives functions. The
drive may want to take corrective action through the fault mechanism if the Master 105
drops off line. Auxcmd's can provide a Link Present bit from the Master lOS and L1NK@1
(EE.3611) would typically be pointed at the appropriate Auxcmd. For more information.
see EE.AUXCMA,B.C,D.
For FLTJP2.9 = O. the sense of fault is 1 = Faulted. 0 = No Fault.
For FLTJP2.9 = 1. the sense of fault is 0 = Faulted, 1 = No Fault.
The enumerations at FLTJP2.6 select the behavior of the fault.
If the fault input pointer is not used (pointed at zero) the fault is disabled.
Possible Causes:
- L1NK@1 (EE.3611) Pointed Incorrectly
- Link Presence detection indicates fault
- Data link communication to lOS lost
360
TESTWRUN
361
362
363
10-34
CTST TIM
Tests 12-19 commanded while drive is already running

Drive must be stopped before a tuneup. cell test, or board test can be initiated from any
source.
Non-latched
state
Cell test inhibited (See EE.2.4)

The cell test or torque proving operations have been invoked although cell test has been
disabled by EE.2.4. Some applications, such as elevators, may require special external
control sequences before cell test should be allowed.
Trip state
Cell test response timeout

The start/stop sequencer timed out waiting for the motor control processor to complete a
cell test/torque proving cycle. Possible causes:
- Failure of DCC/SDCC MCP processor due to noise or intermittent card or IC socket
connection--check U22/U23, etc.
- (DC2000) Line sync power removed then reapplied without a hard reset
Trip fault
No process response to enable request

Blockware or motor control processor has not responded to a request by the start/stop
sequencer. Possible causes:
- CORE block not programmed correctly.
- Other MCP faults exist but are inhibited by EE.4.1 O.
Trip fault
BI006008
GEH-6148

No.
Name
Type Fault
364
PROC_TR
No process response to a regulate torque request (see FLT.363)
Trip fault
365
SS LOGIC
Illegal start/stop sequencer logic state.

This fault indicates the drive's sequencing logic has reached an undefined state, due to a
failure in the DCC/SDCC card firmware.
Trip state
366
MCONOPE
M contactor reporting open/closed when it should be open/closed

Trip state
For DCC, the drive has been commanded to start, and has requested that the main contactor close, but ten seconds have elapsed and the feedback variable, MACLOSFB
IVAR.823), which indicates the status of the contactor, indicates it has not closed. Note:
From revision 1 .82 to 1.91. this fault did not trip the drive.
For SDCC, revision 2.22 to present, the commanded main contactor states (MDACLOSD.
VAR.823 and MDBCLOSD, VAR.766) do not agree with the actual states (MACLOSFB,
VAR.823 and MDBCLSFB, VAR.765) or simulated contactor states. See EE.1498.4 and
VAR.761.
Possible causes:
- MACLOSFB not pointed to contactor input via EE.295, MCLS@1.
- Failure in contactor, wiring, or pilot relay.
- For SDCC, MDBCLSFB not pointed to contactor input via EE.244, MBCL@1.
- For SDCC. MAPDLY, EE.39 set too short.
This fault can be inhibited by FLTJPR.4 IEE.4) beginning with revision 2.31.
367
FAN LOSS
Normally closed "loss of fan" interlock is open

Possible causes:
- Failure of cooling fan(s}, blower fuses, etc.
- Improperly selected source of FAN LOSS (EE.296).
- External interlock from fan open or-improperly connected.
This fault can be changed from an alarm to a trip via FLTJPR.2 (EE.4).
Beginning on revision 4.35, this fault is affected by the fault power-up timer. See EE.36
FUPDLY and VAR.819 FTPUPTIM.
Filtered state
368
OVERTEMP
Normally closed "overtemperature" interlock is open

Possible causes:
- Overheating due to loss of blower, clogged air filters, etc.
- Improperly selected source of OVERTEMP (EE.297).
- External interlock from thermal sensor open or improperly connected.
This fault can be changed from an alarm to a trip via FLTJPR.3 (EE.4).
Beginning on revision 4.35, this fault is affected by the fault power-up timer. See EE.36
FUPDLY and VAR.819 FTPUPTIM.
Filtered state
369
MCONALR
Main contactor feedback alarm

This fault occurs when the contactor feedback status while running does not agree with
the commanded contactor state. Possible causes:
- EE.295. MCLS@I, or EE.244 not pointed at valid contactor status.
- EE.39, MAPDLY, set too short for actual contactor timing.
- EE.45, AUXDLY, set too short for contactor debouncing.
- Failure in contactor coil driver wiring or circuitry.
- Failure in contactor auxiliary contact feedback wiring.
After revision 2.30, this fault can be inhibited by FLTJPR.4 (EE.4).
Non-latched
annunciated
fault
370
REVSPEED
Speed feedback reports reverse speed

This fault is generated when the value of the boolean pointed to by REVS@I IEE.298) is
TRUE. Possible causes:
- Improper address in EE.298.
- SFB shows rotation opposite to that of the speed command.
Trip fault
371
MOPENRUN
RUN request received before main contactor has been closed

This fault occurs when EE.MCRQ@I is not pointed at zero (indicating that the con-tactor
is being controlled externally). EE.SEQJPR.4 is set (indicating that RUN requests should
not be accepted if the contactor has not been closed), VAR.MACLOSED is false
(indicating the contactor is not closed), and a RUN request is received.
Possible causes:
- External start logic sequencing is incorrect.
- EE.SEQJPR.4 is set incorrectly.
Non-latched
state
10-35
BI006008
GEH-6148

Type Fault
DCP general execution fault

Indicates that execution of the foreground module is overflowing the basic execution period
and is doing so to such an extent as to severely limit execution of the background module.
Detection of this condition trips the drive and resets the block interpreter, so that recompilation (or hard reset) is required in order to re-activate the functional block structure.
This fault indicates that the scheduled functions severely stress the execution capabilities
of the DCP CPU, so that adjustment of the source list is almost certainly required.
Trip fault
DCP foreground execution fault

Indicates that execution of the foreground module is overflowing the basic execution period
at a moderate rate. This fault indicates that the scheduled functions somewhat stress the
execution capabilities of the DCP CPU, so that adjustment of the source list may be required. This fault can be inhibited by FLTJPR.5 (EE.4).
Non-latched
annunciated
fault
374
DCP background execution fault

Indicates that average execution rates of the background modules are falling below acceptable levels. See VAR.514-516 for algorithm details. Possible causes:
- Too much foreground loading (block sourcelist loading)
- Too much background loading (winder, serial link, etc.)
This fault can be inhibited by FLTJPR.5 (EE.41.
Non-latched
annunciated
fault
375
Internal DCP watchdog time-out (annunciated). The DCP processor has detected an execution rate failure of the foreground software in the DCP. DCP background increments a byte
(DPRM_DCPF_WDOG) approximately 11 times per second. MCP background also increments this byte, about 22 times per second. DCP foreground resets this byte to zero about
90 times per second. If DCP background ever sees this byte larger than 50, it generates
fault 375. See related FLT.135. Refer to FLT.134 for possible causes.
Latched
annunciated
fault
No.
Name
372
373
DCP FRGD
376
LCP WDOG
DCP/LCC watchdog time out

Trip fault
Failure of watchdog between the drive control processor (DCP) and the LAN control processor (LCP). If LCP is enabled (CFGJPR.O), DCP monitors a byte from LCP every 89 milliseconds. If it is equal to 165, DCP resets a counter, otherwise DCP increments the counter.
Fault 376 is generated by DCP if the counter ever reaches 10. DCP sets the byte to 85 to
allow LCP to verify that DCP is functioning. Possible causes:
- Failure in 3PL or 9PL cable.
- Failure of LCC/SLCC card.
This fault can be inhibited by FLTJPR.9 (EE.4).
377
MCP WDOG
DCP/MCP watchdog time out

The DCP has detected an execution rate failure of the background software in the MCP.
MCP background monitors a byte (DPRM_DCPB_MCPB_WDOG) 22 times per second, and if
it is positive, MCP resets it to O. DCP background increments the byte 11 times per second, and generates fault 377 if it ever gets up to 100 counts. See related fault 134.
Possible causes;
- U22/U23 installed incorrectly (interchanged, backwards, bent pins).
- JP22 on DCC/SDCC card (near crystal X1) not installed.
- U21 failed.
- Failure of DCC/SDCC card
- U22/U23 defective.
- U21, U22, U23, U8 or other socketed parts not fully seated.
- Excessive noise on DCOM bus interfering with DCC/SDCC card.
This fault can be inhibited by FLTJPR.11 (EE.4).
10-36
Trip fault
BI006008
GEH-6148

No.
Name
Type Fault
378
MCPFWD G
MCP foreground watchdog time out

The DCP has detected an execution rate failure of the MCP foreground software. DCP
background increments a byte (DPRM_MCPF_WDOG) about 11 times per second. MCP
background also increments this byte. about 22 times per second. MCP foreground resets
this byte to zero about 360 times per second. If DCP background ever sees this byte larger
than 100, it generates fault 378. See related fault 136. Refer to FLT.134 for possible
causes. This fault can be inhibited by FLTJPR.11 (EE.41.
Trip fault
379
UCP WD
DCP/UCC watchdog time out
Trip fault
380
BAD HEX
Bad records in hex download file from LAN or serial link

During a hex ASCII download to EEROM, a record with a bad length, address, record type,
or checksum was received, possibly due to noise corruption. Only record types 0 (data
record) and 1 (end of file record) are allowed. Possible causes:
- Bad hex file
- More than 5 seconds elapsed between successive download records
- Time-out waiting for end of file record (revision 1.71 to present)
Noise. Try again with drive stopped, or use isolated serial hook-up.
Latched
annunciated
fault
381
EECKSM1
Bad page 1 EE checksum (EE.256 - EE.511)

See FLT.13.
Latched
annunciated
fault
382
EECKSM2
Latched
annunciated
fault
383
EECKSM3
Bad page 3 EE checksum (EE.768 - EE.1 023)
Latched
annunciated
fault
384
EECKSM4
Bad page 4 EE checksum (EE.1 024 - EE.1279)
Latched
annunciated
fault
385
EECKSM5
Bad page 5 EE checksum (EE.1280 - EE.15351
Latched
annunciated
fault
386
EECKSM6
Latched
annunciated
fault
387
EECKSM7
Latched
annunciated
fault
388
EECKSM8
Latched
annunciated
fault
389
EECKSM9
8ad page 9 EE checksum (EE.2304 - EE.2559)
Latched
annunciated
fault
390
EECKSM1
Bad page 10 EE checksum (EE.2560 - EE.2815l
Latched
annunciated
fault
391
EECKSM11
Latched
annunciated
fault
10-37
BI006008
GEH-6148

No.
Name
Type Fault
392
EECKSM12
Latched
annunciated
fault
393
EECKSM13
Bad page 13 EE checksum (EE.3328 - EE.35831
Latched
annunciated
fault
394
EECKSM14
Bad page 14 EE checksum IEE.3584 - EE.38391
Latched
annunciated
fault
395
EECKSM15
Bad page 15 EE checksum IEE.3840 - EE.40151
Latched
annunciated
fault
396
EEBADSIZ
EEROM U9 is the wrong size part for SDCC

The SDCC requires a larger EEROM (28c2561 than was used on the DCC 128c641. The
drive has detected the wrong part in socket U9 of the SDCC. Possible causes:
- The wrong part is installed in U9.
- The first and second EEROM pages of a valid U9 contains identical data. Change any
EEROM location. then hard reset to see if this corrects the fault.
Locked fault
To replace a DCC with an SDCC and keep the DCC configuration, either use ST2000 to
load your configuration into the new SDCC EEROM or use the following commands using a
PC with a program which can communicate serially with the drive via COMPL. and which
can upload and download files.
1. With the desired configuration EEROM installed, upload its configuration to a file in
the PC by sending the following command to the drive:
A x O-4095 < Enter>
Note: You can use either the DCC or SDCC to do this, provided EE.3.4 is set.
2. With the new EEROM installed in the SDCC. download the file to the drive.
Note: If the EEROM is totally blank (no programming label attached). the
Programmer must first be used to set EE.2 and EE.3 to 21 before completing step 2.
397
399
10-38
10SEECHK
10S]LT
105 portion of the drive EEROM has a bad checksum

The drive has detected an incorrect checksum in the 105 portion of the drive EEROM.
Possible causes and solutions:
- 105 EEROM not being used. but does not contain all zeroes. Prior to revision 2.41.
this EEROM was not checked by the firmware. To zero the 105 EEROM. send the
three-character string ":FF" to the drive using RS232 terminal mode.
- If 105 (including command language blocks) is not being used. inhibit the 105 and
this fault by setting EE.5500.0.
- Invalid download of 105 EEROM. Repeat the download.
- Bad EEROM U9 on SDCC.
The 105 checksum may be recalculated without erasing the 105 pattern by setting EE.2.1
temporarily and doing a hard reset. Alternately. the serial hex command" :00FFFF01 01"
will force a calculation of the 105 checksum.
Latched
annunciated
fault
Drive 105 code stack or timing overflow

The 105 portion of the drive firmware has run too long or has corrupted the stack. The
drive trips under this condition. Possible causes:
- The 105 blocks are timed incorrectly. Try using a different pattern of blocks 410-413.
Trip fault
105 portion of drive is faulted

The drive has detected a fault in the 105 portion of the drive firmware.
Possible causes:
- 105 block enabled (BLK.41 O. etc.) but SLCC not installed.
- SLCC not enabled via EE.1.1 (CFGJPRI.
- The 105 has tried to log an out-of-range fault to the fault stack. Fault numbers from
105 must be 800 or greater.
105 blocks include BLK.41 0-BLK.418 (I0Sn. CLNGn. etc.).
Trip fault
BI006008
GEH-6148

No.
Name
400
Type Fault
The internal stack has filled the second-to-Iast byte in the stack area
Possible causes:
- LCC/SLCC is defective. Replace the LCC/SLCC.
- LCP programming error. Replace the LCP software with a previous release.
Trip fault
401
L ECKSU
During initialization, a program code checksum error was found

Possible causes:
- LCC/SLCC EPROMs are defective. Replace the EPROMs.
Trip fault
402
L INTRAM
During initialization, the internal 80C196 RAM failed

Possible causes:
- LCP is defective. Replace the LCP (80C196).
Trip fault
403
L EXTRA
During initialization, the external 80C196 RAM failed

Possible causes:
- The external RAM is defective.
Trip fault
404
L_INTMRS
During initialization, the internal 80C196 timers failed

Possible causes:
- LCP is defective. Replace the LCP (80C196).
Trip fault
405
L_DPRAM
During initialization, the DUAL_PORT_RAM failed

Possible causes:
- The dual-port RAM is defective.
Trip fault
406
L KPDSHT
During initialization, the keypad was shorted

Possible causes:
- The keypad has a row shorted to a column. Replace the keypad.
- A key was pushed during initialization. Remove any pressure that might be on the
face of the keypad during initialization.
Trip fault
407
L STKRA
During initialization, the stack RAM (a portion of the external RAM) failed
Possible causes:
The external RAM is defective.
Trip fault
410
L LANFLT
The BIU is unable to properly receive the data it is transmitting

The BIU has not heard the last 128 bytes sent out on its serial port.
Possible causes:
Jumpers J13, 14, 15, 16, 17, and 18 not set correctly. Check for proper settings.
- The serial lines are shorted. Check for proper wiring connections.
- The SLCC is configured for an isolated DLAN but there is no DLAN power supply
connected to the SLCC. Check for proper wiring connections and power supply if
needed.
- There are too many termination resistors in the DLAN circuit. Check the DLAN
termination resistors (no more than five sets should be on the LAN).
- There is another drop on the DLAN with the same drop number as this drop. Ensure
that all drops have a unique drop number.
All drops are not programmed with the same link size. Ensure that all drops have
the same number programmed for the total number of drops on the LAN.
Hardware driver or receiver, or serial port is defective. Replace the LCC/SLCC.
Latched
annunciated fault
411
L FRZMSK
The Freeze Mask contains more than six variables to be transmitted

Possible causes:
- The Freeze Mask (EE622) contains more than six variables to be transmitted. Adjust
the FREEZE_MASK (EE622) to send no more than six variables.
Latched
annunciated fault
10-39
BI006008
GEH-6148

No.
Name
Type Fault
412
L BIUMSG
The received message does not contain the correct number of bytes
Possible causes:
The receiving hardware is defective.
The serial port of this device is defective. Replace the LCC/SLCC on this drop.
There are too many termination resistors in the circuit. Check the DLAN termination
resistors (no more than five sets should be on the LAN).
The serial link lines were temporarily shorted. Check the DLAN for possible shorts.
Defective driver hardware on the transmitting drop. Replace the sender's DLAN card.
An invalid message was sent on the LAN. If the sender is a user's program, then
check the messages being for proper length.
Latched
annunciated
fault
413
L LANMIS
The DLAN contains drops with EXPECTED_ACK enabled and disabled

This drop has EXPECTED_ACK disabled while another drop (or drops) on the DLAN has
EXPECTED_ACK enabled, or there is more than one drop with the same drop number.
Possible causes:
- Some other drop has EXPECTED_ACK and WEIGHTED_ZERO active while this drop
does not. Ensure that the EXPECTED_ACK and WEIGHTED_ZERO are consistent
between all drops on the LAN.
- Duplicate drop numbers being used on the LAN. Ensure that all drops have a unique
drop number. Ensure that all drops have the same number programmed for the total
number of drops on the LAN.
Trip fault
DCP did not update the DCP watchdog in 240 milliseconds

Possible causes:
- DCP failure. Replace DCC/SDCC.
- Dual Port RAM failure. Replace LCC/SLCC.
- Bad 9PL cable. Replace 9PL cable.
Trip fault
414
416
LARCMSGF
This ARCNET node did not receive an ACK after a transmitted message
This node did not receive an ACK for a message that was transmitted five times.
Possible causes:
- The destination node is not present on the ARCNET LAN. Ensure that the destination
node is present.
- The ARCNET cable is open or shorted. Ensure that the ARCNET cable is not open or
shorted between nodes.
Latched
annunciated
fault
417
LARCTAFL
The destination node does not have any free receiver buffers
This node is unable to send a message because the destination node does not have any
receiver buffers available, or because the ARCNET LAN is constantly being reconfigured.
Possible causes:
- Too many messages are being sent to the destination node. Limit the messages
being sent to a drive (1 OO/sec).
- The ARCNET module is malfunctioning causing constant reconfigurations. Replace
the malfunctioning ARCNET module, if possible.
- The destination node is malfunctioning. Replace the destination node LCC/SLCC.
Latched
annunciated
fault
418
LARCRECO
This node is experiencing ARCNET LAN reconfigurations

This node has experienced at least one reconfiguration every 1.28 seconds for a period of
80 seconds. A soft reset will clear the fault only if a 1.28 second time period has elapsed
without a reconfiguration occurring. Possible causes:
- No other ARCNET nodes visible from this node. Ensure that there are other ARCNET
nodes active on the LAN.
- The ARCNET module for this node has defective drivers or receivers. Replace
ARCNET module.
- An ARCNET module is malfunctioning, causing constant reconfigurations. Replace
defective ARCNET module, if possible.
- There is a 'T' connector in the circuit with an open cable connected to one end.
Remove or terminate the end of the open cable with a 100-ohm resistor.
Latched
annunciated
fault
10-40
BI006008
GEH-6148

No.
Name
Type Fault
419
LARCRSE
This node's ARCNET module unexpectedly experienced a RESET

Possible causes:
- Loose or poor connections to the LCC/SLCC connectors (power, digital, LAN).
Secure or replace all cables connected to the LCC/SLCC.
- Circulating currents due to separated grounds between boards or ARCNET nodes.
- Defective ARCNET module. Replace, if possible.
- Defective LCC/SLCC. Replace.
Latched
annunciated
fault
There is an error in the format of a received ARCNET message

Possible cause:
- The sender produced an invalid message. Correct the message at the source.
Latched
annunciated
fault
420
421
LARCXRA
During initialization, the ARCNET external RAM failed

Possible causes:
- The ARCNET module or external RAM is defective. Replace ARCNET module, if
possible.
- LCC/SLCC is defective. Replace.
Latched
annunciated
fault
422
LARCFBIN
The format of a received STATUS_SJEEDBACK message is incorrect

Possible causes:
An ARCNET cable is open or shorted. Check ARCNET cables for opens and shorts.
- An ARCNET repeater of node is working incorrectly. Check the ARCNET nodes and
repeaters for passing messages.
- The source of the STATUS_S_FEEDBACK message formed the message incorrectly.
Check the source code for proper STATUS_S_FEEDBACK format.
Latched
annunciated
fault
423
LARCRBFL
This ARCNET node's receive buffer has overflowed and a message is lost
Possible cause:
- Some other ARCNET node or nodes are sending messages to this node faster than
this node can accept the messages. Limit communications to this node. Do not
exceed 100 messages per second to this node.
Latched
annunciated
fault
425
LDLANMSG
DCP has passed an erroneous message to LCP to transmit on DLAN

Possible causes:
- DCP has misloaded the outgoing message. Replace evaluation PROMs with released
PROMs (DCP PROMs).
- Hardware fault. Check the 3PL ribbon cable and connectors.
Latched
annunciated
fault
426
LARCOUTM
DCP has passed an erroneous message to LCP to transmit on DLAN PLUS

Possible causes:
DCP has misloaded the outgoing message. Replace evaluation PROMs with released
PROMs (DCP PROMs).
- Hardware fault. Check the 3PL ribbon cable and connectors.
Latched
annunciated
fault
427
LCLKSYNC
This ARCNET node's clock has been resynchronized with the master clock because there
was more than 64 msec of error between the two clocks. FLT.427 is not a fault; it is a
momentary condition. Possible cause:
- Turning the master clock on and off. Ensure that the master clock is not turned off.
Latched
annunciated
fault
428
LARCRBFF
This ARCNET node's receive buffer has overflowed and a message has been lost.
Possible cause:
- Some other ARCNET node or nodes are sending messages to this node faster than
this node can accept the messages. Limit communications to this node. Do not
exceed 1 message per 22 msec to this node.
Latched
annunciated
fault
10-41
BI006008
GEH-6148

No.
Name
Type Fault
429
LACCAPFL
The ac drive's dc bus programmed capacitance is too large

Latched
This fault may show up in a PARENT (the dc bus regulator) or a CHILD (an ac drive tied to annunciated
the dc bus). For the CHILD, this fault means the programmed bus capacitance (EE.587,
fault
CAPVDC) is larger than 32767, and the value will not be sent to the PARENT. For the
PARENT, this fault declares that:
1) A CHILD has sent a capacitance value greater than 32766 and the value has been
discarded.
2) Drop 0 has sent a capacitance value. (there should not be a drop 0 on ARCNET).
3) A capacitor message (PROT 11 h) has been received with an invalid length of message (there should be two bytes to define the cap value).
4) The TOTAL DC BUS CAPACITANCE has exceeded 65535, and has been clamped to
65535. The TOTAL value is passed to DCP through DPRAM DCP VAR.1440.
Possible causes and solutions:
CHILD - EE.587 is larger than 32766. Limit EE.587 to 0 - 32766.
PARENT - A CHILD has sent a capacitor value larger than 32766. The drive firmware
doesn't allow the drives to send a value larger than 32766. Check the senders of the
common dc bus capacitor message (ARCNET protocol 11 h) and limit the value to 0 32766.
PARENT - Drop 0 sent a common dc bus capacitor value. Find which ARCNET drop
has been programmed to be drop 0 and program the correct drop number. There
should not be a drop O.
PARENT - A drop has sent more/less than 2 bytes for the cap value. Find which
ARCNET drop is sending the invalid message and correct the message. (If a drop
sends an invalid message, then that drop's value will not get loaded into the
CAP_TABLE.)
PARENT - The TOTAL DC BUS CAPACITANCE has exceeded 65535. Modify the
CHILDREN capacitance so that the TOTAL does not exceed 65535.
To help debug the Common Bus Capacitor TOTAL, you can (through ST2000 Toolkit,
Drive Configurator, or some other RS232 terminal) examine the capacitor table and TOTAL
value by typing in ALB8DOH <cr> or AL47312 < cr>.
The first two words are the TOTAL calculated capacitance (LSWORD first).
The next word is a mirror of the TOTAL CAP in DPRAM (DCP VAR.1440). This word will
be clamped to 65535 if the accumulated capacitance exceeds 65535. The double word of
TOTAL calc cap does not get clamped.
The next 255 words contain each ARCNET drop's (1-255) capacitor value, or 65535 if no
capacitor value has been received, or the capacitor value received plus 32768 if the
"CHILD" is not in Link Presence. Only the entries with their msbit cleared are added up to
make the TOTAL cap. (See EE.706.4, EE. 706.5{ARCJP1), EE.719(CBREGU), EE.587
(CAPVDC)).
550
10-42
EECKSM16
Latched
annunciated
fault
BI006008
GEH-6148

No.
Name
Type Fault
551
EECKSM1
Latched
annunciated
fault
552
EECKSMl
Bad page 18 EE checksum IEE.4608 - EE.4863)
Latched
annunciated
fault
553
EECKSMl
Bad page 19 EE checksum IEE,4864 - EE.5119)
Latched
annunciated
fault
554
EECKSM2
Latched
annunciated
fault
555
EECKSM21
Latched
annunciated
fault
556
EECKSM22
Latched
annunciated
fault
557
EECKSM23
Latched
annunciated
fault
558
EECKSM24
Latched
annunciated
fault
559
EECKSM25
Latched
annunciated
fault
560
EECKSM26
Latched
annunciated
fault
561
EECKSM27
Latched
annunciated
fault
562
EECKSM28
Latched
annunciated
fault
563
EECKSM29
Latched
annunciated
fault
564
EECKSM30
Latched
annunciated
fault
565
EECKSM31
Latched
annunciated
fault
10-43
BI006008
GEH-6148

No.
Name
Type Fault
567
GND_ANUN
Excess Ground Current Fault Annunciated

A ground current signal is brought into local drive analog lID, conditioned in blockware,
and sent to a SLD which produces an excess-ground-current boolean. The input pointer
GNDA@I IEE.3608) is typically pointed at this boolean to provide an Excess Ground Current fault. For FLTJP2.2 = 0, the sense of fault is 1 = Faulted, 0 = No Fault.
For FLTJP2.2 = 1, the sense of fault is 0 = Faulted, 1 = No Fault. The enumerations at
FLTJP2.0 select the behavior of the fault. If the fault input pointer is not used (pointed at
zero) the fault is disabled.
Possible Causes:
- GNDA@I IEE.3608) Pointed Incorrectly
- Improper sense selected by FLTJP2.2 (EE.3613.2l
- SLD compare level set incorrectly
- Excess Ground Current exceeds annunciate level
Non-latched
annunciated
fault
568
GND_TRIP
Excess Ground Current Fault Trip

Trip fault
A ground current signal is brought into local drive analog lID, conditioned in blockware,
and sent to a SLD which produces an excess-ground-current boolean. The input pointer
GNDT@I (EE.3609) is typically pointed at this boolean to provide an Excess Ground Current Trip fault. The enumerations at FLTJP2.15 select the sense of the fault. For
FLTJP2.1 5 = 0, the sense of fault is 1 = Faulted, 0 = No Fault. For FLTJP2. 15 = 1, the
sense of fault is 0 = Faulted, 1 = No Fault. If the fault input pointer is not used (pointed
at zero) the fault is disabled.
Possible Causes:
- GNDT@I (EE.3609) Pointed Incorrectly
- SLD compare level set incorrectly
- Excess Ground Current exceeds trip level
570
MBD01TRP
Multibridge follower LAN drop #1 is tripped

This fault is displayed at the master drive of a multibridge when a follower drive is
tripped. Check the follower drive fault code to determine the cause.
Trip fault
571
MBD02TRP
Trip fault
572
MBD03TRP
Trip fault
573
MBD04TRP
Trip fault
577
MBD08TRP
Multibridge B group master LAN drop #8 is tripped
Trip fault
578
MBD09TRP
Trip fault
579
MBD10TRP
Trip fault
580
MBD11TRP
Trip fault
581
MBD12TRP
Trip fault
601
MBD01ALM
Multibridge follower LAN drop #1 has a fault

This fault is displayed at the master drive of a multibridge when a follower drive has an
annunciated (not a trip) fault. Check the follower drive fault code to determine the cause.
Note it is possible that the follower fault code was a "brief" annunciated fault, such as
FLT.34 (PLLTRACK), which may no longer be present, giving the appearance that the
master is reporting a follower fault when none exists on the follower's Programmer display. If ST2000 is connected to the master drive in terminal mode when the fault occurs,
the follower fault code and its alphanumeric will be displayed on the screen.
This fault can also be generated by the master when the master is running and has commanded the follower drives to run, but a follower drive reports back that it is not running
(perhaps because the follower was locally commanded to stop). This latter condition may
or may not trip the master drive, depending on EE.607.3.
Non-latched
annunciated
fault
602
MBD02ALM
Non-latched
annunciated
fault
10-44
BI006008
GF2000 Dc Ge rator Field Exciter
GEH-6148

No.
Name
Type Fault
603
MBD03AL
Non-latched
annunciated
fault
604
MBD04AL
Non-latched
annunciated
fault
608
MBD08AL
Multibridge B group master LAN drop #8 has a fault
Non-latched
annunciated
fault
609
MBD09AL
Multibridge B group follower LAN drop #9 has a fault
Non-latched
annunciated
fault
610
MBD10AL
Non-latched
annunciated
fault
611
MBD11AL
Non-latched
annunciated
fault
612
MBD12AL
Non-latched
annunciated
fault
Multibridge follower LAN drop #1 is not responding

This fault is displayed at the master of a multibridge drive when a follower drive is not
communicating with the master drive. For additional diagnosis, check for fault codes at
follower drives to see if follower is able to hear master. Possible causes:
- Follower drive not powered-up or not enabled via EE.607.0.
- Defective, loose, or dirty fiber-optic connection.
- EE.610, MBLTTL, not set correctly to total number of drops.
- Follower drop numbers, EE.609, not assigned sequentially or uniquely.
- MCPs of all bridges not at same firmware revision.
- MBHA card failure or not powered up (check followers for faults).
- SPCB card failure (check SPRS, RX, and TX test points).
- For 12-pulse systems, failure of simplex cable from MBHA C1 MODE to respective
master SPCB MODE.
Non-latched
annunciated
fault
632
633
MBD02NAK
Non-latched
annunciated
fault
634
MBD03NAK
Non-latched
annunciated
fault
635
MBD04NAK
Non-latched
annunciated
fault
639
MBD08NAK
Multibridge B group master LAN drop #8 is not responding
Non-latched
annunciated
fault
640
MBD09NAK
Multibridge B group follower LAN drop #9 is not responding
Non-latched
annunciated
fault
641
MBD10NAK
Non-latched
annunciated
fault
10-45
BI006008
GEH-6148

No.
Name
Type Fault
642
MBD11 NAK
Non-latched
annunciated
fault
643
MBD 12NAK
Non-latched
annunciated
fault
662
HI VOLTS
LNMON Block - High Line Voltage Detected

The LNMON block takes line voltage (VAR.1 08) and scales it by 20000/LMVSCL. If the
result is greater than LMHIVT for LMCTIM milliseconds then VAR.1 088 is set and a fault
occurs.
Possible Causes:
- LMHIVT [3590] set too low
- LMVSCL [3588] set incorrectly
- LMCTIM [3589] set too low
- Line voltage is too high
- See also LNMON BLK.344 and VAR.1 08 ACLINMAG.
663
LO_VOLTS
LNMON Block - Low Line Voltage Detected

The LNMON block takes line voltage (VAR.1 08) and scales it by 20000/LMVSCL. If the
result is less than LMLOVT for LMCTIM milliseconds then VAR.1 089 is set and a fault
occurs.
Possible Causes:
- LMLOVT [3591] set too high
- LMVSCL [3588] set incorrectly
- Line voltage is too low
- See also LNMON BLK.344 and VAR.1 08 ACLINMAG.
664
HI FREQ
LNMON Block - High Line Frequency Detected

The LNMON block takes line frequency (VAR.1 09) and compares it against LMHIFQ
EE.3592. If the result is greater than LMHIFQ for LMCTIM milliseconds then VAR.1148 is
set and a fault occurs.
Possible Causes:
- LMHIFQ [3592] set too low
- Line frequency is too high
- See also LNMON BLK.344 and VAR.1 09 ACLlNFRQ.
665
LOfREQ
LNMON Block - Low Line Frequency Detected

The LNMON block takes line frequency (VAR.1 09) and compares it against LMLOFQ
EE.3593. If the result is less than LMHIFQ for LMCTIM milliseconds then VAR.1149 is set
and a fault occurs.
Possible Causes:
- LMLOFQ [3593] set too high
- Line frequency is too low
- See also LNMON BLK.344 and VAR.1 09 ACLlNFRQ.
10-46
BI006008
GEH-6148

No.
Name
666
AUX_FLT1
Aux Fault 1 - Generic Pointable Fault

Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP1 . If the fault input pointer is not used
- Improperly selected source pointer AXF1@1
- Wrong sense of input determined by AXFJP1.3
- Faulted condition at AXF1 @I
667
AUX_FLT2

Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP1 . If the fault input pointer is not used
Improperly selected source pointer AXF2@1
- Wrong sense of input determined by AXFJP1 .3
- Faulted condition at AXF2@1
668
AUX_FLT3

Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1 . The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable. and is configured with a jumper bit ofAXFJP1. If the fault input pointer is not used
669
AUXfLT4

Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP1 . The input pointer AXF#@I. when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable. and is configured with a jumper bit ofAXFJP1 . If the fault input pointer is not used
670
AUXfLT5

Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP2. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP2. If the fault input pointer is not used
671
AUX_FLT6

Aux faults are generic pointable faults whose behavior is configurable with a jumper enumeration ofAXFJP2. The input pointer AXF#@I, when used, points to the boolean value that signals the fault condition. The sense of the input boolean may be either high-enable or lowenable, and is configured with a jumper bit ofAXFJP2. If the fault input pointer is not used
Type Fault
10-47
BI006008
GEH-6148

No.
Name
672
AUX_FLT7

Aux faults are generic pointable faults whose behavior is configurable with a jumper
enumeration of AXFJP2. The input pointer AXF#@I, when used, points to the boolean
value that signals the fault condition. The sense of the input boolean may be either highenable or low-enable, and is configured with a jumper bit of AXFJP2. If the fault input
673
AUX FLT8

Aux faults are generic pointable faults whose behavior is configurable with a jumper
enumeration of AXFJP2. The input pointer AXF#@I, when used, points to the boolean
value that signals the fault condition. The sense of the input boolean may be either highenable or low-enable, and is configured with a jumper bit of AXFJP2. If the fault input
- Wrong sense of input determined by AXFJP2.1 5
808
DPROMCKS
Main CPU EPROM checksum failure at U11 or U12 (105 page)

Main processor PROM checksum failure detected in 105 code section.
Latched
annunciated
fault
810
DEVERIFY
Value to EEROM, main CPU not verified

The last value loaded to EEROM on the main processor did not verify.
Latched
annunciated
fault
811
SERLCKSM
Checksum of transmitted message does not agree with data received
Latched
annunciated
fault
812
MLDCKSUM
Checksum of transmitted message does not agree with the data in memory
Latched
annunciated
fault
815
EE CKSUM
Main CPU EEROM checksum error detected in 105 section
Latched
annunciated
fault
816
EEID_FLT
Main CPU EEROM identification failure in 105 section

Main processor 105 EEROM identification failure detected.
Latched
annunciated
fault
826
ENGSTALL
105 LAN message buffer full. Permissive engines temporary stop

A LAN message buffer is full and permissive engine processing has been temporarily suspended.
Latched
annunciated
fault
827
LUP WDOG
105 watchdog timer between LAN CPU and main CPU timeout
The watchdog timer between the LAN processor and the main processor has timed out.
Latched
annunciated
fault
831
L RWTOUT
LAN memory read/write sent but drop did not answer

A LAN memory read or write request was sent to a network drop but the drop did not
answer.
Latched
annunciated
fault
832
WVAR MSG
LAN message buffer full. Math engines temporary stop.

A LAN message buffer is full and math engine processing has been temporarily suspended.
Latched
annunciated
fault
10-48
Type Fault
BI006008
GEH-6148

No.
Name
Type Fault
835
E2_CKSU
Main CPU EEROM checksum error in 105 section

Main processor 105 EEROM checksum error detected.
Latched
annunciated
fault
836
E21D FLT
Main CPU identification failure detected in 105 section

Main processor 105 EEROM identification failure detected.
Latched
annunciated
fault
837
EEMCKSU
Main CPU 105 EEROM RAM mirror checksum error

Main processor 105 EEROM RAM mirror checksum error detected.
Latched
annunciated
fault
838
E2MCKSU
Main CPU 105 EEROM RAM mirror checksum error

Main processor 105 EEROM RAM mirror checksum error detected.
Latched
annunciated
fault
839
STAKOVFL
105 scheduler had a task stack overflow

Main processor RTOS operating system task stack overflow.
Latched
annunciated
fault
841
SENGSTAL
LAN message buffer full. Sequence engines temporary stop

A LAN message buffer is full and sequence engine processing has been temporarily suspended.
Latched
annunciated
fault
842
DIAGCOLL
Diagnostic data collection fault

An error has been detected in collecting the data for a diagnostic message.
Latched
annunciated
fault
844
NO_lOS
10S-in-a-Drive is not available

The 10S-in-a-Drive functionality is not available either because it has been disabled or an
EEPROM image has not been downloaded from the 105 configurator. Other causes of this
fault include:
- An invalid or NO EEPROM image was detected by the 10S-in-a-Drive firmware and the
105 EEPROM configuration was required. Either download the correct 105 configuration
or inhibit the fault by clearing 10SJPR (EE.5500.1).
A configuration was downloaded into an 105 with features that are not supported by
the firmware. Either update the firmware or use the correct version of the 105
compiler (upward compatibility error).
Latched
annunciated
fault
845
BRIDGFLT
Primary network bridge fault

The primary network bridge for a network (FO) message was not in link presence. The
message was rerouted through the backup bridge drop.
Latched
annunciated
fault
846
10SINIT
105 portion of 10S-in-a-Drive did not initialize correctly

This error is caused by an invalid EEPROM image or by an EEPROM image that exceeds
the size constraints of RAM or EEPROM.
Latched
annunciated
fault
847
LCP_SYNC
The LCP/IOS initialization had an error

The initialization protocol between the LCP and 105 ended either because the LCP did not
respond within 1 second. or the LCP returned an unexpected initialization state to the
lOS's initialization request.
Latched
annunciated
fault
848
REFRESH
The 105 is sending out too many refresh bits

There are certain control bits on the drive and 105 that must be refreshed every 1.28
seconds after they have been set. The 105 is limited to four such signals active at any
given time. The refresh fault is issued when this limit has been exceeded.
Latched
annunciated
fault
849
ACTR CFG
105 actor/tracker configuration error

The actor/tracker subsystem did not initialize correctly. The tracking system has not been
enabled.
Latched
annunciated
fault
10-49
BI006008
GEH-6148

No.
Name
Type Fault
850
105 BUSY
The 10S-in-a-Orive background tasks are not executing

The 105 portion of the 10S-in-a-Orive is not being given enough time in the drive block
scheduling to complete its background scans. This is caused when the scan time of the
105 exceeds ten seconds. More time must be allocated to the IDS in the drive patterns
by using the IOS1, 1052, 1054, and IOS8 drive blocks if this error occurs.
Latched
annunciated
fault
851
GENI ERR
Error detected on Genius Controller

Geni card controller fault. An error was detected on the GENI controller card. This fault
should never occur on an 10S-in-a-Drive, because there is no Genius I/O support available.
Latched
annunciated
fault
852
BAD MSG
A message was received on ARCNET that had an invalid format

A message was received that could not be successfully decoded by the IDS. The message was ignored and flushed from the message queue.
Latched
annunciated
fault
853
TRKR MSG
An actor/tracker message could not be processed correctly

An actor/tracker message was received that could not be successfully decoded or processed by the tracking subsystem. This includes problems with internal actor event
queues overflowing. The message was ignored and flushed from the message queue.
Latched
annunciated
fault
854
MSG OVFL
The message object could not transmit a message

The LAN message buffer is full so the message block cannot transmit any more messages until buffer space becomes available.
Latched
annunciated
fault
855
ODE FLT
Order of execution recursion fault

A call has been made to an order of execution (ODE) sequence that is currently active.
Check the ODE logic to ensure that there is not a recursive call to an ODE.
Latched
annunciated
fault
856
OBJ FLT
Order of execution calls an unknown object

A request has been made within an ODE to execute an object type that is not yet supported by the firmware. Verify that you have the current versions of 105 firmware and
compiler.
Latched
annunciated
fault
857
105 U857
Latched
Undefined 105 error
A new 105 fault has been generated that is not yet supported by the ST2000 data base
annunciated
files. Please alert PO of the problem. This fault corresponds to fault 157 on a stand alone fault
105.
858
105 U858
Latched
Undefined 105 error
annunciated
A new 105 fault has been generated that is not yet supported by the ST2000 data base
files. Please alert PD of the problem. This fault corresponds to fault 158 on a stand alone fault
105.
859
CLMSGBAO
CLMSG used while 105 enabled

The CLMSG block was called when the 10Sx blocks were also allowed to generate messages. The CLMSG block can only be used when 10SJPR lEE 5500) bits 0, 1, and 2 are
reset, which will disable the 10S-in-a-Drive functionality. Either set 10SJPR to the appropriate value or replace the CLMSG block with an 1051 block to get rid of the fault.
105 Prom Revision Mismatch
The 10SB firmware revision level is less that the level requested by the 10SB EEPROM
configuration. Either update the PROM set to the appropriate level, or recompile the configuration file using the revision level of the 10SB firmware.
860
1023
10-50
Latched
annunciated
fault
RESET
DCC/SDCC is in a hard reset condition

If all ten LEOs on the DCC/SDCC are lit continuously, and no fault code is being displayed via the RS232 link, Programmer, or LAN connection, the control card is probably
being held in reset. Possible causes:
- External reset input, 3TB-58 or STBA-38, is closed, holding reset high.
- Failure in + 5 V dc or 15 V dc control power supplies to the control card.
- EPROMs U22/U23 on the control card not inserted correctly.
- Failure of DCC/SDCC control card.
Trip fault
BI006008
GEH-6148
CHAPTER 11
DIAGNOSTIC LISTS
11-1. INTROD CTION
The GF2000 ex iter software includes the following

three diagnostic eatures that send selected data to
memory:
Motor Cont 01 Processor (MCP) Diagnostic Circular List
Drive Contr 1 Processor (DCP) Circular List

Blocks
LAN Contr 1 Processor (LCP) History Buffer
These features e able variable data to be captured

while the exciter is in operation, and to be read by the
user as an aid in oubleshooting.
The MCP and D
connected comp
(see GEH-5860)
sion (see GEH-6
tended to be acc
2000 (MM2ooo)
Publication GEH
GEH-62l3 provi
P lists are accessed via a serially

er using either the ST2000 Toolkit
r Drive Configurator, LynxOS Ver03). The LCP History Buffer is insed by a Man-Machine Interface
ia the exciter's DLAN + connection.
6212 describes the MM2ooo;
es configuration information.
Tables 11-1 thro gh 11-3, located at the end of this

chapter, defme
EEPROM addresses for each of the
exciter's diagnos c functions.
A set of four pointers determine the MCP variable for

display in the first four columns. These pointers are
EE.6OO (MDAIIN), EE.603 (MDA2IN), EE.552
(MPNTR1), and EE.553 (MPNTR2) for the four columns, respectively, left to right.
The user selects an MCP variable to display in the fIrst
four columns of the list by entering the variable's address (see the description of EE.6282 bit 0 in Table
11-1) into the associated pointer.
The remaining columns display the bridge current, the
fIring angle, the cell pair select counter, and asynchronous current regulator fIring data.
11-2.2. MCP Diagnostic Circular List Operation
Software jumper MDGNJP (addresses EE.6282.0

through EE.6282.4) controls the operation of the MCP
Diagnostic Circular List (see Table 11-1).
11-2.3. Circular List Display
The MCP Diagnostic Circular List can be viewed using the ST2000 Toolkit (see GEH-5860) or Drive
Configurator, LynxOS Version (see GEH-6203). To
display the circular list:
1.
Using the Programmer, ST2000 Toolkit, or Drive

Configurator, select the circular list freeze options
by setting software jumper MDGNJP.
2.
Select an MCP variable to display by entering its

address into one of the four pointers. To do this:
NOSTIC CIRCULAR LIST
While the GF2

exciter is running, selected MCP
data is continuou y sent to memory, providing a circular list of MC variable data. When a stop command, trip, fault, or trigger from the DCP disables the
exciter, the data i latched (frozen) in memory. This
data provides a pi ture of motor control events that
occurred just bef< re the exciter stopped.
11-2.1. Circula List Content
The MCP Diagno tic Circular List resides as a page

in RAM, 8 col
wide by 128 rows deep. Each
column is 1 word wide.
a.
Refer to Table 11-1 to fmd the available variables and their addresses (or use the ST2000
Toolkit or Drive ConfIgurator to read them at
address EE.6282.0). Select up to four variables for anyone Circular List display.
b.
Use the Programmer keypad, ST2000 Toolkit

(EDITIOOO menu item), or Drive Conflgurator to enter this address into a pointer.
11-1
BI006008
GEH-6148
3.
Using the terminal emulation mode of the ST2000

Toolkit or Drive Configurator, enter either of two
RAM dump commands:
A
m 60000 Displays the most recent 22 lines in
the list is determined by the number and size of the

channels used. For example, a circular list consisting
of four 16-bit (two-byte) channels, will be 2048 samples long. If more channels are used, the length of the
list is reduced accordingly.
unsigned format
A
m60000-- Displays the most recent 22 lines in

signed ( +/-) format
m 58288-60336-- Displays all 128 lines in
signed (+/-) format
The output is a nine-column page of data arranged as

follows:
Column 1
Columns 2 - 5
Column 6
Column 7
Column 8
Column 9
Lines 1 - 21
Line 22
Data flow
RAM location (address)

Circular list data, selected MCP
variables
Bridge current, VAR.1092
(IBRIDGE) , 5000 = 1 pu
Firing angle, 0 = full advance,
16383 = 180-degree retard
Cell pair select counter, range 250255 or 0-12 (1000 added if firing reverse bridge; 1oo added if armature firing is enabled)
Asynchronous current regulator firing data
Circular list data
First seven columns: 0oo value =
frozen, valid data; oo1 or 65535
= not frozen, therefore invalid data.
Last column: address of the line corresponding to when the trigger occurred (if displayed in signed format,
add 65536 to obtain the trigger address)
oldest data = top line; newest data
= bottom line
11-3.1. CLST Blocks
Three CLST blocks are available, each corresponding

to a different functional level: CLSTI (basic level),
CLST2 (intermediate level), and CLST3 (advanced
level). Each succeeding functional level builds upon
the functionality of the proceeding level. These levels
are defmed in the following sections.
EEPROM addresses EE.5868 through EE.5881 control
the operation of the CLST block. Variable VAR.1453
contains status information for the block. Table 11-2
defmes these EEPROM and variable addresses, including the CLST block(s) to which each address applies.
11-3.1.1. CLST1 (BASIC) BLOCK. CLSTl requires
the least amount of processor execution time. This list
consists of four 16-bit (two-byte) channels that are
recorded at the block's scheduled rate (defmed in the
block source list described in Chapter 4). Data is recorded while the variable selected by pointer EE.5868
(CL@RUN) is high. Recording stops when the
CL@RUN variable goes low.
Data recording can also be toggled on and off by an *

(asterisk) command via the drive serial link.
11-3.1.2. CLST2 (INTERMEDIATE) BLOCK. In addition to the functions in the CLSTl block, CLST2 includes the following features:
Selectable data recording rate
Post-trigger data capture delay
List overwrite lock
RUN command inverter
NOTE
Typically at least four lines are displayed after

the trigger.
11-3. DCP CIRCULAR LIST BLOCKS
The DCP Diagnostic Circular List (CLST) blocks

capture up to eight user-selected DCP variables, with
each variable assigned to a channel. The total memory
space used by the circular list is 16 kB; the length of
11-2
The data recording rate is selected using EE.5879

(CL_RAT), as defmed in Table 11-2. This enables the
user to collect data at a rate different from (slower
than) the block execution rate. The data recording
rate, entered as milliseconds, is converted to an integer number of scheduled block executions. The actual
collection rate is reported in the status line (header)
when the circular list is read.
BI006008
GEH-6148

The post-trigger data capture delay enables the circular
list to capture a umber of samples, defIned by
EE.5880 (CL_ LY), after the CL@RUN variable
goes low. This ature allows the user to sample data
surrounding a tr gger event.
LD
Returns the status of the circular list when the

list is collecting. When the list is stopped, this
command dumps the contents of the circular
list in ASCII form.
NOTE
The list overwri e lock prevents data surrounding a

trigger event fr
being overwritten by subsequent
restarting of the block. When the variable selected by
pointer EE.587 (CL@LCK) goes high, the circular
list is allowed t start and stop only once.
of the CL@RUN command can be
.5881.0 (CL_JPR).
11-3.1.3. CLST (ADVANCED) BLOCK. In addition to
the functions in e CLSTl and CLST2 blocks,
CLST3 includes the following features:
Eight data c llection channels (rather than four)
g on channels 3 through 6
The first line of a data dump contains the

following "header" information, based upon
which circular list block (CLSTl, CLST2, or
CLST3) is enabled.
For a CLSTl block, the fIrst line of the data
dump contains the following information:
a a
BlockRate
00000 00000
00000 00000
Collection data in bytes (8 bits), words (16

bits), or do ble words (32 bits)
The eight data c

EE.5877 (CL_T
data as bytes, w
through 6 may c
be confIgured to
intervals; and C
bytes.
llection channels are confIgured using

P). Channels 1 and 2 may collect
rds, or double words; Channels 3
llect data as bytes or words, and may
average data over their collection
annels 7 and 8 collect data only as
As in CLST2, e data recording rate is selected using

EE.5879 (CL_ T). When averaging is selected for a
channel, data s pIes are accumulated at the block
execution rate.
e samples are then averaged and
stored as a data oint at the rate defmed by CL_RAT.
11-3.2. Circul r List Display
The contents an lor status of the DCP Circular List

can be viewed ing the ST2()()() Toolkit (see GEH5860) or Drive onfIgurator, LynxOS Version (see
GEH-6203). Us' g the terminal emulation mode of the
ST2000 Toolkit r Drive ConfIgurator, enter any of
the following se ial commands:
L
The LD command can be used with the

terminal emulation mode capture or log
function to save the circular list contents to
a file. The me can then be used for off-line
analysis of the data.
Returns the status of the circular list.
where BlockRate, the scheduled rate of the

circular list block, is equal to 1 (nO/sec), 2
(360/sec), 4 (l80/sec), or 8 (90/sec).
For a CLST2 or CLST3 block, the fIrst line
of the data dump contains the following information:
StopDelay TimeRate BlockRate CollectRate
StpReqTmO StpSamplTm2,1 ,0
where:
StopDelay is equal to EE.5880 (CL_DLY),
the number of data samples collected after the stop request.
TimeRate is equal to EE.5869 (CL_RAT), the
requested data collection rate in milliseconds.
BlockRate, the scheduled rate of the circular
list block, is equal to 1 (nO/sec), 2
(360/sec), 4 (I80/sec), or 8 (90/sec).
CollectRate is the data collection frequency in
number of scans.
11-3
BI006008
GEH-6148
StpReqTmO is the stop request LAN time
(least significant word).

StpSamplTm2,1 ,0 is the stop sample full
LAN time using three words (48 bits).

The second line of the data dump contains the
RUN pointer and all data pointers.
LOn
Returns the status of the circular list when the

list is collecting. When the list is stopped, this
command dumps at least one full screen of
the circular list data in ASCII form. The display begins with data point n, where n is a
number of samples from Sample 0, the stop
sample. Negative values for n refer to samples taken before the stop command; positive
values refer to samples taken after the stop
command. For n values that are too small, the
data dump starts with the oldest collected
sample. For values larger than 20, the data
dump starts 20 samples before the end of the
list data.
The first line of the data dump contains the
RUN pointer and all data pointers.
LR
Resets the list to the beginning (clears the

list). This command also enables a locked list
to be restarted.
Bit# Source
0
1
2
3
4
5
6
7
Bit#
NOFAULT,801
FATALFLT, 803
(or TRIPFLT)
ORWINSPD, 832
RUNACT,804
JOGACT,805
MACLOSED,810
MPWRENAB, 882
PRECOND, 813
8
9
10
11
12
13
14
15
Source
REFENAB, 815
RUNNING, 811
ZEROSPD,812
UPTOSPD, 820
UPTOPOS, 821
REG1 LIM, 895
CURLlM,827
CEMFLlM, 828
EE.647 (lllSTPl) - The DCP variable selected using

this pointer, History Pointer #1.
EE.648 (lllSTP2) - The DCP variable selected using
this pointer, History Pointer #2.
If the history buffer is configured for two variables,
only the HISTP1 and HISTP2 variables are included.
As selected using EE.615.5 (LCPJP1), the trigger to
lock the history buffer can be a LAN command, a trip
fault, and/or the history lock bit. The history lock bit
is selected by pointer EE.649 (HISLOC).
The delay time between frames is selected using bits 0
through 6 of EE.646 (HISTD). The delay in 20 msec
intervals is given by the following formula:
Delay = (HISTD
+ 1) x 20 msec
The minimum time delay between frames is 20 msec

(HISTD = 0); the maximum delay is 1280 msec, or
1.28 sec (HISTD = 63).
11-4. LCP HISTORY BUFFER

NOTE
THE LCP History Buffer is a circular list of periodically sampled variables that are stored in the GF2000
exciter as frames. As selected using EE.615.7
(LCPJP1), the history buffer may contain 51 frames of
five variables, or 102 frames of two variables.
If the history buffer is configured for five variables
per frame, the variables are:
VAR.SS9 (LCPCFB) - Current feedback to LCP,

scaled and fIltered.
VAR.I03 (VFB) - Voltage feedback, a representation
of the motor's applied voltage, as received from
the MCP.
VAR.S90 (RUP_OUTO) - Low word of Status_S output bits RUP OUT (DPRL_STATUS_S_OUT).
RUP- OUTO contains the first 16 of 32 Status- S
outputs from the DCP. The DCP source of each
bit is as follows:
11-4
Only bits 0 through 5 of EE.646 are used to

set the delay time. Bits outside of this range
are ignored.
Table 11-3 lists and defmes the EEPROM addresses
that control the operation of the LCP History Buffer.
Unlike the MCP and DCP circular lists, the LCP
History Buffer is intended to be accessed by an
MM2000 via the exciter's DLAN + connection. The
Drive History Monitor (DS207DHIS) monitors the
exciter's LCP History Buffer and, when the buffer is
locked (data collection stopped), uploads the buffer
contents to disk. The file containing the history data
can be viewed using the Trending Display Console
(TDC) typically implemented on the third virtual console of the MM2000. Refer to publications GEH-6212
and GEH-6213 for information on the MM2000 Drive
History Monitor and TDC.
BI006008
GEH-6148
Table 11-1. MCP Circular List Software Jumpers .6282 (MDGNJP)

Bit
DEfinition
EE.6282.0
Enable fast update rate for MCP circular list

Th e MCP diagnostic circular list is an 8 word wide by 128 deep history of selected motor control processor variab es sampled surrounding a configurable trigger point such as a stop, trip, fault, or trigger from DCP. The list may
be viewed using the serial link RAM dump command.
Ex~mples:
"'m60000
"'m60000-"'m58288-60336--
Display most recent 22 lines in unsigned format

Display most recent 22 lines in + /- signed format
Display all 128 lines in + /- signed format
Th data in this display is interpreted as follows:

Oth column
Address of this line
EE.600, MDA11N, selected MCP variable (see list below)
1st column
2nd column EE.603, MDA2IN, selected MCP variable
3rd column
EE.552, MPNTR1, selected MCP variable
4th column
EE.553, MPNTR2, selected MCP variable
5th column
Bridge current, + /-5000 = 1pu ((BRIDGE, VAR.1 092)
6th column
Firing angle, 0 =full advance, 16383 = 180 degree retard
7th column
Cell pair select counter, range 250-255 or 0-12
1000 added if firing reverse bridge
10000 added if armature firing is enabled
8th column
Asynchronous current regulator firing data
ThE last line in the example displays, at address 60336, contains special data. Columns 1-7 will be 0 if the list is
fro en, and 65535 or -1 if the list is active and hence the data not valid. Column 8 gives the address of the line
cor esponding to when the trigger occurred (if displayed in signed format, add 65536 to get the trigger address).
No mally at least 4 lines are displayed after the trigger.
EE.6282, MDGNJP, contains jumpers to control operation of the circular list. Bit 0 controls the execution rate of
the circular list. Clear = = > once per firing; set = = > every 15 degrees. Bit 1 must be set to enable trigger/hold
frorr DCP via VAR.714 (MCLlSTFR). Bit 2 is a manual trigger/hold. Bit 3 is a "hold next" trigger. Bits 4-6 configure he MCP trigger source.
(Se
help memo for EE.6282.1 for details on these jumper bits.)
Adc resses of MCP variables are:

10 RTCLK
154 IL1
32940 FLOPERR
49572 VARMFB
90 PLLXO
158 IL3
32942 FLOPOUT
49574 VBRGFB
92 TICSDDEG
260 MBBALANC
32954 IRDROP
49620 ACLINMAG
98 ALPHA
32818 SFB
32956 PLLERR
49644 IA1 FB
100 FIRETIME
32868 M_VAFILT
32972 CTCFB
49646 IA2FB
112 IF_OFST
32870 M-'AFILT
49504 DROPIFB
49648 IF1 FB
120 IA OFST
32884 L1NEFREQ
49558 IARMFB
49650 IF2FB
138 ILOPOUT
32934 FIRCMD
49560 IBRIDGE
144 ILOPREF
32936 ILOPERR
49562 CEMF
WA NING--These MCP addresses are for debug use only, not for application level use. These addresses are subject 0 change in future revisions.
Not , during cell test, the circular list pointers are automatically overridden and cell test diagnostic information is
cap ured on the circular list. To capture cell test diagnostics regardless of whether the cell test passes or faults,
set he trigger source to be "MCP preconditioned." Circular list data during cell test is:
Cell test state machine; 1-12 = short, 13-24 = open ckt test
1st column
2nd column CT current (VAR.1 019)
3rd column
Bridge current
4th column
Bridge voltage
5th column
Cell pair counter
6th column
Fault code detected on first trial
7th column
ILOPOUT
8th column
During open ckt test, bit pattern of passed cells
Va/ue
0(0)
1 ( 1)
Description
Update circular list once per firing (- 60 degrees)
Update MCP circular list every 15 degrees
11-5
BI006008
GEH-6148
Table 11-1. MCP Circular List Software Jumpers . 6282 (MDGNJP) - Continued
Bit
Definition
EE.6282.1
Enable trigger/hold from DCP VAR.714, MCLlSTFR

EE.6282, MDGNJP, contains jumpers to control operation of the MCP circular list.
Bit 0 controls the execution rate of the circular list. Normally left clear to capture data once per firing. Set to capture data every 15 degrees to diagnose asynchronous current regulator/firing circuit operation. This bit also controls the update rate of V ARs 290 and 291.
Bit 1 must be set to enable trigger/hold from dcp via VAR.714, MCLlSTFR. When set, if this VAR is true, the circular list will remain frozen. On the active edge of this VAR, if not already triggered, the list will trigger and fault
CIRCLATC will be annunciated briefly.
Bit 2 is a manual trigger/hold. If set, the circular list will trigger and remain frozen until the bit is cleared.
Bit 3 is a "hold next" trigger. If set, the next time the circular list is triggered, it will remain frozen until the bit is
cleared.
Bits 4-6 configure the MCP trigger source:
o Any fault (if EE.570.1 0 =0); MCP precondition (if EE.570.1 0 = 1)
Any trip fault
1
2
MCP preconditioned
3
MCP armature firing disabled
4-7 Reserved
These sources are in addition to the DCP trigger source, if enabled.
See the help memo for EE.6282.0 for additional information.
Value
Description
o ( 0) Ignore DCP trigger source
1 ( 2)
Enable trigger/hold from VAR.714
EE.6282.2
Manually trigger and hold MCP circular list

Value
0(0)
1 (4)
EE.6282.3
Permanently hold data from next circular list trigger

Value
0(0)
1 ( 8)
EE.6282.4
Description
Release circular list data on falling edge of trigger
Lock circular list data on next trigger
MCP circular list trigger/hold event source

Value
0(0)
1 (16)
2 (32)
3 (48)
11-6
Description
Enable automatic triggering of MCP circular list
Manually trigger and hold MCP circular list
Description
Trigger on any fault (unless EE.570.1 0 is set)
Trigger on any trip fault
Trigger when drive is stopped (MCP preconditioned)
Trigger when MCP inhibits armature firing
BI006008
GF2000 Dc Ge ~e rator Field Exciter
GEH-6148
Table 11-2. DCP Circular List Software Jumpers

Address
Mn monic
Definition
CLST Blocks
EE.5868
CL~ RUN
Circular List Run Command Pointer

This EE contains the address of a Boolean which is the circular list run command.
When the run command is High, the block collects data. When it is Low, it stops
collecting data and the data may be read. The RUN Command input can be inverted via the use of the CL_JPR.O jumper (CLST2, CLST3 only).
The restarting of the circular list will cause it to continue collecting data. By the
nature of a circular list, data will eventually be overwritten leaving the last 16
Kbytes of collected data intact. If the Overwrite Lock (EE.5878) is set, the block
will not be allowed to restart, thus preserving previously captured data (CLST2,
CLST3 only).
Additionally, if CL@RUN is set to 0, the keyboard character * (asterisk) will
toggle the starting and stopping of data collection. This status is shown as
an asterisk on the status line when toggled on (collect). The interpretation
of the * command does not depend on the state of CL_JPR.O jumper bit.
All
EE.5869
CL@ CH1
Circular List Channel 1 Data Pointer
All
EE.5870
CL@ CH2
All
EE.5871
CL@ CH3
All
EE.5872
CL@ CH4
All
EE.5873
CL@ ~H5
CLST3
EE.5874
CL@ r'H6
CLST3
EE.5875
CL@ "H7
CLST3
EE.5876
CL@ ~H8
CLST3
EE.5877.0
CL T vp
Circular List Channel 1 Data Type

Value
Description
0(0)
Channel Not Active
1 ( 1)
Collect Byte
2 (2)
Collect Word
4 (4)
Collect Double-Word
CLST3
EE.5877.3
CL T P

Description
Value
0(0)
Channel Not Active
1 ( 8)
Collect Byte
2 (16)
Collect Word
4 (32)
Collect Double-Word
CLST3
EE.5877.6
CL T P

Value
Description
0(0)
Channel Not Active
1 (64)
Collect Byte
2 (128)
Collect Word
3 (192)
Collect Word and Average
CLST3
EE.5877.8
CL_n p

Value
Description
0(0)
Channel Not Active
1 (256)
Collect Byte
2 (512)
Collect Word
3 (768)
CLST3
11-7
BI006008
GEH-6148
Table 11-2. DCP Circular List Software Jumpers - Continued

Address
Mnemonic
Definition
CLST Blocks
EE.5877.10
CL TYP

Value
Description
o {O}
Channel Not Active
1 (1024)
Collect Byte
2 (2048)
Collect Word
3 (3072)
CLST3
EE.5877.12
CL TYP

Value
Description
o (O)
Channel Not Active
1 (4096)
Collect Byte .
2 (8192)
Collect Word
3 (12288)
CLST3
EE.5877.14
CL TYP

Value
Description
o (O)
Channel Not Active
1 (16384)
Collect Byte
CLST3
EE.5877.15
CL TYP

Value
Description
o (O)
Channel Not Active
1 (32768)
Collect Byte
CLST3
EE.5878
CL@LCK
Circular List Overwrite Lock Pointer

This EE contains the address of a logical Boolean which acts as the Overwrite
Lock for the Circular List block. If the Overwrite Lock is set. the block will be allowed to start once and stop once but will not be allowed to restart, thus preserving previously captured data (CLST2, CLST3 only). This feature is intended to
allow unsupervised collection of data surrounding a single event where there is the
possibility of accidentally restarting the circular list and thus overwriting the collected data.
CLST2.
CLST3
EE.5879
CL_RAT
Circular List Data Collection Rate

Specifying the data collection rate allows for data collection at a rate different
from {slower than} the block execution rate. The actual collection rate may be
slightly faster than the rate specified by CL_RAT as the time is rounded to fit an
integer number of block executions. The actual collection rate is reported in the
circular list status when the circular list is read (dumped).
CLST2,
CLST3
EE.5880
CL_DLY
Circular List Capture Stop Delay

CL_DLY contains an integer number of data points to be captured after the Circular List block loses its run enable. This allows the Circular List to capture data
surrounding an event rather than just up to an event. Note that for a value in
CL_DLY that is larger than the list length the delay will be limited to the length of
the list.
CLST2,
CLST3
EE.5881.0
CL_JPR
Circular List RUN command Invert

The RUN command input can be inverted via the use of the CL_JPR.O jumper
{CLST2, CLST3 only}. Note that this jumper bit does not change the interpretation
of the Serial Link" *" command.
Description
Value
0(0)
Do not invert logical sense of Circular List RUN Command
1 { 1}
Invert logical sense of Circular List RUN Command
CLST2.
CLST3
VAR.1453
CL STATE
Circular List State

CL_STATE contains information on the state of operation of the circular list. It
may be deciphered as follows:
Waiting for run command (stopped)
0
Waiting for stop command (collecting)
2
Stop requested in Non-write scan (may occur when CL_RAT < > 0)
4
6
Exhausting Stop Delay
Circular List is Locked (no restart without reset)
8
All
11-8
BI006008
GEH-6148
Table 11-3. LCP History Buffer Software Jumpers

Address
Mn monic
Definition
EE.615.5
LCFJP1
History Circular List Trigger selection

These bits select the trigger to lock the History Circular List. Note that the History 8uffer can be
locked by a LAN command, regardless of the LCPJP1 setting.
Value
Description
o ( 0)
Trip fault or HISTORY LOCK BIT (HISLOC EE.649)
1 (32)
Only the HISTORY_LOCK_BIT (HISLOC EE.649)
Any fault or HISTORY LOCK BIT (HISLOC EE.649)
2 (64)
3 (96)
Neither a fault or HISTORY_LOCK_BIT (HISLOC EE.649)
EE.615.7
LCP P1
Capture 2 or 5 variables per History Snapshot

Defines whether 2 or 5 variables are to be captured per History Snapshot. (A HARD RESET is required after changing this parameter.)
Value
Description
o ( 0)
5 variables per snapshot
1 (128)
2 variables per snapshot
EE.622.8
FRZ JlSK
History variable #1 (HISTORY1) - Freeze Mask is the mask used for selecting up to six freeze parameters which will be sent on the LAN.
Value
Description
o ( 0)
HISTORY VARIABLE #1 (HISTORY1 VAR.586) is not included
1 (256)
HISTORY VARIABLE #1 (HISTORY1 VAR.586) is included
EE.622.9
FRZ ~SK
History variable #2 (HISTORY2) - Freeze Mask is the mask used for selecting up to six freeze parameters which will be sent on the LAN.
Value
Description
o ( 0)
HISTORY VARIABLE #2 (HISTORY1 VAR.587) is not included
1 (512)
HISTORY VARIABLE #2 (HISTORY1 VAR.587) is included
EE.646.0
HISTD
History delay time between History snapshots

History delay time (HISTD.0-.5) defines the delay time between History snapshots in 20 msec intervals. The minimum delay time is 20 msec.
Example:
If HISTD.0-.5
If HISTD.0-.5
= 1, then the delay time is 40 msec.

= 5, then the delay time is 120 msec.
The History buffer contains 51 frames of 5 variables or 102 frames of 2 variables. Inter frame time
is [20msec + (HISTD.0-.5 20msec)]. Frame 0 reports the drive time at lock, 5 or 2 variable
frames, the time delay between frames, and the DCP RAM locations pointed to by HISTP1 and
HISTP2.
If 5 variables per frame are selected, then the variables are
1) Current Feedback (LCPCFB VAR.559)
2) Voltage Feedback (VFB VAR.1 03)
3) Status S OUT (STSSOUTO VAR.590)
4)
@ HISTP1 (EE.647)
5)
@ HISTP2 (EE.648)
If 2 variables per frame are selected, then the variables are
1) @ HISTP1 (EE647)
@ HISTP2 (EE648)
2)
EE.647
HIST 1
History pointer #1 to DCP RAM

History pointer #1 selects the DCP variable to be loaded into HISTORY1 (VAR.586). The SLCC will
store HISTORY1 contents into the History buffer. HISTORY1 is updated every 2.7 msec.
EE.648
HIST 2
History pointer #2 to DCP RAM

History pointer #2 selects the DCP variable to be loaded into HISTORY2 (VAR.587). The SLCC will
store HISTORY2 contents into the History buffer. HISTORY2 is updated every 2.7 msec.
EE.649
HISL DC
History lock pointer used for History lock bit

The history lock pointer determines which DCP Boolean variable (when set) will lock the history circular list (known as the History lock bit).
11-9
BI006008
GEH-6148
Notes:
11-10
BI006008
GEH-6148
CHAPTER 12
PARTS REPLACEMENT
12-1.INTROD eTION
CAUTION
This chapter pro ides instructions for replacing printed
wiring boards
SCR modules in the GF2000 Dc
Generator Field xciter.
GE carefully tes all equipment before shipping, and
does not expect quipment to fail under normal conditions. Most com onents never require repair or replacement.
WARNING
While power is applied to the exciter, do

not remove or re-insert printed wiring
boards or connections. This can damage
the equipment.
To replace a board in the exciter:
1.
Ensure that power to the exciter is off.
2.
Carefully disconnect all cables, as follows:
Disconnect I power supplies before performing an maintenance, adjustments,

serVlcmg, p
replacements, or any other
act requirin physical contact with electrical working components or wiring of this
equipment.
ers, if supplied as part of the
may not disconnect all power
ent (see system elementary
diagrams). hether the ac voltage is
grounded 0 not, high voltage to ground
may be pres nt at many points.
For a ribbon cable, place one hand on each

side of the cable connector that mates with the
board connector. Gently pull the cable connector with both hands.
For a cable with a pull tab, pull the tab.
For a screw terminal connector, loosen the
screw at the top of each terminal and gently
pull each wire free.
3.
Carefully remove the board, as follows:

Some boards are held in place by plastic
snaps (holders). Push these holders back to
release the board.
CAUTION
To prevent mponent damage caused by
static electri ity, treat all boards with static
sensitive h dUng techniques. Use a
grounding s ap when changing boards.
Store boar in anti-static bags or boxes.
Printed wiring bo ds may contain static-sensitive
components, whi h must be considered when handling
and replacing a bard. GE ships replacement boards in
anti-static bags or boxes. It is important that they be
stored and transp rted in these bags or boxes when not
installed in the sy tem.
Some boards are mounted on standoffs with

screws. Remove the screws to release the
board.
4.
On the replacement (new) board, set all jumpers,

pots, and switches in the exact position as those on
the board being replaced.
To fme-tune pots, refer to Chapter 5. If a board
revision has added or eliminated a configurable
component, or readjustment is needed, refer to the
tables in Chapter 5, or the instructions provided
with the replacement board
12-1
BI006008
GEH-6148
NOTE
1.
Lower the card carriers to expose the rear of the

unit, where the SCR module is located.
2.
Disconnect the wires from the damaged SCR

module. If needed, mark the wires so that they
can be connected correctly to the new module.
If the SDCC or SLCC card is replaced, onboard

software from the old card must be transferred to
3.
Remove the bus bar and mounting screws.
the new (replacement) card. Refer to section 54.7.3 for the SDCC or section 5-4.8.2 for the
SLCC for instructions on transferring the onboard
software to the replacement card.
4.
Clean old lubricant and dirt from the mounting

surface.
5.
Apply a thin fIlm of VERSILUBE Plus lubricant

to both contacting surfaces.
6.
Install the new module, reconnecting the wires,

bus bars, and mounting screws. Tighten the
screws to the torque specifications listed in Table
12-1.
Because of upgrades, boards of different

revision levels may not contain identical
hardware. However, GE Drive Systems ensures compatibility of replacement boards.
5.
6.
7.
Install the new board, ensuring that all holders

snap into position or that the board is mounted securely on the standoffs.
Reconnect all cables, ensuring that they are properly seated at both ends.
For mounting screws:

12-3. SCR Module Repair/Replacement
a.
Tighten screws one at a time, progressing

counterclockwise on 4-screw mounting, until
all screws are snug.
b.
Tighten to required torque in opposite order,

progressing clockwise on 4-screw mounting,
beginning with the last screw snugged.
The following procedure is used to replace an SCR

module in the GF2000 exciter.
NOTE
In addition to standard repair tools, this

procedure requires GL322 VERSILUBE
Plus lubricant (part no. 104X214AB059).
7.
Remove all excess VERSILUBE Plus from edges

of SCR module.
Table 12-1. SCR Module Mounting and Connecting Torque Requirements

Torque Requirements
Frame Size
SCR Module Part Number
Heatsink
Mounting Screws
Bus Bar*
Mounting Screws
104X125DC 057
55 in Ib
60 in Ib
C Extension
104X125DC 058,059
55 in Ib
60 in Ib
104X125DC 056
28 in Ib
25 in Ib
12-2
To avoid excess torque on connected modules, support the bus bar while
tightening screws.
BI006008
GEH-6148
CHAPTER 13
SPARE AND RENEWAL PARTS
13-4. PART NUMBER STRUCTURE
This chapter con' information needed when ordering spare and re wal (replacement) parts for the
GF2000 Dc Gen rator Field Exciter. This information
consists of a part listing with the catalog (part) numbers. Both the p
name and the complete part
number must be included when ordering.
GE recommends at the customer keep a set of spare
parts on hand to . . . e system downtime if repair
is needed.
13-2. CUSTO
RENEWAL PARTS LISTING
arts list in this manual, GE provides

a separate Renew Parts List with the exciter's custom instructions r PC software. As indicated, this
custom list applie specifically to the equipment furnished on a custo er's particular application at the
time of shipment.
If this Renewal P s List is missing, contact the nearest GE Sales Offi e or GE Sales Representative to
obtain a copy. In ude the exciter model number,
serial number, d GE requisition number.
A GE part number is structured so that different portions of the number identify the type of equipment and
location of manufacture. For ordering, a customer
does not need to understand this makeup - the equipment's nameplate provides the complete number.
However, since the information is used for some software applications, this section defmes the part number structure.
A part falls into one of four categories:
Order-specific assemblies - major assemblies or
items that make up a specific exciter; made up of
common assemblies
Common assemblies - subassemblies used in many
GE Drive Systems products, not just a particular
exciter or drive
Components - individual parts that make up assemblies
Printed wiring boards
These categories and the makeup of their part numbers
are defmed below.
RENEWAL PARTS
13-4.1. Order-specific Assembly Part Numbers
Renewal parts sh d be ordered by contacting the

nearest Sales Offi e or an authorized GE Sales Representative. Include:
Exciter mode number, located on its nameplate
Part name
Complete p
Parts still under w anty may be obtained directly

from the factory ( esignated on the system elementary
diagram), as descr bed in Appendix F.
Order-specific assemblies make up the particular exciter provided. Other items obtained specifically for
the order may use a similar part number structure.
For example, if 3VXYZ999CDOOl is the part number
for an order-specific assembly:
3V = assembly provided by GE Drive Systems,
Salem, Virginia
XYZ999
= original order identification number
CD = assembly type: CD for core drive; LV for

lineup; CA for case; PN for panel
001
= unit identification number

13-1
BI006008
GEH-6148
13-4.2. Common Assembly Part Numbers
Common assemblies are subassemblies used as components of order-specific assemblies. Common assemblies are not designed for a particular exciter or
drive, but provide a function used in other GE products.
A common assembly part number consists of the number 36 followed by up to 14 alphanumeric characters.
The DS200SDCC portion is the base number that

identifies the printed wiring board, in this case, the
Drive Control Card. The r and u digits are alphabetic
characters that indicate the revision level of the printed
wiring board. The r digit reflects a functional change
that is not downward compatible. It is essentially a
new catalog number. The u digits represent revision
levels that are downward compatible to the r revision
level. The G# identifies a group, which is a variation
Components are the basic parts that make up assemblies. They represent the lowest discrete level of a
system. Component part numbers consist of a combination of alphanumeric characters that defme the class
and specific item.
Other boards contained in the GF2000 exciter are

designated with part numbers beginning with the characters 531X. For example, the Drive Terminal Board
is identified by part number 53lX305NTBcrG#. The
531X305NTB portion is the base number that identifies
the printed wiring board, in this case, the Drive Terminal Board. The c digit can be A or B, depending on
the configuration; the r digit is an alphabetic character
that indicates the revision level of the printed wiring
board. The G# identifies a group, which is a variation
For example, if I04X109AD038 is the part number,

then:
All digits are important when ordering or replacing

any board.
For example, 36C774524AAG35 is the part number

for the GF2000 exciter's IPL cable.
13-4.3. Component Part Numbers
104X
109
= component
= component type (fuse)
AD038 = item or rating (500 V, 3.2 A, FNQ)
NOTE
The factory may substitute later versions of

boards based on availability and design enhancements. However, GE Drive Systems
ensures compatibility of replacement
boards.
13-4.4. Board Part Numbers
A printed wiring board is designated by an alphanumeric part (catalog) number. Two parts numbering
series are commonly used for printed wiring boards at
GE Drive Systems.
Most of the boards contained in the GF2000 exciter
are designated with part numbers beginning with the
characters DS200. For example, the Drive Control
Card is identified by part number DS200SDCCG#ruu.
13-2
13-5. GF2000 DC GENERATOR FIELD EXCITER

PARTS LISTS
The tables included in this section list part numbers for

the boards, subassemblies, and components used in
GF2000 C and CX frame (Table 13-1) and G frame
(Table 13-2) exciters. For a listing of part specific to a
particular exciter, refer to the Renewal Parts List
(described above) provided with the equipment.
BI006008
GF2000 Dc Gent rator Field Exciter

Table 13-1. GF2000
GEH-6148
e and ex Frame Exciter Parts List
Description
Catalog (Part) Number
Balun assemt Iy, ARCNET, requires SLCCG1
368605594AEG01
Balun assemt Iy, DLAN, requires SLCCG2
368605594AEG02
Cable, 11 PL, ~DCC to 11 PLX
336A3485AF G01
Cable, 170 O( THSW to 2TB-11, -12
336A3485AA G02
Cable, 190
336A3485AA G01
O(
THSW to 2TB-3, -4
Cable, 1PL
Qty
36C774524AAG35
Cable, 2PL,
VI
ith SLCC card
368605787ACG01
Cable, 2PL,
VI
ithout SLCC
36B605787AAG01
Cable,3PL
36C774524AAG36
Cable,4PL
36C774524AAG37
Cable,5PL
36C774524AAG38
Cable,6PL
36C774524AAG39
Cable,7PL
36C774524AAG51
Cable, 8PL, w th LTB board
36C774524AAG200
Cable, 8PL, w thout LTB board
36C774524AAG41
Cable, ACFU
CPTFU1-1, CPTFU2-1 (top)
336A3485AB G04
Cable, ACFU
SCRs
36A358218BRG03
Cable, ARCPL with SLCCG1 and ARCNET
368605796AAG01
Cable, ARCPL with SLCCG2 and DLAN
36B605796AAG09
Cable, armatu e shunt to 2TB-1 5, -16
336A3485AL G01
Cable, CPTFU $-2 to 2TB-14 (bottom)
336A3485AB G01
Cable, CPTX tp CPTFU and 2TB-13
336A3485AC G01
Cable, DCFB ' FPL to 2FPLX
336A3485AD G02
Cable, DCFB I:.. 1PL to 2TB-15, -16
336A3485AG G01
Cable, DCFB I :..2PL to 2TB-25, -26
336A3485AG G02
Cable, DCFB I 1PL to 2TB-21, -22
336A3485AJ G01
Cable, DCFB I 2PL to 2TB-25, -26
336A3485AJ G02
Cable, DCFB I PL to 1FPLX
336A3485AD G01
Cable, DCFB 1\ ACPL to 2TB-19, -20
336A3485AK G01
Cable, DCFB tp ACFU & P1, P2 buses
336A3485AH G01
Cable, DCFB \ M 1A, B to 2TB-9, -10
336A3485AE G01
Cable, DCFB \ M2A, B to 2TB-23, -24
336A3485AE G02
Cable, drive st unt to 2TB-29, -30
336A3485AL G04
Cable, FAPL with snubber resistor
36A358218CDG03
Cable, FAPL "" ithout snubber resistor
36A358218CDG01
Cable, IOPL, S CC to SPC
36C774524AAG43
Cable, MET1 tp 11 PLX-1, -4
336A3485AS G01
Cable, MET2 t
336A3485AS G02
11 PLX-2, -5
13-3
BI006008
GEH-6148
Table 13-1. GF2000 C and CX Frame Exciter Parts List - Continued

Description
Cable, MET3 to 11 PLX-3, -6
336A3485AS G03
Cable, MET4 to 11PLX-8,-7
336A3485AS G04
Cable, motor field shunt to 2TB-21, -22
336A3485AQ G01
Cable, NTB/3TB to LTB/RTBA 115 V ac feed
36A359100CYG14
Cable, OPTPL (RTBA jumper)
36A359100CYG13
Cable, P1 and P2 buses to 2TB-9, -10
336A3485AH G09
Cable, RPL
36A359100CRG01
Cable, shunt P1 A to SCR bus P1
36A358218BEG04
Cable, shunt P2C to SCR bus P2
36A358218BEG01
Control power transformer (CPT) assembly, 4.6 A, 230/460 V ac
36B605573BEG01
Control power transformer (CPT) assembly, 4.6 A, 575 V ac
36B605573BEG02
Drive Control Card (SDCC) with firmware
DS215SDCCG1
DS215SDCCG3
Qty
531X305NTBA G1
Fan, Muffin, rack cooling, heat sink
104X21 5CA 003
Fan, Tarzan, SCR bridge (C frame)
104X215CA 004
Ferrite cores
151A7823P37
Fuse, 200 A, 700 V, semiconductor (FU1 - FU3 for 460 V ac input,

107 - 183 A output)
323A2432P72
Fuse, 3.2 A, 600 V, FNQ-R, time delay (CPTFU1, CPTFU2 for 575 V
ac input)
104X109BE 021

108 - 260 A output and 460 V ac input, 128 - 260 A output)
323A2432P53
Fuse, 4.0 A, 600 V, FNQ-R, time delay (CPTFUl, CPTFU2 for 460 V
ac input)
104X109BE 023

184 - 421 A output)
323A2432P74
Fuse, 5.0 A, 600 V, FNQ-R, time delay (CPTFU3 for all input voltages)
104X109BE 024

261 - 525 A output and 460 V ac input, 261 - 505 A output)
104X109AG 027
ac input)
104X109BE 029
Gate leads
36A358218BCG01
Gate leads
36A358218BCG02
Jumpers, voltage select
36A358160XRG02
Keypad, with SLCC card
104X152AE 002
LAN Communications Card (SLCC) with firmware: G1 can be used

with DLAN or ARCNET; G2 with DLAN only; and G3 with neither
DLAN nor ARCNET.
DS215SLCCG1
DS215SLCCG2
DS215SLCCG4
LAN 1/0 Terminal Board (LTB)
531X307LTBA G1
Maintenance kit
36A358941 AAG02
MET1, 125 - 0 - 125%, SMET

MET2, 125 - 0 - 125%, IMET
MET3, 125 - 0 - 125%, VMET
68A7614C22YTAAABOO
68A7614C22YTAAABOO
68A7614C22YTAAABOO
1
1
1
13-4
BI006008
GEH-6148
GF2000 Dc Gen rator Field Exciter

Table 13-1. GF2000
e and ex Frame Exciter Parts List -
Description
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
175
275
325
375
150
200
250
300
500
Continued
P- 175%, IMET
68A7614C22SAEEEBOO
68A7614C22SCBBBBOO
68A7614C22SDDDDBOO
68A7614C22SFAAABOO
68A7614C22YCCCCBOO
68A7614C22YDFFFBOO
68A7614C22YEAAABOO
68A7614C22YFCCCBOO
68A7614C22YHAAABOO
0 - 275%, IMET
0 - 325%, IMET
0 - 375%, IMET
P - 150%, IMET
P- 200%, IMET
250%, IMET
:> - 300%, IMET
:> - 500%, IMET
P-
MET4, 0 - 125%, FMET
68A7614C22BUAAABOO
MET4, 0 - 14D%, FMET
68A7614C22BVBBBBOO
MET4, 0 - 15 D%, FMET
68A7614C22BCCCCBOO
MET4, 0 - 17 %, FMET
68A7614C22CAEEEBOO
Plug (11 PLX), used with any meters
218A4609P1
Potted ferrite pox
246B2333AA G02
Power Conne( t Card (PCCA)
DS200PCCAG#_
DS200DCFBG1
Relay Termina
Relay Termina
Relay Termina
RTBA board re
Board (RTBA),
Board (RTBAl,
Board (RTBAL
quires SLCCGl
Qty
110 V dc relay coils

24 V dc relay coils
115 V ac relay coils
or G2 card.
Resistor, ACS snubber
DS200RTBAG 1
DS200RTBAG2
DS200RTBAG3
104X123DE 014
Resistor, DCS snubber
104X123DE 015
SCR, 160 A, 600 V, for 230 V ac input, 108 - 280 A output (C

frame); 460 V ac input, 128 - 180 A output (C extension); 600 V ac
input, 107 - 280 A output (C frame)
104X125DC 057
SCR, 250 A '~ " 1600 V, for C extension frames, all input voltages,
355 - 516 A (utput
104X215DC 059
SCR, 250 A, 1600 V, for C extension frames, all input voltages, 281 354 A output
104X125DC 058
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
104X149CC 030
104X149CC 031
104X149CC 032
104X149CC 033
104X 149CC 056
50-140034NTAA
50-140034NWAA
104X149CA 006
50-140034PKAA
50-140034PZAA
50-140034RLAA
50-140034RSAA
1A
2 A
5 A
lOA
15 A
50 A
60 A
80 A
100 A
150 A
200 A
250 A
Signal Process r Card (SPC)

Snubber, left,
~ith
PCCA
Snubber, right, with PCCA
531X309SPCA Gl
336A3485AT G02
36A358160FRG07
Switch, discon ect (100 A)
104X203DB 003
Terminal board 32 point (2TB)
246B8210AB G32
Thermal switch assembly with terminals, 170C
336A3390AF GOl
Thermal switch assembly with terminals, 190C
36A358106ARGOl
13-5
BI006008
GEH-6148

Table 13-2. GF2000 G Frame Exciter Parts List
Description
Balun assembly, ARCNET, requires SLCCGl
36B605594AEGOl
Balun assembly, DLAN, requires SLCCG2
368605594AEG02
Cable, 11 5 V ac to 2 fans
36A358160REG05
Cable, 11 PL, SDCC to 11 PLX
336A3485AF GOl
Cable, 170C THSW to 2TB-ll, -12
336A3390AD 001
Cable, 190C THSW to 2TB-3, -4
104X 1 52AC 080
Cable, 1PL
36C774524AAG3 5
Cable, 2PL, with SLCC card
36B605787ACGOl
Cable, 2PL, without SLCC
36B605787AAGOl
Cable,3PL
36C774524AAG36
Cable,4PL
36C774524AAG37
Cable,5PL
36C774524AAG38
Cable,6PL
36C774524AAG39
Cable,7PL
36C774524AAG51
Cable, 8PL, with LTB board
36C774524AAG200
Cable, 8PL, without LTB board
36C774524AAG41
Cable, ACFU to CPTFU 1-1, CPTFU2-1 (top)
336A3485AB G05
Cable, ACFU to SCRs
36A358160FDG05
Cable, ARCPL, with SLCCGl and ARCNET
368605796AAGOl
Cable, ARCPL, with SLCCG2 and DLAN
36B605796AAG09
Cable, CPTFU3-2 to 2TB-14 (bottom)
336A3485AB GOl
Cable, CPTX to CPTFU and 2TB-l 3
336A3485AC GOl
Cable, DCFB IA 1PL to 2TB-l 5, -16
336A3485AG GOl
Cable, DCFB IA2PL to 2TB-25, -26
336A3485AG G02
Cable, DCFB IFl PL to 2TB-21, -22
336A3485AJ GOl
Cable, DCFB IF2PL to 2TB-25, -26
336A3485AJ G02
Cable, DCFB IFPL to 1FPLX
336A3485AD GOl
Cable, DCFB 2FPL to 2FPLX
336A3485AD G02
Cable, DCFB MACPL to 2TB-19, -20
336A3485AK GOl
Cable, DCFB to ACFU & Pl, P2 buses
336A3485AH G17
Cable, DCFB VM 1A, 8 to 2TB-9, -10
336A3485AE GOl
Cable, DCFB VM2A, B to 2TB-23, -24
336A3485AE G02
Cable, disconnect switch to ACFU
36A358218AYG03
Cable, drive shunt to 2TB-29, -30
336A3485AL G04
Cable, FU4-P2 to SCR bus P2
36A358160FAG10
Cable, IOPL, SLCC to SPC
36C774524AAG43
Cable, MEn to 11 PLX-l, -4
336A3485AS GOl
13-6
Qty
BI006008
GEH-6148

Table 13-2. GF2000 G Frame Exciter Parts List - Continued
Description
Qty
Cable, MET2 0 11 PLX-2, -5
336A3485AS G02
Cable, MET3 0 11 PLX-3, -6
336A3485AS G03
Cable, MET4 0 11PLX-8,-7
336A3485AS G04
Cable, NTB/3 B to LTB/RTBA 11 5 V ac feed
36A359100CYG14
Cable, OPTPL (RTBA jumper)
36A359100CYG13
Cable, RPL
36A359100CRG01
Cable, Shunt P1 A to SCR bus P1
36A358160FAG10
Control powe transformer (CPT) assembly, 4.6 A, 230/460 V ac
36B605573BEG01
Control powe transformer (CPT) assembly, 4.6 A, 575 V ac
36B605573BEG02
Drive Control Card (SDCC) with firmware
DS21 5SDCCG 1
DS215SDCCG3
Drive Termin I Board (NTB/3TB)
531X305NTBA G1
Fan, Muffin, ack cooling, heat sink
104X21 5CA 003
Ferrite cores
151 A7823P37
Fuse, 100 A, 500 V, semiconductor (FU 1 - FU3 for 230 V ac input,

56 - 74 A Ol tput and 460 V ac input, 54 - 69 A output)
323A2432P51

59 - 106 A ( utput)
323A2432P71

75 - 107 A utput; 460 V ac input, 70 - 127 A output)
323A2432P52
ac input)
104X 109BE 021
ac input)
104X109BE 023
Fuse, 5.0 A, 600 V, FNQ-R, time delay (CPTFU3 for all input voltages)
104X 109BE 024
Fuse, 60 A, 00 V, semiconductor (FU1 - FU3 for 230 V ac input, 1 55 A output; 460 V ac input, 1 - 53 A output)
323A2432P50
Fuse, 60 A, 00 V, semiconductor (FU1 - FU3 for 600 V ac input, 1 58 A output)
323A2432P70
ac input)
104X 109BE 029
2/3
Gate leads
36A358218BCG01
Gate leads
36A358218BCG02
Jumpers, vol age select
36A358160XRG02
Keypad, with SLCC card
104X 152AE 002
LAN Commu ications Card (SLCC) with firmware: G1 can be used

with DLAN 0 ARCNET; G2 with DLAN only; and G4 with neither
DLAN nor AF CNET.
OS215SLCCG1
OS215SLCCG2
OS21 5SLCCG4
LAN I/O Tern inal Board (LTB)
531X307LTBA G1
Maintenance kit
36A358941 AAG02
MET1, 125 - 0 - 125%, SMET

MET2, 125 - 0 - 125%, IMET
MET3, 125 - 0 - 125%, VMET
68A7614C22YTAAABOO
68A7614C22YTAAABOO
68A7614C22YTAAABOO
13-7
BI006008
GEH-6148
Table 13-2. GF2000 G Frame Exciter Parts List - Continued

Description
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
MET2,
175 275 325 375 150 200 250 300 500 -
0
0
0
0
0
0
0
0
0
175%,
275%,
325%,
375%,
150%,
200%,
250%,
300%,
500%,
68A7614C22SAEEEBOO
68A7614C22SCBBBBOO
68A7614C22SDDDDBOO
68A7614C22SFAAABOO
68A7614C22YCCCCBOO
68A7614C22YDFFFBOO
68A7614C22YEAAABOO
68A7614C22YFCCCBOO
68A7614C22YHAAABOO
IMET
IMET
IMET
IMET
IMET
IMET
IMET
IMET
IMET
MET4, 0 - 125%, FMET
68A7614C22BUAAABOO
MET4, 0 - 140%, FMET
68A7614C22BVBBBBOO
MET4, 0 - 150%, FMET
68A7614C22BCCCCBOO
MET4, 0 - 175%, FMET
68A7614C22CAEEEBOO
Plug (11 PLXl, used with any meters
218A4609P1
Potted ferrite box
246B2333AA G02
DS200PCCAG#
DS200DCFBG1
Relay Terminal Board (RTBAl,

Relay Terminal Board (RTBA),
Relay Terminal Board (RTBAl,
RTBA board requires SLCCG1
110 V dc relay coils

24 V dc relay coils
115 V ac relay coils
or G2 card.
DS200RTBAG 1
DS200RTBAG2
DS200RTBAG3
Resistor, ACS snubber
104X123DE 014
Resistor, DCS snubber
104X123DE 015
SCR, 90 A, 1600 V (All G frames)
104X125DC 056
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
Shunt,
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
104X149CC
1A
2 A
5A
10 A
15 A
20 A
25 A
50 A
75 A
100 A
150 A
030
031
032
033
034
035
036
037
038
039
040
Signal Processor Card (SPC)
531X309SPCA G1
Snubber, left, with PCCA
336A3485AT G02
Snubber, right, with PCCA
36A358160FRG05
Switch, disconnect (100 A)
104X203DB 003
Switch, disconnect (150 A)
TEC36150
Terminal board, 32 point (2TB)
246B8210AB G32
Thermal switch assembly with terminals, 170 C
336A3390AF G01
Thermal switch assembly with terminals, 190 C
36A358106ARG01
13-8
Qty
BI006008
GEH-6148
APPENDIX A
GLOSSARY OF TERMS
IFPL through
6.
L - I/O connectors. See Chapter
IPL through 8P ,1lPL, 16 PL - I/O connectors.

See Chapter 6.
lRPL through
L - I/O connectors. See Chapter
6.
ITB through 3
D/A - Digital-to-analog conversion.

DC2000 drive - A microprocessor-based power converter that produces a controlled dc output for
customer applications.
DCFB - Power Supply Board, DS200DCFB. Furnishes dc power to exciter control boards and
provides instrumentation for field circuits.
- I/O connectors. See Chapter 6.
AID - Analog-to digital conversion.
application soft are - Job-specific software resident

in the excite , designed specifically for the customer's appl cation.
ARCNET - See DLAN+.
ARCPL - I/O c nnector. See Chapter 6.
DCP - Drive Control Processor. An 80Cl86 processor mounted on the SDCC. Its software consists
of user interfaces, outer regulating loops, and
system-level functions.
diagnostics - Software that checks exciter hardware or
software, providing error indications that identify
the type or location of malfunction.
DIP switch - Switch used on some boards to configure I/O options.
BCD - Binary c ded decimal.

iring board.
building blocks
(blocks) of
specific so
regulator).
tion progr
software) - Standard modules

.croprocessor code that perform
are functions (for example, a speed
locks are configured into the applica-
f GF2000 exciter. See Table 4-1.
C Extension fr
Table 4-1.
DLAN - Drive local area network. A communications

link between exciters, drives, and controllers,
featuring a maximum of 32 drops with transmissions at 57.6 kbaud.
DLAN+ (or DLAN PLUS) - GE Drive System's
version of ARCNET, using an ARCNET controller chip with modified ARCNET drivers. A communications link between exciters, drives, and
controllers, featuring a maximum of 255 drops
with transmissions at 25 Mbaud.
e - Size of GF2000 exciter. See
card - Alternate term for printed wiring board.
DPR - Dual-ported RAM. Used for communications

between two processors, such as the DCP and
CMP.
CMP - Co-moto Processor. The TMS320C25 digital

signal proce sor (U35) mounted on the SDCC.
The CMP rforms math-intensive functions to
support the otor control algorithms beyond the
Motor Con I Processor's (MCP's) ability.
Drive Configurator, LynxOS Version - A LynxOSbased software package used to configure and perform diagnostics on the GF2000 exciter. GEH6203 describes the Drive Configurator, LynxOS
Version. See also ST2000 Toolkit.
DVM - Digital voltmeter.
configure - To s lect specific options, either by setting the loca ion of hardware jumpers or loading
software par eters into memory.
EE or E
See EEPROM definition.
A-I
BI006008
GEH-6l48
EE enable device - Device used to "enable" or
"protect" EEPROM programming. A hardware
jumper (JPI) on the SDCC card.

LynxOS - A personal computer operating system produced by Lynx Real-Time Systems, Incorporated.
MA - Main ac contactor.
EEPROM - Electrically erasable programmable read2

only memory, also called EE or E (E squared).
Contains the exciter parameters.
MACPL - I/O connector. See Chapter 6.
EPROM - Erasable programmable read-only memory.
MCP - Motor Control Processor. An 80CI96 microcontroller (V21) located on the SDCC. Its software consists of current regulators, and motor/technology-specific functions.
frame size - Size of exciter cabinet, or cabinets. Determined by hardware components required for
power application.
module - An electronic assembly of boards, components, or a combination of these, that together

perform a specific function.
G frame - Size of GF2000 exciter. See Table 4-1.

GF2000 exciter - A microprocessor-based power
converter that produces a controlled dc output to
excite the field of a dc generator.
hardware (hard) reset - Reset generated by a hardware device, rather than by a software reset. Vsed
to reset the exciter boards, clear some faults, and
allow certain parameter changes. Activated by
pressing the SDCC's RESET button or by connecting NTB/3TB terminal board point 3TB-58 to
+5 or +24 V dc.
IAlPL, IA2PL, IFlPL, IF2PL - I/O connectors. See
Chapter 6.
NTB/3TB - Drive Terminal Board, 531X305NTB.

This board contains the exciter's customer connection terminals (3TB) for most signal-level I/O.
It also contains most of the hardware customizing
jumpers and potentiometers, plus passive interface
circuitry.
OTt through OT8 - I/O connectors. See Chapter 6.
PAL - Programmable array logic. An array of userprogrammable logic gates contained on a single
chip which is used to replace a number of separate
packages.
parameters - Adjustable software settings used to
program and tune the GF2000 exciter.
INl through INS - I/O connectors. See Chapter 6.

I/O - Input/output. Interfaces that allow the flow of
data into and out of a device.
PCCA - Power Connect Card, PCCA. This board

provides an interface between the GF2000 control
circuits and the SCR power bridge.
10PL - I/O connector. See Chapter 6.
PL - Plug (may be plug or receptacle).
KPPL - I/O connector. See Chapter 6.
plug-in connector - A type of I/O connector, typically containing more than one pin, and made so
that a connecting cable (with wires matching the
connector pin-out) plugs onto it as one unit.
LAN - Local area network. A communications link

that enables attached devices to "talk" to each
other over a limited geographical area.
LCP - LAN Control Processor. An 80CI96KC processor (VI) mounted on the SLCC.
LED - Light-emitting diode. Vsed as a visual indicator for a board or exciter function.
LTB - LAN I/O Terminal Board, 531X307LTB. Optional board that provides an interface between the
exciter and external devices, such as contactors,
lights, pushbuttons, and interlocks.
A-2
Programmer (module) - An operator interface module that includes a digital display and keypad, used
for software adjustment, diagnostic testing, and
digital fault code readouts. Included on the SLCC
card.
PROM - Programmable read-only memory. A readonly memory (ROM) chip that is programmed at
the factory for use in a given device.
RAM - Random access memory. Memory that can be
both read from and written to.
BI006008
GEH-6148

RPL - I/O co
RS-232C - A s iallink communications interface
standard for interconnecting data terminal equipment, such printers, CRTs, or computers, to
data comm 'cations equipment, such as modems,
for transmis ions over a telephone line or network. RS-2 2C uses an unbalanced or singleended volta interface. This connection is provided on the GF2000 exciter only for interfacing
with the ST 000 Toolkit or Drive Configurator.
stab - A wide, raised metal post on a printed wiring

board I/O path used a type of jumper connection
to configure various board options. Connection is
made using a wire terminal that plugs onto the
stab.
STIOOO Toolkit - A DOS-based software package
used to configure and perform diagnostics on the
GF2000 exciter. GEH-5860 describes the ST2000
Toolkit. See also Drive Configurator, LynxOS
Version.
RS-422 - A seri link communications interface standard that de es electrical interface characteristics. This st dard permits greater distances between equip ent and faster data transfer than RS232C. RS-4 is characterized by a balanced or
differential ltage interface.
SVAA - Voltage Attenuator Board, DS200SVAA.

This board attenuates the voltage of a generator,
bridge or motor from its rated level to 600 V dc
or less. The SVAA is used to reduce feedback
voltages to levels within the input specifications of
the DCFB board.
RTBA - Relay T rminal Board, DS200RTBA. This

board provid s seven relays that can operate from
voltages sup lied by the LTB or external voltages
supplied by e customer. Each relay has two
form C cont ts. The relays are available with
three coil vol ages: 110 V dc (Gl); 24 V dc (G2);
or 115 V ac, 0/60 Hz (G3).
SVIA - Shunt Isolator Board, DS200SVIA. This

board provides amplification and isolation of shunt
current signals.
SCR - Silicon-co trolled rectifier (thyristor).

SDCC - Drive C ntrol Card, DS200SDCC. The card
contains the e eiter's primary control circuits including three 16-bit microprocessors: the Comotor Proces or (CMP), Drive Control Processor
(DCP), and otor Control Processor (MCP).
TB - I/O connector. See Chapter 6.

terminal board connector - A type of I/O connector
in which individual wires are inserted into a connector point and are fastened by turning a screw
on the terminal.
testpoint - A hardware point, usually a metal ring or
post, located on a printed wiring path, used for
testing a signal or voltage on a board.
TP - Testpoint. See definition above.

SLCC - LAN Co
unications Card, DS200SLCC.
This card pro ides isolated and non-isolated input
circuits for co
unications to the exciter. The
SLCC conta' the Programmer module.
software (soft) r et - Reset initiated by software
input, rather an by a hardware device. Activated
by a serial inp t, or by pressing the Programmer's
RESET key.
DART - Universal asynchronous receiver/transmitter.

VCO - Voltage controlled oscillator. An oscillator
circuit whose output frequency is proportional to
the voltage applied to it.
SPC - Signal Proc ssor Card, 531X309SPC. This

card processes inputs before sending them to the
SDCC. It pro ides encoder feedback, converts
current refere ce signals to voltage reference signals, and rece' es RS-422 inputs.
A-3
BI006008
GEH-6148
Notes:
A-4
BI006008
GEH-6148
APPENDIX B
HARDWARE DRAWINGS
8-1. INTRODU TION

The GF2000 Dc Generator Field Exciter's configuration varies according to the customer application requirements.
Therefore, GE ovides hardware drawings to show the locations of the exciter's terminal board points, printed wiring
boards, connect plugs, and power fuses. These drawings are located in the exciter door pocket.
Figure B-1 inclu es the hardware drawings (336A3511 series) for the GF2000 exciter. Sheet AA applies to C, C extension, and G fame exciters; sheet BA applies only to G frame exciters; sheet CA applies only to C extension frame
exciters; and she t DA applies only to C frame exciters. Note that these drawings also apply to other GE Drive Systems products, s ch as DC2000 Adjustable Speed Drives; therefore, the drawings may show equipment not present in
a GF2000 excite .
NOTE
Exciter har ware drawings may change with product upgrades and revisions. The drawings presented
in this man al are current as of the issue date.
B-1
BI006008
GEH-6148
'G','C'
RIGHT SIJE VIE'w
!~!!M
i.
!,
,..----
PCC~)PCS~)PCR~)
PCN~
DR
I
~ I
( METl)
DCFB)SDCL
DR DCIA
2FP,--X
TE
G {IDS
'--
METER
~ BRACKET
DR
PTCT
CAi<D
Bi<KT
DTCT
CAR]
RIGHT SIJE VIEw
SDCC
3TB/STBA CARD
ARCNET I
OR
DLAN I
LTB CARD
RTB CARD
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COMPANY
03-03-95
09-22-93
w.G,
BAKER
DRIVE SYSTEMS DEPT,

SALEM, W. 'JSA
IGI/C I
CORE:
336A3511AA
CONT.ON SH
Figure 8-1. GF2000 Dc Generator Field Exciter Hardware Drawing 336A3511 (Sheet AA)
B-2
SH. NO
BI006008
GEH-6148
----------------------------------l
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wG
BAKER
DRIVE SYSTEMS DEPT,

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IG
FRAME
CORE
33SA3511BA
CJNT.ON SH.
FL
SH. NO,
Figu e B-1. GF2000 Dc Generator Field Exciter Hardware Drawing 336A3511 (Sheet BA)
B-3
BI006008
GEH-6148
MATB
~ID~~
N01
DA2
SHUNT
C,~
i,
BUS
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~c:
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CM1
N02
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(2) (2) (2);
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OR ---___
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NON-REVERSING SCR'S
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[ell 3ACS ca)
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10-08-93
REV2
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~,AD[
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09-22-93
BY
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DRIVE SYSTEMS DEPT,

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1[1
FRANE:
EXTENSION CORE
336A3511C~,
CONT.or-..: Si-I.
Figure 8-1. GF2000 Dc Generator Field Exciter Hardware Drawing 336A3511 (Sheet CAl
B-4
SH
NO,
BI006008
GEH-6148
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,
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: \
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03-03-95
09-22-93
wG
BAKER
DRIVE SYSTEMS DEPT

SALEM, VA. U.s.A
I=:I
F,~ANE
=:D~E
33SA3511DA
CJNI.[."J $H.
SH. NO.
Fig re 8-1. GF2000 Dc Generator Field Exciter Hardware Drawing 336A3511 (Sheet DA)
B-5
BI006008
GEH-6148
Notes:
B-6
BI006008
GEH6148
APPENDIX C
ELEMENTARY DIAGRAM, C AND C EXTENSION FRAME EXCITERS
C-1. INTRODU~TION
Figure C-l conte ined in this appendix provides a sample elementary diagram for C and C Extension (CX) Frame
GF2000 Dc Gen rator Field Exciters. On the elementary diagram, internal and external wire numbers identify the
elementary diagrflIIl sheet where that wire originates. For example, wire number BBlO originates on sheet BB, line 10.
NOTE
Exciter elen entary diagrams may change with product upgrades and revisions. The elementary
diagram co tained in this appendix is current as of the issue date of this manual.
Table C-l summ lU'izes the contents of each page of the elementary diagram.
Table C-1. GF2000 C and CX Frame Elementary Diagram Sheet Summary

Sheet
Description
BA
Ac power circuit
BB
Dc power circuit
BC
Ac control circuit
CA-:::B
2TB - Control feedback inputs and interlock terminals, 115 V ac output
CB
Meter driver and motor field supply gating
EA
Control board interconnections (LTB, NTB/3TB, RTBA, SDCC, SLCC, and SPC)
EB-E C
Ac and dc feedbacks
EE
SCR gating
FD
SCR bridge
GA
NTB/3TB - Analog and digital I/O
HA
NTB/3TB - Digital I/O and RS-232C link
JA
LTB - High-level digital 110
KA
RTBA - Relay I/O
C-l
BI006008
GEH-6148
A
01
I
01
03 ,
05
05
07
07
AC PO\JER CIRCUIT
09
09
CB
I p~
Ll
~ , O----'Cfr-"-'+-r~__._-r~-~
I
11
**
r - ( 645J
13
cU2
~_
cwcK21
,--'--(BB10J
11
13
T2AI
IS
15
**
r-e6463
17
~~
19
F'J3
17
K3'
19
21
21
23
23
25
25
27
27
29
29
31
31
33
33
35
35
37
37
39
39
41
41
43
[6071--------
45
[6131
47
[615:-------+--1--
43
--------+--.
47
BF
49
49
51
51
,--
53
***
55
BLO\JER
2TB
--'<1] (OlCA351
2TB
---,<IJ3 (OICA371
CENTRIFLiGAL SwITCH
(CLOSED \JHEN BLO\JER
IS RUNNING)
57
59
53
55
57
59
63
63
65
65
67
69
71
73
*
* ,.
***
EXTERNAL CIRCUIT BREAKER.

CONTROL PO\JER MAY COME FROM Ll.2,3
OTHER\JISE IT \JILL BE SEPARATELY FED.
USE ON CEXT. FRAME CONVERTER.
75
77
79
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet SA)
C-2
03
BI006008
GEH-6148

H
!
01
03
03
IV
05
07
THYRISTOR BRIDGE CURRENT
05
C01CA59J
07
C01CA6]]
--------1---- -,
I'"
1
L] i~c;
09
+ PI
+ ~ _
CBAllJ -'-'II--~"=::;
. } - ; - - - - - - - -......-----------,
11
INTERNA" OR
EXTERNA" SHU~T
I
I
lOOMV IRA TE!)

13
FIELD
cO'''",
15
09
....
i3
CUiPU7
MODULE
19
rI
150
I'
tip
21
23
25
27
[BA20J
L ------ -
P2
i----- -
I -
SVAA!
17
~ ::iENERATOR
ARMATURE
i I VD --A-E
II
)I<
151.
C01CA21J
ATT.E~).,'L
19
i+
21
[01CA19J
''---_---.J
23
25
27
GENERATOR
*}
29
. t\
~I-J
FIELD EXCITER
]7
ARMATJRE
CURRENT
(\,
: SVIA
29
1+
f 'f-----iy-+----iisolAn,'::Q' C01CA311
31
31
1 * * * ,CG1CA33J
33
33
35
LOOP
CCNT*ACTDR
37
r-=-
[01CA43J
35
DC ,OTOR ~' :01(A45;

SHUW FIELD'
37
M,
39
+
I-_-~-:
39
41
41
43
43
r
45
I
SVAA
49
51
45
I I
Ul~~
47
MOTeR ARMA TURE
47
V:]L TAGE
[OlCA47J
[J1CA49J
49
51
53
53
55
55
57
57
59
59
61
61
63
63
65
65
67
67
69
69
71
71
73
73
75
75
)I<
77
)1<)1<
79
)I< )1<:0:
EXTERNAL TO
Co.RE DEVICES
77
OPTIONAL
REQUIRED 1F SHUNT IS MOUNTED
ON REMOTE UNEPANEL
79
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet BB)
C-3
BI006008
GEH-6148
G
01
03
~
CONTRe-
POIJER
05
46DVAC
CON,ROL POIJER
07
FUI
230VAC
CONTROL PCIJER
'"
rU2~
FU26 '"
09
'"
II
13
15
12
17
19
21
~B
BIY
B/IJ
23
230VAC
25
23DVAC
CPi
CPT
460V CCNNECT:DN
27
230V :oNNE:noN
29
31
115VAC
33
r--n
4CVAC CT
~X2
r"~ ,,,,,,n-1~'
35
37
39
~fl~
I
FU3F
41
43
5Al
T
[0IC29]_1
45
I
47
I
49
51
-i,
J,
-!,
5
CPil.- ON DCFB
53
55
57
59
61
63
65
67
69
'" FUSE FUl,2 SELECTED BY PRODUCT LINE CHOOSING TRANSFORMER PRIMARY VOLTAGE
(230VAC CR 46DVAC OR 575VAQ)
'" '" CONNECTlONS TO FU1,2 oP7IONAL-DEPENDING ON VOLTAGE
71
73
75
77
79
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet BC)
C-4
BI006008
GF2000 Dc
Gen~rator Field
GEH-6148
Exciter
Q
R
01
01
2131
03
03
-0-
2TB2
05
-0-
05
07
THYRISTOR HEAT SINK THERMAL SwITCH

090'F)
-o~---'=--'----[OlFD74J
07
09
2T34
-o>----------[OlFD77J
09
2T33
2T35
II
11
-0-
2736
13
13
2T37
15
15
2T38
17
GENER TOR
ARMAT RE VOLTAGE
19
:01BB2 ]
21
[01BB1
17
2TB9
' 0
J--------\~i_: 2_T-;:;~~10------------\'ci_;
__
VM1A
[01EB28J
19
V:..M
cc,1"'-3 [01EB30J
21
2131:
23
23
2TB12
25
25
27
2TB13
115VAC GROUND
o>---....:;;:...;..;..:.::...===---____ill-----[OIBC36J
27
29
2TB:4
115VAC QUTPUT
X
0----'-==c..;:.=-"-'-----\,Vl-----[013C43J
29
31
GENER TOR
ARMAT RE CURRENT
[01BS3 J
33
[01B33 J
++__2_--;:;,B~15
____i\_+----"IA-"';..P'=-.-...:..1 C01[C08J
--------\~!_' 2_T-;:; ~16
-\~i- _;. Ic. A: .:IP. .:L:. .-_=_2
__
[ OIE:13:
2TB17
BLOwER SW
0 - - - - = = - - = " - - ' ' - ' ' - - - - - - - - - - - [OIBA53J
35
2TB:8
3LOwER SW
0----===--'=---------[OICA3?]
37
2TB19
47
49
35
37
39
2T _2_0
-_.:..M::.:,A~C:...PL=----'-I [01EB53J
41
MOTOR F1E'~D CJRRENT

[01333 J
++-__2_T"'3_2_1
+-+__I;..F-'-IP
ccL:...-...:...I [01E363J
43
41
45
CONTACT OR DRIVER
33
MACPL -2 [01EB55J
39
43
~,AIN
31
[01B336J
MOTOR ARM ATURE
[01BB4
[013351D
VOL :AGE
2T ;22
2TB23
IF1PL -2 [01EB65J
------.,,-'---0'-------------\;----'--='
~
t ;
-:
2TB24
MOTOR #2
ARMATURE CURRENT
27325
51
2T:26
53
45
VM2A
[01E332J
47
,-
VM23
"'-COIEB34]
49
IA2PL-l [01EC20J
I 2P 2
A L- [01EC25J
~,
0
51
53
2TB27
55
55
2T328
57
59
GENERA OR
FIELD URRENT
57
2TB29
[01BB06
2T;30
[01BB08
IF2PL-l [01EB6n
59
IF2PL-2 [01E369J
61
2T331
63
63
27332
65
65
I
I
67
67
I
I
I
I
69
69
I
I
71
71
I
I
73
73
75
75
I
77
77
I
I
79
EXTE NAL TO CORE DRIVE
I
I
INTERNAL 7Q CORE DRIVE
79
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet CAl
C-5
BI006008
GEH-6148
D
01
03
01
llPL04
llPLX
(4
11PLX4
' " I1PL05
(5
llPLX5
~ I1PLD6
(6
llPLX6
' " I1PL07
(7
I1PLX7
IIPLDB
llPLX8
I1PLX3
C(~
IlPLX2
101EA27J
03
Z GENERATOR FIELD
05
07
CURRENT
05
% LOAD
07
Z SPEED
09
11
13
lS
09
Z ARMATURe:
VOL TAGE
13
15
I
I1P~X1
:~-==-'----i:---L
17
11
19
17
19
INTERNAL TO CORE
EXTERNAL TO C2RE DRIVe:
21
21
23
23
2S
25
27
[DIE B38,
29
31
33
27
""_-"1F-,P-,L:.:l-rg _ _:,;----'l~F.:..P=.L"'Xl'__ _
IFPL2
29
1FPLX2
IFPL3
1FPLX3
IFPL4
IFPLX4
31
33
!:il MOTOR FiEl); SUPPLY
3S
LFPLX5
37
THYR1STOR GA TlNw SIGNALS
IFPLX6
39
IFPLX7
41
FPLX8
35
37
39
41
43
43
45
45
47
47
49
49
51
51
53
53
55
55
57
57
59
59
61
61
63
63
65
65
67
67
69
7i
71
73
73
75
75
77
77
79
79
METER DRIVER &. MfiTOR FIEI D SLJPPI Y GATTNG
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet CBl
C-6
BI006008
GEH-6148
01
01
C3
03
07
IARCPl
s,-cc
05
[OlGA 70J
07
09
09
11
I
7Pl
13
; 3Pl
[lCPl
13
1,
15
17
15
17
13P~
19
19
21
23
7PL
21
I
I
23
25
25
n-+-__+-__-:;11"-P.::.L-'-j41 METER
[01CB03J'
_ _ _..".-_-L
27
/ \
1
29
11Pl5
II!
31
lH
35
39
~1Pl [01EC58J
27
I'
I
I,
I
31
29
33
11Pl7
---;~---+---=--=--'--1ME~ER
37
IMETER 2
!'-++__i -_ _-'-'1l'--P"'l6'--i! ME TE R
33
05
~"[01EC54J
35
37
" i'l
11?L8
COM
i SPl
41
39
41
43
43
45
45
47
47
49
51
53
55
57
59
lOPL
RTB
SEE SHEET
KA roR
CONNECTION
DETAILS
n
!
LTB
6P~
3TB
SEE SHEET
JA FOR
CONNECTION
DETAILS
49
roc
51
53
FOR CONNECTION
DETAILS
SEE SHEET GA So HA
ISPl
55
57
14Pl
[01::C52J
59
61
61
63
63
65
65
67
67
69
69
71
71
73
73
75
75
77
77
79
79
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet EAj
C-7
BI006008
GEH-6148
01
01
AC
DC FC""EpBACKS
03
05
03
DCFB
THYRISTOR BRIDGE
AC VO~ TAG ES
07
Vi
01FD30:
OIFD3,J
09
V2
11
CIFD40J
13
07
IIPL-Il
VCO
09
05
TCQPL
VI-V2
I
SIJI
V3
I
I
II
I
15
17
l:J
V2-V3
SIJ2
I
I
VI-V3
SIJ3
JP:
TCDPL
3
IPL-29
2
13
01
:5
7CDPL
11PL-12
VCO
:9
21
19
THYR:STOR BRIDGE
DC VOLTS
[01
23
[01 F005J
29
31
33
I
I
P1-02
SIJ4
P2A
'
25
27
PtA
FD071ll
VCO
VMIA
VMIB
f\
VM2A
VM2B
- xi
[0ICA21]
MOTOR ARM ATURE
VOL TAG~
[0ICA471
[0:CM9J
VMIA-B
SIJ5
25
vco
29
ANALOG
VM2A-B
SIJ6
lPL-19
39
33
35
IFPL
r-i>---;====;---------"--='--i-[01:B28J
"I
FIRING
41
45
47
IPL-34
49
51
IPL-35
53
55
IPL-36
57
-K
I
-KI
[01CM31
[0ICM5J
IFIPL-I
- X IF1PL-2
[01CA59J
[0ICA611
- X IF2PL-2
VCO
53
[CICA391
55
MACPL
2
3
KI
(P24V) I
57
MACPL
59
#1 SHUNT VCO
,3
IPL-9
65
IF2PL-I
#2 SHUNT vce
'"'v
67
lPL -40
veo
69
- ON
~ON'
~
SHEET EC
75
77
79
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet EBl
C-8
51
[OlCA411
THYRrST OR BRIDGE
73
49
61
CURRENT
W,CPL
1
MOTOR F; ELD CURRENT
-'-'":.....::..L-------'--[01EC69J
I eNP'
[01EC651
CNPL-2
MACPL
59
71
43
2FPL
IPL-18
47
69
42
NPL1,2
45
37
39
PPLl,2
NRX
FIRING
43
67
31
1PL -06
NRP
,5
27
IPL -39
v'
37
63
23
IPL-37
GENERATOR ARMATURE'
VOLTAGE
f\ I
[0ICAI9]
35
61
21
IPL-13
71
73
i
I
BI006008
GEH-6148

P
R
01
01
LCFB
03
05
C7
09
11
13
:;
21
"
25
03
CONT, ;-ROM SHEET EB
II
~ ~
CUR t::NT
--+-1.:.;1A.:.;I_PL=..-.:.;2'--__+--<
[01 CA 3J
JP4
1~,-,""
[OlCA 31 -
!SO'l
~:11PL-08
L-
09
11
II
-6~
3"
15
::
17
~I1-<t__:
JP:;
19
':
! ":'
II
07
"
":
I, ~;~
f----i;5~'
Ph!
_y'-o~
- - --t-"IA.:.::2,-,Plo...-=-2
~')J
UP 7
---------,-1="-"-=----i~~'----_.
"'Wc~1 ,::~w"
!I
rn~~~,----~l~r----v~--w------+-O
[OlC 311
+11A1Pl-1
GENERA OR ARMATURE
[OlCApll
~5
J03
05
IWHO
21
23
I5--------.J
25
JP9
JPj]
27
29
FwD
REV
GPA
lPL
31
27
!
5PL
I
I
29
I1--------------------=--.=-.,.- [01EE48:
,
1
31
33
33
ACCT
35
IFCEUE~~~~TK f---'A..::.N"-A:::L::;OG'-I ATTEN,
!-'l:.;:C,--P=-l
.....,
37
Sw7
"J
39
[Dl BC3 7J
I
CPTPl
I'
--+----='---=-------------:1
7A FU2
1~3
41
I-=--
43
I +5V
45
+15V
47
I
I
49
CR5,
a
a
(To
(To
-15V eTP
+24V (TP
-24V (TP
35
-.:l""Pl=..-..:.l-J
I,
H tr-----"-"'--'=--+I-
37
39
41
COIED37J
CR55
43
P5)
P15)
N15)
FU2)
FU3)
45
III
51
"ec
------=--=+-1-
OPTIONAL
MeTER PANEL
47
[NC]
49
5,
__________
4?.:.;L=+I_ CCIEA58J
53
53
2PLI
------------==+,[01 EA36J
:pJ
55
55
- - - - - - - - - - - ' - ' ' t _ [01 EA2 BJ
57
57
CNP,J
59
61
TCOPL
59
61
63
63
, - - [01EB50J
lTl
65
67
69
71
73
75
65
CNPL-l
~~c
I
I
FUI
05A
67
CPTPl-2
:::':~2
[01EB49J
'------------~))----4--P~=..--:5,.. [01GA05J
.-------------------~1:.1
')-"------=--=-- [OlGAO?]
VAC
'"
W
79
71
~}CARD
73
I
: RA:K-MUFF;N
~
77
69
<_115_>1
*'
FANS
75
* CEXT
OMIT FOR 77
;-RAME
THYRISTOR
BRIDGE
79
rAN
igure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet EC)
C-9
BI006008
GEH-6148
A
01
01
03
03
05
05
07
07
09
09
11
13
13
15
15
17
19
:9
21
21
23
23
25
25
27
THYR:STCJR GATE PULSES
29
PCCA
POwER SONNECT
31
SCR F
33
SCR 3F
FORVARO
THYRISTORS
GATE PULSE
TRANSFORMERS
43
45
33
2FPL -2
IO:cD20J
SCR 4F
SCR 5F
49
SCR 6r
53
<1
[OF-046:
43
5FPl...-21
55
SCR lR
SCR 2R
51
53
65
67
SCR 3R
REVERSE
THYRISTORS
GATE PULSE
TRANSFORMERS
71
5;
(OlFD44]
53
1RPL -2
[01F;)5:1J
55
[01,052J
57
2RPL-2
[01F050J
59
[0IF052:
6:
3RPL-2
[OIr050J
63
i
4RP,--2
[01,D52J
65
[0;F024J
SCR 4R
59
[OlFD46J
3RPL-l
45
[01,046:
<9
6:-Pl...-2
2RPL-l
~ClrD4t.J
47
lRP:"'-l
59
rCIFD44]
6FPL-l
57
39
[01FO'8J
4FPL -2
5FPL-l
51
[O:FD2CJ
4FPL -1
V
5PL
37
3rPL-2 1
SIGNALS
ID1EC30;
35
[01F018J
3FPL-r!
THVRISTOR GATING
31
[OFDi81
2FPL-l 1
39
[OiFJ20:
SCR 2F
37
29
:FPL -2
1FPl...-:' :
35
4RPL-l
5RPL -2 i
67
[01F026J
69
[OlFD24J
1
SCR 5R
5RPL-l
71
IO:F026:
73
75
27
73
SCR 6R
751
77
77:
79
79
i
I
Figure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet EEl
C-I0
BI006008
GEH-6148

D
Dr
THY
,r
6DDVA MAXIMUM
REVER ING
03
05
07
09
11
13
15
17
[01EE32: .:.:R+i-_...---_ _--;

19
'"
I SCR
Zs. iF
[01EE30: ~
21
23
[OLEE661'"
,,-+f\+-,
SCR
4R
_+-_-J
25
27
29
31
33
43
[GIEEJ R
45
01[E421 '"
47
49
01E[54J
SCR
4,
SCR
1R
,,-"'++_+-_-1
51
53
55
57
59
61
63
65
67
69
71
73
THYRISTOR HEAT SINK

THERMAL S"'ITCH
75
~----------[01CA09J
77
79
igure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet FD)
C-ll
BI006008
GEH-6148
r
01
3TB
OPTPL [OlJA62J
0.5A 2 1
----<l-p'---=C.:...r::.Xl'-o-+-a:::~+__
4PL-4 [01EC69J
1l0VAC
8;.::5--.:.;X.::;2_-<>--+-_--<0-- 4PL-5 [OlEC71J
RLYl
89 GR-
__r::
84
GNDI
80
GRCI
.LJ
*~
*
*
!
GND2
86 GRC2
I,i
I
42
CTLNl
44
CTLN2
1 AMP
MAX
EOA
09
13
15
17
* I--<,..:E=.,:O:..::B,--_.::;5-1
19
* f-..<,,...:E:..::C"-":...._--=:9_
i
*h
IEDM
,
*K2
07
A
--<r'/c.:E"'Oc.:_---=-3-j
f-,
* N>-/c.:O
",E;.::B_,--7_
88 GNC2
05
82 GNCI
90
3TB
21
23
25
27
29
73
74
31
33
35
37
40
XSTP
30
Rr24
39
41
43
63 REFP
65 RErN
64
-j5V
93
VC3P
91
VC3N
46
O'
45
47
I,
49
51
53
... *
*
48 P2
50
P3
52 P4
51
is<
NOTE, MET2
ALSO USEO
TO DRIVE
LOAD CURRENT
SEE SHT. EA
ASPC
,*
N:>----ME=-Tc.:1_-'5c..4--j
55
57
59
* I--<:,...:C",O.:...M_ _6::::8'-1
ANALOG
INPUTS
61
63
TX
1-'4..:;9-,,-D..:,.V:.:.M-0--1*
IRX
65
67
69
~~ ~~~~B
CARD
[01EA05J
71
GND
.-..,_7.::;2,---2=-4--,V-O--I*
**
BNC
.-..,..:;1O,--::::CO::;.M'--<>--I*
I
* * RG62
USE BELDEN
A/U TYPE
**
75
!1 ENe
22
GAUGE COAX CABLE
Figure Cot. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet GAl
C-12
73
77
79
BI006008
GEH-6148

A
01
DI::iITA!
liD
' INK
& RS232
01
-,.
03
05
07
09
3TB
j14
Cll
1:
CI2
118
:13
20
CJ4
22
CI5
24
:;6
26
CI7
128
CI8
132
RF24
59
TOIN
61
TDJOt..:T
57
MSSY
68
CO~
11
3TB
0---"*
15
1*
*
1 P,U,
-Q-
RIND
17
RiC
131
RINC
15 1
\",C-'+--0'-''::':'::'--'-'--1
I:
1
PRDGRA~,MABLE
DIGITAL
CONTROL
INPUTS
RLY2
-Q-~
RUN ,;CT
r
!: ,I
ADDR~804
1 P,U,
17
05
RL YI
AVAILAB,-E
13
03
R2C
19
R2NC
21
II
21
* )
25
27
29
31
33
35
37
FA
FB
1 PU
TlMERI
COUNTERI
:NTERRUPT
INPU-:-S
EXSY
10
FCCM
RL Y3
*
*
,
*
1 P,U~ ~
RS422
AVAILABLE
4"
I.
1 P,U,
':
If
47
ICOM
' '
I
49
51
!::j
R232C
R4:
31
R4NC
33
33
35
55
37
39
cR5No
371
41
oJ
15
AVAI,-ABLE
1 P.U:- '"'
24V
~I
-y
47
MSRF
47
I
'
RD
27
3:
~"
~lt
I.
53
25
35 1
.1
23
R4NO
1::1
Ii
45
:51
25(.1:3
19
29
I
COMPL
43
15
AVAILABLE
39
'1'
13
-Q- I R3No 29:

;-'I~
I: I ~R3C 25 i
I: I R3NC 27
~*
12
11
21
AVAILABLE
23
09
17
I
I
19
07
49
51
53
55
57
57
59
59
61
61
63
63
65
65
67
;7
69
69
71
71
~ y~ il~~ A~;~V~~iNTA:T
73
30
75
:-:
).JA
RATINGS'
OMVDC
LO\J LEVEL SIG \.lIRE.
73
75
77
77
79
79
igure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet HAl
C-13
BI006008
GEH-6148
I
I
0:
II
::
LTB
LIB
07
}6U-1
IN1-
~T
iN2-
17
',',}6U-2
~ }6 U-3
21
23
i ... _
6 LO-3
~-t----t
25
I
I
OTlN::
:,:
"eo"
OT2NO
onJ
51~
19
~~-"-4'
15
OTlCMi
----~
I::
6 LO-l
i:
CT3N8!
!~
27
21
23
25
27
29
I-"'IN,-,-4+_ _-o-
3;
'1
"-'-'---0-IN41-
6 LO-4
111
J
I
33
6 U-4
29
DT4CM
---1'
~T
31
OT4NO
33
OT4NC
35
35
~,
37
39
41
43
}6
U,
L:-6
I-"'IN",-S-_-o-_ )
49
rll--- i: : : :1
T
'rl~
IINs+
r6
'
~~
45
47
Ti
~ 1---~L'-+!'
37
39
41
43
45
47
-o---"-OT,-,,,SN.::;,.O
OTSNC
5:
I
53
'i
55
(6 Ll-7
I-I:...;N_7---o----i
57
r
15
59
6:
IN8+
S3
'-'-'''---<>----i
,_IN8-
S5
I
J' 6 L! -
6 LO-7
O~L
I) i
H
I
!1l5V~~tROM
I ~.
V
1 : ~'l
I'
(i-IS)
[01GA04;
[0IGAD4]
-;PL
~)
67
OT7NO
~+-O----=-CT-'-'--7N-"1C
I L.4
OT7C~.
r ; .i
"'-i-"i;----T
1:-]'N7+
RPL TO HB
I
[OlKA71]
S9
71
73
75
OT: THRU OT7 CONTACT

RA TINGS'
e,s
A
2,0 A
77
79
@
@
1l0VDC. 125VAC
30VDC
= STATUS S NAMES
Figure C-1. Sample lementary Diagram, GF2000 C Frame Exciter (Sheet (JAJ
C-14
53
55
BI006008
GF2000 Dc
Gen~rator Field
GEH-6148
Exciter
C
01
01
I
RTB
03
RTB
03
RTB
OPTPL
~2
05
:51
115V
11
K20A
07
09
1~
05
--'----------'
1,
07
~o
09
11
11
13
13
15
15
17
17
K21A
19
21
---i~~-----.f
JP2 Li
~..
~-~
23
25
27
K22A
19
K21
;)
29
K212NO
12
K~12C~ d
21
14 i
23
K212NC
IK?21NC
25
161
~-~
:L-t
IK2.21~= 18
27
29
19
31
31
20
33
33
35
35
K231N~
37
37
K231CM
~ -1;,-,_ _+K.:.:.2;;:3",IN:..::C,---':.2-=-j5
39
T ,~--j-!
IT
K232CM
27
~ -~t---j'-K"C2;:':32=-N:..c.C'--=-2~8"
43
45
30
~-T
49
:L -t'___-+K'-2o-4:.::I'-NC'--...;3"'-,2!
K241CM
47
31
49
K2 4 _ _--I.'-K2o-4:..::2...;N=-O----:3,-,,-,3
51
34
H'
iK242CM
~ -~'-----tlK",2o-4:..::2c.:N.::.C----:3""15
53
55
51
53
55
K251NO
-,l,
57
13
61
63
JP6
j ~
'
II
65
67
43
K26A
381
57
RPL TO L 0 / 4
15B
2 JP7
[eJA67J-<
73
75
CONNEC~
RP'"
ON KEy,
~'___ _+K"'2,:.5=-1~:.::'C-=-39'-j'
59
K25 ,--_
K251C~
_+K",2,:.5=-2N.:.:O,--...;.4",0
~I --T'---\-"'C='--'--'-j
K252CM
41
61
L..-i;
63
1,1<252NC
42
44
'----+-='--'---"1
69
71
371
~ -1'
59
79
43
45
K241NO
47
77
39
6
K,-2",3:.::2,-N=-O---,2'-=-1
41
'I
K~6
~
K261NO
65
-t-'_ _+K<26=-":.::C...;.M_.:..45",
~-t'----+-=-'-'---"1
K261NC
T B TB CARD
67
69
71
73
75
77
79
~igure C-1. Sample Elementary Diagram, GF2000 C Frame Exciter (Sheet KA)
C-15
BI006008
GEH-6148
Notes:
C-16
BI006008
GEH-6148
APPENDIX D
ELEMENTARY DIAGRAM, G FRAME EXCITERS
0-1. INTROOUCIrION
Figure 0-1 contan ed in this appendix provides a sample elementary diagram for G Frame GF2000 Oc Generator Field
Exciters. On the e ementary diagram, internal and external wire numbers identify the elementary diagram sheet where
that wire originate. For example, wire number BB09 originates on sheet BB, line 09.
NOTE
Exciter eleme~tary diagrams may change with product upgrades and revisions. The elementary diagram contain ~d in this appendix is current as of the issue date of this manual.
Table 0-1 summat izes the contents of each page of the elementary diagram. Table 0-2 lists 2TB connections for the G
frame exciter.
Table D-1. GF2000 G Frame Elementary Diagram Sheet Summary

Sheet
De~cription
BA
Ac power circuit
BB
Dc power circuit
BC
Ac control circuit
BD
Fie d exciter plug
CA
2TI - Control feedback inputs and interlock terminals, 11 5 V ac output
EA
Co trol board interconnections (DCFB, LTB, NTB/3TB, RTBA, SDCC, SLCC, SPC, and meters)
EB-EC
Ac Find dc feedbacks
EE
SCI gating
FB
SCI bridge
D-l
BI006008
GEH-6148
Table D-2. Terminal Board 2TB Connections, GF2000 G Frame Exciter
D-2
Terminal
Description
1,2
Not connected
Thermal switch (190 OF) - optional
Thermal switch (1 90 OF) - optional
5-8
Not connected
Generator armature volts (+)
10
Generator armature volts (-)
11
12
13
CPT 11 5 V ground
14
CPT 115 V
15
Generator armature current shunt (+)
16
Generator armature current shunt (-)
17, 18
Not connected
19
MDA coil driver
20
MDA coil driver
21
Motor field current shunt ( + )
22
Motor field current shunt (-)
23
Motor armature volts (+)
24
Motor armature volts (-)
25
CFB motor B ( + )
26
CFB motor B H
27
MDB coil driver
28
MDB coil driver
29
Generator field current shunt (+)
30
Generator field current shunt (-)
31,32
Not connected
BI006008
GFlOOO Dc Gemrator Field Exciter
GEH-6148
r
JJ
01
J3
03
05
05
07
***
DSIJ
09
07
**
AC ?OIJfR 'IRrUTT
r- [BCOIJ
09
rU1
S,;,O-=l_--K"-I......
I------------------1!
11
13
K2
C [B~:3]
'[
~OIJ[R
CONVERTER
rU2
~[BB09]
13
S~..:::;Jl--=.......----------------..J\ ~
15
17
I rOR
rU3
~~:Ol_--"K"-3-------------------11
19
21
15
g~JAIlS ~
SHEET
cA-rB
11
P2,
[BBll]
19
L[EB23J
23
23
25
25
27
27
29
29
31
31
33
33
35
35
37
37
39
39
41
41
43
43
45
47
47
49
49
51
51
53
53
55
55
57
57
59
59
61
61
63
63
65
65
67
67
69
69
71
73
75
71
* '"
'" '" *
CO TROl POIJER MAY COME rROM L1,2,3 Ir VOLTAGE ACCEPTABLE

OT ERIJlSE IJIlL BE SEPARATELY rED TO CPT rUSES
73
OP IONAl
75
77
77
79
79
f [Jure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet 8A)
D-3
BI006008
GEH-6148
r
01
01
DC PO'-''"R "IRCUIT
03
r-e-
05
07
R!
09
.?'
]l[BA1IJ
r--G-
03
THYRISTOR BRIDGE CURRENT
05
WIEB67J
071
[0IEB69]
I ' _
09 i
DA1
~~r-~-~-~-T---r'::~o'''-'----------''''i~---------I---1----
13
FIELD
CURRENT
(INTERNAL
OR EXTERNAU
:,
IS
SHUNT
FIELD EXCITER
17
OUTPUT
MODU~E
19
-'- RCB
I
450!
i. .
'C
'
15
t--+-c::r-~.--f---f>'-[01 EB29:
~15C I
450T
13
*** I '
GE:NERA~OR
21
AR;V1ATURE
VOL TAGE
UD
t--+-c::r--'"-f--'-'f- [01 EB2 8:
!l.
23
25
27
23
l-------I------.J
P2
[BA20J
11
GENERATOR
ARMATURE
CU~RENT
29
31
31
33
33
35
37
MDA
LOOP
CONTACTOR
39
DC MOTOR
[0IEB63J
35
, - C01EB65J
SHUNT FIEL.8t>d>_
37
C01BD20J ~(OlBD37J
41
41
43
43
45
45
***
47
MOTOR A~MAT'JRE
VOLTAGE
'------+-----+0'\--- lOlEB32J
'---------1Q+--- [01EB3/.]
51
51
53
53
55
55
57
57
59
59
61
61
63
63
65
65
67
67
69
69
71
71
73
73
75
*
77
79
75
EXTERNAL TO
CORE DEVICES
,. ,. *
,. *
77
O?TIONAL
79
REQUIRED IF SHUNT IS ,YOUNTED

ON REMeTE LINE?ANEL
Figure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet
D-4
47
aa)
BI006008
GF2000 Dc Gemrator Field Exciter

A
GEH-6148
G
"
CPT CONN:::CTICJNS
**
D:
[B:D='~
D1
D3
CBAI3f----j--t--------------_
D3
05
07
i
09
11
:3
D5
I",,",
"""'
11
13
,-<~
"L f, t'
19
21
LJ
23
B/w
B/R
23DVAC
25
f"
IB/Y
'----v-..v_-_ _--ilIB
23DVAC
21
23
27
29
29
~B~/w
3:
1'1
4.6A
i]
33
35
CEC41
39
19
25
27
37
D9
:5
17
D7
----.j CP
6
PL
I Ll~B
,,)
1 2
[BE251
31
33
CPTFU3
35
6'jP
[BE27J
37
39
41
41
43
43
45
47
47
49
51
49
)I(
53
460VAC CONNECTIONS SHOwN ABOVE

- FOR 23CVAC - REMOVE C:NNEC~ING ~UMPER
BETwEEN 9-7
CONNECT AS FOLLOwS,
- 9 TO BonOM F"U2} ON
- 7 TO BOTTOM FU:
CPT
-
51
53
55
55
57
57
59
59
- 600VAC CP' PIRMARY
CONNECTIONS
61
63
CPTFUI0
FU2
~ID
65
63
~12
65
CPTF"U2
~B
67
CPT
69
**
67
69
CONNECTIONS TO FU1,2 OPTIONAL
71
71
)I(
73
61
* *PPTIONAL ~ NOT AVAILABLE ON C AND G F"RAMES

73
75
75
77
77
79
79
figure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet Be)
D-5
BI006008
GEH-6148
D
II'
:~
03
05
PANEL MOUNTED FIELD SUPPLY
07
, 09
III
,
05
07
09
FIELD EXCITER PLUG
13
11
13
15
:5
17
17
19
19
21
21
23
23
25
25
27
27
29
29
31
31
33
33
35
35
37
37
39
39
41
43
43
45
45
47
47
49
49
51
51
53
53
55
55
57
57
59
59
61
61
63
53
65
65
67
69
69
71
71
73
73
75
77
79
Figure D-1. Sample Iementary Diagram, GF2000 G Frame Exciter (Sheet BD)
D-6
BI006008
GEH-6148

M
C
01
03
I
I
I
05
07
*' * *
SPCA
09
I
i
i
11
IARCPl
*** I
LCC
110Pl
"**
ARCNET
OR
DlAN
BALUN
I
I
'-.1
03
05
07
I 09
~--I"c I
"
3Pl
7P;"
13
I
15
1
1
,3
:5
17
19
21
METE:i;,I--+I
-~.
23
25
27
29
31
~,
I
~
. L-=-JI-.
'Ii,
33
35
eET4
II
37
39
PC
\,;-I--I----'-'::..lP;=..l4'--J""U,, ,
1-4-1--'<'PLX
U '"' i"'""
112(H
I ::
~-"<:: I,
I::
I ,ec
SDCC
DCFB
I 5P'_'
.:'CCI
I'
: !
llPl6 :METER 3
~!
~1,--::"_TER~4--r-~I I I
17
tt ..
41
I'"
43
45
47
I'"'
'I~ :~
I ::
I:~
33
35
3
TJ :
1
::
[SPl r 1-0P-L------+I-sp-c---+1-6-P_---+- - - - + - - - - - - ! ::
49
I,
* *' *'
51
II
LJI'- - _~
i l L IE
* *' *'
i '"'cc
53
55
57
59
3IB
4Pl
51
53
55
57
59
61
61
63
63
65
65
67
67
69
69
71
71
73
73
75
77
79
75
*' *'
* * ,.
=:
NEL MOUNiED
77
= E 2000 oNl y
PTlONAl
79
,. "gure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet EA)
D-7
BI006008
GEH-6148
:~
05
07
DCFB
09
V2
,FB,D,36J
V3
CFB,D,40J
V2-V3
SI,/2
13
EPL
17
19
GEN FLD
(~.)I
BRIDGE [B Al 3J
,r PIA
23
VOL TS
25
GEN ARM [BA211:t1

VOLTS
2 TB
27
31
33
35
-'-"-'-____
(_)'
[0IBB21]2
29
I
I
IS
21
TCPL
VI
[FB,D,30J
' II
[
[CIBBI5J
Ib
P2A
Pl-P2
I'
SI,/4
----------1
'!
vco
IPL-19
NRP
ill
FIRIN"
Ii
IPL -18
45
47
IFPL
i
NRX
~~P
f-_ _........:1'-p-=-'---=3:.::5_1
57
IPL-36
KI
i=Vl
-K
I
I
[OIBB05:
69 WlBBe7]
2TB
9 (+)
ib
2TB
30
(-)
GEN FLD
7'
CURR SHUN
45
CPTPL-l
0 K2
47
4PL-I
49
i/
w,,-'-.----,2
53
MACPL
IR
2
2TB
19
MACPL
3
-
2T B
28
,KI
(P24V) I.
MACPL
4 + R
1,/
t
I
IF1~\.. -1
2T B
2'7
1?L-9
I,/;IF2PL-2
VCD
63
67
IPL-4Q
69
75
77
CPTIDNAL
Figure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet EB)
D-8
59
65
il2 SHUNT VCO
RIIF2Pl.-l
CONT, ON SHEET EC
***
57
ill SHUNT VCD
i
VCO
w IFlPc-2
73
79
51
61
R
(-) I
65 [0IBB35:
43
TB
21 (+)
'",2
39
41
I,=-,=-,=-,=--j,=--'
[BDI8:
-K HL..--;I__ e-=- +~-,:'-~_N" -':"~:- =~:"-~=--~=-_=~-_=M~-A~-~ P-_L~_4:1
37
I
K2
~,TR F LD
CURR SHUNT
2TB
35
NPL..1
~~---'---=--,
FIRING
59
63 [OlBB34:
PPL2
55
33
2~~1
.:cI'--=L,--=-34,--L..~~~~~~----<~
53
PPLl
I
1'-------,----,--="::---1
'
,....'
5:
I,
3:
IPL-06
NPL2
43
29
'
FlRIN"
67
27
ANAL""
VM2A-B
SI,/6
IPL -39
VCO
!
41
39
:PL -37
'-----"
VMIB
r'
MTR ARM VOLTS
PL-l3
SI,/5
2TB
VM2A
[0IBB49: 203:....0.(+..:.)----,.--+_=""--_
_---1
2TB
4
VM2B
[0IBB51J 20--.-:.(-...:)......,iH_="'---_
_---I
'Pl..-12
VCJ
VM:A-B
SI,/3
VMIA
(-)
(.)
Vl-V3
37
61
01 ,
BI006008
GF2000 Dc Gen prator Field Exciter

C
GEH-6148
R
01
01
DCFB
CoNT. FRo.M SHEET EB
03
05
AR
CURR
07
JP5
P'h
JP3
[OIB 29J2TB
1'0'5....:<_+:..,).-....:R+-"IA....:1....:P'-'---..:.1_--.~1
8~----<i>--~~---j--<
r,----,V7i'CCO- I
05
nH
I
II
i3
05
rfJ
HUNT
2TB
Yi
JP4
3 8 ~
A....:1....:.DL'----=2_--.~'--- ..i -
6....:<_-)+--=-1,/+,,1
[01 B'pOJ ['0:
03
Ii
r-
lil
09
P L-OB
-=-JP_7_?-,---".
LI
07
IS~L -=---=-----,
11
IL.
JP6
i5
15
17
JP1C
_J-6;l....:B_--.~
TB
i5
---Irll_~
f-J . I "" i'ec."
22o:5....:<....:+-,>.-_R"-I..:.IA....:2....:P"-C....:.l_--....
!
21
[~'I
y+:T~~
23
22Ti'-:-'-<_.:..>-j--....:I,/:..,I....:I....:A=.:2P.::L__:=-2_ _
25
JP9
rl ~p:r t ~Gr-I
~
JPII
27
29
II ~~3
IPe
31
21
23
-=--=----:
25
27
---"5:-;PL~t-I
1L
SPA
19
29
[0IEE48;
31
33
33
FCE~{~~NCTK' I!
35
-i"--'l:::C,'.::L'---
ATTE~,
37
35
--'-IP....:'-o.--..:.I_
_.:..A:-;N....:AL::;O:..=G'---
37
S'-I7
35
CPTPL
[BA38J -t--::....:.~---r----7 A FU2
-=-=-
41
39
H
)
CRSI
CRSS
I--~
----=:.:SQc....:Pco-
41
7A FU3
43
45
+SV (TP - PS)

+lSV erp - PIS)
47
-ISV erp
I +24 v
49
43
45
N1S)
(TP
FU2)
-24 V erp
FU3)
47
49
51
51
53
53
55
55
57
57
.
59
55
61
61
63
65
Li
69
65
"ec.,
1
----rI'I----1
--=F--::AP-"--L-7-
1<_l!S~
VAC
73
75
77
lIE lIE lIE
= OP
IONAL
67
71
79
~:~-:A-l)- ~ ~L~-i-l~= = = 1
-.1';
63
69
CARD
RACK
FAN
71
HEA~
SINK
FAN
(IF
REQUIRED)
73
75
77
79
} gure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet Eel
D-9
BI006008
GEH-6148
E
.<
II
01
01
03
03
05
05 1
07
07
09
09
11
11
13
13
15
15
17
17
19
19
21
21
23
23
PI
25
2TB9
e--
[NU]
?2~[NU:
27
pee
29
lFPL-211J
CPCCA)
31
SCR IF
II k
2FPL- 2 1J A
1
35
SCR 2F
37
2FPL-lIR
--=-=-':':I-"-+t-
IF _20]
31 1
IF _18J
33
[F _2JJ
35
CF _18]
_ _3_F_P~L_-2=-j,_IJ---r_[F _ 20J
39
FORIJARD
41
27
29
'Ii
lFPL- 1 R
33
25
SCR 3F
_ _.::3:..:FP--,Lo....-.:.:l. :.:.R-++_ [F _18J
37
39
41
GATE PULSE
TRANSFORMERS
43
43
45
45!
47
[01EC30J
SCR 5F
5PL
5FPL-lIR
49
47
C,_44]
49
6FPL -2 1.'
1
5;
SCR 6F
51
53
53
55
SCR lR
55
57
1
59
57
[F _50]
SCR 2R
2R,Oc-lIR
--;;:';"'~~--Jt'--[F_52]
61
3R?L-211J
59
61
----:""-.=...-0'+1-"-...-- IF _5 C)
63
***
REVERSE
65
4RPL-211J
GATE PULSE
TRANSFORMERS
67
SCR 3R
1 1:.:.
_ _::.;3R.::.P..::I.c..-'
t R - r - [F _521
--,-,-.=...-o'-'-"--",r,SCR 4R
63
65
[F _24 J
67
4RPL-l I R
---",,-=--o.l"-f+----1F _26J
69
69
5RPL-2;'W
--"-'--"-''+I-''-rx-[F _241
7:
SCR 5R
5RPL-lIR
71
1
--=-=--'+I"-rt- [, _261
73
75
SCR
6R~~~~:6R=P:L=-:II=R~:i~~::~:::
77
'--
79
73
6RPL -21w
* * * OPTIONAL
Figure D-1. Sample Elementary Diagram, GF2000 G Frame Exciter (Sheet EEl
D-I0
75
77
79
1
1
BI006008
GEH-6148
01
"Drne,
600
RE
AC MAXIMUM
RSING
<rJ
S
01
03
03
05
SH:JNT
......-',~= =~:_,
......_-...P..:l=-BU=-S:......._--.
r-
DAI
.=-..:.=
SEE:
SH,
BB
07
09
05
07
09
1:
11
13
13
15
15
17
19
[EE32~~'"
[EE36]
[EDOJ
[EE34]
, SCR
IF
21
1,1
[E[66] "---.
r-+---.J
25
lACS
39
[[E6Bl c.Rr-l:--+:c-:---<i~----..l401,1
27
TIA
',/ ,
~I
SCR,
! 2" i
~
I
, /j
23
t'
:T
SCR
[EE72]
022
!
;
:"''f,il.~2~
,1,,,,,
T
5R
[EE701',/'
, R
*r-..r.--~
,39
48',/
I T2A
[EE40) 1,1
[EDBI
i SCR
, ls. 3F
[E[741 ',/
[[E761 R
t II!
25
TJA
(FERRITE>
29
,-----t---31
":0.22
[ED081
~(IRONJ
DC
OUTPUT
33
POwER
(FERRITE>
35
AC INPU
PO',/ER
I'
DCS
ClRONJ
500
40',/
(FERRITD
(FERRITE>
41
41
ClRONJ
TIB
t
[EE42]~
[EE44J R
l'
SCR
4F
SCR
IR
401,1
4ACS
53
I,
S:R
~5F
~T=C'22-:I
II
[EE54] 1,1
[EE561 R
2__[_EE_S_B_'
55
[E[46J',/
J
__ u
I
57
[EE52J-0
[EES:I
~ I SCR
i
~~R
ls. 6F
~IO'22-:'
I
I
!
~_-r+-'_Q_~2_J ~-~C~~~-~-"_j
t
1EE62J ',/
~P2A
43
r -+----,- - ' : l 3 9
n39
40 1,1
15ACS
SCR
2R
'_+I
[EE60J~
(FTRRlTD
TJB
j ~tL-_O'2_-j--+----+-----t
t t
51
I,T2B
[EE4BJ~tt
~39
*
49
[EE64/
61
j",", I
63
65
67
69
o:!;'C
TS'W * * *
2TB
11
l,J 40',/
06ACS
*~I.to,22-:
I
!
L....Jf"C
J
I
I
45
47
49
51
53
55
57
59
59
61
1
I
, DA2
63
HIGH TEMPERATURE ALARM

C170"F) <OPENS ON ALARM)
65
67
69
2TB
12
71
71
73
THYRISTOR HEAT SINK

THERMAL S'WlTCH
75
,I
TS'W
77
2TB
3
~~
79
r
39
, r - - - - - t - - - - [E312:
47
r
35
39
45
T:29
'C22
"" 31
'-----r-'
Ir---+----[EBIOJ
37
43
27
*,---:1.,
***
***
73
HIGH TEMPERA TURE TRIP

CI90"F) <OPENS ON TRIP)
!
2TB
4
77
LOCA ED ON PCCA CARD

OPTrD AL
I igure D-1. Sample Elementary Diagram, GF2000
75
79
G Frame Exciter (Sheet FB)
D-ll
BI006008
GEH-6148
Notes:
D-12
BI006008
GF2000Dc
GEH-6148
APPENDIX E
PERIODIC MAINTENANCE
E-1. INTROD eTION
CAUTION
Because the GF
cept for relays,
minimum preve
appendix provid
for the equipme
000 exciter has no moving parts exontactors, fans, and blower motors,
tive maintenance is required. This
s recommended periodic maintenance
t.
WARNING
The equip nt contains a potential hazard
of electric s ock or burn. Only adequately
trained pers nnel who are thorougWy familiar with he equipment and the instructions should maintain the equipment.
E-2. PREVENTI E MAINTENANCE
Preventive mainte ance helps prevent, detect, and

correct conditions that could cause equipment malfunction. It includ s inspections for damage and wear,
tests, and cleanin of equipment at regular intervals.
The schedule for eventive maintenance depends
largely upon the e vironmental conditions around the
equipment. As a 'de, it is suggested that preventive
maintenance be pe formed at least once every two
months in bad env' onments, and on scheduled shutdowns in good env onments.
The following func ions should be performed at regular intervals.
1.
Turn off all wer to the equipment to be inspected and m . tained. Test equipment using
multimeter to e ure that power is off.
2.
Using a vacu
cleaner with a non-metallic nozzle, remove du and dirt from cabinets and electrical compone
Do not use compressed air to remove dust

and dirt, as this may damage components.
3.
Inspect cabinet air filters, if equipped. Shake fllters clean or replace, as required.
4.
Check tightness of all electrical and mechanical

connections. Tighten or replace defective crimpstyle lugs. Resolder loose solder connections.
Tighten or replace all loose or missing hardware.
5.
Inspect wiring for wear (fraying, chipping, or

nicks) and burns or melted insulation. Repair minor defects with a good grade of electrical tape, or
replace if necessary.
6.
Inspect printed wiring board plugs, wiring, and

connectors for wear and burns, and to ensure correct seating.
7.
Inspect fans and blower motors (if equipped) for

correct operation and rotation. Ensure that air passages are clear. Section E-3 provides information
on the life expectancy of the cooling fans used in
the equipment.
8.
Inspect contacts on open (as opposed to sealed)

contactors and relays. Discoloration and rough
contact surfaces are normal. Refer to the component publication supplied with the equipment for
further information.
If beads form due to severe arcing, dress the contact faces with a fme file. Do not use sandpaper or
emery cloth to dress the contacts, and never oil
any part of the power unit.
E-l
BI006008
GEH-6148
E-3. COOLING FANS

The exciter may include cooling fans for the printed
wiring board enclosures and heatsinks. Muffm fans
are typically used to cool the board enclosures, while
Tarzan fans are typically used to cool the heatsinks.
The life expectancy of these fans is determined by the
ambient temperature. The fans are rated at the continuous duty life (in hours), after which 90% of the
units continue to operate at a given ambient temperature.
For example, at an ambient temperature of 40C (104
OF), 90% of Muffm fan units with ball bearings are
expected to be operating after approximately 85000
hours (approximately 9.7 years) of continuous duty.
At 60C (140 OF), 90% of the units are expected to be
running after 55000 hours (approximately 6.3 years)
of continuous duty.
E-2
GF2oo0 Dc Generator Field Exciter

Note that in earlier units, the Muffm fans used were
equipped with sleeve bearings. The life expectancy of
these fans is considerably less than that of fans
equipped with ball bearings. For example, at 40C,
90% of Muffm fan units with sleeve bearings are expected to be operating after approximately 55000
hours (approximately 6.3 years) of continuous duty.
At 60C, 90% of the units are expected to be running
after 25000 hours (approximately 2.9 years) of continuous duty.
At 40C, 90% of Tarzan fan units are expected to be
operating after 25000 hours (approximately 2.9 years)
of continuous duty. At 50 C (122 OF), 90% of the
units are expected to be running after approximately
18000 hours (approximately 2.1 years) of continuous
duty.
BI006008
GF2000 Dc
GEH-6148
enerator Field Exciter
APPENDIX F
F-1. WARR NTY TERMS

The GE Drive Systems Terms and Coru:litions brochure
details produc warranty information, including the
warranty per d and parts and service coverage.
The brochure' included with the customer documentation. It may so be obtained separately from the
nearest GE Sal s Office or authorized GE Sales Representative.
F-2. OBTAINING PARTS AND SERVICE UNDER

WARRANTY
identify the part and application:
Exciter serial number and model number
F-l
BI006008
GEH-6148
Notes:
GE Motors &
Industrial Systems
----------------------------------Industrial SystemsDrive Systems & Turbine Controls

GEI-100020E
BI006008 GEI-100020A
(Supersedes
GEMotors&
Industrial Srste/.
:..-_------+--------------~---------
NTB/3TB TERMINAL BOARD

531X305NTB__G1
These instructi
do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met
during installat on, operation, and maintenance. Iffurther information is desired or ifparticular problems arise that are not covered
sufficientlyfor t purchaser's purpose, the matter should be referred to GE Motors & Industrial Systems.
This document ntains proprietary information ofGeneral Electric Company, USA and is fUrnished to its customer solely to assist th,
customer in the nstallation, testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproducel
in whole or in p rt nor shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systen
CONTENTS
Safety Symbol
Functional Des ription
1
Application Da .2
Testpoints
2
Configurable ardware
3
RenewallWarr ty Replacement
16
Board Identific tion
16
Warranty Te
16
Warranty Parts nd Service
16
Procedure For eplacing Boards
16
WARNING
This equipment contains a potential hazard of

electric shock or burn. Only adequately
trained persons who are thoroughly familiar
with the equipment and the instructions
should install or maintain this equipment.
INTRODUCTION
SYMBOL LEGEND
CAUTION

of equipment
NOTE Indicates
essential or important procedure,
practice, c ndition, or statement.
The 531X305NTB (NTB/3TB) board is located within thl

drive (or exciter) cabinet. The board contains passive interface circuitry and the drive's (or exciter's) connection
terminals for most external signal-levell/a. Figure 1
shows the NTB/3TB layout.
The NTB/3TB connects to the drive control board via
plugs 6PL and 8PL, to the power supply board via plugs
2PL and 4PL, and to external equipment via plug
COMPL and terminal board 3TB. Refer to Tables 5
through 10 for I/O definitions.
The NTB/3TB provides the following interfaces:
Power supply
Encoder
RS-232C and RS422
Relay Outputs
Analog Tach and Reference coarse scaling
Low-level analog l/O
Digital control inputs
BI006008
Drive Terminal Board
,H-I00020B
IWERSUPPLY
e NTB/3TB supplies the Jollowing power outputs for
:ernal use:
Regulated +5 V dc and 15 V dc, each with a current
capacity of 300 rnA
Unregulated 24 V dc, with a current capacity of
500mA
120 V ac, with a current capacity of 0.5 A
duns (line chokes) provide two noise-filtered power
pply outputs for driving digital encoders. Hardware
mpers allow distribution of the encoder loads among the
5 V dc and 15 V dc supplies to balance loading.
NCODERINTERFACE
he NTB/3TB includes a differential A-quad-B encoder
lterface, including a marker channel, that can be conected to the drive. This circuit is optically isolated on the
rive control board. The NTB/3TB includes jumpers to
onfigure the interface for +5 V or 15 V encoders.
~S-232C
AND RS-422 INTERFACES
:::onnector COMPL provides an RS-232C serial link (see

fable 11).
The NTB/3TB includes line termination resistors for a

l1alf-duplex, RS-422 compatible, serial interface to the
drive control board's motor control processor (MCP).
RELAY OUTPUTS
The NTB/3TB provides the following outputs from seven

relays with a 120 V ac, 1 A contact rating:
Form C output from five relays controlled by the

drive control board.
One form A output and one side of the coil from a

sixth relay controlled by the drive control board. This
enables the coil to be controlled by the drive control
board or an external 24 V dc signal. External signals can also access the drive control board's coil
driver output for applications that cannot tolerate the
time delay associated with the relay pickup.
Two form C contacts and both sides of the coil of a

seventh relay for general purpose use. A hardware
jumper selects whether this coil is driven by 24 V
dc or 120 V ac (see Table 2).
The board also supplies form C contacts from the MA

contactor pilot relay on the Power Supply/Interface
Board. These contacts are rated at 120 V ac, 2 A.
ANALOG TACH AND REFERENCE COARSE

SCALING
The NTB/3TB's DIP switches allow coarse scaling of
analog tachometer inputs from 25 to 380 V, and of analog
references from 9 to 29 V (see Table 3). The drive control
board provides fine scaling of these signals.
LOW-LEVEL ANALOG 110

The NTB/3TB includes four potentiometers (pots) for
scaling (5 to 50 V) 10-bit, general-purpose, mediumresolution inputs to the drive control board (see Table 4
for pot settings). The NTB/3TB transfers two highresolution analog inputs to the drive control board, and
receives four 8-bit, 10 V analog outputs from it. These
outputs drive functions such as other drives, analog meters, and diagnostics.
DIGITAL CONTROL INPUTS

Various control inputs pass through the NTB/3TB to the
drive control board. These include special-purpose digital
inputs, such as RESET and CONTROL ON, and 12 general-purpose control inputs (up to 24 V dc). Hardware
jumpers are used to bias unconnected inputs to +24 or
-24 V dc, depending upon whether positive or negative
logic is used (see Table 2).
APPLICATION DATA
TESTPOINTS
The NTB/3TB onboard testpoints permit access to critical
signal paths for test purposes. Table 1 shows information
on the use of each testpoint. Figure 1 shows testpoint locations.
"
BI006008
Drive Termi
Board
GEI100(
Table 1. NTBI3TB Testpoints

Name
De eript/on
DA1
1 V de analog output, same as 3TB pin 53.
DA2
MET1
MET2
DVM
Dig' I voltmeter (Test 03) input, range 50 V de,

sam as 3TB pin 49.
COM
~"
common reference point for test signals,

as 3TB pin 66.
C:l:o
~U
LEHARDWARE
cludes configurable hardware that must
or the application:
Berg-type anually movable) hardware jumpers,

identified b a JP nomenclature (see Table 2)
:[fa.
N
:!-O
DIP switch s, identified by an SW nomenclature (see

Table 3)
~:U
Pots, identi ed by a P nomenclature (see Table 4)
Most of the jum

test data sheets s
drive/exciter do
tions. Table 2 lis
default setting fi
iD
...
O~
'B
I")
~:O ~-
1.
Figure I is a lay t diagram of the NTB/3TB board,

showing the loca ions of the configurable items.
~-
D~ !![O=Di D~
l!;
l!;
Oa
'OJ
...
N
IUt
i::O
~~U
er selections have been factory set. The

pplied with each controller (in the
pocket) indicate these factory set posithe jumper descriptions,showing the
'B
~~U
~n ~n
n~
NO Sl~NO~~ ON
...
_5ldr
ZZdr
~n
:0
~
l;:
!!
~E3
[0:
1I3
IZ
~u~
1O
><
~O:
iii
~u~
~O: :0- NO~
u~ u~ u~
Figure 1. NTBI3TB Board Layout
BI006008
ml00020B
Table 2. Jumpers
.evision
Name
Description
A-Pres
JP1,
JP2
Tennination resistors for the drive control board's motor control processor (MCP) RS-422 interface
(see also JP2)
RS-422 tennination resistors should only be installed at the physical first and last drops (ends of the cable runs).
1.2 Not installed
lA-Pres
JP4
Swap RS-232C RxD and TxD data lines, COMPL pins 2 and 3 (see also JP5)
Note many PCs can be jumpered to either the DCE or DTE configuration, and many cables are wired with pins 2
and 3 interchanged. If communication is not established with JP4 and JP5 in the default position, the alternate
position may be necessary.
1.2 DCE mode for PCltenn interface. drive transmits on pin 3.
1.3 DTE mode for modem interface. drive transmits on pin 2.
\A-Pres
JP5
Swap RS-232C RxD and TxD data lines, COMPL pins 2 and 3 (see also JP4)
3.4 DCE mode for PC/tenn interface. drive transmits on pin 3.
2.4 DTE mode for modem interface. drive transmits on pin 2.
!\A-Pres
JP6
RS-232C RTS (COMPL-4)/CTS (COMPL-5) handshake line options (see also JP7)
3.7 DCE mode forced true handshaking
2.6 DTE mode forced true handshaking
AA-res
JP7
RS-232C RTS (COMPL-4)/CTS (COMPL-5) handshake line options (see also JP6)
The default position bypasses handshaking, generally allowing satisfactory serial communication independent of
whether COMPL pins 4 and 5 are connected to a DTE or DCE port, or not connected at all.
1.5 DCE or DTE forced true handshaking
AA-Pres
JP8
RS-232C DSR (COMPL-6) and DTR (COMPL-20) handshake options (see JP9)
The default position bypasses handshaking, generally allowing satisfactory serial communication, independent
of whether COMPL pins 6 and 20 are connected to a DTE or DCE port, or not connected at all.
1.2 DSR and DTR both tied to +15 V dc (forced true)
1.3 DSR connected to DTR (loopback)
AA-Pres
JP9
RS-232C DSR (COMPL-6) and DTR (COMPL-20) handshake options (see JP8)
3.4 DSR and DTR both tied to +15 V dc (forced true)
2.4 DSR connected to DTR (loopback)
AD-Pres
JP10
RF24 polarity for digital control inputs (see also JP11)

Note that on early prototypes of this board, JP10 and JP11 were identified as JP3A and JP3B.
AD-Pres
JP11
RF24 polarity for digital control inputs (see also JP10)

AA-Pres
JP12
Voltage to encoder supply (EOV1, EOV2)

1.2 EOV1 =+15Vdc
2.3 EOV1 = +5 V dc
AA-Pres
JP13
Voltage to encoder supply (E1V1 , E1V2)

1.2 E1V1 = EOV1 per JP12
2.3 E1V1 = -15 V dc
,., ..
BI006008
Drive Termi at Board
GEI-lOO(
Table 2. Jumpers - Continued

Revision
~ame
AL-Pres
~P14,
P15

JP14 & JP15 settings determine the gain of the first stage of the analog interface circuitry for the (VC3P, VC3
analog inputs to the V3VCO channel, per the following table.
Maximum
Nominal
2.3
2.3
16.9
10.0
1.2
2.3
23.3
13.8
2.3
1.2
34.9
20.6
1.2
1.2
41.3
24.4
Maximum and Nominal values represent differential input voltages at the 318 inputs with the following
significances:
Second max: max voltage for which the first stage will provide linear transfer function independent of the
V3SCLE setting.
Nominal: Voltage which will produce 20000 counts in V3VCOVAR 01AR.184) with the EE.V3SCLE (EE.484)
programmed to 10000. This is the optimum "rated reference" voltage, allowing 25% overrange.
Note that VCO #3 is only available on drives having 05200 series drive control boards, not 531X series drive
control boards.
AA-Pres
JF 17
Encoder 0 optically isolated receiver voltage drive level (EOA)

1.2 15 V dc
2.3 5 Vdc
AA-Pres
JP 8
Encoder 0 optically isolated receiver voltage drive level (EOB)

1.2 15 V dc
2.3 5V dc
AA-Pres
JP 9
Encoder 0 optically isolated receiver voltage drive level (EOM)

1.2 15 V dc
2.3 5 Vdc
AA-Pres
JP~ P
Voltage level of external drive for general purpose relay (GR+ and GR-)
1.2 120 volts
2.3 24 volts
AA-Pres
JP2
Supply -24 volts on COMPL-25

1.2 COMPL-25 is open
2.3 COMPL-25 is connected to -24 V dc
JP2,
JP2~

JP22 & JP23 settings determine the gain of the first stage of the analog interface circuitry for the (VC4P, VC4N)
analog inputs to the V4VCO channel, per the following table.
Maximum
Nominal
2.3 2.3
16.9
10.0
1.2 2.3
23.3
13.8
2.3 1.2
34.9
20.6
1.2 1.2
41.3
24.4
Maximum and Nominal values represent differential input voltages at the 31B inputs with the following
significances:
Second max: maximum voltage for which the first stage will provide linear transfer function independent of the
V4SCLE setting.
Nominal: Voltage which will produce 20000 counts in V4VCOVAR (VAR.185) with the EE.v4SCLE (EE.488)
programmed to 10000. This is the optimum "rated reference" voltage, allowing 25% overrange.
Note that VCO #4 is only available on drives having OS200 series drive control boards, not 531X series drive
control boards.
AL-Pres
Description
BI006008
H.I00020B
Table 2. Jumpers - Continued

levision
Name
Description
.-Pres
JP24
Enable 4-20 mA current loop input to the feedback VCO (FDBP, FDBN)
When the current loop mode is enabled (2.3), a 50C-ohm burden resistor is inserted, yielding 10 volts at 20 mAo
1.2 Voltage input mode, scaled via SW1-5
2.3 Current loop input mode, SW1-5 should be open
A.-AC
JP3A
RF24 polarity for digital control inputs (see also JP3B)

Note that JP3A and JP3B were renamed JP10 and JP11 on subsequent revisions.
A-AC
JP3B
RF24 polarity for digital control inputs. (See also JP3A).

BI006008
Drive Termi 181 Board
GEl-lOOt
Table 3. Switches
Name
SW1-5
Description
Feedback VCO ChanneVAnalog Tach Feedback (FDBP, FDBN) Voltage Range Select
These switch settings determine the gain of the first stage of the analog interface circuitry for the (FDBP, FDBN)
analog inputs to the FBVCO channel. Maximum and Nominal values represent differential input voltages at the
3TB inputs with the following significances:
First max: Voltage for which the VCO stage will saturate with the FBSCl (drive control P6, if present) scaling
potentiometer set to the maximum gain (full CCW) position.
Second max: maximum voltage for which the first stage will provide linear transfer function independent of the
FBSCl setting.
Nominal: Voltage which will produce 20000 counts in FBVCOVAR (VAR.183) with the FBSCL scaling pot set to
maximum gain (full CCW) and the EE.FVSCl# (EE.1386m) programmed to 10000. This is the optimum "rated
feedback" voltage, allowing 25% overrange.
Note that the software scaling function on the VCO channels is only available on DCP Rev 1.24 & later. ALSO
NOTE: When JP7 on the drive control board is in the 2.3 position, each voltage range in the chart should be
~ivided by 6. For use with 4-20 mA current inputs, set all switches off and see JP24 (REV Al and later).
o
1
2
3
4
6
8
12
14
16
20
24
28
31
SW6-7
(all off)
(1 on)
(2 on)
(1,2 on)
(3 on)
(2,3 on)
(4 on)
(3,4 on)
(2-4 on)
(5 on)
(3,5 on)
(4,5 on)
(3-5 on)
(all on)
25-33 volts maximum,

20.0 volts nominal or 4-20 mA

25.1 volts nominal
30.9 volts nominal
35.9 volts nominal
44.0 volts nominal
54.9 volts nominal
70.5 volts nominal
94.5 volts nominal
105.0 volts nominal
140.0 volts nominal
164.0 volts nominal
191.0 volts nominal
215.0 volts nominal
231.0 volts nominal
R ference VCO Channel/Analog Reference (REFP, REFN) Voltage Range Select

T ese switch settings determine the gain of the first stage of the analog interface circuitry for the (REFP, REFN)
ar alog inputs to the RFVCO channel. Maximum and Nominal values represent differential input voltages at the
3 ~ inputs with the following significances:
Fi st max: Voltage for which the VCO stage will saturate with the RFSCl (drive control P5, if present) scaling
po entiometer set to the maximum gain (full CW) position.
Se ond max: maximum voltage for which the first stage will provide linear transfer function independent of the
RF~Cl setting.
No ~inal: Voltage which will produce 20000 counts in RFVCOVAR (VAR.1 82) with the RFSCL scaling pot set to
ma imum gain (full CW) and the EE.RVSCl# (EE.1281m) programmed to 10000. This is the optimum "rated
ref rence" voltage, allowing 25% overrange.
Not ~ that the software scaling function on the VCO channels is only available on DCP Rev 1.24 & later.
o
2
1
(all off)
(7 on)
(6 on)
(all on)
12.5-16.9 volts maximum,

10.0 volts
13.8 volts
20.6 volts
24.4 volts
nominal
nominal
nominal
nominal
BI006008
:H100020B
Table 4. Potentiometers
Name
Description
P1
P2
P3
P4
Table 5. Connector 2PL,

I/O Between the NTBI3TB and Power Supply
Pin No.
Nomenclature
Description
IPSEN
Power supply enable (active low).
-15V
-15 V dc, 5%
+15V
+15 V dc, 5%
DCOM
Digital common
+5V
+5Vdc. 5%
DCOM
Digital common
-24V
-24 V dc, 20%
+24V
+24 V de. 20%
5,6

I/O Between NTBI3TB and Drive Control Boards
Pin No.
NTB/3TB
Terminal
Nomenclature
Description
85
X2
83
FX1
81
MANC
Form C normally closed contact from the MA pilot relay (K2).
79
MANO
Form C normally open contact from the MA pilot relay (K2).
77
MACM
Form C common contact from the MA pilot relay (K2).
BI006008
1
Drive TermiJ: aI Board
GEII000
Table 7. Connector OPTPL,

I/O Between LAN Tenninal and NTBI3TB Boards
Pin Flo.
Nomenclature
Description
X2
Retum for CFX1 120 V ac loads (isolated from COM). Same as NTB/3TB pin 85.
CFX1
120 V ac, 15%, from NTBI3TB board, fused at 500 rnA, including internal fans
(isolated from COM). Same as NTB/3TB pin 83.

Input from Drive Control and LAN Tenninal Boards
Pin No
3TB Tenninal
Nomenclature
Description
FA
Non-inverting RS-422 half-duplex serial data line from the drive

control board's Motor Control Processor (MCP) UART.
FB
Inverting RS-422 half-duplex serial data line from MCP UART.
10
DCOM
12
EXSY
Extemal sync input to MCP.
--
Not connected.
EOAB
Encoder interface Channel A non-inverted differential input.
IEOAB
Encoder interface Channel A inverted differential input. (Tie to

COM for single-ended encoders.)
EOBB
Encoder interface Channel B non-inverted differential input.
IEOBB
Encoder interface Channel B inverted differential input. (Tie to

COM for single-ended encoders.)
10
EOMB
11
11
IEOB
Encoder interface marker channel inverted differential input. (Tie

to COM for single-ended encoders.)
12
--
13
14
CL1
CL1 - CL8 are general-purpose control inputs, 24 V dc maximum with 27 kn input impedance.
14
16
Cl2
See CL1 (pin 13).
15
18
CL3
See CL1 (pin 13).
16
20
CL4
See CL1 (pin 13).
17
22
CL5
See CL1 (pin 13).
18
24
CL6
See Cl1 (pin 13).
19
26
CL7
See CL1 (pin 13).
20
28
CL8
See CL1 (pin 13).
Not connected.
BI006008
m-l00020B
NOTE
The NTB/3TB terminal board provides 95 connector points arrl!!lged in two rows of screw-type terminals.
The terminals are numbered sequentially, with odd numbers in the top row and even numbers in the bottom
row.
CAUTION
The NTBI3TB board DACn and METn outputs are not controlled during power-up or power-down. If these
outputs are being used to control processes that might respond inappropriately to these transient outputs,
steps should be taken to disable the process during these times. One solution is to pass the output through one
of the NTB/3TB relays, which are always dropped out during power-up and power-down. The relay can be
easily configured to pick up after power-up by pointing it at a drive variable such as TRUEREG, VAR.IO.
Table 9. NTBI3TB Tenninals,
liD Between NTBI3TB and External Connections
NTB/3TB
Terminal
Nomenclature
Description
EOA
Encoder channel A non-inverted differential input.

EOA, 1E0A, EOB, EOM, and IEOM are optically coupled inputs. Either +5 V or +15 V
A-quad-B or single channel encoders may be used, check JP17, JP18, and JP19. This
interface can be steered to block ENCP1 in addition to ENCPO.
Specifications for drivelexciter tach interface circuit:
Only differential tachs ( A, lA, B, IB) are recommended and are covered by this spec.
However, a single ended 15 V tach will run if the unused input is tied to +5 V and circuit
is configured for +V operation.
Operation with a marker pulse will degrade maximum frequency and requires special
consideration based on the marker pulse phasing.
These frequency specifications apply to the frequency of either channel of the tach
based on the rpm and pulses per rev, (this rate is multiplied by 4 internal to the drive);
tach and circuit errors were taken into account. The maximum operating frequency is
limited by a filter on the input to the receiver circuit drive control boards. For drive control board DS200LDCC (LDCC) applications, the maximum operating frequency is increased approximately 50% from what is shown below for drive control board
DS200S0CC (SOCC) applications.
Care has to be taken with the line capacitance and frequency when using low impedance line driver because it can cause significant additional current consumption and
power dissipation in the tach and the power supply.
Low impedance driver (15 V supply and 15 V receiver configuration):
Lakeshore or BEl 7406M15; an 88C30 interface is not recommended UNLESS
tachometer has clamping diodes installed on its output.
Maximum frequency: 102 Hz (150 kHz with LOCC)
Current consumption: I = 23 mA + 60 * C(line) * freq, per channel
Lakeshore tach (5 V supply and receiver configuration - may be desirable for high
capacitance line to limit power dissipation in tach driver circuitry):
Maximum frequency: 51 Hz (75 kHz with LOCC)
Current consumption: 1= 15 mA + 20 * C(line) * freq, per channel
OS8830 differential driver (5 V supply and receiver configurations):
Maximum frequency: 34 Hz (Tach driver must be above OC)
Current consumption: 1= 10 mA + 16 * C(line) * freq, per channel
7406 open collector output with 1K pull-up resistors (15 V supply with 5 V receiver):
Maximum frequency: 25 Hz (assumes line capacitance is < .01 I!f)
Current consumption: I = 11 mA, per channel
NOTE: Current stated above is ONLY the current consumed by the receiver circuit and
Wiring. Total current consumption for a two channel tach is:
Itotal = 2 * I + Tack internal current consumption.
.'
BI006008
GEIlOOt
Drive Termi al Board
Table 9. NTBI3TB Terminals - Continued,

I/O Between NTBI3TB and External Connections
NTBI TB
Term nal
Nomenclature
Description
EOV1
Positive side of power supply with balun choke for Encoder EOAlEOB. Either +5 or +15
V dc as set by NTB/3TB jumper JP12.
IEOA
Inverting differential input for Encoder #0, channel A.
EOV2
Return for EOV1, basically at COM potential.
EOB
Non-inverting differential input for Encoder #0, channel B.
FA
Non-inverting RS-422 half-duplex serial data line. Provides a serial channel into the
drive control board's MCP (as opposed to the RS-232C channel into the drive control
board's DCP). This provides a potential high speed channel for tight coupling of drives
at the motor control loop level. EXSY provides an external synchronization input to
MCP. Jumpers JP1 and JP2 are used to connect line termination resistors to FA and
FB (needed at each end of an RS-422 network).
IEOB
Inverting differential input for Encoder #0, channel B.
FB
Inverting RS-422 half-duplex serial data line (see FA, 3TB point 6).
EOM
Encoder interface marker pulse channel non-inverted differential input.
10
FCOM
Signal retum for EXSY (at COM potential).
11
IEOM
Encoder interface marker pulse channel inverted differential input.
12
EXSY
External sync output to drive control board's motor control processor.
13
RiC
Relay #1 common contact. These relay contacts are rated for 120 V ac, 0.5 A.
EEPROM parameters allow these six relays to be driven by any bit of any variable in
the Drive Control Processor of the drive control board. (See EE.216 and following). By
default, these relays are updated 45 times per second. Beginning with DP revision 2.24,
blocks RLYAL (373) and RLAYN (374), allow any or all ofthese relays to be updated 90
to 720 times per second. These relays have a typical mechanical delay of 3 to 4 ms.
14
CI1
General-purpose control input. RUN, JOG, POL, XSTP, and CI1 - CIS are generalpurpose control inputs, 24 V dc maximum with 27 kn input impedance and a 2 ms
hardware filter. Each is automatically sampled 45 times per second by default. Beginning with DP revision 2.24, CI1 - CI8 may be sampled faster, at 90 to 720 times per
second by scheduling a foreground block, BLK.372, CIINS, at the appropriate rate.
15
R1NC
16
CI2
See CI1 (3TB point 14).
17
R1NO
18
CI3
See CI1 (3T8 point 14).
19
R2C
20
CI4
See Cli (3TB point 14).
21
R2NC
22
CI5
23
R2NO
25
R3C
26
CI7
27
R3NC
28
CiS
See CI1 (3TB point 14).
29
R3NO
30
RF24(1)
Voltage reference for digital control inputs. Defaulted to -24 V dc; changes to +24 V dc
via NTBI3TB's jumpers JP1 0 and JP11. Each digital control input is active when connected to RF24, inactive when open. Total 24 V dc load includes loading on RF24.
31
R4C
..
BI006008
m-100020B

NTB/3TB
Terminal
Nomenclature
Description
32
RF24(2)
Voltage reference for digital control inputs (see RF24[1], 3TB point 30).
33
R4NC
34
RUN
General-purpose input Defaulted to, but not limited to, RUN function.
35
R4NO
36
JOG
37
R5NO
38
POL
39
R5NC
40
XSTP
General-purpose input. Defaulted to the XSTOP function (normally closed).
41
R5C
42
CTLN1
Control on input 1. CTLN1 and CTLN2 (3TB point 44) form part of the circuit that picks
up the MA contactor pilot relay. They must be connected together for the drive (or drive
(or exciter) to run. Can also be used to connect external interlocks, providing a fail-safe
(microprocessor independent) way to stop the drive (or exciter).
43
R6NO
44
CTLN2
Control on input 2 (see CTLN1, 3TB point 42).
45
R6C
46
P1
Scaled 1D-bit analog input. P1 through P4 are medium-resolution (10-bit) analog input
channels for voltages from 5 V dc to 50 V dc, scaled via respective pots P1 through
P4 on the NTB/3TB. Input impedance ~ 10 kn, and input filtering is at most 1 ms.
47
MSRF
Relay #6 coil driver (Master Sync Reference output), open collector output. When inactive, MSRF is pulled up to +24 V dc through 1400 n maximum. When active, MSRF is
pulled down to 1.5 V dc maximum through 200 n, not including a maximum drop of 3.4
V across the 200 n due to the relay #6 coil load. If internal control of this relay is not required, relay #6 may be picked up by an external driver capable of pulling MSRF down
to 1.5 V dc maximum sinking 17 rnA. See also 3TB point 13.
48
P2
Scaled 10-bit analog input. See P1 (3TB point 46).
49
DVM
Filtered fixed-scaled 10-bit analog input. DVM is a medium-resolution analog input

channel, with fixed scaling for 51.0 V dc maximum ( 25.5 on early drive control
boards). Input impedance and filtering is 511 kn and 100 ms. In conjunction with drive
(or exciter) test 03, provides a digital voltmeter function with at least 0.5% accuracy for
diagnostic functions.
58
RESET
Hard reset input to the drive (or exciter). Connecting RESET to +5 to +24 V dc resets all
processors in the drive (or exciter). Leaving RESET open or connecting to COM allows
drive (or exciter) operation. The drive control board provides a 20 ms noise filter on this
input.
59
TOIN
Input to internal timer/counter 0 of the drive control board's DCP. Biased to +24 V dc
through 27 kn, and must be pulled to COM (less than +1.5 V dc) to be recognized by
the DCP.
60
+5VDC
+5 V dc source, 10%, 300 rnA (including load on EOV1 and E1V1).
61
TOOUT
TIL output through 200 n from DCP's timer/counter 0 (on drive control board). TOOUT
is useful primarily as a pUlse-train output.
62
+15VDC
+15 V dc source, 10%, 300 rnA (inclUding load on EOV1 and E1V1).
63
REFP
Non-inverting differential analog reference input with REFN, 3TB point 65. Maximum
reference can be 9 - 29 V dc, coarsely selected by NTB/3TB's switches SW1 - SW7.
Fine scaling provided by EE.1281 (RVSCLn). This circuit uses a VCO similar to the one
used by FDBP and FDBN. Input impedance is at least 60 kn with less than 1 ms of filtering. If this circuit is not needed for the drive (or exciter) speed reference, the digitalization of this input is available for other functions requiring high resolution.
t.
..
BI006008
GEI-IOOO
Drive Termill al Board

- -'
...
:.,..,
.....
".~
.'.,~
NTB/3 B
Tenni al
64
Nomenclature
Description
-15VDC
-15 V dc source, 10%, 300 mA (including load on E1V1).
65
REFN
Inverting differential analog reference input, with REFP, 3TB point 63.
66
COM(1)
oV common reference for all drive (or exciter) 110, same as 3TB point 68. COM should
67
RSVD(1)
68
COM(2)
oV common reference for all drive/exciter 110, same as 3TB point 66.
69
FDBP
Non-inverting differential analog tach input (with 3TB point 73). Either ac AN or dc tachometers with a top speed voltage from 25 to 390 V (6 to 65 V if jumper JP7 on the
drive control board is in the 2-3 position) can be connected to these differential inputs.
NTB/3TB's DIP switches SW1 through SW7 provide coarse scaling. drive control
board's jumper JP8 and EE.1386 (FVSCLn) provide fine scaling and analog ac AN tach
rectification. Input impedance of this circuit is at least 300 kO, with less than 1.5 ms of
filtering. If this circuit is not needed for the drive (or exciter) speed feedback, the digitalization of this input is a available for other functions requiring high resolution.
70
+24VDC
+24 V dc source, 25%, unregulated, 500 mA (including load on RF24).
71
RSVD(2)
Not used.
72
-24VDC
-24 V dc source, 25%, unregulated, 500 mA (including load on RF24).
73
FDBN
Inverting differential analog tach input with 3TB point 69.
74
E1V1
Power supply with balun line choke for encoders on SPC board. Either -15 V dc or
same voltage as EOV1 (+5 or +15 V dc) as selected using NTB/3TB jumper JP13.
75
RSVD(3)
Not used.
76
E1V2
Return for E1V1, basically at COM potential.
77
MACM
Form C common contact from MA pilot relay; auxiliary contact from the relay used to
pilot the MA contactor. Rated for 125 V ac, 2A.
78
RSVD(4)
79
MANO
Form C normally open contact from the MA pilot relay; auxiliary contact from the relay
used to pilot the MA contactor. Rated for 125 V ac, 2A'
be used for signal level returns only.
80
GRC1
General-purpose relay common contact of first form C. Rated for 120 V ac, 0.5 A.
81
MANC
Form C normally closed contact from the MA pilot relay; auxiliary contact from the relay
used to pilot the MA contactor. Rated for 125 V ac, 2A.
82
GNC1
General-purpose relay normally closed contact.
83
CFX1
120 V ac, 15%, fused at 500 mA total including internal fans (isolated from COM).
84
GN01
General-purpose relay normally open contact.
85
X2
Return for CFX1 120 V ac loads (CFX1 and X2 isolated from COM).
86
GRC2
General-purpose relay common contact of second form C. Rated 120 V ac, 0.5 A).
87
GR+
GR+ and GR- (3TB point 89) are coil inputs to a general purpose relay. This relay is not
internally connected to any drive (or exciter) circuitry, and may be used as required for
customer applications. The coil may be driven by 24 V or 120 V, either ac or dc, as selected using jumper JP20.
88
GNC2
General-purpose relay normally closed contact. Rated 120 V ac, 0.5 A.
89
GR-
See GR+ (3TB point 87).
90
3N02
General-purpose relay normally open contact. Rated 120 V ac, 0.5 A.
-.
BI006008
8:H-I00020B
Table 9. NT8I3TB Terminals - Continued,

I/O Between NT8I3TB and External Connections
NTB/3TB
Terminal
Nomenclature
Description
91
VC3N
Inverting differential analog input for auxiliary VCO #3. The top reference voltage may
be 9 to 29 V de. Jumpers JP14 and JP15 provide coarse scaling of the inputs. This circuit uses a VCO similar to the one used by REFP and REFN. Input impedance is at
least 60 kn with less than 1 ms of filtering. The digitalization of this input is available at
VAR.184 for functions requiring a high-resolution analog input by using BLK.263
(V3VCO). (VCO #3 is not available on the 531X301DCC Drive Control board.)
92
VC4N
Inverting differential analog input for auxiliary VCO #4. The top reference voltage may
be 9 to 29 V de. Jumpers JP22 and JP23 provide coarse scaling of the inputs. This circuit uses a VCO similar to the one used by REFP and REFN. Input impedance is at
least 60 kn with less than 1 ms of filtering. The digitalization of this input is available at
VAR.185 for functions requiring a high-resolution analog input by using BLK.264
(V4VCO). (VCO #4 is not available on the 531X301DCC Drive Control board.)
93
VC3P
94
VC4P
95
MET3
10 V de analog output from an 8-bit D/A converter (see 3TB point 54).

I/O Between NT8I3TB and Drive Contro/ Board
Pin No.
NTB/3TB
Terminal
Nomenclature
Description
42
CTLN1
Control ON input 1. CTLN1 and CTLN2 (3TB point 44) form part of the circuit
that picks up the MA contactor pilot relay. They can also be used to connect
external interlocks, providing a fail-safe (microprocessor independent) way to
open the MA contactor, if used.
44
CTLN2
See CTLN1 (pin 1).
LBIAS
24 V dc bias for digital inputs from NTB/3TB (for + or - logic).
3
4
61
TOOUT
TTL output through 200 n from DCP's timer/counter 0 (on drive control board).
TOOUT is useful primarily as a pulse-train output.
34
RUN
36
JOG
38
POL
40
XSTP
General-purpose input. Defaulted to XSTP function (normally closed).
47
MSRF
Relay #6 coil driver (Master Sync Reference output), open collector output.
When inactive, MSRF is pulled up to +24 V dc through 1400 n maximum.
When active, MSRF is pulled down to 1.5 V dc maximum through 200 n, not
including a maximum drop of 3.4 V across the 200 n due to the relay #6 coil
load. If intemal control of this relay is not required, relay #6 may be picked up
by an extemal driver capable of pulling MSRF down to 1.5 V dc maximum
sinking 17 mAo See also 3TB point 13.
10 -14
R01-R05
NTB/3TB relay coil output driver lines 1 through 5.
15, 16
P3B,P4B
Scaleable general-purpose analog input from NTB/3TB.
BI006008
Drive Termill at Board
GEII000
Table 10. Connector 6PL -
Continued,
flO Between NTBI3TB and Drive Control Board

._,
NTB/3TB
Terminal
Nomenclature
Description
51
ASPO
Fixed scaled 10-bit analog input. ASPO is a medium-resolution analog input

channel, with fixed scaling (no trim pot). Input impedance and filtering is 10 kn
and 1 ms.
VC3NB
Inverting differential analog input to drive control board auxiliary VCO #3.
VC3PB
Non-inverting differential analog input to drive control board auxiliary VCO #3.
20,21
P1A,P1B
Scaleable general-purpose analog inputs from NTB/3TB.
22
95
MET3
See DA1 (pin 24).
23
49
DVM
Filtered fixed-scaled 10-bit analog input. DVM is a medium-resolution analog input channel, with fixed scaling for 51.0 V dc maximum ( 25.5 on early drive
control boards). Inpu1 impedance and filtering is 511 kn and 100 ms. In conjunction with drive (or exciter) test 03, provides a digital voltmeter function with at
least 0.5% accuracy for diagnostic functions.
24
53
DA1
10 V dc analog output from 8-bit or 12-bit D/A converter. DA1 and DA2 (8 bit
Pin No.
17
18
19
resolu1ion on the drive control board and 12 bits on the drive control board), and
MET1, MET2, and MET3 (8 bit resolution), are outputs from O/A converters and
can source 10 V dc at no load or 8 V dc at a 10 rnA load (200 n series impedance). Any drive variable can be steered to these O/A outputs and can be
scaled to set the value corresponding to 10 V dc output. If the variable attains a
magnitude greater than this value, the O/A output is clamped to 10 volts rather
than rolling over. DA1 and DA2, intended for diagnostics and system applications,
are updated every 1.4 ms. MET1, MET2, and MET3, intended primarily for meter
driver functions, are updated every 2.8 ms. Note MET3 is only present on boards
of rev AM and later, and is only functional when used with OS200 series drive
control boards -it is not prOVided on 531X series drive control boards.
25
55
DA2
See DA1 (pin 24).
26
54
MET1
See OA1 (pin 24).
27
56
MET2
See DA1 (pin 24).
28
57
MSSY
Inpu1 to internal interrupt INTO of the drive control board's DCP. Biased to +24 V
dc though 27 kn, must be pulled to COM (less than +1.5 V dc) to be recognized
by the DCP.
29
59
TOIN
Input to internal timer/counter 0 of the drive control board's OCP. Biased to +24 V
dc through 27 kn, and must be pulled to COM (less than +1.5 V dc) to be recognized by the DCP.
30
58
RESET
Hard reset input to the drive (or exciter). Connecting RESET to +5 to +24 V dc resets all processors in the drive (or exciter). Leaving RESET open or connecting to
COM allows drive (or exciter) operation. The drive control board prOVides a 20 ms
noise filter on this input.
31
TOB
RS-232C channel transmitted from OCP.
32
ROB
RS-232C channel received by the OCP.
33
CTSB
RTSB
RS-232C channel clear-to-receive handshake.
35
RS-232C channel clear-to-send handshake.
VC4NB
Inverting differential analog input for drive control board aUXiliary VCO #4.
36
VC4PB
Non-inverting differential analog input for drive control board auxiliary VCO #4.
37
RFNB
Differential analog input from NTB/3TB to reference VCO, negative line.
34
38
RFPB
39
I-
FBNB
Differential analog input NTB/3TB to feedback VCO, negative line.
FBPB
40
".
BI006008
m-100020B
Table 11. Connector COMPL,

RS-232C I/O Between NTBI3TB Board and User Interface
Pin No.
Nomenclature
Description
The drive (or exciter) includes an RS-232C connection only for use as a serial link with
the drive (or exciter) configuration tools. These software packages are diagnostic and
configuration programs used during installation, tuneup, and troubleshooting. GE does
not intend this communications link to be used for any other purpose.
1-25
WARRANTY TERMS
CAUTION
Do not connect pin 25 of COMPL directly to a

PC (personal computer) unless jumper JP21
is in the 1-2 position, or damage may occur.

NOTE
Although the RS-232C interface should work

correctly with all 25 pins of COMPL connected, using the minimum possible interface
avoids incompatibility and noise problems.
RENEWALIWARRANTY REPLACEMENT
BOARD IDENTIFICATION
A printed wiring board is identified by an alphanumeric

part (catalog) number stamped on its edge. For example,
the NTB/3TB drive terminal board is identified by part
number 531X305NTBcrG1.
The 531X305NTB portion is the base number that specifically identifies the printed wiring board. The c and r digits are alphabetic characters that indicate the board
configuration and revision level, respectively. The G#
identifies a group, which is a variation of a particular
board. The NTB/3 TB has one group, G1.
NOTE
All digits are important when ordering or replacing any board.
The GE Motors & Industrial Systems Terms and Conditions brochure details product warranty information, including the warranty period and parts and service
coverage.
The brochure is included with customer documentation. It
may be obtained separately from the nearest GE Sales
Office or authorized GE Sales Representative.
This board has no fuses or other end-user serviceable

parts. If it fails, it needs to be replaced as a unit.
To obtain a replacement board, or service assistance,
contact the nearest GE Service Office.
GE requisition or shop order number
Board number and description
PROCEDURE FOR REPLACING BOARDS
WARNING
To prevent electric shock, turn off power to

the board, then test to verify that no power
exists in the board before touching it or any
connected circuits.
t..
BI006008
Drive Termi
at Board
GEII00(
CAUTION
CAUTION
To preve t equipment damage, do not remove

boards or connections, or re-insert them,
while po r is applied to the drive.
Avoid dropping mounting hardware into the

unit, which could cause damage.
5.
Treat all oards as static-sensitive. Use a

groundin strap when changing boards and
always sto e boards in anti-static bags or
boxes they were shipped in.
To replace an
1.
Set all contigurable items on the replacement (ne"

board in the exact position as those on the board be
ing replaced (old board).
If a board revision has added or eliminated a conti!
urable component, or re-adjustment is needed, refei
to Configurable Hardware paragraphs and Tables i
this instruction book.
/3TB board:
Turn off t e power to the drive, then wait several

minutes for all the capacitors to discharge. Test any
electrical c' cuits before touching them to ensure the
power is 0
NOTE
Because of upgrades, boards of different revision levels may not contain identical hardware. However, GE Motors & Industrial
Systems ensures backward compatibility of
replacement boards.
2.
Open the vets cabinet door to access the board.

(The NTB/3
is typically located below the drive's
board rack.)
3.
Carefully di onnect all cables from the NTB/3TB

board as foIl ws:
6.
Install the new board on the four standoffs with the

four screws removed in step 4.
For ribb n cables, grasp each side of the cable

connect r that mates with the board connector
and gent y pull the cable connector loose.
7.
Reconnect all cables disconnected in step 3, ensuring

that each connector is properly seated at both ends.
For cabl s with pull tabs, carefully pull the tab.
8.
Reconnect all individual wires disconnected in step 3

(as labeled), ensuring that each wire is properly secured in the terminal.
For wire attached to connector 3TB, loosen the

screw 10 ted at the top of each terminaland
carefully ull each wire free. (Ensure that wires
are labele to simplify reconnection.)
4.
Remove the fi ur screws that secure the NTB/3TB to

the four stand ffs and remove the board.
BI006008
:H-100020B
Notes:
GEMotors&
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~Jn~dustrialSystems
Issue Date: Rev. B, April 1997
1997 by General Electric Company, USA.

All rights reserved.
G,n.,.1 EI,et,le Comp,ny

Industri,1 Systems
1501 Roanoke Blvd.
Salem VA 24153-6492 USA
BI006008
GEJ-1000..
(Supersedes GEI-100022. I
GEMotors&
Industrial Systenl
;.-.--------+----------------------------LAN TERMINAL BOARD
These instruction do not purpon to cover all details or variations in equipment, nor to provide every possible contingency to be met
during installatio'l, operation, and maintenance. Iffurther information is desired or if particular problems arise that are not covered
sufficiently for th purchaser's purpose, the matter should be referred to GE Motors & Industrial Systems.
This document co tains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that
customer in the in tallation, testing, operation, and/or maintenance of the equipment described. This document shall not be rep roduced
in whole or in par nor shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems.
CONTENTS

1
Functional Descri ltion ................................ 1
Application Data
2
Connector Types
Input Specificatio s
Output Specificati ;>ns
I/O Tenninal Wiri g
I/O Connector Tab es
2
2
2
3
3
RenewallWarranty Replacement
Board Identificatio
Warranty Terms
Warranty Parts And Service
Procedure For Repl cing Boards
7
7
7
7
SAFETY ;YMBOL LEGEND
WARNING

I,--_C_A_UT_I_O_N_I

pf equipment
NOTE Indicates an esse tial or important procedure,

practice, conditio ,or statement.
WARNING

INTRODUCTION
The 531X307LTB LAN Terminal Board (LTB) is located
within the drive (or exciter) cabinet. The LTB provides an
interface between control devices (such as drives) and
external devices, such as contactors, indicator lights,
pushbuttons, and interlocks. The LTB does not contain
any adjustable hardware. See Figure 1 for a layout diagram that shows the location of the connector terminals,
connector plugs, and LEDs on the LTB.
There are two groups of the LTB, Gl and G2.
The G1 LTB provides eight 24 V dc configurable

control input plugs, CIlPL - CI8PL. These inputs are
connected to 8PL that carries I/O signals between
LTB, the NTB/3TB terminal board, and the drive
control board. See Table 3.
The G2 LTB omits input plugs CUPL - CI8PL and

the 8PL connector. The G2 LTB can only be used
with dc input signals at connector terminals INl INS.
BI006008
LAN Terminal Board
ON heat dissipation per terminal point is as follows:
CAUTION
Do not connect inputs across an inductive device. Doing so may damage the circuit.
.'he LTB provides eight sets of input terminals for 24 ~40 V ac or dc input signals. The input signals are con,erted to 24 V dc logic signals for use by the drive control
Doard. Note that ac input signals cannot be used on the G2
version LTBs. See Table 1.
The LTB control outputs consist of seven low voltage,
low current, form C relay contact connectors, OT1 - OT?,
with three terminals each. Also, pilot contact connections
function to actuate the seven high voltage, high current
relays, such as on the 53lX191RTB (RTB) or
DS200RTBA (RTBA) relay terminal boards. See Table 2.
24 V
0.2 watt
115 V
0.9 watt
230 V
1.8 watt
Tum-On Threshold:
9 V, 4.6 rnA acldc peak
Tum-Off Threshold:
6 V, 1.0 rnA ac/dc peak
NOTE
Devices connected in series with an input that

has a dc leakage current greater than 1.0 rnA
or ac peak leakage current greater than 4.0
rnA can cause the input to be continuously in
the ON state.
When the LTB and RTBA are used together,

relay contacts from both boards are available.
CONNECTOR TYPES
Heat Dissipation
Revision 53lX307LTBAGGl and later have the following ON/OFF specifications:
NOTE
APPLICATION DATA
Input Voltage
All other revision LTBs have the following ON/OFF

specifications:
Tum-On Threshold:
Tum-Off Threshold:
The LTB contains two types of connectors: plug-in connectors for ribbon cables and terminal board connectors
for individual wires.
Plug-in connectors, identified by PL in its name, carry

signal and power I/O within the control device.
Terminal board connectors, identified by TB in its

name, provide connections for wires from both internal and external devices.
See Tables 1 - 6 for definitions of all connections.
Devices connected in series with an input that

has an ac/dc leakage current greater than 0.5
rnA can cause the input to be continuously in
the ON state.
OUTPUT SPECIFICATIONS
Output voltage and current specifications for the relay
outputs (form C contacts, non-fused) at terminal points
on - OT? are as follows:
INPUT SPECIFICATIONS
Input voltage and current specifications for terminals
IN1 - IN8 are as follows:
NOTE
Voltage
Current
125 Vae
0.6A
Nominal Voltage Range
Current Range
110Vdc
O.6A
24 - 230 V ae, 60 Hz (G1)
4 -10 rnA peak
30Vde
2.0A
115-230 V ae, 50Hz (G1)
4-10 rnA peak
24 - 250 V de (G1 and G2)
4-8rnA
RTB and RTBA pilot outputs are form A contacts.
BI006008
I
GEI-100\
LAN Termi Ilal Board
VO TERMIN"L WIRING
VO CONNECTOR TABLES
All I/O terrninFll wire must be size 28 - 14 AWO.
The LTB connects to the drive control board via conne'l

tor 8PL (01 only), to the LAN control board or
drivelLAN control board via connector lOPL, to the
NTB/3TB terminal board via connector OPTPL, and to
the RTB or RTBA relay terminal boards via connector
RPL.
The maxi l1um length of a 26-conductor ribbon cable

is 20 feet.
The maxin um length of input and output wiring depends on tl ~ application.
Tables 3 - 6 list the I/O pin signals of the different connectors on the LTB. These tables are organized as follows:
NOTE
Do not rout
cables. In ac
of connectio
(INl - INS)
I/O ribbon cables with power

applications, capacitive coupling
wires can cause I/O input
leakage.
Table 3 - 8PL, I/O between the NTB/3TB terminal

board (NTB), the drive control board (SDCC or
LDCC), and LTB
Table 4 - lOPL, I/O between the LAN control board

or drivelLAN control board (SLCC or LDCC) and
LTB
Table 5 - OPTPL, I/O between the NTB/3TB terminal board (NTB) and LTB
Table 6 - RPL, I/O between the relay terminal board

(RTB or RTBA) and LTB
LED INDICATOF S
The LTB provides 5 LED indicators that function as
follows:
Indicator
Description
LED1- LEDS
ION when the source is applied to

ircuits IN1 - INS, respectively
bN when relays RX1
LED17 - LED23
ClIP\.
CI]
~CI]
~CI]
~ -
- RX7 are
nergized, respectively
CI1Pl.
u:::::::::::Jl~
I
B
I
1Il'~
pWlas
,..
lIP\.
::c=:J]~'~
I_
531X307LTB__G1
I'
lil
u:on
,..
LCD21
~(1)11)
~(1)1I
~[I)I.
LED I 7
'-'
'-'
'-'
'"'
'-'
'"'
'"'
'"
'-'
,..
'...."0
0
r:;
i
I/O
J:;
TERr.lIHAL SOARD
I::
f:
I::
S
JCI]
nCI]
,
ro
~
e:t7PI.
~n
RX7
orv
O~
OTIS
IXJ
IX"
lID
I
0_
IXZ
011U
RXI
I
OTft
emil
,TIl
1T87
11M
nn
JtlD
I
1TM
ITII2
1'1111
QIIPI.
Figure 1. L TB Board Layout Diagram
BI006008
LAN Terminal Board
Table 1. Connectors IN1 -INB,

Inputs to LTB
Terminal
Nomenclature
Description
1 (-)
IN,lS*
Low input for signal In,lS

24 - 240 V ac or dc input logic signal is brought in on In~+ and In~- where + is
for the high side and - is for the low or ground side. Each input draws 6 mA
maximum current. The signal is converted to a 24 V dc logic signal for the
Not connected
3 (+)
High input for signal InlS

24 - 240 V ac or dc input logic signal is brought in on ln~+ and In~- where + is
for the high side and - is for the low or ground side. Each input draws 6 rnA
maximum current. The signal is converted to a 24 V dc logic signal for the
* ! corresponds to the input circuit number, IN1 - IN8.
Table 2. Connectors OTt - 0T7,

LTB Form C Relay Contact Outputs
Terminal
Nomenclature
Description
1 (CM)
OT2S*
Relay RXlS* common connection - contact ratings are 0.6 A @ 125 V ac, 0.6 A
@ 110 V dc, or 2.0 A @ 30 V dc
2 (NC)
OT2S*
Relay RX,lS* normally closed connection - contact ratings are 0.6 A @ 125 V
ac, 0.6 A @ 110 V dc, or 2.0 A @ 30 V dc
3 (NO)
OT2S*
Relay RX2$* normally open connection contact ratings are 0.6 A @ 125 Vac,
@ 110 V dc, or 2.0 A @ 30 V dc
0.6 A
2S corresponds to the relay (RX1 - RX7) or relay output circuit number (OTt - OT7).
BI006008
GEII000
LAN Terminal Board

i

I/O Between L TB and Drive Control Board
Pin Nq.
NTB Terminal
Nomenclature
Description
FA
Non-inverting RS422 half-duplex serial data line from the

drive control board's Motor Control Processor (MCP)
UART.
FB
Inverting RS-422 half-duplex serial data line from MCP

UART.
10
DCOM
12
EXSY
External sync input to MCP.
... -_ .........
-_... _..-
Not connected.
EOAB
Encoder interface Channel A non-inverted differential

input.
IEDAB
Encoder interface Channel A inverted differential input.

(Tie to COM for single-ended encoders.)
EDBB
Encoder interface Channel B non-inverted differential

input.
IEDBB
Encoder interface Channel B inverted differential input.

(Tie to COM for single-ended encoders.)
10
EDMB
11
11
IEOB
Encoder interface marker channel inverted differential input. (Tie to COM for single-ended encoders.)
12
...........
------
13
14
CI1PL
CI1 PL - CI8PL are general-purpose control inputs, 24 V

dc maximum with 27 k.Q input impedance.
14
CI2PL
See CI1 PL (pin 13).
Not Connected.
15
CI3PL
16
2(
CI4PL
17
22
CI5PL
See CI1PL (pin 13).
18
24
CI6PL
19
26
CI7PL
20
28
CI8PL
BI006008
LAN Terminal Board
2B

I/O Between LTB and LAN Control Board or Drive/LAN Control Board (SLCG or LDCC)
Pin No.
2-8
Nomenclature
Description
P24
+24 V dc
112 -118
24 V logic lines to the drive

Not Connected
9-16
17
N24
-24 V de
18
111
24 V logic lines to the drive
19-25
101 -107
Relay control lines 0 - 6
26
P24
+24 V dc
Table 5. Connector OPTPL,

I/O Between LTB and NTB/3TB Board
Pin No.
Nomenclature
Description
X2
Return for CFX1 120 V ac loads (isolated from COM) - Same as NTB/3TB
pin 85.
CFX1
120 V ac, 15%, from NTB/3TB board, fused at 500 mA, including internal
fans (isolated from COM) - Same as NTB/3TB pin 83.
Table 6. Connector RPL,

I/O Between LTB and Relay Terminal Board (RTB or RTBA)
Pin No.
Nomenclature
Description
115 V
115 V ac RTBA relay common

Not Connected
RX1
Not Connected
RX2
RX3
RX4
10
11
RX5
16
RTBA relay K10 pilot output 4

Not Connected
RX6
14
15
RTBA relay Kg pilot output 3

Not Connected
12
13

Not Connected
8
9

Not Connected
6
7

Not Connected
RX7

Not Connected
BI006008
GEl10m) I
:
ARRANTVREPLACEMENT
WARNING
A printed wmn
part (catalog) n
the LAN termin
531X307LTBcr
board is identified by an alphanumeric

ber stamped on its edge. For example,
board is identified by part number
#.

connected circuits.
The 531X307LT portion is the base number that specifically identifies th printed wiring board. The c and r digits
are alphabetic ch acters that indicate the board configuration and revisio level, respectively. The G# identifies a
group, which is a ariation of a particular board. The L TB
has two groups, G and G2.
CAUTION
To prevent equipment damage, do not remove
while power is applied to the drive.
NOTE
All digits are i portant when ordering or reo

placing any b rd.
Treat all boards as static-sensitive. Use a

grounding strap when changing boards and
always store boards in anti-static bags or
boxes they were shipped in.
WARRANTY TER S
The GE Motors & In ustrial Systems Terms and Conditions brochure details product warranty information, including the warranty period and parts and service
coverage.
The brochure is indud d with customer documentation. It
may also be obtained s parately from the nearest GE Sales
Office or authorized G Sales Representative.
To replace an LTB board:
1.
Turn off the power to the drive, then wait several

electrical circuits before touching them to ensure the
power is off.
2.
Open the drive's cabinet door to access the board.

(The LTB is typically located below the drive's board
rack.)
3.
Carefully disconnect all cables from the LTB board

as follows:
WARRANTY PARTS
This board has no fuses r other end-user serviceable
parts. If it fails, it needs t be replaced as a unit.
For ribbon cables, grasp each side of the cable

connector that mates with the board connector
and gently pull the cable connector loose.
To obtain a replacement oard, or service assistance,

contact the nearest GE Se ice Office.
For cables with pull tabs, carefully pull the tab.
Please have the following nformation ready to exactly

tion:
identify the part and app
For wires attached to terminals, loosen the screw

located at the top of each terminal and carefully
pull each wire free. (Ensure that wires are labeled
to simplify reconnection.)
r and model number

Board number and desc .ption
4.
Remove the four screws that secure the LTB to the

four standoffs and remove the board.
BI006008
LAN Terminal Board

",
5.
Orient the new LTB in the same position as the one

removed and install the new board on the four standoffs with the four screws removed in step 4.
6.

7.
Reconnect all individual wires disconnected in step 3

(as labeled), ensuring that each wire is properly secured in the terminal.
CAUTION
NOTE
Because of upgrades, boards of different revision levels may not contain identical hardware. However, GE Motors & Industrial
Systems ensures backward compatibility of
replacement boards.
GEMotors&
____________________________-:.::.:Industrial Systems
Issue Date: Rev. B, June 1997
Stln,,,1 Electric Company

Industrial Systems
1501 Roanoke Blvd.
BI006008
GEI-1000;'
(Supersedes GEI-1000;
GE Drive Systen
Replacement Procedures for

DCFB Power Supply Board
DS200cDCFBG 1A:.... -,-,and. DS2DODCEBG 18__
These instruction do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be
met during instal ation, operation, and maintenance. Should further information be desired or should particular problems arise that
are not covered s rfficiently for the purchaser's purpose, the matter should be referred to GE Drive Systems, Salem, Virginia U.S.A.
WARNING
Circuits to instrument numerous ac line and dc

motor or generator signals, including:
Armature current and voltage
This equip ent contains a potential hazard

of electric sock or burn. Only those who
are adequat Iy trained and thoroughly familiar with he equipment and the instructions shoul install, operate, or maintain
this equipm nt.
Field current
Ac line current
Ac line voltage magnitude and phase sequence
INTRODUCTIO
These instruction provide information that may be

needed when repl cing the DS200DCFB Power Supply
Board (DCFB). his information includes instructions
on how to replac the DCFB board in the system as
well as a descript on of fuses, testpoints, and
configurable hard are items (such as jumpers and
switches).
The DCFB board provides control-level power to a dc
drive or exciter d 115 V ac that is typically used to
power enclosureooling fans. The DCFB includes the
following circuits:
15, and 24
Control-level power supplies (+5,

V dc)
Motor or ge erator field power circuits (except the

SCR module

part number imprinted on it. For example, the Power
Supply Board is marked with part number:
DS200DCFBG#ruu
The DS200DCFB portion is the base number that identi
fies the printed wiring board, in this case, the Power
Supply Board. The r and u digits are alphabetic characters that indicate the board revision level. The r digit
reflects a functional change that is not downward compatible. It is essentially a new catalog number. The u
digits represent revision levels that are downward compatible. The G# identifies a group, which is a variation
The DCFB board has only one group, Gl.
Driver circui s for the armature SCR gate pulse

generators
NOTE
All digits are important when ordering or

replacing any board.
BI006008
GEI-I00028A
Power Supply Board
WARNING
6.
If a board revision has added or eliminated a configurable component, or re-adjustment is needed,

refer to Table 1.
To prevent electric shock, turn off power

then test to verify that no power exists before touching this board or any connected
circuits.
NOTE

Tevisionlevels may not contain identical
hardware. However, GE Drive Systems ensures compatibility of its replacement
boards.
CAUTION
While power is applied to the drive, do not

remove printed wiring boards or connections, or re-insert them. This can damage
the equipment.
On the replacement (new) board, set all jumpers

and switches in the exact position as those on the
board being replaced.
7.
Install the new board, ensuring that all holders snap

into position.
8.
The cables are labeled with the correct connector

name, as marked on the board. Reconnect all cables as labeled. Ensure that cables are properly
seated at both ends.
To replace the DCFB board:

1.
Turn off power to the equipment, then wait a

few minutes for the DCFB's capacitors to discharge. Test any electrical circuits before touching
them to ensure power is off.
2.
Open the equipment's cabinet door to access the

printed wiring boards. This exposes the drive control card, which faces the front. The DCFB board
is mounted behind the drive control card, also
facing the front.
3.
Pull the locks located on either side of the cabinet.

Lift the drive control card and tilt forward and
down to expose the DCFB board.
4.
To remove the DCFB board, carefully disconnect

all cables as follows: .
For a cable with a pull tab, carefully pull the
tab.
5.
The DCFB board is held in place by plastic snaps

(holders). Push these holders back to release the
board.
EE PARAMETER ADJUSTMENT
After installing a new DCFB board, adjust the EE parameter for voltage feedback offset, EE.574 (VFBOFS).
To do this, calibrate the voltage feedback by running an
Itune (Test 14) using the drive's Programmer module.
This test reads the board's voltage feedback offset, then
writes this value to the EE.574 Mirror. The mirror
value can then be recorded and copied into EE.574.
These procedures are described below.
1. Perform the Itune, Test 14, as follows:
Key Sequence
a.
b.
c.
d.
e.
f.
Programmer Display
M S
0% I 0%
(SET)(DRV#)(7)(7)(ENTER) PARAMETR E MODE
(MODE)
PARAMETR M MODE
DIAGNOSTIC MODE
(MODE)
(TEST)( 1)(4)(ENTER)
ENTR PAR 1
(ENTER)
ENTR PAR 2
(ENTER)
ITUNE DONE
2. Copy the new voltage feedback offset value into

EE.574:
Key Sequence
a. (PREV)
b.
(PREV)
c. (5)(7)(4)(ENTER)
Programmer Display
DIAGNOSTIC MODE
PARAMETR M MODE
VFBOFS M
abc
(record value abc)
BI006008
Power Supply Bpard
GEI-lOO028;!
d.
e.
f.
g.
3.
(MODE)
(PREV)
(5)(7)(4) (ENTER)
(a)(b)(c)(ENrrER)
Figure 1 shows the layout of the DCFB board, including the locations of DCFB adjustable hardware.
PARAMETR M MODE
PARAMETR- E MODE
VFBOFS
xyz
VFBOFS
abc
FUSES
Restore the (riginal current regulator tuneup values

either by pre sing the drive control card's RESET
button for a ard reset or by cycling power to the
equipment.
The DCFB contains protective fuses FU1 through FU3,

defined in Table 2. Neon light LTl lights if fuse FU1 i!
blown; light-emitting diode (LED) CR51 lights if FU2
is blown and control power is applied to the equipment;
and LED CR55 lights if FU3 is blown and control
". power is' app1ied: Figure 'I 'snows the<Iayoui of 'the
DCFB board including the locations of the fuses, neon
light, and LEDs.
HARDWARE SE~TINGS
The DCFB inclue s Berg-type (manually moveable)

jumpers, identifie~ by a IP nomenclature, and DIP
switches, identifif d by an SW nomenclature. The items
are used for customer options. Table 1 lists and defines
the jumpers and s~itches on the DCFB board.
TESTPOINTS
Most of the jump r and switch selections have been

factory set. The tf st data sheets supplied with each
controller (in the equipment door pocket) indicate these
positions.
The DCFB board contains onboard testpoints for use in

troubleshooting. Testpoints are metal posts located on
specific signal paths. The signals can then be measured
or viewed by connecting an oscilloscope or other measuring instrument to the corresponding testpoint.
As described prev ously, ensure that the jumpers and

switches on the Of w board are placed the same as on
he old board, unless the instructions indicate otherwise.
Table 3 lists and defines the testpoints contained on the

DCFB. Figure 1 shows testpoint locations.
IA1PL
VI
II
V2
II
V3
PIA
II
II
P2A
VMIA
II
II
VMIS
II
VM2A
II
<-.c..c..c..
VM2BARDW~~ti:a:
II 1
Irlrl""'''3
I I II II r
DDDD~
IA2Pl
ROW
~
c....c....':o%
IF1PL
di]o:
"''''''''''''''''3
II
II
I I
DDDD~
,0,,0,
PPL
~Ow
IF2PL
~DW
NPL
SW7
JPI
3:i
~D
08
SQPL
JP2
c=J=J
LTt
I 2 3
FU2
CR51
CO
FU3
CO
5PL
o rr::=J rr::=J
DCQ>,l
I FPL
2FPL
Figure 1. DCFB Board Layout
BI006008
Power Supply Board
GEI-lO0028A
NOTE
The following table defines the jumpers and switches used on the DCFB board. The Revision
column indicates the board's revision number for the item listed. The Name column indicates the
item's identification as marked on the board. (JP=jumper; SW=switch) The Description column
designates the board's group for that item as defined. The default setting for each item is listed
first.
Table 1. DCFB Board Adjustable Hardware
Revision Name
Description
All
JPl
Select source of ac line sync signal passed to the control card

Proper synchronization to the ac line is critical to the operation of the drive, and 1.2 is the only valid setting of this
jumper for a DC2000 drive.
1.2 Generated by DCFB using line voltage 2-3 (DC2000 applications)
2.3 Generated by the TCCB card (EX2000 applications)
All
JP2
Decrease ac contactor drop-out time

Normally, this circuit delays opening of the ac contactor to ensure all load current has been extinguished. Removal
of this jumper can cause the control-on circuit to drop out the MA relay before the current is brought to zero.
1.2 Normal operation, gives about 100 ms delay
o Minimum delay, (and manufacturing test)
All
JP3
Configuration of armature shunt #1 VCO circuit

Jumpers JP3 through JP7 must be set together for proper operation of this voltage controlled oscillator (VCO)
which converts the shunt current to a frequency signal which is then read by the SDCC card. For DC2000/EX2000
G, C, and D frames all jumpers should be in the 1.2 position, enabling the DCFB VCO. For DC2000/EX2000 M, J,
and K frames, JP3 and JP4 should be 1.2 and JP5 through JP7 should be 2.3, bypassing the DCFB VCO and using
the SHVI card VCO instead. For DFM applications, JP3 and JP4 should be 2.3 and JP5 through JP7 should be 1.2,
scaling the DCFB VCO to receive an analog isolator signal. For DFM settings, Vin = -5.0 V gives a frequency
output of approximately 12 Hz and Vin = + 5.0 V gives a frequency output of approximately 488 kHz.
1.2 G, C, D, J, & K frame DC2000 applications
2.3 DFM applications
A.II
JP4

JP5

1:1.11
JP6

2.3 DFM applicatiof1s
1:1.11
JP7

"\11
JP8
Configuration of armature shunt #2 VCO circuit

Jumpers JP8 through JP12 must be set together for proper operation of this VCO, which converts the shunt
current to a frequency signal which is then read by the SDCC card. For DC2000/EX2000 G, C, and D frames all
jumpers should be irl"tne-l.2 pusition,'enablingLhe DCFB veo. -For D'C2000/EX2000 Jand K frames, JP8 and JP9
should be 1.2 and JPl 0 through JP12 should be 2.3, bypassing the DCFB VCO and using the SHVI card VCO
instead. For DFM applications, JP8 and JP9 should be 2.3 and JPl 0 through JP12 should be 1.2, scaling the DCFB
VCO to receive an analog isolator signal. For DFM settings, Vin = -5.0 V gives a frequency output of approximately 12Hz and Vin = + 5.0 V gives a frequency output of approximately 488 kHz.
"\11
JP9

BI006008
Power Supply Bard
GEI-I00028A
Table 1. DCFB Board Adjustable Hardware - Continued

Revision Name
Description
All
JP10
Configuration of.armature shunt #2 VCO circuit (see JP8)

All
JPll

All
JP12
onfiguration of armature shunt #2 VCO circuit (see JP8)

1:2 -G, C, D,J;'&-K-fl'l'lme DC20e6-applications
All
SWl
All
SW2
elect the ac line voltage

o (All off) 308
1
(1 on)
488
2
(2 on)
617
8
(4 on)
364
9
(1 & 4 on) 545
applied to the line sync circuit (see SW1)

max nominal V ac (762 V ac using SHVI attenuators)
All
SW3
elect the ac line voltage

o (All off) 308
1
(1 on)
488
2
(2 on)
617
8
(4 onL
364
9
(1 & 4 on) 545
applied to the line voltage 1-3 circuit (see SW1)

All
SW4
elect the ac line voltage applied to the line voltage 1-2 circuit
Wl and SW3 scale the Vl-2 and Vl-3 line voltage feedbacks into VCOs used to provide the SDCC with a
requency signal proportional to instantaneous line voltages. These are used for phase loss and sequence
etection, and for line sync via the bi-phase PLL. SW2 scales the V2-3 voltage applied to the circuit used to
enerate the ac line synchronization and frequency measurement signal via the zero-crossing detector. Scaling of
Wl-SW3 is in conjunction with the SHVI/M card voltage attenuators, if used.
he maximum nominal V ac is the maximum ac input voltage which may be 15% high without saturating the
nstrumentation circuitry. Switches SWl through SW6 must all be set to the same position. Above 617 Vac,
HVI/M attenuators must be used; refer to SHVI JP9 through JP17. For the DC2000, the setting of these switches
ffect the scaling of VAR.l 08 (ACLINMAG), which affects the phase loss protective fault (see EE.582). For each of
he maximum nominal rms line-line voltage selections, if the input is at the maximum nominal, VAR.l 08 will be
pproximately 25700 counts. For the EX2000, these switches have a similar effect on the phase loss function
rovided by EE.576 (PUATHR). For both drive types, a scale factor, EE.VLL_SF allows these voltages to be scaled
o a 1 pu = 20000 basis prior to being applied to the phase loss function.
o (All off)
1
(1 on)
2
(2 on)
S
(4 on)
9
(1 & 4 on) 545 max nominal V ac (1353 V ac using SHVI attenuators)
elect the voltage applied to the dc bridge voltage feedback VCO circuit
W4 scales the voltage applied to the circuit used to generate the frequency representation of dc bridge voltage
Pl to P2) feedback passed to the drive control card. SW5 scales the voltage applied to the circuit used to
enerate the frequency representation of dc motor voltage feedback passed to the drive control card. SW6 scales
he voltage applied to the circuit used to generate the analog representation of dc motor voltage feedback passed
o the drive control card. Scaling of SW4 through SW6 is in conjunction with the SHVI/M card voltage attenuators,
fused.
he voltages listed in the selection table are maximum nominal V ac and nominal V dc. The maximum nominal V ac
s the maximum ac input voltage which may be 15% high without saturating the VCO channel instrumentation
ircuitry. For the dc VCO channels, nominal V dc is the dc voltage which results in 20,000 counts raw voltage
eedback (VFBRAW) before scaling by EE.1503 (VFBSFn). Switches SWl through SW5 should be set to the same
osition. Above 617 V ac, SHVI/M attenuators must be used; refer to SHVI JP9 through JP17.
o (All off) 308 max nominal V ac (762 V ac using SHVI attenuators)
1
(1 on)
2
(2 on)
8
(4 on)
9
BI006008
GEI-I00028A
Power Supply Board
Table 1. DCFB Board Adjustable Hardware - Continued

Revision Name
Description
All
SW5
Select the voltage applied to the de motor voltage feedback VCO circuit
(All off)
1
(1 on)
2
(2 on)
8
(4 on)
9
All
SW6
Select the voltage applied to the analog de motor voltage feedback circuit
SW6 is an analog instrumentation channel. The channel feeds an AID converter on the SDCC. A 2.5 volt bias
added on the DCFB allows the unipolar' AlDcbniterter to "read" bipolar instrumentation signals. A change of 1 pu
for a de voltage results in a 1.7 volt swing about the + 2.5 volt bias. A 1 pu change for an ac voltage results in
a 1.535 volt swing about the +2.5 volt bias.
o (All off)
154 V ac, 171 V de ( 380 V ac, 422 V de using SHVI attenuators)
1
(1 on)
244 V ac, 270 V de ( 605 Vac, 671 V de using SHVI attenuators)
2
(2 on)
4
(3 on)
11
(1,2,4 on) 426 V ac, 472 V de (1061 Vac, 1175 V de using SHVI attenuators)
5
(1,3 on)
475 V ac, 526 V de (1184 V ac, 1312 V de using SHVI attenuators)
6
(2,3 on)
540 V ac, 598 V de (1345 V ac, 1489 V de using SHVI attenuators)
7
(1,2,3 on) 630 V ac, 697 V de (1570 V ac, 1739 V de using SHVI attenuators)
All
SW7
Select ac line CT burdens as a function of rated drive hp and voltage

These switch settings scale the ac line current transformers as a function of de amps. Correct scaling is essential
for proper operation of the ac IOC protective feature. These CTs are mounted on lines 1 and 3 of the power
converter, and are wired thru plug 1CPL to a common burden resistor. Select the proper setting as a function of
drive current and CT turns ratio. The CT ratio can be determined from its part number and the following table.
PART NUMBER
TURNS RATIO
104X157AB 023
1000:1
104X157AB025
2000:1
104X157AB020
4000:1
104X157AB013
5000:1
104X157AB 024
5000:1
104X157AB 026
8000:1
When set properly, the current magnitude read in VAR.1 019 (CTCFB) should be scaled within 15% of the current
magnitude in VAR.1 04 (CFB). Above 144 mA ACCT secondary current, the CTs are routed through a set of 10: 1
step down CTs on the SHVI/SHVM card, using JP1 through JP8 on the SHVI/SHVM. The enumerations listed are in
terms of the mA input to the DCFB (ACCT secondary mA attenuated by 10:1 SHVI/SHVM attenuation if selected).
At present the SHVI/SHVM boards are used on M, J, K, and L frames only, and then 10: 1 CTs are used only if the
ACCT secondary current is > 144 mAo
The CT secondary current (in mAl is approximated by:
1 pu rated current * 1000

let, mA =
-----------------------------
Combined,CT turns ratio
o
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
(All off)
(1 on)
(2 on)
(1,2 on)
(3 on)
(1,30n)
(2,3 on)
(1,2,3 on)
(4 on)
(1,4 on)
(2,4 on)
(1,2,4 on)
(3,4 on)
(1,3,4 on)
(2,3,4 on)
(All on)
0.0
6.0
13.4
21.1
28.4
39.3
46.7
54.4
61.8
88.7
96.0
103
111
122
129
137
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
<=
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
let,
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
mA
<
<
<
<
<
<
<
<
<
<
<
<
<
<
<
<
6.0
13.4
21.1
28.4
39.3
46.7
54.4
61.8
88.7
96.0
103
111
122
129
137
144
BI006008
Power Supply I oard
GEI-I000281
Table 2. DCFB Board Fuses

Fuse
Function
FU1
Fuse for 115 V ae power supply brought to 3TB; 1/2 A, 2AG, fast acting. FU1 protects the 115 V ac power
supplied for customer use. Check for wiring errors or overload if this fuse blows. When the fuse is blown and
load is cpnnected, neon light LT1 on the DCFB will be lit.
FU2
Fuse for + 24, + 15, and + 5 V de signal-level power supplies; 7 A, 2A G, fast acting. When FU2 is blown, thE
drive is I nable to generate fault messages, but LED CR51 will be illuminated when control power is applied to
the drive. The usual cause of this fuse blowing is an accidental short of +24 V, either while probing or due to
a wiring ,mor at the terminal board. If the fuse continues to blow when 1PL, 2PL, and 5PL are disconnected
from the DCFB,- the. board should be .replaGed.
FU3
Fuse for -24 and -5 V de signal-level power supplies; 7 A, 2 AG, fast acting. When FU3 is blown, the
Programrner is unable to display fault messages, but LED CR55 will be illuminated when control power is
applied tp the drive. The usual cause of this fuse blowing is an accidental short of -24 V, either while probing
or due tc a wiring error at the terminal board. If the fuse continues to blow when 1PL, 2PL, and 5PL are
disconne ted from the DCFB, the board should be replaced.
Table 3. DCFB Board Testpoints

Name
Description
P5
Testpoint for regulated + 5 V dc ( 5 %) power supply.
DCOM
0 V common reference point for test signals.
P15
Testpoint for regulated + 15 V dc ( 5%) power supply.
N 15
Testpoint for regulated -15 V dc ( 5 %) power supply.
ACCT
Testpoint for ACCT signal from DCFB to SDCC.
BI006008
GEI-I00028A
Power Supply Board
Notes:
GE Drive Systems
Salem, Virginia 24153
Date: September 1993
on A: December 1994
GEI100029C
BI006008GEI-1000298)
(Supersedes
GEMotors&
Industrial Systems
----------1--------------------------DRIVE CONTROL CARD

DS215SDCCG_A__
These instructions" 0 not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met
during-installation; lpper-ation;-and maintenaltCeAffurthel'.jnfol'mation.js.desired'OrifJXlrtiC1flar<prdble~rtrise-tl-rat-are-not-c(')vered,
sufficientlyfor the J. urchaser 's purpose, the matter should be referred to GE Motors & Industrial Systems,
This document cont~ins proprietary information ofGeneral Electric Company, USA and is furnished to its customer solely to assist that
customer in the inst llation, testing, operation, and/or maintenance ofthe equipment described This document shall not be reproduced
in whole or in part or shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems,
CONTENTS
Safety Symbol Le ~end
1
Functional Descr'ption ................................................ 1
Application Data .....................................................3
Testpoints
3
Configurable Ha dware
3
Software Configuration Tools
4
I/O Tables
5
RenewallWarran y Replacement
15
15
Board Identifica ion
Warranty Terms
15
Warranty Parts )~d Service
15
Procedure For R placing Boards
15
Hardware Adjus Iments
17
ReplacinglInsertfng Software
17
SAFE"Y SYMBOL LEGEND
WARNING


condition,
or statement that, if
CAUTION
.. ., ..not strictly. obsenred,.could reo
'--------+--' suIt in damage to or destruction
of equipment
NOTE Indicates <tn essential or important procedure,
practice, cpndition, or statement.
WARNING

INTRODUCTION
This instruction book addresses only drive applications of
the DS215SDCCG_A_ _ card (SDCC). The SDCC contains the primary control circuitry and software for a
drive or exciter. The SDCC consists of three 16-bit microprocessors and associated circuits coupled via dualported RAM. (Dual-ported RAM [DPR] is RAM configured as memory arrays that can be independently and
simultaneously accessed by two microprocessors.)
The SDCC also includes interface circuitry that connects

with other boards to form various types of ac and dc
motor drives. The interface circuitry controls and processes driveandmotor signals, and customer I/O. (The
interface circuitry and three main microprocessors are
used for other functions in TC2000 applications.) The
SDCC's three main microprocessors are:
Drive Control Processor (DCP). An 80C186 microcontroller (VI) with numerous built-in peripheral
functions and uses both digital and analog I/O.
BI006008
SDCC Drive Control Card
GEI-I00029C
These functions include address decoding for chip

selects, wait-state generators, an interrupt controller, timer/counters, and the direct memory access
(DMA) controller. DCP software consists of user
interfaces, outer regulating loops (such as speed and
position), and system level functions.
Motor Control Processor (MCP). An 80C196 microcontroller (U21) with high-speed I/O, conventional digital I/O, analog I/O, timer/counters, and a
watchdog timer. MCP software consists of inner
loops .such as curr.ent regulators ...and.motorftechnology specific functions such as dc phase control, ac
motion control, and ac general purpose.
Co-motor Processor (CMP). A TMS320C25 digital
signal processor (U35) that performs math-intensive
functions for motor control algorithms too complex
for the MCP. The SDCC uses this processor and its
associated circuitry only when the drive requires the
additional processing capability. The CMP interfaces only to its EPROM and MCP/CMP dualported RAM.
The DS215SDCC card includes onboard software stored

in five memory chips: four EPROMs (U11, U12, U22,
and U23) that contain configuration data programmed at
the factory and one EEPROM (U9) that contains fieldadjustable parameters. These memory chips are contained in sockets on the SDCC.
CARD CONNECTIONS
The SDCC interfaces with the other boards of the controller and external signals via eight connectors (designated
]L). See Figure 3 for an SDCC layout diagram showing
the locations of the connectors and Tables 3 - 9 for the
pin signals of each connector. Connectors to other boards
are as follows:
~..
IPL - I/O between the Power Supply/Interface Board

(DS200IMCP, DCI, SDCI, or DCFB) and the SDCC
'2'PI::;"'5~i'5~and24VdCihplltsiTomthe'Power"
Supply/Interface Board to the SDCC
3PL - SDCC outputs to the LAN Communications .

Card (DS215SLCC)
6PL - I/O between the Drive Terminal Board

(53IX305NTB) or Simple Drive Terminal Board
(DS200STBA) and the SDCC
7PL - I/O between the Signal Processor Card

(53IX309SPC) or Multibridge Signal Processing
Card (DS200SPCB) and the SDCC (not present on
SDCCG3s)
8PL - I/O between the Drive Terminal Board

(53IX305NTB) or Simple Drive Terminal Board
(DS200STBA) and the SDCC
9PL - Not Used (not present on SDCCG3s)
IIPL - SDCC outputs to meters (not present on

SDCCG3s)
When ordering replacement boards, note that the

DS200SDCC card does not include the five memory
chips mentioned above (the sockets are empty).
AUXILIARY BOARD MOUNTING PROVISIONS

NOTE
When replacing a DCC, specify a
DS215SDCC card as a replacement to ensure
that the five memory chips are included.
CARD GROUPS
There are currently three group numbers of the SDCC
available (G2 versions were never manufactured). The
variations between the gro4Ps 'are as.foJl()ws:
DS200SDCCG IA__: Used in AC2000, DC2000,

and EX2000 drive applications
DS200SDCCG3A__: Variation ofSDCC that has

reduced functionality (used in DCIOOO drives)
DS200SDCCG4A__: Used in TC2000 turbine applications (same as G IA except with enlarged EE parameter storage area and different fIrmware)
The SDCC has mounting provisions for other auxiliary

boards and modules. The following boards can be
mounted on the SDCC:
DS215SLCC or 53lX306LCC LAN Communications Card
53lX309SPC Signal Processor Card
DS200SPCB Multibridge Signal Processor Card
. LED DISPLAY
A bank of 10 diagnostic LEDs is provided on the SDCC
and displays fault codes in either BCD (binary coded
decimal) or binary form, depending on the fault number
(see Figure 3 for location). The LEDs indicate faults in a
blinking mode as follows:
BI006008
SDCC Drive Con rol Card
Faults 1 to 39<
slow blinl rate
BCD patt m (left-most two LEDs encode the
hundreds iigit; next four, the tens digit; rightmost, the mits digit; see Figure 1)
I__CA_UT_I_O_N_I
The system trips when a hard reset is initiated; the system should not normally be reset
when running.
Diagnostic LEOs
. ~ . ~DDD~DDD
~ I
hundred
digit
I I
tens
digit
units
digit
Figure 1. BCD-coded LED Display
Faults 400 to 023

faster blir k rate
9
binary pa em (left-most LED is 2 [or 512], sec8
ond-most LED is 2 [or 256], and so on; see Figure 2)
No fault or drive not running
sequentia blinking, two at a time
blinking f om outer positions inward to center,
and back
These same LEDs an be set by software jumper to also

coarsely display dI ve variables when running. (For example, displayed iJ an absolute or signed bar graph
mode). Setting sofi ware jumpers this way does not inhibit
the LED fault disp ay.
Diagnostic LEOs
~ ~~~~~~~~
IL
29
2 8 (or 256)
(or 512)
Figure . Binary-coded LED Display
GEI-I00029C
A reset can be generated in four ways:
"
By pressing the RESET pushbutton on the SDCC

(See Figure 3 for location.) c''': '
,..'.... ,.....
.-'," -,.....;.l
.,
';~,
,-~."
...
By applying +5 to +24 V dc to customer interface

points on the STBA or NTB/3TB boards (These
points interface with the SDCC through 6PL.)
By the SDCC generating a reset via programmed

softWare control
By the SDCC generating a reset via automatic internal hardware watchdog protection.
APPLICATION DATA
TESTPOINTS
The SDCC includes onboard testpoints for test and troubleshooting purposes. Testpoints are metal posts located
in specific signal paths. These signals can be measured or
viewed on an oscilloscope or other measuring instrument.
Table 1 lists and defmes each testpoint. Figure 3 shows
testpoint locations.
CONFIGURABLE HARDWARE
The SDCC includes configurable hardware that must be
set correctly for the application:
Berg-type (manually movable) hardware jumpers,

identified by a JP nomenclature (see Table 2)
Wire jumpers, identified by a WJnomenclature (see

Table 2)
These jumpers are used for factory test or user application

options. Most of the jumper selections have been factory
. set. The test data sheets supplied with each controller (in
the drive/exciter door pocket) indicate these factory set
positions. Table 2 lists the jumper descriptions, showing
the default setting first.
RESET CIRCUI1 S
The SDCC provid s four reset circuits, including a
RESET pushbutto .
Figure 3 is a layout diagram of the SDCC, showing the

locations of all jumpers.
BI006008
GEI-I00029C
SOFTWARE CONFIGURATION TOOLS

Any adjustment, downloading, or replacement of software
on the SDCC requires the use of the snooo, GE Control
System Toolbox, or LynxOS Drive Configurator. The
applicable drive/exciter instruction book, an appropriate
PC, and the snooo, GE Control System Toolbox, or
LynxOS Drive Configurator instruction book are also required for any software adjustments.
snooo is a DOS based set of software tools for

configuring 9E DIRECTO-MATlC2000 con~ol
equipment. Refer to GEH-5860 for complete information on these tools.
The GE Control System Toolbox is a Windows

based set of software tools for configuring GE
DIRECTO-MATlC 2000 control equipment. Refer
to GEH-6333 for complete information on the toolbox.
The LynxOS Drive Configurator is a set of software

tools for configuring GE DIRECTO-MATIC 2000
control equipment. It is designed to run on a personal
computer (PC) operating with the LynxOS operating
system. Refer to GEH-6203 for complete information
...,,con1h.e..IDolbox... '.' ,,"" ,........,
"-'--~.- ..'", .. "
Windows is a trademark of Microsoft Corporation

DIRECTO-MATIC is a registered trademark of
General Electric Company, USA
LynxOS is a trademark of Lynx Real-Time Systems,
Inc.
:[
JP33
tp
CP5
r
CCIot
:[
~I
"r
CJ:J
1 2 ,'5
7PL
on
Xf
CLR
CII
CDR
0
~)
ib
.,
")
N
0=EJ!
0 ..,TPNT
CJ:JJP14
123
JP22
I ~b
EERe'"
U9
DCOt.l2
~[
J:
JP6
c::::I:J
JP7
JP23
CJ:J CJ:J
P16
fCLK
~I~~~~~~ml @J
c;:] t
'D
IPL
1
RESET
OTP37
OTP29
38
TP8
2PL
DS215SDCCG 1A
Figure 1. SDCC Layout Diagram
c::J:J
8Pl
D~
bb
0 Nt.ll
Ul
o~c
llPL
Ull
00000
~i F":'
W12
HIS P,5 TP4 TPS TP6
..,
OACS
J:
"r
EJu~
FSR
FSX
CLX
:Jl::
JP12
BIO
cox
3PL
'
40
6PL
"]
39
I::3Jl'D
1~.
BI006008
SDCC Drive Cont 01 Card
GEI-I00029C
1/0 TABLES
Table 6 - 6PL, I/O between NTB/3TB or STBA

board and the SDCC
Tables 3 - 9 list th I/O pin signals of the different connectors on the SDC C. The tables are organized as follows:
Table 7 - 7PL, I/O between the SPC or SPCB board

and the SDCC (not present on SDCCG3s)
Table 3 - IPL I/O between the IMCP, DCI, SDCI,

or DCFB boar and SDCC
Table 8 - 8PL, I/O between the NTB/3TB or STBA

board and the SDCC
Table 4 - 2PL Power inputs from the IMCP board

to the SDCC
Table 9 - IIPL, SDCC outputs to meters (not present on SDCCG3s)
Table 5 - 3PL SDCC outputs to th~SLCG

Table 1. SDCC Testpoints
Name
Description
DCCM1
o volt common reference point for test signals, same as DCOM2
DCCM2
o volt common reference point for test signals, same as DCOM1
P5
Testpoint for regulated +5 volt (5%) power supply
TP4
DCP foreground timing flag (720 Hz)
TP5
DCP blockware timing flag (720 Hz)
TP6
DCP slow background timing flag (90 Hz)
RTS
Unused. General purpose testpoint output from DCP
TP8
Analog representation of phase A motor current, with a nominal dc offset of +2.5 V
FCll<
"I'm alive" 8 MHz oscillator output from MCP
NMI
Initiates board test (Test 13) when momentarily tied to +5 volts. For board test only,
not recommended for use in a drive environment.
DACS
Diagnostic D/A converter daughter board select (used with auxiliary diagnostic hardware in conjunction with EE.600)
N15
Testpoint for regulated -15 volt (5%) power supply
P15
Testpoint for regulated +15 volt (5%) power supply
CDF
TMS320 serial data receive
CDX
TMS320 serial data transmit
CLX
TMS320 serial transmit clock input
ClR
TMS320 serial receive clock input.
FSX
TMS320 serial frame sync pulse for transmit
FSR
TMS320 serial frame sync pulse for receive
ClK:*
TMS320 clock oscillator input
CP5
+5 V power supply to TMS32Cl diagnostic
ccrv*
Common power supply return for TMS320 diagnostic D-A daughter board
TP2
Testpoint for input line frequency
TP3
Testpoint for de voltage; Not used on ac drives
D-A daughter board
*The "Ow of testpoints in the upper left comer of the SDCC (CDR, COx, CLX, CLR, FSX, FSR, CLKC, CPS, and
CCM, is reserved for diagnostic purposes for the TMS320C2S processor, via a daughter board which allows
serial diagnostic D-A converters to be added for developmentltest purposes only.
BI006008
GEI-I00029C
Table 2. SDCC Jumpers and Wire Jumpers

Revision
Name
Description
All
JP1
EEPROM parameter write protect

1.2
Write inhibited, safe mode
2.3
Write enabled, must be in this position to modify EEPROM
All
JP7
Enable 6:1 gain increase for feedback voltage controlled oscillator (VCO) circuitry
1.2
Normal gain
2.3
Increased gain
All
JP8
Enable absolute value circuit for feedback VCO circuitry

Note that, due to the 10 V maximum voltllge aVlliIClbjeo!".tbe Sirn"'ple. Qrive"Terminlll.Bo,ard.,(Sl;.BA)..U\e,-.
feedback VCO is not normally suitable for analog tachs unless the Drive Terminal Board (NTB/3TB) is used.
1.2
Bipolar mode for dc tachometers
2.3
Absolute mode for analog ac
D-ACZ
JP15
Enable for DCP crystal

1.2
Enabled (required for normal operation)
Manufacturing test only
All
JP16
Enables FLASH electrically erasable program memory erase/reprogram mode

1.2
Normal mode for EPROM or Flash memory read only
2.3
Reserved for Flash memory reprogramming mode
All
JP22
Enable for MCP crystal

1.2
All
JP23
Signal source into DCP's external DMA channel (used for time tagged inputs)
1.2
From NTB/3TB analog feedback input (for ac AN tach interfaces)
2.3
From NTB/3TB encoder marker track input (EOM)
D-ACZ
JP33
Enable for CMP crystal

1.2
ADB-Pres
WJ1

SDCCG3 omits the 12-bit D/A converter used for DAC1 and DAC2, and instead drives these outputs with the
8-bit D/A used to drive MET3 and MET4 on SDCCG1. MET3 and MET4 are not available on the SDCCG3. If
this jumper is erroneously present on an SDCCG1 card, the D/A outputs will be corrupted; if the jumpers are
missing on an SDCCG3 card, the DAC1/ DAC2 output will not function.
o
SDCCG1, jumper omitted
1.2
SDCCG3, jumper installed
ADB-Pres
WJ2

SDCCG1, jumper omitted
1.2
SDCCG3. jumper installed
ADB-Pres
WJ3
Provide 1O-volt full scale reference for D/A outputs on SDCCG3

If this jumper is set incorrectly for the SDCC group number, the D/A converters will operate improperly.
SDCCG1. uses internal reference from 12-bit D/A, jumper omitted
1.2 . SDCCG3, develops reference from +5 V dc power supply
ADB-Pres
WJ4
Identify card group to firmware

The. firmwar.e_uses.this.jumperJo identify.whether the card . contains Gtor G3 components. Incorrect setting of
this jumper will cause malfunction of the DCP. inclUding inability of processor to powerup and configure card
logic cell arrays, and possible loss of EEPROM drive configuration memory.
Omit jumper. Identifies card as group G1
1.2
Install jumper. Identifies card as group G3
ADB-Pres
WJ5
Configure card for logic cell array (LCA) size

Incorrect setting of this jumper may damage or cause unreliable operation of LCA U32.
o
Jumper omitted on SDCC G3 (LCA is 3042 device)
1.2
Jumper installed on SDCC G1 (LCA is 3064 device)
BI006008
Table 2. SDCC Jumpers and Wire Jumpers Revision
Nam It
ADS-Pres
WJ7
GEI-I00029C
Continued
Description
In all present drive applications, WJ7 and WJ9 must be omitted and WJ8 and WJ1 0 must be installed. The alternate setting allows for future expansion of EEPROM size from 32K to 64K bytes. Incorrect setting of these
jumpers will result in incorrect reading and configuration of the drive EEPROM.
SDCC G1 and G3, jumper omitted
1.2
Reserved for future expansion
ADS-Pres

o
Reserved for future expansion, jumper omitted
Jump~r installed on
an~.~qG9G3
1.2
WJ8
soqC.0J
ADS-Pres
WJ9

Jumper omitted on SDCCG1 and SDCCG3
1.2
Reserved for future expansion
ADS-Pres
WJ1

o
Reserved for future expansion, jumper omitted
1.2
Jumper installed on SDCCG1 and SDCCG3
_"
"
Table 3. Connector 1PL (AC2000 Drives Only),

I/O Between SDCC and Power Supply Board
Pin No.
Nomenclature
Description
DPSEN
Driver power state
DBDUTY
DB IGBT ON signal
PH LOSS
Ac line phase loss signal
VTHRM
Variable voltage output of IIBD temperature sensor circuit
VMAG
Ac line-to-Iine peak for magnitude detection
VSEQ
Ac line voltage for phase sequence detection

Not connected
/IA
Buffered phase A VCO current feedback from IIBD board
/IB
Buffered phase B VCO current feedback from IIBD board
/IC
Buffered phase C VCO current feedback from IIBD board
V(B-A)
Phase (B-A) VCO voltage feedback
V(C-A)
Phase (C-A) VCO voltage feedback
VDC
Dc link voltage feedback
SYOSC
Burst oscillator
veo output
Not connected
UfDA
Up/down command phase A
UfDB
Up/down command phase B
UfDC
Up/down command phase
DBTST
DB tum-on signal
e
7
BI006008
GEI-I00029C
Table 3. Connector 1PL (AC2000 Drives Only) - Continued,

I/O Between SDCC and Power Supply Board
Nomenclature
Description
20
ENA
Enable phase A IGBT gate drive circuit
21
ENB
Enable phase B IGBT gate drive circuit
22
ENC
Enable phase C IGBT gate drive circuit
23
ENDB
Enable DB IGBT
Pin No.
"24
SS1
25
SS2
Same as SS1 (pin 24)
26
SS3
Same as SS1 (pine 24)
27
IFLTRST
Fault reset
28
FAULT2
Inverter gate drive fault signal
29
L1NESYNC
Ac line synchronizing signal
30
FAULT1
DB overvoltage trip signal
31
IRST1
System reset
32,33
34
Not connected
MAC
35 - 37
38
'Soft,-start"SCR"gateenc:ible'
MA contactor control from SDCC card

Not connected
DTYPE
39,40
Drive type identifier (3.3 - 3.8 V de for an AC2000 IGBT drive)

Not connected
Table 4. Connector 2PL (AC2000 Drives Only),

Power Inputs From Power Supply Board
Pin No.
Nomenclature
Description
IPSEN
Power supply enable
N15
Negative 15 V de to the SDCC, SLCC, and NTB/3TB or STBA boards
P15
Positive 15 V de to the SDCC, SLCC, and NTB/3TB or STBA boards
DCOM
15 V de common to the SDCC, SLCC, and NTB/3TB or STBA boards
P5
Positive 5 V de to the SDCC!SLCC, and NTB/3TB or STBA boards
P5
Positive 5 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards
DCOM
Positive 5 V dc common to the SDCC, SLCC, and NTB/3TB or STBA boards
N24
Negative 24 V de to the SDCC, SLCC, and NTB/3TB or STBA boards
P24
Positive 24 V de to the SDCC, SLCC, and NTB/3TB or STBA boards
BI006008
GEI-I00029C

SDCC Output To SLCC
Pin No.
Nomenclature
Description
BOP - BD7
Buffered, demultiplexed SOCC Drive Control Processor (DCP) data bus lines 0 - 7
DeOM
Power supply return (common)
10
P5
Positive 5 V dc regulated power supply for digital circuitry
11
IR~ T3
System reset signal (active low)
12
UI\T
Interrupt from SLCC/SD~C microapplica.tign chiHtoP~P_ ..
13
ILESY
Busy bus control handshake to DCP
14
Buffered address latch enable from DCP
15
BA 2
DeOM
16
IB( SL
SLCC chip select
17
IBF 0
Buffered read control line from DCP
18
IB\~R
Buffered write control line from DCP
19
BA~
Buffered, demultiplexed DCP address line 8
20
BAS
21
IB( SU
SDCC microapplication chip select
22
BA~O
23
BA~1
24
DeOM
25
DeOM
26
P5
BAP - BA?
Buffered, demultiplexed DCP address lines 0 through 7
1-8
9
27 - 34
BI006008
GEI-I00029C

I/O Between SDCC and NTBI3TB or STBA Boards
Pin No.
NTB/3TB
Terminal
STBA
Terminal
42
Nomenclature
Description
CTLN1
CTLN1 and CTLN2 form part of the circuit for picking up the MA
contactor pilot relay and must be connected together to allow the
drive to run. They provide both a place to connect external interlocks and provide a fail-safe (microprocessor independent) means
of stopping the drive.
_CTLN2. ~.
44
LBIAS
24 V dc bias for digital inputs from NTB/3TB (for +/- logic)
61
TOOUT
TIL output through 200 W from timer/counter 0 of SDCC's Drive

Control Processor.
34
RUN
General-purpose digital input defaulted to, but not limited to, RUN
function
36
JOG
General-purpose digital input defaulted to JOG function
38
POL
General-purpose digital input defaulted to the reference polarity

function
40
XSTP
General-purpose digital input defaulted to the XSTOP function

(normally closed)
47
MSRF
Relay #6 coil driver (Master Sync Reference output), open collector driver output
R01 - R05
NTB/3TB relay coil output driver lines 1 through 5
15
P3B
Scalable general-purpose analog input from NTB/3TB
16
P4B
Scalable general-purpose analog input from NTB/3TB
ASPO
Medium resolution analog input with fixed scaling for 5 V dc

maximum from NTB/3TB
18
VC3NB
Inverting differential analog input for SDCC auxiliary VCO #3
19
VC3PB
Non-inverting differential analog input for auxiliary VCO #3
P1B, P2B
Scalable general-purpose analog inputs from NTB/3TB
10 -14
17
51
20,21
22
LO
".' .$ee.CTLN,1 ,.___" -
Not connected
23
49
24
53
25
55
DVM
Medium resolution analog input channel with fixed scaling for

51.0 V dc maximum
34
DA1
Output from 8-bit (DCC and SDCCG3) or 12-bit (SDCCG1) D/A

converter.
Can source 10 V dc at no load or 8 V dc at a 10 mA load
(200 W series impedance).
Any drive variable can be sent to this output and can be
scaled to set the value corresponding to 10 V dc output. (For
diagnostics and system applications)
35
DA2
See DA1 (pin 24)
BI006008
SDCC Drive Con roI Card
GEI-IOOO29C
Table 6. Connector 6PL - Continued,

I/O Between SDCC and NTB/3TB or STBA Boards
Pin No.
NTB 3TB
inal
Ter~
26
14
STBA
Terminal
36
Nomenclature
Description
MET1
Output from 8-bit D/A converter.

Can source 1 0 V dc at no load or 8 V dc at a 10 rnA load
(200 W series impedance).
Any drive variable can be sent to this output and can be
scaled to set what value corresponds to 10 V dc output.
,,(Pr~vi9~~, fc:>r m~terq~i\(.e! fU9c~ions),.
- ...... '
"
.-.'~
27
37
MET2
See MET1 (pin 26)
28
17
-----
MSSY
Input to internal interrupt (INTO) of DCP

Is biased to +24 V dc through 27 kW and must be pulled to
COM (less than +1.5 V dc) to be recognized by DCP.
29
~9
--
TOIN
Input to internal timer/counter 0 of Drive Control Processor (DCP,

located on SDCC)
Is biased to +24 V dc through 27 kW and must be pulled to
COM (less than +1.5 V dc) to be recognized by DCP.
30
RESET
Hard reset input to the drive

Connecting RESET to +5 to +24 V dc causes all processors
in the drive to be reset.
Leaving RESET open or connecting to COM allows drive operation. The SDCC provides a 20 ms noise filter on this input.
31
--
----
TDB
RS-232C channel transmitted from DCP
32
-~
---
RDB
RS-232C channel received by DCP
33
- f--
--
CTSB
RS-232C channel clear-to-send handshake
34
----
RTSB
RS-232C channel clear-to-receive handshake
35
- - f--
---
VC4NB
Inverting differential analog input for SDCC auxiliary VCO #4
36
- -
----
VC4PB
Non-inverting differential analog input for auxiliary VCO #4
37
--
43
RFNB
Differential analog input from NTB/3TB to reference VCO, negative line
38
41
RFPB
Same as pin 37, but positive line
39
49
FBNB
Differential analog input from NTB/3TB to feedback VCO, negative line
40
46
FBPB
Same as pin 39, but positive line 3
38
,.
11
BI006008
GEI-I00029C

I/O Between SDCC and SPC or SPCB Board
Nomenclature
Description
SPA1
5 V dc SPC/SPCS analog channel #1
SPA2
5 V dc SPC/SPCS analog channel #2
E1Z
Marker channel from encoder #1 interface
E2Z
Marker channel from encoder #2 interface
. N15
P15
Positive 15 V dc power supply for analog circuitry on SPC/SPCB
DCOM
SPRS
Digital output from DCP to SPC/SPCS
DCOM
10
P5
Positive 5 V dc power supply for digital circuitry on SPC/SPCB
11
E1UP
Up channel output from encoder #1 interface
12
E1DN
Down channel output from encoder #1 interface
13
E2UP
Up channel output from encoder #2 interface
14
E2DN
Down channel output from encoder #2 interface
15
ORST7
System reset (active low). Not connected on SPCS card
16
DCOM
17
SPSYN
Not connected on SPC card. Sync pulse listener input to SDCC for SPCS card
18
SPSYO
Not connected on SPC card. Sync pulse output from SDCC for SPCB card
19
SPTX
5 V dc output from SDCC's Motor Control Processor (MCP) UART
20
SPRX
5 V dc input to MCP UART
Pin No.
L2
-.
- .....
"
Negative'15'V'dc powersupplY'foranatog"circaftry 'on~SPC7SPCB"
BI006008
GEI-IOOO29C
.
I/O Between SDCC and NTB/3TB or STBA Boards
Pin No.
NTE 3TB
Ten ninal
STBA
Tenninal
Nomenclature
Description
---
FA
Non-inverting RS-422 half-duplex serial data line from the

SDCC's Motor Control Processor (MCP) UART
---
FB
Inverting RS-422 half-duplex serial data line from MCP UART
DCOM
Signal return for EXSY (at COM potential)
'--'j'.
- --
----
_EXSY,
.,
.,
~Exter.nal.synGinpuMO>MGP.
.~
. ,"~,
"
.... ""'.
-----
Not connected
EOAB
Encoder interface Channel A non-inverted differential input
IEOAB
Encoder interface Channel A inverted differential input. (Tie to

COM for single-ended encoders)
EOBB
Encoder interface Channel B non-inverted differential input
IEOBB
Encoder interface Channel B inverted differential input. (Tie to

COM for single-ended encoders)
10
--
EOMB
Encoder interface marker pulse channel non-inverted differential

input
11
-----
IEOMB
Encoder interface marker pulse channel inverted differential input. (Tie to COM for single-ended encoders)
12
- "--
--
--
Not connected
13
CI1
CI1 - CI8 are general-purpose control inputs, 24 V dc maximum with 27 kW input impedance
14
11
CI2
See CI1 (pin 13)
15
13
CI3
See CI1 (pin 13)
16
15
CI4
See CI1 (pin 13)
17
17
CI5
See CI1 (pin 13)
18
19
CI6
See CI1 (pin 13)
19
21
CI7
See CI1 (pin 13)
20
50
cia
See CI1 (pin 13)
..
--
13
BI006008
GEI-I00029C

SOCC Output to Meters
Pin No.
Nomenclature
1, 2
Not connected
DCOM
Drive common connection
MTR1
MTR1 through MTR4 are outputs from an 8-bit D/A converter and can source 10 V dc at no
load or 8 V dc at 10 rnA load (200 W series impedance).
Any drive variable can be steered to these D/A outputs and can be scaled to set what
value c.?rresponds to the 1.9 V q~g_utput.~~es~ 0JJtp,ut~ar~.f2r !'n.,~!er,griv,~r fUf)Etiof1s_~
MTR2
See MTR1 '
MTR3
See MTR1
MTR4
See MTR1
DCOM
Drive common connection
9, 10
os
Description
Not connected
215
SDCC
G#
L - A board revision (artwork change) that is backward compatible.

\
A board revision (functional change) that is backward compatible.

A board revision (functional change) that is not backward compatible. Essentially a new catalog number.
A group, or variation, of a particular board.
Board functional acronym.
Indicates that the board contains firmware. (200 indicates the board does
not contain firmware and/or other components added to the base level
board.)
Identifies GE Motors and Industrial Systems.
Figure 4. Sample Board Part Number, OS Series
[4
BI006008
SDCC Drive Con roJ Card
RENEWA
ARRANTYREPLACEMENT
BOARD IDENTI ICATION

A printed wiring b
part (catalog) num
the Drive Control
fied by part numb
for part number br
ard is identified by an alphanumeric

er stamped on its edge. For example,
ard, with onboard software, is identiDS215SDCCG#ruu. (See Figure 4
akdown.)
NOTE
All digits are mportant when ordering or replacing any bard.
The DS215SDCC ard includes onboard software stored

in five memory ch ps: four EPROMs (UII, U12, U22,
and U23) that con in configuration data programmed at
the factory, and 0 EEPROM (U9) that contains fieldadjustable parame rs. These memory chips are contained
in sockets on the S CC.

WARNING
When ordering re lacement boards, note that the

DS200SDCC card does not include the five memory
chips mentioned a ave (the sockets are empty).
CAUTION
The SDCC m y also be used to replace a

531X301DC Drive Control Card (DCC).
These instru ions include information for
replacing a
C with an SDCC, including
procedures ~ r transferring software configuration para eters from the old DCC to the
new SDCC, a d setting software parameters
Uumpers) on the SDCC for configuration
functions per ormed via hardware jumpers on
the DCC.

grounding strap when changing boards or
software chips, and always store boards in
anti-static bags or boxes they were shipped in.
To replace an SDCC:
I.

power is off.
2.
Open the drive's cabinet door to access the printed

wiring boards. (The DCC or SDCC is located in the
drive's board rack, facing the front.)
WARRANTY TE MS
The GE Motors & Industrial Sys~emsTt:rms and <:;onditions brochure de ils product warranty information, including the warra ty period and parts and service
coverage.

the drive, then test to verify that no power
connected circuits.
NOTE
When replac ng a DCC, specify a

DS215SDCC as a replacement to ensure that
the five mem ry chips are included.
GEI-I00029C
The brochure is in luded with customer documentation. It

may be obtained s parately from the nearest GE Sales
Office or authoriz d GE Sales Representative.
15
BI006008
GEH-lO0029C
3.
If a programmer module is included, remove the pro-
7.
grammer by pulling the snaps (holders, located in

each comer) outward to release the programmer
cover and keypad, then pulling the programmer loose
from the KPPL connector. (The keypad plugs into
connector KPPL on the LCC or SLCC.)
NOTE
It may be necessary to remove auxiliary
boards mounted on the DCC or SDCC as described in step 5 before disconnectirig cables
from the DCC or SDCC.
4.
Carefully disconnect all cables from the DCC or

SDCC (and any auxiliary board mounted on standoffs) as follows:
Move all standoffs from the card being replaced to

the replacement (new) SDCC as follows:
a.
Remove the screws with nylon washers that secure the standoff to the old card by removing the
screws with nylon washers from the back side of
the old card.
b.
Insert the screws with nylon washers into the

same point on the back of the new SDCC as they
were removed from on the old card.
,.c., . .mace. standoffs.>intollPosition-on:.tbe.rollt.sideoL .

the new SDCC and tighten the screws with nylon
washers to secure the standoffs.
8.
Set all configurable items on the replacement (new)

SDCC in the exact position as those on the card being
replaced.
Verify cables are labeled with the correct connector name (as marked on the card) to simplify
reconnection.
NOTE
When replacing an SDCC, if a board revision
has added or eliminated a configurable component, or re-adjustment is needed, refer to
Table 2. If replacing a DCC with an SDCC,
refer to the corresponding paragraph under
Replacing/Inserting Software.

5.
Remove any auxiliary boards mounted to the DCC or

SDCC by removing the screws (with nylon washers)
that secure the board to the standoffs on the DCC or
SDCC, then remove the auxiliary board.
NOTE
Because of upgrades, boards of different revision levels may not contain identical hardware. However, GE Drive Systems assures
compatibility of its replacement boards.
CAUTION
9.
6.
Release the DCC or SDCC from the board rack by

pushing back on the plastic snaps (holders), then remove the DCC or SDCC.
CAUTION
Install the new SDCC into the board rack, ensuring

that all holders snap into position to secure the
SDCC.
10. Reconnect all cables to SDCC as labeled. Ensure that

cables are properly seated at both ends.
II. Install auxiliary boards on standoffs (if applicable)
with screws (with nylon washers) removed in step 5
and reconnect all cables as labeled. Ensure that cables are properly seated at both ends.
. '
Always use the nylon washers when inserting

screws into the card to avoid damage to the
card.
16
12. If a Programmer module is included, carefully plug

the keypad into connector KPPL on the LCC or
SLCC and snap the cover into place.
BI006008
NOTE
After replaci g the SDCC in an application
with critical nalog I/O functions, the gains
and offsets m y require fine-tuning to compensate for v riations in component tolerances betwee the old card and the new.
HARDWARE A
Replacing an SDCC
When replacing an SDCC, transfer the onboard software
to the new card as follows:
NOTE
To ensure compatibility of the onboard software with existing equipment, transfer the
four EPROMs from the old card to the new as
described
in steps 1 and
2.
.. '.. ;,:
USTMENTS
selections have been factory set.uThe

test data sheets su lied with each controller (in the drive
door pocket) indic te these positions. Table 2 lists and
defmes the jumper .
1.
In most applicatio s, all WI jumpers are factory set to the

correct position, d all JP jumpers except JPI should be
in position 1-2 (JP should be in position 2-3). Use these
settings unless the structions indicate otherwise. As described previously ensure that the jumpers on the new
card are placed the same as on the old card, unless the instructions indicate therwise. Refer to Table 2, which lists
the default setting rrst. Figure 3 shows jumper locations.
REPLACINGIIN ERTING SOFTWARE

The SDCC uses a
on the DCC, and s
DCC are impleme
Therefore, the pro
differ, depending
replaced. The foll
dures for replacin
with an SDCC.
ifferent EEPROM chip than that used

me of the hardware jumpers on the
ted as software jumpers on the SDCC.
edures for replacing/inserting software
pon whether a DCC or SDCC is being
ingparagraphs, describe.. the .proce-.
an SDCC, and for replacing a DCC
Remove one of the four EPROM chips (UII, U12,

U22, or U23) from the old card and insert it into the
respective socket on the new SDCC.
CAUTION
To prevent damage to memory chips, ensure
that chips are properly oriented when inserting them into sockets.
2.
Repeat step 1, one chip at a time, for each of the remaining EPROM chips.
3.
Remove the EEPROM (U9) chip from the old card

and insert it into the respective socket in the new
SDCC.
4.
If the failure symptoms that caused the card to be

replaced still exist, perform the following:
NOTE
Some of the c nfiguration functions on the
DCC using h rdware jumpers are implemented on th SDCC via software jumpers
(parameters tored in EEPROM). If replacing
a DCC with n SDCC, refer to the following
section, Repl cinglInserting Software, for information on setting software jumpers on the
SDCC to ma h hardware jumper settings of
the old DCC. (Also see Table 10.)
GEI-I00029C
a.
Install new EPROMs and (blank) EEPROM

(shipped with the new card if a DS215SDCC).
b.
Program the new EEPROM per the customer

software adjustment values using the ST2000
(see GEH-5860), GE Control Systems Toolbox
(see GEH-6333), LynxOS Drive Configurator
(see GEH-6203), or STlOOO Drive Configuration
Tools (see GEH-6341).
Replacing a DCC with an SDCC

When replacing a DCC with an SDCC, the replacement
card must be a DS215SDCC to ensure that the five memory chips are included. The configuration data from the
old DCC must be loaded into the new SDCC's EEPROM
per the procedure in this paragraph.
17
BI006008
GEH-I00029C
The EEPROM (U9) used on an SDCC has twice the capacity of that used on a DCC. Therefore, the chip from
the DCC cannot be merely transferred to the new card. To
maintain the configuration from the DCC, use the STIOOO
(see GEH-5860), GE Control System Toolbox (see GEH6333), or LynxOS Drive Configurator (see GEH-6203) to
load the configuration into the EEPROM supplied with
the SDCC.
If the STIOOO, GE Control System Toolbox, or LynxOS
Drive Configurator is not available, read the configuration
from the DCCEEPROM into a file as describedm the
following procedure. This procedure requires a personal
computer capable of serial communications with the drive
via the COMPL port, and capable of uploading and
down-loading files.
NOTE
Step 1 of the following procedure can be performed with the DCC EEPROM installed in
either the DCC or SDCC. If the DCC
EEPROM is installed in an SDCC, fault 396
(EEBADSIZ) will occur. To prevent this fault
from interfering with the software upload, set
EE.3 to 21.
l8
1.
With the original EEPROM installed, upload its configuration to a file by issuing the following serial
Ax0-4095<Enter>
command to the drive:
NOTE
If the new EEPROM is totally blank (no programming label attached), parameters EE.2
and EE.3 must be set to 21 using a Programmer before performing step 2.
'2. lJistaIltlieriewcEPROM"futhe 'SDCC'aTid dCrwnload
the configuration file to the drive.
Table 10 lists and defmes DCC hardware jumpers that

have been implemented as software jumpers on the
SDCC. After the DCC configuration has been loaded into
the SDCC EEPROM, refer to Table 10 and change any
software jumper settings required to match the hardware
jumper settings of the DCC.
BI006008
GEI-I00029C
.
NOTE
The followinl table defines the hardware jumpers on the DCC Drive Control Card that have been implemented as so tware parameters on the SDee Drive Control Card. When replacing a DCC with an SDCC, if a
DeC hardware jumper listed has been moved from the default position (listed first in the following table), the
corresponding software parameter for the SDeC must be changed to the required value using either the
ST2000 (see GEH-5860), GE Control System Toolbox (see GEH-6333), or LynxOS Drive Configurator (see
GEH-6203).
Table 10. DCCHardware Jumpers Implemented as SDCC Software Jumpers
DCC Hardware Jumper

Name
Descript on
JP19
Source 0 DCP encoder #1 up/down signals

1.2
From NTB/3TB EOA
2.3
From the SPC encoder #1
Corresponding SDCC Software Jumper

Name
EE.7.0
FBKJPR
Description
Select source of hardware encoder signals for software
encoder #1
0.000 From encoder #1 via NTB/3TB or STBA
1.000 From encoder #1 via the SPC card (SDCCG1
only)
SDCCG1 allows encoders 0, 1, and 2 to be used simultaneously with no restrictions, unlike the DCC which had
latency constraints on software encoder #0. This jumper
is used for backward compatibility only.
WARNING - prior to revision 2.22, SDCC firmware tied
hardware encoder 0 to software encoder 0 and hardware
encoder 1 to software encoder 1. Revision 2.22 permits
this mode only by setting EE.7.0; the default mode for
EE.7.0 now becomes backward compatible with the
DCC. Note that hardware encoder #1 is not supported on
the SDCCG3; therefore this jumper should not be set.
JP20
Source 0 encoder #1 up/down signals

1.2
From NTB/3TB EOB
2.3
EE.7.0
FBKJPR
See description above.
JP21
Source 0 encoder #1 marker signal

1.2
From NTB/3TB EOM
2.3
EE.7.0
FBKJPR
See description above.
JP31
Destinati n of motor control processor serial

interface
1.2
Enable NTB/3TB half-duplex RS-422
interface
2.3
Enable SPC full-duplex RS-422 interface
EE.572.3
MBERGJ
Hardware configuration jumper: source of receive for

MCP serial port
0.000 Enable NTB/3TB half-duplex RS-422
interface
1.000 Enable SPC RS-422 or SPCB fiber-optic
interface
This jumper must be set for use with the serial encoder or
DC2000 KlL frame multi-bridge LAN options. Changes to
this jumper only take effect when the drive is stopped.
The serial encoder interface is supported only on
'SDCCG1 cards, and is not available when using
SDCCG3 cards.
JP32
Enable "TB/3TB encoder #0 marker input into the

encoder ~rocessing PAL, U30
1.2
Not Enabled
2.3
Enabled
EE.9.7
CFG2JP
Hardware configuration jumper: enable marker channel

for encoder 0
0.000 Not enabled
1.000 Enabled (valid only with SDCCG1 cards)
Neither SDCCG3 nor STBA boards support the encoder
marker channel. Setting EE.9.7 under these conditions
will cause mis-operation of the encoder #0 feedback.
BI006008
GEH-lO0029C
Table 10. DCC Hardware Jumpers Implemented as SDCC Software Jumpers- Continued
DCC Hardware Jumper
Corresponding SDCC Software Jumper
Name
Description
Name
JP34
Source of signal into DCP's external timer/ counter

input
1.2
From NTB/3TB TOrN
2.3
From signal selected by JP23
2.4
Pulled high, NTB/3TB TOOUT timed
output mode usage
0'
Description
EE9.0
CFG2JP
Hardware configuration jumper: Source for DCP timer/

counter #0
0.000 Enable TOIN from NTB/3TB board
1.000 Enable ANTC from SDCC card
2.000 Enable free-running internal counter
3.000 Inhibit counting
'.
,'.
'~'"
:.,
~".
""
_.-~
~.
'
..
"".,"
... '...... _.:..:.:'
.. ,.,..\<'
.-
"
This jumper is not currently used in the AC/DC2000.

TC2000 uses setting 2 to use the timer as a free-running
counter.
GEMotOfS&
Industrial Systems
-----------------------------------S8n".1 18ct,;c Comp.ny

ssue Date: Rev. C, April 1997
\11 rights reserved.
~
IndustriBI Systems
1501 ROBnoke Blvd.
BI006008
GEI-1001t,
(Supersedes GEI-1001t
GE Drive Systen
Replacement Procedures For

PCCA Power Connect Card
.J;lS200PCC4G1A.:. -,tbru .,....G.1 B.
DS200PCCAG2A
thru -G 1B
DS200PCCAG3A
thru -G 1B
DS200PCCAG4A
thru -G 1B
DS200PCCAG5A
thru -G1B
" .. ,.DS200P.CCAGGA .~.1hr~"B

DS200PCCAG7A
thru -G1B
DS200PCCAG8A
thru -G1B
DS200PCCAG9A
thru -G1 B
DS200PCCAG10A
thru -G10B
These instructio s do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be
met during insta lation, operation, and maintenance. Should further information be desired or should particular problems arise that
are not covered ufficiently for the purchaser 'spurpose, the matter should be referred to GE Drive Systems, Salem, Virginia U.S.A.
WARNING
This equip, nent contains a potential hazard of elec rical shock or burn. Only those
who are ad equately trained and thoroughly familiar with the equipment and the
instruction should install, operate, or
maintain th s equipment.
in a system is determined by the system voltage, frame

size, and whether the system uses regenerative or nonregenerative power conversion.
The armature voltage scaling depends on which group
number is used:
GI, G3, G7, G9 - Regenerative, 240 - 630 volts
G2, G4, G8, GIO - Non-regenerative, 240 - 700 volts
Table 1 summarizes the uses of the various PCCA
group numbers.
INTRODUCTIO"
These instructions provide information that may be

needed when rep acing the DS200PCCA Power Connect
Card (PCCA) in a DC2000 drive. This information includes descriptio ~s of configurable hardware jumpers.
The PCCA provides an interface between the control
circuitry and the SCR power bridge in dc drives and
exciters. The PC:A uses pulse transformers to provide
gate drive to the SCR power"bridge. Fot low to medium horsepower controllers, the PCCA also includes
snubbers to contIpl spikes across the ac lines, the dc
bus, and the gate drivers. For higher horsepower controllers, some or all of the snubbers are omitted from
the PCCA, and a e located elsewhere in the drive.
The PCCA curre tly has ten group numbers (group
numbers are explained further in the Board Identification section of th s instruction). The group number used

part (catalog) number stamped on its edge. For example, the Power Control Card is identified by part number:
DS200PCCAG#ruu
The DS200PCCA portion is the base number that identi

fies the printed wiring board, in this case, the Power
Control Card. The G# identifies a group, which is a
variation of a particular board. The r and u digits are
alphabetic characters that indicate the board revision
level. The r digit reflects a functional change that is not
downward compatible. It is essentially a new catalog
number. The u digits represent revision levels that are
downward compatible to the r revision level.
BI006008
GEI-I00161A
Power Connect Card
Table 1. PCCA Card Uses

G1, G2
Group
G3,G4
G5,G6
G7,G8
G9,G10
Snubbers
Ae & de
De only
None & no
attenuation
string
Ae & de
De only
Frames
C,G
Not used
J, K, L, M
C, G
D, J, M
Ae Volts
=:;;600 V
rms
N/A
$ 1500 V
rms
$600 V
rms
$600 V
rms
Fuses
I.:ine
Reactors
Line
N/A
Bus Transformer
Separate or
Common
N/A
--"
..-.-
I-N/A
NOTE
..
"line
- .. . Leig
Leg
Line
Leg
Separate or
Common
Separate or
Common
Separate or
Common
'teg"-
'
..
2.

wiring boards. This exposes the drive control card,
which faces the front. The power supply board is
mounted behind the drive control card; the PCCA
is mounted on the backside of the power supply
card.
3.
Pull the locks located on either side of cabinet. Lift

the drive control card and tilt forward and down to
expose the power supply board.
4.
Lift the power supply board and tilt forward and

down to expose the PCCA card.
5.
To remove the PCCA card, carefully disconnect all

cables, as follows:
WARNING
Potentially lethal voltages are present on the

PCCA card when powered. To prevent
electric shock, tum off power to the card,
then test to verify that no power exists in the
card before touching it or any connected
circuits.
For ribbon cables, place one hand on each side

of the cable connector that mates with the
CAUTION
To prevent equipment damage, do not remove boards or connections, or re-insert
them, while power is applied to the drive.
grounding strap when changing 'boards and
always store boards in the boxes in which
they were shipped.
For cables with pull tabs, carefully pull the

tab.
6.
The PCCA is held in place by six plastic snaps

(holders). Push these holders back to remove the
card.
7.
On the replacement (new) card, set all configurable

items in the exact position as those on the card
being replaced (old card).
To replace the PCCA:

1.
Tum off power to the drive, then wait a few

minutes for the power supply's capacitors to discharge. Test any electrical circuits before touching
them to ensure power is off.
If a card revision has added or eliminated a configurable component, or re-adjustment is needed,

refer to Table 2.
BI006008
Power Connect Card
GEI-I00161
PIO, as determined by the card group number and

system voltage. Jumpers WP3 and WP4 are used to
connect stab terminals P2A to P2B and PIA to PlB,
respectively. These jumpers select whether the PCCA
snubber capacitors are connected to the same point on
the power bridge as the voltage feedback channel.
NOTE

revision le,,~ls may not contain identical
hardware. fIowever,GE Drive Systems ensures comp iltibility of its replacement
boards.
8.
Install the new PCCA card, ensuring that all holders snap int position.
, 9.
The cables-a rlatTeled-witlr1:he-correet"conrrector

name, as rru ked on the card. Reconnect all cables
as labeled. *ake sure that cables are properly
seated at bo h ends.
HARDWARE ADJUSTMENTS
Most of the jumper selections have been factory set.

The test data sheets supplied with each controller (in th
drive door pocket) indicate these positions.
~
'''Asaescribed 'previbusly, ensure thatthe'jumpers on"the

new card are placed the same as on the old card, unless
the instructions indicate otherwise. Figure I shows the
layout of the PCCA card, including the locations of the
stab terminals. Table 2 lists and defines the placement
of the wire jumpers for the various group numbers and
system voltages.
The PCCA inclu es four wire jumpers, designated JPI,

JP2, WP3, and 'VP4. Jumpers JPI and JP2 must be
connected to the appropriate stab terminals P3 through
a a
2RPL
lRPL
6RPL
o o
o
4RPL
5RPL
3RPL
5PL
2C---=-' ]]26
1
,25
o o
DS200PCCAG1A
4FPL
SFPL
P2B
"
2FPL
lFPL
3FPL
P7
:P2
6FPL
P4
----"
WP3
'
P9
Pl0
P5
P8
P6
P2A
WP2
DCS
P1
lACS
P1A
2ACS
3ACS
4ACS
SACS
6ACS
Figure 1. PCCA Card Layout
BI006008
Power Connect Card
GEI-I00161A
NOTE
The following table defines the jumpers used on the PCCA card. The Name column indicates the item's
identification as marked on the card (JP or WP = wire jumper). The Description column designates the card's
group and revision for that item as defined. The default setting for each item is listed first.
Table 2. PCCA Card Adjustable Hardware
Revision Name
All
JP1
Description
GrQt1fJs,.1, 3" iponly~'6e1eetS"<fC'"1!lT'matm~1701t'8ge-range
'~'C'OflT1ect"'Card
3.8
3.4
7.8
4.7
3.7
370 V dc; Also connect JP2 P6-P1 0
4.8
All
JP2
Groups 1, 3, 7 only - Selects

6.9
240 V dc;
5.6
290 V dc;
10.9
500 V dc;
10.5
550 V dc;
10.6
370 V dc;
5.9
580 V dc;
630 V dc;
dc armature voltage range (See JP1, Groups 1, 3, 7)

Also connect JPl P4-P8
All
JP1

3.8
240 V dc;
3.4
350 V dc;
7.8
390 V dc;
4.7
500 V dc;
3.7
550 V dc;
4.8
595 V dc;
o
700 V dc;
dc armature voltage range on the Power Connect Card

All
JP2

6.9
240 V dc;
5.6
350 V dc;
10.9
390 V dc;
10.5
500 V dc;
10.6
550 V dc;
5.9
595 V dc;
700 V dc;
dc armature voltage range (See JP1, Groups 2, 4, 8)

AAAAAZ
JP1
Group 5 only - Selects dc armature voltage range on the Power Connect Card
3.8
3.4
7.8
4.7
3.7
4.8
BI006008
Power Connect Card
GEI-I00161.
Table 2. PCCA Card Adjustable Hardware - Continued

Revision Name
Description
AAAAAZ
JP2
Group 5 only - Selects dc armature voltage range (See JP1, Group 5)

6.9
5.6
10.9
500 V dc; Also connect JPl P7-P8
10.5
10.6
5.9
o
630 V dc; Leave all P3-Pl 0 open
ABAPres
JP1,
JP2
Group 5 only - Voltage attenuator string and jumpers no longer on Group 5
AAAAAZ
JPl
Group 6 only - Selects dc armature voltage range on the Power Connect Card
3.8
3.4
390 V dc; Also connect JP2 P9-Pl 0
7.8
4.7
500 V dc; Also connect JP2 P5-Pl 0
3.7
4.8
o
700 V dc; Leave all P3-Pl 0 open
AAAAAZ
JP2
Group 6 only - Selects dc armature voltage range (See JP1, Group 6)

6.9
5.6
10.9
10.5
10.6
5.9
700 V dc; Leave all P3-P1 0 open
_.CO._
" ' __ ',
ABAPres
JP1,
JP2
Group 6 only - Voltage attenuator string and jumpers no longer on Group 6
All
WP3
Groups 1-4, 7-10 only - Separateltie card snubbers and voltage feedback channel to same/different point(s)
WP3 and WP4 are wire jumpers on the PCCA card which are connected between stab terminals P2A-P2B and
Pl A-P1 B, respectively. If these jumpers are present the card snubber capacitors are attached to the same point on
the bridge as the voltage feedback channel. WP3 & WP4 may be removed if the card snubbers and voltage
feedback channel need to be connected to different bridge points.
1.2
Jumper IN - Connect snubbers & voltage feedback channel to same point
o
All
WP4
Groups 1-4, 7-10 only - Separate/tie card snubbers and voltage feedback channel to same/different point(s)
1.2
Jumper IN - Connect snubbers & voltage feedback channel to same point
o
BI006008
GEI-I00161A
Power Connect Card
Notes:
GE Drive Systems
~ Date: December 1993
;ion A: December 1994
GEI-100162B
(Supersedes GEI-1 00162A)
BI006008
'.
GEMotors&
Industrial Systems
---------+--------------------------LAN COMMUNICATIONS CARD

DS215SLCCG A__
These instructions a ~ not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met
during installatitm';"' 'JPf!ratirm,"and.",tfintenanc~/f:fttrtheMnf,.",matirminiesirl!d,orifparlicufar_profJtemsW"ise that are not covered
sufficiently for the p rchaser 's purpose, the matter should be referred to GE Motors & Industrial Systems.
customer in the inst llation. testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproduced
in whole or in part or shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems.
CONTENTS
1
Functional Descri ption
1
Introduction
I
Card Groups
2
Card Connectior s
2
Board Mounting
2
Application Data ........................................................... 2
Configurable Ha dware
2
Software Configllration Tools
2
I/O Tables
4
Renewal/Warran y Replacement
8
Board Identifica ion
8
Warranty Terms
8
Warranty Parts 1 nd Service
8
Procedure For R placing Boards
8
Hardware Adjus ments
9
Replacing/Insert mg Software
9
SAFE"Y SYMBOL LEGEND
WARNING
CAUTION

not strictly observed, could resuit in damage to or destruction
of equipment
NOTE Indicates m essential or important procedure,

practice, ondition, or statement.
WARNING

INTRODUCTION
The DS215SLCCG_A__ card (SLCC) contains both

isolated and non-isolated circuits for communications to
the drive or exciter. The SLCC features a 16-position alphanumeric display (and display controller, U18) that
connects to the programmer module. The programmer
module mounts on the SLCC and plugs into connector
KPPL.
The principal microprocessor on the SLCC is the LAN
Control Processor, UI (LCP). The LCP software is
stored in two replaceable EPROMs (U6 and U7). The
LCP dedicated RAM is provided by U8 and U9. Dualported RAM (U5) is used for communications between
the LCP and and the Drive Control Processor (DCP) on
the DS215SDCC Drive Control Card (SDCC) via 3PL.
(Dual-ported RAM [DPR] is RAM configured as memory arrays that can be independently and simultaneously
accessed by two microprocessors.)
SLCC LAN Communications CardBI006008
;EI-IOQI62B
:ARD GROUPS
APPLICATION DATA
'here are currently three group numbers of the SLCC

vailable (G3 versions were never manufactured). The
'ariations between the groups are as follows:
CONFIGURABLE HARDWARE
The SLCC includes configurable hardware that must be
set correctly for the application:
DS2l5SLCCGlA : Includes the circuitry used to

connect the drive bothDLAN and ARCNET
networks
Berg-type (manually movable) hardware jumpers,

identified by a JP nomenclature (see Table 2)
DS2l5SLCCG2A__: Includes the circuitry used to

connect the drive to DLAN networks only
Wire jumpers, identified by a WJ nomenclature (see

Table 2)._
to
DS2l5SLCCG4A_ _ Does not include either DLAN

or ARCNET circuitry
:ARD CONNECTIONS
The SLCC interfaces with the other boards of the controller, external signals, and the network via five connectors
:designated ]L). See Figure 1 for an SLCC layout diagram showing the locations of the connectors and Tables
2 - 6 for the pin signals of each connector. Connectors to
Dther boards are as follows:
2PL - 5, 15, and 24 V de I/O between the Power

Supply/Interface Board (DS200IMCP, DCI, SDCI, or
DCFB), Drive Terminal Board (53lX305NTBA) or
Simple Drive Terminal Board (DS200STBA), Drive
Control Card (DS200SDCC), and the SLCC
3PL - SLCC inputs from the Drive Control Card

(DS200SDCC)
lOPL - I/O between the LAN I/O Terminal Board

(53lX307LTB) and the SLCC
ARCPL - I/O between DLAN and ARCNET signals

and the SLCC
KPPL - I/O between the Programmer Module keypad and the SLCC
BOARD MOUNTING
The SLCC is mounted on four standoffs located on the
SDCC. The programmer module plugs into connector
KPPL on the SLCC and its keypad and cover snap over
the SLCC.
These jumpers are used for factory test or user application

options. Most of the jumper selections have been factory
set. The test data sheets supplied with each controller (in
the drive/exciter door pocket) indicate these factory set
positions. Table 1 lists the jumper descriptions, showing
the default setting first.
Figure 1 is a layout diagram of the SLCC, showing the
locations of all jumpers.
NOTE
A DS215SLCC card can be used to replace a
531X306LCC card (LCC). If replacing an
LCC with an SLCC, refer to publication GEI100021, Tables 1,2, and 3 for LCC jumper
position settings. Set jumpers on the SLCC so
that the respective functions of the jumpers
are the same as on the LCC being replaced.
Do not move software (U6 and U7) from the
LCC to the SLCC.
SOFTWARE
The SLCC's LAN Control Processor (LCP) software in
EPROMs U6 and U7 cannot be configured in the field.
The U6 and U7 EPROMs are replaceable and can be
moved from one board to another.
When ordering replacement boards, note that the
DS200SLCC does not include the two EROMs mentioned previously (the sockets are empty). The EPROMs
from the old board must be moved to the replacement
board.
NOTE
The four posts (STI, ST2, ST3, and ST4) located at the end of the programmer module's
alphanumeric display on the SLCC are present to protect the glass tip of the display
(evacuation point). These are not testpoints.
2
When replacing an SLCC (or LCC) and the EPROMs are

needed, specify a DS2l5SLCC as a replacement to ensure
that the two EPROMs are included.
ARCNET is a registered trademark of Datapoint
Corporation
BI006008
SLCCLANCon munications Card
GEI-IOO162E
'.'
o>~
UilU Ol
"UI"U
):>0
-<z(J)\
C =i \
~6
c
a
;uZ
(J)(J)
- i -i
00
I
I
'" ~
- -- --- --- --
VI
(JI
I
I
I
::E
L
:J~
"'---
00
0
(f)
--- --
I'-)
-"
(J)(J)
- i -i
~VI
\0
I~
(Jl
(f)
2
I
G)
-"
:>
~~
KPPL
0
0
I
0
~
~
~~
eJ
c
~
~I ~II
~~
.3
c=J:::J
JP20
::E
.3
c=J:::J
1 JP17.3
JP19
c=J:::J
1
>
;u
.3
.3 1
.3 1
C J:::J
c=J:::J
c=J:::J
JP14
JP16
JP15
JP18
'"r"U
()
"U
C'
f-
:J~
Figure 1. SLCC Layout Diagram
:3
SLCC LAN Communications Card
EI-I00162B
) TABLES
Table 3 - 3PL, SLCC inputs from the Drive Control

Card (DS200SDCC)
ibles 2 - 6 list the I/O pin signals of the different con:ctors on the SLCC board. The tables are organized as
,Hows:
Table 4 - 10PL, I/O between the LAN 110 Terminal

Board (531X307LTB) and the SLCC
Table 5 - ARCPL, 1/0 between DLAN and

ARCNET signals and the SLCC
Table 6 - KPPL, 110 between the Programmer

Module keypad and the SLCC
Table 2 - 2PL, 5, 15, and 24 V dc I/O between the

Power Supply/Interface Board (DS200IMCP, DCI,
SDCI, or DCFB), Drive Terminal Board
(531X305NTBA) or Simple Drive Terminal Board
(DS200STBA), Drive Control Card (DS200SDCC)
and the SLCC
NOTE
The following table defines the jumpers used on the SLCC. The Revision column designates the card's revision for the item described. The Group column designates the card groups that the item applies to. The
Name column indicates the item's identification as marked on the card (JP = jumper, WJ = wire jumper).
The Description column designates the card function for the item.
Table 1. SLCC Jumpers and Wire Jumpers

Description
Revision
Group
Name
6,11
1&2
Only
JP14
Selects the RS-422 DLAN drivers or the isolated DLAN circuit

1.2
Isolated DLAN circuit
2.3
RS-422 DLAN drivers and receivers
All
1&2
Only
JP15

1.2
2.3
All
1&2
Only
JP16

1.2
2.3
All
1 &2
Only
JP17
Places the DLAN termination resistors in the DLAN circuit

The termination resistors should be added to the drives located at the end of a daisy-chain RS-422
DLAN. Never exceed five sets of termination resistors in an RS-422 DLAN circuit.
1.2
Termination resistors in
2.3
Termination resistors out
All
1&2
Only
JP18
Places the DLAN termination resistors in the DLAN circuit

The termination resistors should be added to the drives located at the end of a daisy-chain RS-422
DLAN. Never exceed five sets of termination resistors in an RS-422 DLAN circuit.
1.2
Termination resistors in
2.3
Termination resistors out
All
1,2,
&4
JP19
Connects the crystal to the processor

1.2
Normal operation
2.3
BI006008
.'
BI006008
SLCC LAN Con munications Card
Table 1. SLCC Jumpers and Wire Jumpers Revision

ACC-Pres
Gr( up
Name
1"
WJ1
&~
GEI-I001621
Continued
Description
Redirects the Ready Line when there is no ARCNET module - This jumper should be in place when
there is no ARCNET module
1.2
No ARCNET module, SLCC G2 and G4
ARCNET module present, SLCC G1
ACC-Pres
1"
WJ2
&~
ACC-Pres
ACC-Pres
ACe-Pres
Conects the LRX signal to ground through a 470 ohm resistor - This jumper should be in place for G4
cards only
LRX signal not connected to ground, SLCC G1 and G2
1.2
LRX signal connected to ground, SLCC G4
1,
&4
WJ3
1"
&4
WJ4
1"
&4
WJ5
Conects the T2CLK signal to ground through a 470 ohm resistor - This jumper should be in place for
G4 cards only
T2CLK signal not connected to ground, SLCC G1 and G2
1.2
T2CLK signal connected to ground, SLCC G4
Conects the input signal to ground through a 470 ohm resistor - This jumper should be in place for G4
cards only
Input signal not connected to ground, SLCC G1 and G2
1.2
Input signal connected to ground, SLCC G4
Conects the input signal to ground through a 470 ohm resistor - This jumper should be in place for G4
cards only
Input signal not connected to ground, SLCC G1 and G2
Input signal connected to ground, SLCC G4
1.2

I/O Between the Power Supply/Interface Board (DS200IMCP, DCI, SDCI, or DCFB), Drive Terminal Board (531X305NTBA)
or ~ imple Drive Terminal Board (DS200STBA), Drive Control Card (DS200SDCC), and the SLCC
Pin No.
Nomenclature
Description
IPSEN
Power supply enable.
N15
Negative 15 V de to the SDCC, SLCC, and NTB/3TB or STBA boards.
P15
Positive 15 V de to the SDCC, SLCC, and NTB/3TB or STBA boards.
DCOM
15 V de common to the SDCC, SLCC, and NTB/3TB or STBA boards.
P5
P5
DCOM
Positive 5 V de common to the SDCC, SLCC, and NTB/3TB or STBA boards.
N24
Negative 24 V de to the SDCC, SLCC, and NTB/3TB or STBA boards.
P24
EI-I00162B
"-

SLCC Input From SDCC
Pin No.
Nomenclature
Description
BOO - BD7
Buffered, demultiplexed SDCC Drive Control Processor (DCP) data bus lines 0 - 7
DCOM
10
P5
11
IRST3
System reset signal (active low)
12
LINT
Interrupt from SLCC/SDCC microapplication E!lip to_~CP
13
ILBSY
Busy bus control handshake to DCP
14
BA12
Buffered address latch enable from DCP
15
DCOM
16
IBCSL
SLCC chip select
17
IBRD
Buffered read control line from DCP
18
IBWR
Buffered write control line from DCP
19
BA8
20
BA9
21
IBCSU
SDCC microapplication chip select
22
BA10
23
BA11
24
DCOM
25
DCOM
26
P5
BAO - BA7
Buffered, demultiplexed DCP address lines 0 through 7
1-8
9
27 - 34
Table 4. Connector 1OPL,

I/O Between SLCC and LTB Board
Pin No.
2-8
Nomenclature
Description
P24
+24 V dc.
112 - 118
24 V logic lines to the drive.

Not connected.
9 -16
17
N24
-24 V dc.
18
111
24 V logic line to the drive.
101 -107
Relay control lines 0 through 6.
P24
+24 V dc.
19 - 25
26
BI006008
SLCCLANCon munications Card
GEI-IOO162E
Table 5. Connector ARCPL,

I/O Between SLCC Card and DLAN or ARCNET
Pin No
Nomenclature
Description
TXA-
TXA+
TXB-
TXB+
P5
Power +5 V dc.
-.---
,---
",.- -
DCOM
Power digital common.
TXB
Transmitting signal selected by JP15 as isolated DLAN circuit or RS-422.
TXA
Receiving signal selected by JP15 as isolated DLAN circuit or RS-422.
Table 6. Connector KPPL,

I/O Between SLCC Card LCP (U1) and Keypad
Pin No.
OS
215
LCC
G#
Connection
U1 pin 19
U1 pin 20
U1 pin 21
U1 pin 22 (PWM1)
U1 pin 23 (PWM2)
U1 pin 30 (BRED)
U1 pin 31 (HLDA)
U1 pin 32 (HOLD)
U1 pin 33 (T2UD)
10
U1 pin 38 (T2CAP)
A board revision (artwork change) that is backward compatible.

Indicates that the board contains firmware. (200 indicates the board does
not contain firmware and/or other components added to the base level
board.)
Figure 2. Sample Board Part Number, DS Series
SLCC LAN Communications Card BI006008
8:H-I00162B
lENEWALlWARRANTY REPLACEMENT
DARD IDENTIFICATION
WARNING
printed wiring board is identified by an alphanumeric
lrt (catalog) number stamped on its edge. For example,
e LAN Communications Card, with onboard software,
identified by part number DS2I5SLCCG#ruu. (See
gure 2 for part number breakdown.)

the drive, then test to verify that no power
connected circuits.
NOTE
CAUTION
he DS2I5SLCC card includes onboard software stored

EPROMs (U6 and U7) that contain configuration
ata programmed at the factory. These EPROMs are
ontained in sockets on the SLCC card.

1 two

grounding strap when changing boards or
EPROMs, and always store boards in antistatic bags or boxes they were shipped in.
Vhen ordering replacement boards, note that the

>S200SLCC card does not include the two EPROMs
lentioned above (the sockets are empty).
To replace an SLCC:
IVARRANTY TERMS
['he GE Motors & Industrial Systems Terms and Condiions brochure details product warranty information, in;luding the warranty period and parts and service
;overage.
[he brochure is included with customer documentation. It
nay be obtained separately from the nearest GE Sales
Jffice or authorized GE Sales Representative.
1.

power is off.
2.

wiring boards. (The SLCC is mounted on the SDCC
located in the drive's board rack, facing the front.)
3.
If a programmer module is included, remove the programmer by pulling the snaps (holders, located in
each comer) outward to release the programmer
cover and keypad, then pulling the programmer loose
from the KPPL connector. (The keypad plugs into
connector KPPL on the SLCC.)



4.
Carefully disconnect all cables from the SLCC as

fonows:
Verify cables are labeled with the correct connector name (as marked on the card) to simplify
reconnection.
BI006008
SLCC LAN Com munications Card
5.
Remove the ~ LCC from the SDCC by removing the

four screws (",ith nylon washers) that secure it to the
standoffs on he SDCC, then remove the SLCC.
CAUTION
Avoid dropp ng mounting hardware into the
unit, which c[ould cause damage.
6.---Set all-confrgprable-itemS\nrthe rephlcernenr(new)
SLCC in the xact position as those on the card being
replaced.
NOTE
When repla( 'ng an SLCC, if a board revision

has added 01 eliminated a configurable component, or rc adjustment is needed, refer to
Table 1.
Also in most applications, all wire jumpers are factory set

to the correct position. Use these settings unless the instructions indicate otherwise. As described previously,
ensure that the jumpers on the new card are placed the
same as on the old card, unless the instructions indicate
otherwise. Refer to Table I, which lists the. default setting
ftrst. Figure I shows jumper locations.
REPLACING/INSERTING SOFTWARE
._-
- The SLCC must include onboard software to function in

the drive. This software is stored in the LCP EPROMs,
U6 and U7. When replacing the SLCC, the onboard software must be transferred to the new card (if a
DS200SLCC).
When replacing an SLCC, transfer the onboard software
to the new card as follows:
1.
Because of upgrades, boards of different revision levels m~y not contain identical hardware. Howe, er, GE Drive Systems assures
compatibilit1 of its replacement boards.

proper extraction/insertion tool when removing and inserting EPROMs.
Always use tile nylon washers when inserting

screws into tile card to avoid damage to the
card.
Install the ne f,r SLCC on the standoffs with the four
screws (with ylon washers) removed in step 5.
8.
Reconnect al cables to the SLCC as labeled. Ensure

that cables ar properly seated at both ends.
9.
If a Programr er module is included, carefully plug

the keypad in 0 connector KPPL on the SLCC and
snap the cove into place.
HARDWARE AI~JUSTMENTS
Most of the jumpt r selections have been factory set. The
test data sheets supplied with each controller (in the drive
door pocket) indic ate these positions. Table I lists and
defmes the jumpe s.
Remove one of the two EPROM chips (U6 or U7)

from the old card and insert it into the respective
socket on the new SLCC.
I_C_A_U_T_IO_N_I
CAUTION
7.
GEI-IOOI62B
To prevent damage to memory chips, ensure

that chips are properly oriented when inserting them into sockets.
2.
Repeat step 1 for the remaining EPROM.
3.
If the failure symptoms that caused the card to be

replaced still exist, install new EPROMs (shipped
with the new card if a DS215SLCC).
:EH-I00162B
.
Notes:
GEMotors&
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-...:l::::odustrial Systems
Issue Date: Rev. B, May 1997

S.n.r.1 Emetrlc Comp.ny

Indust';.' Systems
1501 flo.noke Blvd.
SmelT/, VA 241536492 USA
GEI-100167B
BI006008 GEI-100167A)
(Supersedes
GEMotors&
Industrial System~
--------+----------------------RTBA RELAY TERMINAL BOARD
These instructiom do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met
during installatio~, operation, and maintenance. Iffurther information is desired or ifparticular problems arise that are not covered
.-" .,
sufficiently fo1' fhE pur~!uJlse~Uf4fJf)se-,_#Il~_tte~ bN-efi-ed4&fH3.M(#f}~!!tr'tal-Systems: .
This document co~tains proprietary information ofGeneral Electric Company, USA and isfurnished to its customer solely to assist that
customer in the iYi~tallation, testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproduced
in whole or in pal t nor shall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems
CONTENTS
Safety Symbol egend
Functional Des ription
Introduction
Relay Descrip ions
Board Connec ions
Application Da a
Configurable ~ardware
Jumper and V pTables
RenewallWarr~ nty Replacement
Board Identifi :ation
Warranty Terrns
Warranty Part And Service
Procedure Fm Replacing Boards
1
1
1
2
2
3
3
3
8
8
8
8
8
SAF ~TY SYMBOL LEGEND

WARNING
CAUTIOt'..l
NOTE
Indicat~s an

not strictly observed, could result in damage to. or destmction
of equipment
essential or important procedure,

practice, condition, or statement.
WARNING

INTRODUCTION
The DS200RTBAG_A__ (RTBA) board is an optional

board located within the drive (or exciter) cabinet. The
RTBA board provides ten relays that are driven either di
rectly from the pilot relays on the 531X307LTB LAN II,
Terminal Board (LTB) or remotely by the user. Seven 0
the ten relays have two Form C contacts (DPDT relays)
and the other three relays have four Form C contacts
(4PDT relays). Figure 1 shows a layout diagram of the
RTBA board.
The RTBA board's relays are available with three coil
voltages, depending on the group number as follows:
RTBAGl - 110 V dc
RTBAG2 - 24 V dc
RTBAG3 - 115 V ac
BI006008
GEH-I00167B
Relay Terminal Board
RELAY DESCRIPTIONS AND REPLACEMENT
The ten relays are designated K20 through K29. Relays

K20 - K26 are the DPDT type relays and K27 - K29 are
the 4PDT type (see Figure I). Each relay has an LED that
indicates when the relay in energized (located at the top
of the relay inside the relay's case). All I/O of the relays
is protected by 130 V ac metal oxide varistors (MOVs).
Any of the ten relays can be replaced individually if
needed. Refer to Table I for the part numbers of the relays per RTBA board groupp.um?er.
6.
Replace the retaining clip on the new relay by centering it over the relay and pressing on the top until the
bottom of the clip engages on the relay socket.
BOARD CONNECTIONS
A 16-pin connector (RPL) and a 2-pin connector

(OPTPL) provide RTBA board I/O with the LTBA board.
The usage of certain signals of the RPL connector is
jumper selectable. See Table 2 for RTBA board jumper
., .. ,des~:rjptipns ..S~.e..Ia.bk,.2~ethe.~ctox:.pin.sig
nal descriptions and Table 4 for the OPTPL connector pin
signal descriptions.
CAUTION
or re-insert relays while power is applied to
the drive.
Two stab connectors, CPH (control power hot, positive)

and CPN (control power negative), are provided to supply
control power to certain pluggable circuits. The usage of
these stab connectors is jumper selectable. See Table 2 for
RTBA board jumper descriptions and Table 5 for the stab
connector descriptions.
To replace an RTBA board relay:
1.
Turn off the power to the drive.
2.

(The RTBA board is typically located below the
drive's board rack.)
3.
Remove the retaining clip for the relay to be replaced

by pressing on the top of the retaining clip and pulling on either side of the clip to release it.
4.
Remove the old relay by pulling straight out from the

relay socket.
S.
Orient new relay on the socket (will only fit one way)
and press the relay into seated position in the socket.
The RTBA board provides pluggable circuits and access

to relays K27 - K29 through connectors CIPL - C5PL
and Y9PL - Y37PL. The control power source for these
pluggable circuits is jumper selectable (see Table 2). See
Table 6 for the CIPL - C5PL and Y9PL - Y37PL connector descriptions.
I/O between the RTBA board relays K20 - K26 and external signals can be connected at RTBA board terminals
1 - 52. The control power source for these relays is
jumper selectable (see Table 2). See Table 7 for the terminal descriptions.
Table 1. RTBA Board Relay Part Numbers

Board
Group #
Relay
Designation
Relay
Part Number
Description
G1
K20- K26
68A9663PDC110X
110 V dc coil with 10 A DPDT contacts
K27 - K29
336A51 01 PDC11 0
110 V dc coil with 1 A 4PDT contacts
K20 - K26
68A9663PDC24X
24 V dc coil with 10 A DPDT contacts
K27 - K29
336A51 01 PDC24
24 V dc coil with 1 A 4PDT contacts
K20 - K26
68A9663PAC115X
115 V ac coil with 10 A DPDT contacts
K27 - K29
336A51 01 PAC115
115 V ac coil with 1 A 4PDT contacts
G1, G2, G3
K20 - K26
323A2451P1
Hold-down clip
G1, G2, G3
K27 - K29
68A9662P3
Hold-down clip
G2
G3
BI006008
Relay Terminal oard
GEI-I001671
The RTBA boar includes Berg-type (manually movable)

hardware jumpe ,identified by a JP nomenclature that
must be set corre tly for the application. Most of the
jumper selection have been factory set. The data sheets
supplied with ea h controller (in the drive/exciter door
pocket) indicate ese factory set positions. Table 2 lists
the jumper descr ptions, showing the default setting first.
Figure I is a lay ut diagram of the RTBA board, showing
the locations of e jumpers.
I~
Tables 2 - 7 list e jumper descriptions and I/O of the

different connec ors on the RTBA board. The tables are
organized as foil ws:
Table 2 - J
Table 3 -
per Descriptions
q:~D
;;
u..,
L Connector Pin Descriptions
TPL Connector Pin Descriptions
b Connector Descriptions
Table 6 - C PL - C5PL and Y9PL - Y37PL

Connector escriptions
Table 7 - T rminal Point Descriptions
D:~D
U..,
D!
Figure 1. RTBA Board Layout
BI006008
GEH-I00167B
Table 6. C1PL-C5PL and Y9PL-Y37PL Connectors (RTBA Board Pluggable Circuits)

Description
Connector
C1PL - C5PL, Pin 1
Pluggable circuit control power, positive (hot) side (CPH)
C1 PL - C5PL, Pin 2
Pluggable circuit control power, negative side (CPN)
Y9PL-1
CPH
Y9PL-2
Connected to Y10PL-1; Y9PL and Y10PL form a powered pluggable circuit
Y10PL-1
Connected to Y9PL-2; see Y9PL-2
Y10PL-2
CPN
Y11PL-1
CPH
Y10PL - Y14PL
Two-position plugs forming a series string to coil of relay K27
Y15PL
Jumpers Y18PL-2 to CPN
Y16PL
Relay K27 normally open contacts
Y17PL
Relays K27 and K28 dry contacts in series
Y18PL
Relays K28 and K29 coil leads
Y19PL - Y22PL
Pluggable control circuit with K28 relay interlock
Y23PL - Y24PL
Dry circuit with K29 relay contact
Y25PL - Y28PL
Y29PL - Y30PL
Dry circuit with K29 relay contact
Y31 PL - Y34PL
Y35PL - Y37PL
Pluggable control circuit
Table 7. Terminal Point Descriptions

RTBA
Terminal
Nomenclature
Description
K20A
Relay K20 coil voltage source (see Table 2, JP1)
K201NO
Relay K20 form C contact #1 normally open
K201CM
Relay K20 form C contact #1 common
K201NC
Relay K20 form C contact #1 normally closed
K202NO
K202CM
K202NC
K21A
K211NO
10
K211CM
11
K211NC
RelayK21fOrniC contact #1 normally closed
12
K212NO
13
K212CM
14
K212NC
'.
BI006008
GEI-IOO167l
Table 7. Terminal Point Descriptions- Continued

RTBA
Terminal
Nomenclature
Description
15
K22A
16
K221NO
17
K221CM
18
K221NC
19
K222NO
20
K222CM
'21
......... '.""'.'
1-K222NC

"
........
~-
~~~y1{22fbrm'"C't6i"lfaet1#1h6ffTfiilryCt6seC:f~
22
K23A
23
K231NO
24
K231CM
25
K231NC
26
K232NO
27
K232CM
28
K232NC
29
K24A
30
K241NO
31
K241CM
32
K241NC
33
K242NO
34
K242CM
35
K242NC
36
K25A
37
K251NO
38
K251CM
39
K251NC
40
K252NO
41
K252CM
42
K252NC
43
K26A
44
K261NO
45
K261CM
46
K261NC
47
K262NO
48
K262CM
49
K262NC
50
KCM
Relays K20 - K26 common
51
115V
115 V ac
52
Not Connected
,Ii
,- .,..;-.
... , ,''P'
. _...
_:
BI006008
GEH-I00167B
RENEWAUWARRANTY REPLACEMENT
CAUTION

part (catalog) number stamped on its edge. For example,
the RTBA board is identified by part number
DS200RTBAG#. Figure 2 describes each digit in the part
number.

always store boards in anti-static bags or
NOTE
,~,~_.-
. ".' ..". "",-".,-.bM-.they..wer~>in.,,'"
To replace an RTBA board:

I.

power is off.
2.

(The RTBA board is typically located below the
drive's board rack.)
3.
Carefully disconnect all cables from the RTBA board

as follows:
WARRANTY TERMS
The GE Motors & Industrial Systems Terms and Conditions brochure details product warranty information, including the warranty period and parts and service
coverage.
The brochure is included with customer documentation. It
may be obtained separately from the nearest GE Sales
Office or authorized GE Sales Representative.



For wires attached to RTB terminals, loosen the
screw located at the top of each terminal and
carefully pull each wire free. (Ensure that wires
are labeled to simplify reconnection.)

WARNING
>~'"
Two-conductor plugs (CPIPL-CP5PL and

Y9PL-Y37PL) feature integral holding clips.
Press the connector lever to release the connector.
4.
Remove the four screws with washers that secure the

RTBA board to the four standoffs and remove the
board.
CAUTION
connected circuits.

5.
Set all configurable items on the replacement (new)

board in the exact position as those on the board being replaced (old board).
..
,
BI006008
Relay Terminal Joard
GEI-I00167E
If a board rev' sion has added or eliminated a configurable compc~ent, or re-adjustment is needed, refer
to Configura Ie Hardware paragraph and Table 2 in
this instructic n book.
6.
Install the new board on the four standoffs with the

four screws and washers removed in step 4.
7.

NOTE
8. Reconnect all individual wires disconnected in step 3

(as labeled), ensuring that each wire is properly seBecause of u ~grades, boards of different revision levels m ~y not contain identical hardcured in the terminal.
ware. Howe, er, GE Motors & Industrial
Systems ensll res backward compatibility of
replacement boards.
.
c", c .,~,C""''''''''';c'''''''' ..., .... '" ,~", , ",,:.
..,.<;.,'."'c(c,'.,,~ ~ , ".
'0"
os
200
! TBA
G#
A
I
A board revision (artwork change) that is backward compatible.

L-
L-
'----+--------------
Indicates that the board is a base level board and can contain firmware.
(215 indicates the board is a higher level assembly that can contain firmware and/or other components added to the base level board.
Figure 2. Sample Board Part Number, OS Series
BI006008
GEH-I00167B
"
Notes:
GEMotors&
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.::.:.:Industrial Systems
Issue Date: Rev. B, April 1997

GBnBr.1 EIBetrie CompBny
Industrial Systems
1501 Roanoke Blvd.
BI006008
GEI-10018
GE Olive Systen
Replacement Instructions For
FSAA Single-phase Field Supply Gate Amplifier Board
DS200FSAAG#
These instructi01 s do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be
met during insta Ilation, operation, and maintenance. Should further information be desired or should particular problems arise that
are not covered ufficientiy for the purchaser's purpose, the matter should be referred to GE Drive Systems, Salem, Virginia U.S.A.
WARNING
This equipll ent contains a potential hazard

of electrical shock or burn. Only those who
are adequal ~Iy trained and thoroughly familiar with the equipment and the instructions
should insU I, operate, or maintain this
equipment.
The FSAA is mechanically mounted on a four SCR

(PI, n, N1, N2) full-wave supply bridge.
The FSAA's -G1 (NRP) board phase-controls four
SCRs to allow plugging operation. The board provides
1400 V crowbar protection plus overvoltage protection
for each SCR. The -G1 board has jumpers to allow
NRX operation (see Table 1). This option is provide in
case excessive field problems occur with the particular
NRP application.
NOTE
INTRODUCTIO 1\1
These instructiOl s provide information that may be

needed when rep acing a DS200FSAAG#__ board
(FSAA). This in ludes configurable hardware, such as
jumpers and fusf data.
The FSAA boarc is a field supply gate amplifier board
for the DC2000 )oard family. The board is available in
two forms:
DS200FSAA G1__ for non-reversing, plugging

(NRP) field supplies; has NRX capability
Use the -Gl board's NRX mode only if

continual field application problems occur in
the NRP mode.
The FSAA's -G2 (NRX) board allows SCRs n and N~
to tum themselves on when their anode voltage is positive. The two other SCRs are phase-controlled.
NOTE
The -G2 board can only be run in the NRX

mode.
DS200FSAl G2__ for non-reversing (NRX) field
, BOARD IDENTIFICATION
supplies
The FSAA inc1u
power lines. Thf
to 24 A and the
the onboard fuse
nal fuses feed th
es 30 A fuses on the L2 and L3 input

fuses are designed to protect fields up
c MaV. For fields greater than 24 A,
protect the ac MaV, but larger exterfield.
The ac Mav is ocated on the -G2 (NRX) boards, but

on a subassembl for the -G1 (NRP) boards.
A printed wiring board is identified by an alphanumeril

part (catalog) number stamped on its edge. For example, this board is labelled DS200FSAA#ruu.
The DS200FSAA portion is the base number that identi
fies a specific printed wiring board, in this case, the
Single-phase Field Supply Gate Amplifier Board.
BI006008
GEI-lOO186
Single-phase Field Supply Gate Amplifier Board
The G# identifies a group, which is a variation of a

particular board. The r and u digits are alphabetic characters that indicate the board revision level. The r digit
reflects a functional change that is not downward compatible. It is essentially a new catalog number. The u
digits represent revision levels that are downward compatible to the r revision level.
NOTE


tab.
3.
The FSAA board is mounted on standoffs. Remove

the four screws attaching the board to the standoffs.
4.
If the replacement (new) board is a -Gl, set all

jumpers in the exact position as those on the board
being replaced (old board).
If a board revision has added or eliminated a
configurable component, or re-adjustment is needed, refer to Table 1.
--WARNING

FSAA board when powered. To prevent
electric shock, turn off power to the board,
then test to verify that no power remains on
the board before touching it or any connected circuits.
5.
Install the new board on the standoffs, making sure

that the four screws are secure.
CAUTION
6.
Reconnect all cables and wiring as labeled. Ensure

that cables and wires are properly seated at both
ends.

they were shipped.
The FSAA board mechanically mounts on the field
exciter module (SCR supply bridge), typically located
on front of a DC2000 drive. To replace the board:
1.
2.
NOTE
Turn off power to the board, then wait a few

them to make sure power is off.
To remove the FSAA board, carefully disconnect
all wiring and cables. Make sure each wire and
cable is labelled, then carefully remove them, as
follows:

FUSES
The FSAA includes two fuses mounted in an onboard

fuse block. These fuses are 30 A, 60 V fast-acting type.
HARDWARE ADJUSTMENTS
The FSAA's -Gl (NRP) board contains Berg-type

(manually moveable) jumpers, designated with a iP
nomenclature. As described previously, these jumpers
- are provided ~an NRXoption on the -Gl board.
Figure 1 is a layout of the FSAA board, showing the
locations of the jumpers. Table 1 defmes the jumpers.
The jumpers have been factory set for the default
(NRP) position.
BI006008
Single-phase Fi ~d Supply Gate Amplifier Board
SHP
SHN
SP
II II II II
R
---
MOV3
SN
M0V2
"
PIC
P1PL
JP3
3r1
I I
'"
'"\
PIGI
P2CI P2GI
..
~'
II
mil
I I
II II II II
PICI
0
/
...
\
Ul
3r1
I I
3r1
JP6
~D
~D
JP,
II
N2PL
NIG
liD"
I I
FAC3
II
NIC NIPL
3r1
FU3
AC3R
P2PL
FPR
Dm
~D
~
DS20 DFSAAG1A
~D
3r1
P1G
"0 II 0
Ff'4,2
FU2
GEI-looIS
I I
JP5
3r1
I I
~D
JP4
II
NICI
}1~1 C
:JI
FPL
II II
N2CI N2GI
Figure 2. FSAA * Board Layout
* Jumpers JP1 - JP6 exist on -G 1 board only.
NOTE
The followiI g table defines the jumpers used on the FSAA's -Gl board. (The -G2 board does not include
any jumpen.) The Name column indicates the item's identification as marked on the board. The
Description olumn defines the items, including jumper settings. The default setting (position) is listed
first.
Table 1. FSAA Board Adjustable Hardware

Name
Description
JP1 - JP6
Jumper select for NRP or NRX mode, group -G1 only. Jumpers JP1-JP6 should be set to the same
position, selecting either NRP or NRX mode. Jumpers should be set to NRX mode if field application
problems are occurring with NRP operation.
!Position
NRP mode (default)
1.2
NRX mode
~.3
BI006008
GEI-lOO186
Single-phase Field Supply Gate Amplifier Board
Notes:
GE Drive Systems
e Date: October 1994
GEI-100228
BI006008
GEMotors&
Industrial Systems
RECEIVING AND STORAGE INSTRUCTIONS

FOR DIRECTO-MATIC 2000 EQUIPMENT
These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contingency to be met during installation, oper tion, and maintenance. Iffurther information is desired or ifparticular problems arise that are not covered sufficiently for the purchG er 's purpose, the matter should be referred to GE Motors & Industrial Systems.
rs
This document conta proprietary information ofGeneral Electric Company, USA and is furnished to its customer solely to assist that
customer in the insta lation, testing, operation, and/or maintenance ofthe equipment described. This document shall not be reproduced in
whole or in part nor hall its contents be disclosed to any third party without the written approval ofGE Motors & Industrial Systems.
CONTENTS
Safety Symbol Leglend .................................................... 1
Overview............... .......................................................... 1
Receiving Guidelil es....................................................... l
Handling Guidelinps ....................................................... 2
Storage Guideline .......................................................... 3
Warranty Parts a d Service .......................................... 4
SAFET ~ SYMBOL LEGEND

WARNING
CAUTION

not strictly observed, could resuIt in personal injury or death.
of equipment.
NOTE Indicates n essential or important procedure,

practice, ( ondition, or statement.
OVERVIEW
This document contains guidelines and precautions for
handling and storing DIRECTO-MATIC 2000 equipment upon receipt from a carrier. This document also
contains information for obtaining warranty parts and
service.
Before handling or storing equipment, consult and study
all applicable drawings and instructions.
For assistance, contact:
1501 Roanoke Blvd.
Phone: 001-540-387-7595
Fax: 001-540-387-8606
RECEIVING GUIDELINES
General Electric Company (GE) carefully inspects and
packs all equipment before shipping it from the factory.
GE attaches a packing list, which itemizes the contents of
each package, to the side of each case of the equipment.
GE provides handling guidelines to the carrier. These
direct the carrier not to expose the shipment to excess
moisture or humidity, extreme temperatures, excess temperature changes, or rough handling during transportation.
Receiving.and Storage Instructions for D1RECTO-MAT1C 2000 Equipment BI006008
;EI-I00228
Jpon receiving a shipment, the customer should:

Conduct a visual inspection before or during the
offloading.
Move the shipment to shelter.
Conduct a thorough inspection of the shipment.
Shortage
Damage sustained while enroute
Refer to Receiving Guidelines, Handling Guidelines, and

Storage Guidelines below.
If damage or rough handling is evident, notify the carrier
and GE immediately.
~efer
to Receiving Guidelines, Handling Guidelines, and

torage Guidelines below.
The carrier or GE may require the following information:
Case number
Equipment serial number
Part (model) number
Damaged part (model) name and description
)FFLOADING
nmediately upon receipt of any equipment, conduct a

isual inspection for signs of rough handling or shipping
amage. Conduct this initial inspection before the shiplent is offloaded. If damage is noted, immediately notify
le carrier before they leave the reception site.
rotify the carrier that a thorough inspection was not conucted upon the receipt of the shipment. A thorough in)ection occurs after storage and unpacking.
HANDLING GUIDELINES
.efer to Moving and Lifting and Damage Notification

elow.
CAUTION
HELTERING
Rough handling can damage electrical equipment. To prevent such damage when moving
the equipment, be sure to observe normal
precautions along with all handling instructions printed on the case.
CAUTION
Potential for damage to equipment exists.
Packing cases are not suitable for outdoor
storage, even for short periods of time.
nmediately after the offloading visual inspection, place
Ie equipment under adequate cover to protect it from
jverse conditions.
NOTE
MOVING AND LIFTING
When handling equipment:
Refer to equipment outline drawings for preferred

methods of lifting and moving equipment.
Observe the equipment's center-of-gravity to ensure

that equipment does not fall.
Failure to protect equipment from adverse

conditions will void the equipment warranty.
efer to Handling Guidelines and Storage Guidelines
~low.
~SPECTING
fter moving the equipment to shelter, check the contents

package against the packing list. Check for:
o each
UNPACKING
Consider the following when unpacking a shipment:
If the equipment has been exposed to low temperatures for an extended period, do not unpack it until it
has reached room temperature.
BI006008
_ Receiving and Stor ge Guidelines for DIRECTO-MATIC 2000 Equipment
It is good practi e not to completely unpack the
equipment until it has been placed near its permanent

location or its s rage location.
GEI-I00228
Shipping and ambient storage temperature limits

are: -25C (-5 OF) to 70C (167 OF).
NOTE
Use standard u acking tools to carefully remove

equipment from its container.
Use care when npacking to prevent marring or damaging parts.
Label each item when it is unpacked.
Check the cont ts of each case

list. Report sho ages to GE.
Wipe off partie s of packing materials or foreign

substances that ay be lodged in or between the
parts.
again~t
the packing
Use caution to nsure that small parts (such as bolts

and screws) do at become separated.
Carefully inspe t packing material for loose parts

before discardi g.
These limits are guidelines to ensure a safe

storage environment for all equipment. However, some equipment can tolerate a wider
range. If the above temperature guidelines
cannot be met for your equipment, contact
GE to determine if different tolerances apply.
Surrounding air free of dust and corrosive elements, such as salt spray, or chemical and electrically conductive contaminants.
Ambient relative humidity from 5 to 95% with
provisions to prevent corrosion.
No rodents.
Limit temperature variations that cause moisture
CONDENSATION
STO
GE GUIDELINES
If the unit is not inst lied immediately upon receipt, it

must be stored prop rly to prevent corrosion and deterioration. Since packin cases do not protect the equipment
for outdoor storage, he customer must provide a clean,
dry place free ofte perature variations, high humidity,
and dust.
SPECIFICATION
Use the following g idelines when storing equipment:
Place the equip ent under adequate cover with the

following requi ements:
Keep the e uipment clean and dry, protected
from preci itation and flooding.
Use only b eathable (canvas type) covering material- do ot use plastic.
Unpack the eq 'pment as described in Unpacking
(page 2).
Maintain the fo lowing environment in the storage

enclosure:
CAUTION
Moisture on certain internal parts can cause
electrical failure.
Condensation occurs with temperature drops of
15C (27 OF) at 50% humidity over a 4-hour period.
Condensation also occurs with smaller temperature variations at higher humidity.
If the storage room temperature varies in such a way, install a reliable heating system that keeps the equipment
temperature slightly above that of the ambient air. This
can include space heaters or panel space heaters (when
supplied) inside each enclosure. A 100 W lamp can
sometimes serve as a substitute source of heat.
CAUTION
EI-l00228
Receiving and Storage Instructions for DIRECTO-MA TIC 2000 Equipment
iME LIMITATIONS
OBTAINING PARTS AND SERVICE
1e above specifications apply to shipping and storage

Irations of up to one year. Longer times may require
Iditional treatment.
identify the part and the application:

rARRANTY TERMS
!1e GE Terms and Conditions brochure provides product

arranty information, including the warranty period and
irts and service coverage.
he brochure is included with the customer documenta)n. It may also be obtained separately from the nearest
E Sales Office or authorized GE Sales Representative.
GEMotors&
Industrial Systems
-------------------------------
Date: October 1996
GBnBrll1 EIBctric Complln,

Industrial Systems
1501 Roanoke Blvd.
BI006008
BI006008
Book #1
Section
Field Exciter Instructions

GEH-6328
2243-I.M61
BI006008
BI006008
GEH-6328A
BE Motors &
Industrial
----------+---------------------------
System~
DS2020FEA 50 - 100 Amp NRX/NRP FIELD EXCITER MODULE

DS2020FEANRX
A and DS2020FEANRP
These instruction do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be
met during install tion, operation, and maintenance. Should further information be desired or should particular problems arise that
are not covered s ifficiently for the purchaser's purpose, the matter should be referred to GE Drive Systems & Turbine Controls.
This document co tains proprietary information of General Electric Company, USA and is furnished to its customers solely to assist
that customer in t e installation, testing, and/or maintenance of the equipment described. This document shall not be reproduced in
whole or in part' or shall its contents be disclosed to any third party without the written approval of GE Drive Systems & Turbine
Controls.
SAFETY SYMB)L LEGEND
WARNING
CAUTION
HARDWARE DESCRIPTION
Commands attention to an operating procedure, practice, condition, or statement that, if not

strictly observed, could result in
personal injury or death.
The FEA module is mounted outside the drive core.

The module's I/O connections (see Table 3) are made
on its gating board, the DS200FSAAG1 (for NRP) or
-G2 (for NRX). The -Gl board includes jumpers (see
Table 2) that allow it to function with NRX supplies.
Commands attention to an operating procedure, practice, condition, or statement that, if not

strictly observed, could result in
damage to or destruction of
equipment.
The module receives gate pulse signals from the drive's

power supply board: a DS200SDCI board (SDCI) for
NRX only applications and a DS200DCFB board
(DCFB) for NRX or NRP applications. The SDCI can
control only one FEA module; the DCFB board can
control up to two FEA modules. Table 1 provides a
summary of these interface options.
NOTE Comman s attention to an essential operating

or maintenance procedure, condition, or statement that must be highlighted.
Table 1. FEA Module Interfaces

Supply
Type
Control
Board
NRX
SOCI
NRX
DCFB
NRP
OCFB
FEAN
No.
INTRODUCTIOl\
The DS2020FEA 50 - 100 Amp NRX/NRP Field Exciter Module (FE 'I.) provides excitation for a 50 to
100 A motor field with a DC2000 drive. It can operate
with either of two types of non-reversing field supplies:
non-plugging (NRDc) or plugging (NRP). The FEA
typically is used v ith C, G, J, K, L, and M frame
DC2000 drives.
15t
2nd
15t
2nd
Mounting* * Per
Drive Frame Size
C, J, & M
E
E
E
E
E
E
E
E
E
* SOCI can control only one FEA module.
This document co tains electrical description and theory

of operation for tl e FEA module. It is intended for use
by installation ane maintenance personnel.
** E = external to drive core.
K&L
BI006008
GEH-6328A
DS2020FEA 50 - 100 Amp NRXINRP Field Exciter Module
The FEA consists of the following major components:
Thyristor Bridge
Incoming line fuses
MOV (metal oxide varistor) voltage suppressor
The FEA includes a four-thyristor (PI, P2, N1, N2)

full-wave supply bridge. The bridge provides non-reversing, single-phase, ac/dc voltage conversion.
Ac and dc line filters
Cooling fan
Thyristor bridge
The FSAA board is a field supply gate amplifier board,

available in two forms:
DS200FSAAG1 or -G2 gating board (FSAA)
DS200FSAAG1__ for non-reversing, plugging

(NRP) field supplies
DS200FSAAG2__ for non-reversing (NRX) field

supplies
DS200FSAA Field Supply Gate Amplifier Board
The following paragraphs describe these components.
Line Fuses
The FEA includes 30 A, 600 V fuses on FSAA input
lines AC2 and AC3. These fuses are located on the
FSAA board and sized to protect the MOV from an
overload on the output.
The FEA also includes fuses FU2 and FU3 on the
incoming power lines to protect the module circuitry
(see Figures 5 and 6). These fuses are panel-mounted
and sized per the shunt size, as follows:
Shunt SRI
15, 20, or 25 A
50 A
75 A
100* or 150 A*
Fuse FU2, FU3

40 A, 700 V
60 A, 700 V
100 A, 700 V
150 A, 700 V
*Ratings not for continuous duty
MOV Voltage Suppressor

The MOV limits voltage transients. The MOV is panelmounted in an assembly for NRP and mounted on the
FSAA board for NRX.
The -GI (NRP) board phase-controls four SCRs to

allow plugging operation. The board provides crowbar
protection plus overvoltage protection for each SCR.
The -G1 board has jumpers to allow NRX operation
(see Table 2). (Figure 1 shows jumper locations.)
NOTE
Use the -GI board's NRX mode only if

continual field application problems occur in
the NRP mode.
Table 2. FSAA Board Jumpers
Name
Description
JPl - JP6
Jumper select for NRP or NRX mode,

group -G 1 only.
Jumpers JP1-JP6 should be set to the
same position, selecting either NRP or
NRX mode. Jumpers should be set to
NRX mode if field application problems
are occurring with NRP operation.
Position
1.2
2.3
NRP mode (default)

NRX mode
AC and DC Filters
An ac line filter limits the dv/dt across the thyristors. A
dc filter aids bridge conduction.
Cooling Fan
The FEA includes a fan connected to the 115 V ac
input lines for cooling.
2
The -G2 (NRX) board allows SCRs P2 and N2 to tUm

on when their anode voltage is positive. The two other
SCRs are phase-controlled.
NOTE
The FSAAG2 board only runs in the NRX

mode.
BI006008
DS2020FEA 50
GEH-6328A
100 Amp NRXINRP Field Exciter Module
I/O CONNECTIONS
The FEA module's thyristor and control board I/O is

through connecto s on the FSAA board. (See I/O Connections for detai s.)
The FEA module's thyristor I/O and control board I/O

connections are on the FSAA board. Figure 1 shows thf
connectors and Table 3 defines them. Figures 5 and 6
are module elementary diagrams showing electrical
connections.
The FSAA inelue es 30 A fuses on the input power

lines, as describei above (see Line Fuses). The ac
MOV is located nly on the -G2 (NRX) boards (see
MOV Voltage Su lfJressor).

NOTE
The FSAA is me hanically mounted on standoffs on top

of the FEA's thyristor bridge.
--
1.40V:5
SHP
SHN
SN
1.40V2
II II I
II
II
P1C
II
--
All connections listed may not be present,

depending on the board group number. For
specific connections, refer to the system
elementaries.
PIPL
P1G
P2PL
NIC
II
II
FAC2
RW.W
F'U2
JP3
:5 r1
I I
:5r1
N2PL
NIG
II
FPR
'"
'"\
FU:5
r1
~;'
I I
~0
FAC:5
:5r1
II
II II II II
P1CI
PIGI
P2CI P2GI
:5
JP6
~D
~D
I I
JP5
r1
:5
I I
~D
JP4
II
II
NICI
N1GI
rr:=::Jl
FPL
II II
N2CI N2GI
Figure 1. FSAA * Board Layout
* Jumpers JP1 - JP6 exist

on -G 1 boards
r1
I I
JPl
II
FN
...~
~ Om
AC:5R
I I
'"
DS20)FSAAG1A
~D
N1PL
nly.
Table 3. FEA Module I/O Connections (Located on FSAA Board)

Connection
To
Name
Description
P1 PL-1
Bridge
P1C
P1 SCR cathode, red
P1 PL-2
Bridge
P1G
P1 SCR gate, white
P2PL-1
Bridge
P2C
P2 SCR cathode, red
P2PL-2
Bridge
P2G
P2 SCR gate, white
N1PL-1
Bridge
N1C
N1 SCR cathode, red
N1 PL-2
Bridge
N1G
N1 SCR gate, white
N2PL-1
Bridge
N2C
N2 SCR cathode, red
N2PL-2
Bridge
N2G
N2 SCR gate, white
PPL-1
DCFB
P1C
P1 SCR cathode, red
PPL-2
DCFB
P1G
P1 SCR gate, white
II
II
BI006008
DS2020FEA 50 - 100 Amp NRX/NRP Field Exciter Module
GEH-6328A
Table 3. FEA Module I/O Connections (Located on FSAA Board) Connection
To
Name
Description
NPL-1
DCFB
N1C
N1 SCR cathode, red
NPL-2
DCFB
N1G
N1 SCR gate, white
FPL-1
P24SW
P1 SCR gate, white (same as P1 G1)
*
*
F1 P1
P1 SCR cathode, red (same as P1 C1)
P24SW
N2 SCR gate, white (same as N2G1)
F1N2
N2 SCR cathode, red (same as N2C1)
P24SW
P2 SCR gate, white (same as P2G1)
FPL-6
*
*
*
F1P2
P2 SCR cathode, red (same as P2C1 )
FPL-7
P24SW
N1 SCR gate, white (same as N1G 1)
FPL-8
F1N1
N1 SCR cathode, red (same as N1 C1)
FPL-2
FPL-3
FPL-4
FPL-5
FPL-9
----
----
Not used
FPL-10
----
----
Not used
Stab
TB
P1G1
P1 SCR gate (transformer isolated)
Stab
TB
P1 CI
P1 SCR cathode (transformer isolated)
Stab
TB
P2GI
P2 SCR gate (transformer isolated)
Stab
TB
P2CI
P2 SCR cathode (transformer isolated)
Stab
TB
N1GI
N1 SCR gate (transformer isolated)
Stab
TB
N1CI
N1 SCR cathode (transformer isolated)
Stab
TB
N2GI
N2 SCR gate (transformer isolated)
Stab
TB
N2CI
N2 SCR cathode (transformer isolated)
Stab
SDCI/DCFB
P1G
P1 SCR gate (non-isolated)
Stab
SDCI/DCFB
P1C
P1 SCR cathode (non-isolated)
Stab
SDCIIDCFB
N1G
N1 SCR gate (non-isolated)
Stab
SDCI/DCFB
N1C
N1 SCR cathode (non-isolated)
Stab
Bridge
FPR
Dc snubber
Stab
Bridge
FN
Dc snubber
Stab
Bridge
AC3R
Ac snubber
Stab
Bridge
FAC2
Breakover diodes
Stab
Bridge
FAC3
Breakover diodeslac snubber
Screw
Main line
AC2
L2, main ac into fuse block
Screw
MOV2
FU2 connect to MOV2 via wire jumper
MOV2N
MOV connect to FU2 via wire jumper
Horiz. stab
*
*
*
MOV2/H
Screw
Main line
AC3
L3 main ac into fuseblock
Screw
MOV3
FU3 connect to MOV3 via wire jumper
Vert. stab
MOV3N
Horiz. stab
*
*
FMOV3/H
Stab
Bridge
SHP
Field shunt positive
Stab
Bridge
SHN
Field shunt negative
Vert. stab
Stab
Bridge
SP
Field shunt positive out
Stab
Bridge
SN
Field shunt negative out
* = See module elementary diagrams.
Continued
BI006008
DS2020FEA 50
GEH-6328A
MODULE POW R SPECIFICATIONS
Input (ac):
Ty ical 230/450/575 V ac, 50/60 Hz

M imum 600 V ac 10%
Output (dc): .9
V1nput rms, maximum
Maximum output current: 100 A

Dc shunt:
V out
-----lU U U-!----
Figure 3. Typical NRX Field Supply - Field DC Output
15, 20, 25, 50, 75, 100, or 150 A

(1 0 and 150 A shunt ratings are not for
c ntinuous duty; typical application is
omentary field forcing)
Vout
O----J----i----i~---il__-I__-t------
TROUBLESHO TING
WARNING
Figure 4. Typical NRP Field Supply - Field DC Output
Potentially I thai voltages are present on the

FEA modul when powered. To prevent
electric sho ,turn off power to the module,
then test to erify that no power remains on
the circuit before touching the module or
any connect d circuits.
Refer to Figures 5 and 6 for wiring and connection

details.
Symptoms
Blown line fuses
Field fault trips
The following co tains some symptoms of problems

with the FEA mule with checks to follow for troubleshooting.
Field supply does not properly regulate (unstable)

while at full field or while in field economy
Tools required troubleshooting:
Shorted or open cells (SCRs/diodes)
Oscilloscope
Field phases fully on and stays there
ST2000 Too kit (drive configuration software)

Checks
Figures 2 throug
(V our ) waveforms
connected to the
and connection d
4 show ac input (V in ) and dc output

as they should look on an oscilloscope
EA. See Figures 5 and 6 for wiring
tails.
If any of the above symptoms occur, use the following
checks to determine the cause. These checks are listed

in order of most likely cause first and, therefore,
should be followed in order.
If wiring/connection checks and fuse replacement do no
O-L--------'t1f-----.r------'<-------r
correct the problem, the FEA module should be replaced as a unit.

NOTE
Figure 2. Ac Input Line-to-Line Waveform
To minimize system downtime, GE recommends that the module be replaced as a

unit, not repaired in the field (other than
fuse replacement and wiring checks).
BI006008
GEH-6328A
1.
Is input ac polarity to unit L2-L3 correct?
Phasing synchronization for the field comes from ac

inputs VI, V2, and V3 on the DCFB or SDCI board.
Also, field phasing is sometimes switched in firmware
(see EE.557 FSYADJ, Field Sync Adjust) to allow
multiple I-phase field supplies to balance the 3-phase
transformer loading.
2.
Is the drive firmware set correctly for the field

supply unit?
The drive needs to know how many field supply units

(l or 2) and what type (NRP or NRX) field supply(s).
See ST2000 HELP: PAR_ FEX_BEHAV, EE.573.2
or EEI500.8 MJPROO.
For an NRP supply type, the FSAAG1 board's jumpers
should be set 1-2. For additional jumper information,
see ST2000 hardware HELP: FSAA, JPl-6.
3.
Is the shunt correct size?
Typically, the shunt is sized as close as possible to the

field, but the field amps should not exceed the shunt
size.
7.
Is the di/dt reactor wired correctly?
The input ac line reactor limits the di/dt current through

the power semiconductors. The reactor is connected in
series with the ac input.
The FEA modules can have either of two core designs:
a separate magnetic core on each input phase, or a
common magnetic core.
With a common magnetic core, modules must have the
winding arranged correctly to ensure that the magnetic
fluxes add instead of cancel each other (by right hand
rule). That is, one phase must enter the core on one
side, and the other phase must enter on the other side of
the core.
ST2000 Parameters, Locations, and Variables
The following tables contain ST2000 parameters, locations, and variables that apply to the FEA module. For
more complete information, use the ST2000 program's
HELP feature.
Table 4. ST2000 Bobcat Parameters
For example:
4.
4 A field = 5 A shunt
6 A field = 10 A shunt
Is shunt polarity wiring correct?
The red wire must be on the side of the shunt that

attaches to the bridge (red is for positive feedback).
5.
Are dv/dt resistor/capacitor (rc) snubbers connected?
An rc snubber across the ac input and one across the dc

output protect the bridge against dv/dt transients. Also,
the dc output rc snubber is needed to tum on the cells.
If the dc output rc snubber is not connected, the field
cannot regulate current, which often causes the cells to
cut on and off rapidly. In this case, the dc output
waveform appears severely chopped at greater than
1 kHz.
Function
FLDACINPUT
Field ac input
FSHUNTAMPS
Rated field shunt amps
FEX BEHAV
Field behavior (NRX, NRP)
I MAX FLD
Maximum field current
I MIN FLD
Minimum field current
XFMR FLD
Isolation transformer present
Is gate lead wiring correct?
Each gate lead must go to the appropriate cell: white

wires to the SCR gates, red wires to the SCR cathodes.
6.
Mnemonic
BI006008
DS2020FEA 50
GEH-6328P
Table 5. ST2000 EE Locations

J. ddress
Mnemonic
Description
EE.557
FSYADJ
Adjustment between main line sync and field A ac input
EE.559
FBSYAD
Adjustment between main line sync and field B ac input
EE.563
SCLFIF
Field #A Current Scaling Factor for autotune
EE.570.7
MCNFIG
Enable Field #A enhanced field
EE.570.9
MCNFIG
Enable field #B regulator (#B = enhanced only)
EE.570.13
MCNFIG
Rescale SCLFIA EE.561 and SCLFIF EE.563 by 10:1
EE.573.0
MCNFGB
Select SDCI board
EE.573.2
MCNFGB
Select 2/3, NRX, or NRP Field for Field A
EE.573.12
MCNFGB
Select NRX or NRP Field for Field B
EE.1500.8
MJPROO
Inhibit field economy
EE.1500.9
MJPROO
Enforce field economy
EE.1 500.12
MJPROO
External FLDFB enable
EE.1506
FLDSFO
Field Current shunt #1 (#A) trim scale factor
EE.1523
FL2SFO
Field Current shunt #2 (#B) trim scale factor
EE.1560
FLDECO
Field #A economy percent
IE.1561
FLBECO
Field #B economy percent
IE.1562
FLDLSO
Field #A loss trip level
IE.1563
FTOCGO
Field #A TOC gain
I E.1564
FLBLSO
Field #B loss trip level
E.1565
FBTOCO
Field #B TOC gain
E.1566
FLDMNO
Minimum field current
E.6286
SCFIFB
Field Current Scaling Motor B, DCFB Motor Shunt IF2
Table 6. ST2000 Variable Locations

Address*
Mnemonic
Description
VAR.105
FLDFB
Field #A Standard Current Regulator Feedback (1 pu = 5000 counts
VAR.100
FLOPERR
Field #A Regulator Error, error input to the #A field regulator
VAR.100
FLOPOUT
Field #A Regulator Output, 22400 = Full Advance, 910 = 10 retard
VAR.100
FLOPINT
Field #A Regulator Integrator
VAR.100
FLOPR
Field #A Net Field Reference
VAR.102
FULFLDEN
Field #A, Full Field is enabled (is not in Field Economy)
VAR.102
FLDCM
Enhanced Regulator Command
VAR.109
IFLDAFB
Field #A Enhanced Field Current Regulator Feedback (1 pu = 5000 counts)
VAR.109
IFLDBFB
Field #B Enhanced Field Current Regulator Feedback (1 pu
*For additio al Field B locations, use the ST2000 program.
5000 counts)
00
CI)
'b
~.
ib'
g.
"
0'
g.
C')
Cb
!l!.
C')
Cb
t1:!
iti
~
c::
XFJIl
~
3E
H
R
PlPL-IIE'-'-
PlcI----PJe"-il
{
~
IN'IJT
~{I
PU.SE
NIC
~~~
3ENlPL-21
__~~_~_J
-7
-e 3ENlPL-ll
N1eI
-----------,
lIE I
-----------~
-2
I
-1
PlPL-21-'J
-+"":"::":":'......LI:...:..-/\lPlCi! ""PIG FACe I
XFJIl{
PU.SE
2) HAXIHUM Df 2 fIELD EXCITERS <NRP DR NRX) PER DCF"B.
PUl.SE XfMR STAB INPUTS DR PlA.SE XfHR PLUG INPUT.

PlA.SE XfHR INPUT IS A GATE PULSE SIGNIIL fRDH DCfBTHIS IS PRIMARILY rt:R NRP APPUCATIDNS, BUT HAY BE
USED fOR NRX APPLICATIONS.
tltTESt 1) fINAL El.EHE:NTARY MUST SHD'J ONLY ONE INPUT METHOD.
IN'IJTS
PU.SE
lIElIE_A
FU3
lIElIE_/I
FU2
PU.SE {
SINGlE PHASE NRP~X fIELD SUPPLY

600VAC MAX INPUT
l00ADC M/IX lIUTPUT
S1....
IN'IJT
DS2020fEANRP
{
~
TP
SH1
751\
100A
15011
2011
25/1
5011
151\
SI:IJtIT.
3E
3E
4011
4011
6011
l00A
15011
15011
USE
401\
rue,FU3
JI
P2
IE" Q
J
)/\: N2
FPL-4
N2PL-1
FPL-3
N2PL-2t
N2GI ""
-----------
~
I'I..lX;
IN'IJT
IL
""
:: W::~i
P2GI
-----------~
N2CI------il
390
40'J
R1
~{I
P2CI
lIE I
~------'
i{ ~.$0
CALW
Nl
PI
PU.SE
lIE
lIE
I
I
501\DC
~AN
F"N
fN:'1
(CONNECT DIRECTLY
TO fAN)
lIE lIE
U~AC
fAN fOR DC DUl1't..lr
-~
.1Hf
+
DC
lIUTPUT
CllMPDNENTS MTD
ON fSAA CARD.
(Gl - NRP DR NRX BY CARD JUMPER)
,L__
--,
lIE 1
.FPR
* SEE MDDULE GRDUP ND.

D STAB CllNNECTOR
r--
I1
.roW'
R2
390
SPSN
Q 'I
(1)
~
c..
e.
;::;:
c..
l!.
~
"t:l
<:>
....<:>I
lJ1
<:>
t::l
~
N
00
BI006008
't)
CI)
~
>(
s:
iil
g.
~
A
..,0-
g.
()
NOTES.
STf.Il
IN'UTS
1)
i
~
INPUT
I'
ij'
m il
3EPlPL-l~
3EPlPL-2t-'"
__~~~ __J
-1
-2
~{~
P1LSE
iE---
~~
Xf1Il{
~
2) MAXIMUM lIF 2 FIELD EXCITERS <NRP DR NRX) PER DCFB,

lINLY 1 FIELD EXCITER (NRX lINLY) PER SDCL
FINAL ELEMENTARY MUST SHOll ONl...Y ONE INPUT METHllD.

GATE STAB INPUTS, PULSE XFMR STAB INPUTS OR
PULSE XFMR PLUG INPUT. EXAMPLE OF GATE INPUT
IS A GATE PULSE TRANSfORMER lIUTPUT rRlIH SDCI-THIS IS fllR NRX APPUCATIlINS lINLY. EXAMPlE 1If
PULSE XfHR INPUT IS A GATE PULSE SIGNAL FRlIM IlCFB-THIS IS PRIHARILY FlIR NRP APPLICAnONS, BUT MAY BE
USED FCR NRX APPLICATIONS,
TP
IN'UTS
STIlII
P1LSE{
XF14R
**_A
FU3
**_A
l \)
FU2
IN'UTS
P1LSE
g: {
TP
GflTE
IN'UTS
GflTE
STf.Il
()
l\)
rn
?>
iil
~
c::
600V AC MAX INPUT

l00ADC MAX WTPUT
Xf1Il
PILSE
~
Xf1Il{
PILSE
SHl
100A
150A
20A
25A
50A
75A
15A
SWII.
I~
~~~
<lOA
<lOA
<lOA
60A
10GA
150A
15M
USE
FU2"FU3
__ ~~
3E
IL
Ad3R
.IMF
fAb
JI
r--------li'
-----------~
~ ~P2PL-21-11
PL-5
P2GI
-----------~
N2CI
lIE I
I FPL-<I
N2PL-l~II
FPL-3 EN2PL-2t-
<1011
390
Rl
~{I
1lS2OZ0FEANRX
J;ALllll.
Nl
Pl
iJ,M
PILSE
P2CI
lIE I
Xf1Il ~----------'
XFI4R
PL-6
P2PL-1 ~
PILSE
N2
P2
STAB~
5DADC
fN
FN-l
(CGlNECT DIRECTLY
m FAN)
**
115~FAN
lIE lIE SEE MODULE GRlIUP NO.
1I
lIUTPUT
QO
Q'I
tD
s:~
~...
&
Q.
xx:
l!.
"0
....
o
>
UI
FAN FlIR DC lIUTPUr
lIE = ClIHPlINENTS HT1l

lIN FSAA CARD.
(G2 - NRX lINLY>
IL __
r--
390
<lOll
R2
BI006008
BI006008
GEH-6328A
SPARE AND RENEWAL PARTS
assembly (DS2020FEA), the supply type (NRP or

NRX), and the shunt rating in amps, as follows:
GE recommends that the customer keep spare and

renewal (replacement) parts in stock to minimize system
downtime. Parts should be ordered by contacting the
nearest GE Sales Office or an authorized GE Sales
representative. For defective parts still under warranty,
see the Warranty Parts and Service section below.
The part name and the complete part number must be
included when ordering.
DS2020FEA NRs cccA
P = pLugging
X = non-pLugging
Base number
For example, DS2020FEANRP015A identifies the field

exciter module with a non-reversing, plugging power
supply and 15 A shunt.
As described above (Troubleshooting and Repair), a

defective FEA module should be replaced as a unit, not
repaired. The module includes no replaceable parts,
except for two fuses located on the FSAA board and the
FU2 and FU3 line fuses mounted on the module:
Part Name and Description
Part No.
FSAA fuses, 30 A, 600 V, Type KTK,

Fast Acting (Qty. 2)
104XI09AD 077
FU2 & FU3 fuses, 700 V*, Type XL70F

(Qty. 2):
40 A fuse (15, 20, or 25 A shunt)

60 A fuse (50 A shunt)
100 A fuse (75 A shunt)
150 A fuse (100 or 150 A shunt)
104X109AJ 007
104X109AJ 009
104X109AJ 013
104X109AD 094
* Fuse size determined by shunt size

When ordering a spare or replacement FEA module,
use the catalog number stamped on the current module's
edge. However, if that number is not available, identify
the module needed, as described below.
Module Identification
L--Shunt rat i ng
NOTE
Three digits must be used to indicate the

shunt rating, as shown above.
Warranty Parts and Service
The GE Drive Systems Terms and Conditions brochure

details product warranty, which includes the warranty
period and parts and service coverage.
The brochure is included with customer documentation.
It may also be obtained separately from the nearest GE
Sales Office or authorized GE Sales Representative.
To obtain warranty replacement parts or service assistance, contact the nearest GE Sales and Service Office.
The FEA module is identified by an alphanumeric part

(catalog) number stamped on its edge. The different
portions of the number indicate the basic module
GE Motors &
Industrial Systems
-----------------------------------Industrial SystemsDrive Systems & Turbine Controls

Issued: Dec. 1994
Rev. A: Feb. 1996
1994, 1996 by General Electric Company, USA.

BI006008
Section
Brake Instructions
9.1
Table of Contents -
Solid-S ate Brake Control/Field Exciter Unit - Propel Motor . .. GEI-100184
9.2 Replac ment Procedures for SBCA Static Brake Control Board
2243-I.M61
GEI-100185
BI006008
BI006008
Preliminary GEI-100184
GE Drive Systems
Instructions
Preliminary
Solid-state Brake Control/

Field Exciter Unit
(DS2020SBRCA/DS2020FEXA&-B
Modules)
BI006008
BI006008
Solid-State Brake Control!

Field Exciter Unit
( S2020SBRCA/DS2020FEXA&-B Modules
Preliminary
GEI-I00184
Issue Date: Preliminary, September 1994
These instructions do ot purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met uring installation, operation, and maintenance. Should further information be desired or
should particular prob ems arise that are not covered sufficiently for the purchaser's purpose, the matter should
be referred to GE Dri e Systems, Salem, Virginia, U.S.A.
This document contai
customer solely to assi
This document shall n
without the written ap
proprietary information of General Electric Company, U.S.A. and is furnished to its

t that customer in the installation, testing, and/or maintenance of the equipment described.
t be reproduced in whole or in part nor shall its contents be disclosed to any third party
roval of GE Drive Systems, 1501 Roanoke Boulevard, Salem, Virginia 24153, U.S.A.
BI006008
<r!
1994 by General Electric Company, U.S.A.

BI006008
GEI-I00184
DS2020SBRCA Brak Control, DS2020FEXA&-B Field Exciter
Safety Symbol Legend
WARNING
Commands att ntion to an operating procedure, practice, condition or statement, which, if not strictly
observed, coul result in personal injury or death.
CAUTION
Commands att ntion to an operating procedure, practice, condition or statement, which, if not strictly
observed, coul result in damage to or destruction of equipment.
NOTE
Commands att tion to an essential operating or maintenance procedure, condition, or statement that
must be highli hted.
BI006008
DS2020SBRCA Brake Control, DS2020FEXA&-B Field Exciter
WARNING
GEI-lOO184
Electronic equipment contains a potential hazard of electric shock or burn. Only personnel who
are adequately trained and thoroughly familiar with the equipment and the instructions should
install, operate, or maintain this equipment.
Isolation of test equipment from the equipment under test presents potential electrical hazards. If
the test equipment cannot be grounded to the equipment under test, the test equipment's case
must be shielded to prevent contact by personnel.
To minimize hazard of electrical shock or burn, approved grounding practices and procedures
must be strictly followed.
WARNING
To prevent personal injury or equipment damage caused by equipment malfunction, only

adequately trained persons should modify any programmable machine.
BI006008
SOLID STATE BRAKE CONTROL DS2020SBRCA

FIELD EXCITER UNIT DS2020FEXA DS2020FEXB
DESCRIPTION OF OPERATION
CONTE
1)
DESCRIPTION
2)
DESCRIPTION AND THEORY OF OPERATION

2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
WER SUPPLY
EDBACK SYSTEM SCALING
FERENCE SYSTEM SCALING
RRENT REGULATOR
RING CIRCUIT
ULT RELAY
ATUS RELAY
ST JUMPERS
TERMINAL BOARDS
3)
3.0
3.1
3.2
3.3
3.4
TESTPOINTS
AND INDICATORS
B STABS
LEX CONNECTORS
D TERMINAL BLOCKS
STPOINTS
DS
S AND SWITCHES
4)
4.0
4.1
4.2
5.0
5.1
PERS
ITCHES
PER/SWITCH PHYSICAL LOCATIONS ON BOARD
B KE CONTROL UNIT SPECIFICATIONS

FIELD EXCITER UNIT SPECIFICATIONS
ELEMENTARIES
6)
6.0
6.1
KE CONTROL MODULE ELEMENTARY

LD EXCITER MODULE ELEMENTARY
-i-
BI006008
Notes:
-ii-
DS2020SBRCA Bake Control, DS2020FEXA&-B Field Exciter
BI006008
GEI-I00184
SOLID STATE BRAKE CONTROL/FIELD EXCITER UNIT

1
GENERAL D SCRIPTION
The function
single-phase,
provides powe
The output is
sufficient vo
and has no fr
limit and con
the line so t
action.
f the board is to control the operation of a

non-reversing, plugging full wave SCR circuit that
to release a spring set, electrically released brake.
current regulated so forcing is inherently available if
tage is applied. The power circuit consists of 4 SCR's
e wheeling diodes. The firing circuit provides a retard
inues firing pulses to return stored inductive energy to
at the current is reduced quickly for rapid brake set
A secondary f
single-phase
intended to b
REGULATOR sec
an analog ref
nction of the board is to control the operation of a

ull wave field supply with plugging capability.
It is
used in a fixed field or a slowly (see CURRENT
ion 2.4) varying adjustable field under the control of
renee input.
CIRCUIT D SCRIPTION AND THEORY OF OPERATION

2.0 POWER
The pow r supply consists of a transformer, rectifier,
capaciti e filters, and two series regulators to provide +/24VDC ( nregulated) and regulated +/- 15VDC. The required
power is 115 VAC at approx . . 25A (50/60 Hz) and the
transfo er primary is protected by a 250V, 2A (3AG) board
fuse (F 1). The +/- 24VDC supplies are each fused at .5A
(3AG)
(FU2 and FU3). A zener and a green power on LED (PWR)
are pro ided for indicating the presence of power. LED on
indicate +/- 15VDC power is present.
SYSTEM SCALING
k voltage proportional to the brake coil current (or
rent) is produced by full wave rectification of the
an ACCT in one of the AC leads supplying the unit.
rent ranges are possible by setting JP1.
The
cross a burden resistor is amplified by an
e gain amplifier for fine scaling. The gain
t is implemented by an 8 bit DIP switched (switches
1A and 1 ) resistive ladder network as the amplifier'S
feedback. The value K1 represents the decimal number of the
DIP swit h settings.
-1-
BI006008
GEI-100184
The 8 bit DIP switch arrangement permits selection of the

integer value K1 (0 to 255). One cannot set a number less
than 49 because the resulting gain of the amplifier would be
too high.
The rated current follows the following equations:
Field Exciter
2000:1 CT
CT Used:
Brake Control
1000:1 CT
Low Range:
Irated
0.02 x (K1+1)
0.01 x (K1+1)
Mid Range:
Irated
0.1 x (K1+1)
0.05 x (K1+1)
High Range:
Irated
0.4 x (K1+1)
0.2 x (K1+1)
The resulting current ranges are:
Low Range:
1.0 to 5.12 A
.5 to 2.56 A
Mid Range:
5.0 to 25.6 A
2.5 to 12.8 A
High Range:
20.0 to *102.4 A
*Field Exciter Module Max = 7SA
10.0 to *51.2 A
*Brake Module Max
2SA
NOTE:
1)
FOR FIELD EXCITER MODULES A CROWBAR ASSEMBLY
#246B2309DAG IS INCLUDED ON THE MODULE.
2)
FOR BRAKE MODULES GREATER THAN 1SA (G4 MODULES) A
CROWBAR ASSEMBLY #246B2309DAG NEEDS TO BE ADDED EXTERNALLY. THE G3
BRAKE MODULE IS SUFFICIENT FOR THE A106 BRAKE.
2.2
REFERENCE SYSTEM SCALING

Three reference levels are provided that may be applied to
the current regulator by logic commands. The system is
scaled for a 1.0 pu level of 5.0 volts.
2.2.0 REFA
A fixed +5.0 volt level is established by a fixed gain
amplifier and the -15VDC supply.
-2-
BI006008
GEI-I00184
2.2.1 REFB
wit
net
The
bit
for
equ
djustable reference is established by an amplifier

a 7 bit DIP switched (2A and 2B) R/2R ladder
ork providing a fixed input of .40 pu to 1.67 pu.
MSB of the switch will provide .64 pu and all seven
provide 1.27 pu. A fixed offset will give .40 pu
a K2 = o. The reference in pu follows the
tion:
REFB = 0.01 x K2 + 0.4
K2
ay assume any integral value from 0 to 127.
An
2.2.2 REFX
'nverting unity gain amplifier is provided for
ana og control.
-5.0 volts applied to XIN will produce
a 1.0 pu reference.
An
2.2.3
:.;:R=E=F-==F'=-==,--=S.=E=L=E=C:..=T.=I-=O=N
The ref
by conn
SELX) t
circuit
determi
additiv
then de
between
applied to the current regulator is selected

cting one of the select inputs (SELA, SELB, or
the board's -24V terminal block point.
The
are interlocked so that the first one selected
es the reference applied and the selections are not
To change selections select the new selection
elect the old selection. Recommended time spacing
toggling selections is 1 millisecond.
2.3 CUR ENT REGULATOR

An amplifier circuit serves as the PI current regulator
where t
compensator transfer function Gc is:

c
where:
Kp
l/Ti
Kp * (1 + l/(Ti*s))
Proportional Gain
Integrator Reset Rate
2 sets Kp and l/Ti:
Kp
l/Ti
JP2 2-3)
1.0
5 rad/sec
P2 1-2
3.4
1.4 rad/sec
This transfer unction does not include the internal firing

characteristic
(ramp based with a nonlinear Vo*cos(alpha) block
nor does it in lude the output load characteristics. Thus, this
unit is not re ommended to be used in applications requiring
improved transent response (e.g., field weakening).
-3-
BI006008
GEI-100184
Also, the regulator reference input may be changed by JP7

to provide a two tc one transient reference lead. The amplifier
has a voltage limit.
"In limit'! indication is directed to the
fault relay control.
2.4 FIRING CIRCUIT
The firing circuit provides burst firing to the 4 SCRs. A
ramp generator operating at twice the line frequency
insures phase balance without trimming. Retard limit is
established by the filtering in the synchronizing circuit
and is chosen to be suitable at 50 and 60 Hz. A jumper
(JP6) is provided to keep the phase control gain in limit
at either input frequency.
2.4.0 LINE SYNC
The converter supply voltage is resistance isolated,
filtered and phase shifted. The circuit will operate
on any voltage from 110 to 600 vac. The outputs
include a ramp reset signal and steering signals.
2.4.1 RAMP GENERATOR
The ramp generator is controlled by the ramp reset
signal which is a double frequency signal. The output
is a positive ramp that is quickly reset whenever the
ramp reset signal is high. A jumper selection (JP6) is
provided to decrease the slope of the ramp for use at
50 Hz keeping the ramp excursion constant.
2.4.2 PHASE CONTROL
The phase control sums the ramp and phase control
reference and inverts the result. This negative signal
is compared to a negative threshold. The output ,PH,
goes high whenever the signal is more negative than the
threshold.
2.4.3 OSCILLATOR
A free running, aSYmmetrical 15V, 7khz, 20% duty cycle
oscillator is used to form the pulse trains.
The
response of the regulator and the inductive nature of
the load obviates any need for synchronizing the
oscillator or providing initial pulses.
-4-
BI006008
GEI-I00184
2.4.4 PULSE TRAIN GENERATOR

The pulse train generator uses the phase control
outJut, PH, ramp reset, RR, sync, SY, and delayed sync,
DSY to form two pulse trains.
Latches are included to
keeJ the pulse trains, F1 and F2, on for 180 deg.
The
ramp reset signal serves as a tail end stop to maintain
fir'ng and cause inductive energy to be returned to the
lin~ .
2.4.5 PJLSE AMPLIFIERS
The pulse amplifiers directly interface the pulse
tra ns to the 4 SCR's of a full wave bridge. Four
sep~rate pulse transformers are used.
Proper double
pulse firing is assured by connecting two primaries in
ser es. Using +/- 24V avoided the need for special
tra~sformers.
2.5 FAULT
ELAY
A failu e of the current feedback circuit could result in

damagin< overcurrent in the brake coil. The current
regulat<~r would be "in limit" in this instance and its
indicat on is used to drop out the fault relay and turn-off
the FLT LED.
This action is delayed to allow for brief "in
limit" <peration while forcing. Thus, FLT LED on indicates
no faul .
If the cscillator circuit fails "high", the pulse
transfo mers would saturate and resistors would fail.
A
circuit is included to check for this condition.
Its
output \Jill drop out the fault relay and turn-off the FLT
LED.
A NO cor tact of the fault relay is used to interrupt the
+24V su~ply to the pulse amplifiers. A form C contact pair
(lTB-5, 1TB-6, and 1TB-7) is brought out for use as
requirec by the system. Contacts are rated 115VAC/29VDC,
1A each.
An open collector transistor output
(2TB-11)is also
providec to indicate the status of the fault relay.
The
transistor is on (sinking current) when there is no fault.
-5-
BI006008
GEI-100184
2.6 STATUS RELAY

A relay is provided to indicate status of the unit's
current output. The relay is picked up whenever the
filtered Brake/Field Current (BFC) is greater than a fixed
threshold.
The filter time constant is 47.5 ms and the
threshold level is 0.46V (9 % current based on 1 pu CT
Feedback setting) .
Relay status is indicated by a the RLS green LED. RLS LED
on indicates Brake/Field Current (BFC) is flowing above the
threshold value.
The NO status relay picks up and the NC
status relay drops out when Brake/Field Current is flowing
above 9% current. The contacts are rated 115VAC/29VDC, 1A
each.
In open collector transistor output is also provided
(2TB-12). The transistor is "on" (sinking) when the status
relay is picked up (BFC above threshold) .
2.7 TEST JUMPERS
If the assembly is tested in a system without a load coil
connected to the output terminals of the power assembly the
fault and status relays will not pickup. Means are
provided to pickup the relays artificially. Two pairs of
posts modify the control of the fault and status relays.
2.7.0
JUMPER AB
Connecting the TSTA and TSTB posts will cause the

status relay to pickup whenever any reference is
selected even though there is no output current.
2.7.1
JUMPER XY
connecting the TSTX and TSTY posts will disable the out
of range detection.
In its normal mode
("non-disabled") the fault relay drops out whenever a
selection is made and no current is allowed to flow.
The oscillator failure function is still operative and
the fault relay will drop out if the oscillator should
fail high.
3)
CONNECTORS TERMINAL BOARDS TESTPOINTS AND INDICATORS

3 . 0 PCB STABS
( 0 .25" )
L1 AC Synchronizing Input
L2
"
"
-6-
3.1 MOLEX
GEI-I00184
ONNECTORS
1NPL
PIN)
2NPL
PPL
CTPL
PIN)
PIN)
PIN)
3.2 BOARD
BI006008
Leads to N1 SCR gate & cathode

(White = gate, Red = cathode)
Leads to N2 SCR gate & cathode
Leads to P1 & P2 SCR gates & cathodes
AC line current transformer input
ERMINAL BLOCKS
ITB
1
2
3
4
5
6
7
8
9
10
11
12
AC1
115VAC CONTROL POWER INPUT
AC2 = 115VAC CONTROL POWER INPUT
NO CONNECTION
NO CONNECTION
FLCM
FAULT RELAY CONTACT COMMON
FLNO = FAULT RELAY NO CONTACT
FLNC = FAULT RELAY NC CONTACT
NO CONNECTION
NO CONNECTION
RLCM
RELEASE RELAY CONTACT COMMON
RLNO
RELEASE RELAY NO CONTACT
RLNC
RELEASE RELAY NC CONTACT
2TB
1
2
3
4
= ANALOG REFERENCE INPUT (-5V = 1 pu)

=
FIXED 1 pu REFERENCE SELECT

DIP SWITCH ADJUSTABLE REFERENCE SELECT
ANALOG REFERENCE SELECT
5
6
7
8
9
10
11
12
LOGIC VOLTAGE - +24V / 5.6K PULLUP

LOGIC OUTPUT - FAULT STATUS
LOGIC OUTPUT - COIL/FIELD CURRENT STATUS
-7-
3.3 TESTPOINTS
P24V, P15V, N15V, N24V, & COM
BFC
= BRAKE/FIELD CURRENT
BFR
= BRAKE/FIELD REFERENCE
= OSCILLATOR OUTPUT (15V, '7khz, 20% DUTY CYCLE)
OSC
PR
PHASE CONTROL REFERENCE (REGULATOR OUTPUT)
REFA
FIXED 1 pu REFERENCE (-5V)
DIP SWITCH ADJUSTABLE REFERENCE (40% to 167%)
REFB
REFX
ANALOG REFERENCE (-5V = 1 pu)
SY
= LINE SYNC SIGNAL (50/60HZ SQ WAVE)
TSTA
= RELEASE RELAY ARTIFICIAL PICKUP
TSTB
= RELEASE RELAY ARTIFICIAL PICKUP
TSTX
= FAULT RELAY ARTIFICIAL PICKUP
TSTY
FAULT RELAY ARTIFICIAL PICKUP
3.4 INDICATORS
FLT - GREEN LED,
RLS - GREEN LED,
PWR
GREEN LED,
liON
liON
liON
NO FAULTII
COIL/FIELD CURRENT PRESENT"
POWER ON"
-8-
BI006008
GEI-100184
DS2020SBRCA
4}
B~ake
BI006008
Control, DS2020FEXA&-B Field Exciter
GEI-I00184
JUMPERS Alfrn SWITCHES

4.0 JUMPER
JP1
CT BURDEN SCALING RANGES

BRAKE CONTROL
1000:1 CT
FIELD EXCITER
2000:1 CT
1-2
2-3
3-4
JP2
or
1.0 to 5.12 amps
5.0 to 25.6 amps
or
20.0 to 102.4 amps or
0.5 to 2.56
2.5 to 12.8
10.0 to 51.2
PI COMPENSATOR RESPONSE
(Kp
1-2 DEFAULT
(Kp
2-3 LESS Kp, MORE l/Ti
3.4,
1.0,
amps
amps
amps
l/Ti = 1.5 rad/sec

l/Ti = 5 rad/sec)
JP3
1-2
2-3
DEFAULT
SEL X INCREASE INPUT SELECT PULL-UP CURRENT
1-2
2-3
DEFAULT
SEL B INCREASE INPUT SELECT PULL-UP CURRENT
1-2
2-3
DEFAULT
SEL A INCREASE INPUT SELECT PULL-UP CURRENT
JP4
JP5
4.1
JP6
LI1E FREQUENCY SELECTION

I-260HZ
2-3 50HZ
JP7
REFERENCE INPUT RESPONSE CONTROL TO REGULATOR

1-2 DEFAULT
2-3 FASTER RESPONSE TO REFERENCE INPUT
DIP SWITCHES
SW1A
SW1B
BITS 7-4
BITS 3-0
CURRENT FEEDBACK SCALING
SW2A
SW2B
BITS 7-4
BITS 3-1
REFB ADJUSTMENT
"
"
"
"
-9-
"
BI006008
GEI-100184
4.2
JUMPER/SWITCH PHYSICAL LOCATIONS ON BOARD
DS200SBCAG1AFC
ITB
r--
B
2
cJ
II
L2
L1
lD
eJm
lNPL
"B
2
RLSeJ
N24V
c::::r'
P15V
COM
0
C
:3
r,
r,
JP5
~tJ ~tJ ~tJ

JP:3
JP4
PPL
"D
2NPL
CTPL
_.J
TSTX
JPl
OSC
P24vD
N15vD
N2
R W
zD
1 JP6 3
PWReJ
PI
P2
R W R W
N2
R W
PRTX
2TB
3r,
to
Nl
R W
II
BFR
0''i' 0'i
0''i' 0i
C
LSB
LSB
-10-
0
TSTB
D~
1 JP2 3
1 13
L.J4
CIJ
0
3 r,
1 I
~ DJP7
TSTY
0
TSTA
0
REFS
REFX
o BFC
o
0
REFA
Sy
BI006008

5.0
SOLID ST TE BRAKE CONTROL
DS2020BRCA
GEI-100184
SPECIFICATION
INPUT POWER:
+/-
230VAC
460VAC
575VAC
SINGLE PHASE
50/60 HZ
"
"
"
II
+/- 7 HZ
II
II
II
"
OUTPUT POWER:
MAX AMPS
MAX AMPS
= 15
MAX VOLTS
5.1
FOR G3 MODULES (MOV INCLUDED IN SUBASSEMBLY)

FOR G4 MODULES (EXTERNAL CROWBAR #246B2309DAG NEEDED)
25
0.9 X RMS INPUT VOLTAGE
FIELD E CITER MODULE
DS2020FEXAG
SPECIFICATION
DS2020FEXBG
DS2020FEXA
1800V PIV SCRs
DS2020FEXB = 1600V PIV SCRs
INPUT POWER:
115VAC
230VAC
460VAC
575VAC
+/ -10%
SINGLE PHASE
II
II
"
"
II
UNIT
MAX AC AMPS
50/60 HZ
+/- 7 HZ
"
"
"
"
Gl
14A
82
23A
83
45A
84
68A
G1
15A
82
25A
83
50A
84
75A
"
"
"
OUTPUT POWER:
UNIT
MAX DC AMPS
MAX VOLTS = O.
X RMS INPUT VOLTAGE
EXTERNAL CONTR L POWER NEEDED:
VOLTS= 115VAC
/-10%
SINGLE PHASE
-11-
50/60HZ +/- 7 HZ
POWER= 50VA
BI006008
GEI-100184
UNIT FEATURES:
1)
2)
3)
4)
SINGLE-PHASE FULL WAVE CONTROL

PLUGGING CAPABILITY (DEPENDING UPON SYSTEM VOLTAGE)
SHUNT OUTPUT PROVIDED FOR METERING
CROWBAR CIRCUIT (#24632309DAG01) PROVIDED WITH THE UNIT
OTHER HARDWARE NEEDED:
1) 100A, 700V AC INPUT LINE SEMICONDUCTOR FUSES (GE# 104X109AJ

6
013)
MODULE ELEMENTARIES
The following sheets are elementary diagrams for the DS2020SBRCA Brake
Control Module and the DS20202FEXA/-B Module.
-12-

6.0
BI006008
GEI-100184
BRAKE CO TROL MODULE ELEMENTARY
This section
Sheet 1
Sheet 2
Sheet 3
ontains elementary diagram 246B2353, as follows:

overs G1 and G2 modules.
overs G3 and G4 modules.
overs G5 modules.
-13-
'"
cn
F"
LI
lIA
100001 CT
~2
~
~
Z~T! :=J c::>
F"RRlTES
L2
HZ
-~---
49
47
45
43
41
'~~,
H4
4 TO
2 2HPI.
I
I
I
I
II
I
I
:
:
:
I
I
'---T--..1
I
I
,. __ J.---,
-IAi"
,
DSC!02OIIlCAGI .sA TO 151\ BRI\I([S <AlOO-I\I(6) - HOV IS INCLUDED IN SUBASSEMILY
I
I
I
DS20201llCAG2 151\ TO 250<1 1lRAICES - HOV IS RHllVED AHD A CIlO\III\R CIRCUIT ASSM 124&1l2309DAGOI
NEEJlS TO II: ADDl:D (XTRIlAI..l.Y
.lnF"
1
50 OHMSi
40\1
p"-
3 TO
I
I
I
~J!
to
PI
:~'
L
~
~~
~~
~
CPT!
,r--------
I
I
: Hi
a
R
,,
,
----'5--"
,
0
-------,
4 I
li5V TO 118-2
BRAKI:
COIL
TCONTACTDR
I CONTROL
_______ .J.
I JUHPER DR
J.. EXTERNAL
-----,
1 :
,,:
,
CTI
SOLID STATE BRAKE CONTROLLER

PO\lER CIRCUIT
REF. D\lG. It: DS2020BRCA
1
I
I ... l ....
L21\
700V, 401\
ArCU
IC
LNA
IJTo.
( SIlCA)
CARD
~~"- ~
UCA)
( CARD
39
........
tg:28'hl
37
35
33
31
29
27
25
23
21
19
17
15
13
\I
09
07
05
03
01
1\
....
t;
Q2
511~ I~ I~
21
191t5
171C1:U
w>.JZ ~ ~
151 W 0..
<Ei
.JXI~
<0
131
IIIU
031
01
BI006008
r-l
51
49
45
43
41
3')
J7
J~
3J
31
2')
27
2~
23
21
19
.~/'o
I~/'o
CTa
CTl
LI
LI/'o
TO
INPL
PPL
TO
c=:>
c=>
c=:>
:=J c=:>
(;
,f
~Oll
22 OHMS.
rEI/RITES
LZ
HI
Xl
~Oi'o
HZ
TO
2NP\.
HJ
.Ir"lr
5"V
---"'5--~
,
0
-------,
4
,
BR/'o~E
COIL
II
O\/'oC/'oOll \011(;\ BRi'oKE-1.01le;

12/2/'1
TO 1T1-2
en

POVER CIRCUIT
REF. DVG. II. DS2020BRCA
2JOV
~60V
._--------,
"
-----cPTi------------
PPL
TO
---------
:
::
.!
L2/'o
700V,
Acru
TO 15/'0 IRIUCES (/'0100-/'0106> - HOV IS INCLUOCO IN SUB/'oSSEMBLY

TO 2~ BRi'oKES - MOV IS R(HOVEO /'oNO /'0 CROIII/'oR CIRCUIT /'oSSH 1246823090i'oGOI
N(EDS TO BE /'oDDED EXTERNi'oLLY
100M CT
DS2020IRCIIG3
OS2020BRCIIG4
NOTES,
C/'oRO
TO
( S~~~)
~ ~
L2
17
SIC/'o)
( C/'oRO
/'0
~ZlI9~Z
I~
/'0
TO
LL
13
II
09
07
O~
OJ
01
't
..,
..,
51,,;!
ZI
1')1t5
Ii
>
;ic!i~:
171~ui$
J51w~EiI
0.
131u
iX
w>-l!
..JZ~:l
IIIU
01
BI006008
....
51
49
47
45
43
41
39
37
35
33
31
29
27
25
23
21
19
17
15
13
II
09
07
05
03
01
"
...
('1.J)
l:l:l:2ll9.Z
."-IID]
o
CTI
1.1
LIA
l.2
I(
22 lIHHS.
40101
fERRITES
L2A
ACfU
700101, 40f1
..
.1...
PI
BRME
Call
IUU91
Do'AC"DIl' DIoI~ IRfIlCE-1.DIoIG
,,
---5---
-------,

POIJER CIRCUIT
REF. DIJG. II. DS2020BRCA
15" UflKtS <Aloo-"I06) - MIIV IS INtl..UDED IN SUI"SSEM81.Y W/0 CPTl
INPL
TO
PPL
TO
c=:>
<=:)
g :=J c:::::>
c:::::>
1*'1 CT
DS2020IRCAG5.5f1 TO
NlITES,
( SIC")
C"RD
~~PL ~
SIC")
( CARD
51,,:
21
19,1:5
If
171Cll: ul
>
<i~~'
151d~Ei
Q:
131G
w>- !
IIIU
....
BI006008
.--l
\.0
BI006008
DS2020SBRCA
rake Control, DS2020FEXA&-B Field Exciter
GEI-100184
6.1
ITER MODULE ELEMENTARY
This section
ontains elementary diagram 336A3401AC, sheet 1.
-17-
CD
......
j-
I
~
en
I
)-
3:
l""'l
l""'l
:::0
"'TJ
:::0
I
I
Ie>
rTJ
10
U1I::O
<
MlrTJ
-I
0
lJl
~O I]
-
~
:x~
",0
?(.N
-1
~OJ
~(.N
;;(.N
----.l
IUl
-4
.> I rTJ
-<
<1U1
~1U1
<
-
;:v
::g
-...S)'"
-U)
-J
V>
b.
(21T
m -..L- C2
(2)~
(5)
l2
CT1~
"
TO
N1G
N1C
(8)
=1
P BUS
CT
V1
l""'l
REVISED
R. FREEMAN 12-18-91
(9)
AC5
REVISED
R. FREEMAN 7-15-91
N BUS
1NPl
TO
BUS BAR
AC4
P1G PPl
P1C
CT2
CTPL
~
;0
;0
"
l""'l
TO MFC T61
'
TO SSCA CARD
'"
'"
2000:1
1/
TO SeCA
CARD STABS
L1
AC4
<
--
-- "
3:
,,, "
I-~rzo
10
(6)
TO
N2C
TO
2NPl
P2G PPl
P2C
FP1
~N2G
(7)
-, ,~
--
BUS BAR
AC5
~
CD
FN
CROW
BAR
-,
/,
SSCA CARD
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BI006008
BI006008
BI006008

(703) 387-7000
BI006008
GEI-100185
GE Drive Systems
Replacement Procedures For
SBCA Static Brake Control Board
DS200SBCAG 1A
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be
met during installatlOn, operation, and maintenance. Should further information be desired or should particular problems arise that
are not covered sujJ ciently for the purchaser's purpose, the matter should be referred to GE Drive Systems, Salem, Virginia U.S.A.
WARNING
This equipmer t contains a potential hazard
of electrical sl ock or burn. Only those who
are adequateh trained and thoroughly familiar with the e( uipment and the instructions
should install, operate, or maintain this
equipment.
INTRODUCTION
These instructions rovide information that may be

needed when replae ing a DS200SBCAGIA__ Static
Brake Control BOCllid (SBCA). This information includes
descriptions of con 19urable hardware jumpers and
switches.

part (catalog) number stamped on its edge. For example, the SBCA is identified by part number
DS200SBCAG#ruu.
The DS200SBCA portion is the base number that identifies a specific printed wiring board, in this case, the
Static Brake Control Board. The G# identifies a group,
which is a variation of a particular board. The r and u
digits are alphabetic characters that indicate the board
revision level. The r digit reflects a functional c~ange
that is not downward compatible. It is essentially a new
catalog number. The u digits represent revision levels
that are downward compatible to the r revision level.
The SBCA currently has only one group, Gl.
NOTE
The SBCA operate a single-phase, full-wave siliconcontrolled rectifier SCR) circuit. This circuit provides
power to release a pring-set, electrically-released
brake.
The output is cum nt-regulated, and can be forced when
sufficient voltage i applied. The SCR can fire at retard
limit to quickly ree uce current for rapid brake-setting
action. Alternately the SBCA board can be used to
control the operati< n of a single-phase, full-wave field
supply with pluggi~g capability. It is intended to be
used in either a fix~d field or a slow varying adjustable
field controlled by an analog reference input.

I WARNING

SBCA board when powered. To prevent
electric shock, tum off power to the board,
then test to verify that no power remains on
the board before touching it or any connected circuits.
BI006008
GEI-I00185
Static Brake Control Board
5.
On the replacement (new) board, set all configurable items in the exact position as those on the
board being replaced (old board).
If a board revision has added or eliminated a
configurable component, or re-adjustment is needed, refer to Table 1.

NOTE

they were shipped.
The SBCA board is used in a DS200BRCA Solid-State
Brake Control Module, which is typically mounted
lnside the drive cabinet. The board is mounted on
,tandoffs on front of the module. To replace the SBCA
Joard:
L.
Tum off power to the drive, then wait a few

them to make sure power is off.
~.

wiring boards.
\.
To remove the SBCA board, carefully disconnect

all wiring and cables from the board, as follows:
Two terminal board connectors, designated
1TB and 2TB, are located along one edge of
the SBCA board. Each connector consists of
two sections: the bottom section is mounted on
the board; the top section, which contains
screw terminals, plugs into the bottom section.
Do not disconnect the individual wires from
the screw terminals. Instead, note the location
of each connector, then use a screwdriver to
gently pry apart the connector's top and bottom
sections.

6.
Install the new board on the standoffs, making sure

that the four screws are secure.
7.
On the new board, use a screwdriver to pry apart

the 1TB connector. Set aside the top section. Then
plug the top section from the old board's 1TB
connector (with wires still attached) onto the new
board's 1TB bottom section. Make sure that the
sections are properly seated.
8.
Repeat step 7 for the 2TB terminal board.
9.
The cables are labeled with the correct connector

name, as marked on the board. Reconnect all cables as labeled. Ensure that cables are properly
seated at both ends.
FUSES
The SBCA board contains three protective fuses:
FUI is 2 A, 250 V, 8AG, glass
FU2 is 1 A, 250 V, 8AG, glass
FU3 is 1 A, 250 V, 8AG, glass

Figure 1 shows fuse locations on the board.

tab.
The SBCA board includes three indicating lights:
INDICATING LIGHTS
RLS (green), "on" indicates brake released or field

current present. Goes out when the K2 relay (1 TB
terminals 10-12) is dropped out.
PWR (green), "on" indicates power on (presence

of P24V, N24V, PI5V, and NI5V).
The SBCA board is typically mounted on standoffs.

To remove the SBCA board, remove the four
screws attaching the board to the standoffs.
BI006008
Static Brake Coot 01 Board
GEI-I00185
FLT (green), on" indicates no fault. Goes out if

the oscillator c rcuit fails high or if current feedback does not ollow the current reference and the
regulator goes ~to saturation.
Make sure that the jumpers and switches on the new

board are in the same position as on the old board,
unless the instructions indicate otherwise. Refer to
Table I, which lists the default setting first.
HARDWARE AD. USTMENTS
TESTPOINTS
The SBCA contain Berg-type (manually moveable)

jumpers, designate with a IP nomenclature, and DIP
switches, designated with an SW nomenclature. Figure
I is a layout of the SBCA board, showing the locations
of the jumpers and switches. Tables I and 2 list and define the jumpers ar d switches.
The SBCA board includes onboard testpoints for use in

troubleshooting or making adjustments. These testpoints
are metal posts located on specific signal paths. The
signal can be measured or viewed by connecting an
oscilloscope or other measuring instrument to that
testpoint.
Most of the jumpe selections have been factory set.

The Custom Hardv are Summary supplied with each
controller (in the drive door pocket) indicates these
positions.
Figure I shows SBCA testpoint locations. Table 3 lists

and defines the testpoints.
DS200SBCAG 1f.
[jtJ
L2
L1
II
Nl
R W
II
...'"::>
-<
RT
RLSU
2TB
r--
P24V
N15V
P15V
COM
0
C
c
r,
2'
'--
10
P3
C::T'
--'
1
r,
I
r,
I
~O ~O
JP4
JP5
CTPL
0
N24V
JPl
OSC
0
PRTX
BFR
0'-0'
i i
0'-0'
i i
C
2NPL
zO
JP6
TSTX
PWRU
PPL
N2
R W
2 -
'--
:3
lNPL
N2
R W
vD zO
zO
lTB
P1
P2
R W R W
LSB
0
TSTB
O~,3
1 JP2 :3
0-'
--'
L.J4
r,
Om
I
TSTY
0
TSTA
REFX
o BFC
REFB
LSB
SY
0
REFA
Figure 1. SBCA Board Layout
BI006008
G-EI-I00185
NOTE
The following tables define the jumpers, switches, and testpoints used on the SBCA board. The Name
column indicates the item's identification as marked on the board. The Description column defines the
items, including jumper and switch settings. The default setting (position) is listed first.
Table 1. SBCA Board Jumpers

~ame
Description
IP1
Brake or field current CT range select jumper.

Selects the burdening for the current transformer (CT) used to sense the brake coil current. Fine adjustment of the
current feedback is provided by SW2A and SW2B. The 2000: 1 CT is normally used for field exciter operation and the
1000: 1 CT is used for brake control.
Position
1.2
2.3
3.4
P2
1.0-5.12 amps (2000:1 CT);

0.5-2.56 amps (1000:1 CT)
5.0-25.6 amps (2000:1 CT);
2.5-12.8 amps (1000:1 CT)
20.0-102.4 amps (2000:1 CT); 10.0-51.2 amps_(1000:1 CT)
Brake current PI regulator response compensation.

Allows an increased gain for the brake current regulator. This regular is a PI of the form Gc
= Kp *
[1
1/(s*Ti)].
Position
1.2
2.3
P3
Normal response; Kp = 3.4, Ti = .7 sec

Modified response; Kp = 1.0, Ti = .2 sec
Pull-up current for analog brake reference select input, SELX, 2TB-4. Normal
Setting position 2.3 reduces the impedance to 4.7K ohms.
+ 24 V pull-up impedance is 27K ohms.
Position
1.2
2.3
P4
Normal pull-up
Increased pull-up
Pull-up current for adjustable reference select input, SELB, 2TB-3.
Position
1.2
2.3
P5
Normal pull-u
Increased pull-up
Pull-up current for fixed 1pu reference select input, SELA, 2TB-2.
Position
1.2
2.3
P6
Normal pull-up
Increased pull-up
Ac line frequency select for the brake firing ramp generator. The ramp generator used for the brake firing circuit must
be set to the proper rate based on applied ac line frequency.
Position
1.2
2.3
P7
60 Hz
50 Hz
Brake regulator reference input response select. Setting the jumper 2.3 inserts a lead filter into the reference circuit.
Position
1.2
2.3
Normal response
Fast response
>.
BI006008
GEI-I00185
Table 2. SBCA Board Switches

Name
Descripti n
SW1A,
SW1B
Brake or ield feedback current scaling.

The feed Jack scaling ranges are controlled by JP1 and the ac current transformer ratio (see JP1). Fine tuning within
the selec ed range is accomplished by an a-bit DIP switched (SW1 A and SW1 B) resistance network. SW1 A is the
most sig ificant nibble and SW1 B is the least significant nibble. A scale factor K1 is the decimal representation
(0-255) f the binary pattern set by SW1A and SW1B. This value along with gain G1 determined by the setting of
JP1 and he turns ratio of the CT sets the rated brake or field current feedback. The value of G1 is per the following
table:
J~1 setting
CT ratio
1000:1
1000:1
1000:1
2000:1
2000:1
2000:1
1.2
2.3
3.4
1.2
2.3
3.4
G1
0.01
0.05
0.2
0.02
0.1
0.4
The reql. red value of K is given by K = (lrated / G1) - 1, rounded to the nearest integer. SW1 A (most significant
nibble) a,d SW1 B (least significant nibble) should be set for the binary representation of K1. Note K1 should not be
set for Ie ss than 49 to prevent op amp saturation due to excessive gain. The illustration below shows the location
and bit ~ eight for each switch of SW1.
S~ 1A
SW1B
+-- ---+
: [~ ] I
[~ ]
[~ ]
[~ ]
+-- ---+
+------+
I [*] :
: [*] :
:
:
:
OFF
SW2A,
SW2B
:
:
:
ON
2"7 = 128 (MSB)

2"6
2"5
=
=
2"'3
2"'2
: [*] : 2"'1
64
32
2"4 = 16
: [*] :
+------+
2"'0
=8
=4
=2
=1
(lSB)
OFF ON
CT SCALING DIP SWITCHES
Brake or field adjustable reference scaling.

Adjustat Ie reference B is set by a 7-bit DIP switched (SW2A and SW2B) resistance network. SW2A is the most
significa t nibble. SW2B is the least significant 3 bits (the lowermost switch of SW2B is not used). A scale factor
K2 is th decimal representation (0-127) of the binary pattern set by SW2Aand SW2B. This value is used to
provide fixed input of 0.4 pu to 1.67 pu for the reference B input. A fixed offset gives 0.4 pu for K2 = O. The
required value of K2 to obtain the desired REFB at 2TB.3 (0.4 to 1.67 pu) is
K2 = 100 * (REFB - 0.4)
K2 may assume any integral value from 0 to 127. The illustration below shows the location and bit weight for each
switch (f SW2.
SW2A
SW2B
+------+
I [*] I
+------+
I [*] I
I
:
:
[*]
[*]
[*]
I
:
2"6 = 64 (MSB)
2"5
2"4
2"3
=
=
=
32
16
8
:
:
:
[*]
[*]
[*]
:
:
:
+------+
+------+
OFF
OFF
ON
2"2
=4
2"1 = 2
2"0 = 1 (lSB)
(not used, leave off)
ON
REF B DIP SWITCHES
BI006008
:;EI-I00185
Table 3. SBCA Board Testpoints

~o.
Name
Description
'P1
P15V
Regulated + 15 V dc power supply. P15V, N15V, P24V, and N24V are developed from the 115 V ac control
power input supplied at HB. P24V and N24V, available on 2TB, are each fused at 0.5 A.
'P2
P24V
Unregulated +24 V dc power supply.
'P3
N15V
Regulated -15 V dc power supply.
'P4
N24V
Unregulated -24 V dc power supply.
'P5
COM
Common "ground" point for P24V, N24V, P15V, and N15V.
'P6
BFC
Brake or field current. This feedback is a voltage proportional to brake or field current, and is scaled to be 5 V
corresponds to 1 pu.
'P7
BFR
Brake or field reference. This is the brake or field current reference, scaled -5 V = 1pu. The reference can come
from REFA, REFB, or REFX according to the selection made using SELA, SELB, and SELX on 2TB.
P8
OSC
Oscillator output, 15 V, 7 kHz, 20% duty cycle. The oscillator signal is gated with the SCR enables to provide a
pulse train to the SCR gate drive transformers, so that the transformers won't saturate.
P9
PR
Phase control reference. PR is the output of the current regulator.
P10 REFA
Fixed 1 pu reference (+ 5 V). This is a fixed + 5 V dc reference developed from N15V.
P11
DIP switch adjustable reference. This signal can be set by SW2A and SW2B to values from 0 to + 5 V dc.
REFB
P12 REFX
Analog reference. This signal is equal to -1 * XIN, the 0 to -5 V analog reference at 2TB-1.
P13 SY
Line sync signal (50/60 Hz square wave). This signal is used to synchronize the SCR gating to the ac input at
stab-on points L1 and L2.
P14 TSTA
Release relay artificial pickup. Connecting TSTA to testpoint TSTB causes the status relay to pick up,
independent of the current regulator, for test purposes.
P15 TSTB
Release relay artificial pickup.
P16 'TSTX
Fault relay artificial pickup. Connecting TSTX and TSTY posts disables the out-of-range detection, which would
cause the fault relay to drop out whenever a selection is made and no current is allowed to flow. The relay still
drops out if the oscillator fails high. TSTX and TSTY are for test purposes only.
P17 TSTY
Fault relay artificial pickup.
GE Drive Systems
ate: September 1994
BI006008
Book #1
Section
10

-
Table of Contents -
Instruc ion Manual, Motor Control Center
2100-5.0
and Splicing Instructions
2100-5.1
ance of Industrial Control Equipment

Recom
MCC
ended General Specifications

escription
Unit Di grams
Heater Diagram
Motor
IC-906
2100-2.0
2100-B809089/01
Y-203951-967
Y-203986
ircuit Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2100-2.3.1
Inverse Time Circuit Breakers. . . . . . . . . . . . . . . . . . . . . . . .. 2100-2.3.2

Discon ect Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1494F-6.0
Control Circuit Transformers and Fusing
2100-6.1
Full Vol age Reversing Starters
505-6.0
Full Vol age Starters
509-6.0
Overlo d Relays
592-2.0
Eutexti Alloy Heater Elements
592-2.1
2243-I.M61
BI006008
'1' Roc
ell Automation
BI006008
All n-Bradley
212656-7
FORM ENG.lOO8 2/14/94
PROCEDURE AE!08
BI006008
BI006008
BI006008
Please Read!
This manual is intended to guide qualified personnel in the

installation of CENTERLINE Motor Control Centers. When
additional information is required relating to the installation and/or
operation of CENTERLINE Motor Control Centers, refer to your
local Allen-Bradley Sales Office. For further instructions regarding
the handling, installation, operation, and maintenance of motor
control centers, refer to NEMA Publication ICS 2.3.
Before installing and operating your CENTERLINE Motor Control
Center, carefully read this manual, read all related procedures and
instructions, and observe all precautions. Because of the variety of
uses and applications for this equipment, the user must be satisfied
with the acceptability of each application and use of the equipment.
In no event will Allen-Bradley Company, Inc. be responsible or
liable for indirect or consequential damages resulting from the use or
application of this equipment.
The illustrations shown in this manual and any referenced
publication are intended solely to illustrate the text of the manual or
referenced publication. Because of the many variables and
requirements associated with any particular installation, the
Allen-Bradley Company, Inc. can not assume responsibility or
liability for actual use based upon the illustrative uses and
applications.
Important User
Information
Reproduction of the content of this manual and/or related

procedureslinstructions, in whole or in part, without the written
permission of the Allen-Bradley Company, Inc. is prohibited.
ATTENTION and IMPORTANT notes are used throughout this
manual to make you aware of safety considerations:
ATTENTION: Identifies information about practices
or circumstances that can lead to personal injury or
death, property damage, or economic loss. Attention
notes help you to identify a hazard, avoid a hazard, and
recognize the consequences.
Important: Identifies information that is especially important for

successful application and understanding of the product.
CENTERLINE is a registered trademark of Allen-Bradley Company, Inc
BI006008
Table of Contents
Chapter 1
General Information
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Nameplate Data
UL/ CSA Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Short Circuit Rating Label
Series Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Series Lettering - Units and Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Receiving, Handling, and Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
1-1
1-1
1-1
1-2
1-3
1-4
1-5
1-6
Chapter 2
Installation Procedures .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location Planning
Mounting Considerations .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Securing a Motor Control Center
Seismic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Joining and Splicing New MCCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Joining and Splicing Existing MCCs
Joining and Splicing NEMA Type 3R MCCs
Bus Torque Specifications
Installing and Joining NEMA Type 1 and Type 12 Pull Boxes. . . . . . . . . . . . . . ..
2-1
2-1
2-1
2-4
2-5
2-5
2-5
2-7
2-7
Chapter 3
Conduit and Cable Installation
Installing Conduit
Bottom Entry Conduit
Top Entry Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Installing Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Incoming Line Compartment
Main Fusible Disconnect and Main Circuit Breaker
Cable Bracing
Incoming Line Brace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
3-1
3-1
3-1
3-1
3-2
3-2
3-2
3-3
3-5
Chapter 4
Installing and Removing Plug-In Units
Installing Plug-In Units
Removing Plug-In Unit From a Section (1.0 Space Factor or Larger)
Removing Support Pan
Removing Plug-In Unit From a Section (0.5 Space Factor) . . . . . . . . . . . . . . . ..
Removing Support Pan
4-1
4-1
4-1
4-3
4-4
4-5
Chapter 5
Operator Handle and Unit Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locking Provisions
6-1
6-1
Chapter 7
Energizing Equipment. .. . .. . . .. . . .. . . .. . . . .. . . . . . . .. . . . .. . . .. . . .... . . ... .. .
Energizing Procedure
5-1
5-3
Chapter 6
Final Check List Before Energizing
Final Check Before Energizing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
2-1
7-1
7-1
BI006008
BI006008
Chapter 8
Maintenance
8-1
Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Disconnect Switch Contact Lubrication
Instructions
8-1
8-3
8-4
Chapter 9
Maintenance After Fault Condition
9-1
Chapter 10
Renewal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
Order Information
10-1
Recommended Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-1
Chapter 11
Parts Illustrations
11-1
Chapter 12
Purchased Components and Additional Instruction Sheets. . . . . . . . . . . . . . . . . . . . . . . . . .
12-1
Index
13-1
, . . . . ..
..
BI006008
BI006008
Chapter
General Information
General Desc iption
CENTERLINE Motor Control Centers consist of one or more

vertical sections containing electromagnetic and/or solid state control
devices that are prewired and tested within modular plug-in or frame
mounted (hard-wired) units.
Line power is distributed throughout the motor control center
through an isolated bus work structure. The main horizontal bus is
located in the center of the section. The center-fed 300 ampere rated
vertical bus supplies power to the individual units above and below
the horizontal bus for an effective 600 ampere capacity, allowing
virtually unrestricted unit arrangement.
The individual units house a wide variety of power and logic
devices. Plug-in units are mounted on unit support pans within the
section, and stab assemblies on the back of the unit plug onto the
vertical bus. Mechanical interlocks prevent unit doors from being
opened while units are energized.
Nameplate Da a
Each vertical section has a nameplate located on the vertical wireway

door. On special width sections, the nameplate is located on the
section door. See Figure 1.1. Information on nameplates include:
catalog number / serial number
series letter of the section
maximum bus bar voltage and current rating
section location number
Figure 1.1 Section Nameplate
1-2
BI006008
General Information
Each individual plug-in and frame mounted unit also has an

identification nameplate. The unit nameplate is located on the
interior of the bottom plate of plug-in units or on the interior right
hand side plate of the frame mounted units. See Figure 1.2. The unit
nameplate for each plug-in or frame mounted unit includes:
catalog number / serial number
series letter of the unit
device size
all maximum ratings
Figure 1.2 Unit Nameplate
When communicating with Allen-Bradley about a particular motor

control center or motor control center unit, the catalog number or
serial number and series letter are required to properly identify the
equipment.
UL I eSA Marking
CENTERLINE Motor Control Centers (MCCs) are listed by

Underwriter's Laboratories, Inc. (UL), Standard for Safety UL 845
and certified by the Canadian Standards Association (CSA),
Standard C22-2, No. 14.
Due to standards harmonization, a motor control center may also
carry the UL c designation. UL c is comparable to CSA certification.
All vertical sections and units listed with UL will carry the UL label.
All vertical sections and units certified to CSA standards will carry
the CSA or ULc mark. Vertical sections and units are labeled
independently. Therefore, it is possible to have combinations of
labeled and non-labeled sections and units in the same motor control
center.
Vertical sections and structure options that are UL listed and
CSAlULc certified are marked accordingly. For a section to carry
the UL and/or CSA/ULc designation, all of its components must be
UL listed and/or CSA/ULc certified. The UL and/or CSA/ULc
designation is an integral part of the section nameplate.
See Figure 1.1.
BI006008
General Information
1-3
Units and unit options that are UL listed and CSA/ULc certified are
marked accordingly. For a unit to carry the UL label and/or
CSA/ULc designation, all of its options must be UL listed and/or
CSA/ULc certified. The UL designation is located on the interior of
the bottom plate of plug-in units or on the interior right-hand side
plate of frame mounted units. See Figure 1.3.
Figure 1.3 UL Label and CSA Designation for Units
Short Circuit Rating Label
Motor control center vertical sections that are UL listed and/or

CSA/ULc certified will carry a short circuit rating label. The short
circuit rating label for a vertical section is located on the inside of the
vertical wireway door of standard sections or on the interior
right-hand side plate of special width sections. See Figure 1.4.
Figure 1.4 Short Circuit Label for Sections
Motor control center units that are UL listed and/or CSA/ULc

certified will carry a short circuit rating label located on the bottom
plate of plug-in units or on interior right-hand side plate of frame
mounted units. See Figure 1.5.
Figure 1.5 Short Circuit Label for Units
1-4
BI006008
General Information
ATTENTION:
Read the following information BEFORE
adding new sections or units to an existing
CENTERLINE Motor Control Center.
Series Identification
Table lA gives the history of series letter changes for structures and
units since the original design of the CENTERLINE MCC
manufactured in the United States.
Table 1.A Series Identification
SECTIONS
Series
Letter
Scope
Date Implemented in
U.S.
Description of Change
2-71
-----I
11-76
6-79
A
B
_ _ _ _-+-Original design
All
Changed terminal bloc_ks
_
All
Elimination of external mounting channels
C
D --+----A--II- ----+-=R-ev-e-rs-e- fed 2192's and 2193's
All ---+,=-Re-d--esign gasketing
E
I-------t----~-----c---:All
Modified lop horizontal wireway pan to accept units with handle interlock in
i
F
i, topmost space factor
f-------G
42K
--
4-81
10-82
10-83
------:--
42K bracing-incorporates new bus support & cover

--
------
1-85
7-85
------
65K
65K bracing-incorporates new bus support & cover
1-----+------- ------c----+
---H
All
New hinge design
All
1-86
Changed handle, operating mechanism and circuit breaker to Westinghouse

series C, 150A, 250A and 400A frame
10-86
,
-
K
L-
All
JL'
Changed to new unit grounding system
A_II_C_h_a_ng_e_d_to new 600A_-_12_00_A_circuit bre_ak_e_ro_p_er_at_ing_m_ech_an_is_m_"

2100 UNITS
Redesign of g
Changed to n
Changed to B
Changed to n
its &
Changed to B
Changed han
..L
5-90
2-96
-I
I
BI006008
General Information
ATTENTION:
Read the following information BEFORE
adding new sections or units to an existing
CENTERLINE Motor Control Center.
A
Series Letter ng
-Units and Sections
1-5
When using sections in conjunction with units of different series

letters, consult the MCC Modifications for Unit and Structure
Compatibility table below.
Table 1.8 MCC Modifications for Unit and Structure Compatibility
---
Plug-In Units
If mounted in
this type of
section
O@
pace
actor
Series
--
2100H-UAJl
Requires
Alternate
Top
Horizontal
Wireway
Pan
Requires
Door
Gasketing
Kit
Requires
Retrofit
Kit
2100H-UA1
2100H-UJl
2400H-USPA1
2400H-USPJl
2100H-NA4Al
2100H-NA4J1
2100H-NA4A2
2100H-NA4J2
2100-GJ10
2400H-Rl
Requires
Ground
Bus Kit
@
t 2400H-GSl
F-L
v@
Mor later
v@
---
v
v
N or later
--f-
---
A-E
1. or
la er
--'-------
Requires
Style 3 Unit
Support Pan wI
Bushing
------
-------
NEMAType 1
Series E-J
--
Requires
Style 3
(or 2)
Unit
Support
Pan
--
1. or
la er
o.
Requires
Style 1
Unit Support Pan
i
I
A-E
NEMA Type 1
Series A-D
No
Additional
Parts
Required
----
---
F-L
-------
Mor later
---_._---
o.
1. or
la er
A-L
1. or
la er
Mor later
--
-----
A-E
NEMA Type 1 wI
gasket or Type 12
Series A-D
v
v
---
F-L
M or later
v@
v
-
------
NEMA Type 1 wI
gasket or Type 12
Series E-J
----
Nor later
A-E
1 or
la. er
F-L
v
- -
-------------
M or later
----- ---
NEMA Type 1 w/-----.: fgasket or Type 12 1. or

Series K or later
la er
.-
Nor later
!
!
!
v
--
@
i--
--
--
--I
--
--t!
-I
A-L
_1_ Mor later
--
- _ .. _--
----
I-
--_ .. _ - - -
----
v@
---
-------
O.
---------
Nor later
-,--'---,--
NEMAType 1
Series K or later
---
-----
v
----
--
@
--- 1----
~nit in topmost location in vertical section, care must be taken to comply with the National Electrical Code 6'6" unit
handle-to-floor height limitation, as identified in NEC Article 380-8(a) and UL Standard for Safety 845. A unit operating handle
extender (210m -NE1) is available which allows you to comply with this restriction. See Publication 2100-3.0 for catalog number and
pricing.
@ When Bulletin 2 00 0.5 space factor units are ordered unassembled or ordered for existing sections, a centralized wiring diagram
holder kit (2400 -WDH) should be ordered. See Publication 2100-3.0 for catalog number and pricing.
@ Required only if eries For later 1.0 space factor or larger Bulletin 21 00 unit is installed in topmost location of series Athrough Evertical
sections.
e Permits installat on of 0.5 space factor plug-in units in existing series E through J Bulletin 2100 vertical sections. See Publication
2100-3.0 for ca alog number and pricing.
@ A wire can be u ed to ground units rather than installing a ground bus. See Publication 2100-5.12.
0 When installing
1-6
BI006008
General Information
Receiving, Handling, and

Storage
CENTERLINE Motor Control Centers are shipped upright in

shipping blocks of one to three front-mounted sections or two to six
back-to-back sections as standard. All motor control centers
(MCCs) are mechanically and electrically tested before shipment.
Each MCC is provided with a lifting device for handling
convenience (lifting device is optional on NEMA Type 3R). The
motor control center is bolted to the shipping skid and further
packaged to protect it during upright shipments.
(Refer to Publication 2100-5.5 for receiving, handling, and storage
instructions. This publication is shipped with each MCC, attached to
the outside of the MCC within a layer of clear plastic wrap. For
additional information, consult NEMA ICS 2.3.)
ATTENTION:
Motor control centers are top heavy and front heavy.
To avoid personal injury or structural damage to the
motor control center, never attempt to lift or to move
the motor control center by any means other than the
methods outlined in Publication 2100-5.5, Receiving,
Handling, and Storing Motor Control Centers.
BI006008
Chapter
Installation Procedures
Location Planning
When planning the location for your CENTERLINE Motor Control

Center, take the following items into consideration:
conduits
busways
overall height
alignment with other equipment
future needs
In addition, the area must be level and the environment must be
compatible with the NEMA enclosure rating of the equipment.
Mounting Cor siderations
If the motor control center is equipped with optional external

mounting channels or is mounted on a pad, the height to the center of
the top handles must be checked for compliance with NEC 380-8(a)
and UL Standard 845. If handles are higher than 6'7" (2000mm),
then Unit Operating Handle Extender should be added to these
handles (catalog number 2100-NE1).
Securing a
Motor Contro Center
Anchor bolts (112"(l3mm)) may be pre-located and embedded in

the MCC foundation prior to installation. Two bolts per vertical
section fasten the motor control center through its internal mounting
angle to the foundation (corner sections require three (3) bolts and
40-inch wide sections require four (4) bolts). See Figures 2.1
through 2.6.
Figure 2.1
Mounting Dimensions for 15" and 20" Deep
Front-Mounted Section
[i
IAI~'(1~
I~)
LL
I
r---D
(2)MOUNTING SLOTS
.56 X 1.13 SLOT
(14) X (29) SLOT
\Cj
I
D--I
GROUND BUS
15"DEEP
20"DEEP
DIM 20'y"OE 2S"W1DE 30'WIDE 3S"WIDE 20" WI DE 2S"WIDE 30"WIDE 3S"WIDE
A 0.00(508) 5.00(635)~0.00(762 5.00(889 0.00(508 5.00(635) 30.00(762) 5.00(889
5.00(381) 5.00(381) 5.00(381) 5.00(381)1>0.00(508 0.00(5081>0.00(508) 0.00(508
C
D
1.56(294) 1.56(294) 1.56(294) 1.56(294) 6.56(421) 6.56(421) 6.56(421) 6.56(421)

0.00(254) 2.50(318) 5.00(381) 7.50(445) 0.00(254) 2.50(318) 5.00(381) 7.50(4'5)
2-2
BI006008
Securing a
Motor Control Center continued
Figure 2.2
Mounting Dimensions for 30" and 40" Deep
Back-To-Back Section
---c
i A i
r-
rh
(6) ~187)
7
25 . 8
lIT
1(43)
. 69
B GROUND BUS
(6)
[25
1\
7r
319
1m
J
(81 )
40"DEEP
30"DEEP
Dltv
A
B
C
D
(4)MOUNTING SLOTSJI-- D'=l==D--1

.56 X 1.13 SLOT
(14) X (29) SLOT
20"W1DE 25"W1DE 30"WIDE 35"W1DE 20"WIDE 2S"WIDE

0.00(508) 25.00(635 bO.00{762 5.00(889 20.00(508)
30"WIDE 3S"WIDE
5.00(635) 30.00(762) 35.00(889)
0.00(762) 30.00(762 ~.00(762 0.00(762 40.00(1016) 0.00(1016) 40.00(1016 40.00(1016

11-56(294) 11-56(294) 1.56(294) 1.56(294) 16.56(421)
6.56(421)
16.56(421 ) 16.56(421)
10.00(254 12.50(318) 5.00(381) 7.50(445) 10.00(254)
2.50(318)
15.00(381) 17.50(445)
Figure 2.3
Mounting Dimensions for 25" Deep Back-To-Back Section
r-----.:~;/'GROUNO
I
(187)
7.38
(635)
25.00
LU
tl
1/
(6)
I l(r
.38
~B
(2)MOUNTING SLOTS
.56 X 1.13 SLOT
(14) X (29) SLOT
B~
8US
r 25 (532)
251
20.94
SECTION
WIDTH
20.00'
DIMENSION
A
20.00(508)
10.00(208)
12.50(318)
25.00'
25.00(635)
30.00'
30.00(762)
15.00(381)
35.00'
35.00(889)
17.50(445)
BI006008
Securing a Motor Control

Center - coninued
Figure 2.4 Mounting Dimensions

for 15" and 20" DeeD x 40" Wide Front-Mounted Section
J--~;~.go ~~-L
1(254)
11
I1
;25 \
.1
+-_...
7-l"l_8_ _.L.----iF-
10.00
1 (254)
GROUND BUS"
2-3
f--20.00(508)
DIMENSIONS
SECTION
DEPTH
15" DEEP
20" DEEP
(4)MOUNTING SLOTS
.56 X 1.13 SLOT
(14) X (29) SLOT
11.56(294)
15.00(381)
16.56(421)
20.00(508)
Figure 2.5 Mounting Dimensions for NEMA Type 3R Section
(421 )
16.56
Ie 337)
14.06
LJ
/1
(2)MOUNTING HOLES)
.63 (16)DIA
\
GROUND BUS
INTERIOR
~;~ON
20"
25"
30"
DIMENSIONS
B
25.00(635)
13.75(349)
11.25(286)
30.00(762)
16.25(413)
13.75(349)
35.00(889)
18.75(476)
16.25{413}
Figure 2.6 Mounting Dimensions for 15" and 20" Deep Corner Section
DIMENSION
.~~ x }-\~
( 14)
X \29)
SLOT
SLOT
SECTION DEPTH
15" DEEP 20" DEEP
25.13(638)
30.13(765)
12.63(321)
15.13(384)
16.81(427)
21.81(554)
17.62(448)
22.62(575)
Documentation packages shipped with assembled MCCs include a

CAD drawing (Form 385E) showing an MCC floor plan layout.
2-4
BI006008
Seismic Requirements
When secured as indicated, (see Figure 2.7 for Bolt Down Securing
or Figure 2.8 for Weld Down Securing), the CENTERLINE Motor
Control Centers (20" (508mm) only) will withstand seismic activity
Zones 0 to 4. Zone 4 is the maximum zone magnitude as defined by
the Uniform Building Code (UBC).
Figure 2.7 Seismic Bolt Down Requirements
SEISMIC BOLT-DOWN REQUIREMENTS
* -
HARDWARE REQUIRED IS 1/2 INCH GRADE 2

OR BETTER BOLTS IMBEDDED IN FOUNDATION
REAR
FRONT
LAST SECTION
2ND SECTION AND

ADDITIONAL SECTIONS
FIRST SECTION
f----MOTOR CONTROL CENTER L1NE-UP----I
Figure 2.8 Seismic Weld Down Requirements

SEISMIC WELD-DOWN REQUIREMENTS
TYPICAL FRONT AND REAR WELD LOCATIONS
FOR SINGLE AND MULTIPLE SECTION LINE-UPS
-$6)
""
r-------''''''r-~
REAR .,,-,----...,
FRONT
I 1(38)
. 50
1-
(38)
1.50
FRONTJ
(38)
1.50
(38)
1.50
1.50
FIRST SEcnON 2 D SECTION AND LAST SECTION

ADDInONAL SECTIONS
MOTOR CONTROL CENTER LINE-UP
REAR
FRONT
---J--=_ __ __ __
END VIEW
BI006008
2-5
Joining and plicing

New Motor C ntrol
Centers
A main horizontal bus splice kit must be installed between shipping

blocks of new motor control centers in order to connect the main
horizontal bus. In addition, the neutral bus splice kit (if required)
and the ground bus splice kit must be installed between shipping
blocks. Refer to Publication 2100-5.1, Joining and Splicing Vertical
Sections for joining and splicing IS" (381 mm) or 20" (508mm)
front-mounted sections and 30" (762mm) and 40" (l0l6mm) deep
back-to-back construction.
Joining and plicing

Existing Mot r Control
Centers
A main horizontal bus, a neutral bus (if required), and a ground bus
splice kit must be installed when adding to existing motor control
centers. When adding to existing motor control centers, you must
identify the series of the motor control center that you will be adding
to. If the existing motor control center is Series A or B, you must
consult the factory for joining and splicing procedures. When the
existing motor control center is Series C or later, refer to Publication
2100-5.1, Joining and Splicing Vertical Sections for joining and
splicing IS" (38Imm) or 20" (508mm) front-mounted sections and
30" (762mm) and 40" (l016mm) deep back-to-back construction.
Joining and plicing

NEMA Type RMotor
Control Cent rs
A main horizontal bus, a neutral bus (if required), and a ground bus
splice kit must be installed between the internal sections for new and
existing NEMA Type 3R motor control centers. Refer to Publication
2100-5.1, Joining and Splicing Vertical Sections for splicing Type
3R internal sections.
Refer to Drawing No. 40110-077 (shipped with NEMA Type 3R
sections) for instructions on joining the NEMA Type 3R external
cabinets. Figure 2.9 on the next page is a copy of this drawing for
reference purposes only.
2-6
BI006008
Figure 2.9
Joining Instructions for NEMA Type 3R Sections
[2] WIREWAY EXTENSIONS REQUIRED FOR 15 DEEP STRUCTURE
[4] WIREWAY EXTENSIONS REQUIRED FOR 20 DEEP STRUCTURE
[1]1/4-20 X 3/4 TAPTITE PER WIREWAY EXTENSION
CABINET SPACER
[2]1/4-20 X 1.2 TAPTITE
MCC
MCC
MCC
REMOVE L.H. DRIPHOOD

ANGLE & REMOUNT AFTER
ADJACENT DRIPHOOD HAS
BEEN DRILLED OUT
REMOVE R.H. DRIPHOOD

ANGLE & DISCARD.
DRILL OUT [5] .172 DIA HOLE~l
TO .250 DIA. IN DRIPHOOD.
If
II
~m~
~~
[2]1/4X 1/2
TAPTITES
REMOVE R.H. & L.H. SIDE PLATES

BEFORE JOINING SECTIONS.
GASKET ACROSS TOP OF DRIPHOOD""
& DOWN THE BACKPLATE ON
ONE OF THE JOINING SECTIONS.
~
1'\
GASKE
[2]1/4X 1/2
TAPTITES
GASKET'..,
......
ftp
WIREWAYEXT ENSIONS
[2] OR [4]1/4 X 1/2 TAPTITES
CABINET SPACER
[2]1/4-20 X 1/2 TAPTITE
CABINET SPACER
[2]1/4-20 X 1/2 TAPTITE
r
II
l
BI006008
Bus Torque ~ pecifications
2-7
Tighten all bus connections with a torque wrench and socket at

intervals established by your maintenance policy. If a torque wrench
is not available, tighten until the conical spring washer is flat. Refer
to the table below for bus connection torque values.
Description
Required Torque
Horizontal to Vertical Bus

Connection
38 ft-Ib (50 Nm)
Horizontal Splice
38 ft-Ib (50 Nm)
Lug Attachment Bolts
45 ft-Ib (61 Nm)
The torque values can also be found on the information label located
on the interior of the vertical wireway door or on the interior
right-hand side plate of frame mounted units or in Publication
2100-5.0.1, CENTERLINE Motor Control Centers Start-Up
Procedures.
Installing an< Joining

NEMA Type 1 and Type 12
Pull Boxes
When pull boxes are supplied with your motor control center, refer
to Publication 2100-5.28, Installing a Pull Box on a Bulletin 2100
Vertical Section for installing and joining the pull box onto the
vertical section.
BI006008
BI006008
Chapter

Installing Co duit
When installing conduit, make sure it is installed so that water and

moisture can not enter or accumulate in the MCC enclosure.
Conduits must be installed so that they are compatible with the
NEMA rating of the MCC. The conduit should be placed away from
the horizontal ground bus to avoid physical damage. It is
recommended that the conduit be positioned so as to minimize cable
bending and maintain relative vertical alignment to incoming bus
pads and terminals of main fusible disconnects or main circuit
breakers.
Bottom Entry Conduit

Prepare the installation site so that the foundation is level. Before
the MCC is installed, place and stub up conduit approximately 2"
(5Imm) above floor level. Make sure that all incoming conduit is
clear of the horizontal ground bus.
1.
For approximate section base dimensions and ground bus

locations, refer to Chapter 2, Installation Procedures, Figures
2.1 through 2.6.
2.
For approximate bottom entry locations and wiring schemes for

main fusible disconnects, main circuit breakers, and incoming
line compartments, refer to Publication 2100-4.2, Mains and
Incoming Lines Dimension Reference.
Top Entry Conduit

After the MCC is in place, is leveled, and the sections are joined and
spliced, bring conduit into the top of the incoming section.
1.
Remove the lifting angle and top plate. Modify the top plate for
the necessary conduit entries. (This method helps guard against
metal chips falling into the MCC, which can cause serious
damage.)
2.
Replace the top plate and lifting angle bolts. (This guards
against dust or dirt entering the top horizontal wireway.
3.
Make sure that all incoming conduit is clear of the horizontal

ground bus.
4.
For approximate location of the horizontal ground bus mounted

in the top horizontal wireway, refer to Publication 2100-4.2,
Mains and Incoming Lines Dimension Reference.
3-2
BI006008
Installing Cable
5.
For space availability for incoming cables, refer to the

documentation package shipped with assembled MCCs. This
package includes Form 385E, a CAD drawing showing
available space.
6.
For approximate top entry locations and wiring schemes for

main fusible disconnects, main circuit breakers, and incoming
line compartments, refer to Publication 2100-4.2, Mains and
Incoming Lines Dimension Reference.
Install cable when the temperature is above freezing (32F or OC)

(unless cable is suitable for installation at temperatures below
freezing). This will help prevent cable insulation from cracking or
splitting.
Motor control centers are rated for use with 75C cable for current
ratings above 100 amperes. Cable must be sized using 75C column
in NEC Table 310-16. The actual temperature rating of the lugs
used is not relevant.
Incoming Line Compartment

Top or bottom entry to the incoming line section bus is straight
through to the connection terminals. The vertical bus provides pads
for the incoming lugs. The lug selection should be based on the size,
number, and type of conductor.
1.
Use mechanical screw type lugs when the incoming lines

available short circuit current is under 42,000 amperes RMS
symmetrical.
2.
Use crimp type or compression type lugs when the incoming

lines available short circuit current is above 42,000 amperes
RMS symmetrical.
Main Fusible Disconnect and Main Circuit Breaker

Top entry is straight through to the line side of the main fusible
disconnect and main circuit breaker. However, for bottom entry, the
connection scheme varies depending on the rating of the main
device. In some cases, the bottom entry goes to the top or line side
of the main fusible disconnect or main circuit breaker. In other
cases, the bottom entry would go straight through to the bottom of
the main fusible disconnect or main circuit breaker. This is referred
to as "reverse fed. "
BI006008
3-3
Mechanical screw type lugs are supplied as standard with all main
fusible disconnects or main circuit breakers. Crimp type or
compression type lugs are also available.
Cable Bracing
The CENTERLINE MCC bus work system has been tested and is
qualified to withstand maximum short circuit forces exceeding the
short circuit withstand ratings for the MCC. Incoming line cables
and outgoing feeder cables also need to be supported to withstand the
same short circuit forces.
There are many sizes and types of cables, as well as different means
by which the cables can be supported. Acceptable methods are
shown below in Figures 3.1, 3.2, and 3.3.
In Figure 3.1, glass fiber reinforced tape or glass filament tape is
used. The taping should be continuous from the point the cables
enter the MCC to the point the cables are terminated. It is important
that cables are wrapped several times for additional strength. Cable
slack should be drawn up during wrapping so that individual cables
are supported together by the tape as a single mass.
Figure 3.1 Securing Cables with Glass Tape
BI006008
3-4
Cable Bracing - continued

In Figure 3.2, cables are lashed in a "figure 8" -type configuration
using nylon rope. The rope lashing should be continuous from the
point the cables enter the MCC to the point the cables are terminated.
Other types of rope lashing may be acceptable. However, cable
slack should be drawn up during wrapping so that individual cables
are supported together by the rope as a single mass.
Figure 3.2 Securing Cables with Nylon Rope
In Figure 3.3, a hardwood brace (maple hardwood) made for the

specific application is used. Holes are bored approximately the size
of the cable diameter. Several bolt holes are also bored the breadth
of the hardwood brace. The brace is cut in two pieces and is used as
a clamp to secure the cables.
Figure 3.3 Securing Cables with Hardwood
BI006008
3-5
Cable Bracing - continued

The through bolts are inserted into the brace and tightened so that the
cables are held tightly in place. A second form of hardwood brace
(not shown) is a yolk type in which the cables are passed through.
Holes should be small enough to provide a snug fit for the cables.
The connectors or lugs are attached to the cables and cables are
bolted to the terminals.
When using the hardwood bracing method, the cables should be
braced every 12" (305mm) when the incoming lines available short
circuit current is below 42,000 amperes RMS and every 6" (l53mm)
when the incoming lines available short circuit current is 42,000
amperes RMS or greater.
Incoming Line Brace

Allen-Bradley manufactures an incoming line brace similar to the
hardwood clamping type brace. To order an incoming line brace,
contact your local Allen-Bradley sales office and ask for assembly
number 40113-848-0 I.
Important: Connectors should be installed so that they are in line
with each other and so that there is proper spacing
between phases. Make sure that hardware is torqued
according to the required specifications.
BI006008
BI006008
Chapter
Installing and Removing

Plug-In Units
ATTENTION:
Turn off power to unit before installing
or removing unit.
Installing PI g-In Units
For unit installation, refer to Publication 2100-5.12, Installing Units

with Vertical Operating Handles, and Publication 2400-5.2,
Installing Units with Horizontal Operating Handles.
Removing PI g-In Unit

From a Secti n
(1.0 Space F ctor or
Larger)
1.
Make sure disconnect handle is in the OFF/O position.
2.
Turn door latches 1/4 turn.
3.
Open door completely.
It is not necessary to remove the unit door in order to remove a unit
from a section. However, steps 2 and 3 below may still be necessary

even when door is not removed.
1. Remove hinge pins - slide up with a screwdriver.
2.
Remove control station, if present. Also remove wiring from

meters, if present.
3.
Hang control station on front of unit using square holes adjacent

to top unit latch.
4-2
BI006008
Removing Plug-In Unit

From a Section
(1.0 Space Factor or
Larger)
- continued
1.
Swing door to near closed position.
2.
Lift door off outward.
1.
Disengage captive latches located at front of unit, one at top and

one at bottom. 2.0 space factor units and larger have two
latches at top.
2.
Detach wiring/terminal block(s) from unit. Place wires/terminal

blocks in line with wiring clearance tunnel.
It is not necessary to stuff wires/terminal blocks into vertical

wlreway.
1.
Pull unit forward (outward) using handle provided at lower left

of unit and the tab at the upper right of unit as finger holds.
BI006008
4-3
Removing S pport Pan
1.
Pry the plastic retaining clip from the right hand unit support
using a screwdriver. This is visible in the vertical wireway.
2.
Lift the right side of the support pan approximately 4" (I02mm).
~~ ~~@
or
I'
On
1.
Pull right side of support pan forward to release from left rear
slot on structure.
2.
Push back on left side of support pan until support pan is free
from structure.
NOTE: Vertical sections may be supplied with plug-in stab
opening protective caps, manual shutters, or automatic shutters.
Refer to Step 3 if any of these options are supplied.
3.
Carefully install protective caps or close manual shutters after

unit is removed. Automatic shutters will close as units are
removed.
BI006008
4-4
Removing Plug-In Unit

From a Section
(O.S Space Factor)
1.
Make sure disconnect handle is in the OFF/O position.
2.
Turn door latches 1/4 turn.
3.
Open door completely.
.,
Door removal is not necessary when removing a unit.

1. Remove hinge pins ~ slide up with a screwdriver.
2.
Swing door to near closed position.
3.
Lift door off outward.
1.
Detach wiring/terminal block from unit.
2.
Place wiring/terminal block in vertical wireway to right of unit.
BI006008
4-5
Removing Pug-In Unit

From a Secti n
(0.5 Space F ctor)continued
1.
Push latch mechanism to the left with right hand.
2.
Pull unit forward (outward) with left hand using the left top
portion of the disconnect handle flange as finger hold.
Removing S pport Pan
00 00
1.
Pry the plastic retaining clip from the right hand unit support
using a screwdriver. This is visible in the vertical wireway.
2.
Lift the right side of the support pan approximately 4" (I 02mm).
~~ :j~.@
I
or
1.
2.
3.
Pull right side of support pan forward to release from left rear
slot on structure.
Push back on left side of support pan until support pan is free
from structure. NOTE: Vertical sections may be supplied with
plug-in stab opening protective caps, manual shutters, or automatic shutters. Refer to Step 3 if any of these options are
supplied.
Carefully install protective caps or close manual shutters after
unit is removed. Automatic shutters will close as units are
removed.
BI006008
BI006008
Chapter
Operator Handle and Unit

Interlock
The t1ange operator handle, for either a disconnect or circuit breaker,
is an integral part of the unit insert. No adjustment is required. The
operator handle is interlocked with unit door as outlined by UL 845.
When the unit door is closed and the operator handle is in the ON/I
position, the defeater located just below (1.0 space factor or larger
units) or just to the right (0.5 space factor units) of the pivot point of
the handle, must be deliberately operated to be able to open the unit
door. See Figure 5.1 and 5.2.
Figure 5.1
Operating Handle Defeater for 1.0 Space Factor and Larger
Figure 5.2
Operating Handle Defeater for 0.5 Space Factor
5-2
Operator Handle and Unit Interlock
When the unit door is open and the operator handle is in the OFFIO
position, the defeater lever must be held up (1.0 space factor and
larger units) or held to the left (0.5 space factor units) in order to
move the operator handle to the ON/I position. See Figure 5.3 & 5.4.
Figure 5.3
Defeater Lever for 1.0 Space Factor and Larger
Figure 5.4
Defeater Lever for 0.5 Space Factor
BI006008
BI006008
Locking Pr visions
5-3
To lock the small and medium operator handle in the OFF/O

position, put the shackle of the lock through the opening of the
operator handle. The opening can accommodate up to three (3)
padlocks. See Figure 5.5.
Figure 5.5
Locking Small and Medium Handle in OFF/O Position,
1.0 Space Factor or Larger (Smaller Handle Shown)
The 0.5 space factor units utilize the small handle. The small handle
can be locked in the OFF/O position the same way the small handle
for 1.0 space factor and larger units can be locked. See Figure 5.6.
Figure 5.6
Locking Small Handle in OFF/O Position,
0.5 Space Factor Units
5-4
BI006008
ATTENTION: Locking an operating handle in the

ON/l position may be in conflict with local codes and
emergency shut down requirements.
To lock the small operator handle in the ON/l position, drill out the
top pre-located hole to 318" (9.5mm) diameter maximum, and
padlock. See Figure 5.7 and 5.8.
Figure 5.7
Locking Small Handle in ONII POSITION,
1.0 Space Factor and Larger
" Drill Out
Figure 5.8
Locking Small Handle in ONII Position,
0.5 Space Factor
//
Drill Out '"
BI006008
operator Handle and Unit Interlock
5-5

ON/l position may be in conflict with local codes and
To lock the medium operator handle in the ON/I position, drill out
the bottom pre-located hole to 318" (9.5mm) diameter maximum,
and padlock. See Figure 5.9.
Figure 5.9
Locking Medium Handle in ON/I Position
---- .... Drill Out
To lock the large operator handle in the OFF/O position, put the
shackle of the padlock through the opening of the operator handle.
The opening can accommodate up to three (3) padlocks.
See Figure 5.10.
Figure 5.10
Locking Large Handle in OFF/O Position
BI006008
5-6

ONII position may be in conflict with local codes and
To lock the large operator hand in the ONII position, drill out the
pre-located hole to 318" (9.5mm) diameter maximum, and padlock.
See Figure 5.11.
Figure 5.11
Locking Large Handle in ON/I Position
- - .. Drill Out
BI006008
5-7
The unit interlock, provided with each 1.0 space factor or larger
plug-in unit, prevents the unit from being plugged into or unplugged
out of a vertical section with the operator handle in the ON/I
position. The unit interlock also provides a means by which the unit
can be "locked out with a padlock" preventing installation of the
unit into a vertical section. The lockout feature of the unit interlock
can be used with the operator handle in either the ON/I or OFFIO
position. See Figure 5.12.
Figure 5.12
Unit Interlock, 1.0 Space Factor or larger
BI006008
5-8
The unit interlock provided with the 0.5 space factor units also
prevents the unit from being plugged into or plugged out of a vertical
section when the operator handle is in the ON/I position. Just as
with the unit interlock for 1.0 space factor and larger units, the
interlock mechanism for the 0.5 space factor unit has a lockout
feature. This lockout can be used in either the ON/I or OFFIO
position. See Figure 5.13.
Figure 5.13
Unit Interlock, 0.5 Space Factor
BI006008
Chapter
Final Check List Before

Energizing
The following procedure is provided as general guidance for a final
check before energizing a newly installed CENTERLINE Motor
Control Center. Use this final check list in conjunction with
procedures listed in Publication 2100-5.0.1, CENTERLINE Motor
Control Centers Start-Up Procedure.
ATTENTION: To ensure the safety of personnel
performing the Final Check, make sure that the motor
control center remote power source(s) is disconnected
and locked in the OFF/O position.
Final Check Before Energizing

1.
Remove all blocks or temporary holding means used for

shipment from all component devices in the motor control
center.
2.
Check enclosure and units to see that they have not been
damaged so as to reduce electrical spacings.
3.
Check the motor control center and verify that it is installed

properly, making sure that it is level, supported, and anchored
(if necessary or required).
4.
Check the integrity of splice and other accessible bus

connections. Torque values can be found on the information
label located on the interior of the vertical wireway door or on
the interior right-hand side plate of frame mounted units.
5.
Check that all ground connections are made properly.
6.
Check field wire for proper size. Proper field wire sizing
criteria can be found on the information label located on the
interior of the vertical wireway door or on the interior
right-hand side plate of frame mounted units.
7.
Check field wired circuits for agreement with wiring diagrams,

and make sure the wiring is clear of live bus areas.
8.
Make certain that all incoming and outgoing power wiring is

secure and braced to withstand the effects of a fault current.
Also make sure that the conduit and/or cabling is well
supported.
6-2
BI006008
9.
Check to make sure that the voltage and horsepower ratings of

the motor agree with the ratings stamped on the unit nameplate
of the unit to which it is connected. The unit nameplate is
located on the interior of the bottom plate of plug-in units or on
the interior right-hand side plate of frame mounted units.
10. Set any adjustable current and voltage trip mechanisms to their
proper values. (Circuit breaker trip settings are listed in

Publications 2100-2.3.1 and 2100-2.3.2.)
11. Where applicable, install power circuit fuses in the fusible
switches compliant with local electrical code application

requirements. Make sure that fuses are completely inserted into
the fuse clips.
12. Where applicable, timers should be set for their proper interval
settings.
13. Make sure that the overload relays or heater elements are
selected, installed and/or adjusted to the relative full load
current shown on the motor nameplate.
14. Manually exercise all switches, circuit breakers, their respective
operators, interlocks and any other operating mechanisms to

make certain they operate freely.
ATTENTION:
Do not operate a current transformer
with its secondary open.
15. Check all current transformers to make sure that they are wired
to their respective devices. Where applicable, remove shorting
bars from the secondary of current transformers and make
connections to their respective devices.
16. To avoid injury or possible damage to equipment, check and
make sure that all barriers and parts that may have been
removed during installation have been reinstalled.
17. Before closing the enclosure and/or the individual units, remove
all tools, metal chips, scrap wire, and other debris from the
motor control center interior. If there is an accumulation of dust
or dirt, clean out by using a brush, vacuum cleaner or clean,
lint-free rags. Do not use compressed air, because it will
redistribute contaminants onto other surfaces.
BI006008
6-3
ATTENTION:
Equipment that is sensitive to high test voltages such as
meters, solid state devices, and capacitor units, should
be isolated.
18. Conduct an electrical insulation resistance test to make sure that

the motor control center and field wiring are free from short
circuits and grounds. Conduct this test using an insulation
resistance tester (megger) with a potential of 500-1000 volts.
This test should be conducted phase-to-phase and
phase-to-neutral in the motor control center. This test should
be conducted with all of the switches or circuit breakers opened
or in the OFF/O position.
Electrical Insulation Resistance Test
Typical insulation resistance values are 50 megaohms or

greater.
Next, check the field wiring. For example, motor cables
and/or incoming line cables.
Note that the insulation resistance values are affected by
humidity or dampness that may cause a considerably lower
insulation resistance reading. If this is the case and the
insulation resistance values are below 1 megaohm, or the
motor control center has been stored in a damp or humid
area, it is recommended that the equipment be dried out.
Dry out the motor cables by injecting a low voltage current.
Use space heaters to dry out the motor control center.
When the equipment is dry, repeat the insulation resistance
test. The minimum value for insulation resistance on a new
installation at start-up or energizing is 1 megaohm.
19. Make sure that all latches are secure. Close and latch all doors,
making certain that no wires are pinched. Turn all unit
disconnects or circuit breakers to the open or OFF/O position
before energizing the motor control center.
BI006008
BI006008
Chapter
Energizing Equipment
The following procedure is provided as general guidance for
energizing a newly installed CENTERLINE Motor Control Center
after the Final Check procedure has been completed, (see Chapter 6,
Final Check List Before Energizing). Use this procedure in
conjunction with procedures listed in Publication 2100-5.0.1,
CENTERLINE Motor Control Centers Start-Up Procedure.
ATTENTION: Energizing a motor control center for
the first time is potentially dangerous. Serious damage
and personal injury can result when the power is turned
on. Therefore, only qualified personnel should
energize the equipment.
Energizing Procedure
1.
Review any additional instructions supplied for the proper

operation of special units such as drives, Smart Motor
Controllers (SMCTM), etc., with appropriate personnel.
2.
Make sure that there is no load on the motor control center

when it is energized. Turn off all of the main and unit
disconnect handles. Also, make sure any associated remote
devices are turned off.
3.
Energize the motor control center remote power source.
4.
Energize the main devices followed by the feeder devices and

then the branch circuit devices. Always energize from the
source of the system, working toward the loads.
5.
After all of the disconnect devices have been closed, loads such
as lighting circuits, motor starters, contactors, etc. may be
energized.
A. When power factor correction capacitors are energized along
with the motor windings and the start-up procedure requires
that the respective motors be jogged or inched, temporarily
disconnect the power factor correction capacitors.
B. Verify that any acceleration times are within specific

application specifications.
BI006008
BI006008
Chapter
Maintenance
A periodic maintenance program should be established for your
motor control center to avoid unnecessary downtime due to neglect.
How frequently you service your MCC will depend upon the
equipment usage and the environment in which it operates. The
following is a suggested checklist.
ATTENTION:
De-energize motor control center before servicing.
Maintenance Checklist
1.
Inspect the motor control center at least once per year.
2.
Carefully inspect doors and enclosure sides for evidence of

excessive heat. Generally, any temperature during operation
that the palm of your hand can not stand for approximately 3
seconds may indicate a problem.
3.
Check for moisture or any signs of dampness or drippings inside

the motor control center. Condensation in conduit or dripping
from an outside source is a common cause of motor control
center failure. Eliminate any source of moisture. Seal off
conduit, cracks, and openings that have allowed and/or could
allow moisture to enter the MCC enclosure. Dry or replace and
clean insulating material that is damp or wet or shows signs of
moisture. Check devices such as contactors, circuit breakers,
disconnect switches, relays, pushbuttons, etc., for wetness or
signs of moisture, corrosion, or contamination. Replace
damaged or malfunctioning parts. Make sure that the source
or cause of wetness or contamination is identified and
eliminated.
4.
Check the integrity of bus splice connections. Bus splices can

be easily identified by the label located on the interior of the
vertical wireway door or on the interior right hand side plate of
frame mounted units. Recommended torque values can be
found on the information label located on the interior of the
vertical wireway door or on the interior right-hand side plate of
frame mounted units, and in Chapter 2, Installation Procedures
- Bus Torque Specifications or in Publication 2100-5.0.1,
CENTERLINE Motor Control Centers Start-Up Procedure.
8-2
BI006008
Maintenance
Maintenance Checklist - continued

NOTE: The factory-made power connections are tightened by
a computer-controlled torquing system. The following
connections should never require re-torquing: Vertical to
horizontal bus connections, power conductor to horizontal bus
connections. These factory~made power bus connections do
not require servicing for the life of the motor control center.
5.
Air filters for fans should be periodically cleaned or changed,

depending on the environmental conditions.
6.
Check for proper function and freedom of movement (no

sticking or binding) of the disconnect handle operating
mechanisms and their defeater mechanisms. Replace broken,
deformed, malfunctioning, or badly worn parts or assemblies.
7.
Inspect bus stab connections for wear or corrosion. Wear and/or

corrosion can cause increased resistance causing an increased
temperature of the contact point which can lead to failure.
Replace bus stabs if wear or corrosion is excessive. Lubricate
bus stabs with NO-OX-ID grease (catalog number
2100H-N18 or 2100H-NI8T) before replacing the unit into the
section.
8.
Inspect current carrying parts such as fuse clips, knife blades of

disconnects, and line and load terminals of devices for
discoloration, corrosion or other signs of abnormalities.
9.
Check locking or interlocking devices for proper working

condition and capability of performing their intended functions.
Adjust, repair, or replace any device if necessary.
10. Check contacts for excessive wear and dirt accumulation.

Vacuum or wipe contacts with a soft cloth to remove dirt.
Contacts are not harmed by discoloration and/or slight pitting.
Contacts should never be filed, as this would reduce the life of
the contacts. Contact spray cleaners should not be used, as they
cause sticking on magnetic pole faces or in operating
mechanisms, interfering with the electrical continuity of the
contacts. Contacts should be replaced only after the silver has
become badly worn. Always replace contacts in complete sets
to avoid misalignment and uneven contact pressure.
11. Check for loose connections on power and control circuit

terminals. Loose connections can cause overheating or hot
spots that could lead to equipment malfunction or failure.
Replace any damaged parts or wiring.
BI006008
Maintenance
8-3
Maintenance Checklist - continued

12. Check coils for evidence of overheating - cracking, melting, or
burning of insulation. If there is evidence of overheating, the
coil must be replaced. When a coil needs to be replaced, check
for and correct the overvoltage or undervoltage conditions that
are causing the coil failure. Be sure to clean any residue of
melted coil insulation from other parts of the device, or replace
such parts.
13. Check all pilot lights. Replace burned out lamps and/or
damaged lenses.
14. Check all fuses. When replacement is necessary, always install
the same type and rated fuse that was originally furnished with
the motor control center.
15. Remove accumulated dust and dirt by vacuuming. Do not use
compressed air, as it may contain moisture and blow debris
elsewhere within the enclosure.
16. Refer to individual user policies for periodic servicing of
MCCs, and refer to NFPA 70B, Electrical Equipment
Maintenance.
Disconnect witch
Contact Lub ication
The disconnect switches used within the MCC units are supplied
with proper contact lubrication, and under normal operating
conditions should not require further lubrication. However, if a
switch that is used frequently becomes difficult to operate or is
located in a highly corrosive or caustic environment, it may require
lubrication.
The lubricant to be used is NO-OX-ID Compound (catalog
number 2100H-N18 for a I pint can or 2100H-N18T for a I ounce
tube.) To obtain the lubricant, contact your local Allen-Bradley
sales office, distributor, or Packaged Control Products at
Allen-Bradley, Company, Inc.
ATTENTION: To prevent injury or death to
personnel lubricating disconnect switch contacts, make
sure that the motor control center remove power
source(s) is disconnected and the respective
disconnect(s) is locked in the OFF/O position. In the
case of a plug-in unit, remove the unit from the motor
control center.
ATTENTION: To prevent personal injury or damage

to equipment, make sure that the unit handle operator is
in the OFF/O position before removing the unit.
8-4
BI006008
Maintenance
Disconnect Switch
Contact Lubrication
- continued
Instructions
1.
For Plug-In Construction

If disconnect switch needing lubrication is housed in a plug-in
unit, remove the plug-in unit from the motor control center.
(For removal of unit, refer to Chapter 4, Unit Removal and
Installation.)
For Frame Mounted Construction:
If disconnect switch needing lubrication is housed in a frame
mounted unit, turn off the power source(s) to the motor control
center.
ATTENTION: To prevent injury or death to
personnel lubricating disconnect switch contacts, make
sure that the motor control center remote power
sources (s) is disconnected and the respective
disconnects(s) is locked in the OFF/O position.
2.
Remove the line guard cover and retain.
3.
Remove and retain the arc hood. This allows access to the
disconnect's stationary contacts.
4.
Generously apply the compound (sufficient enough to cover

with a noticeable film) to both sides of the movable contact
blades and to the adjacent insides of the stationary contacts.
5.
Re-install the arc hood that was removed in Step 3.
6.
Re-install the line guard cover that was removed in Step 2.
7.
If the lubricated disconnect switch is housed in a plug-in unit,
reinstall the unit. (For installation of unit, refer to Publication

2100-5.12, Installing Units with Vertical Operating Handles).
NOTE: If the reasons for lubrication are due to corrosion (for
example, a sulfur environment), replacing the unit disconnect may be
required to avoid overheating conditions. Lubrication may reduce
the problem short term; however, replacing the disconnect switch
would be the correct and long term solution.
BI006008
Chapter
Maintenance After Fault

Condition
ATTENTION: Disconnect all power sources to the
motor control center before diagnosing the cause of the
fault condition.
The opening of the short circuit protective device (such as fuses or

circuit breakers) in a properly coordinated motor branch circuit is an
indication of a fault condition in excess of operating overload. This
fault condition must be corrected. Such a condition can cause
damage to control equipment. When a fault occurs, de-energize the
motor control center, repair the cause of the fault, and inspect all
equipment thoroughly per NEMA Standards Publication No. ICS
2.2-1983 Part ICS 2-302 Maintenance of Motor Controllers After A
Fault Condition. Make necessary repairs or replacements prior to
re-energizing the equipment. Be sure that replacements are of
proper rating and are suitable for the application.
In certain cases, it may be necessary to conduct an electrical
insulation resistance test (megger). For procedure, refer to Chapter
6, Final Checklist Before Energizing.
BI006008
BI006008
Chapter
10
Renewal Parts
A Renewal Parts Stocking Program for your motor control center is
recommended in conjunction with a maintenance program. This is
important for minimizing expensive downtime and when repair is
critical.
Factors to consider when developing an effective Renewal Parts
Stocking Program:
1.
The frequency of "ON-OFF" cycling and the amount of "ON"

or operating time.
2.
The need for continuous operation, inherent design limitations,

environmental considerations, etc.
3.
The total number of "like" devices supplied as original

equipment within the motor control center.
4.
The individual user policies governing spare parts.
Consideration should also be given to stocking complete units when

the job site is in an area remote from a distributor or district sales
office or when it is critical to maintain continuous operation of a
system.
Order Inform lion
The following information is required when ordering renewal parts:

description of part or unit
series letter
part or catalog number
quantity
shipping address
motor control center serial number and complete nameplate data
Refer to Chapter 11, Parts Illustration, for pictures and descriptions
of common section and unit parts.
Recommend d Spare
Parts List
The following is an example of a typical Recommended Spare Parts

List that can be supplied with your motor control center, upon
request. Lists contain spare part information specific to the
particular motor control center that was ordered.
NOTE: The information in the following example is accurate at
time of release.
10-2
BI006008
Renewal Parts
Figure 10.1
Sample of Renewal Parts List - Page 1 through 4
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RENEWAL PARTS FOR QUICl SHIP AND EN8INEERED
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C25I)V,1,.XFtllliL "TB.)
Dl
51VA, UOV Pll, 12av INn .PIOT
2S63'~l"-
LISl PRICE
'.10
'01'29-400-54
OlTL.STAT.HOOSING,
XF..It,
'" '" ""
PCP PART
XFP4R.
;; .. "'
"".,."''"''''
PART ItO 1 PESaIPrION
104.01
75VA. 2liD/4iUP. 12GY INn. f>fl:OT
CA-a II
PAClAGED CONTROL pRODUCTS. RENEWAL PARTS SYSTEM

U:NE'W"L PARTS FOR QUICK SHIP AND EMGlIfEE'RED
<SU~ARY OF CUCE REFERENCES>
. . . <rRIC~S SUIJECT TO CH"NGE wJTHOUT tr40TlCE>
CIRCE REFnENCECS) I
A-I ORDER MUMaER<S) I
QUOTATIOM PREFARED FOIt:
IV,
75YA, 2'0/UIP, l20V SEC.
25634-141-Dl
REF NO
REF NO
CONTROL TltAN'SFORf"ERS
XFHR.
sf
SEE CAT .1111
.049S-lt5&01
AUX. CDNTACT
X-2777ft5
FUSE .Loa::,
FRME.BRIR.l N.D.AUX.
USED
SPARE
N~
'0495-455-01
AIJX. CONTACT
rep
REF NO
CIRCUIT IREAIER AUXILIARY SWITCHES

USED
USED
REF
O'NO/"C. 9-30A. IUL.lOl
"'."""." "'
SEE CAL110
LIST rRICE
SPARE
cottrROt FUSE ILl)CI(S
19S-0AlI A
AUX. CDN1ACT. (1) N.D.,3113IOA,aUL.Ioa
PCP PART NO / DESCRIPTION
uSED
SD. GO
195-IA11 A
AUX. totHACT
DISCDNNECT AUXILIARY SWITCHES
PCP PART liD 1 DEscIHPTlOH
REF ND
FIlA"'E IUR . S S.F.
PCP PART NO 1 DSCIIPlION
....='" ""'
..*
SPARE
98.00
F
"14n-~5'-Dl
PACKAGED COIl1TJtOl PRODUCTS. RENEWAL PAinS SySTE"

RaiEWAL PARTS FOR QUICk SHIP AND ENGINEERED
<SUMMARY OF CIRCE KEFERENCES>
<PRICE'S SUBJECT TO CHAN6E 'WITHOul N(]l ICE> *lUf
CIRCE 'REFERENCE( S) ;
A-I (lRDEIt NUMIIERCS);
QUOTAnON PUPAREO FORI
IV,
USED
101l1I.00
AUXILIARY CON1ACTS
Ctlf1C;l>DI5EOC)
ItEAkER
615.00
AUX
pC!" PARt NO I DESCRIPTION
LIST PRICE
215182-256-04
IREAKEJt,W/ND-~C
REF NO
HANDLE ASSY. DISC., SERIES ' . '
PCP 'ART NO / DESCRIP1[ON
(WEST
HAMDLf: ASSY.
SPARE
IEF NO
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(A-a
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NO 1 DESCRI ..n ON
SPARE
(FDI310IU
REF NO
DISCONNECT HANDLE MECHANISMS
PC..
FlJI3]ODL
4IlZ6-UI-1S
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120.00
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640. DO
CUCUlT ."EAKER OPERATING MECHANISMS
IUL.5DO
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pcr
SEE CAT 110
60.11
USED
LIST foR ICE
25115-2'5-11
FDII 100A JREAKER
REF NO
SEE CAT 110
HI~73
..
PCP PART NO I DESCInPTl0t4
25107-&0'-1'
'HIIlCP
~GA
CDNTACfORS
LIST PRICE
DESCRIPTION
C1236
con,
SPARE
234.0'
COILS FOR STARTERS
PCP PART NO
usED
.:"
WESTIHGHIlUSE CIRCUIT IREAI:ERS
FULL VOLTAGE NON-REVERSING STARTERS
..ell' PART
lI'='" ="'
"
06/0&/9
PACKABIED CONnOl PRDDUCTS If RENEWAL PARTS SYSlEM
9:39
tEMEWAl PAns fOR: QUICK SHIP AMD ENGINEERE.D
..AGE 2
<SU""'ARY OF CIRCE REFERENCES>
. . . <PRICES $UIJECT TO CHANGE WITHDUT MOnCE> 15
C[ICE REFUEMCHS) I
A-I ORDER MUKIER(S);
QUOTATlON "REPAIEI) FOR:
IVI
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==:
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=;; .. ::",::= ,,'" .. " .. .., "',.
PCP PART NO I DESCRIPT 10K
'1 LOT
LIGIiTS
LIST PRICE
USED
SPARE
REF"'O
801MR-P16GS D
I"ILDT LlBHT,IZQV.6REII LENS,SCREW' TERM
SEE CAT.LlO
8QOMR-"]6RS D
SEE CA1.llo
PILDT LIGH1.12DY,IIlED
LENS,SCItEW TERM
(A-J PC
BI006008
10-3
Renewal Parts
Figure 10.1 - conti ued

Sample of Renewal Parts List - Page 5 through 7
,...==="'===== =="- "'

PACKAGE
CDNTROl PRODUCTS
n6/08/9
'9:3'9
RENWAl PARTS SYSTEM
PAIns FDIi! QUICK SHIP AND ENGINEERED
RENEW l
<SUMMARY OF CIRCE REFERENCES>

*,*-1IE
PAGE
<PR eES SUBJECT TO CHANGE WHHOUT NOTICE>
CIRCE REFERENCE (S) :

A- B BRDER NUHBER (5' ,
QUOTATION PREPARED FOIL
BY,
==== ====:;;,,=""..,.
~;:=~~:~=~~.:.~~~~~:~~~l ~
PRICE
llST
USED
SPA~E
(A-B
199-FSMAI
25.(J1I
LIST PRICE
PCP PART NO J DESCRIPTl ON
REF NO
[j
PART NO I
USED
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PCP PART NO /
REF NO
"=============',,
4I1i20-410-3e
.,
STAB ASSY, (1 >II0WIRE
7P"
7-
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40120-410-43.
STAB ASSV,(UI10WlRE L6 ft 16'" 20'"
LONG
STAB
ASSY.(1)I~
WIRE 18
18"
*'
CONTACTOR,
:BUl.100~
"
27.00
SPARE
USED
SPARE
REf NO
PCP PART NO /
CAT .110
FtoiM
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(BUSSMAN
250\1, D Al ELEMENT
25 OV. D At
(BUSSMAN
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LIST PRICE
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=== ""''''
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US-ED
SPARE
=== =====""
"''''== ======="''''''
RENEWA
PARTS FOR QUICK SHIP AND ENGINEERED

<SUMMARV OF CIRC'E REFERfNCES>
<PRI ES SU8JECT TO CHAtige WITHOUT NCT leE> U~
====== =='" ",,,,,. '" '" ======",
_==
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BY;
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RESET ASSEKIlLY
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3.14"
USED
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5.00
lONG, 100 .5SF UNIT

HEA.TE~
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HEATER
IS BASEl ON INF~;;;~~~~-P;~VIDED PRIOR TO 5HIPMENT
COHTACT YOUR LOCAL DISTR BUTOR FOR EXCHANGE/REPLACEMENT
PCP PART NO
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9.0D
9.00
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DATA
REF NO-
.,.,'lI
06/08/9
9:3'9
PAGE
....
PANEL MOUNT
USED
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=====
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54.00
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CUCE NEFE'RENCE(S) =
A-I OIlDER NUMBER(S);
QUOTATIOJol PREPARED FOR;
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40120-501 01
RESET.
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500-BDD93".O CA-B II
186.00
"'========-
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40185-469-51
PCP PART NO I
PACUGED CONTROL PRODUCTS 'If RENEWAL PARTS SYSTEM
"'
LIST PRICE
.4 AMP (LITT
IUL 51lD CONTACT OR
REF NO
AMP, BZ400
.4- A, 2511'11, 1 2S"X.25"
~0411-4'4-1)8-123'
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6.111)
PCP PART ptO / DESCRIPTIO
USED
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LIST PRICE
PCP PART NO / DESCRIPTION

OVERLOAD RElAY. 51, B592,
HIM .6
.6,
LIST PRICE
DSCRIPTION
193-.BSC24 B
OVERLOAD RElAV, 16.0 - Z4. 0
liEF NO
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6.00
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COfHACTOR J IULIOO,
LIST PRICE
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REF NO
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PCf PA.RT NO / DESCRIPTION
9A,1J3-5HP,380-4 0'11
PCP PART HI) /
1& AMP.120V CDIl
42.00
150-AD9HI-ND A
SMC-2,
SPARE
A70P,20
LIST PRICE
nEsCluplION
SHART MOTOR CONTROLLERS
PCP- PART NO / DESC!li:IPTlO
PAGE
700\1. CURRENT- LIMIT
40766-456-01-0475
26.00
LONG
4D120-410-ili2
9 ;39
BUL 100;104 CONTACTOR
LIST PRICE
DESCRlfTI1 H
lISED
24.00
0,2
FUSL A70P20,
25178~3D6-
STAB AsSEHBL[ES
per
06/0B/9
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SURGE SUPPRESSORS
41025-351-52
SU~GE SUPPIi'ESSOR,llD\o'.J1.ll 100 & 700F
,.,.= ==< =====;=="" ",,,,,,,-,,,=
PACkAGED CONTROL PRODUCTS

RENEWAL PARTS SYSTEM
RENEW,U PARTS FOR QUICK SHIP A"ND ENGlttEUED
<SUMMARY OF cIRCE REFERENCES:>
. " <PRICES SlIBJECT TO CHANGE WITHOUT NonCE:> I;JHf
CIRCE REFERENCE(S),
A- BORDER NUMBER{ 5) :
QUOTATION PREPARED FOR:
BY,
-------------lIST PRICE
$
LDNG, 1, 3125"BUTTON
12.00
USED
SPARE
REF
NO
BI006008
BI006008
Chapter
Parts Illustrations
Figure 11.1 Typical Section Construction
Lift Angle
Top Horizontal
wireway Baffle
Removable Top Plate
Top Horizontal
Wireway Cover
Left Han
Right Hand Unit

Support Assembly
(Vertical Wireway)
ntal and Vertical Bus Support

Vertical Power Bus
....... '"
L~-
---
Section Nameplate
Horiz ntal Power Bus
Vertical Wireway Door
Left and
Cent r End Plate
Vertic I Plug-In
Steel round Bus
Bus Splice Access Cover
____
Bus Connection
Access Cover
Vertical Bus Cover
- - - Unit Support Pan
Le Hand Side Plate Assembly
Horizontal Ground Bus

Top or Bottom
Sealing Strap
Top and Bottom
Bottom Support Angle
Bottom Horizontal
Wireway Cover
11
11-2
BI006008
Parts Illustrations
Figure 11.2
Typical Unit Construction
(shown - Bulletin 2113 Size 1 with Control Transformer)
Stab Assembly
Captive Latch
Handle
Interlock
Circuit
Breaker
Disconnect
Handle
Control Transformer
Unit Identification
Nameplate
Short Circuit
Rating Label
Captive Latch
UL Label
Control Station
Reset Button
BI006008
Parts Illustrations
11-3
Figure 11.3
Typical 0.5 Space Factor Unit Construction
UNIT STAB
ASSEMBLY
CONTROL CIRCUIT TRANSFORM~
BUL. 100 CONTACTOR
HANDLE MECHANISM---'"
CONTROL
TERMINAL BLOCK
. . . . .J
PLASTIC
RETAINING PIN
BI006008
BI006008
Chapter
12
Purchased Components
and
Additional Instruction Sheets
When equipment such as transformers, metering, PLCs, drives, is
supplied with the motor control center, specific manuals and data
sheets are also supplied. These manuals and data sheets should be
read and understood before installing and operating the motor
control center. Refer to the unit locations of these devices for their
manuals and/or data sheets.
BI006008
BI006008
Index
Bus Torque Specifications, 2-7
Cable - Installing, 3-2
Cable Bracing, 3-3
Incoming Line Brace, 3-5
Incoming Line Compartment, 3-2
Main Fusible Disconnect and Main Circuit Breaker, 3-2
Conduit - Installing, 3-1

Bottom Entry Conduit, 3-1
Top Entry Conduit, 3-1
Contact Lubrication-Disconnect Switch, 8-3

Lubrication Instructions, 8-4
Disconnect Switch Contact Lubrication, 8-3

Lubrication Instructions, 8-4
Electrical Insulation Resistance Test, 6-3

Energizing - Final Check Before, 6-1
Energizing Procedure, 7-1
Fault Condition - Maintenance After, 9-1
Installation
Location Planning, 2-1
Mounting Considerations, 2-1
Securing a Motor Control Center, 2-1
Mounting Dimensions
15" & 20" Deep Corner Section, 2-3
15" & 20" Deep Front Mounted, 2-1
15" &20" Deep x 40" Wide Front-Mounted, 2-3
25" Deep Back-To-Back, 2-2
30" & 40" Deep Back-To-Back, 2-2
NEMA Type 3R Section, 2-3
Instruction Sheets
Additional, 12-1
Drawing No. 40110-077 - Joining NEMA Type 3R, 2-5
Install Units with Horizontal Handles, 4-1
Pub. 2100-4.2 - Mains and Incoming Line Dimension, 3-1, 3-2
Pub. 2100-5.0.1 - MCC Start Up Procedure, 6-1, 8-1
Pub. 2100-5.0.1 - MCC Start-Up Procedures, 2-7
Pub. 2100-5.12 - Install Units with Vertical Handles, 4-1, 8-4
Pub. 21 00-5.12-lnstall Units wI Vertical Handles, 1-5
Pub. 2100-5.28 - Install Pull Box on Bul. 2100 Vertical Section, 2-7
Pub. 2100-5.5 - Receiving,Handling,Storing MCCs, 1-6
Publ. 2100-5.0.1 - MCC Start Up Procedure, 7-1
Publ. 2100-5.1 - Joining & Splicing Vertical Sections, 2-5
Joining & Splicing

Existing MCCs, 2-5
NEMA Type 3R MCCs, 2-5
New MCCs, 2-5
Locking Provisions, 5-3

Maintenance, 8-1
Checklist, 8-1
BI006008
Index
Nameplate Data, 1-1
Section Nameplate, 1-1
Unit Nameplate, 1-2
NO-OX-ID grease, 8-2

Operator Handle & Unit Interlock, 5-1
Defeater Lever for 0.5 Space Factor, 5-2
Defeater Lever for 1.0 Space Factor & Up, 5-2
Locking Handle (Large), 5-5, 5-6
Locking Handle (Medium), 5-5
Locking Handle (Small & Medium) - 1.0 Space Factor, 5-3
Locking Handle (Small) - 0.5 Space Factor, 5-3
Operator Handle &Unit Interlock, 5-1

Operating Handle Defeater for 0.5 Space Factor, 5-1
Operating Handle Defeater for 1.0 Space Factor & Up, 5-1
Unit Interlock - 0.5 Space Factor, 5-8
Unit Interlock - 1.0 Space Factor, 5-7
Parts Illustrations
0.5 Space Factor Unit, 11-3
1.0 Space Factor Unit, 11-2
Section, 11-1
Plug-In Units, Installing into Structure, 4-1

Plug-In Units - Removing from a Section
0.5 Space Factor, 4-4
1.0 Space Factor or Larger, 4-1
Purchased Components, 12-1

Receiving, Handling, and Storing MCCs, 1-6
Renewal Parts, 10-1
Order Information, 10-1
Recommended Spare Parts List, 10-1
Series Identification, 1-4

Series Lettering - Units &Sections, 1-5
Short Circuit Label for Sections, 1-3
Short Circuit Label for Units, 1-3
Seismic Requirements
Bolt Down Requirements, 2-4
Weld Down Requirements, 2-4
Support Pan Removal, 4-3

Type 1 Pull Boxes - Installing &Joining, 2-7
Type 12 Pull Boxes - Installing & Joining, 2-7
UL I CSA Marking, 1-2
BI006008
BI006008
BI006008
BI006008
'1' Rockwell
Automation
AI/en-Bradley
Allen-Bradley, a Rockwell automation business, has been helping its customers improve productivity and quality for more than 90 years, We design, manufacture and support a broad range of
automation products worldwide, They include logic processors, power and motion control devices,
operator interfaces, sensors and avariety of software, Rockwell is one of the world's leading technoiogycompanies,
~
Worldwide representation. - - - - - - - - - - - - - - - - (
Argentina' Australia' Austria' Bahrain' Belgium' Brazil' Bulgaria' Canada' Chile' China, PRC Colombia' Costa Rica' Croatia' Cyprus' Czech Republic' Denmark
Ecuador' Egypt EI Salvador' Finland' France' Germany' Greece Guatemala Honduras Hong Kong' Hungary Iceland' India' Indonesia' Ireland' Israel' Italy
Jamaica' .Japan Jordan' Korea' Kuwait Lebanon' Malaysia' Mexico' Netherlands' New Zealand' Norway' Pakistan Peru Philippines Poland' Portugal
Puerto Rico' Qatar' Romania' Russia-CIS' Saudi Arabia' Singapore' Slovakia' Slovenia' South Africa, Republic' Spain' Sweden' Switzerland' Taiwan' Thailand
Turkey' United Arab Emirates' United Kingdom' United States' Uruguay' Venezuela' Yugoslavia
Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414 382-4444
Publication 2100-5,0 - October 1995
Supersedes Publication 2100-5,0 - August 1987
Copyright 1995 Allen-Bradiey Company, Inc.
Pnnted in USA
BI006008
INSTRUCTIONS
BULLETIN
2100
CENTERLINE MOTOR CONTROL CENTERS

JOINING & SPLI ING VERTICAL SECTIONS
Joinin Centers
The following instructions illustrate the recommended

procedures which should be used when joining
CENTERLINE motor control centers.
Physical restrictions at your installation site may not allow
the following sequence to be followed exactly as stated.
1. The splice kits, if required, are located within a horizontal
wireway or blank unit space. A label (on the outside of the
compartment) designates the location. Remove the splice
kits and label.
2. Remove the end cover plates, if present, exposingjoining
hole(s) at both the top and bottom of the center. Joining
holes not covered by end cover plates may contain 1/4-20
hex head thread rolling screws on the left-hand side and
removable plastic plugs on the right-hand side. These
screws and pIugs are accessible both from within the
vertical wireway and the outside surface of the vertical
side plate and must be removed from the side plates to be
joined.
3. Pull all ttbottom entry" cables, if any, through the conduits
to a point where they will be accessible when the center is
positioned.
4. Remove the power bus side plate covers, vertical wireway
cover and horizontal bus access cover, where applicable,
from both centers to be joined.
5. When positioned, level the new center and, after removing

of the horizontal wireway covers for access, bolt in place to
the floor.
6. Remove the horizontal wireway covers on the existing
center andjoin the two centers using the hardware
furnished with the splice kit.
A. Pass the 1/4-20 hex head thread rolling screw from
inside the left-hand center, through joining holes (A),
see Figure 1, and engage the screws with the holes
located in the right-hand center.
Publication 2100-5.1 - March, 1987
Supersedes Publication 2100-5.1 - August, 1985
BI006008
B. Pass the 1/4-20 x 5/8 hex screw from inside the left-hand
center, through joining hole (B) and secure with the 1/420 steel nut.
7. Inspect the interior for dust and dirt; vacuum cleaning is
recommended. Do not clean using compressed air as it
contains moisture and may blow debris into the
control equipment.
Joining Hole Locations - Vertical Side Plates
A
Figure 1
Splicing Centers
The following instructions illustrate the recommended

procedures that should be followed when splicing
CENTERLINE motor control centers.
A main horizontal bus splice kit must be added between the
horizontal bus work of the existing and new centers. In
addition, the neutral bus splice kit, if required, and the
ground bus splice kit must also be installed to complete the
splicing operation. Refer to Recommended Splicing Procedure
for instructions.
The neutral bus splice kit, if required, and the ground bus
splice kits must be installed to complete the splicing
operation. Refer to Recommended Splicing Procedure for
instructions.
3
BI006008
Recommended Splicing
P cedure
To gain access to the horizontal bus, remove the units in front

of the horizontal bus (Step 1), in the first vertical section of the
right-hand center.
1. Control unit removal is accomplished as follows:
A. Open unit door by turning door latches 1/4 turn. Door
removal is not necessary when removing a unit;
however, if door removal is desired, see Steps lA, 2A,
3A, and 4A. Step 2A may be required even if door is not
removed.
IA. Open door completely.
2A. Ifpresent, remove control station housing by

loosening the 2 captive screws, which are located at
the top and bottom of the control station housing on
the front of the unit door.
3A. Remove hinge pins - slide up with screwdriver.
4A. Swing door to near closed position and lift off.
B. Loosen the screw type latches located at the front of the
unit - one at the top and one at the bottom, 2 space
factor units and larger have two at the top.
C. Detach necessary wiring from uni t.
D. Place wire/terminal block in line with wiring clearance
tunnel at lower right of unit. Pull unit forward to
unplug from bus, using the upper right-hand latch
assembly and the lower left-hand tab handle.
E. Remove the unit support pan. See Figure 2.
IE. Using a screwdriver, pry the plastic retaining clip
from the right side of the support pan, visible in the
vertical wireway.
2E. Lift right side of pan approximately 4 inches.
'3E. Pull right side of pan forward to release from left
rear slot.
4E. Push back on left side of pan until free.
2. Remove the horizontal bus access cover to expose the
horizontal bus for splicing. See Figure 3.
BI006008
Figure 2 - Removal of Support Pan
Figure 3 - Bus Access Cover
3. Assemble splice bars to the buswork of the vertical sections

per Figure 4. If additional access to the splice is desirable,
loosen the fastening screws and remove the bus access
plate located in the vertical wireway of the center to the
left of the splice. The horizontal bus is now exposed to the
left and right of the splice for added convenience. The
splicing kit will contain either two or four sets of hardware
per splice bar depending upon the current rating of the
horizontal bus.
If splicing the 2000A Main Breaker Section to a left hand
center and additional access to the splice is desirable,
loosen the fastening screws and remove the bus access
plate located in the vertical wireway of the center to the
left of the splice. The horizontal bus is now exposed to the
left and right of the splice for the added convenience.
BI006008
Assemble splice bars to the buswork of the vertical secti

per Figure 5 for joining to a standard section and per
Figure 6 for joining to a 20" deep section with 5" deeper
horizontal bus.
4. Tighten to torque specifications in the Torque Table beli
Or, as an alternative, tighten until the conical spring is
flattened on the one-piece nut and washer assembly.
5. Replace covers and plates, and check all bolts and nuts f
tightness. Replace units into their'respective sections.
Main Horizontal and Neutral Bus Splicing
Additionol Moin
Hori zonto! Splice
for 1600 8< 2000
Amp. APPlicotio7
Two Hole or
Four Hole
Moin Horizontal
S pi I ce
/I\;)':~
/'
~. /
/'
\0
\l
:......
~:
/~
:/1\;)
.~.~~~
.~~ / ~ Flat
Front
~i
Washers
Main Horizonc
Bus or Neutral gus
-One-Piece Assembly of
Nut and Conical Spring Washer
Figure 4
2000A Main Breaker
Main
Bus
~MainHorilonfalBUS
O.
Neutral Bus
Ma,nHO'<ZO~
Splice
Figure 5
BI006008
2000A Main Breaker 20" Deep Sections with 5" Deeper Horizontal Bus
Moin Horirontol Bus
0'
Neutrol Bus
Figure 6
Torque Table
Bus Torque Specifications - Tighten all bus
connections with a torque wrench and
socket at intervals established by your
maintenance policy. If a torque wrench is
not available, tighten until conical washer is
flat.
Description
Lug attachment bolts
Horizontal to vertical bus
connection
Horizontal splice connection
!b ALLEN-BRADLEY
iIllillIi7
A ROCKWELL INTERNATIONAL COMPANY
Packaged Control Products Division

Milwaukee, Wisconsin 53204 U.S.A.
Torque in Ft.-lb.
5 ft.-lb.
6N-m
25 ft.-lb. 2 ft.-lb.
34N-m 3N-m
25 ft.-lb. 2 ft.-lb.
34N-m 3N-m
45 ft.-lb.
61 N-m
Instructions BI006008
Industrial
Control
Equipment
MAINTE ANCE OF INDUSTRIAL CONTROL EQUIPMENT

ATTENTION: Se eing energized Industrial Control Equipment can be hazardous. Severe injury or death can result from
electrical shock, b rn, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout
control equipment rom power sources, and release stored energy, if present. Refer to National Fire Protection Association
Standard No. NF A70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources
(LockoutlTagout) nd OSHA Electrical Safety Related Work Practices for safety related work practices, including
.
, procedural require ents for lockout-tagout, and appropriate work practices, personnel qualifications and training
requirements wher it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or
I
I near exposed eirc it parts.
'I
Periodic Inspectio -Industrial

control equipment s ould be inspected
periodically. Inspecti n intervals should
be based on enviro mental and
operating conditions and adjusted as
indicated by experie ceo An initial
inspection within 3 t 4 months after
installation is sugge ted. See National
Electrical Manufacturers Association
(NEMA) Standard N . ICS 1.3,
Preventive Mainten nce of Industrial
Control and System Equipment, for
general guidelines f r setting-up a
periodic maintenanc program. Some
specific guidelines f r Allen-Bradley
products are listed blow.
Contamination - I inspection reveals
that dust, dirt, moist re or other
contamination has r ached the control
equipment, the cau e must be
eliminated. This co Id indicate an
incorrectly selected r ineffective
enclosure, unsealed enclosure openings
(conduit or other) or ncorrect operating
procedures. Replac any improperly
selected enclosure ith one that is
suitable for the envir nmental conditions
- refer to NEMA St ndard No. 250,
Enclosures for Elect fcal Equipment for
enclosure type desc iptions and test
criteria. Replace an damaged or
embrittled elastomer seals and repair or
replace any other da aged or
malfunctioning parts (e.g., hinges,
fasteners, etc.). Dirt wet or
contaminated contro devices must be
replaced unless the can be cleaned
effectively by vacuu ing or wiping.
Compressed air is n t recommended
for cleaning becaus it may displace
dirt, dust, or debris i to other parts or
equipment, or dama e delicate parts.
Cooling Devices -Inspect blowers
and fans used for for ed air cooling.
Replace any that ha e bent, chipped, or
missing blades, or if he shaft does not
turn freely. Apply po er momentarily to
check operation. If u it does not
operate, check and r place wiring, fuse,
or blower or fan mot r as appropriate.
Clean or change air Iters as
recommended in the product manual.
Also, clean fins of he t exchangers so
convection cooling is not impaired.
Hazardous Location Enclosures \ ATTENTION: Explosion hazard.

Always disconnect power before
opening enclosures in hazardous
locations. Close and secure such
I enclosures before reapplying power.
'I
NEMA Types 7 and 9 enclosures require

careful handling so machined flanges do
not get damaged. For removable
covers, remove the cover and set aside
with machined surface up. For hinged
covers, open the cover fully and restrain
in the full open position if necessary.
Clean and examine the flanges on both
the body and cover before reassembly.
If there are scratches, nicks, grooves or
rust on the mating surfaces, replace the
body or cover as necessary. Examine all
bolts and replace any that have
damaged threads. Also check mating
threads for damage and replace
enclosure if necessary. Covers and
bodies of some enclosures are
manufactured as matched sets (not
interchangeable). The manufacturer
should be consulted before replacing a
cover or body unless it is specified by
the manufacturer as interchangeable.
Operating Mechanisms - Check for
proper functioning and freedom from
sticking or binding. Replace any broken,
deformed or badly worn parts or
assemblies according to individual
product renewal parts lists. Check for
and retighten securely any loose
fasteners. Lubricate if specified in
individual product instructions.
Note: Allen-Bradley magnetic starters,
contactors and relays are designed to
operate without lubrication - do not
lubricate these devices because oil or
grease on the pole faces (mating
surfaces) of the operating magnet may
cause the device to stick in the "ON"
mode. Some parts of other devices are
factory lubricated - if lubrication during
use or maintenance of these devices is
needed, it will be specified in their
individual instructions. If in doubt,
consult your nearest Allen-Bradley
Sales Office for information. See page
10-1.
Contacts - Check contacts for

excessive wear and dirt accumulations.
Vacuum or wipe contacts with a soft
cloth if necessary to remove dirt.
Contacts are not harmed by
discoloration and slight pitting. Contacts
should never be filed, as dressing only
shortens contact life. Contact spray
cleaners should not be used as their
residues on magnet pole faces or in
operating mechanisms may cause
sticking, and on contacts can interfere
with electrical continuity. Contacts
should only be replaced after silver has
become badly worn. Always replace
contacts in complete sets to avoid
misalignment and uneven contact
pressure.
Vacuum Contactors - Contacts of
vacuum contactors are not visible, so
contact wear must be checked indirectly.
Vacuum bottles should be replaced
when:
1.
The estimated number of operations

equals one million, or
2.
The contact life line indicator shows

need for replacement, or
3.
The vacuum bottle integrity tests

show need for replacement.
Replace all vacuum bottles in the

contactor at the same time to avoid
misalignment and uneven contact wear.
If the vacuum bottles do not require
replacement, check and adjust
overtravel to the value listed on the
maintenance instructions.
Terminals - Loose connections in
power circuits can cause overheating
that can lead to equipment malfunction
or failure. Loose connections in control
circuits can cause control malfunctions.
Loose bonding or grounding
connections can increase hazards of
electrical shock and contribute to
electromagnetic interference (EMI).
Check the tightness of all terminals and
bus bar connections and tighten
securely any loose connections.
Replace any parts or wiring damaged by
overheating, and any broken wires or
bonding straps.
Arc Hoods - Check for cracks, breaks,
or deep erosion. Arc hoods and arc
chutes should be replaced if damaged
or deeply eroded.
Maintenance of Industrial Control Equipment

Continued
Coils - If a coil exhibits evidence of

overheating (cracked, melted or burned
insulation), it must be replaced. In that
event, check for and correct overvoltage
or undervoltage conditions, which can
cause coil failure. Be sure to clean any
residues of melted coil insulation from
other parts of the device or replace such
parts.
Batteries - Replace batteries
periodically as specified in product
manual or if a battery shows signs of
electrolyte leakage. Use tools to handle
batteries that have leaked electrolyte;
most electrolytes are corrosive and can
cause burns. Dispose of the old battery
in accordance with instructions supplied
with the new battery or as specified in
the manual for the product.
Pilot Lights - Replace any burned out
lamps or damaged lenses.
Photoelectric Switches - The lenses
of photoelectric switches require
periodic cleaning with a soft dry cloth.
Reflective devices used in conjunction
with photoelectric switches also require
periodic cleaning. Do not use solvents
or cleaning agents on the lenses or
reflectors. Replace any damaged lenses
and reflectors.
Solid State Devices -
ATTENTION: Use of other than

factory recommended test equipment
for solid state controls may result in
damage to the control or test
qUiPment or unintended actuation of
the controlled equipment. Refer to
paragraph titled HIGH VOLTAGE
TESTING.
_.--_
... __ ..
_-
'1' Rocllwell Automation

Allen-Bradley
Solid state devices require little more

than a periodic visual inspection.
Discolored, charred or burned
components may indicate the need to
replace the component or circuit board.
Necessary replacements should be
made only at the PC board or plug-in
component level. Printed circuit boards
should be inspected to determine
whether they are properly seated in the
edge board connectors. Board locking
tabs should also be in place. Solid state
devices must also be protected from
contamination, and cooling provisions
must be maintained - refer to
paragraphs titled CONTAMINATION and
COOLING DEVICES on previous page.
Solvents should not be used on printed
circuit boards.
High Voltage Testing - High voltage
insulation resistance (IR) and dielectric
withstanding voltage (DWV) tests should
not be used to check solid state control
equipment. When measuring IR or DWV
of electrical equipment such as
transformers or motors, a solid state
device used for control or monitoring
must be disconnected before performing
the test. Even though no damage is
readily apparent after an IR or DWV
test, the solid state devices are
degraded and repeated application of
high voltage can lead to failure.
Locking and Interlocking Devices Check these devices for proper working
condition and capability of performing
their intended functions. Make any
necessary replacements only with
Allen-Bradley renewal parts or kits.
Adjust or repair only in accordance with
Allen-Bradley instructions.
BI006008
Maintenance After a Fault

Condition - Opening of the short
circuit protective device (such as fuses
or circuit breakers) in a properly
coordinated motor branch circuit is an
indication of a fault condition in excess
of operating overload. Such conditions
can cause damage to control
equipment. Before restoring power,
the fault condition must be corrected
and any necessary repairs or
replacements must be made to restore
the control equipment to good working
order. Refer to NEMA Standards
Publication No. ICS-2, Part ICS2-302 for
procedures.
Replacements - Use only
replacement parts and devices
recommended by Allen-Bradley to
maintain the integrity of the equipment.
Make sure the parts are properly
matched to the model, series and
revision level of the equipment.
Final Check Out - After maintenance
or repair of industrial controls, always
test the control system for proper
functioning under controlled conditions
that avoid hazards in the event of a
control malfunction.
For additional information, refer to
NEMA ICS 1.3, PREVENTIVE
MAINTENANCE OF INDUSTRIAL
CONTROL AND SYSTEMS
EQUIPMENT, published by the
National Electrical Manufacturers
Association, and NFPA70B,
MAINTENANCE, published by the
National Fire Protection Association.
Allen-Bradley, a Rockwell Automation Business, has been helping its customers im prove
productivity and quality for more than 90 years. We design, manufacture and support a broad
range of automation products worldwide. They include logic processors, power and motion control
devices, operator interfaces, sensors and a variety of software. Rockwell is one of the world's
leading technology companies.
~
Worldwide representation.---------------~)
Argentina' Australia' Austria' Bahrain' Belgium' Brazil, Bulgaria' Canada' Chile' China, PRC Colom bia Costa Rica' Croatia' Cyprus' Czech Republic' Denmark
Ecuador Egypt EI Salvador' Finland France' Germany' Greece' Guatemala' Honduras' Hong Kong' Hungary' Iceland' India' Indonesia' Ireland Israel' Italy
Jamaica' Japan' Jordan' Korea' Kuwait Lebanon' Malaysia' Mexico' Netherlands' New Zealand' Norway' Pakistan' Peru' Philippines' Poland Portugal
Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414382-2000 Fax: (1) 414382-4444
Publication 1c-906 - December 1994
Supersedes Publication IC-906 - February 1991
Copyright 1994 Allen-Bradley Company, Inc., aRockwell International company. Printed in USA
BI006008
Allen-B adley
BI006008
Important User Information
Allen-Bradley Company has produced quality Motor Control Centers

since 1948, meeting the requirements of all types of industries. We
sincerely believe that we can satisfy your exacting requirements.
This specification has been written to assist you in preparing bids for
Allen-Bradley CENTERLlNE@ Motor Control Centers. Use in
conjunction with Publication 2100-2.0.1, Specifications Checklist.
The following standards may be referred to in this document:

ANSI - American National Standards Institute
CSA - Canadian Standards Associates
EEMAC - Electrical & Electronic Manufacturers Association Canada
IEC - International Electrotechnical Commission
IEEE - Institute of Electrical & Electronic Engineers
NEC - National Electrical Code
NEMA - National Electrical Manufacturers Association
OSHA - Occupational Safety & Health Act
UL - Underwriters Laboratories
The following acronyms may be referred to in this document:
FCAN - Full Capacity Above Normal (applies to transformers)
FCBN - Full Capacity Below Normal (applies to transformers)
FVNR - Full Voltage Non-Reversing
FVC - Full Voltage Contactor
VFD - Variable Frequency Drive
FVR - Full Voltage Reversing
GFI - Ground Fault Circuit Interrupter (applies to lighting panels)
I/O - Input/Output
KAIC - Thousand Ampere Interrupting Capacity (fault current)
MCB - Main Circuit Breaker
MCC - Motor Control Center
MFD
Main Fusible Disconnect Switch
MLO - Main Lug Only

MTW - Machine Tool Wire
PLC - Programmable Logic Controller
RVAT - Reduced Voltage Autotransformer
SID - Star Delta or Wye Delta
SMC - Solid State Motor Controller
TS1W - Two Speed 1-Winding
TS2W - Two Speed 2-Winding
TS1WR - Two Spped 1-Winding Reversing
TS2WR - Two Speed 2-Winding Reversing
BI006008
Table of Contents
Page No.
Chapter
Gen ral Description & Typical Construction Drawings
Vert cal Section Information
S ctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lreways . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . .. . . . . . . . . . . . .. . . . .
s Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
orizontal Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rtical Bus
round Bus
eutral Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2
2-3
2-3
2-4
2-4
2-5
Inco ing Line and Metering Compartment Information. . . . . . . .

L ne Lug Compartment
ain Fusible Disconnect
ain Circuit Breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
etering Compartment.
3-1
3- 2
3- 2
3- 2
Unit Information
ounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
P wer Stabs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
andle . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
MA/EEMAC Wiring Class.
4
4-1
4-1
4-2
4-3
NEM /EEMAC Rated Controllers (Bulletin 2100) . . . . . . . . . . . . .

isconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C mbination Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6- 1
6-1
Unit for NEMA/EEMAC and Application Rated Design .. . . . . . .

F eders
P ogrammable Logic Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A Drives...................................................
S lid State. . . . . .. . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . .
L ghting Panels. .. . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . .
7-1
7-1
7-2
7-2
7-2
7-3
Nam plates.........................................
App ndix
A plying Ampere Rated Contactors
L fe-Load Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .
B lletin 100/ Bulletin 500 - Comparison by Horsepower
N MA/EEMAC Type & IP Rating
A vantages of CENTERLINE MCCs . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5- 1
5-1
Appl cation Rated Controllers (Bulletin 2400)

isconnecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C mbination Starters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-I
A-2
A- 3
A- 3
A-4
8
A
BI006008
BI006008
Chapter
General Description &

Typical Construction Drawings
The Motor Control Center (MCC) shall be Allen-Bradley Bulletin
2100 (NEMA) and Bulletin 2400 (Application Rated)
CENTERLINE consisting of structure or grouping of structures
with power bus, feed for power bus, and various types of units and
options for the units.
Each MCC shall be of dead front construction and shall incorporate
horizontal and vertical power bus, plus ground and neutral bus bars
as required. The vertical steel plug-in unit ground bus shall be a
standard feature.
The MCC shall consist of one or more vertical sections bolted
together to form a rigid, free-standing assembly and shall be so
designed as to permit future additions of vertical sections and
interchanging of units by the user. MCCs shall be constructed to
meet or exceed the requirements of the latest published standards of
NEMA, EEMAC, IEC, UL and CSA for motor control centers.
Typical Unit Construction

Stab Assembly
Captive Latch
Bulletin 509
Starter
CONTROL C IRCU IT
UNIT STAB
ASSE"BL Y
TRANSFORUER
Han dl e
Interlock
Circuit
Breaker
Control
Transformer
Secondary Fusing
Control
Transformer
__
)d===~~~~~m~;~~:ZZ:~
Q,;;
Disconnect
Han dl e
CONTROL
C IRCU IT
SECONOARY
FUSEBLOCK
HANDlE
"EC"AN IS"
Unit Identification
Nameplate
UNIT LATC" /
INTERLOCK
0.5 Space Factor
BI006008
1-2
Typical Section Construction

LiH Angle
Top Horizontal
Wireway Baffle
Removable Top
Plate
Top Horizonta
Wi reway Cover
Horizo~tal
and Vertico
Bus Support
Right Hand Unit

Support Assembly
(Verti cal Wi r eway)
Vertical
Power Bus
-~-Bus
Splice
Access Cover
Horizontal
Power Bus
Section Nameplate
Vertical Wireway Door

Left Hand
Center End Plate
Bus Cannection
Access Cover
........
Verticol Bus
Cover
-~-Unit Support
Pan
Sealing Strap
Top and Bottom
Left Hand Side

Plate ASSembIY~
Horizantal Ground
Bus Top or Bottom
Lef t Hand
Bot tom End P Iate
Bottom Support
Angle
_--------
___--
_-----/
----------r:--~r~>-~----_/-
Bottom Horizontal
Wireway Cover
BI006008
Chapter
Vertical Section Information

Sections
1. Vertical sections shall be rigid, free-standing structures with
heavy duty internal mounting angles running continuous within
the shipping block. Two clearance holes shall be provided in
each section for bolting or welding to the prepared mounting site.
Optional external mounting channels 1-112" x 3" (38.1mm x
76.2mm) shall be available. A removable continuous steel lifting
means shall be provided on all shipping blocks, except the
NEMA/EEMAC Type 3R and NEMA/EEMAC Type 4 designs
where lifting means is optional.
2. Standard Structure and Shipping Block Dimensions:
Front Only
Back-to-Back
15" (381mm)
20" (508mm)
25" (635mm)
30" (762mm)
40" (1 016mm)
Structure Width
20" (508mm)
20" (508mm)
Structure Height
90" (2286mm)
90" (2286mm)
Normal Number of
Structures Per Shipping
Block
3 (6 sections)
60" (1524mm)
60" (1524mm)
Structure Depth
Maximum Width of
Shipping Block
Any section wider than 20" (508mm) will constitute its own
shipping block. Sections using the 9" wide vertical wireway are
available in a 2-section shipping block.
3. The vertical sections shall be divided into twelve (12) half-space
factors, each half-space factor being 6-1/2" (165.1mm) high.
4. Removable end plates shall be used to cover the horizontal power
bus and horizontal wireway openings on each end of the MCC.
5. Each section shall be equipped with removable one piece top
plate and full metal side sheets (one on each side) to isolate each
vertical section.
6. All enclosure metal work shall have rounded edges and be tightly
fitted with no visible air gaps. Enclosures shall be designed and
built according to NEMA/EEMAC standards.
NEMA/EEMAC Type I shall be available.

NEMA/EEMAC Type 1 with gasketing (l G) in the unit insert
door areas shall be available.
NEMA/EEMAC Type 2 (NEMA/ EEMAC Type 1 with
driphood) shall be available.
BI006008
2-2
NEMA/EEMAC Type 12, completely gasketed (closed cell

neoprene), with a 2-piece bottom plate, shall be available.
Stainless steel NEMA/EEMAC Type 12 enclosures shall also
be available.
The NEMA/EEMAC Type 3R non walk-in enclosure (front
only applications) shall be physically built around the standard
structure, with a 5" (l27mm) open area to the unit door. The
single section door will be closed using a vault style handle
and will have a 2" (50.8mm) roof overhang. The overall
dimensions will be 92-1/2" high x 25-3/8" wide x 20-3/16"
deep (2350mm x 645mm x 766mm).
Stainless steel NEMAIEEMAC Type 4 enclosures shall also
be available.
Wireways
1. Horizontal wireways of standard sections, both top and bottom,
shall extend the full depth of the MCC. Each wireway shall
provide a minimum of 90 square inches (580.7 sq cm) of
unobstructed wiring space. The horizontal wireway shall be not
less than 6" (l52.4mm) high and shall extend the length of the
control center with a 25 square inch (l61.3 sq cm) opening
between sections. A single opening is supplied in 15" depth
(38lmm), and two openings are supplied in 20" depth (508mm)
sections. The wireways shall be isolated from all bus. Horizontal
wireways of back-to-back sections shall allow complete access
from the front section through to the back section. Horizontal
wireways shall have removable covers held closed by captive
screws.
The horizontal wireway of an incoming line section shall be 6"
high and T' deep (l52mm and 178mm), i.e., shall extend across
the incoming line lug section and be isolated from the incoming
line compartment with a barrier.
2. A full height vertical wireway shall be provided in each standard
vertical section and shall be isolated from the horizontal and
vertical bus. Vertical wireways shall be an integral part of each
section and shall be independent of plug-in units. The minimum
dimensions of the wireway shall be 4-3/8" wide and T' deep
(lllmm and 178mm). An optional 9" (228mm) wide vertical
wireway shall be available in a 25" (635mm) wide section. A
removable hinged door with 114 turn pawl type latches shall
cover the vertical wireway and provide access to wiring without
disturbing energized control units. In each section, the vertical
and horizontal wireways shall open to the front to allow wires to
be laid in place. Vertical wireway tie bars shall be an available
option.
BI006008
2-3
3. All structural metal parts shall undergo a multi-step cleaning,

rinsing, and painting process resulting in complete paint coverage
of uniform thickness. This process shall be maintained and
controlled by rigid quality control standards.
4. Surfaces shall be painted in accordance with the following:
Standard - Unless otherwise specified, all interior and exterior

surfaces shall be painted ANSI 49 medium light gray. The
vertical wireways and unit back plates shall be painted high
visibility gloss white.
Custom - When specified, all external surfaces except the
handle assembly surfaces and other door mounted equipment
shall be painted to the custom color requirement.
5. All unpainted parts shall be plated for corrosion resistance.

6. NEMA Type 3R MCCs shall have the exterior cabinet parts
finished with ANSI 49 medium light gray, ultraviolet resistant
paint that is UL recognized for outdoor use.
7. Stainless steel enclosure parts shall not be painted.
Bus Information
The power bus system shall be either aluminum or copper,
supported, braced and isolated by a bus support molded of a high
strength, non-tracking glass polyester material. Horizontal and
vertical buses shall be fastened together with a bus clamp assembly.
Minimum bus bracing of 42kA rms symmetrical shall be standard
with options available for 65kA and 100kA rms symmetrical.
Horizontal Bus Information

The horizontal bus shall be mounted near the horizontal center of the
structure to provide optimum heat distribution, power distribution
and ease of maintenance and splicing. It shall be mounted on~edge
in a vertical plane to provide maximum strength to magnetic forces.
It shall be mounted in recessed channels of the bus support molding
to protect against accumulation of dust and tracking between phases.
The horizontal bus shall be braced within each section and shall be
continuous in each shipping block.
The 25" (635mm) back-to~back motor control center shall have
a common horizontal power bus .
The 30" (762mm) and 40" (l016mm) back~to-backmotor
control center shall have separate horizontal buses. The
horizontal power buses are joined by a factory installed U~shaped
bus splice assembly.
-
The horizontal power bus ampere rating shall include:
BI006008
2-4
Tin plated aluminum 600A and 800A in 15" and 20" deep
front only, plus 30" and 40" deep back-to-back.
- Tin or silver plated copper 600A, 800A, l200A, l600A,
2000A and 2500A sizes shall be available in 15" or 20" deep
front only, as well as 30" or 40" deep back-to-back, and
3000A shall be available in 20" deep or 40" deep
back-to-back. In the 25" deep back-to-back design, l200A,
l600A, 2000A and 2500A bus shall be available.
Splicing horizontal buses shall be accomplished using a splice kit
of the same ampere rating as the horizontal power bus. Double
stud bus clamp assemblies comprised of flat washers and
preassembled nuts with conical washer shall be used. These
assemblies shall provide a minimum of two (2) 3/8" (9.52mm)
bolted onnections to each side of the splice. The splice
connections shall be front accessible for servicing with a torque
wrench. The location of all splices shall be indicated by a label
located on the inside of the vertical wireway door.
Vertical Bus
1. Each vertical bus bar shall be cylindrical to provide optimum
contact with the unit plug-in stab. The vertical bus shall be
continuously braced by a high strength non-tracking glass-filled
polyester material and sandwiched by a glass-filled
polycarbonate molded cover. It shall be isolated from the other
phases and the horizontal power bus.
Back-to-back structures shall be supplied with separate
vertical bus in both the front and rear sections providing the
same phasing on the units, both front and back. There shall be
a full twelve (12) space factor capability, both front and back
standard sections.
2. The vertical power bus ampere rating shall include:
Tin or silver plated copper tube rated 300A above and below
the horizontal power bus for an effective rating of 600A as
standard.
Tin or silver plated copper rod rated 600A above and below
the horizontal bus for an effective rating of l200A as an
option.
Ground Bus
1. The optional horizontal ground bus shall be unplated copper or
tin plated copper and can be located in the top and/or bottom
horizontal wireway.
The horizontal ground bus shall be 1/4" xl" (6.35mm x
25.4mm) with an effective 500A continuous rating or 1/4" x
BI006008
2-5
2" (6.35mm) x 50.8mm) with an effective 900A continuous

rating.
A pressure type mechanical lug shall be mounted on the
ground bus in the incoming line section.
2. The vertical plug-in zinc-plated steel ground bus shall be
supplied in each standard section (unplated copper or tin plated
copper vertical plug-in ground bus shall be available options).
The vertical ground bus shall be connected to the horizontal
ground bus to form a complete internal grounding system.
The vertical ground bus in combination with the unit ground stab
shall establish unit insert grounding before the plug-in power
stabs engage the power bus. Then, as the unit is withdrawn,
grounding shall be maintained until after the plug-in power stabs
are disengaged. The vertical ground bus dimensions shall be
3/16" x 3/4" (4.75mm x 19.05mm).
3. The optional vertical unit load ground bus shall be unplated
copper or tin plated copper and be connected to the horizontal
ground bus. The vertical load ground bus in combination with
the unit load ground connector, shall provide a termination point
for the load ground cable at the unit. This fixed connection shall
not have to be removed when the unit is withdrawn from the
MCC. The bus dimensions shall be 3/16" x 3/4" (4.76mm x
19.05mm).
Neutral Bus
The neutral bus when specified in four wire systems shall be
provided across the full width of the MCC. The horizontal neutral
bus shall be located above or below the horizontal bus determined by
the application. Connection to the neutral shall be made through
neutral connection plates in the various sections. A neutral
termination plate shall also be available for neutral terminations at
the MCC.
BI006008
BI006008
Chapter
Incoming Line and Metering

Compartment Information
Line Lug Compartment (MLO)
1. The main incoming line lug compartment shall be available in
either top or bottom entry and shall utilize mechanical or crimp
compression lugs.
NEMA/EEMAC 2-hole spacing and lugs for either aluminum or
copper conductor shall be used. Dimensions: 1-3/4" (44.45mm)
between hole centers.
2. Incoming line lug compartments for 300A, 600A, SOOA, l200A,
l600A, 2000A and 2500A shall be accessible from the front for
front only structures, and 30" (762mm) and 40" (l016mm)
back-to-back structures and 3000A shall be available in 20" deep
or 40" deep back-to-back with the following space factor
requirements:
Top wireway: 600A with pullbox (top entry only, lugs in rear
portion of partitioned top horizontal wireway).
1.0 space factor: 300A and 600A
1.0 space factor: SOOA and 1200A with pullbox (top entry
only, lugs in rear portion of partitioned top horizontal
wireway).
1.5 space factors: 600A, SOOA.
2.0 space factors: SOOA, 1200A.
6.0 space factors: 600A, SOOA, 1200A, 1600A, 2000A,
2500A, 3000A.
3. Where space is at a premium, two additional incoming line lug

compartments shall be made available.
A 6.0 space factor 10" (254mm) wide incoming line lug

compartment with crimp style lugs only. For front only motor
control centers (l200A maximum).
Placement of the incoming lugs in a corner section (2000A
maximum).
BI006008
3-2
Incoming Line and Metering Compartment Information
Main Fusible Disconnect (MFD)

1. The main fusible disconnect compartment shall consist of a heavy
duty switch and fuse block assembly. It shall be front accessible
and have a removable protective barrier to reduce the possibility
of accidental contact with line terminals.
Main fusible disconnect switches rated through 400A shall be

supplied with a heavy duty disconnect switch with visible
blade type movable contacts and fuse blocks.
Mains rated 600, 800 and 1200A shall incorporate a bolted
pressure contact switch with visible blades and viewing
window.
Main fusible disconnects shall be available for 1600 and 2000
amperes and shall require a full 30" (750mm) wide section.
Main fusible disconnect switches rated through 800A shall be
suitable for service entrance equipment and shall be located in
the top most or bottom most unit space. Mains rated 1200A
may require ground fault for service entrance labeling.
2. The main fusible disconnect compartments through 600A shall be

supplied with either Class J, R, or H fuse blocks, and
compartments above 600A shall be supplied with Class L fuse
blocks.
Main Circuit Breaker (MCB)

The main circuit breaker shall be inverse time (thermal magnetic or
solid state) type. It shall be front accessible and have a removable
protective barrier to reduce the possibility of accidental contact with
line terminals.
Mains rated through 1200A shall be located in the top most or
bottom most unit space. The 1600A, 2000A, and 2500A breakers
shall require a 30" wide full section.
Metering Compartment
Metering shall be available either in separate metering unit
compartments or in a line lug compartment. Ammeter, voltmeter
and watthour metering shall be available as analog devices, with or
without local switching. Digital metering or digital metering system
units shall also be available, as shall power monitor systems, for
either 3-phase, 3-wire or 3-phase, 4-wire systems.
BI006008
Chapter
Unit Information
(General Information applying to all units.)
Mounting
1. Plug-in units shall consist of a unit assembly, unit support pan
and unit door assembly.
2. Each plug-in unit shall be supported and guided by a removable
unit support pan, so that different unit arrangements are easily
accomplished. The rearrangement of a unit support pan from one
location to another shall be accomplished without the use of tools.
Specific to 0.5 space factor plug-in units:
After insertion, each plug-in unit shall be held in place by a
single latch / interlock mechanism requiring no tools to operate.
The latch / interlock mechanism shall have two (2) locked
positions for the unit: Normal operating - where the power stabs
engage the vertical bus, and service position - where the power
stabs are disconnected from the vertical bus, but separate control
power can still be connected. Padlocking shall be possible in the
service position.
Specific to 1.0 through 5.0 space factor plug-in units:
After insertion, each plug-in unit shall be held in place by two (2)
or more multi-turn latches, located at the front of the unit. At
least one latch shall be located at the top of the insert and one at
the bottom, for front accessibility and installation convenience. A
service position shall be provided with the unit supported in the
structure but disengaged from the bus. Padlocking shall be
possible in this position.
3. Both NEMA/EEMAC Bulletin 500 apparatus and application

rated Bulletin 100 apparatus shall use the same structure without
modification.
Power Stabs
1. The unit plug-in power stab assemblies shall be tin plated copper
for a low resistance connection and designed to tighten during
heavy current surges.
2. The stabs shall be backed by stainless steel spring clips to provide
and maintain a high pressure four-point connection to the vertical
bus. They shall be free floating and self aligning during plug-in.
Wiring from the unit disconnecting means to the plug-in stabs
shall not be exposed at the rear of the unit. The power cable
BI006008
4-2
Unit Information
termination at the plug-in stab shall be a maintenance free crimp

type and shall be mounted in a two piece support assembly. This
support shall provide a separate isolated pathway for each phase
minimizing the possibility of a unit fault condition reaching the
power bus system.
3. Starter and contactor units requiring less than six (6) space factors
shall be plug-in. NEMA/EEMAC units sizes 1 through 5 and
ampere rated units 18A through 304A shall be plug-in units.
Stab assemblies shall be sized to match the rating of the units,
with a dual stab arrangement being used on NEMAlEEMAC Size
5 and application rated larger than l80A.
4. The stab openings shall consist of two rectangular openings per
phase. Each opening shall be 1/2" wide x 1-1/2" long (l3mm x
39mm).
5. Automatic or manual shutters or protective caps shall be available
for isolation of unused stab openings.
Handle
1. An industrial, heavy duty, flange mounted handle mechanism
shall be supplied for the control of each disconnect switch or
circuit breaker. This mechanism shall be engaged with the
disconnect device at all times as an integral part of the unit
regardless of unit door position.
2. The operator handles shall pivot in the horizontal plane in
one-half space factor units and in the vertical plane in one space
factor and larger units. The on-off condition of the disconnecting
means shall be indicated by the handle position, red and green
colored indicators (which include the words ON and OFF), and
the international symbols I and 0 along with a pictorial indication
of the handle position. It shall be possible to lock the handle in
the OFF position with up to three (3) 3/8" (9.5mm) diameter
shackle padlocks. All operating handles shall be of a
non-conductive material.
Trip indication on circuit breaker handles (circuit breakers rated
through 2000A) shall be included.
3. The operator handle of all units shall be interlocked with the unit
door so that the disconnect means cannot be switched to the ON
position unless the unit door is closed. A means shall be provided
for purposely defeating this interlock during maintenance or
testing. This interlock shall also prevent opening the unit door
unless the disconnecting means is in the OFF position. An
externally operated defeater requiring the use of a tool shall
provide access to the unit without interrupting service.
BI006008
Unit Information
4-3
4. The operator handle shall be interlocked with the unit so that the
unit cannot be inserted or withdrawn with the operator handle in
the ON position.
NEMA/EEMAC Wiring Class

The MCC shall be wired in accordance with the required NEMA/
EEMAC Class and Type as defined by NEMA Standard ICS 2-322.
1. NEMA/EEMAC Class I - Standard wiring diagrams for

individual units shall consist of drawings that identify electrical
devices, connections, and terminal numbering designations.
Individual unit diagrams are supplied for each unit.
2. NEMA/EEMAC Class II - Similar to Class I but includes
interwiring between units, i.e. electrical interlocking, etc., as
specifically described in an overall interconnection diagram
supplied by the purchaser. A chart indicating factory
interconnections shall be supplied.
3. NEMA/EEMAC Class IS & lIS - Similar to Class I and Class II
except custom drawings with special terminal numbering
designations instead of manufacturer's diagrams.
4. NEMA/EEMAC Type A - User's power and control connections
shall be made directly to the devices within the unit (available
only in Class I wiring).
5. NEMA/EEMAC Type B - Pull-apart terminal blocks shall be

supplied for user control terminations.
Type B user field load wiring for combination motor control
units size 3 or smaller shall be designed as B-D or B-T,
according to the following:
-B-D connects directly to the device terminals, which are
located immediately adjacent and readily accessible to the
vertical wireway.
-B-T connects directly to a load terminal block in or adjacent
to the unit.
Type B user field load wiring for combination motor control
units larger than size 3, and Bulletin 2400 units, and for feeder
tap units, shall connect directly to unit device terminals.
6. NEMA/EEMAC Type C - All features of NEMA/EEMAC Type
B shall be furnished, in addition to track mounted non pull-apart
terminals in a master terminal board compartment, located in the
top or bottom most unit space.
BI006008
BI006008
Chapter
NEMA/EEMAC Rated
Controllers (Bulletin 2100)
Disconnecting
1. Fusible disconnect switches shall be available in combination
starter units.
These disconnects shall have blade type contacts and shall be
supplied with either Class J, R, H, L. HRCII-C, or CC fuse
clips as dictated by available fuse size.
Unit disconnect requirements above 400A shall utilize a
bolted pressure contact switch with visible blade disconnect
mechanism.
2. Circuit breakers shall be available in combination starter units.

3. Circuit breaker type combination starter units shall be provided
with instantaneous circuit breakers (HMCP/GMCP) or with
inverse time (thermal magnetic or solid state) circuit breakers.
The NEMA/EEMAC unit withstand at 480V when the HMCP
circuit breaker disconnecting means is used through Size 5
starters shall be up to 100kA rms symmetrical (50kA at
600V). The rating is without the use of a limiter attachment.
Combination Starters
Starters and contactors shall be available in FVC, FVNR, FVR,
TSIW, TS2W, and RVAT using NEMA/EEMAC Bulletin 500
components to meet specified requirements, in the standard vertical
space factor configuration; also available in NEMA/EEMAC 0.5
space factor Size 1 horizontal design.
1. Magnetic starters and contactors shall be Allen-Bradley Bulletin

500 components to meet specified requirements. They shall be
UL Listed and CSA Certified and meet basic internal codes as
practical.
Coils on all contactors shall be easy to inspect.

Starter units for use with Bulletin 500 contactors shall be
supplied with either:
Bulletin 592 overload relays which are directly heated
eutectic alloy rachet type and utilize class 20 ambient
insensitive type W heater elements. A normally open
isolated alarm contact shall be available.
BI006008
5-2
NEMAlEEMAC Rated Controllers (Bulletin 2100)
Solid state overload relay:

SMP-1 shall provide basic overcurrent and phase loss
protection;
SMP-2 shall provide SMP-1 features plus selectable
ground fault and jam protection and adjustable trip class;
SMP-3 shall provide SMP-2 features plus
communication capabilities and trip cause indication.
SMP-1 and SMP-2 shall provide 1 N.O. and 1 N.C.
isolated auxiliary contact, and SMP-3 provides 1 N.C.
auxiliary contact and 1 N.O. triac output.
2. Control wiring 16 AWG(1.3mm 2) shall be 90C minimum,
machine tool wire (MTW), VW-l rated copper with 14 AWG
(2.1 mm 2 ) wire as optional. Power wiring shall be 90C
minimum, VW-l rated copper conductor size number 10 AWG
(5.3mm 2 ) minimum.
3. Unit control power shall be provided by a control circuit

transformer, separate control source, or common control.
The control circuit transformer shall be mounted within the
unit with a VA of at least twice the sealed VA of the starter.
The secondary side of the control circuit transformer shall
have one leg fused and the other leg grounded. Primary
protection, when required, shall be provided by an inherently
protected control circuit transformer or by the use of primary
fusing.
The separate control source shall have available an auxiliary
contact on the disconnecting means with an option for a
separate control fuse.
The common control source shall operate at line voltage with
an option for common control fusing.
4. Terminal blocks, when specified, shall be mounted within the unit
insert located in front for easy accessibility. Control terminal
blocks shall be pull-apart on plug-in units for easy removal of
the unit from the structure. Terminal blocks on non plug-in
factory mounted units shall be fixed type.
1.0 space factor and larger units shall have a pull-apart

terminal block assembly consisting of a male and female
component held together with captive screws. The assembly
shall be designed to withstand the effects of vibration, yet able
to be pulled apart without difficulty. The terminals of both
portions of the assembly shall be recessed to isolate them from
accidental contact when withdrawn. Terminal marking shall
be provided identifying terminations.
0.5 space factor units, control pull-apart blocks shall be
10-pole (7-pt. active) rated lOA. 300V with #14
AWG(2.1 mm 2 ) maximum wire size.
BI006008
NEMA/EEMAC Rated Controllers (Bulletin 2100)
5-3
Power pull-apart blocks shall be 3-pole rated, 60A, 600V and

shall be supplied on NEMAJEEMAC Size I and 2 starters
with a maximum wire size of #4 AWG (2Imm 2). A non
pull-apart block rated 195A, 600V shall be supplied for Size 3
starters with 1/0 AWG (53mm 2 ) maximum wire size. Power
terminal blocks shall not be supplied on Size 4 and larger
starter units.
5. Each unit shall be provided with a removable door mounted on

removable pin type hinges which allow the door to swing open at
least 110. Doors shall be removable from any location in the
center without disturbing any other doors. The unit doors shall be
fastened to the stationary structure so that it can be closed to
cover the unit space when the insert has been removed. The unit
doors shall be held closed with a minimum of a single 1/4 turn
pawl type latch designed to resist forces during fault conditions.
Each starter door shall be provided with an external low profile
overload reset button.
Units shall be furnished with Allen-Bradley Bulletin 800T

30.5mm type 4/l3 water tight/ oiltight pushbuttons, selector
switches or pilot lights and shall be mounted using a through
the door approach on one-half space factor units and mounted
in a door mounted control station which is easily removable
using captive screws for one space factor and larger units.
Dual function units may be utilized.
A full line of Allen-Bradley accessory equipment including
auxiliary contacts, relays, timers, solid-state relays, motor
winding heaters, and ground fault devices shall be available.
BI006008
BI006008
Chapter
Application Rated Controllers

(Bulletin 2400)
Disconnecting
1. Fusible disconnect switches shall be available in combination
starter units.
These disconnects shall have blade type contacts and shall be
supplied with either Class J, HRCII-C, or CC fuse clips as
dictated by available fuse size.
2. Circuit breakers shall be available in combination starter units.
3. Circuit breaker type combination starter units shall be provided

with instantaneous circuit breakers (HMCP/GMCP) or with
inverse time (thermal magnetic or solid state) circuit breakers.
The ampere rated unit withstand at 480V when the HMCP

circuit breaker disconnecting means is used through 304A
starters will be up to 42kA rms symmetrical (25kA at 600V).
The rating is without the use of a limiter attachment.
The ampere rated unit withstand at 480V, when the type
GMCP magnetic circuit breaker disconnecting means is used
through 75A, shall be up to 25kA rms symmetrical.
Applications greater than 75A will use HMCP circuit breakers
to meet the available fault current.
Combination Starters
Starters and contactors shall be available in FVC, FVNR, FVR types
using application rated Bulletin 100 components to meet specified
requirements.
1. Magnetic starters and contactors shall be Allen-Bradley Bulletin

100 components to meet specified requirements. Both types shall
be UL Listed and CSA Certified and shall meet basic internal
codes as practical.
Coils on all contactors shall be easy to inspect.

Starter units for use with Bulletin 100 contactors shall be
supplied with either:
3-pole Bulletin 193 overload relays, which are ambient
compensated, have single phase sensitivity, and offer class
10 tripping characteristics. Normally open isolated alarm
contact shall be available.
BI006008
6-2
Application Rated Controllers (Bulletin 2400)
Solid state overload relay:

SMP-l shall provide basic overcurrent and phase loss
protection;
SMP-2 shall provide SMP-l features plus ground fault
and jam protection and adjustable trip class;
SMP-3 shall provide SMP-2 features plus communiation
capabilities and trip cause indication.
SMP-l and SMP-2 shall provide 1 N.O. and 1 N.C.
isolated auxiliary contact, and SMP-3 shall provide 1 N.C.
auxiliary contact and 1 N.O. triac output.
2. Control wiring 18 AWG(0.8mm 2 ) shall be 90C minimum, 18

AWG (0.8mm 2) machine tool wire (MTW), VW-l rated copper
with 16 AWG (1.3mm 2) wire as optional. Power wiring shall be
90C minimum, VW-l rated copper conductor size number 10
AWG (5.3mm 2 ) minimum.
3. Unit control power shall be provided by a control circuit
transformer or separate control source.
The control circuit transformer shall be mounted within the

unit with a VA of at least twice the sealed VA of the starter.
The secondary side of the control circuit transformer shall
have one leg fused and the other leg grounded. Primary
protection shall be provided by an inherently protected control
circuit transformer or by the use of primary fusing.
The separate control source shall have available an auxiliary
contact on the disconnecting means with an option for a
separate control fuse.
4. Terminal blocks, when specified, shall be mounted within the unit
insert located in front for easy accessibility. Control terminal
blocks shall be pull-apart on plug-in units for easy removal of
the unit from the structure.
1.0 space factor and larger units shall have a pull-apart

terminal block assembly consisting of a male and female
component held together with captive screws. The assembly
shall be designed to withstand the effects of vibration, yet able
to be pulled apart without difficulty. The terminals of both
portions of the assembly shall be recessed to isolate them from
accidental contact when withdrawn. Terminal marking shall
be provided identifying terminations.
0.5 space factor units, control pull-apart blocks shall be
10-pole rated lOA. 300V, with #14 AWG(2.1mm 2) maximum
wire size.
Power terminal blocks shall not be supplied on Bulletin 2400
units.
5. Each unit shall be provided with a removable door mounted on

removable pin type hinges which allow the door to swing open at
least 110. Doors shall be removable from any location in the
BI006008
Application Rated Controllers (Bulletin 2400)
6-3
center without disturbing any other doors. The unit doors shall be
fastened to the stationary structure so that it can be closed to
cover the unit space when the insert has been removed. The unit
doors shall be held closed with a minimum of a single 1/4 turn
pawl type latch designed to resist forces during fault conditions.
Each starter door shall be provided with an external low profile
overload reset button.
Units furnished with pushbuttons, selector switches or pilot
lights shall be mounted using a through-the-door approach on
one-half space factor units and mounted in a door mounted
control station which is easily removable using captive screws
for one space factor and larger units. Dual function units may
be utilized.
For application rated units: Pushbuttons, selector switches
and pilot lights will be 22.5mm IEC style with a minimum
rating of NEMA/EEMAC Type 13, IEC 144/IP65 protection.
A full line of Allen-Bradley accessory equipment including
auxiliary contacts, relays, timers, solid-state relays, motor
winding heaters, and ground fault devices shall be available.
BI006008
BI006008
Chapter
Units Used in Both

NEMA/EEMAC and Application
Rated Design
Feeders
1. Fusible disconnect switches shall be available from 30 to 1200
amperes.
These disconnects shall be visible blade type and supplied

with either Class J, R, H, L, or CC fuse clips as dictated by
available fuse size (0.5 space factor units shall be Bulletin
I94R).
Unit disconnect requirements above 400A shall utilize a
bolted pressure contact switch with visible blade disconnect
mechanism.
Dual 30, 60, or 100A in any combination shall be available in
a single unit.
0.5 space factor units with horizontal handles shall be
available through 30A.
2. Circuit Breakers shall be available from ISO to 1200A frames.
Feeder circuit breakers shall be thermal magnetic circuit

breakers. The interrupting rating of thermal magnetic circuit
breakers shall meet or exceed the specified available fault
current.
Dual 150A frame circuit breakers in any combination shall
be available in a single unit.
0.5 space factor units with horizontal handle shall be
available through 225A.
Programmable Logic Controllers

The complete line of Allen-Bradley programmable controllers shall
be available including Bulletin 1771 equipment and Bulletin 1746
SLC 500.
I/O racks shall be available in 4, 8, and 16 slot configurations as:
Basic unit - no plug-in stabs, Basic unit - with plug-in stabs (8
slot I/O card maximum) with disconnecting means and control
transformer.
Viewing windows in the door to permit visual verification of the
I/O status indicators shall be provided.
BI006008
7-2
Units Used in Both NEMNEEMAC and Application Rated Design
System processors, power supplies, auxiliary power supplies, rack

mounted power supplies and a full line of input and output cards
can be provided.
The I/O rack shall be capable of accepting an adapter module

allowing it to function with a remote processor through a single
communications cable.
When I/O racks are factory wired and have an I/O rack in each
shipping split, interconnections between I/O racks shall be
through a single communications cable, thereby eliminating the
need to reconnect large bundles of control wires at the jobsite.
A 40" (l0 16mm) wide two-door enclosure shall be available for

housing up to (3) 16-s10t I/O racks and associated peripheral
equipment.
Terminal connection points shall be made available.
AC Drives
Variable frequency AC drives shall be available from 1 to 200Hp.
All drives will incorporate a disconnecting means, overload
protection, and a means to view drive indicators and shall be
manufactured by Allen-Bradley.
Solid State
The Allen-Bradley Bulletin 150 SMC-2 and SMC PLUSTM
controllers shall be available. Integral to the controller will be the
disconnecting means, isolation contactor and fusing for SCR and
branch circuit protection.
Solid state controllers through 400HP at 480V for standard duty

applications shall be available.
Transformers
Lighting transformers shall be available. Insulation will be Class H
for 80C rise.
1. Single phase transformers through 50kVA shall be available.

Three phase transformers through 45kVA shall be available.
2. Tap arrangement on all three phase transformers shall be two (2)

2-1/2% FCAN, while the single phase transformers above
37-1!2kVA will have two (2) 2-112% taps and four (4) 2-112%
taps FCAN and FCBN, respectively.
BI006008
Units Used in Both NEMA/EEMAC and Application Rated Design
7-3
Lighting Panels
Lighting panels shall be available in single phase 3 wire and three
phase 4 wire with or without main breaker.
1. Branch breaker shall have an interrupting capacity of 10,000 or

22,000A rms symmetrical.
2. All branch breakers shall be bolt-on type with a maximum of 42
one pole breakers.
3. Available breakers shall include one, two and three pole breakers
and single pole GFIs.
4. Power panels shall be available in 4801277V 3-phase 3- or

4-wire with or without main breaker, with a configuration of I, 2
and 3 pole branch breakers as required with interrupting rating up
to 65kA.
BI006008
BI006008
Chapter
Nameplates
1. Master nameplate, when specified, shall be 6" x 2" (l52.4mm x
50.8mm), white with black engraved characters. Available letter
sizes shall be 1" (25.4mm), 1/2" (l2.7mm), 3/8" (9.53mm) or
1/4" (6.35mm) Number of lines and characters are dependent
upon letter size.
2. Unit nameplates shall be provided. Dimensions shall be 3-5/8" x
1-1/8" (92.07mm x 28.57mm). Engraved characters shall be
3/16" (4.76mm) high.
Blank cardholder shall be available for customer insert of

printed card. They shall be clear.
Engraved acrylic nameplates shall be available for 3 lines of
15 characters per line. They shall be white with black
characters or black with white characters.
Engraved phenolic nameplates shall be available for 3 lines of
15 characters per line. They shall be white with black
characters, black with white characters, or red with white
characters.
3. Nameplates shall be attached using two steel self-tapping screws.
Stainless steel screws shall be optional.
4. Units shall have an identification label, indicating either a catalog
number or serial number description, and shall be located inside
of the unit compartment.
S. Each vertical section shall have a stamped metallic identification
nameplate, indicating serial number, bus rating and vertical
section reference numbering. The nameplate shall be externally
mounted near the center of the vertical wireway door of each
section.
BI006008
BI006008
Appendix
Applying Ampere Rated Contactors

The ampere ratec performance philosophy is an integral part of the selection procedure. The user must first
identify the u ilization category of the specific application, then tentatively choose a product that has a
capability for handling the intended load in that utilization category. Finally, the user must check that the
manufacture's listed contact life in the appropriate utilization category is adequate for the specific
application. n some instances, proper selection of an ampere rated contactor means a contactor that is
one or two s zes larger than what may be initially indicated on a ratings table must be selected in order to
give the desi ed contact life.
Ampere rated stardards dictate that manufacturers show ratings and performance capabilities under different
utilization ca egories. The most common utilization categories for AC contactors are listed in the table
below.
Utilization
Category
AC1
AC2
AC3
AC4
Typical Duty
~on-inductive or slightly inductive loads
ptarting of slip-ring motors

~tarting of squirrel cage motors and switching off only after the motor is up to speed
~tarting of squirrel cage motors with inching and plugging duty
NOTE: In an AC3 ap Iication, the contactor will never interrupt more than the motor's full load current. If the application requires
interrruption of curren greater than motor FLC, it is an AC4 application.
AC3 and AC4 cat~gories are the most important for someone applying contactors to standard industrial
motors, so tt ese will be addressed in more depth. It is important to remember when looking at these
utilization ca egories that AC3 and AC4 are pure, laboratory test conditions. Users should not make the
incorrect aSE umption that AC3 means "normal duty," while AC4 is "heavy duty." AC3 and AC4 relate to
the different ests that a contactor must pass in order for a manufacturer to claim a specific rating or
contact life. The test conditions within ampere rated only simulate the currents that would be
encountered in specific applications, and as a result, relating these test conditions to actual application
requirement may not always be valid.
Manufacturers ty ically show contactor performance information in the form of curves on a graph with contact
life on one a is and operational current on the other. Users will use these life-load curves to help
determine if he contactor selected from a ratings table has an estimated contact life that the user feels is
adequate for the application. If it does not, the life-load curves will be used to select an appropriate
larger size c mtactor which will provide this life.
Since ampere rat 3d based devices are generally rated closer to their ultimate capabilities than NEMA based
products, us 3 of the curves is necessary for users to achieve the same application confidence level with
ampere rate j based products that normally is achieved with NEMA based devices automatically. Users
should be ca reful, however, not to read more into the curves than is intended. The curves are a
manufacture's report of performance achieved under laboratory test conditions. Actual application
contact life V1 ill often vary because in practice, pure AC3 and AC4 applications are not common.
BI006008
A-2
Life-Load Curves
The Bulletin 100 ampere rated based contactors used in Bulletin 2400 MCC units are designed for superior
performance in a wide variety of applications. When selecting IEC based products, the user must give
consideration to the specific load, utilization category, and required electrical life of the application. The
life-load curves shown here are based on Allen-Bradley tests according to the requirements as defined
in IEC 158-1. Since contact life in application conditions is dependent upon environmental conditions
and duty cycle, actual application contact life may vary from that indicated by the curves shown. To find
the contactor's estimated electrical life, follow these guidelines:
1. Choose the appropriate graph for the utilization category. A chart showing typical duty for each category is
shown below.
2. Locate the intersection of the life-load curve of the appropriate contactor with the application's operational
current (Ie) found on the horizontal axis.
3. Read the estimated contact life in millions of operations along the vertical axis.
-1-----11--t----1-+-+++++---f+--I-+-II++-+-IIt+tf--+I-+~l_+_t+_I_H
-f--------1f-----+-J-+-+-H++---I+-H--II-I-t+lIH-l-I----+l--t-t---IH-H-l-H
""r----jI--t-----1-f-t+t++---I+-H--II-I-t+lIH-l-I----+t-+t---IH-t-H't1
""f----f---t-----1-+-t+t++---I+-H--II-I-t+lIH-tl---+t-+t---IH-H-l+1
OPERATIONAL CURRENT Ie (AMPERES)
",
""I-----l-I-+-HI-++++--IH-+-Ittt--Hlt+tt--tt+t---t-~ttti
OPERATIONAL CURRENT Ie (AMPERES)
BI006008
A-3
Bulletin 100 I Bulletin 500

Comparison by Horsepower
Bu letin
Bulletin
00
100
Ca alog
Nu jnber
A1 ~N*3
A1 SN*3
Current
Ratings
18A
18A
A2 ~N*3
24A
3 Phase Horsepower Ratings
200V
230V
7.5
A3 bN*3
30A
7.5~-~
A3 SN*3
A4 pN*3
38A
10
45A
460V
575V
I
10
10
15
15
20
20
25
25
30
13400
40
50
A6 bN*3
A7 pN*3
60A
15
15
20
75A
20
25
B11 ON*3
110A
25
30
B11 ON*3
110A
30
40
75
BH ON*3
180A
40
50
100~125
50
60
180A
60
60
150
150
250A
75
75
175
200
B2t ON*3
B3( ON*3
B4( ON*3
250A
100
200
300A
100
250
300
300A
125
150
350
400
600A
150
200
400
600A
200
250
NEMAlEEMAC Type
IP Rating Rating
IP
Rating
II
Type 1
Type 1 with gasket
Type3R
Type 4
Type 12
.
=i=.
Size 2
Size 3
-
Size 4
100
B2t ON*3
NEMAlEEMAC
Type
Size 1
BH ON*3
B6( ON*3
B6( ON*3
NEMA
Size
---
IP 40
IP40
IP 65
IP43
---:-:=-=-=----IP 54
------
Size 5
250
Size 6
600
Size 7
BI006008
A-4
Advantages of the
Allen-Bradley Bulletin 2100 and 2400
CENTERLINE Motor Control Center
Forward:
It is our belief that the Allen-Bradley CENTERLlNE Motor Control Centers
are designed and manufactured with quality and customer convenience in mind.
FUIIdepth horizontal
~::~~:~
Restricted access between\lertical wireways anCfISlde of unit enclosed forease of wiring.--units.

-State-of-the-art painting process.
Passes the 250 hour salt spray test.
.._ - - - - - = - - - - - : - - - - - Internal mounting angles.
Completely enclosed at the floor level.
----+-::::---c
-------=---- - - - - - - - - - Full side sheet separates adjacent sections.
Enhanced structural integrity and fault containment.
- - -
. _. -----tArr-wires lay flat. ._ _

Benefits
.-
. . ._
-- -
.---
--_.
- - -
- - - -
-=-~c-
c----c-~
Independently removable unit doors.
No need to remove doors above or below.
Features
Benefits
~~~e~;a7,ca' buscomPletely_enclOSe~ by insulating
I ~~~~ize possfule
contact-o~f-c-ac-bc-Ie-p-u-clc-Ie-rs-a-nd~-::fi-sc-h--
Manual and automatic shutters or protective caps.
.Total dead front construction and provides complete

isolation of vertical bus.
--=---:----:----Individual stab connection holes for each phase.
Minimize possible contact with the power bus by
users and maintenance personnel.
---I-:
Front accessibility of all bus bar connections.
Can be mounted against the wall. Rear access not
,required.
Vertical bus effective current rating of 600A.. -(c-:1-2-0-0-::A-.1 Reducesc-o-n-c-er-ns 0. f overloading of vertical bus.
effective current rating optional.)
.
.
-:----Horizontal power bus located in the center of the sec- .-Even heat distribution.
tion.
-Accomplishment of splicing without standing on a
ladder.
-Ease of maintenance.
-Maximize space available for cable connections and
!
~--:---
Ground bus can be mounted on top andlor bottom

section.
Steel vertical ground strap and unit ground stab.
Standard copper available.
Copper vertical load ground bus available.
01 ~::~~~~stomer/user
wiring.
----c--
Engagement of grounding path before vertical power

i bus is engaged and disengagement after vertical
power us.
Reduces wiring time.
BI006008
A-5
Features
Unit disconnect andle.
Self-aligning sta s.
Benefits
Handle always in control of the disconnect.
i Assures proper alignment of unit stabs on vertical
-------1
-~----.---+-----are pull-apart type.

_~____
__ .~
:ower bus.
Reduces disconnecting time when unit is removed or
replaced.
~~
_______
aSSembIY'~
~ No exposed wires outside of unit.
_ _~
_
Control terminal are located inside the unit.
No intrusion into the vertical wireway.
Starters with a w thstand rating up to the project
Problem free solution to withstand capacity specificarequirements.
tion.
Nameplates with black characters on a white backEasy cleaning feature.
ground.
Can be utilized in existing MCCs.
Units are interch ngeable.
Trip indication with circuit breakers through 400A.
Disconnect hand es and position indication.
Clear ON and OFF indication. Can tell position from
~ievery angle. Red (ON) green (OFF) indicators
marked with international symbols.
- - _ ..
..
Unit lockable po tions.
Both in the normal and service positions.
I
-_.~------+--------~~
" - - "
-"~"--."----"-----
.~
~--_.~
-------
Half-space (0.5) actor unit installation.
~~~----~.~-
"-----~-------~
.-\innovative single point latch design. No need to

_ _ _ _ ~ _ _ ~ _ ___+_-------~~""
tighten any ~crews:results in faster installatio_n_.__
Half-space (0.5) actor high density packaging for
Up to twelve (12) Size 1 full voltage non-reversing,
Bulletin 2100.
reversing, and feeder circuit breakers.
Up to twelve (12) 24A full voltage non-reversing, reHalf-space (0.5) actor high density packaging for
Bulletin 2400.
versing, and feeder fusible disconnect switches per
section.
Support pan bus ing for half-space (0.5) factor units. Prevents unit from being plugged in or removed with
.the operating handle in ON pOSiti_0-c-n_._--:_
All Bulletin 2400 nits utilize Bulletin 100 line or
Proven under application use starting and contactors.
equivalent Allen- radley devices.
I
Additional benef ts:
Notes:
BI006008
BI006008
BI006008
'1' Rockwell
Automation
Allen-Bradley
Allen-Bradley, a Rockwell automation business, has been helping its customers improve
leading technology companies.
~
Worldwide representation. - - - - - - - - - - - - - - -
Ecuador' Egypt EI Salvador' Finland' France' Germany Greece' Guatemala' Honduras' Hong Kong' Hungary' Iceland' India' Indonesia' Ireland' Israel' Italy
Jamaica' Japan' Jordan' Korea' Kuwait Lebanon Malaysia' Mexico' Netherlands' New Zealand Norway' Pakistan' Peru Philippines' Poland' Portugal
Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414 382-2000 Fax: (1) 414382-4444
Publication 2100-2.0 - September, 1995
Supersedes Publication 2100-2.0 - December, 1989
Copyright 1995 Allen-Bradley Company. Inc.
Printed in USA
><
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tUKM
'2i:"
'2M
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.A"'-I<>-.A", (IN"""")
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NEIIA/EDlAC CUSS
~ NEWA/EDlAC ~ "'ACRAW POCKET
W1lHOUT 1N1IJlWl~~..1 "lH INTDlNRlNC
A B-T
LOCATION
'5_
OCSCRIPTIQN
--
.;;.~ HERU
'~R
CABLE KCHIL
TOTAL N~9
PER PHAS
rl
lHTERWJRING DlACRAU
VIlREWAY
RnT
JK - fRON WOU" lING LIN""""}
INlIRWIRIN:
'!nP"'"
AlL
'%:
I mP"'"
.....
SPACE HEATER SECTION NUNBERS
ANQ..
~~~~~~R
r4
.....
ADOlTlON TO EXISTING 2'DD

CENTfRUNE, SERIAL NO. :
225
21D8CABLE SUIT~~I.~ ,NOt. OF
INC. UNE
ENTRy
rno<>n> _
ALUM';
UN SfC So SECT., NO.
RnT.
3BD
RATING lANPERES}
un
N~~A~ r
u '''''' (0E.SCRlP110N)
IlI,(OUNllNG [)iA,NNELS~
9 W1REWAY SECTIONS
OISCONNECT~
u...... ..1 .
LUG TYPE
rRINP r1
Ir-t PH~\.&.rSi H~~
2ear
BDD
LUGS
NAIN CIRCUIT DREAK:J f\)S1BL.E
ONLY r
3~j~
24D
CORNER SECTION NUNBERS PULL BOX SECTION NUNOERS
alSTON.....
PAINT
ST~8~1IIIIi
OPTIONS
"";;'NIN;;"
r.r~r~~:'I~J~~
,J.
SHUTTERS
A"TnUATlO _ NAN"A'
,)C;Jt. U'd/U';1/':U.
::;
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UNI B~E:!0GN~A~HI~
."."nr., . WI.FWAY
.....
E~~~;...j o:~';t~ NU--UXO~ tf~POlJND
.JCAllLE
NAIN BUS RATING ("PERES)

1,....j~UM!.~ul..l
oDoA siEi:i.tt aus
MAIN 8US
BDD_B8D rl,_ro'2DD"'" '611B""'2BBD""'2SBBr1'38e8
(PLATlN;~ TIN
SEAlES COOROINATEO SYSTIEII
AVAlLAIlL.E SHORT CIRCUIT . .PERES lAWS SYMMETRICAL}I
FULLY RATED SYSTOl
,,,,,KA Vt'I"TH I-Ua.IITING WAINS
BRACING
Hll1l'1l'1
~2KA _ 6SKA" 'eeKA .....
I/[RTICAL
GROUND
NON~,
PLATING
HORIZi~AL,~
LOCATION
SIZE NO. or CABLESI
GROUNO BUS
8US
NONEro TIN
1/4 X ,(I~fS. x 2
TOP".OTTOW
PLUG-IN. LOAD r
If"
REQUIRED
OSOIIBE
SYSTEM
AND
NEUTRAL
LOADS
NEUTRAL LOCATION RELATIl/[ :~
BUS
ARO:~ BU;now
CABLE
MISC
10
00216
SALES REP.
032
COL OH
STEVE WILSON-INDIA PROJECT

SALES OmCE
MCC NO.
PROJECT MARION INDRESCO
CUSTOMER
445507-00
EMCORP
C.O. NUMBER
CUSTOMER
.-
Allen-Bradley
RANDY WILLIAMS
DATE
REV
REV
REV
"ALIT.
I
I
REV
D.-V
r-nn.,
Of" 3
............ - -
ISHEET 1
09/15/95 CIRCE REf". NO., SERIAL NUMBER

518827/003
2100 -B809089/0 1 .
15 SEP 1995
A-B ORDER NO. 809089/01
ENGINEER
REV
,
.
'11 Rockllllell Automal;on ~
SYSTEM Will BE 415V 50HZ

WITH MASTER NAMEPLATE LOCATED ON MIDDLE SECTION
LESS THE THERMOSTAT. HEATERS TO BE ACTUATED BY STARTERS
SECTION LINE-UP
DEPTH
OIIr
:lIIr1
4Il .....
3Ilr
25"'"
IW-00TTOW PLA~ OUTDOOR NONWAlJ(-IN
~GASKET ~~
W-CASKET &
NEIlA/EDlAC GENERAl. PURP~~ ....OOTTOW PLATES
. '
aoTTOIol PlATES
TYPE
,
lrlC
1"
3R rTOTAl.
NUNOER
NUNOER OF SECTIONS Pt:R SHIPPING PART
SECTION
SEC'!sONS or PAR)S
COUNT
PI rJ1 P2n P3 n P4 n
P5 n Ptln P7n PBn P9 nPl"n Pl,n P12r
1
CI.ASS/TYPE
CONNECTION
DIMENSIONS IN INCHES / [ DIMENSIONS IN MIWME1ERS
co
:1:
"2c
2A
'1J '2J
1F
UNE
VOLTAGE
,.--!I ~
NEIlA/EDlAC
152
II
K
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i3
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a:
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90[2286J
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~6.1'52.J
15 [38'J
BI006008
BI006008
PW
R
NSR
FCBX
DSX
~
P
\\\~
IN UNIT BIIT NOT INSTAllID.
PART IIlNOI C
RII NAL NI
NI IN
INS RT IIlTH
I
A'
INSER III
FUSl8
DISCONN
T
P
CH
H8C9
Heater element. are -
I01A~Im;;1,,82-Ll
OPlIONAl 2" X 6" PHENOLIC IoIASTrR N.P.
3H
BLOWERS
PROPEL 1I0TOR
21.7B-8OB-IIP-3eCA-7VUT-7~1H5-B13
2118-8'"1
..
VFD
;;wrR,1
R
S~C-H
-RVA
m
PLC
'A
UNIT DESCRIPTION
WITH 415/110V XF\IR MV CENTrR TAP
OR 30 SEC
I
I
I
I
I
I
I
I
I
I
I
I
7.5
7.5
7.5
7.5
7.5
I
I
I
I
I
I
3
7.5
445507-00
--!0!!b0~2l.!16'-
---
'8.8 W52
4.52 W"
CB
IICB
CB
CB
CB
CB
CB
1 F\'NR
1 F\'NR
CB
f'VR
DOOR
CB
F\'NR
F\'NR
F\'NR
F\'NR
F\'NR
I
I
I
I
1
I
SALES REP.
SALES ornCE
032
-l<CO~L~OH!l-
MCC NO . STEVE WILSON-INDIA PROJECT
.1
52IW4413TI
18.8 I W52
18.81 W52
lB.sl W52
lB.sl W52
I
I
I
I
1
I
PROJECT tolAR/ON INORESCO
CUSTOMER ID
I
I
I
I
1
I
lB.s1W52
EMCORP
C.O. NUMBER
CUSTOMER
1. Y-211'867
WITH 415/11BV XF\IR MV CENTrR TAP It (2) 592'S

2113B-BDB-4C-6XP-I5-4llCA-7llUT-S8f'22-8&-751Hs-1r.3
T Y-28'965
Y-2113868
Y-2:I!I39M
Y-2113963
Y-211'962
Y-2113961
Y-28396B
Y-2113858
Y-283858
Y-2113857
2113B-BDB-4G-6P-I5-3BCA-7IlUT-7S1H5-631-8eee
218YZ-AJC-3:icr-7llUT
WITH 415/11BV XF\IR MV CENTrR TAP
?rvc~(,,"V\f-HIf'IJ""~
3l.
SE
3D
1I0TOR BLOYIERS
CPE TRANSFDRlAER
CROWD AND SWlNC
3A
2118-8Jil5
HOIST CABLE WINCH
218YZ-AJC-37CT-7llUT
EXCTER3
D.C. 1I0TOR nEI.D
WITH 415/1IBV XF\IR MV CENTrR TAP
2113B-BDB-SE-4G-IlP-4lICA-79UT-75IH5-II1'
2L
2J
HEATrRS
ANn-CONDEN5AliON
WITH 415/1IBV XFlIR MV CENTrR TAP
2113B-BDB-SE-4G-6P-41lCA-79l1T-751H5-1I13
211
20
AIR COl/PRESSOR
WITH 415/1IBV XFlIR MV CENTrR TAP
2113B-BDB-I-4G-SP-4IJCA-711UT-751H5-II13-8Bllll1
WITH 415/11BV XFlIR MV CENTrR TAP
2113B-BDB-I-4G-SP-4IJCA-711UT-751Hs-1I13-811
WITH 415/11BV XFlIR MV CENTER TAP
2113B-BDB-I-4G-6P4I1CA-711UT-751H5-II13-811
WITH UNDER IIDLTACE AND SHUNT TRIP
IJ 1218SUB-DJO-4SCT-754
WITH lIDL'RIElER. 2 PT5. B135. AND PILOT LICHT
Y-211'85S
I 218Y-AJC-3llCT-711llT
IF
Y-21139M
Y-211'854
Y-21139:l3
Y-2113852
Y-2113951
I
I
I
I
I
I
!',/~,
IE 1218YZ-AJC-=T-7llUT
10 1218YZ-AJC-=-7llUT
lC 1218YZ-AJC-=-7llUT
18 1218YZ-AJC-38CT-7llUT
2E
UNIT DATA
CATALOG NUMBER
lA 1218YZ-AJC-32CT-7llUT
HOIST 1I0TOR
CIl-AB
SEQUENCE RELAY
TRAN5rORlIER
I
I
I
I
I
I
2C
BLOYIER
TRAN5rORlIER
TRAN5rORlIER
I
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f..J~
..fJ
~
>.;
f1l.TrR FAN NO.2
I
I
I
I
I
I
UNE3
(17 CHARACTrRS)
2A
IIAiN BREAKER
I AIR CONDITIONER
I
I nEI.D EXCTrR
I nEI.D EXCTrR
I nEI.D EXCTrR
I r:vr .. PHASE
UNE2
(15 CHARACTrRS)
BLACK
WHITr LETTERS ON BLACK BACKGROUND.
WHlTr LETTERS ON RED BACKGROUND.
lETTERS-; ~~~':'C:;'~~~D'Jf~
[92J/~/
f1l.Tl:R FAN NO.1
AUXlUARY BUS
T-PS DRI\'[
SWlNC GENERATOR
CROWD CENERATOR
HOIST GENERATOR
YlUIlER RECEPTAQ.[
OPERATOR'S CAB
UNEI
(17 CHARACTrRS)
C~~
ENGRAVED PHENOLIC ENGRAVED PHENOLIC ENGRAVED PHENOLIC -
UNIT DOOR NAMEPLATES

1"':1/6 [29J X 3-5/6
CARDHOLDER
IJ BLANK NAlAEPLATrS
ENGRAVED ACRYUC - BLACK LETTERS ON ~ITr BACKGROUND.
I ~ ENCRAVED ACRYUC - ~ITr LETTERS ON BLACK BACKGROUND.
C
C
I
I
I
I
138
75
75
75
75
75
75
75
XI
I X
I X
I X
I
I I I
I
I
I I I
I
lIS
lIS
IS
IS
15
1'5'
1151 II
I I 31
I I I I
xL
xl
I xl
Allen-Bradley
I
I
I
I
I
REV
51B827/003
OF 3
I,ORM 385E-ENGR
I SHEET
12100-B809089/01'
CIRCE REF. NO.ISERJAL NUMBER
REV
09/15/95
15 SEP 1995
REV
0
REV
REV
REV
DATE
QUAlm
'1' RockWell Automation U
3B
15
58
IS
71
38
38
38
3B
38
225
I 381
I SB I
I 58 I
I 58 1
I 5B I
I IS 1
kE~N~G~IN~E:::ER:--~R;:-:A;,N;,DY~W~IL~LI..
AM;.:S:-..::....---A-B ORDER NO .!!8Qj09t!!0!!1:89~/:.!10:.L1
_
HIICP
HIICP
FOB
HlICP
FOB
HIICP
HlICP
HIICP
HlICP
HlICP
KDB
IFOB
IFOB
IFOB
IFOB
1FOB
IFOB
BI006008
BI006008
("11
,t.
7.3e
-----------~------------
I-UKM 3I:J::Jol
FlG 1
II<
3.25
[83)
UDf"O
[111J X 7."" [178J VERTICAL Yt1REWAY

PREFERRED lOCAll00 rOIl POWER Yt1RES WHICH
REQUIRE UORE THAN A 6 INCH BENDING RADIUS
.56 [14J X 1.13 [29J SLOT
LE'1--/"'''''--1
[254J
POWER Yt1RES
.... /
/~ ........
O~/U9/tI"'
t
:11
[ FlG 2
II<
[111J X 7."" [17BJ VERTICAL W1REWAY

PREFERRED lOCAll00 fOR POWER Yt1RES WHICH
REQUIRE UORE THAN A 6 INCH BENDING RADIUS
3.25
[254)
[83J
.56 [14J X 1.13 [29J SlOT
POWER Yt1RES
CD 4.37
GROUND BUS
/~",,,/~~
// // // // // // // // //
""""~ """.. .
I
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rt6~2
21l.1l" [:508J
17.72 [ 4 5 " ) )
(BACK OF ENa.OSURE)
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,
CD 4.37
BKflL
OPT. HORZ
GROUND BUS
:11
21l.1l" [:508J
17.72 [45"J
(BACK OF ENa.OSURE)
--:-:-iNCoiiING-UNES:-:-:
-_-_-_- -_-_-_-_-_
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FLOOR PLAN LAYOUT
ElolCORP
SALE
REP.
032
COL OH
STEVE WILSON-INDIA PROJECT

SALES ornCE
MCC NO.
C.O. NUMBER
5507-00
CUSTOMER 10 _"'00""2.....
16"PROJECT lolARION INDRESCO
CUSTOMER
.'
QUA
__
REV
REV
REV
REV
ISHEET 3 or 3
385E-ENGR
I roRlol
DATE 15 SEP 1995

REV 0 09/15/95 CIRCE REF. NO., SERIAL NUMBER
REV
518827/003
12100-9809089/01'
ENGINEER _-'R~A~N!!!D~Y..!W!!!I:!W~A!!!lol!i!S'__
A-B ORDER NO. ~80~9~0~89~/~0~1
'====--~~~:::-:-:7':":'::__-....:.I;.....-----_1
Allen-Bradle ll
'1' RocllWell Automation ~
.,
"
BI006008
BI006008
'---1--1- -2--'--3- -,-- 4 - 4- - 5 - -,I

I
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BI006008
---------
NOTES
I
I
I
I-
I
I
18
I
I
II
I
IC
I
I
I
II
I
I
ID
I
I
r----------l
L~
TO
HORIZONTAL L~
BUS
:~
I
L1
12B13F
I
I
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I
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'
I
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12B11 F
I
()=I==O
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()=
0---
I
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IE
I
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=()
I
I
I
I
I
I
I
I
USER'S OUTGOING
LOAD CABLES
12B09F
I
I
J
CB
II
I
IF
I
I
I
II
I
UNIT INSTALLATIOf\
IG
I
I
1- References
I
Revision
BUL 2193F
1/2 SPACE FACTOR
ACAD
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Allen-Bradley
CENTERLINE Motor Control Centers

Westinghouse Instantaneous Trip
Motor Circuit Protectors (HMCPIGMCP)
In NEMA/EEMAC Rated
Combination Starter Units
Product Data
86-278-7
Westinghouse 150 Amp frame instantaneous trip motor circuit protector (HMCP).
Application
The information in this publication applies to Westinghouse motor circuit

protectors (HMCP/GMCP), when they are used in NEMAJEEMAC rated
size 1 through size 6 combination starter units. The particular circuit
breaker (trip range) supplied with a unit depends on the horsepower and
voltage that was specified when the unit was ordered. Tables 1 and 2 (pages
3 and 4) list the various combinations of circuit breakers and starter sizes.
When using Tables I and 2, be sure to use the line that applies to your
equipment.
Important: The information in this publication does not apply to inverse
time circuit breakers. For combination starter units with inverse time
circuit breakers, refer to Publication 2100-2.3.2, Westinghouse Inverse
Time Circuit Breakers In NEMAJEEMAC Rated. Combination Starter
Units.
uct Data
inghouse Instantaneous Trip Motor Circuit
ctors (HMCP/GMCP) In NEMA/EEMAC Rated
bination Starter Units
.
uit Breaker Adjustment
The circuit breaker is shipped with the instantaneous trip arrow pointing to
the lowest value. The motor full load current determines the magnetic trip
setting of the HMCP/GMCP circuit breaker. Allen-Bradley Company
recommends selecting a trip setting that is approximately ten (10) times the
motor nameplate full load current. The trip setting can be adjusted to a
position which corresponds to the determined magnetic trip current:
positions A through F for 63A frame, positions A through H for 150A and
600A frames, and A through I for 250A and 400A frames. To adjust the
trip setting:
a. Make certain that the circuit breaker operating handle is in the
OFF / 0 position.
b. Depress the adjustment pointer with a small screwdriver, and tum
clockwise to the determined setting. Verify that the circuit breaker will
not trip during motor starting. If the circuit breaker trips when
attempting to start the motor, tum the pointer clockwise to successively
higher positions, until the circuit breaker no longer trips when
attempting to start the motor. The trip setting of the circuit breaker must
never exceed 13 times the motor full-load current. Refer to the National
Electrical Code (NEC) or the Canadian Electrical Code (CEC) for more
information.
Note: When the devices are energized, motor peak inrush current can
randomly exceed the maximum limit set by the code.
'-To-Trip Mechanism
The push-to-trip mechanism provides a manual means for tripping the

circuit breaker. Depress the red button on the circuit breaker cover. When
the button is pushed, a plunger rotates the trip bar causing the breaker to
trip, thus opening the HMCP/GMCP contacts.
;epower Ratings
The horsepower ratings for combination starters listed in Tables 1 and 2

were determined from full load currents as specified by NEe.
Acceptable performance should occur when the motor full load current is
within 15% of the value which corresponds to the horsepowers and
voltages listed in the NEC. Consult your local Allen-Bradley sales office or
distributor if the motor full load current is not within these limits.
BI006008
1
1
1
2
3
2
3
4
3
4
4
5
5
3
7
/5
30
50
50
50
100
100
100
150L
150L
150H
250
400
600
3
7
15
30
50
30
50
63
1
1
1
1
1
2
2
2
Continuous Current
NEMAlEEMAC
Rating (Amperes) I
Starter Size
10
1/8 -1/2
3/4 -1-1/2
2-3
5
7-1/2
200V
10
15
15
20 - 25
1/8-1/2
2-3
5 -7-1/2
10
460V
250 - 350
125 - 150
200
60
75-100
30 - 50
-
15 - 25
-
3-:-5
7-1/2 -10
1/8 - 1
1-1/2 - 2
460V
1/8-1/2
3/4 -1-1/2
2-3
5-7-1/2
230V
Horsepower Range
60 - 75
100
125 -150
50 - 60
75
30
40-50
20 - 25
-
l'
7-1/2
10
-
1-112-2
3-5
1/8 - 1/3
1/2 - 1
230V
Horsepower Range
100 -150
25
30
40
15 - 20
-
5 - 7-1/2
10
-
1-112-2'
3!
1/8 - 1/3
1/2 - 1
200V
Table 2.
Instantaneous Trip Motor Circuit Protectors (GMCP)
NEMAlEEMAC
Starter Size
Continuous Current
Rating (Amperes)
'
Table 1.
Instantaneous Trip Motor Circuit Protectors (HMCP)
i
i
15
35
75
150
250
150
250
315
~~
1800
1250
2000
450
450
750
300
300
150
150
150
90
9
21
~~
18
42
90
180
300
180
300
378
B
21
49
105
210
350
210
350
441
2400
1405
2250
600
600
1000
400
400
200
200
200
120
12
28
24
56
120
240
400
240
400
504
~~
600
600
300
300
300
~~!
180
18!
42,
700
700
350
350
350
1"c;'5
210
21
49
E
I
152~
800
800
i
400
400
400:
240
24
56
900
900
450
450
450
27
63
63
135
270
Magnetic Trip Setting
1000
1000
500
500
500
30
I
70'
70
15 0
300
3000
1560
2500
4200
1875
3000
27
63
135
270
450
270
450
567
II
30
70
150
300
500
300
500
630
Magnetic Trip
Setting
3600
1720
2750
5400
2185
3500
6000
2340
3750
-
2500
4000
GMCP003AOC
GMCP007COC
GMCP015EOC
GMCP030H1C
GMCP050K2C
GMCP030H1C
GMCP050K2C
GMCP063M2C
Westinghouse
Catalog Number
25102-001-01
25102-001-02
25102-001-03
25102-001-04
25102-001-05
25102-001-04
25102-001-05
25102-001-06
~~g~7~~~~C
HMCP600L5W
HMCP250W5W
HMCP400X5W
HMCP150T4C
HMCP150T4C
HMCP150U4C
HMCP100R3C
HMCP050K2C
HMCP030H1C
HMCP003AOC
HMCP007COC
~~~~~:~~~:~;
25103-412-01
25102-321-02
25102-353-01
25102-258-07
25102-258-07
25102-258-08
25102-258-06
25102-258-05
25102-258-04
25102-258-01
25102-258-02
Allen-Bradley
Part Number
High Interrupting Capacity

Suffix Letter "CA"
Westinghouse
Catalog Number
Allen-Bradley
Part Number
Standard Interrupting Capacity

Suffix Letter "WG"
4800
2030
3250
750
900
1050
1200 \ 1350
1500
750
900
1050
1200
1350
1500
125015001750200022502500
500
500
250
250
250
150
15
35
ABC
250 - 400
125 - 200
-
75
100
40 - 50
60
15 - 25
30
1-1/;-3
7-1/2 -10
1/8 -1
-
575V
~~g;~~~~
ELC3150R
ELC3150R
ELC3150R
ELC3100R
ELC3050R
ELC3030R
ELC3003R
ELC3007R
Westinghouse
Catalog Number
~~~~~:~~~:~;
25107-101-16
25107-101-16
25107-101-16
25107-101-15
25107-101-14
25107-101-13
25107-101-10
25107-101-11
Allen.Bradley
Part Number

w/Current Limiter
Suffix Letter "CC"
Product Data
Westinghouse Instantaneous Trip Motor Circuit
Protectors (HMCP/GMCP) In NEMA/EEMAC Rated,
BI006008
BI006008
Product Data
BI006008
Westinghouse Instantaneous Trip Motor Circuit
Protectors (HMCP/GMCP) In NEMNEEMAC Rat
ATTENTION: The horsepower ratings and corresponding trip

settings in Tables 1 and 2 on pages 3 and 4 are only valid when
the combination starter is equipped with an Allen-Bradley
SMpTM solid state overload relay, Bulletin 592 or Bulletin 593
overload relay (motor running overcurrent protective device)
that has correctly sized heater elements.
When correctly selected, this combination of equipment
protects against short circuit and ground fault damage, and
provides coordinated overcurrent protection in the motor
branch circuit for continuous-duty rated motors, as defined in
the NEC and CEC.
The circuit breaker tripping may indicate the interruption of a
high fault current. To ensure protection against fire and/or
shock hazard, examine the current carrying parts of the
combination starter, and replace if damaged. (Refer to NEMA
Standards Publication number ICS 2.2, Maintenance of Motor
Controllers After a Fault Condition, and NEMA Standard
Publication number ICS 2, Part ICS 2-302.
BI006008
"1' Rockwell Automation

Allen-Bradley
Packaged Control Products
Milwaukee, Wisconsin 53204 U.S.A.
Publication 2100-2.3.1 - July, 1994
Supersedes Publication 2100-2.3.1 - June, 1991
Copyright 1994
Printed in USA
'1' Roclolflell
BI006008
Automation
Allen-Bradley
CENTERLINE Motor Control Centers

Westinghouse
Inverse Time Circuit Breakers
In NEMA/EEMAC Rated
Product Data
~
.,.~
86-278-1
Westinghouse HKD and HJD frame thermal magnetic circuit breakers
Application
The information in this publication applies to Westinghouse inverse time,

thermal magnetic or solid state circuit breakers, when they are used in
NEMAJEEMAC rated, size 1 through size 6, combination starter units.
Important: The information in this publication does not apply to

instantaneous trip circuit breakers (motor circuit protectors). For
combination starter units with instantaneous trip circuit breakers, refer to
Publication 2100-2.3.1, Westinghouse Instantaneous Trip Motor Circuit
Protectors CHMCP) In NEMAJEEMAC Rated, Combination Starter Units.
Circuit Breaker 0 eration
Inverse time circuit breakers are designed to trip at 100% to 125% of their
continuous current rating. They are also designed to trip, on an
inverse-time basis, at overcurrents up to the magnetic or electronic trip
current setting of the circuit breaker. The circuit breaker manufacturer sets
the continuous current ratings for the thermal magnetic circuit breakers.
The continuous current rating of circuit breakers with solid state trip
mechanisms depends on the installed rating plug.
Westinghouse F-frame circuit breakers have a non-adjustable instantaneous
magnetic trip mechanism, which is set by the circuit breaker manufacturer.
All other frame sizes have an adjustable instantaneous trip mechanism,
which can be set to a desired current value. Refer to Tables 2, 3, and 4
(pages 3 and 4) for the instantaneous (magnetic or electronic) trip ranges
and settings.
BI006008
uct Data
tinghouse Inverse Time Circuit Breakers In
NEEMAC Rated, Combination Starter Units
::uit Breaker Adjustment
Determine the desired trip current, using the National Electrical Code
(NEC) or Canadian Electrical Code (CEC), and the instructions provided
with the combination starter unit. Refer to the tables on pages 3 and 4, and
choose the trip setting which has the desired trip current value. Make
certain that the circuit breaker operating handle is in the OFF / 0 position.
Depress each trip setting dial with a screwdriver, and turn clockwise to the
determined setting. If there is more than one dial on the circuit breaker, all
should be set to the same value.
;h-To-Trip Mechanism
The push-to-trip mechanism provides a manual means for tripping the

circuit breaker. Use a small screwdriver to depress the red button on the
circuit breaker cover. When the button is pushed, a plunger rotates the trip
bar and causes the breaker to trip.
'sepower Ratings
The horsepower ratings for combination starters listed in the tables on

pages 3 and 4 were determined from full load currents as specified in the
NEe.
Acceptable performance should occur when the motor full load current is
within 15% of the value which corresponds to the horsepowers and
voltages listed in the NEC. Consult your local Allen-Bradley sales office or
distributor if the motor full load current is not within these limits.
1-5
100
125
150
I
I
25-30,
20
15
15
50
40
-,
30
25
25
15-20
-
7.,~2'~2'0
7,1/2-10
10
1/8 -3
800
800
,
-,
700
600
600
600
500
500
500
500
Min.
50
40
30
20-25
25
10
10
71/2
1/8 - 5
575V
'I
1600
1600
Size
4
4
4
5
5
5
5
125
150
250
50
75
60
200V
25
30
40
40
75
100
60
230V
30
40
50
50
I
I
150
200
125
460V
50 60
75
100
100
Horsepower Ratings
100
200V
I'
I
-
230V
I
~
1'25-'50
! 1<0 - 1 0 ' !
i
250-350
460V
.
Horsepower Ratings
i'
800
Rating
(Amperes)
1
1
200V
Starter
Size I
Continuous .NEMA/I
Current
EEMAC i
I
200
200
230V
I!
400
i
'
2250
-__.,
3X
1800
1500
2400
1310
FD3060
FD3050
FD3040
FD3150
FD3125
FD3100
FD3070
i 1420
11530
I - I 10X
1250
1500
4000
3000
I 2815
3750
i 2500
2340
1640 1'750
1170
1410
5X
1 3600
I
6X
3000
7X
14200
13500
ax
4800
4000
4000
7X
4800
6400
ax
5600 I 6400
I
I!
4800! 5600
6X
7200
9X
25105264,02
25105264,01
Part Number
Allen-Bradley
HFD3150
HFD3125
HFD3100
HFD3070
HFD3060
HFD3050
HFD3040
HFD3030
HFD3020
HFD3015
Catalog Number
Westinghouse
-!
8000
251 04348-09
251 04-369-1 0
251 0436912
2510434806
2510434804
2510434805
Allen-Bradley
Part Number
'i
--
2510340601
2510744705
2510340601
2510744704
Allen-Bradley
Part Number
Westinghouse
Catalog Number
MC3800FI
8MC800
I
I
FDB3150
LF83150
FD83125
LF83150
~~:g;~g
FD83070
LFB3070
FD83060
LF83070
~~:ggig
Westinghouse
Catalog Number
1
2510345001',
25107,450.05
I
I
I
2410340602
2510744705
2510340602
25107-447-04
Allen-Bradley
Part Number
8NES800T
HND3800TWI
Westinghouse
Catalog Number
Allen-Bradley
Part Number
25103456021
25107-455-07
I
-

Suffix Letter "eM"
HLD83600FT35W
6LES600T
MLD83600FT35W
6LES500T
251 04-346-09
2510436710
2510436712
2510434606
2510434604
2510434605
Allen-Bradley
Part Number

Suffix Letter "CM"
HJD3250
HKD3300
HKD3400
HJD3175
HJD3125
HJD3150
Westinghouse
Catalog Number
2510526513
25107.101.09
25105.265-12
25107.101.09
~~~gi:~~~:61
2510526509
25107-101.08
2510526508
25107.101.08
~~~gi:~~~:g~
25105-265-06
2510526504
25107-101-08
2510526502
25107.101.08
2510526501
25107.101.08
Part Number
Allen-Bradley

Suffix Letter "eM"
25105-26313
_
1
2510026312
2510526311 j
2510526309
2510526308
25105-263071
25105.263.06 ,FD83040
25W'2~:;:~:;\--FD83030
:J
!
LF83070
FD83020
2510026302 ,LF83070
Allen-Bradley
Part Number
; Catalog Number
I Westinghouse
w/Current limiter
Suffix letter.'~C_D~"~~_
Standard Interrupti.ng. Capacity
'FD83015
2510026301'
LF83070
Part Number
Allen-Bradley

Suffix Letter "WT"
LDB3600FT35W
6LES600T
LD83600FT35W
6LES500T
Westinghouse
Catalog Number
10X

Suffix Letter "CT"
JD83250
KD83300
KD83400
JD83175
JDB3125
JD83150
Westinghouse
Catalog Number
High Interrupting CapacIty

Suffix Letter "eM"

Suffix Letter "CT"
2510526413
2510526412
25105-26411
25105-26409
2510526408
2510526407
25105.264.06
I
!
:
Electronic Trip Setting (Amperes)
3000
2500!
5X
Electronic Trip Setting (Amperes)
2 00 , 4000
3200
_2.
!.
i 2400
4X
--r3X!
~
!
1600 i 2400
2X
7,5X
940 1 1020 1050
1125 11220 1 1315
~!
4X
'2000
Electronic Trip
Setting (~_~peres)
2X,
FD3020
Magnetic Trip Setting (Amperes)
2510526513
2510526512
2510526511
25105265-09
1875 ! 2030 , 2185

2250 2440 I 2630
3000 3250 3500
1875 ! 2065
2500 , 2750
'/
FD3015
- ' :
2510526508
2510526507
2510526506
Ikjsdf
Westinghouse
Catalog Number
1090 1,200
860
I 1030
.
Medium Interrupting Capacity
Suffix Letter nCB"
25105-265.~-';- ----;,~;~-- ---;5105-2~~~0~
2510526502
25105,26501
Part Number
Allen-Bradley
"eT"
Suffix letter
Capacity
Standard
Interrupting
1565 I 1720-
935
780
Electronic Trip Setting

(Amperes)
11000
575V
700
840
1 980
1250 i 1405
1500 ' 1690
875
625
750
5X

(Amperes)
I 2000
3;0~- 1200
250-300
575V
.
.~l
460V
Horsepower Ratings
125
150 - 200
Table 4. MC, HND Solid State Circuit Breakers (Adjustable Electronic Trip)
600
500
Starter
Size
Rating
(Amperes)
NEMA I
EEMAC
Continuous
Current
575V
50 75
100
Table 3. LD, HLD Solid State Circuit Breakers (Adjustable Electronic Trip)
300
400
175
Starter
Rating
EEMAC
I NEMA I
(Amperes)
Continuous
Current
FD83150
FD83125
FD831 00
FDB3070
1400
FD83060
FD83050
FD83040
FD83030
FDB3020
'. i'
1200!
FD83015
Catalog Number
Westinghouse
"C!_"_~
Suffix Letter
Capacity
Standard
Interrupting
1200
1200
1000
1000
1000
800
Max.
Range
(Amperes)
Magnetic Trip
Table 2. JD, JOB, HJD, HKD, KDB Thermal Magnetic Circuit Breakers (Adjustable Magnetic Trip)
20
20
2
3
60
---'.
70
---
10
10
;:~;~
2
3
I;
;
3
50
40
1
2
1'
30
3,
1/8 - 2
1/8 - 11/2
,1
460V
230V
200V
~~:rt~;
Size
I
Horsepower Ratings
NEMAl II
~
20
! 1
15
(Amperes)
Rating
~~~r~~~
t'
Con-
Table 1. FD, FOB, HFD, FDB-LFB Thermal Magnetic Circuit Breakers (NonAdjustable Magnetic Trip)
Product Data
Westinghouse Inverse Time Circuit Breakers In
NEMA/EEMAC Rated, Combination Starter Units
BI006008
BI006008
Product Data
Westinghouse Inverse Time Circuit Breakers In
NEMA/EEMAC Ftated, Combination Starter Units
BI006008
ATTENTION: The horsepower ratings and corresponding

trip settings in the tables on pages 3 and 4 are only valid
when the combination starter is equipped with an
Allen-Bradley SMpTM solid state overload relay,
Bulletin 592 or Bulletin 593 overload relay (motor
running overcurrent protective device) that has correctly
sized heater elements.
When correctly selected, this combination of equipment

protects against short circuit and ground fault damage, and
provides coordinated overcurrent protection in the motor
branch circuit for continuous-duty rated motors, as defined
in the NEC and CEC.
Circuit breaker tripping may indicate the interruption of a
high fault current. To ensure protection against fire and/or
shock hazard, examine the current carrying parts of the
combination starter, and replace if damaged. (Refer to
NEMA Standards Publication number ICS 2.2,
Maintenance of Motor Controllers After a Fault Condition,
and NEMA Standard Publication number ICS 2,
Part ICS 2-302).
BI006008
Rockwell Automation
Allen-Bradley
kaged Control Products
~aukeeJ Wisconsin 53204 U.S.A.
cation 2100-2.3.2 - July, 1994
rsedes Publication 2100-2.3.2 - June, 1991
Copyright 1994
Printed in USA
BI006008
FLANGE M UNTED DISCONNECT SWITCHES

Right Han Construction
Disconn ct Switches
(withou fuse clips)
1IIIr9.
Arc Hood
G",n"""
. . , Plug Handle
BulletIn 1495 Auxiliary Contacts-
Fuse Clip
Fuse Blocks
(without fuse clips
Ampere
Size
Disconnect Swit hes D

Fusible
Unfused
(less clips)
Part No.
Part No.
Arc
Hood
(only)
Plug
Handle
Guard
Plate
Part No.
Part No.
Part No.
30
X-419114
X-419113
F-24361
F-26083
F26080
60
X-419116
X-419115
X-393591
F-26083
F-26085
100
X-419118
X419117
X-393587
F-26087
F-26086
200
X-419120
X-419119
X-393589
F-26088
F-26081
Fuse Clip Kit

Fuse Clip Ratings
0- 30A ..
0- 30A ..
31- 60A ..
31- 60A ..
61-100A..
101-200A..
201-400A..
250V.
600V.
250V.
600V.
250V.. 600V.
250V.. 600V.
250V.. 60W
Set of Three
use Clips and
M unling Screws D
Catalog No.
1401-N410
1401-N420
1401-N430
1401-N440
1401-N450
1401-N460
Normally Open Contact

Catalog Number 1495-N8
Normally Closed Contact
Catalog Number 1495-N9
Fuse Blocks D
Application
Rating
0- 30A .. 250V.
31- 60A .. 250V.
0- 30A .. 600V.
31- 60A .. 600V.
31- 60A. 250V.
61-100k.250V.
0- 30A.. 600V.
31- 60A. 600V.
61-100A.600V.
61-100A .. 250V.
101-200A .. 250V.
61-l00A .. 600V.
101-200A .. 600V.
101-200A.. 250V.
201-400A.. 250V.
10 1-200A.. 600V.
201-400A .. 600V.
Class H
Dimension
Part No.
X-419141
X-419144
X-419142
X-419145
X-419121
X-419121
X-419121
X-419121
X-419121
X-419122
X-419122
X-419122
X-419122
X-419123
X-419124
X-419123
X-419124
Class J
Dimensions
Part No.
X-419143
X-419146
X-419121
X-419121
X-419121
X419122
X-419122
X-419123
X-419123
WARNING - Do not use this Renewal Parts

Listing for replacement of equipment on ALLENBRADLEY Combination Starters. such as Bulletins506. 512.522. 706. 7120r716. This listing applies only to the Bulletin 1494F Flange
Mounted Disconnect.
o Listed sets of fuse clips are for use on disconnect SWitches and fuse blocks. ConSider the fuse clip rating as well as the
applicatIOn rating when selecting a set of fuse clips for use on a disconnect SWitch or a fuse block. Specify ratings when
ordenng.
NOTE: Parts indicated wi h 0 are recommended spare parts.
Publication 1494F-6.0 - July, 1985

Supersedes Publication 1494F-6.0 Dated October, 1976
HANDLE AND MECHANISM ASSEMBLlES-
--:.<,,,:~:,
. .:..~~ i
,.:
."
BI006008
Bearing Lever
pring
7
.
Def.eat.er
Lever
,~=
.[
Cover
Plate
Defeater Spring
@Oo
"O"Ring
"Nylock" Nut
Gasket
Complete Handle and Mechanism Assembly
REPAIRS - Before attempting repair or

replacement of the handle and mechanism assembly, a concentrated observa
tion of the assembly mounted to the
enclosure should be made. The handle
and mechanism assembly is secured
from within the enclosure by two hex head
cap screws with lock washers and the
"defeater" screw with a "nylock" nut and
washer. Use a socket and ratchet wrench
to remove the screws as well as the
"nylock" nut and washer. The defeater
lever, defeater spring and bearing lever
spring are free to be removed once the
:ap screws and defeater screw are re110ved. The pin end of the handle and
Jearing assembly lever arm must be
'slipped out" of the drive plate to permit
'emoval of the handle and bearing
Issembly as well as the mechanism
Issembly.
Re-assembly is best accomplished by

completing the disassembly procedures
in reverse. NOTE: Handle and mechanism assemblies are provided with gas-
Description
of Part
Complete Handle
and Mechanism
Assembly
Handle and
Bearing Assembly
(only)
kets as well as a rubber O-ring on the

"defeater" screw. Care should be taken
not to damage these gaskets, affecting
their sealing qualities.
30 Ampere
Size
Part No.
60 Ampere
Size
Part No.
100 Ampere
Size
Part No.
200 Ampere
Size
Part No.
Z340660
Z-340660
Z353040
Z-353210
"'
X4030280
X4030280
X4030290
.. -
X4030800
-~.--.",.-_._~
"
..
JOOR HARDWAREDescription
01 Part
Small or
Intermediate
Size
Large Size
Handle Assembly (Includes DRing)

Cam Bearing
Bearing Pin
Top and Bottom Roller
Center Roller (Includes Shims and Screws)
X4021720
8-38031
838029
X402176
1494F-L3
X-4021880
8-38057
8-38029
X402192
1494F-L3
Handle
~i ""mb>
Handle
"0 ".Ring
IJ
Center Roller
(j' Cam Bearing

Bearing
Pin
il~
Top and
Bottom
Roller
ORDERING INFORMATION - Your order cannot be entered unless the following information is given: Part number,
description of part. catalog number and

series letter of disconnect switch.
NOTE: Parts indicated with 0 are recommended spare parts.
III ALLEN-BRADLEY
~
Power Group
Milwaukee,Wisconsin 53204
tml
BI006008
BULLETIN
RENEWAL PARTS
INFORMATION
2100
CONTROL CIRCUIT TRANSFORMERS & FUSING
...........
DESCRIPTION - Control ci rcuit transformers (CCTs) are

used to provide a reduced voltage for control circuits in
Motor Control Center units. CCTs require primary
protection per the National Electrical Code (Article 430nrc]) and U.L. Safety Standard 845. On standard CCTs,
this is accomplished through the use of two (2) Class CC
time delay fuses of the proper voltage and amperage
ratings. Internally protected CCTs meet these requirements without additional primary fusing. Dual-element
time delay fuses are offered for protecting the secondary
side of both standard and internally protected control
ci rcuit transformers.
90100
Continuous VA
Standard Transformers
Primary Voltage
Internally Protected Transformers

Primary Voltage
208\/ -60Hz
Part N umber
240/480V-60Hz
600V-60Hz
208V-60Hz
240V-60Hz
480V-60Hz
600V-60Hz
Part Number
Part Number
Part Number
Part Number
Part Number
Part Number
75
X-3 3917
X-343858
X-343908
25636-101-02
25634-141-01
25634-141-01
N/A
130
X-l 3212
X-183222
X-183202
25636-165-02
25634-098-01
25634-098-01
N/A
200
X-2 0908
X-210922
X-210902
N/A
N/A
25636-201-01
N/A
250
X-3 6525
X-32-6539
X-326524
N/A
N/A
25636-241-01
N/A
350
X-2 1478
X-211272
X-211467
N/A
N/A
25636-321-01
N/A
500
X-2 1493
X-211293
X-211488
N/A
N/A
N/A
N/A
750
X-2 1413
X-231423
X-231400
N/A
N/A
N/A
N/A
1000
X-2 1494
X-231515
X-231499
N/A
N/A
N/A
N/A
FUSING
Secondary Voltage
Primary Voltage
Contin-
208V- OHz
uous
VA
Fuse
Rating
Pa 1 Number
240V-60Hz
Fuse
Rating
480V-60Hz
Part Number
Fuse
Rating
Part Number
120V60Hz
600V-60Hz
Fuse
Rating
Part Number
Fuse
Rating
Part Number
75
.75A
(2)2 183-272-11
.75A
(2)25183-272-11
.75A
(2)25183-272-11
.50A
(2)25183-272-09
.60A
X-276125
130
1.00A
(2)2 183-272-13
1.00A
(2)25183-272-13
1.00A
(2)25183-272-13
1.00A
(2)25183-272-13
1.25A
X-276120
200
2.00A
(2)2 183-272-20
2.00A
(2)25183-272-20
2.00A
(2)25183-272-20
1.00A
(2)25183-272-13
1.80A
X-276132
250
5.00A
(2)2 183-272-29
2.00A
(2)25183-272-20
2.00A
(2)25183-272-20
2.00A
(2)25183-272-20
2.25A
X-276133
350
5.00A
(2)2 183-272-29
5.00A
(2)25183-272-29
3.50A
(2)25183-272-26
2.00A
(2)25183-272-20
3.20A
X-276122
500
5.00A
(2)2 183-272-29
5.00A
(2)25183-272-29
5.00A
(2)25183-272-29
3.50A
(2)25183-272-26
500A
X-276123
750
7.50A
(2)2 183-272-34
7.50A
(2)25183-272-34
5.00A
(2)25183-272-29
5.00A
(2)25183-272-29
6.25A
X-276129
1000
7.50A
(2)2 183-272-34
7.50A
(2)25183-272-34
5.00A
(2)25183-272-29
7.50A
(2)25183-272-34 10.00A
Packaged Control Product Division

Milwaukee. Wisconsin U. .A.
X-276131
Publication 2100-6.1 - April. 1990

Supersedes Publication 2100-6.1 - August. 1988
BI006008
BULLETIN
I 50S
BI006008
RENEWAL PARTS
FULL VOLTAGE REVERSING STARTERS

Size 0 Size 1 Series A Construction
Size 0
Size 1
OPERATION - B Iletin 505 starters are most commonly

used for full voltage starting and reversing of polyphase squirrel c ge motors.
Bulletin 505
ward" and a "r
mon base. Th
mechanically in
tors closing at t
tarters consist essentially of a "forverse" contactor mounted to a comse contactors are electrically and
erlocked to guard against both contace same time.
Starters are quipped with Bulletin 592 block type

manual reset 0 erload relays.
OPERATING ENV RONMENT -
Starters should always

be maintained i a clean and dry condition for dependable operation. hoice of the proper NEMA enclosure
type for the ap lication is very important.
REPAIRS - Start
the "exploded"
following proce
aid in the seque
motor starter.
rs can be disassembled as depicted in

Ilustration on Page 4. Additionally the
ures and techniques are suggested to
tial disassembly and reassembly of a
WARNING - Before part replacements are attempted th

POWER SOURCE MUST BE
DISCONNECT D.
NOTE -
If part are removed from both contactors,

keep them sepa ate and replace them in their original
positions, if r used, to avoid mismatched wear
patterns.
DISASSEMBLY ( artial) - It is not necessary to remove

the starter fro
its enclosure or to remove the line
wiring. The folio ing instructions apply to both the left
hand and right and contactors.
1. Remove all ontrol wires from the operating coil
(item 7) and ie point terminal (item 5).
2. Loosen two aptive screws and lift off the contact
block cover ( tem 1).
3. Loosen four c ptive screws from the coil cover (item
4). The tie point terminal is now free to be removed,
if it is to be r placed.
4. With the coil cover screws loosened the auxiliary
contact block s) (item 6) can be removed and the coil
cover lifted 0 f.
5. Lift out the
ovable contact support and armature
assembly (ite 2), the yoke (item 8) and the operating coil (item ) as a unit. The yoke and the operating
coil can now be lifted up and out of the movable

contact support assembly.
REPLACING CONTACTS - With steps 1 - 5 under DISASSEMBLY completed inspect the contact surfaces for
evidence of wear. When severe contact wear is evidenced it is recommended that all contacts be replaced. Replacing all contacts will guard against uneven and unequal contact closings. Order the
required number of single pole contact sets from
the part listings on Page 4. Follow steps 1-5 under
DISASSEMBLY.
MOVABLE CONTACTS - The following instructions
describe the replacement of movable contacts.
1. Remove the movable contact (item 9) by depressing
the contact spring (item 10) and pushing the contact
out to either side. The contact spring will fall free or
can be lifted out.
2. Hold the replacement spring and contact in one
hand as shown in Figure 1.
3. Seat the contact spring over the "seating project ion" 0 nth e r--------------.,
movable contact
support assembly. Slip the
movable contact
and spring into
position in the
opening on the
movable contact
support
assembly.
4. Check to determine that the
spring is holding
the contact
Figure 1
centered.
FRONT STATIONARY CONTACTS - The mounting screws
that secure the front stationary contacts (item 11) are
accessi ble from th e front and are located directly below
and to the back of the front terminal assemblies.
1. Loosen and remove the screw and lift out the
co ntact.
2. Install the replacement contact (front and rear
stationary contacts are identical) and tighten the
contact mounting screw securely (approximately
8-10 inch pounds).
Publication 505-6.0 -
April, 1977
BI006008
~R
STATIONARY CONTACTS - The mounting screws
the terminals on the stationary contact block and

base assembly. Secure the overload relay to the
mounting plate with the two previously removed
screws with washers (NOTE: Place the flat washers
next to the molded plastic part). Tighten securely
(approximately 20 inch pounds).
6. Retighten securely the three terminal screws.to
overload relay bus (approximately 20-26 inch
pounds).
7. Reconnect control and load wiring.
t secure the rear stationary contacts (item 12) are

essible from the top and are located at an angle in
cavities directly behind the front terminal
emblies.
Loosen and remove the mounting screw while
holding the contact with a finger from within the
contact block assembly.
;:lush the loose contact up and out with the holding
finger or allow it to drop down.
Install the replacement contact from the top catchng it from within the contact block assembly with a
finger.
Insert the mounting screw and tighten securely
:approximately 8-10 inch pounds).
OVERLOAD RELAY TEST MODULE - The overload relay is

equipped with a test module (item 14), on the right
hand side, that allows opening the normally closed
overload co ntact for test pu rposes, without tri ppi ng the
relay.
)LACING THE STATIONARY CONTACT BLOCK AND

SE ASSEMBLY - The block and base assembly (item
1. To remove use an appropriate size screwdriver. Hold

the blade vertically and insert the screwdriver tip
into the slot, provided on the test module, to the
point where it "bottoms". Refer to Figure 7 on
Page 5.
2. Slide the test module out to the right.
3. Slide the replacement test module into place and
press firmly until it locks in place.
can be removed from a partially disassembled

rter if necessary. First follow steps 1-5 under
;ASSEMBLY.
~emove the line wiring and both front and rear
Jower wiring interconnector assemblies (item 16).
fhe right hand contactor block and base assembly is
connected, by bus, to the overload relay. Loosen but
:Jo not remove the three terminal screws that connect the block and base assembly to the overload
relay. (This is not necessary on the left hand
contactor).
Each block and base assembly is secured to the
mounting plate (item 19) by three #8-32 x .609"
Phillips pan head mounting screws with washers
(item 15). Remove these screws and the stationary
contact block and base assembly (item 3) can be
lifted up and out whi Ie tilti ng it slightly to the outsi de
to clear the projection on the mechanical interlock.
REASSEMBLY - The reassembly process is basically

the disassembly procedures in the reverse order.
1. Insert the yoke into the operating coiL It is keyed and
will fit only one way.
2. Insert the yoke and operating coil into the movable
3. Insert all three parts as a unit into the stationary
contact block and base assembly.
4. Replace the coil cover. Check the tie point terminal
for proper position as shown in Figure 2 below.
Tighten the coil cover screws securely (approximately 14-17 inch pounds).
5. Replace contact block cover and tighten screws
securely (approximately 8-10 inch pounds).
6. Install the auxiliary contact block(s). Refer to detailed instructions on Page 5.
If new contacts are not being installed, remove

stationary contacts one at a time from the old block
and base assembly and install them in the same
positions in the new assembly (see instructions
under REPLACING CONTACTS. Follow those instructions also if installing new contact sets).
Install the replacement block and base assembly
and secure with the three screws with washers and
tighten securely (approximately 14-17 inch pounds).
Retighten terminal screws to overload relay bus on
the right hand contactor securely (approximately
20-26 inch pounds).
Reconnect line wiring and front and rear power
wiring interconnector assemblies.
LACING THE OVERLOAD RELAY - The overload relay

m 13) is connected to both the block and base
embly (item 3) and load lines.
~emove the control wire(s) from the overload relay.
~emove the load wiring from the overload relay
erminals.
_oosen but do not remove the three terminal screws
hat connect the overload relay bus to the block and
)ase assembly, approximately 3 turns.
rhe overload relay is secured to its mounting plate
)y two #8-32 X '12" pan head mounting screws with
Nashers. Remove these screws, lift the overload
'elay away from the mounting plate, then slide it
jown and out.
rhe replacement overload relay will be furnished
;ecured to a mounting plate. Remove and discard
he mounting plate. Install the replacement overoad relay being sure the bus connects properly to
Proper Tie Point Terminal Position

Figure 2
REMOVAL OF MECHANICAL LOAD BALANCER -
The
movable contact support and armature assembly must
be completely open (the word "OFF" totally visible).
1. Loosen the two captive screws and lift off the
contact block cover.
2. Remove the load balancer by pivoting the bottom of
the balancer housing away from the contactor and
lifting up and off.
-- 2--
REPLACING MECHA ICALLOAD BALANCER - The movable contact supp rt and armature assembly must be
completely open (t e word "OFF" totally visible). The
contact block cove must be removed.
1. Hold load bala cer at an angle, hooking the three
tabs located alo g the top side edge into the groove
provided on th top edge of the stationary contact
block. See Figu e 3.
2. Push the load b lancer toward the contactor mounting plate as far s possible.
3. Exert pivotal f rce near the bottom of the load
balancer "snap ing" it in place.
IMPORTANT Iways replace the contact block
cover and torqu the two captive screws securely
(8-10 in. Ibs.) Th contact block cover secures the
load balancer in its final position.
Secure the mechanical interlock

to the mounting
BI006008
plate with the two previously removed screws and
tighten securely (approximately 24 to 29 in. Ibs.).
8. Replace the auxiliary contact block used for electrical interlocking on the right hand contactor, position Pl. See page 5 for installation instructions.
9. Replace the left hand contactor to the mounting
plate.
IMPORTANT - Be sure the "projection" on the left

side of the mechanical interlock is inserted into the
slot in the stationary contact block of the left hand
contactor and the cam rests on top of the movable
contact support. (See Figure 4).
Secu re the contactor to the mou nti ng plate with the
three previously removed screws and tighten securely (approximately 24 to 29 in. Ibs.).
10. Replace the rear power wiring interconnector assembly and tighten the front and rear power wiring
interconnector assembly screws securely (approximately 14 to 17 in. Ibs.).
11. Reconnect all control wiring.
Figure 3
REPLACING MECH
Figure 4
1. Remove all co trol wiring from left hand contactor.

2. Loosen the font power wiring interconnector
assembly scr
s on the left hand contactor.
3. Remove rear ower wiring interconnector assembly completel .
4. The left hand contactor is secured to the starter
mounting plat by three #10-32 x 15/64 " Tensil-Lock
pan head scre s. Remove these screws and lift the
contactor off f the mounting plate.
5. Loosen the co I cover on the right hand contactor
and remove t e auxiliary contact block used for
electrical inter ocking. Retighten coil cover screws
securely (app oximately 14-17 in. Ibs.).
6. The mechanic I interlock is secured to the mounti ng plate by t 0 # 10-32 X 15/64 " Tensil-Lock pan
head screws. emove these screws and lift off the
mechanical in erlock.
7. Install the rep acement mechanical interlock.
o D OPERATING COilS
Coil
AC Voltage Range
e sure the "projection" on the

right side of the mechanical interlock is inserted
into the slot in t e stationary contact block of the
right hand cont ctor and the cam rests on top of
the movable co tact support. (See Figure 4).
-3-
Hz.
24
60
115-120
60
110
50
Coil Number
CB013
CB236
110-115
50
CB322
200-208
60
CB249
220-230
50
CB339
60
CB254
230-240
IMPORTANT -
Frequency
50
CB342
380
50
CB354
CB357
415
50
440-460
50
CB360
460-480
60
CB273
500
50
CB364
575-600
60
CB278
For coils other than those listed specify coil number and
complete rating found on coil's identification label.
NOTE - Parts indicated with 0 are recommended spare
pa rts.
BI006008
CONTACTS
Item
1
02
03
Description of Part
Contact Block Cover
Movable Contact Support and Armature Assembly
SIZE 0
SIZE 1
3 Phase
3 Phase
Part Number
Part Number
40410-499-01
40410-499-02
40410-498-01
Right Hand Stationary Contact Block and Base Assembly
40410-494-03
40410-494-04
Left Hand Stationary Contact Block and Base Assembly
40410-495-03
40410-495-04
Coil Cover
Tie Point Terminal
Auxiliary Contact Block (refer to Page 5)
Operating Coil
Yoke (50-60 Hz.)
Movable Contact
40410-496-01
599-TP02
OD595-AB
See Table Page 3
40410-497-01
Order Single Pole Contact Set
10
Contact Spring
11
Front Stationary Contact
12
9-12
Rear Stationary Contact

Single Pole Contact Set (includes [1J each items 9-12)
040410-331-51
040410-331-52
13
Overload Relay (includes item 14 test module)
0592-BOW16
14
Test Module (included with item 13 overload relay)
40185-499-01
15
8-32 x .609" Phillips Pan Head Mtg. Screw w/Washer (3 req'd)
28169-100-26
16
Power Wiring Interconnector Assembly (includes [1]

front and rear interconnector assembly)
599-B01R
40410-342-51
17
Mechanical Load Balancer (Refer to Page 2-3)
18
Mechanical Interlock Assembly (Refer to Page 3)
19
Mounting Plates
40410-341-51
Refer to Factory
o Less contacts, order Single Pole Sets as required.

D Starters are furnished with one of the above auxiliary contact blocks on each contactor as standard for
electrical interlocking contact.
NOTE - Parts indicated with 0 are recommended spare parts.
ORDERING INFORMATION - Your order cannot be entered unless the following information is given: Part number,
description of part, catalog number and series letter of starter, This renewal parts list applies also to these starters
when used on control apparatus listed under other Bulletin numbers.
-4-
BI006008
MODIFICATIONS
Exert
Pivotal
Force
Cat. No. 595-A
Cat. No. 595-AB
7 N.D.)
(7 N.D.-7 N.c.)
AUXILIARY CO TACTS - Bulletin 505 starters are designed to acce t one to four auxiliary contact blocks
which can pro ide up to eight auxiliary contacts of the
user's choice. uxiliary contact blocks mount at positions P1 and 2 on the coil cover of the left hand
contactor, and 3 and P4 on the coil cover of the right
hand contacto Normally, the inboard mounting positions on both c ntactors are used for or obstructed by
factory install d interlock contact blocks. Auxiliary
contact blocks an be mounted without the use of tools
or additional h rdware.
OAuxiliary Contact Description
One
One
One
(1
Two
Two
Normally 0
Normally CI
Normally 0
N.O.-l N.C)
Normally 0
Normally CI
NOTE -
en 11 N.D.)
sed 11 N.C.)
en-One Normally Closed
en (2 N.D.)
sed (2 N.C.)
Figure 6
Catalog Number
AUXILIARY CONTACT (N.O.) FOR OVERLOAD RELAY - This

contact can easily be added to the block type overload
relay used on Bulletin 505 Starters. It mounts in place of
the standard overload relay test module. A typical
application would be for an alarm circuit indicating
when the overload relay has tripped.
595-A
595-B
595-AB
595-AA
595-BB
Parts indicated withOare recommended spare parts.
REMOVAL OFAXILIARY CONTACT BLOCK- Loosen coil

cover and lift 0 tthe auxiliary contact block by pivoting
its back end a ay from starter.
INSTALLING 0 REPLACING AN AUXILIARY CONTACT
BLOCK - The ovable contact support and armature
assembly mus be completely open (the word "OFF"
totally visible) The coil cover must be in place and
properly secur d.
1. Align arrow molded on auxiliary contact block. See
Figure 5.
2. Locate mol ed tabs on side with arrows. See Figure 5.
INSTALLING (N.O.) AUXILIARY CONTACT - First remove

the test module as indicated below.
1. Use an appropriate size screwdriver.
2. Hold the blade vertically and insert the screwdriver
tip into the slot provided on the test module to the
point where it "bottoms". See Figure 7.
4. Slide the N.O. auxiliary contact block into the overload relay in place of the test module.
5. Secure the block, using the mounting screw provided, through the hole in the overload relay housing. See Figure 8.
3. Hook tabs nder coil cover at any pocket location

(P1, P2, P3, r P4).
4. Exert a piv tal force at the lower end of the block
until it snap into place. Refer to Figure 6.
NOTE - When
tact blocks (be
sary to use a t
force because
replacing the "inboard" auxiliary conween the contactors) it may be neces01, such as a screwdriver, to exert this
f restricted space.
Auxiliary
Contact
Block
Molded Tab
Figure 7
Figure 5
-s~
Figure 8
BI006008
~ ALLEN-BRADLEY
~
Allen-Bradley has been helping its customers improve productivity and quality for 90 years.
It designs, manufactures and supports a broad range of control and automation products
worldwide. They include logic processors, power and motion control devices, man-machine
interfaces and sensors. Allen-Bradley is a subsidiary of Rockwell International, one of the
..,,;~)
_ _ _ _w_o_rld_'_s_le_ad_in_g_t_ec_h_n_ol_09_y_c_o_m_p_an_ie_s_.
Vith major offices worldwide.

geria Argentina' Australia Austria' Bahrain' Belgium Brazil' Bulgaria Canada' Chile China, PRC Colombia' Costa Rica Croatia Cyprus' Czech Republic
Denmark Ecuador Egypt EI Salvador Finland France' Germany Greece' Guatemala Honduras Hong Kong Hungary' Iceland' India Indonesia Israel
lly Jamaica' Japan' Jordan Korea Kuwait Lebanon' Malaysia' Mexico' New Zealand Norway Oman Pakistan Peru Phil'lppines Poland Portugal
Jerto Rico Qatar Romania Russia-CIS Saudi Arabia Singapore Slovakia Slovenia South Africa, Republic Spain Switzerland' Taiwan Thailand The
3therlands Turkey' United Arab Emirates United Kingdom United States' Uruguay' Venezuela' Yugoslavia
'arid Headquarters, Allen-Bradley, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel (1) 414 382-2000 Fax: (1) 414 382-4444
Printed in U.S.A.
BULLETIN
I 509
BI006008
RENEWAL PARTS
FULL VOLTAGE STARTERS

Size 0 Size 1 Series A Construction
REPLACING CONTACTS - When severe contact wear is
evidenced it is recommended that all contacts be
replaced. Replacing all contacts will guard against
uneven and unequal contact closings. Order the
required number of single pole contact sets from
the part listings on Page 3. Follow steps 1-5 under
DISASSEMBLY.
MOVABLE CONTACTS -
ese AC full voltage starters are deOPERATION signed for starti g and stopping of polyphase squirrel
cage motors a d the primary control of slip-ring
motors. They ca also be used for self-starting single
phase motors.
The rapid con istent action of these starters makes
them particularly suitable for high speed automatic
operations.
Starters can b operated by remote control with push
buttons, float switches, thermostats, pressure
switches, snap s itches, limit switches or any suitable
form of two or tree wire pilot device.
OPERATING ENV RONMENT - Starters should always

be maintained i a clean and dry condition for dependable operation. hoice of the proper NEMA enclosure
type for the app ication is very important.
REPAIRS - Start
the "exploded"
following proce
aid in the seque
motor starter.
rs can be disassembled as depicted in

lIustration on Page 2. Additionally the
ures and techniques are suggested to
tial disassembly and reassembly of a
WARNING -
Before part replacements are attempted th

POWER SOURCE MUST BE
DISCONNECT D.
DISASSEMBLY ( artial)- It is not necessary to remove

the starter fro
its enclosure or to remove the line
wiring.
1. Remove all ontrol wires from the operating coil
(item 7) and ie point terminal (item 5).
2. Loosen two aptive screws and lift off the contact
block cover ( tem 1).
3. Loosen four aptive screws from the coil cover (item
4). The tie po nt terminal is now free to be removed,
if it is to be r placed.
4. With the coi cover screws loosened the auxiliary
contact block s) (item 6) can be removed and the coil
cover lifted ff.
5. Lift out the ovable contact support and armature
assembly (it m 2), the yoke (item 8) and the operating coil (item ) as a unit. The yoke and the operating
coil can no be lifted up and out of the movable
contact supp rt assembly.
The following instructions

describe the replacement of movable contacts.
1. Remove the movable contact (item 9) by depressing
the contact spring (item 10) and pushing the contact
out to either side. The contact spring will fall free or
can be lifted out.
2. Hold the replacement spring and contact in one
hand as shown in Figure 1.
3. Seat the contact spring over the "seating projection" on the
movable contact
support assembly. Slip the
movable contact
and spring into
position in the
opening on the
movable contact
support
assembly.
4. Check to determine that the
spring is holding
the con t act
Figure 1
centered.
FRONT STATIONARY CONTACTS -
The mounting
screws that secure the front stationary contacts (item
11) are accessible from the front and are located directly below and to the back of the front terminal
assemblies.
1. Loosen and remove the screw and lift out the
contact.
2. Install the replacement contact (front and rear
stationary contacts are identical) and tighten the
contact mounting screw securely (approximately
8-10 inch pounds).
REAR STATIONARY CONTACTS - The mounting screws

that secure the rear stationary contacts (item 12) are
accessible from the top and are located at an angle in
the cavities directly behind the front terminal
assemblies.
1. Loosen and remove the mounting screw while holding the contact with a finger from within the contact
block assembly.
2. Push the loose contact up and out with the holding
finger or allow it to drop down.
3. Install the replacement contact from the top catching it from within the contact block assembly with a
finger.
4. Insert the mounting screw and tighten securely
(approximately 8-10 inch pounds).
Publication 509-6.0-November, 1976
Supersedes Publication 509-6.0 Dated September, 1976
BI006008
CONTACTS
0 Heater Element
- - - Type W (Specify)
arts indicated with
are recommended spare parts.
EPLACING THE STATIONARY CONTACT BLOCK AND

ASE ASSEMBLY - The block and base assembly (item
) can be removed from a partially disassembled
:arter if necessary. First follow steps 1-5 under DISASEMBLY. The block and base assembly is connected to
1e incoming lines and the overload relay (item 13).
Remove the line wiring.
The block and base assembly is connected, by bus,
to the overload relay. Loosen but do not remove the
three terminal screws that connect the block and
base assembly to the overload relay.
The block and base assembly is secured to the
mounting plate (item 16) by three #8.-32 x .609"
Phillips pan head mounting screws with w~shers
(item 15). Remove these screws and the stationary
contact block and base assembly (item 3) can be
lifted up and out.
If new contacts are not being installed, remove
stationary contacts one at a time from the old block
and base assembly and install them in the same
positions in the new assembly (see instructions
under REPLACING CONTACTS. Follow those instructions also if installing new contact sets).
Install the replacement block and base assembly
and secure with the three screws with washers and
tighten secu rely (approximately 14-17 inch pou nds).
Retighten terminal screws to overload relay bus
Reconnect line wiring.
REPLACING THE OVERLOAD RELAY - The overload relay

(item 13) is connected to both the block and base
assembly (item 3) and load lines.
1. Remove the control wire(s) from the overload relay.

2. Remove the load wiring from the overload relay
terminals.
3. Loosen but do not remove the three terminal screws
that connect the overload relay bus to the block and
base assembly, approximately 3 turns.
4. The overload relay is secured to its mounting plate
by two #8-32 x 1,12" pan head mounting screws with
washers. Remove these screws, lift the overload
relay away from the mounting plate, then slide it
down and out.
5. The replacement overload relay will be fur~ished
secured to a mounting plate. Remove and discard
the mounting plate. Install the replacement overload relay being sure the bus connects properly to
the terminals on the stationary contact block and
base assembly. Secure the overload relay to the
mounting plate with the two previously removed
screws with washers (NOTE: Place the flat washers
next to the molded plastic part). Tighten securely
(approximately 20 inch pounds).
6. Retighten securely the three terminal screws to
overload relay bus (approximately 20-26 inch
pounds).
7. Reconnect control and load wiring.
OVERLOAD RELAY EST MODULE- The overload relay is

equipped with a test module (item 14), on the right
hand side, that Ilows opening the normally closed
overload contact or test pu rposes, without tripping the
relay.
1. To remove u e an appropriate size screwdriver.
Hold the blad vertically and insert the screwdriver
tip into the slo , provided on the test module, to the
point where t "bottoms". Refer to Figure 5 on
Page 4.
2. Slide the test odule out to the right.
3. Slide the repl cement test module into place and
press firmly u til it locks in place.
1. Insert the yoke into the operating coil. It is keyed and

BI006008
will fit only one way.
2. Insert the yoke and operating coil into the movable
3. Insert all three parts as a unit into the stationary
contact block and base assembly.
4. Replace the coil cover. Check the tie point terminal
for proper position as shown in Figure 2 below.
Tighten the coil cover screws securely (approximately 14-17 inch pounds).
5. Replace contact block cover and tighten screws
6. Install the auxiliary contact block(s). Refer to detailed instructions on Page 4.
7. Properly reconnect all wiring.
REASSEMBLY - The reassembly process is basically

the disassembly procedures in the reverse order.
Description of Part
Item
Contact Block Cover
02
Movable Contact Support and Armature Assembly
03
Stationary Contact Block and Base Assembly
Coil Cover
Tie Point Terminal
Auxiliary Contact Block (refer to Page 41
SIZE 0
SIZE 1
3 Phase
3 Phase
Part Number
Part Number
40410-499-01
40410-499-02
40410-498-01
40410-494-03
40410-494-04
40410-496-01
599-TP02
o 595-A (used as hold-in contactl
Operating Coil
Yoke 160-50 Hz.)
40410-497-01
Movable Contact
See Table Below
10
Contact Spring
11
Front Stationary Contact
12
Rear Stationary Contact
9-12
13
Single Pole Contact Set (includes [1] each items 9-12)
040410-331-51
040410-331-52
o 592-BOW16
Overload Relay (includes item 14 test module)
14
Test Module (included with item 13 overload relay)
40185-499-01
15
8-32 x .609'" Phillips Pan Head Mtg. Screw w/Washer (3 req'd)
28169-100-26
16
Mounting Plate
Refer to Factory
Less c ntacts, order Single Pole Contact Sets as required.

Parts indicated with 0 are recommended spare parts.
o II OPERATING COILS
Coil
AC Voltage Range
Frequency
24
60
115-120
60
110
50
II
CB013
CB236
110-115
50
CB322
60
CB249
220-230
50
CB339
60
CB254
380
Figure 2
Coil Number
200-208
230-240
Prop r Tie Point Terminal Position
Hz.
50
CB342
50
CB354
415
50
CB357
440-460
50
CB360
460-480
60
CB273
500
50
CB364
575-600
60
CB278
For coils other than those listed specify coil number and
complete rating found on coil's identification label.
ORDERING INFORMATION - Your order cannot be entered unless the following information is given: Part
number, description of part, catalog number and series
letter of starter. This renewal parts list applies also to
these starters when used on control apparatus listed
under other bulletin numbers.
BI006008
MODIFICATIONS
Cat. No. 595-A02

Cat. No. 595-A
(I NO.)
Cat. No. 595-AB

(I NO.-I NC.)
AUXILIARY CONTACT (N.O.) FOR OVERLOAD RElAY - This
AUXILIARY CONTACTS -
Bulletin 509 Starters are designed to accept one to four Bulletin 595 Auxiliary
Contact Blocks which can provide up to eight auxiliary
contacts of the user's choice. Auxiliary contact blocks
mount at positions marked P1, P2, P3 or P4 on the coil
cover. They can be mounted without the use of tools or
additional hardware.
One
One
One
(1
Two
Two
Auxiliary Contact Description

Normally Open (1 N.D.)
Normally Closed (1 N.C.)
Normally Open-One Normally Closed
N.o.-1 N.C.)
Normally Open (2 N.D.)
Normally Closed (2 N.C.)
Parts indicated with

~EMOVAL
Catalog Number
595-A
595-B
595-AB
595-AA
595-BB
are recommended spare parts.
OF AUXILIARY CONTACT BLOCK - Loosen coil
~over and
lift out the auxiliary contact block by pivoting

ts back end away from starter.
contact can easily be added to the block type overload

relay used on Bulletin 509 Starters. It mounts in place of
the standard overload relay test module. A typical
application would be for an alarm circuit indicating
when the overload relay has tripped.
INSTALLING (N.O.) AUXILIARY CONTACT - First remove

the test module as indicated below.
1. Use an appropriate size screwdriver.
2. Hold the blade vertically and insert the screwdriver
tip into the slot provided on the test module to the
point where it "bottoms". See Figure 5.
4. Slide the N.O. auxiliary contact block into the overload relay in place of the test module.
5. Secure the block, using the mounting screw provided, through the hole in the overload relay housing. See Figure 6.
NSTALLING OR REPLACING AN AUXILIARY CONTACT

JLOCK - The movable contact support and armature
Issembly must be completely open (the word "OFF"
otally visible). The coil cover must be in place and
)roperly secu red.
Align arrows molded on auxiliary contact block. See
Figure 3.
Locate molded tabs on side with arrows. See Figure 3.
Hook tabs under coil cover at any pocket location
(P1, P2, P3, or P4).
Exert a pivotal force at the lower end of the block
until it snaps into place. Refer to Figure 4.
Auxiliary
Contact
Block
Align Arrows
Figure 5
Figure 6
Molded Tabs
Figure 3
Exert
Pivotal
Force
Figure 4
~ ALLEN-BRADLEY
~
Power Group
Milwaukee,Wisconsin 53204
BULLETIN
I 592
BI006008
PRODUCT DATA
OVERLOA RELA YS Motor Pr tection Ambient Temperature Correction

Allen-Bradley standard motor overload protection is provided using Type
W heater elements and Bulletin 592 block style overload relays with
Bulletin 500 Line motor controllers. This provides Class 20 overload
protection as defined in Part ICS 2-222 of NEMA Standard ICS 2,
Standards for Industrial Control Devices, Controllers and
Assemblies.When these devices are properly applied, they are capable of
protecting motors against premature damage due to excessive
overcurrents in the vast majority of applications.
The ambient temperature at the motor and controller is the same in most
applications. Under this condition, the overload relay is designed to sense
changes in ambient temperature and also protect the motor over a range
oftemperatures. Heater elements should be selected according to the
directions given in the Industrial Control Catalog.
Output that a motor can safely deliver varies with temperature. The
motor can deliver its full rated horsepower at the ambient temperature
specified by the motor manufacturer, normally 40C (l04F). This is
explained in Figure 1 which shows the percent of normal rated current
that can be drawn by as typical Class B insulated motor.
150
140
C
QJ
......
<3
120
110
100
&
130
t;::f-
r--
STANDARD RATING
TEMPERATURE
40C
........
o
C
QJ
90
Q)
70
1"-_
r--
Dt--
-,...
,/
Class B
Insulation
f-f-
80
Q.
60
f-r--
.--
500
o~.
of
I ~I~ I
30
40
10
I
20
iii
I I I I I
50
60
70
I
80
30
40
50
60
I
70
I
~C
110F
90 100 110 120 130 140 150 160
Ambient Temperature - Degrees

Figure 1
At high temperatures (higher than 40C) less than 100% of the normal
rated current can be drawn from the motor without shortening the
insulation life. At lower temperatures (less than 40C) more than 100% of
the normal rated current could be drawn from the motor without
shortening the insulation life. Thus, there is an inverse relationship
between motor ambient temperature and allowable motor output. In any
motor, allowable output decreases as the ambient temperature is raised
and vice versa.
BI006008
Overload Relays
Insulation life data provided for motors is based on specified operating
and ambient conditions. Motors are constructed to operate at a temperature slightly below the rated insulation temperature when running full
load at rated ambient temperature [normally 40 C 004 F)]. When
compared with low temperature rated motors, motors operating at higher
temperatures will experience a greater temperature increase for equal
percentages of overcurrent. Since insulation degrades with temperature
at an exponential rate, these motors will have a greater reduction in their
expected life when overloaded. Thus, motors with Class For H insulation
have less tolerance to overcurrents than motors with Class A or B
insulation. This is shown in Figure 2.
Motor Life Versus Motor Current

At Constant Ambient Temperature
....e:(
100
90
Class "A" (105C) Insulation
....J
:::>
(J)
80
a::
0
....
0
Class "B" (130C) Insulation
70
Class "F" (155C) Insulation
60
:E
LL
Class "H" (180 C) Insulation
50
LL
:::i
40
....e:(w
30
20
....
z
w
U
a::
w
Q.
10
0
100
105
110
115
120
PERCENT OF MOTOR RATED CURRENT
Figure 2
Figure 3 on Page 3 shows how closely the Type W heater elements are
designed to track the allowable output of a typical motor and protect it at
varying ambient temperatures when both the motor and controller are
located in the same ambient temperature.
But, what if the ambient temperature is different at the controller than at
the motor? Consider the case where the temperature difference is small.
For example: lOoC or less. Again, the Industrial Control Catalog gives
directions for selecting the proper heater element. It depends on whether
the temperature at the controller is higher or lower than at the motor.
BI006008
Overload Relays
Type W . Heater Ambient Temperature Correction Factor Curve
150
-.:::- 140
.9
al
130
::;
120
~u.
l--
1-...
()'';::;
"0 u
110
m8C
a:
100
Ol Ol
5TANDARD RATING
ITEMPERATURE
""'t-., 40C
'0 ~
r...
~.~. ,~~ ~~~
80
0lC-
I
i
ype V ;;,~aters
f'.
90
E2
OlCll
~ Qi
0..
F.:..
t-
..
I
J""ot-
f- ~. - f -
E 70
~ 60
I
~
500
II
0<J
of
10
30
I
40
20
50
60
I
I
70
I
80
30
40
50
I
60
I
I
70
L.L.~C
I I 1 ' .L Iof
90 100 110 120 130 140 150 160
Ambient Temperature - Degrees

Figure 3
When the temperature difference is more than 10C an ambient tempera~

ture correction factor should be used as part of the process for selecting
heater elements. The ambient temperature correction curve as it appear
in Figure 3 shows the factor by which heater selection ratings change wit
ambient temperature changes for Type W heater elements.
When solving problems where ambient temperature correction is

sary, the following simple procedure is recommended:
neces~
Step 1 First find the correction factor ratio (CFR). This is the ratio of
motor ambient temperature correction factor (CF motor) to the
controller ambient temperature correction factor (CF controller)
The formula for calculating the correction factor ratio is:
CFR
= CF motor
CF controller
Both correction factors are selected from the curve for the type of heater
element to be used. The Industrial Control Catalog shows temperature
correction curves for Type B, J, Wand WL heater elements. The heater
element selection tables in the Industrial Control Catalog are based on a
40C ambient temperature. This means the correction factor for a 40C
ambient is 100%.
Step 2 Next, multiply the motor nameplate full load current (FLC) by
the CFR. to obtain a readjusted value of motor full load current
(RFLC).
Step 3 The last step is to refer to the suggested heater element table an<
pick the element whose rating for the given controller size is
closest to RFLC.
BI006008
Overload Relays
To become familiar with this heater element selection process, consider
the following examples. Use Figure 3 on Page 3 to determine the
correction factors for these examples.
Example 1:
3 phase, AC, squirrel cage motor, 25 hp, 460 volts, 60 Hz, 1800 rpm, FLC
of 34 amps, service factor of 1.15. Temperature at controller is 40C.
Temperature at motor is 25C. Type W elements will be used.
In this example, the motor is at a much cooler ambient temperature
(25C) compared to the controller which is at the normal 40C. Because
the motor is normally rated for use at 40C it will deliver a little more
than its rated horsepower. This means that a heater element with a
higher than normal motor nameplate full load current can be used.
Refer to the Type W ambient temperature correction curve (Figure 3 on

Page 3) for a motor at 25C ambient. The motor correction factor (CF
motor) is shown to be 108%. The correction factor for the controller
ambient temperature is 100% since it is at 40C. Thus,
C.F.R.
CF motor
108%
CF controller
100%
1.08
Now using this correction factor, the readjusted full load current value
can be determined by:
RFLC
34 x 1.08
36.7 Amps.
A Bulletin 512, Size 2, was specified for this application. The directions
for heater element selection in the Industrial Control Catalog indicate
that Table 153 should be used. The table shows that 36.7 amps falls
between two values, 35.0 amps (W66) and 38.0 amps (W67). Because 38.0
amps is closer to the RFLC heater element W67 should be used.
Example 2:
This represents a situation where the motor ambient temperature is higher than 40C. In this example, the motor is at 55C ambient temperature
and the controller is at 40C. When the motor is functioning in a warmer
environment it will not be able to deliver the normal horsepower. To
protect it from damage, it becomes necessary to down size the heater
element compared to the same motor operating in a 40C ambient
temperature. Refer to thew Type W ambient temperature correction
curve on Page 3 (Figure 3). The correction factor would be:
C.F.R.
CF motor
91%
CF controller
100%
0.91
Ha ving determined the correction factor, the current rating to be used

when selecting a heater element would be:
RFLC
= 34.0 x 0.91
= 30.9 Amps.
For a Bulletin 512, Size 2, again refer to Table 153. The value of30.9
amps falls between 30.0 amps (W64) and 32.5 amps (W66). Since 30.0 is
closer to 30.9, specify the W64 heater element.
BI006008
Overload Relays
Example 3:
Consider a case where both the controller and the motor are at ambient
temperatures other than 40C. In this example, the temperature of the
controller is 25C ambient (cooler); while the temperature at the motor
is 55C ambient (warmer). As stated previously, a motor running in a
warmer environment will deliver less than its normal horsepower.
This requires down sizing the heater element rating. The controller in
this case is in a cooler environment which prevents the heater element
from heating up as much as in a 40C ambient temperature. This also
requires down sizing the heater element rating to provide adequate protection. Thus, the net effect of a warmer motor and a cooler controller is
to further down size the heater element. Using the Type W temperature correction curve on Page 3 (Figure 3), the correction factor in this
case is:
C.F.R.
CF motor
91%
CF Controller
108%
0.84
The readjusted value offullioad current for this example is:

RFLC
34 x 0.84
= 28.6 Amps
Table 153 shows that this value falls between 28.0 amps (W63) and 30.0
amps (W64). Select heater element W63 because 28.0 amps is closer to
the requirement.
Example 4:
Now, consider the effect of a controller in a warmer environment and a
motor in a cooler environment. In example 4, the controller is at 65C
ambient (warmer) and the motor at 35C ambient (cooler). As mentioned before, a motor at a cooler temperature can deliver more than its normal horsepower. The controller, when in a warmer environment, will
heat up faster causing the eutectic alloy to melt before the normal
overload condition. This requires up sizing the heater element rating.
Refer to the Type W ambient temperature correction curve on Page 3
(Figure 3), the correction factor in this case is:
C.F.R.
CF motor
103%
CF Controller
84.5%
1.22
This correction factor allows a heater element with current rating of:
RFLC
34.0 x 1.22
= 41.5 Amps
Refer to Table 153, this value of 41.5 amps falls between 40.5 amps
(W68) and 43.5 (W69). Select heater element W68 because 40.5 amps is
closer to the requirement.
BI006008
Example 5:
Next, take an example where both the controller and the motor are both
warmer than 40C ambient temperature, but, their ambient
temperatures are different. For instance, the controller could be at 45C
ambient and the motor is at 60C ambient. Since the difference in their
ambient temperature is greater than 10C an ambient temperature
correction must be made. In Example 5 the correction factor is given by:
C.F.R.
CF motor
88%
CF Controller
97%
0.91
This means that the rating of the heater element should be 91 % of the
normal nameplate motor full load current or:
RFLC
=
=
34.0 x 0.91
30.9 Amps
For a Bulletin 512, Size 2 controller, Table 153 shows this rating to fall
between 30.0 amps (W64) and 32.5 amps (W65). Select heater element
W64 because 30.0 amps is closer. Note here that the net effect has been to
down size the heater element rating compared to a normal 40C ambient
operation.
Note - The heater element selection tables are designed to accommodate
motor service factors of 1.15 or greater, as given in the preceding examples. If the service factor had been less than 1.15 (for example: SF = 1.0),
a heater element one rating smaller than selected in each example would
have been the correct choice. This would provide protection at 10% lower
current levels.
The procedures shown above for selecting heater elements for Class B
motors also apply for Class A, F and H. For Class F and H it is even more
important to select the proper heater elements since the expected life
decreases rapidly when motors are subjected to an overcurrent. See
Figure 2 on Page 2 for a comparison of motor insulation classes.
Specific applications may require Class 10 or Class 30 overload
protection. Class 10 overload relays are often used with hermetic motors,
submersible pumps or motors with short locked rotor time capability.
Type J heater elements are available for applications requiring Class 10
overload protection. Class 30 overload relays are often used with motors
driving inertia loads (where additional accelerating time is needed and
the motor permissible locked rotor time is suitable for the application).
Type WL heater elements are available for applications requiring Class
30 overload protection.
7
BI006008
Overload Relays
Ambient temperature compensated overload relays are designed to overcome the effects of ambient temperature on their operation. These relays
only sense the current and not the ambient temperature that a controller
or motor may be subjected to. These relays are only useful in situations
where the controller (starter) is operating in an environment where the
ambient temperature varies widely while the temperature of the motor
remains constant. Applications where the controller temperature is
constant while the motor temperature varies, or where both undergo
wide swings in ambient temperatures are not properly protected by
ambient compensated overload relays. Such applications require special
design considerations and should be referred to Milwaukee.
Allen-Bradley Type W heater elements and Bulletin 592 block style

overload relays are designed to provide accurate and dependable motor
overload protection. When properly applied, these devices are capable
of protecting motors from premature damage in the vast majority of
applications. The ambient temperature correction curve should be used
when the ambient temperatures at the controller and the motor differ
by more than lOoC. For ambient temperature differences less than
lOoC, selection using Rules 1, 2 and 3 listed in the Industrial Control
Catalog will provide protection. Ambient temperature compensated
overload relays (Bulletin 593C) are recommended only when the motor
is at a constant ambient while the controller is subject to varying
ambient temperatures.
BI006008
'1' Rockwell Automation

Allen-Bradley
Allen-Bradley, a Rockwell automation business, has been helping its customers improve
leading technology companies,
~
Worldwide representation. - - - - - - - - - - - - - - - -
Ecuador' Egypt EI Salvador' Finland' France' Germany' Greece' Guatemala' Honduras' Hong Kong Hungary' Iceland' India' Indonesia' Ireland' Israel' Italy
Jamaica' Japan' Jordan' Korea' Kuwait Lebanon' Malaysia' Mexico' Netherlands' New Zealand' Norway' Pakistan' Peru' Philippines' Poland' Portugal
Allen-Bradley Headquarters, 1201 South Second Street, Milwaukee, WI 53204 USA, Tel: (1) 414382-2000 Fax: (1) 414 382-4444
Publicatiou 592-2.0 - March. 1986

Superseues Publication 59:::'-2,0 -
December. J LJS 1
Copyright !l)l).:'i Allen-Bradley Cumpany. Illc.
Prinled in LSA
BI006008
ALLEN-BRADLEY
Bulletin 592
Type Wand WL Eutectic Alloy Heater Elements
For Application on Bulletin 500 Line Starters
Product Data
Bulletin 592
Type WHeater Elements
Table of Contents
Page
Overload Relay Class Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2
Heater Element Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Ambient Temperature Correction
3-4
Heater Element Selection Procedure
4-8
Index To Heater Element Selection Tables

Heater Selection Tables
9
10-22
BI006008
ProdOct Data
Bulletin 592
Overload Relay Class

Designation
Industry standards (NEMA Part ICS 2-222) designate an overload relay by a

class number indicating the maximum time in seconds at which it will trip
when carrying a current equal to 600 percent of its current rating.
A Class 10 overload relay will trip in 10 seconds or less at a current equal
to 600 percent of its rating.

Allen-Bradley standard Bulletin 592 overload relay protection is provided
using Type W heater elements for the 500 Line. This provides Class 20
operation and is recommended for General Applications.
Type B heater equipment used in conjunction with Bulletin 593 Bi-metal
Overload Relays also provide Class 20 protection.
Specific Applications may require Class 10 or Class 30 overload relays.
Class 10 overload relays are often used with hermetic motors, submersible
pumps, or motors with short locked rotor time capability. Class 30 overload
relays should be used with motors driving high inertia loads where additional
accelerating time is needed and the safe permissible locked rotor time of the
motor is within Class 30 performance requirements.
For applications requiring Class 30 protection, Type WL heater elements are
available. To order, use the applicable Type W selection table, follow the
heater element selection instructions and change the "w" in the Heater Type
Number to "WL".
For applications requiring Class 10 overload relays, Type J elements are
available. Refer to the appropriate tables.
Heater Element Selection
The "Full Load Amps." listed in the tables are to be used for heater element
selection. The rating of the relay in amperes at 40C is 115% of the "Full
Load Amps." listed for the "Heater Type No."
Refer to the motor nameplate for the full load current, the service factor,
and/or the mutor classification by application and temperature rise.
Use this motor nameplate information, the application rules, and the "Full
Load Amps." listed in the proper table (see index) to determine the "Heater
Type No."
MOTORS RATED FOR CONTINUOUS DUTY:

MOTORS WITH MARKED SERVICE FACTOR OF NOT LESS
THAN 1.15 OR MOTORS WITH A MARKED TEMPERATURE RISE
NOT OVER 40C.
BI006008
Product Data
Bulletin 592
1. The Same Temperature at the Controller and the Motor - Select the
"Heater Type No." with the listed "Full Load Amps." nearest the full load
value shown on the motor nameplate.
2. Higher Temperature at the Controller than at the Motor CD - If the
full load current value shown on the motor nameplate is between the
listed "Full Load Amps.", select the "Heater Type No." with the higher
value.
3. Lower Temperature at the Controller than at the Motor CD - If the full
load current value shown on the motor nameplate is between the listed
"Full Load Amps.", select the "Heater Type No." with the lower value.
ALL OTHER MOTORS RATED FOR CONTINUOUS DUTY
(INCLUDES MOTORS WITH MARKED SERVICE FACTOR OF 1.0):
Select the "Heater Type No." one rating smaller than determined by the rules
in paragraphs 1,2 and 3.
MOTORS RATED FOR INTERMITTENT DUTY;
Consult Local Allen-Bradley Office.
CD Rules 2 and 3 apply when the temperature difference does not exceed
10C (l8F). See page 4 when the temperature difference is greater.
Ambient Temperature orrection
The ambient temperature at the motor and controller is the same in most
applications. Under this condition, the overload relay is designed to sense
changes in ambient temperature and also protect the motor over a range of
temperatures.
Output that a motor can safely deliver varies with temperature. The motor
can deliver its full rated horsepower at an ambient temperature specified by
the motor manufacturers, normally 40 C (104F). At high temperatures
(higher than 40 C) less than 100% of the normal rated current can be drawn
from the motor without shortening the insulation life. At lower temperatures
(less than 40C) more than 100% of the normal rated current could be drawn
from the motor without shortening the insulation life. Thus, there is an
inverse relationship between motor ambient temperature and motor output. In
any motor, allowable output decreases as the ambient temperature is raised
and vise-versa.
When the temperature difference between the motor and controller does not
exceed 10C the heater elements should be selected according to the
directions given on the first page.
BI006008
Product Data
Bulletin592
When the temperature difference is more than 10 C an ambient temperature

correction factor should be used as part of the process for selecting heater
elements. The ambient temperature correction curve shown below shows the
factor by which heater selection rating changes with ambient temperature
changes.
WAND WL-HEATER AMBIENT TEMPERATURE CORRECTION CURVE
130
1: 120
~
I""l
STANDARD RATING
TEMPERATURE
40C
I""l
Co)
"0
110..
CI)
~ 110
1""'1
"0
I"'lI
1:
CI)
l::!
CI)
IIlo.
Q..
100
IIlo.
90
IIlo.
I'lIIo
I'
20
10
I
40
Heater Element Selection

Procedure
50
60
I
I
70
30
I
40
II
50
II
90
100
80
110 120
Ambient Tell1lerature - Degrees
60
I
130
140
150
1I ~
160 F
In solving problems where ambient temperature correction is necessary, the

following simple procedure is recommended:
Step 1. First find the correction factor ratio ("C.F.R."). This is the
ratio of correction factor of the motor ambient temperature (C.F.m)
to the correction factor for the controller ambient temperature
(C.F.c). The formula for calculating the correction factor ratio is:
C.F.R.
c.F.m
c.F.c
Both correction factors are selected from the curve for the type of
heater element to be used. The heater element selection tables are
based on a 400 C ambient temperature. This means the correction
factor for a 40 C is 1.00. In other words, there is no correction factor
at 40C
BI006008
Product Data
Bulletin 592
Step 2. Next in this heater element selection process is to adjust the

motor nameplate full load current (FLC) by the c.F. Ratio. This
readjusted value of motor nameplate full load current (FLC) is the
yardstick in selecting the proper heater element.
Step 3. The last step is to refer to the suggested heater element table
and pick the element whose rating for the given controller size is
closest to FLC.
Examples - To become familiar with this heater element selection process,
consider a few examples.
Example 1. Starter at Normal 40 C Ambient-Motor Lower. 3 Phase,
AC, squirrel cage motor, 25 hp, 460 volts, 60 Hz, 1800 rpm, FLC of 34
amps, service factor 1.15, Temperature at starter 40C, Temperature at
motor 25 C, Type W heater elements will be used.
In Example 1, the motor is at a much cooler ambient temperature (25C)
compared to the controller which is at the normal 40C. Because the motor is
normally rated for use at 40C, it will deliver a little more than its rated
horsepower. This means that a heater element with a higher than normal
motor nameplate full load current rating can be used.
Referring to the Type W ambient temperature correction curve (on page 4)
for a motor at 25 C ambient, the motor correction factor (C.F. motor) is
shown to be 108%. The correction factor for the starter ambient temperature
is 100% since it is at 40 C. Thus,
C.F. Ratio
C.F. motor
108%
c.F. controller
100%
= ------- =
1.08
Now, using this correction factor, the readjusted full load current value can
be determined by:
FLC
=
=
34 x 1.08
36.7 Amps
A Bulletin 512, Size 2, was specified for this application. The directions for
heater element selection indicate that Table 153 should be used. The table
shows that 36.7 amps falls between two values, 35.0 amps (W66) and 38.0
amps (W67). Because 38.0 amps is closer to FLC heater element, W67
should be used.
Example 2. Starter at Normal 40C Ambient-Motor Higher. 3 Phase,
AC, squirrel cage motor, 25 hp, 460 volts, 60 Hz, 1800 rpm. FLC of 34
Amps. service factor 1.15. Type W heater elements, Temperature at starter
40C, Temperature at motor 55C.
BI006008
,
.. "
'
Product Data
'. BuUetin592
. if~ Wand WL ,eutectiC AHoy Heater Elements
This represents a situation where the motor ambient temperature is higher

than 40C. In this example, the motor is at 55C ambient temperature and
the controller is at 40 C. When the motor is functioning in a warmer
environment than the controller it will not be able to deliver the normal
horsepower. To protect it from damage, it becomes necessary to downsize the
heater element compared to the same motor operating in a 40C ambient
temperature. Referring to the Type W ambient temperature correction curve
(on Page 4), the correction factor would be:
C.F. Ratio
C.P. motor
91 %
C.P. controller
100%
= ------- =
0.91
Having determined the correction factor, the current rating to be used when
selecting a heater element would be:
FLC
=
=
34.0 x 0.91
30.9 Amps
For a Bulletin 512, Size 2, again refer to Table 153. The value of 30.9 amps
falls between 30.0 amps (W64) and 32.5 amps (W66). Since 30.0 is closer to
30.9 specify the W64 heater element.
Example 3: Starter Lower than 40C-Motor Higher. 3 Phase, AC,
squirrel cage motor. 25 hp, 460 volts, 60 Hz, 1800 rpm. FLC of 34 amps,
service factor 1.15 Type W heater elements, Temperature at starter 25C,
Temperature at motor 55C.
Next, consider a case where both the controller and the motor are at ambient
temperatures other than 40C. In Example 3 the temperature of the controller
is 25 C ambient (cooler) while the temperature of the motor is 55 C
ambient (warmer). As stated earlier, a motor running in a warmer
environment will deliver less than its normal horsepower. This requires
downsizing the heater element rating. The controller in this case is in a cooler
environment which prevents the heater element from heating up as much as
in a 40 C ambient temperature. This also requires downsizing the heater
element rating to provide adequate protection. Thus, the net effect of a
warmer motor and a cooler controller is to further downsize the heater
element. Using the Type W temperature correction curve (on page 4), the
correction factor in this case is:
C.P. Ratio
C.P. motor
= ------- =
C.P. controller
91%
108%
0.84
The readjusted value of current FLC for this example is:

FLC
34.0 x 0.84
28.6 Amps
Table 153 shows that this value falls between 28.0 amps (W63) and 30.0
amps (W64). Because 28.0 amps is closer to the requirement, select the
heater element W63.
6
BI006008
Product Data
Bulletin 592
Example 4: Starter Above 40C -Motor Lower. 3 Phase, AC, squirrel

cage motor, 25 hp, 460 volts, 60 Hz, 1800 rpm. FLC of 34 amps, service
factor 1.15, Type W heater elements, Temperature at starter 65C.
Temperature at motor 35C.
Now, consider the effect of a controller in a wanner environment and a motor
in a cooler environment. In Example 4, the controller is at 65C ambient
(wanner) and the motor at 35C ambient (cooler). As mentioned earlier, a
motor at a cooler temperature can deliver more than its nonnal horsepower.
The controller when in a wanner environment will heat up faster causing the
eutectic alloy to melt before the nonnal overload condition. This requires
upsizing the heater element rating. Referring to the Type W ambient
temperature correction curve (on Page 4), the correction factor in this
case is:
C.F. Ratio
C.P. motor
C.P. controller
103%
84.5%
1.22
This correction factor allows a heater element with current rating of :

FLC
=
=
34.0 x 1.22
41.48 Amps
Referring to Table 153, this value of 41.4 Amps falls between 40.5 amps
(W68) and 43.5 amps (W69). Because 40.5 amps is closer to the
requirement, select heater element W68.
Example 5: Starter Above 40C -Motor Above. 3 Phase, AC, squirrel
cage motor, 25 hp, 460 volts, 60 Hz, 1800 rpm. FLC of 35 amps, service
factor 1.15, Type W heater elements. Temperature at starter 45 C,
Temperature at motor 60C,
Next, take an example where both the controller and the motor are both
wanner than 40C ambient temperature but their ambient temperatures are
different. For instance, the controller could be at 45C ambient and the motor
is at 60C ambient. Since the difference in their ambient temperatures is
greater than 10C an ambient temperature correction must be made. In
Example 5 the correction factor is given by:
C.P. Ratio
C.P. motor
= ------- =
c.P. controller
88%
97%
0.91
This means that the rating of the heater element should be 90% of the nonnal
nameplate motor full load current or:
34.0 x 0.91
= 30.9 Amps
7
BI006008
Product Data ,
Bulletin 592
For a Bulletin 512, Size 2 controller, Table 153 shows this rating to fall
between 30.0 amps (W64) and 32.5 amps (W65). Because 30.0 amps is
closer, select heater element W64. Note here that the net effect has been to
downsize the heater element rating compared to a normal 40C ambient
operation.
NOTE: The heater element selection tables are designed to accommodate
motor service factors of 1.15 or greater, as given in all the preceding
examples. If the service factor had been less than 1.15 (for example,
S.F.=1.0) a heater element one rating smaller than selected in each example
would have been the correct choice. This would provide protection at 10%
lower current levels.
TIME - CURRENT CHARACTERISTICS AT 40C
(AVERAGE TRIP CURVES)
1000
900
800
700
600
500
400
300
---
FOR TIME - CURRENT

CHARACTERISTICS OF
SPECIFIC HEATER
ELEMENTS, CONSULT
LOCAL ALLEN-BRADLEY
OFFICE
200
Ui
c
100
90
80
~ 70
60
c..
~ 50
I40
o
IW
30
w...
"
I"
i=
20
10
9
8
7
I-I-I--
.....,.
'III
:E
I--
.....
........
.........
....
WL
-- ......
--
3
2
1
0
200
100
400
300
600
500
1000
800
700
900
PERCENT OF RATED CURRENT

8
1200
1100
1300
BI006008
Product Data
Bulletin 592
Index to Heater Element Selection Tables

Bulletin Number
Size
112
SIn91e Phase
505
Sin91e Phase B<Jted

NEMA 3R,7 & 9
505
3 Phase
505
3 Phase
Open NEMA 1, 12
505
Table Numbers
1Relay
3 Relay
9-24A
180
30-300A
(j)
00
127
0-1
156
168
0-4
151
347
195
168
195
7-8
133
133
{)-4
151
{)-4
146
177
0-2
171
0-2
168
168
{)-4
154
{)-4
149
347
347
{)-4
146
177
0-1
168
3 Phase Bolted
NEMA3R,7&9
505
0-3
171
168
505V
Open Type
{)-4
154
{)-4
149
347
0-4
149
506
347
520
3 Phase NEMA 4
520
3 Phase NEMA 4X
520E
Bolted NEMA 3R, 7 & 9
520V
Open Type
522-523
3 Phase
530
NOTE - When selecting heater

elements for Bulletin 530, divide
l!1e motor nameplate full load
amperes by 2,00- use l!1is value
to select l!1e prOFer "Heater Type
Number"
195
134
0-2
168
168
171
00
127
0-3
155
0-3
156
00
180
7-8
133
592
540
509
wlo Contr<J Trans.
{)-4
155
150
592
509
wlContr<J Trans.
{)-4
156
150
593
509
3 Phase
Open, NEMA 1,12
509
3 Phase
NEMA 1, 4, 12
347
195
{)-4
144
NOTE - When selecting heater

elements for Bulletin 540, divide
l!1e motor nameplate full load
amperes by 1.73- use l!1is value
to select l!1e pr0F8r "Heater Type
Number"
570
3 Phase
Bolted NEMA 3R, 7 & 9
520F & G
3 Phase
520
509
168
3 Phase (Unilock'"C2J)
Single Phase B<Jted

NEMA 3R, 7 & 9
505
509
169
0-3
145
Single Phase
180
509
167
0-2
3 Phase B<Jted NEMA 3R, &g
00
3 Phase NEMA 4X
507
3 Phase Bolted NEMA 3R, 7 & 9
3 Relay
{)-4
505
I
I
513
(Unilock'")
Table Numbers
1Relay
156
3 Phase NEMA 4
507
513
Size
0-1
505
Bulletin Number
Current Transformer Type
600
609, 609RS, 609TS, 609U, 609TU
1232X,1233X
0-3
145
168
1PW-2PW
3PW-4PW
146
5PW
347
6PW
195
7PW-8PW
133
150
1YD--4YO
152
5YO
347
195
6YO
lYO-8YD
133
2-4
154
347
195
7~
133
24-165A
192
181
195
27-45A
112
110
0-2
152
3,4
149
347
o-HP
509
3 Phase NEMA 4
5
177
2052B, 2053B, 2053H
/lJI
CD
509
NEMA 4X
0-2
156
146
143
(Unilock'")
{)-4
1-4
509
168
2106,2107,2112,2113, 2122E, 2122F,

2123E, 2123F
509
3 Phase (Unilock'")
177
171
2106,2107,2112,2113, 2122E, 2123E, 2172,

2173, wil!1 Series L 509 Starter
347
0-3
171
171
2106,2107,2112,2113, 2122E, 2123E, 2172,

2173, wil!1 Series A509 Starter
147
5
{)-4
153
2112,2113
147
347
2162,2163
1,3,5HP
143
195
2172,2173
2-4
152
134
3 Phase Bolted
NEMA 3R, 7 & 9
509
512
512M
513
(j)
C2J
1-2
153
{)-4
146
347
6
7
134
195
See Heater Element Selection Table for element listings

Unilock is a trademark of l!1e Allen B adley Co.
BI006008
Product Data
Bulletin 592
Table 110
Heater
Type
Number
Wl0
Wll
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W2JJ
W29
W30
W31
W32
W33
W34
W35
W36
W37
W36
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
WSO
W51
W52
W53
W54
WSS
W56
W57
wse
W59
W60
W61
W62
W63
Table 112
Full Load Amps.
Size 0
Size 1
Heater
Type
Number
Full Load Amps.

Size 0
Size 1
W50
W51
W52
W53
W54
0.21
0.23
0.25
0.28
0.31
0.34
0.37
0.41
045
049
0.54
0.59
0.65
0.71
0.78
0.86
0.94
1.04
1.14
1.26
1.39
1.53
1.69
1.86
2.05
2.26
2.49
2.74
3.02
3.33
367
404
445
4.89
5.38
5.92
6.51
7.16
7.87
8.66
9.52
10.5
11.5
12.6
13.9
0.21
0.23
0.25
0.28
0.31
034
0.37
041
0.45
0.49
0.54
0.59
0.65
0.71
0.78
0.86
0.94
1.04
1.14
1.26
1.39
1.53
1.69
1.86
2.05
2.26
2.49
2.74
3.02
3.33
367
404
4.45
4.89
5.38
5.92
6.51
7.16
7.87
8.66
9.52
10.5
11.5
12.6
13.9
W55
W56
W57
15.2
16.7
18.3
15.2
16.7
18.3
19.9
21.8
23.8
26.0
28.5
0.18
0.20
022
024
0.27
0.30
0.33
0.36
0.40
0.44
0.48
053
0.59
0.65
0.71
0.78
0.86
0.95
1.05
1.16
1.27
1.41
1.SS
1.71
1.89
2.08
2.30
253
2.79
307
3.38
3.73
4.11
4.51
4.96
5.44
5.98
6.57
7.21
792
8.70
9.57
10.5
11.6
12.7
0.18
0.20
0.22
0.24
0.27
0.30
0.33
036
0.40
0.44
0.48
0.53
0.59
065
0.71
0.78
0.86
0.95
1.05
1.16
1.27
1.41
1.SS
1.71
1.89
2.08
2.30
2.53
2.79
307
3.38
3.73
4.11
4.51
4.96
5.44
5.98
6.57
7.21
7.92
8.70
9.57
10.5
11.6
12.7
Wl0
Wll
W12
W13
W14
14.0
15.4
16.8
18.3
14.0
15.4
16.8
18.3
19.9
21.7
23.6
25.7
28.0
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W35
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
wse
W59
W60
W61
W62
W63
W64
W65
10
Table 127
Size 1P
Heater
Type
Number
Full Load
Amps.
Size 00
Wl0
Wll
W12
W13
W14
0.21
0.23
0.25
0.27
0.30
0.34
0.37
0.41
0.45
0.50
0.55
0.60
0.65
0.71
0.78
0.86
0.95
104
1.14
1.25
1.36
1.50
1.65
1.82
2.01
2.21
2.45
267
3.00
3.31
3.65
4.06
4.49
4.98
5.48
6.06
668
7.35
809
890
9.60
W15
W16
W17
W18
W19
W20
W21
W22
W23
W24
W25
W26
W27
W28
W29
W30
W31
W32
W33
W34
W35
W36
W37
W38
W39
W40
W41
W42
W43
W44
W45
W46
W47
W48
W49
W50
10.5
11.5
126
13.9
15.2
16.7
18.3
19.9
21.8
23.8
26.0
28.5
31.0
34.0
37.0
BI006008
T ble 133
H_eater
Type
I umbers
Tabie "i43
Full Load Amps.
Size 7
Full Load Amps.
Size 8
Heater
Type
Number
Size 7
Heater Type
Number
Size 1
240
261
285
310
340
Wl0
Wll
W12
W13
W14
0.19
021
0.23
0.25
0.28
Full Load Amperes

Size 2
Size 3
Size 4
W2!il
W30
W31
W32
W33
230
248
272
345
375
410
W2!il
W30
W31
W32
W33
W34
W35
W36
W37
W39
305
325
355
390
430
460
485
535
585
645
W34
W35
W36
W37
W39
370
405
445
490
540
W15
W16
W17
W18
W19
0.30
0.33
0.36
0.40
0.44
W40
W41
W42
W43
475
520
575
630
690
710
780
860
945
1035
W39
W40
W41
W42
W43
590
850
710
780
860
W20
W21
W22
W23
W24
0.49
0.53
0.58
0.64
0.70
W44
W45
755
835
1135
1255
W44
W25
W26
W27
W28
W2!il
0.77
0.85
0.93
1.02
1.12
W30
W31
W32
W33
W34
1.23
135
1.48
1.62
1.79
W35
W36
W37
W39
W39
1.97
218
2.40
2.65
292
W40
W41
W42
W43
W44
323
3.58
3.93
4.30
4.71
W45
W46
W47
W48
W49
5.16
5.66
6.28
6.94
7.71
5.26
5.81
6.41
7.09
7.66
W50
W51
W52
W53
W54
8.45
9.29
10.3
11.4
12.5
8.58
9.40
10.4
11.5
12.6
11.0
12.1
13.2
W55
W56
W57
W58
W59
13.7
15.0
16.3
17.7
19.3
13.8
15.1
16.4
17.9
19.5
14.5
15.9
17.5
19.2
21.1
18.1
19.9
21.8
W60
W61
W62
W63
W64
20.9
22.7
24.7
269
292
21.2
23.0
25.1
273
29.7
23.1
25.4
278
30.5
33.5
24.0
26.3
28.9
32.0
35.0
W65
W66
W6?
W68
W69
31.5
345
37.5
41.0
44.0
37.0
40.5
44.5
48.5
53.0
38.5
42.0
46.0
51.0
56.0
W70
W71
W72
W73
W74
47.0
59.0
64.0
69.0
730
77.0
61.0
66.0
71.0
76.0
82.0
81.0
85.0
90.0
88.0
94.0
100.0
106.0
113.0
W75
W76
W77
W78
W79
W80
W81
W82
1200
128.0
135.0
11
BI006008
PrOduct Data
Bulletin 592
Type Wand WI:. Eutectic Anoy Heater Elements
Table 144
Heater
Type
Number
Size 0 Size 1
Size 2 Size 3
Size 4
Table 146
Full Load Amperes
Heater
Type
Number
SizeD
Size 1
Size 2
Heater
Type
Number
Full Load Amperes

SizeD
Size 1
Size 2
Size 3
Size 4
20.6
22.5
24.6
26.8
294
25.5
28.1
31.0
34.0
32.0
35.0
W65
W66
W67
W68
W69
32.0
34.5
375
41.0
44.5
37.0
40.0
43.5
47.0
51
38.5
42.5
46.5
51
55
W70
W71
W72
W73
W74
W70
W71
W72
W73
W74
47.0
55
59
63
67
71
59
64
69
74
79
84
90
96
102
107
W75
W76
W77
W78
W79
W75
76
80
85
90
84
90
96
102
107
113
118
124
130
135
WSO
W81
W82
W83
W84
W80
WSI
WS2
W83
W84
W10
Wll
W12
W13
W14
0.18
0.20
0.22
0.24
0.26
0.18
0.20
0.22
0.24
0.26
WIG
Wll
W12
W13
W14
0.18
0.20
022
0.24
0.27
0.18
0.20
022
0.24
0.27
W10
Wll
W12
W13
W14
0.18
0.20
0.22
0.24
0.27
0.18
020
0.22
0.24
0.27
W15
W16
W17
W18
W19
0.29
0.32
0.35
0.38
0.42
0.29
0.32
0.35
0.38
0.42
W15
W16
W17
W18
W19
0.30
0.33
0.36
0.40
044
0.30
0.33
0.36
0.40
0.44
W15
W16
W17
W18
W19
0.30
0.33
0.36
0.40
0.44
0.30
0.33
0.36
0.40
0.44
W20
W21
W22
W23
W24
0.48
0.51
0.56
0.62
0.88
0.48
0.51
0.56
0.62
0.88
W20
W21
W22
W23
W24
0.49
0.54
0.60
0.66
0.73
049
0.54
0.60
0.66
0.73
W20
W21
W22
W23
W24
0.49
0.54
0.60
0.66
0.73
0.49
0.54
0.60
0.66
0.73
W25
W26
W27
W28
W29
0.75
0.62
0.90
0.99
0.75
0.62
0.90
0.99
1.()9
1.()9
W25
W26
W27
W28
W29
0.80
0.88
0.97
1.06
1.17
0.80
0.88
0.97
1.06
1.17
W25
W26
W27
W28
W29
0.80
0.88
0.97
1.06
1.17
0.80
0.88
0.97
1.06
1.17
W30
W31
W32
W33
W34
1.20
1.32
1.45
1.59
1.75
1.20
1.32
1.45
1.59
175
W3G
W31
W32
W33
W34
1.29
1.42
1.56
171
1.69
1.29
1.42
1.56
171
1.69
W30
W31
W32
W33
W34
1.29
1.42
1.56
1.71
1.89
1.29
1.42
1.56
171
1.89
W35
W36
W37
W38
W39
1.93
2.12
2.33
2.56
2.81
1.93
2.12
2.33
2.56
281
W35
W36
W37
W38
W39
2.08
2.28
2.51
2.76
3.04
2.08
2.28
2.51
2.76
3.04
W35
W36
W37
W38
W39
2.08
2.28
2.51
2.76
304
2.08
2.28
2.51
2.76
3.04
W40
W41
W42
W43
W44
3.09
3.40
3.74
4.11
452
3.09
3.40
374
4.11
4.52
W4G
W41
W42
W43
W44
3.34
3.88
4.05
4.45
4.90
3.34
3.88
4.05
4.45
4.90
W4G
W41
W42
W43
W44
3.34
368
4.05
4.45
4.90
3.34
3.88
4.05
4.45
490
W45
W46
W47
W49
W49
4.97
5.48
601
6.60
7.26
4.97
5.48
601
6.60
7.26
5.60
6.15
6.76
7.43
W45
W46
W47
W48
W49
5.39
5.88
6.41
6.99
7.63
5.39
5.88
6.41
6.99
7.63
5.58
6.11
6.70
734
7.97
W45
W46
W47
W49
W49
5.39
5.88
6.41
6.99
7.63
5.39
588
6.41
6.99
7.63
5.53
604
660
721
7.87
W50
W51
W52
W53
W54
798
8.78
9.65
10.6
117
7.98
8.78
9.65
10.6
117
8.17
8.98
9.87
10.8
11.9
WSO
W51
W52
W53
W54
8.32
9.07
9.89
10.8
11.8
8.32
9.07
9.89
10.8
11.8
8.69
9.52
10.4
11.4
12.5
W50
W51
WS2
W53
W54
8.32
9.07
9.89
10.8
11.8
8.32
9.07
9.89
10.8
11.8
8.60
9.39
10.3
11.2
12.2
WSS
W56
W57
W56
W59
12.8
14.1
15.4
16.8
18.3
12.8
14.1
15.4
16.8
18.3
13.1
14.4
15.7
17.1
18.6
WSS
W56
W57
W58
W59
12.9
14.2
15.5
16.8
18.5
12.9
14.2
15.5
16.8
18.5
13.6
14.9
16.2
17.4
19.3
W55
W56
W57
W58
W59
12.8
14.0
15.3
16.7
18.1
12.8
14.0
15.3
16.7
18.1
13.3
14.6
15.8
17.3
18.9
W60
W61
W62
WfJ3
W64
19.8
21.3
22.7
24.4
26.2
20.1
217
23.1
24.8
28.6
25.5
28.1
31.0
340
32.0
35.0
W60
W61
W62
W63
W64
20.3
22.2
24.0
26.1
28.4
21.0
23.0
25.0
27.1
29.6
W60
W61
W62
WfJ3
W64
19.7
21.5
23.5
25.7
27.5
W65
W66
W67
W88
W69
28.2
30.5
33.0
35.5
38.0
40.5
37.0
40.0
43.5
47.0
51
38.5
42.5
46.5
51
55
W65
W66
W67
W88
W69
32.0
34.5
38.0
41.5
45.0
43.5
47.0
55
59
63
67
71
59
64
69
74
79
76
80
85
90
W70
W71
W72
W73
W74
W75
W76
wn
W78
W79
W60
W81
W82
W83
W84
was
12
Table 145
Full Load Amperes
was
W76
W77
W78
W79
113
118
124
130
135
BI006008
Product Data
Bulletin 592
Type Wand WL Eutectic Alloy Heater Eleme.nts
Table 147
Table 148
Full Load Amperes
Heater
Type
Number
Size 5
Size 6
Size 7
SizeS
Size 9
Heater
Type
Number
W'lS
W3fJ
W31
W32
W33
74
81
88
97
106
144
157
171
186
209
240
261
285
310
340
360
390
430
465
510
600
650
710
780
650
W34
W35
W35
W37
W3B
115
126
138
151
165
222
242
288
294
325
370
405
445
490
540
555
610
670
740
810
Ym
W40
W41
W42
W43
180
197
215
235
256
355
390
430
470
515
590
650
710
780
860
890
970
1070
1170
1290
W44
281
560
Full Load Amperes

Size 0
Size 1
W10
W11
W12
W13
W14
0.19
0.21
0.23
0.25
0.28
0.19
0.21
0.23
0.25
0.28
920
1020
1120
1220
1350
W15
W16
W17
W18
W19
0.30
0.33
036
0.39
0.43
0.30
0.33
0.36
0.39
0.43
1460
1620
1780
1960
2150
W20
W21
W22
W23
W24
0.48
0.52
0.57
0.62
0.69
0.48
0.52
0.57
0.62
0.69
2360
W25
W26
W27
W28
W29
0.76
0.83
0.91
101
112
0.76
0.83
091
1.01
1.12
W30
W31
W32
W33
W34
1.22
1.34
1.47
162
178
122
1.34
147
162
178
W35
W36
W37
W3B
W39
196
2.15
2.36
2.60
2.86
196
2.15
2.36
2.60
2.86
W40
W41
W42
W43
W44
3.16
3.48
3.84
4.22
4.65
3.16
348
3.84
4.22
4.65
W45
W46
W47
W48
W49
5.12
5.63
6.20
6.82
7.51
5.12
5.63
6.20
6.82
7.51
5.13
584
6.22
6.65
7.56
W50
W51
W52
W53
W54
823
9.07
9.95
10.8
119
8.23
907
9.95
108
119
8.45
9.32
10.3
11.4
12.4
10.6
116
12.6
WSS
W56
W57
W58
W59
13.0
14.2
15.5
16.4
17.7
13.0
14.2
15.5
16.4
17.7
13.6
14.8
16.1
17.3
18.7
13.9
15.3
16.9
18.7
20.7
17.3
19.0
210
W60
W61
W62
W63
W84
19.7
19.7
21.7
24.2
27.0
20.6
227
25.2
28.0
30.0
22.8
25.1
27.5
30.5
33.5
23.1
25.5
28.0
31.0
34.0
W65
W66
W67
W68
W69
32.5
35.0
38.0
40.5
43.5
365
39.5
425
46.0
50.0
370
40.0
44.0
48.5
53.0
W70
W71
W72
W73
W74
46.5
54.0
58.0
62.0
670
720
57.0
62.0
67.0
72.0
77.0
76.0
810
86.0
90.0
82.0
870
93.0
99.0
105
W75
W76
W77
W78
W79
W80
W81
W82
W83
W84
Size 2
Size 3
Size 4
112
117
123
129
135
was
13
BI006008
Product Data
Bulletin 592
Table 149
Heater
Type
Number
Table 150
Full Load Amperes
Size 0
Size 1
Wl0
Wll
W12
W13
W14
0.18
0.20
0.22
0.24
0.27
0.18
0.20
0.22
0.24
0.27
W15
W16
W17
W18
W19
0.30
0.33
0.36
0.40
0.44
W20
W21
W22
W23
W24
Size 2
Size 3
Heater
Type
Number
Size 1
Wl0
Wll
W12
W13
W14
0.18
0.20
0.22
0.24
0.26
0.18
0.20
0.22
0.24
0.26
0.30
0.33
0.36
0.40
0.44
W15
W16
W17
W18
W19
0.28
0.31
0.34
0.37
0.41
0.28
0.31
0.34
0.37
0.41
0.49
0.54
0.80
0.66
0.73
0.49
0.54
0.80
0.66
0.73
W20
W21
W22
W23
W24
0.46
0.50
0.55
0.80
0.67
0.46
0.50
0.55
0.80
0.67
W25
W26
W27
W26
W29
080
0.66
0.97
1.06
1.17
0.80
0.66
0.97
1.06
1.17
W25
W26
W27
W26
W29
0.73
0.80
0.88
0.97
107
0.73
080
0.88
0.97
1.07
W30
W31
W32
W33
W34
1.29
1.42
1.56
1.71
1.89
1.29
1.42
1.56
1.71
1.89
W30
W31
W32
W33
W34
1.17
1.29
1.42
1.57
1.73
1.17
1.29
1.42
1.57
1.73
W35
W36
W37
W38
W39
208
2.28
2.51
2.76
304
2.08
2.28
2.51
2.76
3.04
W35
W36
W37
W38
W39
1.90
208
2.28
2.51
2.76
1.90
208
2.28
2.51
2.76
W40
W41
W42
W43
W44
3.34
3.66
4.05
4.45
4.90
3.34
3.68
4.05
4.45
4.90
W40
W41
W42
W43
W44
3.04
3.34
368
4.04
4.46
3.04
3.34
3.88
4.04
4.46
W45
W46
W47
W48
W49
5.39
5.68
6.41
6.99
7.63
5.39
5.68
641
6.99
7.63
553
6.00
6.60
7.20
7.84
W45
W46
W47
W48
W49
4.94
5.46
6.03
665
7.33
4.94
5.46
6.03
6.65
7.33
5.13
5.64
6.22
6.65
7.56
W50
W51
W52
W53
W54
8.32
907
9.89
10.8
11.8
832
907
9.89
10.8
11.8
853
9.30
10.2
11.2
12.2
106
11.6
12.6
W50
W51
W52
W53
W54
8.13
8.95
9.90
10.7
11.7
813
8.95
9.90
10.7
11.7
8.45
9.32
10.3
11.3
12.3
10.4
11.4
12.5
W55
W56
W57
W58
W59
128
14.0
15.3
16.2
17.6
12.8
14.0
15.3
16.2
17.6
13.2
14.4
15.8
16.8
18.3
13.9
15.3
16.9
18.7
20.7
18.5
20.5
22.5
WSS
W56
W57
W58
W59
12.8
14.0
15.3
16.2
17.5
12.8
14.0
15.3
16.2
17.5
13.4
14.5
15.8
16.7
18.0
13.7
15.1
16.7
18.4
203
18.5
20.5
22.5
W60
W61
W62
W63
W64
19.5
19.5
21.5
23.4
25.7
27.5
20.3
22.4
24.4
26.8
28.7
22.8
25.1
275
305
33.5
25.0
27.5
30.0
33.0
36.0
W60
W61
W62
W63
W64
19.4
19.4
21.3
23.3
25.5
27.2
199
21.9
24.2
26.8
28.7
22.5
24.8
27.2
30.0
33.0
25.0
27.5
30.0
33.0
36.0
W65
W66
W67
W68
W69
31.5
34.0
37.0
405
43.5
370
410
44.0
475
52.0
395
43.0
47.5
52.0
56.0
W65
W66
W67
W68
W69
31.0
33.5
36.0
38.5
41.5
36.0
39.5
43.5
47.5
52.0
39.5
43.0
47.0
51.0
56.0
W70
W71
W72
W73
W74
46.5
570
61.0
66.0
71.0
750
61.0
66.0
71.0
76.0
81.0
W70
W71
W72
W73
W74
45.0
56.0
60.0
65.0
690
740
61.0
66.0
71.0
76.0
82.0
79.0
83.0
87.0
910
87.0
930
99.0
105
111
W75
W76
W77
W78
79.0
85.0
91.0
87.0
93.0
99.0
105
111
118
125
132
139
WOO
W81
W82
W83
W84
WOO
W81
W82
W83
W84
W79
W65
14
Full Load Amperes

Size 0
W75
W76
W77
W78
W79
Size 4
Size 2
Size 3
Size 4
118
125
132
139
BI006008
Product Data
Bulletin 592
Table 151
Heater
Type
Number
Table 152
Full Load Amperes
Size 0
Size 1
Wl0
Wl1
W12
W13
W14
0.19
0.21
0.23
0.25
0.28
0.19
021
0.23
0.25
0.28
W15
W16
W17
W18
W19
0.30
0.33
0.36
0.39
0.43
W20
W21
W22
W23
W24
Size 3
Full Load Amperes

Size 1
Wl0
Wll
W12
W13
W14
0.19
0.21
0.23
0.25
0.28
0.19
0.21
0.23
0.25
0.28
0.30
0.33
0.36
0.39
0.43
W15
W16
W17
W18
W19
0.31
0.34
0.37
041
0.45
0.31
034
037
041
045
048
052
057
0.62
0.69
0.48
0.52
0.57
0:62
0.69
W20
W21
W22
W23
W24
0.50
0.55
0.60
0.86
0.73
0.50
0.55
0.60
0.86
0.73
W25
W26
W27
W28
W29
0.76
0.83
0.91
1.01
1.12
0.76
0.83
0.91
1.01
1.12
W25
W26
W27
W28
W29
0.80
0.88
0.97
1.06
1.16
0.60
0.88
0.97
1.06
1.16
W30
W31
W32
W33
W34
1.22
1.34
1.47
1.62
1.78
1.22
1.34
1.47
162
1.78
W30
W31
W32
W33
W34
1.27
1.39
1.51
1.65
1.80
1.27
1.39
1.51
1.65
1.80
W35
W36
W37
W38
W39
1.96
2.15
2.36
2.60
2.86
1.96
2.15
2.36
2.60
2.86
W35
W36
W37
W38
W39
1.96
2.15
2.36
2.60
2.86
1.96
2.15
2.36
2.60
2.86
W40
W41
W42
W43
W44
316
348
3.84
4.22
4.65
3.16
348
3.84
4.22
4.65
W40
W41
W42
W43
W44
3.16
348
3.85
4.23
4.68
3.16
3.48
3.85
423
4.68
W45
W46
W47
W48
W49
5.12
5.63
6.20
6.82
7.51
5.12
5.63
6.20
6.82
7.51
5.13
5.64
6.22
6.85
7.56
W45
W46
W47
W48
W49
5.18
5.68
6.28
6.84
7.71
5.18
5.86
6.28
6.94
7.71
5.25
5.81
641
7.09
7.86
W50
W51
W52
W53
W54
8.23
9.07
9.95
10.8
11.9
8.23
9.07
9.95
10.8
11.9
8.45
9.32
10.3
11.3
12.3
10.6
11.6
12.6
W50
W51
W52
W53
W54
845
9.29
10.3
11.4
12.5
8.45
9.29
10.3
11.4
12.5
8.56
9.40
104
11.5
12.6
10.6
11.6
12.6
W55
W56
W57
W58
W59
13.0
14.2
15.5
164
17.7
13.0
14.2
15.5
16.4
17.7
13.4
14.5
15.8
16.7
18.1
13.9
153
16.9
18.7
20.7
W55
W56
W57
13.7
15.0
16.3
17.6
189
13.7
15.0
16.3
17.6
18.9
13.8
15.1
16.4
17.7
19.1
13.9
15.3
16.9
18.7
20.7
18.5
20.5
22.5
W60
W61
W62
W63
W64
19.7
19.7
21.7
24.2
27.0
20.0
22.0
245
27.3
29.2
22.8
25.1
27.5
30.5
33.5
25.0
277
31.0
340
W60
W61
W62
W63
W64
20.9
22.9
25.0
27.6
21.1
23.2
25.7
28.5
30.5
22.8
25.1
27.5
30.5
335
25.0
27.5
30.0
33.0
36.0
W65
W56
W67
W68
W68
31.5
34.5
37.0
39.5
42.5
36.5
400
44.0
48.0
52.0
38.0
41.5
45.5
49.0
53.0
W65
W66
W67
W68
W69
33.0
35.5
38.5
41.5
45.0
36.5
40.0
44.0
48.5
53.0
39.5
43.0
47.0
51.0
56.0
W70
W71
W72
W73
W74
46.0
57.0
61.0
56.0
70.0
75.0
57.0
62.0
670
720
58.0
62.0
67.0
72.0
77.0
61.0
86.0
720
no
W70
W71
W72
W73
W74
80.0
86.0
92.0
84.0
920
97.0
102
109
W75
W76
W77
W78
W79
82.0
88.0
94.0
89.0
95.0
102
108
116
117
125
130
136
W80
W81
W82
W83
W75
W76
W78
W79
WOO
W81
W82
W83
W84
wes
Size 4
Heater
Type
Number
Size 0
wn
Size 2
wse
W59
Size 2
Size 3
Size 4
no
83.0
123
130
137
BI006008
Product Data
Bulletin 592
ype Wand WL Eutectic Alloy Heater Elements
Table 153
Heater
Type
Number
Table 154
Full Load Amperes
Heater
Type
Number
Size 1
Wl0
Wll
W12
W13
W14
0.19
0.21
0.23
0.25
0.28
019
0.21
0.23
0.25
028
Wl0
Wll
W12
W13
W14
0.20
0.22
0.24
0.26
0.29
0.20
0.22
0.24
026
0.29
W15
W16
W17
W18
W19
0.31
0.34
0.37
041
0.45
0.31
0.34
0.37
0.41
0.45
W15
W16
W17
W18
W19
0.32
0.35
0.38
0.42
0.47
0.32
0.35
0.38
0.42
0.47
W20
W21
W22
W23
W24
0.50
0.55
0.60
0.66
0.73
0.50
0.55
0.60
066
073
W20
W21
W22
W23
W24
0.51
0.56
061
0.67
0.74
0.51
0.56
0.61
0.67
0.74
W'1S
W26
W27
W26
W29
0.80
0.88
0.97
106
116
080
0.88
097
106
116
W25
W26
W27
W28
W29
0.81
0.89
0.98
108
119
0.81
0.89
0.98
108
119
W30
W31
W32
W33
W34
127
1.39
151
165
180
127
1.39
151
165
180
W30
W31
W32
W33
W34
1.30
143
155
1.70
190
1.30
143
155
1.70
190
W35
W3fJ
W37
W38
W39
198
2.18
2.39
2.63
2.90
198
2.18
2.39
263
2.90
W35
W36
W37
W38
W39
2.02
2.22
2.43
2.86
2.96
202
2.22
2.43
2.86
2.96
W40
W41
W42
W43
W44
3.19
3.50
3.85
4.24
4.66
3.19
350
3.85
4.24
4.66
W40
W41
W42
W43
W44
3.25
3.58
394
4.30
4.72
3.25
3.58
3.94
4.30
4.72
W45
W46
W47
W48
W49
5.13
5.64
6.20
6.82
751
5.13
5.64
6.20
6.82
7.51
5.25
5.78
6.35
6.99
7.69
W45
W46
W47
W48
W49
5.22
5.78
6.38
7.06
7.83
5.22
5.78
6.38
7.06
7.83
5.25
5.81
6.41
7.09
7.86
WSO
W51
W52
W53
W54
825
9.07
9.98
110
12.1
825
907
998
110
121
845
9.32
10.3
11.4
124
10.6
116
12.6
W50
W51
W52
W53
W54
8.55
9.41
10.5
116
12.7
8.55
9.41
10.5
116
12.7
8.58
9.46
10.6
11.7
12.8
111
12.2
13.4
W55
W56
W57
W58
W59
133
14.6
16.0
17.4
190
133
146
160
174
190
13.6
15.0
16.4
17.8
19.5
13.9
15.3
16.9
18.7
20.7
18.5
20.5
22.5
W55
W56
W57
W58
W59
14.0
15.3
16.7
190
14.0
15.3
16.7
190
19.3
14.1
15.4
16.9
193
19.9
14.7
16.3
17.9
19.7
21.7
19.5
21.4
23.7
207
227
24.7
27.0
212
23.3
25.3
28.0
30.0
22.8
25.1
27.5
30.5
33.5
25.0
27.5
30.0
33.0
36.0
W60
W61
W62
W63
W64
21.3
233
25.6
291
219
24.2
26.8
29.6
325
23.8
26.1
297
315
34.5
260
297
315
34.5
37.5
W65
W65
W67
W68
W68
32.5
35.0
38.0
40.5
43.5
36.5
39.5
42.5
46.0
50.0
39.5
43.0
47.0
51.0
56.0
W65
W66
W67
W68
W69
35.0
37.5
410
45.0
390
415
45.5
49.5
54
410
44.5
48.5
53
58
W70
W71
W72
W73
W74
46.5
54.0
58.0
62.0
67.0
720
61.0
650
71.0
76.0
82.0
W70
W71
W72
W73
W74
59
64
70
76
81
63
86
74
80
86
76.0
810
86.0
90.0
870
93.0
99.0
105
111
W75
W76
W77
W78
W79
87
93
92
98
105
112
120
118
125
132
139
W80
W81
W82
W83
W84
W60
W61
W62
W63
W64
W75
W76
W77
W78
W79
WOO
W81
W82
W63
W84
Size 2
Size 3
Size 4
W8.5
FUll Load Amperes
Size 0
SizeD
Size 1
Size 2
Size 3
Size 4
128
136
BI006008
Product Data
Bulletin 592
Table 155
Heater
Type
Number
Table 156
Full Load Amperes
Full Load Am peres

Size lP
Size 2
Size 3
Size 4
0.20
0.22
0.24
0.26
029
0.20
0.22
0.24
0.26
0.29
Wl0
Wll
W12
W13
W14
0.20
0.22
0.24
0.26
0.29
0.20
0.22
0.24
0.26
0.29
W15
W16
W17
W18
W19
0.32
0.35
0.39
0.43
0.47
0.32
0.35
0.39
0.43
0.47
W15
W16
W17
W18
W19
0.32
0.35
0.39
0.43
0.47
0.32
0.35
0.39
0.43
0.47
W20
W21
W22
W23
W24
0.51
0.56
0.61
0.67
0.74
0.51
0.56
0.61
0.67
0.74
W20
W21
W22
W23
W24
0.51
0.56
0.61
0.67
0.74
0.51
0.56
0.61
0.67
0.74
W25
W26
W27
W26
W29
0.81
0.89
0.98
108
119
0.81
0.89
0.98
108
119
W25
W26
W27
W28
W29
0.81
0.89
0.98
1.08
119
0.81
0.89
0.98
108
119
W30
W31
W32
W33
W34
1.30
1.43
156
1.70
188
1.30
143
156
1.70
188
W30
W31
W32
W33
W34
1.30
1.43
1.57
1.72
1.90
1.30
143
157
1.72
190
W35
W36
W37
W38
W39
2.05
2.24
2.44
2.69
2.97
2.05
2.24
2.44
2.69
297
W35
W36
W37
W38
W39
2.08
2.28
2.49
2.74
302
2.08
2.28
2.49
2.74
3.02
W40
W41
W42
W43
W44
3.30
3.64
4.10
4.57
5.01
3.30
3.64
4.10
4.57
5.01
W40
W41
W42
W43
W44
3.33
3.68
4.14
4.61
5.06
3.33
3.68
4.14
4.61
5.06
W45
W46
W47
W48
W49
5.51
6.06
6.62
7.22
7.89
551
6.06
6.62
7.22
7.89
5.48
6.09
6.65
7.26
7.94
W45
W46
W47
W48
W49
5.56
6.11
6.72
7.40
8.18
5.56
6.11
6.72
7.40
8.18
5.57
6.12
6.73
7.38
8.20
WSO
W51
W52
W53
W54
862
9.41
10.5
116
12.7
8.62
9.41
10.5
11.6
12.7
11.6
12.7
8.68
9.48
10.6
11.7
12.8
11.5
12.6
13.8
W50
W51
W52
W53
W54
8.68
9.70
10.8
11.8
12.9
8.88
9.70
10.8
118
12.9
118
12.9
8.92
9.81
10.9
119
13.0
11.7
12.8
13.9
WSS
W56
W57
W58
W59
14.0
15.3
16.7
180
14.0
15.3
16.7
18.0
19.3
14.0
15.3
16.7
18.0
19.3
14.1
15.4
16.8
18.1
19.5
15.1
16.7
18.3
20.1
22.1
W55
W56
W57
W59
W59
14.2
15.5
17.0
18.3
14.2
15.5
17.0
18.3
19.9
14.2
15.5
17.0
18.3
199
14.3
15.6
17.1
18.5
20.1
15.2
16.8
18.5
20.2
222
19.5
21.4
23.7
21.3
23.3
25.6
28.1
21.3
23.3
25.6
28.1
30.5
21.5
23.8
26.4
29.2
31.5
24.4
27.0
29.5
32.5
35.0
W60
W61
W62
W63
W64
22.0
24.3
27.0
220
24.3
27.0
295
320
22.2
24.5
272
30.0
33.0
24.5
27.1
29.9
32.5
35.5
26.0
28.7
315
34.5
37.5
32.5
34.0
36.0
34.0
36.5
39.5
42.5
46.0
38.5
42.0
46.0
50
54
W65
W66
W67
W68
W69
34.0
36.0
35.5
38.0
415
45.0
39.0
42.5
47.0
52
57
410
44.5
46.5
53
58
W70
W71
W72
W73
W74
59
64
70
76
81
W70
W71
W72
W73
W74
62
67
73
79
85
63
68.0
74.0
80.0
86.0
W75
W76
87
93
W75
W76
W77
W78
W79
92
930
100
108
116
125
wn
W78
W79
W80
Size 3
Size 1
Wl0
W11
W12
W13
W14
W65
W66
W67
W68
W69
Size 2
SizeD
Size 1
W60
W61
W62
W63
W64
SizelP
Heater
Type
Number
Size 0
W80
W81
W82
W83
W84
135
W65
17
BI006008
Product Data
Bulletin 592
Table 166
Heater
Type
Number
Heater
Type
Number
Full Load Amperes
Size 0
Size 1
Wl0
Wll
W12
W13
W14
.19
.21
.23
.25
.27
.19
.21
.23
.25
.27
Wl0
Wll
W12
W13
W14
0.20
0.22
0.24
0.26
0.28
0.20
0.22
0.24
0.26
0.28
W15
W16
W17
W18
W19
.30
.32
.36
.39
.43
.30
.32
.36
.39
.43
W15
W16
W17
W18
W19
0.31
0.34
0.37
0.41
0.45
0.31
0.34
0.37
0.41
0.45
W20
W21
W22
W23
W24
.47
.52
.56
.62
.68
.47
.52
.56
.62
.68
W20
W21
W22
W23
W24
0.49
0.54
0.59
0.65
0.71
0.49
0.54
0.59
0.65
0.71
W25
W26
W27
W28
W29
.74
62
.90
.98
105
.74
.82
.90
.98
105
72
W25
W26
W27
W29
W29
0.78
0.65
0.93
101
112
0.78
0.85
0.93
101
112
i2
W30
W31
W32
W33
W34
116
129
140
1.55
1.70
116
129
140
155
1.70
78
85
92
100
109
W30
W31
W32
W33
W34
1.22
1.34
1.47
1.61
1.76
122
1.34
1.47
161
1.76
78
84
91
99
107
W35
W36
W37
W38
W39
184
2.02
2.22
2.45
2.63
184
2.02
2.22
2.45
2.63
118
128
139
151
184
W35
W36
W37
W36
W39
193
2.11
2.31
2.53
2.77
193
2.11
2.31
2.53
2.77
116
125
136
147
159
W40
W41
W42
W43
W44
2.89
3.17
3.48
3.82
4.19
2.89
3.17
3.48
3.82
4.19
181
198
218
240
W40
W41
W42
W43
W44
3.03
3.32
3.63
3.97
4.35
3.03
3.32
363
397
4.35
174
191
210
4.56
W45
W46
W47
W48
W49
4.60
5.05
5.54
6.08
668
4.60
5.05
5.54
6.08
6.68
5.10
5.60
6.12
6.65
7.25
W45
W46
W47
W48
W49
4.76
5.21
5.71
6.25
6.64
4.76
521
5.71
6.25
684
5.02
5.50
6.02
6.60
723
W50
W51
W52
W53
W54
7.33
805
883
9.70
10.6
7.33
8.05
8.83
9.70
10.6
7.90
8.60
9.40
10.2
11.2
W50
W51
W52
W53
W54
7.48
8.20
8.83
9.98
10.8
7.48
8.20
8.83
9.98
10.8
792
8.68
9.51
10.4
114
W55
W56
W57
W58
W59
11.7
128
14.1
15.5
17.0
11.7
12.8
14.1
15.5
17.0
12.2
13.4
14.7
16.2
17.7
WSS
W58
W57
W58
W59
118
12.9
14.1
15.5
17.0
118
12.9
14.1
155
17.0
12.5
13.7
15.0
16.4
17.9
W60
W61
W62
W63
W64
18.6
18.6
204
22.4
24.6
270
19.4
21.3
23.4
25.6
28.1
33.5
W60
W61
W62
W63
W64
18.7
25.0
27.3
29.8
32.5
18.7
20.5
22.4
24.6
27.0
19.5
21.3
23.3
25.4
27.4
25.5
28.0
30.5
33.5
320
35.0
W65
W66
W67
W68
W69
30.0
32.5
35.0
37.5
40.0
35.5
39.0
42.0
48.0
510
37.0
40.5
44.5
49.0
54.0
W65
W66
W67
W66
W69
29.5
32.0
34.5
370
390
36.5
40.0
43.5
475
510
38.0
415
45.0
49.0
54.0
W70
W71
W72
W73
W74
42.0
44.5
47.0
55.0
59.0
64.0
69.0
740
59.0
64.0
69.0
74.0
79.0
W70
W71
W72
W73
W74
410
43.0
45.0
55.0
60.0
65.0
69.0
74.0
58.0
63.0
68.0
73.0
79.0
79.0
83.0
88.0
930
64.0
90.0
96.0
102
108
W7S
W76
W77
W78
W78
78.0
83.0
88.0
93.0
85.0
90.0
97.0
103
109
116
123
131
139
WOO
WB1
WB2
W83
W84
W75
W76
W77
W78
W79
wao
W81
W82
W83
W84
W65
l8
Table 167
Full Load Amperes
Size 2
Size 3
Size 4
Size 5
W65
SizeD
Size 1
Size 2
Size 3
Size 4
115
121
126
131
137
Size 5
BI006008
Product Data
Bulletin 592
Table 168
Table 169
Full Load Amperes
Heater
Type
Number
Size 0
Size 1
Wl0
Wll
W12
W13
W14
18
.20
.22
.24
.26
.18
.20
.22
.24
.26
W29
W30
W31
W32
W15
W16
W17
W18
W19
.29
W34
W35
.35
.39
43
.29
.32
.35
.39
.43
W20
W2l
W22
W23
W24
.47
51
.56
.61
.67
.47
.51
.56
.61
67
W25
W26
W27
W20
W29
.74
.82
.94
102
1.12
.74
.82
.94
1.02
1.12
W30
W31
W32
W33
W34
1.23
1.38
1.50
1.64
178
123
1.38
1.50
1.64
178
W35
W36
W37
W38
W39
1.95
2.10
2.28
2.57
2.83
W40
W41
W42
W43
W44
Heater
Type
Number
Full
Load
Amps.
Table 171
Full Load Amperes
Heater
Type
Number
Size 00
Size 0
Size 1
70
77
85
89
94
Wl0
Wll
W12
W13
W14
.17
.19
.21
.22
.25
17
.19
.21
.22
.25
.17
.19
.21
.22
.25
100
107
118
127
140
W15
W16
W17
W18
W19
.28
.31
.34
.37
.42
.28
.31
.34
.37
.42
.28
.31
.34
.37
.42
W40
W41
W42
W43
154
167
181
194
207
W20
W2l
W22
W23
W24
.46
.50
.56
.62
69
.46
.50
.56
.62
.69
.46
.50
.56
.62
.69
W44
221
70
W25
W26
W27
W20
W29
.76
.84
.93
102
1.13
.76
.84
.93
1.02
1.13
.76
.84
.93
1.02
1.13
76
82
90
98
106
W30
W31
W32
W33
W34
125
1.38
149
1.61
174
1.25
1.38
1.49
161
174
1.25
1.38
1.4S
1.61
174
1.95
2.10
2.28
2.57
2.83
115
125
137
150
162
W35
W36
W37
W38
W39
1.89
2.04
2.22
2.49
2.75
1.89
2.04
2.22
2.49
2.75
189
2.04
2.22
2.49
275
11!
131
14<
3.12
3.47
3.84
4.26
4.68
3.12
3.47
3.84
4.26
4.68
478
176
191
210
230
249
W40
W41
W42
W43
W44
3.03
3.37
3.73
413
4.55
303
3.37
3.73
4.13
4.55
3.03
337
373
413
455
1&
201
22:
241
26'
W45
W46
W47
W48
W4S
5.18
5.71
6.28
6.90
7.59
5.18
5.71
6.28
6.90
7.59
5.28
5.79
6.35
6.97
7.65
270
W45
W46
W47
W48
W4S
5.02
5.53
6.08
6.88
7.34
5.02
5.53
6.08
688
7.34
5.02
5.53
6.08
688
734
29l
W50
W51
W52
W53
W54
835
9.28
10.2
11.2
12.1
8.35
9.28
10.2
11.2
12.1
8.40
9.30
10.2
11.2
12.2
W50
W51
W52
W53
W54
8.07
8.95
9.83
8.07
8.95
9.83
10.8
11.6
807
8.95
9.83
108
11.6
8.31
9.26
10.2
11.1
12.1
12.5
W55
W56
W57
W58
W59
13.3
14.5
15.7
16.6
17.8
13.3
14.5
15.7
16.6
17.8
13.4
147
16.1
176
19.3
W55
W56
W57
W58
W59
12.7
13.8
14.9
15.7
17.0
12.7
138
149
157
17.0
13.1
14.5
15.8
16.9
18.1
13.8
15.2
16.5
17.9
19.7
W60
W61
W62
W63
W64
19.6
19.6
21.5
23.5
25.7
28.2
21.1
22.9
25.0
27.1
29.5
340
W60
W61
W62
W63
W64
18.4
25.0
27.7
30.5
34.0
18.4
20.0
21.8
24.5
27.8
198
21.6
23.7
260
28.6
21.8
24.2
26.5
29.3
32.0
33.5
W65
W66
W67
W68
W69
320
34.5
37.0
40.0
42.5
36.5
39.5
42.5
46.0
51
37.0
40.0
44.0
465
53
W65
W66
W67
W68
W69
310
34.0
37.0
40.0
43.0
36.0
38.0
42.0
46.0
50.0
37.0
40.5
44.5
49.0
54
W70
W71
W72
W73
W74
45.0
55
59
64
69
74
57
62
67
72
77
W70
W71
W72
W73
W74
46.0
53
58
62
66
70
59
64
69
74
79
79
83
88
93
82
87
93
99
105
W75
W76
W77
W78
W79
74
80
85
89
94
84
90
96
102
108
112
117
123
129
135
W80
W81
W82
W83
W75
W76
W77
W78
W79
W80
W81
W82
W63
W84
.32
Size 2
Size 3
Size 4
Size 5
W33
W36
W37
W36
W39
..
Size 5
Size 2
Size 3
Size4
SiZI
71
78
85
92
j()
1()
1~
Hi<
116
123
131
139
19
BI006008
Product Data
Bulletin 592
Table 177
Heater
Type
Number
Table 180
Full Load
Amps.
Size 5
Heater
Type
Number
Table 181
Full Load
Amps.
Size 00
Heater
Type
Number
Size 24A
Size 32A
Size 40A
Size 62A
Size 125A
Size 165A
W'B
W3fJ
W32
W33
W34
70
76
90
98
106
Wl0
Wll
W12
W13
W14
.19
.20
.23
.25
.28
Wl0
Wll
W12
W13
W14
.19
.20
.22
.24
.27
.19
.20
22
24
.27
.19
.21
.23
25
28
W35
W36
W37
W36
W39
115
125
137
150
162
W15
W16
W17
W18
W19
.31
.34
.37
.40
.44
W15
W16
W17
W18
W19
.29
.32
.36
.39
.44
.29
.32
36
.39
.44
31
.34
.37
.41
.45
W40
W41
W42
W43
W44
176
191
210
230
248
W20
W21
W22
W23
W24
.49
.55
.61
.69
.77
W20
W21
W22
W23
W24
.49
.54
.60
.67
.74
.49
.54
.60
.67
.74
50
.SS
.60
.66
.73
W45
270
W2S
W26
W27
W28
W'B
.86
.93
1.02
1.11
1.22
W2S
W26
W27
W28
W'B
.84
.90
1.00
110
1.22
.84
.90
1.00
1.10
1.22
.80
.66
.97
1.06
116
W3fJ
W31
W32
W33
W34
1.33
1.50
1.60
1.70
1.90
W3fJ
W31
W32
W33
W34
131
143
1.55
1.66
1.80
131
1.43
1.55
1.66
1.80
1.27
1.39
1.51
1.65
1.80
W35
W36
W37
W36
W39
2.01
2.28
2.50
2.72
3.00
W35
W36
W37
W36
W39
1.97
212
233
2.59
2.84
1.97
2.12
2.33
2.59
2.84
2.15
2.36
2.60
2.86
W40
W41
W42
W43
W44
3.34
3.67
4.00
4.40
5.00
W40
W41
W42
W43
W44
3.15
3.46
3.84
4.27
4.73
3.15
3.46
3.84
4.27
4.73
3.16
348
3.65
4.23
4.66
W45
W46
W47
W48
W49
5.52
5.95
6.60
7.20
8.00
W45
W46
W47
W48
W49
5.36
5.82
6.33
6.97
7.63
5.36
5.82
6.33
6.97
7.63
5.18
5.68
6.28
6.94
7.71
WSO
W51
W52<D
W53<D
W54<D
8.76
9.60
10.7
11.9
13.0
WSO
W51
W52
W53
W54
8.49
9.24
10.1
111
12.2
8.49
924
10.1
11.1
12.2
8.45
9.29
10.3
11.4
12.5
9.40
10.4
11.5
12.6
WSS<D
WS8<D
W57<D
WS8<D
W59<D
14.2
15.5
16.9
18.0
20.0
WSS
WS8
W57
W58
W59
13.6
146
15.7
17.2
189
13.6
14.6
15.7
17.2
18.9
13.7
15.0
16.3
17.6
18.9
13.8
15.1
16.4
17.7
19.1
W60<D
W61<D
21.7
24.0
W60
W61
W62
W53
W64
20.5
22.2
24.3
20.5
222
24.3
26.4
28.5
209
22.9
25.0
27.6
30.0
21.1
23.2
25.7
28.5
30.5
25.1
27.5
30.5
33.5
Heater
Type
Numb",
Maximum
Catalog
Numb",
Prefix
32.5
32.0
34.0
37.0
39.0
41.0
33.0
35.5
38.5
41.5
45.0
36.5
40.0
44.0
48.5
53
43.0
47.0
51
58
W70
W71
W72
W73
W74
48.5
53
58
58
60
58
62
67
72
77
61
66
72
77
53
W75
W76
W77
W78
W79
62
82
88
94
98
102
69
95
102
108
116
108
123
130
137
150
160
W51
W54
W51
112-A
112-B
112-D
<D For applications with

Catalo9 Number 112-A09
throu9h 112-A24 only.
W65
W66
W67
W68
W69
WOO
W81
W82
W83
W84
was
20
Full Load Amperes
1.96
117
125
165
BI006008
Product Data
Bulletin 592
Table 192
Table 195
Full Load Amps.
Heater
Type
Number
Size4DA
Size 62A
FUll Load Amperes

Heater
Type
Number
Wl0
Wll
W12
W13
W14
.21
.23
.25
27
.30
W26
W27
W28
W29
wao
W15
W16
W17
W18
W19
.34
.37
41
45
.50
wa1
wa2
W20
W21
W22
W23
W24
.55
.60
.65
71
78
W'J5
W26
W27
W26
W29
.86
.95
104
114
125
W30
W31
W32
W33
W34
136
1.50
1.65
1.82
2.01
was
W36
W37
W38
W39
2.21
245
2.67
3.00
3.31
W40
W41
W42
W43
W44
3.65
406
449
4.98
548
W45
W46
W47
W48
W49
6.06
6.68
735
809
8.90
9.03
W50
W51
W52
W53
W54
9.80
10.9
12.0
132
14.3
9.96
11.1
12.2
13.3
14.6
W55
W56
W57
W58
W'fIi!
157
17.1
186
197
21.4
15.8
17.5
19.1
20.5
219
W60
W61
W62
W63
W64
234
25.8
284
31.0
35.5
24.1
264
29.1
32.0
35.5
W65
W66
W67
W68
W69
38.5
41.0
39.0
42.5
47.5
53.0
57.0
W70
W71
W72
W73
W74
CatalO,. Number
592- P03DD
CatalO,. Number
592- P04DD
NEMASize6
CatalO,. Number
592- P063D
78
85
94
104
115
125
135
147
185
43eD
45eD
50eD
54eD
59eD
85eD
70
75
81
127
138
114
125
139
150
160
179
196
216
232
260
W40
89
98
110
120
132
151
166
183
198
218
175
195
215
235
260
287
315
350
385
420
W41
W42
W43
W44
W45
143
155
170
193
-
239
260
285
310
293
320
350
380
415
485
515
57012)
630
-
W46
W47
W48
455
500
550
W33
W34
W35
wa6
wa7
W38
W39
eD
12)
CatalO,. Number
592- P02DD
Exceeds 20 seconds at six times ratin9, providin9 Class 30 protection.

Maximum elemant for NEMA Size 6.
60.0
65.0
71.0
21
BI006008
Product Data
Bulletin 592
Bulletin 2052B and 2053 B- All Controllers,\,

Bulletin 2053H Controllers With Fast-Acting SCR Fuse Optionw
200V
30,40 HP
200V
50,60 HP
200V
75 HP
230V
40 HP
230V
50HP
230V
60HP
230V
75,100 HP
460V
60,75 HP
460V
100 HP
460V
125,150HP
460V
200 HP
575V
60,75,100 HP
575V
125,150HP
575V
200 HP
Heater Type
No.
Full Load
Amps
Heater Type
No.
Full Load
Amps
Heater Type
No.
Full Load
Amps
Healer Type
No.
Full Load
Amps
Heater Type
Full Load
Amps
W70
W71
W72
W73
W74
61
W75
W76
W77
W78
W79
81
86
93
98
106
W79
105
112
117
123
129
W36
W37
W40
126
137
150
164
179
W39
WOO
W81
W82
W83
W40
W41
W42
W43
180
197
215
235
256
W75
W76
W77
W78
W79
89
95
102
108
116
WOO
W81
W82
112
118
125
W84
135
W41
W42
W43
W44
196
214
233
256
W44
281
WOO
W81
W82
123
130
137
68
72
77
83
W39
W39
No.
Bulletin 2053H Controllers - Without Fast-Acting SCR Fuse OptioneD
(j)
22
Heater Type No.
Full Load Amps
Heater Type No.
Full Load Amps
W69
W70
W71
W72
W73
56
61
66
W35
72
77
W39
126
138
151
165
180
W74
W75
W76
W77
W78
83
89
95
102
108
W40
W41
W42
W43
W44
197
215
235
256
281
W79
WOO
W81
W82
116
123
130
137
These tables are to be used for standard endosed devices listed in the Indus~ial
Con~oI
W36
W37
W38
Catalog. For devices not listed, consult the nearest ,lJ1en-Bradley [js~icl Office
BI006008
BI006008
Product Data
Bulletin 592
!bALLEN-BRADLEY
. " A ROCKWELL INTERNATIONAL COMPANY
A subsidiary of Rockwell International, one of the world's largest technology companies,

Allen-Bradley meets today's automation challenges with over 85 years of practical plant floor
experience. More than 11,000 employees throughout the world design, manufacture and
apply a wide range of control and automation products and supporting services to help our
yustomers continuously improve quality, productivity and time to market. These products and
services not only control individual machines, but also integrate the manufacturing process
while providing access to vital plant floor data that can be used to support decision-making
throughout the enterprise.
'ith offices in major cities worldwide.

DRLD HEADQUARTERS
len-Bradley
01 South Second Street
Iwaukee, WI 53204 USA
1:(1) 414 382-2000
lex:43 11 016
lX:(1) 414382-4444
EUROPE/MIDDLE EASTI
AFRICA HEADQUARTERS
Allen-Bradley Europe B.V.
Amsterdamseweg 15
1422 AC Uithoorn
The Netherlands
Tel:(31) 2975/43500
Telex:(844) 18042
FAX:(31) 2975/60222
Iblication 592-2.1 - September 1992

",sedes Publication 592-2.1 Daled AU9us11984
ASIA/PACIFIC HEADQUARTERS
CANADA HEADQUARTERS
Allen-Bradley (Hong Kong) Limited
Allen-Bradley Canada Limited
Room 1006, Block B, Sea View Estate 135 Dundas Street
2-8 Watson Road
Cambridge, Ontario N1R 5X1
Hong Kong
Canada
Tel:(852)887-4788
Tel:(1) 519 623-1810
Telex:(780) 64347
FAX:(1) 519623-8930
FAX:(852)51 0-9436
1992 Allen- Bradley Company
LATIN AMERICA
HEADQUARTERS
Allen-Bradley
1201 South Second Street
Milwaukee, WI 53204 USA
Tel:(1) 414 382-2000
Telex:4311 016
FAX:(1) 414 382-2400
PRINTED IN USA
BI006008
BI006008
BI006008
DANGER:
THIS V1ANUAL IS INTENDED TO PROVIDE INFORMATION AND DATA FOR
MAINTENANCE AND OPERATION ON THIS MACHINE. THE ELECTRICAL
EQl~IPMENT INVOLVED SHOULD BE SERVICED ONLY BY QUALIFIED
INDIVI[ UALS WHO HAVE BEEN PROPERLY TRAINED TO WORK WITH HIGH
VOLTA~E SYSTEMS AND WARD-LEONARD LOOP DC DRIVES. FAILURE TO
~OMPLY WOULD RESULT IN PERSONAL INJURY OR DEATH.
DANGER:
DO NOl ATTEMPT ANY MAINTENANCE, MECHANICAL OR ELECTRICAL, ON

THIS r~ACHINE WITHOUT FULL UNDERSTANDING OF THE COMPONENT
OPERAllON AND INTERNAL PARTS. COMPONENTS UTILIZING ELECTRICAL
POWEF , AIR PRESSURE, HYDRAULIC PRESSURE AND COMPRESSION OR
TEf\;SION SPRINGS FOR OPERATION MUST BE DEACTIVATED AND
fSOLATED PRIOR TO DISASSEMBLY.
' - - - - - - - + - - - - - - - - - - - - - - - - - -----------------------------------------
The FEEDER CABLE must contain a provision for a ground connection, especially where
2300 volts ~nd above are used. The power line end must attach (see the paragraph on
ground cire uits) to a suitable permanent ground. The machine end must securely attach
through a bolted connection to ground the machine frame. This provides a constant
ground for he machine and electrical equipment. Failure to provide this adequate
ground encangers employees and equipment.
POWER LlNf= GROUNDING CIRCUIT ADEQUATE FOR THE MACHINE CANNOT BE OVEREMPHASIZED. Without a good grounding system, high voltage exists between the
machine and the ground. The portable cable and power lines supplying the machine
must have c ground wire, ample in capacity, running parallel to the main wires over the
entire distar ce from the transformer to the machine. A suitable grounding system must
be used at t le transformer. Consult the local electric supplier for details.
DANGER:
DUE TO NHERENT'DANGERS IN THE OPERATION OF ANY HIGH VOLTAGE
A SAFE GROUNDING SYSTEM SHOULD INCLUDE
GROUND CONDUCTORS IN THE CABLE, A NEUTRAL GROUNDING
RESI ~TOR, AND RELATED RELAYS AND SWITCHGEAR. A GROUND
CONTINUITY CHECK SYSTEM IS ALSO RECOMMENDED.
ELECTRI(~AL EQUIPMENT,
'-------+--------------~------------------------------------------~
BI006008
BI006008
Marion
182M Mining Shovel
ELECTRICAL SERVICE MANUAL No. 2243

-SN: 23367, 23368
Table of Contents -
This manua is divided into several sections covering various systems and their electrical components of the
18:<M Mining Shovel. Refer to book 2 of this manual for vendor instructions and publications.
Book 1:
Intr< duction
Sectj Dn
1 - SYSTEM OVERVIEW
Sectic n 2 - SYSTEM COMPONENTS and OPERATION

Sectic n 3 - STANDARDS for ELECTRICAL INSTALLATION
Sectic n 4 - CABLE PULLING SCHEDULE
Sectic n
Part No. 140G1 Rev. C

Part No. 211945-5 Rev. A
5 -ELECTRIcAL SETTINGS
Part No. 211946-3
Secticn 6 - EXCAVATOR THEORY

Secticn
7 - DC 2000 DRIVE SYSTEM and
Sectiofl
8 - FIELD EXCITER
Section
9 - BRAKE INSTRUCTIONS
Section
INSTRUCTION MANUALS
INSTRUCTIONS
Part No. 212656-7
Book 2:
Intro :1uction
Sectio~
11 - ELECTRICAL SCHEMATICS OVERVIEW
Sectio
12 - ELECTRICAL SCHEMATICS
SN: 23367
SN: 23368
VENDC R PUBLICATIONS:
Rc tating Equipment
Cc ntrol
Su pport Devices
IMPORTANT NOTE
The information and doc
Technologies, Inc., for th
substantial expense and
subject machine and is n
mentation enclosed were developed and assembled by The l\larioll Power Shovel Company ("f"brion"), a :::ubsidiary ofGloballJldustrial
limited purpose of relating necessary technologieal material to our customers. The contents herein \.. ere developed and. produced at
re valued by Marion at a proprietary level. Therefore, this information and documentation is being furllished solely for use with the
t to be used, reproduced or disclosed in any way, in \vhole or ill part, wit.hout tho prior express written permission of Marion.
1997
2243-I.M61
BI006008
BI006008
Introduction
-
Table of Contents Page
GENERAL I FORMATION
SAFETY A
..................................................
RT SYMBOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
SAFETY P ECAUTIONS
ii
.. iii
FIRE PREV NTION
TRAINING
vi
WARRANT
vii
2243-1.fv161
BI006008
BI006008
Introduction
GENERAL INFORMATION
This manu I is designed to assist the owner in the operation and preventive maintenance
of this mac ine. Following easy to understand step-by-step procedures, maintenance
personnel an perform these tasks in a safe manner. When a systematic and thorough
maintenan e/service procedure (a responsibility of the maintenance superintendent) is
used for thi machine, minimum unplanned downtime and reliable operation will result.
AL IS NOT THE PARTS BOOK, and cannot be used to order parts. A

separate, d tailed parts book has been supplied. Please carefully read the instructions in
it. All parts re listed by group and/or product code numbers with item/part numbers for
THIS SPE IFIC MACHINE. Order parts in exact quantity. Parts ordered by mistake and
returned, a e subject to a rehandling charge. RIGHT HAND and LEFT HAND parts on the
upperfram correspond to the operator's hands at the controls; as seated when
operating t e machine. Please state the correct machine SERIAL NUMBER (located on a
plate in the operator's cab) when corresponding or contacting factory service or parts
departmen . Records on each machine are filed by serial number and when given this
number, yo r machine's specific design and original equipment is accessed quickly by
the Marion arts representative.
itions or revisions may be made to this manual. These will be mailed direct to
you from th factory. Should you require additional information or factory service
assistance ontact your regional service representative or
617 West Center Street
P.O.Box 505
Marion, OH 43301-0505
- or Telephone (614) 383-5211

Fax: (614) 382-2052
It is Marion' policy to improve its products whenever possible and practical to do so. The
company r serves the ri~ht to make changes or add improvements at any time without
incurring a y obligation to install such changes on machines sold previously.
Due to this ontinuous program of product research and development some procedures,
specificatio s and parts may be altered in a constant effort to improve machines.
BI006008
SAFETY ALERT SYMBOLS
This safety alert symbol is used here and throughout this manual to call
your attention to instructions concerning your personal safety. Carefully
read and follow these instructions and observe all SAFETY, DANGER, and
CAUTION graphics mounted on various areas of the machine.
Be certain anyone servicing this machine is aware of these SAFETY SYMBOLS and their
definition. In the event you question your ability to safely perform ~any of the enclosed
maintenance and operational procedures contact your regional Marion service
representative or the factory.
The following defines distinctions between safety instructions. In all these definitions the
safety alert signal is used.
ADANGER:
Denotes extreme intrinsic hazard which exists and could result

in high probability of death or irreparabl~ injury if proper
ACAUTION:
Denotes a reminder of safety practices or directs attention to

unsafe practices which could result in p~rsonal injury if proper
An example of a safety alert symbol and special instructions is shown below.
ADANGER:
Inherent danger exists in the operation of any high voltage

electrical equipment. A safe grounding system includes
ground conductors in the power cable, a neutral grounding
resistor, and related relays and switch-gear. A ground
continuity check system is required by law in many parts of the
world.
Operating, maintaining or servicing this machine is dangerous unless performed

properly. Each person must satisfy himself and his employer that he is alert, has the
necessary skill, knowledge, proper tools and equipment, and that all the methods used
are safe and correct. Factory service representatives and specialists are available to
provide additional information or technical assistance.
The operator must be alert, physically fit, and free from the influence of alcohol, drugs, or
medications that might effect his eyesight, hearing or reactions.
Safety must always be the most important concern. Consult your supervisor when safety
is in doubt.
ii
BI006008
- The own r and/or operator must replace any and all safety and warning product
graphics f they are defaced or removed from the machine.
- Before ding any work on the machine, a qualified electrician must lock out or remove
the electr c power supply from the machine and tag it so personnel are aware that
someone is working on the machine.
rt an engine indoors unless adequate exhaust ventilators are provided. Once
is running, move the machine outdoors as soon as possible.
- Keep ha ds, feet, and clothing away from rotating parts.
- Do not m ve or operate the machine without knowing the location and purpose of all
personn I, plus test or support equipment, in or near the machine.
- Think bef re you act. Carelessness is one luxury the service man cannot afford.
- Do not w ar rings, wrist watches or loose fitting clothing when working on machinery.
They cou d catch on moving parts causing serious injury. Never adjust and/or service a
machine n bare feet, sandals or sneakers.
- Always w ar safety glasses when using a hammer, chisel or other tools that may cause
chips to f y.
'
- Excessiv or repeated skin contact with sealants or solvents may cause skin irritation.
In case 0 skin contact, remove sealant or solvent promptly by washing with soap and
water.
- Never uti ize the machine air or hydraulic systems for support when working on the
machine. Deactivate and isolate the system prior to performing maintenance.
- EqL!ipme t should be parked on level ground at all times during machine servicing and
periods f idleness.
- Cranes a d hoists must be of sufficient capacity to lift the heavier components
(gearcas s, dipper/bucket, boom, etc.) and have an ample safety margin.
- Be sure eavy items are properly supported from cranes or hoists before removing
supporti g members from machine.
- Have su icient service personnel available when removing or installing large heavy
items to aintain control at all times.
- Always u e safety stands in conjunction with hydraulic jacks or hoists. Do not rely on
the jack r hoist to carry the load, they could fail.
- Use safe y catch on all hoist hooks. Do not take a chance, the load could slip off of the
hook.
iii
BI006008
- If a heavy item begins to fall, let it fall, don't try to catch it.
- When disassembling machine, be sure to use safety stands and adequate cribbing to
prevent tipping or rollover of components.
- Keep work area organized and clean. Wipe up oil or spills of any kind. Keep tools and
parts off of the ground. Eliminate the possibility of a fall which could result in serious
injury.
- Floors, walkways and stairways must be clean and dry. After draining operations be
sure all spillage is cleaned up. Electrical cords and wet metal floors make a dangerous
combination.
- Check all wire ropes for telltale signs of early wear or failure. Look for and secure any
loose bolts or locking devices.
- Use extreme caution while working near any electrical lines or equipment whether it be
high or low voltage. Never attempt electrical repairs unless qualified. Check limit
switches for proper operation.
- When using an acetylene torch, always wear welding goggles ~nd gloves. Keep a
"charged" fire extinguisher within reach. Be sure the acetylene and oxygen tanks are
separated by a metal shield and are chained to the cart. Do not weld or heat areas near
transformers or electrical cabinets and utilize proper shielding around lubrication lines.
- Use pullers to remove bearings, bushings, gears, cylinder sleeves, etc. when
applicable. Use hammers, punches and chisels only when absolutely necessary. Then,
be sure to wear safety glasses.
- Be careful when using compressed air to dry parts. Use approved air blow guns, do
not exceed 30 PSI (207 kPa), wear safety glasses or goggles and use proper shielding
to protect everyone in the work area.
- Be sure to promptly reinstall safety devices, guards or shields after adjusting and/or
servicing the machine.
- After servicing, be sure all tools, parts or servicing equipment are removed from the
machine, or secured in an appropriate storage area.
- Protective eye goggles should be worn at all times when working on the air
conditioning system. Work on the air conditioning system only in a well ventilated area.
- Wipe away excess lubricants around bearings and gears. Never lubricate parts in
motion.
- Operate machine on level ground and be constantly aware of swing clearance. Never
hold a load longer than needed in the dump cycle. Use swing brakes only when
machine is stopped.
iv
BI006008
FIRE PREVENTION
- Always ~ave a "charged" fire extinguisher on hand and know how to use it. Inspect and
service he extinguisher as indicated on its instruction plate.
- DO NO smoke while handling flammables or when near batteries.

- Inspect fill lines, tubes, and hoses carefully. Tighten all connections to the
recomm~nded torque. See the Visual Inspection Schedule for the walk around
inspecti n procedure.
- Loose 0 damaged lines, tubes, and hoses, which leak, can cause a fire.
- Make certain that all clamps, guards, and shields are replaced correctly so as to
prevent ibration and the rubbing of one part against another which might result in
heat build-up during operation.
- DO NOT carry flammable fluids such as gasoline or solvents on board the machine.
- DO NOT over-bend or strike pressurized hose lines. 00 NOT install bent or damaged
lines, tut es, or hoses. Replace them with new immediately.
- 00 NOT start the mac!1ine or move any of the controls if a warning tag is attached to
the contrpls or the stalt panel.
- Keep all leaning rags properly stored. 00 NOT discard them into a pile on board.
- Keep all tructural frame compartments, walkways, and work areas clean and free of
lubricant residue.
- NEVER
w~ld,
burn, or perform service on the machine alone.

I
- If a moto or other COrllpOnent is running hot, shutdown the machine until it has cooled
and/or th a cause eliminated.
-----+----~---~----~-~--""~--~~-~-"-~--""-~--~---~-
-----t-----------~~ --~---~ ---~--
----~---
---
--- --
-~-~-~------~--
---
~ ~ - -~-~--~---~----
- - - - - - " - -----~~-~""-----"~---"~--~-"--
-----+--"-----~----
BI006008
TRAINING
Qualified maintenance personnel using a scheduled maintenance program are the best
way to minimize machine downtime and maximize productivity of equipment.
Marion offers factory and mine site maintenance seminars and special familiarization
programs for mechanics, oilers, electricians and operators on a fee basis.
These programs are presented by qualified factory specialists and service technicians.
Special customized training programs can also be developed to meet specific mine
requirements.
Objectives of training and training materials are to provide the means for developing and
maintaining on-site service repair capability.
For further information about Marion service training capabilities and programs contact:
617 West Center St.
P.O.Box 505
Marion, OH 43301-0505
vi
BI006008
~I
RE AIR/SPARE PARTS WARRANTY
The Marion ower Shovel Company ("Marion"), a subsidiary of Global Industrial Technologies,
Inc., warrant that its products, when shipped, for a period of six (6) months from the date of
delivery, F.O B. point of shipment, will meet applicable, agreed specifications, if any with
respect ther to, and will be free from defects in material and workmanship, provided that the
Marion prod cts sold are properly stored, assembled, used and maintained. Products not
manufacture by Marion shall be subject only to such warranty as may be made by the
manufacture thereof. All claims under this warranty must be made in writing immediately
upon discov ry. THE FOREGOING IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES
WHATSOEV R, EXPRESS, IMPLIED AND STATUTORY, INCLUDING, WITHOUT
LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS.
Should any f ilure of the Marion products to conform to this warranty appear within the limited
time period s t forth above, Marion shall, upon Buyer's submission of a claim as provided
above, either 1) repair or replace, F.O.B. point of shipment, any nonconforming part or parts of
Marion's pro ucts which have been returned to it for examination, transportation prepaid, or
otherwise ex mined by Marion, and which examination discloses the nonconformity to
Marion's satis action; or 2) refund an equitable portion of the purchase price.
THE FOREG ING IS MARION'S ONLY OBLIGATION AND BUYER'S EXCLUSIVELY
REMEDY FO BREACH OF WARRANTIES AND, EXCEPT FOR GROSS NEGLIGENCE,
WILLFUL MI CONDUCT, bR REMEDIES PERMITTED UNDER THE PERFORMANCE,
INSPECTION AND ACCEPTANCE CLAUSE OF MARION'S TERMS AND CONDITIONS, THE
FOREGOING IS BUYER'S EXCLUSIVE REMEDY AGAINST MARION FOR ALL CLAIMS
ARISING WI H RESPECT TO MARION PRODUCTS OR RELATING THERETO, WHETHER
SUCH CLAI S ARE BASED ON BREACH OF CONTRACT, TORT (INCLUDING
NEGLIGENC AND STRICT LIABILITY) OR OTHER THEORIES. BUYER'S FAILURE TO
SUBMIT A C AIM AS PRqVIDED ABOVE SHALL SPECIFICALLY WAIVE ALL CLAIMS FOR
DAMAGES 0 OTHER RELIEF, INCLUDING, BUT NOT LIMITED TO, CLAIMS BASED ON
LATENT DEF CTS.
IN NO EVEN
WARRANTIE
SPECIAL, IN
LATE PERFO
IN THE DESI
PRODUCTS
AND WHETH
AND STRICT
RESPECT TO
WITH ONE (1
BARRED.
(INCLUDING, BUT NOT LIMITED TO, AVOIDANCE OF THE ABOVE LIMITED

AND REMEDIES) SHALL BUYER BE ENTITLED TO ANY INDIRECT,
IDENTAL OR
CONSEQUENTIAL DAMAGES, WHETHER ARISING FROM
I
MANCE OR A FAILURE TO PERFORM, DEFICIENCIES OR NEGLIGENCE
N, MANUFACTURE, SALE DELIVERY OR ASSEMBLY OF MARION
R FAILURE,OF MARION PRODUCTS OR FROM ANY CAUSE WHATSOEVER
R BASED ON BREACH OF CONTRACT, TORT (INCLUDING NEGLIGENCE
lABILITY) OR OTHER THEORIES. ANY ACTION BY BUYER ARISING WITH
MARION PRODUCTS OR RELATING THERETO MUST BE COMMENCED
YEAR AFTER THE CAUSE OF ACTION ACCRUES OR IT SHALL BE
.. ------
~~~~~--t-~---~'-----.--_
warranty.m60
REV. 12/6/95
vii
BI006008
----- --------------------
----------------------------
-----------------------------------
-------------------------------------------------------~------------------
---------------
----
----------------------------------------------------------------------------
-----------------------
-----------------
viii
BI006008
Section
11
Electrical Schematics Overview

-Table of Contents Page
(Elementaries) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11.1
T CODES
11.1
CROSS R FERENCI NG .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11.2

ELECTRIC L SYMBOLS
GRAPHIC
2243-11.1\1'61
11.2
RONYMS
11.2
SYMBOLS -ELECTRICAL
11.3
BI006008
BI006008
Section
11
Electrical Schematics Overview

DIAGRAMS (Elementaries)
The 182M 31ectrical schematic drawings are broken down into sections designated by the
following sheet codes:
Sheet
Code Np.
OA-OC
IA-ID
2A-2D
5A-5P
7A-7-G ~
8-8G
Sheet
Code No.
Subject
Legend
System One Line
High Voltage
Master Control
Hoist - Propel
Crowd - Propel
9-9G
12A-12G
14A-14G
15A29A-29E
Subject
Swing
Auto-Lube Control
Lighting
Cabinet Layouts
The legenc section further breaks down the subject material for each sheet code number.
It also lists ~quipment codes used, describes the cross referencing system, and illustrates
some typical symbols.
EQUIPME ~T CODES
The equipn ent codes are numbers in boxes that designate major electrical panels, machine
componen assemblies, and electrical cabinets. These numbers, when found beside an
electrical device, indicates the location of that device. For example:
@]
_'1",VB-D
elecvbd5.wpg
Indicates the VB-D is located in the high voltage cabinet

designated as IT] .
A variation of this equipment code describes the different cabinet locations with common
panel nam ~s. For example:
[I]H
The D.C. control panel in the hoist control cabinet.
[I]c
The D.C. control panel in the crowd control cabinet.
Refer to the legend section of the elementary drawings for a complete list of the equipment
codes.
11.1
BI006008
CROSS REFERENCING
There are two basic kinds of cross referencing:
1. Numbers in brackets "[ ]".
2. Numbers in parenthesis "( )".
The numbers in brackets [] indicate where the wire(s) goes(go), or where a relay is located
when listed beside a relay contact. These numbers include the sheet code number and a
sheet coordinate number. Examples and variations follow:
[2DA17] Sheet code 2DA, line 17.
[A45Q] Sheet code prefix number is the same as the sheet you are on. If you are
on sheet 5B then go to sheet code 5A, coordinates 45Q
[B05]
Sheet code B, line 5. (See above example.)
The numbers in parenthesis ( ) indicates where the wire came from and is the name of that
wire. Sheet code and coordinate numbers are used the same way as described above.
Descriptions of electrical devices and additional cross referencing are provided at the right
hand end of each ladder run. For example:
H
EMSX
OJ
t---------jEMSIf------j
f----
[A31]
EM ERGENCY STOP
B16, B10, F27
-
f
~
"EMERGENCY STOP" describes the emergency stop auxiliary relay "EMSX" and references
a normally closed EMSX contact at B16 and one at F27 (by the underline) and a normally
open EMSX contact at B10.
ELECTRICAL SYMBOLS
The electrical symbols used for the logic cards, the static relays and the signal conditioners
are shown in the legend section of the elementary drawings. All other symbols used are
industry standard and are shown on the following pages.
DEVICE ACRONYMS
Acronyms are used in the elementary drawings for device names. See Section 7 -GENERAL
TROUBLESHOOTING in this manual for these acronyms and their descriptions.
11.2
BI006008
\ 1 - - ..... /
- -
Horn, Siren
or Speaker
..
I.-...J
~1
. .
..
...
.....
....
.:.
Generator, DC
., J
.. . .
.
Generator, AC
..
..
~ -~
'a/
~~
/
1-----------
Generator, AC
Indicating Lamp
"
OR
OR
* Add letter to
indicate color
Field, compensating
or commutating
Indicating Lamp
Meter
-)-
A = Ammeter
V = Voltmeter
PF = Power Factor Meter
TT = Time Meter
W = Wattmeter
WH = Watthour Meter
VAR = Varmeter
SY = Synchroscope
Field, Series
Field, Shunt or
separately excited
*Insert letter to
indicate type
Motor, DC
I
I
elecsyml.wpg
GRAPHICS SYMBOLS -ELECTRICAL
11.3
Key Operator
BI006008
Motor, AC
-{>-
Amplifier
Motor, AC
--e--o-
Switch, Limit N.O.

held closed
Switch, Liquid Level

N.O., Closes on
liquid level DROP
~o-
Switch, Limit N.C.

held open

N.C., Opens on
liquid level DROP
--<>--0-
Switch, Limit N.O.

held closed
~o-

N.O., Closes on
liquid level RISE
OR
60-
0-
Switch, Selector
2 - position
OR
~o-
Contact N.O.,
Time Delay opening
on de-energizing
~
I
--0--0-
Switch, Selector
2 - position
Contact N.C.,
Time Delay closing
on de-energizing
--010-
Coil, Valve or
Solenoid
Contact N.O.,
Time Delay opening
on energizing
-0-
Coil, Relay or
Contactor
;:0elecsym2.wpg
GRAPHIC SYMBOLS -ELECTRICAL
11.4
BI006008
- -...,..-
-....r
11\
--(). r-O-
---0... ~o-
""
-I
Contact N.C.,
Time Delay opening
on engergizing
-0-
Collector Ring
Switch, Flow
closes on increase
in flow
Switch, Flow
opens on increase
in flow
Switch, Limit N.O.
--0--0-
Switch, manually
operated
Switch, Foot operated

opens by foot pressure
Contact, N.O.
1-0."
Switch, Foot operated

~o- closes by foot pressure
-oro-
Switch, Pressure
N.C., closes on
pressure DROP
Switch, Pressure
N.C., opens on
pressure DROP
~o-
Switch, Pressure
N.O., closes on
pressure RISE
-or-
Switch, Pressure
N.C., opens on
pressure RISE
~o-
Switch, Temperature
N.O, closes on
temperature DROP
OR
0- ~
Contact, N.O.
+
-0- '--0-
Pushbutton
N.O. momentary
--0..... ~
Pushbutton
N.O. momentary
--o-n:
r-O i 0I
L..- '7',- J
elecsym3.wpg
Pushbutton
maintained 2-circuit
11.5
BI006008
0-
Pushbutton
Mushroom Head
N.O., Momentary
Switch, Temperature
N.C., Opens on
temperature DROP
-a.J:.!)-
Pushbutton
Mushroom Head
N.C., Momentary
~o-
Switch, Temperature
N.O., Closes on
temperature RISE
-aLr-
Push - Pull
maintained
1-circuit
Switch, Temperature
N.C., Opens on
temperature RISE
....I-
--0

N.C., Opens on
liquid level RISE
ITIIIIJ
Terminal Board
(6-pole shown)
~>--
Connectors,
separable
--o!X.Jo-
Overload Device,
Thermal
Inductor
elecsym4.wpg
Terminal
--.F-
Thryistor (SCR)
,...--..."
Circuit Breaker, Air

(Less than 1500 volts)
--0
0-
+
-rr::n-
11.6
Overload Device,
Magnetic
Fuse
BI006008
Book #2
Section
12
Schematics
Seria No. 23367
Part No. 211946-3
Seria No. 23368
Part No. 212781-4
2243-I.M61
BI006008
--<
en
-.J
UJ
......,
'"
en
r-
rTl
...
:>:
r.r fJnnJrlrATlmJC:: - C::I'I' nr
-$-8
0.00
0.0
THIS SHEET ONLY
NOTE
E~'
~:~~~~~.~:Ut~~~~~fiI~~~TO
OCVHOPEOAT SUBSHNTIAl
)N[R[S[O !NC,i.t.l11 A~~ KlG BEEN
PROpfRTYor II.I.RICNWISIONor
~WJb~R1~~NrSCTC:~~C~i.TJ~JNfOR
iH15DRA\'IINGREfRESEHTSPRO
+1 IMPORTANT
OTHERWISE SPECIFIED -
TOLERANCES UNLESS
KEY 18247
FIRST MADE FOR
TYPE /82-M SHOVEL
18-13-94
unL
ICAtlLUn
CLC
! ROUGH
II"1l.1. MARION,OHIO
r - , . - ..... __ ..............
II"'UI"\C.~vU
DESCRIPTlON,.... ..... , ..- ..,.... ......
ELECTRICAL SCHEMATIC
WT
BI006008
BI006008
BI006008
TABLE OF CONTENTS
SH. CODE/NO
- - /1
- - /2
- - /3
OA-OC
lA-lD
2A-2D
5A-5P
7A-7GA
BA-BG
9A-9G
12A-12U
14A-14C
15A
29A-29E
SUBJECT
TITLE
TABLE OF CONTENTS
KEY INTERLOCK SYSTEM
LE GE NO
ONE -L INE DIAGRAM
HI-VOLT
MASTER CONTROL
HOIST CONTROL
CROWD CONTROL
SWING CONTROL
AUTO-LUBE CONTROL
LIGHT ING
CABINET OUTLINES
MRRION.ELSH.211944-7.SHT2
BI006008
--i
::I:
CJ)
I
-J
to
..,...,.
::I:
CJ)
rt1
......
:;0
:3
:D
L.O.
TRAIL CABLE
J. BOX
COLLECTOR RINGS
MARION DIVISION OF
INDRESCO INC. MARION. OHIO
E
BOLT EXTENDED
W BOLT WITHDRAWN I .
L.O. LOCKED OPEN
L.C. LOCKED CLOSED
DENOTES DOORS MECHAN ICALL Y
CABLE
REEL
TRAIL
CABLE1f------Jr
LOWER FRAME
DISCONNECT
II
DOOR
DOOR
KEY INTERLOCK
SYSTEM
DOOR
FUTURE USE
(IF REQD.)
L.C.
~11r-
AUXILIARY
TRANSFORMER
M.G. SET
DR IVE MOTOR
HIGH VOL TAGE CONTACTOR CABINET
DO~
H.V. FUSE CABINET
BI006008
BI006008
BI006008
MARION DIVISION
INORESCO
SCR CONTROL SYSTEM
FOR
TYPE
182M SHOVEL
C
:2
lJ.
LEGE NO
(.':
lJ.
STANDARD LOCATION SYMBOLS

[DD.C. CONTROL PANEL #M8A
WTRANSFORMER ASSEMBLY #MI4A
[2jRESISTOR ASSEMBL Y #M7A
[i]MOTOR CONTROL CENTER #M68A
I]]HIGH VOL TAGE PANEL #MIOA
[]LOWER FRAME
[2] OPERATOR'S
CAB
~ DIG-PROPEL
TRANSFER PANEL #M35C
D MOUNTE UPPER
0 RE MOTE IE .G. DEV ICE
FRAME ETC.)
ON BOOM,
L OCAT ION/OEST INAT ION CR OSS -RE FERE NeE

NUMBERS LISTED UNDER NAME OF RELAY lOR STARTER.
CONTACTOR, ETC.) DENOTE LOCATION OF INTERLOCKS
IN THIS GROUP. SPARE INTERLOCKS ARE SHOWN
UNDERL INED NO. INDICATES N.C. CONTACTS.
BRACKETED NUMBERS [
] BELOW INTERLOCKS
DENOTE LOCATION OF THE OPERATING COIL.
BRACKETED NUMBERS [
] AT THE END OF A WIRE
INDICATES WHERE THAT WIRE IS CONTINUED
A NUMBER SHOWN IN PARE NTH IS IS I
)
INDICATES WHERE THE WIRE CAME FROM.
AND IS THE NAME OF THAT WIRE.
EXAMPLE:
[5 K 31L...._Q_ _::_HORIZONTAL POSTION ON SHEET

_
_ VERT ICAL POS IT ION ON SHEET
SHEET CODE, ALPHA-NUMERIC.
NUMERIC ONLY SHEET NO.S ARE NOT USED.
CODE NO.
MRRIDN.ELSH.211944-7.DR
OA
BI006008
CONSISTS OF SHEETS 58.";;

BI006008
01
~
01
02
'"
Lg
I'-I
~
~
m
-
iE-
03
03
f'J
04
04
05
05
SHEET NO,
06
06
07
07
08
OA
COVER SHEET
08
INDEX
08
09
09
10
10
II
II
12
12
13
5A
5J
5JA
14
15
16
17
18
19
<tU
<to
r<)
en
Ll1 ;i
en
~
'""
..
(
~
f--
13
INCOMING POWER
14
125 VOLT SUPPLY AND DIPPER TRIP
15
DIG/PROPEL TRANSFER
16
5K
MAGNETICS INTERFACE
5L
LOWER FRAME MAGNETICS INTERFACE
5M
SYSTEM FAULT INDICATION CONTROL
5N
PROPEL EXCITER
17
18
19
20
20
21
21
22
22
23
23
HOIST GENERATOR SHUNT FIELD CONNECTION AND EXCITATION
7A
24
24
78
HOIST ARMATURE CIRCUIT AND GROUND DETECTION
25
7C
HOIST/PROPEL MTR FIELD CONNECTION AND EXCITATION
26
27
70
REGULATOR CONTROL: REF /GND FL T INPUT
7E
EXCITER OVERTEMP/FAULT CONTROL
28
7F
DIG/PROPEL INPUT/GND FL T OUTPUT
29
7G
MAGNETICS
25
26
27
28
29
30
30
31
31
32
32
33
8A
CROWD GENERATOR SHUNT FIELD CONNECTION AND EXCITATION
34
88
8C
CROWD ARMATURE CIRCUIT ANO GROUND DETECTION
80
REGULATOR CONTROL: REF/GND FL T INPUT
35
36
37
33
34
35
CROWD/PROPEL MTR FIELD CONNECTION AND EXCITATION
8E
38
8F
DIG/PROPEL INPUT/GND FL T OUTPUT
39
8G
MAGNETICS
37
o
Z
38
40
41
41
42
42
43
9A
SWING GENERATOR SHUNT FIELD CONNECTION AND EXCITATION
43
44
SWING ARMATURE CIRCUIT AND GROUND DETECTION
45
98
9C
46
90
REGULATOR CONTROL: REF/GND FL T INPUT
9E
49
:r:
.....
SWING MOTOR FIELD CONNECTION AND EXCITATION
9F
GND FAULT OUTPUT
9G
MAGNETICS
<t
;z::;;
O.
(j)e.:>
>~
00
44
;zg
45
ii:g'i
Ou.r
~~
46
47
48
49
50
50
51
51
52
52
53
53
STANDARO LOCATION SYMBOLS
ALL UNMARKED DEVICES SHOWN ON

THIS ELEMENTARY, EXCEPT ROTATING
EQUIPMENT, ARE LOCATED ON OJ
D,C, CONTROL PANEL,
54
55
OJ
D,C, CONTROL PANEL
[] LOWER FRAME
rn
RESISTOR ASSEMBLY
III
rID
~ ~~~J~gR~tRM~~~~~BLY
56
57
58
59
OPERATOR'S CAB
HOIST-PROPEL TRANSFER PANEL
@] A,C, AUXILIARY CONTROL PANEL
[ID HYDRAULIC CONTROL PANEL
~ HIGH VOLTAGE PANEL
REV. :5
REV. 2
07-21-95
REV. 4
ISSUEO
REY.
MADE: BY
03-27-95
~
S, WAMSLEY
IREV.
57
MOUNTED REMOTE (E,G, DEViCE ON

BOOM, UPPER FRAME ETC,)
59
60
APPROVALS
05-11-95
IPRINTS TO
FIRST WADE FOR REO.
37796E181
SOFTWARE NO.
54
55
56
58
60
R
ELEMENTARY DIAGRAM
GENERAL ELECTRIC
DRIVE SYSTEMS
SALEM. VA. USA
INDEX
246B5931AA
I SM. NO.
OC
08
CONT. ON SH.
00::
39
40
47
48
I---
36
MAR ION,ELSH,21194 4- 7,GE -OB
08
BI006008
CONSISTS OF SHEETS 5 ,
BI006008
LIMITAMP EQUIPMENT
NbMENCLATURE
NOMENCLATURE
US M
IA
2A
A
Al
AM
AM
AT
AX
BFI
BfT
Bil
C
C.C
CB
CCM
CO
CH
CM
CPO
CP I
CP I
CR
CT
CTB
CTD
RECP
RIL
RM
RS
RIO
RX
S
SC
S-GR
SH
SHAM
SP HTR
SPR
SR
SS
SSI
SSW
ST
STB
SSX
SX
T
TC
TOAD
TOAE
TO
TI.T2.T3
TB
TH
THY
TIE
TP I
TPIX
TPSW
TR
TRP
TST
TSW
UL
UV
UVTR
VCR
VON
VfSM
VM
VMS
VRM
VRTO
VT
VTD
WHOM
WHM
WM
WTD
MICROPROCESSOR BASED STARTING t PROTECT ION MOOULE

AC AMMETER
DC AMMETER
ACCELERAT ING CONTACTOR
AMBER INOICATING LIGHT
AMMETER
AMMETER SW ITCH
AUTOTRANSFORMER
ACCELERATION TIMIMNG RELAY
BLOWN FUSE INDICATOR
BLOWN FUSE TRIP
BLUE INDICATING LIGHT
CAPACITOR
CLOSING COIL
CIRCU IT BREAKER
CONTACTOR CONTROL MODULE
CAlifORNIA OISCONNECT
CHOKE
FIELD CURRENT CALIBRATION MOOUlE
CAPAC ITOR TR IP DEV ICE
CONTROL POWER INTERLOCK
AUX. RELAY TO CP I
CONTROL RELAY
CURRENT TRANSFORMER
CURRENT TEST BLOCK
CURRENT TRANSOUCER
o
DIOOE
OCC
DC CURRENT TRANSFORMER
OR
OIFFERENTIAL RELAY
OSW
OISCONNECT SWITCH
ErR
EXCITER FIELO RELAY
ETM
ELAPSED TIME METER
EXC
EXCITER
EXC RHEO
EXC ITER RHEOSTAT
FI. 2
SYNC. MOTOR FIELD lEADS
FC
FIELD CONTACTOR
FCX
AUX. FIElO RELAY
FCY
AUX. FIElO RELAY
FOR
FIELD DISCHARGE RESISTOR
FGR
FIELD GROUNO RESISTOR
FLO
SYNC. MOTOR FIELD
FlR
FIELD LOSS RELAY
FLT
FILTER
FRP
FIELD RECTIF IER PANEL
FS
FAST SPEED CONTACTOR
FSI
FAST SPEEO SHORTING CONTACTOR
FSX
AUX, RELAY TO FS
FSW
FEEDER SWITCH
FTRS
FIXEO TAP RESISTOR
FU
FUSE
GCT
GROUNO CURRENT TRANSfORMER
Gf
GROUNO FAULT RELAY
GFX
AUX. RELAY TO GF
GIL
GREEN INOICATING LIGHT
GNO
GROUNO
GRB
GROUNO BUS
GS
GROUND SENSOR
HI.H .H3
OUTGOING TERMINALS TO TRANSFORMER
HAM
HEATER AMMETER
ISW
ISOlAT ING SWITCH
IXR
INCOMPLETE SEGUENCE RELAY
KX
ANTI-KISS RELAY
l ,0.
lATE OPENING
L1.L .L3
INCOMING TERMINALS OR AC BUS
lA
LIGHT ING ARRESTOR
LIT
LIGHT
LOR
LOCKOUT RELAY
lSW
LIGHT SWITCH
LT-I
lODTRAK 4 MOTOR PROTECTION RELAY
LTlG
LODTRAK/GROUNO FAULT
LT10 -OT
LOOTRAK/OVERCURRENT -OVERTEMPERATURE
l T10 -OC
LODTRAK/OVERLOAO-OVERCURRENT
LTlO -PR
LOOTRAK/OPEN PHASE PHASE REVERSAL
LTlO -PU
lODTRAK/OPEN PHASE PHASE UNBALANCE
LT10
LDOTRAK/OVERTEMPERATURE
LTAR
lOOTRAK/AUX. RELAY
M
MA INCONTACTOR
MOT
MOTOR
MOV
METEl OXIOE VARISTOR
MR
CONTACT OR HOlOING RESISTOR RELAY
MSW
MAIN DISCONNECT SWITCH
MX
AUX, RELAY TO M
N
NEUTRAL CONTACTOR
NX
AUX, RELAY TO N
OC
OPERAT IONS COUNTER
OCR
OVERCURRENT RELAY
Ol
OVERLOAO RELAY
OT
OVERTEMPERATURE RELAY
OTX
AUX. RELAY TO OT
PM
POLAR ITY MARK
PB
PUSH BUTTON
PFC
POWER FACTOR CAPACITOR
PFM
POWER FACTOR METER
PG
PLUG
PHA.P B.PHC INCOM ING LI NE TERM INALS
PLR
POWER LOSS RELAY
PRO
CT PROTECTOR ITHYR ITE I
PST
PHASE SHIFTING TRANSFORMER
PT
POTENT IAL TRANSFORMER
PTB
POTENTIAL TEST BLOCK
R
RUN OR REVERSE CONTACT OR
RC
RELEASE COIL OR CONTACT
REC
RECTI FIER
RECEPTACLE
RIL INOICATING LIGHT
RECTIFIER CONTACTOR
RESISTOR
RESISTANCE TEMPERATURE OETECTOR
AUX. RELAY TO R
START CONTACTOR
SURGE CAPACITOR
SLlP-GUARO RELAY
SHUNT
SPACE HEATER AMMETER
SPACE HEATER
STALL PROTECTIVE RELAY
STARTING REACTOR
SLOW SPEEO CONlACTOR
SLOW SPEEO SHORTING CONTACTOR
SELECTOR SWITCH
STAB
SHORTING TERMINAL BOARD
AUX. RELAY TO SS
AUX. RELAY TO S
TRANSfORMER
TIME CLOSING
TIME OELAY AfTER OE-ENERGIZATION
TIME OELAY AfTER ENERGIZATION
TIME OPENING
OUTGOING TERMINALS TO MOTOR
TERMINAL BOARO
THERMOSTAT
THYRlTE
TIE SWITCH
TEST POWER INTERLOCK
AUX. RELAY TO TPI
TEST POWER SWITCH
TIMING RELAY
TRIP RELAY
THERMOSTAT ON AT OR SR
TEST-NORMAL SELECTOR SW ITCH
UNLATCH RELAY
UNOERVOL TAGE RELAY
UNOERVOLTAGE TIM ING RELAY
VOL lAGE CHECK RELAY
VOLTAGE DIVIDER NETWORK
VARIABLE FIELO SUPPLY MOOULE
VOL TMETER
VOLTMETER SW ITCH
VARMETER
VAR TRANSOUCER
VARIABLE AUTOTRANSFORMER
VOL TAGE TRANSOUCER
WATT HOUR OEMAND METER
WATTHOUR METER
WATTMETER
WATTS TRANSOUCER
(
(
le
NOTE A - PURCHASER TO REMOVE JUMPER AFTER CONNECT ING REMOTE OEV ICE.
:r
NOTE B - TDUV IS WIRED FOR TIME OElAY DROp OUT ON lOSS

OF VOLTAGE. THE MAIN CONTACTOR WIll OPEN. THEN REClOSE
IF VOLTAGE IS RESTORED WITHIN THE TIME RANGE OF TOUV.
FOR INSTANEOUS OROP-OUT. PURCHASER SHALL RECONNECT
JUMPER PER ELEMENTARY.
I.L.~
00:
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'"
0,
(J5c..:l
>~
THIS OIAGRAM SHOWS STARTER WITH THE ISOLATING SWITCH IN

THE OISCONNECT POSITION ANO THE TEST POWER INTERLOCK
IN THE TEST POSITION.
00
Z~
Ow
TO TEST - HANOLE MUST BE IN THE DISCONNECT POSITION I OFF I AND

TEST-NORMAL SELECTOR SWITCH. LOCATED IN THE LOW VOLTAGE
COMPARTMENT. MUST BE IN THE I TEST I POSITION. PURCHASER IS TO
CONNECT HIS TEST POWER TO THE PROPER TERMINALS AND NOTE
THAT THE CONTROL CIRCUIT IS NOT GROUNDED WHEN DISCONNECTS ARE OPEN.
BE SURE TO TURN THE TEST -NORMAL SWITCH TO NORMAL
BEFORE MOVING THE DISCONNECT HANOLE TO THE { ON I POSITION.
iX~
<:z
::e
_
I---
CP I - OPENS ONLY WHEN CP I RELEASE ON ISOLAT ING SW ITCH

HANDLE IS PUSHED IN. CAN NOT BE OPENED WHEN MA INLI NE
CONTACTOR IS CLOSEO.
!:J. - START ANO STOP PUSHBUTTONS ARE WIREO THOUGH TERMINAL AT
"TB" IN ORDER THAT REMOTE START-STOP BUTTONS CAN BE REAOllY

CONNECTED INTO THE CIRCUIT WHEN REGUIRED.
o.
AT ATERMINAL ON "TB" AlOOP IN THE CT SECONDARY CIRCUIT WIRE

PERMITS INSERTION OF AHOOK ON AMMETER FOR MEASURING
LI NE CURRENT.
T - DEVICE fURNISHED BY OTHERS MOUNTED REMOTE.

III - TERMINAL BOARO POINT.
NOTE: DEVICE TERMINAL --\~~\
~JlliL
----m m-.1
CONTROLLER GROUNO
.1
SYSTEM GROUNO
WIRE NO.
ELSH.211944-7.0C
oc
BI006008
z
o
Cl
o
o
IMPORTANT NOTE
CABLE REEL
o
E
F
!~,~~ ~F~~ E;..N~ I.T"H"fE~U'~~ ,E",~ AT~,I~G,., ~?"Rn I;~"~~~~~~TE"~~t:,O,,~L~:f?;..~~~R~,DU 7.~E 2,~ ,2 I:E~8,~,~P !~'"
FUSED
GROUND
FAUL T
MODULE
IA TRIP
MARlnN
[C23A]
~-----[C26A]
HI-VOlT
iH~~R~~ II
1:~llr
C}_~
4T5T~6'FMR
230V
7.5 KVA
L __ ~
&
LTG
BUS
02
25
24
23
22
21
20
19
18
17
16
15
14
13
12
II
10
09
08
07
06
05
04
03
30
29
28
27
26
"',
211944-7
DWG. NO
[DD3R]
o-1llH-[D03D]
------[C25C]
1500VI
13AI
r---~
r-__
1
2-P ) -
3 KVA
AUX.XFMR
41S TO 55-0-55V
ONE -L INE
nHln
IwrES
INDRFSCO INC
O-IOOA
l 1"
I N .
I)
311~~_41_5_V
150 KVA
AUX XFMR
6600
MARION DIVISION OF
[BOIK]
D~NECTS
------1
~~~CDNNECT
1I l
'THIS DRAWING REPRESENTS PROPRIETARY AND CONFIDENTIAL INFORMATION AND 15 THE EXCLUSIVE PROPERTY
OF MARION DI~ISIOti OF INDRESCO HK(MIJ AND HAS BEEti DEVELOPED AT SUBSTANTlAL EXPENSE.
:t>
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-J>.
-J>.
l!)
fTl
,(J)
:c
:z:
s::
::0
TRAIL
CABLE
3 PHASE
50 HZ
6600 V
BI006008
BI006008

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BI006008

DO NO ATTEMPT ANY MAINTENANCE, MECHANICAL OR ELECTRICAL, ON

182M Mining Shovel

ELECTRICAL SERVICE MANUAL No. 2243

2 - SYSTEM COMPONENTS and OPERATION

3 - STANDARDS for ELECTRICAL INSTALLATION

- CABLE PULLING SCHEDULE

Part No. 140G1 Rev. C

7 - DC 2000 DRIVE SYSTEM and INSTRUCTION MANUALS

8 - FIELD EXCITER INSTRUCTIONS

10 - MOTOR CONTROL CENTER

Part No. 211946-3

Part No. 212656-7

Section 11 - ELECTRICAL SCHEMATICS OVERVIEW

Part No. 211944-7 Rev. C

Part No. 212781-4 Rev. C

The Marion Power Shovel Company

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

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

- or Telephone (614) 383-5211

SAFETY ALERT SYMBOLS

Denotes extreme intrinsic hazard which exists and could result

Denotes a reminder of safety practices or directs attention to

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

Inherent danger exists in the operation of any high voltage

Operating, maintaining or servicing this machine is dangerous unless performed

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

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

R PAIR/SPARE PARTS WARRANTY

ELECTRIC L SYSTEM OUTLINE

KEY INTER OCK SYSTEM -SN: 23367

KEY INTER OCK SYSTEM -SN: 23368

ONE-LINE E ECTR/CAL DIAGRAMS

COMPRESSED AIR SYSTEM

UTO LUBE CONTROL

Machine Spe ifications -English

ELECTRICAL SYSTEM OUTLINE

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

150 KVA Dry Auxiliary Transformer.

War~-Leonard Power Conversion .

Stat c DC Generator Field Exciters with Digital Control.

Joys ick Control via Expander Boards.

Elec ro-Mechanical Auto Lube Control.

Motor Field Exciters with Digital Cotrol.

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

BOTTOM OF UPPER FRAME

HIGH VOLTAGE CONTACTOR CABINET

H.V. FUSE CABINET

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

BOTTOM OF UPPER FRAME

HIGH VOLTAGE CONTACTOR CABINET

H.V. FUSE CABINET

FUSEO:~:_I ":li~ ""

... rUSE SPEC IAL

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

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

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

ZC/ "'" 11_-~rv~-J15\FILTER

ZA/ C'.> '~~FILTER

DRV CVT IKVA

JI,. 1\1 C'

.75 NOM. 1.0.

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