TÀI LIỆU TRAINNING GEH 6125

GEH-6125A
(Supersedes GEH-6125)

g

GE Industrial Systems

Innovation Series
AC Drives

Load Commutated Inverter
Installation and Startup
for Static Starter Applications



g
GE Industrial Systems
Document: GEH-6125A
Original issue date: 1998-05-29
Rev. A: 2000-05-29

Innovation Series
AC Drives

Load Commutated Inverter
Installation and Startup
for Static Starter Applications


© 1999, 2000 General Electric Company, USA.

All rights reserved.
Printed in the United States of America.
These instructions do not purport to cover all details or variations in equipment, nor
to provide every possible contingency to be met during installation, operation, and
maintenance. If further information is desired or if particular problems arise that are
not covered sufficiently for the purchaser’s purpose, the matter should be referred to
GE Industrial Systems, Salem, Virginia, USA.
This document contains proprietary information of General Electric Company, USA
and is furnished to its customer solely to assist that customer in the installation,
testing, operation, and/or maintenance of the equipment described. This document
shall not be reproduced in whole or in part nor shall its contents be disclosed to any
third party without the written approval of GE Industrial Systems.
Document Identification: GEH-6125, Revision A
Technical Writer/Editor: Teresa Davidson
Technical Responsibility: R.L. Covington, C. Lau

Field ControlTM, GeniusTM, LogicMaster TM, and Series 90TM are trademarks
of GE Fanuc Automation North America, Inc.
Fluke® is a registered trademark of Fluke Corporation.
InnovationTM is a trademark of General Electric Company.
National Electrical Code® and NEC® are registered trademarks of the National
Fire Protection Association.
Windows® is a registered trademark of Microsoft Corporation.


Load Commutated Inverter, Installation and Startup for Static Starter Applications

GEH-6125A

Safety Symbol Legend

Indicates a procedure, practice, condition, or
statement that, if not strictly observed, could
result in personal injury or death.

Indicates a procedure, practice, condition, or
statement that, if not strictly observed, could
result in damage to or destruction of
equipment.

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

Safety Symbol Legend • a


GEH-6125A

Innovation Series AC Drives

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.

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

Note
GE designs equipment and selects components for reliability. However,
component and equipment failures can still occur. Electrical and
environmental conditions beyond the scope of the original design can be
contributing factors.
Since failure modes cannot always be predicted or may depend on the
application and the environment, best practices should be followed when
dealing with I/O that is critical to process operation or personnel safety.
Make sure that potential I/O failures are considered and that appropriate
lockouts or permissives are incorporated into the application. This is
especially true for processes that require human interaction.

b • Safety Symbol Legend


Load Commutated Inverter, Installation and Startup for Static Starter Applications

GEH-6125A

Table of Contents
Section Heading

Page

Section 1, How to Use This Manual

1-1. Structure.............................................................1
1-2. Conventions Used ..............................................1
1-3. How to Get Help ................................................1
Section 2, Handling and Mounting Guidelines

2-1. Drive Handling Procedures................................3
2-1.1. Lifting .............................................................3
2-1.2. Moving............................................................3
2-1.3. Unpacking .......................................................5
2-2. Mounting............................................................5
Section 3, Cabling and Connections

3-1. Power Requirements ........................................... 7
3-1.1. Control Power .................................................. 7
3-2. Drive Connections .............................................. 7
3-2.1. Line Protection................................................. 7
3-2.2. Terminal Board I/O.......................................... 8
3-3. Cabling Guidelines ........................................... 10
3-3.1. Preventing Cable Damage.............................. 10
3-3.2. Installing Power Cable................................... 10
3-3.3. Installing Signal and Communications Cable 11
Section 4, Pre-Startup Installation Checks

4-1. Equipment/Material Needed ............................. 13
4-2. Connections and Wiring ................................... 13
4-3. Power Checks.................................................... 14

4-3.1. Initial Checks and Setup ................................ 14
4-3.2. Meggar Test ................................................... 15
4-3.3. Auxiliary Power Checkout............................. 15
4-4. Series 90-30 PLC and Field Control I/O
Checks ............................................................... 17
4-5. Local (AFE Datapanel) Display Checks........... 18
Section 5. Initial Drive Setup and Operation
Checks

5-1. Equipment/Material Needed ............................. 19
5-2. Cooling System Setup....................................... 20
5-2.1. Check Pump/Blower Rotation ....................... 20
5-2.2. Flush and Clean the Cooling System ............. 20
5-2.3. Fill the System with Coolant ......................... 20
5-3. Control Rack Initialization................................ 22
5-3.1. Upload Firmware ........................................... 22
5-3.2. Download EE Variables for Update .............. 22
5-3.3. Upload Modified EE Variables to DSPC ...... 22
5-4. Set Hardware Suppression Pot.......................... 23
5-5. Bridge Check and Setup.................................... 23
5-5.1. Current Feedback Burden Resistor Value ..... 23

Section Heading

Page

5-5.2.
5-5.3.
5-5.4.
5-5.5.

Shorted SCRs ............................................... 23
SCR Gate Test .............................................. 23
Current Feedback Offset .............................. 28
Null DC Offset at Reconstructed
Flux Testpoints ............................................. 28
5-5.6. Source No Load Full Voltage Checkout ...... 29
5-5.7. Load Control Check ..................................... 31
5-6. External Exciter (EX2000) Interface Checks.. 32
5-7. Crowbar Test ................................................... 32
5-8. Phase Sequence Test ....................................... 33
5-9. Hardware Segment/Keyphase Setup ............... 34
5-10. Checks with the Machine Running ............... 34
5-10.1. Initial Checks and Setup............................. 34
5-10.2. Start and Run the Machine ......................... 35
5-10.3 Load Flux Feedback Check......................... 36
5-10.4. Datapanel Display Readings ...................... 36
Appendix A, Understanding Equipment Drawings

A-1. Introduction .................................................... 37
A-2. Equipment Catalog Number ........................... 37
A-3. Equipment Nameplate .................................... 38
A-4. Basic Drawing Numbers................................. 38
A-5. Outline Drawings............................................ 38
A-6. Terminal Board Drawings .............................. 38
A-7. Elementary Diagrams ..................................... 39
A-7.1. Equipment Reference Information .............. 39
A-7.2. Elementary Drawing Number...................... 39
A-7.3. Wire Number Identification ........................ 39
A-8. Conventions Used With Other Equipment ..... 39

A-8.1. Genius or Field Control I/O Elements......... 39
A-8.2. AC Motor Control Centers .......................... 39
Appendix B, Installing Fiber-Optic Cable

C-1. Cable Characteristics ........................................41
C-1.1. Cable Construction ........................................41
C-1.2. Data Integrity .................................................41
C-1.3. Causes of Cable Damage ...............................42
C-2. Handling Guidelines .........................................42
C-3. Environmental Guidelines ................................42
C-4. Cable Assembly ................................................43
C-4-1. Tools and Materials.......................................43
C-4-2. Attaching a Connector...................................43
C-4.3. Polishing Fiber Ends......................................44
C-5. Inspecting Fiber Ends .......................................45
C-6. Connecting Fiber-Optic Cable to Modules.......47

Contents • i


GEH-6125A

Innovation Series AC Drives

Table of Contents — Continued
Section Heading
C-1.
C-2.
C-3.
C-4.

C-5.
C-6.

Page

Introduction ..................................................... 49
Low-Level Signals (Level L) .......................... 49
Medium-Level Signals (Level M) ................... 49
High-Level Signals (Level H) ......................... 49
Power-Level .................................................... 50
Class Codes ..................................................... 50

Section Heading

Page

C-7. Cableway Spacing Guidelines ......................... 50
C-7.1. General Cableway Spacing........................... 50
C-7.2. Tray/Tray Spacing ........................................ 51
C-7.3. Tray/Conduit Spacing................................... 51
C-7.4. Conduit/Conduit Spacing.............................. 51

List of Figures
Figure Title

Page

1-1. Order of Installation/Startup ..............................1
2-1. Sample of Outline Drawing for Typical LCI
Lineup ...............................................................4

3-1. Location of Terminal Connectors on
DDTB Board ......................................................8
4-1. FCSA Board Layout.........................................16
5-1. Typical Liquid Cooling System Layout...........21
5-2. Location of Overcurrent Pot and Testpoint on
FCGD Board ....................................................23
5-3. Sample Monitor Screen, Changing EE
Variables ..........................................................24
5-4. Sample Monitor Screen, Checking Gating
Signal Path and Current ...................................24
5-5. Location of Resistors R101 and R102 on
FGPA Board.....................................................25
5-6. Oscilloscope Reading for Gate Current
Check................................................................26

Figure Title

Page

5-7. Sample Monitor Screen, Modifying Variable
and Disabling Factory Test................................27
5-8. View of FCGD Board at Front of Control
Rack ...................................................................28
5-9. Oscilloscope Reading for Crowbar Test
Current Check....................................................33
A-1. Sample Panel/Case Catalog Number................37
A-2. Typical Drive Nameplate .................................38
A-3. Sample Drawing Number .................................38
A-4. Sample Sheet Number, Drive System
Elementary Diagram.........................................39

A-5. Sample Wire Number .......................................39
B-1. Fiber-Optic Cable with End Stripped for
Insertion into Connector ....................................41
B-2. Inserting Fiber-Optic Cable into Connector .....41
B-3. Fiber-Optic Cable with Connector Attached ....42
B-4. Polishing Fiber-Optic Cable .............................42

List of Tables
Table Title
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
5-1.

Page

TB1 Connections, Analog I/O and Shields........8
TB2 Connections, Analog I/O and Shields........9
TB3 Connections, High Voltage Input ..............9
TB4 Connections, High Voltage Input ..............9
TB5 Connections, Relay Outputs ......................9
TBPL Pin Assignments....................................10
Variables for Checking SCR Gating Paths ......25

ii • Contents

Table Title

Page

5-2. Chart Recorder Connections for Both
Uncoupled and Coupled Motor Tests.............. 35
B-1. Procedures for Inspecting Fiber-Optic Cable
Ends ................................................................ 45
C-1. Spacing Between Trays .................................. 51
C-2. Spacing Between Trays .................................. 51
C-3. Spacing Between Trays .................................. 51


Load Commutated Inverter, Installation and Startup for Static Starter Applications

1

How to Use This
Document

This document contains installation and startup instructions for static starter applications of the Innovation Series load commutated inverter (LCI). It is
written for a technician who is experienced with the
physical and electrical requirements of installing such
equipment. Additionally, the user should understand
the theory of drive operation and how to use the LCI’s
software configuration tools.

1-1. Structure
This document is structured as sections of related
information, presented in the order that it should be
followed (see Figure 1-1). Appendices provide reference information. For an exact outline of the document’s organization, refer to the Table of Contents.

GE recommends that a detailed installation log be
maintained for each drive as these installation and
startup steps are completed.

Startup

Installation

Start

Installation site
ready; drawings &
documents onhand

Move LCI to
installation site &
mount it

Section 2

Connect cable & I/O

Section 3

Verify correct
functioning of
connected devices
(power, I/O)

Section 4

Prepare LCI for
operation & verify
running condition

Section 5

Stop

GEH-6125A

1-2. Conventions Used
In this document, numbers are used to indicate sequence of instructions: Arabic numerals precede
steps to be followed in order; alphabetic characters
indicate the order of substeps. An empty checkbox
(¨
¨) is used when the sequence of items or instructions
does not matter.
When describing software functions: This typeface is used to differentiate screen text from instructional text, and to distinguish words or characters
typed at a screen prompt. This typeface is used to
indicate a key (for example, Tab).

1-3. How to Get Help
If help is needed beyond the instructions provided in
the LCI system documentation, contact GE as follows:
GE Industrial Systems
Product Service Engineering, Rm. 191
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
Phone: + 1 800 533 5885 (US, Canada, Mexico)

+ 1 540 378 3280 (International)
Fax: + 1 540 387 8606 (All)
“+” indicates the international access code required
when calling from outside of the USA.

LCI ready for
commissioning

Figure 1-1. Order of Installation/Startup
Section 1, How to Use This Document • 1


GEH-6125A

Innovation Series AC Drives

Notes:

2 • Section 1, How to Use This Document


Load Commutated Inverter, Installation and Startup for Static Starter Applications

2

Handling and
Mounting Guidelines

Section 2 of this manual provides instructions for
moving the equipment to the installation site, and then

mounting it. This section is organized as follows:
Section Heading

Page

2-1. Drive Handling Procedures................................3
2-1.1. Lifting .............................................................3
2-1.2. Moving.............................................................3
2-1.3. Unpacking .......................................................5
2-2. Mounting............................................................5
This is general information that applies to all LCI
drives. It must be used along with system outline
drawings and any special instructions provided with
the equipment. The outline drawings show the
configuration and physical size of each customer’s
system.
Shock or stress caused by rough
handling or improper lifting and
moving can damage the equipment.
Be sure to follow the guidelines
provided in this section.

GEH-6125A

2-1. Drive Handling Procedures
It is good practice to not completely unpack the
equipment until it has been moved as near as possible
to its permanent location. Refer to section 2-1.3 for
unpacking guidelines.
Before lifting and moving the drive, always refer to

the equipment outline drawings. (Figure 2-1 shows a
sample.) Become familiar with the designated lift
points, stress points, and any specified handling instructions.
While lifting and moving the drive, be sure to follow
the suggested methods of lifting and moving the
equipment, along with normal handling precautions.
Additionally, it is important to observe any instructions that may be printed on or attached to the equipment container or wrapping.
2-1.1. Lifting
o Be sure to use lifting equipment suitable for the
weight and configuration of the drive. (The outline
drawing should include the drive weight.)
o Observe the center-of-gravity.
o Make sure that the lifting beams (lifting angles) are
secured to the drive.
o Use at least four hooks for lifting.
o The lift cables should be at an angle greater than
45° from the horizontal.
o Lift the drive in a slow and steady manner to an
acceptable clearance height.
o Check for any flexing of the equipment. If noticed,
lower drive and re-position cables.
2-1.2. Moving
o If using a crane, be sure that motions are slow and
smooth so that the equipment does not swing.
o If using other moving devices, such as rollers, be
sure to place the rollers in the proper areas to reduce potential stress.
o Make sure that all doors are closed and latched.

Section 2, Handling and Mounting Guidelines • 3

[27.6]
700
CONTROL

AUXILIARY OR
EXCITER (IF REQ.)

[47.25]
1200

SOURCE BRIDGE

[63]
1600

4 • Section 2 , Handling and Mounting Guidelines
LOAD BRIDGE

[63]
1600

FRONT VIEW

18 FT 4.5 IN
5600

1

PUMP

AUXILIARY

[47.25]
1200

Figure 2-1. Sample of Outline Drawing for Typical LCI Lineup
ISSUED

DRAWN BY
MADE BY

[92.3] 2344.5

[8] 152.4

[55.12] 1400

[4]
101.6

CONT ON SHEET 3

GE DRIVE SYSTEMS
SALEM, VA.

RIGHT SIDE VIEW

CONT ON SHEET 3

259B1234

5. ALL DIMENSIONS IN MILLIMETERS
[ ] = DIMENSIONS IN INCHES

SH NO. 2

4. DC LINK REACTOR TO BE MOUNTED REMOTELY.

3. HEAT EXCHANGER TO BE MOUNTED REMOTELY.

2. LIFTING BEAMS ARE REMOVABLE AFTER INSTALLATION

SH NO. 2

259B1234

1. ESTIMATED WEIGHT 10,000 lbs. (4536 Kg.)

LCI

LCI LINEUP

FIRST MADE FOR

TITLE

GENERAL ELECTRIC
COMPANY

GEH-6125A
Innovation Series AC Drives

REVISIONS


Load Commutated Inverter, Installation and Startup for Static Starter Applications

GEH-6125A

2-2. Mounting

2-1.3. Unpacking
o If the equipment has been exposed to low temperatures for an extended period, do not unpack it
until it has reached room temperature (location
where LCI will be mounted)
o Use standard unpacking tools, including a nail
puller.
o When unpacking, check the contents of each case
against the packing list. Report any shortage to GE.
o Carefully remove packaging and move the equipment from its container, still observing all lifting
and handling guidelines.
o While unpacking, inspect for damage that may not
have been detected at time of receipt. !!!!
o Wipe off any particles of packing materials or
foreign substances that may be lodged in or between the parts.
o Small parts (such as bolts and screws) are packed
in special containers to keep them together, but
may become separated. For this reason, carefully
inspect packing material for loose parts before discarding it.

The system outline drawing specifies the LCI dimensions and mounting requirements. This drawing is
specific to each customer’s equipment and configuration. Figure 2-1 is a sample outline drawing for a
typical LCI lineup.
When mounting the LCI, use the system outline
drawing, along with the following general guidelines:
o Position the drive to permit heat radiation from all
surfaces and proper ventilation (cooling air).
o Provide front clearance of at least the width of the
enclosure door so that the door may be fully
opened for easy access.
o After positioning the equipment, lifting beams/
angles may be removed.
o The mounting surface should be level. Imperfections in mounting surfaces (such as high or low
spots in flooring) may cause door misalignment.

If Damage is Found. If equipment damage is discovered while unpacking:

1. Stop unpacking immediately and report this finding
to the carrier (transportation company).
2. Photograph the damage (photographs may be
needed later in processing the claim).
3. File a claim with the carrier.
4. Contact the local service office of GE Industrial
Systems for assistance.

Note
Be sure to include the serial number, part
(model) number, drive code, GE requisition
number, and case number when identifying

missing or damaged parts.

Section 2, Handling and Mounting Guidelines • 5


GEH-6125A

Innovation Series AC Drives

Notes:

6 • Section 2 , Handling and Mounting Guidelines


Load Commutated Inverter, Installation and Startup for Static Starter Applications

3

3-1. Power Requirements

Cabling and
Connections

Section 3 of this manual contains guidelines for connecting cable to the drive during installation. This
information is organized as follows:
Section Heading

GEH-6125A

Page

3-1. Power Requirements ........................................... 7
3-1.1. Control Power .................................................. 7
3-2. Drive Connections .............................................. 7
3-2.1. Line Protection................................................. 7
3-2.2. Terminal Board I/O.......................................... 8
3-3. Cabling Guidelines............................................ 10
3-3.1. Preventing Cable Damage.............................. 10
3-3.2. Installing Power Cable................................... 10
3-3.3. Installing Signal and Communications Cable 11
This information must be used along with the following equipment drawings:
o Elementary diagrams, which show electrical connections and wiring, including terminal board I/O

The LCI’s line supply unit is either a 6-pulse or series
12-pulse thyristor bridge. The LCI is normally configured with the following power requirements:
Supply voltage:

6-pulse converter: 2300, 4160, or 6600 V ac
12-pulse converter: 2080 or 3300 V ac each
bridge
Supply frequency: 50 or 60 Hz
Supply phase: 3-phase
Output voltage: 0 – 2300, 4160, or 6600 V ac

Refer to the drawings supplied with the drive for the
exact power specifications of that particular system.
3-1.1. Control Power
The control receives a 115 V ac input to the control
rack from the secondary winding of the control power
transformer (CPT). All logic power is derived from

this.

o Terminal board and outline diagrams, which show
physical location of the terminal board and other
connection points

3-2. Drive Connections

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, and conduit
sizing.

o Incoming ac line connections L1, L2, and L3
(source ac input)

Do not assume any cable or any
circuitry to be without power if one
end of that cable could be connected
to a power source. To prevent accidental electrical shock, do not touch
any circuitry or bare wire without
first ensuring that it does not carry
electricity.
When testing for the presence of
electricity and when measuring any
electrical circuit, use only the equipment approved for contact with those
voltage levels.

Cabling and wiring connections to the drive include
(refer to the elementary diagram):

o Outgoing ac power connections M1, M2, and M3
to the motor (load ac output)
o Drive interface control connections to terminal
board DS200DDTB (see section 3-2.2)
o Connections to the dc link reactor, mounted remotely from the drive
3-2.1. Line Protection
The LCI includes fused ac filter modules on both the
input and output power lines.

Section 3, Cabling and Connections • 7


GEH-6125A

Innovation Series AC Drives

3-2.2. Terminal Board I/O
Terminal board connections to the LCI are made by
wiring to the DS200DDTB I/O terminal connectors
(see Figure 3-1 for location):

Term.
No.

Signal
Name

XA

CT6+

XB

CT6−

X1

IL1IN+

X2

IL1IN−

3-position terminal strip and clamp
for high voltage inputs two VCOs.
See Tables 3-3 and 3-4.

X3

IL2IN+

X4

IL2IN−

X5

VIN−

6-position, terminal strip and clamp,
20 A form C relay contact terminals
for two relays. See Table 3-5.

X6

VIN+

X7

LEM1+

X8

LEM1−

60-pin ribbon cable connector, interface to DS200ADMA daughterboard.
See Table 3-6.

X9

LEM2+

X10

LEM2−

X11

LEM3+

X12

LEM3−

X13

AOUT1

Analog output 1.

X14

ACOM

Analog common, return for AOUT1.

X15

IL1OUT+

X16

IL1OUT−

4 – 20 mA current loop output,
differential pair.

GRD

GRD

YA

AOUT2

Analog output 2.

YB

ACOM

Analog common, return for AOUT2.

Y1

IL2OUT+

Y2

IL2OUT−

4 –20 mA current loop output,
differential pair.

Y3

AOUT3

Analog output 3.

Y4

ACOM

Analog common for AOUT3.

Y5

AOUT4

Analog output 4.

Y6

ACOM

Analog common for AOUT4.

Y7

GND

Chassis ground (shields).

Y9

DOUT1+

Y10

DOUT1−

Y11

DOUT2+

Optically isolated discrete outputs,
solid-state. Fours differential pairs
rated 48 V maximum, 10 mA each.

Y12

DOUT2−

Y13

DOUT3+

Y14

DOUT3−

Y15

DOUT4+

Y16

DOUT4−

Name

Function

TB1 &
TB2

36-position, double-row terminal strip
(screw terminals) for analog I/O and
shields. See Tables 3-1 and 3-2.

TB3 &
TB4
TB5

TBPL

E1

TB1

Y15 Y13 Y11 Y9
Y7
Y5
Y3
Y1
YA
Y16 Y14 Y12 Y10 Y8
Y6

Y4
Y2 YB

TB1

TB3
TB3

1

TB4
TB4

1

E2

GRD

TBPL

1
2

E6

X15 X13 X11 X9
X7
X5
X3

X1
XA
X16 X14 X12 X10 X8
X6
X4
X2 XYB

TBPL

E3

Y15 Y13 Y11 Y9
Y7
Y5
Y3
Y1
YA
Y16 Y14 Y12 Y10 Y8
Y6
Y4
Y2 YB

TB2

Table 3-1. TB1 Connections, Analog I/O
and Shields

E4

GRD

TB5

TB5

1

X15 X13 X11 X9
X7
X5
X3
X1
XA
X16 X14 X12 X10 X8
X6
X4
X2 XYB

E5

TB2

Figure 3-1. Location of Terminal Connectors on
DDTB Board

8 • Section 3, Cabling and Connections

Signal Description
Current transformer input 6,
differential pair (inputs 1 – 5 on

TB2). High current signal.
4 20 mA current loop inputs,
differential pairs.

Undedicated voltage input,
differential pair.
Active current transformer inputs,
differential pairs. Low current
signals.

Ground.

Y8


Load Commutated Inverter, Installation and Startup for Static Starter Applications

Table 3-2. TB2 Connections, Analog I/O
and Shields
Term.
No.

Signal
Name

XA

K2-CMN

X1

K2-NO

X3

K2-NC

XB

K1-CMN

X2

K1-NO

X4

K1-NC

X5

GND

GEH-6125A

Table 3-3. TB3 Connections, High Voltage Input

Signal Description

Term.

No.

Signal
Name

Signal Description

1

PT1P

Positive input for VCO 0.

2

N/C

Not connected.

3

PT1N

Negative input for VCO 0.

10 A, form C relay contacts, relays
K1 and K2. Common, normally
open, and normally closed connections.

Table 3-4. TB4 Connections, High Voltage Input

Chassis ground (shields).

X6
X7

DIN1+

X8

DIN1−

X9

DIN2+

X10

DIN2−

X11

DIN3+

X12

DIN3−

X13

DIN4+

X14

DIN4−

X15

DIN5+

X16

DIN5−

GRD

GRD

Ground.

YA

DIN6+

YB

DIN6−

Y1

DIN7+

Y2

DIN7−

Optically isolated discrete inputs,
universal. Three differential pairs
rated 24 – 250 V dc or 24 – V ac
at 60 Hz, or 125 – 230 V ac at 50
Hz.

Y3

DIN8+

Y4

DIN8−

Y5

GND

Chassis ground (shields).

Y7

CT1+

Y8

CT1−

Y9

CT2+

Current transformer inputs 1 5,
differential pairs (input 6 on TB-1).
High current signals.

Y10

CT2−

Y11

CT3+

Y12

CT3−

Optically isolated discrete inputs,
universal. Five differential pairs
rated 24 – 250 V dc or 24 – 230 V
ac at 60 Hz, or 125 – 230 V ac at
50 Hz each.

Term.

No.

Signal
Name

Signal Description

1

PT2P

Positive input for VCO 1.

2

N/C

Not connected.

3

PT2N

Negative input for VCO 1.

Table 3-5. TB5 Connections, Relay Outputs
Term.
No.

Signal

Name

1

K6-NO

2

K6-CMN

3

K6-NC

4

K4-NO

5

K4-CMN

6

K4-NC

Signal Description
20 A, form C relay contacts, relays
K4 and K6. Common, normally open,
and normally closed connections.

Y6

Y13

CT4+

Y14

CT4−

Y15

CT5+

Y16

CT5−

Section 3, Cabling and Connections • 9


GEH-6125A

Innovation Series AC Drives

Table 3-6. TBPL Pin Assignments

3-3. Cabling Guidelines

Term. No.

Signal
Name

Signal Description

3-3.1. Preventing Cable Damage

1, 4, 7, 10, 13,
16, 19, 22, 25

DCOM

Power digital common.

To protect the cable and equipment from damage
during installation and afterward:

2

DO1

Discrete logic outputs.

3

DO2

5

DO3

6

DO4

8

DO5

9

DO6

11

DO7

12

DO8

14

DI1

15

DI2

17

DI3

18

DI4

20

DI5

21

DI6

23

DI7

24

DI8

o Be sure to comply with OSHA (Occupational
Safety and Health Administration) and other applicable regulations.
o Observe minimum installation temperature to avoid
damage to shielding and insulation.
o Do not pull cables around corners with sharp edges

or corners that prohibit the minimum allowable cable-pulling radius.

Discrete logic inputs.

o Avoid high mechanical stress (pull tension). The
cable should not be excessively twisted, stretched,
or flexed.
o Before pulling cable, inspect all cable trays. Cable
should only be pulled into clean trays. Install
bushings and dropouts, as necessary.

26

IDDATA

Identification line.

o Make sure that cable ends are sealed before, during,
and after pulling the cable. This prevents the entrance of water or other contaminants.

27

0TBOK

Terminal board connection
okay.

3-3.2. Installing Power Cable

28, 30, 32, 34,

P5
36, 38, 40, 42, 44

Power +5 V dc.

29

AOUT1

Analog outputs.

31

AOUT2

33

AOUT3

35

AOUT4

37

HSAD0

39

HSAD1

41

HSAD2

43

HSAD3

45

HSAD4

47

HSAD5

49

HSAD6

51

HSAD7

53

HSAD8

Sampled analog inputs.

Grounding

o Ground the drive common (CCOM bus bar connector) at only one point. If the reference is supplied by numerical control or by a process
instrument with a grounded common, do not provide a separate ground for the drive common.
o The isolation transformer should not be grounded.
Shielding. GE does not recommend the use of

shielded power cable with the LCI.
If a system configuration requires shielded cable,
select cable with an insulation-level rating of 15 kV,
133% for lengths greater than 50 ft. This should minimize then effect of stray capacitance.

46 & 48

N15

Power -15 V dc.

50 & 52

P15

Power +15 V dc.

54, 56, 58, 60

ACOM

Power analog common.

55

AVCO0

Analog inputs to VCOs.

57

AVCO1

59

AVCO2

10 • Section 3, Cabling and Connections


Load Commutated Inverter, Installation and Startup for Static Starter Applications

3-3.3. Installing Signal and Communications
Cable
o Be sure to strictly follow the cable manufacturer’s installation instructions. These will vary
based on the type of installation required.
o Signal inputs to analog and digital blocks or to
programmable logic control (PLC)-related devices
should be run as shielded twisted-pair (for example,
inputs from RTDs and encoders).

GEH-6125A

o For shielded and twisted shielded wire, ground the
shields on one end only, preferably at the drive end.
Provisions have been made to tie shields to chassis
ground on the DDTB drive terminal board.
o To use the LCI’s Monitor program, connect the
DS200DSPC board’s serial communications port to
the operator terminal. (The DSPC board is located
in the LCI’s control cabinet.)
Cable and connectors are provided with the requisition as a kit, GE part no. IC690ACC901B.

Section 3, Cabling and Connections • 11


GEH-6125A

Innovation Series AC Drives

Notes:

12 • Section 3, Cabling and Connections


Load Commutated Inverter, Installation and Startup for Static Starter Applications

4

Pre-Startup
Installation Checks

Section 4 of this manual contains instructions to verify
that the drive is ready for startup. This includes checks
and procedures to ensure that the drive’s communications, I/O, and power connections are working correctly. This section must be completed before
beginning startup.
Section 4 assumes that the drive and connected devices have already been installed, and that all wiring
and cabling are completed. This section is presented as
follows:
Section Heading

Page

4-1.
4-2.
4-3.
4-4.

Equipment/Material Needed ............................. 13
Connections and Wiring.................................... 13
Power Checks.................................................... 14
Series 90-30 PLC and Field Control I/O
Checks ............................................................... 17
4-5. Local (AFE Datapanel) Display Checks........... 18
With power applied, 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.
To prevent component damage
caused by static electricity, treat all
boards with static-sensitive handling

techniques. Wear a wrist grounding
strap when handling boards or components, but only after boards or
components have been removed from
potentially energized equipment and
are at a normally grounded workstation.

GEH-6125A

4-1. Equipment/Material Needed
The following equipment and materials are needed for
the procedures in Section 4.
Safety Equipment
¨ High voltage detector (using an insulated pole
of appropriate length)
¨ Static-charge wrist-straps
Test/Maintenance Equipment and Tools
¨ Source of dry, low-pressure compressed air (less
than 15 psi) or clean, dry cloth
¨ Heatsink spreader tool (part 246B9953BPG1)
¨ 1000 V meggar
¨ GE Fanuc handheld monitor (such as GeniusTM
model IC660HHM501)
¨ Personal computer (2 MB free on hard drive, 386
or better processor, 2 MB minimum RAM)
Reference Documents
¨ Elementary diagrams, which show electrical connections and wiring
¨ Terminal board and outline drawings, which show
physical location of the terminal board and other
connection points
¨ GEH-6373 (LCI User’s Manual)

4-2. Connections and Wiring
All GE drives are factory-tested and operable when
shipped to the customer’s site. However, connections
can loosen during shipping, handling, and installation.
To verify the integrity of wiring and connections
before applying power, complete the following checks:
1. Using dry, low-pressure compressed air or a clean,
dry cloth, remove any dust that may have accumulated in the drive’s interior. (Dust in loose connections can cause loss of signal integrity.)
2. Inspect all compartments for loose/unattached
hardware and debris. (Such materials could shortout connections.)
3. Check that all devices, modules, and boards are
secure in their mounting and have not been
damaged during handling or installation.

Section 4, Pre-Startup Installation Checks • 13


GEH-6125A

Innovation Series AC Drives

4. Check that incoming wiring/cabling is complete
and agrees with the elementary drawings supplied
with the drive.
5. Check that fiber-optic cable ends have been properly finished (correct length in holder, polished,
and secure), and that the ends are connected to the
correct boards. (See Appendix B for guidelines on
terminating fiber-optic cabling.)
7. Inspect wiring to ensure that it has not been damaged or frayed during installation. Replace if necessary.

8. Check that stab connections and electrical terminal
connections are tight.
As a general practice and unless otherwise directed
in the system documentation, electrical bus connection hardware should be torqued as follows:
SAE Thread

Torque (lbs ft)

1/4-20
3/8-16
1/2-13
5/8-11

4
14
35
70

Metric Size
M6
M4
M8

Torque
5Nm ±15% (44.25 in/lb)
2Nm ±5% (17.7 in/lb)
8 to 10Nm (70.8 to 88.5 in/lb)

Note
To ensure that electrical connections remain

tight, they should be re-checked within three
to six months after initial powerup, and annually thereafter. Use screwdrivers and
torque wrenches or an infrared survey for
these checks.
9. If a current transformer is supplied, make sure that
its secondary circuit is closed. Check that it does
not have a shipping jumper.
10. Operate each magnetic device by hand to make
sure that all moving parts operate freely. Check
all electrical interlocks for proper operation.

14 • Section 4, Pre-Startup Installation Checks

4-3. Power Checks
To prevent electric shock, make sure
that all power to this equipment is off
before performing any adjustments,
servicing, or other act requiring
physical contact with the electrical
components or wiring.
Power checks are performed in three stages, as follows:
Section Heading

Page

4-3.1. Initial Checks and Setup.................................14
4-3.2. Meggar Test....................................................15
4-3.3. Auxiliary Power Checkout .............................15
4-3.1. Initial Checks and Setup
1. Verify that the lineup is grounded per grounding

practices described on drive elementary sheet 0AD.
2. On the bridge, check the SCR stack’s clamp pressure and adjust if necessary (as described GEH6373, Section 8).
3. Open all circuit breakers (refer to drive elementary
sheet BA for the pump panel and sheets CB and CC
for the control panel).
4. In the LCI control cabinet, partially extract all
boards from the control rack so that they are no
longer connected within their slots.
Use static handling techniques, including a grounding strap when
handling boards or components.
5. If this drive uses tach feedback, disconnect the
interface wires at the tach to avoid damage. Interface wires will be terminated after the polarity of
the tach control power is checked. Tach control
power is supplied from the control rack’s backplane board (VPBL).


Load Commutated Inverter, Installation and Startup for Static Starter Applications

4-3.2. Meggar Test
1. Disconnect the ribbon cable at the NATO boards in
the source and load bridges.
2. Remove NATO ground at stab JG.
3. Disconnect the load bridge ac filter neutral ground
at the top of the load bridge compartment.
4. Confirm that both source and load side circuit
interrupters are open.
5. Using temporary jumpers, connect together:
¨

source side buses L1A, L2A, L3A (L1B, L2B,

L3B)

¨

dc buses DCPA, DCNA, (DCPB, DCNB)
DCPL, DCNL

¨

load side buses M1, M2, M3

All buses should now be tied together.

GEH-6125A

4-3.3. Auxiliary Power Checkout
Potentially hazardous voltages are
present in the drive circuits when
power is applied. Use extreme caution
when checking circuitry and voltages.
1. To ensure that power does not exist on the circuits,
verify that all breakers are open (see drive elementary sheets BA and CB).
2. Unplug LEMPS on the FCSA-L board (see Figure
4-1 and drive elementary sheet AF).
3. Remove the three LCI power fuses: FU2S (electronic), FUG (gating), and FUCP (control panel), as
shown on drive elementary sheet CB.
Control Transformer Secondary. Check for correct

voltage, as follows:

6. From any bus, meggar to ground using a 1000 V
meggar. Indicated resistance should be greater than
5 megohms.

1. Close the incoming control power circuit breaker
(typically, CB1).

7. If this drive has a load side interrupter, connect
together (with temporary jumpers) its output terminals and meggar to ground. Indicated resistance
should be greater than 100 megohms.

3. Close circuit breaker CB2.

8. Remove temporary jumpers and reconnect the
ribbon cables and grounds.

2. Verify that voltage at the T1 transformer is between
115 V ac and 130 V ac.
4. Verify that voltage at the T2 transformer is between
115 V ac and 130 V ac.
5. Open CB1 and CB2. Replace fuses FU2S, FUG,
and FUCP.
Electronic Power Supply. Check for correct voltage
for the control electronics, as follows:

1. Close CB2. Then at the control rack (VMEbus
rack), verify the presence of P5, P15, N15 and P24
at the VPBL board (backplane).
2. Open CB2. Then re-insert the boards into the rack.
To prevent equipment damage, do not

remove or insert boards while power
is applied to the equipment.
3. Close CB2. Then verify that P5, P15, N15, and P24
remain constant.

Section 4, Pre-Startup Installation Checks • 15


GEH-6125A

Innovation Series AC Drives

4. With all boards in, if necessary, adjust the power
supply (PS) to obtain the following voltages at the
VPBL board.
¨ Adjust V1 until P5 = +5.0 ±0.1 V

Load Bridge Current Sensor Power Supply. Check

for correct voltage, as follows:
1. At the FCSA-L (load bridge) LEMPS plug (see
Figure 4-1), verify these voltages:

¨ Adjust V2 until P15 = +15 ±0.2 V

¨ P15 at pin 1

¨ Adjust V3 until N15 = -15 ±0.2 V

¨ ACOM at pin 2

¨ Adjust V4 until P24 = +24 ±2.0 V

¨ N15, pin 3
2. Reconnect the LEMPS plug at FCSA-L.

3

1 CSPL

12

LEMPS
1

3

10

LEM1

LEM2

1
TB2

TB4

CT1P

CT2P

TB3

1

TB5
TB1

E1
CT1N

CT2N

GND

Figure 4-1. FCSA Board Layout

16 • Section 4, Pre-Startup Installation Checks

DS200FCSAG1A

E2


Load Commutated Inverter, Installation and Startup for Static Starter Applications

4-4. Series 90™-30 PLC and Field
Control™ I/O Checks

GEH-6125A

2. Download using LM90 software as follows:
a. Select: LogicMaster Programmer Package

Check that these devices are connected correctly, as
follows:

b. Select: F7 (Programmer Mode and Setup)

1. Close CB1 to apply power.

d. Press: Tab until ONLINE is displayed

2. Verify that the PLC is energized by checking the
LEDs on the power supply unit: PWR, OK, and
RUN (green) should be on solid (not blinking).

e. Press: Enter, Esc, Esc

3. Check that the OK LED (green) on each PLC plugin is on.

g. Select: F1 (Select Program Folder)

4. The Field Control I/O has been configured at the
factory. If necessary, use the Hand-held Monitor to
check the configuration of each Field I/O Module
against drive elementary sheet GB.

c. Select: F2 (Set Programmer Mode)

f. Select: F8 (Program Folder Functions)
h. Use arrow keys to highlight the desired folder
and press Enter
i. When prompted Folder found, backup
contents, press Y
j. Press: Esc, Esc

4-4.1. Configuring the PLC

k. Select: F9 (UTILITY:

The Series 90-30 PLC has been configured at the
factory. If necessary, reconfigure and download as
follows:

l. Select: F2 (Store from programmer to PLC)

1. Set the PLC ID using LogicMaster™ 90 (LM90)
software as follows:
a. Select: LogicMaster Configuration Package

Load\Store\Etc.)

m. Onscreen, select:
Y

PROGRAMMING LOGIC
CONFIGURATION
REFERENCE TABLES

Y
N

b. Select: F7 (Programmer Mode and Setup)

n. Press Enter to start download.

c. Select: F2 (Set Programmer Mode)

o. Press Y to continue to download if any prompts
appear, such as Overwrite existing program or PLC Name does not match programmer.

d. Press: Tab until ONLINE is displayed
e. Press: Enter, Esc, Esc
f. Select: F2 (CPU Configuration)
g. Select: F3 (Assign PLC ID)
h. Type: LCI Enter

p. When STORE COMPLETE appears at the
screen’s upper left, the download is complete.
Press Esc to exit.

Section 4, Pre-Startup Installation Checks • 17