GEI-100029C (Supersedes GEI-100029B) DRIVE CONTROL CARD DS215SDCCG_A_ _ 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 Motors & Industrial Systems. 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 Motors & Industrial Systems. CONTENTS Safety Symbol Legend .................................................... 1 Functional Description ................................................... 1 Application Data ............................................................. 3 Testpoints...................................................................... 3 Configurable Hardware................................................. 3 Software Configuration Tools....................................... 4 I/O Tables ..................................................................... 5 Renewal/Warranty Replacement ................................ 15 Board Identification .................................................... 15 Warranty Terms .......................................................... 15 Warranty Parts And Service........................................ 15 Procedure For Replacing Boards ................................ 15 Hardware Adjustments ................................................ 17 Replacing/Inserting Software ...................................... 17 FUNCTIONAL DESCRIPTION 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 This instruction book addresses only drive applications of the DS215SDCCG_A_ _ card (SDCC). The SDCC contains the primary control circuitry and software for a SAFETY SYMBOL LEGEND drive or exciter. The SDCC consists of three 16-bit microprocessors and associated circuits coupled via dual- WARNING Indicates a procedure, practice, condition, or statement that, if not strictly observed, could result in personal injury or death. ported 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 CAUTION Indicates a procedure, practice, condition, or statement that, if not strictly observed, could result in damage to or destruction of equipment with other boards to form various types of ac and dc motor drives. The interface circuitry controls and processes drive and motor 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: NOTE Indicates an essential or important procedure, practice, condition, or statement. • Drive Control Processor (DCP). An 80C186 microcontroller (U1) with numerous built-in peripheral functions and uses both digital and analog I/O. GEI-100029C SDCC Drive Control Card These functions include address decoding for chip CARD CONNECTIONS 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 The SDCC interfaces with the other boards of the controller and external signals via eight connectors (designated _PL). 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: • 1PL − I/O between the Power Supply/Interface Board (DS200IMCP, DCI, SDCI, or DCFB) and the SDCC • 2PL − ±5, 15, and 24 V dc inputs from the Power Supply/Interface Board to the SDCC • 3PL − SDCC outputs to the LAN Communications Card (DS215SLCC) • 6PL − I/O between the Drive Terminal Board (531X305NTB) or Simple Drive Terminal Board (DS200STBA) and the SDCC • 7PL − I/O between the Signal Processor Card (531X309SPC) or Multibridge Signal Processing Card (DS200SPCB) and the SDCC (not present on SDCCG3s) • 8PL − I/O between the Drive Terminal Board (531X305NTB) or Simple Drive Terminal Board (DS200STBA) and the SDCC • 9PL − Not Used (not present on SDCCG3s) • 11PL − SDCC outputs to meters (not present on SDCCG3s) watchdog timer. MCP software consists of inner loops such as current regulators, and motor/technology 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. 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 in cluded. The SDCC has mounting provisions for other auxiliary boards and modules. The following boards can be mounted on the SDCC: • DS215SLCC or 531X306LCC LAN Communications Card CARD GROUPS • 531X309SPC Signal Processor Card There are currently three group numbers of the SDCC available (G2 versions were never manufactured). The variations between the groups are as follows: • DS200SPCB Multibridge Signal Processor Card • DS200SDCCG1A_ _: Used in AC2000, DC2000, and EX2000 drive applications LED DISPLAY • DS200SDCCG3A_ _: Variation of SDCC that has reduced functionality (used in DC1000 drives) • DS200SDCCG4A_ _: Used in TC2000 turbine applications (same as G1A except with enlarged EE parameter storage area and different firmware) 2 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: SDCC Drive Control Card • GEI-100029C Faults 1 to 399 − slow blink rate − BCD pattern (left-most two LEDs encode the hundreds digit; next four, the tens digit; rightmost, the units digit; see Figure 1) Diagnostic LEDs • hundreds tens units digit digit digit Faults 400 to 1023 − faster blink rate − binary pattern (left-most LED is 29 [or 512], second-most LED is 28 [or 256], and so on; see Figure 2) No fault or drive 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 drive variables when running. (For example, displayed in an absolute or signed bar graph mode). Setting software jumpers this way does not inhibit the LED fault display. Diagnostic LEDs 2 The system trips when a hard reset is initiated; the system should not normally be reset when running. A reset can be generated in four ways: Figure 1. BCD-coded LED Display • CAUTION 8 (or 256) 9 (or 512) 2 Figure 2. Binary-coded LED Display RESET CIRCUITS The SDCC provides four reset circuits, including a RESET pushbutton. • By pressing the RESET pushbutton on the SDCC (See Figure 3 for location.) • 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 defines 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 WJ nomenclature (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. Figure 3 is a layout diagram of the SDCC, showing the locations of all jumpers. 3 GEI-100029C SDCC Drive Control Card SOFTWARE CONFIGURATION TOOLS Any adjustment, downloading, or replacement of software on the SDCC requires the use of the ST2000, GE Control System Toolbox, or LynxOS Drive Configurator. The applicable drive/exciter instruction book, an appropriate PC, and the ST2000, GE Control System Toolbox, or LynxOS Drive Configurator instruction book are also required for any software adjustments. • ST2000 is a DOS based set of software tools for configuring GE DIRECTO-MATIC 2000 control 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-MATIC 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 on these tools. 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. Figure 1. SDCC Layout Diagram 4 SDCC Drive Control Card GEI-100029C I/O TABLES • Tables 3 − 9 list the I/O pin signals of the different connectors on the SDCC. The tables are organized as follows: Table 6 − 6PL, I/O between NTB/3TB or STBA board and the SDCC • Table 7 − 7PL, I/O between the SPC or SPCB board and the SDCC (not present on SDCCG3s) • Table 3 − 1PL, I/O between the IMCP, DCI, SDCI, or DCFB board and SDCC • • Table 4 − 2PL, Power inputs from the IMCP board to the SDCC Table 8 − 8PL, I/O between the NTB/3TB or STBA board and the SDCC • • Table 5 − 3PL, SDCC outputs to the SLCC Table 9 − 11PL, SDCC outputs to meters (not present on SDCCG3s) Table 1. SDCC Testpoints Name Description DCOM1 0 volt common reference point for test signals, same as DCOM2 DCOM2 0 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 FCLK “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 CDR* 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 CLKC* TMS320 clock oscillator input CP5* +5 V power supply to TMS320 diagnostic D-A daughter board CCM* Common power supply return for TMS320 diagnostic D-A daughter board TP29 Testpoint for input line frequency TP37 Testpoint for dc voltage; Not used on ac drives *The row of testpoints in the upper left corner of the SDCC (CDR, CDX, CLX, CLR, FSX, FSR, CLKC, CP5, and CCM) is reserved for diagnostic purposes for the TMS320C25 processor, via a daughter board which allows serial diagnostic D-A converters to be added for development/test purposes only. 5 GEI-100029C SDCC Drive Control Card Table 2. SDCC Jumpers and Wire Jumpers Revision Name 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 voltage available on the Simple Drive Terminal Board (STBA), the 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 0–ACZ JP15 Enable for DCP crystal 1.2 Enabled (required for normal operation) 0 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 Enabled (required for normal operation) 0 Manufacturing test only 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) 0–ACZ JP33 Enable for CMP crystal 1.2 Enabled (required for normal operation) 0 Manufacturing test only ADB–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 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. 0 SDCCG1, jumper omitted 1.2 SDCCG3, jumper installed ADB–Pres WJ2 Remap MET4 D/A to DAC2 output for SDCCG3 0 SDCCG1, jumper omitted 1.2 SDCCG3, jumper installed ADB–Pres WJ3 Provide 10-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. 0 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 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 inability of processor to powerup and configure card logic cell arrays, and possible loss of EEPROM drive configuration memory. 0 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. 0 Jumper omitted on SDCC G3 (LCA is 3042 device) 1.2 Jumper installed on SDCC G1 (LCA is 3064 device) 6 Description SDCC Drive Control Card GEI-100029C Table 2. SDCC Jumpers and Wire Jumpers — Continued Revision Name Description ADB–Pres WJ7 Configure card for EEPROM size In all present drive applications, WJ7 and WJ9 must be omitted and WJ8 and WJ10 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. 0 SDCC G1 and G3, jumper omitted 1.2 Reserved for future expansion ADB–Pres WJ8 Configure card for EEPROM size 0 Reserved for future expansion, jumper omitted 1.2 Jumper installed on SDCCG1 and SDCCG3 ADB–Pres WJ9 Configure card for EEPROM size 0 Jumper omitted on SDCCG1 and SDCCG3 1.2 Reserved for future expansion ADB–Pres WJ10 Configure card for EEPROM size 0 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 1 DPSEN Driver power state 2 DBDUTY DB IGBT ON signal 3 PHLOSS Ac line phase loss signal 4 VTHRM Variable voltage output of IIBD temperature sensor circuit 5 VMAG Ac line-to-line peak for magnitude detection 6 VSEQ Ac line voltage for phase sequence detection 7 ---- Not connected 8 /IA Buffered phase A VCO current feedback from IIBD board 9 /IB Buffered phase B VCO current feedback from IIBD board 10 /IC Buffered phase C VCO current feedback from IIBD board 11 V(B-A) Phase (B-A) VCO voltage feedback 12 V(C-A) Phase (C-A) VCO voltage feedback 13 VDC Dc link voltage feedback VCO output 14 SYOSC Burst oscillator 15 ---- Not connected 16 U/DA Up/down command phase A 17 U/DB Up/down command phase B 18 U/DC Up/down command phase C 19 DBTST DB turn-on signal 7 GEI-100029C SDCC Drive Control Card Table 3. Connector 1PL (AC2000 Drives Only) Continued, I/O Between SDCC and Power Supply Board Pin No. 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 24 SS1 Soft-start SCR gate enable 25 SS2 Same as SS1 (pin 24) 26 SS3 Same as SS1 (pine 24) 27 /FLTRST Fault reset 28 FAULT2 Inverter gate drive fault signal 29 LINESYNC Ac line synchronizing signal 30 FAULT1 DB overvoltage trip signal 31 /RST1 System reset 32, 33 ------ Not connected 34 MAC MA contactor control from SDCC card ---- Not connected DTYPE Drive type identifier (3.3 - 3.8 V dc for an AC2000 IGBT drive) ------ Not connected 35 - 37 38 39, 40 Table 4. Connector 2PL (AC2000 Drives Only), Power Inputs From Power Supply Board Pin No. 8 Nomenclature Description 1 /PSEN Power supply enable 2 N15 Negative 15 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards 3 P15 Positive 15 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards 4 DCOM ±15 V dc common to the SDCC, SLCC, and NTB/3TB or STBA boards 5 P5 Positive 5 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards 6 P5 Positive 5 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards 7 DCOM Positive 5 V dc common to the SDCC, SLCC, and NTB/3TB or STBA boards 8 N24 Negative 24 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards 9 P24 Positive 24 V dc to the SDCC, SLCC, and NTB/3TB or STBA boards SDCC Drive Control Card GEI-100029C Table 5. Connector 3PL, SDCC Output To SLCC Pin No. Nomenclature Description BD0 - BD7 Buffered, demultiplexed SDCC Drive Control Processor (DCP) data bus lines 0 - 7 DCOM Power supply return (common) 10 P5 Positive 5 V dc regulated power supply for digital circuitry 11 /RST3 System reset signal (active low) 12 LINT Interrupt from SLCC/SDCC microapplication chip to DCP 13 /LBSY Busy bus control handshake to DCP 14 BA12 Buffered address latch enable from DCP 15 DCOM Power supply return (common) 16 /BCSL SLCC chip select 17 /BRD Buffered read control line from DCP 18 /BWR Buffered write control line from DCP 19 BA8 Buffered, demultiplexed DCP address line 8 20 BA9 Buffered, demultiplexed DCP address line 9 21 /BCSU SDCC microapplication chip select 22 BA10 Buffered, demultiplexed DCP address line 10 23 BA11 Buffered, demultiplexed DCP address line 11 24 DCOM Power supply return (common) 25 DCOM Power supply return (common) 26 P5 Positive 5 V dc regulated power supply for digital circuitry BA0 - BA7 Buffered, demultiplexed DCP address lines 0 through 7 1-8 9 27 - 34 9 GEI-100029C SDCC Drive Control Card Table 6. Connector 6PL, I/O Between SDCC and NTB/3TB or STBA Boards Pin No. 10 NTB/3TB Terminal STBA Terminal Nomenclature Description 1 42 ------ 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. 2 44 ------ CTLN2 See CTLN1 3 -- ------ LBIAS ±24 V dc bias for digital inputs from NTB/3TB (for +/- logic) 4 61 ------ T0OUT TTL output through 200 W from timer/counter 0 of SDCC's Drive Control Processor. 5 34 ------ RUN General-purpose digital input defaulted to, but not limited to, RUN function 6 36 ------ JOG General-purpose digital input defaulted to JOG function 7 38 ------ POL General-purpose digital input defaulted to the reference polarity function 8 40 ------ XSTP General-purpose digital input defaulted to the XSTOP function (normally closed) 9 47 ------ MSRF Relay #6 coil driver (Master Sync Reference output), open collector driver output 10 - 14 ------ ------ RO1 - RO5 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 51 ------ ASP0 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 20, 21 ------ ------ P1B, P2B Scalable general-purpose analog inputs from NTB/3TB 22 ------ ------ ------ Not connected 23 49 ------ DVM Medium resolution analog input channel with fixed scaling for ± 51.0 V dc maximum 24 53 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) 25 55 35 DA2 See DA1 (pin 24) SDCC Drive Control Card GEI-100029C Table 6. Connector 6PL Continued, I/O Between SDCC and NTB/3TB or STBA Boards Pin No. NTB/3TB Terminal STBA Terminal Nomenclature Description 26 54 36 MET1 Output from 8-bit 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 what value corresponds to 10 V dc output. (Provided for meter driver functions) 27 56 37 MET2 See MET1 (pin 26) 28 57 ------ MSSY Input to internal interrupt (INT0) 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 59 ------ T0IN 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 58 38 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 ------ ------ CTSB RS-232C channel clear-to-send handshake 34 ------ ------ RTSB RS-232C channel clear-to-receive handshake 35 ------ ------ 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 11 GEI-100029C SDCC Drive Control Card Table 7. Connector 7PL, I/O Between SDCC and SPC or SPCB Board Pin No. 12 Nomenclature Description 1 SPA1 ±5 V dc SPC/SPCB analog channel #1 2 SPA2 ±5 V dc SPC/SPCB analog channel #2 3 E1Z Marker channel from encoder #1 interface 4 E2Z Marker channel from encoder #2 interface 5 N15 Negative 15 V dc power supply for analog circuitry on SPC/SPCB 6 P15 Positive 15 V dc power supply for analog circuitry on SPC/SPCB 7 DCOM Power supply return (common) 8 SPRS Digital output from DCP to SPC/SPCB 9 DCOM Power supply return (common) 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 0RST7 System reset (active low). Not connected on SPCB card 16 DCOM Power supply return (common) 17 SPSYN Not connected on SPC card. Sync pulse listener input to SDCC for SPCB 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 SDCC Drive Control Card GEI-100029C Table 8. Connector 8PL, I/O Between SDCC and NTB/3TB or STBA Boards Pin No. NTB/3TB Terminal STBA Terminal Nomenclature Description 1 6 ------ FA Non-inverting RS-422 half-duplex serial data line from the SDCC's Motor Control Processor (MCP) UART 2 8 ------ FB Inverting RS-422 half-duplex serial data line from MCP UART 3 10 7 DCOM Signal return for EXSY (at COM potential) 4 12 ------ EXSY External sync input to MCP 5 ------ ------ ------ Not connected 6 1 1 E0AB Encoder interface Channel A non-inverted differential input 7 3 3 /E0AB Encoder interface Channel A inverted differential input. (Tie to COM for single-ended encoders) 8 5 5 E0BB Encoder interface Channel B non-inverted differential input 9 7 6 /E0BB Encoder interface Channel B inverted differential input. (Tie to COM for single-ended encoders) 10 9 ------ E0MB Encoder interface marker pulse channel non-inverted differential input 11 11 ------ /E0MB Encoder interface marker pulse channel inverted differential input. (Tie to COM for single-ended encoders) 12 ------ ------ ------ Not connected 13 14 9 CI1 CI1 − CI8 are general-purpose control inputs, ± 24 V dc maximum with 27 kW input impedance 14 16 11 CI2 See CI1 (pin 13) 15 18 13 CI3 See CI1 (pin 13) 16 20 15 CI4 See CI1 (pin 13) 17 22 17 CI5 See CI1 (pin 13) 18 24 19 CI6 See CI1 (pin 13) 19 26 21 CI7 See CI1 (pin 13) 20 28 50 CI8 See CI1 (pin 13) 13 GEI-100029C SDCC Drive Control Card Table 9. Connector 11PL, SDCC Output to Meters Pin No. Nomenclature Description ------ Not connected 3 DCOM Drive common connection 4 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 mA load (200 W series impedance). Any drive 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. 5 MTR2 See MTR1 6 MTR3 See MTR1 7 MTR4 See MTR1 8 DCOM Drive common connection ------ Not connected 1, 2 9, 10 DS 215 SDCC G# A A A 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, DS Series 14 SDCC Drive Control Card RENEWAL/WARRANTY REPLACEMENT BOARD IDENTIFICATION A printed wiring board is identified by an alphanumeric part (catalog) number stamped on its edge. For example, the Drive Control Card, with onboard software, is identified by part number DS215SDCCG#ruu. (See Figure 4 for part number breakdown.) GEI-100029C WARRANTY PARTS AND SERVICE 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. Please have the following information ready to exactly identify the part and application: NOTE • GE requisition or shop order number All digits are important when ordering or replacing any board. • Equipment serial number and model number • Board number and description 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. PROCEDURE FOR REPLACING BOARDS WARNING When ordering replacement boards, note that the DS200SDCC card does not include the five memory chips mentioned above (the sockets are empty). To prevent electric shock, turn off power to the drive, then test to verify that no power exists in the board before touching it or any connected circuits. NOTE The SDCC may also be used to replace a 531X301DCC Drive Control Card (DCC). These instructions include information for replacing a DCC with an SDCC, including procedures for transferring software configuration parameters from the old DCC to the new SDCC, and setting software parameters (jumpers) on the SDCC for configuration functions performed via hardware jumpers on the DCC. When replacing a DCC, specify a DS215SDCC as a replacement to ensure that the five memory chips are included. CAUTION To prevent equipment damage, do not remove boards or connections, or re-insert them, while power is applied to the drive. Treat all boards as static-sensitive. Use a 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: 1. Turn off the power to the drive, then wait several minutes for all the capacitors to discharge. Test any electrical circuits before touching them to ensure the 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 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. 15 GEH-100029C 3. SDCC Drive Control Card If a programmer module is included, remove the programmer by pulling the snaps (holders, located in each corner) 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.) 7. NOTE It may be necessary to remove auxiliary boards mounted on the DCC or SDCC as described in step 5 before disconnecting 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: − 5. 8. Verify cables are labeled with the correct connector name (as marked on the card) to simplify reconnection. − For ribbon cables, grasp each side of the cable connector that mates with the board connector and gently pull the cable connector loose. − For cables with pull tabs, carefully pull the tab. CAUTION Always use the nylon washers when inserting screws into the card to avoid damage to the card. 16 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. Place standoffs into position on the front side of the new SDCC and tighten the screws with nylon washers to secure the standoffs. Set all configurable items on the replacement (new) SDCC in the exact position as those on the card being replaced. NOTE Because of upgrades, boards of different revision levels may not contain identical hardware. However, GE Drive Systems assures compatibility of its replacement boards. 9. Release the DCC or SDCC from the board rack by pushing back on the plastic snaps (holders), then remove the DCC or SDCC. 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. 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. CAUTION 6. a. NOTE 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. Avoid dropping mounting hardware into the unit, which could cause damage. Move all standoffs from the card being replaced to the replacement (new) SDCC as follows: 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. 11. 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. 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. SDCC Drive Control Card NOTE After replacing the SDCC in an application with critical analog I/O functions, the gains and offsets may require fine-tuning to compensate for variations in component tolerances between the old card and the new. GEI-100029C 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. HARDWARE ADJUSTMENTS Most of the jumper selections have been factory set. The test data sheets supplied with each controller (in the drive door pocket) indicate these positions. Table 2 lists and defines the jumpers. 1. In most applications, all WJ jumpers are factory set to the correct position, and all JP jumpers except JP1 should be in position 1-2 (JP1 should be in position 2-3). 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 2, which lists the default setting first. Figure 3 shows jumper locations. 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 configuration functions on the DCC using hardware jumpers are implemented on the SDCC via software jumpers (parameters stored in EEPROM). If replacing a DCC with an SDCC, refer to the following section, Replacing/Inserting Software, for information on setting software jumpers on the SDCC to match hardware jumper settings of the old DCC. (Also see Table 10.) REPLACING/INSERTING SOFTWARE The SDCC uses a different EEPROM chip than that used on the DCC, and some of the hardware jumpers on the DCC are implemented as software jumpers on the SDCC. Therefore, the procedures for replacing/inserting software differ, depending upon whether a DCC or SDCC is being replaced. The following paragraphs describe the procedures for replacing an SDCC, and for replacing a DCC with an SDCC. Remove one of the four EPROM chips (U11, U12, U22, or U23) from the old card and insert it into the respective socket on the new SDCC. 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 ST1000 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 GEH-100029C SDCC Drive Control Card 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 ST2000 (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 ST2000, GE Control System Toolbox, or LynxOS Drive Configurator is not available, read the configuration from the DCC EEPROM into a file as described in 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 downloading 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. 18 1. With the original EEPROM installed, upload its configuration to a file by issuing the following serial command to the drive: ^x0-4095<Enter> 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. Install the new EEPROM in the SDCC and download the configuration file to the drive. Table 10 lists and defines 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. SDCC Drive Control Card GEI-100029C NOTE The following table defines the hardware jumpers on the DCC Drive Control Card that have been implemented as software parameters on the SDCC Drive Control Card. When replacing a DCC with an SDCC, if a DCC hardware jumper listed has been moved from the default position (listed first in the following table), the corresponding software parameter for the SDCC 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. DCC Hardware Jumpers Implemented as SDCC Software Jumpers DCC Hardware Jumper Name Description JP19 Source of DCP encoder #1 up/down signals 1.2 From NTB/3TB E0A 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 of encoder #1 up/down signals 1.2 From NTB/3TB E0B 2.3 From the SPC encoder #1 EE.7.0 FBKJPR See description above. JP21 Source of encoder #1 marker signal 1.2 From NTB/3TB E0M 2.3 From the SPC encoder #1 EE.7.0 FBKJPR See description above. JP31 Destination 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 K/L 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 NTB/3TB encoder #0 marker input into the encoder processing 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. 19 GEH-100029C SDCC Drive Control Card Table 10. DCC Hardware Jumpers Implemented as SDCC Software Jumpers Continued DCC Hardware Jumper Name Description JP34 Source of signal into DCP's external timer/ counter input 1.2 From NTB/3TB T0IN 2.3 From signal selected by JP23 2.4 Pulled high, NTB/3TB T0OUT timed output mode usage Corresponding SDCC Software Jumper Name EE9.0 CFG2JP Description Hardware configuration jumper: Source for DCP timer/ counter #0 0.000 Enable T0IN 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. Issue Date: Rev. C, April 1997 © 1997 by General Electric Company, USA. All rights reserved.