GE AF-650 GP Series Operating Instructions Manual Download Page 125

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9.2.4 Soft Charge Card

Remove power card mounting plate in accordance with instructions.

From soft charge card, disconnect connectors MK1, MK2, Mk3, and MK4.

Remove soft charge card from mounting plate by removing four screws (T25) fastening card to mounting plate. Note insulation sheet below soft charge
card. Remove and keep the insulation sheet for reinstallation.

Reinstall in reverse order of this procedure. Tighten mounting screws to 2.3 Nm (20 in-lbs).

Soft charge card

Attaching screw (step 3)

High Power Service Manual for Unit Sizes 6x

124

Summary of Contents for AF-650 GP Series

Page 1: ...GE AF 650 GP AF 600 FPTM High Power Service Manual Unit Sizes 6x Operating Instructions AF 650 GP AF 600 FP TM High Power Service Manual Unit Sizes 6x DET 712...

Page 2: ...ogramming Through the Keypad 15 Keypad 15 Display Area 16 Menu Keys 16 Navigation Keys 17 Controller Operation Keys 17 Tips and Tricks 18 Status Messages 20 Service Functions 24 Frequency Converter In...

Page 3: ...er Repair Tests 60 5 Frequency Converter and Motor Applications 61 Torque Limit Current Limit and Unstable Motor Operation 61 Overvoltage Trips 62 Mains Phase Loss Trips 62 Control Logic Problems 63 P...

Page 4: ...Sensor Test 89 Testing Current Feedback with the Signal Test Board 90 Input Terminal Signal Test 91 Module level Static Test Procedures 93 Inverter Module 93 Rectifier Module 93 After Repair Drive Te...

Page 5: ...Optional 117 IGBT Module 118 9 Disassembly Assembly Rectifier Module 121 For Your Safety 121 GE Training Required 121 Rectifier Module 121 Internal Access 121 Power Card 122 Power Card Mounting Plate...

Page 6: ...capable of operating a great variety of applications and incorporate a wide range of control and communication options These models are available in NEMA 1 IP21 or NEMA 12 IP54 enclosures 1 3 For Your...

Page 7: ...480 VAC AF 650 GP 380 480 VAC Power kW 400 VAC HP 460 VAC Unit Size 450 500 600 650 61 63 500 560 650 750 61 63 560 630 750 900 62 64 630 710 900 1000 62 64 710 800 1000 1200 62 64 800 1000 1200 1350...

Page 8: ...37 924 1100 Nominal kVA 500 V 632 675 771 909 1005 1195 Typical shaft output kW 400 V 450 500 560 630 710 800 HP 460 V 600 650 750 900 1000 1200 kW 500 V 530 560 630 710 800 1000 400V Power loss Light...

Page 9: ...1 1056 1255 Nominal kVA 690 V 753 872 1016 1129 1267 1506 Typical shaft output kW 550 V 500 560 670 750 850 1000 HP 575 V 650 750 950 1050 1150 1350 kW 690 V 630 710 800 900 1000 1200 600V Power loss...

Page 10: ...Ratchet Hex wrench set Screwdrivers Standard and Philips Additional Tools Recommended for Testing Digital volt ohmmeter must be rated for 1200 VDC for 690 V units Analog voltmeter Oscilloscope Clamp...

Page 11: ...e similar 1 DC link inductor 9 Module heatsink fan 2 Fan transformer 10 Fan door cover 3 DC bus bar 11 Optional brake output bus bar 4 DC bus bar 12 Motor output bus bar 5 Mounting bracket 13 SMPS fus...

Page 12: ...plate 7 High frequency board 2 Inverter power card 8 IGBT module 3 Panel connectors 9 Current sensor 4 SMPS fuse and fan fuse 10 Fan assembly 5 Upper capacitor bank assembly 11 Lower capacitor bank a...

Page 13: ...d on vertical strut 2 DC bus bar 8 Module heatsink fan 3 SMPS fuse 9 Fan door cover 4 Optional back AC fuse mounting bracket T 10 SMPS fuse 5 Optional middle AC fuse mounting bracket S 11 Power card 6...

Page 14: ...over plate 7 Soft charge cards 2 Power card 8 Soft charge card mounting plate 3 Panel connectors 9 SCR module 4 SMPS fuse 10 Fan assembly 5 Power card mounting plate flange 11 Diode module 6 Power car...

Page 15: ...4 5 130BX334 11 Option cabinet exploded view 1 Contactor 4 Circuit breaker or disconnect 2 RFI filter 5 AC mains line fuses 3 Mains AC power input terminals High Power Service Manual for Unit Sizes 6x...

Page 16: ...faults outside of the frequencyconverter Thisservicemanualprovidestechniquesandtestprocedurestohelpisolateafaultconditionwhetherinthefrequencyconverterorelsewhere Familiarity with the information prov...

Page 17: ...de and status messages appear on this line Illustration 2 2 Keypad Display Area 2 2 4 Menu Keys Menu keys are used for parameter set up toggling through status display modes during normal operation an...

Page 18: ...hoice LED indicator lights The green ON LED is activated and display panel lit when the frequency converter receives power from mains voltage a DC bus terminal or an external 24 V supply When a pendin...

Page 19: ...n cleared For an alarm trip power must be recycled to the controller before pressing the reset key The key can be Enabled 1 or Disabled 0 in par K 43 Reset Button on Keypad 2 2 7 Tips and Tricks For t...

Page 20: ...31 Address Par O 32 Drive Port Baud Rate Par O 35 Minimum Response Delay Par O 36 Max Response Delay Par O 37 Maximum Inter Char Delay Par ID 00 Operating Hours to par ID 05 Over Volt s Par ID 20 Hist...

Page 21: ...al preset references Local The reference is given via the Keypad Operation Status AC Brake AC Brake was selected in par B 10 Brake Function The motor is slowed down via the active down ramp and feeds...

Page 22: ...is selected as a function for a digital input parameter group E The corresponding terminal is not active 3 The DC Brake is activated via serial communication DC Voltage U0 In par H 41 Motor Control Pr...

Page 23: ...he mains supply to the frequency converter is cut off but the control card is still supplied with 24 V Pre magnetize Pre magnetization is selected in par H 80 Function at Stop A stop command e g Stop...

Page 24: ...time has expired Start fwd rev Enable start forward and Enable start reverse were selected as functions for two different digital inputs parameter group E To start the motor a direction dependent sta...

Page 25: ...y converter nameplate data The service information is ac cessed by displaying items in the frequency converter s ID parameter group Parameter settings are displayed by pressing the Main Menu key on th...

Page 26: ...us A serial communication protocol supplies commands and references to the frequency converter can program the frequency converter and reads status data from the frequency converter The serial bus con...

Page 27: ...The RS 485 serial communication connector is wired to terminals 68 and 69 Terminal 61 is common and may be used for terminating screens only when the control cable run between frequency converters not...

Page 28: ...details on changing parameters and the functions available for each control terminal In addition the input terminal must be receiving a signal Confirm that the control and power sources are wired to...

Page 29: ...alog and digital outputs for indicating values such as frequency reference current and torque The analog signal is 0 4 to 20 mA at a maximum of 500 The digital signal is 24 VDC at a minimum of 500 50...

Page 30: ...ectricalnoisemayoccurthatcandisturbtheentiresystem Thiscanberesolved by fitting an equalizing cable next to the control cable Minimum cable cross section is 8 AWG 50 60 Hz earth loops When using very...

Page 31: ...High Power Service Manual for Unit Sizes 6x 30 3...

Page 32: ...ontrols the motor speed or maintains a constant speed as the load on the motor changes The frequency converter can also stop and start a motor without the mechanical stress associated with a line star...

Page 33: ...ce between the frequency converter s internal digital logic and the operator All the frequency converter s programmable parameter settings can be uploaded into the EEPROM of the Keypad This function i...

Page 34: ...r card provides conditioning of these signals Scaling of current feedback and voltage feedback is accomplished by the control card The power card contains a switch mode power supply SMPS which provide...

Page 35: ...e DC bus and the other in the negative The coil reduces mains harmonics The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing circuitry Each inverter module contain...

Page 36: ...ventually adding enough resistance to the circuit to prevent significant current flow This protects the soft charge resistor from damage along with any other components that could be damaged by contin...

Page 37: ...L4 R1 SW1 RFI CARD BRAKE OPTION UDC UDC MK1 BRAKE GATE RES CARD GATE EM COL BRAKE IGBT EXT BRAKE R 82 81 R RESISTOR IGBT4 DC PCA9 62 DOOR FAN 1 1 3 2 3 2 CN4 GND FAN FAN 1 1 2 3 2 3 CN2 FU4 COM FAN T...

Page 38: ...section is the high frequency HF filter card for each inverter module It contains a high frequency filter circuit to reduce naturally occurring currents in the HF range to prevent interference with ot...

Page 39: ...Illustration 3 5 Intermediate and inverter sections High Power Service Manual for Unit Sizes 6x 38 3...

Page 40: ...o see in an AC system The frequency of the waveform is then determined by the rate at which the pulses occur By employing a sophisticated control scheme the frequency converter is capable of deliverin...

Page 41: ...Illustration 3 7 Inverter section High Power Service Manual for Unit Sizes 6x 40 3...

Page 42: ...rhauling load causing regenerative energy to be returned to the DC bus This occurs for example when the load drives the motor causing the voltage to return to the DC bus circuit Placing the brake resi...

Page 43: ...Illustration 3 8 Brake option High Power Service Manual for Unit Sizes 6x 42 3...

Page 44: ...of 10 minutes 3 3 6 Fan Speed Control The cooling fans are controlled with sensor feedback which regulates fan operation and speed control as described below IGBT thermal sensor measured temperature...

Page 45: ...n of an external temperature switch The input could be used to monitor the temperature of an external brake resistor Two input configurations are possible A normally closed switch may be connected bet...

Page 46: ...nstruction and service manuals A thorough understanding of the unit is the best approach If ever in doubt consult the factory or authorized repair centre for assistance 4 2 Exterior Fault Troubleshoot...

Page 47: ...or damaged power components or carbon deposits resulting from catastrophic component failure Check for cracks or breaks in the housings of power semiconductors or pieces of broken component housings...

Page 48: ...trol wiring or a fault within the frequency converter itself The first step is to rule out a problem in the control wiring To do this disconnect all control wiring by unplugging the control terminal b...

Page 49: ...but the reference speed command is zero or missing Check the control wiring to ensure that the proper reference signal is present at the frequency converter input terminals and that the unit is prope...

Page 50: ...ameters including all motor compensation settings Slip Compensation Load Compensation etc For Closed Loop operation check PID settings Motor runs rough Possible over magnetization incorrect motor sett...

Page 51: ...reason may be that its cause has not been rectified or the alarm is trip locked see also table on following page Alarms that are trip locked offer additional protection since the mains supply must be...

Page 52: ...phase V missing X X X H 78 32 Motor phase W missing X X X H 78 33 Inrush fault X X 34 Network communication fault X X 36 Mains failure X X 37 Phase imbalance X 38 Internal fault X X 39 Heatsink sensor...

Page 53: ...rupt X 82 CSIV parameter error X 90 Feedback Monitor X X EC 61 91 Analog input 54 wrong settings X 92 No Flow X X AP 2 93 Dry Pump X X AP 2 94 End of Curve X X AP 5 95 Broken Belt X X AP 6 96 Start De...

Page 54: ...000 16384 Mains ph Loss Mains ph Loss Out of Speed Range 15 00008000 32768 Auto Tune Not OK No Motor OVC Active 16 00010000 65536 Live Zero Error Live Zero Error 17 00020000 131072 Internal Fault 10V...

Page 55: ...The frequency converter is still active WARNING ALARM 7 DC over voltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Connect a brake resistor Exten...

Page 56: ...inverterpeakcurrentlimit approx 200 oftheratedcurrent isexceeded Turn off the frequency converter and check if the motor shaft can be turned and if the motor size matches the frequency converter Troub...

Page 57: ...or is short circuited ALARM WARNING 28 Brake check failed Brake resistor fault the brake resistor is not connected working ALARM 29 Heatsink temp The maximum temperature of the heatsink has been excee...

Page 58: ...w 2821 Serial port overflow 2822 USB port overflow 2836 cfListMempool to small 3072 5122 Parameter value is outside its limits 5123 Option in slot A Hardware incompatible with Control board hardware 5...

Page 59: ...activated To resume normal operation apply 24 V DC to terminal 37 then send a reset signal via Bus Digital I O or by pressing RE SET For correct and safe use of the Safe Stop function follow the relat...

Page 60: ...ight inverter module in 61 or 63 drive 3 right inverter module in 62 or 64 drive 5 rectifier module ALARM 245 Heatsink sensor Thisalarmisonlyforunitsize6xfrequencyconverters ItisequivalenttoAlarm 39 T...

Page 61: ...pin 4 This procedure must be performed on each inverter module Each waveform should approximate the illustration below 8 Connect a 24 VDC power supply to the DC bus of the drive This can be done on th...

Page 62: ...t waveform in response to the changing demands of the application Par P 04 Auto Tune activates the automatic motor adaptation auto tune function When auto tune is performed the frequency converter mea...

Page 63: ...y converter This will actually increase the rate of deceleration Less often is the case that the overvoltage condition is caused by the load while it is running at speed In this case the dynamic brake...

Page 64: ...ter must be set up correctly for the motor s connected to it Parameters P 02 P 07 must have data from the motor nameplate entered into the frequency converter This enables the frequency converter proc...

Page 65: ...ses Open Blown Fuses The drive contains fuses protecting internal circuits from excessive damage in the event of a component failure It must be emphasized that an open fuse is an indication of a probl...

Page 66: ...ndication of a fraction of an amp is tolerable However that value should be considerably less than one amp If the display shows more than one amp of current there is a defective current sensor To dete...

Page 67: ...the fixed DCbus voltagecreating a variable frequency variable voltage PWM waveform This high rate of voltage change dV dt is the primary source of the frequency converter generated EMI The high rate o...

Page 68: ...verter s DC bus via the earth circuit and a high frequency HF bypass network within the frequency converter itself However imperfections in the frequency converter earthing or the equipment earth syst...

Page 69: ...AC Line Drive Illustration 5 4 Alternate Signal Conductor Currents High frequency currents can be coupled into the mains supplying the frequency converter when the mains conductors are located close t...

Page 70: ...ables A simple alternative is to twist the existing single conductors to provide a balanced capacitive and inductive coupling thus cancelling out differential mode interference While not as effective...

Page 71: ...nded practices the closer an installation resembles this example the better immunity the network will have against EMI Should EMI problems arise in an installation refer to this example Attempt to rep...

Page 72: ...blems can be diagnosed simply with these tests Static tests are performed with little or no disassembly Perform these tests on any unit suspected of containing faulty power components prior to applyin...

Page 73: ...er and provides easy access to test points The test board plugs into the top of the modules Its use is described in the procedures where called out See Section 9 Signal Test Board for detailed pin des...

Page 74: ...res described in this section in the order presented for best troubleshooting results Diode Drop A diode drop reading will vary depending on the model of ohmmeter Whatever the ohmmeter displays as a t...

Page 75: ...eye bolts mounted on vertical strut 2 DC bus bar 8 Module heatsink fan 3 SMPS fuse 9 Fan door cover 4 Optional back AC fuse mounting bracket T 10 SMPS fuse 5 Optional middle AC fuse mounting bracket S...

Page 76: ...2 Soft Charge and Rectifier Circuit Test Both the rectifier and soft charge circuits are tested simultaneously The soft charge circuit is made up of the soft charge rectifier fuses and the soft charg...

Page 77: ...shorted or the SCRs are shorted in the SCR Diode module To isolate between SCRs or the soft charge rectifier internal module testing must be performed Main rectifier circuit test part III 1 Connect po...

Page 78: ...nts in the module remove the bus bars as follows 1 If brake option is present remove 2 brake option jumpers bus bars from each module by removing attaching nut on each end of bus bar 2 Remove 3 motor...

Page 79: ...n that inverter module Replace the IGBT module according to the disassembly instructions The inverter module must be removed to replace the IGBT module Inverter test part III 1 Connect the positive me...

Page 80: ...acitance is charged within the frequency converter Brake IGBT test part II 1 Connect the positive meter lead to the brake resistor terminal R 81 2 Connect the negative meter lead to the brake resistor...

Page 81: ...f different problems 1 Perform the Rectifier Module Soft Charge Fuse Test If any soft charge fuses are open replace the fuse and retest the fan continuity 2 Check the wire harness between the Rectifie...

Page 82: ...net perform the Option Cabinet Door Fan test 3 If the above checks do not identify the problem remove the faulty Rectifier Module and check the connections between the connectors on the top of the mod...

Page 83: ...module the various logic circuits can be tested without the danger of damaging the power components The other provides low voltage power to the DC capacitors and the output IGBTs for test purposes A...

Page 84: ...age 6 3 4 Input Voltage Test 1 Apply power to drive 2 Use DVM to measure input line voltage between drive input terminals in turn L1 to L2 L1 to L3 L2 to L3 For 380 480 V drives all measurements must...

Page 85: ...successful then continue Remember to check out the customer connections 2 Measure 10 V DC control voltage at terminal 50 with respect to terminal 55 Meter should read between 9 2 and 11 2 VDC An inco...

Page 86: ...cate a possible problem with the mains supply to the frequency converter or a problem within the frequency converter itself One way to determine if the mains supply is at fault is to swap two of the i...

Page 87: ...owing measurements require an oscilloscope with voltage and current probes Under normal operating conditions the waveform of a single phase of input AC voltage to the frequency converter appears as in...

Page 88: ...rming a conclusion The current waveform will follow the voltage waveform If the voltage waveform is incorrect proceed to investigate the reason for the AC supply problem If the voltage waveform on all...

Page 89: ...ignal test board Observe the waveform on terminals 25 30 in turn Each reading should appear similar to the figure shown 7 Repeat this procedure for each inverter module Incorrect reading If one or mor...

Page 90: ...tizing DC hold DC brake or other parameter setups are disabled that create a holding torque while at zero speed Current displayed will exceed 1 to 2 amps if such parameters are not disabled 3 Run driv...

Page 91: ...e 5 Using a DVM connect negative meter lead to terminal 4 common of signal test board 6 Run drive with a zero speed reference 7 In turn measure AC voltage at terminals 1 2 and 3 of signal test board T...

Page 92: ...read between 21 and 27 VDC If the 24 V supply voltage is not present conduct the Control Card Test 6 3 17 later in this section If the 24 V is present proceed with checking the individual inputs as f...

Page 93: ...dividual inputs as follows 2 Connect negative meter lead to reference terminal 55 3 Connect positive meter lead to desired terminal 53 54 or 60 For analog input terminals 53 and 54 a DC voltage betwee...

Page 94: ...1 Use ohmmeter set to read 2 Unplug connector MK103 on power card and measure across cable leads The full range of the sensor is 787 to 10K where 10K equals 25 C and 787 equals 95 C The higher the tem...

Page 95: ...T in sequence Each reading should show open Incorrect Reading An incorrect reading here indicates the soft charge rectifier is faulty The rectifier is not serviced as a component Replace the entire so...

Page 96: ...renced to pin 4 This procedure must be performed on each inverter module Each waveform should approximate the illustration below 8 Connect a 24 VDC power supply to the DC bus of the drive This can be...

Page 97: ...High Power Service Manual for Unit Sizes 6x 96 7...

Page 98: ...y Voltages so low that they cannot be felt seen or heard can be harmful to electronic components Use standard ESD protective procedures whenever handling ESD sensitive components Failure to conform to...

Page 99: ...yle ammeter Test cable p n 6KAF6H8439 Signal test board p n 6KAF6H8437 Power supply 610 800 VDC 250 mA to supply external power to 4 power cards and the control card Power supply 24 VDC 2 A for extern...

Page 100: ...d in the back needs to be replaced remove front and middle fuses to gain access to the back fuse If additional access is necessary the left most inverter module can be removed from the inverter cabine...

Page 101: ...verter cabinet to gain access 2 Remove bus bars securing top of fuses by removing attaching bolts 8mm 3 Remove bolts securing bottom of fuses 8mm 2 3 1 4 5 1 Top DC link fuse bus bar 4 DC link fuse 2...

Page 102: ...an is installed with the printed arrow on the fan pointing inward Incorrect installation can cause excess heating and an overtemperature fault Tighten nuts to 20 in lbs 2 3 Nm 7 2 4 Heatsink Fans 1 Re...

Page 103: ...e rectifier unit not shown 7 Remove two nuts M6 from bracket at back of rectifier securing module to cabinet NOTE Four eye bolts and washers are stored at left bottom side of rectifier cabinet for use...

Page 104: ...are stored at left bottom side or inverter cabinet for use in lifting inverter If desired attach bolts to holes provided at top of inverter module Module weighs approx 136 kg 300 lbs 7 Remove 2 nuts M...

Page 105: ...s left most 6 pin connector on MDCIC board Remove rectifier control cable from MDCIC board 5 Remove relay connector from MDCIC panel 6 Remove any customer interconnect wiring 7 Remove MDCIC panel by r...

Page 106: ...nector from fan transformer 3 Remove nut M8 from center of fan transformer securing transformer to panel Reinstall fan transformer in reverse order of this procedure 1 2 3 130BX255 10 1 Fan transforme...

Page 107: ...nted to by removing screw 8mm from each mounting bracket 4 Remove remaining short bus bars attached to angle bracket bus bars by removing two 8mm screws from each bus bar 5 Note that DC link reactors...

Page 108: ...1 2 2 2 2 3 3 4 4 130BX254 10 1 DC link inductor step 5 3 Short bus bars step 4 2 Mounting bracket bus bar step 3 4 Angle bracket bus bar not removed High Power Service Manual for Unit Sizes 6x 107 7...

Page 109: ...bles 5 Note position of rectifier control cable MK101 connected to left 6 pin connector for reassembly Disconnect rectifier control cable NOTE Scaling card one on each module must be retained to reins...

Page 110: ...ver step 3 5 MDCIC mounting panel 2 Scaling card step 5 6 Ribbon cable step 4 3 MK101 connector step 5 7 Left side ribbon cable step 2 4 MDCIC board attaching screw step 6 High Power Service Manual fo...

Page 111: ...High Power Service Manual for Unit Sizes 6x 110 8...

Page 112: ...ork conducted by non certified technicians can result in personal injury or equipment damage 8 2 Inverter Module 8 2 1 Inverter Module Exploded View 1 2 3 4 5 6 7 8 9 10 11 12 1 Right side cover plate...

Page 113: ...d MK105 on power card 2 Disconnect cable from MK107 on power card 3 Remove two red wires from 15A fuse block attached to cover plate flange 4 Free cable entirely with the 2 red wires attached to it by...

Page 114: ...r and lower capacitor banks 3 Remove four retaining nuts 10mm securing capacitor bank assembly 4 NOTE Capacitor bank assembly may weigh up to 9 kg 20 lbs Remove capacitor bank assembly Reassembly is d...

Page 115: ...or MK100 on high frequency board 3 Remove two screws T25 from high frequency board 4 Remove one nut 8mm from high frequency board standoff and remove board Reassembly is done in reverse order 1 2 3 13...

Page 116: ...brake option MK105 2 Remove gate drive card by removing 6 mounting screws T25 from standoffs Reinstall in reverse order of this procedure Tighten mounting screws to 2 3 Nm 20 in lbs 1 2 3 4 5 6 130BX2...

Page 117: ...ed to output bus bar 5 Unplug wire from current sensor not shown 6 Remove two screws 7mm attaching base of current sensor to back panel 7 Remove bus bar and slide current sensor free from bus bar 8 Fo...

Page 118: ...om connector on each of the two brake IGBT modules 4 Remove bus bar attached to left side of panel and to left most brake IGBT by removing two nuts at each end of bus bar 5 Remove jumper bus bar betwe...

Page 119: ...BT is present remove the two screws T30 connecting the IGBT Ind bus bar assembly to each brake IGBT module 6 Remove nine snubber capacitors by removing two screws T30 for from each capacitor 7 Remove...

Page 120: ...IGBT module step 10 4 Snubber capacitor step 6 2 High frequency board step 2 5 IGBT capacitor bus bar step 7 3 IGBT Ind bus bar assembly steps 5 and 9 6 Current sensor step 3 High Power Service Manua...

Page 121: ...High Power Service Manual for Unit Sizes 6x 120 9...

Page 122: ...n are intended for GE qualified technicians Repair work conducted by non certified technicians can result in personal injury or equipment damage 9 2 Rectifier Module 9 2 1 Internal Access 1 Remove rec...

Page 123: ...heet behind power card can be left in place Ensure its is in place for reassembly NOTE Power card may remain installed if power card mounting plate is being removed to access soft charge boards Discon...

Page 124: ...rom back side of flange 4 Remove power card mounting plate by removing four retaining nuts 8mm securing plate NOTE At this point soft charge cards are accessible for changing fuses Two soft charge car...

Page 125: ...card from mounting plate by removing four screws T25 fastening card to mounting plate Note insulation sheet below soft charge card Remove and keep the insulation sheet for reinstallation Reinstall in...

Page 126: ...ge cards for units with three inverter modules 3 Disconnect MK3 and MK4 from each soft charge card 4 Remove soft charge card mounting plate by removing four nuts 8mm attaching mounting plate Soft char...

Page 127: ...nted on side panel one on each side for units with two inductors an additional one for units with three inverters 4 Loosen bottom 8mm nut 5 Remove top 8mm nut to remove soft charge resistor Reinstall...

Page 128: ...Remove six nuts 13mm two from each SCR module on DC bus bar 4 Remove two nuts 17mm DC bus bar and remove DC bus bar 5 Remove six nuts 13mm two from each SCR module from AC input bus bar 6 If removing...

Page 129: ...on AC input side and one on DC side of module 4 Remove diode module by removing four retaining screws T30 and washers from corners of module Reassembly 1 Replace diode module in accordance with instr...

Page 130: ...ltage power for the SMPS By powering only the SMPS in each module the various logic circuits can be tested without the danger of damaging the power components The other provides low voltage power to t...

Page 131: ...tables on the following pages list the pins located on the signal test board For each pin its function description and voltage levels are provided Details on performing tests using the test fixture a...

Page 132: ...abled 0 VDC SCRs enabled 8 RL1 Control Card signal Signal from Control Card to provide status of Relay 01 0 VDC Relay active 0 7 VDC inactive 9 Not used 10 Not used 11 VPOS 18 VDC regulated sup ply 16...

Page 133: ...ply 4 75 to 5 25 VDC 25 GUP_T IGBT gate signal buf fered U phase positive Signal originates on Control Card 2v div 100us div Run 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 26 GUN_T IGBT gate signa...

Page 134: ...11 Block Diagrams High Power Service Manual for Unit Sizes 6x 133 11...

Page 135: ...Illustration 11 1 Unit Size 6x drive Top Level Block Diagram High Power Service Manual for Unit Sizes 6x 134 11...

Page 136: ...nt Connector 44 pin Panel Mount Connector 3 10 11 1 8 5 7 6 5 7 3 10 11 14 PIN 8 MK112 RELAY AUX 2 NC NO C 2 3 1 NC NO C RELAY AUX 1 6 5 4 8 7 6 11 10 9 8 PIN 5 1 5 8 8 4 4 1 12 PIN BLK RED WHT BLK RE...

Page 137: ...GUP2 GLO2 ELO1 EUP1 GLO1 GUP1 MK100 U 8 5 1 4 ELO3 GUP3 CUP3 EUP3 GLO3 NTC OUT IN NTC2 NTC1 MK103 NTC 1 2 3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 G...

Page 138: ...information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred to the GE company AF 650 GP and AF 600 FP are t...

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