GE DS200SDCIG2A Dc Power Supply

The DS200SDCIG2A is a Dc Power Supply and Instrumentation Board designed by General Electric (GE) Drive Systems for its DC2000 series DC drives. Belonging to the SDCI (Dc Power Supply and Instrumentation Board) series, this board is part of the G2 group and represents revision A. It is a critical component within the DC2000 DC drive system, responsible for power conversion, signal conditioning, and instrumentation measurement, and is suitable for drive applications with input voltages up to 600 V ac.

The primary function of the SDCI Dc Power Supply and Instrumentation Board is to convert input power from the control power transformer into the various logic power supplies required by the drive control system. Additionally, it provides armature SCR gating circuits, and measurement and conditioning of AC line and DC motor signals. This board integrates multiple functions, including power conversion, signal measurement, and gate driving, making it a core component for achieving precise control and reliable protection in DC2000 drive systems.

The G2 version of the SDCI board differs from the G1 version primarily in that it does not include an internal field exciter circuit and is instead designed for use with an external exciter. This makes the G2 version suitable for high-power DC drive applications requiring higher field currents or more flexible configuration. The DS200SDCIG2A board is designed to meet the demands of industrial drive applications and features the following characteristics:

• Multiple Power Outputs: Provides +5 V dc (4 A), ±15 V dc (0.4 A each), ±24 V dc, and 115 V ac (0.4 A) logic power supplies.

• Armature SCR Gating Circuit: Drives the gate pulse transformers for the armature SCRs.

• Comprehensive Signal Measurement: Measures armature current, armature voltage, field current, AC line current, AC line voltage magnitude, and phase sequence.

• External Exciter Interface: Supports connection to an external field exciter to meet high-power application requirements.

• Configurable Hardware Jumpers: Supports configuration of various functions through hardware jumpers.

• Comprehensive Protection Circuits: Multiple fuses with status indicators for convenient fault diagnostics.

This product is widely used in high-power DC drive systems and industrial drive control applications, particularly in high-power industrial environments requiring external exciters.

II. Key Functions

1. Multiple Logic Power Outputs

The DS200SDCIG2A board converts input power from the control power transformer into multiple stable DC and AC outputs:

• +5 V dc, 4 A: Provides core operating power for the main control board (SDCC) of the drive control system.

• ±15 V dc, 0.4 A each: Powers analog circuits and signal conditioning circuits.

• ±24 V dc: Provides power for relays and external loads.

• 115 V ac, 0.4 A: Provides AC power for external devices such as cabinet fans.

All power outputs are protected with overcurrent protection, and fuse status is indicated via LEDs or neon lamps.

2. External Field Exciter Interface

Unlike the G1 version, the G2 version of the SDCI board does not include an internal field exciter circuit and is instead designed for use with an external field exciter. This allows the G2 version to meet the requirements of high-power DC drive applications that demand higher field currents or more flexible configuration. The external field exciter connects to the SDCI board via the appropriate terminal board, with control signals and power support provided by the SDCI board.

3. Armature SCR Gating Circuit

The DS200SDCIG2A board provides circuits to drive the gate pulse transformers for the armature SCRs. It interfaces with the main control board (SDCC) via the 1PL connector, receiving trigger signals from the SDCC and converting them into the power level required to drive the SCR gates.

4. Signal Measurement and Instrumentation Circuits

The DS200SDCIG2A board integrates multiple signal measurement circuits for monitoring drive system operating conditions:

• Armature Current Measurement: Measures armature current via a shunt.

• Armature Voltage Measurement: Measures armature voltage magnitude.

• Field Current Measurement: Measures motor field current (from external exciter).

• AC Line Current Measurement: Measures AC line current on phases L1 and L3 via AC current transformers (ACCTs).

• AC Line Voltage Measurement: Measures AC line voltage magnitude and phase sequence.

These measurement signals are transmitted to the SDCC main control board via the 1PL connector for closed-loop control and protection functions.

5. MA Contactor Control Circuit

The DS200SDCIG2A board includes an MA AC contactor control circuit. Hardware jumper JP2 is used to configure the contactor dropout delay. During normal operation, this circuit delays the opening of the AC contactor to ensure that all load current has been extinguished. The JP2 jumper provides approximately 100 ms delay (normal operation) or minimum delay (manufacturing test).

6. MD Contactor Control Circuit

The SDCI board provides an MD contactor drive output. Hardware jumper JP1 is used to configure the control source for the MD contactor:

• Position 1-2: MD is independently controlled by MCP software (normal operation).

• Position 2-3: MD hardware is slaved to MA operation.

7. AC Line Current Transformer Interface

The DS200SDCIG2A board uses switch SW1 to select the burden resistance for the AC line current transformers, accommodating drive systems with different rated currents. The 16-position SW1 settings are selected based on the drive’s rated DC current and CT turns ratio, ensuring correct operation of the AC instantaneous overcurrent (IOC) protection function. When the main line ACCT secondary current exceeds 144 mA, the CTs are routed through 10:1 step-down CTs on the SHV/SHVM board.

III. Hardware Architecture

1. Board Structure

The DS200SDCIG2A board uses a standard printed circuit board structure and is installed in the drive control cabinet, located behind the SDCC main control board. The board includes:

• Multiple Power Circuits: Provide +5 V, ±15 V, ±24 V dc and 115 V ac outputs.

• Signal Measurement Circuits: For measuring armature current, voltage, field current, AC line current, and AC line voltage.

• Gate Drive Circuits: Drive the armature SCR gate pulse transformers.

• External Exciter Interface: For connecting an external field exciter.

• Protection Circuits: Multiple fuses (FU1-FU3, FU5, FU6).

• Status Indicators: Neon lamps (LT1, LT5, LT6) and LEDs (CR51, CR55).

• Configurable Components: Jumpers JP1, JP2 and switch SW1.

• Multiple Connectors: 1PL, 2PL, 5PL, 1CPL, CNPL, CPTPL, FAPL, NPL, PPL, etc.

2. Key Differences from G1 Version

3. Mounting Location

The DS200SDCIG2A board is installed in the board carrier of the drive control cabinet, located behind the SDCC main control board. To replace the SDCI board, the SDCC board must be lifted forward to access the SDCI board.

4. Connector Description

The DS200SDCIG2A board includes various connectors for power, control signals, and measurement signals:

5. Fuses and Indicators

IV. Detailed Interface Description

1. Connector 1PL

The 1PL connector is the primary communication interface between the SDCI board and the SDCC main control board, transmitting:

• Power status signals (DPSEN)

• Phase current feedback signals (/IA, /IB, /IC)

• Voltage feedback signals (V(B-A), V(C-A), VDC)

• Line synchronization signal (LINESYN)

• Gate drive enable signals (ENA, ENB, ENC)

• Fault signals (FAULT1, FAULT2)

• System reset signal (/RST1)

2. Connector 2PL

The 2PL connector provides power inputs from the power supply board to the SDCI, including:

• /PSEN: power supply enable signal

• ±15 V dc, ±24 V dc, and +5 V dc power

• DCOM: power supply common

3. Connector 5PL

The 5PL connector connects to the PCCA Power Connect Card, transmitting SCR gate pulse signals.

4. Connector 1CPL

The 1CPL connector connects to AC current transformers (ACCTs) on phases L1 and L3, bringing CT secondary current signals into the SDCI board.

5. Connectors CNPL, CPTPL, FAPL

These connectors interface with external devices:

• CNPL: MA contactor control output

• CPTPL: Control power transformer output

• FAPL: Fan power output

6. Connectors NPL, PPL

These connectors interface with the SCR module gate and cathode:

• NPL: N2 SCR cathode and gate

• PPL: P1 SCR cathode and gate

V. Configuration and Settings

1. Hardware Jumper Configuration

The configurable hardware on the SDCI board includes two jumpers (JP1, JP2) and one DIP switch (SW1):

2. DIP Switch SW1 Settings

SW1 selects the burden resistance for the AC line current transformers. The setting is based on the drive’s rated DC current and CT turns ratio:

3. Fuse Replacement Considerations

• FU1: 115 V ac power supply fuse. If blown, check for wiring errors or overload. When blown and a load is connected, neon lamp LT1 illuminates.

• FU2: +24 V, +15 V, +5 V power supply fuse. Commonly caused by accidental short of +24 V. If the fuse continues to blow with 1PL, 2PL, and 5PL disconnected, replace the SDCI board.

• FU3: -24 V, -15 V power supply fuse. Commonly caused by accidental short of -24 V. If the fuse continues to blow with 1PL, 2PL, and 5PL disconnected, replace the SDCI board.

• FU5/FU6: External exciter-related circuit fuses. If blown, neon lamps LT5/LT6 illuminate. Possible causes include external exciter failure, wiring short, or SDCI board failure.

VI. Installation and Maintenance

1. Mounting Location

The SDCI board is installed in the board carrier of the drive control cabinet, located behind the SDCC main control board. To replace the SDCI board, the SDCC board must be lifted forward to access the SDCI board.

2. Replacement Procedure

1. Power Off: Turn off power to the drive, wait several minutes for power supply capacitors to discharge, and test to verify that no power exists.

2. Open Cabinet Door: Access the printed wiring board area, locating the front-facing SDCC board.

3. Lift SDCC Board: Pull the locks on either side of the cabinet, lift the SDCC board, and tilt it forward to expose the SDCI board.

4. Disconnect Cables: Carefully disconnect all cables. For ribbon cables, grasp the sides of the cable connector and gently pull; for cables with pull tabs, carefully pull the tab.

5. Release Snaps: Push back the plastic snaps to remove the old SDCI board.

6. Configure New Board: Set all configurable components (JP1, JP2, SW1) on the new board to the same positions as on the board being replaced.

7. Install New Board: Install the new SDCI board, ensuring all snaps snap into position.

8. Reconnect Cables: Reconnect all cables as labeled, ensuring they are properly seated at both ends.

9. Reset SDCC Board: Return the SDCC board to its position and secure the locks.

3. Maintenance Recommendations

• ESD Precautions: Always wear a grounding strap when handling boards. Store boards in anti-static bags.

• Periodic Inspection: Check connectors for looseness and fuse status indicators for proper operation.

• External Exciter Inspection: Regularly check the connection and operating status of the external exciter.

• Spare Parts Management: It is recommended to keep at least one identical SDCI board on-site as a spare to minimize downtime.

VII. Applications

The DS200SDCIG2A Dc Power Supply and Instrumentation Board is widely used in the following industrial applications:

• DC2000 High-Power DC Drive Systems: Provides power conversion and signal measurement functions for high-power DC motor drives requiring external exciters.

• High-Power DC Drives: Suitable for DC drive applications requiring high field currents.

• Industrial Process Control: Provides control power and feedback measurement in industrial processes requiring high-power DC motor drives.

• System Upgrades and Retrofit Projects: Replaces power supply and instrumentation boards in older drive systems, enhancing system reliability.