The DS200PCCAG5A is a Power Connect Card designed by General Electric (GE) Industrial Control Systems for its DC2000 series drive systems. Belonging to the PCCA (Power Connect Card) series, this board is part of the G5 group and represents revision A. It serves as a critical interface component within GE drive systems, connecting the control circuitry to the SCR power bridge, specifically designed for high-voltage, high-power drive applications on J, K, and M-frame drives.
The primary function of the PCCA Power Connect Card is to provide gate drive signals to the SCR power bridge, achieving electrical isolation between the control circuit and the power circuit through pulse transformers. The board receives trigger signals from the DCFB power supply board or SDCI power supply board and converts them into power pulses required to drive the SCR gates. These signals are output to the SCR bridge via connectors 1FPL-6FPL and 1RPL-6RPL. Unlike the G1 group, the G5 group board is specifically designed for high-voltage applications and does not include snubber circuits or voltage attenuation strings; these are provided by other system components.
The DS200PCCAG5A board is a G5 group product, suitable for non-regenerative (two-quadrant) power conversion applications with an input voltage range of 240-700 V dc. It supports J, K, and M-frame high-voltage drives and is powered by the DCFB power supply board. The board is designed to meet the demands of high-voltage, high-power industrial drive applications and features the following characteristics:
Gate Drive Outputs: Provides 6 forward and 6 reverse SCR gate drive pulse outputs.
Pulse Transformer Isolation: Uses pulse transformers to achieve electrical isolation between control circuits and power circuits.
No Snubber Circuits: Designed for high-voltage, high-power applications; snubber circuits are provided by other system components.
Voltage Feedback Scaling: Configurable jumpers for setting armature voltage feedback scaling.
Flexible Voltage Configuration: Supports DC armature voltages ranging from 240 V to 700 V.
Modular Design: Works in conjunction with the DCFB power supply board and drive control board to form a complete drive control system.
This product is widely used in high-voltage DC2000 DC drive systems, industrial drive control, non-regenerative power conversion applications, and various high-power power electronics applications requiring SCR gate drive.
II. Key Functions
1. SCR Gate Drive Outputs
The core function of the PCCA board is to convert trigger signals from the DCFB power supply board into power pulses required to drive the SCR gates. The board provides 6 forward gate pulse outputs via connectors 1FPL-6FPL and 6 reverse gate pulse outputs via connectors 1RPL-6RPL (for reversing bridges). Each output is isolated by pulse transformers, ensuring safe isolation between control circuits and power circuits.
| Output Type | Connector | Description |
|---|
| Forward Gate Pulses | 1FPL-6FPL | Drives forward bridge SCRs; red and white wires correspond to positive and negative gate pulse terminals |
| Reverse Gate Pulses | 1RPL-6RPL | Drives reverse bridge SCRs; used only in reversing bridge applications |
2. Pulse Transformer Isolation
The PCCA board employs pulse transformers as isolation elements for gate drive signals. The pulse transformers convert low-voltage trigger signals from the DCFB board into power signals required to drive the SCR gates, while providing electrical isolation between control circuits and power circuits, preventing high-voltage side interference from affecting normal operation of the control circuits.
3. No Snubber Circuit Design
Unlike lower-voltage groups such as G1 and G2, the G5 group board does not include AC line snubber circuits or DC bus snubber circuits. For J, K, and M-frame high-voltage, high-power drives, snubber circuits and voltage attenuation strings are provided by other system components, such as the SHVI (SCR High Voltage Interface Board) or SHVM board. This design simplifies the PCCA board structure and improves reliability in high-voltage applications.
4. Armature Voltage Feedback Scaling
The PCCA board provides armature voltage feedback scaling through configurable jumpers JP1 and JP2. By selecting different jumper connection combinations, the board can adapt to various armature voltage levels ranging from 240 V to 700 V DC, providing accurate armature voltage feedback signals to the control system.
Important Note: For G5 group boards, in revisions AAA-AAZ, JP1 and JP2 jumpers are used for voltage configuration. In revisions ABA and later, these jumpers have been deleted, and voltage attenuation strings and jumpers are no longer used.
5. Snubber and Voltage Feedback Channel Connection Selection
The PCCA board uses wire jumpers WP3 and WP4 to select the connection method between snubber circuits and voltage feedback channels. For G5 group boards, since snubber circuits are not included, WP3 and WP4 jumpers are typically not applicable, though they remain on the board for design commonality with other group boards.
III. Hardware Architecture
1. Board Structure
The DS200PCCAG5A board uses a standard printed circuit board structure with dimensions compatible with GE drive system board carriers. The board includes:
6 Forward Gate Pulse Output Connectors (1FPL-6FPL)
6 Reverse Gate Pulse Output Connectors (1RPL-6RPL, for reversing bridges only)
1 Power/Control Signal Input Connector (5PL)
Configurable Jumpers: JP1, JP2 (voltage scaling selection, early versions only) and WP3, WP4 (snubber circuit connection selection)
Pulse Transformers: 12 (6 forward, 6 reverse)
No Snubber Circuits: AC line and DC bus snubber circuits are provided by other system components
2. Stab Terminals
The PCCA board provides multiple stab terminals for voltage feedback scaling and system connections:
| Stab Terminal | Description |
|---|
| P1 | Positive DC bus |
| P1A, P1B | Positive DC bus voltage feedback; when WP3 is connected, the board’s snubber capacitors are connected to the same point as the voltage feedback channel (typically not used for G5) |
| P2 | Negative DC bus |
| P2A, P2B | Negative DC bus voltage feedback; when WP4 is connected, the board’s snubber capacitors are connected to the same point as the voltage feedback channel (typically not used for G5) |
| P3-P10 | Voltage feedback scaling resistor connection points (early versions) |
| DCS | To DC snubber circuit (not used for G5) |
| 1ACS-6ACS | To AC snubber circuits (not used for G5) |
3. Mounting Location
The PCCA board is installed on the back of the board carrier in the drive control cabinet, located behind the power supply board (DCFB). To replace the PCCA board, the drive control card and power supply board must first be lifted forward for access.
4. Connection with DCFB Board
The PCCA board connects to the DCFB power supply board via the 5PL connector, receiving 24 V power and SCR gate trigger signals from the DCFB. The 5PL connector is a 26-pin plug-in connector with the following pin assignments:
| Pin | Signal | Description |
|---|
| 5PL-1 | A6F | Drives cell 6F gate pulse transformer |
| 5PL-2 | P24 | +24 V output |
| 5PL-3 | A5F | Drives cell 5F gate pulse transformer |
| 5PL-4 | P24 | +24 V output |
| 5PL-5 | A4F | Drives cell 4F gate pulse transformer |
| 5PL-6 | P24 | +24 V output |
| 5PL-7 | A3F | Drives cell 3F gate pulse transformer |
| 5PL-8 | P24 | +24 V output |
| 5PL-9 | A2F | Drives cell 2F gate pulse transformer |
| 5PL-10 | P24 | +24 V output |
| 5PL-11 | A1F | Drives cell 1F gate pulse transformer |
| 5PL-12 | P24 | +24 V output |
| 5PL-13 | A1R | Drives cell 1R gate pulse transformer (reversing bridges) |
| 5PL-14 | P24 | +24 V output |
| 5PL-15 | A2R | Drives cell 2R gate pulse transformer (reversing bridges) |
| 5PL-16 | P24 | +24 V output |
| 5PL-17 | A3R | Drives cell 3R gate pulse transformer (reversing bridges) |
| 5PL-18 | P24 | +24 V output |
| 5PL-19 | A4R | Drives cell 4R gate pulse transformer (reversing bridges) |
| 5PL-20 | P24 | +24 V output |
| 5PL-21 | A5R | Drives cell 5R gate pulse transformer (reversing bridges) |
| 5PL-22 | P24 | +24 V output |
| 5PL-23 | A6R | Drives cell 6R gate pulse transformer (reversing bridges) |
| 5PL-24 | P24 | +24 V output |
| 5PL-25 | DCN | Test attenuation (negative) |
| 5PL-26 | DCP | Test attenuation (positive) |
IV. Detailed Interface Description
1. 5PL Connector
The 5PL connector is the primary interface between the PCCA board and the DCFB power supply board, receiving 24 V power and SCR gate trigger signals. This 26-pin plug-in connector’s pin assignments are detailed in the previous table.
2. 1FPL-6FPL Connectors
These connectors output forward bridge SCR gate pulse signals:
| Connector | Pin | Signal | Description |
|---|
| 1FPL-6FPL | 1 | Forward gate pulse | Red wire to corresponding SCR |
| 1FPL-6FPL | 2 | Forward gate pulse | White wire to corresponding SCR |
3. 1RPL-6RPL Connectors
These connectors output reverse bridge SCR gate pulse signals, used only in reversing bridge applications:
| Connector | Pin | Signal | Description |
|---|
| 1RPL-6RPL | 1 | Reverse gate pulse | Red wire to corresponding SCR |
| 1RPL-6RPL | 2 | Reverse gate pulse | White wire to corresponding SCR |
V. Configuration and Settings
1. Voltage Scaling Jumper Configuration (JP1, JP2) – Early Versions Only
For G5 group boards of revisions AAA-AAZ, the armature voltage range is configured through combinations of JP1 and JP2 jumpers. The following table shows the configuration for G5 group (non-regenerative):
| Voltage (V dc) | JP1 Position | JP2 Position | Additional Connections |
|---|
| 240 | 3-8 | 6-9 | JP1 P3-P8, JP2 P6-P9 |
| 350 | 3-4 | 5-6 | JP1 P3-P4, JP2 P5-P6 |
| 390 | 7-8 | 9-10 | JP1 P7-P8, JP2 P9-P10 |
| 500 | 4-7 | 5-10 | JP1 P4-P7, JP2 P5-P10 |
| 550 | 3-7 | 6-10 | JP1 P3-P7, JP2 P6-P10 |
| 595 | 4-8 | 5-9 | JP1 P4-P8, JP2 P5-P9 |
| 700 | 0 | 0 | All P3-P10 open |
Important Notes:
JP1 and JP2 pin numbers correspond to stab terminals P3-P10; jumpers should be connected between the specified terminals.
For G5 group boards of revisions ABA and later, JP1 and JP2 jumpers have been deleted, and voltage attenuation strings are no longer used. Voltage feedback scaling functions are provided by other system components (such as SHVI/SHVM boards).
2. Snubber Circuit Connection Jumper Configuration (WP3, WP4)
For G5 group boards, since snubber circuits are not included, WP3 and WP4 jumpers are typically not applicable. However, when sharing design with other group boards, these jumpers remain on the board:
| Jumper | Position | Function |
|---|
| WP3 | IN | Positive DC bus snubber capacitors connected to the same bridge point as the voltage feedback channel (not applicable for G5) |
| WP3 | OUT | Positive DC bus snubber capacitors connected to a different bridge point than the voltage feedback channel (not applicable for G5) |
| WP4 | IN | Negative DC bus snubber capacitors connected to the same bridge point as the voltage feedback channel (not applicable for G5) |
| WP4 | OUT | Negative DC bus snubber capacitors connected to a different bridge point than the voltage feedback channel (not applicable for G5) |
3. Board Replacement Considerations
When replacing a PCCA board, ensure that all jumper settings on the new board match those on the board being replaced. Since different group and revision boards may have different hardware configurations, replacement boards must be of the same group. For G5 group boards, pay special attention to:
Confirm the revision of the board being replaced (AAA-AAZ or ABA and later).
For boards of revision ABA and later, JP1 and JP2 jumpers are deleted and require no configuration.
Voltage attenuation is provided by external components such as SHVI/SHVM boards.
VI. Installation and Maintenance
1. Mounting Location
The PCCA board is installed on the back of the board carrier in the drive control cabinet, located behind the power supply board (DCFB). To replace the PCCA board, the drive control card and power supply board must first be lifted forward for access.
2. Installation Steps
Verify Power is Off: Turn off power to the drive, wait several minutes for power supply capacitors to discharge, and test to verify no power exists.
Open Cabinet Door: Access the printed wiring board area.
Lift Front Board Carrier: Pull the lock tabs on either side of the board rack, lift the front board carrier (with the drive control card), and tilt it forward and down.
Lift Second Board Carrier: Lift the second board carrier (with the power supply board) and tilt it forward and down to access the PCCA board.
Disconnect Cables: Carefully disconnect all cables from the PCCA board.
Release Snaps: Push back on the six plastic snaps to release the PCCA board from the board carrier.
Configure New Board: Set all jumpers (JP1, JP2, WP3, WP4) on the new board to the same positions as on the board being replaced. For boards of revision ABA and later, JP1 and JP2 are deleted and require no configuration.
Install New Board: Install the new PCCA board onto the board carrier, ensuring all six plastic snaps snap into position.
Reconnect Cables: Reconnect all cables as labeled, ensuring they are properly seated at both ends.
Reset Board Carriers: Return the second board carrier and front board carrier to their positions and secure the locks.
3. Removal Steps
Verify Power is Off: Ensure the system has been de-energized and test to verify no power is present.
Lift Board Carriers: Lift the front board carrier and second board carrier.
Disconnect Cables: Carefully disconnect all connectors.
Release Snaps: Push the plastic snaps to remove the PCCA board.
4. Maintenance Recommendations
ESD Precautions: Always wear a grounding strap when handling boards. Store boards in anti-static bags.
Periodic Inspection: Regularly check that connectors are secure and jumpers are firmly in place.
Spare Parts Management: It is recommended to keep at least one identical PCCA board on-site as a spare to minimize downtime.
High-Voltage Safety: The G5 group is used for high-voltage applications (up to 700 V dc); always observe high-voltage safety precautions during maintenance.
VII. Applications
The DS200PCCAG5A Power Connect Card is widely used in the following industrial applications:
DC2000 High-Voltage DC Drive Systems: Provides gate drive signals for J, K, and M-frame high-voltage SCR power bridges.
Non-Regenerative Power Conversion Applications: Suitable for two-quadrant high-voltage DC drive systems.
J, K, and M-Frame Drives: Compatible with corresponding frame sizes for high-voltage drive systems.
Industrial Process Control: Provides gate drive in industrial processes requiring precise high-voltage DC motor control.
System Upgrades and Retrofit Projects: Replaces power connect cards in older high-voltage drive systems.
