The DS200SDCCG1A is a Drive Control Card designed by General Electric (GE) Motors & Industrial Systems for its DIRECT-O-MATIC 2000 series drives and exciters. Belonging to the SDCC (Drive Control Card) series, this board is part of the G1 group and represents revision A. It serves as the core control component for GE 2000 series drive systems, integrating three 16-bit microprocessors that work in concert via dual-port RAM to provide complete control functions for AC and DC motor drives.
The primary function of the SDCC drive control card is to provide primary control for drives and motors, signal processing, and customer I/O interfaces. The board employs a three-processor architecture, including a Drive Control Processor (DCP), a Motor Control Processor (MCP), and a Co-motor Processor (CMP), which handle user interfaces and system-level functions, inner-loop current regulation and motor-specific functions, and math-intensive processing tasks, respectively. Onboard software is stored in five memory chips: four EPROMs (containing factory-programmed configuration data) and one EEPROM (containing field-adjustable parameters).
The DS200SDCCG1A board embodies GE’s advanced technology in drive control and features the following characteristics:
Three-Processor Architecture: Integrates three 16-bit microprocessors handling control, application, and I/O functions respectively.
Onboard Diagnostic LEDs: 10 LEDs display fault codes in BCD or binary mode, facilitating on-site troubleshooting.
Multiple Reset Options: Supports onboard pushbutton reset, external signal reset, software reset, and watchdog protection.
Rich I/O Interfaces: Provides multiple analog, digital, frequency, and communication interfaces.
Auxiliary Board Mounting Capability: Accommodates LAN communication cards, signal processor cards, and other auxiliary boards.
Flexible Configuration Options: Supports various hardware jumpers and software parameters.
This product is widely used in DC drive systems, AC variable frequency systems, excitation systems, and various industrial process control applications, particularly in industrial drive applications requiring high-performance control.
II. Key Functions
1. Three-Processor Control Architecture
The DS200SDCCG1A card contains three 16-bit microprocessors that operate in coordination via dual-port RAM (DPR), a RAM configuration that can be independently and simultaneously accessed by two microprocessors:
| Processor | Location | Function Description |
|---|
| Drive Control Processor (DCP) | U1 | 80C186 microcontroller with numerous built-in peripheral functions, including address decoding (for chip selects), wait-state generators, an interrupt controller, timer/counters, and a 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) | U21 | 80C196 microcontroller with high-speed I/O, conventional digital I/O, analog I/O, timer/counters, and a 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) | U35 | TMS320 C25 digital signal processor that performs math-intensive functions for motor control algorithms too complex for the MCP. Used only in drives requiring additional processing capability. The CMP interfaces only to its EPROM and MCP/CMP dual-port RAM. |
2. Onboard Software and Memory
The DS200SDCCG1A card stores software in five memory chips:
EPROMs (U11, U12, U22, U23): Four EPROMs containing factory-programmed configuration data.
EEPROM (U9): One EEPROM containing field-adjustable parameters.
Important Note: The DS200SDCCG1A card (the version without memory chips) has empty sockets. When ordering a replacement board, specify the DS215SDCCG1A card to ensure that the five memory chips are included.
3. LED Diagnostic Display
The DS200SDCCG1A card provides 10 diagnostic LEDs that display fault codes in a blinking mode:
| Fault Code Range | Display Mode |
|---|
| 1-399 | Slow blink rate BCD pattern (leftmost 2 LEDs encode the hundreds digit, next 4 LEDs encode the tens digit, rightmost LED encodes the units digit) |
| 400-1023 | Faster blink rate binary pattern (leftmost LED is 2^9=512, second LED is 2^8=256, and so on) |
| 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 (such as in absolute or signed bar graph mode). This setting does not inhibit the LED fault display.
4. Reset Circuits
The DS200SDCCG1A provides four reset methods, including a RESET pushbutton:
| Reset Method | Description |
|---|
| Onboard Button | Press the RESET pushbutton on the SDCC. |
| External Signal | Apply +5 to +24 V dc to customer interface points on the STBA or NTB/3TB boards (interfaced to the SDCC through 6PL). |
| Software Control | SDCC generates a reset via programmed software control. |
| Watchdog Protection | SDCC generates a reset via automatic internal hardware watchdog protection. |
Caution: A hard reset trips the system; the system should not normally be reset while running.
III. Hardware Architecture
1. Card Groups
Three SDCC group numbers are currently available (G2 versions were never manufactured):
| Group | Application |
|---|
| DS200SDCCG1A_ | Used in AC2000, DC2000, and EX2000 drive applications |
| DS200SDCCG3A_ | Reduced functionality version used in DC1000 drives |
| DS200SDCCG4A_ | Used in TC2000 turbine applications (same as G1A except with enlarged EE parameter storage area and different firmware) |
2. Card Connectors
The SDCC interfaces with other controller boards and external signals via eight connectors (designated _PL):
| Connector | Interface |
|---|
| 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) |
3. Auxiliary Board Mounting
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
531X309SPC Signal Processor Card
DS200SPCB Multibridge Signal Processing Card
4. Testpoints
The SDCC provides multiple onboard testpoints for test and troubleshooting:
| Testpoint | Name | Description |
|---|
| DCOM1/DCOM2 | Common reference | 0 volt common reference point |
| P5 | +5 V power | Regulated +5 V power supply (±5%) |
| TP4 | DCP foreground timing flag | 720 Hz |
| TP5 | DCP blockware timing flag | 720 Hz |
| TP6 | DCP slow background timing flag | 90 Hz |
| RTS | General purpose testpoint | General purpose testpoint output from DCP |
| TP8 | Phase current | Analog representation of phase A motor current, with a nominal dc offset of +2.5 V |
| FCLK | Oscillator output | “I’m alive” 8 MHz oscillator output from MCP |
| NMI | Board test | Initiates board test (Test 13) when momentarily tied to +5 V. For board test only. |
| DACS | D/A daughterboard select | Diagnostic D/A converter daughterboard select |
| N15 | -15 V power | Regulated -15 V power supply (±5%) |
| P15 | +15 V power | Regulated +15 V power supply (±5%) |
| TP29 | Input line frequency | Testpoint for input line frequency |
| TP37 | DC voltage | Testpoint for dc voltage (not used on ac drives) |
IV. Detailed Interface Description
1. Connector 1PL (AC2000 Drives Only)
The 1PL connector provides I/O between the SDCC and the power supply board, transmitting drive power status, IGBT signals, phase current feedback, voltage feedback, line synchronization signals, and more.
2. Connector 2PL
The 2PL connector provides power inputs from the power supply board to the SDCC, including:
/PSEN: power supply enable signal
±15 V dc, ±24 V dc, and +5 V dc power
DCOM: power supply common
3. Connector 3PL
The 3PL connector provides SDCC outputs to the SLCC (LAN communication card), including:
Buffered data bus lines (BD0-BD7)
Buffered address lines (BA0-BA12)
System reset, interrupt, chip select, read/write control signals
4. Connector 6PL
The 6PL connector is the primary interface between the SDCC and the drive terminal board (NTB/3TB or STBA), including:
Control Lines: CTLN1/CTLN2 (MA contactor control circuit)
Digital Inputs: RUN (run), JOG (jog), POL (polarity), XSTP (auxiliary stop)
Analog Inputs: P1B-P4B, ASPO, VC3NB/VC3PB, VC4NB/VC4PB
Analog Outputs: DA1/DA2 (8-bit or 12-bit D/A), MET1-MET3 (8-bit D/A)
Communication Interface: TDB/RDB/RTSB/CTSB (RS-232C)
Reset Input: RESET (+5 to +24 V dc)
Frequency Inputs: MSSY, TOIN
5. Connector 7PL
The 7PL connector provides I/O between the SDCC and the SPC or SPCB board, transmitting:
Encoder signals (E1UP/E1DN, E2UP/E2DN, E1Z/E2Z)
SPC analog channels (SPA1, SPA2)
Synchronization signals (SPSYN, SPSYNO)
Serial communication (SPTX, SPRX)
6. Connector 8PL
The 8PL connector provides I/O between the SDCC and the drive terminal board, including:
RS-422 communication (FA, FB)
Encoder interface (EOAB, EOBB, EOMB and their inverted inputs)
General purpose control inputs (CI1-CI8)
7. Connector 11PL
The 11PL connector provides SDCC outputs to meters, including four meter outputs (MTR1-MTR4) driven by an 8-bit D/A converter.
V. Configuration and Settings
1. Hardware Jumper Configuration
The DS200SDCCG1A includes various configurable hardware jumpers, most of which are factory-set. Table 2 lists all jumper definitions, with default settings listed first.
| Jumper | Function | Default Position | Description |
|---|
| JP1 | EEPROM write protect | 2.3 (write enabled) | 1.2 = write inhibited (safe mode) |
| JP7 | Feedback VCO gain | 1.2 (normal gain) | 2.3 = increase gain 6:1 |
| JP8 | Feedback VCO absolute value circuit | 1.2 (bipolar mode) | 2.3 = absolute mode (for analog AC tachometers) |
| JP15 | DCP crystal enable | 1.2 (enabled) | 0 = manufacturing test only |
| JP16 | FLASH program mode | 1.2 (normal read mode) | 2.3 = FLASH reprogramming mode |
| JP22 | MCP crystal enable | 1.2 (enabled) | 0 = manufacturing test only |
| JP23 | DCP DMA channel signal source | 1.2 (from NTB/3TB analog feedback) | 2.3 = from encoder marker input |
| JP33 | CMP crystal enable | 1.2 (enabled) | 0 = manufacturing test only |
2. Wire Jumper Configuration
| Jumper | Function | Default Position | Description |
|---|
| WJ1 | Map MET3 D/A to DAC1 | 0 (SDCCG1, jumper omitted) | 1.2 (SDCCG3, jumper installed) |
| WJ2 | Map MET4 D/A to DAC2 | 0 (SDCCG1, jumper omitted) | 1.2 (SDCCG3, jumper installed) |
| WJ3 | 10 V full scale reference for D/A outputs | 0 (SDCCG1, jumper omitted) | 1.2 (SDCCG3, jumper installed) |
| WJ4 | Identify card group to firmware | 0 (jumper omitted, identifies G1) | 1.2 (jumper installed, identifies G3) |
| WJ5 | Configure logic cell array size | 0 (SDCCG3 jumper omitted) | 1.2 (SDCCG1 jumper installed) |
| WJ7-WJ10 | Configure EEPROM size | As per Table 2 | Specific configuration for all present drive applications |
3. Software Configuration Tools
Any adjustment, downloading, or replacement of software on the SDCC requires the use of one of the following tools:
ST2000: A DOS-based set of software tools for configuring GE DIRECT-O-MATIC® 2000 control equipment.
GE Control System Toolbox: A Windows-based set of software tools for configuring GE DIRECT-O-MATIC® 2000 control equipment.
LynxOS Drive Configurator: A set of software tools designed to run on a personal computer operating with the LynxOS operating system.
VI. Installation and Maintenance
1. Installation Steps
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.
Open Cabinet Door: Access the printed wiring board area.
Disconnect Cables: Carefully disconnect all cables; verify that cables are labeled to simplify reconnection.
Remove Auxiliary Boards: If any auxiliary boards are mounted, remove the mounting screws and take off the auxiliary boards.
Release Snaps: Push back the plastic snaps to remove the old card.
Move Standoffs: Transfer standoffs from the old card to the new card.
Configure New Card: Set all configurable components on the new card to the same positions as on the card being replaced.
Install New Card: Install the new SDCC card, ensuring all snaps snap into position.
Reconnect Cables: Reconnect all cables as labeled, ensuring they are properly seated at both ends.
Install Auxiliary Boards: Reinstall any auxiliary boards and connect cables.
Install Programmer Module: If applicable, plug the keypad into the KPPL connector and snap the cover into place.
2. Replacing/Inserting Software
When replacing an SDCC:
Transfer the four EPROMs (U11, U12, U22, U23) from the old card to the new card.
Transfer the EEPROM (U9) from the old card to the new card.
If the failure symptoms persist, install new EPROMs and a blank EEPROM (shipped with the new card if it is a DS215SDCC) and program the EEPROM using software tools.
When replacing a DCC with an SDCC:
Use the DCC EEPROM to upload the configuration to a file.
Install the new EEPROM in the SDCC and download the configuration file.
According to Table 10, set the software jumpers on the SDCC to match the hardware jumper settings of the DCC.
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 plastic snaps for secure fastening.
Spare Parts Management: It is recommended to keep at least one identical SDCC card on-site as a spare to minimize downtime.
Hardware Adjustments: After replacing a card in an application with critical analog I/O functions, gains and offsets may require fine-tuning to compensate for component tolerance variations.
VII. Applications
The DS200SDCCG1A Drive Control Card is widely used in the following industrial applications:
DC2000 DC Drive Systems: Provides complete control functions for DC motor drives.
AC2000 AC Variable Frequency Systems: Provides control functions for AC motor drives.
EX2000 Excitation Systems: Used for generator excitation control.
TC2000 Turbine Control Systems: Used for turbine control applications.
Multi-Bridge Drive Systems: Supports large multi-bridge drive applications.
System Upgrades: Can replace the 531X301DCC Drive Control Card.
