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Rayal3&4 VFD Ti

This document provides test instructions and requirements for testing an LCI channel, contactor panel, and common control panel. It outlines the necessary test equipment, drawings, preliminary considerations, and detailed test procedures. Key points include testing a wireless SEM rack as part of product enhancement, using only approved test documents, verifying connections and components match drawings, applying preliminary checks, and conducting high voltage testing on auxiliary circuits. Safety protocols like verifying proper grounding and clearances are also emphasized.

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0% found this document useful (0 votes)

42 views57 pages

Rayal3&4 VFD Ti

Uploaded by

Devas Shukla

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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!

" ## $ $ $ %& ' &$ ()( (&%%* ( +,# % --

" +-$-.$ --/
WBS NO : CE/0089-SH1/SH2-70-01 to 06
For LCI Channel, Contactor Panel, Common Control Panel
APGENCO AND DESEIN APPROVED TEST PROTOCOL
DOC. NO.D&PS/ACD/TESTPROT/RAYAL 3,4 REV.01 DTD. 30/11/04.
VIDE DESEIN LETTR REF.1312/CC-20/BLR/106 DTD.14.12.2004.
ONE (1) NO. WIRELESS SEM RACK ALSO TO BE FULLY TESTED IN ONE
CHANNEL. THIS IS PART OF PRODUCT ENHANCEMENT FEATURE. ALL
TESTS EXCEPT TYPE TEST TO BE DONE ON THIS RACK.
In case of any clarification
Contact Drives & Power Supplies Dept. Phone : 8384, 8329, 8346
NOTE:

1. TEMPERATURE RISE (TYPE TEST) IS APPLICABLE FOR THIS PROJECT.

TEST PROCEDURE FOR THE SAME (4SHEETS)IS ADDED AT THE END OF THIS
DOCUMENT.

2. DO NOT START ANY TESTING UNLESS BRAIDED (16 SQ MM CABLE FROM SEM
TO EXTRUSION AND 25 SQ MM CABLE FROM EXTRUSION TO GROUND BUS
ARE PRESENT. CHECK PAINT REMOVED ON EXTRUSION AND SEM AT
CONNECTION POINT AREAS (IF SEM RACK IS NOT PLATED). ALSO 25 SQ MM
CABLE FROM PANEL TO PANEL GROUND BUS SHOULD BE PRESENT.

3. MONITOR INPUT VOLTAGE TO SEM / PSFF / IOMA THROUGHOUT.

4. CHECK WITH ENGG. FOR LATEST / APPLICABLE SCHEMATIC DRAWING NO.

WITH REVISION NO. TESTING TO GET ALL THE APPLICABLE DRAWINGS FROM
WRENCH.

5. USE ONLY WRENCH RELEASED DOCUMENT. ANY OTHER DOCUMENT SHOULD

NOT BE USED. CHECK WITH ENGG FOR LATEST REVISION.

6. CHECK EARTH/CMOS SOCKET AND BRAID IS PRESENT IN THE PANEL.

7. CHECK DOUBLE WIRE WRAP ON SEM BACK PLANE FOR 2A/36 TO C21,
2B/36 TO B11, AND 2C/36 TO C11.

8. SWITCH OFF POWER TO PRINTER CONTROLLER BEFORE INSERTION

OR REMOVAL OF CONNECTORS.

1
TEST EQUIPMENT AND POWER REQUIREMENTS

STRUCTURED LCI FINAL TEST INSTRUCTIONS

I. TEST EQUIPMENT REQUIRED

A. Reactor, 100mH, 100A.

B. Transformer, 100KVA, 415/415V, 3 phase.

C. Transformer with variac on incoming line, 0-15000 volt output, 215KVA, 3 phase.

D. Resistor bank and 200 amp supply.

E. Switch terminal bank

F. 6 NOS, 221 ohm, 1%, 1/4 watt resistors.

G. EVC resistive load bank.

H. Instruments

1. VT100 or VT220 terminal or equivalent.

2. Dual channel oscilloscope with time delay
3. Current probe
4. Digital multimeter
5. Clamp on ammeter
6. Milliohmmeter (usually checked out to incoming inspection)
7. Corona tester
8. QC test software for structured LCI's with AC field exciter (D&PS-SM-QC-
LCI-00 DT:3/3/92 ). CONTACT ENGG DEPT.
9. PLLA Requisition Software CONTACT ENGG DEPT.

Prom set to be returned to Engg. after test.

I. One (1) ED660HNMBA00 null modem if hand held Terminal is used.

II. POWER REQUIREMENTS

A. Auxiliary AC 3 phase, 415 volt, 50 Hz, 100KVA source (adjustable)

B. 230 volt single phase, 50 Hz outlets for test equipment

C. 230 volts, 1 Ph, 50 Hz, 8 Amps UPS supply

IMPORTANT: UPS Power supply to be connected wherever the same is called for in the
Schematics

2
DRAWINGS REQUIRED

III. DRAWINGS REQUIRED

A. Schematic Drawing (please ensure that you are using the correct drawing meant
for this project : 3-660-00-50210( avail from WRENCH)

B. Electronics module elementary ED660LCGAA00 DRG NO 3-660-00-50095

D. I/O module elementary ED660IOMAAOO

E. SFF (field exciter) elementary 80 AMPS rated CE.689.41.DAB.002

F. Power supply elementary ED660PSFFA00. This power supply is used to power the
SEM modules.

PRELIMINARY CONSIDERATIONS

IV. PRELIMINARY CONSIDERATIONS

A. Verify that the panel has been wire checked.

B. Verify variable component values in the SEM module per sheet DA of the drive
elementary.

C. Verify berg jumpers as shown on drive elementary sheet DA.

D. Verify that the SEM module has S4 and S2 header stab connectors tied together with a
jumper and braid cable is present from SEM to extrusion. See if paint removed at both
ends.

E. Install the test software (D&PS-SM-QC-LCI-00) in the HMPG (U22, U23, U24, and
U25) and DMPB (U2 and U3). If any PROMs are installed already, remove it.
HANDOVER PROMS TO ENGG. It will be reinstalled after burning the drive running
(Requisition software) after the end of test.

F. Refer to elementary sheet AF that shows the SFE. Connect the EVC resistive load to
ETB1, ETB2, and ETB3.

G. Inspect all compartments for loose hardware/debris removing any such material prior to
applying power.

H. DO NOT connect source and load side converters together until instructed. Most jobs
will have a jumper between P1 and P2 which will have to be disconnected.

I. Open all circuit breakers, refer to Schematic Drawing.

J. Check with the concerned engineer for any changes. Check if you are using the latest
revision of test instructions applicable for this job.

K. Open or turn off all switches and power supplies.

L. Partially extract all PWB's from the SIM (if used) and SEM (SEM) modules.

3
M. Null all meters.

N. Check the orientation of the SCR symbol stamped on each leg cell module bus and
make sure it is installed in the proper direction.

O. Check the attenuator connections as per the bridge elementary.

P. On each leg cell module verify that all the connections to the HPTF JB,LC,JD.JF
connections are tight.

Q. Refer to drive elementary sheet BF that shows the I/O module outputs and inputs.
Remove any metal jumpers that are called for on this elementary sheet (Note: jumpers
can be on the I/O module terminal strips or on the customer terminal strips if provided.
These jumpers will be installed after test. Connect a 221 ohm, 1/4 watt, 1% resistor
across each of the following 4-20mA outputs:

1) TB80.51 to TB80.52 (Motor Speed Output)

TB80.53 to TB80.54 (Motor Current Output)

ONLY IF TRANSDUCERS FOR MOTOR SPEED & CURRENT TRA1/TRA2 ARE

APPLICABLE FOR THIS M.O OR (REFER SHT.BF)

TB7.12 to TB7.13 (motor speed Output)

TB7.14 to TB7.15 (motor current Output)

ONLY IF TRANSDUCERS FOR MOTOR SPEED & CURRENT TRA1/TRA2 ARE NOT
APPLICABLE FOR THIS M.O OR (REFER SHT.BF)

2) TB7.1 to TB7.2 (CS1P)

TB7.3 to TB7.4 (CS2P)
TB7.5 to TB7.6 (CS3P)
TB6.16 to TB6.17 (CS4P)

These resistors will provide a load for the 4-20 mA outputs.

S. Verify that the panel is grounded per SI (501-09-23).

T. Check component make and type as per device list.

U. Check wire type and size as per wiring chart.

V. Check wire routing and type of wires between shipping sections. Check whether
ferrules are present at both ends.

W. Observe keenly the routing of the high voltage cables, and sufficient clearance to
ground. Check SEM grounded properly and connection given to earth bus through
braid and 16 sq.mm cable. Check braid is attached to moving part of SEM. Check
IOMA body earthed to earth bus and paint scraped. Check continuity to IOMA mother
boards commons with earth. Check cable shorting between earth Busbars at panel
rear.

X. Check routing of leads in power module.It must be as per wiring chart

instructions.Check HV silicone sleeve through which ribbon cable to power module
passes does not touch the Busbars.

Y. Check crimping of connectors & orientation. Check Molex white connector pin
orientation & crimping and pin locking in power modules and all other places in panels.

4
Z. FRP sheets, angles for cable routing at the rear of bridge panel to be mounted on FRP
spacer / insulator to avoid corona. See the routing of High voltage PTFE cables for
clearances in fan and filter and bridge panels.

A1. If ribbon cables are wrapped with copper foil- check earthing at one end at C&EXE
panel. See end at power module has sleeve to prevent unwrap.

A2. Check for a very small air gap clearance between FRP sheets and busbar at the rear of
ACIP and ACOP panels. Check cable gland plate is of aluminium in ACIP and ACOP
with magnet. Check cable wire rack channels through which HV cables pass do not
have aluminium strip.

A3. All C Profiles and extrusions must show continuity to earth bus. Check paint removed
on mounting clamp area for capacitor mounting C profiles. All painted C profiles must
show continuity to earth bus. Scrape paint wherever required.

A4. Check the attenuator connections and sense in each power module from bridge
elementary.

A5. Check connections to snubbers in power module are tight.

A6. Conduct HV Test on all auxiliary circuits as per the following voltage levels. Pl. note
that these are for power auxiliary circuits only.

HV test to be done as follows with grouping:

1) 415V A.C ckt - 2.5 kV FOR 1 MIN

2) 220V A.C ckt - 1.5 kV FOR 1 MIN

Control ckt, heater & illumination ckt

3) 110V A.C ckt - 1.5 kV FOR 1 MIN

CVT, control ckt

4) Less than 60V - 500 V FOR 1 MIN

Electronic ckt, CT, PT secondary etc

5) Potential free contacts - 1.2 kV FOR 1 MIN

- 220V A.C

6) EARTH

Note: No HV test to be done on 1.2 kV main power ckt.

7) Megger before and after HV test with the following voltages:

Megger Test Voltage: D.C volts

415 volts ckt - 1000 V megger

220 volts ckt - 1000 V megger
110 volts ckt - 1000 V megger
24 volts ckt - 500 V megger
Potential free contacts - 1000 V megger

5
CORONA TEST
MAKE CONNECTIONS WITH EQUIPMENT AND INSTRUMENTS AS GIVEN IN FIGURE-1

V. CORONA TEST

A. The Silco bridges are tested as one unit (source and load tied together). Check that
busbar-shorting piece across P1 and P2 is present.

Perform the corona test as per the following instructions:

B. PREPARATION (refer to the bridge elementary)

1. AC line filters: (load and source)

a. Check connections are tight at all points in the power ckt starting from busbar
tapping points. Remove AC filter fuses FU1, FU2, FU3, FU8, FU9 and FU10.

2. DC line filters: (load and source). Remove four DC filter fuses FU4, FU5, FU6,
and FU7

a. Check connections are tight at all points in the power ckt starting from busbar
tapping pts.

3. Current transformers:

a. Short the primary and secondary of each of the eight CTs at their terminals and
check whether they are earthed thro the TBS in the terminal block in ACIP and
ACOP panels.

4. Remove the JH ribbon cable connectors from source and load XTFX’s.

5. Short the P28 supply by shorting TB28-6 to TB 28-8 in AC Input Panel.

6. Electronics module (SEM): Partially extract all PWB's from the SEM in the
control cabinet. Back each PWB out far enough to insure the PWB is not
making contact with the back plane connector.

7. Remove the ribbon cable from the NSFC's.

8. Bridge: Remove all twelve ten-pin ribbon cables (JAs) from the HPTF in the leg
cell modules. Set each cable as far away from the high voltage bus work as
possible and tie them close to earth.

6
7
9. Grounds on the leg cell modules:

a. Make sure the ground connection for the pulse transformer shield
(GND) is securely made and clear of any high voltage leads.

10. Buswork: Use flexible high voltage cables stored in the cabinet to make the
following connections:

a. Jumper L1, L2, L3, P1, N1, M1, M2, M3, P2, and N2 together on the busses in
the back. The connection to the N1 bus may be made by jumpering across leg
STM 4. The connection to the N2 bus may be made by jumpering across leg
LTM 2. This is left to the testing engineer choice.

Make sure that all of the installed jumpers are clear of any grounded surface.
Check all cable jumper lugs are properly crimped and have no sharp edges. All
lugs must have sleeves. Check that HV ckt. Wires are away from the ground.
Check the routing, especially at the top of AC output cubicle. Check whether
there exists a small gap between FRP sheets and busbars. This reduces
corona substantially. Check HV and LV wires are not mixed in cubicles.

11. Corona test in this equipment includes the entire power ckt except MOVs and
Capacitors.

C. CONNECTIONS TO THE CORONA MACHINE

1. Connect power to the corona control unit using the power leads connected to
the corona tester.

2. Ground connections from high voltage transformer ground stab:

a. To I beam to pick up earth

b. To unit under test

3. Make sure the ground stick is in the high voltage transformer.

D. SETUP PROCEDURE FOR CALIBRATION OF DISCHARGE DETECTOR:

(i) 700 AS Unit: Select filtering frequency band: 20 kHz to 200 kHz.

(ii) 700G Gating Unit: Select "NORMAL" Set Gates (2 switches) = "ON"

(iii) 700 CRH Calibration Pulse Generator: Set toggle switch ="ON"

1. Switch on the system and wait for 10 minutes to allow warm up of the system.
At the commencement of every test, standard pulse is fed to the standard
calibration capacitor (Cq = 50 pf:Input No. 3). This is displayed as a pulse of
standard magnitude on the discharge magnitude meter and also on the screen.

2. Set the selector switch "Output PC with Cq" to 200 mark. This means that the
magnitude of the standard pulse is 2V x 50 pf = 100 picocoulomb.

3. Using the "Rotate Pulse" potentiometer, keep the reference pulses within
gating bands. Adjust the "Gate Width" in 700G Unit. Confirm that both pulses
are within the gating bands.

4. Adjust the "Variable Gain Pot" in 700 AS Unit so as to read full scale (100%) on
the discharge magnitude meter. This is equivalent to 100 picocoulomb.
8
5. Notice that the height of the pulses will be approximately 2cm (2 divisions high)
on the discharge screen.

The PD Discharge equipment is now set to read the discharge from the
test object. Switch on the red flashing light.

E. Measurement during Corona Test:

1. Switch off selector switch in 700 CRH Unit to remove pulse from screen.

2. Slowly apply the test voltage as per the reference table below:

CORONA TEST VOLTAGE TABLE

BRIDGE HIGH LOW Engineering note:

VOLTAGE VOLTAGE VOLTAGE This table gives the
0.9KV 1.4KV 1.3KV corona high and low
voltages for 0.9KV,
1.0KV 1.5KV 1.4KV
1.0KV and 1.2KV,
1.2KV 1.9KV 1.7KV
2.3KV, 4.1 KV bridges.
2.3KV 4.2KV 3.8KV
4.1KV 7.2KV 6.9KV

Use these voltages to fill in the test instructions.

3. Rotate position of gate to cover the discharge and take

measurement on the analog discharge magnitude meter, which has already
been calibrated during setup.

4. Turn the variac CW to increase the voltage. Stop increasing voltage at either
1.9kV (high) or when the analog magnitude meter records spikes that are
greater than 100 pC (i.e, greater than full scale on the meter), whichever
comes first.

5. Passing criterion:

a. If the voltage reaches 1.9kV (high) and all of the spikes (if any) are less
than 100 pC (full scale deflection on meter), the unit is good.

< OR >

b. If at 1.9kV (high) there are spikes that are greater than 100 pC,
decrease the voltage by turning the variac CCW until all of the spikes
as recorded on the meter are less than 100%. If the voltage is greater
than or equal to 1.7kV(low), the unit is good.

6. Power down: Turn the variac fully CCW (0 volts), push 'HIV' red stop button,
insert ground stick.

7. If the unit is passed, record the value of the highest spike.

------- pC at ------- kV (Note: 100pC is 2 divisions high)

8. If the unit or section fails corona test, check out the corona sniffer from the QC
tool crib and locate the corona breakdown area(s).

9
9. Possible areas of corona leakage:

a. Check that all the leads are dressed properly and that the connections
are all tight.
b. Make sure that none of the jumper leads are too close to any grounded
surface.
c. Look at the leg cell ground wires and make sure they are not running
too close to any high voltage leads.
d. Make sure the filter fuse control wires are not tied to the fuse itself.
e. Loose connections in power ckt.
f. Shorting wires too close to ground.
g. Cable routing PVC channels may have metal strip underneath. This is
not allowed where HV cable run.
h. Small gap on FRP sheet referred where busbar passes through in
ACIP and ACOP panels.
i. A sudden high increase in discharge at a certain voltage indicates
air breakdown.

F. CORONA TEST COMPLETION (refer to the bridge elementary):

1. AC line filters: Put back 6 nos. fuses FU1 to FU3 and FU8 to FU10.

2. DC line filters: Put back 4 nos. fuses FU4 to FU7.

3. Current transformers: Remove all shortings done on the CTs.

4. Reconnect the JH ribbon cables to source and load XTFXs.

5. Remove the P28 supply shortings (TB28-6 to TB28-8 in ACIP).

6. Reconnect the ribbon cables to the NSFC's.

7. Bridge: Reconnect the twelve ten pin ribbon cables (JA's) to HPTF PWBs in the
leg cell modules.

8. Remove Busbar jumper between P1 and P2.

9. Check no loose shorting wires are left back at places from where they have
been removed.

10. Buswork: Remove the high voltage bus jumpers from the buswork. Also
remove the jumper from the leg cells (if used).

11. Reconfirm routing of all HV cables have not been disturbed during
reconnection. Check spacing, routing.

12. Lower the red flashing light.

AUXILIARY POWER
VI. AUXILIARY POWER

A. Connect control power as tabulated below:

Voltage Terminal Nos.

415 V, 3 PH, 50 Hz TB25-01, 02,03
240 V, 1 PH, 50 Hz TB24-07 & TB24-08

as shown on drive elementary sheet # 1BB.

10
IMPORTANT: For the Project under test, check if power supply input to Bridge Blowers
(Ckt.Breaker CB3 Input) is shown from Common Control Panel (Schematic Drg. sht.1BB03P /
2BB03P) and no internal looping is present. If so, make a temporary cable connection between
2
CB3 input and TB25-01, 02 & 03 (415V supply) with 4mm cable. Remove connection after
completion of all tests.

B. Verify the phase sequence of the control power that was just connected. This is
important for the blower rotation and the field exciter (SFE) test.

C. Close the circuit breaker that controls 240 volt (CB2).

D. Apply 240 volt, 50Hz, and single-phase control power by closing CB2. Verify secondary
of transformer T1, drive elementary sheet 1BB, is 110V AC RMS +/- 10%

E. Close the circuit breaker that controls 415 volts (CB1).

F. Verify that the arrows on all of the blowers are pointing up. The arrows should be
visible from the front of the blower compartment.

G. Put blower select switch located in the control or the fan compartment in 'TOP' (for
redundant fans only). Close circuit breaker CB3. Verify the top blower is on. Check for
proper direction of rotation, air should enter the front of the bridge compartment and
exit the top of the fan compartment when the fan doors are closed.

H. Measure the phase current of each winding. Currents should be within 5% of each
other. Set overload relays ST1OL and ST2OL.

I. Note the overload setting then trip the overload on ST1 shown on drive elementary
sheet AE. Verify that the top blower turns off and the bottom blower turns on. Reset
overload.

J. Put the blower select switch in 'Bottom'. Repeat part D on the bottom blower. Trip
overload on ST2. Top blower should turn on.

POWER SUPPLIES
VII. POWER SUPPLIES

A. With the SEM module circuit boards unplugged, turn on the control power supply.

B. Verify presence of P5, P28, P15, and N15 at the SEM module backplane.

C. Turn off control power.

D. Insert the PWB's, turn control power on, and verify that the power supply remains
constant.

E. With all PWB's in, adjust the power supply to obtain the following voltages at the SEM
module.

1. Adjust R1 on NPPB until P5 = + 5.0 +/- 0.1 volts

2. Adjust R6 on NPSK until P15 = + 15.0 +/- 0.2 volts
3. Adjust R7 on NPSK until N15 = - 15.0 +/- 0.2 volts
4. P28 = +28 volts (not adjustable, should be between 25 and 30 VDC)
Check the voltages at ACIP TB-06 and TB28-08.

11
F. Verify the following I/O module voltages:

1. Output of the I/O module P105 VDC supply (DPSA). You can measure the
voltage on DPSA TP1 (P105).
2. Check for 28 VDC on XBPH TP4 (test point between TB3 and HROA's).
3. Check for -15 VDC on XBPH TP5 (test point between TB3 and HROA's).

INITIALIZATION
VIII. ELECTRONICS MODULE INITIALIZATION

NOTE: If the control module has a HTCA in slot 1F, turn off control power, remove the HTCA,
use a jumper to tie 1F65 to 1F67, and turn control power back on. The HTCA will be
tested as part of the additional tests.

A. Adjust the potentiometers in table 1 to obtain test point voltage values given on drive
elementary sheet DC. If no value is given on the elementary for a particular
potentiometer, do not attempt to adjust it.
TABLE 1
---------------------------------------------------------------
CARD SLOT POT. TEST POINT
---------------------------------------------------------------
SOURCE
NLIB 1C UV (R9) UVR (TP19)
NLIB 1C SUPP (R6) SUPPR (TP16)
NLIB 1C VDC (R4) VDC (TP8)
NOTE: Min on NLIB VDC is full CCW

LOAD
NLIB 1D SUPP (R6) SUPPR (TP16)
NLIB 1D VDC (R4) VDC (TP8)
NOTE: Min on NLIB VDC is full CCW
-----------------------------------------------------------------

B. Set the overvoltage pot. 'OV' (R8) on DLIB (1D) full CW. 'OVA' (TP18) should read
about -11 VDC.

C. Set the overvoltage pot. 'OV' (R8) on DLIB (1C) full CW. 'OVA' (TP18) should read
about -11 VDC.

D. Set the undervoltage pot. 'UV' (R9) on DLIB (1D) full CCW. 'UVA' (TP19) should read
about -3.6 VDC.

E. Set the NSFC (2B) VDC (R1) pot full CCW (min gain).

F. Set the NSFC (2C) VDC (R1) pot full CCW (min gain).

G. Set the NLCB (1E) OSP (R4) pot for -10.5 VDC on OSP (TP10). It will be set to the
elementary value later.

H. Set the NLCB (1E) RTD (R7) pot full CCW or 15 VDC on RTD (DLCB TP11). It will be
set to the elementary value later.

I. Connect the VT100 or VT220 terminal to the HMPG (2F) RS232 port (JB) via the
DS3800HNMB null modem. Verify that J1 berg on the HNMB is in the NORM position
and that the connector marked PROC is attached to the HMPG. Set the terminal up for
2400 baud.

J. Connect a test jumper between HLCB (2E) TIN0 (TP6) and NSFC (2C) ACOM (TP11).
12
K. Turn the DMPB (2F) WREN switch on (the WREN red LED on the DMPB should come on).

L. Reset the HMPG (2F) by shorting HMPG RST and DCOM test points (TP1 and TP2).
After a few seconds, the HMPG IMOK LED should come on. This procedure should
have downloaded the default values into the DMPB EEPROM.

Possible problems:

1. If the HMPG IMOK LED does not come on, the HMPG is probably defective or
the PROMS are installed improperly.

2. If an EEPROM transfer problem message is printed out to the screen, the U4

and/or U5 of the DMPB are defective or the DMPB is bad.

M. Turn the DMPB (2F) WREN switch off (the WREN red LED on the DMPB should go
out).

N. Remove the test jumper between HLCB (2E) TIN0 (TP6) and NSFC (2C) ACOM
(TP11) (jumpers are no longer needed to call test software).

O. Reset the HMPG by shorting HMPG RST and DCOM test points (TP1 and TP2). After
a few seconds, the test menu should be printed out on the screen.

P. Check out hand held terminal and HNMB to be shipped with panel (if applicable):

1. Enter "CTRL A". You should get the "A." prompt.

2. Enter "B<CR>". This changes the baud rate of the HMPG to 300. Change the
terminal baud rate to 300.

3. Enter "CTRL A". You should return to the test menu.

4. Disconnect the VT100 or VT220 and HNMB from the HMPG.

5. Locate the hand held terminal, ED660HNMBA00 ten pin ribbon that will be
shipped with the unit.

6. Remove the back cover of the hand held terminal and set the 6 switches as
follows:

SWITCH - 1 2 3 4 5 6
POSITION - OFF ON OFF ON OFF OFF

7. Connect the hand held terminal to the HMPG (2F) RS232 port (JB) via the
DS3800HNMB null modem. Verify that the HNMB berg jumpers are all to the
pocket terminal setting and that the connector marked PROC is attached to the
HMPG.

8. Plug the ten pin ribbon cable into HNMB JC and DMPB (2F) JA.

9. Enter <CR> from the hand held terminal. The test menu should be printed out.
The characters will be printed out faster than you can read them, but the last
few characters should be "NUMBER?".

10. Enter "11" and verify that "11" is on the hand held terminal display. Enter
another "1". This will generate an error and the menu will be printed out.

13
Q. Reconnect the VT100 or VT220 terminal to the HMPG (2F) RS232 port (JB) via the
DS3800HNMB null modem. Change the terminal baud rate to 2400. Reset the HMPG
(2F) by shorting HMPG RST and DCOM test points (TP1 and TP2). After a few
seconds, the HMPG IMOK LED should come on and the test menu should be printed
out.

EEPROM CHECK AND SELF-TEST

IX. EEPROM CHECK

A. Run EEPROM CHECK by typing "1<CR>".

B. If "EEPROM INIT. FAIL, RETURN TO CONTINUE" is printed out, one or more of the
following things could be wrong:

1. U4 and/or U5 on the DMPB are bad.

2. The DMPB is bad.
3. The HMPG is bad.
4. The EEPROM initialization has NOT been done.

Do NOT continue until this problem has been fixed.

X. SELF TEST

A. Refer to elementary sheet AF and verify that power is applied to the field exciter
package (DS3820SFF) located in the back of the control compartment.

B. Select SELF TEST (2) by typing "2" followed by "RETURN". Self-test will be run until a
failure is detected or until it runs the last test. If self-test fails, a message will be printed
on the screen explaining the failure and giving possible solutions. Self-test should pass
all tests before going on.

PLEASE RETURN BLANK PROMS TO ENGINEERING FOR PROGRAMMING.

HISA INPUTS
XI. HISA INPUTS

A. Refer to drive elementary sheets BD and BE, which show the inputs to the I/O module
which go to the HRIA's in the I/O module to the HISA in the SEM module.

NOTE: The HRIA in slot 2A is the left one and the HRIA in 2B is the right.

B. Look at the I/O module, XBPG. If any wiring is going to TB4, TB5, and TB6, remove the
wiring or replace the top section of the terminal strip with a blank section.

C. Verify that HISA (1B) LED's I00 thru I17 are off.

D. Use table 2 to verify that the inputs are getting to SEM module by shorting the inputs
specified and looking for the HISA (1B) LED to come on. Only one of the HISA LED's
from the I00 thru I17 group should be on at one time.

NOTE: TB4 and TB5 inputs are routed thru the HRIA in I/O module slot 2B (lower right
slot) to the HISA. The rest of the HISA LEDs are driven by the HRIA in slot 2A
(lower left slot).

14
TABLE 2

SHORTED TB POINTS HISA LED

TB4-1 to TB4-2 I00
TB4-3 to TB4-4 I01
TB4-5 to TB4-6 I02
TB4-7 to TB4-8 I03
TB4-9 to TB4-10 I04
TB4-11 to TB4-12 I05
TB4-13 to TB4-14 I06
TB4-15 to TB4-16 I07
TB5-1 to TB5-2 I08
TB5-3 to TB5-4 I09
TB5-5 to TB5-6 I0A
TB5-7 to TB5-8 I0B
TB5-9 to TB5-10 I0C
TB5-11 to TB5-12 I0D
TB5-13 to TB5-14 I0E
TB6-1 to TB6-2 I0F
TB6-1 to TB6-3 I10
TB6-1 to TB6-4 I11
TB6-1 to TB6-5 I12
TB6-1 to TB6-6 I13
TB6-1 to TB6-7 I14
TB6-1 to TB6-8 I15
TB6-1 to TB6-9 I16
TB6-10 to TB6-11 I17

E. Move the LOCAL/REMOTE switch to the REMOTE position. Verify that the HISA I19
LED is out.

F. Move the LOCAL/REMOTE switch to the LOCAL position. Verify that the HISA I19 LED
is on.

G. The HISA I1B LED should be on. It is tied to the P105 power supply thru the HRIA in
slot 2A.

H. HISA LEDs I1C and I1D should be off.

I. Push the RESET button on the DOOR MODULE located above the printer. HISA LED
I1C should come on.

J. Push the DRIVE STATUS button on the DOOR MODULE. HISA LED I1D should come
on.

K. Replace the top sections of TB4, TB5, and TB6 if any have been removed or reinstall
the wiring.

HRDD AND SEM MODULE RELAY OUTPUTS

XII. HRDA AND SEM MODULE RELAY OUTPUTS

A. Refer to drive elementary sheets BG, BH and BJ, which show the outputs from the I/O
module. Most of the outputs are driven by the HRDA in the SEM module thru the
HROA's in slots 1A and 1B of the I/O module.

NOTE: The HROA in slot 1A is the left one and the HROA in 1B is the right.

15
B. Look at the I/O module, XBPH. If any wiring is going to TB1, TB2, and TB3 remove the
wiring or replace the top section of the terminal strip with a blank section. Also remove
any wiring that might disturb checking the relay contacts wired to TB8 (see drive
elementary sheet BJ).

C. Put the I/O module CHNL SEL switch in the ON position and I/O module
LOCAL/REMOTE switch in the LOCAL position. Install a jumper from TB3-12 to TB3-
13.

D. Select RELAY DRIVER TEST (3) by typing "3" followed by "RETURN". "RELAY TEST
1, "RETURN" TO CONTINUE, "E" TO EXIT" should be printed out on the screen.

E. Verify that the HRDD (SEM slot 1A) LED's and NLCB (SEM slot 1E) LED's are all out
(except the yellow IMOK LED's).

F. Refer to the I/O module. Verify that the following HROA LEDs are on:
R8 - HROA 1A
R8 - HROA 1B
R9 - HROA 1A

All other HROA LED's should be out. The RUN, FAULT, ALARM, and READY (if used)
lights on the front of the control compartment door should be off. Verify that the "PUSH
TO TEST" feature of the lights works.

G. Verify that the SWGR relay and RUN relay are dropped out. Also verify that the ECX
relay and EC contactor are dropped out if used.

H. For relay tests 2 thru 10, use table 3 to check for open or short between the terminal
points listed and verify that the LEDs listed are on for each of the RELAY TESTS. To
go to the next relay test, hit "RETURN" on the terminal.

TABLE 3

==================================================================================
RELAY OPEN SHORTED
TEST POINTS POINTS LED(s)
==================================================================================

2 TB1-2 to TB1-3 TB1-1 to TB1-2 NLCB (SEM 1E) FT2

TB1-16 to TB1-15 HROA (I/O 1B) R1
The FAULT light on the door should also be on

3 TB1-1 to TB1-2 TB1-4 to TB1-5 HRDD (SEM 1A) 0

TB1-5 to TB1-6 TB2-17 TO TB1-17 HROA (I/O 1B) R2
TB1-16 to TB1-15

4 TB1-4 to TB1-5 TB1-7 to TB1-8 HRDD (SEM 1A) 1

TB1-8 to TB1-9 HROA (I/O 1B) R3

5 TB1-7 to TB1-8 TB1-10 to TB1-11 HRDD (SEM 1A) 2

TB1-11 to TB1-12 HROA (I/O 1B) R4

6 TB1-10 to TB1-11 TB2-6 to TB2-7 HRDD (SEM 1A) B

TB2-7 to TB2-8 HROA (I/O 1A) R2

7 TB2-6 to TB2-7 TB2-9 to TB2-10 HRDD (SEM 1A) C

TB2-10 to TB2-11 HROA (I/O 1A) R3

16
8 TB2-9 to TB2-10 TB2-12 to TB2-13 HRDD (SEM 1A) D
TB2-13 to TB2-14 HROA (I/O 1A) R4
The ALARM light on the door should also be on.

9 TB2-12 to TB2-13 TB2-1 to TB2-2 HRDD (SEM 1A) A

TB2-2 to TB2-3 HROA (I/O 1A) R1
TB2-4 to TB2-5
The RUN light on the door should also be on.
Verify that TB3-16 is at 105 VDC.

10 TB2-1 to TB2-2 TB2-15 to TB2-16 HRDD (SEM 1A) E

TB2-4 to TB2-5 HROA (I/O 1A) R5

I. Hit "RETURN" to go on to RELAY TEST 11. Verify the following:

1. TB2-15 to TB2-16 should be open.
2. HRDD (SEM 1A) light 3 on.
3. HROA (I/O 1B) light R5 on.
4. ECX relay and the EC contactor picked up (if used)
5. HISA (SEM 1B) light I17 on.
6. HISA I18 LED is off.

J. Hit "RETURN" to go on to RELAY TEST 12. Verify that HRDD (SEM 1A) light 5 and
HROA (I/O 1B) light R7 are on.

K. Push and release the I/O module LOCAL START button. Verify the following:

1. TB8-5 to TB8-6 shorted.

2. TB3-11 is at 105 VDC.
3. TB3-9 is at 105 VDC.
4. HISA I18 LED is on.

L. With a meter still on TB3-9 (should be at 105 VDC), move the I/O module CHANNEL
SELECTOR switch to OFF, the 105 VDC should go away. Move the CHANNEL
SELECTOR to ON, push LOCAL START, the 105 VDC should come back.

M. Move the I/O module LOCAL/REMOTE switch to REMOTE, the 105 VDC should go
away. Move the LOCAL/REMOTE switch to LOCAL, push LOCAL START, the 105
VDC should come back.

N. Push the I/O module LOCAL STOP, the 105 VDC should go away. Verify that TB8-7 to
TB8-8 is shorted.

O. Hit "RETURN" to go on to RELAY TEST 13. Verify that HRDD (SEM 1A) light 4 and 5
are on and that HROA (I/O 1B) light R6 and R7 are on. Push LOCAL START and verify
that TB3-7 is at 105 VDC.

P. Hit "RETURN" to go on to RELAY TEST 14. Connect the meter to TB3-14 with it set up
to measure 105 VDC. It should NOT read 105 VDC at this time.

Q. Turn the RTD pot (NLCB 1E R7) full CW and press and release the HLCB (2E) FAULT
RESET switch (SW1). Verify the following:

1. NLCB (SEM 1E) RSRT LED is on.

2. HROA (I/O 1A) light R6 is on.
3. TB3-14 is at 105 VDC.

17
R. Hit "RETURN" to go on to RELAY TEST 15. Verify the following:

1. NLCB (SEM 1E) RSRT LED is off.

2. HROA (I/O 1A) light R6 is off.
3. TB3-14 is at 0 VDC.
4. NLCB (SEM 1E) FT1 is on.
5. HROA (I/O 1A) light R7 on.
6. TB3-4 is at 105 VDC.

S. Adjust the RTD pot (NLCB 1E R7) to obtain RTD (TP11) test point voltage values given
on drive elementary sheet DC. If no value is given, turn the RTD pot full CCW.

T. Hit "RETURN" to go on to RELAY TEST 16. Verify that the READY light, if there is one,
on the front of the door is on.

U. Hit "RETURN" to go on to RELAY TEST 17. Verify the following:

1. TB3-4 is at 0 VDC.

2. Jumper TB3-1 to TB3-2. Verify:

a. HROA (I/O 1B) light R9 on.
b. TB3-4 and TB3-3 are at 105 VDC.
c. TB8-1 to TB8-2 is open.
d. TB8-3 to TB8-4 is shorted.
e. HISA I1A LED is on.

3. Remove jumper from TB3-1 to TB3-2.

4. Jumper TB3-1 to TB3-5. Verify:

a. TB8-1 to TB8-2 is shorted.
b. TB8-3 to TB8-4 is open.
c. HISA I1A LED is off.
5. Remove jumper from TB3-1 to TB3-5.

V. Hit "RETURN", "ALL CLOSED, RETURN TO CONTINUE" will be printed out. Verify
that all of the HRDD (SEM 1A) relay driver LEDs are on.

W. Hit "RETURN". If "HLCB FAULT RESET (SW1) ON, SHOULD NOT BE" is printed out,
verify that HLCB SW1 (2E) is in the center position.

X. After about 2 seconds, "ALL OPEN, RETURN TO CONTINUE" will be printed out.
Verify that all of the HRDD (SEM 1A) relay driver LEDs are off and the HMPG (2F)
IMOK LED is off.

Y. Hit "RETURN", "ALL CLOSED, RETURN TO CONTINUE" will be printed out. Verify
that all of the HRDD (SEM 1A) relay driver LEDs are on and the HMPG (2F) IMOK LED
is on.

Z. Enter "E" to exit the relay test and return to the test menu screen.

NOTE. Replace the top sections of TB1, TB2, and TB3 if any have been removed
or reinstall the wiring. Replace wiring to TB8.

ANALOG I/O TEST

XIII. ANALOG I/O TEST

A. Select ANALOG I/O TEST (4) by typing "4" followed by "RETURN". The ANALOG I/O
TEST menu should be printed out.

18
B. LOCAL SPEED POT

1. Select the local speed pot test (1) by typing "1".

2. The screen will have "FULL CW, RETURN TO CONTINUE" printed out. Turn
the LOCAL SPEED POT full CW and type return. Full CW should give you 15
VDC out of the wiper of the pot.

3. The value of the reading will be printed to the screen and a "OK" or "FAILED"
message. See appendix B at the end of the test instructions if there is a
problem.

4. The screen will have "FULL CCW, RETURN TO CONTINUE" printed out. Turn
the LOCAL SPEED POT full CCW and type return. Full CCW should give you
0.0 VDC out of the wiper of the pot.

5. The value of the reading will be printed to the screen and a "OK" or "FAILED"
message. See appendix B at the end of the test instructions if there is a
problem.

6. If either test fails, set the pot to that position and trouble shoot the signal path.
Refer to appendix B at the end of the test instructions for the signal path.

C. D/A 4 OUT TEST

1. Select the D/A 4 OUT test (2) by typing "2".

2. The screen will have "0.0 VDC, RETURN TO CONTINUE" printed out. Connect
a DVM to TB7.10 and TB7.11 with the positive lead on TB7.10. The voltage
should be 0.0 +/- 0.15 VDC.

3. Type "RETURN". The screen will have "7.5 VDC, RETURN TO CONTINUE"
printed out. The voltage should be 7.5 +/- 0.15 VDC.

4. Type "RETURN". The screen will have "-7.5 VDC, RETURN TO CONTINUE"
printed out. The voltage should be -7.5 +/- 0.15 VDC.

5. Type "RETURN" to return to the analog I/O test menu.

6. If any of the tests fail, recall the test and go to the point of failure to verify the
signal path. Start by verifying that the proper voltage is on the HLCB (2E) DA4
test point (TP5). Refer to appendix B at the end of the test instructions for the
signal path.

D. A/D 7 IN TEST

1. Install the following jumpers:

a. TB7.10 TO TB7.16.
b. TB7.11 TO TB7.17.

2. Select the A/D 7 IN test (3) by typing "3".

3. The test will run automatically printing out the results and an "OK" or "FAIL"
message. If any test fails, verify that the TB jumpers are installed properly and
rerun the test. Refer to appendix B at the end of the test instructions for the
signal path.

19
4. Remove the following jumpers:
a. TB7.10 TO TB7.16.
b. TB7.11 TO TB7.17.

E. SPEED REF IN TEST

1. Install the following jumpers:

a. TB7.10 TO TB7.8.
b. TB7.11 TO TB7.9.

2. Select the speed ref in test (4) by typing "4".

3. "ENTER 1 FOR CURRENT OR 2 FOR VOLTAGE -" will be printed out. Refer
to elementary sheet 1DA which shows the berg jumpers. If the DLCB BJ1 and
BJ2 jumpers are in the "20mA" position, enter "1". If they are in the "VIN"
position, enter "2".

4. The test will drive the SPEED REF IN with 0.0 VDC. If the signal passes, an
"OK" message followed by "RETURN TO CONTINUE" will be printed out.

If it fails, a "FAIL" message will be printed and the test will end. If the test fails,
verify that the TB jumpers are installed properly, verify that the DLCB (1E) berg
jumpers are in the proper position, and rerun the test. Refer to appendix B at
the end of the test instructions for the signal path.

5. Hit "RETURN", the test will drive the SPEED REF IN with a positive signal. If
the voltage is proper, an "OK" message followed by "RETURN TO CONTINUE"
will be printed out.

If it fails, a "FAIL" message will be printed and the test will continue. If the test
fails, verify that the TB jumpers are installed properly, verify that the DLCB (1E)
berg jumpers are in the proper position, and rerun the test. Refer to appendix B
at the end of the test instructions for the signal path.

6. Remove the following jumpers:

a. TB7.10 TO TB7.8.
b. TB7.11 TO TB7.9.

SPEED REF CIRCUIT CHECK FOR REMOTE REFERENCE:

1. Exit all tests.

2. Set the Local/Remote Switch on IOMA Module in the REMOTE position

3. Check that the Berg Jumper in NLCB Module is in 20mA position.

4. Using a mA Current Source, connect the same across IOMA TB7-8 and 9
+ve to TB7-8 (SPDRP - Scheme Sht. 1BF51E / 2BF51E)
-ve to TB7-9 (SPDRN - Scheme Sht. 1BF53E / 2BF53E)

5. Apply 4 mA current input.

6. Check voltage across Test Point REF on NLCB Module is 2V +/- 0.2 V

7. Repeat for 20 mA current input.

8. Check voltage across Test Point REF is 9.5V +/- 0.2 V

9. If the above is OK, test is passed.

20
10. Put back the Local/Remote Switch on IOMA in the LOCAL position.

F. MOTOR CURRENT OUT

1. Select the MOTOR CURR OUT test (5) by typing "5".

2. "CURRENT OFF, RETURN TO CONTINUE" will be printed out. Verify the

following voltages:

a. SEM module, backplane pin 1C-34 is 0.0 +/- 0.1 VDC.

b. Voltage across the motor current meter (if used) is 0.0 +/- 0.1 VDC.
c. Voltage from I/O module
TB7.14 to TB7.15 (IF TRANSDUCERS FOR MOTOR CURRENT &
SPEED ARE NOT APPLICABLE FOR THIS M.O)
OR
TB80.53 to TB80.54 (IF TRANSDUCERS FOR MOTOR CURRENT &
SPEED ARE APPLICABLE FOR THIS M.O)
REFER SHT.BF
(across the 221 ohm resistor) Is 0.884 +/- 0.1 VDC.

3. Type "RETURN". "CURRENT ON, RETURN TO CONTINUE" will be printed

out. Adjust DLIB (1C) IM (R5) for 5.00 VDC on SEM module backplane pin 1C-
34.

a. Voltage across the motor current meter (if used) is 5.0 +/- 0.1 VDC.
Adjust the meter for ½ scale deflection (adjustment on back of meter).
b. Voltage from I/O module TB7.14 to TB7.15 (across the 221 ohm r
resistor) is 2.65 +/- 0.1 VDC.

4. Type "RETURN" to return to the analog I/O test menu.

5. If any of the tests fail, recall the test and go to the point of failure to verify the
signal path. Refer to the signal path in appendix B at the end of the
test instructions.

G. HORSE POWER

1. Select the HORSE PWR TEST (6) by typing "6".

2. "0.0 VDC, RETURN TO CONTINUE" will be printed out. Verify the following
voltages:

a. HLCB (2E) DA3 test point (TP4) is at 0.0 +/- 0.1 VDC.
b. SEM module, backplane pin 1E-20 is 0.0 +/- 0.1 VDC.
c. Voltage across the horse power meter (if used) is 0.0 +/- 0.1 VDC.

3. Type "RETURN". "-7.5 VDC, RETURN TO CONTINUE" will be printed out.

Adjust DLCB (1E) HPM (R5) for 7.50 VDC on SEM module backplane pin 1E-
20. Verify the following voltages:

a. HLCB (2E) DA3 test point (TP4) is at -7.5 +/- 0.1 VDC.

4. Type "RETURN". "FULL SCALE, RETURN TO CONTINUE" will be printed out.

Adjust DLCB (1E) HPM (R5) for 10.00 VDC on SEM module backplane pin 1E-
20.

5. Voltage across the horse power meter (if used) is 10.00 +/- 0.1 VDC. Adjust the
meter for full scale deflection (adjustment on back of meter).

21
6. Type "RETURN" to return to the analog I/O test menu.

7. If any of the tests fail, recall the test and go to the point of failure to verify the
signal path. Start by verifying that the proper voltage is on the HLCB (2E) DA3
test point (TP4). Refer to appendix B at the end of the test instructions for the
signal path.

H. D/A 1 OUT

1. Select the D/A 1 OUT (7) by typing "7".

2. "0.0 VDC, RETURN TO CONTINUE" will be printed out.

Verify the following voltages:

a. HLCB (2E) DA1 test point (TP2) is at 0.0 +/- 0.1VDC.

3. Type "RETURN". "7.5 VDC, RETURN TO CONTINUE" will be printed out.

Verify the following voltages:

a. HLCB (2E) DA1 test point (TP2) is at 7.5 +/- 0.1VDC.

4. If any of the tests fail, recall the test and go to the point of failure to verify the
signal path. Refer to appendix B at the end of the test instructions for the signal
path.

I. D/A 2 OUT

1. Select the D/A 2 OUT (8) by typing "8".

2. "0.0 VDC, RETURN TO CONTINUE" will be printed out.

Verify the following voltages:

a. HLCB (2E) DA2 test point (TP3) is at 0.0 +/- 0.1VDC.

3. Type "RETURN". "7.5 VDC, RETURN TO CONTINUE" will be printed out.

Verify the following voltages:

a. HLCB (2E) DA2 test point (TP3) is at 7.5 +/- 0.1VDC.

4. If any of the tests fail, recall the test and go to the point of failure to verify the
signal path. Refer to appendix B at the end of the test instructions for the signal
path.

J. SFE CURRENT OUT

1. Select the SFE CURR OUT test (9) by typing "9".

2. "CURRENT OFF, RETURN TO CONTINUE" will be printed out. Verify the

following voltages:

a. NSFE(2A) EIM (TP10, 5th from top) 0.0 +/- 0.1 VDC.

3. Type "RETURN". "CURRENT ON, RETURN TO CONTINUE" will be printed

out. Adjust DSFE(2A) EIMTR (R1) for 7.5 VDC on NSFE (2A) EIM (TP10, 5th
from top). (Note: NLIB (1C/1D) OV LED and the FAULT light could come on
during this test.)

4. Type "RETURN" to return to the analog I/O test menu.

22
5. If any of the tests fail, recall the test and go to the point of failure to verify the
signal path. Refer to the signal path in appendix B at the end of the test
instructions.

K. Enter "E" to exit the ANALOG I/O TEST.

L. Verify the following output signals with their inputs at zero:

MOTOR SPEED:
TB7.12 to TB7.13 (IF TRANSDUCERS FOR MOTOR SPEED &
CURRENT TRA1/TRA2 ARE NOT
APPLICABLE FOR THIS M.O - REFER
SHT.BF)
OR
TB80.51 to TB80.52 (IF TRANSDUCERS FOR MOTOR SPEED &
CURRENT TRA1 / TRA2 ARE APPLICABLE
FOR THIS M.O - REFER SHT.BF)

(across 221 ohm resistor) should be 0.884 +/- 0.1 VDC.

MOTOR SPEED METER - Verify that there is 0.0 +/- 0.1 VDC across the motor speed
meter (if used).

MOTOR VOLTAGE METER - Verify that there is 0.0 +/- 0.1 VDC across the motor
voltage meter (if used).

See appendix B at the end of the test instructions for signal path information if any of
the above tests fail.

PRINTER TEST WITH DOOR MOUNTED DIGITEC PRINTER – ONLY IF APPLICABLE

XIV. PRINTER TEST

A. Select PRINTER TEST (5) by typing "5" followed by "RETURN".

B. The door-mounted printer should print out a message in the following format:

10/26/50 11:11:11 <- double high (this format, but not real time/date and not this exact
time/date)
PRINTER <- double wide/double high (CAPS)
TEST <- double wide/double high (CAPS)
Printer test <- normal print (small letters)

The printout should be printed so that it is upside down as it comes out of the printer.
Also, a form feed should be printed at the end of the printout so that the printout can be
torn off without having to feed any paper and without losing any of the test printout.

If the printer does not print out or if one of the following failure messages is printed out,
the test fails:

1. "DOOR MODULE PRINTER DID NOT RESPOND". This message means that
either the RS232 cable to the printer is not connected or that power is not
applied. See appendix B at the end of the test instructions for the signal path.

2. "DOOR MODULE PRINTER ERROR". This message means that one of the
following things might be wrong:

a. out of paper
b. printer door open
23
c. printer print buffer is full
d. TEST switch is pressed
e. printer in SET CLOCK mode
f. printer mechanism failure

3. "DOOR MODULE PRINTER STALLED". This message means that the printer
has not accepted a character in 5 seconds. This could happen if the printer
failed while it was receiving the test message.

4. If the printer prints out "garbage", verify that the switches inside the printer are
set up per elementary sheet DA. If they need to be reset, power down printer,
reset the switches, then power back up

SOURCE GATE TEST

XV. SOURCE GATE TEST

A. Select SOURCE GATE TEST (6) by typing "6" followed by "RETURN". "CELL 1"
should be printed out indicating that source side cell 1 is firing.

B. Connect channel one of the oscilloscope to HLCB (2E) 'SFT3' (TP10). Trigger the
scope on channel 1.

1.2 kV BRIDGE FRONT VIEW

SOURCE LOAD

STM1 LTM1

STM4 LTM4

STM3 LTM3

STM6 LTM6

STM5 LTM5

STM2 LTM2

2 DEVICES IN SERIES PER MODULE ANODE REAR,CATHODE FRONT

C. The following is the test set up and test for the STM1 leg:

1. Verify that the red gate pulse LED on the HPTK of the leg being fired is on. All of the
other HPTK pulse LEDs should be out.

2. Connect the current probe to the scope and hook the probe to the gate lead (white
wire) of the first SCR in the leg being fired (see below) with the arrow on the current
probe pointing away from the gate lead termination point on the HPTK card.

3. Set the scope up to display two or three individual gate pulses

(10usec/division).
24
4. Verify that the ON pulse is 15 usec long with 30 usec between pulses. If the
ON pulse is 30 usec wide and there is only 15 usec between pulses, the pulse
transformer or gate leads to the HPTK are backwards.

5. Verify that the SCR gate current waveform has the following characteristics:

a. The first pulse should have a peak value greater than 400 mA.

b. The first pulse has a 10% to 90% rise time of less than 0.5
microseconds.

c. Check the supply input voltage to PSFF power supply if these are not
met.

6. There are two series cells, move the current probe to the second cell in the leg
and verify its gate pulse characteristics.

D. Type "RETURN". "CELL 2" should be printed out indicating cell 2 is firing. The STM2
cells should be firing. Repeat step C-1 thru C-6 for STM2.

E. Type "RETURN". "CELL 3" should be printed out indicating cell 3 is firing. The STM3
cells should be firing. Repeat step C-1 thru C-6 for STM3.

F. Type "RETURN". "CELL 4" should be printed out indicating cell 4 is firing. The STM4
cells should be firing. Repeat step C-1 thru C-6 for STM4.

G. Type "RETURN". "CELL 5" should be printed out indicating cell 5 is firing. The STM5
cells should be firing. Repeat step C-1 thru C-6 for STM5.

H. Type "RETURN". "CELL 6" should be printed out indicating cell 6 is firing. The STM6
cells should be firing. Repeat step C-1 thru C-6 for STM6.

I. Type "E" to exit the test and return to the menu screen.

LOAD GATE TEST

XVI. LOAD GATE TEST

A. Select LOAD GATE TEST (7) by typing "7" followed by "RETURN". "CELL 1" should be
printed out indicating that load side cell 1 is firing.

B. Connect channel one of the oscilloscope to HLCB (2E) 'SFT3' (TP10). Trigger the
scope on channel 1.

C. The following is the test set up and test for the LTM1 leg:

1. Verify that the red gate pulse LED on the HPTF of the leg being fired is on. All
of the other HPTF pulse LEDs should be out.

2. Connect the current probe to the scope and hook the probe to the gate lead
(white wire) of the first SCR in the leg being fired (see below) with the arrow on
the current probe pointing away from the gate lead termination point on the
HPTF card.

25
4. Verify that the ON pulse is 15 usec long with 30 usec between pulses. If the
ON pulse is 30 usec wide and there is only 15 usec between pulses, the pulse
transformer or gate leads to the HPTF are backwards.

5. Verify that the SCR gate current waveform has the following characteristics:

a. The first pulse should have a peak value greater than 1000 mA.

b. The first pulse should be 500 mA for greater than 8 microseconds.

c. The second pulse should have a peak value greater than 625 mA.All
other points same as XV 5C source gate test.

6. There are three series cells, move the current probe to the second cell in the
leg and verify its gate pulse characteristics. Repeat for third.

D. Type "RETURN". "CELL 2" should be printed out indicating cell 2 is firing. The LTM2
cells should be firing. Repeat step C-1 thru C-6 for LTM2.

E. Type "RETURN". "CELL 3" should be printed out indicating cell 3 is firing. The LTM3
cells should be firing. Repeat step C-1 thru C-6 for LTM3.

F. Type "RETURN". "CELL 4" should be printed out indicating cell 4 is firing. The LTM4
cells should be firing. Repeat step C-1 thru C-6 for LTM4.

G. Type "RETURN". "CELL 5" should be printed out indicating cell 5 is firing. The LTM5
cells should be firing. Repeat step C-1 thru C-6 for LTM5.

H. Type "RETURN". "CELL 6" should be printed out indicating cell 6 is firing. The LTM6
cells should be firing. Repeat step C-1 thru C-6 for LTM6.

I. Type "E" to exit the test and return to the menu screen.

J. Turn off control power.

SOURCE BRIDGE HIGH VOLTAGE TEST

XVII. SOURCE BRIDGE HIGH VOLTAGE TEST

A. Connect 0-15000 VAC test power to incoming bus L1, L2, L3. Refer to figure 5. Phase
sequence should be 1-2-3. Make sure there are no external connections between P1
and P2 or N1 and N2. (Check for open circuit with an ohmmeter).

SOURCE BRIDGE HIGH VOLTAGE TEST HOOK UP

L1 P1 P2 M1
1 Source
L2 Bridge M2
2
L3 N1 N2 M3
3

0-4500 VAC
TEST
TRANSFORMER
Figure - 5
26
B. Turn on control and bridge power. Bridge fans MUST be running, the fan door(s) must
be closed, and all of the removable bridge panels should be in place except for those
removed to wire in the bus voltage. This will insure that the leg cell modules get the air
flow that is required to keep them from overheating.

C. Slowly increase the source bridge voltage to nominal line-to-line voltage of # 1.20
KVRMS. (Note: A high input impedance meter (Fluke 8050 or equivalent) must be used
to make this measurement. DO NOT use a Simpson.)

D. Using an oscilloscope and multimeter, measure the voltage on NSFC (2C) 'VBA' (TP7),
'VCB' (TP8), and 'VAC' (TP9). Each voltage should measure approximately 3.393
VRMS (source nominal) with a phase sequence of TP7, TP8, and TP9. If the voltage is
not the proper magnitude, verify that the source XTFX R43 to R52 components is right.
(see elem. sheet DA).

E. Measure the integrated voltage signals on the NLIB (1C) FAB (TP1), FBC (TP2), and
FCA (TP3). Each side should have balanced signals and measure approximately 4.75
VRMS. Adjust the corresponding pots (R1, R2, R3) on the DLIB (1C) if necessary.

F. Adjust DLIB (1C) R7 (VM) until backplane pin 1C-10 reads 10.0 VDC.

G. Connect a DVM to NSFC (2C) -VDC (TP11) and verify that the voltage is 0.0 VDC.

H. With the line-to-line test voltage at the nominal voltage, select the SOURCE BRIDGE
POWER test (8) by typing "8" followed by "RETURN". The test software does a
preliminary check on some of the SEM module inputs. A message will be printed out if
anything is wrong. These problems must be cleared before you can go on.

I. If there are any faults or alarms, a message will be printed on the screen. Clear all
faults, if any, and push the RESET button on the control panel door. The following
message should be printed on the screen:

READY
PUSH I/O MODULE "START" TO START FIRING "E" TO RETURN TO MENU IF
FIRING DOES NOT START The READY light (if used) on the control panel door
Should be on.
J. Connect channel one of the oscilloscope to HLCB (2E) 'VA1' (TP12) and trigger on
this signal. Adjust the variable time/division scale so that one period equals six major
divisions. (i.e. 60 degrees per major division or 12 degrees per minor division).

K. Connect channel two of the scope to NSFC (2C) SIG1 (TP1) and verify that the cells
are not firing.

L. Push the I/O module "START” button. "RUNNING" should be printed out on the
screen. SIG1 firing should start 120 degrees (2 major divisions) +/- 12 degrees after the
rising edge of VA1 and be 120 degrees (2 major divisions) long. The RUN light on the
control panel door should be on. If not, verify that TB3-12 to TB3-13 is jumpered.

M. Connect channel two of the scope to NSFC (2C) –VDC (TP11). Verify that there are 6
humps on VDC per cycle. All off the humps should be approximately equal. Further
there should not be any spurious pulses in SIG-1 to SIG-6 in NSFC 2C waveforms
when firing angle is varied from full retard to full advance.

N. Slowly decrease the source bridge voltage to 1/2 nominal line-to-line voltage. SOURCE
LOW LINE fault should occur within 10 seconds (printed out to screen). Verify that the
FAULT light on the control panel door is on.

O. Exit the SOURCE BRIDGE test by typing "E" and return to the menu screen.
27
P. Reduce the bridge voltage to zero, and turn off all power.

WARNING: Turn the variac on the high voltage transformer down so that the
voltage is zero BEFORE opening the breakers.

Q. Disconnect the 0-15000 VAC Source from L1, L2, and L3.

LOAD BRIDGE HIGH VOLTAGE TEST

XVIII. LOAD BRIDGE HIGH VOLTAGE TEST

A. Connect 0-4500 VAC test power to incoming bus M1, M2, M3. Refer to figure 6. The
transformer should be hooked up delta to delta. Phase sequence should be 1-2-3. Make
sure there are no external connections between P1 and P2 or N1 and N2. (Check for open
circuit with a ohmmeter).

LOAD BRIDGE HIGH VOLTAGE TEST HOOK UP

L1 P1 P2 M1
Source Load 1
L2 Bridge Bridge M2
2
L3 N1 N2 M3
3

0-4500 VAC
TEST
TRANSFORMER
Figure - 6

B. Turn on control and bridge power. Bridge fans MUST be running, the fan door(s) must
be closed, and all of the removable bridge panels should be in place except for those
removed to wire in the bus voltage. This will insure that the leg cell modules get the
airflow that is required to keep them from overheating.

C. Slowly increase the load bridge voltage to nominal line-to-line voltage of 1.2K VRMS.
(Note: A high input impedance meter (Fluke 8050 or equivalent) must be used to make
this measurement. DO NOT use a Simpson.)

D. Using an oscilloscope and multimeter, measure the voltage on NSFC (2B) 'VBA' (TP7),
'VCB' (TP8), and 'VAC' (TP9). Each voltage should measure approximately # 3.393
VRMS (load nominal) with a phase sequence of TP7, TP8, TP9. If the voltage is not the
proper magnitude, verify that the load XTFX R43 to R52 components is right. (see
elem. sheet DA).

E. Measure the integrated voltage signals on the NLIB (1D) FAB (TP1), FBC (TP2), and
FCA (TP3). Each side should have balanced signals and measure approximately 4.75
V RMS. Adjust the corresponding pots (R1, R2, R3) on the DLIB (1D) if necessary.
Also check if load flux adjustment on sheet 1DC possible. Revert to 4.75 V RMS.

F. Adjust DLIB (1D) R7 (VM) until backplane pin 1D-10 reads 10.0 VDC. Adjust the
MOTOR VOLTS panel meter, if used, for full-scale deflection (adjustment on back of
meter).

G. Adjust DLIB (1D) R7 (VM) until motor VM (if used) reads VAC (load nominal).
28
H. Set up the overspeed pot as follows:

1. Set the overspeed pot. 'OSP' (R4) on DLCB (1E) full CW. 'OSP' (TP10) should
read about -11.9 VDC.

2. Adjust 'SPD' (R3) on DLCB (1E) until backplane pin 1E-8 equals -10.5 VDC.

3. Adjust 'OSP' (R4) on the DLCB (1E) until 'OSP' LED comes on.

I. Readjust 'SPD' (R3) on DLCB (1E) until backplane pin 1E-8 equals -10.0 VDC. Adjust
SPM (R6) on DLCB (1E) until the backplane pin 1E-12 equals +10.0 VDC.

J. Adjust the panel MOTOR SPEED (if used) for full-scale deflection (adjustment is on the
back of the meter). Refer to elementary sheet BF; verify that there is 4.42 +/- 0.2 VDC
across the output on the I/O module driven by the 4-20 mA speed signal generated on
the NLCB (TB7.12 to TB7.13). Refer to appendix B for signal path information.

K. Readjust SPM (R6) on DLCB (1E) until the panel speed meter reads RPM, which is the
rated speed.

L. Connect a DVM to NSFC (2B) -VDC (TP11) and verify that the voltage is 0.0 VDC.

M. With the line-to-line test voltage at the nominal voltage, select the LOAD BRIDGE
POWER test (9) by typing "9" followed by "RETURN". The test software does a
preliminary check on some of the module SEM module inputs. A message will be
printed out if anything is wrong. These problems must be cleared before you can go on.

N. If there are any faults or alarms, a message will be printed on the screen. Clear all
faults, if any, and push the RESET button on the control panel door. The following
message should be printed on the screen:

READY
PUSH I/O MODULE "START" TO START FIRING
"E" TO RETURN TO MENU IF FIRING DOES NOT START

The READY light (if used) on the control panel door should be on.

O. Connect channel one of the oscilloscope to HLCB (2E) 'VA2' (TP13) and trigger on this
signal. Adjust the variable time/division scale so that one period equals six major
divisions. (i.e. 60 degrees per major division or 12 degrees per minor division).

P. Connect channel two of the scope to NSFC (2B) SIG1 (TP1) and verify that the cells
are not firing.

Q. Push the I/O module "START" button. "RUNNING" should be printed out on the screen.
SIG1 firing should start 120 (2 major divisions) +/- 12 degrees after the rising edge of
VA2 and be 120 degrees (2 major divisions) long. The RUN light on the control panel
door should be on. If not, verify that TB3-12 to TB3-13 is jumpered.

R. Connect channel two of the scope to NSFC (2B) –VDC (TP11). Verify that there are 6
humps on VDC per cycle. All off the humps should be approximately equal. Further
there should not be any spurious pulses in SIG-1 to SIG-6 in NSFC 2B waveforms
when firing angle is varied from full retard to full advance.

S. Exit the LOAD BRIDGE test by typing "E" and return to the menu screen.

T. Reduce the bridge voltage to zero, and turn off all power and disconnect the 0-4500
VAC source from M1, M2, and M2.

29
WARNING: Turn the variac on the high voltage transformer down so that the voltage
is zero BEFORE opening the breakers.

SOURCE SIDE RESISTOR LOAD TEST

XIX. SOURCE SIDE RESISTOR LOAD TEST

A. Using the resistor bank/200A supply, connect the resistor bank across the rectifier
output terminals P1 and N1. Refer to figure 7. The resistance should be approximately
11 ohms.

Engineering note: 415 VAC x 1.35 = 560 VDC (assume alpha is 0); therefore
IDC = 50 amps.

SOURCE RESISTOR TEST HOOK UP

SOURCE BRIDGE HIGH VOLTAGE TEST HOOK UP

L1 P1 P2 M1
1 Source Load
L2 Bridge 11
Bridge M2
2 OHMS

L3 M3
3 N1 N2

415 VAC

Figure - 7

B. Connect temporary jumpers to source and load attenuators on the HPTK cards in the
leg cell modules. Use the 1.2KV jumper connection. See next page for 1.2KV bridge.
This recalibrates the attenuators for the tests that follow using 415 VAC.

1.2KV ATTENUATOR JUMPER POSITIONS

Out of 8 Nos. of 249K resistors in HPTF card in each power module, by-pass 4 Nos.
with jumpers and keep only 4 Nos. in circuit. By-pass or include resistors to get 3.12 V
AC on NSFC VAC. NOTE THE JUMPERING DETAILS AND VOLTAGE VALUES AND
INCORPORATE IN TEST REPORT. CHECK WITH HPTF CARD DETAILS.

C. Remove JH (10 pin ribbon cable), JJ (wire harness) from the Source XTFX. Check
R54, R55 for correct resistance and check berg jumpers (ALL) per drive elementary
sheet DA. Connect the milliohmmeter per the table 3 and adjust the corresponding
potentiometers per the burden resistor specification shown on drive elementary sheet
EA for 'CURRENT FEEDBACK BURDEN SETTING'. See sht. No 4GA also.

NOTE: If you do not use the HP4328 milliohmmeter, make

sure you compensate for the meter lead resistance
when the burden resistor measurements are made.

30
Pl refer the card detail ED660XTFXA00.
TABLE 3

CONNECT HP4328 ACROSS ADJUST THIS

THIS RESISTOR POTENTIOMETER

1-2 R54 R53

JJ
XTFX-SOURCE 5-6 R55 R17

1-2 R54 R53

JJ
XTFX-LOAD 5-6 R55 R17

D. After all adjustments are made, reconnect connectors of the source and load XTFX
circuits.(4 nos.).

E. Using the resistor bank/200A supply, connect 415 VAC to L1, L2, and L3. Refer to
figure 6. The phase sequence should be 1-2-3. Do NOT connect bridge power to the
load at this time. Turn on the control and bridge voltages. The bridge fans MUST be
running, the fan door(s) must be closed, and all of the removable bridge panels should
be in place except for those removed to wire in the bus voltage. This will insure that the
leg cell modules get the air flow that is required to keep them from overheating.

F. Measure the line to line input voltage and record the value here. This value will be
needed if the voltage is not 415 VAC.

Line to line bridge voltage _________________ VAC

G. Measure the voltage on NSFC (2C) 'VBA' (TP7), 'VCB' (TP8), and 'VAC' (TP9). Each
voltage should measure approximately 3.12 VRMS (source at 415) with a phase
sequence of TP7, TP8, and TP9 (See appendix C if the bridge voltage is not 415).

H. Select the SOURCE RESISTOR POWER test (10) by typing "10" followed by
"RETURN". The test software does a preliminary check on some of the SEM module
inputs. A message will be printed out if anything is wrong. These problems must be
cleared before you can go on.

READY
PUSH I/O MODULE "START" TO START FIRING
"E" TO RETURN TO MENU IF FIRING DOES NOT START

The READY light (if used) on the control panel door should be on.

J. Connect channel one of the oscilloscope to HLCB (2E) 'VA1' (TP12) and trigger on this
signal. Adjust the variable time/division scale so that one period equals six major
divisions. (I.e. 60 degrees per major division or 12 degrees per minor division).

K. Connect channel two of the scope to NSFC (2C) SIG1 (TP1) and verify that the cells
are not firing.

31
L. Push the I/O module "START" button. "RUNNING" should be printed out on the screen.
SIG1 firing should start 30 to 60 degrees (0.5 to 1 major division) after the rising edge
of VA1 and be 120 degrees (2 major divisions) long.

The RUN light on the control panel door should be on. If not, verify that TB3-12 to TB3-
13 is jumpered. The bridge will normally go to full firing on pressing "START" button.

M. Connect channel one of the oscilloscope to NSFC (2C) SIG1 (TP1) and channel two to
NLIB (1C) 0IA (TP11). The negative cycle of the current signal should line up with the
SIG1 firing. This verifies the polarity of the current transformer. If the current signal is
inverted from the above mentioned figure and channel two of the oscilloscope is NOT
in the inverted mode, the current transformer is probably wired backwards.

N. Connect channel one of the oscilloscope to NSFC (2C) SIG5 (TP5) and channel two to
NLIB (1C) 0IC (TP9). The negative cycle of the current signal should line up with the
SIG5 firing. This verifies the polarity of the current transformer.

O. Observe the waveform at IFB (NLIB-SOURCE 1C). Check whether all the humps are
present and there is no missing hump. This ensures that all the thyristors are
conducting. Also, check the waveforms: 0IA, 0IB, 0IC testpoints in NLIB-SOURCE 1C
are all right and there are no missing humps. Check for gate pulse waveforms as in pt.
M of Source Bridge High Voltage Test.

P. Connect the DVM to OVA (TP18) DLIB (1C). Decrease (CCW) the overvoltage pot.
'OVA' (R8) on DLIB (1C) until the voltage is -5.0 VDC. SOURCE OVERVOLTAGE fault
should occur within 10 seconds (printed out to screen). Verify that the FAULT light on
the control panel door is on.

Q. Exit the SOURCE RESISTOR test by typing "E" and return to the menu screen.

R. Refer to elementary sheet DC. Set the DLIB (1C) OVA (R8) pot to the value given on
OVA (TP18).

S. Turn off all power and disconnect the resistor bank. DO NOT remove the attenuator
jumpers or the 480/415 VAC connections to L1, L2 and L3 at this time for they will
be needed in the next test.

LOAD SIDE RESISTOR LOAD TEST

XX. LOAD SIDE RESISTOR LOAD TEST

A. Using the resistor bank/200A supply, connect the resistor bank across the rectifier
output terminals P2 and N2. Refer to figure 8. The resistance should be approximately
11 ohms which can be obtained by connecting between BIG BLUE terminals J3 and J8.

Engineering note: 415 VAC x 1.35=560 VDC (assume alpha is 0); therefore
IDC = 50 amps.

32
LOAD RESISTOR TEST HOOK UP

SOURCE BRIDGE HIGH VOLTAGE TEST HOOK UP

415/425 100KVA
ISOLATION
TRANSFORMER

3 3
2 2
1 1

P1 P2 M1
L1 Source Load
1
L2 Bridge 11
Bridge M2
2 OHMS

L3 M3
3
N1 N2
415 VAC
BIG BLUE
Figure - 7

B. Connect the source and load converters as shown in figure 10.

C. Turn on the control and bridge voltage. Bridge fans MUST be running, the fan door(s)
must be closed, and all of the removable bridge panels should be in place except for
those removed to wire in the bus voltage. This will insure that the leg cell modules get
the air flow that is required to keep them from overheating.

D. Measure the line to line input voltage and record the value here. This value will be
needed if the voltage is not 415 VAC.

Line to line bridge voltage _________________ VAC

E. Measure the voltage on NSFC (2B) 'VBA' (TP7), 'VCB' (TP8), and 'VAC' (TP9). Each
voltage should measure approximately # 3.12 VRMS (load at 415) with a phase
sequence of TP7, TP8, TP9. (See appendix C if the bridge voltage is not 415).

F. Select the LOAD RESISTOR POWER test (11) by typing "11" followed by "RETURN".
The test software does a preliminary check on some of the SEM module inputs. A
message will be printed out if anything is wrong. These problems must be cleared
before you can go on.

G. If there are any faults or alarms, a message will be printed on the screen. Clear all
faults, if any, and push the RESET button on the control panel door. The following
message should be printed on the screen:

READY
PUSH I/O MODULE "START" TO START FIRING
"E" TO RETURN TO MENU IF FIRING DOES NOT START

The READY light (if used) on the control panel door should be on.
33
H. Connect channel one of the oscilloscope to HLCB (2E) 'VA2' (TP13) and trigger on this
signal. Adjust the variable time/division scale so that one period equals six major
divisions. (i.e. 60 degrees per major division or 12 degrees per minor division).

I. Connect channel two of the scope to NSFC (2B) SIG1 (TP1) and verify that the cells
are not firing.

J. Push the I/O module "START" button. "RUNNING" should be printed out on the screen.
SIG1 firing should start 30 to 60 degrees (0.5 to 1 major division) after the rising edge
of VA2 and be 120 degrees (2 major divisions) long.

The RUN light on the control panel door should be on. If not, verify that TB3-12 to TB3-
13 is jumpered. The bridge normally goes to full firing after "START" button is pressed.

K. Connect channel one of the oscilloscope to NSFC (2B) SIG1 (TP1) and channel two to
NLIB (1D) 0IA (TP11). The negative cycle of the current signal should line up with the
SIG1 firing. This verifies the polarity of the current transformer. If the current signal is
inverted from the above-mentioned figure and channel two of the oscilloscope is NOT
in the inverted mode, the current transformer is probably wired backwards.

L. Connect channel one of the oscilloscope to NSFC (2B) SIG5 (TP5) and channel two to
NLIB (1D) 0IC (TP9). The negative cycle of the current signal should line up with the
SIG5 firing. This verifies the polarity of the current transformer.

M. Connect the DVM to OVA (TP18) DLIB (1D). Decrease (CCW) the overvoltage pot.
'OVA' (R8) on DLIB (1D) until the voltage is -5.0 VDC. LOAD OVERVOLTAGE fault
should occur within 10 seconds (printed out to screen). Verify that the FAULT light on
the control panel door is on.

N. Observe the waveform at IFB (NLIB-LOAD 1D). Check whether all the humps are
present and there is no missing hump. This ensures that all the thyristors are
conducting. Also, check the waveforms: 01A, 01B, 01C test points in NLIB-LOAD 1D
are all right and there are no missing humps. Check for gate pulse waveforms as in pt.
R of Load Bridge High Voltage Test.

O. Exit the LOAD RESISTOR test by typing "E" and return to the menu screen.

P. Refer to elementary sheet DC. Set the DLIB (1D) OVA (R8) pot to the value given on
OVA (TP18).

Q. Turn off all power. Remove the resistor bank from the P2 and N2 bus. DO NOT
remove the attenuator jumpers because they will be needed in the next test.

PUMP BACK TEST

XXI. PUMP BACK TEST (DO NOT ATTEMPT THIS TEST UNLESS SOURCE AND LOAD RESISTOR
TESTS ARE FULLY CLEARED)

A. Connect the power converter per figure 8. Do not turn on power at this time. The P1 to
P2 jumper needs to carry about 100 amps (use 0 AWG).

PUMP BACK TEST HOOK UP

415/425 100KVA
ISOLATION
TRANSFORMER
34
3 3
2 2
Retain this 1 1
setup, as it
is required
L1 P1 P2 M1
for crowbar
Source Load
test
L2 Bridge Bridge M2
mentioned
ahead in
L3 N1 N2 M3
Additional
tests.

TEST
LINK REACTOR

Figure - 8

B. Turn on the control and bridge voltage. Bridge fans MUST be running, the fan door(s)
must be closed, and all of the removable bridge panels should be in place except for
those removed to wire in the bus voltage. This will insure that the leg cell modules get
the air flow that is required to keep them from overheating.

C. Select PUMP BACK test (12) by typing "12" followed by "RETURN".

D. "ENTER RATED DC LINK CURRENT - " will be printed out on the screen. Enter # 757
(1 per unit DC link current) followed by a return.

E. The test software does a preliminary check on some of the SEM module inputs. A
message will be printed out if anything is wrong. These problems must be cleared
before you can go on.

F. If there are any faults or alarms, a message will be printed on the screen. Clear all
faults, if any, and push the RESET button on the control panel door. The following
message should be printed on the screen:
READY
PUSH I/O MODULE "START" TO START FIRING
"E" TO RETURN TO MENU IF FIRING DOES NOT START

The READY light (if used) on the control panel door should be on.

G. Push the I/O module "START" button. The RUN light on the control panel door should
come on and the following should be printed out:

PUSH I/O MODULE "STOP" TO STOP FIRING,

"START" TO START FIRING,
"RESET" ON DOOR TO CLEAR FAULTS
"RETURN" TO CONTINUE, "E" TO EXIT

H. Type "RETURN". The current will increment up to 80 amps. (Note: 80 amps will be the
DC link current. The AC current shown on the current meter (if used) will be about 62
amps.). It might take as much as a minute for the current to increment up. One of the
following messages will be printed out:

35
1. Pass message :
DC LINK CUR = aaa
80 amps = bbbb
OK
SOURCE LINK CUR = cccc
LOAD LINK CUR = dddd
BALANCED

"RETURN" TO CONTINUE, "E" TO EXIT

2. Failure message 1:
DC LINK CUR = aaaa
80 amps = bbbb
NOT WITHIN TOLERANCE
SOURCE LINK CUR = cccc
LOAD LINK CUR = dddd
NOT BALANCED

"RETURN" TO CONTINUE, "E" TO EXIT

3. Failure message 2:
DC LINK CUR = aaaa
80 amps = bbbb
OK
SOURCE LINK CUR = cccc
LOAD LINK CUR = dddd
NOT BALANCED

"RETURN" TO CONTINUE, "E" TO EXIT

4. Failure message 3:
DC LINK CUR = aaaa
80 amps = bbbb
NOT WITHIN TOLERANCE
SOURCE LINK CUR = cccc
LOAD LINK CUR = dddd
BALANCED

"RETURN" TO CONTINUE, "E" TO EXIT

NOTE:
aaaa, bbbb, cccc, and dddd are in hex counts
aaaa = (measured source IFB + load IFB)/2
bbbb = hex value of 80 amps
cccc = measured source IFB
dddd = measured load IFB

failure messages mean the following:

Failure message 1 - The average of the source and load currents is not equal to 80
amps +/- 5% and the source and load currents are not within 5% of each other in value.
Failure message 2 - The average of the source and load currents is equal to 80 amps
+/- 5%; however, the source and load currents are not within 5% of each other in value.
Failure message 3 - The average of the source and load currents is not equal to 80
amps +/- 5%; however, the source and load currents are within 5% of each other in
value.

36
One possible problem is that the burden resistors are not set up properly. Measure the
source NLIB (1C) IFB (TP7) and load NLIB (1D) IFB (TP7). They should be VDC, +/-
5% (80 amps).

J. Exit the PUMP BACK test by typing "E" and return to the menu screen.

K. Refer to elementary sheet DC. Set the NLCB (1E) OSP (R4) pot to the value given on
OSP (TP10).

L. Turn off all power.

FIELD EXCITER GATE TEST

XXII. FIELD EXCITER PRELIMINARY CHECKS

A. Verify that the EVC resistive load is connected to the field excitor package. (Refer to
elementary sheet AF which shows the SFF. The load should be attached to ETB1,
ETB2, and ETB3.)

B. Verify that there is a green wire running from the SFE NHVL JK stab to the case of the
SFE.Check connection from case to earth bus present.

C. Verify that the 2 saddle clamp resistors (R70/R71) on the NHVL are the proper value:

30 amp SFE - 121 and 1.21K ohm

60 or 80amp SFE - 56.2 and 100 ohm –Applicable for this job.
150 amp SFF - 100 and 220 ohms

D. Connect a DVM across two of the three lines on the output side of the excitor package.

E. Connect a CLAMP ON AMMETER to one of the output phases of the exciter package.

F. Turn on the control, SFE,and bridge voltages (source voltage must be on during this
test).

G. Connect channel one of the scope to NSFC (2C), VAC (TP9). Adjust the variable
time/division scale so that one cycle equals six major divisions. (i.e. 60 degrees per
major division or 12 degrees per minor division).

H. Connect channel two to NSFE (2A), LAC (TP9, 3d from top). Measure the phase
difference. If it is greater than 30 degrees (+ or -), turn all power off, roll the phases (1
to 2, 2 to 3, and 3 to 1) of the 415 VAC power into the SFF package (do NOT change
the power connection to the source bridge),and turn power back on.

I. Record the phase difference in degrees between channel one and two ("+" if channel
one (NSFC VAC) is leading channel two (NSFE LAC) or "-" if it is lagging, range is -30
to +30).
J.
PHASE DIFFERENCE _________________

J. Verify that the speed pot on the I/O module is turned full CCW.

XXIII. FIELD EXCITOR GATE TEST

A. Turn off the control, SFE, and bridge voltages and connect a current probe to the wire
from the NHVL (in the SFE module) JD1 with the arrow on the probe pointing away
from the NHVL.

37
B. Turn on the control and SFE voltages. Select EVC TEST (13) by typing "13" followed
by "RETURN".

EXCITER GATE TEST

"RETURN" TO CONTINUE, "E" TO EXIT
CELL 1 will be printed out.

C. Verify that NHVL amber LED "1" is on and the rest are off.