quadramaticPGEI 5329

Document number: PGEI-5329
Page: 1 of 67
Date issued: May 5, 2009
Instruction
Manual

GE Energy
Quadramatic
TM
Drive
Instruction Manual
Supersedes: New

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection
with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered
sufficiently for the purchasers purposes, the matter should be referred to the nearest office of GE Canada.

General Electric Canada 2009. All rights reserved.

GE Quadramatic
TM
Drive
Instruction Manual


GE Quadramatic
TM
Drive
Instruction Manual
Page: 2 of 67

TABLE OF CONTENTS

1. SCOPE .......................................................................................................5
2. RELATED DOCUMENTS..............................................................................5
3. SAFETY PRECAUTIONS...............................................................................5
4. QUADRAMATIC CONTROL THEORY ........................................................ 7
5. DESCRIPTION OF OPERATION..................................................................10
6. START-UP AND MAINTENANCE NOTES ................................................... 20
6.1 Initial Quadramatic Inspection (after Installation) 21
6.3 Q-field Supply Check 24
6.4 Q-Current Test 26
6.5 Clutch Test 27
6.6 Calibrate Clutch 28
6.7 Manual Clutch Pulse - Load 1/2 29
7. QUADRAMATIC CONTROL MILL COMMISSIONING.................................32
7.1 Q-field Current Regulator Tuning 33
7.2 Kilowatt Difference Regulator Tuning 36
7.3 Effect of Q-Current on kW Difference (QKW_AMP) 38
8. PREVENTATIVE MAINTENANCE............................................................... 39
8.1 Power-Off Checks 40
8.2 Q-Axis Exciter Maintenance and Troubleshooting 42
APPENDIX A - QUADRAMATIC DRIVE SPECIFICATIONS ............................................... 50
APPENDIX B QUAD CONTROL PERMISSIVES LOGIC DIAGRAM............................. 51
APPENDIX C MODBUS INTERFACE TO QUADRAMATIC CONTROL PLC................... 52
APPENDIX D DESCRIPTION OF SELECTED QUAD VARIABLES .................................. 55
APPENDIX E MILL MARKER INSTRUCTIONS................................................................ 57
APPENDIX F SUMMARY OF GE WIRING PRACTICE (PGEI-1343C).............................. 59
APPENDIX G LIST OF POSSIBLE START-UP PROBLEMS.............................................. 61
APPENDIX H RENEWAL PARTS...................................................................................... 63
APPENDIX I GLOSSARY................................................................................................... 65
SERVICE............................................................................................................................... 66
INDEX ............................................................................................................................... 67


GE Quadramatic
TM
Drive
Instruction Manual
Page: 3 of 67

TABLE OF FIGURES

Figure 1: Quadramatic Drive System.............................................................................................................................7
Figure 2: Principles of Quadratorque Operation.....................................................................................................8
Figure 3: Quadramatic Drive Control Diagram.........................................................................................................9
Figure 4: Mill Floor Station (typical) .............................................................................................................................. 10
Figure 5: Typical Pre-trip Circuit.................................................................................................................................... 12
Figure 6: Mill Start Sequence........................................................................................................................................... 13
Figure 7: Quadramatic Drive HMI Home Screen ................................................................................................... 14
Figure 8: Clutch pulsing Rough adjustment ........................................................................................................ 17
Figure 9: Quadramatic Drive Line-up.......................................................................................................................... 22
Figure 10: Clutch Valve Cabinet ..................................................................................................................................... 27
Figure 11: Clutch Calibration Cycle.............................................................................................................................. 28
Figure 12: Clutch Test Diagram...................................................................................................................................... 31
Figure 13: Q-regulator Tuning........................................................................................................................................ 35
Figure 14: Quad PID Regulator Diagram................................................................................................................... 37
Figure 15: AC1 to AC2 Waveform.................................................................................................................................. 43
Figure 16: Terminated Cell SCR Mounting Details................................................................................................ 45
Figure 17: 53mm Presspack Cell Assembly.............................................................................................................. 46
Figure 18: Converter Control Timing Waveforms................................................................................................. 49

TABLES

Table 1: Communication Protocols .............................................................................................................................. 19
Table 2: Q-Field Current Regulator Polarity ............................................................................................................ 34
Table 3: Troubleshooting Checks Drive Does Not Operate.......................................................................... 47


GE Quadramatic
TM
Drive
Instruction Manual
Page: 4 of 67

DANGER indicates an imminently hazardous situation
that, if not avoided, may result in death or serious
injury. This signal word is to be limited to the most
extreme situations.

WARNING indicates a potentially hazardous situation
that, if not avoided, could result in death or serious
injury.

CAUTION indicates a potentially hazardous situation
that, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.

CAUTION without the exclamation symbol indicates a
situation in which equipment/property damage can
occur, but personal safety is not at risk.

NOTICE is used for non-safety related items that the
author wishes to highlight for importance.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 5 of 67

1. SCOPE

This document provides instructions for the installation, commissioning, and operation of the GE
Quadramatic Drive System. It is recommended that a person trained in the Quadramatic System perform this
commissioning.

2. RELATED DOCUMENTS

PGEI-217--- Motor Instruction Manual
PGEI-1343C GE Drive Systems Wiring Practices
PGEI-5296 Medium Term Storage of Motor Systems Electronic Equipment
PGEI-5334 Quadramatic Drive Simplified PLC Loading Instructions
GFK-0356Q Series 90-30 PLC Installation and Hardware Manual
0234B2--- Quadramatic Drive Elementary Drawings
4002B------ Pneumatic schematic for the clutch valve cabinets

3. SAFETY PRECAUTIONS

Only qualified individuals should install, operate, troubleshoot, and maintain this drive.
Do not touch energized circuits.
To avoid electric shock, disconnect all power sources from the equipment before initiating
maintenance or troubleshooting procedures. The control power supply may be feed from a
separate source then the main power supply. Review the project-specific elementary drawings
to ensure that all power sources are de-energized.
Follow appropriate lock-out/tag-out procedures.
Always wear appropriate personal protection equipment (PPE) for the task at hand.
Never run the drive with cabinet doors open. The only exception is the control cabinet, which
contains low voltages.
Never install the drive where hazardous, explosive, or combustible vapours or dust may be
present.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 6 of 67

Isolation of test equipment from the equipment under test presents potential electrical
hazards. If the test equipment cannot be grounded to the equipment under test, the test
equipments case must be shielded to prevent contact by personnel.
Always lift the drive using the removable lifting angles, which have been provided.
Always confirm the lifting rating of cranes, hooks, and slings when lifting the drive.

Always be aware of electrostatic discharge (ESD) when working on or near components inside
the drive cabinets. Use the wrist strap provided when handling ESD sensitive components.
Before removing any covers from electrical equipment, ensure that no dust or harmful
material will enter as the cover is being removed or during the time that it is removed.
Handling and servicing of components that are sensitive to ESD should be done only by
qualified personnel and only after reading and understanding proper ESD techniques.
When transporting the drive line-up, the truck bed must be even and flat. Before unloading, be
sure that the concrete pad is level for storage as well as permanent positioning
The drive line-up must be transported and stored in the upright position.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 7 of 67

4. QUADRAMATIC CONTROL Theory

The Quadramatic drive system is comprised of two low-speed, synchronous motors driving through air-
clutches to two pinions connected by a common ring gear. To facilitate an initial load sharing, a special
clutch pulsing technique has been developed to bring the two motor rotors into near equal load angles.
Quadratorque motors then maintain load sharing by continuously, and automatically, adjusting for load
differences between the two.

kW load balance between the two motors is controlled by the motor Q-axis fields, which vary the motor load
angle, and by motor clutch pulsing for coarse balance control. Quadramatic-controlled motors offer a high
performance system to correct for clutch unbalances and mill gear eccentricities while maintaining excellent
steady state load sharing.
Figure 1: Quadramatic Drive System

ESP1 -
EXCITER
CONTROL FOR
MOTOR A -
(controls motor
DC exciter)
QUADRAMATIC DRIVE
- includes Q-PLC
(controls cutch and q-axis power)
VALVE
CONTROL
CABINET -
controlled by Q-
PLC (operates
mill air clutch)
D
Q
MOTOR
A
ESP1 EXCITER
CONTROL FOR
MOTOR B -
(controls motor
DC exciter)
D
Q
MOTOR
B
VALVE
CONTROL
CABINET -
controlled by Q-
PLC (operates mill
air clutch)
to DCS
(to initiate mill start and stop,
send faults, and status)
SWITCHGEAR (BY OTHERS)
MCC SUPPLY (BY
OTHERS)
MILL FLOOR
OPERATOR STATION
- motor and mill start/
stop. Sends signal
direct to Q-PLC

Dynamic (fine) load balance is done by controlling current through the two motors quadrature field
windings connected in anti-parallel for improved control gain. The controlled quadrature current increases
the load angle on the lighter-loaded motor and decreases the load angle on the heavier-loaded motor so

GE Quadramatic
TM
Drive
Instruction Manual
Page: 8 of 67

that the two motor loads are balanced (KW difference 0). The control configuration uses an outer KW
difference regulator and an inner quadrature field current regulator. These regulators act quickly to maintain
a minimal KW difference through such disturbances as mill out-of-round, gear eccentricity, mill load shift, etc.
The motor load angle can be controlled to approximately +/- 25% of rated motor power. If the quadrature
fields current average over a mill revolution is above a pre-set level, or the motors KW difference without
quadrature field current control is above a preset level, then the coarse load balance strategy of clutch
pulsing is initiated.

Principles of Quadratorque Operation

The apparent magnetic position of the rotor poles, with respect to the stator poles, can be changed rapidly in
a Quadratorque motor. This enables the two motors to share load equally within their dynamic range, in spite
of average and transient errors in rotor position due to initial clutch lock-up and instantaneous gear run-out.

Since this system has a very short time constant, it can also be made to act as a system damper.
The main flux produced by the direct-axis field winding is symmetrical about the centre line of the rotor pole.
If a flux is created in the quadrature axis i.e. symmetrical about the interpolar centre line, it will combine
with the main flux to produce a resultant flux, which is offset from the main flux. The degree of offset is
determined by the magnitude and direction of the current flowing in the quadrature axis winding. By
connecting the quadrature axis winding of the two motors in push-pull (or anti-parallel), a wide dynamic
range of adjustment is achieved.

Figure 2: Principles of Quadratorque Operation


GE Quadramatic
TM
Drive
Instruction Manual
Page: 9 of 67

The Quadramatic Drive controls the clutches and balances the two motor loads, including compensation for
gear run-out between the twin synchronous motors, which are coupled to the mill. The Quad-control is
packaged in one line-up and includes both the motors quadrature windings excitation power equipment
and the operators control interface.

Figure 3: Quadramatic Drive Control Diagram
KW1
TRANSDUCER
KW2
TRANSDUCER
KW
KW
KW
PID loop
+
+
+ _
_ +
DKW_REF
Q-CURRENT
PID loop
QCURREF
GPG
Q_CURR
Q
BRUSHLESS
EXCITER
Q
BRUSHLESS
EXCITER
RING GEAR
PINION 1
PINION 2
PR2
PRV
AIR
STORAGE
TANK
100PSI
PR1
PRV
QTS-1
QTS-2
Q-PLC
CLUTCH PULSING
CONTROL
START/STOP MILL
MOTOR 1/2 READY
MILL READY
SYSTEM PROTECTION
EXTERNAL
CONTROL
SIGNALS
QUADRAMATIC DRIVE
Q-PLC LOGIC
MV2
MV1
SERIAL OR ETHERNET
COMMUNICATION
FIELD
SUPPLY
PT2
PT1
D
D
CLUTCH 2
CONTROL CABINET
CLUTCH 1
CONTROL CABINET
EXCITATION PANEL


GE Quadramatic
TM
Drive
Instruction Manual
Page: 10 of 67

5. DESCRIPTION OF OPERATION

Once installation, start-up, and commissioning have been completed, the Quad-control is automatic. The Q-
current control should be in AUTO, clutch pulse control in AUTO, and start / stop motors and mill from the Mill
Floor Station or DCS. It is only when electrical maintenance will be performed that any other selection will be
required.

Emergency Stop

All Emergency stop pushbuttons / contacts (such as Mill Floor Station, Quad-control door, exciter control
cubicle door, plant DCS, PROCESS PLC, Quad-control PLC = Q-PLC) are normally closed, open for E-stop, and
are accumulated into one relay (NESTP1/2) in the Quad-control. Loss of relay power, open circuit, pushing a
button or opening a contact will drop out the relay, making this a fail-safe configuration. The Q-PLC logic will
open the clutches, disable Q-current, and drop out the Q-current contactors, so that the mill will rock to a
standstill and the motors will coast until friction stops them.

Figure 4: Mill Floor Station (typical)

Mill Starting Sequence

1) All control equipment and protection must be powered-up and ready, including motor direct-axis
exciters, Quad-control, DCS, MCCs, switchgear, etc.
2) Motor start permissives from the Quad-control must be healthy to allow a start. These include clutch
open, Quad-current control test successful, Quad-shorting contactor closed to short out the Quad-
winding current induced during start. Motor start permissives from the DCS include motor high-pressure
lift pumps operating. The Mill Floor Station Motor Ready light will be on when all permissives are OK.
Other mill run interlocks such as gear lube spray are satisfied through the DCS.
3) Individual motor start/stop (clutch open) is by closing/opening the motor breaker. Control is normally
from the Mill Floor Station. Under special circumstances, motor starts and stops can also be done at the
associated breaker (local control) or by the DCS. All stops and Emergency Stops are active at all times.
To allow the motor to synchronize, the exciter control turns on the motor direct-axis exciter field current
a fixed time after the motor breaker closes, then tells the Quad-control that the motor is synchronized
and ready to load if all remains OK.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 11 of 67

Note: The motor brushless exciter controls are independent, and each operates entirely on its own to apply
motor field and protection in a timed sequence after the main motor contactor (or circuit breaker) closes,
finishing by telling the Q-PLC that the motor is ready to load = synchronized.

4) With both motors ready to load, all process systems ready, the Quad-control ready, and all motor and
mill auxiliaries ready, the Mill Floor Station Mill Ready light is turned on.

Mill start/stop is by the Quad-control closing/opening the two clutches together, after a 5-second start
warning horn. There is a separate control valve cabinet for each clutch. Each cabinet has a dump valve and
a pressure-regulating valve. To engage the clutches, the Q-PLC closes the two dump valves and ramps both
clutch air pressures to typically 2.5 times motor rated torque (should be less than the motor pullout torque) to
accelerate the mill, then down to run pressure (typically 2 times motor rated torque) to lock in the clutches
for running.

Note: Mill start/stop control is normally from the Mill Floor Station, but can also be from the DCS. Mill starts are
never initiated at the Quad-control HMI display. All stops and Emergency Stops are active at all times. The
load balance control is initiated when the mill has stabilized at run speed.

5) After the mill is stabilized at operating speed, the Quad-control operates contactors to enable motor
quadrature field excitation control for fine load balance, and then enables clutch pulsing for coarse
load balance if the Quad-field current is high or selected off.
6) After at least one mill revolution and if the mill is at least 95% of rated speed, the Quad-control will tell
the DCS that the mill is running, so that mill feeder conveyors can be started.

Stopping the motors

The two motors are stopped separately by opening their individual contactors (or circuit breakers). This is
can be by the plant DCS, local Stop Motor PBs, process PLC operator, or even manually at the switchgear. A
permissive from the Q-PLC and MUC PLC (if provided) is directly wired into the contactor, these contacts may
also stop the motor.

Normal operation will stop the mill (open the clutches) before stopping a motor, but if the mill is running when
a motor is stopped, then the Q-PLC opens both clutches immediately.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 12 of 67

Note: A pre-trip input should be supplied to in order to prevent possible damage to the field control SCRs when
the main motor circuit breaker is tripped. This pre-trip signal will allow the SCRs to be phased off before
the main motor circuit breaker opens.

Figure 5: Typical Pre-trip Circuit

86
TRIP
CIRCUIT
86
QUAD
E-STOP
ESP1
MFS
STOP
MOTOR
TS 86
52a
TO
QUAD
DRIVE
Others

Stopping the Mill

Mill stop is by the plant DCS, the local Stop Mill PB on the Mill Floor Station, a Stop Mill PB on the
Quadramatic HMI (Human-Machine Interface) screen, or from the PROCESS PLC, all as inputs to the Q-PLC.
Both clutches are disengaged simultaneously by opening the two dump valves and calling for zero pressure
from the two pressure-regulating valves. The motors will continue to run until their breakers are opened.
The mill will not be ready to run again for five minutes. This allows time for the mill to stop.

GE Quadramatic
TM
Drive
Instruction Manual
Page: 13 of 67

Figure 6: Mill Start Sequence
psi
60
40
10
0
90
%I8
QCTESTM
Q-Current Test ->Required to start the motors
%M15
CL_RDY
Two motors synchronized. No clutch faults
%I22
LSCLILK
Mill lube system running from PPLC
%I31
MILRDYP
Mill ready to start from DCS
%M3
CL_PERM
Clutch close permissive
%I29
MILRUNP
Mill run request from DCS
%M58
CLSCLRQ
Close clutches request
%M60
CLOSECL
Close clutches command
5 sec
Sound mill horn
Close dump valves (MV1 & 2)
%Q4 / Q5
QPULS1/2
%M65
FULLSPD
Mill accelerated up to full speed
~12 sec
%M2
Q_PERM
Q-field current control permissive
%Q2
QXCP
Close Q-field contactor (QXCC)
0.5 sec
Delay for contactor to operate
%M27
QFCR_EN
%M63
FULSPDT
5 sec
Reduce clutch pressure to running
%M197
CLCTLAV
5 sec
Clutch pulsing allowed
5
%R1002 =RUNPR =200% of rated motor
%R1012 =ACCELPR =250% of rated motor torque
%AQ3/4
PRRF1/2AQ
15
psi Pressure feedback
(%AI5 / AI6)
15 psi/sec
Clutch calibrate


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TM
Drive
Instruction Manual
Page: 14 of 67

Parameter Indications (on Quad-control door):
Total Motor KW meter (i.e. both motors, Q-PLC analog output)
Motors KW Difference meter (Q-PLC analog output)
(reads zero with Q-current auto, else follows mill gear run-out)
Q-current meter (from shunt, follows mill gear run-out when Q-current is in auto)
HMI digital displays / trend graphs of KW difference, Q-current, clutch pressures, and also viewing of
adjustable set-up parameters, alarms / faults, load balance conditions when a fault occurred, etc.

HMI screens:
Faults / alarms list is included on all screens except Quad Fault Log.
Overview motors load balance general status.
Clutch operate clutch pulse control mode select, manual clutch pulse initiation, view clutch pressure
values + trend graph, view clutch control data, view clutch logic progression.
Q-current operate Q-current control mode select, manual Q-current reference, view KW difference and
Q-current values + trend graph, view Q-current control data, view Q-current logic progression.
Clutch set-up test / calibrate / find slip for both clutches, view clutch pressure values + trend graph,
view / adjust clutch control parameters.
Q-current set-up toggle regulator reference square waves on / off, initiate Q-current test, view KW
difference and Q-current values + trend graph, view / adjust Q-current control parameters.
Process PLC Signals view logic / values for data to / from Process PLC.

Figure 7: Quadramatic Drive HMI Home Screen

Quad Fault Log load balance conditions stored in the Q-PLC when faults occur, including fault number
(in PLC program), PLC time stamp, two motor KWs, two clutch pressures, two Q-currents.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 15 of 67

Load Balance control device hierarchy (devices on the Quad-control HMI):

Q-current control
OFF AUTO
Clutch pulse control
OFF AUTO

The Mill can still operate if both controls are selected OFF, but the Q-PLC will not do any load sharing
adjustments. This is not a recommended mode of operation. Selected load balance controls will operate
only after the mill has stabilized at run speed.

Load Balance by motor quadrature field windings current:
The motor loads can be adjusted to be equal within a close range by sending current in opposite directions
through the quadrature windings of the two motors (approx. 25% of rated KW can be added or subtracted
per motor). This is equivalent to a fine adjustment for motors load balance whereas clutch pulsing is a
more coarse adjustment.

The normal mode of operation for the Q-current control is AUTO:
With Q-current control selected AUTO, the Q-PLC compensates for KW difference between the two
motors continuously, so the KW difference meter should stay near zero (unless the Q-current
requirement reaches its limit). This is the normal mode of operation.

If there are any regulation issues while in AUTO mode, manual control can be selected:
With Q-current control selected MANUAL, the quadrature fields current is per the HMI Q-current manual
reference value (Q-current operate screen). The manual reference outline will be green when manual
reference is operating, red when not. The operator would not try to catch every movement of the KW
difference meter, but would try to move the KW difference average to zero. Increasing the reference + (to
load motor B) makes Q-current move the KW difference meter average right (showing more motor B
load). Conversely, decreasing the reference will add load to motor A. The KW difference average over the
past mill revolution is displayed with the immediate (dynamic) value.

During certain commissioning checks of the clutch pulsing, the Q-current control is selected OFF:
No current balance operates if Q-current control is selected OFF (Q-current operate screen -- the OFF
button will be green, the other two will be grey). In this case, the Q-field supply has zero output, and the
two contactors are dropped out, one blocking Q-field supply current and the other shorting both motor
quad-field windings. The clutch pulse load sharing can still operate.

Manual Q-curr
ref.
Manual clutch
pulse

GE Quadramatic
TM
Drive
Instruction Manual
Page: 16 of 67

Load Balance by clutch pulsing (Refer to Figure 6):

By opening the clutch dump valve of the more heavily loaded motor momentarily, the rotor of the more
heavily loaded motor is allowed to move ahead with less load while the lighter loaded motor is pulled back
slightly. The motor load angles will be better matched after the clutch pulsing, if the pulsing time has been
set up correctly. Loading one motor means pulsing the clutch of the other motor.

If the clutch pulse did not improve the average KW difference by a preset amount, then the pulse time is
increased (within an upper limit) on the next pulse for improved effectiveness. The effective pulse time is
remembered for the next time this clutch is pulsed.

Before a clutch pulse occurs, the clutch pressure of the heavier-loaded motor is reduced from run pressure
to pulse pressure so that the dump valve doesnt have to blow off as much air before getting some clutch
slip on the heavier loaded motor. This also makes the clutch pulsing more responsive. Once clutch pulsing is
completed, the clutch pressure is ramped up to run pressure again.

The normal mode of operation for the clutch pulse control is AUTO:
With clutch pulse control selected AUTO, clutch pulses are generated if the average KW difference
between the motors over one mill revolution goes outside a deadband. The average KW difference is
calculated using the Q-current feedback plus the actual KW difference remaining between the motors.
Clutch pulses always occur at a preset mill rotation position. The KW difference is averaged over the next
complete mill revolution to see if further correction is required. If the clutch pulse did not improve the
average KW difference by a preset amount, then the pulse time is increased on the next pulse for
improved effectiveness. The effective pulse time is remembered for the next time this clutch is pulsed.
If auto clutch pulses continue for longer than a preset time, then auto clutch pulses are stopped and an
alarm is set.

If there are any regulation issues while in AUTO mode, manual control can be selected:
With clutch pulse control selected MANUAL, clutch pulses are generated by pressing the Manual pulse
button (Clutch operate screen) -- the button outlines will be green if manual clutch pulses are permitted,
red if not. The operator would be watching the Q-current meter (if Q-current is AUTO) or the KW
difference meter (if Q-current is OFF) to determine that one motor is more heavily loaded than the other.
Pressing a Manual clutch pulse button will cause one clutch pulse -- the button colour will be grey
normally, but red when a manual clutch pulse is armed, waiting for clutch air pressure to reduce to
pulse pressure and also for the preset mill rotation position where all clutch pulses occur (no less than
every second mill revolution). After the clutch pulse, the average reading on the Q-current or KW
difference meter will swing towards the motor that is adding load.

During certain commissioning checks of the Q-current control, the clutch pulsing control is selected OFF:
No clutch pulses are generated by the Q-PLC if clutch pulse control is selected OFF (Clutch operate
screen -- the OFF button will be red, the other two buttons will be green).


GE Quadramatic
TM
Drive
Instruction Manual
Page: 17 of 67

Figure 8: Clutch pulsing Rough adjustment
Mill marker
pulse
MARK_OS
%M140
Mill Rotation Time
MROTTIM
%R336
Clutch 2 Pulse
Pressure
Command
PULPR_2
%M83
Clutch 2 Pressure
reference
CL2PREF
%R253
Clutch 2 Pulse
pressure OK
PULPOK2
%M80
Clutch pulse timer
CLP_TIM
%M141
Clutch 2 Pulse
CLPULS2
%M94
If the average KW
difference >1250 kW; then
auto clutch pulse
100 ms 100 to 200 ms The pulse width adjusts
according the feedback on the
effectiveness of the pulse
Pulse 2 Output
QPULS2
%Q5
{MV2 Dump valve
solenoid}
Clutch 2 Pressure
CL2_PRS
%R206
14.6 mA =66 PSI
=RUNPR (%R1002)
10.2 mA =39 PSI
=NOMPPR (%R1000)
66 PSI
PULSEPR (%R83) =39 PSI
TRUE if the clutch
pressure is lower than
44 PSI
The mill rotation timer is
reset by each mill marker
pulse
The mill marker is a
proximity switch that counts
the mill revolutions
-12.5 PSI/sec (%R1006)
If the load unbalance is not reduced to less than
25%of the unbalance limit (1250 kW) within 5
minutes, the pulsing will time-out
0 PSI
4 mA
1 sec
Clutch pulsing pressure level (PULSEPR) is
adjusted depending on the kW unbalance
0V
24V
If the clutch pulsing is successful, load balance will
re-start using automatic Q-field current regulation.


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TM
Drive
Instruction Manual
Page: 18 of 67

Other standalone functions:

Faults / alarms are displayed on every HMI screen (except Quad Fault log), showing HMI time when the
fault / alarm was seen; alarm ID (= Q-PLC mnemonic), descriptive message. The faults / alarms area
includes buttons to:
Silence Horn (Q-door buzzer),
Ack All and Ack (acknowledge all or just the selected faults / alarms display lines will change
colour to Acknowledged),
Help (to view an explanation and guidance file for the selected fault / alarm),
Reset Quad (open fault seals in the Q-PLC logic, so that you can operate again).
Display lines will change colour to Normal when the fault is cleared in the PLC, but a display line will
disappear from the list only after that fault / alarm has been both acknowledged and cleared.

The HMI reads data from the PLC on a 250 ms cycle which is the resolution of its time stamp in the faults /
alarms area. The PLC is where faults / alarms are recognized and action taken the HMI is only the operator
interface / monitor. When the PLC sees a process-related fault, it stores current load balance conditions for
that fault at the same time. These include:
Fault number (in the PLC program)
PLC time stamp (resolution is PLC scan time, approx. 10 ms)
Motor A and B KW
Clutch A and B pressure
Motor A and B Q-current

Faults / alarms which have this detail data available will have as part of their descriptive message Fault xx
Quad Fault log. Go to that screen, and then find the fault number to see what the Q-PLC saw when the
fault occurred.

General note: the HMI / PLC communication is by Ethernet, so response is quick but not instantaneous. The
operator should continue pressing an HMI button until he sees some confirmation e.g. some colour change.

The HMI Q-current test button (Q-current set-up screen) will close the Q-contactors and force a preset
low current for a short time. The Q-PLC will measure the voltage and determine whether a short or open
circuit exists in the Quadramatic system by checking if the voltage drop across the q-axis field is within a
preset range. This manual Q-test is only permitted when the clutches are open, and the motors are
stopped or synchronized never when a motor is starting, because of the Q-current induced back from
the motor quadrature winding during motor start. The same Q-test is automatically performed per
PROCESS PLC command with the motors at standstill
A successful Q-test is required before every motor start.

Stop the mill for sustained high load unbalance and for instantaneous high load unbalance (preset
levels and time delays) not corrected by Q-current or clutch pulses.

There is a trap in the Q-PLC logic for when the PROCESS PLC stops the mill -- coil PROCESS PLCSTP
%M12. This shows up on the alarms as Mill stopped by PROCESS PLC.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 19 of 67

The Quad can communicate to a remote DCS via several protocols (see Table 1). The Modbus signal interface
is described in more detail in Appendix B.

Table 1: Communication Protocols

Communication Protocol
RS485 Serial Ethernet

Hardwired
Modbus RTU Slave Modbus TCP/IP
Server
Standard

Option 1
Option 2

GE Quadramatic
TM
Drive
Instruction Manual
Page: 20 of 67

6. START-UP AND MAINTENANCE NOTES

PLC Program Support

The PLC CPU contains the Quadramatic Drive application programming and configuration. Since these are
special purpose programs, which are used to control and protect the synchronous motor, GE does not
encourage users to make changes to program or configuration. Any changes must be restricted to changing
parameters and options in the setup portion. The PLC program is password protected. The password is
available if there is concurrence between the customer and GE on the validity of proposed changes.

Since the application programming contains proven failure detection, it should not be necessary to monitor
operation of the logic for trouble shooting purposes.

The GE Fanuc PLC Series 90/30 CPU may be replaced with one that contains the same program without any
configuration effort. Simply remove power, replace the module, and re-apply power. Replacing the module
with an unprogrammed CPU requires that the flash EEPROM be reloaded when power is re-applied. This is
done using a PC and the software and cable supplied with the equipment. See PGEI-5334 for step-by-step
instructions. The procedure will restore the program to the "As Shipped" status, so if any setup parameters
are changed in commissioning, the program should be updated. GE will provide this service free for the first
commissioning revision. Note that the PLC RAM capacitor is not required to retain the program without
power.

Contained on the CD-ROM diskette that is shipped with the Drive is a folder, which contains all the logic in the
application program. This folder can be used with the concurrence of GE to modify the program using the
programming software.

Receiving

Immediately upon receipt, place all equipment under adequate covers, as unless otherwise noted, the
packing cases are not suitable for outdoor storage. To prevent the condensation of moisture on equipment,
which has been subjected to low temperatures, covers should remain in place and cartons should remain
unopened until the temperature of the contents has risen to the indoor temperature.

Examine each shipment carefully and check the contents against the packing list. Promptly report and
shortage or damage incurred in shipping to the carrier and to GE Canada.

Handling

Shipping boxes or skids, and the outline drawing should be checked to determine if special lifting positions
have been designated.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 21 of 67

Storage

Storage recommendations are contained in the Instruction PGEI-5296 Medium Term Storage of Motor
Systems Electronic Equipment.

Periodic energizing of the PLC is not required since the PLC program is stored on the CPU EEPROM during the
factory testing. Before the PLC leaves the factory, the battery connection plug is disconnected from the PLC
power supply post (PL1) to prevent premature discharge of the battery. Once the plug is re-connected and
the PLC is powered up at site, it will be ready to use with the correct program already loaded into it.

The PLC back-up battery should be replaced annually.

6.1 Initial Quadramatic Inspection (after Installation)

Step Description
6.1.1 Examine the Quadramatic Drive for any damage that occurred during shipping or installation.
6.1.2 Ensure that the Quad line-up has been bolted to the foundation using anchor bolts (by others) as
per the outline drawing.
6.1.3 Remove the packing material from the contactors QSC and QXCC.
6.1.4 Remove the Industrial PC from its packing material and install it on the control cubicle back wall
on the pre-tapped mounting holes.
6.1.5 Install the AC line filter (#BA-ACF) above the Q-axis excitation cubicle.
6.1.6 Confirm that the main power cables have been adequately sized.
6.1.7 Confirm that the Drive has been grounded as recommended in PGEI-1343 (minimum 1/0 AWG
cable, common ground point, at least one ground connection per shipping section).
6.1.8 Confirm that the ambient temperature of the electrical room is within the specification limits for
the Drive.
6.1.9 Check the cable interconnections (no power) and prove out signals (with power) between
locations motor breakers, motors, Quad-control, direct-axis exciters, customers PROCESS PLC,
mill floor station, clutch valve cabinets, etc.
All interconnecting cables should be properly tightened, terminated, and free from stress
throughout their length.
6.1.10 Ensure that the different signals are separated as per PGEI-1343 Drive Systems Wiring
Practices. The wiring may have to be re-routed for adequate noise level separation to support a
reliable installation.

Note that the Quad-control 120Vac power is distributed to a fuse block. These fuses allow the control power
supplies to be individually connected for commissioning or test purposes.

The Quad-control does not need to be commissioned before the mill motors since the motors are normally
started individually and unloaded (clutches open / disengaged), with direct-axis field applied per time after
motor breaker close. Any interface signals required between the Quad-control and the PROCESS PLC may be
overridden in the software during the mill motor commissioning.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 22 of 67

The motors are shipped with a shorting bar across the quad-field windings (to provide a path for the current
induced in the quad-fields during motor start, and to prevent overvoltage on the quad-field windings). This
bar must be place if the motors are being started without the Quad control. The motor slip rings and
brush riggings for external connection to the quad-field windings would not be used yet. Once the control
has been commissioned, there is a shorting contactor in the Quad contactor cubicle to perform the same
function as the motor-mounted shorting bar.

Figure 9: Quadramatic Drive Line-up

Incoming
Power
Q-axis
Exciter
Contactor
Cubicle
Control
Cubicle
6.2 System Verification

To prevent any possibility of a motor moving the mill, the initial motor start should be done before clutch air
is piped to the motor non-drive-end Rotorseal
TM
(or equivalent). If this approach is not feasible, it may be
possible to open the manual valve in the clutch air feed line on the clutch valve control cabinet to block air to
the clutch. All installation safety procedures must be followed.

A separate contract-specific Instruction Book PGEI section EC describes the interface to the self-contained
direct-axis exciter control, with installation, start-up, and trouble-shooting procedures. These exciters allow
for the motor VARs to be controlled. However, the initial motor starts should have the exciter set to field
current control mode. The control can be changed over to VAR control once the motor starts are acceptable
and the VAR feedback has been proven correct (also required for motor pull-out protection).


GE Quadramatic
TM
Drive
Instruction Manual
Page: 23 of 67

Required brushless exciter control interconnections are detailed in the project-specific elementary (typical
sheets are 04FC,FD, FM, GA, 05AA,AB, 06AA,AB):
AC power input;
Switchgear potential transformers (PTs), current transformers (CTs), breaker auxiliary contact (52a),
breaker trip contact (EXC READY), start block contact (NO START BLOCK);
Motor DC brushless exciter field F1, F2, Rotector power and data;
Interface to the Q-PLC EXC READY, OK to load, field force contacts, motor KW feedback;
Interface to the PROCESS PLC motor OK to load contacts, Modbus serial link, and remote VAR
reference.

Other motor connections must be made as per the motor accessories connection drawing. These include:
Stator power
Differential CTs
Stator and bearing RTDs
High-pressure lift pump switches and motors
Space heaters

The first motor starts may require the high-pressure lift pumps to be operated manually, on for at least 30
seconds before motor start and left on until the motor is synchronized. This process is normally controlled by
the DCS, which can be proven later.

Do not touch energized circuits. To avoid electric shock, disconnect all power sources
from the machine and accessories before initiating maintenance procedures.

Follow appropriate lock-out/tag-out procedures and wear appropriate PPE.

The function and method of operation of the circuit must be clearly understood. The
slightest doubt must be cleared up before attempting to energize.

With the incoming power is available to the Quad-control line-up:

Step Description
6.2.1 With all breakers open (elem #BA-QSCB and #BA-CB5 in the incoming cubicle door, #BA-CB4 in
the Q-field supply door):
Verify correct 3-phase line-to-line voltage on the incoming external connection bus stubs.
Check that the phase rotation is 1-2-3 (required for Q-field supply operation).
6.2.2 Close the incoming breaker #BA-QSCB, then:
Verify correct 125VAC voltages on the 125KVA transformer secondary
Confirm that all three lights are lit on the roof-mounted AC-line filter
Leave the Q-field supply power breaker #BA-CB4 open until youre ready to work on the field
supply remember that CB4 has a shunt trip.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 24 of 67

6.2.3 With all fuses #BA-FU13 to FU18 and #BB-FU1, 2,3 (on the exciter fan assembly) on the load side
of the 3KVA transformer #BA-T5 opened, close the small auxiliary breaker #BA-CB5, then verify
correct 240VAC voltages on the 3KVA transformer secondary.
6.2.4 Open all load isolation fuses on the 120VAC 750VA transformer #DA-T6 secondary.
There are two (2) on the contactors diode exciter #DM-FU1, 2, and 12 TB fuse holders (elem #DA)
in the Quad-control cubicle.
6.2.5 Open the small auxiliary breaker #BA-CB5 in the incoming cubicle again so you can safely insert
the three 10A fuses #BA-FU16 to FU18 feeding the 750VA transformer. Close the small auxiliary
breaker (CB5) and then verify correct 120VAC voltages on the 750VA transformer secondary.
6.2.6 Close fuse #DA-FU21 in the control cubicle to power on the PLC.
6.2.7 Close fuse #DA-FU34 in the control cubicle to power on the Industrial PC. Turn on the PC.
6.2.8 Close the other fuses used only within the Quadramatic line-up:
#DA-FU11 for Quad-line-up contacts.
#DA-FU13 for control relays (elem #FL).
#DA-FU31 for the Q-field supply breaker shunt trip coil.
#DA-FU33 for the +/-15V power supply, for Q-current control transducers / isolators.

6.2.9 Enter factory preset Quadramatic control parameters by pressing the HMI Set Factory Values
button (Clutch set-up or Q-current set-up screens). Press the HMI Reset Quad button (any
screen except Quad Fault log) to clear any Q-PLC fault seals except those caused by signals
not commissioned yet.

Perform the following tests after the motor Quad-field
connections are made, before the mill is ready

Once the motor quad-field Q1 and Q2 slip ring connections are wired back to the Q-contactors cubicle, there
is a shorting contactor to provide the path for quad-fields induced current. The motor-mounted shorting bar
must be opened to permit Quad-control load balance current in the motor quadrature fields winding.

Note that the two motors Q1 and Q2 must be separately connected to the Quad-control bus in the contactor
cubicle (4 cables), in order to achieve effective load balancing.

Check that the two motor quad-fields are connected in anti-parallel i.e. motor 1 Q1 and motor 2 Q2 to one
bus in the Quad-control contactor cubicle, motor 1 Q2 and motor 2 Q1 to the other bus.

6.3 Q-field Supply Check

The motor must be at standstill during these checks.

Step Description
6.3.1 The two fuses in the diode rectifier for contactor coil power should be pulled out, so that no Q-
current can flow (elem #DM).
6.3.2 In the incoming cubicle, open the small auxiliary breaker #BA-CB5 before inserting the three 3A
fuses for 240VAC Q-field supply phasing #BA-FU13 to FU15.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 25 of 67

6.3.3 Insert 120VAC fuses on the Q-field supply fans (elem #BB), and then close the small auxiliary
breaker again. The Q-field supply should pick up relays #BD-UV1 and PL, and the three fan
relays.
#BB-FANxOK should pick up with cooling air through the self-heated airflow sensors.
6.3.4 Disconnect the Q-PLC analog output supplying the Q-field supply GPG reference 1TB29 (elem
#BD) and connect an adjustable +/-10VDC test power supply to the GPG reference leave the
power supply turned off or set to 0V to start. There is still no power to the Q-field supply SCRs
because the Q-field supply breaker is still open.
6.3.5 Connect oscilloscope 10X probes in differential DC mode to the Q-field supply output DC bus
bars.
6.3.6 Close the Q-field supply breaker. Nothing should happen no voltage, no current, and no
contactor operation.
6.3.7 Verify that the Q-field supply breaker shunt trip works, either by closing the PLC output contact
(#FL-QXBTRIP) or by overriding it ON through PLC logic. Restore the PLC contact and leave the
breaker closed.

6.3.8 Turn up the test power supply voltage to around 5V to get an open-circuit voltage output from
the Q-field supply. Use the oscilloscope to verify that the bus voltage DC waveform is uniform
i.e. that all field supply SCRs are firing and blocking correctly. Repeat for the opposite voltage
polarity from the power supply. Verify the operation of the voltage feedback transducer
#CA-VT1 and the corresponding Q-PLC analog input (elem #GD) with this open-circuit voltage.
6.3.9 Turn the test power supply to 0-V.
6.3.10 The next test is to control some small (25A) current through the motor Quad-fields. Pick up the
Q-field contactors, by overriding ON Q-PLC output #FL-QXCP %Q2 to pick up the #FL-QXCP relay.
6.3.11 With the power off, replace the fuses in the diode rectifier (elem #DM) contactor coil power.
Restore power, this will close the N.O. bus contactor (elem #DM-QXCC) and open the N.C. bus
shorting contactor (elem #DM-QSC) to permit current to the motors quad-windings.
CAUTION the QSC coil is only short-time rated if the holding resistor is not inserted by
PLC logic output QSCX %Q3 picking up relay #FL-QSCX within a short time, the contactor coil
may be damaged > drop out QXCP or open the rectifier fuses if this happens.
6.3.12 Move the oscilloscope leads to the shunt (elem #CA-SH) or even better (isolated and higher
voltage ~3.7VDC instead of ~30mV) across one of the current feedback isolator outputs (elem
#CA-MTBC16 to 06, MTBC 17 to 05).
6.3.13 Turn up the power supply voltage carefully until there is a little current (25A) flowing, and verify
that the current waveforms are uniform i.e. that all field supply SCRs are firing and blocking
correctly.
6.3.14 Repeat for the opposite current polarity.
CAUTION: Do not apply current for more than 30 seconds on the motor slip rings at standstill
in order to avoid local overheating and damage. Check that equal current flows to the two
quad-field windings, connected in anti-parallel but with no other current-sharing mechanism.
6.3.15 Turn the test power supply to 0-V, open the Q-field supply breaker, and remove any Q-PLC
override on QXCP %Q2 so that the contactors drop out.
6.3.16 Replace the wire from the Q-PLC analog output to the Q-field supply GPG reference 1TB29.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 26 of 67

6.4 Q-Current Test

Perform the following tests after the clutch valve cabinets are connected and verified (air &
electrical) but before the mill is ready.
The clutch air supply system should have already been purged to ensure that it is free of debris.

Step Description
6.4.1 Perform a controlled Q-current test per the HMI Q-current test button (Q-current set-up
screen) with the two motors either both stopped (stator breakers open) or synchronized
(unloaded). This test will request 100 Amps for 2 seconds to the two motors quadrature fields
windings (50 Amps per motor), which is low enough and short enough to not damage the motor
slip-ring connections at standstill.
Note that the Q-current regulator has not been tuned yet, and initial regulator performance is
deliberately slow (Kp = 10, Ki = 1000) to allow the regulators to turn on, even if they dont perform
satisfactorily yet.
The Q-Drive may not produce precisely 100 Amps in the Q-current test with such low regulator
gains. The Q-current test may fail because the winding volts are less than expected. Ignore that
fault for now just reset it if needed. The response of the Q-current regulator is different when the
motors are powered but uncoupled, when the motors are coasting, or when the motors are
running clutched to the mill. The Q-current regulator should be tuned once the mill is ready
(Section 7.1).
6.4.2 Look at the clutch valve cabinet pneumatic schematic and Quadramatic elementary sheets
#MA, MB for electrical interface. In the Quad-control cubicle, with no power, close in fuses:
#DA-FU32 for the 24VDC power supply for both clutch valve cabinets regulator and
dump valves, pressure transducer.
#DA-FU12 for valve cabinet system pressure switches and test pushbuttons (elem #FE).
CAUTION FU12 also powers the mill marker proximity switch and lube system clutch
interlock. Remove external wires from 3TBA54, 55,66,67 if that wiring has not been
verified.
6.4.3 Both manual valves MEV1 and MEV2 should be fully open. The mill air systems should be
supplying 100psi to the two clutch valve cabinets. The air supplies should be equal /
symmetrical, and comply with GE recommendations (as per the pneumatic schematic for the
clutch valve cabinets). The clutch control requires that the regulating valves are working within
the spec tolerances. If the regulating valve malfunctions, it will have to be recalibrated, repaired,
or replaced.
The installation of the clutch valve cabinets by the customer pneumatic instrument technicians
should reviewed by the GE commissioning technician.
6.4.4 Verify that the incoming air pressure switch System Pressure OK (SPOK) picks up at 85 psi
(increasing) for 100-psi air supply to Q-PLC inputs CL1SPOK %I18 and CL2SPOK %I19.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 27 of 67

6.5 Clutch Test

There is a clutch test pushbutton on each clutch valve cabinet, meant for clutch pressure tests at start-up /
maintenance when the mill and this motor are stopped (motor breaker open). There is also a pair of clutch
test buttons on the HMI (Clutch set-up screen), outlined in green when clutch test is permitted, in red when
not. Pressing a clutch test button closes its dump valve and ramps the clutch pressure up to a preset level as
long as the button is pressed. Releasing the clutch test button vents clutch air through the dump valve.

Figure 10: Clutch Valve Cabinet

PR1 Pressure regulator
Clutch test
pushbutton
MV1
Dump
l

Step Description
6.5.1 With mill and motor stopped, press and hold the clutch test button at least three (3) times to
prove that the clutch operates correctly.
6.5.2 Verify that the pressure-regulating valve (PR1) receives 4-20mA from the PLC to make 0-100psi.
6.5.3 Verify that the pressure transducer makes 4-20mA = 0-200psi (12mA = 100psi, 20mA = 200psi).
Do not try to adjust transducer zero / span outside a pneumatic instrument lab. The factory
settings should be good. Do not touch the pilot-regulating valve zero / span pots either,
because there is a Q-PLC calibrate sequence that is discussed below.
6.5.4 When clutch air pressure is at maximum, close both manual valves, release the clutch test
button, and monitor clutch air pressure drop should be less than 5 psi in 10 minutes, to prove
that there are no leaks in the clutch, motor shaft, rotorseal, or valve cabinet.
6.5.5 Repeat the above three steps for the other clutch.

Note that the clutch test pushbutton can also be used to slow / stop a coasting (unpowered) motor against
mill inertia. With the motor breakers open, and mill still rocking, PULSE the clutch test pushbuttons when the
mill is rocking in the opposite direction to motor rotation.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 28 of 67

Most of the motors rotational energy will then appear as insignificant clutch heating. In this way, the motor
coasting times of approximately 20 minutes can be reduced to about 45 seconds.

6.6 Calibrate Clutch

Calibrate both clutches per the HMI Calibrate Clutch buttons (Clutch set-up screen). The PLC steps clutch
air pressure to 75psi and back to 15psi (3 times), adjusting the PLC analog output span for feedback error at
75psi, adjusting PLC analog output zero for feedback error at 15psi.

Figure 11: Clutch Calibration Cycle
CLTSTPR
%R1024
90
psi
70
50
30
10
5
0
Step 1
Step 2
Step 3
Step 4
Step 5
Step 6
Time
mA
mA
Difference =
reference -
feedback
psi
+20
+15
+10
+5
0
-10
Close the
dump
valve
(MV1)
Open the
dump
valve
(MV1)
75
Open the
dump
valve
(MV1)
Too
low


GE Quadramatic
TM
Drive
Instruction Manual
Page: 29 of 67

The feedback should match the reference pressure very closely. Do not adjust the factory-set zero and span
pots on the clutch pressure transducer outside a pressure instrument lab, and only adjust the pilot regulating
valve zero / span pots if you get an HMI alarm message that says the Q-PLC calibration sequence wanted a
reference outside of control range Clutch x calibrate fault high / low reference. In that case, you will need
to do a rough calibration of the regulating valves, as follows:

Step Description
6.6.1 Reset the Q-PLC analog output zero / span to 0 / 32000 at AQxZERO / AQxSPAN on the HMI
clutch set-up screen (AQ3 for clutch 1, AQ4 for clutch 2).
6.6.2 Test the clutch at 75psi (CLTSTPR = 75.0 on the HMI clutch set-up screen), and adjust the pilot
regulating valve span to give 75psi output pressure on the valve cabinet gauge or in the Q-PLC
(variable CL1_PRS %R205 or CL2_PRS %R206).
6.6.3 Test the clutch at 15psi (CLTSTPR = 15.0 on the HMI clutch set-up screen), and adjust the pilot
regulating valve zero to give 15psi actual pressure on the valve cabinet gauge or in the Q-PLC.
6.6.4 Repeat steps 2 and 3 until no further zero / span pot adjustment is required (maybe 2 repeats).
6.6.5 Repeat the Q-PLC fine calibrate sequence to gain more precise pressure control by adjusting
AQxZERO / AQxSPAN. This time, the sequence should finish without any fault message.

6.7 Manual Clutch Pulse - Load 1/2

With all required checks completed and all required permits in place, you can close the clutches and make
manual clutch pulses with the mill and motors at standstill i.e. simulate clutch operation as if the mill were
running. Alternatively, you would have to wait for the mill to be running, and coordinate with mechanical /
production requirements for any changes in clutch control.

Step Description
6.7.1 On the HMI, select clutch pulse control MANUAL (Clutch operate screen), Q-current control OFF
(Q-current operate screen).
6.7.2 To enable clutch functions, override the Q-PLC program logic as follows:
At the clutch permissive coil CL_PERM %M3 in the CLUTCH block, override ON what you
need to get the coil picked up e.g. MILRDYP, BKR1_CL, BKR2_CL, RDY1_LD, and RDY2_LD.
At the test marker coil TSTMRKR %M2000 in the CLUTCH block, change the ALW_OFF
contact to ALW_ON. If you didnt do this, then CL_PERM would drop out per mill speed not
up SPDNUP %M78.
6.7.3 Monitor clutch pressures on either HMI clutch screen.
6.7.4 Pick up the clutches close request coil CLSCLRQ %M58 in the CLUTCH block by overriding the
logic contacts as necessary (toggle the PROCESS PLC mill start contact to seal CLSCLRQ, so you
can use the HMI or Mill Floor Station Stop Mill button to stop) this will close the two clutches
by ramping the pressures to ACCELPR %R1012, then to run pressure RUNPR %R1002 as preset
in the Q-PLC program SYSSU block. The outline of the HMI Manual pulse Load 1 / 2 buttons
(Clutch operate screen) will change from red to green when that action is permitted.
6.7.5 Press the HMI Manual pulse Load 1 button. The button will blink amber to say that a clutch
pulse is armed i.e. waiting for the right conditions to activate. The clutch 2 pressure will go
down to NOMPPR / 3, a minimum for standstill testing (in the CLUTCH block 3 rungs above the
coil for PULPOK1 %M79), and the clutch 2 dump valve will pulse.

GE Quadramatic
TM
Drive
Instruction Manual
Page: 30 of 67

6.7.6 The HMI Clutch Pulse 2 light should flash (Clutch operate screen), and/or you can watch for
the Q-PLC output card (rack 0, slot 6) status light for QPULS2 %Q5 to flash, and/or you can hear
the QPULS2 relay operate (elem #FL), and/or you can hear the air blast from the clutch valve
cabinet as the dump valve opens and re-closes.
6.7.7 If you press the HMI Manual pulse Load 1 button more times, the clutch pulse will be longer
each time by one Q-PLC scan time you should be able to hear the difference in the QPULS2
relay and the valve cabinet air blast after several pulses.
6.7.8 Repeat for Manual pulse Load 2 and clutch 1.
6.7.9 After these tests, remove the PLC program overrides at CL_PERM %M3 coil and CLSCLRQ %M58
coil; change ALW_ON back to ALW_OFF at TSTMRKR %M2000 coil.
6.7.10 Reduce the remembered clutch pulse times C1PTBAS %R1018 and C2PTBAS %R1019 to original
values (on the HMI clutch set-up screen by Set Factory Values (which affects ALL preset
values) or on the clutch operate screen by manually making each equal to CPTBASE %R1020,
shown on the clutch set-up screen).


GE Quadramatic
TM
Drive
Instruction Manual
Page: 31 of 67

Figure 12: Clutch Test Diagram

psi
100
90
80
70
60
50
40
30
20
10
0
mA
20
12
4
0 1 2 3 4 5 6 7 8 9 10 sec.
5
%R999 (MAXPR) =100 PSI =Maximum clutch pressure
PLC REFERENCE
5
%R252 =CLA PREF =Clutch A pressure reference =
%AQ3 (2TBA06(+), 2TBA07(-)
%R253 =CLB PREF =Clutch B pressure reference =
%AQ4 (2TBA10(+), 2TBA11(-)
%R1004 =CLACLSR =
15 PSI/sec =Clutch A
closing pressure rate
%R1005 =Clutch B
psi
100
90
80
70
60
50
40
30
20
10
0
V
10
5
0
0 1 2 3 4 5 6 7 8 9 10 sec.
5
%AI9 =Clutch A PR feedback
pressure (2TBA23(+), 2TBA24(-))
%AI10 =Clutch B PR feedback
pressure (2TBA27(+), 2TBA28(-))
5
psi
100
90
80
70
60
50
40
30
20
10
0
mA
12
8
4
0 1 2 3 4 5 6 7 8 9 10 sec.
PLC
counts
32000
12
0
counts
32000
12
0
%R205 =CLA_PRS =Clutch A pressure feedback =
%AI5 (2TBA14(+), 2TBA15(-)
%R206 =CLB_PRS =Clutch B pressure feedback =
%AI6 (2TBA19(+), 2TBA20(-)
Close the
"dump" valve
Open the
"dump" valve
counts
32000
12
0
Difference between reference
and actual pressure


GE Quadramatic
TM
Drive
Instruction Manual
Page: 32 of 67

7. QUADRAMATIC CONTROL Mill Commissioning

Perform the following tests when the mill is ready

Step Description
7.1 Before the mill can run, the following must be verified:
Emergency stop devices and wiring (elem #DP) so that you can close in fuse #DA-FU22
for that circuit.
Exciter control inputs (elem #FC & FD) so that you can close in fuse #DA-FU11 for that
circuit.
Mill/Clutch cabinet inputs and wiring (elem #FE & FF) so that you can close in fuse #DA-
FU12) for that circuit.
Mill Locked Charge contacts wiring (elem #FJ) so that you can close in fuse #DA-FU14 for
that circuit.
Switchgear inputs (elem #FF) so that you can close in fuse #DA-FU15 for that circuit.
Now all external connections should be verified, and all #DA fuse holders should be closed.
7.2 Early mill starts / stops will be mainly for the mechanical verification.
Select Q-current control OFF and clutch pulse control OFF for early mill starts / stops.
7.3 Once the electrical system is ready, select AUTO for both Q-current control and clutch pulse
control, to let the Quadramatic control system operate with full effectiveness in all modes.
7.4 During the preliminary mill starts, the Q-PLC has been adjusting the mill start ramp rate of clutch
2 air pressure relative to clutch 1 so that the motors are at the same KW (within 5%) after the
mill start. Check the HMI Clutch set-up screen to see if theres any difference between the two
clutch close rates.
This background function can be turned off in the Q-PLC logic by changing ALW_ON to
ALW_OFF in the rung for coil SAVAVDK %M1621 or by overriding OFF SAVAVDK, then reset by
making clutch 2 ramp rate the same as clutch 1 on the HMI Clutch set-up screen. Further, if
you change the behaviour of one clutch vs. the other, then clutch 2-ramp rate should be pre-
biased manually to compensate for the anticipated new difference between the two clutches.

Remaining steps to be taken include:
Tune Q-current regulator.
Tune KW difference regulator.
Determine the effect of Q-current on KW difference QKW_AMP.

All those functions can be done with an empty mill, but should be checked (and repeated if required) when
the mill has significant load and when the results will be more reliable and accurate.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 33 of 67

7.1 Q-field Current Regulator Tuning

With both motors and the mill running, tune the Q-current inner regulator first, and then the KW difference
outer regulator. Remember that you can turn Q-current OFF from the HMI Q-current set-up screen to verify
Q-current or regulator tuning. There are regulator tune-up instructions in the Q_CURR program block
comments, which are reproduced here for reference.

Step Description
7.1.1 When the mill is running and Q-current control is on, tune the Q-field current regulator with the
Q-current reference selected MANUAL (i.e. from the HMI manual reference) so that it is steady.
7.1.2 Toggle field current regulator tune FCRTUNE %M1007 ON to turn on a test step for Q-field
current regulator response. FCRTUNE also blocks a fault QCURFLT %M43 for current feedback
not following reference within a preset tolerance for a preset time.
7.1.3 FCRTUNE toggle is on the HMI Q-current set-up screen. When FCRTUNE is ON, it enables a
square wave on the Q-field current reference, sec at the manual reference and sec. at
(man.ref 50A).
7.1.4 Set up a >= 2-channel chart recorder, one channel on a Q-current feedback (control cubicle left
wall MTBs on the R-C filter output, elem sht #GA) and the other channel on Q-current reference
(put QCREF+S %R251 through the CHART block to a Q-PLC analog output on 1TB, elem sht #GC).
7.1.5 View FC_KP and FC_KI on the HMI Q-current set-up screen, or in the PLC using PME at the
register table, at the program instruction MOVEing constants into them, by zooming on the FC
PID instruction. With the manual reference turned enough that all Q-current is one polarity,
increase FC_KI until you get feedback jumps during the flat part of the reference square wave,
then reduce FC_KI just enough that the jumps are gone. Previous projects have ended up with
FC_KI around 8000.
7.1.6 Increase FC_KP to sharpen the currents step transition edge without overshoot. Previous
projects have ended up with FC_KP around 100.
7.1.7 Store the final values as constants at the PLC program instruction MOVE constants into FC_KP
and FC_KI.
7.1.8 Re-check that equal current flows to the two quad-field windings, connected in anti-parallel but
with no other current-sharing mechanism.
7.1.9 Check for same performance with the manual reference turned so that all Q-current is the
opposite polarity.
7.1.10 Check for same performance with the manual reference turned so that Q-current is back-and-
forth through zero. To get the current stepping OK through zero (the field supply deadband),
factory tests have led to setting the current regulator bias FC_BIAS at +/-19000 per the sign of
the reference.
7.1.11 Record the response charts for future comparison.
7.1.12 Toggle FCRTUNE OFF from the HMI Q-current set-up screen.
7.1.13 Zero the Q-current manual control reference, then select Q-current control AUTO.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 34 of 67

%R912 =16 : BIT 12 OF PID =0 =POSITIVE =MOTORS CCW / MILL CW (looking at the ring gear facing the motor ODE)
Table 2: Q-Field Current Regulator Polarity
%R912 =18 : BIT 12 OF PID =1 =NEGATIVE =MOTORS CW / MILL CCW (looking at the ring gear facing the motor ODE
kW Difference =
NEGATIVE
{Motor A load =high}
kW Difference =
POSITIVE
{Motor B load =high}
kW Difference =
NEGATIVE
{Motor A load =high}
kW Difference =
POSITIVE
{Motor B load =high}
DC(+) BUS
=POSITIVE
DC(+) BUS
=NEGATIVE
DC(+) BUS
=NEGATIVE
DC(+) BUS
=POSITIVE
MOTOR A REDUCE LOAD INCREASE LOAD REDUCE LOAD INCREASE LOAD
MOTOR B INCREASE LOAD REDUCE LOAD INCREASE LOAD REDUCE LOAD
MOTORS CCW
BIT 12 OF PID = 0
MOTOR CW
BIT 12 OF PID = 1

GE Quadramatic
TM
Drive
Instruction Manual
Page: 35 of 67

Figure 13: Q-regulator Tuning
QMANCUR
%R220
1/2 sec
Q_CURR
%R201
3 cases:
+300A
-300A
+25A
3 cases:
+250A
-350A
-25A
50A
FC_KP and
FC_KI =Too low
time
FC_KI =Too high
FC_KI =Good
FC_KP =Too low
FC_KP =Too high
Correct


GE Quadramatic
TM
Drive
Instruction Manual
Page: 36 of 67

7.2 Kilowatt Difference Regulator Tuning

Kilowatt Difference Regulator
With both motors clutched to the mill, tune the KW difference regulator with the Q-current reference selected
AUTO (i.e. from this regulator). Toggle the KW difference regulator tune KWRTUNE %M1008 ON to make the
KW difference reference a square wave of +/-300KW.

NOTE: tune the Q-current regulator BEFORE the KW difference regulator.

Remember that you can turn Q-current OFF from the HMI Q-current set-up screen to verify the Q-current or
regulator tuning.

Step Description
7.2.1 KWRTUNE toggle is on the HMI Q-current set-up screen. When KWRTUNE is ON, it enables a
square wave on the KW difference reference, 5 sec at +300KW and 5 sec at -300KW.
7.2.2 Set up a >= 2-channel chart recorder, one channel on actual KW difference (back of the Q-door
meter) and the other channel on KW difference reference (put DKW_REF %R45 through the
CHART block to a Q-PLC analog output on 1TB, elem sht #GC).
7.2.3 View KW_KP and KW_KI on the HMI Q-current set-up screen, or in the PLC using PME at the
register table, at the program instruction MOVEing constants into them, by zooming on the KW
PID instruction.
7.2.4 Increase KW_KI until you get feedback jumps during the flat part of the reference square wave,
then reduce KW_KI just enough that the jumps are gone. Previous projects have ended up with
KW_KI around 7000.
7.2.5 Increase KW_KP to sharpen the KW difference step transition edge without overshoot. Previous
projects have ended up with KW_KP around 200.
7.2.6 Record the final values as constants at the PLC program instruction MOVEing constants into
KW_KP and KW_KI.
7.2.7 Toggle KWRTUNE OFF from the HMI Q-current set-up. The Q-door KW difference should stay
on zero, while the Q-current meter will correct for any motors KW unbalance.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 37 of 67

Figure 14: Quad PID Regulator Diagram

DEADBAND
%R903/904
=0
PROPORTIONAL
GAIN - Kp
%R905
INTEGRAL GAIN -
Ki
%R907
SLEW
LIMIT
%R911
=0
UPPER/LOWER
CLAMP
%R909/%R910
=+/- 600A
POLARITY
%R912
Bit 1
SP
%R45
DKW_REF
=0 kW
PV
%R257
DIFF_KW
CV
%R250
QCURREF
DEADBAND
%R943/944
=0
PROPORTIONAL
GAIN - Kp
%R945
INTEGRAL GAIN -
Ki
%R947
SLEW
LIMIT
%R951
=0
UPPER/LOWER
CLAMP
%R949/%R950
=+/- 75% max
POLARITY
%R952
Bit 1
CV
%AQ1
QGPGREF
+
-
BIAS
%R908
=0
PV
%R199
Q_CURR
SP
+
-
BIAS
%R948 =
+/- 19000
KW PID Regulator
FC PID Regulator


GE Quadramatic
TM
Drive
Instruction Manual
Page: 38 of 67

7.3 Effect of Q-Current on kW Difference (QKW_AMP)

The last parameter to tune is the effect of Q-current on KW difference QKW_AMP. This determines what the
motors KW difference would be if Q-current were OFF. If the KW difference is too large, the clutch is pulsed as
the coarse adjustment to restore load balance.

Step Description
7.3.1 With the mill running with at least 1/4 load, press the HMI Determine QKW/AMP button (Clutch
set-up screen).
7.3.2 The automatic procedure collects:
With Q-current ON, average Q-current and average (leftover) motors KW difference over
a full mill revolution.
With Q-current OFF, average motors KW difference over a full mill revolution.
7.3.3 The overall KW difference is the same, so the scale factor QKW_AMP on Q-current to make
equivalent motors KW difference is calculated. The value can be seen on the HMI Clutch set-
up screen.

With the mill running, Q-current control selected AUTO, clutch pulse control selected MANUAL, you can
exercise all the Quadramatic control components by doing several manual clutch pulses on the same motor
(e.g. Load 1 = pulse clutch 2). Dont do so many manual clutch pulses that you cause a sustained load
unbalance fault and mill stop; just enough to go over the preset to initiate AUTO clutch pulses when you
select AUTO.

The manual clutch pulses will cause a large motor KW difference, which can be seen by the increase in Q-
current the KW difference meter will still read zero. If you then turn clutch pulse control to AUTO, you will
get clutch pulses on the other motor (e.g. clutch 1) to reduce the overall motors KW difference, which you can
see by the decrease in Q-current the KW difference meter will still read zero. When the auto clutch pulses
stop, you could repeat the test by several manual clutch pulses on the other motor (e.g. Load 2 = pulse
clutch 1) and verify Quadramatic control operation for KW difference from that direction too.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 39 of 67

8. PREVENTATIVE MAINTENANCE

Periodic preventive maintenance extends equipment-operating life and minimizes downtime. For maximum
benefit, preventive maintenance needs to be performed at scheduled intervals by a qualified technician. The
required frequency for each procedure depends on:
How much the equipment is used
Ambient environmental conditions
In addition, an inspection of wiring and components should be completed before re-applying power after an
overcurrent trip.

Maintenance Record
GE recommends that the customer keep a detailed record of maintenance for every drive. This record is
intended for two purposes:
To verify that all equipment is routinely checked
To provide a history of equipment maintenance and problems that will be useful for both preventing
and troubleshooting equipment failure
For example, the record should include the time and date of the maintenance checks, detail any equipment
defects found, and specify repairs or corrective action.

Tools/Materials Needed

The tools and materials listed below may be needed when performing preventive maintenance on the drive:
High quality tools, including screwdrivers and pliers, designed specifically for working with electrical
wiring systems
Socket set
Wrench set
Feeler gauge
Electrical tape
Fine file
Clean dry cloth
Soft-bristled brush (such as a paintbrush)
Insulation resistance tester
Vacuum cleaner with non-metallic nozzle and finely woven, high efficiency filter
Replacement components, if required, including fuses, wiring, and cabling

GE Quadramatic
TM
Drive
Instruction Manual
Page: 40 of 67

8.1 Power-Off Checks

Power must be de-energized before performing any adjustments, servicing, or
other act requiring physical contact with the electrical components or wiring.

Power-off checks involve cleaning the equipment and checking for wear and damage through visual
inspection and functional tests.

Before starting, the equipment must be prepared as follows:
1. De-energized
2. Tagged and locked out
3. Tested for zero voltage (using a tester approved for the voltage level being measured)
4. Safety grounded
Do not deviate from these conditions. If safety requirements cannot be met completely, or if you do not
understand them, do not work on the equipment.

Cleaning the Equipment

Build up of dust on electrical components and wiring can damage
components and may cause malfunctions.
The electrostatic wristband that is provided in the control cubicle should
be used when working around any of the control cards.

Dust Removal
Build-up of dust on components can increase operating temperature, reducing their normal life. On
standoff insulators, it can collect enough moisture to produce a current path from bus bars to chassis
ground.
Dust on wire surfaces can cause tracking between connector pins. Tracking is usually capacitive in
nature and involves a build-up of electrical charge along the wire surface. This can cause intermittent
problems that are hard to find.
Check for and remove accumulated dust as follows:
1. Clean bus bars and standoff insulators with a clean dry cloth do not use any solvents.
2. Using a fine-filtered vacuum cleaner with a non-metallic nozzle, remove dust and dirt from
wiring and electrical components.

GE Quadramatic
TM
Drive
Instruction Manual
Page: 41 of 67

Note: Make sure that the air source is directed so that dust and foreign matter is removed rather
than relocated

Do not use high-pressure compressed air, which may damage components.

Printed Circuit Boards
If boards in a module are dirty:
1. Vacuum to remove dust from around the board slots/connections (before unplugging). A soft-
bristled brush may be used to loosen dirt.
2. Vacuum the boards, using a soft brush, if necessary, to help loosen dust.

Loose Connections
Vibration during equipment operation can loosen mechanical and electrical connections, causing
intermittent equipment failure. Additionally, dust and moisture can accumulate in loose connections.
This can cause loss of low-level signals at terminal boards and also thermal runaway at bus
connections.
1. Check all hardware and electrical connections, and tighten if needed.
2. Tighten or replace any loosened crimp-style lugs.
3. Tighten or replace all loose or missing hardware.
4. Inspect printed wiring boards for correct seating, and check that any plugs, wiring, and bus
connectors are tight.
To prevent component damage caused by static electricity, treat all boards with static sensitive
handling techniques. Use a grounding strap when handling boards or components.

Damaged Insulation
Wires and cables with damaged insulation are dangerous when carrying electricity. They can also
intermittently short, causing equipment and functional failure.
1. Check all wires and cables for fraying, chipping, nicks, wear, or rodent damage.
2. Check all wires and cables for signs of overheating or carbonization.
3. Replace any damaged cables or wires.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 42 of 67

Contactors and Relays
1. If possible, manually trip the device to ensure that it works properly.
2. Inspect contacts on open (as opposed to sealed) contactors and relays. Discoloration and
rough contact surfaces are normal.
3. If beads have formed because of severe arcing:
a. Dress the contact faces with a fine file. Do not use emery cloth or sandpaper. Remove
any carbon residue.
b. Identify and correct the cause of arcing.
c. Refer to the components publication for detailed instructions on maintenance, repair,
and replacement procedures.

8.2 Q-Axis Exciter Maintenance and Troubleshooting

The SCR cells and cooling fins should be kept free from dirt, oil and grease, since an accumulation of dirt may
cause overheating. Check for loose power or control connections to the conversion unit.

The fans should be inspected regularly. Check for:
Excessive noise or vibration.
Loose mounting.
Fan blade striking housing.
Motor overheating.
Dirty blades.

The airflow switch should also be checked.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 43 of 67

Phase Shift Network Checks
The angles of the phasing signals can be easily checked with a differential oscilloscope by connecting the
two probes across the input power lines AC-1 and AC-2 with the top probe on AC-1.

When checking phasing on the AC lines, caution must be exercised to avoid injury.
Ensure that only 10X or 100X probes are used.
Do not connect or remove the probes when the power is on.

When checking the phasing voltages on the card, ensure that the drive contactor is not energized
in case of accidental shorting, which can cause random SCR firing and damage components.

Set the oscilloscope triggering to AC line and adjust the waveform to give one cycle on the scope face as
shown in Figure 15.
Figure 15: AC1 to AC2 Waveform
0 180 360

The probes can now be removed and used to check the phasing signal inputs to the card for correct
magnitudes, which should be approximately 30 volts peak-to-peak, and for the correct phase relationships
as outlined below:

CP205 - Common 0 (i.e. in phase with AC1-AC2)
CP204 -
Common
180
CP203 -
Common
60 (i.e. lags AC1-AC2 by 60)
CP202 -
Common
240
CP201 -
Common
120
CP200 -
Common
300


GE Quadramatic
TM
Drive
Instruction Manual
Page: 44 of 67

The phase-shifted signal should have amplitude of approximately 20 volts peak-to-peak and will have phase
relationships with AC1 - AC2 as follows:

CP210 - Common 30 (i.e. lags AC1-AC2 by 30)
CP211 -
Common
210
CP212 -
Common
90
CP213 -
Common
270
CP214 -
Common
150
CP215 -
Common
330

Circuit Card Removal and Replacement

If it should ever be necessary to replace a circuit card, the following procedure should be used:

1) Ensure that power to the drive is removed and locked out.
2) Attach the anti-static wristband.
3) Remove the cover from the circuit card by depressing the retaining latch of each of the supporting
standoffs and pulling the card cover until free.
4) Carefully pull off all wires going to the stab connectors on the circuit card.
5) Loosen the screws on the circuit card connector terminal board (1TB) approximately two turns.
6) Loosen the top of the circuit card from the conversion unit by depressing the retaining latch of each
of the supporting stand-offs and carefully pull the card forward until free.
7) Remove the circuit card, taking care not to bend the 1TB connectors. Replace the card cover on the
card assembly to ensure that it does not get damaged.
8) Install the new circuit card by using the reverse of the above procedures. All wires terminating on
stab connectors on the card have sleeve markers to indicate the correct position. Ensure that the
circuit card sits squarely on 1TB before tightening the 1TB screws.
9) When the replacement card has been installed, recheck all wire numbers on the stab connectors and
set the potentiometers shown on the new card to match those on the old card. Wiper positions of the
potentiometers on the old card can be determined by using a small screwdriver to turn the pot
setting to either end stop and noting the amount of turning required.
10) The circuit card should now be ready to run. Ensure that no tools or loose hardware have been left in
the control enclosure before reapplying ac power.
11) When the power is reapplied, check that the phase rotation light is on and then run the drive.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 45 of 67

SCR Removal and Replacement

Terminated Cell

1) For the removal of a terminated cell SCR, it is suggested that the aluminium heat sink be unbolted
from its insulated standoffs so that the SCR retaining nut (3/4 - 16) can be easily removed. Note the
routing of the SCR gating leads before removing them from the stab connectors of the SCR
Disconnect Cards.
2) Ensure that the gating leads of the replacement SCR are cut to the same length as those on the SCR
being removed. Transfer all insulating and marking sleeves from the removed SCR to the
replacement and crimp the new stab connectors securely.
3) Referring to Figure 16, ensure that the surface noted has sufficient silicone grease (GE No. 623, Dow
Corning
DC3 / DC4, or equivalent) to completely cover it. Insufficient grease will impair heat transfer
from the cell to the heat sink and may damage the SCR.
4) The correct position of the Belleville washer is concave towards the aluminium heat sink
5) Before tightening the SCR to the heat sink, rotate the cell in the hole so that its terminal lug end can
be connected without strain on the cell.
6) Torque the - 16 retaining nut to approximately 28Nm (250 inch-pounds).
7) Wipe excess grease from around the base of the cell to prevent excessive accumulation of dust.
8) Ensure that all gating and snubber leads are routed exactly as they were before the SCR change.

Figure 16: Terminated Cell SCR Mounting Details


GE Quadramatic
TM
Drive
Instruction Manual
Page: 46 of 67

Press pack Cell

Since the press pack cell assemblies are tested after assembly into the heat sinks, the cells are not
individually replaceable by the customer and must be returned to the factory for repair. Note the routing of
control wires, which make connections to the press pack cell assembly to be removed before removing it.
The identical routing should be maintained after the replacement is made.

All bolts used to make connections to the press pack heat sinks can be tightened to normal torques for the
particular bolt size and type used. Ensure that when a cell is replaced, it is oriented in the same direction as
the original. For reference, a copy of the cell orientation will be found on the rear of the conversion unit door.

Figure 17: 53mm Press pack Cell Assembly


GE Quadramatic
TM
Drive
Instruction Manual
Page: 47 of 67

Table 3: Troubleshooting Checks Drive Does Not Operate

Step Check Point Action
1 Control Card Lights If all lights on the control card are extinguished, this may indicate that two or more
phases of input ac power are not present on the converter. This same condition
may also be indicated by all of the cell monitor lights being extinguished. If any
lights are illuminated, go to Step 2.
If all lights are out, check the line-to-line voltages between the top terminals of
FU4, FU5, and FU6 which should be within 10% of the ac input voltage as shown
on the elementary diagram.
2 Phase Loss Light
(L181)
If the Phase Loss Light (L181) is illuminated, press and release PB100. If the light
extinguishes, try to operate the drive. If the light remains illuminated, this may
indicate that one of the three AC input power phases is not present on the
conversion unit.
If two cell monitor lights, which monitor the same AC phase, are out, this may
indicate that input power to that phase is not present. Confirm that the line-to-line
input voltages between the top terminals of FU4, FU5 and FU6 are within 10% of
the AC input voltage as shown on the elementary diagram.
If the voltages appear correct go to Step 3.
3 FU4, 5, 6 If it appears that AC power is not present on the circuit card, or if the phase loss
circuit remains tripped with proper line-to-line voltages measured between the
tops of FU4, FU5, and FU6; check that the same line-to-line voltages appear on the
bottoms of FU4, FU5, and FU6.
If the same line-to line voltages appear, go to Step 4.
If one or more of the line-to-line voltages measured on the bottom of the fuses
differs from those measured on the top, remove power from the drive and check
fuses FU4, FU5, and FU6 with a multimeter. Replace any open fuses with the exact
type specified in the spare parts list or that supplied with the drive.
Reapply power and go to Step 5.
4 Phasing Inputs If it appears that AC power is not present on the circuit card, or if the phase loss
circuit remains tripped with proper line-to-line voltages measured between the
bottoms of FU4, FU5 and FU6; check for the proper phasing inputs to the circuit
card by following the procedures outlined earlier in the maintenance section titled
"Phase Shift Network Checks".
Defective wiring or a defective phasing transformer may cause incorrect phasing
inputs to the control card.
If the correct phasing inputs are present on the control card, go to Step 5.
5 Control Card Power
Supplies
Check the control card power supplies with respect to the ACOM bus for the
following levels:
P15V on 1TB39: +15 Vdc 1.5 Vdc
P10V on 1TB40: +10 Vdc 0.1 Vdc
P5V on CP206: + 5 Vdc 0.2 Vdc
N10V on 1TB36: -10 Vdc 0.1 Vdc
N15V on 1TB37: -15 Vdc 1.5 Vdc

GE Quadramatic
TM
Drive
Instruction Manual
Page: 48 of 67

Step Check Point Action
6 Cell Monitor Lights Do not attempt to operate the drive if any cell monitor lights are extinguished. Any
cell monitoring light being out may indicate that a fuse in series with it may be
open or that an SCR in parallel with it is shorted. Check suspect fuses for continuity
with an ohmmeter and, if necessary, replace it with the exact type specified in the
spare parts list or that supplied with the drive.
Check suspect SCR's as described in Step 7.
7 SCRs Use a multimeter to check the resistance from anode to cathode and reverse. A
reading of 20k or less indicates a faulty cell, which should be replaced (a failed
cell usually is a short circuit).
NOTE: Presspack SCR cells are not individually replaceable by the customer.
Presspack units such as those shown in figure 17 must be returned to the factory for
repair.
8 Diodes Use a multimeter to check the resistance of diodes from anode to cathode and
reverse. The reading one-way should be 20 k or more and the other way should
be 5 to 2000 ohms (a failed diode is usually short circuited in both directions).
9 HMI or PLC Faults Ensure that there are no active faults in the Q-PLC logic. If there are active faults,
proceed to troubleshoot the particular fault.
Reset the faults once the source of the fault has been identified and corrected.
10 Magnetics Attempt to run the drive.
If all the required control logic and drive contactors pick-up, go to Step 11.
If one or more coils do not pick-up, check for the proper coil voltage on suspect
devices. If the proper coil voltage is present, remove power for the entire drive and
check the devices movement by hand to ensure that it is free to move. If the
devices movement is free then replace the coil.
11 Regulator and Converter
Control
Apply a manual current reference for the forward direction and attempt to run the
drive. If it does not operate then monitor the output with a multimeter and stop at
any point where the reading does not agree.
Correct the problem.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 49 of 67

Figure 18: Converter Control Timing Waveforms
0 60 120 180 240 300 0 60 120 180 240 300 0 60
L1-L2
L2-L3
L3-L1
L2-L1
L3-L2
L1-L3
0 60 120 180 240 300 0 60 120 180 240 300 0 60
L1-N
L2-N
L3-N
P3
N2
P2
N3
P1
N2
P2
N1
P1
N3
P3
N1
P2
N3
P3
N2
P2
N1
P1
N2
P3
N1
P1
N3
P3
N2
P2
N3
P1
N2
P2
N1
P1
N3
P3
N1
P2
N3
P3
N2
P2
N1
P1
N2
P3
N1
P1
N3
RECTIFYING
INVERTING
P1
N1
P2
N2
P3
N3
POSSIBLE SCR
CONDUCTION
RANGE
(MAX CI=120 deg)
a =0 a =180 (for SCR P1)
deg.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 50 of 67

APPENDIX A - QUADRAMATIC DRIVE SPECIFICATIONS

Input Power Supply kVA 125
Input Voltage V 400, 480, 600, or special
Input Frequency Hz 50 or 60
Physical Dimensions of Quad Drive Width {mm} 4 270 (168 inches)
Depth {mm} 765 (30 inches)
Height {mm} 2 660 (90 inches)
{not including 380 high AC filter}
Weight {kg} 2 200 (4800 lb)
Recommended operating location Indoors, HVAC Controlled, Non-corrosive,
Clean environment
Ambient Air Operating Temperature Range C 0 40
Ambient Air Storage Temperature Range C 0 60
Humidity %R.H. 0 95 (non-condensing)
Cooling System Type Forced air (internal)
Heat Loss Rejected into Electrical Room kW 6
Enclosure NEMA Rating 1
Enclosure Door Access Front
Cable Entry locations Power Side or top
Control Top or bottom
Field Transformer Type Dry, ANN
Field Transformer Winding Material Copper
Field Transformer Protection Provided Overload, short circuit, and overtemperature
Field Transformer Location Inside Incoming Power Cubicle
Operator Interface HMI Display on Control Cubicle door
Control System Type GE Fanuc 90/30 PLC in Quad Drive
Hardwired I/O Yes
Digital Communication Interface(s) Standard SRTP standard
Optional Modbus RS-485 Slave
Ethernet Modbus TCP Server or other
Torque Regulation Accuracy 0.5% (steady-state)
Torque Control Maximum Imbalance
between motors
20% of motor rating


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TM
Drive
Instruction Manual
Page: 51 of 67

APPENDIX B QUAD CONTROL PERMISSIVES LOGIC DIAGRAM

%I1 - No Emergency Stop
%Q8 - No Emergency Stop
%I6 / I14 - No Exciter A / B faults
%M36 / M37 - Clutch A / B opened fault
%M68 / 73 - Clutch A / B lowpressure fault
%M70 / M72 - Clutch A / B pressure not =ref
%M39 / M41 - Clutch A / B pressure not =run
%M78 - Mill not up to 95%speed
%M221 / 223 - High load unbalance
%M1 - PERMX
Auxili ary permissi ves
%I73 / 74 - Analog module 2 OK
%M318 / 319 - Clutch A calibrate fault
%M348 / 349 - Clutch B calibrate fault
%I25 / 26 - Motor A / B breaker closed
%I7 / 15 - Motor A / B ready to load
%M15 - CL_RDY
Clutches ready for operation
%I22 - Lube systemOK
%I31 - Mill run permissive - DCS
%M205 - Clutch reclose block
%M60 - Clutch close command
%M3 - CL_PERM
Clutch close permissive
Clutch Close Permissive Logic Q-Current Permissive Logic
%I13 - Q-breaker closed
%I5 - Q-exciter OK
%M16 - Q-exciter fans fault
%I65/66/89/90 - Analog I/O card fault
%M21 - Q-contactors fault
%M43 - Q-current not =ref fault
%M121 - Q-overcurrent
%M123 - Q-overvoltage
%M125 - Q-crowbar fault
%M127 - Q-shorting contactor fault
%M46 / 53 - kW or QC PID calculation fault
%M5 - QCPERMX
Q-current control
permissi ve
%I7 / 15 - Motor A / B ready to load
%M64 - Both clutches closed
%M65 - Mill up to 95% speed
%M26 - Q-current test fault
%M7 - Q-control in manual
%M8 - Q-control in auto
%M2 - Q_PERM
Q-field control
permissive
%M33 - QTSTPRM
Q-current test permissive
%M60 - Clutches closed

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TM
Drive
Instruction Manual
Page: 52 of 67

APPENDIX C MODBUS INTERFACE TO QUADRAMATIC CONTROL PLC

The Q-PLC will act as a slave on the MODBUS link. The MODBUS master must issue commands to the
slave to read data from the Q-PLC registers. The registers used have been grouped into a contiguous
set for speed and ease of communication. It is important that only that registers defined here are
used.
CAUTION: MODBUS RTU protocol does not support any form of memory protection. It is possible to
write data to any reference in the PLC memory. It is important to ensure that the correct registers are
addressed as defined in this document. Failure to do this may result in unexpected operation or
process shutdown.
Ethernet link status signals (80 bits long) {if this option is selected}
PLC REGISTER
MODBUS
REGISTER
BIT DEFINITION (for bit true)
1-7 Reserved
8 AAUI (90-30) fuse blown
9 Any SRTP Channel Error
10-12 Reserved
13 LAN OK
14 Resource problem
15 Reserved
16 LAN Interface OK
17 Connection Open - Channel 1
18 Reserved
. ...
47 Connection Open - Channel 16
48 Reserved
%I1001 101001
49-80 Reserved for 90-30
Fault (trip) signals
PLC REGISTER
MODBUS
REGISTER
BIT DEFINITION (for bit true) Same logic as
1 Class 1 Fault (Stop Mill) %Q0021
2 Quad-PLC Fault %Q0017
3 Spare
%R2700 431884
4 Spare

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TM
Drive
Instruction Manual
Page: 53 of 67

Alarm (non-tripping) Signals
PLC REGISTER
MODBUS
REGISTER
Same logic
as
1 Class 2 Fault (Alarm) %Q0022
2 Load Balance Alarm %Q0025
3 Just one clutch engaged Alarm %Q0026
4 Spare
%R2701 431885
5 Spare
Status Signals
PLC REGISTER
MODBUS
REGISTER
Same logic
as
1 Mill Stopped (clutches open)
2 Mill Running (above 95% speed) %Q0029
3
Clutch Pulsing Available (mill
running, pulses manual, or
t )
%Q0020
4 Quad-Current Control Available
5 Quad-Control Healthy %Q0024
6 D-axis exciter A healthy %I0006
7 D-axis exciter B healthy %I00014
8 Spare
9 Spare
10 Motor A Start Permissive
(1)
%Q0011
11 Motor B Start Permissive
(1)
%Q0012
12 Motor A Ready to Load %I0007
13 Motor B Ready to Load %I0015
14 Clutches Close Permissive
(2)
%Q0028
15 Load Balance Stopped %Q0027
%R2702 431886
16 Spare
1 Quad-Current Test in Progress
2 Sound Mill Start Horn %Q0032
3
Both Clutches Feed Air
Pressure OK
%Q0023
4 Clutch A & B engaged %Q0009
5 Spare
%R2703 431887
6 Quad-Current Auto

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TM
Drive
Instruction Manual
Page: 54 of 67

7 Quad-Current Off
8 Quad-Current Manual
9 Spare
10 Clutch Pulses Auto
11 Clutch Pulses Off
12 Clutch Pulses Manual
13 Clutch Engagement Blocked
(3)

14 Spare
15 Spare

16 Spare
Variable Signals
PLC REGISTER
MODBUS
REGISTER
SCALING DEFINITION
%R2704 431888 1 = 1 kW Motor A Power Input
%R2705 431889 1 = 1 kW Motor B Power Input
%R2706 431890 1 = 0.1 A Motor A Quad-Field Current
%R2707 431891 1 = 0.1 A Motor B Quad-Field Current
%R2708 431892 1 = 0.1 PSI Clutch A Pressure
%R2709 431893 1 = 0.1 PSI Clutch B Pressure
%R2710 431894 Spare
%R2711 431895 Spare
Notes:
1) According to Quad-control only; must be combined with DCS motor auxiliary permissives for
DCS reply "Motor Ready to Start/Run"
2) According to Quad-control only; must be combined with DCS mill auxiliary permissives for
DCS reply "Mill Ready to Start/Run"
3) Mill rocking or clutches hot (5 minute time delay between mill starts)
4) Register data sent as integer data (e.g. variables) are sent as 16 bit signed integers with the
most significant bit set to indicate a negative sign, or zero to indicate a positive number. The
range of integers is from -32,768 to +32,768
5) Register bit sequence:

where Bit value = 1 = TRUE
Bit value = 0 = FALSE


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TM
Drive
Instruction Manual
Page: 55 of 67

APPENDIX D DESCRIPTION OF SELECTED QUAD VARIABLES

PLC
REGISTER
VARIABLE
NAME
DRAWING DESCRIPTION DETAILED DESCRIPTION
%I17 QCTESTM Test Q-Current Field Circuit
{#FE06}
A Q-current test has to be successfully performed prior to a
motor start. This can be done by touching the HMI display on
the Quad or by this signal from the DCS.
%I18/I19 CL1SPOK/
CL2SPOK
Valve Cabinet A/B (SPOK)
{#FE12/18}
This contact indicates that the inlet air pressure into the clutch
control cabinet is high enough for the Quad system to operate.
It is usually set between 80-90 psi depending on the specific
project requirements.
%I21 MILMRKR Mill Marker {#FE30} GE supplies the mill marker magnet and proximity switch loose.
The mill marker consists of a proximity switch, which is
mounted on the mill floor (adjacent to the mill) and a magnet
that is mounted on the mill shell (by others).
The mill marker contact is used to indicate the position of the
mill. This input into the Quad allows it to determine when the
mill has accelerated in order to enable the load balancing. It
also provides a fixed reference so that the kW unbalance is
always measured over a complete revolution and that the
clutch pulsing (when required) is performed at the same axial
location of the mill.
%I22 LSCLILK Lube System Clutch
Interlock {#FE36}
This contact is from the Mill Lubrication system. It indicates that
the mill lube system is running. It is one of the permissives that
allows the Quad to close the clutches.
%I28/I29 BKR1_CL/
BKR2_CL
Closed for Motor A/B Main
Breaker closed, opens
when breaker is asked to
trip (before actual trip)
{#FF06/12}
"If the motors are operated by switchgear with a 3-5 cycle trip
time, receiving the trip signal from the switchgear 86 relay will
allow sufficient time to turn the SCRs off. If this logic is
implemented, there is no need for an intentional time delay on
the breaker trip circuit.
%Q11/
Q12
M1STRPP/
M2STRPP
Motor A/B Start Permissive
{#FM23/28}
The Quad motor start permissive includes: the DCS motor
ready to start, no emergency stop, ESP1 exciter ready (no
alarms or trips), the Q-axis field has to be shorted, a successful
Q-current test completed, and the clutch pressure has to below
5 psi.
%Q17 QPLCOKP Fault Quad {#FN04} This contact is open when the Quad PLC is shutdown.
%Q18 QRESETP Quad control reset (status)
{#FN07}

%Q19 CPULRP Remote clutch control
pulse {#FN10}
This contact is closed when either of the clutches is pulsed.
%Q20 QCONRP Quad control remote
(status)
This contact is closed when clutch pulsing is allowed.
%Q21 CL1FLTP Class 1 Fault (Stop Mill)
{#FN16}
This contact is closed if the Quad loses the clutch close
permissive. This permissive contains: no emergency stop,
ESP1 A/B ready, clutch pressure interlocks OK, mill not
accelerated, or sustained / instantaneous high load unbalance.
%Q22 CL2FLTP Class 2 Fault (Alarm)
{#FN19}
This contact is closed if there is a Quad-control fault, the load
unbalance is high, Q-field current is high, or if the clutch pulsing
has timed out.

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TM
Drive
Instruction Manual
Page: 56 of 67

PLC
REGISTER
VARIABLE
NAME
DRAWING DESCRIPTION DETAILED DESCRIPTION
%Q23 AIROKP Both clutch air supply
pressures OK {#FN22}
This contact is open if the inlet air pressure into either clutch
control cabinet is too low.
%Q24 QCRDYP Quad control ready to
operate {#FN25}
This contact is closed when the Quad current control is ready
for operation.

%Q25 HLUAP Load balance alarm
{#FN28}
This contact is closed when there is a high load unbalance.
%Q26 JOCP Just one clutch (alarm) This contact is closed when either clutch is not closed.
%Q27 CBFP Clutch balance failure This contact is closed if the clutch pulsing has timed out.
%Q28 CLCLSPP Clutches close permissive
{#FN37}
This contact is closed if the Quad clutch permissives are true.
These permissives include both motor breakers closed, mill lube
system running, ESP1 ready to load, no faults, and Quad control
OK.
%Q29 MILRNGP Mill Running {#FN40} This contact is closed when the mill is up to full speed (the Quad
has received two mill marker pulses and the speed is above
95% of rated).
%Q30 CPRMP Clutch Control Permissive
(Status) {#FN43}
This contact is closed when clutch pulsing is allowed.
%Q31 QREXP Q-current regulator enable
{#FN46}
This contact is closed when the Q-current regulator is ready to
operate.
%Q32 MILHRNP Sound Mill Start Horn
{#FN49}
This contact is closed when a clutch close request is received.
The clutches are closed after a short time delay (usually 5
seconds).


GE Quadramatic
TM
Drive
Instruction Manual
Page: 57 of 67

APPENDIX E MILL MARKER INSTRUCTIONS

The mill marker consists of a proximity switch, which is mounted on the floor and a magnet
that is mounted on the mill shell (by others). GE supplies these devices loose to be installed
on the mill by others.

The mill marker contact is used to indicate the position of the mill. This input into the Quad
allows it to determine when the mill has accelerated in order to enable the load balancing. It
also provides a fixed reference so that the kW unbalance is always measured over a
complete revolution and that the clutch pulsing (when required) is performed at the same
axial location of the mill.

The specific mounting requirements of the mill marker is described in the following
documents:
GE Drawing no. 0218B1121CA Conceptual Drawing for Mill Rotation Sensor
W.A. Electric Datasheet (WA100A-0994)
W.A. Electric Drawing no. 189A8918 Outline CR9440QST2 Proximity Switch
W.A. Electric Drawing no. 615B722 Outline & Operating Dimensions Magnetector
limit switch & signal magnets

The approximate thread length of the magnet (QM4A) is 3/4" long. The approximate thread
length of the proximity switch (QST2) is 1/2" long. The long axis of switch and magnet can be
mounted anti-parallel (threaded ends pointing in opposite directions) and perpendicular to
each other (as in Figure 4, 5, and 6 of the manual).

Switch mounting
Current carrying conductors should be kept away from the switch (see PGEI-1343).
The switch-mounting bracket should be adjustable to allow installation as per the
mounting directions in the manual.
This switch should be assembled on the mill floor once the mill has been set in
position. The proper operation of the switch should be confirmed prior to starting the
mill.
The manufacturer recommends a 3/4" non-magnetic spacer for both the magnet and
switch. However, we know of successful installations that have used steel mounting
hardware.
Non-magnetic conduit fittings such as aluminium can be used to provide the
recommended spacer.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 58 of 67

Magnet mounting
As a general rule, all steel work should be a minimum distance of 6 inches from the
magnet centre.
Mounting the magnet on steel as opposed to a non-magnetic surface may reduce the
minimum operating distance by 3". As per the W.A. Electric manual, we recommend
that a mock-up of the application be tested prior to final installation.
The magnet mounting location should be guarded to prevent injury to personnel from
the rotating parts.

GE Quadramatic
TM
Drive
Instruction Manual
Page: 59 of 67

APPENDIX F SUMMARY OF GE WIRING PRACTICE (PGEI-1343C)

Grounding

There should only be one common ground for the control system.
A minimum 1/0 AWG (50mm
2
) diameter cable is recommended for control cubicle
grounding.
All control cubicles should be tied into a common ground point (star grounded
system).
There should be at least one chassis ground per shipping section. This ground
connection should be connected to a good earth ground.

Methods of Reducing Signal Noise

1. Re-route sources of noise away from signal wires.
2. Use noise-suppressors on relay and contactor coils.
3. Use shielded wire.
4. Use twisted pair wires.
5. Electrostatic shielded transformers.
6. Chassis ground.
7. Common control system ground.

To reduce signal noise, wires of like signals or power levels should be physically grouped
together and run in separate groups known as levels. Normally, customer interconnections
between equipment will require all four levels of separation. However, in control panels, the
conductor length is considerable shorter so it may be possible to combine the four into two or
three levels.

Most sensitive to noise
Level 1 Low Analog signals less than 50Vdc, Digital signals 0-12Vdc.
Level 2 Medium Analog signals greater than 50Vdc with less than 28Vac ripple. 28Vdc
light and switching circuits.
Level 3 High DC switching signals greater than 28V. Analog signals greater than
50Vdc with greater than 28Vac ripple. Regulating signals greater than
50V with current less than 20A. AC feeders less than 20A.
Level 4 Power AC and DC, 0-800V with current 20-800A.
Least sensitive to noise


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TM
Drive
Instruction Manual
Page: 60 of 67

Implementation of Level Wiring

1. The wire levels should be adhered to as closely as possible.
2. Wires should be kept as short as possible.
3. The levels should be separated by as large a distance possible (as is practical) or by a
grounded metal barrier.
4. Wiring that must cross a different level should cross at 90.

Rules of Level Wiring

1. Each level of wire must be run in a separate cable tray or conduit.
2. The recommended spacing between cable trays of unlike levels should be
accordance with the following table:

Spacing in mm Level
1 2 3 4
1 0 0 150 650
2 0 0 150 650
3 150 150 0 0
4 650 650 0 0

3. Level 3 & 4 may run in a common tray but should be separated by a barrier.
4. When separate trays are impractical, different levels may be combined in a common tray
provided that a grounded steel barrier separates levels.
5. When unlike signals levels must cross, they should cross at 90 angles.
6. Trays containing level 1 & 2 wiring should have solid bottoms.
7. Tables 2 & 3 in PGEI-1343C detail the required spacing between levels when conduit is used.
8. PGEI-1343C lists additional rules, which more fully describe the proper level separation of wiring.

Note: This is only summary of GE recommended wiring practices. GE Instruction Manual PGEI-1343C should
be reviewed for a complete description of our recommendations.


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TM
Drive
Instruction Manual
Page: 61 of 67

APPENDIX G LIST OF POSSIBLE START-UP PROBLEMS

PROBLEM SOLUTION
PLC program will not compile without
several warnings about duplicate coils and
name mismatches.
1. In the Options tab of the Navigator, expand the
PLC folder.
2. Change <Multiple Coil Use Warning> to <No Warning>
3. Change <Type Mismatch warning> to <No warning>
4. Change <Duplicate addresses> to <Ignore>
5. Recompile the PLC program
The computer is slow to boot up and gets
hung up for fifteen seconds and then states
No DHCP offers received.
1. DHCP Dynamic Host Configuration Protocol. The
service provider normally assigns a random IP address to
each device on a network. If the IP addresses are already
assigned, as in our typical HMI set-up, this step wont
work and isnt needed.
2. Type [SHIFT] + [F10] to go into the BOOTP BIOS
3. Enter [TAB] until {Network boot disabled, boot local
devices} is selected.
The HMI screens do not display
automatically when the computer is
booted up.
1. Go to the <Start> menu. Select <Settings>, then <Taskbar
and Start Menu>. Select the <Advanced> tab and the
<Advanced> button.
2. Select the <Programs\Startup> folder. Insert a shortcut
to the Home screen. The following should be displayed
under the properties of the shortcut:
3. Target: C:\CIMPLICITY\HMI\exe\CimView.exe
/alwaysmaximized /waitforproject <ProjectName>
C:\CIMPLICITY\HMI\projects\<Your project
name>\screens\<the home screen>
a. Start in: C:\Cimplicity\HMI\exe
b. Run: Normal window
Cannot load the settings into the PLC.
PLC and computer cannot communicate.
1. Ensure that the correct physical port is assigned in the
properties of the target.
2. Ensure that the port properties are correct: 9600 baud, 8
bits, odd parity, and one stop bit.
The alarm buzzer is continually alarming
during the commissioning checks.
Temporarily turn off the alarm buzzer switch (BUZZ-#FL)
inside the control cabinet during the commissioning checks.
Cannot modify the PLC program logic
blocks.
The program logic password is 7 and the last three numerical
digits of the Quadramatic serial number.


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TM
Drive
Instruction Manual
Page: 62 of 67

PROBLEM SOLUTION
The communication between the HMI
display and the Q-PLC CPU module is
sporadic. The LANOK (%I1013) frequently
changes state from high (1) to low (0) and
the HMI display temporarily flashes.
1. Confirm that the Ethernet cable between the PLC and the
HMI has not been damaged and is routed away any
120V or higher cables.
2. Replace the Ethernet cable and confirm if the fault
condition still exists.
3. Confirm that the HMI and PLC program have not been
corrupted.
4. Review the status logs of Cimplicity HMI to verify if there
were any issues with the HMI program when the LANOK
bit changes state.
5. Try running the HMI software through a laptop computer
and confirm if the same faults still exist. If the faults are
no longer active over the same test period, then the HMI
software should be re-installed.
6. If so, connect a laptop through the spare Ethernet port of
the PLC CPU. In PME, set the IP address of the Target to
10.0.0.1. Set the Network Connections of the laptop to IP
10.0.0.3.
7. If there are periodic disconnections in the status screen
of PME, then the PLC CPU is faulty and should be
replaced during the next planned shutdown.


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TM
Drive
Instruction Manual
Page: 63 of 67

APPENDIX H RENEWAL PARTS

This appendix contains a sample spare parts list for a GE Quadramatic Drive. The quantity and part numbers
are typical values, which may not exactly correspond to the particular model of drive at your location.
Contact the GE Customer Service centre for more information. Spare parts lists are subject to change without
notice. Installations in remote, inaccessible regions may require a more extensive spare parts list.

Quadramatic Drive Renewal Parts
Part Description Part Number Quantity
per Drive
Tier Quantity of
Spares
Fuse, 550A, 660V 0177A1376P008 6 1 10
Fuse, 20A, 600V 0177A1380P006 3 1 6
Fuse, 15A, 600V 0177A1377P009 6 1 6
Fuse, 5A, 600V 0177A1377P005 6 1 6
Fuse, 15A, 250V 0177A1374P060 2 1 5
Fuse, 5A, 250V 0177A1374P048 2 1 5
Fuse, 2A, 250V 0177A1374P043 3 1 5
Fuse, 1.5A, 250V 0177A1374P016 2 1 5
Fuse, 0.5A, 250V 0177A1374P035 8 1 10
Air Filter, 20 x 25 X 1 thick 0291A6850BDP001 1 1 2
Air Filter, 16 x 25 X 1 thick 0291A6850BDP002 2 1 4
SCR Cell stack assembly, 53mm 0195C3368G001 6 1 2
SCR Assembly, 28 mm, Crowbar 0186B6542ADG001 1 1 1
Circuit card, 3-phase FRP, Control 0621L0213G002 1 1 1
Circuit card, 3-phase FRP, Cell Conduction sensor 0621L0254G001 1 1 1
Circuit card, Cell monitor light 0621L0401G001 1 1 1
Circuit card, Crowbar firing assembly 0519L0241G004 1 1 1
Fan, 1-phase 0239A2010P004 3 1 1
Airflow sensor TBA 3 1 1
Light bulb
120V 0177A1524P021 3 1 3
230V 0177A1524P018 3 1 3
Diode bridge, 600V 0177A1802P003 1 1 1
Diode, 300V, 12A 0177A1095P031 2 1 1
Line Filter, PLC, 6A, 120V 0291A6800ANP007 2 1 1
Noise suppressor 0291A6800ANP013 5 1 1
Noise suppressor 0517L0130G002 2 1 1
PLC Batteries, CPU & PCM, 3V Lithium (2 each) 0291A6820AAP058 1 1 2
PLC Power Supply, high capacity 0291A6820AAP020 1 2 1
PLC CPU 374+ 0291A6820AAP052 1 2 1
PLC Card, Analog combo 0291A6820AAP004 4 2 1

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TM
Drive
Instruction Manual
Page: 64 of 67

Part Description Part Number Quantity
per Drive
Tier Quantity of
Spares
PLC Card, Digital input 0291A6820AAP015 2 2 1
PLC Card, Relay output 0291A6820AAP012 2 2 1
HMI Display TBD 1 2 1
Relay Assembly, 24V 4006L4015AAG001 5 2 1
Relay Assembly, 120V 0291A6814ACP008 5 2 1
Space Heater, 240V, 250W 0291A6800AAP024 3 2 1
Resistor, 2 M, 0.12 W 0177A1460P392 1 2 1
Resistor, 225, 5 W 0177A1029P022 3 2 1
Capacitor, 0.22 F, 200V (for 50 Hz projects) 0177A1057P029 3 2 3
Contactor, 400A DC, 1-pole 0291A6814AMP001 1 2 1
Contactor, 900A DC, 600V, 1-pole 0291A6814AEP010 1 2 1
Switch, mill marker 0291A6813AFP001 1 2 1
Magnet, mill marker 0291A6813AFP002 1 2 1

Tier 1 = Recommended
Tier 2 = Optional (should be considered for remote locations)


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TM
Drive
Instruction Manual
Page: 65 of 67

APPENDIX I GLOSSARY

CCW Counter clockwise.
CPU Central Processing Unit.
CW Clockwise.
DCS Distributed Control System (DCS) is a medium to large controller that is typically
networked to other controllers, PLCs or field devices.
Dump valve The dump valve (#MB-MV1) can be used rapidly released pressure from the clutch
during clutch pulsing or a mill stop.
EEPROM Electrically Erasable Programmable Read-Only Memory.
HMI Human-Machine Interface or Operator Interface. The Quad uses a flat-panel, touch-
screen LCD monitor for its HMI. The HMI communicates to the PLC via the Ethernet
SRTP link.
MCC Motor Control Centre.
ODE Opposite Drive End of the motor. This is the end of the motor, which is opposite the
end that is connected to the clutch.
PID A proportional-integral-derivative (PID) controller attempts to correct the error
between a measured process variable and a desired setpoint by calculating and
then outputting a corrective action that can adjust the process accordingly.

The PID controller calculation (algorithm) involves three separate parameters: the
Proportional, the Integral and Derivative values. The Proportional value determines
the reaction to the current error, the Integral determines the reaction based on the
sum of recent errors and the Derivative determines the reaction to the rate at which
the error has been changing. The weighted sum of these three actions is used to
adjust the process via a control element such as the position of a control valve.
PLC Programmable Logic Controller.
PME Proficy Machine Edition is the GE Fanuc software used to program the Q-PLC.
Press pack Press pack SCRs are used in high power applications because they have a two-sided
cooling surface. They are designed for mounting in a high-pressure compression
heat sink assembly such as the assembly used in this drive.
They are also known as hockey puck style SCRs.
Q-PLC Quadramatic Drive Control Programmable Logic Controller (PLC). A GE Fanuc 90-30
Series PLC controls the Quadramatic Drive.
Rotorseal
TM
The rotorseal applies pressurized air to the clutch via a rotating, flexible fluid
coupling mounted to the opposite drive end of the motor shaft.
Rotorseal is a registered trademark of the Eaton Corporation.
SCR A silicon-controlled rectifier (SCR) is a four-layer, three-terminal, unidirectional, solid-
state device that controls current.
SRTP Service Request Transport Protocol is the GE Fanuc Ethernet protocol that the PLC
and HMI Computer use to communicate information to each other.


GE Quadramatic
TM
Drive
Instruction Manual
Page: 66 of 67

Service

GE Motors has a highly motivated, technically-skilled and knowledgeable support
team which is fully integrated with sales, technology, manufacturing, and field
support. These people are truly connected to your solutions!

Installation, Commissioning, Start-up, and Inspection
Our field services and consulting experts are on call to provide a wide range
of service and repairs on GE equipment and engineered systems in Industrial
Systems.
Our technical personnel are experienced in the inspection, test, installation,
service, and repair of GE Quadramatic Drive systems.

You can contact us at:

Customer Service (705) 7488486
Motor Parts (705) 7487703
Product Service (warranty) (705) 7487228
Technical Data (non warranty) (705) 7488098

For the latest information, please visit:

http://www.gemotors.com

GE Large Motors & Generators
Peterborough, Ontario, Canada
107 Park St. N. K9J 7B5

2009 General Electric Company All Rights Reserved
GE and g are trademarks of General Electric Company

GE Quadramatic
TM
Drive
Instruction Manual
Page: 67 of 67

INDEX

BRUSHLESS EXCITER .............................................................................................................................................................................11, 23
CALIBRATE CLUTCH...................................................................................................................................................................................... 28
CLUTCH PULSING.................................................................................................................................................................. 7, 8, 11, 15, 16
CLUTCH TEST ............................................................................................................................................................................................27, 31
DCS.................................................................................................................................................................. 10, 11, 12, 19, 23, 54, 55, 65
DUMP VALVE...............................................................................................................................................................11, 16, 27, 29, 30, 65
DYNAMIC (FINE) LOAD BALANCE............................................................................................................................................................ 7
EEPROM.......................................................................................................................................................................................................20, 21
EMERGENCY STOP......................................................................................................................................................................................... 10
HEAT LOSS......................................................................................................................................................................................................... 50
KILOWATT DIFFERENCE REGULATOR................................................................................................................................................... 36
LANOK................................................................................................................................................................................................................. 62
MILL FLOOR STATION.............................................................................................................................................................10, 11, 12, 29
MILL MARKER.............................................................................................................................................................................26, 55, 56, 57
MILL START SEQUENCE ............................................................................................................................................................................... 13
MODBUS.............................................................................................................................................................................................. 52, 53, 54
NOISE.................................................................................................................................................................................................... 21, 42, 59
PHASE LOSS...................................................................................................................................................................................................... 47
PHASING............................................................................................................................................................................................................ 47
PID...................................................................................................................................................................................................33, 36, 37, 65
PME.................................................................................................................................................................................................33, 36, 62, 65
PRESS PACK...............................................................................................................................................................................................46, 65
PREVENTIVE MAINTENANCE..................................................................................................................................................................... 39
Q-CURRENT TEST ............................................................................................................................................................................ 14, 18, 26
Q-PLC................................................................................................................................................................................................................... 65
QUADRATORQUE ......................................................................................................................................................................................... 7, 8
ROTORSEAL........................................................................................................................................................................................ 22, 27, 65
SCR .............................................................................................................................................................................3, 42, 43, 45, 48, 63, 65
SERVICE .......................................................................................................................................................................................... 2, 63, 65, 66
SRTP ...................................................................................................................................................................................................... 50, 52, 65
TUNING........................................................................................................................................................................................................33, 35

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