GE SCR-001 Rev A1

GE
Power Conversion
SCR POWER CONVERSION SYSTEM CONTROLLER
DESCRIPTION AND TEST PROCEDURE
Change Number: 00
Author: George Bonner
Design Office: SD - Glasgow
Reason for new issue: Initial Issue
©COPYRIGHT 2012 GENERAL ELECTRIC COMPANY AND/OR ITS AFFILIATES. All rights reserved. This document and
the information it contains is the property of the General Electric Company and/or its affiliates. It has been
provided solely for private use. Copying, reproducing, selling, importing, exporting, displaying, transmitting or
distributing this document and any of the information it contains is strictly prohibited except as expressly
authorized in writing by the General Electric Company and/or its affiliates.
CLASS II (GE INTERNAL NON-CRITICAL)

Author : G Bonner Revision : 00
DocRef : SCR Controller Description and Test Procedure Date : 26 Jan 2013
File : GE SCR - 001 Page : 1/17
©COPYRIGHT 2012 GENERAL ELECTRIC COMPANY AND/OR ITS AFFILIATES. All rights reserved.
GE
Power Conversion
CONTENTS
Motor Control Using the GE Energy P.C.S. ................................................................... 3
Outline .................................................................................................................................................... 3
Control of Separately Excited Shunt DC Motors by Armature Voltage Control..... 3
Control of Series Wound DC Motors by Armature Voltage Control ............................ 4
Functional Description.................................................................................................... 4
SCR Bay Assembly ............................................................................................................................ 4
SCR Bridge Controller ...................................................................................................................... 5
Protection of SCR Bridge. ............................................................................................................... 6
Pictures .............................................................................................................................. 7
SCR Control Pan Inspection & Test Procedure ......................................................... 11
Test Rig Arrangement ................................................................................................................... 11
Pre Test Inspection ......................................................................................................................... 11
Test Setup ........................................................................................................................................... 11
Energisation Procedure ................................................................................................................ 11
Test Equipment ................................................................................................................................ 11
Test Results ..................................................................................................................... 12
Pre Test Checks Of SCR Pan. ...................................................................................................... 13
Establishment of Supplies ........................................................................................................... 13
Tests ...................................................................................................................................................... 13
Series Motor Simulation Tests ................................................................................................... 16

GE
Power Conversion
Motor Control Using the GE Energy P.C.S.
Outline
The GE Energy power conversion system uses six pulse fully controlled SCR bridge rectifiers as the power source
for the DC drive system. Control of the firing angle of the SCR’s is the fundamental process by which motor speed
is controlled. The firing angle control system is based on a multi function control circuit, which may be arranged
to:-
i. Control shunt or series motors without the need for a tacho speed signal.
ii. Control series connected or parallel connected motor pairs.
iii. Regulate the dynamic braking of shunt and series motors.
iv. Operate in conjunction with other convertor controls on a master/slave basis to control motors, which are
mechanically coupled but supplied from more than one convertor.
The selection of the particular functions required at any time is made via the logic system of a programmable logic
controller and the control circuit is provided with digital inputs and outputs for this purpose. As well as the speed
control features the control circuit incorporates protection features for the SCR convertor. Some of these features
such as current limiting and temperature limiting will cause ‘phasing back’ of the firing angle. Others such as
incorrect phase rotation, phase loss, or SCR fuse rupture, will result in a complete shut down of the convertor.
The speed control principles upon which the Converteam PCS is based are detailed below.
Control of Separately Excited Shunt DC Motors by Armature Voltage Control
A DC motor operating with constant field excitation has an armature

voltage/speed relationship, which is almost V – KN where V is the applied
armature voltage, N is the motor speed and K is a constant.
Therefore, by controlling the voltage applied to the motor the speed of the motor is effectively controlled. As the
armature voltage is supplied by the SCR convertor, the problem is one of controlling the convertor voltage.
Controlling’ means making the armature voltage take some desired value, which in this case is the speed (or
voltage) demand set by the throttle. A fundamental closed loop control system is utilised. Any difference between
output voltage and throttle setting, results in an error signal which is amplified and used to adjust the convertor
firing angle to minimise the error.
Thus the output voltage follows the throttle setting. This basic control system suffers from the disadvantage that
excessive current can flow to the motor at start-up, since the feedback signals will be very small at standstill (and
low speeds), while the demand may be high. The convertor will thus try to produce a voltage matching the
demand, whilst feeding a low resistance load (the stalled motor). Damaging high current may result unless some
means of reducing the current is adopted. The method used in the GE Energy SCR system is to incorporate a
current control loop within the main voltage control loop.
A signal proportional to the maximum current to be allowed is supplied to the ‘minimum selector’ circuit along with
the output voltage regulator. The output of the minimum selector is limited to a maximum value set by the current
limit, hence the maximum ‘current demand’ is limited to a safe value. Under start-up conditions, when the voltage
feedback is low but the throttle setting (voltage demand) may be high, the convertor firing angle is phased back to
produce a current matching the current limit. This persists until the motor speed builds up to the point where the
voltage feedback signal is sufficient to reduce the voltage regulator output below the current limit value. The final
motor speed (voltage) will match the speed demand (voltage demand) whilst the current will be dependent on the
loading.

GE
Power Conversion
Control of Series Wound DC Motors by Armature Voltage Control
The fundamental difference with controlling a DC motor with the field and armature windings connected in series
is that the motor voltage feedback alone is not indicative of motor speed.
Motor speed is a function of motor voltage and motor current feedback.
SCR PCS controllers that may be assigned to control series wound motors are equipped with a speed calculator
multiplier IC which takes voltage and current feedback signals to calculate motor speed. The calculated motor
speed is then used to establish a voltage demand and the controller operates in the same manner as a shunt
wound controller.
Therefore, by measuring the current and voltage feedback and matching the voltage applied to the motor with the
current being consumed, the speed of the motor is effectively controlled.
Functional Description
SCR Bay Assembly
600V AC is supplied to the SCR Bridge usually through a 2000 amp withdrawable ACB. The air circuit breaker is
fitted with a 120V AC undervoltage trip coil.
The SCR bridge is normally mounted below the ACB. The chassis holds six thyristor/heatsink assemblies, six hard
firing circuit cards, six hard firing circuit supply transformers and six R-C snubber networks. All the
thyristor/heatsink assemblies are interchangeable. Care must be exercised when changing the thyristors.
The top two outside heatsinks of each SCR bridge are fitted with an analogue temperature device to monitor
heatsink temperature.
When the heatsink temperature reaches approximately 98-100°C the thermal limit LED on the SCR status indicator
will illuminate.
A 3 phase cooling fan is mounted above the SCR Bridge. The fan will come on when the SCR circuit breaker is
closed and the blower motor starter contactor is employed to give a running/fail indication on the SCR status
indicator.
The GE Energy SCR controller is mounted on the inside of the cubicle door. Connections carrying control signals to
and from the controller are made using ampliversal plugs and sockets and a short terminal strip. The following
electronic control cards are fitted inside the control pan:
BB98 - Analogue control card

BB99 - Firing card
PCO105 - Isolated dc voltage feedback card.
PCO107A - DC earth detector/blower motor on card.
The control pan also contains synchronising transformers, secondary current transformers and a power supply
transformer for the electronics. Mounted above the pan is an SCR status indicator card, PCO104. This card
displays the status of the SCR Bridge/Controller and is connected to the control pan by a 25 way D-Type
connector.
All the electronic cards used in the SCR control pan are factory set and under normal conditions no adjustments
are necessary, although PCO105 (isolated DC voltage feedback card) will require final trimming during
commissioning:

GE
Power Conversion
SCR Bridge Controller
The analogue control card (BB98) and firing circuit card (BB99) form the centre of the DC motor control system.
The control card is supplied with an analogue throttle and current limit signal via the PLC. The PLC also supplies
digital control signals to allow the SCR’s to be fired. The firing pulses are generated by the firing circuit card.
The AC line currents are fed back and used for control.
These signals are derived from three 2000/5A current transformers.
One side of the CT secondary is grounded for protection and safety reasons. On no account should this earth be
removed, since dangerously high voltages could be produced under fault conditions on the interposing 5/0.1A
current transformers on the control pan. The three phase voltage supply to the bridge is also fed to the control
card via the synchronising transformers. These voltages allow firing pulses to be generated in the correct
sequence for full wave rectification control.
Across this supply there are three varistors. These semi-conductor devices protect the system against high
voltage spikes, which could cause damage to the system controller and SCR’s.
The control card also requires a DC voltage feedback signal. This is an isolated voltage proportional to the DC
busbar voltage and is produced by the PCO105.
When the PLC logic is satisfied i.e. throttle off, field ‘on’ and auxiliaries running an enable signal will be sent to the
controller thus allowing the firing circuit card to produce firing pulses.
The controller drives the SCR status indicator card PCO104. The indications are as follows:-
Supply On - Status Power On
Blower On - Status Blower Overload Healthy
SCR Available - Status all PCB supplies healthy and correct phase rotation present.
SCR Enable - Status firing circuit ready to generate firing pulses.
Current Limit - Indication SCR has reach pre-set current limit setting.
Thermal Limit - Indication SCR has reached maximum operating temperature.
Overcurrent - Alarm/Lockout SCR has locked out on instantaneous overcurrent at 6250 amps
Fuse Fail - Alarm/lockout. An SCR fuse has blown.
Earth Fault - Alarm. A DC path to earth less than 25kohm is present.
A pushbutton is mounted on the status indicator to reset overcurrent.

GE
Power Conversion
Protection of the SCR Bridge.
Each SCR converter in the GE Energy power conversion system has a number of features incorporated in it’s
design to ensure as far as possible the safe operation of both the converter itself and the drive to which it is
connected. These features may be divided into four categories:-
1. DV/DT protection of the SCR’s; this involves the connection of non-linear voltage limiting ‘varistors’ between
phases of the converter AC supply and the use of a series resistor-capacitor ‘snubber’ circuit across each SCR
to limit the rate of rise of voltage;
2. Controlled phase back of the converter to limit current at the pre-set level. This is carried out automatically by
the converter main control card in response to the current feedback and current limit signals.
3. Controller phase back of the converter to limit SCR temperature. The temperature being detected by high
accuracy semi-conductor temperature transducers located on the top outside heatsinks.
4. Immediate disabling of the converter by removal of firing pulses, due to any of the following circumstances:-
(a) Rupture of any SCR fuse;
(b) Converter exceeding the instantaneous overcurrent setting;
(c) Incorrect phase rotation of the AC supply, or the reduction of the voltage one or more phases to less than 75%
of the normal 600 volt.
(d) Reduction to less than 10V of either of the +/- 15V DC supplies for the converter control circuits

GE
Power Conversion
Pictures
Test Rig Controls
SCR Control Pan In Test Rig Test Rig SCR Bridge
SCR Control Pan
Plug No1 Plugs No2-5
PC105 & PC107A BB99 Card
Current Transformers
Control Transformer BB98 Card
Synchronising Tx’s Terminal Block Connections

GE
Power Conversion
Test Rig Controls 3 x 240v lamps in series (load)
Ampliversal Plug Connections Terminal Block Connections

GE
Power Conversion
SCR Volts SCR Amps Synchronising Transformers Current Transformers
PC104 Status Indicator Card
BB99 Firing Card BB98 Control Card

GE
Power Conversion
PC105 Voltage Feedback Card PC107A Earth Fault Card

GE
Power Conversion
SCR Control Pan Inspection & Test Procedure
This section describes the inspection and test strategy to be applied for each SCR control pan.
The test results section may be replicated and completed for each SCR control pan tested in a batch.
Test Rig Arrangement

The test rig consists of a single SCR bridge, which is fed with 600v 3 phase ac from the test supply control box. The
motor armature load is represented by 3 x 240v lamps wired in series mounted on top of the test rig.This allows full
functional tests of the control pan to be performed with the exception of current feedback measurement. The
correct operation of the current feedback function will be performed on separate test rig.
Above the SCR bridge a number of lamps, switches and potentiometers represent the analogue and digital I/O that
would normally be exchanged between the SCR controller and the controlling PLC.
Pre Test Inspection

Verify all installed components are correct to the requirements of the standard SCR control pan schematic
diagram.
Verify all wiring is correct to the requirements of the standard SCR control pan schematic diagram.
Verify the security of all electrical connections made within the SCR control pan including soldered connections at
the transformers and PCB terminal strips.
Carry out a brief visual inspection of the BB98 card, and BB99 to ensure components are correctly installed.
Ensure the frequency selector on the BB99 card is fitted and set to the 50 hertz position.
Test Setup
Fit the SCR control pan on the inside of the test rig door.
Connect the 11 wires at the15 way control pan terminal block on the lower right hand side.
Connect the 4 ampliversal plugs marked 2-5 to the sockets on the right hand side of the SCR control pan.
Connect the 25 way D plug (No.1) at the top of the SCR control pan.
Energisation Procedure
Ensure that the 120vac supply isolator on the right hand side of the test rig is on.
Energise the test supplies box and press the SCR start pushbutton.
Proceed through each test case in the test results section and acknowledge completion by signature.

GE
Power Conversion
Test Equipment
Record details of the test equipment used during testing: -
Test Equipment Serial Number Calibration Due

Fluke or equivalent test multimeter
Oscilloscope.
0-24v Variable Power Supply.
Test Results
The following information should be completed, prior to testing commencing.
Project/Site
Contract Number
Test Serial Number
Print Name Signature Initial Date
Tester
Card Modifications Record

Include any component changes that have been carried out on the BB98 control card.

GE
Power Conversion
Pre Test Checks Of SCR Pan.
Test Checked
Case By
TC1 Confirm the pre test inspection of the SCR control pan has been completed.
TC2 Ensure a light load of 3 x 240 lamps is connected across the DC output of the
SCR.
Establishment of Supplies
Test Checked
Case By
TC1 Energise the 600vac supply at the test box. Verify the voltage and phase
rotation are correct.
TC2 Energise the 110vac supply on the side of the SCR stack and measure the
voltage.
TC3 Measure the following voltages on both the BB98 and the BB99 cards TP1
= +15vdc, TP2 = 0v, TP3 = - 15v. TP2 will be used as reference for all
measurements on the BB98 and BB99 cards.
Tests
Test Checked
Case By
Verify the operation of the blower on indication LED. Operate the blower
TC1 overload located on the pan at the right hand side of the SCR bridge.
Switch on the enable switch at the test rig and verify the operation of the
TC2 enable input to the SCR control pan.
Toggle the series and then shunt switches at the test rig and verify the
operation of the series and shunt selection inputs to the SCR control pan.
TC3
(Series = LED 6, Shunt = LED 5). Select shunt to proceed with test.

GE
Power Conversion
Confirm the output voltage of the SCR through the full voltage range in
response to a throttle input of 0-8.25vdc.
Operating the throttle potentiometer on the test rig simulates the throttle
input. The throttle input can be measured at TP5 of the BB98 card wrt TP2.
Measure the voltage feedback at terminals 1 & 2 of the PC105 card. Calibrate
TC4
the voltage range between 30v and 750v in response to a throttle input of 2v
and 8.25v respectively. Potentiometers P1 and P2 on the PC1O5 card provide
zero and span calibration functions.
Calibrate the DC voltmeter when measuring 750v, using pot P1 on PC104
Remove the synchronising supply from terminal 4,5 or 6 on the BB99 card
and ensure the SCR disables and LED 1 on the BB99 card comes on. This can
TC5 be done by removing one of the 600v 3 phase synchronising supply fuses
located on the pan at the right hand side of the SCR bridge.
Inject Test point 17 on the BB98 card to simulate current feedback and
TC6 calibrate the DC ammeter, using P2 on the PC104. (TP17 7.5v = 2500 Amps).
TP2 is used as the 0v reference.
Verify the operation of the over current lockout circuit. Disconnect the lead
that is connected to TP17 and increase the voltage setting on the power
TC7 supply to 20v.Tap TP17 with the 20v and ensure the over current lockout
operates and the SCR stops firing.
Whilst running, reduce the current limit value to below the injected current
value and confirm that the output of the SCR ramps down to zero. The
TC8
current limit value is determined by a potentiometer located on the test rig.
Verify the operation of the shunt braking request. Disconnect cable 34 on the
PC105 card. Inject a variable power supply at – 4.0vdc on to TP41. Enable the
SCR and take the throttle up to 8 v. Reduce the throttle to zero and LED 8
TC9 should come on to indicate that the conditions for the shunt braking request
have been met. Reduce the injected voltage to below – 1.0vdc and ensure
LED 8 goes off.
Operate one of the series connected fuse fail indicator trip switches and
verify that operation of the DC fuse fail circuit immediately inhibits the SCR
TC10 output. The fuse fail condition should also be displayed on the status
indicator display.
Verify the operation of the DC earth fault detection circuit. Connect a link
between R3 on the PC107 card and earth and verify an earth fault is
detected when the SCR output is ramped up. The earth fault should be
TC11 detected at approximately 500vdc.The SCR should continue to be controlled
up to full output of 750vdc.
Verify the operation of the SCR thermal limit circuit. The functionality of this
circuit can be demonstrated by selecting the resistance measurement on the
multimeter and connecting the leads across the terminals of the
temperature sensors. This should result in immediate detection of the
thermal limit being exceeded. The thermal limit LED on the status indicator
TC12 display illuminates and the SCR output reduces to zero. (In practice this
function will operate dynamically with a output phase back in response to
slow temperature changes measured in the SCR bridge)
Enable the SCR and run up to full voltage whilst shunt selected. Select slave
input at the test rig and ensure the output of the SCR reduces to zero.

GE
Power Conversion
(During Current Tests)

The slave function can be verified during current testing of the SCR controller
in the load run test rig or during heat run tests within a switchboard. Whilst
TC13 running as a master with an output of 1000 amps, measure the speed loop
output at terminal 74 on the BB98 card. Select the slave function and verify
the output reduces. Inject TP48 with the same value and polarity of signal as
previously measured at terminal 74 and ensure the measured output current
goes to 1000 amps.
Return to normal master operation and measure the DC output waveform on

the voltage feedback card with an oscilloscope and verify even firing of the
thyristors. The oscilloscope leads are placed across resistor 3 of the PC 105
TC14
card. With the time-base set at 2 ms there should be 6 even positive going
humps displayed.
Measure the following waveforms on test points on the BB99 card.

TP4,TP5,TP6 wrt TP2 = Sine waves
TP8 through to TP13 wrt TP2 = Square waves
TC15 TP14 through to TP19 wrt TP2 = Saw tooth waves

TP20 through to TP25 wrt TP2 = Square waves (Variable width)
TP26 through to TP31 wrt TP2 = Positive Pulse train
TP34 through to TP39 wrt TP2 = Square wave firing pulses
Remove both the shunt and series selections from the SCR controller. Vary
TC 16 the propulsion throttle potentiometer located on the test rig to produce 0 to
10v at TP43 and ensure the bay output varies between 0 and 700vdc
Test the operation of the SCR when operating as a series wound motor
TC17 controller. Select series wound motor at the test rig and carry out the series
motor tests. These tests are only required if the controller is to be used for
series wound motor control. IC19 fitted in BB98 card.

GE
Power Conversion
Series Motor Simulation Tests
IC19 is fitted to the BB98 card when a series wound motor is being controlled.
When a shunt wound motor is being used the relationship between voltage and speed is almost linear,
therefore the voltage demand of the motor is directly proportional to the voltage feedback.
When a series wound motor is used the voltage output of the SCR is restricted until there is a load on the
motor. Lightly loaded series wound motors require relatively low voltages to achieve desired speed.
The load on the motor is the current, therefore the voltage demand of the motor is the result of the voltage
feedback and the current feed back.
All configuration selections ie 1 motor selection, 2 motor selection, series connected motors and parallel
connected are made at the test rig.
1. Select series motors.
2. Inject TP17 to read 500 amps.
3. Enable the SCR bay.
4. Increase the throttle to 50% (TP5 = 4.1v)
5. Measure DC voltage feedback on the PC105.
6. TP22 = DC Voltage Feedback

0.006 x 50 x I motor
Selection BB98 Card TP22 SCR DC Volts Motor Current (Im) Checked By
1 motor parallel
connect
2 motors parallel
connect
2 motors series
connect
7. Check TP23 is DC Volts when either 1 or 2 motors selected in parallel configuration.

600

GE
Power Conversion
8. Select 2 motors, parallel configuration and carry out the following simulations.
TP 14 = Speed TP21= Motor current. TP29= Voltage TP29= Voltage Checked By

demand. Varied Injected using power supply. demand demand
by the throttle (Ammeter will not read) Expected Measured Results
input. Results
1.647v = 3v = 500A 1.85v . .
250rpm 6v = 1000A 2.46v . .
9v = 1500A 2.83v . .
3.3v = 500rpm 3v = 500A 3.68v . .
6v = 1000A 4.75v . .
9v = 1500A 5.35v . .
5.0v = 750 rpm 3v = 500A 5.57v . .
6v = 1000A 7.15v . .
9v = 1500A 7.98v . .
6.17v = 3v = 500A 6.86v . .
1000rpm 6v = 1000A 8.78v . .
9v = 1500A 9.85v . .
Position of 50/60hz link on BB99 card should be reset to 60hz position unless advised
otherwise.
Tick Box
50Hertz
60Hertz
Comments/Remarks


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GE

SCR POWER CONVERSION SYSTEM CONTROLLER

DESCRIPTION AND TEST PROCEDURE

CLASS II (GE INTERNAL NON-CRITICAL)

CLASS II (GE INTERNAL NON-CRITICAL)

Motor Control Using the GE Energy P.C.S.

ii. Control series connected or parallel connected motor pairs.

iii. Regulate the dynamic braking of shunt and series motors.

Control of Separately Excited Shunt DC Motors by Armature Voltage Control

A DC motor operating with constant field excitation has an armature

CLASS II (GE INTERNAL NON-CRITICAL)

Control of Series Wound DC Motors by Armature Voltage Control

SCR Bay Assembly

BB98 - Analogue control card

CLASS II (GE INTERNAL NON-CRITICAL)

SCR Bridge Controller

These signals are derived from three 2000/5A current transformers.

Supply On - Status Power On

Blower On - Status Blower Overload Healthy

SCR Enable - Status firing circuit ready to generate firing pulses.

Thermal Limit - Indication SCR has reached maximum operating temperature.

Fuse Fail - Alarm/lockout. An SCR fuse has blown.

Earth Fault - Alarm. A DC path to earth less than 25kohm is present.

A pushbutton is mounted on the status indicator to reset overcurrent.

CLASS II (GE INTERNAL NON-CRITICAL)

Protection of the SCR Bridge.

(a) Rupture of any SCR fuse;

(b) Converter exceeding the instantaneous overcurrent setting;

CLASS II (GE INTERNAL NON-CRITICAL)

SCR Control Pan In Test Rig Test Rig SCR Bridge

SCR Control Pan

Plug No1 Plugs No2-5

PC105 & PC107A BB99 Card

Control Transformer BB98 Card

Synchronising Tx’s Terminal Block Connections

CLASS II (GE INTERNAL NON-CRITICAL)

Test Rig Controls 3 x 240v lamps in series (load)

Ampliversal Plug Connections Terminal Block Connections

CLASS II (GE INTERNAL NON-CRITICAL)

SCR Volts SCR Amps Synchronising Transformers Current Transformers

PC104 Status Indicator Card

BB99 Firing Card BB98 Control Card

CLASS II (GE INTERNAL NON-CRITICAL)

PC105 Voltage Feedback Card PC107A Earth Fault Card

CLASS II (GE INTERNAL NON-CRITICAL)

SCR Control Pan Inspection & Test Procedure

Test Rig Arrangement

Pre Test Inspection

CLASS II (GE INTERNAL NON-CRITICAL)

Test Equipment Serial Number Calibration Due

The following information should be completed, prior to testing commencing.

Card Modifications Record

CLASS II (GE INTERNAL NON-CRITICAL)

Pre Test Checks Of SCR Pan.

CLASS II (GE INTERNAL NON-CRITICAL)

CLASS II (GE INTERNAL NON-CRITICAL)

(During Current Tests)

Return to normal master operation and measure the DC output waveform on

Measure the following waveforms on test points on the BB99 card.

TC15 TP14 through to TP19 wrt TP2 = Saw tooth waves

CLASS II (GE INTERNAL NON-CRITICAL)

Series Motor Simulation Tests

1. Select series motors.

2. Inject TP17 to read 500 amps.