GE DS200SDCCG1AEC Drive Control Board

DS200: Prefix for the Mark V/Mark VI system hardware platform. Distinguished from the DS600 prefix of the later Mark VIe series, the DS200 series represents "classic drive control and signal processing modules". These modules are compatible with the Mark V system backplane bus and can be downwardly adapted to some Mark IV upgrade projects.

SDCC: Function code, where "S=Speed Control", "D=Drive", and "CC=Current Control". This clearly defines its core function as "speed-current dual closed-loop control of the drive system", while also integrating torque regulation and power limiting capabilities.

G1AEC: Hardware version and configuration details. "G1" denotes the 7th hardware revision (with letters corresponding to revision numbers: A=1, B=2... G=7), which features optimized chip computing speed and heat dissipation design compared to earlier versions. "A" indicates compatibility with AC drive systems (differentiated from the "B" version dedicated to DC drives). "E" signifies support for "energy feedback control" (suitable for variable-frequency speed regulation scenarios). "C" confirms the inclusion of a "redundant communication interface" to enhance data transmission reliability.

Gas Turbine Starter Drive Control: During the gas turbine start-up phase, it controls the closed-loop speed regulation of the starter motor (e.g., 10kV high-voltage asynchronous motor). It drives the gas turbine rotor from a stationary state to the ignition speed (typically 800–1200 RPM) according to a preset curve (e.g., 50RPM/s speed rise rate). After successful ignition, it automatically switches to "idle speed control" and disconnects the starter motor.

Metallurgical Rolling Mill Main Drive Control: Adapted to rolling mill main motors (e.g., 6kV synchronous motors), it enables "speed-torque" dual-mode control. During rolling, it maintains constant rolling force in torque mode (to avoid deviations in steel plate thickness). During roll changes, it adjusts roller speed rapidly in speed mode, with a response time of ≤10ms.

High-Voltage Drive Control for Pump Stations/Fans: Used for variable-frequency drive control of large pump stations (e.g., urban water supply high-voltage pumps) and power plant induced draft fans. It supports "PID speed regulation" (automatically adjusting motor speed based on pipeline pressure/airflow demands) and is equipped with "overload limiting" (preventing motor burnout due to overcurrent) and "undervoltage protection" (stabilizing output during grid fluctuations).

Industrial Compressor Drive Control: Adapted to the variable-frequency drive systems of screw or centrifugal compressors, it maintains the compressor’s discharge pressure at the set value (e.g., 0.8MPa) through "speed-pressure" closed-loop control, with a deviation of ≤±0.02MPa. It also suppresses speed oscillations caused by load fluctuations (e.g., anti-disturbance control during sudden airflow changes).

Speed Loop Control: Receives the speed setpoint (e.g., 1500 RPM) from the upper-level computer and actual speed feedback from the motor encoder. It calculates the "current setpoint" (e.g., 500A) via a PI regulator and superimposes "speed feedforward compensation" (adjusting current in advance based on the speed change rate to reduce overshoot). For example, when the motor load suddenly increases, the speed loop quickly increases the current setpoint to prevent speed drop, with a steady-state recovery time of ≤30ms.

Current Loop Control: Collects the three-phase current output by the frequency converter (via current transformers and Hall sensors) and compares it with the "current setpoint" output by the speed loop. It quickly adjusts the frequency converter’s trigger pulses (e.g., IGBT conduction angle) via a P regulator (proportional regulation) to stabilize the actual current at the setpoint, suppressing current fluctuations (e.g., current surges caused by grid voltage fluctuations).

Control Mode Switching: Supports "disturbance-free switching". For instance, when a rolling mill switches from "speed mode" to "torque mode", the module automatically uses the torque value corresponding to the current speed as the "initial torque setpoint". During switching, the output torque ripple is ≤3%, avoiding product defects caused by sudden changes in steel plate rolling force.

Overload Protection: Monitors motor current in real time. When the current exceeds 120% of the rated current, it triggers "current limiting" (maintaining 120% rated current output to prevent motor burnout due to overcurrent). If the current exceeds 150% of the rated current for 50ms, it immediately outputs a "shutdown command", cuts off the frequency converter’s power supply, and records the fault code (e.g., "F01-Motor Overload").

Undervoltage/Overvoltage Protection: Monitors grid voltage (e.g., 6kV bus voltage). When the voltage is lower than 85% of the rated value, it automatically reduces the motor speed (to lower power demand) to prevent the frequency converter from tripping due to undervoltage. When the voltage exceeds 115% of the rated value, it triggers "voltage limiting" to restrict the frequency converter’s output voltage and protect the IGBT module.

Fault Diagnosis and Recording: Features a built-in fault diagnosis circuit capable of detecting 12 types of common faults (e.g., encoder disconnection, current sensor fault, communication interruption). When a fault occurs:

Feedback Control Logic: When the motor is in the "power generation state" (e.g., fan deceleration, elevator descent), the module detects an increase in the frequency converter’s DC bus voltage (e.g., exceeding 1100V). It automatically triggers the "energy feedback loop" (controlling the IGBT conduction direction) to feed the electricity generated by the motor back to the grid (requiring a supporting feedback transformer). It also maintains DC bus voltage stability (deviation ≤5%) through "voltage closed-loop control".

Energy-Saving Effect: Taking a fan as an example, when airflow demand drops to 50%, the motor speed can be reduced to 50% of the rated speed (per fluid mechanics laws, power is proportional to the cube of speed). Compared with "fixed-speed operation + damper adjustment", the energy-saving rate can reach 40%–60%.

Feedback Protection: If grid faults (e.g., voltage sag) prevent normal operation of the feedback channel, the module immediately switches to "dynamic braking" mode (consuming excess electricity via braking resistors) to prevent the DC bus voltage from becoming too high and damaging the frequency converter.

Communication Redundancy: Equipped with 2 CAN bus interfaces (main-standby redundancy). During normal operation, the main bus transmits data, and the standby bus synchronizes data in real time. If the main bus communication is interrupted (e.g., cable fault), the standby bus automatically takes over communication within ≤10ms without data loss.

Power Supply Redundancy: Supports dual power module supply (DC 5V main power + DC 5V standby power). If the main power supply fails, the standby power supply switches to provide power within ≤5ms, ensuring no interruption to the module’s control logic (avoiding drive system shutdown).

Hardware Redundancy: Core chips (e.g., DSP, current sampling chip) adopt a "hot backup" design. The main chip runs control logic, and the standby chip synchronizes data from the main chip in real time. If the main chip fails, the standby chip takes over control within ≤20ms to ensure continuous operation of the drive system (suitable for non-interruptible production scenarios, such as chemical reactor agitator drives).

Upper-Level Control Systems: GE Mark V/Mark VI turbine control system, GE DriveView drive monitoring system.

Frequency Converters/Inverters: GE medium- and high-voltage frequency converters (e.g., MV7000 series 6kV frequency converter, MV6000 series 10kV frequency converter).

Feedback Components: GE incremental encoders (e.g., 1024-line/2048-line, 5V differential signal output), GE Hall current sensors (e.g., CSNH series, output 4–20mA).

Power Modules: GE DS200PCCAG1A (DC 5V/±15V dual output), DS200PCCAG2A (redundant power module).

Configuration Software: GE DriveTool software (version ≥ V6.2), used for parameter configuration (e.g., PID gain, protection threshold), fault diagnosis, and control mode switching.