Upgrading Your DC Electric Power Rectifiers Control

TM Drive-DC FCR Product Guide

Increase your DC power rectifier system's life, and obtain a higher performance, friendly diagnostic tools and wide LAN communication options using digital control at low cost.>

Digital Controls

The FCR (Firing Circuit Replacement) is a TMEIC GE microprocessor-based process controller with dedicated I/O system, designed to be the controller of medium to large complexity SCR (Thyristor) bridges where the need for advanced control requirements, high speed response, expanded diagnostic capability and various interfaces are beyond the capability of conventional analog control.

Firing Commands, Fast As Light

The fiber optic technology is a great advantage of the FCR, where the gating commands do not have any lag on the sequence and response. Using Electric-Light conversion technology with FOT (Fiber Optic Transmission Board), the firings are sent to a Light-Electric inversion board.

The firing pulses are sent to the Light-Electric transmission board, which allows the FCR to control multiple bridge converters in 6 and 12 pulse configuration using 1 CPU and up to 24 pulse configuration using 2 CPU's.

Each fiber optic firing board has its healthy signals in benefit of maintenance and diagnose. Fiber optic is also immune to electromagnetic interference, a very important feature while working in high current applications.

Diagnostic Tools

The GE Control System Toolbox is a WindowsR-based operator interface program used to configure, tune, and monitor FCRis. Its user-friendly interface by using diagrams to view signal flow, sequencing, and regulator control in the FCR, which helps the operator in all levels of setup and operation with password security levels for protecting the configuration.

Regulation and sequencing is driven by a set of parameters which can be edited/monitored using any of three operator-selected methods:

Functionally organized menus block diagrams that detail the regulators and sequencing function.
Wizards that guide the user through a complete drive configuration and tune-ups.
The drive control window which allows the user to control the system from the toolbox, having the look and feel of the drive diagnostic Interface.

Trend Recorder

The trend recorder monitors and graphs signal values from toolbox and graphs data collection analysis (.dca) files. Data can also be saved and exported for other applications, such as spreadsheets like Microsoft Excel.

This application is configured using drag-and-drop to move a variable from the block diagram view to the trend recorder window which has an intuitive VCR-style interface for data record and playback. Live data can be sampled and viewed as fast as 20 ms.

It uses three methods to collect data:

Real Time

Mode is for low-to-medium-data collection rates, typically used for live monitoring.

Capture Buffer

Using the trace back data feature which trends several preset variables at high speed, during fault events and save them on non volatile memory for its post-analysis.

Data Historian

mode for historical data contained *.Dca files. a given trend can display one or multiple data historian files using an innovation series controller, and a personal computer (pc). The program runs in the background as a service on the pc that is running the windows nt operating

system and records the values of any egd or srtp signal on any ethernet connected to the pc on which the program is running.

Trace Back Data

If you experience a fault on FCR equipment, Toolbox allows you to view Fault History and Traceback Data. This feature is capable to collect up to 8 events, and several selected variables at speeds up to 244 us storing the event on non volatile memory, remaining even while powering down the equipment. It also eliminates the need of using an oscilloscope during the failure solution, because it is able to display the information of these variables in a trend recorder window.

Remote Diagnostic Support

AMI GE offers the remote support option, where the distance monitoring is possible using either an internet connection, or telephone links to control the installed equipments through the maintenance pc and customers network. This feature reduces the time of diagnose and usually the equipments are put back in service faster.

Adaptability

FCR is 100% compatible with the Canadian General Electric Indoor DC rectifier, and matches with several DC power bridges where AMI GE offers different options of replacement depending on the application and customer needs. The FCR is provided with fast connectors (same as existing) to reduce transition time between existing and new system. Control/fiber optic transmission/fiber optic reception/ gating commands conditioning (partial or complete replacement of gate drive panel).

Instrumentation Interface

Standar Display

The digital display alternates between speed,current, and fault code in the event of an error
RJ-45 ethernet port for local/remote toolbox connection
Ready, run, and alarm/fault LED's
Interlock button disables drive

Optional Graphic Keypad

Four configurable variable bar graphs with descriptive legends
Status icons reflecting health of drive at a glance
Dedicated drive control keys for manual operation of the drive
Full access to all parameters and variables

Configuration

RJ-45 Ethernet interface
10 Mbps maximum
Drive navigator option of TOSLINE-S20 to Ethernet connection using V-Series controller as gateway
Toolbox option of ISBus to Ethernet using Innovation Series R Controller as gateway.

Meter Outputs

Armature and field current, ± 10V
Quantity 5 configurable,± 10 V
8-bits resolution

I/O Interface

Digital Inputs

Opto-coupled 20 mA
Quantity 6 configurable mapping

Digital Inputs

Opto-coupled 10 mA
Quantity 1 configurable mapping
Quantity 1 dedicated mapping

Digital Outputs

Open collector 70 mA
Quantity 6 user defined

Analog Outputs

Quantity 2±10 V or 4-20mA
Differential 8, inputs impedance
12-bits resolution

External Analog Outputs

Quantity 3±10 V, 10mA max
User defined
8-bits resolution

Environmental

Operating Temperature

0 to 40° C (32 to 104°F) at rated load at converter inlet.
-20 to 50°C (-4 to 122°F) with derating.

Altitude

0 to 3500m (1148ft.) above sea level
Derate 2% per 200m above 1000m altitude.

Storage Temp.

-25 to 55°C (-13 To 131°F.

Humidity

5 to 95% relative humidity, non-condensing

Installation Support

AMI GE used to provide all the necessary information to properly install the supplied equipment. This information includes, single-line diagrams, hardware prints, installation manuals, installation best practices and necessary environmental conditions to ensure trouble free operation for many years to come.

Besides, AMI GE offers different options of projects, including:

Power bridge audits. As an option, the cells verification is recommended to ensure the reliability and good conditions of the rectifier.
Snubbers and fuses status verification. The protection devices revision is an additionalservice to help preventing from future malfunctioning on the cells.
Complete start up and commissioning service with "turnkey" option*

*Terms and Conditions should be discussed in agreement.

FCR Upgrade for Electric Power Circuit

The rectifiers supplied before the 80's use old-fashion analog technology, which used to be reliable, but nowadays productivity and quality requirements on manufacturing processes require an urgent upgrade, to keep being competitive on the market

Upgrade could become expensive regarding equipment, and installation requirements, but the replacement can be selective, reusing the existing power rectifiers and devices in good conditions which most of the time, represents the biggest part of the investment cost.

Motors generally can also be reused, unless the new control scheme requires higher torque or speed.

The FCR is an AMI GE product, offered to solve the needs of upgrade, which otherwise, would represent a huge and sometimes, not really needed big investment. The FCR is designed to substitute analog gating control of SCR is with new digital circuitry, obtaining with it, ultimate generation diagnostic tools.

Depending on the system, the FCR can be complemented with a master control for processes, Interlocks and additional I/O either with a PLC or ISC (Innovation Series Controller) and user friendly HMI or COI (Control Operator Interface) screens.

Applications

Electric Arc Furnace (EAF)

An Electric Arc Furnace (EAF) is a furnace that heats charged material by means of an electric arc. EAF range in size from small units of approximately one ton capacity up to about 400 ton units. Electric arc furnace differs from induction furnaces in that the charge material is directly exposed to the electric arc, and the current in the furnace terminals passes through the charged material.

For steelmaking, direct current (DC) arc furnaces are used, with a single electrode in the roof and the current return through a conductive bottom lining or conductive pins in the base. The advantage of DC is lower electrode consumption per ton of steel produced, since only one electrode is used, as well as less electrical harmonics and other similar problems.

Ship Propulsion

DC Machines are still used nowadays on ship propulsion, where usually 3 or more diesel generators, are used to supply medium voltage power to Isolation transformers, which feed 12 pulses non-regenerative SCR power bridges.

Roller or Break Down Mill

A Rolling Mill is a machine or factory for shaping metal by passing it between a pair of work rolls. Rolling mills are often incorporated into integrated steelworks, but also exist as separate plants and can be used for other metals, and other materials. Depending on the temperature of the metal being rolled, rolling mills are typically hot or cold rolling mills.

For more information go to: http://www.firingcircuitreplacement.com
AMI GE International
Blvd. Diaz Ordaz #402
Col. Rincon de Santa Maria
Monterrey, N.L., Mexico
P. + 52 (81) 1001-4050
F. + 52 (81) 1001-4051

AMI GE Argentina
Blvd. Alvarez #150
San Nicolas,
Buenos Aires, Argentina
+54 (93) 461-665-222
AMI GE Brasil
Av. das Nacones Unidas,
8501-2 andar,
Sao Paulo, Brazil
+55 (11) 461-665-222

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