DICU control electronics

Hardware, Software and Operation

Original Manual

BA 01-006-EN v2

As at: 26th April 2017

ABP Induction Systems GmbH Tel.: +49 - (0)231 / 997 0

Kanalstr. 25 Fax: +49 - (0)231 / 997 24 67
D-44147 Dortmund info@abpinduction.com
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Table of Contents

Contents

1 HARDWARE: CONVERTERS AND THE DICU.................................................. 8

1.1 Converter models – description of functioning......................................... 12

1.1.1 Rectifier models ........................................................................................ 12
1.1.1.1 6-pulse rectifier ..................................................................................... 12
1.1.1.2 12-pulse rectifier ................................................................................... 13
1.1.1.3 24-pulse rectifier ................................................................................... 15
1.1.2 Inverter models ......................................................................................... 19
1.1.3 High power converters .............................................................................. 21
1.1.4 High power converters – further development .......................................... 26

2 DICU HARDWARE ........................................................................................... 27

2.1 Design ........................................................................................................... 28

2.2 DICU 6/12p, GES9898032............................................................................. 32

2.2.1 Detailed plug assignment for the DICU 6/12p ........................................... 34
2.2.2 Jumpers for selecting the operating mode ................................................ 45

2.3 DICU 24p, GES9898033................................................................................ 48

2.3.1 Detailed plug assignment for the DICU 24p .............................................. 50
2.3.2 Jumpers for selecting the operating mode ................................................ 52

2.4 Difference between DICU Dortmund & DICU USA..................................... 53

2.5 Description of the individual components in the DICU ............................ 54

2.5.1 CPU-1 card GES9898030P29 / P1(outdated, unavailable since April 1997)
55
2.5.1.1 Function of the CPU card ..................................................................... 55
2.5.1.2 CPU LEDs and measuring sockets ...................................................... 57
2.5.2 SIO-1 card Signal Input Output GES9898030P2 ...................................... 58
2.5.2.1 Function of the SIO card ....................................................................... 58
2.5.2.2 LEDs, inputs and outputs on the SIO card ........................................... 58
2.5.3 GRS-1 card - rectifier control GES9898030P3 ......................................... 61
2.5.3.1 GRS card function ................................................................................ 61
2.5.3.2 LEDs and measuring sockets on the GRS card ................................... 63
2.5.4 GRE-1 card - rectifier firing pulse amplifiers GES9898030P32 / P4
(outdated, unavailable since September 2000)......................................... 65
2.5.4.1 GRE card function ................................................................................ 65
2.5.4.2 LEDs and measuring sockets on the GRE card ................................... 66
2.5.5 WRS-1 card - inverter control and pulse amp GES9898030P5 / P30 ....... 68
2.5.5.1 WRS card function................................................................................ 68
2.5.5.2 LEDs and measuring sockets on the WRS card ................................... 70
2.5.6 GES9898030P7/P23 power supply unit (for the firing pulses) .................. 71
2.5.6.1 Function of the 48V power supply unit.................................................. 71

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2.5.7 Multiple power unit GES9898030P6 / P20 / P22 / P26 (outdated,

unavailable since February 2010) and GES9898030P40 / P41: for 5V,
12V, 24V ................................................................................................... 73
2.5.7.1 Function of the multiple power unit ....................................................... 73
2.5.8 Additional board for measuring current ..................................................... 76
2.5.8.1 Function of the additional board for measuring current ........................ 76
2.5.9 INV current measurement with the sum current transformer .................... 78

2.6 DICU component fittings ............................................................................. 79

2.6.1 EPROM and PROM fittings....................................................................... 80
2.6.2 Filters fitted on the WRS card ................................................................... 84
2.6.3 Fittings for the MF voltage transformers ................................................... 85
2.6.4 Jumper arrangement ................................................................................ 86
2.6.5 GRS card fittings....................................................................................... 87

3 ADDITIONAL EQUIPMENT FOR DICU ............................................................ 88

3.1 Customer module GES9898029P4 (P1, P2 and P3 not available since

autumn 1996) ................................................................................................ 88
3.1.1 Description ................................................................................................ 88
3.1.1.1 Design and plug assignment ................................................................ 88

3.2 LEM adapter GES9401057P3 / P1, P2 (old, unavailable since November

2003) .............................................................................................................. 93
3.2.1 Description ................................................................................................ 93
3.2.1.1 Design and connection ......................................................................... 94
3.2.1.2 Fittings and calculation ......................................................................... 96

3.3 Fiber-optic adapters..................................................................................... 97

3.3.1 Fiber-optic adapter GES9421237 / GES9421086 (outdated, unavailable
since January 2009) ................................................................................. 97
3.3.1.1 Description ........................................................................................... 97
3.3.1.2 Design and connection ......................................................................... 98
3.3.2 Fiber-optic adapter GES9421118P1 ....................................................... 100
3.3.2.1 Description ......................................................................................... 100

3.4 Booster GES9898104P3 / P1, P2 outdated, not available ....................... 101

3.4.1 Design, LEDs and plug assignment ........................................................ 101
3.4.2 Description .............................................................................................. 103

3.5 Fiber-optic transducers for DICU GES9898105P1 / P2 ........................... 104

3.5.1 Design and plug assignment................................................................... 104

3.6 Current monitoring RIFAM GES9898106P1 ............................................. 106

3.6.1 Design and plug assignment................................................................... 107

3.7 Pulse block GES9898107P1 ...................................................................... 110

3.7.1 Design and plug assignment................................................................... 110

4 DICU GRTEST SOFTWARE ........................................................................... 112

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4.1 GrTest structure on a PC........................................................................... 113

4.2 Starting the GrTest program ..................................................................... 114

4.2.1 Starting the GrTest program offline......................................................... 115
4.2.2 Starting the GrTest program online......................................................... 116

4.3 Design of the windows on the service PC screen ................................... 119

4.4 DICU windows ............................................................................................ 120

4.4.1 Help windows.......................................................................................... 121
4.4.1.1 Window H General Help ..................................................................... 121
4.4.1.2 Window H1 General Help cont., direct commands and function keys 122
4.4.1.3 Window H2 General Help continued, more help about command
groups ................................................................................................ 124
4.4.1.4 Window HF Windows and displays, PC only ...................................... 125
4.4.1.5 Window HFF Windows and displays continued, PC only ................... 126
4.4.1.6 Window HFU Converter data and settings, PC only ........................... 127
4.4.1.7 Window HFx (x=any number), Converter setting windows, PC only... 128
4.4.2 Navigation and command windows ........................................................ 129
4.4.2.1 Window HA Language and display on the customer module ............. 129
4.4.2.2 Window HB Data communication and test operation, * PC only ......... 130
4.4.2.3 Windows HB1, HB2, HB3, Data protocol for COM ports, PC/DICU .... 132
4.4.2.4 Window HE, Data communication between PC and DICU, PC only... 134
4.4.2.5 Window HG, Rectifier control, 6/12p and 24p ..................................... 135
4.4.2.6 Window HR, Control and energy management, SP and TP ............... 137
4.4.2.7 Window HS, Start/Stop converter, SP and TP .................................... 139
4.4.2.8 Window HU, Converter data, PC only ................................................ 141
4.4.2.9 Window HW, Inverter control, SP and TP ........................................... 143
4.4.2.10 Window HZ, Error lists, PC only ......................................................... 145
4.4.3 Windows for entering system parameters ............................................... 146
4.4.4 Current measured values and status from system operation .................. 147
4.4.4.1 Windows FG1 and FG2, Rectifier status ............................................ 147
4.4.4.2 Windows FW1 and FW2, Inverter status ............................................ 149
4.4.4.3 Windows FP1 and FP2, Line phases.................................................. 150
4.4.4.4 Windows FN1 and FN2, Line – Voltage and Current .......................... 152
4.4.4.5 Windows FL1 and FL2, Inverter load circuit ....................................... 154
4.4.4.6 Windows FK1 and FK2, Load Circuit, Test data ................................. 157
4.4.4.7 Windows FS1 IO/SIO PLC interface and FE1 Supervision: time and
energy ................................................................................................ 158
4.4.4.8 Window Fuxx, DICU parameters ........................................................ 160
4.4.4.9 Windows FR1, FR2, FR3 and FR4, Regulation .................................. 161
4.4.4.10 Windows FX1 - FX6, Data ports, data exchange ................................ 163
4.4.4.11 Windows FB1, FB2, FD1, FD2, FO1 - FO6, FT1 - FT9, FY1 - FY7 .... 164
4.4.4.12 Windows FU-1 and FU-2, Settings for inverter 1 and 2 ...................... 165
4.4.4.13 Windows FU-3 und FU-4, Settings for rectifiers 1 and 2..................... 168
4.4.4.14 Window FU-20, DICU parameters ...................................................... 171
4.4.4.15 Windows FU-5 - FU-19 and FU-21 - FU-29 ........................................ 171

4.5 GrView......................................................................................................... 172

4.6 DICU data interchange protocol ............................................................... 173

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4.7 SCOM .......................................................................................................... 174

4.8 GrSim – DICU simulation program ........................................................... 178

4.8.1 Operating GrSim ..................................................................................... 178

5 MEANING OF THE PARAMETERS IN WINDOWS F1-F21 ........................... 180

5.1 Standard settings ....................................................................................... 180

5.2 Tabular depiction and description of the parameters............................. 181

5.2.1 Window F1, INV 1 nominal data, transformer ratios ............................... 183
5.2.2 Window F2, Inverter 1 V/P - reduction .................................................... 185
5.2.3 Window F3, Inverter 1 - limits ................................................................. 187
5.2.4 Window F4, INV 2 - nominal data, limits ................................................. 189
5.2.5 Window F5, REC – nominal data, transformers, line .............................. 191
5.2.6 Window F6, Rectifier - limits ................................................................... 194
5.2.7 F7 Start window - parameters ................................................................. 195
5.2.8 Window F8, Regulation - parameters 1 .................................................. 198
5.2.9 Window F9, Regulation - parameters 2 .................................................. 199
5.2.10 Window F10, Regulation - parameters 3 ................................................ 200
5.2.11 Window F11, Inverters 1/2 - electronics 1 ............................................... 202
5.2.12 Window F12, Inverters 1/2 - electronics 2 ............................................... 204
5.2.13 Window F13 rectifier - electronics ........................................................... 207
5.2.14 Window F14, Logbook, supervising, bus, CPU, SIO............................... 208
5.2.15 Window F15, Customer module, communication, COM2 ....................... 209
5.2.16 Window F16, Check INV 1/2, turn-off time, start ..................................... 211
5.2.17 Window F17, Check INV 2, V/P - reduction ............................................ 212
5.2.18 Window F18, Check INV 2, limits............................................................ 213
5.2.19 Window F19, Check rectifier ................................................................... 214
5.2.20 Window F20, Check electronics, COM1 ................................................. 215
5.2.21 Window F21, Check internal data ........................................................... 215

6 CUSTOMER MODULE – HANDLING AND OPERATION.............................. 216

6.1 General notes ............................................................................................. 217

6.2 Customer module offline ........................................................................... 218

6.3 Customer module online ........................................................................... 219

6.3.1 Incorrect data or software ....................................................................... 220

6.4 Displaying the latest actual values during operation ............................. 221

6.5 Disturbances, error displays ..................................................................... 222

6.5.1 Disturbances, extended display .............................................................. 223

6.6 Setting the language .................................................................................. 224

6.7 Energy input ............................................................................................... 225

6.7.1 Entering energy values in the customer module ..................................... 225

6.8 Operating the system with 2 customer modules..................................... 228

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6.9 Connecting the customer module to COM2 ............................................ 229

6.10 Displaying setpoints (old customer module software versions, not up-to-
date) ............................................................................................................ 230

6.11 Testing the analog outputs of the customer module .............................. 232
6.11.1 Setting the analog outputs ...................................................................... 232

7 COMMISSIONING A DICU CONVERTER ...................................................... 233

7.1 Equipment required ................................................................................... 233

7.2 Summary of the most frequent commands ............................................. 234

7.3 Creating a data record ............................................................................... 237

7.3.1 Entering parameters ............................................................................... 238
7.3.1.1 Window F1 ......................................................................................... 238
7.3.1.2 Window F2 ......................................................................................... 239
7.3.1.3 Window F3 ......................................................................................... 239
7.3.1.4 Window F4 ......................................................................................... 240
7.3.1.5 Window F5 ......................................................................................... 240
7.3.1.6 Window F6 ......................................................................................... 241
7.3.1.7 Window F7 ......................................................................................... 241
7.3.1.8 Window F8 ......................................................................................... 243
7.3.1.9 Window F9 ......................................................................................... 243
7.3.1.10 Window F10 ....................................................................................... 244
7.3.1.11 Window F11 ....................................................................................... 244
7.3.1.12 Window F12 ....................................................................................... 245
7.3.1.13 Window F13 ....................................................................................... 245
7.3.1.14 Window F14 ....................................................................................... 246
7.3.1.15 Window F15 ....................................................................................... 246
7.3.2 Saving parameters.................................................................................. 247

7.4 Starting the DICU with the converter........................................................ 248

7.5 Testing converters without high voltage ................................................. 250

7.5.1 Testing the inverter firing pulses ............................................................. 250

7.6 Testing converters with high voltage ....................................................... 255

7.6.1 Checking the settings for line voltage ..................................................... 255
7.6.2 Testing the rectifier firing pulses ............................................................. 258
7.6.2.1 Checking the position of the rectifier firing pulses .............................. 258
7.6.2.2 Checking the rectifier firing pulses ...................................................... 260
7.6.3 Testing converters with power ................................................................ 262
7.6.3.1 Converter short start ........................................................................... 264
7.6.3.2 Converter long start ............................................................................ 271
7.6.3.3 Continuous operation ......................................................................... 273
7.6.4 Final DICU adjustment ............................................................................ 279

7.7 Operating the converter with a customer module or a processor ......... 282
7.7.1 Operation with the customer module ...................................................... 282
7.7.1.1 Operation with the customer module and service PC as monitor ....... 282
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7.7.2 Operation with the processor (Prodapt, or PLC communication processor)

284
7.7.2.1 Operation with the processor and service PC as monitor ................... 284
7.7.3 Emergency operation with the customer module .................................... 285

7.8 DICU database ............................................................................................ 285

7.9 Testing the DICU without the system ....................................................... 286

7.10 Testing the DICU cards individually ......................................................... 288

8 TROUBLESHOOTING IN SYSTEMS WITH DICU CONTROL ....................... 289

8.1 Troubleshooting using DICU error messages ......................................... 289

8.1.1 DICU error texts ...................................................................................... 291
8.1.2 List of DICU warnings ............................................................................. 314
8.1.3 Classification in the DICU error list, SIO card outputs ............................ 315

8.2 DICU error logs........................................................................................... 317

8.2.1 Description and structure of the error log file .......................................... 317

9 ANNEX ............................................................................................................ 320

9.1 Annex A1: Instructions for a DOSBox for DICU ...................................... 320

9.2 Annex A2: GrView ...................................................................................... 320

9.3 Annex A3: DICU – Data Interchange Protocol ......................................... 320

9.4 Annex A4: DICU database ......................................................................... 320

9.5 Annex A5: Setting values and test protocol for MF converters ............. 320

9.6 Annex A6: Specimen file for DICU adjustment ........................................ 320

9.7 Annex A7: Exchanging the fiber-optic adapter for the DICU ................. 320

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1 Hardware: converters and the DICU

The DICU (Digital Inverter Control Unit) serves to control a load-controlled, parallel
resonant circuit converter for inductive heating.

The first DICU (called DICU1) was developed for single power converters. After a
short prototype series, the extended DICU (called DICU2) was developed which can
also control TWIN POWER converters.
The DICU1 was practically never deployed correctly, so that these prototypes have
been destroyed.
Since then, the DICU2 has simply been called DICU. The name DICU alone is used
in this manual.

This manual describes the hardware architecture and its fittings and settings, the
software, the parameters, the relevant commands, how to start up the converters and
the error messages.
Figure 1.1 shows a diagram of how the DICU is integrated in the system. Digital
signals are exchanged with the PLC via the SIO card. These include incoming
signals, such as "Release", "On/Off", "Furnace selection", reducer bits etc. The DICU
issues digital outputs such as "Converter running", "Power pulses", "Faults" etc.
A serial protocol is deployed for communications with the processor (PRODAPT,
PROMELT) and with the customer module, in that setpoints are sent to the DICU. In
the other direction, the DICU sends actual values back. If a fault occurs, the DICU
issues error messages (both as plain text and with an error code) to the PRODAPT
and the customer module. These serve to analyze the errors. This topic is discussed
in Chapter 8.

Figure 1.1: Block circuit diagram of a system with DICU

A converter which only supplies power to one load (furnace) is a called Single Power
system (referred to below as SP). Even if several furnaces can be mechanically
switched, power is supplied as SP. Figure 1.2 shows the simplest SP converter.

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ON/OFF

Command

Voltage reduction
Reset

Power reduction

Converter running

Control limit
Service

Common fault

Electronic fault, Selftest

Release

LWL Adapter
Data-Modem

Service PC

Customer
module
Figure 1.2: Single Power, SP, converter with DICU

In the case of TWIN POWER systems (referred to below as TP), one converter can
supply power to two loads (furnaces) at the same time. Power can be distributed in
any proportion between both furnaces. The simplest TP converter is depicted in
Figure 1.3.

Figure 1.3: TWIN POWER, TP, converter with DICU

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The converter generally consists of a rectifier (designated as GR), a DC intermediate

circuit filter (DC choke) and one (SP) or two (TP) inverters (designated as WR). The
resonance load circuit is connected as a coil (furnace) and load capacitor connected
in parallel. A starter device is required to excite the first voltage oscillations in the
load circuit during start-up.

The signals required to control the converter are fed to the DICU via transducers
(current/voltage). The limit values are monitored and, if they are exceeded, an alarm
is triggered and the converter is switched off. The converter is controlled solely by the
firing pulses.

The DICU is installed in a standardized compound sub-rack. The input and output
lines (cables) are connected to the DICU by plug terminals.
There are 2 basic versions of the DICU:
• DICU 12-pulse (DICU 12p) in SP or TP execution, Figure 1.4. This DICU
works with 6-pulse or 12-pulse rectifiers (two rectifiers connected in series).

Figure 1.4: DICU 12-pulse, DICU 12p

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• DICU 24-pulse (DICU 24p) in SP or TP configuration, Figure 1.5. This DICU

works with 24-pulse or 12-pulse rectifiers (rectifiers connected in parallel).

Supply Unit

Hole Plug
WRS - 1

WRS - 1
Reserve

Reserve
Reserve

Reserve

Reserve
GRS - 1

GRE - 1

GRS - 1

GRE - 1
CPU - 1

SIO - 1

+48V

191
268
P T P T
F- F-
M M

Figure 1.5: DICU 24-pulse, DICU 24p

Both DICU models use the same cards and power units. Only the backplanes are
different.
Both DICU models can be configured in different versions:
• Line frequency 50Hz or 60Hz
• Supply voltage 230V or 115V
• Measurement current 1A or 5A
Further details are contained in Chapter 2.

As far as functions are concerned, DICU can be sub-divided as follows:

• CPU card: processor, EPROMs, EEPROM and RAM
• SIO card: digital inputs and outputs
• GRS card: rectifier controller two 6-pulse bridges
• GRE card: rectifier pulse generator for two 6-pulse bridges
• WRS card: inverter controller and pulse amplifier
• Power unit to supply the electronics
• Power unit to supply the pulse amplifiers

In reality, the cards are designated CPU-1, SIO-1, GRS-1, GRE-1 and WRS-1.
However, these cards are referred to below as CPU, SIO, GRS, GRE and WRS.

Just one or two identical cards (GRS, GRE und WRS) are deployed, depending on
the application. The cards are addressed according by the PROM sets deployed and
are given the relevant functions.

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1.1 Converter models – description of functioning

1.1.1 Rectifier models

1.1.1.1 6-pulse rectifier

Figure 1.1.1: 6p rectifier

Figure 1.1.1 shows a 6p rectifier (referred to below as GR6p). The transformers

required to control the rectifier are:
• 2 voltage transformers (PTs) to read the line voltage
• 2 current transformers (CTs) to read the line currents

The current IL2 is calculated from the relationship IL1+IL2+IL3=0. A current transformer
is not installed in the phase L2 for this reason.
A GRS and a GRE card are required in the DICU to control a 6p rectifier. The rectifier
is controlled from the GRS card. Target values are sent via the DICU bus to the
backplane by the CPU and the GRE card serves as a firing pulse amplifier.

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1.1.1.2 12-pulse rectifier

A 12p rectifier (referred to below as GR12p) consists of two 6p rectifiers, which can
be connected either in parallel or in series. If they are in series, the DC voltages are
added together; if switched in parallel, the DC currents are added together. The
benefit of a higher pulse rate lies in the reduced voltage distortion in the supply
network caused by harmonic currents.

L´ L´-L´´ - coupled DC-choke

DICU
REC
#2 (2)
ThGAT#2
GRE GRS CPU UW
ThGAT#1
(1)
(1) (2)

REC
#1
IGR1
UGR#1
UGR#2

L´´
63v06

Figure 1.1.2: 12p rectifier, rectifiers connected in series

Figure 1.1.2 shows a 12p rectifier with two 6p rectifiers switched in series. The
transformers required are:
• 4 line voltage transformers in both systems to read the line voltage
• 2 line current transformers to read the line currents in one system

Current measurement is not required in the second system because identical

currents can be assumed if the rectifiers are connected in series.
Only one GRS card and a GRE card are required in the DICU.

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Figure 1.1.3: 12p rectifier, rectifiers connected in parallel

Figure 1.1.3 shows a 12p rectifier with two 6p rectifiers in parallel. A smoothing choke
is required for each rectifier. The transformers required are:
• 4 line voltage transformers in both systems to read the line voltage
• 4 line current transformers in both systems to read the line currents

The current needs to be measured in the second system because identical currents
cannot be assumed, when if the rectifiers are switched in parallel.
The secondary line voltages (star and delta connection), the smoothing choke and
the DICU hardware are never identical, so that different currents flow at the same
Alpha control angle in both rectifiers.
Both currents need to be balanced at start-up (Chapter 7.6.3).
Two sets of GRS and GRE cards are required in the DICU to control a 12p rectifier
with 2 rectifiers in parallel (a DICU 24p is deployed).

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1.1.1.3 24-pulse rectifier

In the 24p configuration (referred to below as GR24p), the four 6p line rectifiers can
be switched in three different ways. The DICU 24p recognizes the switching
arrangement from the currents input into the rectifier and the inverter.

• If the line current is exactly the same as the MF current, the four rectifiers are
connected in series (as a rule in systems up to approx. 4MW).
• If the line current is a quarter of the MF current, the four rectifiers are switched
in parallel (seldom used, only older systems, due to problems with balancing
the DC currents).
• If the line current is half of the MF current, the rectifier then consists of two 12p
rectifiers in parallel, which in turn each consist of two 6p rectifiers in series
(systems between 4 and 42MW).

At least one smoothing choke is required for each rectifier set connected in parallel,
whereby the currents in the rectifier are correspondingly lower. The direct current to
be controlled in the rectifier is then usually in the range of about 1500A to 10000A.

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Figure 1.1.4: 24p rectifier

Figure 1.1.4 shows the configuration for a 24p system. This is ABP's standard at the
present time.
Two 6p rectifiers are connected in series to make a 12p series rectifier and then two
of these groups are connected in parallel. Fluctuations in the voltage amplitudes or
the phase angle of the system's high voltage transformers and, in particular,
measuring inaccuracies originating from the line transformers on the backplane and
the GRS cards, can cause different currents in the rectifiers, which can lead to
problems in low power operation. This needs to be adjusted at start-up. GRS cards
should then only be exchanged as a matched set.

Twice as many transformers are required compared to a 12p series rectifier:

• 8 line voltage transformers to read the line voltage
• 4 current transformers to read the line currents

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Figure 1.1.5: 24p rectifier, 4 rectifiers in series

In rare cases, systems can also be configured with 4 rectifiers in series (Figure
1.1.5). Only one smoothing choke is then required. The drawback is that all
connections between the line transformers and the rectifiers must be executed for full
nominal current (the transformers and the converters are normally placed quite some
distance from each other).
The same transformers and the same DICU should be deployed as for a standard
24p rectifier.

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L4´
L4´-L4´´
coupled DC-choke

ThGAT#4

REC
#4

L4´´

L3´
L3´-L3´´
coupled DC-choke

(2)

GRE GRS
#2 #2
ThGAT#3
(1)
(1) (2)
REC
#3
IGR3 X3
IGR4 X7
X4
UGR#3
UGR#4

L3´´ UW

L2´
L2´-L2´´
coupled DC-choke

DICU

ThGAT#2
GES9898035P1

REC
Subprint

#2

L2´´

L1´
L1´-L1´´
coupled DC-choke

(2)

GRE GRS
CPU
#1 #1
ThGAT#1
(1)
(1) (2)
REC
#1
IGR1 X1
IGR2 X6
X2
UGR#1
UGR#2

L1´´
67v03

Figure 1.1.6: 24p rectifier, 4 rectifiers in parallel

In rare cases (old systems), systems can also be configured with 4 rectifiers switched
in parallel (Figure 1.1.6). The line current is then a quarter of the MF current,
although 4 smoothing chokes are required. Such systems have major problems with
balancing the DC currents. GRS cards should then only be exchanged as a matched
set.
8 line voltage transformers, 8 current transformers and the same DICU should be
deployed as for a standard 24p rectifier, whereby a sub-board for measuring the line
current is required in addition.

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1.1.2 Inverter models

The inverter is executed as a single phase, parallel resonant circuit which works with
a current source. The rectifier with the smoothing choke in the DC link acts as a
current source. The load circuit forms a parallel resonant circuit, consisting of the
furnace coil and the load capacitor. A starter device is connected in parallel to the
load capacitor, which allows the first voltage oscillations to be excited in the load
circuit during start-up.

Figure 1.1.7: Single Power (SP) inverter

Figure 1.1.7 shows an SP (Single Power) inverter. The transformers required to

control the inverter are:
• 1 MF voltage transformer to read the furnace voltage
• 1 MF current transformer to read the inverter-output current

Only one WRS card is required to control an inverter. Setpoints are specified by the
CPU via the DICU bus on the backplane.

Figure 1.1.8: TWIN POWER (TP) inverter

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Power can be supplied to 2 furnaces simultaneously with 2 inverters connected in

series. This arrangement is referred to as TWIN POWER (TP) and has been
patented by ABP. Each inverter is supplied with a common current source and can
work with its own voltage, power and frequency. The distribution of power between
the two inverters can be controlled in any proportion. The power from each individual
inverter is measured with the help of an LEM module and an LEM adapter (Chapter
3.2).
The transformers required to control the TP inverter are:
• 2 MF voltage transformers to read the furnace voltage
• 2 MF current transformers to read the inverter's output current
• 2 LEM modules and 2 LEM adapters to measure the power

A further WRS card is simply plugged into the DICU to control a second inverter. The
DICU then automatically recognizes the converter as TWIN POWER. The inverters
are controlled via these cards. Setpoints are specified by the CPU via the DICU bus
on the backplane.

Figure 1.1.9: SP inverter with capacitive voltage increase (C1/C2)

Figure 1.1.9 shows an SP (Single Power) inverter with capacitive voltage increase in
the load circuit. This load arrangement is often referred to as C1/C2. The inverter is
controlled as a normal SP converter, although the power with a TP system is
measured using an LEM module. The transformers required to control the inverter
are:
• 1 MF voltage transformer to read the furnace voltage
• 1 MF current transformer to read the inverter's output current
• 1 LEM module and 1 LEM adapter to measure the power

Only one WRS card is needed to control a C1/C2 inverter.

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1.1.3 High power converters

The market has developed over the course of time and has come to demand ever
greater power. Switching several rectifiers and inverters in parallel leads to problems
in balancing currents in the converter.
ABP has therefore split the 24p rectifier into two 12p rectifiers. Each 12p rectifier
feeds an inverter (SP systems) or a TP inverter circuit. The two systems are first
connected in parallel on the load circuit. The current sources of both systems GR/WR
are then isolated from each other.

Figure 1.1.10: 24p rectifier for high power

Both 12p rectifier systems are isolated from each other, although they are controlled
by the same DICU 24p.

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Figure 1.1.11: SP inverter for high power

Figure 1.1.11 shows a SP high power inverter. Each inverter is supplied by a 12p
rectifier. Both inverters are controlled synchronously from a single WRS card. An
extra board for current addition is only needed to measure the sum current of both
inverters.

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Figure 1.1.12: TP inverter for high power

Figure 1.1.12 shows a TP high power inverter system. 2 inverters are connected in
parallel for each furnace. Current is supplied to each two TP inverters from a 12p
rectifier. The center points of the 4 TP inverters are interconnected. Although current
does not flow in this connection in theory, the connection is required to equalize the
potential of the systems.

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Each parallel inverter system is controlled synchronously from one WRS card. Both
WRS cards have identical configuration, as for normal TP systems. Extra boards are
only needed to measure the sum currents of both TP inverters.

Figure 1.1.13: TP inverter for high power with short-circuit (bypass) thyristors (ST)

Figure 1.1.13 shows a TP high power inverter system. This circuit is almost identical
to the circuit shown in Figure 1.1.12.

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When an inverter is operated in short-circuit mode (SP operation of a TP system), not

all the inverter's branches always conduct the short-circuit current. The short-circuit is
created through the left or right branch of the inverter, which overloads the thyristors.
A short-circuit (bypass) thyristor (referred to below as ST) was introduced parallel to
each inverter input for this reason. In short-circuit mode, the short-circuit thyristor
switched in parallel is connected instead of the inverter thyristors. This is
implemented toggling the inverter gate pulses via relays to the short-circuit thyristor.
The short-circuit thyristor is able to conduct the inverter's full DC input current.

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1.1.4 High power converters – further development

In the meantime, the market has stated to demand even higher power. ABP is
therefore now constructing converters with a power output of up to 42MW.
As shown in Figure 1.1.10, the 24p rectifier has remained, but now much more
powerful line thyristors are deployed.
The high power inverter now consists of up to 6 inverters switched in parallel. New
techniques for measuring the inverter output currents have been developed for these
powerful inverters. The way the sum current transformer works is described in more
detail in Chapter 2.5.9.
The firing energy required for several thyristors working in parallel can no longer be
drawn directly from the DICU. The cables between the DICU and the thyristors have
also become much longer and cause considerable losses. ABP has invented a new
system for firing the thyristors. This includes the boosters (Chapter 3.4), which are
addressed via fiber-optic cable by special fiber optic adapters installed on the DICU
(Chapter 3.5).
The individual inverters also need to be monitored for the internal short-circuit
current. A current monitoring RIFAM plug-on board (Chapter 3.6) for the sum current
transformer monitors the current in each channel. An error message sent from the
RIFAM via a fiber-optic cable provides an extremely fast blockage of the further firing
pulses – see pulse blocking (Chapter 3.7).

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2 DICU hardware

The DICU serves to control a parallel resonant circuit converter and is constructed
completely in digital technology. Adjustments and synchronization are made using a
normal PC. Potentiometers no longer feature in the DICU. All analog input signals are
digitized and passed on to the BUS, where they are received and digitally processed.
Some signals are subject to extensive filtering before being digitized. Only these
filters need to be adjusted to the range of the converter's working frequency.
The functions of each of the DICU cards are determined by how the PROM sets are
plugged. Different fitting arrangements enable the DICU to control 6p, 12p and 24p
rectifiers. One (SP) or two (TP) inverters can be controlled.

In the case of new systems or DICU modernizations retrofits, a test protocol is

compiled after the DICU has been fitted and adjusted. These test protocols are
archived in the test department. The test protocol form for the DICU is contained in
Annex A5.

The ABP server hosts an Access DICU database. The database is described in
Annex A4. The database stores the details of all systems which work with a DICU
(although the database does not at present contain any details of systems which
ABP-USA has supplied).

Only ABP service personnel are allowed to adjust and calibration the DICU.

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2.1 Design
The DICU is installed in a compound rack 2 * DIN 3 U, 84R. The racks are shielded
to protect against inductive or capacitive interference noise voltage. For this reason,
signal lines laid outside the rack must likewise be shielded.

Dimensions: L * H * D = 483 * 268 * 270 mm

Supply voltage: 230/115VAC +5%/-10%, 50/60Hz
Consumption power: ≈ 200VA
Ambient temperature: 0°C ÷ 50°C, no condensation water
Fuse F1 (48V pulse amplifiers) 2A/T
Fuse F2 (multiple power supply) 1A/T

The DICU consists of a rack with a backplane and several cards. The functions of the
cards can be listed as follows:
• CPU card: Processor, EPROM´s, EEPROM and RAM
• SIO card: Digital inputs and outputs
• GRS card: Rectifier control set for 2 6p bridges
• GRE card: Rectifier firing pulse amplifier for 2 6p bridges
• WRS card: Control set and pulse amplifiers for one inverter
• Subprint 24p: For rectifier 3 & rectifier 4, only for DICU 24p
• Multiple power unit to supply the electronics
• Power unit to supply the pulse amplifiers

There are 2 basic versions for the electronics:

• DICU 6/12p GES 9 898 032
• DICU 24p GES 9 898 033

Both DICU versions can be executed in different combinations:

• Supply voltage 230V or 115V
• Measurement current 1A or 5A
• Line frequency 50Hz or 60Hz
• Rectifier 6p, 12p or 24p
• Single Power (SP) or TWIN POWER (TP)
• Working frequency <200Hz or >200Hz

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The DICU 6/12p GES9898032 can control various converters. The GES2282051 bill
of material is shown in Figure 2.1.1 below (the GES9898030P12 MF-transformers
are located on the backplane):

GES2282051 Rxx
Rxx Rectifier pulses Line frequency Converter Line DICU Measurement current
p Hz Type V A
1 6 50 SP 230 1
2 12 series 50 SP 230 1
3 6 50 TP 230 1
4 12 series 50 TP 230 1
5 6 60 SP 115 1
6 12 series 60 SP 115 1
7 6 60 TP 115 1
8 12 series 60 TP 115 1
9 6 60 SP 230 1
10 12 series 60 SP 230 1
11 6 60 TP 230 1
12 12 series 60 TP 230 1
13 6 50 SP 115 1
14 12 series 50 SP 115 1
15 6 50 TP 115 1
16 12 series 50 TP 115 1
17 6 50 SP, 5kHz 230 1
18 6 60 SP, 5kHz 115 1
19 6 50 SP 115 5
20 12 series 50 SP 115 5
21 6 50 SP 230 5
22 6 50 TP 230 5
23 12 series 50 SP 230 5
24 12 series 50 TP 230 5

Figure 2.1.1: Table with variants of the GES2282051 bill of material

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The DICU 24p GES9898033 can control various converters. The GES2282052 bill of
material is shown in Figure 2.1.2 below (the GES9898030P12 MF-transformers are
located on the backplane):

GES2282052 Rxx
Rectifier Line Measureme
Rxx pulses frequency Converter Line DICU nt current
p Hz Type V A
1 24 50 SP 230 1
2 24 50 TP 230 1
3 24 60 SP 115 1
4 24 60 TP 115 1
5 24 50 SP 115 1
6 24 50 TP 115 1
7 24 60 SP 115 5
8 24 60 TP 115 5
9 12/parallel 50 SP 230 1
10 12/parallel 50 TP 230 1
11 12/parallel 60 SP 115 1
12 12/parallel 60 TP 115 1
13 12/parallel 60 SP 230 1
14 12/parallel 60 TP 230 1
15 12/parallel 50 SP 115 1
16 12/parallel 50 TP 115 1
17 24 60 SP 230 1
18 24 60 TP 230 1
19 12/parallel 50 SP, 5kHz 230 1
20 24 50 SP 230 5
21 24 50 TP 230 5

Figure 2.1.2: Table with variants of the GES2282052 bill of material

Figure 2.1.3 lists individual components in the DICU rack. These components can be
procured separately.

Components DICU 6/12p DICU 24p

GES9898030 xxxxx Measurement current Measurement current
1A 5A 1A 5A
Rack with backplane (24p with P0008 P0031 P0019 P0028
subprint)
Backplane (24p without subprint) P0009 P0027 P0035 P0036
Backplane with 24p subprint --- --- P0033 P0034
24p subprint --- --- P0021 P0025
Rack, only mechanics (without P0042 P0043
backplane or cards)
MF voltage transformer GES9898030P12

Figure 2.1.3: Table with components in the DICU rack

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A sticker is applied to the side wall of the DICU with the fittings variants. The crosses
on the sticker (Figures 2.1.4 and 2.1.5) define the fittings in the DICU.

Fitted to
GES2 282 051 R
X = installed
Straight TWIN-POWER

50 Hz 60 Hz

6-pulse 12-pulse

Measurement Measurement
current 1A current 5A
DICU line 230V DICU line 115V

Figure 2.1.4: Sticker for the DICU 6/12p

Fitted to
GES2 282 052 R
X = installed
Straight TWIN-POWER

50 Hz 60 Hz

24-pulse 12p-rectifiers in
parallel
Measurement Measurement
current 1A current 5A
DICU line 230V DICU line 115V

Figure 2.1.5: Sticker for the DICU 24p

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2.2 DICU 6/12p, GES9898032

Figure 2.2.1: DICU 6/12p, design, without cover

A second WRS card is added for TWIN POWER systems.

Figure 2.2.2: Lower part of the front of the backplane 6/12p

There are internal components on the front of the backplane (under the cover with
the ABP logo) for measuring the analog signals.
There are 6 identical line voltage transformers for measuring the rectifier's
synchronous voltage in area (3).
Area (4) contains 2 MF voltage transformers for measuring the furnace voltage.
These transformers are exchanged with the converter working at low nominal
working frequencies (<200Hz) (Chapter 2.6.3). The soldered in MF voltage
transformer can only be exchanged by the DICU manufacturer.
The load resistors for a line current (area (5)) are identical to the load resistors for the
MF current (area (6)). The standard fitting for a measurement current of 1A is 1Ω.
These resistors are replaced by 0.2Ω for a measurement current of 5A (consisting of
resistors of 0.22Ω and 2.2Ω soldered in parallel). The soldered resistors can only be
exchanged by the DICU manufacturer.

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F2

F1

Figure 2.2.3: Back of the backplane 6/12p

The plugs (2) for inputting and outputting all analog and digital signals are located on
the backplane. Codable pin headers are installed in the DICU. These are arranged in
2 rows at a grid spacing of 5.08mm, consisting of the series 231 pin header and the
series 232 raised pin header made by the WAGO Company.
This area also contains two Dsub9 plugs for communication with the CPU card.
Power is supplied to the DICU via plug X13. Ground is connected to screw X14 (8).
Area (7) contains the F1 fuse for the 48V power unit of the firing pulse amplifiers and
the F2 fuse for the multiple power unit of the complete digital and analog electronics.
There is also a relay in this area that switches on the supply voltage for the 48V
power unit after start-up.
There are more socket strips for plugging the individual cards into the DICU on the
front of the backplane. 2 jumpers must be plugged into the rear of the backplane,
matching the socket strip, for each socket strip that is not used – in the area at the
top right. Jumpers do not need to be plugged for the socket strip on the second WRS
card that is not used.
There are further jumpers on the rear backplane for the DICU operating mode –
Chapter 2.2.2.

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2.2.1 Detailed plug assignment for the DICU 6/12p

Coding for the plugs made by the WAGO Company:

Plug Coding pin

X300 4
X301 3
X302 2
X303 1
X600 5
X601 6
X700 3
X701 4
X702 1
X703 2
X900 3
X901 4
X902 5
X903 6
X1000 1
X1001 2
X1500 1
X1501 2
X1600 9
X1601 10
X1700 7
X1701 8

Figure 2.2.4: Coding of plugs on the backplane (same coding for the DICU 24p)

General: "E" = input

"A" = output
"S" = power supply or drawing potential

Supply voltage
230/115V, 50/60Hz

Plug X13

1 S L1
2 S N

Screw X14

1 S PE, ground (minimum 6 mm2)

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Data communication with the CPU card

Plug X100
Serial interface COM1, RS232, plug
Parameters: 9600 baud, 8 data bits, odd parity, 1 stop bit
Electrical connection, normal: 2,3,5 and use shield
Fiber-optic cable: use an adapter
"0" = -12V, "1" = +12V, referred to ground.

1 E DCD
2 E RXD, received data
3 A TXD, transmitted data
4 A DTR
5 S Signal ground
6 E DSR
7 A RTS
8 E CTS
9 E RI
S Housing = ground = shield

Plug X101
Serial interface COM2, RS422/485, plug
Parameter: variable baud rate, 8 data bits, odd parity, 1 stop bit
Electrical connection, normal: 1,2,3,4,5 and use shield
Fiber-optic cable: use an adapter
"0" = -5V, "1" = +5V, difference +-

1 S Signal ground
2 A RTS+, received data +
3 A RTS-, received data -
4 A TXD+, transmitted data +
5 A TXD-, transmitted data -
6 E CTS+,
7 E CTS-,
8 E RXD+, received data +
9 E RXD-, received data -
S Housing = ground = shield

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Digital signals of the SIO card

Digital inputs : +24V 7mA, "0" = -1V up to +8V
"1" = +17V up to +30V
Digital outputs : +24V / 100mA, "0" = 0V
"1" = +24V

Inputs 0 - 2 and 10 : level-controlled

Inputs 3 - 9 and 11 - 23: edge-controlled
Input 9 : only active with Single Power
Inputs 16-23 : only active with TWIN-POWER
Input 10 : set to "1" => all other inputs except E0 = "Release" are
are recognized as "0", regardless of the actual level.

Remark: The commands to the inputs E2, E8, E9, E10, E11, E15, E16, E17 and E23
are only executed when the converter is switched off (thus if operating, only after the
OFF command).

Table for binary coding of the voltage and power reduction inputs:

Level Bit 1 Bit 0

0 0 0
1 0 1
2 1 0
3 1 1

Level Bit 2 Bit 1 Bit 0

0 0 0 0
1 0 0 1
2 0 1 0
3 0 1 1
4 1 0 0
5 1 0 1
6 1 1 0
7 1 1 1

Figure 2.2.5: Binary coding of the voltage and power levels

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Plug X300 inputs

1 S +24V
2 E0 Converter enable 0 = off/blocked 1 = enable
3 E1 On/Off 0 = off 1 = on (start test in test mode)
4 E2 Test mode 0 = inactive 1 = release test (start pulse)
5 E3 Acknowledgement 0 = inactive 1 = delete fault
6 E4 Voltage red. REC bit 0,  00 = nominal inverter voltage
7 E5 Voltage red. REC bit 1,  11 = level 3
8 E6 Voltage red. INV1 bit 0,  00 = nominal rectifier voltage
9 E7 Voltage red. INV1 bit 1,  11 = level 3
10 E8 Cust. module 1-2 0 = cust. mod1 1 = cust. mod2
11 E9 Setpoint 1-2 0 = pot1 1 = pot2
12 S Ground

Plug X301 inputs

The power reduction inputs have different functions depending on parameter UD208
in F14:

Parameter UD208 = 7:
1 S +24V
2 E10 Inputs active, 0 = active 1 = all inputs inactive except release
3 E11 Command priority 0 = COM1, 1 = COM2
4 E12 Power red. INV1 bit 0, 
5 E13 Power red. INV1 bit 1,  000 = nominal power
6 E14 Power red. INV1 bit 2,  111 = level 7
7 E15 Energy mode INV1 0 = no energy preselection1 = preselection
8 E16 Operating mode INV1 0 = normal operation 1 = short-circuit
9 E17 Operating mode INV2 0 = normal operation 1 = short-circuit
10 E18 Voltage red. INV2 bit 0,  00 = nominal voltage
11 E19 Voltage red. INV2 bit 1,  11 = level 3
12 S Ground

Parameter UD208 = 3:
1 S +24V
2 E10 Inputs active 0 = active 1 = all inputs inactive except release
3 E11 Command priority 0 = COM1, 1 = COM2
4 E12 Power red. INV1 bit 0,  00 = nominal power
5 E13 Power red. WR1, bit 1,  11 = level 3
6 E14 Power red. REC, bit 0, 00 = nominal power, 11 = level 3
7 E15 Energy mode WR1, 0 = no energy preselection, 1 = with preselection
8 E16 Op. mode WR1, 0 = normal operation 1 = short-circuit
9 E17 Op. mode WR2, 0 = normal operation 1 = short-circuit
10 E18 Voltage red. WR2, bit 0,  00 = nominal voltage
11 E19 Voltage red. WR2, bit 1,  11 = level 3
12 S Ground

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Plug X302 inputs and outputs

The power reduction inputs have different functions depending on parameter UD208
in F14:

Parameter UD208 = 7:
1 S +24V
2 E20 Power red. INV2 bit 0, 
3 E21 Power red. INV2 bit 1,  000 = nominal power
4 E22 Power red. INV2 bit 2,  111 = level 7
5 E23 Energy mode INV2 0 = no energy preselection, 1 = with preselection
6 not assigned
7 not assigned
8 not assigned
9 not assigned
10 A10 Control limit reached or Alfa = Alfa-Min and Phi regulation off
11 A11 Energy reached INV2 or KWh pulse of INV2
12 S Ground

Parameter UD208 = 3:
1 S +24V
2 E20 Power red. INV2 bit 0, 00 = nominal power
3 E21 Power red. INV2, bit 1, 11 = level 3
4 E22 Power red. REC bit 1, 00 = nominal power, 11 = level 3
5 E23 Energy mode INV2, 0 = no energy preselection, 1 = with preselection
6 not assigned
7 not assigned
8 not assigned
9 not assigned
10 A10 Control limit reached or Alfa = Alfa-Min and Phi regulation off
11 A11 Energy reached INV2 or KWh pulse of INV2
12 S Ground

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Plug X303 outputs, active "1"

1 S +24V
2 A0 Converter running Remains "1" as long as switch off is
running with ramp, thus until the converter
is actually switched off
3 A1 Collective error
4 A2 Current error IDmax, IDmin, differential current
5 A3 Line error UDmin/max/diff, phase error
6 A4 INV voltage/load circuit error UWmax, UOmax, UZmax, hold time,
Commutation
7 A5 Energy reached INV1 or KWh pulse of INV1
8 A6 INV frequency error Fmin/max
9 A7 Electronics error Hardware error, software error,
whist UT is A7=1 (do not start)
10 A8 Watchdog or data communication error, no connection via interface
11 A9 Phi regulation active, Twin Power: both inverters to Phi regulation
12 S Ground

Plug X500

Not used

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Rectifier control

Rectifier designations:

Figure 2.2.6: Rectifier, standard designations

Plug X600 Line input voltages, nominal level 100 / 120V (AC), delta connection

1 E Line 1 Phase L1

2 E Line 1 Phase L2 6-pulse, 12-pulse and 24-pulse
3 E Line 1 Phase L3
4 E Line 2 Phase L1
5 E Line 2 Phase L2 only 12-pulse (2 rectifiers in series) and 24-pulse
6 E Line 2 Phase L3

Plug 601 Line 1 phase current "1L1" and "1L3", nominal level 1 or 5A(AC)

1 E 1IL1 Phase
2 E 1IL1 Zero (shield winding)
3 S Ground Shield (2 connected with 3 on the backplane)
4 E 1IL3 Phase
5 E 1IL3 Zero (shield winding)
6 S Ground Shield (5 connected with 6 on the backplane)

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Rectifier firing pulse amplifiers

Plug X700 Rectifier 1 firing pulses: 6-pulse, 12-pulse and 24-pulse

1 A R+ pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A R- pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A S+ pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

Plug X701 Rectifier 1 firing pulses: 6-pulse, 12-pulse and 24-pulse

1 A S- pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A T+ pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A T- pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

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Plug X702 Rectifier 2 firing pulses: only 12-pulse (2 rectifiers in series) and
24-pulse

1 A R+ pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A R- pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A S+ pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

Plug X703 Rectifier 2 firing pulses: only 12-pulse (2 rectifiers in series) and
24-pulse

1 A S- pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A T+ pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A T- pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

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Inverter control
Plug X900 Inverter 1: INV1 - voltage
Standard: 1-3 nominal level 100V(AC), 4-6 leave free
TWIN POWER, C1/C2: 1-3 nominal level 100V(AC), 4-6 nominal
level 10V(DC) LEM adapter

1 E Output voltage phase

2 E Output voltage zero (shield winding)
3 S Ground = shield
4 E LEM output adapter
5 E LEM ground adapter
6 S Ground = shield

Plug X901 Inverter: INV1 & INV2 - current, nominal level 1 or 5A(AC)
SP and C1/C2: 1-3 not used, connect 4-6
TWIN POWER: Connect 1-3 and 4-6

1 E Inverter2 Output current phase

2 E Output current zero (shield winding)
3 S Ground = shield (2 connected with 3 on the
backplane)
4 E Inverter1 Output current phase
5 E Output current zero (shield winding)
6 S Ground = shield (5 connected with 6 on the
backplane)

Plug X902 Inverter1: firing pulses

Standard, C1/C2, TWIN POWER : Connect 1-6

1 S +48V
2 A Pulse A Diagonal A (+/U, -/V) and pre-mag current
3 S Ground Shield winding for pulse transformer
4 S +48V
5 A Pulse B Diagonal B (+/V, -/U)
6 S Ground Shield winding for pulse transformer

Plug X903 Inverters 1 & 2: Firing pulses for start thyristors

SP und C1/C2 : 1-3 not used, connect 4-6
TWIN POWER: Connect 1-3 and 4-6

1 S +48V
2 A Inverter 2 Start pulse
3 S Ground Shield winding for pulse transformer
4 S +48V
5 A Inverter 1 Start pulse
6 S Ground Shield winding for pulse transformer

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Plug X1000 Inverter 2: INV2 - voltage

SP and C1/C2 : Not used
TWIN POWER: 1-3 nominal level 100V(AC), 4-6 nominal
level 10V(DC) LEM adapter

1 E Output voltage phase

2 E Output voltage zero (shield winding)
3 S Ground = shield
4 E LEM adapter output
5 E LEM adapter ground
6 S Ground = shield

Plug X1001 Inverter 2: Firing pulses

SP and C1/C2: Not used
TWIN POWER: Connect 1-6

1 S +48V
2 A Pulse A Diagonal A (+/U, -/V) and pre-mag current
3 S Ground Shield winding for pulse transformer
4 S +48V
5 A Pulse B Diagonal B (+/V, -/U)
6 S Ground Shield winding for pulse transformer

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2.2.2 Jumpers for selecting the operating mode

The DICU can work in 2 operating modes:

• Single Power SP
• TWIN POWER TP or C1/C2
The furnace voltage and the LEM voltage must be conducted differently from the
plugs to the WRS cards for each operating mode. This switching is done
mechanically with the jumpers.
The jumpers are located on the rear of the backplane. The jumpers are arranged in
two rows: top (6 jumpers) and bottom (2 jumpers).
The jumpers on the backplane of the DICU 24p are arranged identically and have the
same functions.

Figure 2.2.7: Switching for the jumpers on the backplane

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Figure 2.2.8: Jumper arrangement for an SP DICU

Only the furnace voltage is measured for Single Power SP operating mode. The
measurement voltage is transformed to around 10V by the MF voltage transformer
and conducted to both measuring channels on the WRS. Only one WRS card is used
in the DICU for SP systems.

Figure 2.2.9 shows the jumpers required for SP operating mode – only jumpers J902
and J903. The other jumpers are removed.

Figure 2.2.9: Jumpers plugged for an SP DICU

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Figure 2.2.10: Jumper arrangement for a TP or C1/C2 DICU

The furnace voltage of both furnaces is measured in the TWIN POWER operating
mode. This voltage is required to control the timing of the converter and is conducted
to the first channels on the WRS cards by MF voltage transformers.
The LEM voltage measures the power of the individual inverters. This DC voltage
comes from the LEM adapter and is conducted directly to the second channels on the
WRS cards.

Figure 2.2.11 shows the jumpers for the TP and C1/C2 operating mode. All jumpers
are plugged.

Figure 2.2.11: Jumpers plugged for a TP or C1/C2 DICU

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2.3 DICU 24p, GES9898033

Supply Unit

Hole Plug
WRS - 1

WRS - 1
Reserve

Reserve
Reserve

Reserve

Reserve
GRS - 1

GRE - 1

GRS - 1

GRE - 1
CPU - 1

SIO - 1

+48V

191
268
PT PT
F- F-
M M

Figure 2.3.1: DICU 24p, design, without cover plate

A second WRS card is plugged in addition for TWIN POWER systems.

The 24p DICU has a second set of cards (GRS + GRE) for rectifiers 3 and 4 - which
is why there is not another plug-in socket for the multiple power unit on the front. The
multiple power unit is fastened to the upper cover plate at the rear and connected to
plug X12 on the backplane by a cable.

PT PT
F- F-
M M

Figure 2.3.2: Lower part of the front of the backplane 24p

There are internal components on the front of the backplane (under the cover with
the ABP logo) for measuring the analog signals.
There are 6 identical line voltage transformers for measuring the rectifier's
synchronous voltage in area (3).
Area (4) contains 2 MF voltage transformers for measuring the furnace voltage.
These transformers are replaced when the converter works at low nominal working
frequencies (<200Hz) (Chapter 2.6.3). The soldered in MF voltage transformers can
only be replaced by the DICU manufacturer.
The load resistors for the line current (area (5)) are identical to the load resistors for
the MF current (area (6)). The standard fitting for a measurement current of 1A is 1Ω.
These resistors are replaced by 0.2Ω for a measurement current of 5A (consisting of

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resistors of 0.22Ω and 2.2Ω soldered in parallel). The soldered resistors can only be
replaced by the DICU manufacturer.

F1
F2

Figure 2.3.3: Rear of the backplane 24p

The DICU 24p can control two further rectifiers. The additional plugs are situated on
a subprint plugged into the backplane. Further line voltage transformers for
measuring the rectifier's synchronous voltage and the load resistors for line current
are located on this subprint. The line voltage transformers and the load resistors on
the subprint must be identical to the components on the backplane (Figure 2.3.2).
The plugs (2) for inputting and outputting all analog and digital signals are located on
the backplane and on the subprint. 2 rows of codable pin headers are installed in the
DICU at a grid spacing of 5.08mm, consisting of the series 231 pin header and the
series 232 raised pin header made by the WAGO Company.
This area also contains two Dsub9 plugs for communication with the CPU card.
Power is supplied to the DICU via plug X13. Ground is connected to screw X14 (8).
Area (7) contains the F1 fuse for the 48V power unit of the firing pulse amplifiers and
the F2 fuse for the multiple power supply unit of the complete digital and analog
electronics. There is also a relay in this area that switches on the supply voltage for
the 48V power unit after start-up.
The multiple power unit is fastened to the top cover sheet at the rear and connected
to plug X12 on the spring strip on the backplane by a cable (9).
On the front of the backplane, there are more socket strips for plugging the individual
cards into the DICU than the number of cards used. Two jumpers must be plugged
on the rear of the backplane for each socket strip, matching the socket strip (top
right). Jumpers do not need to be plugged for the socket strip on the second WRS
that is not used.
There are further jumpers below the sub-board on the rear of the backplane for
selecting the operating mode of the DICU (Chapter 2.3.2).

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2.3.1 Detailed plug assignment for the DICU 24p

The plugs on the backplane of the DICU 24p are identical to those of the DICU 6/12p
– Chapter 2.2.1. This concerns the following plugs: X13, X14, X100, X101, X300,
X301, X302, X303, X600, X601, X700, X701, X702, X703, X900, X901, X902, X903,
X1000 and X1001.
Plug X12 is additionally located on the backplane for connecting an external multiple
power unit.

Plug X12 Multiple power supply unit (the pins are numbered from the card side
and are thus a mirrored image of all other plugs)

1 S +5V
2 S GND
3 S +12V
4 S GND
5 S -12V
6 S +24V
7 E Internal error (no longer used)
8 Free
9 Free
10 S N
11 S L1
12 S PE, ground

Sub-board: rectifier control

Plug X1500 Line input voltages, nominal level 100 or 120V(AC), delta connection

1 E Line 3 Phase L1

2 E Line 3 Phase L2 12-pulse (2 rectifiers in parallel) and 24-pulse
3 E Line 3 Phase L3
4 E Line 4 Phase L1
5 E Line 4 Phase L2 only 24-pulse
6 E Line 4 Phase L3

Plug 1501 Line 3 phase current 3L1 und 3L3, nominal level 1 or 5A(AC) or
line 2 for rectifier 12p, 2 rectifiers in parallel.

1 E 3IL1 Phase
2 E 3IL1 Zero (shield winding)
3 S Ground Shield (2 connected with 3 on the backplane)
4 E 3IL3 Phase
5 E 3IL3 Zero (shield winding)
6 S Ground Shield (5 connected with 6 on the backplane)

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Plug X1600 Rectifier 3 firing pulses: 24-pulse or REC2 with 2 rectifiers in parallel

1 A R+ pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A R- pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A S+ pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

Plug X1601 Rectifier 3 firing pulses: 24-pulse or REC2 with 2 rectifiers in parallel

1 A S- pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A T+ pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A T- pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

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Plug X1700 Rectifier 4 firing pulses: only 24-pulse

1 A R+ pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A R- pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A S+ pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

Plug X1701 Rectifier 4 firing pulses: only 24-pulse

1 A S- pulse
2 S +48V
3 A Free
4 S Ground = shield winding for pulse transformer
5 A T+ pulse
6 S +48V
7 A Free
8 S Ground = shield winding for pulse transformer
9 A T- pulse
10 S +48V
11 A Free
12 S Ground = shield winding for pulse transformer

2.3.2 Jumpers for selecting the operating mode

The jumpers for selecting the DICU's operating mode are located below the sub-
board on the rear of the backplane. The DICU 24p jumpers are identically arranged
and have the same functions as those of the DICU 6/12p - Chapter 2.2.2.

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2.4 Difference between DICU Dortmund & DICU USA

ABP constructs identical converters for inductive heating throughout the world. Even
though they may have identical technical properties, some components can vary.
Current transformers with a secondary current of 5A are used in some countries as a
matter of principle. The line voltage transformers can also have a secondary voltage
of 120V.
115V at 60Hz is often deployed as the control voltage (supply voltage).

The DICU can control these different converters without problem:

• The DICU can work at a supply voltage of 50Hz or 60Hz without any changes
being needed. The GRS card (or cards in the case 24p rectifiers or 12p
rectifiers in parallel) must naturally be fitted with the according PROMs.
• Changes need to be made in the power unit for switching the supply voltage to
230V or 115V – Chapters 2.5.6 and 2.5.7.
• Load resistors of 1.0Ω are deployed for measurement currents of 1A. Load
resistors of 0.2Ω (consisting of resistors of 0.22Ω and 2.2Ω soldered in
parallel) are required for measurement currents of 5A. These resistors are
soldered onto the backplane and onto the subprint; the can only be exchanged
by the DICU manufacturer or by ABP specialist personnel.
• A line voltage of 120V – instead of the usual 100V - requires changes to be
made to the fittings on the GRS card (Chapter 2.6.5) and the parameters also
need to be amended (Chapter 5.2).

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2.5 Description of the individual components in the DICU

General

The following designations are used in this sub-section:

LEDn LED with the number "n"

MBn Measuring socket with the number "n"
En Input with the number "n"
An Output with the number "n"

Measuring sockets:
Preliminary resistance: Generally 10k, ground 100Ω
Voltages: Nominal level peak value
Socket diameter: 2 mm
Note: Please do not use the "digital ground" or "analog ground"
measuring sockets as the reference point for measuring with an
oscilloscope. Always use the frame ground or screw X14 PE on
the backplane as the reference point.

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2.5.1 CPU-1 card GES9898030P29 / P1(outdated, unavailable since April

1997)

2.5.1.1 Function of the CPU card

The CPU collects all measurement data. Based on this data, it calculates the angle
required to fire the rectifier and inverter thyristors. The absolute value and the trend
of the measured values are monitored constantly and, if necessary, amended angle
set-points are transmitted to the pulse amp cards for rectifiers and inverters.
Measurement and control data are furthermore transmitted to the processor on
request.
The customer-specific data are stored in an EEPROM memory where they cannot be
wiped out by power blackouts.
When the supply voltage is switched on, the software is loaded from two EPROMs
and started. An extensive self-test program is then run through. The data are
furthermore transmitted from the EEPROM to RAM memory, where they are
available for cyclic processing. Wide-ranging fault reports are saved in another part of
the RAM memory. The RAM memory is buffered by the battery. If a fault occurs, the
actual load status is stored together with all measured values (although unfortunately
only at a couple of ms delay, at worse 21.4ms).

Figure 2.5.1: Block circuit diagram of the CPU card

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Figure 2.5.2: Side view of the CPU card with EPROMs and the battery

EPROM: Two identical EPROMs 1M (e.g. M27C1001-10F1, SST39SF010A) with

the up-to-date version (16-bit bus saved in in 2 bytes, E for "even" byte
and O for "odd" byte). The version number and date are shown on the
two stickers.

Battery: U=3.6V (available from local retail outlets)

Q=60-100mAh
Diameter<16.2mm, with soldering flags

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2.5.1.2 CPU LEDs and measuring sockets

Figure 2.5.3: Front plate of the CPU card

LED1 green/red red = hardware error

LED2 green/red red = internal data transmission error
LED3 green/red red = watchdog error, no data link via serial
interface
LED4 green/red green = converter is running
LED5 green/red green = Phi regulation active, for TP : both inverters
to Phi regulation
LED6 green/red red = control limit reached
LED7 green/red red = processor processing log book / regulation /
PLC functions
LED8 green/red red = processor processing command
LED9 green green = CPU accessing BUS
LED10 red red = reset or configuration, card out of operation

MP11 digital ground – do not use for oscilloscope

MP12 hardware error
Board AB 1076 AB: 5V digital transition 0-1: hardware error
Board AB 1076 AC: 5V digital transition 1-0: hardware error (since 1996)

Please note: Software errors are not output from socket MP12.

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2.5.2 SIO-1 card Signal Input Output GES9898030P2

2.5.2.1 Function of the SIO card

The SIO card receives commands from a meta-level control system via digital inputs.
The inputs are designed for a signal level of 24V and are decoupled by opto-
couplers. The digital outputs are executed as transistor outputs, which deliver 24V at
a maximum 100mA. The card serves as a level transformer for incoming and
outgoing signals.
Please note: The SIO card recognizes incoming signals <17V as 0 signals.

Digital inputs: +24V / 7mA, "0" = -1V up to +8V

"1" = +17V up to +30V
Digital outputs: +24V / 100mA, "0" = 0 V
"1" = +24 V

2.5.2.2 LEDs, inputs and outputs on the SIO card

Figure 2.5.4: Front plate of the SIO card

LEDs

Green E0 ÷ E23 : inputs 0 ÷ 23, "1" = LED lights up

Yellow A0 ÷ A11 : outputs 0 ÷11, "1" = LED lights up
Yellow LED dim : load not connected, no contact

Inputs

Inputs 0 ÷ 2 and 10 level-controlled

Inputs 3 ÷ 9 and 11 ÷ 23 edge-controlled
Input 9 only if Single Power is active
Inputs 16 ÷ 23 only if Twin Power is active
Input E10 if this input is at 1, then all other inputs are recognized
as 0 except input E0.

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Remark: The commands to the inputs E8, E11, E15, E16, E17 and E23 are only
executed when the converter is switched off (thus if it is in operation, only after the
OFF command.

The power reduction inputs have different functions depending on parameter UD208
in F14.

Parameter UD208=7 (limits the furnace power)

E0 Converter release : 0=block/1=release
E1 On/Off : 0=off/1=on (start test in test mode)
E2 Test mode : 0=inactive/1=release test (swing down)
E3 Acknowledge : 0=inactive/1=delete error
E4 Voltage reduction REC : Bit 0  (00=nominal voltage)
E5 Voltage reduction REC : Bit 1  (11= reduction level 3)
E6 Voltage reduction INV1 : Bit 0  (00=nominal voltage)
E7 Voltage reduction INV1 : Bit 1  (11= reduction level 3)
E8 Customer module 1-2 : 0=customer module1/1=customer module2
E9 Setpoint 1-2 : 0=potentiometer1/1= potentiometer2
E10 Inputs active : 0=active/1=inputs inactive except E0
E11 Command priority : 0=COM1/1=COM2
E12 Power reduction INV1 : Bit0  (000=nominal power)
E13 Power reduction INV1 : Bit1 
E14 Power reduction INV1 : Bit2  (111= reduction level 7)
E15 Energy mode INV1 : 0=no energy preselection/1=energy preselection
E16 Operating mode INV1 : 0=normal operation/1=short-circuit
E17 Operating mode INV2 : 0=normal operation/1=short-circuit
E18 Voltage reduction INV2 : Bit0  (00=nominal voltage)
E19 Voltage reduction INV2 : Bit1  (11= reduction level 3)
E20 Power reduction INV2 : Bit0  (000=nominal power)
E21 Power reduction INV2 : Bit1 
E22 Power reduction INV2 : Bit2  (111= reduction level 7)
E23 Energy mode INV2 : 0=no energy preselection/1=energy preselection

Parameter UD208=3 ( limits the converter power)

E12 Power reduction INV1 : Bit0  (00=nominal power)
E13 Power reduction INV1 : Bit1  (11= reduction level 3)

E20 Power reduction INV2 : Bit0  (00=nominal power)

E21 Power reduction INV2 : Bit1  (11= reduction level 3)

E14 Power reduction REC : Bit0  (00=nominal power)

E22 Power reduction REC : Bit1  (11= reduction level 3)
Note: The rectifier sum output limitation is only active in TWIN POWER mode. The
levels for INV1 or INV2 are active in Single Power mode.
If TWIN POWER limitation is active in TP and, for example, limitation for INV1 is also
active at the same time, then TWIN POWER limitation is limited.
If the limited target output of INV1 and INV2 is greater than the TWIN POWER
limitation, the power of INV1 and INV2 is reduced proportionally.

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Outputs

Output active = 1

A0 Converter running Remains "1" as long as switch off with ramp is

running (thus until the converter is actually
switched off.
A1 Common fault
A2 Current fault IWmax, IDmax, IDmin, Idiff
A3 Line fault UDmax,phase error, UDmin, differential voltage
A4 INV voltage fault UWmax, UOmax, UZmax, hold time, commutation
A5 Energy reached INV1 or energy pulse INV1
A6 INV frequency fault Fmin, Fmax
A7 Electronics fault Hardware error, software error or self-test
running (do not start)
A8 Watchdog or data communication error, no connection via interface
A9 Phi regulation active, for TWIN POWER both INVs to Phi regulation
A10 Control limit reached or Alfa=Alfamin and Phi regulation blocked
A11 Energy reached INV2 or energy pulse INV2

Remark:
Common fault active and fault active => Disturbance
Common fault inactive but fault active => Warning

Note: If INV1 or INV2 are operating without energy preselection (input E15=0 or
E23=0), then (≈100mS) "1" pulse for each processed kWh appears briefly at output
A5 or A11 (1kWh cannot be changed). As the power increases, the energy pulses
appear more frequently and at a certain time the cycle becomes shorter than 200mS
(ratio pulse to pause 1:1, from ≈16MW). The DICU then changes the pulse length to
≈75mS, ≈50ms or, in the case of still higher power, to 25mS (pulse length: parameter
UD79 from F14 (21.86mS) times factor 1, 2, 3 or 4).

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2.5.3 GRS-1 card - rectifier control GES9898030P3

2.5.3.1 GRS card function

The rectifier control prepares the values measured for line current and line voltage.
The rectifier input voltage is transformed to 100V (or 120V – Chapter 2.6.5) by two
external voltage transformers for each 3-phase current system. These voltages
contain the full commutation notches generated by the working rectifier. These
voltages must therefore be conducted through an analog filter of the third order. The
zero-crossings of the filtered voltages are recorded and forwarded to the CPU. The
CPU thereby takes account of the run time of the filters. The voltages are furthermore
monitored for compliance with the following values:

• Minimum voltage
• Maximum voltage
• Frequency deviation
• Phase angle error

The limit values are set via the CPU.

The currents in phase L1 and L3 continue to be measured by rectifier 1. The currents
are first converted to a voltage by the load resistors located on the backplane, then
rectified and added on the GRS card. This gives a waveform of the direct current Id.
The rectified current likewise runs through a filter before it is digitized. The current is
monitored for compliance with the following limit values:

• Minimum current
• Maximum current
• Differential current

The CPU notifies the card of the firing angle α at which the rectifier is to be operated.
The phase information measured is used to generate the 6 or 12 rectifier pulses and
these are transmitted to the pulse amplifier.

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Figure 2.5.5: Block circuit diagram of the GRS card

The socket in the backplane, the PROMs deployed on the card and whether the R29
plug resistor is deployed/removed (Chapter 2.6.1) determine whether the card is
responsible for REC1 & 2 or for REC3 & 4.

Figure 2.5.6: GRS card fitted for 6p rectifiers

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Figure 2.5.7: GRS card fitted for 12p rectifiers in series

2.5.3.2 LEDs and measuring sockets on the GRS card

Figure 2.5.8: Front plate of the GRS card

LEDs

1 Green = bus access

2 Red = reset or configuration, card not ready for operation
3 Yellow = test mode
4 Red = error

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Measuring sockets

1 Synchronous pulse 5V dig. edge 1-0 (pre-current pulse has triggered)

2 Hardware error 5V dig. edge 0-1 (hardware monitoring has
triggered)
3 Phase line 2/4 5V dig. firing on=>frequency 300Hz (USA 360 Hz)
4 Phase line 1/3 5V dig. firing on=>frequency 300Hz (USA 360 Hz)
phase shift to line 2/4 = 30°
5 Phase current 1IL3/3IL3 5V dig. no signal with converter at standstill
6 Phase current 1IL1/3IL1 5V dig. no signal with converter at standstill
7 Line voltage 1L2/3L2 10V sine (USA 12V), phase shift 8° or 11°
8 Line voltage 1L1/3L1 10V sine (USA 12V), phase shift 8° or 11°
9 Line voltage 2L1/4L1 10V sine (USA 12V), phase shift 8° or 11°
10 Line voltage 1L3/3L3 10V sine (USA 12V), phase shift 8° or 11°
11 Line voltage 2L3/4L3 10V sine (USA 12V), phase shift 8° or 11°
12 Line voltage 2L2/4L2 10V sine (USA 12V), phase shift 8° or 11°
13 Line current 1IL3/3IL3 approx. 1V square wave
14 Line current 1IL1/3IL1 approx. 1V square wave
15 UD1+2/3+4 waveform 5V DC voltage + ripple
16 ID1/3 waveform 5V DC voltage + ripple. Rectified signal from MB13
and MB14 multiplied by 5.1
17 Analog ground
18 Analog ground

Remark: The line voltages to sockets MB7 to MB12 come from the small, black line
voltage transformers 230V/9V located on the backplane / on the sub-board. These
transformers cause a phase shift in the secondary voltages. Transformers with a
power output of 0.33VA have a phase shift of -8°el. At a power output of 0.5VA, they
have a phase shift of -11°el.

Pressing the OFF button immediately sends the rectifier into the inverter limit position
(135°el). If the converter is running, the error message Emergency-Off (error 040) is
issued.

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2.5.4 GRE-1 card - rectifier firing pulse amplifiers GES9898030P32 / P4

(outdated, unavailable since September 2000)

2.5.4.1 GRE card function

The rectifier firing pulse amplifiers generates the pulses for a maximum 12 thyristors.
In the case of a 6-pulse rectifier, only 6 of the outputs are connected.
The maximum current per pulse is some 2A. The pulse length is determined by the
rectifier control unit to 400mS. A check is made to see whether an firing pulse
transmitter is connected at the output. A short-circuit (monitoring the drain voltage) or
an interruption are likewise recognized and reported to the CPU.
GRE card GES9898030P4 has been replaced by the GRE card GES9898030P32,
which has no effects upon the connections or functions.

Both GRE cards GES9898030P32 or GES9898030P4 must be of the same type in a

24p DICU.

MB3
gate R-(A-)
GRS

control STATE
MONITOR
signals
DRIVER

MB4

pulse transformers
R+(A+)
drivers state MB5
S-(B-)
MB6
S+(B+)
firing pulses MB7
T-(C-)
MB8
T+(C+)

Gate Drivers +48V

LOGIC Rectifier 1 MB16

MB9
STATE
R-(A-)
MONITOR

DRIVER

MB10
pulse transformers

R+(A+)
drivers state MB11
S-(B-)
MB12
S+(B+)
firing pulses MB13
T-(C-)
auxiliary
CPU

control MB14
signals
T+(C+)

Gate Drivers
PROM D2 Rectifier 2 54v04

Figure 2.5.9: Block circuit diagram of the GRE card

The socket in the backplane and the PROMs deployed on the card (Chapter 2.6.1)
determine whether the card is responsible for REC 1 & 2 or for REC 3 & 4.

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Figure 2.5.10: Fitting of the GRE card

2.5.4.2 LEDs and measuring sockets on the GRE card

Figure 2.5.11: Front plate of the GRE card

LEDs

1 green = bus access

2 red = reset or configuration, card not ready for operation
3 yellow = test mode
4 red = error

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Measuring sockets:

Figure 2.5.12: Rectifier, standard designations

1 Digital ground
2 Hardware error : 5V dig. edge 0-1, hardware monitoring has triggered
3 Firing pulse R1/3- : approx.48V line system1/3 R negative half-wave, 0=firing
4 Firing pulse R1/3+ : dto. R positive half-wave, 0=firing
5 Firing pulse S1/3- : dto.
6 Firing pulse S1/3+ : dto.
7 Firing pulse T1/3- : dto.
8 Firing pulse T1/3+ : dto.
9 Firing pulse R2/4- : approx.48V line system2/4 R negative half-wave, 0=firing
10 Firing pulse R2/4+ : dto. R positive half-wave, 0=firing
11 Firing pulse S2/4- : dto.
12 Firing pulse S2/4+ : dto.
13 Firing pulse T2/4- : dto.
14 Firing pulse T2/4+ : dto.
15 Pulse amp ground
16 Terminal voltage of transistors, approx. 48VDC

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2.5.5 WRS-1 card - inverter control and pulse amp GES9898030P5 / P30

2.5.5.1 WRS card function

The furnace voltage (UWR) measured by an external voltage transformer is filtered

and digitized. The zero-crossing of the voltage is transmitted to the CPU. The inverter
output current is likewise measured, filtered and digitized via an external current
transformer. The CPU determines the present operating status from the zero-
crossings of current and voltage and from other data. Limit value overshoots are
likewise monitored by the inverter control unit:
• Maximum frequency
• Minimum frequency
• Maximum voltage
• Minimum voltage
• Maximum current
• Minimum current (discontinued current)
• Differential current

The CPU notifies the inverter control unit of the firing time to be operated. The time at
which a firing pulse needs to be triggered is decided on the basis of the momentary
working frequency. Despite the purely digital processing of the signals, the firing
pulses are triggered with a time precision of 1/1000th , referred to the minimum
frequency of the system. The pulses are likewise generated and monitored by the
card. The admissible output current per pulse is around 50A, or in the case of TWIN
POWER only around 25A, when all 4 thyristor groups are fired simultaneously for the
inverter running along in short-circuit mode. The pulse duration is a uniform 20µs.
The pre-mag current pulse is 80µs. The start pulse to fire the start thyristor is
generated and monitored by an additional transistor.

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current sensor

CPU
LEM

pulse transformers
PT transformer

CPU
Comparator
Limit

CPU
I2C

+
-

-
BUW

BUOF

BUOF
MIN

MIN

GID
BIW
MAX

BUW

MAX

Figure 2.5.13: Block circuit diagram of the WRS card

The socket in the sub-rack and the PROMs deployed on the card determine whether
the card is responsible for INV1 or INV2 (Chapter 2.6.1). The pluggable filters enable
the range of the inverter's working frequency to be changed (Chapter 2.6.2).
GES9898030P5 this card can be adapted to working frequencies in the range of
50Hz to 1.5kHz by changing the filters.
GES9898030P30 this card has permanently installed fittings and is suitable for
a frequency range of 750Hz up to 5kHz.

Figure 2.5.14: Fitting of the WRS card

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2.5.5.2 LEDs and measuring sockets on the WRS card

Figure 2.5.15: Front plate of the WRS card

LEDs:

1 green = bus access

2 red = reset or configuration, card not ready for operation
3 yellow = test mode
4 red = error

Measuring sockets:

1 Phase output voltage : 5V dig. edge at Tfilt+Tchip after UWR=0

2 Hardware error : 5V dig. edge 0-1, monitoring has triggered
3 Phi=90°, U-maximum : 5V dig. 0=maximum, pulse width ≈250nS
4 Converter start phase : 5V dig. edge 0-1 start voltage reached
5 Commutation Start : 5V dig. edge 0-1 or 1-0=> commutation
6 Turn-off time control active : 5V dig. 1=control active
7 UOF furnace voltage/LEM : Normal 10V sinus, inverted; TP 10V DC
8 UWR output voltage : 10V sine, inverted
9 UW waveform : 5V rectified sine
10 IWR output current : 1V square wave
11 UW control signal : 3.5V DC voltage
12 IW waveform : 5V rectified square wave + ripple.
rectified signal from MB10 multiplied by 4.7
13 Differential current comparator : +10V=>OK -10V=>differential current
14 IW control signal : 5V DC voltage
15 Firing pulse B : +/V and –/U approx.48V 0=firing
16 Firing pulse A, pre-mag curr. : +/U and –/V approx.48V 0=firing
17 Power supply pulse amplifiers : approx. 48V DC voltage
18 Start thyristor firing pulse : approx. 48V 0=firing
19 Analog ground
20 Analog ground

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2.5.6 GES9898030P7/P23 power supply unit (for the firing pulses)

2.5.6.1 Function of the 48V power supply unit

The power supply unit provides 48V-DC voltage to the firing pulse amplfiers of the
GRE and WRS cards. The power supply unit is a non-stabilized voltage source
consisting of a toroidal transformer, a rectifier and capacitors.
The power supply unit is first switched onto the line voltage by a relay after the DICU
start command. The line voltage is also briefly switched on upon the UT command
from the PC for test purposes.
The green LED signals that the unit is in operation. This LED extinguishes once the
converter is switched off. The red LED4 on the GRE and WRS cards subsequently
lights up, although this does not indicate a disturbance.
The +48V is monitored on the CPU card.

Figure 2.5.16: Front plate of the 48V power supply unit

The 48V power supply unit can be supplied with a voltage of 230V 50/60Hz or 115V
50/60Hz. The corresponding voltage is determined by resoldering wires in the device,
whereby the power supply unit must be taken apart to do so.
After conversion to a different line voltage, the change should be noted on the rating
plate of the power supply unit.

GES9898030P7: supply voltage 230V

GES9898030P23: supply voltage 115V
Output voltage: 48VDC / 1.2A (transformer 60VA)

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4z VCC+48
6d GND
8z
10d
12z
14d
16z
18d
20z
22d
24z
26d N
28z N
30d L1
32z PE
VG-15H

soldering switch

blue blue
violet
grey
violet
grey
brown brown

soldering switch soldering switch

in 115V position in 230V position 23v08

Figure 2.5.17: Board of the 48V power supply unit

LED:

Green = 48V power unit in operation

Plugs:

4z S +48V
6d S GND
8z Free
10d Free
12z Free
14d Free
16z Free
18d Free
20z Free
22d Free
24z Free
26d S N
28z S N
30d S L1
32z S PE, ground

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2.5.7 Multiple power unit GES9898030P6 / P20 / P22 / P26 (outdated,

unavailable since February 2010) and GES9898030P40 / P41: for 5V,
12V, 24V

2.5.7.1 Function of the multiple power unit

The DICU electronics (digital and analog parts) are supplied by a multiple power unit.
The electronics require +5V, +/-12V and +24V supply voltages. Two models of the
finished multiple power units are deployed:
DICU 6/12p: the multiple power unit is assembled on a DICU plug-in card.
DICU 24p: the multiple power unit is assembled on the top cover sheet of the bus
wall and connected to the DICU via plug X12.
The multiple power unit delivers the following voltages:
• +5V +/-5%, 8A
• +12V +/-5%, 2A
• -12V +/-5%, 1A
• +24V +/-10%, 2A
The multiple power unit is supplied with a voltage of 230V 50/60Hz or 115V 50/60Hz.

Figure 2.5.18: Front plate of the multiple power unit

Two types of multiple power units are deployed nowadays. Although the old device
has been replaced by a new type, both models fulfil the DICU prerequisites. Only the
setting for the line voltage is different.

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The multiple power units:

GES9898030P6: old, line voltage 230V, for DICU 6/12p
GES9898030P22: old, line voltage 115V, for DICU 6/12p
GES9898030P20: old, line voltage 230V for DICU 24p
GES9898030P26: old, line voltage 115V for DICU 24p
GES9898030P40: new, line voltage 230V or 115V for DICU 6/12p
GES9898030P41: new, line voltage 230V or 115V for DICU 24p (with cable
and aluminum sheet)

Figure 2.5.19: Multiple power unit, old model

In the old multiple power unit, a jumper under the protective sheet must be re-
plugged. With a little dexterity, the position of the jumper can be changed using a pair
of pointed pliers without having to take the housing apart.

Figure 2.5.20: Multiple power unit, new model

The new multiple power unit has a sliding switch installed on the side to change the
line voltage. After conversion to the new line voltage, the change should be entered
on the rating plate of the power supply unit.

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This new multiple power unit features a potentiometer for precise +5V adjustment.
The default value for the voltage is set to ≈5.1V (given 1A load current). Do not
change it, only adjust in an emergency.

Plugs:

Multiple power unit GES9898030P6, P22 and P40

4z S +5V
6d S GND
8z S +12V
10d S GND
12z S -12V
14d Free
16z S +24V
18d E internal error (no longer used)
20z S GND
22d Free
24z Free
26d S N
28z S N
30d S L1
32z S PE, ground

Multiple power unit GES9898030P20, P26 and P41

Plug X12 Multiple power unit (the pins are numbered from the card side and are
thus a mirrored image of all other plugs)

1 S +5V
2 S GND
3 S +12V
4 S GND
5 S -12V
6 S +24V
7 E internal error (no longer used)
8 Free
9 Free
10 S N
11 S L1
12 S PE, ground

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2.5.8 Additional board for measuring current

2.5.8.1 Function of the additional board for measuring current

The 24p DICU has 2 GRS cards and 4 inputs for measuring the current from 2
rectifiers. That is sufficient for a 24p rectifier:
• 4 rectifiers switched in series (Figure 1.1.5)
• 2 systems switched in parallel, each consisting of 2 rectifiers switched in series
(Figure 1.1.4).

If 4 rectifiers are switched in parallel (Figure 1.1.6), there are 8 line current
transformers.

Figure 2.5.21: Subprint GES9898035P1

The line currents L1 and L3 of rectifiers 1-4 are each rectified via a diode bridge on
the sub-board GES9898035P1 and conducted to the DICU inputs.
These high power converters basically have 2 inverters working in parallel. As the
DICU has only 1 channel for measuring the inverter current, both current signals
must be connected in parallel (Figure 1.1.11, Figure 1.1.12 and Figure 1.1.13). Each
current signal has 1A and both together form a 2A signal. The DICU has a load
resistance of 1Ω and, at a 2A current, a measurement voltage of 2V is formed. These
2V are too high for the WRS card, so that the measurement signal needs to be
halved. A 0.5Ω measurement resistance is created by connecting an additional
resistor of 1Ω in parallel to the existing load resistor and the measurement voltage at
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this sum resistance then drops to 1V. This additional 1Ω resistor is located on the
GES9898035P1 sub-board.

The technical solution with 4 rectifiers switched in parallel has not proven itself in
practice and is no longer used.

Two or more inverters are always connected in parallel for higher power. Both 1A MF
currents are summed for the parallel connection of two inverters. As described
above, the measurement resistance needs to be halved (Figure 1.1.11, Figure 1.1.12
and Figure 1.1.13). Sub-board GES9898065P1 is deployed for this purpose.

Figure 2.5.22: Subprint GES9898065

Sub-board GES9898065P2 with a resistance of 0.2Ω is deployed for a measurement

current of 5A.

Figure 2.5.23: Board of sub-board GES9898065P1

The sub-board is installed on the side of the 24p DICU.

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2.5.9 INV current measurement with the sum current transformer

This technical solution using an additional measurement resistor has not proven itself
for several inverters working in parallel. Much better results are achieved with a sum
current transformer.
A 6-way sum current transformer GES9401081P2 is deployed as standard. 5A
signals from the individual inverters are connected to the primary side of the
transformer. All 6 inputs must be used.

∑
=
6

In the meantime, ABP deploys the 2-way sum current transformer GES9401081P3.
Sub-board GES9898065 is not necessary if two inverters are connected in parallel.
Both inputs of the sum current transformer must likewise be used here.

∑"
" =
2

A 5A signal is available at the output. This signal is reduced to 1A in a 5A/1A

transformer and forwarded to the DICU current input.

6-way sum current transformer 2-way sum current transformer

Figure 2.5.24: Sum current transformers

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2.6 DICU component fittings

The individual cards for plugging into the DICU and the backplane need to be
configured for the required scope of use (frequency, number of rectifier pulses, TWIN
POWER etc.). This is primarily done by fitting different EPROMs, or PROMs and
filters to the cards. The desired function of the ASIC deployed on the card is burned
into these programmed components and is thus protected against power failures.
The two EPROMs on the CPU card store the current program for the entire DICU
functions. This program is the same for all desired operating modes. The program
obtains the information of whether, for example, 6-pulse or 24-pulse operation is
required from the PROMs installed on the other cards.

IC fertig zum
IC inICnew
im Neuzustand
condition IC ready to insert
Einstecken

Static charges can destroy the components. For this reason, the components may
only be mounted on a conductive work surface. The components should be left in
their packaging until they are ready for assembly. Equalize the potential before
touching the connections. In the case of new components, the IC connections slightly
splayed out (see diagram) and therefore do not fit in the socket. Carefully bend the
connections straight. The best way to do this is by pressing them gently onto the
work table until the connections are parallel on both side (see diagram).
When removing EPROMs or PROMs from their sockets, lift the component evenly on
all sides (without tilting) as otherwise the connections could be bent. Immediately
place the component in a suitable, conductive wrapper.

In addition, the filters for the desired frequency range need to be fitted. The filter
capacitors are permanently soldered in and only the resistors need to be exchanged.
Sockets are provided for all resistors or networks that need to be exchanged.
Soldering work is not required to change the fittings and no special tools are needed.
The resistor networks have 8 connections and consist of 4 identical resistors situated
next to each other. The networks are symmetrical and can therefore by fitted in either
direction.

Soldering work is required to exchange the MF voltage transformers or load resistors

on the backplane. This work is performed by the manufacturer of the DICU.

Soldering work is required to change the supply voltage of the customer module, of
the LEM adapter or of the 48V power unit. The changes are made in the ABP works
when inspecting new systems or before spare parts are shipped by the Service
Department.

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2.6.1 EPROM and PROM fittings

The CPU card has 2 EPROMs which store the software for the DICU. The PROM
sets (2 PROMs each) are located on the GRS and WRS cards. The GRE card only
has 1 PROM.
The place number for each of the DICU cards is printed on the central divider in the
DICU rack.

Figure 2.6.1: DICU 6/12p, front view

Figure: 2.6.2 DICU 24p, front view

The table in Figure 2.6.3 shows the combinations of EPROMs and PROMs for a line
frequency of 50Hz, Figure 2.6.4 depicts a line frequency of 60Hz.

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*1) *2)
Plug-in 6/12-pulse 0 20 24 / / 36 42
place 24p/12pRECpar 0 20 24 36 40 52 58
Card CPU-1 GRS-1 GRE GRS-1 GRE WRS-1 WRS-1
-1 -1
Model O E D2 D3 R29 D2 D2 D3 R29 D2 D2 D3 D2 D3
6p Standard, C1/C2 O E G6 G6 no ES12 / / / / WS WS / /
D2E D3E D2 D2 D3
6p TWIN POWER O E G6 G6 no ES12 / / / / WT1 WT1 WT2 WT2
D2E D3E D2 D2 D3 D2 D3
12p Standard, C1/C2 O E G12 G12 yes ES12 / / / / WS WS / /
D2E D3E D2 D2 D3
12p TWIN POWER O E G12 G12 yes ES12 / / / / WT1 WT1 WT2 WT2
D2E D3E D2 D2 D3 D2 D3
12pStand./RECparallel O E G13 G13 no ES12 G14 G14 no ES22 WS WS / /
D2E D3E D2 D2E D3E D2 D2 D3
12pTWIN/RECparallel O E G13 G13 no ES12 G14 G14 no ES22 WT1 WT1 WT2 WT2
D2E D3E D2 D2E D3E D2 D2 D3 D2 D3
24p Standard O E G21 G21 yes ES12 G22 G22 yes ES22 WS WS / /
D2E D3E D2 D2E D3E D2 D2 D3
24p TWIN POWER O E G21 G21 yes ES12 G22 G22 yes ES22 WT1 WT1 WT2 WT2
D2E D3E D2 D2E D3E D2 D2 D3 D2 D3
*1) – Can also be ES1 or ES11, dependent on GRE card version
*2) – Can also be ES2 or ES21, dependent on GRE card version

Figure 2.6.3: Table of EPROM and PROM fittings for a line frequency of 50Hz

*1) *2)
Plug-in 6/12-pulse 0 20 24 / / 36 42
place 24p/12pRECpar 0 20 24 36 40 52 58
Card CPU-1 GRS-1 GRE GRS-1 GRE WRS-1 WRS-1
-1 -1
Model O E D2 D3 R29 D2 D2 D3 R29 D2 D2 D3 D2 D3
6 p Standard, C1/C2 O E G6 G6 no ES12 / / / / WS WS / /
D2U D3U D2 D2 D3
6 p TWIN POWER O E G6 G6 no ES12 / / / / WT1 WT1 WT2 WT2
D2U D3U D2 D2 D3 D2 D3
12 p Standard, C1/C2 O E G12 G12 yes ES12 / / / / WS WS / /
D2U D3U D2 D2 D3
12 p TWIN POWER O E G12 G12 yes ES12 / / / / WT1 WT1 WT2 WT2
D2U D3U D2 D2 D3 D2 D3
12pStand./GRparallel O E G13 G13 no ES12 G14 G14 no ES22 WS WS / /
D2U D3U D2 D2 E D3 E D2 D2 D3
12pTWIN/GRparallel O E G13 G13 no ES12 G14 G14 no ES22 WT1 WT1 WT2 WT2
D2U D3U D2 D2 E D3 E D2 D2 D3 D2 D3
24 p Standard O E G21 G21 yes ES12 G22 G22 yes ES22 WS WS / /
D2U D3U D2 D2 E D3 E D2 D2 D3
24 p TWIN POWER O E G21 G21 yes ES12 G22 G22 yes ES22 WT1 WT1 WT2 WT2
D2U D3U D2 D2 E D3 E D2 D2 D3 D2 D3
*1) – Can also be ES1 or ES11, dependent on GRE card version
*2) – Can also be ES2 or ES21, dependent on GRE card version

Figure 2.6.4: Table of EPROM and PROM fittings for a line frequency of 60Hz

The table show which card needs to be fitted with which PROMs or EPROMs. The
resistor R29 on the GRS card needs to be removed in some cases.
The figures show the position of the PROMs or EPROMs. When installing them,
make sure that the polarity is correct. The resistors or networks of resistors are
likewise marked.

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CPU card:
The two EPROMs on the CPU have a sticker showing the date of production and/or
the version number. The PC program software (GRTEST) version must agree with
these.

O E

CPU
CPU.DRW

Figure 2.6.5: CPU fitting

slot 0

GRS card: The figures below show the PROMs for a line frequency of 50 Hz.

R29

GRS-1 GRS-1
R5 R5
R1 R1

GRS06.DRW GRS12.DRW

Figure 2.6.6: Rectifier control unit 6p Figure 2.6.7: Rectifier control unit 12p
slot 20 rectifiers in series, slot 20

GRS12P_1.DRW GRS12P_2.DRW

Figure 2.6.8: Rectifier control unit 12p Figure 2.6.9: Rectifier control unit 12p
inverters in parallel, slot 20 rectifiers in parallel, slot 36

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R29 R29

GRS-1 GRS-1
R5 R5
R1 R1

GRS24_1.DRW GRS24_2.DRW

Figure 2.6.10: Rectifier control unit 24p Figure 2.6.11: Rectifier control unit 24p
slot 20 slot 36

GRE card:
Fittings for GRE card GES9898030P4. PROMs ES1 and ES2, later ES11 and ES21.

GRE-1 GRE-1

GRE12.DRW GRE24.DRW

Figure 2.6.12: Rectifier pulse amp Figure 2.6.13: Rectifier pulse amp
6p, 12p and 24p, slot 24 12p parallel, and 24p, slot 40

Fittings for GRE card GES9898030P32: PROMs ES12 and ES22.

GRE12.DRW GRE24.DRW

Figure 2.6.14: Rectifier pulse amp Figure 2.6.15: Rectifier pulse amp
6p, 12p and 24p, slot 24 12p parallel, and 24p, slot 40

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WRS card:

WRS-1
WR1
R22
R23
R24
R19 R16
R20
R3 R21 R17

WRSS.DRW

Figure 2.6.16: Standard INV control.

slot 36 or 52

WRS-1
WRS-1
WR2
WR1
R22 R22
R23 R23
R24 R24
R19 R16 R19 R16
R20 R20
R3 R21 R17 R3 R21 R17

WR1T.DRW WR2.DRW

Figure 2.6.17: INV control TP. Card 1. Figure 2.6.18: INV control TP. Card 2.
slot 36 or 52 slot 42 or 58

2.6.2 Filters fitted on the WRS card

Various filters with resistors need to be fitted to the inverter cards. The table below
(Figure 2.6.19) shows which resistors and which MF transformers are responsible for
which frequency range. The DICU is delivered with standard fittings intended for a
working frequency of 300 to 1500Hz (dashed area). Either networks with 4 resistors
or individual resistors are plugged in. The position of the resistors is shown in Figures
2,6.16, 2.6.17 and 2.6.18 in Chapter 2.6.1 or Figure 3.2.3 in Chapter 3.2.1.1, LEM
adapter.
The filter fittings cannot be changed for a working frequency >1.0kHz. In such a case,
the standard WRS card GES9898030P5 is replaced by the WRS card
GES9898030P30.
The function, fittings and calculation of the parameters for LEM adapters are
described in detail in Chapter 3.2.1.2.

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Figure 2.6.19: Table for the fittings of the WRS cards, backplane and LEM adapters

2.6.3 Fittings for the MF voltage transformers

The standard MF voltage transformers GES9898030P12 on the backplane are

suitable for all working frequencies >200Hz (Figures 2.2.2 and 2.3.2). Both MF
voltage transformers need to be exchanged if the converter's nominal working
frequencies are below 200Hz. The conversion to the MF voltage transformer
GES9898030P11 is quite complex and is therefore only performed by the
manufacturer of the DICU or an ABP technician.
A change to the MF voltage transformer GES9898030P11 on the backplane is
associated with an obligatory change to the fittings on the WRS card. This concerns
resistors R19 ÷ R24 (Figure 2.6.19).

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2.6.4 Jumper arrangement

A detailed description of the jumper functions can be found in Chapter 2.2.2. A brief
summary is given again below.
The DICU can operate in 2 modes:
• Single Power SP
• TWIN POWER TP or C1/C2
The furnace voltage and the LEM voltage must be conducted differently from the
plugs on the WRS cards for each operating mode. This switching is done
mechanically with the jumpers. The jumpers are located on the rear of the backplane.
The jumpers are arranged in 2 rows: top (6 jumpers) and bottom (2 jumpers).
The jumpers on the backplane of the DICU 6/12p and DICU 24p are arranged
identically and have the same functions.

Figure 2.6.20: Jumpers plugged for a SP DICU

Figure 2.6.21: Jumpers plugged for a TP or C1/C2 DICU

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2.6.5 GRS card fittings

The secondary voltage of the line voltage transformer (also DICU input voltage, plug
X600 or X1500) is in the range of 100V (Europe) or 120V (USA).
This voltage is reduced once more in the DICU to an electronic level of some 5V.
There are 6 small, black 230V/9V line voltage transformers on the backplane (also on
the subprint for the 24p DICU). Parameter UD70 needs to be adapted to the
transformer output.
These transformers had a power output of 0.33VA up to 2012 and have had a power
output of 0.5VA since 2012.
In the 24p DICU 24p, the same transformers on the backplane must also be on the
subprint.

The filters fitted to the GRS card need to be adapted and the relevant parameters
changed in the DICU data record (Figure 2.5.6, Figure 2.5.7, or Figures 2.6.6 –
2.6.11).

Line voltage Networks R1 and R5 Parameter UD124 Parameter UD70 (Window F13)
range (e.g. Figures 2.5.6, 2.5.7) (Window F5)
0.33 VA transformer 0.5 VA transformer
100V 4 x 8.2kΩ 0 20 24.0
120V 4 x 6.8kΩ 1 22.2 26.6

Figure 2.6.22: Table showing the fittings for the GRS card

Pluggable resistor R29 = 10kΩ.

Resistor R29 is removed for 6p rectifiers and 12p rectifiers in parallel.

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3 Additional equipment for DICU

3.1 Customer module GES9898029P4 (P1, P2 and P3 not available
since autumn 1996)
3.1.1 Description

The so-called customer module is the unit which communicates between the
customer and the DICU.
Data and disturbances are shown on an illuminated, 4-line display.
4 keys enable extended displays to be called up.
If the converter is working in manual mode, one or two potentiometers are connected
here for declaring setpoints. In addition, up to 6 analog instruments can be connected
to display measured values. A detailed description of all the customer module's
operating functions is contained in Chapter 6.

3.1.1.1 Design and plug assignment

Dimensions: 144 * 96 mm, front panel assembly

Supply voltage: 230/115 VAC +5%/-10%, 50/60Hz, voltage can be
changed by soldered bridges
Power consumption: ≈ 10VA
Ambient temperature: 0°C ÷ 50°C, no condensation water
Fuse F1 0.2A/T
EPROM: 512k (e.g. M27C512-12F1)
Default status: Soldered bridges to 230V, labelling on the rear: 230V

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Figure 3.1.1: Customer module, front

Figure 3.1.2: Customer module, rear

The following details are written by hand on the rear:

• Hardware version: P4
• Software version: Date
• Supply voltage: 230V or 115V

General: "E" = input

"A" = output
"S" = power supply or drawing potential

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Plug X8

1 S L1
2 S N

Plug X6
Serial interface COM1, RS232, plug
Parameters: 9600 baud, 8 data bits, odd parity, 1 stop bit
Electrical connection, normal: 2,3,5 and use shield
Fiber-optic cable: use an adapter
"0" = -12V, "1" = +12V, referred to ground.

1 E DCD
2 E RXD, received data
3 A TXD, transmitted data
4 A DTR
5 S signal ground
6 E DSR
7 A RTS
8 E CTS
9 E RI
S housing = ground = shield

Plug X7
Serial interface COM2, RS232, plug
Parameter: 9600 baud, 8 data bits, odd parity, 1 stop bit
Electrical connection, normal: 2,3,5 and use shield
Fiber-optic cable: Use an adapter
"0" = -12V, "1" = +12V, referred to ground.

1 E DCD
2 E RXD, received data
3 A TXD, transmitted data
4 A DTR
5 S signal ground
6 E DSR
7 A RTS
8 E CTS
9 E RI
S housing = ground = shield

Plug X1 - inputs

Not used

Plug X2 - outputs

Not used

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Plug X3 – E/A and plug X4 – E/A

GES9898029P1 GES9898029P2
GES9898029P4 GES9898029P3
Analog inputs 0..10V Re=20kΩ 0..10V Re=20kΩ
Analog outputs 0..10V / 10mA 0..1mA Re<200Ω
Potentiometer supply 10V / 1mA 5V / 1mA

Please note : "ground" – data communication = "ground" - analog

X3.1 S ground, Measuring devices "-"

X4.1 A0 Measuring device 1, SP: I, TP: U1
X3.2 A1 Measuring device 2, SP: U, TP: P1
X4.2 A2 Measuring device 3, SP: P, TP: F1
X3.3 A3 Measuring device 4, SP: F, TP: U2
X4.3 A4 Measuring device 5, SP: TP: P2
X3.4 A5 Measuring device 6, SP: TP: F2

X4.4 S +10V, Potentiometer 1 "+"

X3.5 E0 Input 1, Potentiometer 1 slider
X4.5 S +10V, Potentiometer 2 "+"
X3.6 E1 Input 2, Potentiometer 2 slider
X4.6 S ground, Potentiometers 1 and 2: "-"

EPROM

TRAFO

FUSE
200 mA/T
F1

1 8 1 6

L N X2 X4
X8 X1 X3
33v05

Figure 3.1.3: Front of the customer module board

The socket for the EPROM is longer than the EPROM itself. The EPROM with the
software must be plugged in flush with the transformer.

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Figure 3.1.4: Rear of the customer module board

The customer module can be supplied with a voltage of 230V 50/60Hz or 115V
50/60Hz. The required voltage is determined by resoldering wire bridges on the back
of the board, whereby the customer module must be taken apart to do so.
After conversion to a different line voltage, the change should be noted on the rear of
the customer module.

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3.2 LEM adapter GES9401057P3 / P1, P2 (old, unavailable since

November 2003)
3.2.1 Description

Figure 3.2.1: Block circuit diagram of the LEM adapter

The LEM adapter is required for TWIN POWER and C1/C2 systems.
In TWIN POWER operating mode, both inverters are switched electrically in series.
Large Beta control angles of up to around 90°el are required for the power changes
for each inverter in the range of 3% to 95%. The normal calculation of active power
using the formula P = U ⋅ I ⋅ cos( β ) is not precise enough. In order to determine the
exact active power of each inverter, the mean value of each inverter's input voltage is
measured and the CPU multiplies this by the value measured for the direct current.
The inverter input voltage is measured by a direct voltage measuring module made
by the LEM Company. This voltage must be filtered because it has a very high AC
ratio, whilst the DICU only requires the mean value. The LEM adapter serves this
purpose. It contains a filter of the third order, an amplifier and the +/- 15V power unit
for the LEM module. The filter must be adapted to the desired working frequency
range via the R2 network. The amplification factor must be determined on the LEM
module used and the nominal system voltage with resistors R1 and R3.

The measurement modules made by the LEM Company make use of the Hall Effect,
in which a Hall generator measures the magnetic flow density of a magnetic field
generated by a current conductor. This type of measurement is suitable for AC and
DC measurements.
There are other firms (such as ABB-Control) which construct measuring modules that
work on the principle of the Hall Effect. ABP deploys these modules for the C1/C2
converters. However, ABP usually refers to these modules and their associated
adapters as LEM modules and LEM adapters.

The LEM adapters GES9401057P1 and P2 have been replaced by the LEM adapter
GES9401057P3. This has no effect on the connections or functions.

Fuse: 63mA/T

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3.2.1.1 Design and connection

Dimensions: 125 * 95 mm,

Supply voltage: 230/115 VAC +5%/-10%, 50/60Hz, voltage can be
changed by soldered bridges
Power consumption: ≈ 10VA
Ambient temperature: 0°C ÷ 50°C, no condensation water
Fuse F1 63mA/T
Default status: Soldered bridges to 230V
R1 = 100 Ω
R2 = 4 x 220 kΩ (network)
R3 = 120 kΩ

Bestückung
100 x 220k x
R1
R2 470k
R3 1M

power supply
LEM - ADAPTER indicator

GES9 401 057 P0003

230V x
115V
For voltage- X3
selection, use 2
wirebridges inside ! 1
X1 X2

L N 1

41v06

Figure: 3.2.2: Front cover of the LEM adapter

There is a sticker on the front which details the fittings for the LEM adapter. After
conversion to different filter fittings or another line voltage, the change should be
noted on the sticker.
The supply voltage is signaled by a green LED.

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Figure 3.2.3: LEM adapter board

Plug X1

1 S L1
2 S N

Plug X2 LEM module

1 S +15VDC 
2 E M  LEM module
3 S -15VDC 

Plug X3 Analog output

1 Free
2 A UR (LEM Out)
3 S GND

LED

Green = supply voltage on

The LEM adapter can be supplied with a voltage of 230V 50/60Hz or 115V 50/60Hz.
The corresponding voltage is determined by resoldering wire jumpers on the board,
whereby the LEM adapter must be taken apart to do so.
The resistor R1=100Ω is soldered in and is not exchanged.
The network R2 and the resistor R3 can be unplugged and exchanged.
The resistance network has 8 connections and consists electrically of 4 identical
resistors situated next to each other. The network is and can therefore be plugged in
either way.

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3.2.1.2 Fittings and calculation

A detailed description of how the fittings and parameters for the LEM adapter are
calculated is contained in a file ULEM.STZ, which is stored in the HELP directory of
the DICU software.

The LEM modules are deployed most frequently in systems with a furnace voltage
around 3000V. An LEM module is used there with 3500Veff and ILEM=50mA:
LV100-3500, GES9401056P3. A simplified calculation for this LEM module is given
below.

Example calculation for a 3000V, 250Hz 24p system with a line voltage of 845V.

Udnominal = 2276V (parameter UD145, from Window F19)

R1 = 0.1kΩ (fixed)
R2 = 470kΩ (network R2, Chapter 2.6.2, Figure 2.6.19)
Rd = 2.8kΩ (filter fittings, Chapter 2.6.2, Figure 2.6.19)
Parameter UD56 = 21.3 (MF transformer, Chapter 2.6.2, Figure 2.6.19)
R3 = 180kΩ (calculation see below)

Determining R3:

R3[kΩ] ≥ U dNENN [V ]⋅ R2[kΩ]⋅143 ⋅10−6

R 3 ≥ 2276 × 470 ⋅143 ⋅10 −6 kΩ

R3 ≥ 153kΩ selected: R3 = 180kΩ

Calculating parameter UD54:

R3[kΩ] × (0,2 + Rd [kΩ])

Parameter54 = 1480 ×
R 2[kΩ] × Rd [kΩ] × Parameter56

180 × (0,2 + 2,8)

Parameter 54 = 1480 ×
470 × 2,8 × 21,3

Parameter54 = 28,51

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3.3 Fiber-optic adapters

3.3.1 Fiber-optic adapter GES9421237 / GES9421086 (outdated,

unavailable since January 2009)

3.3.1.1 Description

The DICU has 2 serial interfaces - COM1 (X100) and COM2 (X101). The interfaces
are executed as 2 DSub9 plugs. COM1 is an RS232 interface and COM2 is an
RS422 interface. The DICU communicates with the customer module, the PLC or the
processor via these interfaces.
The electrical and magnetic interference fields are quite strong around the system
and can influence communications.
Signals can be transmitted by fiber-optic cable without disturbances and fiber-optic
cables can be laid without problem right across the system.
The distance between the DICU and other components can be up to 100m.

b – blue
g – gray

Figure 3.3.1: The DICU's fiber-optic link

The fiber-optic adapters each have a channel for COM1 and COM2. On the DICU
side, the fiber-optic adapter has a channel with an interface COM1, RS232, and a
channel with an interface COM2, RS422. Both sockets are DSub9.
On the customer module or the processor side, the fiber-optic adapter likewise has
two channels, although both are RS232. The sockets can be DSub9 or Dsub25.

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The fiber-optic adapters installed in a housing to be mounted separately and require

an external power supply via a separate cable. The supply voltage is 24VDC from the
system or - in difficult cases - 12VAC from a plug-in power unit.

3.3.1.2 Design and connection

Supply voltage: 15 ÷ 30VDC or 12VAC 50/60Hz

Figure 3.3.2: Front of the fiber-optic adapter

The old GES9421086 fiber-optic adapter can no longer be supplied and has been
replaced by the GES9421237 fiber-optic adapter.
The new fiber-optic adapter has the same function as the old fiber-optic adapter. The
fastening holes are likewise in the same positions.
The old plug for the 24 VDC supply is identical to the new plug. This cable can
continue to be used.
The light converters deployed in the new fiber-optic adapters have different fiber-optic
plugs. For this reason, the fiber-optic cables must be exchanged at the same time as
the new fiber-optic adapters.
It is relatively simple to exchange the fiber-optic adapter and the fiber-optic cable and
this can be done by a trained electrician.

A description of how to exchange a fiber-optic adapter GES9421086Pxx for a fiber-

optic adapter GES9421237Pxx can be found in the Operating Manual BA53.701-
6.024 (Annex A7).

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The fiber-optic adapter is available in the following executions:

Figure 3.3.3: Executions of the fiber-optic adapter

In case of distances greater than 100m, the fiber-optic adapter can be deployed as
an intermediate optical amplifier – GES9421237P51.
By modifying the fiber-optic adapter GES9421237P21 the intermediate optical
amplifier GES9421237P51 is created. Both cables with DSub9 connectors must be
removed and connectors X1/1-X3/3 and X1/4-X3/1 must be soldered in.
An optical signal arrives at fiber-optic input COM1, which is converted into an
electrical signal COM1 and is connected directly in the adapter as electrical input for
COM2. This electrical signal is converted into an optical signal COM2 and forwarded
in full strength via a fiber-optic cable.

Remark: The fiber-optic adapter GES9421237P21 has two identical electrical RS232
connections - namely interfaces COM1 and COM2, although these are positioned
differently on the soldering pads on the board.

Figure 3.3.4: RS232 connections of fiber-optic adapter GES9421237P21

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3.3.2 Fiber-optic adapter GES9421118P1

3.3.2.1 Description

Figure 3.3.5: Fiber-optic adapter GES9421118P1

A processor is often not deployed for smaller converters. The system is controlled
solely from the customer module in manual mode. The setpoints are entered via
potentiometers connected to the customer module.
Only channel COM1 on the DICU is used for this application. COM1 on the DICU and
COM1 on the customer module are RS232 interfaces.
The GES9421118P1 adapter has a socket and is plugged directly into the COM1
DSub9 plug of the DICU and of the customer module. Voltage is supplied to the
adapter directly from the DSub9 socket. The fiber-optic cable does not have a plug,
but is inserted directly into the fiber-optic connection. A clean, vertical interface at the
end of the fiber-optic cable is extremely important here (use a new cutting knife).

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3.4 Booster GES9898104P3 / P1, P2 outdated, not available

Where high power converters are concerned, the energy required to fire several
thyristors working in parallel could no longer be drawn directly from the DICU. The
lines between the DICU and the thyristors have also become noticeably longer. This
causes considerable losses along the lines and degrades the leading edge (di/dt) of
the gate pulse.
ABP has developed a new system for firing the thyristors. This includes a booster
which is addressed via optical cable by special light transmitters (Chapter 3.5) on the
DICU side. The booster is installed in the inverter cabinet.

3.4.1 Design, LEDs and plug assignment

ABP Booster GES9898104P3

H3
H2 green A
H1 green H4

B
S1 X7 X5
T1 3 GND
230V
A 2 Pulse

1 +DC

115V

F1 X8 X6
3 GND

B 2 Pulse

1 +DC

X1 H5
T2
L1 1
yellow
N 2
100V
70V
50V

X9 GND

X2 X3 X4

96v07

Figure 3.4.1: Booster

Dimensions: GES9898104P3: 200 * 155 * 90 mm

GES9898104P1, P2: 200 * 140 * 90 mm
Hole size: GES9898104P1, P2, P3: 188 * 128, Ø 4.5 mm
Supply voltage: 230/115 VAC +5%/-10%, 50/60Hz, the voltage can be
changed with switch S1
Firing voltage: 100V/(X2), 75V/(X3), 50V/(X4), can be changed by
soldered bridges X2, X3 or X4
Ambient temperature: 0°C ÷ 50°C, no condensation water
Fuse F1: 1A/T
Default status: Line switch at 230V, Firing voltage at 100V
(soldered bridge at X2)

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Plug X1 Supply voltage

1 S L1
2 S N

Screw X9

1 S PE, ground (minimum 6 mm2)

Plug X5 Firing pulse

1 S +50 - 100 V
2 A Pulse A Diagonal A (+/U, -/V) and pre-mag current
3 S Ground Shield winding for pulse transformer

Plug X7 Firing pulse

1 S +50 - 100 V
2 A Pulse A Diagonal A (+/U, -/V) and pre-mag current
3 S Ground Shield winding for pulse transformer

Plug X6 Firing pulse

1 S +50 - 100 V
2 A Pulse B Diagonal B (+/V, -/U)
3 S Ground Shield winding for pulse transformer

Plug X8 Firing pulse

1 S +50 - 100 V
2 A Pulse B Diagonal B (+/V, -/U)
3 S Ground Shield winding for pulse transformer

Plug H3 Firing pulse A via fiber-optic cable

Plug H4 Firing pulse B via fiber-optic cable

Soldered bridges:

X2 Firing voltage 100VDC (in GES9898104P1 and P2: 70VAC)

X3 Firing voltage 75VDC (in GES9898104P1 and P2: 50VAC)
X4 Firing voltage 50VDC (in GES9898104P1 and P2: 35VAC)

LEDs:

H1 green = +5V is OK
H2 green = +10V is OK
H5 yellow = Firing voltage (50V, 75V, 100V) is OK

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3.4.2 Description

The GES9898104P3 booster has the same functions as the boosters P1 and P2. The
labelling for the firing voltage has changed - see above.

The supply voltage can be changed using the labelled slider switch.
The presence of the internal voltages is signaled by green (+5VDC and +10VDC) and
yellow (firing voltage) LEDs.
When the supply voltage is switched on (up to 100V!), the firing voltage is always
present at output plugs X5 to X8 (the firing voltage at the firing pulse outputs on the
DICU is not present until the system is started or just for a short time after GRTEST
UT command).
The openings for plugs H3 and H4 for fiber-optic signals should never be left
open. The stray light could switch the output transistors on, thereby permanently
feeding DC firing voltage to the pulse transformers, which would become saturated
and subsequently be destroyed.

Note 1: Older high power systems with the GES9558013P1 inverter pulse
transformers can be retrofitted with a booster.
These pulse transformers are powered directly from the DICU with 48V pulses. It has
recently been found that the no-load voltage of the gate firing pulses generated from
this is too small.
Investigations have shown that these pulse transformers can be addressed with
100V without any problem. This doubles the gate no-load voltage, which in turns
gives the firing pulse a doubled current amplitude. The di/dt of the current waveform
likewise becomes steeper. The booster must solely be set to 100V – bridge X2
soldered in.

Note 2: ABP has introduced the new GES9558046P1 pulse transformers. The
connections for these pulse transformers are situated so close together that they
could touch the installed 6.3mm Faston plug connectors and cause a short-circuit in
the booster. The power transformer on the booster board would be loaded on the
secondary side over with a short-circuit with a 12Ω resistance (the resistance in the
pulse transformers) and destroyed after just a short time.
Fully isolated 6.3mm plug connectors (Faston plugs) must always be used on
the primary side for new GES9558046P1 pulse transformers.

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3.5 Fiber-optic transducers for DICU GES9898105P1 / P2

The GES9898104 boosters should be addressed with fiber-optic signals. These
signals, the firing pulses for diagonals A and B, although also the firing pulse for the
starter device, are available at the plugs X902, X903 and X1001 on the DICU. The
GES9898105 fiber-optic transducer convert these electrical signals into light signals.
These signals can be sent by a fiber-optic cable over distances of up to 100m.
The fiber-optic transducers draw very little current from the DICU, so that these are
not recognized by the DICU when they are in operation and the DICU would report a
pulse amp error. That is why there are load resistors on the fiber-optic transducer
board, which "fool" the DICU into believing that the pulse transformers are
connected.
When fiber-optic transducers are used, the inverter pulse amp monitoring error 055
is ineffective. The firing pulse amplifiers monitor only recognizes if the light
transmitters are connected.

3.5.1 Design and plug assignment

Dimensions: 77 * 31mm
Hole size: 68.5 mm, Ø 4.5 mm

The are two light transmitter models:

Fiber-optic transducer for DICU GES9898105P1

Plug X1 Electrical signals for diagonals A or B

1 S +48 Volt
2 E Pulse

Plugs XT1 to XT6 6 fiber-optic transducers in parallel

Figure 3.5.1. Fiber-optic transducer with 6 channels

This fiber-optic transducer is intended for systems which have more than two
inverters working in parallel. The fiber-optic transducer only has one channel and
translates only one electrical signal into 6 fiber-optic signals. Two of these fiber-optic

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transducers are required to transmit pulses for diagonals A and B. If several starter
devices are supplied by one booster, fiber-optic transducer is added.

Fiber-optic transducer for DICU GES9898105P2

Plug X1 Electrical signals for diagonals A and B

1 S +48 Volt
2 E Pulse A
3 E Pulse B

Plugs XT1 and XT2 2 fiber-optic transducers in parallel for diagonal A

Plugs XT3 and XT4 2 fiber-optic transducers in parallel for diagonal B

Figure 3.5.2: Fiber-optic transducer with 2+2 channels

This transducer is intended for systems which have one or two inverters working in
parallel. The GES9898105P2 transducer has 2 electrical channels which are each
converted into 2 fiber-optic signals. A fiber-optic transducer can convert the signals
for diagonals A and B into light. If several starter devices are supplied by one
booster, another transducer is added.

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3.6 Current monitoring RIFAM GES9898106P1

A 6-way GES9401081P2 sum current transformer for several inverters working in
parallel is described in Chapter 2.5.9. The sum current signal is required to regulate
the DICU. The internal short-circuit current of the individual inverters must also be
monitored. The RIFAM plug-on board for the sum current transformer is responsible
for monitoring the current for each channel. An error message sent via a fiber-optic
cable activates an immediate blockage of further firing pulses – pulse block (Chapter
3.7).

X8/7
LED
R

&

LED
FC

LPF
=100ms
0K1
0K1 5A
LEM1 k=2,83 S opto-relay
X1/1
X8/1
R Q
5A1
equiv. LED
X1/2 300 K1
=0.5 s +24V

0K2
0K2 5A
LEM2
X2/1

5A2 X8/2

X2/2

0K3
0K3 5A
LEM3
X3/1

5A3 X8/3

X3/2

0K4
LEM4
X4/1

5A4 X8/4
5A 0K4
X4/2

0K5
LEM5
X5/1

5A5 X8/5
5A 0K5
X5/2

0K6
LEM6
X6/1

5A6 X8/6
5A 0K6
X6/2

600
k=-1 U 15V

P1 Rref
display D
(option)
J1 A 5k
Uref
measuring point
94v01

Figure 3.6.1: Block circuit diagram of the RIFAM current monitor

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The circuit consists of 6 galvanically separated channels with measurement and

monitoring functions. The reference signal for monitoring overcurrent is the same for
all 6 channels. Each disturbance is shown in individual channels, is stored and
forwarded to the PLC by galvanically separated lines. The sum disturbance is
forwarded to the GES9898107P1 rapid pulse block on the DICU side through a fiber-
optic cable.

3.6.1 Design and plug assignment

+15V
-15V

190

Figure 3.6.2: Front view of the RIFAM current monitor

Dimensions: 173 * 190 mm, installed on the GES9401081P2 multiple

current transformer. Fastening set: GES9898106R1000
Supply voltage: +18VDC ÷ 36VDC
Ambient temperature: 0°C ÷ 50°C, no condensation water

Plug X7 Supply voltage

1 S +24VDC
2 S 0V

Screw X10

1 S PE, ground (minimum 6 mm2)

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Plug X1 Current measuring channel 1

1 E 0K1
2 E 5A1 5ARMS

Plug X2 Current measuring channel 2

1 E 0K2
2 E 5A2 5ARMS

Plug X3 Current measuring channel 3

1 E 0K3
2 E 5A3 5ARMS

Plug X4 Current measuring channel 4

1 E 0K4
2 E 5A4 5ARMS

Plug X5 Current measuring channel 5

1 E 0K5
2 E 5A5 5ARMS

Plug X6 Current measuring channel 6

1 E 0K6
2 E 5A6 5ARMS

Plug X8 – 24VDC inputs/outputs

1 A K1OUT channel 1, optical relay Imax=500mA

2 A K2OUT channel 2, optical relay Imax=500mA
3 A K3OUT channel 3, optical relay Imax=500mA
4 A K4OUT channel 4, optical relay Imax=500mA
5 A K5OUT channel 5, optical relay Imax=500mA
6 A K6OUT channel 6, optical relay Imax=500mA
7 E Reset optical coupler input at the input
8 S GND internal with 0V connected to the +24VDC external supply
voltage

Plug X9 Overcurrent disturbance, fiber-optic transmitter

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LEDs:

FC red = overcurrent sum disturbance

K1 red = overcurrent disturbance channel 1
K2 red = overcurrent disturbance channel 2
K3 red = overcurrent disturbance channel 3
K4 red = overcurrent disturbance channel 4
K5 red = overcurrent disturbance channel 5
K6 red = overcurrent disturbance channel 6
R green = reset
+15V green = +15V OK
-15V green = -15V OK

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3.7 Pulse block GES9898107P1

The GES9898106P1 booster monitors overcurrent in each channel. In order to
minimize damage to the inverter, it is necessary to stop any further inverter firing
pulses immediately. The monitor reports the sum disturbance to the DICU. The DICU
does not have an input which could stop the firing pulses immediately.
The pulse block is an additional board which is connected between the DICU's firing
pulse output and the fiber-optic transducer. The pulse block is activated via the fiber-
optic input, whereby the 48V voltage off is switched off immediately.

3.7.1 Design and plug assignment

Dimensions: 74 * 42mm
Hole size: 63.5 * 34.5mm, Ø 4.5 mm

Figure 3.7.1: Block circuit diagram of the pulse block

Figure 3.7.2: Front of the pulse block

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Plug X1 DICU addressing

1 S +48VDC
2 E Pulse A, input
3 S 0V, GND
4 S +48VDC
5 E Pulse B, input
6 S 0V, GND

Plug X2 Pulse A, to fiber-optic transducer

1 S +48VDC
2 A Pulse A, output

Plug X3 Pulse B, to fiber-optic transducer

1 S +48VDC
2 A Pulse B, output

Plug XR1 Fiber-optic receiver, sum disturbance from the RIFAM

LEDs

D1 5V = yellow +5VDC OK
D2 48V = yellow +48VDC OK
D3 Switch on = green block inactive

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4 DICU GrTest software

GrTest is a software program which communicates with the DICU converter

electronics unit and enables it to be set and operated.
Only ABP service technicians or license holders trained by ABP are allowed to work
with this program.

GrView (a simplified version of the GrTest program) is available for customers. This
version works like GrTest, with the exception that changes to individual parameters
and the start of the converter from the service PC are disabled. More details can be
found in Chapter 4.5.

GrTest is a DOS-based program and which requires the service computer to be

specially configured (virtual machine, DOS box, USB adapter or a PCMCIA card). An
RS232 serial interface is needed to communicate with the DICU.
The set-up for the service PC is described in detail in Annex A1.

GrTest commands (printed in BOLD below) are input from the keyboard and
confirmed by pressing ENTER. A differentiation is not made between upper case and
lower case in the commands.
In commands, the ? key can be replaced by the H key and the = key by the P key.

In what follows in this manual, placeholders nn (printed in italics) are used for file
names. When inputting such commands, nn should be replaced by a file name of up
to 8 characters in length.

The complete program is available two languages: German and English. All windows
are displayed in these two languages. The default setting at program start is always
German. The language can be changed at any time by inputting the following
commands:

AL1 English
AL0 German

Further languages are available for error messages.

When one of these languages is selected, the GUI is displayed in English and only
the error messages are issued in the selected language:

AL2 Turkish
AL3 Polish
AL4 Portuguese
AL5 Swedish
AL6 Italian
AL7 French
AL8 Spanish
AL9 Czech

A crossed serial (zero modem) cable with Dsub9 sockets is required for connecting to
the DICU.

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4.1 GrTest structure on a PC

As GrTest is a DOS program, none of the directory or file names can be longer than
8 characters.
The DICU programs are saved in the main GR directory, which also contains the
LOAD.BAT file.
The GR directory contains sub-directories created for the different DICU versions or
for customer-specific requirements.
These directories are normally named after the DICU version and always start with
GR. The DICU programs with the names GRnn are described below. nn stands for
the version or customer names.
The directory tree must have the following structure:

├GR
├GRnn
├DAT
├ERR
├EXE
├HELP
└TEXT

The files in each of the sub-directories must originate from the same DICU software
version.
• DAT: this must at least contain the GLODAT.DAT file. Customer-specific files
and sample files can also be found here.
• ERR: there does not have to be a file here. Error files are saved to this
directory, from where they are later exported to the DICU. Screenshots
(Function key <F1>) made from the service PC are also saved in this directory
in the GRTEST.LOG file - Chapter 4.4.1.2.
• EXE: this must contain the GRTEST.EXE file. When working with the GrView
program, the GRVIEW.EXE file must be copied to this directory.
The SCOM.EXE or GRSIM.EXE files can also be copied to here – a detailed
description can be found in Chapters 4.7 and 4.8.
• HELP: there do not need to be any files here. It can contain the nn.HLP and
nn.STZ text files which describe the DICU in abbreviated form. The files can
be opened with the Editor.
• TEXT: this directory must contain the GLOTEXT.TXT file and 7 nn.TXS files.
The screen texts are missing or are incomplete without these files. The files
can be opened with the Editor.

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4.2 Starting the GrTest program

The GrTest program is started from the DOS level or from a DOS window. Thus if
you are using a Windows OS, a DOS window must first be opened (e.g. with
Start=>Execute=>cmd).
Then call up the GR directory. The DICU programs located in this directory can be
launched from there.
The load GRnn command calls up the program with the name GRnn from the GR
directory.

A new DICU directory tree can be created from the GR directory with the command:
load GRnn1 NEW. GRnn1 is the name of the new directory. Then copy the required
files – as described above – into this directory tree. The program cannot be started
until all the necessary files are in this directory.

Providing the load GRnn command has been executed correctly, the cursor _ should
be at the end of the line ……\GR\GRnn\>_

The GrTest program can be launched on the service PC in 2 ways.

• Offline: the GrTest program runs on the service PC in simulation mode
without being connected to the DICU. This operating mode allows the
customer data to be prepared from an office workplace, to establish that
the program is running properly or to analyze the collected data (error files
or screenshots) at a later time.
• Online: the service PC is connected to the DICU. Data can be exchanged
between the DICU and the PC. The converter can be started and the
parameters optimized. Observation mode is also possible.

The data are loaded with the ULnn command and saved with the USnn command.
More details are given in Chapter 4.4.2.8.

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4.2.1 Starting the GrTest program offline

The program is started with the GRTEST XYZ command:

X: 5 for line frequency 50 Hz and 6 for line frequency 60 Hz
Y: Rectifier pulse rate: 6, 12, 13 or 24 (13 is for 12p REC in parallel)
Z: S for SINGLE POWER and T for TWIN POWER systems
Important: it is essential that the XYZ parameters correspond to the system in
question.
Note: in online operation, the program is started with the GRTEST command and the
parameters are read out from the DICU automatically.

Example:
The system is supplied from a 50 Hz grid (typical for Europe), has 12-pulse rectifiers
switched in series and is a TWIN POWER model. The program is started with the
following command:
GRTEST 512T

Figure 4.2.1: GrTest started in offline mode

The computer screen shows the FG1 and FW1 status windows and the SIMUL
message can be seen in the top right-hand corner
The parameters were loaded from the GLODAT.DAT file in the DAT directory.

The GrTest program can be ended with the Q command.

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4.2.2 Starting the GrTest program online

The DICU's COM1 interface (X100) must be connected to the service PC with a zero
modem cable. The DICU must be switched on.
The uppermost LED on the CPU card can be green or red. The first red LED signals
a DICU error, although this does not prevent communication being built up with the
service PC. The second LED on the CPU card should be lit in green.
LED11 on the SIO card (command priority) must be off or the "DICU Test" service
switch switched on, which is signaled by LED10 (inputs active) being lit on the SIO
card. This switch is usually located in the door of the converter cabinet or is mounted
on the DICU in the converter cabinet.
The link with the DICU is only initiated with the GRTEST command. The computer
subsequently attempts to establish the link to the DICU.
If the software versions on the service PC and the DICU are different, an error
message appears in the bottom line. The software versions of the DICU and of the
service PC are shown there. During this time the screen looks as follows.

Figure 4.2.2: Incorrect GrTest version started.

Start the service PC with the software version which matches the DICU software or
exchange both EPROMs on the CPU card to match the software version on the
service PC. Then reboot the DICU and make the connection with the GRTEST
command.
After the GrTest program has started correctly and communication has been
established with the DICU, the third LED from the top on the CPU card lights up in
green. The computer screen displays the FG1 and FW1 status windows and the
ONLINE message appears in the top right-hand corner. Any DICU errors are shown
at the bottom of the screen.

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Figure 4.2.3: GrTest started in online mode

The system's parameters are read out from the EEPROM on the DICU's CPU card.
The details concerning the line frequency, the configuration of the rectifier and the
type of converter (SP or TP) are read out from the PROMs on the GRS und WRS
cards.
The DICU runs a self-test, during which the +48V DC power unit is briefly switched
on and the outputs for the pulse transformers are tested.
As the power unit was only switched on for a short time, the +48V DC drops within a
couple of seconds to 0V. The screen then displays the errors for the pulse amplifiers,
which is normal.

Figure 4.2.4: GrTest started in online mode, a few seconds later

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Note: The service PC and the DICU can also be linked via the DICU's COM2
interface (X101). The same type of connection is used to connect the customer
module to the DICU's COM2 interface.
However, this type of connection requires changes to be made to the hardware and
to the DICU's parameters. It is described in Chapters 6.9 and 7.7.2.1.
The GrTest program is ended with the Q command.

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4.3 Design of the windows on the service PC screen

The image on the computer screen consists of 4 parts.

• The uppermost line, highlighted in white, provides information on the software
version and the type of connection - ONLINE or SIMUL. (simulation mode,
offline).
• Up-to-date information is displayed in the middle in the form of windows. One
large window or two smaller windows (left and right window) can be displayed
in the middle at the same time. If a large window is visible, the two small
windows are hidden behind it. The small windows do not become visible until
the large one is closed.
• Below the windows is a line, highlighted in white, containing references to the
most frequently used commands.
• There are 5 at the bottom. Commands can be entered here and the DICU
gives feedback on the execution of the commands or issues error messages.

The small windows can be positioned on the left or right of the screen.
L at the end of the window entry in the "Input" line positions the window that appears
on the left, R at the end positions the window that appears on the right.
Example:
F3R = window F3 right
FL1L = window FL1 left
When calling up a window from the "Input" line, the confirmation appears in the next
"Done" line with a letter at the end. This letter informs the user that the window was
position left L, right R or as a large window in the middle M.
In the same way, the windows on the left, right or the large window can be closed.
The F-L command closes the left window, F-R closes the right window and F-M
closes the large window. The entry F- has the same effect as F-M.

The screen currently being displayed on the service PC can be saved to the
GRTEST.LOG text file as a screenshot with the <F1> function key. The size of this
file is unlimited and all further screenshots are appended to the end of this file. This
file is stored in the ERR directory of the running program.
Please note: When saving a screenshot to the GRTEST.LOG text file in the ERR
directory with the <F1> function key, the values highlighted in red are saved without
this red background.

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4.4 DICU windows

The GrTest program features more than 200 windows. Many of these windows are
provided for debugging purposes or for internal hardware diagnosis.
This chapter only describes the windows that are relevant for operation, for declaring
settings or for diagnosing the converter. Moreover, only the lines of relevance in the
windows are commented on and explained.

The windows are grouped as follows:

• Help windows: general information on the program run.
• Navigation windows: the commands are presented here which determine the
running of the program or control data transfers.
• Input windows for entering parameters for the system.
• The latest measured values and states from system operation.

The windows are categorized in groups and then introduced in alphabetic order.

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4.4.1 Help windows

The help windows provide general help for the work with the GrTest program.

The help windows are called up with commands that start with the letter H.

4.4.1.1 Window H General Help

Figure 4.4.1: Window H, general help

The content of this window is discussed in Chapter 4.2.1 above.

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4.4.1.2 Window H1 General Help cont., direct commands and function keys

Figure 4.4.2: Window H1, general help, continuation

The <F1> function key saves a screenshot of the service PC's current screen to the
GRTEST.LOG file in the ERR directory. If the <F1> function key is pressed
repeatedly, the screenshot of the service PC is saved to the same GRTEST.LOG file
and the new content is appended to the end of the file. The size of the GRTEST.LOG
file is unlimited and any number of screenshots of the service PC can be saved to the
file.
The <F2> function key has the same effect as the <F1> function key, although it
additionally saves all messages from the COM1 and COM2 interfaces, from the
console and from the keyboard command buffer.
Please note: When saving a screenshot to the GRTEST.LOG text file in the ERR
directory with the <F1> function key, the values highlighted in red are saved without
this red background.

<F3>, <F4>: These function keys allow the last or the next commands to be called up
from the keyboard buffer. This function can be useful if the same command is to be
executed several times in a row.
This is sometimes useful when repeating a command several times such as the WS
command or repeating the STN0 short start.

Q, ‘ and ] (German version: Q, # and +), as the most frequent commands, are always
visible in a dedicated line.
• Q: Ends the program and in online operation terminates the link to the DICU.
• ‘: Switches the converter off. Same effect as switch off with the SIO input E1,
On/Off – Chapters 2.2.1 and 2.5.2.1. This is a normal switch off with ramp.
Even if the service PC does not have command priority and is only functioning
as a monitor, the ‘ key is effective and triggers switch off (with the error
message "!CMD Emergency Stop m1_090_001_001").

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• ]: Deletes/acknowledges errors. Errors displayed are deleted. The UT function

– DICU test – is run automatically for the majority of errors.
If errors are displayed and further commands are nevertheless entered without
first deleting the errors, these errors then continue to be displayed. They keep
being displayed until the ] command is executed.
• . (dot) and , (comma): These commands are very useful in standby mode
(converter off but line power on, system ready to be switched on). The dot
command displays the measured values collected during a period without
filtering. The comma command displays the average of the measured values
collected over several periods.
Example: The line values are measured in order to determine the line phase
angle or the direction of field rotation.

HNN: This command displays help for the NN command.

H- displays the current version of the PC software and of the DICU software in the
bottom line, an example of which is shown in Figure 4.2.4.

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4.4.1.3 Window H2 General Help continued, more help about command groups

Figure 4.4.3: Window H2, general help, continuation

This window contains references to other windows providing information on the

commands. These other windows each start with the same letters, which points to
the matching command group. Further explanations on these windows are given
below.

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4.4.1.4 Window HF Windows and displays, PC only

Window 4.4.4: Window HF, windows and displays, PC only

Reference to further windows (small windows) is made here. These windows provide
information on the status and data of the converter. Further explanations on these
windows are given below.

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4.4.1.5 Window HFF Windows and displays continued, PC only

Figure 4.4.5: Window HFF, windows and displays, continuation, PC only

An extension of window HF. The further windows referred to in this window are
explained later in this chapter.

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4.4.1.6 Window HFU Converter data and settings, PC only

Figure 4.4.6: Window HFU, converter data and settings, PC only

This help window refers to further windows, in which settings and reference values
for rectifiers and inverters are given, among other things. Explanations on these
windows can be found further below.

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4.4.1.7 Window HFx (x=any number), Converter setting windows, PC only

Figure 4.4.7: Window HF1, converter setting windows, PC only

This help window refers to further windows, in which the DICU parameters can be
determined. The parameters in the windows F1 to F15 can be set at will. The
parameters in windows F16 to F21 only serve monitoring purposes and cannot be
changed or only changed indirectly. A detailed description of these windows is given
in Chapter 5.2.

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4.4.2 Navigation and command windows

4.4.2.1 Window HA Language and display on the customer module

Figure 4.4.8: Window HA, language and display on the customer module

ALxx: Set language number xx. The language is only changed temporarily and only
remains set as long as the program is running. After the program has been ended
with Q and restarted, the language is taken from the F15 window. More details can
be found in Chapter 5.2.15.

AZ and AP are used for the DICU's serial communication with the processor. More
details are given in BA53.701-6.025 in Annex A3.

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4.4.2.2 Window HB Data communication and test operation, * PC only

Figure 4.4.9: Window HB, data communication and test operation, PC only

BR: Regulation on/off. This command freezes regulation Alpha (rectifier) and Phi
(Beta inverter) during operation. The converter runs on in controlled mode. Stable
measured values can then be seen in the FL load window. The limit values continue
to be active.

BS: This command enables the outputs on the SIO card to be tested. The converter
must be switched off.
BS1 – even (0, 2, 4….) LEDs and outputs are switched on
BS2 – odd (1, 3, 5….) LEDs and outputs are switched on
BS3 – all LEDs and outputs are switched on
BS0 – all LEDs and outputs are switched off.
The states of the SIO outputs are also shown in the FS window.

BT: Bus reset. This deletes all data held in RAM on the CPU card and buffered with
the battery. This means that the entire list of errors is deleted and both energy
counters are also reset to 0. The CPU card is stopped, the third LED is lit red, further
with UT.

BF: If the service PC is connected to the DICU by a cable, the PC – DICU linkage
can be terminated with the BF0 command, or re-established with the BF1 command.
The service PC can switch from online to offline mode and vice-versa.

BW: When the program is ended in online mode with the Q command, the current
time is normally taken from the PC and exported to the DICU.
When the GrTest program is run on the PC as a virtual machine, it is not possible to
switch it off with the Q command (the computer crashes). The PC – DICU linkage

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must first be terminated with the BF0 command and only then can the Q command
be executed properly.
The BW-1 command must be executed in online mode in order to import the time
from the PC. Only then can the program be ended with BF0 and Q. The new current
time is used when the GrTest program is restarted. The current date and time of the
PC and the DICU are shown in the FE window.

BK: In order to test the analog output on the customer module, the customer module
must be connected to the service PC's COM1 interface by a normal "DICU cable" –
same linkage as with the DICU. The analog outputs of the customer module are set
to the nominal values derived from the F15 window with the BK1 command. This
procedure can take up to 20 seconds. The digital display on the customer module
remains at zero. The BK0 command terminates the connection. More details in
Chapter 6.11.

The connection between the PC and the DICU is defined in the HB window. The
DICU's COM1 interface has a fixed baud rate of 9600. The baud rate of the COM2
interface can be defined at will in the F15 window. The further parameters are the
same for both interfaces: 8 data bits, odd parity, 1 stop bit.

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4.4.2.3 Windows HB1, HB2, HB3, Data protocol for COM ports, PC/DICU

Figure 4.4.10: Window HB1, data protocol for COM ports, PC/DICU, standard
commands

Figure 4.4.11: Window HB2, data protocol continued, operating modes of COM ports

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Figure 4.4.12: Window HB3, format of output data

The DICU protocols are described in these windows. A detailed description can be
found in the BA53.701-6.025 manual in Annex A3.

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4.4.2.4 Window HE, Data communication between PC and DICU, PC only

Figure 4.4.13: Window HE, data communication between PC and DICU, PC only

Data can be transferred to and fro between PC and DICU in online mode.
The most frequent commands used are EUS- and EZL-.
EUS: The EUS- command copies the data from the PC's RAM (current data record in
the GrTest program) to the DICU's EEPROM and replaces the old data record held in
the EEPROM.
EUL: the EUL- command reads the out of the DICU's EEPROM and copies them to
the PC's RAM. These data are kept in temporary memory and must be stored in the
DAT directory with a further US-, USnn or UPnn command.

EZL: The DICU saves all of the last 128 errors to a memory buffered by battery on
the CPU card. This error list can be transferred from the error memory to the PC's
RAM with the EZL- command. The error list must subsequently be saved in plain text
as an nn.ERX file in the ERR directory with the ZPnn command.
It is very important that the errors have the correct time stamp in order to analyze
them further. Before reading out the error list from the DICU, it is advisable to
synchronize the times on the PCs and on the DICU. The FE window shows both
times. Chapter 4.4.4.7.

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4.4.2.5 Window HG, Rectifier control, 6/12p and 24p

Figure 4.4.14: Window HG, rectifier control, 6/12-pulse

Figure 4.4.15: Window HG, rectifier control, 24-pulse

In the case of the DICU 6/12p, the content of the HG window differs somewhat from
that of the DICU 24p. The commands that can be used are nevertheless identical.

GU: The DICU's 48V DC power unit can be switched on using a relay stage. This
power unit is not switched on until the start command has been issued for the
converter. When checking the DICU, the power unit can be switched on with the GU1
command, so that the 48VDC voltage at the measuring sockets of the GRE and WRS

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cards or the plugs on the backplane can be tested. Switch the power unit off with the
GU0 command.

GAxxx: Having an adjustable Alpha firing angle is quite helpful when checking the
firing pulses for the rectifier thyristors. The firing pulses can be shifted to the angle
xxx°el with the GAxxx command. The angle 120°el is typically used because the line
voltage has a zero-crossing at this angle and the firing pulses can be easily tested
using an oscilloscope.

GZ: The converter must be switched off, although the line voltage remains switched
on. The GZ1 or GZ2 command switches on all rectifier firing pulses and positions
them at the angle set with the GAxxx command. At the same time, rapid
measurement (. - dot) is activated with the GZ1 command or average measurement
(, - comma) with the GZ2 command.
Switch the firing pulses off with the GZ0 command. More details in Chapter 7.6.2.

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4.4.2.6 Window HR, Control and energy management, SP and TP

Figure 4.4.16: Window HR, Control and energy management, SP system

Figure 4.4.17: Window HR, Control and energy management, TP system

In the case of Single Power systems, the content of the HR window differs somewhat
from that of TWIN POWER systems. The meaning of the commands is identical, only
the syntax differs between SP and TP.

RN: Once the system has started, the converter runs with the setpoints taken from
the start command. The type of setpoint – voltage, current or power – is determined
by parameter UD119 in the F10 window. During the further procedure, the setpoints
can be altered with the RNxxx (SP system) and RNxxx=yyy commands (TP
system). In this context, xxx is the setpoint for Inverter1 and yyy is the setpoint for
Inverter2 in a TP system.

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RU/RI/RPxxx: This command allows both the setpoints and the control strategy to be
changed. RUxxx determines voltage control, RIxxx current control and RPxxx power
control. The control strategies RU and RI in a TP system are only possible in single
operation. Only power control is allowed in TP mode.

RF: This command is practically only ever used in SP mode.

If the DC current has a high ripple, the strong effect can be noticed in Phi regulation
and the Beta angle varies. As a result, the commutation time and the hold time do not
have constant values. The RF0 command allows Phi regulation (Beta regulation) to
be frozen to the present value, which enables a clean measurement to be made with
an oscilloscope. Alpha regulation continues to be active.
RF1 causes the inverter to run on at Phi-Min (Phi-Opt).
RF2 releases Phi regulation, although naturally only if allowed by parameter UD120
from the F10 window.

RRU, RRP, RRT: Window F2 contains the values for voltage reduction (3 levels) and
for power reduction (7 levels). These levels are normally activated through the SIO
inputs. When operating the converters with the service PC, however, these levels can
also be activated from the keyboard.

SP systems:
RRUy, RRPy: y can take the values 1 to 3 for voltage reduction RRUy and the
values 1 to 7 for power reduction RRPy. y=0 means that reduction is inactive.

TP systems:
RRUx=y, RRPx=y, RRTy: y can take the values 1 to 3 for voltage reduction
RRUx=y and the values 1 to 7 for power reduction of the individual inverters
RRPx=y. x determine the inverter number INV1 or INV2. RRTy limits the sum
power of a TP system. y=0 means that reduction is inactive.

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4.4.2.7 Window HS, Start/Stop converter, SP and TP

Figure 4.4.18: Window HS, Start/Stop converter, SP system

SNxxx: Starts the converter with setpoint xxx. The type of setpoint – voltage, current
or power – is determined by parameter UD119 in the F10 window.

SU/SI/SPxxx: The converter is started with the defined control strategy. SUxxx
means start with voltage control, SIxxx start with current control and SPxxx start with
power control.

STN/U/I/P0: Short start, abort after the warm-up phase, parameter UD102 from the
F7 window. STN0 means start with the default control strategy (parameter UD119,
window F10), STU0 start with voltage control, STI0 start with current control and
STP0 start with power control.

STN/U/I/P1: Long start, abort after the start control time, parameter UD103 from the
F7 window. Control strategy as with the STN0 command.

The ‘, dot and comma commands are explained in Chapter 4.4.1.2.

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Figure 4.4.19: Window HS, Start/Stop converter, TP system

SNxxx=yyy: Starts the TP converter with power setpoints xxx and yyy.

STN1-3=0: Short start, abort after the warm-up phase, parameter UD102 from the F7
window. STN1=0 – start only INV1, STN2=0 – start only INV2 and STN3=0 – start in
TP mode.

STN1-3=1: Long start, abort after the start control time, parameter UD103 from the
F7 window. STN1=1 – start only INV1, STN2=1 – start only INV2 and STN3=1 – start
in TP mode.

The ‘, dot and comma commands are explained in Chapter 4.4.1.2.

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4.4.2.8 Window HU, Converter data, PC only

Figure 4.4.20: Window HU, Converter data, PC only

The data records are saved to the DAT directory.

Data are saved to the nn.DAT file only numbers in HEX format.
Data are saved to the nn.DAX file as plain text (parameter name and value) in text
format.
The current working data record is always saved to the GLODAT.DAT file.
The commands described below execute the data movements between the RAM
working memory and the DAT directory.

UL: The UL- command loads the data from the GLODAT.DAT file into RAM and the
ULNN command from the nn.DAT file.

US: The US- command writes the data from RAM in to the GLODAT.DAT file and the
USNN command to the nn.DAT file.

UP: The UP- command writes the data in plain text from RAM to the GLODAT.DAX
file and the UPNN command to the nn.DAX file.

UR: The command is seldom used. The data are normally saved to the nn.DAT file.
The nn.DAX file only contains the data for monitoring or for text processing. If the
nn.DAT file is not available, the data can be loaded from the nn.DAX file with the
URNN command. The DICU answers with "UR 148", which means that 148
parameters were read. Please check the parameters because not all parameters are
available when data are loaded from older GrTest versions and they could be written
incorrectly. For example, parameter UD214 in the F5 window (phase difference for
REC12p) could have a zero value instead of 30°el.

UD: Change parameters. The UD command is described in detail in Chapter 5.2.

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UE: Once the parameters have been entered, save the data to the GLODAT.DAT file
with the US- command. The UE command starts the internal calculation and setting
of all further parameters in the DICU Software. The reference values are checked
and any errors reported.

UT: After the UT command, the UE command is executed and the DICU hardware is
checked in addition.

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4.4.2.9 Window HW, Inverter control, SP and TP

Figure 4.4.21: Window HW, Inverter control, SP system

WS: Inverter ringing test. The WS command sends a firing pulse to the thyristors of
the starter device without turning on the inverter.

Figure 4.4.22: Window HW, Inverter control, TP system

WS: In TP systems, the WS1 command fires the thyristors of the starter device for
INV1 and the WS2 command fires the thyristors of the starter device for INV2.

WT: There is the option in TP systems of testing the inverter firing pulses. The WT1
command switches on the firing pulses of INV1 or the WT2 command switches on
the firing pulses of INV2 at a frequency of 60Hz. The firing pulses can only be

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switched on for INV1 or for INV2. The WT0 command switches the inverter firing
pulses off.

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4.4.2.10 Window HZ, Error lists, PC only

Figure 4.4.23: Window HZ, Error lists, PC only

ZP: The EZL- command was explained in the context of window HE (Chapter
4.4.2.4). Save the error list read out from the DICU to an nn.ERX plain text file in the
ERR directory with the ZPNN command.

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4.4.3 Windows for entering system parameters

The system parameters, the converter's operating parameters and the DICU's
internal parameters are entered in windows F1 to F21.
A detailed description of all parameters can be found in Chapter 5.2.

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4.4.4 Current measured values and status from system operation

These windows display the system's current measured values and status. Defective
values or states are highlighted in red. When saving a screenshot to the
GRTEST.LOG text file in the ERR directory with the <F1> function key, the values
highlighted in red are saved without this red background.
Non-uniform numbers are often displayed on the left for the measured values in V, A
or °el. These are the internal numbers originating from the A/D converter which are
explained in the FU-X windows.

4.4.4.1 Windows FG1 and FG2, Rectifier status

After the GrTest program has been launched, the FG1 status window appears on the
left-hand side of the screen. The FW1 status window is displayed on the right. This
window provides general information about the converter.

Only the FG1 window is available for REC 6p and REC 12p (rectifiers in series).
The FG2 window is also available for REC 12p (rectifiers in parallel) and REC 24p.
The FG1 window shows the values from the first record of the GRS and GRE cards
(REC1 + REC2) and the FG2 window shows the second record from the GRS and
GRE cards (REC3 + REC4).

Figure 4.4.24: Windows FG1 and FG2, rectifier status

In the off state, the measured values are collected after the "." command (dot, means
fast) or "," command (comma, means average). Measurements are taken
automatically while the converter is operating.

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Line frequency: The measured line frequency

Alfa control: The rectifier's present Alpha angle. The converter is switched off in
Figure 4.4.24 and the firing pulses are in the inverter limit position of 135°el.

Line rotation: The line voltage rotation for System1 and System2 (in FG2 for
System3 and System4) is shown here. R stands for a line rotating to the right and L
for a line rotating to the left. The figure in brackets codes this information:
0 System1 right, System2 right
1 System1 right, System2 left
2 System1 left, System2 right
3 System1 left, System2 left
This number must be entered as parameter UD117 in the F5 window.
The number for rotation from the FG2 window is entered as parameter UD129 in the
F5 window.

Premag. Thyristor: The rectifier thyristor for the pre-mag current pulse determined
by the software is stated here. The figure in brackets must be entered as parameter
UD118 in the F5 window.
The number for the pre-mag current thyristor from the FG2 window is entered as
parameter UD130 in the F5 window.

Further lines are reserved for error messages. An error is signaled with +++
highlighted in red. Whilst the converter is operating, detailed error messages are
displayed below and described in Chapter 8.1.1.

Ignition RED1: The status of the firing pulse outputs for REC1 and REC2 on the first
GRE card is displayed here. Outputs that are incorrectly connected are highlighted in
red. This display is only shown correctly immediately after the UT command has
been executed (Chapter 7.4) or during operation.
The FG2 window displays the status of the firing pulse outputs for REC3 and REC4
on the second GRE card.

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4.4.4.2 Windows FW1 and FW2, Inverter status

After the GrTest program has been launched, the FW1 status window appears on the
right-hand side of the screen. This window provides general information on the
inverter.
In the case of TWIN POWER systems, the FW1 status window is available for INV1
and the FW2 status window for INV2.
Both windows have identical content and only the messages can differ.

Figure 4.4.25: Windows FW1 and FW2, inverter status

INV Operat.Mode: This can be "Off" when the system is turned off, "On" when the
system is running or "Short Circuit" for inverters running in short-circuit mode.

Phi Control: The inverter's firing time, identical to TFire in FL1.

Further lines are reserved for error messages. An error is signaled with +++
highlighted in red. During operation, detailed error messages are displayed below
and described in Chapter 8.1.1.

Ignition/Drivers: The status of the firing pulse outputs for the two diagonals Imp1
(diagonal A) and Imp2 (diagonal B) and for the start thyristor ImpS for each WRS
card (INV1 and INV2) is shown here. Outputs that are incorrectly connected are
highlighted in red. This display is only shown correctly immediately after the UT
command has been executed (Chapter 7.4) or during operation.

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4.4.4.3 Windows FP1 and FP2, Line phases

Only the FP1 window is available for REC 6p and REC 12p (rectifiers in series).
The FP2 window is also available for REC 12p (rectifiers in parallel) and REC 24p.
The FP1 window shows the values from the first record of the GRS and GRE cards
(REC1 + REC2) and the FP2 window shows the second record from the GRS and
GRE cards (REC3 + REC4).
In the off state, the measured values are collected after the "." command (dot, means
instantaneous) or the "," command (comma, means average). Measurements are
taken automatically while the converter is operating.

Figure 4.4.26: Windows FP1 and FP2, Rectifier line phases; phase errors

The FP windows contain details of the phase change of the voltages in both line
systems that are connected to a GRS card.
Figure 4.4.26 shows the details of a 24p. The FP1 window contains details of line
systems 1 and 2 that are connected to the first GRS card. The FP2 window contains
details of line systems 3 and 4 that are connected to the second GRS card.
As the converter is switched off and there is therefore no current flowing, there are no
values for the phase currents. The values for the phase angle between voltage and
current are highlighted in red. During operation, the true measured values are
displayed and the red background disappears.
In Figure 4.4.26, the phase angle between the individual voltages in window FP2 for
the line system 2 are highlighted in red. As the values for the phase angle are correct
at 120°el and at 240°el, the direction of the rotation field must be false, other than
stated in the F5 windows. The values were not taken over correctly from the FG
window – Chapter 7.6.1. After correction, windows FP1 and FP2 should look as
shown below in Figure 4.4.27.
The phase changes between the two line systems U1 and U2 of a GRS card are
displayed at the bottom of windows FP1 and FP2. Given the same rotations in both
line systems, the values are around 330°el (can also be around 30°el), which is OK.

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These values indicate the 30°el phase shift between both line systems. If the two line
systems are rotating differently, the values are around 30°el, 150°el, 270°el or 330°el,
which is likewise OK.

Figure 4.4.27: Windows FP1 and FP2, Rectifier line phases; no phase error

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4.4.4.4 Windows FN1 and FN2, Line – Voltage and Current

Only the FN1 window is available for REC 6p and REC 12p (rectifiers in series).
The FN2 window is also available for REC 12p (rectifiers in parallel) and REC 24p.
The FN1 window shows the values from the first record of the GRS and GRE cards
(REC1 + REC2) and the FN2 window shows the second record from the GRS and
GRE cards (REC3 + REC4).
In the off state, the measured values are collected after the "." command (dot, means
fast) or the "," command (comma, means average). Measurements are taken
automatically while the converter is operating.

Figure 4.4.28: Windows FN1 and FN2, Rectifier, voltage and current; no error

Figure 4.4.29: Windows FN1 and FN2, Rectifier, voltage and current; error

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This window displays the values measured for the line voltages and line currents.
Only the values in the top lines VD0, VD1 and VD2 and at the bottom in line ID are of
significance.

VD0, VD1, VD2: Voltage VD1 is the output voltage of REC1 and voltage VD2 is the
output voltage of REC2. VD0 is the sum voltage from both rectifiers switched in
series.

ID: Rectifier output current averaged.

The other values for the voltage line 1, line 2 and for the currents IR, IT are not stable
und "fluctuate" greatly. The reason for this is the momentary values for the sinus
voltage or the unfiltered current from the A/D transformer. They only serve to show
that current and voltage are present.

Figure 4.4.29 shows an example of the FN2 window. The line voltages for line
systems 3 and 4 are missing here, whereby the values for VD1 and VD2 are
highlighted in red.

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4.4.4.5 Windows FL1 and FL2, Inverter load circuit

Both windows have identical content and show current measured values for both
inverters, data for rectifier operation and the status of the regulators.
Only the FL1 window is available for SP systems.
In the case of TP systems, the FL1 window shows the measured values for INV1 and
the FL2 windows shows the measured values for INV2.

Figure 4.4.30 shows an example for a TP system in TP mode. Figure 4.4.31 shows
the measured data for the same TP system, although in SP mode – INV2 in short-
circuit operation.

Figure 4.4.30: Windows FL1 and FL2, Inverter load circuit; TP mode

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Figure 4.4.31: Windows FL1 and FL2, Inverter load circuit; TP in SP mode

The data field in the left-hand column contains internal figures from the A/D
converter. These figures are not explained.

REC1 α/Cosα: Rectifier firing angle α and calculated actual cos α.

In the case of the 24p DICU (rectifier 24p or 12p GRs in parallel), the data from the
first GRS card are shown in window FL1 and the data from the second GRS card are
shown in window FL2.
Remark: The data measured for SP systems (24p rectifier or 12p rectifiers in parallel)
are found in the FL1 window. The FL1 window is reloaded after the FL2 command,
although with details for the second GRS card.

VD0*Cosα: Calculated actual DC rectifier output voltage – account is taken of the

firing angle α.

INV Per/Frq: Period length and output frequency of the voltage at the inverter output.

TFire/ФFire: The inverter's firing time and firing angle – measured between the time
of firing and the zero-crossing of the inverter output voltage.

TComm/ФI,V: Commutation time and angle between zero-crossing of the inverter

output current and the inverter output voltage.

TOff/CosФ: Hold-off time for the inverter thyristors and cosФ (also called cosPhi or
cosBeta), whereby Ф is an angle between the zero-crossing of the inverter output
current and the inverter output voltage.

dI/dt II-IF: Current rise di/dt, calculated for the current IW (inverter output current)
and for the current IZ (rectifier output current at the time of firing).

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VInv Output: The inverter output voltage is the same as the furnace voltage in both
SP and TP systems. The furnace voltage is measured for C1/C2 systems and is
shown here, although it is not the same as the inverter output voltage (translation
through C1/C2).

VFur FurLEM: In the case of TP and C1/C2 systems, the rectifier output voltage is
measured at the inverter input with the LEM module. This measurement is not filtered
– this voltage was already filtered in the LEM adapter.
The furnace voltage is the same as the inverter output voltage in SP systems. As this
measurement has no filtering, the voltage is shown as "for reference only". Account is
not taken of this voltage during regulation.

VFir Ignit: Firing voltage – calculated inverter output voltage at the time of firing. di/dt
limit is calculated with this voltage.

IInv Output: Inverter output current averaged.

IFir Ignit: Inverter output current at the time of firing.

Remark: Internal measured values from the WRS card are displayed in the middle
column for VInv, VFur, VFir, IInv and IFir.

PInv Output: Inverter output power.

The nominal power is measured in TP systems, in that the direct current IW is
multiplied by the inverter input voltage ULEM.
The power for SP systems is calculated using the formula P = VInv ⋅ IInv ⋅ cos(φ ) (also
called cosPhi or cosBeta).

Regul-Stat: Status message for regulation. The status message has 4 digits,
although only the last one is of importance. This figure shows the limit that the DICU
has reached and what is limiting the operation of the system:
0 = no limit reached
1 = nominal voltage, parameter UD10 in window F1
2 = minimum voltage, parameter UD15 in window F3
3 = nominal current, parameter UD19 in window F1
4 = minimum current, parameter UD21 in window F3
5 = firing voltage, parameter UD16 in window F1

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4.4.4.6 Windows FK1 and FK2, Load Circuit, Test data

Both windows have identical content and display calculated and actual measured
values for both inverters.
Only the FK1 window is available for SP systems.
In TP systems, the FK1 window shows the values measured for INV1 and the FK2
shows the values measured for INV2.

Figure 4.4.32: Windows FK1 and FK2, load circuit; test data

The top 3 lines show hypothetical values for the system parameters calculated by the
internal simulator of the GrTest software. These values should not be too far
removed from the converter data.

The next 4 lines contain internally calculated values for the Phi angle (Beta angle)
and various working points of the inverter. More on the FU-1 window in Chapter
4.4.4.12.

Lower down there are 2 columns showing the values measured and calculated for a
number of the inverter's parameters. After start-up, the measured and calculated
values should be quite close together.

T-Comm, T-Off, dI/dt (IInv), VInv Output and IInv Output are identical to the
corresponding values in the FL1 window.

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4.4.4.7 Windows FS1 IO/SIO PLC interface and FE1 Supervision: time and
energy

Figure 4.4.33: Windows FS1, IO/SIO and FE1, time and energy

FS1 window:

This window shows the logical states of the inputs and outputs on the SIO card. What
the DICU really sees at these inputs is displayed here. This diagnosis window helps
in the search for loose contacts in the wiring or insufficient amplitudes in the signals
from the PLC.

The SIO inputs from I0 to I23 are displayed as 8-bit words from right to left. The value
0 means that the voltage at this input is 0V, while the value 1 means that a 24V DC
signal is present.
The same depiction runs from right to left for the SIO outputs O0 to O11. The value 0
means that the voltage at this input is 0V, while the value 1 means that a 24V DC
signal is present.

SIO status:

The actual states of a number of DICU functions are displayed here. These functions
depend upon the status of the SIO inputs. More information in Chapter 2.5.2.

ON: converter ON = 1, OFF = 0.

WS: ring test
E1 und E2: Energy mode of INV1 and INV2. E1 = 1 or E2 = 1 means that the inverter
in question is running with energy preselection. E1 = 0 or E2 = 0 means no energy
preselection.
AC: Reset key pressed.
UD: Reduced line voltage. Levels 0, 1, 2 or 3.

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U1 and U2: Levels for the reduced inverter output voltage of INV1 or INV2. Levels 0,
1, 2 or 3.
P1, P2 or PT: Levels for the reduced power of INV1, INV2 or sum power for TP.
KM: Active customer module. KM = 0, customer module does not have command
priority. It makes no difference whether the customer module is connected to COM1
or COM2.
KS: Active potentiometer on the customer module. KM = 1 – potentiometer 1, KM = 2
– potentiometer 2, KM = 3 – both potentiometers are active, TP mode.
WM: The inverter's operating mode. WM = 1 – INV1 running, WM = 2 – INV2
running, WM = 3 – TP mode.
IN: Status of the SIO inputs. If E10 = 1 (test mode), then IN = 0 is displayed.
EN: Release. EN = 1, release issued, the converter is ready for operation.
CM: Command priority. CM = 0 – Command priority to COM1,
CM = 1 – Command priority to COM2.

FE1 window:

This window displays the date and time for the service PC and the DICU as well as
the reading for of the energy counter for INV1 and INV2.

Date and Time: The present date and time of the service PC and the DICU is
displayed here. The figures from the DICU are only real during the first connection
with the DICU. When the connection to the DICU is terminated with the Q command,
the DICU takes the time details from the service PC – Chapter 4.4.2.2.
If the DICU's time details were a long way off the real time, that could well mean that
the battery on the CPU card is defective.

24-h reset: PC column: counter reading for the duration of the current PC – DICU
session.
DICU column: the reading of the internal DICU counter which is responsible for the
24-h DICU self-test is shown here. This information is not particularly important
because the 24-h time is reset to zero after the PC – DICU connection has been
terminated.
The self-test is run automatically 24 hours after the counter has been reset. If the
converter is still operating after 24 hours, the DICU waits for the next OFF command
before running the self-test.

Total: The readings of the internal energy counters for both inverters are displayed
here. The counter overrun is 231 (10-figure decimal display). Both counters are reset
to zero with the BT command.

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4.4.4.8 Window Fuxx, DICU parameters

Figure 4.4.34: Window FUxx, DICU setpoints

The DICU's UDxx parameters are displayed continuously in this large window - 32
parameters are visible at the same time. The FUxx command displays the
parameters from parameter UDxx in ascending order.
All DICU parameters are presented in detail in windows F1 to F21 – Chapter 5.2.

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4.4.4.9 Windows FR1, FR2, FR3 and FR4, Regulation

Figure 4.4.35: Windows FR1 and FR2, Regulation, control data, hold-off time
optimization

Figure 4.4.36: Windows FR3 and FR4, Simulation REC/INV

In these four windows, only the top line in the FR1 window is of interest.
Setp 1-2: The current setpoints for INV1 or also for INV2 (TP system) are found here.
The unit for the setpoints is drawn from parameter UD119 in F10. In the case of TP
systems, the only possible setpoints are for power.
The setpoints displayed take account of the active reduction levels for power (type of
power setpoint) or voltage (type of voltage setpoint).

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The converter's simulation mode runs with the GrSim program, details of this can be
found in the FR3 window – Chapter 4.8.

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4.4.4.10 Windows FX1 - FX6, Data ports, data exchange

Figure 4.4.37: Windows FX1 and FX2, COM1 and COM2 interfaces

Figure 4.4.38: Windows FX3 and FX4, Datacom console 3 and keyboard command
buffer

These windows show the latest communications between the DICU and the PC
interfaces. The latest message is in top line and the oldest in the bottom line. The
lines starting with W were sent from the service PC; the lines starting with R come
from the DICU.

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Figure 4.4.39: Windows FX5 and FX6, Data exchange PC <> DICU

These windows contain debugging messages and internal commands. These

windows are not used for error diagnosis.

4.4.4.11 Windows FB1, FB2, FD1, FD2, FO1 - FO6, FT1 - FT9, FY1 - FY7

These windows are not used during start-up or diagnosis of the DICU or the
converter. They are not described here.

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4.4.4.12 Windows FU-1 and FU-2, Settings for inverter 1 and 2

Figure 4.4.40: Window FU-1, settings for inverter 1.

The FU-1 window (large window) shows further parameters calculated internally and
reference values required to operate inverter 1. These values are calculated from the
parameters in windows F1 to F21.
In TP systems, analog values for inverter 2 can be seen in the FU-2 window. The two
inverters are almost always identical and so too are the values in the FU-1 and FU-2
windows. The values are only a little different if the parameters in window F4 deviate.
If the values calculated are outside the admissible ranges, they are highlighted in red.

Data for different operating modes are found in the left half of the window.
The right half of the window contains reference values for various measured values.

Left-hand side of the window:

Internal values for DICU calculations can be seen in the data column on the left.

Phase-Clock: internal Clock time for A/D converter scanning. The clock time, and
thus the accuracy of the measurement, depends on the system's Fmin frequency
(parameter UD3 in F3).

Min-Freq.: minimum working frequency of INV1 from window F3.

Start- 1.Imp: wait time for the first firing pulse after the pre-mag current pulse –
parameter UD4 from the F7 window.

Offset 2.Imp: time for calculating the second firing pulse in the start phase.

Phi-Start: number for counting the firing in the start wait time (UD7 in F7). The
calculation is explained in Chapter 7.3.1.7.

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Phi-WarmUp: Phi angle (Beta angle) in the warm-up control time (UD102 in F7). The
"Phi warm-up" angle is called "warm-up" in the FK window. The calculation is
explained in Chapter 7.3.1.7.

Phi-UminInom: Phi angle calculated for operating the inverter with minimum voltage
and nominal current.

Phi-αminUnom: Phi angle calculated for operating the inverter with REC at αmin and
nominal value of the inverter output voltage.

Phi-αminInom: Phi angle calculated for operating the inverter with REC at αmin and
nominal value of the inverter output current.

Phi-Min: The inverter's smallest possible Phi angle.

Right-hand side of the window:

The reference values calculated for individual measured values can be seen in the
column on the left. The reference values must be between 0 and 63.
The middle column contains internal maximum measurement voltages on the WRS
card calculated from reference values. These voltages are practically never
measured.
The limit values for voltages or for currents which could still be measured can be
seen on the right. These limit values take account of the nominal values and the
corresponding overvoltage or overcurrent factors.

Ref-Test: test channel D/A converter, 5V

RefVFur/LEM: reference voltage for LEM voltage (inverter input voltage) or furnace
voltage – UD8 in F1.

Ref-VInv: reference voltage for furnace voltage or converter output voltage – UD10 in
F1.

Ref-VStart: no longer used.

Ref-VFire: reference voltage for the firing voltage - UD16 in F1.

Ref-IInv: reference current for the inverter output current - UD19 in F1.

Ref-IDif: reference value for the differential current - UD22 in F3.

Ref-DriveV1: reference value for the pulse amplifier voltage if a cable breaks in the
OFF state.

Ref-DriveV2: reference value for the pulse amplifier voltage in case of a short-circuit
in the ON state.

Ref-DriveI1: reference value for measuring the firing pulse current with the inverter
operating in normal mode. See UD63 in F11.

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Ref-DriveI2: reference value for measuring the firing pulse current with the inverter
operating in short-circuit mode in TP systems.

Ref-DriveI3: reference value for measuring the firing pulse current with UT.

IInv-Premag: pre-mag current value – UD23 in F7.

IInv-Max: maximum inverter output current – UD20 in F3.

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4.4.4.13 Windows FU-3 und FU-4, Settings for rectifiers 1 and 2

Figure 4.4.41: Window FU-3, Settings for rectifier 1.

The FU-3 window (large window) shows further parameters calculated internally and
reference values required to operate rectifiers 1 and 2 (first GRS card). These values
are calculated from the parameters in windows F1 to F21.
The FU-4 windows displays analog values for rectifiers 3 and 4 (second, right-hand
GRS card) for systems with 24p or 12p rectifiers in parallel. Both GRS cards are
always identical, as are the values in windows FU-3 and FU-4.
If the calculated values are outside the admissible ranges, the values are highlighted
in red.

Data for different operating modes are found in the left half of the window.
The right half of the window contains reference values for various measured values.

Left-hand side of the window:

Internal values for DICU calculations can be seen in the data column on the left.

Line-Frequency: the line frequency in online is read out from the PROMs record on
the GRS card. The frequency in offline mode is taken from the GrTest start command
GRTEST XYZ.

Line-Pulse cnt: rectifier pulse count. The pulse count in online mode is read out from
the PROMs record on the GRS card. The pulse count in offline mode is taken from
the GrTest start command GRTEST XYZ.

Line-Firing: length of the rectifier firing pulse – UD143 in F19.

Line-Phdiff.1-2: phase difference for the two line systems on a GRS card – UD214 in
F5.

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Factor IInv/ID: factor between the inverter current IW (UD19 in F1) and the rectifier
current ID (UD49 in F5). This factor determines how many rectifiers work in parallel.

Factor VD/VLine: factor between the rectifier output voltage UD and the line voltage
(UD45 in F5). This factor has the value of 1.35 for a 6p rectifier.

In the example FU-3 window in Figure 4.4.41, the DICU has recognized a 24p
rectifier:
• 2 rectifiers in series – VD/VLine factor = 2,70.
• 2 rectifier systems switched in parallel – IInv/ID factor = 2.

Right-hand side of the window:

The reference values calculated for individual measured values can be seen in the
column on the left. The reference values must be between 0 and 63.
The middle column contains internal maximum measurement voltages on the WRS
card calculated from reference values. These voltages are practically never
measured.
The limit values for voltages or for currents which could still be measured can be
seen on the right. These limit values take account of the nominal values and the
corresponding overvoltage or overcurrent factors.

At the end are the values for the limit parameters of the rectifier control angle, which
is converted by means of an internal resolution.

Ref-Test: test channel D/A converter, 5V

Ref-VDmax: reference voltage for the maximum rectifier output voltage – UD146 in
F19.

Ref-IDmax: reference current for the maximum rectifier output current - UD148 in
F19.

Ref-IDmin: reference current for minimum current – UD149 in F19.

Ref-IDdisc: reference current for intermittent current – UD50 in F6.

VDC-Nom,α=0: rectifier output voltage calculated for α=0 – UD145 in F19.

α-Min: rectifier's minimum control angle α – UD39 in F6.

α-Max: rectifier's maximum control angle α (inverter limit position) – UD144 in F19.
Please note: in the English version of the program, the labels α-Min and α-Max have
been mixed up.

α Diff (24p): difference angle between the two line systems (between both GRS
cards – 24p or 12p REC in parallel) – UD213 in F5.

α-Premag: rectifier's pre-mag current angle – UD40 in F7.

αWarmup Std: warm-up angle for an SP system – UD41 in F7.

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αWarmupTwin: warm-up angle for a TP system – UD42 in F7.

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4.4.4.14 Window FU-20, DICU parameters

Figure 4.4.42: Window FU-20, DICU parameters

This window displays all DICU parameters as characters in HEX format. The last
figure on the bottom right (2082 in Figure 4.4.42) is a check sum for all DICU
parameters. This check sum immediately shows whether the data records are the
same. If the data records of the nn.DAT or nn.DAX files have the same check sum at
the end, then the data records are identical.
Please note: the data record does not contain the line frequency, the rectifier's pulse
count or the type of inverter (SP or TP). In online mode, these parameters are read
out from the PROMs. In offline mode, these parameters are entered as attributes with
the GRTEST command.

4.4.4.15 Windows FU-5 - FU-19 and FU-21 - FU-29

These windows are not used during start-up or diagnosis of the DICU or the
converter. They are not described here.

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4.5 GrView

Several customers have shown great interest in acquiring the DICU software.
Unfortunately this is not possible. The GrTest software allows the converter to be
switched on and controlled from the service PC. During operation from the service
PC, a number of monitoring functions are deactivated or disabled. The system can
suffer a great deal of damage if the converter is not operated properly. People would
also be put at risk.
Normal training in the GrTest software, linked to operating the system, takes up to
one year at ABP.

In the case of systems which only have the DICU but do not have a processor, the
error messages are only shown on the screen of the customer module. These
messages disappear from the screen of the customer module after the errors have
been acknowledged and are no longer available. Although disturbances continue to
be saved on the CPU card of the DICU, they are not available without further ado.

For this reason, a further software package has been developed on the basis of the
GrTest software, although some functions are disabled.

The GrView program is a simplified software package to enable communication with

the DICU. For example, the error file can be read out or data records transmitted and
the converter data can also be observed during on-going operations. Only the
functions to change individual parameters and the test start are not available.

Annex A2 contains two operating manuals:

• "Setting up a service PC for the rectifier software", BA 53.701-6.018
• "Description of the GrView software", BA 53.701-6.019

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4.6 DICU data interchange protocol

The DICU communicates with the service PC, the customer module, the processors
or other external devices via the serial interfaces COM1 and COM2. The relevant
data protocols are exchanged through these as telegrams between the individual
components.
If the DICU is to work with processors or other external devices, it is essential that the
structure of the telegrams and the use of communications are precisely described.

Annex A3 contains the operating manual "DICU2 – data interchange protocol", BA

53.701-6.025. This describes communications via the serial interfaces in great detail.

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4.7 SCOM

When searching for errors in communications between the DICU and external
devices, the option of watching the telegrams along the communication route is very
useful. The SCOM.exe software has been developed for this purpose.
The SCOM.EXE file is stored in the EXE directory of the higher level GR directory.

Remark: Only the German version of the SCOM program is available.

An additional computer with two RS232 serial interfaces is required for the
application. If a computer does not have any serial interfaces, these can be emulated
with two USB/RS232 adapters. The test structure is depicted in Figure 4.7.1.

Figure 4.7.1: Test structure for SCOM telegram monitoring

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The SCOM software allows the telegrams to be observed in both directions between
the DICU and an external device. SCOM also allows only the telegrams received by
a single end device to be examined. In such a case, only the computer's COM1
interface is used.

Declare the two USB/RS232 adapters as COM1 and COM2 – identical to declaring
the USB/RS232 adapter in Annex A1. The COM1 interface must always be declared.

SCOM processes the telegrams in the DICU format: 8 bits, 1 stop bit, odd parity. The
baud rate is adjustable.

Use the command line/input prompt to start the SCOM software. Start the input
prompt (cmd) under Windows and change to the "EXE" directory (cd command).
Please note: The DOS box or the LOAD GRnn command may not be used.

Figure 4.7.2: Selecting the SCOM directory

Launch the SCOM program with the SCOM xxx=yyy command:

xxx: baud rate for the COM1 interface
yyy: baud rate for the COM2 interface
xxx=0 or yyy=0 means that the COM1 interface or the COM2 interface are not used.
The baud rate should be adapted to the DICU and any other external device.
Select baud rate 9600 when examining the connection route with the customer
module (the customer module can only work at a baud rate of 9600).
Select a baud rate of 4800 for the link to the Prodapt. The DICU basically works at a
baud rate of 4800 with the Prodapt or the communication processor.
The SCOM command is equivalent to the SCOM 9600=9600 command.

After the SCOM xxx=yyy command, the communication telegrams along the
monitored link are displayed on the screen of the service PC.
The lines starting with 1 originate from the COM1 interface; the lines starting with 2
come from the COM2 interface.
The latest telegrams are shown at the bottom of the screen, the older telegrams are
accordingly moved upwards. Once the screen is filled with telegrams and a new
telegram appears at the bottom, the topmost telegram disappears.
Entries made from the keyboard appear in the bottom line. After an entry has been
confirmed by pressing ENTER, it appears at the bottom starting with the number 3.

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Figure 4.7.3: Communication via the COM1 (DICU) and COM2 (customer module)
interfaces.

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The SCOM ? command opens the help window for the SCOM program – Figure
4.7.4.

Figure 4.7.4: Help window for the SCOM program

The < key saves the communication in the SCOM.LOG file in the EXE directory.
Please note: The SCOM.LOG file is actually saved to the EXE directory, in contrast
to what is stated in the help window for the SCOM program.
The latest telegrams are saved on top in the SCOM.LOG file and older telegrams
below (opposite to that on the PC screen).
Note: If problems occur in displaying the telegrams, keep the cable connected and
restart the computer.

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4.8 GrSim – DICU simulation program

When the system is operating in normal mode, the DICU sends the converter's actual
values to the processor or the PLC communication processor. These values are
further-processed there and new setpoints are subsequently sent to the DICU.

When testing new systems in ABP's test bed, one of the things that are tested is the
DICU communications with the melt-processor or with the PLC communication
processor. As the systems are not in operation, only "zero values" can be sent.
These "zero values" do not really allow communications along the link between the
DICU and external devices to be tested in a reliable manner.

The GRSIM.EXE software package has been developed for this purpose. The
GRSIM.EXE file is stored in the EXE directory of the higher level GR directory.

The computer's COM1 (COM1 adapter) interface is connected to the melt-processor

or to the communication processor by a crossover cable or by a fiber-optic adapter.

The Prodapt communication port or the communication processor port must be set to
9600 baud. The GrSim program only runs without problems at a transmission speed
of 9600 baud.

4.8.1 Operating GrSim

Start the computer running the GrTest program. Instead of starting GrTest with the
GRTEST command, enter the command GRSIM XYZ:
X: 5 for a 50 Hz line frequency and 6 for a 60 Hz line frequency
Y: Number of rectifier pulses: 6, 12, 13 or 24
Z: S for SINGLE POWER or T for TWIN POWER systems
It is essential that the parameters chosen for XYZ are those of the actual system.
Once the program has started, several errors could be reported. Ignore these error
messages for the time being.

Load the correct nn.DAT data record with the ULnn command. Save the data in the
GLODAT.DAT file with the US- command.
The simulation program runs quite slowly and internal monitoring limits need to be
adapted. The following parameters should be changed in the data record:
• Window F9: UD95=2
• Window F14:UD80=5
• Window F14:UD81=20
• Window F15: UD76=9600
Save the amended parameters to the GLODAT.DAT file with the US- command,
acknowledge errors with the + command and start the self-test with the UT
command. Error messages should no longer appear after the self-test. The program
is now ready for simulation mode.

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Declare the fastest program run with the BW0 command. BW0 is the shortest cycle
time and BW999 the longest cycle time. The cycle time for the GrTest program is
normally set to BW500.

Start the GrSim program with the SNxxx or SNxxx=yyy command (Chapter 4.4.2.7).
The program calculates the converter's operating values. The results are displayed in
the windows for the actual measured values and states from system operation (e.g.
window FL1 or FP1). The energy counters in the FE1 window counts upwards.

Figure 4.8.1: Service PC in GrSim mode

The setpoints can be changed from the service PC keyboard with the RNxxx or
RNxxx=yyy command. New setpoints can also be specified from the processor via
the serial interface.

The quality of the load circuits can be changed with the BZx=y command, whereby x
is the quality of furnace 1 and y is the quality of furnace 2. The same command can
be used to change the quality for an SP system. The present quality of the furnace is
shown in Window FR3.

The converter can be stopped with the # command and the program ended with the
Q command.

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5 Meaning of the parameters in windows F1-F21

5.1 Standard settings
Specimen data records are available to create a new DICU data record. These are
prepared according to the type of system (SP or TP) and the frequency range of the
system.
If a new data record needs to be created on-the-spot (e.g. if the CPU version is
upgraded), such a data record should be used. The system-specific settings are then
taken over in this data record (Chapter 7.3). These data records are stored in the
DAT directory of the respective version. The following files are available:

STND56 SP, line 50 Hz, nominal furnace frequency between 55Hz-200Hz

STND66 SP, line 60 Hz, nominal furnace frequency between 55Hz-200Hz
STND206 SP, line 50 Hz, nominal furnace frequency between 200Hz-500Hz
STND266 SP, line 60 Hz, nominal furnace frequency between 200Hz-500Hz
STND506 SP, line 50 Hz, nominal furnace frequency between 500Hz-1500Hz
STND566 SP, line 60 Hz, nominal furnace frequency between 500Hz-1500Hz
STND2006 SP, line 50 Hz, nominal furnace frequency between 1500Hz-4000Hz
STND2066 SP, line 60 Hz, nominal furnace frequency between 1500Hz-4000Hz
TWIN56 TP, line 50 Hz, nominal furnace frequency between 55Hz-200Hz
TWIN66 TP, line 60 Hz, nominal furnace frequency between 55Hz-200Hz
TWIN206 TP, line 50 Hz, nominal furnace frequency between 200Hz-500Hz
TWIN266 TP, line 60 Hz, nominal furnace frequency between 200Hz-500Hz
TWIN506 TP, line 50 Hz, nominal furnace frequency between 500Hz-1500Hz
TWIN566 TP, line 60 Hz, nominal furnace frequency between 500Hz-1500Hz
TWIN2006 TP, line 50 Hz, nominal furnace frequency between 1500Hz-4000Hz
TWIN2066 TP, line 60 Hz, nominal furnace frequency between 1500Hz-4000Hz

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5.2 Tabular depiction and description of the parameters

The DICU parameters are distributed over 21 windows. The parameters are grouped
according to the range of the converter (rectifier, inverter) or to their functions
(control, display).
Parameters can be changed from the computer keyboard in windows F1 to F15.
Windows F16 to F21 are for monitoring purposes only; the parameters there are
either fixed or can only be influenced indirectly by the parameters in windows F1 to
F15.
The parameter windows are small, so that two windows can be displayed next to one
another on the computer screen at the same time.
The only parameters that can be changed are those currently visible on screen.
Therefore first open the relevant window and only then alter the parameters.
The input format for the individual parameters is as follows:
UDnn=XXX (also udnn=XXX)
or UDnnpXX.X
"UD" is the command for setting parameters,
"nn" is the number of the parameter,
"p" replaces the "=" character,
"XXX" or "XX.X" stands for the parameter value. The decimal point is entered as "."
(dot) in the parameter value.
Some of the values displayed by the software are rather weird fractions, which is
attributable to the resolution set for analog/digital conversion. This is not an error and
they can be left as they are.

In what follows, the parameter number is always depicted as "Udnn" (so that there is
no danger of confusing them with the simple numbers for the values).

Once the new parameters have been entered, the data should be stored immediately
with US- in the GLODAT.DAT file. The customer-specific file cannot be created until
all parameter changes have been completed.

If an error message appears when entering a parameter, please refer to the

Description of Errors (Chapter 8.1).

The table below was created to simplify the search for the window containing the
desired parameter. The table lists all the UDnn parameters and their assignment to
the Fnn input window.

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UDnn Fnn UDnn Fnn UDnn Fnn UDnn Fnn UDnn Fnn UDnn Fnn UDnn Fnn UDnn Fnn
0 21 26 2 55 1 82 8 108 15 135 9 163 11 189 17
1 1 27 2 56 11 83 8 109 15 136 16 164 4 190 17
2 3 28 2 57 11 84 8 110 15 138 16 165 18 191 17
3 3 29 2 58 11 85 8 111 21 139 16 166 4 192 17
4 7 30 2 59 1 86 8 112 21 141 19 167 7 193 17
5 7 31 2 60 11 87 8 113 14 142 19 168 7 194 17
6 7 32 2 61 11 88 8 114 12 143 19 169 7 195 17
7 7 33 1 62 11 89 8 115 11 144 19 170 16 196 4
8 1 35 1 63 11 90 8 116 11 145 19 171 4 198 4
9 3 38 12 64 11 91 8 117 5 146 19 172 18 201 16
10 1 39 6 65 12 92 8 118 5 147 19 173 4 203 16
11 2 40 7 66 12 93 8 119 10 148 19 174 17 204 16
12 2 41 7 67 13 94 8 120 10 149 19 175 17 205 19
13 2 42 7 69 5 95 9 121 10 150 20 176 17 206 19
14 3 43 6 70 13 96 10 122 15 151 20 177 18 207 19
15 3 44 6 71 5 97 9 123 15 152 20 178 18 208 14
16 1 45 5 72 13 98 9 124 5 153 20 179 4 209 10
17 3 46 6 73 13 99 9 125 12 154 20 180 18 210 10
18 7 47 6 74 14 100 9 126 12 155 20 181 16 211 6
19 1 48 6 75 14 101 9 127 12 156 20 182 16 212 10
20 3 49 5 76 15 102 7 128 12 157 20 183 18 213 5
21 3 50 6 77 14 103 7 129 5 158 20 184 18 214 5
22 3 51 12 78 14 104 15 130 5 159 20 185 18
23 7 52 12 79 14 105 15 132 9 160 20 186 16
24 1 53 12 80 14 106 15 133 9 161 20 187 4
25 2 54 1 81 14 107 15 134 9 162 11 188 17

Figure 5.2.1: Table of UDnn parameters with assignment to the Fnn input window

In the case of new systems, please always use a specimen data record as a template
(Chapter 5.1) and enter all parameters accordingly. When entering the parameters,
always start with the F1 Window and save the data with US- before moving on to the
next window. Do not start monitoring with UE or UT until the entries in the windows
F1 to F5 have been completed. The parameters in the F1 and F4 windows are linked
to the parameters in the F5 window, so that a check carried out too early would lead
to error messages.

The values at the end of some parameter descriptions named default originate from
the specimen data records.

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5.2.1 Window F1, INV 1 nominal data, transformer ratios

Enter the nominal values for furnace 1 and all transformers installed in inverter 1
in the F1 window. In the case of TP systems, note that the transformers in inverter
1 must be identical to the transformers in inverter 2. In addition, furnace 1 must
have the same or greater power than furnace 2. The nominal frequencies of the
two furnaces can at most differ by a factor of 2, whereby it does not matter which
furnace has the higher frequency. If the frequencies are different, note that the
same arrangement of filters must be fitted to both WRS inverter cards.

nn Name Description
1 WR1 Nom-Frequenz...: The nominal frequency of furnace 1 can deviate from the
IN1 Nom-Frequency..: nominal frequency of the system. Some explanations on this: As
the DICU fires the inverter thyristors from the load voltage and
only the first few pulses are controlled, the nominal frequency
(the first firings are derived from this declaration) must more or
less correspond to the actual oscillation frequency.
The resonant frequency of the furnace can be determined by
entering the WS (ring test) command (WS1 or WS2 for TP). This
ring test should be done when the furnace is empty. Set a
nominal frequency which is something like 1.35 times larger than
the measured ring test frequency.
Parameters 2/3/4/5/6 are changed automatically
10 WR1 Nom-Ausgangspg. Nominal operating voltage of INV1 according to the data sheet.
IN1 Nom-Output-Volt: Identical to the furnace voltage for systems without C1/C2.
Parameters 11/12/13/14/15/16/17/18 are changed automatically
8 WR1 Nom-Ofenspg/LEM: In the case of TWIN-POWER, the average DC voltage is
IN1 Nom-FurVolt/LEM: measured at the inverter input by an LEM transformer, The value
is equal to UD at the rectifier output when only one inverter is
operating ( second inverter in by-pass mode). The parameter
value in this condition is identical to parameter UD145 Nom-UD
in window F19.
In standard SP systems, the parameter value is identical to
parameter UD10.
Parameters 9/139 are changed automatically
16 WR1 Nom-Zuendspg...: Limit of firing voltage in INV1 during operation. The commutation
IN1 Nom-Firing Volt: choke and circuitry are designed for this voltage. The di/dt
regulation limits the firing voltage to this value. The setting value
should be taken from the inverter calculation sheet. This value
should be checked during start-up and corrected, if necessary.
This voltage is automatically set to nominal voltage (UD10),
which corresponds to a firing angle of 45° at nominal voltage.
Default: UD10 from F1
Parameter 17 is changed automatically
19 WR1 Nom-Strom.... .: Nominal MF current according to the inverter calculation sheet. It
IN1 Nom-Current....: is the sum current if several inverters are connected in parallel.
Parameters 20/21/22/23/49/50/148/149/182/183/184/185/186
are changed automatically
24 WR1 Nom-Leistung...: Enter the converter's nominal output power according to the
IN1 Nominal-Power..: inverter calculation sheet.
In the case of TWIN-POWER, the nominal power is measured in
that the direct current Id is multiplied by the inverter input voltage
ULEM.
In SP systems, the power is P = UW ⋅ IW ⋅ cos(φ ) (also called
cosPhi or cosBeta).
Parameters 25/26/27/28/29/30/31/32 are changed automatically
33 WR1 Freiwzeit/IWNom: Recovery time of the inverter thyristors according to the inverter
IN1 Trec/IInv-Nom..: calculation sheet. The DICU then attempts to regulate a holf-off

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time of 1.4 times UD33 (UD136 in F16) at nominal current.

Parameter 136 is changed automatically
35 WR1 dIdtàMinèMinINom The value is the steepness of the current slope for INV thyristors
IN1 dIdtàMinèMinINom at nominal current, Beta-min and the rectifier driven to full scale.
That corresponds to the lowest furnace voltage at which nominal
power can be reached. The value can be taken from the inverter
calculation sheet, although it must be confirmed by
measurement and corrected, if necessary. The DICU calculates
di/dt from IW-control and Tcom.
Please note! Parameter UD35 must always be adjusted
precisely. See Chapter 7.6.3.3.
55 WRE UW-Wandler-ext.: Translation factor for the furnace/converter output voltage
INE UW-Trans.-ext..: transformer.
The admissible range can be calculated:

Nennspannu ng
66V ≤ ≤ 150V
UD 55
Parameters UD54 and UD55 must be the same in SP systems.
54 WRE UO/LEM-Wand.ext: Inverter voltage transformer ratio. In SP systems: the
INE UO/LEM-Transext: furnace voltage is identical to the converter output voltage. Only
one MF voltage transformer is used. Identical to parameter
UD55.
TWIN POWER: The input voltage of both inverters must
be measured for this operating mode. This is done by a DC
voltage measuring transformer, e.g. from the LEM company, with
an LEM adapter connected downstream. This factor contains the
voltage ratio of the LEM transformer and LEM adapter.
How the factor is calculated is described in Chapter 3.2.1.2.
SP systems with C1/C2: Such systems are run and
adjusted in the same way as TWIN POWER systems.
59 WRE IW-Wandler-ext.: Translation factor for the MF current transformer. Complete
INE IW-Trans.-ext..: factor for the chain of main and auxiliary current transformers,(~I
inverter /5A) and (5A/1A).
The secondary transformer current is translated to a voltage by a
load resistor in the DICU. Given a secondary transformer current
of 1A, the load resistor is 1Ω (European version). Given a
secondary transformer current of 5A, the load resistor is 0.2Ω
(USA version). The translated power amounts to 5W.
The admissible range can be calculated:

Nom - MF - Current
0,66V ≤ ≤ 1,55V
UD59

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5.2.2 Window F2, Inverter 1 V/P - reduction

Values for voltage and power reduction for furnace 1.

nn Name Description
11 WR1 Red-Spannung 1.: These three levels can be activated by the SIO inputs E6 and E7
IN1 Reduced-Volt.1.: for INV1 and E18 and E19 for INV2 (UD174, UD175 and UD176
12 WR1 Red-Spannung 2.: in F17). Requirement:
IN1 Reduced-Volt.2.: INV NomVolt > RedVolt1 > RedVolt2 > RedVolt3.
13 WR1 Red-Spannung 3.: The levels are set automatically to 85%, 70% and 55%.
IN1 Reduced-Volt.3.: The same three voltage levels are foreseen for the rectifier (with
the same factor), if the Line infeed is provided with switchable
taps (UD205, UD206 und UD207 in F19). If the values do not
match the actual line voltages, change parameters UD11, UD12
and UD13 proportionately.

If rectifier reduction is active, inverter limitation is also activated

automatically. This ensures at a reduced input voltage that the
inverter does not try to reach a Beta angle greater than the
nominal voltage.
Coding for the SIO card:

INV1 INV2 REC

Level E7 E6 E19 E18 E5 E4
1 0 1 0 1 0 1
2 1 0 1 0 1 0
3 1 1 1 1 1 1
Parameters 174/175/176/205/206/207 are changed
automatically
25 WR1 Red-Leistung 1.: There are two different versions for power limitation, which are
IN1 Reduced-Power 1: selected with parameter UD208 in window F14.
26 WR1 Red-Leistung 2.:
INV Reduced-Power 2: Parameter UD208=7:
27 WR1 Red-Leistung 3.: INV1 and INV2 each have 7 power levels. SIO inputs E12, E13
IN1 Reduced-Power 3: and E14 limit the maximum power of INV1; SIO inputs E20, E21
28 WR1 Red-Leistung 4.: and E22 limit the maximum power of INV2.
IN1 Reduced-Power 4: Levels 1 to 7 are set automatically to 90/80/70/60/50/40/30% of
29 WR1 Red-Leistung 5.: parameter UD24.
IN1 Reduced-Power 5: The power values can then be changed, although no power
30 WR1 Red-Leistung 6.: value may be greater than the preceding one. The power values
IN1 Reduced-Power 6: setting in for INV2 can be monitored in window F17 as
31 WR1 Red-Leistung 7.: parameters UD188 to UD194. The values for INV2 are
IN1 Reduced-Power 7: calculated from the nominal power of INV2 and the factors from
INV1.
Coding for the SIO card:

INV1 INV2
Level E14 E13 E12 E22 E21 E20
1 0 0 1 0 0 1
2 0 1 0 0 1 0
3 0 1 1 0 1 1
4 1 0 0 1 0 0
5 1 0 1 1 0 1
6 1 1 0 1 1 0
7 1 1 1 1 1 1

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Parameter UD208=3:
INV1, INV2 and the sum power (REC power) each have 3 power
levels. SIO inputs E12 and E13 limit the maximum power of
INV1; SIO inputs E20 and E21 limit the maximum power of INV2;
SIO inputs E14 and E22 limit the maximum sum power of the
system (REC power).
The power of INV1 is taken for limiting the sum power. INV2 can
have a lower nominal power. Levels 1 to 3 are set automatically
to 90/80/70% by parameter UD24. The power values can then
be changed, although no power value may be greater than the
preceding one. Parameters UD28 to UD31 are ineffective but
must comply with the foregoing rule.

Coding for the SIO card:

INV1 INV2 Sum REC
Level E13 E12 E21 E20 E22 E14
1 0 1 0 1 0 1
2 1 0 1 0 1 0
3 1 1 1 1 1 1

The power values setting in for INV2 can be monitored in

window F17 as parameters UD188 to UD194. The values for
INV2 are calculated from the nominal power of INV2 and the
factors from INV1.
Parameters 188/189/190/191/192/193/194 are changed
32 WR1 Min-Leistung...: The minimum power is set automatically to 2% of the INV1
IN1 Minimal-Power..: nominal power. The value can then be changed.
Default: 0.02 * UD24 from F1
Parameter 195 is changed

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5.2.3 Window F3, Inverter 1 - limits

Limit values for inverter 1. A fixed factor is drawn on as the basis setting for each
value. Based on the nominal values in entered in window 1, the limit values are
set with these factors. They can naturally be changed individually.

nn Name Description
2 WR1 Max-Frequenz...: Maximum admissible operating frequency of the system. An
IN1 Max-Frequency..: error message is issued if it is overshot.
The error message is disabled in TWIN POWER mode because
a higher frequency is operated with TWIN POWER due to the
large angle shift. However, the voltage does not reach the
system's nominal voltage, which is why this is not dangerous.
Default: 1.2 * UD1 from F1
Parameter 165 is changed
3 WR1 Min-Frequenz...: Minimum admissible operating frequency. The frequency should
IN1 Min-Frequency..: not be set lower than one half of nominal frequency because the
time resolution of the inverter control and thus the accuracy of
hold time regulation is set to this frequency. The lowest value
allowed by the software is 33% of the nominal frequency. The
time resolution amounts to: period duration of minimum
frequency / 1000.
Example: at Fmin=200Hz, the resolution is 1/200Hz/1000=5µS.
The minimum frequency UD3 may not be greater than the ring
test frequency – otherwise no firing pulses are generated during
ring test.
Default: 0.67 * UD1 from F1
14 WR1 Max-Ausgangsspg: Overvoltage trip level for inverter 1. Overshoots lead to switch off
IN1 Max-Output Volt: and an error message is issued.
Default: 1.15 * UD10 from F1
Parameter 177 is changed automatically
15 WR1 Min-Ausgangsspg: Minimum output voltage admissible during operation.
IN1 Min-Output Volt: Default: 0.1 * UD10 from F1
Parameters 139/178/204 are changed automatically
9 WR1 Max-Ofenspg/LEM: Maximum admissible voltage. In TP systems this value is equal
IN1 Max-FurVolt/LEM: to the maximum DC voltage. In SP systems it is equal to UD14.
Default: 1.15 * UD8 from F1
Parameter 172 is changed automatically
17 WR1 Max-Zuendspg...: Due to the regulation of the system, overshoots can occur when
IN1 Max-Firing Volt: changing the power distribution to the furnaces (TWIN POWER
operating mode). Such problems can also occur if 2 limit values
(e.g. nominal voltage and nominal firing voltage) are addressed
at the same time. Overshoots lead to switch-off and an error
message is issued.
This parameter can be set to values up to 1.3 * UD10 without
further ado.
Default: 1.15 * UD10 from F1
Parameter 180 is changed automatically
20 WR1 Max-Strom......: Overcurrent trip level. If the disturbance is attributable to the
IN1 Max-Current....: momentary value, i.e. due to the current ripple, the distance to
the nominal current must be sufficiently large. Overshoots lead
to switch-off and an error message is issued.
The currents are measured in the rectifier and in both inverters
(TP) and monitored referred to this level.
For 2 inverters in parallel, the sum current is monitored.
Default: 1.25 * UD19 from F1
Parameters 148/183 are changed
21 WR1 Min-Strom......: Minimum current limit during operation. If the current is reduced,
IN1 Min-Current....: check that intermittent (discontinuous) current does not occur.

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Default: 0.15 * UD19 from F1

Parameters 149/184 are changed automatically
22 WR1 Differenz-Strom: Differential current trip level. The differential current is only
IN1 Diff-Current...: evaluated in the time between the voltage's zero-crossing and
the time of the firing pulse. If the current transformer in the
rectifier and inverter are the same, the admissible differential
current is then almost identical to the programmed value.
If the current transformers are different, the differential current
that actually sets in adjusted according to the following formula
(internal, automatic):

UD 22 ⋅ UD 71 ⋅ UD 72
Idif =
UD 59 ⋅ UD 60

The calculated value Ref-IDif can be read off in the FU-1

window. If the transformer factors in REC and INV differ greatly,
a relatively high value emerges as the lowest possible
differential current. This means that switch-off with the
differential current happens quite late.
Default: 0.15 * UD19 from F1
Parameter 185 is changed automatically

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5.2.4 Window F4, INV 2 - nominal data, limits

Nominal values for the furnace and inverter 2 in TWIN POWER systems.
It is recommendable for SP systems to take over the values for INV1.
The values from INV1 are taken over for INV2 by entering UD164=0.

nn Name Description
164 WR2 Nom-Frequenz...: The nominal frequency of furnace 2 can deviate from the
IN2 Nom-Frequency..: nominal frequency of the systems. Some explanations on this:
As the DICU fires the inverter thyristors from the load voltage
and only the first few firing pulses are controlled, the nominal
frequency (the first pulses are derived from this declaration)
must more or less correspond to the actual oscillation frequency.
The furnace resonant frequency can be determined with the
WS2 command (swing down). This swing down should be done
when the furnace is empty. Set a nominal frequency which is
something like 1.35 times larger than the measured swing down
frequency.
UD164=0 imports all INV1 values for INV2.
Parameters 165/166/167/168/169 are changed automatically
166 WR2 Min-Frequenz...: Minimum admissible operating frequency of furnace 2. The
IN2 Min-Frequency..: frequency should not be set lower than one half of nominal
frequency because the time resolution of the inverter control and
thus the accuracy of hold-off time regulation is set to this
frequency. The lowest value allowed by the software is 33% of
the nominal frequency. The time resolution amounts to: period
duration of minimum frequency / 1000.
Example: at Fmin=200Hz, the resolution is 1/200Hz/1000=5µS.
The minimum frequency UD166 may not be greater than the
swing down frequency – otherwise no firing pulses during ring
test.
Default: 1.2 * UD164 from F4
173 WR2 Nom-Ausgangspg.: Nominal operating voltage limit of INV2 according to the data
IN2 Nom-Output-Volt: sheet, identical to the furnace voltage.
Parameters 174/175/176/177/178/179/180/181 are changed
automatically
171 WR2 Nom-Ofenspg/LEM: In the case of TWIN-POWER, the nominal DC voltage is
IN2 Nom-FurVolt/LEM: measured at the inverter input by an LEM transformer, and the
sum of both LEM outputs is equal to UD at the rectifier output.
The parameter value is identical to parameter UD145 Nom-UD in
window F19.
Parameters 172/204 are changed automatically
179 WR2 Nom-Zuendspg...: Admissible firing voltage in INV2 during operation. The
IN2 Nom-Firing Volt: commutation choke and circuitry are designed for this voltage.
The di/dt regulation limits the firing voltage to this value. The
setting value should be taken from the converter calculation.
This value should be checked during start-up and corrected, if
necessary. This voltage is automatically set to nominal voltage
(UD173), which corresponds to an firing angle of 45° at nominal
voltage.
Default: UD173 in F4
Parameter 180 changes automatically
187 WR2 Nom-Leistung...: INV2 nominal power. The INV2 power must be the same or
IN2 Nominal-Power..: down to 50% lower than the INV1 power. The nominal power is
measured for TWIN POWER, in that the direct current Id is
multiplied by the inverter input voltage ULEM.
Parameters 188/189/190/191/192/193/194/195 are changed

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automatically
196 WR2 Freiwzeit/IWNom: Recovery time for the inverter thyristors according to the
IN2 Trec/IInv-Nom..: converter calculation sheet. The DICU then attempts to regulate
a hold-off time of 1.4 times UD33 (UD136 in F16) at nominal
current.
Parameter 201 is changed automatically
198 WR2 dIdtàMinèMinINom The value describes the steepness of the current slope for the
IN2 dIdtàMinèMinINom INV thyristors at nominal current, at Beta-min and the rectifier
driven to full scale. That corresponds to the lowest furnace
voltage at which nominal power can be reached. The value can
be taken from the converter calculation sheet, although it must
be confirmed by measurement and corrected, if necessary. The
DICU calculates di/dt from IW-control and Tcom.
Please note! Parameter UD198 must always be adjusted
precisely, see Chapter 7.6.3.3.

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5.2.5 Window F5, REC – nominal data, transformers, line

Rectifier nominal values

nn Name Description
45 GR Nom-Netzspg....: Nominal line voltage of the converter infeed. In 12p and 24p
REC Nom-Mains Volt.: systems, all line voltages must have the same values.
Parameters 46/47/48/145/146/147/205/206/207 are changed
automatically.
49 GR Nom-Strom......: In the case of 6p and 12p (two rectifiers in series), the rectifier
REC Nom-Current....: current is identical to the inverter current (UD19 in F1).
In the case of 12p (rectifiers in parallel) or 24p (2 or 4 rectifiers in
parallel), the rectifier current is respectively ½ or ¼ of the
inverter current. Recognizing the INV/REC current ratio allows
the DICU to determine the REC circuitry automatically and to
calculate the other internal parameters.
Parameters 148/149s are changed automatically.
69 GRE UD-Wandler-ext.: Transformer ratio for the line voltage transformer. All line voltage
REE UD-Trans.-ext..: transformers must have the same factor. The secondary voltage
should be in the following range:

Nomvoltage
66V ≤ ≤ 150V
UD69
In systems in the USA, it is possible that the secondary voltage
is around 120V – see parameter UD124 in F5.
71 GRE ID-Wandler-ext.: Transformer ratio for the line current transformer. The standard
REE ID-Trans.-ext..: transformer is current transformer Id/1A. Sometimes 2
transformers are connected in series, so that the factor then
applies to the complete current transformer chain Id/5A and
5A/1A.
The secondary transformer current is translated to a voltage by a
load resistor in the DICU. Given a secondary transformer current
of 1A, the load resistor is 1Ω (European version). Given a
secondary transformer current of 5A, the load resistor is 0.2Ω
(USA version). The translated power amounts to 5W.
The admissible range can be calculated:

NomDCcurrent
0,66V ≤ ≤ 1,55V
UD71
117 GR DrehsinnNetz1/2: The DICU can process right-rotating and left-rotating fields for
REC Line Rot. 1/2..: the infeed. The phase angles created between the two systems
likewise do not matter, although there must be an angle of up to
30°el between each phase of system 1 and 2 - see parameter
UD214 in F5.
There are four alternatives, which are measured out by the DICU
itself. Once the voltage has been switched on, the data for both
lines can be collected in window FG1 by pressing the "." key.
The combination of rotary fields are shown in brackets.
0- both fields rotating right
1- field 1 rotating left, field 2 rotating right
2- field 1 rotating right, field 2 rotating left
3- both fields rotating left
The figure found by the DICU must now be entered and saved
with US-, EUS- and with UT.
Default: 0

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118 GR Vorstrom-Thyr.2: As with UD117, read off in window FG1.

REC Adv.Curr.Thyr.2: As the phase rotation and phase distribution of both systems can
be random, the pre-mag current pulse must be simultaneously
applied to the "correct" thyristor of system 2 in 12p operation.
The DICU selects the correct phase. The figure found by the
DICU must then be entered and saved with US-, EUS- and with
UT.
Default: 0
129 GR DrehsinnNetz3/4: Only required for 24p systems.
REC Line Rot. 3/4..: The DICU can process right-rotating and left-rotating fields for
the rectifier infeed. The phase angles created between the two
systems likewise do not matter, although there must be an angle
of up to 30°el between each phase of system 3 and 4. In
addition, it is essential that there is an angle of + or - 15°el
between L1+ of system 1 and L1+ of system 3. The DICU cannot
measure out the angle between systems 1/2 and 3/4 because
two different GRS cards are responsible for making the
measurement and these cards do not exchange analog data. If
the angle is not 15°el, then the entire system is not 24-pulse in
its line harmonic current spectrum.
There are four alternatives in systems 3 and 4, which are
measured out by the DICU itself. Once the voltage has been
switched on, the data for both lines can be collected in window
FG2 by pressing the "." key. The combination of rotary fields are
shown in brackets.
0- both fields rotating right
1- field 1 rotating left, field 2 rotating right
2- field 1 rotating right, field 2 rotating left
3- both fields rotating left
The figure found by the DICU must now be entered and saved
with US-, EUS- and with UT
.
Default: 0
130 GR Vorstrom-Thyr.4: As with UD129, read off in window FG2.
REC Adv.Curr.Thyr.4: As the rotary fields and phase distribution of both systems can
be random, the pre-mag current pulse must be simultaneously
applied to the "correct" thyristor of system 4 in 24-pulse
operation. The DICU selects the correct phase. The figure found
by the DICU must then be entered and saved with US-, EUS-
and with UT.
Default: 0
213 GR Alfa-Diff (24p): Only required for 12p (rectifiers in parallel) or 24p systems.
REC Alfa-Diff (24p): Both GRS cards receive the same Alpha angle from the CPU
card. Minor differences in the hardware (GRS cards, line
transformers on the backplane, synchronizing transformers, and
power transformers) mean that the rectifiers connected in
parallel deliver different DC voltages for the same Alpha angle
and thus different DC currents. This UD213 angle allows these
differences to be compensated to a certain extent. UD213 can
have positive or negative values.
This parameter can only be set at the installation site.
Default: 0
214 GR Phasen-Diff.1-2: The phase angle between the two systems is normally 30°el. It
REC Phase-Diff.1-2.: does not matter whether the phase angle between both line
systems is +30°el or -30°el. Parameter UD214 then has a value
of 30.
It is sometimes necessary to work with a different phase angle –
emergency operation in a 12p system with 2 separate 6p
transformers with the same switch groups. Parameter UD214 is
then set to 0°el. The system works as 6p (no 12p mode).
Parameter UD214 can only take on the values 0 or 30.

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Default: 30
124 UWG Typ Europa/USA.: The secondary voltage of the line voltage transformers (thus the
UWG Type Europe/USA. DICU input voltage) is 100V (Europe) or 120V (USA). The
measurement range can be changed with this parameter. The
filters fitted on the GRS card need to be adapted (Chapter 2.6.5).
0- stands for Europe
1- stands for USA
Change parameter UD70 in F13.
Parameters UD152 (to 100V or 120V) and UD159 (to 230V or
115V) are then automatically set in F20.
Default: 0

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5.2.6 Window F6, Rectifier - limits

Rectifier limit values.

nn Name Description
46 GR Max-Netzspg....: Maximum line voltage. Overshoots lead to switch-off and an
REC Max-Mains Volt.: error message is issued.
Default: 1.15 * UD45 from F5
Parameter 146 is changed automatically
47 GR Min-Netzspg....: This disturbance is determined by the software. Undershoots
REC Min-Mains Volt.: lead to switch-off after a couple of seconds and an error
message is issued.
Default: 0.8 * UD45 from F5
Parameter 147 is changed automatically
48 GR Diff-Netzspg...: Only applies to 12p and 24p systems. This value defines the
REC Diff-Mains Volt: largest admissible deviation between the voltages of the
individual systems. Overshoots lead to switch-off and an error
message is issued.
Default: 0.05 * UD45 in F5
50 GR Lueck-Strom....: Undershoots lead to switch-off and an error message is issued.
REC Discont-Current: As the unsmoothed current is scanned, the value should be set
to around 5% for a desired minimum current of 15%. The bottom
current peaks then more or less extend to the set value.
Default: 0.33 * UD149 in F19
211 GR Lueckstr. aktiv: Activates intermittent current monitoring.
REC DiscCurr.active: 0 – monitoring switched off
1 – monitoring active
Default: 1
43 GR Netz-FreqFehler: Largest admissible deviation from the nominal line frequency.
REC Mains Frequ-Err: This disturbance is determined by the software. Overshoots lead
to switch-off after a couple of seconds and an error message is
issued.
Default: 1
44 GR Netz-PhasFehler: Largest admissible angle error between the line phases. This
REC Mains Phase-Err: disturbance is determined by the software. Undershoots lead to
switch-off after a couple of seconds and an error message is
issued.
Default: 5
39 GR Alfa-Min.......: Alpha-min for the rectifier. In theory, the value could be 0°el
REC Alfa-Min.......: (best cosPhi, lowest harmonics). However, practice has shown
that the rectifier firing pulse can come to nothing if line
fluctuations occur (e.g. if an electric arc furnace is working in the
vicinity at an angle of 0°el) This is because the voltage at the
thyristor to be fired is still not positive. It is better to set an angle
of minimum 5°el because cos5 = 0.996 is always close to 1.
Default: 1

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5.2.7 F7 Start window - parameters

These parameters are templates and need to be checked and corrected at the
installation site.

nn Name Description
23 WR1 Vor-Strom......: The pre-mag current pulse fires the necessary rectifier and
IN1 Advance-Current: inverter thyristors simultaneously. A current circuit is built up.
Once the pre-mag current has been reached, the starter device
ignites the start thyristor.
Default: 0.1 * UD19 from F1
Parameter 186 is changed automatically
18 WR1 Start-Spannung.: This value is only used for calculating the warm-up angle and is
IN1 Start-Voltage..: practically without meaning. This voltage is not evaluated at the
start. The warm-up angle is used in the start phase during the
time UD102 from F7.
Default: 0.1 * UD10 from F1
Parameter 181 is changed automatically
4 WR1 Start Zeit-1Imp: This is the time between the start pulse sent to the start thyristor
IN1 Start Time-1Imp: and the next pulse for the INV1 diagonal B.
Monitor the start on the oscilloscope and check whether this
pulse lags approximately 100µs behind the maximum MF
voltage peak. If the firing is in front of the maximum, energy is
withdrawn from the load circuit again. The value may need to be
changed. The pulse should be sent at the earliest when the start
thyristor is blocked again, i.e. when the furnace voltage is lower
again, just beyond the peak.
Default: 0.15/UD1 (0.15 of the period) from F1
5 WR1 Start Zeit-2Imp: After the start pulse and the first pulse to diagonal B have been
IN1 Start Time-2Imp: sent, the MF voltage swings once through zero. This zero-
crossing is recognized by the control system and the second
firing pulse (diagonal A) is derived from this with UD5 and UD6
(Chapter 7.5).
Default: 0.15/UD1 (0.15 of the period) from F1
6 WR1 Start Phi-Regel: This parameter determines Phi start in window FU-1, left-hand
IN1 Start Phase-Reg: column, for INV1. This value determines the inverter's further
firing pulses the start phase during the start-wait time (UD7 in
F7). After entering the parameter, execute US- and UT. The
value for Phi start in window FU-1 must be:
TWIN POWER system: around 204
SP system: around 125 (<127)
Check the position of the INV pulses with the oscilloscope
(Chapter 7.5).
Default: 0.3/UD1 (0.3 of the period) from F1
167 WR2 Start Zeit-1Imp: This is the time between the start pulse sent to the start thyristor
IN2 Start Time-1Imp: and the next pulse for the INV2 diagonal B.
Monitor the start on the oscilloscope and check whether this
pulse lags approximately 100µs behind the maximum MF
voltage. If the firing is in front of the maximum, energy is
withdrawn from the load circuit again. The value may need to be
changed. The pulse should be sent at the earliest when the start
thyristor is blocked again, i.e. when the furnace voltage is lower
again.
Default: 0.15/UD164 (0.15 of the period) in F4
168 WR2 Start Zeit-2Imp: After the start pulse and the first pulse to diagonal B have been
IN2 Start Time-2Imp: sent, the MF voltage swings once through zero. This zero-
crossing is recognized by the control system and the second

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firing pulse (diagonal A) is derived from this with UD168 and

UD169 (Chapter 7.5).
Default: 0.15/UD164 (0.15 of the period) from F4
169 WR2 Start Phi-Regel: This parameter determines Phi start in window FU-2, left-hand
IN2 Start Phase-Reg: column, for INV2. This value determines the inverter's further
firing pulses the start phase during the start-wait time (UD7 in
F7). After entering the parameter, execute US- and UT. The
value for Phi start in window FU-2 must be:
TWIN POWER system: around 204
SP system: around 125 (<127)
Check the position of the INV pulses with the oscilloscope
(Chapter 7.5).
Default: 0.3/UD1 (0.3 of the period) from F1
40 GR Alfa-Vorstrom..: This is the rectifier firing angle for the L1+ thyristor for the first
REC Alfa-Adv.-Curr.: firing pulse which generates the rising pre-mag current. As all
other minus rectifier thyristors and the inverter thyristors in
diagonal A are fired at the same time in INV1 (and also in INV2
in TP systems), a positive overall voltage results so that a
current can flow. Select the angle as large as possible to ensure
that the current Id does not rise too steeply. In the case of 12p
and 24p systems, certain combinations of rotary fields and
phase shifts in the individual line systems can mean that pre-
mag current cannot be generated at an angle of 100°el (error
message "Start abort"). The angle should then be reduced in
stages of 5°el until a clean current rise is achieved.
The angle 100°el is good for 12p systems with 2 rectifiers in
series, in which the rectifier system 2 lags behind – the angle
between system U1 and U2 in window FP is 30°el. At an angle
of 330°el, the pre-mag current angle should be reduced.
Default: 120
41 GR AlfaAnlauf Norm: After the first firing (parameter UD40), all rectifier thyristors are
REC AlfaWarmUp Norm: initially fired at this angle. The current controller monitors the
current at a scanning speed around 30 times as high and
ensures that the current does not rise or fall too quickly (by
altering the rectifier firing angle). This process is critical because
a very great impedance change occurs in the load circuit in a
very short time during the start phase (no-load and cold start
should use the same setting).
An angle of 80°el is usually quite good If problems occur during
the start, change this angle in 5°el stages and monitor the start
(operation with just one inverter). If a better value is found, test it
under extreme load states (no-load, and ramming form).
Default: 80
42 GR AlfaAnlauf Twin: As above, although for TWIN POWER operation. As both
REC AlfaWarmUp Twin: inverters work in series in TWIN POWER mode, the impedance
is almost twice as great at the same load states. That leads to a
greater rectifier voltage in the warm-up phase and thus to a
narrower angle.
Default: 70
7 WR1 Start Wartezeit: Further rectifier thyristors are fired with parameter UD41 or
IN1 Start Waittime.: UD42 during the start wait time UD7 after the first firing with
102 REG Anlauf-Steuerz.: Alpha pre-mag current UD40. At the same time, the inverter
REG Warm-Up-Time...: thyristors are fired to the pattern UD4, UD5 and UD6.
103 REG Start-Regelzeit: The start wait time UD7 must be at least as great as parameter
REG Start-Reg.-Time: UD53 in F12 (IW control filter), minimum the full period length of
the MF frequency.
In the warm-up control time UD102, the INV control moves to the
Phi warm-up angle and keeps to it. The REC control runs at the
Alpha warm-up angle and tries to keep the current horizontal
with Alpha control. The current controller monitors the current at
a scanning speed around 30 times as high and ensures that the

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current does not rise or fall too quickly (by altering the rectifier
firing angle).
In start control time UD103, the INV control switches (in a couple
of milliseconds) from the Phi warm-up angle to Phi-Min. Alpha
continues to work at a scanning speed around 30 times greater
than the current. The controller attempts to stabilize U and I to
around 35% or P to around 15% of the nominal value.
The controller does not move to the prescribed setpoints until the
start control time UD103 has expired.
In the case of slow systems (<100Hz), the time UD103 needs to
be shortened due to start aborts in step 012 and, in extreme
cases, be reduced to 0.
Default:

Frequency range
UDnn
50Hz 200Hz 500Hz 2kHz
7 10 5 5 2
102 50 50 50 20
103 140 140 140 80

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5.2.8 Window F8, Regulation - parameters 1

Regulation part 1.

nn Name Description
82 REG Int -Anteil.UP: These control parameters have been tried and tested in systems
REG Int -Part...UP: between 0.5kW and 42MW at frequencies between 100Hz and
83 REG Diff -Anteil.UP: 4kHz in TWIN POWER and SINGLE POWER modes. These
REG Diff -Part...UP: values do not need to be changed as a rule.
84 REG Brems-Anteil.UP: These parameters contain values for control purposes and are
REG Brake-Part...UP: predefined for SP and TP systems.
85 REG Alfa -Verst..UP: If the system starts to oscillate slightly and these swings cause
REG Alfa -Amplfy.UP: the system to shut down, the controllers can be calmed down by
86 REG Phi -Verst..UP: taking parameters from a column further to the left.
REG Phi -Amplfy.UP:
87 REG Start-Verst..UP: Parameter Freq. low Freq. medium Freq. high
REG Start-Amplfy.UP: UDnn ~50Hz ~200Hz ~500Hz
88 REG Int -Anteil..I:
85 20 50 50
REG Int -Part... I:
89 REG Diff -Anteil..I: 86 20 50 50
REG Diff -Part... I:
87 20 50 50
90 REG Brems-Anteil..I:
REG Brake-Part... I: 88 0.02 0.02 0.01
91 REG Alfa -Verst...I:
91 50 50 100
REG Alfa -Amplfy..I:
92 REG Phi -Verst...I: 92 50 50 100
REG Phi -Amplfy..I:
93 50 50 100
93 REG Start-Verst...I:
REG Start-Amplfy..I:
94 REG Diff -Verst...T: If the control parameters are taken from the "Freq. low" column,
REG Diff -Amplfy..T: set the ramp time (UD209 in F10) to at least 5 seconds. The
switch-off time (UD212 in F10) can remain at 2 seconds.

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5.2.9 Window F9, Regulation - parameters 2

Regulation part 2.

nn Name Description
95 REG Tendenz-Faktor.: These control parameters have been tried and tested in systems
REG Tendency-Factor: between 0.5kW and 42MW at frequencies between 100Hz and
97 REG Brems-Schwelle.: 4kHz in TWIN POWER and SINGLE POWER modes. These
REG Brake-Level ...: values do not need to be changed as a rule.
99 REG UI-GrenzWarnung: Set UD95=2 for the GrSIM.exe program.
REG UI-WarningLevel: Default:
98 REG Ansprech-Grenze: UD95=3, UD97=UD99=0.1, UD98=10, UD100=64, Ud101=4
REG Responce-Level.:
100 REG Max-Regelhub...:
REG Max-Reg.Action.:
101 REG Hub-Reduktion..:
REG Reduced-Action.:
132 REG Phi-Opt Norm...: Two values are possible in SINGLE POWER mode.
REG Phi-Opt Norm...: 0 - The commutation time is determined by the parameters
entered (calculated, not measured). The time is determined
according to the process, as with parameter UD127 in F12.
1 - Phi regulation is used with the commutation time being
measured according to the process set with parameter
UD125 in F12 and UD134 in F9.
Default: 1, recommended.
134 REG Fakt.Ts/Tk Norm: Two values are possible in SINGLE POWER mode, although
REG Fact.Th/Tc Norm: they are only active with Phi regulation (Parameter UD132 = 1 in
F9):
1 - The hold-off time is always at least as long as the
commutation time.
2 - The hold-off time is always at least twice as long as the
commutation time. This can cause problems during the start.
Default: 1, recommended.
133 REG Phi-Opt Twin...: Two values are possible in TWIN POWER mode.
REG Phi-Opt Twin...: 0 - The commutation time is determined by the parameters
entered (calculated, not measured). The time is determined
according to the process, as with parameter UD127 in F12.
1 - Phi regulation is used with the commutation time being
measured according to the process set with parameter
UD125 in F12 and UD135 in F9. However, only the inverter
operating with Phi-min is optimized.
Default: 1, recommended.
135 REG Fakt.Ts/Tk Twin: Two values are possible in TWIN POWER mode, although they
REG Fact.Th/Tc Twin: are only active with Phi regulation (Parameter UD133- = 1 in F9):
1 - The hold time is always at least as long as the commutation
time.
2 - The hold time is always at least twice as long as the
commutation time. This can cause problems during the start.
Default: 1, recommended.

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5.2.10 Window F10, Regulation - parameters 3

Regulation part 3.

nn Name Description
119 REG U/I/P-Regelung.: States which type of target value is to be stipulated from outside
REG V/I/P-Regulator: (potentiometer or processor). The two remaining setpoints are
limited to their nominal values.
Entry:
1 = voltage control
2 = current control
3 = power control
Note: only power control is possible in TWIN POWER systems,
thus only "3" is admissible.
Default: 3
120 REG Phi-Regelung...: 0, 1 or 2 are possible.
REG Phase-Regulator: Meaning:
0 - Phi-min is used from window "FU-1". The influence of
Thold/Tcom (parameter UD134 in F9, factor 1 or 2) is not
taken into account.
1 - Hold-off time optimization to minimum hold-off time, the
influence of Thold/Tcom is taken into account. If this
operating mode is selected, this corresponds to the "Phi-min
mode" of the Badener Elektronik Company.
2 - Phi regulation (β regulation) active. The nominal furnace
voltage can only be reached in this operating mode.
Default: 2, recommended.
209 REG Rampen-Zeit....: The ramp time determines the time taken for the setpoint to rise
REG Slope-Time.....: from 0% to 100% or to fall from 100% to 0%. In the case of a
smaller target value change, the change is performed with the
same ramp, thus proportionally in a shorter time.
The "normal" Off command is executed with ramp.
The converter is switched off immediately without delay (without
ramp) if the switch off is caused by a DICU error or by an
Emergency-Off.
Default: 2, for systems with low frequencies: 5
212 REG Abschalt-Zeit..: The switch-off time is the delay between the "Off" command on
REG Off-Time.......: the SIO card or the off key on the service computer and the
actual converter switch-off. During this time, the target value
addressed drops with the ramp declared in parameter UD209
from F10. If the system is working with a small target value, the
target value drops to a minimum value and is not switched off
until the time UD212 has expired.
The converter is switched off immediately without delay (without
ramp) if the switch off is caused by a DICU error or by an
Emergency-Off.
Default: 0
96 REG AnlaufVerstaerk: Amplifies the current controller during the start phase during the
REG Warm-Up Amplify: warm-up time (parameter UD102 in F7). If the current oscillates
during this time, make the parameter smaller.
Default: 200, recommended.
210 REG Anlauf mit ID..: The following current is taken for current control in the warm-up
REG Warm-Up with ID: phase:
0 – Iw, inverter current, heavily filtered, slow regulation
1 – Id, line current, faster regulation
Default: 1, recommended.
121 REG Anlauf Phi-Opt.: Not used.

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REG Warm-Up Phi-Opt: Default: 0, recommended.

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5.2.11 Window F11, Inverters 1/2 - electronics 1

Inverters 1 and 2. Internal electronics factors - part1

nn Name Description
56 WRE UW(O)-Fakt.-int: The "100V" voltage from the external MF voltage transformer is
INE UW(O)-Fact.-int: reduced once more in the DICU to an electronic level of around
5V by an internal MF voltage transformer. This parameter is an
internal ratio factor. The value depends upon the internal MF
voltage transformers deployed and whether the system is run
with or without LEM transformers (Chapter 2.6.3).
The MF voltage transformer GES9898030P11 is soldered onto
the backplane for frequencies <200Hz. The MF voltage
transformer GES9898030P12 remains soldered to the backplane
(original state) for working frequencies >200Hz.
Please note: If the MF voltage transformer GES9898030P11 is
used, the filter fittings on the WRS card need to be changed
(Chapter 2.6.2).
Default:
GES9898030P11 GES9898030P12
Udnn
with LEM without with LEM without
LEM LEM
56 20.2 20.7 21.3 21.8

58 WRE UW-Offset......: If the display in the PC window FL is not zero at "converter off",
INE UW-Offset......: the value can be set to zero with the offset.
Default: 0
57 WRE UO/LEM-Offset..: If the display in the PC window FL is not zero at "converter off",
INE UO/LEM-Offset..: the value can be set to zero with the offset.
Default: 0
60 WRE IW-Faktor-int..: The MF current converted by the load resistor to 1V is
INE IW-Factor-int..: subsequently amplified to around 5V. There are two different
hardware versions with different factors:
WRS card Rev.B 0.204
Rev.C 0.213 (since 1996)
Default: 0.213
61 WRE IW-Offset......: If the display in the PC window FL is not zero at "converter off",
INE IW-Offset......: the value can be set to zero with the offset.
Default: 0
162 WRE PW-Faktor......: This factor allows the power measurement to be corrected. The
INE PW-Factor......: power displayed by the DICU on the service PC, customer
module and Prodapt amounts to:
Pdisplay = Pact * UD162
If UD162 is <1, the power displayed is lower than the actual
power.
Default: 1
163 WRE PW-Offset......: If the display in the PC window FL is not zero at "converter off",
INE PW-Offset......: the value can be set to zero with the offset.
Default: 0
63 WRE Endstufe IZ....: Internal current monitoring for the INV pulse amplifiers. The
INE Drive-Current .: admissible current per INV diagonal is entered.
The maximum admissible current for SP and C1/C2 systems is
15A.
As both diagonals in TP systems can be fired simultaneously

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(short-circuit mode), the maximum admissible current is 7.5A (if

UD64 = 2.249).
The fittings on the WRS card have changed over the course of
the years. The real, maximum admissible current of the INV
diagonal is around 25A for SP systems and around 12.5A for TP
systems – measurement resistance on the WRS card 0.047Ω
(since 1998).
The measurement resistance on the WRS card was changed in
September 2012 and has been 0.022Ω since then. The real,
maximum admissible current of the INV diagonal is around 50A
for SP systems and around 25A for TP systems.
The declarations for parameter UD63 have not been changed
and the real, admissible current must be converted
proportionately.
Default: 10
64 WRE Endstufe IZ-Fkt: Internal hardware factor for monitoring the firing current. The
INE Drive-Curr.Fact: factor in the specimen file is incorrect at present and should be
changed to 2.249.
Default: 3.635
62 WRE IDIF-Faktor-int: Concerns internal hardware. Do not change.
INE IDIF-Factor-int: Default: 1
115 WRE Zeit Vorstromp.: Duration of the pre-mag current pulse. The REC and INV
INE Time Adv.-Pulse: thyristors must reach the holding current in this time.
Pulses longer than 80µS are not possible with the old
GES9558013P1 firing transmitter as it becomes saturated.
The new GES9558046P1 firing transmitter can transmit pulses
of up to 400µS.
80µS and 144µS are the only values which can be entered.
Default: 80
116 WRE Mit LEM-Wandler: 0 - measurement without LEM. The MF power is then
INE With LEM-Meas..: determined at
P = UWR * IWR * cos β (on the INV side)
1 - measurement with LEM. The MF power is determined on the
direct current side of the INV at
P = ULEM * ID
Default: SP system: 0, TP system: 1

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5.2.12 Window F12, Inverters 1/2 - electronics 2

Inverters 1 and 2. Internal electronics factors - part 2

nn Name Description
51 WRE UW-EntstoerFilt: The run time of the ripple filter for measuring the inverter's
INE UW-Ripple-Filt.: voltage is determined by WRS inverter card deployed. Do not
change!
Default: WRS card GES9898030P5: 55
WRS card GES9898030P30: 12
52 WRE IW-EntstoerFilt: The run time of the ripple filter for measuring the inverter's output
INE IW-Ripple-Filt.: current is determined by the hardware. Do not change!
Default: 3
53 WRE IW-Regel-Filter: The inverter current is rectified and filtered. The filtered current is
INE IW-Regul.-Filt.: used for current control. The start wait time (parameter UD7 in
F7) cannot be shorter than parameter UD53. The value is
determined by the fittings on the WRS card, network R17,
(Chapter 2.6.2).
Default: WRS card GES9898030P5, R17=4*470k: 4700
WRS card GES9898030P5, R17=4*220k: 2200
WRS card GES9898030P30: 2200
128 WRE IW-Einfluss....: 0 – No hardware influence on the time of firing from the IW
INE Iinv-Influence.: value. The time of firing is only changed by the CPU using an
internal process, which is intended to ensure that the hold-off
time is always long enough. The maximum commutation time
is determined by parameter UD114.
1 – The firing time is shifted forward dependent on IW by an
assessment factor that cannot be changed. The time of firing
follows the momentary current ripple. The minimum
commutation time is determined by parameter UD114.
Default: 0
114 WRE AufloesIW-Einfl: Resolution of the IW measurement which determines the current
INE Resol.IInv-Infl: influence on the firing time.
If parameter UD128 = 1, the lower limit of the measurement of
Tcom is then important for control purposes and is limited by the
following setting:
5 bit Tcom > 5 µS
4 bit Tcom < 5 µS
If parameter UD128 = 0, the upper limit of the measurement of
Tcom is then important for control purposes and is limited by the
following setting:
5 bit Tcom < 256 µS
4 bit Tcom < 128 µS
Default: WRS card GES9898030P5: 5
WRS card GES9898030P30: 4
125 WRE Tkom-Messg.Norm: Determines the procedure for measuring commutation in normal
INE Tcomm-Meas.Norm: mode (SP mode):
0 - Commutation is measured as follows: the measurement
starts when the thyristors are fired. The measuring time ends
once the rectified INV current has again reached the same
current value as at firing. In general, this measurement works
satisfactorily in normal mode. If the current has too many
ripples, too many measurements are then incorrect (question
mark on the screen behind the commutation time
measurement in window FL). In this case, set parameter
UD125 to 1.
1 - Commutation is measured from firing up to the current zero-

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crossing, the rest is then calculated by an extensive

mathematical procedure. This measurement procedure has
proven itself over the course of time.
Default: 1
126 WRE Tkom-Messg.Twin: Processing is identical to parameter UD125. Yet as the current
INE Tcomm-Meas.Twin: ripple is higher in TWIN POWER than in normal mode, the
problems are greater.
Determines the procedure for measuring commutation in TWIN
POWER mode:
0 - Commutation is measured as follows: the measurement
starts when the thyristors are fired. The measuring time ends
once the rectified INV current has again reached the same
current value as at firing. In general, this measurement works
satisfactorily. However, there can be problems with TWIN
POWER systems. The current can have ripples because it is
influenced by both inverters. Too many measurements are
then incorrect (question mark on the screen behind the
commutation time measurement in window FL). In this case,
set parameter UD126 to 1.
1 - Commutation is measured from firing up to the current zero-
crossing, the rest is then calculated by an extensive
mathematical procedure.
Parameter should basically be set to 1 for TWIN POWER
systems. This measurement procedure has proven itself over the
course of time.
Default: 1
127 WRE Tkom-Berechnung: Two types of calculation are possible:
INE Tcomm-Calculate: 0 - "Old" calculation model. The commutation time is calculated
from parameter UD35 in window F1 and UD38 as well as by
linear equation.
1 - "New" calculation model. Commutation is calculated using
parameter UD35 from the F1 window with an improved
procedure (complex procedure, sine half-wave with straight to
the calculated zero-crossing from the point of firing). This
calculation is important for the "UE" command, the values
Phi-min and Phi warm-up are calculated with this and can be
seen in window FU-1.
Default: 1
38 WRE EinflussUW/Komm: The value must be between 0 (no influence) and 1 (full
INE Corr..UInv/Tcom: influence). This factor is used immediately after the start phase
when the warm-up phase begins, or if the system can only be
operated with a controlled hold-off time because the
commutation time measurement does not function.
If UD127 = 1, this parameter UD38 is ineffective.
Default: 0.4
65 WRE D/A-Hub........: Declares the D/A range of the D/A converter deployed on the
INE D/A-Range......: WRS card. This value has changed due to the scattering of the
Z-diodes deployed on GRS/WRS cards or of a new chip for the
reference voltage. Developer's most recent recommendation
(2009): UD65=6.8.
Remark:
This error is difficult to rectify if GRS and WRS cards produced
many years apart are working in a DICU at the same time.
Parameter UD65 or UD66 should be smaller for old cards than
for newer ones. A compromise is sometimes tricky to find. This
can be rectified by replacing an old card with a new one.
Default: 6.6
Parameter 150 is changed
66 WRE D/A-Offset.....: Declares the D/A offset of the D/A converter deployed on the
INE D/A-Offset.....: WRS card. This value has changed due to the scattering of the
Z-diodes deployed on GRS/WRS cards or of a new chip for the

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reference voltage. Developer's most recent recommendation

(2009): UD66=0.275.
See remark for UD65.
Default: 0.325
Parameter 151 is changed

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5.2.13 Window F13 rectifier - electronics

Rectifier electronics data

nn Name Description
70 GRE UD-Faktor-int.: The "100V" (Europe) or "120V" (USA) fed in by the line voltage
REE UD-Factor-int.: transformers are again reduced by the electronics to the electronic
level of around 5V.
There are 6 small, black 230V/9V line voltage transformers installed
on the backplane (also on the sub-board for a DICU 24p). These
transformers are quite "weak" and the secondary voltage very much
depends upon the power of the transformers. Parameter UD70
should be adapted to match the transformer power.
For Europe:
Until 2012 these transformers had a power output of 0.33VA:
UD70=20
As from 2012 these transformers have a power output of 0.5VA:
UD70=24
The same transformers must be installed on the backplane and on
the sub-board as in the DICU 24p. More in Chapter 2.6.5.
Default: 20
72 GRE ID-Faktor-int.: The line current converted to 1V by the load resistor is subsequently
REE ID-Factor-int.: amplified to 5V. There are two hardware versions for the GRS card:
GRS card Rev.B 0.204
Rev.C 0.196 (since 1996)
Default: 0.196
73 GRE IDMIN-Fkt.-int: Internal hardware, do not change.
REE IDMIN-Fact-int: Default: 0.319
67 GRE UR-Nullwinkel.: Electronics hardware.
REE UR Zero-Angle.: Deviation of the zero-crossing of the line voltage to the zero-
crossing of the measured line voltage. Nowadays is 48°el. (filter
36°el + Chip 20°el - transformer adjustment 8°el).
There are 6 small, black 230V/9V line voltage transformers installed
on the backplane (also on the sub-board for the DICU 24p).
Parameter UD67 should be adapted to match the transformer
power.
Until 2012 these transformers had a power output of 0.33VA:
UD67=48
As from 2012 these transformers have a power output of 0.5VA:
UD67=51
The same transformers must be installed on the backplane and on
the sub-board of the DICU 24p.
Default: 48

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5.2.14 Window F14, Logbook, supervising, bus, CPU, SIO

CPU, bus, power unite

nn Name Description
79 LOG Zyklus-Zeit....: The value is set to 20ms * 47/43. The value for the USA is
LOG Timing-Cycle...: 18.217mS (16.667mS * 47/43). This is the scan time for measuring
all values after the start phase. The value can be changed if slow
beats occur, although please take great care here.
Default: 21860
80 LOG Fehlerzeit Gr.1: Software monitoring time for errors in group 1 (INV and control
LOG Error-Time Gr.1: errors). The error message is triggered if more than 30% of all
values measured in this time are incorrect.
Is set for the GrSIM.exe program: UD80=5
Default: 1
81 LOG Fehlerzeit Gr.2: Software monitoring time for errors in group 2 (REC and line
LOG Error-Time Gr.2: errors). The error message is triggered if more than 30% of all
values measured in this time are incorrect.
Is set for the GrSIM.exe program: UD81=20
Default: 5
113 BUS System-Takt....: Internal hardware, do not change.
BUS System-Clock...: Default: 8000
74 CPU ADC-Referenz...: Internal hardware, do not change.
CPU ADC-Reference..: Default: 5
75 CPU RMS-Scalefaktor: Internal hardware, do not change.
CPU RMS-Scalefactor: Default: 1
77 CPU Zuendspannung..: Internal monitoring of voltage for the firing pulse amplifiers, do not
CPU Driver-Voltage : change.
Default: 48
78 CPU ZuendMessteiler: Internal hardware, do not change.
CPU DrvVolt-Divider: Default: 15.681
208 SIO PRed 7/3 Stufen: States the number of power reduction levels that can be set in
SIO PRed 7/3 Level.: window F2. 7 levels are used for SP systems and 3 levels for TP
systems.
Default: 7

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5.2.15 Window F15, Customer module, communication, COM2

Customer module, data, communication

nn Name Description
110 TEX Stand.-Sprache.: The complete program on the service PC can be set to two
TEX Def.-Language..: languages: German and English. German is always the default
language when the program starts.
0- German
1- English
Error messages can be issued in other languages beside these.
If one of these languages is selected, the GUI is in English and
only the error messages are issued in the selected language:
2- Turkish
3- Polish
4- Portuguese
5- Swedish
6- Italian
7- French
8- Spanish
9- Czech
Default: 0
104 ANZ Eichwert I-WR..: At this current (A), the customer module's analog output delivers
DIS MaxRange I-Inv.: 10V. If measuring devices are connected with a 110% scale, for
example, nominal current needs to be programmed at times 1.1
for a "10V" value. For example: 1900A times 1.1 = 2090. Always
enter 4 or 5 places before the decimal point, fill out figures with 2
or 3 places to 4 place figures with zeros.
Default: 1000
105 ANZ Eichwert U-WR..: At this voltage (V), the customer module's analog output delivers
DIS MaxRange U-Inv.: 10V. If measuring devices are connected with a 110% scale, for
example, nominal voltage needs to be programmed at times 1.1
for a "10V" value. For example: 3000V times 1.1 = 3300. Always
enter 4 or 5 places before the decimal point, fill out figures with 2
or 3 places to 4 place figures with zeros.
Default: 1000
106 ANZ Eichwert P-WR..: At this power (kW), the customer module's analog output
DIS MaxRange P-Inv.: delivers 10V. If measuring devices are connected with a 110%
scale, for example, nominal power needs to be programmed at
times 1.1 for a "10V" value. For example: 4300kW times 1.1 =
4730. Always enter 4 or 5 places before the decimal point, fill out
figures with 2 or 3 places to 4 place figures with zeros.
16
The maximum value is 65534 (2 – 2).
Example: Value 40 Enter 4000
Value 52000 Enter 52000
Default: 1000
107 ANZ Eichwert F-WR..: At this frequency (Hz), the customer module's analog output
DIS MaxRange F-Inv.: delivers 10V. If measuring devices are connected with a 110%
scale, for example, nominal frequency needs to be programmed
at times 1.1 for a "10V" value. For example: 500Hz times 1.1 =
550. Always enter 4 or 5 places before the decimal point, fill out
figures with 2 or 3 places to 4 place figures with zeros, thus 5500
Default: 1000
108 ANZ Eichwert The programmed value for potentiometer 1 on the right-hand
Potentiometer 1: margin is the maximum possible target value for the DICU.
DIS MaxRange Pot 1.: Parameter UD119 in the F10 window determines the type or
regulation required. Only power regulation is possible for TWIN

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POWER.
Default: 1000
109 ANZ Eichwert The programmed value for potentiometer 2 on the right-hand
Potentiometer 2: margin is the maximum possible target value for the DICU.
DIS MaxRange Pot 2.: Only one potentiometer is active in standard mode or C1/C2.
The active potentiometer is selected via SIO input E9.
There are two modes in TWIN POWER operation for combining
potentiometers 1 and 2. Parameter UD122 makes this selection
UD122=0 potentiometer 1 determines the sum power;
potentiometer 2 determines how the power is
distributed to furnaces 1 and 2.
UD122=1 potentiometer 1 determines the power of furnace 1;
potentiometer 2 determines the power of furnace 2.
The sum power can obviously not be greater than the nominal
power. If the potentiometers are set higher, nominal power is
distributed in accordance with the ratio of potentiometer settings.
Example: potentiometer 1 at 50%; potentiometer 2 at 100%. Set
the power setpoints at 1/3 and 2/3.
Default: 1000
122 ANZ Poti1=P1+P2/P1.: Selects the function of the potentiometers connected to the
DIS Pot1=P1+P2/P1..: customer module.
0 - potentiometer 1 determines the sum power; potentiometer 2
determines how the power is distributed between furnace 1
and furnace 2.
1 - potentiometer 1 determines the power of furnace 1;
potentiometer 2 determines the power of furnace 2.
Default: 0
123 ANZ ComKanal KModul: This parameter defines the DICU interface for connection to the
DIS ComChan. CModul: customer module:
1 - COM1 (standard)
2 - COM2; parameter UD76 must then be set to 9600 BAUD.
Default: 1
76 CPU COM2-Baudrate..: Baud rate of the COM2 interface. This interface is used for
CPU COM2-Baudrate..: connection to a PRODAPT, to another higher level computer or
to a second customer module. The DICU can send data to the
computer via the interface (e.g. actual values) and receive data
from the computer (e.g. setpoints).
The program must be restarted if the baud rate is changed. Only
then is the change adopted. The baud rate must agree with
PRODAPT. If a second customer module is connected, the baud
rate must be set to 9600 BAUD.
Default: 4800

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5.2.16 Window F16, Check INV 1/2, turn-off time, start

Monitoring inverters 1 and 2. Limit values and hold time

nn Name Description
136 WR1 Schonzeit/IWnom: Nominal hold time of the inverter thyristors at nominal current.
IN1 Holdtime/IWnom.: The value is calculated automatically by the DICU from nominal
recovery time (parameter UD33 in F1) times parameter UD138.
Can be changed indirectly with parameter UD33 in F1.
138 WR1 Fakt.Tsch/Tfrei: Factor used to determine parameter UD136. The value of 1.4 is
IN1 Fact. Thld/Trec: fixed.
139 WR1 Min-Ofenspg/LEM: Minimum admissible INV1 voltage or LEM voltage during
IN1 MinFur.Volt/LEM: operation. Can be changed indirectly with parameter UD8 in F1
or UD15 in F3.
182 WR2 Nom-Strom.... .: Nominal MF current of INV2 according to the UR calculation
IN2 Nom-Current....: sheet. If several inverters are switched in parallel – sum current.
Can be changed indirectly with parameter UD19 in F1.
201 WR2 Schonzeit/IWnom: Nominal hold-off time of the INV2 thyristors at nominal current.
IN2 Holdtime/IWnom.: Can be changed indirectly with parameter UD196 in F4.
203 WR2 Fakt.Tsch/Tfrei: The factor used to determine parameter UD201. The value of 1.4
IN2 Fact. Thld/Trec: is fixed.
204 WR2 Min-Ofenspg/LEM: Minimum admissible INV2 voltage or LEM voltage during
IN2 MinFur.Volt/LEM: operation. Can be changed indirectly with parameter UD15 in F3
or UD171 in F4.
186 WR2 Vor-Strom......: The pre-mag current pulse fires the necessary rectifier and
IN2 Advance-Current: inverter thyristors simultaneously. A circuit current is built up.
Once the pre-mag current has been reached in INV2, the start
thyristor fires.
Can be changed indirectly with parameter UD19 in F1 or UD23
in F7.
181 WR2 Start-Spannung.: This value is only used for calculating the warm-up angle to be
IN2 Start-Voltage..: used in the start phase in the time UD102 from F7.
Can be changed indirectly with parameter UD173 in F4 or UD18
in F7.
170 WR2 Start Wartezeit: See window F7, parameter UD7.
IN2 Start Waittime.: Can be changed indirectly with parameter UD7 in F7.

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5.2.17 Window F17, Check INV 2, V/P - reduction

Monitoring inverter 2, voltage and power reduction. If these values do not match in
stand-alone cases, they can only be changed by altering the reduction values for
furnace 1.

nn Name Description
174 WR2 Red-Spannung 1.: See window F2, parameter UD11.
IN2 Reduced-Volt.1.: Can be changed indirectly with parameter UD11 in F2 or UD173
in F4.
175 WR2 Red-Spannung 2.: See window F2, parameter UD12.
IN2 Reduced-Volt.2.: Can be changed indirectly with parameter UD12 in F2 or UD173
in F4.
176 WR2 Red-Spannung 3.: See window F2, parameter UD13.
IN2 Reduced-Volt.3.: Can be changed indirectly with parameter UD13 in F2 or UD173
in F4.
188 WR2 Red-Leistung 1.: See window F2, parameter UD25.
IN2 Reduced-Power 1: Can be changed indirectly with parameter UD25 in F2 or UD187
in F4.
189 WR2 Red-Leistung 2.: See window F2, parameter UD26.
IN2 Reduced-Power 2: Can be changed indirectly with parameter UD26 in F2 or UD187
in F4.
190 WR2 Red-Leistung 3.: See window F2, parameter UD27.
IN2 Reduced-Power 3: Can be changed indirectly with parameter UD27 in F2 or UD187
in F4.
191 WR2 Red-Leistung 4.: See window F2, parameter UD28.
IN2 Reduced-Power 4: Can be changed indirectly with parameter UD28 in F2 or UD187
in F4.
192 WR2 Red-Leistung 5.: See window F2, parameter UD29.
IN2 Reduced-Power 5: Can be changed indirectly with parameter UD29 in F2 or UD187
in F4.
193 WR2 Red-Leistung 6.: See window F2, parameter UD30.
IN2 Reduced-Power 6: Can be changed indirectly with parameter UD30 in F2 or UD187
in F4.
194 WR2 Red-Leistung 7.: See window F2, parameter UD31.
IN2 Reduced-Power 7: Can be changed indirectly with parameter UD31 in F2 or UD187
in F4.
195 WR2 Min-Leistung...: See window F2, parameter UD32.
IN2 Minimal-Power..: Can be changed indirectly with parameter UD32 in F2 or UD187
in F4.

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5.2.18 Window F18, Check INV 2, limits

Monitoring inverter 2, limit values. See the remark in Chapter 5.2.17. Changes can
only be made by altering the limit values for inverter 1.

nn Name Description
165 WR2 Max-Frequenz...: As with parameter UD2 in window F3, only for inverter 2 here.
IN2 Max-Frequency..: Can be changed indirectly with parameter UD2 in F3 or UD164
in F4.
177 WR2 Max-Ausgangsspg: Maximum admissible output voltage for furnace 2. The value is
IN2 Max-Output Volt: automatically set with the same factor as for furnace 1.
Overshoots lead to switch-off and an error message is issued.
Can be changed indirectly with parameter UD14 in F3 or UD173
in F4.
178 WR2 Min-Ausgangsspg: Minimum output voltage for furnace 2 during operation. The
IN2 Min-Output Volt: value is automatically set with the same factor as for furnace.
Can be changed indirectly with parameter UD15 in F3 or UD173
in F4.
172 WR2 Max-Ofenspg/LEM: Maximum admissible voltage.
IN2 Max-FurVolt/LEM: Can be changed indirectly with parameter UD9 in F3 or UD171
in F4. Applies to the LEM output for TwinPower or C1/C2
systems
180 WR2 Max-Zuendspg...: See window F3, parameter UD17.
IN2 Max-Firing Volt: Can be changed indirectly with parameter UD17 in F3 and
UD173 or UD179 in F4.
183 WR2 Max-Strom......: See window F3, parameter UD20.
IN2 Max-Current....: Can be changed indirectly with parameter UD19 in F1 or UD20
in F3.
184 WR2 Min-Strom......: See window F3, parameter UD21.
IN2 Min-Current....: Can be changed indirectly with parameter UD19 in F1 or UD21
in F3.
185 WR2 Differenz-Strom: See window F3, parameter UD22.
IN2 Diff-Current...: Can be changed indirectly with parameter UD19 in F1 or UD22
in F3.

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5.2.19 Window F19, Check rectifier

Monitoring the rectifier data

nn Name Description
141 GR Netz-Frequenz..: Line frequency. It is read out from the PROMs on the GRS card.
REC Mains Frequency: The line frequency is determined by the parameters entered
when running the service PC without a DICU (Chapter 4.2.1).
142 GR Puls-Zahl......: Admissible values: 6p, 12p and 24p. The pulse rate is read out
REC Pulse-Number...: from the PROMs on the GRS card when the DICU boots up. The
line frequency is determined by the parameters entered when
running the service PC without a DICU (Chapter 4.2.1).
143 GR Zuendung.......: Length of the rectifier firing pulses. A length of 400µs is common
REC Firing.........: at present. The VAC pulse transformer used at present becomes
saturated at around 400µs. The 400µs pulse width is
programmed fixed in the REC PROM record.
205 GR Red-Spannung 1.: See window F2, parameter UD11.
REC Reduced-Volt.1.: Can be changed indirectly with parameter UD11 in F2 or UD45
in F5.
206 GR Red-Spannung 2.: See window F2, parameter UD12.
REC Reduced-Volt.2.: Can be changed indirectly with parameter UD12 in F2 or UD45
in F5.
207 GR Red-Spannung 3.: See window F2, parameter UD13.
REC Reduced-Volt.3.: Can be changed indirectly with parameter UD13 in F2 or UD45
in F5.
145 GR Nom-UD, à=0....: Nominal DC voltage. This is determined automatically from the
REC Nom-UD, à=0....: line voltage entered: REC nominal line voltage (parameter UD45
in F5) * 1.35 * the number of rectifiers connected in series. The
program determines the number of rectifiers connected in series
from the entries for INV and REC nominal current and the pulse
rate of the circuit. The value is just for information and cannot be
changed. Can be changed indirectly with parameter UD45 in F5.
146 GR Max-UD, à=0....: Maximum DC voltage.
REC Max-UD, à=0....: Can be changed indirectly with parameter UD45 in F5 or UD46
in F6.
147 GR Min-UD, à=0....: Minimum DC voltage.
REC Min-UD, à=0....: Can be changed indirectly with parameter UD45 in F5 or UD47
in F6.
148 GR Max-Strom......: Trigger threshold for overcurrent. The hardware comparator is
REC Max-Current....: set to this value which signals overcurrent. Leads to switch-off
and an error message is issued.
IWRmax
I GRmax = ⋅ I GRnenn
IWRnenn
Can be changed indirectly with parameter UD20 in F3 or UD49
in F5.
149 GR Min-Strom......: Mean value of the minimum admissible rectifier current.
REC Min-Current....: IWRmin
I GRmin = ⋅ I GRnenn
IWRnenn
Can be changed indirectly with parameter UD21 in F3 or UD49
in F5.
144 GR Alfa-Max.......: The rectifier's maximum firing angle (so-called inverter limit
REC Alfa-Max.......: position). A value of 135°el is normal and cannot be changed.

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5.2.20 Window F20, Check electronics, COM1

Monitoring the electronics and communications

nn Name Description
150 GRE D/A-Hub........: Internal hardware. Identical to parameter UD65 in F12.
REE D/A-Range .....: Can be changed indirectly with parameter UD65 in F12.
151 GRE D/A-Offset.....: Internal hardware. Identical to parameter UD66 in F12.
REE D/A-Offset.....: Can be changed indirectly with parameter UD66 in F12.
160 WRE U-Wandler-Spg..: Internal hardware. States the internal nominal transformer
INE U-Trans.-Volt..: voltage for INV. Cannot be changed.
152 GRE U-Wandler-Spg..: Internal hardware. States the internal nominal transformer
REE U-Trans.-Volt..: voltage for REC. Is determined automatically by parameter
UD124 in F5.
Can be changed indirectly with parameter UD124 in F5.
153 W/G I-Wandler-Spg..: Internal hardware. States the nominal internal voltage for
I/R I-Trans.-Volt..: measuring current in REC and INV.
154 ALL OPA-Nom.Pegel..: Internal hardware. States the nominal level in the electronics.
ALL OpAmp Nom-Level:
155 ALL VCC-Digital....: Internal hardware. Voltage supply to the digital electronics.
ALL VCC-Digital....:
156 ALL VCC-Analog +...: Internal hardware. Positive voltage supply to the analog
ALL VCC-Analog +...: electronics.
157 ALL VCC-Analog -...: Internal hardware. Negative voltage supply to the analog
ALL VCC-Analog -...: electronics.
158 ALL VCC-SPS-I/O....: Internal hardware. Voltage of SIO input and output signals.
ALL VCC-PLC-I/O....:
159 ALL Netzspannung...: Line voltage for the DICU. This is determined automatically by
ALL Mains Voltage..: parameter UD124 in F5. Only for information purposes without
effect on the power units.
The hardware of the power units must be set accordingly for a
line voltage of 230V or 115V.
Can be changed indirectly with parameter UD124 in F5.
161 CPU COM1-Baudrate..: Baud rate for the DICU's COM1 communication interface.
CPU COM1-Baudrate..: Cannot be changed.

5.2.21 Window F21, Check internal data

Monitoring internal data.

nn Name Description
0 -- DatenChecksumme. Internal hardware, cannot be changed. Shows the hardware check
-- Data-Checksum... sum. The value is determined by the structure of the data files.
111 ALL Binaerdaten.1.: Internal data, cannot be changed.
ALL Binary-Data 1.:
112 ALL Binaerdaten.2.: Internal data, cannot be changed.
ALL Binary-Data 2.:

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6 Customer module – handling and operation

The customer module hardware is described in detail in Chapter 3.1.

The operation of the customer module is discussed here.

Figure 6.1: The front of the customer module

The customer module has an illuminated, 4-line display and a foil keypad with 4 keys.

The texts on the display can be shown in a number of languages. The language is
defined by parameter UD110 in the F15 window – Chapter 5.2.15.

2 potentiometers can be connected to the customer module to specify setpoints. In

addition, up to 6 analog instruments can be connected to display measured values.

Setpoints cannot be declared with the potentiometers or energy input via the keys
unless the customer module has command priority.
Without command priority, the customer module works as a monitor and simply
displays the latest measured values or errors.

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6.1 General notes

Display: Data display and inputs
Line 1 = top line,
Line 4 = bottom line

Keypad: Key 1 = left key

Key 4 = right key

Key 1: Go to first line

Key 2: One line up
Key 3: One line down
Key 4: Confirm entry

There must be at least 0.5 seconds between each keystroke and each pause
between 2 keystrokes for these to be recognized.
Key functions which confirm a value or call up a menu or an altered display require at
least 2 seconds time to be accepted.
The display generally returns to the normal screen of its own accord 10 seconds after
the last keystroke.

Buzzer: Notifies errors, any keystroke turns the buzzer off.

Potentiometers 1 and 2: Enter setpoints

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6.2 Customer module offline

When the voltage supply to the customer module is switched on, the customer
module attempts to establish communication with the DICU. If this does not succeed,
asterisks appear in the top 3 rows of the display after a couple of seconds.

Figure 6.2.1: Customer module offline, without linkage to the DICU

The customer module checks the linkage to the DICU all the time in the background
and, if communication is established, runs a system self-test of its own accord.

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6.3 Customer module online

If the customer module finds the link to the DICU, communication is established and
a system self-test is subsequently run through.

Figure 6.3.1: Customer module running the system self-test

If any errors occur during the self-test, these messages are either displayed correctly
in the 4th line or the DICU reboots several times if a useful error display does not
appear.

If the self-test is completed successfully, the customer module displays the actual
values.

Figure 6.3.2: Customer module display after running a self-test. On the left – an SP
system, on the right – a TP system.

A system self-test can also be started from the customer module's keypad. Hold
down key 1 and key 2, press key 3 twice, then release the keys
=> triggers a system self-test.

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6.3.1 Incorrect data or software

If the software version on the DICU's CPU card does not match the data record in the
EEPROM on the CPU card, the following message is displayed.

Figure 6.3.3: Software version does not match the data record

The same message also appears if a new CPU card is deployed which does not yet
have a valid data record. The customer module must then be disconnected from the
DICU and the correct data imported to the CPU card from the service PC.

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6.4 Displaying the latest actual values during operation

When the system is running, the DICU shows the actual values on the customer
module display. If the system is at standstill, only zero values are normally shown.
The 4th line remains free. Error messages are displayed in this line.

Figure 6.4.1: Latest actual values. On the left – an SP system, on the right – a TP
system

An extended display of measured values can be called up with the following key
combination:
Hold down key 1, press key 2 twice, release key 1 => displays measured data.

Figure 6.4.2: Extended display of measured values for an SP system

In TP systems, key 2 calls up the measured values for INV1 and key 3 those for
INV2.

Figure 6.4.3: Extended display of measured values for a TP system

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6.5 Disturbances, error displays

If an error occurs during operation of the converter or in the DICU, the system is
stopped and the error(s) is/are displayed. The buzzer sounds.
The error message appears in the 4th line of the display. If there are several error
messages, the message in the 4th line flashes.

Figure 6.5.1: Error message. Left – SP system, right – TP system

The keys have the following functions:

Key 1 : first error message
Key 2 : previous error message
Key 3 : next error message
Key 4 : hold down for 2 seconds => acknowledge the error

Please note: If the DICU disturbance is deleted from the key on the operating
cabinet or on the customer module, this then disappears from the display. Old
disturbances can no longer be called up on the customer module.
This disturbances are stored on the CPU card and are also available in the processor
(MD, Promelt, etc.). Errors can only be read out from the CPU card with the service
PC – Chapter 4.4.2.4.

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6.5.1 Disturbances, extended display

In order to analyze errors in detail, not only the error messages are useful, but also
the associated messages with figures.
Activate the extended display:
Hold down key 1, press key 3 twice, release key 1 => shows the extended error
display.

Figure 6.5.2: Extended error display

The keys have the following functions:

Key 1 : first error message
Key 2 : previous error message
Key 3 : next error message
Key 4 : back to the normal display

The display generally returns to the normal screen of its own accord 10 seconds after
the last keystroke, although the error messages are not lost. The extended error
display can be recalled with the key combination described above.

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6.6 Setting the language

Once the customer module has established the link to the DICU, the texts on the
display are shown in the language stored in the data record on the CPU card. The
language is defined in the F15 window – Chapter 5.2.15.
Another language for displaying errors can be set temporarily in the work with the
customer module. This language is valid as long as the link to the DICU exists.
When the DICU is rebooted, the display language returns to that stored in the data
record on the CPU card.

Hold down key 2, press key 3 twice, release key 2 => enter the number of the
language.
The number of the language now in use is shown in the 2nd line.

Figure 6.6.1: Language entry. Left – call up the function, right – after the number of
the language has been entered

The desired language is set with the keys. After selection, confirm the language with
key 4.
The keys have the following functions:
Key 1 : language 0 (German)
Key 2 : reduce the number of the language
Key 3 : increase the number of the language
Key 4 : confirm entry and return to the normal display

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6.7 Energy input

The energy required by melting systems with a melt processor is determined and
monitored by the processor.
Smaller systems without a melt processor can also work with specified energy. The
energy setpoint (in kWh) is entered in the customer module and, after the convertor
has been switched on, is worked down to zero.
Energy can be specified for both SP and TP systems.

6.7.1 Entering energy values in the customer module

First call up the menu to enter energy specifications. Select a line from the menu
(INV1 or INV2). Then change or select the energy value and save it. If a key is not
pressed for 10 seconds, the display returns to normal. If the input has still not been
concluded, call up the input menu again.
The menu and entries are blocked if there is a converter disturbance.

Selection menu:
Hold key 1 down until the selection menu appears → release
The selected line flashes.

Figure 6.7.1: Selection menu. Left - SP system, right - TP system

Key 1 : first menu line

Key 2 : one line back
Key 3 : one line forward
Key 4 : confirm

After confirmation with key 4, the menu appears for inputting energy values in kWh.

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Figure 6.7.2: Energy input menu

The menu data are shown in line 1 on the display.

In line 2, the cursor "*" marks the present position of the entry. After the entry has
been called up, the cursor is at the end. Key 1 shifts the cursor to the left. Each time
Key 4 is pressed, the cursor moves one space to the right.

Key 1 : first figure

Key 2 : increase figure at the cursor position
Key 3 : decrease figure at the cursor position
Key 4 : confirm figure, move the cursor one position to the right
Key 4 : pressed at the last input position = confirm the entire input

The individual values are set with key 2 and key 3. After confirmation at the last
position, the display returns to normal.

The energy mode for the inverter in question is selected via the SIO inputs E15=1 for
INV1 or E23=1 for INV2 (Chapter 2.5.2.2). The converter can be started. The energy
values entered are shown in the 4th line and are worked through down to zero.

Figure 6.7.3: Operation with energy specification active. Left - SP system, right - TP
system

Once the zero value has been reached, the corresponding SIO output on the DICU
(A5 for INV1 and A11 for INV2) moves to 1, the converter runs on at the set power.
The "Input energy!" message is displayed in the 4th line. The PLC should ensure that
the converter is switched off.
Note that when the furnace is not operated with energy preselection, output A5 or
A11 emits a pulse for each kWh consumed.

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Figure 6.7.4: Energy target values worked through. Left - SP system, right - TP
system

The process can be repeated. The energy setpoints entered are saved in the DICU
and remain available. These values can naturally be corrected.

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6.8 Operating the system with 2 customer modules

The DICU allows the system to be operated with 2 customer modules.

The two customer modules are connected to the DICU's COM1 serial interface.

DICU

X100 X101
COM1 COM2

Customer Module 1

Customer Module 2

102v01

Figure 6.8.1: DICU with 2 customer modules

The measured values and error messages are visible on both customer modules. If
the COM2 interface has command priority, error messages are only visible on the
first customer module (KM1).
If the COM1 interface has command priority, only the potentiometers on one of the
two customer modules are active.
The customer module in question is enabled by the SIO inputs (X301/3 and X300/10)
on the SIO card.
A switch from one customer module to the other can only be made when the
converter is switched off. A change of status for inputs E8 and E11 is ineffective
during operation (Chapter 2.5.2.2).
A self-test is always run through if command priority changes from COM1 to COM2
(or vice versa) and if command priority passed to COM1 on one customer module to
the other (or vice versa). This means that the current error display is lost.

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E11 E8 Processor Cust. module 1 Cust. module 2

X301/3 X300/10 to COM2 KM1 to COM1 KM2 to KM1
1 0 or 1 Active Only display Only display
0 0 Inactive Master, Only display
potentiometers
active
0 1 Inactive Only display Master,
potentiometers
active

Figure 6.8.2: DICU with 2 customer modules, operating alternatives

6.9 Connecting the customer module to COM2

The customer module is normally connected to the DICU's COM1 interface. The
baud rate of this RS232 interface is set to matching that of the customer module.

COM2 on the DICU is an RS422 interface with an adjustable baud rate. The other
parameters are identical to those of the COM1 interface.

The customer module can also be connected to the COM2 interface, although this
requires some extra devices, cables and amendments to the data record.

Figure 6.9.1: Customer module connected to the DICU's COM2 interface

• An RS422/RS232 converter (GES9421109P1 from W&T) is deployed between

COM2 and the customer module
• A special cable GES3 520 391R1 socket/socket (made by ABP) connects
COM2 and the converter
• A null modem cable (DICU cable) connects the converter to the customer
module
• Set the SIO input E11=1 (X301/3) to give command priority to COM2
• Set the following parameters in the data record in window F15: UD76=9600
(baud rate) and UD123=2 (command priority to COM2). Save the amended
data record in the DICU
• Reboot the DICU. The customer module should run via COM2

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6.10 Displaying setpoints (old customer module software versions,

not up-to-date)
The old software versions (versions 06.05.97, 26.01.98 and 12.04.00) show the
setpoints from the potentiometers connected to the customer module on the module's
display.

Figure 6.10.1: Setpoint display. Left – customer module has command priority, right –
customer module without command priority

The entries of both potentiometers are displayed on the customer module. The
position of the slider is converted to the appropriate target power or target voltage.
The type of setpoints is determined by parameter UD119 in window F10.
Line 1 : target value of potentiometer 1
Line 2 : target value of potentiometer 2

The active potentiometer in SP systems is selected by the SIO input E9 (X300/11) on

the DICU. Both potentiometers are active in TP systems.

If the customer module has command priority and the potentiometers are active, the
setpoints taken on by the DICU are displayed in lines 3 and 4. The values set with
the potentiometers are not taken on by the DICU until the potentiometers are no
longer moved. The values taken on can deviate from those input due to rounding off
or to voltage/power reduction.
Line 3 : DICU target value 1
Line 4 : DICU target value 2

The display switches back to normal some 5 seconds after the last adjustment of a
potentiometer of its own accord. The next time a potentiometer is adjusted, the target
value display is shown again.

Wire-wound potentiometers are sometimes connected to the customer module. If the

slider is positioned over the transition between two of the potentiometer's windings or
if there are heavy vibrations, the customer module regards this as a constant
adjustment of the potentiometer and assesses this as small changes to the target
value. In such a case, practically only the target value is shown on the display and
the actual values are seldom switched to.
This is unacceptable in systems without a processor which are controlled solely
through potentiometers. The customer requires the actual values on the customer
module display. This is why later versions of the customer module software show
only the actual value and not the setpoint.

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For this reason, this target value display is disabled in the current customer module
software. The system reacts immediately to the adjustment of a potentiometer, so
that the latest actual values can always be seen on the display.

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6.11 Testing the analog outputs of the customer module

The actual values are displayed on the customer module. In addition, the customer
module has 6 analog outputs for the latest actual values. The analog outputs of the
customer module are described in Chapter 3.1.1.1.
The nominal values are defined in window F1 and the calibrated values for the
analog outputs in window F15 – Chapter 5.2.15. In TP systems, the calibrations for
both the voltages and the frequencies are identical.
As the reference voltage of the customer module is not defined precisely and is
approx. 11 VDC, the amplitude of the voltages at the analog outputs cannot be
calculated exactly.

In test mode, the DICU offers the option of setting the analog outputs to the nominal
values. The analog outputs can be set to the nominal values in window F1 from the
service PC. The amplitudes of the analog voltages can be adapted with the
parameters in window F15. The voltages at the outputs can be measured with a
voltmeter.
Please note: The digital display remains at zero during this test!

6.11.1 Setting the analog outputs

• Connect the service PC directly with the customer module using the null
modem cable (DICU cable)
• Start the service PC in offline mode
• Set the calibrated values in window F15, US-, UT
• Activate the analog outputs of the customer module with the BK1 command.
The analog outputs react with a delay of up to 20 seconds
• Measure the analog values
• Disconnect the link to the customer module with the BK0 command
• Only now can the values in window F15 be effectively changed. Save the new
parameters with US- and set internally with UT
• Repeat the process with the commands BK1, measurement, BK0, change
parameters, save etc. until the settings of the analog outputs are correct

Subsequently save the parameters to the customer file and in the DICU.

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7 Commissioning a DICU converter

This chapter describes the commissioning of the DICU with a frequency converter.
This description is also useful for repairing or maintaining a DICU converter.

A prerequisite for commissioning the DICU is that the converter and all the
associated equipment has been checked and set.
This description assumes that:
• the system has been properly assembled
• the wiring has been performed in accordance with the circuit diagram
• the high voltage infeed, along with high voltage power switches, transformers,
monitoring etc., has been checked and set
• the water cooling has been examined and is functioning properly
• the hydraulics are in good working order
• the PLC is functioning properly
• the grounding of the converter and the furnace has been checked and is in
order

Observe all safety instructions associated with work on electrical equipment,

particularly the ABP directives.

7.1 Equipment required

The following measuring devices at least should be available to commission a DICU

converter:
• a service PC with the necessary software
• DICU cable
• a digital storage oscilloscope, preferably with 4 channels and a band width of
200MHz
• a high voltage differential probe 1000:1
• 4 voltage probes 10:1 or 1:1
• 1 current clamp, measuring range 30A, to measure the firing pulses
• 1 flexible current loop, measuring range 2000A
• 1 multi-meter

An up-to-date circuit diagram of the system is required. A converter calculation sheet

and a furnace calculation sheet facilitate the adjustment of the system.

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7.2 Summary of the most frequent commands

What follows is a summary of the most frequently used commands for the GrTest
software. A detailed description of all DICU commands can be found in Chapter 4.

Loading/saving data

Data are stored in the DAT directory or on the EEPROM of the CPU card.

UL- This command loads the GLODAT.DAT file – work file (HEX characters)
from the RAM of the service PC
ULNN Loads the data from the nn.DAT file (HEX characters); nn = file name.
URNN Loads the data from the nn.DAX file (plain text). This command is seldom
used and the results should be checked carefully.
EUL- Loads the data from the EEPROM on the CPU card.

US- Writes the data to the GLODAT.DAT file

USNN Saves the data to the nn.DAT file (HEX characters)
UPNN Saves the data to the nn.DAX file (plain text)
EUS- Writes the data to the EEPROM on the CPU card. The data are definitively
saved in the DICU after commissioning.

FU-20 The last number in this window (bottom right) is the check sum for the
current data record held in the PC's RAM.

Changing parameters

The only parameters that can be changed are those currently visible on screen. Thus
first open the relevant window and only then change the parameters.

UDNN=XXX although also UDNNPXXX. nn is the parameter number and XXX the
parameter value (Chapter 5.2).

Saving the error log file

Before saving the error log file, it is recommendable to synchronize the DICU time
with the service PC time (Chapter 4.4.2.2).

EZL- Saves the error list from RAM (RAM buffered by battery) on the CPU card
to the PC's RAM.
ZPNN Saves the error list from RAM as plain text to the nn.ERX file in the ERR
directory. The ZPNN command should be executed promptly after the
EZL- command.

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Converter swing down, short start, long start and operation

SP and C1/C2 systems:

WS Inverter ring test. The WS command sends a firing pulse to the thyristors
of the starter device. Release or line voltage are not required.
STN0 Short start, abort after the warm-up phase - UD102 in F7. Start with the
default control strategy - UD119 in F10
STN1 Long start, abort after the start control time - UD103 in F7. Control strategy
as with the STN0 command.
SNxxx Starts the converter with the target value xxx. The type of setpoint – of the
voltage, of the current or of the power – is determined by UD119 in F10.

TP systems:
WS1-2 In TP systems, the WS1 command fires the starter device of inverter 1
and the WS2 command fires the starter device of inverter 2.
STN1-3=0 Short start, abort after the warm-up phase - UD102 in F7. STN1=0 –
short start only INV1, STN2=0 – short start only INV2 and STN3=0 –
short start in TP mode.
STN1-3=1 Long start, abort after the start control time - UD103 in F7. STN1=1 –
long start only INV1, STN2=1 – long start only INV2 and STN3=1 – long
start in TP mode.
SNxxx=yyy Starts the TP converter with the power setpoints xxx and yyy.

Switching the converter off

# Switches the converter off. Same effect as switch-off from SIO input E1,
on/off – Chapter 2.2. Normal switch-off with ramp.
## Press the # key twice. After the second # keystroke, the converter is
switched off immediately without a ramp.
Note: Even if the service PC does not have command priority and is only
functioning as an observer, the # is effective and initiates switch-off (with
the error message "!CMD Emergency-Off m1_090_001_001").

Deleting errors

+ Deletes (acknowledges) errors. Errors displayed are deleted. The function

UT, DICU self-test, is executed automatically for the majority of errors.
If errors are displayed but commands are nevertheless entered without
having first deleted the errors, these errors then continue to be displayed.
The continued display of error messages is first stopped by the +
command.

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Switching firing pulses on for test purposes

GAxxx The firing pulses are shifted to the angle xxx°el.

GZ The GZ1 or GZ2 command switches all rectifier firing pulses on and
positions them at the angle set with GAxxx. At the same time, rapid
measurement is started with the GZ1 command (. – dot) and medium
measurement with the GZ2 command (, - comma).
The GZ0 command switches the firing pulses off. More in Chapter 7.6.2.
WT In TP systems, the WT1 command switches on the firing pulses for
inverter 1 or the WT2 command the firing pulses for inverter 2 at a
frequency of around 60Hz. The firing pulses can only be switched on for
one inverter at one time. The WT0 command switches the inverter firing
pulses off.

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7.3 Creating a data record

A new data record is always created for new systems or after a DICU retrofit. The
system-specific parameters and factors are entered in this data record.

Remark: It is not recommendable to take an existing data record and adapt it to a

new system. Each finished data record has its own specific settings that cannot
always be superimposed on a new system.

These specimen data records are kept in the DAT directory of the respective version.
The following files are available:

STND56 SP, line 50 Hz, nominal furnace frequency between 55Hz-200Hz

STND66 SP, line 60 Hz, nominal furnace frequency between 55Hz-200Hz
STND206 SP, line 50 Hz, nominal furnace frequency between 200Hz-500Hz
STND266 SP, line 60 Hz, nominal furnace frequency between 200Hz-500Hz
STND506 SP, line 50 Hz, nominal furnace frequency between 500Hz-1500Hz
STND566 SP, line 60 Hz, nominal furnace frequency between 500Hz-1500Hz
STND2006 SP, line 50 Hz, nominal furnace frequency between 1500Hz-4000Hz
STND2066 SP, line 60 Hz, nominal furnace frequency between 1500Hz-4000Hz
TWIN56 TP, line 50 Hz, nominal furnace frequency between 55Hz-200Hz
TWIN66 TP, line 60 Hz, nominal furnace frequency between 55Hz-200Hz
TWIN206 TP, line 50 Hz, nominal furnace frequency between 200Hz-500Hz
TWIN266 TP, line 60 Hz, nominal furnace frequency between 200Hz-500Hz
TWIN506 TP, line 50 Hz, nominal furnace frequency between 500Hz-1500Hz
TWIN566 TP, line 60 Hz, nominal furnace frequency between 500Hz-1500Hz
TWIN2006 TP, line 50 Hz, nominal furnace frequency between 1500Hz-4000Hz
TWIN2066 TP, line 60 Hz, nominal furnace frequency between 1500Hz-4000Hz

A detailed description of all DICU parameters can be found in Chapter 5.2. Only the
values are changed in this chapter, without explaining this in any detail.

It is assumed that the DICU hardware (PROMs, jumpers, filter fittings, MF

transformer) matches the system (operating mode, frequency) – Chapter 2.6.

What is given here is just a "rough guide" for preparing a new system file. Only the
necessary parameters are changed. The new file can be prepared at a desk without
a link to the DICU.
Some further parameters are adapted later on when the converter is commissioned.
These are explained further below.

Enter the parameters one by one from window F1 to window F15. After a window has
been completed, save the data with the US- command. A self-test only makes sense
at the earliest after entering the parameters in window F5. The parameters in
windows F1 to F5 are heavily dependent on each other and a premature self-test
would obviously lead to a host of error messages.

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7.3.1 Entering parameters

Launch the GrTest software with the attributes to match the system in offline mode
(GRTEST XYZ).
Load the relevant specimen file and save it with US-. An error message can appear,
but this can be ignored for the time being.

A data record is prepared in this chapter based on the following example system:
• 24p rectifier, connected in parallel/series, line 50Hz, 845V
• TWIN POWER, both furnaces identical, 4.25MW, 3000V, 250Hz
• Language: Polish

Launch the software with the GRTEST 524T command. Load the specimen file with
the ULTWIN206 command and save it with US- as GLODAT.DAT. After entering the
parameters in each window, save the data with US-.

In the following figures, the input window from the specimen file is shown on the left
and the values to be input (plus any comments) can be seen on the right.

7.3.1.1 Window F1

F1 INV 1 Nom-Data, Transformer-Ratios

1 IN1 Nom-Frequency..: 200.000 Hz 250, is corrected later during commissioning

(Chapter 7.5.1)

10 IN1 Nom-Output-Volt: 1000.000 V 3000

8 IN1 Nom-FurVolt/LEM: 1000.000 V 2276, is entered later
16 IN1 Nom-Firing Volt: 1000.000 V appears automatically, as with UD10
19 IN1 Nom-Current....: 1000.000 A 2000 – from the UR calculation sheet
24 IN1 Nominal-Power..: 500.000 kW 4250

33 IN1 Trec/IInv-Nom..: 100.000 æs 130, UR calculation sheet Phi-Min

35 IN1 dIdtàMinèMinINom 30.000 A/æs 26 – from the UR calculation sheet

55 INE UW-Trans.-ext..: 10.000 V/V 30 - from the circuit diagram

54 INE UO/LEM-Transext: 10.000 V/V 28.51, is entered later
59 INE IW-Trans.-ext..: 1000.000 A/V 2000 – from the circuit diagram

Figure 7.3.1: Window F1

The nominal frequency UD1 is subsequently set correctly during commissioning.

Parameters UD8 and UD54 are first determined after entry in Window F5 – Chapter
7.3.1.5

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7.3.1.2 Window F2

F2 Inverter 1 V/P - Reduction

11 IN1 Reduced-Volt.1.: 2548.828 V

12 IN1 Reduced-Volt.2.: 2100.586 V first UD13=1400, then UD12=1500
13 IN1 Reduced-Volt.3.: 1649.414 V 1400

25 IN1 Reduced-Power 1: 3826.660 kW

26 IN1 Reduced-Power 2: 3399.170 kW
27 IN1 Reduced-Power 3: 2975.830 kW
28 IN1 Reduced-Power 4: 2548.340 kW
29 IN1 Reduced-Power 5: 2125.000 kW
30 IN1 Reduced-Power 6: 1701.660 kW
31 IN1 Reduced-Power 7: 1274.170 kW

32 IN1 Minimal-Power..: 83.008 kW 210, ca. 5% der nominal power UD24 in F1

Figure 7.3.2: Window F2

The furnace sinter voltage is set by ABP Dortmund to 50% of nominal voltage, thus
1500V. During sintering mode, the PLC activates level 2 of the reduced voltage.
As level 3 is equivalent to 1649V, thus greater than 1500V, this voltage must first be
set smaller. Only then can level 2 be set correctly.

The power levels are normally adjusted at the installation site itself.

Experience has shown that it is best to set the minimum power UD32 to around 5%
of nominal power.

7.3.1.3 Window F3

F3 Inverter 1 - Limits

2 IN1 Max-Frequency..: 300.049 Hz

3 IN1 Min-Frequency..: 166.748 Hz 125, 50% of nominal frequency UD1 from F1

14 IN1 Max-Output Volt: 3451.172 V

15 IN1 Min-Output Volt: 298.828 V
9 IN1 Max-FurVolt/LEM: 1150.391 V
17 IN1 Max-Firing Volt: 3451.172 V
20 IN1 Max-Current....: 2500.000 A
21 IN1 Min-Current....: 300.781 A
22 IN1 Diff-Current...: 300.781 A

Figure 7.3.3: Window F3

Only the minimum frequency is set to 50% of nominal frequency in this window.
Parameter UD9 is automatically corrected only after the later entry of UD8 in F1.

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7.3.1.4 Window F4

F4 INV 2 - Nominal Data, Limits

164 IN2 Nom-Frequency..: 200.000 Hz 0, import data from F1

166 IN2 Min-Frequency..: 133.398 Hz

173 IN2 Nom-Output-Volt: 1000.000 V

171 IN2 Nom-FurVolt/LEM: 1000.000 V
179 IN2 Nom-Firing Volt: 1000.000 V
187 IN2 Nominal-Power..: 500.000 kW

196 IN2 Trec/IInv-Nom..: 100.000 æs

198 IN2 dIdtàMinèMinINom 30.000 A/æs

Figure 7.3.4: Window F4

As both furnaces are identical, import the data from window F1 into window F4 with
the UD164=0 command.
In SP systems, although the values in F4 are unimportant in theory, they are
nevertheless always set identically to those in F1.

7.3.1.5 Window F5

F5 REC - Nom-Data, Transformers, Line

45 REC Nom-Mains Volt.: 500.000 V 845

49 REC Nom-Current....: 2000.000 A 1000, for two 12p rectifiers in parallel
69 REE UD-Trans.-ext..: 5.000 V/V 10 - from the circuit diagram
71 REE ID-Trans.-ext..: 1000.000 A/V 1000 - from the circuit diagram

117 REC Line Rot. 1/2..: 0.000 --

118 REC Adv.Curr.Thyr.2: 0.000 --
129 REC Line Rot. 3/4..: 0.000 --
130 REC Adv.Curr.Thyr.4: 0.000 --

213 REC Alfa-Diff (24p): 0.000 ø

214 REC Phase-Diff.1-2.: 30.000 --
124 UWG Type Europe/USA. 0.000 --

Figure 7.3.5: Window F5

The 24p rectifier consists of two 12p rectifiers connected in parallel, which in turn
consist of two 6p rectifiers connected in series. That is why the line current is half the
size of the MF current (UD19 in F1). This declaration enables the DICU to recognize
the rectifier's circuit arrangement automatically.

The other line parameters are first determined during commissioning.

Only now is the nominal rectifier output voltage (thus the inverter input voltage)
calculated correctly as parameter UD145 in window F19. This voltage is now entered
as parameter UD8 in window F1. Parameter UD54 in window F1 can be calculated
with this voltage – Chapter 3.2.1.2. Then update the values in window F4 with the
UD164=0 command and save them with US-.

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The self-test UT can be started after making these entries (if errors are displayed,
acknowledge them for the time being with +). An error message should not normally
appear after the self-test. If an error message is nevertheless shown please refer to
Chapter 8.1.1.

7.3.1.6 Window F6

F6 Rectifier - limit values

46 GR Max-Netzspg....: 972.080 V
47 GR Min-Netzspg....: 675.835 V
48 GR Diff-Netzspg...: 42.085 V

50 REC Discont-Current: 50.081 A

211 REC DiscCurr.active: 1.000 --

43 REC Mains Frequ-Err: 1.000 Hz

44 REC Mains Phase-Err: 5.000 ø

39 REC Alfa-Min.......: 1.000 ø 5

Figure 7.3.6: Window F6

Alpha-Min is set to 5°el. In systems connected to quite weak power grids, this angle
is sometimes increased during commissioning from 7°el to 10°el.

7.3.1.7 Window F7

F7 Start - Parameters
23 IN1 Advance-Current: 199.219 A
18 IN1 Start-Voltage..: 298.828 V stays, warm-up OK
4 IN1 Start Time-1Imp: 601.563 æs
5 IN1 Start Time-2Imp: 601.563 æs
6 IN1 Start Phase-Reg: 1199.219 æs 1200, check Phi start in FU-1
167 IN2 Start Time-1Imp: 601.563 æs
168 IN2 Start Time-2Imp: 601.563 æs
169 IN2 Start Phase-Reg: 1199.219 æs 1200, check Phi start in FU-2

40 REC Alfa-Adv.-Curr.: 120.000 ø 100, from experience, correct at commissioning

41 REC AlfaWarmUp Norm: 80.000 ø
42 REC AlfaWarmUp Twin: 70.000 ø

7 IN1 Start Waittime.: 5.000 ms

102 REG Warm-Up-Time...: 50.000 ms
103 REG Start-Reg.-Time: 140.000 ms

Figure 7.3.7: Window F7

The pre-mag current angle UD40=100 has proven itself over the years and is
changed during the DICU adjustment. The pre-mag current angle and the warm-up
angle are corrected during commissioning.
Set the value for Phi start in window FU-1 (INV1) to around 125 for SP systems or to
around 204 for TP systems. In TP systems, Phi start must also be set for INV2 in
window FU-2 (INV2).
Change Phi start with parameter UD6 or UD169.

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Change parameter UD6, save the data and, after UT, check the value in window FU-
1. Repeat the process until the value for Phi start is correct.

Check Phi-Min and warm-up in window FK. These values can be found in window
FK1 for INV1 and in window FK2 for INV2.

FK1 INV1 Load Circuit, Test-Data

F0 1/(2ã*ûLC)....: 247.7 Hz
LK Commut.-Coil..: 19.2 æH
VInv àminèminInom: 2566.5 V
---------------------------------------
Phi-Min: 31 182.1æs 16.3ø 249.3Hz
àminInom 37 217.4æs 19.5ø 250.0Hz
VminInom 90 528.8æs 47.7ø 252.1Hz
WarmUp.: 90 528.8æs 47.7ø 252.1Hz

Figure 7.3.8: Window FK, section

A value of around 20°el is recommended for Phi-min. The value for the warm-up
should be between 45°el – 70°el (better 65°el).

LK from window FK is first approximately adapted to the inductivity of the

commutation choke from the UR calculation sheet with parameter UD35 from F1.
Phi-min is then influenced by parameter UD33 from F1. Parameter UD35 from F1
also affects Phi-min and both parameters have a mutual influence on each other.
These parameters are checked and definitively optimized during commissioning.

Warm-up is influenced by parameter UD18 (start voltage) from F7. Start voltage
UD18 is practically without meaning and is only used for calculation purposes.

Parameter UminInom in window FK may not be highlighted in red and its value is
unimportant. If VminInom is highlighted in red, increase parameter UD15 from F5
until VminInom is no longer highlighted in red.

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7.3.1.8 Window F8

F8 Regulation - Parameters 1

82 REG Int -Part...UP: 0.020 --

83 REG Diff -Part...UP: 0.000 --
84 REG Brake-Part...UP: 1.000 --
85 REG Alfa -Amplfy.UP: 50.000 --
86 REG Phi -Amplfy.UP: 50.000 --
87 REG Start-Amplfy.UP: 50.000 --

88 REG Int -Part... I: 0.020 --

89 REG Diff -Part... I: 0.000 --
90 REG Brake-Part... I: 1.000 --
91 REG Alfa -Amplfy..I: 50.000 --
92 REG Phi -Amplfy..I: 50.000 --
93 REG Start-Amplfy..I: 50.000 --

94 REG Diff -Amplfy..T: 10.000 --

Figure 7.3.9: Window F8

All parameters remain unchanged. The parameters are set to the optimum value from
experience.

7.3.1.9 Window F9

F9 Regulation - Parameters 2

95 REG Tendency-Factor: 3.000 --

97 REG Brake-Level ...: 0.100 --
99 REG UI-WarningLevel: 0.100 --

98 REG Responce-Level.: 10.000 --

100 REG Max-Reg.Action.: 64.000 --
101 REG Reduced-Action.: 4.000 --

132 REG Phi-Opt Norm...: 1.000 --

134 REG Fact.Th/Tc Norm: 1.000 --
133 REG Phi-Opt Twin...: 1.000 --
135 REG Fact.Th/Tc Twin: 1.000 --

Figure 7.3.10: Window F9

All parameters remain unchanged. The parameters are set to the optimum value from
experience. Exception: UD98, which has to be increased to around 30 on some very
low frequency systems (<75 Hz) in order to stabilize regulation at voltage limit.

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7.3.1.10 Window F10

F10 Regulation - Parameters 3

119 REG V/I/P-Regulator: 3.000 --

120 REG Phase-Regulator: 2.000 --

209 REG Slope-Time.....: 2.000 s 5

212 REG Off-Time.......: 0.000 s 3

96 REG Warm-Up Amplify: 200.000 --

210 REG Warm-Up with ID: 1.000 --
121 REG Warm-Up Phi-Opt: 0.000 --

Figure 7.3.11: Window F10

UD119=3 remains because the melting system is power-controlled.

The ramp time and switch-off time are set a little higher to prevent flicker. These
values should be discussed during commissioning with the customer or the power
supply utility.

7.3.1.11 Window F11

F11 Inverter 1/2 - Electronic 1

56 INE UW(O)-Fact.-int: 21.300 V/V Default for TP and MF transformer P12

58 INE UW-Offset......: 0.000 V
57 INE UO/LEM-Offset..: 0.000 V
60 INE IW-Factor-int..: 0.213 V/V
61 INE IW-Offset......: 0.000 A
162 INE PW-Factor......: 1.000 --
163 INE PW-Offset......: 0.000 kW

63 INE Drive-Current .: 10.000 A 7.5

64 INE Drive-Curr.Fact: 3.635 A/V 2.249
62 INE IDIF-Factor-int: 1.000 V/V

115 INE Time Adv.-Pulse: 80.000 æs

116 INE With LEM-Meas..: 1.000 --

Figure 7.3.12: Window F11

If the correct specimen file has been selected, parameter UD56 has the correct
value. Compare with the table in Figure 2.6.19.

Parameter UD63 is set to 7.5 for TP systems. UD63=10 can remain for SP systems.
Parameter UD64 is corrected to 2.249.

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7.3.1.12 Window F12

F12 Inverter 1/2 - Electronic 2

51 INE UW-Ripple-Filt.: 55.000 æs

52 INE IW-Ripple-Filt.: 3.000 æs
53 INE IW-Regul.-Filt.: 4700.000 æs

128 INE Iinv-Influence.: 0.000 --

114 INE Resol.IInv-Infl: 5.000 BIT
125 INE Tcomm-Meas.Norm: 1.000 --
126 INE Tcomm-Meas.Twin: 1.000 --

127 INE Tcomm-Calculate: 1.000 --

38 INE Corr..UInv/Tcom: 0.400 --

65 INE D/A-Range .....: 6.600 V 6.8

66 INE D/A-Offset.....: 0.325 V 0.275

Figure 7.3.13: Window F12

If the correct specimen file has been selected, the filter parameters have the correct
values. Compare with the table in Figure 2.6.19.

Parameters UD65 and UD66 are corrected in line with the latest knowledge.

7.3.1.13 Window F13

F13 Rectifier - Electronic

70 REE UD-Factor-int..: 20.000 V/V 24, line transformer 0.5VA

72 REE ID-Factor-int..: 0.196 V/V

73 REE IDMIN-Fact-int.: 0.319 V/V

67 REE UR Zero-Angle..: 48.000 ø 51, line transformer 0.5VA

Figure 7.3.14: Window F13

The line voltage transformers on the backplane and the subprint (for the DICU 24p)
have had a power output of 0.5VA since 2012, which means that parameters UD67
and UD70 need to be changed (Chapter 5.2.13).

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7.3.1.14 Window F14

F14 Logbook,Supervising, Bus,CPU,SIO

79 LOG Zyklus-Zeit....: 21860.000 æs

80 LOG Fehlerzeit Gr.1: 1.000 s
81 LOG Fehlerzeit Gr.2: 5.000 s

113 BUS System-Takt....: 8000.000 kHz

74 CPU ADC-Referenz...: 5.000 V

75 CPU RMS-Scalefaktor: 1.000 V/V
77 CPU Zuendspannung..: 48.000 V
78 CPU ZuendMessteiler: 15.681 V/V

208 SIO PRed 7/3 Stufen: 7.000 -- 3

Figure 7.3.15: Window F14

Only 3 power reduction levels are selected for TP systems. This also allows the sum
power (REC power) to be limited.

7.3.1.15 Window F15

F15 Customer-Mod., Communication,COM2

110 TEX Def.-Language..: 0.000 -- 3, Polish

104 DIS MaxRange I-Inv.: 1000.000 --

105 DIS MaxRange U-Inv.: 1000.000 --
106 DIS MaxRange P-Inv.: 1000.000 --
107 DIS MaxRange F-Inv.: 1000.000 --

108 DIS MaxRange Pot 1.: 1000.000 -- 4250

109 DIS MaxRange Pot 2.: 1000.000 -- 4250

122 DIS Pot1=P1+P2/P1..: 0.000 -- 1

123 DIS ComChan. CModul: 1.000 --

76 CPU COM2-Baudrate..: 4800.000 BAUD

Figure 7.3.16: Window F15

The system is installed in Poland, which is why Language 3 (Polish) is selected for
error messages.

The calibrated values for both potentiometers must correspond to the nominal power.

Parameter UD122=1 determines that each potentiometer is responsible for each

furnace (sum power cannot be adjusted).

Further windows, F16 to F21, only serve monitoring purposes and the values
displayed there cannot be changed directly.

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7.3.2 Saving parameters

Save the new data record after all parameters have been entered, related
parameters checked in windows FK, FU-1 and FU-2 and the self-test has been
successfully run with UT.
Until now, the data have been saved to the GLODAT.DAT file with the US-
command. Save the data to the customer-specific nn.DAT and nn.DAX files with the
USNN and UPNN commands.
Once the new DICU is available, the service PC can be connected to the DICU. Save
the data on the CPU card with the EUS- command (Chapter 7.9).

Annex A6 contains a printout for the customer file MUSTERE.DAX compiled here.
The check sum for this file – DD87 – can be read off in window FU-20.

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7.4 Starting the DICU with the converter

The DICU is normally installed in the door of the converter cabinet. The plug for the
line supply voltage is cabled.
The customer module is connected to COM1 (X100), either directly or indirectly via a
fiber-optic link.
A processor or a PLC communication processor can be connected to COM2 (X101)
via a fiber-optic link.

Pull the plug from COM1 and connect the service PC to the DICU with a null modem
cable.

Switch the control voltage on. The DICU boots up (which can take up to one minute).
After boot-up, the topmost LEDs on the CPU card can be lit green or red. The first
red LED signals a converter or DICU error, although this does not prevent
communication being established with the service PC.
The second LED on the CPU card should light up in green (internal DICU
communication – otherwise a DICU hardware error).

Switch the "DICU Test" service switch on, which is signaled by LED10 lighting
up on the SIO card (inputs active). This switch is usually located in the door of the
converter cabinet or is mounted in the converter cabinet at the side of the DICU.

LED 0 on the SIO card (release) must not necessarily be lit when establishing the link
between the DICU and the service PC.

Launch the software on the service PC in the version matching the DICU hardware –
Chapter 4.2.2.
Start the connection to the DICU with the GRTEST command. The computer
attempts to establish a link to the DICU. Providing the GrTest program has been
started correctly and communication with the DICU has been established, the third
LED from the top on the CPU card lights up green. The computer screen displays the
FG1 and FW1 status windows and ONLINE appears in the top right-hand corner. Any
DICU errors are displayed at the bottom of the screen.
Once the self-test has ended, there should not be any messages highlighted in red
for the pulse amplifiers displayed in the bottom lines of the two status windows.
Further pulse amplifier messages for a 24p DICU or TP DICU can be found in
windows FG2 and FW2.
As the +48V DC power unit was only switched on briefly, the +48V DC drops in a
couple of seconds to 0V. The screen then displays the errors for the pulse amplifiers,
which is normal.
Any other errors are displayed below the windows. Such errors could be caused by
an incorrect data record in the DICU.
When the DICU boots up, a data record is loaded from the DICU's CPU. Check the
correctness of the data in windows F1 to F15 or the check sum in window FU-20.
The correct data record should then be loaded, if necessary.
Initially acknowledge errors with +. Load the nn.DAT data record in the DAT directory
with the ULNN command. Save the data record in the GLODAT.DAT working file with
the US- command and send the data to the DICU's CPU card with the EUS-

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command, where they are stored in the EEPROM. Subsequently set and test the
DICU for the new data with the UT command.
No further error messages should appear.

If error messages do appear, please follow the procedure in Chapter 8.1.

Once the DICU has booted up and the first 3 LEDs on the CPU card are lit green, the
further tests can be made.

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7.5 Testing converters without high voltage

Some DICU settings can be tested by the system, without high voltage being
switched on.
In principle, the wiring and the parameters for the rectifier and inverter firing pulses in
new systems have already been tested. However, the correct position of the firing
pulses can only be tested with the complete system.

The energy from the starter device can be used to excite swings in the load circuit.
The inverter firing pulses for diagonals A and B are generated in the DICU by the
measured furnace voltage (load circuit voltage).
Check whether the load circuit is complete and correctly connected (cut-off switch
closed, furnace ground switch open, starter device connected and supplied with
voltage). The relay for switching the supply voltage to the starter device may need to
be bridged or permanently clamped. Check the DC voltage on the start capacitor.

In the best case scenario, ring test should be made with the furnace empty. The
oscillations are not damped so heavily when the furnace is empty and more periods
of the furnace voltage are therefore visible.

7.5.1 Testing the inverter firing pulses

The pulse arrangement and feedback of the inverter's output voltage (furnace
voltage) is fixed for the thyristor converter and also for the IGBT converter.

Figure 7.5.1: The inverter's firing pulse arrangement

The pre-mag current pulse is supplied to the thyristors of diagonal A (thyristors

between L+ at the input and rail U at the output and L– at the input and rail V at the
output).
The energy from the starter device must discharge on rail U.

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Channel 1: connect the probes with the necessary voltage rating to "U" and
•
"V" ("U" to "+" input, "V" to "-" input).
• Channel 2: connect the "UWR output voltage" (MB8 on the WRS card)
• Channel 3: "firing pulse A, pre-mag current" (MB16 on the WRS card)
• Channel 4: "firing pulse B" (MB15 on the WRS card)
• Trigger: "firing pulse A, pre-mag current" signal (MB16 on the WRS card)
negative slope, "single shot". set the trigger point to approx. 10% of the
screen
The screen should depict 7 to 8 half-waves.

The ring test process is triggered by WS in SP systems and by WS1 or WS2 in TP

systems.
Decaying oscillations in the inverter output voltage or furnace voltage and the firing
pulses for diagonals A and B should appear.
Figure 7.5.2 shows the influence of the filling level in the furnace. The more the
furnace is filled, the more the load resonant circuit is damped and there are fewer
periods of load voltage.

3 4

Ring test with the furnace empty

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Ring test with the furnace in sinter operation

Channel 1, blue: furnace voltage, measured directly

Channel 2, turquoise: WRS card; MB8 "UWR output voltage"
Channel 3, lilac: WRS card, MB16 "firing pulse A"
Channel 4, green: WRS card, MB15 "firing pulse B"
Trigger: Channel 4, "single shot"

Figure 7.5.2: Ring test

The real U/V voltage should start with a positive half-wave. The voltage at MB8 on
the WRS card should start with the same course, although with a negative half-wave.
The voltage at MB8 is inverted compared to the real inverter output voltage.
If the real inverter output voltage starts with a negative half-wave, the starter device if
probably connected incorrectly. If the real inverter output voltage is in phase with the
waveform of the voltage at MB8, the MF voltage transformer has been wrongly wired.

If the waveform is correct, measurement of the high voltage with probes is not
necessary for the time being. The voltage from MB8 on the WRS card is sufficient.

If nothing happens after the WS command (WS1 or WS2), the pulse transformers are
probably connected incorrectly, the pulse current limit of the pulse amplifiers is set
too low (UD63 in F11) or there is some other hardware error (e.g. defective WRS
card).

Search hints:
1. Firing pulse present for start thyristors at MB18 on the WRS card?
2. Measure the firing pulse with a current probe; present at the gate of the start
thyristors?
3. Is the DC voltage on the start capacitor correct?
4. Does this voltage collapse after the WS command?
5. Decaying oscillations present on the secondary side of the MF voltage
transformers?
6. Does the real inverter output voltage begin with a positive half-wave?
7. Is the voltage at MB8 on the WRS card identical to the real inverter output
voltage or is it inverted?

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Now the firing pulses for diagonals A and B can be checked. Instead of the high
voltage probes, a small current probe can now be used to measure the thyristor firing
pulses. The firing pulses are first tested for the one diagonal and then for the other,
one after the other for all inverter thyristors.
The firing pulses for diagonal B (+/V, -/U), MB15, appear on the negative half-wave,
for diagonal A (+/U, -/V), MB16, on the positive half-wave of the voltage waveform at
MB8. If the figure deviates from this, there is a fault in the firing pulse wiring. The
current level of the pulses on the thyristor side of the pulse transformer should be at
least 1 A, and pulse width 18 µS. If the width is very small, it may mean that the pulse
transformer primary is reversed.

Error:
Oscillations but no firing pulses – only the calculated firing pulses appear (pre-mag
current, start pulse of the starter device and the 1st firing pulse). Voltage is present at
MB8.
Cause: Fmin UD3 in F3 is set greater than the oscillation frequency. Further firing
pulses are then disabled.

In a TP system, perform the same test with INV2.

Once all firing pulses are present, the position of the pulses can then be optimized.

First check the nominal frequency (parameter UD1 in F1) of the resonant circuit. With
the furnace empty (empty coil, without ramming form), determine the resonant
frequency on the oscilloscope from the waveform of the MF voltage (preferably
calculated from the 2nd period because the 1st period is falsified by discharge of the
starter device). Multiply the no-load frequency by a factor of 1.35 and enter as
parameter UD1 in window F1. The frequency determined in this way corresponds to
the natural resonance frequency of the furnace in a fully liquid state.
The correct value for nominal frequency is critical in ensuring that the converter starts
up in the optimum manner.

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Figure 7.5.3: Position of the firing pulses during ring test

First set parameter UD4 in F7 (1st firing pulse). This is the time between the start
pulse sent to the start thyristor and the next pulse for INV1 diagonal B. This pulse
should lag approximately 100µs behind the crest of the MF voltage. If firing lies
before the maximum, the energy is again drawn from the load circuit. The value may
need to be changed. The pulse should not be generated until the start thyristor is
blocked again, i.e. when the furnace voltage is smaller again. The length of the rising
edge of the MF voltage (start capacitor discharge and load capacitor charging) does
not depend upon the furnace status. Parameter UD4 is correct for all furnace states.

Then check the position of the further firing pulses. Parameter UD6 in F7 determines
the position for further pulses (from the 3rd firing pulse). These firing pulses should lie
just behind the crest value of the MF voltage. If parameter UD6 was calculated by the
procedure described in Chapter 5.2.7 or Chapter 7.3.1.7, these firing pulses should
be in the right position.

Subsequently set the position of the second firing pulse with parameter UD5 in F7.
This firing pulse should also lie just behind the crest value of the MF voltage.

In TP systems, parameters UD167, UD168 and UD169 in F7 should be checked and

set accordingly for INV2.

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7.6 Testing converters with high voltage

Line voltage needs to be connected to make further settings for the converter.
Check the system once more, observe all safety regulations.

Switch the high voltage on. High voltage should be signaled on the operating cabinet.

7.6.1 Checking the settings for line voltage

The line voltage is transformed by the line voltage transformer to a voltage of around
100V AC and is fed to the DICU. This voltage is reduced further in the DICU and
passed on to the GRS card. These voltages are available on MB7 to MB12.
In REC 24p or REC 12p (rectifiers in parallel) systems, these voltages are also
available on the second GRS card.

Open windows FG1 and FP1. Start the measurement with "." (dot).

Figure 7.6.1: Windows FG1 and FP1

Take the values in brackets from the lines "line rotation" and "Premag. Thyristor" in
window FG1 and enter these as parameters UD117 and UD118 in window F5
(Chapter 5.2.5). These parameter define the rotation of line systems and select the
correct rectifier thyristors for forming the pre-mag current.
The values from window FG2 should also be taken on for several line systems.

Window FP1 contains details of the phase change of the voltages in both line
systems connected to one GRS card (Chapter 1.1.1).
There are no values for the phase currents because the converter is switched off and
current is therefore not flowing.
The phase angle should not be highlighted in red. The values for the phase angle
should be around 120°el or 240°el. This means that the parameters concerning the
direction of rotation of the line systems are correct.

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If the phase angles are at 120°el or 240°el and the values are nevertheless
highlighted in red (Figure 7.6.2), this points to incorrect declarations for the rotation of
the line systems. The values were not taken correctly from window FG1 – Chapter
5.2.5. After correction, the values in window FP1 should no longer be highlighted in
red.
The phase changes between the two line systems U1 und U2 are displayed at the
bottom of window FP1. Given the same rotations of both line systems, the values are
around 30°el (can also be around 330°el), which is OK, and point to the 30°el phase
shift between both line systems. Given different rotations of both line systems, the
values are around 30°el, 150°el, 270°el or 330°el, which is likewise OK.

In a REC 12p (rectifiers in series) system, the pre-mag current angle (UD40 in F7) is
predetermined, where the REC system 2 lags behind the REC system 1. The angle
between the two line systems U1 and U2 is 30°el. At an angle of 330°el between the
two line systems U1 und U2, the angle for the pre-mag current needs to be reduced
during commissioning.

In REC 24p and REC 12p (rectifiers in parallel) systems, perform the same
measurements for the second GRS card in window FP2.

In REC 24p and REC 12p (rectifiers in parallel) systems, the phase shift between line
system1 (first GRS card) and line system 3 (second GRS card) is not measured
directly in the DICU.
This phase shift is 15°el for REC 24p and 30°el for REC 12p (rectifiers in parallel).

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Open window FN1, the measurement should run on.

Figure 7.6.2: Window FP1 (with phase error) and FN1

Only the values in the top lines VD0, VD1 and VD2 are of significance.
Voltage VD1 is the DC output voltage of REC 1 and voltage VD2 is the DC output
voltage of REC 2. VD0 is the DC sum voltage from both rectifiers switched in series.
The voltage values should correspond to the DC voltage (UD145 in F19) calculated
for parameter UD45 (nominal line voltage) from F5. Values outside the admissible
range are highlighted in red.
In REC 24p and REC 12p (rectifiers in parallel) systems, perform the same
measurements for the second GRS card in window FN2.

If the measured values are OK, stop the measurement with the "#" command.

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7.6.2 Testing the rectifier firing pulses

Now all firing pulses can be tested individually at the outputs of the pulse
transformers. The position and level of the firing pulses can be measured with the
oscilloscope. The amplitude should be at least 1A.

As these tests are performed with high voltage switched on, observe all ABP safety
regulations for such measurements. Switch the high voltage off before reconnecting
probes during the measurement.

7.6.2.1 Checking the position of the rectifier firing pulses

The correct position of the rectifier firing pulses is best tested at an firing angle of
120°el. The rectifier firing pulses fall on the line voltage zero-crossing at this angle.
This measurement is seldom taken because new systems are tried and tested with
line voltage in the works.
Although this measuring method is good, it is unfortunately involves a lot of work. The
high voltage must be switched off, the rectifier cabinet opened and then closed again
and the high voltage switched back on for each measurement.

• Channel 1: connect the probes with the necessary dielectric strength to

"L1" and "L2" of line system 1 ("L1" to "+" input, "L2" to "-" input). Instead of
taking the line voltage directly, the matching voltage can be used from plug
X600 (and additionally from plug X1500 for a DICU 24p).
• Channel 2: connect the matching rectifier firing pulse from the GRE card
• Channel 3: connect the current measuring probe (current range approx.
30A). Connect this probe to the gate of the rectifier thyristors, matching
Channel 2
• Trigger: "Line"

Switch the firing pulses on with the GZ1 command and then shift to an firing angle of
120°el with the GA120 command.
If the rectifier firing pulses deviate from the voltage zero crossing by more than 5°el,
this quite possibly indicates a hardware error.

After completing the measurement, switch the firing pulses off with the GZ0
command.

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1 3
4

GA120, firing angle 120°el

GA5, firing angle 5°el GA135, firing angle 135°el, limit position

Channel 1, blue: line voltage L1-L2, measured directly

Channel 2, turquoise: firing pulse R1+, current probe
Channel 3, lilac: GRE card, MB4 " firing pulse R1/3+"
Channel 4, green: GRE card, MB3 " firing pulse R1/3-"
Trigger: line

Figure 7.6.3: Measuring the rectifier firing pulses vs. line voltage

Figure 7.6.3 depicts correct measured values for the phase L1 and the thyristor R+.
Repeat this measurement for all other rectifier thyristors.

When measuring the firing pulses, the phase voltage at the Measuring sockets MB7
to MB12 of the GRS card can be used as reference voltage.
The three-phase voltage at the converter input is transformed by the line voltage
transformers to the 100V level and applied to the DICU. The phase voltages are
generated in the DICU from these interrelated voltages. In case of fields rotating to
the right, these voltages lag 60°el behind the interrelated voltages. In the DICU, the
transformers on the backplane and the filters on the GRS card cause a phase shift in
this voltage of 51°el (parameter UD67 in F13). This means that the phase voltage at
the measuring sockets is 9°el before the interlinked line voltage.
Referred to the phase voltage, the rectifier firing pulses in the voltage zero-crossing
lie at a control angle of 111°el (GA111).

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All these voltages and the firing pulses are depicted in Figure 7.6.4.

A line period, GA111 Section around the voltage zero-crossing

Channel 1, blue: line voltage L1-L2, measured directly

Channel 2, turquoise: line voltage X600/1-X600/2 (secondary voltage L1-L2)
Channel 3, lilac: GRS card, MB8 "line voltage 1L1/3L1"
Channel 4, green: firing pulse R1+, current probe
Trigger: line

Figure 7.6.4: Measuring the rectifier firing pulses vs. MB on the GRS card

7.6.2.2 Checking the rectifier firing pulses

The rectifier firing pulses are tested more frequently at the output of the pulse
transformer in comparison to the firing pulses on the GRE card. This measurement is
important in searching for the cause of errors in the rectifier, e.g. after an intermittent
(discontinuous) current error. The high voltage must also be switched off for this
measurement, the rectifier cabinet opened and then closed again and the high
voltage switched back on.

• Channel 1: connect the matching rectifier firing pulse from the GRE card
(MB3 to MB14)
• Channel 2: connect a current measuring probe (current range approx.
30A). Connect this probe to the gate of the rectifier thyristors, matching
Channel 1
• Trigger: set "line" or Channel 1

This measurement only checks the correct wiring of the firing pulses and their current
amplitudes.

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Pulse arrangement OK Pulse arrangement wrong

Channel 1, blue: GRE card, MB " firing pulse"

Channel 2, turquoise: REC firing pulse, current probe
Trigger: Line

Figure 7.6.5: Checking the arrangement of the rectifier firing pulses

Figure 7.6.5 shows a correct measurement and an incorrect measurement of the

pulse arrangement for a rectifier firing pulse.
Repeat the measurement for all firing pulses or only for those to be tested.

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7.6.3 Testing converters with power

The arrangement and position of the rectifier and inverter firing pulses have been
checked, the line settings have been made (field rotation, pre-mag thyristor). The
converter can now be tested with power.

It is best to run test mode with the furnace close to nominal load (nominal quality).
This can be achieved by lowering a starter block into the furnace. A furnace with a
ramming form has a very low Q-factor and reacts as in an extreme cold start.
Operation with an empty furnace is practically impossible. The Q is very high and the
converter may trip off during the start with a discontinuous current trip or a "INV
overvoltage" trip.

The DICU has 2 operating modes:

• Start phase: The complete CPU power is used for the start sequence and
for current control during the start phase. Only limit values are monitored
for other parameters. The current is controlled at 30 times the speed.
• Normal operation: The DICU only changes to normal regulation after the
start phase has finished and then takes account of the selected setpoints.

In service mode, initiate the start phase from the keyboard and in normal mode from
the SIO input with the start command.

Figure 7.6.6: Example of an optimum start sequence

Figure 7.6.6 shows an optimum start sequence. The start sequence is explained in
more detail below.

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The start procedure consists of 12 steps. If an error occurs during the start phase, the
following message is generated:
!CMD Start aborted.. M1_089_XXX_001
This message never appears alone, but is always accompanied by one or more other
messages. The number in the middle shows the step in the start procedure (001 to
012) in which the error occurred. All errors are described in detail in Chapter 8.1.

The start phase runs through the following steps:

1. The data are prepared and various internal parameters calculated
2. The hardware is readied for the start, rectifier and inverter firing pulse
amplifiers are tested, rectifier firing pulses are shifted to the rectifier's limit
position, rectifier firing pulses run (no current) and line overvoltage is
monitored
3. Hardware monitoring and the error output of the CPU card are active
4. The pre-mag current is built up - the rectifier and inverter thyristors are started
by the DICU synchronous with the line
5. The DICU waits for the pre-mag current at the inverter output
6. The DICU waits for oscillations (voltage zero-crossings) in “start wait time“
(UD7 in F7). Monitoring of the limit values for current/voltage is activated
7. "Alpha warm-up" is activated during "start wait time" (UD7 in F7) after the pre-
mag current angle (first firing pulse)
8. Phi warm-up is activated during "warm-up time" (UD102 in F7)
9. Idmin and Idisc are active in "warm-up time" (UD102 in F7)
10. Uzmax and Idiff are active in "warm-up time" (UD102 in F7)
11. Warm-up control is monitored for limit values in "warm-up time" (UD102 in F7)
12. Regulation is released in "start reg. time“" (UD103 in F7), Phi regulation is
disabled

Steps 8, 9, 10 and 11 practically run simultaneously.

Regulation moves to normal operation after step 12. The DICU can then process
commands again.

When testing the converter, the system need not be started immediately in normal
mode. The DICU has special test functions foreseen for first-time commissioning or
for tracking down errors.

• Short start: The converter is started and operation is aborted after the
warm-up control time (UD102 in F7) has finished
• Long start: The converter is started and operation is aborted after the start
control time (UD103 in F7) has finished

The converter runs very briefly during these start phases and there is hardly any risk
of destroying the system. The times are nevertheless long enough to optimize the
start and the control settings.

In TP systems, each furnace is synchronized individually in SP mode.

It is quite useful to measure the real inverter input voltage during these tests. This
voltage should be measured with a high voltage differential probe. The crest value

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(the effective voltage can be calculated from the crest value by dividing by √2), the
firing voltage, the hold-off time, di/dt and the frequency can be determined very well
from this voltage.
The furnace voltage from MB8 on the WRS card can naturally also be used, although
this voltage does not provide as much information as the real inverter input voltage.

The following items are recommended for measurements with the oscilloscope:
• Channel 1: connect the inverter input voltage via a high voltage differential
probe with the necessary dielectric strength. Alternatively, you can use
individual 100:1 or 1000:1 voltage probes and set the scope for differential
operation
• Channel 2: "ID1/3 signal", MB16 on the GRS card
• Channel 3: "firing pulse A, pre-mag current" MB16 on the WRS card
• Channel 4: "firing pulse B", MB15 on the WRS card
• Trigger: "single shot", Channel 3 – "firing pulse A“ (simultaneous pre-mag
current pulse) negative slope, MB16 on the WRS card

7.6.3.1 Converter short start

Short start is executed with the following commands:

SP system: STN/U/I/P0. STN0 means start with the default control strategy (UD119
in F10), STU0 start with voltage control, STI0 start with current control and STP0
start with power control.

TP system: STN1-3=0. STN1=0 – start only INV1, STN2=0 – start only INV2 and
STN3=0 – start in TP mode.

After the switch on command for the converter, the DICU prepares the necessary
parameters, checks the pulse amplifiers (steps 1 to 3) and sends a firing pulse
synchronous with the line to build up the pre-mag current (step 4). The firing angle for
the pre-mag current is specified by parameter UD40 in F7.
This firing pulse is sent simultaneously to selected REC-Plus thyristors (UD118 or
UD130 in F7), all REC-Minus thyristors and all INV thyristors of diagonal A. In TP
systems, diagonals A are fired in both inverters. When operating a TP system in SP
mode, the thyristors of diagonal A of the active inverter and all thyristors (both
diagonals) of the inverter to run in short-circuit mode are fired.
A current circuit is built up, producing a positive rectifier output voltage, and the
current rises in this circuit.
This first inverter firing pulse is longer at 80 µS. The current rises from zero during
this time and should reach the holding current of the inverter thyristors before the
firing pulse ends.

The current rise depends on the pre-mag current angle (UD40 in F7). The current is
measured at the inverter output.

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Figure 7.6.7: Start sequence

Once the pre-mag current value (UD23 in F7) has been reached, the start thyristor of
the starter device is fired. The energy from the start capacitors is discharged into the
load circuit. Resonant oscillations follow and further inverter thyristors are fired, as
described in Chapter 7.5.1.
After the first rectifier firing pulses (parameter UD40 in F7), all rectifier thyristors are
initially fired at the Alpha warm-up angle (UD41 or UD42 in F7). The current controller
observes and regulates the current at a scanning speed something like 30 times as
high (by altering the rectifier firing angle) and ensures that the current does not rise or
fall too quickly.

Check the current value at the moment of starter device firing with the oscilloscope
(set the screen to approx. twice the "start wait time" UD7 in F7). Check the position
for further inverter firing pulses (Chapter 7.5.1) and correct, if necessary – Figure
7.6.8. Check the commutations and hold-off times after each firing pulse.

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Channel 1, blue: INV input voltage, measured directly

Channel 2, turquoise: WRS card, MB10 "IWR output current", 1V-square wave
Channel 3, lilac: WRS card, MB16 " firing pulse A"
Channel 4, green: WRS card, MB15 " firing pulse B"
Trigger: Channel 3, "single shot"

Figure 7.6.8: Start sequence, measurement with the inverter input voltage

The same measurement, referred to the furnace voltage, can also be performed from
MB8 on the WRS card. This measurement is shown in Figure 7.6.9.

Channel 1, blue: WRS card; MB8 "UWR output voltage"

Channel 2, turquoise: WRS card, MB18 "start thyristor firing pulse"
Channel 3, lilac: WRS card, MB16 " firing pulse A"
Channel 4, green: WRS card, MB15 " firing pulse B"
Trigger: Channel 3, "single shot"

Figure 7.6.9: Start sequence, measured with the furnace voltage, MB8 on the WRS
card

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The oscilloscope screen should now cover more than the total time taken by the
"start wait time" and "warm-up control time" (UD7 + UD102 in F7).

Cold start with sinter template Start with the furnace empty

Channel 1, blue: WRS card; MB8 "UWR output voltage“

Channel 2, turquoise: GRS card, MB16 "ID1/3 signal"
Channel 3, lilac: WRS card, MB18 "start thyristor firing pulse"
Trigger: Channel 3, "single shot"

Figure 7.6.10: Short start

After the first firing (build up of pre-mag current), the rectifier current should not reach
more than 80% of the nominal current. The current then falls, but should not pulsate,
which means that the current may not undershoot the REC discontinuous current
value (UD50 in F7).
The current rises up to the end of the "start wait time". It then falls and is dependent
on the load state of the furnace.
At normal load, the current should then run more or less horizontally and reach
something like 35% of the nominal current. During sintering, the current generally
rises further and then flattens off at a high level. The current drops relatively quickly
in no-load operation, it is caught by the controller shortly before ID=0 and should then
remain more or less constant.
The inverter firing pulses are set to the warm-up angle during the warm-up time. The
impedance of the load circuit rises, which also causes the furnace voltage to rise
slowly. If the furnace is underfilled, the voltage rises noticeably quicker.
As the current rises, the furnace voltage must likewise rise (the firing voltage must
rise) to ensure reliable commutation and adequate hold-off time.

Figure 7.6.10 shows short starts for very different furnace states. The DICU settings
remain the same.

The amplitude of the 1st current pulse should be set with parameter UD40 in F7.
Further values for the current depend upon parameter UD41 in F7 in SP mode or
from UD42 in F7 in TP mode.

Observe the rectifier current (MB16 on the GRS card) and the inverter current (MB12
on the WRS card) at the same time with the oscilloscope. In REC 6p and REC 12p
(rectifiers in series) systems, both currents should take an identical course and have
identical amplitudes.

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Channel 1, blue: WRS card, MB10 "IWR output current" (1V-square wave)
Channel 2, turquoise: GRS card, MB14 "line current 1IL1" (current IR 1V signal)
Channel 3, lilac: WRS card, MB18 "start thyristor firing pulse"
Trigger: Channel 3, "single shot"

Figure 7.6.11: Short start, currents IIL1, and IWR (1V signals).

Figure 7.6.11 shows both the line phase current (IL1, also called IR) and the inverter
output current as voltage waveform on the 1Ω resistors. As the line and inverter
current transformers both have the same translation factors, the amplitudes of the
currents are identical.
Although "ID signal" (GRS card, MB16) and "IW signal" (WRS card, MB12) both have
the same currents, (Figure 7.6.12), there are clear differences in the amplitudes.
"ID waveform " is the rectified line current multiplied by a factor of 5.1. "IW signal" is
the rectified inverter output current multiplied by a factor of 4.7. These different
factors result in a difference of some 8.5% in the amplitudes. Given the same
translation factors for the line current transformer and inverter current transformer,
"ID signal" is 8.5% larger than "IW signal".

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Channel 1, blue: WRS card, MB12 "IW signal"

Channel 2, turquoise: GRS card, MB16 "ID1/3 signal"
Channel 4, green: WRS card, MB16 "firing pulse A"
Trigger: Channel 4, "single shot"

Figure 7.6.12: Short start, ID1 and IW current waveform.

In REC 24p and REC 12p (rectifiers in parallel) systems, additionally observe the
rectifier current on the second GRS card (MB16). The two rectifier currents are only
different at the start, but should take the same course after a few mS.

Channel 1, blue: GRS card (DICU 24p: left), MB16 "ID1/3 signal"
Channel 2, turquoise: GRS card (DICU 24p: right), MB16 „ID1/3 signal“
Channel 3, lilac: WRS card, MB12 "IW signal"
Channel 4, green: WRS card, MB16 "firing pulse A"
Trigger: Channel 4, "single shot"

Figure 7.6.13: Short start, ID1, ID2, and IW currents.

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The rectifier currents are different because all rectifiers are fired simultaneously at the
start and the corresponding line voltages have different amplitudes at this moment in
time. Each rectifier fires synchronously thereafter with its own line voltage, so that the
amplitudes should close in on each another.
It is possible that both rectifier currents have the same course, but there is a
difference in their amplitudes.
The reason for this is that the line transformers, the line voltage transformers and the
DICU hardware (small line transformers, GRS cards) can differ slightly. These
differences mean that, given the same rectifier firing angle, the two REC systems
have different DC voltages, thus rectifier currents. This problem is discussed further
below in the stationary operation of the converter in Chapter 7.6.3.3.

The converter is switched off after the short start. The latest recent measured values
are saved in window FL. The value for angle α (top line) should not differ too much
from the corresponding REC Alpha warm-up angle Normal (UD41 in F7) in SP mode,
or from REC Alpha warm-up Twin (UD42 in F7) in TP mode. Almost the same values
mean that the DICU did not need to alter the rectifier firing angle very much during
the short start.

If the short start runs without error messages, the current at the end is horizontal. The
test can now be performed as a long start.

Remark: Figure 7.6.14. "ID1/3 signal" at MB16 on the GRS card is formed from the
sum of the two line currents 1IL1 (MB14 on the GRS card, IR current) and 1IL3
(MB13 on the GRS card, IT current). As the current is missing the third line phase, a
collapse occurs in the waveform every 10ms (50Hz line). Such collapses are normal
and do not mean an intermittent current. The collapse is masked out in the software
for intermittent current monitoring.

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Channel 1, blue: GRS card, MB14 "1IL1 line current" (IR current 1V signal)
Channel 2, turquoise: GRS card, MB13 "1IL3 line current" (IT current 1V signal)
Channel 3, lilac: GRS card, MB16 "ID1 signal"
Trigger: Line

Figure 7.6.14: Line currents and ID signal.

7.6.3.2 Converter long start

A long start is executed with the following commands:

SP system: STN/U/I/P1. Control strategy as with the STN0 command.

TP system: STN1-3=1. STN1=1 – start only INV1, STN2=1 – start only INV2 and
STN3=1 – start in TP mode.

The settings for the oscilloscope should be the same as for a short start. The
oscilloscope screen should now cover more than the total time taken by the "start
wait time", the "warm-Up time" and the "Start-Reg. time" (UD7 + UD102 + UD103 in
F7).
Please note: Not every oscilloscope can be set to "single shot" mode for such a long
time. The oscilloscope changes earlier to "roll mode". Set the maximum admissible
time for "single shot".

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Channel 1, blue: WRS card; MB8 "UWR output voltage"

Channel 2, turquoise: GRS card, MB16 "ID1/3 signal“
Channel 3, lilac: WRS card, MB18 "start thyristor firing pulse"
Trigger: Channel 3, "single shot"

Figure 7.6.15: Long start, furnace "fully liquid".

In the "start-reg. time", the inverter firing pulses wander slowly from the warm-up
angle to the Phi-min angle. The furnace voltage rises, which is particularly noticeable
if the furnace is underfilled. As the current rises and the firing pulses wander
backwards (impedance rises), the furnace voltage must likewise rise (the firing
voltage must rise) to ensure reliable commutation and the adequate hold-off time.

Regulation transfers to current and voltage control, Phi regulation (Beta regulation) is
blocked.

In normal load operation or in sintering mode, current and voltage remain at a low to
medium level or they are slowly reduced. In no-load operation, the current more or
less reaches "Minimum current" (UD21 in F3) and the voltage rises quickly, even in
the warm-up phase. It is usually not possible to start the converter without load (thus
without material in the furnace) due to the high furnace impedance. This often leads
to aborted starts with the error messages "REC intermittent current" or "INV
overvoltage".

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The controllers need to be "calmed down" if current and voltage swings occur which
could lead to a converter switch off with this error message. The controllers are
"calmed down" by taking the parameters for the controllers in F8 from a column
further to the left (Chapter 5.2.8).

Parameter Freq. low Freq. medium Freq. high

UDnn ~50Hz ~200Hz ~500Hz
85 20 50 50
86 20 50 50
87 20 50 50
88 0,02 0,02 0,01
91 50 50 100
92 50 50 100
93 50 50 100

If the control parameters are taken from the "Freq. low" column, change the ramp
time (UD209 in F10) to at least 5 seconds. The switch-off time (UD212 in F10) can
remain at 2 seconds.

In REC 24p and REC 12p (rectifiers in parallel) systems, also check both rectifier
currents for even running – as described above for short start (Chapter 7.6.3.1).

The "start-reg. time" will not be run through successfully unless the long start ends
with something approaching a flat current course!

7.6.3.3 Continuous operation

After the short starts and long starts have been positively concluded, continuous
converter operation can now be tested.

Normal operation is started with the following commands:

SP system: SNxxx: Start the converter with the target value xxx. The type of the
setpoints – voltage, current or power – is determined by UD119 in F10.
TP system: SNxxx=yyy: Start the TP converter with the power setpoints xxx and
yyy. Enter yyy as 0 for SP operation of INV1 and xxx as 0 for SP operation of INV2.

The setpoints can be changed later during operation with RNxxx or RNxxx=yyy.

Set the "switch-off time" parameter (UD212 in F10) to 0. The values then seen on the
service PC screen are the latest operating values recorded before switch-off.

As test mode is normally run with an unlined furnace and with only one starter block,
a long period of continuous operation is not possible. The final settings can only be
made with a furnace that has been lined, sintered and dried. This only establishes

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whether the converter is running stably, whether the power can be controlled and
whether the measured values are more or less correct.

Remark 1: The "DICU Test" service switch must remain switched on. If the service
switch is not switched on and the converter is started with the service PC, the DICU
switches the converter off after a second or so; an error message is not issued.
The DICU accepts the command from the service PC and starts the converter. The
converter is switched off because the DICU tests the inputs on the SIO card at cyclic
intervals and finds that input E1 is set to OFF (if the service switch is on, all inputs on
the SIO card are disabled except release).
Remark 2: After completing the tests with the service PC, do not forget to switch the
service switch off. If the service switch were to stay switched on, the customer would
not be able to start the converter – the inputs on the SIO card would be disabled.

Open windows FL and FK (Chapters 4.4.4.5 and 4.4.4.6).

Figure 7.6.16: Window FL1 und FK1

The following items are recommended for measurements with the oscilloscope:
• Channel 1: connect the inverter input voltage via voltage probes with the
necessary dielectric strength
• Channel 2: connect the "UWR output voltage" (MB8 on the WRS card)
• Channel 3: connect "IWR output current", 1V square wave, (MB10 on the
WRS card)
• Channel 4: measure the inverter output current with the current loop
• Trigger: Channel 1

The screen should depict 3 to 4 half-waves.

Start the converter at around 20% nominal power and let it run. If the converter is
running stably after 10 seconds or so and error messages have not been issued, the
general settings of the DICU are OK. The values on the service PC should not have
any question marks, exclamation marks or be highlighted in red.

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Set the factors for all channels on the oscilloscope so that the courses are well visible
throughout the complete amplitudes. Do not overload the current loop for measuring
the inverter output current.
Alpha (rectifier) and Phi (Beta-inverter) regulation is put on hold during operation with
the BR0 command. The converter runs on in controlled mode, so that stable
measured values can be seen in load window FL1. The limit values continue to be
active (Chapter 4.4.2.2).
Save the present oscilloscope screenshot and switch the converter off.

Channel 1, blue: INV input voltage, measured directly

Channel 2, turquoise: WRS card; MB8 "UWR output voltage"
Channel 3, lilac: WRS card, MB10 "IWR output current", 1V square wave
Channel 4, green: IWR measured with current loop
Trigger: Channel 1, negative slope

Figure 7.6.17: Operation.

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The correctness of the DICU measurements can be determined from the curve
diagrams saved from the oscilloscope screen and from the values in windows FL1
and FK1.

Figure 7.6.18: Sample diagram for evaluating the measured values.

Channel 1, blue: INV input voltage, measures directly

Channel 3, lilac: WRS card, MB10 "IWR output current", 1V square wave
Channel 4, green: IWR measured with current loop
Trigger: Channel 1, negative slope

Figure 7.6.19: Operation, evaluating the operating values

Read off the crest value for the inverter voltage (UWRmax) from Channel 1 of the
oscilloscope (inverter input voltage). Convert this voltage to the effective value by
dividing it by √2. This effective voltage should correspond to the "UW output" in
window FL1. A deviation greater than 3% or so means that there is something wrong
with the measurement chain in the converter and the DICU.
Inspect: External UMF transformer, UMF transformer on the backplane, internal
DICU factors.

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The commutation time (T-Comm) and the hold time (T-Off) can likewise be read off
from the inverter input voltage (Channel 1) – Figure 7.6.19. Compare these T-Comm
and T-Off values with the values displayed in window FK1, "Measurement " column.
The values read off from the inverter input voltage should not deviate too greatly from
the values in window FK1, "Measurement" column. The measurement is determined
by the hardware and cannot be adjusted.
Inspect: The filter components on the WRS card, MF transformer on the backplane,
the WRS card itself.

There are additional values for T-Comm and T-Off in the "Calculation" column in
window FK1, which should more or less correspond to the values in the
"Measurement" column. Chapter 7.6.4 compares these values in more detail.

Read off the amplitude of the IWR current from Channel 3 of the oscilloscope ("IWR
output current“, 1V square wave). This corresponds to the voltage measured directly
at the load resistor for measuring current. The "IWR output current" has a certain
ripple, something like an average amplitude should be read off here. The measured
value multiplied by the factor "IW-Transformer-ext" (UD59 in F1) produces the value
for the inverter output current. The value calculated in this way should correspond to
the "IW output" in window FL1.

Read off the amplitude of the inverter output current from Channel 4 of the
oscilloscope. The amplitude of the inverter output current should correspond to the
"IW output" in window FL1.

A deviation greater than 3% or so means that there is something wrong with the
measurement chain in the converter and the DICU.
Inspect: External Imf transformer, intermediate Imf transformer if applicable, and
internal DICU factors.

The value for di/dt (steepness of current in the inverter thyristors) can be calculated
by dividing the values determined above for the inverter output current and the
commutation time. The value calculated for di/dt should not deviate too much from
the value for dI/dt in window FL1 or window FK1, "Measurement" column.
There is an additional value for di/dt in the "Calculation" column in window FK1,
which should more or less agree with the value in the "Measurement" column.
Chapter 7.6.4 describes a more exact comparison of this value.

The firing voltage and the furnace frequency can also be read off from the waveform
in Channel 1 (inverter input voltage). These values should likewise not deviate too
much from the relevant values in window FL1.

In REC 24p and REC 12p (rectifiers in parallel) systems, also check both rectifier
currents for even running – as described above for short start (Chapter 7.6.3.2).
Connect both rectifier currents (MB16 on both GRS cards) to the oscilloscope for this
purpose.
The converter should be operated at 15-20% power – Alpha angle in FL1 approx.
60°el.

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Both currents should have the same amplitudes. Any differences in amplitude can be
compensated with parameter "Alpha-Diff (24p)" (UD213 in F5) to a limited extent.
UD213 can take on positive or negative values.
In conclusion, do not forget to reset the "switch-off time" parameter (UD212 in F10) to
the correct value.

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7.6.4 Final DICU adjustment

Once the furnace has dried (i.e. when the furnace has an isolation value > 1.5 kΩ for
at least 1 day), the last settings can be made for the DICU.

The final settings should be made with the furnace in a "fully liquid" state (nominal
point of the furnace). The UR calculation sheet data refer to this operating point.
With a "fully liquid" furnace, the converter can run fairly stably with power for several
seconds, thus enabling a precise measurement to be made with the oscilloscope.

In TP systems, each furnace is synchronized individually in SP mode.

For a heating system, all coils should be filled with material. The temperature profile
should run over the coils from cold at the infeed to hot at the discharge (nominal
operation).

The final settings should correspond to the UR calculation sheet.

The "DICU Test" service switch should be switched on, which is signaled by LED10
(inputs inactive) being lit on the SIO card.

It is recommended to set the "Off-Time" parameter (UD212 in F10) to 0 for the final
tests. The values then displayed on the screen of the service PC correspond to the
last values recorded from operation before switch-off.

The final settings can be made without an oscilloscope. Even so, it is better to
connect the oscilloscope, as described in Chapter 7.6.3.3.

First check and adjust the nominal frequency. Open windows FL1 and FK1 (Chapters
4.4.4.5 and 4.4.4.6).

Start the converter in SP mode at nominal power (nominal voltage for a heater).
Disable Phi regulation (Beta regulation) with the RF1 command. The rectifier is now
driven at full scale to the "Alfa-Min" angle (UD39 in F6).

The frequency read off in window FL1 should agree with the nominal frequency (UD1
in F1). Otherwise correct the frequency UD1 in F1. If there is a large difference
between the frequency measured from FL1 and nominal frequency from F1, check
the positions of the first firing pulses again after correcting the frequency and make
any improvements that are required (Chapter 7.5.1).

As already described in Chapter 7.6.3.3, the hold-off time, the commutation time and
the di/dt should be checked – the values measured from the oscilloscope should
agree with the measured values in window FK1.

Now compare the values in the "Measurement" column and "Calculation" column in
the FK1 window. The aim is to narrow down any differences between the measured
and calculated values. Parameter UD35 in F1 is adapted for this purpose. Only adjust
parameter UD35 ("dI/dt") by something like half of the difference between theory
(calculated) and reality (measured) because the firing time changes at the same time

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and thus in turn "dI/dt". Repeat this until the calculated and measured values have
equated.
As parameter UD35 likewise has great influence on the converter's start behavior,
check this after synchronization and, if necessary, subsequently adjust "warm-up" in
parameter UD18 in F7 (Chapter 7.3.1.7). Also subsequently adjust "Phi-min" with
parameter UD33 in F1 (Chapter 7.3.1.1).

In what follows, some control limits are approached with different setpoints for test
purposes. The DICU should report correctly when limits are reached.
The regulation status message has 4 digits, although only the last one is of
importance. This figure shows the limit that the DICU has reached and what is
limiting the operation of the system:
0 = no limits reached
1 = nominal voltage, parameter UD10 in window F1
2 = minimum voltage, parameter UD15 in window F3
3 = nominal current, parameter UD19 in window F1
4 = minimum current, parameter UD21 in window F3
5 = firing voltage, parameter UD16 in window F1

Release Phi regulation (Beta regulation) with the RF0 command, unless this has
already been done.

Observe the number at the bottom left under "Regul-Stat" (status number) in window
FL1. The last digit defines the active limit.
Start the converter with the SNxxx command or a TP system in SP mode.
Declare the minimum power with RN1. The last digit of the status number in window
FL1 should be 2 or 4. The converter attempts to approach the power and hereby
comes up against limit 2 ("Min output voltage", UD15 in F3) or limit 4 ("Min current ",
UD21 in F3).
The latest values measured are displayed in the FL1 window. If limit 2 was reported,
"UW output" should take on the value "Min output voltage" (UD15 in F3). In case of
limit 4, "IW output" should take on the value "Min current" (UD21 in F3).

Stipulate the nominal power with the RNxxx command. If the furnace is underfilled,
"UW output" in window FL1 reaches the value "Nom output voltage" (UD10 in F1)
and the last digit of the status number is 1.
If the converter reaches nominal power without the nominal voltage, the last digit of
the status number is 0 – no limit active.

The inverter nominal current limit ("Nom current", UD19 in F1) is normally reached
after a cold start and when the target nominal power is entered. The last digit of the
status number is then 3.

Power measurement is not so simple to test; especially not in TP systems working

with LEM modules. This power can be measured with special gauges connected to
the rectifier input. The total power is determined for REC 12p or REC 24p by
multiplying the measured value by 2 or 4.
Most ABP converters are equipped with an energy counter at the rectifier's input.
Depending on where the energy counter is installed and how it is scaled, the display
for REC 12p or REC 24p must be multiplied by 2 or 4.

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The furnace should "completely liquid". Start the converter at around 80% power.
Check that the converter has reached the power and is running stably. Monitor the
energy counter for a certain time with a stop watch and note the kWh processed
during this time. The average power can be calculated from the energy and the time.
This power should more or less agree with the power in window FL1. The power in
window FL1 can be lower because this power is measured at the inverter. The
energy counter measures the power at the rectifier's input, thus the power by which
the losses in the rectifier and in the DC choke is greater.
The power displayed on the service PC, on the customer module or on the processor
can be corrected by factor UD162 in the F11 window. The power displayed is:

Pdisplay = Pactual * UD162

If UD162 is <1, the power displayed is less than the real power.

In TP systems, repeat the measurements and settings for the second furnace.

Note: If no power is displayed for a TP system, even though the converter is running
(the furnace is noisy, furnace voltage and inverter output current are present), check
the LEM adapter. If there is no voltage from the LEM adapter, (UO furnace LEM in
FL), the DICU regards the furnace power as zero and raises the voltage and the
current until a certain limit is reached. A LEM module could also be defective.

In conclusion, do not forget to reset the "Off-Time" parameter (UD212 in F10) to the
correct value again.

Once all settings have been successfully concluded and the system is running
satisfactorily, do not forget to save latest data correctly in the DICU, on the service
PC and subsequently to the ABP database.

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7.7 Operating the converter with a customer module or a processor

The DICU has 2 serial interfaces (Chapter 2.2.1):
• COM1, X100, RS232
• COM2, X101, RS422

The DICU communicates with the service PC (COM1), with the customer module
(COM1) or with the processors (COM2) via these serial interfaces. The DICU is given
setpoints and sends actual values and error messages via the interfaces. Only one
interface can be active and have command priority (input E11 on the SIO card).
Input E10 on the SIO card must be 0 (no service mode).

7.7.1 Operation with the customer module

The customer module (Chapter 3.1) is connected to the DICU's COM1 interface by a
crossover cable or via a fiber-optic adapter. A more detailed description of the
functions of the customer module and how to operate it can be found in Chapter 6.
Only a brief description of the use of the customer module is given here.

Input E11 on the SIO card must be 0 (COM1 is active and has command priority).

The DICU boots up and communication is established with the customer module.
Once the self-test has been successfully concluded, LED1, LED2 and LED3 are lit in
green on the CPU card. The customer module displays the actual values.

If the DICU has received the release (input E0 lights up on the SIO card), the
converter can be started from SIO1 input E1.
Setpoints can be issued with the potentiometer(s) connected to the customer module.
The display shows the latest actual values. If a disturbance occurs, the DICU
switches off automatically and the errors can be read off from the display.

7.7.1.1 Operation with the customer module and service PC as monitor

If the system is operated with the customer module (connected to the COM1
interface), the service PC can be connected to the COM2 interface. Considerably
more operating data can be seen from the service PC than from the customer
module.

Operation of the service PC on the COM2 interface is initiated in a similar way to

operation of the system with the customer module on the COM2 interface – Chapter
6.9.

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Figure 7.7.1: Service PC connected to the DICU's COM2 interface

• An RS422/RS232 transducer (GES9421109P1 from W&T) is deployed

between COM2 and the customer module
• A special cable GES3 520 391R1 socket/socket (made by ABP) connects
COM2 to the transducer
• A null modem cable (DICU cable) connects the transducer to the customer
module
• Set the following parameters in the data record in window F15: UD76=9600
(baud rate) and UD123=1 (command priority to COM1). Save the amended
data record in the DICU

Connect the service PC to the COM2 interface. Launch the DICU software on the
service PC. The converter must be switched off. Input E11 on the SIO card may not
be switched to 1. Establish the link to the DICU with the GRTEST command. The
DICU reboots. Acknowledge any error messages with the + key. The service PC
should be online and work as a monitor. Observe the converter's parameters in
normal mode.
The service PC can be disconnected from the DICU at any time without problem.

With command priority given to the COM2 interface (input E11 on SIO card 1), a
variety of test functions can naturally be started from the service PC (swing down,
short start, long start etc.).

Remark: The service switch may not be switched on, input E10 on the SIO card must
remain 0. If the service switch is active, input E11 is recognized as 0, so that the
COM2 interface cannot have command priority.

Continuous operation is not possible with the service PC on the COM2 interface. As
the inputs of the SIO card are active (E10 on the SIO card = 0), the system first starts
after the start command from the service PC. However, input E1 (on/off) on the SIO
card remains at 0, which means "do not start". The DICU checks this input and
switches the converter off after approx. one second; an error message is not issued.

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7.7.2 Operation with the processor (Prodapt, or PLC communication

processor)

A Prodapt or a PLC communication processor is connected to the DICU's COM2

interface by a fiber-optic link.

Input E11 on the SIO card must be 1 (COM2 is active and has command priority).
The signal for E11 is switched by the PLC.

Once communication has been established and the DICU is ready for operation,
LED1, LED2 and LED3 light up in green on the CPU card. Release (input E0 on the
SIO card) must be lit. The converter can be started from the SIO1 input E1.
The Prodapt sends the power specifications to the DICU and in return receives actual
values and other messages.

The customer module does not have command priority, only the latest actual values
or error messages are displayed. The potentiometers are inactive.

7.7.2.1 Operation with the processor and service PC as monitor

When operating the system with the processor (COM2 active), the service PC can be
connected to the COM1 interface as a monitor. Considerably more operating data
can be seen on the service PC.
The system must be switched off. Disconnect the customer module from the COM1
interface and connect the service PC to COM1.
Switch the "DICU Test" service switch on, which is signaled by LED10 (inputs active)
lighting up on the SIO card. The COM1 interface has command priority. Launch the
GrTest program on the service PC and establish communication with the DICU. The
third LED from the top on the CPU card should be lit in green.
Switch the "DICU Test" service switch off, LED10 (inputs active) on the SIO card
should extinguish. Command priority passes to the COM2 interface.
Switch the system on and operate it with the processor. Watch the actual operating
values on the screen of the service PC.
Even though the service PC does not have command priority and only functions as a
monitor, the # is effective and triggers switch-off (the error message "!CMD
Emergency-Off m1_090_001_001" is issued).

If the service PC is to no longer work as a monitor, simply switch the system off,
disconnect the service PC from the COM1 interface and connect the customer
module to the COM1 interface. The system is then ready to operate again. Actual
measured values should appear on the customer module.

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7.7.3 Emergency operation with the customer module

When operating with the Prodapt via the COM2 interface, the customer module
(connected to the COM1 interface) acts as a monitor without command priority.
Input E11 on the SIO card is switched on.

If the Prodapt fails or if communication with the Prodapt is faulty or interrupted, yet
the PLC remains in normal operation, after a minute or so the PLC switches input
E11 on the SIO card from 1 to 0. Command priority then passes to the customer
module.
Setpoints are specified by the potentiometers. The converter can continue to work
and the melting process set forth to the end. The actual values and error messages
continue to be displayed on the customer module.
Prodapt functions (such as energy monitoring, temperature calculation etc.) are
naturally no longer active. Particular care must be taken in operating the converter.

7.8 DICU database

An DICU database in Access format is stored on the ABP server. This database is
described in Annex A4.

The details of all systems which work with a DICU are stored in this database (the
database does not contain any details of systems delivered by ABP-USA or ABP-
India at present).
All processes, repairs and other important information on each system are recorded
in a log book.
Each system is allocated a directory to store up-to-date data records (nn.dat and
nn.dax files) and nn.erx error log files.

These data enable us to help customers quickly. Spare parts can be arranged and
sent without delay. Expert advice over the telephone can also be given.

For this reason, it is very important to update the records in the database as quickly
as possible after commissioning, repair work or a different deployment by the
customer.

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7.9 Testing the DICU without the system

In case of retrofit orders or deliveries to replace a DICU, the matching data records
must be imported and the DICUs tested.
Even if a complete DICU is repaired, an attempt is first made to read out the latest
data and the error log file from the DICU.
The DICU boots up once it is connected to the supply voltage. Once the self-test has
run, the +48VDC voltage for the firing pulse amplifiers is switched on and any
possible pulse amplifier errors are reported. The DICU checks the connections to the
pulse transformers and establishes that no pulse transformers are connected.

Figure 7.9.1: DICU boots up with no pulse transformers connected

In order to "fool" the DICU, matching resistors must be connected to the normal DICU
plugs (called test plugs) at the DICU outputs for the pulse transformers. These
resistors should have a value between 100Ω and 1000Ω and power of at least 0.5W.
The resistors don’t all have to be the same value. The resistors are connected to the
12-pin test plugs (rectifier pulse transformers) and 8-pin test plugs (inverter pulse
transformers).
12-pin test plug: 3 resistors connected to pins 1-2, 5-6 and 9,10
8-pin test plug: 2 resistors connected to pins 1-2, and 4-5

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Figure 7.9.2 shows a table with the test plugs required.

Plugs
X700
System X701 X702 X1600 X1700
X1001
X902 X703 X1601 X1701
X903
REC 6p SP X
REC 6p TP X X
REC 12p serial SP X X
REC 12p serial TP X X X
REC 12p parallel SP X X
REC 12p parallel TP X X X
REC 24p SP X X X X
REC 24p TP X X X X X

Figure 7.9.2: Table listing the test plugs required

Figure 7.9.3 shows an example arrangement of test plugs for a DICU 12p series TP.

Figure 7.9.3: DICU 12p TP with test plugs for the firing pulses

Once the test plugs have been connected, switch the supply voltage on and the
DICU boots up without an pulse amplifier error message. The DICU can then be set,
as described in Chapter 7.4.

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7.10 Testing the DICU cards individually

Individual DICU cards often need to be calibrated or tested. When DICU cards are
repaired, a test run is performed and an attempt is first made to read out the data and
the error log file from the CPU card.
A test system is used for this purpose.
ABP in Dortmund maintains a TP test system. This system is configured in such a
way that the filter fitted to the GRS cards or WRS cards have no influence on the
functions of the cards (not on the measured values). The customer-specific data
records can be imported onto CPU cards.

Caution: When calibrating a CPU card for an SP system, the second WRS card for
INV2 must be removed from the DICU in the test system and a WS PROMs set
plugged onto the first WRS card for INV1.

Note: When testing used DICU cards that have been sent in for repair, the most
frequent cause of errors is poor contacts on the DICU card plugs. Clean the plug with
a contact spray (such as "Kontakt 60"). Then test the card once more.
The contacts on the cards should also be cleaned with a contact spray during visits to
customers or if problems occur with the DICU.

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8 Troubleshooting in systems with DICU control

8.1 Troubleshooting using DICU error messages

When an error occurs, the customer module generates a message on its

display (extended display) in the following format:

!CMD Start aborted.. M1_089_004_001

!REC No Sync-Impuls. G1_042_016_001
A B C

These messages are saved in the DICU's error log and are also sent to the
processors (MD, MX, Promelt etc.) via COM2.

When the service PC is connected, all error messages appear in the lower
part of the screen.

The same messages can be saved on the computer in the ERR directory as
an nn.ERX file (nn – name of the file, can be chosen at will) in the following
format (Chapter 8.2.1):

!CMD Start aborted.. M1_089_004_001 * Hardware-Error..

!REC No Sync-Impuls. G1_042_016_001 * REC Line-Fault..
A B C D

A: error message (text)

B: function group, source of the error message
C: number messages
D: classification of the error

Remark: If communication between the DICU and the customer module is

disturbed but still running, the error messages sometimes appear in code on
the customer module display (for instance, W01370401). In this example,
groups B (w01) and C (370401) are merged. Group C consists of 3 two-digit
HEX characters. The HEX characters, converted to decimal numbers, produce
group C in the format described above.
In this example, the HEX character 37 corresponds to the decimal number 55,
which indicates a pulse amp error. The HEX character 4 corresponds to the
decimal number 4 and signifies an error at the output for the start thyristor
Chapter 8.1.1.

Error messages (A) can be issued in various languages (first change the
language with ALx and then save the error log file).

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The source of the error can be seen in the B-group. The location of the error is
defined as follows:

Function group Location/card

G1 or G2 GRS
I1 or I2 GRE
K1 Global data incorrect
L1 Log book error
M1 Command processor
P1 CPU
Q1 SIO
R1 Regulation
T1 Text file
V1 BUS/backplane
W1 or W2 WRS
X1 COM1
X2 COM2
X3 Keyboard
N1 Customer module/Prodapt

The first three digits in the number message (group C) – in the example the
numbers 089 and 042 – define the line number of the error in the
GLOTEXT.TXT file. This contains the text part of the error messages in
several languages. However, the number message is independent from the
selected language.

The meaning of the texts and that of the second three digits of the number
message is described in Chapter 8.1.1.
The last three digits of the number message only state how often the error
occurs.

There are additional classifications of errors (group D) in the nn.ERX file,

which group the errors by their origin. The classification is used to determine
the outputs on the SIO card (see Chapter 8.1.3).

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8.1.1 DICU error texts

000 !- -Allg. Fehler.. !- - General Error..

An error without any specific category. This message is not used at the
present time.

001 !- - Kein Fehler.. !- - No Error..

Refers to the internal software management and is only used for
indexing. It also stands for the start condition for the error log. If you see
this message in an error log file, it means that the error log is empty.
After BT has been executed, the error log is emptied and filled with the
"!- - No error.. " message.

002 !COM Falsche Version.. !COM Wrong Version..

The service PC software is not compatible with the DICU software.
Nothing works in such cases.

003 !COM Empfang.. !COM Receive..

Input buffer overflow. Not used at the present time.

004 !COM Sendung.. !COM Transmit..

Output buffer overflow. This can occur if the melt processor tried to
send too many instructions at once to the DICU.

The buffer is not processed during the DICU self-test. As PRODAPT

sends telegrams every 1.0s or so, buffer overflows can happen. This
can be prevented in that the DICU sends the _11 command to
PRODAPT immediately before the self-test to stop data being sent to
the DICU. The _00 command is sent to PRODAPT to end the self-test
and release data transmissions to the DICU.
The _11 and _00 commands are always sent twice to safeguard against
transmission errors.
The commands have been visible in the PRODAPT communication
window since 2014.
COM Transmit X2_004_062_001
X2 => interface has command priority
062 => the length of the telegram
The buffer in the DICU has 256 bytes

Possible cause: Too low voltage for the 5 V power unit. A

communication element is not functioning properly. The CPU
transmitter element has failed.

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005 !COM Debug-Timeout.. !COM Debug-Timeout..

No reaction from the DICU. Communication breakdown between the
DICU and the PC. Only refers to service software/service PC and is
generally caused by PC problems.
Check the cable connecting the DICU to the PC. A null modem cable or
a fiber-optic adapter is required.

006 !COM Debug-Chksum.. !COM Debug-Chksum..

The PC has sent an instruction and received a damaged telegram back
from the DICU.

007 !COM Debug-Befehl.. !COM Debug-Command..

DICU has refused to accept a command just received from the service
PC (due to an internal error status) or there is a communication
breakdown.

008 !COM Debug-Daten.. !COM Debug-Data..

A service PC has received incorrect data from the DICU. This is usually
caused by a poor or intermittent connection.

009 !COM Debug-Fehler.. !COM Debug-Error..

Error messages sent by the DICU to the PC are invalid or incorrect. See
error 008.

010 !COM Trans-Timeout.. !COM Trans-Timeout..

Occurs when the service PC is reading data in or out from the DICU
(such as error lists, setpoints etc.). Triggered by a time overshoot, which
indicates a communication loss. This is generally caused by the PC and
not by the DICU because the PC occasionally suffers from connection
problems.

011 !COM Trans-Daten.. !COM Trans-Data..

The PC received incorrect data during a transmission (too many, too
few, wrong check sum, etc.). See error 010.

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012 !COM Befehlsgewalt.. !COM Priority..

This error can occur if you try to address an inactive communication
port on the DICU or the PC (COM1, COM2). As far as we know, this
has never happened with a DICU because both COM ports are
permanently active.

013 !COM Watchdog-Time.. !COM Watchdog-Time..

The DICU COM port addressed has not received any control signals
whatsoever for one minute before the timeout. Concerns the
connections to the melt processor, service PC or customer module.
This message concerns the DICU COM port that has command priority.
The inactive DICU COM port is not monitored.
This message is not issued if you disconnect the customer module
while the melt processor is active and also has command priority.
Cause: No commands issued for one minute by the interface with
command priority or transmitter element on the CPU.

014 !BUS ueber COM.. !BUS via COM..

Used to rectify hardware errors in association with the service software
during access to the internal backplane. Normally only used by the
service software.

015 !BUS Buserror.. !BUS Buserror..

Usually a DICU hardware problem with the backplane or one of the
cards plugged into it. In theory, this error could also be caused by
certain types of internal software errors, glitches, noise interference etc.

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016 !BUS Timeout.. !BUS Timeout..

Bus-related hardware damage or software crash. Particularly if a CPU
plug-in card has failed to respond.
Hardware: a card has failed to report itself.

! BUS Timeout _ 016_XXX_001

XXX => Number of the card decimal coded converted to HEX, same
coding as "!CMD Hardware-Error" (error 091), although a different
coding to "I2C Acknowledge" (error 021) or "I2C Hardware" (error 022).

Dec HEX DICU card

018 12 WRS for INV1
019 13 WRS for INV2
036 24 GRE for REC1&2
037 25 GRE for REC3&4
038 26 GRE (does not exist)
039 27 GRE (does not exist)
049 31 GRS for REC1&2
050 32 GRS for REC3&4
051 33 SIO

017 !BUS Hardware.. !BUS Hardware..

Hardware failure in the backplane, defect in a plug-in card or an internal
software crash.

018 !BUS Belegt.. !BUS Busy..

This message was intended for a multi-processor version of the
software which was never written. Therefore inactive.

019 !BUS INT0 defect.. !BUS INT0 Fail..

Interrupt zero error. The CPU cannot reset the interrupt zero flag. This
normally means that the CPU or a plug-in card is defective.

020 !I2C ueber COM.. !I2C via COM..

Failure in the ‘I2C’ bus communication. This bus is used internally on
several cards. Only significant when operating with a service PC. A
communication error or hardware problem is suspicious.

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021 !I2C Acknowledge.. !I2C Acknowledge..

Hardware error on the serial bus of the internal plug-in card or software
crash. The second code shows the card or module responsible for the
faulty function.
Same coding as for error 022.

!I2C Acknowledge.. V1_021_XXX_010

XXX => Number of the card decimal coded converted to HEX, same
coding as "Bus Timeout" (error 016) or "CMD Hardware-Error" (error
091).

Dec HEX Dec HEX

0 0 34 22
1 1 35 23
2 2 48 30
3 3 49 31
16 10 50 32
17 11 51 33
18 12 64 40
19 13 65 41
32 20 66 42
33 21 67 43

HEX 1st digit:

0=> CPU itself (EEPROM)
1 => GRS for REC1&2
2 => GRS for REC3&4
3 => WRS for INV1
4 => WRS for INV2
SIO and GRE cards are not reported

HEX 2nd digit (operating status):

0 => no access allowed (software)
1 => stop cycle not OK
2 => read error
3 => write error

022 !I2C Hardware.. !I2C Hardware..

Similar to error 021, although refers to a general hardware error.

023 !I2C Belegt.. !I2C Busy..

Can be caused by a defective chip on one of the cards. Was originally
intended for the multi-processor version (see error 018). This message
is inactive.

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024 !CPU Einstelldaten.. !CPU Adjust Data..

Means that a parameter is outside the value range after calculation as
long as UT or UE commands are active. The service software shows
inadmissible parameters highlighted in red in FU-17.

025 !CPU Falsche Version.. !CPU Wrong Version..

Not used at the present time. The DICU software can serve both types
of CPU. Potential application case later: serving different CPU versions

026 !CPU A/D-Wandler.. !CPU A/D Converter..

Analog / Digital converter not functioning properly.
Cause: error on the card or damaged software. This is a serious error
which can only be reset with the UE/UT command.

027 !CPU Test Netzteil.. !CPU Test PWR-Supl..

24V or 48V supply is outside tolerance.
!CPU Test PWR-Supl P1_027_004_001 - power unit 48VDC
is not OK.
!CPU Test PWR-Supl P1_027_005_001 - power unit 24VDC
is not OK (24V for the SIO card).

The start was aborted as early as the second step (error 089, Start
abort_002_) due to an error with the 24VDC power unit.

Check the terminal voltage and try changing the power units.
The 48VDC is monitored on the CPU card – that is the only location of
an A/D converter.

Rectification for 24VDC:

Basically voltage too high. A load is needed on 24VDC (470 Ohm
resistance between 0V and 24V). This load resistor has been installed
since 1998.

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Rectification for 48VDC:

1. Check the fuses on the backplane
2. Green LED fails to light on the 48VDC power unit. Probably a
short-circuit in a pulse transformer. Disconnect all plugs for the pulse
transformers. The following messages can appear after UT or
acknowledgement of the 48VDC power unit error and restart:
!REC Alfa-Max active.. G1_035_016_001
!INV Test Driver.. W1_055_007_001
!RED Test Driver 1 I1_059_063_001
!RED Test Driver 2 I2_060_063_001
!CMD Start aborted M1_089_002_001
although no "power unit error". Then reconnect each of the plugs
individually and find the error.

028 !CPU Test COM1/2.. !CPU Test COM1/2..

This check is made in the course of the extended test. Is normally only
used by the manufacturer during the first system tests.

029 !GR Einstelldaten.. !REC Adjust-Data..

Is calculated during a UE or UT instruction and indicates that a rectifier
parameter is outside the admissible value range. The parameter in
question is highlighted in red in FU-3, FU-4.

030 !GR Referenzdaten.. !REC Reference-Data..

The calculated reference voltages for the rectifier hardware
comparators or the associated parameters are outside the admissible
value range; see error 029.

031 !GR Ref.Einstellung.. !REC Reference-Adj..

An error occurred during UT whilst monitoring or setting the reference
generator for the rectifier hardware comparators. Usually means that
either the GRS card is damaged or the hardware parameters for the
inverter D/A range and the D/A offset need to be re-adjusted (see
window F12)

The following messages appear after UT or UE:

!REC Reference-Adj G1_031_002_001
!REC Reference-Adj G1_031_003_001
or !INV Reference-Adj W1_045_007_001
No values are highlighted in red in windows FU-1, FU-2, FU-3 or FU-4.
These messages can be issued due to scattering of Z-diodes or of a
new chip for the reference voltage on GRS/WRS cards.
Rectification:
Set in window F12 (developer's most recent recommendation 2009)
UD65=6.8

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UD66=0.275
Remark: This error is difficult to rectify if GRS and WRS cards
produced many years apart are working in a DICU at the same time.
Parameter UD65 or UD66 should be smaller for old cards than for
newer ones. A compromise is sometimes tricky to find. This can be
rectified by replacing an old card with a new one.

032 !GR Falsche Version.. !REC Wrong Version..

Wrong PROMS in the GRS card or damaged hardware (e.g. a 24-pulse
system fitted with 6-pulse PROMs.

033 !GR IRQ-Vektor.. !REC IRQ-Vector..

Internal software error. Please contact ABP in Dortmund.

034 !GR Analog-Mux an.. !REC Analog-Mux on..

Either a defective GRS card or a software error. Exchange the card and
try again.

035 !GR Alfa-Max aktiv.. !REC Alfa-Max active..

As long as any type of current, voltage or pulse amp error is active, the
hardware locks Alpha (rectifier firing angle) at the maximum firing angle
(135°el). The DICU tried to unlock Alpha during start-up or a test
without success. The cause of the error is notified in a second
message.

036 !GR Phasen-Mux.. !REC Phase-Mux..

Internal software error. An inadmissible signal combination occurred
during the phase measurement in the supply line.

037 !GR Lückstrom.. !REC Discont.Curr..

The rectifier current pulsates. Can be caused by a false start or
incorrect regulation parameters, too low minimum current, a loose
contact in the power pack or defective pulse transformers etc. Check
the rectifier current measuring circuit. Low loads, such as an empty
furnace, can also cause intermittent current.

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038 !GR Überstrom.. !REC Overcurrent..

Rectifier overcurrent. Hardware switch-off. This type of monitoring is
faster than the inverter current monitoring.
Typically caused by a wrong setting of the inverter hold-off time.
A thyristor in the rectifier is defective, although also a short-circuit in the
inverter or in the load circuit (load capacitors). Check the rectifier
current measuring circuit.

039 !GR Überspannung.. !REC Overvoltage..

Rectifier overcurrent. Hardware switch-off. Means that the incoming line
voltage is too high (often at times of weak loads and weak grids). You
can see the voltage errors in the FG window and read off the voltage
level in the FN window (press ‘.’).
The start was aborted as early as the second step (error 089, Start
abort_002_).
Check the factor for line voltage transformers, parameter UD46 in F6
and increase it, if necessary.

040 !GR Not-Aus.. !REC Emergency Stop..

Someone has pressed the small "panic button" on the front plate of the
GRS card during operation. This triggers immediate switch-off with an
error message.

041 !GR Bus-Fehler.. !REC Bus-Error..

Defective GRS card. FPGA chip on the board is damaged.

042 !GR Kein Sync-Imp.. !REC No Sync-Impuls..

Rectifier and inverter are started by the DICU to build up pre-mag
current, but the synchronous pulse (simultaneous firing pulse for REC
and INV) fails to arrive because there is no line voltage or a grid failure.
No line voltage to the DICU plug (no high voltage), line overvoltage or a
hardware failure during the attempted start. Likewise check the line
voltage transformer and wiring to the DICU.
Only the line voltage L1-L2 for REC1 is monitored during the start.
Check the values in window FN and FP. See error 089, Start
abort_004_.

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043 !WR Einstelldaten.. !INV Adjust-Data..

An inverter parameter was outside the value range during a UE or UT
instruction. The parameter in question is highlighted in red in FU-1, FU-
2. Check: Phi start > Phi warm-up > Phi min

044 !WR Referenzdaten.. !INV Reference-Data..

Reference voltages calculated (in FU-1, FU-2) for the inverter hardware
comparators or for other associated parameter are outside the value
range; see error 043. overcurrent is such an example.
The reference values are in FU-1, FU-2 on the right:
0 < reference value < 63.

045 !WR Ref.Einstellung.. !INV Reference-Adj..

An error occurred when monitoring or setting the reference voltage
generators for the inverter hardware comparators during UT. This
usually means that the WRS card is damaged or the hardware
parameters for the A/D range and for the D/A offset need to be re-
adjusted. See window F12.
Also see error 031.

046 !WR Falsche Version.. !INV Wrong Version..

Wrong PROMS on the WRS card or hardware error.

047 !WR IRQ-Vektor.. !INV IRQ-Vektor..

Internal software error; see error 033.

048 !WR Analog-Mux an.. !INV Analog-Mux..

Either a defective WRS card or a software failure.

049 !WR SzTeiler falsch.. !INV Wrong Trec-Div..

WRS card hardware defect or software error.

050 !WR Ueberspg.UW/UO.. !INV Overvolt.UW/UO..

The voltage is too high either at the inverter output or the LEM output.
Control problems caused by critical line conditions or instabilities could
be the reason.
The values for UW output and UO furnace LEM can be seen in
windows FL1 and FL2.
In an SP system, only the UW voltage is important and is taken for
regulation. The UO voltage is not filtered and shows a momentary
value. This variable cannot be used, although the Umax switch-off is
active for both channels.

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In a TP system, the Ulem voltage is connected instead of the UO

voltage - the Ulem voltage is filtered in the LEM adapter.
As usual, firing pulses for the rectifier thyristors are blocked after the
error message. However, this error also blocks further firing pulses for
the inverter thyristors. The last inverter diagonal remains conducting
until the current drops to zero.
Check voltage transformers and LEM module/LEM transformer.

051 !WR Ueberspg. UZ.. !INV Overvolt. UZ..

Firing voltage too high. Possibly incorrect WRS parameters or a control
problem as a result of critical load conditions. Uz and Uzmax are only
calculated and not measured! These values come from the calculation
Ufurnace, Tcomm-time and Toff-time.

052 !WR Ueberstrom.. !INV Overcurrent..

The inverter current overshot the trigger limit. Failure of the control
limiters, also high current ripple, short-circuit in the load circuit, load
capacitor defective. Check the inverter current measuring circuit.

053 !WR Differenzstrom.. !INV Diff.-Current..

Id (rectifier current) exceeded IWR (inverter current) by more than the set
limit – check waveform with an oscilloscope.
This monitoring is put on hold during inverter commutation. The
differential current is only evaluated in the time between the voltage
zero-crossing and the time of firing. Typical causes are defective
thyristors in the inverter (cooling, switching), defective pulse
transformers or commutation errors due to an incorrect recovery time
setting. Check the current measurement circuit.

054 !WR Frequenz Fmin.. !INV Frequency-Min..

Internal counter overflow. No furnace voltage zero-crossing.
The working frequency during operation is too low – this really can
happen. Check voltage waveform at MB8 on the WRS card with an
oscilloscope.
The error can have a number of causes, e.g. no MF voltage, defective
start device, loss of the furnace voltage feedback signal, commutation
error. Check the voltage measuring circuit. Short-circuit in the load
circuit (load capacitor) or power cable breakage. See error 089, Start
abort_006_.

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055 !WR Test Endstufe.. !INV Test Driver..

WRS card is damaged, the pulse transformer is poorly connected,
overcurrent. If several pulse transformers are connected in parallel, only
the sum current is monitored and not each single pulse transformer.
The message arrives after UT or UE or during operation.
The pulse transformers can only be disconnected from the DICU one
second after the actual converter switch-off with ramp (A0 is "0" on the
SIO card) - e.g. when switching the firing pulses to the short-circuit
thyristor ST in TP systems.

!INV Test Driver.. W1_055_XXX_001

XXX – defines the defective channel of the firing pulse. XXX can be
greater by +128.

000 Overcurrent
001 Diagonal A(1)
002 Diagonal B(2)
003 Diagonals A(1) and B(2)
004 Start thyristor
005 Diagonal A(1) and start thyristor
006 Diagonal B(2) and start thyristor
007 Diagonal A(1), diagonal B(2) and start thyristor

000 in the middle means overcurrent for the switch transistors on the
WRS card. Sum current is measured at the 6W ceramic resistor (below,
at the plug). The new GES9558046P1 pulse transformers require more
current. These have therefore had a measurement resistance of
0.022Ω since autumn 2012 (the measurement resistance was
previously 0.047Ω). The DICU parameters remain unchanged. This
means that the admissible sum firing current has practically doubled.

Inverter firing pulses via booster: the pulse transformer connections are
not monitored in this case because they are connected directly to the
booster. Only the fiber-optic driver is connected to the DICU's firing
pulse output.

056 !WR Bus-Fehler.. !INV Bus-Error..

WRS card defective. FPGA chip on the card is damaged.

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057 !WR Fehlstart.. !INV Start failed..

Start aborted in step 5 (see error 089). The current measured at the
inverter output failed to reach the pre-mag current value.
Cause: Inverter thyristors defective, inverter current measurement, no
rectifier or inverter firing pulses.
TP systems: if the cause lies in INV2 (e.g. defective thyristors), the
message nevertheless comes for INV1, as shown below:
!INV Start failed... W1_057_018_001

058 !GE Falsche Version.. !RED Wrong Version..

Defective or wrong PROMs on the GRE card or a hardware defect.

059 !GE Test Endstufe 1.. !RED Test Driver 1..

Error in pulse amplifiers set #1 of the first 6-pulse rectifier on the GRE
card or an external hardware error.

!RED Test Driver 1..I1_059_XXX_001

XXX – defines pulse amplifier. XXX can be greater by +128.

XXX is binary coded and consists of the sum 2n. XXX depicted as the
sum of 1, 2, 4, 8, 16, 32 and 128.

20 1 Pulse amp R+
21 2 Pulse amp R-
22 4 Pulse amp S+
23 8 Pulse amp S-
24 16 Pulse amp T+
25 32 Pulse amp T-
26 Always 0
27 Added 128

If an error occurs, the message then comes for both pulse amp sets on
the GRE card. The GRE pulse amp set that is OK has the number 000
in the middle.

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If both messages have _000_ in the middle, the GRE card is probably
defective!

Example 1:
Error message !RED Test Driver 1..I1_059_008_001 means:
The "008" in the middle means that the error is located at the output for
thyristor S- in REC 1, plug X701.

Example 2:
Error message !RED Test Driver 1..I1_059_135_001 means:
The "135" in the middle means: 135
-128 deduct 128
7
-4 thyristor S+
3
-2 thyristor R-
1
-1 thyristor R+
0
The "135“" in the middle means that the errors occurred at the outputs
for thyristors R+, R- and S+ in REC 1, plug X700. Check plug X700.

060 !GE Test Endstufe 2.. !RED Test Driver 2..

The same as error 059 for pulse amplifiers set #2, second 6-pulse
rectifier on the GRE card or external hardware error.

!RED Test Driver 2..I1_060_XXX_001

XXX – same coding as for error 059.

061 !GE Bus-Fehler.. !RED Bus-Error..

GRE card is defective. FPGA chip on the card is damaged.

062 !IO Falsche Version.. !IO Wrong Version..

Wrong GAL chip on the SIO card or card is defective.

063 !IO Fehler Ausgang.. !IO Output Error..

Output on the SIO card is damaged or poorly connected; not used at
the present time.

064 !IO Bus-Fehler.. !IO Bus-Error..

SIO card defective, bus interface damaged.

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065 !REG Einstelldaten 1.. !REG Adjust-Data 1..

A nominal value calculated during a UE or UT instruction is outside the
admissible value range. The parameter is question is highlighted in red
in FU-6 to FU-12.

066 !REG Einstelldaten 2.. !REG Adjust-Data 2..

As with error 065, but concerns the calculated control parameters.

Please note: All LOG errors are calculated by the software. The error
determination time is determined by parameter UD80 or
UD81 in window F14.

067 !LOG Einstelldaten.. !LOG Adjust-Data..

A log book parameter calculated during a UE or UT instruction is
outside the admissible value range. The parameter is question is
highlighted in red in FU-13 to FU-16

068 !LOG Frequenz Fmax.. !LOG Frequency Max..

Only active in Single Power mode.
The mean value for the inverter frequency calculated by the software is
too high.
Too few load capacitors, furnace is heavily washed out.

069 !LOG Schonzeit Min.. !LOG Circuit TOT Min..

The DICU cannot keep the hold-off time constant. Can be caused by
unsuitable start or control parameters.

070 !LOG di/dt Max.. !LOG di/dt Max..

Di/dt is determined by the value of the firing voltage.
The firing voltage calculated by the software is too high. Control
problem which particularly surfaces with Twin-Power systems at critical
load conditions. Causes a howling sound. Basically caused when two
different limit values (e.g. nominal voltage and firing voltage) are
approached simultaneously.

071 !LOG Frequenz-Messg.. !LOG Measur.-Freq..

Difficulties in stably recording the inverter frequency. Generally causes
knock-on disturbances and leads to repeated error switch-offs.

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072 !LOG TKomm-Messung.. !LOG Measur.-Tcomm..

Unstable commutation usually due to high current ripple, thereby
making uniform measurement impossible. Also WRS card defective.

073 !LOG Ueberspg. UW.. !LOG Overvolt. UW..

Overvoltage triggered by the software (mean value), runs with the
momentary value for the voltage. Particularly with reduced voltage
through SIO inputs or service software.

074 !LOG Netz UD 1.. !LOG Line UD 1..

The intermediate circuit voltage UD1 of the first 6p rectifier on the GRE
card that has been calculated (from line voltages) is too high or too low.
The UD voltage is shown in the FN window. Values that are too
high/low are highlighted in red.
The line voltage is too high, too low or the line parameters are incorrect.
If the line voltage is too low, UD1 error is issued after the start of the
LOG line after some 5 seconds. For a 12p rectifier (both voltages too
small), the error message only comes with UD1.
If the line voltage is too high, the start is aborted in step 2, rectifier
overvoltage.

There are 6 small, black 230V/9V line voltage transformers installed on

the backplane (and also on the subprint for a 24p DICU).
Adapt parameter UD70 I window F13 to match the transformer power.
These transformers had a power of 0.33VA up to 2012: UD70=20
These transformers have had a power of 0.5VA since 2012: UD70=24
The same transformers must be in the 24p DICU as on the backplane
and on the sub-board.

075 !LOG Netz UD 2.. !LOG Line UD 2..

As with error 074, only for the second 6p rectifier on the GRE card.

076 !LOG Netz UD 1-2.. !LOG Line UD 1-2..

The software has found an excessive difference between the line
voltage of rectifiers 1 and 2 (12-pulse system). As with error 074. Line
transformer or line voltage transformer is faulty.

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077 !LOG Netz UD 12-34.. !LOG Line UD 12-34..

Excessive difference between the first and the second pair of rectifier
supply voltages in a 24-pulse system. Same tolerance as for error 076.

078 !LOG Netz Phase 1.. !LOG Line Phase 1..

The phase shift is measured in the line cables between the phases of
rectifier 1. The software monitors whether there is a shift of 120/240
degrees between phases 1&2, 2&3 and 3&1, and confirms the (correct)
phase rotation. This message is issued if the measured values are
outside tolerance or if there is a different phase rotation. The measured
values can be seen in window FP.

079 !LOG Netz Phase 2.. !LOG Line Phase 2..

Similar to error 078, although for rectifier 2 in a 12-pulse system.

080 !LOG Netz Phase 1-2.. !LOG Line Phase 1-2..

Phase shift between rectifier 1 and 2 is outside the tolerance limit. It
does not agree with any uneven multiple of 30 degrees (parameter
UD214 in F5). Only the phase shift between phases L1 (rectifier 1) and
L1 (rectifier 2) are measured.

081 !DAT Datei/EEPROM.. !DAT File/EEPROM..

The data record in the EEPROM on the CPU card does not match the
format on the EPROM (software version).
Same message if the CPU card is new and has never had a data
record.
If such a CPU card is installed in the DICU and only the customer
module is connected, the display then shows three lines with asterisks
and the error message: !DAT File/EEprom in the 4th line. The CPU does
not boot further and remains at standstill.
Rectification: load the correct data record from the service PC.

082 !DAT Index-Fehler.. !DAT Index-Error..

Internal software failure. If you ever notice the precise circumstances
under which this error occurred, please notify us at ABP in Dortmund.

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083 !DAT Zu klein/gross.. !DAT Too small/big..

The parameter values just entered on the service PC are outside the
admissible range.
The number in the middle of the message is the number of the
parameter that is too small/big.
In the example below, parameter UD12 is too small/big.

UD !DAT Too small/big..K1_083_012_001

Detailed information on the admissible parameter ranges is given in

Chapter 5.2.

084 !DAT Uebertragung.. !DAT Transmit..

The PC tried to send data to or receive data from the DICU without
success. Check the serial connection cable, PC and CPU card.

085 !TEX Datei-Fehler.. !TEX File-Error..

The PC could not find or load the GLOTEXT.TXT file when the service
program was launched. Use LOAD-batch before starting GRTEST and
check the content of the TEXT sub-directory.

086 !ANZ Einstelldaten.. !DIS Einstelldaten..

A display parameter calculated for the customer module or for the melt
processor during a UE or UT instruction is outside the value range. The
parameter in question is highlighted in red in FU-5.

087 !ANZ Datei-Fehler.. !DIS File-Error..

PC problem when writing the display or log buffer contents (FX1 to FX6)
to a file or when loading the screen text data. If the service software is
unable to find the files for the screen text (*.TXS), it ends the operation
with a runtime error and displays an appropriate message. See error
085, check TXS files.

088 !CMD Start-Parameter.. !CMD Start-Paramet..

A start parameter calculated during a UE or UT instruction is outside the
value range. The parameter in question is highlighted in red in FU-12.

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089 !CMD Start-Abbruch.. !CMD Start aborted..

This message never comes alone, but is followed by a second or third
message. The number in the middle shows the step in the start
procedure (001-012) in which the error occurred. Always note all
messages in order to find the cause of the problem.
Chapter 7.6.3 contains a detailed description of the start procedure.
Example (start aborted in step 2):
!CMD Start aborted.. M1_089_002_001
!INV Test Driver.. W1_055_004_001
!REC Alfa-Max active.G1_035_018_001

Start abort_001_:
A software error occurred when setting various data at the beginning of
the start procedure.

Rectification: acknowledge and start again. If the error is repeated,

check the program and run it again.

Start abort_002_:
The hardware was made ready for start-up and the rectifier firing pulse
amplifiers switched on (rectifier firing pulses to the inverter's limit
position 135°el). A line error (rectifier overvoltage), a hardware error
(REC and INV pulse amps) or a CPU test 24VDC power unit error
occurred.
There is either an external error (e.g. line voltage too high or pulse
transformer wrongly connected) or the DICU hardware is defective.
If the power supply 48VDC or the including fuse F1 are damaged, driver
errors for all REC and INV pulse transformers appear.
If a rectifier thyristor is defective, a short-circuit occurs in the rectifier
during this step (other rectifier thyristors are receiving firing pulses) and
rectifier overcurrent is reported. The DICU blocks the firing pulses and,
if no further rectifier thyristor has been damaged, the current is switched
off. In such a case, do not attempt any further starts but check the
rectifier thyristors.

Rectification: switch the line voltage on and check it (if necessary,

amend UD45 in F5 and UD46 in F6), switch the rectifier firing pulses on
(GZ1), check the GRS status (FG window), the line data (FP/FN
windows) and the WRS Status (FW window), inspect the line voltage
transformers and cables.
Any further error messages – test the hardware.

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Start abort_003_:
The interrupt-controlled hardware monitoring and the error output on the
CPU card were enabled, and this led to an error.
Rectification: See Start abort_002_.

Start abort_004_:
Rectifiers and inverters are started by the DICU to build up the pre-mag
current. There is no synchronous pulse (simultaneous firing pulse for
REC and INV) due to the absence of line voltage or to a line error or a
hardware error occurs. The DICU only monitors the line voltage L1-L2
at start-up.
It can happen that the customer has forgotten to provide the high
voltage. The power switch is turned on, although the upstream cut-off
switch is still open.
The line voltage is most often missing in this step, although other line
errors, such as "REC overvoltage", are also possible.
Rectification: see Start abort_002_. Measure the line voltage.

Start abort_005_
After the converter has started, the DICU waits in vain for the current at
the inverter output. The pre-mag current value from the inverter current
was not reached in a certain time, the system overshot limit values for
current/voltage, or a hardware error occurred.
Possibly re-start, observe the GRS-ID waveform (MB16) and WRS-IW
waveform (MB12) with the oscilloscope. If current does not flow, either
the current measurement circuit is interrupted or the inverter thyristors
are defective, the holding current was not reached or there is a wiring
error. If ID current (GRS MB16) is present but there is no IW current
(WRS MB12), the thyristors in the inverter are defective.
In case of overcurrent or greatly differing current waveforms, the current
transformers may well be wrongly connected or the transformer factors
are incorrect.
Rectification: check the current limit values, rectifier and inverter wiring,
measurement transformers, pulse transformers and the DICU.
Change the Alpha pre-mag current (UD40) and/or, if the current is
missing, extend the pre-mag current pulse (UD115) to 144µs. Re-
calculate the transformer factors. Inspect the inverter thyristors.

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Start abort_006_:
Ring test or commutation failed during the preset "start wait time"
(UD7), the system overshot limit values for current/voltage, wait time, or
a hardware error occurred. The starter device did not function.
The DICU did not recognize a furnace voltage zero-crossing.
Possibly re-start, observe the WRS-UWR output voltage (MB8) and
WRS-IWR output current (MB10) and WRS firing pulses (MB15 and
MB16) with the oscilloscope.
Rectification: Ring-test/commutation (F-Min) – test the function and
polarity of the starter device and of the resonant circuit voltage on the
DICU and the wiring. Check the real ocillation frequency, “Min-
Frequency“ (UD3 in F3), "Start Time-1Imp", "Start Time-2Imp" and
"Start Phase-Reg" (UD4, UD5, UD6 und UD167, UD168, UD169 in F7).
As a last remedy, the "Advance-Current" (UD23 in F7) can also be
changed, although this normally does not have any noticeable
influence.
Further error messages – test the hardware.

Start abort_007_:
After switching to "Alpha warm-up", limit values were exceeded,
commutation failed or a hardware error occurred.
Rectification: see Start abort_006_.

Start abort_008_:
Steps 008, 009 and 010 start with a small time lag to each other and
then run down parallel.

After switching the "warm-up control time" (UD102) to "Phi warm-up",

limit values were exceeded, commutation failed or a hardware error
occurred.
Rectification: see Start abort_006_.

Start abort_009_:
The Idmin and Idisc monitors were enabled in this step. Limit values
were overshot after the release, commutation failed or a hardware error
occurred.
Rectification: see Start abort_006_.

Start abort_010_:
The Uzmax and Idiff monitors were released in this step. Limit values
were overshot after the release, commutation failed or a hardware error
occurred.
Rectification: see Start abort_006_.

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Start abort_011_:
In the warm-up control phase, limit values were overshot, commutation
failed or a hardware error occurred.
Possibly re-start, observe the WRS-IW waveform (MB12) and WRS-UW
waveform (MB9) with the oscilloscope. The controller attempts to keep
the current horizontal.
Rectification: limit values/commutation – check "Start wait time"
(UD7),"Alpha-Adv.-Curr." (UD40),"AlfaWarmUp Norm" (UD41), "Start-
Voltage" (UD18) and "Warm-Up Amplify" (UD96). If the current and the
control data for Alpha oscillate, first reduce the "Warm-Up Amplify", then
test again and, if necessary, extend the "warm-up control time"
(UD102).
Further error messages – test the hardware.

Start abort _012_:

In the start control phase, limit values were overshot, commutation
failed or a hardware error occurred, see Start abort_011_.
An error in the start control phase is usually attributable to an
unfavorable course taken in the warm-up control phase! Start-up in
extreme furnace states, such as cold start or empty furnace, is
especially difficult.
Rectification: limit values/commutation – the start control phase is
influenced by all the inverter and control parameters. These should only
be changed if the warm-up control phase ends with a flat current course
and errors still occur!
Basic rule:
Reduce oscillation current/voltages =>"Start-Amplify" (UD87 and
UD91).
System only stabilizes slowly =>reduce "Start-Amplify", possibly extend
"Start Control Time" (UD103).
Further error messages – test the hardware.

090 !CMD Not-Aus.. !CMD Emergency Stop..

A stop command was sent to the DICU by a device that does not have
command priority. This could happen if the melt processor connected to
COM2 has priority (SIO inputs active - service switch set to "Off", input
E11=1) and the service PC is connected to COM1 to observe the
system, and the Off key (#) on its keyboard is pressed. The converter
stops immediately and the following error code is issued:
!CMD Emergency Stop. M1_090_001_001

DICU software version 641 and upwards: the DICU switches off
immediately (without ramp) and issues the following error message:
!CMD Emergency Stop. M1_090_002_001
This happens if the release (input E0 on the SIO card) is retracted E0=0
during operation (input E1=1 on the SIO card).
The DICU behaves in exactly the same way during test mode with a
service PC. This error could occur if there is a loose contact in the

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release circuit or the release voltage is around 21V and can be

interpreted by the SIO card as logically being 0.

091 !CMD Karte defekt.. !CMD Hardware-Error..

The software has examined the system configuration after a reset and
found that either cards are missing or are defective. Check the
arrangement of cards.

!CMD Hardware-Error.. M1_091_XXX_001

XXX => Decimally coded number of the card, same coding as
“BUS Timeout” (see error 016), although a different coding to "I2C
Acknowledge" (see error 021) or "I2C Hardware" (see error 022).

Dec HEX DICU card

018 12 WRS for INV1
019 13 WRS for INV2
036 24 GRE for REC1&2
037 25 GRE for REC3&4
038 26 GRE (does not exist)
039 27 GRE (does not exist)
049 31 GRS for REC1&2
050 32 GRS for REC3&4
051 33 SIO

092 !CMD Quit durch UT.. !CMD ErrReset by UT..

A serious software or hardware error has occurred that can only be
reset with a UE or UT command, e.g. A/D converter error, bus error.

093 !ERR Quittung.. !ERR Reset..

Not used. Taken over from earlier versions.

094 !?? falscher Fehler.. !?? False Error..

Undefined CPU RAM content. RAM supply voltage lost –defective
battery. The software has found a false error code in the error log. The
error code file was damaged when uploading the data to the service
PC.

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8.1.2 List of DICU warnings

Warning messages are issued as explanations when issuing

commands from the keyboard of the computer or melt processor. They
start with "?". (These warnings are not saved in the error log).

095 ?COM Timeout.. ?COM Timeout..

No reaction at the other end of the line; generally the cable connecting
the PC and the DICU. Happens when a service PC is used.

096 ?COM CheckSumme.. ?COM CheckSum..

An instruction containing a false check sum was sent to COM1/COM2
on the DICU or the PC. Generally indicates a faulty connection cable or
connection problems with the PC.

097 ?COM Befehl falsch.. ?COM Wrong Command..

The software does not understand the input command.

098 ?COM Syntax-Fehler.. ?COM Syntax-Error..

Syntax error in an instruction string; e.g. SN100=0 for a Single Power
system.

099 ?COM Befehl gesperrt.. ?COM Cmd Prohibited..

You have tried to enter an instruction on the service PC for which you
do not have command priority (the service switch is possibly in the
wrong position).

100 ?COM Daten geaendert.. ?COM Data Changed..

The instruction has been blocked due to changed internal data. A data
record was loaded or only one parameter was changed without
subsequently executing UE or UT.

101 ?COM Quittung fehlt.. ?COM No Err.-Reset..

As a reminder; you must first enter reset (+) before you continue with
the present instruction.

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8.1.3 Classification in the DICU error list, SIO card outputs

Error classes are groups which serve to classify error codes. They are
used for internal software purposes and attached to the error list
printouts as explanations. This classification is given in error log file
behind the error message (Text) for each error. Classes begin with *.
The class of the error is set accordingly high at SIO card outputs.

102 *GR/WR StromStoerung *REC/INV Curr.-Fault

Line or inverter current was too high or too low. SIO output: A2.

103 *GR Netz-Stoerung.. *REC Line-Fault..

Difficulties with the line voltage or with the line phases. SIO output: A3.

104 *WR Ueberspannung.. *INV Overvoltage..

Inverter voltage was too high. SIO output: A4.

105 *WR ThyristorFehler.. *INV Thyristor-Fault..

Problems with the commutation or firing voltage or with inverter
measurement. SIO output: A4.

106 *WR Frequenz-Grenze.. *INV Frequency-Limit..

Maximum or minimum frequency overshot/undershot. SIO output: A6.

107 *WR Erdschluss.. *INV Earth-Leakage..

Not used.

108 *GR Not-Aus.. *REC Emergency-Stop..

Someone has pressed the small "panic button" on the front plate of the
GRS card or has sent an Off command without having control over the
DICU. SIO output: A3.

109 *CPU Fehler DataCom.. *CPU DataCom-Error..

Service PC or DICU communication error. SIO output: A7.

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110 *Einstell-Fehler.. * Adjust-Error..

Parameters calculated for the data record are outside the value range.

111 * Datenbasis-Fehler.. * Database-Error..

It was not possible to load the EEPROM on the CPU card or the
parameter file on the service PC. A review of the internal database
discovered an error. SIO output: A8.

112 * Hardware-Fehler.. * Hardware-Error..

General hardware error in the DICU. SIO output: A7.

113 * Software-Fehler.. * Software-Error..

Software error in the compiled code. Program error; please note the
circumstances of the error and inform ABP Dortmund. SIO output: A7.

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8.2 DICU error logs

The error logs are saved in a nn.ERX file in the ERR directory. The measured
data are kept in error logs. These measured data are not recorded at the
instant an error occurs. The DICU saves the measured data at intervals
(cycles of approx. 21 mS). The measured data saved are the last cyclically
recorded values before the error occurred.

8.2.1 Description and structure of the error log file

An error log file consists of 128 lines. If more than 128 lines were recorded,
the oldest record is overwritten.

The file header contains the following information:

EPROM software version with creation date (GrTest 6.5 06.07.06)
When the file was saved (30.09.2013 08:31:14:040)

An example error log file for a Single Power system (compiled with the GrView
software). One line for the data measured for the converter:

GrView 6.5 06.07.06 (C) RBW-Elektronik

Erstellt/Created : 13.11.2013 13:36:01:660
Anzahl/Count : 96
Format : Error-Text Error-Code Error-Type Date Time
: Status Alfa Soll1 UW1 IW1 PW1 UZ1 F1 TK1 TS1

!CMD Start aborted.. M1_089_006_001 * Hardware-Error... 13.11.2013 13:31:32:270

8130 134.8 ø 0.0 kW 10.5 V 60.4 A 1.2 kW 1.9 V 1515.2?Hz 0.0?æs 50.7 æs

!INV Frequency-Min.. W1_054_000_001 *INV Frequency-Limit.13.11.2013 13:31:32:270

8130 134.8 ø 0.0 kW 10.5 V 60.4 A 1.2 kW 1.9 V 1515.2?Hz 0.0?æs 50.7 æs

!CMD Start aborted.. M1_089_011_001 * Hardware-Error... 13.11.2013 13:30:30:800

8130 134.8 ø 0.0 kW 65.4 V 214.3 A 7.3 kW 16.7 V 1225.5?Hz 0.0?æs 114.6 æs

!INV Diff.-Current.. W1_053_180_001 *REC/INV Curr.-Fault 13.11.2013 13:30:30:800

8130 134.8 ø 0.0 kW 65.4 V 214.3 A 7.3 kW 16.7 V 1225.5?Hz 0.0?æs 114.6 æs

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An example error log file for a TWIN POWER system compiled with the
GrView software). Two lines for the data measured for the converter (INV1
and INV2):

GrTest 6.5 06.07.06 (C) RBW-Elektronik

Erstellt/Created : 30.09.2013 08:31:14:040
Anzahl/Count : 1740
Format : Error-Text Error-Code Error-Type Date Time
: Status Alfa Soll1 UW1 IW1 PW1 UZ1 F1 TK1 TS1
: Soll2 UW2 IW2 PW2 UZ2 F2 TK2 TS2

!REC Overcurrent... G1_038_025_001 *REC/INV Curr.-Fault 02.09.2013 19:59:22:450

5345 6.3 ø 6173.7 kW 2958.2 V 3241.2 A 5731.1 kW 3135.9 V 193.2 Hz 42.9 æs 651.6 æs
2292.8 kW 1962.3 V 3210.0 A 2169.4 kW 2650.3 V 164.2 Hz 55.5 æs 1106.6 æs

!CMD Start aborted.. M1_089_012_001 * Hardware-Error... 23.08.2013 05:57:41:640

C141 20.2 ø 2169.7 kW 3228.0 V 889.6 A 1968.1 kW 2941.7 V 143.2 Hz 0.0 æs 779.2 æs
609.5 kW 848.7 V 780.4 A 357.8 kW 915.8 V 188.4 Hz 35.3 æs 690.0 æs

!REC Discont.Curr... G2_037_026_001 *REC/INV Curr.-Fault 23.08.2013 05:57:41:640

C141 20.2 ø 2169.7 kW 3228.0 V 889.6 A 1968.1 kW 2941.7 V 143.2 Hz 0.0 æs 779.2 æs
609.5 kW 848.7 V 780.4 A 357.8 kW 915.8 V 188.4 Hz 35.3 æs 690.0 æs

!INV Diff.-Current.. W1_053_180_001 *REC/INV Curr.-Fault 25.07.2013 20:34:15:140

5340 6.3 ø 4965.8 kW 2472.5 V 3511.8 A 4937.1 kW 2768.2 V 194.0 Hz 48.4 æs 689.7 æs
3534.2 kW 2345.0 V 3480.5 A 3824.5 kW 2941.7 V 145.5 Hz 49.9 æs 1112.5 æs

!CMD Emergency Stop..M1_090_002_001 *REC Emergency-Stop..24.07.2013 10:53:53:440

1330 6.3 ø 0.0 kW 14.7 V 5.2 A 0.0?kW 0.0?V45977.0?Hz 0.0?æs 0.0?æs
6201.6 kW 2972.9 V 2533.7 A 6217.5 kW 1935.7 V 174.8 Hz 58.1 æs 374.9 æs

Information on the format of saved error messages and measured data:

Format : Error-Text Error-Code Error-Type Date Time
: Status Alfa Soll1 UW1 IW1 PW1 UZ1 F1 TK1 TS1
: Soll2 UW2 IW2 PW2 UZ2 F2 TK2 TS2

As an example, the following error message:

!CMD Start aborted.. M1_089_011_001 * Hardware-Error... 13.01.2003 07:21:11:560
8130 134.8 ø 0.0 kW 29.4 V 8.3 A 0.0?kW 0.0?V60606.1?Hz 0.0?æs 0.0?æs
0.0 kW 171.7 V 1864.6 A 62.6 kW 270.6 V 436.0 Hz 0.0 æs 573.7 æs

!INV Diff.-Current.. W2_053_180_001 *REC/INV Curr.-Fault 13.01.2003 07:21:11:560

8130 134.8 ø 0.0 kW 29.4 V 8.3 A 0.0?kW 0.0?V60606.1?Hz 0.0?æs 0.0?æs
0.0 kW 171.7 V 1864.6 A 62.6 kW 270.6 V 436.0 Hz 0.0 æs 573.7 æs

Both messages appear at the same time because the problem occurred during
start-up.
The "Start abort" error message is always followed by further error messages.
The messages that belong together can be identified from the time stamp.
Messages with the same time stamp belong together (a difference of up to 200
mS is admissible).
As start-up was interrupted in step 11, there are no proper measured values.

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Another example message for an error in normal operation:

!INV Diff.-Current.. W1_053_180_001 *REC/INV Curr.-Fault 25.07.2013 20:34:15:140
5340 6.3 ø 4965.8 kW 2472.5 V 3511.8 A 4937.1 kW 2768.2 V 194.0 Hz 48.4 æs 689.7 æs
3534.2 kW 2345.0 V 3480.5 A 3824.5 kW 2941.7 V 145.5 Hz 49.9 æs 1112.5 æs

The measured electrical values should be interpreted as follows:

5340 Status No limit reached. See details below.
6.3 ° Alpha REC firing angle
4965.8 kW Soll1 Power target value for INV1
2472.5 V UW1 Inverter output voltage INV1
3511.8 A IW1 Inverter output current INV1
4937.1 kW PW1 Inverter output power INV1
2768.2 V UZ1 Firing voltage INV1
194.0 Hz F1 Frequency INV1
48.4 æs TK1 Commutation time INV1 (in µS)
689.7 æs TS1 Hold time INV1 (in µS)

The second line in the error message shows the values for the second
inverter.

Meaning of the status message:

The status message has 4 digits, although only the last one is of importance.
This figure shows the limit that the DICU has reached and what is limiting the
operation of the system.

0 = no limits reached
1 = nominal voltage, parameter UD10 in window F1
2 = minimum voltage, parameter UD15 in window F3
3 = nominal current, parameter UD19 in window F1
4 = minimum current, parameter UD21 in window F3
5 = firing voltage, parameter UD16 in window F1

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9 Annex

9.1 Annex A1: Instructions for a DOSBox for DICU

Setting up access to the DICU by means of a DOSBox from the service PC is
described in the "Anleitung DOSBox für DICU.docx" file.

9.2 Annex A2: GrView

How to set up a service PC for the REC software is described in "BA 53.701-6.018".
The GrView software is described in "BA 53.701-6.019".

9.3 Annex A3: DICU – Data Interchange Protocol

The DICU's Data Interchange Protocol is described in "BA 53.701-6.025".

9.4 Annex A4: DICU database

The DICU database is presented in the "DICU Datenbank1 Öztürk.docx" file.

9.5 Annex A5: Setting values and test protocol for MF converters
Setting values and the test protocol for DICU adjustments are described in the
"Prüf12.doc" file.

9.6 Annex A6: Specimen file for DICU adjustment

The creation of a new parameter file for the DICU is described in Chapter 7.3.1. The
results are stored in the "Muster.dat" file (HEX characters) and "Muster.dax" file (text
file).

9.7 Annex A7: Exchanging the fiber-optic adapter for the DICU
How to exchange the fiber-optic adapter is described in "BA 53.701-6.024".

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