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S S
GENERATOR SETUP

INVERTER CONTROL
PCB OVERVIEW
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S GXR Inverter control

RV5
board overview
Potentiometer & switch locations

RV16
RV3 SW1
RV4 RV1
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RV6 RV8
RV2

RV9
SW2

RV12 RV11 RV10

SW3

RV13

RV14
BOTTOM
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S GXR
SW1
Inverter control board overview
Switch descriptions

A – Auto / Manual frequency control – UP = manual / Down = Auto

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B – Not used
C – Not used
D – Not used

SW2
Position 1 (left) – Manual power control (generator panel)
Position 2 (middle) – Proportional (line speed)
Position 3 (right) – Remote (PLC)
SW3
A – UTS frequency – Up = high / down = low
B – UTS override – Up = override / Down = sensor
C – Not used
D – Power demand I/P – Up = 0-10V / Down = 4-20mA
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S GXR



Inverter control board overview
Potentiometer descriptions

RV1 – Meter calibration frequency

RV2 – Maximum frequency (25kHz)
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 RV3 – Reactive power zero calibration
 RV4 – Meter calibration true power
 RV5 – Main power calibration - DO NOT ADJUST
 RV6 – Proportional control speed / power setpoint
❑ RV7 – N/A
 RV8 – Minimum frequency (10 kHz)
 RV9 – Control voltage (10v) offset
 RV10 – Reactive power isolator - 5.00 v at 0.00 Kvar (O/P)
 RV11 – True power isolator - 10 v @ maximum power (O/P)
 RV12 – Power demand isolator - 10 v for maximum power (I/P)
 RV13 – Min Speed (up to speed)
 RV14 – Current trip level (over current)
❑ RV15 – N/A
 RV16 – Auto frequency control gain
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S GXR Inverter control board overview
LED locations S
LED 1 LED 2 LED 3

ABCDEFGHIJ ABCDEFGHIJ ABCDEFGHIJ

BOTTOM
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S GXR Inverter

LED 1
control board overview
LED Descriptions

LED2 LED3
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A – 24v (A) A – Shutdown A – UTS signal
B – 15v (B) B – + Mismatch B – Rotation sensor (pulses)
C – -15v (B) C – - Mismatch C – N/A
D – 15V (C) D – Overcurrent trip D – Treat on
E – Interlocks closed E – Skip E – N/A
F – Overtemperature (OK) F – Skip signal F – N/A
G – 24v (B) G – Remote skip / treat G – No error IGBT driver 1
H – Start H – High alarm H – No error IGBT driver 2
I – Relays closed I – Low alarm I – Remote not stop
J – Line up to speed J – UTS signal J – Remote / Local
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S S
GENERATOR SETUP

MATCHING GENERATOR TO
TREATER STATION
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S Matching generator to
treater station
• The following steps show how to match a
S
GXR generator to a treater station
• This ensures the generator, HT
transformer and treater station are running
at there most efficient
• Matching should be carried out when a
system is first installed or when a
substantial change has occurred i.e.
changing air gap to suit a different material
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S CAUTION S
IN ORDER TO CARRY OUT THE FOLLOWING
ADJUSTMENTS THE GENERATOR CABINET
DOOR WILL NEED TO OPEN WHEN THE
GENERATOR IS RUNNING

HIGH VOLTAGES ARE PRESENT INSIDE THE

GENERATOR CABINET

ADJUSTMENTS SHOULD ONLY BE MADE BY

QUALIFIED PERSONNEL
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S Matching generator to treater station
1/4 - Generator into manual frequency & local control mode S
1 0.00
2 4 3

1 – Turn SW2 to position 1 (local control)

2 – Ensure SW1 is in the UP position (manual frequency control)
3 – Turn power dial to zero
4 – Turn frequency dial to zero
5 – Ensure selector switch is set to TRUE () power
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S
Matching generator to treater station (cont)

Caution
2/4 Set HT transformer tap S

Generator
To
Ensure generator is switched off HT3
and isolated from the supply
before commencing any work on
the HT transformer

NOTE: The picture shows an

HT8
an HT 3 will only have one set of
taps (dotted area)
Connect the wires as shown in the diagram. The same numbered taps should be
linked with 6mm sq cable
When starting to match the generator to the treater station the HT transformer
should be on taps 1 & 7
If two HT transformers are used for each generator (GX150-200R) they should be
connected in exactly the same way
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S Matching generator to treater station (cont)
3/4 – Obtain full power

A 15.00
2
S
5 4.12 3
18.0 B
4

1 – Press start button

2 – Increase power dial to MAX
3 – Adjust frequency dial until full power is displayed on true power meter (A).
 If full power CANNOT be achieved the HT transformer tap must be changed (go to next step 4/4)
 If full power is achieved (go to automatic frequency control set-up)
NOTE: If generator goes into mismatch (B) follow steps below
4 – Reset generator
5 – Adjust RV3 so reactive power meter reads 0.00 +/- 1.00 and continue from step 3.
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S Matching generator to treater station (cont)

Caution
4/4 Unable to achieve full power S
1
Ensure generator is switched off
and isolated from the supply
before commencing any work
on the HT transformer

If unable to achieve full power in the previous step (3/4)

1 – The HT transformer tap should be moved to the next lowest tap i.e. from tap 7 to tap 6.
The previous step (3/4) should then be repeated.
This should be repeated until full power can be achieved
If two HT transformers are used for each generator (GX150-200R) they should be
connected in exactly the same way
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S S
GENERATOR SETUP

AUTOMATIC FREQUENCY
CONTROL
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S Automatic frequency control S
• The following steps show how to re-set the
automatic frequency control
• This ensures the generator is running at its
most efficient throughout the power range
• The automatic frequency control should be
re-adjusted whenever a new control PCB
or a new HT transformer is installed
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S CAUTION S
IN ORDER TO CARRY OUT THE FOLLOWING
ADJUSTMENTS THE GENERATOR CABINET
DOOR WILL NEED TO OPEN WHEN THE
GENERATOR IS RUNNING

HIGH VOLTAGES ARE PRESENT INSIDE THE

GENERATOR CABINET

ADJUSTMENTS SHOULD ONLY BE MADE BY

QUALIFIED PERSONNEL
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S Automatic frequency control
1/4 - Generator into manual frequency & local control mode S
0.00
1
2 4 3

1 – Turn SW2 to position 1 (local control)

2 – Ensure SW1 A is in the UP position (manual frequency control)
3 – Turn power dial to zero
4 – Turn frequency dial to zero
5 – Ensure selector switch is set to TRUE power ()
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S Automatic frequency control (cont)
2/4 - Obtain maximum power (manual frequency mode) S
5.00
6 3 2
5 B
4
1

1 – Press start button

2 – Increase power dial to MAX
3 – Increase frequency dial until full power is displayed on digital meter
NOTE: If generator goes into mismatch (B) follow steps below
4 – Reset generator
5 – Move selector switch to REACTIVE power ()
6 – Adjust RV3 so reactive power meter reads 0.00 +/- 1.00 and continue from step 3.
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S Automatic frequency control (cont)
3/4 - Adjust reactive power to zero S
0.00
1

1 – Adjust RV3 until 0.00 +/- 0.03 is shown on

Reactive power meter (A)
2 – Press stop button
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S Automatic frequency control (cont) S
4/4 - Generator into automatic frequency mode & achieve full power

5.00
4
1
3
1

3
1 – Put SW1 A in the down position (auto frequency control)
2 – Press start button,
3 – Ensure true power meter (A) reads full power & reactive
power meter (B) reads 0.00 +/- 0.05. If not return to step
2/4.
3 – Press stop button

Automatic Frequency control setup is now complete

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S TROUBLE SHOOTING
&
S
FAULT FINDING
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S
A
Generator circuit overview
B
Key Voltages & waveforms

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A – Site supply 380-420v B – 240v AC 50/60Hz C – 330v +/- 10% DC
AC 50/60 Hz
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S Generator circuit overview
Key Voltages & waveforms

D
S E

D – 330v +/- 10% DC (switched) E – 250-550v 10-25 kHz AC (Load dependent)

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S S
TROUBLE SHOOTING
&
FAULT FINDING
Front Panel Status Indicators
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S Trouble shooting
Status indicators – Up To Speed

 Generator NOT up to speed

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 Generator will not treat 0.00
0.00
Causes
00.0

I. Ensure line is up to speed – Adjust RV13  to

make generator treat at a lower line speed

II. If line speed is monitored externally i.e. PLC –

Ensure SW3 B is in the up position “UTS override”

III. Sensor not sensing – Ensure magnetic sensor is 5-

10mm away from magnets or inductive sensor is 1-
2mm away from sensing disc – Check LED3 B for
pulses

IV. Faulty sensor – Replace sensor

V. Fault on control PCB – See circuit A2/500001/05

(1,8 / 16)
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S Trouble shooting
 Interlock circuit open
Status indicators - Interlocks
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 Generator will not start 0.00
0.00
Causes 00.0

I. Interlock circuit open – Check all doors, hoods,

electrodes, airflow switches, E-stops etc – Ensure
all switches are closed

Check circuit diagram “treater installation” supplied

with the treater station

II. Remote stop signal open (if applicable) – Ensure

the remote stop contact is closed
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S Trouble shooting
Status indicators – Treat on

 Generator is on but no corona present

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 Indicator only 0.00
0.00
Causes 00.0

I. Power is set to minimum – Increase power

II. Generator in standby – Ensure UTS is OK

III. Generator in skip mode – Ensure no skip signal is

present

IV. HT transformer has failed – Check fault finding HT

transformer

V. Fault on control PCB – See circuit A2/500001/05

(1,8 / 16)
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 Generator off
Trouble shooting
Status indicators – Inverter supply
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 Indicator only 0.00
0.00
Causes 00.0

I. Generator has not been started – Press start button

II. Fault on control PCB – See circuit A2/500001/05

(1,8 / 16)
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S Trouble shooting
Fault indicators - Shutdown

 Generator is stopped or in standby

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 Indicator only 0.00
0.00
Causes 00.0

I. Generator has not been started – Press start button

II. Generator in standby – Ensure UTS is OK

III. Generator is in skip mode – Ensure skip contact is

closed

IV. Fault on control PCB – See circuit A2/500001/05

(1,8 / 16)
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S Trouble shooting
Fault indicators - Overtemperature

 Inverter heatsink assy is to hot

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 Shuts down generator 0.00
0.00
Causes 00.0
I. Heatsink cooling fan failed – Check fan is free to
rotate
II. Heatsink cooling fan supply failed – Check FS1
III. Filter panels blocked – Check & clean filter panels
in generator door
IV. Ambient air too high – Extra cooling may be
required
V. Generator not correctly matched to treater station –
Carry out matching procedure
VI. Frequency too high – Try re-tapping HT transformer
to a lower tap and re-match
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S Trouble shooting
Fault indicators - Overcurrent

 Generator output current is too high

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 Shuts down generator 0.00
0.00
Causes 00.0
I. Problem with treater station - Check for signs of
arcing inside treater station, especially on
insulators & HT connections
II. Problem with treater roll - Check for pin holes in roll
coating
III. Generator not matched correctly - Carry out
matching procedure
IV. HT transformer incorrectly tapped - Try re-tapping
HT transformer to a higher tap
V. Fault with HT transformer - Carry out transformer
test
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S Trouble shooting
Fault indicators - Mismatch

 Reactive power kVAR too high / low

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 Shuts down generator 0.00
7.50
Causes 00.0

I. Problem with treater station - Check for signs of

arcing inside treater station, especially on
insulators & HT connections
II. Problem with treater roll - Check for pin holes in roll
coating
III. Generator not matched correctly - Carry out
matching procedure
IV. Fault with HT transformer - Carry out transformer
test
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S Trouble shooting
Fault indicators – High / Low Alarm

 Generator output power is running below / above

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alarm threshold 0.00
 Indicator only 0.00
00.0
Causes

I. Alarm dials incorrectly set - Reset dials so output

power is within alarm limits
II. Generator output power low / high - Check output
power levels are correct
III. Fault on control PCB – See circuit A2/500001/05
(8 / 16)
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S S
TROUBLE SHOOTING
&
FAULT FINDING
Common faults
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S

Trouble shooting
General faults
Circuit breaker CB 1 trips on start up
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Try restarting the generator immediately after this fault has occurred if the
generator starts OK there is a fault with the capacitor pre-charge circuit

Capacitor pre-charge circuit faulty (see diagram on next page)

I. Ensure Resistors R1-3 are OK
II. Ensure Resistor R4 is OK
II. Ensure K2 is not stuck closed
III. Ensure K2 energises after a 2-3 second delay
IV. Decrease the value of R127 on control PCB from 330KΩ to 250KΩ – This
modification will increase the delay between K1 & K2 energising

Inverter heatsink assy faulty

I. Check for damaged IGBT’s & smoothing capacitors
II. Follow faultfinding inverter heatsink assembly instructions
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S
A C
Generator circuit overview
Capacitor Pre-charge & Inverter Assembly

J I G
S
H

D E F
B

A – Contactor K1 F – IGBT’s x 4
B – Contactor K2 G – Pulse driver 1
C – Resistor 100Ω R1-R3 H – Pulse driver 2
D – Bridge rectifier BR1 I – Capacitor discharge resistor 1kΩ R4
E – Smoothing capacitors C2 J – Thermal switch TH1
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S

Trouble shooting
General faults
Generator does not reach full power when started in automatic
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frequency control or after a web splice. Generator may become
noisy

I. Automatic frequency control not set correctly – Follow automatic frequency

control set up procedure
II. Frequency high (>23 kHz) – If possible re-tap HT transformer to a lower tap and
reset automatic frequency
III. Automatic frequency control gain requires adjusting – Turn the power down to
half and reset generator. Increase power until full power is achieved. Adjust
RV16  until the reactive power kVAR meter increases to approximately 0.10.
Stop & restart generator at full power, if generator does not reach full power
adjust RV16  until the reactive power kVAR meter increases to approximately
0.20. Stop & restart the generator at full power.
IV. Change the Inverter control PCB – Tolerances within components can cause the
generator to not match properly when running at high frequency.
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
Trouble shooting
General faults
Generator trips or goes into mismatch when started at full power
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I. Adjust RV14  one full turn – Will make overcurrent trip circuit less sensitive
II. Ensure 0.22μF capacitor is fitted across IC 38 pins 4 & 8 on reverse of control
PCB. If generator continues to trip increase value of capacitor to 0.47μF.
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S S
TROUBLE SHOOTING
&
FAULT FINDING
Inverter Heatsink Assembly
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S Fault Finding
Inverter heatsink assy – PWM circuit test

4
S
7.50
2
TB2 3 4.12
10 5
18.0
1
1
6

1 – Remove wire 22 from TB 2

2 – Put SW2 into position 1 (local control)
3 – Put SW1 A in up position (manual frequency) NOTE:
4 – Set power dial to half power With wire 22 disconnected
K1 will not energise
5 – Set frequency dial to half therefore no 3 phase will
6 – Press start button (interlocks must be closed & UTS be present on the inverter
must be OK) heatsink assy
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S Fault Finding
Inverter heatsink assy PWM circuit test

TB7
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1 10 CAUTION
1
Ensure Oscilloscope ground
TP6
2 has been removed.

Inputs must be isolated

from each other

If possible use a portable

1 – Connect oscilloscope probes to TB7 pins 5 / 6 scope meter with isolated
2 – Connect ground clips to TP6 (0v B) inputs i.e.
Fluke 123 scopemeter
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S
7.50
Fault Finding
Inverter heatsink assy – PWM circuit test (cont)
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4.12
1
18.0 A

1 – Adjust the frequency up & down. Frequency of pulses should change (A)
 If frequency stays fixed ensure generator is in manual frequency
 If no waveform check PWM circuit DWG A4.500001.05/06 paying attention to IC1,16
 As can be seen from the waveform the pulses are 180 degrees out of phase
 I waveform OK then go to pulse driver test
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S Fault Finding
1/2 Inverter heatsink assy – Pulse driver test
1 – Connect oscilloscope probe on G1 & ground
clip to E1 on master driver PCB. Check for
square wave (A) G2 R3
S Conn
R4 1
2 – Connect oscilloscope probe on G1 & ground DRIVER
E2 R5
clip to E1 on Slave driver PCB. Check for
SKHI 22A
square wave (A). 1 R3
E1
R4
G1 R5

A Master

G2
R4
E2 R5

2 E1 R6
R7
 If no waveform present go to next step 2/2 G1
 If waveform present go to IGBT test Slave
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S Fault Finding
2/2 Inverter heatsink assy – Pulse driver test
1 – Connect oscilloscope probe on right hand side
of R4 & ground clip to E2 on master driver G2 R3
1
S Conn
PCB. Check for square wave. Repeat for R5 R4 1
DRIVER
E2 R5
2 – Connect oscilloscope probe on right hand side 2
of R6 & ground clip to E1 on master driver SKHI 22A
R6
PCB. Check for square wave. Repeat for R7 E1
R7
3 – Repeat above for slave PCB G1 R8

Master
 If no square wave present driver device
(SKHI 22A) faulty – Replace driver or
complete driver PCB assembly
 If square wave OK, resistors failed – Replace
resistors and return to step 1/2
G2 3
R4
E2 R5
Resistor values

Generator
Resistor E1 R6
GX 100R GX 150R R7
G1
R3, R8 15KΩ 15KΩ
Slave
R4 - R7 56Ω 10Ω
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S Fault Finding
Inverter heatsink assy – IGBT test
NOTE: If testing IGBT’s in inverter, DC smoothing capacitors must be removed prior to testing
Use a Digital multi meter (diode function) to measure between the following points
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IGBT types

Generator GX 100R GX 150R

IGBT SKM 150 SKM 200

OC – Open circuit
SC – Short circuit
FD – Forward diode (0.3v dc)

Red Lead + Black Lead - Result Red Lead + Black Lead - Result
1 2 OC 1 5 SC
2 1 FD 1 4 OC
1 3 FD 7 1 FD
3 2 OC 6 1 OC
1 7 OC 5 1 SC
1 6 OC 4 1 OC
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S S
TROUBLE SHOOTING
&
FAULT FINDING
HT Transformer
HT 8
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S Fault Finding
HT Transformer – HT8

HT transformers can fail if they are subjected

to abnormal loads which can occur if
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I. Generator & treater station are not matched
correctly
II. HT transformer is not tapped correctly
III. Air gap is to large
IV. Material being treated is to thick
V. Treater Roll covering is not suitable i.e.
Dielectric constant is too high

The most likely failure point is a short circuit

within the secondary windings of the
transformer where voltages can be very high

A generator that continually goes into

mismatch or repeatedly goes into overcurrent
trip indicates that the HT transformer has
possibly failed
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S Fault Finding

If an HT8 transformer appears to be

HT Transformer – HT8
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faulty the following checks can be
made using an LCR meter
If any of the values measured are
significantly different than the figures
below the transformer has failed

Secondary Secondary
Open circuit Short circuit
TAP’S mH  mH
( WRT 1 )
7 8.86 .22 .068
6 7.18 .21 .058
5 5.68 .20 .049
4 4.35 .20 .040
3 3.20 .20 .032
2 2.22 .20 .024
OUTPUT 0.913H .301 S/C
TO
GROUND