GEK 91764 543 Control Group

GE Transportation
17KG543 Control Group for

200 Ton AC Drive Systems
Document No. GEK-91764
GEK-91764
17KG543 Control Group for 200 Ton AC Drive Systems
GE CONFIDENTIAL TECHNICAL INFORMATION
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Revision History
Rev Date By Description
NEW Apr-2013 KA Initial release
ii GE Proprietary and Confidential Information

GEK-91764
TABLE OF CONTENTS
Section Page
1. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. RELATED PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. WEIGHT AND DIMENSIONS OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4. UNIT EXCHANGE COMPONENT HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.5. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2. CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1. MAIN CONTROL CABINET ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2. CAPACITOR CHARGE LIGHTS AND SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3. CONTROL CABINET COMPONENT LAYOUT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1. POWER GENERATION AND DISTRIBUTION DRIVE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2. DRIVE SYSTEM CONTROLLER (DSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3. DC LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.4. INSULATED GATE BIPOLAR TRANSISTOR (IGBT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5. CHOPPER MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6. CHOPPER DIODES (17KG543B1 AND EARLIER MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . 22
3.7. GRID BLOWER MOTOR CAPACITOR (GBMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.8. RECTIFIER DIODE (RD) PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.9. POWER SUPPLY (PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.10. CONTROL POWER DISTRIBUTION (CPD) MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.11. GATE DRIVER POWER CONVERTER (GDPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.12. AMBIENT TEMPERATURE (AMBT) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.13. BAROMETRIC PRESSURE SENSOR (BAROP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.14. CONTROL GROUP PRESSURE SWITCH (CGPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.15. FILTER DISCHARGE RESISTOR (FDR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.16. GROUND RESISTOR PANEL (GRR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.17. FILTER PANEL (FP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.18. CURRENT MEASURING SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.19. GENERATOR FIELD RELAY (GFR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.20. GENERATOR FIELD (GF) CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.21. DYNAMIC RETARDING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.22. VOLTAGE ATTENUATION MODULES (VAM1 – VAM5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.23. INVERTER AND CHOPPER FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.24. LINK FILTER CAPACITORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.25. ALTERNATOR FIELD STATIC EXCITER (AFSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.26. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4. SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
GE Proprietary and Confidential Information iii

GEK-91764
TABLE OF CONTENTS (CONTINUED)
Section Page
5. REMOVAL AND REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.1. CAPACITOR DISCHARGE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2. DRIVE SYSTEM CONTROLLER (DSC) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.3. GATE DRIVER POWER CONVERTER (GDPC1 OR GDPC2) REPLACEMENT . . . . . . . . . . . . . . . 53
5.4. POWER SUPPLY (PS) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.5. VOLTAGE ATTENUATION MODULE (VAM1 – VAM5) REPLACEMENT . . . . . . . . . . . . . . . . . . . 56
5.6. INSULATED GATE BIPOLAR TRANSISTOR PHASE MODULE (IGBT) AND
CHOPPER MODULE (CM) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.7. INVERTER AND CHOPPER MODULE FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.8. DC HORIZONTAL BUS (DCHB) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.9. DC LINK CAPACITOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5.10. GRID BLOWER MOTOR CAP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
5.11. BATTERY FUSE (BATFU) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
5.12. ALTERNATOR FIELD STATIC EXCITER (AFSE) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.13. ALTERNATOR FIELD (GF) CONTACTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.14. CURRENT SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
5.15. GENERATOR FIELD RELAY (GFR) CONTROL RELAY REPLACEMENT . . . . . . . . . . . . . . . . . . . . 76
5.16. GROUND RESISTOR PANEL (GRR) AND FILTER DISCHARGE RESISTOR (FDR)
PANEL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5.17. FILTER PANEL (FP) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.18. RECTIFIER DIODE (RD) PANEL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
5.19. CONTROL POWER DISTRIBUTION (CPD) REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
5.20. CONTROL POWER DISTRIBUTION (CPD) FUSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 82
6. SUMMARY DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
iv GE Proprietary and Confidential Information

GEK-91764
LIST OF FIGURES
Figure Page
1 Main Control Cabinet Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Control Switch Arrangement in Control Area 1 (CA1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Main Control Cabinet Components, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Main Control Cabinet Component List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Main Control Cabinet Components, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6 System Block Diagram - Alternator Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7 System Block Diagram - #1 Wheel Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
8 System Block Diagram - #2 Wheel Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9 System Block Diagram - Grid Blower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 Drive System Controller (DSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
11 Drive System Controller (DSC) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
12 Inputs to Drive System Controller (DSC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
13 Outputs from Drive System Controller (DSC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
14 CN Connector Pin Arrangement, DSC Socket and Wire Harness Plug . . . . . . . . . . . . . . . . 19
15 Pin Arrangement for Control Cabinet CNX Connector Sockets . . . . . . . . . . . . . . . . . . . . . . 20
16 Location of Chopper Modules in CA4 and CA5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
17 Chopper Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
18 GBMC Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
19 Location of GBMC (Top View) and GBMR (CA3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
20 Rectifier Diode Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
21 Arrangement of Power Supply and CPD in CA1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
22 Power Supply Connector Pin Arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
23 Power Supply LED Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
24 Control Power Distribution (CPD) Module Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
25 CPD Connector 1, Connector 2, and Connector 3 Electrical Block Diagrams . . . . . . . . . 29
26 CPD Connector 4 Electrical Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
27 Typical Gate Driver Power Converter (GDPC) Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . 31
28 Ambient Temperature (AMBT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
29 Barometric Pressure Sensor (BAROP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
30 CGPS, FDR, GRR, and FP Arrangement in CA7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
31 Typical Current Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
32 GFR, GF, and VAM Locations in CA3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
33 Model 17EM155 Dynamic Retarding Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
34 Eight-Channel VAM (Left) and Five-Channel VAM (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
35 Phase Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
36 Link Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
37 Typical AFSE Main Component Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
38 Diagnostic Information Display (DID) Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
39 Switch Panel with Control Power Switch (CPS) and Generator Field Cut Out
(GFCO) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
40 Control Group 17KG543 Capacitor Discharge Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
GE Proprietary and Confidential Information v

GEK-91764
LIST OF FIGURES (CONTINUED)
Figure Page
41 Capacitor Charge Lights Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
42 Capacitor Positive (+) and Negative (-) Terminal Posts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
43 DC Meter on Capacitor Positive and Negative Terminal Posts . . . . . . . . . . . . . . . . . . . . . . . 47
44 Ground Stick Pair Ground Lead Attachment Point on Weldment. . . . . . . . . . . . . . . . . . . . . 48
45 GND1 and GND2 Block Location in Low-Voltage Compartment (Right Wall) . . . . . . . . . . 49
46 Ground Stick Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
47 Application of Ground Stick Pair to Capacitor Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
48 Jumper all Terminals on Isolator Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
49 Typical GDPC Mounting Arrangement for Two Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
50 Power Supply Location in CA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
51 Eight-Channel (Left) and Five-Channel (Right) Voltage Attenuation Modules (VAM) . . . . 56
52 Phase Module Disassembly and Reassembly Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
53 Chopper Module Disassembly and Reassembly Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
54 Chopper Diode Module Disassembly and Reassembly Items . . . . . . . . . . . . . . . . . . . . . . . . 61
55 Bolted Joint Stack Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
56 Phase Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
57 DC Horizontal Bus (DCHB) Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
58 Link Capacitor Mounting Hardware Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
59 Location of GBMC in CA6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
60 Typical Battery Fuse (BATFU) in Low Voltage Control Area 1 (CA1). . . . . . . . . . . . . . . . . . . . 72
61 Typical AFSE Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
62 Location of GF Contactor in CA3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
63 Typical Current Sensor Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
64 Component Arrangement in CA7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
65 Location of RD Panel in CA2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
66 Rectifier Diode (RD) Panel Connection Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
67 Location of CPD and Power Supply in CA1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
68 Control Power Distribution (CPD) Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
vi GE Proprietary and Confidential Information

GEK-91764
1. GENERAL INFORMATION
1.1. INTRODUCTION
The 17KG543 Control Group contains all the control equipment and power devices used in the GE 200-Ton AC Elec-
tric Drive System, excluding remotely located sensors. The 17KG543 Control Group includes the following:
• Drive System Controller Panel (DSC)

• Alternator Control and Power Devices
• Main Rectifier
• Traction Inverter Control and Power Devices
• Chopper Control and Power Devices
Refer to Figure 1 for the Control Group cabinet arrangement. The Control Group cabinet includes a high-voltage area
and a low-voltage area. The high-voltage area contains the Inverter Phase Modules, Chopper Modules, Gate Driver
power supplies, and other associated equipment. The low- voltage area contains power supplies, control electronics,
and other associated equipment.
Figure 2, Figure 3, Figure 4, and Figure 5 depict the location of major components of the Control Group. Figure 6, Fig-
ure 7, Figure 8, and Figure 9 provide block diagrams of the system.
(CA3) (CA1)
(CA5) (CA4)
(CA2)
LEFT SIDE FRONT RIGHT SIDE
CUST
AUX
BOX
AREA
CA8
CA7
CA6
REAR
E-53293A
Figure 1. Main Control Cabinet Arrangement
1.2. RELATED PUBLICATIONS
When using the related publications listed in Table 1, obtain the highest letter revision for the most current informa-
tion. Contact your GE Representative or the GE website for more information on ordering publications.
GE Proprietary and Confidential Information 1

GEK-91764
Table 1. Related Publications
Publication Number Publication Title

GEK-91769 OHV Planned Maintenance for 200 Ton AC Drive Systems
GEK-91748 17EM155 Dynamic Retarding Assembly for 200 and 240 Ton AC Electric Drive Systems
GET-6885 Vehicle Test Instructions for OHV 17KG543 Control Group
1.3. WEIGHT AND DIMENSIONS OF MAJOR COMPONENTS

Table 2. Component Weights and Dimensions
Component Lbs. Kg Inches mm

Alternator Field Static Exciter (AFSE) 45 20 15 x 12 x 11 381 x 304 x 280
Control Cabinet 4920 2232 101 x 70 x 60 2565 x 1778 x 1524
Drive System Controller (DSC) Panel* 40 18 20 x 21 x 12 508 x 533 x 305
Link Capacitor 80 37 30 x 11 x 9 762 x 279 x 229
Phase Module (PM) 58 23 10 x 14 x 6 254 x 355 x 153
Power Supply (PS) 32 13 16 x 12 x 7 406 x 305 x 178
Rectifier Diode (RD) Panel 100 45 22 x 15 x 15 558 x 381 x 381
RP / GF Contactor 53 24 11 x 12 x 4 280 x 304 x 102
* The Drive System Controller (DSC) Panel weighs approximately 60 lbs. (27 kg) with cards installed.
1.4. UNIT EXCHANGE COMPONENT HANDLING
Electronic components should be stored in the packaging as received. Remove replacement electronic components
only when ready for installation on the truck. Personnel should be using a grounding strap when handling electronic
components. Unit Exchange components should be repackaged into the received packaging including anti-static
covers or bags for return and repair.
1.5. SAFETY INFORMATION
All applicable local regulations, including any OEM test facility, Mine, Government, and Industry rules for working
with high voltage must be followed. Required personal protective equipment, including but not limited to safety
shoes, high voltage gloves, and safety glasses, must be worn.
Safety WARNINGS and CAUTIONS appear throughout the instructions.
WARNING Indicates the potential for personal injury.
CAUTION Indicates the potential for equipment damage.
The following is a summary of the WARNINGS and CAUTIONS that are found in this publication. Observe this safety
information carefully to avoid personal injury or equipment damage.
2 GE Proprietary and Confidential Information

GEK-91764
NOTE: Read these Warnings and Cautions before proceeding to other sections of this publication.
WARNING Hazardous voltages are present in the equipment. Ensure that the Control Power
Switch (CPS) is in the OFF position and that the Generator Field Contactor (GFCO)
switch is in the CUTOUT position before attempting any work on the control
components. Check that Capacitor Charge Lights (CCLs) are not illuminated. Use
measurement and protective equipment rated for 2000 VDC minimum to verify that no
voltage is present before touching any terminal. Verify functionality of the
measurement equipment using site-approved procedures both before and after
performing control group measurement. Failure to observe these precautions may
result in death or serious personal injury.
WARNING Verify that the Capacitor Charge Lights (CCL) above the High Voltage contactor area
are not illuminated before opening the doors to the High Voltage area or the High Volt-
age Contactor area. Use measurement and protective equipment rated for 2000 VDC
minimum to verify that no voltage is present before touching any terminals. Verify
functionality of the measurement equipment using site-approved procedures both
before and after performing control group measurement. Failure to observe these pre-
cautions may result in death or serious personal injury.
WARNING Hazardous voltages are present in this equipment. Avoid touching any energized
equipment when the door to the Low Voltage area is open. Failure to do so may result
in personal injury and equipment damage.
WARNING Hazardous voltages may be present in this equipment even if the engine and
Capacitor Charge Lights are off. Use measurement and protective equipment rated for
2000 VDC minimum to verify that no voltage is present before touching any terminals.
Verify functionality of the measurement equipment using site-approved procedures
both before and after performing control group measurement. Failure to observe
these precautions may result in death or serious personal injury.
WARNING Voltages in excess of 1500 VDC may be present. Any measurement and/or protective
equipment used must be rated at 2000 VDC minimum. Verify functionality of the mea-
surement equipment using site-approved procedures both before and after perform-
ing control group measurements. Failure to observe these precautions may result in
death or serious personal injury.
WARNING Hazardous voltages may be present in this equipment. Ensure that the Control Power
switch is in the CUTOUT position before attempting any work on control components.
Check that the Capacitor Charge Lights (CCL1 and CCL2) are not illuminated. Use a
VOM to verify no voltage is present before touching any terminal. Failure to observe
WARNING Discharge the capacitors before proceeding with any control activity. Failure to do so
may result in death or serious personal injury.
WARNING A Phase Module weighs approximately 50 lbs. (23 kg). Use appropriate handling proce-
dures. Failure to do so may result in personal injury or equipment damage.

GEK-91764
WARNING The DSC weighs approximately 40 lbs. (18 kg) without cards installed, or 60 lbs. (27 kg)
with cards installed. Use appropriate handling procedures. Failure to do so may result
in personal injury or equipment damage.
WARNING A Link Capacitor weighs approximately 80 lbs. (37 kg). Use appropriate handling pro-
cedures. Failure to do so may result in personal injury or equipment damage.
WARNING GF weighs approximately 53 lbs. (24 kg). Use appropriate handling procedures. Failure
to do so may result in personal injury or equipment damage.
WARNING The Rectifier Diode (RD) panel weighs approximately 100 lbs. (45 kg). Use appropriate
handling procedures to avoid personal injury or equipment damage.
CAUTION The Power Supply (PS) weighs approximately 28 lbs. (13 kg). Use appropriate handling
procedures. Failure to do so may result in equipment damage.
CAUTION The DCHB weighs approximately 40 lbs. (18 kg). Use appropriate handling procedures.
Failure to do so may result in equipment damage.
CAUTION AFSE weighs approximately 45 lbs. (20 kg). Use appropriate handling procedures.
CAUTION Hardware (bolts, nuts, washers, etc.) and other components are designed for specific
applications. Use only GE OHV parts from the Drive System Parts Catalog for repair or
replacement. Failure to do so may result in premature failure and possible warranty
disqualification.
CAUTION Do not pull on the control cable connectors. Be sure to turn the connector center lock
until loose from the threads, and twist the locked ring of the connector until released
before attempting to remove connectors. Pulling on connectors may damage them.
CAUTION Always shut off control power prior to replacing or removing control circuit fuses.
Removing or replacing control circuit fuses with power applied may result in electrical
circuit and/or electronic component damage.
CAUTION Always use replacement fuses rated the same as the original fuses. Failure to do so
may result in electrical circuit and/or electronic component damage.
CAUTION Always use antistatic bags when storing control cards to prevent electronic compo-
nent damage.
CAUTION Refer to the Gate Driver Housing sticker color to ensure that the correct IGBTs are
matched, to prevent possible equipment damage.

GEK-91764
2. CONTROLS AND INDICATORS
2.1. MAIN CONTROL CABINET ARRANGEMENT
The main Control Cabinet is arranged in control areas as shown in Figure 1. Control Area 1 (CA1) through Control
Area 5 (CA5) are accessible from the front of the Control Cabinet. Control Area 6 (CA6) through Control Area 8 (CA8)
are accessible from the rear of the Control Cabinet.
2.2. CAPACITOR CHARGE LIGHTS AND SWITCH PANEL
Capacitor Charge Lights (CCL1 and CCL2) are in a small housing located above Control Area 3 (CA3) on top of the
main Control Cabinet (Figure 1). When illuminated (on), the lights indicate dangerous voltage is present within the
high-voltage area of the Control Cabinet. Do not work on control components until the capacitor discharge proce-
dure has been followed and both CCL1 and CCL2 are extinguished (off). The capacitor discharge procedure is
described in section 5.1., CAPACITOR DISCHARGE PROCEDURE, in this publication. Open the door of the low-voltage
Control Area 1 (CA1) to access to the Switch Panel (Figure 2). The following switches are located on the Switch Panel:
• Control Power switch (CPS) ON/OFF – In the ON position, this switch applies truck battery power to the Control
Group. The Key Switch must be ON and the Battery Switch must be closed to supply battery power to the Control
Power switch.
• Generator Field Contactor (GFCO) switch – In the CUTOUT position, this switch prevents closing of the GF con-
tactor, which in turn prevents the alternator from being energized.
• Control Lights (LTS) switch — This switch turns the Control Cabinet illumination lights ON and OFF. Lights are
located in the various Control Areas.
CONTROL GENERATOR FIELD CONTROL

POWER CONTACTOR (GF) LIGHTS
ON NORMAL ON
OFF CUTOUT OFF
PULL TO UNLOCK
E-55897
Figure 2. Control Switch Arrangement in Control Area 1 (CA1)

GEK-91764
2.3. CONTROL CABINET COMPONENT LAYOUT DIAGRAMS
The main components of the Control Areas are shown and listed in Figure 3, Figure 4, and Figure 5.
TB1, TB2
BATFU
CPD
ETC2
CA1 (BEHIND PANEL)
USC1
CAN1, CAN2
PS
AFSE
LTS
CPS GFCO
DSC
BAROP
GDP
(BEHIND PANEL)
CNX1-CNX5
CA2
RD
VAM1
CCL2
GBMR
VAM3
VAM4
VAM2
GFR
GRR10, GRR9
VAM5
R1
CA3
CMT LINKI
CCL1
CMAF
GF
TH1
LFC1
P1A- P1B- P1C-
P1A+ P1B+ P1C+

CA4
LFC2
CM2A CM1A
DCHB
LFC3
CM2B CM1B
LFC4
P2A- P2B- P2C-

P2A+ P2B+ P2C+
LFC5
CA5
LFC6
CM2 CM4
CM1 CM3
CM1I
CM2I
CM3I
CM4I
E-53294AP1
Figure 3. Main Control Cabinet Components, Front

GEK-91764
REF. DESCRIPTION REF. DESCRIPTION

AFSE ALTERNATOR FIELD STATIC EXCITER PANEL GBMR GRID BLOWER MOTOR CAPACITOR DISCHARGE RESISTOR
BAROP BAROMETRIC PRESSURE SENSOR GFR GENERATOR FIELD RELAY
BATFU SYSTEM FUSE GRR9 GROUND RESISTOR
CAN1 CAN #1 CONTROL GROUP CONNECTOR GRR10 GROUND RESISTOR
CAN2 CAN #2 CONTROL GROUP CONNECTOR LFC1 LINE FILTER CAPACITOR 1
CCL1 CAPACITOR CHARGE LIGHT 1 LFC2 LINE FILTER CAPACITOR 2
CCL2 CAPACITOR CHARGE LIGHT 2 LFC3 LINE FILTER CAPACITOR 3
CM1 CHOPPER MODULE 1 LFC4 LINE FILTER CAPACITOR 4
CM4 CHOPPER MODULE 4 LINK1 LINK CURRENT SENSOR
CM1A INVERTER 1 PHASE A CURRENT SENSOR LTS LIGHT SWITCH
CM1B INVERTER 1 PHASE B CURRENT SENSOR P1A- INVERTER 1 PHASE A- MODULE
CM2A INVERTER 2 PHASE A CURRENT SENSOR P1A+ INVERTER 1 PHASE A+ MODULE
CM2B INVERTER 2 PHASE B CURRENT SENSOR P1B- INVERTER 1 PHASE B- MODULE
CM1I CHOPPER CURRENT MODULE 1 P1B+ INVERTER 1 PHASE B+ MODULE
CM2I CHOPPER CURRENT MODULE 2 P1C- INVERTER 1 PHASE C- MODULE
CM3I CHOPPER CURRENT MODULE 3 P1C+ INVERTER 1 PHASE C+ MODULE
CM4I CHOPPER CURRENT MODULE 4 P2A- INVERTER 2 PHASE A- MODULE
CMAF ALTERNATOR FIELD CURRENT SENSOR P2A+ INVERTER 2 PHASE A+ MODULE
CMT TERTIARY WINDING CURRENT SENSOR P2C- INVERTER 2 PHASE C- MODULE
CNX1 CONTROL CONNECTOR 1 P2C+ INVERTER 2 PHASE C+ MODULE
CNX2 CONTROL CONNECTOR 2 PS POWER SUPPLY
CNX3 CONTROL CONNECTOR 3 R1 BATTERY BOOST RESISTOR
CNX4 CONTROL CONNECTOR 4 RD RECTIFIER DIODE PANEL
CNX5 CONTROL CONNECTOR 5 TB1 TERMINAL BOARD
CPD CONTROL POWER DISTRIBUTION MODULE TB2 TERMINAL BOARD
CPS CONTROL POWER SWITCH TH1 ALTERNATOR FIELD DISCHARGE THYRITE
DCHB DC HORIZONTAL BUS BAR USC1 USB 1 CONTROL GROUP CONNECTOR
DSC DRIVE SYSTEM CONTROLLER PANEL VAM1 VOLTAGE ATTENUATION MODULE 1
ETC2 ETHERNET #2 CONTROL GROUP 2 CONNECTOR VAM2 VOLTAGE ATTENUATION MODULE 2
GDP GATE DRIVE POWER CONVERTOR VAM3 VOLTAGE ATTENUATION MODULE 3
GF GENERATOR FIELD CONTACTOR VAM4 VOLTAGE ATTENUATION MODULE 4
GFCO GENERATOR FIELD CUTOUT SWITCH VAM5 VOLTAGE ATTENUATION MODULE 5
E-53294AP2
Figure 4. Main Control Cabinet Component List

GEK-91764
FDR
GRR
FP
CGPS
BMFF BM2I
BM1I
AMBT
GRIDI
GBMC
CA8 CA7 CA6
REF. DESCRIPTION REF. DESCRIPTION

AMBT AMBIENT AIR TEMPERATURE SENSOR FDR FILTER DISCHARGE RESISTOR PANEL
BM1I GRID BLOWER 1 CURRENT SENSOR FP THREE PHASE FILTER PANEL
BM2I GRID BLOWER 2 CURRENT SENSOR GBMC GRID BLOWER MOTOR CAPACITOR
BMFF GRID BLOWER MOTOR FIELD BUS BAR GRIDI GRID CURRENT SENSOR
CGPS CONTROL GROUP PRESSURE SWITCH GRR GROUND RESISTOR PANEL
E-53295A
Figure 5. Main Control Cabinet Components, Rear

GEK-91764
3. FUNCTIONAL DESCRIPTION
3.1. POWER GENERATION AND DISTRIBUTION DRIVE OVERVIEW
Refer to Figure 6, Figure 7, Figure 8, and Figure 9 for electrical block diagrams for the AC Drive System.
Power generation is in the form of alternating current produced by the main alternator coupled directly to the
engine. The alternator produces 3-phase AC power from the stationary windings in the stator. Output from the 3-
phase windings leaves the alternator through T1, T2, and T3. This action turns the mechanical energy of the engine
into electrical energy (Figure 6).
Excitation of the alternator is needed for AC output. This is accomplished by sending DC power to the rotor through
F1 and F2 field connections. The F1 and F2 field connections supply the DC power through the brushes on the slip
rings.
The initial DC excitation power (at first power up of the system) is supplied from the truck batteries. For a short time
(less than 5 seconds), the truck batteries allow the alternator to produce power. When the power level of the tertiary
(AC output of T19 and T20) is sufficient to continue alternator excitation, the battery power is shut off and the tertiary
continues providing power for excitation.
The tertiary output supplies the Alternator Field Static Exciter (AFSE) with AC power to replace the truck batteries
after initial excitation. The AC power is converted to DC power by the AFSE. This power is then fed into the rotor as
excitation power. The excitation power level is controlled by the Drive System Controller (DSC). The excitation power
is increased as the system demands increase, and it is decreased as system demands decrease.
The 3-phase output of T1, T2, and T3 is converted to DC power. The power is routed to the Rectifier Diode (RD) panel.
The Rectifier Diode panel converts the AC power into full-wave DC power and provides that power to the DC link.
The DC link consists of a positive (DCP) and negative (DCN) bus. The DC power is available to the phase modules of
each traction motor and the chopper modules of the retard circuitry. The DC link has 10 filter capacitors to stabilize
the power by filtering current spikes.
During the retard mode of the truck, the IGBT Phase modules are used to direct power generated by the Motorized
Wheel to the DC link. To sustain the retard mode, voltage is applied to the wheel motor and then generated power is
directed back to the DC link.
The Chopper Modules (CM1, CM2, CM3, and CM4) are turned on as required across the DC link when retarding, to
direct the power generated by the Motorized Wheel to the retard grid resistors. The Chopper Modules turn on and off
as required during the retard mode to vary the resistive load across the DC link.

10
GEK-91764
VAM4
FP
AFSE T20 DCP
AC1 T1 RD
ALTERNATOR FIELD
STATIC EXCITER T19
AC2
T2
CMT
F1
DC+
T3
BATT BOOST F2
DC+ DC- DC-
GF CMAF VAM3
VAM4 LINKI
SYSTEM BLOWER
ESS ENGINE SPEED SENSOR

R1
GFR
BATTERY
BATFU
+ -
CHASIS GROUND
KEYSW CPS +/- 24 VDC CPD - GDP2
Figure 6. System Block Diagram - Alternator Circuit

+/- 15 VDC CONTROL POWER GATE DRIVE POWER
+ (IF EQUIPPED)
+5 VDC DISTRIBUTION MODULE TO PHASE AND
- CHOPPER MODULES
DSC GDP1
DRIVE SYSTEM +
CONTROL PANEL DCN
PS
E-53305A
GE Proprietary and Confidential Information

GEK-91764
SS1
DCP
DCN
TB1
TC1
TA1
CM1A
CM1B
P1C+
P1C-
INVERTER 1
P1B+
P1B-
I1F3
P1A+
P1A-
I1F2
I1F1
VAM1
LFC3
LFC2
L1F1
CCL2
VAM5
VAM3
GROUND
CHASIS
50 Ω 10 Ω
GROUND FAULT
DETECTION
GRR9 GRR10
1500 Ω 1500 Ω
GRR
DCN
DCP
E-53302
Figure 7. System Block Diagram - #1 Wheel Motor Circuit

GEK-91764
DCP
DCN
SS2
TB2
TC2
TA2
CM2A
CM2B
P2C+
P2C-
INVERTER 2
P2B+
I2F3
P2B-
I2F2
P2A+
P2A-
I2F1
VAM2
LFC6
LFC5
LFC4
DCN
DCP
E-53304
Figure 8. System Block Diagram - #2 Wheel Motor Circuit

GEK-91764
DCP
DCP
1500 Ω 1500 Ω
FDR
VAM5
CCL1
CF2
CF1
CD4
CM4I
CM4
RG4A RG4B RG4C
CD2
CM2I
CM2
GRIDI
RG2A RG2B RG2C
CD3
CM3I
CM3
RG3A RG3B RG3C
CM1I CD1
CM1
RG1A RG1B RG1C
BM2I
BM2
BM1I
VAM4
BM1
GBMC
GBMR
DCP
DCP
E-53303A
Figure 9. System Block Diagram - Grid Blower Circuit

GEK-91764
3.2. DRIVE SYSTEM CONTROLLER (DSC)
The 17FL454 Drive System Controller (DSC) provides the control electronics for the Control Group.
For the location of the DSC panel in Control Area 1 (CA1), refer to Figure 3.
For the control card layout for DSC, refer to Figure 10 and Figure 11.
The DSC contains the following circuit cards:
• FODC1 and FODC2 — (Slot 1 and Slot 2) Fiber-optic cards provide phase module (Inverter 1 and Inverter 2 phase
modules) firing commands through the fiber-optic cards.
• 17FB190 — (Slot 3 and Slot 4) Traction Motor Controller cards provide power control for Traction Motor 1 (TM1)
and Traction Motor 2 (TM2).
• 17FB173 — (Slot 5) DSC Analog Input/Output (I/O) card provides the DSC with Analog inputs and outputs from
various control components.
• 17FB104 — (Slot 6 and Slot 7) DSC Digital Input/Output (I/O) cards provide the DSC with Digital inputs and out-
puts from various control components.
• 17FB191 — (Slot 8) DSC Ethernet Switch card provides DSC with communications capability.
• 17FB187 — (Slot 9) DSC Main Central Processing Unit (CPU) card provides DSC with control and calculations for
the drive system.
Figure 12 and Figure 13 depict inputs and outputs of the circuit cards of the DSC.
E-56013
Figure 10. Drive System Controller (DSC)

GEK-91764
23
24
25 25
26 26
27 27
28- 28-
FODC1 FODC2 17FB190 17FB173 17FB104 17FB187

17FB190 17FB104 17FB191
E-53301A
Figure 11. Drive System Controller (DSC) Layout

16
ANALOG INPUTS ANALOG INPUTS
CURRENT SENSORS:
VOLTAGE ATTENUATION MODULE (VAM1): RETARD LEVER
DC LINK (LINKI)
GEK-91764
INV #1 DC LINK VOLTS GRID BLOWER #1 (BM1I) RETARD PEDAL

INV #1 PHASE VOLTS A,B,C GRID BLOWER #2 (BM2I) ENGINE SPEED SENSOR (FREQUENCY)
ALTERNATOR MAIN FIELD (CMAF) BAROMETRIC PRESSURE
CURRENT SENSORS:
ALTERNATOR TERTIARY WINDING (CMT) POT REFERENCE SIGNAL
INV #1 PHASE A (CM1A)
AFSE TEMPERATURE AMBIENT AIR TEMPERATURE
INV #1 PHASE B (CM1B)
GROUND FAULT DETECTION ACCELERATION PEDAL
CHOPPER SENSORS:
TOTAL GRID CURRENT (GRIDI) RETARD SPEED CONTROL/CRUISE
CHOPPER 1 (CM1I)
BATTERY POWER CONTROL BATTERY VOLTAGE
CHOPPER 2 (CM2I) VOLTAGE ATTENUATION MODULES (VAM3,4):
CHOPPER 3 (CM3I)
ALTERNATOR 3 PHASE VOLTAGES
CHOPPER 4 (CM4I) DC LINK VOLTS
FREQUENCY INPUTS
ALTERNATOR FIELD VOLTS
TRACTION MOTOR #1 SPEED SENSOR (SS1) ALTERNATOR TERTIARY VOLTAGE
(QUADRATURE FREQUENCY) GRID BLOWER MOTOR VOLTAGE
17FB173 17FB104 17FB104 17FB191 17FB187

17FB190 17FB190
DSC ANALOG DSC DIGITAL DSC DIGITAL ETHERNET MAIN CPU
FODC1 FODC2 TMC #1 CARD TMC #2 CARD
CARD CARD CARD SWITCH CARD CARD
SLOT 1 SLOT 2 SLOT 3 SLOT 4 SLOT 5 SLOT 6 SLOT 7 SLOT 8 SLOT 9
FREQUENCY INPUTS
FRONT WHEEL
FIBER OPTICS SPEED SENSORS (2)
FEEDBACKS: ENGINE SPEED
INV #1 PHASE INV #2 PHASE FEEDBACK SIGNAL
CHOPPER #1 & #2 CHOPPER #3 & #4
DIGITAL INPUTS PROPEL LOCKOUT ENGINE SHUTDOWN
CONTROL POWER ON OEM ACCEL INHIBIT ENGINE WARNING
Figure 12. Inputs to Drive System Controller (DSC)

KEY SWITCH FORWARD DIRECTION REQUEST ENGINE START REQUEST
ANALOG INPUTS CONTROL POWER SUPPLY REVERSE DIRECTION REQUEST TRUCK FULLY LOADED
VOLTAGE ATTENUATION MODULE (VAM2): GF CONTACTOR FEEDBACK DATA STORE OVER PAYLOAD
CAPACITOR DISCHARGE/GFCO REQUEST CRUISE CONTROL COMMAND LAMP TEST
INV #2 DC LINK VOLTS CONTROL GROUP PRESSURE SWITCH RESET/DUMP BODY OVERRIDE
INV #2 PHASE VOLTS A,B,C AXLE BOX PRESSURE SWITCH REST MODE REQUEST
CURRENT SENSORS: ALTERNATOR BLOWER PRESSURE SWITCH ENGINE WARMUP REQUEST
INV #2 PHASE A (CM2A) SERVICE BRAKE APPLIED WHEEL SPIN/SLIDE DISABLE REQUEST
INV #2 PHASE B (CM2B) PARK BRAKE REQUEST AUTONOMOUS MODE REQUEST
FREQUENCY INPUTS LOAD BRAKE APPLIED BRAKE TEST REQUEST
TRACTION MOTOR #2 SPEED SENSOR (SS2) DUMP BODY DOWN
(QUADRATURE FREQUENCY) ENGINE SPEED INCREASE #1
ENGINE SPEED INCREASE #2
E-53298A

POWER SUPPLY (PS)
CONROL POWER DISTRIBUTION (CPD) +5VDC
+5VDC TO DSC ±15VDC
±15VDC TO DSC COM
±24VDC TO DSC
ANALOG OUTPUTS ON CARD (FOR CURRENT MODULE) OEM
AVAILABLE THRU CARD +15VDC TO OPERATOR DEVICES: ETHERNET
DB25 CONNECTOR CPD
(INV1 #1-#4) ACCELERATION PEDAL
RETARD PEDAL DSC PTU
DRIVE SYSTEM
CRUISE CONTROL DID PANEL CONTROLLER
RETARD LEVER (IF USED) DIAGNOSTIC INTERFACE
INFORMATION
FIBER OPTICS DISPLAY J1939
MODULE FIRING COMMANDS: ANALOG OUTPUTS ON CARD
AVAILABLE THRU CARD ENGINE CAN
INV #1 PHASE INV #2 PHASE DB25 CONNECTOR
CHOPPER #1 & #2 CHOPPER #3 & #4 (INV2 #1-#4)
RS232
CAN1

17FB191 USB1
17FB173 17FB104 17FB104 ETHERNET 17FB187
FODC1 17FB190 17FB190
FODC2 DSC ANALOG DSC DIGITAL DSC DIGITAL SWITCH MAIN CPU
TMC #1 CARD TMC #2 CARD CARD
CARD CARD CARD CARD
ETHERNET2
SLOT 1 SLOT 2 SLOT 3 SLOT 4 SLOT 5 SLOT 6 SLOT 7 SLOT 8 SLOT 9
RS232
CAN2
RS232
FREQUENCY OUTPUT
ENGINE SPEED COMMAND
BUFFERED SPEED SENSOR MMD DSC PTU
BUFFERED SPEED SENSOR OEM DISPATCH DRIVE SYSTEM
SENSOR #4 CAN SYSTEM CONTROLLER
TRUCK SPEED INTERFACE INTERFACE
FREQUENCY OUTPUT
BUFFERED SPEED SENSOR DIGITAL OUTPUTS SYSTEM FAULT (PROPULSION DISABLED)
SENSOR #1 CONTROL POWER RELAY (PS) SYSTEM FAULT (RETARD DISABLED)
FREQUENCY OUTPUT ENGINE SPEED > SPEED SET PRE-SHIFT BRAKE TEST LIGHT
Figure 13. Outputs from Drive System Controller (DSC)

BUFFERED SPEED AFSE POWER RETARD MODE ACTIVE (TO WEIGH SYSTEM)
FREQUENCY OUTPUT SENSOR TRUCK SPEED > SPEED SET #1 PROPEL MODE ACTIVE (TO WEIGH SYSTEM)
SPEED SENSOR #1 SENSOR #2 TRUCK SPEED > SPEED SET #2 RETARD LIGHT
TEST CONNECTOR RETARD MODE ACTIVE (EXTERNAL LIGHT) PROPULSION SYSTEM OVERTEMPERATURE
FREQUENCY OUTPUT TRUCK IN REVERSE LIGHT
SPEED SENSOR #2 GF COIL LINK ON LIGHT
TEST CONNECTOR GRF COIL RETARD AT CONTINUOUS LEVEL
AFSE BATTERY BOOST REDUCED PROPEL LIGHT
ENGINE ISC HIGH SPEED SYSTEM NOT READY/SYSTEM FAULTED LIGHT
ENGINE ISC MEDIUM SPEED REST MODE ACTIVE LIGHT
FORWARD DIRECTION OUTPUT
REVERSE DIRECTION OUTPUT
PROPULSION SYSTEM WARNING
E-53299A
17
GEK-91764
GEK-91764
3.2.1. Drive System Controller (DSC) CN Connector Arrangement
Many of the wiring interface connections with the Drive System Controller (DSC) are through the CN connectors.
Refer to Figure 3 for location of the DSC panel in Control Area 1 (CA1). The CN connectors (CNA through CNE) are
arranged across the top of DSC, as shown in Figure 11.
The pin arrangement of the CN connectors, with the DSC female socket on the left side of the figure and the wire
harness male plug on the right side, is shown in Figure 14.
3.2.2. OEM Interface Connector Arrangement
Many of the OEM wiring interface connections to the control group are through the CNX connectors located on the
rear of the control group cabinet. Refer to Figure 5 for location and layout of the CNX connectors in Control Area 8
(CA8).
The pin arrangement for the CNX Control Cabinet sockets is shown in Figure 15.

GEK-91764
C 54 39 A A 39 54 C
52 52
55 40 40 55
78 56 28 1 1 28 56 78
92 68 41 15 15 41 68 92
2 2
79 57 29 29 57 79
93 93
69 42 16 16 42 69
80 58 30 3 3 30 58 80
94 70 43 17 17 43 70 94
81 59 31 4 4 31 59 81
44 44
95 71 18 18 71 95
60 32 32 60
82 5 5 82
72 45 19 19 45 72
96 96
83 33 6 6 33 83
97 20 20 97
84 7 7 84
98 21 21 98
85 8 8 85
99 22 22 99
86 86
9 9
73 73
100 23 23 100
61 34 34 61
87 10 10 87
46 46
101 74 24 24 74 101
88 62 35 11 11 35 62 88
102 75 47 25 25 47 75 102
89 63 36 12 12 36 63 89
103 103
76 48 26 26 48 76
13 13
90 64 37 37 64 90
104 77 49 27 27 49 77 104
91 65 38 14 14 38 65 91
66 50 50 66
53 53
67 51 51 67
D B B D
FLANGE RECEPTACLE (SOCKETS) CABLE PLUG (PINS)

(DSCAP, DSCBP, DSCCP, DSCD, DSCEP) (DSCAP, DSCBP, DSCCP, DSCDP, DSCEP)
E-53328A
Figure 14. CN Connector Pin Arrangement, DSC Socket and Wire Harness Plug

GEK-91764
34
34
47 47
35 35
46 20 20 33 46
33
32 8 36 36 8 32
31 19 9 21 21 31
9 19
18 2 22 22
2 18
30 10
3 23 10 30
45 7 1 37 23 3
29 1 7 45
11 37
17 24 29
44 5 11
38 24 17
16
6 4 12 44
38 5
14 39 16
43 4 6
28 15 13 25 12
40 39 14
26 25 13 28 43
42 27 15
41 40
26 27 42
41

(CNX1 AND CNX4) (CNX1 AND CNX4)
9 19 18
8 10 35
20
34
20 11 7
7 2 21 8 17
19 9 16 33
12 22 2 6
6 1 3
23 10 1 32
3 5 15
18
5 13 31
17 4 24 4
11 14
14 30
16 13
15 25 12
29
26 28
27

(CNX2) (CNX3)
18 19 9
35 10 8
20
34
17 7 21
8 11 20
33 9 2 7
16 6 2 22
32 1 10 23 19
15 5 3 12
31 3 1 6
24
14 4 11
30 18
13 25 13 5
12
29 28 4 17
26
14
27 16
15

(CNX3) (CNX2)
17 33
16 32
33 17 18
32 16
18 6
6 19 15
15 19 7 31
31 7
1 14
30 14 1 20 20 30
5 8 8 5
29 13 2 2 13 29
21 21
4 4
12 3 9
28 22 9 3 12
22 28
11 10
27 23 10 11
26 25 23
24 27
25 26
24

(CNX5) (CNX5)
E-53329A
Figure 15. Pin Arrangement for Control Cabinet CNX Connector Sockets

GEK-91764
3.3. DC LINK
The term “DC Link” is used to describe the DC power bus that Inverter 1 and Inverter 2 draw power from in propel
and send power to during retard mode. The voltage of the DC Link exists across the DCP bus (positive) and the DCN
bus (negative). The Rectifier Diode (RD) panel converts the AC main alternator output to DC. This DC power is supplied
to the DC Link. The DC Link voltage is always present unless the truck is shut down or in the rest mode while the truck
is running. Under normal operating conditions, the DC Link voltage can vary from 600 volts to 1600 volts DC, based
on alternator excitation or retarding power input.
3.4. INSULATED GATE BIPOLAR TRANSISTOR (IGBT)
The Insulated Gate Bipolar Transistor (IGBT) is an electronic switch. The IGBT is used to control current, volts, and fre-
quency for the AC Traction Motor 1 (TM1) and AC Traction Motor 2 (TM2). The IGBT is switched on and off by the Drive
System Controller (DSC) based on speed, DC link voltage, and requested torque. When an IGBT is switched on, the
power from the DC link flows through the IGBT to the stator field of the AC motor. IGBTs are also used as Chopper
Modules to direct retard power to the grid package resistors.
There are three positive and negative IGBT modules in each Inverter to allow both positive and negative current flow
in the three traction motor phases. Refer to Figure 3 and Figure 16 for Phase and Chopper Module locations in Con-
trol Area 4 (CA4) and Control Area 5 (CA5).
NOTE: 17KG543B1 and earlier groups have dual diodes.
CM1
CM2
DUAL DIODES ARE

ON 17KG543B1 AND
EARLIER MODELS ONLY
INVERTER 1
CM3
CM4
CM1I
CM2I
INVERTER 2
CM3I
CM4I
E-56026
Figure 16. Location of Chopper Modules in CA4 and CA5

GEK-91764
3.5. CHOPPER MODULES
Refer to Figure 16 for Chopper Module locations in the High-Voltage Inverter Area and to Figure 17 for a depiction of
a typical module. The Chopper Modules (CM1, CM2, CM3, and CM4) switch additional resistor paths in or out of the
resistor grid package in response to the call for more or less retarding. Refer also to Figure 9 for Chopper Module
electric circuit representations. Chopper Module switching is controlled by the Drive System Controller (DSC).
REMOVE ATTACHING HARDWARE

FROM THESE TERMINALS TO
DISCONNECT CHOPPER MODULE
FROM VERTICAL BUS BAR
E-56143
Figure 17. Chopper Module
3.6. CHOPPER DIODES (17KG543B1 AND EARLIER MODELS ONLY)
Chopper Diodes (CD1, CD2, CD3, and CD4) work in conjunction with the Chopper Modules. The Chopper Diodes are
dual diode modules. Panel CDDM1 consists of CD1 and CD3, and panel CDDM2 consists of CD2 and CD4. Refer to
Figure 9 for Chopper Diode electrical circuit.

GEK-91764
3.7. GRID BLOWER MOTOR CAPACITOR (GBMC)
The Grid Blower Motor Capacitor (GBMC) is used to condition the current during blower operation. The GBMC is
located in Control Area 6 (CA6). A Grid Blower Motor Capacitor Discharge Resistor (GBMR) works in conjunction with
the GBMC. The GBMR is located in Control Area 3 (CA3). Refer to Figure 18 and Figure 19 for location of GBMC and
GBMR.
GRID BLOWER MOTOR CAPACITOR

VIEW FROM BACKSIDE OF CONTROL GROUP
E-56175
Figure 18. GBMC Location

GEK-91764
ALTERNATOR
GBMC CONNS
WHEEL MOTOR ALTERNATOR
CONNS CABLE INLET
LFC6
LFC5
LFC4
LFC3
LFC2
LFC1
CAPACITORS
TOP VIEW
LT6 LT5 LT4 LT3 LT1
GF R1
GFR DSC
CMAF
THI
CA3
VAM5
PS
GRR10
GBMR
CA1
GRR9
LT2
DCHB
RD AFSE
CA5 CA4
CA2
FRONT VIEW
E-56158
Figure 19. Location of GBMC (Top View) and GBMR (CA3)

GEK-91764
3.8. RECTIFIER DIODE (RD) PANEL
The Rectifier Diode panel (RD, Figure 20) contains a 3-phase full wave bridge rectifier. The RD receives 3-phase AC
output from the alternator and rectifies it to DC. The DC output voltage from RD is connected to the DC Link via
cables. The six diode/heat sink assemblies on the bottom of the RD are cooled via forced air exhausting out the side
of the cabinet.
DC-
AC1
AC2
AC3
DC+
E-44654
Figure 20. Rectifier Diode Panel
3.9. POWER SUPPLY (PS)
Refer to Figure 21 for arrangement of the Power Supply in CA1. The 17FH43 Power Supply provides +5.1 VDC, ± 15
VDC, and ± 24 VDC to the DSC panel, cab-mounted DID panel, current sensors, and other low-voltage powered
devices. Many of the electronic devices are powered from the Control Power Distribution (CPD) module, located in
Control Area 1 (CA1). Refer to section 3.10., CONTROL POWER DISTRIBUTION (CPD) MODULE, for more information on
the CPD.
Figure 22 depicts the Power Supply connector pin arrangement for PS1 and PS2. The output tolerance of the Power
Supply is:
• +5.1 VDC ± 2%
• +15, –15 VDC ± 5%
• +24, –24 VDC ± 5%
LEDs on the Power Supply front panel are illuminated when the corresponding output voltage is present. Separate
LEDs indicate the presence of +5.1, +15, –15, +24, and –24 VDC. The Power Supply has voltage indication lights that
will illuminate when voltage is present in certain areas of the power supply. Refer to Figure 23 for the Power Supply
LED layout.

GEK-91764
CONTROL POWER
DISTRIBUTION (CPD)
L-R:
CNT2, CNT1, RTN, BATT
POWER SUPPLY (PS)
LED'S
E-56014
Figure 21. Arrangement of Power Supply and CPD in CA1
CONNECTOR PS1 CONNECTOR PS2
58 53 48 43 38 34 32 30 26 21 16 11 6 1
3 6 9
AMP
2 5 8
1 4 7
62 57 52 47 42 37 33 31 29 25 20 15 10 5
E-53398
Figure 22. Power Supply Connector Pin Arrangements

GEK-91764
E-56230
Figure 23. Power Supply LED Layout

GEK-91764
3.10. CONTROL POWER DISTRIBUTION (CPD) MODULE
The Control Power Distribution (CPD) module (Figure 24) provides a centralized connection point for power from the
Power Supply (PS) to the electronic devices in the control system. Refer to Figure 3 and Figure 21 for CPD location in
Control Area 1 (CA1). Figure 21 depicts the location of CPD in relation to the Power Supply (PS).
CPD4
1 4 SPARE +5/5A DID +5/5A
5 9
10 15 SPARE B +15/3A
16 22 SPARE A +15/3A DID +15/3A
23 28
29 33 SPARE B -15/3A
34 37 SPARE A -15/3A DID -15/3A
CPD3 CPRA +BAT/5A
CPS +BAT/5A CPRB +BAT/5A
1 2 LINKI +24/2A
3 6 SPARE +24/2A BM1I +24/2A
7 10
11 14 CCM1 +24/2A
15 16 CPD2 CMAF +24/2A CCM3 +24/2A
LINKI -24/2A
SPARE -24/2A BM1I -24/2A
CPD1
1 4 CCM1 -24/2A
5 9 CMAF -24/2A CCM3 -24/2A
10 15
16 20
21 24
TPPR TPRTN TP+15

TP CR1 TP5 TP-15
E-53331
Figure 24. Control Power Distribution (CPD) Module Arrangement
Figure 25 and Figure 26 show the connectors to CPD to the PS and electronic devices. Power to some electronic
devices is routed through CPD to the Drive System Controller (DSC) to the electronic devices. Blade-type circuit fuses
and fuse ratings are to the right of the CPD multi-pin connectors.
CPD input voltage is from the vehicle battery with a range of +19 to +40 VDC; the nominal truck battery voltage is
28 VDC. Battery level input will turn the Power Supply on, and removal of this input will turn it off.

CPD CONNECTOR #1 CPD CONNECTOR #2 AND #3
RETURN BUS -24 BUS RETURN BUS

+24 BUS LINKI+24/2A
+5V BUS 3-1 LGF24B1
1-1 10P5VB PS1-8 DSCE-60
LD9 R2
LINKI-24/2A 3-2 LGF24W1
1-3 10RTNW PS1-19 DSCE-72
LD15 R2
BMI1+24/2A 3-3 BMF24B1
1-5 11P5VB PS1-9 DSCE-71
LD10 R2
1-2 11RTNW PS1-20 BMI1-24/2A 3-4 BMF24W1 DSCE-82
TP +5 LD16 R2
1-6 12P5VB PS1-10 CMAF+24/2A 3-5 CMF24B1
DSCE-32
LD11 R2
1-7 12RTNW PS1-21 CMAF-24/2A 3-6 CMF24W1
+15V BUS DSCE-45

1-4 13P15VB PS1-28 LD17 R2
CCM1+24/2A 3-7 C1F24B1
DSCE-6
1-8 13RTNW PS1-33 LD12 R2
TP +15 CCM1-24/2A 3-8 C1F24W1
DSCE-20
1-9 14P15VB PS1-29 LD18 R2
CCM3+24/2A 3-9 C3F24B1
TP -15 1-13 14RTNW PS1-34 DSCE-19
LD13 R2
-15V BUS CCM3-24/2A 3-10 C3F24W1
1-10 15N15VB PS1-40 DSCE-33
LD19 R2
1-11 15RTNW SPARE+24/2A 3-11 SPARE
PS1-42
+24 BUS LD14 R2
20P24VB PS1-49 SPARE-24/2A 3-12 SPARE
1-18
LD20 R2
1-23 20P24VR PS1-50 2-1 SPARE
1-12 20RTNW PS1-43 2-2 SPARE
-24 BUS
1-22 21N24VB PS1-59
2-3 SPARE
1-21 21N24VR PS1-60
TPRTN SPARE A+15/3A 3-13 SPARE
CPS +BAT BUS 1-17 21N24VB PS1-53 LD3 R2
SPARE A-15/3A 3-14 SPARE
1-20 4CPS1 PS1-T1 LD4 R2
-15V BUS
1-19 22BAT1 PS1-2
+15V BUS
1-24 23BAT1 PS1-52
Figure 25. CPD Connector 1, Connector 2, and Connector 3 Electrical Block Diagrams
GND 60RTN1 GND2-BLK
CPR +BAT BUS
E-53318
29
GEK-91764
GEK-91764
CPD CONNECTOR #4
+5V BUS RETURN BUS
SPARE +5/5A 4-4

SPARE
R2 4-1
SPARE
DID +5/5A LD2 DIP5AB1 CNX5-14
4-8 DID PANEL
R1 4-12 DIP5AW1 CNX5-15 CONNECTOR
LD1 IN OP CAB
DIP5AS1
4-2 DIP5BB1 CNX5-17 P5VDC
DID-5
4-6 DIP5BW1 CNX5-16 P15VDC
DID-6
DIP5BS1 N15VDC
DID-9
4-3 DIP5CB1 CNX5-32 RTN
DID-10
4-7 DIP5CW1 CNX5-33
-15 BUS
DIP5CS1
SPARE B-15/3A 4-15
SPARE
R8 4-21 SPARE
LD8
DID -15/3A 4-9 DP15AB1 CNX5-4
R7 4-14 DP15AW1 CNX5-3
+15 BUS LD7
DP15AS1
SPARE B+15/3A 4-5
SPARE
R4 4-13
SPARE
LD4
DID +15/3A 4-10 DP15AB1 CNX5-1

R5 4-18 DP15AW1 CNX5-2
LD5
DP15AS1
4-11 DP15BB1 CNX5-7
4-24 DP15BW1 CNX5-8
CPS +BAT BUS
DP15BS1
CPS +BAT/5A CNX5-10
4-28 CPS1
CPR +BAT BUS
R21
CPRA +BAT/5A LD21 CNX5-29
4-22 CPRA1
R22
CPRB +BAT/5A LD22 CNX5-25
4-27 CPRB1
R23
LD23
4-33
SPARE
E-53317
Figure 26. CPD Connector 4 Electrical Block Diagram

GEK-91764
3.11. GATE DRIVER POWER CONVERTER (GDPC)
Refer to Figure 3 for location of the GDPC in Control Area 1 (CA1).
The Gate Driver Power Converter (GDPC) produces 100 Vrms, 25 kHz, square wave power to drive the phase mod-
ules. Figure 27 depicts a control group with two GDPCs.
NOTE: 17KG543B2 and later groups have only one GDPC.
TWIST LOCK
TO REMOVE
CONNECTOR
GDPC1
GDPC2
CIRCUIT BREAKER 1
(CB1) AND CIRCUIT
MOUNTING BREAKER 2 (CB2)
STUDS
AND NUTS,
BOTH SIDES
E-56015
Figure 27. Typical Gate Driver Power Converter (GDPC) Arrangement

GEK-91764
3.12. AMBIENT TEMPERATURE (AMBT) SENSOR
Refer to Figure 28. The Ambient Temperature (AMBT) sensor provides ambient air temperature input to the Control
Group. AMBT is located in Control Area 7 (CA7) as shown in Figure 5.
E-54748A
Figure 28. Ambient Temperature (AMBT) Sensor

GEK-91764
3.13. BAROMETRIC PRESSURE SENSOR (BAROP)
Refer to Figure 29. The Barometric Pressure Sensor (BAROP) provides altitude input to the control electronics. BAROP
is located in Control Area 1 (CA1) as shown in Figure 3.
NOTE: Arrangement for 17KG543B1 and earlier groups is shown in the following figure.
BAROMETRIC
PRESSURE
POWER SUPPLY (PS)
SENSOR
(BAROP)
E-56027
Figure 29. Barometric Pressure Sensor (BAROP)

GEK-91764
3.14. CONTROL GROUP PRESSURE SWITCH (CGPS)
The Control Group Pressure Switch (CGPS) provides control input of the control component cooling air pressure in the
duct. Refer to Figure 30 for location of CGPS in Control Area 6 (CA6).
3.15. FILTER DISCHARGE RESISTOR (FDR)
Refer to Figure 30. The Filter Discharge Resistor Panel (FDR) is a resistor divider network connected across the DC
link. FDR provides a secondary discharge link for the DC Link capacitors. Normal discharge is through Chopper Mod-
ules to the grid resistors. Refer to Figure 5 for location of the FDR in Control Area 7 (CA7).
3.16. GROUND RESISTOR PANEL (GRR)
Refer to Figure 30. The Ground Resistor Panel (GRR) is a resistor divider network connected across the DC link. GRR is
used with GRR9 and GRR10 to detect system ground faults. Refer to Figure 5 for location of the GRR in Control Area 7
(CA7). Refer to Figure 3 for location of GRR9 and GRR10 in Control Area 3 (CA3).
3.17. FILTER PANEL (FP)
Refer to Figure 30. The Filter Panel (FP) is a 3-phase resistor-capacitor (RC) filter across the alternator AC output.
Refer to Figure 5 for location of the FP in Control Area 7 (CA7).
FDR
GRR
CGPS
FP
E-56025
Figure 30. CGPS, FDR, GRR, and FP Arrangement in CA7

GEK-91764
3.18. CURRENT MEASURING SENSORS
Current sensors are used to measure the current flow through a conductor which passes through an opening in the
current sensor. The output of the sensor is proportional to the current flowing through the cable. There are two types
of current sensors used in the AC Control Group: 1000 Amps and 2000 Amps.
Refer to Figure 31. The sensor depicted on the left has a nominal rating of 2000 Amps and measures AC current. The
sensor depicted on the right has a nominal rating of 1000 Amps and measures DC current.
The two sensors are used in the following applications:
• BM1I — measures DC current through the retarding grid blower motor #1

• BM2I — measures DC current through the retarding grid blower motor #2
• CM1A — measures AC current to Traction Motor 1 (TM1), phase A
• CM1B — measures AC current to Traction Motor 1 (TM1), phase B
• CM2A — measures AC current to Traction Motor 2 (TM2), phase A
• CM2B — measures AC current to Traction Motor 2 (TM2), phase B
• CM1I — measures DC current through Chopper Module 1 (CM1)
• CMAF — measures DC current to the Alternator Field
• CMT — measures AC current from the Alternator Tertiary winding
• GRID1 — measures grid current
• LINK1 — measures DC Link current
2000 AMP (NOMINAL) 1000 AMP (NOMINAL)
E-44655A
Figure 31. Typical Current Modules

GEK-91764
3.19. GENERATOR FIELD RELAY (GFR)
The Generator Field Relay (GFR) is a 17LV66 Relay (Figure 32), form J46-T, with a coil resistance of 30.9 ohms at 25°C,
and a maximum pick-up rating of 0.381 Amps. GFR, when energized, applies battery voltage to AFSE. GFR is located
in Control Area 3 (CA3) as shown in Figure 3 and Figure 32.
NOTE: Arrangement for 17KG543B1 and earlier groups is shown in the following figure.
R1
GF
VAM1
GFR
VAM2
CMAF
VAM5
VAM3
TH1 VAM4
E-56028
Figure 32. GFR, GF, and VAM Locations in CA3
3.20. GENERATOR FIELD (GF) CONTACTOR
The Generator Field (GF) contactor controls excitation power for the main alternator rotor excitation field connected
to the rotor slip rings. When open, it interrupts the alternator main excitation field, thereby preventing the alternator
from developing any output. The GF contactor is located in Control Area 3 (CA3) as shown in Figure 3 and Figure 32.

GEK-91764
3.21. DYNAMIC RETARDING ASSEMBLY
Refer to Figure 33 for a depiction of the Dynamic Retarding Assembly.
The Dynamic Retarding Assembly contains the Grid Resistors, Grid Blower Motor (BM1), and Grid Blower Motor 2
(BM2). The resistors are used to dissipate energy from the wheel motors as heat in Retarding mode. The Grid Blower
Motors are used to cool the resistor elements. Chopper Modules (CM1, CM2, CM3, and CM4) are used to connect var-
ious resistor paths contained in the Dynamic Retarding Assembly. The Dynamic Retarding Assembly is not part of the
Control Group but is explained in relation to the Control Group.
Figure 33. Model 17EM155 Dynamic Retarding Assembly

GEK-91764
3.22. VOLTAGE ATTENUATION MODULES (VAM1 – VAM5)
Refer to Figure 3 and Figure 32 for VAM location in Control Area 3 (CA3). Voltage Attenuation Modules (VAM1 through
VAM5) are used to monitor both AC and DC voltages for feedback signals to the Drive System Controller (DSC). VAMs
attenuate high voltages to a level that can be input to DSC. Two different types of VAMs (Figure 34) are used: one
which can attenuate eight different voltage sources, and one which can attenuate five different voltages.
NOTE: On 17KG543B2 and later models, only the five-channel VAM is used.
HIGH VOLTAGE
INPUTS
REDUCED VOLTAGE
REDUCED VOLTAGE
OUTPUT
OUTPUT
E-44656
Figure 34. Eight-Channel VAM (Left) and Five-Channel VAM (Right)
3.23. INVERTER AND CHOPPER FUSES
The Inverter Fuses provide circuit protection to the DC Link when phase modules produce power to the traction
motors. There are three Inverter Fuses in parallel for each Inverter stack. The fuses are located at the bottom of the
Inverter stack vertical bus bar behind the DC Horizontal Bus (DCHB) as shown in Figure 35.
CAUTION Chopper modules will fail if the system is powered up without chopper fuses installed.
Be sure the chopper fuses are properly installed to avoid equipment damage.
The Chopper Fuses provide circuit protection during Chopper Module operation. There are two fuses in parallel
located in the Control Cabinet Control Area 5 (CA5) at the bottom of the Chopper Module vertical bus bar behind the
DC Horizontal Bus (DCHB) similar to fuses shown in Figure 35.

GEK-91764
REMOVE FUSE MOUNTING HARDWARE.

NOTE HARDWARE ARRANGEMENT FOR ASSEMBLY.
ON INSTALLATION, TORQUE TO 14 LB–FT (19 NM).
E-53415A
Figure 35. Phase Fuse Location

GEK-91764
3.24. LINK FILTER CAPACITORS
Refer to Figure 36 for a depiction of the Link Capacitors.
The Filter Capacitors absorb and release current to the DC link when a positive or negative current spike occurs. Six
Filter Capacitors are used in the DC Link. All six capacitors are connected to the horizontal bus bar which connects to
each of the three vertical stacks. Refer to Figure 3 and to Figure 36 for location of the Filter Capacitors in the High-
Voltage Inverter Area.
CAPACITOR
FLOOR MOUNTING
LOCATION - 4 PLACES
E-56029
Figure 36. Link Capacitors
3.25. ALTERNATOR FIELD STATIC EXCITER (AFSE)
The Alternator Field Static Exciter (AFSE) provides excitation current in the rotating field of the traction alternator. The
excitation current is developed by controlling a full wave bridge SCR circuit in AFSE. To control the SCR circuit, the
DSC calculates the desired field current and generates SCR firing commands. The AFSE is located in Control Area 2
(CA2) as shown in Figure 3. Refer also to Figure 37.

GEK-91764
SELF GATED SCR BATTERY

(TERMINAL A TO R1) BOOST CARD
AFSE
CONNECTOR
BATTERY BOOST
(TRUCK BATTERY
OR GROUND)
DC-
PULSE GATE FIRING

TRANSFOMERS MODULES
AC
D2 D1
SCR3 SCR4 DC+
SCR2 SCR1 AC
TEMPERATURE SENSOR TS1

(MOUNTED ON HEAT SINK)
E-49767
Figure 37. Typical AFSE Main Component Arrangement

GEK-91764
3.26. DIAGNOSTIC INFORMATION DISPLAY (DID) PANEL
Refer to Figure 38. The Diagnostic Information Display (DID) panel is located in the Operator’s Cab. This panel’s two-
line display provides the number and description of active faults. Certain faults may be cleared and reset by the
operator. Other faults require more extensive knowledge to troubleshoot or to clear and reset; these must be left to
the maintainer.
The maintainer can also use the DID to monitor various operating conditions or to run diagnostic self-tests, such as
Loadbox, Capacitance Test, or View Software versions.
MESSAGE LINE
MENU LINE
ALL FUNCTIONS ARE

CONTROLLED THROUGH F1 F2 F3 F4 F5
FUNCTION KEYS F1 − F5
E-33575b
Figure 38. Diagnostic Information Display (DID) Panel
4. SCHEDULED MAINTENANCE
Refer to section 1.2., RELATED PUBLICATIONS, for the Planned Maintenance publication for this drive system.
5. REMOVAL AND REPLACEMENT PROCEDURES
5.1. CAPACITOR DISCHARGE PROCEDURE
The purpose of this section is to outline a discharge procedure for the DC Link Capacitors in case of failure of the
built-in discharge circuits in GE IGBT control groups.

GEK-91764
To perform the capacitor discharge procedure, the following special tools and material are required:
• Personal Protective Equipment (PPE) for working with 2000 VDC.

• 2000 VDC meter (Bierer RCDC 1000 or equivalent). For further information refer to www.bierermeters.com.
• Grounding stick pair (HVR Advanced Power Components MAS-000039 Ground Stick Pair or equivalent).
• Multimeter for ground resistance measurement.
5.1.1. Warnings for Capacitor Discharge Procedure
shoes, high-voltage gloves, and safety glasses, must be worn.
Safety precautions appear throughout the instructions. WARNING indicates the potential for personal injury and
CAUTION indicates the potential for equipment damage.
Read the following WARNINGS before working on this drive system.
equipment when the door to the Low Voltage area is open. Failure to do so may result
Capacitor Charge lights are off. Use measurement and protective equipment rated for
2000 VDC minimum to verify no voltage is present before touching any terminal. Verify
before and after performing control group measurements. Failure to observe these
precautions may result in death or serious personal injury.
may result in injury or death.

GEK-91764
equipment used must be rated at 2000 VDC minimum. Verify functionality of the
performing control group measurements. Failure to observe these precautions may
5.1.2. Manual DC Link Capacitor Discharge Procedure
5.1.2.1. Preparation
shoes, high-voltage gloves, and safety glasses, must be worn.
Verify the following prior to performing work within the Control Cabinet:
1. The diesel engine is shut down and the Park Brake is set.
2. The generator field is cut out via the GF switch in the Low-Voltage Area (CA1) of the Control Cabinet (Figure 39).
3. Apply control power for a minimum of 30 seconds. Then turn off control power, using the Control Power switch
(CPS) on the switch panel (Figure 39).
4. With control power on, a Chopper Module turns on and discharges the DC Link through the retarding grids in
less than 10 seconds. Refer to Figure 40 for Chopper Module position across the DC Link.
E-55902
Figure 39. Switch Panel with Control Power Switch (CPS) and Generator Field Cut Out (GFCO) Switch

GEK-91764
RETARDER GROUP
NORMAL (FAST) DISCHARGE PATH:
RG2 CIRCUIT
CHOPPER MODULE THOUGH
+ CM2 RETARD GRID ELEMENTS
RG2_X
SECONDARY (SLOW) DISCHARGE PATH:
- FDR AND GRR
IVB2
IVB1
CVB
FDR
GRD BUS
1+ - + - + - 56
DCHB
GRR
A
B
LFC1 LFC2 LFC3 LFC4 LFC5 LFC6
E-56033
Figure 40. Control Group 17KG543 Capacitor Discharge Path
5.1.2.2. Capacitor Charge Lights (CCL1 and CCL2)
Observe both Capacitor Charge Lights (CCL1, CCL2). For the 17KG543 Control Group, both CCL1 and CCL2 lights are
located above CA3 (Figure 41) on the Control Cabinet. The lights will stay illuminated as long as the voltage on the DC
link is greater than 50 VDC. Refer to Figure 41, showing the 17KG535 Control Group CCL1 and CCL2 location.
5.1.2.3. Failure of Capacitor Discharge System
If the Capacitor Charge Lights remain illuminated, a failure of the Normal (Fast) Capacitor Discharge System (the
chopper discharge path) has likely occurred. The Slow Discharge Resistors that are hard-wired across the DC Link
should then discharge the capacitors. The Slow Discharge Resistors will discharge the DC Link to less than 1 VDC in
less than 7.5 minutes. If after 7.5 minutes, the Capacitor Charge Lights (CCL1 and/or CCL2) are still illuminated, it
must be assumed that the automatic discharge system is not working and that high voltage is present in the High-
Voltage Area.

GEK-91764
CCL1 CCL2
E-56034
Figure 41. Capacitor Charge Lights Location
5.1.2.4. Measure DC Voltage on the Capacitors
NOTE: This procedure must be completed each time the cabinet is opened.
Open the High-Voltage Area doors. For Control Group 17KG543, the capacitors are connected across the horizontal
bus (DCHB) as shown in Figure 42.
With a suitable high-voltage meter rated for at least 2000 VDC, such as a Bierer RCDC1000 or equivalent, plus suit-
able protective equipment, measure the voltage across each of the DC Link capacitors.
Place one meter lead on the positive (+) capacitor terminal, and the other meter lead on the diagonally located neg-
ative (-) capacitor terminal, and observe the voltage. Refer to Figure 43 for a measurement example.
If the voltage is less than 1.0 V, the capacitor is sufficiently discharged. Repeat on all DC Link capacitors.
If the voltage of any capacitor is above 1.0 VDC, manually discharge the capacitor as described in section
5.1.2.5., MANUAL DISCHARGE OF CAPACITORS.

GEK-91764
+ + + + + +
- - - - - -
E-56035
Figure 42. Capacitor Positive (+) and Negative (-) Terminal Posts
E-56036
Figure 43. DC Meter on Capacitor Positive and Negative Terminal Posts

GEK-91764
5.1.2.5. Manual Discharge of Capacitors
If the voltage is greater than 1.0V on any of the capacitors, the capacitor must be manually discharged. With a suit-
able capacitor discharge device, such as a HVR Advanced Power Components MAS-000039 Ground Stick Pair, dis-
charge the capacitors where needed per the following instructions:
1. With the Control Cabinet high-voltage compartment doors closed, connect the Ground Stick Pair ground lead to
ground. The most convenient location is the angle bracket that is welded onto the weldment and centered over
the high-voltage compartments, CA4 and CA5. Attach the Ground Stick Pair ground lead using a 0.50-13 hex cap
screw and finished bolt with a minimum thread length of 3/4 inch. Refer to Figure 44.
2. Verify the ground connection and ground stick resistance levels. Measure the resistance between each individ-
ual ground stick tip to either the GND1 or GND2 ground block in the Low-Voltage compartment of the Control
Cabinet using a multimeter. Ensure that the resistance is within the manufacturer’s specifications for the ground
sticks. Refer to Figure 45 and Figure 46 for GND1 and GND2 block location and Ground Stick Pair check.
NOTE: For MAS-000039 Ground Stick Pair, the valid range is 80 to 125 ohms per stick.
equipment when the door to the low-voltage area is open. Failure to do so may result
E-55989
Figure 44. Ground Stick Pair Ground Lead Attachment Point on Weldment

GEK-91764
E-56038
Figure 45. GND1 and GND2 Block Location in Low-Voltage Compartment (Right Wall)
USE MULTIMETER TO MEASURE OHMS

BETWEEN EACH GROUND STICK TIP
AND EITHER GND1 ON GND2.
CONNECT GROUND LEAD HERE
E-56039
Figure 46. Ground Stick Check

GEK-91764
3. Discharge the relevant capacitors. Open the door(s) and place one grounding stick on one of the positive (+)
capacitor terminals and the other on the diagonally located negative (-) terminal. Refer to Figure 42 and Figure
47. Attempt to minimize the time between application of the positive stick and the negative stick so that the cur-
rent flow will be positive to negative rather than either to ground. Leave sticks in place until capacitors are dis-
charged. Refer to Figure 47.
NOTE: If using adjacent terminals, use care to keep the tips separated while discharging or else use a positive
terminal on one capacitor and negative terminal of the adjacent capacitor on the same bus bar.
NOTE: For MAS-000039, the discharge times from 2000 Volts are:
• 15 seconds (maximum) for two capacitors

• 75 seconds (maximum) for six capacitors
equipment used must be rated at 2000 VDC minimum. Verify functionality of the
performing control group measurements. Failure to observe these precautions may
4. Measure voltage on all capacitors again, as described in section 5.1.2.4., MEASURE DC VOLTAGE ON THE CAPAC-
ITORS. Discharge any capacitors that show voltage.
5. If all capacitors read discharged, verify the meter is functioning correctly using site-approved procedures. If the
meter is properly functioning, proceed to the next section.
E-56037
Figure 47. Application of Ground Stick Pair to Capacitor Terminals

GEK-91764
5.1.2.6. Short Isolated Capacitor Terminals
Any capacitor that is isolated from the DC Link and confirmed discharged must have its terminals electrically
shorted together to prevent static charge build up. Use bare wire to jumper all four terminals on the capacitor. Refer
to Figure 48, showing capacitor terminals shorted together.
Proceed to troubleshoot and repair the control group to restore it to original functionality.
E-53240
Figure 48. Jumper all Terminals on Isolator Capacitor

GEK-91764
5.2. DRIVE SYSTEM CONTROLLER (DSC) REPLACEMENT
The Drive System Controller (DSC) is located in Control Area 1 (CA1) as shown in Figure 3. To replace the DSC:
switch is in the CUTOUT position before attempting any work on the control compo-
nents. Check that Capacitor Charge Lights (CCLs) are not illuminated. Use measure-
ment and protective equipment rated for 2000 VDC minimum to verify that no voltage
is present before touching any terminal. Verify functionality of the measurement
equipment using site-approved procedures both before and after performing control
group measurement. Failure to observe these precautions may result in death or seri-
ous personal injury.
1. Open the door to the Low-Voltage Control Area (CA1) to access the Switch Panel switches CPS and GFCO (refer to
Figure 2).
2. Remove power by setting CPS to the OFF position and setting GFCO to the CUTOUT position.
3. Open the Battery Switch (BATTSW) and lock out.
NOTE: For details on DSC and connections, refer to section 3.2., DRIVE SYSTEM CONTROLLER (DSC), in this publi-
cation.
CAUTION Always use antistatic bags when storing control cards to prevent electronic compo-
nent damage.
4. Remove all control cards from DSC. Store the control cards in antistatic bags in a protected location until reuse.
5. Identify and remove fiber optic cables. Fiber optic connectors have a lock lever that must be depressed to pull
from the socket.
CAUTION Do not pull on the control cable connectors. Be sure to turn the connector center lock
until loose from the threads, and twist the locked ring of the connector until released
before attempting to remove the connectors. Pulling on the connectors may damage
them.
6. Remove all CN connectors (CNA through CNE). The connector center lock bolt should be turned until loose from
threads to pull connector from socket.
7. Remove all control cable connectors (multiple connectors in a vertical column) on the right side of DSC. Twist the
locking ring of the connector until released before pulling from the socket.
CAUTION DSC weighs approximately 40 lbs. (18 kg) without cards installed or 60 lbs. (27 kg) with
cards. Use appropriate handling procedures. Failure to do so may result in equipment
damage.
8. With the weight of the DSC supported, remove the upper mounting nuts and lower bolts and remove the DSC
from the Control Cabinet.
9. Align the replacement DSC in position and thread the mounting hardware into position.

GEK-91764
10. Torque the mounting hardware to 12 to 14 lb.-ft. (16 to 19 Nm).
11. Connect all control cable connectors (multiple connectors in a vertical column) on the right side of the DSC. After
connector installation into the socket, twist the lock ring until locked.
12. Connect all CN connectors (CNA through CNE). The connector center lock bolt should be tightened after the con-
nector is firmly in the socket.
13. Connect all fiber-optic cables, ensuring the connector locking lever is engaged in the socket lock.
14. Install control cards.
5.3. GATE DRIVER POWER CONVERTER (GDPC1 OR GDPC2) REPLACEMENT
To replace a Gate Driver Power Converter unit (GDPC1 or GDPC2, if equipped):
NOTE: 17KG543B1 and earlier models have two GDPCs; 17KG543B2 and later models have only one GDPC.
1. Open the door to the Control Area 1 (CA1) Low-Voltage Control Area to access the Switch Panel switches: CPS
and GFCO (Figure 2).
2. Remove power by setting CPS to OFF position and setting GFCO to CUTOUT position.
4. GDPC1 and GDPC2 are located in CA1 as shown in Figure 3.
5. Set CB1 and CB2 to the OFF (OPEN) position on the GDPC unit being removed. Refer to Figure 49 for typical GDPC
mounting arrangement.
6. Remove the circular connector from GDPC.
7. Remove the nuts and washers that secure GDPC to the cabinet.
8. Remove GDPC from the cabinet.
9. Align the replacement GDPC onto the mounting studs and assemble the washers and nuts onto the studs. Note
the low torque value. Torque the mounting nuts to 74 to 83 lb.-in. (8 to 9 Nm).
10. Insert the wire harness connector into the GDPC plug and twist lock in place.
11. Ensure CB1 and CB2 are in the ON (CLOSED) position.

GEK-91764
TWIST LOCK
TO REMOVE
CONNECTOR
GDPC1
GDPC2
CIRCUIT BREAKER 1
(CB1) AND CIRCUIT
MOUNTING BREAKER 2 (CB2)
STUDS
AND NUTS,
BOTH SIDES
E-56015
Figure 49. Typical GDPC Mounting Arrangement for Two Units
5.4. POWER SUPPLY (PS) REPLACEMENT
To replace the Power Supply (PS):
WARNING Hazardous voltages may be present in this equipment. Ensure that the Control Power
switch is in the CUTOUT position before attempting any work on control components.
Check that the Capacitor Charge Lights (CCL1 and CCL2) are not illuminated. Use a
VOM to verify no voltage is present before touching any terminal. Failure to observe
1. Open the door to the Low-Voltage Control Area 1 (CA1) to access the Switch Panel switches: CPS and GFCO (refer
to Figure 2).
4. The Power Supply (PS) is located on the lower right wall of CA1 as shown in Figure 3 and Figure 50.
5. Verify that the red input voltage LED is not illuminated.
6. Using a VOM, verify no voltage is present across the RTN and BATT, RTN and CNT1, and RTN and CNT2 terminals.
7. Identify and remove wire connections on PS terminals CNT2, CNT1, RTN, and BATT.

GEK-91764
CONTROL POWER
DISTRIBUTION (CPD)
L-R:
POWER SUPPLY (PS)
LED'S
E-56014
Figure 50. Power Supply Location in CA1
8. Remove the PS1 connector by unscrewing the center lock bolt and pulling the connector from the socket.
9. Remove the PS2 connector by twisting the retaining ring off and pulling the connector from the socket.
CAUTION The Power Supply weighs approximately 40 lbs. (18 kg). Use appropriate handling
procedures. Failure to do so may result in equipment damage.
10. Remove the PS mounting hardware while supporting the weight and remove PS from the cabinet.
11. Align the replacement PS and thread the mounting hardware in position.
13. Align wire connections on PS terminals CNT2, CNT1, RTN, and BATT and thread mounting hardware into position.
14. Not the low torque value. Torque wire connections hardware to 35 to 39 lb.-in. (395 to 440 NCM).
15. Install the PS2 connector by plugging the connector into the PS socket and twist the retaining ring on.
16. Install the PS1 connector by plugging the connector into the PS socket and threading center locking bolt tight.

GEK-91764
5.5. VOLTAGE ATTENUATION MODULE (VAM1 – VAM5) REPLACEMENT
All VAM modules (VAM1 through VAM5) are located in Control Area 3 (CA3) as shown in Figure 3. Prior to working on
VAM modules, always follow the DC Link capacitor discharge procedure as described in section 5.1., CAPACITOR DIS-
CHARGE PROCEDURE, in this publication. To replace a VAM module:
may result in injury or death.
1. Discharge the capacitors as described in section 5.1., CAPACITOR DISCHARGE PROCEDURE, in this publication.
2. Disconnect the circular connector from the VAM. Refer to Figure 51.
NOTE: On 17KG543B2 and later models, only the five-channel VAM is used.
3. Tag and remove all high-voltage wires from the VH terminals.
4. Remove the four nuts and washers that secure the VAM to the cabinet.
HIGH VOLTAGE
INPUTS
REDUCED VOLTAGE
REDUCED VOLTAGE
OUTPUT
OUTPUT
E-44656
Figure 51. Eight-Channel (Left) and Five-Channel (Right) Voltage Attenuation Modules (VAM)

GEK-91764
5. Remove the VAM.
6. Replacement is the reverse of removal. Torque wire terminal connection to 35 to 39 in.-lbs. (395 to 440 NCM).
5.6. INSULATED GATE BIPOLAR TRANSISTOR PHASE MODULE (IGBT) AND CHOPPER MODULE
(CM) REPLACEMENT
The IGBT (phase modules) and Chopper module replacement procedures are the same.
Phase module connections are shown in Figure 52. Figure 53 shows Chopper Module connections. Figure 54 shows
Chopper Diode Module connections. Figure 55 shows the bolted joint stack up. Refer to Figure 17 for a depiction of
the typical bolted electrical connections for chopper modules.
NOTE: Chopper Diode Modules are on 17KG543B1 and earlier models only.
WARNING Discharge the capacitors as described in section 5.1., CAPACITOR DISCHARGE

PROCEDURE, before proceeding with any control activity. Failure to do so may result in
injury or death.
To replace an IGBT module or Chopper module:
2. The phase modules are located in Control Area 4 (CA4) and Control Area 5 (CA5) as shown in Figure 3. Chopper
Modules are located in Control Area 5 (CA5).
3. Remove the two fiber-optic connectors by depressing the lock lever and pulling the connectors from the sockets
(Figure 52).
4. Remove the circular connector from the module by twisting the connector locking ring to unlock position and
pulling the connector from the socket (Figure 52).
5. Remove the power cables.
a. For the phase modules (Figure 52), remove the bolts and pull the cables back.
b. For the chopper modules (Figure 53 and Figure 54), remove the bolt and nut and pull the cable to the side.
Slide the module out.
6. Remove the bolted electrical hardware connections (Figure 55) noting the hardware arrangement for each con-
nection. The hardware arrangement must be the same during assembly.

GEK-91764
WARNING A phase module weighs approximately 50 lbs. (23 kg). Use appropriate handling
procedures. Failure to do so may result in personal injury or equipment damage.
7. Remove the through mounting bolts as shown in Figure 52. Note the mounting hardware arrangement for
assembly of replacement module.
8. Remove the rear mounting nuts from the studs as shown in Figure 52. Note the mounting hardware arrange-
ment for assembly of replacement module.
9. Pull the module out over the rear mounting studs using the upper and lower through mounting arms. Do not
grasp or pull the module by the module front-mounted components or damage will result. The rear cooling gas-
ket may be difficult to pull loose from the cooling duct.
10. Inspect the replace module rear cooling gasket. Replace gasket if damaged.
CAUTION Hardware used for mounting modules and electrical connections are specic applica-
tions hardware. Do not use standard hardware (bolts, nuts, washers, etc.) when
assembling modules. Failure to use replacement parts from the system Parts Catalog
may cause premature failure and warranty disqualification.
11. Slide the replacement module inward onto the rear mounting studs until flush with the rear cooling duct.
12. Thread the washers and nuts onto the rear mounting studs. Do not tighten the nuts until all other mounting and
electrical connection hardware is installed.
13. Align the through mounting holes and thread the mounting hardware into position. Do not tighten until all other
mounting and electrical connection hardware is installed.
14. Align the electrical connections through holes and thread the connection hardware into position. Do not tighten
until all other mounting and electrical connection hardware is installed.
15. Torque the rear mounting bolts to 47 lb.-ft. (64 Nm) as shown in Figure 52.
16. Torque the through mounting bolts to 25 lb.-ft. (34 Nm) as shown in Figure 52.
17. Torque the through bus bar electrical connection hardware to 14 lb.-ft. (19 Nm) as shown in Figure 52.
18. Re-install the power cables previously removed.
a. For the chopper modules, torque to 47 lb.-ft. (64 Nm).
b. For the phase modules, torque to 19 lb.-ft. (26 Nm).
CAUTION Refer to the Gate Driver Housing sticker color to ensure that the correct IGBTs are
matched, to prevent possible equipment damage.
19. Install the fiber-optic cables into the sockets, ensuring the lock lever locks in the socket.
20. Align and push the circular connector into the socket and tighten the connector locking ring by twisting until
tight.

GEK-91764
REMOVE THE TWO 2 PLACES, REAR 2 PLACES, THROUGH

POWER CABLES MOUNTING BOLTS MOUNTING BOLTS
TORQUE TO TORQUE TO
47 LBS–FT (64 NM) 25 LBS–FT (34 NM)
FIBER OPTIC CABLES,

PRESS LOCK LEVER TO
RELEASE
GATE POWER CABLES,
TWIST RETAINING RING
TO UNLOCK AND PULL TO
REMOVE CONNECTOR
6 PLACES, THROUGH
BUS BAR ELECTRICAL
CONNECTIONS, TORQUE
TO 14 LB-FT (19 NM)
E-53399A
Figure 52. Phase Module Disassembly and Reassembly Items

GEK-91764
METAL
SPACER
VERTICAL
BUS BAR
METAL
IGBT SPACER IGBT
BUS BAR BUS BAR
METAL
SPACER VERTICAL
BUS BAR
LOCK
IGBT
WASHER
NUT BUS BAR
BOLT LENGTH: 2-1/2” METAL
SPACER
LOCK
METAL NUT WASHER
SPACER BOLT LENGTH: 2-1/2”
L BRACKET
CHOPPER MODULE METAL
BUS BAR SPACER
VERTICAL
BUSHING BUS BAR
CABLE
LUG IGBT
METAL BUS BAR
SPACER METAL
LOCK SPACER
WASHER NUT LOCK
WASHER
BOLT LENGTH: 1-1/2” NUT
BOLT LENGTH: 2-1/2”
E-56129
Figure 53. Chopper Module Disassembly and Reassembly Items

GEK-91764
METAL
SPACER
CHOPPER METAL
DIODE SPACER
BUS BAR VERTICAL
BUS BAR
VERTICAL
BUS BAR CHOPPER
CHOPPER DIODE
DIODE BUS BAR
BUS BAR METAL
SPACER
METAL
LOCK
SPACER
LOCK WASHER
NUT
WASHER
NUT BOLT LENGTH: 3-1/4”
BOLT LENGTH: 4”
E-56128
Figure 54. Chopper Diode Module Disassembly and Reassembly Items

GEK-91764
WASHER
IGBT
HOUSING +
VERTICAL
BUS BAR
IGBT
HOUSING -
METAL WASHER
METAL SPACER LOCK
NUT
SPACER WASHER
CABLE LUG
VERTICAL
BUS BAR
METAL
SPACER
LOCK
METAL
WASHER
SPACER
NUT
BOLT LENGTH: 2” VERTICAL
BUS BAR
IGBT
BUS BAR
METAL
SPACER
METAL LOCK
SPACER WASHER
NUT
VERTICAL
BUS BAR
IGBT
BUS BAR +
METAL
SPACER METAL
SPACER
LOCK IGBT
WASHER NUT BUS BAR +
VERTICAL
BUS BAR
IGBT
BUS BAR -
METAL
SPACER
LOCK
WASHER
NUT
E-54721A
Figure 55. Bolted Joint Stack Up

GEK-91764
5.7. INVERTER AND CHOPPER MODULE FUSE REPLACEMENT
The Inverter phase module and Chopper module fuses are located at the bottom or base of the module stack as
shown in Figure 56. There are three fuses at the bottom of each Inverter stack and two fuses at the bottom of the
chopper module stack. When replacing fuses, it is recommended to replace all fuses on the stack due to deteriora-
tion of the fuses that did not fail.

injury or death.
CAUTION Chopper modules will fail if the system is powered up without chopper fuses installed.
Be sure the chopper fuses are properly installed to avoid equipment damage.
To replace the fuses:
2. The fuses are located at the bottom of each Inverter stack and Chopper Module stack (refer to Figure 56).
3. Remove the fuse mounting hardware and remove the fuse.
4. Align the replacement fuse in position and thread the mounting hardware into place.
5. Torque the mounting hardware to 14 lb.-ft. (19 Nm) as shown in Figure 56.

GEK-91764
REMOVE FUSE MOUNTING HARDWARE.

NOTE HARDWARE ARRANGEMENT FOR ASSEMBLY.
ON INSTALLATION, TORQUE TO 14 LB–FT (19 NM).
E-53415A
Figure 56. Phase Fuse Location

GEK-91764
5.8. DC HORIZONTAL BUS (DCHB) REPLACEMENT
The DC Horizontal Bus (DCHB) provides connection points for Inverter and Chopper stacks. The DCHB may be
replaced or require removal for link capacitor replacement.
To remove or replace the DCHB:

injury or death.
2. The DC Horizontal Bus (DCHB) is located across Control Area 4 (CA4) and Control Area 5 (CA5) (refer to Figure 3).
CAUTION The DCHB weighs approximately 40 lbs. (18 kg). Use appropriate handling procedures.
3. Remove the control and power cable connections (Figure 57), noting the hardware arrangement for each con-
nection. Hardware must be installed correctly during assembly.
4. Remove the bolted electrical connections to the vertical bus bars and capacitors, except two locations (Figure
57). Note hardware arrangement for each connection. Hardware must be properly arranged during assembly.
5. With the DCHB secured, remove the remaining capacitor electrical connection hardware (Figure 57). Note the
hardware arrangement for proper assembly.
6. Remove DCHB from the Control Cabinet.
CAUTION Hardware used for mounting and electrical connections are specic applications
hardware. Do not use standard hardware (bolts, nuts, washers, etc.) when assembling
modules. Failure to use replacement parts from the system Parts Catalog may cause
premature failure and warranty disqualification.
7. When installing the DCHB, lift the DCHB and align it in position. To align the DCHB:
c. Loosen the cap mounting hardware, then slide the cap back.
d. Mount the DCHB to verticals (finger-tight).
e. Slide the caps forward to meet the DCHB.
f. Install the cap electrical hardware (finger-tight).

GEK-91764
g. Torque the cap mounting hardware to 62 lb.-ft. (84 Nm) as shown in Figure 57.
h. Torque the verticals to 25 lb.-ft. (34 Nm) as shown in Figure 57.
i. Torque the caps electrical hardware to 14 lb.-ft. (19 Nm) as shown in Figure 57.
8. Thread the mounting bolts (Figure 57) in position. Do not tighten until all hardware is installed.
9. Thread the bolted electrical connections (Figure 57) to the capacitors and vertical bus bars in position. Do not
tighten until all hardware is installed.
10. Thread the control and power cable connections (Figure 57) in position. Do not tighten until all hardware is
installed.
11. Torque the mounting bolts to 62 lb.-ft. (84 Nm) as shown in Figure 57.
12. Torque the capacitor bolted electrical connections to 14 lb.-ft. (19 Nm) as shown in Figure 57.
13. Torque the vertical bus bar bolted electrical connections to 25 lb.-ft. (34 Nm) as shown in Figure 57.
14. Torque the power cable bolted electrical connections to 25 lb.-ft. (34 Nm) as shown in Figure 57.
15. Note the low torque value in pound-inches (Newton-centimeters) of small control cable hardware. Torque the
control cable connections to 37 lb.-in. (415 NCM) as shown in Figure 57.

GEK-91764
REMOVE CONTROL CABLE REMOVE VERTICAL BUS BAR CONNECTION REMOVE CONTROL CABLE
CONNECTIONS TO HRB. ON HARDWARE. NOTE HARDWARE ARRANGEMENT CONNECTIONS TO HRB. ON
ASSEMBLY, TORQUE TO TO ENSURE CORRECT ARRANGEMENT. ON ASSEMBLY, TORQUE TO
37 LB–IN (415 NCM). ASSEMBLY, TORQUE TO 25 LB–FT (34 NM). 37 LB–IN (415 NCM).
REMOVE CABLE MOUNTING REMOVE CAPACITOR CONNECTION REMOVE CABLE MOUNTING

HARDWARE. NOTE HARDWARE HARDWARE ON THE HORIZONTAL HARDWARE (DCN & DCP
ARRANGEMENT FOR ASSEMBLY. BUS BAR (HRB). NOTE THE HARDWARE CONNECTIONS). NOTE
TORQUE TO 62 LB–FT (84 NM). POSITION DURING REMOVAL. THE HARDWARE ARRANGEMENT
APPROPRIATE HARDWARE MUST BE FOR ASSEMBLY. TORQUE
INSTALLED IN THE APPROPRIATE PLACES TO 25 LB–FT (34 NM).
DURING ASSEMBLY. ON ASSEMBLY,
TORQUE TO 14 LB–FT (19 NM).
E-53414A
Figure 57. DC Horizontal Bus (DCHB) Components

GEK-91764
5.9. DC LINK CAPACITOR REPLACEMENT
There are six DC Link capacitors (LFC1 through LFC6) mounted in the lower portion of Control Area 4 (CA4) and Con-
trol Area 5 (CA5).
To remove and replace a capacitor:

injury or death.
2. Six DC Link capacitors (LFC1 to LFC6) are located across Control Area 4 (CA4) and Control Area 5 (CA5) (Figure 3).
3. The DC Horizontal Bus (DCHB) must be removed to remove capacitors. Remove the DCHB as described in section
5.8., DC HORIZONTAL BUS (DCHB) REPLACEMENT, in this publication.
4. Remove the front and rear capacitor mounting bolts as shown in Figure 58.
WARNING A Link Capacitor weighs approximately 80 lbs. (37 kg). Use appropriate handling
procedures. Failure to do so may result in personal injury or equipment damage.
5. Remove the capacitor from the Control Cabinet and apply shorting wire across the terminals.
6. Install the new capacitor. Leave mounting hardware loose for alignment.
CAUTION Hardware used for mounting and electrical connections are specic applications
hardware. Do not use standard hardware (bolts, nuts, washers, etc.) when assembling
modules. Failure to use replacement parts from the system Parts Catalog may cause
premature failure and warranty disqualification.
7. Refer to section 5.8., DC HORIZONTAL BUS (DCHB) REPLACEMENT, in this publication, for DCHB installation and
capacitor mounting torquing.

GEK-91764
REMOVE FRONT CAPACITOR MOUNTING BOLTS. THERE ARE

TWO SETS OF MOUNTING HARDWARE PER CAPACITOR.
ON INSTALLATION, TORQUE BOLTS TO 62 LB-FT (84 NM).
REMOVE REAR CAPACITOR MOUNTING BOLTS. THERE ARE

TWO SETS OF MOUNTING HARDWARE PER CAPACITOR.
ON INSTALLATION, TORQUE BOLTS TO 62 LB-FT (84 NM).
E-53416A
Figure 58. Link Capacitor Mounting Hardware Location

GEK-91764
5.10. GRID BLOWER MOTOR CAP REPLACEMENT
To replace the Grid Motor Blower Capacitor:
2. Tag and remove cables.
3. Remove mounting hardware.
4. Remove capacitor from cabinet.
5. Mount new capacitor into the cabinet with mounting hardware. Torque to 6 lb.-ft. (8 Nm).
6. Re-attach cables and torque hardware to 14 lb.-ft. (19 Nm).
The GBMC is located in Control Area 6 (CA6). Refer to Figure 59.
GRID BLOWER MOTOR CAPACITOR

VIEW FROM BACKSIDE OF CONTROL GROUP
E-56175
Figure 59. Location of GBMC in CA6

GEK-91764
5.11. BATTERY FUSE (BATFU) REPLACEMENT
To replace the Battery Fuse (BATFU):
to Figure 2).
3. Verify Capacitor Charge Lights (CCL1 and CCL2) are off (not illuminated).
5. BATFU is located on the upper right wall of CA1 as shown in Figure 3
6. Remove the BATFU cover
7. Remove the two wing nuts and remove BATFU.
8. Install the replacement BATFU and thread and tighten the two wing nuts onto the BATFU mounting studs.
9. Install the BATFU cover.

GEK-91764
REMOVE NUTS AND

REMOVE FUSE TO REPLACE
VIEW WITH COVER
VIEW WITH COVER REMOVED
E-56016
Figure 60. Typical Battery Fuse (BATFU) in Low Voltage Control Area 1 (CA1)
5.12. ALTERNATOR FIELD STATIC EXCITER (AFSE) REPLACEMENT
To replace AFSE:

injury or death.
2. AFSE is located in Control Area 2 (CA2) as shown in Figure 3.
3. Remove the circular connector from AFSE (Figure 61).
4. Identify and remove the power cables from the left and right side terminals (Figure 61).

GEK-91764
CAUTION AFSE weighs approximately 45 lbs. (20 kg). Use appropriate handling procedures.
5. Remove the lower three bolts that secure AFSE to the cabinet. Support the unit and remove the top three bolts.
6. Remove AFSE from the cabinet. If the rear cooling gasket material hinders removal, slide a flat blade under the
AFSE panel edges to release the panel.
7. Inspect the rear cooling air sealing gasket of the replacement AFSE. Replace the gasket if damaged.
8. Align the replacement AFSE on the mounting holes and thread the mounting bolts into position.
9. Torque the mounting bolts to 22 to 25 lb.-ft. (30 to 34 Nm).
10. Connect power cables to appropriate electrical lugs and thread the mounting hardware into position.
11. Torque the electrical connection to 22 to 25 lb.-ft. (30 to 34 Nm).
12. Connect the electrical plug and tighten the retaining ring.
REMOVE ALL
CABLES
AND CONTROL
CONNECTOR
REMOVE ALL
MOUNTING HARDWARE
(TOP AND BOTTOM)
WHILE SECURING AFSE
PANEL IN PLACE
E-46617
Figure 61. Typical AFSE Arrangement

GEK-91764
5.13. ALTERNATOR FIELD (GF) CONTACTOR REPLACEMENT
The Alternator Field (GF) contactor is located in Control Area 3 as shown in Figure 62. To remove and replace GF:

injury or death.
2. Identify and remove all control wires and power cables from the GF.
WARNING GF weighs approximately 50 lbs. (23 kg). Use appropriate handling procedures. Failure
to do so may result in personal injury or equipment damage.
R1
GF
VAM1
GFR
VAM2
CMAF
VAM5
VAM3
TH1 VAM4
E-56028
Figure 62. Location of GF Contactor in CA3

GEK-91764
3. Remove GF mounting bolts and remove GF from the Control Cabinet.
4. Align the replacement GF into position and thread the mounting hardware into place.
5. Tighten the mounting hardware. Torque to 14 lb.-ft. (18.9 Nm).
6. Connect all control wires and power cable in position.
5.14. CURRENT SENSOR REPLACEMENT
Refer to Figure 63. Current sensor arrangement is similar for all current sensors. A power cable passes through the
center of the sensor with three control wires connected to the sensor: +25 VDC, -25 VDC, and common or ground.
The replacement procedure is the same for all current sensors. For more details on current sensors, refer to section
3.18., CURRENT MEASURING SENSORS, in this publication.
2000 AMP (NOMINAL) 1000 AMP (NOMINAL)
E-44655A
Figure 63. Typical Current Sensor Modules
To remove and replace a sensor:

GEK-91764

injury or death.
2. Remove the three control wires connected to the sensor, or remove the connector, depending on the model.
3. Remove the sensor mounting hardware so that the sensor is free to move.
4. Follow the power cable passing through the sensor to the nearest point the cable may be disconnected.
5. Disconnect the power cable from the nearest connection point.
6. Using a combination of moving the sensor toward the free end of the power cable and pulling the power cable
through the sensor, remove the sensor from the circuit.
7. Slide the replacement sensor onto the power cable and move to the sensor mounting position.
8. Thread the sensor mounting hardware into place and tighten.
9. Connect the three control wires to the sensor and tighten the connections, or replace the connector, depending
on the model.
10. Connect the power cable in place and tighten.
5.15. GENERATOR FIELD RELAY (GFR) CONTROL RELAY REPLACEMENT
GFR is located in Control Area 3 (CA3) as shown in Figure 62. To replace the GFR:

injury or death.
2. Identify and remove wires from GFR contacts and coil.
3. Remove GFR mounting hardware and remove GFR from the Control Cabinet.
4. Align the replacement GFR in position and thread the mounting hardware in position.

GEK-91764
5. Tighten the GFR mounting hardware.
6. Connect the wires to GFR contacts and coil.
5.16. GROUND RESISTOR PANEL (GRR) AND FILTER DISCHARGE RESISTOR (FDR) PANEL
REPLACEMENT
The Ground Resistor Panel (GRR) and Filter Discharge Resistor (FDR) panel are located in Control Area 7 (CA7) as
shown in Figure 64.
To replace the GRR or FDR panel:

injury or death.
FDR
GRR
CGPS
FP
E-56025
Figure 64. Component Arrangement in CA7

GEK-91764
2. Remove the bolts and washers securing the screened panel in CA7 over the resistor networks. Remove the
screened panel.
3. Remove and identify (mark) the wires from all terminals of GRR or FDR.
4. Remove the four nuts and washers that secure GRR or FDR to the cabinet.
5. Replace the failed resistor(s), if desired, or simply replace the entire GRR or FDR unit.
6. Align the replacement unit in position and thread the mounting hardware into position.
7. Note the low torque value. Torque the mounting hardware to 74 to 83 lb.-in. (8 to 9 Nm).
8. Connect the wires to the appropriate terminals of the resistor network.
9. Align the screened panel over CA7 and install the mounting hardware.
5.17. FILTER PANEL (FP) REPLACEMENT
The Filter Panel (FP) is located in Control Area 7 (CA7) as shown in Figure 64. To replace the FP:

injury or death.
2. Remove the bolts and washers securing the screened panel in CA7 over the FP. Remove the screened panel.
3. Remove and identify (mark) the wires from all terminals of FP.
4. Remove the nuts and washers that secure FP to the cabinet.
6. Note the low torque value. Torque the mounting hardware to 74 to 83 lb.-in. (8 to 9 Nm).
7. Connect the wires to the appropriate terminals of the resistor network.
8. Align the screened panel over CA7 and install the mounting hardware.

GEK-91764
5.18. RECTIFIER DIODE (RD) PANEL REPLACEMENT
The RD panel is located in Control Area 2 (CA2) as shown in Figure 65.
To replace the Rectifier Diode (RD) panel:

injury or death.
2. Remove the cables from DC+ and DC- terminal connection points (Figure 66).
3. Identify and remove all cables from AC1, AC2, and AC3 (Figure 66). Remove the smaller sensing wires as well.
RECTIFIER DIODE
(RD) PANEL
E-56160
Figure 65. Location of RD Panel in CA2

GEK-91764
DC-
AC1
AC2
AC3
DC+
E-44654
Figure 66. Rectifier Diode (RD) Panel Connection Points
WARNING The Rectifier Diode (RD) panel weighs approximately 100 lbs. (46 kg). Use appropriate
handling procedures. Failure to do so may result in personal injury or equipment
damage.
4. Remove the mounting bolts that secure the RD panel to the cabinet while supporting the weight.
5. Remove the RD panel from the Control Cabinet.
6. Inspect the cabinet the RD panel seal area to ensure it is clean for the replacement RD panel.
7. Inspect the seal on the replacement RD panel. Replace if damaged.
9. Torque the RD panel mounting bolts to 22 to 25 lb.-ft. (30 to 34 Nm).
10. Connect the power cables to the appropriate terminal connection points (Figure 66) and thread the mounting
hardware into position.
11. Torque the cable mounting hardware to 22 to 25 lb.-ft. (30 to 34 Nm).

GEK-91764
5.19. CONTROL POWER DISTRIBUTION (CPD) REPLACEMENT
To replace the Control Power Distribution (CPD) module (Figure 67):
to Figure 2).
3. CPD module is located on the right wall of CA1 (Figure 67).
4. Remove the twist lock ring from connectors CPD1, CPD3, and CPD4, and pull the plugs from the CPD sockets.
5. Detach connector CPD2 by unlatching lock lever and pulling CPD2 from the socket.
6. Remove the mounting hardware securing CPD to the cabinet wall and remove CPD.
7. Align the replacement CPD in position on the cabinet wall and assemble the mounting hardware in place.
CONTROL POWER
DISTRIBUTION (CPD)
L-R:
POWER SUPPLY (PS)
LED'S
E-56014
Figure 67. Location of CPD and Power Supply in CA1

GEK-91764
9. Plug CPD2 cable into the CPD socket, ensuring the plug lock lever engages in the socket.
10. Plug CPD1, CPD3, and CPD4 into appropriate CPD sockets and twist lock the retaining ring of the plug.
5.20. CONTROL POWER DISTRIBUTION (CPD) FUSE REPLACEMENT
The Control Power Distribution (CPD) module (Figure 68) has low-voltage control circuit fuses mounted to the right of
the CPD multi-pin connectors. Three current-rated fuses currently used on CPD:
• 41A296321BJP1 — 2-Amp fuse

• 41A296321BJP2 — 3-Amp fuse
• 41A296321BJP3 — 5-Amp fuse
CPD4
1 4 SPARE +5/5A DID +5/5A
5 9
10 15 SPARE B +15/3A
16 22 SPARE A +15/3A DID +15/3A
23 28
29 33 SPARE B -15/3A
34 37 SPARE A -15/3A DID -15/3A
CPD3 CPRA +BAT/5A
CPS +BAT/5A CPRB +BAT/5A
1 2 LINKI +24/2A
3 6 SPARE +24/2A BM1I +24/2A
7 10
11 14 CCM1 +24/2A
15 16 CPD2 CMAF +24/2A CCM3 +24/2A
LINKI -24/2A
SPARE -24/2A BM1I -24/2A
CPD1
1 4 CCM1 -24/2A
5 9 CMAF -24/2A CCM3 -24/2A
10 15
16 20
21 24
TPPR TPRTN TP+15

TP CR1 TP5 TP-15
E-53331
Figure 68. Control Power Distribution (CPD) Module
Never remove circuit fuses with power applied; damage to electronic devices may occur. Replace fuse with same
current-rated fuse as stated on the CPD module. Do not substitute fuse values.
To replace a fuse on the Control Power Distribution (CPD) module:

GEK-91764
CAUTION Always shut off control power prior to replacing or removing control circuit fuses.
Removing or replacing control circuit fuses with power applied may result in electrical
circuit and/or electronic component damage.
CAUTION Always use replacement fuses rated the same as the original fuses. Failure to do so
may result in electrical circuit and/or electronic component damage.
to Figure 2).
3. CPD module is located on the right wall of CA1 (Figure 3).
4. Identify fuse for replacement and pull from blade socket.
5. Replace open fuse with a new fuse with the same current rating.
6. Align the replacement fuse blades with the socket and push into place.
6. SUMMARY DATA
Not applicable

GEK-91764

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17KG543 Control Group for

GE CONFIDENTIAL TECHNICAL INFORMATION

Rev Date By Description

NEW Apr-2013 KA Initial release

ii GE Proprietary and Confidential Information

GE Proprietary and Confidential Information iii

TABLE OF CONTENTS (CONTINUED)

5. REMOVAL AND REPLACEMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

iv GE Proprietary and Confidential Information

GE Proprietary and Confidential Information v

LIST OF FIGURES (CONTINUED)

vi GE Proprietary and Confidential Information

• Drive System Controller Panel (DSC)

LEFT SIDE FRONT RIGHT SIDE

Figure 1. Main Control Cabinet Arrangement

1.2. RELATED PUBLICATIONS

GE Proprietary and Confidential Information 1

Table 1. Related Publications

Publication Number Publication Title

1.3. WEIGHT AND DIMENSIONS OF MAJOR COMPONENTS

Component Lbs. Kg Inches mm

1.4. UNIT EXCHANGE COMPONENT HANDLING

1.5. SAFETY INFORMATION

Safety WARNINGS and CAUTIONS appear throughout the instructions.

WARNING Indicates the potential for personal injury.

CAUTION Indicates the potential for equipment damage.

2 GE Proprietary and Confidential Information

GE Proprietary and Confidential Information 3

4 GE Proprietary and Confidential Information

2. CONTROLS AND INDICATORS

2.1. MAIN CONTROL CABINET ARRANGEMENT

2.2. CAPACITOR CHARGE LIGHTS AND SWITCH PANEL

CONTROL GENERATOR FIELD CONTROL

OFF CUTOUT OFF

Figure 2. Control Switch Arrangement in Control Area 1 (CA1)

GE Proprietary and Confidential Information 5

2.3. CONTROL CABINET COMPONENT LAYOUT DIAGRAMS

P1A+ P1B+ P1C+

P2A- P2B- P2C-

Figure 3. Main Control Cabinet Components, Front

6 GE Proprietary and Confidential Information

REF. DESCRIPTION REF. DESCRIPTION

Figure 4. Main Control Cabinet Component List

GE Proprietary and Confidential Information 7

CA8 CA7 CA6

REF. DESCRIPTION REF. DESCRIPTION

Figure 5. Main Control Cabinet Components, Rear

8 GE Proprietary and Confidential Information

3.1. POWER GENERATION AND DISTRIBUTION DRIVE OVERVIEW

GE Proprietary and Confidential Information 9

ESS ENGINE SPEED SENSOR

KEYSW CPS +/- 24 VDC CPD - GDP2

Figure 6. System Block Diagram - Alternator Circuit

GE Proprietary and Confidential Information

Figure 7. System Block Diagram - #1 Wheel Motor Circuit

GE Proprietary and Confidential Information 11

Figure 8. System Block Diagram - #2 Wheel Motor Circuit

12 GE Proprietary and Confidential Information