Application Guide Volume VII AG2016-20

SEL-2240 Axion Retrofit Cables for GE D20

Francisco Chumbiauca

INTRODUCTION
SEL has developed a set of retrofit cables that allow GE D20 Substation Controller to SEL-2240
Axion migration with no need to disconnect and reconnect individual input and output (I/O)
wiring signals. Significant time can be saved from no longer having to rewire I/O, especially if a
large number of I/O points are involved. This application guide describes how to integrate the
existing I/O wiring of a GE D20 remote terminal unit (RTU) system into the SEL Axion I/O
modules. It provides a broad description of the GE D20 RTU system and the peripheral I/O
system, and it will explain the step-by-step procedure to perform the I/O migration to the
SEL-2240 Axion system.

GE D20 SYSTEM TOPOLOGY DESCRIPTION

A D20 system consists of a main chassis equipped with a CPU card, power supply, and
communication cards, as well as the I/O peripheral modules. These peripheral modules are
connected to the main chassis through a 250 kbps EIA-485 network called D.20 Link. As many as
31 peripheral I/O modules can be connected to a D.20 Link network. See Figure 1 for an
illustration of the architecture of a GE D20 system.

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D20 CPU

D20 Power Supply

D.20 Link

D20 I/O Modules

Figure 1 GE D20 System

GE D20 Digital-Input Peripheral Modules

D20 digital-input (DI) peripheral modules have two parts: a WESDAC logic panel and a
WESTERM D20S termination panel. The WESDAC D20S logic panel is a metal enclosure with
a semitransparent acrylic cover that contains the electronic circuitry of the input module. The
WESTERM D20S termination panel contains the connectors for the field I/O wiring, the signal-
conditioning circuitry, and the DB-9 connectors for the D.20 Link network. The logic panel plugs
into the termination panel, and this termination panel mounts directly in a 19-inch rack. Figure 2
illustrates the two parts of the D20 DI peripheral module.

WESDAC D205

D20 DI Peripheral Module

WESTERM D20S

Figure 2 GE D20 WESDAC Logic Panel and WESTERM Termination Panel

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There are different variations of D20S termination panels according to the termination option
used to connect to the field DI wiring:
• D20S—Fixed-board mounted screw terminals
• D20SX—Plug-on screw terminals
• D20SB—Barrier terminals
• D20SD—DB-25 connectors
Figure 3 illustrates the WESTERM termination panel fixed-board mounted screw terminals and
the DB-25 connector options.
D20S D20SD

Screw Terminals DB-25 Connectors

Figure 3 Screw Terminals and DB-25 Field-Wiring Termination Options

In the case of the WESTERM D20SD termination panel, the DB-25 connectors connect to the
field terminal blocks through use of eight GE 977-0068 cables. Each GE 977-0068 cable carries
the signals of eight digital-input channels. A GE 977-0068 cable has a DB-25 connector on one
end and wire ferrules on the other end. Figure 4 illustrates a typical GE D20 digital-input system
with a D20SD (DB-25 termination option) termination panel.

WESDAC D20S

WESTERM D20 SD

TB1 Terminal
DB-25 DB-25 DB-25

Wire
Ferrules GE 977-0068 Cables

Terminal Blocks

DI Field Wiring

Figure 4 GE D20 Digital-Input System With the DB-25 Termination Option

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The input field signals can be dry contacts or wetted contacts. When dry contacts are used, a local
wetting voltage source is required. The WESTERM D20 SD termination panel supports three
different options for wetting voltage:
• Internally wetted inputs—the wetting voltage is applied at the termination panel via the
peripheral DI module power source.
• Externally wetted inputs—the wetting voltage is supplied by an external power supply
connected to the TB1 terminal of the WESTERM D20 SD termination panel (see
Figure 4).
• Wetted field contacts—the wetting voltage is applied in the field, so no local power
supply is needed.
These three wetting voltage options are jumper-configurable in the WESTERM D20 SD
termination panel.

GE D20 Digital Output Peripheral Modules

The D20 digital output peripheral system has three modules: a WESDAC D20K logic panel, a
WESTERM D20KR termination panel, and two or four WESTERM D20KI termination panels.
The WESDAC D20K logic panel plugs into the D20KR termination panel, which mounts directly
in the 19-inch rack. The D20KR termination panel includes 32 output control relays. The
WESTERM D20KI termination panel is composed of 16 interposing relays and the field-wiring
terminal blocks, and it connects to the WESTERM D20KR panel via a GE 977-0069 cable, which
has DB-25 connectors on both ends.
The interposing relays in the D20KI panel are grouped in pairs: TRIP/CLOSE pairs and
RAISE/LOWER pairs. Hardware configuration defines the pair type. With a TRIP/CLOSE
configuration, each output control relay on the D20KR panel operates two interposing relays on
the D20KI panel. A D20K panel supports as many as 32 TRIP/CLOSE output pairs (or 4 D20KI
panels). On the other hand, with a RAISE/LOWER configuration, each output control relay on
the D20KR panel operates one interposing relay on the D20KI panel. A D20K panel supports as
many as 16 RAISE/LOWER output pairs (or 2 D20KI panels).
Figure 5 illustrates the D20 digital output peripheral system.

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WESDAC D20K

WESTERM D20KR

GE 977-0069 Cable
Field Wiring
Terminal Blocks Interposing Relays

WESTERM D20KI

Figure 5 GE D20 Digital Output Peripheral System With the DB-25 Termination Option

GE D20 Analog-Input Peripheral Modules

As with the digital-input peripheral system, the analog-input peripheral system has two
detachable modules: a WESDAC D20A logic panel and a WESTERM termination panel. The
WESDAC D20A logic panel supports 32 differential analog inputs and plugs into the
WESTERM termination panel, which mounts directly in a 19-inch rack. The WESTERM
termination panel can have different termination options: fixed-screw terminal blocks (D20A),
removable-screw terminal blocks (D20AX), DB-25 connectors (D20AD), or barrier terminals
(D20AB). In the specific case of the D20AD termination panel, four DB-25 connectors are used
to connect to the analog-input signals in the field. Each DB-25 connector carries the signals of
eight analog channels. Figure 6 illustrates the D20 analog-input peripheral system.

WESDAC D20A

WESTERM D20AD

DB-25

To analog-input field signals

Figure 6 GE D20 Analog-Input System With the DB-25 Termination Option

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CONNECT D20 I/O FIELD WIRING TO AXION I/O MODULES

SEL has developed a set of D20 replacement cables that allow GE D20 to SEL-2240 Axion
migration without I/O rewiring. These replacement cables can be used to integrate GE D20 I/O
signals into the SEL-2240 Axion I/O modules. In general terms, the replacement cables connect
to the SEL-2240 Axion I/O modules on one end and the DB-25 connectors of the GE I/O cables
on the other end. External-wetting voltage may have to be applied, depending on system
configuration.
It is important to note that the replacement cables presented in this document are designed to
connect to the existing I/O signals either via the existing DB-25 connectors on the GE termination
cables or via the two 40-pin connectors in the WESTERM board. These cables can be used to
connect to the I/O signals of the WESTERM panels with termination options listed in Table 1. If
your GE I/O WESTERM panel termination option is not listed in Table 1, the cables this guide
discusses cannot be used.

Table 1 Panel Termination Options

I/O Type WESTERM Panel SEL CABLE
Termination Option
Digital inputs DB-25 C758
Digital inputs Fixed-board mounted screw 915900183 kit
terminals
Digital outputs DB-25 connectors on the D20KI C755
interposing relay panel
Analog inputs DB-25 C754

Connecting D20 Digital-Input Field Wiring to the SEL-2244 DI Module

We have two solutions to connect the D20 digital-input field wiring to an SEL-2244 DI module,
depending on the type of DI wiring termination option in the WESTERM D20S termination
panel:
• WESTERM D20S termination option is DB-25 connectors (D20SD, part number
517-0179) – Use SEL-C758 D20 retrofit cable.
• WESTERM D20S termination option is fixed-board mounted screw terminals (D20S,
part number 517-0165) – Use the SEL 915900183 retrofit cable kit.
Details of the procedure to implement both solutions follow.

WESTERM DI Module With DB-25 Connectors

In this section, we describe how to connect the D20 digital-input field wiring to an SEL-2244
digital-input module through use of the SEL-C758 D20 retrofit cable. The SEL-2244 Axion DI
module connects directly to the GE 977-0068 cable via DB-25 connectors. The procedure to
connect to the GE D20 DI field wiring follows.

Step 1
Disconnect the GE 977-0068 cables from the DI termination panel. Remove the GE DI peripheral
module from the panel, if necessary.

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Step 2
Connect the DB-25 end of the GE 977-0068 cables to the SEL-2244 Axion DI module by using
the SEL-C758 D20 retrofit cable. Each SEL-C758 D20 retrofit cable accommodates 24 digital-
input signals, so you will need one SEL-C758 D20 retrofit cable for every three GE 977-0068
cables. Figure 7 shows how to establish the connection.

SEL-2244 DI SEL-2244 DI
Module Module

SEL-C758 D20
Retrofit Cable

GE 977-0068 Cables

DI Field Wiring

Figure 7 Connecting the SEL-2244 DI Module to the D20 DI Field Termination Wiring by Using the SEL-C758
D20 Retrofit Cable

Step 3
Connect the wetting voltage power supply, if required.
The SEL-C758 D20 retrofit cable has two AWG-16 wires for an external-wetting voltage power
supply. If the WESTERM D20 termination panel was configured for internally or externally
wetted voltage (see GE D20 Digital Input Peripheral Modules) these two wires must connect to
an external-wetting voltage power supply (if the D20 WESTERM termination panel was
configured for external-wetted voltage, we can use the same external power source that was
connected to the terminal TB1 of the WESTERM D20 termination panel). Verify that the power-
supply rated voltage is the same as the input voltage rating of the SEL-2244 DI module to which
you are connecting. If the DI signals are wetted field contacts (see GE D20 Digital Input
Peripheral Modules), do not connect an external-wetting voltage power supply to the two
AWG-16 wires of the SEL-C758 D20 retrofit cable.
Figure 8 shows the DI field termination before and after the GE D20 replacement procedure (the
figure does not show the wetting voltage connection).

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DB-25 DB-25 DB-25 SEL-2244 DI SEL-2244 DI

Module Module

Wire
Ferrules

DI Field Wiring

DI Field Wiring

Figure 8 Digital-Input Field Termination Wiring Connected to the GE D20 Peripheral Module (Left) and the
SEL-2244 DI Module (Right) Through Use of the SEL-C758 D20 Retrofit Cable

WESTERM DI Module With Fixed-Board Mounted Screw Terminals

In this section, we describe how to connect the D20 digital-input field wiring to an SEL-2244
digital-input module through use of the SEL 915900183 retrofit kit. The existing GE D20S
WESTERM termination panel (517-0165) and DI wiring remain in place. The WESTERM
termination panel supports 64 input channels. Therefore, three SEL-2244 DI modules will be
required to handle all the DI signals.
The SEL 915900183 retrofit kit includes the following items:
• CA714 cable – This cable has two 40-pin connectors on one end (used to connect to the
D20S WESTERM board) and six 16-pin EURO connectors on the other end (used to
connect to the three SEL-2244 DI modules).
• Twenty-four 420-0448 16-pin DIP jumpers.
Details of the procedure follow.

Step 1
Unmount the WESDAC D20 logic panel from the WESTERM D20S termination panel. Refer to
the D20 GE documentation for detailed instructions on how to remove the WESDAC D20
module.

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Step 2
Remove the 24 resistor networks from their DIP sockets, which are located on the WESTERM
D20S termination panel and are labeled RN2 to RN25. Refer to Figure 9 for the exact location of
the resistor networks.
WESTERM D20S 517-0165

P1 P2 P3

24 slots: RN2 to RN25

Figure 9 Location of the Resistor Network Slots

Step 3
Insert the 24 jumpers (supplied with the SEL 915900183 retrofit kit) in the sockets of the 24
resistor networks (RN2 to RN25).

Step 4
In the WESTERM D20S termination panel board, locate the 40-pin sockets labeled as P2 and P3.
Refer to Figure 10 for the exact location of these sockets. Connect the two 40-pin connectors on
the CA714 cable into these sockets. Observe the following:
• Cable connector labeled as P2 shall connect to the P2 socket of the WESTERM D20S
board. Similarly, the cable connector labeled as P3 shall connect to the P3 socket of the
board. Cable connector labels are wrapped around the wire.
• The black wire on each 40-pin connector shall be at the top of the 40-pin socket.

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WESTERM D20S 517-0165

P1 P2 P3

P2 and P3 sockets

Figure 10 Location of P2 and P3 40-Pin Sockets

Step 5
Connect the EURO connectors of the CA714 cable to the SEL-2244 DI modules.
• Connect the EURO connectors labeled J1 and J2 to the first SEL-2244 DI module. Inputs
1 to 24 of this Axion DI module correspond to the inputs 1 to 24 of the WESTERM
terminal block.
• Connect the EURO connectors labeled J3 and J4 to the second SEL-2244 DI module.
Inputs 1 to 24 of this Axion DI module correspond to the inputs 25 to 48 of the
WESTERM terminal block.
• Connect the EURO connectors labeled J5 and J6 to the third SEL-2244 DI module.
Inputs 1 to 16 of this Axion DI module correspond to the inputs 49 to 64 of the
WESTERM terminal block. Inputs 17 to 24 of this Axion DI module are available for
other applications.

Connecting D20 Digital Output Field Wiring to the SEL-2244 DO Module

The SEL-2244 Axion digital output (DO) module connects directly to the WESTERM D20KI
through use of the SEL-C755 D20 retrofit cable, which has two 16-pin EURO connectors on the
Axion end, a DB-25 connector on the WESTERM D20KI end, and an additional wire for the
positive wetting voltage. This allows the SEL-2244 DO module to operate all 16 of the
interposing relays of the D20KI independently. Details of the procedure are in the following text.

Step 1
Disconnect the GE 977-0069 cables from the WESTERM D20KI termination panel. Remove the
WESDAC D20K and WESDAC D20DR, if necessary.

Step 2
In the WESTERM D20KI termination panel, place jumpers Z2 to Z9 across Pins 2 and 3.
Disconnect all eight jumpers on the Z1 bank.

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Step 3
Connect the DB-25 connector of the SEL-C755 D20 retrofit cable to the J1 socket on the
WESTERM D20KI termination panel.

Step 4
Connect the two EURO connectors of the SEL-C755 D20 retrofit cable to the SEL-2244 DO
module.

Step 5
Obtain an external power supply of the same voltage level as the rated coil voltage of the
interposing relays on the WESTERM D20KI panel.
Connect the positive terminal of the power supply to the +VDC wire of the SEL-C755 D20
retrofit cable. Connect the negative terminal to Pin 3 of the TB9 connector on the WESTERM
D20KI termination panel.
Figure 9 illustrates this solution.

+VDC
External power supply with
proper voltage rating to
energize the interposing relays.

SEL-C755 D20
Retrofit Cable

J1
Interposing Relays

WESTERM D20KI

TB9

Figure 11 Connecting the SEL-2244 DO Module to the D20KI Interposing Relays Panel Through Use of the
SEL-C755 D20 Retrofit Cable
In the WESTERM D20KI board, the interposing relays are labeled from K1 to K16. If the board
is configured as described in Step 2, OUTPUT_001 of the SEL-2244 DO module operates
interposing relay K1, OUTPUT_002 operates interposing relay K2, and so on. Figure 10
illustrates the DO assignment after completion of the replacement procedure.

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SEL-2244 DO Module

OUTPUT_001
OUTPUT_002
OUTPUT_003
OUTPUT_004
OUTPUT_005
OUTPUT_006
K1 K2 K3 K4 K5 K6 K7 K8
OUTPUT_007
OUTPUT_008
K9 K10 K11 K12 K13 K14 K15 K16
OUTPUT_009
OUTPUT_010
OUTPUT_011
OUTPUT_012
OUTPUT_013 WESTERM D20KI
OUTPUT_014
OUTPUT_015
OUTPUT_016

Figure 12 Digital Output Assignment Between the SEL-2244 DO Module and the Interposing Relays in the
D20KI Panel

Connecting D20A Analog-Input Field Wiring to the SEL-2245 AI Module

The SEL-C754 D20 retrofit cable conveys the analog-input field-wiring signals from the DB-25
interface of the field-wiring termination cable to the SEL-2244 AI module. Each SEL-C754 D20
retrofit cable conveys eight signals; therefore, two SEL-C754 D20 retrofit cables are required per
SEL-2244 AI module. Two SEL-2244 AI modules are required to replace an entire D20A analog-
input peripheral system. The procedure is as follows.

Step 1
Disconnect the DB-25 connector of the field-wiring termination cable from the WESTERM
D20AD termination panel. Remove the WESDAC D20A and WESDAC D20AD modules, if
necessary.

Step 2
Use the SEL-C754 D20 retrofit cables to connect the DB-25 end of the field-wiring termination
cables to the SEL-2245 AI module. Each SEL-C754 D20 retrofit cable accommodates eight
analog-input signals; therefore, you will need two SEL-C754 D20 retrofit cables for each
SEL-2245 AI module.
Figure 11 illustrates the AI system before and after D20A module replacement.

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SEL-C754 D20
Retrofit Cable

To analog-input field signals

To analog-input field signals

Figure 13 Analog-Input DB-25 Termination Field Wiring Connected to the D20A Termination Panel (Left) and
to the SEL-2245 AI Module (Right) by Using the SEL-C754 D20 Retrofit Cable

CONCLUSION
This application guide provides instructions on how to connect the GE D20 I/O signals to the
SEL-2240 I/O modules through use of the D20 replacement cables. These replacement cables
allow a direct connection between the DB-25 connectors of the GE I/O field termination cables
and the EURO connector on the SEL-2240 I/O modules, eliminating the need for I/O rewiring
and saving hours of labor during the migration process.

FACTORY ASSISTANCE
We appreciate your interest in SEL products and services. If you have questions or comments,
please contact us at:
Schweitzer Engineering Laboratories, Inc.
2350 NE Hopkins Court
Pullman, WA 99163-5603 U.S.A.
Telephone: +1.509.338.3838
Fax: +1.509.332.7990
selinc.com
[email protected]

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*AG2016-20*
SEL Application Guide 2016-20 Date Code 20180921