一、系统存在的缺点
美国通用电气公司出品的可编程控制器系列6和系列90，以及晶闸管整流器DC300、DC2000和IGBT逆变器AC2000是早期产品，此系统存在如下缺点。
1．运营成本较高。集装箱场桥用柴油发电机组供电，燃油成本成为电控系统的评价标准。相同配置下，GE系统耗油为14.7L/h，而安川系统耗油为12.5L/h。
2．变频器散热量大。散热量大对变频器运行不利，易造成变频器损坏，尤其夏季，要保障环境温度满足变频器运行要求。
3．备件贵且采购周期长。一个通信模块售价3万多元，一个电路板售价5万多元。仅这两种元件，每年的损耗达到60多万元，而且采购周期长达半年。部分零部件GE公司已停止生产。
4．港口机械环境潮湿，GE系统不适应，故障时有发生。
针对以上问题，进行如下改进。
DS215KLDCG1AZZ03A GE DS200全系列
DS215KLDCG1AZZ03A GE DS200全系列 DS215KLDCG1AZZ03A GE DS200全系列
DS215KLDCG1AZZ03A GE DS200全系列
二、改换GE电控系统中部分单元
以安川61665和686CR5变频器取代GEAC2000变频器；CP316H可编程控制器取代系列9030可编程控制器；不更换电动机；更换测速编码器并辅以相应的线路；更新控制继电器。
三、针对原系统故障对口改进
1．可编程序控制器（PLC）系列6智能总线故障系统工作时，智能总线上各个模块的通信线连接出现松动导致工作不稳定，控制电源断开。
措施：一是将智能模块通信线接口增加接线端子；二是定期检修模块接口和总线的连接情况，检测智能总线两端阻值。
2．AC2000变频器129#故障
变频器在初始上电时经常出现129#故障，其故障为初始上电检查故障，当变频器中央处理器检查其工作电压（3.3~3.8V）正常后，变频器才进入正常工作状态。而电源插头出现松动或插针出现氧化时，可使中央处理器不能检测到正确的电压值：
处理方法：定期对电源插头和插针进行清洁并紧固，同时对插针进行防氧化处理。
3．AC2000变频器IGBT烧毁故障
变频器出现功率元件IGBT损坏：原因是IG-BT工作时散热快，环境温升高；变频器各接插元件出现松动，导致IGBT控制紊乱而损坏。
整改措施：(1)在电气室安装空调制冷；(2)在变频器的外围控制电路中增加一级控制延时，减少因接插件松动而产生的误动作，并对接插件进行紧固处理。
四、设备的维护保养
1．加强发动机的保养及调速系统的检查。
2．确保电器元件接线紧固插口清洁。
3．加强变频电机的保养。由于高次谐波的影响，变频电机的温升、绕组绝缘的破坏及轴承损耗比普通异步电动机高。因此要做好口常维护：(1)保证电机外壳清洁及冷却风道畅通；(2)噪声及绝缘检查；(3)按说明书及技术文件要求进行润滑。
4．电动机附件的保养，包括超速开关、编码器的清理等。
经过局部整改和预防性维护保养，设备利用率由原20％提高到50%；设备故障时间由约15h／月降低到现在的约3h／月。
GE Fanuc VMIC VMIVME-7750-754 Circuit Board With Tews TPMC917-10 Card, Used
Applied Theory USNR X-073145 AT-3160 Card / Circuit Board, New
York 664-01274-000 Seal End Main Bearing For 6-3/4”X5” Compressor, New
BF Goodrich Cutless Bearing, 1-1/2” ID X 2-3/8” OD X 6” Long, New
Numatics 554JJ600O000000 Double Solenoid Pneumatic Valve, Lot Of Two, Used
NTN NU424AC5NA Roller Bearing With NTN Inner Race, For Fuller Compressor, New
FAG 2 NU424-RL-1W/70 NU424 Cylindrical Roller Bearing, New
Siemens 15-172-787-021 Voltage Transformer, 7200V Primary BIL 110kV, 1500VA, New
Mycom A Aftermarket 2-29-A Discharge Valve Cage, New
USNR LB210 Light Bank For?? Lumber Scanner? 24” Long, New
Applied Theory USNR M4-03204 AT-EDET Light Curtain Circuit Board, New
Motorola MVME 2604 761 I/O 01-W1713B12D VME CPU Circuit Board, Lightly Used
Danfoss GEA 1214774 Four Way Solenoid Block Valve, 501298372, New
Applied Theory USNR M4-03236 AT-Thicket Card / Circuit Board, Used
Motorola MVME 162-513A 01-W3960B62D CPU Circuit Board, Lightly Used
Sporlan KP19-0090 KP190090 Internal Parts Kit For Type O Thermostatic Valve, New
Motorola MVME 2600-1 01-W1619B76F CPU Circuit Board, Lightly Used
Motorola MVME 2600-1 01-W1619B76B CPU Circuit Board, Lightly Used
Parker R20E84 Solenoid Valve, 1/2" ODF Connection, 1/4" Orifice, New
Groschopp / Signode SK9404 Motor Assembly For MHT-80 Bander, 433359, New
Mercoid 9-5107SA Mercury Control Switch, New
ENIDINE OEMXT 2.0Mx6 Shock Absorber, MF22195, New
Lot Of 10 NAPA Belden MAX 702418 Coil on Plug Spark Plug Boot, New
D-Link DES-608M Ethernet Switch, Used
Lot Of 75 Auveco 10055 Extruded U Nuts / Fender Nuts, 3/8"-16, New
Applied Theory USNR M4-03206 AT-ELF Card / Circuit Board, New
XYCOM XVME-401 70401-001 VMEbus Circuit Board, Lightly Used
Motorola MVME 162-022A 01-W3884B-67A CPU Circuit Board, Used
Hansen Technologies MOVT Manual Operator For Sealed Motor Valve, New
ABB SAB3000-LGC-2/4 Logic Control Circuit Board For Electric Brake, Used
ABB SAB3000-PWR-2/4 Logic Control Circuit Board For Electric Brake, Used
Allen Bradley 836-C7A Pressure Switch, Series A, Type 1 Enclosure, Used
Motorola MVME 162-022A 01-W3884B-67D CPU Circuit Board, M4-03680, Lightly Used
GE GENERAL ELECTRIC 151670G6, 55 151670G006 CONTACT SET NEW
Applied Theory USNR M4-03199 AT-Combo Card / Circuit Board, Used
Applied Theory USNR X-073145 AT-3160 Card / Circuit Board, Used
YALE 917314402 Plug In Relay, New
Applied Theory USNR M4-03227 AT-Recvr Card / Circuit Board, Used
KEB 0803824-270U Electric Clutch For Signode MHT-MP44 Bander, 280100, New
Mycom Mayekawa CR0329-FB Shaft Mechanical Seal Assembly B/R, New
Deltran PT 305-12-046 Spring Clutch For Signode MHT-80 Bander, 280617, New
Motorola MVME 2600-1 01-W1675B12A CPU Circuit Board, Lightly Used
Carrier 5F20276 5F20-276 Shaft Seal Assembly, New
Lochinvar RLY20134 Bacnet Interface Board, 100191023 MTR-01, New
Greer Company TWG A450672 Computer Assembly, Parts Only
SKF NU 322 ECM/C3 Cylindrical Roller Bearing 110mm Bore 240mm 50mm, New
Binks 6-1310 Back Pressure Valve Repair Kit, New
Applied Theory USNR AT-Combo AT-Commix Card / Circuit Board, Used
Ring Set For Lindsey 2 Cylinder 8-1/2 X 8-1/2 Ammonia Compressor, New
Mitsubishi FR-BU-H30K Transistorized Inverter Brake Unit, FR-BU-H30K-UL, New
SULLAIR 20289 ( 20289C ) MP Valve Housing For SULLAIR Air Compressor, New
Partlow MF-2 Temperature Controller 4A 125V 2A 250V 50VA, 100-1000* F, New Other
Timken Torrington CRSBE-24 Needle Bearing, New
Hansen VLT-04N 40” Techni-Level Transducer Probe, 4-20 mA Output, New
Lot Of 6 Cables To Go GTG 40026 6FT 6’ BNC Male Coaxial Cable, RG59/U, New
FES Systems 261-00008M-204 D/B Shaft Seal Kit For Compressor, Reconditioned
Caloritech CXFT230P248MY 48” Immersion Tank Heater, 120/240V 3000W, Used
McLean Midwest 13-0116-G0002 Electronic Enclosure Air Conditioner, 1000 BTU
Baker Pax Mite 11A116D 13A13 Oil Pump, Used, MAKE OFFER!
EG&G Sealol RSD 5710 Shaft Seal For Worthington 5X5 Compressor, New
Mycom CA-115C-0B Single Mechanical Shaft Seal, CA-115A-00, CA-1180-00, New
Parker Refrigeration 207660 Seal Cap For Hand Valves, New
Hansen Technologies HMMRC/5 Flanged 2" (50 mm) Sealed Motor Valve, New
Porter Cable? 913322 Power Tool Field / Motor, New
Applied Theory USNR M4-03204 AT-EDET Light Curtain Circuit Board, Used
Red Lion Controls MDI2Y11A Intelligent Message Display Unit, New
Graco 214968 214-968 Repair Kit For 206513 Automatic Hydra Spray Gun, New
MTS GHT0060UD60AV0 G-Series Temposonic Sensor, 6” Analog Sensing Length, New
Allen Bradley GG-473 GG473 Coil For 100 Series Contactor, 120VAC 60Hz, New
Vilter 450XL Connecting Rod Assembly, Set Of 6, Used
Tescom 64-2663KRH11 Stainless Steel Regulator, 3500 PSI Max In, 250 PSI Out, New
Altronix Maximal33D Access Power Controller, 12VDC & 24VDC Out, 16 Outputs, New
MyCom A Manual / Auto Unloader Control Panel, S51125, SL-32(1), New Old Stock
BEI Industrial Encoders H25D-SS-1024-ABC-28V/5-TB-S, 01002--8319 Encoder, New
Texas Instruments Klixon CDM-25 25 Amp Manual Circuit Breaker, New
UWT RN 6001 A011FQ1B3D GmbH Rotonivo Level Control, 24-230VAC/DC Supply, New
Grote 48272 Universal Turn Signal Switch Kit With 69680 Wiring Harness, New
Carrier 06EA400583 Valve, New Old Stock
Carrier 6L1202632 6-L-120-2632 Adapter Plate, New
White Rodgers RBM 125-105111-3COIL 124-902 12VDC Solenoid, New
Lot Of 2 Allen Bradley 1489-M1C050 1 Pole 5A Circuit Breaker, Series D, New
Honeywell AT72D 1048 Transformer, 24V NEMA Type D, 120V / 39VA, New
Johnson Controls Penn A19AAA-18 Temperature Control, 30 / 110*F, New
Penn Baso Counterline P61BH-1 Pressure Switch, 1/4” FNPT Port, 9/25 PSIG, New
ALCO Controls KS30019 Parts Kit For Solenoid Valves, New
SKF 33206/Q Tapered Roller Bearing With Cup, New
Lot Of 2 Vickers RV3-16-S-0-35 Screw In Pressure Relief Cartridge Valve, Used
Fuji 5 Inch Size 80 Gear, 20 To 1 Ratio, New
BRADY PS-187-2-WT 2" Wide White PermaSleeve Wire Marker, Partial Roll, New
Morse 17375 PB-8A Inner Race Drives C CW Cam Clutch, 1” Bore, New
Sauer Danfoss 162B6014 Joystick Cable For Electric Remote Control, 4000 mm, New
Mycom CB-115A-00 And CB-1180-00 Shaft Seal Collar And Ring, Single, New
Red Lion Controls LNXCC000 Contact Input Counter, New In Sealed Packaging
Zebra Technologies 41001M Printhead, Genuine New
Syracuse / Relay Specialties Inc. TNR-00311 TNR00311 60 Second Timer Relay, New
Carrier? 0L35X371 Oil Pump For Refrigerant Compressor, Used
Teledyde 453-1S2-6 1” In Line High Pressure Check Valve, 5000 Psi, Used
Sporlan KT-23-AC DAE-5-C Power Head For Thermostatic Valve, Lot Of 2, New
Lot Of 12 2 Bolt Bearing Housing For Size 205 Insert Bearing, New
Lot Of 4 Parker 201401 Refrigerant Solenoid Coil, 120V 60Hz, Used
Lot Of 6 Russell & Stoll Russellstoll Receptacles, 3754, 3753, 3743, Used
MYCOM CS1060-0E Teflon V-Ring For 200S/L Seal Ring, New
Henry 300B-E 1/4” Ammonia Globe Expansion Valve With Handwheel, 1/4” FPT, New
Banner Engineering SMA30PELQD AC / DC Light Emitter, Used
MYCOM CR15200-A08 Unloader Suction Cover 8A Gasket, New
Johnson Controls Penn Baso RLY13A-617R 45 Second Time Delay Relay, 120/240V, New
SKF 3NU22 NH322 Cylindrical Roller Bearing, New
Lot Of 20 Bussmann LP-CC-30 30 Amp Low Peak Class CC Fuses, 600V, New
Allen Bradley 802T-A1P Oiltight Limit Switch, Series J, Lightly Used
Carrier Transicold 5H40471 5-H-40-471 .020 Connecting Rod Bearing, Set Of 4, New
Carrier 5F403442 5F-40-3442-010 Seal End Main Bearing, .010 Under, New
Carrier Transicold 5F20461 5F20-461 .010 Under Size Bearing, Set Of 6, New
Lot Of 4 Genuine Takeuchi 1900-91734 Dust Seal, New
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