Ex2100 Startup Guide

gGE Industrial Systems

GEH-6631A

EX2100™ Excitation Control

Full Static Control

Installation and Startup Guide

GEH-6631 EX2100 Installation and Startup Contents � i

Contents

Chapter 1 OverviewIntroduction.............................................................................................................................1-1How to Use This Document....................................................................................................1-3

Structure of the Document........................................................................................1-3Text Conventions......................................................................................................1-3

How to Get Help.....................................................................................................................1-5Equipment Covered ................................................................................................................1-5Related Documents .................................................................................................................1-7

Document Distribution .............................................................................................1-7Acronyms and Abbreviations .................................................................................................1-8

Chapter 2 Installation PlanningIntroduction.............................................................................................................................2-1Installation Support.................................................................................................................2-2

Early Planning ..........................................................................................................2-2GE Installation Documents.......................................................................................2-2As-Shipped Drawings...............................................................................................2-2Technical Advisory Options.....................................................................................2-3

Siting EX2100 Equipment ......................................................................................................2-5Operating Environment ............................................................................................2-5Equipment Clearances ..............................................................................................2-6Cable and Conduit Routing and Schedules...............................................................2-6

Chapter 3 Handling and Mounting GuidelinesIntroduction.............................................................................................................................3-1Exciter Handling Procedures ..................................................................................................3-2

Lifting.......................................................................................................................3-2Moving .....................................................................................................................3-3Unpacking ................................................................................................................3-4

Mounting ................................................................................................................................3-5Securing the Exciter Lineup to the Floor..................................................................3-8

Chapter 4 Cabling and ConnectionsIntroduction.............................................................................................................................4-1Exciter Connections................................................................................................................4-2Grounding and Cable Entry ....................................................................................................4-6

Cable Entry...............................................................................................................4-6Control Power.........................................................................................................................4-9Converter Power ...................................................................................................................4-10Field Flashing .......................................................................................................................4-11Generator Field Connections ................................................................................................4-11

� Contents GEH-6631 EX2100 Installation and Startupii

Signal and Communications Cabling Guidelines..................................................................4-11

Generator PT and CT Inputs...................................................................................4-11Contact Inputs.........................................................................................................4-12Data Highway.........................................................................................................4-15PC Interface ............................................................................................................4-16

Preventing Cable Damage.....................................................................................................4-16

Chapter 5 Pre-Power On Installation ChecksIntroduction.............................................................................................................................5-1Equipment/Material Needed ...................................................................................................5-2Securing the Equipment for Safety .........................................................................................5-2Hardware Checks ....................................................................................................................5-3Optional Megger Test .............................................................................................................5-5

Pre-Test Power Checks.............................................................................................5-5Ac Input Bus and PPT Secondary.............................................................................5-5Dc Output Bus ..........................................................................................................5-6

Chapter 6 Initial Startup and CommissioningIntroduction.............................................................................................................................6-1Before Beginning....................................................................................................................6-2

Order of Startup ........................................................................................................6-2Information Needed..................................................................................................6-2Equipment/Material Needed.....................................................................................6-3

Panel Lights, Heaters and Fans ...............................................................................................6-6Verifying Control Power.........................................................................................................6-8Control Module Processor Start............................................................................................6-12Using the Exciter Configuration Tools .................................................................................6-13

Using Toolbox Online Help....................................................................................6-13Starting the Toolbox ...............................................................................................6-14Open an EX2100 File .............................................................................................6-14Checking Toolbox/EX2100 Pattern Compatibility.................................................6-14Downloading to the EX2100 ..................................................................................6-14Optional: Upgrading the .ecb File..........................................................................6-15Checking for Correct Firmware and Hardware ......................................................6-15

Checking the Keypad (EDI)..................................................................................................6-16Using the Keypad for Startup and Commissioning ................................................6-16Adjusting Keypad Display Contrast .......................................................................6-17

Commissioning the Exciter...................................................................................................6-18Overview of EX2100 Parameters ...........................................................................6-18Running Simulator Mode .......................................................................................6-21Temporary Load Checks.........................................................................................6-26Initial Roll and Off Line Checks.............................................................................6-29On-Line Checks......................................................................................................6-39Additional Testing ..................................................................................................6-40

Appendix A Understanding Equipment DrawingsIntroduction............................................................................................................................A-1Data Nameplate......................................................................................................................A-2Identifying the Equipment .....................................................................................................A-3

Equipment Catalog Number ....................................................................................A-3Drawing Numbers..................................................................................................................A-3Outline Drawings ...................................................................................................................A-4Panel Drawings ......................................................................................................................A-4

GEH-6631 EX2100 Installation and Startup Contents � iii

Elementary Diagrams ............................................................................................................A-5Equipment Reference Information ..........................................................................A-5

Elementary Drawing Number..................................................................................A-5Wire Number Identification.....................................................................................A-5

Conventions Used with Other Equipment .............................................................................A-6

Appendix B Cable Separation and RoutingIntroduction............................................................................................................................B-1Low-Level Signals (Level L).................................................................................................B-2Medium-Level Signals (Level M) .........................................................................................B-2High-Level Signals (Level H)................................................................................................B-2Power (Level P) .....................................................................................................................B-2Class Codes............................................................................................................................B-2Cableway Spacing Guidelines ...............................................................................................B-3

General Cableway Spacing......................................................................................B-3Tray/Tray Spacing ...................................................................................................B-4Tray/Conduit Spacing..............................................................................................B-4Conduit/Conduit Spacing ........................................................................................B-4

Appendix C Installing Fiber-Optic CableIntroduction............................................................................................................................C-1Cable Characteristics .............................................................................................................C-2

Cable Construction ..................................................................................................C-2Data Integrity...........................................................................................................C-2Causes of Cable Damage.........................................................................................C-2

Handling Guidelines ..............................................................................................................C-3Environmental Guidelines .....................................................................................................C-4Cable Assembly .....................................................................................................................C-4

Tools and Materials .................................................................................................C-4Attaching a Connector .............................................................................................C-5Polishing Fiber Ends................................................................................................C-7

Inspecting Fiber Ends ............................................................................................................C-9Connecting Fiber-Optic Cable to Modules ..........................................................................C-11

Appendix D Printed Wiring Board Reference

Glossary of Terms

Index

GEH-6631 EX2100 Installation and Startup Chapter 1 Overview � 1-1

Chapter 1 Overview

IntroductionThis document is an installation and startup guide for the EX2100� ExcitationControl (EX2100, see Figures 1-1 and 1-2). It assumes the following:� All receiving, handling and storage procedures were strictly followed, as defined

in document GEI-100256.� You are ready to move the exciter(s) to the installation site.� The installation site was previously prepared and cables run per GE

specifications, and all necessary system parts are at the site.

Additionally, these instructions require that the user:� Be adequately trained to thoroughly understand and strictly follow all safety

procedures necessary for working with and around high voltages.� Know the physical and electrical requirements of installing high voltage

equipment.� Understand the theory of exciter operation.� Be experienced in using the EX2100 configuration software (the GE Control

System Toolbox).� Understand the structure and conventions of this document in order to follow the

instructions exactly as required.

This first chapter provides an overview of how to use this document correctly, asfollows:

Section Page

How to Use This Document .....................................................................................1-3Structure of the Document.................................................................................1-3Text Conventions ..............................................................................................1-3

How to Get Help.......................................................................................................1-5Equipment Covered ..................................................................................................1-5Related Documents...................................................................................................1-7

Document Distribution ......................................................................................1-7Acronyms and Abbreviations ...................................................................................1-8

The remainder of the document is organized in the order required for installing andstarting the exciter (see How to Use This Document).

1-2 � Chapter 1 Overview EX2100 Installation and Startup GEH-6631

Figure 1-1. Typical EX2100 Excitation Control

Figure 1-2. Typical EX2100 Excitation Control Components


How to Use This Document

Structure of the DocumentGE recommends that adetailed installation log ismaintained for the exciter asthese installation and startupsteps are completed.

Sections of related procedures are presented in the order that they should befollowed (see Figure 1-3).

Appendices provide reference information, as follows:� Appendix A, Understanding Equipment Drawings

� Appendix B, Cable Separation and Routing� Appendix C, Installing Fiber-Optic Cable� Appendix D, Printed Wiring Board Reference

For an exact outline of the document’s organization, refer to the Table of Contents.

Text Conventions

Convention Meaning

� A procedure follows.

Numbered list Procedural steps to be followed in order (for example,1, 2, 3).

Alphabetized list Procedural substeps (of numbered steps) to befollowed in order (for example, a, b, c).

Bulleted (�) list Related items or procedures, but order does notmatter.

� A procedure with only one step.

Boxed (�) list A checklist.

Arial Bold When describing software, indicates the actualcommand or option that is chosen from a menu ordialog box.

Monospace Represents examples of screen text or words andcharacters that are typed in a text box or at thecommand prompt.


Chapter 2,Handling and MountingGuidelines

Connect cables& I/O wiring

Chapter 3,Cabling and Connections

Mount and installexternal devices

Chapter 4,Device Installation

StartProcedures

Installation site ready,drawings & documents onhand, all site parts present

Verify correctfunctioning ofconnected devices(power, I/O)

Chapter 5,Pre-Startup InstallationChecks

Star

tup

Inst

alla

tion

Move exciter toinstallation site and

install it

Apply power, starttoolbox, run checks

Chapter 6,Initial Setup and OperationChecks

End ofProcedures

Figure 1-3. Structure of Document for Use in Installation and Startup


How to Get HelpIf help is needed beyond the instructions provided in the exciter systemdocumentation, contact GE as follows:

“+” indicates theinternational access coderequired when calling fromoutside the USA.

GE Industrial SystemsProduct Service Engineering1501 Roanoke Blvd.Salem, VA 24153-6492 USA

Phone: + 1 888 GE4 SERV (888 434 7378, United States)+ 1 540 378 3280 (International)

Fax: + 1 540 387 8606 (All)

Equipment CoveredIn this document, the term“exciter” refers to theEX2100 digital static exciter.

An exciter is a combination of one or more power conversion modules (PCMs) withtheir associated control and protection equipment (see Figure 1-4). The generatorfield current and voltage requirements, and the redundancy requirements determinethe number of PCMs and the total number of cabinets. The available exciter sizes areas follows:

ExciterCurrent

Capability PCM

RedundancyNumber of

PCMs

Number ofBridge/Aux.

Cabinets

Number ofControl

Cabinets

TotalNumber ofCabinets

1000 A dc None, simplex 1 1 1 2

2000 A dc None, simplex 1 1 1 2

1000 A dc Warm backup 2 2 1 3

2000 A dc Warm backup 2 2 1 3

The EX2100 can be powered from the generator by a potential source (PPT only), ora compound source (PPT and PCT), or from an auxiliary ac source (through a PPT).


Figure 1-4. EX2100 Cabinet Lineup Components


Related DocumentsIf needed for supplementary information, refer to the following EX2100 productdocuments, as applicable:

Subject Document Content

EX2100 Toolbox GEH-6414 GE Control System Toolbox instructions for the EX2100

EX2100 User’s Guide GEH-6632 Functional description, technical data, customer I/O connections,keypad overview; application guides

EX2100 Maintenance,Parts Replacement, andTroubleshooting Guide

GEH-6633 Preventive maintenance, online maintenance, component replacement,fault list, and troubleshooting information

EX2100 Receiving,Handling and Storage

GEI-100256 Procedures, precautions, and environmental requirements for receivingthe exciter from the shipper and storing it before installation

Printed wiring boards See AppendixD for a list ofGEIs

Board function within the exciter, I/O designations, fuses, jumpers, testpoints, and board replacement procedure

Document DistributionGE Industrial Systems supplies product documents to its customers to support theequipment provided for each requisition. The contract documents define the terms ofthe document distribution. If provided (per contract), the following documentscontain requisition information about the exciter system.� Requisition drawings, including outline and elementary diagrams� Renewal Parts listing

Note If differences exist between the general product documentation and therequisition documentation, the requisition documentation should be considered themore exact representation of your equipment or system configuration.


Acronyms and Abbreviations

A ampere(s) in-lbs inch-pounds (torque)ac alternating current I/O input and outputACLA Application Control Layer Module IPN intelligent part numberACOM analog common J405 cable connector at row 4, location 05AVR Automatic Voltage Regulator kg kilogramsC protection controller in a redundant system LAN local area networkCCOM control common LED light-emitting diode CT current transformer level H high-level signalDACA Ac to dc converter in control power supply level H(S) high-level signal, special handlingdc direct current level L low-level signalDCOM digital common level M medium-level signalDSPX Digital Signal Processor Board level P power signalEACF Exciter Ac Feedback Board level P(S) power signal, special handlingEBKP Exciter Backplane Board m metersECTB Exciter Contact Terminal Board M1 primary controllerEDCF Exciter Dc Feedback Board M2 backup controllerEDEX Exciter De-excitation Board max maximumEGD Ethernet Global Data min minimumEGDM Exciter Ground Detector Module NEC National Electrical Code�EGPA Exciter Gate Pulse Amplifier Board OSHA Occupational Safety and Health ActEISB Exciter ISBus Board P125 positive side of 125 V dc power supply EMIO Exciter Main I/O board PC Personal ComputerEPBP Exciter Power Backplane PCM Power Conversion ModuleEPCT Exciter PT/CT Board PCT Power Current TransformerEPDM Exciter Power Distribution Module PLC programmable logic controllerEPSM Exciter Power Supply Module PPT Power Potential TransformerESEL Exciter Selector Board PSS Power System StabilizerEXAM Exciter Attenuator Module PT potential transformerEXCS Exciter Current Sensor R125 return side of 125 V dc power supply EXHS Exciter High-Speed Relay Driver Board RTDs resistance thermal devicesEXTB Exciter Terminal Board SCR silicon-controlled rectifierft foot, feet SHCOM shield commonft-lbs foot-pounds (torque) TMR Triple Modular Redundantft/min feet per minute UEL Under Excitation Limit controlGE General Electric Company V ac volts ac (alternating current)GPA Gate Pulse Amplifier VAR volt amperes reactiveHMI Human Machine Interface V dc volts dc (direct current)in. inch(es)

GEH-6631 Installation and Startup Chapter 2 Installation Planning � 2-1

Chapter 2 Installation Planning

IntroductionThis chapter discusses installation planning and requirements for the EX2100excitation control system. Specific topics include GE installation support, siting theequipment, and environmental requirements.

Before installation, consult and study all furnished drawings. These should includeoutline drawings, elementary diagram, connection diagrams, and a summary of theequipment.

This chapter is organized as follows:

Section Page

Installation Support ..................................................................................................2-2Early Planning ...................................................................................................2-2GE Installation Documents................................................................................2-2As-Shipped Drawings........................................................................................2-2Technical Advisory Options..............................................................................2-3

Siting EX2100 Equipment........................................................................................2-5Operating Environment .....................................................................................2-5Equipment Clearances.......................................................................................2-6Cable and Conduit Routing and Schedules .......................................................2-6

2-2 � Chapter 2 Installation Planning EX2100 Installation and Startup GEH-6631

Installation Support GE’s system warranty provisions require both quality installation and that a qualifiedservice engineer be present at the initial equipment startup. To assist the customer,GE offers both standard and optional installation support. Standard support consistsof documents that define and detail installation requirements. Optional support istypically the advisory services that the customer may purchase.

Early PlanningTo help ensure a fast and accurate exchange of data, a planning meeting among allparties is recommended early in the project. This meeting should include thecustomer’s project management and construction engineering representatives as wellas local GE service personnel. It should accomplish the following:� Familiarize the customer and construction engineers with the equipment.� Set up a direct communication path between GE and the party making the

customer’s installation drawings.� Determine a drawing distribution schedule that meets construction and

installation needs.� Establish working procedures and lines of communication for drawing

distribution.

GE Installation DocumentsInstallation documents consist of both general and requisition-specific information.The cycle time and the project size determine the quantity and level ofdocumentation provided to the customer.

General information, such as this manual, provides product-specific guidelines forthe equipment. They are intended as supplements to the requisition-specificinformation.

Requisition documents, such as outline drawings and elementary diagrams; providedata specific to a custom application. Therefore, they reflect the customer’s specificinstallation needs and should be used as the primary data source.

As-Shipped DrawingsThese drawings include changes made during manufacturing and test. They areissued when the equipment is ready to ship. As Shipped drawings consist primarily ofelementary diagrams revised to incorporate any revisions or changes made duringmanufacture and test.

Revisions made after the equipment ships, but before start of installation, are sent asa Field Change, with the changes circled and dated.


Technical Advisory OptionsTo assist the customer, GE Power Systems offers the optional technical advisoryservices of field engineers for:� Review of customer’s installation plan � Installation support

These services are not normally included as installation support or in basic startupand commissioning services, shown in Figure 2-1. GE presents installation supportoptions to the customer during the contract negotiation phase.

InstallationSupport

Startup

Commissioning

BeginInstallation

CompleteInstallation

SystemAcceptance

Product Support - On goingBeginFormalTesting

Figure 2-1. Startup and Commissioning Services Cycle

Review of Installation PlanIt is recommended that a GE field representative review all installation/constructiondrawings, and the cable and conduit schedule when completed. This optional reviewservice ensures that the drawings meet installation requirements and are complete.

Installation SupportOptional installation support is offered: planning, practices, equipment placement,and onsite interpretation of construction and equipment drawings. Engineeringservices are also offered to develop transition and implementation plans to install andcommission new equipment in both new and existing (revamp) facilities.

Customer’s Conduit and Cable ScheduleThe customer’s finished conduit and cable schedule should include:� Interconnection wire list (optional)� Level definitions� Shield terminations


Level DefinitionsThe cable and conduit schedule should define signal levels and classes of wiring (seesection, Cable and Conduit Routing and Schedules and Appendix B). Thisinformation should be listed in a separate column to help prevent installation errors.

The cable and conduit schedule should include the signal level definitions in theinstructions. This provides all level restriction and practice information neededbefore installing cables.

Shield TerminationsThe conduit and cable schedule should indicate shield termination practice for eachshielded cable (refer to the section, Cable and Conduit Routing and Schedules andAppendix B).


Siting EX2100 Equipment Prior to receipt of the equipment, all plans should be finalized as to the location theequipment will be installed. This section is a general guide as to the factors that mayinfluence the choice of this site.

Operating EnvironmentOf prime concern in the choice of equipment location is the operating environment.The EX2100 control panel is suited to most industrial environments. To ensureproper performance and normal operational life, the environment should bemaintained as follows:

Ambient temperature (acceptable): Control Module 0 �C (32 �F) to 45 �C (113 �F)PCM Module 0 �C (32 �F) to 50 �C (122 �F)

Ambient temperature (preferred): 20 �C (68 �F) to 30 �C (87 �F)

Maximum rate of temperature change: 0.1ºC per min

Relative humidity: 5 to 95%, non-condensing.

Maximum rate of relative humidity change: 1% per min

Note Higher ambient temperature decreases the life expectancy of any electroniccomponent. Keeping ambient air in the preferred (cooler) range should extendcomponent life.

Maximum concentration of corrosive gases at 50% relative humidity and 40ºC perEN50178: 1994 Section A.6.1.4 Table A.2 (m).

Sulfur dioxide (SO2) 30 ppbHydrogen sulfide (H2S) 10 ppbNitrous fumes (NOx) 30 ppbChlorine (Cl2) 10 ppbHydrogen fluoride (HF) 10 ppbAmmonia (NH3) 500 ppbOzone (O3) 5 ppb

Particle sizes from 10 � 100 microns for the following materials:Aluminum Oxide Sand/Dirt Cement Lint Coal/Carbon dustSteel Mill Oxides Paper Soot Ink

Seismic: Universal Building Code (UBC) - Seismic Code section 2312 Zone 4

Vibration: Maximum of 1.0 G horizontal, 0.5 G vertical @ 15 to 120 Hz.

Elevation: Normal Operation: 0 to 3000 feet (101.3 – 89.8 KPa)Extended Operation: 3300 – 10000 feet (89.8 – 69.7 KPa)Shipping: 15000 feet maximum (57.2 KPa)


Environments that include excessive amounts of any of the following elementsreduce panel performance and life:� Power line fluctuations.� Electromagnetic interference or noise introduced by:

� Radio frequency signals, typically from nearby portable transmitters.� Stray high voltage or high frequency signals, typically produced by arc

welders, unsuppressed relays, contactors, or brake coils operating nearcontrol circuits.

The preferred location for the EX2100 excitation control system cabinet would be inan environmentally controlled room. The panel should be mounted where the floorsurface allows for attachment in one plane (a flat, level, and continuous surface). Themounting hardware is provided by the customer. Lifting lugs are provided and ifused, the lifting cables must not exceed 45� from the vertical plane. Finally, the panelis equipped with a door handle, which can be locked for security.

Equipment ClearancesEach EX2100 is supplied with an outline drawing that provides the physicaldimensions of the cabinet. Overhead clearance for fan discharge and front panelclearance for personell entry and egress are particularly important. Sufficient spacefor the equipement must be allocated such that the following minimum clearancesare maintained:

Excitation Cabinet Sidewalls: 0 inches minimum.Excitation Cabinet Rear Panel: 0 inches minimumExcitation Cabinet Top Panel: 6 inches minimum (12 inches preferred) from

highest protrusion of fans, line filters, and de-excitation resistors.

Excitation Cabinet Doors: 24 inches minimum with doors open at a 90degree angle.

Special attention to the door clearances should be made in order to maintaincompliance with local regulations regarding proper entry and egress to workingspaces.

Cable and Conduit Routing and SchedulesInterconnecting cables can be brought into the panel from the top or the bottom viaremovable access plates. Review of equipment spaces prior to installation shouldinclude access to the area via cable trays and conduit, station grounds, routing ofinterconnecting bus and location of the excitation transformer.

A thorough cable and conduit schedule should be developed to allow properplanning of the necessary materials and time to install the EX2100 using theinterconnection information provided in the system elementary.

Size and location of external station service requirements for lighting, heaters, powersupplies and other equipment should be reviewed. Attention to items that willfacilitate plant lock-out and tag-out procedures should be followed.

Proper cooling of the panel requires that conduits be sealed to the access plates.Also, air passing through the conduit must be within the acceptable temperaturerange, as listed above. This applies to both top and bottom access plates. Appendix Bof this document addresses other cable routing and separation concerns.

GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines � 3-1

Chapter 3 Handling and MountingGuidelines

IntroductionGE document GEI-100256provides receiving andstorage guidelines.

This chapter provides general guidelines for moving the exciter to the installationsite, and then installing it. The requisition drawings provided with the equipmentprovide specific information and are a required supplement to this document. Thischapter is organized as follows:

Section Page

Exciter Handling Procedures ....................................................................................3-2Lifting................................................................................................................3-2Moving ..............................................................................................................3-3Unpacking .........................................................................................................3-4

Mounting ..................................................................................................................3-5Securing the Exciter Lineup to the Floor...........................................................3-8

Note Dimensions shown in Figures in this chapter are given in inches withmillimeters shown in parantheses.

3-2 � Chapter 3 Handling and Mounting Guidelines EX2100 Installation and Startup GEH-6631

Exciter Handling Procedures

Shock or stress caused by rough handling or improper liftingand moving can damage the equipment. Be sure to follow theguidelines provided in this chapter.

The shipped equipment consistsof three cabinets securedtogether in a lineup, typicallynot exceeding 15 ft in length.

GE recommends that you do not completely unpack the equipment until it has beenmoved as near as possible to its permanent location. This practice helps ensure thatloose parts remain with the exciter. Additionally, the shipping enclosure helpsprotect the equipment during storage.

Before lifting and moving the exciter, always refer to the equipment outlinedrawings. Become familiar with the designated lift points and the stress points, andany specified handling instructions.

While lifting and moving the exciter, be sure to follow the suggested methods inthis chapter for handling the equipment, along with normal handling precautions.Additionally, it is important to observe any instructions that may be printed on orattached to the equipment container or wrapping.

LiftingLifting beams are attachedacross the top of the exciter atthe factory.

� Make sure that the lifting equipment is suitable for the configuration and weightof the exciter as follows:� 1000 A – 4400 lbs / 1996 kg� 2000 A – 5600 lbs / 2535 kg

� Observe the center-of-gravity.� Use four hooks for lifting at the openings in the lifting beam (see Figure 3-1).� Make sure the lifting beams are tightly secured to the exciter (see Figure 3-2).� The lift cables should be at an angle greater than 45 degrees from the horizontal.

Use spreader bars or similar equipment to ensure this angle (see Figure 3-2).� Lift the exciter(s) in a slow and steady manner to an acceptable clearance height.� Check for any flexing of the equipment. If noticed, lower the lineup and

re-position the cables.

Do not lift and move the exciter using equipment that appliespressure from below, such as a forklift. Doing so coulddamage the exciter frame. If a crane is not available forlifting, contact GE for guidelines on using other methods.

Figure 3-1. EX2100 Lineup Lifting Beam


Use four hooks in openingsin lifting beams (two in front

and two in back).

Angle must be45 degrees orgreater.

Figure 3-2. Proper Lifting Method for EX2100 Lineup

Moving� When using a crane, be sure that motions are slow and smooth so that the

equipment does not swing.� If using other moving devices, such as rollers:

� Be sure to place the rollers at the shipping splits and at the corners to reducepotential stress.

� Roll only on the shipping pallets that are attached to the cabinets whenshipped from the factory.

� Do not move with a forklift, since the weight of the exciter against the forklifttines would put damaging pressure on the exciter frame.

� Make sure that all doors are closed and latched.


UnpackingRecommended: Do notcompletely unpack theequipment until it is placed asnear as possible to itspermanent location.

� If the equipment has been exposed to low temperatures for an extended period,do not unpack it until it has reached room temperature (location where exciterwill be mounted).

� Use standard unpacking tools, including a nail puller.� When unpacking, check the contents of each case against the packing list.

Report any shortage to GE.� Carefully remove the packaging and move the equipment from its container, still

observing all lifting and handling guidelines.� While unpacking, inspect for damage that may not have been detected at the

time of receipt.� Wipe off any particles of packing materials or foreign substances that may be

lodged in or between the parts.� Small parts (such as bolts and screws) are packed in special containers to keep

them together, but may become separated. For this reason, carefully inspect thepacking material for loose parts before discarding it.

Document and report anyequipment damage to GE.

� If equipment damage is discovered while unpacking1. Stop unpacking immediately and report this finding to the carrier (transportation

company).

2. Photograph the damage (photographs may be needed later in processing theclaim).

3. File a claim with the carrier.

4. Contact the local service office of GE Industrial Systems for assistance.

5. When identifying missing or damaged parts, be sure to includethe followinginformation (refer to Appendix A):� Serial number� Part (model) number� Exciter code� GE requisition number� Case number


MountingFigures 3-3 through 3-5 are simplified outline drawing examples that provide thefollowing installation data:� Exciter dimensions� Door clearance� Exciter weight� Heat loss� Airflow requirements� Mounting base bolt hole location

Note Dimensions shown in Figures 3-3 through 3-5 are given in inches withmillimeters shown in parantheses.

The requisition outlinedrawings show specific lineupand installation details.

Along with the information shown on the outline drawings, use the followingmounting guidelines:� The mounting surface should be smooth and level to prevent door misalignment.� Position the exciter to permit heat radiation from all surfaces and proper

ventilation (cooling air).� Provide front clearance of at least the width of the enclosure door so that the

door can be fully opened for easy access.� Lifting beams must be removed to allow for redundant fans to be replaced.� Lifting beams must be removed if discharge resistors will be mounted on the top

of the cabinet.� If lifting beams are removed after positioning the equipment, then lifting beam

hardware must be replaced in the holes in the enclosure top and re-tightened.

Connecting the GroundsThe EX2100 must be grounded to protect against the risk of electrical shock or burnand toprotect the equipment from fire or other damage due to ground faults orlightning strikes. Proper grounding also helps improve the equipment’s immunity toelectrical noise originating within or outside of the equipment. Follow the proceduresprovided on the EX2100 requisition elementary diagram sheet 0D, GroundingInstructions. Complete instructions, recommended cable sizes, and diagrams areprovided there.

The ground connections must be complete to ensure propergrounding of the equipment.


ExciterSize Weight (kg / lbs)

Heat Loss(Watts)*

Airflow Req.(ft3/min)**

Standard OutlineDwg.

1000 A 1996/4400 5,000 2500 151X1207AA1SA01

2000 A 2535 /5,600 10,000 2500 151X1207AA1SA01

*Two PCMs per cabinet, one active in warm backup configuration.**Airflow throughput requirements for proper cooling.

Figure 3-3. EX2100 Lineup Length and Door Opening Dimensions


Figure 3-4. EX2100 Width, Height, and Clearance Dimensions


Securing the Exciter Lineup to the FloorThe exciter lineup must be secured to the floor using mounting studs. Figure 3-5shows the location of mounting holes in the exciter base. Refer to the exciter outlinedrawing sheet 1 for additional information about securing the lineup.

Figure 3-5. Location of Mounting Base Holes for Securing Exciter to Floor

GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections � 4-1

Chapter 4 Cabling andConnections

IntroductionThis chapter assumes thatcabling was previously run tothe installation site and isready for connection to theexciter.

This chapter contains guidelines for connecting cable to the exciter duringinstallation. This information must be used along with the project specificelementary diagrams and outline diagrams supplied with the equipment.

Do not assume any cable or any circuitry to be without powerif one end of that cable could be connected to a power source.To prevent accidental electrical shock, do not touch anycircuitry or bare wire without first ensuring that it does notcarry electricity.

When testing for the presence of electricity and whenmeasuring any electrical circuit, use only the equipmentapproved for contact with those voltage levels.

All installations should meet the requirements of both the National Electrical Code®(NEC®) and any applicable local codes. Use these codes to determine such factors aswire size, insulation type, and conduit sizing. This chapter is organized as follows:

Section Page

Exciter Connections..................................................................................................4-2Grounding and Cable Entry......................................................................................4-6

Cable Entry........................................................................................................4-6Control Power...........................................................................................................4-9Converter Power.....................................................................................................4-10Field Flashing (Optional)........................................................................................4-11Generator Field Connections ..................................................................................4-11Signal and Communications Cabling Guidelines ...................................................4-11

Generator PT and CT Inputs............................................................................4-11Contact Inputs .................................................................................................4-12Data Highway..................................................................................................4-15PC Interface.....................................................................................................4-16

Preventing Cable Damage ......................................................................................4-16

4-2 � Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631

Exciter ConnectionsCabling and wiring connections to the exciter include the following:� One cabinet ground� Incoming ac control power (terminals on the Exciter Power Distribution

Module)� Incoming dc control power (terminals on the Exciter Power Distribution

Module)� Incoming ac power to the Power Conversion Cabinet.� Power for field flashing (terminals in the Auxiliary cabinet)� Dc outgoing power connections to the generator field (Field+, Field�)� Exciter I/O connections to terminal boards (contact inputs to ECTB board)

Note The component nomenclature examples (see Figures 4-1, 4-2, and 4-3) showthe location of connection points, fuses, and other exciter components. A devicenomenclature sticker, located on the inside of the exciter cabinet door identifies theexciter’s major components and their locations within the cabinet.

Complete outline diagrams are supplied with the exciter.

The exciter User’s Guide,GEH-6632, describes theterminal board I/O.

Customer cabling to the exciter’s terminal boards must comply with level-separationguidelines (refer to Appendix B) after it enters the exciter cabinet. To meet CEMark requirements, all I/O wires leaving a building must be routed insidecontinuous metal conduit.


Figure 4-1. Sample Component Layout, Exciter Control Cabinet

Space Heater 1(optional)

Cutout for CustomerConnections

DACA 1 (DACA2 optional)

Power Supply Rack

TB1

ECTB Wiring(Refer to elementary sheet

7A and 11A for details)

Breaker 3120 V ac, 5 A

Breaker 1, 2120 V ac, 15 A

CT2

CT1(optional) PT2

PT1

EPCT

ECTB

Cutout for CustomerConnections

EXHS/EXTB

Control Rack

Ethernet Link to ACLA(Refer to elementary sheet 8Aand 11A for details)

EPDM(FU1 – FU12 on EPDM,

refer to elementary sheet7A and 11A for details)


Figure 4-2. Sample Component Layout, Exciter Auxiliary Cabinet

Ac Line Filter

LFU2 (optional), FU1 – FU3

LFU1, FU1 – FU3

EACF

Ac input from PPTPhase A – Front ShuntPhase B – Middle ShuntPhase C – Rear Shunt

Ground Lug

Dc Field Flashing (optional)

FF, FU1 and FU2

Space Heater 2 (optional)

(optional) PTB1125 V dc, 15% AFNL

De-excitation Module

(optional) EDCF - C

(optional) EDCF – M2

EDCF – M1

EXAM

Shaft Voltage Suppressor


Figure 4-3. Sample Component Layout, Exciter Power Conversion Cabinet

Dc Bus Connections(optional)

Ground Lug

Dc Contactors 41A, 41B(optional)

Ac Disconnect(less than 600 V ac

applications only)

Ground Lug

Ac Input Connections(optional)

Dc Bus Connnections

Fans 4 – 6(optional)

Fans 1 – 3

EGPA M1

EGPA M2

Drip Shield (optional)

Bridge 2Bridge 1

Thermal Sensors


Grounding and Cable EntryFor both safety and proper functioning of the equipment, it is important that theexciter be properly grounded. The installation site must have a reliable buildinggrounding system and the exciter’s grounding cable must be securely fastened to thissystem per the elementary diagram. Follow the procedures provided in the EX2100requisition elementary diagram sheet 0D, Grounding Instructions. Completeinstructions, recommended cable sizes, and diagrams are provided there.

Note If you have an engineered system, consult your requisition elementarydrawings for the grounding method recommended for your installation.

For shielded and twisted wire, ground the shields on one end only, preferably at theexciter end. Provisions have been made to tie shields to chassis ground on severalexciter terminal boards.

Cable EntrySee EX2100 outline drawingsfor complete information.

Removable access panels for cable entry are provided in the top and bottom of thecontrol cabinet, the bottom of the auxiliary cabinet, and the bottom of the converterportion of the power conversion cabinet. Refer to Figures 4-4 through 4-6 for thelocation of these panels. Refer to Figures 4-7 and 4-8 for connection point locations.

Figure 4-4. Control Cabinet Cable Entries

Figure 4-5. Auxiliary Cabinet Cable Entry


Figure 4-6. Converter Cable Entry (Power Conversion Cabinet)

Figure 4-7. Auxiliary Cabinet Power Connection Points

Standard Ac Connections

Ground Bus

Optional AcConnections

Wire Entry Bottom


Figure 4-8. Power Conversion Cabinet Power Connection Points

Ground Bus Optional Ac ConnectionsDoor


Control PowerThe exciter requisitiondrawings specify the powerrequirements for theapplication and showconnection points.

The exciter control power requirements are as follows:Voltage: Nominal 115 V ac, �15% at 60 Hz; single phase, 10 A rms max Nominal 125 V dc from battery, 10.6 A dc maxNominal line frequency: 50 or 60 Hz, �2%

The ac to dc converter(s)(DACA) are mounted at thebottom of the control cabinet.

The Exciter Power Distribution Module (EPDM) produces 125 V dc for the controlpower modules. It is located on the side of the power supply module. Redundantpower sources for the control modules ensure high supply reliability. Both ac and dcsources are wired to TB1 on the EPDM, refer to Figure 4-9. A second ac source andDACA can be used if required.

J91

3

12

12

12

12

12

12

12

1 10

3 12

JDACA2

JDACA1

1 10

3 12

J8A

J8B

J8C

J1M1

J1M2

J1C

SW3

SW1

SW2

SW4

SW5

SW6

SW7 SPRE

P125Vdc2468

1012141618202224

x

x

x

x

x

x

x

x

x

x

x

x

x

13579

11131517192123

x

x

x

x

x

x

x

x

x

x

x

x

x

TB1

P125VdcP125Vdc

R125VdcR125Vdc

R125Vdc

AC1HAC1HAC1NAC1NAC2HAC2HAC2N

AC2N

125 V dcfrom battery

115 V acsupply #1

115 V acsupply #2

EPDM Exciter Power Distribution Module

Figure 4-9. Control Power Input Connections to Power Distribution Module

The EPDM outputs feed 125 V dc to the three exciter power supply modules(EPSMs), and the EGPA and EXTB OR EXHS boards. Individual outputs are fusedand can be isolated with a switch.


Converter PowerThe main ac power supply for the exciter can come from a potential source, acompound source, or an auxiliary bus. Figure 4-10 shows supply from a powerpotential transformer (PPT) connected to the generator output.

Exciter Power Conversion Cabinet

To Bridge 1and LineFilters

H3

H2

H1

X3X2

X1

PPTPR

I VAC

: 12

470

SEC

VAC

: 65

0

KVA

128

0

L3L2

L1

K3K2

K1

41AC1

1

2

3Phase Rotation

Figure 4-10. Power Potential Transformer Connections

Power is brought into the power conversion cabinet on either cables or a bus.Specification of this supply is the responsibility of the user or his engineeringcompany. If help is needed contact:

“+” indicates theinternational access coderequired when calling fromoutside the USA.

GE Industrial SystemsProduct Service Engineering1501 Roanoke Blvd.Salem, VA 24153-6492 USA

Phone: + 1 888 GE4 SERV (888 434 7378, United States)+ 1 540 378 3280 (International)

Fax: + 1 540 387 8606 (All)


Field Flashing (Optional)Figure 4-11 shows the optional Field Flashing Module noting the locations of thestation battery terminals and fuses FU1 and FU2. Other connections to the moduleinclude status contacts from the EXHS board. Power output goes to the generatorfield. Refer to the elementary diagram sheet 4A for additional information.

Figure 4-11. Field Flashing Module

Generator Field ConnectionsThe external generator field connections must be meet all applicable codes andcomply with the generator manufacturer’s guidelines. Connecting cables must besized properly and insulated per IEEE 421-3 guidelines.

Signal and Communications Cabling Guidelines� Be sure to strictly follow the cable manufacturer’s installation instructions.

These will vary based on the type of installation required.� To meet CE Mark requirements, all I/O wires leaving a building must be

routed inside continuous metal conduit.

Generator PT and CT InputsThe generator PTs and CTs are customer supplied. The connections to the switchesin the control cabinet are shown in Figure 4-12.

Note Connections on the CTs can be either 1 amp or 5 amp. Refer to the elementarydiagram for specifics.


53

1

64

2

31

42

31

42

PTSW1H

3H

2H

1

X3X2

X1

PT1

PRI V

AC :

1440

0SE

C V

AC :

120

(OPE

N

OR

GR

OU

ND

ED Y

)

53

1

64

2

PTSW2

H3

H2

H1

X3X2

X1

PT2

PRI V

AC :

1440

0SE

C V

AC :

120

(OPE

N

OR

GR

OU

ND

ED Y

)

CTSW3

CTSW1

-

Supplied by Others

To Bridge 1

Generator Field +

Generator Field -

PT

CT

PT

PT

PT

CT

EPCT

5H

5L1H

1L

5H

5L1H

1L

X1

X2

X1

X2

Phase Rotation

+

Fan-

out c

ircui

ts

J305

J308

J315

ToEMIO(M1)

ToEMIO(M2)

ToEMIO(C)

Exciter Control cabinet

13

57

911

1315

24

68

1012

1416

1719

2123

1820

2224

TB1

43

21

TB2

43

21TB3

1

2

3

CT

CT

Figure 4-12. Typical PT and CT Connections to Switches in Power Conversion Cabinet

The cable length between the PT and the EPCT board can be up to 1000 ft (305meters) of #12 AWG twisted shielded wire. The cable length between the CT and theEPCT board can be up to 1000 ft (305 meters), using up to #10 AWG wire.

Contact InputsThe ECTB board provides terminals for contact inputs from the customer's devices.Six auxiliary contact inputs, and contact inputs from 52G and 86G areaccommodated. These contacts are wetted with 70 V dc from ECTB. See Figures 4-13 and 4-14 for ECTB layout diagrams. For specific terminal information, refer toGEI-100457.


Four General Purpose Relay Outputs as

CustomerPower toContacts

125 V dc

Two Trip Relay Outputs as

P24M1CustomerPower toContacts125 V dc

(1 of 2)

CoilK#M1

RelayDriver

M1

M1

J405

AuxiliaryContactInputs

Six Circuits as Above

86GContact

52GContact

P70Vdc

Current Limit

Red LED

P70Vdc

Current Limit

Red LED

From M1(EMIO)

P70Vdc

P70 V dc

CoilK#GP

RelayDriver

P24D

From M1J13M1

NO

COM

NC

P24M1

ECTBG2 (Simplex)TB1

TB2

Current LimitTo Optocoupler on M1 (EMIO)

P24D 18

19

20

1

5

33

34

45

46

47

48(Openfor Trip)

(Closedonline)

Term. 1&5Ex. trip toCustomer 86

(1 of 6)

Figure 4-13. ECTBG2 Terminal Board, Simplex


Four General Purpose Relay Outputs as


125 V dc

Two Trip Relay Outputs as

P24M1


125 V dc

CoilK#M2

RelayDriver

CoilK#M1

RelayDriver

CoilK#C

RelayDriver

M1 M2

CM2

C M1

P24M2

P24C

J405

J408

J415

M1

M2

C

From M2(EMIO)

From C(EMIO)

AuxiliaryContactInputs

Six Circuits as Above

86GContact

52GContact

P70Vdc

Current Limit

Red LED

P70Vdc

Current Limit

Red LED

M1M2C

From M1(EMIO)

Current Limit

P70Vdc

Current Limit

Current Limit

To M1 (EMIO)

To M2 (EMIO)

To C (EMIO)

From M2J13M2

P70 V dc

P70M2

P24DP24M1

P24M2

CoilK#GP

VotedRelayDriver

P24D

From M1J13M1

P70M1

NO

COM

NC

P24M1

P24M2

ECTBG1 (Redundant)TB1

TB2

18

19

20

1

5

33

34

45

47

46

48

Term. 1&5Ex. Trip toCustomer 86

(Closedonline)

(Openfor Trip)

(1 of 6)

Figure 4-14. ECTBG1 Terminal Board, Redundant


Data HighwayA typical exciter connection to the redundant Unit Data Highway (UDH) network isshown in Figure 4-15. This shows redundant control with two ACLA modules,(simplex control has one ACLA with one UDH). The UDH is implemented usingcommercially available fast Ethernet switches. 10Base-T cabling is used for shortdistances between the controller and the T-Switch, and any local HMI. 100Base-FXfiber-optic cabling is used for longer distances between the local control area and thecentral control room.

Ethernet Port,RJ-45

ENET

CO

M21

STATUS

ACLAH1A

gGE IndustrialSystems

ENET

CO

M21

STATUS

ACLAH1A

gGE IndustrialSystems

From other Units From other Units

From other Controllers From other Controllers

T-Switch BT-Switch A

100Base-FXconnections

Local Control Area

To local HMIViewer,10Base-T

10Base-Tconnections

Exciter ControlCabinet

Central Control Room

FastEthernetSwitch A

FastEthernetSwitch B

Figure 4-15. Ethernet Cable Connections

The 10Base-T ports in the ACLA and the T-Switch use RJ-45 connectors. Themaximum distance using unshielded twisted pair cable is 328 ft (100 meters).

The 100Base-FX ports in the T-Switch and the Fast Ethernet Switch are for SC typefiber-optic connectors. The maximum distance using 100Base-FX fiber-optic cablesis 2 km.


PC InterfaceControl program downloadsare usually made from a PC onthe UDH Unit Data Highwayusing the toolbox software.

A PC can be connected to the controller to download firmware into the DSPX board.The PC connects to J303B (M1 Tool) located on the control rack backplane. In aredundant system, connectors J310B or J313B can be used for accessing the DSPXboard in M2 or C.

Note The PC-to-exciter cable is not provided with the exciter and must be orderedseparately. Part numbers are:

336A3582P1 COM1 to EX2100 backplane or keypad 9-pin D connector336A4929G1 COM1 to EX2100 ACLA serial port 9-pin micro D connector

Preventing Cable Damage� Be sure to comply with OSHA and other applicable regulations.� Observe minimum installation temperature to avoid damage to shielding and

insulation.� Do not pull cables around corners with sharp edges or corners that prohibit the

minimum allowable cable-pulling radius.� Avoid high mechanical stress (pull tension). The cable should not be excessively

twisted, stretched, or flexed.� Before pulling cable, inspect all cable trays. Cable should only be pulled into

clean trays. Install bushings and dropouts, as necessary.� Make sure that cable ends are sealed before, during, and after pulling the cable.

This prevents the entrance of water or other contaminants.

GEH-6631 Installation and Startup Guide Chapter 5 Pre-Power On Installation Checks � 5-1

Chapter 5 Pre-Power OnInstallation Checks

IntroductionThis chapter must becompleted before applyingpower to the excitationsystem.

This chapter contains instructions to verify that the EX2100 lineup is ready for initialpower up. This includes checks and procedures to ensure that the exciter has beeninstalled correctly and can be safely energized.

All instructions must be followed and completed in the orderpresented.

It is good practice to check off each procedure when youcomplete it. For this purpose, this chapter includescheckboxes next to each procedure heading.

This chapter assumes that the excitation lineup and connected devices have alreadybeen installed, and that all wiring and cabling are installed correctly includingcontrol and power connections. It is presented as follows:

Section Page

Equipment/Material Needed.....................................................................................5-2Securing the Equipment for Safety...........................................................................5-2Hardware Checks......................................................................................................5-3Optional Megger Test...............................................................................................5-5

Pre-Test Power Checks .....................................................................................5-5Ac Input Bus and PPT Secondary .....................................................................5-5Dc Output Bus...................................................................................................5-6

5-2 � Chapter 5 Pre-Power On Installation Checks EX2100 Installation and Startup GEH-6631

Equipment/Material NeededCheckboxes should be markedto verify that equipment isonhand.

Check that the following equipment and materials are available for the procedures inthis chapter. � Locks and tags, danger and caution tape� Source of low-pressure, compressed, dry air (less than 15 psi) or clean, dry cloth� Small standard (flat-head) screwdriver� Torque wrench� Socket sets, standard and metric� Digital multimeter� One dc megger tester (voltage not to exceed 500 V), optional� EX2100 unit specific Elementary Diagrams.� EX2100 unit specific Outline Drawings.� EX2100 User’s Guide, document GEH-6632� EX2100 Circuit Card GEI Instructions (refer to Appendix D for list)

Securing the Equipment for Safety� All procedures in this section

were completed successfully.1. Lock out and tag out all voltage sources to the exciter. Apply safety grounds per

local rules and regulations.

2. Place appropriate barriers and warnings at the generator brush rigging whiletesting.

3. Verify that the generator collector ring brushes are not installed and/or theexciter generator field leads are disconnected at the EX2100 cabinet.


Hardware Checks� All procedures in this section

were completed successfullyfor:� Control� Auxiliary� Power Conversion

All exciters are factory-tested and operable when shipped to the installation site.However, connections could loosen during shipping and handling. To help ensuresuccessful startup, check the hardware after installation and before initial powerup.

� Check EX2100 hardware as follows1. Become familiar with the exciter one-line on elementary sheet 1A.

2. Make sure that the equipment is secured for safety as required in the previoussection.

3. Using an approved tester for the voltage levels being measured, verify thatpower has not yet been applied to the circuitry.

With power applied, high voltages are present on somecircuitry. To prevent accidental injury, do not touch anycircuitry without first ensuring that it does not carry thesevoltages and is grounded.

When testing for the presence of high voltages and whenmeasuring any electrical circuit, use only the equipmentapproved for contact with those voltage levels.

4. Using either low-pressure, compressed, dry air or a clean, dry rag, remove anydust that may have accumulated in the exciter’s interior.

5. Inspect wiring to ensure that it has not been damaged or frayed duringinstallation. Replace if necessary.

6. Check that all electrical terminal connections are tight.

7. Check that all devices, modules, and boards have not been damaged duringhandling or installation and that they are secure in their mounting connections.

To prevent component damage caused by static electricity,treat all boards and devices with static-sensitive handlingtechniques. Wear a wrist grounding strap when handlingboards or components, but only after boards or componentshave been removed from potentially energized equipmentand are at a normally grounded workstation.

Note To ensure that electrical connections remain tight, re-check them within threeto six months after initial powerup, and annually thereafter. Use screwdrivers andtorque wrenches for these checks.

8. Check that the correct shunt has been installed and that the shunt cables areinstalled correctly. (Refer to the elementary data sheet 0E.)

9. Check fusing in the excitation cabinet. (Refer to the elementary sheet 0E or tothe nomenclature sticker located inside the excitation cabinet door).

10. Verify that all control power switches on the Power Distribution Module are inthe off or open position. All power disconnects and circuit breakers should beopen.


11. Verify that the circuit cards listed on the EX2100 elementary data sheet 0E havecorrect settings for hardware jumpers. Location of hardware jumpers can befound using the appropriate card GEI (refer to Appendix D for list).

12. Check incoming wiring/cabling, as follows:� It should be complete and agree with the elementary drawings supplied with

the EX2100.� It should conform to the cable separation guidelines defined in Appendix B.

13. Verify that the cabinet is properly grounded. Reference elementary sheet 0D.

14. Operate each magnetic device by hand to make sure that all moving partsoperate freely. Check all electrical interlocks for proper operation.

15. Verify that the incoming and outgoing buses are not grounded. To do this:� Either use an ohmmeter to measure all buses connected to the exciter to

ground to ensure insulation integrity,� Or perform the optional megger test (refer to the following section).


Optional Megger TestA megger (megohm meter)measures resistance byplacing voltage across adevice with respect to ground.

This optional test verifies that the system-to-ground insulation has not been damagedduring installation. All EX2100 lineups have been high potential tested prior toshipment. It is recommended that the EX2100 be disconnected from all bus or cablesto be megger checked.

To prevent circuit damage:� The megger voltage should not exceed 500 V dc.� Do not use ac meggers for this procedure.

Pre-Test Power Checks

With power applied, dangerous voltages are present on somecircuitry. To prevent accidental injury, do not touch anycircuitry without first ensuring that it does not carry thesevoltages and is grounded.

� Before conducting the megger test on any component, check for thepresence of power on the circuitry, as follows

1. Check that the ac bridge power, PPT primary power, and all sources of controlpower have been locked out and tagged out.

The exciter outline drawingshows location of fuses,disconnects, and othercomponents within theexcitation cabinet.

2. Open all the control power inputs and AC input disconnect (circuit breaker orswitch) in the power conversion module.

Note There could be multiple sources of power in the enclosure.

3. Remove all collector ring brushes from the generator brush rigging. Placeappropriate barriers and warnings at the brush rigging while testing.

4. Using a voltmeter, check that the bus voltages have discharged to below 1 volton the following circuits.

Use the checkbox to markeach completed measurement.

� PPT input line to line� PPT input line to ground

� Dc output positive to negative� Dc output positive and negative to ground

Ac Input Bus and PPT Secondary� All procedures in Ac Input Bus

and PPT Secondary meggerwere completed successfully.

1. Do not proceed until completing all requirements under Pre-Test Power Checks

2. Short the ac input buses together using jumpers or wire.

3. Connect one side of the megger to one of the buses and the other side to ground.

4. Apply the megger voltage (not exceeding 500 V dc). The reading should begreater than 100 megohms.

5. If readings are low, identify and correct the problem before proceeding.

6. Remove all jumpers or wires from the bus before applying any power.


Dc Output Bus� All procedures in Dc Output

Bus megger section werecompleted successfully.

1. Do not proceed until completing all requirements under Pre-Test Power Checks.

2. Short the dc output buses together using jumpers or wire.

3. Connect one side of the megger to one of the buses and the other side to ground.

4. Apply the megger voltage (not exceeding 500 V dc). The reading should begreater than 100 megohms.

5. If readings are low, identify and correct the problem before proceeding.

6. Remove all jumpers or wires from the bus before applying any power.

GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning � 6-1

Chapter 6 Initial Startup andCommissioning

Introduction. This chapter provides instructions to verify that the EX2100 excitation system is

ready for operation. This includes control power checks, software setup, use of thekeypad and offline and online commissioning guidelines.

This chapter is organized as follows:

Section Page

Before Beginning......................................................................................................6-2Order of Startup.................................................................................................6-2Information Needed...........................................................................................6-2Equipment/Material Needed..............................................................................6-3

Panel Lights, Heaters and Fans.................................................................................6-6Verifying Control Power ..........................................................................................6-8Control Module Processor Start .............................................................................6-12Using the Exciter Configuration Tools...................................................................6-13

Using Toolbox Online Help ............................................................................6-13Starting the Toolbox........................................................................................6-14Open an EX2100 File ......................................................................................6-14Checking Toolbox/EX2100 Pattern Compatibility .........................................6-14Downloading to the EX2100...........................................................................6-14Optional: Upgrading the .ecb File ..................................................................6-15Checking for Correct Firmware and Hardware ...............................................6-15

Checking the Keypad (EDI) ...................................................................................6-16Using the Keypad for Startup and Commissioning .........................................6-16Adjusting Keypad Display Contrast ................................................................6-18

Commissioning the Exciter ....................................................................................6-19Overview of EX2100 Parameters....................................................................6-19Running Simulator Mode ................................................................................6-22Temporary Load Checks .................................................................................6-27Initial Roll and Offline Checks .......................................................................6-30Online Checks .................................................................................................6-52Additional Testing...........................................................................................6-53

6-2 � Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631

Before BeginningBefore beginning the procedures in this chapter, the following conditions must exist:� All pre-startup and installation checks from the previous chapters are completed

successfully.� All interconnecting wires and cables are in place, connected, and ready for

power on.� Power is not yet applied.

For CE Mark Radiated Emissions compliance, one ferritecore (Fair-Rite P/N 2643164251 or equivalent) must beplaced on each Ethernet network cable near the IS200ACLAtermination point. Verify this before applying power to thecontrol rack.

Note The EX2100 meets the following noise level specifications:

FanQuantity

Doors Closed, One Meterfrom Enclosure

Doors Open, Adjacent toEnclosure

Average Maximum Maximum

3 69.9 dBA 71.4 dBA 79.4 dBA

6 75.5 dBA 76.5 dBA 82.2 dBA

User’s Guide, GEH-6632, includes a functional descrip-tion of the EX2100, includinghardware structure.

Order of StartupThe EX2100 Excitation Control can be provided in a variety of ratings and applica-tions. The basic design incorporates a common hardware and software structure,therefore the startup and commissioning procedures are similar for the differentpossible applications.

Whether a simplex or redundant control configuration or single or multiple bridgeconfiguration, each EX2100 should be started and commissioned using the followingbasic guidelines:� Follow the procedures in this chapter in the order presented.� Figure 6-1 is a flowchart for use as a visual guide to the startup and commis-

sioning process once control power has been applied and operation of heaters,lights and fans have been verified.

The order of startup is important.

All instructions must be followed and completed in the orderpresented in this chapter.

Tip � It is good practice to check off each procedure when you complete it. Forthis purpose, this chapter includes checkboxes next to each procedure heading.

Information NeededBefore beginning, you should review the applicable elementary and outline drawingsto become familiar with the type of EX2100 supplied. Make sure you know thepower requirements and location of components, connections, and power switches.


Software for the EX2100 will befound either on the turbinecontrol master HMI or suppliedseparately for stand-alone ex-citation systems.

When commissioning the exciter with the GE Control System Toolbox for the firsttime, each EX2100 will have its own unique software file scaled and tailored for thegenerator applied using a common file extension .ecb for both DSPX and ACLAprocessors. It should be verified that the file to be used is correct and the most up todate available. The software is tested at the factory prior to shipment and shouldrequire a minimum of changes during commissioning.

Checkboxes should be marked toverify that equipment is onhand.

Equipment/Material Needed

Safety Equipment� Appropriate safety gear (may include safety boots, safety glasses, hard-hat, high

voltage gloves, and face shield)� Locks, tags, and danger and caution tape

Typical Test Equipment

When testing for the presence of high voltages and whenmeasuring any electrical circuit, use only the equipmentapproved for contact with those voltage levels.

� Digital multimeters (2)� Oscilloscope� Small standard (flat-head) screwdriver� Socket sets, standard and metric� Flashlight� Small inspection mirror� Fuse puller� Phase rotation meter� Temporary load capable of carrying 3 or more amps and ceiling voltage.� Personal computer (PC) with the GE Control System Toolbox installed and the

appropriate cables. These cables include the following available from GE Sa-lem.336A3582P1 COM1 to EX2100 back plane or keypad 9 pin D connector.336A4929G1 COM1 to EX2100 ACLA serial port 9 pin micro D connector.

Reference Documents� System elementary (required)

Tip � It is good practice to study the elementary before working on the excitationsystem.

� EX2100 outline drawings� EX2100 User’s Guide, GEH-6632� EX2100 Maintenance, Parts Replacement, and Troubleshooting Guide, GEH-

6633� EX2100 GE Control System Toolbox (toolbox) document, GEH-6414

The information contained in the toolbox document GEH-6414 and in the section, Specific Fault Troubleshooting ofGEH-6633 is also available as Help files within the toolboxprogram (refer to Using Toolbox Help in this chapter).


Control Power Applied & Lights

Heaters and Fans Operational

Install ToolboxInstall Drive Components

No

Yes

Start Toolbox

Obtain Configuration FilesFrom HMI or RequisitionEngineering (.ecb for DSPXand ACLA)

No

Yes

Open the EX2100

Configuration Files (.ecb)

(Toolbox Version is

Automatically Verified)

Message: File last saved with

older version toolbox?

Get Old Toolboxor Upgrade the file

Yes

Start

B

1

1a

2

4

Get New Toolbbox

NoMessage:

File last saved withnewer version toolbox

?

Yes

Are EX2100Configuration files

Available?

Is Control SystemToolbox Installed?

4a 4b

No

Refer to sectionsVerifying Control Power andPanel Lights, Heaters, andFans

Refer totoolbox documentGEH-6414 (Chapter 3).

4a and 4bRefer to toolbox documentGEH-6414 (chapter 3).

Yes

3




Figure 6-1. Overview of EX2100 Startup and Commissioning (Part 1 of 2)


Review Release NotesCreate Version Summary

B

EstablishCommunications

with the EX2100

Do EX2100 and Fileversions agree?

Yes

No Is EX2100 newerthan file?

Upgrade File

Yes

Download Flash

(File is newer than EX2100)

No

5

6a

6b

7

6

Check HardwareCheck FirmwareCheck Keypad

8

Perform SimulatorandTemporaryLoad Checks

9

Perform Off and On-lineCommissioning Checks

10

End

5 and 6

and sectionChecking the Keypad (EDI)

Refer to sectionsSimulator andTemporary Load Checks

Refer to sectionsOff-line ChecksandOn-line Checks





6a and 6b

Figure 6-1. Overview of EX2100 Startup and Commissioning (Part 2 of 2)


Panel Lights, Heaters and FansEach EX2100 will have power conversion module cooling fans supplied. Optionalpanel heaters and lights may also be provided. These items should be energizedand operation verified prior to energizing the control power. Refer to the applicablesystem elementary for options provided. Refer to the applicable panel outlinedrawings for location of components.

Refer to Figure 6-1, Block 1and Figure 6-2.

All procedures in this sectionwere completed successfullyfor: � Lights � Heaters � Fans

With power applied, this equipment contains a potentialhazard of electric shock or burn. Only personnel who areadequately trained and thoroughly familiar with the equip-ment and the instructions should install, operate, or maintainthis drive.

To minimize hazard of electrical shock or burn, approvedgrounding practices and procedures must be strictly fol-lowed.

1. Verify all temporary shipping constraints for panel lights have been removed.These may consist of tape or protective wraps.

2. Energize the ac power feed for the panel lights and heaters. Measure the line-to-line voltage of the ac feed for proper voltage as specified on the applicable sys-tem elementary. Verify that the line and neutral connections are consistent withthe system drawings.

3. Turn the ac breaker switch for the panel lights to the on position. Each panellight should turn on.

4. Each heater has been hipot checked at the factory prior to shipping. It is not rec-ommended to megger check heater circuits in the field. Verify that no flamma-ble materials are in contact with the panel heaters.

5. Turn the ac breaker switch for the panel heaters to the on position. Each panelheater should energize. Verify heater operation with an infrared heat detectiondevice or carefully feeling for heat several inches above the heater surface.

The heaters are not used tomaintain a constant tem-perature but to merely keepthe EX2100 above ambienttemperature.

Once energized, panel heaters can be very hot. Keep alldebris and flammable materials from contacting the heatersurfaces. Heater surfaces should never be touched whileenergized.

6. Verify that EGPA board jumper settings for JP1 – JP5 agree with elementarydiagram sheet 0E.

7. Energize the ac power feed for the power conversion module cooling fans.Measure the line-to-line voltage of the ac feed for proper voltage as specified onthe applicable system elementary. Verify that the line and neutral connectionsare consistent with the system drawings.

8. Turn the ac breaker switch for the cooling fans to the ON position and immedi-ately turn back OFF. Visually verify that each fan is turning in a counter clock-wise direction (left to right) when viewed through the fan box window.

9. Repeat steps 6 and 7 for the redundant set of cooling fans if supplied.


J1_M1 J1_M2 J1_C

FANEXTB

EETBEDEX

ECTB

M1

J602

CONTROL

MEDIACONV

EDEX EDCF

EGDM EDEX CROWBAR

FANEXTB

EETBEDEX

ECTB

M2

J602

CONTROL

MEDIACONV

EDEX EDCF

EGDM EDEX CROWBAR

FANEXTB

EETBEDEX

ECTB

C

J602

CONTROL

MEDIACONV

EDEX EDCF

EGDM EDEX CROWBAR

J2C GROUNDDETECT

EPSMPowerSupply

M1

EGDMGroundDetector

M1

Blankplate

Fan Fan Fan

Power to Control Module

To M1 To M2 To C

EPSMPowerSupply

M2

EPSMPowerSupply

C

EGDMGroundDetector

M2

EGDMGroundDetector

C

To J1CTo J1M2

To J1M1

EPDM Exciter PowerDistribution Module

125 V dc115 V acSupplies

J91

3

12

12

12

12

12

12

1 10

3 12JDACA2

JDACA11 10

3 12

J8A

J8B

J8C

J1M1

J1M2

J1C

SW3

SW1

SW2

SW4

SW5

SW6

24681012141618202224

x

x

x

x

x

x

x

x

x

x

x

x

x

1357911131517192123

x

x

x

x

x

x

x

x

x

x

xx

x

TB1

PCMFans

PCMFans

PCMFans

Heaters

Breakers

Figure 6-2. Front View of Power Supply Module


Verifying Control PowerRefer to Figure 6-1, Block 1and Figures 6-2, 6-3, and 6-4.

All procedures in this sectionwere completed successfullyfor: � Master 1 � Master 2 � Control

Refer to the Power Supply section of the system elementary and GEI-100463 for anoverview of the EX2100’s control power circuitry.

With power applied, this equipment contains a potentialhazard of electric shock or burn. Only personnel who areadequately trained and thoroughly familiar with the equip-ment and the instructions should install, operate, or maintainthis exciter.

To minimize hazard of electrical shock or burn, approvedgrounding practices and procedures must be strictly fol-lowed.

1. Before energizing the power supply inputs, verify that all toggle switches on theEPDM are in the OFF position. Disconnect the DACA1 and DACA2 plugjumpers JDACA1 and JDACA2, also found on the EPDM (see Figure 6-3).

2. Remove plug J9 from the EXTB or EXHS board.

3. Apply the source 120 V ac power for the DACA1 module and measure the line-to-line voltage on pins 1 and 3 of the JDACA1 plug. Remove the 120 V acsource power for the DACA modules.

4. Reconnect the JDACA1 plug and re-apply the 120 V ac source power. Measurethe voltage at FU1 and FU2 for a nominal 125 V dc to the EPDM distributionswitches.

5. Remove the 120 V ac DACA source power and repeat steps 3 and 4 for the sec-ond DACA module if supplied. Remove 120 V ac source power for the DACAmodules.

6. Apply the 125 V dc control power source as shown on the elementary powersupply sheets. Again measure the voltage at FU1 and FU2 for a nominal 125 vdcto the EPDM distribution switches.

7. Remove the 125 V dc power and plug connector J9 on the EXTB or EXHSboard back in.

8. Apply 125 V dc power to the EPDM. This will apply power to the EXTB orEXHS board. There are no external indications of power to this board. Relayoperation will be verified at a later time.

9. Close SW8A on the EPDM. This will apply power to the EGPA card in the pri-mary power converter. Verify that the EGPA1 PSOK green LED is on (see Fig-ure 6-4).

10. Close SW8B on the EPDM. This will apply power to the EGPA card in thebackup power converter. Verify that the EGPA2 PSOK green LED is on.

11. The EPSM power supplies are unstable when not loaded. It is not possible tocheck power supply voltages without having the cards in the EBKP control rackinserted in their proper position. These supplies are tested and verified at thefactory during card test and system test prior to shipping.


Fuse DataTable

IS200EPDMG1AE3 E4

E1

E2

CHASGND

CHASGND1

SFTYGND

TB1

FU1

FU2

FU4

FU3

FU6

FU5

FU8

FU7

FU10

FU9

FU12

FU13

FU14

FU11

SW7

SW6

SW5

SW4

SW3

SW2

SW1

SPARE

SW1C

SW1M2

SW1M1

SW8C

SW8B

SW8A

JDCA1

JDCA2

J9

J8A

J8B

J8C

J1M1

J1M2

J1C

SPARE

DS1

DS2

DS3

DS5

DS6

DS7

DS8

DS4

PS1C

PS1M

2PS

1M1

PS8C

PS8B

PS8A

PS9

Figure 6-3. EPDM Board Layout


PSOK

DC Power Source130 V dc (nominal)80 - 140 V dc

Disable coolant tripRTD Coolant Temp

Fan Rotation Sensor 1

Klixon (T=170F, Alarm)

Klixon (T=190F, Fault)

Line Filter Sensor

ALARM

FAULT

6X GatesFan Rotation Sensor 2

TPxx TPxx

TPxx TPxx

Figure 6-4. EGPA Board LED Locations

Carefully follow the procedures documented in the circuitboard instruction manuals for inserting the boards into thecontrol rack.

12. Insert all circuit boards in the exciter backplane control rack for M1, M2 and C(see Figure 6-5).

13. The EPSM cooling fan for each module energized should be operating when theEPSM is energized. Verify counter-clockwise rotation of each fan.

14. One at a time, close EPDM switches SW1M1, SW1M2, and SW1C. This willapply power to the M1, M2 and C control circuit boards in the control rack.These include the ACLA, DSPX, EISB, EMIO, and ESEL boards as well as thecontrol rack fans located above these boards. Each board has a power statusgreen LED that will illuminate indicating power is applied. The DSPX andACLA will also begin an initialization process.


ACLADSPX

EMIO ESEL ESEL EMIO

ACLA

EISB EISB EMIOEISB

DSPX

ENET

COM

21

OKACTIVEENETFLASH

RST

STATUS

ENET

COM

21

OKACTIVEENETFLASH

RST

STATUS

Fan Fan

DSPX ACLA

M1 Boards M2 Boards C Boards

Figure 6-5. Exciter Backplane Control Rack Boards (Front View)


Control Module Processor StartRefer to Figures 6-5, 6-6, and6-7.

All procedures in this sectionwere completed successfullyfor:� Master 1 � ACLA � DSPX� Master 2 � ACLA � DSPX� Control � DSPX

Verify the that the DSPX processor board, located in the control rack, has startedcorrectly, as follows:

1. The DSPX should boot-up with the following LED indications:� Green status LED steady on or blinking� Red fault LED blinking indicating an alarm status or off (solid red indicates

a fault condition)

2. The ACLA should boot-up with the following LED indications:� Green OK LED steady on� Green ACTIVE LED steady on� Green ENET LED blinking if the Ethernet communications are connected

and active. Off, if no Ethernet communications are enabled.� Green Status LEDs will be alternating in a clockwise progression.

3. For the other boards in the rack, check that the green power LEDs are steady onand the green status LEDs are steady on for the active master.

DSPXH1A

STATUS

FAULT

EMUL

HS

SERIAL

PORT

g GE Motors &Industrial Systems

Figure 6-6. DSPX Faceplate

ENET

CO

M21

OKACTIVEENETFLASH

RST

STATUS

g GE Motors &Industrial Systems

ACLAH1A

Figure 6-7. ACLA Faceplate


Using the Exciter Configuration ToolsGE document GEH-6414describes the EX2100 toolboxinstallation and use.

The GE Control System Toolbox is a Microsoft® Windows®-based, configurationprogram used to tune and commission the exciter as needed for each application. Thetoolbox is designed with menus, block diagrams, dialog boxes, and wizards thatsimplify and guide you through the startup and commissioning process.

For detailed information, you should refer to either the toolbox online Help or theproduct documents listed in the Tools/Materials Needed section.

Using Toolbox Online Help

Tip � It is good practice to refer to the toolbox Help for any part of toolbox opera-tion or menu and dialog options that you do not fully understand. You can access theHelp files at any time after the toolbox is installed on your PC.

The toolbox Help feature provides detailed information about using the toolbox. Thisincludes installation and operation, as well as drive configuration instructions. Thereare several ways to access Help while running the toolbox.

For Do this Menu commands Highlight the command and press function key F1.

Dialog boxes Press F1 when the dialog box displays on the screen.

Block information Click on the desired block with the right mouse buttonand choose Item Help.

Help contents Choose Help then Contents.

Help Choose Help then Using Help.

Specific word(s) Choose Help then Contents and Find. From there,enter the word(s) you want to find.

When you choose Help on the toolbox main menu bar, a drop-down menu providesseveral options for finding information.

Contents displays Help files for the toolbox. It also contains the Find tab with awork list to search for specific topics.

Using Help displays general instructions on how to use Help.

Item Help displays help for the item selected in the Outline View.

Product Help displays the Help file for the currently loaded product. The filecontains help on parameters, faults, diagrams, and wizards.

Release Notes provides product changes in the toolbox.

Send Problem Report allows you to submit a system change request for the tool-box.


Goto Toolbox Web Site takes you to the toolbox home page. (This feature is onlyavailable if you have a connection to the GE intranet.)

About Toolbox… displays the version number of the toolbox.

Refer to Figure 6-1, Block 2.


GE provides the toolbox on theControl System Solutions CD.Software files will be availableon the Turbine HMI or suppliedseparately.

Starting the ToolboxThe remaining procedures in this chapter require that you use the toolbox and theEX2100 toolbox document, GEH-6414 Chapter 3. Instructions for performing theprocedures are located there.


All procedures in this sectionwere completed successfully for:� Master 1 � ACLA � DSPX� Master 2 � ACLA � DSPX� Control � DSPX

Open an EX2100 FileTo download exciter software with the toolbox, you must open the exciter configu-ration (.ecb) file for all three controls, M1, M2 and C. All EX2100 exciters are pre-engineered and this file should be available on the turbine control HMI or a softwareCD supplied with the excitation equipment. Refer to GEH-6414, Chapter 3.

Refer to Figure 6-1, Blocks 5and 6.

All procedures in this sectionwere completed successfullyfor:� Master 1� Master 2� Control

Checking Toolbox/EX2100 Pattern CompatibilityThe firmware pattern used to create the .ecb file must be the same version as thepattern loaded in the exciter (the ACLA and DSPX boards). If it is not, then eitherthe flash code (which contains the pattern version) must be downloaded from thetoolbox to the controls, or the .ecb file must be upgraded. Refer to GEH-6414,Chapter 3.

Note The toolbox requires the pattern directory to be located under the exact struc-ture of GE Control System Solutions / EX2100. If this exact directory structureis not present, you must correct it.

Refer to Figure 6-1, Block 6A. Downloading to the EX2100Refer to GEH-6414, Chapter 3 to download the firmware pattern from the toolbox tothe EX2100.


Refer to Figure 6-1, Block 6B.

All procedures in this sectionwere completed successfullyfor:� Master 1� Master 2� Control

Optional: Upgrading the .ecb FileAssociated with the firmware version in the drive are parameters that vary, depend-ing on each application. These parameters are stored in the .ecb file.

Tip � .ecb files are typically stored in a project directory. To establish the defaultdirectory from the toolbox, select Options, Settings, and the tab Directories.Then from the Default Project text box, select the browse button to find (for exam-ple) C:\Jobs\GESalem\JobName\CTRL.ecb.

The revision of the firmware used to create the .ecb file must be the same as thefirmware revision loaded into the DSPX and ACLA. To achieve this, it may be nec-essary to upgrade the .ecb file to a more recent version. The toolbox can automati-cally upgrade older .ecb files to newer revisions. Refer to GEH-6414, Chapter 3.

Note If the version required does not appear, it needs to be installed from theControl System Solutions CD.



Checking for Correct Firmware and HardwareTypically, firmware and hardware revisions are backward compatible with olderrevisions. However, occasionally the firmware depends upon a minimum revision ofhardware. The release notes (RelNotes.txt, provided with the toolbox files), providean overview of the EX2100 hardware and software relationship. Refer to GEH-6414,Chapter 3.


Checking the Keypad (EDI)Refer to Figure 6-1, Block 8.

All procedures in this sectionwere completed successfullyfor: � Master 1 � Master 2.

The two operator interfaces located on the control cabinet front door are the EX2100Diagnostic Interface modules (EDI, most commonly called keypad). Facing thekeypads (with the door closed), the left side keypad is used to interface with Master1 and the right side with Master 2. Both keypads can access data and parameters forControl.

1. Observe that each display’s heartbeat icon is pulsing (see Figure 6-8). Thisindicates that the keypads can communicate with the EX2100. (The cable fromthe keypads connects to the rack’s J303A and J310A connectors.)

Note If the keypad’s display cannot be read or contrast is poor, refer to AdjustingKeypad Display Contrast in the following section before proceeding to step 2.

2. If faults are present, use toolbox Help (select Help, Product Help, Contents,Faults) or EX2100 Troubleshooting, Preventative and Online MaintenanceGuide (listed in Equipment/Material Needed in this chapter) for information.

The keypad and toolbox screens presented in this documentare samples that represent one possible application. Thescreens for your EX2100 should display information that isspecific to your configuration and application.

Using the Keypad for Startup and CommissioningThe keypad can be used to check firmware and hardware versions, run the exciter,set parameters, reset the EX2100, and provide many other functions to control theexciter. This information is provided in the EX2100 User’s Guide GEH-6632.

Exciter Health& State Icons

Run (Green)

Stop (Red)

ResetFaults

CommandMenu

Voltage Level

Exciter Control

Status

Menu

Escape

Navigation

FVR Feedback 0.0 Volts

FldCurrAmps 0.00 Amps

EX2100 ExcitationC

g

-30% 0% 150%

Auto

Man

On

Off

100%

Vmag

Freq_Hz

Imag Watts

Exciter Pll Vars55.00

0.000.00

60.00

0.00

0.00

-30% 0% 150%100%

Display:

Status Screens provide analogand digital representationof exciter functions andvalues.

MenuScreens provide text-basedaccess to parameters,wizards, and faults.

Pushbuttons:Organized into functional groups:

Navigation

Buttons for using the menu

Exciter Control

Run and Stop buttons

Enter

Figure 6-8. Front View of the Keypad


Adjusting Keypad Display ContrastYou can improve visibility of the keypad display by adjusting the contrast. This canbe done using either the keypad or the toolbox.

� To adjust keypad display contrast using the toolboxYou should not see “Offline” onthe toolbox status bar (bottomright side of screen).

1. Check that the EX2100 is communicating with the PC (the Go on/offline

button is selected).

2. In the toolbox work area, expand the items displayed in the Outline View byclicking on the plus sign next to Main Menu, General Setup, Keypad, andKeypad Meters.

3. Double-click Keypad contrast adj to display the associated Edit Parame-ter dialog box.

4. The dialog box displays the value Range for this parameter. In the Value textbox area, enter a number, then click Send To Drive and OK.

5. Reset the exciter as shown below, which resets the display to the new value.

Toolbox menubar selections.

6. If the display is still not readable, contact GE Product Service (see Chapter 1,How to Get Help).

� To adjust keypad display contrast using the keypadHold the orange MENU button down and press the Up Arrow (�) or Down Arrow(�) navigation buttons to increase or decrease the contrast (see Figure 6-8).


Commissioning the ExciterCommissioning is the final stage of starting up an EX2100 lineup. To complete thefollowing steps, it is assumed that the EX2100 has all connections completed, con-trol power has been applied, software has been loaded and all faults cleared. Duringthis testing, some access to the turbine control HMI will be necessary, but most stepscan be run from the exciter keypad(s).

Typically, the primary power converter module and Master 1 controls are commis-sioned first, then Master 2 and the backup power converter commissioned. The stepsmust be performed in the following order, with each step for both controls completedbefore proceeding to the next phase of commissioning.1. Simulator checks2. Temporary load checks3. Initial roll and offline checks4. Online checks

Overview of EX2100 Parameters

The parameter settings are pre-engineered prior to shippingand should not require adjustment. GE Salem should becontacted prior to any parameter modifications.

Note The procedures in this chapter are based on SAMPLE parameter values. Anyparameter values referenced should not be used for any specific job. If a parametervalue is in doubt, contact GE Salem for clarification.

Application specific data has been entered into the EX2100 parameters found in thetoolbox software files. These parameters provide the data for the application rulesused in the toolbox during the validation and calculation of settings for the EX2100.Occasionally, specific parameter values require changes prior to initial operation ofthe equipment. Any changes to parameters should be saved in the .ecb file by up-loading the parameter values from the EX2100 to the toolbox (refer to Optional:Uploading the .ECB File in this chapter).

To access the block diagrams,select “Diagram” from thetoolbox work area, outlineview.

Parameters may be adjusted individually from the toolbox menus, the block diagram,or the keypad. Changing parameter values while the EX2100 is running is notrecommended, although some parameters, such as diagnostic setups, can be adjustedwith minimal risk while running. In the following paragraphs, parameters will bedesignated with parenthesis (MRNLM) and variables will be designated with carats<MANREF>.

Downloads of EX2100 parameters are performed in two separate steps. Both the ap-plication layer software (ACLA) and the exciter regulator software (DSPX) are sentto the EX2100. The RED and BLUE down arrow icons are used through the toolbox.While individual parameters can be changed while the exciter is running, an entireparameter download to the DSPX processor (using the BLUE down arrow icon) isnot allowed. After a download, the master core will reset which would trip the unit.The toolbox does not allow this to happen and will notify the user that the exciter isnot stopped. (Refer to document GEH-6414, EX2100 Toolbox.)


An entire download of the application layer software, ACLA, (using the RED downarrow icon) is allowed while the exciter is running. For most application layerchanges, this will be benign to the user, but a warning to the user that the exciter isnot stopped is generated by the toolbox when these parameters are sent. It is possibleduring this process that communications with the EX2100 will be temporarily inter-rupted.


Viewing Parameter DifferencesHaving the pattern versions loaded equally into the file and the EX2100 does notmean that the parameters in the toolbox and the EX2100 are equal.

If the parameters in the toolbox are not equal to what is in the exciter, a not equalsign � displays in the Status bar at the bottom of the toolbox window. To display thedifferences, double-click on the not equal sign �. This causes the toolbox to compareits parameter values with those in the EX2100.

Calculate Parameter Final ValuesFinal values are calculated from parameters. These values are present in the EX2100,but are not normally viewable in the toolbox unless they are overwritten. The � signat the bottom of the pattern screen does not include final values. The toolbox indi-cates that overrides exist in the pattern by displaying a red O at the bottom of thescreen.

The toolbox uses the parameter settings that were entered to calculate the parameterfinal values. If parameter final values are overridden, running the toolboxBuild/Calc routine will not update these values.

Privilege levels provide differ-ent types of access to the devices.

Level 4 allows changingparameters and editing hard-ware, and requires a password.

� To view and clear overrides with Level 4 privilege

1. From the toolbox, select the Finder button , then Overrides, andUpdate.

2. Double-click on the item selected.

3. Select Clear then Override.4. Select Device, Reset Drive, Hard Reset.

Overrides are typically not required and should be avoided.


Running Simulator ModeRefer to the Control Systems Toolbox .ecb file Simulator Scaling for representa-tions of the system models and simulator scaling.


All procedures in this sectionwere completed successfullyfor: � Master 1 � Master 2

Operation of some relays may occur in Simulator Mode.Verify that flashing power and ac power to the bridge isremoved or isolated from the generator field and personnelare clear from any moving devices.

The EX2100 contains a built-in simulator that models a generator and staticexcitation system. When simulator mode is selected, the feedbacks presented to thecontrol regulators are switched, by software, from the real feedback inputs tofeedbacks derived by mathematical models mimicking the generator and field circuitbehavior.

The EX2100 controls then react in a manner close to the way they would react innormal operation. The simulator can serve as a valuable startup, maintenance, andtraining tool. While the simulator mode in the EX2100 is a very close approximationof the actual operating look and feel of the exciter, there will be some instability onthe operator displays and EGD page information due to the coordination of dataamong the three controllers. Changes to regulator gains should not be made fromobservations made in simulator mode.

The simulator is scaled to represent the actual system as accurately as possible. Thismeans that when a start command is given to the EX2100, it follows a normal startsequence. Unlike the EX2000, the EX2100 will not generate actual commands toclose field breakers and flashing contactors. Operation of these devices will be testedin the Temporary Load section that follows.

The generator armature and field models, as well as the exciter stator and fieldmodels, provide the feedbacks for exciter field voltage and current, and generatorstator voltage and current. These feedbacks are handled by the transduceringalgorithms the same way real feedbacks are used to calculate watts, vars, speeddeviation, and frequency. If the model scaling is correct, the display data cannot bedistinguished from real data. Main generator field voltages and currents are alsosimulated internally and used for correct model operation.

The exciter regulator can be raised and lowered in automatic or manual regulator,both online and offline. The regulator limits activate at the same levels as in non-simulated operation. The regulator responses provide a good representation of whatcan be expected of the real system in response to step changes.

By changing the parameter containing the value representing model shaft torque it ispossible to raise or lower the simulated generator real power output when simulatingonline operation. The exciter changes the system vars in response to changes in theexciter voltage setpoints.

Block diagrams are accessibleby selecting the EX2100 Over-view diagram and clicking onthe appropriate page button.

In the following procedures, various block diagrams are referenced to allowaccess to parameters and variables for testing. These diagrams can be found inthe .ecb file. The finder function in the toolbox can also be used to locate pa-rameters and variables.


EX2100 Overview

Innovation ControlDevice name: Date:

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16 GE Motors andIndustrial Systems

Salem, Va. USA

PRODUCT:

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A B C D E F G H I J K L M N O P Q R S T U

A B C D E F G H I J K L December 12, 2000saved date:

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Page name:

####

$ StatorSimSimulator: Stator and Saturation Curve

$ Diag_UtilD/A's and General Purpose Filters

$ CaptureCapture Buffer Configuration

$ FlashStartStart Stop Sequencing: Flashed Start

$ AuxBusStart Aux. Bus Start

$ FiringControl SCR Firing Control

$ FieldSim Field Side

$ Keys_StatesAuto/Manual, PT Failure, Run RequestsSimulator Enable, VAR/PF & PSS Enables

$ AlarmStringAlarm and Diagnostic Strings

$ TripString Trip String with enables

$ AlarmsAlarms: Individual functions

$ Trips Trips: Individual functions

DSPX Side

$ GP_In_OutGeneral Purpose Inputs/Outputs (and 52,86)

$ EMIO_DiagFbkEMIO Outputs with Diagnostic Feedbacks

$ VCOAnalog Feedbacks Field Signals, Test A/D's, andBridge Temperatures

Dual Port Memory (DPM)

$ Dpm1DPM Signal Map (pages 1 & 2)

$ DpmBits1DPM Boolean Signals (bits 0-15)

$ DpmBits2DPM Boolean Signals (bits 16-31)

$ Dpm2DPM Signal Map (page 3)

$ EGPA1LogicGate Pule Amplifier Logic: Bridge 1

XY Charts $C.Synchro $C.LOE $C.OEL $C.VHz

$C.Satcurve

$ EGPA2Logic Bridge 2

$ InnerLoopInner Loops: Field voltage and current regulators

$ TransferC3 Logic: Transfer State Machine$ ProtectXfer Out of Bounds protective transfers

$ GenInstrGenerator Stator Side Instruments

$ PTCT_Wiring PT and CT Wiring

$ Problems Problems: Master Asks for a Transfer

$ BodeILInner Loop Bode Analysis

$ CondSenseConduction Sensing (Sensor Failure)

$ FGD_InField Ground Detector: Input Filtering$ FGD_SeqSequencing$ FGD_CalcFault Calc / Freq Component

$ BridgeThermBridge Thermal Alarms and Trips

$ KeyPadKeyPad

Outer Loop Functions

$ AVR $ AutoRef $ EXASP $ MANREF

$ PSS $ VARPF

$ HTSEN $ UELHTC $ UELREG

$ GenRatingsGenerator Ratings

$ VCO_Zero Analog Feedbacks Offset Removal

Figure 6-9. Block Overview Diagram


The Exciter Control Windowanimated bar graph display is

available using the icon

in the .ecb file of the toolbox.

The EX2100 can be controlled from the toolbox by using the animated bar graphdisplay instead of the door-mounted keypads. The keypads can then be used tomonitor variables and I/O states while testing.

Bar Graphs and metersprovide feedback of thecurrent state of the device.

Click + to increase or - todecrease the voltage.

Click On to putthe exciter in therun mode.

Use Off to take theexciter out of runmode.

Click to reset faults.

Auto controls terminalvoltage on thegenerator.

Man controls voltageon the field.

1. Place the EX2100 controls in simulator mode from the Controls Systems Tool-box or local keypad (EDI) by changing (SimMode) to a true state. Once insimulator mode, the exciter simulated speed should begin to increase. This canbe monitored via <Spd_Ref>. Set simulated speed to 100% via (SimSpeedRef).

Note The following procedures do NOT purport to cover all settings of the pa-rameters in the EX2100. These checks are an assurance that the basic control fea-tures of the EX2100 are in place and will control the generator safely prior tooperation with actual field voltage and current.

2. Temporarily jumper the contact input on the ECTB board TB2-47and 48 tosimulate 86G lockout relay reset condition. Verify that <Aux86> is in a truestate. (Keypad menu: GP_In_Out). Removal of the jumper should toggle thevariable to a False state. Replace the jumper so that <Aux86> is true.

3. Verify the Master 1 and Master 2 controls are in automatic regulator mode byselecting Auto on the operator keypad (Figure 6-5). <ASP_AA> will be true.

4. Start the excitation in simulator mode by selecting the (1) on the operatorkeypad. Simulated terminal voltage, field voltage, and field current should buildto rated no-load values.

An upper case M1 or M2 in thekeypad display indicates theactive master. Lower case m1or m2 indicates backup.

Only the active master can effect changes to the EX2100. Control must betransferred to the backup master through the keypad menu before the backupmaster keypad will raise/lower, toggle from auto to manual, or start/stop theexciter.


V/HZ Limit Verification1. With the unit at rated terminal voltage, decrease (SimSpeedRef) to zero so that

turbine speed will begin to decrease. At the appropriate value set by (ASPVHZ),terminal voltage will begin to decrease and the V/HZ Limit Active alarm willannunciate when <ASPVHZA> is true.

2. Return the simulated torque to the preset value and terminal voltage will beginto increase. At the (ASPVHZ) value, terminal voltage will stop increasing andthe V/HZ Limit Active alarm <ASPVHZA> will clear.

Lockout Trip Verification1. Remove the contact jumper on ECTB board TB1-47 and 48 for 86G lockout

simulation.

2. Verify that the exciter stops immediately.

3. Replace contact jumper, clear any alarms or faults and restart the exciter.

AVR Preset VerificationWhen the exciter is restarted, if the simulator is at 100% turbine speed, the automaticregulator will build terminal voltage to the preset generator rated terminal voltage,(AR_ZV).

PT Failure Detection VerificationThe PT failure function will only operate when the 52G input contact is open if theexciter controls are using two sets of PT inputs for the detection or the exciter PPT isfed directly from the generator terminals instead of an auxiliary bus. If there is onlyone set of PT inputs, and the PPT is fed from an auxiliary bus, then this test can onlybe performed when the unit is online.

1. Using the PT failure picks on the GenInstr.vsd software function screen, per-form the PT failure simulation. This should activate the PTUV detection as wellas transfer the controls from automatic to manual regulator.

2. De-activate the PT failure, Reset the PT failure alarms from the keypad com-mand menu, and then transfer the exciter back to automatic regulator.

Note It should not be possible to select automatic regulator without clearing the PTfailure and resetting the PT failure alarms.

AVR/FVR Upper and Lower Limits1. Monitor the functions on the Auto_Ref.vsd software function screen. In auto-

matic regulator, lower excitation to the low limit of terminal voltage (ARNLM),usually –10% of rated. <ARLLM> should be true. <ARSTAT> should be avalue of five.

2. Transfer the controls to manual regulator and again continue to lower excitationwhile observing the Man_Ref.vsd software function screen. In manual regulator,the excitation should stop at a value equal to (MRNLM) or 80% of no load fieldvoltage. <MRSTAT> should be a value of 5. <MRLLM> should be true.

3. Observe that the balance indication on the keypad display no longer reads a zerovalue but has an offset (since the manual regulator is set below the AVR lowlimit).

Note It is not possible to check the manual regulator upper limit (MRPLM) in off-line simulation mode.


FVR Preset Verification1. With excitation stopped, transfer the EX2100 to manual mode.

2. Start the exciter and observe that the simulated field voltage builds to a valueequal to (MR_ZV).

Offline Over Excitation Limit (OEL)The offline over excitation limitonly operates when the EX2100is in manual regulator.

With the EX2100 operating in manual, raise excitation voltage until the value of(FcrRefOffline) is reached. <FldMode> should change from a true to a zero value.(FcrRefOffline) is found on Alarms.vsd. <FldMode> is found on InnerLoop.vsd.

Disconnect ECTB board TB1-1 and 5 to prevent 86G op-eration. See system elemen-tary for details.

Once the simulator is online, the 94EX contact output can beoperated inadvertently. This may cause unintentional opera-tion of protective devices outside the EX2100. Lifting of the94EX output contacts is recommended during simulator andtemporary load operation.

AVR Under Excitation Limit (UEL)With the previous offline simulated operation checks complete, the EX2100 is readyfor simulated online operation.

1. Temporarily jumper the contact input on the ECTB board TB2-45 and 46 tosimulate 52G breaker closure and verify that <Aux52G> is in a true state.(Keypad menu: GP_In_Out). Removal of the jumper should toggle the variableto a False state. Replace the jumper so that <Aux52G> is true.

2. Once <Aux52G> is true, raising or lowering the terminal voltage should nowchange the value of <VARs>. Changing the value of (SimTorqueRef) will alterthe value of <Watts>. These variables can be viewed on the keypad display oruse the (Tramp Up/Down) adjustment on the Statorsim.vsd diagram.

3. While monitoring the XY chart for UEL operation, and using the values of(UELX0, UELY0) through (UELX10, UELY10) as a guide, lower the terminalvoltage until the UEL becomes active. Because the takeover point of the UEL ismodified by the square of the terminal voltage, actual takeover points may notcorrelate exactly to the parameter values. Check operation of the UEL at variousvalues of (SimTorqueRef). When the UEL is active, <UELACT> should be atrue value.

4. Raise excitation terminal voltage so that the UEL is no longer active, but thegenerator is at less than rated voltage. Lower (SimTorqueRef) to the originaloffline operation value.

V/Hz Trip and 94EX Verification1. With the generator in simulator mode and operating at less than rated terminal

voltage, temporarily change (VHz1TripLev) from the normal value of 1.18 pu to1.01 pu.

2. Raise the simulated terminal voltage so that it exceeds the 1.01 pu value for theV/HZ trip relay. The EX2100 should generate a 94EX lockout trip request aftera time delay found in (VHz1TripSec).

3. Verify that ECTB board terminals TB1-1 to TB1-5 are shorted (closed). Closedcontacts will request a trip of the generator lockout device.

4. Remove temporary jumper for 52G and clear all alarms and faults. This con-cludes simulator mode testing.


Temporary Load ChecksOperation of the EX2100 core with a temporary load is highly recommended.Temporary load operation confirms that the EX2100 is capable of gating cells andproducing excitation voltage. This can eliminate many frustrating hours of trouble-shooting during initial turbine roll and generator energization if performed prior torunning the unit.



Zeroing VCO Offsets1. With no ac input voltage applied to the EX2100, voltage controlled oscillator

offsets should be zeroed for the following feedback variables. (This test must berun with the exciter not gating the SCRs.)� Field Ground Detector Feedback� Field Voltage Feedback� Field Current Feedback.

2. Using the VCO_ZERO.vsd diagram, click on each feedback’s respective zeroVCO button on the far right of the diagram (see Figure 6-10). The controls willautomatically zero the VCOs and indicate Ready when complete.

Flashing and 41A, 41B Verification1. With no ac input voltage applied to the EX2100, start the exciter by selecting the

green start button on the operator’s keypad. This will cause the EX2100 to tripafter attempting the start sequence.

Disconnect ECTB board TB1-1 and 5 to prevent 86G op-eration. See system elemen-tary for details.

Operation of contactors and relays will occur in while testingwith a temporary load. Verify that personnel are clear fromany moving devices and are clear of exposed components andleads.

2. Verify that both 41A and 41B contactors close by monitoring <Aux41> as wellas visual verification. Use the AuxBusStart or Flash_Start page in the .ecb file asper the application being tested.

3. For units with flashing, also verify contactors 53A and 53B for proper operationby monitoring <Aux53B> and <Aux53A> as well as visual verification.

4. For units with flashing, verify that the proper polarity voltage appears on the DCvoltmeter connected to the temporary load. This value can be monitored at<FldVoltVolts>. The EX2100 will regulate field current at the values specifiedin (FlashingAmpsMin) and (FlashingAmpsMax) on the FLASHSTART.vsd dia-gram.

5. After the EX2100 trips, due to a lack of ac input voltage, reset all faults andalarms.

6. Repeat steps one through five with M2 selected as Master.


Figure 6-10. VCO Calibrate Zero Offset Diagram


Manual Voltage Regulation and Bridge Firing

The main generator field leads must be disconnected duringthis testing. Power will be applied to ac input circuits and dcoutput circuits. Personnel safety practices must be observedduring this testing.

1. Confirm that the dc output to generator field is disconnected from the EX2100.

2. Referring to the EX2100 control system elementary, identify the applicable PPTsecondary voltage. An ungrounded three-phase source voltage as close to thisPPT secondary voltage as possible should be connected to the ac input leads L1,L2, and L3 of the EX2100. These connections are found in the Power ConverterModule. If this voltage source is significantly different than the normal PPT in-put voltage, (PPT_Vrms) can be adjusted for this test. This parameter is foundon the Firing Control block of the .ecb file. For EX2100 units supplied from anauxiliary bus, it is possible to use the normal ac input for test purposes.

3. Connect a resistive load capable of carrying generator field ceiling voltage andat least 3 amps to the dc (+) and dc (�) output leads. An oscilloscope using dif-ferential mode and a dc voltmeter should also be connected to this temporaryload.

4. Verify the Master 1 and Master 2 controls are in manual regulator mode by se-lecting Manual on the operator keypad (Figure 6-8).

5. Apply the ac input voltage to the EX2100. The 41AC disconnect should beclosed. Monitor <expll_volts> and verify that the measured ac input voltageagrees with the ac voltmeter reading of the ac input voltage.

6. Confirm the manual regulator preset (FvrPreset) is suitable for the temporaryload chosen.

7. Once again, start the exciter using the primary master’s keypad by pressing thegreen start pushbutton.

8. After both 41A and 41B close and the flashing sequence is completed, theEX2100 should begin to gate cells and develop and output voltage equal to thevalue in (FvrPreset).

Note A three-phase voltage and current source can be used to simulate generatorfeedback signals during temporary load testing. If PT feedback is not simulated intothe ECPT board inputs, the EX2100 will alarm a PT under voltage condition. Thisalarm will not reset until the exciter is stopped or PT feedback is simulated whilerunning.

9. Observe on the active power converter’s EGPA board that both the six gatepulse input LEDs and the six gate pulse output LEDs are lit indicating cell firing(see Figure 6-11).

GT1

I

PHB

PHA

GT5

IG

T3I

GT4

IG

T2I

GT6

I

170F

FAN

SA

LRM

PSO

K

PHC

190F

FALT

FUSE

GT1

O

GT5

O

GT4

O

GT2

OG

T6O

GT3

O

CO

OL

Figure 6-11. EGPA Board LEDs Example


10. The oscilloscope connected across the temporary load monitoring the dc outputshould indicate six distinct cell firings of equal magnitude and duration. Thevoltage level on the dc voltmeter should agree with the value monitored at<FldVoltVolts> and be equal to the value in (FvrPreset).

11. From the keypad of the active master, raise (+) and lower (�) the exciter outputvoltage. The dc output voltage should respond is a smooth, controlled manner.The oscilloscope display should show an increasing and decreasing firing angleon the display. The values in (MRPLM) and (MRNLM) are the upper and lowerlimit of field voltage while operating in the manual regulator.

12. Repeat steps one through seven with M2 selected as Master.

Core Transfer Operation1. Continue to monitor the bridge output voltage on the oscilloscope and dc volt-

meter, as well as trending <FldVoltVolts>.

2. With the unit running at any output voltage, using Command Menu #2 of thekeypad of the active master, transfer control to the backup master.

3. The primary power converter should now stop gating cells as indicated by thesix yellow output LEDs on the EGPA board and the backup power convertershould begin gating cells. The output LEDs on the backup power converterEGPA board should now be lit.

4. Verify that there is no change in dc output voltage and oscilloscope waveshape.The trend of <FldVoltVolts> should indicate that a bumpless transfer from pri-mary to backup power converter has taken place.

5. Using Command Menu #2 of the active master, transfer control back to theoriginal primary power converter and again verify bumpless operation.

Static Start Voltage Reference OperationOn large gas turbines, the exciter is used to supply generator field flux for the LCIduring static start operation. This control should be tested prior to startup. EX2100exciters on steam or hydro turbines will not have a static start reference input.

1. The static start input reference can be a 0�10 volt input, 4�20ma input, or anEGD page input. If it is a hard-wired input signal, a temporary source should beconnected to the ECPT board TB1 21 – 23.

2. With the EX2100 stopped and M1 as master, force the logic in the turbine con-trol to place the exciter in static start mode operation.

3. Start the EX2100 with the static start input reference at its minimum value. TheEX2100 should start but the dc output voltage should be zero.

4. Using the hard-wire input reference or EGD input reference, raise the exciteroutput to the maximum LCI reference of no-load field voltage while in staticstart mode.

5. Repeat steps one through five with M2 as the primary master.

Initial Roll and Offline ChecksRefer to Figure 6-1, Block 9.


Initial operation of the EX2100 should not be attempted until temporary loadoperation has confirmed that the EX2100 is capable of gating cells and producingexcitation voltage. All temporary connections and jumpers should be removed.Doors, wire tray covers, and personnel barriers should be in their proper positions.


During initial roll and off line testing, high voltages andcurrents will be present in the EX2100 and applied to themain generator field. Generator protective relaying checksshould be verified as complete and plant personnel safetypractices must be observed during this testing.

On large gas turbine applications, the initial operation of the EX2100 is usually dur-ing cranking or initial firing checks of the gas turbine as the field exciter for the LCI.If all simulator mode and temporary load checks in this manual have been com-pleted, the EX2100 should be capable of providing field excitation during the com-missioning of the static starter.

Turbine control logic forcingwill be necessary during theinitial startup of the EX2100.

For the initial operation of the EX2100, the turbine controlshould not be allowed to automatically start the exciter.Allow the turbine to come to full speed, no load operationfirst and start the exciter through manual intervention of theoperator. Subsequent starts can then be made with theautomatic sequencing.

The EX2100 should be first started in manual regulator to verify correct generatorPT feedback values before starting in automatic regulator. Subsequent starts can thenbe made in automatic regulator once the unit has proven to be capable of operation inthat mode. Extensive use of the step test, circular list, and trend recorder feature ofthe toolbox will allow for quick evaluation of correct operation of the EX2100.

Preparations for Initial Start1. Verify that the PT and CT disconnect switches are closed.

2. Verify that generator field collector ring brushes have been installed and prop-erly seated in the brush rigging.

3. All power supply sources for the EX2100 should be on and the 41AC disconnectdevice should be closed.

4. An oscilloscope using differential mode and a dc voltmeter should be connectedto the generator field.

5. The turbine should be at full speed, no load.

6. The Circular List should be collecting and ready, trending variables <FldVolt-Volts>, <FldCurrAmps>, and <Vmag>

Initial Start Procedure1. Start the exciter using the primary master’s keypad by pressing the green start

pushbutton.

2. The EX2100 should execute its start/stop sequence in manual regulator andbuild generator field voltage to a value equal to <FvrPreset>. Field current andgenerator terminal voltage should trend as in the following startup recording fora start command in manual mode at full speed, no load (see Figure 6-12 andFigure 6-13).


Start Stop State

Voltage Magnitude

Voted Field Current

FvrFeedback

Cmd53A

Cmd53B

Cmd41

Start/State Fld Curr

Figure 6-12. Manual_startM1 Trend Recording Example


E1\GN_VMAG

E1\GN_IFG

E1\GN_VFLD

E1\FIRCMD

E1\GN_FREQ

E1\EX_41DC_CLSD

AVR\UEL_ERROR

Figure 6-13. ACL_manual_startM1 Trend Recording Example


3. Generator terminal voltage should be independently verified by measuring thefeedback on the PT disconnect switch and calculating the terminal voltage fromthe known PT transformer ratio. <Vmag> should agree with this value. If itdoes not, do not proceed further until this discrepancy is resolved. Also verifycorrect phase sequence input from the PT feedback at the PT disconnectswitch(es).

4. Alarms and diagnostics for improper phasing of the PT feedback should annun-ciate if incorrect. Monitor the Alarms diagram of the .ecb file for reversedphasing alarms and troubleshooting help.

5. Raise the EX2100 output voltage slowly until rated generator terminal voltage isreached. At this point it is important to verify control feedback and scaling val-ues for several key variables. <FldVoltVolt>, <FldCurrAmps>, <Vmag>, and<PPT_Vrms> should be checked for agreement with measured values using acalibrated measuring device. Field shunt millivolts can be used for field currentverification in place of a clamp on current device.

6. Verify that the keypad display of regulator balance reads zero at this time (thenit is ready for transfer to automatic regulator).

7. Using the active master’s keypad, transfer the EX2100 to automatic regulator.A smooth, bumpless transfer should occur. Again, using the trend recorder col-lecting variables <FldVoltVolts>, <FldCurrAmps>, and <Vmag>, and using thestep test function in the Control System Toolbox, apply a 2% step to the auto-matic regulator for a period of 5 seconds. Generator terminal voltage shouldchange by 2% with no instability, overshoots, or undershoots in voltage.

8. Stop the EX100 and restart in automatic regulator. The EX2100 should nowbring the generator to the value found in (AR_ZV). See Figure 6-14 and Figure6-15.


Start Stop State

Voltage Magnitude

Voted Field Current

FvrFeedback

Cmd53A

Cmd53B

Cmd41

Start/State Fld Curr

Figure 6-14. DSPX_auto_start Trend Recording Example


E1\GN_VMAG

E1\GN_IFG

E1\GN_VFLD

E1\FIRCMD

E1\GN_FREQ

E1\EX_41DC_CLSD

AVR\UEL_ERROR

Figure 6-15. ACL_auto_start Trend Recording Example


Automatic Regulator Step TestWith the unit at rated terminal voltage, step the automatic regulator with a 2% step toverify proper control using the AVR step test Wizard. The test can be started fromthe EX2100 Overview screen of the toolbox (see Figure 6-9). Select Inner LoopBode Analysis ($ BodeIL) to get to the Frequency (Bode) Analysis or StepTest of Regulator Loops screen (see Figure 6-16). Complete instructions for thetest can be printed by selecting Help from this screen in the toolbox.

See Figure 6-17 and Figure 6-18 for trend recording examples of the tests.

If, at any time during this testing, the AVR operation be-comes unstable, immediately transfer the EX2100 to manualregulator.

File name:

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PRODUCT:

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A B C D E F G H I J K L M N O P Q R S T U

A B C D E F G H I J K L 09/04/01 11:47 AM

�+

-

V.FvrSetpoint

V.FvrFeedbackV.FldVoltVolts

P.FvrFbLag

1

s�2 + 1

�2 =

Feedback Lag

V.FvrError

Frequency (Bode) Analysisor

Step Test of Regulator Loops$ Overview

Back to

V.PrbsOut

�

V.FvrSet+

+

AAFilter1

AAFilter2

V.AAFilter1

V.AAFilter2

V.Avr_sp

V.Avr_fb

P.Bode_Type

0 None1 FVR2 FCR3 AVR4 UEL5 PSS6 GPdata

P.FvrBodeScl

P.Bode_PreTrig # of passes prior toaveraging

P.Bode_Size 512 (5.12 sec)1024 (10.24 sec)default 2048 (20.48 sec)

V.BodePrePass

V.BodeNowPassP.Bode_Passes # of passes used foraveraging

|(V.BodePreDone

|(V.BodeAveDone

Pre Passes Done

Averaging Done

At Prepass

At NowPass

Third order Chebyin task 1 with break

at 50 Hz

{P#.Bode_Type=0,1~

{P#.Bode_Type=3,4,5~

{P#.Bode_Type=3~

{P#.Bode_Type=1~

{P#.Bode_Type=1~

{P#.Bode_Type=0,1~

V.FirCmd{P#.Bode_Type=2~

V.FcrError{P#.Bode_Type=2~

Input

Output

!C.60

|(V.BodeActive

{P#[email protected]

@P.BodePtr2 {P#.Bode_Type=6~

|~V.BodeActive

PRBS

Pseudo Randon Binary SequenceOutputs +1 -1

Toggle Start/Stop

P.ACLBodeScl

V.ACLPrbsOut

StepOutputs +1, 0

P.StepTime

|~P.StepPrbs

EX2100 Excitation Control

P.Margin

For UEL step tests via AVR,raise margin so that UELbecomes active quickly

V.StepSync

1 sec delay

0.25 sec low going pulse

(also passed to ACL forbuffer synchronization)

0{P#.Bode_Type=2,3,4,5,6~

{P#.Bode_Type=2,3,4,5,6~

V.Uelerr{P#.Bode_Type=4~

V.Pssllo{P#.Bode_Type=5~

@P.BodePtr1

@P.BodePtr2

Figure 6-16. BodeIL Toolbox Screen Example


DPM GP ref 1

Voltage Magnitude

Figure 6-17. DSPX_Vmag_AVRSP Trend Recording Example


E1\AUTO_FB

E1\GN_IFG

E1\GN_VFLD

E1\GN_VMAG

E1\FIRCMD

AVR\UEL_ERROR

E1\WATTS

E1\VARS

Figure 6-18. ACL_1pc_step_into_AVR Trend Recording Example


Offline OEL and V/HZ TestingThe offline OEL and V/HZ limit testing completed during simulator mode checksare sufficient for verification of limit operation. If desired, these tests can be repeatedat this time with the unit in operation with actual feedback values. Use the tests aswritten for simulator mode testing except for adjusting actual turbine speed and volt-ages.

Online ChecksPrior to initial synchronization, other equipment commissioning procedures willalso be performed. Phasing of the generator and protective relay device operationshould be completed. Verification of the synchroscope and tests of the 52G deviceshould be complete. All parties involved in the initial unit commissioning shouldagree that the unit is ready to connect to the power grid.

Refer to Figure 6-1, Block10.

All procedures in this sectionwere completed successfullyfor: � Master 1 � Master 2 The EX2100 should be first synchronized while in manual

regulator to verify correct generator CT feedback beforeoperating in automatic regulator. Subsequent synchroniza-tion and testing can then be made in automatic regulatoronce the unit has been proven capable of operation in thatmode.

The EX2100 should be operated in automatic regulator at all times when online. Theunit will only transfer to manual regulator if there is a problem sensed with the PTfeedback. For the initial synchronization, it is recommended to operate in manualregulator until CT feedback wiring can be verified as correct. Improper CT wiringcan cause misoperation of displays, UEL, LOE and other software controls.

CT Feedback Verification1. Synchronize the generator and load the unit to a minimum load, preferably at

least 5% of rated load and unity power factor.

2. Verify correct CT wiring per the following table. All values listed are per unit.EX2100 displays should agree with other plant indications as to terminal volt-age, frequency, stator current, watts, and vars. Do not proceed with testing untilconditions are corrected.

<Vmag> <FreqHz> <Imag> <Watts> <Vars> <Ireal> <Ireact> Possible Cause

1.0 �1.0 1.0 0.0 0.0 0.0 0.0 V12 and V13 swapped

1.2 -1.0 1.0 0.0 �0.58 �0.16 �0.22 V12 polarity reversed

1.2 �1.0 1.0 0.0 0.58 0.16 0.22 V23 polarity reversed

1.0 1.0 0.58 0.5 �0.29 0.5 �0.29 I1 CT opened

1.0 1.0 0.58 0.5 0.29 0.5 0.29 I3 CT opened

1.0 1.0 0.58 0.0 �0.58 0.0 �0.58 I1 polarity reversed

1.0 1.0 0.58 0.0 0.58 0.0 0.58 I3 polarity reversed

1.0 1.0 0.12 0.0 0.0 0.0 0.0 I1, I3 CT’s swapped

1.0 1.0 0.12 0.0 0.0 0.0 0.0 I1 CT wired to phase 2

1.0 1.0 0.12 0.0 0.0 0.0 0.0 I3 CT wired to phase 2

1.0 1.0 0.81 0.66 0.0 1.0 0.0 Frequency scaling


Other equipment may be af-fected if CT wiring is changedat the CT’s. Check one-linescarefully.

Do not open CT wiring with unit on line. Potential damageto equipment may occur. CT disconnect switches are makebefore break switches and CT wiring errors can be correctedon the EX2100 side of disconnect switches if needed.

PT Failure Operation1. With the unit on line, operate the EX2100 in manual regulator. Monitor the Key

States diagram. Open the PT input disconnect switch to the ECPT card. TheEX2100 will annunciate a PT failure and the variables on the Key States dia-gram should indicate <Vmag> less than 10% and <PT Instantaneous> should betrue.

2. Attempt to place the EX2100 in auto regulator from the keypad or control win-dow animated display. The EX2100 should NOT allow operation in auto regu-lator mode.

3. Restore the inputs to the ECPT board and reset the PT failure annunciation usingkeypad Command Menu #2.

4. Place the EX2100 in automatic regulator mode.

5. Once again, open the inputs to the ECPT card while trending <Vmag>, <Field-VoltVolts>, <FieldCurrAmps>, <AutoActive> and <PTUV Instantaneous>.The trend should show an approximate one second delay between the loss of PTfeedback and the switch to manual regulator.

6. If a second PT input has been provided for the EX2100, both PT signals must beopened to produce the transfer to manual regulator.

7. Restore the PT inputs and reset the PT failure annunciation.

Under Excitation Limit VerificationThe Under Excitation Limit (UEL) testing completed during simulator mode checksshould be repeated at this time with the unit in operation with actual feedback values.Use the tests as written for simulator mode testing if an operation check at actualUEL limit is desired.

A partial test of the UEL can also be performed. The UEL limit should be raised to avalue allowing operation in a slightly leading power factor region. The unit can thenbe lowered slowly or stepped into the UEL limit through a step input to the Auto-matic Voltage Regulator. The limit should be reset to the customer supplied or fac-tory default settings if tested at a higher limit value.

Additional TestingAt this time, the EX2100 is considered ready for full load operation. Additionaltesting of supplied options may be required to fully commission the exciter. Theseinclude options such as VAR/Pf control and the Power System Stabilizer. Check thesystem software and documentation for options provided on a given application.

Refer to the EX2100 toolbox document (GEH-6414) for instructions on using wiz-ards to perform additional tests and to tune-up the exciter.