GEH-6632 g GE Industrial Systems ™ EX2100 Excitation Control User’s Guide
g GE Industrial Systems Document: Issue Date: GEH-6632 2000-09-30 EX2100™ Excitation Control User’s Guide
© 2000 General Electric Company, USA. All rights reserved. Printed in the United States of America. These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. If further information is desired or if particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial Systems, Salem, Virginia, USA.
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This equipment contains a potential hazard of electric shock or burn. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate, or maintain this equipment. Isolation of test equipment from the equipment under test presents potential electrical hazards. If the test equipment cannot be grounded to the equipment under test, the test equipment’s case must be shielded to prevent contact by personnel.
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Contents Chapter 1 Equipment Overview 1-1 Introduction............................................................................................................................ 1-1 System Overview ................................................................................................................... 1-2 Hardware Overview ............................................................................................................... 1-5 Software Overview........................................
Chapter 3 Printed Wiring Boards Overview 3-1 Introduction............................................................................................................................ 3-1 Control Boards ....................................................................................................................... 3-2 Exciter Backplane (EBKP) ...................................................................................... 3-2 Digital Signal Processor Board (DSPX) ...............................
Changing Display Units........................................................................................... 5-7 Adjusting Display Contrast...................................................................................... 5-7 Status Screen .......................................................................................................................... 5-8 Reading the Meters ..................................................................................................
Notes iv • Contents GEH-6632 EX2100 User’s Guide
Chapter 1 Equipment Overview Introduction The EX2100ä Excitation Control (EX2100 or exciter) produces the field excitation current to control generator ac terminal voltage and/or the reactive volt-amperes. It is a full static excitation system designed for generators on both new and retrofit steam, gas, and hydro turbines. This chapter introduces the exciter and defines the document contents. Its purpose is to present a general product overview as follows: Section/Topic Page System Overview..............
System Overview The exciter is a flexible modular system that can be assembled to provide a range of available output currents and several levels of system redundancy. These options include power from a potential, compound, or auxiliary source. Single or multiple bridges, warm backup bridges, and simplex or redundant controls are available. An overview of the turbine generator excitation system is shown in Figure 1-1.
Transmission Line Step-up Transformer Air Circuit Breaker (52G) Current Transformers (CTs) Potential Transformers (PTs) Turbine Exciter Power Potential Transformer (PPT) Generator Controlled dc to Field EX2100 Exciter Data Highway to Turbine Control, HMI, & DCS Power Conversion Module (Bridge) Control, Sequencing, Protection Ac Source Instrumentation Figure 1-1 Overview of Generator and Exciter System EX2100 User’s Guide GEH-6632 Chapter 1 Equipment Overview • 1-3
AC AC Load Diagnostic Interface (Keypad) Unit Data Highway DC Control Power Supplies Customer I/O Current CT PT I/O Voltage Bridge I/O Aux Source Generator AC AC CB Control M1 Control M2 Control C PPT PCT (3) Compound Source only Linear Reactors (3) Line Filter Gating Selector AC CB or Disconnect Power Conversion Modules (Bridge) AC DC Flashing Control DC CB or Contactor Active Field Ground Detector Shunt Deexcitation Crowbar PT: Potential Transformer CT: Current Transformer CB: C
Hardware Overview The EX2100 hardware is contained in three cabinets as follows: • control cabinet for the control, communication, and I/O boards • auxiliary cabinet for field flashing and protection circuits such as de-excitation and shaft voltage suppression • power conversion cabinet for the power SCR cells, cooling fans, dc contactors, and ac disconnect The exciter's power converter consists of bridge rectifiers, resistor/capacitor filter configurations, and control circuitry.
Software Overview Microprocessor-based controllers (ACLA and DSPX) execute the exciter control code. The software consists of modules (blocks) combined to create the required system functionality. Block definitions and configuration parameters are stored in flash memory, while variables are stored in random-access memory (RAM). The exciter application software emulates traditional analog controls. It uses an open architecture system, with a library of existing software blocks configured from the toolbox.
Input/Output QTY Potential transformers (PTs) 2 3-phase standard, single phase available 120 V ac nominal 1 VA nominal burden Current transformers (CTs, 1 or 5 A) 2 Any two phases, single phase available 1 VA nominal burden 86G dedicated contact input 1 open for trip 52G dedicated contact input 1 closed for online Trip rated contact outputs 2 At 125 V dc with relay break characteristics: Resistive load 0.5 A Inductive load 0.
How to Get Help “+” indicates the international access code required when calling from outside of the USA. If help is needed beyond the instructions provided in the drive system documentation, contact GE as follows: GE Industrial Systems Product Service Engineering 1501 Roanoke Blvd.
Chapter 2 Functional Description Introduction This chapter describes the function of the EX2100 static exciter and the individual control and protection circuits. Power supplies and the distribution of power is also covered. The functional description information is organized as follows: Section Page Exciter Hardware ..................................................................................................... 2-2 Exciter Configurations .............................................................
Exciter Hardware The EX2100 exciter consists of the following basic components.
Exciter Configurations EX2100 Exciters can be supplied with single or redundant control, and with single or redundant bridges. Variations of the single control type are shown in Figure 2-1. Simplex Control with Single PCM Control with I/O and Operator Keypad PCM Simplex Control with Parallel PCMs Control with I/O and Operator Keypad PCM 1 PCM 2 PCM 3 PCM 4 PCM 5 PCM 6 Figure 2-1.
Exciters with dual (redundant) control are shown in Figure 2-2. Multiple PCMs can be supplied in simplex, warm backup, or redundant n+1 or n+2 modes (with n+1 or n+2 equal to 6).
Power Conversion Cabinet The Power Conversion cabinet contains the Power Conversion Module (PCM), the Exciter Gate Pulse Amplifier (EGPA) board, ac circuit breaker, and the dc circuit contactor. Three-phase power for the PCM comes from a PPT external to the exciter. The ac supply comes into the cabinet through the ac circuit breaker (if supplied), and is filtered by 3-phase line filters in the auxiliary cabinet.
Current Shunt A dc shunt provides the bridge output current feedback signal. The mV output signal is input to a differential amplifier on the EDCF board. The amplifier output voltage controls the frequency of an oscillator, which generates a fiber-optic signal sent to the control module. The bridge output voltage feedback signal is generated in a similar way.
Cooling Fan Assembly The SCR bridge assembly is cooled with forced air. From two to six overhead fans are used, depending on the bridge rating and redundancy requirements. The fans are powered by single-phase 115 V ac supplied by the customer. In redundant applications, a fan may be replaced while the exciter is running. Main Dc Contactors.
Auxiliary Cabinet The auxiliary cabinet is located next to the power conversion cabinet and contains modules to protect the generator and provide startup dc power. Modules for filtering the incoming ac power, for de-excitation, shaft voltage suppression, and field flashing are mounted in this cabinet. Ac Line-to-Line Filters Fuse protected line-to-line series RC filter circuits (snubbers) are provided to damp the ac system to prevent voltage spikes at the completion of SCR commutation.
Shaft Voltage Suppressor The Shaft Voltage Suppressor protects the shaft bearings. Excitation systems, which produce a dc voltage from ac through a solid state rectification process, produce ripple and spike voltages at the exciter output. Due to their rapid rise and decay times, these voltages are capacitively coupled from the field winding to the rotor body. This creates a voltage on the shaft relative to ground. Shaft voltage, if not effectively controlled, can be damaging to both journals and bearings.
Control Cabinet The control cabinet contains the keypad control rack, control power distribution module and supplies, and I/O terminal boards. Diagnostic Interface (Keypad) The keypad is a local operator interface that is mounted on the control cabinet door. Refer to Figure 2-4 for a view of the keypad and a summary of the operator and maintenance functions available. Chapter 5 describes the keypad in detail. A second keypad is provided for redundant controls. g EX2100 Excitation Control FVR Feedback 0.
Control Module The control module is a VME-style rack with boards cable connected to the I/O terminal boards. This rack is divided into three independently powered sections for the M1, M2, and C controllers. Each controller consists of control and I/O processor boards. If the rack contains only the M1 controller then it is a simplex control system; if the rack contains all three controllers then it is a redundant control system.
Simplex Control System The interconnections between the simplex control and the terminal boards, generator protection modules, and power supply are shown in Figure 2-5. Only one EPSM power supply is used but this can have both ac and dc supplies for increased reliability.
Redundant Control System A redundant control system has three controllers and three redundant power supplies, one for each controller. The power supply rack also holds three ground detector modules. Figure 2-6 shows three EDCF boards, and there can be three EPCT boards, if required. Up to two Ethernet cables are connected to the ACLA controllers (one to M1 and one to M2) for redundant communication with the turbine control and HMIs. Two keypads are shown connected to M1 and M2.
Controller C Controller C is only used with redundant systems. It is mounted in the control rack and is physically similar to the M1 and M2 controllers, however, C is not responsible for bridge firing and therefore does not contain an ESEL, or ACLA board. Controller C receives the same feedback voltage and current inputs as the other controllers and contains similar software.
addition there is an isolated 70 V dc output for use by EXTB and ECTB for contact wetting. Up to three ground detection modules (EGDM) are also mounted in the EPBP, as shown in Figure 2-9. These communicate with the EXAM module, which is located in the auxiliary cabinet. Exciter Power Distribution Module (EPDM) N125V P125V TB1 1 2 P125 FU2 3 4 5 125 V dc Filter FU4 AC1 Hot 7 JDACA1 SW3 10 10 9 9 2 12 12 J91 3 AC1 Neu.
Power to Exciter Backplane EBKP (Control Rack) To M1 M2 M1 EDEX EDCF To M2 EDEX EDCF CONTROL C EDEX EDCF CONTROL CONTROL EDEX EDEX J602 To C J602 EETB EDEX J602 EETB EETB ECTB ECTB ECTB EXTB Exciter Power EDEX EGDM FAN MEDIA Distribution CROWBAR CONV Module EPDM Fan EXTB EDEX EGDM FAN MEDIA CONV CROWBAR EXTB EDEX EGDM FAN MEDIA CONV CROWBAR J1C EPSM Power Supply M1 Blank plate Fan Fan J1M2 EPSM Power Supply M2 EGDM Ground Detector M1 EPSM Power Supply C EGDM Ground Detector M
Exciter Software The exciter software is configured and loaded from the toolbox, and resides in the controllers. The software is represented on the toolbox screen by control blocks linked together to show the signal flow. Figure 2-10 is a simplified overview of the exciter control system displaying the main control functions. Both the generator field and stator currents and voltages are measured and input to the control system. In normal operation the ac regulator is selected.
Voltage/Current Sensing DC Regulator DC Voltage adjust Exciter Bridge Generator AC Regulator AC Voltage adjust Exciter System Stabilizer Circuits Over-excitation Limiter Under-excitation Limiter V/Hz Limiter & Protection VAR/Power Factor Control Voltage Sensing & Load Compensation Power System Stabilizer Figure 2-10.
External Raise/ Lower Reactive Current AUTO REF EXASP Setpoint Watts Slip Exciter AVR Setpoint. V/Hz Limit; Reactive Current Compensation. PSS Power System Stabilizer AVR Setpoint and Tracking Frequency Watts AVR VMAG UEL VARs Under Generator Excitation Terminal Limit Voltage (VMAG) VMAG Automatic Voltage Regulator FVR Track Value Setpoint FVR External Raise/ Lower Field Voltage Regulator Setpoint MANUAL REF Field Voltage Regulator Min.
Auto Reference – AUTO REF The AUTOREF block generates an auto (or Auto Control (AC)) setpoint for the Automatic Voltage Regulator (AVR) based on user-supplied parameters and conditions. Raise/lower inputs to AUTO REF come in from the other devices on the Data Highway such as the turbine control or HMI. A variable rate integrator generates the output setpoint within preset limits.
Preset Condition S Preset State True Q Q Preset Not True R 0.05 a b a>b? Proportional Gain Enable Software Jumper 0 Q Software Jumper 1 Output Value 1 Gain Scaling AVR Setpoint + Integral Gain Error Tracking Control Preset State 1 s Σ - Generator Voltage Σ - Status of Regulators Antiwindup + + Σ Output Negative Limit Integrator Tracking Input + Positive Limit Integration Output Tracking Gain r/s AVR Status Preset Value + Σ - Figure 2-12.
voltage regulator loop such as compound exciters and some high ceiling exciters, the FVR uses a setpoint from either the AVR or the MANUAL REF block, and is always operational whether in manual or automatic operation. The Field Current Regulator (FCR) is a special application of the manual regulator and uses the generator field current as the feedback input.
Operator Interface The HMI contains exciter and turbine graphic displays. Operator and engineering work stations such as the HMI (Human Machine Interface) and the toolbox communicate with the exciter. This allows operator monitoring and control of the exciter, and engineering access to system diagnostics and control block configuration Turbine Control HMI An HMI can be mounted in a control console or on a tabletop.
Notes 2-24 • Chapter 2 Functional Description GEH-6632 EX2100 User’s Guide
Chapter 3 Printed Wiring Boards Overview Introduction This chapter describes the EX2100 printed wiring boards and their operation. These boards fall into four functional groups; control rack boards including controller boards and I/O processors, I/O terminal boards, bridge control and protection modules, and power supply boards. This chapter is organized as follows: Section Page Control Boards.........................................................................................................
Control Boards The control boards are located in the control module. This module consists of the exciter backplane (EBKP) and the metal chassis that holds the boards (refer to Figure 3-1).
Fan Fan RST RST OK ACTIVE ENET FLASH OK ACTIVE ENET FLASH S T A T U S S T A T U S DSPX EISB EMIO ESEL ESEL EMIO 2 1 2 1 ACLA DSPX ACLA DSPX EISB EISB J304 J305 J306 J307 J308 J309 E P C T Keypad M1 Tool M1 E G P A 1 E G P A 2 J314 J315 E P C T Keypad M2 Keypad C Tool M2 Tool C E P C T J404 J405 J406 J407 J408 J409 E C T B Test Rings M1 E G P A 3 E G P A 4 J414 J415 E C T B J612 J514 J515 E A C F 1 2 J610 10 4 3 3 M2 Power 4 3 1 IS200EBKPG1AAA E A C F 2 1 1 2
ACLA Board ACLA handles network communications and outer loop functions. The ACLA board is a double-slot, 3U high module located next to the DSPX. ACLA provides Ethernet communications with the turbine control, LCI, and HMI, and runs outer loop control functions including the following: • Automatic Voltage Regulator (AVR) • Power System Stabilizer (PSS) • Under Excitation Limit control (UEL) • VAR/power factor regulator (VAR/PF) For more information refer to Chapter 4 and GEI-100434.
I/O Terminal Boards The exciter terminal boards are as follows: • IS200EPCT Exciter PT/CT board (EPCT) • IS200ECTB Exciter Contact Terminal Board (ECTB) • IS200EXTB Exciter Terminal Board (EXTB) • IS200EDCF Exciter Dc Feedback board (EDCF) • IS200EACF Exciter Ac Feedback board (EACF) EPCT Board EPCT receives and conditions generator PT and CT feedbacks. The EPCT contains isolation transformers for critical generator voltage and current measurements.
EDCF Board EDCF handles bridge dc voltage and current feedback. The EDCF board measures field current and field voltage at the SCR bridge, and interfaces to the EISB board in the control panel over a high-speed fiber-optic link. The fiber-optics provides voltage isolation between the two boards, and high noise immunity. Field current is measured using a shunt in the dc field circuit.
Bridge and Protection Boards and Modules The exciter bridge and protection boards are as follows: • IS200EGPA Exciter Gate Pulse Amplifier board (EGPA) • IS200EXCS Conduction Sensor board (EXCS) • IS200EDEX Exciter De-Excitation board (EDEX) • IS200EGDM Exciter Field Ground Detector Module (EGDM) • IS200EXAM Exciter Attenuator Module (EXAM) • Crowbar module EGPA Board Bridge control passes through EGPA. One EGPA is required per PCM. The EGPA board interfaces the control to the power bridge.
In a redundant system, the set of three EGDM boards are configured as a Controller (C), Master 1 (M1) and Master 2 (M2). The configuration for each EGDM is controlled by a set of program pins on the P2 connector. The C controller receives information from the active DSPX on which EGDM master should provide the drive signal to the sense resistor in the Attenuator Module. The active master receives an Oscillator Signal over the fiber optic link that it converts to a ±50 V signal.
Power Supply Boards The exciter power supply boards are as follows: • IS200EPDM Exciter Power Distribution Module (EPDM) • IS200EPBP Exciter Power Backplane (EPBP) • IS200EPSM Exciter Power Supply Module (EPSM) • DACA Module EPDM Module The EPDM provides the power for the control, I/O, and protection boards. It is mounted on the side of the EPBP and accepts a 125 V dc supply from the station battery, and one or two 115 V ac supplies. All supply inputs are filtered.
M2 M1 EDEX EDCF CONTROL J17 J16 EDEX M1 M1 J602 EETB J15M1 ECTB J13M1 J18 M1 J19 M1 J20 M1 J21M1 J15M2 ECTB J13M2 EXTB J12M2 J18 M2 J20 M2 J21M2 J15C ECTB J13C EXTB J12C J18 C J19 C J20 C J21C EPSM J14C BARCODE J1_C EGDM P217 P213 J2C J1_M2 P117 P113 EGDM P211 P207 P205 P201 IS200EPBPG1 EPSM EDEX EDCF CONTROL J17 J16 EDEX C C J602 EETB EDEX EGDM FAN MEDIA CONV CROW BAR P111 EGDM P107 EPSM J19 M2 J14M2 EDEX EGDM FAN MEDIA CROW CONV BAR P105 P101 J1_M1 EDE
Related Board Publications For a more detailed description of each board's circuitry and application data, refer to the following documents: EX2100 User’s Guide GEH-6632 • GEI-100460 IS200EBKP Exciter Backplane • GEI-100267 IS200DSPX Digital Signal Processor Board • GEI-100434 IS215ACLAH1 Application Control Layer Board • GEI-100454 IS200EISB Exciter ISBus board • GEI-100453 IS200EMIO Exciter Main I/O board • GEI-100456 IS200ESEL Exciter Selector board • GEI-100459 IS200EPCT Exciter PT/CT boa
Notes 3-12 • Chapter 3 Printed Wiring Boards Overview GEH-6632 EX2100 User’s Guide
Chapter 4 Terminal Board I/O and Equipment Connections Introduction This chapter describes the customer's equipment connections, and inputs and outputs (I/O) available through terminal board wiring. System cabling to provide desired functionality is also defined. The information is organized as follows: Section Page Power Connections and Analog I/O......................................................................... 4-2 Power Potential Transformer Inputs ..............................................
Power Connections and Analog I/O Figure 4-1 displays a typical connection diagram of the common power and analog I/O for an excitation system.
Power Potential Transformer Inputs In the EX2100 excitation system, a 3-phase source of ac power is converted to a controlled dc output. This ac input can be from one of several sources. Most common is a generator terminal connected Y-Delta power potential transformer. The primary and secondary voltages as well as kVA ratings are sized for the particular application. An auxiliary bus fed PPT is also commonly used.
Customer Contact I/O Customer contact inputs and relay contact outputs are wired to the ECTB board. In addition to six general purpose contact inputs, there are two dedicated contact inputs, wetted by 70 V dc from the exciter, as follows: • 86G contact input used as a lockout during normal operation • 52G contact input gives the online status of the generator ECTB provides four general purpose Form C contact outputs controlled by EMIO. These are used for 94EX and 30EX and other outputs.
J13M1 ECTBG2 (Simplex) P70 V dc From M1 P24M1 TB1 P24D 18 NO P24D J405 Relay Driver COM Coil K#GP NC From M1 (EMIO) 19 Customer Power to Contacts 20 125 V dc Ex. Fault to Mark VI Four General Purpose Relay Outputs as Above 1 Relay Driver Coil K#M1 P24M1 M1 Customer Power to Contacts M1 5 125 V dc Two Trip Relay Outputs as Above Term. 1&5 Ex.
Power Supply Inputs The customer’s ac and dc power inputs are wired to the exciter’s Power Distribution Module (EPDM), which is located on the left hand side of the exciter power backplane rack. Figure 4-3 shows the screw terminals for the 125 V dc battery source, and the 115 V ac suply, AC1. A second ac supply, AC2, can also be connected.
Line Filter Connections The 600 V filter is connected to fuse board LFU1. The 1000 V filter has two filter circuits and is connected to fuse boards LFU1 and LFU2. The filters are located at the top of the auxiliary cabinet. Connections to the line filter are shown in Figure 44. Auxiliary Enclosure Linefilter EACF1 TB4 1 From PPT L1 L2 L1 L2 L3 DISC 1 1 Coil1_L 3 Coil2_H 4 Coil2_L TB3 J5 04 J5 04 EMIO M1 J5 09 J5 09 EMIO M2 J5 14 J5 14 EMIO C 4 F U2 3 6 F U3 5 2 F U1 1 480V : 1.
Exciter Internal I/O Exciter AC Feedback The EACF board measures the exciter ac supply voltage and current. The terminal board contains transformers for a 3-phase voltage measurement, and terminals for two flux/air core coils. The cable between EACF and the EBKP control backplane can be up to 90 m in length. Cable shield terminal screws attached to chassis ground are located within three inches of the input screws where applicable.
Field Current Feedback The field current is measured across a dc shunt at the SCR bridge. This generates a nominal 100 mV signal, which is input to a differential amplifier. The output voltage from the amplifier ranges from –5 V to +5 V. A VCO produces a linear proportional frequency of 0 to 2 MHz with an accuracy of 1% of full scale reading. These pulses drive the LED in the optical isolator coupled to the fiber-optic cable.
Auxiliary Cabinet Control Cabinet EDCF-1 EISB M1 Generator Field Voltage VFOF CFOF PPT Scaling P2 2 2 WH + - 1 BK 2 1 PSM1 P1 VCO - BK P24VDC Current Shunt (mv) Dc Shunt 1 + Volts Current E1 VCO Duplex FiberOptic Link To Bridge 2 41A + 1 Generator Field + BK - 2 WH Auxiliary Cabinet HS + De-Excit.
De-Excitation During shutdown of the generator, the stored energy of the generator field inductance must be dissipated. In the EX2100 exciter, this is the function of the EDEX de-excitation module and field discharge resistor or inductor (when supplied). Standard de-excitation is provided by a freewheeling diode. For higher performance applications, the de-excitation module consists of a thyristor (53 mm or 77 mm cell size) mounted in a large heatsink assembly with attached snubber network.
Control Cabinet Auxiliary Cabinet De-Excitation Generator Field + HS- HS+ DEPL Generator Field - Conduction Sense Circuit Converter Cabinet EXTB G1 - Contactor Mode (Simplex version is G2) J505 FDI 2 J515 EDEX M1 De-Excit. Status M2 De-Excit.
Auxiliary Cabinet Control Cabinet De-Excitation Generator Field + HS- HS+ DEPL 2 Conduction Sense Circuit M1 DeExc Status M2 DeExc Status Generator Field - EXTB G3 - Breaker Mode (Simplex version is G4) J505 To M1 FDI J508 1 2 To M2 J515 EDEX 2 J8 M1 2 Status 5 5 J8 M2 Status Self Firing P24V M2 Firing Command 1 Status J6 Feedback 3 4 3 4 4 Ct 7 5 Bkr Ct 8 6 N24V M1 M2 41 Trip M2 C 1 P24 M1 M2 1 41 Close M2 C COM 2 COM 2 N24 3 N24 To EPBP J17M1 6 C M1 P125 P24
Crowbar The optional crowbar subsystem limits high negative voltages that can be induced into the PCM during a pole slip (loss of synchronization) event. Like the deexcitation module, the crowbar will self-fire based on selective field voltage limits. It includes a discharge resistor, which may be shared with the de-excitation function when the two are supplied together. This is typically only provided on generators with salient poles (hydro applications).
Control Cabinet Auxiliary Cabinet Generator Field - Generator Field + From Flashing 53B Power Backplane EPBP Ground Detector Attenuator Module EXAM Control Backplane EBKP J2 Ground Detector Voltage EISB - M1 EGDM - M1 Optical Receiver VCO Oscillator Optical control Transmitter Oscillator 1 M2 M2 Optical Receiver VCO C Optical Receiver VCO Control +/-65 Vdc +5V +/-15V To DSPX Counters Oscillator Optical control Transmitter Oscillator 2 C To DSPX Counters Optical Transmitter To DSPX Co
Field Flashing The station battery is used to initiate the field current. An auxiliary ac source can also be used. Field flashing relays 53A and 53B are controlled from drivers on the EMIO board, through pilot relays on EXTB. In redundant control, the three driver signals actuate pilot relays on EXTB that are contact voted to output a single voltage. These outputs actuate the 53A and 53B relays in the Auxiliary Cabinet.
From Shunt1 + Generator Field - Station Battery 125 Vdc Auxiliary Panel Flashing 1 PTB-1 2 - + Shaft Voltage Suppresser w v 53B 53A 53B x x Y Y 53B J1 Aux 1 EXAM 1 TB1 J1 3 2 1 7 8 FBK1 FU1 2 4 2 3 3 5 3 FU2 1 2 6 4 EXTB 2 53B B A J7 4 4 M1 M2 10 10 M2 C 6 6 SUP SUP 53A A 9 9 2 2 5 5 1 53A Aux 2 C 53B P70Vdc J7 1 B M1 53B M2 53B Current Limit Circuit J5M1 M1-EMIO (J5) J5M2 M2-EMIO C M1 (J5) K53B relay contacts M1 M2 J5C C-EMIO (J5)
Shaft Voltage Suppressor Excitation systems, which produce a dc voltage from an ac supply through a solid state rectification process, cause ripple and spike voltages at the exciter output. Due to their rapid rise and decay times these voltages are capacitively coupled from the field winding to the rotor body. This creates a voltage on the shaft relative to ground that, if not effectively controlled, can damage both journals and bearings.
Data Highway Connections The Data Highway integrates several different single control systems. The EX2100 exciter communicates over the same data highway as the Mark VI turbine control and the HMI. A typical exciter connection to the redundant Unit Data Highway (UDH) network is shown in Figure 4-12. This shows redundant control with two ACLAs. The UDH is implemented using commercially available fast Ethernet switches.
Control System Toolbox Connection The toolbox connector on the exciter backplane supports an RS-232C cable, which connects an external computer to the DSPX board. This connection is for maintenance purposes. There are three 9-pin connectors located at J303B, J310B, and J313B to support communication with controllers M1, M2, and C. (Refer to Figure 4-13). The UDH can also provide a toolbox interface using the Ethernet port on the ACLA.
Chapter 5 Diagnostic Interface-Keypad Introduction This chapter provides operating guidelines for the Diagnostic Interface, more commonly called the keypad. The keypad is a door-mounted, local control unit that enables you to: • Monitor frequency, current, power, and voltage • Start and stop the exciter • Set and adjust configuration parameters • Examine and reset fault conditions This chapter is organized as follows: Section Page Using the Pushbuttons.............................................
Using the Pushbuttons The keypad includes membrane-type pushbuttons to access exciter values and to control the exciter. Tables 5-1 and 5-2 define the pushbutton functions for menu navigation and exciter control (see Figure 5-1). g EX2100 Excitation Control Exciter Health & State Icons FVR Feedback 0.0 Volts FldCurrAmps 0.00 Amps Vmag Imag 0.00 0.00 Freq_Hz Balance Meter 60.00 -30% 0% 100% 150% -30% 0% 100% 150% Watts 0.00 Vars 0.00 0.
Table 5-1. Navigation Pushbuttons Button Function Status Displays the default Status Screen, which shows eight parameters as numbers or bargraphs. A set of Health icons (displayed at all times; see Exciter Health and State Icons) provides additional exciter status information. Menu If pressed while displaying a Menu screen (see Menu Selections), displays the Main Menu.If pressed while displaying a Status screen, displays the last Menu screen.
Table 5-2. Exciter Control Pushbuttons Button Reset Faults Command Menu Function Resets faults.
Reading the Display The keypad displays information as both text and animated graphics. There are two types of content screens, selected by pressing the corresponding Navigation button: Status and Menu. The Status Screen (Figure 5-2) is the default screen that displays after exciter startup, following an initialization screen. It uses animated meters with associated text to present exciter performance data. An alternate Status Screen can also be accessed (see Status Screen).
Table 5-3. Exciter Health and State Icons Group Icon Heartbeat Control Blank Fault State blinking o Indication Description Communications OK Animated line (its center raises and lowers) shows that there is communication between the keypad and the exciter. Communications not established Animated metronome icon shows that the keypad is attempting to establish communication with the exciter, but cannot. Auto mode Regulates terminal voltage. Manual mode Regulates field voltage.
Changing Display Units Ø To change the type of measurement units displayed 1. From the Main Menu, select General Setup. 2. Select Display Units. 3. Select the display units parameter to edit it (see below). 4. Highlight, then select the preferred display units. Press ENTER to accept, ESC to leave Display units New Value = Metric (SI) Present Value = Metric (SI) Adjusting Display Contrast Shortcut – Press and hold the Menu key. Press the Up and Down arrows to adjust the display contrast.
Status Screen The Status screen displays up to eight variables (parameters). The first two parameters are displayed both in text and animated meters. Table 5-4 defines the characteristics of the bar graphs for these parameters. Reading the Meters A variable shown as a bar graph is over range when it is either greater than + 100% or less than –100%. The over range mark is shown with a vertical bar through the bar graph at the +100% and the –100% marks. Not Over Range +100% -100% Over Range Table 5-4.
Using the Menus The keypad’s Main Menu leads to other menu screens, where data can be reviewed and modified. The Main Menu can be accessed from any screen, as follows: • If already in a Menu screen, press the Menu button. • If in a Status screen, press the Menu button once or twice. Main Menu Fault List Alarms Alarm String Application data Diagnostic and utility General setup i I/O interface Note The Main Menu selections may vary from product to product.
2. To view detail on a particular fault, select that fault (listed on the Active Fault Display screen). The following screen displays. SELECTED FAULT - PRESS Low AC V, B 006:40:11.008 Low AC input volts detected on the field exciter. 3. Reset the faults either of two ways: - Select Reset Faults Now in the Fault Display screen. - Press the Reset Faults button. Ø This display list may be multiple screens long.
2. For an Option parameter: a. Use the Up or Down Arrow buttons to select a new parameter value. b. Press the Enter button to accept the change or Escape to exit and keep the present value. Press ENTER to accept, ESC to leave TripVHiTrip New Value = Trip disabled Present Value = Trip enabled 3. For a Numeric parameter: a. Use the Left or Right Arrow buttons to highlight the digit to be changed.
2. Press Enter to make a backup copy of the parameters or Escape to cancel. Ø To restore a parameter from backup 1. Stop the exciter. (This function cannot be executed with the exciter running.) 2. From the Main Menu, select Parameter Backup Functions then select Restore Parameters from Backup. Press to restore Parameters from Backup -- WARNING -The active parameter values will be replaced, and can not be recovered. Press ENTER to continue. 3. ESC cancels.
Firmware and Hardware Information Ø To view the firmware versions for the DSPX board and the keypad From the Main Menu select: 1. General Setup 2. Firmware Version & Hardware Info 3. Display Firmware Version The following screen displays: GE Generator Control EX2100 DSPX Firmware Version: V02.06.00B DSPX Boot Monitor Version: V02.02.00C DDI Firmware Version: V02.00.00B Press ESC to exit Ø To view exciter hardware information From the Main Menu select: 1. General Setup 2.
Protecting the Keypad To protect the exciter from unauthorized operation or reconfiguration, the keypad includes two security controls, Password and Privilege Level. The Password is a 5-digit number that protects the Password and Privilege Level from being changed by unauthorized personnel. The default Password is 00000. Privilege Level specifies which operational and configuration functions are disabled in the keypad.
2. Enter the password as follows: a. Use the Up and Down Arrow buttons to index through the valid digits (0 through 9). b. Use the Right and Left Arrow buttons to move the cursor to the digit to edit. - Press Enter to accept the Password. - If the password that was entered matches the saved Password value, you can then modify the Privilege Level or Password. Keypad Security Keypad privilege Keypad password =Configure & = If it does not match, the keypad displays an error message.
Notes 5-16 • Chapter 5 Diagnostic Interface-Keypad GEH-6632 EX2100 User’s Guide
Appendix A Warranty and Renewal Parts Introduction When ordering a replacement part for a GE exciter, the customer needs to know: • How to accurately identify the part • If the part is under warranty • How to place the order This information helps ensure that GE can process the order accurately and as soon as possible. To minimize system downtime if repair is needed, GE recommends that the customer keep a set of spare parts on hand. The Renewal Parts Quotation lists recommended spares.
Identifying the Part An exciter component, or part, is identified by its assigned part number and description. The part number is normally found on a nameplate on the component. The description is included in the system renewal parts list. Renewal Parts List The Renewal Parts List is a separate document that lists the parts of a complete system. This list applies specifically to the equipment furnished on a customer’s particular application (requisition) at the time of shipment.
Order Specific Assemblies These parts make up the particular exciter. Other items obtained specifically for the order may also use a similar part number structure, which provides information about the equipment. 3V AAA 123 XX### Unit & sequence number of Sequence/projec Order product line Unique to req'n Identifies manufacturer as GE Systems, Salem, Sample Part Number for Order-Specific Assembly Common Assemblies Common assemblies are subassemblies used as components of order-specific assemblies.
Printed Wiring Boards A printed wiring board is identified by an alphanumeric part (catalog) number stamped near its edge. The structure of a board’s part number is described below. Note All digits are important when ordering or replacing any board. The factory may substitute later versions of boards based on availability and design enhancements. However, GE Industrial Systems ensures compatibility of replacement boards.
How to Order Parts Parts still under warranty may be obtained directly from the factory: GE Industrial Systems Product Service Engineering 1501 Roanoke Blvd. Salem, VA 24153-6492 USA Phone: + 1 800 533 5885 (United States, Canada, Mexico) + 1 540 378 3280 (International) Fax: + 1 540 387 8606 (All) (“+” indicates the international access code required when calling from outside of the USA.) Renewals (spares or those not under warranty) should be ordered by contacting the nearest GE Sales or Service Office.
Notes A-6 • Appendix A Warranty and Renewal Parts GEH-6632 EX2100 User’s Guide
Appendix B Ratings and Specifications The actual equipment rating is on your exciter nameplate. This appendix indicates the range of possible product offerings but not necessarily the capability of your exciter.
Input/Output QTY Potential transformers (PTs) 2 3-phase standard, single-phase available 120 V ac nominal 1 VA nominal burden Current transformers (CTs, 1 or 5 A) 2 Any two phases, single phase is available 1 VA nominal burden 86G dedicated contact input 1 Open for trip 52G dedicated contact input 1 Closed for online Trip rated contact outputs 2 At 125 V dc the relay break characteristics are: Resistive load 0.5 A Inductive load 0.
Cabinet Dimensions & Weight Redundant control with dual PCM redundant converter in a three-cabinet lineup Width 141.74 in (3600 mm) Height 104.32 in (2650 mm) Depth 31.5 in (800 mm) Weight of Converter cabinet 3,600 lbs. Weight of Total Lineup (Converter, Control, and Auxiliary cabinets) 5,600 lbs.
Notes B-4 • Appendix B Ratings and Specifications GEH-6632 EX2100 User’s Guide
Glossary of Terms 6U Full height Versa Module Eurocard (VME) board application code Software that controls the machine or process, specific to the application. ASCII American Standard Code for Information Interchange. An 8-bit code used for data. auxiliary source A source of three-phase ac power for the exciter, but not from the generator being controlled. automatic voltage regulator (AVR) AVR is controller software that maintains the generator terminal voltage through the Field Voltage Regulator.
block Instruction blocks contain basic control functions, which are connected together during configuration to form the required machine or process control. Blocks can perform math computations, sequencing, or regulator (continuous) control. board Printed wiring board or card. bus Upper bar for power transfer, also an electrical path for transmitting and receiving data. bumpless No disruption to the exciter when transferring control.
DCS (Distributed Control System) Control system, usually applied to control of boilers and other process equipment. de-excitation The de-excitation circuit provides a conduction path through a discharge resistor to dissipate the field current after a unit trip. device A configurable component of a control system. DRAM Dynamic Random Access Memory, used in microprocessor-based equipment. EGD Ethernet Global Data, a control network and protocol for the controller.
fault code A message from the controller to the HMI indicating a system warning or failure. field flashing The supply of initial exciter current during startup, usually from station batteries. field ground detector The field ground detector is an active circuit that detects a ground in either the ac or dc sections of the exciter and field wiring.
hot backup Two bridges are used but only one is connected to the field, the other (the backup) is connected to a small dummy load. If the active bridge fails it is disconnected from the field by relays, and the backup is connected. ICS Integrated Control System. ICS combines various power plant controls into a single system. IEEE Institute of Electrical and Electronic Engineers. A United States-based society that develops standards.
Modbus A serial communication protocol developed by Modicon for use between PLCs and other computers. multiple bridges Several power producing bridges operate in parallel to produce a high field current. These share the exciter current load to provide redundancy and increased reliability. NEMA National Electrical Manufacturers Association; a U.S. standards organization. non-volatile Memory specially designed to store information even when the power is off, for example Flash memory.
product code (runtime) Software stored in the controller’s Flash memory that converts application code (pcode) to executable code. PRV Peak Reverse Voltage is limited with pole slip resistors, wired across the SCRs. PT Potential Transformer, used for measuring voltage in a power cable. real-time Immediate response, referring to control systems that must respond instantly to changing conditions. reboot To restart the controller or toolbox.
sampling rate The rate at which process signal samples are obtained, measured in samples/second. serial loader Connects the controller to the toolbox PC using the RS-232C COM ports. The Serial Loader initializes the controller flash file system and sets its TCP/IP address to allow it to communicate with the toolbox over Ethernet. server A PC, which gathers data over Ethernet from plant devices, and makes the data available to PC-based operator interfaces known as Viewers.
toolbox A Windows NT -based software package used to configure the EX2100 and Mark VI turbine controller. under-excitation limit (UEL) UEL software functions to prevent generator over-heating caused by under excitation. unit data highway (UDH) Connects the EX2100, Mark VI turbine controllers, LCI, PLCs, and other GE provided equipment to the HMI Servers; runs at 10/100 Mbaud and supports Peer-toPeer communications.
Notes x • Glossary of Terms GEH-6632 EX2100 User’s Guide
Index A ac disconnect 1-5, 2-5 Ac Line-to-Line Filters 2-1, 2-8 Ac to Dc Converter 1-6, 2-14, 3-1, 3-9, 3-11, B-1 ACLA (see Application Control Layer Module) Analog I/O 4-1, 4-2 Analog Input 4-1, 4-3 Application Control Layer Module 1-6, 2-11, 2-13, 214, 3-1, 3-2, 3-4, 4-19, 4-20 AUTO REF (see Auto Reference) Auto Reference 2-1, 2-20 Automatic Voltage Regulator 2-1, 2-20, 2-21, 3-4 auxiliary cabinet 1-5, 1-7, 2-5, 2-8, 2-15, 4-7, B-2 Auxiliary Cabinet 2-1, 2-8, 3-9, 4-16 Ac Line-to-Line Filters 2-1, 2-8 De
De-Excitation 3-7, 3-11, 4-1, 4-11 – 4-13 Crowbar 2-2, 3-6, 3-7, 3-10, 3-11, 4-1, 4-14, 4-18 Field Flashing 2-1, 2-9, 3-2, 4-1, 4-16, 4-17 Field Ground Detector 2-1, 2-9, 3-7, 4-1, 4-14, 4-15 Shaft Voltage Suppressor 2-1, 2-9, 4-1, 4-18 De-excitation module 2-2, 2-8 De-excitation Module 2-1, 2-8, 3-1, 3-6 – 3-8, 3-10, 3-11, 4-11 Diagnostic Interface 1-1, 2-1, 2-2, 2-10, 5-1 Alternate Status Screen 5-1, 5-8 Changing Display 5-1, 5-7 Editing Parameters 5-1, 5-10, 5-15 Faults 5-1, 5-9 Keypad 2-10, 5-1 Protecti
G O Gate Pulse Amplifiers 2-1, 2-6 Generator Current Measurement 4-3 Generator Voltage Measurement 4-3 operator interface 1-2, 2-10 H PCM (see Power Conversion Module) Potential transformers 1-7, B-2 Power Connections 4-1, 4-2 power conversion cabinet 1-5, 2-8 Power Conversion Cabinet 2-1, 2-5, 4-11 Free Wheeling Diode 2-1, 2-7 Gate Pulse Amplifiers 2-1, 2-6 Main Dc Contactors 2-1, 2-7 Manual Ac Disconnect 2-1, 2-5 Power Converter Module 1-6, 2-1, 2-5 power conversion module 1-2, 1-6, 1-7, 2-1, 2-2, 2-
T Technical Characteristics 1-1, 1-6 Thyrite 2-8, 4-18 TMR (see Triple Modular Redundant) Toolbox (see Control System Toolbox) Triple Modular Redundant 2-2, 2-14 U UDH (see Unit Data Highway) UEL (see Under Excitation Limiter) Under Excitation Limiter 2-1, B-2 Unit Data Highway 1-2, 4-19 W Warm backup bridge configuration 2-2 Warranty and Renewal Parts 1-1, A-1 iv • Index GEH-6632 EX2100 User’s Guide
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