Ex1200 Guide Manual PDF

GEH-6631A
g GE Industrial Systems
EX2100 Excitation Control

Full Static Control
Installation and Startup Guide
Contents
Chapter 1 Overview
Introduction.............................................................................................................................1-1
How to Use This Document....................................................................................................1-3
Structure of the Document........................................................................................1-3
Text Conventions......................................................................................................1-3
How to Get Help .....................................................................................................................1-5
Equipment Covered ................................................................................................................1-5
Related Documents .................................................................................................................1-7
Document Distribution .............................................................................................1-7
Acronyms and Abbreviations .................................................................................................1-8
Chapter 2 Installation Planning

Introduction.............................................................................................................................2-1
Installation Support.................................................................................................................2-2
Early Planning ..........................................................................................................2-2
GE Installation Documents.......................................................................................2-2
As-Shipped Drawings...............................................................................................2-2
Technical Advisory Options.....................................................................................2-3
Siting EX2100 Equipment ......................................................................................................2-5
Operating Environment ............................................................................................2-5
Equipment Clearances ..............................................................................................2-6
Cable and Conduit Routing and Schedules...............................................................2-6
Chapter 3 Handling and Mounting Guidelines

Introduction.............................................................................................................................3-1
Exciter Handling Procedures ..................................................................................................3-2
Lifting.......................................................................................................................3-2
Moving .....................................................................................................................3-3
Unpacking ................................................................................................................3-4
Mounting ................................................................................................................................3-5
Securing the Exciter Lineup to the Floor..................................................................3-8
Chapter 4 Cabling and Connections

Introduction.............................................................................................................................4-1
Exciter Connections................................................................................................................4-2
Grounding and Cable Entry ....................................................................................................4-6
Cable Entry...............................................................................................................4-6
Control Power.........................................................................................................................4-9
Converter Power ...................................................................................................................4-10
Field Flashing .......................................................................................................................4-11
Generator Field Connections ................................................................................................4-11
GEH-6631 EX2100 Installation and Startup Contents i

Signal and Communications Cabling Guidelines..................................................................4-11
Generator PT and CT Inputs...................................................................................4-11

Contact Inputs.........................................................................................................4-12
Data Highway .........................................................................................................4-15
PC Interface ............................................................................................................4-16
Preventing Cable Damage.....................................................................................................4-16
Chapter 5 Pre-Power On Installation Checks

Introduction.............................................................................................................................5-1
Equipment/Material Needed ...................................................................................................5-2
Securing the Equipment for Safety .........................................................................................5-2
Hardware Checks ....................................................................................................................5-3
Optional Megger Test .............................................................................................................5-5
Pre-Test Power Checks.............................................................................................5-5
Ac Input Bus and PPT Secondary.............................................................................5-5
Dc Output Bus ..........................................................................................................5-6
Chapter 6 Initial Startup and Commissioning

Introduction.............................................................................................................................6-1
Before Beginning ....................................................................................................................6-2
Order of Startup ........................................................................................................6-2
Information Needed ..................................................................................................6-2
Equipment/Material Needed .....................................................................................6-3
Panel Lights, Heaters and Fans ...............................................................................................6-6
Verifying Control Power.........................................................................................................6-8
Control Module Processor Start............................................................................................6-12
Using the Exciter Configuration Tools .................................................................................6-13
Using Toolbox Online Help....................................................................................6-13
Starting the Toolbox ...............................................................................................6-14
Open an EX2100 File .............................................................................................6-14
Checking Toolbox/EX2100 Pattern Compatibility.................................................6-14
Downloading to the EX2100 ..................................................................................6-14
Optional: Upgrading the .ecb File..........................................................................6-15
Checking for Correct Firmware and Hardware ......................................................6-15
Checking the Keypad (EDI)..................................................................................................6-16
Using the Keypad for Startup and Commissioning ................................................6-16
Adjusting Keypad Display Contrast .......................................................................6-17
Commissioning the Exciter...................................................................................................6-18
Overview of EX2100 Parameters ...........................................................................6-18
Running Simulator Mode .......................................................................................6-21
Temporary Load Checks.........................................................................................6-26
Initial Roll and Off Line Checks.............................................................................6-29
On-Line Checks......................................................................................................6-39
Additional Testing ..................................................................................................6-40
Appendix A Understanding Equipment Drawings

Introduction............................................................................................................................A-1
Data Nameplate......................................................................................................................A-2
Identifying the Equipment .....................................................................................................A-3
Equipment Catalog Number ....................................................................................A-3
Drawing Numbers..................................................................................................................A-3
Outline Drawings ...................................................................................................................A-4
Panel Drawings ......................................................................................................................A-4
ii Contents GEH-6631 EX2100 Installation and Startup

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

Wire Number Identification.....................................................................................A-5
Conventions Used with Other Equipment .............................................................................A-6
Appendix B Cable Separation and Routing

Introduction............................................................................................................................ B-1
Low-Level Signals (Level L)................................................................................................. B-2
Medium-Level Signals (Level M) ......................................................................................... B-2
High-Level Signals (Level H)................................................................................................ B-2
Power (Level P) ..................................................................................................................... B-2
Class Codes............................................................................................................................ B-2
Cableway Spacing Guidelines ............................................................................................... B-3
General Cableway Spacing...................................................................................... B-3
Tray/Tray Spacing ................................................................................................... B-4
Tray/Conduit Spacing.............................................................................................. B-4
Conduit/Conduit Spacing ........................................................................................ B-4
Appendix C Installing Fiber-Optic Cable

Introduction............................................................................................................................ C-1
Cable Characteristics ............................................................................................................. C-2
Cable Construction .................................................................................................. C-2
Data Integrity........................................................................................................... C-2
Causes of Cable Damage......................................................................................... C-2
Handling Guidelines .............................................................................................................. C-3
Environmental Guidelines ..................................................................................................... C-4
Cable Assembly ..................................................................................................................... C-4
Tools and Materials ................................................................................................. C-4
Attaching a Connector ............................................................................................. C-5
Polishing Fiber Ends................................................................................................ C-7
Inspecting Fiber Ends ............................................................................................................ C-9
Connecting Fiber-Optic Cable to Modules .......................................................................... C-11
Appendix D Printed Wiring Board Reference
Glossary of Terms
Index
GEH-6631 EX2100 Installation and Startup Contents iii

Chapter 1 Overview
Introduction
This document is an installation and startup guide for the EX2100 Excitation
Control (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, as
follows:
Section Page
How to Use This Document .....................................................................................1-3
Structure of the Document.................................................................................1-3
Text Conventions ..............................................................................................1-3
How to Get Help.......................................................................................................1-5
Equipment Covered ..................................................................................................1-5
Related Documents...................................................................................................1-7
Document Distribution ......................................................................................1-7
Acronyms and Abbreviations ...................................................................................1-8
The remainder of the document is organized in the order required for installing and
starting the exciter (see How to Use This Document).
GEH-6631 EX2100 Installation and Startup Chapter 1 Overview 1-1

Figure 1-1. Typical EX2100 Excitation Control
Figure 1-2. Typical EX2100 Excitation Control Components
1-2 Chapter 1 Overview EX2100 Installation and Startup GEH-6631

How to Use This Document
Structure of the Document

GE recommends that a Sections of related procedures are presented in the order that they should be
detailed installation log is followed (see Figure 1-3).
maintained for the exciter as
Appendices provide reference information, as follows:
these installation and startup
steps are completed. 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 documents 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 be
followed in order (for example, a, b, c).
Bulleted () list Related items or procedures, but order does not
matter.
w A procedure with only one step.
Boxed () list A checklist.
Arial Bold When describing software, indicates the actual
command or option that is chosen from a menu or
dialog box.
Monospace Represents examples of screen text or words and
characters that are typed in a text box or at the
command prompt.

Start Installation site ready,
Procedures drawings & documents on
hand, all site parts present
Move exciter to Chapter 2,

installation site and Handling and Mounting
install it Guidelines
Installation
Connect cables Chapter 3,

& I/O wiring Cabling and Connections
Mount and install Chapter 4,

external devices Device Installation
Verify correct
functioning of Chapter 5,
Pre-Startup Installation
connected devices
Checks
Startup
(power, I/O)
Apply power, start Chapter 6,

Initial Setup and Operation
toolbox, run checks Checks
End of
Procedures
Figure 1-3. Structure of Document for Use in Installation and Startup

How to Get Help
If help is needed beyond the instructions provided in the exciter system
documentation, contact GE as follows:
+ indicates the GE Industrial Systems
international access code Product Service Engineering
required when calling from 1501 Roanoke Blvd.
outside the USA. 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 Covered
In this document, the term An exciter is a combination of one or more power conversion modules (PCMs) with
exciter refers to the their associated control and protection equipment (see Figure 1-4). The generator
EX2100 digital static exciter. field current and voltage requirements, and the redundancy requirements determine
the number of PCMs and the total number of cabinets. The available exciter sizes are
as follows:
Exciter Number of Number of Total

Current PCM Number of Bridge/Aux. Control Number of
Capability Redundancy PCMs Cabinets Cabinets Cabinets
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), or
a compound source (PPT and PCT), or from an auxiliary ac source (through a PPT).

Figure 1-4. EX2100 Cabinet Lineup Components

Related Documents
If needed for supplementary information, refer to the following EX2100 product
documents, as applicable:
Subject Document Content

EX2100 Toolbox GEH-6414 GE Control System Toolbox instructions for the EX2100
EX2100 Users Guide GEH-6632 Functional description, technical data, customer I/O connections,
keypad overview; application guides
EX2100 Maintenance, GEH-6633 Preventive maintenance, online maintenance, component replacement,
Parts Replacement, and fault list, and troubleshooting information
Troubleshooting Guide
EX2100 Receiving, GEI-100256 Procedures, precautions, and environmental requirements for receiving
Handling and Storage the exciter from the shipper and storing it before installation
Printed wiring boards See Appendix Board function within the exciter, I/O designations, fuses, jumpers, test
D for a list of points, and board replacement procedure
GEIs
Document Distribution
GE Industrial Systems supplies product documents to its customers to support the
equipment provided for each requisition. The contract documents define the terms of
the document distribution. If provided (per contract), the following documents
contain 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 the
requisition documentation, the requisition documentation should be considered the
more 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 output
ACLA Application Control Layer Module IPN intelligent part number
ACOM analog common J405 cable connector at row 4, location 05
AVR Automatic Voltage Regulator kg kilograms
C protection controller in a redundant system LAN local area network
CCOM control common LED light-emitting diode
CT current transformer level H high-level signal
DACA Ac to dc converter in control power supply level H(S) high-level signal, special handling
dc direct current level L low-level signal
DCOM digital common level M medium-level signal
DSPX Digital Signal Processor Board level P power signal
EACF Exciter Ac Feedback Board level P(S) power signal, special handling
EBKP Exciter Backplane Board m meters
ECTB Exciter Contact Terminal Board M1 primary controller
EDCF Exciter Dc Feedback Board M2 backup controller
EDEX Exciter De-excitation Board max maximum
EGD Ethernet Global Data min minimum
EGDM Exciter Ground Detector Module NEC National Electrical Code
EGPA Exciter Gate Pulse Amplifier Board OSHA Occupational Safety and Health Act
EISB Exciter ISBus Board P125 positive side of 125 V dc power supply
EMIO Exciter Main I/O board PC Personal Computer
EPBP Exciter Power Backplane PCM Power Conversion Module
EPCT Exciter PT/CT Board PCT Power Current Transformer
EPDM Exciter Power Distribution Module PLC programmable logic controller
EPSM Exciter Power Supply Module PPT Power Potential Transformer
ESEL Exciter Selector Board PSS Power System Stabilizer
EXAM Exciter Attenuator Module PT potential transformer
EXCS Exciter Current Sensor R125 return side of 125 V dc power supply
EXHS Exciter High-Speed Relay Driver Board RTDs resistance thermal devices
EXTB Exciter Terminal Board SCR silicon-controlled rectifier
ft foot, feet SHCOM shield common
ft-lbs foot-pounds (torque) TMR Triple Modular Redundant
ft/min feet per minute UEL Under Excitation Limit control
GE General Electric Company V ac volts ac (alternating current)
GPA Gate Pulse Amplifier VAR volt amperes reactive
HMI Human Machine Interface V dc volts dc (direct current)
in. inch(es)

Chapter 2 Installation Planning
Introduction
This chapter discusses installation planning and requirements for the EX2100
excitation control system. Specific topics include GE installation support, siting the
equipment, and environmental requirements.
Before installation, consult and study all furnished drawings. These should include
outline drawings, elementary diagram, connection diagrams, and a summary of the
equipment.
This chapter is organized as follows:
Section Page
Installation Support ..................................................................................................2-2
Early Planning ...................................................................................................2-2
GE Installation Documents................................................................................2-2
As-Shipped Drawings........................................................................................2-2
Technical Advisory Options..............................................................................2-3
Siting EX2100 Equipment........................................................................................2-5
Operating Environment .....................................................................................2-5
Equipment Clearances.......................................................................................2-6
Cable and Conduit Routing and Schedules .......................................................2-6
GEH-6631 Installation and Startup Chapter 2 Installation Planning 2-1

Installation Support
GEs system warranty provisions require both quality installation and that a qualified
service engineer be present at the initial equipment startup. To assist the customer,
GE offers both standard and optional installation support. Standard support consists
of documents that define and detail installation requirements. Optional support is
typically the advisory services that the customer may purchase.
Early Planning
To help ensure a fast and accurate exchange of data, a planning meeting among all
parties is recommended early in the project. This meeting should include the
customers project management and construction engineering representatives as well
as 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
customers 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 Documents
Installation documents consist of both general and requisition-specific information.
The cycle time and the project size determine the quantity and level of
documentation provided to the customer.
General information, such as this manual, provides product-specific guidelines for
the equipment. They are intended as supplements to the requisition-specific
information.
Requisition documents, such as outline drawings and elementary diagrams; provide
data specific to a custom application. Therefore, they reflect the customers specific
installation needs and should be used as the primary data source.
As-Shipped Drawings
These drawings include changes made during manufacturing and test. They are
issued when the equipment is ready to ship. As Shipped drawings consist primarily of
elementary diagrams revised to incorporate any revisions or changes made during
manufacture and test.
Revisions made after the equipment ships, but before start of installation, are sent as
a Field Change, with the changes circled and dated.
2-2 Chapter 2 Installation Planning EX2100 Installation and Startup GEH-6631

Technical Advisory Options
To assist the customer, GE Power Systems offers the optional technical advisory
services of field engineers for:
Review of customers installation plan
Installation support
These services are not normally included as installation support or in basic startup
and commissioning services, shown in Figure 2-1. GE presents installation support
options to the customer during the contract negotiation phase.
Installation
Support
Startup
Begin
Installation
Commissioning
Complete
Installation
Begin Product Support - On going

Formal
Testing
System
Acceptance
Figure 2-1. Startup and Commissioning Services Cycle
Review of Installation Plan

It is recommended that a GE field representative review all installation/construction
drawings, and the cable and conduit schedule when completed. This optional review
service ensures that the drawings meet installation requirements and are complete.
Installation Support
Optional installation support is offered: planning, practices, equipment placement,
and onsite interpretation of construction and equipment drawings. Engineering
services are also offered to develop transition and implementation plans to install and
commission new equipment in both new and existing (revamp) facilities.
Customers Conduit and Cable Schedule

The customers finished conduit and cable schedule should include:
Interconnection wire list (optional)
Level definitions
Shield terminations

Level Definitions
The cable and conduit schedule should define signal levels and classes of wiring (see
section, Cable and Conduit Routing and Schedules and Appendix B). This
information should be listed in a separate column to help prevent installation errors.
The cable and conduit schedule should include the signal level definitions in the
instructions. This provides all level restriction and practice information needed
before installing cables.
Shield Terminations
The conduit and cable schedule should indicate shield termination practice for each
shielded cable (refer to the section, Cable and Conduit Routing and Schedules and
Appendix B).

Siting EX2100 Equipment
Prior to receipt of the equipment, all plans should be finalized as to the location the
equipment will be installed. This section is a general guide as to the factors that may
influence the choice of this site.
Operating Environment
Of prime concern in the choice of equipment location is the operating environment.
The EX2100 control panel is suited to most industrial environments. To ensure
proper performance and normal operational life, the environment should be
maintained 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: 0.1C 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 electronic
component. Keeping ambient air in the preferred (cooler) range should extend
component life.
Maximum concentration of corrosive gases at 50% relative humidity and 40C per
EN50178: 1994 Section A.6.1.4 Table A.2 (m).
Sulfur dioxide (SO2) 30 ppb
Hydrogen sulfide (H2S) 10 ppb
Nitrous fumes (NOx) 30 ppb
Chlorine (Cl2) 10 ppb
Hydrogen fluoride (HF) 10 ppb
Ammonia (NH3) 500 ppb
Ozone (O3) 5 ppb
Particle sizes from 10 - 100 microns for the following materials:
Aluminum Oxide Sand/Dirt Cement Lint Coal/Carbon dust
Steel 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 elements
reduce 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 near
control circuits.
The preferred location for the EX2100 excitation control system cabinet would be in
an environmentally controlled room. The panel should be mounted where the floor
surface allows for attachment in one plane (a flat, level, and continuous surface). The
mounting hardware is provided by the customer. Lifting lugs are provided and if
used, the lifting cables must not exceed 45 from the vertical plane. Finally, the panel
is equipped with a door handle, which can be locked for security.
Equipment Clearances
Each EX2100 is supplied with an outline drawing that provides the physical
dimensions of the cabinet. Overhead clearance for fan discharge and front panel
clearance for personell entry and egress are particularly important. Sufficient space
for the equipement must be allocated such that the following minimum clearances
are maintained:
Excitation Cabinet Sidewalls: 0 inches minimum.
Excitation Cabinet Rear Panel: 0 inches minimum
Excitation 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 90
degree angle.
Special attention to the door clearances should be made in order to maintain
compliance with local regulations regarding proper entry and egress to working
spaces.
Cable and Conduit Routing and Schedules

Interconnecting cables can be brought into the panel from the top or the bottom via
removable access plates. Review of equipment spaces prior to installation should
include access to the area via cable trays and conduit, station grounds, routing of
interconnecting bus and location of the excitation transformer.
A thorough cable and conduit schedule should be developed to allow proper
planning of the necessary materials and time to install the EX2100 using the
interconnection information provided in the system elementary.
Size and location of external station service requirements for lighting, heaters, power
supplies and other equipment should be reviewed. Attention to items that will
facilitate 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 temperature
range, as listed above. This applies to both top and bottom access plates. Appendix B
of this document addresses other cable routing and separation concerns.

Chapter 3 Handling and Mounting
Guidelines
Introduction
GE document GEI-100256 This chapter provides general guidelines for moving the exciter to the installation
provides receiving and site, and then installing it. The requisition drawings provided with the equipment
storage guidelines. provide specific information and are a required supplement to this document. This
chapter is organized as follows:
Section Page
Exciter Handling Procedures ....................................................................................3-2
Lifting................................................................................................................3-2
Moving ..............................................................................................................3-3
Unpacking .........................................................................................................3-4
Mounting ..................................................................................................................3-5
Securing the Exciter Lineup to the Floor...........................................................3-8
Note Dimensions shown in Figures in this chapter are given in inches with
millimeters shown in parantheses.
GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines 3-1
Exciter Handling Procedures
Shock or stress caused by rough handling or improper lifting

and moving can damage the equipment. Be sure to follow the
guidelines provided in this chapter.
The shipped equipment consists GE recommends that you do not completely unpack the equipment until it has been
of three cabinets secured moved as near as possible to its permanent location. This practice helps ensure that
together in a lineup, typically loose parts remain with the exciter. Additionally, the shipping enclosure helps
not exceeding 15 ft in length. protect the equipment during storage.
Before lifting and moving the exciter, always refer to the equipment outline
drawings. Become familiar with the designated lift points and the stress points, and
any specified handling instructions.
While lifting and moving the exciter, be sure to follow the suggested methods in
this chapter for handling the equipment, along with normal handling precautions.
Additionally, it is important to observe any instructions that may be printed on or
attached to the equipment container or wrapping.
Lifting
Lifting beams are attached Make sure that the lifting equipment is suitable for the configuration and weight
across the top of the exciter at of the exciter as follows:
the factory. - 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 applies
pressure from below, such as a forklift. Doing so could
damage the exciter frame. If a crane is not available for
lifting, contact GE for guidelines on using other methods.
Figure 3-1. EX2100 Lineup Lifting Beam
3-2 Chapter 3 Handling and Mounting Guidelines EX2100 Installation and Startup GEH-6631
Use four hooks in openings
in lifting beams (two in front
and two in back).
Angle must be
45 degrees or
greater.
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 reduce
potential stress.
- Roll only on the shipping pallets that are attached to the cabinets when
shipped from the factory.
Do not move with a forklift, since the weight of the exciter against the forklift
tines would put damaging pressure on the exciter frame.
Make sure that all doors are closed and latched.
Unpacking
Recommended: Do not If the equipment has been exposed to low temperatures for an extended period,
completely unpack the do not unpack it until it has reached room temperature (location where exciter
equipment until it is placed as will be mounted).
near as possible to its Use standard unpacking tools, including a nail puller.
permanent location.
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 the
packing material for loose parts before discarding it.
Document and report any If equipment damage is discovered while unpacking

equipment damage to GE.
1. Stop unpacking immediately and report this finding to the carrier (transportation
company).
2. Photograph the damage (photographs may be needed later in processing the
claim).
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 following
information (refer to Appendix A):
Serial number
Part (model) number
Exciter code
GE requisition number
Case number
Mounting
Figures 3-3 through 3-5 are simplified outline drawing examples that provide the
following 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 with
millimeters shown in parantheses.
The requisition outline Along with the information shown on the outline drawings, use the following
drawings show specific lineup mounting guidelines:
and installation details. 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 Grounds

The EX2100 must be grounded to protect against the risk of electrical shock or burn
and toprotect the equipment from fire or other damage due to ground faults or
lightning strikes. Proper grounding also helps improve the equipments immunity to
electrical noise originating within or outside of the equipment. Follow the procedures
provided on the EX2100 requisition elementary diagram sheet 0D, Grounding
Instructions. Complete instructions, recommended cable sizes, and diagrams are
provided there.
The ground connections must be complete to ensure proper

grounding of the equipment.
Exciter Heat Loss Airflow Req. Standard Outline
3
Size Weight (kg / lbs) (Watts)* (ft /min)** Dwg.
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 Floor
The exciter lineup must be secured to the floor using mounting studs. Figure 3-5
shows the location of mounting holes in the exciter base. Refer to the exciter outline
drawing sheet 1 for additional information about securing the lineup.
Figure 3-5. Location of Mounting Base Holes for Securing Exciter to Floor
Chapter 4 Cabling and
Connections
Introduction
This chapter assumes that This chapter contains guidelines for connecting cable to the exciter during
cabling was previously run to installation. This information must be used along with the project specific
the installation site and is elementary diagrams and outline diagrams supplied with the equipment.
ready for connection to the
exciter.
Do not assume any cable or any circuitry to be without power

if one end of that cable could be connected to a power source.
To prevent accidental electrical shock, do not touch any
circuitry or bare wire without first ensuring that it does not
carry electricity.
When testing for the presence of electricity and when
measuring any electrical circuit, use only the equipment
approved 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 as
wire size, insulation type, and conduit sizing. This chapter is organized as follows:
Section Page
Exciter Connections..................................................................................................4-2
Grounding and Cable Entry......................................................................................4-6
Cable Entry........................................................................................................4-6
Control Power...........................................................................................................4-9
Converter Power.....................................................................................................4-10
Field Flashing (Optional)........................................................................................4-11
Generator Field Connections ..................................................................................4-11
Signal and Communications Cabling Guidelines ...................................................4-11
Generator PT and CT Inputs............................................................................4-11
Contact Inputs .................................................................................................4-12
Data Highway..................................................................................................4-15
PC Interface.....................................................................................................4-16
Preventing Cable Damage ......................................................................................4-16
GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections 4-1
Exciter Connections
Cabling 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) show
the location of connection points, fuses, and other exciter components. A device
nomenclature sticker, located on the inside of the exciter cabinet door identifies the
exciters major components and their locations within the cabinet.
Complete outline diagrams are supplied with the exciter.
The exciter Users Guide, Customer cabling to the exciters terminal boards must comply with level-separation
GEH-6632, describes the guidelines (refer to Appendix B) after it enters the exciter cabinet. To meet CE
terminal board I/O. Mark requirements, all I/O wires leaving a building must be routed inside
continuous metal conduit.
4-2 Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631
Cutout for Customer
Connections
ECTB
ECTB Wiring
(Refer to elementary sheet EXHS/EXTB
7A and 11A for details)
Control Rack
EPCT
PT1
(optional) PT2 Ethernet Link to ACLA
(Refer to elementary sheet 8A
CT1 and 11A for details)
CT2
Power Supply Rack

Breaker 1, 2
120 V ac, 15 A
Breaker 3
120 V ac, 5 A
EPDM DACA 1 (DACA

(FU1 FU12 on EPDM, 2 optional)
refer to elementary sheet
7A and 11A for details)
Space Heater 1
(optional)
TB1
Cutout for Customer

Connections
Figure 4-1. Sample Component Layout, Exciter Control Cabinet
Ac Line Filter
Shaft Voltage Suppressor
LFU2 (optional), FU1 FU3
LFU1, FU1 FU3

EXAM
EDCF M1
EACF
(optional) EDCF M2
(optional) EDCF - C
Ac input from PPT
Phase A Front Shunt
De-excitation Module
Phase B Middle Shunt
Phase C Rear Shunt
Ground Lug
(optional) PTB1 Dc Field Flashing (optional)

125 V dc, 15% AFNL
FF, FU1 and FU2
Space Heater 2 (optional)
Figure 4-2. Sample Component Layout, Exciter Auxiliary Cabinet
Drip Shield (optional) Fans 4 6
(optional)
Dc Bus Connections
(optional) Fans 1 3
Ground Lug
EGPA M1
EGPA M2
Dc Contactors 41A, 41B
(optional)
Ac Disconnect
(less than 600 V ac
applications only)
Ground Lug
Ac Input Connections
(optional)
Dc Bus Connnections
Bridge 2
Bridge 1
Thermal Sensors
Figure 4-3. Sample Component Layout, Exciter Power Conversion Cabinet
Grounding and Cable Entry
For both safety and proper functioning of the equipment, it is important that the
exciter be properly grounded. The installation site must have a reliable building
grounding system and the exciters grounding cable must be securely fastened to this
system per the elementary diagram. Follow the procedures provided in the EX2100
requisition elementary diagram sheet 0D, Grounding Instructions. Complete
instructions, recommended cable sizes, and diagrams are provided there.
Note If you have an engineered system, consult your requisition elementary

drawings for the grounding method recommended for your installation.
For shielded and twisted wire, ground the shields on one end only, preferably at the
exciter end. Provisions have been made to tie shields to chassis ground on several
exciter terminal boards.
Cable Entry
See EX2100 outline drawings Removable access panels for cable entry are provided in the top and bottom of the
for complete information. control cabinet, the bottom of the auxiliary cabinet, and the bottom of the converter
portion of the power conversion cabinet. Refer to Figures 4-4 through 4-6 for the
location 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
Optional Ac
Connections
Wire Entry Bottom
Figure 4-6. Converter Cable Entry (Power Conversion Cabinet)
Standard Ac Connections
Ground Bus
Figure 4-7. Auxiliary Cabinet Power Connection Points
Ground Bus Optional Ac Connections
Door
Figure 4-8. Power Conversion Cabinet Power Connection Points
Control Power
The exciter requisition The exciter control power requirements are as follows:
drawings specify the power Voltage: Nominal 115 V ac, 15% at 60 Hz; single phase, 10 A rms max
requirements for the Nominal 125 V dc from battery, 10.6 A dc max
application and show
connection points. Nominal line frequency: 50 or 60 Hz, 2%
The ac to dc converter(s) The Exciter Power Distribution Module (EPDM) produces 125 V dc for the control
(DACA) are mounted at the power modules. It is located on the side of the power supply module. Redundant
bottom of the control cabinet. power sources for the control modules ensure high supply reliability. Both ac and dc
sources are wired to TB1 on the EPDM, refer to Figure 4-9. A second ac source and
DACA can be used if required.
EPDM Exciter Power Distribution Module
1
SW7 SPRE 2
1
SW6 J1C 2
1
SW5 J1M2 2
1
SW4 J1M1 2
1
SW3 J8C 2
x
TB1
1
x 1 P125Vdc SW2 J8B 2
125 V dc R125Vdc x 2
x 3 P125Vdc
from battery R125Vdc x 4
R125Vdc x 6
x 5 P125Vdc
x 7 1
x 8 SW1 J8A 2
x 9
x 10
x 11
x 12
115 V ac x 13 AC1H
x 14 1
supply #1 x 15 AC1H
x 16 J9
x 18
x 17 AC1N 3
x 20
x 19 AC1N 1
1
115 V ac AC2N x 22
x 21 AC2H 0
supply #2 AC2N x 24
x 23 AC2H JDACA1
x 3 12
1
1
0
JDACA2
3 12
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 fused
and can be isolated with a switch.
Converter Power
The main ac power supply for the exciter can come from a potential source, a
compound source, or an auxiliary bus. Figure 4-10 shows supply from a power
potential transformer (PPT) connected to the generator output.
PPT 41AC1
Exciter Power Conversion Cabinet
X1
H1
K1
L1
PRI VAC : 12470
SEC VAC : 650
To Bridge 1
X2
H2
K2
L2
and Line
KVA 1280
Filters
X3
H3
K3
L3
Phase Rotation
3
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 engineering
company. If help is needed contact:
+ indicates the GE Industrial Systems
international access code Product Service Engineering
required when calling from 1501 Roanoke Blvd.
outside the USA. 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 the
station battery terminals and fuses FU1 and FU2. Other connections to the module
include status contacts from the EXHS board. Power output goes to the generator
field. Refer to the elementary diagram sheet 4A for additional information.
Figure 4-11. Field Flashing Module
Generator Field Connections

The external generator field connections must be meet all applicable codes and
comply with the generator manufacturers guidelines. Connecting cables must be
sized properly and insulated per IEEE 421-3 guidelines.
Signal and Communications Cabling Guidelines

Be sure to strictly follow the cable manufacturers 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 Inputs

The generator PTs and CTs are customer supplied. The connections to the switches
in 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 elementary
diagram for specifics.
Supplied by Others
+ Generator Field +
To Bridge 1
-
Exciter Control cabinet
Generator Field -
PT1 PTSW1
OR GROUNDED Y)
TB1
X1
H1
PRI VAC : 14400
2
1
SEC VAC : 120 PT PT
1
X2
H2
2
4
3
3
4
5
X3
H3
6
5
PT PT
6
To
7
(OPEN
24 22 20 18 16 14 12 10 8
EMIO
23 21 19 17 15 13 11 9
PT2 PTSW2 (M1)
J305
OR GROUNDED Y)
X1
H1
2
PRI VAC : 14400
1
SEC VAC : 120
To
X2
H2
4
3
Fan-out circuits
EMIO
(M2)
X3
H3
J308
6
5
(OPEN
To
CT CTSW1 TB2 EMIO
5H
X2 (C)
1
2
J315
1
5L
CT
2
1H
4
3
1L
X1
TB3 4
CTSW3 5H
CT
1
X2 5L CT
2
1H
3
4
1L
EPCT
4
X1
Phase Rotation
3
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 (305
meters) of #12 AWG twisted shielded wire. The cable length between the CT and the
EPCT board can be up to 1000 ft (305 meters), using up to #10 AWG wire.
Contact Inputs
The ECTB board provides terminals for contact inputs from the customer's devices.
Six auxiliary contact inputs, and contact inputs from 52G and 86G are
accommodated. 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 to
GEI-100457.
J13M1
From M1 P70 V dc ECTBG2 (Simplex)
TB1
P24M1 P24D 18
NO
Customer
J405 P24D 19 Power to
COM
Relay Coil Contacts
Driver K#GP 125 V dc
20
From M1 NC
(EMIO)
Four General Purpose Relay Outputs as
1
P24M1 M1
Relay Coil
Customer
Driver K#M1
Power to
M1 Contacts
125 V dc
(1 of 2)
5
Two Trip Relay Outputs as

Term. 1&5
Ex. trip to
Customer
86
P70Vdc Auxiliary
Red LED Contact
33
Inputs
34 (1 of 6)
Current Limit
Six Circuits as Above

P70Vdc 52G
Red LED 45 Contact
(Closed
46 online)
Current Limit
P70Vdc 86G
47 Contact
To Optocoupler on M1 (EMIO) (Open

48 for Trip)
Current Limit
TB2
Figure 4-13. ECTBG2 Terminal Board, Simplex
J13M1
P24M1 ECTBG1 (Redundant)
From M1 P70M1
P24D TB1
P70 V dc
P24M2 18
J13M2
From M2 NO
P70M2
Customer
P24M1 19 Power to
Voted P24D COM
J405 Coil Contacts
Relay
K#GP
Driver 20 125 V dc
From M1 NC
(EMIO)
Four General Purpose Relay Outputs as
P24M2 M1 P24M1 M1 M2
Relay Coil
Driver K#M1 Customer
J408 M2 C Power to
M2 P24M2 Contacts
Relay Coil
From M2 Driver K#M2
(EMIO) C M1 125 V dc
5
C P24C
Relay Coil
Driver K#C
Term. 1&5
Ex. Trip to
Two Trip Relay Outputs as Customer
86
J415 P70Vdc Auxiliary

Red LED 33 Contact
From C Inputs
(EMIO)
34 (1 of 6)
Current Limit
Six Circuits as Above

P70Vdc 52G
Red LED 45 Contact
(Closed
M1 46 online)
M2 Current Limit
C P70Vdc 86G
47 Contact
To M1 (EMIO)
Current Limit (Open
48 for Trip)
To M2 (EMIO) Current Limit
To C (EMIO) TB2
Current Limit
Figure 4-14. ECTBG1 Terminal Board, Redundant
Data Highway
A typical exciter connection to the redundant Unit Data Highway (UDH) network is
shown in Figure 4-15. This shows redundant control with two ACLA modules,
(simplex control has one ACLA with one UDH). The UDH is implemented using
commercially available fast Ethernet switches. 10Base-T cabling is used for short
distances between the controller and the T-Switch, and any local HMI. 100Base-FX
fiber-optic cabling is used for longer distances between the local control area and the
central control room.
Central Control Room
Fast Fast
Ethernet Ethernet
Switch A Switch B
From other Units From other Units 100Base-FX

connections
T-Switch A T-Switch B
To local HMI
Viewer, 10Base-T
10Base-T connections
Local Control Area From other Controllers From other Controllers
Exciter Control
gGE Industrial
Systems Cabinet gGE Industrial
Systems
S S
T T
A A
T T
U U
S S
COM
COM
1
1
2
2
ENET
ENET
Ethernet Port,
ACLA RJ-45 ACLA
H1A H1A
Figure 4-15. Ethernet Cable Connections
The 10Base-T ports in the ACLA and the T-Switch use RJ-45 connectors. The
maximum 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 type
fiber-optic connectors. The maximum distance using 100Base-FX fiber-optic cables
is 2 km.
PC Interface
Control program downloads A PC can be connected to the controller to download firmware into the DSPX board.
are usually made from a PC on The PC connects to J303B (M1 Tool) located on the control rack backplane. In a
the UDH Unit Data Highway redundant system, connectors J310B or J313B can be used for accessing the DSPX
using the toolbox software. board in M2 or C.
Note The PC-to-exciter cable is not provided with the exciter and must be ordered
separately. Part numbers are:
336A3582P1 COM1 to EX2100 backplane or keypad 9-pin D connector
336A4929G1 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.
Chapter 5 Pre-Power On
Installation Checks
Introduction
This chapter must be This chapter contains instructions to verify that the EX2100 lineup is ready for initial
completed before applying power up. This includes checks and procedures to ensure that the exciter has been
power to the excitation installed correctly and can be safely energized.
system.
All instructions must be followed and completed in the order

presented.
It is good practice to check off each procedure when you
complete it. For this purpose, this chapter includes
checkboxes next to each procedure heading.
This chapter assumes that the excitation lineup and connected devices have already
been installed, and that all wiring and cabling are installed correctly including
control and power connections. It is presented as follows:
Section Page
Equipment/Material Needed.....................................................................................5-2
Securing the Equipment for Safety...........................................................................5-2
Hardware Checks......................................................................................................5-3
Optional Megger Test...............................................................................................5-5
Pre-Test Power Checks .....................................................................................5-5
Ac Input Bus and PPT Secondary .....................................................................5-5
Dc Output Bus...................................................................................................5-6
GEH-6631 Installation and Startup Guide Chapter 5 Pre-Power On Installation Checks 5-1
Equipment/Material Needed
Checkboxes should be marked Check that the following equipment and materials are available for the procedures in
to verify that equipment is this chapter.
onhand. o Locks and tags, danger and caution tape
o Source of low-pressure, compressed, dry air (less than 15 psi) or clean, dry cloth
o Small standard (flat-head) screwdriver
o Torque wrench
o Socket sets, standard and metric
o Digital multimeter
o One dc megger tester (voltage not to exceed 500 V), optional
o EX2100 unit specific Elementary Diagrams.
o EX2100 unit specific Outline Drawings.
o EX2100 Users Guide, document GEH-6632
o EX2100 Circuit Card GEI Instructions (refer to Appendix D for list)
Securing the Equipment for Safety

o All procedures in this section 1. Lock out and tag out all voltage sources to the exciter. Apply safety grounds per
were completed successfully. local rules and regulations.
2. Place appropriate barriers and warnings at the generator brush rigging while
testing.
3. Verify that the generator collector ring brushes are not installed and/or the
exciter generator field leads are disconnected at the EX2100 cabinet.
5-2 Chapter 5 Pre-Power On Installation Checks EX2100 Installation and Startup GEH-6631
Hardware Checks
o All procedures in this section All exciters are factory-tested and operable when shipped to the installation site.
were completed successfully However, connections could loosen during shipping and handling. To help ensure
for: successful startup, check the hardware after installation and before initial powerup.
o Control
o Auxiliary Check EX2100 hardware as follows
o Power Conversion 1. 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 previous
section.
3. Using an approved tester for the voltage levels being measured, verify that
power has not yet been applied to the circuitry.
With power applied, high voltages are present on some

circuitry. To prevent accidental injury, do not touch any
circuitry without first ensuring that it does not carry these
voltages and is grounded.
When testing for the presence of high voltages and when
4. Using either low-pressure, compressed, dry air or a clean, dry rag, remove any
dust that may have accumulated in the exciters interior.
5. Inspect wiring to ensure that it has not been damaged or frayed during
installation. Replace if necessary.
6. Check that all electrical terminal connections are tight.
7. Check that all devices, modules, and boards have not been damaged during
handling 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 handling
techniques. Wear a wrist grounding strap when handling
boards or components, but only after boards or components
have been removed from potentially energized equipment
and are at a normally grounded workstation.
Note To ensure that electrical connections remain tight, re-check them within three
to six months after initial powerup, and annually thereafter. Use screwdrivers and
torque wrenches for these checks.
8. Check that the correct shunt has been installed and that the shunt cables are
installed correctly. (Refer to the elementary data sheet 0E.)
9. Check fusing in the excitation cabinet. (Refer to the elementary sheet 0E or to
the nomenclature sticker located inside the excitation cabinet door).
10. Verify that all control power switches on the Power Distribution Module are in
the off or open position. All power disconnects and circuit breakers should be
open.
11. Verify that the circuit cards listed on the EX2100 elementary data sheet 0E have
correct settings for hardware jumpers. Location of hardware jumpers can be
found 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 parts
operate 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 Test
A megger (megohm meter) This optional test verifies that the system-to-ground insulation has not been damaged
measures resistance by during installation. All EX2100 lineups have been high potential tested prior to
placing voltage across a shipment. It is recommended that the EX2100 be disconnected from all bus or cables
device with respect to ground. to 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 some

circuitry. To prevent accidental injury, do not touch any
circuitry without first ensuring that it does not carry these
voltages and is grounded.
Before conducting the megger test on any component, check for the
presence of power on the circuitry, as follows
1. Check that the ac bridge power, PPT primary power, and all sources of control
power have been locked out and tagged out.
The exciter outline drawing 2. Open all the control power inputs and AC input disconnect (circuit breaker or
shows location of fuses, switch) in the power conversion module.
disconnects, and other
components within the Note There could be multiple sources of power in the enclosure.
excitation cabinet.
3. Remove all collector ring brushes from the generator brush rigging. Place
appropriate barriers and warnings at the brush rigging while testing.
4. Using a voltmeter, check that the bus voltages have discharged to below 1 volt
on the following circuits.
Use the checkbox to mark o PPT input line to line
each completed measurement. o PPT input line to ground
o Dc output positive to negative

o Dc output positive and negative to ground
Ac Input Bus and PPT Secondary

o All procedures in Ac Input Bus 1. Do not proceed until completing all requirements under Pre-Test Power Checks
and PPT Secondary megger
2. Short the ac input buses together using jumpers or wire.
were completed successfully.
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 be
greater 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
o All procedures in Dc Output 1. Do not proceed until completing all requirements under Pre-Test Power Checks.
Bus megger section were
completed successfully.
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 be
greater 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.
Chapter 6 Initial Startup and
Commissioning
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 the
keypad and offline and online commissioning guidelines.
This chapter is organized as follows:
Section Page
Before Beginning......................................................................................................6-2
Order of Startup.................................................................................................6-2
Information Needed...........................................................................................6-2
Equipment/Material Needed..............................................................................6-3
Panel Lights, Heaters and Fans.................................................................................6-6
Verifying Control Power ..........................................................................................6-8
Control Module Processor Start .............................................................................6-12
Using the Exciter Configuration Tools...................................................................6-13
Using Toolbox Online Help ............................................................................6-13
Starting the Toolbox........................................................................................6-14
Open an EX2100 File ......................................................................................6-14
Checking Toolbox/EX2100 Pattern Compatibility .........................................6-14
Downloading to the EX2100 ...........................................................................6-14
Optional: Upgrading the .ecb File ..................................................................6-15
Checking for Correct Firmware and Hardware ...............................................6-15
Checking the Keypad (EDI) ...................................................................................6-16
Using the Keypad for Startup and Commissioning .........................................6-16
Adjusting Keypad Display Contrast ................................................................6-18
Commissioning the Exciter ....................................................................................6-19
Overview of EX2100 Parameters....................................................................6-19
Running Simulator Mode ................................................................................6-22
Temporary Load Checks .................................................................................6-27
Initial Roll and Offline Checks .......................................................................6-30
Online Checks .................................................................................................6-52
Additional Testing...........................................................................................6-53
GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning 6-1
Before Beginning
Before 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 ferrite

core (Fair-Rite P/N 2643164251 or equivalent) must be
placed on each Ethernet network cable near the IS200ACLA
termination point. Verify this before applying power to the
control rack.
Note The EX2100 meets the following noise level specifications:

Fan Doors Closed, One Meter Doors Open, Adjacent to
Quantity from Enclosure Enclosure
Average Maximum Maximum
3 69.9 dBA 71.4 dBA 79.4 dBA
6 75.5 dBA 76.5 dBA 82.2 dBA
Users Guide, GEH-6632, Order of Startup

includes a functional descrip-
tion of the EX2100, including The EX2100 Excitation Control can be provided in a variety of ratings and applica-
hardware structure. tions. The basic design incorporates a common hardware and software structure,
therefore the startup and commissioning procedures are similar for the different
possible applications.
Whether a simplex or redundant control configuration or single or multiple bridge
configuration, each EX2100 should be started and commissioned using the following
basic 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 order
presented in this chapter.
Tip It is good practice to check off each procedure when you complete it. For
this purpose, this chapter includes checkboxes next to each procedure heading.
Information Needed
Before beginning, you should review the applicable elementary and outline drawings
to become familiar with the type of EX2100 supplied. Make sure you know the
power requirements and location of components, connections, and power switches.
6-2 Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631
Software for the EX2100 will be When commissioning the exciter with the GE Control System Toolbox for the first
found either on the turbine time, each EX2100 will have its own unique software file scaled and tailored for the
control master HMI or supplied generator applied using a common file extension .ecb for both DSPX and ACLA
separately for stand-alone ex- processors. It should be verified that the file to be used is correct and the most up to
citation systems. date available. The software is tested at the factory prior to shipment and should
require a minimum of changes during commissioning.
Checkboxes should be marked to Equipment/Material Needed

verify that equipment is onhand.
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 when

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 excitation
system.
EX2100 outline drawings
EX2100 Users 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 of
GEH-6633 is also available as Help files within the toolbox
program (refer to Using Toolbox Help in this chapter).
Start
1
Refer to sections
Control Power Applied & Lights Verifying Control Power and
Panel Lights, Heaters, and
Heaters and Fans Operational
Fans
Yes
1a
Refer to
Is Control System No Install Toolbox
toolbox document
Toolbox Installed? Install Drive Components GEH-6414 (Chapter 3).
Yes
Refer to
Start Toolbox toolbox document
GEH-6414 (Chapter 3).
3
Are EX2100 Obtain Configuration Files Refer to
Configuration files No From HMI or Requisition
toolbox document
Available? Engineering (.ecb for DSPX
and ACLA)
Yes
Open the EX2100 4

Configuration Files (.ecb) Refer to
(Toolbox Version is toolbox document
Automatically Verified)
Message: Message:
File last saved with No File last saved with No
older version toolbox newer version toolbox
? ?
Yes Yes
4a 4b
Get Old Toolbox

Get New Toolbbox
or Upgrade the file
4a and 4b
Refer to toolbox document
GEH-6414 (chapter 3).
B
Figure 6-1. Overview of EX2100 Startup and Commissioning (Part 1 of 2)
B
5
Establish 5 and 6
Communications Refer to
with the EX2100 toolbox document
6 6a
No No Download Flash
Do EX2100 and File Is EX2100 newer
versions agree? than file?
(File is newer than EX2100)
Yes Yes
6b 6a and 6b
Refer to
toolbox document
Upgrade File
Review Release Notes Refer to

toolbox document
Create Version Summary
8
Check Hardware Refer to
Check Firmware toolbox document
Check Keypad
and section
Checking the Keypad (EDI)
9
Perform Simulator Refer to sections
andTemporary
Simulator andTemporary Load Checks
Load Checks
10
Perform Off and On-line Refer to sections

Commissioning Checks Off-line Checks
and
On-line Checks
End
Figure 6-1. Overview of EX2100 Startup and Commissioning (Part 2 of 2)
Panel Lights, Heaters and Fans
Refer to Figure 6-1, Block 1 Each EX2100 will have power conversion module cooling fans supplied. Optional
and Figure 6-2. panel heaters and lights may also be provided. These items should be energized
and operation verified prior to energizing the control power. Refer to the applicable
All procedures in this section
system elementary for options provided. Refer to the applicable panel outline
were completed successfully
drawings for location of components.
for:
Lights
Heaters With power applied, this equipment contains a potential
Fans hazard of electric shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the equip-
ment and the instructions should install, operate, or maintain
this drive.
To minimize hazard of electrical shock or burn, approved
grounding 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 with
the system drawings.
3. Turn the ac breaker switch for the panel lights to the on position. Each panel
light 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 panel
heater should energize. Verify heater operation with an infrared heat detection
device or carefully feeling for heat several inches above the heater surface.
The heaters are not used to Once energized, panel heaters can be very hot. Keep all
maintain a constant tem- debris and flammable materials from contacting the heater
perature but to merely keep surfaces. Heater surfaces should never be touched while
the EX2100 above ambient energized.
temperature.
6. Verify that EGPA board jumper settings for JP1 JP5 agree with elementary
diagram 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 on
the applicable system elementary. Verify that the line and neutral connections
are 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.
Power to Control Module
To M1 To M2 To C
Breakers
PCM
Fans
M1 M2 C
PCM EDEX EDCF CONTROL EDEX EDCF CONTROL EDEX EDCF CONTROL
Fans EDEX EDEX EDEX
J602 J602 J602
EETB EETB EETB
PCM ECTB ECTB ECTB
Fans EXTB EXTB EXTB
EDEX EGDM FAN MEDIA EDEXEGDM FAN MEDIA EDEX EGDM FAN MEDIA
CROWBAR CONV CROWBAR CONV CROWBAR CONV
Heaters
Fan Fan Fan
EPDM Exciter Power

Distribution Module Blank EPSM EGDM EPSM EGDM EPSM EGDM
plate Power Ground Power Ground Power Ground
J1C SW6
1
2
Supply Detector Supply Detector Supply Detector
M1 M1 M2 M2 C C
1
J1M2 SW5 2
J1M1 SW4
1
2
1
J8C SW3 2
x
TB1
1
x 2
x 1 J8B SW2 2
x 3
x 4
x 5
x 6
x 7 1
x 8
x 9
J8A SW1 2
x 10
x 11
x 12
x 13
x 14 1
x 15
x
x
16
18
x 17 J9 3
x 19
x 20 1 10
x 21
x
x
22
24
x 23 JDACA1 J1_M1 J1_M2 J1_C J2C GROUND
x 3 12
1 10 DETECT
JDACA2
3 12
125 V dc To J1M1
115 V ac To J1M2
Supplies To J1C
Figure 6-2. Front View of Power Supply Module
Verifying Control Power
Refer to Figure 6-1, Block 1 Refer to the Power Supply section of the system elementary and GEI-100463 for an
and Figures 6-2, 6-3, and 6-4. overview of the EX2100s control power circuitry.
for:
Master 1
Master 2
Control
With power applied, this equipment contains a potential

hazard of electric shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the equip-
ment and the instructions should install, operate, or maintain
this exciter.
To minimize hazard of electrical shock or burn, approved
grounding practices and procedures must be strictly fol-
lowed.
1. Before energizing the power supply inputs, verify that all toggle switches on the
EPDM are in the OFF position. Disconnect the DACA1 and DACA2 plug
jumpers 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 ac
source power for the DACA modules.
4. Reconnect the JDACA1 plug and re-apply the 120 V ac source power. Measure
the voltage at FU1 and FU2 for a nominal 125 V dc to the EPDM distribution
switches.
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 DACA
modules.
6. Apply the 125 V dc control power source as shown on the elementary power
supply sheets. Again measure the voltage at FU1 and FU2 for a nominal 125 vdc
to the EPDM distribution switches.
7. Remove the 125 V dc power and plug connector J9 on the EXTB or EXHS
board back in.
8. Apply 125 V dc power to the EPDM. This will apply power to the EXTB or
EXHS board. There are no external indications of power to this board. Relay
operation 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 the
backup 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 to
check power supply voltages without having the cards in the EBKP control rack
inserted in their proper position. These supplies are tested and verified at the
factory during card test and system test prior to shipping.
IS200EPDMG1A SFTYGND
E3 E4
FU13
SW7
SPARE
FU14
Fuse Data SPARE
Table SW1C DS8
FU11
PS1C
SW6
FU12
J1C
SW1M2 DS7
FU9
PS1M2
SW5
FU10
J1M2
SW1M1 DS6
FU7
PS1M1
SW4
FU8
J1M1
SW8C DS5
CHASGND1 FU5
E1
PS8C
SW3
FU6
J8C
TB1 SW8B DS3
FU3
SW2 PS8B
FU4
J8B
SW8A DS2
FU1
SW1
PS8A
FU2
J8A
DS1
PS9
J9 DS4
JDCA1
CHASGND JDCA2
E2
Figure 6-3. EPDM Board Layout
DC Power Source
130 V dc (nominal)
80 - 140 V dc
PSOK TPxx TPxx Line Filter Sensor
Fan Rotation Sensor 1

TPxx TPxx
Fan Rotation Sensor 2

6X Gates
Klixon (T=170F, Alarm)
ALARM Klixon (T=190F, Fault)
FAULT Disable coolant trip
RTD Coolant Temp
Figure 6-4. EGPA Board LED Locations
Carefully follow the procedures documented in the circuit

board instruction manuals for inserting the boards into the
control 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 the
EPSM is energized. Verify counter-clockwise rotation of each fan.
14. One at a time, close EPDM switches SW1M1, SW1M2, and SW1C. This will
apply 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 the
control rack fans located above these boards. Each board has a power status
green LED that will illuminate indicating power is applied. The DSPX and
ACLA will also begin an initialization process.
Fan Fan
RST RST
OK OK
ACTIVE ACTIVE
ENET ENET
FLASH FLASH
S S
T T
A A
T T
U U
S S
COM COM
1 2 1 2
ENET ENET
DSPX DSPX ACLA DSPX

ACLA
EISB EMIO ESEL ESEL EMIO EISB EISB EMIO
M1 Boards M2 Boards C Boards
Figure 6-5. Exciter Backplane Control Rack Boards (Front View)
Control Module Processor Start
Refer to Figures 6-5, 6-6, and Verify the that the DSPX processor board, located in the control rack, has started
6-7. correctly, as follows:
All procedures in this section 1. The DSPX should boot-up with the following LED indications:
were completed successfully Green status LED steady on or blinking
for:
Master 1 ACLA DSPX Red fault LED blinking indicating an alarm status or off (solid red indicates
Master 2 ACLA DSPX a fault condition)
Control DSPX
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 on
and the green status LEDs are steady on for the active master.
g GE Motors &
Industrial Systems
g GE Motors &
Industrial Systems
STATUS
FAULT RST
OK
ACTIVE
ENET
FLASH
E
M
U S
L T
A
T
U
S
COM
H
S
P
1
S
O
E
R
R
ENET
T
I
A
L
DSPX ACLA
H1A
H1A
Figure 6-6. DSPX Faceplate Figure 6-7. ACLA Faceplate
Using the Exciter Configuration Tools
GE document GEH-6414 The GE Control System Toolbox is a Microsoft Windows-based, configuration
describes the EX2100 toolbox program used to tune and commission the exciter as needed for each application. The
installation and use. toolbox is designed with menus, block diagrams, dialog boxes, and wizards that
simplify and guide you through the startup and commissioning process.
For detailed information, you should refer to either the toolbox online Help or the
product 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 the
Help files at any time after the toolbox is installed on your PC.
The toolbox Help feature provides detailed information about using the toolbox. This
includes installation and operation, as well as drive configuration instructions. There
are 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.
Click on the desired block with the right mouse button
Block information
and choose Item Help.
Help contents Choose Help then Contents.
Help Choose Help then Using Help.
Choose Help then Contents and Find. From there,
Specific word(s)
enter the word(s) you want to find.
When you choose Help on the toolbox main menu bar, a drop-down menu provides
several options for finding information.
Contents displays Help files for the toolbox. It also contains the Find tab with a
work 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 file
contains 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 only
available 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. Starting the Toolbox

All procedures in this section The remaining procedures in this chapter require that you use the toolbox and the
were completed successfully EX2100 toolbox document, GEH-6414 Chapter 3. Instructions for performing the
for: procedures are located there.
Master 1
Master 2
Control
GE provides the toolbox on the
Control System Solutions CD.
Software files will be available
on the Turbine HMI or supplied
separately.
Refer to Figure 6-1, Block 4. Open an EX2100 File

All procedures in this section To download exciter software with the toolbox, you must open the exciter configu-
were completed successfully ration (.ecb) file for all three controls, M1, M2 and C. All EX2100 exciters are pre-
for: engineered and this file should be available on the turbine control HMI or a software
Master 1 ACLA DSPX CD supplied with the excitation equipment. Refer to GEH-6414, Chapter 3.
Master 2 ACLA DSPX
Control DSPX
Refer to Figure 6-1, Blocks 5 Checking Toolbox/EX2100 Pattern Compatibility

and 6.
The firmware pattern used to create the .ecb file must be the same version as the
All procedures in this section pattern loaded in the exciter (the ACLA and DSPX boards). If it is not, then either
were completed successfully the flash code (which contains the pattern version) must be downloaded from the
for: toolbox to the controls, or the .ecb file must be upgraded. Refer to GEH-6414,
Master 1 Chapter 3.
Master 2
Control
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 structure
is not present, you must correct it.
Refer to Figure 6-1, Block 6A. Downloading to the EX2100

Refer to GEH-6414, Chapter 3 to download the firmware pattern from the toolbox to
the EX2100.
Refer to Figure 6-1, Block 6B. Optional: Upgrading the .ecb File
All procedures in this section Associated with the firmware version in the drive are parameters that vary, depend-
were completed successfully ing on each application. These parameters are stored in the .ecb file.
for:
Master 1
Tip .ecb files are typically stored in a project directory. To establish the default
Master 2
directory from the toolbox, select Options, Settings, and the tab Directories.
Control
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 the
firmware 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 the
Control System Solutions CD.
Refer to Figure 6-1, Block 8. Checking for Correct Firmware and Hardware
All procedures in this section Typically, firmware and hardware revisions are backward compatible with older
were completed successfully revisions. However, occasionally the firmware depends upon a minimum revision of
for: hardware. The release notes (RelNotes.txt, provided with the toolbox files), provide
Master 1 an overview of the EX2100 hardware and software relationship. Refer to GEH-6414,
Master 2 Chapter 3.
Control
Checking the Keypad (EDI)
Refer to Figure 6-1, Block 8. The two operator interfaces located on the control cabinet front door are the EX2100
Diagnostic Interface modules (EDI, most commonly called keypad). Facing the
keypads (with the door closed), the left side keypad is used to interface with Master
1 and the right side with Master 2. Both keypads can access data and parameters for
for:
Control.
Master 1
Master 2 1. Observe that each displays heartbeat icon is pulsing (see Figure 6-8). This
. indicates that the keypads can communicate with the EX2100. (The cable from
the keypads connects to the racks J303A and J310A connectors.)
Note If the keypads display cannot be read or contrast is poor, refer to Adjusting
Keypad 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 Maintenance
Guide (listed in Equipment/Material Needed in this chapter) for information.
The keypad and toolbox screens presented in this document

are samples that represent one possible application. The
screens for your EX2100 should display information that is
specific to your configuration and application.
Using the Keypad for Startup and Commissioning

The 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 the
exciter. This information is provided in the EX2100 Users Guide GEH-6632.
g EX2100 Excitation
C
Display: Exciter Health
FVR Feedback
Status & State Icons
0.0 Volts -30% 0% 100% 150%
Screens provide analog FldCurrAmps

and digital representation 0.00 Amps -30% 0% 100% 150%
of exciter functions and Vmag Imag Watts

values. 0.00 0.00 0.00
Freq_Hz Exciter Pll Vars
60.00 55.00 0.00
Menu
On
Screens provide text-based Navigation Exciter Control
access to parameters,
Run (Green)
wizards, and faults. Reset
Auto
Status Faults
Pushbuttons:
Organized into functional
Stop (Red)
groups: Command Man
Menu Menu
Navigation
Voltage Level
Buttons for using the menu Off
Escape Enter
Exciter Control
Run and Stop buttons
Figure 6-8. Front View of the Keypad
Adjusting Keypad Display Contrast
You can improve visibility of the keypad display by adjusting the contrast. This can
be done using either the keypad or the toolbox.
To adjust keypad display contrast using the toolbox

You should not see Offline on 1. Check that the EX2100 is communicating with the PC (the Go on/offline
the toolbox status bar (bottom
right side of screen). button is selected).
2. In the toolbox work area, expand the items displayed in the Outline View by
clicking on the plus sign next to Main Menu, General Setup, Keypad, and
Keypad 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 text
box 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 menu
bar 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 keypad

Hold the orange MENU button down and press the Up Arrow (s) or Down Arrow
(t) navigation buttons to increase or decrease the contrast (see Figure 6-8).
Commissioning the Exciter
Commissioning is the final stage of starting up an EX2100 lineup. To complete the
following 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. During
this testing, some access to the turbine control HMI will be necessary, but most steps
can 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 steps
must be performed in the following order, with each step for both controls completed
before proceeding to the next phase of commissioning.
1. Simulator checks
2. Temporary load checks
3. Initial roll and offline checks
4. Online checks
Overview of EX2100 Parameters
The parameter settings are pre-engineered prior to shipping

and should not require adjustment. GE Salem should be
contacted prior to any parameter modifications.
Note The procedures in this chapter are based on SAMPLE parameter values. Any
parameter values referenced should not be used for any specific job. If a parameter
value is in doubt, contact GE Salem for clarification.
Application specific data has been entered into the EX2100 parameters found in the
toolbox software files. These parameters provide the data for the application rules
used in the toolbox during the validation and calculation of settings for the EX2100.
Occasionally, specific parameter values require changes prior to initial operation of
the 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, Parameters may be adjusted individually from the toolbox menus, the block diagram,
select Diagram from the or the keypad. Changing parameter values while the EX2100 is running is not
toolbox work area, outline recommended, although some parameters, such as diagnostic setups, can be adjusted
view. with minimal risk while running. In the following paragraphs, parameters will be
designated 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 sent
to 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 entire
parameter download to the DSPX processor (using the BLUE down arrow icon) is
not 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 is
not stopped. (Refer to document GEH-6414, EX2100 Toolbox.)
An entire download of the application layer software, ACLA, (using the RED down
arrow icon) is allowed while the exciter is running. For most application layer
changes, this will be benign to the user, but a warning to the user that the exciter is
not stopped is generated by the toolbox when these parameters are sent. It is possible
during this process that communications with the EX2100 will be temporarily inter-
rupted.
Viewing Parameter Differences
Having the pattern versions loaded equally into the file and the EX2100 does not
mean 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 equal
sign displays in the Status bar at the bottom of the toolbox window. To display the
differences, double-click on the not equal sign . This causes the toolbox to compare
its parameter values with those in the EX2100.
Calculate Parameter Final Values

Final 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 sign
at 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 the
screen.
The toolbox uses the parameter settings that were entered to calculate the parameter
final values. If parameter final values are overridden, running the toolbox
Build/Calc routine will not update these values.
Privilege levels provide differ- To view and clear overrides with Level 4 privilege
ent types of access to the
devices. 1. From the toolbox, select the Finder button , then Overrides, and
Update.
Level 4 allows changing
parameters and editing hard- 2. Double-click on the item selected.
ware, and requires a password. 3. Select Clear then Override.
4. Select Device, Reset Drive, Hard Reset.
Overrides are typically not required and should be avoided.
Running Simulator Mode
Refer to Figure 6-1, Block 9. Refer to the Control Systems Toolbox .ecb file Simulator Scaling for representa-
tions of the system models and simulator scaling.
for: Operation of some relays may occur in Simulator Mode.
Master 1 Verify that flashing power and ac power to the bridge is
Master 2 removed or isolated from the generator field and personnel
are clear from any moving devices.
The EX2100 contains a built-in simulator that models a generator and static
excitation system. When simulator mode is selected, the feedbacks presented to the
control regulators are switched, by software, from the real feedback inputs to
feedbacks derived by mathematical models mimicking the generator and field circuit
behavior.
The EX2100 controls then react in a manner close to the way they would react in
normal operation. The simulator can serve as a valuable startup, maintenance, and
training tool. While the simulator mode in the EX2100 is a very close approximation
of the actual operating look and feel of the exciter, there will be some instability on
the operator displays and EGD page information due to the coordination of data
among the three controllers. Changes to regulator gains should not be made from
observations made in simulator mode.
The simulator is scaled to represent the actual system as accurately as possible. This
means that when a start command is given to the EX2100, it follows a normal start
sequence. Unlike the EX2000, the EX2100 will not generate actual commands to
close field breakers and flashing contactors. Operation of these devices will be tested
in the Temporary Load section that follows.
The generator armature and field models, as well as the exciter stator and field
models, provide the feedbacks for exciter field voltage and current, and generator
stator voltage and current. These feedbacks are handled by the transducering
algorithms the same way real feedbacks are used to calculate watts, vars, speed
deviation, and frequency. If the model scaling is correct, the display data cannot be
distinguished from real data. Main generator field voltages and currents are also
simulated 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 what
can be expected of the real system in response to step changes.
By changing the parameter containing the value representing model shaft torque it is
possible to raise or lower the simulated generator real power output when simulating
online operation. The exciter changes the system vars in response to changes in the
exciter voltage setpoints.
Block diagrams are accessible In the following procedures, various block diagrams are referenced to allow
by selecting the EX2100 Over- access to parameters and variables for testing. These diagrams can be found in
view diagram and clicking on the .ecb file. The finder function in the toolbox can also be used to locate pa-
the appropriate page button. rameters and variables.
A B C D E F G H I J K L M N O P Q R S T U
01 01
EX2100 Overview
02 02
DSPX Side Generator Ratings $ GenRatings
03 03
Simulator: Stator and Saturation Curve $ StatorSim
C3 Logic: Transfer State Machine $ Transfer
Field Side $ FieldSim Out of Bounds protective transfers $ ProtectXfer
04 Problems: Master Asks for a Transfer $ Problems 04

Generator Stator Side Instruments $ GenInstr
PT and CT Wiring $ PTCT_Wiring

Field Ground Detector: Input Filtering $ FGD_In
05 Sequencing $ FGD_Seq 05
Start Stop Sequencing: Flashed Start $ FlashStart Fault Calc / Freq Component $ FGD_Calc
Aux. Bus Start $ AuxBusStart KeyPad $ KeyPad

06 06
Auto/Manual, PT Failure, Run Requests

$ Keys_States
Simulator Enable, VAR/PF & PSS Enables
07 XY Charts $C.Synchro $C.LOE $C.OEL $C.VHz
07
Inner Loops: Field voltage and current regulators $ InnerLoop
$C.Satcurve
SCR Firing Control $ FiringControl

08 08
Inner Loop Bode Analysis $ BodeIL
Bridge Thermal Alarms and Trips $ BridgeTherm
09
Alarms: Individual functions $ Alarms
09
Dual Port Memory (DPM)
Alarm and Diagnostic Strings $ AlarmString
DPM Signal Map (pages 1 & 2) $ Dpm1

10
Trips: Individual functions $ Trips
10
DPM Signal Map (page 3) $ Dpm2
Trip String with enables $ TripString
DPM Boolean Signals (bits 0-15) $ DpmBits1

Field Signals, Test A/D's, and
11 Analog Feedbacks Bridge Temperatures
$ VCO 11
DPM Boolean Signals (bits 16-31) $ DpmBits2
Analog Feedbacks Offset Removal $ VCO_Zero
12 Gate Pule Amplifier Logic: Bridge 1 $ EGPA1Logic Outer Loop Functions 12
Bridge 2 $ EGPA2Logic
$ AVR $ AutoRef $ EXASP $ MANREF
13 13
Conduction Sensing (Sensor Failure) $ CondSense
$ PSS $ VARPF
General Purpose Inputs/Outputs (and 52,86) $ GP_In_Out

14 $ HTSEN $ UELHTC $ UELREG 14
D/A's and General Purpose Filters $ Diag_Util
15 15
Capture Buffer Configuration $ Capture
16
EMIO Outputs with Diagnostic Feedbacks $ EMIO_DiagFbk GE Motors and
PRODUCT:
Innovation Control
Page name:
Industrial Systems saved date: Device name: Date:

A B C D E F G H I J K L Salem, Va. USA December 12, 2000 #### ????
Figure 6-9. Block Overview Diagram
The Exciter Control Window The EX2100 can be controlled from the toolbox by using the animated bar graph
animated bar graph display is display instead of the door-mounted keypads. The keypads can then be used to
monitor variables and I/O states while testing.
available using the icon
in the .ecb file of the toolbox.
Click to reset faults.
Click On to put
the exciter in the
run mode.
Auto controls terminal

voltage on the
generator.
Man controls voltage

on the field.
Use Off to take the

exciter out of run
mode.
Bar Graphs and meters Click + to increase or - to
provide feedback of the decrease the voltage.
current state of the device.
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 in
simulator mode, the exciter simulated speed should begin to increase. This can
be 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 to
operation with actual field voltage and current.
2. Temporarily jumper the contact input on the ECTB board TB2-47and 48 to

simulate 86G lockout relay reset condition. Verify that <Aux86> is in a true
state. (Keypad menu: GP_In_Out). Removal of the jumper should toggle the
variable 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 by
selecting 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 operator
keypad. Simulated terminal voltage, field voltage, and field current should build
to rated no-load values.
An upper case M1 or M2 in the Only the active master can effect changes to the EX2100. Control must be
keypad display indicates the transferred to the backup master through the keypad menu before the backup
active master. Lower case m1 master keypad will raise/lower, toggle from auto to manual, or start/stop the
or m2 indicates backup. exciter.
V/HZ Limit Verification
1. 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 will
annunciate when <ASPVHZA> is true.
2. Return the simulated torque to the preset value and terminal voltage will begin
to increase. At the (ASPVHZ) value, terminal voltage will stop increasing and
the V/HZ Limit Active alarm <ASPVHZA> will clear.
Lockout Trip Verification

1. 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 Verification

When the exciter is restarted, if the simulator is at 100% turbine speed, the automatic
regulator will build terminal voltage to the preset generator rated terminal voltage,
(AR_ZV).
PT Failure Detection Verification

The PT failure function will only operate when the 52G input contact is open if the
exciter controls are using two sets of PT inputs for the detection or the exciter PPT is
fed directly from the generator terminals instead of an auxiliary bus. If there is only
one set of PT inputs, and the PPT is fed from an auxiliary bus, then this test can only
be 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 well
as 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 PT
failure and resetting the PT failure alarms.
AVR/FVR Upper and Lower Limits

1. 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 a
value of five.
2. Transfer the controls to manual regulator and again continue to lower excitation
while 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 field
voltage. <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 zero
value but has an offset (since the manual regulator is set below the AVR low
limit).
Note It is not possible to check the manual regulator upper limit (MRPLM) in off-
line simulation mode.
FVR Preset Verification
1. With excitation stopped, transfer the EX2100 to manual mode.
2. Start the exciter and observe that the simulated field voltage builds to a value
equal to (MR_ZV).
Offline Over Excitation Limit (OEL)

The offline over excitation limit With the EX2100 operating in manual, raise excitation voltage until the value of
only operates when the EX2100 (FcrRefOffline) is reached. <FldMode> should change from a true to a zero value.
is in manual regulator. (FcrRefOffline) is found on Alarms.vsd. <FldMode> is found on InnerLoop.vsd.
Disconnect ECTB board TB1- Once the simulator is online, the 94EX contact output can be
1 and 5 to prevent 86G op- operated inadvertently. This may cause unintentional opera-
eration. See system elemen- tion of protective devices outside the EX2100. Lifting of the
tary for details. 94EX output contacts is recommended during simulator and
temporary load operation.
AVR Under Excitation Limit (UEL)

With the previous offline simulated operation checks complete, the EX2100 is ready
for simulated online operation.
1. Temporarily jumper the contact input on the ECTB board TB2-45 and 46 to
simulate 52G breaker closure and verify that <Aux52G> is in a true state.
(Keypad menu: GP_In_Out). Removal of the jumper should toggle the variable
to a False state. Replace the jumper so that <Aux52G> is true.
2. Once <Aux52G> is true, raising or lowering the terminal voltage should now
change the value of <VARs>. Changing the value of (SimTorqueRef) will alter
the value of <Watts>. These variables can be viewed on the keypad display or
use 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 terminal
voltage until the UEL becomes active. Because the takeover point of the UEL is
modified by the square of the terminal voltage, actual takeover points may not
correlate exactly to the parameter values. Check operation of the UEL at various
values of (SimTorqueRef). When the UEL is active, <UELACT> should be a
true value.
4. Raise excitation terminal voltage so that the UEL is no longer active, but the
generator is at less than rated voltage. Lower (SimTorqueRef) to the original
offline operation value.
V/Hz Trip and 94EX Verification

1. 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 to
1.01 pu.
2. Raise the simulated terminal voltage so that it exceeds the 1.01 pu value for the
V/HZ trip relay. The EX2100 should generate a 94EX lockout trip request after
a time delay found in (VHz1TripSec).
3. Verify that ECTB board terminals TB1-1 to TB1-5 are shorted (closed). Closed
contacts 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 Checks
Refer to Figure 6-1, Block 9. Operation of the EX2100 core with a temporary load is highly recommended.
Temporary load operation confirms that the EX2100 is capable of gating cells and
producing excitation voltage. This can eliminate many frustrating hours of trouble-
shooting during initial turbine roll and generator energization if performed prior to
for:
running the unit.
Master 1
Master 2
Zeroing VCO Offsets

1. With no ac input voltage applied to the EX2100, voltage controlled oscillator
offsets should be zeroed for the following feedback variables. (This test must be
run 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 feedbacks respective zero
VCO button on the far right of the diagram (see Figure 6-10). The controls will
automatically zero the VCOs and indicate Ready when complete.
Flashing and 41A, 41B Verification

1. With no ac input voltage applied to the EX2100, start the exciter by selecting the
green start button on the operators keypad. This will cause the EX2100 to trip
after attempting the start sequence.
Disconnect ECTB board TB1- Operation of contactors and relays will occur in while testing
1 and 5 to prevent 86G op- with a temporary load. Verify that personnel are clear from
eration. See system elemen- any moving devices and are clear of exposed components and
tary for details. leads.
2. Verify that both 41A and 41B contactors close by monitoring <Aux41> as well
as visual verification. Use the AuxBusStart or Flash_Start page in the .ecb file as
per the application being tested.
3. For units with flashing, also verify contactors 53A and 53B for proper operation
by monitoring <Aux53B> and <Aux53A> as well as visual verification.
4. For units with flashing, verify that the proper polarity voltage appears on the DC
voltmeter connected to the temporary load. This value can be monitored at
<FldVoltVolts>. The EX2100 will regulate field current at the values specified
in (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 and
alarms.
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 during

this testing. Power will be applied to ac input circuits and dc
output circuits. Personnel safety practices must be observed
during 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 PPT
secondary voltage. An ungrounded three-phase source voltage as close to this
PPT 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 Converter
Module. 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 found
on the Firing Control block of the .ecb file. For EX2100 units supplied from an
auxiliary 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 and
at 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 temporary
load.
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 be
closed. Monitor <expll_volts> and verify that the measured ac input voltage
agrees with the ac voltmeter reading of the ac input voltage.
6. Confirm the manual regulator preset (FvrPreset) is suitable for the temporary
load chosen.
7. Once again, start the exciter using the primary masters keypad by pressing the
green start pushbutton.
8. After both 41A and 41B close and the flashing sequence is completed, the
EX2100 should begin to gate cells and develop and output voltage equal to the
value in (FvrPreset).
Note A three-phase voltage and current source can be used to simulate generator
feedback signals during temporary load testing. If PT feedback is not simulated into
the ECPT board inputs, the EX2100 will alarm a PT under voltage condition. This
alarm will not reset until the exciter is stopped or PT feedback is simulated while
running.
9. Observe on the active power converters EGPA board that both the six gate
pulse input LEDs and the six gate pulse output LEDs are lit indicating cell firing
(see Figure 6-11).
FANS
PHA
FALT
ALRM
FUSE
PSOK
PHB
PHC
COOL
170F
190F
GT1I
GT6I
GT2I
GT4I
GT3I
GT5I
GT1O
GT6O
GT2O
GT3O
GT5O
GT4O
Figure 6-11. EGPA Board LEDs Example
10. The oscilloscope connected across the temporary load monitoring the dc output
should indicate six distinct cell firings of equal magnitude and duration. The
voltage 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 output
voltage. The dc output voltage should respond is a smooth, controlled manner.
The oscilloscope display should show an increasing and decreasing firing angle
on the display. The values in (MRPLM) and (MRNLM) are the upper and lower
limit of field voltage while operating in the manual regulator.
12. Repeat steps one through seven with M2 selected as Master.
Core Transfer Operation

1. 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 the
keypad of the active master, transfer control to the backup master.
3. The primary power converter should now stop gating cells as indicated by the
six yellow output LEDs on the EGPA board and the backup power converter
should begin gating cells. The output LEDs on the backup power converter
EGPA 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 the
original primary power converter and again verify bumpless operation.
Static Start Voltage Reference Operation

On large gas turbines, the exciter is used to supply generator field flux for the LCI
during static start operation. This control should be tested prior to startup. EX2100
exciters 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 an
EGD page input. If it is a hard-wired input signal, a temporary source should be
connected 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. The
EX2100 should start but the dc output voltage should be zero.
4. Using the hard-wire input reference or EGD input reference, raise the exciter
output to the maximum LCI reference of no-load field voltage while in static
start mode.
5. Repeat steps one through five with M2 as the primary master.
Initial Roll and Offline Checks

Refer to Figure 6-1, Block 9. Initial operation of the EX2100 should not be attempted until temporary load
operation has confirmed that the EX2100 is capable of gating cells and producing
excitation voltage. All temporary connections and jumpers should be removed.
Doors, wire tray covers, and personnel barriers should be in their proper positions.
for:
Master 1
Master 2
During initial roll and off line testing, high voltages and
currents will be present in the EX2100 and applied to the
main generator field. Generator protective relaying checks
should be verified as complete and plant personnel safety
practices 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 forcing For the initial operation of the EX2100, the turbine control
will be necessary during the should not be allowed to automatically start the exciter.
initial startup of the EX2100. Allow the turbine to come to full speed, no load operation
first and start the exciter through manual intervention of the
operator. Subsequent starts can then be made with the
automatic sequencing.
The EX2100 should be first started in manual regulator to verify correct generator
PT feedback values before starting in automatic regulator. Subsequent starts can then
be made in automatic regulator once the unit has proven to be capable of operation in
that mode. Extensive use of the step test, circular list, and trend recorder feature of
the toolbox will allow for quick evaluation of correct operation of the EX2100.
Preparations for Initial Start

1. 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 disconnect
device should be closed.
4. An oscilloscope using differential mode and a dc voltmeter should be connected
to 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 Procedure

1. Start the exciter using the primary masters keypad by pressing the green start
pushbutton.
2. The EX2100 should execute its start/stop sequence in manual regulator and
build generator field voltage to a value equal to <FvrPreset>. Field current and
generator terminal voltage should trend as in the following startup recording for
a start command in manual mode at full speed, no load (see Figure 6-12 and
Figure 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 the
feedback on the PT disconnect switch and calculating the terminal voltage from
the known PT transformer ratio. <Vmag> should agree with this value. If it
does not, do not proceed further until this discrepancy is resolved. Also verify
correct phase sequence input from the PT feedback at the PT disconnect
switch(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 reversed
phasing alarms and troubleshooting help.
5. Raise the EX2100 output voltage slowly until rated generator terminal voltage is
reached. 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 a
calibrated measuring device. Field shunt millivolts can be used for field current
verification in place of a clamp on current device.
6. Verify that the keypad display of regulator balance reads zero at this time (then
it is ready for transfer to automatic regulator).
7. Using the active masters 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 the
step 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 should
change by 2% with no instability, overshoots, or undershoots in voltage.
8. Stop the EX100 and restart in automatic regulator. The EX2100 should now
bring the generator to the value found in (AR_ZV). See Figure 6-14 and Figure
6-15.
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 Test
With the unit at rated terminal voltage, step the automatic regulator with a 2% step to
verify proper control using the AVR step test Wizard. The test can be started from
the EX2100 Overview screen of the toolbox (see Figure 6-9). Select Inner Loop
Bode Analysis ($ BodeIL) to get to the Frequency (Bode) Analysis or Step
Test of Regulator Loops screen (see Figure 6-16). Complete instructions for the
test 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 manual
regulator.
A B C D E F G H I J K L M N O P Q R S T U
01 0 None 01
Back to
Frequency (Bode) Analysis 1 FVR
$ Overview or P.Bode_Type
2
3
FCR
AVR
Step Test of Regulator Loops 4 UEL
02 5 PSS 02
P.StepTime 6 GPdata Toggle Start/Stop
0.25 sec low going pulse |(V.BodeActive
1 sec (also passed to ACL for P.Bode_Size 512 (5.12 sec) !C.60
|~P.StepPrbs
delay buffer synchronization) 1024 (10.24 sec)
03 03
StepOutputs +1, 0 default 2048 (20.48 sec)
At Prepass |(V.BodePreDone
# of passes prior to V.BodePrePass Pre Passes Done
V.StepSync P.Bode_PreTrig
PRBS averaging
04 Pseudo Randon Binary Sequence At NowPass |(V.BodeAveDone 04
P.Bode_Passes # of passes used for V.BodeNowPass
Outputs +1 -1 Averaging Done
|~V.BodeActive averaging
{P#.Bode_Type=1~
P.FvrBodeScl V.PrbsOut
05 {P#.Bode_Type=2,3,4,5,6~ 05
P.ACLBodeScl 0 @P.BodePtr1 {P#.Bode_Type=0,1~
Input
V.AAFilter1
AAFilter1
06 @P.BodePtr2 {P#.Bode_Type=0,1~ 06
Output
{P#.Bode_Type=2,3,4,5,6~ V.AAFilter2
AAFilter2
V.ACLPrbsOut
{P#.Bode_Type=2~
{P#.Bode_Type=1~ Third order Cheby
07 V.FirCmd in task 1 with break 07
at 50 Hz
{P#.Bode_Type=2~
V.FvrSet V.FcrError
08 + 08
V.FvrSetpoint + + V.FvrError
S S {P#.Bode_Type=3,4,5~
V.Avr_sp
-
09 1 {P#.Bode_Type=3~ 09
V.FldVoltVolts V.FvrFeedback For UEL step tests via AVR, V.Avr_fb
raise margin so that UEL
st2 + 1 becomes active quickly
{P#.Bode_Type=4~
P.FvrFbLag
10 t2 = P.Margin V.Uelerr
10
Feedback Lag
{P#.Bode_Type=5~
V.Pssllo
11 11
@P.BodePtr1 {P#.Bode_Type=6~
12 12
@P.BodePtr2 {P#.Bode_Type=6~
13 13
14 14
15 15
PRODUCT: File name:
General Electric g EX2100 Excitation Control

Firmware Revision: Issued Date --- Initials:
Salem, Va. USA
16
Revsion Date -- intials:
A B C D E F G H I J K L 09/04/01 11:47 AM
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 Testing
The offline OEL and V/HZ limit testing completed during simulator mode checks
are sufficient for verification of limit operation. If desired, these tests can be repeated
at this time with the unit in operation with actual feedback values. Use the tests as
written for simulator mode testing except for adjusting actual turbine speed and volt-
ages.
Online Checks
Refer to Figure 6-1, Block Prior to initial synchronization, other equipment commissioning procedures will
10. also be performed. Phasing of the generator and protective relay device operation
should be completed. Verification of the synchroscope and tests of the 52G device
should be complete. All parties involved in the initial unit commissioning should
agree that the unit is ready to connect to the power grid.
for:
Master 1
Master 2 The EX2100 should be first synchronized while in manual
regulator to verify correct generator CT feedback before
operating in automatic regulator. Subsequent synchroniza-
tion and testing can then be made in automatic regulator
once the unit has been proven capable of operation in that
mode.
The EX2100 should be operated in automatic regulator at all times when online. The
unit will only transfer to manual regulator if there is a problem sensed with the PT
feedback. For the initial synchronization, it is recommended to operate in manual
regulator until CT feedback wiring can be verified as correct. Improper CT wiring
can cause misoperation of displays, UEL, LOE and other software controls.
CT Feedback Verification
1. 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 until
conditions 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 CTs 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- Do not open CT wiring with unit on line. Potential damage
fected if CT wiring is changed to equipment may occur. CT disconnect switches are make
at the CTs. Check one-lines before break switches and CT wiring errors can be corrected
carefully. on the EX2100 side of disconnect switches if needed.
PT Failure Operation
1. 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. The
EX2100 will annunciate a PT failure and the variables on the Key States dia-
gram should indicate <Vmag> less than 10% and <PT Instantaneous> should be
true.
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 using
keypad 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 PT
feedback and the switch to manual regulator.
6. If a second PT input has been provided for the EX2100, both PT signals must be
opened to produce the transfer to manual regulator.
7. Restore the PT inputs and reset the PT failure annunciation.
Under Excitation Limit Verification

The Under Excitation Limit (UEL) testing completed during simulator mode checks
should 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 actual
UEL limit is desired.
A partial test of the UEL can also be performed. The UEL limit should be raised to a
value allowing operation in a slightly leading power factor region. The unit can then
be 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 Testing
At this time, the EX2100 is considered ready for full load operation. Additional
testing of supplied options may be required to fully commission the exciter. These
include options such as VAR/Pf control and the Power System Stabilizer. Check the
system 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.

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GEH-6631A

EX2100 Excitation Control

Chapter 2 Installation Planning

Chapter 3 Handling and Mounting Guidelines

Chapter 4 Cabling and Connections

GEH-6631 EX2100 Installation and Startup Contents i

Generator PT and CT Inputs...................................................................................4-11

Chapter 5 Pre-Power On Installation Checks

Chapter 6 Initial Startup and Commissioning

Appendix A Understanding Equipment Drawings

ii Contents GEH-6631 EX2100 Installation and Startup

Elementary Drawing Number..................................................................................A-5

Appendix B Cable Separation and Routing

Appendix C Installing Fiber-Optic Cable

Appendix D Printed Wiring Board Reference

GEH-6631 EX2100 Installation and Startup Contents iii

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

Figure 1-2. Typical EX2100 Excitation Control Components

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

Structure of the Document

GEH-6631 EX2100 Installation and Startup Chapter 1 Overview 1-3

Move exciter to Chapter 2,

Connect cables Chapter 3,

Mount and install Chapter 4,

Apply power, start Chapter 6,

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

1-4 Chapter 1 Overview EX2100 Installation and Startup GEH-6631

Exciter Number of Number of Total

1000 A dc None, simplex 1 1 1 2

GEH-6631 EX2100 Installation and Startup Chapter 1 Overview 1-5

1-6 Chapter 1 Overview EX2100 Installation and Startup GEH-6631

Subject Document Content

GEH-6631 EX2100 Installation and Startup Chapter 1 Overview 1-7

1-8 Chapter 1 Overview EX2100 Installation and Startup GEH-6631

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

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

Begin Product Support - On going

Figure 2-1. Startup and Commissioning Services Cycle

Review of Installation Plan

Customers Conduit and Cable Schedule

GEH-6631 Installation and Startup Chapter 2 Installation Planning 2-3

2-4 Chapter 2 Installation Planning EX2100 Installation and Startup GEH-6631

GEH-6631 Installation and Startup Chapter 2 Installation Planning 2-5

Cable and Conduit Routing and Schedules

2-6 Chapter 2 Installation Planning EX2100 Installation and Startup GEH-6631

Shock or stress caused by rough handling or improper lifting

Figure 3-1. EX2100 Lineup Lifting Beam

Figure 3-2. Proper Lifting Method for EX2100 Lineup

Document and report any If equipment damage is discovered while unpacking

Connecting the Grounds

The ground connections must be complete to ensure proper

*Two PCMs per cabinet, one active in warm backup configuration.

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

Do not assume any cable or any circuitry to be without power

Power Supply Rack

EPDM DACA 1 (DACA

Cutout for Customer

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

Shaft Voltage Suppressor

LFU2 (optional), FU1 FU3

LFU1, FU1 FU3

(optional) PTB1 Dc Field Flashing (optional)

Space Heater 2 (optional)