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GEH-6631A

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 ·

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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

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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

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.....................................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)............ Be adequately trained to thoroughly understand and strictly follow all safety procedures necessary for working with and around high voltages................................................................................................................................................................. Additionally........... these instructions require that the user: · · · · · This first chapter provides an overview of how to use this document correctly................................ as follows: Section Page How to Use This Document ........................................ It assumes the following: · · · All receiving........ handling and storage procedures were strictly followed.......... Understand the theory of exciter operation.1-3 How to Get Help.............. Know the physical and electrical requirements of installing high voltage equipment.... Understand the structure and conventions of this document in order to follow the instructions exactly as required..............................1-5 Related Documents.................................1-7 Acronyms and Abbreviations ....... GEH-6631 EX2100 Installation and Startup Chapter 1 Overview · 1-1 ........................ as defined in document GEI-100256.....................................1-3 Text Conventions ...................... You are ready to move the exciter(s) to the installation site................................... Be experienced in using the EX2100 configuration software (the GE Control System Toolbox).................1-5 Equipment Covered ................................... see Figures 1-1 and 1-2)........................ and all necessary system parts are at the site........ The installation site was previously prepared and cables run per GE specifications..................1-3 Structure of the Document...............1-7 Document Distribution .........Chapter 1 Overview Introduction This document is an installation and startup guide for the EX2100ä Excitation Control (EX2100......................................................................................................

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

Monospace GEH-6631 EX2100 Installation and Startup Chapter 1 Overview · 1-3 . Related items or procedures. 1. b. c). When describing software. A procedure with only one step. Installing Fiber-Optic Cable Appendix D. 3). Understanding Equipment Drawings Appendix B. indicates the actual command or option that is chosen from a menu or dialog box. Sections of related procedures are presented in the order that they should be followed (see Figure 1-3).How to Use This Document Structure of the Document GE recommends that a detailed installation log is maintained for the exciter as these installation and startup steps are completed. A checklist. Procedural substeps (of numbered steps) to be followed in order (for example. as follows: · · · · Appendix A. but order does not matter. a. Appendices provide reference information. Cable Separation and Routing Appendix C. Printed Wiring Board Reference For an exact outline of the document’s organization. refer to the Table of Contents. 2. Represents examples of screen text or words and characters that are typed in a text box or at the command prompt. Text Conventions Convention Ø Numbered list Alphabetized list Bulleted (·) list w Boxed (¨) list Arial Bold Meaning A procedure follows. Procedural steps to be followed in order (for example.

Structure of Document for Use in Installation and Startup 1-4 · Chapter 1 Overview EX2100 Installation and Startup GEH-6631 . I/O) Chapter 5. Cabling and Connections Mount and install external devices Chapter 4. Initial Setup and Operation Checks End of Procedures Figure 1-3. start toolbox. Pre-Startup Installation Checks Apply power.Start Procedures Installation site ready. drawings & documents on hand. run checks Chapter 6. Handling and Mounting Guidelines Installation Connect cables & I/O wiring Chapter 3. all site parts present Move exciter to installation site and install it Chapter 2. Device Installation Startup Verify correct functioning of connected devices (power.

GEH-6631 EX2100 Installation and Startup Chapter 1 Overview · 1-5 . The available exciter sizes are as follows: Number of Bridge/Aux. VA 24153-6492 USA Phone: + 1 888 GE4 SERV (888 434 7378. GE Industrial Systems Product Service Engineering 1501 Roanoke Blvd. and the redundancy requirements determine the number of PCMs and the total number of cabinets. simplex Warm backup Warm backup Number of PCMs 1 1 2 2 The EX2100 can be powered from the generator by a potential source (PPT only).How to Get Help If help is needed beyond the instructions provided in the exciter system documentation. Cabinets 1 1 2 2 Number of Control Cabinets 1 1 1 1 Total Number of Cabinets 2 2 3 3 Exciter Current Capability 1000 A dc 2000 A dc 1000 A dc 2000 A dc PCM Redundancy None. or from an auxiliary ac source (through a PPT). or a compound source (PPT and PCT). simplex None. the term “exciter” refers to the EX2100 digital static exciter. contact GE as follows: “+” indicates the international access code required when calling from outside the USA. An exciter is a combination of one or more power conversion modules (PCMs) with their associated control and protection equipment (see Figure 1-4). Salem. The generator field current and voltage requirements. United States) + 1 540 378 3280 (International) Fax: + 1 540 387 8606 (All) Equipment Covered In this document.

EX2100 Cabinet Lineup Components 1-6 · Chapter 1 Overview EX2100 Installation and Startup GEH-6631 .Figure 1-4.

fuses. and Troubleshooting Guide EX2100 Receiving. jumpers. test points. precautions. the requisition documentation should be considered the more exact representation of your equipment or system configuration. component replacement. · · Requisition drawings. keypad overview. application guides Preventive maintenance. I/O designations. GEH-6631 EX2100 Installation and Startup Chapter 1 Overview · 1-7 . including outline and elementary diagrams Renewal Parts listing Note If differences exist between the general product documentation and the requisition documentation. fault list. technical data. If provided (per contract). the following documents contain requisition information about the exciter system. and environmental requirements for receiving the exciter from the shipper and storing it before installation Board function within the exciter. and board replacement procedure GEI-100256 See Appendix D for a list of GEIs Document Distribution GE Industrial Systems supplies product documents to its customers to support the equipment provided for each requisition.Related Documents If needed for supplementary information. customer I/O connections. Parts Replacement. The contract documents define the terms of the document distribution. and troubleshooting information Procedures. online maintenance. as applicable: Subject EX2100 Toolbox EX2100 User’s Guide EX2100 Maintenance. Handling and Storage Printed wiring boards Document GEH-6414 GEH-6632 GEH-6633 Content GE Control System Toolbox instructions for the EX2100 Functional description. refer to the following EX2100 product documents.

Acronyms and Abbreviations A ac ACLA ACOM AVR C CCOM CT DACA dc DCOM DSPX EACF EBKP ECTB EDCF EDEX EGD EGDM EGPA EISB EMIO EPBP EPCT EPDM EPSM ESEL EXAM EXCS EXHS EXTB ft ft-lbs ft/min GE GPA HMI in. location 05 kilograms local area network light-emitting diode high-level signal high-level signal. ampere(s) alternating current Application Control Layer Module analog common Automatic Voltage Regulator protection controller in a redundant system control common current transformer Ac to dc converter in control power supply direct current digital common Digital Signal Processor Board Exciter Ac Feedback Board Exciter Backplane Board Exciter Contact Terminal Board Exciter Dc Feedback Board Exciter De-excitation Board Ethernet Global Data Exciter Ground Detector Module Exciter Gate Pulse Amplifier Board Exciter ISBus Board Exciter Main I/O board Exciter Power Backplane Exciter PT/CT Board Exciter Power Distribution Module Exciter Power Supply Module Exciter Selector Board Exciter Attenuator Module Exciter Current Sensor Exciter High-Speed Relay Driver Board Exciter Terminal Board foot. special handling low-level signal medium-level signal power signal power signal. feet foot-pounds (torque) feet per minute General Electric Company Gate Pulse Amplifier Human Machine Interface inch(es) in-lbs I/O IPN J405 kg LAN LED level H level H(S) level L level M level P level P(S) m M1 M2 max min NEC OSHA P125 PC PCM PCT PLC PPT PSS PT R125 RTDs SCR SHCOM TMR UEL V ac VAR V dc inch-pounds (torque) input and output intelligent part number cable connector at row 4. special handling meters primary controller backup controller maximum minimum National Electrical CodeÒ Occupational Safety and Health Act positive side of 125 V dc power supply Personal Computer Power Conversion Module Power Current Transformer programmable logic controller Power Potential Transformer Power System Stabilizer potential transformer return side of 125 V dc power supply resistance thermal devices silicon-controlled rectifier shield common Triple Modular Redundant Under Excitation Limit control volts ac (alternating current) volt amperes reactive volts dc (direct current) 1-8 · Chapter 1 Overview EX2100 Installation and Startup GEH-6631 .

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

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

equipment placement. shown in Figure 2-1. and the cable and conduit schedule when completed. Startup and Commissioning Services Cycle Review of Installation Plan It is recommended that a GE field representative review all installation/construction drawings. GE Power Systems offers the optional technical advisory services of field engineers for: · · Review of customer’s installation plan Installation support These services are not normally included as installation support or in basic startup and commissioning services. GE presents installation support options to the customer during the contract negotiation phase. Engineering services are also offered to develop transition and implementation plans to install and commission new equipment in both new and existing (revamp) facilities.On going System Acceptance Figure 2-1. practices. Installation Support Optional installation support is offered: planning. and onsite interpretation of construction and equipment drawings. Installation Support Startup Begin Installation Complete Installation Commissioning Begin Formal Testing Product Support .Technical Advisory Options To assist the customer. Customer’s Conduit and Cable Schedule The customer’s finished conduit and cable schedule should include: · · · Interconnection wire list (optional) Level definitions Shield terminations GEH-6631 Installation and Startup Chapter 2 Installation Planning · 2-3 . This optional review service ensures that the drawings meet installation requirements and are complete.

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 provides all level restriction and practice information needed before installing cables. The cable and conduit schedule should include the signal level definitions in the instructions. 2-4 · Chapter 2 Installation Planning EX2100 Installation and Startup GEH-6631 . Cable and Conduit Routing and Schedules and Appendix B). This information should be listed in a separate column to help prevent installation errors. Shield Terminations The conduit and cable schedule should indicate shield termination practice for each shielded cable (refer to the section.

2 (m).100 microns for the following materials: Aluminum Oxide Sand/Dirt Cement Lint Coal/Carbon dust Steel Mill Oxides Paper Soot Ink Seismic: Vibration: Elevation: Universal Building Code (UBC) .3 – 89.8 – 69. 0. 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 .1ºC per min 5 to 95%. Normal Operation: 0 to 3000 feet (101. all plans should be finalized as to the location the equipment will be installed.Siting EX2100 Equipment Prior to receipt of the equipment.7 KPa) Shipping: 15000 feet maximum (57.8 KPa) Extended Operation: 3300 – 10000 feet (89.1. Maximum concentration of corrosive gases at 50% relative humidity and 40ºC per EN50178: 1994 Section A.2 KPa) GEH-6631 Installation and Startup Chapter 2 Installation Planning · 2-5 . The EX2100 control panel is suited to most industrial environments.6. To ensure proper performance and normal operational life.Seismic Code section 2312 Zone 4 Maximum of 1. the environment should be maintained as follows: Ambient temperature (acceptable): Control Module PCM Module Ambient temperature (preferred): Maximum rate of temperature change: Relative humidity: Maximum rate of relative humidity change: 0 °C (32 °F) to 45 °C (113 °F) 0 °C (32 °F) to 50 °C (122 °F) 20 °C (68 °F) to 30 °C (87 °F) 0.0 G horizontal.4 Table A. Keeping ambient air in the preferred (cooler) range should extend component life. non-condensing.5 G vertical @ 15 to 120 Hz. 1% per min Note Higher ambient temperature decreases the life expectancy of any electronic component. Operating Environment Of prime concern in the choice of equipment location is the operating environment. This section is a general guide as to the factors that may influence the choice of this site.

Review of equipment spaces prior to installation should include access to the area via cable trays and conduit. This applies to both top and bottom access plates. or brake coils operating near control circuits. Electromagnetic interference or noise introduced by: . typically produced by arc welders. air passing through the conduit must be within the acceptable temperature range. Cable and Conduit Routing and Schedules Interconnecting cables can be brought into the panel from the top or the bottom via removable access plates. Sufficient space for the equipement must be allocated such that the following minimum clearances are maintained: Excitation Cabinet Sidewalls: 0 inches minimum. which can be locked for security. as listed above. Equipment Clearances Each EX2100 is supplied with an outline drawing that provides the physical dimensions of the cabinet. power supplies and other equipment should be reviewed. the lifting cables must not exceed 45° from the vertical plane. Proper cooling of the panel requires that conduits be sealed to the access plates. Overhead clearance for fan discharge and front panel clearance for personell entry and egress are particularly important. 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. station grounds. Excitation Cabinet Doors: 24 inches minimum with doors open at a 90 degree angle. typically from nearby portable transmitters. Attention to items that will facilitate plant lock-out and tag-out procedures should be followed. Appendix B of this document addresses other cable routing and separation concerns. Finally. level. Size and location of external station service requirements for lighting. and deexcitation resistors. the panel is equipped with a door handle. Excitation Cabinet Rear Panel: 0 inches minimum Excitation Cabinet Top Panel: 6 inches minimum (12 inches preferred) from highest protrusion of fans. unsuppressed relays. . heaters. routing of interconnecting bus and location of the excitation transformer. contactors. The preferred location for the EX2100 excitation control system cabinet would be in an environmentally controlled room.Environments that include excessive amounts of any of the following elements reduce panel performance and life: · · Power line fluctuations. line filters.Stray high voltage or high frequency signals. The panel should be mounted where the floor surface allows for attachment in one plane (a flat. The mounting hardware is provided by the customer. 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. Lifting lugs are provided and if used. 2-6 · Chapter 2 Installation Planning EX2100 Installation and Startup GEH-6631 .Radio frequency signals. and continuous surface). Also.

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

typically not exceeding 15 ft in length. Lift the exciter(s) in a slow and steady manner to an acceptable clearance height. Additionally. If a crane is not available for lifting. Make sure the lifting beams are tightly secured to the exciter (see Figure 3-2). Doing so could damage the exciter frame. Lifting Lifting beams are attached across the top of the exciter at the factory.Exciter Handling Procedures Shock or stress caused by rough handling or improper lifting and moving can damage the equipment. The shipped equipment consists of three cabinets secured together in a lineup. such as a forklift. If noticed. be sure to follow the suggested methods in this chapter for handling the equipment. The lift cables should be at an angle greater than 45 degrees from the horizontal. · Make sure that the lifting equipment is suitable for the configuration and weight of the exciter as follows: . EX2100 Lineup Lifting Beam 3-2 · Chapter 3 Handling and Mounting Guidelines EX2100 Installation and Startup GEH-6631 . Use spreader bars or similar equipment to ensure this angle (see Figure 3-2). along with normal handling precautions. Do not lift and move the exciter using equipment that applies pressure from below. · · · · · · Figure 3-1. Use four hooks for lifting at the openings in the lifting beam (see Figure 3-1). Check for any flexing of the equipment.1000 A – 4400 lbs / 1996 kg . This practice helps ensure that loose parts remain with the exciter. Become familiar with the designated lift points and the stress points. Be sure to follow the guidelines provided in this chapter. While lifting and moving the exciter. GE recommends that you do not completely unpack the equipment until it has been moved as near as possible to its permanent location. it is important to observe any instructions that may be printed on or attached to the equipment container or wrapping. always refer to the equipment outline drawings. lower the lineup and re-position the cables. and any specified handling instructions.2000 A – 5600 lbs / 2535 kg Observe the center-of-gravity. the shipping enclosure helps protect the equipment during storage. Additionally. contact GE for guidelines on using other methods. Before lifting and moving the exciter.

· · GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines · 3-3 .Roll only on the shipping pallets that are attached to the cabinets when shipped from the factory. since the weight of the exciter against the forklift tines would put damaging pressure on the exciter frame. If using other moving devices. Make sure that all doors are closed and latched.Be sure to place the rollers at the shipping splits and at the corners to reduce potential stress. be sure that motions are slow and smooth so that the equipment does not swing. Figure 3-2. .Use four hooks in openings in lifting beams (two in front and two in back). Proper Lifting Method for EX2100 Lineup Moving · · When using a crane. Angle must be 45 degrees or greater. Do not move with a forklift. such as rollers: .

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. While unpacking. File a claim with the carrier. including a nail puller. Photograph the damage (photographs may be needed later in processing the claim). carefully inspect the packing material for loose parts before discarding it. Carefully remove the packaging and move the equipment from its container. 2. 3. · · · · · · Document and report any equipment damage to GE. Ø If equipment damage is discovered while unpacking 1.Unpacking Recommended: Do not completely unpack the equipment until it is placed as near as possible to its permanent location. Report any shortage to GE. do not unpack it until it has reached room temperature (location where exciter will be mounted). When unpacking. inspect for damage that may not have been detected at the time of receipt. 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 3-4 · Chapter 3 Handling and Mounting Guidelines EX2100 Installation and Startup GEH-6631 . · If the equipment has been exposed to low temperatures for an extended period. but may become separated. still observing all lifting and handling guidelines. 4. 5. Contact the local service office of GE Industrial Systems for assistance. Use standard unpacking tools. check the contents of each case against the packing list. For this reason. Stop unpacking immediately and report this finding to the carrier (transportation company).

Position the exciter to permit heat radiation from all surfaces and proper ventilation (cooling air). Lifting beams must be removed to allow for redundant fans to be replaced. Along with the information shown on the outline drawings. recommended cable sizes. Lifting beams must be removed if discharge resistors will be mounted on the top of the cabinet. 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. and diagrams are provided there. Complete instructions. Provide front clearance of at least the width of the enclosure door so that the door can be fully opened for easy access.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. use the following mounting guidelines: · · · · · · The mounting surface should be smooth and level to prevent door misalignment. Proper grounding also helps improve the equipment’s immunity to electrical noise originating within or outside of the equipment. Follow the procedures provided on the EX2100 requisition elementary diagram sheet 0D. The ground connections must be complete to ensure proper grounding of the equipment. The requisition outline drawings show specific lineup and installation details. Grounding Instructions. then lifting beam hardware must be replaced in the holes in the enclosure top and re-tightened. GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines · 3-5 . If lifting beams are removed after positioning the equipment.

Figure 3-3. **Airflow throughput requirements for proper cooling. 151X1207AA1SA01 151X1207AA1SA01 *Two PCMs per cabinet.000 10. one active in warm backup configuration. 3 (ft /min)** 2500 2500 Standard Outline Dwg. EX2100 Lineup Length and Door Opening Dimensions 3-6 · Chapter 3 Handling and Mounting Guidelines EX2100 Installation and Startup GEH-6631 .Exciter Size 1000 A 2000 A Weight (kg / lbs) 1996/4400 2535 /5.000 Airflow Req.600 Heat Loss (Watts)* 5.

EX2100 Width. Height.Figure 3-4. and Clearance Dimensions GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines · 3-7 .

Location of Mounting Base Holes for Securing Exciter to Floor 3-8 · Chapter 3 Handling and Mounting Guidelines EX2100 Installation and Startup GEH-6631 .Securing the Exciter Lineup to the Floor The exciter lineup must be secured to the floor using mounting studs. Figure 3-5. Refer to the exciter outline drawing sheet 1 for additional information about securing the lineup. Figure 3-5 shows the location of mounting holes in the exciter base.

................... 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........ When testing for the presence of electricity and when measuring any electrical circuit.................................................................4-16 GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-1 ..........................................................................................................................................4-11 Signal and Communications Cabling Guidelines ......4-11 Contact Inputs ........4-11 Generator Field Connections .............................................. To prevent accidental electrical shock.................. Use these codes to determine such factors as wire size............................................................................... This chapter is organized as follows: Section Page Exciter Connections..................................................................4-15 PC Interface....................Chapter 4 Cabling and Connections Introduction This chapter assumes that cabling was previously run to the installation site and is ready for connection to the exciter............................... do not touch any circuitry or bare wire without first ensuring that it does not carry electricity...4-9 Converter Power.................................................................................................................................4-6 Control Power............. use only the equipment approved for contact with those voltage levels..........................4-12 Data Highway..... This chapter contains guidelines for connecting cable to the exciter during installation............................. and conduit sizing.......................................................................................................4-16 Preventing Cable Damage .............. This information must be used along with the project specific elementary diagrams and outline diagrams supplied with the equipment........................................................4-6 Cable Entry..................................................4-11 Generator PT and CT Inputs..................................................................................................................4-2 Grounding and Cable Entry................................. All installations should meet the requirements of both the National Electrical Code® (NEC®) and any applicable local codes....4-10 Field Flashing (Optional)............................................. insulation type............................................................

The exciter User’s Guide. all I/O wires leaving a building must be routed inside continuous metal conduit. and 4-3) show the location of connection points. Field-) Exciter I/O connections to terminal boards (contact inputs to ECTB board) Note The component nomenclature examples (see Figures 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. To meet CE Mark requirements. A device nomenclature sticker. GEH-6632. located on the inside of the exciter cabinet door identifies the exciter’s major components and their locations within the cabinet. 4-2 · Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631 . 4-2. describes the terminal board I/O. Customer cabling to the exciter’s terminal boards must comply with level-separation guidelines (refer to Appendix B) after it enters the exciter cabinet. Complete outline diagrams are supplied with the exciter. fuses. and other exciter components. Power for field flashing (terminals in the Auxiliary cabinet) Dc outgoing power connections to the generator field (Field+.

Exciter Control Cabinet GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-3 . refer to elementary sheet 7A and 11A for details) TB1 Power Supply Rack DACA 1 (DACA 2 optional) Space Heater 1 (optional) Cutout for Customer Connections Figure 4-1.Cutout for Customer Connections ECTB ECTB Wiring (Refer to elementary sheet 7A and 11A for details) EPCT PT1 (optional) PT2 CT1 CT2 EXHS/EXTB Control Rack Ethernet Link to ACLA (Refer to elementary sheet 8A and 11A for details) Breaker 1. 2 120 V ac. 15 A Breaker 3 120 V ac. 5 A EPDM (FU1 – FU12 on EPDM. Sample Component Layout.

C Ac input from PPT Phase A – Front Shunt Phase B – Middle Shunt Phase C – Rear Shunt Ground Lug (optional) PTB1 125 V dc. Sample Component Layout.Ac Line Filter Shaft Voltage Suppressor LFU2 (optional). FU1 – FU3 EXAM EDCF – M1 (optional) EDCF – M2 (optional) EDCF . Exciter Auxiliary Cabinet 4-4 · Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631 . FU1 – FU3 LFU1. 15% AFNL Dc Field Flashing (optional) FF. FU1 and FU2 Space Heater 2 (optional) EACF De-excitation Module Figure 4-2.

41B (optional) EGPA M2 Ac Disconnect (less than 600 V ac applications only) Ground Lug Ac Input Connections (optional) Dc Bus Connnections Bridge 1 Bridge 2 Thermal Sensors Figure 4-3. Exciter Power Conversion Cabinet GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-5 .Drip Shield (optional) Dc Bus Connections (optional) Fans 4 – 6 (optional) Fans 1 – 3 Ground Lug EGPA M1 Dc Contactors 41A. Sample Component Layout.

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.Grounding and Cable Entry For both safety and proper functioning of the equipment. Provisions have been made to tie shields to chassis ground on several exciter terminal boards. Cable Entry See EX2100 outline drawings for complete information. it is important that the exciter be properly grounded. The installation site must have a reliable building grounding system and the exciter’s grounding cable must be securely fastened to this system per the elementary diagram. consult your requisition elementary drawings for the grounding method recommended for your installation. Control Cabinet Cable Entries Figure 4-5. Auxiliary Cabinet Cable Entry 4-6 · Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631 . Follow the procedures provided in the EX2100 requisition elementary diagram sheet 0D. Removable access panels for cable entry are provided in the top and bottom of the control cabinet. Complete instructions. preferably at the exciter end. ground the shields on one end only. and diagrams are provided there. For shielded and twisted wire. the bottom of the auxiliary cabinet. Refer to Figures 4-7 and 4-8 for connection point locations. Note If you have an engineered system. Grounding Instructions. Figure 4-4. recommended cable sizes.

Auxiliary Cabinet Power Connection Points GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-7 . Converter Cable Entry (Power Conversion Cabinet) Standard Ac Connections Ground Bus Figure 4-7.Optional Ac Connections Wire Entry Bottom Figure 4-6.

Ground Bus Door Optional Ac Connections Figure 4-8. Power Conversion Cabinet Power Connection Points 4-8 · Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631 .

±2% The Exciter Power Distribution Module (EPDM) produces 125 V dc for the control power modules. 10 A rms max Nominal 125 V dc from battery. single phase. EPDM Exciter Power Distribution Module SW7 SPRE 1 2 SW6 J1C 1 2 SW5 J1M2 1 2 SW4 J1M1 1 2 SW3 TB1 x x x x x x x x x x x x J8C 1 2 x 125 V dc from battery R125Vdc R125Vdc R125Vdc x x x x x 115 V ac supply #1 x x x x x 115 V ac supply #2 AC2N AC2N x x 2 4 6 8 10 12 14 16 18 20 22 24 x 1 3 5 7 9 11 13 15 17 19 21 23 P125Vdc P125Vdc P125Vdc SW2 J8B 1 2 SW1 AC1H AC1H AC1N AC1N AC2H AC2H J8A 1 2 1 J9 3 1 1 0 JDACA1 3 1 12 1 0 JDACA2 3 12 Figure 4-9. A second ac source and DACA can be used if required.6 A dc max Nominal line frequency: 50 or 60 Hz. Control Power Input Connections to Power Distribution Module The EPDM outputs feed 125 V dc to the three exciter power supply modules (EPSMs). Both ac and dc sources are wired to TB1 on the EPDM. It is located on the side of the power supply module. ±15% at 60 Hz. GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-9 . Redundant power sources for the control modules ensure high supply reliability. The ac to dc converter(s) (DACA) are mounted at the bottom of the control cabinet. Individual outputs are fused and can be isolated with a switch. and the EGPA and EXTB OR EXHS boards.Control Power The exciter requisition drawings specify the power requirements for the application and show connection points. The exciter control power requirements are as follows: Voltage: Nominal 115 V ac. refer to Figure 4-9. 10.

Converter Power The main ac power supply for the exciter can come from a potential source. a compound source. Specification of this supply is the responsibility of the user or his engineering company. or an auxiliary bus. If help is needed contact: “+” indicates the international access code required when calling from outside the USA. Figure 4-10 shows supply from a power potential transformer (PPT) connected to the generator output. PPT H1 X1 PRI VAC : 12470 SEC VAC : 650 41AC1 K1 L1 Exciter Power Conversion Cabinet To Bridge 1 and Line Filters H2 X2 KVA 1280 H3 X3 Phase Rotation 3 1 2 Figure 4-10. GE Industrial Systems Product Service Engineering 1501 Roanoke Blvd. VA 24153-6492 USA Phone: + 1 888 GE4 SERV (888 434 7378. Power Potential Transformer Connections Power is brought into the power conversion cabinet on either cables or a bus. United States) + 1 540 378 3280 (International) Fax: + 1 540 387 8606 (All) 4-10 · Chapter 4 Cabling and Connections K3 L3 K2 L2 EX2100 Installation and Startup GEH-6631 . Salem.

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 manufacturer’s 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 manufacturer’s installation instructions. These will vary based on the type of installation required. To meet CE Mark requirements, all I/O wires leaving a building must be routed inside continuous metal conduit.

Generator PT and CT 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.

GEH-6631 EX2100 Installation and Startup

Chapter 4 Cabling and Connections · 4-11

Supplied by Others + Generator Field + To Bridge 1 Generator Field PT1
OR GROUNDED Y)

Exciter Control cabinet PTSW1
TB1

H1

PRI VAC : 14400 SEC VAC : 120

X1

1

2

H2

X2

3

4

PT PT

PT PT J305
Fan-out circuits

2 4 6 5 3

H3

X3

5

6

1

24 22 20 18 16 14 12 10 8

PT2
OR GROUNDED Y)

PTSW2
X1 1 2 X2

23 21 19 17 15 13 11 9

To EMIO (M1) To EMIO (M2) To EMIO (C)

H1

PRI VAC : 14400 SEC VAC : 120

H2

(OPEN

H3

X3

3

4

7

(OPEN

CT
X2

CTSW1
2 1

TB2 1

2

5L 1H 1L

4

3

CT

X1

CT
X2

1

CTSW3
2 1

TB3

4

3

5H 5L 1H 1L

CT EPCT

4

3

X1

Phase Rotation
3 1 2

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 413 and 4-14 for ECTB layout diagrams. For specific terminal information, refer to GEI-100457.

4-12 · Chapter 4 Cabling and Connections

EX2100 Installation and Startup GEH-6631

4

3

2

J315

5H

J308

5

6

From M1

J13M1

P70 V dc P24D

ECTBG2 (Simplex)
NO P24D Relay Driver Coil K#GP

TB1 18 19 20 Customer Power to Contacts 125 V dc

P24M1 J405

COM NC

From M1 (EMIO)

Four General Purpose Relay Outputs as 1 Relay Driver Coil K#M1 P24M1 M1 M1 Customer Power to Contacts 125 V dc 5 Two Trip Relay Outputs as Term. 1&5 Ex. trip to Customer 86 (1 of 2)

P70Vdc Red LED 33 34 Current Limit Six Circuits as Above Red LED P70Vdc

Auxiliary Contact Inputs (1 of 6)

45 46

52G Contact
(Closed online)

Current Limit P70Vdc 47 48

86G Contact
(Open for Trip)

To Optocoupler on M1 (EMIO) Current Limit

TB2

Figure 4-13. ECTBG2 Terminal Board, Simplex

GEH-6631 EX2100 Installation and Startup

Chapter 4 Cabling and Connections · 4-13

From M1

J13M1 P70M1

P24M1

ECTBG1 (Redundant)
P24D TB1 NO 18

P70 V dc From M2
J13M2 P70M2

P24M2

P24M1 J405 From M1 (EMIO)

Voted Relay Driver

Coil K#GP

P24D

Customer 19 Power to COM Contacts NC 20 125 V dc

Four General Purpose Relay Outputs as 1 P24M2 J408 From M2 (EMIO) M2 Relay Driver Relay Driver Coil K#M2 Coil K#C M1 Relay Driver Coil K#M1 P24M1 M1 M2 C P24C M2 C M1 Customer Power to Contacts 5 125 V dc

P24M2

C

Two Trip Relay Outputs as

Term. 1&5 Ex. Trip to Customer 86 P70Vdc Auxiliary Contact Inputs (1 of 6)

J415 From C (EMIO) Red LED

33 34 Current Limit Six Circuits as Above

Red LED M1 M2 C To M1 (EMIO)

P70Vdc

45 46

52G Contact
(Closed online)

Current Limit P70Vdc Current Limit 48 Current Limit Current Limit TB2 47

86G Contact
(Open for Trip)

To M2 (EMIO) To C (EMIO)

Figure 4-14. ECTBG1 Terminal Board, Redundant

4-14 · Chapter 4 Cabling and Connections

EX2100 Installation and Startup GEH-6631

Central Control Room Fast Ethernet Switch A Fast Ethernet Switch B From other Units T-Switch A From other Units T-Switch B 100Base-FX connections To local HMI Viewer. RJ-45 ACLA H1A GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-15 . 1 1 ACLA H1A 2 2 ENET ENET Ethernet Port. and any local HMI. This shows redundant control with two ACLA modules. 10Base-T 10Base-T connections From other Controllers From other Controllers Local Control Area gGE Industrial Systems Exciter Control Cabinet gGE Industrial Systems S T A T U S S T A T U S COM COM Figure 4-15. 10Base-T cabling is used for short distances between the controller and the T-Switch. Ethernet Cable Connections The 10Base-T ports in the ACLA and the T-Switch use RJ-45 connectors.Data Highway A typical exciter connection to the redundant Unit Data Highway (UDH) network is shown in Figure 4-15. The maximum distance using unshielded twisted pair cable is 328 ft (100 meters). The UDH is implemented using commercially available fast Ethernet switches. (simplex control has one ACLA with one UDH). The maximum distance using 100Base-FX fiber-optic cables is 2 km. The 100Base-FX ports in the T-Switch and the Fast Ethernet Switch are for SC type fiber-optic connectors. 100Base-FX fiber-optic cabling is used for longer distances between the local control area and the central control room.

Cable should only be pulled into clean trays. inspect all cable trays. The cable should not be excessively twisted. or flexed. The PC connects to J303B (M1 Tool) located on the control rack backplane. stretched. as necessary. 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. Do not pull cables around corners with sharp edges or corners that prohibit the minimum allowable cable-pulling radius. Observe minimum installation temperature to avoid damage to shielding and insulation. This prevents the entrance of water or other contaminants. In a redundant system. and after pulling the cable. Install bushings and dropouts. during. Avoid high mechanical stress (pull tension). Make sure that cable ends are sealed before. 4-16 · Chapter 4 Cabling and Connections EX2100 Installation and Startup GEH-6631 . A PC can be connected to the controller to download firmware into the DSPX board. Before pulling cable.PC Interface Control program downloads are usually made from a PC on the UDH Unit Data Highway using the toolbox software. connectors J310B or J313B can be used for accessing the DSPX board in M2 or C.

...............5-5 Dc Output Bus.................................5-2 Securing the Equipment for Safety.........5-5 Pre-Test Power Checks ................................................... this chapter includes checkboxes next to each procedure heading. It is good practice to check off each procedure when you complete it............................................................................................. For this purpose......................................................... This chapter assumes that the excitation lineup and connected devices have already been installed.................................................................................................. This includes checks and procedures to ensure that the exciter has been installed correctly and can be safely energized................5-5 Ac Input Bus and PPT Secondary ......................................Chapter 5 Pre-Power On Installation Checks Introduction This chapter must be completed before applying power to the excitation system.......................................................... It is presented as follows: Section Page Equipment/Material Needed............................... and that all wiring and cabling are installed correctly including control and power connections..........5-2 Hardware Checks............................ All instructions must be followed and completed in the order presented........................5-6 GEH-6631 Installation and Startup Guide Chapter 5 Pre-Power On Installation Checks · 5-1 ..........................5-3 Optional Megger Test.......................... This chapter contains instructions to verify that the EX2100 lineup is ready for initial power up......

dry air (less than 15 psi) or clean. o EX2100 unit specific Outline Drawings. o Locks and tags. 2. Verify that the generator collector ring brushes are not installed and/or the exciter generator field leads are disconnected at the EX2100 cabinet. Place appropriate barriers and warnings at the generator brush rigging while testing. standard and metric o Digital multimeter o One dc megger tester (voltage not to exceed 500 V). Lock out and tag out all voltage sources to the exciter. 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. optional o EX2100 unit specific Elementary Diagrams. dry cloth o Small standard (flat-head) screwdriver o Torque wrench o Socket sets. o EX2100 User’s Guide. compressed. were completed successfully. danger and caution tape o Source of low-pressure. Apply safety grounds per local rules and regulations. Check that the following equipment and materials are available for the procedures in this chapter. 5-2 · Chapter 5 Pre-Power On Installation Checks EX2100 Installation and Startup GEH-6631 .Equipment/Material Needed Checkboxes should be marked to verify that equipment is onhand. 3.

verify that power has not yet been applied to the circuitry. 9. All power disconnects and circuit breakers should be open. dry air or a clean. check the hardware after installation and before initial powerup. compressed.) Check fusing in the excitation cabinet. However. but only after boards or components have been removed from potentially energized equipment and are at a normally grounded workstation. Make sure that the equipment is secured for safety as required in the previous section. Become familiar with the exciter one-line on elementary sheet 1A. re-check them within three to six months after initial powerup. Check that all devices. Replace if necessary. Verify that all control power switches on the Power Distribution Module are in the off or open position. 6. Using an approved tester for the voltage levels being measured. 4. high voltages are present on some circuitry. Ø Check EX2100 hardware as follows 1. remove any dust that may have accumulated in the exciter’s interior. Inspect wiring to ensure that it has not been damaged or frayed during installation. modules. Check that all electrical terminal connections are tight. treat all boards and devices with static-sensitive handling techniques. (Refer to the elementary data sheet 0E. To prevent component damage caused by static electricity. When testing for the presence of high voltages and when measuring any electrical circuit. dry rag. 10. Use screwdrivers and torque wrenches for these checks. and boards have not been damaged during handling or installation and that they are secure in their mounting connections. (Refer to the elementary sheet 0E or to the nomenclature sticker located inside the excitation cabinet door). 2. use only the equipment approved for contact with those voltage levels. GEH-6631 Installation and Startup Guide Chapter 5 Pre-Power On Installation Checks · 5-3 . To help ensure successful startup. 8. do not touch any circuitry without first ensuring that it does not carry these voltages and is grounded. connections could loosen during shipping and handling. Check that the correct shunt has been installed and that the shunt cables are installed correctly. and annually thereafter. To prevent accidental injury.Hardware Checks o All procedures in this section were completed successfully for: o Control o Auxiliary o Power Conversion All exciters are factory-tested and operable when shipped to the installation site. Wear a wrist grounding strap when handling boards or components. Note To ensure that electrical connections remain tight. With power applied. 3. 7. Using either low-pressure. 5.

Verify that the circuit cards listed on the EX2100 elementary data sheet 0E have correct settings for hardware jumpers. Reference elementary sheet 0D. Verify that the cabinet is properly grounded. To do this: · · Either use an ohmmeter to measure all buses connected to the exciter to ground to ensure insulation integrity. Check incoming wiring/cabling. 15. Location of hardware jumpers can be found using the appropriate card GEI (refer to Appendix D for list). Verify that the incoming and outgoing buses are not grounded. 5-4 · Chapter 5 Pre-Power On Installation Checks EX2100 Installation and Startup GEH-6631 . Check all electrical interlocks for proper operation. It should conform to the cable separation guidelines defined in Appendix B. 12. as follows: · · It should be complete and agree with the elementary drawings supplied with the EX2100.11. 14. Or perform the optional megger test (refer to the following section). 13. Operate each magnetic device by hand to make sure that all moving parts operate freely.

Do not proceed until completing all requirements under Pre-Test Power Checks Short the ac input buses together using jumpers or wire. Open all the control power inputs and AC input disconnect (circuit breaker or switch) in the power conversion module. 4. If readings are low. dangerous voltages are present on some circuitry. Ø Before conducting the megger test on any component. and all sources of control power have been locked out and tagged out. o PPT input line to line o PPT input line to ground o o Use the checkbox to mark each completed measurement. and other components within the excitation cabinet. · Do not use ac meggers for this procedure. All EX2100 lineups have been high potential tested prior to shipment. check for the presence of power on the circuitry. The reading should be greater than 100 megohms. To prevent accidental injury. as follows 1. were completed successfully. Note There could be multiple sources of power in the enclosure. Using a voltmeter. To prevent circuit damage: · The megger voltage should not exceed 500 V dc. 4. It is recommended that the EX2100 be disconnected from all bus or cables to be megger checked. PPT primary power. check that the bus voltages have discharged to below 1 volt on the following circuits. and PPT Secondary megger 2. The exciter outline drawing shows location of fuses. 3. Connect one side of the megger to one of the buses and the other side to ground. 2. Dc output positive to negative Dc output positive and negative to ground Ac Input Bus and PPT Secondary o All procedures in Ac Input Bus 1. This optional test verifies that the system-to-ground insulation has not been damaged during installation. disconnects. Pre-Test Power Checks With power applied. Remove all jumpers or wires from the bus before applying any power. GEH-6631 Installation and Startup Guide Chapter 5 Pre-Power On Installation Checks · 5-5 . 6. 5. identify and correct the problem before proceeding. Remove all collector ring brushes from the generator brush rigging. do not touch any circuitry without first ensuring that it does not carry these voltages and is grounded.Optional Megger Test A megger (megohm meter) measures resistance by placing voltage across a device with respect to ground. Apply the megger voltage (not exceeding 500 V dc). Place appropriate barriers and warnings at the brush rigging while testing. 3. Check that the ac bridge power.

Do not proceed until completing all requirements under Pre-Test Power Checks. 6. 4. 5. Short the dc output buses together using jumpers or wire. If readings are low. identify and correct the problem before proceeding. The reading should be greater than 100 megohms. Apply the megger voltage (not exceeding 500 V dc). 5-6 · Chapter 5 Pre-Power On Installation Checks EX2100 Installation and Startup GEH-6631 . 2. 1. Remove all jumpers or wires from the bus before applying any power. Connect one side of the megger to one of the buses and the other side to ground. 3.Dc Output Bus o All procedures in Dc Output Bus megger section were completed successfully.

.............................................................................................................................................................6-19 Running Simulator Mode ..6-6 Verifying Control Power .......................................................................6-22 Temporary Load Checks ....6-27 Initial Roll and Offline Checks ....................................................................................................6-14 Open an EX2100 File ..................................................................................................................................................6-13 Starting the Toolbox...............................6-3 Panel Lights.............................................................................6-12 Using the Exciter Configuration Tools........................................................................................................ecb File ............................. Heaters and Fans.................Chapter 6 Initial Startup and Commissioning Introduction .................6-53 GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-1 ......6-30 Online Checks ............................................................... use of the keypad and offline and online commissioning guidelines.........6-14 Checking Toolbox/EX2100 Pattern Compatibility .............................................................. This includes control power checks...............................................6-19 Overview of EX2100 Parameters................6-2 Order of Startup......... This chapter is organized as follows: Section Page Before Beginning.........................................................................6-15 Checking the Keypad (EDI) .................................................6-14 Optional: Upgrading the .....................................................6-18 Commissioning the Exciter ........................................................................................................................ This chapter provides instructions to verify that the EX2100 excitation system is ready for operation......................................................................6-2 Information Needed........................................................6-2 Equipment/Material Needed............6-8 Control Module Processor Start .......6-16 Using the Keypad for Startup and Commissioning ..........................................................................................................................6-16 Adjusting Keypad Display Contrast .......................................................................................................................................6-15 Checking for Correct Firmware and Hardware ............................................................................... software setup....................................................6-14 Downloading to the EX2100 .......................................................................................6-52 Additional Testing..................................6-13 Using Toolbox Online Help ..............

you should review the applicable elementary and outline drawings to become familiar with the type of EX2100 supplied. connections. GEH-6632.9 dBA 75. lights and fans have been verified. Information Needed Before beginning. Adjacent to Enclosure Maximum 79. and power switches. and ready for power on. The basic design incorporates a common hardware and software structure.5 dBA Doors Open.2 dBA User’s Guide. Figure 6-1 is a flowchart for use as a visual guide to the startup and commissioning process once control power has been applied and operation of heaters. therefore the startup and commissioning procedures are similar for the different possible applications.Before Beginning Before beginning the procedures in this chapter. Note The EX2100 meets the following noise level specifications: Fan Quantity Doors Closed. For CE Mark Radiated Emissions compliance. each EX2100 should be started and commissioned using the following basic guidelines: · · Follow the procedures in this chapter in the order presented. connected.4 dBA 82. Whether a simplex or redundant control configuration or single or multiple bridge configuration. Power is not yet applied. Tip Ä It is good practice to check off each procedure when you complete it. The order of startup is important. Order of Startup The EX2100 Excitation Control can be provided in a variety of ratings and applications.4 dBA 76. All interconnecting wires and cables are in place.5 dBA Maximum 71. 6-2 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . one ferrite core (Fair-Rite P/N 2643164251 or equivalent) must be placed on each Ethernet network cable near the IS200ACLA termination point. including hardware structure. Make sure you know the power requirements and location of components. includes a functional description of the EX2100. One Meter from Enclosure Average 3 6 69. Verify this before applying power to the control rack. the following conditions must exist: · · · All pre-startup and installation checks from the previous chapters are completed successfully. All instructions must be followed and completed in the order presented in this chapter. For this purpose. this chapter includes checkboxes next to each procedure heading.

Software for the EX2100 will be found either on the turbine control master HMI or supplied separately for stand-alone excitation systems. GEH-6632 ¨ EX2100 Maintenance. Personal computer (PC) with the GE Control System Toolbox installed and the appropriate cables. tags. It should be verified that the file to be used is correct and the most up to date available. The software is tested at the factory prior to shipment and should require a minimum of changes during commissioning. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-3 . 336A4929G1 COM1 to EX2100 ACLA serial port 9 pin micro D connector. ¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨ ¨ Digital multimeters (2) Oscilloscope Small standard (flat-head) screwdriver Socket sets. use only the equipment approved for contact with those voltage levels. and danger and caution tape Typical Test Equipment When testing for the presence of high voltages and when measuring any electrical circuit. hard-hat. Checkboxes should be marked to verify that equipment is onhand. Specific Fault Troubleshooting of GEH-6633 is also available as Help files within the toolbox program (refer to Using Toolbox Help in this chapter).ecb for both DSPX and ACLA processors. and Troubleshooting Guide. ¨ EX2100 outline drawings ¨ EX2100 User’s Guide. high voltage gloves. standard and metric Flashlight Small inspection mirror Fuse puller Phase rotation meter Temporary load capable of carrying 3 or more amps and ceiling voltage. each EX2100 will have its own unique software file scaled and tailored for the generator applied using a common file extension . safety glasses. When commissioning the exciter with the GE Control System Toolbox for the first time. GEH-6414 The information contained in the toolbox document GEH6414 and in the section. Equipment/Material Needed Safety Equipment ¨ Appropriate safety gear (may include safety boots. Reference Documents ¨ System elementary (required) Tip Ä It is good practice to study the elementary before working on the excitation system. 336A3582P1 COM1 to EX2100 back plane or keypad 9 pin D connector. Parts Replacement. GEH6633 ¨ EX2100 GE Control System Toolbox (toolbox) document. and face shield) ¨ Locks. These cables include the following available from GE Salem.

Heaters. and Fans 1a Is Control System Toolbox Installed? No Install Toolbox Install Drive Components Refer to toolbox document GEH-6414 (Chapter 3). Yes 2 Start Toolbox Refer to toolbox document GEH-6414 (Chapter 3). Figure 6-1.ecb for DSPX and ACLA) Refer to toolbox document GEH-6414 (Chapter 3).Start 1 Control Power Applied & Lights Heaters and Fans Operational Yes Refer to sections Verifying Control Power and Panel Lights. 3 Are EX2100 Configuration files Available? No Obtain Configuration Files From HMI or Requisition Engineering (. Message: File last saved with older version toolbox ? Yes No Message: File last saved with newer version toolbox ? Yes No 4a Get Old Toolbox or Upgrade the file Get New Toolbbox 4b B 4a and 4b Refer to toolbox document GEH-6414 (chapter 3). Overview of EX2100 Startup and Commissioning (Part 1 of 2) 6-4 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 .ecb) (Toolbox Version is Automatically Verified) 4 Refer to toolbox document GEH-6414 (Chapter 3). Yes Open the EX2100 Configuration Files (.

Overview of EX2100 Startup and Commissioning (Part 2 of 2) GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-5 . 8 Check Hardware Check Firmware Check Keypad Refer to toolbox document GEH-6414 (Chapter 3).B 5 Establish Communications with the EX2100 5 and 6 Refer to toolbox document GEH-6414 (Chapter 3). 7 Review Release Notes Create Version Summary Refer to toolbox document GEH-6414 (Chapter 3). 6 Do EX2100 and File versions agree? Yes No Is EX2100 newer than file? Yes No Download Flash (File is newer than EX2100) 6a 6b Upgrade File 6a and 6b Refer to toolbox document GEH-6414 (Chapter 3). and section Checking the Keypad (EDI) 9 Perform Simulator andTemporary Load Checks Refer to sections Simulator andTemporary Load Checks 10 Perform Off and On-line Commissioning Checks Refer to sections Off-line Checks and On-line Checks End Figure 6-1.

3. panel heaters can be very hot. Energize the ac power feed for the panel lights and heaters. this equipment contains a potential hazard of electric shock or burn. 7. Measure the line-toline voltage of the ac feed for proper voltage as specified on the applicable system elementary. Keep all debris and flammable materials from contacting the heater surfaces. Block 1 and Figure 6-2. operate. The heaters are not used to maintain a constant temperature but to merely keep the EX2100 above ambient temperature. 9. Optional panel heaters and lights may also be provided. Energize the ac power feed for the power conversion module cooling fans. It is not recommended to megger check heater circuits in the field. Refer to the applicable system elementary for options provided. 2. Turn the ac breaker switch for the cooling fans to the ON position and immediately turn back OFF. Verify that the line and neutral connections are consistent with the system drawings. 5. Once energized. Verify that EGPA board jumper settings for JP1 – JP5 agree with elementary diagram sheet 0E. To minimize hazard of electrical shock or burn.Panel Lights. approved grounding practices and procedures must be strictly followed. or maintain this drive. Repeat steps 6 and 7 for the redundant set of cooling fans if supplied. Turn the ac breaker switch for the panel heaters to the on position. Turn the ac breaker switch for the panel lights to the on position. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install. 1. Measure the line-to-line voltage of the ac feed for proper voltage as specified on the applicable system elementary. Verify that no flammable materials are in contact with the panel heaters. 6-6 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . These may consist of tape or protective wraps. With power applied. Refer to the applicable panel outline drawings for location of components. 4. Each panel heater should energize. Heater surfaces should never be touched while energized. 8. All procedures in this section were completed successfully for: ¨ Lights ¨ Heaters ¨ Fans Each EX2100 will have power conversion module cooling fans supplied. Verify heater operation with an infrared heat detection device or carefully feeling for heat several inches above the heater surface. Visually verify that each fan is turning in a counter clockwise direction (left to right) when viewed through the fan box window. Verify all temporary shipping constraints for panel lights have been removed. Each panel light should turn on. Verify that the line and neutral connections are consistent with the system drawings. These items should be energized and operation verified prior to energizing the control power. Each heater has been hipot checked at the factory prior to shipping. Heaters and Fans Refer to Figure 6-1. 6.

Power to Control Module To M1 To M2 To C Breakers PCM Fans M1 M2 EDEX EDCF CONTROL EDEX J602 EETB ECTB EXTB EDEXEGDM FAN MEDIA CROWBAR CONV C EDEX EDCF CONTROL EDEX J602 EETB ECTB EXTB EDEX EGDM FAN MEDIA CROWBAR CONV PCM Fans PCM Fans Heaters EDEX EDCF CONTROL EDEX J602 EETB ECTB EXTB EDEX EGDM FAN MEDIA CROWBAR CONV Fan Fan Fan EPDM Exciter Power Distribution Module J1C SW6 1 2 Blank plate EPSM Power Supply M1 EGDM Ground Detector M1 EPSM Power Supply M2 EGDM Ground Detector M2 EPSM Power Supply C EGDM Ground Detector C J1M2 SW5 J1M1 SW4 J8C SW3 x x x x x x x x x x x x x 1 2 1 2 1 2 TB1 x x x x x x x x x x x x 2 4 6 8 10 12 14 16 18 20 22 24 x 1 3 5 7 9 11 13 15 17 19 21 23 J8B SW2 J8A SW1 J9 1 10 1 2 1 2 1 3 JDACA1 3 1 12 10 J1_M1 J1_M2 J1_C J2C GROUND DETECT JDACA2 3 12 125 V dc 115 V ac Supplies To J1M1 To J1M2 To J1C Figure 6-2. Front View of Power Supply Module GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-7 .

Remove the 125 V dc power and plug connector J9 on the EXTB or EXHS board back in. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control With power applied. 2. Reconnect the JDACA1 plug and re-apply the 120 V ac source power. Remove plug J9 from the EXTB or EXHS board. The EPSM power supplies are unstable when not loaded. Verify that the EGPA2 PSOK green LED is on. Verify that the EGPA1 PSOK green LED is on (see Figure 6-4). Refer to the Power Supply section of the system elementary and GEI-100463 for an overview of the EX2100’s control power circuitry.Verifying Control Power Refer to Figure 6-1. Relay operation will be verified at a later time. 6. Apply 125 V dc power to the EPDM. operate. This will apply power to the EGPA card in the primary power converter. 3. or maintain this exciter. Before energizing the power supply inputs. It is not possible to check power supply voltages without having the cards in the EBKP control rack inserted in their proper position. 5. verify that all toggle switches on the EPDM are in the OFF position. 6-3. 1. 8. Close SW8B on the EPDM. There are no external indications of power to this board. Again measure the voltage at FU1 and FU2 for a nominal 125 vdc to the EPDM distribution switches. also found on the EPDM (see Figure 6-3). Remove the 120 V ac DACA source power and repeat steps 3 and 4 for the second DACA module if supplied. 10. Apply the 125 V dc control power source as shown on the elementary power supply sheets. Close SW8A on the EPDM. Measure the voltage at FU1 and FU2 for a nominal 125 V dc to the EPDM distribution switches. 7. Remove the 120 V ac source power for the DACA modules. approved grounding practices and procedures must be strictly followed. Remove 120 V ac source power for the DACA modules. Disconnect the DACA1 and DACA2 plug jumpers JDACA1 and JDACA2. 9. 11. 4. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install. this equipment contains a potential hazard of electric shock or burn. Block 1 and Figures 6-2. and 6-4. This will apply power to the EXTB or EXHS board. This will apply power to the EGPA card in the backup power converter. To minimize hazard of electrical shock or burn. These supplies are tested and verified at the factory during card test and system test prior to shipping. 6-8 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . Apply the source 120 V ac power for the DACA1 module and measure the lineto-line voltage on pins 1 and 3 of the JDACA1 plug.

EPDM Board Layout GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-9 PS9 PS8A PS8B PS8C PS1M1 PS1M2 PS1C .E3 IS200EPDMG1A FU13 FU14 Fuse Data Table FU11 FU12 E4 SFTYGND SW7 SPARE SPARE SW1C SW6 DS8 J1C FU9 FU10 J1M2 FU7 FU8 CHASGND1 E1 FU6 J8C TB1 FU3 FU4 SW8A SW1 FU2 J8A J8B SW8B SW2 FU5 SW8C SW3 J1M1 SW1M1 SW4 SW1M2 SW5 DS7 DS6 DS5 DS3 DS2 FU1 DS1 J9 JDCA1 DS4 CHASGND E2 JDCA2 Figure 6-3.

This will apply power to the M1. Alarm) Klixon (T=190F. EMIO.140 V dc PSOK TPxx TPxx Line Filter Sensor Fan Rotation Sensor 1 Fan Rotation Sensor 2 TPxx TPxx 6X Gates ALARM FAULT Disable coolant trip Klixon (T=170F. M2 and C control circuit boards in the control rack. One at a time. close EPDM switches SW1M1.DC Power Source 130 V dc (nominal) 80 . Each board has a power status green LED that will illuminate indicating power is applied. DSPX. and SW1C. The DSPX and ACLA will also begin an initialization process. M2 and C (see Figure 6-5). 14. EGPA Board LED Locations Carefully follow the procedures documented in the circuit board instruction manuals for inserting the boards into the control rack. 12. Verify counter-clockwise rotation of each fan. SW1M2. Insert all circuit boards in the exciter backplane control rack for M1. These include the ACLA. EISB. and ESEL boards as well as the control rack fans located above these boards. Fault) RTD Coolant Temp Figure 6-4. The EPSM cooling fan for each module energized should be operating when the EPSM is energized. 6-10 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . 13.

Fan Fan RST OK ACTIVE ENET FLASH S T A T U S RST OK ACTIVE ENET FLASH S T A T U S COM COM 1 2 1 2 ENET ENET ACLA DSPX DSPX ACLA DSPX EISB EMIO ESEL ESEL EMIO EISB EISB EMIO M1 Boards M2 Boards C Boards Figure 6-5. Exciter Backplane Control Rack Boards (Front View) GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-11 .

The DSPX should boot-up with the following LED indications: · · Green status LED steady on or blinking Red fault LED blinking indicating an alarm status or off (solid red indicates a fault condition) 2. ACLA Faceplate 2 ENET 6-12 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . 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. and 6-7. if no Ethernet communications are enabled. has started correctly. located in the control rack. All procedures in this section were completed successfully for: ¨ Master 1 ¨ ACLA ¨ DSPX ¨ Master 2 ¨ ACLA ¨ DSPX ¨ Control ¨ DSPX Verify the that the DSPX processor board.Control Module Processor Start Refer to Figures 6-5. as follows: 1. DSPX Faceplate Figure 6-7. For the other boards in the rack. g GE Motors & Industrial Systems g GE Motors & Industrial Systems STATUS FAULT RST OK ACTIVE ENET FLASH S T A T U S E M U L COM H S P S O E R R T I A L 1 DSPX H1A ACLA H1A Figure 6-6. check that the green power LEDs are steady on and the green status LEDs are steady on for the active master. 3. Off. 6-6. Green Status LEDs will be alternating in a clockwise progression.

For Do this Menu commands Dialog boxes Block information Help contents Help Specific word(s) Highlight the command and press function key F1. Product Help displays the Help file for the currently loaded product. Release Notes provides product changes in the toolbox. Contents displays Help files for the toolbox. diagrams. The toolbox is designed with menus. Press F1 when the dialog box displays on the screen. block diagrams. Using Help displays general instructions on how to use Help. It also contains the Find tab with a work list to search for specific topics. as well as drive configuration instructions. The file contains help on parameters. a drop-down menu provides several options for finding information. Item Help displays help for the item selected in the Outline View.Using the Exciter Configuration Tools GE document GEH-6414 describes the EX2100 toolbox installation and use. Choose Help then Contents. From there. The GE Control System Toolbox is a Microsoft® Windows®-based. Send Problem Report allows you to submit a system change request for the toolbox. Choose Help then Using Help. Using Toolbox Online Help Tip Ä It is good practice to refer to the toolbox Help for any part of toolbox operation or menu and dialog options that you do not fully understand. faults. There are several ways to access Help while running the toolbox. This includes installation and operation. and wizards that simplify and guide you through the startup and commissioning process. The toolbox Help feature provides detailed information about using the toolbox. Click on the desired block with the right mouse button and choose Item Help. Choose Help then Contents and Find. you should refer to either the toolbox online Help or the product documents listed in the Tools/Materials Needed section. When you choose Help on the toolbox main menu bar. configuration program used to tune and commission the exciter as needed for each application. dialog boxes. enter the word(s) you want to find. You can access the Help files at any time after the toolbox is installed on your PC. and wizards. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-13 . For detailed information.

Downloading to the EX2100 Refer to GEH-6414. you must open the exciter configuration (. Refer to Figure 6-1. Refer to Figure 6-1. M2 and C.) About Toolbox… displays the version number of the toolbox. Instructions for performing the procedures are located there. Blocks 5 and 6. then either the flash code (which contains the pattern version) must be downloaded from the toolbox to the controls. Open an EX2100 File To download exciter software with the toolbox. Software files will be available on the Turbine HMI or supplied separately. 6-14 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . If this exact directory structure is not present.ecb) file for all three controls.ecb file must be upgraded. Block 2. you must correct it. Refer to GEH-6414. If it is not. Block 4. GEH-6414 Chapter 3. Note The toolbox requires the pattern directory to be located under the exact structure of GE Control System Solutions / EX2100. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control GE provides the toolbox on the Control System Solutions CD.ecb file must be the same version as the pattern loaded in the exciter (the ACLA and DSPX boards). (This feature is only available if you have a connection to the GE intranet. or the . Chapter 3. All EX2100 exciters are preengineered and this file should be available on the turbine control HMI or a software CD supplied with the excitation equipment. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control Checking Toolbox/EX2100 Pattern Compatibility The firmware pattern used to create the . Chapter 3. M1. Block 6A.Goto Toolbox Web Site takes you to the toolbox home page. All procedures in this section were completed successfully for: ¨ Master 1 ¨ ACLA ¨ DSPX ¨ Master 2 ¨ ACLA ¨ DSPX ¨ Control ¨ DSPX Starting the Toolbox The remaining procedures in this chapter require that you use the toolbox and the EX2100 toolbox document. Refer to Figure 6-1. Chapter 3 to download the firmware pattern from the toolbox to the EX2100. Refer to Figure 6-1. Refer to GEH-6414.

Block 6B. firmware and hardware revisions are backward compatible with older revisions. occasionally the firmware depends upon a minimum revision of hardware.ecb file to a more recent version. These parameters are stored in the . it may be necessary to upgrade the . Tip Ä . Settings. select Options. Refer to Figure 6-1. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control Optional: Upgrading the . and the tab Directories. it needs to be installed from the Control System Solutions CD. Block 8. To establish the default directory from the toolbox. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control Checking for Correct Firmware and Hardware Typically. provided with the toolbox files). Chapter 3.ecb files are typically stored in a project directory. provide an overview of the EX2100 hardware and software relationship. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-15 .ecb.ecb file.ecb file must be the same as the firmware revision loaded into the DSPX and ACLA. The release notes (RelNotes. select the browse button to find (for example) C:\Jobs\GESalem\JobName\CTRL. Note If the version required does not appear. Then from the Default Project text box.Refer to Figure 6-1.ecb File Associated with the firmware version in the drive are parameters that vary.ecb files to newer revisions. Chapter 3. Refer to GEH-6414. Refer to GEH-6414. However. To achieve this.txt. depending on each application. The revision of the firmware used to create the . The toolbox can automatically upgrade older .

00 Amps 0. reset the EX2100. Both keypads can access data and parameters for Control. Preventative and Online Maintenance Guide (listed in Equipment/Material Needed in this chapter) for information. wizards.00 60.) Note If the keypad’s display cannot be read or contrast is poor. (The cable from the keypads connects to the rack’s J303A and J310A connectors. Front View of the Keypad 6-16 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 .00 Exciter Pll Watts 0. Faults) or EX2100 Troubleshooting. The screens for your EX2100 should display information that is specific to your configuration and application. Facing the keypads (with the door closed).0 Volts FldCurrAmps 0.Checking the Keypad (EDI) Refer to Figure 6-1.00 Vmag Freq_Hz Imag Exciter Health & State Icons -30% 0% 100% 150% 0. set parameters. Block 8. Using the Keypad for Startup and Commissioning The keypad can be used to check firmware and hardware versions. Product Help. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 . Observe that each display’s heartbeat icon is pulsing (see Figure 6-8). This information is provided in the EX2100 User’s Guide GEH-6632. The keypad and toolbox screens presented in this document are samples that represent one possible application. refer to Adjusting Keypad Display Contrast in the following section before proceeding to step 2. g Display: Status Screens provide analog and digital representation of exciter functions and values. Contents. 2.00 0. The two operator interfaces located on the control cabinet front door are the EX2100 Diagnostic Interface modules (EDI. If faults are present.00 55. the left side keypad is used to interface with Master 1 and the right side with Master 2. Status Navigation Exciter Control Reset Faults Auto On Run (Green) Pushbuttons: Organized into functional groups: Navigation Buttons for using the menu Exciter Control Run and Stop buttons Escape Enter Voltage Level Command Menu Menu Man Stop (Red) Off Figure 6-8. and provide many other functions to control the exciter.00 Vars Menu Screens provide text-based access to parameters. run the exciter. EX2100 Excitation C -30% 0% 100% 150% FVR Feedback 0. use toolbox Help (select Help. 1. This indicates that the keypads can communicate with the EX2100. most commonly called keypad). and faults.

Keypad. then click Send To Drive and OK. Reset the exciter as shown below. contact GE Product Service (see Chapter 1. Check that the EX2100 is communicating with the PC (the Go on/offline button 2. This can be done using either the keypad or the toolbox. General Setup. enter a number. and Keypad Meters. In the Value text box area. is selected). Double-click Keypad contrast adj to display the associated Edit Parameter dialog box. In the toolbox work area.Adjusting Keypad Display Contrast You can improve visibility of the keypad display by adjusting the contrast. Ø 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). How to Get Help). 4. expand the items displayed in the Outline View by clicking on the plus sign next to Main Menu. 1. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-17 . 3. Ø To adjust keypad display contrast using the toolbox You should not see “Offline” on the toolbox status bar (bottom right side of screen). Toolbox menu bar selections. If the display is still not readable. 6. which resets the display to the new value. The dialog box displays the value Range for this parameter. 5.

Downloads of EX2100 parameters are performed in two separate steps. the block diagram.) 6-18 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . Occasionally. EX2100 Toolbox. Note The procedures in this chapter are based on SAMPLE parameter values. select “Diagram” from the toolbox work area. The toolbox does not allow this to happen and will notify the user that the exciter is not stopped. (Refer to document GEH-6414. To complete the following steps. While individual parameters can be changed while the exciter is running. The steps must be performed in the following order. the master core will reset which would trip the unit. 1. Simulator checks 2. In the following paragraphs. Any parameter values referenced should not be used for any specific job. control power has been applied. parameters will be designated with parenthesis (MRNLM) and variables will be designated with carats <MANREF>. Application specific data has been entered into the EX2100 parameters found in the toolbox software files. software has been loaded and all faults cleared. Online checks Overview of EX2100 Parameters The parameter settings are pre-engineered prior to shipping and should not require adjustment. although some parameters. Both the application layer software (ACLA) and the exciter regulator software (DSPX) are sent to the EX2100. Changing parameter values while the EX2100 is running is not recommended. Any changes to parameters should be saved in the . can be adjusted with minimal risk while running. The RED and BLUE down arrow icons are used through the toolbox. Typically. it is assumed that the EX2100 has all connections completed. with each step for both controls completed before proceeding to the next phase of commissioning. then Master 2 and the backup power converter commissioned. During this testing. To access the block diagrams. such as diagnostic setups. GE Salem should be contacted prior to any parameter modifications. some access to the turbine control HMI will be necessary. After a download.ECB File in this chapter). or the keypad. If a parameter value is in doubt.ecb file by uploading the parameter values from the EX2100 to the toolbox (refer to Optional: Uploading the . but most steps can be run from the exciter keypad(s). the primary power converter module and Master 1 controls are commissioned first. Temporary load checks 3. outline view. contact GE Salem for clarification. These parameters provide the data for the application rules used in the toolbox during the validation and calculation of settings for the EX2100. Parameters may be adjusted individually from the toolbox menus. Initial roll and offline checks 4. specific parameter values require changes prior to initial operation of the equipment.Commissioning the Exciter Commissioning is the final stage of starting up an EX2100 lineup. an entire parameter download to the DSPX processor (using the BLUE down arrow icon) is not allowed.

ACLA. (using the RED down arrow icon) is allowed while the exciter is running. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-19 . this will be benign to the user. For most application layer changes.An entire download of the application layer software. 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 interrupted.

select the Finder button Update. 2. . 6-20 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . The toolbox uses the parameter settings that were entered to calculate the parameter final values. double-click on the not equal sign ¹.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. From the toolbox. Select Device. Double-click on the item selected. If parameter final values are overridden. then Overrides. Level 4 allows changing parameters and editing hardware. and Overrides are typically not required and should be avoided. Calculate Parameter Final Values Final values are calculated from parameters. a not equal sign ¹ displays in the Status bar at the bottom of the toolbox window. Reset Drive. Ø To view and clear overrides with Level 4 privilege 1. 4. These values are present in the EX2100. Select Clear then Override. and requires a password. Privilege levels provide different types of access to the devices. Hard Reset. The toolbox indicates that overrides exist in the pattern by displaying a red O at the bottom of the screen. To display the differences. running the toolbox Build/Calc routine will not update these values. This causes the toolbox to compare its parameter values with those in the EX2100. If the parameters in the toolbox are not equal to what is in the exciter. but are not normally viewable in the toolbox unless they are overwritten. The ¹ sign at the bottom of the pattern screen does not include final values. 3.

as well as the exciter stator and field models.Running Simulator Mode Refer to Figure 6-1. maintenance. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-21 . Block diagrams are accessible by selecting the EX2100 Overview diagram and clicking on the appropriate page button. Main generator field voltages and currents are also simulated internally and used for correct model operation. Block 9.ecb file. In the following procedures. Changes to regulator gains should not be made from observations made in simulator mode. the display data cannot be distinguished from real data. there will be some instability on the operator displays and EGD page information due to the coordination of data among the three controllers. and training tool. The regulator responses provide a good representation of what can be expected of the real system in response to step changes. If the model scaling is correct. The EX2100 contains a built-in simulator that models a generator and static excitation system. Verify that flashing power and ac power to the bridge is removed or isolated from the generator field and personnel are clear from any moving devices. 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.ecb file Simulator Scaling for representations of the system models and simulator scaling. These feedbacks are handled by the transducering algorithms the same way real feedbacks are used to calculate watts. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 Refer to the Control Systems Toolbox . both online and offline. the feedbacks presented to the control regulators are switched. The exciter changes the system vars in response to changes in the exciter voltage setpoints. by software. 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 simulator can serve as a valuable startup. vars. speed deviation. Operation of these devices will be tested in the Temporary Load section that follows. the EX2100 will not generate actual commands to close field breakers and flashing contactors. The regulator limits activate at the same levels as in nonsimulated operation. The finder function in the toolbox can also be used to locate parameters and variables. provide the feedbacks for exciter field voltage and current. The exciter regulator can be raised and lowered in automatic or manual regulator. These diagrams can be found in the . and frequency. When simulator mode is selected. it follows a normal start sequence. and generator stator voltage and current. Operation of some relays may occur in Simulator Mode. This means that when a start command is given to the EX2100. The simulator is scaled to represent the actual system as accurately as possible. While the simulator mode in the EX2100 is a very close approximation of the actual operating look and feel of the exciter. various block diagrams are referenced to allow access to parameters and variables for testing. The generator armature and field models. Unlike the EX2000.

LOE $C. PT Failure. VAR/PF & PSS Enables 06 $ Keys_States 07 XY Charts $ InnerLoop $ FiringControl $ BridgeTherm $ Alarms $ AlarmString $ Trips $ TripString $ VCO $ VCO_Zero $ EGPA1Logic $ EGPA2Logic $ CondSense $ PSS $C. Run Requests Simulator Enable. Bus Start Auto/Manual. 2000 Page name: Device name: Date: #### ???? Figure 6-9.Synchro $C.A 01 B C D E F G H I J K L M N O P Q R S T U 01 EX2100 Overview 02 02 DSPX Side 03 Generator Ratings $ GenRatings $ StatorSim $ FieldSim $ GenInstr $ PTCT_Wiring 03 Simulator: Stator and Saturation Curve Field Side C3 Logic: Transfer State Machine Out of Bounds protective transfers Problems: Master Asks for a Transfer Field Ground Detector: Input Filtering Sequencing Fault Calc / Freq Component KeyPad $ Transfer $ ProtectXfer $ Problems $ FGD_In $ FGD_Seq $ FGD_Calc $ KeyPad 04 Generator Stator Side Instruments PT and CT Wiring 04 05 05 Start Stop Sequencing: Flashed Start 06 $ FlashStart $ AuxBusStart Aux.VHz 07 Inner Loops: Field voltage and current regulators SCR Firing Control 08 Bridge Thermal Alarms and Trips 09 Inner Loop Bode Analysis $ BodeIL 08 Alarms: Individual functions Alarm and Diagnostic Strings Dual Port Memory (DPM) DPM Signal Map (pages 1 & 2) DPM Signal Map (page 3) DPM Boolean Signals (bits 0-15) DPM Boolean Signals (bits 16-31) $ Dpm1 09 10 Trips: Individual functions Trip String with enables 10 $ Dpm2 $ DpmBits1 11 $ DpmBits2 11 Analog Feedbacks Field Signals.Satcurve $C. Va. and Bridge Temperatures Analog Feedbacks Offset Removal 12 Gate Pule Amplifier Logic: Bridge 1 Bridge 2 Outer Loop Functions $ AVR $ AutoRef $ EXASP $ MANREF 12 13 Conduction Sensing (Sensor Failure) 13 $ VARPF General Purpose Inputs/Outputs (and 52.OEL $C.86) 14 $ GP_In_Out $ HTSEN $ UELHTC $ UELREG 14 $ Diag_Util D/A's and General Purpose Filters 15 Capture Buffer Configuration EMIO Outputs with Diagnostic Feedbacks A B C D E F G H $ Capture 15 16 $ EMIO_DiagFbk I J K L GE Motors and Industrial Systems Salem. Block Overview Diagram 6-22 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . USA PRODUCT: saved date: Innovation Control December 12. Test A/D's.

The EX2100 can be controlled from the toolbox by using the animated bar graph display instead of the door-mounted keypads. Once in simulator mode. (Keypad menu: GP_In_Out). 1. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-23 . Verify that <Aux86> is in a true state. or start/stop the exciter. 4. Control must be transferred to the backup master through the keypad menu before the backup master keypad will raise/lower. Click to reset faults. Lower case m1 or m2 indicates backup. An upper case M1 or M2 in the keypad display indicates the active master. This can be monitored via <Spd_Ref>. the exciter simulated speed should begin to increase.to decrease the voltage. These checks are an assurance that the basic control features of the EX2100 are in place and will control the generator safely prior to operation with actual field voltage and current. toggle from auto to manual. The keypads can then be used to monitor variables and I/O states while testing. Temporarily jumper the contact input on the ECTB board TB2-47and 48 to simulate 86G lockout relay reset condition. Simulated terminal voltage. Use Off to take the exciter out of run mode.The Exciter Control Window animated bar graph display is available using the icon in the . 2. field voltage. 3. Place the EX2100 controls in simulator mode from the Controls Systems Toolbox or local keypad (EDI) by changing (SimMode) to a true state. Start the excitation in simulator mode by selecting the (1) on the operator keypad. Set simulated speed to 100% via (SimSpeedRef). and field current should build to rated no-load values. <ASP_AA> will be true. Auto controls terminal voltage on the generator. Click On to put the exciter in the run mode. Removal of the jumper should toggle the variable to a False state.ecb file of the toolbox. Man controls voltage on the field. Bar Graphs and meters provide feedback of the current state of the device. Click + to increase or . Note The following procedures do NOT purport to cover all settings of the parameters in the EX2100. Verify the Master 1 and Master 2 controls are in automatic regulator mode by selecting Auto on the operator keypad (Figure 6-5). Only the active master can effect changes to the EX2100. Replace the jumper so that <Aux86> is true.

vsd software function screen. 6-24 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . the automatic regulator will build terminal voltage to the preset generator rated terminal voltage.vsd software function screen. Replace contact jumper. 2. and then transfer the exciter back to automatic regulator. <ARSTAT> should be a value of five. 3. At the appropriate value set by (ASPVHZ). In automatic regulator. Remove the contact jumper on ECTB board TB1-47 and 48 for 86G lockout simulation. perform the PT failure simulation. <MRLLM> should be true. if the simulator is at 100% turbine speed. lower excitation to the low limit of terminal voltage (ARNLM). then this test can only be performed when the unit is online. If there is only one set of PT inputs. At the (ASPVHZ) value. Monitor the functions on the Auto_Ref.vsd software function screen. decrease (SimSpeedRef) to zero so that turbine speed will begin to decrease.V/HZ Limit Verification 1. usually –10% of rated. 2. 3. Note It should not be possible to select automatic regulator without clearing the PT failure and resetting the PT failure alarms. Transfer the controls to manual regulator and again continue to lower excitation while observing the Man_Ref. 1. Reset the PT failure alarms from the keypad command menu. Note It is not possible to check the manual regulator upper limit (MRPLM) in offline simulation mode. 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). Lockout Trip Verification 1. Return the simulated torque to the preset value and terminal voltage will begin to increase. Using the PT failure picks on the GenInstr. (AR_ZV). AVR Preset Verification When the exciter is restarted. and the PPT is fed from an auxiliary bus. <MRSTAT> should be a value of 5. 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. terminal voltage will stop increasing and the V/HZ Limit Active alarm <ASPVHZA> will clear. This should activate the PTUV detection as well as transfer the controls from automatic to manual regulator. 2. AVR/FVR Upper and Lower Limits 1. In manual regulator. With the unit at rated terminal voltage. terminal voltage will begin to decrease and the V/HZ Limit Active alarm will annunciate when <ASPVHZA> is true. De-activate the PT failure. Verify that the exciter stops immediately. 2. the excitation should stop at a value equal to (MRNLM) or 80% of no load field voltage. <ARLLM> should be true. clear any alarms or faults and restart the exciter.

3. UELY0) through (UELX10. Check operation of the UEL at various values of (SimTorqueRef). This may cause unintentional operation of protective devices outside the EX2100. raise excitation voltage until the value of (FcrRefOffline) is reached. <FldMode> is found on InnerLoop. transfer the EX2100 to manual mode. <FldMode> should change from a true to a zero value. AVR Under Excitation Limit (UEL) With the previous offline simulated operation checks complete. but the generator is at less than rated voltage. Remove temporary jumper for 52G and clear all alarms and faults. and using the values of (UELX0.01 pu value for the V/HZ trip relay. 2. Removal of the jumper should toggle the variable to a False state. Once the simulator is online.FVR Preset Verification 1. While monitoring the XY chart for UEL operation. 2.01 pu. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-25 .vsd. 3. See system elementary for details. 4. 4. Once <Aux52G> is true. With the EX2100 operating in manual. the 94EX contact output can be operated inadvertently. This concludes simulator mode testing. Closed contacts will request a trip of the generator lockout device. Because the takeover point of the UEL is modified by the square of the terminal voltage. The EX2100 should generate a 94EX lockout trip request after a time delay found in (VHz1TripSec). lower the terminal voltage until the UEL becomes active. Raise excitation terminal voltage so that the UEL is no longer active. Lower (SimTorqueRef) to the original offline operation value. (FcrRefOffline) is found on Alarms. Start the exciter and observe that the simulated field voltage builds to a value equal to (MR_ZV). <UELACT> should be a true value. Disconnect ECTB board TB11 and 5 to prevent 86G operation. With excitation stopped. Raise the simulated terminal voltage so that it exceeds the 1.vsd diagram. Verify that ECTB board terminals TB1-1 to TB1-5 are shorted (closed). When the UEL is active. These variables can be viewed on the keypad display or use the (Tramp Up/Down) adjustment on the Statorsim. actual takeover points may not correlate exactly to the parameter values.vsd. raising or lowering the terminal voltage should now change the value of <VARs>. With the generator in simulator mode and operating at less than rated terminal voltage. 2. temporarily change (VHz1TripLev) from the normal value of 1.18 pu to 1. the EX2100 is ready for simulated online operation. 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. 1. V/Hz Trip and 94EX Verification 1. Offline Over Excitation Limit (OEL) The offline over excitation limit only operates when the EX2100 is in manual regulator. Lifting of the 94EX output contacts is recommended during simulator and temporary load operation. Changing the value of (SimTorqueRef) will alter the value of <Watts>. Replace the jumper so that <Aux52G> is true. (Keypad menu: GP_In_Out). UELY10) as a guide.

5. verify that the proper polarity voltage appears on the DC voltmeter connected to the temporary load. 2. Repeat steps one through five with M2 selected as Master.Temporary Load Checks Refer to Figure 6-1. Verify that both 41A and 41B contactors close by monitoring <Aux41> as well as visual verification. start the exciter by selecting the green start button on the operator’s keypad. Flashing and 41A.ecb file as per the application being tested. After the EX2100 trips. click on each feedback’s respective zero VCO button on the far right of the diagram (see Figure 6-10). due to a lack of ac input voltage. For units with flashing. This will cause the EX2100 to trip after attempting the start sequence. Block 9. reset all faults and alarms.vsd diagram. 6-26 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . See system elementary for details.vsd diagram. Temporary load operation confirms that the EX2100 is capable of gating cells and producing excitation voltage. With no ac input voltage applied to the EX2100. Using the VCO_ZERO. (This test must be run with the exciter not gating the SCRs. This value can be monitored at <FldVoltVolts>. With no ac input voltage applied to the EX2100. Field Ground Detector Feedback Field Voltage Feedback Field Current Feedback. Zeroing VCO Offsets 1. This can eliminate many frustrating hours of troubleshooting during initial turbine roll and generator energization if performed prior to running the unit.) · · · 2. 6. Disconnect ECTB board TB11 and 5 to prevent 86G operation. The EX2100 will regulate field current at the values specified in (FlashingAmpsMin) and (FlashingAmpsMax) on the FLASHSTART. The controls will automatically zero the VCOs and indicate Ready when complete. Operation of contactors and relays will occur in while testing with a temporary load. voltage controlled oscillator offsets should be zeroed for the following feedback variables. 3. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 Operation of the EX2100 core with a temporary load is highly recommended. For units with flashing. Verify that personnel are clear from any moving devices and are clear of exposed components and leads. 4. Use the AuxBusStart or Flash_Start page in the . also verify contactors 53A and 53B for proper operation by monitoring <Aux53B> and <Aux53A> as well as visual verification. 41B Verification 1.

VCO Calibrate Zero Offset Diagram GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-27 .Figure 6-10.

Verify the Master 1 and Master 2 controls are in manual regulator mode by selecting Manual on the operator keypad (Figure 6-8). 3. The 41AC disconnect should be closed. If PT feedback is not simulated into the ECPT board inputs. 8. L2. Monitor <expll_volts> and verify that the measured ac input voltage agrees with the ac voltmeter reading of the ac input voltage. Referring to the EX2100 control system elementary. 6. Power will be applied to ac input circuits and dc output circuits. Confirm the manual regulator preset (FvrPreset) is suitable for the temporary load chosen. This alarm will not reset until the exciter is stopped or PT feedback is simulated while running.ecb file. These connections are found in the Power Converter Module. the EX2100 will alarm a PT under voltage condition. After both 41A and 41B close and the flashing sequence is completed. start the exciter using the primary master’s keypad by pressing the green start pushbutton. 7. the EX2100 should begin to gate cells and develop and output voltage equal to the value in (FvrPreset). An ungrounded three-phase source voltage as close to this PPT secondary voltage as possible should be connected to the ac input leads L1. Once again. 9. Personnel safety practices must be observed during this testing. 2. Connect a resistive load capable of carrying generator field ceiling voltage and at least 3 amps to the dc (+) and dc (-) output leads. 5. and L3 of the EX2100. FANS ALRM PSOK FUSE FALT PHA COOL 170F 190F GT1I GT6I GT2I GT4I GT3I GT5I PHB PHC GT1O GT6O GT2O GT4O GT3O Figure 6-11. EGPA Board LEDs Example 6-28 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 GT5O . it is possible to use the normal ac input for test purposes. For EX2100 units supplied from an auxiliary bus. An oscilloscope using differential mode and a dc voltmeter should also be connected to this temporary load. 4. This parameter is found on the Firing Control block of the . Apply the ac input voltage to the EX2100. Observe on the active power converter’s 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). Note A three-phase voltage and current source can be used to simulate generator feedback signals during temporary load testing. Confirm that the dc output to generator field is disconnected from the EX2100. identify the applicable PPT secondary voltage. If this voltage source is significantly different than the normal PPT input voltage. (PPT_Vrms) can be adjusted for this test.Manual Voltage Regulation and Bridge Firing The main generator field leads must be disconnected during this testing. 1.

raise the exciter output to the maximum LCI reference of no-load field voltage while in static start mode. controlled manner. and personnel barriers should be in their proper positions. The values in (MRPLM) and (MRNLM) are the upper and lower limit of field voltage while operating in the manual regulator. 3. Start the EX2100 with the static start input reference at its minimum value. Repeat steps one through seven with M2 selected as Master. The oscilloscope connected across the temporary load monitoring the dc output should indicate six distinct cell firings of equal magnitude and duration. Block 9. The trend of <FldVoltVolts> should indicate that a bumpless transfer from primary to backup power converter has taken place. Verify that there is no change in dc output voltage and oscilloscope waveshape. The static start input reference can be a 0-10 volt input. EX2100 exciters on steam or hydro turbines will not have a static start reference input. With the EX2100 stopped and M1 as master. Using Command Menu #2 of the active master. 2. 1. Using the hard-wire input reference or EGD input reference. Core Transfer Operation 1. a temporary source should be connected to the ECPT board TB1 21 – 23. 5. Doors. Continue to monitor the bridge output voltage on the oscilloscope and dc voltmeter. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-29 . raise (+) and lower (-) the exciter output voltage. Static Start Voltage Reference Operation On large gas turbines. using Command Menu #2 of the keypad of the active master. From the keypad of the active master. or an EGD page input. force the logic in the turbine control to place the exciter in static start mode operation. wire tray covers. The oscilloscope display should show an increasing and decreasing firing angle on the display. transfer control back to the original primary power converter and again verify bumpless operation. If it is a hard-wired input signal. the exciter is used to supply generator field flux for the LCI during static start operation. 2. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 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. With the unit running at any output voltage. The dc output voltage should respond is a smooth. as well as trending <FldVoltVolts>. Repeat steps one through five with M2 as the primary master. 4. 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.10. 3. This control should be tested prior to startup. Initial Roll and Offline Checks Refer to Figure 6-1. 4. 12. 11. All temporary connections and jumpers should be removed. The voltage level on the dc voltmeter should agree with the value monitored at <FldVoltVolts> and be equal to the value in (FvrPreset). The EX2100 should start but the dc output voltage should be zero. transfer control to the backup master. 4-20ma input. 5.

Preparations for Initial Start 1. Allow the turbine to come to full speed. 6-30 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . 4. no load operation first and start the exciter through manual intervention of the operator. <FldCurrAmps>. no load. Extensive use of the step test. Subsequent starts can then be made in automatic regulator once the unit has proven to be capable of operation in that mode. If all simulator mode and temporary load checks in this manual have been completed. 6. Turbine control logic forcing will be necessary during the initial startup of the EX2100. the EX2100 should be capable of providing field excitation during the commissioning of the static starter. For the initial operation of the EX2100. 2. and trend recorder feature of the toolbox will allow for quick evaluation of correct operation of the EX2100. All power supply sources for the EX2100 should be on and the 41AC disconnect device should be closed. Field current and generator terminal voltage should trend as in the following startup recording for a start command in manual mode at full speed. An oscilloscope using differential mode and a dc voltmeter should be connected to the generator field. no load (see Figure 6-12 and Figure 6-13). and <Vmag> Initial Start Procedure 1. Subsequent starts can then be made with the automatic sequencing. 2. The EX2100 should execute its start/stop sequence in manual regulator and build generator field voltage to a value equal to <FvrPreset>. Generator protective relaying checks should be verified as complete and plant personnel safety practices must be observed during this testing. The Circular List should be collecting and ready. 5. the initial operation of the EX2100 is usually during cranking or initial firing checks of the gas turbine as the field exciter for the LCI. 3. Start the exciter using the primary master’s keypad by pressing the green start pushbutton. trending variables <FldVoltVolts>. On large gas turbine applications. high voltages and currents will be present in the EX2100 and applied to the main generator field.During initial roll and off line testing. circular list. The EX2100 should be first started in manual regulator to verify correct generator PT feedback values before starting in automatic regulator. Verify that generator field collector ring brushes have been installed and properly seated in the brush rigging. the turbine control should not be allowed to automatically start the exciter. The turbine should be at full speed. Verify that the PT and CT disconnect switches are closed.

Manual_startM1 Trend Recording Example GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-31 .Start Stop State Voltage Magnitude Voted Field Current FvrFeedback Cmd53A Cmd53B Cmd41 Start/State Fld Curr Figure 6-12.

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 6-32 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 .

If it does not. bumpless transfer should occur. transfer the EX2100 to automatic regulator. and <PPT_Vrms> should be checked for agreement with measured values using a calibrated measuring device. 6. See Figure 6-14 and Figure 6-15. <FldVoltVolt>. <Vmag>. or undershoots in voltage. <FldCurrAmps>. Again. Field shunt millivolts can be used for field current verification in place of a clamp on current device. 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.ecb file for reversed phasing alarms and troubleshooting help. 4. Generator terminal voltage should change by 2% with no instability. GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-33 . 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). At this point it is important to verify control feedback and scaling values for several key variables. apply a 2% step to the automatic regulator for a period of 5 seconds. Stop the EX100 and restart in automatic regulator. A smooth. 5. Raise the EX2100 output voltage slowly until rated generator terminal voltage is reached. Using the active master’s keypad.3. Verify that the keypad display of regulator balance reads zero at this time (then it is ready for transfer to automatic regulator). Alarms and diagnostics for improper phasing of the PT feedback should annunciate if incorrect. and using the step test function in the Control System Toolbox. 8. The EX2100 should now bring the generator to the value found in (AR_ZV). <Vmag> should agree with this value. using the trend recorder collecting variables <FldVoltVolts>. <FldCurrAmps>. overshoots. and <Vmag>. 7. Monitor the Alarms diagram of the .

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 6-34 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 .

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 GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-35 .

USA 09/04/01 11:47 AM Figure 6-16.BodeActive V.5.5.BodePtr2 {P#.ACLBodeScl {P#.StepTime 1 sec delay |~P. BodeIL Toolbox Screen Example 6-36 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 .1~ Output 07 07 08 V.Uelerr {P#. immediately transfer the EX2100 to manual regulator.Avr_fb {P#.FvrFbLag Feedback Lag 11 @P.Pssllo 10 09 Third order Cheby in task 1 with break at 50 Hz V.4.Bode_Type=0.24 sec) default 2048 (20.3.BodeAveDone Averaging Done 04 |(V.FvrSet V.PrbsOut 05 {P#.BodePtr1 P.Bode_Type=2.Bode_Type=4~ V.6~ 0 @P. at any time during this testing.Bode_Type=1~ P. 0 Frequency (Bode) Analysis or Step Test of Regulator Loops 0.BodePtr1 12 {P#.Avr_sp {P#.Bode_Type=5~ V.FcrError 08 {P#.Bode_Type=6~ 12 13 13 14 14 15 PRODUCT: File name: Issued Date --.Bode_Type=2~ V. raise margin so that UEL becomes active quickly P.4. See Figure 6-17 and Figure 6-18 for trend recording examples of the tests.48 sec) # of passes prior to averaging # of passes used for averaging P. Select Inner Loop Bode Analysis ($ BodeIL) to get to the Frequency (Bode) Analysis or Step Test of Regulator Loops screen (see Figure 6-16). If.Bode_PreTrig PRBS 04 Pseudo Randon Binary Sequence Outputs +1 -1 {P#.Bode_Type=2.FldVoltVolts V.12 sec) 1024 (10.Bode_Type=2~ V.BodePtr2 {P#.Initials: Revsion Date -.intials: 15 EX2100 Excitation Control Firmware Revision: 16 A B C D E F G H I J K L General Electric g Salem. step the automatic regulator with a 2% step to verify proper control using the AVR step test Wizard.Automatic Regulator Step Test With the unit at rated terminal voltage.1~ Input AAFilter1 V.BodeNowPass |(V.Bode_Type=3.60 03 At Prepass V.BodePrePass At NowPass V.Margin 10 t2 = P. The test can be started from the EX2100 Overview screen of the toolbox (see Figure 6-9).Bode_Type=3~ V. A 01 B Back to $ Overview C D E F G H I J K L 0 1 2 3 4 5 6 None FVR FCR AVR UEL PSS GPdata M N O P Q R S T U 01 02 P.Bode_Size 03 512 (5.AAFilter2 06 {P#.StepSync P.Bode_Type=1~ @P.Bode_Passes |~V.BodeActive P.3.StepPrbs StepOutputs +1.FvrFeedback For UEL step tests via AVR.5~ V. the AVR operation becomes unstable.FirCmd {P#.BodePreDone Pre Passes Done |(V.4.Bode_Type=6~ 11 @P.ACLPrbsOut {P#. Va.FvrSetpoint + + S 1 st2 + 1 + - S V. Complete instructions for the test can be printed by selecting Help from this screen in the toolbox.FvrBodeScl 05 P.6~ {P#.AAFilter1 06 AAFilter2 V.25 sec low going pulse (also passed to ACL for buffer synchronization) V.FvrError 09 V.Bode_Type 02 Toggle Start/Stop !C.Bode_Type=0.

DSPX_Vmag_AVRSP Trend Recording Example GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-37 .DPM GP ref 1 Voltage Magnitude Figure 6-17.

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 6-38 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 .

58 0.0 1.5 0. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 Prior to initial synchronization.2 1.0 0. 2.58 0.0 1.58 0.0 1.0 0.22 V12 and V13 swapped V12 polarity reversed V23 polarity reversed -1. Verification of the synchroscope and tests of the 52G device should be complete.0 1.0 -0. <Watts> <Vars> <Ireal> <Ireact> Possible Cause <Vmag> <FreqHz> -1.58 0.0 0.12 0. watts. The unit will only transfer to manual regulator if there is a problem sensed with the PT feedback.58 0.0 0.0 0. Online Checks Refer to Figure 6-1.12 0.0 -1.0 1.0 1.0 0. All values listed are per unit. Use the tests as written for simulator mode testing except for adjusting actual turbine speed and voltages.0 -0.58 0.5 0. Block 10. UEL. I3 CT’s swapped I1 CT wired to phase 2 I3 CT wired to phase 2 Frequency scaling GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning · 6-39 .0 0. The EX2100 should be operated in automatic regulator at all times when online.0 0. preferably at least 5% of rated load and unity power factor.0 0.0 0.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.22 1.0 1.0 0.81 0. EX2100 displays should agree with other plant indications as to terminal voltage.0 1.66 0. LOE and other software controls.29 0.29 I1 CT opened I3 CT opened I1 polarity reversed I3 polarity reversed 0.16 0. Improper CT wiring can cause misoperation of displays.0 -0.0 0.0 1.0 0. If desired.0 0.0 1.0 1. Do not proceed with testing until conditions are corrected. these tests can be repeated at this time with the unit in operation with actual feedback values. frequency.29 -0.0 1. Synchronize the generator and load the unit to a minimum load.58 0.58 1.0 -0. The EX2100 should be first synchronized while in manual regulator to verify correct generator CT feedback before operating in automatic regulator.0 I1.0 0.0 1.0 0.0 1.0 1.5 0. CT Feedback Verification 1.0 -0. Subsequent synchronization and testing can then be made in automatic regulator once the unit has been proven capable of operation in that mode.0 0. All parties involved in the initial unit commissioning should agree that the unit is ready to connect to the power grid.2 1.0 0. Phasing of the generator and protective relay device operation should be completed.0 1.58 0.0 1. stator current.29 -0. For the initial synchronization.0 0.5 0.0 0. it is recommended to operate in manual regulator until CT feedback wiring can be verified as correct. and vars. other equipment commissioning procedures will also be performed.0 0.58 0.0 <Imag> 1.0 1.0 0.12 0.16 0. Verify correct CT wiring per the following table.

6. 6-40 · Chapter 6 Initial Startup and Commissioning EX2100 Installation and Startup GEH-6631 . Potential damage to equipment may occur. If a second PT input has been provided for the EX2100. Use the tests as written for simulator mode testing if an operation check at actual UEL limit is desired. Place the EX2100 in automatic regulator mode. 2. The trend should show an approximate one second delay between the loss of PT feedback and the switch to manual regulator. Monitor the Key States diagram. the EX2100 is considered ready for full load operation. Do not open CT wiring with unit on line. Open the PT input disconnect switch to the ECPT card. Additional testing of supplied options may be required to fully commission the exciter. 7. These include options such as VAR/Pf control and the Power System Stabilizer. 5.Other equipment may be affected if CT wiring is changed at the CT’s. The limit should be reset to the customer supplied or factory default settings if tested at a higher limit value. operate the EX2100 in manual regulator. <FieldVoltVolts>. <AutoActive> and <PTUV Instantaneous>. <FieldCurrAmps>. Check the system software and documentation for options provided on a given application. 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. both PT signals must be opened to produce the transfer to manual regulator. Refer to the EX2100 toolbox document (GEH-6414) for instructions on using wizards to perform additional tests and to tune-up the exciter. Check one-lines carefully. The EX2100 should NOT allow operation in auto regulator mode. Restore the PT inputs and reset the PT failure annunciation. Additional Testing At this time. A partial test of the UEL can also be performed. Restore the inputs to the ECPT board and reset the PT failure annunciation using keypad Command Menu #2. open the inputs to the ECPT card while trending <Vmag>. Once again. Attempt to place the EX2100 in auto regulator from the keypad or control window animated display. The unit can then be lowered slowly or stepped into the UEL limit through a step input to the Automatic Voltage Regulator. The EX2100 will annunciate a PT failure and the variables on the Key States diagram should indicate <Vmag> less than 10% and <PT Instantaneous> should be true. With the unit on line. 4. PT Failure Operation 1. The UEL limit should be raised to a value allowing operation in a slightly leading power factor region. 3. CT disconnect switches are make before break switches and CT wiring errors can be corrected on the EX2100 side of disconnect switches if needed.