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GEI-100545B
Alterrex, EX2100, and LS2100 are trademarks of General Electric Company, USA.
Ethernet is a registered trademark of Xerox Corporation.
Modbus is a registered trademark of Schneider Automation.
NEMA is a registered trademark of the National Electrical Manufacturers Association.
VersaMax is a registered trademark of GE Fanuc Automation North America, Inc.
Windows is a registered trademark of Microsoft Corporation.
Contents
Section
Page
Introduction .................................................................................................... 3
Related Publications ....................................................................................... 3
Hardware ........................................................................................................ 4
Digital Controller (IGBT-based Systems)................................................ 6
Redundancy (Power Bridge - Warm Backup).......................................... 7
Cabinet ..................................................................................................... 8
Control Boards ......................................................................................... 9
Backplane Boards................................................................................... 14
Customer Interface Boards..................................................................... 16
Internal Interface Boards ........................................................................ 19
Modules.................................................................................................. 21
Software........................................................................................................ 22
Testing .......................................................................................................... 29
Routine Factory Tests............................................................................. 29
Customer Witness Tests ......................................................................... 29
Option A................................................................................................. 30
Option B ................................................................................................. 31
Standards Supported ..................................................................................... 32
Introduction
The EX2100 Excitation Control System is GEs latest state-of-the-art control
offering for both new and retrofit steam, gas, or hydro generation. GE has
supplied more than 6,000 thyristor and regulator systems in over 70 countries
during the last 40 years. EX2100 is GEs third-generation digital excitation
control system. There are over 1,500 first and second-generation GE digital
excitation controls operating in 27 countries.
Hardware and software design is closely coordinated between GEs system
engineering and controls engineering to ensure delivery of a true system
solution. Integration between EX2100, Mark VI, Mark VI Integrated Control
System (ICS), LS2100 Static Starter, and Human-Machine Interface (HMI) is
seamless. For stand-alone retrofit applications, integration with customer
distributed control systems (DCS) through serial or Ethernet Modbus is
supported. This product description specifically addresses applications for the
EX2100 Excitation Control System, 35 A regulator.
Related Publications
GE provides system instruction documents for the different components of each
product. For questions or additional documents, contact the nearest GE sales
office or authorized GE sales representative.
Hardware
The EX2100 is available in several configurations to provide flexibility for
thyristor and regulator control. For small regulator applications, the pulse-width
modulated (PWM) system utilizes insulated gate bipolar transistors (IGBT) to
provide up to 35 A output. This system can support the following applications:
SCT-PPT regulator
The architecture is a single or redundant control with customer interface subsystem, local operator keypad(s), optional control operator interface (COI)
remote touchscreen interface, control power input module, and power module.
The power module consists of a bridge interface sub-system, power bridge, ac
and dc filter networks, and ac and/or dc isolation devices.
In SCT-PPT regulator and dc rotating exciter regulator applications, the EX2100
can desensitize the effect of the exciter time constant. The EX2100 regulator
incorporates direct measurement of the generator field voltage and field current
to enhance speed of response to system transients.
The EX2100 supports Ethernet local area network (LAN) communication to:
Mark VI, Mark VI ICS, HMI, PI Historian, OSM, COI, and VersaMax
extended I/O modules using the Ethernet Global Data (EGD) protocol
The following diagram shows EX2100 regulator max case major functional
components, board, and interconnection overview.
Ac
load
Diagnostic EGD
or
interface
ModBus
(Keypad)
Control
power
supplies
Customer I/O
CT
Current
PT-1
Optional PT-2
Brushless
or dc
rotating
exciter
Auxiliary
source
I/O
Voltage
Ac
Ac circuit
breaker
Bridge I/O
Control
M1
Generator
PMG
(Optional)
Line filter
125, 250 Vdc House dc
(Optional)Power
Conversion modules
(Bridge#2)
PPT
Control
M2
Control
C
(Optional)
1-phase or
3-phase input
power
Gating selector
Warm Backup:
M1 control to Bridge 1
M2 control to Bridge 2
Ac circuit breaker
Full wave
rectifier
Power
conversion
modules
(Bridge #1)
To control
power supply
IGBT firing
Dc contactor
Shunt
PT
CT
I/O
PPT
PMG
Potential transformer
Current transformer
Input/output
Power potential transformer
Permanent Magnet Generator
Simplified EX2100 Max Case Major Functional Components (35 A Regulator System)
Two I/O boards - Exciter Regulator I/O Board (ERIO) and Exciter
Regulator Options Card (EROC)
Serial/
Ethernet
Modbus
ACLE
M1
DPM
Communication
across
backplane
DSPX
M1
DSPX
M2
ACLE
M2
DPM
Serial/
Ethernet
ModBus
DSPX
C
HMI
M1
M2
C
DPM
Human-Machine Interface
Controller master #1
Controller master #2
Controller protection
Dual-ported memory
ISBus
Cabinet
Control Boards
The control boards for the 35 A regulator are described in the following
paragraphs.
Status LEDs
RST
OK
ACTIVE
ENET
FLASH
OK
- Watchdog timer enabled
ACTIVE - Microprocessor accessing
memory
ENET - Ethernet activity
FLASH - Flash memory write operation
in progress
COM1
COM2
Ethernet ports, RJ-45
ENET1
ENET2
ACLE Faceplate Diagram
Ethernet
Serial RS-232C
Limiter functions
Balance meter
Generator simulator
Local operator interface control functions use a serial interface to a keypad and
display unit mounted on the door of the control enclosure and supports:
Display and changing of internal control data and alarm and status
information from the DSPX or its paired ACLE control
ECTB
J13M1 70Vdc
J13M2 70Vdc
M1 Rack
J4
ERBP
Module
M1
J13
24AVdc
J5M1
EROC Card Front
J3
5VdcM1
15VdcM1
-15VdcM1
24AVdcM1
J16M1
EDCF M1
J16 24BVdc
M2 Rack
ERRB
EDCF M2
J16 24BVdc
Module
C
J3
Module
M2
J16M2
J10 24AVdc M1
24AVdc M2
J16C
J5M2
J13
EROC Card
Front
J10
Keypad
EDCF C
J16 24BVdc
ERRB
J4
24AVdc
GE ground detector
Keypad support
The field ground detector option is available with SCT-PPT and rotating dc
exciter regulator applications. This function is not available with brushless
excitation unless a special generator instrumentation ring is available.
Using the EROC board, the GE ground detector finds leakage resistance to
ground at any point in the generator field circuit. The active detection system
applies a low voltage with respect to ground and monitors current flow through a
high impedance ground resistor. Grounds in the generator field can be detected
even while the regulator is not running (gating IGBTs).
This field ground detector (patent pending) also features:
Field ground location, in percent, from the physical center of the field
The EROC communicates with the keypad using RS-232C and provides data
transmission to two locations in the regulator rack. A keypad connector is
located on the EROC faceplate and another on the backplane (ERBP simplex,
ERRB redundant). Only one keypad can be connected to a module. The two
locations are to support different mounting options of the keypad.
Backplane Boards
The backplane boards for the exciter regulator are described in the following
paragraphs.
EDCF FAN
FAN
EROC
RST
Keypad
J3
J1F2 PWR
M1 to C
J4
J110
J107
ERDD
J105
EPSM
J104
ERIO
DSPX
J102
ACLE
J101
ERRR FAN
J1F1
OK
ACTIVE
ENET
FLASH
JP1
COM1
Barcode
S
T
A
T
U
S
COM2
J201
J204
J205
J207
J208
J210
E N E T 1
EISB
E N E T 2
Mal
e
PWR NEG
TB2
PWR POS
TB1
Link Input
Voltage
J3
PWR
M1 to C
J101
J102
FAN
J104
J103
J106
J16
FAN1
J1F2
EDCF
J5M2
FAN2
ERRR
J4
J11
ERRR
Keypad
J112
J109
ERDD
EPSM
Test
J107
EROC
ERIO
RST
ACLE
DSPX
ERIO
DSPX
Test
ERRR
J1F1
ISBus
OK
ACTIVE
FLASH
ECTB
KeyPad
S
T
A
T
U
S
Barcode
ENET
ECTB
Tool
CO M1
J202
J206
J209
J210
J212
EPCT
Gnd
Detector
E N E T 2
Reset
J207
ECTB
P70
E N E T 1
EISB
EISB
EPCT
J203
CO M2
J201
Redundant
Reset
Male
Link Input
Voltage
PWR_IN_N
TB2
PWR_IN_P
Tool -C
TB1
Vab, Vbc, Ic, Vab, Vbc, Ib; Vab, Vbc, Ia (3-phase voltage, single-phase
current)
Each board contains two trip contact outputs driving a customer lockout and
four general-purpose Form-C relay contact outputs controlled by the EMIO
board. Six auxiliary contact inputs are powered (wetted) with 70 V dc by ECTB.
Also, the 52 G and 86 G contact inputs are powered and monitored by ECTB. In
redundant applications, power comes from the M1 and M2 power supplies.
EX2100 Excitation
FVR Feedback
0.0 Volts
FldCurrAmps
0.00 Amps
Vmag
-30%
0%
100%
150%
-30%
0%
100%
150%
Imag
0.00
Watts
0.00
Freq_Hz
0.00
Bal Meter
60.00
Vars
0.00
00.00
Navigation
Exciter Control
Status
Reset
Faults
Auto
Menu
Command
Man
Menu
On
Run (Green)
Stop (Red)
Voltage Level
Escape
Exciter Health
and State
I
Off
Enter
Display:
Pushbuttons:
Control of the charging relay (K3) in all applications and control of the
bridge output contactor (K41) in simplex applications
The following diagram shows the ERDD applied to the simplex regulator
system:
Signals through ERBP
backplane
ERSC
ERDD
RDS
Dc/dc
converter
0RESET*
Dc link voltage
feedback
Leg W lower
gate drive
UD_U*
UD_V*
Fault Reports
Fault Resets
Leg V
Leg U upper
gate drive
Leg U
RDD
Output current
feedback
DDTEST*
ODD_CMD*
ODD_FBK*
Output voltage
feedback
FLT_RST*
DD_RST*
Dynamic Discharge
DD Test
DD duty commanded
DD duty feedback
Leg V lower
gate drive
OFLT_U*
OFLT_V*
OFLT_DD*
VTHRM
(Analog)
Leg W
DD
Leg U fault
Leg V fault
DD fault
Over-temp alarm
Dc link
Dc link power
Bridge Feedbacks
VDCLINKP(VCO)
VOP (VCO)
IOP (VCO)
OFLT_OC*
C_VOP (VCO)
C_IOP (VCO)
OFLT_OC_C
EPLD gate/
fault logic
K41
Dc link voltage
Output voltage
Output current
Overcurrent fault
Output voltage (C)
Output current (C)
Overcurrent fault (C)
HV Isolation
M2/C voltage/
current feedback
(redundant only)
R
R
K41_DRV*
K41 pilot
C R
L
Board ID
BRD_ID/
BRD_ID_RTN
Board ID
*Logic signal
Bridge
RTD
Shunt
Field
Modules
The modules for the 35 A regulator are described in the following paragraphs.
Dc Interrupting Device
For all regulator applications, a field interrupting dc contactor in the rectifier
bridge dc positive output is used to connect the regulator to the exciter field
leads. The dc contactor is internal to the regulator and is not accessible once
power is applied. The dc contactor and the dynamic discharge circuitry together
form the internal field breaker function used to remove stored energy in the
exciter field during trip events.
Ac Isolation Device
A 30 A, molded case ac circuit breaker is supplied as the standard ac isolation
device between ac input power and the regulator module.
Software
EX2100 software supports high performance by helping users to understand,
install, and maintain the system. The following sections define major software
functions shown in the diagram below:
Voltage/current
sensing
Dc
regulator
Dc voltage
adjust
Exciter
bridge
Generator
Ac
regulator
Ac
voltage
adjust
Exciter system
stabilizer circuits
Over-excitation
limiter
Under-excitation
limiter
V/Hz limiter &
protection
Voltage sensing &
load compensation
Power system
stabilizer
Software Overview Block Diagram
The generator PTs and CTs are the source of the control signals needed by the
automatic (generator terminal voltage) regulator, most limiters, and protection
functions. The system simultaneously samples the ac waveform at high speed
and uses advanced mathematical algorithms to digitally generate the variables
needed.
The EX2100 creates and uses the following signals:
Generator voltage
External
Raise/
Lower
AUTO
REF
Reactive
Current
EXASP
Setpoint
Watts
Slip
Exciter AVR
Setpoint.
V/Hz Limit;
Reactive
Current
Compensation.
PSS
Power
System
Stabilizer
AVR
Setpoint
and
Tracking
Frequency
Watts
AVR
VMAG
UEL
VARs
Under
Generator
Excitation
Terminal
Limit
Voltage
(VMAG)
VMAG
Automatic
Voltage
Regulator
FVR
Track
Value
Setpoint
FVR
External
Raise/
Lower
Field
Voltage
Regulator
Min.
Field Volts from Bridge Output
FCR Setpoint
(User Input)
Firing
Commd
to
Bridge
FCR
Field
Current
Regulator
Auto Regulator Reference (AUTO REF) generates the auto control (AC)
setpoint variable for the automatic voltage regulator (AVR). Operator
commands, (raise and lower inputs) come in from direct inputs or over a data
link from an HMI operator station or from a plant DCS or remote dispatch
system. AUTO REF and MAN REF can be configured with upper and lower
limits, presets, and up/down ramp times.
Manual Regulator Reference (MANUAL REF) generates the manual
setpoint variable for the manual voltage regulator (MVR). Operator commands,
(raise and lower inputs) come in from direct inputs or over a data link from an
HMI operator station or from a plant DCS or remote dispatch system.
Automatic and Manual Reference Follower (Tracking) are software
implemented ramp functions that adjust the non-active regulator output to
automatically track the active regulator. That is, when the auto regulator is
controlling the generator, the manual regulator tracks, and when the manual
regulator is controlling the generator, the auto regulator tracks. This provides for
smooth transition when a transfer occurs from one regulator to the other.
Exciter AVR Setpoint (EXASP) combines a number of functions to produce
the reference input to the AVR and the variables to support regulator tracking.
The reference output from this block is a summation of:
External test signal to support injection of white noise and step test signals
Volts per Hertz Protection (24G) serves as a backup to the V/Hz limiter and
can be supported with or without the C (protection) controller. The protection
scheme consists of two levels of V/Hz protection. One level is set at 1.10 per
unit over V/Hz with an inverse time period, and the other level is set at 1.18 per
unit with a two second time period. Both trip and time setpoints are adjustable.
In operation, this means:
From 1.10 to, but not exceeding, 1.18 per unit an alarm is activated with trip
time inversely proportional to the magnitude of the over volts per hertz
At 1.18 per unit, trip time is 45 seconds (adjustable from 6-60 seconds)
If over volts per hertz exceeds 1.18 per unit, either initially or during the
inverse time period, trip activation occurs in 2 seconds (adjustable from 1.7
to 2.8 seconds)
Each of the two relays characteristics (offset, diameter, time delay) are
independently adjustable, and can be used to initiate a TRIP signal. GE
recommends the use of two relay characteristics since there is some concern
about the performance of the voltage regulator when it is operating on the underexcited limit. The regulator may undershoot while trying to maintain the limit,
and cause the apparent impedance to momentarily enter the relay characteristic.
If only one relay characteristic is used (small diameter), there may be undesired
operation as a result of any regulator undershoot. Using the large diameter
setting with time delay helps to avoid this problem with undershoot.
Offline Over-excitation Protection (OLOT) serves as backup to the over
excitation limiter when the generator is offline. If the generator field current
exceeds 120% of no-load field current while operating offline in either the
automatic or manual regulator mode, and the limiter can not correct an overexcitation condition, this function will initiate a trip signal after a time delay.
Generator Field Temperature Calculation measures the resistance by
dividing the field voltage by the field current. From the known field resistance at
25C and the linear resistance temperature change in copper, the algorithm
calculates operating temperature. An adjustable high temperature alarm output
contact is also included. Generator field temperature calculation is not available
with EX2100 brushless regulators. Exciter field temperature calculation is not
available with any EX2100 regulator configuration.
Testing
The GE Salem facility is ISO-9001 and Ticket-certified. Below is a brief
description of the quality assurance tests performed on each 35 A regulator.
Option A
This normal production inspection, performed immediately prior to shipment,
verifies the mechanical integrity, conformance to special purchaser hardware
requirements, appearance, and design completeness of the enclosure. The
purchaser can elect to participate in this inspection at no charge. This inspection
lasts approximately two hours, and includes:
Test instructions
Test log
Engineering log
Shortages
As-shipped prints
The customer usually inspects the hardware the day before the unit is sent to
shipping. At this point, the unit will have been completely tested and inspected.
The customer can inspect the unit to ensure that its appearance meets
expectations before it is shipped. Generally, the customer reviews the quality of
workmanship, looking at paint, wiring, crimping, assembly, and so on. The
duration of this witness point is two hours.
The second part of this option is a review with the engineer. The customer can
review all paperwork relevant to the engineering and testing of the requisition.
This would include the elementary, I/O list, alarm list, layouts, outlines, test
sign-off sheets, and such. This documentation provides the basis for certification
that the customer's hardware and software went through the proper engineering,
verification, and test processes. The duration of this witness point is
approximately two hours.
Customers should advise GE Salem eight weeks prior to shipment of their intent
to visit the factory to inspect his equipment. GE will inform the customer two
weeks prior to the inspection date so that appropriate travel arrangements can be
made. There is no additional cost associated with this option.
Option B
This option consists of two demonstrations:
Hardware demonstration
Software demonstration
The engineer uses the simulation method to verify the integrity of the system by
also exercising any special functions. The duration of this witness demonstration
is approximately four hours.
Option B, if selected, should be included as part of the initial purchase order. If a
customer decides to purchase this option after the initial ordering drawing
release, an amendment to the PO is required. If option B was not initially
purchased, then notification of a change order is required at least eight weeks
prior to shipment of the equipment. GE will inform the customer two weeks
prior to the test date so that the customer can make travel arrangements. There is
an additional cost associated with this customer witness point.
Standards Supported
Safety
IEEE
Notes
g GE Energy
GEI-100545B
050211
Revised 050609