GEH-6784 EX2100e System Maintenace Guide - Feb 2014

GEH-6784D
EX2100e Excitation Control Regulator Systems

Maintenance Guide
For troubleshooting and alarms, refer to the following document:
GEH–6788, EX2100e Excitation Control Diagnostic Alarms for Regulator Systems Troubleshooting Guide.
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be used,
shown, reproduced, or disclosed outside of GE without the express written consent of GE.
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met during installation, operation, and maintenance. The information is supplied for informational
purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications,
and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected
herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to
the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced
herein.
GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this
document does not provide any license whatsoever to any of these patents.
GE provides the following document and the information included therein as is and without warranty of any kind, expressed
or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose.
For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales
Representative.
Revised: Sept 2013

Issued: Dec 2010
© 2010 – 2013 General Electric Company, All rights reserved.

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All other trademarks are the property of their respective owners.
We would appreciate your feedback about our documentation.

Please send comments or suggestions to controls.doc@ge.com
Document History
Version Date Update Description
D Sept 2013 Throughout the document Content added for the 120 A Regulator system
GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and is intended for internal use only. It may not be
used, shown, reproduced, or disclosed outside of GE without the express written consent of GE.
Safety Symbol Legend
Indicates a procedure, condition, or statement that, if not

strictly observed, could result in personal injury or death.
Warning
Indicates a procedure, condition, or statement that, if not

strictly observed, could result in damage to or destruction of
equipment.
Caution
Indicates a procedure, condition, or statement that should be

strictly followed to improve these applications.
Attention
GEH-6784D Maintenance Guide 3

To prevent personal injury or damage to equipment, follow all
equipment safety procedures, Lockout Tagout (LOTO), and site
safety procedures as indicated by Employee Health and Safety
(EHS) guidelines.
Warning
This equipment contains a potential hazard of electric shock,

burn, or death. Only personnel who are adequately trained and
thoroughly familiar with the equipment and the instructions
should install, operate, or maintain this equipment.
Warning
Isolation of test equipment from the equipment under test

presents potential electrical hazards. If the test equipment
cannot be grounded to the equipment under test, the test
equipment’s case must be shielded to prevent contact by
personnel.
Warning To minimize hazard of electrical shock or burn, approved

grounding practices and procedures must be strictly followed.
To prevent personal injury or equipment damage caused by

equipment malfunction, only adequately trained personnel
should modify any programmable machine.
Warning
Always ensure that applicable standards and regulations are

followed and only properly certified equipment is used as a
critical component of a safety system. Never assume that the
Human-machine Interface (HMI) or the operator will close a
Warning safety critical control loop.
4 GEH-6784D EX2100e Excitation Control for Regulator Systems

Contents
1 Overview ............................................................................................................................................. 7
1.1 Equipment and Material Requirements.........................................................................................................9
1.2 Safety Precautions ................................................................................................................................. 10
1.3 Acronyms and Abbreviations ................................................................................................................... 16
1.4 Related Documents ................................................................................................................................ 17
2 Preventive Maintenance ............................................................................................................... 19
2.1 Scheduled Maintenance Intervals .............................................................................................................. 19
2.2 Maintenance Record............................................................................................................................... 20
2.3 Maintenance Procedures ......................................................................................................................... 20
2.4 Short-circuit Damage.............................................................................................................................. 26
3 Parts Replacement......................................................................................................................... 27
3.1 Safety and Replacement Guidelines........................................................................................................... 27
3.2 Control Module ..................................................................................................................................... 28
3.3 Standard and Optional Modules................................................................................................................ 56
4 Hardware Verification and Checks............................................................................................. 67
4.1 Preliminary Checks ................................................................................................................................ 68
4.2 ToolboxST Application Downloads ........................................................................................................... 69
4.3 Bridge Output and Operation Checks......................................................................................................... 70
Glossary of Terms ................................................................................................................................ 71
GEH-6784D Maintenance Guide 5

Notes

1 Overview
Refer to GEH-6788, EX2100e This document provides recommended preventive maintenance and component
Excitation Control Diagnostic replacement procedures for the EX2100e Control Regulator system, which is available in
Alarms for Regulator Systems two versions: 35 A and 120 A. These designations represent the nominal dc output current
Troubleshooting Guide. ratings of the Power Conversion Modules (PCMs).
EX2100e Regulator
EX2100e Control RegulatorControl
System IGBT-IGBT-based
based Power
PCM forConversion
35 A RegulatorModule
(PCM)
System
Overview GEH-6784D Maintenance Guide 7

UCSB Controller IGBT-based PCM for 120 A Regulator System
UCSB Controllers and 35 A Regulator System PCMs (Dual)

1.1 Equipment and Material Requirements
Check boxes should be marked The equipment and material in the following checklists should be on hand for the
to verify that equipment is on procedures in this document.
hand.
1.1.1 Safety Equipment
□ Site-specific safety/confined space manual
□ Personal safety gear (such as safety boots, safety glasses, hard hat, high-voltage
gloves, face shield, safety jacket)
□ High-voltage ac/dc detector (with an insulated pole of appropriate length)
□ Locks and tags, danger and caution tape
□ Protective grounding cables and grounding stick
□ Static-charge wrist straps
1.1.2 Typical Maintenance Tools

□ High quality tools, including screwdrivers and pliers, designed specifically for
working with electrical wiring systems
□ Socket set (metric and standard)
□ Hex wrench set (metric and standard)
□ 1-inch adjustable wrench
□ Torque wrench
□ Electrical tape
□ Fine file
□ Clean dry cloth
□ Soft-bristled brush (such as a paintbrush)
□ Mild solution of distilled water and laboratory detergent (Axarel® MicroCare 2200
recommended)
□ Isopropyl alcohol and citrus based cleaner
□ Digital meter
□ High-voltage voltmeter
□ One megger tester (capable of dc testing from 500 V up to 5 kV)
□ Source of dry, low-pressure compressed air
□ Vacuum cleaner with non-metallic nozzle and finely woven, high efficiency filter
□ Fuse puller
□ Replacement components, if required, including fuses, wire, and cable

1.2 Safety Precautions
This equipment contains a potential hazard of electric shock or
burn. Only personnel who are adequately trained and
thoroughly familiar with the equipment and the instructions
should install, operate, or maintain this equipment, or have
Warning access to the location where it is installed.
To prevent electric shock or burn while servicing the

equipment, personnel must understand and follow all safety
requirements for working around dangerous voltages. Obey
local site lockout/tagout (LOTO) procedures, wear appropriate
personal protective equipment (PPE), and follow GE
instructions when performing any adjustments, services, or
Warning other tasks requiring physical proximity or contact with the
circuit boards, electrical components, or wiring of the exciter.
Due to the large amount of energy passing through the exciter

power converter, failure to properly reinstall shields or to
completely latch doors and covers compromises these
safeguards and places personnel at higher risk when within the
environs of the exciter. Understand and follow the safety
procedures and warning labels.
Shock and burn hazard boundaries for the Excitation Control

Equipment are dependent upon the specific site application
conditions, including Power Potential Transformer (PPT)
voltage, the mega volt-ampere (MVA) and impedance ratings,
and fault overcurrent clearing time of the power sources
Warning feeding the exciter. It is the responsibility of the customer to
perform an arc flash analysis of the system, understand the
hazard boundaries that exist, and employ adequate safeguards
to protect personnel who may be in the proximity of the exciter,
whether working on it or not. These safeguards include
restricted access for unqualified personnel, prohibition of
unsafe online maintenance practices, and use of appropriate
LOTO procedures and PPE for qualified personnel who must
access the exciter.
To prevent personal injury or death, personnel must be aware

of arc flash hazards, and must maintain safe distances at all
times as determined by released energy calculations. The extent
of arc flash hazards is not known until the site-specific
installation is evaluated; therefore GE recommends that an arc
Warning flash assessment be conducted for each installation.

The following table illustrates the Arc Flash Protection Boundary (AFPB) and Hazard
Risk Category Number (HRC#) based on assumed installation conditions that might exist
in a typical exciter application. These calculations are based on equations published in
NFPA™-70E, Electrical Safety in the Workplace (2012). These numbers are illustrative
only, and must not be interpreted as applicable to any customer site installation. It is the
responsibility of the customer to perform an arc flash analysis of his installation and
implement appropriate safeguards as mentioned above. Consider modifications to the
installation to reduce the hazard levels during periods when maintenance personnel must
be present to perform online repair procedures. These modifications might include the use
of reduced energy let-through (RELT) circuit breakers, arc flash detection technology, or
faster fault clearing time settings used during maintenance periods.
Note When the control cabinet is attached to the power converter lineup, the control
cabinet may be within the hazard boundaries of the power converter. Appropriate PPE
levels to access the control cabinet may therefore be higher than might be expected based
solely on hazards within the control cabinet itself.
Exciter Source MVA Upstream Fault AFPB HRC #

Clearing Time
100 mm Multi-bridge 15 0.1 sec 2480 mm (98 in) 4
0.3 sec 4300 mm (169 in) Extreme Hazard
100 mm Warm Backup 6 0.1 sec 1570 mm (62 in) 3
(WBU) 0.3 sec 2720 mm (107 in) Extreme Hazard
77 mm 3.25 0.1 sec 1160 mm (45 in) 2
0.3 sec 2000 mm (79 in) 3
53 mm 1.6 0.1 sec 810 mm (32 in) 1
0.3 sec 1400 mm (55 in) 3
42 mm 0.45 0.1 sec 480 mm (19 in) 1
0.3 sec 830 mm (33 in) 1
120 A Regulator 0.075 0.3 sec 340 mm (13 in) 0
2.0 sec 1240 mm (49 in) 3
35 A Regulator 0.01 0.3 sec 120 mm (5 in) 0

1.2.1 Grounding Balls
Some models of the EX2100e excitation control may be equipped with grounding balls
for temporary grounding of power busses during maintenance, in accordance with site
safety and LOTO procedures.
Grounding Balls Specifications
Model Grounding Ball Part Grounding Ball Grounding Ball Rating
Number Diameter (per IEC-61230)
EX2100e 100 mm 151X1227RG02PC01 30 mm (1.2 in) 60 kA (250 ms)
EX2100e 77 mm and smaller 151X1227RG01PC01 25 mm (1.0 in) 35 kA (250 ms)
LS2100e 8.5 MVA and 14 MVA 151X1227RG01PC01 25 mm (1.0 in) 35 kA (250 ms)
To safely use the grounding balls within this equipment, site personnel must be properly
qualified and aware of site specific installation parameters as follows:
• Before using the grounding balls, verify the available short circuit current and
clearing time of the overcurrent protective equipment does not exceed their rating.
These parameters are site specific, and not necessarily determined by equipment
within GE scope of supply.
• Use grounding clamps and cables that are compatible with the grounding balls and
properly rated for the site parameters.
• Comply with site safety procedures and relevant standards such as those provided in
the following list.
For more information, refer to relevant standards, including:
• IEC 61230, Portable Equipment for Earthing or Earthing and Short-Circuiting

• ASTM F855, Temporary Protective Grounds to Be Used on De-energized Electric
Power Lines and Equipment
• IEEE 1246, Guide for Temporary Protective Grounding Systems Used in Substations

1.2.2 Arc Flash Events
Evaluation of the root cause of arc flash failures in exciters, static starters, and similar
power conversion equipment shows that many arc flash events can be prevented with
diligent installation and maintenance procedures.
Causes and Preventive Practices for Arc Flash Events
Causes Best Preventive Practices
Loose power bus, bolts, and harnesses (contributed □ Torque all power connections.
to more than 25% of the events evaluated)
□ Apply torque marks.
□ Periodically inspect that marks are aligned.
□ Verify that all connectors are snug.
□ Verify that all connectors are free of mechanical stress.
Foreign objects such as tools, animals, loose parts, □ Verify that all tools and parts are removed after installation and
or moisture left in or ingested into the equipment maintenance.
(caused approximately 25% of the events
□ Retrieve and remove dropped fasteners and any chips or shavings
evaluated)
from installation.
□ Do not store spare parts within the cabinets.
□ Replace all shields and barriers after maintenance work.
□ Cover openings to keep out water, contaminants, and animals.
□ Keep cabinet doors securely closed.
Other poor installation practice, such as cable □ Follow installation procedures carefully.
protection and energized part separation distances
□ Inspect cables for protection, support, and separation.
□ Inspect components and assemblies for adequate mounting and
voltage clearances.
Poor maintenance practice, such as keeping □ Follow maintenance guidelines appropriate for site conditions.
openings sealed and air filters clean
Catastrophic component failures, sometimes due to □ Monitor and mitigate external conditions that can lead to
external causes such as inadequate cooling, premature failures.
excessive vibration, damage to insulating mica
□ Be careful not to damage new or reused parts during installation
sheets or sleeves, transient overvoltage, or
procedures.
application beyond ratings
□ Do not reuse questionable parts.
□ Know the equipment ratings and do not exceed them.

1.2.3 Digital Front-end, Kits, and Separated Controls
Cabinet Applications
Some EX2100e excitation control and LS2100e static starter control installations may
include a control cabinet that is separated from the power converter lineup. Examples
include EX2100e and LS2100e DFE applications and some combined EX2100e and
LS2100e LCI Exciter Compartment (LEC) installations, which locate the controls in a
separate room of the LEC from the power converters, to isolate personnel in the controls
area from the arc flash hazards of the power converter. While such an arrangement greatly
reduces the risks of shock, burn, and injury from arc blast pressures, personnel should
understand that hazardous voltage and energy levels are present in the vicinity, and are
exposed when the control cabinet door is opened.
Personnel should perform the following safety practices:
• Wear appropriate PPE for the equipment. For a separated EX2100e control cabinet,
this is typically PPE-0. For a separated LS2100e control or pump panel, this is
typically PPE-1.
• Field installation of harnesses for separated control cabinets or field mounted kits can
introduce hazards and failure modes if proper procedures are not followed. Failures
at wire and cable connections are one of the leading causes of electrical equipment
misoperation, including unnecessary trips and failure of protective functions such as
the 86 lockout circuit to operate when needed. Watch out for:
− Open circuits or loose connections
− Short circuits
− Inadvertent contact and energization of cables with unintended voltages
− Insulation damage from installation or abrasion over time
− Conductor damage such as kinks, stretching, and stray strands at terminations
− Voltages present on harnesses during maintenance due to remote equipment not
locked out. Establishing an electrically safe state for work on the controls in
some situations may also require lock-out to be performed on the power
converter, and vice versa.
− Poor terminations and stress on connectors. If harnesses are supplied
pre-terminated, ensure the terminations and connectors are not damaged during
harness installation.
Refer to the section, Related − Poor routing and protection of harnesses. Where harnesses pass through building
Documents. or cabinet walls, provide adequate protection against damage and sealing to
prevent propagation of contaminants during normal operation and arc blast gases
during fault events. Refer to the applicable Installation and Startup manual, the
section, Preventing Cable Damage for the equipment.
− Failure to separate harnesses by voltage and electromagnetic compatibility
(EMC) levels. For the equipment, refer to applicable Installation and Startup
manual, the section, General Cable Specification and Routing Guidelines.
For grounding details, refer to • Be sure protective and functional grounding is provided for the detached equipment,
the equipment elementary per instructions provided in the system elementary diagram. A minimum #2 AWG
diagram, sheet 0D. grounding wire must be provided from the detached control equipment to the
building system ground point. The power conversion cabinets must also be bonded to
this point.
• Look for hazards such as those in the above subsections during inspections following
installation and maintenance.

1.2.4 Additional Safety Reminders
• Always know the voltage approach and arc flash boundaries for the equipment you
work on or are exposed to, and wear appropriate PPE.
• PPE always includes hearing protection. Arc flash events generate high sound levels
and blast pressure waves that can cause permanent hearing damage.
• While PPE may provide protection from shocks and burns, it does not provide
protection from injuries such as falling or being thrown by an arc blast pressure
wave. For example, for a typical 77 mm EX2100e control installation with 300 ms
clearing time, the arc blast pressure at 0.9 m (3 ft) from the arc could be 640 kg/m2
(130 lbs/ft2). To avoid such injuries, always de-energize and apply lockout for all
maintenance activities in areas where arc flash hazards exist.
• Equipment may be energized from multiple sources, including unintended or
inadvertent sources. Never assume any conductor is safe to touch.
• Electromechanical devices such as relays and contactors are not suitable lockout
devices, since they can be re-energized electrically.
• When equipment is installed in rooms with small volumes, consider adding room
pressure relief vents that open during arc blast events to reduce the blast pressure.
The exhaust from these vents must be directed away from personnel and other
equipment.
• Consider installing ground fault protection on control power supplies to the
equipment, to provide additional safety for site personnel.
• Always be alert to safety. Shock, burns, and other injuries may happen in an
unanticipated instant, but can cause a lifetime of impact.

1.3 Acronyms and Abbreviations
ACOM Analog common
AFPB Arc Flash Protection Boundary
AVR Automatic or ac voltage regulator
CCOM Control common
CT Current transformer
DCOM Digital common
EDFF Exciter dc feedback
EDSL Exciter Regulator Dual Selector
EGD Ethernet Global Data
EHS Environmental Health and Safety
EMI Electromagnetic Interference
ERAX Exciter Regulator Auxiliary I/O
ERBI Exciter 120 A Regulator Bridge Interface
ERGT Exciter Third-party Ground Detector Terminal Board
ERSC Exciter Regulator Static Converter
ERSD Exciter Regulator Static Converter (Version D)
ERSN Exciter 120 A Regulator Dual Selector Snubber Board
ESWA GE Industrial Ethernet Switch with 8 ports
ESYS EX2100e System Interface Board for Customer I/O
EXAM Exciter Attenuator Module
HMI Human-machine Interface
HRC Hazard Risk Category Number
IGBT Insulated Gate Bipolar Transistor
M1 Primary controller
M2 Backup controller
MOV Metal Oxide Varistor transient suppressor
NFPA National Fire Protection Association
OEL Offline Overexcitation Limit
OSHA Occupational Safety and Health Administration
PCM Power conversion module
PCT Power current transformer
PLC Programmable logic controller
PMG Permanent magnet generator
PPE Personal Protective Equipment
PPT Power Potential Transformer
PRV Peak reverse voltage sharing resistors
PSS Power system stabilizer
RTD Resistance temperature device
SCM Shunt Contactor Module (35 A Regulator)
SCR Silicon-controlled rectifier
SVS Shaft voltage suppressors
TCM Transfer Control Module (120 A Regulator)
TMR Triple modular redundant
UCSB Universal Controller Stand-alone Version B
UEL Underexcitation limit
WBU Warm backup

1.4 Related Documents
For specific information or • GEH-6676, EX2100 and EX2100e Excitation Control Power System Stabilizer User
instructions on auxiliary Guide
equipment, such as
• GEH-6707, ToolboxST User Guide for EX2100e Excitation Control
transformers, protective relays,
and dc output contactors, refer • GEH-6781, EX2100e Excitation Control User Guide
to the documents supplied with
• GEH-6783, EX2100e Excitation Control for Regulator Systems Installation and
those products.
Startup Guide
• GEH-6784, EX2100e Excitation Control for Regulator Systems Maintenance Guide
• GEH-6788, EX2100e Excitation Control Diagnostic Alarms for Regulator Systems
Troubleshooting Guide
• GEI-100256, Receiving, Handling and Storage of GE Drive and Excitation Control
Equipment
• GEI-100509, EX2100 and EX2100e Excitation Control Exciter Attenuation Module
(EXAM) Instruction Guide
• GEI-100525, Excitation Control Exciter Regulator Static Converter (ERSC and
ERSD) Instruction Guide
• GEI-100531, Excitation Control Exciter Regulator Third-party Ground Detector
Terminal Board (ERGT) Instruction Guide
• GEI-100665, Mark VIe Controllers UCCx and UCSx Instruction Guide
• GEI-100770, EX2100e Excitation Control DC Fanned Feedback (EDFF) Board
Instruction Guide
• GEI-100771, EX2100e Excitation Control Regulator Auxiliary I/O (ERAX) Board
Instruction Guide
• GEI-100772, EX2100e Excitation Control System I/O Interface (ESYS) Module
Instruction Guide
• GEI-100773, EX2100e Excitation Control Dual Regulator Selector (EDSL and
ERSN) Board Instruction Guide
• GEI-100775, EX2100e Excitation Control CT Expansion (ECTX) Board Instruction
Guide
• GEI-100782, High-speed Serial Link Interface (HSLA) Board Instruction Guide
• GEI-100784, EX2100e Excitation Control for 35 A and 120 A Regulator Systems
Application Guide
• GEI-100787, EX2100e Excitation and LS2100e Static Starter Control Systems
Touchscreen Local Operator Interface Instruction Guide
• GEI-100796, Excitation Control Exciter Regulator Bridge Interface (ERBI)
Instruction Guide
• GEI-100810, Industrial Ethernet Switch (ESWx) Instruction Guide

Notes

2 Preventive Maintenance
Preventive maintenance helps to prevent, detect, and correct conditions that could cause
equipment malfunction. This includes inspections for damage and wear, testings, and
cleaning of equipment at regular intervals.

burn. Only adequately trained persons who are thoroughly
familiar with the equipment and the instructions should
maintain this equipment.
To prevent electric shock while servicing the equipment,

Warning personnel must understand and follow all safety requirements
for working around dangerous voltages.
2.1 Scheduled Maintenance Intervals

Environmental specifications For maximum benefit, preventive maintenance should be performed at scheduled
are defined in GEH-6783, intervals by a qualified technician. GE recommends that preventive maintenance be
EX2100e Excitation Control performed at least once every two months in environments that do not meet
for Regulator Systems specifications, and on normally scheduled shutdowns in environments that do meet the
Installation and Startup Guide. environmental specifications. The schedule should include an inspection of wiring and
components before re-applying power.
Refer to the section,
Maintenance Procedures. The required frequency for each procedure depends on:
• How much the equipment is used

• Operating load conditions
• Ambient environmental conditions
The following table lists the components that require scheduled preventive replacement
during the normal life of the Regulator system.
Scheduled Preventive Replacement
Component Required Replacement Interval
Air filters on the cabinet door When dirty
Optional door fan Every seven years
Fans on 120 A PCM Every seven years
DC link capacitors in PCM Every four to seven years
Preventive Maintenance GEH-6784D Maintenance Guide 19

2.2 Maintenance Record
GE recommends that the customer keep a detailed record of maintenance (such as a log
book) for every excitation control. A maintenance record can be used for the following
purposes:
• Verifies that equipment is routinely checked

• Aids troubleshooting and prevention of equipment failure by providing a history of
equipment maintenance and problems
2.3 Maintenance Procedures

Maintenance procedures involve cleaning the equipment and checking for wear and
damage through visual inspection and functional tests.
To prevent electric shock, make sure all power supplies to the

exciter cabinets are turned off. Ground and discharge
equipment before performing any adjustments, servicing, or
other acts requiring physical contact with the electrical
Warning components or wiring.
Before performing any maintenance procedures, the exciter

must be de-energized. Do not deviate from the provided
de-energizing procedures. If safety requirements cannot be met
completely, or if you do not understand them, do not work on
the equipment.
Circuit breakers, fuses, and electromechanical devices within

the exciter cabinet should not be used as lockout devices.
Warning
Breakers do not isolate wiring and devices on the line side of the
breaker, and electromagnetic devices are not positive isolation
since they can be electrically operated.
The following procedures should be performed at appropriate intervals determined by the

environment.
1. Remove dust and dirt from cabinets and electrical components.
2. Check all external screw and bolt connections.
3. Inspect wiring inside the Regulator system cabinet for abrasive wear, burns, or
melted wire insulation.
4. Inspect all boards, plugs, connectors and wiring for signs of looseness, corrosion,
overheating, arcing, component rupture or venting, or other damage. Repair or
replace as necessary.
5. Test all fuses, such as those on the ac line/Metal Oxide Varistor (MOV) filter module,
and verify that they are not open. Check the contacts on the K41 and K5T contactors
(if present).
6. Temporarily remove the front cover of the PCM(s) and similarly inspect components
inside. Being cautious of stored charge, check the capacitors, diode modules,

contactors, power resistors, connectors, wiring, and boards. Using a digital voltmeter,
verify that the following devices are neither shorted nor open circuit:
• Front-end diode modules

• Power resistors
• DC link capacitors
• K3 relay on the left side of the PCM (120 A Regulator system) or on the
ERSC/ERSD (35 A Regulator system)
7. Check the operation of all fans.
8. Check the integrity and proper operation of the space heater.
9. Check the integrity of the field ground detector circuits. Third-party ground detector
circuits, such as the Accumetrics ground detector used on KATO™ and EM Brushless
exciters, should be checked using the original equipment manufacturers’ (OEM)
recommendations.
10. When inspections and reassembly have been completed, energize the control system
and check for correct operation. Use a computer or the optional touchscreen to
communicate to the control and correct all alarms and faults reported by the system.

2.3.1 Dust Removal
Build up of dust on electrical components and wiring can

damage components and cause misoperation.
Caution
Build up of dust on components can increase operating temperature, reducing their

normal life. On stand-off insulators, dust can collect enough moisture to produce a current
path to chassis ground. Dust (especially metallic dust) on wire surfaces can cause tracking
between connector pins. Tracking is usually capacitive in nature and involves a build up
of electrical charge along the wire surface. This can cause intermittent problems that are
hard to find.
Ø To remove dust from the components

1. Clean stand-off insulators with a clean, dry cloth. Do not use any solvents.
2. Using a fine-filtered vacuum cleaner with a non-metallic nozzle, remove dust and dirt
from wiring and electrical components.
3. Inspect cabinet air filters, if equipped. Shake or vacuum filters clean, or replace, as
required.
Note Dust is best removed by vacuuming with a grounded vacuum nozzle/brush. A less
desirable method is blowing with a low-pressure air source that is filtered and has a
water/oil separator.
Do not use high-pressure compressed air, which may damage

components.
If a blow nozzle with a tube extension is used, tape the area

around the tip of the tube to prevent damage to insulation.
When blowing some areas, contamination in other areas may
become worse. Cover areas such as the power converter
Caution
assemblies, boards, and transformers to prevent increased
contamination.
4. After cleaning, examine the parts for pitting or other signs of metal deposits on
insulation or insulated parts. If parts are pitted, do not reuse.

2.3.2 Cleaning Up Oil or Similar Fluids
Ø To clean oil or similar fluids inside the cabinet
Wear gloves and eye protection when using cleaning fluids and
use them only in a well-ventilated area.
Warning
1. Clean oil or other similar fluids that have accumulated inside the cabinets, such as
from a power device failure. Use a cleaner that is strong enough to remove
contaminates, but one that does not harm the components and does not leave a
residue. A recommended product is Axarel MicroCare 2200 (best for boards and
other delicate devices). Other good products to use are citrus-based solvents.
Normal household cleaners may leave a salt residue behind and

must not be used.
Caution
2. After cleaning, examine the parts for pitting or other signs of metal deposits on
insulation or insulated parts. If parts are pitted, do not reuse.
Note Contaminated Nomex™ insulation should not be reused.

2.3.3 Loose Connections
Vibration during equipment operation can loosen mechanical and electrical connections
and cause intermittent equipment failure. Additionally, dust and moisture in loose
connections can cause loss of low-level signals at terminal boards and also thermal
runaway at bus connections.
Ø To check connections
1. Check all hardware and electrical connections by attempting to move the device/wire,
and tighten them if needed.
2. Tighten or replace any loosened crimp-style lugs.
3. Tighten or replace all loose or missing hardware.
4. Inspect boards for correct seating, and check that any plugs, wiring, and bus
connectors are tight.
To prevent component damage caused by static electricity, treat

all boards and devices with static-sensitive handling techniques.
Wear a wrist grounding strap when handling boards or
components, but only after boards or components have been
removed from potentially energized equipment and are at a
normally grounded workstation.
Caution To prevent equipment damage, do not remove, insert, or adjust
board connections while power is applied to the equipment.
2.3.4 Damaged Insulation

Wires and cables with damaged insulation are dangerous when carrying electricity. They
can also intermittently short, causing equipment and functional failure.
Ø To check wires and cables

1. Check all wires and cables for fraying, chipping, nicks, wear, or rodent damage.
2. Check all wires and cables for signs of overheating or carbonization.
3. Repair minor low-voltage insulation damage with a good grade of electrical tape. If a
damaged cable carries high voltages, replace the cable.
4. Replace any cables or wires that have excessive damage.

2.3.5 Breakers and Relays
Ø To check breakers and relays
1. If possible, manually trip the device to ensure that it works properly.
2. Inspect contacts on open (as opposed to sealed) breakers and relays. Discoloration
and rough contact surfaces are normal.
3. If beads have formed because of severe arcing:
a. Dress the contact faces with a fine file. Do not use an emery cloth or sandpaper.
b. Identify and correct the cause of arcing.
c. Refer to the component’s document for instructions on maintenance, repair, and
replacement procedures.
2.3.6 Boards and Modules

Ø To clean boards/modules
1. Vacuum to remove dust from around the board connections before and after
unplugging.
Refer to the section, Related 2. Remove the boards using the instructions provided in Chapter 3, Parts Replacement,
Documents. or the individual board document. Be sure to observe personnel and equipment safety
instructions.
3. Vacuum to remove dust from the board and connections. A soft-bristled brush may
be used to loosen dirt.
4. If excessively dirty, wash the boards as follows:
a. Use a soft-bristled brush to scrub the board in a lukewarm (37.7°C, 100 °F), mild
solution of distilled water and household or laboratory detergent. Harsh
chemicals and solutions will damage the board. Do not use solvents containing
ammonia, aldehydes, alkalis, aromatic hydrocarbons, or ketones.
b. Rinse thoroughly by dipping the board several times in fresh, lukewarm, distilled
water. Do not soak the board.
c. Dry the board by shaking off excess water, immersing and agitating the board in
isopropyl alcohol, and then air-drying for a few hours.

2.4 Short-circuit Damage
If a short circuit occurs, overcurrent protective devices on the circuit should cut off power
to the equipment. This normally prevents electrical damage, except at the point of the
short. However, the heat produced by an electrical arc can carbonize some organic
insulating materials, which then lose insulating qualities.
After repairing the cause of the short, but prior to re-energizing the EX2100e Excitation
Control system:
• Inspect the system thoroughly for damage to conductors, insulation, or equipment.

Replace these components if any damage is detected.
• Check insulation resistance.
• Inspect the overcurrent protection devices for damage to insulation and contacts.
Replace or repair, as needed.
• Check and replace any open fuses.

3 Parts Replacement
Contact GE if additional The Regulator system installation may consist of a complete system with all modules
information is needed for a installed in a stand-alone cabinet supplied by GE. Alternately, the installation may consist
specific application. of field-mounted modules supplied by GE as a parts kit. Replacement procedures
generally refer to the stand-alone system, but provide guidelines for other installations.
Replaceable parts for the Regulator system are located in the control module and various
Refer to the section, Online other modules mounted in the stand-alone cabinet. In the simplex Regulator systems,
Repair. there are no online maintainable components. For the redundant Regulator systems, only
certain parts can be considered as online-maintainable after a system review.
3.1 Safety and Replacement Guidelines

Refer to the section, Equipment Before starting any replacement procedures, make sure that shutting down the equipment
and Material Requirements. does not interfere with plant operations.
With power applied, this equipment contains a potential hazard

of electric shock or burn. Only adequately trained persons who
are thoroughly familiar with the equipment and the instructions
should maintain this equipment.
Warning

personnel must understand and follow all safety requirements
for working around dangerous voltages. Make sure that all
power sources to the equipment are turned off, then ground and
discharge the equipment before performing any adjustments,
Warning servicing, or other acts requiring physical contact with the
electrical components or wiring.
Note It may be necessary to clean the exciter before beginning replacement procedures.
Refer to the sections, Dust Removal and Cleaning Up Oil or Similar Fluids.
Observe the following guidelines when performing any parts replacement procedures:
• Strictly follow all lockout tagout (LOTO) procedures and safety precautions.
• Always install wiring in the routing in the order it was removed. The wiring should
be labeled before being disconnected so that it can be connected in the same location.
Wire routing is important due to interference and partial discharge control.
• Carefully terminate all fiber-optic cables and observe the minimum bend radius of
50.8 mm (2 in).
• Always reinstall any items removed to gain access to parts being replaced, such as
module covers, LEXAN* barriers, and terminal board covers.
• Follow the recommended torque requirements as provided in the following table.
Parts Replacement GEH-6784D Maintenance Guide 27

Torque Requirements for General Hardware
Electrical Connections Mechanical Connections
Hardware Size Torquing the Bolt Torquing the Nut Torquing the Bolt Torquing the Nut
nm (in-lbs) nm (in-lbs) nm (in-lbs) nm (in-lbs)
10 - 32 or M5x0.8 3.4 (30) 2.8 (25) 3.4 (30) 2.8 (25)
1/4 - 20 or M6x1.0 6.6 (58) 5.4 (48) 11.4 (101) 9.5 (84)
5/16 - 18 or M8x1.25 13 (115) 10.8 (96) 26 (230) 21.7 (192)
3/8 - 16 or M10x1.5 22.8 (202) 19 (168) 40.7 (360) 34 (300)
1/2 - 13 or M12x1.75 57 (504) 47.5 (420) 117 (1037) 95 (840)
5/8 - 11 or M16x2 114 (1008) 95 (840) 236 (2088) 196.6 (1740)
3.2 Control Module

Refer to GEI-100665, Mark* The Universal Controller Stand-alone version B (UCSB) controller is a stand-alone,
VIe Controllers UCCx and single-board controller with scalable processing power. The UCSB controller has built-in
UCSx Instruction Guide. power supplies, requires no fans, no batteries, and no jumper settings. The controller(s)
runs ControlST* software that provides a common software environment for rotating
machinery and Balance of Plant equipment to simplify operations and maintenance.
The EX2100e control Regulator system offers simplex and dual control options. The
simplex control uses one UCSB controller, while the dual control uses two identical
UCSB controllers.
Simplex UCSB Controller Dual UCSB Controllers

3.2.1 Online Repairs
The Regulator system was not designed for online repair. It is
recommended that all repairs be made with the unit
de-energized. Some online repair is possible, but only in very
specific redundant control configurations. Contact the nearest
GE sales or service office, or an authorized GE sales
Warning representative for further assistance and recommendations
regarding online repair.
The following conditions must exist for online repair of a component in a redundant
Regulator system to be possible:
All of these conditions must exist to even consider online

repair and maintenance.
Attention
• The system must be a dual control Regulator system.

• Separate disconnects, such as ac and dc circuit breakers, must be provided to allow
removal of all power sources to the control module for which board replacement is
required. These disconnects must be clearly identified to ensure the active module is
not inadvertently shut off.
• The module to be powered down must not be the active module (the one controlling
the exciter). Using the touchscreen display or the ToolboxST* application screens,
determine if Master 1 (M1) or Master 2 (M2) is currently active.
• Consult with local GE representatives to confirm online repair is possible and
determine which specific components (such as UCSB controller, control power
supply, and touchscreen) are online-repairable.
Refer to the section, Safety • The technician making the repair must be familiar with the equipment, qualified to
Precautions. work in an environment near hazardous voltages, and protected with appropriate PPE
for hazards. Make sure site-specific hazard levels are known so that appropriate PPT
can be selected.

3.2.1.1 Touchscreen
Optional touchscreens that are mounted separately from the control module, if safely
accessible, may be replaced while the control is energized. Disconnecting and
reconnecting the touchscreen cable while energized will not harm the touchscreen or
disturb Regulator system operation.
Ø To replace the touchscreen
Care must be taken not to short any of the circuitry to the

enclosure walls while the cable is plugged in and energized. Use
the power switch on the back of the touchscreen to turn off the
device during replacement.
Caution
1. Remove the mounting screws securing the touchscreen to EX2100e control Regulator
system panel.
2. Remove the touchscreen carefully.
Do not pull directly out. The touchscreen cable connector is

located on the bottom of the assembly and damage to the
connector or circuit board is possible. The touchscreen should
be removed slowly and partially to allow access to this cable for
disconnecting before completely removing the touchscreen.
Caution
3. With the touchscreen is partially removed, disconnect the touchscreen wiring, then
remove the touchscreen completely.
4. Orient the replacement touchscreen in the same position as the one removed,
reconnect cables, and mount it with the mounting screws removed in step 1. Take
care to not damage the cable or board during insertion.
For connections, refer to the 5. Tighten hardware.
table, Torque Requirements for
6. If touchscreen configuration is required, refer to GEI-100787, EX2100e Excitation
General Hardware.
and LS2100e Static Starter Control Systems Touchscreen Local Operator Interface
Instruction Guide.
Touchscreen Front View Touchscreen Rear View

3.2.2 Offline and De-energized Repairs
It is recommended that all repairs be made with the unit offline and de-energized.

burn. Only adequately trained persons who are thoroughly
familiar with the equipment and the instructions should
maintain this equipment. To prevent electric shock while
servicing the equipment, personnel must understand and follow
Warning all safety requirements for working around dangerous voltages.
Do not remove or insert a board in any section of the controller

that is energized. EX2100e control boards are not designed for
energized changing.
Caution
All LEXAN pieces and metallic module covers in the Regulator

system are important and should be in place during operation.
If removed for maintenance access they should be re-installed
before the exciter is energized again. Missing barriers and
covers create a safety hazard.
Caution
3.2.2.1 De-energizing
Before attempting to replace any standard or optional module, observe the following steps
and precautions.
Ø To de-energize modules
1. Verify that all ac and dc power sources to the Regulator system are turned off.
2. Follow all local LOTO procedures and safety precautions.
3. Verify that there is no voltage on any incoming terminals using a suitable voltmeter.
4. Verify that the generator is shut down and the rotor is not moving. Remove PPT fuses
or open the PPT breaker, if applicable.
5. Wait at least two minutes (35 A Regulator system) or five minutes (120 A Regulator
system) after all power is removed for each of the capacitors in the assemblies to
discharge. During disassembly, use a voltmeter to verify all capacitors are
discharged, especially if there is any evidence of broken capacitor or discharge
resistor leads.

3.2.2.2 Circuit Boards and Modules
The Regulator system must be de-energized before repairing or replacing any of the
following boards or modules in a simplex or dual control system:
• High-speed Serial Link Interface (HSLA) board (mounted to ESYS and ERAX
boards)
• EX2100e System I/O Interface (ESYS) module (different groups are used for
simplex and dual configurations)
• EX2100e Exciter Attenuation Module (EXAM)
• Exciter Regulator Third-part Ground Detector Terminal (ERGT) board
• EX2100e Regulator Auxiliary (ERAX) I/O board (located inside the PCM; different
groups are used for 35 A and 120 A Regulator systems)
• Universal Controller Stand-alone version B (UCSB) controller
• EX2100e DC Fanned Feedback (EDFF) board (different groups are used for simplex
and dual configurations)
• EX2100e Dual Select (EDSL) board (different groups are used for 35 A and 120 A
Regulator systems)
• EX2100e Snubber (ERSN) board (used only on 120 A Regulator system dual
configuration)

power sources to the equipment are turned off (main power
supply and control power supply), then ground the main ac
power cables in the power conversion cabinet before
Warning performing any adjustments, servicing, or other acts requiring
physical contact with the electrical components or wiring.
Do not remove or insert a board in any section of the controller

that is energized. EX2100e control boards are not designed for
energized changing.
Caution
All LEXAN pieces and metallic module covers in the EX2100e

control Regulator system are important and should be in place
during operation. If removed for maintenance access they
should be re-installed before the exciter is energized again.
Missing barriers and covers create a safety hazard.
Caution

Ø To replace boards and modules
1. Verify that all ac and dc power sources to the Regulator system are turned off and
LOTO procedures have been followed.
It is not safe to download the code to controller for a simplex

exciter while it is in operation. At the end of the process, the
system is reset and the exciter will trip.
Caution
Note These circuit boards are not designed for hot swapping and cannot safely be
replaced while the control is energized. Light-emitting diodes (LED) in the control may
indicate the presence of power, but should not be relied upon to indicate the absence of
power. Never replace a board while any of its LEDs are illuminated.
Refer to the section, Related 2. Replace the board using the replacement instructions in the applicable individual
Documents. board document.
3. Perform any necessary hardware verifications and tests. Refer to the applicable
procedure in GEH-6783, EX2100e Excitation Control for Regulator Systems
Installation and Startup Guide.

3.2.2.3 Power Converter Module
For field installed kit The power converter module is located on the top area of the cabinet and below other
applications, device locations power modules, such as line and battery filters and the charge/discharge resistor modules.
may differ from what is shown The power converter module for M1 and M2 are identical. In the event of a failure, the
in factory assembled cabinets. power converter should be replaced as a complete unit, although a failed ERAX board
inside the PCM may be replaced without removing and replacing the entire power
Refer to the device converter module.
nomenclature sticker located
inside the Regulator system The power converter module is composed of the following primary modules:
cabinet to locate specific
• Power Conversion Module (PCM) that includes:
devices.
− Heatsink
− DC link components
− Inverter components
− Power terminal board
− Wire harnesses
− ERAX board
− ERSC or ERSD board (35 A Regulator system)
− Discharge resistor module (35 A Regulator system)
− ERBI board (120 A Regulator system)
• Shunt Contactor Module (SCM) (35 A Regulator system) that includes:
− Shunt
− DC output contactor
− Transfer relay (dual)
− EDSL board (dual)
• Transfer Control Module (TCM) (120 A Regulator system) that includes:
− EDSL and ERSN boards
− Transfer diode and SCR modules

Typical Device Nomenclature Sticker for120 A Regulator System
Typical Device Nomenclature Sticker for35 A Regulator System

35 A Regulator System PCM 120 A Regulator System PCM

35 A Regulator System SCM 120 A Regulator System TCM
Ø To replace the PCM or SCM (35 A Regulator system)

1. Verify all ac and dc power sources to the Regulator system are turned off and that
LOTO procedures have been followed. These modules cannot be replaced while any
power is applied to the control.
2. Using a suitable voltmeter, verify that there is no voltage on any incoming terminals.
3. Verify the generator is shut down and the rotor is not moving. Remove the PPT fuses
or open the PPT circuit breaker, if supplied.
4. Wait at least two minutes after all power is removed to allow capacitors in the
assembly to discharge. During disassembly, use a voltmeter to verify that all
capacitors are discharged, especially if there is any evidence of broken capacitor or
discharge resistor leads.
5. Disconnect all wires from the terminal board on the module. Be sure they are
correctly identified for proper re-installation.
6. Unplug all connectors from the front and left rear side of the module.
7. Remove the mounting nuts that mount the module to the panel, and carefully remove
the module.
8. Reverse these steps to install the replacement module.

Refer to the section, Shunt 9. When replacing the SCM, verify that the correct shunt size is present at the bottom of
Replacement. the module.
Refer to GEH-6783, EX2100e

Note Make sure the correct shunt for the application is installed in the module.
Excitation Control for
Regulator Systems Installation
and Startup Guide, the section, 10. Perform any necessary hardware verification and tests.
Verify Control Power.
Ø To replace the PCM (120 A Regulator system)
The PCM weighs 32 kg (70 lbs). Use a mechanical lifting

system such as displayed in the following figure to assist
in PCM replacement. Example of Mechanical Lifting
System
Caution
Removal:
1. Turn off the unit following normal procedure.

2. Shut down control power and bridge power following normal procedure.
3. Perform LOTO for the unit following local procedures.
4. Verify that there is no voltage present in the unit. Pay special attention to the dc link
Mechanical Lifting System
capacitors.
5. Apply safety grounding equipment to 3–phase service if required by local codes and
regulations.
6. Disconnect all control cabling connected to the PCM being removed.
7. Disconnect all power wiring connected to the PCM being removed (10 mm socket).
Make sure all wiring is properly identified for correct reassembly.
8. Unplug the two fan power harnesses for the PCM.
9. Secure power and control cables in a way that removal of the PCM is possible.
10. Remove fans by removing the four bolts that attach them to the PCM (7 mm socket).
Take care not to damage the flexible fan flap.
11. Remove all mounting bolts attaching the PCM to the backplane of the cabinet except
the top two mounting bolts (0.5 in socket).
12. Loosen the top two mounting bolts 12.7 mm (0.5 in) so that the PCM can be
removed.
13. Using a mechanical lifting system, lift the PCM off the top two mounting bolts and
out of the cabinet.
14. Place PCM backside down on a flat surface.

Replacement and Reinstallation:
1. Remove the fans from the replacement PCM by removing the four bolts that attach
them to the PCM.
2. Place PCM with the bottom on the mechanical lifting system.
3. Using the mechanical lifting system, place the PCM on the top two bolts protruding
from the cabinet.
4. By hand, install the remaining mounting bolts and achieve a few turns of threads of
each bolt.
5. Using a torque ratchet with extension, torque all mounting bolts to specified values
(0.5 in socket).
6. Re-connect all power cables to their proper location and torque nuts to the specified
value (10 mm socket).
7. Re-connect all control cables.
8. Re-connect the fans and flexible fan flap to the PCM by fastening the four bolts that
were removed in step 1 (7 mm socket).
9. Re-connect the fan power plugs.
10. Perform a visual inspection to confirm all connections have been made correctly and
are torqued.
11. Remove safety grounding equipment, if used.
12. Remove LOTO equipment.
13. Apply control power and bridge power.

Ø To replace the TCM (120 A Regulator system)
1. Turn off the unit following normal procedure.
2. Shut down control power and bridge power following normal procedure.
3. Perform LOTO for the unit following local procedures.
4. Carefully disconnect the power wires and external wiring plug connectors, making
sure they are properly labeled to ensure correct reassembly.
5. Remove the bracket mounting bolts while holding the TCM to prevent it from falling.
6. Verify that the replacement TCM has the correct boards and power devices and they
are installed correctly.
7. Check the connections from the EDSL board to the SCR gate terminals.
8. Install the replacement TCM and tighten the mounting bolts.
9. Restore all connections and verify operation.
3.2.2.4 Fans
Refer to the table, Scheduled Only the 120 A Regulator system includes fans on the PCM. Both the 35 A and 120 A
Preventive Replacement. Regulator systems may include a fan on the door. Fans should be replaced during
preventive maintenance or when failures are observed during maintenance. Fans should
also be checked if unexplained PCM overtemperature alarms frequently occur.
Door Fan Fans on 120 A Regulator System PCM

Ø To replace one or both PCM fans (120 A Regulator system)
1. Verify that all ac and dc sources to the Regulator system are turned off, LOTO
procedures have been performed, and the PCM capacitors have been allowed at least
five minutes to discharge.
2. Disconnect the power supply cable from each fan to be replaced. The connector may
be inside the harness tray beneath the fans, accessed by removing the cover.
3. Remove the four mounting screws for each fan to be replaced. If desired, the sheet
The fan flap prevents cooling metal bracket that holds both fans may be removed first to allow fan replacement to
air from one fan leaking out be performed on a more convenient work surface.
the other fan path should it be
4. Observe the orientation of the fan blade guard and the fan to ensure correct
out of operation.
reassembly. Also observe the flexible flap between the two fans.
Make sure the orientation arrows

on both fans point into the unit .
Fan Flap
Flexible Fan Flap in a 120 A Regulator System
5. Observe the fan direction of the rotation arrow on the body of the fan. The fan must
be oriented to blow air upward into the bottom of the PCM.
Note Improper rotation direction cannot be corrected by reversing the polarity of the
dc input power.
6. Attach the replacement fan and guard to the bracket, being careful not to overtighten
the screws and break the plastic mounting tabs. If the metal bracket was removed,
reinstall it to the bottom of the PCM.
7. Reconnect the fan power connectors.
8. Reapply control power and verify the fans turn in the proper direction (pushing air
up) and turn freely and quietly.

Ø To replace a door fan
1. Verify that all ac and dc sources to the Regulator system are turned off and that
LOTO procedures have been performed.
2. Disconnect the fan power and ground connections at the fan.
3. Remove the complete fan and filter assembly by pressing the retention tabs around
the perimeter of the housing and pushing the assembly out through the door. Be
careful not to let the assembly fall to the floor.
4. If replacing just the fan and not the complete assembly, remove the filter cover and
filter to provide access to the fan mounting hardware. Pay attention to fan rotation
markings and mount the fan to pull air into the cabinet through the lower door filter.
5. Snap the assembly with the replacement fan back into the door until all mounting
tabs are secure. Be sure the orientation matches the original configuration.
6. Reconnect the power and ground wires, and verify the wires are secure and have
adequate strain relief and protection across the door hinge.
7. Reapply fan power.
8. Verify there is proper direction of rotation and freedom of movement, and the fan
guard is in place.

3.2.2.5 DC Link Capacitors
DC link capacitors in the PCMs should be replaced every four to seven years as part of
routine maintenance. Capacitor life depends on operating temperature and ripple current.
Capacitors in a PCM operating at less than 2/3 rating and in a climate controlled ambient
of 30°C (86 °F) should operate reliably for at least seven years. Those operated under
more severe conditions should be replaced sooner.
Charged capacitors pose a potential hazard of electric shock or

burn. Only adequately trained persons should maintain this
equipment.
Although bleed resistors are provided on the equipment to

discharge these capacitors to a safe level within 5 minutes after
power is removed, hazardous voltages may be present if the
bleed resistors have failed or been disconnected. Additionally,
open circuit electrolytic capacitors that have previously been
discharged can exhibit a recovery voltage phenomenon due to
internal dielectric polarization. The capacitor voltage may
Warning
continue to increase for several weeks after it has been
discharged, and can produce startling sparks and damaging
currents if the terminals are suddenly shorted. To avoid these
hazards, always check the voltage across the capacitors before
performing maintenance, and discharge them through 100 to 1
kΩ resistors as necessary.
Aluminum electrolytic capacitors are polarized. If reverse

voltage is applied even briefly, the capacitor is damaged and
should not be used. Even a reverse voltage as small as 1 or 2 V
for a few seconds is destructive. Be sure the polarity is correct
during installation.
Caution
Aluminum electrolytic capacitors that have been in storage

without power applied for more than two years need special
treatment called reforming before being put into service. This is
because normal leakage current flow helps maintain the
aluminum oxide dielectric layer on the anode foil. With no
power applied, the layer deteriorates over time to the point that
Caution sudden reapplication of power causes destructive leakage
currents to flow.

Ø Methods to reform PCM capacitors
Note The following reforming methods are only necessary for dc link capacitors that
have been in de-energized storage for two years or more.
1. The preferred method of reforming a capacitor that has been de-energized for two
years or more is to connect it to rated dc voltage through a 1000 Ω, 100 W resistor
for at least one hour – 400 V dc for the 120 A PCM capacitors and 350 V dc for the
35 A PCM capacitors.
2. If the preferred method is not available, or if the capacitors have already been
installed in the PCM, reforming can be done in the assembled and mounted PCM by
connecting 100 Ω, 50 W resistors in series with the ac input phases to the PCM, and
applying the maximum normal input voltage for the site specific application to the
PCM for 1 hour (without running the exciter). Control power should be left off. After
the series resistors are removed, the PCM power should be reapplied again at full
voltage, for at least 15 minutes before running the exciter.
3. If series resistors are not available, a third method of forming the resistors, again
within the assembled and mounted PCM, is to temporarily apply voltage to the PCM
in steps of approximately 100 V using available power sources. For example, the first
step could be from the 125 V dc station battery. The next step could be from 120 V ac
– the PCM rectifies this to 170 V dc at the dc link. Each step should be applied for at
least 15 minutes, with control power turned off. The next step could be 240 V ac, and
this is near enough rated input voltage for the 35 A Regulator system that it would be
the final step. For the 120 A Regulator system, if it is to normally operated from 480
V ac, one more intermediate step such as 380 V ac is recommended. The final
forming step should be at the highest normal input voltage for the site specific
application, for 15 minutes with control power not applied.
4. For PMG applications, if the PMG can be spun up gradually over a period of at least
one half hour, forming can be accomplished in the PCM by this method, leaving
control power off and only PMG power applied to the PCM. If initial forming can be
done using 125 V dc battery power for 15 minutes, the PMG spin up time can be
reduced to 15 minutes.
5. Application of one of these forming methods is only necessary for dc link capacitors
that have been in de-energized storage for two years or more.

Ø To replace the dc link capacitors (35 A Regulator system)
that LOTO procedures have been followed. The capacitors cannot be replaced while
any power is applied to the control.
2. Using a suitable voltmeter, verify that there is no voltage on any incoming terminals.
3. Verify that the generator is shut down and that the rotor is not moving. Remove the
PPT fuses or open the PPT circuit breaker, if supplied.
4. Wait at least two minutes after all power is removed to allow capacitors in the
assembly to discharge. During disassembly, use a voltmeter to verify that all
capacitors are discharged, especially if there is any evidence of broken capacitors or
discharge resistor leads.
5. Remove the PCM.
6. Set the PCM down on a flat and stable surface.
7. Remove the PCM left side and top sheet metal pieces to gain access to the capacitors.
Observe the orientation of the capacitors and their connections. Remove the
connections, making sure they are properly labeled for correct reassembly.
35 A Regulator System Capacitor Orientation 35 A Regulator System Capacitor Assembly

8. Remove the two terminal screws from each large blue capacitor (four screws total).
Remove the two large nylon nuts from the studs that are attached to the bottom of the
capacitors.
9. Remove the capacitors.
10. Install the replacement capacitors. Make sure they are the same value as the ones
removed (4700 μF, 350 V)
Refer to the applicable
procedure in Chapter 4, Note Be certain to orient the replacement capacitors such that the positive terminals are
Hardware Verification and both toward the center of the heatsink and the ERSx/IGBT module.
Checks, or GEH-6783,
EX2100e Excitation Control 11. Re-attach the large nylon nuts and the terminal screw connections.
for Regulator Systems
Installation and Startup Guide, 12. Reverse the remaining steps to re-install the refurbished PCM onto the regulator
the section, Verify Control cabinet.
Power. 13. Perform any necessary hardware verification and tests.

Ø To replace the dc link capacitors (120 A Regulator system PCM)
1. Remove the PCM and fans using the procedure, To replace the dc link capacitors (35
A Regulator system). Allow five minutes for the dc link capacitor to discharge.
2. If not already done, remove the fan assembly from the bottom of the PCM.
3. Remove the front plates from the PCM. The plate on the right has connectors
attached and care must be taken to not damage the wiring. Either carefully use the
slack to set the plate out of the way, or temporarily remove the connectors from the
plate paying attention to ensure correct reassembly.
4. Observe the connections to the capacitors, the capacitor orientation, and the number
of washers used to make the bus connections (three washers on the front capacitors
and two on the rear).
5. Taking care to provide support for the capacitors so as not to damage the flexible bus
assembly, remove the bottom bracket from the PCM.
6. Remove the reinforced plastic capacitor mounting plate.
7. One at a time, disconnect the capacitor connections and remove each capacitor.
8. Be sure the new capacitors are discharged, then working form the rear forward,
reconnect the capacitors paying attention to polarity and number of washers.
9. Hand-tighten the capacitor terminal screws, one by one until all four are connected to
the dc link bus.
10. Attach the plastic plate to the bottom of the capacitors.
11. Tighten the capacitor studs to the plastic plate.
12. Attach the bottom metal bracket to the PCM and tighten.
13. Screw the plastic plate to this bracket.
14. Tighten the capacitor terminal screws to 5.1 Nm (45 in-lbs).
15. Verify that all parts and fasteners are accounted for, that orientation and wiring are
correct, and the dc link bus insulation integrity has been preserved.
16. Reattach the PCM front plates, reinstall the PCM and fans, and test the operation.

Observe capacitor polarity.
Do not install backwards. CAP-NEUTRAL1
Three brass washers, CAP-NEUTRAL2

in these locations
CAP-NEG
Tighten CAP
terminal screws to
5.1 Nm (45 in-lbs)
Two brass washers,

in these locations
CAP-POS
120 A Regulator System Capacitor Bank Assembly

3.2.2.6 Discharge Resistor Module
The discharge resistor In the 35 A Regulator system, the discharge resistor is enclosed inside the bottom right
dissipates excess energy in the side of the PCM. Replacing the complete PCM assembly is the recommended procedure.
Regulator system dc link. It can be accessed and replaced following a procedure similar to the procedure for
replacing the PCM.
In the 120 A Regulator system, the discharge resistors are located with the dc link
charging resistors in an enclosed assembly above each PCM. For replacement, follow
LOTO and dc link capacitor discharge, disconnect the wiring, and remove the four
mounting bolts. The module weighs approximately 10 kg (23 lbs).
Under certain conditions, the discharge resistor can become

very hot. Allow approximately a one-hour time lapse for this
resistor to cool to ambient temperature before attempting to
replace this resistor module.
Warning
35 A Regulator System RDD Discharge Resistor 120 A Regulator System Charge/Discharge Modules

3.2.2.7 ERAX Board
Refer to GEI-100771, EX2100e The ERAX board is mounted to the left inside wall of the 35 A Regulator system PCM
Excitation Control Regulator and the right inside wall of the 120 A Regulator system PCM. The 35 A Regulator system
Auxiliary I/O Board PCM uses an ERAXH1 board, while the 120 A PCM uses an ERAXH2 board. The
Instruction Guide. replacement procedures are similar.
3.2.2.8 Shunt Replacement

The shunt is located on the SCM in the 35 A Regulator system, and just above the TCM
on the back panel of the 120 A Regulator system. It provides regulator current feedback
for the Regulator system for all applications. During initial startup and testing, it may be
necessary to change the shunt to the appropriate value for the application. Also, if a unit
has a performance upgrade or modification, it may be necessary to increase the output of
the regulator. The shunt is the only hardware component that is dependent upon the output
of the regulator for that application.
Shunt Location on SCM in 35 A Regulator System Shunt Location in 120 A Regulator System

Ø To replace the shunt
LOTO procedures have been followed. This assembly cannot be replaced while
2. Remove the LEXAN cover (if necessary) to locate the shunt.
3. Confirm that the wiring connections to the shunt instrument and power wiring are
clearly labeled. Replace or repair the labels, if necessary.
4. Remove the two screws and nuts for the red and white instrumentation wires on the
shunt, observing the color coding to ensure the polarity is maintained during
reinstallation.
5. Remove the two nuts for the power wiring to the shunt.
6. Loosen and remove the two nuts holding the shunt onto the module and remove the
shunt.
For connections, refer to the 7. Confirm the rating marked on the shunt. Orient and replace the new shunt on to
table, Torque Requirements for the module using the hardware removed in step 6.
General Hardware.
Note The shunt rating parameter in the ToolboxST application must match the rating
of the shunt in the Regulator system.
Refer to the applicable 8. Re-terminate the shunt power wiring using the hardware removed in step 5.
procedure in Chapter 4,
9. Re-terminate the shunt instrumentation wiring using the hardware removed in step 4.
Hardware Verification and
Checks or GEH-6783, 10. Reinstall the LEXAN cover, if removed.
EX2100e Excitation Control
11. Perform any necessary hardware verification and tests.
Installation and Startup Guide,
the section, Verify Control
Power.

3.2.3 DC Output (K41) and Transfer (K5T) Contactors
The dc output contactor (K41) is located inside the SCM of the 35 A Regulator system,
and on the back panel of the 120 A Regulator system. For dual regulators, the transfer
contactor (K5T) is located on top of the SCM of the 35 A Regulator system, and on the
back panel of the 120 A Regulator system.
For the 120 A Regulator system, the offline

replacement procedure should be straightforward.
120 A Regulator System DC Output Contactor 120 A Regulator System Transfer Contactor
Ø To replace the output contactor in a SCM (35 A Regulator system)

Warning


GE safety procedures, LOTO, and site safety procedures as
indicated by EHS.
Warning
2. Remove the front LEXAN cover by opening the four screws.
LEXAN Cover Screws
3. Disconnect all wires from the contactor.
Contactor Mounting Screws (Simplex)

4. Take out the contactor by removing the three screws that mount the contactor to the
plate.
5. Mount the replacement contactor with the screws that were removed in step 4.
Refer to GEH-6783, EX2100e 6. Connect all the wires that were disconnected in step 3.
7. Place the LEXAN cover back on and tighten it with the screws removed in step 2.
Ø To replace the K5T Transfer contactor in a dual SCM (35 A Regulator

System)

Warning


GE safety procedures, LOTO, and site safety procedures as
indicated by EHS.
Warning
2. Disconnect the wires from the contactor that mount on the SCM.
3. Remove the four screws and the take out the contactor (the fourth screw is not
displayed in the following figure).

Contactor Mounting Screws (Dual)
Refer to GEH-6783, EX2100e 4. Mount the new contactor with the screws that were removed in step 3.
5. Connect all the wires that were disconnected in step 2.

3.3 Standard and Optional Modules
Each Regulator system contains additional mounted modules. Some of these modules are
standard with each control, while others are supplied optionally as the application
requires.
Standard modules include:
• I/O module, which includes the ESYS and potential transformer (PT) and current
transformer (CT) disconnect switches
• Control power supplies
Optional modules include:
• AC line filter or AC line MOV module

• AC EMI filter
• DC battery filter
• Generator field feedback, including one EDFF board
• Ground detector, including the EXAM or ERGT boards
The Regulator system modules were not designed for online maintenance. All power must
be removed from the regulator before any replacement or repairs of the modules can be
done. The main ac power supply and the user dc power supply to the regulator must be
OFF before beginning any parts replacement procedures.

Warning

All LEXAN pieces and metallic module covers in the EX2100e

control Regulator system are important and should be in place
during operation. If removed for maintenance access they
should be re-installed before the exciter is energized again.
Missing barriers and covers create a safety hazard or alter the
Caution proper airflow inside the cabinet.

3.3.1 ESYS Module
Refer to GEI-100772, EX2100e The ESYS I/O module contains the ESYS board, which is wired to the PT and CT
Excitation Control System I/O disconnect switches. The ESYS also contains customer analog and digital I/O signals, trip
Interface (ESYS) Module and general purpose relays. It is not necessary to remove each individual wire to replace
Instruction Guide. the ESYS. The board terminal strips can be removed without de-terminating the wiring.
The I/O module contains all customer-wired connections to the EX2100e control
Regulator system.
ESYS Module

3.3.2 AC Line Filter (35 A Regulator System, If
Supplied)
Only units fed from an The Regulator system ac line filter is used to protect against unknown voltage transients
auxiliary ac source will have from the auxiliary source ac bus. This module has three fuses located under the metallic
an ac line filter module. cover of the filter. The filter metallic cover is optional and may not be supplied on all
units.
35 A Regulator System AC Line Filter
Ø To replace ac line filter module fuse(s)
Under normal operation, the ac line filter resistors can become

very hot. Allow approximately a one hour time lapse for these
resistors to cool to ambient temperature before attempting to
replace this filter.
Warning
1. Verify that the exciter has been properly de-energized.
2. Remove the metallic cover from the module (if supplied) by removing the two
self-tapping screws from the cover and lifting the cover off.
3. Remove each of the three filter fuses using an appropriate fuse pulling device. Verify
and record which fuse(s) is/are open.
For connections, refer to the 4. Replace the new fuses ensuring they are properly seated.
5. Replace the metallic cover over the module removed in step 2 and tighten them.
General Hardware.

Ø To replace an ac line filter module
2. Remove the metallic cover from the module by removing the two self-tapping screws
from the cover and lifting the cover off.
If any of the capacitor leads are broken, verify the voltage of the
capacitors and discharge them with a 5 W 10 KΩ resistor
before touching them.
Warning
3. After inspecting the wiring labels and making sure they are properly labeled for
accurate re-termination, remove the wiring from the filter module.
4. Loosen and remove the four self-tapping screws that hold the ac line filter module in
place and remove the module. Properly support the module during this process.
For connections, refer to the 5. Properly orient the replacement ac line filter module. Verify that the fuses in the
table, Torque Requirements for module are installed and functional. Remount the module using the self-tapping
General Hardware. screws removed in step 4 and tighten them.
6. Re-terminate the wiring removed in step 3.
Refer to the applicable 7. Verify all wiring connections to the filter (poor connection can contribute to hot
procedure in GEH-6783, spots).
8. Replace the metallic cover over the module if still removed and tighten them.
Installation and Startup Guide. 9. Perform any necessary hardware verifications and tests.

3.3.3 AC Line EMI Filter (35 A Regulator System)
The EMI filter is used on some systems to attenuate conducted interference from the
PCM back onto the plant power distribution network. The EMI filter requires a solid
ground connection, provided by a short grounding strap (visible in the upper right corner
of the following figure). The module is mounted on an insulated base to facilitate
isolation of the module ground during dielectric testing of the regulator.
35 A Regulator System AC Line EMI Filter
Ø To replace the EMI filter

1. Verify that the system has been de-energized and shut down.
2. Carefully disconnect the ground strap and line and load power connections from the
filter.
3. Observing the orientation, remove the filter from the reinforced plastic mounting
bracket.
4. Attach the new filter in the same orientation. Do not overtighten the screws.
5. Verify that the mounting screws do not protrude too far through the bracket and
violate ground clearances.
6. Reattach the ground strap securely and verify that the ground to the cabinet is clean
and tight also.
7. Carefully reconnect and tighten the line and load power connections.
8. Inspect and check all work before re-energizing.

3.3.4 AC Line/MOV Filter Module (120 A Regulator
System)
The ac line/MOV filter module, located in the top left corner of the control cabinet,
Replacement of the module, if protects the EX2100e control from external transient voltage spikes. The MOVs are sized
necessary, is straightforward. to handle spikes that might reasonably be expected to occur on the ac supply. If a spike
exceeds the MOV rating, fuses are provided on the module to protect the MOVs from
Refer to the fuse label and the rupture. These specialized fuses are surge rated to match the MOV surge rating. If they
Regulator system elementary to have blown (measuring open circuit), they must be replaced with identical fuses. Standard
determine the correct fuse part fuses only have current ratings and should not be used in the MOV filter. Holes are
number. provided in the touch-safe LEXAN cover of the module to facilitate testing of the fuses.
This module is connected to the line side of the bridge ac input

breakers, and is not isolated by opening these breakers.
Warning
MOV Filter Module

3.3.5 DC Battery Filter (35 A Regulator System)
The DC battery filter module protects the EX2100e control from externally induced
voltages and spikes from the station service battery bus. This module has two fuses
located under the metallic cover of the filter. The filter metallic cover is optional and may
not be supplied on all units. DC battery filter fuses are accessible by removing the
metallic cover of the filter module.
DC Battery Filter Module
Ø To replace dc battery filter module fuse(s)

3. Using an appropriate fuse-pulling device, remove each of the two filter fuses. Check
and record which fuse(s) is/are open.
For connections, refer to the 4. Replace the new fuses ensuring they are properly seated.
5. Replace the metallic cover over the module using the screws removed in step 2 and
General Hardware.
tighten them

Ø To replace a dc battery filter module
If any of the capacitor leads are broken, verify the voltage of the
capacitors and discharge them with a 5 W 10 KΩ resistor
before touching them.
Warning
3. After inspecting the wiring labels and ensuring they are properly labeled for accurate
re-termination, remove the wiring from the filter module.
4. Loosen and remove the four self-tapping screws that hold the dc battery filter module
in place and remove the module. Properly support the module during this process.
For connections, refer to the 5. Properly orient the replacement dc battery filter module. Verify that the fuses in the
table, Torque Requirements for module are installed and functional. Remount the module using the self-tapping
General Hardware. screws removed in step 4 and tighten them.
6. Re-terminate the wiring removed in step 3.
Refer to the applicable 7. Verify all wiring connections to the filter (poor connection can contribute to hot
procedure in GEH-6783, spots).
8. Replace the metallic cover over the module if still removed and tighten.

3.3.6 Generator Field Feedback Module
The generator field feedback module may contain the following boards that isolate the
high voltages from the main generator field from the Regulator system control section:
The ToolboxST application
software can assist with • Exciter Attenuation Module (EXAM)
troubleshooting any problems • EX2100e DC Fanned Feedback (EDFF)
related to these modules and
boards. These boards are not be supplied on Bushless exciter applications. One or both may be
supplied on SCT/PPT or rotating dc Regulator systems.
Generator Field Feedback Module
Ø To replace the EXAM

1. Verify that the Regulator system has been properly de-energized.
2. Remove the LEXAN barrier from around the generator field feedback module by
removing the four self-tapping screws holding it in place.
3. Verify that the wiring and cables being removed are properly labeled. Remove the
external wiring to the EXAM board, including one plug connector, two stab-on
connectors, one D-shell cable connector, and one ground wire screw.
4. Remove the EXAM board from the board holder of the module by loosening the four
nuts in the corners of the board.

For connections, refer to the 5. Correctly orient the replacement board and install it in the board holder of the
table, Torque Requirements for module. Set all berg jumpers identical to the original board in the module. Tighten
General Hardware. the board holder down using the nuts removed in step 4.
6. Reconnect the wiring and cables removed in step 3.
procedure in GEH-6783, 7. Re-install the LEXAN barrier removed in step 2 using the self-tapping screws and
EX2100e Excitation Control re-tighten.
8. Perform any necessary hardware verifications and tests.
Ø To replace the EDFF board

1. Remove the LEXAN barrier from around the generator field feedback module by
removing the four self-tapping screws holding it in place.
2. Verify that the wiring and cables to be removed are properly labeled. Remove the
external wiring to the EDFF board, including two or three plug connectors, one screw
connector, and one fiber-optic connector.
For connections, refer to the 3. Remove the EDFF board from the board holder of the module by depressing the
table, Torque Requirements for plastic hook latch pins in the corners of the board.
General Hardware.
4. Correctly orient the replacement board and install it in the board holder of the
module. Set all berg jumpers identical to the original board in the module.
procedure in GEH-6783, 5. Reconnect the wiring and cables removed in step 3.
6. Re-install the LEXAN barrier removed in step 2 using the self-tapping screws and
re-tighten them.
7. Perform any necessary hardware verifications and tests.
3.3.7 Power Potential Transformer

The PPT can be either a If the Regulator system is fed from an ac source other than a permanent magnet generator
1-phase or 3-phase (PMG) , an isolation transformer is required. The Power Potential Transformer (PPT)
transformer. supplies ac power to generate the voltage of the dc link. In the 35 A Regulator system, the
PPT may be located in the bottom of the cabinet. In the 120 A Regulator system, the PPT
is normally external. The EX2100e exciter requires only a single ac or dc input power to
operate the Regulator system. Often, both ac and dc input power is supplied.
The PPT in the Regulator system can be heavy. Appropriate

lifting and handling precautions are advised.
Caution

PPT
Ø To remove the PPT (35 A Regulator system)

2. Remove the LEXAN barrier from around the PPT by removing the four self-tapping
screws holding it in place.
3. Make sure the wiring to the PPT is properly labeled. Remove the external wiring to
the PPT primary and secondary terminal strips.
4. Loosen the hold-down bolts on the bottom of the PPT.
5. Using appropriate lifting means, remove the PPT.
For connections, refer to the 6. Inspect and replace any damaged or overheated wiring on the PPT.
7. Using appropriate lifting and handling techniques, correctly orient the replacement
General Hardware.
PPT and install it in the control cabinet.
8. Tighten the PPT hold-down bolts that were removed in step 4.
9. Reconnect the wiring to the PPT primary and secondary terminal strips that were
Refer to the applicable removed in step 3.
procedure in GEH-6783,
EX2100e Excitation Control 10. Re-install the LEXAN barrier that was removed in step 2 using the self-tapping
for Regulator Systems screws and re-tighten.

4 Hardware Verification and Checks
After replacing certain components of the EX2100e control, or after troubleshooting and
correcting a fault, it may be necessary to perform hardware verifications and checks
before placing the system back into normal operation.

Warning

Hardware Verification and Checks GEH-6784D Maintenance Guide 67

4.1 Preliminary Checks
After routine or emergency maintenance of the Regulator system, perform preliminary
checks using some basic guidelines to verify that the equipment was properly
reconnected.
Ø To perform preliminary checks

1. Account for all tools, equipment, and hardware used during the maintenance work.
2. Check all connections for tightness, and frayed or loose terminals and insulation.
3. Verify that all fuses for the ac line filter, ac MOV filter, and dc battery filter, as
applicable, are installed.
Refer to the EX2100e control 4. Wire check any connectors removed during the maintenance work, including:
system elementary for
verification of interconnecting • Ethernet connectors to the UCSB controller
wires. • Cable connections to the ESYS
• Wiring to the line filter and battery filter modules
• Output connections to the exciter field
• PPT or permanent magnet generator (PMG) input wiring connections
• Ground detector wiring and connections
• Interconnections between M1 and M2 control modules
• Fiber-optic connections from the generator field I/O module
5. If desired, megger the power circuit to ground, as follows:
a. Verify that all bridge and generator power sources have been locked out.
b. Close the bridge ac and dc input breakers.
Refer to system elementary.
c. Disconnect the following ground connections, if present:
i. AC line filter or MOV filter
ii. Battery filter
iii. EMI filter
iv. PCM midpoint ground (M1 and M2)
d. Jumper together all the line-side connections to the bridge input breakers.
e. Jumper together the PCM outputs BR+, BR-, and DX (M1 and M2).
f. Jumper together the poles of the 41DC output contactor.
g. Megger at 500 V dc. Impedance should be greater than 1 MΩ.
h. Undo these megger configuration steps before proceeding.
6. After wiring and tool accountability checks are complete, re-apply dc control power
from the battery and ac power to the PPT.
7. Prior to restarting the unit, complete the additional preliminary checks as described in
GEH-6783, EX2100e Excitation Control for Regulator Systems Installation and
Startup Guide, the section, Hardware Checks.

4.2 ToolboxST Application Downloads
Refer to GEH-6707, ToolboxST If any of the UCSB controllers were replaced during maintenance procedures, they must
User Guide for EX2100e be reconfigured to restart the control system, which requires the ToolboxST application
Excitation Control. software for the Regulator system. To download Regulator system software using the
ToolboxST application, open the exciter configuration (*.tcw) file for both controls, M1
All EX2100e control Regulator and M2.
system .tcw files are
pre-engineered.
Note GE provides the ToolboxST application on the ControlST DVD. Software files will
be available on the Turbine HMI or supplied separately.
4.2.1 UCSB Controller Configuration (M1 and M2)

Ø To configure the UCSB controller
Note A USB Flash drive is required if the IP settings of the UCSB controller must be
configured.
1. Follow the instructions provided in the ToolboxST application Download Wizard.

2. Download the file to the EX2100e control Regulator system.
3. Reset the control and check the board revisions.
4. Repeat steps 1 through 3 for each UCSB controller in the system (M1 and M2)
replaced during any maintenance procedures.
4.2.2 I/O and Feedbacks

Refer to GEH-6783, EX2100e Ø To check I/O and feedbacks
1. From the ToolboxST application Diagrams tab Tree View, select Overview.
and Startup Guide. 2. Click GP_In_Out and check all general-purpose I/O.
3. Click PTCT_Wiring and verify that all ESYS I/O is functioning correctly.
4. Click AnalogFbk1 and check all VCO feedbacks.
Hardware Verification and Checks GEH-6784D Maintenance Guide 69

4.3 Bridge Output and Operation Checks
Refer to GEH-6783, EX2100e Any maintenance procedures requiring removal or disconnecting the wiring from the
Excitation Control for PCM, SCM, or UCSB controller(s) requires a load test, which checks bridge output and
Regulator Systems Installation power converter operation. The turbine must be stopped or in turning gear for these tests
and Startup Guide, the chapter, to be performed.
Initial Startup and
Commissioning.
When power is applied, this equipment contains a potential
hazard of electric shock or burn. Only adequately trained
persons who are thoroughly familiar with the equipment and
the instructions should maintain this equipment.
Warning

for working around dangerous voltages. Make sure that bridge
power is turned OFF, then ground and discharge the equipment
before performing any adjustments, servicing, or other acts
Warning requiring physical contact with the electrical components or
wiring.
Tip Ä Checkout of the Regulator system from a temporary 120 V ac source can help to
identify wiring and configuration errors in a lower energy environment than if the main
power source to the Regulator system is used for initial operation checks.
Ø To perform a load test

1. Zero VCO offsets.
2. Check dc link voltage.
3. Check external breaker operation for SCT/PPT and Rotating DC applications.
4. Check manual voltage regulation and bridge firing.
5. Check control transfer operation for redundant systems, if applicable.

Glossary of Terms
Application code Software that controls the machine or process, specific to the
application.
Automatic Voltage Regulator (AVR) AVR is controller software that maintains the
generator terminal voltage through the Field Voltage Regulator.
Auxiliary source A source of three-phase ac power for the exciter, but not from the
generator being controlled.
Board Printed circuit board
Bus Upper bar for power transfer, also an electrical path for transmitting and receiving
data.
Configure To select specific options, either by setting the location of hardware

jumpers or loading software parameters into memory.
CT Current transformer, used to measure current in an ac power cable.
DACA Ac-to-dc converter for power supply, produces 125 V dc.
De-excitation The de-excitation circuit produces a conduction path through a

discharge resistor or inductor to dissipate the field current after a unit trip.
Device A configurable component of a control system.
Dual Redundancy An operation that uses two sets of control, I/O, and power
channels in a redundant configuration for higher reliability.
EDIS Exciter Power Distribution Module distributes 125 V dc to the power supplies.
EGD Ethernet Global Data, a control network and protocol for the controller. Devices
share data through EGD exchanges (pages).
Ethernet LAN with a 10/100 Mbit collision avoidance/collision detection system used
to link one or more computers together. Basis for TCP/IP and I/O services layers that
conform to the IEEE 802.3 standard.
EX2100e Exciter GE static exciter; regulates the generator field current to control the
generator output voltage.
Field flashing The supply of initial exciter current during startup, usually from station
batteries.
Field ground detector The field ground detector is an active circuit that detects a
ground in either the ac or dc sections of the exciter and field wiring.
Firmware The set of executable software that is stored in memory chips that hold their
content without electrical power, such as EEPROM or Flash.
Gating Controlling the conduction of the power IGBTs or SCRs with an input pulse
train (or a voltage).
GEH-6784D Glossary of Terms 71

HMI Human-machine Interface, usually a computer running Windows and
CIMPLICITY HMI software.
I/O Input/output interfaces that allow the flow of data into and out of a device.
IP address The address assigned to a device on an Ethernet communication network.
Line filter Filter networks across the three-phase input lines to the exciter to minimize
the voltage spikes that result from the abrupt decay of current during SCR commutations.
Power Conversion Module (PCM) The PCM or Bridge consists of six thyristors
connected in a three-phase bridge, with associated protection and control devices, to
generate the dc field voltage.
Power Current Transformer (PCT) A PCT can be attached to the generator line to
provide a portion of the three-phase power for the exciter, part of a compound source.
Power Distribution Module (EDIS) The PDM distributes 125 V dc to the power
supplies for the controllers and I/O termination boards.
Permanent Magnet Generator (PMG) source An application in which the exciter

receives ac power for the field from a PMG mounted on the shaft of the generator. The
PMG output frequency is typically 420 Hz or higher.
Power Potential Transformer (PPT) A PPT is attached to the generator terminals

or an auxiliary bus to provide three-phase power for the exciter; referred to as a potential
source.
Power System Stabilizer (PSS) PSS software produces a damping torque on the
generator to reduce generator oscillations.
Product code (runtime) Software stored in the controller's memory that converts
application code (pcode) to executable code.
PRV resistors These resistors reduce stress on the SCRs by balancing voltages on the
SCRs during pole slip events.
PT Potential Transformer, used for measuring voltage in a power cable.
Redundant A system containing of duplicated components (boards or modules),

which can transfer functionality from a failed component to one of the duplicate
components without loss of the entire system's functionality.
RTD Resistance Temperature Device, used for measuring temperature.
Runtime errors Controller problems indicated on the front panel by coded flashing
LEDs, and also in the Log View of the ToolboxST application.
Signal The basic unit for variable information in the controller.
Simplex System with only one set of control and I/O modules. Contrast with
redundant control systems.
TCP/IP Communications protocols developed to inter-network dissimilar systems. It is

a de facto UNIX standard, but is supported on almost all systems. TCP controls data
transfer and IP provides the routing for functions.
72 EX2100e Excitation Control for Regulator Systems

TMR Triple Modular Redundancy. An operation that uses three sets of control and I/O
(channels M1, M2, and C) and votes the results.
ToolboxST application A Windows-based software package used to configure the

EX2100e and Mark VIe turbine controller.
Touchscreen Diagnostic Display Interface also referred as keypad provides exciter

status icons and displays fault information. It can also be used to run the exciter, reset the
exciter, display data, and provide other control functions.
Unit Data Highway (UDH) Connects the EX2100e, Mark VIe turbine controllers,
LS2100e, PLCs, and other GE provided equipment to the HMI servers; runs at 10/100
Mbaud and supports peer-to-peer communications.
Warm backup (WBU) Two bridges are connected to the field but only one is actively
producing power. The other bridge does not receive gating pulses until it is required to
take over from the active bridge.
GEH-6784D Glossary of Terms 73

Notes
74 EX2100e Excitation Control for Regulator Systems

1501 Roanoke Blvd. GE Proprietary and Internal (Class II) – This document contains proprietary information of GE and
Salem, VA 24153 USA is intended for internal use only. It may not be used, shown, reproduced, or disclosed outside of GE
without the express written consent of GE.

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GEH-6784D

EX2100e Excitation Control Regulator Systems

Revised: Sept 2013

© 2010 – 2013 General Electric Company, All rights reserved.

We would appreciate your feedback about our documentation.

Indicates a procedure, condition, or statement that, if not

Indicates a procedure, condition, or statement that, if not

Indicates a procedure, condition, or statement that should be

GEH-6784D Maintenance Guide 3

This equipment contains a potential hazard of electric shock,

Isolation of test equipment from the equipment under test

Warning To minimize hazard of electrical shock or burn, approved

To prevent personal injury or equipment damage caused by

Always ensure that applicable standards and regulations are

4 GEH-6784D EX2100e Excitation Control for Regulator Systems

GEH-6784D Maintenance Guide 5

6 GEH-6784D EX2100e Excitation Control for Regulator Systems

Overview GEH-6784D Maintenance Guide 7

UCSB Controllers and 35 A Regulator System PCMs (Dual)

8 GEH-6784D EX2100e Excitation Control for Regulator Systems

1.1.2 Typical Maintenance Tools

Overview GEH-6784D Maintenance Guide 9

To prevent electric shock or burn while servicing the

Due to the large amount of energy passing through the exciter

Shock and burn hazard boundaries for the Excitation Control

To prevent personal injury or death, personnel must be aware

10 GEH-6784D EX2100e Excitation Control for Regulator Systems

Exciter Source MVA Upstream Fault AFPB HRC #

Overview GEH-6784D Maintenance Guide 11

For more information, refer to relevant standards, including:

• IEC 61230, Portable Equipment for Earthing or Earthing and Short-Circuiting

12 GEH-6784D EX2100e Excitation Control for Regulator Systems

Overview GEH-6784D Maintenance Guide 13

Personnel should perform the following safety practices:

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Overview GEH-6784D Maintenance Guide 15

16 GEH-6784D EX2100e Excitation Control for Regulator Systems

Overview GEH-6784D Maintenance Guide 17

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This equipment contains a potential hazard of electric shock or

To prevent electric shock while servicing the equipment,

2.1 Scheduled Maintenance Intervals

• How much the equipment is used

Preventive Maintenance GEH-6784D Maintenance Guide 19

• Verifies that equipment is routinely checked

2.3 Maintenance Procedures

To prevent electric shock, make sure all power supplies to the

Before performing any maintenance procedures, the exciter

Circuit breakers, fuses, and electromechanical devices within

The following procedures should be performed at appropriate intervals determined by the

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• Front-end diode modules

Preventive Maintenance GEH-6784D Maintenance Guide 21

Build up of dust on electrical components and wiring can

Build up of dust on components can increase operating temperature, reducing their

Ø To remove dust from the components

Do not use high-pressure compressed air, which may damage

If a blow nozzle with a tube extension is used, tape the area

22 GEH-6784D EX2100e Excitation Control for Regulator Systems

Normal household cleaners may leave a salt residue behind and

Note Contaminated Nomex™ insulation should not be reused.

Preventive Maintenance GEH-6784D Maintenance Guide 23

To prevent component damage caused by static electricity, treat