Ex2100 Startup Guide

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g

GE Industrial Systems

GEH-6631A

EX2100

™

Excitation Control

Full Static Control

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Chapter 1 Overview

Introduction...1-1 How to Use This Document...1-3 Structure of the Document...1-3 Text Conventions...1-3 How to Get Help...1-5 Equipment Covered ...1-5 Related Documents...1-7 Document Distribution ...1-7 Acronyms and Abbreviations ...1-8

Chapter 2 Installation Planning

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

Chapter 3 Handling and Mounting Guidelines

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

Chapter 4 Cabling and Connections

Introduction...4-1 Exciter Connections...4-2 Grounding and Cable Entry ...4-6 Cable Entry...4-6 Control Power...4-9 Converter Power ...4-10 Field Flashing ...4-11 Generator Field Connections ...4-11

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· Contents GEH-6631 EX2100 Installation and Startup ii

Signal and Communications Cabling Guidelines...4-11 Generator PT and CT Inputs...4-11 Contact Inputs...4-12 Data Highway...4-15 PC Interface ...4-16 Preventing Cable Damage...4-16

Chapter 5 Pre-Power On Installation Checks

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

Chapter 6 Initial Startup and Commissioning

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

Appendix A Understanding Equipment Drawings

Introduction...A-1 Data Nameplate...A-2 Identifying the Equipment ...A-3 Equipment Catalog Number ...A-3 Drawing Numbers...A-3 Outline Drawings...A-4 Panel Drawings ...A-4

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Elementary Diagrams ...A-5 Equipment Reference Information ...A-5 Elementary Drawing Number...A-5 Wire Number Identification...A-5 Conventions Used with Other Equipment ...A-6

Appendix B Cable Separation and Routing

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

Appendix C Installing Fiber-Optic Cable

Introduction... C-1 Cable Characteristics ... C-2 Cable Construction ... C-2 Data Integrity... C-2 Causes of Cable Damage... C-2 Handling Guidelines ... C-3 Environmental Guidelines ... C-4 Cable Assembly ... C-4 Tools and Materials ... C-4 Attaching a Connector... C-5 Polishing Fiber Ends... C-7 Inspecting Fiber Ends ... C-9 Connecting Fiber-Optic Cable to Modules ... C-11

Appendix D Printed Wiring Board Reference

Glossary of Terms

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

Chapter 1 Overview

Introduction

This document is an installation and startup guide for the EX2100ä Excitation Control (EX2100, see Figures 1-1 and 1-2). It assumes the following:

· All receiving, handling and storage procedures were strictly followed, as defined in document GEI-100256.

· You are ready to move the exciter(s) to the installation site. · The installation site was previously prepared and cables run per GE

specifications, and all necessary system parts are at the site. Additionally, these instructions require that the user:

· Be adequately trained to thoroughly understand and strictly follow all safety

procedures necessary for working with and around high voltages.

· Know the physical and electrical requirements of installing high voltage equipment.

· Understand the theory of exciter operation.

· Be experienced in using the EX2100 configuration software (the GE Control System Toolbox).

· Understand the structure and conventions of this document in order to follow the instructions exactly as required.

This first chapter provides an overview of how to use this document correctly, as follows:

Section Page

How to Use This Document ...1-3 Structure of the Document...1-3 Text Conventions ...1-3 How to Get Help...1-5 Equipment Covered ...1-5 Related Documents...1-7 Document Distribution ...1-7 Acronyms and Abbreviations ...1-8 The remainder of the document is organized in the order required for installing and starting the exciter (see How to Use This Document).

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Figure 1-1. Typical EX2100 Excitation Control

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How to Use This Document

Structure of the Document

GE recommends that a detailed installation log is maintained for the exciter as these installation and startup steps are completed.

Sections of related procedures are presented in the order that they should be

followed (see Figure 1-3).

Appendices provide reference information, as follows: · Appendix A, Understanding Equipment Drawings · Appendix B, Cable Separation and Routing · Appendix C, Installing Fiber-Optic Cable · Appendix D, Printed Wiring Board Reference

For an exact outline of the document’s organization, refer to the Table of Contents.

Text Conventions

Convention Meaning

Ø A procedure follows.

Numbered list Procedural steps to be followed in order (for example,

1, 2, 3).

Alphabetized list Procedural substeps (of numbered steps) to be followed in order (for example, a, b, c). Bulleted (·) list Related items or procedures, but order does not

matter.

w A procedure with only one step. Boxed (¨) list A checklist.

Arial Bold When describing software, indicates the actual command or option that is chosen from a menu or dialog box.

Monospace Represents examples of screen text or words and characters that are typed in a text box or at the command prompt.

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Chapter 2,

Handling and Mounting Guidelines

Connect cables & I/O wiring

Chapter 3,

Cabling and Connections

Mount and install

external devices Chapter 4,Device Installation

Start Procedures

Installation site ready, drawings & documents on hand, all site parts present

Verify correct functioning of connected devices (power, I/O) Chapter 5, Pre-Startup Installation Checks Startup Install a tion Move exciter to installation site and

install it

Apply power, start toolbox, run checks

Chapter 6,

Initial Setup and Operation Checks

End of Procedures

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How to Get Help

If help is needed beyond the instructions provided in the exciter system documentation, contact GE as follows:

“+” indicates the international access code required when calling from outside the USA.

GE Industrial Systems Product Service Engineering 1501 Roanoke Blvd.

Salem, VA 24153-6492 USA

Phone: + 1 888 GE4 SERV (888 434 7378, United States) + 1 540 378 3280 (International)

Fax: + 1 540 387 8606 (All)

Equipment Covered

In this document, the term “exciter” refers to the EX2100 digital static exciter.

An exciter is a combination of one or more power conversion modules (PCMs) with their associated control and protection equipment (see Figure 1-4). The generator field current and voltage requirements, and the redundancy requirements determine the number of PCMs and the total number of cabinets. The available exciter sizes are as follows: Exciter Current Capability PCM Redundancy Number of PCMs Number of Bridge/Aux. Cabinets Number of Control Cabinets Total Number of Cabinets 1000 A dc None, simplex 1 1 1 2 2000 A dc None, simplex 1 1 1 2 1000 A dc Warm backup 2 2 1 3 2000 A dc Warm backup 2 2 1 3

The EX2100 can be powered from the generator by a potential source (PPT only), or a compound source (PPT and PCT), or from an auxiliary ac source (through a PPT).

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Document Distribution

GE Industrial Systems supplies product documents to its customers to support the equipment provided for each requisition. The contract documents define the terms of the document distribution. If provided (per contract), the following documents contain requisition information about the exciter system.

· Requisition drawings, including outline and elementary diagrams · Renewal Parts listing

Note If differences exist between the general product documentation and the

requisition documentation, the requisition documentation should be considered the more exact representation of your equipment or system configuration.

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Acronyms and Abbreviations

A ampere(s) in-lbs inch-pounds (torque)

ac alternating current I/O input and output

ACLA Application Control Layer Module IPN intelligent part number

ACOM analog common J405 cable connector at row 4, location 05

AVR Automatic Voltage Regulator kg kilograms

C protection controller in a redundant system LAN local area network

CCOM control common LED light-emitting diode

CT current transformer level H high-level signal

DACA Ac to dc converter in control power supply level H(S) high-level signal, special handling

dc direct current level L low-level signal

DCOM digital common level M medium-level signal

DSPX Digital Signal Processor Board level P power signal

EACF Exciter Ac Feedback Board level P(S) power signal, special handling

EBKP Exciter Backplane Board m meters

ECTB Exciter Contact Terminal Board M1 primary controller

EDCF Exciter Dc Feedback Board M2 backup controller

EDEX Exciter De-excitation Board max maximum

EGD Ethernet Global Data min minimum

EGDM Exciter Ground Detector Module NEC National Electrical CodeÒ

EGPA Exciter Gate Pulse Amplifier Board OSHA Occupational Safety and Health Act

EISB Exciter ISBus Board P125 positive side of 125 V dc power supply

EMIO Exciter Main I/O board PC Personal Computer

EPBP Exciter Power Backplane PCM Power Conversion Module

EPCT Exciter PT/CT Board PCT Power Current Transformer

EPDM Exciter Power Distribution Module PLC programmable logic controller

EPSM Exciter Power Supply Module PPT Power Potential Transformer

ESEL Exciter Selector Board PSS Power System Stabilizer

EXAM Exciter Attenuator Module PT potential transformer

EXCS Exciter Current Sensor R125 return side of 125 V dc power supply

EXHS Exciter High-Speed Relay Driver Board RTDs resistance thermal devices

EXTB Exciter Terminal Board SCR silicon-controlled rectifier

ft foot, feet SHCOM shield common

ft-lbs foot-pounds (torque) TMR Triple Modular Redundant

ft/min feet per minute UEL Under Excitation Limit control

GE General Electric Company V ac volts ac (alternating current)

GPA Gate Pulse Amplifier VAR volt amperes reactive

HMI Human Machine Interface V dc volts dc (direct current)

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

Chapter 2 Installation Planning

Introduction

This chapter discusses installation planning and requirements for the EX2100 excitation control system. Specific topics include GE installation support, siting the equipment, and environmental requirements.

Before installation, consult and study all furnished drawings. These should include outline drawings, elementary diagram, connection diagrams, and a summary of the equipment.

This chapter is organized as follows:

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

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Installation Support

GE’s system warranty provisions require both quality installation and that a qualified service engineer be present at the initial equipment startup. To assist the customer, GE offers both standard and optional installation support. Standard support consists of documents that define and detail installation requirements. Optional support is typically the advisory services that the customer may purchase.

Early Planning

To help ensure a fast and accurate exchange of data, a planning meeting among all parties is recommended early in the project. This meeting should include the customer’s project management and construction engineering representatives as well as local GE service personnel. It should accomplish the following:

· Familiarize the customer and construction engineers with the equipment. · Set up a direct communication path between GE and the party making the

customer’s installation drawings.

· Determine a drawing distribution schedule that meets construction and installation needs.

· Establish working procedures and lines of communication for drawing distribution.

GE Installation Documents

Installation documents consist of both general and requisition-specific information. The cycle time and the project size determine the quantity and level of

documentation provided to the customer.

General information, such as this manual, provides product-specific guidelines for the equipment. They are intended as supplements to the requisition-specific information.

Requisition documents, such as outline drawings and elementary diagrams; provide data specific to a custom application. Therefore, they reflect the customer’s specific installation needs and should be used as the primary data source.

As-Shipped Drawings

These drawings include changes made during manufacturing and test. They are issued when the equipment is ready to ship. As Shipped drawings consist primarily of elementary diagrams revised to incorporate any revisions or changes made during manufacture and test.

Revisions made after the equipment ships, but before start of installation, are sent as a Field Change, with the changes circled and dated.

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Technical Advisory Options

To assist the customer, GE Power Systems offers the optional technical advisory services of field engineers for:

· Review of customer’s installation plan · Installation support

These services are not normally included as installation support or in basic startup and commissioning services, shown in Figure 2-1. GE presents installation support options to the customer during the contract negotiation phase.

Installation Support Startup Commissioning Begin Installation Complete Installation System Acceptance

Product Support - On going Begin

Formal Testing

Figure 2-1. Startup and Commissioning Services Cycle

Review of Installation Plan

It is recommended that a GE field representative review all installation/construction drawings, and the cable and conduit schedule when completed. This optional review service ensures that the drawings meet installation requirements and are complete.

Installation Support

Optional installation support is offered: planning, practices, equipment placement, and onsite interpretation of construction and equipment drawings. Engineering services are also offered to develop transition and implementation plans to install and commission new equipment in both new and existing (revamp) facilities.

Customer’s Conduit and Cable Schedule

The customer’s finished conduit and cable schedule should include: · Interconnection wire list (optional)

· Level definitions · Shield terminations

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Level Definitions

The cable and conduit schedule should define signal levels and classes of wiring (see section, Cable and Conduit Routing and Schedules and Appendix B). This

information should be listed in a separate column to help prevent installation errors. The cable and conduit schedule should include the signal level definitions in the instructions. This provides all level restriction and practice information needed before installing cables.

Shield Terminations

The conduit and cable schedule should indicate shield termination practice for each shielded cable (refer to the section, Cable and Conduit Routing and Schedules and

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Siting EX2100 Equipment

Prior to receipt of the equipment, all plans should be finalized as to the location the equipment will be installed. This section is a general guide as to the factors that may influence the choice of this site.

Operating Environment

Of prime concern in the choice of equipment location is the operating environment. The EX2100 control panel is suited to most industrial environments. To ensure proper performance and normal operational life, the environment should be maintained as follows:

Ambient temperature (acceptable): Control Module 0 °C (32 °F) to 45 °C (113 °F) PCM Module 0 °C (32 °F) to 50 °C (122 °F) Ambient temperature (preferred): 20 °C (68 °F) to 30 °C (87 °F) Maximum rate of temperature change: 0.1ºC per min

Relative humidity: 5 to 95%, non-condensing. Maximum rate of relative humidity change: 1% per min

Note Higher ambient temperature decreases the life expectancy of any electronic

component. Keeping ambient air in the preferred (cooler) range should extend component life.

Maximum concentration of corrosive gases at 50% relative humidity and 40ºC per EN50178: 1994 Section A.6.1.4 Table A.2 (m).

Sulfur dioxide (SO2) 30 ppb Hydrogen sulfide (H2S) 10 ppb Nitrous fumes (NOx) 30 ppb Chlorine (Cl2) 10 ppb Hydrogen fluoride (HF) 10 ppb Ammonia (NH3) 500 ppb Ozone (O3) 5 ppb

Particle sizes from 10 - 100 microns for the following materials:

Aluminum Oxide Sand/Dirt Cement Lint Coal/Carbon dust Steel Mill Oxides Paper Soot Ink

Seismic: Universal Building Code (UBC) - Seismic Code section 2312 Zone 4 Vibration: Maximum of 1.0 G horizontal, 0.5 G vertical @ 15 to 120 Hz. Elevation: Normal Operation: 0 to 3000 feet (101.3 – 89.8 KPa)

Extended Operation: 3300 – 10000 feet (89.8 – 69.7 KPa) Shipping: 15000 feet maximum (57.2 KPa)

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Environments that include excessive amounts of any of the following elements reduce panel performance and life:

· Power line fluctuations.

· Electromagnetic interference or noise introduced by:

- Radio frequency signals, typically from nearby portable transmitters. - Stray high voltage or high frequency signals, typically produced by arc

welders, unsuppressed relays, contactors, or brake coils operating near control circuits.

The preferred location for the EX2100 excitation control system cabinet would be in an environmentally controlled room. The panel should be mounted where the floor surface allows for attachment in one plane (a flat, level, and continuous surface). The mounting hardware is provided by the customer. Lifting lugs are provided and if used, the lifting cables must not exceed 45° from the vertical plane. Finally, the panel is equipped with a door handle, which can be locked for security.

Equipment Clearances

Each EX2100 is supplied with an outline drawing that provides the physical dimensions of the cabinet. Overhead clearance for fan discharge and front panel clearance for personell entry and egress are particularly important. Sufficient space for the equipement must be allocated such that the following minimum clearances are maintained:

Excitation Cabinet Sidewalls: 0 inches minimum. Excitation Cabinet Rear Panel: 0 inches minimum

Excitation Cabinet Top Panel: 6 inches minimum (12 inches preferred) from highest protrusion of fans, line filters, and de-excitation resistors.

Excitation Cabinet Doors: 24 inches minimum with doors open at a 90 degree angle.

Special attention to the door clearances should be made in order to maintain compliance with local regulations regarding proper entry and egress to working spaces.

Cable and Conduit Routing and Schedules

Interconnecting cables can be brought into the panel from the top or the bottom via removable access plates. Review of equipment spaces prior to installation should include access to the area via cable trays and conduit, station grounds, routing of interconnecting bus and location of the excitation transformer.

A thorough cable and conduit schedule should be developed to allow proper planning of the necessary materials and time to install the EX2100 using the interconnection information provided in the system elementary.

Size and location of external station service requirements for lighting, heaters, power supplies and other equipment should be reviewed. Attention to items that will facilitate plant lock-out and tag-out procedures should be followed.

Proper cooling of the panel requires that conduits be sealed to the access plates. Also, air passing through the conduit must be within the acceptable temperature range, as listed above. This applies to both top and bottom access plates. Appendix B of this document addresses other cable routing and separation concerns.

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GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines · 3-1

Chapter 3 Handling and Mounting

Guidelines

Introduction

GE document GEI-100256 provides receiving and storage guidelines.

This chapter provides general guidelines for moving the exciter to the installation site, and then installing it. The requisition drawings provided with the equipment provide specific information and are a required supplement to this document. This chapter is organized as follows:

Exciter Handling Procedures...3-2 Lifting...3-2 Moving ...3-3 Unpacking ...3-4 Mounting ...3-5 Securing the Exciter Lineup to the Floor...3-8

Note Dimensions shown in Figures in this chapter are given in inches with

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Exciter Handling Procedures

Shock or stress caused by rough handling or improper lifting and moving can damage the equipment. Be sure to follow the guidelines provided in this chapter.

The shipped equipment consists of three cabinets secured together in a lineup, typically not exceeding 15 ft in length.

GE recommends that you do not completely unpack the equipment until it has been moved as near as possible to its permanent location. This practice helps ensure that loose parts remain with the exciter. Additionally, the shipping enclosure helps protect the equipment during storage.

Before lifting and moving the exciter, always refer to the equipment outline

drawings. Become familiar with the designated lift points and the stress points, and any specified handling instructions.

While lifting and moving the exciter, be sure to follow the suggested methods in

this chapter for handling the equipment, along with normal handling precautions. Additionally, it is important to observe any instructions that may be printed on or attached to the equipment container or wrapping.

Lifting

Lifting beams are attached across the top of the exciter at the factory.

· Make sure that the lifting equipment is suitable for the configuration and weight of the exciter as follows:

- 1000 A – 4400 lbs / 1996 kg - 2000 A – 5600 lbs / 2535 kg · Observe the center-of-gravity.

· Use four hooks for lifting at the openings in the lifting beam (see Figure 3-1). · Make sure the lifting beams are tightly secured to the exciter (see Figure 3-2). · The lift cables should be at an angle greater than 45 degrees from the horizontal.

Use spreader bars or similar equipment to ensure this angle (see Figure 3-2). · Lift the exciter(s) in a slow and steady manner to an acceptable clearance height. · Check for any flexing of the equipment. If noticed, lower the lineup and

re-position the cables.

Do not lift and move the exciter using equipment that applies pressure from below, such as a forklift. Doing so could damage the exciter frame. If a crane is not available for lifting, contact GE for guidelines on using other methods.

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GEH-6631 EX2100 Installation and Startup Chapter 3 Handling and MountingGuidelines · 3-3 Use four hooks in openings

in lifting beams (two in front and two in back).

Angle must be 45 degrees or greater.

Figure 3-2. Proper Lifting Method for EX2100 Lineup

Moving

· When using a crane, be sure that motions are slow and smooth so that the equipment does not swing.

· If using other moving devices, such as rollers:

- Be sure to place the rollers at the shipping splits and at the corners to reduce potential stress.

- Roll only on the shipping pallets that are attached to the cabinets when shipped from the factory.

· Do not move with a forklift, since the weight of the exciter against the forklift tines would put damaging pressure on the exciter frame.

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Unpacking

Recommended: Do not

completely unpack the equipment until it is placed as near as possible to its permanent location.

· If the equipment has been exposed to low temperatures for an extended period, do not unpack it until it has reached room temperature (location where exciter will be mounted).

· Use standard unpacking tools, including a nail puller.

· When unpacking, check the contents of each case against the packing list. Report any shortage to GE.

· Carefully remove the packaging and move the equipment from its container, still observing all lifting and handling guidelines.

· While unpacking, inspect for damage that may not have been detected at the time of receipt.

· Wipe off any particles of packing materials or foreign substances that may be lodged in or between the parts.

· Small parts (such as bolts and screws) are packed in special containers to keep them together, but may become separated. For this reason, carefully inspect the packing material for loose parts before discarding it.

Document and report any

equipment damage to GE. Ø If equipment damage is discovered while unpacking_{1. Stop unpacking immediately and report this finding to the carrier (transportation}

company).

2. Photograph the damage (photographs may be needed later in processing the claim).

3. File a claim with the carrier.

4. Contact the local service office of GE Industrial Systems for assistance. 5. When identifying missing or damaged parts, be sure to includethe following

information (refer to Appendix A): · Serial number

· Part (model) number · Exciter code

· GE requisition number · Case number

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Mounting

Figures 3-3 through 3-5 are simplified outline drawing examples that provide the following installation data:

· Exciter dimensions · Door clearance · Exciter weight · Heat loss

· Airflow requirements

· Mounting base bolt hole location

Note Dimensions shown in Figures 3-3 through 3-5 are given in inches with

millimeters shown in parantheses.

The requisition outline drawings show specific lineup and installation details.

Along with the information shown on the outline drawings, use the following mounting guidelines:

· The mounting surface should be smooth and level to prevent door misalignment. · Position the exciter to permit heat radiation from all surfaces and proper

ventilation (cooling air).

· Provide front clearance of at least the width of the enclosure door so that the door can be fully opened for easy access.

· Lifting beams must be removed to allow for redundant fans to be replaced. · Lifting beams must be removed if discharge resistors will be mounted on the top

of the cabinet.

· If lifting beams are removed after positioning the equipment, then lifting beam hardware must be replaced in the holes in the enclosure top and re-tightened.

Connecting the Grounds

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

The ground connections must be complete to ensure proper grounding of the equipment.

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Exciter

Size Weight (kg / lbs) Heat Loss(Watts)* Airflow Req.(ft3/min)** Standard OutlineDwg.

1000 A 1996/4400 5,000 2500 151X1207AA1SA01

2000 A 2535 /5,600 10,000 2500 151X1207AA1SA01

*Two PCMs per cabinet, one active in warm backup configuration. **Airflow throughput requirements for proper cooling.

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Securing the Exciter Lineup to the Floor

The exciter lineup must be secured to the floor using mounting studs. Figure 3-5 shows the location of mounting holes in the exciter base. Refer to the exciter outline drawing sheet 1 for additional information about securing the lineup.

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GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-1

Chapter 4 Cabling and

Connections

Introduction

This chapter assumes that cabling was previously run to the installation site and is ready for connection to the exciter.

This chapter contains guidelines for connecting cable to the exciter during installation. This information must be used along with the project specific elementary diagrams and outline diagrams supplied with the equipment.

Do not assume any cable or any circuitry to be without power if one end of that cable could be connected to a power source. To prevent accidental electrical shock, do not touch any circuitry or bare wire without first ensuring that it does not carry electricity.

When testing for the presence of electricity and when measuring any electrical circuit, use only the equipment approved for contact with those voltage levels.

All installations should meet the requirements of both the National Electrical Code® (NEC®) and any applicable local codes. Use these codes to determine such factors as wire size, insulation type, and conduit sizing. This chapter is organized as follows:

Exciter Connections...4-2 Grounding and Cable Entry...4-6 Cable Entry...4-6 Control Power...4-9 Converter Power...4-10 Field Flashing (Optional)...4-11 Generator Field Connections ...4-11 Signal and Communications Cabling Guidelines ...4-11 Generator PT and CT Inputs...4-11 Contact Inputs ...4-12 Data Highway...4-15 PC Interface...4-16 Preventing Cable Damage ...4-16

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Exciter Connections

Cabling and wiring connections to the exciter include the following: · One cabinet ground

· Incoming ac control power (terminals on the Exciter Power Distribution Module)

· Incoming dc control power (terminals on the Exciter Power Distribution Module)

· Incoming ac power to the Power Conversion Cabinet. · Power for field flashing (terminals in the Auxiliary cabinet)

· Dc outgoing power connections to the generator field (Field+, Field-) · Exciter I/O connections to terminal boards (contact inputs to ECTB board)

Note The component nomenclature examples (see Figures 4-1, 4-2, and 4-3) show

the location of connection points, fuses, and other exciter components. A device

nomenclature sticker, located on the inside of the exciter cabinet door identifies the

exciter’s major components and their locations within the cabinet. Complete outline diagrams are supplied with the exciter.

The exciter User’s Guide, GEH-6632, describes the terminal board I/O.

Customer cabling to the exciter’s terminal boards must comply with level-separation guidelines (refer to Appendix B) after it enters the exciter cabinet. To meet CE

Mark requirements, all I/O wires leaving a building must be routed inside

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

Space Heater 1 (optional)

Cutout for Customer Connections

DACA 1 (DACA 2 optional)

Power Supply Rack

TB1 ECTB Wiring (Refer to elementary sheet 7A and 11A for details)

Breaker 3 120 V ac, 5 A Breaker 1, 2 120 V ac, 15 A CT2 CT1 (optional) PT2 PT1 EPCT ECTB Cutout for Customer

Connections

EXHS/EXTB Control Rack

Ethernet Link to ACLA

(Refer to elementary sheet 8A and 11A for details)

EPDM (FU1 – FU12 on EPDM, refer to elementary sheet 7A and 11A for details)

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Figure 4-2. Sample Component Layout, Exciter Auxiliary Cabinet

Ac Line Filter

LFU2 (optional), FU1 – FU3 LFU1, FU1 – FU3

EACF

Ac input from PPT

Phase A – Front Shunt Phase B – Middle Shunt Phase C – Rear Shunt Ground Lug

Dc Field Flashing (optional) FF, FU1 and FU2

Space Heater 2 (optional) (optional) PTB1 125 V dc, 15% AFNL De-excitation Module (optional) EDCF - C (optional) EDCF – M2 EDCF – M1 EXAM Shaft Voltage Suppressor

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Figure 4-3. Sample Component Layout, Exciter Power Conversion Cabinet

Dc Bus Connections (optional) Ground Lug Dc Contactors 41A, 41B (optional) Ac Disconnect (less than 600 V ac applications only) Ground Lug Ac Input Connections (optional) Dc Bus Connnections Fans 4 – 6 (optional) Fans 1 – 3 EGPA M1 EGPA M2 Drip Shield (optional)

Bridge 2 Bridge 1

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Grounding and Cable Entry

For both safety and proper functioning of the equipment, it is important that the exciter be properly grounded. The installation site must have a reliable building grounding system and the exciter’s grounding cable must be securely fastened to this system per the elementary diagram. Follow the procedures provided in the EX2100 requisition elementary diagram sheet 0D, Grounding Instructions. Complete instructions, recommended cable sizes, and diagrams are provided there.

Note If you have an engineered system, consult your requisition elementary

drawings for the grounding method recommended for your installation.

For shielded and twisted wire, ground the shields on one end only, preferably at the exciter end. Provisions have been made to tie shields to chassis ground on several exciter terminal boards.

Cable Entry

See EX2100 outline drawings for complete information.

Removable access panels for cable entry are provided in the top and bottom of the control cabinet, the bottom of the auxiliary cabinet, and the bottom of the converter portion of the power conversion cabinet. Refer to Figures 4-4 through 4-6 for the location of these panels. Refer to Figures 4-7 and 4-8 for connection point locations.

Figure 4-4. Control Cabinet Cable Entries

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Figure 4-6. Converter Cable Entry (Power Conversion Cabinet)

Figure 4-7. Auxiliary Cabinet Power Connection Points

Standard Ac Connections

Ground Bus Optional Ac

Connections

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Figure 4-8. Power Conversion Cabinet Power Connection Points

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Control Power

The exciter requisition drawings specify the power requirements for the application and show connection points.

The exciter control power requirements are as follows:

Voltage: Nominal 115 V ac, ±15% at 60 Hz; single phase, 10 A rms max Nominal 125 V dc from battery, 10.6 A dc max

Nominal line frequency: 50 or 60 Hz, ±2%

The ac to dc converter(s) (DACA) are mounted at the bottom of the control cabinet.

The Exciter Power Distribution Module (EPDM) produces 125 V dc for the control power modules. It is located on the side of the power supply module. Redundant power sources for the control modules ensure high supply reliability. Both ac and dc sources are wired to TB1 on the EPDM, refer to Figure 4-9. A second ac source and DACA can be used if required.

J9 1 3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 1₀ 3 12 JDACA2 JDACA1 1 1₀ 3 12 J8A J8B J8C J1M1 J1M2 J1C SW3 SW1 SW2 SW4 SW5 SW6 SW7 SPRE P125Vdc 2 4 6 8 10 12 14 16 18 20 22 24 x x x x x x x x x x x x x 1 3 5 7 9 11 13 15 17 19 21 23 x x x x x x x x x x x x x TB1 P125Vdc P125Vdc R125Vdc R125Vdc R125Vdc AC1H AC1H AC1N AC1N AC2H AC2H AC2N AC2N 125 V dc from battery 115 V ac supply #1 115 V ac supply #2

EPDM Exciter Power Distribution Module

Figure 4-9. Control Power Input Connections to Power Distribution Module

The EPDM outputs feed 125 V dc to the three exciter power supply modules (EPSMs), and the EGPA and EXTB OR EXHS boards. Individual outputs are fused and can be isolated with a switch.

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Converter Power

The main ac power supply for the exciter can come from a potential source, a compound source, or an auxiliary bus. Figure 4-10 shows supply from a power potential transformer (PPT) connected to the generator output.

Exciter Power Conversion Cabinet

To Bridge 1 and Line Filters H3 H2 H1 X3 X2 X1 PPT P R I V A C : 12470 SE C VAC : 6 50 KVA 1280 L3 L2 L1 K3 K2 K1 41AC1 1 2 3 Phase Rotation

Figure 4-10. Power Potential Transformer Connections

Power is brought into the power conversion cabinet on either cables or a bus. Specification of this supply is the responsibility of the user or his engineering company. If help is needed contact:

“+” indicates the international access code required when calling from outside the USA.

GE Industrial Systems Product Service Engineering 1501 Roanoke Blvd.

Salem, VA 24153-6492 USA

Phone: + 1 888 GE4 SERV (888 434 7378, United States) + 1 540 378 3280 (International)

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Field Flashing (Optional)

Figure 4-11 shows the optional Field Flashing Module noting the locations of the station battery terminals and fuses FU1 and FU2. Other connections to the module include status contacts from the EXHS board. Power output goes to the generator field. Refer to the elementary diagram sheet 4A for additional information.

Figure 4-11. Field Flashing Module

Generator Field Connections

The external generator field connections must be meet all applicable codes and comply with the generator manufacturer’s guidelines. Connecting cables must be sized properly and insulated per IEEE 421-3 guidelines.

Signal and Communications Cabling Guidelines

· Be sure to strictly follow the cable manufacturer’s installation instructions. These will vary based on the type of installation required.

· To meet CE Mark requirements, all I/O wires leaving a building must be routed inside continuous metal conduit.

Generator PT and CT Inputs

The generator PTs and CTs are customer supplied. The connections to the switches in the control cabinet are shown in Figure 4-12.

Note Connections on the CTs can be either 1 amp or 5 amp. Refer to the elementary

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5 31 6 42 31 42 31 42 PTSW1 H3 H2 H1 X3 X2 X1 PT1 P R I V A C : 14400 SEC VAC : 1 20 (OP E N OR GROUNDE D Y ) 5 31 6 42 PTSW2 H3 H2 H1 X3 X2 X1 PT2 P R I V A C : 14400 SEC VAC : 1 20 (OP E N OR GROUNDE D Y ) CTSW3 CTSW1 -Supplied by Others To Bridge 1 Generator Field + Generator Field -PT CT PT PT PT CT EPCT 5H 5L 1H 1L 5H 5L 1H 1L X1 X2 X1 X2 Phase Rotation + Fan-out c irc ui ts J305 J308 J315 To EMIO (M1) To EMIO (M2) To EMIO (C) Exciter Control cabinet

1 3 5 7 9 11 13 15 2 4 6 8 10 12 14 16 17 19 21 23 18 20 22 24 TB1 43 21 TB2 43 21 TB3 1 2 3 CT CT

Figure 4-12. Typical PT and CT Connections to Switches in Power Conversion Cabinet

The cable length between the PT and the EPCT board can be up to 1000 ft (305 meters) of #12 AWG twisted shielded wire. The cable length between the CT and the EPCT board can be up to 1000 ft (305 meters), using up to #10 AWG wire.

Contact Inputs

The ECTB board provides terminals for contact inputs from the customer's devices. Six auxiliary contact inputs, and contact inputs from 52G and 86G are

accommodated. These contacts are wetted with 70 V dc from ECTB. See Figures 4-13 and 4-14 for ECTB layout diagrams. For specific terminal information, refer to GEI-100457.

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GEH-6631 EX2100 Installation and Startup Chapter 4 Cabling and Connections · 4-13 Four General Purpose Relay Outputs as

Customer Power to Contacts 125 V dc

Two Trip Relay Outputs as P24M1 Customer Power to Contacts 125 V dc (1 of 2) Coil K#M1 Relay Driver M1 M1 J405 Auxiliary Contact Inputs

Six Circuits as Above

86G Contact 52G Contact P70Vdc Current Limit Red LED P70Vdc Current Limit Red LED From M1 (EMIO) P70Vdc P70 V dc Coil K#GP Relay Driver P24D From M1 J13M1 NO COM NC P24M1

ECTBG2 (Simplex)

TB1 TB2 Current Limit To Optocoupler on M1 (EMIO) P24D 18 19 20 1 5 33 34 45 46 47

48 (Openfor Trip) (Closed online) Term. 1&5 Ex. trip to Customer 86 (1 of 6)

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Four General Purpose Relay Outputs as

Customer Power to Contacts 125 V dc

Two Trip Relay Outputs as P24M1 Customer Power to Contacts 125 V dc Coil K#M2 Relay Driver Coil K#M1 Relay Driver Coil K#C Relay Driver M1 M2 C M2 C M1 P24M2 P24C J405 J408 J415 M1 M2 C From M2 (EMIO) From C (EMIO) Auxiliary Contact Inputs

Six Circuits as Above

86G Contact 52G Contact P70Vdc Current Limit Red LED P70Vdc Current Limit Red LED M1 M2 C From M1 (EMIO) Current Limit P70Vdc Current Limit Current Limit To M1 (EMIO) To M2 (EMIO) To C (EMIO) From M2 J13M2 P70 V dc P70M2 P24D P24M1 P24M2 Coil K#GP Voted Relay Driver P24D From M1 J13M1P70M1 NO COM NC P24M1 P24M2 ECTBG1 (Redundant) TB1 TB2 18 19 20 1 5 33 34 45 47 46 48 Term. 1&5 Ex. Trip to Customer 86 (Closed online) (Open for Trip) (1 of 6)

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Data Highway

A typical exciter connection to the redundant Unit Data Highway (UDH) network is shown in Figure 4-15. This shows redundant control with two ACLA modules, (simplex control has one ACLA with one UDH). The UDH is implemented using commercially available fast Ethernet switches. 10Base-T cabling is used for short distances between the controller and the T-Switch, and any local HMI. 100Base-FX fiber-optic cabling is used for longer distances between the local control area and the central control room.

Ethernet Port, RJ-45 EN ET COM 2 1 S T A T U S ACLA H1A gGEIndustrial Systems EN ET COM 2 1 S T A T U S ACLA H1A gGEIndustrial Systems

From other Units From other Units

From other Controllers From other Controllers T-Switch B

T-Switch A

100Base-FX connections

Local Control Area

To local HMI Viewer, 10Base-T 10Base-T connections Exciter Control Cabinet Central Control Room

Fast Ethernet Switch A Fast Ethernet Switch B

Figure 4-15. Ethernet Cable Connections

The 10Base-T ports in the ACLA and the T-Switch use RJ-45 connectors. The maximum distance using unshielded twisted pair cable is 328 ft (100 meters). The 100Base-FX ports in the T-Switch and the Fast Ethernet Switch are for SC type fiber-optic connectors. The maximum distance using 100Base-FX fiber-optic cables is 2 km.

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PC Interface

Control program downloads are usually made from a PC on the UDH Unit Data Highway using the toolbox software.

A PC can be connected to the controller to download firmware into the DSPX board. The PC connects to J303B (M1 Tool) located on the control rack backplane. In a redundant system, connectors J310B or J313B can be used for accessing the DSPX board in M2 or C.

Note The PC-to-exciter cable is not provided with the exciter and must be ordered

separately. Part numbers are:

336A3582P1 COM1 to EX2100 backplane or keypad 9-pin D connector 336A4929G1 COM1 to EX2100 ACLA serial port 9-pin micro D connector

Preventing Cable Damage

· Be sure to comply with OSHA and other applicable regulations.

· Observe minimum installation temperature to avoid damage to shielding and insulation.

· Do not pull cables around corners with sharp edges or corners that prohibit the minimum allowable cable-pulling radius.

· Avoid high mechanical stress (pull tension). The cable should not be excessively twisted, stretched, or flexed.

· Before pulling cable, inspect all cable trays. Cable should only be pulled into clean trays. Install bushings and dropouts, as necessary.

· Make sure that cable ends are sealed before, during, and after pulling the cable. This prevents the entrance of water or other contaminants.

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GEH-6631 Installation and Startup Guide Chapter 5 Pre-Power On Installation Checks · 5-1

Chapter 5 Pre-Power On

Installation Checks

Introduction

This chapter must be completed before applying power to the excitation system.

This chapter contains instructions to verify that the EX2100 lineup is ready for initial power up. This includes checks and procedures to ensure that the exciter has been installed correctly and can be safely energized.

All instructions must be followed and completed in the order

presented.

It is good practice to check off each procedure when you complete it. For this purpose, this chapter includes

checkboxes next to each procedure heading.

This chapter assumes that the excitation lineup and connected devices have already been installed, and that all wiring and cabling are installed correctly including control and power connections. It is presented as follows:

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

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Equipment/Material Needed

Checkboxes should be marked to verify that equipment is onhand.

Check that the following equipment and materials are available for the procedures in this chapter.

o Locks and tags, danger and caution tape

o Source of low-pressure, compressed, dry air (less than 15 psi) or clean, dry cloth

o Small standard (flat-head) screwdriver

o Torque wrench

o Socket sets, standard and metric

o Digital multimeter

o One dc megger tester (voltage not to exceed 500 V), optional

o EX2100 unit specific Elementary Diagrams.

o EX2100 unit specific Outline Drawings.

o EX2100 User’s Guide, document GEH-6632

o EX2100 Circuit Card GEI Instructions (refer to Appendix D for list)

Securing the Equipment for Safety

o All procedures in this section were completed successfully.

1. Lock out and tag out all voltage sources to the exciter. Apply safety grounds per local rules and regulations.

2. Place appropriate barriers and warnings at the generator brush rigging while testing.

3. Verify that the generator collector ring brushes are not installed and/or the exciter generator field leads are disconnected at the EX2100 cabinet.

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Hardware Checks

o All procedures in this section were completed successfully for:

o Control o Auxiliary

o Power Conversion

All exciters are factory-tested and operable when shipped to the installation site. However, connections could loosen during shipping and handling. To help ensure successful startup, check the hardware after installation and before initial powerup. Ø Check EX2100 hardware as follows

1. Become familiar with the exciter one-line on elementary sheet 1A.

2. Make sure that the equipment is secured for safety as required in the previous section.

3. Using an approved tester for the voltage levels being measured, verify that power has not yet been applied to the circuitry.

With power applied, high voltages are present on some circuitry. To prevent accidental injury, do not touch any circuitry without first ensuring that it does not carry these voltages and is grounded.

When testing for the presence of high voltages and when measuring any electrical circuit, use only the equipment approved for contact with those voltage levels.

4. Using either low-pressure, compressed, dry air or a clean, dry rag, remove any dust that may have accumulated in the exciter’s interior.

5. Inspect wiring to ensure that it has not been damaged or frayed during installation. Replace if necessary.

6. Check that all electrical terminal connections are tight.

7. Check that all devices, modules, and boards have not been damaged during handling or installation and that they are secure in their mounting connections.

To prevent component damage caused by static electricity, treat all boards and devices with static-sensitive handling techniques. Wear a wrist grounding strap when handling boards or components, but only after boards or components have been removed from potentially energized equipment and are at a normally grounded workstation.

Note To ensure that electrical connections remain tight, re-check them within three

to six months after initial powerup, and annually thereafter. Use screwdrivers and torque wrenches for these checks.

8. Check that the correct shunt has been installed and that the shunt cables are installed correctly. (Refer to the elementary data sheet 0E.)

9. Check fusing in the excitation cabinet. (Refer to the elementary sheet 0E or to the nomenclature sticker located inside the excitation cabinet door).

10. Verify that all control power switches on the Power Distribution Module are in the off or open position. All power disconnects and circuit breakers should be open.

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11. Verify that the circuit cards listed on the EX2100 elementary data sheet 0E have correct settings for hardware jumpers. Location of hardware jumpers can be found using the appropriate card GEI (refer to Appendix D for list).

12. Check incoming wiring/cabling, as follows:

· It should be complete and agree with the elementary drawings supplied with the EX2100.

· It should conform to the cable separation guidelines defined in Appendix B. 13. Verify that the cabinet is properly grounded. Reference elementary sheet 0D. 14. Operate each magnetic device by hand to make sure that all moving parts

operate freely. Check all electrical interlocks for proper operation. 15. Verify that the incoming and outgoing buses are not grounded. To do this:

· Either use an ohmmeter to measure all buses connected to the exciter to ground to ensure insulation integrity,

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Optional Megger Test

A megger (megohm meter) measures resistance by placing voltage across a device with respect to ground.

This optional test verifies that the system-to-ground insulation has not been damaged during installation. All EX2100 lineups have been high potential tested prior to shipment. It is recommended that the EX2100 be disconnected from all bus or cables to be megger checked.

To prevent circuit damage:

· The megger voltage should not exceed 500 V dc.

· Do not use ac meggers for this procedure.

Pre-Test Power Checks

With power applied, dangerous voltages are present on some circuitry. To prevent accidental injury, do not touch any circuitry without first ensuring that it does not carry these voltages and is grounded.

Ø Before conducting the megger test on any component, check for the

presence of power on the circuitry, as follows

1. Check that the ac bridge power, PPT primary power, and all sources of control power have been locked out and tagged out.

The exciter outline drawing shows location of fuses, disconnects, and other components within the excitation cabinet.

2. Open all the control power inputs and AC input disconnect (circuit breaker or switch) in the power conversion module.

Note There could be multiple sources of power in the enclosure.

3. Remove all collector ring brushes from the generator brush rigging. Place appropriate barriers and warnings at the brush rigging while testing.

4. Using a voltmeter, check that the bus voltages have discharged to below 1 volt on the following circuits.

Use the checkbox to mark

each completed measurement. o _o PPT input line to line_{PPT input line to ground} o Dc output positive to negative

o Dc output positive and negative to ground

Ac Input Bus and PPT Secondary

o All procedures in Ac Input Bus and PPT Secondary megger were completed successfully.

1. Do not proceed until completing all requirements under Pre-Test Power Checks 2. Short the ac input buses together using jumpers or wire.

3. Connect one side of the megger to one of the buses and the other side to ground. 4. Apply the megger voltage (not exceeding 500 V dc). The reading should be

greater than 100 megohms.

5. If readings are low, identify and correct the problem before proceeding. 6. Remove all jumpers or wires from the bus before applying any power.

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Dc Output Bus

o All procedures in Dc Output Bus megger section were completed successfully.

1. Do not proceed until completing all requirements under Pre-Test Power Checks. 2. Short the dc output buses together using jumpers or wire.

3. Connect one side of the megger to one of the buses and the other side to ground. 4. Apply the megger voltage (not exceeding 500 V dc). The reading should be

greater than 100 megohms.

5. If readings are low, identify and correct the problem before proceeding. 6. Remove all jumpers or wires from the bus before applying any power.

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GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning _{· 6-1}

Chapter 6 Initial Startup and

Commissioning

Introduction

. This chapter provides instructions to verify that the EX2100 excitation system is ready for operation. This includes control power checks, software setup, use of the keypad and offline and online commissioning guidelines.

This chapter is organized as follows:

Before Beginning...6-2 Order of Startup...6-2 Information Needed...6-2 Equipment/Material Needed...6-3 Panel Lights, Heaters and Fans...6-6 Verifying Control Power ...6-8 Control Module Processor Start ...6-12 Using the Exciter Configuration Tools...6-13 Using Toolbox Online Help ...6-13 Starting the Toolbox...6-14 Open an EX2100 File...6-14 Checking Toolbox/EX2100 Pattern Compatibility ...6-14 Downloading to the EX2100...6-14 Optional: Upgrading the .ecb File ...6-15 Checking for Correct Firmware and Hardware ...6-15 Checking the Keypad (EDI) ...6-16 Using the Keypad for Startup and Commissioning ...6-16 Adjusting Keypad Display Contrast...6-18 Commissioning the Exciter ...6-19 Overview of EX2100 Parameters...6-19 Running Simulator Mode ...6-22 Temporary Load Checks ...6-27 Initial Roll and Offline Checks ...6-30 Online Checks ...6-52 Additional Testing...6-53

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Before Beginning

Before beginning the procedures in this chapter, the following conditions must exist: · All pre-startup and installation checks from the previous chapters are completed

successfully.

· All interconnecting wires and cables are in place, connected, and ready for power on.

· Power is not yet applied.

For CE Mark Radiated Emissions compliance, one ferrite core (Fair-Rite P/N 2643164251 or equivalent) must be placed on each Ethernet network cable near the IS200ACLA termination point. Verify this before applying power to the control rack.

Note The EX2100 meets the following noise level specifications:

Fan

Quantity Doors Closed, One Meterfrom Enclosure Doors Open, Adjacent toEnclosure

Average Maximum Maximum

3 69.9 dBA 71.4 dBA 79.4 dBA

6 75.5 dBA 76.5 dBA 82.2 dBA

User’s Guide, GEH-6632, includes a functional descrip-tion of the EX2100, including hardware structure.

Order of Startup

The EX2100 Excitation Control can be provided in a variety of ratings and applica-tions. The basic design incorporates a common hardware and software structure, therefore the startup and commissioning procedures are similar for the different possible applications.

Whether a simplex or redundant control configuration or single or multiple bridge configuration, each EX2100 should be started and commissioned using the following basic guidelines:

· Follow the procedures in this chapter in the order presented.

· Figure 6-1 is a flowchart for use as a visual guide to the startup and commis-sioning process once control power has been applied and operation of heaters, lights and fans have been verified.

The order of startup is important.

All instructions must be followed and completed in the order presented in this chapter.

Tip Ä It is good practice to check off each procedure when you complete it. For

this purpose, this chapter includes checkboxes next to each procedure heading.

Information Needed

Before beginning, you should review the applicable elementary and outline drawings to become familiar with the type of EX2100 supplied. Make sure you know the power requirements and location of components, connections, and power switches.

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GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning _{· 6-3}

Software for the EX2100 will be found either on the turbine control master HMI or supplied separately for stand-alone ex-citation systems.

When commissioning the exciter with the GE Control System Toolbox for the first time, each EX2100 will have its own unique software file scaled and tailored for the generator applied using a common file extension .ecb for both DSPX and ACLA processors. It should be verified that the file to be used is correct and the most up to date available. The software is tested at the factory prior to shipment and should require a minimum of changes during commissioning.

Checkboxes should be marked to

verify that equipment is onhand.

Equipment/Material Needed

Safety Equipment

¨ Appropriate safety gear (may include safety boots, safety glasses, hard-hat, high voltage gloves, and face shield)

¨ Locks, tags, and danger and caution tape

Typical Test Equipment

When testing for the presence of high voltages and when measuring any electrical circuit, use only the equipment approved for contact with those voltage levels.

¨ Digital multimeters (2) ¨ Oscilloscope

¨ Small standard (flat-head) screwdriver ¨ Socket sets, standard and metric ¨ Flashlight

¨ Small inspection mirror ¨ Fuse puller

¨ Phase rotation meter

¨ Temporary load capable of carrying 3 or more amps and ceiling voltage. ¨ Personal computer (PC) with the GE Control System Toolbox installed and the

appropriate cables. These cables include the following available from GE Sa-lem.

336A3582P1 COM1 to EX2100 back plane or keypad 9 pin D connector. 336A4929G1 COM1 to EX2100 ACLA serial port 9 pin micro D connector.

Reference Documents

¨ System elementary (required)

Tip Ä It is good practice to study the elementary before working on the excitation

system.

¨ EX2100 outline drawings

¨ EX2100 User’s Guide, GEH-6632

¨ EX2100 Maintenance, Parts Replacement, and Troubleshooting Guide, GEH-6633

¨ EX2100 GE Control System Toolbox (toolbox) document, GEH-6414

The information contained in the toolbox document GEH-6414 and in the section, Specific Fault Troubleshooting of GEH-6633 is also available as Help files within the toolbox program (refer to Using Toolbox Help in this chapter).

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Control Power Applied & Lights Heaters and Fans Operational

Install Toolbox Install Drive Components No

Yes

Start Toolbox

Obtain Configuration Files From HMI or Requisition Engineering (.ecb for DSPX and ACLA)

No

Yes Open the EX2100 Configuration Files (.ecb)

(Toolbox Version is Automatically Verified)

Message: File last saved with

older version toolbox

?

Get Old Toolbox or Upgrade the file

Yes Start B 1 1a 2 4

Get New Toolbbox No File last saved withMessage:

newer version toolbox

? Yes Are EX2100 Configuration files Available? Is Control System Toolbox Installed? 4a 4b No Refer to sections

Verifying Control Power and Panel Lights, Heaters, and Fans

Refer to

toolbox document GEH-6414 (Chapter 3).

4a and 4b

Refer to toolbox document GEH-6414 (chapter 3). Yes 3 Refer to toolbox document GEH-6414 (Chapter 3). Refer to toolbox document GEH-6414 (Chapter 3). Refer to toolbox document GEH-6414 (Chapter 3).

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GEH-6631 EX2100 Installation and Startup Chapter 6 Initial Startup and Commissioning _{· 6-5} Review Release Notes

Create Version Summary

B

Establish Communications

with the EX2100

Do EX2100 and File versions agree? Yes No _{Is EX2100 newer} than file? Upgrade File Yes Download Flash (File is newer than EX2100) No 5 6a 6b 7 6 Check Hardware Check Firmware Check Keypad 8 Perform Simulator andTemporary Load Checks 9

Perform Off and On-line Commissioning Checks

10

End

5 and 6

and section

Checking the Keypad (EDI)

Refer to sections

Simulator andTemporary Load Checks

Refer to sections Off-line Checks and On-line Checks Refer to toolbox document GEH-6414 (Chapter 3). Refer to toolbox document GEH-6414 (Chapter 3). Refer to toolbox document GEH-6414 (Chapter 3). Refer to toolbox document GEH-6414 (Chapter 3). 6a and 6b