Ex2100 Startup Guide
March 22, 2017 | Author: MADDOX45 | Category: N/A
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Description
GEH-6631A
g
GE Industrial Systems
EX2100™ Excitation Control Full Static Control Installation and Startup Guide
Contents
Chapter 1
Overview
Introduction.............................................................................................................................1-1 How to Use This Document....................................................................................................1-3 Structure of the Document........................................................................................1-3 Text Conventions......................................................................................................1-3 How to Get Help .....................................................................................................................1-5 Equipment Covered ................................................................................................................1-5 Related Documents .................................................................................................................1-7 Document Distribution .............................................................................................1-7 Acronyms and Abbreviations .................................................................................................1-8
Chapter 2
Installation Planning
Introduction.............................................................................................................................2-1 Installation Support.................................................................................................................2-2 Early Planning ..........................................................................................................2-2 GE Installation Documents.......................................................................................2-2 As-Shipped Drawings...............................................................................................2-2 Technical Advisory Options.....................................................................................2-3 Siting EX2100 Equipment ......................................................................................................2-5 Operating Environment ............................................................................................2-5 Equipment Clearances ..............................................................................................2-6 Cable and Conduit Routing and Schedules...............................................................2-6
Chapter 3
Handling and Mounting Guidelines
Introduction.............................................................................................................................3-1 Exciter Handling Procedures ..................................................................................................3-2 Lifting.......................................................................................................................3-2 Moving .....................................................................................................................3-3 Unpacking ................................................................................................................3-4 Mounting ................................................................................................................................3-5 Securing the Exciter Lineup to the Floor..................................................................3-8
Chapter 4
Cabling and Connections
Introduction.............................................................................................................................4-1 Exciter Connections................................................................................................................4-2 Grounding and Cable Entry ....................................................................................................4-6 Cable Entry...............................................................................................................4-6 Control Power.........................................................................................................................4-9 Converter Power ...................................................................................................................4-10 Field Flashing .......................................................................................................................4-11 Generator Field Connections ................................................................................................4-11
GEH-6631 EX2100 Installation and Startup
Contents ·
i
Signal and Communications Cabling Guidelines..................................................................4-11 Generator PT and CT Inputs...................................................................................4-11 Contact Inputs.........................................................................................................4-12 Data Highway .........................................................................................................4-15 PC Interface ............................................................................................................4-16 Preventing Cable Damage.....................................................................................................4-16
Chapter 5
Pre-Power On Installation Checks
Introduction.............................................................................................................................5-1 Equipment/Material Needed ...................................................................................................5-2 Securing the Equipment for Safety .........................................................................................5-2 Hardware Checks ....................................................................................................................5-3 Optional Megger Test .............................................................................................................5-5 Pre-Test Power Checks.............................................................................................5-5 Ac Input Bus and PPT Secondary.............................................................................5-5 Dc Output Bus ..........................................................................................................5-6
Chapter 6
Initial Startup and Commissioning
Introduction.............................................................................................................................6-1 Before Beginning ....................................................................................................................6-2 Order of Startup ........................................................................................................6-2 Information Needed ..................................................................................................6-2 Equipment/Material Needed .....................................................................................6-3 Panel Lights, Heaters and Fans ...............................................................................................6-6 Verifying Control Power.........................................................................................................6-8 Control Module Processor Start............................................................................................6-12 Using the Exciter Configuration Tools .................................................................................6-13 Using Toolbox Online Help....................................................................................6-13 Starting the Toolbox ...............................................................................................6-14 Open an EX2100 File .............................................................................................6-14 Checking Toolbox/EX2100 Pattern Compatibility.................................................6-14 Downloading to the EX2100 ..................................................................................6-14 Optional: Upgrading the .ecb File..........................................................................6-15 Checking for Correct Firmware and Hardware ......................................................6-15 Checking the Keypad (EDI)..................................................................................................6-16 Using the Keypad for Startup and Commissioning ................................................6-16 Adjusting Keypad Display Contrast .......................................................................6-17 Commissioning the Exciter...................................................................................................6-18 Overview of EX2100 Parameters ...........................................................................6-18 Running Simulator Mode .......................................................................................6-21 Temporary Load Checks.........................................................................................6-26 Initial Roll and Off Line Checks.............................................................................6-29 On-Line Checks......................................................................................................6-39 Additional Testing ..................................................................................................6-40
Appendix A Understanding Equipment Drawings Introduction............................................................................................................................A-1 Data Nameplate......................................................................................................................A-2 Identifying the Equipment .....................................................................................................A-3 Equipment Catalog Number ....................................................................................A-3 Drawing Numbers..................................................................................................................A-3 Outline Drawings ...................................................................................................................A-4 Panel Drawings ......................................................................................................................A-4
ii · Contents
GEH-6631 EX2100 Installation and Startup
Elementary Diagrams ............................................................................................................A-5 Equipment Reference Information ..........................................................................A-5 Elementary Drawing Number..................................................................................A-5 Wire Number Identification.....................................................................................A-5 Conventions Used with Other Equipment .............................................................................A-6
Appendix B Cable Separation and Routing Introduction............................................................................................................................ B-1 Low-Level Signals (Level L)................................................................................................. B-2 Medium-Level Signals (Level M) ......................................................................................... B-2 High-Level Signals (Level H)................................................................................................ B-2 Power (Level P) ..................................................................................................................... B-2 Class Codes............................................................................................................................ B-2 Cableway Spacing Guidelines ............................................................................................... B-3 General Cableway Spacing...................................................................................... B-3 Tray/Tray Spacing ................................................................................................... B-4 Tray/Conduit Spacing.............................................................................................. B-4 Conduit/Conduit Spacing ........................................................................................ B-4
Appendix C Installing Fiber-Optic Cable Introduction............................................................................................................................ C-1 Cable Characteristics ............................................................................................................. C-2 Cable Construction .................................................................................................. C-2 Data Integrity........................................................................................................... C-2 Causes of Cable Damage......................................................................................... C-2 Handling Guidelines .............................................................................................................. C-3 Environmental Guidelines ..................................................................................................... C-4 Cable Assembly ..................................................................................................................... C-4 Tools and Materials ................................................................................................. C-4 Attaching a Connector ............................................................................................. C-5 Polishing Fiber Ends................................................................................................ C-7 Inspecting Fiber Ends ............................................................................................................ C-9 Connecting Fiber-Optic Cable to Modules .......................................................................... C-11
Appendix D Printed Wiring Board Reference Glossary of Terms Index
GEH-6631 EX2100 Installation and Startup
Contents · iii
Chapter 1
Overview
Introduction This document is an installation and startup guide for the 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).
GEH-6631 EX2100 Installation and Startup
Chapter 1 Overview · 1-1
Figure 1-1. Typical EX2100 Excitation Control
Figure 1-2. Typical EX2100 Excitation Control Components
1-2 · Chapter 1 Overview
EX2100 Installation and Startup GEH-6631
How to Use This Document Structure of the Document GE recommends that a 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.
GEH-6631 EX2100 Installation and Startup
Chapter 1 Overview · 1-3
Start Procedures
Startup
Installation
Move exciter to installation site and install it
Connect cables & I/O wiring
Installation site ready, drawings & documents on hand, all site parts present
Chapter 2, Handling and Mounting Guidelines
Chapter 3, Cabling and Connections
Mount and install external devices
Chapter 4, Device Installation
Verify correct functioning of connected devices (power, I/O)
Chapter 5, Pre-Startup Installation Checks
Apply power, start toolbox, run checks
Chapter 6, Initial Setup and Operation Checks
End of Procedures
Figure 1-3. Structure of Document for Use in Installation and Startup
1-4 · Chapter 1 Overview
EX2100 Installation and Startup GEH-6631
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).
GEH-6631 EX2100 Installation and Startup
Chapter 1 Overview · 1-5
Figure 1-4. EX2100 Cabinet Lineup Components
1-6 · Chapter 1 Overview
EX2100 Installation and Startup GEH-6631
Related Documents If needed for supplementary information, refer to the following EX2100 product documents, as applicable: Subject
Document
Content
EX2100 Toolbox
GEH-6414
GE Control System Toolbox instructions for the EX2100
EX2100 User’s Guide
GEH-6632
Functional description, technical data, customer I/O connections, keypad overview; application guides
EX2100 Maintenance, Parts Replacement, and Troubleshooting Guide
GEH-6633
Preventive maintenance, online maintenance, component replacement, fault list, and troubleshooting information
EX2100 Receiving, Handling and Storage
GEI-100256
Procedures, precautions, and environmental requirements for receiving the exciter from the shipper and storing it before installation
Printed wiring boards
See Appendix D for a list of GEIs
Board function within the exciter, I/O designations, fuses, jumpers, test points, and board replacement procedure
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.
GEH-6631 EX2100 Installation and Startup
Chapter 1 Overview · 1-7
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)
in.
inch(es)
1-8 · Chapter 1 Overview
EX2100 Installation and Startup GEH-6631
Chapter 2
Installation Planning
Introduction This chapter discusses installation planning and requirements for the EX2100 excitation control system. Specific topics include GE installation support, siting the equipment, and environmental requirements. Before installation, consult and study all furnished drawings. These should include outline drawings, elementary diagram, connection diagrams, and a summary of the equipment. This chapter is organized as follows:
Section
Page
Installation Support ..................................................................................................2-2 Early Planning ...................................................................................................2-2 GE Installation Documents................................................................................2-2 As-Shipped Drawings........................................................................................2-2 Technical Advisory Options..............................................................................2-3 Siting EX2100 Equipment........................................................................................2-5 Operating Environment .....................................................................................2-5 Equipment Clearances.......................................................................................2-6 Cable and Conduit Routing and Schedules .......................................................2-6
GEH-6631 Installation and Startup
Chapter 2 Installation Planning · 2-1
Installation Support 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.
2-2 · Chapter 2 Installation Planning
EX2100 Installation and Startup GEH-6631
Technical Advisory Options To assist the customer, GE Power Systems offers the optional technical advisory services of field engineers for: ·
Review of 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
Begin Installation
Startup
Complete Installation
Commissioning
Product Support - On going
Begin Formal Testing
System Acceptance
Figure 2-1. Startup and Commissioning Services Cycle
Review of Installation Plan It is recommended that a GE field representative review all installation/construction drawings, and the cable and conduit schedule when completed. This optional review service ensures that the drawings meet installation requirements and are complete.
Installation Support Optional installation support is offered: planning, practices, equipment placement, and onsite interpretation of construction and equipment drawings. Engineering services are also offered to develop transition and implementation plans to install and commission new equipment in both new and existing (revamp) facilities.
Customer’s Conduit and Cable Schedule The customer’s finished conduit and cable schedule should include: ·
Interconnection wire list (optional)
·
Level definitions
·
Shield terminations
GEH-6631 Installation and Startup
Chapter 2 Installation Planning · 2-3
Level Definitions The cable and conduit schedule should define signal levels and classes of wiring (see section, Cable and Conduit Routing and Schedules and Appendix B). This information should be listed in a separate column to help prevent installation errors. The cable and conduit schedule should include the signal level definitions in the instructions. This provides all level restriction and practice information needed before installing cables.
Shield Terminations The conduit and cable schedule should indicate shield termination practice for each shielded cable (refer to the section, Cable and Conduit Routing and Schedules and Appendix B).
2-4 · Chapter 2 Installation Planning
EX2100 Installation and Startup GEH-6631
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 PCM Module
0 °C (32 °F) to 45 °C (113 °F) 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)
GEH-6631 Installation and Startup
Chapter 2 Installation Planning · 2-5
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 deexcitation 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.
2-6 · Chapter 2 Installation Planning
EX2100 Installation and Startup GEH-6631
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:
Section
Page
Exciter Handling Procedures ....................................................................................3-2 Lifting................................................................................................................3-2 Moving ..............................................................................................................3-3 Unpacking .........................................................................................................3-4 Mounting ..................................................................................................................3-5 Securing the Exciter Lineup to the Floor...........................................................3-8
Note Dimensions shown in Figures in this chapter are given in inches with millimeters shown in parantheses.
GEH-6631 EX2100 Installation and Startup
Chapter 3 Handling and MountingGuidelines · 3-1
Exciter Handling Procedures Shock or stress caused by rough handling or improper lifting and moving can damage the equipment. Be sure to follow the guidelines provided in this chapter. The shipped equipment consists 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.
Figure 3-1. EX2100 Lineup Lifting Beam
3-2 · Chapter 3 Handling and Mounting Guidelines
EX2100 Installation and Startup GEH-6631
Use four hooks in openings in lifting beams (two in front and two in back).
Angle must be 45 degrees or greater.
Figure 3-2. Proper Lifting Method for EX2100 Lineup
Moving ·
When using a crane, be sure that motions are slow and smooth so that the equipment does not swing.
·
If using other moving devices, such as rollers: - Be sure to place the rollers at the shipping splits and at the corners to reduce potential stress. - Roll only on the shipping pallets that are attached to the cabinets when shipped from the factory.
·
Do not move with a forklift, since the weight of the exciter against the forklift tines would put damaging pressure on the exciter frame.
·
Make sure that all doors are closed and latched.
GEH-6631 EX2100 Installation and Startup
Chapter 3 Handling and MountingGuidelines · 3-3
Unpacking Recommended: Do not completely unpack the equipment until it is placed as near as possible to its permanent location.
Document and report any equipment damage to GE.
·
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.
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
3-4 · Chapter 3 Handling and Mounting Guidelines
EX2100 Installation and Startup GEH-6631
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.
GEH-6631 EX2100 Installation and Startup
Chapter 3 Handling and MountingGuidelines · 3-5
Exciter Size
Weight (kg / lbs)
Heat Loss (Watts)*
Airflow Req. 3 (ft /min)**
Standard Outline Dwg.
1000 A
1996/4400
5,000
2500
151X1207AA1SA01
2000 A
2535 /5,600
10,000
2500
151X1207AA1SA01
*Two PCMs per cabinet, one active in warm backup configuration. **Airflow throughput requirements for proper cooling. Figure 3-3. EX2100 Lineup Length and Door Opening Dimensions
3-6 · Chapter 3 Handling and Mounting Guidelines
EX2100 Installation and Startup GEH-6631
Figure 3-4. EX2100 Width, Height, and Clearance Dimensions
GEH-6631 EX2100 Installation and Startup
Chapter 3 Handling and MountingGuidelines · 3-7
Securing the Exciter Lineup to the Floor The exciter lineup must be secured to the floor using mounting studs. Figure 3-5 shows the location of mounting holes in the exciter base. Refer to the exciter outline drawing sheet 1 for additional information about securing the lineup.
Figure 3-5. Location of Mounting Base Holes for Securing Exciter to Floor
3-8 · Chapter 3 Handling and Mounting Guidelines
EX2100 Installation and Startup GEH-6631
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:
Section
Page
Exciter Connections..................................................................................................4-2 Grounding and Cable Entry......................................................................................4-6 Cable Entry........................................................................................................4-6 Control Power...........................................................................................................4-9 Converter Power.....................................................................................................4-10 Field Flashing (Optional)........................................................................................4-11 Generator Field Connections ..................................................................................4-11 Signal and Communications Cabling Guidelines ...................................................4-11 Generator PT and CT Inputs............................................................................4-11 Contact Inputs .................................................................................................4-12 Data Highway..................................................................................................4-15 PC Interface.....................................................................................................4-16 Preventing Cable Damage ......................................................................................4-16
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-1
Exciter Connections Cabling and wiring connections to the exciter include the following: ·
One cabinet ground
·
Incoming ac control power (terminals on the Exciter Power Distribution Module)
·
Incoming dc control power (terminals on the Exciter Power Distribution Module)
·
Incoming ac power to the Power Conversion Cabinet.
·
Power for field flashing (terminals in the Auxiliary cabinet)
·
Dc outgoing power connections to the generator field (Field+, Field-)
·
Exciter I/O connections to terminal boards (contact inputs to ECTB board)
Note The component nomenclature examples (see Figures 4-1, 4-2, and 4-3) show the location of connection points, fuses, and other exciter components. A device nomenclature sticker, located on the inside of the exciter cabinet door identifies the 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 continuous metal conduit.
4-2 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
Cutout for Customer Connections ECTB
ECTB Wiring (Refer to elementary sheet 7A and 11A for details)
EXHS/EXTB Control Rack
EPCT PT1 (optional) PT2 CT1
Ethernet Link to ACLA (Refer to elementary sheet 8A and 11A for details)
CT2
Breaker 1, 2 120 V ac, 15 A
Power Supply Rack
Breaker 3 120 V ac, 5 A EPDM (FU1 – FU12 on EPDM, refer to elementary sheet 7A and 11A for details)
DACA 1 (DACA 2 optional) Space Heater 1 (optional)
TB1
Cutout for Customer Connections
Figure 4-1. Sample Component Layout, Exciter Control Cabinet
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-3
Ac Line Filter
Shaft Voltage Suppressor LFU2 (optional), FU1 – FU3 LFU1, FU1 – FU3 EXAM EDCF – M1 (optional) EDCF – M2
EACF
(optional) EDCF - C
De-excitation Module
Ac input from PPT Phase A – Front Shunt Phase B – Middle Shunt Phase C – Rear Shunt Ground Lug
(optional) PTB1 125 V dc, 15% AFNL
Dc Field Flashing (optional) FF, FU1 and FU2 Space Heater 2 (optional)
Figure 4-2. Sample Component Layout, Exciter Auxiliary Cabinet
4-4 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
Drip Shield (optional) Dc Bus Connections (optional)
Fans 4 – 6 (optional) Fans 1 – 3
Ground Lug EGPA M1 EGPA M2
Dc Contactors 41A, 41B (optional)
Ac Disconnect (less than 600 V ac applications only) Ground Lug Ac Input Connections (optional)
Dc Bus Connnections Bridge 1
Bridge 2 Thermal Sensors
Figure 4-3. Sample Component Layout, Exciter Power Conversion Cabinet
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-5
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
Figure 4-5. Auxiliary Cabinet Cable Entry
4-6 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
Optional Ac Connections
Wire Entry Bottom
Figure 4-6. Converter Cable Entry (Power Conversion Cabinet)
Standard Ac Connections
Ground Bus
Figure 4-7. Auxiliary Cabinet Power Connection Points
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-7
Ground Bus
Door
Optional Ac Connections
Figure 4-8. Power Conversion Cabinet Power Connection Points
4-8 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
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:
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.
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%
EPDM Exciter Power Distribution Module
SW7 SPRE
x
1
SW5 J1M2
1
SW4 J1M1
1
125 V dc from battery
R125Vdc R125Vdc R125Vdc
x x x x x
115 V ac supply #1
x x x x
115 V ac supply #2
AC2N AC2N
x x
2 4 6 8 10 12 14 16 18 20 22 24 x
SW3
J8C
SW2
J8B
SW1
J8A
TB1 x x x x x x x x x x x x
1 3 5 7 9 11 13 15 17 19 21 23
P125Vdc P125Vdc P125Vdc
AC1H AC1H AC1N AC1N AC2H AC2H
2
J1C
SW6
x
1
2
2
2
1 2
1 2
1 2
1
J9 3 1 0
1
JDACA1 3 1
12 1 0
JDACA2 3
12
Figure 4-9. Control Power Input Connections to Power Distribution Module
The EPDM outputs feed 125 V dc to the three exciter power supply modules (EPSMs), and the EGPA and EXTB OR EXHS boards. Individual outputs are fused and can be isolated with a switch.
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-9
Converter Power The main ac power supply for the exciter can come from a potential source, a compound source, or an auxiliary bus. Figure 4-10 shows supply from a power potential transformer (PPT) connected to the generator output.
PPT
K1 K2 K3
L1 L2 L3
X2 X3
SEC VAC : 650
KVA 1280
PRI VAC : 12470
H3
H2
H1
X1
41AC1
Exciter Power Conversion Cabinet To Bridge 1 and Line Filters
Phase Rotation 3 1 2
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) Fax: + 1 540 387 8606 (All)
4-10 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
Field Flashing (Optional) Figure 4-11 shows the optional Field Flashing Module noting the locations of the station battery terminals and fuses FU1 and FU2. Other connections to the module include status contacts from the EXHS board. Power output goes to the generator field. Refer to the elementary diagram sheet 4A for additional information.
Figure 4-11. Field Flashing Module
Generator Field Connections The external generator field connections must be meet all applicable codes and comply with the generator manufacturer’s guidelines. Connecting cables must be sized properly and insulated per IEEE 421-3 guidelines.
Signal and Communications Cabling Guidelines ·
Be sure to strictly follow the cable manufacturer’s installation instructions. These will vary based on the type of installation required.
·
To meet CE Mark requirements, all I/O wires leaving a building must be routed inside continuous metal conduit.
Generator PT and CT Inputs The generator PTs and CTs are customer supplied. The connections to the switches in the control cabinet are shown in Figure 4-12. Note Connections on the CTs can be either 1 amp or 5 amp. Refer to the elementary diagram for specifics.
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-11
Supplied by Others +
Generator Field + To Bridge 1
-
Exciter Control cabinet
Generator Field -
2
TB1 1
PT
PT
PT
PT
5L
J305 J308
To EMIO (M1) To EMIO (M2) To EMIO (C)
3
CT
J315
1
5H 1H
3
4
2
1
2
X2
TB2
Fan-out circuits
24 22 20 18 16 14 12 10 8
2 4 6
CTSW1
CT
23 21 19 17 15 13 11 9
7
6
5
4
3
4 6
2
3 5 1 3 5
X1 X2 X3
OR GROUNDED Y)
PTSW2
(OPEN
H3
H2
H1
PT2 PRI VAC : 14400 SEC VAC : 120
1
X1 X2 X3
OR GROUNDED Y)
PTSW1
(OPEN
H1 H2 H3
PRI VAC : 14400 SEC VAC : 120
PT1
4
X1
TB3
2 4
3
1 3
4
2
X2
1
CTSW3
CT
X1
1L
5H 5L
CT
1H 1L
EPCT
Phase Rotation 3 1 2
Figure 4-12. Typical PT and CT Connections to Switches in Power Conversion Cabinet
The cable length between the PT and the EPCT board can be up to 1000 ft (305 meters) of #12 AWG twisted shielded wire. The cable length between the CT and the EPCT board can be up to 1000 ft (305 meters), using up to #10 AWG wire.
Contact Inputs The ECTB board provides terminals for contact inputs from the customer's devices. Six auxiliary contact inputs, and contact inputs from 52G and 86G are accommodated. These contacts are wetted with 70 V dc from ECTB. See Figures 413 and 4-14 for ECTB layout diagrams. For specific terminal information, refer to GEI-100457.
4-12 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
From M1
J13M1
ECTBG2 (Simplex)
P70 V dc
P24M1
TB1
P24D
18
NO P24D
J405 Relay Driver
COM
Coil K#GP
NC
From M1 (EMIO)
19
Customer Power to Contacts
20
125 V dc
Four General Purpose Relay Outputs as 1 Relay Driver
Coil K#M1
P24M1
M1
Customer Power to Contacts 125 V dc
M1
5
(1 of 2)
Two Trip Relay Outputs as Term. 1&5 Ex. trip to Customer 86
P70Vdc Red LED
33 34 Current Limit Six Circuits as Above
Red LED
P70Vdc
45 46
Current Limit P70Vdc
To Optocoupler on M1 (EMIO) Current Limit
47 48
Auxiliary Contact Inputs (1 of 6)
52G Contact (Closed online)
86G Contact (Open for Trip)
TB2
Figure 4-13. ECTBG2 Terminal Board, Simplex
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-13
From M1
J13M1 P70M1
P24D
P70 V dc From M2
ECTBG1 (Redundant)
P24M1
J13M2 P70M2
P24M1 J405
Voted Relay Driver
From M1 (EMIO)
TB1
P24M2
18
NO
Coil K#GP
Customer 19 Power to COM Contacts
P24D
20 125 V dc
NC
Four General Purpose Relay Outputs as 1 P24M2
M1
Relay Driver
Coil K#M1
J408 M2
From M2 (EMIO)
C
Relay Driver Relay Driver
Coil K#M2 Coil K#C
P24M1
M1
M2
P24M2
M2
C
C
M1
Customer Power to Contacts 5
P24C
Term. 1&5 Ex. Trip to Customer 86
Two Trip Relay Outputs as
J415
P70Vdc 33
Red LED
From C (EMIO)
34 Current Limit Six Circuits as Above Red LED M1 M2 C To M1 (EMIO)
To M2 (EMIO) To C (EMIO)
125 V dc
P70Vdc
(1 of 6)
45
52G Contact
46
(Closed online)
47
86G Contact
48
(Open for Trip)
Current Limit P70Vdc
Auxiliary Contact Inputs
Current Limit Current Limit Current Limit
TB2
Figure 4-14. ECTBG1 Terminal Board, Redundant
4-14 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
Data Highway A typical exciter connection to the redundant Unit Data Highway (UDH) network is shown in Figure 4-15. This shows redundant control with two ACLA modules, (simplex control has one ACLA with one UDH). The UDH is implemented using commercially available fast Ethernet switches. 10Base-T cabling is used for short distances between the controller and the T-Switch, and any local HMI. 100Base-FX fiber-optic cabling is used for longer distances between the local control area and the central control room.
Central Control Room Fast Ethernet Switch B
Fast Ethernet Switch A
From other Units
From other Units
T-Switch A
100Base-FX connections
T-Switch B
To local HMI Viewer, 10Base-T
Local Control Area
10Base-T connections From other Controllers
gGE
Industrial Systems
From other Controllers
Exciter Control Cabinet
gGE
S T A T U S
Industrial Systems
S T A T U S
2
COM
1
2
COM
1
ENET
ENET
Ethernet Port, RJ-45
ACLA H1A
ACLA H1A
Figure 4-15. Ethernet Cable Connections
The 10Base-T ports in the ACLA and the T-Switch use RJ-45 connectors. The maximum distance using unshielded twisted pair cable is 328 ft (100 meters). The 100Base-FX ports in the T-Switch and the Fast Ethernet Switch are for SC type fiber-optic connectors. The maximum distance using 100Base-FX fiber-optic cables is 2 km.
GEH-6631 EX2100 Installation and Startup
Chapter 4 Cabling and Connections · 4-15
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.
4-16 · Chapter 4 Cabling and Connections
EX2100 Installation and Startup GEH-6631
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:
Section
Page
Equipment/Material Needed.....................................................................................5-2 Securing the Equipment for Safety...........................................................................5-2 Hardware Checks......................................................................................................5-3 Optional Megger Test...............................................................................................5-5 Pre-Test Power Checks .....................................................................................5-5 Ac Input Bus and PPT Secondary .....................................................................5-5 Dc Output Bus...................................................................................................5-6
GEH-6631 Installation and Startup Guide
Chapter 5 Pre-Power On Installation Checks · 5-1
Equipment/Material Needed Checkboxes should be marked 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 1. were completed successfully.
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.
5-2 · Chapter 5 Pre-Power On Installation Checks
EX2100 Installation and Startup GEH-6631
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.
GEH-6631 Installation and Startup Guide
Chapter 5 Pre-Power On Installation Checks · 5-3
11. Verify that the circuit cards listed on the EX2100 elementary data sheet 0E have correct settings for hardware jumpers. Location of hardware jumpers can be found using the appropriate card GEI (refer to Appendix D for list). 12. Check incoming wiring/cabling, as follows: ·
It should be complete and agree with the elementary drawings supplied with the EX2100.
·
It should conform to the cable separation guidelines defined in Appendix B.
13. Verify that the cabinet is properly grounded. Reference elementary sheet 0D. 14. Operate each magnetic device by hand to make sure that all moving parts operate freely. Check all electrical interlocks for proper operation. 15. Verify that the incoming and outgoing buses are not grounded. To do this: ·
Either use an ohmmeter to measure all buses connected to the exciter to ground to ensure insulation integrity,
·
Or perform the optional megger test (refer to the following section).
5-4 · Chapter 5 Pre-Power On Installation Checks
EX2100 Installation and Startup GEH-6631
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
The exciter outline drawing shows location of fuses, disconnects, and other components within the excitation cabinet.
1.
Check that the ac bridge power, PPT primary power, and all sources of control power have been locked out and tagged out.
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. o PPT input line to line o PPT input line to ground
Use the checkbox to mark each completed measurement.
o o
Dc output positive to negative Dc output positive and negative to ground
Ac Input Bus and PPT Secondary o
All procedures in Ac Input Bus 1. and PPT Secondary megger 2. were completed successfully. 3.
Do not proceed until completing all requirements under Pre-Test Power Checks Short the ac input buses together using jumpers or wire. 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.
GEH-6631 Installation and Startup Guide
Chapter 5 Pre-Power On Installation Checks · 5-5
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.
5-6 · Chapter 5 Pre-Power On Installation Checks
EX2100 Installation and Startup GEH-6631
Chapter 6
Initial Startup and Commissioning
Introduction .
This chapter provides instructions to verify that the EX2100 excitation system is ready for operation. This includes control power checks, software setup, use of the keypad and offline and online commissioning guidelines. This chapter is organized as follows: Section
Page
Before Beginning......................................................................................................6-2 Order of Startup.................................................................................................6-2 Information Needed...........................................................................................6-2 Equipment/Material Needed..............................................................................6-3 Panel Lights, Heaters and Fans.................................................................................6-6 Verifying Control Power ..........................................................................................6-8 Control Module Processor Start .............................................................................6-12 Using the Exciter Configuration Tools...................................................................6-13 Using Toolbox Online Help ............................................................................6-13 Starting the Toolbox........................................................................................6-14 Open an EX2100 File ......................................................................................6-14 Checking Toolbox/EX2100 Pattern Compatibility .........................................6-14 Downloading to the EX2100 ...........................................................................6-14 Optional: Upgrading the .ecb File ..................................................................6-15 Checking for Correct Firmware and Hardware ...............................................6-15 Checking the Keypad (EDI) ...................................................................................6-16 Using the Keypad for Startup and Commissioning .........................................6-16 Adjusting Keypad Display Contrast ................................................................6-18 Commissioning the Exciter ....................................................................................6-19 Overview of EX2100 Parameters....................................................................6-19 Running Simulator Mode ................................................................................6-22 Temporary Load Checks .................................................................................6-27 Initial Roll and Offline Checks .......................................................................6-30 Online Checks .................................................................................................6-52 Additional Testing...........................................................................................6-53
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-1
Before Beginning Before beginning the procedures in this chapter, the following conditions must exist: ·
All pre-startup and installation checks from the previous chapters are completed successfully.
·
All interconnecting wires and cables are in place, connected, and ready for power on.
·
Power is not yet applied. For CE Mark Radiated Emissions compliance, one ferrite core (Fair-Rite P/N 2643164251 or equivalent) must be placed on each Ethernet network cable near the IS200ACLA termination point. Verify this before applying power to the control rack.
Note The EX2100 meets the following noise level specifications: Fan Quantity
User’s Guide, GEH-6632, includes a functional description of the EX2100, including hardware structure.
Doors Closed, One Meter from Enclosure
Doors Open, Adjacent to Enclosure
Average
Maximum
Maximum
3
69.9 dBA
71.4 dBA
79.4 dBA
6
75.5 dBA
76.5 dBA
82.2 dBA
Order of Startup The EX2100 Excitation Control can be provided in a variety of ratings and applications. 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 commissioning 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. 6-2 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Software for the EX2100 will be found either on the turbine control master HMI or supplied separately for stand-alone excitation 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 Salem. 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, GEH6633 ¨ EX2100 GE Control System Toolbox (toolbox) document, GEH-6414 The information contained in the toolbox document GEH6414 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).
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-3
Start
1 Control Power Applied & Lights Heaters and Fans Operational
Refer to sections Verifying Control Power and Panel Lights, Heaters, and Fans
Yes
1a No
Is Control System Toolbox Installed?
Install Toolbox Install Drive Components
Refer to toolbox document GEH-6414 (Chapter 3).
Yes
2 Refer to toolbox document GEH-6414 (Chapter 3).
Start Toolbox
3 Are EX2100 Configuration files Available?
No
Obtain Configuration Files From HMI or Requisition Engineering (.ecb for DSPX and ACLA)
Refer to toolbox document GEH-6414 (Chapter 3).
Yes
4
Open the EX2100 Configuration Files (.ecb) (Toolbox Version is Automatically Verified)
Message: File last saved with older version toolbox ?
Refer to toolbox document GEH-6414 (Chapter 3).
No
Message: File last saved with newer version toolbox ?
No
Yes
Yes
4b
4a Get Old Toolbox or Upgrade the file
B
Get New Toolbbox
4a and 4b Refer to toolbox document GEH-6414 (chapter 3).
Figure 6-1. Overview of EX2100 Startup and Commissioning (Part 1 of 2)
6-4 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
B
5 Establish Communications with the EX2100
5 and 6 Refer to toolbox document GEH-6414 (Chapter 3).
6a
6 Do EX2100 and File versions agree?
No
Is EX2100 newer than file?
No
Download Flash (File is newer than EX2100)
Yes
Yes
6b
6a and 6b Refer to toolbox document GEH-6414 (Chapter 3).
Upgrade File
7 Refer to toolbox document GEH-6414 (Chapter 3).
Review Release Notes Create Version Summary
8 Check Hardware
Refer to toolbox document GEH-6414 (Chapter 3). and section Checking the Keypad (EDI)
Check Firmware Check Keypad
9 Perform Simulator andTemporary Load Checks
Refer to sections Simulator andTemporary Load Checks
10 Perform Off and On-line Commissioning Checks
Refer to sections Off-line Checks and On-line Checks
End
Figure 6-1. Overview of EX2100 Startup and Commissioning (Part 2 of 2)
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-5
Panel Lights, Heaters and Fans Refer to Figure 6-1, Block 1 and Figure 6-2. All procedures in this section were completed successfully for: ¨ Lights ¨ Heaters ¨ Fans
Each EX2100 will have power conversion module cooling fans supplied. Optional panel heaters and lights may also be provided. These items should be energized and operation verified prior to energizing the control power. Refer to the applicable system elementary for options provided. Refer to the applicable panel outline drawings for location of components. With power applied, this equipment contains a potential hazard of electric shock or burn. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate, or maintain this drive. To minimize hazard of electrical shock or burn, approved grounding practices and procedures must be strictly followed. 1.
Verify all temporary shipping constraints for panel lights have been removed. These may consist of tape or protective wraps.
2.
Energize the ac power feed for the panel lights and heaters. Measure the line-toline voltage of the ac feed for proper voltage as specified on the applicable system elementary. Verify that the line and neutral connections are consistent with the system drawings.
3.
Turn the ac breaker switch for the panel lights to the on position. Each panel light should turn on.
4.
Each heater has been hipot checked at the factory prior to shipping. It is not recommended to megger check heater circuits in the field. Verify that no flammable materials are in contact with the panel heaters.
5.
Turn the ac breaker switch for the panel heaters to the on position. Each panel heater should energize. Verify heater operation with an infrared heat detection device or carefully feeling for heat several inches above the heater surface.
The heaters are not used to maintain a constant temperature but to merely keep the EX2100 above ambient temperature.
Once energized, panel heaters can be very hot. Keep all debris and flammable materials from contacting the heater surfaces. Heater surfaces should never be touched while energized. 6.
Verify that EGPA board jumper settings for JP1 – JP5 agree with elementary diagram sheet 0E.
7.
Energize the ac power feed for the power conversion module cooling fans. Measure the line-to-line voltage of the ac feed for proper voltage as specified on the applicable system elementary. Verify that the line and neutral connections are consistent with the system drawings.
8.
Turn the ac breaker switch for the cooling fans to the ON position and immediately turn back OFF. Visually verify that each fan is turning in a counter clockwise direction (left to right) when viewed through the fan box window.
9.
Repeat steps 6 and 7 for the redundant set of cooling fans if supplied.
6-6 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Power to Control Module To M1
To M2
To C
Breakers PCM Fans M2
M1
PCM Fans
EDEX EDCF CONTROL EDEX J602 EETB
PCM Fans
EDEX EDCF CONTROL EDEX J602 EETB
EDEX EDCF CONTROL EDEX J602 EETB
ECTB
ECTB
ECTB
EXTB EDEX EGDM FAN MEDIA CROWBAR CONV
EXTB EDEXEGDM FAN MEDIA CROWBAR CONV
EXTB EDEX EGDM FAN MEDIA CROWBAR CONV
Heaters
Fan
EPDM Exciter Power Distribution Module J1C
x x x x x x x x x x x x x
2 4 6 8 10 12 14 16 18 20 22 24
TB1 x x x x x x x x x x x x
1 3 5 7 9 11 13 15 17 19 21 23
SW6
1 2
J1M2 SW5
1 2
J1M1 SW4
1 2
J8C SW3
1 2
J8B SW2
1 2
J8A SW1
1 2
C
Fan
EPSM Power Supply M1
Blank plate
EGDM Ground Detector M1
Fan
EPSM Power Supply M2
EGDM Ground Detector M2
EPSM Power Supply C
EGDM Ground Detector C
1
J9
3
1
10
3 1
12 10
3
12
JDACA1
x
J1_M1
J1_M2
J1_C
J2C
GROUND DETECT
JDACA2
125 V dc 115 V ac Supplies
To J1M1
To J1M2
To J1C
Figure 6-2. Front View of Power Supply Module
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-7
Verifying Control Power Refer to Figure 6-1, Block 1 and Figures 6-2, 6-3, and 6-4.
Refer to the Power Supply section of the system elementary and GEI-100463 for an overview of the EX2100’s control power circuitry.
All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control With power applied, this equipment contains a potential hazard of electric shock or burn. Only personnel who are adequately trained and thoroughly familiar with the equipment and the instructions should install, operate, or maintain this exciter. To minimize hazard of electrical shock or burn, approved grounding practices and procedures must be strictly followed. 1.
Before energizing the power supply inputs, verify that all toggle switches on the EPDM are in the OFF position. Disconnect the DACA1 and DACA2 plug jumpers JDACA1 and JDACA2, also found on the EPDM (see Figure 6-3).
2.
Remove plug J9 from the EXTB or EXHS board.
3.
Apply the source 120 V ac power for the DACA1 module and measure the lineto-line voltage on pins 1 and 3 of the JDACA1 plug. Remove the 120 V ac source power for the DACA modules.
4.
Reconnect the JDACA1 plug and re-apply the 120 V ac source power. Measure the voltage at FU1 and FU2 for a nominal 125 V dc to the EPDM distribution switches.
5.
Remove the 120 V ac DACA source power and repeat steps 3 and 4 for the second DACA module if supplied. Remove 120 V ac source power for the DACA modules.
6.
Apply the 125 V dc control power source as shown on the elementary power supply sheets. Again measure the voltage at FU1 and FU2 for a nominal 125 vdc to the EPDM distribution switches.
7.
Remove the 125 V dc power and plug connector J9 on the EXTB or EXHS board back in.
8.
Apply 125 V dc power to the EPDM. This will apply power to the EXTB or EXHS board. There are no external indications of power to this board. Relay operation will be verified at a later time.
9.
Close SW8A on the EPDM. This will apply power to the EGPA card in the primary power converter. Verify that the EGPA1 PSOK green LED is on (see Figure 6-4).
10. Close SW8B on the EPDM. This will apply power to the EGPA card in the backup power converter. Verify that the EGPA2 PSOK green LED is on. 11. The EPSM power supplies are unstable when not loaded. It is not possible to check power supply voltages without having the cards in the EBKP control rack inserted in their proper position. These supplies are tested and verified at the factory during card test and system test prior to shipping.
6-8 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
E3
IS200EPDMG1A FU13
E4
SFTYGND SW7 SPARE
FU14 FU11
SW1C
SPARE
SW6 FU12 J1C
DS7
SW1M2
PS1M2
FU9
SW5 FU10 J1M2 SW1M1 SW4 FU8 FU5
E1
J1M1
SW3 FU6 J8C FU3
SW8B SW2
FU4
FU1
SW8A
DS3
PS8B
TB1
DS5
PS8C
CHASGND1
SW8C
DS6
PS1M1
FU7
DS8
PS1C
Fuse Data Table
J8B
PS8A
SW1
DS2
FU2 J8A
PS9
DS1
J9
DS4
JDCA1
CHASGND
JDCA2
E2
Figure 6-3. EPDM Board Layout
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-9
DC Power Source 130 V dc (nominal) 80 - 140 V dc PSOK
Line Filter Sensor
TPxx TPxx
Fan Rotation Sensor 1
TPxx TPxx
Fan Rotation Sensor 2 6X Gates
Klixon (T=170F, Alarm)
ALARM FAULT
Klixon (T=190F, Fault) Disable coolant trip
RTD Coolant Temp
Figure 6-4. EGPA Board LED Locations
Carefully follow the procedures documented in the circuit board instruction manuals for inserting the boards into the control rack.
12. Insert all circuit boards in the exciter backplane control rack for M1, M2 and C (see Figure 6-5). 13. The EPSM cooling fan for each module energized should be operating when the EPSM is energized. Verify counter-clockwise rotation of each fan. 14. One at a time, close EPDM switches SW1M1, SW1M2, and SW1C. This will apply power to the M1, M2 and C control circuit boards in the control rack. These include the ACLA, DSPX, EISB, EMIO, and ESEL boards as well as the control rack fans located above these boards. Each board has a power status green LED that will illuminate indicating power is applied. The DSPX and ACLA will also begin an initialization process.
6-10 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Fan
Fan
RST
RST
OK ACTIVE ENET FLASH
OK ACTIVE ENET FLASH
S T A T U S
S T A T U S
COM
1
COM
2
1 2
ENET
ENET
ACLA
DSPX
EISB
EMIO ESEL ESEL EMIO
M1 Boards
DSPX ACLA
DSPX
EISB
EISB
M2 Boards
EMIO
C Boards
Figure 6-5. Exciter Backplane Control Rack Boards (Front View)
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-11
Control Module Processor Start Refer to Figures 6-5, 6-6, and 6-7.
Verify the that the DSPX processor board, located in the control rack, has started correctly, as follows:
All procedures in this section were completed successfully for: ¨ Master 1 ¨ ACLA ¨ DSPX ¨ Master 2 ¨ ACLA ¨ DSPX ¨ Control ¨ DSPX
1.
2.
3.
g
The DSPX should boot-up with the following LED indications: ·
Green status LED steady on or blinking
·
Red fault LED blinking indicating an alarm status or off (solid red indicates a fault condition)
The ACLA should boot-up with the following LED indications: ·
Green OK LED steady on
·
Green ACTIVE LED steady on
·
Green ENET LED blinking if the Ethernet communications are connected and active. Off, if no Ethernet communications are enabled.
·
Green Status LEDs will be alternating in a clockwise progression.
For the other boards in the rack, check that the green power LEDs are steady on and the green status LEDs are steady on for the active master.
GE Motors & Industrial Systems
g
GE Motors & Industrial Systems
STATUS
RST
FAULT
OK ACTIVE ENET FLASH
E M U L
S T A T U S
COM
H S
Figure 6-6. DSPX Faceplate
6-12 · Chapter 6 Initial Startup and Commissioning
ENET
H1A
2
DSPX
1
P S O E R R T I A L
ACLA H1A
Figure 6-7. ACLA Faceplate
EX2100 Installation and Startup GEH-6631
Using the Exciter Configuration Tools GE document GEH-6414 describes the EX2100 toolbox installation and use.
The GE Control System Toolbox is a Microsoft® Windows®-based, configuration program used to tune and commission the exciter as needed for each application. The toolbox is designed with menus, block diagrams, dialog boxes, and wizards that simplify and guide you through the startup and commissioning process. For detailed information, you should refer to either the toolbox online Help or the product documents listed in the Tools/Materials Needed section.
Using Toolbox Online Help Tip Ä It is good practice to refer to the toolbox Help for any part of toolbox operation or menu and dialog options that you do not fully understand. You can access the Help files at any time after the toolbox is installed on your PC. The toolbox Help feature provides detailed information about using the toolbox. This includes installation and operation, as well as drive configuration instructions. There are several ways to access Help while running the toolbox. For
Do this
Menu commands
Highlight the command and press function key F1.
Dialog boxes
Press F1 when the dialog box displays on the screen.
Block information
Click on the desired block with the right mouse button and choose Item Help.
Help contents
Choose Help then Contents.
Help
Choose Help then Using Help.
Specific word(s)
Choose Help then Contents and Find. From there, enter the word(s) you want to find.
When you choose Help on the toolbox main menu bar, a drop-down menu provides several options for finding information.
Contents displays Help files for the toolbox. It also contains the Find tab with a work list to search for specific topics. Using Help displays general instructions on how to use Help. Item Help displays help for the item selected in the Outline View. Product Help displays the Help file for the currently loaded product. The file contains help on parameters, faults, diagrams, and wizards. Release Notes provides product changes in the toolbox. Send Problem Report allows you to submit a system change request for the toolbox. GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-13
Goto Toolbox Web Site takes you to the toolbox home page. (This feature is only available if you have a connection to the GE intranet.) About Toolbox… displays the version number of the toolbox. Refer to Figure 6-1, Block 2.
Starting the Toolbox
All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control
The remaining procedures in this chapter require that you use the toolbox and the EX2100 toolbox document, GEH-6414 Chapter 3. Instructions for performing the procedures are located there.
GE provides the toolbox on the Control System Solutions CD. Software files will be available on the Turbine HMI or supplied separately. Refer to Figure 6-1, Block 4.
Open an EX2100 File
All procedures in this section were completed successfully for: ¨ Master 1 ¨ ACLA ¨ DSPX ¨ Master 2 ¨ ACLA ¨ DSPX ¨ Control ¨ DSPX
To download exciter software with the toolbox, you must open the exciter configuration (.ecb) file for all three controls, M1, M2 and C. All EX2100 exciters are preengineered and this file should be available on the turbine control HMI or a software CD supplied with the excitation equipment. Refer to GEH-6414, Chapter 3.
Refer to Figure 6-1, Blocks 5 and 6.
Checking Toolbox/EX2100 Pattern Compatibility
All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control
The firmware pattern used to create the .ecb file must be the same version as the pattern loaded in the exciter (the ACLA and DSPX boards). If it is not, then either the flash code (which contains the pattern version) must be downloaded from the toolbox to the controls, or the .ecb file must be upgraded. Refer to GEH-6414, Chapter 3.
Note The toolbox requires the pattern directory to be located under the exact structure of GE Control System Solutions / EX2100. If this exact directory structure is not present, you must correct it.
Refer to Figure 6-1, Block 6A.
Downloading to the EX2100 Refer to GEH-6414, Chapter 3 to download the firmware pattern from the toolbox to the EX2100.
6-14 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Refer to Figure 6-1, Block 6B.
Optional: Upgrading the .ecb File
All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control
Associated with the firmware version in the drive are parameters that vary, depending on each application. These parameters are stored in the .ecb file. Tip Ä .ecb files are typically stored in a project directory. To establish the default directory from the toolbox, select Options, Settings, and the tab Directories. Then from the Default Project text box, select the browse button to find (for example) C:\Jobs\GESalem\JobName\CTRL.ecb. The revision of the firmware used to create the .ecb file must be the same as the firmware revision loaded into the DSPX and ACLA. To achieve this, it may be necessary to upgrade the .ecb file to a more recent version. The toolbox can automatically upgrade older .ecb files to newer revisions. Refer to GEH-6414, Chapter 3. Note If the version required does not appear, it needs to be installed from the Control System Solutions CD.
Refer to Figure 6-1, Block 8.
Checking for Correct Firmware and Hardware
All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 ¨ Control
Typically, firmware and hardware revisions are backward compatible with older revisions. However, occasionally the firmware depends upon a minimum revision of hardware. The release notes (RelNotes.txt, provided with the toolbox files), provide an overview of the EX2100 hardware and software relationship. Refer to GEH-6414, Chapter 3.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-15
Checking the Keypad (EDI) The two operator interfaces located on the control cabinet front door are the EX2100 Diagnostic Interface modules (EDI, most commonly called keypad). Facing the keypads (with the door closed), the left side keypad is used to interface with Master 1 and the right side with Master 2. Both keypads can access data and parameters for Control.
Refer to Figure 6-1, Block 8. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2 .
1.
Observe that each display’s heartbeat icon is pulsing (see Figure 6-8). This indicates that the keypads can communicate with the EX2100. (The cable from the keypads connects to the rack’s J303A and J310A connectors.)
Note If the keypad’s display cannot be read or contrast is poor, refer to Adjusting Keypad Display Contrast in the following section before proceeding to step 2. If faults are present, use toolbox Help (select Help, Product Help, Contents, Faults) or EX2100 Troubleshooting, Preventative and Online Maintenance Guide (listed in Equipment/Material Needed in this chapter) for information.
2.
The keypad and toolbox screens presented in this document are samples that represent one possible application. The screens for your EX2100 should display information that is specific to your configuration and application.
Using the Keypad for Startup and Commissioning The keypad can be used to check firmware and hardware versions, run the exciter, set parameters, reset the EX2100, and provide many other functions to control the exciter. This information is provided in the EX2100 User’s Guide GEH-6632.
g Display: Status Screens provide analog and digital representation of exciter functions and values.
EX2100 Excitation C
FVR Feedback 0.0 Volts FldCurrAmps 0.00 Amps Vmag
Exciter Health & State Icons -30%
0%
100%
150%
-30%
0%
100%
150%
Imag
0.00
Watts
0.00
0.00
Exciter Pll
Freq_Hz
60.00
Vars
55.00
0.00
Menu Screens provide text-based access to parameters,
Navigation
Exciter Control
Status
Reset Faults
Auto
Command
Man
wizards, and faults.
On Run (Green)
Pushbuttons: Organized into functional groups:
Menu
Menu
Stop (Red)
Navigation Voltage Level
Buttons for using the menu Exciter Control
Escape
Off
Enter
Run and Stop buttons
Figure 6-8. Front View of the Keypad 6-16 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Adjusting Keypad Display Contrast You can improve visibility of the keypad display by adjusting the contrast. This can be done using either the keypad or the toolbox. Ø To adjust keypad display contrast using the toolbox You should not see “Offline” on the toolbox status bar (bottom right side of screen).
1.
Check that the EX2100 is communicating with the PC (the Go on/offline button
is selected).
2.
In the toolbox work area, expand the items displayed in the Outline View by clicking on the plus sign next to Main Menu, General Setup, Keypad, and Keypad Meters.
3.
Double-click Keypad contrast adj to display the associated Edit Parameter dialog box.
4.
The dialog box displays the value Range for this parameter. In the Value text box area, enter a number, then click Send To Drive and OK.
5.
Reset the exciter as shown below, which resets the display to the new value. Toolbox menu bar selections.
6.
If the display is still not readable, contact GE Product Service (see Chapter 1, How to Get Help).
Ø To adjust keypad display contrast using the keypad Hold the orange MENU button down and press the Up Arrow (s) or Down Arrow (t) navigation buttons to increase or decrease the contrast (see Figure 6-8).
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-17
Commissioning the Exciter Commissioning is the final stage of starting up an EX2100 lineup. To complete the following steps, it is assumed that the EX2100 has all connections completed, control power has been applied, software has been loaded and all faults cleared. During this testing, some access to the turbine control HMI will be necessary, but most steps can be run from the exciter keypad(s). Typically, the primary power converter module and Master 1 controls are commissioned first, then Master 2 and the backup power converter commissioned. The steps must be performed in the following order, with each step for both controls completed before proceeding to the next phase of commissioning. 1. Simulator checks 2. Temporary load checks 3. Initial roll and offline checks 4. Online checks
Overview of EX2100 Parameters The parameter settings are pre-engineered prior to shipping and should not require adjustment. GE Salem should be contacted prior to any parameter modifications.
Note The procedures in this chapter are based on SAMPLE parameter values. Any parameter values referenced should not be used for any specific job. If a parameter value is in doubt, contact GE Salem for clarification. Application specific data has been entered into the EX2100 parameters found in the toolbox software files. These parameters provide the data for the application rules used in the toolbox during the validation and calculation of settings for the EX2100. Occasionally, specific parameter values require changes prior to initial operation of the equipment. Any changes to parameters should be saved in the .ecb file by uploading the parameter values from the EX2100 to the toolbox (refer to Optional: Uploading the .ECB File in this chapter). To access the block diagrams, select “Diagram” from the toolbox work area, outline view.
Parameters may be adjusted individually from the toolbox menus, the block diagram, or the keypad. Changing parameter values while the EX2100 is running is not recommended, although some parameters, such as diagnostic setups, can be adjusted with minimal risk while running. In the following paragraphs, parameters will be designated with parenthesis (MRNLM) and variables will be designated with carats . Downloads of EX2100 parameters are performed in two separate steps. Both the application layer software (ACLA) and the exciter regulator software (DSPX) are sent to the EX2100. The RED and BLUE down arrow icons are used through the toolbox. While individual parameters can be changed while the exciter is running, an entire parameter download to the DSPX processor (using the BLUE down arrow icon) is not allowed. After a download, the master core will reset which would trip the unit. The toolbox does not allow this to happen and will notify the user that the exciter is not stopped. (Refer to document GEH-6414, EX2100 Toolbox.)
6-18 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
An entire download of the application layer software, ACLA, (using the RED down arrow icon) is allowed while the exciter is running. For most application layer changes, this will be benign to the user, but a warning to the user that the exciter is not stopped is generated by the toolbox when these parameters are sent. It is possible during this process that communications with the EX2100 will be temporarily interrupted.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-19
Viewing Parameter Differences Having the pattern versions loaded equally into the file and the EX2100 does not mean that the parameters in the toolbox and the EX2100 are equal. If the parameters in the toolbox are not equal to what is in the exciter, a not equal sign ¹ displays in the Status bar at the bottom of the toolbox window. To display the differences, double-click on the not equal sign ¹. This causes the toolbox to compare its parameter values with those in the EX2100.
Calculate Parameter Final Values Final values are calculated from parameters. These values are present in the EX2100, but are not normally viewable in the toolbox unless they are overwritten. The ¹ sign at the bottom of the pattern screen does not include final values. The toolbox indicates that overrides exist in the pattern by displaying a red O at the bottom of the screen. The toolbox uses the parameter settings that were entered to calculate the parameter final values. If parameter final values are overridden, running the toolbox Build/Calc routine will not update these values. Privilege levels provide different types of access to the devices. Level 4 allows changing parameters and editing hardware, and requires a password.
Ø To view and clear overrides with Level 4 privilege 1.
From the toolbox, select the Finder button Update.
2.
Double-click on the item selected.
3. 4.
Select Clear then Override. Select Device, Reset Drive, Hard Reset.
, then Overrides, and
Overrides are typically not required and should be avoided.
6-20 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Running Simulator Mode Refer to Figure 6-1, Block 9. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2
Refer to the Control Systems Toolbox .ecb file Simulator Scaling for representations of the system models and simulator scaling. Operation of some relays may occur in Simulator Mode. Verify that flashing power and ac power to the bridge is removed or isolated from the generator field and personnel are clear from any moving devices. The EX2100 contains a built-in simulator that models a generator and static excitation system. When simulator mode is selected, the feedbacks presented to the control regulators are switched, by software, from the real feedback inputs to feedbacks derived by mathematical models mimicking the generator and field circuit behavior. The EX2100 controls then react in a manner close to the way they would react in normal operation. The simulator can serve as a valuable startup, maintenance, and training tool. While the simulator mode in the EX2100 is a very close approximation of the actual operating look and feel of the exciter, there will be some instability on the operator displays and EGD page information due to the coordination of data among the three controllers. Changes to regulator gains should not be made from observations made in simulator mode. The simulator is scaled to represent the actual system as accurately as possible. This means that when a start command is given to the EX2100, it follows a normal start sequence. Unlike the EX2000, the EX2100 will not generate actual commands to close field breakers and flashing contactors. Operation of these devices will be tested in the Temporary Load section that follows. The generator armature and field models, as well as the exciter stator and field models, provide the feedbacks for exciter field voltage and current, and generator stator voltage and current. These feedbacks are handled by the transducering algorithms the same way real feedbacks are used to calculate watts, vars, speed deviation, and frequency. If the model scaling is correct, the display data cannot be distinguished from real data. Main generator field voltages and currents are also simulated internally and used for correct model operation. The exciter regulator can be raised and lowered in automatic or manual regulator, both online and offline. The regulator limits activate at the same levels as in nonsimulated operation. The regulator responses provide a good representation of what can be expected of the real system in response to step changes. By changing the parameter containing the value representing model shaft torque it is possible to raise or lower the simulated generator real power output when simulating online operation. The exciter changes the system vars in response to changes in the exciter voltage setpoints.
Block diagrams are accessible by selecting the EX2100 Overview diagram and clicking on the appropriate page button.
In the following procedures, various block diagrams are referenced to allow access to parameters and variables for testing. These diagrams can be found in the .ecb file. The finder function in the toolbox can also be used to locate parameters and variables.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-21
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
01
01
EX2100 Overview 02
02
DSPX Side 03
Generator Ratings
$ GenRatings
Simulator: Stator and Saturation Curve
$ StatorSim
Field Side 04
C3 Logic: Transfer State Machine
$ FieldSim
Generator Stator Side Instruments
$ GenInstr
PT and CT Wiring
$ PTCT_Wiring
Start Stop Sequencing: Flashed Start
$ FlashStart
Aux. Bus Start
06
$ Keys_States
Inner Loops: Field voltage and current regulators
$ InnerLoop $ FiringControl
Bridge Thermal Alarms and Trips
$ BridgeTherm
Alarms: Individual functions
$ Alarms
Alarm and Diagnostic Strings
$ AlarmString
Trips: Individual functions
10
Analog Feedbacks
11
13
Field Signals, Test A/D's, and Bridge Temperatures
$ VCO
$ EGPA1Logic
Bridge 2
$ EGPA2Logic
(Sensor Failure)
A
General Purpose Inputs/Outputs (and 52,86)
$ GP_In_Out
D/A's and General Purpose Filters
$ Diag_Util
Capture Buffer Configuration
$ Capture
B
C
D
E
$C.Synchro
$C.LOE
$C.OEL
06
$C.VHz
07
08
$ BodeIL
09
DPM Signal Map (pages 1 & 2)
$ Dpm1
DPM Signal Map (page 3)
$ Dpm2
DPM Boolean Signals (bits 0-15)
$ DpmBits1
DPM Boolean Signals (bits 16-31)
$ DpmBits2
10
11
$ AVR
$ AutoRef
$ PSS
$ VARPF
$ HTSEN
$ UELHTC
12
$ EXASP
$ MANREF 13
$ CondSense
EMIO Outputs with Diagnostic Feedbacks
16
$ KeyPad
Outer Loop Functions
14
15
05
$ VCO_Zero
Gate Pule Amplifier Logic: Bridge 1
Conduction Sensing
$ FGD_Calc
Dual Port Memory (DPM)
$ TripString
Analog Feedbacks Offset Removal 12
$ FGD_Seq
Fault Calc / Freq Component
Inner Loop Bode Analysis
$ Trips
Trip String with enables
04
$ FGD_In
$C.Satcurve
08
09
$ Problems
Sequencing
XY Charts
07
SCR Firing Control
Problems: Master Asks for a Transfer
KeyPad
$ AuxBusStart
Auto/Manual, PT Failure, Run Requests Simulator Enable, VAR/PF & PSS Enables
$ ProtectXfer
Field Ground Detector: Input Filtering
05
03
$ Transfer
Out of Bounds protective transfers
F
15
$ EMIO_DiagFbk G
H
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$ UELREG
J
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GE Motors and Industrial Systems Salem, Va. USA
PRODUCT:
Innovation Control
saved date:
Page name: Device name:
December 12, 2000
####
Date:
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Figure 6-9. Block Overview Diagram
6-22 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
The EX2100 can be controlled from the toolbox by using the animated bar graph display instead of the door-mounted keypads. The keypads can then be used to monitor variables and I/O states while testing.
The Exciter Control Window animated bar graph display is available using the
icon
in the .ecb file of the toolbox. Click to reset faults. Click On to put the exciter in the run mode. Auto controls terminal voltage on the generator. Man controls voltage on the field.
Use Off to take the exciter out of run mode. Bar Graphs and meters provide feedback of the current state of the device.
Click + to increase or - to decrease the voltage.
1.
Place the EX2100 controls in simulator mode from the Controls Systems Toolbox or local keypad (EDI) by changing (SimMode) to a true state. Once in simulator mode, the exciter simulated speed should begin to increase. This can be monitored via . Set simulated speed to 100% via (SimSpeedRef).
Note The following procedures do NOT purport to cover all settings of the parameters in the EX2100. These checks are an assurance that the basic control features of the EX2100 are in place and will control the generator safely prior to operation with actual field voltage and current.
An upper case M1 or M2 in the keypad display indicates the active master. Lower case m1 or m2 indicates backup.
2.
Temporarily jumper the contact input on the ECTB board TB2-47and 48 to simulate 86G lockout relay reset condition. Verify that is in a true state. (Keypad menu: GP_In_Out). Removal of the jumper should toggle the variable to a False state. Replace the jumper so that is true.
3.
Verify the Master 1 and Master 2 controls are in automatic regulator mode by selecting Auto on the operator keypad (Figure 6-5). will be true.
4.
Start the excitation in simulator mode by selecting the (1) on the operator keypad. Simulated terminal voltage, field voltage, and field current should build to rated no-load values.
Only the active master can effect changes to the EX2100. Control must be transferred to the backup master through the keypad menu before the backup master keypad will raise/lower, toggle from auto to manual, or start/stop the exciter.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-23
V/HZ Limit Verification 1.
With the unit at rated terminal voltage, decrease (SimSpeedRef) to zero so that turbine speed will begin to decrease. At the appropriate value set by (ASPVHZ), terminal voltage will begin to decrease and the V/HZ Limit Active alarm will annunciate when is true.
2.
Return the simulated torque to the preset value and terminal voltage will begin to increase. At the (ASPVHZ) value, terminal voltage will stop increasing and the V/HZ Limit Active alarm will clear.
Lockout Trip Verification 1.
Remove the contact jumper on ECTB board TB1-47 and 48 for 86G lockout simulation.
2.
Verify that the exciter stops immediately.
3.
Replace contact jumper, clear any alarms or faults and restart the exciter.
AVR Preset Verification When the exciter is restarted, if the simulator is at 100% turbine speed, the automatic regulator will build terminal voltage to the preset generator rated terminal voltage, (AR_ZV).
PT Failure Detection Verification The PT failure function will only operate when the 52G input contact is open if the exciter controls are using two sets of PT inputs for the detection or the exciter PPT is fed directly from the generator terminals instead of an auxiliary bus. If there is only one set of PT inputs, and the PPT is fed from an auxiliary bus, then this test can only be performed when the unit is online. 1.
Using the PT failure picks on the GenInstr.vsd software function screen, perform the PT failure simulation. This should activate the PTUV detection as well as transfer the controls from automatic to manual regulator.
2.
De-activate the PT failure, Reset the PT failure alarms from the keypad command menu, and then transfer the exciter back to automatic regulator.
Note It should not be possible to select automatic regulator without clearing the PT failure and resetting the PT failure alarms.
AVR/FVR Upper and Lower Limits 1.
Monitor the functions on the Auto_Ref.vsd software function screen. In automatic regulator, lower excitation to the low limit of terminal voltage (ARNLM), usually –10% of rated. should be true. should be a value of five.
2.
Transfer the controls to manual regulator and again continue to lower excitation while observing the Man_Ref.vsd software function screen. In manual regulator, the excitation should stop at a value equal to (MRNLM) or 80% of no load field voltage. should be a value of 5. should be true.
3.
Observe that the balance indication on the keypad display no longer reads a zero value but has an offset (since the manual regulator is set below the AVR low limit).
Note It is not possible to check the manual regulator upper limit (MRPLM) in offline simulation mode.
6-24 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
FVR Preset Verification 1.
With excitation stopped, transfer the EX2100 to manual mode.
2.
Start the exciter and observe that the simulated field voltage builds to a value equal to (MR_ZV).
Offline Over Excitation Limit (OEL) The offline over excitation limit only operates when the EX2100 is in manual regulator.
With the EX2100 operating in manual, raise excitation voltage until the value of (FcrRefOffline) is reached. should change from a true to a zero value. (FcrRefOffline) is found on Alarms.vsd. is found on InnerLoop.vsd.
Disconnect ECTB board TB11 and 5 to prevent 86G operation. See system elementary for details.
Once the simulator is online, the 94EX contact output can be operated inadvertently. This may cause unintentional operation of protective devices outside the EX2100. Lifting of the 94EX output contacts is recommended during simulator and temporary load operation.
AVR Under Excitation Limit (UEL) With the previous offline simulated operation checks complete, the EX2100 is ready for simulated online operation. 1.
Temporarily jumper the contact input on the ECTB board TB2-45 and 46 to simulate 52G breaker closure and verify that is in a true state. (Keypad menu: GP_In_Out). Removal of the jumper should toggle the variable to a False state. Replace the jumper so that is true.
2.
Once is true, raising or lowering the terminal voltage should now change the value of . Changing the value of (SimTorqueRef) will alter the value of . These variables can be viewed on the keypad display or use the (Tramp Up/Down) adjustment on the Statorsim.vsd diagram.
3.
While monitoring the XY chart for UEL operation, and using the values of (UELX0, UELY0) through (UELX10, UELY10) as a guide, lower the terminal voltage until the UEL becomes active. Because the takeover point of the UEL is modified by the square of the terminal voltage, actual takeover points may not correlate exactly to the parameter values. Check operation of the UEL at various values of (SimTorqueRef). When the UEL is active, should be a true value.
4.
Raise excitation terminal voltage so that the UEL is no longer active, but the generator is at less than rated voltage. Lower (SimTorqueRef) to the original offline operation value.
V/Hz Trip and 94EX Verification 1.
With the generator in simulator mode and operating at less than rated terminal voltage, temporarily change (VHz1TripLev) from the normal value of 1.18 pu to 1.01 pu.
2.
Raise the simulated terminal voltage so that it exceeds the 1.01 pu value for the V/HZ trip relay. The EX2100 should generate a 94EX lockout trip request after a time delay found in (VHz1TripSec).
3.
Verify that ECTB board terminals TB1-1 to TB1-5 are shorted (closed). Closed contacts will request a trip of the generator lockout device.
4.
Remove temporary jumper for 52G and clear all alarms and faults. This concludes simulator mode testing.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-25
Temporary Load Checks Refer to Figure 6-1, Block 9. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2
Operation of the EX2100 core with a temporary load is highly recommended. Temporary load operation confirms that the EX2100 is capable of gating cells and producing excitation voltage. This can eliminate many frustrating hours of troubleshooting during initial turbine roll and generator energization if performed prior to running the unit.
Zeroing VCO Offsets 1.
2.
With no ac input voltage applied to the EX2100, voltage controlled oscillator offsets should be zeroed for the following feedback variables. (This test must be run with the exciter not gating the SCRs.) ·
Field Ground Detector Feedback
·
Field Voltage Feedback
·
Field Current Feedback.
Using the VCO_ZERO.vsd diagram, click on each feedback’s respective zero VCO button on the far right of the diagram (see Figure 6-10). The controls will automatically zero the VCOs and indicate Ready when complete.
Flashing and 41A, 41B Verification 1.
Disconnect ECTB board TB11 and 5 to prevent 86G operation. See system elementary for details.
With no ac input voltage applied to the EX2100, start the exciter by selecting the green start button on the operator’s keypad. This will cause the EX2100 to trip after attempting the start sequence. Operation of contactors and relays will occur in while testing with a temporary load. Verify that personnel are clear from any moving devices and are clear of exposed components and leads.
2.
Verify that both 41A and 41B contactors close by monitoring as well as visual verification. Use the AuxBusStart or Flash_Start page in the .ecb file as per the application being tested.
3.
For units with flashing, also verify contactors 53A and 53B for proper operation by monitoring and as well as visual verification.
4.
For units with flashing, verify that the proper polarity voltage appears on the DC voltmeter connected to the temporary load. This value can be monitored at . The EX2100 will regulate field current at the values specified in (FlashingAmpsMin) and (FlashingAmpsMax) on the FLASHSTART.vsd diagram.
5.
After the EX2100 trips, due to a lack of ac input voltage, reset all faults and alarms.
6.
Repeat steps one through five with M2 selected as Master.
6-26 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Figure 6-10. VCO Calibrate Zero Offset Diagram GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-27
Manual Voltage Regulation and Bridge Firing The main generator field leads must be disconnected during this testing. Power will be applied to ac input circuits and dc output circuits. Personnel safety practices must be observed during this testing. 1.
Confirm that the dc output to generator field is disconnected from the EX2100.
2.
Referring to the EX2100 control system elementary, identify the applicable PPT secondary voltage. An ungrounded three-phase source voltage as close to this PPT secondary voltage as possible should be connected to the ac input leads L1, L2, and L3 of the EX2100. These connections are found in the Power Converter Module. If this voltage source is significantly different than the normal PPT input voltage, (PPT_Vrms) can be adjusted for this test. This parameter is found on the Firing Control block of the .ecb file. For EX2100 units supplied from an auxiliary bus, it is possible to use the normal ac input for test purposes.
3.
Connect a resistive load capable of carrying generator field ceiling voltage and at least 3 amps to the dc (+) and dc (-) output leads. An oscilloscope using differential mode and a dc voltmeter should also be connected to this temporary load.
4.
Verify the Master 1 and Master 2 controls are in manual regulator mode by selecting Manual on the operator keypad (Figure 6-8).
5.
Apply the ac input voltage to the EX2100. The 41AC disconnect should be closed. Monitor and verify that the measured ac input voltage agrees with the ac voltmeter reading of the ac input voltage.
6.
Confirm the manual regulator preset (FvrPreset) is suitable for the temporary load chosen.
7.
Once again, start the exciter using the primary master’s keypad by pressing the green start pushbutton.
8.
After both 41A and 41B close and the flashing sequence is completed, the EX2100 should begin to gate cells and develop and output voltage equal to the value in (FvrPreset).
Note A three-phase voltage and current source can be used to simulate generator feedback signals during temporary load testing. If PT feedback is not simulated into the ECPT board inputs, the EX2100 will alarm a PT under voltage condition. This alarm will not reset until the exciter is stopped or PT feedback is simulated while running.
GT5O
GT4O GT3O
GT2O
GT6O
GT1O
PHC
PHB
PHA
190F
FALT
170F
FUSE
FANS
ALRM
COOL
Observe on the active power converter’s EGPA board that both the six gate pulse input LEDs and the six gate pulse output LEDs are lit indicating cell firing (see Figure 6-11).
GT5I
GT3I
GT4I
GT2I
GT6I
GT1I
PSOK
9.
Figure 6-11. EGPA Board LEDs Example
6-28 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
10. The oscilloscope connected across the temporary load monitoring the dc output should indicate six distinct cell firings of equal magnitude and duration. The voltage level on the dc voltmeter should agree with the value monitored at and be equal to the value in (FvrPreset). 11. From the keypad of the active master, raise (+) and lower (-) the exciter output voltage. The dc output voltage should respond is a smooth, controlled manner. The oscilloscope display should show an increasing and decreasing firing angle on the display. The values in (MRPLM) and (MRNLM) are the upper and lower limit of field voltage while operating in the manual regulator. 12. Repeat steps one through seven with M2 selected as Master.
Core Transfer Operation 1.
Continue to monitor the bridge output voltage on the oscilloscope and dc voltmeter, as well as trending .
2.
With the unit running at any output voltage, using Command Menu #2 of the keypad of the active master, transfer control to the backup master.
3.
The primary power converter should now stop gating cells as indicated by the six yellow output LEDs on the EGPA board and the backup power converter should begin gating cells. The output LEDs on the backup power converter EGPA board should now be lit.
4.
Verify that there is no change in dc output voltage and oscilloscope waveshape. The trend of should indicate that a bumpless transfer from primary to backup power converter has taken place.
5.
Using Command Menu #2 of the active master, transfer control back to the original primary power converter and again verify bumpless operation.
Static Start Voltage Reference Operation On large gas turbines, the exciter is used to supply generator field flux for the LCI during static start operation. This control should be tested prior to startup. EX2100 exciters on steam or hydro turbines will not have a static start reference input. 1.
The static start input reference can be a 0-10 volt input, 4-20ma input, or an EGD page input. If it is a hard-wired input signal, a temporary source should be connected to the ECPT board TB1 21 – 23.
2.
With the EX2100 stopped and M1 as master, force the logic in the turbine control to place the exciter in static start mode operation.
3.
Start the EX2100 with the static start input reference at its minimum value. The EX2100 should start but the dc output voltage should be zero.
4.
Using the hard-wire input reference or EGD input reference, raise the exciter output to the maximum LCI reference of no-load field voltage while in static start mode.
5.
Repeat steps one through five with M2 as the primary master.
Initial Roll and Offline Checks Refer to Figure 6-1, Block 9. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2
Initial operation of the EX2100 should not be attempted until temporary load operation has confirmed that the EX2100 is capable of gating cells and producing excitation voltage. All temporary connections and jumpers should be removed. Doors, wire tray covers, and personnel barriers should be in their proper positions.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-29
During initial roll and off line testing, high voltages and currents will be present in the EX2100 and applied to the main generator field. Generator protective relaying checks should be verified as complete and plant personnel safety practices must be observed during this testing. On large gas turbine applications, the initial operation of the EX2100 is usually during cranking or initial firing checks of the gas turbine as the field exciter for the LCI. If all simulator mode and temporary load checks in this manual have been completed, the EX2100 should be capable of providing field excitation during the commissioning of the static starter. Turbine control logic forcing will be necessary during the initial startup of the EX2100.
For the initial operation of the EX2100, the turbine control should not be allowed to automatically start the exciter. Allow the turbine to come to full speed, no load operation first and start the exciter through manual intervention of the operator. Subsequent starts can then be made with the automatic sequencing. The EX2100 should be first started in manual regulator to verify correct generator PT feedback values before starting in automatic regulator. Subsequent starts can then be made in automatic regulator once the unit has proven to be capable of operation in that mode. Extensive use of the step test, circular list, and trend recorder feature of the toolbox will allow for quick evaluation of correct operation of the EX2100.
Preparations for Initial Start 1.
Verify that the PT and CT disconnect switches are closed.
2.
Verify that generator field collector ring brushes have been installed and properly seated in the brush rigging.
3.
All power supply sources for the EX2100 should be on and the 41AC disconnect device should be closed.
4.
An oscilloscope using differential mode and a dc voltmeter should be connected to the generator field.
5.
The turbine should be at full speed, no load.
6.
The Circular List should be collecting and ready, trending variables , , and
Initial Start Procedure 1.
Start the exciter using the primary master’s keypad by pressing the green start pushbutton.
2.
The EX2100 should execute its start/stop sequence in manual regulator and build generator field voltage to a value equal to . Field current and generator terminal voltage should trend as in the following startup recording for a start command in manual mode at full speed, no load (see Figure 6-12 and Figure 6-13).
6-30 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Start Stop State
Voltage Magnitude
Voted Field Current
FvrFeedback
Cmd53A
Cmd53B
Cmd41
Start/State Fld Curr
Figure 6-12. Manual_startM1 Trend Recording Example GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-31
E1\GN_VMAG
E1\GN_IFG
E1\GN_VFLD
E1\FIRCMD
E1\GN_FREQ
E1\EX_41DC_CLSD
AVR\UEL_ERROR
Figure 6-13. ACL_manual_startM1 Trend Recording Example 6-32 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
3.
Generator terminal voltage should be independently verified by measuring the feedback on the PT disconnect switch and calculating the terminal voltage from the known PT transformer ratio. should agree with this value. If it does not, do not proceed further until this discrepancy is resolved. Also verify correct phase sequence input from the PT feedback at the PT disconnect switch(es).
4.
Alarms and diagnostics for improper phasing of the PT feedback should annunciate if incorrect. Monitor the Alarms diagram of the .ecb file for reversed phasing alarms and troubleshooting help.
5.
Raise the EX2100 output voltage slowly until rated generator terminal voltage is reached. At this point it is important to verify control feedback and scaling values for several key variables. , , , and should be checked for agreement with measured values using a calibrated measuring device. Field shunt millivolts can be used for field current verification in place of a clamp on current device.
6.
Verify that the keypad display of regulator balance reads zero at this time (then it is ready for transfer to automatic regulator).
7.
Using the active master’s keypad, transfer the EX2100 to automatic regulator. A smooth, bumpless transfer should occur. Again, using the trend recorder collecting variables , , and , and using the step test function in the Control System Toolbox, apply a 2% step to the automatic regulator for a period of 5 seconds. Generator terminal voltage should change by 2% with no instability, overshoots, or undershoots in voltage.
8.
Stop the EX100 and restart in automatic regulator. The EX2100 should now bring the generator to the value found in (AR_ZV). See Figure 6-14 and Figure 6-15.
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-33
Start Stop State
Voltage Magnitude
Voted Field Current
FvrFeedback
Cmd53A
Cmd53B
Cmd41
Start/State Fld Curr
Figure 6-14. DSPX_auto_start Trend Recording Example 6-34 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
E1\GN_VMAG
E1\GN_IFG
E1\GN_VFLD
E1\FIRCMD
E1\GN_FREQ
E1\EX_41DC_CLSD
AVR\UEL_ERROR
Figure 6-15. ACL_auto_start Trend Recording Example GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-35
Automatic Regulator Step Test With the unit at rated terminal voltage, step the automatic regulator with a 2% step to verify proper control using the AVR step test Wizard. The test can be started from the EX2100 Overview screen of the toolbox (see Figure 6-9). Select Inner Loop Bode Analysis ($ BodeIL) to get to the Frequency (Bode) Analysis or Step Test of Regulator Loops screen (see Figure 6-16). Complete instructions for the test can be printed by selecting Help from this screen in the toolbox. See Figure 6-17 and Figure 6-18 for trend recording examples of the tests.
If, at any time during this testing, the AVR operation becomes unstable, immediately transfer the EX2100 to manual regulator.
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1 sec delay
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Frequency (Bode) Analysis or Step Test of Regulator Loops
Back to
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P.Bode_Type
(also passed to ACL for buffer synchronization)
|~P.StepPrbs
P.FvrBodeScl
Q
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S
T
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02
P.Bode_PreTrig
# of passes prior to averaging
P.Bode_Passes
# of passes used for averaging
|~V.BodeActive
{P#.Bode_Type=1~
P
Toggle Start/Stop
512 (5.12 sec) 1024 (10.24 sec) default 2048 (20.48 sec)
PRBS Pseudo Randon Binary Sequence Outputs +1 -1
O
01
P.Bode_Size
StepOutputs +1, 0
05
N
None FVR FCR AVR UEL PSS GPdata
0.25 sec low going pulse
V.StepSync 04
M 0 1 2 3 4 5 6
|(V.BodeActive
!C.60 03 At Prepass V.BodePrePass
|(V.BodePreDone
At NowPass V.BodeNowPass
|(V.BodeAveDone
Pre Passes Done 04 Averaging Done
V.PrbsOut 05
{P#.Bode_Type=2,3,4,5,6~ P.ACLBodeScl
{P#.Bode_Type=0,1~
@P.BodePtr1
0
Input AAFilter1
06
{P#.Bode_Type=0,1~
@P.BodePtr2 {P#.Bode_Type=2,3,4,5,6~
V.AAFilter1 06
Output AAFilter2
V.AAFilter2
V.ACLPrbsOut {P#.Bode_Type=2~
{P#.Bode_Type=1~
07
V.FirCmd
Third order Cheby in task 1 with break at 50 Hz
07
{P#.Bode_Type=2~ V.FvrSet 08
+
V.FvrSetpoint
+
+
S
V.FcrError 08
V.FvrError
S
{P#.Bode_Type=3,4,5~ V.Avr_sp
09
1
V.FldVoltVolts
For UEL step tests via AVR, raise margin so that UEL becomes active quickly
V.FvrFeedback
st2 + 1
t2 =
10
P.FvrFbLag
P.Margin
{P#.Bode_Type=3~
09
V.Avr_fb {P#.Bode_Type=4~ V.Uelerr
10
Feedback Lag
{P#.Bode_Type=5~ V.Pssllo
11
11
12
@P.BodePtr1
{P#.Bode_Type=6~
@P.BodePtr2
{P#.Bode_Type=6~
12
13
13
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15 PRODUCT:
General Electric g Salem, Va. USA
16
File name:
EX2100 Excitation Control Firmware Revision:
Issued Date --- Initials: Revsion Date -- intials:
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L
11:47 AM
Figure 6-16. BodeIL Toolbox Screen Example
6-36 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
DPM GP ref 1
Voltage Magnitude
Figure 6-17. DSPX_Vmag_AVRSP Trend Recording Example
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-37
E1\AUTO_FB
E1\GN_IFG
E1\GN_VFLD
E1\GN_VMAG
E1\FIRCMD
AVR\UEL_ERROR
E1\WATTS
E1\VARS
Figure 6-18. ACL_1pc_step_into_AVR Trend Recording Example
6-38 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
Offline OEL and V/HZ Testing The offline OEL and V/HZ limit testing completed during simulator mode checks are sufficient for verification of limit operation. If desired, these tests can be repeated at this time with the unit in operation with actual feedback values. Use the tests as written for simulator mode testing except for adjusting actual turbine speed and voltages.
Online Checks Prior to initial synchronization, other equipment commissioning procedures will also be performed. Phasing of the generator and protective relay device operation should be completed. Verification of the synchroscope and tests of the 52G device should be complete. All parties involved in the initial unit commissioning should agree that the unit is ready to connect to the power grid.
Refer to Figure 6-1, Block 10. All procedures in this section were completed successfully for: ¨ Master 1 ¨ Master 2
The EX2100 should be first synchronized while in manual regulator to verify correct generator CT feedback before operating in automatic regulator. Subsequent synchronization and testing can then be made in automatic regulator once the unit has been proven capable of operation in that mode. The EX2100 should be operated in automatic regulator at all times when online. The unit will only transfer to manual regulator if there is a problem sensed with the PT feedback. For the initial synchronization, it is recommended to operate in manual regulator until CT feedback wiring can be verified as correct. Improper CT wiring can cause misoperation of displays, UEL, LOE and other software controls.
CT Feedback Verification 1.
Synchronize the generator and load the unit to a minimum load, preferably at least 5% of rated load and unity power factor.
2.
Verify correct CT wiring per the following table. All values listed are per unit. EX2100 displays should agree with other plant indications as to terminal voltage, frequency, stator current, watts, and vars. Do not proceed with testing until conditions are corrected.
Possible Cause
1.0
-1.0
1.0
0.0
0.0
0.0
0.0
V12 and V13 swapped
1.2
-1.0
1.0
0.0
-0.58
-0.16
-0.22
V12 polarity reversed
1.2
-1.0
1.0
0.0
0.58
0.16
0.22
V23 polarity reversed
1.0
1.0
0.58
0.5
-0.29
0.5
-0.29
I1 CT opened
1.0
1.0
0.58
0.5
0.29
0.5
0.29
I3 CT opened
1.0
1.0
0.58
0.0
-0.58
0.0
-0.58
I1 polarity reversed
1.0
1.0
0.58
0.0
0.58
0.0
0.58
I3 polarity reversed
1.0
1.0
0.12
0.0
0.0
0.0
0.0
I1, I3 CT’s swapped
1.0
1.0
0.12
0.0
0.0
0.0
0.0
I1 CT wired to phase 2
1.0
1.0
0.12
0.0
0.0
0.0
0.0
I3 CT wired to phase 2
1.0
1.0
0.81
0.66
0.0
1.0
0.0
Frequency scaling
GEH-6631 EX2100 Installation and Startup
Chapter 6 Initial Startup and Commissioning · 6-39
Other equipment may be affected if CT wiring is changed at the CT’s. Check one-lines carefully.
Do not open CT wiring with unit on line. Potential damage to equipment may occur. CT disconnect switches are make before break switches and CT wiring errors can be corrected on the EX2100 side of disconnect switches if needed.
PT Failure Operation 1.
With the unit on line, operate the EX2100 in manual regulator. Monitor the Key States diagram. Open the PT input disconnect switch to the ECPT card. The EX2100 will annunciate a PT failure and the variables on the Key States diagram should indicate less than 10% and should be true.
2.
Attempt to place the EX2100 in auto regulator from the keypad or control window animated display. The EX2100 should NOT allow operation in auto regulator mode.
3.
Restore the inputs to the ECPT board and reset the PT failure annunciation using keypad Command Menu #2.
4.
Place the EX2100 in automatic regulator mode.
5.
Once again, open the inputs to the ECPT card while trending , , , and . The trend should show an approximate one second delay between the loss of PT feedback and the switch to manual regulator.
6.
If a second PT input has been provided for the EX2100, both PT signals must be opened to produce the transfer to manual regulator.
7.
Restore the PT inputs and reset the PT failure annunciation.
Under Excitation Limit Verification The Under Excitation Limit (UEL) testing completed during simulator mode checks should be repeated at this time with the unit in operation with actual feedback values. Use the tests as written for simulator mode testing if an operation check at actual UEL limit is desired. A partial test of the UEL can also be performed. The UEL limit should be raised to a value allowing operation in a slightly leading power factor region. The unit can then be lowered slowly or stepped into the UEL limit through a step input to the Automatic Voltage Regulator. The limit should be reset to the customer supplied or factory default settings if tested at a higher limit value.
Additional Testing At this time, the EX2100 is considered ready for full load operation. Additional testing of supplied options may be required to fully commission the exciter. These include options such as VAR/Pf control and the Power System Stabilizer. Check the system software and documentation for options provided on a given application. Refer to the EX2100 toolbox document (GEH-6414) for instructions on using wizards to perform additional tests and to tune-up the exciter.
6-40 · Chapter 6 Initial Startup and Commissioning
EX2100 Installation and Startup GEH-6631
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