Category: GE

Digital Controller (IGBT-based Systems)

The EX2100e Excitation control products offer a Regulator control system in a 800 mm

(32 in) enclosure with supporting hardware based on the particular application. Other

packaging options are available. The Regulator system can be purchased as part of a

finished cabinet, or individual components can be shipped separately for onsite mounting

to better serve retrofit applications.

Power conversion consists of an input section, a dc link, and the converter output section.

The input section is a 3-phase diode bridge with input filters. The system accepts a

primary ac input range of 90 to 280 Vrms, nominal for the 35 A system, and up to 480 V

rms for the 120 A system. The ac input is 480 Hz (maximum), which can be supplied as

1-phase or 3-phase from a permanent magnet generator (PMG), auxiliary bus, or

generator terminals.

To process application software, two independent Universal Controller Stand-alone Board

Version B (UCSB) controllers, with separate PCMs and an output selector module (SCM

or TCM), provide the dc output current for the exciter field (or SCTcontrol winding).

The active power bridge receives the gating commands from the active control (M1 or

M2), and supports the full-field voltage and current needs of the exciter field while the

backup power bridge’s gating circuit is inhibited. The operator has full control to select

which of the dual power bridges is active or inactive. Bi-directional, bumpless transfer

between active and inactive bridges is standard. The active master can also self-diagnose

a failure or missed operation and activate the backup control and power bridge without

operator intervention.

ControlHardware

The EX2100e Regulator system is available in several configurations to provide control

flexibility for Thyristor and Regulator systems. For small Regulator systems, two

pulse-width modulated (PWM) power converter modules use Insulated Gate Bipolar

Transistors (IGBT) to provide up to 35 A or 120 A nominal output. These systems can

support the following applications:

• Saturable Current Transformers / Power Potential Transformers (SCT/PPT) regulator

• Brushless exciter regulator

• Directcurrent (dc) rotating exciter regulator

In the SCT/PPT regulator and dc rotating exciter regulator applications, the EX2100e

Regulator system can de-sensitize the effect of the exciter time constant. It incorporates

direct measurement of the generator field voltage and field current to enhance speed of

response to system transients.

The architecture is a single control with a single Power Control Module (PCM) or dual

control with dual PCM, including a customer interface sub-system, optional diagnostic

local operator interface (touchscreen), optional control operator interface (COI) remote

touchscreen interface, control power input module, and PCM. The PCM consists of a

bridge interface sub-system, power bridge, optional ac and dc filter networks, and

alternating current (ac) and/or dc isolation devices. For expanded input and output (I/O)

capability, either VersaMax or Mark VIe control IONet I/O modules may be added.

Overview

The EX2100e Excitation Control Regulator system is GE’s most recent state-of-the-art

control system for steam, gas, or hydro generators for both new and retrofit units. Control

hardware and software design is closely coordinated between GE’s system and controls

engineering to ensure delivery of a true system solution. Integration is seamless between

Excitation Control systems, Turbine Control systems, Static Starter Control systems,

Integrated Control Systems (ICS), and the Human-machine Interface (HMI). For

stand-alone retrofit applications, integration with customer distributed control systems

(DCS) through serial or Modbus ® Ethernet is supported. This document specifically

addresses applications for the 35 A and 120 A (nominal) series of EX2100e Control

Regulator systems.

The EX2100e Regulator system supports Ethernet local area network (LAN)

communication to the following:

• Turbine controls and ICS, HMI, Proficy*-based Historian, Programming Interface

(PI-based) Historian, Onsite Monitoring System (OSM), and COI

• ExtendedI/O modules using the Ethernet Global Data (EGD) protocol

• CustomerDCSthrough Ethernet or Modbus Ethernet remote terminal unit (RTU)

• ToolboxST application

• GE OnsiteSupport for monitoring and diagnostics

Protection and Features:

 • Electronic thermal motor protection against overload.

 • Temperature monitoring of the heatsink ensures that the frequency converter trips in case of overtemperature

 • The frequency converter is protected against short-circuits between motor terminals U, V, W.

 • If a motor phase is missing, the frequency trips and issues an alarm.

 • If a mains phase is missing, the frequency converter trips or issues a warning (depending on the load).

 • Monitoring of the intermediate circuit voltage ensures that the frequency converter trips if the intermediate circuit voltage is too low or too high.

 • The frequency converter is protected against earth faults on motor terminals U, V, W

Derating for Ambient Temperature

 The ambient temperature measured over 24 hours should be at least 5 °C lower than the max. ambient temperature.

 If the frequency converter is operated at high ambient temperature, the continuous output current should be decreased.

 The frequency converter has been designed for operation at max 50 °C ambient temperature with one motor size smaller than nominal. Continuous operation

 at full load at 50 °C ambient temperature will reduce the lifetime of the frequency converter.

Derating for Low Air Pressure

 The cooling capability of air is decreased at low air pressure.

 For altitudes above 2000 m, please contact GE .

 Below 1000 m altitude no de-rating is necessary but above 1000 m the ambient temperature or the maximum output current should be decreased.

 Decrease the output by 1% per 100 m altitude above 1000 m or reduce the max. ambient temperature by 1 degree per 200 m

Safety Instructions

• Make sure the frequency converter is properly connected to earth.

 • Do not remove mains connections, motor connections or other power connections while the frequency converter is connected to power.

 • Protect users against supply voltage.

 • Protect the motor against overloading according to national and local regulations.

 • The earth leakage current exceeds 3.5 mA.

 • The [OFF] key is not a safety switch. It does not disconnect the frequency converter from mains.

Fuses

 Branch circuit protection:

 In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be short-circuited and

 overcurrent protected according to national/international regulations.

 Short circuit protection:

 GE Drive is suitable for a circuit capable of supplying a maximum of 100,000 Arms (symmetrical), 480 V maximum.

 Overcurrent protection:

 Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be carried out according to national

 regulations.

 Non UL compliance:

 If UL/cUL is not to be complied with, GE recommends using the fuses mentioned in the below table, which will ensure compliance with EN50178/IEC61800-5-1:

 In case of malfunction, not following the fuse recommendation may result in damage to the frequency converter

Highlights

 Supports two independent 10/100 Ethernet LANs. LAN1 has only one port and is dedicated to highspeed Ethernet and whereas LAN2 comprises of 3 switched ports configurable as either an embedded Ethernet controller or an embedded PROFINET controller. All four ports are located on the front panel, as shown in Figure 1.

 The embedded communications interface has dedicated processing capability, which permits the CPU to independently support LAN1 and LAN2 with:

o up to 16 combined SRTP Server and Modbus TCP Server connections out of which Modbus TCP cannot exceed more than 8 connections (or) up to 16 simultaneous SRTP Server connections (or) up to 8 simultaneous Modbus TCP Server connections.

o 8 Clients are permitted; each may be SRTP or Modbus TCP or a Combination of both.

o up to 8 simultaneous Class 1 Ethernet Global Data (EGD) exchanges.

o When used in combination for optimal performance, user must not exceed 4 Channels for Server (Modbus/SRTP) & 4 Channels for client (Modbus/SRTP), 8 PROFINET nodes and 8 EGD data exchanges.

 Ability to display serial number and date code in PME Device Information Details.

 Operating temperature range -40C to 70C (-40F to 158F).

User Features

The PACSystems* RSTi-EP EPSCPE100. is an enhanced performance standalone 1GHz programmable controller equipped with 1MB of user memory and four Ethernet ports to run real time deterministic control applications. LAN1 is dedicated to highspeed Ethernet and LAN2 comprised of 3 switched ports configurable as either an embedded Ethernet controller or an embedded PROFINET controller, which provides the PROFINET functionality and supports only simplex mode of operation. It is a standalone PLC that supports distributed I/O. From now on in rest of the document this controller will be referred to as CPE100.

The CPE100 is programmed and configured over Ethernet via GE’s Proficy Machine Edition (PME) software. It can control/process up to 2K I/O points.

Highlights include:

 A built-in PACSystems RSTi-EP PLC CPU

o User may program in Ladder Diagram, Structured Text, Function Block Diagram.

o Contains 1Mbytes of configurable data and program memory.

o Supports auto-located Symbolic Variables that can use any amount of user memory.

o Reference table sizes include 2k bits for discrete %I and %Q and up to 2k words each for analog %AI and %AQ. Bulk memory (%W) also supported for data exchanges.

o Supports up to 512 program blocks. Maximum block size is 128KB.

The PACSystems* RX3i Redundancy CPU can be used to 

perform real time control of machines, processes, and 

material handling systems. The CPU communicates with the 

programmer and HMI devices via a serial port using SNP 

Slave protocol. It communicates with I/O and smart option 

modules over a dual backplane bus that provides: 

▪ High-speed PCI backplane for fast throughput of new advanced I/O. 

▪ Serial backplane for easy migration of existing Series 90*-30 I/O. 

Features 

▪ Hot standby (HSB) redundancy. Two redundant units 

make up a redundancy system. Each unit requires one 

Redundancy CPU (IC695CRU320) and a redundancy 

Memory Xchange module (IC695RMX128/228) configured as a redundancy link. 

▪ Contains 64 Mbytes of battery-backed user memory and 

64 Mbytes of non-volatile flash user memory. 

▪ Provides access to bulk memory via reference table %W. 

▪ Configurable data and program memory. 

▪ Programming in Ladder Diagram, Structured Text, 

Function Block Diagram, and C. Refer to PACSystems RX7i 

& RX3i CPU Programmer’s Reference Manual, GFK-2950. 

▪ Supports auto-located Symbolic Variables that can use 

any amount of user memory. 

▪ Reference table sizes include 32Kbits for discrete %I and 

%Q and up to 32K words each for analog %AI and %AQ. 

▪ Supports most Series 90-30 modules and expansion 

racks. For a list of supported I/O, Communications, 

Motion, and Intelligent modules, refer to the PACSystems 

Functions

The Programmable Coprocessor Module (PCM) is a

Coprocessor to the PLC CPU.  It can be programmed

to perform operator interface, real time computations,

data storage, data acquisition and data communica

tions functions.  It communicates with the PLC CPU

over the backplane and can access user and system

data using extensions to the powerful MegaBasic lan

guage.  No application program support is required in

the PLC CPU.

Many PCMs can be supported in a single IC697 PLC

system and each can accommodate an optional ex

pansion memory up to 512 Kbytes.

Dual tasking allows running a MegaBasic program at

the same time the PCM is used as a communications

interface.  Operation of the module may be initialized

by a pushbutton or by an attached PCM development

system.  The status of the PCM is indicated by three

green LEDs on the front of the module.

Installation

• Installation should not be attempted without refer

ring to the applicable Programmable Controller

Installation Manual (see reference 5).

• Make sure rack power is off.

• Install expansion memory if required.

• Connect the battery to either of the battery con

nectors on the module. (See figure 2)

• Install in the rack. (See figure 1)

• Turn on power.

The module should power up and blink the top LED.

When the diagnostics have completed successfully the

top LED stays on.

Features

• Single slot Coprocessor

• Dual Tasking

• MegaBasic

• CCM2 Protocol

• 12 Mhz, 80C186 microprocessor

• 90% of an IBM AT performance

• Up to 96 Kbytes battery-backed CMOS logic and

data memory on board

• Supports up to 512 Kbytes optional expansion memory

• Programmed by IC647. IC640 or IBM-compatible

Personal Computer

• Two RS-422/RS-485 or RS-232 serial ports

• High performance access to PLC memory

• Real time calendar clock synchronized to PLC

• Reset pushbutton

• Three Status LEDs

• Soft Configuration (No dip switches or jumpers)

with MS-DOS or Windows based programming

software configuration function

• Simultaneous communications on both ports at up

to 9.6 Kbaud, or up to 19.2 Kbaud individually.

Expansion Memory

The PCM can operate with or without an expansion

memory daughter board.  The base memory on the

PCM board has up to 95 Kbytes user memory.  The ex

pansion memory daughter board permits expansion of

program/data memory by 64. 128. 256 or 512 Kbytes.

The battery which supports this memory is located on

the base board housing as shown in figure 2.