Category: Industry Trends

Software

The ControlST software suite is comprised of several

high performance tools for ease of use by operators and

maintenance personnel. These include the WorkstationST*

software for management of HMI and Historian functions, the

ToolboxST application for configuration and diagnostics, and

a CIMPLICITY graphics user interface. Seamless integration

provides direct connectivity from parameters on operator

screens to their corresponding alarm history, trends, logic

diagrams, watch windows, and browsers.

Software tools include system diagrams with signal flow,

sequencing, and regulator control within the excitation

control. The diagrams display variables and their values in

engineering units and in real time. Parameters shown in the

diagrams can be modified.

The flexible communication architecture enables connectivity

to other plant control systems through standard protocols and interfaces.

Dedicated Excitation Retrofit Experts

GE Vernova provides a full range of services and support

capabilities for the EX2100e excitation systems:

• Hardware, software and integration engineering

• Application expertise to support custom solutions

• Installation design and documentation packages

• Single point system responsibility – PPT, cable, bus,

networks, enclosures

• Comprehensive PSS and Modeling services

and documentation

• Project management, installation and

commissioning services

• Nuclear grade retrofit packages and DCN support

Cybersecurity

Upgrading to GE Vernova’s suite of security products allows

you to take advantage of our comprehensive cybersecurity

solutions, helping reduce your risk and ensure maximum

uptime. With over 10 years of industrial network protection

experience and hundreds of installations worldwide, our

cybersecurity solutions provide defense-in-depth protection

and have undergone strict cybersecurity best practices

demonstrating to customers that systems are developed

and implemented securely. The SecurityST platform and

GE Vernova’s Validated Patching Program are designed to

support the plant operation’s compliance to cybersecurity

standards and guidelines including NERC CIP, NEI 08-09 and

ISA99/IEC 62443.

Life Cycle Support

GE Vernova offers System Service Agreements (SSAs) and

Multi-Year Agreements (MYAs) designed to reduce the risk

and cost of maintaining your system. Subscribers benefit from

our expertise and a true partnership in the maintenance and

servicing of control systems. Service Agreement costs are

predictable, simplifying annual maintenance budgets, and

provide a proactive approach to maintenance that reduces

the risk of forced outages.

Comprehensive software libraries – drawing upon years

of OEM experience to ensure safety-related software

updates are delivered as well as built-in generator simulator for training.

I/O expandability – flexible and modular architecture allows

for future growth of capabilities and applications.

Additional capabilities available

Additional options are available with the EX2100e DFE

migration, including a power system stabilizer to meet

system grid connect requirements. Other added features and

protective functions include:

• Autotracking regulators

• PT failure throw-over

• Temperature biasing

• Volts per hertz limit

• Over excitation limit

• Under reactive ampere limit

• Under excitation limit

Benefits of EX2100e Technology

Improved performance – through a precise control and

protection system that maintains unit stability and enhances

operational flexibility.

Maintenance efficiency improvements – a simplified

architecture that shares technology with turbine and plant

controls for improved lifecycle management support and

reduced obsolescence.

Increased operational productivity − user-friendly HMI

graphics, alarm/event management, and trending leading to

improved operator recognition and resolution of system faults.

Enhanced data capture and analysis tools support regulatory

requirements.

Improved flexibility − wide range of configurations for mixed

generator fleets with redundancy options to fit application

and budget demands.

Improved reliability – available TMR controller redundancy

provides 2-out-of-3 voting to improve reliability and eliminate

single-point communication failures within the control.

Intuitive features – powerful ToolboxST software, with

modern drag-and-drop type editors, industry leading

trender with video type forward-reverse-freeze capability,

and code-compare tools.

As a backup, the system accepts a secondary power input from a dc battery bank (125 to

250 Vdc nominal). The dc secondary input is diode-isolated and combined with the

3-phase diode bridge output. These sources energize the dc link, which is an unregulated

source voltage for the control output power through the IGBTs. The dynamic discharge

(DD) circuit limits the dc link voltage level during events such as load rejection or unit trip.

The converter output section uses IGBTs to pulse-width modulate the dc link source

voltage to its final value. The chopping frequency of the IGBTs is approximately 1.000

Hz. This output is fed to the exciter field as a regulated voltage or current. An output

shunt monitors the field current. Continuous dc output is provided up to 100% rating with

temporary forcing capabilities up to 210%. Regulated output flows through a dc contactor

to the exciter field.

The EX2100e Regulator system contains interface boards that are interconnected through

a high-speed serial link (HSSL) and cabled to their associated I/O terminal boards.

DualControl (Power Bridge Warm Backup)

The EX2100e Regulator system is available in a warm backup (WBU) configuration,

which includes dual exciter control I/O and protection. The control includes M1 (Master

One) and M2 (Master Two), with two IGBT bridges that can accept separate or shared ac

input power. The control configuration can also share a common dc output circuit to the

exciter field through the transfer module. M1 and M2 are independent controls, each with

automatic and manual regulator functions. Either M1 or M2 can control bridge firing, as

determined by the operator. In the WBU configuration, M1 controls bridge #1. and M2

controls bridge #2.

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