GE IS200EBKPG1C Exciter Backplane

The IS200EBKPG1C is an Exciter Backplane designed by General Electric (GE) for its EX2100™ Excitation Control System. This board is a core component of the EX2100 control module, providing the mounting base and electrical connections for various control boards, as well as interfaces for I/O terminal board cables. The IS200EBKPG1C board is divided into three independent controller sections: M1, M2, and C. Each section has its own independent power supply, ensuring electrical isolation and redundant operation between controllers.

In a typical EX2100 system, the M1 and M2 sections each host control boards such as ACLO or ACLE, DSPX, EISB, EMIO, and ESEL, while the C section hosts DSPX, EISB, and EMIO boards. The EBKPG1C backplane is mounted in a rack that holds these control boards, with two cooling fans at the top to ensure reliable operation of the boards within the rated temperature range.

The upper part of the IS200EBKPG1C backplane contains 24 DIN connectors for plugging in various control boards; the lower part contains 27 D-SUB connectors, three circular DIN connectors, three 12-pin power plugs, three fan power plugs, and 30 test points. All connectors are clearly labeled for easy on-site wiring and maintenance. The board design meets industrial-grade standards and is suitable for critical applications in power plant excitation systems.

II. Main Functions

The primary functions of the IS200EBKPG1C include, but are not limited to, the following:

1. Control Board Mounting and Interconnection

The IS200EBKPG1C backplane provides physical mounting locations and electrical connections for various control boards in the EX2100 Excitation Control System, including:

• ACLO/ACLE: AC Feedback Board

• DSPX: Digital Signal Processor Board

• EISB: Exciter Interface Board

• EMIO: Exciter Multi-function Input/Output Board

• ESEL: Exciter Select Board

Through the DIN connectors on the backplane, these boards can achieve high-speed signal interconnection, forming the core of the excitation control system.

2. I/O Terminal Board Interfaces

The lower part of the backplane features multiple D-SUB connectors for connecting various I/O terminal boards, including:

• EGPA/EHPA: Exciter Gate Pulse Amplifier (supports up to 6 boards)

• ECTB: Exciter Contact Terminal Board

• EXTB/EXHS: Exciter Terminal Board / Exciter High-Speed Interface Board

These interfaces connect the control boards to field signals (such as voltage, current, contact I/O, pulse triggering, etc.), enabling monitoring and control of the excitation system.

3. Independent Power Sections

The IS200EBKPG1C backplane provides independent power connections for the three controller sections M1, M2, and C. Power for each section comes from the corresponding EPSM power module and is input via the 12-pin power connectors on the backplane (J602T, J610, J612). The power supplies include:

• +24 V DC

• +15 V DC

• +5 V DC

• -15 V DC

• Digital Common

• Analog Common

The independent power sections ensure electrical isolation between controllers, enhancing system reliability and redundancy.

4. Cooling Fan Power Supply

The backplane features three 4-pin Mini-Mate-N-Lock fan power connectors (J502, J510, J512), providing power to the cooling fans for the M1, M2, and C sections, respectively. The fan power is +24 V DC, ensuring adequate heat dissipation for the boards within the rack.

5. Test Points and Signal Outputs

The IS200EBKPG1C backplane provides a set of seven test points for each controller section for diagnostic and debugging purposes. The test points include:

• 4 DAC outputs (from the EMIO board)

• 2 differential ADC inputs (to the EMIO board)

• Analog Common

The function of these test points can be configured using the Toolbox software, enabling monitoring of key signals. On Rev C and later boards, the four DAC outputs from the M1 and C sections are also available via connectors J604 and J614, which can be connected to DIN rail-mounted analog output isolation modules for metering and monitoring applications.

6. Human-Machine Interface and Communication

The backplane provides the following for each controller section:

• Keypad Connectors (J303A, J310A, J313A): Connect to the keypad on the cabinet door for local operation and display.

• Tool Connectors (J303B, J310B, J313B): Provide an RS-232C communication interface for debugging and diagnostics between an external computer and the DSPX board.

  
  

III. System Applications

1. Application in EX2100 Excitation Control System

The IS200EBKPG1C is the carrier and interconnection hub for all control boards within the EX2100 Excitation Control System. Its roles within the system include:

• Mechanical Support: Provides a stable mounting location for control boards such as DSPX, EISB, EMIO, and ESEL.

• Electrical Interconnection: Facilitates power distribution and signal transmission between control boards via the printed traces on the backplane.

• I/O Expansion: Connects the control boards to field terminal boards (e.g., ECTB, EXTB, EGPA) via the various lower connectors, enabling comprehensive monitoring and control of the excitation system.

• Redundant Isolation: Independent power supplies for the three controller sections ensure that a fault in one section does not affect the normal operation of the others.

2. Typical Application Scenarios

• Synchronous Generator Excitation Systems

• Steam Turbine Generator Excitation Control

• Hydro Turbine Generator Excitation Control

• Gas Turbine Excitation Systems

• Industrial Synchronous Motor Excitation

  
  

IV. Detailed Interface Description

1. EGPA Connectors (J306, J307, J406, J407, J506, J507)

These 37-pin connectors are used to connect EGPA or EHPA Gate Pulse Amplifier boards, supporting up to 6 Power Conversion Modules (PCMs). Signals transmitted by each connector include:

• 6 Gate Drive Positive/Negative signals (to EGPA)

• Three-phase Conduction Sensor signals (to M1 and M2)

• Alarm signal (to M1 and M2)

• Trip signal (to M1 and M2)

• Ground

2. ECTB Connectors (J405, J408, J415)

These 25-pin D-SUB connectors are used to connect the ECTB Exciter Contact Terminal Board, providing the interface between the EMIO and customer relay contacts. Main signals include:

• Auxiliary Contact Inputs (8)

• Relay Driver Commands (from EMIO)

• Relay Status Feedback (to EMIO)

• +24 V Power and Return

3. EXTB Connectors (J505, J508, J515)

These 25-pin D-SUB connectors are used to connect the EXTB or EXHS Exciter Terminal Board, providing the interface between the EMIO and pilot relays. The J515 connector for the C section does not include de-excitation and crowbar signals. Main signals include:

• Crowbar Return signal

• De-excitation Return signal

• K41, K53A, K53B coil drive and status feedback

• Contact Inputs

• +24 V Power and Common

4. Keypad Connectors (J303A, J310A, J313A)

8-pin circular connectors for connecting the keypad on the cabinet door. Signals include:

• +24 V Power

• RS-232C TX/RX/RTS (communication with EISB)

• Power Return

5. Tool Connectors (J303B, J310B, J313B)

9-pin D-SUB connectors for connecting an external computer for debugging. Signals include:

• Isolated RS-232C TX/RX/RTS (from EISB)

• Isolated Common

6. Power Connectors (J602T, J610, J612)

12-pin power connectors from the EPSM power modules. Pin assignments:

• Pin 1: Analog Common

• Pins 2, 3: 24 V Power Common

• Pin 4: -15 V Supply

• Pin 5: Digital Common

• Pins 6, 9: +24 V Supply

• Pin 7: Analog Common

• Pins 8, 11: +5 V Supply

• Pin 10: +15 V Supply

• Pin 12: Digital Common

7. Fan Power Connectors (J502, J510, J512)

4-pin Mini-Mate-N-Lock connectors providing power to the cooling fans. Pin assignments:

• Pin 1: +24 V Supply

• Pins 2, 3: 24 V Power Common

• Pin 4: Not Connected

8. Test Points

Each test point group (M1 shown as example) includes:

• TP1_M1: DAC1 Output

• TP2_M1: DAC2 Output

• TP3_M1: DAC3 Output

• TP4_M1: DAC4 Output

• TP5N_M1/TP5P_M1: ADC1 Differential Input Negative/Positive

• TP6N_M1/TP6P_M1: ADC2 Differential Input Negative/Positive

• TP7_M1/TP8_M1: Analog Common

9. Signal Conditioner Output Connectors (J604/J614, Rev C+)

12-pin connectors for connecting analog output isolation modules. Pin assignments:

• Pins 1-4: Analog Common for DAC1-4 signals

• Pins 5, 6: +24 V Power Supply to signal conditioners (max load 0.2A per pin)

• Pins 7, 8: Common Return for +24V supply

• Pins 9-12: DAC1-4 Outputs to signal conditioners

  
  

V. Installation and Configuration Instructions

1. Mounting Location

The IS200EBKPG1C backplane is pre-installed in the EX2100 control rack, which is mounted inside the excitation control cabinet. Cooling fans are located at the top of the rack. It is recommended that customers stock either a complete control rack (including backplane and fans) or just the EBKP backplane itself.

2. Board Installation

Control boards (e.g., DSPX, EISB, EMIO, etc.) are inserted into the DIN connectors on the upper part of the backplane and secured with screws. The DSPX and EISB boards are typically joined together.

3. Cable Connections

All connectors on the lower part of the backplane are clearly labeled. Cables should be connected according to these labels. It is recommended to label cables before disconnection to simplify reconnection.

4. Using Test Points

The function of the test points can be configured using the Toolbox software. Key signals can be measured at the test points using an oscilloscope or multimeter.

VI. Board Replacement and Maintenance

1. Preparation Before Replacement

• De-energize and Discharge: Power to the excitation system must be turned off before replacing the board. Follow the complete de-energizing procedures outlined in the Installation and Startup Guide (GEH-6631) and adhere to all local Lock-out/Tag-out practices. Allow time for capacitors to discharge.

• ESD Precautions: The EBKP backplane may contain static-sensitive components. ESD handling procedures must be followed: store boards in anti-static bags and wear a grounding strap when handling.

2. Replacement Procedure

1. Verify Power Off: Before opening the excitation control cabinet door, test electrical circuits to ensure power is off.

2. Label Cables: Verify all cables are correctly labeled for easy reconnection.

3. Disconnect Cables:

• Disconnect all cables from the lower part of the backplane.

• Disconnect fiber-optic cables from the EISB.

• Disconnect the Ethernet cable from the ACLx.

4. Remove Control Boards: Remove all control boards from the upper part of the backplane (note that DSPX and EISB are joined together).

5. Remove Rack: Remove the rack mounting screws and pull the entire rack out of the cabinet.

6. Replace Backplane:

• If a complete rack (with backplane and fans) is stocked, insert the new rack directly into the cabinet.

• If only the EBKP backplane is stocked, first remove the old backplane from the rack, install the new backplane, and then insert the rack into the cabinet.

7. Secure Rack: Replace the mounting screws and tighten.

8. Reinstall Control Boards: Insert all control boards into their correct slots and tighten the mounting screws.

9. Reconnect Cables:

• Reconnect all cables to the corresponding connectors on the lower backplane according to labels and tighten.

• Reconnect the Ethernet cable to the ACLx.

• Reconnect the fiber-optic cables to the EISB.

• Reconnect the fan power plugs.

10. Close Door: Close the excitation control cabinet door after completing the replacement.