6F2J0750

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO.,LTD

Vung Ang 2 Thermal Power Prant
Excitation and Generator
Control System
Instruction Manual

(O/# M258010:#1)
(O/# M258011:#2)

Jun, 2023

© TOSHIBA Energy Systems & Solutions Corporation 2023

All Rights Reserved.
 6F2J0750

Table of Contents

1. Introduction ·················································································· 2
2. Precautions for Safety ···································································· 2
3. Precautions for Handling ······························································· 21
4. Overview ····················································································· 22
5. Excitation Control Cubicle ····························································· 22
5.1 Specification ··········································································· 22
5.2 System Configuration ······························································· 23
5.3 Configuration of Control Cubicle ················································· 25
5.4 Power Supply ········································································· 25
6. Controller Printed Circuit Boards ···················································· 29
6.1 CPUL (CPU Unit) ···································································· 30
6.2 PIFL (Protocol Converter) ·························································· 31
6.3 PRCL (Power generation Regulating Controller Module) ·················· 32
6.4 EIOL (Excitation system I/O Module)············································ 34
6.5 MIOL (Multipurpose I/O Module) ················································· 36
6.6 TRCL (Thyristor Rectifier Control Module) ····································· 38
7. Description of Functions ······························································· 41
7.1 Control Functions ···································································· 41
7.2 Operation Mode ······································································ 43
7.3 Diagnostic Function ································································· 44
7.4 Transient Phenomena Recording Function ···································· 45
8. Description of Operations ······························································ 46
8.1 AVR Operation········································································ 46
8.2 Operation Procedure at Starting ·················································· 48
9. What to Do in The Event of Failure ·················································· 49
9.1 Operation and Inspection When Alarm is Issued ····························· 49
10. Maintenance and Inspection··························································· 57
10.1 Items of Inspection ··································································· 57
10.2 Periodical Replacement Parts····················································· 58
10.3 Operation for Failure of System ·················································· 58
10.4 How to Retrieve Error Log ························································ 58
10.5 Handling of Controller Printed Circuit Boards ································ 59
11. Drawing List ················································································ 62

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1. Introduction
This manual is written to ensure safe handling of the generator excitation, control equipment.
Before operation, maintenance or inspection, be certain to read this manual for proper use of
the equipment. This manual should be kept near the equipment so that it can be promptly
referred in time of need.

2. Precautions for Safety

Signs and messages in this manual and on the equipment body are important for
management, operation, maintenance and inspection. They are given to avoid possible
injuries and damages as well as to ensure correct handling of the equipment. The following
signs and short messages should thoroughly be understood before reading this manual. It is
advised that you also read the instruction manuals of related equipment and components.

This sign warns that the area is connected to a dangerous high voltage, and
you must never touch it.

This sign means that you should refer to the corresponding section of the
operation manual for important information before proceeding.

IMPORTANT MESSAGES
Read this manual and follow its instructions. Signal words such as DANGER, WARNING,
CAUTION and NOTE, will be followed by important safety information that must be carefully
reviewed.

Indicates an imminently hazardous situation, which will result in death or

! DANGER serious injury if you do not follow instructions.

Indicates an imminently hazardous situation, which could result in death or

! WARNING serious injury if you do not follow instructions.

Indicates an imminently hazardous situation, which if not avoided, may

! CAUTION
result in moderate or minor injury.
Indicates an imminently hazardous situation, which if not avoided, may
NOTICE
result in property damage.
Gives you helpful information.
NOTE

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APPLICATION
This equipment is designed for excitation control of generators. Never use this for other purposes.
This instruction manual does not include all information necessary for every possible contingency
concerning the installation, operation and maintenance of the Toshiba generator excitation system.
Further information about the Toshiba generator excitation system, particularly for the situation
which is not covered by this instruction manual, should be referred to Toshiba Energy Systems &
Solutions Corporation.

WARRANTY AND LIMITATION OF LIABILITY

TOSHIBA ENERGY SYSTEMS & SOLUTIONS CORPORATION AND THE

USER’S DIRECT SELLER ACCEPT NO LIABILITY FOR ANY INJURY, LOSS OR
DAMAGE THAT RESULTS OR MAY RESULT FROM ANY FAILURE TO
OBSERVE THE PROCEDURES, INSTRUCTIONS, WARNINGS, DESCRIPTIONS,
DATA AND INFORMATION CONTAINED IN THIS INSTRUCTION MANUAL.
THE PROCEDURES，INSTRUCTIONS，WARNINGS，DESCRIPTIONS，DATA AND
INFORMATION CONTAINED IN THIS INSTRUCTION MANUAL SHALL NOT BE
INTERPRETED AS ANY FORM OF GUARANTEE OR WARRANTY MADE BY
TOSHIBA ENERGY SYSTEMS & SOLUTIONS OR THE USER’S DIRECT
SELLER．TOSHIBA ENERGY SYSTEMS & SOLUTIONS DOES NOT MAKE ANY
GUARANTEES OR WARRANTIES OTHER THAN THOSE CONTAINED IN THE
FINAL WRITTEN PURCHASE CONTRACT BETWEEN TOSHIBA ENERGY
SYSTEMS & SOLUTIONS AND THE PURCHASER DIRECTLY PURCHASING
THE EQUIPMENT FROM TOSHIBA ENERGY SYSTEMS & SOLUTIONS ，
SUBJECT TO ALL THE LIMITATIONS PROVIDED THEREIN. ALL THE
GUARANTEES AND WARRANTIES UNDER SUCH CONTRACT RUN TO AND
ONLY TO THE BENEFIT OF SUCH DIRECT PURCHASER．THE USER’S DIRECT
SELLER DOES NOT MAKE ANY GUARANTEES OR WARRANTIES OTHER
THAN THOSE CONTAINED IN THE FINAL WRITTEN PURCHASE CONTRACT
BETWEEN THE USER’S DIRECT SELLER AND THE USER，SUBJECT TO ALL
THE LIMITATIONS PROVIDED THEREIN.

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QUALIFIED PERSONS ONLY

AS A MINIMUM SAFETY REQUIREMENT, ONLY A “QUALIFIED PERSON”
SHOULD INSTALL, OPERATE OR MAINTAIN EXCITATION AND GENERATOR
CONTROL UNIT. THIS INSTRUCTION MANUAL IS WRITTEN SOLELY FOR
USE BY A “QUALIFIED PERSON”.
ONLY A “QUALIFIED PERSON” SHOULD INSTALL, OPERATE AND MAINTAIN
THE EXCITATION AND GENERATOR CONTROL UNIT IN ACCORDANCE WITH
ALL APPLICABLE LAWS, REGULATIONS AND SAFETY PROCEDURES.

TO BE A “QUALIFIED PERSON”, YOU SHOULD HAVE SATISFIED ALL OF THE

FOLLOWING CRITERIA:
(1) YOU MUST HAVE CAREFULLY READ AND UNDERSTOOD THE
INSTRUCTION MANUAL AND ANY OTHER MANUALS OF THE
ASSOCIATED DEVICES AND COMPONENTS OF THE INSTRUCTION
MANUAL.
(2) YOU MUST HAVE RECEIVED TRAINING OFFERED BY TOSHIBA. BEFORE
YOU INSTALL, OPERATE OR MAINTAIN THE EXCITATION AND
GENERATOR CONTROL UNIT, YOU MUST HAVE BEEN SO AUTHORIZED
BY THE PURCHASER.
(3) BEFORE YOU INSTALL, OPERATE OR MAINTAIN THE EXCITATION AND
GENERATOR CONTROL UNIT, YOU MUST HAVE BEEN TRAINED BY
PURCHASER AND/OR TOSHIBA IF SPECIFIED FOR THAT ACTIVITY.
YOUR INSTALLATION, OPERATION AND MAINTENANCE MUST ALSO BE
DONE IN ACCORDANCE WITH ALL APPLICABLE NATIONAL, STATE AND
LOCAL CODES AND PURCHASER’S OWN PRACTICES.
(4) YOU MUST BE COMPETENT FOR THE INSTALLATION, OPERATION OR
MAINTENANCE OF THE EXCITATION AND GENERATOR CONTROL UNIT.
(5) YOU MUST HAVE BEEN TRAINED IN THE PROPER CARE AND USE OF
PROTECTIVE EQUIPMENT IN ACCORDANCE WITH ALL APPLICABLE
NATIONAL, STATE AND LOCAL CODES AND PURCHASER’S OWN
PRACTICES. PROTECTIVE EQUIPMENT INCLUDES A HARD HAT, A FACE
SHIELD, RUBBER GLOVES, SAFETY GLASSES AND FLASH CLOTHING;
(6) YOU MUST HAVE BEEN TRAINED TO GIVE FIRST AID.

Note: In no event should a person who does not satisfy all of the above criteria of a “Qualified
Person” install, operate or provide maintenance services for a Toshiba Steam Turbine and
Generator Unit.

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SAFETY SIGN

(1) To ensure safety, all the SAFETY SIGNS (including DANGER LABELS, WARNING LABELS,
CAUTION LABELS and NOTE LABELS) must be read and understood
(2) All the SAFETY SIGNS (including DANGER LABELS, WARNING LABELS, CAUTION
LABELS and NOTE LABELS) must be kept in such condition that they can be easily seen.
They must be clear enough to be clearly visible and never be removed or blocked from view.

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! WARNING

■ Do not touch the live parts of field main circuit immediately after
machine is stop operated.

Electric charge may remain in a capacitor and you will get electrocuted.

■ Never modify or relocate the equipment by the user or a third

party.

Modification or relocation of the equipment can cause electrocution

hazard, injuries or damages.

■ Never remove the covers in the cubicles without getting the

approval by person in charge.

Exposed live parts may cause electrocution.

■ Do not touch live parts and terminal board when the excitation
control cubicle is energized, including during operation.

This is a high-voltage circuit and you will get electrocuted.

■ Before starting the inspection, turn OFF all the "power supplies to
control circuits". Attach a tab reading "NEVER OPERATE" to the
switches to prevent possible undesired operations during the
inspection work.

If you fail to turn OFF the main circuit and power switches and also take
steps against undesired operation of the switches, other persons may
unknowingly operate these switches, causing electrocution or injury to a
person performing the inspection work.

■ Before starting the work, ground the main circuit.

Unless the main circuit is grounded, there is a potential electrocution

hazard. Before touching the live part, use a tester to ensure that there is
no voltage.

■ After the insulation resistance measurement is taken (with a

megger), be sure to discharge the capacitor.

Undischarged capacitor may lead to electrocution hazard.

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! WARNING

■ During replacement work, internal parts must be replaced with

parts specified by Toshiba.

Use of unauthorized parts can result in fire, electrocution or damage.

■ Old parts that were removed must be disposed of as industrial

waste.

If disposed of as general waste or burned, they can burst or produce

noxious gases, leading to injury or poisoning.

■ Operation, maintenance, inspection, and repair must be

performed by an authorized person (*).

Unauthorized person not familiar with these works is likely to have an

electrocution hazard or get injured.

(*) Authorized person: according to the user's definition (example: a chief

electric engineer and a person recognized as competent by the chief
electric engineer.)

■ Before starting maintenance and inspection work, be sure to turn

off the MCCBs of the power distribution unit.

■ Personnel shall attend required training before starts working.

Working without taking proper training may cause serious
accident.

■ Wiring check shall be performed after modification to verify that

modification is in line with the connection diagram.

■ Wipe water including sweat before starting the work to prevent

against the electrical hazards.

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 6F2J0750

! WARNING

■ Put up Keep Out sign/notice at all related equipment to warn the

employees about the hazardous area. Otherwise, personnel might
be exposed to danger.

■ Preserve the sharp edge (like labyrinth) prior to start working.

■ 2 personnel must check the setting value adjustment to avoid miss

setting.

■ Notify the surrounding personnel before starting the equipment.

■ All temporary setting needed on the test shall be returned to default

value prior to starting the equipment.

■ Heavy objects shall be lifted by 2 personnel.

■ Be careful not to drop the items.

Wear PPE (safety shoes).

■ Be careful not to pinch your fingers when you open and close the
door.

■ Do not touch the transformer, resistor and space heater.

These components may very hot and can cause burns.

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 6F2J0750

! WARNING

■ Worker falls by stumbled.

Watch your step. Establish prohibited entry area. Indicate caution (safety
stripe tape, cover with box, safety cone, etc.)

Keep the equipment organize at all time.

■ Wear personal protective equipment (Safety shoes, protective glove,

helmet, etc.).

■ Conduct safety education for operator.

All the workers shall be trained and supposed to understand safety

precaution, and follow the indication of the Instruction manual and safety
warning labels.

■ Meeting (daily and before start work).

Confirm the procedure and precaution of the work at the daily and pre-work
meeting in order to understand and share the safety information with all the
workers.

■ Establish prohibited entry area.

Arrange fence with warning sign to keep out people from the area where
residual risks are remain.

■ Arrange watchman and whistle a warning for danger.

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 6F2J0750

! WARNING

■ The front and rear doors must be locked at all times, including during
operation. The person in charge of management shall keep the key in safe
storage.
Live parts are located inside the equipment and personnel who are using medical
implants (pace maker etc) may be affected by the electromagnetic wave and can
cause electrocution .

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! CAUTION

 The connection of virus infected USB devices and other external

medias such as flash memory drives, CDs, DVDs, etc. to the OPS/IES
workstations may lead to miss operation and/or damage to the control
system.
Any USB devices and other external medias must be scanned and verified to
be free of viruses and malware before connection to the OPS/IES
workstations.
Any damages or repair costs incurred from the connections of virus infected
external medias to the OPS/IES workstations are the sole responsibility of
the Owner.

 The front and rear doors must be locked at all times, including during
operation. The person in charge of management shall keep the key in
safe storage.

There are live parts inside and you will get electrocuted.

 Do not touch devices in the electrical control panel immediately after

the stopping.
The devices are very likely to be hot. If you touch them, you will get burned.

 Preserve the sharp edge (like labyrinth) prior to start working.

 Wear personal protective equipment (electrical-proof shoes

etc.)Unless wear personal protective equipment, there is a potential
electrocution hazard.

 Conduct safety education for operator.

 Remind in the daily meeting to confirm work descriptions.

 The person who received safety education works according to an

engineer’s directions

 Be careful not to pinch your fingers when you open and close the
door.

 Unless wipe up water prior to start work, there is a potential

electrocution hazard.

 Do not touch the transformer, resistor and space heater.

These components may very hot and can cause burns.

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NOTICE

 While in operation, do not remove the relays.

Removing a relay during plant operation may result in a wrong signal being
issued, leading to a plant shutdown.

 When any abnormal condition such as abnormal sound, smell or

smoke result during operation, stop the operation immediately.
This abnormal condition may lead to fire.

 When moving or transporting the electrical control panel, not to apply

vibrations or impacts of more than 0.5G.
Greater impacts or vibrations may damage the equipment.

 Before turning on power of the D-AVR cubicle, check that the input
voltage is in the normal range.
Input voltage outside the normal range will cause damage to the equipment.

 Before starting operation after inspection, maintenance or repair,

check the schematic connection diagram, outline drawing and
instructions manual to see that the components are correctly mounted
and connected.
Operation without the components being correctly mounted and connected
will cause damage to the equipment.

 Before starting operation after inspection, maintenance or repair, be

sure that tools or cut chips are not left inside the equipment.
Tools or cut chips, left inside, may cause a short-circuit fault during operation
leading to fire or damage.

 Never turn OFF the MCCB while the plant is being operated.

If the MCCB is turned OFF while the plant is being operated, the protection
function of the plant may become inactive.

 Never open the fuse while the plant is being operated.

If the fuse is opened while the plant is being operated, the protection function
of the plant may become inactive.

 When replacing the fuse, always replace the fuse with a new one
having the same rating.

If a fuse with different rating is used, the protection function may become
inactive, causing the unit to burn.

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! CAUTION

 Do not use the relay for a load that exceeds the rated value of the relay
contact.

Using the relay for such a load may cause insulation defect, melting of the
contact or contact defect, leading to damage or fire.

 Do not apply an overvoltage or wrong voltage to the relay coil or carry

out wrong wiring for each terminal.

Applying a wrong voltage or wiring may prevent the relay function from being
fully exploited or adversely affect the external circuit, leading to damage or
burnout of the relay itself.

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NOTE
■ For detail, see the control block diagram and schematic connection diagram,
listed in “11. Drawing List.”

■ Before pressing the “RESET” switch, check the contents of a failure according
to “9. What to Do in the Event of Failure. ”

■ For the detailed external dimensions of the OPS, see the drawing listed in “11.
Drawing List.

■ When removing the power distribution unit, you must check that the power
line is de-energized and ground the terminal block.

■ Since there is a possibility that apparatus may be damaged if procedure is

mistaken, please be careful.

■ Wear personal protective equipment (Safety shoes etc.). Conduct safety

education for operator. Remind in the daily meeting to confirm work
descriptions.

■ The equipment must be used in the range of conditions (*) defined by the
specification.

The operation outside the specified range may result in failures.

* : Ambient temperature, relative humidity, vibration and impact, rain, wind, dust
and corrosive gases at the site of installation.

■ Around the equipment, a space necessary for inspection and other

works must be provided.
Insufficient space will hinder operation and inspection.

■ In the event of failure-caused stopping or fault annunciation, identify

the cause of trouble and take necessary steps according to the
manuals.
If the equipment is restarted with the cause of trouble left unremoved, a
greater problem will result.

■ During replacement work, use caution not to drop fastenings into the
equipment.
Fastenings, once dropped into the equipment, are difficult to recover.
They may cause a short-circuit fault.

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WARNING LABEL

This equipment is attached with warning labels. The kinds and locations of the
warning labels are shown below.
The warning labels must be kept clean. Do not contaminate, remove or block their view by
the cover.

TOSMAP

A A
↓ ↓

Right Side View Front View

Outline of AVR/GCP Cubicle

SAFETY INSTRUCTIONS
1.Read and understand the instruction
manual before operation.
2.Keep the doors locked during
operation.
3.Keep personnel clear of live parts.

Attached to the surface of all the doors of the AVR/GCP cubicle

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WARNING LABEL

Section A – A
AVR/GCP CUBICLE (1) AVR/GCP CUBICLE (2) AVR/GCP CUBICLE (3)

Arrangement of AVR/GCP Cubicle AVR/GCP (1)

Left Side

! WARNING ! WARNING ! WARNING

Hazardous voltage Hazardous voltage
Hazardous voltage
can shock, burn can shock, burn
can shock, burn
or cause death. or cause death.
or cause death.
Turn off power Ground equipment
Keep hands away
before servicing. before operation
from live parts.

Near the Earth Terminal.

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WARNING LABEL

Outline of FCB Cubicle

SAFETY INSTRUCTIONS
1.Read and understand the instruction
manual before operation.
2.Keep the doors locked during
operation.
3.Keep personnel clear of live parts.

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WARNING LABEL

! WARNING ! DANGER
Hazardous voltage
Hazardous voltage
can shock, burn
can shock, burn or cause death.
or cause death. ・Do not remove cover
Keep hands away While power on.
from live parts. ・Do not touch live parts.

! WARNING
Hazardous voltage
can shock, burn
or cause death.
Ground equipment
before operation

Near the Earth Terminal

and Busbar.
Rear View

! WARNING
! WARNING
Hazardous voltage
Hazardous voltage
can shock, burn
can shock, burn
or cause death.
or cause death.
Turn off power
Keep hands away
before servicing.
from live parts.

Left Side View Front View

Arrangement of FCB Cubicle

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WARNING LABEL

Outline of OVP Cubicle

SAFETY INSTRUCTIONS
1.Read and understand the instruction
manual before operation.
2.Keep the doors locked during
operation.
3.Keep personnel clear of live parts.

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WARNING LABEL

Front View Back View

! WARNING
Hazardous voltage
can shock, burn
or cause death.
Keep hands away
from live parts. ! WARNING
Hazardous voltage
can shock, burn
! DANGER or cause death.
Turn off power before
Hazardous voltage
servicing.
can shock, burn
or cause death. ! WARNING
・Do not remove cover
Hazardous voltage
While power on.
can shock, burn
・Do not touch live parts.
or cause death.
Ground equipment
before operation.

Left side View Right side View

Arrangement of OVP Cubicle

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3. Precautions for Handling

To prevent a possible failure, these precautions must be followed.

■ The equipment must be used in the range of conditions (*) defined by the
specification.

The operation out of the specified range may result in failures.

* : Ambient temperature, relative humidity, vibration and impact, rain, wind, dust and
corrosive gases at the site of installation.

■ Around the equipment, a space necessary for inspection and other works must
be provided.

Insufficient space will hinder operation and inspection.

■ In the event of failure-caused stopping or fault annunciation, identify the cause

of trouble and take necessary steps according to the manuals.

If the equipment is restarted with the cause of trouble left unremoved, a greater
problem will result.

■ During replacement work, use caution not to drop fastenings into the
equipment.

Fastenings, once dropped into the equipment, are difficult to recover. They may
cause a short-circuit fault.

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4. Overview
This manual describes the excitation control equipment.

5. Excitation Control Cubicle

5.1 Specification
This control equipment is manufactured to the specification shown in Table 5.1.1.
Table 5.1.1 Specification of the excitation control equipment

No. Item Specification Remarks

1 Generator rating TAKS-2P-820,000kVA-3000rpm-23,500V-20146A-50Hz-0.85pf-
520kPag
2 Thyristor rating 3021kW 530V 5300A 1S-5P-6A
3 Applicable standard ANSI / IEEE Std. 421.2
IEC 60034-1 (2017)
Toshiba Manufacture’s Std.
4 Excitation system Thyristor excitation system
5 Voltage setting range 90%-110% of the generator rated voltage
6 Overall voltage variation Within ±1.0%
7 Environment condition Ambient temperature:
･Indoor Installation: 0～40℃
8 Insulation resistance 5Mohms or more using DC500V megger

9 Withstand voltage Control circuit: AC1500V for 1 minute

Main circuit: AC5140V for 1 minute
10 Paint color - AVR/GCP, THY, INI cubicle
Outside surface : RAL 1015 (semi gloss)
Inside surface : RAL 1015 (semi gloss)
Channel base : RAL 1015 (semi gloss)
Components mounted inside : Supplier's standard
11 VT input VT rating : 23500/√3 V / 110/√3V
Class : CL.0.2
12 CT input CT rating : 22000/5A
Class : 0.3B-1.8
13 AC control power Rated voltage : 230V 50Hz
Voltage variation range : ±10%
14 DC control power Rated voltage : 230V
Voltage variation range : -10%～+15%

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5.2 System Configuration

Fig. 5.2.1 shows the system configuration of the excitation control system. In the thyristor
excitation system, the 6.9kV SWGR voltage is converted through an excitation transformer and
a thyristor rectifier into DC voltage for excitation power.
Main components of excitation control system are AVR (digital automatic voltage regulator)
which has 32 bits CPU, EIOL(Excitation system I/O Module) which is the detecting circuits of
generator operating situation for the controller.
The inputs of EIOL are secondary signals of generator output VT and CT.
Input signals to the EIOL are isolated and translated to adequate values in it. AI (Analog Input)
block in the controller detects these values and the controller calculates the output by installed
operation-software according to these values.
The calculated result is translated to TRCL (Thyristor Rectifier Control Module) and outputs to
thyristor rectifier.
The Master(PRC-A/B) controller is duplicated so that a fault in the main system will result in an
automatic switchover to a stand-by system.

NOTE

■ For detail, see the control block diagram and schematic connection diagram,
listed in “11. Drawing List.”

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－24－
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Fig. 5.2.1 System Configuration of Excitation Control System

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5.3 Configuration of Control Cubicle

The control cubicle consists of AVR cubicle and GCP Cubicle.
The AVR cubicle accommodates the Master(PRC-A/B) controllers and performs main function
as generator excitation control.
The GCP cubicle accommodates the System(CPU-A/B) controllers and performs auxiliary
function such as AVR interfacing for monitoring and operation.

5.4 Power Supply

(1) Power Supply Unit
Two power supply units are provided to accommodate both of AC and DC input.

(2) Power Distribution for Excitation Control System

Fig. 5.4.1, Fig. 5.4.2, Fig. 5.4.3 shows the power distribution for the excitation control system.
(a) The power supplies for controllers and the pulse amplifier are a two-input AC and DC
system.
(b) Power monitor relays are provided for each control power input and for each power unit
output to issue an alarm in the event of abnormality.

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AVR/GCP CUBICLE
AC MCCB CP
INPUT FLT PWU-A A-MASTER
(120V) CONTROLLER
CP
TC B-MASTER
84 CONTROLLER
CP A-SYSTEM
MCCB CONTROLLER
DC
FLT PWU-D CP
INPUT B-SYSTEM
(125V) TC DIODE CONTROLLER
CP
84 etc.
MCCB
FLT PWU-A FOR IO

TC
84
MCCB
FLT PWU-D

TC DIODE
84
MCCB
HPIP AC POWER

MCCB
AVR COMMON

RY

RY：POWER SUPPLY VOLTAGE MONITOR RELAY

84：OVERVOLTAGE MONITORING RELAY

Fig.5.4.1 Power distribution for AVR/GCP cubicle

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FCB CUBICLE
MCCB CP
AC
FLT PWU-A A-MIOL
INPUT
(120V) CP
TC B-MIOL
84
MCCB
DC
FLT PWU-D
INPUT
(125V) TC DIODE
84
MCCB
FLT PWU-A FOR IO

TC FOR OVP
84
MCCB
FLT PWU-D

TC DIODE
84
MCCB AUT
TRANSDUCER

AC MCCB F
INPUT RECEPTACLE
(127V) LIGHTING UNIT
SPACE HEATER

84：OVERVOLTAGE MONITORING RELAY

OVP CUBICLE
AC MCCB F
INPUT LIGHTING UNIT
(127V) SPACE HEATER

Fig.5.4.2 Power distribution for FCB cubicle, OVP cubicle

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THY CUBICLE
MCCB
AC
FLT
INPUT
(120V)
MCCB
DC
FLT
INPUT
(125V)

MCCB CP
PWU-A A-TRCL
CP
TC B-TRCL
84
MCCB C-TRCL
PWU-D

TC DIODE
84
MCCB
PWU-A FOR IO

TC
84
MCCB
PWU-D

TC DIODE
84
DIODE
PWU
-A1

PWU
-D1
DIODE
PWU GPOL-1
-A2
GPOL-2

PWU
-D2

AC F
INPUT LIGHTING UNIT
(127V) SPACE HEATER

84：OVERVOLTAGE MONITORING RELAY

Fig.5.4.3 Power distribution for THY cubicle

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6. Controller Printed Circuit Boards

Printed circuit boards for the System(CPU) controller, the Master(PRC) controller and the main
components of this cubicle are shown in Table 6.1 and 6.2.

Table 6.1 List of PC boards for the System(CPU) controller

Module name Module type
CPU Unit CPUL01
Protocol Converter PIFL01

Table 6.2 List of PC boards for the Master(PRC) controller

Module name Module type
Power generation Regulating Controller module
PRCL01G001
(PRCL)

Excitation system I/O Module EIOL01G001

(EIOL) EIOL02G001

Multipurpose I/O Module MIOL01G001

(MIOL) MIOL02G001

Thyristor Rectifier Control Module

TRCL01G001
(TRCL)
TRCL02G001
Gate Pulse Output Module
GPOL01G001
(GPOL)

The printed circuit boards are mounted with various switches and LEDs. In the following pages,
the switches and LEDs are described.

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6.1 CPUL (CPU Unit)

This equipment is the TOSMAP-LX series CPU unit CPUL01.This equipment sends control
commands to the protocol converter PIFL01, which converts the protocols between the 1
Gbps/100 Mbps/10 Mbps Ethernet and PROFIBUS. This equipment, combined with PIFL01,
can realize a redundant network structure.

NOTE

■ Do not turn on/off CPUL01 by turning on/off of +24 VDC power supply. Be sure
to turn on/off CPUL01 by operating the power switch of CPUL01. Otherwise, it
may cause damage or failure of the equipment.

■ Do not insert or remove the power supply connector to CPUL01 when +24 VDC
is applied. It may cause damage or failure of the equipment.

Table 6.1.1 Description LED

LED Color State
PW R Blue Turns on when the power switch is pressed Power switch
and CPUL01 is booting up.
Turns off when the power switch is pressed
and CPUL01 is shutting down.
SSD Blue Turns on when the SSD data is accessed.
PRM Blue Turns on when used as the regular system in a
redundant structure.
STB Blue Turns on when used as the stand-by system in
a redundant structure.
RUN Blue Turns on during the RUN/TEST mode.
ERR Red Turns on when a failure occurs.
INIT Blue Turns on during initialization or the INIT mode.
TEST Blue Turns on during the Test mode.
Status Green Turns on in green during the 1000BASE-T
mode.
Orange Turns on in orange during the 100BASE-TX
mode.
Off Turns off during the 10BASE-T mode.
Active Orange Turns on when the link is established.
Blinks during transmission and reception.
Off Turns off when the link is not established.

Table 6.1.2 Description Switch

ﾛｹｰｼｮﾝ 名称 機能
Fig.6.1.1 CPUL Face Plate

+24VDC Power Supply Connector

Rotary Switch for RGB Connector

IP Address Setting for Debug/Maintenance
Fig.6.1.2 Top view of CPUL USB Connector
for Debug/Maintenance

Fig.6.1.3 Bottom view of CPUL

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6.2 PIFL (Protocol Converter)

This equipment is a protocol converter unit between the 1 Gbps/100 Mbps/10 Mbps Ethernet for
the control of the TOSMAP-LX series and the PROFIBUS. This unit works on the control
commands from the upper level CPU CPUL01. This equipment, combined with CPUL01, can
realize a redundant network structure

Table 6.2.1 Description LED

LED Color State
PWR Blue Turns on when energized.
RUN Blue Turns on in the normal operation state.
INIT Blue Turns on during initializing the board.
COM Blue Turns on during the PROFIBUS
communication.
ERR Red Turns on when an error occurs.
PROFIBUS Green Turns on or blink in green or red depending on
RUN/ERR the state of the PROFIBUS communication. (*)
Status Yellow Turns on in yellow during the 1000BASE-T Reset switch
mode.
Green Turns on in green during the 100BASE-TX
mode. Status
Off Turns off during the 10BASE-T mode.
Active Green Turns on when the link is established. Active
Blinks during transmission and reception. PROFIBUS
Off Turns off when the link is not established. connecter
Status
Table 6.2.2 Display Pattern of Profibus RUN/ERR LED (*) Active
Color ON/OFF Description
Green On Communication has been established with
all the slave units. If the state of
communication establishment with slave
units is unstable, the green and red LEDs
can turn on alternately.
Periodical blink Although PROFIBUS connection has been
configured, there are no bus communication
applications.
Non-periodical A connection error or stack error occurs. Fig.6.2.1 PIFL Face Plate
blink
Red On Communication has not been established
with any slave unit.
Non-periodical Communication has not been established
blink with at least one slave unit. (The connection
with one or more slave units is abnormal.
There are some slave units connected
correctly.)

+24VDC Power Supply Connector

Rotary switch for

IP Address Setting

Fig.6.2.2 Top view of PIFL Fig.6.2. Bottom view of PIFL

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6.3 PRCL (Power generation Regulating Controller Module)

This unit is a power generation regulating controller (PRC) module: PRCL01 of TOSMAP-LX
series.
This controller is appropriate for high-speed sampling control (e.g., closed loop control system)
and applied to a control unit that requires high-speed calculation such as generator excitation
control.
The connection is established with TOSMAP-LX series CPU unit CPUL01 via 1 Gbps Ethernet
for control, and with indicator (Local Control Terminal) via 100 Mbps Ethernet. Various system
configurations are allowed by connecting with IO module that realizes high-speed sampling via
dedicated PRC Module Link (PM-Link) that realizes high-speed response. Depending on the
importance and reliability requirements for control equipment, duplex or single system can be
configured.
In the duplex configuration, high-speed communication between each PRC module is possible
with the tracking link.
If the reset switch is pressed in the failed state where the error LED is lit, PRCL will shift to the
initialization mode in which the control program stops.
If the RUN/STOP switch is set to STOP, PRCL will shift to maintenance mode in which CPU is
shutdown.

NOTE

■ Do not set the RUN/STOP switch to STOP except when replacing PRCL01
module.

NOTE

■ Do not remove the power connector when the RUN/STOP switch is on "RUN"
while the DC + 24 V power is on. Failure to follow the instruction could result in
damage of control program.

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Table 6.3.1 Description LED

LED Color State Reset switch RUN STOP
PWR Blue Turns on when energized. switch
OPR Blue Turns on when selected as the operating
system in a redundant structure.
RUN Blue Turns on during the RUN or TEST mode. PM-Link
ERR Red Turns on when a failure occurs. connector
INIT Blue Turns on during initialization or the INIT mode.
Active
TEST Blue Turns on during the Test mode.
CH0 Blue Turns on during PM-Link CH0 communication.
Status
CH1 Blue Turns on during PM-Link CH1 communication. PM-Link
CH2 Blue Turns on during PM-Link CH2 communication.
Active connector
CH3 Blue Turns on during PM-Link CH3 communication.
Status
Status Green Turns on in green during the 1000BASE-T
mode.
Active PM-Link
Orange Turns on in orange during the 100BASE-TX
mode. connector
Status
Active Orange Turns on when the link is established.
Blinks during transmission and reception. Active
Off Turns off when the link is not established. PM-Link
Status connector
Table 6.3.2 Specifications of Recommended Optical Cable(PM-Link)
Item Description Remarks
Fiber type MMF (multi-mode optical fiber)
Core/clad 62.5 ± 3.0 μm/125 ± 3.0 μm
diameters
Numerical 0.275 ± 0.015
aperture (NA)
Modal bandwidth 200 MHz ・ km @ 850 nm and Fig.6.3.1 PRCL Face Plate
more
Maximum 3.5dB/km @ 850 nm or less
attenuation
Optical connector DSC IEC 61754-4,
JIS C 5973(F04)

Table 6.1.3 Description Connector

Rotary Switch for
MODE Switch
+24VDC power supply connector

Rotary Switch for

IP address setting
Fig.6.3.2 Top view of PRCL
Fig.6.3.3 Bottom view of PRCL

Table 6.3.2 shows the specifications of recommended optical cable(PM-Link). An optical cable
shall be in accordance with the following specifications (EIA/TIA 568 standard).
The cable of core/clad diameter 50/125 μm, although usable, will increase the attenuation at the
connector connection and thus reduce the maximum transmission distance; it is recommended
to use the cable of 62.5/125 μm.
The cabling shall be in accordance with the ANSI wiring standard EIA/TIA-568 (or ISO/IEC
11801).

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6.4 EIOL (Excitation system I/O Module)

This unit is TOSMAP-LX series excitation system I/O module.
This module is equipped with general-purpose analog input, analog output, digital input, and
digital output, performs I/O with various external equipment connected to the AVR panel,
and communicates with the PRC module.
This module consists of a multiplexing part(EIOL01) and a common part(EIOL02). Duplex
configuration is implemented with two multiplexing parts and one common part.
If the RUN/STOP switch is set to STOP, EIOL01 will shift to maintenance mode in which module
functions including output signals, PM-link and SV-Link stop. As a result, the related system
becomes equivalent to a failure.

NOTE

■ Do not set the RUN/STOP switch to STOP except when replacing EIOL01
module.

NOTE

■ When removing the power connector while the DC + 24 V power is on, make
sure to turn the RUN/STOP switch to “STOP” before removing the connector.

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RUN/STOP
Table 6.4.1 Description LED switch
LED Color State
PWR Blue Turns on when energized.
ERR Red Turns on when an error occurs.
CH0 Blue Turns on when SV-Link Data transmission
CH1 Blue Turns on when PM-Link Data transmission

Table 6.1.2 Description Switch

ﾛｹｰｼｮﾝ 名称 機能
MODE switch

Table 6.1.3 Description Connector

ﾛｹｰｼｮﾝ 用途 備考
40Pin フラットコネクタ

Fig.6.4.1 EIOL01 Face Plate

Fig.6.4.2 EIOL02 Face Plate

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6.5 MIOL (Multipurpose I/O Module)

This unit is TOSMAP-LX series general-purpose I/O module.
This module is equipped with general-purpose analog input, analog output, digital input, and
digital output, performs I/O with various equipment mounted on a field circuit breaker
cubicle and communicates with the PRC module.
This module consists of a multiplexing part(MIOL01) and a common part(MIOL02). Duplex
configuration is implemented with two multiplexing parts and one common part.
If the RUN/STOP switch is set to STOP, MIOL01 will shift to maintenance mode in which module
functions including output signals and PM-Link stop. As a result, the related system become
equivalent to a failure.

NOTE

■ Do not set the RUN/STOP switch to STOP except when replacing MIOL01
module.

NOTE

■ When removing the power connector while the DC + 24 V power is on, make
sure to turn the RUN/STOP switch to “STOP” before removing the connector.

－36－
 6F2J0750

Table 6.5.1 Description LED RUN/STOP

LED Color State switch
PWR Blue Turns on when energized.
ERR Red Turns on when an error occurs.
CH0 Blue Turns on when PV-Link Data transmission

名称 機能
Table 6.1.2
Description
Switch MODE switch
ﾛｹｰｼｮﾝ

Table 6.1.3 Description Connector

ﾛｹｰｼｮﾝ 用途 備考
40Pin フラットコネクタ

Fig.6.5.1 MIOL01 Face Plate

Fig.6.5.2 MIOL02 Face Plate

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6.6 TRCL (Thyristor Rectifier Control Module)

This module is equipped with synchronizing signal input, field current input, gate pulse
output, individual system digital input, general-purpose digital input, and general-purpose
digital output. This module performs I/O with various equipment mounted on the thyristor
rectifier panel, and communicates with the PRC module.
This module consists of a multiplexing part (TRCL01), a common part (TRCL02), and a
pulse output part (GPOL01). Duplex configuration is implemented with two multiplexing
parts and one common part.
If the RUN/STOP switch is set to STOP, TRCL01 will shift to maintenance mode in which
module functions including output signals and PM-Link stop. As a result, the related system
become equivalent to a failure.
If the ON/OFF switch is set to OFF, GPOL01 will shift to maintenance mode in which output
pulses stop. As a result, the related thyristor bridge become equivalent to a failure.

NOTE

■ Do not set the RUN/STOP switch to STOP except when replacing TRCL01
module.

NOTE

■ Do not set the ON/OFF switch to OFF except when replacing GPOL01 module.

NOTE

■ When removing the power connector while the DC + 24 V power is on, make
sure to turn the RUN/STOP switch to “STOP” before removing the connector.

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Table 6.6.1 Description LED RUN/STOP

LED Color State switch
PWR Blue Turns on when energized.
ERR Red Turns on when an error occurs.
CH0 Blue Turns on when SV-Link Data transmission
CH1 Blue Turns on when PM-Link Data transmission
U Blue For maintenance
V Blue
W Blue

名称 機能 MODE switch
Table 6.1.2 SET switch
Description PHS switch
Switch
ﾛｹｰｼｮﾝ

Table 6.1.3 Description Connector

ﾛｹｰｼｮﾝ 用途 備考
40Pin フラットコネクタ

Fig.6.6.1 TRCL01 Face Plate

Fig.6.6.2 TRCL02 Face Plate

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ON/OFF
Table 6.6.2 Description LED switch
LED Color State
PWR Blue Turns on when control power energized.
PFD Red Turns on when an pulse failure detect.
U Blue Turns on when U phase output.
V Blue Turns on when V phase output.
W Blue Turns on when W phase output.
X Blue Turns on when X phase output.
Y Blue Turns on when Y phase output.
Z Blue Turns on when Z phase output.
100V Blue Turns on when DC100V energized.

名称 機能
Table 6.1.2
Description
Switch
ﾛｹｰｼｮﾝ

Table 6.1.3 Description Connector

ﾛｹｰｼｮﾝ 用途 備考
40Pin フラットコネクタ

Fig.6.6.3 GPOL01 Face Plate

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7. Description of Functions
7.1 Control Functions
The control function of the excitation controller is explained below. The control functions are
performed by the Master(PRC-A/B) controller and the System(CPU-A/B) controller.

Table 7.1.1 Control functions

Division
Function Outline of Function SC MC
(CPU) (PRC)

Automatic voltage The gate pulse phase of the thyristor rectifier is adjusted so
regulator that the generator terminal voltage and the voltage set value ○
(AVR) (90R) agree.
Manual excitation The gate pulse phase of the thyristor rectifier is adjusted so
controller that the generator field current and the field current set value ○
(MEC) (70R) agree.
Voltage setting The AVR control target value (voltage set value) is
(90R) calculated and output.
○
At starting by AVR, the voltage raise control is performed
using a ramp function after reaching 90% voltage.
Field current setting The MEC control target value (field current set value) is
○
(70R) calculated and output.
Over excitation limiter This function limits the field over current of the generator.
(OEL) This function has an operation delay characteristic (inverse
○
time characteristic) to allow for over excitation operation that
supplies fault current in the event of power system fault.
Under excitation limiter This function ensures that the leading power factor
(UEL) operation will not exceed the following characteristic
equation ○
2 2
Q/et = -a+b(P/et ) .
A two-line setting can be made.
V/Hz limiter This function limits over voltage per hertz of generator and
○
(VPFL) main step-up generator transformer.
Automatic reactive The AQR regulates the reactive power of the generator by
power regulator controlling the 90R (the reference of AVR). The control
(AQR) equation is “Q=a+bP”. The parameter a and b are set
by the setter on the OPS screen. If the reactive power(Q)
○
of the generator deviates from “ Q=a+bP”, the AQR
function raise or lower the 90R in order to pull back the
reactive power to the above equation.

－41－
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Division

Function Outline of Function SC MC

(CPU) (PRC)

A PSS-2B function is provided. A stabilization signal to

Power system stabilizer
suppress active power fluctuation of the generator is ○
(PSS)
added to the AVR input signal.

90R automatic follow-up 90R of the standby system is made to follow 90R of the
○
(AFU) active system.

Generator Auxiliaries This function performs monitoring of the generator

condition (alarm and indication) , to operate auxiliary units. ○
control

Auto- excitation
mated system This function performs automatic start sequential control
○
function starting during excitation system starting.

Test OPS interface This function performs operation and display processing
○
on OPS.
Transient
recording This function performs the step signal input processing
○
function and the transient recording processing.

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7.2 Operation Mode

The outline of the operation mode of the excitation system is explained below. For the detailed
operation procedure, see Section 8.
In the following figures, represents the step performed by the operator and
represents the step that is automatically performed.

7.2.1 Automatic Starting Mode

This mode automates the excitation control and the paralleling control at the starting. After the
turbine has reaches the rated speed, starting the excitation and paralleling control sequences
results in automatic execution of a series of controls up to synchronous paralleling.

Field circuit breaker is closed Field circuit breaker close command is send from
EHC.

AVR is put in service

These controls are automatically executed by D-AVR.
There is no need for an operator to take any action.

Generator voltage is established

Voltage matching Raise or lower commands are sent from GCP.

Fig. 7.2.1.1 Automatic starting mode

7.2.2 Manual Starting Mode

This mode allows an operator to manually perform a series of controls, from closing the field
circuit breaker and, after the generator voltage is established, operating 90R for voltage
matching to paralleling.

Close field circuit breaker FIELD CIRCUIT BREAKER [CLOSE] is operated.

AVR is put in service

These controls are automatically executed by
D-AVR.
There is no need for an operator to take any action.
Generator voltage is established

Voltage matching 7-90R [Raise/Lower] is operated to match the

voltages.

Paralleling Generator CB [ON] is operated.

Fig. 7.2.2.1 Manual starting mode

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7.3 Diagnostic Function

The major contents of diagnostic functions are shown below.

Table 7.3.1 Contents of major diagnostic functions

Category Item Diagnostic

Detection of failure in each controller including

Controller failure detection Master(PRC) controller and System(CPU)
controller

System diagnostic Special module failure Detection of failure in special modules such as
detection EIO, TRC, MIO and IO cards

Communication failure Detection of failure in IO Net, C-Net, CPU

detection tracking and Profibus protocol connection cable

Phase control failure Pulse output open phase Detection of open phase in thyristor gate
detection detection pulses automatically

Fuse blown Fuse failure detection Detection of failure in thyristor fuse

Detection of over voltage at output for DC24V

Over voltage detection
power supply unit through monitoring relay
Power unit failure
detection
Under voltage detection Detection of output under voltage

The results of diagnostics are shown on OPS.

The self-diagnostic results are recorded as error logs that help identify the cause of trouble.

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7.4 Transient Phenomena Recording Function

This controller cubicle receives many control quantities such as generator voltage and field
current.
The master(PRC) controller has the function of recording these control quantities cyclically.
With this function it is possible to precisely reproduce the transient phenomena that occurred
at generator and exciter failures, providing data that are very useful in the analysis of the fault.

Table 7.4.1 Transient phenomena recording function

Item Specification
Recording * 32 points x device (bit) data A total of 32 points including failure
items signals and digital inputs.
* 8 points x analog (value) data A total of 8 points including
generator voltage, active power, reactive power and field current.
Recording items can be changed.

Method of While the generator is running normally, record is taken at all time.
The recording is stopped according to the fault condition of the
recording
exciter. The recording can also be stopped by the touch operation
(manual hold) on the OPS, thus allowing easy gathering of dynamic
characteristic test data.

Period of The number of recorded points is 1000 for each signal.

recording The standard period of recording is 10 seconds.
The recording time can be set (or changed) arbitrarily.

700 point 300 point

200 point 800 point

Method of Recorded data is transferred to a maintenance tool, where it is

reproducing displayed as a graph (trend data).
recorded data
Other The recorded data can be reproduced repetitively.
The recorded data disappear when the master(PRC) controller
power is lost.

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8. Description of Operations
8.1 AVR Operation
The operation of the excitation control system is performed by the control switches.
Table 8.1.1 shows the functions of control switch.
Table 8.1.1 Functions of control switches
Switch Function Location

FIELD CIRCUIT OPEN / CLOSE switch for field circuit OPS/

BREAKER breaker.
GCP
OPEN CLOSE

EXCITATION MODE MEC / AVR selection switch for OPS

EXCITATION MODE.
MEC AVR

A or B channel selection switch for OPS

AVR CHANNEL
AVR.
A B

PSS OFF / ON switch for PSS. OPS

OFF ON

AQR OFF / ON switch for AQR. OPS

OUT OF IN
SERVICE SERVICE

90 R S E T T E R
Adjustment switch for generator OPS/
voltage.
GCP

70 R S E T T E R Adjustment switch for field current. OPS

55 R S E T T E R Adjustment switch for power factor. OPS

57 R S E T T E R Adjustment switch for reactive power. OPS

－46－
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Table 8.1.1 Functions of control switches

Switch Function Location
THYRISTOR COOLING A or B channel selection switch OPS
FAN SELECT for Thyristor cooling fan.
A B

A/B THYRISTOR
RELEASE / STOP LOCK/ OPS
COOLING FAN STOP / START switch for
STOP
Thyristor cooling fan operation
RELEASE STOP START mode.
LOCK

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8.2 Operation Procedure at Starting

The operation procedure at starting is explained for each starting mode.

8.2.1 Auto Start Mode

Table 8.2.1.1 Operation procedure for auto start
Item Operation procedure What to check

Operation * Turbine speed must be 3,528 rpm or higher.

condition * Either A-system or B-system of the PRC
check controller is selected.
* No alarm associated with exciter is issued.
Excitation * 41E is closed automatically. * Check that FIELD CIRCUIT BREAKER
start [CLOSE] lights up.
* Check that the generator voltage is
established.
Voltage * Voltage matching is performed
matching automatically.

8.2.2 Manual Start Mode

Table 8.2.2.1 Operation procedure for manual start
Item Operation procedure What to check

Operation * Turbine speed must be 3,528 rpm or higher.

condition * Either A-system or B-system of the PRC
check controller is selected.
* No alarm associated with exciter is issued.
Closing of * Operate FIELD CIRCUIT * Check that FIELD CIRCUIT BREAKER
41E BREAKER[CLOSE]. [CLOSE] lights up.
* Check that the generator voltage is
established.
Voltage * Operate 7-90R [Lower/Raise] to
matching effect voltage matching.

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9. What to Do in The Event of Failure

9.1 Operation and Inspection When Alarm is Issued
In the event that a trouble occurs with this controller cubicle, the corresponding failure item
lights up on the OPS. Check shall be made according to the following steps.
(1) Record the failure items that are shown lit on the OPS.

NOTE

■ Two or more items may be showing.

(2) Press the [ACK] switch on the OPS.

If the fault can be cleared, it means that the fault is fleeting or transient.
(3) Record the fault items that remain lit even after the [ACK] switch was pressed.
The faults that could not be cleared are in the permanent fault state.
(4) According to Table 9.1.1, check the contents of fault and take necessary steps.

NOTE

■ The necessary steps in Table 9.1.1 represent the temporary steps that need to
be taken when abnormal condition occurs.
If the abnormal condition persists or detailed investigations are needed, please
consult us.

－49－
 Table 9.1.1 Failure display on OPS
Failure item Contents of failure Result Necessary steps
System(CPU-△) controller
CPU-△(SC-△) Abnormal condition is The CPU-△ controller ・ Check the CPUL(CPU-△) in question.
FAILURE detected in the CPU-△ in question is removed ・ If the CPUL(CPU-△) is faulty, replace it.
Controller. from service and is
automatically switched
over to the standby
system.
PIFL01 (IF-△) Abnormal condition is The Protocol ・ Check the PIFL(IF-△) in question.
MODULE FAILURE detected in the Protocol Converter-△ in ・ If the PIFL(IF-△) is faulty, replace it.
Converter-△. question is removed
from service and is
automatically switched
over to the standby
system.
AVR-SC Parameter revision Operation is continued. ・ Check the parameter revision.
PARAMETER between two CPU ・ If the parameter revisions are in unmatched
UNMATCH controllers do not match. condition, rewrite CPU-△ controller software from
IES.
SVS▲ FAIL The SVS▲ is in failure Operation is continued. ・ Check the SVS▲
condition.
－50－

SC-△ FAN ALARM Abnormal condition is Operation is continued. ・ Check the CPUL(CPU-△) in question.
detected in the CPU-△ ・ If the CPUL(CPU-△) is faulty, replace it.
controller’s fan.
CYCLIC COUNTER Cyclic counter stop Operation is continued. ・ Check the network connection.
STOP(MC) condition is detected
from Master(PRC)
controller.
◎ (I/O-▲-01～15) Abnormality is detected Operation is continued. ・ Check the IO unit 1-2 slot 01-15.
CARD FAILURE(*) in the IO unit 1-2 slot ・ If the IO unit is faulty, replace it.
01-15.
AVR SC CPU TEST Control logic inside CPU If the simulated logic do ・ Check CPUL for simulated logics and check
MODE is being simulated not create any trip, purposes of logic simulation.
operation is continued.

(*): IO UNIT 1 - SLOT 5,9, 10,

(*): IO UNIT 2 - SLOT 11,12 are dummy modules

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△ : A or B ▲ : 1 or 2 ∇: AC or DC ◎: Board Type
 Table 9.1.1 Failure display on OPS

Failure item Contents of failure Result Necessary steps

Common
COMMON DC Voltage drop of Operation is continued ・ Check the common control power and investigate
POWER LOST common control power in the present state. the cause of voltage drop.
is detected.
PWU-∇1 The output of the ∇1 Operation is continued. ・ Check the input/output voltage of the failed power
POWER LOST (AVR) Power unit (AVR) has unit and investigate the cause of failure. When the
dropped. power unit is faulty, replace it.
PWU-∇2 The output of the ∇2 Operation is continued. ・ Check the input/output voltage of the failed power
POWER LOST (AVR) Power unit (AVR) for IO unit and investigate the cause of failure. When the
has dropped. power unit is faulty, replace it.
AVR LIGHT FAULT Light fault has been Operation is continued ・ Check other related alarms to investigate the
detected in excitation cause of failure.
system including
AVR/GCP, THY, FCB
and OVP Cubicle.
GEN VOLTAGE The voltage failed to be The field circuit breaker ・ VT signal input or gate pulse output is possibly
BUILD UP established 0.9PU is opened. abnormal. Check the EIO and TRC modules of
ABNORMAL within 15 seconds after
active system
－51－

the field circuit breaker

was closed
Communication abnormal
SC-△ IO-NET ▲ Abnormal condition is Operation is continued ・ Check the CPU-△, IO-NET-▲-HUB and Ethernet
FAILURE detected in the in the present state. cable.
communication
between the CPU-△ ・ If there is faulty, replace it.
controller and the
IO-NET-▲-HUB
IF-△ IO-NET ▲ Abnormal condition is Operation is continued ・ Check the IF-△, IO-NET-▲-HUB and Ethernet
FAILURE detected in the in the present state cable.
communication
between the IF-△ ・ If there is faulty, replace it.
protocol converter and
the IO-NET-▲-HUB
AVR C-NET▲ FAIL Abnormal condition is Operation is continued ・ Check the CPU-△, C-NET-▲-HUB and Ethernet
(SC-△) detected in the in the present state. cable.
communication
between the CPU-△ ・ If there is faulty, replace it.

6F2J0750
controller and the
C-NET-▲-HUB.

△ : A or B ▲ : 1 or 2 ∇: AC or DC ◎: Board Type
 Table 9.1.1 Failure display on OPS
Failure item Contents of failure Result Necessary steps
Communication abnormal
AVR C-NET▲ FAIL Abnormal condition is Operation is continued ・ Check the PRC-△, C-NET-▲-HUB and Ethernet
(MC-△) detected in the in the present state. cable.
communication
between the PRC-△ ・ If there is faulty, replace it.
controller and the
C-NET-▲-HUB.
SC-MC△ Abnormal condition is Operation is continued ・ Check the CPU-A, B, C-NET HUB, PRC-△ and
TRANSMISSION detected in the in the present state. Ethernet cable.
FAILURE communication
between the both CPU ・ If there is faulty, replace it.
controllers and the
PRC-△ controller.
PIFL01(IF-△) Abnormal condition is Operation is continued ・Check the PIFL01 (IF-△) PROFIBUS cable, and
PROFIBUS LINK detected in the PIFL01 in the present state. Ethernet cable
FAIL(I/O-▲) (IF-△) PROFIBUS
LINK.
Master(PRC-△) controller
PRC-△(MC-△) A failure is detected in The PRC-△controller ・ Check the PRCL(PRC-△) in question.
FAILURE the PRC-△ controller. in question is removed
・ Check other alarm that might lead to channel
－52－

from service and is

automatically switched fault.
over to the standby ・ If the PRCL(PRC-△) is faulty, replace it.
system.
AVR MC-△ CPU Control logic inside If the simulated logic do ・ Check the PRC-△ in question for simulated logics
TEST MODE PRC-△ is being not create any trip, and check purposes of logic simulation.
simulated operation is continued
EIOL01(EIO△) Abnormality is detected The EIO-△ in question ・ Check the EIO-△ in question.
MODULE FAILURE in the Excitation system is removed from
I/O Module (EIO-△). service and is ・ If the EIO-△ is faulty, replace it.
automatically switched
over to the standby
system.
PRC(△) VT FUSE VT input voltage fall is The PRC-△ controller ・ Retrieve the transient records of the PRC
BLOWN detected. in question is removed controllers of both systems and investigate the
from service and is
switched over to the cause of trouble.
standby system.

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PRC(△) OVER Over excitation The PRC-△ controller ・ Retrieve the transient records of the PRC
EXCITATION protection was operated in question is removed controllers of both systems and investigate the
from service and is
switched over to the cause of trouble.
standby system.

△ : A or B ▲ : 1 or 2 ∇: AC or DC ◎: Board Type
 Table 9.1.1 Failure display on OPS

Failure item Contents of failure Result Necessary steps

Master(PRC-△) controller
PRC(△) PHC PULSE The TRC-△ detect The PRC-△controller ・ Check the input/output characteristic of the
FAULT output pulse fault. in question is removed TRC-△ and investigate the cause of trouble.
from service and is
switched over to the ・ If the TRC-△ is faulty, replace it.
standby system.
UEL OPERATED Under excitation limiter Operation is continued. ・ Check the operating condition of generator MW
was operated. and MVAR.
OEL OPERATED Over excitation limiter Operation is continued. ・ Check the operating condition of generator field
was operated. current.
VPFL OPERATED Volt per Frequency Operation is continued. ・ Check the operating condition of generator
limiter was operated. frequency and generator voltage.
PRC(△) VPFL Generator frequency This anomaly will be ・ Investigate the cause of the decrease in
ABNORMAL dropped to 0.5PU detected by both frequency while remaining excited.
during VPFL operation PRCs.86E will be
－53－

under no-load triggered and trip the

condition. generator.

MC TRACKING Standby channel PRC Operation is continued. ・ Check the PRCL(PRC-△) in question.
FAILURE doesn’t track the
running channel PRC ・ If the PRCL(PRC-△) is faulty, replace it.
controller.
PRC(△) STATION NO. A failure is detected in The PRC-△ controller ・Check the PRCL(PRC-△) in question
ERROR the PRC-△ controller. in question is removed ・Check the other alarm that might lead to channel
from service and is fault.
automatically switched ・If the PRCL(PRC-△) is faulty, replace it
over to the standby
system.
90R MANUAL Manual operation of Operation is continued. ・ Check if 90R has been manually operated or not.
OPERATION 90R while AQR is AQR is out of service.
functioning has been ・ Avoid operating 90R manually when AQR is in
detected. service.
AQR AQR function has been Operation is continued. ・ Investigate the cause that locked AQR function.
LOCK(RAISE/LOWER) locked. AQR does not function

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during AQR lock.

△ : A or B ▲ : 1 or 2 ∇: AC or DC ◎: Board Type
 Table 9.1.1 Failure display on OPS
Failure item Contents of failure Result Necessary steps
FCB
PWU-∇1 The output of the ∇1 Operation is continued. ・ Check the input/output voltage of the failed power
PWR LOST (FCB) Power unit (FCB) has unit and investigate the cause of failure. When the
dropped.
power unit is faulty, replace it.
PWU-∇2 The output of the ∇2 Operation is continued. ・ Check the input/output voltage of the failed power
PWR LOST (FCB) Power unit (FCB) for IO unit and investigate the cause of failure. When the
has dropped.
power unit is faulty, replace it.
MIOL01(MIO-△) Abnormality is detected The MIO-△ in question ・ Check the MIO-△ in question.
MODULE FAILURE in the Multipurpose I/O is removed from service
Module (MIO-△) and is automatically ・ If the MIO-△ is faulty, replace it.
switched over to the
standby system.
64F OPERATED(▲) 64F relay detects Operation is continued. ・ Stop the generator and perform a megger check
generator field ground of the field winding and the excitation main circuit.
failure.
41E OPEN FAILURE 41E is not properly Field current is limited ・ Open 41E by manual operation.
opened. by gate shift-gate block
operation. ・ Check whether there are any abnormalities in 41E
main part.
－54－

41E TRIP 41E is opened by Operation is stopped ・ Retrieve the transient records of the master
interlock system not by controllers of both systems and investigate the
manual open command.
cause of 41E trip.
INSTRUMENT Instrument power has Operation is continued. ・ Check the instrument power input.
POWER LOST lost. Vf TRD and If TRD lose
power and stop
functioning.
OVP
OVP OPERATED Overvoltage Protection Overvoltage in the field ・Check the operating condition of generator, and
was operated circuit is suppressed by field circuit.
the formation of a
bypass circuit
associated with OVP
operation.

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 Table 9.1.1 Failure display on OPS
Failure item Contents of failure Result Necessary steps
THY
Confirm “IMPORTANT MESSAGE” (DANGER, WARNING, CAUTION, NOTE)
of maintenance inspection of THY.
THY COOLING FAN More than 15 seconds 86E will be triggered. ・ Check the thyristor cooling fan and the power
BOTH TRIP have passed since the When the generator supply circuit.
cooling fans of both circuit breaker is
groups stopped with the closed, this fault results
field circuit breaker in 86G trip.
closed.
THYRISTOR Abnormality is detected Operation is continued ・ Check the thyristor cooling fan and power circuit.
COOLING FAN △ in the △ group cooling using normal cooling
14F OPERATED fan. fans.

THYRISTOR △THY cooling fan is Operation is continued ・ Check the thyristor cooling fan and power circuit.
COOLING FAN △ overcurrent using normal cooling
49F OPERATED fans.
－55－

THYRISTOR THYRISTOR cooling Operation is continued. ・ Check the cooling fan condition.
COOLING FAN △ fan △ is stopped and 86E will be triggered
STOP LOCKED locked to prevent during start-up ・ Release the fan when it is not in maintenance
accidentally start operation when both of condition.
operation during cooling fans are in stop
maintenance. locked condition as
both fans will fail to
start.
THYRISTOR Thyristor cooling fan△ Operation is continued ・ Check the thyristor cooling fan and power circuit.
COOLING FAN △ has failed. using normal cooling
TROUBLE fans.
THYRISTOR Temperature inside the Operation is continued. ・ Check the cooling fan air flow, and cooling air filter
CUBICLE TEMP rectifier cubicle is high. condition. If the cooling air filters are dirty, clean
HIGH
them.

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 Table 9.1.1 Failure display on OPS

Failure item Contents of failure Result Necessary steps

THY
Confirm “IMPORTANT MESSAGE” (DANGER, WARNING, CAUTION, NOTE)
of maintenance inspection of THY .
THYRISTOR FUSE Thyristor fuse is blown. Operation is continued. ・ Replace the failed tray.
BLOWN (U1-Z3) The thyristor rectifier
can run at 100% ・ Repair the failed tray.
capacity even if one of (Replace the thyristor stack and fuse.)
the thyristor fuses fails.
PWU24-A1/D1 The output of the ∇1 Operation is continued. ・ Check the input/output voltage of the failed power
POWER LOST (THY) Power unit (THY) for unit and investigate the cause of failure. When
TRC has dropped.
the power unit is faulty, replace it.
PWU24-A2/D2 The output of the ∇2 Operation is continued. ・ Check the input/output voltage of the failed power
POWER LOST (THY) Power unit (THY) for IO unit and investigate the cause of failure. When
has dropped.
the power unit is faulty, replace it.
PWU48-A▲/D▲ The output of the ∇▲ Operation is continued ・ Check the input/output voltage of the failed power
POWER LOST (THY) Power unit (THY) for unit and investigate the cause of failure. When
－56－

GPO has dropped.

the power unit is faulty, replace it.
TRCL01(TRC-△) Abnormality is detected The TRC-△ in question ・ Check the TRC-△ in question.
MODULE FAILURE in the Thyristor Rectifier is removed from service
Control Module and is automatically ・ If the TRC-△ is faulty, replace it.
(TRC-△). switched over to the
standby system.
GPO PFD FAILURE Pulse fault in all GPO 86E will be triggered ・ Check the condition of the GPO module.
modules is detected. and trip the generator. ・ If the TRCL or GPO is faulty, replace it.
GPOL01(GPO-1-3) Pulse fault in the GPO Operation is continued. ・ Check the condition of the GPO module.
PULSE FAULT modules (1-3) is Thyristor bridge
detected. connected to GPO ・ If the TRCL or GPO is faulty, replace it.
modules in question ・ Stop the generator when pulse fault occurred in
will stop operation. two thyristor arms.
The thyristor rectifier
can run at 100%
capacity even if one of
the GPO modules fails.

6F2J0750
GPOL01(GPO-4)(FOR Pulse fault in the GPO Operation is continued. ・ Check the condition of the GPO module.
TEST USE) PULSE modules (4) is detected.
FAULT ・ If the TRCL or GPO is faulty, replace it.

△ : A or B ▲ : 1 or 2 ∇: AC or DC ◎: Board Type
 6F2J0750

10. Maintenance and Inspection

10.1 Items of Inspection
The main constitutional devices of this controller cubicle are highly reliable static devices
consisting mainly of semiconductor circuits. Known as microcomputers, these static devices
have self-diagnostic functions and thus require no special maintenance services in terms of
hardware, other than the inspections that are performed on general cubicles. For long and
stable operation, it is advised that these static devices are subjected to regular inspections
and that the installation environments conform to the specifications.
The major difference of this controller from the ordinary equipment is that the controller has
software. Maintenance of software includes check on programs and on set values. The
items of maintenance and inspection for this equipment are summarized in Table 10.1.1.

Table 10.1.1 Items for maintenance and inspection

No. Category Item Remarks
1 Visual check (1) Are environmental conditions of specification Any time
met?
(2) Is dust not accumulated?
(3) Is there no direct sun light?
(4) Is there no corrosive gas?
(5) Is ventilation good?
(6) Is there no vibration?
2 Check on (1) Are fastenings not loose? At regular
mounting (2) Is connector firmly mounted? inspection
condition (3) Are cable and wiring not broken?
3 Check on (1) Is input/output voltage within the specified At regular
power unit range? inspection
(2) Are ripples within the specified range?
4 Check on (1) Check the level of analog input signal. At regular
interface with (2) Check the sequence of contact signal. inspection
external circuit (3) Do these signals input to TOSMAP correctly?
5 Components (1) Is [RUN] LED lighted? At regular
(2) Is the input/output characteristic good? inspection
(3) Is the program not corrupted?
(4) Are set values not changed? Check on (3) and
(4) is made by comparing the memory card and
the backup DVD.
6 Others (1) Are lamps and indicators not broken? At regular
(2) Is the operation of relays normal? inspection
(3) Is there no any anomaly with other devices?

－57－
 6F2J0750

10.2 Periodical Replacement Parts

Parts that need to be replaced periodically are listed in Table 10.2.1.
Table 10.2.1 Parts that need to be replaced periodically
Parts name Replacement interval Replacement
method
Electrolytic capacitor About 5-7 years (Actual interval may Whole of power
for the control power vary depending on the service unit is replaced.
temperature)

10.3 Operation for Failure of System

If a fault occurs, record the time of fault, the operation situation and fault annunciations, and
check the display contents on the OPS. Please inform us of the details of the abnormal
condition.
How the equipment is to be operated for the time being after the fault depends on the contents
of the fault. For detail, see “9. What to Do in The Event of Failure”.

10.4 How to Retrieve Error Log

The error log can be checked using a maintenance tool.
For detail, see “TOSMAP-LX General Information manual”: 6F2B0238.

－58－
 6F2J0750

10.5 Handling of Controller Printed Circuit Boards

The handling of equipment installed in the following units is explained.
(1) System(CPU) controller (A-system/B-system)
(2) Master(PRC) controller (A-system/B-system)
The procedure for mounting and removing the controller equipment varies depending on the
kind of equipment.
The procedure for replacing these equipment will be explained below.

10.5.1 CPUL, PIFL

Replacement procedure
When you replace the unit, be careful for the following.
(1) Confirm that the model of a replacement unit is the same as that of the previous unit. Be
careful for the difference in the hardware revision and software revision as well. Operate the
power switch to turn off the unit (only for CPUL01).
(2) Before dismounting the unit, match mark all the cables connected to the unit and disconnect
them.
(3) Dismount the unit from the Panel. Follow the instructions of the mounting bracket for how to
dismount the Panel.
(4) Set the values of the DIP switch in the replacement unit same as in the previously installed
unit.
(5) Mount the unit to the Panel. Follow the instructions of the mounting bracket for how to
mount the Panel.
(6) After mounting the unit, connect the cables. Operate the power switch to turn on the unit
(only for CPUL01).
(7) Confirm that the equipment is operating normally.

NOTE

■ Do not perform any replacement except that it is performed by trained

maintenance personnel. Failure to follow the instruction could result in
electric shock as well as damage and failure of equipment.

－59－
 6F2J0750

10.5.2 PRCL
Replacement procedure
(1) Check that the program revision and the set point revision are the same between the
control unit (PRC module) and the maintenance tool (X500) on the CPU write screen of the
maintenance tool (X500).
(2) Check that the RUN/STOP switch on the module front panel is set to “STOP”. If it is
“RUN”, set to “STOP”.
(3) Turn off the DC + 24 V (control power).
(4) Remove the power connector.
(5) Match mark all the cables connected to the module and then remove them.
(6) Remove the module from the DIN rail. For removing from the DIN rail, follow the mounting
bracket handling procedures.
(7) Make sure that the module to replace with is of the same model as that of the existing
module.
(8) Check if the revision of hardware and software is the same too.
(9) Set the DIP switch of the newly mounted module at the same values as those set for the
existing module. (except hardware revision)
(10) Mount the module on the DIN rail. For mounting on the DIN rail, follow the mounting
bracket handling procedures.
(11) Connect (restore) the cables removed in (5) above.
(12) Insert the power connector.
(13) Turn on the power of DC + 24 V.
(14) Check that the RUN/STOP switch on the module front panel is set to “RUN”. If it is
“STOP”, set to “RUN”.
(15) Check that the current time of the control unit can be obtained on the time setting screen
of the maintenance tool (X500) and then set up the current time of the control unit.
(16) Check that the program revision and the set point revision are the same between the
control unit (PRC module) and the maintenance tool on the CPU write (old revision) screen of
the maintenance tool (X500). If the program revision or the set point revision is different,
perform CPU write (old revision).
(17) Shift to the RUN mode by changing the operation mode on the maintenance tool.
(18) Check that the new module operates normally.

NOTE

■ Do not perform any replacement except that it is performed by trained

maintenance personnel. Failure to follow the instruction could result in
electric shock as well as damage and failure of equipment.

－60－
 6F2J0750

10.5.3 EIOL, MIOL, TRCL

Replacement procedure
(1) Check that the RUN/STOP switch on the module front panel is set to “STOP”. If it is
“RUN”, set to “STOP”.
(2) Turn off the DC + 24 V (control power).
(3) Remove the power connector.
(4) Match mark all the cables connected to the module and then remove them.
(5) Remove the module from the control panel.
(6) Make sure that the module to replace with is of the same model as that of the existing
module. Check if the revision of hardware and software is the same too.
(7) Set the DIP switch and jumper pins of the newly mounted module at the same values as
those set for the existing module (except hardware revision).
(8) Mount the module on the control panel.
(9) Connect (restore) the cables removed in (4) above.
(10) Insert the power connector.
(11) Turn on the power of DC + 24 V.
(12) Check that the RUN/STOP switch on the module front panel is set to “RUN”. If it is
“STOP”, set to “RUN”.
(13) Check that the new module operates normally.

NOTE

■ Do not perform any replacement except that it is performed by trained

maintenance personnel. Failure to follow the instruction could result in
electric shock as well as damage and failure of equipment.

! WARNING

■ Do not touch internal parts of CPU boards during

replacement work. Some IC inside CPU board may be hot.

－61－
 6F2J0750

11. Drawing List

No Drawing Drawing name

number

1 2S2J4693 OUTLINE OF AVR/GCP CUBICLE

2 2S2J4694 ARRAMGEMENT OF AVR／GCP CUBICLE

3 1S2J0404 OUTLINE OF THY CUBICLE(1)

4 1S2J1703 OUTLINE OF THY CUBICLE(2)

5 2S2J1877 CHANNEL BASE OF THY CUBICLE

6 2S2J4695 OUTLINE OF INI CUBICLE

7 2S2J1836 ARRANGEMENT OF INI CUBICLE

8 2S2J1854 CHANNEL BASE OF FCB CUBICLE

9 5G2J0228 AUTOMATIC SYNCHRONIZER & SYNCHRONISM CHECK RELAY SETTING

10 7K2J2076 LOGIC DIAGRAM OF GENERATOR EXCITATION CONTROL SYSTEM

11 7K2J2075 SCHEMATIC DIAGRAMS FOR GENERATOR AND EXCITATION CONTROL SYSTEM

12 7K2J2064 SCHEMATIC DIAGRAMS FOR THYRISTOR RECTIFIER CUBICLE

13 7K2J2065 SCHEMATIC DIAGRAM FOR INI CUBICLE CUBICLE

14 6N2J0215 OPS DISPLAY FORMAT OF AVR/GCP

15 6N2J0216 TAG MAPPING LIST

16 6F2B0238 TOSMAP-LX GENERAL INFORMATION MANUAL

－62－
 6F2J0750

変 更 記 録 REVISIONS
変更記号
REV.MARK ページ 変 更 箇 所 ・ 変 更 内 容 承認 調査 担当 保 管
変更発行日 PAGE CHANGED PLACE AND CONTENTS APPROVED BY CHECKED BY PREPARED BY REGISTERED
REV.ISSUED

0 First Issue T.Kobayashi

Jun.15.23

配付先 部数 発行 承認
DISTRIBUTION COPY ISSUED APPROVED BY Jun.15.23
Power Generation
Systems Electrical 調査
Machinery Control CHECKED BY Jun.15.23
Group
担当
PREPARED BY Jun.15.23

Ｆ 保管 REGISTERED

－63－
 6F2J0750

－64－