Description

The GE DS215KLDCG1AZZ03A is a field current regulator and power interface board used in GE’s EX2000 and EX2100 static excitation systems,which provide precise DC field excitation to large synchronous generators in power plants,industrial cogeneration facilities,and hydroelectric stations.

This board—often referred to as the KLD(Field Current Regulator)board—serves as the core analog control interface between the digital regulator(e.g.,DMC or SPC board)and the thyristor power bridges.It performs critical real-time functions including:

Field current measurement and conditioning

Firing pulse generation for SCR bridges(via fiber-optic links)

Overcurrent and di/dt protection

Field flashing control

Feedback signal isolation and scaling

The suffix”AZZ03A”indicates a specific hardware revision,firmware compatibility level,and I/O configuration tailored for certain generator/exciter ratings and system architectures(e.g.,self-excited vs.PMG-supplied).

Note:The DS215KLDCG1AZZ03A is not a standalone controller—it operates as part of a multi-board architecture within the EX2000/EX2100 cabinet and requires coordination with the main processor(e.g.,DS215SDCCG1A),gate driver boards,and power supplies.

Application Scenarios

At a 600 MW combined-cycle plant in Texas,Unit 2 experienced repeated“Excitation Field Overcurrent”trips during startup.Diagnostics revealed degraded pulse transformer performance on the DS215KLDCG1AZZ03A board,causing uneven SCR firing and current spikes.After replacing the KLD board with a fully tested DS215KLDCG1AZZ03A,the excitation system achieved smooth voltage buildup with<1%ripple and zero nuisance trips over 500+start cycles—restoring grid dispatch reliability and avoiding$850k/day capacity penalties.

Parameter

Main Parameters Value/Description

Product Model DS215KLDCG1AZZ03A

Manufacturer GE Power Conversion/GE Vernova(Legacy Industrial Solutions)

Product Category Excitation System Control Board–EX2000/EX2100 Platform

Function Field current regulation,SCR gate pulse generation,analog signal conditioning

Compatible Systems GE EX2000,EX2100(including EX2100e)static excitation systems

Field Current Input±10 V or 4–20 mA scaled signal from shunt or Hall-effect sensor

Pulse Output Fiber-optic signals to gate driver cards(e.g.,DS215TCCAG1A)

Protection Features•Field overcurrent

•Fast di/dt detection

•Loss of field sensing

•Bridge fuse monitoring

Power Requirements+5 VDC,±15 VDC,+24 VDC(from system backplane)

Mounting Slide-in module with DIN rail or card cage mounting

Operating Temperature 0°C to+60°C(derated above 50°C)

Standards Compliance IEEE 421.5,IEC 60034-16,UL 508

Technical Principles and Innovative Values

Innovation Point 1:Hybrid Analog-Digital Architecture

While modern excitation uses full digital control,the DS215KLDCG1AZZ03A preserves high-speed analog loop response for field current regulation—critical for transient stability during grid faults—while interfacing with digital setpoint commands.

Innovation Point 2:Optical Isolation for High-Noise Immunity

Fiber-optic pulse transmission to thyristor gates eliminates ground loops and EMI susceptibility in high-power environments(>10 kA field circuits).

Innovation Point 3:Integrated Di/dt Protection

Detects rapid current changes indicative of shorted rotor windings or flashovers—triggering bridge blocking within microseconds to protect SCRs and diodes.

Innovation Point 4:Seamless Redundancy Support

Works in dual-channel EX2100 systems where two KLD boards operate in hot standby—ensuring continuous excitation during board-level faults.

Application Cases and Industry Value

During a life-extension retrofit at a nuclear station in Ontario,engineers replaced aging EX2000 KLD boards with new DS215KLDCG1AZZ03A units as part of a regulatory-mandated safety system upgrade.Post-installation testing demonstrated:

Voltage recovery within 150 ms during 3-phase faults(meeting NERC PRC-024)

Zero cross-talk between redundant channels

Full compatibility with existing Mark VIe turbine controls

The project avoided a$12M full excitation system replacement and extended the plant’s operating license by 10 years.

Related Product Combination Solutions

Main Processor Board:DS215SDCCG1A(System Drive Control Card)

Gate Driver Board:DS215TCCAG1A(Thyristor Control Card)

Power Supply:DS215PSDG1A(for board-level voltages)

Field Current Shunt/Sensor:e.g.,100 mV 5,000 A

Fiber-Optic Cables:Duplex ST or SMA connectors for gate pulses

Configuration Software:EX Toolbox or ToolboxST(for system tuning)

Test Equipment:EX2000 simulator rack for bench validation

Modern Equivalent:EX2100e with integrated digital regulators(for new builds)

Installation,Maintenance,and Full-Cycle Support

Installation Guidelines:

De-energize excitation system and discharge field energy(<50 V confirmed)

Use ESD-safe handling procedures(wrist strap,grounded mat)

Verify backplane connector alignment—do not force

Perform loop calibration after installation(field current vs.feedback)

Critical Notes:

Firmware/software version must match the EX system baseline

Never operate without proper field discharge path(risk of>2 kV transients)

Inspect fiber connectors for dust or cracks before mating

Every DS215KLDCG1AZZ03A we supply undergoes:

Full functional test on EX2000/EX2100 simulator

Pulse timing verification(phase angle accuracy±1°)

Analog input/output linearity check

Thermal cycling and vibration screening

We offer a 12-month warranty,legacy firmware archives,and expert support for system integration or failure analysis.Our inventory includes both new surplus and refurbished-tested units—all traceable to original GE documentation.

Contact us for a customized solution—whether you’re repairing an EX2000 excitation system,performing preventive upgrades,or securing critical spares for your power generation fleet.With the GE DS215KLDCG1AZZ03A,you restore precision,reliability,and grid-compliant performance to one of the most critical subsystems in your plant.

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