GEH-6421System Manual For Mark VI
GEH-6421System Manual For Mark VI
GEH-6421System Manual For Mark VI
*(,QGXVWULDO6\VWHPV
System Guide
for the SPEEDTRONIC™ Mark VI Turbine Control
Publication: GEH-6422
Issued: 1999-10-20
System Guide
for the SPEEDTRONIC™ Mark VI Turbine Control
© 1999 General Electric Company, USA.
All rights reserved.
These instructions do not purport to cover all details or variations in equipment, nor to provide
every possible contingency to be met during installation, operation, and maintenance. If further
information is desired or if particular problems arise that are not covered sufficiently for the
purchaser’s purpose, the matter should be referred to GE Industrial Systems, Salem, Virginia,
USA.
This document contains proprietary information of General Electric Company, USA and is
furnished to its customer solely to assist that customer in the installation, testing, operation,
and/or maintenance of the equipment described. This document shall not be reproduced in whole
or in part nor shall its contents be disclosed to any third party without the written approval of GE
Industrial Systems.
Devices
J1
Cable Plug Connector Case Ground
Conventions
P Power Wiring
Contents
Chapter 1 Overview 1-1
Introduction............................................................................................................................ 1-1
Acronyms and Abbreviations................................................................................................. 1-3
System Guide Outline ............................................................................................................ 1-3
Related Publications............................................................................................................... 1-4
How to Get Help .................................................................................................................... 1-4
Index I-1
Introduction
This manual describes the SPEEDTRONIC™ Mark VI turbine control system.
Mark VI is used for the control and protection of steam and gas turbines in electrical
generation and process plant applications.
This flexible control system is available as a Simplex control or a Triple Modular
Redundant (TMR) control, with single or multiple racks, and local or remote I/O.
The I/O interface is designed for direct interface to the sensors and actuators on the
turbine, to eliminate the need for interposing instrumentation, and the reliability and
maintenance issues associated with that instrumentation. To obtain the highest
reliability, Mark VI uses a TMR architecture with sophisticated signal voting
techniques.
The guide describes the system hardware, firmware, and networking in detail. The
operator interface, standard turbine control blocks, and application configuration are
briefly discussed.
The main functions of the Mark VI turbine control system are as follows:
• Speed control during turbine startup
• Automatic generator synchronization
• Turbine load control during normal operation on the grid
• Protection against turbine overspeed on loss of load
Figure 1-1 shows a typical Mark VI control system for a steam turbine.
(16) RTDs
(24) Thermocouples
Actuator
Actuator
Remote I/O
Inlet Pressure
Trip
Generator
Speed
Extraction Pressure
Exhaust Pressure
Shaft Voltage & Current Monitor
Automatic Synchronizing
Vibration, Thrust, Eccentricity
Temperature (RTDs)
Temperature (Thermocouples)
Generator 3-Phase PTs & CT
The main features of the Mark VI control system covered in the various chapters of
this guide are as follows:
• Optional Triple Modular Redundant (TMR) controllers, I/O, I/O
communication, termination boards, and sensors, as required for the desired
level of reliability.
• Software voting of incoming turbine data, and hardware voting of outgoing
control signals to tolerate faults and identify failed components.
• TMR hardware and voting to allow the system to continue operation if any
major component fails. The failed component, including the control processor,
can be shutdown, replaced, and reloaded with the system online.
• Redundant Ethernet communication with the Mark VI controllers, I/O, operator
interfaces, and with other control modules including LCI Static Starter, Exciter
control, Heat Recovery Steam Generator, and Balance of Plant control.
• Interface with the plant distributed control system, and with other control
equipment including programmable logic controllers (PLC), allowing
centralized operator control.
• Library of turbine control algorithms in control function block form, for
graphical configuration of the application program.
• High speed acquisition of Sequence of Events (SOE) data, to 1 ms resolution,
for display and analysis of turbine events.
Related Publications
In addition to this Mark VI System Guide, publications on other aspects of the
system are available.
• GEH-6403 Control System Toolbox for Configuring a Mark VI Turbine
Controller, for further details of configuring and downloading the control
system.
• GEH-6422 Turbine Historian System Guide for further details of configuring
and using the Historian.
• GEH-6408 Control System Toolbox for Configuring the Trend Recorder, for
details of configuring the toolbox trend displays.
• GEH-6372 GEMIS Tools for CIMPLICITY.
• GEH-6410 Innovation™ Series Controller System Manual.
• GEI-100189 System Database (SDB) Windows based Client/Server
• GEI-100271 System Database (SDB) Browser.
Introduction
This chapter defines the main components of the turbine control system architecture,
including the communication networks. It also discusses the various levels of
redundancy to obtain the required reliability.
The Mark VI can use two Ethernet™- based local area networks (LANs), the Unit
Data Highway (UDH) and the Plant Data Highway (PDH). The UDH communicates
data between all the unit level controls for a turbine-generator set including gas
turbine, steam turbine, generator excitation, generator protection, static starter, heat
recovery steam generator (HRSG), and auxiliary equipment.
The PDH links the control functions to the operator stations and engineering work
stations in the central control room, as shown in Figure 2-1. Primary control and
protection is normally performed within a unit level control; but all UDH controls
have peer-to-peer communication capability. Larger plants with multiple turbine-
generator sets have several UDHs connected to a common PDH.
System Components
This section summarizes the main subsystems that make up the Mark VI system.
Control Cabinet
The control cabinet contains either a single (Simplex) Mark VI control module or
TMR control modules. These are linked to their remote I/O by a single or triple high
speed I/O network called IONet, and are linked to the UDH by their controller
Ethernet port. Optional Genius Bus ports are available for additional I/O. The control
module requires 125 V dc for a power source. The NEMA 1 control cabinet housing
the controller is rated for operation in a 45Û&DPELHQWWHPSHUDWXUH
Router
CIMPLICITY Viewer Viewer Viewer Engineering LaserJet LaserJet
Field
Redundant Support Work Station Printer Printer
Transciever
P LANT D ATA H IGHWAY HUB
P LANT D ATA H IGHWAY HUB
CIMPLICITY
Servers
hardwire
UC2000 UC2000 GPP Mark VI Bently Nev. Mark VI 90-70 PLC 90-70 PLC
AC AC GE Fanuc GE Fanuc
90-70 PLCs 90-70 PLCs
Innovation Hot Backup Hot Backup
From
Buffered
Outputs HRSG/ Balance
LCI EX-
Auxiliaries of Plant
Static 2000 Gener./ Gas Steam
Starter Exciter Transfr. Turbine Turbine
Protectn. Control Genius Genius
Control
IONet IONet Bus Bus
Mark VI Mark VI Mark VI Mark VI Genius Genius Genius Genius Genius Genius
Remote Mark VI I/O Remote Mark VI I/O Genius Field I/O Genius Field I/O
Servers
Redundant data servers are CIMPLICITY servers collect data on the UDH and use the PDH to communicate
optional, and if supplied, with viewers. If two servers are used, one acts as the primary server and passes
communication with the synchronized data to the backup server in a configuration called host redundancy.
viewers continues, even if one
server fails.
Operator Console
The turbine control console is a modular design which can be expanded from two
monitors, with space for one operator, to four monitors, with space for three
operators. Printers can be table-top mounted, or on pedestals under the counter. The
full size console is 5507.04 mm (18 ft 0 13/16 in) long, and 2233.6 mm (7 ft 3 15/16
in) wide. The center section, with space for two monitors and a phone/printer bay, is
a small console 1828.8 mm (6 ft) wide.
Generator Protection
The generator protection system is mounted in a single, indoor, free standing cabinet,
designed for an operating temperature range of –20 to +40Û&7KHHQFORVXUHLV
NEMA 1, and weighs 2500 lbs. The Generator Panel interfaces to the Mark VI with
hardwired I/O, and has an optional Modbus interface to the HMI.
Control Module
The control module is available as an integrated control and I/O module, or as a
standard controller only. The combined control and I/O rack can be either a 21-slot
or 13-slot VME size. The back-plane has P1 and P2 connectors for the VME boards.
The P1 connectors communicate data across the back-plane, and the P2 connectors
communicate data between the board and 37-pin J3 and J4 connectors located
directly beneath each board. Cables run from the J3 and J4 connectors to the
termination boards.
The control module can be Simplex or TMR, and each of these configurations
supports remote I/O via IONet. The Simplex control modules can be configured to
support up to three independent parallel IONet systems for higher I/O throughput.
Multiple communication boards may be used in a control module to increase the
IONet throughput.
Shown in Figure 2-2 is a 21-slot rack with a three-IONet VCMI communication
board, a two-slot controller (UCVB), and an Interface board (VDSK). The remaining
slots are filled with I/O boards. The overhead fan cools the controller.
UDH
Port x x x x x x x x x x x x x x x x
Power
Supply
VCMI
Communication
Board, with One
or Three IONet
Ports
VME Chassis,
21 slots
x x x x x x x x x x x x x x x x x x x x x
Figure 2-2. Control Module with Control, Communication, Memory, and I/O Boards
The stand alone controller module is a VME rack, shown in Figure 2-3,
accommodating the controller board (UCVB), VCMI, and Interface board VDSK.
This version is for systems where all the I/O is remote to save wiring costs. The
VME backplane has P1 connectors for data transfer, and P2 connectors only for the
VCMI and VDSK. The rack is powered by an integrated power supply. The VDSK
board is ribbon cabled to the VCMI in the back. It supplies 24 V dc to the cooling
fan mounted under the rack, and monitors the Power Distribution Module (PDM)
through the 37-pin connector on the front.
VME Rack
POWER
SUPPLY
Power Supply
x x x x
Figure 2-3. Rack with Controller, VCMI, and VDSK (No I/O Boards)
Interface Module
The interface module houses the I/O boards remote from the control module. The
rack, shown in Figure 2-4, is similar to the control module VME rack but without the
controller, VDSK, and cooling fan. Each I/O board occupies one or two slots in the
module and has backplane connection to a pair of 37-pin D connectors mounted on
an apron beneath the VME rack. Cables run from the 37-pin connectors to the
termination boards. Most I/O boards can be removed, with power removed, and
replaced without disconnecting any signal or power cable. Communication with the
module is via a VCMI with a single IONet port, located in the left-hand slot. The
module backplane contains a switch wired to slot 1, which is read by the
communication board to obtain the identity of the module.
VCMI
Communication x x x x x x x x x x x x x x x x x x x x
Board with one
IONet Port Power
Supply
IONet Link
to Control
Module
x x x x x x x x x x x x x x x x x x x x x
Controller
The controller is a two-slot VME board set housing a high speed processor and
DRAM. The base software includes appropriate portions of the existing Big Block
Library (BBL) control function libraries for the steam, gas, and Land-Marine aero-
derivative (LM) products. The controller can execute a total of 100,000 BBL rungs
or blocks per second, and run its program at up to 100 Hz, (10 ms frame rate),
depending on the system configuration.
External data is transferred to/from the controller over the VME bus by the VCMI
communication board. In a Simplex system, the data consists of the process inputs
from the I/O boards, and in a TMR system, it consists of voted data.
The controller provides communication interfaces to the UDH through Ethernet, to
Genius I/O through Genius Bus, and to other computers over a serial RS-232C port
using Modbus.
Control Module R
VCMI Board
with V U
Three IONet C C I/O
Ports M V Boards
I B
IONet - T to other Control, Interface, & Protection Modules
IONet - S to other Control, Interface, & Protection Modules
IONet - R
Interface Module R1
VCMI Board with V
One IONet Port C I/O
M Boards
I
IONet to other
Interface Modules &
Protection Module
Figure 2-5. VCMI Boards providing I/O Communication and I/O Voting
In TMR mode, the VCMI voter in the control module is always the master of the
IONet and also provides the IONet clock. Time synch messages from the time source
on the UDH are sent to the controllers and then to the VCMIs. All input data from a
single rack is sent in one or more IONet packets (approximately 1500 bytes per
packet maximum). The VCMI in the control module broadcasts all data for all
remote racks in one packet, and each VCMI in the remote rack extracts the
appropriate data from the packet.
IONet
The IONet connection on the VCMI is a BNC for 10Base2 Ethernet. The interface
circuit is high impedance allowing “T” tap connections with 50 ohm termination at
the first and last node. The cabling distances are restricted to 185 meters per segment
with up to eight nodes, using RG-58C/U or equivalent cable.
I/O Boards
Most I/O boards are single width VME boards of similar design and front panel,
using the same digital signal processor (TMS320C32).
The central processing unit (CPU) is a high speed processor designed for digital
filtering and for working with data in IEEE 32-bit floating point format. The task
scheduler operates at a one ms and five ms rate to support high speed analog and
discrete inputs. The I/O boards synchronize their input scan to complete a cycle
before being read by the VCMI board. Contact inputs in the VCCC and VCRC are
time stamped to 1 ms to provide a sequence of events monitor (SOE).
Each I/O board contains the required sensor characteristic library, for example
thermocouple and RTD linearizations. Bad sensor data and alarm signal levels, both
high and low, are detected and alarmed. The I/O configuration in the toolbox can be
downloaded over the network to change the online program. This means that I/O
boards can accept tune-up commands and data while running.
Each I/O board sends an identification message (ID packet) to the VCMI when
requested. The packet contains the hardware catalog number of the I/O board, the
hardware revision, the board barcode serial number, the firmware catalog number,
and the firmware version. Also each I/O board identifies the connected termination
boards via the ID wire in the 37-pin cable. This allows each connector on each
termination board to have a separate identity.
Termination Boards
The termination board provides the customer wiring connection point, and fans out
the signals to three separate 37-pin D connectors for cables to the R, S, and T I/O
boards. A typical example is shown in Figure 2-6. Each type of I/O board has its own
special termination board, some with a different combination of connectors. For
example, one version of the thermocouple board does not fanout and has only two
connectors for cabling to one I/O board. A new version of the thermocouple board
does fan out and has six connectors for R, S, and T. Since the fanout circuit is a
potential single point failure, the termination board contains a minimum of active
circuitry limited primarily to filters and protective devices. Power for the outputs
usually comes from the I/O board, but for some relay and solenoid outputs, separate
power plugs are mounted on the termination board.
Figure 2-6. Typical Termination Board with Cabling to I/O Boards in VME Rack
To TREG
Power In
125 Vdc
Operating Systems
All operator stations, communication servers, and engineering work stations use the
Microsoft Windows NT® operating system. The HMIs and servers run CIMPLICITY
software, and the engineer’s work station runs toolbox software for system
configuration.
The Mark VI I/O system, because of its TMR requirements, uses a proprietary
executive system designed for this special application. This executive is the basis for
the operating system in the VCMI and all of the I/O boards.
The controller uses the QNX operating system from QNX Software Systems Ltd.
This is a real time, POSIX compliant, operating system ideally suited to high speed
automation applications such as turbine control and protection.
Vote
Controller
Simplex systems in a typical power plant are used for applications requiring normal
reliability such as control of auxiliaries and balance of plant (BOP). A single GE
Fanuc 90-70 PLC with local and remote I/O might be used in this application. In a
typical Mark VI, many of the I/O are non-critical and are installed and configured as
Simplex. These Simplex I/O boards can be mixed with TMR boards in the same
interface module. Although the Simplex board exists in only one channel, all three
controllers process the Simplex data, and can control the output if one controller
fails.
Triple Redundant control systems, such as Mark VI, are used for the demanding
turbine control and protection application. Here the highest reliability ensures the
minimum plant downtime due to control problems, since the turbine can continue
running even with a failed controller or I/O channel. With continuous input and
output voting, a failure is always masked. Failures are detected and annunciated, and
can be repaired online. This means the turbine protection system can be relied on to
be fully operational if a turbine problem occurs.
TMR Architecture
As shown in Figure 2-9, the TMR control architecture has three duplicate hardware
controllers labeled R, S, and T. A high speed serial network connects each controller
to its associated set of I/O modules, resulting in three independent I/O networks.
Each network is also extended to connect to separate ports on each of the three
controllers producing a very robust I/O communication structure. Each of the three
controllers has three independent I/O communication ports to allow each controller
to receive data from all of the I/O modules on all three I/O networks. The three
protection modules are also on the I/O networks.
IONet - R
IONet - S
IONet - T
Figure 2-9. TMR Architecture with Local & Remote I/O, and Protection Module
Each of the three controllers is loaded with the same software image, so that there
are three copies of the control program running in parallel. External computers, such
as the HMI operator stations, acquire data from only the designated controller. The
designated controller is determined by a simple algorithm, as described later.
A separate protection module is an independent TMR subsystem, complete with its
own controllers and integral power supplies, that adds the capability of reliable trip
operation. Separate independent sensor inputs and voted trip relay outputs are used.
Figure 2-10 displays a possible layout of equipment in the cabinets.
1 Genius Power
1 Serial <R n > Interface Module Supply
Termination
V DC Boards
Power DC C
V C I I I I I I
/
Supply / M U
C
V
D IONET M / / / 21 SLOT / / /
DC I O O O VME RACK O O O DC
I V S <R> H
H B K Ethernet 1
2
10Base2
<R> Control Module Thin
Coax
1 Genius Power
1 Serial <S n> Interface Module Supply
V DC
Power DC V U V C I I I I I I
/
Supply / C D IONET M / / / 21 SLOT / / /
DC M C I O O O VME RACK O O O
DC
I V S <S>
H B K H
2 Ethernet 1
10Base2
<S> Control Module
Thin
Coax
Power
1 Genius
1 Serial <T n> Interface Module Supply
V DC
Power DC V U V C I I I I I I
/
Supply / C
M C D IONET M / / / 21 SLOT / / /
DC
DC I O O O VME RACK O O O
I V S <T> H
H B K Ethernet 1
2 10Base2
<T> Control Module Thin
Coax
HUB
Input
+125Vdc
REPEATER <R> Internal
Power Protection V V V
Converter Power
<S> Buss Modules P P P
Input to R R R
Input T
Power <T> Power IONET Power O O O
Supplies Interface <X> <Y> <Z> R
Converter Converter
to I
Input other I/O <R> P
Input
Power Cabinet Power <S>
Lineups +125Vdc
Converter Converter <T> Internal Power
(Optional)
Busses to
Input <X> Power Supplies
Power <Y> & Termination
Converter <Z> Cards
Input Contact Input Excitatn. To
Power Termination
Solenoid Power Cards
Cond.
Customer
Customer Supplied Sensor Cables
Power Input(s)
Figure 2-10. Typical Cabinet Layout of Mark VI Triple Modular Redundant System
Designated Controller
Although three controllers R, S, T contain identical hardware and software, some of
the functions performed are individually unique. The designated controller performs
the following functions:
• Provides data to all external computers.
• Keeps the master time clock.
• Receives and replicates all commands.
• Handles any peer I/O and in turn replicates all inputs from peers for the voting
trio.
• Generates process alarms.
For purposes of deciding which controller is to be the designated controller, each
VCMI nominates itself based on a weighting scheme using the following algorithm:
1*(if previously designated controller) + 2*(number of stable I/O nets) + 3*(if UDH
traffic visible)
UDH communicator
For normal operation, the designated controller and the UDH communicator are the
same module. For some UDH communication failures, multiple controllers need to
be the UDH communicator. The primary communicator is the same as the designated
controller under normal circumstances.
The primary UDH communicator is the spokesperson for the three voting controllers.
A secondary UDH communicator sends and receives peer I/O pages that cannot be
sent or received by the primary communicator if a UDH failure causes the network
to split. The secondary communicator provides necessary control signal flow to and
from the other control panels. Thus Ethernet Global Data (EGD) data is sent to both
networks if a split occurs. On the receiving side of EGD messages, since EGD pages
are identified by exchange number and not by IP address, the change in IP address
does not change the data flow. However, depending on the UDH failure mode, only
one controller in a TMR system may be receiving EGD data, thus IONet forwarding,
of only that portion of EGD data actually used in sequencing, takes place. This
forwarding occurs in the idle IONet portion of the compute frame. This data is input
as if it were Simplex data, and distributed to all three controllers thus maintaining
symmetry. Multiple senders of the same data on split networks are allowed, since
other receiving controllers use the last data set received.
Output Processing
The system outputs are that portion of the calculated data that have to be transferred
to the external hardware interfaces and then to the various actuators that control the
process. Most of the outputs from the TMR system are voted in the output hardware,
but the system can output individual signals in a Simplex system.
Normally, outputs from the TMR system are calculated independently by the three
voting controllers and each controller sends the output to its associated I/O hardware,
for example, R controller sends to R I/O. The three independent outputs are then
combined into a single output by some voting mechanism. Different signal types
require different methods of establishing the voted value.
The signal outputs from the three controllers fall into three groups.
• Signals exist in only one I/O channel and are driven as single ended non-
redundant outputs.
• Signals exist in all three controllers and output separately to an external voting
mechanism.
• Signals exist in all three controllers but are merged into a signal by the output
hardware.
I/O Board KR KS
Channel R Relay KR
Coil
Driver
KS KS KT Relay Output
I/O Board Relay
Coil
Channel S Driver
KT KT KR
Relay
I/O Board Coil
Driver
Channel T
I/O Boards
Servo Driver
Channel S
D/A
Servo Driver
Channel T
D/A
Hydraulic
Servo
Valve
Figure 2-12. TMR Circuit to Combine Three Analog Currents into a Single Output
Figure 2-13 shows 4-20 ma signals combined through a 2/3 current sharing circuit
that allows the three signals to be voted to one. This unique circuit ensures the total
output current is the voted value of the three currents. Failure of a 4-20 mA output is
sensed and a suicide relay contact is opened.
I/O Boards
4-20 mA Driver Output Current
Channel R Termination Feedback
D/A Board
Output
4-20 mA Driver
Load
Channel S
D/A
4-20 mA Driver
Channel T
D/A
Input processing
All inputs are available to all three controllers but there are several ways that the
input data is handled. For those input signals that exist in only one I/O module, the
value is used by all three controllers as common input without voting as in Figure
2-14. Signals that appear in all three I/O channels may be voted to create a single
input value. The triple inputs may come from three independent sensors or may be
created from a single sensor by hardware fanning at the termination board.
A SC R
A single input can be brought to the three controllers without any voting as shown
above. This is used for non-critical, generic I/O, such as monitoring 4-20 mA inputs,
contacts, thermocouples, and RTDs.
One sensor can be fanned to three I/O boards as above for medium integrity
applications, as in Figure 2-15. This is used for sensors with medium to high
reliability. Three such circuits are needed for three sensors, see later. Typical inputs
are 4-20 mA, contacts , thermocouples, and RTDs.
SC S Voted (A)
S Voter
SC T Voted (A)
T Voter
Figure 2-15. One Sensor with Fanned Input & Software Voting
Figure 2-16. Three Independent Sensors with Common Input, Not Voted
Figure 2-17 shows three sensors, each one fanned and then SIFT voted. This
provides a high reliability system for current and contact inputs, and temperature
sensors.
Field Wiring Termin. Bd. I/O Board VCMI IONet VCMI Controller
B SC S Voted "A"
Control
Same S Voter Voted "B"
Block
Voted "C"
SC T Voted "A"
C Control
Same T Voter Voted "B"
Block
Voted "C"
Figure 2-17. Three Sensors, Each One Fanned and Voted, for Medium to High
Reliability Applications
Field Wiring Termin. Bd. I/O Board VCMI IONet VCMI Controller
SC R Voted (A,B,C)
A
R Voter
B SC S Voted (A,B,C)
S Voter
SC T Voted (A,B,C)
C
T Voter
Figure 2-18. Three Sensors with Dedicated Inputs, Software Voted for High
Reliability Applications
State Exchange
Voting all of the calculated values in the TMR system is unnecessary and not
practical. The actual requirement is to vote the state of the controller database
between calculation frames. Calculated values such as timers, counters, and
integrators are dependent on the value from the previous calculation frame. Logic
signals such as bistable relays, momentary logic with seal-in, cross-linked relay
circuits and feedbacks have a memory retention characteristic. A small section of the
database values is voted each frame.
Sensor
981 910 1020
1
Figure 2-19. Median Value Voting Examples with Normal & Bad Inputs
Peer I/O
In addition to the data from the I/O modules, there is a class of data that comes from
other controllers in other panels that are connected via a common data network. For
the Mark VI controller the common network is the UDH. For integrated systems, this
common network provides a data path between multiple turbine control panels and
possibly the controls for the generator, the exciter, or the HRSG/boiler.
Selected signals from the controller database may be mapped into a page of peer
outputs that are broadcast periodically on the UDH to provide external panels a
status update. For the TMR system this action is performed by the UDH
communicator using the data from its internal voted database.
Several pages of peer inputs may be received by the TMR panel as the other control
panels on UDH are broadcasting their status pages. The designated
controller/primary communicator may have the responsibility for receiving the pages
and replicating the content for the other controllers in the voting trio. The operation
is similar to the input of common input data from a single I/O module, but in this
case the data is broadcast on the I/O network by the designated controller.
Command Action
All of the commands to the TMR control panel need special processing to cause the
three voting controllers to perform the same action at the same time. Since the source
is a standard computer connected to the UDH and sending messages over a single
network, there is very little benefit for voting the commands in each controller. The
situation is complicated by commands being sent from one of several redundant
computers at the operator position or positions.
In Mark VI, the designated controller receives all commands, and the response of the
voting trio is synchronized by issuing the commands to all three controllers at the
same frame time.
Rate of Response
Mark VI can execute selected control programs at the rate of 100 times per second,
(10 ms frame rate) for Simplex systems, and 25 times per second (40 ms frame rate)
for TMR systems. This is the fastest rate for the TMR system. The timing diagram is
shown in Figure 2-20. In this example, bringing the data from the interface modules
to the control module and voting it takes three ms, executing the control program
takes four ms, and sending the data back to the interface modules takes three ms.
Control
Background Compute Control Sequence & Blocks Background
Module
CPU
Vote
Control State Fast Fast Prevote
Module Vote R1 R2 Compare
Voting
Power Sources
In a TMR system each control module and I/O module have their own power supply
to guard against a single power supply causing a double fault. A reliable source of
power is required for the input to the power supplies from either a battery, or from
multiple power converters that are connected in a redundant fashion, or maybe a
combination of both. The multiple power converters connected as high-select
provide the required redundancy.
Failure Handling
The general philosophy on failures is that corrective or default action takes place in
both directions away from the fault. This means that, in the control hierarchy
extending from the termination screws up through I/O boards, backplanes, networks
and main CPUs, when a fault occurs, there is a reaction at the I/O processor and also
at the main controller if still alive. When faults are detected, health bits are reset in a
hierarchical fashion. If a signal goes bad, the health bit is set false at the control
module level. If a board goes bad, all signals associated with that board whether
input or output have their health bits set false. A similar situation exists for the I/O
rack. In addition, there are preconfigured default failure values defined for all input
and output signals so that normal application code may cope with failures without
excessive healthy bit referencing. Healthy bits in TMR systems are voted if the
corresponding signal is TMR.
Software
Voting
Note Power down only the module that has the fault. Failure to observe this rule
may cause an unexpected shutdown of the process. To this end, each module has its
own power disconnect or switch. The modules are labeled such that the diagnostic
messages identify the faulty module.
Reliability
Reliability is represented by the Mean Time Between Forced Outages (MTBFO). In
a Simplex system, failure of the controller or I/O communication may cause a forced
outage. Failure of a critical I/O module will cause a forced outage, but there are non-
critical I/O modules which can fail and be changed out without a shutdown. The
MTBFO is calculated using published failure rates for components at the maximum
operating temperature.
Availability is the percentage of time the system is operating, taking into account the
time to repair a failure. Availability is calculated as follows:
MTBFO x 100%
MTBFO+MTTR
where:
MTTR is the Mean Time To Repair the system failure causing the forced outage, and
MTBFO is the Mean Time Between Forced Outages
With a TMR system there can be failures without a forced outage because the system
can be repaired while it continues to run. The MTBFO calculation is complex since
essentially it is calculating the probability of a second (critical) failure in another
channel during the time the first failure is being repaired. The time to repair is an
important input to the calculation.
The availability of a well designed TMR system with timely online repair is
effectively 100%. Possible forced outages may still occur if a second failure of a
critical circuit comes before the repair can be completed. Other possible forced
outages may occur if the repairman erroneously powers down the wrong module.
Note To avoid possible forced outages from powering down the wrong module,
check the diagnostics for identification of the modules which contain the failure.
Reliability data was determined by calculating the Failures In Time (FIT) (failures
per 109 hours) based on the Bellcore TR-332 Reliability Prediction Procedure for
Electronic Equipment. The Mean Time Between Failures (MTBF) is the inverse of
the FITS. The Mean Time Between Forced Outage (MTBFO) of the control system
is a function of which boards are being used to control and protect the turbine.
The complete system MTBFO depends on the size of the system, number of Simplex
boards, and the amount of sensor triplication.
Mark VI
Controller PLANT DATA HIGHWAY
x x
To Plant Data
Highway (PDH)
UCVB
x x Ethernet
Figure 2-22. Optional Communication Links to Third Party Distributed Control System
Introduction
This chapter defines the various communication networks making up the Mark VI
system. These networks provide communication with the operator interfaces, servers,
controllers, and I/O. Communication to Genius I/O and to the plant distributed
control system is included.
Network Overview
The Mark VI system is based on a hierarchy of networks that are used to
interconnect the individual nodes. These networks separate the different
communications traffic into layers according to their individual functions. This
hierarchy extends from the I/O and controllers, which provide real-time control of
the turbine and its associated equipment, through the operator interface systems, and
up to facility wide monitoring or DCS systems. Each layer uses standard
components and protocols to simplify integration between different platforms and
Ethernet is used for all improve overall reliability and maintenance. The layers are designated as the
Mark VI data highways and Enterprise, Supervisory, Control, and I/O layers, and are more fully described in the
the I/O network following sections, and shown in Figure 3-1.
Enterprise Layer
The Enterprise layer serves as an interface from the turbine or stage control into a
facility wide or group control layer. These higher layers are provided by a DCS
vendor or by the customer. The network technology used in this layer is generally
determined by the customer and may include either Local Area Network (LAN) or
Wide Area network (WAN) technologies, depending on the size of the facility. The
Enterprise layer is generally separated from other stage control layers via a router,
which isolates the traffic on both sides of the interface. Where unit control
equipment is required to communicate with a facility wide or DCS system, GE
prefers to use either a Modbus interface or a TCP/IP protocol known as GSM (GE
Standard Messaging).
Supervisory Layer
The Supervisory layer provides operator interface capabilities such as to coordinate
HMI viewer and server nodes, and other functions like data collection (Historian),
remote monitoring, and vibration analysis.
To Optional
Customer Network
(Enterprise Layer)
Router
HMI HMI HMI Field
Viewer Viewer Viewer OSM
Support
Supervisory Network
PLANT DATA H IGHWAY HUB
PLANT DATA HIGHWAY HUB
Bently-Nevada
HMI Servers Vibration Analysis Control Network
U NIT D ATA H IGHWAY HUB
U NIT DATA H IGHWAY HUB
Control Layer
The Control layer provides continuous operation of the power generation equipment.
The controllers on this layer are highly coordinated to support continuous operation
without interruption. This synchronization operates the control network at a
fundamental rate called the frame rate. During each frame, all controllers on the
network transmit their internal state to all other nodes. An optimized protocol based
on UDP/IP known as Ethernet Global Data (EGD) provides data exchange between
nodes at a nominal frame rate of 25 Hz. Redundancy is important on the Control
layer to ensure that a failure of any single component does not cause a turbine trip.
This is accomplished with a shared dual network configuration known as the Unit
Data Highway (UDH).
Printer
Printer
Network Hub A
Network Hub A
Controller Controller
Type 3 Redundancy Nodes such as
duplex or TMR controllers are tightly
coupled so that each node can send the
same information. By connecting each
controller to alternate networks, data is still
Network Hub B available if a controller or network fails.
Network Hub A
Redundant
Transceiver Redundant
Transceiver Type 4 Redundancy This provides
redundant controllers and redundant network
links for the highest reliability. This is useful if
the active controller network interface cannot
Network Hub B sense a failed network condition.
Network Hub A
Laser printer
Laser printer
Redundant Redundant
Transceiver Transceiver
Figure 3-3. Redundant Plant Data Highway Communication with Operator Stations
Fiber optic cable provides the best signal quality, completely free of EMI and RFI.
Large point-to-point distances are possible, and since the cable does not carry
electrical charges, ground potential problems are eliminated.
The PDH network hardware is listed in the following table.
Type of Network Ethernet CSMA/CD using Ethernet Global Data (EGD) protocol; in
single or redundant network configuration
Media and Distance Ethernet 10Base-T for hub to controller/device connections. The
cable is 22 to 26 AWG unshielded twisted pair (standard telephone
wire); category 5 EIA/TIA 568 A/B. Distance is up to 100 meters
Ethernet 10Base-FL with fiber optic cable optional for network
backbone; distance is two km.
Number of Nodes With 10 nodes, system provides a 25 Hz data rate. For other
configurations contact the factory.
Type of Nodes Supported Mark VI Controllers; will also support Innovation Series Controllers,
GE Fanuc PLCs, CIMPLICITY MMI Products, and Windows-based
PCs (with appropriate drivers)
Protocol EGD protocol based on the UDP/IP standard (RFC 768), also
SRTP (Serial Request Transfer Protocol) protocol
Message Integrity 32-bit CRC appended to each Ethernet packet plus integrity checks
built into UDP and EGD
External Time Synch. Options Timecode signals supported: IRIG-A, IRIG-B, NASA-36, 2137.
Global Position System (GPS); also periodic pulse option.
Figure 3-4 shows the UDH with connections to the controllers and HMI servers.
HMI HMI
Server Server
Node Node
Control Network
UNIT DATA HIGHWAY - HUB B
UNIT DATA
UNIT DATAHIGHWAY - ’B’A
HIGHWAY - HUB
UCVX
VCMI
DISK
RCM
I/O
I/O DISK VCMI
CPU
EX7
I/O
I/O
UCVX
VCMI
I/O
RCM
CPU
Simplex EX7
UCVX
DISK
I/O
I/O
Redundant
TMR
Transceiver
Figure 3-4. Unit Data Highway showing Connections to Simplex, Duplex, & TMR
Controllers
Plug-in Module
with 12 Ethernet
RJ45 ports
Rear View
Ethernet 10BASE-T HUB
PWR
OUT Interconnect IN
Figure 3-5. Typical Stackable Ethernet Hub with Connection to Fiber Optic Converter
Network A BC X Y Z
Type Type Network Number Controller/Device Number Unit Number Type of Device
UDH 1 01 - 99 1 = Gas Turbine Controllers 1 = Unit 1 1 = R0
2 = Steam Turbine 2 = Unit 2 2 = S0
Controllers
. 3 = T0
9 = Unit 9 4 = HRSG A
5 = HRSG B
6 = EX2000 A
7 = EX2000 B
8 = EX2000 C
9 = Not assigned
0 = Static Starter
0 = All other devices on the 02 – 15 = Servers
UDH 16 – 25 = Workstations
26 – 37 = Other stations (Viewers)
38 = Historian
39 = OSM
40 – 99 = Aux Controllers, such as ISCs
Note Each item on the network such as a controller, server, or viewer must have an
IP address. The above addresses are recommended but the customers may choose
their own scheme.
IONet
IONet is an Ethernet 10Base-2 network used to communicate data between the
VCMI communication board in the control module, the I/O boards, and the three
independent sections of the Protection Module <P>. In large systems, it is used to
communicate with an expansion VME board rack containing additional I/O boards.
These racks are called interface modules since they contain exclusively I/O boards
and a VCMI. IONet also communicates data between controllers in TMR systems.
Another application is to use the interface module as a remote I/O interface located
at the turbine or generator. Since there is no central processor in the rack, all boards
are specified for an external cabinet ambient temperature of 50 °C. IONet uses ADL
to poll the interface module and Protection Module for data instead of using the
standard collision detection mechanisms provided in Ethernet LANs.
Figure 3-6 shows a TMR configuration using remote I/O and a protection module.
R S T X Y Z
TMR System V
V U V U V U V V
with Remote P
C C C C C C P P
I/O Racks R
M V M V M V R R
I X I X I X O O O
IONet - R
IONet - S
IONet - T
R1 S1 T1 UCVX is Controller,
V V V VCMI is Bus Master,
VPRO is Protection
C I/O C I/O C I/O Module,
M Boards M Boards M Boards I/O are VME boards.
I I I (Termination Boards
IONet Supports
not shown)
Multiple Remote
I/O Racks
Figure 3-6. IONet Communications with Controllers, I/O, and Protection Modules
Genius Bus
Genius Bus is a serial communication link to communicate from the Mark VI
controller to either a Flat Panel operator interface station, or to the GeniusTM family
of remote I/O blocks. Figure 3-7 shows typical connections.
x x
Mark VI Controller
in Control Module
Genius Bus
x x
Genius I/O
Genius Bus
The Genius bus is a LAN using a shielded, twisted-pair wire, daisy-chained from
block to block and terminated at both ends. A maximum of 32 devices can be
supported on the bus at 153.6 Kbaud. The bus is a token passing network with a
typical bus scan time between 20 and 30 ms.
Control Task
Wiring
Genius bus is daisy-chained between stations, as shown in Figure 3-9. Both the input
and output wires for SER1 and SER2 join at the controller.
Terminating Terminating
Resistor Resistor
Serial 1 Serial 1
Serial 2 Serial 2
Shield In Shield In
Shield Out Shield Out
The cables listed in the following table have been tested and recommended for use.
Table 3-8. Genius Bus Cables
Serial Modbus
Serial Modbus is used to communicate between the Mark VI and the plant
Distributed Control System (DCS). This is shown as the Enterprise layer in the
introduction to this Chapter. The serial Modbus communication link allows an
operator at a remote location to make an operator command by sending a logical
command or an analog setpoint to the Mark VI. Logical commands are used to
initiate automatic sequences in the controller. Analog setpoints are used to set a
target such as turbine load, and initiate a ramp to the target value at a predetermined
ramp rate.
The HMI Server and the Mark VI controller support serial Modbus as a standard
interface. Communication through the HMI is the preferred method. The DCS sends
a request for status information to the HMI, or the message can be a command to the
turbine control. The HMI or controller is always a slave responding to requests from
the serial Modbus master, and there can only be one master.
Note This section discusses serial Modbus communication in general terms; refer to
the Mark VI controller and HMI manuals for details.
Hardware Configuration
The Serial Modbus link to the DCS can come from the HMI Server or the Mark VI
controller. In the controller, the Serial Modbus driver uses the COM2 port. This is a
9-pin RS-232C Micro-D receptacle. A special short adapter cable to go from Micro-
D to standard size D-connector is available, GE Catalog Number 336A4929G1.
Refer to GEH-6410 Innovation™ Series Controller System Manual.
(DCS)
Redundant
Transceiver
Ethernet Ethernet
GSM Modbus
Modbus Communication
Figure 3-10. Communication to DCS from HMI using Modbus or Ethernet Options
Administration Messages are sent from the HMI to the DCS with a Support Unit
message which describes the systems available for communication on that specific
link, and general communication link availability.
Fiber Optics
Fiber optics is an effective substitute for copper coax cabling, especially when longer
distances are required, or electrical disturbances are a serious problem.
The main advantages of fiber optic transmission in the power plant environment are:
• Fiber segments can be longer than copper because the signal attenuation per foot
is less.
• In high lightning areas, copper cable can pick up currents, which damage the
communications electronics. The use of fiber optic segments avoids pickup and
reduces lightning caused outages.
• Grounding problems are avoided with optical cable. The ground potential can
rise when there is a ground fault on transmission lines, caused by currents
coming back to the generator neutral point.
• Optical cable can be routed through a switchyard or other electrically noisy area
and not pick up any interference. This can shorten the required runs and simplify
the installation.
• Fiber optic cable with proper jacket materials can be run direct buried, in trays,
or in conduit.
• High quality optical fiber cable is light, tough, and easily pulled. With careful
installation it can last the life of the plant.
• The total cost of installation and maintenance of a fiber optic segment may be
less than a coax segment.
Disadvantages of fiber optics as follows:
• Fiber optic links require powered hubs with a reliable source of AC power.
Failure of power to the hub on either end of the fiber segment causes a link
failure.
• Light travels more slowly in a fiber than electricity does in a coax conductor. As
a result the effective distance of a fiber segment is 1.25 times the electrical cable
distance.
Components
Basics
Each fiber link consists of two fibers, one outgoing, the other incoming, to form a
duplex channel. The outgoing fiber is driven by a light emitting diode, and the
incoming fiber illuminates a phototransistor, which generates the incoming electrical
signal.
Multimode fiber, with a graded index of refraction core and outer cladding, is
recommended for the optical links. The fiber is protected with "buffering" which is
the equivalent of insulation on metallic wires. Mechanical stress is bad for fibers so a
strong sheath is used, sometimes with pretensioned Kevlar fibers to carry the stress
of pulling and vertical runs.
Connectors for a power plant need to be fastened to a reasonably robust cable with
its own buffering. The bayonet ST type connector is recommended because of a
better field performance record, particularly under diverse conditions and installation
skills. This connector is widely used for local area networks, and is readily available.
Note Never look directly into a fiber. Although most fiber links use light emitting
diodes which cannot damage the eyes, some longer links use lasers which can cause
permanent damage to the eyes.
Fiber Converter
The Mark VI communication system uses an Ethernet Media Converter to convert
selected UDH and PDH electrical signals to fiber optic signals. The typical media
converter converts 12 Ethernet 10Base-T signals to 12 Ethernet 10Base-FL signals.
Each fiber link consists of a pair of unidirectional transmit and receive cables
The media converter mounts adjacent to the Ethernet hub. The selected electrical
signals are brought in from the hub on a multi-twisted pair cable which plugs into a
50-pin RJ-71 connector on the back. The fiber optic cables plug into ST ports on the
front. The diagnostic display is a matrix of LEDs providing visual monitoring of the
power and link status of the fiber optic links. A typical converter is shown in Figure
3-11.
Diagnostics RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX Rx TX RX TX RX TX
12 11 10 9 8 7 6 5 4 3 2 1
Dual Fiber
Optic Cable
with ST plugs
Rear View
50-Pin Connector
PWR
Connectors
The 10Base-FL standard for Ethernet networks defines one style of connector as
being acceptable for both multimode and single mode fiber optic cabling. This is the
Straight-Tip or ST connector (note that ST connectors for the two modes are
different in construction and are not interchangeable). The ST connector replaces the
earlier Sub-Miniature Assembly (SMA) type connector.
The ST connector is a keyed, locking connector that automatically aligns the center
strand of the fiber with the transmission or reception points of the network device.
The connector is shown in Figure 3-12. An integral spring helps to keep the ST
connectors from being crushed together, to avoid damaging the fiber.
Solid Glass
Center
System Considerations
When designing a fiber optic network, note the following considerations.
Redundancy should be considered for continuing central control room (CCR) access
to the turbine controls. Redundant HMIs, fiber optic links, Ethernet hubs, and hub
power supplies are recommended.
The optical power budget for the link should be considered. The total budget refers
to the brightness of the light source divided by the sensitivity of the receiver. These
power ratios are measured in dBs to simplify calculations. The difference between
the dB power of the source and the dB power of the receiver represents the total
power budget. This must be compared to the link losses made up of the connector
and cable losses.
Installation of the fiber can decrease its performance compared to factory new cable.
Installers may not make the connectors as well as experts can, resulting in more loss
than planned. The LED light source can get dimmer over time, the connections can
get dirty, the cable loss increases with aging, and the receiver can become less
sensitive. For all these reasons there must be a margin between the available power
budget and the link loss budget, of a minimum of 3 dB. Having a 6 dB margin is
more comfortable, helping assure a fiber link that will last the life of the plant.
Installation
Planning is important for a successful installation. This includes the layout for the
required level of redundancy, cable routing distances, proper application of the
distance rules, and procurement of excellent quality hubs, UPS systems, and
connectors. Considerations include the following:
• Install the fiber optic cable in accordance with all local safety codes.
Polyurethane and PVC are two possible options for cable materials that might
meet the local safety codes (see next section).
• Select a cable strong enough for indoor and outdoor applications, including
direct burial.
• Adhere to the manufacturer’s recommendations on the minimum bend radius and
maximum pulling force.
• Test the installed fiber to measure the losses. A substantial measured power
margin is the best proof of a high quality installation.
• Use trained people for the installation. If necessary hire outside people with
fiber LAN installation experience.
• The fiber hubs/repeaters need reliable power, and should be placed in a location
that will minimize the amount of movement they must endure, yet keep them
accessible for maintenance.
Cisco Systems
West Tasman Drive
San Jose, CA
www.cisco.com
3COM Corporation
5400 Bayfront Plaza,
Santa Clara, CA 95052
www.3com.com
Time Synchronization
The time synchronization option synchronizes all turbine controls, generator
controls, and Operator Interfaces (HMIs) on the Unit Data Highway to a Global
Time Source (GTS). Typical GTSs are Global Positioning Satellite (GPS) receivers
such as the StarTime GPS Clock or similar time processing hardware. The preferred
time sources are Coordinated Universal Time (UTC) or GPS.
A time/frequency processor board, either the BC620AT or BC627, is placed in the
HMI PC. This board acquires time from the GTS with a high degree of accuracy.
When the HMI receives the time signal, it makes the time information available to
the turbine and generator controls on the network by way of Network Time Protocol
(NTP). The HMI Server provides time to time slaves either by broadcasting time, or
by responding to NTP time queries, or by both methods. Refer to RFC 1305 Network
Time Protocol (Version 3) dated March 1992 for details
Redundant time synchronization can be provided by supplying a time/frequency
processor board in another HMI Server as a backup. Normally, the primary HMI
Server on the UDH is the time master for the UDH, and other PCs without the time /
frequency board are time slaves. The time slave computes the difference between the
returned time and the recorded time of request and adjusts its internal time. Each
time slave can be configured to respond to a time master via unicast mode or
broadcast mode.
Introduction
This chapter describes the cabinet configurations used to house the Mark VI control
equipment, and gives the main dimensions.
Equipment Cabinets
Control Cabinet
The control cabinet contains either a single (Simplex) Mark VI Control Module
(CM) or triple modular redundant (TMR) CMs. These are linked to their I/O by a
single or triplicated high-speed I/O network (IONet), and to the UDH by the
controller Ethernet port. The NEMA 1 control cabinet contains its own power
distribution module, and ac/dc converters.
The front door has a window allowing the controllers to be viewed, and the back
door allows access to the power supplies. Since the cabinet contains the Pentium-
based controller, it is rated for operation in a 45 degree C ambient. This cabinet is
usually used in TMR systems with remote I/O.
Figure 4-1. NEMA 1 Enclosure for Controllers in a System with Remote I/O
Introduction
This chapter discusses the codes, standards, and environmental guidelines used for
the design of all PWAs, modules, cores, panels, and cabinet line-ups in the Mark VI.
Requirements for harsh environment applications, such as marine, are not covered
here.
Safety Standards
UL 508A Safety Standard Industrial Control Equipment
CSA 22.2 No. 14 Industrial Control Equipment
Electrical
Printed Wire Board Assemblies
UL 796 Printed Circuit Boards
GE Salem is a UL recognized card manufacturer, UL file number E110691. Mark VI
boards are currently manufactured by UL recognized GE Fanuc Automation.
ANSI IPC guidelines
ANSI IPC/EIA guidelines
Supply Voltage
Line Variations
AC Supplies – Operating Line variations of –10 %, +10 %
IEEE Std 141-1993 defines the Equipment Terminal Voltage – Utilization voltage.
The above meets IEC 204-1 1996, and exceeds IEEE Std 141-1993, and
ANSI C84.1-1989.
DC Supplies – Operating line variations of -30 %, +20 %.
This meets IEC 204-1 1996.
Voltage Unbalance
Less than 2 % of positive sequence component for negative sequence component.
Less than 2 % of positive sequence component for zero sequence component.
This meets IEC 204-1 1996, and IEEE Std 141-1993.
Harmonic Distortion
Voltage: Less than 10 % of total rms voltage between live conductors for 2nd
through 5th harmonic.
Additional 2% of total rms voltage between live conductors for sum of 6th – 30th.
This meets IEC 204-1 1996.
Current: The system specification is not per individual equipment
Less than 15 % of maximum demand load current for harmonics less than 11
Less than 7 % of maximum demand load current for harmonics between 11 and 17
Less than 6 % of maximum demand load current for harmonics between 17 and 23
Less than 2.5 % of maximum demand load current for harmonics between 23 and 35.
The above meets IEEE Std 519-1992.
Frequency Variations
Frequency variation of –5 % +5 % when operating from AC supplies (20 Hz/sec
slew rate).
This exceeds IEC 204-1 1996.
Clearances
NEMA Tables 1-111-1 and 1-111-2 from NEMA ICS1-1993.
This meets IEC 61010-1:1993/A2:1995, CSA 22.2 #14, and UL 508C, and exceeds
EN50178 (low voltage).
Power Loss
100 % Loss of supply - minimum 10 ms for normal operation of power products.
100 % Loss of supply - minimum 500 ms before control products require reset.
This exceeds IEC 61000-4-11.
Environmental
Temperature Ranges
Ambient temperature ranges for the Mark VI equipment are as follows.
• Operating I/O cards and termination boards 0 to 50° C
• Operating controller with forced air cooling 0 to 45° C
• Shipping and Storage -40 to 80° C
The allowable temperature change without condensation is +/- 15° C per hour
Humidity
The ambient humidity range is 5 % to 95 %.
This exceeds EN50178:1994
Elevation
Equipment elevation is related to the equivalent ambient air pressure.
• Normal Operation 0 to 3300 feet (101.3 KPa – 89.8 KPa)
• Extended Operation 3300 to 10000 feet (89.8 KPa – 69.7 KPa)
• Shipping 15000 feet maximum (57.2 KPa)
The extended operation and shipping specifications exceed EN50178:1994.
Dust
Particle Sizes from 10 – 100 microns for the following materials:
Aluminum oxide Ink Sand/Dirt
Cement Lint Steel Mill Oxides
Coal/Carbon dust Paper Soot
This exceeds IEC 529:1989-11 (IP20)
Vibration
Seismic
Universal Building Code (UBC) – Seismic Code section 2312 Zone 4
Operating/Installed at Site
Vibration of 1.0 G Horizontal, 0.5 G Vertical at 15 to 120 Hz.
See Seismic UBC for frequencies lower than 15 Hz.
Packaging
The standard Mark VI cabinets meet NEMA 1 requirements (similar to the IP-20
cabinet).
Optional cabinets for special applications meet NEMA 12 (IP-54), NEMA 4 (IP-65),
and NEMA 4X (IP-68) requirements. Redundant heat exchangers or air conditioners,
when required, can be supplied for the above optional cabinets.
Introduction
This chapter defines installation requirements for the Mark VI control system.
Specific topics include GE installation support, wiring practices, grounding,
equipment weights and dimensions, power dissipation and heat loss, and
environmental requirements.
Before installation, consult and study all furnished drawings. These should include
panel and layout drawings, connection diagrams, and a summary of the equipment.
Installation Support
GE’s system warranty provisions require both quality installation and that a qualified
service engineer be present at the initial equipment startup. To assist the customer,
GE offers both standard and optional installation support. Standard support consists
of documents that define and detail installation requirements. Optional support is
typically the advisory services that the customer may purchase.
Early Planning
To help ensure a fast and accurate exchange of data, a planning meeting with the
customer is recommended early in the project. This meeting should include the
customer’s project management and construction engineering representatives. It
should accomplish the following:
• Familiarize the customer and construction engineers with the equipment.
• Set up a direct communication path between GE and the party making the
customer’s installation drawings.
As-Shipped Drawings
These drawings include changes made during manufacturing and test. They are
issued when the equipment is ready to ship. As Shipped drawings consist primarily of
elementary diagrams revised to incorporate any revisions or changes made during
manufacture and test.
Revisions made after the equipment ships, but before start of installation, are sent as
Field Change, with the changes circled and dated.
• Installation support
These services are not normally included as installation support or in basic startup
and commissioning services, shown in Figure 6-1. GE presents installation support
options to the customer during the contract negotiation phase
Installation
Support
Startup
Begin
Installation
Commissioning
Complete
Installation
System
Acceptance
Installation Support
Optional installation support is offered: planning, practices, equipment placement,
and onsite interpretation of construction and equipment drawings. Engineering
services are also offered to develop transition and implementation plans to install and
commission new equipment in both new and existing (revamp) facilities.
Level Definitions
The cable and conduit schedule should define signal levels and classes of wiring (see
section on Cable Separation). This information should be listed in a separate column
to help prevent installation errors.
The cable and conduit schedule should include the signal level definitions in the
instructions. This provides all level restriction and practice information needed
before installing cables.
Shield Terminations
The conduit and cable schedule should indicate shield termination practice for each
shielded cable (refer to the section Connecting the System in the chapter).
Storage
If the system is not installed immediately upon receipt, it must be stored properly to
prevent corrosion and deterioration. Since packing cases do not protect the
equipment for outdoor storage, the customer must provide a clean, dry place, free of
temperature variations, high humidity, and dust.
Use the following guidelines when storing the equipment:
• Place the equipment under adequate cover with the following requirements:
- Keep the equipment clean and dry, protected from precipitation and
flooding.
- Use only breathable (canvas type) covering material – do not use plastic.
• Unpack the equipment as described, and label it.
• Maintain the following environment in the storage enclosure:
- Recommended ambient storage temperature limits from –20 °C (-4 °F) to
55 °C (131 °F).
- Surrounding air free of dust and corrosive elements, such as salt spray or
chemical and electrically conductive contaminants.
- Ambient relative humidity from 5 to 95% with provisions to prevent
condensation.
- No rodents.
- No temperature variations that cause moisture condensation.
Condensation occurs with temperature drops of 15 °C (27 °F) at 50% humidity over
a 4-hour period, and with smaller temperature variations at higher humidity.
Operating Environment
The Mark VI control panel is suited to most industrial environments. To ensure
proper performance and normal operational life, the environment should be
maintained as follows:
Ambient temperature (acceptable): Control Module 0°C (32 °F) to 45 °C (113 °F)
I/O Module 0°C (32 °F) to 50 °C (122 °F)
Ambient temperature (preferred): 20 °C (68 °F) to 30 °C (87 °F)
Relative humidity: 5 to 95%, non-condensing.
Note Higher ambient temperature decreases the life expectancy of any electronic
component. Keeping ambient air in the preferred (cooler) range should extend
component life.
Environments that include excessive amounts of any of the following elements
reduce panel performance and life:
• Dust, dirt, or foreign matter.
• Vibration or shock.
• Moisture or vapors.
• Rapid temperature changes.
• Caustic fumes.
• Power line fluctuations.
• Electromagnetic interference or “noise” introduced by:
- Radio frequency signals, typically from nearby portable transmitters.
- Stray high voltage or high frequency signals, typically produced by arc
welders, unsuppressed relays, contactors, or brake coils operating near
control circuits.
The preferred location for the Mark VI control system cabinet would be in an
environmentally controlled room or in the control room itself. The panel should to be
mounted where the floor surface allows for attachment in one plane (a flat, level, and
continuous surface). The mounting hardware is provided by the customer. Lifting
lugs are provided and if used, the lifting cables must not exceed 45° from the vertical
plane. Finally, the panel is equipped with a door handle which can be locked for
security.
610 mm
(24)
237.5
(9.35)
237.5
(9.35) 18 holes, 16 mm (0.635
inch) dia, in base for
62.5
customers mounting
(2.46) 1475.0 875.0 1475.0
(34.45) (58.07)
studs or bolts.
(58.07)
Full Console
5507 mm
(18 ’- 0 13/16 ")
Short Console
1828.8 mm
(72 ")
or Main Module
Monit e
d u l
Mo
M
M onit
od or
ule 2233.61 mm
Modular Desktop
(7 ’- 3 15/16")
Phone Phone
Printer
Monitor Monitor Monitor Monitor
1181.1mm
Printer Undercounter Keyboards (46.5 ")
Pedestal
Power Requirements
The Mark VI control panel can accept power from multiple power sources. Each
power input source (example: the dc and two ac sources) should feed through its own
external 30 Ampere two-pole thermal magnetic circuit breaker before entering the
Mark VI enclosure. The breaker ratings are 250 volts and 30 amperes with a
minimum withstand of 10,000 amperes. The breaker should be supplied in
accordance with required site codes.
For a single cabinet containing three controllers only, the nominal power
requirements are as follows.
Figure 6-5. Typical System Topology showing Interfaces to Heat Recovery Steam
Generator and Balance of Plant Equipment
Equipment Grounding
Equipment grounding and signal referencing have two distinct purposes:
• Equipment grounding protects personnel and equipment from risk of electrical
shock or burn, fire, or other damage caused by ground faults or lightning.
• Signal referencing helps protect equipment from the effects of internal and
external electrical noise such as from lightning or switching surges.
Installation practices must simultaneously comply with all codes in effect at the time
and place of installation, and practices which improve the immunity of the
installation. In addition to codes, IEEE Std 142-1991 IEEE Recommended Practice
for Grounding of Industrial and Commercial Power Systems and IEEE Std 1100-
1992 IEEE Recommended Practice for Powering and Grounding Sensitive
Electronic Equipment provide guidance in the design and implementation of the
system. Chapter 9, and in particular 9.10, of Std 1100-1992 is very relevant and
informative. Code requirements for safety of personnel and equipment must take
precedence in the case of any conflict with noise control practices.
The Mark VI system has no special or nonstandard installation requirements, if
installed in compliance with all of the following:
• The NEC® or local codes
• With a signal reference structure (SRS) designed to meet IEEE Std 1100
• Interconnected with signal/power-level separation, as defined later
This section provides equipment grounding and bonding guidelines for control and
I/O cabinets. These guidelines also apply to motors, transformers, brakes, and
reactors. Each of these devices should have its own grounding conductor going
directly to the building ground grid.
– For dc circuits only, the NEC allows the equipment grounding conductor to
be run separate from the circuit conductors.
• With certain restrictions, the NEC allows the metallic raceways or cable trays
containing the circuit conductors to serve as the equipment grounding
conductor:
– This use requires that they form a continuous, low-impedance path capable of
conducting anticipated fault current.
– This use requires bonding across loose-fitting joints and discontinuities. See
NEC Article 250 for specific bonding requirements. This chapter includes
recommendations for high frequency bonding methods.
– If metallic raceways or cable trays are not used as the primary equipment
grounding conductor, they should be used as a supplementary equipment
grounding conductor. This enhances the safety of the installation and
improves the performance of the Signal Reference Structure (see later).
• The equipment grounding connection for the Mark VI cabinets is copper bus or
stub bus. This connection is bonded to the cabinet enclosure using bolting that
keeps the conducting path’s resistance at 1 ohm or less.
• There should be a bonding jumper across the ground bus or floor sill between all
shipping splits. The jumper may be a "plated" metal plate.
• The non-current carrying metal parts of the equipment covered by this section
should be bonded to the metallic support structure or building structure
supporting this equipment. The equipment mounting method may satisfy this
requirement. If supplementary bonding conductors are required, size them the
same as equipment grounding conductors.
• SRS must consist of multiple paths. This lowers the impedance and the
probability of wave reflections and resonance.
In general, a good signal referencing system can be obtained with readily available
components in an industrial site. All of the items listed below can be included in an
SRS:
• Metal building structural members.
Control
Common Two 25 mm sq. (4 AWG)
(CCOM) Green/Yellow insulated
bonding jumpers
Equipment grounding conductor,
Identified 120 mm sq. (4/0 AWG),
Insulated Wire, short a distance
as possible Protective Conductor Terminal
(Chassis Safety Ground Plate)
PE
Building Ground
System
If acceptable by local codes, the bonding jumpers may be removed and a 4/0 AWG
identified insulated wire run from CCOM to the nearest accessible point on the
building ground system, or to another ground point as required by the local code.
The distance between the two connections to building ground should be
approximately 15 feet, but not less than 10 feet.
Grounding for a larger system is shown in Figure 6-11. Here the control common is
still connected to the control electronics section, but the equipment grounding
conductor is connected to the center cabinet chassis. Individual control and I/O
panels are connected with bolted plates.
Panel Grounding
Connection Plates
Control
Common Two 25 mm sq. 4AWG
(CCOM) Green/Yellow Bonding
Jumper wires
Notes on Grounding
Bonding to building structure. The cable tray support system typically provides
many bonding connections to building structural steel. If this is not the case,
supplemental bonding connections must be made at frequent intervals from the cable
tray system to building steel.
Bottom connected equipment. Cable tray installations for bottom connected
equipment should follow the same basic principles as those illustrated for top
connected equipment, paying special attention to good high frequency bonding
between the cable tray and the equipment.
Cable spacing. Maintain cable spacing between signal levels in cable drops, as
recommended here.
Conduit sleeves. Where conduit sleeves are used for bottom-entry cables, the
sleeves should be bonded to the floor decking and equipment enclosure with short
bonding jumpers.
Level L
Solid
Bottom
Tray
• 4 – 20 ma current loops
The following are specific examples of level L signals used in the Mark VI cabling:
• All analog and digital signals including thermocouples, LVDTs, Servos, RTDs,
Analog Inputs & Outputs, and Pyrometer signals.
• Phone circuits
Note Signal input to analog and digital blocks or to programmable logic control
(PLC)-related devices should be run as shielded twisted-pair (for example, input
from RTDs).
• 24 V dc switching circuits
Magnetic pickup signals are examples of level M signals used in the Mark VI
The following are specific examples of level H signals used in Mark VI cabling:
• Contact inputs
• Relay outputs
• Solenoid outputs
• PT and CT circuits
Power (Level P)
Power wiring is designated as level P. This consists of ac and dc buses 0 – 800 V
with currents 20 A – 800 A.
The following are specific examples of level P signals used in plant cabling:
• Motor armature loops 20 A and above
Note If using color codes to identify signal/ power levels, care must be taken to
ensure that the color-coding is accurate and complete.
General Practices
The following general practices should be used for all levels of cabling:
• All cables of like signal levels and power levels must be grouped together in
cableways.
• If wires are the same level and same type signal, group those wires from one
panel to any one specific location together in multiconductor cables.
• Where the tables show tray or conduit spacing as 0, the levels can be run
together. Spacing for other levels must be based on the worst condition.
• Trays for all levels should be metal and solidly grounded with good ground
continuity. Conduit should be metal to provide shielding. (Use Figure 6-13,
Table 1 for non-metal conduit/tray spacing).
The following general practices should be used for specific levels of cabling:
• When separate trays are impractical, levels L and M can combined in a common
tray if a grounded steel barrier separates levels. This practice is not as effective as
tray separation, and may require some rerouting at system startup. If levels L and
M are run side-by-side, a 25 mm (1-inch) minimum spacing is recommended.
• Locate levels L and M trays and conduit closest to the control panels.
• Trays containing level L and level M wiring should have solid bottoms and be
covered to provide complete shielding. There must be positive and continuous
cover contact to side rails to avoid high-reluctance air gaps, which impair
shielding.
• Trays containing levels other than L and M wiring can have ventilation slots or
louvers.
• Trays and conduit containing levels L, M, and H(S) should not be routed parallel
to high power equipment enclosures of 100 kVA and larger at a spacing of less
than 1.5 m (5 ft) for trays, and 750 mm (2 1/2 ft) for conduit.
• Level H and H(S) can be combined in the same tray or conduit, but cannot be
combined in the same cable.
• Level H(S) is listed only for information since many customers want to isolate
unfused high voltage potential wires.
• Levels H and P can be run in a common tray if levels are separated by a barrier.
This barrier does not have to be grounded. Spacing should be for level P.
• Where practical for level P and/or P(S) wiring, route the complete power circuit
between equipment in the same tray or conduit. This minimizes the possibility of
power and control circuits encircling each other.
Level L M H H(S) P P(S) Recommended minimum distance between the outside surfaces of
L 0 1 4 4 18 18 metal trays and conduit:
M 0 4 4 12 18
H 0 0 4 8 Use Table 1 for tray/conduit spacing if trays or conduit are non-
H(S) 0 6 12 metal,
P or if level L and M trays are not covered (Table 2 assumes they are
0 0
P(S) 0 covered),
or if the distance between trays or conduit and power equipment up
to 100 kVA is less than 1.5 m (5 ft).
Table 3. Spacing Between Metal Conduit Runs (inches)
Transitional Areas
When entering or leaving conduit or trays, make sure that cables of unlike levels do
not intermix. If the installation needs parallel runs over 1.5 m (5 ft), grounded steel
barriers may be needed for proper level separation.
RF Interference
To prevent radio frequency (RF) interference, take care when routing power cables
in the vicinity of radio-controlled devices (for example, cranes) and audio/visual
systems (public address and closed-circuit television)
Suppression
Unless specifically noted otherwise, suppression (for example, a snubber) is required
on all inductive devices controlled by an output. This suppression minimizes noise
and prevents damage caused by electrical surges. Mark VI relay and solenoid outputs
always have suppression.
Cable Specifications
It is standard practice to use shielded cable with control equipment. Shielding
provides the following benefits:
• Generally, shielding protects a wire or grouping of wires from its environment.
Note The specifications listed are for sensitive computer-based controls. Cabling
for less sensitive controls should be considered on an individual basis.
General Specifications
• Individual minimum stated wire size is for electrical needs.
• Clamp-type terminals use 14 AWG maximum wire.
• Mark VI terminal blocks accept two 12 AWG wires.
Note Belden refers to the Belden Wire & Cable Company, a subsidiary of Belden,
Inc.
Other Cables
UTP Cable (for Data Highways)
• High quality, category 5 UTP cable, for 10Base-T Ethernet
• Four pairs of twisted 22 or 24 AWG wire
• Protective PVC jacket
• Impedance: 75 – 165 ohms
• Connector: RJ45 UTP connector for solid wire
RS-232C Communications
• Modbus communication from the HMI: for short distances use RS-232C cable;
for distances over 15 m (50 feet) add a modem.
• Modbus communication from the controller COM2 port: for use on small
systems, RS-232C cable with Micro-D adapter cable (GE catalog No.
336A4929G1); for longer distances over 15 m (50 feet) add a modem.
• For more information on Modbus and wiring, refer to Chapter 3 Networks.
Instrument Cable, 4 – 20 ma
• With Tefzel insulation and jacket: Belden catalog no. 85231 or equivalent
• With PVC jacket: Belden catalog no. 9316 or equivalent
Plate
Mounting Panel
Lexan Tray for
I/O Cables
I/O Cable
3/4 inch Cable
Cleat for Power
Cables
Riser
Bracket
Insulating Plate
Figure 6-14. Cable Trays & Mounting Brackets for Termination Boards
The first of the two diagrams in Figure 6-15 shows routing of the I/O cables and
power cables in a typical 1600 mm panel line up. Dotted outlines show where boards
will be mounted on top. The cables are not visible from the front.
The second diagram shows routing of IONet and customer field wiring to the I/O
modules and termination boards. This wiring is visible and accessible from the front.
PDM
T Main
125 V dc
Supply
IM
R
IM
S
IM
T
Shield
Terminal
Block
Shield
Termination
Board
Shield
Cable
Figure 6-16 I/O Wiring Shielding Connections to Ground Bar at Termination Board
The grounded shield bars provide an equipotential ground plane to which all cable
shield drain wires should be connected, with as short a pigtail as practical. The
length should not exceed 5 cm (2 in) to reduce the high-frequency impedance of the
shield ground. Reducing the length of the pigtail should take precedence over
reducing the length of exposed wire within the panel. Pigtails should not be
connected except at the grounding bars provided, to avoid loops and maintain a
radial grounding system. Shields should be insulated up to the pigtail. In most cases
shields should not be connected at the far end of the cable, to avoid circulating
power-frequency currents induced by pickup.
A small capacitor may be used to ground the far end of the shield, producing a
hybrid ground system, and may improve noise immunity. Shields must continue
across junction boxes between the control and the turbine, and should match up with
the signal they are shielding. Avoid hard grounding the shield at the junction boxes,
but small capacitors to ground at junction boxes may improve immunity.
Installing Ethernet
The Mark VI modules communicate over several different Ethernet LANs (refer to
Chapter 3 Networks). IONet uses Ethernet 10Base-2 cable. The data highways use a
number of 10Base-T segments and 10Base-2 segments connected to a dual Ethernet
hub. These guidelines comply with IEEE 802.3 standards for Ethernet. For details on
installing individual Ethernet LAN components, refer to the instructions supplied by
the manufacturer of that equipment.
Preventing Reflections
Short segments should have no breaks with 50-ohm terminations on both ends. This
produces minimal reflections from cable impedance discontinuities.
A coaxial barrel connector is used to join smaller segments. However, the joint
between the two segments makes a signal reflection point. This is caused by
impedance discontinuity from the batch-to-batch impedance tolerance of the
manufactured cable.
If cables are built from smaller sections, all sections should either come from the
same manufacturer and lot, or with one of the IEEE recommended standard segment
lengths.
10Base-2 Connectors
Description: Connector for Ethernet 10Base-2 trunk ThinWire coax cable
Part number: BNC coax connector with gold-plated pin, MilesTek catalog no.
10-02001-233
10Base-2 Terminator
Description: BNC terminator for Ethernet trunk coax cable, 50 ohm,
Part number: MilesTek catalog no. 10-02406-009
Note On the PDH and UDH only, use a terminator with grounding tether if the
repeater BNC output is not grounded
Cable
Description: Low capacitance twinaxial cable, 150 ohm, 22 AWG twisted-pair
conductors, 22 AWG stranded tinned copper drain wire
Part no:
With Teflon FEP jacket and foamed Teflon FEP wire insulation: Belden no.
89182 or equivalent.
With PVC jacket: Belden no. 9182 or equivalent.
Characteristics:
• Electrical properties: Belden no. 89182, or equivalent.
• Tinned copper conductors, 22 AWG (19 x 34), 14 ohms per 304.8 m (1000 ft).
• Tinned copper drain wire, 24 AWG stranded.
• Foil shield 100%, 18 ohms per 304.8 m (1000 ft).
• Nominal capacitance: 28.9 pF/m (8.8 pF/ft).
• Nominal impedance: 150 ohms.
• Colors: Jacket = black tint
Wire = white with black stripe
Wire = white with yellow stripe
Standards: Each wire is to be CSA listed and UL recognized (if applicable). This
wire is: NEC Article 725, UL classified, Class 2 circuits, and passes flame retard
standard UL94V-1.
Terminator
Description: Prefabricated termination module for use on Genius blocks and Field
Control modules; 150 ohm, 1/2 W 5% terminating resistors. Required for both ends
of the bus
Part no: GE part no. IC660BLM506
Inspect the control panel components for any damage which might have occurred
during shipping. Check for loose cables or wires, connections or loose components
such as relays or retainer clips. Report any damage that may have occurred during
shipping to GE Product Service.
Refer to Grounding section in this chapter for equipment grounding instructions.
Board Inspections
Perform the following to inspect the printed circuit boards, jumpers, and wiring:
• Inspect the boards in each module checking for loose or damaged components.
The VCMI is always in slot 1 • Verify the Berg jumpers on each I/O board are set correctly for the slot number
and has no jumpers. in the VME rack , refer to Figure 6-17. At this point do not replug the I/O
boards. This will be done after the rack power supply check.
Board ID
Berg
1 2 4 8 16
Jumpers
Jumper Binary Values
1 2
RO-SMP
Startup
This equipment contains a potential hazard of
electric shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the
equipment and the instructions should install,
operate, or maintain this equipment.
Assuming all the above checks are complete, use the following steps to apply power,
load the application code, and startup the Mark VI system.
Applying Power
It is recommended that the initial rack energization be done with all the I/O boards
removed to check the power supply in an unloaded condition.
½ To energize the rack for the first time
1. Unlock the I/O boards and slide them part way out of the racks.
2. Apply power to the PDM and to the first VME I/O rack power supply.
P15 N15
VME Rack Power Supply
Test Points
ACOM P28AA
P28BB
P28CC
P28DD
P28EE
PCOM
N28
DCOM
SCOM
4. If the rack voltages check out, switch off the power supply, and carefully replace
the boards in that rack.
5. Reapply power. All the I/O boards should flash green within five minutes
showing normal operation in the RUN condition.
6. Repeat the above for all the racks.
If the system is a remote I/O system, the controller is in a separate rack powered by a
GE Fanuc power supply. Apply power to this rack, wait for the controller and VCMI
to boot up, and check that they are in the RUN condition.
Check the VPRO modules, if present, to make sure all three are in the RUN
condition.
Controller Download
If you have a new controller, before application code can be downloaded, the TCP/IP
address must be loaded. Refer to Chapter 7 Tools for details.
½ To download the TCP/IP address to a new controller
1. Downloading the TCP/IP address is done from a PC using the Serial Loader
attached to the controller serial port (COM1). Load the Flash File system and the
TCP/IP address. This procedure could take about forty-five minutes.
2. Cycle rack power to reboot the controller.
3. Download the runtime software from the toolbox over the Ethernet-based UDH.
Runtime software, also known as product code, manages the application code in
the controller.
4. Remove the serial loader cable and download the application code.
5. Power cycle the rack to reboot the controller.
I/O Checkout
Install the input and output wiring to the termination boards. The fuses on TRLY
have been removed by the factory for safety reasons. Conduct individual loop
energization checks per standard practices, and install the fuses as required.
Maintenance
This equipment contains a potential hazard of
electric shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the
equipment and the instructions should install,
operate, or maintain this equipment.
Note Return the failed board to GE for repair. Do not attempt to repair it on site.
Component Replacement
This equipment contains a potential hazard of
electric shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the
equipment and the instructions should install,
operate, or maintain this equipment.
Replacing a VCMI
½ To replace and reload the VCMI
1. If a VCMI or VPRO has failed, the rack should be powered down, and the
IONet connector unplugged from the board front, leaving the network still
running through the T-fitting.
2. Remove the VCMI and replace it with a spare VCMI that has a clear flash disk
memory, then power up the rack.
3. From the toolbox Outline View, find the failed rack under Mark VI I/O. Find
the VCMI, which is usually under the Simplex rack, and right click the VCMI.
A menu displays.
4. From the menu, click Download. The topology downloads into the new board.
5. Power cycle the rack to establish communication with the controller.
For a successful download, the flash disk memory in the replacement VCMI should
be clear, because an old topology stored in flash can sometimes cause problems. If
the memory needs to be cleared, contact GE.
Cable Replacement
The I/O cables or power cables are supported in plastic brackets behind the mounting
panels as shown in Figure 6-14. Since these brackets are not continuous, it is not
recommended that the replacement cable be pulled through behind the panel.
½ To replace an I/O cable
1. Power down the interface module and disconnect the failed cable from the
module. Leave the cable in place.
2. Disconnect the failed cable from the termination board.
3. Connect the replacement cable to the termination board, and lay the new cable in
the field-wiring trough at the side of the I/O termination boards. Use space at the
top and bottom of the panel to run the cable across the cabinet to the interface
module.
Introduction
This chapter summarizes the tools used for configuring, loading, and operating Mark
VI. These include the Control System Toolbox, CIMPLICITY HMI, Mark VI
Runtime, and the Historian.
The Toolbox
The Control System Toolbox is PC-based software for configuring and maintaining
the Mark VI control system. The software is Windows-based and runs on a Pentium
100 or higher PC, usually the engineering workstation or a CIMPLICITY HMI
located on the Plant Data Highway. This section summarizes the toolbox features;
for details refer to GEH-6403 Control System Toolbox for a Mark VI Turbine
Controller.
Computer Requirement
The minimum PC requirements for running the toolbox software are as follows:
• 100 MHz processor (Pentium 166 or higher recommended).
• Microsoft® Windows® 95, Windows 98, or Windows NT® 4.0 (recommended).
• VGA display (640 x 480 x 16 color gray scale).
• 16 MB RAM in Windows 95 (32 MB recommended) or 24 MB RAM in
Windows NT (64 MB recommended).
• Ethernet board for data highway communication.
Point Configuration
Each board contains several points, such as thermocouples, contact inputs, or
solenoid outputs. Each of these points is configured with the desired characteristics
including high and low limits, alarm settings, and type of input linearization. The
points are listed under the terminal board which supports those points. If the board is
not selected, then those associated points are not configured.
Figure 7-3 shows the Outline View with the I/O board, terminal board, points, and
point configuration.
Blocks
The Standard Block library contains over 60 different control blocks designed for
discrete and continuous control applications. Blocks provide a simple graphical way
for the engineer to configure the control system. Figure 7-4 displays a math block.
Input signals
MENG computes a mathematical
function of four floating point
inputs A, B, C, and D
Pins
Tasks act as a grouping This block is computed every time the task that contains it is run. Tasks can be run at
mechanism for blocks different frame rates (scan periods) from 10 to 256 ms, depending on the needs and
priority of the control application.
Pins
The Relay Ladder Diagram
(RLD) displays in the block
The control system is configured in the toolbox work area, displayed in Figure 7-6.
The Outline View on the left-hand side of the screen displays the control device and
six configuration items. Under the item Hardware and I/O Definitions are the I/O
and networks, and under the item Functions are the control tasks.
The Summary View on the right side of the screen displays the graphical
configuration of the selected item. Block inputs and outputs are connected with
signals to form the control configuration. These connections are created by dragging
and dropping from a block output to another block input. The connected blocks form
macros, and at a higher level, the blocks and macros form tasks covering major
sections of the complete control.
CIMPLICITY HMI
The CIMPLICITY Human-Machine Interface (HMI) is the main operator interface
to the Mark VI turbine control system. HMI is a PC with a Microsoft Windows NT
operating system and CIMPLICITY graphics display system, communicating with
the controllers over Ethernet. For details refer to GFK-1180 CIMPLICITY HMI for
Windows NT and Windows 95 User’s Manual. For details on how to configure the
graphic screens refer to GFK-1396 CIMPLICITY HMI for Windows NT and
Windows 95 CimEdit Operation Manual.
Basic Description
The Mark VI HMI consists of three distinct elements:
• HMI Server
• Signal Database
• HMI Viewer (Client)
HMI server is the hub of the system, channeling data between the UDH and the
PDH, and providing data support and system management. The server also has the
responsibility for device communication for both internal and external data
interchanges.
Signal database establishes signal management and definition for the control
system, provides a single repository for system alarm messages and definitions, and
contains signal relationships and correlation between the controllers and I/O. It is
used for system configuration, but not required for running.
HMI Viewer provides the visualization function, and is the client of the server. It
contains the operator interface software which allows the operator or maintenance
personnel to view screen graphics, data values, alarms, and trends, issue commands,
edit control coefficient values, and obtain system logs and reports.
Figure 7-7. Interactive Operator Display for Steam Turbine & Generator
In the above graphic display, special displays can be obtained using the buttons in
the column on the right hand side. Also note the setpoint button for numeric entry,
and the raise/lower arrows for opening and closing valves.
Product Features
The HMI contains a number of product features important for power plant control:
• Dynamic graphics
• Alarm displays
Optional Features
The WebGateway allows operators to access HMI data from anywhere in the world
over the Internet.
Third party interfaces allow the HMI to exchange data with DCS systems,
programmable logic controllers, I/O devices, and other computers.
COM1 Mark VI
Controller
Controller Setup
The following steps define how to set up the controller for the first time. It is
assumed that the toolbox and controller software is already installed in the PC.
½ To set up the controller
1. Load the flash and configure TCP/IP with the Serial Loader over a serial cable
(see the section, Loading the Flash File System).
2. Cycle power to activate the new IP settings.
A soft reboot from the toolbox
is not sufficient. 3. From the toolbox, load the product code (runtime).
4. Then, load the application code (Pcode) and symbol files to permanent
storage only.
5. Cycle power again.
A short adapter cable is required to plug into the controller COM1 Micro-D size
connector. This cable can be ordered as part number 336A4929G1. The Serial
Loader can load the Flash File System and configure the TCP/IP software in the
controller.
½ To connect the Loader serial cable
1. Connect the end of the converter cable to COM1 (9-pin connector) on the front
of the controller.
2. Connect the end of the serial cable labeled UC2000 connector to the converter
cable.
3. Connect the end of the serial cable labeled PC COM Port to one of the PC COM
ports.
Click
to Start the selected
commands.
Note The button, Source Directory points to the location of the BIOS, CMOS, and
flash binary files. It is enabled when CPU Type is either Custom or Mark V LM. The
controller directory is automatically set to platform (C:\Program Files\GE Control
System Solution\MarkVI_Controller\platform).
Tip © All IP addresses and masks are represented in dotted decimal notation,
within each of the four bytes of the address, separated with periods, such as
3.29.22.27. To determine the correct IP addresses and masks, see your network
administrator.
Click OK.
3. Select the Device menu, Download, and Product Code (Runtime). The
Download File dialog box displays.
4. Click Select.dnl and click Open. All possible files that can be downloaded
display in the dialog box shown in Figure 7-14.
5. Click on to uncheck any feature not used by the controller (in order to
conserve flash space). The toolbox deletes the entire directory and then
downloads only the checked items. Click OK. The following message displays.
3. Click OK.
4. Wait until the red FLSH LED on the controller has turned off.
5. Reboot the controller using the power switch.
Software Modifications
The following sections describe how to modify the application code in the controller
and how to upgrade the product code software to a newer version.
Pcode is written when the ½ To change the application code in the controller
menu command, Build
1. From the toolbox, modify the application code.
application control code is
selected. This file contains all
the application software for 2. Select Validate and Build.
the controller. 3. From the Device menu, select Download and then Download Application
Code.
4. Select the desired download option from the Download application code
dialog box displayed in Figure 7-17.
Major/Minor Differences
The toolbox detects differences between the application code loaded into it and that
loaded into the controller by comparing the revision dates. The revision in the
toolbox and the controller is stored as two date and time values. These values are
cleared in the toolbox when a major or minor change occurs and set when the
configuration is built (Pcode). When the toolbox is online with a controller, the
major/minor revision of the downloaded configuration in the controller is compared
with the current configuration in the toolbox. A typical toolbox display of the
revisions is shown in Figure 7-18.
3. Install the new controller product code using the setup utility. This is displayed
in Figure 7-21.
4. Select the Device menu, Download, and then Product code (Runtime).
6. Click on to uncheck any file not used by the controller (in order to conserve
flash space). The toolbox deletes the entire directory and then downloads only
the checked items. Click OK. The following message displays.
Note This will create a new Work Area to merge the application code (.tre files)
with the new product code.
10. Select Validate and Build to create a new Pcode file (.pcd) from the
application code.
Load Application
Pcode Startup specified I/O drivers
Generates
flashing error Create Data Collection
Can only be modified at boot-up
codes Memory
Load Block
Load standard control block library
Library
Expand Application
Create task scheduling lists
Pcode
Synchronize with
other 2 Controllers This step implemented only if the system is TMR
Historian
The Historian is a data archival system based on client-server technology, that
provides data collection, storage, and display of power island and auxiliary process
data. Depending on the requirements, the product can be configured for just turbine-
related data, or for broader applications that include balance of plant process data.
The Historian combines high-resolution digital event data from the turbine controller
with process analog data to create a sophisticated tool for investigating cause-effect
relationships. It provides a menu of predefined database query forms for typical
analysis relating to the turbine operations. Flexible tools enable the operator to
quickly generate custom trends and reports from the archived process data.
System Configuration
The GE Historian provides historical data archiving and retrieval functions. When
required, the system architecture provides time synchronization to ensure time
coherent data.
The Historian accesses turbine controller data via the UDH as shown in Figure 7-26.
Additional Historian data acquisition is performed through Modbus and/or Ethernet
based interfaces. Data from third party devices such as Bently Nevada monitors, or
non-GE PLCs is usually obtained via Modbus, while Ethernet is the preferred
communication channel for GE/Fanuc PLC products.
The HMI and other operator interface devices communicate to the Historian through
the PDH. Network technology provided by the Microsoft Windows NT Operating
System allows interaction from network computers including query and view
capabilities using the Historian Client Tool Set. The interface options include the
ability to export data into spreadsheet applications.
TR
System Capability
The Historian provides an on-line historical database for collecting and storing data
from the Mark VI turbine controls. Up to 20,000 total point tags may be configured
and collected from as many as eight turbine controls.
A typical turbine control application uses less than 1,000 points of time tagged
analog and discrete data per unit. The length of time that the data is stored on disk
before off-line archiving is required depends upon collection rate, dead-band
configuration, process rate of change, and disk size.
Data Flow
The Historian has three main functions: data collection, storage, and retrieval. Data
collection is over the UDH and Modbus. Data is stored in the Exception Database for
SOE, events, and alarms, and in the archives for analog values. Retrieval is by way
of a web browser, or standard trend screens. Figure 7-27 shows these functions and
data flow.
3rd Party
Mark VI PLC Devices
Ethernet Ethernet Modbus
Process
Turbine Control
Data Archives
Exception
Dictionary (Analog
Database Values)
(SOE)
Server Side
Client Side
Details
Data is collected by various methods. For the Mark VI, the process is centered about
the Control Signal Database (CSDB) which is the real-time database used by the
controller. The Mark VI scans the CSDB for alarm and event state changes. When a
state change occurs, it is sent to the Historian. Contact inputs, or Sequence of Event
(SOE) changes are scanned, sent to the Historian and stored in the Exception
Database with the alarms and event state changes. These points are time-tagged by
the Mark VI at the frame rate. The Mark VI also distributes one-second periodic
updates scanned from the CSDB.
Time synchronization and time coherency are extremely important when the operator
or maintenance technician is trying to analyze and determine the root cause of a
problem. To provide this, the data is time-tagged at the controller and offers system
time-sync functions as an option to ensure that PLC and Mark VI data remain time-
coherent.
Data points configured for collection in the archives are sampled once per second
from the Data Dictionary. Analog data that exceeds an exception dead-band and
digital data that changes state are sent to the archives. The Historian uses the
swinging door compression method that filters on the slope of the value to determine
when to save a value. This allows the Historian to keep orders of magnitude more
data on-line than in conventional scanned systems.
The web browser interface provides access to the Alarm & Event Report, the Cross-
Plot, the Event Scanner, and several Historian status displays. Configurable trend
displays are the graphical interface to the history stored in the archives. They provide
historical and real-time trending of all process data.
Reports
The data link provides a vehicle to extract data from the archives into application
packages such as Excel. Excel, and other software packages such as Access, SQL,
and Minitab can be used to generate reports and analyze data. Numerous reports such
as maintenance and shift reports can be generated to provide the customer with
needed information to better manage his plant assets.
Introduction
This chapter discusses troubleshooting and alarm handling in the Mark VI system.
The configuration and creation of process alarms is covered, and the creation and
handling of diagnostic alarms caused by control system equipment failures.
Overview
Two kinds of alarms are generated by the Mark VI system, process alarms and
diagnostic alarms. Process alarms are routed to the operator display, and diagnostic
alarms are routed to the engineering workstation (toolbox). Figure 8-1 shows the
alarm routings.
Alarm Diagnostic
HMI HMI Toolbox
Display Display
UDH
Diagnostic
I/O SOEs I/O I/O
Alarm Bits
Process Alarms
Process alarms can be generated in two ways. One way is via the application
software running in the controller. Signals used to generate these alarms are tied to
an alarm group which is scanned for state changes by the controller.
Process alarms are also triggered in the I/O board by System Limit Checking. Limit
checking takes place at the frame rate, and resulting alarms are sent to the controller
where they are time stamped and given an ID. They are then sent over the UDH to
the HMI where, with appropriate configuration, the HMI creates alarm messages for
the operator.
• Two System Limits are available for each process input, including
thermocouple, RTD, current, voltage, and pulse rate inputs. System Limit 1 can
be the high or low alarm setting, and System Limit 2 can be a second high or
low alarm setting. These limits are configured from the toolbox in engineering
units.
• There are several choices when configuring System Limits. Limits can be
configured as enabled or disabled, latched or unlatched, and greater than or less
than the preset value.
• System out of limits can be reset with the RESET_SYS signal.
• Process alarm logicals can be used in the application program. In TMR systems
limit logic signals are voted and the resulting composite diagnostic is present in
each controller.
Control
Blocks Alarm
Group
Block
Figure 8-2. Generating Process Alarms using the Alarm Group Block
Diagnostic Alarms
The controller and I/O boards all generate diagnostic alarms, including the VCMI
which generates diagnostics for the power subsystem. Alarm bits are created in the
I/O board by hardware limit checking. Raw input checking takes place at the frame
rate, and resulting alarms are queued.
VTCC 16 System Limit Checking is Disabled. If any The configuration setting for "System
thermocouple or cold junction sensor input exceeds the Limits" was set to "Disable".
configured system limits, the system limit alarm will not be
set
32 Thermocouple ## Raw Counts High. The ## A condition such as stray voltage or
thermocouple input to the analog to digital converter noise caused the input to exceed +63
exceeded the converter limits and will be removed from millivolts.
scan
33 Thermocouple ## Raw Counts Low. The ## The board has detected a
thermocouple input to the analog to digital converter thermocouple open and has applied a
exceeded the converter limits and will be removed from bias to the circuit driving it to a large
scan negative number, or the TC is not
connected, or a condition such as stray
voltage or noise caused the input to
exceed -63 millivolts.
34 Calibration Reference # Raw Counts High. The precision reference voltage on the
Calibration Reference # input to the A/D converter board has failed.
exceeded the converter limits. If Cal. Ref. 1, all even
numbered TC inputs will be wrong; if Cal. Ref. 2, all odd
numbered TC inputs will be wrong
35 Calibration Reference # Raw Counts Low. The precision reference voltage on the
Calibration Reference # input to the A/D converter board has failed.
exceeded the converter limits. If Cal. Ref. 1, all even
numbered TC inputs will be wrong; if Cal. Ref. 2, all odd
numbered TC inputs will be wrong
36 Null Reference # Raw Counts High. The null (zero) The null reference voltage signal on the
reference number # input to the A/D converter has board has failed.
exceeded the converter limits. If null ref. 1, all even
numbered TC inputs will be wrong; if null ref. 2, all odd
numbered TC inputs will be wrong.
37 Null Reference # Raw Counts Low. The null (zero) The null reference voltage signal on the
reference number # input to the A/D converter has board has failed.
exceeded the converter limits. If null ref. 1, all even
numbered TC inputs will be wrong; if null ref. 2, all odd
numbered TC inputs will be wrong.
38 Cold Junction # Raw Counts High. Cold junction The cold junction device on the
device number # input to the A/D converter has exceeded termination board has failed.
the limits of the converter. Normally two cold junction
inputs are averaged; if one is detected as bad then the
other is used. If both cold junctions fail, a predetermined
value is used.
39 Cold Junction # Raw Counts Low. Cold junction The cold junction device on the
device number # input to the A/D converter has exceeded termination board has failed.
the limits of the converter. Normally two cold junction
inputs are averaged; if one is detected as bad then the
other is used. If both cold junctions fail, a predetermined
value is used.
VRTD 16 System Limit Checking is Disabled. System limit Checking was disabled by configuration.
checking on the VRTD board has been disabled by
configuration; no alarms will be generated until corrected.
32 RTD # has Raw Volt Counts High and Counts are Y. An RTD wiring/cabling open, or an
open on the VRTD board, or a VRTD
hardware problem (such as
multiplexer), or the RTD device has
failed.
33 RTD # has Raw Volt Counts Low and Counts are Y. An RTD wiring/cabling short, or a short
on the VRTD board, or a VRTD
hardware problem (such as
multiplexer), or the RTD device has
failed.
34 RTD # has Raw Current Counts High and Counts are Y. The current source on the VRTD is
bad, or the measurement device has
failed.
35 RTD # has Current Raw Counts Low and Counts are Y. An RTD wiring/cabling open, or an
open on the VRTD board, or a VRTD
hardware problem (such as
multiplexer), or the RTD device has
failed.
36 RTD # has Linearization Table Index High and it is Y The wrong type of RTD has been
Ohms. RTD # has a higher value than the table and the configured or selected by default, or
value is Y. there are high resistance values
created by faults 32 or 35, or both 32
and 35.
37 RTD # has Linearization Table Index Low and it is Y The wrong type of RTD has been
Ohms TRD # has a lower value than the table and the configured or selected by default, or
value is Y. there are low resistance values created
by faults 33 or 34, or both 33 and 34.
38-61 Voltage Circuits for RTDs, or Current Circuits for RTDs Internal VRTD problems such as a
Voltage or current circuits have Reference raw counts high damaged reference voltage circuit, or a
or low, or Null raw counts high or low. bad current reference source, or the
voltage/current null multiplexer is
damaged.
VAIC 16 System Limit Checking is Disabled. System limit System checking was disabled by
checking on the VAIC board has been disabled by configuration.
configuration; no alarms will be generated until corrected.
32 Analog Input # Unhealthy. Excitation to transducer, bad
transducer, open or short circuit.
33 Output # Individual Current Too High Relative to Total Board failure.
Current.
34 Output # total Current Varies from Reference Current. Board failure, or open circuit.
35 Output # Reference Current Error. Board failure (D/A converter).
VAOC 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VAOC board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
32 Analog Input # Unhealthy Excitation to transducer, bad
transducer, open or short circuit.
33 Output # Total Current Too High Relative to Total Board failure.
Current. An individual current is N mA more than half
the total current, where N is the configurable TMR_Diff
Limit.
34 Output # Total Current Varies from Reference Current. Board failure, or open circuit.
Total current is N mA different than the reference current,
where N is the configurable TMR_Diff Limit.
35 Output # Reference Current Error. The difference Board failure (D/A converter).
between the output reference and the input feedback of
the output reference is greater than the configured DA_Err
Limit measured in percent.
36 Output # Individual Current Unhealthy. Simplex Board failure.
mode alarm indicating current is too high or too low.
37 Output # Suicide Relay Non-Functional. The suicide Board failure (Relay or driver).
relay is not responding to commands.
38 Output # Suicide Active. One output of three has Board failure.
suicided, the other two boards have picked up the current.
VCCC 16 System Limit Checking is Disabled. System limit Checking was disabled by
and checking on the VCCC board has been disabled by configuration.
VCRC configuration; no system alarms will be generated until
corrected.
32/33 TBCI J3/J4 Contact Input # Not Responding to Test Normally a VCCC problem, or the
Mode. A single contact or group of contacts could battery reference voltage is missing to
not be forced high or low during VCCC self-check. the TBCI termination board.
34/35 TRLY J3/J4 Relay Output Coil # Does Not Match The relay termination board TRLY may
Requested State. A relay coil monitor shows that not exist, or there may be a problem
current is flowing or not flowing in the relay coil, so the with this relay, or, if TMR, one VCCC
relay is not responding to VCCC commands. may have been out-voted by the other
two VCCC boards.
36/37 TRLY J3/J4 Relay Driver # Does Not Match Requested The relay termination board TRLY may
State. The relay is not responding to VCCC not exist and the relay is still configured
commands. as used, or there may be a problem
with this relay driver.
VSVO 16 System Limit Checking is Disabled. System limit VSVO is configured to disable limit
checking on the VSVO board has been disabled by checking.
configuration; no system alarms will be generated until
corrected.
32 LVDT # RMS Voltage Out of Limits. Minimum and The LVDT may need recalibration.
maximum LVDT limits are configured.
33 Calibration Mode Enabled. The VSVO was put into calibration
mode.
34 VSVO Board Not Online, Servos Suicided. The servo The controller (R, S, T) or IONet is
is suicided because the VCMI is not on-line. down.
35 Servo Current # Disagrees with Reference, Suicided. A cable/wiring open circuit, or board
The servo currents error (reference – feedback) is greater problem.
than the configured current suicide margin.
36 Servo Current # Short Circuit. This is not currently NA
used.
37 Servo Current # Open Circuit. The servo voltage is A cable/wiring open circuit, or board
greater than 5V and the measured current is less than problem.
10%.
38 Servo Position # Feedback Out of Range, Suicided. LVDT or board problem.
Regulator number # position feedback is out of range,
causing the servo to suicide.
39 Configuration Message Error for Regulator Number #. The LVDT Minimum and maximum
There is a problem with the VSVO configuration and the voltages are equal or reversed, or an
servo will not operate properly. invalid LVDT, regulator, or servo
number is specified.
40 On Board Calibration Voltage Range Fault. The A/D A problem with the Field Programmable
calibration voltages read from the FPGA are out of limits, Gate Array (FPGA).
and the VSVO will use default values instead.
41 LVDT Excitation # Voltage Short Circuit. There is a problem with the LVDT
excitation source on the VSVO board.
VPRO 16 System Limit Checking is Disabled. System limit System checking was disabled by
checking on the VPRO board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
33 P15=####.## Volts is Outside of Limits. The P15 Analog +/- 15 Volt power supply on
power supply is out of the specified +12.75 to +17.25 Volts VPRO board has failed.
operating limits.
34 N15=####.## Volts is Outside of Limits. The N15 Analog +/- 15 Volt power supply on
power supply is out of the specified –17.25 to –12.75 Volts VPRO board has failed.
operating limits.
35 (Reserved)
36 (Reserved)
VTUR 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VTUR board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
32 Solenoid # Relay Driver Feedback Incorrect. The solenoid relay driver on the TRPG
Solenoid (1-6) relay driver feedback is incorrect as board has failed, or the cabling
compared to the command; VTUR cannot drive the relay between VTUR and TRPG is incorrect.
correctly until the hardware failure is corrected.
33 Solenoid # Contact Feedback Incorrect. Solenoid (1- The solenoid relay driver or the
6) relay contact feedback is incorrect as compared to the solenoid relay on the TRPG board has
command; VTUR cannot drive the relay correctly until the failed, or the cabling between VTUR
hardware failure is corrected. and TRPG is incorrect.
34 TRPG # Solenoid Power Absent. P125/24 V dc Power may not be coming into TRPG
power is not present on TRPG termination board; VTUR on the J1 connector, or the monitoring
cannot energize trip solenoids 1 through 3, or 4 through 6 circuit on TRPG is bad, or the cabling
until power is present. between TRPG and VTUR is at fault.
35 TRPG # Flame Detector Volts Low at Y Volts. TRPG 1 Power comes into TRPG via J3, J4,
or 2 flame detect voltage is low; the ability to detect flame and J5. If the voltage is less than 314.9
by detectors 1 through 8, or 9 through 16 is questionable. V dc, this should be investigated. If the
voltage is above this value, the
monitoring circuitry on TRPG or the
cabling between TRPG and VTUR is
suspect.
36 TRPG # Flame Detector Volts High at Y Volts. TRPG 1 This power comes into TRPG via J3,
or 2 flame detect voltage is high; the ability to detect flame J4, and J5. If the voltage is greater than
by detectors 1 through 8, or 9 through 16 is questionable 355.1 V dc, this should be investigated.
because the excitation voltage is too high and the devices If the voltage is below this value, the
may be damaged. monitoring circuitry on TRPG or the
cabling between TRPG and VTUR is
suspect.
VGEN 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VGEN board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
32 Analog 4-20 mA Auto Calibration Faulty One of the 3 Volt or 9 Volt precision reference or
analog 4-20 mA auto calibration signals has failed. Auto null reference on VGEN is defective, or
calibration or 4-20 mA inputs are invalid, 4-20 mA inputs multiplexer or A/D converter circuit on
are invalid. VGEN is defective.
33 PT Auto Calibration Faulty. One of the PT auto Precision reference voltage or null
calibration signals has gone bad. Auto calibration of PT reference is defective on VGEN, or
input signals is invalid, PT inputs are invalid. multiplexer or A/D converter circuit on
VGEN is defective.
34 CT Auto Calibration Faulty. One of the CT auto Precision reference voltage or null
calibration signals has gone bad. Auto calibration of CT reference is defective on VGEN, or
input signals is invalid, CT inputs are invalid. multiplexer or A/D converter circuit on
VGEN is defective.
35 (Reserved)
39 Analog Input # Unhealthy. Analog Input 4-20 mA ## Analog input is too large, TGEN jumper
has exceeded the A/D converter’s limits. (JP1, JP3, JP5, JP7) is in the wrong
position, signal conditioning circuit on
TGEN is defective, multiplexer or A/D
converter circuit on VGEN is defective.
40 Relay Output Coil # does not Match Requested State. Relay is defective, connector cable J4
There is a mismatch between the relay driver command to TRLY J1 is disconnected.
and the state of the current sensed on the relay coil on
TRLY.
41 Relay Driver # does not Match Requested State. Faulty relay driver circuit or drive
There is a mismatch between the relay driver command sensors on VGEN.
and the state of the output to the relay as sensed by
VGEN.
42 Fuse # and/or # Blown. One or both of the listed One or both of the listed fuses is blown,
fuses is blown, or there is a loss of power supply. or there is a loss of power on TB3.
VPYR 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VPYR board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
32 Slow Average Input Unhealthy. Milliamp input Specified pyrometer’s average output is
associated with the slow average temperature is faulty, or VPYR or TPYR is faulty.
unhealthy.
33 Slow Max Input Unhealthy. Milliamp input associated Specified pyrometer’s max. output is
with the slow maximum peak temperature is unhealthy. faulty, or VPYR or TPYR is faulty.
34 Slow Average Peak Input Unhealthy. Milliamp input Specified pyrometer’s peak output is
associated with the slow average peak temperature is faulty, or VPYR or TPYR is faulty.
unhealthy.
35 Fast Input Unhealthy. Milliamp input associated with Specified pyrometer’s fast output is
the fast temperature is unhealthy. faulty, or VPYR or TPYR is faulty.
36 Fast Calibration Reference. The fast calibration VPYR is faulty.
reference is out of limits.
37 Fast Calibration Null. The fast calibration null is out of VPYR is faulty.
limits.
38 Slow Calibration Reference. The slow calibration VPYR is faulty.
reference is out of limits.
39 Slow Calibration Null. The slow calibration null is out VPYR is faulty.
of limits.
40 Board ID Failure. The board ID device is not being read VPYR is faulty, or ID chip is not
correctly. programmed.
41 P3 ID Failure. The P3 terminal board ID device is not VPYR or TPYR is faulty, or ID chip on
being read correctly. TPYR is not programmed.
VCMI 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VCMI board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
32 P5=###.## Volts is Outside of Limits. The P5 power Probably a VME rack backplane wiring
supply is out of the specified operating limits. problem and/or power supply problem.
ACTIVE H L
SLOT1 S
BMAS
ENET T
A F
SYS
T
BSLV F
U
S
F
FLSH
GENA
is error 0x43, decimal 67
If the controller detects certain system errors (typically during boot-up or download),
it displays flashing and non-flashing codes on these green status LEDs. These codes
correspond to runtime errors described in the controller manual, refer to GEH-6410
Innovation Series Controller System Manual. These error numbers and descriptions
are also listed in the controller help file. The following table describes the types of
errors displayed by the LEDs.
Troubleshooting
To start troubleshooting, be certain the racks have correct power supply voltages;
these can be checked at the test points on the left hand side on the VME rack.
First level troubleshooting uses the LEDs on the front of the I/O and VCMI boards.
If more information on the board problems and I/O problems is required, use the
toolbox diagnostic alarm display for details.
Orange Light
If the orange Status LED lights on one board, this indicates there is an I/O or system
diagnostic in queue in that board. This is not an I/O board failure, but may be a
sensor problem.
½ To see the diagnostic message
1. From the toolbox Outline View, select Online using the Go on/offline
button.
Red Light
If a board has a red Fail LED lit, it indicates the board is not operating. Check if it is
loose in its slot and, if so, switch off the rack power supply, push the board in, and
turn on the power again. Figure 8-4 shows a typical I/O board with chip locations.
I/O Board
Controller Failures
If the controller fails, the rotating green LED on its front panel stops. Power down
the controller rack and reboot by bringing power back (do not use the Reset button).
If the controller stays failed after reboot, replace it with a spare.
If several LEDs are stopped and flashing, this indicate a runtime error, typically a
boot-up or download problem. The LED hex code indicates the type of error
encountered, refer to GEH-6410 Innovation Series Controller System Manual. The
controller Help screen on the toolbox also displays all the runtime errors together
with suggested actions.
If the controller, or it’s VCMI, fails then the IONet on this channel stops sending or
receiving data. This drives the outputs on the failed channel to their fail safe state.
This does not affect the other two IONet channels which keep running.
Introduction
This chapter describes all the Mark VI boards including the controller, VCMI
communication boards, VDSK board, and the I/O boards, along with their associated
termination boards. The power distribution module and the VME rack power
supplies are also described.
Controller
The Mark VI controller is a 6U high, two-slot VME module housing a high-speed
processor. The controller mounts in a VME module called the control module, and
communicates with the turbine I/O through the VME bus. The operating system is
QNX which is a real time, multitasking OS designed for high-speed industrial
applications. In addition to the VME interface to the turbine I/O, four
communication ports provide links to operator interfaces, a distributed control
system, and PLC I/O:
• Ethernet connection to the UDH for communication with HMIs and other
control equipment.
• RS-232C connection using COM2 port for communication with a DCS using the
Modbus protocol.
• Genius Bus interface to remote Genius I/O blocks, Field Control I/O, and GE
Fanuc Data Panels.
• DLAN+ high speed LAN interface for special communication applications.
Controller Operation
The controller software includes appropriate portions of the existing Big Block
Library (BBL) libraries for the Steam, Gas, and LM (Land-Marine aero-derivative)
products. The controller is capable of executing a total of 100,000 BBL rungs or
blocks per second, assuming a typical collection of average size blocks. Application
software can be modified online without requiring a restart. The controller is shown
in Figure 9-1.
x x
DLAN DROP
1 0
8
ETHERNET
Ethernet Port for Unit Data DLAN Network Drop Number
Highway Communication Configuration Dip Switches
1
ACTIVE H L
SLOT1
Controller and Communication BMAS Status LEDs showing Runtime Error Codes
ENET
Status LEDs SYS resulting from Bootup, Configuration, or
BSLV
RESET
Download Problems
FLSH
GENA
Monitor Port for GE Use
MONITOR
Only
Connector for Ribbon Cable to VME
HARD DISK
Interface (VDSK)
COM1 RS-232C Port for
COM1
COM2
UCVB
G1A
x x
Item Specification
DLAN+ Interface Interface to DLAN+, a high speed multidrop network based on ARCNET,
using a token passing, peer to peer protocol
Power Requirements +5 V dc, 5.64 A
+12 V dc, 900 mA
-12 V dc, 200 mA
Temperature 0-45 C at inlet to controller (recommend 100 ft/min forced air cooling)
Humidity 10-95 % relative humidity, non-condensing
Diagnostics
If a failure occurs in the Mark VI controller while it is running application code, the
rotating green LEDs on the front panel stop and a fault code is generated.
If the controller detects certain system errors (typically during boot-up or download)
it displays flashing codes on the eight-segment bank of status LEDs located on the
front panel. These codes are called runtime errors, and descriptions are available on
the toolbox Help screen. The error numbers and descriptions are additionally
available on the controller serial port (COM1). For further information, refer to
Chapter 8, Troubleshooting & Diagnostics.
Installation
The VME-bus control module contains the controller, VCMI, and a VDSK board.
There are three rack types which can be used, the GE Fanuc PLC rack shown in
Figure 9-2, and two sizes of Mark VI rack. The GE Fanuc rack is shorter and is used
for systems with remote I/O only, whereas the Mark VI rack is longer and can be
used for local or remote I/O. Whichever rack is used, a cooling fan is mounted either
above or below the controller.
VME Rack
POWER
SUPPLY
Power Supply
x x x x
x x
VCMI is OK
P P
A A
R R
A A
L L
L L
E E
L L
M M
O8 IONet Node O8
D4 D4 TX
U2 U2 RX
L L
E1 E1 CD
IONET3
10Base 2
R Channel ID
S R TX
T S RX
Transmitting Packets T CD
Receiving Packets IONET2
TX 10Base 2
Collisions on IONet
RX
CD TX
IONET RX IONET1
10Base 2 CD 10Base 2
VCMI VCMI
H1A H2A
x x
Communication Communication
Board - 1 IONET Board - 3 IONETs
Figure 9-3. VCMI Board, Single Network and Triple Network Versions
R R1
V U V
Simplex System with
C C I/O C I/O
M V Boards M Local & Remote I/O
Boards
I X I
IONet
R R1
V U V
C C C I/O Simplex System with
M V M Boards Multiple IONets &
I X I Remote I/O
IONet
R2
V
C I/O
M Boards
I
IONet
Figure 9-4. Simplex System Configurations with Local & Remote I/O
Two sizes of TMR systems are shown in Figure 9-5. The first example is a small
system where all the I/O can be mounted in the VME control rack so no remote I/O
racks are required. Each channel (R, S, T) has its own IONet, and the VCMI has
three IONet ports.
R S T
TMR System with
V U V U V U Local I/O
C C I/O C C I/O C C I/O
M V Boards M V Boards M V Boards UCVX is Controller
I X I X I X
VCMI is Bus Master
I/O are VME Boards
IONet - R Termination Boards
IONet - S not shown
IONet - T
IONet - R
IONet - S
IONet - T
R1 S1 T1
V V V
C I/O C I/O C I/O
IONet Supports
M Boards M Boards M Boards Multiple Remote
I I I I/O Racks
Figure 9-5. TMR System Configurations with Local & Remote I/O
VCMI Features
The VCMI architecture is based on the 32-bit Texas Instruments TMS320C32 digital
signal processor (DSP). The main hardware features are:
• Interface to VME bus
• Three 10Base-2 Ethernet ports
• One RS-232C serial port
• One parallel port
• Power system monitoring
• Board and cable ID reading
• Processor watchdog timer
Performance
The Simplex frame rate is 10 milli-seconds allowing turbine control at 100 Hz, while
the TMR frame rate is 40 ms for control at 25 Hz.
The control module is synchronized to the wall clock ensuring the sequence of
events (SOE) times are within 1 ms of the actual event time.
Watchdog Timer
The watchdog timer protects against a processor stall condition. If a stall occurs the
watchdog times out after approximately 200 ms and resets the processor. It notifies
the VME backplane that the processor has been reset, and shuts off IONet
communication while stalled. The front panel reset button (if present) can be used to
force the timer to the stalled state from which it transitions to the operational state.
On line testing of the watchdog function can be performed.
Item Specification
VCMI Diagnostics
The internal 5V, 12V, 15V, and 28V power supply buses are monitored and alarmed.
The alarm settings are configurable and usually set at 3.5%, except for the 28-Volt
supplies which are set at 5.5%.
Diagnostic signals from the Power Distribution Module, connected through J301, are
also monitored. These include ground fault and over/under voltage on the P125V
bus, two differential +/-5Vdc analog inputs, P28A and PCOM for external monitor
circuits, and digital inputs.
Descriptions of the VCMI diagnostics are in Chapter 8, Troubleshooting &
Diagnostics.
J4
J3
24 V dc Supply to Cooling
Fan below Rack
VDSK
x x x
Cable to Power Sub-System
Board Operation
The VDSK board is a solid state assembly which emulates a hard disk, but with
negligible access time. The VDSK board directly interfaces with the controller CPU
board via a standard 44-pin ribbon cable. In addition to data storage, VDSK supports
several other functions as follows:
- Interconnects the PDM with the power subsystem monitoring functions of the
VCMI through the 96-pin P2 backplane connector and the 37-pin sub-miniature
D connector on the front panel. This connection is through a 64-pin ribbon cable
connected at the back of the VME backplane.
- Interconnects +12 V dc and –12 V dc from the 96-pin P1 backplane connector to
a front panel mounted 2-pin connector to power the 4.3 watt 24 V dc VME rack
mounted fan assembly. This is from the front panel J4 connector.
- Provides a board mounted 16-pin Ethernet ID connector which interfaces to the
VCMI board through the P2 backplane connector ribbon cable.
x
x
x
x 2
x 1 TBTC, capacity for RUN
x 3 FAIL
x 4 24 thermocouple inputs STAT
TC x 6
x 5
Inputs x 8
x 7
x 10
x 9
x 11 VME Bus to VCMI
x 12
x 14
x 13 Communication Board
x 16
x 15
x 18
x 17
x 19 37-pin "D" shell
x 20 JA1
x 21 type connectors
x 22
x 23 with latching
x 24
x
fasteners
x
x 26
x 25
x 28
x 27
TC x 30
x 29
32
x 31
Inputs x
x 33 JB1
x 34
x 36
x 35
x 38
x 37 Cables to VME
x 40
x 39 Rack
VTCC
x 42
x 41 x
x 44
x 43
x 46
x 45 Connectors on J3
x 48
x 47 VME Rack
x
x
Shield Bar
Ground
J4
BarrierType Terminal
Blocks can be unplugged
from board for
maintenance
Figure 9-7. Thermocouple Input Termination Board, I/O Board, and Cabling
Thermocouple
High
Noise
Low Suppression
(12) thermocouples
Thermocouple Type E J K T
Cold Junctions
There are two cold junctions (CJ) sensors on each termination board, one per
connector J3 and J4. Both CJ signals go into signal space and are available for
monitoring. Normally the average of the two is used. Acceptable limits are
configured, and if a CJ goes outside the limit, a logic signal is set. A 1 F error in the
CJ compensation will cause a 1F error in the TC reading.
Hard coded limits are set at 32 to 158 F, and if a CJ goes outside these, it is
regarded as bad. Most CJ failures are open or short circuit. If one CJ fails, the good
one is used. If both CJs go bad, the backup value is used, which can be derived from
CJ readings on other termination boards, or can be the configured default value.
Diagnostics
Three LEDs at the top of the front panel provide status information. The normal
RUN condition is a flashing green, and FAIL is a solid red. The third LED is
normally off but shows a steady orange if a diagnostic alarm condition exists in the
board.
Each termination board has its own ID device which is interrogated by the I/O board.
The board ID is coded into a read-only chip containing the termination board serial
number, board type, revision number, and the JA1/JB1 connector location. Details of
the VTCC diagnostics are in Chapter 8, Troubleshooting & Diagnostics.
Calibration
The thermocouple inputs and cold junction inputs are automatically calibrated using
the filtered calibration reference and zero voltages.
Item Specification
Number of Channels 24 channels per termination board & I/O board
Thermocouple types E, J, K, T thermocouples, and mV inputs
Span -8 mV to +45 mV
Converter Resolution 16-bit A/D converter with better than 14 bit resolution
Cold junction compensation Reference junction temperature measured at two locations
on each TC termination board
Cold junction temperature error Cold junction accuracy 2 F
Conformity error Maximum software error 0.25 F
Measurement accuracy 53 microvolts (excluding cold junction reading)
Example: 3 F, type K, at 1000 F, including cold junction
contribution (RSS)
Common mode rejection AC common mode rejection 110 dB @ 50/60 Hz, for
balanced impedance input
Common mode voltage +/- 5 Volts
Normal mode rejection Rejection of 250 mV Rms is 80 dB @ 50/60 Hz
Scan time All inputs are sampled at 120 times per second for 60 Hz
operation; for 50 Hz operation it is 100 times per second .
Fault detection High/low (hardware) limit check
High/low system (software) limit check
Diagnostics
Each thermocouple type has Hardware Limit Checking based on preset (non-
configurable) high and low levels set near the ends of the operating range. If this
limit is exceeded a logic signal is set and the input is no longer scanned. If any one of
the 24 inputs hardware limits is set it creates a composite diagnostic alarm,
L3DIAG_VTCC, referring to the entire board. Details of the individual diagnostics
are available from the toolbox. The diagnostic signals can be individually latched,
and then reset with the RESET_DIA signal.
Each thermocouple input has System Limit Checking based on configurable high and
low levels. These limits can be used to generate alarms, and can be configured for
enable/disable, and as latching/nonlatching. RESET_SYS resets the out of limit
signals. In TMR, Systems Limit logic signals are voted and the resulting composite
diagnostic is present in each controller. VTCC diagnostics are described in Chapter
8, Troubleshooting & Diagnostics.
x
x 1 Input 1 (+)
Input 1 (-) x 2
x 3 Input 2 (+)
Input 2 (-) x 4
Input 3 (-)
x 5 Input 3 (+)
x 6
Input 4 (-)
x 7 Input 4 (+)
x 8
x 9 Input 5 (+)
Input 5 (-) x 10
x 11 Input 6 (+)
Input 6 (-) x 12
Input 7 (-)
x 13 Input 7 (+)
x 14
x 15 Input 8 (+) JA1
Input 8 (-) x 16
x 17 Input 9 (+)
Input 9 (-) x 18
x 19 Input 10(+)
Input 10(-) x 20
Input 11(-)
x 21 Input 11(+)
x 22
Input 12(-)
x 23 Input 12(+)
x 24
x
x
x 25 Input 13(+)
Input 13(-) x 26
28
x 27 Input 14(+)
Input 14(-) x
x 29 Input 15(+) JB1 Cable to I/O
Input 15(-) x 30
Input 16(-) x 32
x 31 Input 16(+) Rack J3
Input 17(-)
x 33 Input 17(+)
x 34
Input 18(-) x 36
x 35 Input 18(+)
Input 19(-)
x 37 Input 19(+)
x 38
Input 20(-) x 40
x 39 Input 20(+)
Input 21(-)
x 41 Input 21(+)
x 42
x 43 Input 22(+)
Input 22(-) x 44
Input 23(-) x 46
x 45 Input 23(+)
Input 24(-) x 48
x 47 Input 24(+)
x
x
x
x 2
x 1 TRTD capacity for RUN
x 4
x 3 FAIL
8 RTD x 5 16 RTD inputs STAT
x 6
Inputs x 8
x 7
x 10
x 9
x 12
x 11 VME Bus to VCMI
x 14
x 13 Communication Board
x 16
x 15
x 18
x 17
x 20
x 19 JA1 37-pin "D" shell
x 22
x 21
x 23 type connectors
x 24 with latching
x
fasteners
x
x 26
x 25
x 28
x 27
8 RTD x 30
x 29
Inputs x 32
x 31
x 33 JB1
x 34
x 36
x 35
x 38
x 37 Cables to
x 40
x 39 VME Rack
VRTD
x 42
x 41 x
x 44
x 43
x 46
x 45 Connectors on J3
x 48
x 47 VME Rack
x
x
Shield
Bar
J4
BarrierType Terminal
Blocks can be unplugged
from board for
maintenance
Figure 9-10. RTD Input Termination Board, I/O Board, & Cabling
J3 Excit.
JA1
Excitation
RTD Noise
Signal Suppression
Return
Grounded or (8) RTDs
ungrounded Connectors
at I/O Core
bottom of A/D Processor VMEbus
VME Bus
VME rack TMS320C32
JB1 J4 Excit.
Excitation
RTD Noise
Signal Suppression
VCO Type A/D
Return Converter
Grounded or (8) RTDs
ungrounded
Calibration
RTD inputs are automatically calibrated using the filtered calibration source and null
voltages.
Front panel
Three LEDs at the top of the VRTD front panel provide status information. The
normal RUN condition is a flashing green, FAIL is a solid red. The third LED is
normally off but shows a steady orange if a diagnostic alarm condition exists in the
board.
Each termination board has its own ID device which is interrogated by the I/O board.
The board ID is coded into a read-only chip containing the termination board serial
number, board type, revision number, and the JA1/JB1 connector location.
Item Specification
System Limits Enable or disable all system limit checking Enable, disable
Group A Rate Sampling rate and system frequency filter for 4 Hz, 50 Hz filter
first group of 8 inputs 4 Hz, 60 Hz filter
25 Hz
Group A Gain Gain 2.0 is for higher accuracy if ohms<190, Normal_1.0
first group of 8 inputs Gain_2.0
10 ohm Cu_10.0
Group B Rate Sampling rate and system frequency filter for 4 Hz, 50 Hz filter
second group of 8 inputs 4 Hz, 60 Hz filter
25 Hz
Group B Gain Gain 2.0 is for higher accuracy if ohms<190, Normal_1.0
second group of 8 inputs Gain_2.0
10 ohm Cu_10.0
J3J4:IS200TRTDG1A
SysLim1 Latch Determines whether the limit condition will latch Latch, unlatch
or unlatch for each RTD; reset used to unlatch.
SysLim1 Type Limit occurs when the temperature is greater Greater than or equal,
than or equal (>=), or less than or equal to Less than or equal
(<=) a preset value.
System Limit 1 Enter the desired value of the limit temperature, -60 to 1,300
Deg F or Ohms
SysLim2 Latch Determines whether the limit condition will latch Latch, unlatch
or unlatch; reset used to unlatch.
SysLim2 Type Limit occurs when the temperature is greater Greater than or equal,
than or equal (>=), or less than or equal to Less than or equal
(<=) a preset value.
System Limit 2 Enter the desired value of the limit temperature, -60 to 1,300
Deg F or Ohms
Input 1 (Sig)
x 1 Input 1 (Exc)
x 2
x 3 Input 1 (Ret)
Input 2 (Exc) x 4
x 5 Input 2 (Sig)
Input 2 (Ret) x 6
x 7 Input 3 (Exc)
Input 3 (Sig) x 8
Input 4 (Exc)
x 9 Input 3 (Ret)
x 10
x 11 Input 4 (Sig)
Input 4 (Ret) x 12
x 13 Input 5 (Exc)
Input 5 (Sig) x 14
Input 6 (Exc)
x 15 Input 5 (Ret) JA1
x 16
Input 6 (Ret)
x 17 Input 6 (Sig)
x 18
x 19 Input 7 (Exc)
Input 7 (Sig) x 20
x 21 Input 7 (Ret)
Input 8 (Exc) x 22
Input 8 (Ret)
x 23 Input 8 (Sig)
x 24
x
x
x 25 Input 9 (Exc)
Input 9 (Sig) x 26
x 27 Input 9 (Ret) Cable to I/O
Input 10 (Exc) x 28
Input 10 (Ret)
x 29 Input 10 (Sig) Rack, J3
x 30
Input 11 (Sig)
x 31 Input 11 (Exc)
x 32
x 33 Input 11 (Ret) JB1
Input 12 (Exc) x 34
x 35 Input 12 (Sig)
Input 12 (Ret) x 36
Input 13 (Sig)
x 37 Input 13 (Exc)
x 38
Input 14 (Exc)
x 39 Input 13 (Ret)
x 40
x 41 Input 14 (Sig)
Input 14 (Ret) x 42
x 43 Input 15 (Exc)
Input 15 (Sig) x 44
Input 16 (Exc)
x 45 Input 15 (Ret)
x 46
Input 16 (Ret)
x 47 Input 16 (Sig)
x 48
x
Cable to I/O
Terminal Blocks can be unplugged from Rack, J4
terminal board for maintenance
x
x x
x
x JT1 JT1
x 2
x 1 x 2
x 1 37-pin "D" shell RUN
x 3 4
x 3 type connectors FAIL
x 4 x
STAT
x 5 6
x 5
x 6 x
7
with latching
x 8
x 7 x 8
x
x 9 x 9 fasteners
x 10 x 10
x 11 12
x 11
x 12 x
x 13 14
x 13
x 14 x
x 15 16
x 15
x 16 x
x 17 18
x 17 VME Bus to VCMI
x 18 x
x 19 JS1 20
x 19 JS1
x 20 x Communication
x 21 22
x 21
x 22 x
Board
x 23 To 24
x 23
x 24 x
x Rack x
T
x x
x 25 26
x 25 Cable to VME
x 26 x
x 27 28
x 27
x 28 x
29
Rack T
x 29 30
x
x 30 To x
31
32
x 31 x 32
x
x
x 33 JR1 Rack x 33 JR1 Cable to VME
x 34 x 34
x 35 S 36
x 35 Rack S
x 36 x
x 37 38
x 37
x 38 x
x 39 40
x 39 VAIC
x 40 x
x 41 42
x 41 x
x 42 x
x 43 44
x 43
x 44 x
x 45 46
x 45 Connectors on
x 46 x J3
x 47 48
x 47 VME Rack
x 48 x
x x
x x
Shield
Bar
J4
BarrierType Terminal
Blocks can be unplugged Cables to VME
from board for maintenance Rack R
Figure 9-13. Analog Input Termination Boards, I/O Board, & Cabling (TMR System)
Controller
Application Software
8 Circuits per Term. Board
Noise
Suppr
.
P28V
+24Vdc Current Limit
PCOM
Connectors
at
2 Circuits per Term. Board bottom of
VME rack
Noise
Suppr. P28V
+24vdc Current Limit Excit.
1 ma J#A JR1 J3/4
+/-1 ma
20 ma
4-20 ma 250
ohm 5k ohms
Return
J#B
Open Return
Current
Regulator/
Two Output Circuits Power Supply
#2 Circuit is 4-20 ma 200 ma JO
only Noise
Signal Suppr. 20 ma
Maximum Load
4-20 ma, 500 ohms
0-200 ma, 50 ohms
Return
Controller
8 Circuits per Term. Board Application Software
Noise
P28V<T>
Suppr. P28VR P28V<S>
+24vdc Current Limit
Connectors
at
2 Circuits per Term. Board bottom of
Noise VME rack
Suppr P28VR
+24vdc . Current Limit
Excit.
1 ma J#A
+/-1 ma JR1 J3/4
20 ma Filter 2 Pole
4-20 ma
250
ohm 5k ohms
Return
J#B
Open Return
Current
S Regulator/
Two Output Circuits T Power Supply
JT1
To Rack<S>
To Rack<T>
Noise Filtering
Hardware filters on the termination board suppress high frequency noise. Additional
software filters on VAIC provide configurable low pass filtering. With the above
noise suppression and filtering, the AC common mode rejection (CMR) is 60 dB,
and DC CMR is 80 dB.
Front panel
Three LEDs at the top of the VAIC front panel provide status information. The
normal RUN condition is a flashing green, and FAIL is a solid red. The third LED is
normally off but displays a steady orange if a diagnostic alarm condition exists in the
board.
Each termination board has its own ID device, which is interrogated by the I/O
board. The board ID is coded into a read-only chip containing the termination board
serial number, board type, revision number, and the JR, JS, JT connector location.
Item Specification
Noise Suppression The first ten circuits (J3) have a hardware filter
with single pole down break at 500 radians/sec.
The second ten circuits (J4) have a two pole down
break at 72 and 500 radians/sec.
A software filter, using a two pole low pass filter, is
configurable for: 0, 1.5 Hz, 3 Hz, 6 Hz, 12 Hz
Common mode voltage range +/- 5 Volts (+/- 1 Volt for the +/- 10 Volt inputs)
Diagnostics
Each analog input has Hardware Limit Checking based on preset (non-configurable)
high and low levels set near the ends of the operating range. If this limit is exceeded
a logic signal is set and the input is no longer scanned. If any one of the 16 input’s
hardware limits is set, it creates a composite diagnostic alarm, L3DIAG_VAIC,
which refers to the entire board. Details of the individual diagnostics are available
from the toolbox. The diagnostic signals can be individually latched, and then reset
with the RESET_DIA signal.
Each input has System Limit Checking based on configurable high and low levels.
These limits can be used to generate alarms, and can be configured for
enable/disable, and as latching/nonlatching. RESET_SYS resets the out of limits.
Details of the diagnostics are in Chapter 8, Troubleshooting & Diagnostics.
To I/O
Rack R
x
x 26 x 25
28 x 27 Cables to VME
8 Analog x
x 29
x 30 Rack S
Outputs x 32 x 31
x 33 JR1 JR2
x 34
x 36 x 35
x 38 x 37
x 40 x 39 VAOC
x 42 x 41 x
x 44 x 43
46 x 45 Connectors on
x
x 47 J3
x 48 VME Rack R
x
x
Shield
Bar
J4
Figure 9-17. Analog Output Termination Board, I/O Board, and Cabling
<R> Module
Noise Filtering
Filters reduce high frequency noise and suppress surge on each output near the point
of signal exit.
Front panel
Three LEDs at the top of the VAOC front panel provide status information. The
normal RUN condition is a flashing green, and FAIL is a solid red. The third LED is
normally off but displays a steady orange if a diagnostic alarm condition exists in the
board.
Item Specification
Configuration Overview
Like all I/O boards, the VAOC board is configured using the Control System
Toolbox. This software usually runs on a data-highway connected CIMPLICITY
station or workstation. The table below summarizes the configuration choices. Refer
to GEH-6403 Control System Toolbox for Configuring the Mark VI Turbine
Controller.
Diagnostics
Standard diagnostic information is available on the inputs and outputs, including
high and low limit checks, and high and low system limit checks (configurable). If
any one of the 16 outputs goes unhealthy a composite diagnostic alarm,
L3DIAG_VAOC, occurs. Details of the individual diagnostics are available from the
toolbox. The diagnostic signals can be individually latched, and then reset with the
RESET_DIA signal if they go healthy. Refer to Chapter 8, Troubleshooting &
Diagnostics.
Output 1 (Ret)
x 1 Output 1 (Sig)
x 2
x 3 Output 2 (Sig)
Output 2 (Ret) x 4
x 5 Output 3 (Sig)
Output 3 (Ret) x 6
Output 4 (Ret)
x 7 Output 4 (Sig)
x 8
Output 5 (Ret)
x 9 Output 5 (Sig) To I/O
x 10
x 11 Output 6 (Sig) Rack T
Output 6 (Ret) x 12
x 13 Output 7 (Sig) J4
Output 7 (Ret) x 14
Output 8 (Ret)
x 15 Output 8 (Sig)
x 16
x 17 Output 9 (Sig) JS1 JS2
Output 9 (Ret) x 18 To I/O
x 19 Output 10(Sig)
Output 10(Ret) x 20 Rack T
x 21 Output 11(Sig)
Output 11(Ret) x 22 J3
Output 12(Ret)
x 23 Output 12(Sig)
x 24
x
x
Output 13 (Sig) To I/O
x 25
Output 13 (Ret) x 26 Rack S
x 27 Output 14 (Sig)
Output 14 (Ret) x 28 J4
Output 15 (Ret)
x 29 Output 15 (Sig)
x 30
Output 16 (Ret)
x 31 Output 16 (Sig)
x 32 JR1 JR2 To I/O
x 33
x 34 Rack S
x 35
x 36 J3
x 37
x 38
x 39
x 40
x 41
x 42
x 43
x 44
x 45
x 46 To I/O
x 47
x 48 Rack R
x J4
To I/O
Rack R
J3
I/O Terminal Block with Barrier Terminals
Terminal Blocks can be unplugged from
terminal board for maintenance
VME Rack
J1
VCCC
VCCC Daughter Board
Board
J2 J2
J4 J4
Termination Boards
TB3 JF1 JF2 TB3 JF1 JF2 JE1 JE2 JE1 JE2
Power Plugs Power Plugs Power Plugs Power Plugs
Figure 9-21. Boards & Cabling for Contact Inputs and Relay Outputs, SMX
x
x
x 37-pin "D" shell
x 1
JT1 type connectors
x 2 RUN
x 4
x 3 with latching FAIL
x 6
x 5 fasteners STAT
12 Contact x 7 JE1 JE2
x 8
Inputs x 10
x 9
x 12
x 11 VME Bus to VCMI
x 14
x 13
x 16
x 15
x 18
x 17
x 20
x 19 JS1
x 21 Cable to VME
x 22
x 24
x 23 Rack T
x
x
x 25 Cable to VME
x 26
x 28
x 27 Rack S
x 29
12 Contact x 30
x 32
x 31
Inputs x 33 JR1
x 34
x 36
x 35
x 38
x 37
x 40
x 39 Cable to VME VCCC
x 42
x 41 Rack R x
x 44
x 43
x 46
x 45
x 47 Connectors on J3 J3
x 48
x VME Rack R
x
Shield
Bar
J4 J4
Figure 9-22. Contact Input Termination Board, I/O Board, & Cabling
(+) Sup.
Gate
(-) Ref.
Gate
Field Contact Sup. JS1 J3
(+)
Gate
(-)
Optical Isolation
Field Contact Gate
(+) Sup.
JT1 J3
(-) J4
Field Contact From Second TBCI
(+) Sup.
(-)
Field Contact
(+) Sup.
(-) Each contact input
Field Contact terminates on one (1)
Sup. point and is fanned to
(+)
<R> <S> <T>
(-)
Field Contact 24 Contact Inputs per
Termination Board
Noise Filtering
Filters reduce high frequency noise and suppress surge on each input near the point
of signal exit. Noise and contact bounce is filtered with a 4 ms filter. AC voltage
rejection (50/60 Hz) is 60 V rms with 125 V dc excitation, and 12 V rms with 24 V
dc excitation.
Front panel
Three LEDs at the top of the VCCC front panel provide status information. The
normal RUN condition is a flashing green, FAIL is a solid red. The third LED is
normally off but shows a steady orange if a diagnostic alarm condition exists in the
board.
Each cable on the termination board has its own ID device which is interrogated by
the I/O board. The ID device is a read-only chip coded with the termination board
serial number, board type, revision number, and the JR, JS, JT connector location.
Diagnostics
The dry (isolated) external contacts are monitored, and also the excitation voltage. If
the excitation drops to below 40% of the nominal voltage, a diagnostic alarm is set
and latched. All inputs associated with this TB are forced to the open contact (fail
safe) state. Any input that fails the diagnostic test is forced to the failsafe state.
If any one of the 48 inputs goes unhealthy a composite diagnostic alarm,
L3DIAG_VCCC occurs. Details of the individual diagnostics are available from the
toolbox. The diagnostic signals can be individually latched, and then reset with the
RESET_DIA signal if they go healthy. Refer to Chapter 8, Troubleshooting &
Diagnostics
Item Specification
x
3 3
Input 1 (Ret)
x 1 Input 1 (Pos) JE1 JE2
x 2
x 3 Input 2 (Pos)
Input 2 (Ret) x 4 Contact Excitation
x 5 Input 3 (Pos)
Input 3 (Ret) x 6 Source, 125 Vdc
x 7 Input 4 (Pos)
Input 4 (Ret) x 8
Input 5 (Ret)
x 9 Input 5 (Pos)
x 10
x 11 Input 6 (Pos)
Input 6 (Ret) x 12
x 13 Input 7 (Pos) To Rack T
Input 7 (Ret) x 14
Input 8 (Ret)
x 15 Input 8 (Pos)
x 16
Input 9 (Ret)
x 17 Input 9 (Pos)
x 18 JS1
x 19 Input 10 (Pos)
Input 10 (Ret) x 20
x 21 Input 11 (Pos)
Input 11 (Ret) x 22
Input 12 (Ret) x 23 Input 12 (Pos)
x 24
x
x
x 25 Input 13 (Pos)
Input 13 (Ret) x 26
x 27 Input 14 (Pos)
Input 14 (Ret) x 28
Input 15 (Ret)
x 29 Input 15 (Pos) To Rack S
x 30
Input 16 (Ret)
x 31 Input 16 (Pos)
x 32 JR1
x 33 Input 17 (Pos)
Input 17 (Ret) x 34
x 35 Input 18 (Pos)
Input 18 (Ret) x 36
x 37 Input 19 (Pos)
Input 19 (Ret) x 38
Input 20 (Ret)
x 39 Input 20 (Pos)
x 40
x 41 Input 21 (Pos)
Input 21 (Ret) x 42
x 43 Input 22 (Pos)
Input 22 (Ret) x 44 Inputs 22, 23,
Input 23 (Ret)
x 45 Input 23 (Pos)
x 46 24 are 10 ma
Input 24 (Ret)
x 47 Input 24 (Pos)
x 48
x
To Rack R
Features
The TICI is similar to the TBCI, except for the following items:
• TICI input voltage ranges are:
- 16-32 V dc, nominal 24 V dc
- 70-145 V dc, nominal 125 V dc
- 200-250 V dc, nominal 250 V dc
- 90-132 V rms, nominal 15 V rms, 47-63 Hz
- 190-264 V rms, nominal 230 V rms, 47-63 Hz
• Input hardware filtering is provided using time delays of 10 msec, nominal. In
addition, the contact input state is software filtered using configurable time
delays.
Refer to the section Contact Inputs TBCI for information on the VCCC board.
VME Rack
J1
VCCC
VCCC Daughter Board
Board
J2 J2
J4 J4
Termination Boards
TB3 JF1 JF2 TB3 JF1 JF2 JE1 JE2 JE1 JE2
Power Plugs Power Plugs Power Plugs Power Plugs
Figure 9-26. Cabling for Contact Inputs and Relay Outputs, SMX
Solenoid
Shield Power
Bar Cables to Relay J4 J4
Output Terminal
Boards
Barrier Type Terminal
Blocks can be unplugged
from board for maintenance To Second
TRLY
Figure 9-27. Relay Output Termination Board, I/O Board, & Cabling
Coil
K1
RD
Monitor
"12" of the above
circuits
Connectors Monitor
at bottom
of VME
Rack P125/24 Vdc FUX JPX K# K#
NO
TB3 Com
1 24 V dc or +
125 V dc or Field
Power 2 K#
115 V ac NC Solenoid -
Source 3 240 V ac
(20 Amp) 4
N125/24 Vdc FUY Sol
JF1 "6" of the above circuits
1 3.2 Amp
K# K# NO
Alternate slow-blow
3
Power
Source JF2 Com Special
1
(7Amp) Circuit
3 K#
NC
Available for
JG1
GT Ignition 1
Transformers Sol
3
(6 Amp at 120 Vac
"1" of the above circuit
3 Amp at 240 Vac)
<T>
<S> Relay Termination Board - TRLY
<R>
K# K# NO
VCCC
Relay
Output Com Dry
Contact,
JA1 Form-C
K# NC
Shown for JR1
J3/4 P28V
<R> "5" of these circuits
JA1
Coil K1
J3/4 JS1 RD
Same for
<S>
Monitor
J3/4 JT1 "12" of the above circuits
Same for Monitor
<T>
FUX JPX K# K#
P125/24 V dc NO
TB3 Com
24 V dc or +
1
125 V dc or
Power 2 Field
115 V ac K#
NC Solenoid -
Source 3 240 V ac
(20 Amp) 4 FUY
N125/24 Vdc Sol
JF1 1 3.2 Amp "6" of the above circuits
K# K#
slow-blow NO
Alternate 3
Power
Source JF2 Com Special
1
(7Amp) Circuit
3 K#
NC
Available for
JG1
GT Ignition 1
Transformers 3 Sol
(6 Amp at 120 Vac "1" of these circuits
3 Amp at 240 Vac)
Relay Characteristics
Relays have a 3.0 Amp rating. The rated contact to contact voltage is 500 V ac for
one minute, and the rated coil to contact voltage is 1,500 V ac for one minute. The
typical time to operate is 10 ms.
Failsafe Outputs
The relay outputs have failsafe features so that when a cable is unplugged, the inputs
vote to de-energize the corresponding relays. Similarly, if communication with the
associated VME board is lost, the relays de-energize.
Front panel
Three LEDs at the top of the VCCC front panel provide status information. The
normal RUN condition is a flashing green, FAIL is a solid red. The third LED is
normally off but shows a steady orange if a diagnostic alarm condition exists in the
board.
Each cable on the termination board has its own ID device which is interrogated by
the I/O board. The ID device is a read-only chip coded with the termination board
serial number, board type, revision number, and the JA, JR, JS, JT plug location.
Diagnostics
The output of each relay (coil current) is monitored and checked against the
command, at the frame rate. If there is no agreement for two consecutive checks, an
alarm is latched. The solenoid excitation voltage is monitored downstream of the
fuses and an alarm is latched if it falls below 12 Volts (AC or DC).
Item Specification
Number of Relay Channels on 12 relays: 6 relays with optional solenoid driver voltages
one TRLY board 5 relays with dry contacts only
1 relay with 7 Amp rating
VCCC total is 24 relays on two TRLY boards
Rated Voltage on Relays a: Nominal 125 V dc or 24 V dc
b: Nominal 120 V ac or 240 V ac
P1
VCRC
Single Width
Front Panel
P2
J33 37
J44 37
VME
J3 backplane
wiring
J4
Termination
Boards
Figure 9-31. VCRC with Boards and Cabling to Contact Inputs & Relay Outputs
x
x
x
x 1 JT1
x 2 RUN
x 3 FAIL
x 4 STAT
x 6
x 5
12 Contact x 7 JE1 JE2
x 8
Inputs x 10
x 9 VME Bus to VCMI
x 12
x 11
x 14
x 13
x 16
x 15
x 18
x 17
x 20
x 19 JS1 Cable to VME J33
x 22
x 21
x 23 Rack T
x 24
x
x
x 25 Cable to VME
x 26 J44
x 28
x 27 Rack S
x 29
12Contact x 30
x 32
x 31
Inputs x 33 JR1
x 34
x 36
x 35 VCRC
x 38
x 37 x
x 40
x 39
x 41 Cable to VME
x 42 J3
x 44
x 43 Rack R
x 46
x 45
x 48
x 47
Connectors
x
x on VME
Rack R
J4
Shield Bar
BarrierType Terminal
Blocks can be unplugged
Cable from Second TBCI
from board for maintenance
x
x 26 x 25 JS5
x 28 x 27 Cables to VME
x 30 x 29 Rack S
x 32 x 31
x 34 x 33 JR1
x 36 x 35
x 38 x 37 JR5
x 40 x 39 VSVO
x 42 x 41 x
x 44 x 43
x 46 x 45
x 47 J3
x 48
x
x
Shield Connectors on
Bar VME Rack R J4
LVDT 1 JR1 J3
A/D Regulator
3.2k Hz, 7 V rms
Excitation Source 6 Ckts.
Connector at
2 bottom of D/A
VME rack
or LVDR Servo Driver P28V J3
Voltage
Limit
Suicide
Current P28V Relay
P24V 41 Limit
Configurable
Gain To Servo
42
Pulse Rate Outputs
JR5 J5 3.2KHz
Inputs 43
Pulse Excitation To TSVO
Active Probes PR Rate
44
0 - 12 k Hz To
P24V 45 CL Connector
Second
Only available on on front of
TSVO
1 of 2 TSVOs 46 VSVO board
47
Pulse Rate
Inputs PR 48
Active Probes Noise Suppr.
0 - 12 k Hz
<R>
Controller
Application Software
17 3.2KHz,
J5 3.2KHz JR5 7V rms
S
Pulse Excitation 2 Ckts. U Excitation
Rate P 18
Source
To for
Connector on
Second LVDTs
front of VSVO TSVO
<R>
<S>
<T>
Controller
Application Software
LVDT 1 JR1 J3
3.2k Hz, A/D Regulator
7 V rms
6 Ckts.
Excitation
2 JS1 J3
Source P28V D/A
Same for <S>
Servo Driver To Servo
Voltage
JT1 J3 Limit Outputs
P28V on TSVO
Same for <T>
Diode Select
P24V 41 CL Connector on Configurable
front of VSVO Gain
42 card in <R>
Pulse Rate JR5 J5 To TSVO
Inputs 43 3.2KHz
Pulse Excitation
Active Probes PR 44 Rate
0 - 12 k Hz
P24V 45 CL JS5 J5 in <S>
Only available
on 1 of 2 46
TSVOs JT5
47 J5 in <T>
Pulse Rate PR 48
Inputs
Active Probes
0 - 12 k Hz
Noise Suppr.
<R>
<S>
<T>
Controller
Application Software
Termination Board
Servo Board TSVO
VSVO Servo Current Range
10,20,40,80,120 ma
JD1
A/D Regulator P28VR Trip input from
1
JS1 2 <P> Not Used for
From Suicide JT1 TMR
TSVO JD2
D/A Relay JP1
LVDT 120B
1
J5 17 3.2KHz,
3.2KHz JR5
Pulse
S 7V rms
Excitation 2 Ckts. U
Excitation
Rate P 18
Source
Connector on J3 JS1 JP2 For LVDTs
front of VSVO 120B
120 Servo coil driven
card 80
40
27 from <S>
20
10 S
U
P
2 Ckts. 28
21 3.2KHz,
S 7V rms
1 Ckt. U
Excitation
P 22
Source
J3 JT1 JP3 For LVDTs
120B
120 Servo coil driven
80
40
29 from <T>
20
10 S
U
P
2 Ckts. 30
23
3.2KHz,
S
1 Ckt. U 7V rms
P 24 Excitation
Source
For LVDTs
.
Regn_suicide L Suicide
o LVDT
g
ServoOutputn i Fan
Signal c Connection
Space
SuicideForce
6 ccts per
TB
JR5
JS5
JT5
I/O PRType
Config LVDT
PRScale
Fan
Signal FlowRate1 flow hz PR/D Connection
Space
6 ccts per
I/O PRType TB
Config JR5
PRScale
JS5
P5 JT5
Signal FlowRate2 flow hz PR/D Pulse Rate
Space Pickup
Fan
Connection
PRType JR5
I/O JS5
Config PRScale
P5 JT5 Pulse
Rate
Signal FlowRate1 flow hz PR/D PR condit’n cct Pickup
Space
Fan
Connection
PRType
I/O
Config PRScale
2 ccts
Signal FlowRate2 flow hz PR/D
per TB
Space second PR cct
Notes:
1: where "n" in signal space has values 1 to 4 (i.e. four regulators)
Figure 9-39. Servo Regulator with LVDT Feedback
VSVO
Insert Regulator (IO Config) Software Hareware
RegNumber Reg3 (exam) 200 hz, 4 Regulators per card TSVO #1
EnableCurSuic
Suicide
I/O EnableFdbkSuic Function
Config RegType 2_PulseRateMax(exam)
SuicideForce
DitherAmpl Servo
RegNullBias RD JR1 coil;
Suicide
RegGain Current JS1 positive
Regn_GainMod not used Gain Driver P2 J3 JT1 current to
D shutdown
++
Regn_Ref I D/A Ref1 +
+- X + D/A
+ T Dedicated
Regn_Error H total connection
Regn_NullCor of 4 R
ccts 2 ccts per S
CalibEnabn T
Calib TB per
function Servo_MA_Out
Controller
Regn_suicide L Suicide
o LVDT
g
ServoOutputn i Fan
Signal c Connection
Space
SuicideForce
6 ccts per
TB
JR5
JS5
JT5
PRType
LVDT
PRScale
Fan
Signal FlowRate1 flow hz PR/D PR1 Connection
Space
6 ccts per
I/O PRType TB
Config JR5
PRScale
JS5
P5 JT5
Signal FlowRate2 flow hz PR/D PR2 Pulse Rate
Space Pickup
Fan
Connection
6 ccts per
JR5 TB
JS5
JT5
PRType
LVDT
PRScale
Fan
FlowRate1 flow hz PR/D Connection
6 ccts per
PRType TB
JR5
PRScale JS5
P5 JT5
FlowRate2 flow hz PR/D Pulse Rate
Pickup
Fan
Connection
Notes:
1: where "n" in signal space has values 1 to 16 (i.e. up to 16 monitors)
View Position
Gain & Offset
Force Actuator to Constants for
Minimum End Position each LVDT
(positive current,
shutdown) Calibrate; the
System Learns
the Voltage
Force Actuator to Ranges for
Maximum End future use
Position (negative
current, maximum Save the
capacity) Measured Values
to Controller
Fix; take the Flash Memory
Measured Values
Verify
Performance by
Actual Values for all
Stroking the
Regulators
Actuator under
Manual Control,
Position
Regulator 1 Reference (Setpt.)
Ramping,
Regulator 1 Feedback (LVDT)
or Step Current
Servo 1 Output Current (ma)
Regulator 1 Null Error
Regulator 1 Null Correction Manual Entry of
Actuator Position
Calibrate Sequence. The Min End Position command is sent to the VSVO board,
which checks the permissive logic, then manipulates the valve current reference to
the servo valve. The servo valve drives the actuator to its end stop where the LVDT
voltage is read. Clicking the Max End Position button causes the actuator to be
driven to the other end stop where the LVDT voltage is read again. The difference
represents a known stroke. These voltage fixes are used in conjunction with the I/O
configuration definition of the end stops to map the LVDT voltages into the actuator
stroke, in engineering units. The normal voltage range is learned during the
calibration, a margin is added, and the result is used for suicide and diagnostic limits.
Front panel
Three LEDs at the top of the VSVO front panel provide status information. The
normal RUN condition is a flashing green, and FAIL is a solid red. The third LED is
normally off but displays a steady orange if an alarm condition exists in the board.
Connectors JR1, JS1, JT1 on the termination board have their own ID device which
is interrogated by the I/O board. The ID device is a read-only chip coded with the
terminal board serial number, board type, revision number, and the plug location.
Item Specification
JP2 Servo 01 S
x
x
x 37-pin "D" shell
x
x 1 JT1 type connectors
x 2 RUN
x 4 x 3 with latching FAIL
x 6 x 5 fasteners STAT
x 8 x 7
x 10 x 9
x 12 x 11
x 14 x 13
x 16 x 15
x 18 x 17 Cables to VME
x 20 x 19 JT5 JS1 Rack T
x 22 x 21
24 x 23
x VME Bus to VCMI
x
x
x 25 JS5
x 26
x 28 x 27 Cables to VME
x 30 x 29 Rack S J
x 32 x 31 5
x 34 x 33 JR1
x 36 x 35
x 38 x 37 JR5
x 40 x 39 VTUR
x 42 x 41 x
x 44 x 43
x 46 x 45
x 47 J3
x 48
x
x
Shield Connectors on
Bar VME Rack R J4
BarrierType Terminal
Blocks can be unplugged Cables to VME
from board for maintenance Rack R
Cable to TRPG
Figure 9-44. Turbine Control Termination Board, Processor Board, and Cabling
MAN
AUTO
BKRH
Shaft
J4
23
Noise
14V P125Gen
Suppr To
24 Connectors
TRPG 52G
at bottom of
b
Machine Case JR5 VME rack
41 Bkr Coil
#1 Primary Filter
Magnetic Suppr. Clamp
42 AC
N125Gen
Speed PU Coupling
43
#2 Primary Filter
Magnetic Suppr. Clamp
44 AC
Speed PU Coupling Note: Signal to K25A
comes from TREG
#3 Primary 45 Filter through TRPG & VTUR
Clamp
Magnetic 46
Suppr.
AC
Speed PU Coupling
#4 Primary 47 Filter
Clamp
Magnetic Suppr.
AC
48
Speed PU Coupling
Figure 9-45. Turbine Control Inputs, Synchronizing, and Primary Trip Interface, SMX
52G
Generator Breaker a
<T>
<S> Feedback
<R> Termination Board
02 01
Termination Board TTUR Turbine TTUR (continued)
Board
JR1 J3 VTUR
17 28Vdc
J3 JR1 JP1
Gen. Volts Noise f()
TMR
120 vac Suppr
SMX K25P Synch. perm.
18 Pr/D 2 Equival. 52Z
from PT MUX RD
J3 JS1 3
A/D TMR JP2
SMX K25 Close gener.
AC&DC 2
19 breaker
Line JS1 shaft RD
J3 JT1 3
Volts Noise test
120 vac 20 Suppr K25A Synch. check
from PT Equival. GXS
J5
To
TPRO
21 Mon
Noise JT1
175V 22 Suppr
08 06,7 05 04 03
J4
BKRH
MAN
AUTO
Shaft
23
To 52G
Noise Connectors
14V TRPG b P125Gen
Suppr at bottom of
24
VME rack Bkr Coil
Machine Case JR5 N125Gen
41
#1 Primary Filter
Clamp
Magnetic Suppr.
AC
42 Coupling
Speed PU
4 Circuits
JS5 Note: Signal to K25A
33
#2 Primary Filter
comes fromTREG
Magnetic Clamp via TRPG and VTUR
Suppr.
AC To Rack S
Speed PU 34 Coupling
4 Circuits
JT5
25
#3 Primary Filter
Clamp
Magnetic Suppr.
AC
To Rack T
26
Speed PU Coupling
4 Circuits
Figure 9-46. Turbine Control Inputs, Synchronizing, and Primary Trip Interface, TMR
Item Specification
Shaft Voltage Monitor Monitors frequencies between 5 and 3,200 Hz, and generates a
DC signal with less than 1% ripple at 60 Hz.
Voltage signal is +/- 5 V dc pulses from 0 to 2,000 Hz
Shaft Voltage wiring Up to 300 m (984 ft), with maximum two-way cable resistance of
15 ohms
Shaft Voltage DC Test Applies a 6 V (max) source producing 300 mA (max); circuit reads
a differential resistance between 0 and 150 ohms within ± 5 ohms.
Readings above 50 ohms indicate a fault. Returned signal has 40
dB of noise attenuation at 60 Hz.
Shaft Voltage AC Test Applies a test voltage of 1 kHz to the input of the VTUR shaft
voltage circuit (R module only).
Generator and Bus Voltage Two Single Phase Potential Transformers, with fused (10 A max.)
Sensors secondary output supplying a nominal 115 V rms.
Each PT is magnetically isolated with a 1,500 V rms barrier
Cable length can be up to 1,000 ft. of 18 AWG wiring
Diagnostics
Diagnostic information includes feedback from the solenoid relay driver and contact,
high flame detector voltage, slow synch check relay, slow auto synch relay, and
locked up K25 relay.
Automatic Synchronizing
All synchronizing connections are located on the TTUR termination board. The
generator and bus voltages are supplied by two, single phase, potential transformers
(PTs) with a fused secondary output supplying a nominal 115 V rms. Measurement
accuracy between the zero crossing for the bus and generator voltage circuits is 1
degree.
Turbine speed is matched against the bus frequency, and the generator and bus
voltages are matched by adjusting the generator field excitation voltage from
commands sent between the turbine controller and the EX2000 over the Unit Data
Highway (UDH). A command is given to close the breaker when all permissives are
satisfied, and the breaker is predicted to close within the calculated phase/slip
window. An external synch check relay is connected in series with the internal K25P
synch permissive relay and the K25 auto synch relay through TB points 05 and 06 on
the TTUR termination board. Feedback of the actual breaker closing time is provided
by a 52G/a contact from the generator breaker (not an auxiliary relay) to update the
data base. An internal K25A synch check relay is provided on the TTUR; however,
the backup phase/slip calculation for this relay is performed in the <P> Protection
Module. Diagnostics monitor the current flowing through each relay coil to
determine if the relay properly energizes or de-energizes upon command.
Synchronizing Modes
There are three basic synchronizing modes. Traditionally, these modes are selected
from a generator panel mounted selector switch:
• Off The breaker will not be closed by the Mark VI control. The check relay will
not pickup.
• Manual The operator initiates breaker close, which is still subject to the K25A
Synch Check contacts driven by VPRO. The manual close is initiated from an
external contact on the generator panel, normally connected in series with a
Synch Mode in Manual contact.
Synch Check
The K25A synch check function is based on phase lock loop techniques. It performs
limit checks against adjustable constants as follows:
• Generator undervoltage
• Bus undervoltage
• Voltage error
• Frequency error (slip), with a maximum value of 0.33 Hz, typically set to
0.27 Hz.
• Phase error with a maximum value of 30 degrees, typically set to 10 degrees.
In addition, synch check arms logic to enable the function, and provides bypass logic
for deadbus closure. The synch window in Figure 9-47 is based on typical settings:
SLIP
+0.27 Hz
PHASE
-10 +10 Degrees
-0.27 Hz
Auto Synch
The Auto Synch K25 function uses zero voltage crossing techniques. It compensates
for the breaker time delay which is defined by two adjustable constants with logic
selection between the two ( for two breaker applications). The calculations include
phase, slip, acceleration, and anticipated time lead for the breaker delay. Based on
the measured breaker close time, the time delay parameter is adjusted, up to certain
limits.
In addition, auto synch arms logic to enable the function, and bypasses logic to
provide for deadbus or manual closure. The auto synch projected synch window is
shown in Figure 9-48.
The projected window is based on current phase, current slip, and current
acceleration. The generator must currently be lagging and have been lagging for the
last 10 consecutive cycles. Auto synch will not allow the breaker to close with
negative slip; speed matching typically aims at around +0.12 Hz slip.
Synchronization Display
A special synchronization screen is available on the HMI with a graphical phase
display and control pushbuttons. The display provides the real time items listed in
Table 9-26.
x
TMR SMX TMR SMX
x 1 52G (H)
52G (L) x 2
x 3 P125GEN
AUTO x 4 K3
BKRH x 6
x 5 MAN
N125GEN x 8
x 7 BKRH
x 9
x 10
x 11
x 12 K2
x 13
x 14
x 15
x 16
x 17 Gen (H)
Gen (L) x 18
Bus (L) x 19 Bus (H)
x 20
x 21 ShaftV (H)
ShaftV (L) x 22
x 23 ShaftC (H)
ShaftC (L) x 24
x
To Connectors
x
JR5, JS5, JT5,
x 25 MPU 1T (H)
MPU 1T (L) x 26 JR1, JS1, JT1
MPU 2T (L) x 28
x 27 MPU 2T (H)
MPU 3T (L) x 30
x 29 MPU 3T (H)
MPU 4T (L) x 32
x 31 MPU 4T (H)
x 33 MPU 1S (H)
MPU 1S (L) x 34
MPU 2S (L) x 36
x 35 MPU 2S (H)
MPU 3S (L) x 38
x 37 MPU 3S (H)
x 39 MPU 4S (H)
MPU 4S (L) x 40
x 41 MPU 1R (H) Terminal Blocks can be unplugged
MPU 1R (L) x 42
MPU 2R (L) x 44
x 43 MPU 2R (H) from terminal board for maintenance
MPU 3R (L) x 46
x 45 MPU 3R (H)
x 47 MPU 4R (H) Up to two #12 AWG wires per
MPU 4R (L) x 48
x point with 300 volt insulation
x
x 26 x 25
x 28 x 27 Cables to VME
x 30 x 29 Rack S J
x 32 x 31 5
x 34 x 33 JR1
x 36 x 35
x 38 x 37
x 40 x 39 VTUR
x 42 x 41 J2 x
x 44 x 43
x 45 J4
x 46 J5 J3
x 48
x 47
J3
x
x Cable to TTUR
Connectors on
Shield Bar VME Card Rack R
J4
335 V from
Rack Power Cable to Cable to TTUR
Supplies TREG
R, S, T
8 Signals to 3 Monitor
JR1,JS1,JT1 Signals to J3
Voltage Sply
JR1,JS1,JT1 and Monitor 335 Vdc from R
33 J4
NS Voltage Sply
34 and Monitor 335 Vdc from S
NS
Voltage Sply J5
Supply 8 and Monitor 335 Vdc from T
Eight Flame
Detectors
Detector Circuits
Flame Detectors
Up to eight flame detectors can be used for gas turbine applications. The detectors
are supplied with 335 V dc, 0.5 mA through plugs J3, J4, and J5.
With no flame present the detector charges up to the supply voltage, but presence of
the flame causes the detector to charge to a level and then discharge through the
TRPG board. As the flame intensity increases the discharge frequency increases.
When the detector discharges, VTUR and TRPG convert the discharged energy into
a voltage pulse. The pulse rate varies from 0 to 1,000 pulses/sec. These voltage
pulses are fanned out to all three modules. Voltage pulses above 2.5 volts generate a
logic high, and the pulse rate over a 40 ms time period is measured in a counter.
Item Specification
Diagnostics
Descriptions of the TRPG diagnostics are listed under VTUR. The diagnostics
include feedback from the trip solenoid relay driver and contact, solenoid power loss,
and the flame detector excitation voltage too low or too high.
The VTUR diagnostics are in Chapter 8, Troubleshooting & Diagnostics.
2
x 1 125 Vdc (P)
Trip Solenoid 1 or 4 x
4
x 3 125 Vdc (P)
Trip Solenoid 2 or 5 x
6
x 5 125 Vdc (P)
Trip Solenoid 3 or 6 x
x 7
x 8
x 9 125 Vdc (N)
125 Vdc (N) x 10
x 11
x 12 To Connectors
x 13
x 14 JR1, JS1, JT1
x 15
x 16
x 17
x 18
x 19
x 20
x 21
x 22
x 23
x 24
x
To Connectors
x JR1, JS1, JT1
x 25
x 26
x 27
x 28
x 30
x 29 J2
x 31
x 32
Flame 1 (L) x 33 Flame 1 (H) Cable to TREG
x 34
x 35 Flame 2 (H)
Flame 2 (L) x 36
x 37 Flame 3 (H)
Flame 3 (L) x 38
x 39 Flame 4 (H) 335 Vdc
Flame 4 (L) x 40 J4
Flame 5 (L) x 42
x 41 Flame 5 (H)
x 43 Flame 6 (H) 335 Vdc
Flame 6 (L) x 44 J5
x 45 Flame 7 (H) 335 Vdc
Flame 7 (L) x 46
x 47 Flame 8 (H) J3
Flame 8 (L) x 48
x
To Second TREG
(optional)
Shield 37-pin "D" shell
Bar type connectors
with latching
BarrierType Terminal fasteners
Blocks can be
unplugged
from board for
maintenance
Figure 9-53. Trip Emergency Termination Board, VPRO Board, and Cabling
Trip
Termination Termination Board TREG <P>
Solenoid JX1
Board TRPG VPRO
1 or 4 KE1 KX1 KY1 KX1 RD
02 - + 01 Section X
J3
KY1 KZ1 KX2 RD
J2 J2
Mon KX3 RD
04
KZ1 KX1
Optional P28X1 Mon
Economizing 03
Resistor, Trip K4X KX1,2,3
28vdc
100 ohm, Solenoid
70W 04 2 or 5 05
KE2 KX2 KY2 JY1 <P>
- +
VPRO
KY1 RD
KY2 KZ2 Section Y
J2 J2 J3
KY2 RD
Mon
08
KZ2 KX2
KY3 RD
07
Trip P28Y1 Mon
Solenoid K4Y KY1,2,3
28vdc
3 or 6 KE3 KX3 KY3
06 - + 09
JZ1 <P>
KY3 KZ3 KZ1 VPRO
J2 J2 RD
Section Z
Mon J3
KZ3 KX3 KZ2 RD
12
11 KZ3 RD
02
P28Z1 Mon
06
Sol Pwr Monitor K4Z KZ1,2,3
10 JX1 28vdc
Mon JY1
J2 J2 JZ1 KE1,2,3 JX1
- N125V
+ P125V
P28VV RD 2 JY1
3 JZ1
Three Economizing Relay Circuits
To TSVO K4CL JX1 Trip Interlock
P28VV RD 2 JY1 To P125X
Boards on J1 3 35 seven circuits
SMX Systems JZ1 JX1 NS
K4CL K4CL 36
JY1 NS
JZ1
Servo Clamp Mon 13,14
P28VV CL
To Relay
15 E-Stop
K25A on J2 J2 K4X
JX1
TTUR 16
RD 2 JY1 K4Y
3 JZ1
Mon K4Z 17
JH1
P125X
JX1 P28X1 18
N125X
JY1 Mon P28Y1
JZ1 P28Z1
Item Specification
Number of Trip Solenoids (TREG) 3 Solenoids per TREG (total of 6 per VPRO)
Trip Solenoid Rated 125 V dc standard with 1 Amp draw
Voltage/Current 24 V dc is alternate with 3 Amp draw
Trip Solenoid Circuits Circuits rated for NEMA class E creepage and clearance.
Circuits can clear a 20 A fuse with all circuits fully loaded.
Solenoid Response Time Solenoid L/R time constant is 0.1 sec.
Relay outputs 3 Economizer relay outputs, 2 second delay to energize
Breaker relay K25A on TTUR
Solenoid Control Relay Contacts Contacts are rated to interrupt inductive solenoid loads at
125 V dc, 1 A
Bus voltage can vary from 70 to 145 V dc
Trip Inputs 7 trip interlocks to VPRO protection module
1 Emergency Stop hardwired trip interlock
Diagnostics
Descriptions of the TREG diagnostics are contained in the VPRO section. The
diagnostics cover the trip relay driver and contact feedbacks, solenoid voltage,
economizer relay driver and contact feedbacks, K25A relay driver and coil, servo
clamp relay driver and contact feedback, and the solenoid voltage source.
A list of the VPRO diagnostics is in Chapter 8, Troubleshooting & Diagnostics.
x
JZ1
2
x 1 SOL 1 or 4
PWR_N1 x
x 3 RES 1A
RES 1B x 4
6
x 5 SOL 2 or 5
PWR_N2 x
RES 2B x 8
x 7 RES 2A
x 9 SOL 3 or 6
PWR_N3 x 10
12
x 11 RES 3A
RES 3B x
14
x 13 E-TRP 1 (H)
E-TRP 2 (H) x
x 15 TRP 3
TRP 4 x 16
E-TRP 6 (L) x 18
x 17 E-TRP 5 (L)
x 20
x 19 JY1
x 21
x 22
x 23
x 24
x
x
x 25
x 26
x 27
x 28
PWR_P2 (for probe) x 29
x 30 JX1
x 31 PWR_P1 (for probe)
x 32
x 33
x 34
x 35 TRP 1 (H)
TRP 1 (L) x 36
x 37 TRP 2 (H)
TRP 2 (L) x 38
x 39 TRP 3 (H)
TRP 3 (L) x 40
x 41 TRP 4 (H)
TRP 4 (L) x 42
x 43 TRP 5 (H)
TRP 5 (L) x 44
TRP 6 (L) x 46
x 45 TRP 6 (H)
x 47 TRP 7 (H)
TRP 7 (L) x 48
x
Figure 9-56. Turbine Protection Termination Board, VPRO Board, and Cabling
Figure 9-57 shows how the VTUR and VPRO processor boards share in the turbine
protection scheme. Either one can independently trip the turbine via the relays on
TRPG or TREG. Figure 9-58 provides details of the TPRO termination board.
J3 J4 J5
JR1
TRPG
JS1
J3
JT1
To second
TRPG board 9 Relays
J4 J4 (optional) (3 x 3 PTR’s)
J1
J2
125 VDC
J2 J1
TREG Trip signal to
JX1
TSVO TB’s
JY1
VPRO
JZ1
J3
To second 12 Relays
J4 TREG Board
(9 ETR’s,
(optional)
J5 3 Econ Relays)
JH1
J6
P125 V dc from <PDM>
NEMA class F
JX1 Two
xfrs
JY1
Line J6 J6 J6
3
Volts JY1
Noise
120 Vac 4 Suppr
from PT
To TREG
TCX1H NS Overspeed Overspeed Overspeed
Three TC ccts to X Em Stop Em Stop Em Stop
TCX1L NS Sync Check Sync Check Sync Check
JZ1 Overtemp Overtemp Overtemp
TCY1H NS
Three TC ccts to Y
TCY1L NS
TCZ1H NS
Three TC ccts to Z J5 J5 J5
TCZ1L NS
P28VV
P28V,X
P24Vx Current P28V,Y J3 J3 J3
Limiter P28V,Z
VDC VDC
JPA1
20mAx 20 ma
To X,Y, Z J4 J4 J4
250 ohms
mAret
One of the above ccts
Open Ret
JPB1
Current P28VV
P28Vx To TREG and
Limiter
Trip Solenoids
20 mAx
250
To X, Y, Z
ohms
Two of the above ccts
#1 JX5
Emergency 31
Magnetic Filter
Clamp
Speed Suppr.
AC
32
PU Coupling
3 Circuits
#2 JY5
Emergency 37
Filter
Magnetic Clamp
Suppr. AC
Speed 38 Coupling
PU
3 Circuits
#3 JZ5
Emergency 43
Filter
Magnetic Clamp
Speed Suppr.
AC
44 Coupling
PU
3 Circuits
VPRO Features
Speed Control and Overspeed Protection
Speed control and overspeed protection is implemented with six passive, magnetic
speed pickups. The first three are monitored by the control module(s) which use the
median signal for speed control and the primary overspeed protection. The second
three are separately connected to the X, Y, and Z sections of the Protection Module.
Provision is made for nine passive magnetic speed pickups or active pulse rate
transducers (TTL type) on the TPRO termination board with three being monitored
by each of the X, Y, and Z sections. This capability is not used for industrial steam
turbine applications. Separate overspeed trip settings are programmed into the
application software for the primary and emergency overspeed trip limits, and a
second emergency overspeed trip limit must be programmed into the I/O
configurator to confirm the EOS trip point.
The speed is calculated by counting passing teeth on the wheel and measuring the
time involved. Another protection feature is the calculation of the rate of change of
speed which is compared with 100%/sec and transmitted to the control module to trip
the unit if it is detected after the turbine reaches a predetermined steady-state speed.
This steady-state speed limit is a tuning constant located in the controller’s
application software. Another speed threshold which is monitored by the EOS
system is 10% speed. This is transmitted to the control module to verify that there is
no gross disagreement between the first set of three speed pickups being monitored
by the controller (for speed control and the primary overspeed protection) and the
second set of three speed pickups being monitored by the EOS system.
Item Specification
VPRO: 5 V dc and 28 V dc
Slot 1 VPRO
Turbine_Type Define the type of turbine from selection of ten Two gas turbine
types Two LM, Two large steam
One medium steam
One small steam
Two Stag GT
OT_Trip_Enbl Enable Overtemperature Trip Enable, Disable
OvrTemp_Trip Iso-thermal Overtemperature Trip Setting for -60 to 2,000
Exhaust Thermocouples in Degree F
CPD_Corner Overtemperature Trip Compressor Discharge 0 to 450
Pressure in psi at which CDP Bias Starts
CPD_Slope Overtemperature Trip Compressor Discharge -10 to 0
Pressure Bias Slope in Degree F/psi
Auto Reset Automatic Restoring of Thermocouples removed Enable, Disable
from scan
Min_MA_Input Minimum MA for Healthy 4-20 mA Input 0 to 21
Max_MA_Input Maximum MA for Healthy 4-20 mA Input 0 to 21
L3DIAG_VPRO Point Edit
J5:IS200TPROG1A J5 cable section of TPRO board
PulseRate1 First of three speed inputs Point Edit
PRType Selects Gearing (Resolution) Unused, PR<6,000 Hz,
PR>6,000 Hz
PRScale Pulses per revolution (output RPM) 0 to 1,000
OS_Setpoint Overspeed Trip Setpoint in RPM 0 to 20,000
OS_Tst_Delta Offline Overspeed Test Setpoint Delta in RPM -2,000 to 2,000
Zero_Speed Zero Speed for this Shaft in RPM 0 to 20,000
Min_Speed Minimum Speed for this Shaft in RPM 0 to 20,000
Accel_Trip Enable Acceleration trip Enable, Disable
Acc-Setpoint Accelerate Trip Setpoint in RPM/second 0 to 20,000
TMR_DiffLimt Difference Limit for Voted Pulse Rate Inputs in 0 to 20,000
Engineering Units
J6:IS200TPROG1A J6 Cable section of TPRO board
BusPT_KVolts Bus Potential Transformer Point edit
PT_Input PT input in kilovolts rms for PT_Output 0 to 1,000
PT_Output PT output in Volts rms for PT_Input-typically 115 60 to 150
TMR_DiffLimt Difference Limit for Voted PT Inputs in Per Cent 0 to 100
GenPT_KVolts Generator PT, configuration similar to Bus PT Point Edit
TC1X Thermocouple 1, for X module (three TC per Point Edit
module)
ThermCplType Select Thermocouple Type or mV Input Unused, mV, T, K, J, E
Cold Junction Cold Junction for Thermocouples Point Edit
TMR_DiffLimt Difference Limit for Voted TMR Cold Junction -60 to 2,000
Inputs in Deg F
AnalogIn1 First of Three Analog Inputs Point Edit
Diagnostics
The diagnostics cover the thermocouple limits, reference voltage, cold junction,
analog input health, and contact input test failure. Relay diagnostics cover the trip
relay driver and contact feedbacks, solenoid voltage, economizer relay driver and
contact feedbacks, K25A relay driver and coil, and the servo clamp relay driver and
contact feedback. Voltage diagnostics cover the solenoid power bus, and the voltage
to the solenoids.
Descriptions of the VPRO diagnostics are contained in Chapter 8, Troubleshooting
& Diagnostics.
Protection Logic
The following Figures 9-59 through 9-69 define the protection algorithms coded in
the VPRO firmware. These algorithms are configurable from the toolbox. A
configurable parameter is illustrated with the abbreviation CFG(xx) where xx
indicates where the configuration is located. Some parameters/variables are followed
with a SS indicating they are outputs from Signal Space (meaning they are driven
from the CSDBase); other variables are followed with IO indicating they are
hardware I/O points.
L5ESTOP2
KESTOP2_Fdbk, IO
Estop2
Trip
L5ESTOP2 L86MR, SS
Cont1_TrEnab
Used Enable
ContactInput, CFG (J3, Contact1)
TripEnable, CFG (J3, Contact1)
L5Cont1_Trip
Contact1, IO Cont1_TrEnab
Contact
TDPU Trip
L5Cont1_Trip L86MR, SS
MIN
B
OS_Setpoint_PR1
OS_Stpt_PR1
A A
OfflineOS1test, SS
OnlineOS1test, SS
PulseRate1, IO
A
A>=B OS1
OS_Setpoint_PR1
B
OS1_Trip
OS1
Overspeed Trip
OS1_Trip L86MR, SS
A
PR1_Min
A>B
Min_Speed, CFG (J5, PulseRate1)
B
S PR1_Accel
(Der) A
PR1_Dec
A<B
-100 %/sec*
B
A
PR1_Acc
A>B
Acc_Setpoint, CFG (J5,PulseRate1)
B
Dec1_Trip
PR1_DEC
Decel Trip
Dec1_Trip L86MR,SS
Enable Acc1_Trip
PR1_ACC Acc1_TrEnab
Accel Trip
Acc1_Trip L86MR,SS
PR_Max_Rst PR1_Max_Rst
PR1_Zero_Old PR1_Zero
PR1_Zero
0.00
PR1_Max_Rst PR1_Max
Max
PulseRate1
PR1_Zero PR1_Zero_Old
TC_MED
A
L26T
A>=B
OT_Setpoint
B
Enable OT_Trip
L26T OT_TrEnab Over
Temp Trip
OT_Trip L86MR, SS
L5Cont2_Trip
L5Cont3_Trip
L5Cont4_Trip
L5Cont5_Trip
L5Cont6_Trip
L5Cont7_Trip
LargeSteam2
MediumSteam
SmallSteam
L5CFG1_Trip
L5Cont_Trip
Acc1_Trip
Cross_Trip, SS
OT_Trip SteamTurbOnly
HPZeroSpdByp, SS PR1__Zero
ComposTrip2
ComposTrip1 Stag_GT_1Sh Composite
Trip 2
Stag_GT_1Sh
OS1_Trip
Dec1_Trip
L5CFG1_Trip
L5Cont_Trip
Acc1_Trip
Cross_Trip, SS
Figure 9-66. VPRO Protection Logic - Trip & Economizing Relays ( J3, TREG)
Figure 9-67. VPRO Protection Logic - Trip & Economizing Relays (J4, TREG)
RelayOutput, CFG
(J3,K4CL_Fdbk)
Figure 9-68. VPRO Protection Logic - Servo Clamp & Synch Check Relays (J3,
TREG)
SynCk_Perm, SS GenFreq, SS
SynCk_ByPass, SS BusFreq, SS
Synch Check Function
GenVolts, SS
BusVolts, SS
GenFreqDiff, SS
Slip
DriveFreq GenPhaseDiff, SS
GenVoltsDiff, SS
Phase
Synch
Window
GenPT_KVolts, IO
BusPT_KVolts, IO
L25A_Cmd, IO
Turbine Protection
Termination Board TPRO ma VOLTS
x JP1A
x 1 Gen (H)
Gen (L) x 2
Bus (L) x 4
x 3 Bus (H) OPEN RETURN
x 5 P24 (1)
20mA (1) x 6
mA ret x 8
x 7 VDC
x 9 P24V (2) JP1B
20mA (2) x 10
20mA (3) x 12
x 11 P24V (3)
TC1X (L) x 14
x 13 TC1X (H)
x 15 TC2X (H)
TC2X (L) x 16
x 17 TC3X (H)
TC3X (L) x 18
x 19 TC1Y (H)
TC1Y (L) x 20
TC2Y (L) x 22
x 21 TC2Y (H)
24
x 23 TC3Y (H)
TC2Y (L) x
x To Connectors
JX5, JY5, JZ5,
JX1, JY1, JZ1
x
x 25 TC1Z (H)
TC1Z (L) x 26
x 27 TC2Z (H)
TC2Z (L) x 28
TC3Z (L) x 30
x 29 TC3Z (H)
MX1 (L) x 32
x 31 MX1 (H)
x 33 MX2 (H)
MX2 (L) x 34
MX3 (L) x 36
x 35 MX3 (H)
MY1 (L) x 38
x 37 MY1 (H)
x 39 MY2 (H)
MY2 (L) x 40
x 41 MY3 (H)
MY3 (L) x 42
MZ1 (L) x 44
x 43 MZ1 (H)
MZ2 (L) x 46
x 45 MZ2 (H)
x 47 MZ3 (H)
MZ3 (L) x 48
x
x
x
x 37-pin "D" shell
x 1 ...JA1
... JT1 type connectors
x 2 ...
. RUN
x 4 x 3 ... with latching FAIL
...
6 x 5 . STAT
x
x 7
...
... fasteners
Vibration x 8 .
...
x 10 x 9 ...
.
Signals x 11 ...
x 12 ...
. JB1
x 14 x 13 ...
...
.
x 16 x 15
x 17
...
...
.
Cable to VME
x 18
x 20 x 19 ...
...
. JS1 Rack T
x 22 x 21
24 x 23 JC1
x VME Bus to VCMI
x
x
x 26 x 25
x 28 x 27 Cable to VME
x 29 JD1 Rack S
Vibration x 30
x 32 x 31
Signals x 33 JR1
x 34 P2 P1
x 36 x 35
x 38 x 37
x 40 x 39 P6 P5 P4 P3 VVIB
x 42 x 41 x
x 44 x 43
x 46 x 45 P10 P9 P8 P7 J3
x 47 Connectors on
x 48
x 14 13 12 P11 VME Rack R
x
Shield Bar
To Portable Bentley- J4
Cable to VME
Nevada Data Gathering &
Rack R
Monitoring Equipment
N28V
DB25
Buffer P1-P8 JC1 J4
CL
Amplifier
37 N24V
S
P 38 PR13H DB25
R S
O 39 PR13L P9-P12
S BNC JD1
X J4
Buffer Connectors DB9
Reference Amplifier
or PCOM
Keyphasor
Prox. One of the above ccts for Mark VI.
Two of the above ccts for B/N interface
P13-P14
Four cables to Bentley
Nevada 3500 System
Figure 9-72. TVIB Board, Vibration Probes, and Bentley Nevada Interface
VVIB Features
Vibration Functions
Vibration probe inputs are normally used for four protective functions in turbine
applications as follows:
Vibration: Proximity probes monitor the peak-to-peak radial displacement of the
shaft (the shaft motion in the journal bearing) in two radial directions. This system
uses non-contacting probes and Proximitors, and results in alarm, trip, and fault
detection.
Rotor Axial Position: A probe is mounted in a bracket assembly off the thrust
bearing casing to observe the motion of the thrust collar on the turbine rotor. This
system uses non-contacting probes and Proximitors, and results in thrust bearing
wear alarm, trip, and fault detection.
Differential Expansion: This application uses non-contacting probe(s) and
Proximitor(s) and results in alarm, trip, and fault detection for excessive expansion
differential between the rotor and the turbine casing.
Rotor Eccentricity: A probe is mounted adjacent to the shaft to continuously sense
the surface and update the turbine control. The calculation of eccentricity is made
once per revolution while the turbine is on turning gear. Alarm and fault indications
are provided.
Probes
The eight vibration inputs on each termination board can be applied as either
proximitor, accelerometer, seismic (velocity), or velomitor inputs. Jumpers on the
termination board are used to assign a specific vibration sensor type to each input
point with the seismic type assigned to point (S), the velomitor type assigned to point
(V), and the proximitor and accelerometer types sharing point (P/A). A proximitor
reads a shaft keyway to generate a once per revolution KeyPhasor input for phase
angle reference.
Item Specification
Probe Power -24 V dc from the –28 V dc bus; each probe supply is current limited.
Probe Signal Sampling 16-bit A/D converter with 14-bit resolution on the VVIB
Sampling rate is 4,600 samples per second in fast scan mode (4,000 to 17,500 rpm)
Sampling rate is 2,586 samples per second for nine or more probes.
All inputs are simultaneously sampled in time windows of 160 ms.
S P,V,A
Vibration Termination B/N Buffer Jumper
Board TVIB Sensor Input Positions
V P,A
S
JP1B Probe
x JP1A Selection
x 1 N24V (01) JP2B Jumpers
PR01 (H) x 2
N24V (02) x 4
x 3 PR01 (L) JP2A
x 5 PR02 (H) JP3B
PR02 (L) x 6
x 7 N24V (03) JP3A
PR03 (H) x 8 JP4B
x 9 PR03 (L)
N24V (04) x 10 JP4A
x 11 PR04 (H) JP5B
PR04 (L) x 12
14
x 13 N24V (05) JP5A
PR05 (H) x
x 15 PR05 (L) JP6B
N24V (06) x 16
PR06 (L) x 18
x 17 PR06 (H) JP6A
PR07 (H)
x 19 N24V (07) JP7B
x 20
N24V (08) x 21 PR07 (L) JP7A
x 22
x 23 PR08 (H) JP8B
PR08 (L) x 24
JP8A
x
Connectors JR1, JS1, JT1, to VME Racks
TB1 x
x 37-pin "D" shell
x JT1
x 2 x 1 type connectors
RUN
x 4 x 3 with latching FAIL
Current x 6 x 5
fasteners STAT
Inputs & x 8 x 7
x 10 x 9
Gen PT x 11
x 12
Signals x 14 x 13
x 16 x 15
x 18 x 17 Cable to VME
x 20 x 19 JS1 Rack T
x 22 x 21
x 24 x 23
VME Bus to VCMI
x
TB2
Cable to VME
Rack S
Gen CT TB3 JR1
Signals
VGEN
x
TB4
Connectors on J3
VME Rack R
x
Cable to VME
Shield Bar Rack R
J4
<R>
<S>
<T>
Termination Board TGEN Controller
TB1 Noise
Suppr. Generator
+24Vdc Current Limit
Board
vdc JP1 VGEN
+/-5,10Vdc
20 ma
4-20 ma
250 ohms
Return
JP2 Shown
for <R>
Open Return
JR1 J3 +28 Vdc
PCOM
17
115 Vrms yields
TB1
18 PCOM 1.5333 Vrms A/D
A 19 TP-GA
Generator To TRLY
3-Phase B 20
TP-GB from
Volts <R>
TP-GC JS1 J3 Buffer <S>
(115VAC) C 21
<T>
TP-BA Same for
A 22
Bus <S>
3-Phase TP-BB
B 23
Volts TP-BC
(115VAC) C 24
TB2 JT1 J3
TP-IA1
H1 01 1:2000
Current - 100
H2 02
Phase A TP-IA2 ohms Same for
L1 03
(115VAC) <T>
L2 04
TB3 TP-IB1
H1 01 1:2000
Current - H2 02 100
Phase B L1 03
TP-IB2 ohms
(115VAC) L2 04
TP-IC1 Connectors at bottom
H1 01 1:2000
100 of VME Racks
Current - H2 02
Phase C L1 03
TP-IC2 ohms
(115VAC) L2 04 5 amps yields 0.25 Vrms (l-n)
TB4 Noise Suppr. or 0.433 Vrms (l-l)
Figure 9-75. TGEN Board showing Potential & Current Transformer Inputs
Power Monitoring
The generator and bus PT inputs are three-wire, open delta, voltage measurements
which are used to calculate all three line-to-line voltages. They are not used for
automatic synchronizing which requires two separate single-phase PT inputs. Each
PT input is nominally 115 V rms, and the PTs are magnetically isolated.
Three single-phase CT inputs are provided with a normal current range of 0 to 5 A
continuous. The CTs are magnetically isolated on TGEN. Terminations for the CTs
are on non-pluggable terminal blocks with captive lugs acepting are up to 10 AWG.
Test points are provided for all PT and CT inputs to verify the phase in the field. The
following parameters are calculated from these inputs:
• Total MWatts
• Total MVars
• Total MVA
• Power Factor
• Bus Frequency (5 to 66 Hz)
The four analog inputs can accept 4-20 mA inputs or +/-5,10 V dc inputs. A +24 V
dc source is available for all four circuits with individual current limits for each
circuit. The 4-20 mA transducer can be connected to use the +24 V dc source from
the turbine control or as a self-powered source. A jumper is located on the
termination board to select between current and voltage inputs for each circuit. High
frequency and 50/60 Hz noise is reduced with an analog hardware filter
Item Specification
CurAH1 1
CurAH2 2
CurAL1 TB2
3
CurAL2 4
To Connectors
CurBH1 1 JR1, JS1, JT1
CurBH2 2
TB3
CurBL1 3
CurBL2 4
CurCH1 1
CurCH2 2
TB4
CurCL1 3
CurCL2 4
x
x 26
x 25
x 28
x 27
x 30
x 29
KeyPhasor x 31
x 32 JR1
Wiring x 34
x 33
x 36
x 35
x 38
x 37
x 40
x 39 Cable to VME VPYR
x 42
x 41 Rack R x
44
x 43
x
45
Connectors on
x 46
x J3
x 47 VME Rack
x 48
x
x
Shield Bar
J4
BarrierType Terminal
Blocks can be unplugged
from board for maintenance
<T>
Chan A TPYR Termination Board <S>
<R>
Chan B JS1 J3
13 P24B Current P28VX
14 PCOM Limiter Same for
P28VS <S>
15 N24B Current N28VX
16 PCOM Limiter N28VS
P 17
y 18 Avg
r
o
m 19
e 20 Pk
t
e 21
r 22 Avg-Pk
23 JT1 J3
24 Fast
Same for<T>
30 N24Pr1 Current N28VX P28VT
Limiter
31 PrH1 N28VT
32 PrL1
P28VR
KeyPhasor#1
P28VX P28VS
33 N24Pr2 Current N28VX P28VT
Limiter
34 PrH2 N28VR
35 PrL2
N28VX N28VS
KeyPhasor#2 N28VT
Noise Suppression on all
Inputs & Power Outputs
KeyPhasor Inputs
Two keyphasors are used for shaft position reference, one as a backup. These
keyphasor probes and associated circuitry are identical to those used with
TVIB/VVIB. They sense a shaft keyway or pedestal to provide a time stamp.
Item Specification
Diagnostics
VPYR provides system limit checking on the KeyPhasor gap signals. The two
pyrometer inputs are compared against configuration limits to determine if they are
tracking, and the fast data is compared with other inputs to check validity.
Descriptions of the VPYR diagnostics are contained in Chapter 8, Troubleshooting
& Diagnostics.
PCOM1 (A) x 2
x 1 P24 (A)
x 3 N24 (A)
PCOM2 (A) x 4
x 5 20ma (A1)
Ret (A1) x 6
x 7 20ma (A2)
Ret (A2) x 8
x 9 20ma (A3)
Ret (A3) x 10
x 11 20ma (A4) Cable to <R>
Ret (A4) x 12
14
x 13 P24 (B)
PCOM1 (B) x
x 15 N24 (B)
PCOM2 (B) x 16
x 17 20ma (B1) JS1
Ret (B1) x 18
20
x 19 20ma (B2)
Ret (B2) x
Ret (B3) x 22
x 21 20ma (B3)
Ret (B4) x 24
x 23 20ma (B4)
x
x
x 25 Cable to <S>
x 26
x 27
x 28
x 29
N24 Pr (1) x 30
PrL (1) x 32
x 31 PrH (1) JT1
PrH (2) x 34
x 33 N24Pr (2)
x 35 PrL (2)
x 36
x 37
x 38
x 39
x 40
x 41
x 42
x 43
x 44
x 45
x 46
x 47
x 48 Cable to <T>
x
POWER
SUPPLY
Pull to Toggle
On
Off
Normal
Fault
Availabl
125 Vdc
28 V dc 335 from
(special) V dc PDM
Figure 9-80. VME Rack Power Supply, Front, Side & Bottom Views
Output Filtering
Power Supply Modules Mounted under the
M-100 M-101 M-102 M-103 Circuit Boards on the Heat Sink
+5V +5V +28V +28V
Output Board
Module Board
M-304 M-305 M-306 M-307
+12V -12V +15V -15V
125 V dc
Power Input
Figure 9-81. Inside View of VME Power Supply showing Power Modules
P335V
1.68 W
PS335 + Ret
P335VDC P28V P28V P28V P28V P28V
1
2 50/100 W 50/100 W 50/100 W 50/100 W 50/100 W
+ Ret + Ret + Ret + Ret + Ret 3 PS28A
3 2
1
3 PS28B
2
1
3 PS28C
2
1
PSA 24 22 20 18 16 14 12 10 8 6
*PS28C
"Normal"
To Safety Ground
*PS28C
"Isolation"
s s s s s
PCOM
PCOM
SCOM
Slots 1 thru 5 Slots 6 thru 9 Slots 10 thru 13 Slots 14 thru 17 Slots 18 thru 21
P125 (power)
enable
28 26 3220 30
18 8 6 12 10 16 14 24,28,32 22,26,30 20 18
PSA PSB
P15V s P12V s
s s s s
ACOM
ACOM
s s N12V
N15V
s PCOM
PCOM SCOM
s
N28V
*SCOM
Figure 9-83. VME I/O Rack Power Supply & Cables, continued
Item Description
Diagnostics
Incoming and outgoing voltages and currents are monitored for control and
protection purposes. The following protective actions can occur:
• An input 110 V dc undervoltage condition sets the fault latch, shuts off all
power supplies, and lights the Red LED. Upon recovery, the fault can be reset
with the on/off switch.
• Any power supply output overvoltage fault turns off the bad power supply and
lights the Red LED. Reset by turning off the power supply.
• Undervoltage on the +5 Volt supply (output less than 4.7 Volts) cuts off all the
power supplies until the 5 Volts comes back. The red LED is lit.
• The 335 V dc supply has an overvoltage circuit that lights the Red LED and
shuts down the 335 Volts and other supplies. The output has current limiting.
Test points for all these voltages are located at the left hand side of the VME rack
(refer to the diagram in Chapter 6, Installation for the test point location).
Power cables to
VME Chassis
Fan
+/- 12 Volts x x x x x x x x x x x x x x x x x x x PSA
to Fan, used PSB
with Controller Power
Supply
Plug Position
P28 Normal
Plug Position
P28 Isolated
VME Chassis,
21 slots for I/O
and Control, or x x x x x x x x x x x x x x x x x x x x x
for just I/O
J301
Power Supply
Test Points
GND
Rack Ethernet
ID Plug 125
Vdc
Input
from
P28C Power to External PDM
Peripheral Device (Move
Cable from
Plug from Normal to 335 V dc
PDM Monitor
Isolated Position)
Figure 9-84. Power Supply, VME Chassis, & Cabling to External Devices
Each of the five 28 Volt power modules supplies a section of the VME rack. These
sections are labeled A, B, C, D, E, and F in Figure 9-84. The P28C output at the
bottom of the power supply can be used to power an external peripheral device. To
do this the jumper plug shown on the bracket to the left of the rack must be moved
from the Normal position to the Isolated position below. This allows Module D to
supply rack sections D and E, and Module E to supply the external load via P28C.
Note that the 28 Volt power modules A, B, C, are not related to P28A, B, C; also
note that normally only P28C is used.
The fan, only used when the controller is mounted in the rack, is powered by +/- 12
Volts from the top connector on the same bracket on the left side of the rack.
Diagnostics to
VCMI via J301
in <R> Rack
Power Cables to
Interface Modules
125 V dc, 115/230 V ac
DIN rail
Termination
Output Power Board
Connectors
TB2 TB1
Power
TB3 Input Filters
Terminals Filtered DC
and AC power
to PDM
JTX1 AC/DC
115 V Converter
Cable to
Cable to PDM JZ2
Transformer or JZ3
inside AC/DC JTX2
JZ
Converter 230 V
TB1
TB1 1 2 3 4 5 6 7 8 9 10 11 12
Chassis Chassis
DS2020PDMAG6 DS200TCPD
DCLO AC1N AC
DCHI AC2H AC2N Fuse Feeders
AC1H
J17
JZ4 J18
For Bus P125V J19
JZ5 J20
Monitoring 125 VDC
BJS To TREG,
TB3 ACSHI JH1,
P125 VR JZ2 DACA#1
1 Contact
P125S Inputs
2 332k
(+1.82V)
JZ3 DACA#2 +
3
10k -
Chassis 4
5 TB3
6
10k DC 12 11 10
N125 S 7 feeders
8 332k Fuse Switch J1R J1T
(-1.82V) J2R J2T
9 J1S J1C
N125 VR J2S J1D
R1 1 R2 1
Fuse 22 22
J8A ohm ohm
J8B 70 70
J8C W 2W 2
JZ1 J8D
1
10
TB2 9
Door
6
1 2 3 4 Fuse Switch
J7X
P125 VR J7Y
N125 VR
4 J7Z
7
11 J7A
12
R3 R4
1 1 1 J7W P125 V
Fuse 2 N125 V
22 22 Door
J12A
ohm 2ohm 2 J12B
70 W 70 W 3 J12C
2
+ P125 V J16
3
2
R5, 50 ohm,* 70 W Fuse 1
Fuse
3.2
1 2
3.2 Amp J15
Amp 1
2
R6, 50 ohm,* 70 W 3
1 2
Diagnostic Info JPD
*Note: Field configurable
TB3
P125 VR
1 37-pin
332k P125S (+1.82V) connector
2
+28 Analog In 1
3
10k Chassis 29 P125_Grd
4
5 27 Analog In 2
6 10k
+26 N125_Grd
7 37-wire cable
N125 S (-1.82V) +7
N125 VR 8 332k Analog In 3
9 8 Spare01
One to one
+5 Analog In 4 compatability Connect to VCMI
6 Spare02 between via J301, in <Rx>
screw (TB) I/O Rack
and 37-pin
connector
numbers.
10 P5V
9 DCOM
JPD
35 DIN1, Logic_In_1
P5V 7 34 DIN2, Logic_In_2
DCOM 8
33 DIN3, Logic_In_3
BAT 1
AC1 2 32 DIN4, Logic_In_4
AC2 3
31 DIN5, Logic_In_5
Spare 4
J19 Fuse31 5 30 DIN6, Logic_In_6
J20 Fuse32 6 16 DIN7, Logic_In_7
J17 Fuse29 9
MOV Suppression
In+ Gnd In- In+ Gnd In- In+ Gnd In-
DCF1 ACF1 ACF2
120/250 V, 30 Amp 120/250 V, 30 Amp 120/250 V, 30 Amp Power Filters
Out+ Out- Out+ Out- Out+ Out-
DS200TCPD AC Feeders to
AC1H AC1N
DCHI DCLO AC2H AC2N Fuse TRLY Boards
J17
JZ4 J18
P125V J19
JZ5 J20
BJS
ACSHI DACA#1
DACA#2
JZ2
JZ3
Fuse Switch
J1R DC Feeders to
J1S
J1T Controller Racks
<R0>,<S0>,<T0>
Din Rail Transition Term. Board
+ 28 Analog In 1 37- pin
P125 V TB2 P125S (+1.82V)
29 P125_Grd connector
1
332k
2 27 Analog In 2
3
10k N125 S + 26 N125_Grd
4
(-1.82V) + 7 Analog In 3 Cable to VCMI
5
10k 8 Spare 01 via VDSK on
6 Chassis
+ 5 Analog In 4 front of <R0>
7
8 332k
One to one Control Rack.
6 Spare 02 compatability
9 between screw
N125 V 10 P5V (TB) and 37-pin
connector
9 DCOM numbers.
Diagnostic Information JPD 35 DIN1, Logic_In_1
P5V 7 34 DIN2, Logic_In_2
DCOM 8 33 DIN3, Logic_In_3
BAT 1
AC1 2 32 DIN4, Logic_In_4
AC2 3 31 DIN5, Logic_In_5
Spare 4
J19 Fuse31 5 30 DIN6, Logic_In_6
J20 Fuse32 6 16 DIN7, Logic_In_7
J17 Fuse29 9
J1C Spare
J1D Spare
J7A TRPG#1
J7W TREG
J8A TRLY
J8B TRLY
JZ1
J8C TRLY
J8D TRLY
J12A TBCI
Ground reference J12B TBCI
Jumper BJS J12C TBCI
J15 Miscellaneous
J16 Miscellaneous
J17 TRLY
J18 TRLY
J19 TRLY
J20 TRLY
Figure 9-89. PDM Circuit Board showing Terminals, Fuses, Switches, & Lights
Values for the fuses in the PDM (IS2020CCPD) for the controller cabinet are
similar, except the rating for fuses FU1-FU6 is 5 Amps instead of 15 Amps.
Note: When more than one PDM is supplied from a common 125 V dc source,
remove all the BJS connections except one.
ADL
Asynchronous Device Language, an application layer protocol used for I/O
communication on IONet.
application code
Software that controls the machines or processes, specific to the application.
ARCNET
Attached Resource Computer Network. A LAN communications protocol developed
by Datapoint Corporation. The physical (coax and chip) and datalink (token ring and
board interface) layer of a 2.5 MHz communication network which serves as the
basis for DLAN+. See DLAN+.
ASCII
American Standard Code for Information Interchange. An 8-bit code used for data.
attributes
Information, such as location, visibility, and type of data that sets something apart
from others. In signals, an attribute can be a field within a record.
baud
A unit of data transmission. Baud rate is the number of bits per second transmitted.
Bently Nevada
A manufacturer of shaft vibration monitoring equipment.
bind
A toolbox command in the Device menu used to obtain information from the SDB..
bit
Binary Digit. The smallest unit of memory used to store only one piece of
information with two states, such as One/Zero or On/Off. Data requiring more than
two states, such as numerical values 000 to 999, requires multiple bits (see Word).
block
Instruction blocks contain basic control functions, which are connected together
during configuration to form the required machine or process control. Blocks can
perform math computations, sequencing, or continuous control. The toolbox receives
a description of the blocks from the block libraries.
board
Printed wiring board.
Boolean
Digital statement that expresses a condition that is either True or False. In the
toolbox, it is a data type for logical signals.
bus
An electrical path for transmitting and receiving data.
bumpless
No disruption to the control when downloading.
byte
A group of binary digits (bits); a measure of data flow when bytes per second.
CIMPLICITY
Operator interface software configurable for a wide variety of control applications.
CMOS
Complementary metal-oxide semiconductor.
COM port
Serial controller communication ports (two). COM1 is reserved for diagnostic
information and the Serial Loader. COM2 is used for I/O communication
configure
To select specific options, either by setting the location of hardware jumpers or
loading software parameters into memory.
CT
Current Transformer, used to measure current in an ac power cable.
datagrams
Messages sent from the controller to I/O blocks over the Genius network.
Data Server
A PC which gathers control data from input networks and makes the data available
to PCs on output networks.
dead band
A range of values in which the incoming signal can be altered without changing the
output response.
device
A configurable component of a process control system.
DLAN+
GE Industrial System’s LAN protocol, using an ARCNET controller chip with
modified ARCNET drivers. A communications link between exciters, drives, and
controllers, featuring a maximum of 255 drops with transmissions at 2.5 MBPS.
DRAM
Dynamic Random Access Memory, used in microprocessor-based equipment.
gateway
A device that connects two dissimilar LANs or connects a LAN to a wide-area
network (WAN), PC, or a mainframe. A gateway can perform protocol and
bandwidth conversion.
EGD
Ethernet Global Data is a control network and protocol for the controller. Devices
share data through EGD exchanges (pages).
EMI
Electro-magnetic interference; this can affect an electronic control system
event
A property of Status_S signals that causes a task to execute when the value of the
signal changes.
EX2000 (Exciter)
GE generator exciter control; regulates the generator field current to control the
generator output voltage.
Fanned Input
An input to the termination board which is connected to all three TMR I/O boards.
fault code
A message from the controller to the HMI indicating a controller warning or failure.
Finder
A subsystem of the toolbox for searching and determining the usage of a particular
item in a configuration.
firmware
The set of executable software that is stored in memory chips that hold their content
without electrical power, such as EEPROM.
flash
A non-volatile programmable memory device.
forcing
Setting a live signal to a particular value, regardless of the value blockware or I/O is
writing to that signal.
frame rate
Basic scheduling period of the controller encompassing one complete
input-compute-output cycle for the controller. It is the system dependent scan rate.
function
The highest level of the blockware hierarchy, and the entity that corresponds to a
single .tre file.
gateway
A device that connects two dissimilar LAN or connects a LAN to a wide-area
network (WAN), PC, or a mainframe. A gateway can perform protocol and
bandwidth conversion.
Graphic Window
A subsystem of the toolbox for viewing and setting the value of live signals.
health
A term that defines whether a signal is functioning as expected.
Heartbeat
A signal emitted at regular intervals by software to demonstrate that it is still active.
hexadecimal (hex)
Base 16 numbering system using the digits 0-9 and letters A-F to represent the
decimal numbers 0-15. Two hex digits represent 1 byte.
HMI
Human Machine Interface, usually a PC running CIMPLICITY software.
HRSG
Heat Recovery Steam Generator using exhaust from a gas turbine.
ICS
Integrated Control System. ICS combines various power plant controls into a single
system.
IEEE
Institute of Electrical and Electronic Engineers. A United States-based society that
develops standards.
initialize
To set values (addresses, counters, registers, and such) to a beginning value prior to
the rest of processing.
I/O drivers
Interface the controller with input/output devices, such as sensors, solenoid valves,
and drives, using a choice of communication networks.
I/O mapping
Method for moving I/O points from one network type to another without needing an
interposing application task.
IONet
The Mark VI I/O Ethernet communication network; controlled by the VCMIs.
insert
Adding an item either below or next to another item in a configuration, as it is
viewed in the hierarchy of the Outline View of the toolbox.
instance
Update an item with a new definition.
item
A line of the hierarchy of the Outline View of the toolbox, which can be inserted,
configured, and edited (such as Function or System Data).
IP Address
The address assigned to a device on an Ethernet communication network.
logical
A statement of a true sense, such as a Boolean.
macro
A group of instruction blocks (and other macros) used to perform part of an
application program. Macros can be saved and reused.
Median
The middle value of three values; the median selector picks the value most likely to
be closest to correct.
module
A collection of tasks that have a defined scheduling period in the controller.
MTBFO
Mean Time Between Forced Outage, a measure of overall system reliability.
NEMA
National Electrical Manufacturers Association; a U.S. standards organization.
non-volatile
The memory specially designed to store information even when the power is off.
online
Online mode provides full CPU communications, allowing data to be both read and
written. It is the state of the toolbox when it is communicating with the system for
which it holds the configuration. Also, a download mode where the device is not
stopped and then restarted.
pcode
A binary set of records created by the toolbox, which contain the controller
application configuration code for a device. Pcode is stored in RAM and Flash
memory.
period
The time between execution scans for a Module or Task. Also a property of a
Module that is the base period of all of the Tasks in the Module.
pin
Block, macro, or module parameter that creates a signal used to make
interconnections.
PLC
Programmable Logic Controller. Designed for discrete (logic) control of machinery.
It also computes math (analog) function and performs regulatory control.
Proximitor
Bently Nevada's proximity probes used for sensing shaft vibration.
PT
Potential Transformer, used for measuring voltage in a power cable.
QNX
A real time operating system used in the controller.
realtime
Immediate response, referring to process control and embedded control systems that
must respond instantly to changing conditions.
reboot
To restart the controller or toolbox.
RFI
Radio Frequency Interference; this is high frequency electromagnetic energy which
can affect the system.
register page
A form of shared memory that is updated over a network. Register pages can be
created and instanced in the controller and posted to the SDB.
Resources
Also known as groups. Resources are systems (devices, machines, or work stations
where work is performed) or areas where several tasks are carried out. Resource
configuration plays an important role in the CIMPLICITY system by routing alarms
to specific users and filtering the data users receive.
runtime
See product code.
runtime errors
Controller problems indicated on the front panel by coded flashing LEDS, and also
in the Log View of the toolbox.
sampling rate
The rate at which process signal samples are obtained, measured in samples/second.
Serial Loader
Connects the controller to the toolbox PC using the RS-232C COM ports. The Serial
Loader initializes the controller flash file system and sets its TCP/IP address to allow
it to communicate with the toolbox over Ethernet.
Server
A PC which gathers data over Ethernet from plant devices, and makes the data
available to PC-based operator interfaces known as Viewers.
SIFT
Software Implemented Fault Tolerance, a technique for voting the three incoming
I/O data sets to find and inhibit errors. Note that Mark VI also uses output hardware
voting.
signal
The basic unit for variable information in the controller.
Simplex
Operation that requires only one set of control and I/O, and generally uses only one
channel. The entire Mark VI control system can operate in Simplex mode, or
individual VME boards in an otherwise TMR system can operate in Simplex mode.
simulation
Running a system without all of the configured I/O devices by modeling the behavior
of the machine and the devices in software.
Status_S
GE proprietary communications protocol that provides a way of commanding and
presenting the necessary control, configuration, and feedback data for a device. The
protocol over DLAN+ is Status_S. It can send directed, group, or broadcast
messages.
SOE
Sequence of Events, a high speed record of contact closures taken during a plant
upset to allow detailed analysis of the event.
Status_S pages
Devices share data through Status_S pages. They make the addresses of the points on
the pages known to other devices through the system database.
symbols
Created by the toolbox and stored in the controller, the symbol table contains signal
names and descriptions for diagnostic messages.
task
A group of blocks and macros scheduled for execution by the user.
TCP/IP
Communications protocols developed to inter-network dissimilar systems. It is a
de facto UNIX standard, but is supported on almost all systems. TCP controls data
transfer and IP provides the routing for functions, such as file transfer and e-mail.
time slice
Division of the total module scheduling period. There are eight slices per single
execution period. These slices provide a means for scheduling modules and tasks to
begin execution at different times.
TMR
Triple Modular Redundancy. An operation that uses three identical sets of control
and I/O (channels R, S, and T) and votes the results.
toolbox
A Windows-based software package used to configure the Mark VI controllers, also
exciters and drives.
trend
A time-based plot to show the history of values, similar to a recorder, available in the
Historian and the toolbox.
UCVB
A version of the Mark VI controller.
VCMI
The Mark VI VME communication board which links the I/O with the controllers.
VME board
All the Mark VI boards are hosted in Versa Module Eurocard (VME) racks.
VPRO
Mark VI Turbine Protection Module, arranged in a self contained TMR subsystem.
Windows NT
Advanced 32-bit operating system from Microsoft for 386-based PCs and above.
word
A unit of information composed of characters, bits, or bytes, that is treated as an
entity and can be stored in one location. Also, a measurement of memory length,
usually 4, 8, or 16-bits long.
E M
EGD, 2-2, 2-18, 3-2, 3-6, 3-8 magnetic pickups, 2-10, 2-29, 9-66–9-67
engineering work stations, 2-1, 2-12 master time clock, 2-17
Mean Time Between Forced Outages, 2-30
Ethernet, 1-2, 2-1, 2-3–2-4, 2-7–2-8, 2-31, 3-2, 3-4–3-9,
3-10, 3-23–3-26, 4-1, 6-22, 6-29, 6-33–6-34, 6-37, mean time to repair, 2-30
6-40, 7-1, 7-6, 9-1, 9-3, 9-8, 9-9, 9-11, 9-13, 9-88, Median Value, 2-24
9-97 Median values, 2-22
EX2000, 2-4, 3-9, 9-73, 9-78 MTBFO, 2-30
MTTR, 2-30
Exciter, 1-2, 2-2, 2-4, 2-25, 6-23
exhaust overtemperature, 2-11
O
F On-line Repair, 2-29
Failure Handling, 2-26 operator stations, 2-1, 2-3, 2-12, 2-15, 3-4
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