GEH-6421bb

Mark* VI Control, Volume I

System Guide
Sept 2015

GE Internal
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met during installation, operation, and maintenance. The information is supplied for informational
purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications,
and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected
herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to
the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced
herein.
GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this
document does not provide any license whatsoever to any of these patents.
GE Internal – This document contains information that belongs to the General Electric Company 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 or the information it contains shall not be reproduced in whole or in part or disclosed to any third party
without the express written consent of GE.
GE provides the following document and the information included therein as is and without warranty of any kind, expressed
or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose.
For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales
Representative.

Revised: Sept 2015

Issued: Jan 2004

Copyright © 2004 – 2015 General Electric Company, All rights reserved.

___________________________________
* Indicates a trademark of General Electric Company and/or its subsidiaries.
All other trademarks are the property of their respective owners.

We would appreciate your feedback about our documentation.

Please send comments or suggestions to controls.doc@ge.com

Document Updates
Location Description
The section, Control Module Added a margin note about legacy racks

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Safety Symbol Legend

Indicates a procedure, condition, or statement that, if not strictly observed, could

result in personal injury or death.
Warning

Indicates a procedure, condition, or statement that, if not strictly observed, could

result in damage to or destruction of equipment.

Caution

Indicates a procedure, condition, or statement that should be strictly followed to

improve these applications.

Attention

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Control System Warnings

To prevent personal injury or damage to equipment, follow all equipment safety

procedures, Lockout Tagout (LOTO), and site safety procedures as indicated by
Employee Health and Safety (EHS) guidelines.
Warning

This equipment contains a potential hazard of electric shock, burn, or death. Only
personnel who are adequately trained and thoroughly familiar with the equipment
and the instructions should install, operate, or maintain this equipment.
Warning

Isolation of test equipment from the equipment under test presents potential electrical
hazards. If the test equipment cannot be grounded to the equipment under test, the
test equipment’s case must be shielded to prevent contact by personnel.

To minimize hazard of electrical shock or burn, approved grounding practices and

Warning procedures must be strictly followed.

To prevent personal injury or equipment damage caused by equipment malfunction,

only adequately trained personnel should modify any programmable machine.
Warning

Always ensure that applicable standards and regulations are followed and only
properly certified equipment is used as a critical component of a safety system. Never
assume that the Human-machine Interface (HMI) or the operator will close a safety
critical control loop.
Warning

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 Contents
1 Overview ............................................................................................................................................. 7
1.1 Acronyms and Abbreviations .....................................................................................................................8
1.2 Related Documents ..................................................................................................................................9
2 System Architecture ...................................................................................................................... 11
2.1 System Components .............................................................................................................................. 11
2.2 Levels of Redundancy ............................................................................................................................ 30
2.3 Control and Protection Features ............................................................................................................... 31
2.4 Turbine Protection ................................................................................................................................. 44
2.5 Reliability and Availability ...................................................................................................................... 46
2.6 Third-Party Connectivity......................................................................................................................... 48
3 Networks and Communications ................................................................................................. 49
3.1 Network Layers..................................................................................................................................... 50
3.2 Data Highways...................................................................................................................................... 52
3.3 IONet .................................................................................................................................................. 55
3.4 Ethernet Global Data .............................................................................................................................. 57
3.5 Modbus Communications........................................................................................................................ 58
3.6 Ethernet GSM ....................................................................................................................................... 63
3.7 PROFIBUS® Communications ................................................................................................................. 64
3.8 Fiber-optic Cables.................................................................................................................................. 66
3.9 Single-mode Fiber-optic Cabling .............................................................................................................. 70
3.10 Time Synchronization............................................................................................................................. 71
4 Technical Regulations, Standards, and Environment .......................................................... 73
4.1 Safety Standards.................................................................................................................................... 73
4.2 Electrical.............................................................................................................................................. 73
4.3 Environment ......................................................................................................................................... 76
5 Installation and Configuration .................................................................................................... 81
5.1 Equipment Receiving and Handling .......................................................................................................... 81
5.2 Weights and Dimensions ......................................................................................................................... 82
5.3 Power Requirements .............................................................................................................................. 88
5.4 Grounding ............................................................................................................................................ 89
5.5 Cable Specifications............................................................................................................................... 97
5.6 Connecting the System ..........................................................................................................................102
5.7 Startup Checks .....................................................................................................................................107
5.8 Startup and Configuration ......................................................................................................................111
6 Tools and System Interface ....................................................................................................... 117
6.1 Toolbox ..............................................................................................................................................117
6.2 Human-machine Interface ......................................................................................................................120
6.3 Computer Operator Interface...................................................................................................................123
6.4 GE Historian........................................................................................................................................124
7 Maintenance and Diagnostics...................................................................................................127
7.1 Maintenance .......................................................................................................................................127
7.2 Component Replacement........................................................................................................................128
7.3 Alarm Overview ..................................................................................................................................132

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 7.4 Process Alarms ....................................................................................................................................133
7.5 Diagnostic Alarms ...............................................................................................................................135
7.6 Troubleshooting ...................................................................................................................................137
7.7 Online Download.................................................................................................................................141
8 Applications...................................................................................................................................149
8.1 Generator Synchronization ....................................................................................................................149
8.2 Overspeed Protection Logic ....................................................................................................................162
8.3 Power Load Unbalance ..........................................................................................................................184
8.4 Early Valve Actuation............................................................................................................................188
8.5 Fast Overspeed Trip in VTUR .................................................................................................................190
8.6 Compressor Stall Detection ....................................................................................................................193
8.7 Ground Fault Detection Sensitivity..........................................................................................................197
Glossary of Terms ..............................................................................................................................199
Index.......................................................................................................................................................205

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1 Overview
To obtain the highest This document describes the Mark VI control system, used for the control and protection
reliability, the Mark VI control of steam and gas turbines in electrical generation and process plant applications.
uses a TMR architecture with
The main functions of the Mark VI control system are as follows:
sophisticated signal voting
techniques. • 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
The Mark VI 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 to avoid the reliability and
maintenance issues associated with that instrumentation.
The following figure shows a typical Mark VI control system for a steam turbine with the
important inputs and control outputs.

Typical Turbine Control System

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1.1 Acronyms and Abbreviations
ADL Asynchronous Device Language
ASCII America Standard Code for Information Interchange
AWG American Wire Gauge
BIOS Basic Input/Output System
BOP Balance of Plant
CCR Central Control Room
CMOS Complementary Metal-Oxide Semiconductor
COI Computer Operator Interface
CPU Central Processing Unit
CRC Cyclic Redundancy Code/Check
CT Current Transformer
DCE Data Communication Equipment
DCS Distributed Control System
DDE Data Distribution Equipment
DRAM Dynamic Random Access Memory
DTE Data Terminal Equipment device
EGD Ethernet Global Data
EMC Electromagnetic Capability
EMI Electromagnetic Interference
EVA Early Valve Actuation
FE Functional Earth
FIT Failures in Time
GPS Global Position System
GSM GE Standard Messaging
GTS Global Time Source
HMI Human-Machine Interface
HRSG Heat Recovery Steam Generator
IEC International Electrotechnical Commission
IEEE® Institute of Electrical and Electronics Engineers
LAN Local Area Network
MOV Metal Oxide Varistor
MTBF Mean Time Between Failures
MTBFO Mean Time Between Forced Outage
MTTR Mean Time To Repair
NEC® National Electrical Code
NEMA National Electrical Manufacturer’s Association
NFPA National Fire Protection Association
NTP Network Time Protocol
NVRAM Non-volatile Random Access Memory
OPC® OLE process control server
PDH Plant Data Highway
PDM Power Distribution Module
PE Protective Earth
PLC Programmable Logic Controller
PLU Power Load Unbalance
PT Potential Transformer
RFI Radio Frequency Interference
RPM Revolutions Per Minute
RPSM Redundant Power Supply Module

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 RTD Resistance Temperature Device
RTU Remote Terminal Unit
SDB Systems Database
SIFT Software Implemented Fault Tolerance
SIS Safety Instrumented System
SOE Sequence of Events
SOF Start of Frame
TMR Triple Modular Redundancy
TTL Transistor-Transistor Logic
UART Universal Asynchronous Receiver/Transmitter
UBC Universal Building Code
UDH Unit Data Highway
UDP User Datagram Protocol
USB Universal Serial Bus
UTC Coordinated Universal Time
VLAN Virtual Local Area Network
WAN Wide Area Network

1.2 Related Documents

For additional information, refer to the following documents:

• GEH-6403, Control System Toolbox for a Mark VI Controller (for details of

configuring and downloading the control system)
• GEH-6422, Turbine Historian System Guide (for 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)
• GEI-100534, Control Operator Interface (COI) for Mark VI and EX2100 Systems
• GEI-100535, Modbus® Communications
• GEI-100536, Profibus Communications
• GEI-100189, System Database (SDB) Server User's Guide
• GEI-100271, System Database (SDB) Browser

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Notes

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2 System Architecture
More detailed information on This chapter defines the system hardware components and various levels of redundancy
control system equipment is that are possible. This equipment includes the controllers, IONet switches, I/O modules,
found in GEH-6721_Vol_II. and power distribution. Control system reliability and availability are also discussed.

2.1 System Components

The following sections define the main hardware in the control system. This equipment
includes the controllers, I/O modules, and power distribution.

2.1.1 Control Cabinet

The control cabinet contains either a single (simplex) Mark VI control module or three
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 Unit Data Highway (UDH) by their
controller Ethernet port. Local or remote I/O is possible. The control cabinet requires
120/240 V ac and/or 125 V dc power. This is converted to 125 V dc to supply the
modules.

2.1.2 I/O Cabinet

The I/O cabinet contains either single or triple interface modules. These are linked to the
controllers by IONet, and to the terminal boards by dedicated cables. The terminal boards
are in the I/O cabinet close to the interface modules. Power requirements are 120/240 V
ac and/or 125 V dc power.

2.1.3 Unit Data Highway

The current systems supply The UDH connects to the controller and communicates with the HMI or HMI/Data
UDH and PDH connections on Server. The network media is UTP or fiber-optic Ethernet. Redundant cable operation is
a common set of network optional and, if supplied, unit operation continues to function even if one cable is faulted.
switches and media trunks. Dual cable networks still comprise one logical network. Similar to the plant data highway
(PDH), the UDH can have redundant, separately powered network switches, and
fiber-optic communication. UDH command data can be replicated to three controllers.
The UDH Communicator transmits UDH data.
Single mode cable (SMF) is now approved for the Mark VI UDH system. The advantage
of SMF over multi-mode cable (MMF) is the cables can be longer because the signal
attenuation per foot is less.
Refer to section, UDH UDH command data is replicated to all three controllers. This data is read by the master
Communicator. communication controller board (VCMI) and transmitted to the other controllers. Only
the UDH communicator transmits UDH data

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 Typical Mark VI Integrated Control System

2.1.4 Plant Data Highway

The optional Plant Data Highway (PDH) connects the HMI/data server with remote
operator stations, printers, historians, and other customer computers. It does not connect
directly to the controller. The media is UTP or fiber-optic Ethernet running at 10/100
megabits per second, using the TCP/IP protocol. Redundant cables are required by some
systems, but these form part of one single logical network. The hardware consists of two
redundant Ethernet switches with optional fiber-optic outputs for longer distances, such as
to the central control room. On smaller systems, the PDH and the UDH may physically be
the same network, as long as there is no peer-to-peer control on the UDH.

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 2.1.5 Human-machine Interface
Typical Human-machine Interfaces (HMI) are computers running the Windows®
operating system with communication drivers for the data highways and CIMPLICITY
graphical user interface (GUI). The operator initiates commands from the real-time
graphic displays, and views real-time turbine data and alarms. Detailed I/O diagnostics
and system configuration are available. An HMI can be configured as a server or viewer,
containing tools and utility programs.
An HMI can be linked to one data highway, or redundant network interface boards can be
used to link the HMI to both data highways for greater reliability. The HMI can be
cabinet, control console, or table-mounted.

2.1.5.1 Servers
Servers collect data on the UDH and use the PDH to communicate with viewers. Multiple
servers can be used to provide redundancy. Configuration servers, Historian servers, and
Alarm Servers are used for large system scaling. Redundant data servers are optional, and
if supplied, communication with the viewers continues even if one server fails.

2.1.6 Control Operator Interface

The Control Operator Interface (COI) consists of a set of product and application specific
operator displays running on a small panel computer (10.4 or 12.1 inch touchscreen)
hosting embedded Windows operating system. The COI is used where the full capability
of the HMI is not required. The embedded Windows operating system uses only the
components of the operating system required for a specific application. This results in all
the power and development advantages of a Windows operating system in a much smaller
footprint.
The COI can be installed in many different configurations, depending on the product line
and specific requisition requirements. The only cabling requirements are for power and
for the Ethernet connection to the UDH. Network communication is through the
integrated auto-sensing 10/100Base-TX Ethernet connection. Expansion possibilities for
the computer are limited, although it does support connection of external devices through
floppy disk drives (FDD), intelligent drive electronics (IDE), and universal serial bus
(USB) connections.
The COI can be directly connected to the turbine or excitation control system, or it can be
connected through an EGD Ethernet switch. A redundant topology is available when the
controller is ordered with a second Ethernet port.

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 2.1.6.1 Interface Features
EGD pages transmitted by the controller are used to drive numeric data displays. The
refresh rate depends on the rate at which the controller transmits the pages, and the rate at
which the COI refreshes the fields. Both are set at configuration time.
The COI uses a touchscreen, and no keyboard or mouse is provided. The color of
pushbuttons is driven by state feedback conditions. To change the state or condition, press
the button. The color of the button changes if the command is accepted and the change
implemented by the controller.
Touching an input numeric field on the COI touchscreen displays a numeric keypad for
entering the desired number. An Alarm Window is provided and an alarm is selected by
touching it. Then Acknowledge, Silence, Lock, or Unlock the alarm by pressing the
corresponding button. Multiple alarms can be selected by dragging through the alarm list.
Pressing the button then applies to all selected alarms.

2.1.7 Link to Distributed Control System

External communication links are available to communicate with the plant Distributed
Control System (DCS). A serial communication link, using Modbus® protocol (RTU
binary), can be supplied from an HMI or from a gateway controller. This allows the DCS
operator access to real time Mark VI data, and provides for discrete and analog
commands to be passed to the Mark VI control. In addition, an Ethernet link from the
HMI supports periodic data messages at rates consistent with operator response, plus
sequence of events (SOE) messages with data time tagged at a 1 ms resolution.

2.1.8 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-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.

2.1.9 Excitation Control

Refer to GEH-6632, EX2100 The excitation control system supplies dc power to the field of the synchronous generator.
Excitation Control User’s The excitation control system controls the generator ac terminal voltage and/or the
Guide. reactive volt-amperes by means of the field current. The excitation control system is
supplied in NEMA 1 freestanding floor-mounted indoor type metal cabinets. The cabinet
lineup consists of several cabinets bolted together.

2.1.10 Generator Protection

The generator protection system is mounted in a single, indoor, freestanding cabinet. The
enclosure is NEMA 1, and weighs 1134 Kg (2500 lb). The generator panel interfaces to
the control system with hard-wired I/O, and has an optional Modbus interface to the HMI.

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 2.1.11 Static Starter Control System
The static starter cabinet is a The static starter control system is used to start a gas turbine by running the generator as a
ventilated NEMA 1 starting motor. The static starter system is integrated into the control system along with
free-standing enclosure made the excitation control system. The control supplies the run, torque, and speed setpoint
of 12-gauge sheet steel on a signals to the static starter, which operates in a closed loop control mode to supply
rigid steel frame designed for variable frequency power to the generator stator. The excitation control system is
indoor mounting. controlled by the static starter to regulate the field current during startup.
The control cabinet contains an Innovation Series controller in a Versa Module Eurocard
(VME) control rack. The controller provides the Ethernet link to the UDH and the HMI,
and communication ports for field control I/O and Modbus. The field control I/O are used
for temperature inputs and diagnostic variables.

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 2.1.12 Control Module
The I/O racks and the I/O The control module is available as an integrated control and I/O module, or as a
processor boards are shielded stand-alone control module only. The integrated control and I/O rack can be either a
to control EMI/RFI emissions. 21-slot or 13-slot VME size. The 13-slot rack can accommodate all the boards for control
This shielding also protects the of a small turbine. The backplane has P1 and P2 connectors for the VME boards. The P1
processor boards against connectors communicate data across the backplane, and the P2 connectors communicate
interference from external data between the board and DC-37 pin J3 and J4 connectors located directly beneath each
sources. board. Cables run from the J3 and J4 connectors to the terminal boards.
Legacy racks may contain There can be one control module (simplex) or three TMR control modules. Each of these
jumpers. Newer racks do not configurations supports remote I/O over IONet. The simplex control modules can be
have these jumpers because configured to support up to three independent parallel IONet systems for higher I/O
this functionality was throughput. Multiple communication boards may be used in a control module to increase
incorporated into the VCMI. the IONet throughput.
The following figure shows a 21-slot rack with a three-IONet VCMI communication
board, and a UCVx controller. The UCVx must go in slot 2. The remaining slots are filled
with I/O boards.

Control Module with Control, Communication, and I/O Boards

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 Do not plug the UCVx controller into any rack that
has J302 and J402 connectors.
Warning
The stand-alone controller module is a VME rack with the UCVx controller board, VCMI
communication board, and VDSK interface board as displayed in the following figure.
This version is for remote I/O systems. The rack is powered by an integrated power
supply.
VDSK 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. The VDSK
board is ribbon-cabled in the back to the VCMI to transmit the PDM diagnostics.

Rack with Controller, VCMI, and VDSK (No I/O Boards)

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 2.1.13 Interface Module
The interface module houses the I/O boards remote from the control module. The rack,
displayed in the following figure is similar to the control module VME rack, but without
the controller, interface board VDSK, and cooling fan. Each I/O board occupies one or
two slots in the module and has a backplane connection to a pair of DC-37 pin connectors
mounted on an apron beneath the VME rack. Cables run from the connectors to the
terminal 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 through a VCMI communication board with a single
IONet port, located in the left slot. The module backplane contains a plug wired to slot 1,
which is read by the communication board to obtain the identity of the module on the
IONet.

Interface Module with VCMI and I/O Boards

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 2.1.14 Controller
The controller is a single-slot VME board, housing a high-speed processor, DRAM, flash
memory, cache, an Ethernet port, and two serial RS-232C ports. It must always be
inserted in slot 2 of an I/O rack designed to accommodate it. These racks can be identified
by the fact that there are no J3 and J4 connectors under slot 2. The controller provides
communication with the UDH through the Ethernet port, and supports a low-level
diagnostic monitor on the COM1 serial port. The base software includes appropriate
portions of the existing Turbine Block Library of control functions for the steam, gas, and
Land-Marine aero-derivative (LM) products. The controller can run its program at up to
100 Hz, (10 ms frame rate), depending on the size of 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 I/O from the
I/O boards, and in a TMR system, it consists of voted I/O. Refer to GEH-6421, Mark VI
Control, Volume II System Guide.

UCVx Controller Front Cabinet

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 2.1.15 VCMI Communication Board
The VCMI board in the control and interface module communicates internally to the I/O
boards in its rack, and to the other VCMI boards through the IONet. There are two
versions, one with one Ethernet IONet port for simplex systems, and the other with three
Ethernet ports for TMR systems. Simplex systems have one control module connected to
one or more interface modules using a single cable. The VCMI with three separate IONet
ports is used in TMR systems for communication with the three I/O channels Rx, Sx, and
Tx, and with the two other control modules.
Software Implemented Fault Tolerance (SIFT) voting is implemented in the VCMI board.
Input data from each of the IONet connections is voted in each of the R, S, and T VCMI
boards. The results are passed to the control signal database in the controllers (labeled
UCVx in the diagram) through the backplane VME bus.

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-synchronous 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.

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 2.1.16 IONet
IONet supports control The IONet connection on the VCMI is a BNC for 10Base2 Ethernet. The interface circuit
operation at up to 100 times is high impedance that allows T tap connections with a 50 Ω terminal at the first and last
per second. node. The cabling distances are restricted to 185 meters (607 ft) per segment with up to
eight nodes, using RG-58C/U or equivalent cable.
The Link Layer protocol is IEEE 802.3 standard Ethernet. The application layer protocol
uses Asynchronous Device Language (ADL) messaging with special adaptations for the
input/output handling and the state exchanges.
The VCMI board acts as IONet master and polls the remote interface module for data.
The VCMI master broadcasts a command to all slave stations on a single IONet causing
them to respond with their message in a consecutive manner. To avoid collisions on the
media, each station is told how long to delay before attempting to transmit. Using this
master/slave mechanism, and running at 10 Mb/s, the IONet is capable of transmitting a
1000 byte packet every millisecond (8 MHz bit rate).
In a multiple module or multiple cabinet system, powering down one module of a channel
does not disrupt IONet communication between other modules within that channel. If one
IONet stops communicating then the I/O boards, in that channel, time out and the outputs
go to a safe state. This state does not affect TMR system operation. If two IONets stop,
the I/O boards in both channels go to a safe state that results in a turbine trip, if the
turbine was generating.

2.1.17 I/O Boards

Most I/O boards are single width VME boards, of similar design and front cabinet, 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 1 ms and 5 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 an
SOE monitor.
Each I/O board contains the required sensor characteristic library, for example
thermocouple and resistance temperature devices (RTDs) 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 program
online. This means that I/O boards can accept tune-up commands and data while running.
Certain I/O boards, such as the servo and turbine board, contain special control functions
in firmware. This allows loops, such as the valve position control, to run locally instead of
in the controller. Using the I/O boards in this way provides fast response for a number of
time critical functions. Servo loops, can be performed in the servo board at 200 times per
second.
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 boards through the ID wire in the DC-37 pin
cable. This allows each connector on each terminal board to have a separate identity.

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Processor Terminal I/O Signal Types No. Board Type Comments
VAIC TBAI (2) Analog inputs, 0–1 mA, 4–20 mA, voltage 20 TMR, simplex
Analog outputs, 4–20 mA, 0–200 mA 4
VAOC TBAO Analog outputs, 4–20 mA 16 TMR, simplex
VCCC and TBCI (2) Contact inputs 48 TMR, simplex (VCCC is two slots)
VCRC TRLY (2) Relay Outputs 24

Refer to the table. Relay Terminal Board

Features.
VCCC TICI (2) Point Isolated Contact inputs 48 TMR, simplex VCCC-only in place of
TBCI (optional)
VGEN TGEN Analog inputs, 4–20 mA 4 TMR, simplex
Potential transformers 2
Current transformers 3
TRLY Relay outputs (optional) 12
VPRO (3) TPRO Pulse rate 3 TMR Emergency Protect
Potential transformers 2
Thermocouples 3
Analog inputs, 4–20 mA 3
TREG (2) Solenoid drivers 6 TMR Gas turbine
Trip contact inputs 7
Emergency stop 2 Hardwire, Trip, Clamp
TREL Solenoid drivers 3 TMR Large steam
Trip contact inputs 7
TRES Solenoid drivers 3 TMR, simplex Small/medium steam
Trip contact inputs 7
VPYR TPYR Pyrometers (4 analog inputs each) 2 TMR, simplex
KeyPhasor shaft position sensors 2
VRTD TRTD Resistance Temperature Devices (RTD) 16 TMR, simplex 3 wire
VSVO TSVO (2) Servo outputs to valve hydraulic servo 4 TMR, simplex Trip, Clamp, Input
LVDT inputs from valve 12
LVDT excitation 8
Pulse rate inputs for flow monitoring 2
Pulse rate excitation 2
VTCC TBTC Thermocouples 24 TMR, simplex

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 Process- Terminal I/O Signal Types No. Board Type Comments
or
VTUR TTUR Pulse rate magnetic pickups 4 TMR, simplex
Potential transformers, gen. and bus 2
Shaft current and voltage monitor 2
Breaker interface 1
TRPG Flame detectors (Geiger Mueller) 8 TMR, simplex Gas turbine
Solenoid drivers 3

VTURH2 occupies two slots and supports

two TRPG boards, with flame detector
support on only the first TRPG.

TRPL Solenoid drivers 3 TMR Large steam

Emergency stop 2
TRPS Solenoid drivers 3 TMR, simplex Small/medium steam
Emergency stop 2

VVIB TVIB (2) Shaft vibration probes (Bently Nevada) 16 TMR, simplex Buffered using BNC
Shaft proximity probes (Displacement) 8
Shaft proximity reference (KeyPhasor) 2

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 2.1.18 Terminal Boards
The terminal board provides the customer wiring connection point, and fans out the
signals to three separate DC-37 pin connectors for cables to the R, S, and T I/O boards.
Each type of I/O board has its own special terminal board, some with a different
combination of connectors. For example, one version of the thermocouple board does not
fan out and has only two connectors for cabling to one I/O board. The other version does
fan out and has six connectors for R, S, and T. Since the fan out circuit is a potential
single point failure, the terminal 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 terminal board.

Typical Terminal Board with Cabling to I/O Boards in VME Rack

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 2.1.18.1 DIN-rail Mounted Terminal Boards
Smaller DIN-rail mounted terminal boards are available for simplex applications. These
low cost, small size simplex control systems are designed for small gas and steam
turbines. IONet is not used since the D-type terminal boards cable directly into the control
chassis to interface with the I/O boards.
Types of DIN-rail Boards
DIN Euro Size Number of I/O Description Associated I/O
Terminal Board Points Processor Board
DTTC 12 Thermocouple temperature inputs with one cold junction reference VTCC
DRTD 8 RTD temperature inputs VRTD
DTAI 10 Analog current or voltage inputs with on-board 24 V dc power supply VAIC
2 Analog current outputs, with choice of 20 mA or 200 mA
DTAO 8 Analog current outputs, 0–20 mA VAOC
DTCI 24 Contact Inputs with external 24 V dc excitation VCRC (or VCCC)
DRLY 12 Form-C relay outputs, dry contacts, customer-powered VCRC (or VCCC)
DTRT —— Transition board between VTUR and DRLY for solenoid trip functions VTUR
DTUR 4 Magnetic (passive) pulse rate pickups for speed and fuel flow VTUR
measurement
DSVO 2 Servo-valve outputs with choice of coil currents from 10 mA to 120 mA VSVO
6 LVDT valve position sensors with on-board excitation
2 Active pulse rate probes for flow measurement, with 24 V dc excitation
provided
DVIB 8 Vibration, Position, or Seismic, or Accelerometer, or Velometer VVIB
4 Position prox probes
1 KeyPhasor (reference)
DSCB 6 Serial communication ports supporting RS-232C, RS-422 and RS-485 VSCA

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 2.1.18.2 Relay Terminal Boards
The following table compares the features offered by the different relay terminal boards.

Relay Terminal Board Features

Board Relays Power Feedback Relay Redundancy Suppression Terminals
Distribution Type
DRLYH1A 12 form C relays none none soldered none, simplex No 72 Euro-box
24 dc at 10 A sealed only
125 dc at 0.5 A mechanical
120 ac at 10 A relays
240 ac at 3 A
DRLYH1B 12 form C relays none none soldered none, simplex No 72 Euro-box
24 dc at 2 A sealed only
125 dc at 0.5 A mechanical
120 ac at 1 A relays
240 ac at 0.5 A
TRLYH1B 12 form C relays 6 fused voted coil socketed Coil drive = MOV 48 Barrier
24 dc at 3 A branches, 1 drive sealed voted TMR
125 dc at 0.6 A special mechanical input or simplex
120/240 ac at 3 A unfused relays input
TRLYH1C 12 form C relays 6 fused isolated socketed Coil drive = MOV and R-C 48 Barrier
125 dc at 0.6 A branches, 1 contact sealed voted TMR
120/240 ac at 3 A special voltage mechanical input or simplex
unfused feedback relays input
TRLYH2C 12 form C relays 24 6 fused isolated socketed Coil drive = MOV and R-C 48 Barrier
dc at 3 A branches, 1 contact sealed voted TMR
special voltage mechanical input or simplex
unfused feedback relays input
TRLYH1D 6 form A relays 6 fused ohm meter socketed Coil drive = MOV 24 Barrier
24 dc at 3 A 125 branches (dc solenoid sealed voted TMR
dc at 0.6 A integrity mechanical input or simplex
monitor) relays input
TRLYH1E 12 form A relays none isolated soldered Coil drive = No 24 Barrier
120/240 ac at 6 A contact solid-state voted TMR
voltage relays input or simplex
feedback input
TRLYH2E 12 form A none isolated soldered Coil drive = No 24 Barrier
relays 24 dc at 7 A contact solid-state voted TMR
voltage relays input or simplex
feedback input
TRLYH3E 12 form A relays none isolated soldered Coil drive = No 24 Barrier
125 dc at 3 A contact solid-state voted TMR
voltage relays input or simplex
feedback input
TRLYH1F 12 form A relays none without non-voted soldered Relay contact No 48 Barrier (24
WPDF coil drive sealed voting, TMR used)
mechanical only
relays
TRLYH1F 12 form A relays With WPDF, non-voted soldered Relay contact No 48 Barrier
12 fused coil drive sealed voting, TMR
outputs mechanical only
relays

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 Relay Terminal Board Features (continued)
Board Relays Power Feedback Relay Redundancy Suppression Terminals
Distribution Type
TRLYH2F 12 form B relays none without non-voted soldered Relay contact No 48 Barrier (24
WPDF coil drive sealed voting, TMR used)
mechanical only
relays
TRLYH2F 12 form B relays With WPDF, non-voted soldered Relay contact No 48 Barrier
12 fused coil drive sealed voting, TMR
outputs mechanical only
relays

2.1.18.3 Trip Terminal Boards

The following table compares the features offered by the different trip terminal boards.

Board TMR Simplex Output Output E-Stop Input Contacts Input Contacts Economy
Contacts, 125 Contacts, 24 Dry 125 V dc Dry 125 V dc Resistor
V dc, 1 A V dc, 3 A
TRPGH1A* Yes No Yes No No No No No
TRPGH1B Yes No Yes Yes No No No No
TRPGH2A* No Yes Yes No No No No No
TRPGH2B No Yes Yes Yes No No No No
TREGH1A* Yes No Yes No Yes Yes No Yes
TREGH1B Yes No Yes Yes Yes Yes No Yes
TREGH2B Yes No Yes Yes Yes No Yes Yes
TRPLH1A Yes No Yes Yes Yes No No No
TRELH1A Yes No Yes Yes No Yes No No
TRELH2A Yes No Yes Yes No No Yes No
TRPSH1A Yes Yes Yes Yes Yes No No No
TRESH1A Yes Yes Yes Yes No Yes No No
TRESH2A Yes Yes Yes Yes No No Yes No
* These boards will become obsolete

2.1.19 Power Sources

A reliable source of power is provided to the rack power supplies from either a battery, or
from multiple power converters, or from a combination of both. The multiple power
sources are connected as high select in the PDM to provide the required redundancy.
A balancing resistor network creates a floating dc bus using a single ground connection.
From the 125 V dc, the resistor bridge produces +62.5 V dc (referred to as P125) and
-62.5 V dc (referred to as N125) to supply the system racks and terminal boards. The
PDM has ground fault detection and can tolerate a single ground fault without losing any
performance and without blowing fuses. Since this fault is alarmed, it can be repaired.

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 2.1.20 Turbine Protection Module
The Turbine Protection Module (VPRO) and associated terminal boards (TPRO and
TREG) provide an independent emergency overspeed protection for turbines that do not
have a mechanical overspeed bolt. The protection module is separate from the turbine
control, and consists of triple redundant VPRO boards, each with their own on-board
power supply. VPRO controls the trip solenoids through relay voting circuits on the
TREG, TREL, and TRES boards.

Turbine Protection Module with Cabling Connections

The TPRO terminal board provides independent speed pickups to each VPRO, which
processes them at high speed. This high speed reduces the maximum time delay to
calculate a trip and signal the ETR relay driver to 20 ms. In addition to calculating speed,
VPRO calculates acceleration, which is another input to the overspeed logic.
TPRO fans out generator and line voltage inputs to each VPRO where an independent
generator synchronization check is made. Until VPRO closes the K25A permissive relay
on TTUR, generator synchronization cannot occur. For gas turbine applications, inputs
from temperature sensors are brought into the module for exhaust over temperature
protection.
The VPRO boards do not communicate over the VME backplane. Failures on TREG are
detected by VPRO and fed back to the control system over the IONet. Each VPRO has an
IONet communication port equivalent to that of the VCMI.

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 2.1.21 Operating Systems
All operator stations, communication servers, and engineering workstations use the
Windows operating system. The HMIs and servers run CIMPLICITY software, and the
engineer's workstation runs toolbox software for system configuration.
The 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

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2.2 Levels of Redundancy
The need for higher system reliability has led vendors to develop different systems of
increasing redundancy.
Simplex systems have only one chain, and are the least expensive. Reliability is average.
TMR systems have a very high reliability, and since the voting software is simple, the
amount of software required is reasonable. Input sensors can be triplicated, if required.

Single and Triple Redundant Systems

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 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.
Triple Modular Redundant (TMR) 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. In a TMRsystem, 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.

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2.3 Control and Protection Features
This section describes the fault tolerant features of the TMR part of the control system.
The control system can operate in two different configurations:

• Simplex configuration is for non-redundant applications where system operation

after a single failure is not a requirement.
• TMR configuration is for applications where the probability of a single failure
causing a process shutdown has to be taken to an extremely low value.

2.3.1 Triple Modular Redundancy

A TMR system is a special case of N-modular redundancy where N=3. It is based on
redundant modules with input and output voting.
Input signal voting is performed by software using an approach known as Software
Implemented Fault Tolerance (SIFT). Output voting is performed by hardware circuits
that are an integral part of the output terminal boards.
The voting of inputs and outputs provides a high degree of fault masking. When three
signals are voted, the failure of any one signal is masked by the other two good signals.
This is because the voting process selects the median of the three analog inputs. In the
case of discrete inputs, the voting selects the two that agree. In fact, the fault masking in a
TMR system hides the fault so well that special fault detection functions are included as
part of the voting software. Before voting, all input values are compared to detect any
large differences. This value comparison generates a system diagnostic alarm.
In addition to fault masking, there are many other features designed to prevent fault
propagation or to provide fault isolation. A distributed architecture with dc isolation
provides a high degree of hardware isolation. Restrictions on memory access using
dual-port memories prevent accidental data destruction by adjacent processors. Isolated
power sources prevent a domino effect if a faulty module overloads its power supply.

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 2.3.2 TMR Architecture
The TMR control architecture has three duplicate hardware controller modules labeled R,
S, and T. A high-speed network connects each control module with 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 other controllers. Each of the three controllers
has a VCMI communication board with 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.

TMR Architecture with Local and 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.
A separate protection module provides for very reliable trip operation. The VPRO is an
independent TMR subsystem complete with its own controllers and integral power
supplies. Separate independent sensor inputs and voted trip relay outputs are used.

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 Typical Cabinet Layout of Mark VI TMR System

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 2.3.3 TMR Operation
Voting systems require that the input data be voted, and the voted result be available for
use on the next calculation pass. The sequential operations for each pass are input, vote,
calculate, and output. The time interval that is allotted to these operations is referred to as
the frame. The frame is set to a fixed value for a given application so that the control
program operates at a uniform rate.
For SIFT systems, a significant portion of the fault tolerance is implemented in software.
The advantage to this approach is software does not degrade over time. The SIFT design
requires little more than three identical controllers with some provision of transferring
data between them. All of the data exchange, voting, and output selection may be
performed by software. The exception to the all software approach is the modification to
the hardware output circuitry for hardware voting.
With each controller using the same software, the mode control software in each
controller is synchronizing with, and responding to, an identical copy of itself that is
operating in each of the other controllers. The three programs acting together are referred
to as the distributed executive and coordinate all operations of the controllers including
the sequential operations mentioned above.
There are several different synchronization requirements. Frame synchronization enables
all controllers and associated I/O modules to process the data at the same time for a given
frame. The frame synchronization error is determined at the start of frame (SOF) and the
controllers are required to adjust their internal timing so that all three controllers reach
SOF of the same frame at the same time.
The acceptable error in time of SOF is typically several microseconds in the 10 to 25 Hz
control systems that are encountered. Large errors in SOF timing will affect overall
response time of the control since the voter will cause a delay until at least two controllers
have computed the new values. The constraining requirement for synchronization comes
from the need to measure contact SOE times with an accuracy of 1 ms.

2.3.4 Designated Controller

Although three controllers R, S, and T contain identical hardware and software, some of
the functions performed are individually unique. A single designated controller is
automatically selected to perform the following functions:

• Supply initialization data to the other two controllers at boot-up

• Keep the master time clock
• Calculate the control state data for the cabinet if one of the other controllers fails.
The VCMIs determine the designated controller through a process of nomination and
voting based upon local visibility of the IONet and whether a designated controller
currently exists. If all controllers are equal, a priority scheme is used favoring first R, then
S, and then T. If a controller, which was designated, is powered down and then powered
up, the designated controller will move and not come back if all controllers are equal.
This ensures that a toggling designated controller is not automatically reselected.

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 2.3.4.1 UDH Communicator
Controller communications takes place across the UDH. A UDH communicator is a
controller selected to provide the cabinet data to that network. This data includes both
control signals (EGD) and alarms. Each controller has an independent, physical
connection to the UDH. In the event that the UDH fractures and a controller becomes
isolated from its companion controllers, it assumes the role of UDH communicator for
that network fragment. While for one cabinet there can be only one designated controller,
there may be multiple UDH communicators. The designated controller is always a UDH
communicator.

2.3.4.2 Fault Tolerant EGD

When a controller does not receive expected external EGD data from its UDH
connection, (for example, due to a severed network) it will request that the data be
forwarded across the IONet from another UDH communicator. One or more
communicators may supply the data and the requesting controller uses the last data set
received. Only the EGD data used in sequencing by the controllers is forwarded in this
manner.

2.3.5 Output Processing

The system outputs are the portion of the calculated data transferred to the external
hardware interfaces and then to the various actuators controlling the process. TMR
outputs are voted in the output voting hardware. Any system can output individual data
through simplex hardware.
The three voting controllers calculate TMR system outputs independently. Each controller
sends the output to its associated I/O hardware (for example, the R controller sends output
to the R I/O). The three independent outputs are then combined into a single output by a
voting mechanism. Different data types require different methods of establishing the
voted value.
The outputs from the three controllers fall into three groups:

• Outputs are driven as single ended non-redundant outputs from individual I/O
networks
• Outputs exist on all three I/O networks and are merged into a single output by the
hardware
• Outputs exist on all three I/O networks and are output separately to the controlled
process. This process may contain external voting hardware.
For normal relays, the three outputs feed a voting relay driver, which operates a single
relay per channel. For critical protective signals, the three outputs drive three independent
relays, with the relay contacts connected in the typical six-contact voting configuration.

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 Relay Output Circuits for Protection
For servo outputs, the three independent currents drive a three-coil servo actuator, which
adds them by magnetic flux summation, as displayed in the following figure. Failure of a
servo driver is sensed and a deactivating relay contact is closed to short the servo coil.

TMR Circuit to Combine Three Analog Currents into a Single Output

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 The following figure displays 0-20 mA outputs combined through a 2/3 current sharing
circuit that allows the three outputs to be voted to one. Failure of a 0-20 mA output is
sensed and a deactivating relay contact is opened.

TMR Circuits for Voted 0-20 mA Outputs

2.3.6 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 SIFT-voting as displayed in the
following figure. Signals that appear in all three I/O channels may be application-voted to
create a single input value. The triple inputs either may come from three independent
sensors or may be created from a single sensor by hardware fanning at the terminal board.
A single input can be brought to the three controllers without any voting as displayed in
the following figure. This arrangement is used for non-critical, generic I/O, such as
monitoring 4-20 mA inputs, contacts, thermocouples, and RTDs.

Single Input to Three Controllers, Not Voted

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 One sensor can be fanned to three I/O boards for medium-integrity applications as
displayed in the following figure. This configuration is used for sensors with
medium-to-high reliability. Three such circuits are needed for three sensors. Typical
inputs are 4-20 mA inputs, contacts, thermocouples, and RTDs.

Single Input to Three Controllers, Not Voted

One Sensor with Fanned Input and Software Voting

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 Three independent sensors can be brought into the controllers without voting to provide
the individual sensor values to the application. Median values can be selected in the
controller, if required. This configuration, displayed in the following figure, is used for
special applications only.

Three Independent Sensors with Common Input, Not Voted

The following figure shows three sensors, each one fanned and then SIFT-voted. This
arrangement provides a high-reliability system for current and contact inputs, and
temperature sensors.

Three Sensors, Each One Fanned and Voted, for Medium to High Reliability Applications

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 Speed inputs to high-reliability applications are brought in as dedicated inputs and then
SIFT-voted. The following figure shows the configuration. Inputs such as speed control
and overspeed are not fanned so there is a complete separation of inputs with no hardware
cross-coupling that could propagate a failure. RTDs, thermocouples, contact inputs, and
4-20 mA signals can also be configured this way.

Three Sensors with Dedicated Inputs, Software Voted for High Reliability Applications

2.3.7 Voting
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 bi-stable 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.

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 2.3.7.1 Median Value Analog Voting
The analog signals are converted to a floating-point format by the I/O pack. The voting
operation occurs in each of the three controller modules (R, S, and T). Each controller
receives a copy of the data from the other two channels. For each voted data point, the
controller has three values including its own. The median value voter selects the middle
value of the three as the voter output. This is the most likely of the three values to be
closest to the true value.

Median Value Voting Examples with Normal and Bad Inputs

2.3.7.2 Two Out of Three Logic Voter

Each of the controllers has three copies of the data as described above for the analog
voter. The logical values are stored in the controller database in a format that requires a
byte per logical value. Voting is a simple logic process, which inputs the three values to
find the two values that agree.
The logical data has an auxiliary function called forcing, which allows the operator to
force the logical state to be either true or false and have it remain in that state until
unforced. The logical data is packed in the input tables and the state exchange tables to
reduce the bandwidth requirements. The input cycle involves receive, vote, unpack, and
transfer to the controller database. The transfer to the database must leave the forced
values as they are.

2.3.7.3 Disagreement Detector

Failure of one of the three A disagreement detector continuously scans the input prevote input data sets and
voted input circuits has no produces an alarm bit if a disagreement is detected between the three values. Any
effect on the controlled process disagreement between the prevote logical signals generates an alarm. For analog signals,
since the fault is masked by comparisons are made between the voted value and each of the three prevote values. The
SIFT. Without a disagreement delta for each value is compared with a user programmable limit value. The limit can be
detector, a failure could go set as required to avoid nuisance alarms, but give indication that one of the prevote values
unnoticed until a second has moved out of normal range. Each controller is required to compare only its prevote
failure occurs. value with the voted value; for example, R compares only the R prevote value with the
voted value. Nominal, analog voting limits are set at a 5% adjustment range, but can be
configured to any number for each analog input.

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 2.3.8 Forced Variables
The controller has a feature called Forced Variables. This allows the maintenance
technician using application software to set analog or logical variables to forced values.
Variables remain at the forced value until unforced. Both compute and input processing
respect forcing. Any applied forcing is preserved through power down or restart of the
controller.

Logic Forcing is for offline software checkout and

troubleshooting and should only be used in
conjunction with proper lockout/tag out procedures.
Forcing of protective functions is never permissible
Warning for an operating unit.

2.3.9 Peer I/O

In addition to the data from the I/O modules, there is a class of data coming from other
controllers in other cabinets connected through the UDH network. For integrated systems,
this network provides a data path between multiple turbine controllers and possibly the
controls for the generator, the exciter, or the HRSG/boiler.
Selected signals from the controller database can be mapped into pages of peer outputs
that are broadcast periodically on the UDH I/O to peer controllers. For TMR systems, the
UDH communicator performs this action using the data from its internal database. In the
event of a redundant UDH network failure, the controller will request data over the
remaining network, the IONet.

2.3.10 Command Action

Commands sent to the TMR control require special processing to ensure that the three
voting controllers perform the requested action at the same time. Typically, the
commanding device is a computer connected to the UDH that sends messages over a
single network so there is no opportunity to vote the commands in each controller.
Commands may be sent from one of several redundant computers at the operator
position(s).
By default, the HMIs send all When any TMR controller receives a command message, it synchronizes the
commands to the UDH corresponding response of all three controllers by retransmitting the command to its
communicator. companions across the IONet and cues it for action at the start of the next frame.

2.3.11 Rate of Response

The control system can run selected control programs at the rate of 100 times per second
(10 ms frame rate) for simplex systems and 50 times per second (20 ms frame rate) for
TMR systems.

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 2.3.12 Failure Handling
The general operating principle on failures is that corrective or default action takes place
in both directions away from the fault. When a fault occurs in the control hierarchy
extending from the terminal mounts through I/O boards, backplanes, networks, and main
CPUs, there is a reaction at the I/O processor. There is also a reaction at the main
controller, if still operating. 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 the
health bits set false. A similar situation exists for the I/O rack. In addition, there are
pre-configured 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.
Loss of Control Module in Simplex System - If a control module fails in a simplex
system, the output boards go to the configured default output state after a timeout. The
loss of the controller board propagates down through the IONet so that the output board
knows what to do. This is accomplished by shutting down the IONet.
Loss of Control Module in TMR System - If a control module fails in a TMR system,
the TMR outputs and simplex outputs on that channel timeout to the configured default
output state. TMR control continues using the other two control modules.
Loss of I/O VCMI in TMR System - If the VCMI in an interface module in a TMR
system fails, the outputs timeout to the configured default output state. The inputs are set
to the configured default state so that resultant outputs, such as UDH, can be set correctly.
Inputs and output healthy bits are reset. A failure of the VCMI in Rack 0 is viewed as
equivalent to a failure of the control module itself.
Loss of I/O VCMI in Simplex System - If the VCMI in an interface module in a simplex
system fails, the outputs and inputs are handled the same as a TMR system.
Loss of I/O Board in Simplex System - If an I/O board in a simplex system fails,
hardware on the outputs from the I/O boards set the outputs to a low power default value
given typical applications. Input boards have the input values set to the pre-configured
default value in the master VCMI board.
Loss of Simplex I/O Board in TMR System - If the failed simplex I/O board is in a
TMR system, the inputs and outputs are handled as described herein if they were in a
simplex system.
Loss of TMR I/O Board in TMR System - If a TMR I/O board fails in a TMR system,
inputs and outputs are handled. TMR, SIFT, and hardware output voting keep the process
running.
Loss of IONet in Simplex System - If the IONet fails in a simplex system, the output
boards in the I/O racks timeout and set the pre-configured default output values. The
master VCMI board defaults the inputs so that UDH outputs can be correctly set.
Loss of IONet in TMR System - If the IONet fails in a simplex system, outputs follow
the same sequence as for a Loss of Control Module in simplex. Inputs follow the same
sequence as for Loss of I/O VCMI in TMR.

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2.4 Turbine Protection
Turbine overspeed protection is available in three levels, control, primary, and emergency.
Control protection comes through closed loop speed control using the fuel/steam valves.
Primary overspeed protection is provided by the controller. The TTUR terminal board and
VTUR I/O board bring in a shaft speed signal to each controller where they are median
selected. If the controller determines a trip condition, the controller sends the trip signal to
the TRPG terminal board through the VTUR I/O board. The three VTUR outputs are 2/3
voted in three-relay voting circuits (one for each trip solenoid) and power is removed
from the solenoids.

Primary and Emergency Overspeed Protection

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 Emergency overspeed protection is provided by the independent triple redundant VPRO
protection system. This uses three shaft speed signals from magnetic pickups, one for
each protection module. These are brought into TPRO, a terminal board dedicated to the
protection system. Either the controllers or the protection system can independently trip
the turbine. Each VPRO independently determines when to trip, and the signals are
passed to the TREG terminal board. TREG operates in a similar way to TRPG, voting the
three trip signals in relay circuits and removing power from the trip solenoids. This
system contains no software voting, making the three VPRO modules completely
independent. The only link between VPRO and the other parts of the control system is the
IONet cable, which transmits status information.
Additional protection for simplex systems is provided by the protection module through
the Servo Terminal Board, TSVO. Plug J1 on TREG is wired to plug JD1 on TSVO, and
if this is energized, relay K1 disconnects the servo output current and applies a bias to
force the control valve closed.

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2.5 Reliability and Availability
System reliability and availability can be calculated using the component failure rates.
These numbers determine whether to use simplex circuits or TMR circuits. TMR systems
have the advantage of online repair, which is discussed in the next section.

2.5.1 Online Repair for TMR Systems

The high availability of the TMR system is a result of being able to do repair online. It is
possible to shut down single modules for repair and leave the voting trio in full voting
mode operation, which effectively masks the absence of the signals from the powered
down module. However, there are some restrictions and special cases that require extra
attention.
Many signals are reduced to a single customer wire at the terminal boards so removal of
the terminal board requires that the wires be disconnected momentarily. Each type of
terminal board must be evaluated for the application and the signal type involved.
Voltages in excess of 50 V are present in some customer wiring. Terminal boards that
have only signals from one controller channel may be replaced at any time if the faulty
signals are being masked by the voter. For other terminal boards such as the relay outputs,
the individual relays may be replaced without disconnecting the terminal board.
For those singular signals driven from only one I/O board, there is no redundancy or
masking. These are typically used for non-critical functions such as pump drives, where
loss of the control output simply causes the pump to run continuously. Application
designers must avoid using such singular signals in critical circuits. The TMR system is
designed such that any of the three controllers may send outputs to the singular signals,
keeping the function operational even if the normal sending controller fails.

Note Before performing an online repair, power down only the module (rack) that has
the fault. Failure to observe this rule may cause an unexpected shutdown of the process
(each module has its own power disconnect or switch). The modules are labeled such that
the diagnostic messages identify the faulty module.

Repair the faulty modules as soon as possible. Although the TMR system will survive
certain multiple faults without a forced outage, a hidden fault problem may exist after the
first unrepaired failure occurs. Multiple faults within the same module cause no concern
for online repair since all faults will be masked by the other voters. If a second unrelated
fault occurs in the same module set, either of the faulty powered-down modules
introduces a dual fault in the same three-signal set. This may cause a process shutdown.

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 2.5.2 Reliability
Reliability is represented by the Mean Time Between Forced Outage (MTBFO) of the
control system. The MTBFO 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.
In a simplex system, failure of the controller or I/O communication may cause a forced
outage. Failure of a critical I/O module also causes a forced outage. However, there are
non-critical I/O modules that can fail and be replaced without a shutdown. The MTBFO is
calculated using published failure rates for components.
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.
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 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.
To avoid possible forced The availability of a well-designed TMR system with timely online repair is effectively
outages from powering down 100%. Possible forced outages can still occur if a second failure of a critical circuit occurs
the wrong module, check the before the repair is completed. Other possible forced outages can occur if the repairman
diagnostics to identify the erroneously powers down the wrong module.
modules that contain the
System reliability has been determined by calculating the Failures In Time (FIT) (failures
failure.
per 109 hours) based on the Bellcore TR-332 Reliability Prediction Procedure for
Electronic Equipment. The Mean Time Between Failures (MTBF) can be calculated from
the FIT.

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2.6 Third-Party Connectivity
The Mark VI control can be linked to the plant DCS in one of the following three ways:
The Mark VI control can be • Modbus Ethernet link from the HMI Server RS-232C port to the DCS
operated from the plant control • High-speed 10 Mbaud Ethernet link using the Modbus over TCP/IP protocol
room. • High-speed 10 Mbaud Ethernet link using the TCP/IP protocol with an application
layer called GEDS Standard Messages (GSM)
The GSM supports turbine control commands, Mark VI control data and alarms, the
alarm silence function, logical events, and contact input sequence of events records with 1
ms resolution. Modbus Ethernet is widely used to link to the DCS, but Ethernet GSM has
the advantage of speed, distance, and functionality.

Optional Communication Links to Third-Party Distributed Control System

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3 Networks and Communications
This chapter defines the various networks in the control system that communicate with
the operator interfaces, servers, controllers, and I/O. This chapter also provides
information on fiber-optic cables, including components and guidelines.

Mark VI Control as Part of Integrated Control System

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3.1 Network Layers
The Enterprise layer serves as an interface from specific process control into a
facility-wide or group control layer. This higher layer is provided 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 separated from other control
layers through 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 uses either a Modbus interface or a TCP/IP protocol known as GE Standard
Messaging (GSM).
The Supervisory layer provides operator interface capabilities such as coordination of the
HMI viewer and server nodes, as well as other functions like data collection (Historian),
remote monitoring, and vibration analysis. This layer may be used as a single or dual
network configuration. A dual network provides redundant Ethernet switches and cables
to prevent complete network failure if a single component fails. The network is known as
the PDH.
Other fieldbus based devices The Control layer provides continuous operation of the process equipment. The
may not be restricted to EGD controllers on this layer are highly coordinated to support continuous operation without
data transfers. interruption. The controllers operate at a fundamental rate called the frame rate, which
can be between 6-100 Hz. These controllers use EGD to exchange data between nodes.
Various levels of redundancy for the connected equipment are supported by the
supervisory and control layers.

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 Redundant Networks for Different Applications

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3.2 Data Highways
3.2.1 Plant Data Highway
The Plant Data Highway (PDH) is the plant level supervisory network. The PDH
connects the HMI server with remote viewers, printers, historians, and external interfaces.
The PDH has no direct connection to the control system, which communicate over the
unit data highway (UDH). Using the Ethernet with the TCP/IP protocol over the PDH
provides an open system for third-party interfaces. The following figure displayed the
equipment connections to the PDH.

Typical Plant Data Highway Layout

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 PDH Network Features
Feature Description
Type of Network IEEE 802.3 Ethernet in a single or redundant star or ring configuration

Speed 100 megabit per second or with 1000 megabit per second trunks interconnecting switches

Media and Distance Ethernet 100Base-TX is used for switch to controller/device connections. Cable is CAT 5e compliant.
Distance is up to 100 m (328 ft). Fiber-optic† connections, Ethernet 100FX, 1000SX, 1000 LX are used
for distances of 2 km (1.24 mi), 550 m (1804.46 ft), and 5 km (3.11 mi), respectively.

Number of Nodes Up to 1024 nodes supported

Protocols Ethernet-compatible protocol, typically TCP/IP-based. Use GSM or Modbus over Ethernet for external
communications.
Message Integrity 32-bit cyclic redundancy code (CRC) appended to each Ethernet packet plus additional checks in
protocol used.

External Interfaces Various third-party interfaces are available; GSM and Modbus are the most common.
† Fiber-optic cable provides the best signal quality, completely free of electromagnetic interference (EMI) and radio frequency
interference (RFI). Large point-to-point distances are possible, and since the cable does not carry electrical charges, ground
potential problems are eliminated.

3.2.2 Unit Data Highway

The Unit Data Highway (UDH) is an Ethernet-based network that provides direct or
broadcast peer-to-peer communications between controllers and an operator/maintenance
interface. It uses EGD, which is a message-based protocol for sharing information with
multiple nodes based on UDP/IP. UDH network hardware is similar to the PDH hardware.
The following figure displays redundant UDH networks with connections to the
controllers and HMI servers.
UDH Network Features
Feature Description
Type of Network Ethernet, full duplex, in a single or redundant star configuration

Media and Distance Ethernet 100Base-TX for switch to controller/device connections. The cable is 22 to 26 AWG
unshielded twisted pair; category 5e EIA/TIA 568 A/B. Distance is up to 100 m. Ethernet
100Base-FX with fiber-optic cable optional for distances up to 2 km (1.24 mi).

Number of Nodes At least 25 nodes, given a 25 Hz data rate. For other configurations, contact the factory.

Type of Nodes Supported Controllers, PLCs, operator interfaces, and engineering workstations

Protocol EGD protocol based on the UDP/IP

Message Integrity 32-bit CRC appended to each Ethernet packet plus integrity checks built into UDP and EGD

Time Sync. Methods Network time protocol (NTP), accuracy ±1 ms.

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 Typical Unit Data Highway Layout

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3.3 IONet
Remote I/O can be located up IONet is an Ethernet 10Base2 network used to communicate data between the VCMI
to 185 m (607 ft) from the communication board in the control module, the I/Oboards, and the three independent
controller. 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. The following figure shows a TMR configuration using remote I/O
and a protection module.

IONet Communications with Controllers, I/O, and Protection Modules

IONet Features
IONet Feature Description
Type of Network Ethernet using extension of ADL protocol

Speed 10 Mb/s data rate

Media and Distance Ethernet 10Base2, RG-58 coax cable is standard

Distance to 185 m (607 ft)
Ethernet 10BaseFL with cable and converters
Distance is 2 km (1.24 miles)

Number of Nodes 16 nodes

Protocol Extension of ADL protocol designed to avoid message collisions; Collision Sense
(CSMA) functionality is still maintained

Message Size Maximum packet size 1500 bytes

Message Integrity 32-bit CRC appended to each Ethernet packet

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 3.3.1 VCMI Communications Interface
Communication between the control module (control rack) and interface module (I/O
rack) is handled by the VCMI in each rack. In the control module, the VCMI operates as
the IONet master, while in the interface module it operates as an IONet slave. The VCMI
establishes the network ID, and displays the network ID, channel ID, and status on its
front cabinet LEDs.
The VCMI serves as the master frame counter for all nodes on the IONet. Frames are
sequentially numbered and all nodes on IONet run in the same frame. This ensures that
selected data is being transmitted and operated on correctly.

3.3.2 I/O Data Collection

I/O Data Collection, Simplex Systems - When used in an interface module, the VCMI
acts as the VME bus master. It collects input data from the I/O boards and transmits it to
the control module through IONet. When it receives output data from the control module,
it distributes it to the I/O boards.
The VCMI in slot 1 of the control module operates as the IONet master. As packets of
input data are received from various racks on the IONet, the VCMI collects them and
transfers the data through the VME bus to the I/O table in the controller. After application
code completion, the VCMI transfers output values from the controller I/O table to the
VCMI where the data is then broadcast to all the I/O racks.
I/O Data Collection and Voting, TMR Systems - For a small TMR system, all the I/O
may be in one module (triplicated). In this case, the VCMI transfers the input values from
each of the I/O boards through the VME bus to an internal buffer. After the individual
board transfers are complete, the entire block of data is transferred to the pre-vote table,
and also sent as an input packet on the IONet. As the packet is being sent, corresponding
packets from the other two control modules are being received through the other IONet
ports. Each of these packets is then transferred to the pre-vote table.
After all packets are in the pre-vote table, the voting takes place. Analog data (floating
point) goes through a median selector, while logical data (bit values) goes through a
two-out-of-three majority voter. The results are placed in the voted table.
The master VCMI boards must transfer a selected portion of the controller variables (the
states such as counter/timer values and sequence steps) to the other master VCMI boards
to be included in the vote process. At completion of the voting, the voted table is
transferred through the VME bus to the state table memory in the controller.
For a larger TMR system with remote I/O racks, the procedure is very similar except that
packets of input values come into the master VCMI over IONet. After all the input data is
accumulated in the internal buffer, it is placed in the pre-vote table and also sent to the
other control modules over IONet. After all the packets and states are in the pre-vote
table, they are voted, and the results are transferred to the controller.
Output Data Packet - All the output data from a control module VCMI is placed in
packets. These packets are then broadcast on the IONet and received by all connected
interface and control modules. Each interface module VCMI extracts the required
information and distributes to its associated I/O boards.

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3.4 Ethernet Global Data
The EGD protocol on the UDH is used for controller to HMI communications, and is
configured using the Toolbox application. Controller data configured for transmission
over EGD is separated into groups called exchanges. Multiple exchanges make up pages.
Pages can be configured either to a specific address (unicast), if supported, or to multiple
consumers at the same time (broadcast or multicast), if supported.
Each page is identified by the combination of a Producer ID and an Exchange ID. The
consumer recognizes the data and knows where to store it. EGD allows one controller
component, referred to as the producer of the data, to simultaneously send information at
a fixed periodic rate (frame rate) to any number of peer controller components, known as
the consumers. This network supports a large number of controller components capable of
both producing and consuming information.
The exchange contains a configuration signature, which displays the revision number of
the exchange configuration. If the consumer receives data with an unknown configuration
signature, it makes that data unhealthy. If a transmission is interrupted, the receiver waits
three periods for the EGD message, after which it times out and the data is considered
unhealthy.

EGD Communications Features

Feature Description
Example types of Supervisory data is transmitted periodically at either 480 or 960 ms.
communication Controller data is transmitted to the HMI at frame rate.
Message Type Broadcast – a message sent to all stations on a subnet
Unicast – a directed message to one station
Multicast – a message sent to a group of destinations simultaneously in a single transmission

Sizes Each exchange can contain a maximum of 1400 bytes of data (or payload). Pages can contain
multiple exchanges. The number of exchanges within a page and the number of pages within
an EGD node are limited by each EGD device type. The controller does not limit the number of,
exchanges, or pages.

Message Integrity Ethernet supports a 32-bit CRC appended to each Ethernet packet.
Reception timeout is determined by EGD device type. The exchange times out after an
exchange update had not occurred within four times the exchange period, using Sequence ID.
Missing/out of order packet detection
UDP and IP header checksums
Configuration signature (data layout revision control)
Exchange size validation

Function Codes EGD allows each controller to send a block of information to, or receive a block from, other
controllers in the system.

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3.5 Modbus Communications
The Modbus support is The Mark VI control platform can be a Modbus Slave on either the COM2 RS-232C
available in either the simplex serial connection or over Ethernet. In the TMR configuration, commands are replicated to
or TMR configurations. multiple controllers so only one physical Modbus link is required. The same functions
supported over the serial ports are supported over Ethernet. All Ethernet Modbus
messages are received on Ethernet port 502.

Messages are transmitted and received using the Modbus RTU transmission mode where
data is transmitted in 8-bit bytes. The other Modbus transmission mode where characters
are transmitted in ASCII is not supported. The supported Modbus point data types are
bits, shorts, longs, and floats. These points can be scaled and placed into compatible Mark
VI signal types.
There are four Modbus register page types used:

• Input coils
• Output coils
• Input registers
• Holding registers
Refer to sections, Ethernet Since the Mark VI has high-priority control code operating at a fixed frame rate, it is
Modbus Slave and Serial necessary to limit the amount of CPU resources that can be taken by the Modbus
Modbus Slave, and interface. To limit the operation time, a limit on the number of commands per second
GEI-100535, Modbus received by the Mark VI is enforced. The Mark VI control code also can disable all
Communications. Modbus commands by setting an internal logical signal.
There are two diagnostic utilities that can be used to diagnose problems with the Modbus
communications on a Mark VI. The first utility prints out the accumulated Modbus errors
from a network and the second prints out a log of the most recent Modbus messages. This
data can be viewed using the toolbox.

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 3.5.1 Ethernet Modbus Slave
The Mark VI controller directly supports Ethernet Modbus as a standard Slave interface.
Ethernet establishes high-speed communication between the various portions of the
control system, and the Ethernet Modbus protocol is layered on top of the TCP/IP stream
sockets. The primary purpose of this interface is to allow a third-party Modbus Master
computer or DCS to read and write signals that exist in the controller, using a subset of
the Modbus function codes. The control system will respond to Ethernet Modbus
commands received from any of the Ethernet ports supported by its hardware
configuration.
This Modbus communication link would allow an operator at a remote location to make
an operator command by sending a logical command or an analog setpoint to the
controller. 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 ramp rate predetermined by the application software.
To configure a controller's Modbus Slave Holding Register and/or a Holding Coil to
accept a Write command from a Modbus Master, the External Access property of the
connected variable assigned to the targeted Modbus Slave address must be configured as
Read/Write.
Ethernet Modbus Features
Feature Description
Communication Type Multidrop Ethernet CSMA/CD, employing TCP/IP with Modbus Application Protocol
(MBAP) layered on top. Slave protocol only

Speed 10 Mb/s data rate

Media and Distance Using 10Base2 RG-58 coax, the maximum distance is 185 m (607 ft).
Using 10BaseT shielded twisted pair, with media access converter, the maximum distance
is 100 m (328 ft)
Using 10BaseFL fiber-optics, with media access converter, a distance of several kilometers
is possible
Only the coax cable can be multidropped; the other cable types use a hub forming a Star
network.
Message Integrity Ethernet supports a 32-bit CRC appended to each Ethernet packet.

Redundancy Responds to Modbus commands from any Ethernet interface supported by the controller
Supports register map sharing with serial Modbus

Function Codes
01 Read Coil Read the current status of a group of 1 to 2000 Boolean signals

02 Read Input Read the current status of a group of 1 to 2000 Boolean signals

03 Read Registers Read the current binary value in 1 to 125 holding registers

04 Read Input Read the current binary values in 1 to125 analog signal registers

05 Force Coil Force a single Boolean signal to a state of ON or OFF

06 Preset Register Set a specific binary value into holding registers

07 Read Exception Read the first 8 logic coils (coils 1-8) - short message length permits rapid reading

15 Force Coils Force a series of 1 to 800 consecutive Boolean signals to a specific state

16 Preset Registers Set binary values into a series of 1 to 100 consecutive holding registers

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 3.5.2 HMI Serial Modbus Slave
The Mark VI controller also In this setup, the third-party DCS sends a request for status information or a command to
supports serial Modbus slave the Mark VI control system HMI. The HMI is always a slave, responding to requests from
as a standard interface. the serial Modbus Master (DCS), and there can only be one Master.

Serial Communication Features

Serial Modbus Feature Description
Type of Communication Master/Slave arrangement with the slave controller following the master; full duplex,
asynchronous communication

Speed 19200 baud is standard; available range of 2400 to 57600 baud

Media and Distance Using an RS-232C cable without a modem, the distance is 15.24 m (50 ft); using an
RS-485 converter, it is 1.93 km (1.2 mi).

Remote Terminal Unit (RTU) Mode Each 8-bit byte in the message is sent with no translation, which packs the data more
efficiently than the ASCII mode, providing about twice the throughput at the same
baud rate
Redundancy Supports register map sharing with Ethernet Modbus.

Message Security An optional parity check is done on each byte and a CRC16 check sum is appended
to the message in the RTU mode; in the ASCII mode an LRC is appended to the
message instead of the CRC.

3.5.2.1 Serial Modbus Configuration

Systems are configured as single point-to-point RS-232C communication devices. A GE
device on Serial Modbus is a Slave supporting binary RTU full duplex messages with
CRC. Both dedicated and broadcast messages are supported. A dedicated message is a
message addressed to a specific slave device with a corresponding response from that
Slave. A broadcast message is addressed to all Slaves without a corresponding return
response.
The binary RTU message mode uses an 8-bit binary character data for messages. RTU
mode defines how information is packed into the message fields by the sender and
decoded by the receiver. Each RTU message is transmitted in a continuous stream with a
2-byte CRC checksum, containing a Slave address. A Slave station’s address is a fixed
unique value in the range of 1 to 255.
Both the Master and Slave The Serial Modbus communications system supports none, even, or odd parity, and 7 or 8
devices must be configured data bits.
with the same baud rate,
The RS-232C standard specifies 25 signal lines: 20 lines for routine operation, two lines
parity, and data bit count. for modem testing, and three remaining lines are unassigned. Nine of the signal pins are
used in a nominal RS-232C communication system. Cable references in this document
refer to the 9-pin cable definition found in the following table.
Terms describing the various signals used in sending or receiving data are expressed from
the point of view of the data terminal device (DTE). For example the signal, transmit data
(TD), represents the transmission of data coming from the DTE device going to the data
communication device (DCE).

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 Each RS-232C signal uses a single wire. The standard specifies the conventions used to
send sequential data as a sequence of voltage changes signifying the state of each signal.
Depending on the signal group, a negative voltage (less than -3 V) represents a binary one
data bit, a signal mark, or a control off condition. A positive voltage (greater that +3 V)
represents a binary zero data bit, a signal space, or a control on condition. An RS-232C
cable cannot be longer than 50 feet because of voltage limitations.
A DTE device is identified as a device transmitting serial data on pin 3 (TD) of a 9-pin
RS-232C cable (see pin definitions in the following table). A DCE is identified as a
device transmitting serial data on pin 2 (RD) of a 9-pin RS-232C cable.
Using this definition, the GE Slave serial Modbus device is a DTE device because it
transmits serial data on pin 3 (TD) of the 9-pin RS-232C cable. If the Master serial
Modbus device is also a DTE device, connecting the Master and Slave devices together
requires an RS-232C null modem cable.

RS-232C Connector Pinout Definition

DB 9 DB 25 Description DTE DTE Signal Function
Output Input Type
1 8 Data Carrier Detect (DCD) X Control Signal comes from the other RS-232C device
telling the DTE device that a circuit has been
established.
2 3 Receive Data-(RD) X Data Receiving serial data
3 2 Transmit Data (TD) X Data Transmitting serial data
4 20 Data Terminal Ready DTR X Control DTE device places positive voltage on this pin
when powered up.
5 7 Signal Ground (GND) Ground Must be connected
6 6 Data Set Ready (DSR) X Control Signal from other RS-232C device telling the
DTE device that the other RS-232C device is
powered up.
7 4 Request To Send (RTS) X Control DTE device has data to send and places this
pin high to request permission to transmit.
8 5 Clear To Send (CTS) X Control DTE device looks for positive voltage on this
pin for permission to transmit data.
9 22 Ring Indicator (RI) X Control A modem signal indicating a ringing signal on
the telephone line.

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 Nine of the 25 RS-232C pins are used in a common asynchronous application. All nine
pins are necessary in a system configured for hardware handshaking. The Modbus system
does not use hardware handshaking; therefore it requires just three wires, receiving data
(RD), transmitting data (TD), and signal ground (GND) transmitting and receiving data.
The nine RS-232C signals used in the asynchronous communication system can be
broken down into four groups of signals: data, control, timing, and ground.
Data Signal wires are used to send and receive serial data. Pin 2 (RD) and pin 3 (TD) are
used for transmitting data signals. A positive voltage (> 3 V) on either of these two pins
signifies a logic 0 data bit or space data signal. A negative voltage (< -3 V) on either of
these two pins signifies a logic one data bit or mark signal.
Control Signals coordinate and control the flow of data over the RS-232C cable. Pins 1
(DCD), 4 (DTR), 6 (DSR), 7 (RTS), and 8 (CTS) are used for control signals. A positive
voltage (> 3 V) indicates a control on signal, while a negative voltage (< -3 V) signifies a
control off signal. When a device is configured for hardware handshaking, these signals
are used to control the communications.
Timing signals are not used in an asynchronous 9-wire cable. These signals, commonly
called clock signals, are used in synchronous communication systems to synchronize the
data rate between transmitting and receiving devices. The logic signal definitions used for
timing are identical to those used for control signals.
Signal Ground on both ends of an RS-232C cable must be connected. Frame ground is
sometimes used in 25-pin RS-232C cables as a protective ground.

3.5.2.2 Serial Port Parameters

An RS-232C serial port is driven by a computer chip called a universal asynchronous
receiver/transmitter (UART). The UART sends an 8-bit byte of data out of a serial port
preceded with a start bit, the eight data bits, an optional parity bit, and one or two stop
bits. The device on the other end of the serial cable must be configured the same as the
sender to understand the received data. The software configurable setup parameters for a
serial port are baud rate, parity, stop and data bit counts.
Device number is the physical RS-232C communication port.
Baud rate is the serial data transmission rate of the Modbus device measured in bits per
second. The GE Modbus Slave device supports 9600 and 19200 baud (default).
Stop bits are used to pad the number of bits that are transmitted for each byte of serial
data. The GE Modbus Slave device supports one or two stop bits. The default is one stop
bit.
Parity provides a mechanism to error check individual serial 8-bit data bytes. The GE
Modbus Slave device supports none, even, and odd parity. The default parity is none.
Code (byte size) is the number of data bits in each serial character. The GE Modbus
Slave device supports 7 and 8-bit data bytes. The default byte size is eight bits
Transmission baud rate signifies the bit transmission speed measured in bits per second.
Parity adds an extra bit that provides a mechanism to detect corrupted serial data
characters. Stop bits are used to pad a serial data character to a specific number of bits. If
the receiver expects 11 bits for each character, the sum of the start bit, data bits, parity bit,
and the specified stop bits should equal 11. The stop bits are used to adjust the total to the
desired bit count.

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 UARTs support three serial data transmission modes: simplex (one way only), full duplex
(bi-directional simultaneously), and half duplex (non-simultaneous bi-directional). GE’s
Modbus slave device supports only full duplex data transmission.

3.6 Ethernet GSM

The Mark VI HMI server is the Some applications require transmitting alarm and event information to third-party DCS.
source of the Ethernet GSM This information includes high-resolution local time tags in the controller for alarms (25
communication. Hz), system events (25 Hz), and SOEs for contact inputs (1 ms). An available Ethernet
link, using TCP/IP, transmits data with the local time tags to the plant level control. The
link supports all alarms, events, and SOEs in the control cabinet. GE supplies an
application layer protocol called GSM, which supports four classes of application level
messages.

3.6.1 GSM Messages

Administration Messages are sent from the HMI to the DCS with a Support Unit
message, describing the systems available for communication on that specific link, and
general communication link availability.
Event Driven Messages are sent from the HMI to the DCS spontaneously when a system
alarm or system event occurs or clears, or a contact input (SOE) closes or opens. Each
logic point transmits with an individual time tag.
Periodic Data Messages are groups of data points, defined by the DCS and transmitted
with a group time tag. All of the 5000 data points in the Mark control are available for
transmission to the DCS at periodic rates down to 1-second. One or multiple data lists can
be defined by the DCS using controller names and point names.
Common Request Messages, including turbine control commands and alarm queue
commands, are sent from the DCS to the Mark VI control system HMI. Turbine control
commands include momentary logical commands such as raise and lower, start and stop,
and analog setpoint target commands. Alarm queue commands consist of silence, plant
alarm horn, and reset commands as well as alarm dump requests causing the entire alarm
queue to be transmitted from the Mark VI control system to the DCS.

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3.7 PROFIBUS® Communications
PROFIBUS functionality is PROFIBUS is used in wide variety of industrial applications. It is defined in PROFIBUS
only available in simplex, Standard EN 50170 and in other ancillary guideline specifications. PROFIBUS devices
non-TMR Mark VI control are distinguished as masters or slaves. Masters control the bus and initiate data
systems. communication. They decide bus access by a token passing protocol. Slaves, not having
bus access rights, only respond to messages received from masters. Slaves are peripherals
such as I/O devices, transducers, valves, and such devices. PROFIBUS is an open
fieldbus communication standard.
At the physical layer, PROFIBUS supports three transmission mediums: RS-485 for
universal applications; IEC 1158-2 for process automation; and optical fibers for special
noise immunity and distance requirements. The Mark VI PROFIBUS controller provides
opto-isolated RS-485 interfaces routed to 9-pin D-sub connectors. Termination resistors
are not included in the interface and must therefore be provided by external connectors.
Various bus speeds ranging from 9.6 kbit/s to 12 Mbit/s are supported, although
maximum bus lengths decrease as bus speeds increase.
The Mark VI control operates To meet an extensive range of industrial requirements, PROFIBUS consists of three
as a PROFIBUS-DP Class 1 variations: PROFIBUS-DP, PROFIBUS-FMS, and PROFIBUS-PA. Optimized for speed
master exchanging information and efficiency, PROFIBUS-DP is utilized in approximately 90% of PROFIBUS slave
(generally I/O data) with slave applications. The Mark VI PROFIBUS implementation provides PROFIBUS-DP master
devices each frame. functionality. PROFIBUS-DP masters are divided into Class 1 and Class 2 types. Class 1
masters cyclically exchange information with slaves in defined message cycles, and Class
2 masters provide configuration, monitoring, and maintenance functionality.
PROFIBUS information can be Mark VI UCVE controller versions are available providing one to three PROFIBUS-DP
obtained at www.profibus.com. masters. Each may operate as the single bus master or may have several masters on the
same bus. Without repeaters, up to 32 stations (masters and slaves) may be configured per
bus segment. With repeaters, up to 126 stations may exist on a bus.

PROFIBUS Features
Feature Description
Type of communication PROFIBUS-DP Class 1 master/slave arrangement with slaves responding to masters once
per frame; a standardized application based on the ISO/OSI model layers 1 and 2

Network topology Linear bus, terminated at both ends with stubs possible

Speed 9.6 kbit/s, 19.2 kbit/s, 93.75 kbit/s, 187.5 kbit/s, 500 kbit/s, 1.5 Mbit/s, 12 Mbit/s

Media Shielded twisted pair cable

Number of stations Up to 32 stations per line segment; extendable to 126 stations with up to 4 repeaters

Connector 9-pin D-sub connector

Number of masters From 1-3 masters per UCVE

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 PROFIBUS Bus Length
kb/s Maximum Bus Length
9.6 1200 m (3937 ft)
19.2 1200 m (3937 ft)
93.75 1200 m (3937 ft)
187.5 1000 m (3281 ft)
500 400 m (1312 ft)
1500 200 m (656 ft)
12000 100 m (328 ft)

3.7.1 Configuration
GSD files define the properties The properties of all PROFIBUS master and slave devices are defined in electronic device
of all PROFIBUS devices. data sheets called GSD files (for example, SOFTB203.GSD). PROFIBUS can be
configured with configuration tools such as Softing AG’s PROFI-KON-DP. These tools
enable the configuration of PROFIBUS networks that comprise devices from different
suppliers, based on information imported from corresponding GSD files.
The third-party tool is used rather than the toolbox to identify the devices making up
PROFIBUS networks as well as specifying bus parameters and device options (also called
parameters). The toolbox downloads the PROFIBUS configurations to Mark VI
permanent storage along with the normal application code files.

Note Although the Softing AG’s PROFI-KON-DP tool is provided as the PROFIBUS
configuration tool, any tool with the binary configuration file produced in the Softing
format can be used.

3.7.2 I/O and Diagnostics

PROFIBUS diagnostics can be PROFIBUS I/O transfer with slave devices is driven at the Mark VI application level by a
monitored by the toolbox and set of standard block library blocks. Pairs of blocks read and write analog, Boolean, and
the Mark VI application. byte-oriented data types. The analog blocks read two, four, or eight bytes, depending on
associated signal data types, and handle the proper byte swapping. The Boolean blocks
automatically pack and unpack bit-packed I/O data. The byte-oriented blocks access
PROFIBUS I/O as single bytes without byte swapping or bit packing. To facilitate
reading and writing unsigned short integer-oriented PROFIBUS I/O (needed since
unsigned short signals are not available), a pair of analog-to-word/word-to-analog blocks
work in tandem with the PROFIBUS analog I/O blocks as needed.
Refer to GEI-100536, Data transfers initiated by multiple blocks operating during a frame are fully coherent
PROFIBUS for Mark VI since data exchange with slave devices takes place at the end of each frame.
Controllers.
PROFIBUS defines three types of diagnostic messages generated by slave devices:

Presence of any of these • Station-related diagnostics provide general station status.

diagnostics can be monitored • Module-related diagnostics indicate certain modules having diagnostics pending.
by the toolbox, as well as in the • Channel-related diagnostics specify fault causes at the channel (point) level.
Mark VI applications by a
PROFIBUS diagnostic block
that is included in the Standard
Block library.

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3.8 Fiber-optic Cables
Fiber-optic cable is an effective substitute for copper cable, 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 can damage the
communications electronics. Since the glass fiber does not conduct electricity, 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, or lightning.
• 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 connections normally have higher signal levels and decreased chances of
packet discard from noise corruption. Typical differences in error rate is 10000 lower
for fiber-optic cables.
• The cost per connection for fiber may now be less than copper cables. Large,
multifiber trunk cables contain many fibers, so cost per foot for each connection may
actually cost less than multiple copper cables.
• Fiber-optic cable with proper jacket materials can be run direct buried in trays or in
conduit.
• High-quality fiber-cable is light, tough, and easily pulled. With careful installation, it
can last the life of the plant.
Disadvantages of fiber optics include:

• The cost, especially for short runs, may be more for a fiber-optic link.
• Inexpensive fiber-optic cable can be broken during installation, and is more prone to
mechanical and performance degradation over time. The highest quality cable avoids
these problems.

3.8.1 Basics
Each fiber link consists of two fibers, one outgoing and the other incoming, to form a
duplex channel. A LED drives the outgoing fiber, and the incoming fiber illuminates a
phototransistor, which generates the incoming electrical signal. 1000SX and 1000LX use
laser diodes instead of LEDs.
Multi-mode fiber, with a graded index of refraction core and outer cladding, is
recommended for the optical links. The fiber is protected with buffering that is the
equivalent of insulation on metallic wires. Mechanical stress is bad for fibers so a strong
sheath is used, sometimes with pre-tensioned Kevlar® fibers to carry the stress of pulling
and vertical runs.
Connectors for a power plant should be fastened to a reasonably robust cable with its own
buffering. The square connector (SC) type connector is recommended. This connector is
widely used for LANs, and is readily available.

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 3.8.2 Multi-mode Fiber-optic Cable

Never look directly into a fiber. Although most fiber

links use LEDs that cannot damage the eyes, some
longer links use lasers, which can cause permanent
damage to the eyes.
Warning
Multi-mode fibers are rated for use at 850 nm and 1300 nm wavelengths. Cable
attenuation is between 3.0 and 3.3 dB/km at 850 nm. The core of the fiber is normally
62.5 µ in diameter, with a gradation of index of refraction. The higher index of refraction
is at the center, gradually shifting to a medium index at the circumference. The higher
index slows the light, therefore, a light ray entering the fiber at an angle curves back
toward the center, out toward the other side, and then back toward the center. This ray
travels further but goes faster because it spends most of its time closer to the
circumference where the index is less. The index is graded to keep the delays nearly
equal, thus preserving the shape of the light pulse as it passes through the fiber.
The inner core is protected with a low index of refraction cladding, which for the
recommended cable is 125 µ in diameter. 62.5/125 fiber-optic cable is the most common
type of cable and should be used.

3.8.2.1 Guidelines on Cables Usage

• Gel filled (or loose tube) cables should not be used because of difficulties making
installations, terminations, and the potential for leakage in vertical runs.
• Use a high-quality breakout cable, which makes each fiber a sturdy cable, and helps
prevent bends that are too sharp.
• Sub-cables are combined with more strength and filler members to build up the cable
to resisting mechanical stress and the outside environment.
• Two types of cable are recommended, one with armor and one without. Rodent
damage is a major cause of optical cable failure. If this is a problem in the plant, the
armored cable should be used, although it is heavier, has a larger bend radius, is more
expensive, attracts lightning currents, and has lower impact and crush resistance.
• Optical characteristics of the cable can be measured with an optical time domain
reflectometer (OTDR). Some manufacturers will supply the OTDR printouts as proof
of cable quality. A simpler instrument is used by the installer to measure attenuation,
and they should supply this data to demonstrate the installation has a good power
margin.
• Cables described here have four fibers, enough for two fiber-optic links. This can be
used to bring redundant communications to a central control room. The extra fibers
can be retained as spares for future plant enhancements. Cables with two fibers are
available for indoor use.

3.8.2.2 Connectors
The 100Base-FX fiber-optic cables for indoor use in the control system have SC type
connectors. The connector, displayed in the following figure, is a keyed, snap-in
connector that automatically aligns the center strand of the fiber with the transmission or
reception points of the network device. An integral spring helps to keep the SC
connectors from being crushed together, avoiding damage to the fiber. The two plugs can
be held together as displayed, or they can be separate.

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 SC Connector for Fiber-optic Cables

The process of attaching the fiber connectors involves stripping the buffering from the
fiber, inserting the end through the connector, and casting it with an epoxy or other
plastic. This requires a special kit designed for that particular connector. After the epoxy
has hardened, the end of the fiber is cut off, ground, and polished. An experienced person
can complete the process in five minutes.

3.8.2.3 System Considerations

Redundancy should be considered for continuing central control room (CCR) access to
the turbine controls. Redundant HMIs, fiber-optic links, Ethernet switches, and power
supplies are recommended. The link design can deliver greater than 6 dB signal to noise
ratio from GE design process and component selection. This makes control systems more
reliable against minor defects in field installations and component aging over a 20-year
plant life.
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.

3.8.2.4 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 switches, UPS systems, and connectors.

• Install the fiber-optic cable in accordance with all local safety codes. Polyurethane
and PVC are two possible options for cable materials that might NOT meet the local
safety codes.
• 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 contractors with fiber LAN installation experience.
• The fiber switches and converters need reliable power, and should be placed in a
location that minimizes the amount of movement they must endure, yet keep them
accessible for maintenance.

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 3.8.3 Component Sources
The following are typical sources for fiber-optic cable, single mode fiber-optic,
connectors, converters, and switches.
Fiber-optic Cable:
Optical Cable Corporation
5290 Concourse Drive
Roanoke, VA 24019
Phone: (540)265-0690
Part Numbers (from OCC)
Each of these cables are SMF 8.3/125 um Core/Cladding diameter with a numeric
aperture of 0.13.
OC041214-01 4 Fiber Zero Halogen Riser Rated Cable.
OC041214-02 4 Fiber Zero Halogen with CST Armor.
OC041214-03 4 Fiber with Flame Retardant Polyurethane.
OC041214-04 4 Fiber with Flame Retardant Polyurethane with CST Armor
Corning Cable Systems
PO Box 489
Hickory, NC 28603-0489
Phone: (800)743-2671
Fiber-optic Connectors:
3M® - Connectors and Installation kit
Thomas and Betts - Connectors and Assembly polishing kit
Amphenol - Connectors and Termination kit

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3.9 Single-mode Fiber-optic Cabling
Single-mode fiber-optic (SMF) cabling is approved for the Mark VI control system,
including both IONet and UDH/PDH network applications. This extends the distance of
the control system beyond the traditional multi-mode fiber-optic (MMF) cablling limit of
2000 m to 15000 m (6561.7 to 49212.6 ft)
The following figure displays the differences between multi-mode and single-mode cable
types with a typical 62.5/125 µm MMF segment.

Since the cladding material Light (typically from a LED) enters through an aperture at the left, 62.5 µm in diameter.
has a different index of This aperture is many times the dimension of the typical 1500 µm wavelength used for
refraction than the core, these transmission. This difference between the aperture and the wavelengths allows waves to
waves will be reflected due to enter at multiple angles. Because of different angles, there are many paths the light can
the large angle of incidence make through the fiber with each taking a different time to arrive at the detector. This
(Snells Law). difference between the minimum time and maximum time for light transmission through
the fiber is known as dispersion. Dispersion is the main property that degrades the signal
through multi-mode fiber and limits the useful limit to 2 km (1.24 mi).
In the SMF cable, the aperture is reduced to ~9 µm, comparable to the 1500 µm
wavelength of transmission. In this small aperture, there is little difference in the angle of
incidence of the light and as such, the light propagates with little dispersion. The
attenuation is the main property that degrades the signal and as such, much greater
distances are achievable. The main advantage of SMF cable over traditional MMF cable
in the power plant environment is that fiber-optic segments can now be longer than 2000
m (6561.68 ft) because the signal attenuation per foot is less.

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3.10 Time Synchronization
The time synchronization option synchronizes all turbine controls, generator controls, and
HMIs on the UDH to a Global Time Source (GTS) or master time source. Typical GTS
systems 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 is placed in the HMI. This board acquires time from
the master time source 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 NTP. The HMI server provides time-to-time slaves either by
broadcasting time, or by responding to NTP time queries, or both methods.
Supplying a time/frequency processor board in another HMI server as a backup can
provide redundant time synchronization. Normally, the primary HMI server on the UDH
is the time master for the UDH, and other computers 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 through unicast mode or broadcast mode.
Local time is used for display of real time data by adding a local time correction to UTC.
A node’s internal time clock is normally UTC rather than local. This is done because
UTC time steadily increases at a constant rate while corrections are allowed to local time.
Historical data is stored with global time to minimize discontinuities.
If the master time source or GTS becomes inoperative, the backup is to switch the time
board to flywheel mode with a drift of ±2 ms/hour. In most cases, this allows sufficient
time to repair the master time source without severe disruption of the plant’s system time.
If the time master becomes inoperative, then each of the time slaves picks the backup
time master. This means that all nodes on the UDH lock onto the identical reference for
their own time even if the primary and secondary time masters have different time bases
for their reference. If multiple time masters exist, each time slave selects the current time
master based on whether or not the time master is tracking the master time source, which
time master has the best quality signal, and which master is listed first in the
configuration file.
For more information, refer to The time synchronization software does not support all time sources supported by the
RFC 1305 Network Time time board. A list of time sources supported by both the time board and the time
Protocol (Version 3) dated synchronization software includes:
March 1992.
• Modulated IRIG-A, IRIG-B, 2137, or NASA-36 timecode signals
− Modulation ratio 3:1 to 6:1
− Amplitude 0.5 to 5 V peak-to-peak
• Dc level shifted modulated IRIG-A, IRIG-B, 2137, or NASA-36 timecode signals
− TTL/CMOS compatible voltage levels
• 1PPS (one pulse per second) using the External 1PPS input signal of the BC620AT
board
− TTL/CMOS compatible voltage levels, positive edge on time
• Flywheel mode using no signal, using the low drift clock on the BC620AT board
− Flywheel mode as the sole time source for the plant

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Notes

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4 Technical Regulations, Standards,
and Environment
This chapter describes the technical regulations, standards, and environmental guidelines
used for the design of all printed circuit boards, modules, core components, panels, and
cabinet line-ups in the control system. Requirements for harsh environments, such as
marine applications, are not covered here.

4.1 Safety Standards

EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use, Part 1: General Requirements

CAN/CSA® 22.2 No. 1010.1-92 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use, Part 1: General Requirements

ANSI®/ISA 82.02.01 1999 Safety Standard for Electrical and Electronic Test, Measuring, Controlling, and
Related Equipment – General Requirements

IEC® 60529 Intrusion Protection Codes/NEMA 1/IP 20

4.2 Electrical
4.2.1 Printed Circuit Board Assemblies
UL 796 Printed Circuit Boards
ANSI IPC guidelines
ANSI IPC/EIA guidelines
Printed Circuit Boards

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 4.2.2 Electromagnetic Compatibility Directive (EMC)
2004/108/EC

Equipment is not approved for use in a residential,

commercial or light industrial environment and
should not be connected to a residential electric
power network.
Attention
Code Description
EN 55011:2007 ISM equipment - Electromagnetic disturbance characteristics
EN 61000-6-2: 2005 Generic Immunity Industrial Environment
IEC 61000-4-2:1995 Electrostatic Discharge Susceptibility
IEC 61000-4-3:2006 Radiated RF Immunity
IEC 61000-4-4:2005 Electrical Fast Transient Susceptibility
IEC 61000-4-5:2006 Surge Immunity
IEC 61000-4-6:1996 Conducted RF Immunity
IEC 61000-4-11:2004 Voltage Variation, Dips and Interruptions

4.2.3 Low Voltage Directive 2006/95/EC

EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control,
and Laboratory Use, Part 1: General Requirements

4.2.4 Supply Voltage

4.2.4.1 Line Variations

Ac Supplies – Operating line variations of ±10%
IEEE STD 141-1993 defines the Equipment Terminal Voltage – Utilization voltage.
The above meets IEC 60204-1 2005, and exceeds IEEE STD 141-1993, and ANSI
C84.1-1989.
Dc Supplies – Operating line variations of -30%, +20% or 145 V dc. This meets IEC
60204-1 2005.

4.2.4.2 Voltage Unbalance

Less than 2% of positive sequence component for negative sequence component
Less than 2% of positive sequence component for zero sequence components
This meets IEC 60204-1 2005 and IEEE STD 141-1993.

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 4.2.4.3 Harmonic Distortion Voltage Unbalance
Voltage: Less than 10% of total rms voltages between live conductors for 2nd through 5th
harmonic
Additional 2% of total rms voltages between live conductors for sum of 6th through 30th
harmonic
This meets IEC 60204-1 2005.
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.

4.2.4.4 Frequency Variations

Frequency variation of ±5% when operating from ac supplies (20 Hz/sec slew rate)
This exceeds IEC 60204-1 2005.

4.2.4.5 Surge
Withstand 2 kV common mode, 1 kV differential mode
This meets IEC 61000-4-5 (ENV50142), and ANSI C62.41 (combination wave).

4.2.4.6 Clearances
NEMA Tables 7.1 and 7.2 from NEMA ICS 1-2000
This meets IEC 61010-1:1993/A2: 1995, CSA C22.2 #14, and UL 508C.
The following clearance table is from CTLDP214.

NEMA/ICS 1 Tables 7.1 and 7.2 SPACINGS

EN 61010-1 D.4 and D.10 SPACINGS
CSA C22.2 #14 SPACINGS
UL 508C SPACINGS

4.2.4.7 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 (only
applicable to ac powered systems with DACAs; not applicable to dc-only powered Mark
VI control systems).
This exceeds IEC 61000-4-11.

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4.3 Environment
4.3.1 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 for the Mark VI controller are
from -40 to 80°C (-40 to 176 °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, snakes, birds or insects
− No temperature variations that cause moisture condensation

Moisture on certain internal parts can cause

electrical failure.

Attention
Condensation occurs with temperature drops of 15°C (59 °F) at 50% humidity over a
four-hour period, and with smaller temperature variations at higher humidity.
If the storage room temperature varies in such a way, install a reliable heating system that
keeps the equipment temperature slightly above that of the ambient air. This can include
space heaters or cabinet space heaters (when supplied) inside each enclosure. A 100 W
lamp can sometimes serve as a substitute source of heat.

To prevent fire hazard, remove all cartons and other

such flammable materials packed inside units before
energizing any heaters.
Attention

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 4.3.2 Operating Environment
To ensure proper performance and normal operational life, the control room environment
should be maintained as follows:

Location Ambient Temperature at Bottom of Module

Control Module with running fans 0 to 60°C (32 to 140 °F)

I/O Module 0 to 60°C (32 to 140 °F)

Higher ambient temperature Ambient temperature (preferred): 20 to 30°C (68 to 86 °F)

decreases the life expectancy of Relative humidity: 5 to 95%, non-condensing
any electronic component.
Keeping ambient air in the Environments that include excessive amounts of any of the following elements reduce
preferred (cooler) range cabinet performance and life:
should extend component life.
• Dust, dirt, or foreign matter
• Vibration or shock
• Moisture or vapors
• Rapid temperature changes
• Acid or caustic fumes
• Power line fluctuations
• EMI 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
Enclosures can be custom The preferred location for the control system cabinet would be in an environmentally
engineered for other locations controlled room or in the control room itself. The cabinet should be mounted where the
if desired. floor surface allows for attachment in one plane (a flat, level, and continuous surface).
The customer provides the mounting hardware. Lifting lugs are provided and if used, the
lifting cables must not exceed 45° from the vertical plane. Finally, the cabinet is equipped
with a door handle, which can be locked for security.
Interconnecting cables can be brought into the cabinet through removable access plates.
Convection cooling of the cabinet requires that conduits be sealed to the access plates. In
addition, air passing through the conduit must be within the acceptable temperature range
as listed previously.

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 4.3.3 Elevation
Equipment elevation is related to the equivalent ambient air pressure.
The extended operation and • Normal operation: 0 to 1000 m (0 to 3280.8 ft) at 101.3 to 89.8 kPa
shipping specifications exceed • Extended operation: 1000 to 3050 m (3280.8 to 10006.5 ft) at 89.8 to 69.7 kPa
EN50178. • Shipping: 4600 m (15091.8 ft) at 57.2 kPa max

Note For extended altitude operation, the maximum ambient temperature rating of the
equipment should be reduced by 1°C (34 °F) for each additional 410 m (1345 ft) above
1000 m (3280.83 ft). This is because the maximum ambient rating of the equipment
decreases linearly by 5°C (41 °F) starting at altitudes above 1000 m through 3050 m
(3280.8 ft through 10006.5 ft). Therefore, an I/O pack rated for 65°C (149 °F) at 1000 m
(3280.8 ft) will be rated for 60°C (140 °F) at 3050 m (10006.5 ft).

4.3.4 Corrosive Gases

The control equipment withstands the following concentrations of corrosive gases at 50%
relative humidity and 40°C (104 °F):
This meets EN50178 Section Corrosive Gas Concentration
A.6.1.4 Table A.2 (m).
Sulfur dioxide (SO2) 30 ppb

Hydrogen sulfide (H2S) 10 ppb

Nitrous fumes (NO) 30 ppb

Chlorine (Cl2) 10 ppb

Hydrogen fluoride (HF) 10 ppb

Ammonia (NH3) 500 ppb

Ozone (O3) 5 ppb

4.3.5 Vibration

4.3.5.1 Seismic
Universal Building Code (UBC) - Seismic Code section 2312 Zone 4 (Optional)

4.3.5.2 Operating/Installed at Site

Vibration of 1.0 G Horizontal, 0.5 G Vertical at 15 to 120 Hz
Refer to Seismic UBC for frequencies lower than 15 Hz.

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 4.3.6 Packaging
The standard Mark VI control cabinets meet NEMA1 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.

4.3.7 UL Class 1 Division 2 Listed Boards

Certain boards used in the Mark VI control systems are UL listed (E207685) for Class 1
Division 2, Groups A, B, C, and D, Hazardous Locations, Temperature Class T4 using
UL-1604. Division 2 is described by NFPA 70 NEC® 1999 Article 500 (NFPA - National
Fire Protection Association, NEC - National Electrical Code).

Note For a list of UL Class 1 Division 2 boards, go to the following internet address:
http://www.ul.com
Select the Certifications link, select the Online Certifications Directory link, type
E207685 into the basic search UL File Number field, and click Search.

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Notes

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5 Installation and Configuration
This chapter defines installation requirements for the control system. Specific topics
include GE installation support, wiring practices, grounding, typical equipment weights
and dimensions, and power dissipation and heat loss.

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,
Warning operate, or maintain this equipment.

5.1 Equipment Receiving and Handling

GE inspects and packs all equipment before shipping it from the factory. A packing list,
itemizing the contents of each package, is attached to the side of each case.

Only personnel who are adequately trained and

thoroughly familiar with the equipment and
instructions should install, operate, or maintain the
equipment. To prevent damage to the equipment,
personnel injury, or death, safe equipment lifting
practices must be followed. For example, use
adequate tie-off, load-spreading mechanisms,
Warning
precise lifting control, managed acceleration, the
correct forklift/crane rated for equipment tonnage,
and so forth.

Upon receipt, carefully examine the contents of each shipment and check them with the
packing list. Immediately report any shortage, damage, or visual indication of rough
handling to the carrier. Then notify both the transportation company and GE. Be sure to
include the serial number, part (model) number, GE requisition number, and case number
when identifying the missing or damaged part.

Immediately upon receiving the system, place it

under adequate cover to protect it from adverse
conditions. Packing cases are not suitable for
outdoor or unprotected storage. Shock caused by
rough handling can damage electrical equipment. To
prevent such damage when moving the equipment,
Attention observe normal precautions along with all handling
instructions printed on the case.

If technical assistance is required beyond the instructions provided in the documentation,

contact the nearest GE Sales or Service Office or an authorized GE Sales Representative.

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 Junction boxes can weigh well over 45.36 Kg (100
lb). Installation should be planned to protect both
the box and the personnel. The use of an overhead
crane may be required. Consult the site specific
shipping and junction box documents. Follow all
standard safety practices.

Warning Only personnel who are adequately trained and

thoroughly familiar with the equipment and the
instructions should install, operate, or maintain this
equipment.

5.2 Weights and Dimensions

A single Mark VI cabinet, including dimensions, clearance, bolt holes, lifting lugs, and
temperature information, is displayed in the following figure. The enclosure can house
three controllers used in a system with all remote I/O.

Typical One-door Controller Cabinet

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Installation and Configuration GEH-6421bb System Guide 83
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 The controller cabinet is for small gas turbine systems (simplex only). It contains control,
I/O, and power supplies, and weighs 620 kg (1,367 lbs) complete.

Typical Controller Cabinet

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 The two-door cabinet displayed in the following figure is for small gas turbine systems. It
contains control, I/O, and power supplies, and weighs approximately 720 kg (1,590 lbs)
complete. A 1600 mm wide version of this cabinet is available, and weighs approximately
912 kg (2,010 lbs) complete. For installation information, refer to the requisition specific
GE drawings.

Typical Two-door Controller Cabinet

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 A typical lineup for a complete Mark VI system is displayed in the following figure.
These cabinets contain controllers, I/O, and terminal boards, or they can contain just the
remote I/O and terminal boards.

Typical Mark VI Cabinet Lineup

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 5.2.1 Control Console (Example)
The turbine control HMI computers can be table-mounted, or installed in the optional
control console displayed in the following figure. The console is modular and expandable
from an 1828.8 mm version with two computers. A 5507 mm version with four
computers is displayed. The console rests on feet and is not usually bolted to the floor.

Turbine Control Console with Dimensions

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5.3 Power Requirements
The control cabinet can accept power from multiple power sources. Each power input
source (such as the dc and two ac sources) should feed through its own external 30 A
two-pole thermal magnetic circuit breaker before entering the control system enclosure.
The breaker should be supplied in accordance with required site codes.
Power sources can be any combination of 125 V dc and 120/240 V ac sources. The power
distribution hardware is configured for the required sources, and not all inputs may be
available in a configuration.
Power requirements for a typical three-bay (five-door) 4200 mm (165 in) cabinet
containing controllers, I/O, and terminal boards are shown in the following table. The
power shown is the heat generated in the cabinet, which must be dissipated. For the total
current draw, add the current supplied to external solenoids as shown in the notes below
the table. These external solenoids generate heat inside the cabinet. Heat Loss in a typical
4200 mm (165 in) TMR cabinet is 1500 W fully loaded.
For a single control cabinet containing three controllers only (no I/O), the following table
shows the nominal power requirements. This power generates heat inside the control
cabinet. Heat Loss in a typical TMR controller cabinet is 300 W.
The current draw number in the following table assumes a single voltage source, if two or
three sources are used, they share the load. The actual current draw from each source
cannot be predicted because of differences in the ac/dc converters.

Cabinet Voltage Frequency Current Draw

4200 mm 125 V dc 100 to 144 V dc (see note 5) N/A N/A 10.0 A dc (see note 1)
120 V ac 108 to 132 V ac (see note 6) 50/60 Hz ±3 Hz 10.0 A dc (see note 1)
240 V ac 200 to 264 V ac 50/60 Hz ±3 Hz 8.8 A rms (see notes 3 and 4)

Controller 125 V dc 100 to 144 V dc (see note 5) N/A N/A 1.7 A dc

120 V ac 108 to 132 V ac (see note 6) 50/60 Hz ±3 Hz 3.8 A rms
240 V ac 200 to 264 V ac 50/60 Hz ±3 Hz 1.9 A rms

Notes 1, 2, 3, and 4 are external and do not create cabinet heat load:
1. Add 0.5 A dc continuous for each 125 V dc external solenoid powered.
2. Add 6.0 A rms for a continuously powered ignition transformer (2 maximum).
3. Add 3.5 A rms for a continuously powered ignition transformer (2 maximum).
4. Add 2.0 A rms continuous for each 120 V ac external solenoid powered (inrush 10
A).
5. Supply voltage ripple is not to exceed 10 V peak-to-peak.
6. Supply voltage total harmonic distortion is not to exceed 5.0%.

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5.4 Grounding
This section defines grounding and signal-referencing practices for the control system.
This can be used to check for proper grounding and signal reference structure (SRS) after
the equipment is installed. If checking the equipment after the power cable has been
connected or after power has been applied to the cabling, be sure to follow all safety
precautions for working around high voltages.

To prevent electric shock, make sure that all power

supplies to the equipment are turned off. Then
discharge and ground the equipment before
performing any act requiring physical contact with
the electrical components or wiring. If test
equipment cannot be grounded to the equipment
Warning under test, the test equipment's case must be
shielded to prevent contact by personnel. Be sure to
follow the site LOTO and safety practices.

5.4.1 Equipment Grounding

Equipment grounding and signal referencing have two distinct purposes:

• Equipment grounding protects personnel from risk of serious or fatal electrical shock,
burn, fire, and/or other damage to equipment caused by ground faults or lightning.
• Signal referencing helps protect equipment from the effects of internal and external
electrical noise, such as lightning or switching surges.
Installation practices must simultaneously comply with all codes in effect at the time and
place of installation, and with all practices that improve the immunity of the installation.
Code requirements for safety of personnel and equipment must take precedence in the
case of any conflict with noise control practices.

Note In addition to technical regulations, guidance from IEEE Std 142-2007 IEEE
Recommended Practice for Grounding of Industrial and Commercial Power Systems, and
IEEE Std 1100-2005 IEEE Recommended Practice for Powering and Grounding
Electronic Equipment are provided by the design and implementation of the system.

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 The control system has no special or non-standard installation requirements, if installed in
compliance with all of the following:

• The NEC or local codes

• With 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.

• Ground each cabinet or cabinet lineup to the equipment ground at the source of
power feeding it.
− See NEC Article 250 for sizing and other requirements for the
equipment-grounding conductor.
− 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 SRS.
• The equipment-grounding connection for the control cabinets is plated 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.

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 5.4.2 Building Grounding System
This section provides guidelines for the building grounding system requirements. For
specific requirements, refer to NEC article 250 under the heading Grounding Electrode
System.
The guidelines below are for metal-framed buildings. For non-metal framed buildings,
consult the GE factory.
The ground electrode system should be composed of steel reinforcing bars in building
column piers bonded to the major building columns.

• A buried ground ring should encircle the building. This ring should be interconnected
with the bonding conductor running between the steel reinforcing bars and the
building columns.
• All underground, metal water piping should be bonded to the building system at the
point where the piping crosses the ground ring.
• NEC Article 250 requires that separately derived systems (transformers) be grounded
to the nearest effectively grounded metal building structural member.
• Braze or exothermically weld all electrical joints and connections to the building
structure, where practical. This type of connection keeps the required good electrical
and mechanical properties from deteriorating over time.

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 5.4.3 Signal Reference Structure
The provisions covered in this On modern equipment communicating at high bandwidths, signals are typically
document may not apply to all differential and/or isolated electrically or optically. The modern Signal Reference
installations. Structure (SRS) system replaces the older single-point grounding system with a much
more robust system. The SRS system is also easier to install and maintain.
The goal of the SRS is to hold the electronics at or near case potential to prevent
unwanted signals from disturbing operation. The following conditions must all be met by
an SRS:

• Bonding connections to the SRS must be less than 1/20 wavelength of the highest
frequency to which the equipment is susceptible. This prevents standing waves. In
modern equipment using high-frequency digital electronics, frequencies as high as
500 MHz should be considered. This translates to about 30 mm (1 in).
• SRS must be a good high-frequency conductor. (Impedance at high frequencies
consists primarily of distributed inductance and capacitance.) Surface area is more
important than cross-sectional area because of skin effect. Conductivity is less
important (steel with large surface area is better than copper with less surface area).
• 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

• Galvanized steel floor decking under concrete floors
• Woven wire steel reinforcing mesh in concrete floors
• Steel floors in pulpits and power control rooms
• Bolted grid stringers for cellular raised floors
• Steel floor decking or grating on line-mounted equipment
• Galvanized steel culvert stock
• Ferrous metallic cable tray systems
• Raceway (cableway) and raceway support systems
• Embedded steel floor channels

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 Connection of the protective earth (PE) terminal to the installation ground system must
first comply with code requirements and second provide a low-impedance path for
high-frequency currents, including lightning surge currents. This grounding conductor
must not provide, either intentionally or inadvertently, a path for load current. The system
should be designed so that there is no way possible for the control system to be an
attractive path for induced currents from any source. This is best accomplished by
providing a ground plane that is large and low impedance, so that the entire system
remains at the same potential. A metallic system (grid) will accomplish this much better
than a system that relies upon earth for connection. At the same time all metallic
structures in the system should be effectively bonded both to the grid and to each other, so
that bonding conductors rather than control equipment become the path of choice for
noise currents of all types.
In the control cabinet, the base is insulated from the chassis and bonded at one point. The
grounding recommendations, displayed in the following figure, call for the equipment
grounding conductor to be 120 mm2 (4/0 AWG) gauge wire, connected to the building
ground system. The Functional Earth (FE) is bonded at one point to the PE ground using
two 25 mm2 (6 AWG or larger) green/yellow bonding jumpers.

Grounding Recommendations for Single Control Cabinet

If acceptable by local codes, the bonding jumpers may be removed and a 4/0 AWG
identified insulated wire run from FE to the nearest accessible point on the building
ground system, or to another ground point as required by the local code.

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 The grounding method for a larger system is displayed in Figure B. Here the FE 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 bases are connected
with bolted plates.
For armored cables, the armor is an additional current carrying braid that surrounds the
internal conductors. This type cable can be used to carry control signals between
buildings. The armor carries secondary lightning-induced earth currents, bypassing the
control wiring, thus avoiding damage or disturbance to the control system. At the cable
ends and at any strategic places between, the armor is grounded to the building ground
through the structure of the building with a 360° mechanical and electrical fitting. The
armor is normally terminated at the entry point to a metal building or machine. Attention
to detail in installing armored cables can significantly reduce induced lightning surges in
control wiring.

Grounding Recommendations for Control Cabinet Lineup

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 5.4.3.1 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.
Connected equipment - Cable tray installations for connected equipment should pay
special attention to good high-frequency bonding between the cable tray and the
equipment.
Cable spacing - Maintain appropriate cable spacing between signal levels in cable drops.
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.
Embedded conduits - Bond all embedded conduits to the enclosure with multiple
bonding jumper connections following the shortest possible path.
Galvanized steel sheet floor decking - Floor decking can serve as a high-frequency
signal reference plane for equipment located on upper floors. With typical building
construction, there will be a large number of structural connections between the floor
decking and building steel. If this is not the case, then an electrical bonding connection
must be added between the floor decking and building steel. The added connections need
to be as short as possible and of sufficient surface area to be low impedance at high
frequencies.
High-frequency bonding jumpers - Jumpers must be short, less than 500 mm (20 in)
and good high-frequency conductors. Thin, wide metal strips are best with length not
more than three times width for best performance. Jumpers can be copper, aluminum, or
steel. Steel has the advantage of not creating galvanic half-cells when bonded to other
steel parts.
Jumpers must make good electrical contact with both the enclosure and the signal
reference structure. Welding is best. If a mechanical connection is used, each end should
be fastened with two bolts or screws with star washers backed up by large diameter flat
washers.
Each enclosure must have two bonding jumpers of short, random lengths. Random
lengths are used so that parallel bonding paths are of different quarter wavelength
multiples. Do not fold bonding jumpers or make sharp bends.
Metallic cable tray - System must be installed per NEC Article 318 with appropriate
signal level spacing. This serves as a signal reference structure between remotely
connected pieces of equipment. The large surface area of cable trays provides a low
impedance path at high frequencies.
Metal framing channel - Metal framing channel cable support systems also serve as
parts of the SRS. Make certain that channels are well bonded to the equipment enclosure,
cable tray, and each other, with large surface area connections to provide low impedance
at high frequencies.
Noise-sensitive cables - Try to run noise-sensitive cables tight against a vertical support
to allow this support to serve as a reference plane. Cables that are extremely susceptible
to noise should be run in a metallic conduit, preferably ferrous. Keep these cables tight
against the inside walls of the metallic enclosure, and well away from higher-level cables.
Power cables - Keep single-conductor power cables from the same circuit tightly bundled
together to minimize interference with nearby signal cables. Keep 3-phase ac cables in a
tight triangular configuration.

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 Woven wire mesh - Woven wire mesh can serve as a high-frequency signal reference
grid for enclosures located on floors not accessible from below. Each adjoining section of
mesh must be welded together at intervals not exceeding 500 mm (20 in) to create a
continuous reference grid. The woven wire mesh must be bonded at frequent intervals to
building structural members along the floor perimeter.
Conduit terminal at cable trays - To provide the best shielding, conduits containing
level L cables (see Leveling channels) should be terminated to the tray's side rails (steel
solid bottom) with two locknuts and a bushing. Conduit should be terminated to ladder
tray side rails with approved clamps.
Where it is not possible to connect conduit directly to tray (such as with large conduit
banks), conduit must be terminated with bonding bushings and bonded to tray with short
bonding jumpers.
Leveling channels - If the enclosure is mounted on leveling channels, bond the channels
to the woven wire mesh with solid-steel wire jumpers of approximately the same gauge as
the woven wire mesh. Bolt the enclosure to leveling channel, front and rear.
Solid-bottom tray - Use steel solid bottom cable trays with steel covers for low-level
signals most susceptible to noise.

Enclosure and Cable Tray Installation Guidelines

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5.5 Cable Specifications
5.5.1 General Requirements
• Maximum length (unless specified) 300 m (984.25 ft)
• Individual minimum stated wire size is for electrical needs
• Clamp-type terminals accept two 14 AWG wires or one 12 AWG wire
• Terminal blocks accept two 12 AWG wires
• PTs and CTs use 10 AWG stranded wire

Note Wires with appropriate temperature ratings must be used, especially in applications
where the internal panel ambient temperature can exceed 60°C (140 °F).

It is standard practice to use shielded cable with control equipment. Shielding provides
the following benefits:

• Generally, shielding protects a wire or combination of wires from its environment.

• Low-level signals may require shielding to prevent signal interference due to the
capacitive coupling effect between two sources of potential energy.

5.5.2 Wire Sizes

The recommended current carrying capacity for flexible wires up to 1,000 V, PVC
insulated, based on DIN VDE 0298 Part 4, is displayed in following table. Cross section
references of mm2 versus AWG are based on EN 60204 Part 1, VDE 0113 Part 1. NFPA
70 (NEC) may require larger wire sizes based on the type of wire used.

Recommended Wire Sizes

Wire Area (mm2) Wire Area Max Current Wire Size AWG
(Circular mils) (Approx. Amp) No.
0.75 1,480 15
0.82 1,618 16 18
1 1,974 19
1.31 2,585 22 16
1.5 2,960 24
2.08 4,105 29 14
2.5 4,934 32
3.31 6,532 37 12
4 7,894 42
5.26 10,381 50 10
6 11,841 54
8.36 16,499 65 8
10 19,735 73
13.3 26,248 87 6
16 31,576 98
21.15 41,740 116 4
25 49,338 129
33.6 66,310 154 2
35 69,073 158
42.4 83,677 178 1
50 98,676 198

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 Recommended Wire Sizes (continued)
Wire Area (mm2) Wire Area Max Current Wire Size AWG
(Circular mils) (Approx. Amp) No.
53.5 105,584 206 1/0
67.4 133,016 239 2/0
70 138,147 245
85 167,750 273 3/0
95 187,485 292
107 211,167 317 4/0
120 236,823 344
127 250,000 354 250 MCM
150 296,029 391
185 365,102 448
240 473,646 528
253 500,000 546 500 MCM
300 592,058 608
400 789,410 726

5.5.3 Low-voltage Shielded Cable

This section defines the minimum requirements for low-voltage shielded cable. These
guidelines should be used along with the level practices and routing guidelines provided
previously.

Note The specifications listed are for sensitive computer-based controls. Cabling for less
sensitive controls should be considered on an individual basis.

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 5.5.3.1 Single-conductor Shielded Cable, Rated 300 V
• 18 AWG minimum, stranded single-conductor insulated with minimum 85% to 100%
coverage shield
• Protective insulating cover for shield
• Wire rating: 300 V minimum
• Maximum capacitance between conductor and shield: 492 pF/m (150 pF/ft)

5.5.3.2 Multi-conductor Shielded Cable, Rated 300 V

• 18 AWG minimum, stranded conductors individually insulated per cable with
minimum 85 to 100% coverage shield
• Protective insulating cover for shield
• Wire rating: 300 V minimum
• Mutual capacitance between conductors with shield grounded: 394 pF/m (120 pF/ft)
maximum
• Capacitance between one conductor and all other conductors and grounded shield:
213 pF/m (65 pF/ft)

5.5.3.3 Shielded Twisted Pair (STP) Cable, Rated 300 V

• Two 18 AWG minimum, stranded conductors individually insulated with minimum
85 to 100% coverage shield
• Protective insulating cover for shield
• Wire rating: 300 V minimum
• Mutual capacitance between conductors with shield grounded: 394 pF/m (120 pF/ft)
maximum
• Capacitance between one conductor and the other conductor and grounded shield:
213 pF/m (65 pF/ft) maximum

5.5.3.4 Unshielded Twisted Pair (UTP) Cable (for Data

Highways and IONet)
• High-quality, category 5e UTP cable, for 10/100Base-TX Ethernet
• Four pairs of twisted 22 AWG or 24 AWG wire
• Protective plastic jacket
• Impedance: 75 – 165 Ω
• Connector: RJ45 UTP connector for solid wire

5.5.3.5 Serial Modbus RS-232C Communications

• Serial Modbus communication from the Mark VI control system HMI for short
distances use RS-232C cable; for distances over 15 m (49.21 ft) add a modem
• Serial Modbus communication from the UCCA 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 (49.21 ft), add a modem.

5.5.3.6 Instrument Cable, 4 – 20 mA

• With Tefzel® insulation and jacket: Belden® catalog no. 85231 or equivalent
• With plastic jacket: Belden catalog no. 9316 or equivalent

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 5.5.3.7 Fiber-optic Cable, Outdoor Use (Data Highways)
• Multi-mode fiber, 62.5/125 µ core/cladding, 850 nm infrared light
• Four sub-cables with elastomeric jackets and aramid strength members, and plastic
outer jacket
• Cable construction: flame retardant pressure extruded polyurethane. Cable diameter:
8.0 mm (0.31 in). Cable weight: 65 Kg/km
• Optical Cable Corporation part number: RK920929-A

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 eye damage.
Warning

5.5.3.8 Fiber-optic Cable, Heavy Duty Outdoor Use

• Multi-mode fiber, 62.5/125 µ core/cladding, 850 nm infrared light
• Four sub-cables with elastomeric jackets and aramid strength members, and armored
outer jacket
• Cable construction: flame retardant pressure extruded polyurethane. Armored with
0.155 mm (0.01 in) steel tape, wound with 2 mm (0.08 in) overlap, and covered with
polyethylene outer jacket, 1 to 1.5 mm (0.04 to 0.06 in) thick. Cable diameter: 13 mm
(0.51 in). Cable weight: 174 Kg/km
• Optical Cable Corporation part number: RK920929-A-CST

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 5.5.3.9 Fiber-optic Cable, Indoor Use (Data Highways)
• Multi-mode fiber, 62.5/125 µ core/cladding, 850 nm infrared light
• Twin plastic jacketed cables (Zipcord) for indoor use
• Cable construction: tight-buffered fibers surrounded by aramid strength members
with a flexible flame retardant jacket. Cable dimensions: 2.9 mm (0.11 in) diameter x
5.8 mm (0.23 in) width. Cable weight: 15 Kg/km
• Corning Cable Systems part number: 002K58-31141–24

Media converters should not be used on the network

to convert between copper and fiber media because
they use a store and forward type of mechanism that
introduces time delays into the packet transmission.
This would cause a deviation from system design
Attention assumptions and possibly result in erratic network
operation.

5.5.3.10 Single-mode Fiber-optic Cable (SMF), Indoor Use

(UDH Only)
• Single-mode fiber-optic cable is validated for use on the UDH network.
• SMF cable lengths can be zero to 15 km (9.32 mi) in length.
• SMF cables MUST be terminated and/or spliced by a certified fiber-optic cable
installer. SMF cable CANNOT be terminated and/or spliced by installations
engineers.
• SMF cables are 8.3/125 µm Core/Cladding diameter with a numeric aperture of 0.13.
• Optical Cable Corporation part numbers: OC041214-01, -02, -03, and -04.

5.5.4 Coaxial Cable RG-58/U (for IONet and UDH)

• 20 AWG stranded tinned copper conductor with FEP insulation with a 95% coverage
braid shield
• Protective Flamarrest™ insulating jacket for shield
• Normal attenuation per 30.48 m (100 ft): 4.2 dB at 100 MHz
• Nominal capacitance: 50.5 pF/m (25.4 pF/ft)
• Nominal impedance: 50 ohms
• Example supplier: Belden Coax Cable part no. 82907

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5.6 Connecting the System
The panels come complete with the internal cabling. This cabling will probably never
need to be replaced. I/O cables between the control modules and interface modules and
the I/O racks are run in plastic racks behind the mounting plates as displayed in the
following figure.
Power cables from the Power Distribution Module to the control modules, interface
modules, and terminal boards are secured by plastic cable cleats located behind the riser
brackets. Mounting brackets and plates cover most of this cabling.

Cable Trays and Mounting Brackets for Terminal Boards

In the following figure, the top diagram displays the routing of the I/O cables and power
cables in a typical 1600 mm cabinet line-up. Dotted outlines indicate where terminal
boards and I/O modules will be mounted on top. These cables are not visible from the
front. The bottom diagram displays the routing of the cables and customer field wiring to
the I/O modules and terminal boards. This wiring is visible and accessible from the front
so that boards and field wiring can be replaced.

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 Typical Cabinet Wiring and Cabling

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 5.6.1 I/O Wiring
I/O connections are made to terminal blocks on the control system terminal boards.
Shielding connections to the shield bar located to the left of the terminal board are
displayed in the following figure.

I/O Wiring Shielding Connections to Ground Bar at Terminal 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 cabinet. 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 instances, shields should not be connected at the far
end of the cable, to avoid circulating power-frequency currents induced by pickup.
A small capacitor can be used to ground the far end of the shield, producing a hybrid
ground system, improving 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.

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 5.6.2 Terminal Block Features
Many of the terminal boards in These terminal blocks have the following features:
the Mark VI control use a
• Made from a polyester resin material with 130°C (266 °F) rating
24-position pluggable barrier
terminal block (173C9123BB). • Terminal rating is 300 V, 10 A, UL class C general industry, 0.375 in (9.525 mm)
creepage, 0.250 in (6.35 mm) strike
• UL and CSA code approved
• Screw size used is 6-32
• Opening width .32"
• Screws finished in zinc clear chromate and contacts in tin
• Each block screw is number labeled 1 through 24 or 25 through 48 in white
• Recommended screw tightening torque is 8 in lbs (0.92 Nm)

5.6.3 Power System

The DS200TCPD board in the The 125 V dc supply must be installed and maintained such that it meets requirements of
PDM must provide the single, IEC 61010-1 cl. 6.3.1 to be considered Not Hazardous Live. The BJS berg jumper must
monitored, ground reference be installed in the PDM to provide the monitored ground reference for the 125 V dc. If
point for the 125 V dc system. there are multiple PDMs connected to the dc mains, only one has the Berg jumper
Refer to section, Wiring and installed. If the dc mains are connected to a 125 V dc supply (battery) it must be floated,
Circuit Checks. that is isolated from ground.

5.6.4 Installing Ethernet

Refer to Networks and The Mark VI modules communicate over several different Ethernet LANs. IONet uses
Communications. Ethernet 10Base2 cable. The data highways use a number of 10BaseT segments, and
some 10Base2 segments and fiber-optic segments. 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 equipment manufacturer.

5.6.4.1 Installing Ethernet 10Base2 Coax Cable for IONet

10Base2 cable (Thinwire™) is a 20 AWG copper-centered wire used for connecting the
interface modules and control modules. Use the following guidelines when installing
10Base2:

• Maximum length of a 10Base2 coax cable segment is 185 m (610 ft)

• Both ends of each segment should be terminated with a 50 Ω resistor
• All connectors and terminators must be isolated from ground to prevent ground loops
(grounding of shield controlled by Mark VI boards)
• Maximum length of cable is 925 m (3035 ft) using the IEEE 5-4-3 rule
• Maximum length of a transceiver and repeater cable is 50 m (164 ft)
• Minimum distance between transceivers is 2.5 m (8.2 ft)
• Maximum device connections (taps) per segment is 100, including repeater taps
• In systems with repeaters, transceivers should have the SQE test (heartbeat) switch
disabled

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 5.6.4.2 Preventing Reflections
Cables of non-standard length Short segments should have no breaks with 50 Ω terminations on both ends. This
produce impedance produces minimal reflections from cable impedance discontinuities.
mismatches that cause signal A coaxial barrel nut connector is used to join smaller segments. However, the joint
reflections and possible data
between the two segments makes a signal reflection point. This is caused by impedance
loss.
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.
IEEE standard segment lengths are:
23.4 m (76.75 ft)
117 m (383.76 ft)
70.2 m (230.25 ft)
500 m (1640 ft)
These standard sections can be used to build a cable segment up to 500 m (1640 ft) long.
To prevent excessive reflections, the segment should be an odd multiple of 23.4 m (76.75
ft) lengths. For example:
3 x 23.4 m (or 3 x 76.75 ft)
7 x 23.4 m (or 7 x 76.75 ft)
9 x 23.4 m (or 9 x 76.75 ft)
These lengths are odd integral multiples of a half wavelength in the cable at 5 MHz. Any
mix of these cable sections (only) can be used.

Ethernet Cable Component Descriptions

Component Description Part Number

10Base2 Connector Connector for Ethernet 10Base2 trunk ThinWire BNC coax connector with gold-plated pin,
coax cable MilesTek catalog no. 10-02001-233
BNC F-Adapter, MilesTek catalog no. 10-02918
BNC Goal Post Adapter, MilesTek catalog no.
10-02914
10Base2 Terminator BNC terminator for Ethernet trunk coax cable, MilesTek catalog no. 10-02406-009
50 Ω
10Base2 Connection Quick crimp tool kit for crimping connectors on MilesTek catalog no. 40-50156/GE
Tools Ethernet trunk 10Base2 coax cable, including
strip tool, flush cutter, and case.

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5.7 Startup Checks
All control system panels have cables pre-installed and factory-tested before shipment.
However, final checks should be made after installation and before starting the
equipment.

This equipment contains a potential hazard of

electrical shock or burn. Power is provided by the
control system to various input and output devices.
External sources of power may be present in the
control system that are NOT switched by the control
power circuit breaker(s). Before handling or
Warning connecting any conductors to the equipment, use
proper safety precautions to ensure all power is
turned off.

Inspect the cabinet components for any damage possibly occurring during shipping.
Check for loose cables, wires, connections, or loose components, such as relays or
retainer clips. Report all damage that occurred during shipping to GE Product Service.

5.7.1 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.
• Verify the Berg jumpers on each I/O board are set correctly for the slot number in the
VME rack. If the boards do not have Berg jumpers, the VCMI identifies all the I/O
boards during startup by communication over the VME backplane. At this point, do
not reconnect the I/O boards. This will be done after the rack power supply check.
• Check the EMI spring-gasket shield on the right hand side of the board front. If the
installed boards do not have EMI emissions shielding, and a board with a shield
gasket is present, remove this gasket by sliding it out vertically. Failure to do this
could result in a damaged board.

ID Jumper Positions on VME Board

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 EMI Emissions Shield Gasket

• Check wire harnesses and verify they are securely connected.

• Verify that the terminal board hardware jumpers match the toolbox configuration
settings, and move the jumper(s) if necessary.
• Verify all plug-in relays are firmly inserted into their sockets (refer to Volume II of
the system guide). Verify the jumpers on TRLY are removed.
• Check the Ethernet ID plug located at the left side of the rack under the power test
points. The jumpers on this plug define the number of the rack (0, 1, 2, 3) in the
IONet channel. The jumper positions are displayed in the following figure.

Rack Ethernet ID Plug

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 Ethernet ID Plug Jumper Positions
Conn. Connector Pins Pins Pins Pins Pins Pins Pins Pins Notes
P/N Label 1-2 3-4 5-6 7-8 9-10 11-12 13-14 15-16
10 R0-SMP X X X X X X
11 R1 X X X X X
12 R2 X X X X X
13 R3 X X X X
14 R4 X X X X X
15 R5 X X X X
16 R6 X X X X
17 R7 X X X
18 R8 X X X X X
19 R9 X X X X
20 R10 X X X X
21 R11 X X X
22 R12 X X X X
23 R13 X X X
Future
28 R0-DPX X X X X X X
29 R0-TPX X X X X X
30 R0-TMR X X X X X X X
Future
40 S0-SMP X X X X X X
41 S1 X X X X X
42 S2 X X X X X
43 S3 X X X X
44 S4 X X X X X
45 S5 Future
46 S6 Future
47 S7 Future
48 S8 X X X X X Future
Future
60 S0-TMR X X X X X X X
Future
70 T0-SMP X X X X X
71 T1 X X X X
72 T2 X X X X
73 T3 X X X
74 T4 X X X X
75 T5 Future
76 T6 Future
77 T7 Future
78 T8 X X X X
Future
90 T0-TMR X X X X X X

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 5.7.2 Wiring and Circuit Checks
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,
Warning operate, or maintain this equipment.

The following steps should be completed to check the cabinet wiring and circuits.

➢ To check the power wiring

1. Check that all incoming power wiring agrees with the supplied elementary drawings.
2. Make sure that the incoming power wiring conforms to approved wiring practices.
3. Check that all electrical terminal connections are tight.
4. Make sure that no wiring has been damaged or frayed during installation. Replace if
necessary.
5. Check that incoming power (125 V dc, 115 V ac, 230 V ac) is the correct voltage and
frequency, and that it is clean and free of noise. Make sure the ac to dc converters, if
used, are set to the correct voltage (115 or 230 V ac) by selecting the JTX1 or JTX2
jumper positions on the front of the converter.
6. If the installation includes more than one PDM on an interconnected 125 V dc
system, the BJS jumper must be installed in one and only one PDM. This
arrangement is required because the parallel connection of more than one ground
reference circuit will reduce the impedance to the point where the 125 V dc no longer
meets the Not Hazardous Live requirement.
To verify that the 125 V dc is properly grounded, a qualified person using appropriate
safety procedures should make tests. Measure the current from first the P125 V dc, and
then the N125 V dc, using a 2000 Ω, 10 W resistor to the protective conductor terminal of
the Mark VI in series with a dc ammeter. The measured current should be 1.7 to 2.0 mA
(the tolerance will depend on the test resistor and the PDM tolerances). If the measured
current exceeds 2.0 mA, the system must be cleared of the extra ground(s). A test current
of about 65 mA, usually indicates one or more hard grounds on the system, while currents
in multiples of 1 mA usually indicate more than one BJS jumper is installed.

Note At this point, the system is ready for initial powerup.

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5.8 Startup and Configuration
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,
Warning operate, or maintain this equipment.

It is recommended that the Assuming all the above checks are complete, use the following steps to apply power, load
initial rack powerup be done the application code, and startup the Mark VI system.
with all the I/O boards
➢ To energize the rack for the first time
disconnected from the VME
rack backplane to check the 1. Unlock the I/O boards and slide them part way out of the racks.
power supply in an unloaded
2. Apply power to the PDM and to the first VME I/O rack power supply.
condition.
3. Check the voltages at the test points located at the lower left side of the VME rack.
These are displayed in the following figure.
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 displaying
normal operation in the RUN condition.
6. Repeat steps 1 through 5 for all other VME racks.

VME Rack Power Supply Test Points

If the system is a remote I/O system, the controller is in a separate rack. 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.

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 5.8.1 Topology and Application Code Download
Network topology defines the location of the control and interface modules (racks) on the
IONet network, and is stored in the VCMI.

Note If you have a new controller, before application code can be downloaded, the
TCP/IP address must be loaded. Refer to GEH-6403, Control System Toolbox for a Mark
VI .

➢ To download topology and application code

1. From the toolbox Outline View, right-click the first VCMI (R0).
2. From the shortcut menu, select Download. The network topology configuration
downloads to the master VCMI in the first controller rack and now knows the
location of the Interface Modules (R0, R1, R2, ...).
3. Repeat for all the master VCMIs in the controller racks S, and T.
4. Cycle power to reboot all three controllers. The controllers reboot and initialize their
VCMIs. The VCMIs expect to see the configured number of racks on IONet. If an
Ethernet ID plug does not identify a rack, communication with that rack is not
possible. Similarly if a VCMI is not responding, communication with that rack is not
possible. The VCMI will work even if there are no I/Oin its rack.
5. Following the above procedure, download the network topology to the slave VCMI
in the I/O racks (R1, R2, R3 ...). The VCMI now knows what I/O boards are in its
rack. Download to each rack in turn, or all racks at once.
6. Cycle power to reboot all racks.
7. Download the I/O configuration to all the I/O boards, one at a time or all at once.
With all racks running, check the I/O.

5.8.2 Online Download

When there are minor changes to the application code, the new code can be downloaded
online using the toolbox. The advantage of online downloading is that it does not require
restarting the controller (as in an offline download); the controllers continue to operate
during and after the online download. The code is downloaded both to memory and
storage.

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 5.8.2.1 Download Prerequisites
Before downloading new code, adhere to the following prerequisites to support continued
turbine operation after the new code is downloaded.

• Diagnostic Messages and Alarms–Check the controller for diagnostic messages and
alarms and do not download new code if any exist. Resolve and clear all diagnostic
messages and before downloading. Otherwise, the download may not proceed
properly and cause the system to trip.

Note If conditions warrant downloading with existing diagnostic messages and alarms,
record and examine every alarm message for potential failure modes and incident
recovery after the controllers are powered up with the new code.

• Code Compatibility –Verify that the new code is compatible with the existing code
and TMR interface to prevent inadvertent trips after the new code has been
downloaded.
• Review TMR Test – Each time new code is downloaded, the TMR system must be
tested online to verify that the new code is compatible, operates the system properly,
and maintains TMR capability. Before beginning, review the records from the last
TMR test from the previous download.

5.8.2.2 Performing an Online Download

➢ To perform an online download
1. Refer to section, Download Prerequisites and verify that these requirements have
been met.
2. From the toolbox, select the Device menu, then select Download, Application
Code
or
Click the Download Application Code button. The Download Application
Code dialog box displays. The Download to Memory option and Download to
Storage option are already checked by default indicating that the application code
will be downloaded to memory and storage.
3. Click OK.
4. Perform the TMR Test from the procedures in the following section, Post-Download
TMR Test.

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 5.8.3 Offline Download
When there are major changes to the application code, the new code must be downloaded
offline using the toolbox. An offline download consists of making a build image of the
code, downloading the code, restarting the controller, and testing the TMR. The code is
downloaded to storage.

➢ To perform an offline download

1. Refer to section, Download Prerequisites and verify that these requirements have
been met.
2. From the toolbox, select the Device menu, then select Download, Application
Code
or
Click the Download Application Code button. The Download Application
Code dialog box displays. The Download to Memory option and Download to
Storage option are already checked by default indicating that the application code
will be downloaded to memory and storage.
3. Click OK.
4. Perform the TMR Test from the procedures in the section, Post-Download TMR Test.

5.8.4 Post-Download TMR Test

After downloading new code, test the TMR System online again to verify that the new
code is compatible, operates the system properly, and maintains TMR capability. This test
is required to assure online serviceability for continued system operation and trip
reliability and prevent inadvertent hardware failures.
Prior to performing TMR testing, verify that the system is:

• Clear of all alarm messages

• Operational and could trip after a fault

➢ To perform the TMR test

1. Power down one controller/protective module at a time from the PDM. For R0, S0,
T0, R8, S8, T8, and optional R7, S7, and T7 processors, power down one at a time in
random order.
2. Wait 10 seconds, then power back up.
3. Wait for the processor to go back online.
4. Check for alarm messages.
5. Verify that there are no messages requesting a trip condition. Clear all alarm
messages.
6. Once the system returns online, wait five minutes before powering down the next
processor.

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 5.8.5 Offline While System Online
Problem: After multiple online code downloads without TMR testing on previous
downloads, including those with EGD page differences, one controller (usually R) may
remain offline while the other two controllers are online.
Corrective Action:

• Check and correct field wiring problems.

• Check the controller.
• Check compatibility of the application code with the TMR function.
• If there are no field wiring or code incompatibility problems, perform the following
recovery procedure (which will keep the system running and protected):

➢ To perform the recovery procedure

1. Power down the controller that is offline.
2. Download code to permanent storage as well as to memory of the powered-down
controller.
3. Perform the TMR test as instructed in the section, Post-Download TMR Test.
4. Power up the controller. This controller should now come online with the other two
controllers, running the new downloaded code that is compatible with the old code on
the other two controllers.
5. Allow the restored online controller to run at least five minutes.
6. Verify that there are no diagnostic messages or alarms.
7. Repeat this recovery procedure, then download the new code to just one of the
remaining two controllers.
8. Wait another five minutes before going online, then repeat the above procedure for
the remaining controller. If the application code is TMR-capable, and all the field
wiring is correct, the unit will remain running and be protected.

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 5.8.6 Offline Trip Analysis
Problem: System tripped – the usual cause is an application code issue (since the standard
product has passed TMR testing).
Corrective Action:
1. Review all alarm and trip logs.
2. If trip logs are unavailable, use the Trend Recorder to upload the individual capture
block data from the controllers as follows:
a. From toolbox, select the File menu and New.
b. From the Utilities List, select Trend Recorder.
c. From the Trend Recorder, select the Edit menu and Configure. The Trend
Recorder dialog box displays.
d. Under Trend Type, select Block Collected.
e. Select the Block Collected device and Capture Buffer.
f. Select each signal and upload.
As a result, approximately five trend files will be produced per controller.
3. Analyze the trip to determine the cause.
4. Correct the cause of the trip.

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6 Tools and System Interface
This chapter summarizes the tools used for configuring, loading, and operating the Mark
VI system. These include the Control System Toolbox (toolbox), Mark VI control system
HMI with CIMPLICITY operator interface, and the Turbine Historian.

6.1 Toolbox
Refer to GEH-6403, Control The toolbox is Windows®-based software for configuring and maintaining the Mark VI
System Toolbox for a Mark VI control system. The software usually runs on an engineering workstation or HMI located
Controller. on the PDH.
IONet communicates with all the control and interface racks. This network topology is
configured using the toolbox. Similarly, the toolbox configures all the I/O boards in the
racks and the I/O points in the boards. the following figure displays the toolbox screen
used to select the racks.
The Outline View on the left side of the screen is used to select the racks required for the
system. This view displays all the racks inserted under Mark VI I/O. In the example, three
TMR Rack 0s are included under the heading Rack 0 Channel R/S/T (TMR).

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 Configuring the Equipment Racks

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 6.1.1 Configuring the Application
The turbine control application is configured in the toolbox using graphically connected
control blocks, which display in the Summary View. These blocks consist of basic analog
and discrete functions and a library of special turbine control 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. The turbine block library contains more than 150 additional blocks
relating to turbine control applications.
The control system is configured in the toolbox work area, as displayed in the following
figure. The Outline View on the left side of the screen displays the control device. 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 a signal 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.

Connecting Control Blocks in the Work Area

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6.2 Human-machine Interface
The HMI is the main operator interface to the Mark VI turbine control system. The HMI
is a computer with a Windows operating system and CIMPLICITY graphics user
interface (GUI), communicating with the controllers over Ethernet.
Refer to the following documentation:

• GEH-6126, HMI Application Guide

• GFK-1180, CIMPLICITY HMI for Windows NT and Windows 95 User's Manual
• GFK-1396 CIMPLICITY HMI for Windows NT and Windows 95 CimEdit Operation
Manual (how to configure the graphic screens)

6.2.1 Basic Description

The Mark VI HMI consists of three distinct elements:
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 provides device
communication for both internal and external data interchanges.
System 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. The database is used
for system configuration, but not required for running the system.
HMI viewer provides the visual functions, 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, as well as issue commands, edit control
coefficient values, and obtain system logs and reports.

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 Depending on the size of the system, these three elements can be combined into a single
computer, or distributed in multiple units. The modular nature of the HMI allows units to
be expanded incrementally as system needs change. A typical Viewer screen using
graphics and real-time turbine data is displayed in the following figure. In the graphic
display, special displays can be obtained using the buttons in the column on the right side.
Also note the setpoint button for numeric entry and the raise/lower arrows for opening
and closing valves.

Interactive Operator Display for Steam Turbine and Generator

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 6.2.2 Product Features
The HMI contains a number of product features important for power plant control:

• Dynamic graphics
• Alarm displays
• Process variable trending
• Point control display for changing setpoints
• Database logger
• HMI access security
• Data Distribution Equipment (DDE) application interface
The graphic system performs key HMI functions and provides the operator with real time
process visualization and control using the following:
CimEdit is an object-oriented program that creates and maintains the users graphic
screen displays. Editing and animation tools, with the familiar Windows environment,
provide an intuitive, easy to use interface. Features include:

• Standard shape library

• OLE
• Movement and rotation animation
• Filled object capabilities, and interior and border animation
Optional features include the CimView is the HMI runtime portion, displaying the process information in graphical
Web Gateway that allows formats. In CimView the operator can view the system screens, and screens from other
operators to access HMI data applications, using OLE automation, run scripts, and get descriptions of object actions.
from anywhere in the world Screens have a one-second refresh rate, and a typical graphical display that takes only one
over the Internet. second to repaint.
Alarm Viewer provides alarm management functions, such as sorting and filtering by
priority, by unit, by time, or by source device. Also supported are configurable alarm field
displays, and embedding dynamically updated objects into CimView screens.
Third-party interfaces allow Trending, based on ActiveX® technology, gives users data analysis capabilities. Trending
the HMI to exchange data with uses data collected by the HMI, or data from other third-party software packages or
DCS systems, PLCs, I/O interfaces. Trending includes multiple trending charts per graphic screen with unlimited
devices, and other computers. pens per chart, and the operator can resize or move trend windows to convenient locations
on the display.
Point control panel is a right-click menu, which is normally used during troubleshooting
to access variables for trends and watch windows.
The basic control engine allows users to define control actions in response to system
events. A single event can invoke multiple actions, or one action can be invoked by many
events. The program editor uses a Visual Basic for Applications compliant programming
language.

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6.3 Computer Operator Interface
Refer to GEH-6403, Control The Computer Operator Interface (COI) consists of a set of product and application
System Toolbox for a Mark VI specific operator displays running on a small cabinet computer (10.4 or 12.1 inch touch
Controller. screen) hosting the embedded Windows operating system. This operating system uses
only the components of the operating system required for a specific application. This
results in all the power and development advantages of a Windows operating system.
Development, installation or modification of requisition content requires the GE Control
System Toolbox (toolbox).
The COI can be installed in many different configurations, depending on the product line
and specific requisition requirements. For example, it can be installed in the cabinet door
for Mark VI applications or in a control room desk for Excitation Control System
applications. The only cabling requirements are for power and for the Ethernet connection
to the UDH. Network communication is through the integrated auto-sensing 10/100BaseT
Ethernet connection. Expansion possibilities for the computer are limited, although it does
support connection of external devices through FDD, IDE, and USB connections.
The networking of the COI to The COI can be directly connected to the Mark VI or Excitation Control System, or it can
the Mark VI control is be connected through an EGD Ethernet switch. A redundant topology is available when
requisitioned or the controller is ordered with a second Ethernet port.
customer-defined.

6.3.1 Interface Features

Refer to GEI-100434, Numeric data displays are driven by EGD pages transmitted by the controller. The refresh
Computer Operator Interface rate depends both on the rate at which the controller transmits the pages, and the rate at
(COI) for Mark VI or EX2100 which the COI refreshes the fields. Both are set at configuration time in the toolbox.
control systems.
The COI uses a touch screen, and no keyboard or mouse is provided. The colors of
push-buttons are feedbacks and represent state conditions. To change the state or
condition, press the button. The color of the button changes, if the command is accepted
and the change is implemented by the controller.
Numeric inputs on the COI touch screen are made by touching a numeric field that
supports input. A numeric keypad then displays and the desired number can be entered.
An Alarm Window is provided and an alarm is selected by touching it. Then Ack,
Silence, Lock, or Unlock the alarm by pressing the corresponding button. Multiple alarms
can be selected by dragging through the alarm list. Pressing the button then applies to all
selected alarms.

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6.4 GE Historian
The Historian is a data archival system based on client-server technology. This 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 BoP process data. Flexible tools enable the
operator to quickly generate custom trends and reports from the archived process data.
The Historian combines high-resolution digital event data from the turbine controller with
process analog data, creating a sophisticated tool for investigating cause-effect
relationships.

6.4.1 System Configuration

The Historian provides historical data archiving and retrieval functions. When required,
the system architecture provides time synchronization to ensure time coherent data.
Turbine controller data is accessed through the UDH as displayed in the following figure.

Data Transmission to the Historian and HMI

Additional Historian data acquisition is performed through Modbus and/or Ethernet-based
interfaces. Data from devices such as Bently Nevada* condition monitors, or third-party
programmable logic controllers (PLCs) is usually obtained through Modbus, while
Ethernet is the preferred communication channel for GE Intelligent Platforms PLC
products. The HMI and other operator interface devices communicate to the Historian
through the PDH. Network technology provided by the Windows 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.

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 6.4.2 System Capability
The Historian provides an Packages of 1,000, 5,000, or 10,000 point tags* can be configured and collected from
online historical database for multiple process controllers. A typical turbine control application uses less than 1,000
collecting and storing data points of time-tagged analog and discrete data per unit. The length of time that the data is
from the control system. stored on disk, before offline archiving is required, depends upon collection rate,
dead-band configuration, process rate of change, and the disk size.

6.4.3 Data Flow

Historian Main Functions
Function Description
Data collection Data is collected over the UDH and Modbus
Data storage Stored in the Exception database for SOE, events, and alarms
Stored in the archives for analog and Boolean values
Data retrieval Data can be retrieved through a web browser or a standard trend
screen

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Notes

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7 Maintenance and Diagnostics
This chapter discusses board maintenance and component replacement, alarm handling,
and troubleshooting in the Mark VI control system. The configuration of process alarms
and events is described, and also the creation and handling of diagnostic alarms caused by
control system equipment failures.

7.1 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,
Warning operate, or maintain this equipment.

Do not use compressed air to clean the boards. The

compressed air may contain moisture that could
combine with dirt and dust and damage the boards.
If the compressed air pressure is too strong,
components could be blown off the boards or
Caution delicate solder runs could be damaged.

Note For replacement of modules and boards for nuclear applications refer to
GEI-100657, Mark VI Maintenance Procedures for Replacing Circuit Boards on Nuclear
Lineups.

7.1.1 Modules and Boards

Return the failed board to GE The Mark VI control system should be inspected every 30,000 hours (3.4 years) to ensure
for repair. Do not attempt to the components are functioning properly. This inspection should include, but not be
repair it on site. limited to, terminal boards, VME boards, and cables.
After long service in a very dirty environment, the terminal boards and VME boards
should be cleaned. Remove dirt and dust using a grounded, natural bristle drapery brush.
A grounded, natural bristle paintbrush could also be used.
To clean cables, disconnect them from terminal boards and modules. A damp, lint free,
cotton cloth works best.

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7.2 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,
Warning operate, or maintain this equipment.

7.2.1 Replacing a Controller

➢ To replace and reload the UCVx
1. If a controller has failed, powered down the rack and disconnect all cables from the
controller panel.
2. Loosen the top and bottom screws on the controller board.
3. Use the upper and lower ejector tabs to disengage the controller from the backplane.
4. Remove the controller and replace it with a spare controller.
5. Use the upper and lower ejector tabs to install the new controller.
6. Tighten the top and bottom screws to secure the controller to the VME rack.
7. Connect the serial loader cable between the computer and COM1 of the controller.
a. If the controller is a UCVB or UCVD, use the serial loader to download the flash
file system to the controller
b. If the controller is a UCVE or later, use the compact flash programmer to
download the flash file system. (The programmer is included in the service kit)
c. Use Toolbox to download the compact flash.
8. Use the serial loader to configure the controller with its TCP/IP address.
9. Reconnect the Ethernet cable to the controller and power up the rack.
10. Use the Toolbox to download runtime to the controller.
11. Use the Toolbox to download application code, to permanent storage only, in the
controller.
12. Power down the rack.
13. Power up the rack.

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 7.2.2 Replacing a VCMI
➢ 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. Loosen the top and bottom screws on the VCMI or VPRO board.
3. Use the upper and lower ejector tabs to disengage the controller from the backplane
4. Remove the VCMI and replace it with a spare VCMI.
5. Use the upper and lower ejector tabs to install the new VCMI or VPRO board.
6. Tighten the top and bottom screws to secure the new VCMI or VPRO to the VME
rack.
7. Power on the VME rack.
8. From the toolbox Outline View, under item Mark VI I/O, locate the failed rack.
Locate the VCMI, which is usually under the simplex rack, and right-click the
VCMI.
9. From the shortcut menu, click Download. The topology downloads into the new
board.
10. Cycle power to the rack to establish communication with the controller.

7.2.3 Replacing an I/O Board in an Interface Module

➢ To replace an I/O Board
1. Power down the interface VME rack.
2. Loosen the top and bottom screws on the I/O board.
3. Use the upper and lower ejector tabs to disengage the controller form the backplane.
4. Replace the board with a spare board of the same type, first checking that the jumper
positions match the slot number (the same as the old board).
5. Use the upper and lower ejector tabs to install the new I/O board.
6. Tighten the top and bottom screws to secure the new I/O board to the VME rack.
7. Power up the rack.
8. From the toolbox Outline View, under item Mark VI I/O, locate the failed rack.
Find the slot number of the failed board and right-click the board.
9. From the shortcut menu, click Download. The board configuration downloads.
10. Cycle power to the rack to establish communication with the controller.

Note Newer I/O boards do not have Berg jumpers.

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 7.2.4 Replacing a Terminal Board
The terminal boards do not contain software requiring reload, but some have power
supplied to them.

This equipment contains a potential hazard of

electric shock or burn. Power is provided by the
Mark VI control cabinet to various input and output
devices. External sources of power may be present
in the Mark VI cabinet that are NOT switched on or
of by the control power circuit breaker(s). Before
handling or connecting any conductors to the
equipment, use proper safety precautions to ensure
all power is turned off. To minimize risk of personal
injury, damage to the control equipment, or damage
Warning to the controlled process, it is recommended that all
power to a terminal board be removed before
replacement of the terminal board. Most terminal
boards are supplied from all three power supplies of
a TMR system as well as multiple external sources
and therefore may require shutdown of the turbine
before replacement is made.

➢ To replace a terminal board

1. Disconnect any power cables coming into the terminal board, and unplug all the I/O
cables (J-plugs).
2. Loosen the two screws on the wiring terminal blocks and remove the blocks. Tie off
to the side, if necessary, leaving the field wiring attached.
3. Remove the failed terminal board by removing the mounting screws.
4. Replace it with a spare board, checking that any jumpers are set correctly (the same
as the old board).
5. Securely tighten the terminal board mounting screws.
6. Screw the terminal blocks back in place and plug in the J-plugs and the power cables.

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 7.2.5 Cable Replacement
The I/O cables are supported in plastic brackets behind the back base and the power
cables (125 V dc) in cablecleats behind the mounting panels. Since these brackets are not
continuous, it is not recommended that the replacement cable be pulled through behind
the back bases. It is recommended the new cables be run across the top or bottom of the
back base and down the side of the I/O wiring trough to the module power supply.

➢ To replace an I/O cable or power cable

1. Power down the interface module and disconnect the failed cable from the module.
Leave the cable in place. Do not remove the failed cable from the enclosure.
2. Disconnect the failed cable from the terminal board.
Additional required cables for 3. Connect the replacement cable to the terminal board, and lay the new cable in the
system expansion are installed field-wiring trough at the side of the I/O terminal boards. Use space at the top and
in the same way. bottom of the cabinet to run the cable across the cabinet to the interface module.
4. Connect the cable to the interface module and power up the module. Secure the cable
in place with tie wraps.

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7.3 Alarm Overview
Three types of alarms are generated by the control system:
Process alarms are caused by machinery and process problems. They alert the operator
through messages on the HMI screen. The alarms are created in the controller using alarm
bits generated in the I/O boards or in sequencing. The user configures the desired analog
alarm settings in sequencing using the current toolbox application. As well as generating
operator alarms, the alarm bits in the controller can be used as interlocks in the
application program.
Hold list alarms are similar to process alarms; additionally the scanner drives a specified
signal, True, whenever any hold list signal is in the alarm state (hold present). This signal
is used to disable automatic turbine startup logic at various stages in the sequencing.
Operators may override a hold list signal so that the sequencing can proceed even if the
hold condition has not cleared.
Diagnostic alarms are caused by controller equipment problems and have configurable
settings in the boards. Diagnostic alarms identify the failed module helping the service
engineer quickly repair the system.

Three Types of Alarms Generated by The Controller

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7.4 Process Alarms
Hold alarms are managed in Process alarms are generated by the transition of Boolean or analog signals configured by
the same way, but are stored in the toolbox application with the alarm attribute. The signals are driven by sequencing or
a separate queue. Additionally, tied to input points to map values directly from I/O boards. Process alarm signals are
hold alarms cannot be locked scanned during each frame after the sequencing is run. In TMR systems, process signals
but can be overridden. are voted and the resulting composite is present in each controller.
The operator or the controller Process and hold alarms are time stamped and stored in a local queue in the controller.
can take action based on Changes representing alarms are time stamped and sent to the alarm queue. Reports
process alarms. containing alarm information are assembled and sent over the UDH to the HMIs. Here the
alarms are again queued and prepared for operator display by the alarm viewer.
Operator commands from the HMI, such as alarm Acknowledge, Reset, Lock, and
Unlock, are sent back over the UDH to the alarm queue where they change the status of
the appropriate alarms. An alarm entry is removed from the controller queue when it has
returned to normal and has been acknowledged by an operator.
Process alarms can also be created by having the WorkstationST scan variables and create
alarms. This is useful when alarms need to be created from data coming from third party
equipment.
A useful application for process alarms is the annunciation of system limit-checking.
Limit-checking takes place in the I/O boards at the frame rate, and the resulting Boolean
status information is transferred to the controller and mapped to process alarm signals.
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.

Note To configure the alarm scanner on the controller, refer to GEH-6403, Control
System Toolbox for Mark VI Controller. To configure the controller to send alarms to all
HMIs, use the UDH broadcast address in the alarm IP address area.

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 Controller UDH HMI

Input Signal

Alarm Alarm Alarm

Report Receiver Viewer
Alarm
Scanner

Alarm
Comm
Alarm Queue
Input Signal Operator Commands:
Alarm Queue • Acknowledge
including Time
• Reset
• Lock
• Unlock
Alarm Logic Variable • Override for hold
list

Alarm ID

Generating Process Alarms

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7.5 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.

• Each type of I/O board 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 various types of input are removed
from the scan.
• In TMR systems, a limit alarm associated with TMR Diff Limt is created if any of
the three inputs differ from the voted value by more than a preset amount. This limit
value is configured by the user and creates a voting alarm indicating a problem exists
with a specific input.
• If any one of the diagnostic alarms is set, it creates a board composite diagnostic
alarm, L3DIAG_xxxx, where xxxx is the board name. This signal can be used to
trigger a process alarm. Each board has three L3DIAG_ signals, L3DIAG_xxxx1, 2,
and 3. Simplex boards use only L3DIAG_xxxx1. TMR boards use all three with the
first assigned to the board in R, the second assigned to the same board in S, and the
third assigned to the same board in T.
• The diagnostic signals can be individually latched, and then reset with the RESET_
DIA signal, typically in the form of a message from the HMI.
• Generally diagnostic alarms require two consecutive occurrences before being set
True (process alarms only require one occurrence).
In addition to inputs, each board has its own diagnostics. The VCMI and I/O boards have
a processor stall timer that generates a signal SYSFAIL. This signal lights the red LED on
the front cabinet. The watchdog timers are set as follows:

VCMI communication board 150 ms

I/O boards 150 ms

If an I/O board times out, the outputs go to a fail-safe condition which is zero (or open
contacts) and the input data is put in the default condition, which is zero.
The three LEDs at the top of the front cabinet 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.
The controller has extensive self-diagnostics. These are available directly at the toolbox.
In addition, UCVB and UCVD runtime diagnostics, which may occur during a program
download, are displayed on LEDs on the controller front cabinet.
Each terminal 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 terminal board serial number,
board type, revision number, and the J type connector location.

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 7.5.1 Voter Disagreement Diagnostics
Each I/O board produces diagnostic alarms when it is configured as TMR and any of its
inputs disagree with the voted value of that input by more than a pre-configured amount.
This feature allows the user to find and fix potential problems that would otherwise be
masked by the redundancy of the control system. The user can view these diagnostics the
same way one views any other diagnostic alarms. The VCMI triggers these diagnostic
alarms when an individual input disagrees with the voted value for a number of
consecutive frames. The diagnostic clears when the disagreement clears for a preset
number of frames.
The user configures voter disagreement diagnostics for each signal. Boolean signals are
all enabled or disabled by setting the DiagVoteEnab signal to enable under the
configuration section for each input. Analog signals are configured using the TMR_
DiffLimit signal under configuration for each point. This difference limit is defined in one
of two ways. It is implemented as a fixed engineering unit value for certain inputs and as
a percent of configured span for other signals. For example, if a point is configured as a
4-20 mA input scaled as 0-40 engineering unit, its TMR_DiffLimit is defined as a percent
of (40-0). The type of limit checking used is spelled out in the dialog box for the TMR_
DiffLimit signal for each card type. These signal are summarized in the following table.

Type of TMR Limit-Checking

I/O Processor Board Type of I/O Delta Method

VAIC % of Configured Span

VGEN Analogs % of Configured Span

PT, CT Engineering Units

VPRO Pulse rates Engineering Units

Thermocouples Engineering Units
Analogs % of Configured Span
PT, CT Engineering Units

VPYR mA % of Configured Span

Gap Engineering Units

VRTD —————— Engineering Units

VSVO Pulse rates Engineering Units

POS Engineering Units
mA % of Configured Span

VTCC —————— Engineering Units

VTURH1/H2 Pulse rates Engineering Units

PT
Flame
Shaft monitor
VVIB Vibration signals Engineering Units

For TMR input configuration, refer to GEH-6403, Control System Toolbox for a Mark VI
Controller. All unused signals will have the voter disagreement checking disabled to
prevent nuisance diagnostics.

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 Totalizers are timers and counters that store critical data such as number of trips, number
of starts, and number of fired hours. The controller provides a special block, Totalizer,
which maintains up to 64 values in a protected section of non-volatile RAM (NVRAM).
This Totalizer block should be placed in a protected macro to prevent the logic driving its
counters from being modified.
Users with sufficient privilege may set and clear Totalizer counter values from the
toolbox dialogue box. An unprivileged user cannot modify the data. The standard block
library help file provides more details on using the Totalizer block.

7.6 Troubleshooting
To start troubleshooting, be certain the racks have correct power supply voltages; these
can be checked at the test points on the left side on the VME rack.
Refer to Help files as required. From the toolbox, click Help for files on Runtime Errors
and the Block Library. Also, from the Start button, navigate to the Mark VI controller to
see help files on Runtime, I/O networks, Serial Loader, Standard Block Library, and
Turbine Block Library.

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,
Warning operate, or maintain this equipment.

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.

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 7.6.1 I/O Board LEDs

7.6.1.1 Green - Normal Operation

During normal operation, all the Run LEDs on the board front panels flash green. All
boards in all racks should flash green.

7.6.1.2 Orange - System Diagnostic in Queue

An orange Status LED lit on one board 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.

➢ To view the diagnostic message

1. From the toolbox Outline View, select Online using the Go on/offline button.
2. Locate the rack in the Summary View and right-click the board. A shortcut menu
displays.
3. From the shortcut menu, select View Diagnostic Alarms. The Diagnostic Alarms
table displays. The following data is displayed in tabular form:
a. Time - The time when the diagnostic was generated
b. Fault Code - The fault code number
c. Status - A 1 indicates an active alarm, and a 0 indicates a cleared, but not reset
(acknowledged), alarm
d. Description - A short message describing the diagnostic
This diagnostic screen is a snapshot, but not real time. For new data, select the Update
command.
To display all of the real time I/O values in the Summary View, left-click the board on the
screen. The I/O values will display. All the real time I/O values display in the Summary
View. At the top of the list is the L3DIAG board alarm, followed by the board point
system limit values, and with the I/O (sensor) values at the bottom. From these alarms and
I/O values, determine whether the problem is in the terminal board or in the sensor.
For example, if all the I/O points in a board are bad, the board has failed, a cable is loose,
or the board has not been configured. If only a few I/O points are bad, the I/O values are
bad, or part of the terminal board is burned up.

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 7.6.1.3 Red - Board Not Operating
If a board has a red Fail LED lit, it indicates the board is not operating. Check if it is loose
in its slot. If so, switch off the rack power supply, and push the board in, using the top and
bottom injector/ejector tabs. Check to see if the top and bottom mounting screws are loose
and tighten, if necessary. Turn the power on again.
If the red light still comes on, power down the rack, remove the board and check the
firmware flash memory chip. If the board has a socketed flash memory chip, this chip can
be plugged in the wrong way, which damages it. The following figure shows a typical I/O
board with the chip location. The chamfer on the chip should line up with the chamfer on
the receptacle, as displayed. If no flash chip is installed, replace the board with a new one.
Newer boards have a soldered flash chip so no adjustment is possible.

I/O Board with Flash Memory Chip

Earlier I/O board versions had a reset button on the front. If your board has this, check to
see if this button is stuck in. If so replace the board with a new one.
It is possible the failure is in the rack slot and not in the board. This can be determined by
board swapping, assuming the turbine is shut down. Remove the same good board from
the same slot in an adjacent TMR rack, and move the bad board to this good slot. Be sure
to power down the racks each time. If the problem follows the board, replace the board. If
it does not, there may be a problem with the VME backplane. Inspect the board slot for
damage; if no damage is visible, the original board may not have been seated properly.
Check the board for proper seating.
If a whole rack of I/O boards show red LEDs, it is probably caused by a communication
failure between the slave VCMI and the I/O boards in the rack. This can result from a
controller or VCMI failure or an IONet cable break. The failure could also be caused by a
rack power supply problem. Either the master or slave VCMI could be at fault, so check
the Fail LEDs to see where the problem is. If several but not all I/O boards in a rack show
red, this is probably caused by a rack power supply problem.

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 7.6.2 Controller Failures
If the controller fails, check the VCMI and controller diagnostic queues for failure
information. Power down the controller rack, and reboot it by bringing the power back
(do not use the Reset button). If the controller stays failed after reboot, replace it with a
spare.
If a controller fails to start, this usually indicates a runtime error that is typically a boot-up
or download problem. The runtime error number is usually displayed after an attempted
online download. The controller Runtime Errors Help screen on the toolbox displays all
the runtime errors together with suggested actions.
If the controller or its 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. The
failure does not affect the other two IONet channels, which keep running.

7.6.3 Power Distribution Module Failure

The PDM is a very reliable module with no active components. However, it does contain
fuses and circuit switches, and may have an occasional cabling or connector problem.
Most of the outputs have lights indicating voltage across their supply circuit. Open the
PDM front door to see the lights, switches, and fuses.
PDM diagnostic information is collected by the VCMI, including the 125 V dc bus
voltage and the status of the fuses feeding relay output boards. These can be viewed on
the toolbox by right-clicking the VCMI board, and then selecting View Diagnostic
Alarms.

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7.7 Online Download
It is recommended that you The Mark VI control system is designed to perform some types of control configuration
read this entire section prior to downloads to an operating system, referred to as online downloads, which are made to a
planning an online download. control while it is actually controlling the system. Online downloads are made without
restarting control processors or board racks. Because downloads to an operating system
can cause process actions that may take the system to a state that the control considers a
trip condition, these downloads should only be made after the current state of the system
has been carefully reviewed for process changes that could occur during the download.
Refer to section, TMR Test Since these downloads could reveal a condition that compromises the TMR ability of the
Procedure. control, it is recommended that they be made only to systems that are proven to be
TMR-capable by successfully passing a TMR test.

7.7.1 Preliminary Checks for Online Download

➢ To perform preliminary checks before starting the online download
1. Ensure all the turbine auxiliaries are in appropriate control states.
2. Secure systems as necessary and review control logic for auxiliary systems carefully
before initiating a download, as process disturbances can occur during the process.
3. Select an operationally robust system operating point and allow sufficient time for
the system to reach a stable operating condition before starting the download. If the
download could change the system performance, select a system state that will be
minimally affected by the change.
4. Check every controller, VCMI, and VPRO for active diagnostic alarms. Active
diagnostic alarms may indicate that the TMR capability of the control is
compromised, and can increase the chances the system could trip. Clear all active
alarms.
5. If, however, the download is made with active diagnostic alarm conditions, record
and examine each diagnostic alarm for potential failure modes when the controllers
are activated with the new code. The root cause of each process alarm must be
understood to know if the download process occurred correctly.
6. The new code or constants must be compatible with keeping the turbine running,
such as with TMR and the application. Instances where simplex trips were added
through new code have occurred, and the installation of this code resulted in trips.
Other instances have introduced changes in operating states that could not be reached
without first encountering a trip condition, such as valve out-of-position.
7. Check site records for past successful TMR checks on the system. These TMR
checks should be performed after each code installation to verify that the application
code still maintains TMR capability.

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 ➢ To perform control state checks
1. From the Control System Toolbox (toolbox) open the system's configuration file
(m6b). Connect to the control, and verify that the file is equal and online
(controlling). For all racks in a TMR system, check that the UCVx (controller) I/O
state = 6A hex (106 decimal) and that the control state is CA hex as follows:

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 2. For older systems that lack the feature to display this data from the toolbox, this
information is found by using telnet to connect directly to the controllers in turn by
their IP address, and using the monitor ma command to verify the IOC = CA and
STATE = 6A:
# monitor ma
ID = <R> IOC = CA SRTP_OK = 0 UDH COMM = 1 STATE = 6A CLK = EXT TMR
DC = <R>

Note Online downloads can be used to resolve minor revision differences, such as those
that occur in tuning. To resolve a major revision, you must restart the controller after a
download to permanent storage. A file that is equal, but will not go online (into the
control state), can only be resolved by restarting the controller.

3. Before the online download is performed, all control constants that are not the same
in the currently running control as in the configuration (.m6b) file must be identified
and confirmed since when the download is performed, all constants changes that
were made to the configuration file are initiated into the control.
4. For TMR systems, resolve all the issues related to TMR operation and make sure all
the controllers are online before performing the download. View the diagnostic
alarms and make sure no mismatch diagnostic alarms are present. Inconsistent
diagnostic alarms can indicate hardware or application software issues that could
compromise TMR operation. Use the following procedures to view, record, and
compare values. Resolve all issues before proceeding with the download.

➢ To review and record control constants

1. While online to the controller, from the toolbox, select the File menu and Open.
Select the master configuration file (.m6b).
2. From the View menu, select Control Constants. The Control Constant List
View displays. Review and record any constants that are different (disregard
differences in any library modules).
3. Select the File menu and Export to .csv to produce a record of the constants. Each
difference must be recorded and understood before the download. Differences may
reflect things such as experimental changes to operating conditions.

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 ➢ To view and record the logic forcing
1. From the toolbox, select View menu and Force Lists. The Forced Lists window
displays. Forced signals must be recorded and understood before the download.
2. Record the decision and value for each to be used after the download.

➢ To compare the configuration

1. From the toolbox, under Hardware and I/O Definitions, right-click Mark VI I/O and
select Compare Configuration. Solve any differences before proceeding, since
they represent changes made to boards that were not saved in the configuration file.
2. If necessary to record the differences produce and print a differences report.
3. Make any necessary corrections to the configuration file.

➢ To check for active diagnostic alarms on Mark VI I/O boards

A yellow LED on an I/O board 1. From the toolbox, expand the items Hardware and I/O Definitions and Mark VI I/O.
or a VCMI board indicates that
2. Right-click each board and select View Diagnostic Alarms, and record any active
a diagnostic alarm (not
diagnostic alarms.
necessarily active) is present.
However, the lack of an LED 3. It may be necessary to first clear inactive diagnostic alarms to reach the state where
may simply indicate a failed the diagnostic board point is zero. Resolve or understand all active diagnostic alarms
LED. before proceeding with the download.

Download Checklist
Unit ML Number Unit ML Number Unit ML Number
Item Name Item Status for Unit Item Status for Unit Item Status for Unit
Pre-Update Checklist
1 Code Suitability
2 Diagnostics
3 Previous TMR Checks
4.1 MkVI
Control State
Control Constants
Alarm Drops
Logic Forcing
I/O Configuration
Active Diagnostics
TMR Mismatch
Diagnostics
Download Checklist
5 Mark VI Downloads Validate/Build/Down-
load Application,
Symbols, Compressed .
m6b
5.1 Application Save .m6b

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 7.7.2 TMR Test Procedure
The following procedure should be used to test the TMR capability of the turbine control
system. This test places the system in a simplex mode while the controller restarts, which
increases the possibility for the system to trip.

➢ To prepare the system for TMR testing

Note Prior to conducting any type of TMR test, overall system design, including
especially all simplex I/O and simplex outputs to external control systems, must be
reviewed to make sure that the fundamental system design is TMR-capable. This review
must include a thorough examination of all simplex control sequencing code and I/O.

1. Review all standing and intermittent process alarms on the turbine control panel.
Resolve all alarms related to TMR devices and critical control functions. If any
alarms remain uncleared, make a print out to document the status of the alarm queue
prior to the test.
2. Review all I/O board standing and intermittent diagnostic alarms on the turbine
control panel. Resolve all alarms related to TMR devices and critical control
functions.
3. Ensure that the trip logs are properly configured and obtaining the proper data.
4. Create a high resolution data trend that includes the following:
a. TMR analog transducers
b. Each speed pickup
c. LVDT inputs
d. Exhaust thermocouple values
e. Gas valve position commands
f. IBH valve position commands
g. Liquid fuel bypass valve commands (if applicable)
h. IGV position commands
i. servo current signals
j. Digital status and trip signals

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 ➢ To test the R, S, and T controllers

Note The designated controller should be tested last, since it will be the controller that is
supplying data for the Trend Recorder. If the designated controller is R, then the testing
order should be T, S, R. Or, if S is the designated controller, then test R, T, and the S
controller last. This procedure assumes R is the designated controller.

1. With the unit at steady-state and either Full Speed No Load or Spinning Reserve (or
other appropriate operating point as determined by the operations), from the toolbox
View menu select Trend Recorder and begin recording the designated controller. The
requirement is to always record data from a controller that is not going to be
shutdown.

Note The user when connecting online determines the controller that the Trend Recorder
collects data from.

If there is a TMR issue, a 2. Power down the T controller and make sure the system maintains its current
shutdown may be issued. operational state.
3. Power up the T controller, and using the toolbox monitor T until it returns to the
controlling state (IO State = 0x6A, Control State 0xCA). Wait at least five minutes
for the unit to stabilize before continuing.
4. Stop the Trend Recorder and save the trend file using an appropriate file name
including date, time, and ID of the controller that was powered down. Record the file
name.
5. Start a new trend file on the R controller (designated).
If there is a TMR issue, a 6. Power down the S controller, and make sure the system maintains its current
shutdown may be issued. operational state.
7. Power up the S controller, and using the toolbox monitor S until it returns to the
controlling state (IO State = 0x6A, Control State 0xCA). Wait at least five minutes
for the unit to stabilize before continuing.
8. Stop the Trend Recorder and save the trend file. Record the file name.
9. Start a new trend file on the S controller, since it will become the designated
controller when the R controller is powered down.
If there is a TMR issue, a 10. Power down the R controller and make sure the system maintains its current
shutdown may be issued. operational state.
11. Power up the R controller, and using the toolbox, monitor R until it returns to the
controlling state (IO State = 0x6A, Control State 0xCA). Wait at least five minutes
for the unit to stabilize before continuing.
12. Stop the Trend Recorder and save the trend file. Record the file name.

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 ➢ To test the turbine protection module (VPRO)
1. Determine the control state of the protection module. The three protection modules
are identified using either of two names - X, Y, and Z, or synonymously VPROR,
VPROS, and VPROT respectively. Use the toolbox to view the health of the
appropriate L3DIAG_VPROx to determine when the VPRO has come back to
controlling state after it is powered up.
In this example, the X VPRO has not reached it's control state as evidenced by the
unhealthy L3DIAG_VPROR signal while both Y and Z are in their control state.

2. Start a new trend file using the designated controller.

3. Power down the X VPRO, observe that the unit continues to operate, even though
L3DIAG_VPROR is unhealthy. Note if there is a TMR issue a shutdown may also be
issued.
4. Power up the X VPRO. Using the health of L3DIAG_VPROR, monitor the X
controller until it returns to the controlling state: Once this occurs, wait an additional
five minutes before continuing.
5. Stop the trend file and save it. Start a new trend file.
6. Power down the Y VPRO and observe that the unit continues to operate, even though
L3DIAG_VPROS is unhealthy. Note if there is a TMR issue a shutdown may also be
issued.
7. Power up the Y VPRO. Using the health of L3DIAG_VPROS, monitor the Y VPRO
until it returns to the controlling state. Once this occurs, wait an additional five
minutes before continuing.
8. Stop the trend file and save it. Start a new trend file.

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 9. Power down the Z VPRO, observe that the unit continues to operate, even though
L3DIAG_VPROT is unhealthy. Note if there is a TMR issue a shutdown may also be
issued.
10. Power up the Z VPRO. Using the health of L3DIAG_VPROT, monitor the Z
controller until it returns to the controlling state. Once this occurs, wait an additional
five minutes before continuing.
11. Stop the trend file and save it.

7.7.2.1 In Case of Trip

If a trip occurs when a control is powered down in this test, BEFORE the control is
restarted save the trip log, the individual controller capture blocks, the alarm, and the
event files (.D03). The data in the individual controller capture blocks will be lost when
the controller is re-started. The capture block data from the two controllers that were
powered at the time of the trip must be uploaded and saved as trend files. Using the Trend
Recorder, go online with both controllers, one at time, upload the block collected data and
save it.
The trip log is usually stored in the local HMI directory, E:\Historian_Data\Gn_TripLog.
Each trip is stored in an individual file in a date-stamped subdirectory. From toolbox,
open the appropriate trip log (.dca file) to verify the correct trip event.
On a standard customer HMI, there is a shortcut icon for Internet Explorer on the desktop
labeled Alarm And Event Logger, which opens the TCI Homepage for the HMI. Select
the Alarm and Event Report link and fill in the appropriate request for all of the alarm and
event information surrounding the trip. Save this report to a file.
Review the trip log and events to determine the cause of the trip. The combination of two
alarms may indicate the root cause. For example, LVDT mismatch or loss of LVDT
combined with the power down of a controller may cause a gas control valve not
following trip and alarm. This type of root cause should be resolved on site by fixing the
faulty TMR device and documenting the root cause and resolution as part of the trip
report.
Another potential root cause could be I/O used in control code as critical inputs has been
terminated in the control as simplex points. If this is uncovered a PAC case should be
written and sent to the controls requisition engineer. Attachments for this PAC case
should be the current .m6b file and the four sets of files - trend files, trip log, event file,
and the diagnostic alarm file.
If the trip RCA indicates that the trip was caused by a controller fault, capture all
diagnostic alarms from each VCMI and the I/O boards into a file. Contact your GE
support representative and provide the four sets of files - trend files, trip log, alarm and
event files, and the diagnostic alarm file. The report should describe at what point in the
TMR testing the trip occurred and include a description of the specific sequence of events
leading to the trip.

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8 Applications
This chapter describes some of the applications of the Mark VI hardware and software,
including the servo regulators, overspeed protection logic, generator synchronization, and
ground fault detection.

8.1 Generator Synchronization

This section describes the Mark VI Generator Synchronization system. This system is
suitable for synchronizing generator breakers where the control can adjust
speed/frequency. It is not designed for transmission line breaker synchronizing where
there may be fixed phase relationships. Its purpose is to momentarily energize the breaker
close coil, at the optimum time and with the correct amount of time anticipation, so as to
close the breaker contact at top center on the synchroscope. Top center is often known as
top dead center. Closure will be within one degree of top center. It is a requirement that a
normally closed breaker auxiliary contact be used to interrupt the closing coil current.
The synchronizing system consists of three basic functions, each with an output relay,
with all three relays connected in series. All three functions have to be true (relay picked
up) simultaneously before the system applies power to the breaker close coil. Normally
there will be additional external permissive contacts in series with the Mark VI system,
but it is required that they be permissive only, and that the precise timing of the breaker
closure be controlled by the Mark VI system. The three functions are:

• Relay K25P, a synchronize permissive; turbine sequence status

• Relay K25A, a synchronize check; checks that the slip and phase are within a
window (rectangle shape); this window is configurable
• Relay K25, an auto synchronize; optimizes for top dead center
The K25A relay should close before the K25 so that the synchronous check function will
interfere with the auto synchronous optimizing. If this sequence is not executed, a
diagnostic alarm will be posted, a lockout signal will be set true in signal space, and the
application codemay prevent any further attempts to synchronize until a reset is issued
and the correct coordination is set up.

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 8.1.1 Hardware
The synchronizing system interfaces to the breaker close coil through the TTUR terminal
board as in the following figure. Three Mark VI relays must be picked up, plus external
permissive contacts must be true, before a breaker can close.
The K25P relay is directly driven from the controller application code. In a TMR system,
it is driven from R, S, and T controllers, using 2/3 logic voting. In a simplex system, it
may be configured, by jumper, to be driven from the R controller only.
The K25 relay is driven from the VTUR auto synchronous algorithm, which is managed
by the controller application code. In a TMR system, it is driven from R, S, and T
controller, using 2/3 logic voting. Again for a simplex system, it may be configured, by
jumper, to be driven from the R controller only.
The K25A relay is located on TTUR, but is driven from the VPRO synchronous check
algorithm, which is managed by the controller application code. The relay is driven from
VPRO, <R8>, <S8>, and <T8>, using 2/3 logic voting in TREG/L/S.
The synchronous check relay driver (located on TREG/L/S) is connected to the K25A
relay coil (located on TTUR) through cabling through J2 to TRPG/L/S. It then goes
through JR1 (and JS1, JT1) to J4 and VTUR, then J3, JR1 to TTUR.
Both sides of the breaker close coil power bus must be connected to the TTUR board.
This provides diagnostic information and also measures the breaker closure time, through
the normally open breaker auxiliary contact for optimization.
The breaker close circuit is rated to make (close) 10 A at 125 V dc, but to open only 0.6
A. A normally open auxiliary contact on the breaker is required to interrupt the closing
coil current.

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 Generator Synchronizing System

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 8.1.2 Application Code
The application code must sequence the turbine and bring it to a state where it is ready for
the generator to synchronize with the system bus. For automatic synchronization, the code
must:

• Match speeds
• Match voltages
• Energize the synchronous permissive relay, K25P
• Arm (grant permission to) the synchronization check function (VPRO, K25A)
• Arm (grant permission to) the auto synchronization function (VTUR, K25)
The following illustrations represent positive slip (Gen) and negative phase (Gen).

Generator Synchronizing System

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 8.1.3 Algorithm Descriptions
This section describes the synchronizing algorithms in the VTUR, and the VPRO.

8.1.3.1 Automatic Synchronization Control in VTUR (K25)

The VTUR runs the auto synchronization algorithm. Its basic function monitors two
potential transformer (PT) inputs, generator and bus, to calculate phase and slip
difference. When armed (enabled) from the application code, and when the calculations
anticipate top center, the breaker attempts to close by energizing the K25 relay. If the K25
relay is energized, then the synchronization process begins. The algorithm uses the zero
voltage crossing technique to calculate phase, slip, and acceleration. It compensates for
breaker closure time delay (configurable), with self-adaptive control when enabled. It is
interrupt-driven, and uses generator voltage to function. The configuration can manage
the timing on two separate breakers. For details, refer to the figure below.
The algorithm has a bypass function, and two signals for redundancy, to provide dead bus
and manual breaker closures. Anticipating top dead center, it uses a projected window,
based on current phase, slip, acceleration, and breaker closure time. To pickup K25, the
generator must be currently lagging, have been lagging for the last 10 consecutive cycles,
and projected (anticipated) to be leading when the breaker actually reaches closure. Auto
synchronization will not allow the breaker to close with negative slip. In this fashion,
assuming the correct breaker closure time has been acquired, and the synchronous check
relay is not interfering, breaker closures with less than 1 degree error can be obtained.
Slip is the difference frequency (Hz). Positive frequency is when the generator is faster
than the bus. Positive phase means the generator is leading the bus, and the generator is
ahead in time, or the right-hand side on the synchroscope. The standard window is fixed
and not configurable. However, a special window has been provided for synchronous
condenser applications where a more permissive window is needed. It is selectable with a
signal space Boolean, and has a configurable slip parameter.
The algorithm validates both PT inputs with a requirement of 50% nominal amplitude or
greater. That is, they must exceed approximately 60 V rms before they are accepted as
legitimate signals. This is to guard against cross talk under open circuit conditions. The
monitor mode is used to verify that the performance of the system is correct, and to block
the actual closure of the K25 relay contacts; it is used as a confidence builder. The signal
space Input Gen_Sync_Lo will become true if the K25 contacts are closed when they
should be open, or if the Synch Check K25A is not picked up before the Auto Synch K25.
It is latched and can be reset with Synch_Reset.
The algorithm compensates for breaker closure time delay, with a nominal breaker close
time, provided in the configuration in milliseconds. This compensation is adjusted with
self-adaptive control, based upon the measured breaker close time. The adjustment is
made in increments of one cycle (16.6/20 ms) per breaker closure and is limited in
authority to a configurable parameter. If the adjustment reaches the limit, a diagnostic
alarm Breaker #n Slower/Faster Than Limits Allows is posted.

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 Automatic Synchronizing on VTUR

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 8.1.3.2 Synchronization Check in VPRO (K25A)
The synchronous check algorithm is performed in the VPRO boards. Its basic function is
to monitor two Potential Transformer (PT) inputs, and to calculate generator and bus
voltage amplitudes and frequencies, phase, and slip. When it is armed (enabled) from the
application code, and when the calculations determine that the input variables are within
the requirements, the relay K25A will be energized. The above limits are configurable.
The algorithm uses the phase lock loop technique to derive the above input variables, and
is therefore relatively immune from noise disturbances.
The algorithm has a bypass function to provide dead bus closures. The window in this
algorithm is the current window, not the projected window (as used on the auto
synchronous function), therefore it does not include anticipation.
The synchronous check allows the breaker to close with negative slip. Slip is the
difference frequency (Hz), positive when the generator is faster than the bus. Positive
phase means the generator is leading the bus, the generator is ahead in time, or the right
hand side on the synchroscope. The window is configurable, and both phase and slip are
adjustable within pre-defined limits.

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 Synchronization Check on VPRO

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 8.1.4 Configuration

8.1.4.1 VTUR Configuration

VTUR configuration of the auto synchronous function is provided the following table.
The configuration is located under J3 J5: IS200VTUR, signal Ckt_Bkr.

VTUR Parameter Description Selection Choice

SystemFreq System Frequency 50 Hz, 60 Hz
CB1CloseTime Breaker #1 closing time 0 to 500 ms
CB1AdaptLimt Breaker #1 adaption limit 0 to 500 ms
CB1AdaptEnabl Breaker #1 adaption enable Enable, disable
CB1FreqDiff Breaker #1 allowable frequency difference for the special window 0.15 to 0.66 Hz
CB1PhaseDiff Breaker #1 allowable phase difference for the special window 0 to 20 degrees
CB2CloseTime Breaker #2 closing time 0 to 500 ms
CB2AdaptLimt Breaker #2 adaption limit 0 to 500 ms
CB2AdaptEnabl Breaker #2 adaption enable Enable, disable
Breaker #2 allowable frequency difference for the special window 0.15 to 0.66 Hz
CB2PhaseDiff Breaker #2 allowable phase difference for the special window 0 to 20 degrees

8.1.4.2 VPRO Configuration

VPRO configuration of the synchronous check function is provided in the following table.
The configuration is located under J3: IS200TREX, signal K25A_Fdbk.

VPRO Auto Synchronous Configuration

VPRO Parameter Description Selection Choice
SynchCheck Enable Used, unused
SystemFreq System Frequency 50 Hz, 60 Hz
ReferFreq Phase Lock Loop center PR_Std, SgSpace
frequency PR_Std means use PulseRate1 on a single shaft application -
use PulseRate2 on all multiple shaft applications
SgSpace means use generator freq (Hz), from signal space
(application code), DriveFreq
TurbRPM Load Turbine rated RPM 0 to 20,000
Used to compensate for driving gear ratio between the turbine
and the generator
VoltageDiff Allowable voltage difference 1 to 1,000 Engineering units, kV or percent
FreqDiff Allowable freq difference 0 to 0.5 Hz
PhaseDiff Allowable phase difference 0 to 30 degrees
GenVoltage Allowable minimum gen voltage 1 to 1,000 Engineering units, kV or percent
BusVoltage Allowable minimum bus voltage 1 to 1,000 Engineering units, kV or percent

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 8.1.4.3 Available Inputs and Outputs
This section defines all inputs and outputs in signal space that are available to the
application code for synchronization control. The breaker closure is not given directly
from the application code. Rather, the synchronizing algorithms, located in the I/O
boards, are armed from this code. In special situations, the synchronous relays are
operated directly from the application code, for example when there is a dead bus.
The VTUR signal space interface for the auto synchronous function is provided in the
following tables.

VTUR Auto Synchronous Signal Space Interface

Output Description Comments

Sync_Perm_AS Auto Synch permissive Traditionally known as L83AS

Sync_Perm Synch permissive mode, L25P Traditionally known as L25P; interface to control the K25P relay

Sync_Monitor Auto Synch monitor mode Traditionally known as L83S_MTR; enables the Auto Synch
function, except it blocks the K25 relays from picking up

Sync_Bypass1 Auto Synch bypass Traditionally known as L25_BYPASS; to pickup L25 for Dead Bus
or Manual Synch

Sync_Bypass0 Auto Synch bypass Traditionally known as L25_BYPASSZ; to pickup L25 for Dead Bus
or Manual Synch

CB2 Selected #2 Breaker is selected Traditionally known as L43SAUTO2; to use the breaker close time
associated with Breaker #2
AS_WIN_SEL Special Auto Synch window New function, used on synchronous condenser applications to
give a more permissive window

Synch_Reset Auto Synch reset Traditionally known as L86MR_TCEA; to reset the synch Lockout
function

Input Description Comments

Ckt_BKR Breaker State (feedback) Traditionally known as L52B_SEL

CB_Volts_OK Breaker Closing Coil Voltage is present Used in diagnostics

CB_K25P_PU Breaker Closing Coil Voltage is present downstream of Used in diagnostics

the K25P relay contacts

CB_K25_PU Breaker Closing Coil Voltage is present downstream of Used in diagnostics

the K25 relay contacts

CB_K25A_PU Breaker Closing Coil Voltage is present downstream of Used in diagnostics

the K25A relay contacts

Gen_Sync_LO Synch Lock out Traditionally known as L30AS1 or L30AS2; it is

a latched signal requiring a reset to clear
(Synch_Reset). It detects a K25 relay problem
(picked up when it should be dropped out) or a
slow Synch Check (relay K25A) function

L25_Comand Breaker Close Command to the K25 relay Traditionally known as L25

GenFreq Generator frequency Hz

BusFreq Bus frequency Hz

GenVoltsDiff Difference Voltage between the Generator and the Bus Engineering units, kV or percent

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 Input Description Comments
GenFreqDiff Difference Frequency between the Generator and the Hz
Bus
GenPhaseDiff Difference Phase between the Generator and the Bus Degree

CB1CloseTime Breaker #1 measured close time ms

CB2CloseTime Breaker #2 measured close time ms
GenPT_Kvolts Generator Voltage Engineering units, kV or percent

BusPT_Kvolts Bus Voltage Engineering units, kV or percent

The VPRO signal space interface for the synchronous check function is provided in the
following tables.

VPRO Synchronous Check Signal Space Interface

Output Description Comments

SynCk_Perm Synch Check permissive Traditionally known as L25X_PERM

SynCk_ByPass Synch Check bypass Traditionally known as L25X_BYPASS; used for dead
bus closure
DriveRef Drive (generator) frequency (Hz) used for Traditionally known as TND_PC; used only for
Phase Lock Loop center frequency non-standard drives where the center frequency can
not be derived from the pulserate signals

Input Description Comments

K25A_Fdbk Feedback from K25A relay

L25A_Cmd The synch check relay close command Traditionally known as L25X

BusFreq Bus frequency Traditionally known as SFL2, Hz

GenFreq Generator frequency Hz

GenVoltsDiff The difference voltage between the gen and bus Traditionally known as DV_ERR,
engineering units kV or percent

GenFreqDiff The difference frequency (slip) between the gen and bus Traditionally known as SFDIFF2, Hz

GenPhaseDiff The difference phase between the gen and bus Traditionally known as SSDIFF2, degrees

GenPT_Kvolts Generator voltage Traditionally known as DV, engineering

units kV or percent

BusPT_Kvolts Bus voltage Traditionally known as SVL, engineering

units kV or percent

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 8.1.5 VTUR Diagnostics for the Auto Synchronous
Function
L3BKR_GXS – Synch Check Relay is Slow. This means that K25 (auto
synchronization) has picked up, but K25A (synchronous check) or K25P has not picked
up, or there is no breaker closing voltage source. If it is due to a slow K25A relay, the
breaker will close but the K25A is interfering with the K25 optimization. It will cause the
input signal Gen_Sync_LO to become TRUE.
L3BKR_GES – Auto Synch Relay is Slow. This means the K25 (auto synchronization)
relay has not picked up when it should have, or the K25P is not picked up, or there is no
breaker closing voltage source. It will cause the input signal Gen_Sync_LO to become
TRUE.
Breaker #1 Slower than Adjustment Limit Allows. This means, on breaker #1, the
self-adaptive function adjustment of the Breaker Close Time has reached the allowable
limit and can not make further adjustments to correct the Breaker Close Time.
Synchronization Trouble – K25 Relay Locked Up. This means the K25 relay is picked
up when it should not be. It will cause the input signal Gen_Sync_LO to become TRUE.

8.1.6 VPRO Diagnostics for the Auto Synchronous

Function
K25A Relay (synch check) Driver mismatch requested state. This means VPRO
cannot establish a current path from VPRO to the TREx terminal board.
K25A Relay (synch check) Coil trouble, cabling to P28V on TTUR. This means the
K25A relay is not functional; it could be due to an open circuit between the TREx and the
TTUR terminal boards or to a missing P28 V source on the TTUR terminal board.

8.1.7 Hardware Verification Procedure

The hardware interface may be verified by forcing the three synchronizing relays,
individually or in combination. If the breaker close coil is connected to the TTUR
terminal board, the breaker must be disabled to prevent the generator from connecting to
the system bus.

➢ To verify the hardware interface

1. Operate the K25P relay by forcing output signal Sync_Perm found under VTUR,
card points. Verify that the K25P relay is functional by probing TTUR screws 3 and
4. The application code has direct control of this relay.
2. Simulate generator voltage on TTUR screws 17 and 18. Operate the K25 relay by
forcing TTUR, card point output signals Sync_Bypass1 =1, and Sync_Bypass0 = 0.
Verify that the K25 relay is functional by probing screws 4 and 5 on TTUR.
3. Simulate generator voltage on TPRO screws 1 and 2. Operate the K25A relay by
forcing TPRO, card point output signals SynCK_Bypass =1, and SynCk_Perm 1. The
bus voltage must be zero (dead bus) for this test to be functional. Verify that the
K25A relay is functional by probing screws 5 and 6 on TTUR.

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 8.1.8 Synchronization Simulation
➢ To simulate a synchronization
1. Disable the breaker.
2. Establish the center frequency of the VPRO PLL; this depends on the VPRO
configuration, under J3:IS200TREx, signal K25A_Fdbk, ReferFreq.
a. If ReferFreq is configured PR_Std, and <P> is configured for a single shaft
machine, then apply rated speed (frequency) to input PulseRate1; that is TPRO
screw pairs 31/32, 37/38, and 43/44.
b. If ReferFreq is configured PR_Std and <P> is configured for a multiple shaft
machine, then apply rated speed (frequency) to input PulseRate2, that is TPRO
screw pairs 33/34, 39/40, and 45/46.
c. If ReferFreq is configured SgSpace, force VPRO signal space output DriveRef
to 50 or 60 (Hz), depending on the system frequency.
3. Apply the bus voltage, a nominal 115 V ac, 50/60 Hz, to TTUR screws 19 and 20,
and to TPRO screws 3 and 4.
4. Apply the generator voltage, a nominal 115 V ac, adjustable frequency, to TTUR
screws 17 and 18 and to TPRO screws 1 and 2. Adjust the frequency to a value to
give a positive slip, that is VTUR signal GenFreqDiff of 0.1 to 0.2 Hz. (10 to 5 sec
scope).
5. Force the following signals to the TRUE state:

• VTUR, Sync_Perm, then K25P should pick up

• VTUR, Sync_Perm_AS, then K25 should pulse when the voltages are in
phase
• VPRO, SynCK_Perm, then K25A should pulse when the voltages are in phase
6. Verify that the TTUR breaker close interface circuit, screws 3 to 7, is being made
(contacts closed) when the voltages are in phase.
7. Run a trend chart on the following signals:
VPRO: GenFreqDiff, GenPhaseDiff, L25A_Command, K25A_Fdbk
VTUR: GenFreqDiff, GenPhaseDiff, L25_Command, CB_K25_PU, CB_K25A_PU
8. Use an oscilloscope, voltmeter, synchroscope, or a light to verify that the relays are
pulsing at approximately the correct time.
9. Examine the trend chart and verify that the correlation between the phase and the
close commands is correct.
10. Increase the slip frequency to 0.5 Hz and verify that K25 and K25A stop pulsing and
are open.
11. Return the slip frequency to 0.1 to 0.2 Hz, and verify that K25 and K25A are pulsing.
Reduce the generator voltage to 40 V ac and verify that K25 and K25A stop pulsing
and are open.

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8.2 Overspeed Protection Logic
The figures in this section define the protection algorithms coded in the VPRO firmware.
VTUR contains similar algorithms. A configurable parameter from the toolbox is
illustrated with the abbreviation CFG(xx), where xx indicates the configuration location.
Some parameters/variables are followed with an 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.

VPRO Protection Logic - Online Overspeed Test

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 VPRO Protection Logic - Overspeed Trip, HP

Applications GEH-6421bb System Guide 163

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 VPRO Protection Logic - Overspeed Trip, HP (continued)

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 VPRO Protection Logic - Overspeed Trip, HP (continued)

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 VPRO Protection Logic - Overspeed LP

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 VPRO Protection Logic - Overspeed LP (continued)

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 VPRO Protection Logic - Overspeed LP (continued)

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 VPRO Protection Logic - Overspeed IP

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 VPRO Protection Logic - Overspeed IP (continued)

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 VPRO Protection Logic - Overspeed IP (continued)

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 VPRO Protection Logic - Over-Temperature

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 VPRO Protection Logic - Trip Anticipation

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 Stale Speed Trip

Control Watchdog Trip

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 VPRO Protection Logic - Trip Logic

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 VPRO Protection Logic - Trip Logic (continued)

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 VPRO Protection Logic - Trip Logic (continued)

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 VPRO Protection Logic - ETR 1, 2, and 3

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 VPRO Protection Logic - ETR 4, 5, and 6

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 VPRO Protection Logic - Servo Clamp

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 VPRO Protection Logic - Hardware I/O Definition

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 VPRO Protection Logic - Signal Space

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 VPRO Protection Logic - Signal Space (continued)

Applications GEH-6421bb System Guide 183

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8.3 Power Load Unbalance
The Power Load Unbalance (PLU) option is used on large steam turbines to protect the
machine from overspeed under load rejection. The PLU function looks for an unbalance
between mechanical and electrical power. Its purpose is to initiate Control Valve (CV)
and Intercept Valve (IV) fast closing actions under load rejection conditions where rapid
acceleration could lead to an overspeed event. Valve actuation does not occur under stable
fault conditions that are self-clearing (such as grid faults).
Valve action occurs when the difference between turbine power and generator load is
typically 40% of rated load or greater, the difference has been sustained for at least 10
milliseconds and the load is lost at a rate equivalent to going from 22.5% rated load to
zero in approximately 6 ms (a PLU rate threshold of 37.5 Per Unit Current/Second).
The 40% PLU level setting is standard. If it becomes necessary to deviate from this
setting for a specific unit, the fact will be noted by the unit-specific documentation. The
PLU unbalance threshold, (PLU_Unbal), may be adjusted from the toolbox.
Turbine mechanical power is derived from a milliamp reheat steam pressure signal. The
mechanical power signal source is configurable as follows:

• The mid value of the first three mA inputs (circuits 1, 2, 3)

• The max value of the first two mA inputs (circuits 1, 2)
• A single transducer, circuit 1
• A single transducer, circuit 2
• A signal from signal space, where mechanical power is calculated in the controller, in
percent
The generator load should be proportional to the sum of the 3-phase currents, thereby
discriminating between load rejection and power line faults. This discrimination would
not be possible if a true MW signal was used.
The PLU signal actuates the CV and IV fast closing solenoids and resets the Load
Reference signal to the no-load value while performing some auxiliary functions.

The PLU function is an important part of the

overspeed protective system. Do not disable during
turbine operation.
Attention
The three current signals from the station current transformers are reduced by three
auxiliary transformers on TGEN. These signals are summed in the controller and
compared to the power pressure signal from the reheat pressure sensor. The signals are
qualified (normalized) according to the current rating and press rating configuration
parameters. This comparison yields a qualified unbalance measure of the PLU, as
displayed by signal B in the following figure. The output of the total generator current is
also fed into the current rate amplifier. This comparison provides a measure of the rate of
change of the generator current, signal A. The current rate level may be adjusted through
the PLU rate threshold function (PLU_Rate). This value must be set at 37.5 (PU/Sec).

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 PLU Valve Actuation Logic

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 If these comparators operate simultaneously, PLU action is initiated and latched, making
continuation of the PLU action dependent only on the unbalance for all functions except
IV fast closing. The IVs do not lock in, but remain closed for approximately one second
and then begin to re-open regardless of PLU duration.
A time-delay may be implemented for the PLU function. To initiate the delay, go to the
Enable PLU response delay parameter (PLU_Del_Enab) and select Enable. The duration
of the time-delay can be adjusted by altering the value of the PLU delay (PLU_Delay)
parameter.
These dropout times have been arrived at based on experience, and are used to reduce the
transient load on the hydraulic system.
The IVs and CVs may be operated through test signals from the controller. These signals
are executed individually and are logic ORed with the above signals as displayed in
following figure. The IVs may also be driven by the Early Valve Actuation (EVA) and IV
Trigger (IVT) functions. Each solenoid has a unique dropout time delay, refer to the
following table and figure.

Solenoid Drop-Out Point Delay Values

Steam Valve IV1 IV2 IV3 IV4 IV5 IV6 CV1 CV2 CV3 CV4
Dropout Delay, seconds 1.35 1.5 1.75 1.35 1.75 1.5 1.1 2 3 4

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 Fast Acting Solenoid Sequencing

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8.4 Early Valve Actuation
The Early Valve Actuation (EVA) system was developed for power systems where
instability, such as the loss of synchronization, is a problem. When the EVA senses a fault
that is not a load rejection, it closes the intercept valves for approximately one second.
This action reduces the available mechanical power to that of the already reduced
electrical power, and therefore prevents too large an increase in the machine angle and the
consequent loss of synchronization. Refer to the following figure for the valve actuation
diagram.

EVA Valve Actuation Logic

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 8.4.1 Intercept Valve Trigger
Refer to the figure, EVA Valve The peak speed following rejection of 10% or greater rated load cannot be maintained
Actuation Logic. within limits on some units by the normal speed and servo control action. Approximately
70% of turbine power is generated in the reheat and low-pressure turbine sections (the
boiler re-heater volume represents a significant acceleration energy source). Fast closing
of the IVs can therefore quickly reduce turbine power and peak overspeed. The action
fulfills the first basic function of normal overspeed control, limiting peak speed. The
Intercept Valve Trigger (IVT) signal is produced in the controller by the IVT algorithm
and associated sequencing.

8.4.2 Early Valve Actuation

The megawatt signal is derived The Early Valve Actuation (EVA) function may be implemented on sites where
from voltage and current instability, such as loss of synchronization, presents a problem. EVA closes the IVs for
signals provided by approximately one second upon sensing a fault that is not a load rejection. This action
customer-supplied reduces the available mechanical power, thereby inhibiting the loss of synchronization
transformers located on the that can occur as a result of increased machine angle (unbalance between mechanical and
generator side of the circuit electrical power). If the fault persists, the generator loses synchronization and the turbine
breaker. is tripped by the overspeed control or out-of-step relaying.
The EVA is enabled in the toolbox by selecting Enable for the EVA_Enab parameter. The
conditions for EVA action are as follows:

• The difference between mechanical power (reheat pressure) and electrical power
(megawatts) exceeds the configured EVA unbalance threshold (EVA_Unbal) input
value.
• Electrical power (megawatts) decreases at a rate equivalent to (or greater than) one of
three rates configured for EVA megawatt rate threshold (EVA_Rate). This value is
adjustable according to three settings: HIgh, MEdium, and LOw. These settings
correspond to 50, 35, and 20 ms rates respectively.
The EVA_Unbal value represents the largest fault a particular generator can sustain
without losing synchronization. Although the standard setting for this constant is 70%, it
may be adjusted up or down 0 to 2 per unit from the toolbox. All EVA events are
annunciated.

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8.5 Fast Overspeed Trip in VTUR
In special cases where a faster overspeed trip system is required, the VTUR Fast
Overspeed Trip algorithms may be enabled. The system employs a speed measurement
algorithm using a calculation for a predetermined tooth wheel. Two overspeed algorithms
are available in VTUR as follows:

• PR_Single. This uses two redundant VTUR boards by splitting up the two redundant
PR transducers, one to each board.
• PR_Max. This uses one VTUR board connected to the two redundant PR transducers.
PR_Max allows broken shaft and deceleration protection without the risk of a
nuisance trip if one transducer is lost.
The fast trips are linked to the output trip relays with an OR-gate as displayed in the
following figures. VTUR computes the overspeed trip, not the controller, so the trip is
very fast. The time from the overspeed input to the completed relay dropout is 30 msec or
less.

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 Fast Overspeed Algorithm, PR-Single

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 Fast Overspeed Algorithm, PR-Max

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8.6 Compressor Stall Detection
Gas turbine compressor stall detection is included with the VAIC firmware and is
executed at a rate of 200 Hz. There is a choice of two stall algorithms and both use the
first four analog inputs, scanned at 200 Hz. One algorithm is for small LM gas turbines
and uses two pressure transducers. The other algorithm is for heavy-duty gas turbines and
uses three pressure transducers, refer to the following figures.
Real-time inputs are separated from the configured parameters for clarity. The parameter
CompStalType selects the type of algorithm required, either two transducers or three. PS3
is the compressor discharge pressure, and a drop in this pressure (PS3 drop) is an
indication of a possible compressor stall. In addition to the drop in pressure, the algorithm
calculates the rate of change of discharge pressure, dPS3dt, and compares these values
with configured stall parameters (KPS3 constants). Refer to the following figures.
The compressor stall trip is initiated by VAIC, and the signal is sent to the controller
where it is used to initiate a shutdown. The shutdown signal can be used to set all the fuel
shut-off valves (FSOV) through the VCRC and TRLY or DRLY board.

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 Small (LM) Gas Turbine Compressor Stall Detection Algorithm

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 Heavy Duty Gas Turbine Compressor Stall Detection Algorithm

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 Configurable Compressor Stall Detection Parameters

The variables used by the stall detection algorithm are defined as follows:

PS3 Compressor discharge pressure

PS3I Initial PS3

KPS3_Drop_S Slope of line for PS3I versus dPS3dt

KPS3_Drop_I Intercept of line for PS3I versus dPS3dt

KPS3_Drop_Mn Minimum value for PS3I versus dPS3dt

KPS3_Drop_Mx Maximum value for PS3I versus dPS3dt

KPS3_Delta_S Slope of line for PS3I versus Delta PS3 drop

KPS3_Delta_I Intercept of line for PS3I versus Delta PS3 drop

KPS3_Delta_Mx Maximum value for PS3I versus Delta PS3 drop

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8.7 Ground Fault Detection Sensitivity
Ground fault detection on the floating 125 V dc power bus is based upon monitoring the
voltage between the bus and the ground. The bus voltages with respect to ground are
normally balanced (in magnitude), that is the positive bus to ground is equal to the
negative bus to ground. The bus is forced to the balanced condition by the bridging
resistors, Rb, as displayed in the following figure. Bus leakage (or ground fault) from one
side will cause the bus voltages with respect to ground to be unbalanced. Ground fault
detection is performed by the VCMI using signals from the PDM. Refer to Volume II of
this System Guide.

Ground Fault on Floating 125 V dc Power Bus

On the Mark V control, the There is a relationship between the bridge resistors, the fault resistance, the bus voltage,
bridging resistors are 33 K and the bus to ground voltage (Vout) as follows:
each so different Vout values
Vout = Vbus x Rf / [2 x (Rf + Rb/2)]
result.
Therefore, the threshold sensitivity to ground fault resistance is as follows:

Rf = Vout x Rb / (Vbus – 2 x Vout).

The ground fault threshold voltage is typically set at 30 V, that is Vout = 30 V. The
bridging resistors are 82 K each. Therefore, from the formula above, the sensitivity of the
control panel to ground faults (assuming it is on one side only) is as displayed in the
following figure.

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 Sensitivity to Ground Faults
Vbus - Bus Voltage Vout - Measured Bus to Rb -Bridge Resistors Rf - Fault Control
Ground Voltage (threshold) (balancing) Resistor System
105 30 82 kΩ 55 kΩ Mark VI
125 30 82 kΩ 38 kΩ Mark VI
140 30 82 kΩ 31 kΩ Mark VI
105 19 82 kΩ 23 kΩ Mark VI
125 19 82 kΩ 18 kΩ Mark VI
140 19 82 15 Mark VI
105 10 82 kΩ 10 kΩ Mark VI
125 10 82 kΩ 8 kΩ Mark VI
140 10 82 kΩ 7 kΩ Mark VI
105 30 33 kΩ 22 kΩ Mark V
125 30 33 kΩ 15 kΩ Mark V
140 30 33 kΩ 12 kΩ Mark V

The results for the case of 125 V dc bus voltage with various fault resistor values is
displayed in the following figure.

Threshold Voltage as Function of Fault Resistance

8.7.1 Analysis of Results

On the Mark VI control, when the voltage threshold is configured to 30 V and the voltage
bus is 125 V dc, the fault threshold is 38 kΩ. When the voltage threshold is configured to
17 V and the voltage bus is 125 V dc, the fault threshold is 15 kΩ.
The sensitivity of the ground fault detection is configurable. Balanced bus leakage
decreases the sensitivity of the detector.

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Glossary of Terms
Application code Software that controls the machines or processes, specific to the
application.

ASCII American Standard for Code for Information Interchange (ASCII). An 8-bit code
used for data.

Asynchronous Device Language (ADL) An application layer protocol used for

I/O communication on IONet.

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.

Balance of Plant (BOP) Plant equipment other than the turbine that needs to be
controlled.

Basic Input/Output System (BIOS) Performs the controller boot-up, which

includes hardware self-tests and the file system loader. The BIOS is stored in EEPROM
and is not loaded from the toolbox.

bBaud A unit of data transmission. Baud rate is the number of bits per second
transmitted.

Bently Nevada A manufacturer of shaft vibration monitoring equipment.

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.

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.

COM port Serial controller communication ports (two). COM1 is reserved for
diagnostic information and the Serial Loader. COM2 is used for I/O communication.

Computer Operator Interface (COI) Interface that consists of a set of product and
application specific operator displays running on a small cabinet computer hosting
Embedded Windows NT.

Configure To select specific options, either by setting the location of hardware

jumpers or loading software parameters into memory.

Current Transformer (CT) Measures current in an ac power cable.

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 Cyclic Redundancy Check (CRC) Detects errors in Ethernet and other
transmissions.

Data server A computer that gathers control data from input networks and makes the
data available to computers 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.

DIN-rail European standard mounting rail for electronic modules.

Distributed Control System (DCS) Control system, usually applied to control of

boilers and other process equipment.

Ethernet LAN with a 10/100 M baud collision avoidance/collision detection system

used to link one or more computers together. Basis for TCP/IP and I/O services layers that
conform to the IEEE 802.3 standard, developed by Xerox, Digital, and Intel®.

Ethernet Global Data (EGD) Control network and protocol for the controller.
Devices share data through EGD exchanges (pages).

Excitation control system Latest version of GE generator exciter control; regulates

the generator field current to control the generator output voltage.

Fanned input An input to the terminal board that 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.

Frmware 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 LANs or connects a LAN to a

wide-area network (WAN), computer, 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.

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 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.

I/O Input/output interfaces that allow the flow of data into and out of a device.

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.

Initialize To set values (addresses, counters, registers, and such) to a beginning value
prior to the rest of processing.

Innovation Series Controller A process and logic controller used for several types
of GE industrial control systems.

Instance Update an item with a new definition.

IONet The Mark VI I/O Ethernet communication network

IP Address The address assigned to a device on an Ethernet communication network.

Item A line of hierarchy of the outline view of the toolbox application, which can be
inserted, configured, and edited (such as Function or System Data).

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.

Mark VI Turbine Controller A controller hosted in one or more racks that perform
turbine-specific speed control, logic, and sequencing.

Median The middle value of three values; the median selector picks the value most
likely to be closest to correct.

Modbus A serial communication protocol developed by Modicon for use between

PLCs and other computers.

Module A collection of tasks that have a defined scheduling period in the controller.

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. Online is 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.

PDM Power Distribution, Modular consists of core components and branch components
that make up the power distribution system for the Mark VI Controller. The PDM can be
customized for specific applications.

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.

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 Pin Block, macro, or module parameter that creates a signal used to make
interconnections.

Plant Data Highway (PDH) Ethernet communication network between the HMI
Servers and the HMI Viewers and workstations

Potential Transformer (PT) Measures voltage in a power cable.

Power Load Unbalance (PLU) Detects a load rejection condition which can cause
overspeed.

Product code (runtime) Software stored in the controller’s Flash memory that
converts application code (pcode) to executable code.

PROFIBUS An open fieldbus communication standard defined in international

standard EN 50 170 and is supported in simplex Mark VI systems.

Programmable Logic Controller (PLC) Designed for discrete (logic) control of

machinery. It also computes math (analog) function and performs regulatory control.

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.

Redundant Power Supply Module (RPSM) IS2020RPSM Redundant Power

Supply Module for VME racks that mounts on the side of the control rack instead of the
power supply. The two power supplies that feed the RPSM are mounted remotely.

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 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 cabinet 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.

Sequence of Events (SOE) A high-speed record of contact transitions taken during

a plant upset to allow detailed analysis of the event.

Serial Loader Connects the controller to the toolbox computer 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 the Ethernet.

Server A computer that gathers data over the Ethernet from plant devices, and makes
the data available to computer-based operator interfaces known as viewers.

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.

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 simulation Running a system without all of the configured I/O devices by modeling
the behavior of the machine and the devices in software.

Software Implemented Fault Tolerance (SIFT) A technique for voting the three
incoming I/O data sets to find and inhibit errors. Note that Mark VI control also uses
output hardware voting.

Stall detection Detection of stall condition in a gas turbine compressor.

Static starter This runs the generator as a motor to bring a gas turbine up to starting
speed.

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 Communication 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.

Trend A time-based plot to show the history of values, similar to a recorder, available
in the Turbine Historian and the toolbox.

Triple Module Redundancy (TMR) An operation that uses three identical sets of
control and I/O (channels R, S, and T) and votes the results.

Unit Data Highway (UDH) Connects the Mark VI controllers, static starter control
system, excitation control system, PLCs, and other GE provided equipment to the HMI
Servers.

Validate Makes certain that toolbox items or devices do not contain errors, and verifies
that the configuration is ready to be built into pcode.

Windows NT Advanced 32-bit operating system from Microsoft for 386-based

computers 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.

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Notes

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 dual network 50
Modbus 60
Index Simplex 31
system 13, 19, 29
TMR 31, 55
Connecting the System 102
A Contaminants 78
Acronyms and Abbreviations 8 Control
alarms 14, 113, 120, 123 Cabinet 11
Diagnostic 113, 132, 135 Operator Interface (COI) 13
Overview 132 Controller 19
process 127, 132–133 Designated 34
ANSI 73 Failures 140
application code 112–115, 149, 152 Replacing a 128

B D
boards 55, 111–112, 117 Data Highway 52
I/O 16, 21, 129, 135, 137, 139, 148, 158 Plant 12
Inspections 107 Unit 11
Maintenance 127 Disagreement Detector 41
replacement 127 Documents
terminal 11, 16, 24–27, 46, 102, 127, 130, 160 Related 9
TRES 28 Download 114
UL Class 1 Division 2 Listed 79 Online 112, 141
VCMI 20, 56, 135, 137, 139 Topology and Application Code 112
VME 16, 127
VPRO 28, 155
VTUR 190 E
Early Valve Actuation 188
Electrical 73
C Elevation 78
cable 21, 106, 131 Environment 76
10Base2 105 Operating 77
Coaxial 101 Ethernet
Ethernet 105, 128 GSM 63
fiber-optic 49, 66–68, 101 Modbus Slave 59
Guidelines 67
Installation 68
Instrument 99 F
IONet 45, 102, 139 Fault Detection
replacement 131 Ground 197
RS-232C 60–62, 99 Features
shielded 97–98 Control and Protection 5, 31
SMF 11, 101 Interface 14, 123
Specifications 97 Product 122
UTP 99 Terminal Block 105
CIMPLICITY 13, 29, 117, 120, 202 Fiber-Optic Cables 66
code downloads 115 Forcing 42
codes 73 Frequency Variations 75
Command Action 42
Communications
IONet 56 G
Modbus 58
PROFIBUS 64 Generator Protection 14
RS-232C 99 Grounding 89
Component Sources 69 Notes on 95
Components System 91
System 11
Computer Operator Interface (COI) 123
configuration 21, 157

GEH-6421bb Index 205

GE Internal
H Turbine 5, 28, 44
Hardware Verification Procedure 160
Harmonic Distortion 75
Historian 124
Q
configuration 124 QNX 29
Human-machine Interface (HMI) 13

R
I Replacing 129
I/O
Boards 21
Cabinet 11 S
Data Collection 56
Peer 42 Safety Standards 73
Wiring 104 sequence of events (SOE) 14
Installation 81 standards 73
IONet 21, 55–56 Startup Checks 107
Storage 76
Synchronization
L Generator 149
Simulation 161
Levels of Redundancy 30 Time 71
Line Variations 74 system 11
Low Voltage Directive 74 Considerations 68
Operating 29
Power 105
M
Median Value Analog 41
Modbus 48
T
Serial 60 Third-Party Connectivity 5, 48
module TMR 30
and Boards 127 Architecture 32
control 16 Operation 34
interface 18 Test Procedure 145
Turbine Protection 28 Toolbox 117
MTBFO 47 Turbine
Protection 28

N
NEMA 14–15, 79
U
Network UDH Communicator 11, 35
Layers 50

V
O Vibration 78
Online Repair 46 Voltage Unbalance 74
Voting 40

P
Power Load Unbalance 184
W
Power Requirements 88 Weights and Dimensions 82
Power Sources 88 Wire Sizes 97
Process Alarms 133
Processing
Input 37
Output 35
PROFIBUS
configuration 65
I/O and Diagnostics 65
Protection

206 Mark VI Control System Guide Volume I

GE Internal
GE Internal