GEH-6421System Manual For Mark VI

GEH-6421
*(,QGXVWULDO6\VWHPV
System Guide
for the SPEEDTRONIC™ Mark VI Turbine Control
Publication: GEH-6422
Issued: 1999-10-20
System Guide
for the SPEEDTRONIC™ Mark VI Turbine Control
© 1999 General Electric Company, USA.
All rights reserved.
Printed in the United States of America.
These instructions do not purport to cover all details or variations in equipment, nor to provide
every possible contingency to be met during installation, operation, and maintenance. If further
information is desired or if particular problems arise that are not covered sufficiently for the
purchaser’s purpose, the matter should be referred to GE Industrial Systems, Salem, Virginia,
USA.
This document contains proprietary information of General Electric Company, USA and is
furnished to its customer solely to assist that customer in the installation, testing, operation,
and/or maintenance of the equipment described. This document shall not be reproduced in whole
or in part nor shall its contents be disclosed to any third party without the written approval of GE
Industrial Systems.
ARCNET is a registered trademark of Datapoint Corporation.

CIMPLICITY is a trademark of GE Fanuc Automation North America, Inc.
Ethernet is a trademark of Xerox Corporation.
Genius is a registered trademark of GE Fanuc Automation North America, Inc.
IBM is a registered trademark of International Business Machines Corporation.
Intel is a registered trademark of Intel Corporation.
Modbus is trademark of Gould Inc.
Pentium is a registered trademark of Intel Corporation.
PC is a registered trademark of International Business Machines Corporation.
PI-ProcessBook is a registered trademark of OSI Software Inc.
PI-Data Archive and PI-DataLink are trademarks of OSI Software Inc.
Series 90 is a trademark of GE Fanuc Automation North America, Inc.
SPEEDTRONIC is a trademark of General Electric Company, USA.
QNX is a registered trademark of QNX Software Systems, LTD.
Windows is a registered trademark of Microsoft Corporation.
Windows NT is a registered trademark of Microsoft Corporation.
Safety Symbol Legend
Indicates a procedure or condition that, if not

strictly observed, could result in personal injury or
death.
Indicates a procedure or condition that, if not

strictly observed, could result in damage to or
destruction of equipment.
Indicates a procedure or condition that should be

strictly followed in order to optimize these
applications.
Note Indicates an essential or important procedure, condition, or statement.

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,
or maintain this equipment.
To prevent personal injury or equipment damage
caused by equipment malfunction, only adequately
trained personnel should modify any
programmable machine.
The example and setup screens in this manual do

not reflect the actual application configurations. Be
sure to follow the correct setup procedures for
your application.
Safety Symbol Legend
Symbol Publication Description
IEC 417, No. 5031 Direct Current
IEC 417, No. 5032 Alternating Current
IEC 417, No. 5033 Both direct and alternating current
3 IEC 617-2, Three-phase alternating current

No. 02-02-06
IEC 417, No. 5017 Earth (CCOM signal ground) Terminal
IEC 417, No. 5019 Protective Conductor Terminal

(Chassis Safety Ground)
Protective Conductor Terminal
PE (Chassis Safety Ground)
IEC 417, No. 5020 Frame or Chassis Terminal
IEC 417, No. 5021 Equipotentiality
IEC 417, No. 5007 On (Supply)
IEC 417, No. 5008 Off (Supply)
IEC 417, No. 5172 Equipment protected throughout by

Double Insulation or Reinforced
Insulation (equivalent to Class II of IEC
536)
ISO 3864, No. B.3.6 Caution, risk of electric shock
ISO 3864, No. B.3.1 Caution

Drawing Symbols
Locations
O Supplied by Others Purchaser’s Equipment
R Remotely Mounted Bus Aux Compt Device

D Door Mounted Generator Compt Device
1 2 Mounted on Door 1, 2, and so on G Generator Terminal Enclosure

P Panel Mounted Packaged Electrical Cont. CTR (PEEC)
OS Mounted in Main Operator Station PEECC MCC
E Equipment Exists in place SS Static Starter
EX EX2000 Exciter LCI

Load Commutated Inverter
Generator Control Panel ISO Isolation Transformer
Turbine Control Generator Excitation Compartment
Devices
J1
Cable Plug Connector Case Ground
Jumper Ground Bus
Relay Coil Signal Ground
Solenoid Coil Contact Actually Shown Elsewhere
Flame Detector Customer Connection
Conventions
Twisted Pair Wire
1. For wire runs internal to the controller, twisted

Twisted Shielded Pair Wire pairs are adequate.
2. For wire runs external to the controller (and

internal to the controller when longer than 20
Shielded Pair Wire feet), shielded twisted pair is required.
3. All shield drain wires should be terminated on

Low Level Signal Wiring one end only, that end being the shield ground
Practices Required points immediately adjacent to the termination
boards. The other end should be cut off and the
Delta wire taped to prevent grounding.
Wye 4. None of the shield drain wires should ever

be routed through any controller terminal
L Low Level Wiring board-mounted ferrite cores.
H High Level Wiring
P Power Wiring
Contents
Chapter 1 Overview 1-1
Introduction............................................................................................................................ 1-1
Acronyms and Abbreviations................................................................................................. 1-3
System Guide Outline ............................................................................................................ 1-3
Related Publications............................................................................................................... 1-4
How to Get Help .................................................................................................................... 1-4
Chapter 2 System Architecture 2-1

Introduction................................................................................................................... ......... 2-1
System Components............................................................................................................... 2-1
Control Cabinet........................................................................................................ 2-1
Remote I/O Termination Cabinet............................................................................. 2-1
Unit Data Highway (UDH) ...................................................................................... 2-2
Human Machine Interface (HMI) ............................................................................ 2-3
Link to Distributed Control System (DCS).............................................................. 2-3
Plant Data Highway ................................................................................................. 2-3
Operator Console ..................................................................................................... 2-3
EX2000 Exciter ....................................................................................................... 2-4
Generator Protection ................................................................................................ 2-4
LCI Static Starter ..................................................................................................... 2-4
Control Module........................................................................................................ 2-4
Interface Module...................................................................................................... 2-6
Controller ................................................................................................................. 2-7
VCMI Communication Board.................................................................................. 2-8
IONet ....................................................................................................................... 2-8
I/O Boards................................................................................................................ 2-9
Termination Boards ............................................................................................... 2-10
Turbine Protection Module .................................................................................... 2-11
Operating Systems ................................................................................................. 2-12
Levels of Redundancy.......................................................................................................... 2-13
Control and Protection Philosophy....................................................................................... 2-14
Triple Modular Redundancy .................................................................................. 2-14
TMR Architecture.................................................................................................. 2-14
TMR Operation...................................................................................................... 2-17
Designated Controller ............................................................................................ 2-17
Output Processing .................................................................................................. 2-18
Input processing..................................................................................................... 2-20
State Exchange....................................................................................................... 2-23
Median Value Analog Voting ................................................................................ 2-24
Two Out of Three Logic Voter .............................................................................. 2-24
Disagreement Detector........................................................................................... 2-25
Peer I/O.................................................................................................................. 2-25
Command Action................................................................................................... 2-25
Rate of Response ................................................................................................... 2-25
GEH-6421 Mark VI System Guide Contents • 1

Power Sources........................................................................................................ 2-26
Failure Handling .................................................................................................... 2-26
Turbine Protection................................................................................................................ 2-28
Reliability & Availability..................................................................................................... 2-29
Online Repair for TMR Systems ........................................................................... 2-29
Reliability............................................................................................................... 2-30
Third Party Connectivity...................................................................................................... 2-31
Chapter 3 Networks 3-1

Introduction................................................................................................................... ......... 3-1
Network Overview ................................................................................................................. 3-1
Plant Data Highway ............................................................................................................... 3-4
Unit Data Highway ................................................................................................................ 3-6
UDH & PDH Ethernet IP Address Rules ............................................................................... 3-9
IONet.................................................................................................................................... 3-10
IONet – Communications Interface ....................................................................... 3-11
I/O Data Collection ................................................................................................ 3-11
Genius Bus ........................................................................................................................... 3-12
Genius Bus............................................................................................................. 3-12
Signal Flow in Controller....................................................................................... 3-14
Wiring .................................................................................................................... 3-14
Serial Modbus ...................................................................................................................... 3-16
Modbus Configuration ........................................................................................... 3-17
Ethernet GSM ...................................................................................................................... 3-20
Fiber Optics.......................................................................................................................... 3-21
Components ........................................................................................................... 3-22
System Considerations........................................................................................... 3-25
Installation ............................................................................................................. 3-25
Component Specifications ..................................................................................... 3-26
Time Synchronization .......................................................................................................... 3-26
Redundant Time Sources ....................................................................................... 3-27
Selection of Time Sources ..................................................................................... 3-27
Chapter 4 Packaging 4-1

Introduction............................................................................................................................ 4-1
Equipment Cabinets ............................................................................................................... 4-1
Control Cabinet........................................................................................................ 4-1
I/O Termination Cabinets ........................................................................................ 4-2
Chapter 5 Codes & Standards 5-1

Introduction............................................................................................................................ 5-1
Safety Standards..................................................................................................................... 5-1
Electrical ................................................................................................................................ 5-1
Printed Wire Board Assemblies............................................................................... 5-1
Electromagnetic Compatibility (EMC) .................................................................... 5-1
Low Voltage Directive............................................................................................. 5-2
Supply Voltage ........................................................................................................ 5-2
Environmental ........................................................................................................................ 5-3
Temperature Ranges ................................................................................................ 5-3
Humidity .................................................................................................................. 5-3
Elevation .................................................................................................................. 5-3
Contaminants ........................................................................................................... 5-4
Vibration .................................................................................................................. 5-4
Packaging ............................................................................................................................... 5-4
2 • Contents GEH-6421 Mark VI System Guide

Chapter 6 Installation 6-1
Introduction................................................................................................................... ......... 6-1
Installation Support ................................................................................................................ 6-1
Early Planning.......................................................................................................... 6-1
GE Installation Documents ...................................................................................... 6-2
Technical Advisory Options .................................................................................... 6-2
Equipment Receiving, Handling, and Storage ....................................................................... 6-3
Receiving and Handling........................................................................................... 6-3
Storage ..................................................................................................................... 6-4
Operating Environment............................................................................................ 6-5
Weights & Dimensions .......................................................................................................... 6-6
Cabinets ................................................................................................................... 6-6
Control Console (Example) ..................................................................................... 6-8
Power Requirements .............................................................................................................. 6-8
Installation Support Drawings.............................................................................................. 6-10
Grounding ............................................................................................................................ 6-15
Equipment Grounding............................................................................................ 6-15
Building Grounding System................................................................................... 6-16
Signal Reference Structure (SRS).......................................................................... 6-17
Cable Separation & Routing ................................................................................................ 6-21
Signal/Power Level Definitions ............................................................................. 6-22
Cableway Spacing Guidelines ............................................................................... 6-24
Cable Routing Guidelines ...................................................................................... 6-26
Cable Specifications............................................................................................................. 6-27
Low Voltage Shielded Cable ................................................................................. 6-28
Other Cables .......................................................................................................... 6-29
Connecting the System......................................................................................................... 6-30
I/O Wiring.............................................................................................................. 6-32
Power System ........................................................................................................ 6-33
Installing Ethernet.................................................................................................. 6-33
Installing Genius Cable.......................................................................................... 6-35
Startup Checks ..................................................................................................................... 6-36
Board Inspections .................................................................................................. 6-36
Wiring and Circuit Checks..................................................................................... 6-38
Startup .................................................................................................................................. 6-39
Maintenance ......................................................................................................................... 6-41
Modules and Boards .............................................................................................. 6-41
Component Replacement ..................................................................................................... 6-42
Replacing a VCMI ................................................................................................. 6-42
Replacing an I/O Board in an Interface Module .................................................... 6-42
Replacing a Termination Board ............................................................................. 6-43
Cable Replacement ................................................................................................ 6-43
Chapter 7 Tools 7-1

Introduction............................................................................................................................ 7-1
The Toolbox........................................................................................................................... 7-1
Computer Requirement............................................................................................ 7-1
Configuring the Equipment Racks........................................................................... 7-1
Configuring the Application .................................................................................... 7-4
CIMPLICITY HMI ................................................................................................................ 7-6
Basic Description..................................................................................................... 7-6
Product Features ...................................................................................................... 7-7
Optional Features..................................................................................................... 7-8
Controller Software Setup...................................................................................................... 7-8

Controller Setup....................................................................................................... 7-9
Serial Loader.......................................................................................................... 7-10
Initializing the Flash .............................................................................................. 7-10
Configuring TCP/IP............................................................................................... 7-12
Product Code (Runtime) Software......................................................................... 7-12
Application Code ................................................................................................... 7-15
Software Modifications ........................................................................................................ 7-15
Modifying the Application Code ........................................................................... 7-15
Upgrading the Product Code (Runtime) Software ................................................. 7-20
Rebooting the Controller........................................................................................ 7-23
Historian............................................................................................................................... 7-24
System Configuration ............................................................................................ 7-24
Data Flow............................................................................................................... 7-25
Historian Optional Tools ....................................................................................... 7-27
Chapter 8 Troubleshooting & Diagnostics 8-1

Introduction............................................................................................................................ 8-1
Overview................................................................................................................................ 8-1
Process Alarms....................................................................................................................... 8-2
Generating Process Alarms...................................................................................... 8-2
Diagnostic Alarms.................................................................................................................. 8-3
I/O Board Alarms..................................................................................................... 8-5
Controller Runtime Errors ..................................................................................... 8-15
Troubleshooting ................................................................................................................... 8-16
I/O Board LEDs ..................................................................................................... 8-16
Controller Failures ................................................................................................. 8-18
Power Distribution Module Failure ....................................................................... 8-18
Chapter 9 I/O Description 9-1

Introduction............................................................................................................................ 9-1
Controller ............................................................................................................................... 9-1
Controller Operation ................................................................................................ 9-1
Installation ............................................................................................................... 9-4
Bus Master Controller - VCMI .............................................................................................. 9-6
VCMI Features ........................................................................................................ 9-8
Board VDSK ........................................................................................................................ 9-13
Board Operation..................................................................................................... 9-13
Thermocouple Inputs TBCC ................................................................................................ 9-14
Thermocouple Board Operation ............................................................................ 9-15
VTCC Features ...................................................................................................... 9-16
Installation ............................................................................................................. 9-19
RTD Inputs TRTD ............................................................................................................... 9-20
RTD Board Operation............................................................................................ 9-21
VRTD Features ...................................................................................................... 9-22
Installation ............................................................................................................. 9-26
Analog Inputs TBAI............................................................................................................. 9-27
Analog Input Board Operation............................................................................... 9-28
VAIC Features ....................................................................................................... 9-30
Installation ............................................................................................................. 9-33
Analog Outputs TBAO ........................................................................................................ 9-34
Analog Output Board Operation............................................................................ 9-35
VAOC Features...................................................................................................... 9-37
Installation ............................................................................................................. 9-39
Contact Inputs TBCI ............................................................................................................ 9-40

Contact Input Board Operation.............................................................................. 9-42
VCCC Features ...................................................................................................... 9-44
Installation ............................................................................................................. 9-46
Isolated Digital Inputs TICI ................................................................................................. 9-47
Features.................................................................................................................. 9-47
Relay Outputs TRLY ........................................................................................................... 9-48
Relay Output Board Operation .............................................................................. 9-50
VCCC-Relay Features ........................................................................................... 9-52
Installation ............................................................................................................. 9-54
Contact Input/Relay Output Board VCRC ........................................................................... 9-55
Servo/LVDT TSVO ............................................................................................................. 9-57
Servo Board Operation .......................................................................................... 9-58
VSVO Features ...................................................................................................... 9-66
Installation ............................................................................................................. 9-71
Turbine Control TTUR ........................................................................................................ 9-72
Turbine Board Operation ....................................................................................... 9-73
Turbine Control Features ....................................................................................... 9-75
Automatic Synchronizing ...................................................................................... 9-78
Installation ............................................................................................................. 9-82
Primary Trip TRPG1............................................................................................................ 9-83
Primary Trip Operation.......................................................................................... 9-84
TRPG Features....................................................................................................... 9-85
Installation ............................................................................................................. 9-87
Turbine Emergency Trip TREG........................................................................................... 9-88
Emergency Trip Operation .................................................................................... 9-89
TREG Features ...................................................................................................... 9-90
Installation ............................................................................................................. 9-93
Turbine Protection TPRO & VPRO..................................................................................... 9-94
Protection System Operation ................................................................................. 9-97
VPRO Features ...................................................................................................... 9-97
Protection Logic................................................................................................... 9-101
Installation ........................................................................................................... 9-113
Vibration/Position TVIB................................................................................................... 9-114
Vibration Board Operation .................................................................................. 9-115
VVIB Features ..................................................................................................... 9-116
Installation ........................................................................................................... 9-119
Generator TGEN ............................................................................................................... 9-120
Generator Monitor Operation .............................................................................. 9-121
Generator Board Features .................................................................................... 9-122
Installation ........................................................................................................... 9-125
Pyrometer Board – TPYR .................................................................................................. 9-126
Pyrometer Board Operation ................................................................................. 9-127
VPYR Features .................................................................................................... 9-128
Installation ........................................................................................................... 9-131
VME Rack Power Supply .................................................................................................. 9-132
Power Supply Operation ...................................................................................... 9-133
Installation ........................................................................................................... 9-137
Power Distribution Module................................................................................................ 9-138
PDM Operation.................................................................................................... 9-139
Installation ........................................................................................................... 9-143
Glossary of Terms G-1
Index I-1

Notes

List of Figures
Figure 1-1. Typical Turbine Control System ................................................................................................................... 1-2
Figure 2-1. Mark VI Integrated Control System .............................................................................................................. 2-2
Figure 2-2. Control Module with Control, Communication, Memory, and I/O Boards................................................... 2-5
Figure 2-3. Rack with Controller, VCMI, and VDSK (No I/O Boards) .......................................................................... 2-6
Figure 2-4. Interface Module with VCMI and I/O Boards............................................................................................... 2-7
Figure 2-5. VCMI Boards providing I/O Communication and I/O Voting...................................................................... 2-8
Figure 2-6. Typical Termination Board with Cabling to I/O Boards in VME Rack ...................................................... 2-11
Figure 2-7. Turbine Protection Module with Cabling Connections. .............................................................................. 2-12
Figure 2-8. Single and Triple Redundant Systems......................................................................................................... 2-13
Figure 2-9. TMR Architecture with Local & Remote I/O, and Protection Module ....................................................... 2-15
Figure 2-10. Typical Cabinet Layout of Mark VI Triple Modular Redundant System.................................................. 2-16
Figure 2-11. Relay Output Circuits for Protection ......................................................................................................... 2-19
Figure 2-12. TMR Circuit to Combine Three Analog Currents into a Single Output.................................................... 2-20
Figure 2-13. TMR Circuits for Voted 4-20 mA Outputs................................................................................................ 2-20
Figure 2-14. Single Input to Three Controllers, Not Voted ........................................................................................... 2-21
Figure 2-15. One Sensor with Fanned Input & Software Voting................................................................................... 2-21
Figure 2-16. Three Independent Sensors with Common Input, Not Voted.................................................................... 2-22
Figure 2-17. Three Sensors, Each One Fanned and Voted, for Medium to High Reliability Applications ................... 2-22
Figure 2-18. Three Sensors with Dedicated Inputs, Software Voted for High Reliability Applications........................ 2-23
Figure 2-19. Median Value Voting Examples with Normal & Bad Inputs .................................................................... 2-24
Figure 2-20. TMR System Timing Diagram for System with Remote I/O .................................................................... 2-26
Figure 2-21. Primary and Emergency Overspeed Protection......................................................................................... 2-28
Figure 2-22. Optional Communication Links to Third Party Distributed Control System ............................................ 2-31
Figure 3-1. Turbine Control as Part of Integrated Control System .................................................................................. 3-2
Figure 3-2. Redundant Networks and Transceivers for Different Applications.............................................................. 3-3
Figure 3-3. Redundant Plant Data Highway Communication with Operator Stations.................................................... 3-4
Figure 3-4. Unit Data Highway showing Connections to Simplex, Duplex, & TMR Controllers.................................... 3-7
Figure 3-5. Typical Stackable Ethernet Hub with Connection to Fiber Optic Converter ................................................. 3-8
Figure 3-6. IONet Communications with Controllers, I/O, and Protection Modules..................................................... 3-11
Figure 3-7. Genius I/O Connected to Mark VI Controller ............................................................................................. 3-12
Figure 3-8. Controller Signal Flow ................................................................................................................................ 3-14
Figure 3-9. Genius Bus Wiring between Stations .......................................................................................................... 3-15
Figure 3-10. Communication to DCS from HMI using Modbus or Ethernet Options ................................................... 3-20
Figure 3-11. Media Converter, Ethernet Electric to Ethernet Fiber Optic ..................................................................... 3-24
Figure 3-12. ST Connector for Fiber Optic Cables ........................................................................................................ 3-24
Figure 4-1. NEMA 1 Enclosure for Controllers in a System with Remote I/O................................................................ 4-1
Figure 4-2. Two-Bay NEMA 1 Enclosure for Small Mark VI System ............................................................................ 4-2
Figure 4-3. Five-Bay NEMA 1 Enclosure for a Larger Mark VI System ........................................................................ 4-2
Figure 4-4. Integrated Mark VI & Auxiliary Equipment Cabinet Line Up..................................................................... 4-3
Figure 6-1. Startup and Commissioning Services Cycle.................................................................................................. 6-2
Figure 6-2. Controller Cabinet ......................................................................................................................................... 6-6
Figure 6-3. Typical Mark VI Panel Lineup...................................................................................................................... 6-7
Figure 6-4. Turbine Control Console with Dimensions ................................................................................................... 6-8
Figure 6-5. Typical System Topology showing Interfaces to Heat Recovery Steam Generator and Balance of Plant
Equipment ............................................................................................................................................................... 6-10
Figure 6-6. Typical I/O Cabinet Drawing showing Dimensions, Cable Access, Lifting Angles, & Mounting ............. 6-11
Figure 6-7. Controller Cabinet with Protection Module ................................................................................................ 6-12
GEH-6421 Mark VI System Guide List of Figures • 1

Figure 6-8. Inside Layout of I/O Panel showing Termination Boards & Power Supplies ............................................ . 6-13
Figure 6-9. Typical Circuit Diagram of TRPG Termination Board ............................................................................... 6-14
Figure 6-10. Grounding Recommendations for Single Mark VI Cabinet ...................................................................... 6-18
Figure 6-11. Grounding Recommendations for Mark VI Cabinet Lineup ..................................................................... 6-19
Figure 6-12. Cable Tray Installation Guidelines ............................................................................................................ 6-21
Figure 6-13. Tray and Conduit Spacing ......................................................................................................................... 6-26
Figure 6-14. Cable Trays & Mounting Brackets for Termination Boards ..................................................................... 6-30
Figure 6-15. Typical Cabinet Wiring and Cabling......................................................................................................... 6-31
Figure 6-16 I/O Wiring Shielding Connections to Ground Bar at Termination Board ................................................... 6-32
Figure 6-17. ID Jumper Positions on VME Board......................................................................................................... 6-36
Figure 6-18. Rack Ethernet ID Plug............................................................................................................................... 6-37
Figure 6-19. VME Rack Power Supply Test Points....................................................................................................... 6-40
Figure 7-1. Configuring the Equipment Racks ............................................................................................................... 7-2
Figure 7-2. Terminal Board Configuration ..................................................................................................................... 7-3
Figure 7-3. Point Configuration ...................................................................................................................................... 7-4
Figure 7-4. Math Engine (MENG) block ......................................................................................................................... 7-4
Figure 7-5. Boolean Engine Block................................................................................................................................... 7-5
Figure 7-6. Connecting Control Blocks in the Work Area............................................................................................... 7-6
Figure 7-7. Interactive Operator Display for Steam Turbine & Generator ...................................................................... 7-7
Figure 7-8. Cabling between PC and Controller for Loading Software ........................................................................... 7-9
Figure 7-9. Serial Loader Cable ..................................................................................................................................... 7-10
Figure 7-10. Serial Loader dialog box ........................................................................................................................... 7-11
Figure 7-11. TCP/IP Settings dialog box ....................................................................................................................... 7-12
Figure 7-12. Controller Properties Dialog Box .............................................................................................................. 7-13
Figure 7-13. Download file ............................................................................................................................................ 7-13
Figure 7-14. I\O Driver Selection Menu ........................................................................................................................ 7-14
Figure 7-15. Controller Reboot Warning ....................................................................................................................... 7-14
Figure 7-16. Download Application Code dialog box ................................................................................................... 7-15
Figure 7-17. Download Application Code dialog box ................................................................................................... 7-17
Figure 7-18. Display of Minor and Major Revisions ..................................................................................................... 7-18
Figure 7-19. Status of Changes to the Configuration ..................................................................................................... 7-19
Figure 7-20. Export Application Code dialog box ......................................................................................................... 7-20
Figure 7-21. SetupUtility Dialog Box ............................................................................................................................ 7-21
Figure 7-22. Driver File Download Dialog Box ............................................................................................................ 7-21
Figure 7-23. I/O Driver Selection Menu ........................................................................................................................ 7-22
Figure 7-24. Controller Reboot Warning ....................................................................................................................... 7-22
Figure 7-25. Controller Boot-up Sequence .................................................................................................................... 7-23
Figure 7-26. Data Transmission to the Historian and HMI............................................................................................ 7-25
Figure 7-27. Historian Functions & Data Flow.............................................................................................................. 7-26
Figure 7-28. Typical Multi-Pen Process Trend Display................................................................................................. 7-28
Figure 8-1. Two Types of Alarms generated by Mark VI................................................................................................ 8-1
Figure 8-2. Generating Process Alarms using the Alarm Group Block ........................................................................... 8-3
Figure 9-1. Mark VI Controller Front Panel .................................................................................................................... 9-2
Figure 9-2. Typical Controller Mounted in Rack with Communication Board ............................................................... 9-5
Figure 9-3. VCMI Board, Single Network and Triple Network Versions ....................................................................... 9-6
Figure 9-4. Simplex System Configurations with Local & Remote I/O .......................................................................... 9-7
Figure 9-5. TMR System Configurations with Local & Remote I/O............................................................................... 9-8
Figure 9-6. VDSK Board with Adjacent Controller....................................................................................................... 9-13
Figure 9-7. Thermocouple Input Termination Board, I/O Board, and Cabling.............................................................. 9-14
Figure 9-8. Thermocouple Inputs and Processor Board................................................................................................. 9-15
Figure 9-9. TBTC Wiring and Cabling .......................................................................................................................... 9-19
Figure 9-10. RTD Input Termination Board, I/O Board, & Cabling............................................................................. 9-20
Figure 9-11. RTD Inputs & Signal Processing............................................................................................................... 9-21
Figure 9-12. RTD Termination Board Wiring ............................................................................................................... 9-26
Figure 9-13. Analog Input Termination Boards, I/O Board, & Cabling (TMR System) ............................................... 9-27
Figure 9-14. Analog Input Processing, SMX ................................................................................................................. 9-28
2 • List of Figures GEH-6421 Mark VI System Guide

Figure 9-15. Analog Input Processing, TMR..................................................................................... ............................ 9-29
Figure 9-16. TBAI Termination Board Wiring .................................................................................... .......................... 9-33
Figure 9-17. Analog Output Termination Board, I/O Board, and Cabling.......................................................... ........... 9-34
Figure 9-18. Analog Output Processing, SMX .............................................................................................................. 9-35
Figure 9-19. Analog Output Processing, TMR .............................................................................................................. 9-36
Figure 9-20. TBAO Termination Board Wiring ............................................................................................................ 9-39
Figure 9-21. Boards & Cabling for Contact Inputs and Relay Outputs, SMX............................................................... 9-40
Figure 9-22. Contact Input Termination Board, I/O Board, & Cabling ......................................................................... 9-41
Figure 9-23. Contact Input Processing, SMX ................................................................................................................ 9-42
Figure 9-24. Contact Input Processing, TMR ................................................................................................................ 9-43
Figure 9-25. TBCI Termination Board Wiring .............................................................................................................. 9-46
Figure 9-26. Cabling for Contact Inputs and Relay Outputs, SMX ............................................................................... 9-48
Figure 9-27. Relay Output Termination Board, I/O Board, & Cabling.......................................................................... 9-49
Figure 9-28. Relay Output Processing, SMX................................................................................................................. 9-50
Figure 9-29. Relay Output Processing, TMR................................................................................................................. 9-51
Figure 9-30. TRLY Termination Board Wiring............................................................................................................. 9-54
Figure 9-31. VCRC with Boards and Cabling to Contact Inputs & Relay Outputs ....................................................... 9-55
Figure 9-32. VCRC with Contact Input Board and Cabling .......................................................................................... 9-56
Figure 9-33. Servo/LVDT Termination Board, Processor Board, and Cabling ............................................................. 9-57
Figure 9-34. LVDT and Pulse Rate Inputs, SMX .......................................................................................................... 9-58
Figure 9-35. Servo Coil and LVDT Outputs, SMX ....................................................................................................... 9-59
Figure 9-36. LVDT and Pulse Rate Inputs, TMR .......................................................................................................... 9-60
Figure 9-37. Servo Coil Outputs and LVDT Excitation, TMR...................................................................................... 9-61
Figure 9-38. Servo Regulator with LVDT feedback...................................................................................................... 9-62
Figure 9-39. Servo Regulator with LVDT Feedback ..................................................................................................... 9-63
Figure 9-40. Servo Regulator with Pulse Rate Feedback............................................................................................... 9-64
Figure 9-41. Servo Monitor ........................................................................................................................................... 9-65
Figure 9-42. LVDT Auto Calibration Screen on the Toolbox ....................................................................................... 9-67
Figure 9-43. Servo/LVDT Termination Board Wiring .................................................................................................. 9-71
Figure 9-44. Turbine Control Termination Board, Processor Board, and Cabling ........................................................ 9-72
Figure 9-45. Turbine Control Inputs, Synchronizing, and Primary Trip Interface, SMX .............................................. 9-73
Figure 9-46. Turbine Control Inputs, Synchronizing, and Primary Trip Interface, TMR .............................................. 9-74
Figure 9-47. Typical Synch Window ............................................................................................................................. 9-79
Figure 9-48. Auto Synch Window ................................................................................................................................. 9-80
Figure 9-49. TTUR Termination Board ......................................................................................................................... 9-82
Figure 9-50. TRPG Termination Board, I/O Board & Cabling...................................................................................... 9-83
Figure 9-51. TRPG and Trip Solenoids ......................................................................................................................... 9-84
Figure 9-52. TRPG Termination Board Wiring ............................................................................................................. 9-87
Figure 9-53. Trip Emergency Termination Board, VPRO Board, and Cabling ............................................................. 9-88
Figure 9-54. TREG Board, Trip Interlocks, and Trip Solenoids.................................................................................... 9-89
Figure 9-55. TREG Termination Board ......................................................................................................................... 9-93
Figure 9-56. Turbine Protection Termination Board, VPRO Board, and Cabling ......................................................... 9-94
Figure 9-57. Turbine Control & Protection Boards ....................................................................................................... 9-95
Figure 9-58. TMR Protection System ............................................................................................................................ 9-96
Figure 9-59. VPRO Protection Logic - Contact Inputs ................................................................................................ 9-102
Figure 9-60. VPRO Protection Logic - Overspeed Trip .............................................................................................. 9-103
Figure 9-61. VPRO Protection Logic - Overspeed Trip, continued ............................................................................. 9-104
Figure 9-62. VPRO Protection Logic - Overspeed Trip, continued.............................................................................. 9-105
Figure 9-63. VPRO Protection Logic - Overtemperature Trip..................................................................................... 9-106
Figure 9-64. VPRO Protection Logic - Turbine Trip................................................................................................... 9-107
Figure 9-65. VPRO Protection Logic - Turbine Trip, continued ................................................................................. 9-108
Figure 9-66. VPRO Protection Logic - Trip & Economizing Relays ( J3, TREG) ...................................................... 9-109
Figure 9-67. VPRO Protection Logic - Trip & Economizing Relays (J4, TREG) ....................................................... 9-110
Figure 9-68. VPRO Protection Logic - Servo Clamp & Synch Check Relays (J3, TREG) ......................................... 9-111
Figure 9-69. VPRO Protection Logic - Synchronization Check .................................................................................. 9-112
Figure 9-70. Termination Board TPRO ....................................................................................................................... 9-113
GEH-6421 Mark VI System Guide List of Figures • 3

Figure 9-71. Vibration Termination Board, Processor Board, and Cabling........................................................ ......... 9-114
Figure 9-72. TVIB Board, Vibration Probes, and Bentley Nevada Interface............................................................... 9-115
Figure 9-73. Termination Board TVIB ........................................................................................................................ 9-119
Figure 9-74. Generator Termination Board, Processor Board, and Cabling ................................................................ 9-120
Figure 9-75. TGEN Board showing Potential & Current Transformer Inputs ............................................................. 9-121
Figure 9-76. Termination Board TGEN and Wiring.................................................................................................... 9-125
Figure 9-77. Pyrometer Termination Board, Processor, and Cabling .......................................................................... 9-126
Figure 9-78. TPYR Termination Board and Processor Board ..................................................................................... 9-127
Figure 9-79. Termination Board TPYR and Wiring .................................................................................................... 9-131
Figure 9-80. VME Rack Power Supply, Front, Side & Bottom Views........................................................................ 9-132
Figure 9-81. Inside View of VME Power Supply showing Power Modules................................................................ 9-133
Figure 9-82. VME I/O Rack Power Supply & Cables ................................................................................................. 9-134
Figure 9-83. VME I/O Rack Power Supply & Cables, continued................................................................................ 9-135
Figure 9-84. Power Supply, VME Chassis, & Cabling to External Devices................................................................ 9-137
Figure 9-85. Power Distribution Module, AC to DC Converter, & Diagnostic Cabling ............................................. 9-138
Figure 9-86. Power Distribution Module for I/O Cabinet............................................................................................ 9-140
Figure 9-87. PDM Diagnostic Monitoring in I/O Cabinet ........................................................................................... 9-141
Figure 9-88. PDM for Controller Cabinet.................................................................................................................... 9-142
Figure 9-89. PDM Circuit Board showing Terminals, Fuses, Switches, & Lights ...................................................... 9-143
4 • List of Figures GEH-6421 Mark VI System Guide

List of Tables
Table 2-1. I/O Boards .................................................................................................................................................... 2-10
Table 3-1. PDH Network Features................................................................................................................................... 3-5
Table 3-2. PDH Network Hardware................................................................................................................................. 3-5
Table 3-3. UDH Network Features .................................................................................................................................. 3-6
Table 3-4. Ethernet IP Address Rules .............................................................................................................................. 3-9
Table 3-5. IONet Features.............................................................................................................................................. 3-10
Table 3-6. Genius Bus Features ..................................................................................................................................... 3-13
Table 3-7. Genius I/O Diagnostics................................................................................................................................. 3-13
Table 3-8. Genius Bus Cables........................................................................................................................................ 3-15
Table 3-9. Serial Modbus Features ................................................................................................................................ 3-16
Table 3-10. Modbus Function Codes ............................................................................................................................. 3-17
Table 3-11. RS-232C Connector Pinout Definition ....................................................................................................... 3-18
Table 6-1. Power Requirements for 4200 mm Panel ....................................................................................................... 6-9
Table 6-2. Power Requirements for Controller Cabinet................................................................................................... 6-9
Table 6-3. American Wire Gage (AWG) Wire Sizes..................................................................................................... 6-28
Table 6-4. Ethernet ID Plug Jumper Positions ............................................................................................................... 6-38
Table 8-1. I/O Board Diagnostic Alarms ......................................................................................................................... 8-5
Table 8-2. Flashing Controller Status LEDs Indicate Error Codes ............................................................................... 8-15
Table 8-3. Controller Runtime Errors ............................................................................................................................ 8-16
Table 8-4. I/O Board showing Flash Memory Chip...................................................................................................... 8-17
Table 9-1. Controller Specification.................................................................................................................................. 9-3
Table 9-2. VCMI Specification...................................................................................................................................... 9-11
Table 9-3. VCMI Toolbox Configuration ...................................................................................................................... 9-11
Table 9-4. Thermocouple Types and Range .................................................................................................................. 9-16
Table 9-5. Typical VTCC Specification ........................................................................................................................ 9-17
Table 9-6. Thermocouple Board Configuration ............................................................................................................. 9-18
Table 9-7. RTD Types and Ranges ................................................................................................................................ 9-22
Table 9-8. VRTD Specification ..................................................................................................................................... 9-23
Table 9-9. RTD Accuracy.............................................................................................................................................. 9-23
Table 9-10. Typical VRTD Configuration ..................................................................................................................... 9-24
Table 9-11. Quantity and Types of Analog Inputs and Outputs..................................................................................... 9-30
Table 9-12. VAIC Specification .................................................................................................................................... 9-31
Table 9-13. Typical VAIC Configuration ...................................................................................................................... 9-32
Table 9-14. VAOC Specification ................................................................................................................................... 9-37
Table 9-15. Typical VAOC Configuration .................................................................................................................... 9-38
Table 9-16. VCCC Specification ................................................................................................................................... 9-45
Table 9-17. Typical VCCC Configuration..................................................................................................................... 9-45
Table 9-18. VCCC Relay Output Specification ............................................................................................................. 9-53
Table 9-19. Typical VCCC Relay Configuration.......................................................................................................... 9-53
Table 9-20. Servo Coil Ratings...................................................................................................................................... 9-66
Table 9-21. TSVO Specification................................................................................................................................... 9-68
Table 9-22. Typical VSVO Configuration ..................................................................................................................... 9-70
Table 9-23. VTUR Specification ................................................................................................................................... 9-76
Table 9-24. Typical VTUR Configuration ..................................................................................................................... 9-77
Table 9-25. Synchronizing Display Items...................................................................................................................... 9-81
Table 9-26. TRPG Specification .................................................................................................................................... 9-85
Table 9-27. Typical TRPG Configuration...................................................................................................................... 9-86
2 • List of Tables GEH-6421 Mark VI System Guide

Table 9-28. TREG Specification................................................................................................ .................................... 9-91
Table 9-29. Typical TREG Configuration ........................................................................................ ............................. 9-92
Table 9-30. VPRO Specification................................................................................................ .................................... 9-99
Table 9-31. Typical VPRO Configuration ........................................................................................ ........................... 9-100
Table 9-32. VVIB Specification ................................................................................................ .................................. 9-117
Table 9-33. VVIB Configuration ................................................................................................ ................................. 9-118
Table 9-34. VGEN Specification ................................................................................................ ................................. 9-123
Table 9-35. Typical VGEN Configuration........................................................................................ ........................... 9-124
Table 9-36. VPYR Specification................................................................................................ .................................. 9-129
Table 9-37. Typical VPYR Configuration ........................................................................................ ........................... 9-129
Table 9-38. Power Supply Specification........................................................................................ .............................. 9-136
Table 9-39. I/O Cabinet PDM Fuse Ratings ...................................................................................... .......................... 9-144
GEH-6421 Mark VI System Guide List of Tables • 3

Chapter 1 Overview
Introduction
This manual describes the SPEEDTRONIC™ Mark VI turbine control system.
Mark VI is used for the control and protection of steam and gas turbines in electrical
generation and process plant applications.
This flexible control system is available as a Simplex control or a Triple Modular
Redundant (TMR) control, with single or multiple racks, and local or remote I/O.
The I/O interface is designed for direct interface to the sensors and actuators on the
turbine, to eliminate the need for interposing instrumentation, and the reliability and
maintenance issues associated with that instrumentation. To obtain the highest
reliability, Mark VI uses a TMR architecture with sophisticated signal voting
techniques.
The guide describes the system hardware, firmware, and networking in detail. The
operator interface, standard turbine control blocks, and application configuration are
briefly discussed.
The main functions of the Mark VI turbine control system are as follows:
• Speed control during turbine startup
• Automatic generator synchronization
• Turbine load control during normal operation on the grid
• Protection against turbine overspeed on loss of load
Figure 1-1 shows a typical Mark VI control system for a steam turbine.
GEH-6421 Mark VI System Guide Chapter 1 Overview • 1-1

RS-232C Modbus
To Plant DCS
Flat Panel Mark VI I/O Board Rack
Touch PC Interface
Laptop
Screen Comm Controller
VCCC
VSVO VTUR VAIC or VVIB VRTD VTCC VGEN
VCMI UCVB VCRC
Ethernet
Genius Bus
(48) Contact Inputs. 1 ms SOE
(2) 3-Phase Gen/Line Voltage, (1) 3-Phase Gen. Current

(24) Relays
Proximitors: (16) Vibration, (8) Position, (2) KP
(16) RTDs
(24) Thermocouples
Actuator
Actuator
Remote I/O
Inlet Pressure
Trip
Generator
Speed
Extraction Pressure
Exhaust Pressure
Shaft Voltage & Current Monitor
Automatic Synchronizing
Vibration, Thrust, Eccentricity
Temperature (RTDs)
Temperature (Thermocouples)
Generator 3-Phase PTs & CT
Figure 1-1. Typical Turbine Control System
The main features of the Mark VI control system covered in the various chapters of
this guide are as follows:
• Optional Triple Modular Redundant (TMR) controllers, I/O, I/O
communication, termination boards, and sensors, as required for the desired
level of reliability.
• Software voting of incoming turbine data, and hardware voting of outgoing
control signals to tolerate faults and identify failed components.
• TMR hardware and voting to allow the system to continue operation if any
major component fails. The failed component, including the control processor,
can be shutdown, replaced, and reloaded with the system online.
• Redundant Ethernet communication with the Mark VI controllers, I/O, operator
interfaces, and with other control modules including LCI Static Starter, Exciter
control, Heat Recovery Steam Generator, and Balance of Plant control.
• Interface with the plant distributed control system, and with other control
equipment including programmable logic controllers (PLC), allowing
centralized operator control.
• Library of turbine control algorithms in control function block form, for
graphical configuration of the application program.
• High speed acquisition of Sequence of Events (SOE) data, to 1 ms resolution,
for display and analysis of turbine events.
1-2 • Chapter 1 Overview GEH-6421 Mark VI System Guide

• Control System Toolbox for system configuration, program download, and
display of diagnostics and trends.
• CIMPLICITY®, an advanced graphical human-machine interface (HMI), for the
operator interface to all real-time turbine data and control functions.
Acronyms and Abbreviations

CT Current transformer, senses the current in a cable
DCS Distributed Control System, for the balance of plant and auxiliary
equipment
EGD Ethernet Global Data, a control network and communication protocol
HMI Human-Machine Interface, usually a PC with CIMPLICITY
software
HRSG Heat Recovery Steam Generator, used with gas turbine plants
KP KeyPhasor®, a shaft position sensor for rotational position sensing
Modbus® A protocol used for serial communication between Mark VI and
other control systems
MTBF Mean Time Between Failures, a measure of reliability
MTTR Mean Time To Repair, used with MTBF to calculate system
availability
PDH Plant Data Highway, links HMIs to the Mark VI
®
Proximitor Non-contact probe for shaft vibration monitoring
PT Potential Transformer, senses the voltage in a cable
RTD Resistance Temperature Device, senses temperature in the process
SIFT Software Implemented Fault Tolerance, employs "2 out of 3" voting
SOE Sequence of Events, a record of high-speed contact closures during
an upset
TMR Triple Modular Redundant, uses three sets of controllers and I/O
UDH Unit Data Highway, links the controllers to the HMI servers
System Guide Outline

The System Guide is organized as follows:
Chapter 1 Overview. This chapter outlines the Mark VI system and chapters in
this manual.
Chapter 2 System Architecture. This chapter describes the main system
components, the networks, and details of the TMR architecture.
Chapter 3 Networks. This chapter discusses the data highways and other
communication networks, including the links to other control systems.
Chapter 4 Packaging. This chapter outlines the various cabinets used for different
size systems.
GEH-6421 Mark VI System Guide Chapter 1 Overview • 1-3

Chapter 5 Codes & Standards. This chapter lists the codes and standards
governing the Mark VI design, manufacture, and test.
Chapter 6 Installation. This chapter provides instructions for system installation,
wiring, grounding, checkout, and startup.
Chapter 7 Tools. This chapter summarizes the toolbox, CIMLICITY HMI,
controller download, and the Historian.
Chapter 8 Troubleshooting & Diagnostics. This chapter describes how process
and diagnostic alarms are generated and displayed for the operator and
service engineer, a listing of the board diagnostics, and an introduction
to system troubleshooting.
Chapter 9 I/O Descriptions. Describes the I/O boards, termination boards,
controller, communication boards, and power supplies.
Glossary The Glossary provides definitions of the terms for the Mark VI turbine
control system.
Index The Index provides a list of the key words and their location in this
guide.
Related Publications
In addition to this Mark VI System Guide, publications on other aspects of the
system are available.
• GEH-6403 Control System Toolbox for Configuring a Mark VI Turbine
Controller, for further details of configuring and downloading the control
system.
• GEH-6422 Turbine Historian System Guide for further details of configuring
and using the Historian.
• GEH-6408 Control System Toolbox for Configuring the Trend Recorder, for
details of configuring the toolbox trend displays.
• GEH-6372 GEMIS Tools for CIMPLICITY.
• GEH-6410 Innovation™ Series Controller System Manual.
• GEI-100189 System Database (SDB) Windows based Client/Server
• GEI-100271 System Database (SDB) Browser.
How to Get Help

If help is needed beyond the instructions provided in the system documentation,
contact GE as follows:
GE Industrial Systems
Product Service Engineering
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
Phone: + 1 800 533 5885
Fax: + 1 540 387 8606
("+" indicates the international access code required when calling from outside of the
USA.)
1-4 • Chapter 1 Overview GEH-6421 Mark VI System Guide

Chapter 2 System Architecture
Introduction
This chapter defines the main components of the turbine control system architecture,
including the communication networks. It also discusses the various levels of
redundancy to obtain the required reliability.
The Mark VI can use two Ethernet™- based local area networks (LANs), the Unit
Data Highway (UDH) and the Plant Data Highway (PDH). The UDH communicates
data between all the unit level controls for a turbine-generator set including gas
turbine, steam turbine, generator excitation, generator protection, static starter, heat
recovery steam generator (HRSG), and auxiliary equipment.
The PDH links the control functions to the operator stations and engineering work
stations in the central control room, as shown in Figure 2-1. Primary control and
protection is normally performed within a unit level control; but all UDH controls
have peer-to-peer communication capability. Larger plants with multiple turbine-
generator sets have several UDHs connected to a common PDH.
System Components
This section summarizes the main subsystems that make up the Mark VI system.
Control Cabinet
The control cabinet contains either a single (Simplex) Mark VI control module or
TMR control modules. These are linked to their remote I/O by a single or triple high
speed I/O network called IONet, and are linked to the UDH by their controller
Ethernet port. Optional Genius Bus ports are available for additional I/O. The control
module requires 125 V dc for a power source. The NEMA 1 control cabinet housing
the controller is rated for operation in a 45Û&DPELHQWWHPSHUDWXUH
Remote I/O Termination Cabinet

The I/O cabinet contains either single or triple interface modules. These are linked to
the controllers by IONet, and to the termination boards by dedicated cables. The
interface module requires 125 V dc as a power source. Termination boards may be in
the I/O cabinet or in a separate termination cabinet.
GEH-6421 Mark VI System Guide Chapter 2 System Architecture • 2-1

Unit Data Highway (UDH)
The UDH network supports The UDH connects the Mark VI control panels with the HMI or HMI/Data Server.
the Ethernet Global Data The network media is 10BaseT Ethernet. Redundant cable operation is optional and,
(EGD) protocol for if supplied, unit operation continues even if one cable is faulted. Dual cable
communication with other networks still comprise one logical network. Similar to the PDH, the UDH can have
Mark VIs, HRSG, Exciter, redundant, separately powered, network hubs, and be configured as a 10BaseFL
Static Starter, and Balance of fiber optic network.
Plant (BOP) control.
UDH data is replicated to all three controllers. This data is read by the master
communication controller board (VCMI) and transmitted to the other controllers.
Only the designated processor transmits UDH data, refer to the section on
Designated Controller, page 2-17.
To Optional Customer Network

Optional Control Console (Enterprise Layer)
Router
CIMPLICITY Viewer Viewer Viewer Engineering LaserJet LaserJet
Field
Redundant Support Work Station Printer Printer
Transciever
P LANT D ATA H IGHWAY HUB
P LANT D ATA H IGHWAY HUB
CIMPLICITY
Servers
U NIT D ATA H IGHWAY HUB

hardwire
UC2000 UC2000 GPP Mark VI Bently Nev. Mark VI 90-70 PLC 90-70 PLC
AC AC GE Fanuc GE Fanuc
90-70 PLCs 90-70 PLCs
Innovation Hot Backup Hot Backup
From
Buffered
Outputs HRSG/ Balance
LCI EX-
Auxiliaries of Plant
Static 2000 Gener./ Gas Steam
Starter Exciter Transfr. Turbine Turbine
Protectn. Control Genius Genius
Control
IONet IONet Bus Bus
Mark VI Mark VI Mark VI Mark VI Genius Genius Genius Genius Genius Genius
Remote Mark VI I/O Remote Mark VI I/O Genius Field I/O Genius Field I/O
Figure 2-1. Mark VI Integrated Control System
2-2 • Chapter 2 System Architecture GEH-6421 Mark VI System Guide

Human Machine Interface (HMI)
Typical HMI systems are PCs running Windows NT®, with communication drivers
for the data highways, and CIMPLICITY operator display software. The operator
initiates commands from the real-time graphic displays, and can view all the turbine
alarms on the CIMPLICITY graphic displays. Detailed I/O diagnostics and system
configuration are available using the Control System Toolbox (toolbox) software on
a viewer or separate PC. An HMI can be configured as a server or viewer, and can
contain tools and utility programs.
HMIs are linked to one data highway, or a redundant transceiver can be used to link
the HMI to both data highways for greater reliability. The HMI can be mounted in an
optional control console, or on a tabletop.
Servers
Redundant data servers are CIMPLICITY servers collect data on the UDH and use the PDH to communicate
optional, and if supplied, with viewers. If two servers are used, one acts as the primary server and passes
communication with the synchronized data to the backup server in a configuration called host redundancy.
viewers continues, even if one
server fails.
Link to Distributed Control System (DCS)

External communication links are available to communicate with the plant
distributed control system. A serial communication link, using Modbus protocol
(RTU binary), can be supplied from either an HMI or the controller in the control
module. This allows the operator at the DCS console access to real time turbine data,
and provides for discrete and analog commands to be passed to the turbine control.
In addition, an Ethernet link from the HMI supports periodic data messages at rates
consistent with operator response, plus sequence of events messages with data time
tagged at a one millisecond resolution.
Plant Data Highway

The optional PDH connects the CIMPLICITY HMI/Data Server with remote
operator stations, printers, historians, and other customer PCs. It does not connect
with the Mark VI directly. The media is 10BaseT or 10BaseFL fiber optic Ethernet
running at 10 Mbps, 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 hubs with optional fiber optic outputs for longer
distances, such as to the central control room. On small 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.
Operator Console
The turbine control console is a modular design which can be expanded from two
monitors, with space for one operator, to four monitors, with space for three
operators. Printers can be table-top mounted, or on pedestals under the counter. The
full size console is 5507.04 mm (18 ft 0 13/16 in) long, and 2233.6 mm (7 ft 3 15/16
in) wide. The center section, with space for two monitors and a phone/printer bay, is
a small console 1828.8 mm (6 ft) wide.

EX2000 Exciter
The EX2000 digital static exciter supplies dc power to the field of the synchronous
generator. By means of the field current the exciter controls the generator ac terminal
voltage and/or the reactive volt amperes.
The exciter is supplied in a NEMA 1 free-standing, indoor type metal enclosure for
floor mounting. The enclosure lineup consists of a number of case sections that are
bolted together. Cable entry can be through the top or bottom. The enclosure and
contained equipment are designed for operation in an ambient temperature of 0 to
50Û&
Generator Protection
The generator protection system is mounted in a single, indoor, free standing cabinet,
designed for an operating temperature range of –20 to +40Û&7KHHQFORVXUHLV
NEMA 1, and weighs 2500 lbs. The Generator Panel interfaces to the Mark VI with
hardwired I/O, and has an optional Modbus interface to the HMI.
LCI Static Starter

The LCI Static Starter system is used to start a gas turbine by running the generator
as a starting motor. The static starter system is integrated into the Mark VI control
system along with the EX2000 digital excitation system. The Mark VI control
supplies the run, torque, and speed setpoint signals to the LCI, which operates in a
closed loop control mode to supply variable frequency power to the generator stator.
The EX2000 is controlled by the LCI to regulate the field current during startup.
The control cabinet contains an Innovation Series™ controller in a VME (Versa
Module Eurocard) control rack. The controller provides the Ethernet link to the UDH
and the HMI, and communication ports for Genius field control I/O and Modbus.
The Genius I/O are used for temperature inputs and diagnostic variables.
The LCI cabinet is a ventilated NEMA 1 free standing enclosure made of 12-gauge
sheet steel on a rigid steel frame, designed for indoor mounting. The total enclosure
weight is 7400 lbs., and the operating temperature range is 0 to 50Û&
Control Module
The control module is available as an integrated control and I/O module, or as a
standard controller only. The combined control and I/O rack can be either a 21-slot
or 13-slot VME size. The back-plane has P1 and P2 connectors for the VME boards.
The P1 connectors communicate data across the back-plane, and the P2 connectors
communicate data between the board and 37-pin J3 and J4 connectors located
directly beneath each board. Cables run from the J3 and J4 connectors to the
termination boards.
The control module can be Simplex or TMR, and each of these configurations
supports remote I/O via IONet. The Simplex control modules can be configured to
support up to three independent parallel IONet systems for higher I/O throughput.
Multiple communication boards may be used in a control module to increase the
IONet throughput.
Shown in Figure 2-2 is a 21-slot rack with a three-IONet VCMI communication
board, a two-slot controller (UCVB), and an Interface board (VDSK). The remaining
slots are filled with I/O boards. The overhead fan cools the controller.

Controller Interface Fan
UCVB VDSK I/O Boards
UDH
Port x x x x x x x x x x x x x x x x
Power
Supply
VCMI
Communication
Board, with One
or Three IONet
Ports
VME Chassis,
21 slots
x x x x x x x x x x x x x x x x x x x x x
Connectors for Cables to

Termination Boards (J3 & J4)
Figure 2-2. Control Module with Control, Communication, Memory, and I/O Boards
The stand alone controller module is a VME rack, shown in Figure 2-3,
accommodating the controller board (UCVB), VCMI, and Interface board VDSK.
This version is for systems where all the I/O is remote to save wiring costs. The
VME backplane has P1 connectors for data transfer, and P2 connectors only for the
VCMI and VDSK. The rack is powered by an integrated power supply. The VDSK
board is ribbon cabled to the VCMI in the back. It supplies 24 V dc to the cooling
fan mounted under the rack, and monitors the Power Distribution Module (PDM)
through the 37-pin connector on the front.

VCMI Communication Board with Controller Interface Board
Three IONet Ports (VCMI with One UCVX VDSK
IONet is for Simplex systems)
VME Rack
POWER
SUPPLY
Power Supply
x x x x
Cooling Fan Fan 24 Vdc

behind Panel Power
Figure 2-3. Rack with Controller, VCMI, and VDSK (No I/O Boards)
Interface Module
The interface module houses the I/O boards remote from the control module. The
rack, shown in Figure 2-4, is similar to the control module VME rack but without the
controller, VDSK, and cooling fan. Each I/O board occupies one or two slots in the
module and has backplane connection to a pair of 37-pin D connectors mounted on
an apron beneath the VME rack. Cables run from the 37-pin connectors to the
termination boards. Most I/O boards can be removed, with power removed, and
replaced without disconnecting any signal or power cable. Communication with the
module is via a VCMI with a single IONet port, located in the left-hand slot. The
module backplane contains a switch wired to slot 1, which is read by the
communication board to obtain the identity of the module.

VME Chassis, I/O Boards
21 slots
VCMI
Communication x x x x x x x x x x x x x x x x x x x x
Board with one
IONet Port Power
Supply
IONet Link
to Control
Module
x x x x x x x x x x x x x x x x x x x x x
Connectors for Cables to

Termination Boards (J3 & J4)
Figure 2-4. Interface Module with VCMI and I/O Boards
Controller
The controller is a two-slot VME board set housing a high speed processor and
DRAM. The base software includes appropriate portions of the existing Big Block
Library (BBL) control function libraries for the steam, gas, and Land-Marine aero-
derivative (LM) products. The controller can execute a total of 100,000 BBL rungs
or blocks per second, and run its program at up to 100 Hz, (10 ms frame rate),
depending on the system configuration.
External data is transferred to/from the controller over the VME bus by the VCMI
communication board. In a Simplex system, the data consists of the process inputs
from the I/O boards, and in a TMR system, it consists of voted data.
The controller provides communication interfaces to the UDH through Ethernet, to
Genius I/O through Genius Bus, and to other computers over a serial RS-232C port
using Modbus.

VCMI Communication Board
The VCMI board in the control and interface module communicates internally to the
I/O boards, and to the other VCMI cards through 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 Rn, Sn,
and Tn, and with the two other control modules. This is shown in Figure 2-5.
Software Implemented Fault Tolerant (SIFT) voting is implemented in the VCMI
board. Input data from each of the IONet connections is voted in each of the R, S, &
T VCMI. The results are passed to the control signal database in the controllers
(labeled UCVB in the diagram) through the backplane VME bus.
Control Module R
VCMI Board
with V U
Three IONet C C I/O
Ports M V Boards
I B
IONet - T to other Control, Interface, & Protection Modules
IONet - S to other Control, Interface, & Protection Modules
IONet - R
Interface Module R1
VCMI Board with V
One IONet Port C I/O
M Boards
I
IONet to other
Interface Modules &
Protection Module
Figure 2-5. VCMI Boards providing I/O Communication and I/O Voting
In TMR mode, the VCMI voter in the control module is always the master of the
IONet and also provides the IONet clock. Time synch messages from the time source
on the UDH are sent to the controllers and then to the VCMIs. All input data from a
single rack is sent in one or more IONet packets (approximately 1500 bytes per
packet maximum). The VCMI in the control module broadcasts all data for all
remote racks in one packet, and each VCMI in the remote rack extracts the
appropriate data from the packet.
IONet
The IONet connection on the VCMI is a BNC for 10Base2 Ethernet. The interface
circuit is high impedance allowing “T” tap connections with 50 ohm termination at
the first and last node. The cabling distances are restricted to 185 meters per segment
with up to eight nodes, using RG-58C/U or equivalent cable.

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. Utilizing this master/slave mechanism, and running at 10 Mbps, the IONet
is capable of transmitting a 1000 byte packet every millisecond (8 MHz bit rate).
In a multiple module or multiple panel 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 then the I/O boards in both channels go to a safe state
and a turbine trip occurs.
I/O Boards
Most I/O boards are single width VME boards of similar design and front panel,
using the same digital signal processor (TMS320C32).
The central processing unit (CPU) is a high speed processor designed for digital
filtering and for working with data in IEEE 32-bit floating point format. The task
scheduler operates at a one ms and five ms rate to support high speed analog and
discrete inputs. The I/O boards synchronize their input scan to complete a cycle
before being read by the VCMI board. Contact inputs in the VCCC and VCRC are
time stamped to 1 ms to provide a sequence of events monitor (SOE).
Each I/O board contains the required sensor characteristic library, for example
thermocouple and RTD linearizations. Bad sensor data and alarm signal levels, both
high and low, are detected and alarmed. The I/O configuration in the toolbox can be
downloaded over the network to change the online program. This means that I/O
boards can accept tune-up commands and data while running.
Each I/O board sends an identification message (ID packet) to the VCMI when
requested. The packet contains the hardware catalog number of the I/O board, the
hardware revision, the board barcode serial number, the firmware catalog number,
and the firmware version. Also each I/O board identifies the connected termination
boards via the ID wire in the 37-pin cable. This allows each connector on each
termination board to have a separate identity.

Table 2-1. I/O Boards
I/O Board I/O Signal I/O Termination Boards

VAIC Analog Inputs, 0-1ma, 4-20 mA, voltage 20 TMR, SMX, TBAI (2)
Analog Outputs, 4-20 mA, 0-200 mA 4 TMR, SMX, TBAI (2)
VAOC Analog Outputs, 4-20 mA 16 TMR, SMX, TBAO
VCCC & VCRC Contact Inputs 48 TMR, SMX, TBCI (2), (VCC is two slots)
Solenoids 12 TMR, SMX, TRLY (2)
Dry contact relays 12
VGEN Analog Inputs, 4-20 mA 4 TMR, SMX, TGEN
Potential Transformers 3 TRLY for FAS (PLU)
Current Transformers 2
VPRO (3) Pulse rate 3/9 Emergency Protection, TMR, TPRO
Potential Transformers 2
Current Transformers 3/9
Analog Inputs, 4-20 mA 3
Solenoids 6 TMR, TREG (2)
Contact Inputs 14
Emergency-Stop 1 Hardwire, Trip Clamp, Interconnect to
TRPG
VPYR Pyrometers 2 (8) TMR, SMX, TPYR
VRTD Resistance Temperature Device, RTD 16 SMX, TRTD, (3 wire)
VSVO Servo Outputs to valve hydraulic servo 4 TMR, SMX, TSVO (2), Trip Clamp Input
LVDT Inputs from valve 12
LVDT Excitation 8
Pulse Rate Inputs for Flow Monitoring 2
Pulse Rate Excitation 2
VTCC Thermocouples 24 SMX, TBTC
VTUR Pulse Rate magnetic pickups 4/12 TMR, SMX, TTUR
Potential Transformers, Generator & Bus 2
Shaft Current & Voltage Monitor 2
Breaker Interface -
Flame Detectors (Geiger Mueller) 16 TMR, TRPG (2), J4, (Daughter board)
Solenoids 6 Interconnect to TREG
VVIB Shaft Vibration probes (Bently Nevada) 16, 8 TMR, SMX, TVIB (2), Buffered outputs using
BNC
Shaft Proximity Probes (Displacement) 8,16
Shaft Proximity Reference (KeyPhasor) 2
Termination Boards
The termination board provides the customer wiring connection point, and fans out
the signals to three separate 37-pin D connectors for cables to the R, S, and T I/O
boards. A typical example is shown in Figure 2-6. Each type of I/O board has its own
special termination board, some with a different combination of connectors. For
example, one version of the thermocouple board does not fanout and has only two
connectors for cabling to one I/O board. A new version of the thermocouple board
does fan out and has six connectors for R, S, and T. Since the fanout circuit is a
potential single point failure, the termination board contains a minimum of active
circuitry limited primarily to filters and protective devices. Power for the outputs
usually comes from the I/O board, but for some relay and solenoid outputs, separate
power plugs are mounted on the termination board.

TBAI Termination Board
37-pin "D" shell
x x type connectors
x JT1
x
x with latching
x
x x fasteners
x x
x x
x x
Customer Wiring x x
x x
x x
x x JS1 Cable to VME Rack T
x x
x x
x
Shield Bar
x
x x
x x
x
x
x Cable to VME Rack S
x JR1
x x
x
Customer Wiring x
x x
x x
x x
x x
x x
BarrierType Terminal x x
Blocks can be x Cable to VME Rack R
x
unplugged from board
for maintenance
Figure 2-6. Typical Termination Board with Cabling to I/O Boards in VME Rack
Turbine Protection Module

The Turbine Protection Module (VPRO), and associated termination 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, as shown in Figure 2-7. VPRO controls the trip solenoids via
relay voting circuits on the TREG board.
The TPRO termination 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, generator synchronization cannot occur. For gas turbine
applications, inputs from temperature sensors are brought into the module for
exhaust overtemperature protection.
The VPRO boards do not communicate over a VME backplane, and do not
participate in software voting like the controllers. Failure of a VPRO is detected on
the TREG board and fed back to the control system over IONet. Each VPRO has an
IONet communication port equivalent to that of the VCMI.

VPRO X VPRO Y VPRO Z
x x x x x x x x x x x
x x
I RUN I RUN I RUN

IONet R O FAIL O FAIL O FAIL
IONet S N STAT N STAT N STAT
E 8 X E 8 X E 8 X
IONet T T 4 Y T 4 Y T 4 Y
T 2 Z T 2 Z T 2 Z
R 1 R 1 R 1
C C C
S S S
E E E
Ground R J R J R J
6 J 6 6
J P5 P5 J P5
COM 5 COM COM
5 5
P28A P28A P28A
P28B P28B P28B
E E E
T T T
To TPRO H H H
R R R
x J J J J J J
To TPRO P
4
P P x
3 4 A P
3 A P
3 4 A P
R O R O R O
A W A W A W
F N L E F N L E F N L E
To TREG VPRO R VPRO R VPRO R
x x x x x x x x x x x
To TREG
Power In
125 Vdc
Figure 2-7. Turbine Protection Module with Cabling Connections.
Operating Systems
All operator stations, communication servers, and engineering work stations use the
Microsoft Windows NT® operating system. The HMIs and servers run CIMPLICITY
software, and the engineer’s work station runs toolbox software for system
configuration.
The Mark VI I/O system, because of its TMR requirements, uses a proprietary
executive system designed for this special application. This executive is the basis for
the operating system in the VCMI and all of the I/O boards.
The controller uses the QNX operating system from QNX Software Systems Ltd.
This is a real time, POSIX compliant, operating system ideally suited to high speed
automation applications such as turbine control and protection.

Levels of Redundancy
The need for higher system reliability has led vendors to develop different redundant
systems of increasing complexity, as illustrated in Figure 2-8:
• Simplex systems are the simplest systems having only one chain, and are
therefore 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.
Simplex System Redundancy Reliability

Type (MTBF)
Input Controller Output
Simplex Average
Triple Redundant System

Triple Very
Input Controller (TMR) High
Vote
Controller Vote Output
Vote
Controller
Figure 2-8. 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 GE
Fanuc 90-70 PLC with local and remote I/O might be used in this application. In a
typical Mark VI, many of the I/O are non-critical and are installed and configured as
Simplex. These Simplex I/O boards can be mixed with TMR boards in the same
interface module. Although the Simplex board exists in only one channel, all three
controllers process the Simplex data, and can control the output if one controller
fails.
Triple Redundant control systems, such as Mark VI, are used for the demanding
turbine control and protection application. Here the highest reliability ensures the
minimum plant downtime due to control problems, since the turbine can continue
running even with a failed controller or I/O channel. With continuous input and
output voting, a failure is always masked. Failures are detected and annunciated, and
can be repaired online. This means the turbine protection system can be relied on to
be fully operational if a turbine problem occurs.

Control and Protection Philosophy
This section describes the fault tolerant features of the TMR part of the Mark VI.
The Mark VI system is designed to operate in one of two different configurations:
• Simplex configuration is for non-redundant applications where system survival
after single failures is not a requirement.
• TMR configuration is for applications where single failures do not cause a
shutdown of the controlled process.
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 Tolerant (SIFT). Output voting is performed by hardware circuits
that are an integral part of the output termination 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 voter. Before voting, all input values are
compared to detect any large differences. This value comparator 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 prevents accidental data destruction by adjacent processors.
Isolated power sources prevent a domino effect if a faulty module overloads its
power supply.
TMR Architecture
As shown in Figure 2-9, the TMR control architecture has three duplicate hardware
controllers labeled R, S, and T. A high speed serial network connects each controller
to its associated set of I/O modules, resulting in three independent I/O networks.
Each network is also extended to connect to separate ports on each of the three
controllers producing a very robust I/O communication structure. Each of the three
controllers has three independent I/O communication ports to allow each controller
to receive data from all of the I/O modules on all three I/O networks. The three
protection modules are also on the I/O networks.

Control Module R Control Module S Control Module T
VCMI Board TMR System with
with Three V U V U V U Local & Remote I/O,
IONet Ports C C I/O C C I/O C C I/O Terminal Boards not
M V Boards M V Boards M V Boards shown
I X I X I X
IONet - R
IONet - S
IONet - T
Interface Module R1 Interface Module S1 Interface Module T1

VCMI Board
with One V V V
IONet Port C I/O C I/O C I/O IONet Supports
M Boards M Boards M Boards Multiple Remote
I I I I/O Racks
VPRO VPRO VPRO Protection

X Y Z Module
Figure 2-9. TMR Architecture with Local & Remote I/O, and Protection Module
Each of the three controllers is loaded with the same software image, so that there
are three copies of the control program running in parallel. External computers, such
as the HMI operator stations, acquire data from only the designated controller. The
designated controller is determined by a simple algorithm, as described later.
A separate protection module is an independent TMR subsystem, complete with its
own controllers and integral power supplies, that adds the capability of reliable trip
operation. Separate independent sensor inputs and voted trip relay outputs are used.
Figure 2-10 displays a possible layout of equipment in the cabinets.

Redundant
Unit Data
Highway Control Cabinet Termination Cabinet
1 Genius Power
1 Serial <R n > Interface Module Supply
Termination
V DC Boards
Power DC C
V C I I I I I I
/
Supply / M U
C
V
D IONET M / / / 21 SLOT / / /
DC I O O O VME RACK O O O DC
I V S <R> H
H B K Ethernet 1
2
10Base2
<R> Control Module Thin
Coax
1 Genius Power
1 Serial <S n> Interface Module Supply
V DC
Power DC V U V C I I I I I I
/
Supply / C D IONET M / / / 21 SLOT / / /
DC M C I O O O VME RACK O O O
DC
I V S <S>
H B K H
2 Ethernet 1
10Base2
<S> Control Module
Thin
Coax
Power
1 Genius
1 Serial <T n> Interface Module Supply
V DC
Power DC V U V C I I I I I I
/
Supply / C
M C D IONET M / / / 21 SLOT / / /
DC
DC I O O O VME RACK O O O
I V S <T> H
H B K Ethernet 1
2 10Base2
<T> Control Module Thin
Coax
HUB
Input
+125Vdc
REPEATER <R> Internal
Power Protection V V V
Converter Power
<S> Buss Modules P P P
Input to R R R
Input T
Power <T> Power IONET Power O O O
Supplies Interface <X> <Y> <Z> R
Converter Converter
to I
Input other I/O <R> P
Input
Power Cabinet Power <S>
Lineups +125Vdc
Converter Converter <T> Internal Power
(Optional)
Busses to
Input <X> Power Supplies
Power <Y> & Termination
Converter <Z> Cards
Input Contact Input Excitatn. To
Power Termination
Solenoid Power Cards
Cond.
45 Degree C Ambient 50 Degree C Ambient
Customer
Customer Supplied Sensor Cables
Power Input(s)
Figure 2-10. Typical Cabinet Layout of Mark VI Triple Modular Redundant System

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, often referred to as the Frame,
that is allotted to these operations is set to a fixed value for a given application so
that the control program executes 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 executing the same software, the mode control software in each
controller is synchronizing with, and responding to, an identical copy of itself that is
executing 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
hertz 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 1 ms
accuracy.
Designated Controller
Although three controllers R, S, T contain identical hardware and software, some of
the functions performed are individually unique. The designated controller performs
the following functions:
• Provides data to all external computers.
• Keeps the master time clock.
• Receives and replicates all commands.
• Handles any peer I/O and in turn replicates all inputs from peers for the voting
trio.
• Generates process alarms.
For purposes of deciding which controller is to be the designated controller, each
VCMI nominates itself based on a weighting scheme using the following algorithm:
1*(if previously designated controller) + 2*(number of stable I/O nets) + 3*(if UDH
traffic visible)

The nominating values are voted among the VCMIs and the majority value is used. If
there is a tie, or no majority, the priority is R, then S, then T. If a controller, which
was designated, is powered down and repowered, 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.
UDH communicator
For normal operation, the designated controller and the UDH communicator are the
same module. For some UDH communication failures, multiple controllers need to
be the UDH communicator. The primary communicator is the same as the designated
controller under normal circumstances.
The primary UDH communicator is the spokesperson for the three voting controllers.
A secondary UDH communicator sends and receives peer I/O pages that cannot be
sent or received by the primary communicator if a UDH failure causes the network
to split. The secondary communicator provides necessary control signal flow to and
from the other control panels. Thus Ethernet Global Data (EGD) data is sent to both
networks if a split occurs. On the receiving side of EGD messages, since EGD pages
are identified by exchange number and not by IP address, the change in IP address
does not change the data flow. However, depending on the UDH failure mode, only
one controller in a TMR system may be receiving EGD data, thus IONet forwarding,
of only that portion of EGD data actually used in sequencing, takes place. This
forwarding occurs in the idle IONet portion of the compute frame. This data is input
as if it were Simplex data, and distributed to all three controllers thus maintaining
symmetry. Multiple senders of the same data on split networks are allowed, since
other receiving controllers use the last data set received.
Output Processing
The system outputs are that portion of the calculated data that have to be transferred
to the external hardware interfaces and then to the various actuators that control the
process. Most of the outputs from the TMR system are voted in the output hardware,
but the system can output individual signals in a Simplex system.
Normally, outputs from the TMR system are calculated independently by the three
voting controllers and each controller sends the output to its associated I/O hardware,
for example, R controller sends to R I/O. The three independent outputs are then
combined into a single output by some voting mechanism. Different signal types
require different methods of establishing the voted value.
The signal outputs from the three controllers fall into three groups.
• Signals exist in only one I/O channel and are driven as single ended non-
redundant outputs.
• Signals exist in all three controllers and output separately to an external voting
mechanism.
• Signals exist in all three controllers but are merged into a signal by the output
hardware.

For normal relay outputs, the three signals feed a voting relay driver which operates
a single relay per signal. For more critical protective signals, the three signals drive
three independent relays with the relay contacts connected in the classic six-contact
voting configuration. Figure 2-11 illustrates the two types of output boards.
Termination Board, Relay Outputs

I/O Board
Channel R
I/O Board Voted

Channel S Relay Coil
Driver
Relay Output
I/O Board
Channel T
Termination Board, High Reliability Relay Outputs
I/O Board KR KS
Channel R Relay KR
Coil
Driver
KS KS KT Relay Output
I/O Board Relay
Coil
Channel S Driver
KT KT KR
Relay
I/O Board Coil
Driver
Channel T
Figure 2-11. Relay Output Circuits for Protection

For servo outputs as in Figure 2-12, the three independent current signals drive a
three-coil servo actuator which performs the voting function by magnetic flux
summation. Failure of a servo driver is sensed and a suicide relay contact is opened.
I/O Boards
Servo Driver Output

Termination Coils
Channel R
D/A Board on Servo
Valve
Servo Driver
Channel S
D/A
Servo Driver
Channel T
D/A
Hydraulic
Servo
Valve
Figure 2-12. TMR Circuit to Combine Three Analog Currents into a Single Output
Figure 2-13 shows 4-20 ma signals combined through a 2/3 current sharing circuit
that allows the three signals to be voted to one. This unique circuit ensures the total
output current is the voted value of the three currents. Failure of a 4-20 mA output is
sensed and a suicide relay contact is opened.
I/O Boards
4-20 mA Driver Output Current
Channel R Termination Feedback
D/A Board
Output
4-20 mA Driver
Load
Channel S
D/A
4-20 mA Driver
Channel T
D/A
Figure 2-13. TMR Circuits for Voted 4-20 mA Outputs
Input processing
All inputs are available to all three controllers but there are several ways that the
input data is handled. For those input signals that exist in only one I/O module, the
value is used by all three controllers as common input without voting as in Figure
2-14. Signals that appear in all three I/O channels may be voted to create a single
input value. The triple inputs may come from three independent sensors or may be
created from a single sensor by hardware fanning at the termination board.

I/O Rack Control Rack
Field Wiring Termin. Bd. I/O Board VCMI IONet VCMI Controller
Sensor Direct Signal Exchange No Control System

Input Condition Vote Data Base
Alarm Limit
A SC R
Figure 2-14. Single Input to Three Controllers, Not Voted
A single input can be brought to the three controllers without any voting as shown
above. This is used for non-critical, generic I/O, such as monitoring 4-20 mA inputs,
contacts, thermocouples, and RTDs.
One sensor can be fanned to three I/O boards as above for medium integrity
applications, as in Figure 2-15. This is used for sensors with medium to high
reliability. Three such circuits are needed for three sensors, see later. Typical inputs
are 4-20 mA, contacts , thermocouples, and RTDs.

Sensors Fanned Signal Prevote Exchange Voter Control

Input Condition System Data
Base
SC R Voted (A)
A
R Voter
SC S Voted (A)
S Voter
SC T Voted (A)
T Voter
Figure 2-15. One Sensor with Fanned Input & Software Voting

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, shown in Figure 2-16, is
used for special applications only.

Sensors Common Signal No Median Control System

Input Condition Vote Select Data Base
Alarm Limit Block
A MSB Median (A,B,C)
SC
A B A
R R B
C
C

B SC
B S A
S B
C
C
SC
C B A
T T
C B
C
Figure 2-16. Three Independent Sensors with Common Input, Not Voted
Figure 2-17 shows three sensors, each one fanned and then SIFT voted. This
provides a high reliability system for current and contact inputs, and temperature
sensors.
I/O Rack Controller Rack
Sensors Fanned Signal Prevote Exchange Voter Control System

Input Condition Data Base
Alarm Limit
SC R Voted "A"
A Control
R Voter Voted "B"
Block
Voted "C"
B SC S Voted "A"
Control
Same S Voter Voted "B"
Block
Voted "C"
SC T Voted "A"
C Control
Same T Voter Voted "B"
Block
Voted "C"
Figure 2-17. Three Sensors, Each One Fanned and Voted, for Medium to High
Reliability Applications

Speed inputs to high reliability applications are brought in as dedicated inputs and
then SIFT voted. Figure 2-18 shows this configuration. Inputs such as speed control
and overspeed are not fanned so there is a complete separation of inputs with no
hardware cross coupling which could propagate a failure. RTDs, thermocouples,
contact inputs, and 4-20 mA signals can also be configured this way.
Sensors Dedicated Signal Prevote Exchange Voter Control System

Input Condition Data Base
Alarm Limit
SC R Voted (A,B,C)
A
R Voter
B SC S Voted (A,B,C)
S Voter
SC T Voted (A,B,C)
C
T Voter
Figure 2-18. Three Sensors with Dedicated Inputs, Software Voted for High
Reliability Applications
State Exchange
Voting all of the calculated values in the TMR system is unnecessary and not
practical. The actual requirement is to vote the state of the controller database
between calculation frames. Calculated values such as timers, counters, and
integrators are dependent on the value from the previous calculation frame. Logic
signals such as bistable relays, momentary logic with seal-in, cross-linked relay
circuits and feedbacks have a memory retention characteristic. A small section of the
database values is voted each frame.

Median Value Analog Voting
The analog signals are converted to floating point format by the I/O interface boards.
The voting operation occurs in each of the three controller modules (R, S, and T).
Each module receives a copy of the data from the other two channels. For each voted
data point, the module 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. Figure 2-19 shows some examples.
The disagreement detector (see the section on Disagreement Detector) checks the
signal deviations and sets a diagnostic if they exceed a preconfigured limit, thereby
identifying failed input sensors or channels.
Median Value Voting Examples
Sensor Median Sensor Median Sensor Median

Sensor Inputs
Input Selected Input Selected Input Selected
Value Value Value Value Value Value
Sensor
981 910 1020
1
Sensor 985 981 985 978 985 985

2
Sensor 978 978 978

3
Configured TMR No TMR Diagnostic TMR Diagnostic TMR Diagnostic

Deviation = 30 on Input 1 on Input 1
Figure 2-19. Median Value Voting Examples with Normal & Bad Inputs
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 and finds the two values which 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.

Disagreement Detector
Failure of one of the three A disagreement detector is provided to continuously scan the prevote data sets and
voted input circuits has no produce an alarm bit if a disagreement is detected between the three values in a
effect on the controlled voted data set. The comparisons are made between the voted value and each of the
process since the fault is three prevote values. The delta for each value is compared with a user programmable
masked by the SIFT limit value. The limit can be set as required to avoid nuisance alarms but give
technique. A failure could go indication that one of the prevote values has moved out of normal range. Each
unnoticed until an occurrence controller is required to compare only its prevote value with the voted value, for
of a second failure of the example, R compares only the R prevote value with the voted value.
same signal set.
Note Earlier versions of the Mark VI do not have the Disagreement Detector.
Peer I/O
In addition to the data from the I/O modules, there is a class of data that comes from
other controllers in other panels that are connected via a common data network. For
the Mark VI controller the common network is the UDH. For integrated systems, this
common network provides a data path between multiple turbine control panels and
possibly the controls for the generator, the exciter, or the HRSG/boiler.
Selected signals from the controller database may be mapped into a page of peer
outputs that are broadcast periodically on the UDH to provide external panels a
status update. For the TMR system this action is performed by the UDH
communicator using the data from its internal voted database.
Several pages of peer inputs may be received by the TMR panel as the other control
panels on UDH are broadcasting their status pages. The designated
controller/primary communicator may have the responsibility for receiving the pages
and replicating the content for the other controllers in the voting trio. The operation
is similar to the input of common input data from a single I/O module, but in this
case the data is broadcast on the I/O network by the designated controller.
Command Action
All of the commands to the TMR control panel need special processing to cause the
three voting controllers to perform the same action at the same time. Since the source
is a standard computer connected to the UDH and sending messages over a single
network, there is very little benefit for voting the commands in each controller. The
situation is complicated by commands being sent from one of several redundant
computers at the operator position or positions.
In Mark VI, the designated controller receives all commands, and the response of the
voting trio is synchronized by issuing the commands to all three controllers at the
same frame time.
Rate of Response
Mark VI can execute selected control programs at the rate of 100 times per second,
(10 ms frame rate) for Simplex systems, and 25 times per second (40 ms frame rate)
for TMR systems. This is the fastest rate for the TMR system. The timing diagram is
shown in Figure 2-20. In this example, bringing the data from the interface modules
to the control module and voting it takes three ms, executing the control program
takes four ms, and sending the data back to the interface modules takes three ms.

Start of One Frame Time (10 ms)
Frame
1 2 3 4 5 6 7 8 9 SOF
(SOF)
Control
Background Compute Control Sequence & Blocks Background
Module
CPU
Vote
Control State Fast Fast Prevote
Module Vote R1 R2 Compare
Voting
Control Fast Fast Out State

R1 R2 Xchg.
Module
Input Input
Comm
I/O Module Fast Fast Background Receive

Comm Scatter
Gather Send Send
Scale Set Scan Scale Write

I/O Module Background
Calc Output Input Calc Data
Board
Read
Data
Just in Time to Start
Figure 2-20. TMR System Timing Diagram for System with Remote I/O
Power Sources
In a TMR system each control module and I/O module have their own power supply
to guard against a single power supply causing a double fault. A reliable source of
power is required for the input to the power supplies from either a battery, or from
multiple power converters that are connected in a redundant fashion, or maybe a
combination of both. The multiple power converters connected as high-select
provide the required redundancy.
Failure Handling
The general philosophy on failures is that corrective or default action takes place in
both directions away from the fault. This means that, in the control hierarchy
extending from the termination screws up through I/O boards, backplanes, networks
and main CPUs, when a fault occurs, there is a reaction at the I/O processor and also
at the main controller if still alive. When faults are detected, health bits are reset in a
hierarchical fashion. If a signal goes bad, the health bit is set false at the control
module level. If a board goes bad, all signals associated with that board whether
input or output have their health bits set false. A similar situation exists for the I/O
rack. In addition, there are preconfigured default failure values defined for all input
and output signals so that normal application code may cope with failures without
excessive healthy bit referencing. Healthy bits in TMR systems are voted if the
corresponding signal is TMR.

Loss of Control Module in Simplex System
Output boards go to their configured default output state after a timeout. This means
that the loss of a 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
Since there can be three possible masters on any given IONet, some recovery from a
control failure is possible. The voter VCMI in the failed control module stops
communicating on IONet, even if it is possible to continue. Output boards note that
the IONet has stopped for that processor and commence the timeout. Before this
timeout finishes, the voter VCMI board in the next control module (in R,S,T,R order)
sends its output packet on the quiet IONet. The receiving VCMIs note that the
normal master is no longer talking, then ignore the TMR output boards and transmit
the simplex outputs to the correct boards. These simplex outputs continue to work.
The TMR outputs timeout and assume their configured default output states, and
hardware voting copes with the failure. The substitute VCMI also requests the input
data which enables the remaining two controllers to continue voting input data.
Loss of I/O VCMI in TMR System
If the VCMI in an interface module fails, outputs timeout to their configured default
output state. Inputs are set at their configured default state so that resultant outputs,
such as UDH and Genius, may 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
Hardware on outputs from the I/O Boards set the outputs to a low power default
value given typical applications. Input boards have their input values set to the
preconfigured 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 if they were in a Simplex system.
Loss of TMR I/O Board in TMR System
Inputs and outputs are handled as described previously. TMR SIFT and hardware
output voting keep the process running.
Loss of IONet in Simplex System
The output boards in the I/O racks timeout and set the preconfigured default output
values. The master VCMI board defaults the inputs so that UDH and Genius outputs
can be correctly set.
Loss of IONet in TMR System
Outputs follow as for a Loss of Control Module in Simplex. Inputs follow as for
Loss of I/O VCMI in TMR.

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 termination 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 termination board via 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. Figure
2-21 shows the two levels of protection.
Software
Voting
High Speed Shaft R Controller

TTUR TRPG
&
VTUR Termination
Termination
R Board
Board
High Speed Shaft S
Controller Primary
& Hardware Protection
VTUR Voting
S
High Speed Shaft (Relays)
T
Controller
&
VTUR
Magnetic T
Speed
Pickups
(3 used) Trip Solenoids
(Up to three)
High Speed Shaft X TPRO

VPRO TREG
Termination X Termination
Board Board
High Speed Shaft Y
VPRO
Y Hardware Emergency
Voting Protection
High Speed Shaft Z
(Relays)
VPRO
Z
Magnetic
Speed Trip Signal
Pickups to Servo
(3 used) Termination
Board
TSVO
Figure 2-21. Primary and Emergency Overspeed Protection

Emergency overspeed protection is provided by the independent triple redundant
VPRO protection system, as shown in Figure 2-7. This uses three shaft speed signals
from magnetic pickups, one for each protection module. These are brought into
TPRO, a termination board dedicated to the protection system. Each VPRO
independently determines when to trip, and the signals are passed to the TREG
termination 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 via
the Servo Termination 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 drive the control valve closed.
Reliability & Availability

System reliability and availability can be calculated using the component failure
rates. These numbers are important for deciding when to use Simplex circuits versus
the TMR circuits. TMR systems have the advantage of on-line repair discussed in the
following section.
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 termination boards so
removal of the termination board requires that the wires be disconnected
momentarily. Each type of termination board must be evaluated for the application
and the signal type involved. Voltages in excess of 50 volts are present in some
customer wiring. Termination 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 termination boards such as the relay outputs, the individual relays
may be replaced without disconnecting the termination board.
For those singular signals that are 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 Power down only the module that has the fault. Failure to observe this rule
may cause an unexpected shutdown of the process. To this end, each module has its
own power disconnect or switch. The modules are labeled such that the diagnostic
messages identify the faulty module.

Repair the faulty modules as soon as possible. Although the TMR system will
survive certain multiple faults without a forced outage, a lurking 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.
However, once a second unrelated fault occurs in the same module set, then either of
the faulty modules of the set that is powered down will introduce a dual fault in the
same three signal set which may cause a process shutdown.
Reliability
Reliability is represented by the Mean Time Between Forced Outages (MTBFO). In
a Simplex system, failure of the controller or I/O communication may cause a forced
outage. Failure of a critical I/O module will cause a forced outage, but there are non-
critical I/O modules which can fail and be changed out without a shutdown. The
MTBFO is calculated using published failure rates for components at the maximum
operating temperature.
Availability is the percentage of time the system is operating, taking into account the
time to repair a failure. Availability is calculated as follows:
MTBFO x 100%
MTBFO+MTTR
where:
MTTR is the Mean Time To Repair the system failure causing the forced outage, and
MTBFO is the Mean Time Between Forced Outages
With a TMR system there can be failures without a forced outage because the system
can be repaired while it continues to run. The MTBFO calculation is complex since
essentially it is calculating the probability of a second (critical) failure in another
channel during the time the first failure is being repaired. The time to repair is an
important input to the calculation.
The availability of a well designed TMR system with timely online repair is
effectively 100%. Possible forced outages may still occur if a second failure of a
critical circuit comes before the repair can be completed. Other possible forced
outages may occur if the repairman erroneously powers down the wrong module.
Note To avoid possible forced outages from powering down the wrong module,
check the diagnostics for identification of the modules which contain the failure.
Reliability data was determined by calculating the Failures In Time (FIT) (failures
per 109 hours) based on the Bellcore TR-332 Reliability Prediction Procedure for
Electronic Equipment. The Mean Time Between Failures (MTBF) is the inverse of
the FITS. The Mean Time Between Forced Outage (MTBFO) of the control system
is a function of which boards are being used to control and protect the turbine.
The complete system MTBFO depends on the size of the system, number of Simplex
boards, and the amount of sensor triplication.

Third Party Connectivity
Mark VI can be linked to the plant Distributed Control System (DCS) in four
different ways.
• Modbus link using the controller RS-232C COM2 port. This serial
communication runs at either 9,600 or 19,200 baud.
• Modbus link from the HMI Server RS-232C port to the DCS, similar to the
controller link.
• A high speed 10 Mbaud Ethernet link using the Modbus over TCP/IP protocol.
• A high speed 10 Mbaud Ethernet link using the TCP/IP protocol with an
application layer called GEDS Standard Messages (GSM). GSM supports
turbine control commands, Mark VI data and alarms, the alarm silence function,
logical events, and contact input sequence of events records with one ms
resolution.
Figure 2-22 shows the four options. Modbus is widely used to link to DCSs, but
Ethernet GSM has the advantage of speed, distance, and functionality.
To DCS To DCS To DCS To DCS

Serial Modbus Serial Modbus Ethernet Modbus Ethernet GSM
Mark VI
Controller PLANT DATA HIGHWAY
x x
HMI Server Node
To Plant Data
Highway (PDH)
Ethernet Ethernet Ethernet
UCVB
x x Ethernet
UNIT DATA HIGHWAY
Figure 2-22. Optional Communication Links to Third Party Distributed Control System

Notes

Chapter 3 Networks
Introduction
This chapter defines the various communication networks making up the Mark VI
system. These networks provide communication with the operator interfaces, servers,
controllers, and I/O. Communication to Genius I/O and to the plant distributed
control system is included.
Network Overview
The Mark VI system is based on a hierarchy of networks that are used to
interconnect the individual nodes. These networks separate the different
communications traffic into layers according to their individual functions. This
hierarchy extends from the I/O and controllers, which provide real-time control of
the turbine and its associated equipment, through the operator interface systems, and
up to facility wide monitoring or DCS systems. Each layer uses standard
components and protocols to simplify integration between different platforms and
Ethernet is used for all improve overall reliability and maintenance. The layers are designated as the
Mark VI data highways and Enterprise, Supervisory, Control, and I/O layers, and are more fully described in the
the I/O network following sections, and shown in Figure 3-1.
Enterprise Layer
The Enterprise layer serves as an interface from the turbine or stage control into a
facility wide or group control layer. These higher layers are provided by a DCS
vendor or by the customer. The network technology used in this layer is generally
determined by the customer and may include either Local Area Network (LAN) or
Wide Area network (WAN) technologies, depending on the size of the facility. The
Enterprise layer is generally separated from other stage control layers via a router,
which isolates the traffic on both sides of the interface. Where unit control
equipment is required to communicate with a facility wide or DCS system, GE
prefers to use either a Modbus interface or a TCP/IP protocol known as GSM (GE
Standard Messaging).
Supervisory Layer
The Supervisory layer provides operator interface capabilities such as to coordinate
HMI viewer and server nodes, and other functions like data collection (Historian),
remote monitoring, and vibration analysis.
GEH-6421 Mark VI System Guide Chapter 3 Networks • 3-1

This layer uses Ethernet in a shared dual network configuration, which provides
redundant hubs and cables to prevent complete network failure if a single component
fails. This network is known as the Plant Data Highway (PDH).
To Optional
Customer Network
(Enterprise Layer)
Router
HMI HMI HMI Field
Viewer Viewer Viewer OSM
Support
Supervisory Network
PLANT DATA H IGHWAY HUB
PLANT DATA HIGHWAY HUB
Bently-Nevada
HMI Servers Vibration Analysis Control Network
U NIT DATA H IGHWAY HUB
Gas Turbine Steam Turbine Generator

Control TMR Control Protection BOP Exciter
Mark VI Mark VI GP 90-70 PLC EXCITER
Mark VI
Mark VI HRSG LCI

Innovation
90-70 PLC
Series
Controller
Genius Genius Genius
IONet IONet
Bus Bus Bus
I/O Boards I/O Boards I/O Boards I/O Boards I/O Boards
Figure 3-1. Turbine Control as Part of Integrated Control System
Control Layer
The Control layer provides continuous operation of the power generation equipment.
The controllers on this layer are highly coordinated to support continuous operation
without interruption. This synchronization operates the control network at a
fundamental rate called the frame rate. During each frame, all controllers on the
network transmit their internal state to all other nodes. An optimized protocol based
on UDP/IP known as Ethernet Global Data (EGD) provides data exchange between
nodes at a nominal frame rate of 25 Hz. Redundancy is important on the Control
layer to ensure that a failure of any single component does not cause a turbine trip.
This is accomplished with a shared dual network configuration known as the Unit
Data Highway (UDH).
3-2 • Chapter 3 Networks GEH-6421 Mark VI System Guide

Various levels of redundancy for the connected equipment are supported by the
Supervisory and Control layers. Four redundancy levels are shown in Figure 3-2.
Printer
Printer
Type 1 Redundancy Non-critical nodes

such as printers can be connected without
using additional communication devices.
Network Hub B
Network Hub A
Type 2 Redundancy Nodes that are only

available in Simplex configuration, such as
an HMI, can be connected with redundant
Redundant transceivers. These automatically sense a
Transceiver failed network component (cable or hub)
Network Hub B and failover to a secondary link.
Network Hub A
Controller Controller
Type 3 Redundancy Nodes such as
duplex or TMR controllers are tightly
coupled so that each node can send the
same information. By connecting each
controller to alternate networks, data is still
Network Hub B available if a controller or network fails.
Network Hub A
Redundant
Transceiver Redundant
Transceiver Type 4 Redundancy This provides
redundant controllers and redundant network
links for the highest reliability. This is useful if
the active controller network interface cannot
Network Hub B sense a failed network condition.
Network Hub A
Figure 3-2. Redundant Networks and Transceivers for Different Applications

Controller Input/Output
Communication between the I/O boards and the Mark VI controllers is based on
Ethernet, using an extension of the Asynchronous Device Language (ADL) protocol.
The network is either a Simplex or TMR system. This redundancy provides very
high reliability and superior communications diagnostics.
Plant Data Highway

The PDH is the plant level supervisory network. PDH connects the HMI Server with
remote viewers, printers, historians, and external interfaces. Usually there is no direct
connection to the Mark VI controllers, which communicate over the UDH. Use of
Ethernet with the TCP/IP protocol over PDH provides an open system for third party
interfaces. Figure 3-3 shows the equipment connections to the PDH.
HMI View Node HMI View Node
Laser printer
Laser printer
Redundant Redundant
Transceiver Transceiver
PLANT DATA HIGHWAY - BUS B
PLANT DATA HIGHWAY - BUS A
HMI Server Node HMI Server Node
From UDH From UDH
Figure 3-3. Redundant Plant Data Highway Communication with Operator Stations

Table 3-1. PDH Network Features
PDH Feature Description
Type of Network Ethernet CSMA/CD in a single or redundant Star configuration.

Speed 10 Mbps data rate (100 Mbps optional).
Media and Distance Ethernet 10Base-T for hub to controller/device connections. The
cable is 22 to 26 AWG with unshielded twisted pair, category 5
EIA/TIA 568 A/B. Distance is up to 100 meters.
Ethernet 10Base-FL with fiber optic cable for network backbone;
distances of 2 km.
Number of Nodes Up to 1024 nodes supported.
Protocols Any Ethernet compatible protocol, typically TCP/IP based. Use
GE Standard Messaging (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 EMI and RFI.
Large point-to-point distances are possible, and since the cable does not carry
electrical charges, ground potential problems are eliminated.
The PDH network hardware is listed in the following table.
Table 3-2. PDH Network Hardware
PDH Network Hardware Description
UTP Cable Unshielded Twisted Pair (UTP) cable, 4 pair, Category 5

EIA/TIA 568 A/B or better, including RJ-45 connectors.
Fiber Cable Optical fiber cable, Ethernet 10base-FL type, 6 fiber (3 pair),
62.5/125 micron, dual window, graded index profile,
multimode glass-on-glass construction, thermoplastic jacket,
including ST connectors.
Network Hubs PDH Network Hubs (2), Cabletron SEHI (1) and SEH (1), are
examples.
Transceivers Fault Tolerant Multi-Port Transceivers, Digi International
MIL-301X is an example.

Unit Data Highway
The UDH is an Ethernet based network which provides peer-to-peer communications
between controllers and an operator/maintenance interface. This network uses
Ethernet Global Data (EGD) which is a message based protocol for sharing
information with multiple nodes based on the UDP/IP standard. Data can be sent
directly or broadcast to peer controllers or other control systems on the network.
Table 3-3. UDH Network Features
UDH Feature Description
Type of Network Ethernet CSMA/CD using Ethernet Global Data (EGD) protocol; in
single or redundant network configuration
Speed 10 Mbps data rate
Media and Distance Ethernet 10Base-T for hub to controller/device connections. The
cable is 22 to 26 AWG unshielded twisted pair (standard telephone
wire); category 5 EIA/TIA 568 A/B. Distance is up to 100 meters
Ethernet 10Base-FL with fiber optic cable optional for network
backbone; distance is two km.
Number of Nodes With 10 nodes, system provides a 25 Hz data rate. For other
configurations contact the factory.
Type of Nodes Supported Mark VI Controllers; will also support Innovation Series Controllers,
GE Fanuc PLCs, CIMPLICITY MMI Products, and Windows-based
PCs (with appropriate drivers)
Protocol EGD protocol based on the UDP/IP standard (RFC 768), also
SRTP (Serial Request Transfer Protocol) protocol
Message Integrity 32-bit CRC appended to each Ethernet packet plus integrity checks
built into UDP and EGD
Time Synch. Methods Network Time Protocol (NTP), accuracy 1 ms.
External Time Synch. Options Timecode signals supported: IRIG-A, IRIG-B, NASA-36, 2137.
Global Position System (GPS); also periodic pulse option.
Figure 3-4 shows the UDH with connections to the controllers and HMI servers.

To Plant Data Highway
HMI HMI
Server Server
Node Node
Control Network
UNIT DATA HIGHWAY - HUB B
UNIT DATA
UNIT DATAHIGHWAY - ’B’A
HIGHWAY - HUB
Mark VI Mark VI 90-70 PLC

GAS TURBINE STEAM TURBINE HRSG
UCVx
VCMI
UCVX
VCMI
DISK
RCM
I/O
I/O DISK VCMI
CPU
EX7
I/O
I/O
UCVX
VCMI
I/O
RCM
CPU
Simplex EX7
UCVX
DISK
I/O
I/O
Redundant
TMR
Transceiver
Figure 3-4. Unit Data Highway showing Connections to Simplex, Duplex, & TMR
Controllers
Data Highway Hubs

The UDH and PDH networks use Ethernet hubs. The network equipment is cabled
into the hubs to create a star type network architecture. Redundancy is obtained by
using two hubs with an interconnecting cable.
A typical hub is described here and shown in Figure 3-5. The Ethernet cables plug
into a multi-port 10BaseT adapter on the front of the hub. The adapter has RJ45
ports. If fiber optic cables are required an externally mounted fiber optic media
converter can be connected using a multi-conductor cable. For system diagnostics
there is an LED status monitoring and diagnostic display on the front showing the
power status, and the receive, link, and collision status on the Ethernet cables.

Ethernet UTP
Cables from
Network Devices
Plug-in Module
with 12 Ethernet
RJ45 ports
Ethernet 10Base-T HUB

Interface
Status LEDs
24X 13X
Interface
Status LEDs
12X 1X
50-Pin Champ Connector Cable to Fiber

Optic Converter
Rear View
Ethernet 10BASE-T HUB
PWR
OUT Interconnect IN
Cable to next Hub Cable from previous Hub
Figure 3-5. Typical Stackable Ethernet Hub with Connection to Fiber Optic Converter
Ethernet Global Data (EGD)

Controller data configured for transmission over EGD is known as an exchange. An
exchange has the same meaning as a page in the control system toolbox. EGD
provides for the repeated transmission of an exchange from a controller, called a
producer, to other devices such as CIMPLICITY HMI, called consumers. Each
controller can support several exchanges, and these may be configured to be sent to
either a specific address (unicast) or to multiple consumers at the same time
(broadcast).
Each exchange is identified by the combination of a Producer ID and an Exchange
ID so the consumer recognizes the data and knows where to store it. The exchange
contains a configuration signature, which shows the revision number of the exchange
configuration. If the consumer receives data with an unknown configuration
signature then it sets the data "unhealthy".

In the case of a transmission interruption, the receiver waits three periods for the
EGD message, after which it times out and the data is considered unhealthy. Data
integrity is preserved by:
• 32-bit Cyclic Redundancy Code (CRC) in the Ethernet packet
• Standard checksums in the UPD and IP headers
• Configuration signature
• Data size field
Error handling services are included to handle lost packets and device failure
conditions.
UDH & PDH Ethernet IP Address Rules

This section defines the recommended IP addresses of the various items on the UDH
and PDH. The standard IP address is:
192. 168. ABC. XYZ.
These address letters are defined in the following table.
Table 3-4. Ethernet IP Address Rules
Network A BC X Y Z
Type Type Network Number Controller/Device Number Unit Number Type of Device
UDH 1 01 - 99 1 = Gas Turbine Controllers 1 = Unit 1 1 = R0
2 = Steam Turbine 2 = Unit 2 2 = S0
Controllers
. 3 = T0
9 = Unit 9 4 = HRSG A
5 = HRSG B
6 = EX2000 A
7 = EX2000 B
8 = EX2000 C
9 = Not assigned
0 = Static Starter
0 = All other devices on the 02 – 15 = Servers
UDH 16 – 25 = Workstations
26 – 37 = Other stations (Viewers)
38 = Historian
39 = OSM
40 – 99 = Aux Controllers, such as ISCs
PDH 2 01 - 54 2 to 199 are reserved for

customer supplied items
200 to 254 are reserved for

GE supplied items such as
Viewers and Printers

The following are examples of IP addresses:
192.168.104.133 would be UDH number 4, gas turbine unit number 3, T0 core.
192.168.102.215 would be UDH number 2, steam turbine unit number 1, HRSG B
192.168.201.201 could be a Cimplicity Viewer supplied by GE, residing on PDH#1.
192.168.205.10 could be a customer supplied printer residing on PDH#5
Note Each item on the network such as a controller, server, or viewer must have an
IP address. The above addresses are recommended but the customers may choose
their own scheme.
IONet
IONet is an Ethernet 10Base-2 network used to communicate data between the
VCMI communication board in the control module, the I/O boards, and the three
independent sections of the Protection Module . In large systems, it is used to
communicate with an expansion VME board rack containing additional I/O boards.
These racks are called interface modules since they contain exclusively I/O boards
and a VCMI. IONet also communicates data between controllers in TMR systems.
Another application is to use the interface module as a remote I/O interface located
at the turbine or generator. Since there is no central processor in the rack, all boards
are specified for an external cabinet ambient temperature of 50 °C. IONet uses ADL
to poll the interface module and Protection Module for data instead of using the
standard collision detection mechanisms provided in Ethernet LANs.
Figure 3-6 shows a TMR configuration using remote I/O and a protection module.
Table 3-5. IONet Features
IONet Feature Description
Type of Network Ethernet using extension of ADL protocol

Speed 10 Mbps data rate
Media and Distance Ethernet 10Base-2, RG-58 coax cable is standard
Distance to 185 meters.
Ethernet 10Base-FL with fiber optic cable and converters
Distance is 2 km
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

IONet – 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 panel LEDs.
The VCMI serves as the master Frame counter for all nodes on the IONet. Execution
frames are sequentially numbered and all nodes on IONet execute in the same frame
This ensures that selected data is being transmitted and operated on correctly.
R S T X Y Z
TMR System V
V U V U V U V V
with Remote P
C C C C C C P P
I/O Racks R
M V M V M V R R
I X I X I X O O O
IONet - R
IONet - S
IONet - T
R1 S1 T1 UCVX is Controller,
V V V VCMI is Bus Master,
VPRO is Protection
C I/O C I/O C I/O Module,
M Boards M Boards M Boards I/O are VME boards.
I I I (Termination Boards
IONet Supports
not shown)
Multiple Remote
I/O Racks
Figure 3-6. IONet Communications with Controllers, I/O, and Protection Modules
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 via 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 execution, 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, via the VME
bus, the input values from each of the I/O boards 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
via 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) go through a median selector, while logical data (bit values) go
through a two out of three majority voter. The results are placed in the voted table.
A selected portion of the I/O table (the states such as counter/timer values and
sequence steps) must be transferred from each of the VCMI boards to the other
VCMI boards to be included in the vote process. At completion of the voting the
voted table is transferred via the VME bus to the I/O 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.
For more information on the VCMI see Chapter 9 I/O Descriptions.
Genius Bus
Genius Bus is a serial communication link to communicate from the Mark VI
controller to either a Flat Panel operator interface station, or to the GeniusTM family
of remote I/O blocks. Figure 3-7 shows typical connections.
x x
Mark VI Controller
in Control Module
Field Control I/O
Genius Bus
x x
Genius I/O
Figure 3-7. Genius I/O Connected to Mark VI Controller
Genius Bus
The Genius bus is a LAN using a shielded, twisted-pair wire, daisy-chained from
block to block and terminated at both ends. A maximum of 32 devices can be
supported on the bus at 153.6 Kbaud. The bus is a token passing network with a
typical bus scan time between 20 and 30 ms.

Several types of devices can communicate on the bus including the controller,
Genius I/O blocks, Field Control Stations, remote drops, and hand-held monitors.
Typical busses reserve two locations for the bus controller and one location for a
Hand-Held monitor. The Hand-Held monitor can be used as a portable device, or it
can be permanently mounted. It provides a convenient installation interface for block
setup, data monitoring, and diagnostics.
For more information refer to GEK-90486F Genius I/O System and Communications
– User's Manual.
Table 3-6. Genius Bus Features
Genius Bus Feature Description

Type of Communication Multidrop serial network using a token passing protocol
Speed Speed configurable from 38.4 to 153.6 Kbaud
Modulation Frequency Shift Keying (FSK)
Media and Distance At a speed of 38.4 Kbaud the bus distance is 7,500 feet using shielded
twisted pair cable; at 153.6 Kbaud the distance is 3,500 feet
Redundancy Dual Genius bus with cable switching available
Nodes Up to 32 devices at 153.6 Kbaud
Bus Controller Mark VI controller, or PLC, or a PC
Message Integrity The system rejects single dipulse errors using a 2/3 voting scheme; a
cyclic redundancy code (CRC) is appended to each message
Bus Isolation 2,000 Volts Hi-Pot, 1,500 Volts transient common mode rejection
Signal/Noise Ratio 60 dB
Field Control I/O System

Field Control I/O provides a cost effective I/O system on the Genius bus, with
limited diagnostics relative to the Genius blocks. Each I/O station is made up of a
Bus Interface Unit (BIU), field terminal bases, and field I/O modules. Several
terminal block options are designed to eliminate the need for auxiliary terminal
blocks. The BIU interfaces the I/O station to the Genius bus, and controls up to eight
field terminal bases, all of which are DIN-rail (Deutsche Industrie Norm) mounted.
Genius I/O Diagnostics

Genius I/O blocks have a number of self-diagnostic features as listed below:
Table 3-7. Genius I/O Diagnostics

Discrete I/O Blocks Analog I/O Blocks
Open-wire detection (inputs) Open-wire detection (inputs)
Sense shorted wire (inputs) High alarm (inputs)
Failed switch (inputs/outputs) Low alarm (inputs)
Over temperature (inputs/outputs) Internal fault (inputs)
Loss I/O power (inputs/outputs) Wiring error (inputs)
Overload (outputs) Input short (inputs)
Short-circuit (outputs) Under-range (input/outputs)
Load state feedback (outputs) Over-range (inputs/outputs)
Pulse Test (outputs) Feedback error (output)
No-load (outputs)

This diagnostic information can be referenced in the controller with two additional
signals which are automatically defined for each point. These diagnostic "health"
signals can be used in the control logic to react to electrical or mechanical faults, and
to annunciate the fault in the HMI.
Signal Flow in Controller

Figure 3-8 illustrates the controller signal flow from the Genius bus input driver to
the control task. Inputs in the I/O Table are scaled and passed to the Software Signal
Table where they are used in the control task. Outputs from the task are scaled and
passed to the I/O Table for output through the I/O driver.
I/O Table Software Signal Table

Genius
I/O
Driver
ST1\WEDGE\IRS\CHAHTRK
Control Task
Figure 3-8. Controller Signal Flow
Wiring
Genius bus is daisy-chained between stations, as shown in Figure 3-9. Both the input
and output wires for SER1 and SER2 join at the controller.

Start of End of
Bus Bus
Terminating Terminating
Resistor Resistor
Serial 1 Serial 1
Serial 2 Serial 2
Shield In Shield In
Shield Out Shield Out
Figure 3-9. Genius Bus Wiring between Stations
The cables listed in the following table have been tested and recommended for use.
Table 3-8. Genius Bus Cables
Cable Outer Terminating Number of Di-Electric Ambient Maximum

Number& Diameter Resistor1/2 Conductors/ Voltage Temperature Length at
Make Watt AWG Rating Rating 153.6Kb (E)
(A) 9823 0.350 in 150 ohms 2 / #22 30 v 60 C 3,500 ft
(B) 9182 8.89 mm 1,061 m
(C) 4596
(B) 89128 0.322 in 150 ohms 2 / #22 150 v 200 C 3,500 ft
8.18 mm 1,061 m
(B) 9841 0.270 in 120 ohms 2 / #24 30 v 80 C 1,500 ft
6.86 mm 455 m
(A) 9818C 0.330 in 100 ohms 2 / #20 300 v 80 C 2,500 ft
(B) 9207 8.38 mm 758 m
(A) 9109 0.282 in 100 ohms 2 / #20 150 v 200 C 2,500 ft
(B) 89207 7.16 mm 758 m
(C) 4798
(A) 9818D 0.330 in 100 ohms 2 / #20 2,500 ft
(B) 9815 8.38 mm 758 m
(A) 9818 0.315 in 100 ohms 4 two pair / 150 v 60 C 1,700 ft
(B) 9855 8.00 mm #22 516 m
(A) 9110 0.274 in 100 ohms 4 two pair / 150 v 200 C 1,700 ft
(B) 89696 6.96 mm #22 516 m
(C) 89855
(A) 9814C 0.243 in 75 ohms 2 / #20 150 v 60 C 1,500 ft
(B) 9463 6.17 mm 455 m
(A) 5902C 0.244 in 75 ohms 4 two pair / 300 v 80 C 500 ft
(B) 9302 6.20 mm #22 152 m
Manufacturers: A = Alpha, B = Belden, C = Consolidated

Fiber optic cable can be used for a greater transmission distance, for noise immunity
in environments such as high-yard areas, or for lightning immunity. At least two
modems are required. The first is connected to the controller with a standard
electrical cable. Each additional modem is connected at the end of each fiber optic
link up to a maximum distance of 3,030 m (10,000 feet).
A conventional cable with up to 8 to 10 devices can be attached to each remote
modem. Note that the maximum number of devices on the bus is still 32.
Modems for use with fiber optic cable are available from 3M Fiber Optics,
10 Industrial Way East, PO Box 90, Eatontown, NJ 07724 (908-389-6822).
3M can supply fiber optic cable for plenum, indoor, or outdoor installation as well as
the connectors needed to interface the fiber optic cables to the modems.
Serial Modbus
Serial Modbus is used to communicate between the Mark VI and the plant
Distributed Control System (DCS). This is shown as the Enterprise layer in the
introduction to this Chapter. The serial Modbus communication link allows an
operator at a remote location to make an operator command by sending a logical
command or an analog setpoint to the Mark VI. Logical commands are used to
initiate automatic sequences in the controller. Analog setpoints are used to set a
target such as turbine load, and initiate a ramp to the target value at a predetermined
ramp rate.
The HMI Server and the Mark VI controller support serial Modbus as a standard
interface. Communication through the HMI is the preferred method. The DCS sends
a request for status information to the HMI, or the message can be a command to the
turbine control. The HMI or controller is always a slave responding to requests from
the serial Modbus master, and there can only be one master.
Table 3-9. Serial Modbus Features
Serial Modbus Feature Description

Type of Communication Master/slave arrangement with the slave controller following the master;
full duplex, asynchronous communication
Speed 19,200 baud is standard; 9,600 baud is optional
Media and Distance Using an RS-232C cable without a modem, the distance is 15.24 m (50
feet); using an RS-485 converter it is 1.93 km (1.2 miles).
Mode ASCII Mode - Each 8-bit byte in the message is sent as two ASCII
characters – the hexadecimal representation of the byte. (Not available
from the HMI Server)
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
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.
Note This section discusses serial Modbus communication in general terms; refer to
the Mark VI controller and HMI manuals for details.

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 (Remote Terminal
Unit) 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 in transmitted in a continuous
stream with a 2-byte CRC checksum, and contains a slave address. A slave station’s
address is a fixed unique value in the range of 1 to 255.
The Serial Modbus communications system supports 9600 and 19,200 baud; none,
even or odd parity, and 7 or 8 data bits. Both the master and slave devices must be
configured with the same baud rate, parity and data bit count. The Mark VI
controller communication is configured from the toolbox; refer to GEH-6403
Control System Toolbox for Configuring a Mark VI Turbine Controller.
Table 3-10. Modbus Function Codes
Function Title Message Description

Codes
01 01 Read Holding Coils Read the current status of a group of 1 to 2000
Boolean signals
02 02 Read Input Coils Read the current status of a group of 1 to 2000
Boolean signals
03 03 Read Holding Registers Read the current binary values in 1 to 125 analog
signal registers
04 04 Read Input Registers Read the current binary values in 1 to125 analog
signal registers
05 05 Force Single Holding Coil Force (or write) a single Boolean signal to a state of
ON or OFF
06 06 Preset Single Holding Preset (or write) a specific binary value into a holding
Register register
07 07 Read Exception Status Read the first 8 logic coils (coils 1-8). Short message
length permits rapid reading of these values
08 08 Loopback Test Loopback diagnostic to test communication system
15 15 Force Multiple Coils Force a series of 1 to 800 consecutive Boolean signals
to a specific state
16 16 Preset Multiple Holding Set binary values into a series of 1 to 100 consecutive
Registers analog signals
Hardware Configuration
The Serial Modbus link to the DCS can come from the HMI Server or the Mark VI
controller. In the controller, the Serial Modbus driver uses the COM2 port. This is a
9-pin RS-232C Micro-D receptacle. A special short adapter cable to go from Micro-
D to standard size D-connector is available, GE Catalog Number 336A4929G1.
Refer to GEH-6410 Innovation™ Series Controller System Manual.

The RS-232C standard specifies twenty-five signal lines: twenty lines for routine
operation, two lines 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 will refer to the nine 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 DTE device. For example the signal,
transmit data (TD), represents the transmission of data coming from the DTE device
going to the DCE device.
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 volts)
represents either a “binary one” data bit, a “signal mark”, or a “control off”
condition, while a positive voltage (greater that +3 volts) represents either a “binary
zero” data bit, a “signal space”, or a “control on” condition. Because of voltage
limitations, an RS-232C cable may not be longer than fifty feet.
A Data Terminal Device (DTE) is identified as a device that transmits serial data on
pin 3 (TD) of a 9-pin RS-232C cable (see pin definitions in the following table). A
Data Communication Device (DCE) is identified as a device that transmits serial
data on pin 2 (RD) of a 9-pin RS-232C cable.
Using this definition, the GE slave Serial Modbus device is a Data Terminal
Equipment (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.
Table 3-11. RS-232C Connector Pinout Definition
DB 9 DB Description DTE DTE Signal Function

25 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 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 that the other RS-232C device
is powered up.
7 4 Request To Send (RTS) X Control DTE has data to send and places this pin
high to request permission to transmit.
8 5 Clear To Send (CTS) X Control DTE 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.
Nine of the twenty-five 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, receive data (RD), transmit data (TD) and signal ground
(GND), to transmit and receive data.

The nine RS-232C signals used in the asynchronous communication system can be
broken down into four groups of signals: data, control, timing, ground.
Data Signals 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 volts) on either
of these two pins signifies a logic 0 data bit or space data signal. A negative voltage
(< -3 volts) on either of these two pins signifies a logic 1 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 volts) indicates a “control on” signal, while a negative
voltage (< -3 volts) 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.
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 8 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.
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 eleven bits for each character, the sum of the start bit,
data bits, parity bit, and the specified stop bits should equal eleven. The stop bits are
used to adjust the total to the desired bit count.
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.
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 9,600 and 19,200 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 1 or 2 stop bits. The default is 1
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 8 bits.

Ethernet GSM
Some applications require transmitting alarm and event information to the DCS. This
information includes high-resolution local time tags in the controller for alarms (25
Hz), system events (25 Hz), and sequence of events (SOEs) for contact inputs (1ms).
Traditional SOEs have required multiple contacts for each trip contact with one
contact wired to the turbine control to initiate a trip and the other contact to a
separate SOE instrumentation rack for monitoring. The Mark VI uses dedicated
processors in each contact input board to time stamp all contact inputs with a 1ms
time stamp, thus eliminating the initial cost and long term maintenance of a separate
SOE system.
An Ethernet link is available using TCP/IP to transmit data with the local time tags to
the plant level control. GE supplies an application layer protocol called GSM (GEDS
Standard Messages) which supports four classes of application level messages.
The HMI Server is the source of the Ethernet GSM communication as shown in
Figure 3-10.
HMI View Node
PLANT DISTRIBUTED CONTROL SYSTEM
(DCS)
Redundant
Transceiver
Ethernet Ethernet
GSM Modbus
PLANT DATA HIGHWAY - BUS B
PLANT DATA HIGHWAY - BUS A
HMI Server Node HMI Server Node
Modbus Communication
From UDH From UDH
Figure 3-10. Communication to DCS from HMI using Modbus or Ethernet Options
Administration Messages are sent from the HMI to the DCS with a Support Unit
message which describes the systems available for communication on that specific
link, and general communication link availability.

Event Driven Messages are sent from the HMI to the DCS spontaneously when a
system alarm occurs or clears, a system event occurs or clears, or a contact input
(SOE) closes or opens. Each logic point is transmitted with an individual time tag.
Periodic Data Messages are groups of data points which are defined by the DCS
and transmitted with a group time tag. All of the 5,000 data points in the Mark VI 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 are sent from the DCS to the HMI including turbine
control commands and alarm queue commands. Turbine control commands include
momentary logical commands such as raise / lower, start / stop, and analog setpoint
target commands. Alarm queue commands consist of silence (plant alarm horn) and
reset commands as well as alarm dump requests which cause the entire alarm queue
to be transmitted from the Mark VI to the DCS.
The link supports all the alarms, events, and SOEs in the Mark VI panel.
Fiber Optics
Fiber optics is an effective substitute for copper coax cabling, especially when longer
distances are required, or electrical disturbances are a serious problem.
The main advantages of fiber optic transmission in the power plant environment are:
• Fiber segments can be longer than copper because the signal attenuation per foot
is less.
• In high lightning areas, copper cable can pick up currents, which damage the
communications electronics. The use of fiber optic segments avoids pickup and
reduces lightning caused outages.
• Grounding problems are avoided with optical cable. The ground potential can
rise when there is a ground fault on transmission lines, caused by currents
coming back to the generator neutral point.
• Optical cable can be routed through a switchyard or other electrically noisy area
and not pick up any interference. This can shorten the required runs and simplify
the installation.
• Fiber optic cable with proper jacket materials can be run direct buried, in trays,
or in conduit.
• High quality optical fiber cable is light, tough, and easily pulled. With careful
installation it can last the life of the plant.
• The total cost of installation and maintenance of a fiber optic segment may be
less than a coax segment.
Disadvantages of fiber optics as follows:
• Fiber optic links require powered hubs with a reliable source of AC power.
Failure of power to the hub on either end of the fiber segment causes a link
failure.
• Light travels more slowly in a fiber than electricity does in a coax conductor. As
a result the effective distance of a fiber segment is 1.25 times the electrical cable
distance.

• The extra equipment required for fiber links, such as fiber hubs and any UPS
systems, can contribute to communications downtime.
• 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.
Components
Basics
Each fiber link consists of two fibers, one outgoing, the other incoming, to form a
duplex channel. The outgoing fiber is driven by a light emitting diode, and the
incoming fiber illuminates a phototransistor, which generates the incoming electrical
signal.
Multimode fiber, with a graded index of refraction core and outer cladding, is
recommended for the optical links. The fiber is protected with "buffering" which is
the equivalent of insulation on metallic wires. Mechanical stress is bad for fibers so a
strong sheath is used, sometimes with pretensioned Kevlar fibers to carry the stress
of pulling and vertical runs.
Connectors for a power plant need to be fastened to a reasonably robust cable with
its own buffering. The bayonet ST type connector is recommended because of a
better field performance record, particularly under diverse conditions and installation
skills. This connector is widely used for local area networks, and is readily available.
Fiber Optic Cable

Multimode fibers are rated for use at 850 nanometers and 1300 nanometers
wavelength. Cable attenuation is between 3.0 and 3.3 db/km at 850 nm. The core of
the fiber is normally 62.5 microns 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, back toward the center, etc. This ray travels further but goes faster
because it spends most of it’s time nearer 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 microns in diameter. 62.5/125 optical cable is the most
used type of cable and should be used if possible.
Note Never look directly into a fiber. Although most fiber links use light emitting
diodes which cannot damage the eyes, some longer links use lasers which can cause
permanent damage to the eyes.
Some guidelines on cables:

• Gel filled (or loose tube) cables should not be used because of difficulties
making installations, and terminations, and the potential for leakage in vertical
runs.

• Use a high quality break out cable which makes each fiber a sturdy cable, and
helps prevent too sharp bends.
• Sub-cables are combined with more strength and filler members to build up the
cable to resist 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 your
plant, the armored cable should be used. If not, the armor is not recommended
because 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. Some manufacturers will supply the OTDR printouts as proof of
cable quality. A simpler instrument is used by installers 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, or the
extra fibers can be retained as spares for future plant enhancements. It would be
less expensive to get the same cable with only two fibers.
Fiber Converter
The Mark VI communication system uses an Ethernet Media Converter to convert
selected UDH and PDH electrical signals to fiber optic signals. The typical media
converter converts 12 Ethernet 10Base-T signals to 12 Ethernet 10Base-FL signals.
Each fiber link consists of a pair of unidirectional transmit and receive cables
The media converter mounts adjacent to the Ethernet hub. The selected electrical
signals are brought in from the hub on a multi-twisted pair cable which plugs into a
50-pin RJ-71 connector on the back. The fiber optic cables plug into ST ports on the
front. The diagnostic display is a matrix of LEDs providing visual monitoring of the
power and link status of the fiber optic links. A typical converter is shown in Figure
3-11.

Front View
Ethernet Media Converter
Diagnostics RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX RX TX Rx TX RX TX RX TX
12 11 10 9 8 7 6 5 4 3 2 1
Dual Fiber
Optic Cable
with ST plugs
Rear View
50-Pin Connector
PWR
50-Pin Feeder cable

(12 twisted pair
segments), from
10Base-T Ethernet Hub
Figure 3-11. Media Converter, Ethernet Electric to Ethernet Fiber Optic
Connectors
The 10Base-FL standard for Ethernet networks defines one style of connector as
being acceptable for both multimode and single mode fiber optic cabling. This is the
Straight-Tip or ST connector (note that ST connectors for the two modes are
different in construction and are not interchangeable). The ST connector replaces the
earlier Sub-Miniature Assembly (SMA) type connector.
The ST connector is a keyed, locking connector that automatically aligns the center
strand of the fiber with the transmission or reception points of the network device.
The connector is shown in Figure 3-12. An integral spring helps to keep the ST
connectors from being crushed together, to avoid damaging the fiber.
Solid Glass
Center
Keyed Key Guide Cladding

Connector Channel
Figure 3-12. ST 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. The
complete process takes an experienced person about five minutes.
System Considerations
When designing a fiber optic network, note the following considerations.
Redundancy should be considered for continuing central control room (CCR) access
to the turbine controls. Redundant HMIs, fiber optic links, Ethernet hubs, and hub
power supplies are recommended.
The optical power budget for the link should be considered. The total budget refers
to the brightness of the light source divided by the sensitivity of the receiver. These
power ratios are measured in dBs to simplify calculations. The difference between
the dB power of the source and the dB power of the receiver represents the total
power budget. This must be compared to the link losses made up of the connector
and cable losses.
Installation of the fiber can decrease its performance compared to factory new cable.
Installers may not make the connectors as well as experts can, resulting in more loss
than planned. The LED light source can get dimmer over time, the connections can
get dirty, the cable loss increases with aging, and the receiver can become less
sensitive. For all these reasons there must be a margin between the available power
budget and the link loss budget, of a minimum of 3 dB. Having a 6 dB margin is
more comfortable, helping assure a fiber link that will last the life of the plant.
Installation
Planning is important for a successful installation. This includes the layout for the
required level of redundancy, cable routing distances, proper application of the
distance rules, and procurement of excellent quality hubs, UPS systems, and
connectors. Considerations include the following:
• Install the fiber optic cable in accordance with all local safety codes.
Polyurethane and PVC are two possible options for cable materials that might
meet the local safety codes (see next section).
• Select a cable strong enough for indoor and outdoor applications, including
direct burial.
• Adhere to the manufacturer’s recommendations on the minimum bend radius and
maximum pulling force.
• Test the installed fiber to measure the losses. A substantial measured power
margin is the best proof of a high quality installation.
• Use trained people for the installation. If necessary hire outside people with
fiber LAN installation experience.
• The fiber hubs/repeaters need reliable power, and should be placed in a location
that will minimize the amount of movement they must endure, yet keep them
accessible for maintenance.

Component Specifications
This section provides specifications for fiber optic cable, and the fiber optic media
converter. Recommended component vendors are as follows:
Fiber Optic Cable:
Optical Cable Corporation
5290 Concourse Drive
Roanoke, VA 24019
Phone (540)265-0690
Fiber Optic Connectors:
3M - Connector model 6100
Installation kit model 6150A
Thomas & Betts - Connector model 91810-125-2P
Assembly polishing kit model 91000AKP
Amphenol - Connector model 953-101-5010
Termination kit model 927-100-5000
Ethernet Media Converters (and Ethernet Electrical Hubs)
Cisco Systems
West Tasman Drive
San Jose, CA
www.cisco.com
3COM Corporation
5400 Bayfront Plaza,
Santa Clara, CA 95052
www.3com.com
Time Synchronization
The time synchronization option synchronizes all turbine controls, generator
controls, and Operator Interfaces (HMIs) on the Unit Data Highway to a Global
Time Source (GTS). Typical GTSs are Global Positioning Satellite (GPS) receivers
such as the StarTime GPS Clock or similar time processing hardware. The preferred
time sources are Coordinated Universal Time (UTC) or GPS.
A time/frequency processor board, either the BC620AT or BC627, is placed in the
HMI PC. This board acquires time from the GTS with a high degree of accuracy.
When the HMI receives the time signal, it makes the time information available to
the turbine and generator controls on the network by way of Network Time Protocol
(NTP). The HMI Server provides time to time slaves either by broadcasting time, or
by responding to NTP time queries, or by both methods. Refer to RFC 1305 Network
Time Protocol (Version 3) dated March 1992 for details
Redundant time synchronization can be provided by supplying a time/frequency
processor board in another HMI Server as a backup. Normally, the primary HMI
Server on the UDH is the time master for the UDH, and other PCs without the time /
frequency board are time slaves. The time slave computes the difference between the
returned time and the recorded time of request and adjusts its internal time. Each
time slave can be configured to respond to a time master via unicast mode or
broadcast mode.

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 global rather than local. This is done
because global time steadily increases at a constant rate while corrections are
allowed to local time. Historical data is stored with global time to minimize
discontinuities.
Redundant Time Sources

If either the GTS or time master becomes inoperative, the backup is to switch the
BC620AT to flywheel mode with a drift of +/-2 ms/hour. In most cases, this allows
sufficient time to repair the GTS 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 GTS, which time master has the best quality signal, and which master is
listed first in the configuration file.
Selection of Time Sources

The BC620AT board supports the use of several different time sources; however, the
time synchronization software does not support all sources supported by the
BC620AT board. A list of time sources supported by both the BC620AT and the
time synchronization software includes:
• Modulated IRIG-A, IRIG-B, 2137, or NASA-36 timecode signals
- Modulation ratio 3:1 to 6:1
- Amplitude 0.5 to 5 volts 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

Notes

Chapter 4 Packaging
Introduction
This chapter describes the cabinet configurations used to house the Mark VI control
equipment, and gives the main dimensions.
Equipment Cabinets
Control Cabinet
The control cabinet contains either a single (Simplex) Mark VI Control Module
(CM) or triple modular redundant (TMR) CMs. These are linked to their I/O by a
single or triplicated high-speed I/O network (IONet), and to the UDH by the
controller Ethernet port. The NEMA 1 control cabinet contains its own power
distribution module, and ac/dc converters.
The front door has a window allowing the controllers to be viewed, and the back
door allows access to the power supplies. Since the cabinet contains the Pentium-
based controller, it is rated for operation in a 45 degree C ambient. This cabinet is
usually used in TMR systems with remote I/O.
Dimensions of Single Mark VI Cabinet
Width Depth Height
600 mm 600 mm 1842 mm
24" 24" 72.5"
Figure 4-1. NEMA 1 Enclosure for Controllers in a System with Remote I/O
GEH-6421 Mark VI System Guide Chapter 4 Packaging •4-1

The two-bay cabinet shown below is used for small Simplex systems. For small
steam turbine applications it usually contains one VME rack and 26 termination
boards, plus power supply components.
Dimensions of Two Bay Mark VI Cabinet
Width Depth Height
1350 mm 903.9 mm 2324.3 mm
53.15" 35.59" 91.5"
Figure 4-2. Two-Bay NEMA 1 Enclosure for Small Mark VI System
I/O Termination Cabinets

The I/O cabinet contains either single or triple Interface Modules (IM), and
associated termination boards. The IM are linked to the controllers in a separate
Controllers can be mounted
cabinet by IONet. The power distribution module and AC/DC converters are
in this cabinet
mounted in the right most cabinet.
The NEMA 1 enclosure lineup consists of three sections bolted together. The
assembly is lifted and shipped in one piece. Cable entry can be through the top or
bottom. Since the I/O is rated for operation in a 50 degree C ambient, the cabinet can
be remote from the CM, closer to the turbine. This can reduce I/O wiring costs. This
size of cabinet is typically used for Gas and Steam Turbine TMR control systems.
I/O Control I/O

Section Section Section
Dimensions of Five-Bay Mark VI Cabinet
Width Depth Height
4200 mm 602.0 mm 2324.3 mm
165.35" 23.7" 91.5"
Figure 4-3. Five-Bay NEMA 1 Enclosure for a Larger Mark VI System
4-2 • Chapter 4 Packaging GEH-6421 Mark VI System Guide

The cabinet lineup shown below integrates the Mark VI cabinet with an auxiliary
cabinet holding equipment such as generator protection. All the sections are bolted
together and lifted in one piece. Cable entry is through the top or bottom. A typical
application is a gas turbine TMR system.
I/O Control I/O Auxiliary

Section Section Section Section
Dimensions of Five-Bay Mark VI Cabinet
with Auxiliary Equipment
Width Depth Height
5800 mm 602.0 mm 2324.3 mm
228.34" 23.62" 91.5"
Figure 4-4. Integrated Mark VI & Auxiliary Equipment Cabinet Line Up
GEH-6421 Mark VI System Guide Chapter 4 Packaging •4-3

Notes
4-4 • Chapter 4 Packaging GEH-6421 Mark VI System Guide

Chapter 5 Codes & Standards
Introduction
This chapter discusses the codes, standards, and environmental guidelines used for
the design of all PWAs, modules, cores, panels, and cabinet line-ups in the Mark VI.
Requirements for harsh environment applications, such as marine, are not covered
here.
Safety Standards
UL 508A Safety Standard Industrial Control Equipment
CSA 22.2 No. 14 Industrial Control Equipment
Electrical
Printed Wire Board Assemblies
UL 796 Printed Circuit Boards
GE Salem is a UL recognized card manufacturer, UL file number E110691. Mark VI
boards are currently manufactured by UL recognized GE Fanuc Automation.
ANSI IPC guidelines
ANSI IPC/EIA guidelines
Electromagnetic Compatibility (EMC)

EN 55081-2 General Emission Standard
EN 50082-2:1994 Generic Immunity Industrial Environment
EN 55011 Radiated and Conducted Emissions
IEC 61000-4-2:1995 Electrostatic Discharge Susceptibility
IEC 61000-4-3:1997 Radiated RF Immunity
IEC 61000-4-4:1995 Electrical Fast Transient Susceptibility
GEH-6421 Mark VI System Guide Chapter 5 Codes & Standards • 5-1

IEC 61000-4-5:1995 Surge Immunity
IEC 61000-4-6:1995 Conducted RF Immunity
IEC 61000-4-11:1994 Voltage Variation, Dips, and Interruptions
ANS/IEEE C37.90.1 Surge
Low Voltage Directive

EN 61010-1 Safety of Electrical Equipment, Industrial Machines
IEC 529 Intrusion Protection Codes/NEMA 1/IP 20
Supply Voltage
Line Variations
AC Supplies – Operating Line variations of –10 %, +10 %
IEEE Std 141-1993 defines the Equipment Terminal Voltage – Utilization voltage.
The above meets IEC 204-1 1996, and exceeds IEEE Std 141-1993, and
ANSI C84.1-1989.
DC Supplies – Operating line variations of -30 %, +20 %.
This meets IEC 204-1 1996.
Voltage Unbalance
Less than 2 % of positive sequence component for negative sequence component.
Less than 2 % of positive sequence component for zero sequence component.
This meets IEC 204-1 1996, and IEEE Std 141-1993.
Harmonic Distortion
Voltage: Less than 10 % of total rms voltage between live conductors for 2nd
through 5th harmonic.
Additional 2% of total rms voltage between live conductors for sum of 6th – 30th.
This meets IEC 204-1 1996.
Current: The system specification is not per individual equipment
Less than 15 % of maximum demand load current for harmonics less than 11
Less than 7 % of maximum demand load current for harmonics between 11 and 17
Less than 6 % of maximum demand load current for harmonics between 17 and 23
Less than 2.5 % of maximum demand load current for harmonics between 23 and 35.
The above meets IEEE Std 519-1992.
Frequency Variations
Frequency variation of –5 % +5 % when operating from AC supplies (20 Hz/sec
slew rate).
This exceeds IEC 204-1 1996.
5-2 • Chapter 5 Codes & Standards GEH-6421 Mark VI System Guide

Surge
Withstand 2 kV common mode, 1 kV differential mode.
This meets IEC 61000-4-5 (ENV50142), and ANSI C62.41 (Combination wave).
Clearances
NEMA Tables 1-111-1 and 1-111-2 from NEMA ICS1-1993.
This meets IEC 61010-1:1993/A2:1995, CSA 22.2 #14, and UL 508C, and exceeds
EN50178 (low voltage).
Power Loss
100 % Loss of supply - minimum 10 ms for normal operation of power products.
100 % Loss of supply - minimum 500 ms before control products require reset.
This exceeds IEC 61000-4-11.
Environmental
Temperature Ranges
Ambient temperature ranges for the Mark VI equipment are as follows.
• Operating I/O cards and termination boards 0 to 50° C
• Operating controller with forced air cooling 0 to 45° C
• Shipping and Storage -40 to 80° C
The allowable temperature change without condensation is +/- 15° C per hour
Humidity
The ambient humidity range is 5 % to 95 %.
This exceeds EN50178:1994
Elevation
Equipment elevation is related to the equivalent ambient air pressure.
• Normal Operation 0 to 3300 feet (101.3 KPa – 89.8 KPa)
• Extended Operation 3300 to 10000 feet (89.8 KPa – 69.7 KPa)
• Shipping 15000 feet maximum (57.2 KPa)
The extended operation and shipping specifications exceed EN50178:1994.
GEH-6421 Mark VI System Guide Chapter 5 Codes & Standards • 5-3

Contaminants
Gas
The control equipment withstands the following concentrations of corrosive gases at
50 % relative humidity and 40° C:
• Sulfur dioxide (SO2) 30 ppb
• Hydrogen sulfide (H2S) 10 ppb
• Nitrous fumes (NOx) 30 ppb
• Chlorine (Cl2) 10 ppb
• Hydrogen fluoride (HF) 10 ppb
• Ammonia (NH3) 500 ppb
• Ozone (O3) 5 ppb
The above meets EN50178:1994 Section A.6.1.4 Table A.2 (m).
Dust
Particle Sizes from 10 – 100 microns for the following materials:
Aluminum oxide Ink Sand/Dirt
Cement Lint Steel Mill Oxides
Coal/Carbon dust Paper Soot
This exceeds IEC 529:1989-11 (IP20)
Vibration
Seismic
Universal Building Code (UBC) – Seismic Code section 2312 Zone 4
Operating/Installed at Site
Vibration of 1.0 G Horizontal, 0.5 G Vertical at 15 to 120 Hz.
See Seismic UBC for frequencies lower than 15 Hz.
Packaging
The standard Mark VI cabinets meet NEMA 1 requirements (similar to the IP-20
cabinet).
Optional cabinets for special applications meet NEMA 12 (IP-54), NEMA 4 (IP-65),
and NEMA 4X (IP-68) requirements. Redundant heat exchangers or air conditioners,
when required, can be supplied for the above optional cabinets.
5-4 • Chapter 5 Codes & Standards GEH-6421 Mark VI System Guide

Chapter 6 Installation
Introduction
This chapter defines installation requirements for the Mark VI control system.
Specific topics include GE installation support, wiring practices, grounding,
equipment weights and dimensions, power dissipation and heat loss, and
environmental requirements.
Before installation, consult and study all furnished drawings. These should include
panel and layout drawings, connection diagrams, and a summary of the equipment.
Installation Support
GE’s system warranty provisions require both quality installation and that a qualified
service engineer be present at the initial equipment startup. To assist the customer,
GE offers both standard and optional installation support. Standard support consists
of documents that define and detail installation requirements. Optional support is
typically the advisory services that the customer may purchase.
Early Planning
To help ensure a fast and accurate exchange of data, a planning meeting with the
customer is recommended early in the project. This meeting should include the
customer’s project management and construction engineering representatives. It
should accomplish the following:
• Familiarize the customer and construction engineers with the equipment.
• Set up a direct communication path between GE and the party making the
customer’s installation drawings.
• Determine a drawing distribution schedule that meets construction and

installation needs.
• Establish working procedures and lines of communication for drawing

distribution.
GEH-6421 Mark VI System Guide Chapter 6 Installation • 6-1

GE Installation Documents
Installation documents consist of both general and requisition-specific information.
The cycle time and the project size determine the quantity and level of
documentation provided to the customer.
General information, such as this manual, provides product-specific guidelines for
the equipment. They are intended as supplements to the requisition-specific
information.
Requisition documents, such as outline drawings and elementary diagrams; provide
data specific to a custom application. Therefore, they reflect the customer’s specific
installation needs and should be used as the primary data source.
As-Shipped Drawings
These drawings include changes made during manufacturing and test. They are
issued when the equipment is ready to ship. As Shipped drawings consist primarily of
elementary diagrams revised to incorporate any revisions or changes made during
manufacture and test.
Revisions made after the equipment ships, but before start of installation, are sent as
Field Change, with the changes circled and dated.
Technical Advisory Options

To assist the customer, GE Power Systems offers the optional technical advisory
services of field engineers for:
• Review of customer’s installation plan
• Installation support
These services are not normally included as installation support or in basic startup
and commissioning services, shown in Figure 6-1. GE presents installation support
options to the customer during the contract negotiation phase
Installation
Support
Startup
Begin
Installation
Commissioning
Complete
Installation
Begin Product Support - On going

Formal
Testing
System
Acceptance
Figure 6-1. Startup and Commissioning Services Cycle
6-2 • Chapter 6 Installation GEH-6421 Mark VI System Guide

Review of Installation Plan
It is recommended that a GE field representative review all installation/construction
drawings, and the cable and conduit schedule when completed. This optional review
service ensures that the drawings meet installation requirements and are complete.
Installation Support
Optional installation support is offered: planning, practices, equipment placement,
and onsite interpretation of construction and equipment drawings. Engineering
services are also offered to develop transition and implementation plans to install and
commission new equipment in both new and existing (revamp) facilities.
Customer’s Conduit and Cable Schedule

The customer’s finished conduit and cable schedule should include:
• Interconnection wire list (optional)
• Level definitions
• Shield terminations
Level Definitions
The cable and conduit schedule should define signal levels and classes of wiring (see
section on Cable Separation). This information should be listed in a separate column
to help prevent installation errors.
The cable and conduit schedule should include the signal level definitions in the
instructions. This provides all level restriction and practice information needed
before installing cables.
Shield Terminations
The conduit and cable schedule should indicate shield termination practice for each
shielded cable (refer to the section Connecting the System in the chapter).
Equipment Receiving, Handling, and Storage

This section is a general guide to the receiving, handling, and storage of a Mark VI
control system.
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.
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
Industrial Systems. 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, observe normal precautions
along with all handling instructions printed on the
case.
If assistance is needed contact:

GE Industrial Systems
Product Service Engineering
1501 Roanoke Blvd.
Salem, VA 24153-6492
Phone: +1 540 378 3280
Fax: +1 540 387 8606
Replace + with the international access code.
Storage
If the system is not installed immediately upon receipt, it must be stored properly to
prevent corrosion and deterioration. Since packing cases do not protect the
equipment for outdoor storage, the customer must provide a clean, dry place, free of
temperature variations, high humidity, and dust.
Use the following guidelines when storing the equipment:
• Place the equipment under adequate cover with the following requirements:
- Keep the equipment clean and dry, protected from precipitation and
flooding.
- Use only breathable (canvas type) covering material – do not use plastic.
• Unpack the equipment as described, and label it.
• Maintain the following environment in the storage enclosure:
- Recommended ambient storage temperature limits from –20 °C (-4 °F) to
55 °C (131 °F).
- Surrounding air free of dust and corrosive elements, such as salt spray or
chemical and electrically conductive contaminants.
- Ambient relative humidity from 5 to 95% with provisions to prevent
condensation.
- No rodents.
- No temperature variations that cause moisture condensation.
Moisture on certain internal parts can cause

electrical failure.
Condensation occurs with temperature drops of 15 °C (27 °F) at 50% humidity over
a 4-hour period, and with smaller temperature variations at higher humidity.

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 panel space heaters (when supplied) inside each enclosure.
A 100-watt 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.
Operating Environment
The Mark VI control panel is suited to most industrial environments. To ensure
proper performance and normal operational life, the environment should be
maintained as follows:
Ambient temperature (acceptable): Control Module 0°C (32 °F) to 45 °C (113 °F)
I/O Module 0°C (32 °F) to 50 °C (122 °F)
Ambient temperature (preferred): 20 °C (68 °F) to 30 °C (87 °F)
Relative humidity: 5 to 95%, non-condensing.
Note Higher ambient temperature decreases the life expectancy of any electronic
component. Keeping ambient air in the preferred (cooler) range should extend
component life.
Environments that include excessive amounts of any of the following elements
reduce panel performance and life:
• Dust, dirt, or foreign matter.
• Vibration or shock.
• Moisture or vapors.
• Rapid temperature changes.
• Caustic fumes.
• Power line fluctuations.
• Electromagnetic interference or “noise” introduced by:
- Radio frequency signals, typically from nearby portable transmitters.
- Stray high voltage or high frequency signals, typically produced by arc
welders, unsuppressed relays, contactors, or brake coils operating near
control circuits.
The preferred location for the Mark VI control system cabinet would be in an
environmentally controlled room or in the control room itself. The panel should to be
mounted where the floor surface allows for attachment in one plane (a flat, level, and
continuous surface). The mounting hardware is provided by the customer. Lifting
lugs are provided and if used, the lifting cables must not exceed 45° from the vertical
plane. Finally, the panel is equipped with a door handle which can be locked for
security.

Interconnecting cables can be brought into the panel from the top or the bottom via
removable access plates. Convection cooling of the panel requires that conduits be
sealed to the access plates. Also, air passing through the conduit must be within the
acceptable temperature range, as listed above. This applies to both top and bottom
access plates.
Weights & Dimensions

Cabinets
A single Mark VI cabinet is shown below. This can house three controllers used in a
system with all remote I/O. Dimensions, clearance, bolt holes, lifting lugs, and
temperature information is included.
Lift Bolts with 38 mm (1.5 in) dia

hole, should be left in place after
installation for Seismic Zone 4. If
removed, fill bolt holes. Single Control Panel
Total Weight 400 lbs
Cabinet Depth 610.0 mm

(24 in)
Window
Cable Entry Space for wire entry
in base of cabinet
1842 mm Equipment Access Front and

(72.5) rear access doors, no side access.
Front door has clear plastic
window.
Air
A
A Intake Service Conditions NEMA1
enclosure for standard indoor use.
610 mm
(24)
Six 16 mm (0.635 inch)

dia holes in base for
236.5
customers mounting
(9.31)
610 studs or bolts.
(24.0) 236.5
(9.31)
View of base looking
down in direction "A"
475
(18.6875)
Figure 6-2. Controller Cabinet

A typical panel lineup for a complete Mark VI system is shown below. This cabinet
can house controllers, I/O, and termination boards, or it can house just the remote I/O
and termination boards.
Lift Angles front and back, Three Panel Lineup (five

should be left in place for doors)
Seismic Zone 4, if removed,
fill bolt holes. Total Weight 3,500 lbs
Cabinet Depth 602 mm

(23.7 in)
Cable Entry Removable

I/O I/O Control I/O Power covers top and bottom.
2324.3 mm
Equipment Access Front
(91.5)
doors only, no rear or side
access. Door swing
clearance 977.9 mm (38.5).
Mounting Holes in Base

A Six 16 mm (0.635 in) dia
holes in base of each of the
three cabinets for customers
mounting studs or bolts, for
1600 mm
details see GE dwgs.
1000mm 1600 mm
(62.99) (39.37) (62.99)
Service Conditions
4200 mm
Standard NEMA1 enclosure
(165.35)
for indoor use.
237.5
(9.35)
237.5
(9.35) 18 holes, 16 mm (0.635
inch) dia, in base for
62.5
customers mounting
(2.46) 1475.0 875.0 1475.0
(34.45) (58.07)
studs or bolts.
(58.07)
62.5 125.0 125.0 62.5

(2.46) (4.92) (4.92) (2.46)
View of base looking down in direction of arrow "A"
Figure 6-3. Typical Mark VI Panel Lineup

Control Console (Example)
The turbine control HMI PCs can be tabletop mounted, or installed in the optional
control console shown below. The console is modular and expandable from an
1828.8 mm version with two PCs. A 5507 mm version with four PCs is shown. The
console rests on feet and is not usually bolted to the floor.
Full Console
5507 mm
(18 ’- 0 13/16 ")
Short Console
1828.8 mm
(72 ")
or Main Module
Monit e
d u l
Mo
M
M onit
od or
ule 2233.61 mm
Modular Desktop
(7 ’- 3 15/16")
Phone Phone
Printer
Monitor Monitor Monitor Monitor
1181.1mm
Printer Undercounter Keyboards (46.5 ")
Pedestal
Figure 6-4. Turbine Control Console with Dimensions
Power Requirements
The Mark VI control panel can accept power from multiple power sources. Each
power input source (example: the dc and two ac sources) should feed through its own
external 30 Ampere two-pole thermal magnetic circuit breaker before entering the
Mark VI enclosure. The breaker ratings are 250 volts and 30 amperes with a
minimum withstand of 10,000 amperes. The breaker should be supplied in
accordance with required site codes.

Power sources can be any combination of a 125 V dc source and/or up to two
120/240 V ac sources. Each module within the panel has its own power supply
board, each of which operates from a common 125 V dc panel distribution bus.
Power requirements for a typical three-bay (five-door) 4200 mm panel for
Controllers, I/O, and Termination Boards are shown below. For further details on the
panel power distribution system, refer to Chapter 9, I/O Descriptions.
Table 6-1. Power Requirements for 4200 mm Panel
Voltage Frequency Current Draw

Nominal Tolerance Nominal Tolerance (at nominal voltage)
125 V dc 100 to 144 V dc (see Note 5) N/A N/A 10.0 Amps dc (see Note 1)
120 V ac 108 to 132 V ac (see Note 6) 50/60 Hz +/- 3 Hz 17.3 Amps RMS (see Notes 2 & 4)
240 V ac 200 to 264 V ac 50/60 Hz +/- 3 Hz 8.8 Amps RMS (see Notes 3 & 4)
Notes on power source table:

1. Add .5 A dc continuous for each 125 V dc 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 solenoid powered (inrush 10 A).
5. Ripple not to exceed 10 volts peak-to-peak.
6. Total Harmonic Distortion not to exceed 5.0%.
For a single cabinet containing three controllers only, the nominal power
requirements are as follows.
Table 6-2. Power Requirements for Controller Cabinet
Voltage Frequency Current Draw

Nominal Tolerance Nominal Tolerance (at nominal voltage)
125 V dc 100 to 144 V dc (see Note 5) N/A N/A 1.7 Amps dc (see Note 1)
120 V ac 108 to 132 V ac (see Note 6) 50/60 Hz +/- 3 Hz 3.8 Amps RMS (see Notes 2 & 4)
240 V ac 200 to 264 V ac 50/60 Hz +/- 3 Hz 1.9 Amps RMS (see Notes 3 & 4)

Installation Support Drawings
This section describes GE installation support drawings. These drawings are usually
B-size AutoCAD drawings covering all hardware aspects of the system. A few
sample drawings are included:
• System Topology; Panels, Data Highways, and Human Machine Interfaces
• Steam Turbine I/O Cabinets; Panel Lineup with dimensions
• Gas Turbine Control Panel Layout Diagram; Protection and Controller Modules
• Panel Layout Diagram, Termination Boards
• Termination Board Layout Diagram, Turbine Primary Trip (TRPG)
In addition to the above drawings, site personnel will need the following:
• The Control Sequence Program with cross references (CSP with XREF
• The Alarm Database (Alarm.dat)
• The I/O Assignments (IO Report).
Figure 6-5. Typical System Topology showing Interfaces to Heat Recovery Steam
Generator and Balance of Plant Equipment

Figure 6-6. Typical I/O Cabinet Drawing showing Dimensions, Cable Access, Lifting
Angles, & Mounting

Figure 6-7. Controller Cabinet with Protection Module

Figure 6-8. Inside Layout of I/O Panel showing Termination Boards & Power
Supplies

Figure 6-9. Typical Circuit Diagram of TRPG Termination Board

Grounding
This section defines grounding and signal-referencing practices for the Mark VI
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
under test, the test equipment’s case must be shielded
to prevent contact by personnel.
Equipment Grounding
Equipment grounding and signal referencing have two distinct purposes:
• Equipment grounding protects personnel and equipment from risk of electrical
shock or burn, fire, or other damage caused by ground faults or lightning.
• Signal referencing helps protect equipment from the effects of internal and
external electrical noise such as from lightning or switching surges.
Installation practices must simultaneously comply with all codes in effect at the time
and place of installation, and practices which improve the immunity of the
installation. In addition to codes, IEEE Std 142-1991 IEEE Recommended Practice
for Grounding of Industrial and Commercial Power Systems and IEEE Std 1100-
1992 IEEE Recommended Practice for Powering and Grounding Sensitive
Electronic Equipment provide guidance in the design and implementation of the
system. Chapter 9, and in particular 9.10, of Std 1100-1992 is very relevant and
informative. Code requirements for safety of personnel and equipment must take
precedence in the case of any conflict with noise control practices.
The Mark VI system has no special or nonstandard installation requirements, if
installed in compliance with all of the following:
• The NEC® or local codes
• With a signal reference structure (SRS) designed to meet IEEE Std 1100
• Interconnected with signal/power-level separation, as defined later
This section provides equipment grounding and bonding guidelines for control and
I/O cabinets. These guidelines also apply to motors, transformers, brakes, and
reactors. Each of these devices should have its own grounding conductor going
directly to the building ground grid.

• 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 Signal Reference Structure (see later).
• The equipment grounding connection for the Mark VI cabinets is copper bus or
stub bus. This connection is bonded to the cabinet enclosure using bolting that
keeps the conducting path’s resistance at 1 ohm or less.
• There should be a bonding jumper across the ground bus or floor sill between all
shipping splits. The jumper may be a "plated" metal plate.
• The non-current carrying metal parts of the equipment covered by this section
should be bonded to the metallic support structure or building structure
supporting this equipment. The equipment mounting method may satisfy this
requirement. If supplementary bonding conductors are required, size them the
same as equipment grounding conductors.
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.
Signal Reference Structure (SRS)

On modern equipment communicating at high bandwidths, signals are typically
differential and/or isolated electrically or optically. The modern 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.
• 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.
• Metallic cable tray systems.
• Raceway (cableway) and raceway support systems.
• Embedded steel floor channels.
Note All provisions may not apply to an installation.

The connection of the protective earth 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 such that in so far as is possible the control
system is NOT 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 Mark VI cabinet the electronics panel is insulated from the chassis and bonded
at one point. The grounding recommendations illustrated in Figure 6-10 call for the
equipment grounding conductor to be 120 mm2 (AWG 4/0) gage wire, connected to
the building ground system. The Control Common (CCOM) is bonded at one point
to the chassis safety ground using two 25 mm 2 (4 AWG) green/yellow bonding
jumpers.
Control & I/O

Electronics
Panel
Mark VI
Cabinet
Control
Common Two 25 mm sq. (4 AWG)
(CCOM) Green/Yellow insulated
bonding jumpers
Equipment grounding conductor,
Identified 120 mm sq. (4/0 AWG),
Insulated Wire, short a distance
as possible Protective Conductor Terminal
(Chassis Safety Ground Plate)
PE
Building Ground
System
Figure 6-10. Grounding Recommendations for Single Mark VI Cabinet
If acceptable by local codes, the bonding jumpers may be removed and a 4/0 AWG
identified insulated wire run from CCOM to the nearest accessible point on the
building ground system, or to another ground point as required by the local code.
The distance between the two connections to building ground should be
approximately 15 feet, but not less than 10 feet.
Grounding for a larger system is shown in Figure 6-11. Here the control common is
still connected to the control electronics section, but the equipment grounding
conductor is connected to the center cabinet chassis. Individual control and I/O
panels are connected with bolted plates.

Control
I/O Panel Electronics I/O Panel
Panel
Panel Grounding
Connection Plates
Control
Common Two 25 mm sq. 4AWG
(CCOM) Green/Yellow Bonding
Jumper wires
Equipment grounding conductor,

Identified 120 mm sq. (4/0 AWG), Protective Conductor Terminal
insulated wire, short a distance (Chassis Safety Ground plate)
as possible
PE
Building Ground System
Figure 6-11. Grounding Recommendations for Mark VI Cabinet Lineup
On a cable carrying conductors and/or shielded conductors, 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 via the
structure of the building, with a 360-degree 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.
Notes on Grounding
Bonding to building structure. The cable tray support system typically provides
many bonding connections to building structural steel. If this is not the case,
supplemental bonding connections must be made at frequent intervals from the cable
tray system to building steel.
Bottom connected equipment. Cable tray installations for bottom connected
equipment should follow the same basic principles as those illustrated for top
connected equipment, paying special attention to good high frequency bonding
between the cable tray and the equipment.
Cable spacing. Maintain cable spacing between signal levels in cable drops, as
recommended here.
Conduit sleeves. Where conduit sleeves are used for bottom-entry cables, the
sleeves should be bonded to the floor decking and equipment enclosure with short
bonding jumpers.

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. These 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. 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 installed per NEC Article 318, with signal level
spacing per the next section. This serves as a signal reference structure between
remotely connected pieces of equipment. The large surface area of cable tray
provides a low impedance path at high frequencies.
Metal framing channel. Metal framing channel cable support system also serves as
part of the signal reference structure. 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. 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.
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.

Level P
Level L
Solid
Bottom
Tray
Bond leveling channels to the

woven wire mesh with solid steel
wire jumpers of approximately the
same gage as the wire mesh.
Jumpers must be short, less than

200 mm (8 in). Weld to mesh and
leveling steel at random intervals of
300 - 500 mm (12-20 in).
Weld
Weld the enclosure to the leveling
Leveling steel, front and rear at
Channels approximately 600 mm (24 in)
intervals.
Wire
Mesh
Figure 6-12. Cable Tray Installation Guidelines
Conduit termination at cable trays. To provide the best shielding, conduits

containing level L cables (see next section) should be terminated to solid bottom tray
side rails 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. Weld the enclosure to leveling steel, front and
rear.
Signal and power levels. See the next section for cable separation guidelines.
Solid-bottom tray. Use solid bottom cable trays with covers for low-level signals
most susceptible to noise.
Cable Separation & Routing

This section provides recommended cabling practices to reduce electrical noise.
These include signal/power level separation and cable routing guidelines.
Note Electrical noise from cabling of various voltage levels can interfere with
microprocessor-based control systems, causing a malfunction. If a situation at the
installation site is not covered in this manual, or if these guidelines cannot be met,
please contact GE before installing the cable.

The customer and customer’s representative are responsible for the mechanical and
environmental locations of cables, conduit, and trays. They are also responsible for
applying the level rules and cabling practices defined here.
To help ensure a lower cost, noise-free installation, GE recommends early planning
of cable routing that complies with these level-separation rules. The customer’s
representative should distribute these level rules to all electrical and mechanical
contractors, as well as construction personnel.
Early planning also enables the customer’s representatives to design adequate
separation of embedded conduit. On new installations, sufficient space should be
allowed to efficiently arrange mechanical and electrical equipment.
On revamps, level rules should be considered during the planning stages to help
ensure correct application and a more trouble-free installation.
Signal/Power Level Definitions

Signal/power carrying cables are categorized into four defining levels: low,
medium, high, and power. Each level can include classes.
Low-Level Signals (Level L)

Low-level signals are designated as level L. In general these consist of:
• Analog signals 0 through ±50 V dc
• Digital (logic-level) signals less than 28 V dc
• 4 – 20 ma current loops
• AC signals less than 24 V ac
The following are specific examples of level L signals used in the Mark VI cabling:
• All analog and digital signals including thermocouples, LVDTs, Servos, RTDs,
Analog Inputs & Outputs, and Pyrometer signals.
• Network communication bus signals: Genius, Ethernet, IONet, UDH, PDH,

RS-232C, and RS-422
• Phone circuits
Note Signal input to analog and digital blocks or to programmable logic control
(PLC)-related devices should be run as shielded twisted-pair (for example, input
from RTDs).
Medium-Level Signals (Level M)

Medium-level signals are designated as level M. These signals consist of:
• Analog signals greater than 50 V dc with less than 28 V ac ripple
• 28 V dc light and switching circuits
• 24 V dc switching circuits
• Analog pulse rate circuits

Note Level M and level L signals may be run together only inside the control panel.
Magnetic pickup signals are examples of level M signals used in the Mark VI
High-Level Signals (Level H)

High-level signals are designated as level H. These signals consist of:
• Dc switching signals greater than 28 V
• Analog signals greater than 50 V dc with greater than 28 V ac ripple
• Ac feeders less than 20 A
The following are specific examples of level H signals used in Mark VI cabling:
• Contact inputs
• Relay outputs
• Solenoid outputs
• Flame detector (GM) type signals, 335 V dc.
• PT and CT circuits
Power (Level P)
Power wiring is designated as level P. This consists of ac and dc buses 0 – 800 V
with currents 20 A – 800 A.
The following are specific examples of level P signals used in plant cabling:
• Motor armature loops 20 A and above
• Generator armature loops 20 A and above
• Ac power input and dc outputs 20 A and above
• Primaries and secondaries to transformers above 5 kVA
• SCR field exciter ac power input and dc output greater than 20 A
• Static exciters (regulated and unregulated) ac power and dc output
• 250 V shop bus
• Machine fields over 20 A

Class Codes
Certain conditions can require that specific wires within a level be grouped in the
same cable. This is indicated by class codes, defined as follows:
S Special handling of specified levels can require special spacing of conduit and
trays. Check dimension chart for levels. These wires include:
• Signals from COMM field and line resistors
• Signals from line shunts to regulators
U High voltage potential unfused wires over 600 V dc
PS Power greater than 800 V dc and/or greater than 800 A
If there is no code, there are no grouping restrictions
Marking Cables to Identify Levels

It is good practice to mark the cableway cables, conduit, and trays in a way that
clearly identifies their signal/power levels. This helps ensure correct level separation
for proper installation. It can also be useful during equipment maintenance.
Cables can be marked by any means that makes the level easy to recognize (for
example, coding or numbering). Conduit and trays should be marked at junction
points or at periodic intervals.
One method of identification is color-coding the outer jackets of the interconnecting
cables. Another method is to attach color-coded tags at the cables’ termination ends.
For example, red and black could be used for level P and P(S), yellow for level L,
white for level M, and blue for level H.
Note If using color codes to identify signal/ power levels, care must be taken to
ensure that the color-coding is accurate and complete.
Cableway Spacing Guidelines

Spacing (or clearance) between cableways (trays and conduit) depends on the level
of the wiring inside them. For correct level separation when installing cable, the
customer should apply the general practices along with the specific spacing values
for tray/tray, conduit/tray, and conduit/conduit cableways as discussed below.
General Practices
The following general practices should be used for all levels of cabling:
• All cables of like signal levels and power levels must be grouped together in
cableways.
• In general, different levels must run in separate cableways, as defined in the

different classes. Intermixing cannot be allowed, except as noted by exception.
• Interconnecting wire runs should carry a level designation.
• If wires are the same level and same type signal, group those wires from one
panel to any one specific location together in multiconductor cables.

• When unlike signals must cross in trays or conduit, cross them in 90° angles at a
maximum spacing. Where it is not possible to maintain spacing, place a grounded
steel barrier between unlike levels at the crossover point.
• When entering terminal equipment where it is difficult to maintain the specific

spacing guidelines shown in the following tables, keep parallel runs to a
minimum, not to exceed 1.5 m (5 ft) in the overall run.
• Where the tables show tray or conduit spacing as 0, the levels can be run
together. Spacing for other levels must be based on the worst condition.
• Trays for all levels should be metal and solidly grounded with good ground
continuity. Conduit should be metal to provide shielding. (Use Figure 6-13,
Table 1 for non-metal conduit/tray spacing).
The following general practices should be used for specific levels of cabling:
• When separate trays are impractical, levels L and M can combined in a common
tray if a grounded steel barrier separates levels. This practice is not as effective as
tray separation, and may require some rerouting at system startup. If levels L and
M are run side-by-side, a 25 mm (1-inch) minimum spacing is recommended.
• Locate levels L and M trays and conduit closest to the control panels.
• Trays containing level L and level M wiring should have solid bottoms and be
covered to provide complete shielding. There must be positive and continuous
cover contact to side rails to avoid high-reluctance air gaps, which impair
shielding.
• Trays containing levels other than L and M wiring can have ventilation slots or
louvers.
• Trays and conduit containing levels L, M, and H(S) should not be routed parallel
to high power equipment enclosures of 100 kVA and larger at a spacing of less
than 1.5 m (5 ft) for trays, and 750 mm (2 1/2 ft) for conduit.
• Level H and H(S) can be combined in the same tray or conduit, but cannot be
combined in the same cable.
• Level H(S) is listed only for information since many customers want to isolate
unfused high voltage potential wires.
• Do not run levels H and H(S) in the same conduit as level P.
• Levels H and P can be run in a common tray if levels are separated by a barrier.
This barrier does not have to be grounded. Spacing should be for level P.
• Where practical for level P and/or P(S) wiring, route the complete power circuit
between equipment in the same tray or conduit. This minimizes the possibility of
power and control circuits encircling each other.

Tray and Conduit Spacing
The following tables show the recommended distances between metal and plastic
cable trays and conduit carrying cables with various signal levels.
Table 1. Spacing Between Cable Trays (inches)
Level L M H H(S) P P(S)

L 0 3 6 6 26 26 Recommended minimum distances between trays:
M 0 6 6 18 26 from the top of one tray to the bottom of the tray above,
H 0 0 4 12 or between the sides of adjacent trays.
H(S) 0 8 18
0 0
P Table 1 also applies if the distance between trays and power
0
P(S) equipment up to 100 kVA is less than 1.5 m (5 ft).
Table 2. Spacing Between Metal Trays and Conduit (inches)
Level L M H H(S) P P(S) Recommended minimum distance between the outside surfaces of
L 0 1 4 4 18 18 metal trays and conduit:
M 0 4 4 12 18
H 0 0 4 8 Use Table 1 for tray/conduit spacing if trays or conduit are non-
H(S) 0 6 12 metal,
P or if level L and M trays are not covered (Table 2 assumes they are
0 0
P(S) 0 covered),
or if the distance between trays or conduit and power equipment up
to 100 kVA is less than 1.5 m (5 ft).
Table 3. Spacing Between Metal Conduit Runs (inches)
Level L M H H(S) P P(S)

L 0 1 3 3 12 12 Recommended minimum distance between the outside surfaces
M 0 3 3 9 12 of metal conduit run in banks.
H 0 0 3 8
H(S) 0 6 9 Use Table 1 for conduit/conduit spacing if conduit are non-metal,
P 0 0 or if the distance between conduit and power equipment up to
P(S) 0 100 kVA is less than 750 m (2.5 ft).
Figure 6-13. Tray and Conduit Spacing
Cable Routing Guidelines

Pullboxes and Junction Boxes
Keep signal/power levels separate inside pullboxes and junction boxes. Use
grounded steel barriers to maintain level spacing.
Tray-to-conduit transition spacing and separation are a potential source of noise. Be
sure to cross unlike levels at right angles and maintain required separation. Protect
transition areas per the level spacing recommendations.
Transitional Areas
When entering or leaving conduit or trays, make sure that cables of unlike levels do
not intermix. If the installation needs parallel runs over 1.5 m (5 ft), grounded steel
barriers may be needed for proper level separation.

Cabling for Retrofits
Reducing electrical noise on retrofits requires careful planning. Lower and higher
levels should never encircle each other or run parallel for long distances.
It is practical to use existing conduit or trays as long as the level spacing can be
maintained for the full length of the run. Existing cables are generally of high voltage
potential and noise producing. Therefore, route levels L and M in a path apart from
existing cables, when possible.
Use barriers in existing pullboxes and junction boxes for level L wiring to minimize
noise potential.
Do not loop level L signals around high control or level P conduit or trays.
Conduit Around and Through Machinery Housings

Care should be taken to plan level spacing on both embedded and exposed conduit in
and around machinery. Runs containing mixed levels should be minimized to 1.5 m
(5 ft) or less in the overall run.
Conduit running through and attached to a machinery housing should follow level
spacing recommendations. This should be discussed with the contractor early in the
project.
Trunnions entering floor mounted operator station cabinets should be kept as short as
possible when used as cableways. This helps minimize parallel runs of unlike levels
to a maximum of 1.5 m (5 ft) before entering the equipment.
Where different signal/power levels are running together for short distances, each
level should be connected by cord ties, barriers, or some logical method. This
prevents intermixing.
RF Interference
To prevent radio frequency (RF) interference, take care when routing power cables
in the vicinity of radio-controlled devices (for example, cranes) and audio/visual
systems (public address and closed-circuit television)
Suppression
Unless specifically noted otherwise, suppression (for example, a snubber) is required
on all inductive devices controlled by an output. This suppression minimizes noise
and prevents damage caused by electrical surges. Mark VI relay and solenoid outputs
always have suppression.
Cable Specifications
It is standard practice to use shielded cable with control equipment. Shielding
provides the following benefits:
• Generally, shielding protects a wire or grouping of wires from its environment.
• Because of the capacitive coupling effect between two sources of potential

energy, low-level signals may require shielding to prevent signal interference.

Low Voltage Shielded Cable
This section defines 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.
General Specifications
• Individual minimum stated wire size is for electrical needs.
• Clamp-type terminals use 14 AWG maximum wire.
• Mark VI terminal blocks accept two 12 AWG wires.
Table 6-3. American Wire Gage (AWG) Wire Sizes
AWG No. 24 20 18 16 14 12 10 8 6 4 2 1 1/0 2/0 4/0

Area (mm²) 0.2 0.5 0.75 1.0 1.5 4.0 6.0 10.0 16.0 25.0 35.0 50.0 60.0 70.0 120
Single-Conductor Shielded Cable, Rated 600 V

• 18 AWG minimum, stranded single-conductor insulated with minimum 85% to
100% coverage shield.
• Protective insulating cover for shield.
• Wire rating: 600 V minimum.
• Maximum capacitance between conductor and shield: 492 pF/m (150 pF/ft).
Multiconductor Shielded Cable, Rated 600 V

• 18 AWG minimum, stranded conductors individually insulated per cable with
minimum 85% to 100% coverage shield.
• 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).
Shielded Twisted-Pair Cable, Rated 600 V

• Two 18 AWG minimum, stranded conductors individually insulated with
minimum 85% to 100% coverage shield
• 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.
Coaxial Cable RG-58/U (for IONet & UDH)

• 20 AWG stranded tinned copper conductor with FEP insulation, and 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.
• Supplier: Belden Coax Cable no. 82907 (no substitute).
Note Belden refers to the Belden Wire & Cable Company, a subsidiary of Belden,
Inc.
Other Cables
UTP Cable (for Data Highways)
• High quality, category 5 UTP cable, for 10Base-T Ethernet
• Four pairs of twisted 22 or 24 AWG wire
• Protective PVC jacket
• Impedance: 75 – 165 ohms
• Connector: RJ45 UTP connector for solid wire
RS-232C Communications
• Modbus communication from the HMI: for short distances use RS-232C cable;
for distances over 15 m (50 feet) add a modem.
• Modbus communication from the controller COM2 port: for use on small
systems, RS-232C cable with Micro-D adapter cable (GE catalog No.
336A4929G1); for longer distances over 15 m (50 feet) add a modem.
• For more information on Modbus and wiring, refer to Chapter 3 Networks.
Instrument Cable, 4 – 20 ma
• With Tefzel insulation and jacket: Belden catalog no. 85231 or equivalent
• With PVC jacket: Belden catalog no. 9316 or equivalent
Fiber Optic Cable (for Data Highways)

• Multimode fiber, 62.5/125 micron core/cladding, 850 nm infra-red light
• Four multiple sub-cables with elastomeric jackets and aramid strength members
• Cable construction: flame retardant pressure extruded polyurethane
• Optical Cable Corporation Part No. RK920929-A

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
shown in Figure 6-14. Power cables from the Power Distribution Module to the
control modules, interface modules, and termination boards are secured by plastic
cable cleats located behind the riser brackets. Most of this cabling is covered by the
mounting brackets and plates.
Plate
Mounting Panel
Lexan Tray for
I/O Cables
I/O Cable
3/4 inch Cable
Cleat for Power
Cables
Riser
Bracket
1 inch Cable Cleat

Termination
Board
Insulating Plate
Figure 6-14. Cable Trays & Mounting Brackets for Termination Boards
The first of the two diagrams in Figure 6-15 shows routing of the I/O cables and
power cables in a typical 1600 mm panel line up. Dotted outlines show where boards
will be mounted on top. The cables are not visible from the front.
The second diagram shows routing of IONet and customer field wiring to the I/O
modules and termination boards. This wiring is visible and accessible from the front.

Tray I/O Powr
Tray for I/O Cables

Tray for I/O Power
R
PDM
Tray for 115 V dc Power

S
Tray for I/O Cables
Tray for I/O Cables
T Main
125 V dc
Supply
Typical Power & I/O Cabling behind Mounting Brackets
Tie wrap Wiring to

vertical perforated
side plate
IM
R
IM
S
IM
T
Customer IONet Customer

I/O Wiring Cables I/O Wiring
Typical Communication & Customer I/O Wiring in Front of Panel
Figure 6-15. Typical Cabinet Wiring and Cabling

I/O Wiring
I/O connections are made to terminal blocks on the Mark VI Termination Boards.
The various termination boards and types of I/O devices used are described in
Chapter 9 I/O Descriptions. Shielding connections to the shield bar next to the
termination board are illustrated in Figure 6-16 below.
Grounded Shield Bar
Shield
Terminal
Block
Shield
Termination
Board
Shield
Cable
Figure 6-16 I/O Wiring Shielding Connections to Ground Bar at Termination Board
The grounded shield bars provide an equipotential ground plane to which all cable
shield drain wires should be connected, with as short a pigtail as practical. The
length should not exceed 5 cm (2 in) to reduce the high-frequency impedance of the
shield ground. Reducing the length of the pigtail should take precedence over
reducing the length of exposed wire within the panel. Pigtails should not be
connected except at the grounding bars provided, to avoid loops and maintain a
radial grounding system. Shields should be insulated up to the pigtail. In most cases
shields should not be connected at the far end of the cable, to avoid circulating
power-frequency currents induced by pickup.
A small capacitor may be used to ground the far end of the shield, producing a
hybrid ground system, and may improve noise immunity. Shields must continue
across junction boxes between the control and the turbine, and should match up with
the signal they are shielding. Avoid hard grounding the shield at the junction boxes,
but small capacitors to ground at junction boxes may improve immunity.

Power System
The 125 V dc supply must be installed and maintained such that it meets
requirements of IEC 61010-1 cl. 6.3.1 to be considered Not Hazardous Live. The
BJS berg jumper must be installed in the PDM to provide the monitored ground
reference for the 125 V dc. If there are multiple PDMs connected to the dc mains,
only one has the Berg jumper installed. If the dc mains are connected to a 125 V dc
supply (battery) it must be floated, that is isolated from ground. The DS200TCPD
board in the PDM must provide the single, monitored, ground reference point for the
125 V dc system. Refer to Wiring and Circuit Checks later in this chapter.
Installing Ethernet
The Mark VI modules communicate over several different Ethernet LANs (refer to
Chapter 3 Networks). IONet uses Ethernet 10Base-2 cable. The data highways use a
number of 10Base-T segments and 10Base-2 segments connected to a dual Ethernet
hub. These guidelines comply with IEEE 802.3 standards for Ethernet. For details on
installing individual Ethernet LAN components, refer to the instructions supplied by
the manufacturer of that equipment.
Installing Ethernet 10Base-2 Coax Cable for IONet

10Base-2 cable (Thinwire™) is a 20 AWG copper-centered wire used for connecting
the interface modules and control modules. Use the following guidelines when
installing 10Base-2:
• The maximum length of a 10Base-2 coax cable segment is 185 m (607 ft).
• Both ends of each segment should be terminated with a 50-ohm resistor.
• All connectors and terminators must be isolated from ground to prevent ground
loops (grounding of shield controlled by Mark VI boards).
• The maximum length of cable is 3035 ft (925 m) using the IEEE 5-4-3 rule.
• Maximum length of a transceiver and repeater cable: 164 ft (50 m).
• Minimum distance between transceivers: 8.2 ft (2.5 m).
• Maximum device connections (taps) per segment: 100, including repeater taps.
• In systems with repeaters, transceivers should have the SQE test (heartbeat)
switch disabled.
Preventing Reflections
Short segments should have no breaks with 50-ohm terminations on both ends. This
produces minimal reflections from cable impedance discontinuities.
A coaxial barrel connector is used to join smaller segments. However, the joint
between the two segments makes a signal reflection point. This is caused by
impedance discontinuity from the batch-to-batch impedance tolerance of the
manufactured cable.
If cables are built from smaller sections, all sections should either come from the
same manufacturer and lot, or with one of the IEEE recommended standard segment
lengths.
Note Cables of non-standard length produce impedance mismatches that cause

signal reflections and possible data loss.

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 × 23.4 m (or 3 × 76.75 ft)
7 × 23.4 m (or 7 × 76.75 ft)
9 × 23.4 m (or 9 × 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.
Grounding Ethernet Cable

On the PDH and UDH only, connect the Ethernet 10Base-2 cable to a reliable earth
ground at only one point. The actual connection to ground can be made at any point
on the cable, but is usually easier at the terminator connector.
For all Ethernet cables, insulate all connections, except grounded ones, from any
other metallic surface. This prevents chance grounding, which creates a ground loop.
Ground loops can introduce noise and add hazardous voltage potential onto the coax
cable because of different earth ground reference points. All connectors must be
insulated.
10Base-2 Connectors
Description: Connector for Ethernet 10Base-2 trunk ThinWire coax cable
Part number: BNC coax connector with gold-plated pin, MilesTek catalog no.
10-02001-233
BNC F-Adapter, MilesTek catalog no. 10-02918
BNC Goal Post Adapter, MilesTek catalog no. 10-02914
10Base-2 Terminator
Description: BNC terminator for Ethernet trunk coax cable, 50 ohm,
Part number: MilesTek catalog no. 10-02406-009
Note On the PDH and UDH only, use a terminator with grounding tether if the
repeater BNC output is not grounded
10Base-2 Connection Tools

Description: Quick crimp tool kit for crimping connectors on Ethernet trunk
10Base-2 coax cable, including strip tool, flush cutter, and case.
Part number: MilesTek catalog no. 40-50156/GE

Installing Genius Cable
This section provides guidelines for installing a Genius bus to communicate with GE
Fanuc I/O in a Mark VI system.
Genius I/O blocks and the Genius handheld monitor require cabling practices
specific to that equipment. For additional information, refer to the individual
instruction manuals for the Genius equipment.
Note Do not use T or Star connections with Genius bus.
Genius Cable Specifications

The cabling hardware defined in the following sections are for use between Genius
blocks and the Mark VI controller. For cabling between Genius blocks, refer to
Chapter 3 Networks or to the documentation supplied with that equipment.
Cable
Description: Low capacitance twinaxial cable, 150 ohm, 22 AWG twisted-pair
conductors, 22 AWG stranded tinned copper drain wire
Part no:
With Teflon FEP jacket and foamed Teflon FEP wire insulation: Belden no.
89182 or equivalent.
With PVC jacket: Belden no. 9182 or equivalent.
Characteristics:
• Electrical properties: Belden no. 89182, or equivalent.
• Tinned copper conductors, 22 AWG (19 x 34), 14 ohms per 304.8 m (1000 ft).
• Tinned copper drain wire, 24 AWG stranded.
• Foil shield 100%, 18 ohms per 304.8 m (1000 ft).
• Nominal capacitance: 28.9 pF/m (8.8 pF/ft).
• Nominal impedance: 150 ohms.
• Colors: Jacket = black tint
Wire = white with black stripe
Wire = white with yellow stripe
Standards: Each wire is to be CSA listed and UL recognized (if applicable). This
wire is: NEC Article 725, UL classified, Class 2 circuits, and passes flame retard
standard UL94V-1.
Terminator
Description: Prefabricated termination module for use on Genius blocks and Field
Control modules; 150 ohm, 1/2 W 5% terminating resistors. Required for both ends
of the bus
Part no: GE part no. IC660BLM506

Startup Checks
All Mark VI control panels are pre-cabled 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 Mark VI
control panel to various input and output devices.
External sources of power may be present in the Mark
VI panel that are NOT switched by the control power
circuit breaker(s). Before handling or connecting any
conductors to the equipment, use proper safety
precautions to insure all power is turned off.
Inspect the control panel components for any damage which might have occurred
during shipping. Check for loose cables or wires, connections or loose components
such as relays or retainer clips. Report any damage that may have occurred during
shipping to GE Product Service.
Refer to Grounding section in this chapter for equipment grounding instructions.
Board Inspections
Perform the following to inspect the printed circuit boards, jumpers, and wiring:
• Inspect the boards in each module checking for loose or damaged components.
The VCMI is always in slot 1 • Verify the Berg jumpers on each I/O board are set correctly for the slot number
and has no jumpers. in the VME rack , refer to Figure 6-17. At this point do not replug the I/O
boards. This will be done after the rack power supply check.
VME I/O Board Example:
VME Slot Position = 17

1 0 0 0 16
Board ID
Berg
1 2 4 8 16
Jumpers
Jumper Binary Values
Figure 6-17. ID Jumper Positions on VME Board
• Check wire harnesses and verify they are securely connected.

• Verify that the termination 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 Chapter 9
I/O Descriptions).
• 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 shown in Figure 6-18 and are
defined in Table 6-4 on the next page.
VME Rack Wire Jumper VME Rack

Backplane Ethernet ID Plug Positions per Table front view
1 2
RO-SMP
Ethernet ID Plug located

at Bottom Left Hand Side
15 16 of VME Rack
Figure 6-18. Rack Ethernet ID Plug

Table 6-4. Ethernet ID Plug Jumper Positions
Wire Jumper Locations Pin to Pin

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
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
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, operate, or
maintain this equipment.

The following steps should be completed to check the wiring and circuits.
½ To check the power wiring

1. Check that all incoming wiring agrees with the elementary drawings supplied
with the panel, and is complete and correct.
2. Make sure that the incoming wiring conforms to approved wiring practices, as
described previously.
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 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 berg jumper must be installed in one and only one PDM, since
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 measure the current from first the P125 V
dc and then the N125 V dc using a 2000 Ohm, 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 mA 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 berg jumper is installed.
At this point the system is ready for initial rack energization.
Startup
adequately trained and thoroughly familiar with the
equipment and the instructions should install,
operate, or maintain this equipment.
Assuming all the above checks are complete, use the following steps to apply power,
load the application code, and startup the Mark VI system.
Applying Power
It is recommended that the initial rack energization be done with all the I/O boards
removed to check the power supply in an unloaded condition.
½ To energize the rack for the first time
1. Unlock the I/O boards and slide them part way out of the racks.
2. Apply power to the PDM and to the first VME I/O rack power supply.

3. Check the voltages at the test points located at the lower left side of the VME
rack. These are shown in Figure 6-19 below.
VME Rack Backplane
P15 N15
VME Rack Power Supply
Test Points
ACOM P28AA
P28BB
P28CC
P28DD
P28EE
PCOM
N28
DCOM
SCOM
Figure 6-19. VME Rack Power Supply Test Points
4. If the rack voltages check out, switch off the power supply, and carefully replace
the boards in that rack.
5. Reapply power. All the I/O boards should flash green within five minutes
showing normal operation in the RUN condition.
6. Repeat the above for all the racks.
If the system is a remote I/O system, the controller is in a separate rack powered by a
GE Fanuc power supply. Apply power to this rack, wait for the controller and VCMI
to boot up, and check that they are in the RUN condition.
Check the VPRO modules, if present, to make sure all three are in the RUN
condition.
Controller Download
If you have a new controller, before application code can be downloaded, the TCP/IP
address must be loaded. Refer to Chapter 7 Tools for details.
½ To download the TCP/IP address to a new controller
1. Downloading the TCP/IP address is done from a PC using the Serial Loader
attached to the controller serial port (COM1). Load the Flash File system and the
TCP/IP address. This procedure could take about forty-five minutes.
2. Cycle rack power to reboot the controller.
3. Download the runtime software from the toolbox over the Ethernet-based UDH.
Runtime software, also known as product code, manages the application code in
the controller.
4. Remove the serial loader cable and download the application code.
5. Power cycle the rack to reboot the controller.

Topology & 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. Refer to Chapter 7, Tools.
½ To download topology and application code
1. Using the toolbox, download the turbine application code to permanent storage
in the controller.
2. From the toolbox Outline View, select the first VCMI (R), and right click on it.
A menu displays.
3. From the menu, select Download. The network topology configuration
downloads to the master VCMI in the first controller rack. The VCMI now
knows where the Interface Modules (R0, R1, R2, ...) are.
4. Repeat for all the master VCMIs in the controller racks S, and T.
5. Cycle rack 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 then communication
with that rack is not possible. Similarly if a VCMI is not responding then
communication with that rack is not possible. The VCMI will work even if there
are no I/O boards in its rack.
6. 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.
7. Power cycle to reboot all racks.
8. Download the I/O configuration to all the I/O boards, one at a time or all at
once. With all racks running you are now ready to check the I/O.
I/O Checkout
Install the input and output wiring to the termination boards. The fuses on TRLY
have been removed by the factory for safety reasons. Conduct individual loop
energization checks per standard practices, and install the fuses as required.
Maintenance
Modules and Boards

System troubleshooting should be taken to the board level. This is described in
Chapter 8, Troubleshooting & Diagnostics.
The failed board or module should be removed and replaced with a spare, see the
following section Component Replacement for downloading.
Note Return the failed board to GE for repair. Do not attempt to repair it on site.

After long service in a very dirty environment it may be necessary to clean the
boards. If there is a dust build up it may be advisable to vacuum round the rack and
the front of the boards before removing them. Remove the boards from the cabinet
before cleaning them. Dust can be removed with a low-pressure air jet. If there is dirt
which cannot be removed with the air jet, it should be cleaned off using deionized
water. Shake off and allow the board to air-dry before re-applying power.
Component Replacement
Replacing a VCMI
½ To replace and reload the VCMI
1. If a VCMI or VPRO has failed, the rack should be powered down, and the
IONet connector unplugged from the board front, leaving the network still
running through the T-fitting.
2. Remove the VCMI and replace it with a spare VCMI that has a clear flash disk
memory, then power up the rack.
3. From the toolbox Outline View, find the failed rack under Mark VI I/O. Find
the VCMI, which is usually under the Simplex rack, and right click the VCMI.
A menu displays.
4. From the menu, click Download. The topology downloads into the new board.
5. Power cycle the rack to establish communication with the controller.
For a successful download, the flash disk memory in the replacement VCMI should
be clear, because an old topology stored in flash can sometimes cause problems. If
the memory needs to be cleared, contact GE.
Replacing an I/O Board in an Interface Module

½ To replace an I/O Board
1. Power down the rack and remove the failed I/O board.
2. Replace the board with a spare board of the same type, first checking that the
Berg jumper positions match the slot number (the same as the old board).
3. Power up the rack.
4. From the toolbox, go to the Outline View under Mark VI I/O, and find the
failed rack. Find the slot number of the failed board and right click the board. A
menu displays.
5. From the menu, click Download. The board configuration downloads.
6. Power cycle the rack to establish communication with the controller.

Replacing a Termination Board
The termination boards do not contain software requiring reload but some have
power supplied to them.

electric shock or burn. Power is provided by the
Mark VI control panel to various input and output
devices. External sources of power may be present in
the Mark VI panel that are NOT switched 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 to the controlled
process, it is recommended that all power to a
termination board be removed before replacement of
the termination board. Most termination 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.
½ To replace a termination board

1. Disconnect any power cables coming into the termination board, and unplug the
I/O cables (J-plugs).
2. Loosen the two screws on the wiring terminal blocks and remove the blocks,
leaving the field wiring attached.
3. Remove the termination board and replace it with a spare board, checking that
any Berg jumpers are set correctly (the same as the old board).
4. Screw the terminal blocks back in place, plug in the J-plugs, and the power
cables.
Cable Replacement
The I/O cables or power cables are supported in plastic brackets behind the mounting
panels as shown in Figure 6-14. Since these brackets are not continuous, it is not
recommended that the replacement cable be pulled through behind the panel.
½ To replace an I/O cable
1. Power down the interface module and disconnect the failed cable from the
module. Leave the cable in place.
2. Disconnect the failed cable from the termination board.
3. Connect the replacement cable to the termination board, and lay the new cable in
the field-wiring trough at the side of the I/O termination boards. Use space at the
top and bottom of the panel to run the cable across the cabinet to the interface
module.

4. Connect the cable to the interface module and power up the module. Tie wrap
the cable in place.
Additional cables that may be The power cables (125 V dc) are held in cable cleats behind the mounting panels. If
required for system expansion a power cable needs to be replaced, it is recommended it be run across the top or
can be installed in this same bottom of the mounting panel and down the side of the I/O wiring trough to the
way module power supply.

Chapter 7 Tools
Introduction
This chapter summarizes the tools used for configuring, loading, and operating Mark
VI. These include the Control System Toolbox, CIMPLICITY HMI, Mark VI
Runtime, and the Historian.
The Toolbox
The Control System Toolbox is PC-based software for configuring and maintaining
the Mark VI control system. The software is Windows-based and runs on a Pentium
100 or higher PC, usually the engineering workstation or a CIMPLICITY HMI
located on the Plant Data Highway. This section summarizes the toolbox features;
for details refer to GEH-6403 Control System Toolbox for a Mark VI Turbine
Controller.
Computer Requirement
The minimum PC requirements for running the toolbox software are as follows:
• 100 MHz processor (Pentium 166 or higher recommended).
• Microsoft® Windows® 95, Windows 98, or Windows NT® 4.0 (recommended).
• VGA display (640 x 480 x 16 color gray scale).
• 16 MB RAM in Windows 95 (32 MB recommended) or 24 MB RAM in
Windows NT (64 MB recommended).
• Ethernet board for data highway communication.
Configuring the Equipment Racks

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 then is used to configure details of the I/O points in the boards.
Figure 7-1 shows the screen used to select the racks.
GEH-6421 Mark VI System Guide Chapter 7 Tools • 7-1

Selecting the Racks
The Outline View on the left-hand side of the screen is used to select the racks
required for the system. This view, shown in Figure 7-1, displays all the racks
inserted under Mark VI I/O. In the example, three TMR Rack 1s are included under
the heading Rack 1 Channel R/S/T (TMR). The heading Rack 1 Channel R
(SIMPLEX) shows the location of any Simplex boards in that rack.
TMR Rack in Outline and Summary View

Click on the TMR rack in the Outline View (Rack 1 The Summary View displays a
A TMR rack displays four in this example) to view all the channels at the graphic of each rack and all the
lines in the Outline View, same time in the Summary View. boards they contain.
which represent the rack
and three channels. The
first line displays the rack
number, the rack name
Channel R/S/T and the
type TMR. Click on this
line to insert boards that
operate in TMR mode.
The next three lines define

each of the three
channels, R, S, and T,
including the rack number,
channel name, and rack
type Simplex.
Click on one of these lines
to insert boards that
operate in Simplex mode.
Note: The TMR cards
visible in this entry line
cannot be modified here.
To modify TMR selection,
go to the TMR entry above.
Figure 7-1. Configuring the Equipment Racks
Selecting the Boards

The I/O board is selected from a menu of boards shown in Figure 7-2, and then its
VME slot number is entered. If the I/O board has several I/O terminal boards that
can be attached to it, for example J3 and J4, the Terminal Boards dialog box
displays. This is used for selecting the desired boards.
7-2 • Chapter 7 Tools GEH-6421 Mark VI System Guide

Choose a board and
click OK.
The Mark VI Board

dialog box displays.
Enter the slot number

that the board will occupy
in the rack and click OK.
If the selected board has

several terminal board
configurations available,
the Terminal Boards
dialog box will be
displayed.
Choose the terminal

boards that will be used
with the VME board
selected above and click
on the check boxes.
Click OK.
Figure 7-2. Terminal Board Configuration
Point Configuration
Each board contains several points, such as thermocouples, contact inputs, or
solenoid outputs. Each of these points is configured with the desired characteristics
including high and low limits, alarm settings, and type of input linearization. The
points are listed under the terminal board which supports those points. If the board is
not selected, then those associated points are not configured.
Figure 7-3 shows the Outline View with the I/O board, terminal board, points, and
point configuration.

Left click on board and I/O
data displays in the
Summary View.
Right click and a menu
displays with View
The board, VTCC contains a Diagnostic Alarms and
terminal board connected to Download choices. Alarms
jumpers J3 and J4, called display in the Summary
IS200TBTCG1A. View.
The point, ThermCpl3 contains

configuration, which can be
modified.
Figure 7-3. Point Configuration
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.
Blocks
The Standard Block library contains over 60 different control blocks designed for
discrete and continuous control applications. Blocks provide a simple graphical way
for the engineer to configure the control system. Figure 7-4 displays a math block.
The Mathematical function

displays next to the label EQUAT,
and the result displays at the
OUT pin.
Input signals
MENG computes a mathematical
function of four floating point
inputs A, B, C, and D
Pins
Figure 7-4. Math Engine (MENG) block
Tasks act as a grouping This block is computed every time the task that contains it is run. Tasks can be run at
mechanism for blocks different frame rates (scan periods) from 10 to 256 ms, depending on the needs and
priority of the control application.

A MENG block can accept up to eight inputs and be configured with a selection of
math functions including square root, absolute value, round to nearest integer, and
trigonometric functions.
The input pins are connected to signals which come from other blocks. In the
example above the input signals are MXSYPRESS, MXSYOUT, SYS_OFF, and
SYS_IN. The output signal is SYSPRS.
Process control is possible Continuous control applications can be configured using a selection of continuous
using the Standard Blocks. blocks including the PID (Proportional, Integral, Derivative) control block.
Servo regulators do not need Continuous control, for example closed loop control can be configured by
to be created since they exist connecting the continuous and math blocks using signals and pins.
in the Mark VI firmware.
As another example, the Boolean Engine (BENG) block is a discrete control
instruction block configured using a relay ladder diagram (RLD). This is displayed in
Figure 7-5. The BENG block accepts up to 16 discrete inputs, computes the Boolean
equation, and generates one discrete output. Just like the continuous control blocks,
the discrete control blocks are connected using signals and pins, and run when the
task containing them runs.
The Boolean equation

displays next to the EQN
pin, and the out put is
available at the OUT pin
Logic Input signals
Pins
The Relay Ladder Diagram
(RLD) displays in the block
Figure 7-5. Boolean Engine Block
The control system is configured in the toolbox work area, displayed in Figure 7-6.
The Outline View on the left-hand side of the screen displays the control device and
six configuration items. Under the item Hardware and I/O Definitions are the I/O
and networks, and under the item Functions are the control tasks.
The Summary View on the right side of the screen displays the graphical
configuration of the selected item. Block inputs and outputs are connected with
signals to form the control configuration. These connections are created by dragging
and dropping from a block output to another block input. The connected blocks form
macros, and at a higher level, the blocks and macros form tasks covering major
sections of the complete control.

Figure 7-6. Connecting Control Blocks in the Work Area
CIMPLICITY HMI
The CIMPLICITY Human-Machine Interface (HMI) is the main operator interface
to the Mark VI turbine control system. HMI is a PC with a Microsoft Windows NT
operating system and CIMPLICITY graphics display system, communicating with
the controllers over Ethernet. For details refer to GFK-1180 CIMPLICITY HMI for
Windows NT and Windows 95 User’s Manual. For details on how to configure the
graphic screens refer to GFK-1396 CIMPLICITY HMI for Windows NT and
Windows 95 CimEdit Operation Manual.
Basic Description
The Mark VI HMI consists of three distinct elements:
• HMI Server
• Signal Database
• HMI Viewer (Client)
HMI server is the hub of the system, channeling data between the UDH and the
PDH, and providing data support and system management. The server also has the
responsibility for device communication for both internal and external data
interchanges.
Signal database establishes signal management and definition for the control
system, provides a single repository for system alarm messages and definitions, and
contains signal relationships and correlation between the controllers and I/O. It is
used for system configuration, but not required for running.
HMI Viewer provides the visualization function, and is the client of the server. It
contains the operator interface software which allows the operator or maintenance
personnel to view screen graphics, data values, alarms, and trends, issue commands,
edit control coefficient values, and obtain system logs and reports.

Depending on the size of the system, these three elements can be combined into a
single PC, 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 Figure 7-7.
Alarm Summary Setpoint Entry Alarm Detail Shaft Vibration

window selection display selection display selection
Figure 7-7. Interactive Operator Display for Steam Turbine & Generator
In the above graphic display, special displays can be obtained using the buttons in
the column on the right hand side. Also note the setpoint button for numeric entry,
and the raise/lower arrows for opening and closing valves.
Product Features
The HMI contains a number of product features important for power plant control:
• Dynamic graphics
• Alarm displays

• Process variable trending
• Point control display for changing setpoints
• Database logger
• HMI access security
• 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
• Object Linking and Embedding (OLE)
• Movement and rotation animation
• Filled object capabilities, and interior and border animation
CimView is the HMI run-time portion, displaying the process information in
graphical formats. In CimView the operator can view the system screens, and
screens from other applications, using OLE automation, run scripts, and get
descriptions of object actions. Screens have a one-second refresh rate, and a typical
graphical display takes one 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.
Trending, based on Active X technology, gives users data analysis capabilities.
Trending uses data collected by the HMI, or data from other third-party software
packages or interfaces. Data comparisons between current and past variable data can
be made for identification of process problems. Trending includes multiple trending
charts per graphic screen with unlimited pens per chart, and the operator can resize
or move trend windows to convenient locations on the display.
The point control panel provides a listing of points in the system, with real-time
values and alarm status. Operators can view and change local and remote set points
using the up/down arrows or by direct numeric entry. Alarms can be enabled and
disabled, and alarm limits modified by authorized personnel.
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.
Optional Features
The WebGateway allows operators to access HMI data from anywhere in the world
over the Internet.
Third party interfaces allow the HMI to exchange data with DCS systems,
programmable logic controllers, I/O devices, and other computers.
Controller Software Setup

The following sections describe how to setup the software portion of the controller
for the first time. Special terms are described below.

Downloading is when a component of a configuration is sent to component’s
controller.
Flash is a non-volatile memory technology that contains the real-time operating
system, the file system, and the TCP/IP software. These are installed with the Serial
Loader, so the remaining runtime and configuration can be downloaded more
efficiently over Ethernet.
The controller is shipped with Basic I/O system (BIOS) performs the boot-up, including hardware self-tests and
the BIOS, the real time the Serial Loader.
operating system, and the
Product code (runtime) software converts application code (Pcode) configurations
runtime software installed,
to executable code (software) and schedules them.
however to insure that the
latest software is loaded Application code (Pcode) (.pcd) file, created by the toolbox, contains the controller
perform the controller setup, configuration.
described in the next section..
Symbols table file (.sym), created by the toolbox, contains signal names and
descriptions for diagnostic messages. The information is read into RAM as needed,
making updating the file in permanent storage sufficient.
Ethernet or UDH Cable
Toolbox Software &

Serial Loader
Software
COM1 Mark VI
Controller
RS-232C Serial Loader Cable
Figure 7-8. Cabling between PC and Controller for Loading Software
Controller Setup
The following steps define how to set up the controller for the first time. It is
assumed that the toolbox and controller software is already installed in the PC.
½ To set up the controller
1. Load the flash and configure TCP/IP with the Serial Loader over a serial cable
(see the section, Loading the Flash File System).
2. Cycle power to activate the new IP settings.
A soft reboot from the toolbox
is not sufficient. 3. From the toolbox, load the product code (runtime).
4. Then, load the application code (Pcode) and symbol files to permanent
storage only.
5. Cycle power again.
Note The remaining sections define each of these steps.

Serial Loader
The Serial Loader initializes the controller flash file system and sets its TCP/IP
address to allow it to communicate with the toolbox over Ethernet. It requires an
RS-232C serial cable, which can be ordered through your local GE authorized
distributor, as part number 336A3582P1. The cable specifications are shown in
Figure 7-9.
Controller PC
Pin Pin
Adapter Cable DCD 1 1 DCD
to Controller DSR 6 6 DSR
RD 2 2 RD
COM1 Port
RTS 7 7 RTS
TD 3 3 TD
CTS 8 8 CTS
DTR 4 4 DTR
RI 9 9 RI
GND 5 5 GND
9-Pin Plug 9-Pin 9-Pin 9-Pin Plug

Subminiature D Subminiature D
Receptacle Receptacle
Figure 7-9. Serial Loader Cable
A short adapter cable is required to plug into the controller COM1 Micro-D size
connector. This cable can be ordered as part number 336A4929G1. The Serial
Loader can load the Flash File System and configure the TCP/IP software in the
controller.
½ To connect the Loader serial cable
1. Connect the end of the converter cable to COM1 (9-pin connector) on the front
of the controller.
2. Connect the end of the serial cable labeled UC2000 connector to the converter
cable.
3. Connect the end of the serial cable labeled PC COM Port to one of the PC COM
ports.
Initializing the Flash

The Flash File System is loaded using the Serial Loader during installation of the
system.
½ To start the Serial Loader
1. From the Start menu, click Programs, GE Control Systems Solutions,
Mark VI Controller, and Serial Loader. The Serial Loader dialog
box displays.
2. Enter the correct setting as defined in the following Serial Loader dialog box.
This is displayed in Figure 7-10.
3. Click Start Command(s).

TCP/IP Settings include Computer Name, IP Address, Subnet Mask, and
Router IP. (Obtain this information from your network administrator.) Click
this button to display the dialog box to enter this network data (see the
section, Configuring TCP/IP).
Select Mark VI from the

drop-down box.
Click the Serial Port

Settings button to define
the PC COM port. Make
sure this port matches the
hardware cable port
(usually COM2 or COM3).
Click Load Flash File

System .
Click Display Summary

Information to display
information in this status
window.
Click
to Start the selected
commands.
When the load completes,

the following message box
displays.
Figure 7-10. Serial Loader dialog box
Note The button, Source Directory points to the location of the BIOS, CMOS, and
flash binary files. It is enabled when CPU Type is either Custom or Mark V LM. The
controller directory is automatically set to platform (C:\Program Files\GE Control
System Solution\MarkVI_Controller\platform).

Configuring TCP/IP
Obtain the Computer Name, IP Address, Subnet Mask, Broadcast Mask, and Router
Click on in IP from your network administrator. Enter this data into the proper fields displayed
the Serial Loader dialog box. in Figure 7-11.
Enter the Internet Protocol (IP) host

name. For Ethernet networks with a
global name server, the host name
can be used interchangeably with
the IP Address when
communicating to a controller.
IP Address is used to identify a

node on a network and specify
routing information on an Internet.
Enter the 32-bit value used by the

IP software to extract the network
ID and host ID from the IP
address. To be valid, the mask
must contain a "1" for all of the
network bits of the IP address
class (shown above).
This field is calculated

automatically .
Enter the 32-bit value used by the IP software Choose to load or save
to route external network messages. these settings (.ssf file) to
the local PC.
Figure 7-11. TCP/IP Settings dialog box
Tip © All IP addresses and masks are represented in dotted decimal notation,
within each of the four bytes of the address, separated with periods, such as
3.29.22.27. To determine the correct IP addresses and masks, see your network
administrator.
½ To change only the TCP/IP from it’s initial setting

1. Modify the TCP/IP Settings dialog box.
2. In the Serial Loader dialog box, check Configure TCP/IP and Display
summary Information.
3. Then, click the Start Command(s) button.
4. After the command completes, reboot the controller for the change to take
effect.
Product Code (Runtime) Software

Product code is loaded over Ethernet by the toolbox.
½ To load the product code (runtime)
1. From the toolbox, create a new Mark VI controller, or load an existing file.

2. From the Summary View double-click on the controller name. The
Properties dialog box displays, as in Figure 7-12.
From the tab General,

enter the IP address that
was configured by the
Serial Loader.
Select the Platform from

the drop-down box, such
as UCVBG1(which
displays on the extracter
tab of the controller
board itself).
Click OK.
Figure 7-12. Controller Properties Dialog Box
3. Select the Device menu, Download, and Product Code (Runtime). The
Download File dialog box displays.
Some controller versions may

show two files, Runtime.dnl
or Select.dnl.
Runtime.dnl is an obsolete
download file that loads all of
the drivers and uses the most
flash memory.
Figure 7-13. Download file
4. Click Select.dnl and click Open. All possible files that can be downloaded
display in the dialog box shown in Figure 7-14.

Figure 7-14. I\O Driver Selection Menu
5. Click on to uncheck any feature not used by the controller (in order to
conserve flash space). The toolbox deletes the entire directory and then
downloads only the checked items. Click OK. The following message displays.
Figure 7-15. Controller Reboot Warning
6. Select No. Do not reboot. Continue to load application code.

Application Code
After validating and building application code, it should be downloaded.
½ To download application code
Or click Download
1. From the Device menu, choose Download and Application Code.... The
Download Application Code dialog box displays.
2. The default screen display with all options checked. Click on Download to
memory to uncheck that option.
Click on this option box to

remove the check mark.
Do not download to
memory.
Figure 7-16. Download Application Code dialog box
3. Click OK.
4. Wait until the red FLSH LED on the controller has turned off.
5. Reboot the controller using the power switch.
Software Modifications
The following sections describe how to modify the application code in the controller
and how to upgrade the product code software to a newer version.
Modifying the Application Code

The controller executes the application code from RAM. Each time the controller is
rebooted the application code is copied from permanent storage in the flash into the
RAM. This allows the user to try out new application code by downloading it into
RAM and then to restore the original configuration by rebooting. Or, alternately the
new code may be made the default by writing it to permanent storage.

Some application code changes, including editing, inserting, or deleting blockware
may be downloaded to RAM without stopping the control process. This is known as
an online download.
Some application code changes, including modifications to I/O, scales, or variable
addresses may only be downloaded to RAM by stopping and restarting the control
process. This is known as an offline download.
Still other application code changes, including modifications to system memory sizes
cannot be downloaded to RAM but must be downloaded to permanent storage only
and the controller rebooted. Any change that may be implemented with an online or
an offline download may also be performed this way. Refer to the section, Major and
Minor Differences.
Pcode is written when the ½ To change the application code in the controller
menu command, Build
1. From the toolbox, modify the application code.
application control code is
selected. This file contains all
the application software for 2. Select Validate and Build.
the controller. 3. From the Device menu, select Download and then Download Application
Code.
4. Select the desired download option from the Download application code
dialog box displayed in Figure 7-17.

Check here to replace the current running configuration with the new application code. Then,
select from Memory Download Mode:
Offline - Restart controller stops the controller execution before expanding and loading new
code. All contents are initialized. Use this mode when there is a major configuration change.
Downloads to Online - Init all constants replaces the running configuration without stopping for a fast
RAM download. Since all constants are initialized the process increases.
Online - Init only new constants replaces the running configuration without stopping for a
fast bumpless download.
Check here to download the

new application code (.pcd file)
to flash memory to be used
when the controller is rebooted.
This does not change the
current running configuration.
Downloads to Enter the correct .pcd file name
Flash or choose Browse...
Check here to download the

.sym file to permanent storage.
This changes the active
symbol table in the controller.
Enter the correct .sym file
name or choose Browse...
Note When all options are selected, the symbol table is

downloaded first. Then the application code is downloaded to
memory. If the download to memory succeeds, the code is
downloaded to permanent storage. If it fails the download to
permanent storage is canceled.
Figure 7-17. Download Application Code dialog box
Major/Minor Differences
The toolbox detects differences between the application code loaded into it and that
loaded into the controller by comparing the revision dates. The revision in the
toolbox and the controller is stored as two date and time values. These values are
cleared in the toolbox when a major or minor change occurs and set when the
configuration is built (Pcode). When the toolbox is online with a controller, the
major/minor revision of the downloaded configuration in the controller is compared
with the current configuration in the toolbox. A typical toolbox display of the
revisions is shown in Figure 7-18.

Major and Minor
revision differences
are indidcated in the
Summary View.
The connection/revision status is displayed here.
Figure 7-18. Display of Minor and Major Revisions

The controller application files consist of Pcode files and diagnostic symbol table
files. Pcode can be downloaded to either the active RAM to replace the configuration
that is running, or to permanent storage. Permanent storage is flash memory for the
controller for use the next time the controller boots.
Pcode can be downloaded to the controller RAM in either an online mode, where the
configuration is switched over quickly, or offline where the controller is completely
stopped and then restarted. It is usually beneficial to use the online download, but the
amount of configuration change could make this impossible. Refer to the next
section, Major/Minor Differences.
A major difference means that the major revision in the toolbox is different from the
major revision in the controller. A minor difference means that the minor revisions
differ, but the major revisions are the same. Equal means that both major and minor
revisions are the same. These differences all display in the Status Bar.
A bumpless download does It is not always possible to download online when a change is made to the
not disrupt the control as a configuration that prevents the download from being bumpless, such as numerous
result of the download. changes to signals in regard to their address tokens, or changes to scales or I/O. In
the toolbox, a major change is one that does not allow an online download. These
include changes caused by additions of hardware modules, or packing signals.
Packing involves reclaiming unused tokens (this does not include connecting signals
to points). Minor changes are any other changes to the configuration including
editing, inserting, or deleting blockware.

The status of changes to the configuration can be seen from the Summary View, as
shown in Figure 7-19 below. The first example shows a configuration just built, the
second has minor changes, and the third major changes.
Figure 7-19. Status of Changes to the Configuration

Upgrading the Product Code (Runtime) Software
The following steps define how to install a new version of the product code software
in a previously configured controller. It is assumed that the toolbox and a previous
version of the product code are already installed in the PC, and that an application
code file (.m6b or .ucb) exists.
½ To upgrade the product code

1. From the toolbox, select File menu and Open, and select the existing
application code file (.m6b).
2. From the File menu, select Export All and select an option to export the
application code into its tree file (.tre) components and a project file (.prj).
Figure 7-20. Export Application Code dialog box
3. Install the new controller product code using the setup utility. This is displayed
in Figure 7-21.

Figure 7-21. SetupUtility Dialog Box
4. Select the Device menu, Download, and then Product code (Runtime).
Some controller versions may

show two files, Runtime.dnl
or Select.dnl.
Runtime.dnl is an obsolete
download file that loads all of
the drivers and uses the most
flash memory.
Figure 7-22. Driver File Download Dialog Box

5. Click Select.dnl and click Open. All possible files that can be downloaded
display in the dialog box shown in Figure 7-23.
Figure 7-23. I/O Driver Selection Menu
6. Click on to uncheck any file not used by the controller (in order to conserve
flash space). The toolbox deletes the entire directory and then downloads only
the checked items. Click OK. The following message displays.
Figure 7-24. Controller Reboot Warning
7. Select No. Do not reboot.

8. From the File menu, select Close.
9. From the File menu, select Open and open the project file. This imports the
component files (.tre) back into the toolbox by opening the project file (.prj).
Note This will create a new Work Area to merge the application code (.tre files)
with the new product code.
10. Select Validate and Build to create a new Pcode file (.pcd) from the
application code.

11. From the File menu, select Save.
12. From the Device menu, choose Download and Application Code.... The
Download Application Code dialog box displays.
13. Check Download to permanent storage and Download symbols.
14. Click OK.
15. Wait until the red FLSH LED on the controller has turned off.
16. Reboot the controller using the power switch.
Rebooting the Controller

The reboot sequence starts with the microprocessor reading the BIOS startup code
from EPROM. This initiates hardware self-tests and memory checks. The controller
front panel diagnostic LEDs light in a fixed sequence. If any hardware faults are
detected, these diagnostic lights freeze and the fault can be determined from the
indicated number. Refer to Chapter 8, Diagnostics.
Test Generates non-flashing error codes on

BIOS the status LEDs
Load Operating Generates three non-flashing error codes:

System
3E-TCP/IP address has not been loaded
3D-Runtime code has not been loaded
3C-Application code has not been loaded
Load Application
Pcode Startup specified I/O drivers
Create System Memory allocation can only be modified at bootup

Memory
Generates
flashing error Create Data Collection
Can only be modified at boot-up
codes Memory
Load Block
Load standard control block library
Library
Expand Application
Create task scheduling lists
Pcode
Synchronize with
other 2 Controllers This step implemented only if the system is TMR
Start Application Code

Scheduler Begin executing application code
Figure 7-25. Controller Boot-up Sequence

Figure 7-25 shows the reboot sequence. The microprocessor loads the operating
system from flash memory. This provides the real time functioning of the controller.
Following this the runtime code is loaded from flash memory. This software converts
Pcode (application code) to executable code and schedules them.
The application code is loaded from flash memory, along with the selected I/O
drivers. Local variables are created and initialized, and any forced I/O or forced
Booleans are restored out of Non Volatile Read Only Memory (NOVRAM).
The application code is expanded and the task scheduling charts are created. In the
final step, the microprocessor starts running the application code. The different I/O
drivers have different delays (sometimes several seconds) before starting
communication with their I/O and networks.
Historian
The Historian is a data archival system based on client-server technology, that
provides data collection, storage, and display of power island and auxiliary process
data. Depending on the requirements, the product can be configured for just turbine-
related data, or for broader applications that include balance of plant process data.
The Historian combines high-resolution digital event data from the turbine controller
with process analog data to create a sophisticated tool for investigating cause-effect
relationships. It provides a menu of predefined database query forms for typical
analysis relating to the turbine operations. Flexible tools enable the operator to
quickly generate custom trends and reports from the archived process data.
System Configuration
The GE Historian provides historical data archiving and retrieval functions. When
required, the system architecture provides time synchronization to ensure time
coherent data.
The Historian accesses turbine controller data via the UDH as shown in Figure 7-26.
Additional Historian data acquisition is performed through Modbus and/or Ethernet
based interfaces. Data from third party devices such as Bently Nevada monitors, or
non-GE PLCs is usually obtained via Modbus, while Ethernet is the preferred
communication channel for GE/Fanuc PLC products.
The HMI and other operator interface devices communicate to the Historian through
the PDH. Network technology provided by the Microsoft Windows NT Operating
System allows interaction from network computers including query and view
capabilities using the Historian Client Tool Set. The interface options include the
ability to export data into spreadsheet applications.

Plant Data Highway
HMI Server # 1 HMI Server # 2 HMI Viewer Historian

DAT
Tape
TR
Unit Data Highway
Figure 7-26. Data Transmission to the Historian and HMI
System Capability
The Historian provides an on-line historical database for collecting and storing data
from the Mark VI turbine controls. Up to 20,000 total point tags may be configured
and collected from as many as eight turbine controls.
A typical turbine control application uses less than 1,000 points of time tagged
analog and discrete data per unit. The length of time that the data is stored on disk
before off-line archiving is required depends upon collection rate, dead-band
configuration, process rate of change, and disk size.
Data Flow
The Historian has three main functions: data collection, storage, and retrieval. Data
collection is over the UDH and Modbus. Data is stored in the Exception Database for
SOE, events, and alarms, and in the archives for analog values. Retrieval is by way
of a web browser, or standard trend screens. Figure 7-27 shows these functions and
data flow.

I/O I/O I/O
3rd Party
Mark VI PLC Devices
Ethernet Ethernet Modbus
Process
Turbine Control
Data Archives
Exception
Dictionary (Analog
Database Values)
(SOE)
Server Side
Client Side
Web Browser Trend generation DataLink
Alarm & Event Report Process Data Excel for

Cross Plot (Trends) Reports &
Event Scanner Analysis
Figure 7-27. Historian Functions & Data Flow
Details
Data is collected by various methods. For the Mark VI, the process is centered about
the Control Signal Database (CSDB) which is the real-time database used by the
controller. The Mark VI scans the CSDB for alarm and event state changes. When a
state change occurs, it is sent to the Historian. Contact inputs, or Sequence of Event
(SOE) changes are scanned, sent to the Historian and stored in the Exception
Database with the alarms and event state changes. These points are time-tagged by
the Mark VI at the frame rate. The Mark VI also distributes one-second periodic
updates scanned from the CSDB.
Time synchronization and time coherency are extremely important when the operator
or maintenance technician is trying to analyze and determine the root cause of a
problem. To provide this, the data is time-tagged at the controller and offers system
time-sync functions as an option to ensure that PLC and Mark VI data remain time-
coherent.
Data points configured for collection in the archives are sampled once per second
from the Data Dictionary. Analog data that exceeds an exception dead-band and
digital data that changes state are sent to the archives. The Historian uses the
swinging door compression method that filters on the slope of the value to determine
when to save a value. This allows the Historian to keep orders of magnitude more
data on-line than in conventional scanned systems.
The web browser interface provides access to the Alarm & Event Report, the Cross-
Plot, the Event Scanner, and several Historian status displays. Configurable trend
displays are the graphical interface to the history stored in the archives. They provide
historical and real-time trending of all process data.

The data link provides a vehicle to extract data from the archives into application
packages such as Excel for report generation and analysis.
Historian Optional Tools

The Historian has a selection of tools, screens, and reports available to ensure that
the operator can make efficient use of the collected data. Examples of a just a few of
these are illustrated below.
• Alarms and Events Report is a tabular display of the alarms, events, and SOE
(Sequence of Events) for all Mark VI units connected to the Historian. This
report presents the following information on a point’s status: time of pickup (or
dropout), unit name, status, processor drop number, and descriptive text. This is
a valuable tool to aid in the analysis of the system, especially after an upset.
• Historical Cross Plot references the chronological data of two signal points,
plotted one against another, for example temperature against RPM. This
function permits visual contrasting and correlation of operational data.
• Event Scanner function uses logic point information (such as: start, trip,
shutdown, or user-defined) stored in the historical database to search and
identify specific situations in the unit control.
• Event/Trigger Query Results shows the user’s inputs and a tabular display of
resulting event triggers. The data in the Time column represents the time-tag of
the specified Event Trigger.
• Process Data (Trends). The Historian can trend any analog or digital point. It is
fully configurable and has the ability to auto-range the scales or set fixed
indexes. For accurate read out, the trend cursor displays the exact value of all
points trended at a given point in time. The Historian can be set up to mimic
strip chart recorders, analyze the performance of particular parameters over
time, or help trouble-shoot root causes of a turbine upset. The trend display in
Figure 7-28 is an example of a turbine start-up.

Figure 7-28. Typical Multi-Pen Process Trend Display
Reports
The data link provides a vehicle to extract data from the archives into application
packages such as Excel. Excel, and other software packages such as Access, SQL,
and Minitab can be used to generate reports and analyze data. Numerous reports such
as maintenance and shift reports can be generated to provide the customer with
needed information to better manage his plant assets.

Chapter 8 Troubleshooting &
Diagnostics
Introduction
This chapter discusses troubleshooting and alarm handling in the Mark VI system.
The configuration and creation of process alarms is covered, and the creation and
handling of diagnostic alarms caused by control system equipment failures.
Overview
Two kinds of alarms are generated by the Mark VI system, process alarms and
diagnostic alarms. Process alarms are routed to the operator display, and diagnostic
alarms are routed to the engineering workstation (toolbox). Figure 8-1 shows the
alarm routings.
Alarm Diagnostic
HMI HMI Toolbox
Display Display
UDH
<R> Process <S> <T> Diagnostic

Controller Alarms Controller Controller Alarms
Diagnostic
I/O SOEs I/O I/O
Alarm Bits
Figure 8-1. Two Types of Alarms generated by Mark VI
GEH-6421 Mark VI System Guide Chapter 8 Troubleshooting & Diagnostics • 8-1

Process alarms are caused by machinery and process problems, and alert the
operator by means of 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 toolbox. As well
as generating operator alarms, the alarm bits in the controller can be used as digital
interlocks in the application program.
Diagnostic alarms are caused by Mark VI equipment problems, and use settings
factory programmed in the boards. Diagnostic alarms identify the failed module to
help the service engineer quickly repair the system. For details of the failure, the
operator can request a display on the toolbox screen.
Process Alarms
Process alarms can be generated in two ways. One way is via the application
software running in the controller. Signals used to generate these alarms are tied to
an alarm group which is scanned for state changes by the controller.
Process alarms are also triggered in the I/O board by System Limit Checking. Limit
checking takes place at the frame rate, and resulting alarms are sent to the controller
where they are time stamped and given an ID. They are then sent over the UDH to
the HMI where, with appropriate configuration, the HMI creates alarm messages for
the operator.
• Two System Limits are available for each process input, including
thermocouple, RTD, current, voltage, and pulse rate inputs. System Limit 1 can
be the high or low alarm setting, and System Limit 2 can be a second high or
low alarm setting. These limits are configured from the toolbox in engineering
units.
• There are several choices when configuring System Limits. Limits can be
configured as enabled or disabled, latched or unlatched, and greater than or less
than the preset value.
• System out of limits can be reset with the RESET_SYS signal.
• Process alarm logicals can be used in the application program. In TMR systems
limit logic signals are voted and the resulting composite diagnostic is present in
each controller.
Generating Process Alarms

Process alarms are generated in the controller by both the turbine Big Blocks and
primitive control blocks. These control blocks are configured to multi-input Alarm
Group Blocks. Each alarm input consists of two signals, the alarm logic variable, and
the alarm ID, refer to Figure 8-2. The Alarm Group Block places the alarm status bits
in an alarm bit array which is scanned for changes by the alarm scanner. Changes
representing alarms are time stamped and sent to the alarm queue. Reports
containing alarm information are assembled and sent over the UDH to the
CIMPLICITY HMI. Here the alarms are 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.
8-2 • Chapter 8 Troubleshooting & Diagnostics GEH-6421 Mark VI System Guide

Mark VI Controller UDH Mark VI HMI
Control
Blocks Alarm
Group
Block
Alarm Alarm Alarm

Control Report Receiver Viewer
Blocks Alarm
Scanner
Alarm
Alarm
Comm
Alarm Group
-and Alarm
Block
Logic
Alarm Queue
variable
Queue
Alarm including
ID Time Operator
Commands:
- Ack
Toolbox Alarm Bit - Reset
representation Array - Lock
of Control/Alarm
- Unlock
configuration
Figure 8-2. Generating Process Alarms using the Alarm Group Block
Mark VI Alarm Scanner

If the controller’s Alarm IP Address is configured with an HMI’s IP Address, then
that HMI will be the only HMI capable of gathering alarms from the controller. In
the case of a user who requires two HMI servers to have alarm viewing, the
controller should be given an UDH Broadcast Address instead of an Alarm IP
Address. The controller then broadcasts alarms on the UDH and all the HMIs gather
and display alarms.
To set up controller alarm scanning, go to the Outline View on the toolbox and
double click on the device name (example: mkvi1) at the top of the tree. From the
menu tabs, select Alarm Scanner, and then select Enable Alarm Scanner. In the
Alarm IP Address area, enter the UDH Broadcast Address. This configures the
controller to send alarms to all UDH stations.
If the plant DCS requires turbine alarms from Mark VI, these must come through an
HMI on the UDH. Without an HMI, the DCS can only gather process data, and will
have to generate its own alarms for display on the operator screen.
Hardware failures in the system create diagnostic alarms which are handled in a
different way, as discussed below.
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 some types of input are removed from
scan.
• In TMR systems, a limit alarm called 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 hardware limits is set it creates a board composite diagnostic
alarm, L3DIAG_Vxxx, where Vxxx is the I/O board. This signal can be used to
trigger a process alarm. Each board has three L3DIAG_ signals;
L3DIAG_Vxxx1, 2, and 3. Simplex boards only use L3DIAG_Vxxx1. 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, or with a message from the HMI.
• Generally diagnostic alarms require two occurrences before coming true
(process alarms only require one occurrence).
In addition to inputs, each board has it’s own diagnostics. The I/O boards have a
processor stall timer which generates a signal SYSFAIL. This signal lights the red
LED on the front panel. The watchdog timers on the various boards are set as
follows:
• Controller (UCVB) board 1.2 seconds
• 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
default condition on contact inputs is subject to the inversion mask.
The three LEDs at the top of the front panel provide status information. The normal
RUN condition is a flashing green, FAIL is a solid red. The third LED is normally
off but shows a steady orange if a diagnostic alarm condition exists in the board.
The controller has extensive self-diagnostics which are planned to be made available
at the toolbox. In addition, runtime diagnostics, which may occur during a program
download, are displayed on LEDs on the controller front panel.
Each termination board has its own ID device, which is interrogated by the I/O
board. The board ID is coded into a read-only chip containing the termination board
serial number, board type, revision number, and the J type connector location.
Viewing Diagnostic Alarms

To view diagnostic alarms, go to the toolbox and select the I/O board of interest.
Right click the board to reveal the menu, and select View Diagnostic Alarms. A list
of the diagnostic alarms displays in the diagnostic view window. The diagnostics
may be reset from this window.

I/O Board Alarms
The following diagnostic alarms are generated by the I/O boards, the VCMI, and the
VPRO protection module. They are viewed on the toolbox.
Table 8-1. I/O Board Diagnostic Alarms
Board Fault Fault Description Possible Cause
VTCC 16 System Limit Checking is Disabled. If any The configuration setting for "System
thermocouple or cold junction sensor input exceeds the Limits" was set to "Disable".
configured system limits, the system limit alarm will not be
set
32 Thermocouple ## Raw Counts High. The ## A condition such as stray voltage or
thermocouple input to the analog to digital converter noise caused the input to exceed +63
exceeded the converter limits and will be removed from millivolts.
scan
33 Thermocouple ## Raw Counts Low. The ## The board has detected a
thermocouple input to the analog to digital converter thermocouple open and has applied a
exceeded the converter limits and will be removed from bias to the circuit driving it to a large
scan negative number, or the TC is not
connected, or a condition such as stray
voltage or noise caused the input to
exceed -63 millivolts.
34 Calibration Reference # Raw Counts High. The precision reference voltage on the
Calibration Reference # input to the A/D converter board has failed.
exceeded the converter limits. If Cal. Ref. 1, all even
numbered TC inputs will be wrong; if Cal. Ref. 2, all odd
numbered TC inputs will be wrong
35 Calibration Reference # Raw Counts Low. The precision reference voltage on the
numbered TC inputs will be wrong
36 Null Reference # Raw Counts High. The null (zero) The null reference voltage signal on the
reference number # input to the A/D converter has board has failed.
exceeded the converter limits. If null ref. 1, all even
numbered TC inputs will be wrong; if null ref. 2, all odd
numbered TC inputs will be wrong.
37 Null Reference # Raw Counts Low. The null (zero) The null reference voltage signal on the
38 Cold Junction # Raw Counts High. Cold junction The cold junction device on the
device number # input to the A/D converter has exceeded termination board has failed.
the limits of the converter. Normally two cold junction
inputs are averaged; if one is detected as bad then the
other is used. If both cold junctions fail, a predetermined
value is used.
39 Cold Junction # Raw Counts Low. Cold junction The cold junction device on the
value is used.

40 Thermocouple ## Linearization Table High. The thermo- The thermocouple has been configured
couple input has exceeded the range of the linearization as the wrong type, or a stray voltage
(lookup) table for this type. The temperature will be set to has biased the TC outside of its normal
the table’s maximum value. range, or the cold junction
compensation is wrong.
41 Thermocouple ## Linearization Table Low. The thermo The thermocouple has been configured
-couple input has exceeded the range of the linearization as the wrong type, or a stray voltage
the table’s minimum value. range, or the cold junction
VRTD 16 System Limit Checking is Disabled. System limit Checking was disabled by configuration.
checking on the VRTD board has been disabled by
configuration; no alarms will be generated until corrected.
32 RTD # has Raw Volt Counts High and Counts are Y. An RTD wiring/cabling open, or an
open on the VRTD board, or a VRTD
hardware problem (such as
multiplexer), or the RTD device has
failed.
33 RTD # has Raw Volt Counts Low and Counts are Y. An RTD wiring/cabling short, or a short
on the VRTD board, or a VRTD
failed.
34 RTD # has Raw Current Counts High and Counts are Y. The current source on the VRTD is
bad, or the measurement device has
failed.
35 RTD # has Current Raw Counts Low and Counts are Y. An RTD wiring/cabling open, or an
open on the VRTD board, or a VRTD
failed.
36 RTD # has Linearization Table Index High and it is Y The wrong type of RTD has been
Ohms. RTD # has a higher value than the table and the configured or selected by default, or
value is Y. there are high resistance values
created by faults 32 or 35, or both 32
and 35.
37 RTD # has Linearization Table Index Low and it is Y The wrong type of RTD has been
Ohms TRD # has a lower value than the table and the configured or selected by default, or
value is Y. there are low resistance values created
by faults 33 or 34, or both 33 and 34.
38-61 Voltage Circuits for RTDs, or Current Circuits for RTDs Internal VRTD problems such as a
Voltage or current circuits have Reference raw counts high damaged reference voltage circuit, or a
or low, or Null raw counts high or low. bad current reference source, or the
voltage/current null multiplexer is
damaged.
VAIC 16 System Limit Checking is Disabled. System limit System checking was disabled by
checking on the VAIC board has been disabled by configuration.
configuration; no alarms will be generated until corrected.
32 Analog Input # Unhealthy. Excitation to transducer, bad
transducer, open or short circuit.
33 Output # Individual Current Too High Relative to Total Board failure.
Current.
34 Output # total Current Varies from Reference Current. Board failure, or open circuit.
35 Output # Reference Current Error. Board failure (D/A converter).

36 Output # Individual Current Unhealthy. Simplex mode Board failure.
only alarm if current out of bounds.
37 Output # Suicide Relay Non-Functional. The suicide Board failure (Relay or driver).
relay is not responding to commands.
38 Output # 20/200 mA Selection Non-Functional. Configured output type does not match
Feedback from the relay indicates incorrect 20/200 mA berg jumper selection, or VAIC board
relay selection (not berg jumper selection) failure (relay).
39 Output # 20/20 mA Suicide Active. One output Board failure.
of the three has suicided, the other two boards have
picked up current
VAOC 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VAOC board has been disabled by configuration.
configuration; no system alarms will be generated until
corrected.
32 Analog Input # Unhealthy Excitation to transducer, bad
transducer, open or short circuit.
33 Output # Total Current Too High Relative to Total Board failure.
Current. An individual current is N mA more than half
the total current, where N is the configurable TMR_Diff
Limit.
34 Output # Total Current Varies from Reference Current. Board failure, or open circuit.
Total current is N mA different than the reference current,
where N is the configurable TMR_Diff Limit.
35 Output # Reference Current Error. The difference Board failure (D/A converter).
between the output reference and the input feedback of
the output reference is greater than the configured DA_Err
Limit measured in percent.
36 Output # Individual Current Unhealthy. Simplex Board failure.
mode alarm indicating current is too high or too low.
37 Output # Suicide Relay Non-Functional. The suicide Board failure (Relay or driver).
relay is not responding to commands.
38 Output # Suicide Active. One output of three has Board failure.
suicided, the other two boards have picked up the current.
VCCC 16 System Limit Checking is Disabled. System limit Checking was disabled by
and checking on the VCCC board has been disabled by configuration.
VCRC configuration; no system alarms will be generated until
corrected.
32/33 TBCI J3/J4 Contact Input # Not Responding to Test Normally a VCCC problem, or the
Mode. A single contact or group of contacts could battery reference voltage is missing to
not be forced high or low during VCCC self-check. the TBCI termination board.
34/35 TRLY J3/J4 Relay Output Coil # Does Not Match The relay termination board TRLY may
Requested State. A relay coil monitor shows that not exist, or there may be a problem
current is flowing or not flowing in the relay coil, so the with this relay, or, if TMR, one VCCC
relay is not responding to VCCC commands. may have been out-voted by the other
two VCCC boards.
36/37 TRLY J3/J4 Relay Driver # Does Not Match Requested The relay termination board TRLY may
State. The relay is not responding to VCCC not exist and the relay is still configured
commands. as used, or there may be a problem
with this relay driver.

38/39 TRLY J3/J4 Fuse # Blown. The fuse monitor requires the The relay termination board TRLY may
jumpers to be set and to drive a load, or it will not respond not exist, or the jumpers are not set
correctly. and there is no load, or the fuse is
blown.
40/41 TBCI J3/J4 Excitation Voltage Not Valid, TBCI J3 The contact input termination board
Contact Inputs Not Valid. The VCCC monitors the TBCI may not exist, or the contact
excitation on all TBCI boards, and the contact input excitation may not be on, or be
requires this voltage to operate properly. unplugged, or the excitation may be
below the 125 V level.
VSVO 16 System Limit Checking is Disabled. System limit VSVO is configured to disable limit
checking on the VSVO board has been disabled by checking.
corrected.
32 LVDT # RMS Voltage Out of Limits. Minimum and The LVDT may need recalibration.
maximum LVDT limits are configured.
33 Calibration Mode Enabled. The VSVO was put into calibration
mode.
34 VSVO Board Not Online, Servos Suicided. The servo The controller (R, S, T) or IONet is
is suicided because the VCMI is not on-line. down.
35 Servo Current # Disagrees with Reference, Suicided. A cable/wiring open circuit, or board
The servo currents error (reference – feedback) is greater problem.
than the configured current suicide margin.
36 Servo Current # Short Circuit. This is not currently NA
used.
37 Servo Current # Open Circuit. The servo voltage is A cable/wiring open circuit, or board
greater than 5V and the measured current is less than problem.
10%.
38 Servo Position # Feedback Out of Range, Suicided. LVDT or board problem.
Regulator number # position feedback is out of range,
causing the servo to suicide.
39 Configuration Message Error for Regulator Number #. The LVDT Minimum and maximum
There is a problem with the VSVO configuration and the voltages are equal or reversed, or an
servo will not operate properly. invalid LVDT, regulator, or servo
number is specified.
40 On Board Calibration Voltage Range Fault. The A/D A problem with the Field Programmable
calibration voltages read from the FPGA are out of limits, Gate Array (FPGA).
and the VSVO will use default values instead.
41 LVDT Excitation # Voltage Short Circuit. There is a problem with the LVDT
excitation source on the VSVO board.
VPRO 16 System Limit Checking is Disabled. System limit System checking was disabled by
checking on the VPRO board has been disabled by configuration.
corrected.
33 P15=####.## Volts is Outside of Limits. The P15 Analog +/- 15 Volt power supply on
power supply is out of the specified +12.75 to +17.25 Volts VPRO board has failed.
operating limits.
34 N15=####.## Volts is Outside of Limits. The N15 Analog +/- 15 Volt power supply on
power supply is out of the specified –17.25 to –12.75 Volts VPRO board has failed.
operating limits.
35 (Reserved)
36 (Reserved)

37 P28A=####.## Volts is Outside of Limits. The P28A The P28A power supply on VPWR
power supply is out of the specified 23.8 to 31.0 Volts board has failed, test P28A at VPRO
operating limits. front panel, otherwise there may be a
bad connection at J9, the VPWR to
VPRO interconnect.
38 P28B=####.## Volts is Outside of Limits. The P28B The P28B power supply on VPWR
power supply is out of the specified 23.8 to 31.0 Volts board has failed, test P28B at VPRO
operating limits. front panel, otherwise there may be a
bad connection at J9, the VPWR to
VPRO interconnect.
39 (Reserved)
40 Thermocouple ## Raw Counts High. The ## A condition such as stray voltage or
thermocouple input to the analog to digital converter noise caused the input to exceed +63
exceeded the converter limits and will be removed from millivolts.
scan.
41 Thermocouple ## Raw Counts Low. The ## The board detected a thermocouple
thermocouple input to the analog to digital converter open and applied a bias to the circuit
exceeded the converter limits and will be removed from driving it to a large negative number, or
scan. the TC is not connected, or a condition
such as stray voltage or noise caused
the input to exceed -63 millivolts.
42 Calibration Reference # Raw Counts High. The precision reference voltage on the
43 Calibration Reference # Raw Counts Low. The precision reference voltage on the
44 Null Reference # Raw Counts High. The null (zero) The null reference voltage signal on the
45 Null Reference # Raw Counts Low. The null (zero) The null reference voltage signal on the
46 Cold Junction # Raw Counts High. Cold junction The cold junction device on the
value is used.
47 Cold Junction # Raw Counts Low. Cold junction The cold junction device on the
value is used.

48 Thermocouple ## Linearization Table High. The thermo The thermocouple has been configured
the table’s maximum value. range, or the cold junction
49 Thermocouple ## Linearization Table Low. The thermo The thermocouple has been configured
the table’s minimum value. range, or the cold junction
55 Analog Input # Unhealthy. The number # analog input The input has exceeded 4-20 ma
to the A/D converter has exceeded the converter limits. range, or for input #1 if jumpered for
±10 V, it has exceeded ±10 V range, or
the 250-ohm burden resistor on TPRO
has failed.
56 Contact Input # Not Responding to Test Mode. Trip Contact input circuit failure on VPRO or
interlock number # is not reliable. TREG board.
57 Trip Relay (ETR) Driver # Mismatch Requested State. The ETR # relay driver or relay driver
The state of the command to the Emergency Trip Relay feedback monitor on the TREG
(ETR) does not match the state of the relay driver terminal board has failed, or the cabling
feedback signal; the ETR cannot be reliably driven until between VPRO and TREG is incorrect.
corrected.
58 Trip Relay (ETR) Contact # Mismatch Requested State. The relay driver on TREG may have
The state of the command to the ETR does not match the failed, or the ETR on the TREG board
state of the ETR contact feedback signal; the ETR cannot has failed, or the cabling between the
be reliably driven until corrected. VPRO and TREG is incorrect.
59 Solenoid Voltage # Mismatch Requested State. The trip solenoid # voltage monitor on
The state of the trip solenoid # does not match the TREG has failed or ETR # driver failed,
command logic of the voted ETR # on TREG, and the or PTR # driver failed. There may be a
voted primary trip relay (PTR) # on TRPG, the ETR cannot loss of 125 V dc via the J2 connector
be reliably driven until corrected. from TRPG, which has a diagnostic.
60 Econ Relay Driver # Mismatch Requested State. Economizing relay driver # or relay
The state of the command to the economizing relay does driver feedback monitor on TREG
not match the state of the economizing relay driver board has failed, or the cabling
feedback signal; cannot reliably drive the economizing between VPRO and TREG is incorrect.
relay until corrected.
61 Econ Relay Contact # Mismatch Requested State. Economizing relay driver # on TREG
The state of the command to the economizing relay does board has failed, or the economizing
not match the state of the economizing relay contact relay on TREG has failed, or the
feedback signal; cannot reliably drive the economizing cabling between VPRO and TREG is
relay until corrected. incorrect.
62 K25A Relay (Synch Check) Driver Mismatch K25A relay driver or relay driver
Requested State. The state of the command to the feedback on the TREG board has
K25A relay does not match the state of the K25A relay failed, or the cabling between VPRO
driver feedback signal; cannot reliably drive the K25A relay and TREG is incorrect.
until corrected.
63 K25A Relay (Synch Check) Coil Trouble, Cabling to The K25A relay driver or relay driver
P28V on TTUR. The state of the command to the feedback on the TREG board has
K25A relay does not match the state of the K25A relay failed, or the K25A relay on TTUR has
contact feedback signal; cannot reliably drive the K25A failed, or the cabling between VPRO
relay until the problem is corrected. The signal path is from and TTUR is incorrect.
VPRO to TREG to TRPG to VTUR to TTUR.
64 Servo Clamp Relay Driver Mismatch Requested State. The servo clamp relay driver or relay
The state of the command to the servo clamp relay does driver feedback monitor on the TREG
not match the state of the servo clamp relay driver board has failed, or the cabling
feedback signal; cannot reliably drive the servo clamp between VPRO and TREG is incorrect.
relay until corrected.

65 Servo Clamp Relay Contact Mismatch Requested The servo clamp relay driver or the
State. The state of the command to the servo clamp servo clamp relay on the TREG board
relay does not match the state of the servo clamp relay has failed, or the cabling between
contact feedback signal; cannot reliably drive the servo VPRO and TREG is incorrect.
clamp relay until corrected.
66 TREG1 Solenoid Voltage Source is Missing. The P125 The power detection monitor on the
V dc source for driving the trip solenoids is not detected; TREG1 board has failed, or there is a
cannot reliably drive the trip solenoids. loss of P125 V dc via the J2 connector
from TRPG board, or the cabling
between VPRO and TREG1 or
between TREG1 and TRPG is
incorrect.
67 TREG2 Solenoid Voltage Source is Missing. The P125 The power detection monitor on the
V dc source for driving the trip solenoids is not detected; TREG2 board has failed, or there is a
cannot reliably drive the trip solenoids K4-K6. loss of P125 V dc via the J2 connector
from TRPG board, or the cabling
between VPRO and TREG2 or
between TREG2 and TRPG is
incorrect. Also trip relays K4-K6 may be
configured when there is no TREG2
board.
68 Contact Excitation Voltage Test Failure. Contact Loss of P125x voltage caused by
excitation self test has failed, trip interlock monitoring disconnection of JH1 to TREG, or
voltage is lost disconnect of JX1, JY1, JZ1 on TREG
to J3 on VPRO, or VPRO contact
excitation test circuit may have failed.
VTUR 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VTUR board has been disabled by configuration.
corrected.
32 Solenoid # Relay Driver Feedback Incorrect. The solenoid relay driver on the TRPG
Solenoid (1-6) relay driver feedback is incorrect as board has failed, or the cabling
compared to the command; VTUR cannot drive the relay between VTUR and TRPG is incorrect.
correctly until the hardware failure is corrected.
33 Solenoid # Contact Feedback Incorrect. Solenoid (1- The solenoid relay driver or the
6) relay contact feedback is incorrect as compared to the solenoid relay on the TRPG board has
command; VTUR cannot drive the relay correctly until the failed, or the cabling between VTUR
hardware failure is corrected. and TRPG is incorrect.
34 TRPG # Solenoid Power Absent. P125/24 V dc Power may not be coming into TRPG
power is not present on TRPG termination board; VTUR on the J1 connector, or the monitoring
cannot energize trip solenoids 1 through 3, or 4 through 6 circuit on TRPG is bad, or the cabling
until power is present. between TRPG and VTUR is at fault.
35 TRPG # Flame Detector Volts Low at Y Volts. TRPG 1 Power comes into TRPG via J3, J4,
or 2 flame detect voltage is low; the ability to detect flame and J5. If the voltage is less than 314.9
by detectors 1 through 8, or 9 through 16 is questionable. V dc, this should be investigated. If the
voltage is above this value, the
monitoring circuitry on TRPG or the
cabling between TRPG and VTUR is
suspect.
36 TRPG # Flame Detector Volts High at Y Volts. TRPG 1 This power comes into TRPG via J3,
or 2 flame detect voltage is high; the ability to detect flame J4, and J5. If the voltage is greater than
by detectors 1 through 8, or 9 through 16 is questionable 355.1 V dc, this should be investigated.
because the excitation voltage is too high and the devices If the voltage is below this value, the
may be damaged. monitoring circuitry on TRPG or the
cabling between TRPG and VTUR is
suspect.

37 L3BKRGXS – Synch Check Relay is Slow. The auto The synch check relay I3BKRGXS,
synchronization algorithm has detected that during known as K25A, on TTUR is suspect;
synchronization with no dead bus closure (synch bypass also the cabling between VTUR and
was false) the auto synch relay I3BKRGES closed before TTUR may be at fault.
synch relay I3BKRGEX closed.
38 L3BKRGES – Auto Synch Relay is Slow. The auto The Auto synch relay I3BKRGES also
synchronization algorithm has detected that the auto synch known as K25, on TTUR is suspect;
relay I3BKRGES had not closed by two cycle times after also the cabling between VTUR and
the command I25 was given. TTUR may be at fault.
39 Breaker # Slower than Adjustment Limit Allows. The breaker is experiencing a problem,
Breaker 1 or 2 close time was measured to be slower than or the operator should consider
the auto synch algorithms adaptive close time adjustment changing the configuration (both
limit allows. nominal close time and self-adaptive
limit in ms can be configured).
40 Synchronization Trouble – K25 Relay Locked Up. K25 on TTUR is most likely stuck
The auto synchronization algorithm has determined that closed, or the contacts are welded.
the auto synch relay I3BKRGES, also known as K25, is
locked up. Auto synch will not be possible until the relay is
replaced.
VGEN 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VGEN board has been disabled by configuration.
corrected.
32 Analog 4-20 mA Auto Calibration Faulty One of the 3 Volt or 9 Volt precision reference or
analog 4-20 mA auto calibration signals has failed. Auto null reference on VGEN is defective, or
calibration or 4-20 mA inputs are invalid, 4-20 mA inputs multiplexer or A/D converter circuit on
are invalid. VGEN is defective.
33 PT Auto Calibration Faulty. One of the PT auto Precision reference voltage or null
calibration signals has gone bad. Auto calibration of PT reference is defective on VGEN, or
input signals is invalid, PT inputs are invalid. multiplexer or A/D converter circuit on
VGEN is defective.
34 CT Auto Calibration Faulty. One of the CT auto Precision reference voltage or null
calibration signals has gone bad. Auto calibration of CT reference is defective on VGEN, or
input signals is invalid, CT inputs are invalid. multiplexer or A/D converter circuit on
VGEN is defective.
35 (Reserved)
39 Analog Input # Unhealthy. Analog Input 4-20 mA ## Analog input is too large, TGEN jumper
has exceeded the A/D converter’s limits. (JP1, JP3, JP5, JP7) is in the wrong
position, signal conditioning circuit on
TGEN is defective, multiplexer or A/D
converter circuit on VGEN is defective.
40 Relay Output Coil # does not Match Requested State. Relay is defective, connector cable J4
There is a mismatch between the relay driver command to TRLY J1 is disconnected.
and the state of the current sensed on the relay coil on
TRLY.
41 Relay Driver # does not Match Requested State. Faulty relay driver circuit or drive
There is a mismatch between the relay driver command sensors on VGEN.
and the state of the output to the relay as sensed by
VGEN.
42 Fuse # and/or # Blown. One or both of the listed One or both of the listed fuses is blown,
fuses is blown, or there is a loss of power supply. or there is a loss of power on TB3.

VVIB 16 System Limit Checking is Disabled. System limit Checking was disabled by configuration.
checking on the VVIB board has been disabled by
corrected.
32 VVIB A/D Converter 1 Calibration Outside of Spec. The hardware failed (if so replace the
VVIB monitors the Calibration Levels on the 2 A/D. If any board), or there is a voltage supply
one of the calibration voltages is not within 1% of its problem.
expected value, this alarm is set.
33 VVIB A/D Converter 2 Calibration Outside of Spec. The hardware failed (if so replace the
VVIB monitors the Calibration Levels on the 2 A/D. If any board), or there is a voltage supply
one of the calibration voltages is not within 1% of its problem.
expected value, this alarm is set.
34/35 TVIB J3/J4 Analog Input Saturated. VVIB monitors the The TVIB0 or TVIB1 board may not
Signal Levels from the 2 A/D. If any one of the voltages is exist, but the sensor is specified as
above the max value, this diagnostic is set. used; or the sensor may be bad, or the
wire fell off, or the device is miswired.
VPYR 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VPYR board has been disabled by configuration.
corrected.
32 Slow Average Input Unhealthy. Milliamp input Specified pyrometer’s average output is
associated with the slow average temperature is faulty, or VPYR or TPYR is faulty.
unhealthy.
33 Slow Max Input Unhealthy. Milliamp input associated Specified pyrometer’s max. output is
with the slow maximum peak temperature is unhealthy. faulty, or VPYR or TPYR is faulty.
34 Slow Average Peak Input Unhealthy. Milliamp input Specified pyrometer’s peak output is
associated with the slow average peak temperature is faulty, or VPYR or TPYR is faulty.
unhealthy.
35 Fast Input Unhealthy. Milliamp input associated with Specified pyrometer’s fast output is
the fast temperature is unhealthy. faulty, or VPYR or TPYR is faulty.
36 Fast Calibration Reference. The fast calibration VPYR is faulty.
reference is out of limits.
37 Fast Calibration Null. The fast calibration null is out of VPYR is faulty.
limits.
38 Slow Calibration Reference. The slow calibration VPYR is faulty.
reference is out of limits.
39 Slow Calibration Null. The slow calibration null is out VPYR is faulty.
of limits.
40 Board ID Failure. The board ID device is not being read VPYR is faulty, or ID chip is not
correctly. programmed.
41 P3 ID Failure. The P3 terminal board ID device is not VPYR or TPYR is faulty, or ID chip on
being read correctly. TPYR is not programmed.
VCMI 16 System Limit Checking is Disabled. System limit Checking was disabled by
checking on the VCMI board has been disabled by configuration.
corrected.
32 P5=###.## Volts is Outside of Limits. The P5 power Probably a VME rack backplane wiring
supply is out of the specified operating limits. problem and/or power supply problem.

33 P15=###.## Volts is Outside of Limits. The P15 power If "Remote Control", disable diagnostic
supply is out of the specified operating limits. and ignore; otherwise probably a back
plane wiring or VME power supply
problem.
34 N15=###.## Volts is Outside of Limits. The N15 power If "Remote Control", disable diagnostic
supply is out of the specified operating limits. and ignore; otherwise probably a VME
backplane wiring and/or power supply
problem.
35 P12=###.## Volts is Outside of Limits. The P12 power If "Remote I/O", disable diagnostic and
supply is out of the specified operating limits. ignore; otherwise probably a VME
problem.
36 N12=###.## Volts is Outside of Limits. The N12 power If "Remote I/O", disable diagnostic and
supply is out of the specified operating limits. ignore; otherwise probably a VME
problem.
37 P28A=###.## Volts is Outside of Limits. The P28A If "Remote Control", disable diagnostic
power supply is out of the specified operating limits. and ignore; otherwise probably a VME
problem.
38 P28B=###.## Volts is Outside of Limits. The P28B If "Remote Control", disable diagnostic
power supply is out of the specified operating limits. and ignore; otherwise probably a VME
problem.
39 P28C=###.## Volts is Outside of Limits. The P28C If "Remote Control" disable diagnostic.
power supply is out of the specified operating limits. Disable diagnostic if not used;
otherwise probably a backplane wiring
and/or power supply problem.
40 P28D=###.## Volts is Outside of Limits. The P28D If "Remote Control" disable diagnostic.
41 P28E=###.## Volts is Outside of Limits. The P28E If "Remote Control" disable diagnostic.
42 N28=###.## Volts is Outside of Limits. The N28 power If "Remote Control" disable diagnostic.
supply is out of the specified operating limits. Disable diagnostic if not used;
43 125 Volt Bus=###.## Volts is Outside of Limits. The A source voltage or cabling problem;
125 Volt bus voltage is out of the specified operating limits. disable diagnostic if not applicable.
44 125 Volt Bus Ground =###.## Volts is Outside of Leakage or a fault to ground causing
Limits. The 125 Volt bus voltage ground is out of the an unbalance on the 125 V bus; disable
specified operating limits. diagnostic if not applicable.
45 IONet-1 Communications Failure. Loose cable, rack power, or VCMI
problem.
problem.
problem.
48 VME Bus Error Detected (Total of ### Errors). The sum of errors 60 through 66.
49 Using Default Input Data, Rack R.# IONet communications failure.
50 Using Default Input Data, Rack S.# IONet communications failure.
51 Using Default Input Data, Rack T.# IONet communications failure.

52 Missed Time Match Interrupt (## uSec). Possible VCMI hardware failure.
53 VCMI Scheduler Task Overrun. Possibly too many I/O.
54 Auto Slot ID Failure (Perm. VME Interrupt).
56 Topology File/Board ID Mismatch). ID chip mismatch.
57 UCVx Sequencing Overrun. Too much application code used in
controller.
58 UCVx PCODE Version Mismatch between R, S, & T. Error during controller download.
59 For future use
60-66 VME Error Bit # (Total ## Errors) VME backplane errors.
67 UCVx Board is Offline. Controller failed or is powered down.
68-87 I/O Board in Slot # is Offline. I/O board is failed or removed.
Controller Runtime Errors

The Status LED group on the front of the controller contains eight segments in a two
vertical column layout as shown in Figure 8-2. These LEDs display controller errors
if a problem occurs. The rightmost column makes up the lower hexadecimal digit
and the leftmost column makes up the upper digit (the least significant bits on the
bottom). Numerical conversions are provided with the fault code definitions.
Controller front panel For example, flashing F

in this pattern:
ACTIVE H L
SLOT1 S
BMAS
ENET T
A F
SYS
T
BSLV F
U
S
F
FLSH
GENA
is error 0x43, decimal 67
Figure 8-2. Flashing Controller Status LEDs Indicate Error Codes
If the controller detects certain system errors (typically during boot-up or download),
it displays flashing and non-flashing codes on these green status LEDs. These codes
correspond to runtime errors described in the controller manual, refer to GEH-6410
Innovation Series Controller System Manual. These error numbers and descriptions
are also listed in the controller help file. The following table describes the types of
errors displayed by the LEDs.

Table 8-3. Controller Runtime Errors
Controller Condition Status LED Display

Controller successfully completes its boot-up Display a “walking ones” pattern consisting of a
sequence and begins to execute application single lighted green LED rotating through the bank
code. of LEDs.
Error occurs during the BIOS phase of the Non-flashing error code is displayed
boot-up sequence.
Error occurs during the application code load. Flashing error codes are displayed until the error
has been corrected and either the application
code is downloaded again, or the controller is
rebooted.
Error occurs while the controller is running. May freeze with only a single LED lighted. No
useful information can be interpreted from the
LED position. Fault codes are generated
internally.
Troubleshooting
To start troubleshooting, be certain the racks have correct power supply voltages;
these can be checked at the test points on the left hand side on the VME rack.
This equipment contains a potential hazard of electric

shock or burn. Only personnel who are adequately
trained and thoroughly familiar with the equipment
and the instructions should install, operate, or maintain
this equipment.
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.
I/O Board LEDs

Green Light
During normal operation all the Run LEDs on the board front panels flash green
together. All boards and all racks should flash green in synchronism. If one light is
out of sequence there could be a problem with the synchronizing on that board which
should be investigated. Contact your turbine control representative and have the
firmware revision number for that board available.
Orange Light
If the orange Status LED lights on one board, this indicates there is an I/O or system
diagnostic in queue in that board. This is not an I/O board failure, but may be a
sensor problem.
½ To see the diagnostic message
1. From the toolbox Outline View, select Online using the Go on/offline
button.

2. Locate the rack in the Summary View and right-mouse click the board. A
pop-up menu displays.
3. From the pop-up menu, select View Diagnostic Alarms. The Diagnostic
Alarms table displays. The following data is displayed in tabular form:
• Time. The time when the diagnostic was generated
• Fault Code. The fault code number, in this chapter’s I/O Board Alarm list.
• Status. A "1" indicates an active alarm, and a "0" indicates a cleared
but not reset (acknowledged) alarm.
• Description. A short message describing the diagnostic.
This diagnostic screen is a snapshot, but not real time. For new data, Update the
screen.
Use the left-mouse button and click on the board. 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
termination board or in the sensor. For example, if all the I/O points in a board are
bad, probably the board has failed, or a cable is loose, or the card has not been
configured. If only a few I/O points are bad, probably the I/O are bad, or part of the
termination board is burned up.
Red Light
If a board has a red Fail LED lit, it indicates the board is not operating. Check if it is
loose in its slot and, if so, switch off the rack power supply, push the board in, and
turn on the power again. Figure 8-4 shows a typical I/O board with chip locations.
I/O Board
I/O Board Generic

Circuitry
Flash
Memory
Flash
Chip
Memory
Socket
I/O Board Specific

Circuitry
Figure 8-4. I/O Board showing Flash Memory Chip

If the red light still comes on, power down the rack, remove the board and check the
firmware flash chip. This chip can be plugged in the wrong way, which damages it;
refer to Figure 8-4 for orientation. The chamfer on the chip should line up with the
chamfer on the receptacle, as shown. If no flash chip is installed, replace the board.
Earlier I/O board versions had a reset button on the front. If your board has a reset,
check to see if this button is stuck in; if so replace the board.
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 careful 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 none is visible it may be the original
board was not seated correctly.
Multiple Red Lights

If a whole rack of I/O boards show red lights, 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. Either the
master or slave VCMI could be at fault, so check the Fail lights to see where the
problem is. The failure could also be caused by a rack power supply problem.
If several but not all I/O boards in a rack show red lights, this is probably caused by a
rack power supply problem.
Controller Failures
If the controller fails, the rotating green LED on its front panel stops. Power down
the controller rack and reboot by bringing power back (do not use the Reset button).
If the controller stays failed after reboot, replace it with a spare.
If several LEDs are stopped and flashing, this indicate a runtime error, typically a
boot-up or download problem. The LED hex code indicates the type of error
encountered, refer to GEH-6410 Innovation Series Controller System Manual. The
controller Help screen on the toolbox also displays all the runtime errors together
with suggested actions.
If the controller, or it’s VCMI, fails then the IONet on this channel stops sending or
receiving data. This drives the outputs on the failed channel to their fail safe state.
This does not affect the other two IONet channels which keep running.
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 selecting and right-clicking the VCMI board, and then selecting
View Diagnostic Alarms. These diagnostics are listed in this chapter under
VCMI alarms.

Chapter 9 I/O Description
Introduction
This chapter describes all the Mark VI boards including the controller, VCMI
communication boards, VDSK board, and the I/O boards, along with their associated
termination boards. The power distribution module and the VME rack power
supplies are also described.
Controller
The Mark VI controller is a 6U high, two-slot VME module housing a high-speed
processor. The controller mounts in a VME module called the control module, and
communicates with the turbine I/O through the VME bus. The operating system is
QNX which is a real time, multitasking OS designed for high-speed industrial
applications. In addition to the VME interface to the turbine I/O, four
communication ports provide links to operator interfaces, a distributed control
system, and PLC I/O:
• Ethernet connection to the UDH for communication with HMIs and other
control equipment.
• RS-232C connection using COM2 port for communication with a DCS using the
Modbus protocol.
• Genius Bus interface to remote Genius I/O blocks, Field Control I/O, and GE
Fanuc Data Panels.
• DLAN+ high speed LAN interface for special communication applications.
Controller Operation
The controller software includes appropriate portions of the existing Big Block
Library (BBL) libraries for the Steam, Gas, and LM (Land-Marine aero-derivative)
products. The controller is capable of executing a total of 100,000 BBL rungs or
blocks per second, assuming a typical collection of average size blocks. Application
software can be modified online without requiring a restart. The controller is shown
in Figure 9-1.
GEH-6421 Mark VI System Guide Chapter 9 I/O Description • 9-1

External data is transferred to and from the Control Signal Database (CSDB) in the
controller over the VME bus by the VCMI communication board. In a Simplex
system, the data consists of the process inputs and outputs from the I/O boards. In a
TMR system, the data consists of the voted inputs from the input boards, singular
inputs from simplex boards, computed outputs to be voted by the output hardware,
and the internal state values that must be exchanged between the controllers.
Mark VI Controller
x x
DLAN DROP
1 0
8
ETHERNET
Ethernet Port for Unit Data DLAN Network Drop Number
Highway Communication Configuration Dip Switches
1
ACTIVE H L
SLOT1
Controller and Communication BMAS Status LEDs showing Runtime Error Codes
ENET
Status LEDs SYS resulting from Bootup, Configuration, or
BSLV
RESET
Download Problems
FLSH
GENA
Monitor Port for GE Use
MONITOR
Only
Connector for Ribbon Cable to VME
HARD DISK
Interface (VDSK)
COM1 RS-232C Port for
COM1
COM2
Initial Controller Setup;

COM2 RS-232C Port for
Modbus Communication
LPT1
DLAN Network Connection

DLAN
KEYBOARD MOUSE
Special Ports for GE Use,

Printer, Keyboard, and
Mouse GENIUS
Receptacle for Genius Cable Plug
UCVB
G1A
x x
Figure 9-1. Mark VI Controller Front Panel
Each control module is capable of receiving process data at a rate of 512,000

bytes/second on each IONet port. This permits 512 byte data packets flowing at one
packet per millisecond.
An external clock interrupt permits the CPU/OS to synchronize to the clock on the
communication board. Synchronization is to within ±100 microseconds of the
communication board clock.
The controller identifies all interface modules using the ID packet. This packet is
received each time a rack is reset or powered up, and is verified for correct hardware
configuration before system startup. For more information refer to GEH-6410
Innovation Series Controller System Manual.
9-2 • Chapter 9 I/O Description GEH-6421 Mark VI System Guide

Table 9-1. Controller Specification
Item Specification
Microprocessor Intel Pentium 133 MHz

Memory 16 MB DRAM,
4 MB Flash Memory in UCVB
256 KB of level 2 cache
Operating System Multitasking operating system using QNX
LEDs LEDs on the faceplate provide status information as follows:
Active Processor is active
Slot 1 Controller configured as slot 1 controller in VME rack
BMAS VME master access is occurring
ENET Ethernet packets are being transmitted
BSLV VME slave access is occurring
STATUS Display rotating LED pattern when OK
Display flashing error code when faulted
FLSH Writing to Flash memory
GENX Genius I/O is active
Programming Control block language with Analog & Discrete blocks; Boolean logic
represented in relay ladder diagram format. Supported data types include:
- Boolean
- 16-bit signed integer
- 32-bit signed integer
- 32-bit floating point
- 64-bit long floating point
Ethernet Interface Thinwire 10Base-2, BNC connector;
- TCP/IP protocol used for communication between controller and
toolbox
- Serial Request Transfer Protocol (SRTP) interface between controller
and HMI
- Ethernet Global Data (EGD) protocol for communication with
CIMPLICITY HMI, and Series 90-70 PLCs
- Ethernet Modbus™ protocol supported for communication between
controller and third party Distributed Control System (DCS)
COM Ports Two Micro-miniature 9-pin D connectors:
COM1- reserved for diagnostics, 9600 baud, 8 Data bits, no parity, 1 stop
bit
COM2- used for serial protocols, such as Modbus communication between
controller (slave only) and DCS as follows:
Parameter Description
Baud Rate 9600, 19200
Mode Binary (Remote Terminal Unit), ASCII
Data Bits 7, 8
Parity None, Odd, Even
Stop Bits 1, 2

Genius Bus Interface Genius Bus controller integrated with the central processing unit
DLAN+ Interface Interface to DLAN+, a high speed multidrop network based on ARCNET,
using a token passing, peer to peer protocol
Power Requirements +5 V dc, 5.64 A
+12 V dc, 900 mA
-12 V dc, 200 mA
Temperature 0-45 C at inlet to controller (recommend 100 ft/min forced air cooling)
Humidity 10-95 % relative humidity, non-condensing
Controller Configuration Overview

Like all the I/O boards, the controller is configured using the Control System
Toolbox. This software is summarized in Chapter 7 Tools. The toolbox software
usually runs on a data-highway connected CIMPLICITY station or workstation. For
details refer to GEH-6403 Control System Toolbox for Configuring the Mark VI
Turbine Controller.
Diagnostics
If a failure occurs in the Mark VI controller while it is running application code, the
rotating green LEDs on the front panel stop and a fault code is generated.
If the controller detects certain system errors (typically during boot-up or download)
it displays flashing codes on the eight-segment bank of status LEDs located on the
front panel. These codes are called runtime errors, and descriptions are available on
the toolbox Help screen. The error numbers and descriptions are additionally
available on the controller serial port (COM1). For further information, refer to
Installation
The VME-bus control module contains the controller, VCMI, and a VDSK board.
There are three rack types which can be used, the GE Fanuc PLC rack shown in
Figure 9-2, and two sizes of Mark VI rack. The GE Fanuc rack is shorter and is used
for systems with remote I/O only, whereas the Mark VI rack is longer and can be
used for local or remote I/O. Whichever rack is used, a cooling fan is mounted either
above or below the controller.

VCMI Communication Board with Controller Interface Board
Three IONet Ports (VCMI with One UCVX VDSK
IONet is for Simplex systems)
VME Rack
POWER
SUPPLY
Power Supply
x x x x
Cooling Fan Fan 24 Vdc

behind Panel Power
Figure 9-2. Typical Controller Mounted in Rack with Communication Board

Bus Master Controller - VCMI
The bus master controller, known as the VCMI, is the communication interface
between the controller and the I/O boards, and the communication interface to the
system control network, known as IONet. VCMI is also the VME bus master in the
control racks and I/O racks, and manages the IDs for all the boards in the rack and
their associated termination boards. In the case of TMR systems the three-network
version (VCMI H2A) votes all incoming data from the I/O boards and passes the
results to the controller for processing. The two VCMI are shown in Figure 9-3.
VCMI H1A VCMI H2A
x x
VCMI is OK
RUN Error or Power up Failure RUN

FAIL FAIL
STATUS STATUS
Pushbutton
RESET RESET
S S
E E
R R
I VME Bus to I/O I VME Bus to I/O
A Boards and Controller A Boards and Controller
L L
P P
A A
R R
A A
L L
L L
E E
L L
M M
O8 IONet Node O8
D4 D4 TX
U2 U2 RX
L L
E1 E1 CD
IONET3
10Base 2
R Channel ID
S R TX
T S RX
Transmitting Packets T CD
Receiving Packets IONET2
TX 10Base 2
Collisions on IONet
RX
CD TX
IONET RX IONET1
10Base 2 CD 10Base 2
VCMI VCMI
H1A H2A
x x
Communication Communication
Board - 1 IONET Board - 3 IONETs
Figure 9-3. VCMI Board, Single Network and Triple Network Versions

The following diagrams in Figure 9-4 show three Simplex system configurations
with local and remote I/O using the VCMI. Multiple I/O racks can be connected to
IONet, each rack with its own VCMI board. To increase data throughput for
applications requiring low latency, a second IONet port on the VCMI can be used as
a parallel IONet as shown in the lower diagram.
Simplex System with

V U Local I/O
C C I/O
M V Boards
I X
UCVX is Controller
VCMI is Bus Master
I/O are VME Boards
R R1
V U V
Simplex System with
C C I/O C I/O
M V Boards M Local & Remote I/O
Boards
I X I
IONet
R R1
V U V
C C C I/O Simplex System with
M V M Boards Multiple IONets &
I X I Remote I/O
IONet
R2
V
C I/O
M Boards
I
IONet
Figure 9-4. Simplex System Configurations with Local & Remote I/O
Two sizes of TMR systems are shown in Figure 9-5. The first example is a small
system where all the I/O can be mounted in the VME control rack so no remote I/O
racks are required. Each channel (R, S, T) has its own IONet, and the VCMI has
three IONet ports.

The second example is a larger system employing remote I/O racks. Each IONet
supports multiple I/O racks, but only one rack is shown here. All I/O channels R, S,
T, are identical in terms of I/O boards and points.
R S T
TMR System with
V U V U V U Local I/O
C C I/O C C I/O C C I/O
M V Boards M V Boards M V Boards UCVX is Controller
I X I X I X
VCMI is Bus Master
I/O are VME Boards
IONet - R Termination Boards
IONet - S not shown
IONet - T
R S T TMR System with

V U V U V U Remote I/O,
C C C C C C Termination Boards
M V M V M V not shown
I X I X I X
IONet - R
IONet - S
IONet - T
R1 S1 T1
V V V
C I/O C I/O C I/O
IONet Supports
M Boards M Boards M Boards Multiple Remote
I I I I/O Racks
Figure 9-5. TMR System Configurations with Local & Remote I/O
VCMI Features
The VCMI architecture is based on the 32-bit Texas Instruments TMS320C32 digital
signal processor (DSP). The main hardware features are:
• Interface to VME bus
• Three 10Base-2 Ethernet ports
• One RS-232C serial port
• One parallel port
• Power system monitoring
• Board and cable ID reading
• Processor watchdog timer

VME Interface
The VCMI is the VME bus master in the control and I/O racks. It identifies all
boards in the rack and initializes all the boards. VCMI provides a block transfer rate
of 40 Mbytes/second across the VME backplane.
IONet – 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.
VCMI establishes the network ID, and displays the network ID, channel ID and
status on its front panel.
Physically, IONet communication is 10Base-2 Ethernet using thin wire RG-58 coax
cable. VCMI supports all three ports simultaneously.
The VCMI serves as the master frame counter for all nodes on the IONet. Execution
frames are sequentially numbered and all nodes on IONet execute in the same frame
This ensures that selected data is transmitted and operated on correctly.
I/O Data Collection - Simplex Systems

When used in an interface module, the VCMI acts as a VME bus master. It collects
input data from the I/O boards and transmits it to the control module over 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 transfers them
through the VME bus to the Mark VI controller. After application code execution,
the VCMI transfers output values from the controller 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, over the VME bus, the input values from each of the I/O boards
to the pre-vote table, and also sends them as an input packet on the IONet. Each of
the three 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) go through a
median selector, while logical data (bit values) go through a two-out-of-three
majority voter. The results are placed in the voted table.
A selected portion of the I/O table (the states such as counter/timer values and
sequence steps) must be transferred from each of the VCMI boards to the other
VCMI boards to be included in the vote process. At completion of the voting the
voted table is transferred over the VME bus to the I/O 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, 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,
the voting takes place. The voting results are then transferred to the I/O table
memory in the controller as above.

Output Data Packet
All the output data from a control module VCMI is placed in one packet. This packet
is 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.
Voter Disagreement Detector

The first pass through the pre-vote data determines the control values to be used. On
the second pass, the VCMI determines whether bad values exist by comparing its set
of local channel pre-vote values with the voted result. If there is any disagreement
then the local value has been outvoted and represents a bad value. For analog values,
a dead band is defined to allow minor variations in the pre-vote values without
creating an alarm. For logic values, any disagreement is considered bad. A time
delay is required before generating an alarm to eliminate the problem of transients
causing false alarms.
Performance
The Simplex frame rate is 10 milli-seconds allowing turbine control at 100 Hz, while
the TMR frame rate is 40 ms for control at 25 Hz.
The control module is synchronized to the wall clock ensuring the sequence of
events (SOE) times are within 1 ms of the actual event time.
Watchdog Timer
The watchdog timer protects against a processor stall condition. If a stall occurs the
watchdog times out after approximately 200 ms and resets the processor. It notifies
the VME backplane that the processor has been reset, and shuts off IONet
communication while stalled. The front panel reset button (if present) can be used to
force the timer to the stalled state from which it transitions to the operational state.
On line testing of the watchdog function can be performed.
Board IDs and Addresses

Each termination board has an ID chip for each cable connector that is read serially
into the I/O board. Each I/O board in the VME rack, plus the VCMI, also has its own
ID chip which is read by the VCMI, so the VCMI can acquire the identity of all the
boards and associated termination boards in its rack. In addition, there is an eight-bit
configuration switch on the backplane tied to slot 1 of the VME rack. This switch
provides the IONet address and R/S/T channel identity, and is read by the VCMI to
determine what channel it is on.
The VCMI in the control rack acquires packages of ID information from each I/O
rack. These contain the catalog number, serial number, and revision of each board in
the module along with the slot number, and the identity of each termination board
with its slot P3/P4 location. This information is captured and stored in the controller.

Table 9-2. VCMI Specification
Item Specification
Board Type 6U high VME board, 0.787 inch wide

Processor Texas Instruments TMS320C32 32-bit digital signal processor
Memory Dual-port memory, 32 Kbytes in 32 bit transfer configuration
SRAM, 64k x 32
Flash memory, 128k x 8
Communication H1A version: One IONet 10 Base2 Ethernet Port, BNC connector, 10
Mbits/sec
H2A version: Three IONet 10 Base2 Ethernet Ports, BNC connectors, 10
Mbits/sec
VME bus block transfers
1 RS-232C Serial Port, male "D" style connector, 9600, 19,200, or 38,400
bits/sec
1 Parallel Port, eight bit bi-directional , EPP Version1.7 mode of IEEE 1284-
1994
Frame Rate 10 ms (100 Hz) for Simplex
40 ms (25 Hz) for TMR
Table 9-3. VCMI Toolbox Configuration
Parameter Description Choices
System Limits Enable or disable All System Limits Enable, disable

PS_Limit1 +/-Power Supply Limits for P5, P15, N15 in 0 to 10
percent
PS_Limit2 +/-Power Supply Limits for P12, N12, P28, N28 0 to 10
in percent
PwrBusLimits Enable or disable Power Bus Diagnostics Enable, disable
125 vBusHlim High Limit for 125 Volt DC Bus in Volts 0 to 150
125 vBusLlim Low Limit for 125 Volt DC Bus in Volts 0 to 150
125 vBusGlim Low Volts to Ground Limit for 125 Volt DC bus 0 to 150
(diagnostic)
J3 Power Monitor
Logic_In_1 First of 12 logical inputs Point Edit
Logic_In Configurable Item Used, Unused
P125_Grd Point Edit
Input Type Type of Analog Input Used, Unused
Low_Input Input Volts at Low Value -10 to +10
Low_Value Input Value in engineering units at Low MA -3.4082e+038 to
3.4028e+038
High_Input Input Volts at High Value -10 to +10
High_Value Input Value in engineering units at High MA -3.4082e+038 to
3.4028e+038
Input _Filter Bandwidth of input signal filter in Hz Unused, .75 Hz, 1.5 Hz,
3 Hz,

TMR_DiffLimit Difference limit for Voted TMR inputs in % of 0 to 10
high-low values
Sys Lim 1 Enabl Enable System Limit 1 Fault Check Enable, disable
Sys Lim 1 Latch Input fault latch Latch, unlatch
Sys Lim 1 Type Input fault type Greater than or equal
Less than or equal
Sys Lim 1 Input limit in Engineering Units -3.4082e+038 to
3.4028e+038
Sys Lim 2 Same as above for Sys Lim 1 Same as for Sys Lim 1
N125 Gnd Same as for P125 Grd Same as for P125 Grd
Spare 01 Similar to P125 Grd Similar to P125 Grd
Spare 02 Similar to P125 Grd Similar to P125 Grd
VCMI Diagnostics
The internal 5V, 12V, 15V, and 28V power supply buses are monitored and alarmed.
The alarm settings are configurable and usually set at 3.5%, except for the 28-Volt
supplies which are set at 5.5%.
Diagnostic signals from the Power Distribution Module, connected through J301, are
also monitored. These include ground fault and over/under voltage on the P125V
bus, two differential +/-5Vdc analog inputs, P28A and PCOM for external monitor
circuits, and digital inputs.
Descriptions of the VCMI diagnostics are in Chapter 8, Troubleshooting &
Diagnostics.

Board VDSK
The VME VDSK board is mounted adjacent to the Mark VI controller as shown in
Figure 9-6.
Mark VI x x x VDSK Board

Controller
J4
J3
24 V dc Supply to Cooling
Fan below Rack
VDSK
x x x
Cable to Power Sub-System
Figure 9-6. VDSK Board with Adjacent Controller
Board Operation
The VDSK board is a solid state assembly which emulates a hard disk, but with
negligible access time. The VDSK board directly interfaces with the controller CPU
board via a standard 44-pin ribbon cable. In addition to data storage, VDSK supports
several other functions as follows:
- Interconnects the PDM with the power subsystem monitoring functions of the
VCMI through the 96-pin P2 backplane connector and the 37-pin sub-miniature
D connector on the front panel. This connection is through a 64-pin ribbon cable
connected at the back of the VME backplane.
- Interconnects +12 V dc and –12 V dc from the 96-pin P1 backplane connector to
a front panel mounted 2-pin connector to power the 4.3 watt 24 V dc VME rack
mounted fan assembly. This is from the front panel J4 connector.
- Provides a board mounted 16-pin Ethernet ID connector which interfaces to the
VCMI board through the P2 backplane connector ribbon cable.

Thermocouple Inputs TBCC
The VME thermocouple board accepts 24 type E, J, K, or T thermocouple inputs.
These inputs are wired to two barrier type blocks on the termination board TBTC.
Cables with molded plugs connect the termination board to the VME rack where the
VTCC thermocouple processor board is located, as shown in Figure 9-7. Input data is
transferred over the VME backplane from VTCC to the VCMI and then to the
controller. A TMR version of the TBTC is also available.
TBTC Termination Board VTCC VME Board
x
x
x
x 2
x 1 TBTC, capacity for RUN
x 3 FAIL
x 4 24 thermocouple inputs STAT
TC x 6
x 5
Inputs x 8
x 7
x 10
x 9
x 11 VME Bus to VCMI
x 12
x 14
x 13 Communication Board
x 16
x 15
x 18
x 17
x 19 37-pin "D" shell
x 20 JA1
x 21 type connectors
x 22
x 23 with latching
x 24
x
fasteners
x
x 26
x 25
x 28
x 27
TC x 30
x 29
32
x 31
Inputs x
x 33 JB1
x 34
x 36
x 35
x 38
x 37 Cables to VME
x 40
x 39 Rack
VTCC
x 42
x 41 x
x 44
x 43
x 46
x 45 Connectors on J3
x 48
x 47 VME Rack
x
x
Shield Bar
Ground
J4
BarrierType Terminal
Blocks can be unplugged
from board for
maintenance
Figure 9-7. Thermocouple Input Termination Board, I/O Board, and Cabling

Thermocouple Board Operation
The 24 thermocouple inputs can be grounded or ungrounded. They can be located up
to 300 meters (984 feet) from the turbine control cabinet with a maximum two-way
cable resistance of 450 ohms. High frequency noise suppression and two cold
junction reference devices are mounted on the TBTC termination board as shown in
Figure 9-8.
Linearization for individual thermocouple types is performed in software. A
thermocouple, which is determined to be out of the hardware limits, is removed from
the scanned inputs in order to prevent adverse affects on other input channels. If both
cold junction devices are within the configurable limits, then the average of the two
is used for cold junction compensation. If only one cold junction device is within the
configurable limits, then that cold junction is used for compensation. If neither cold
junction device is within the configurable limits, then a default value is used.
<R> or <S> or <T> Control Rack

Termination Board TBTC
Thermocouple Input Board VTCC
Cold Junction Excit.

JA1 J3
Reference
Thermocouple
High
Noise
Low Suppression
Grounded or (12) thermocouples

Connectors at I/O Core
ungrounded
bottom of A/D Processor VMEbus
VME rack TMS320C32
Cold Junction Excit.
JB1 J4
Reference
Sampling Type A/D

Converter(16-Bit)
Thermocouple
High
Noise Accuracy = 4 Deg F
Low Suppression Resolution = 14 Bits
(12) thermocouples
Figure 9-8. Thermocouple Inputs and Processor Board

VTCC Features
Thermocouple Limits
Thermocouple inputs are supported over a full-scale input range of –8.0 mV to +45.0
mV. The following table shows typical input voltages for different thermocouple
types versus minimum and maximum temperature range. It is assumed the cold
junction temperature ranges from +32 to +158 F.
Table 9-4. Thermocouple Types and Range
Thermocouple Type E J K T
Low range, F -60F -60F -60F -60F

C -51C -51C -51C -51C
mV at low range with reference -7.174 -6.132 -4.779 -4.764
at 158 F (70 C)
High range, degree F 1100F 1400F 2000F 750F

degree C 593 798 1093 399
mV at high range with 44.547 42.922 44.856 20.801
reference at 32 F (0 C)
Cold Junctions
There are two cold junctions (CJ) sensors on each termination board, one per
connector J3 and J4. Both CJ signals go into signal space and are available for
monitoring. Normally the average of the two is used. Acceptable limits are
configured, and if a CJ goes outside the limit, a logic signal is set. A 1 F error in the
CJ compensation will cause a 1F error in the TC reading.
Hard coded limits are set at 32 to 158 F, and if a CJ goes outside these, it is
regarded as bad. Most CJ failures are open or short circuit. If one CJ fails, the good
one is used. If both CJs go bad, the backup value is used, which can be derived from
CJ readings on other termination boards, or can be the configured default value.
Diagnostics
Three LEDs at the top of the front panel provide status information. The normal
RUN condition is a flashing green, and FAIL is a solid red. The third LED is
normally off but shows a steady orange if a diagnostic alarm condition exists in the
board.
Each termination board has its own ID device which is interrogated by the I/O board.
The board ID is coded into a read-only chip containing the termination board serial
number, board type, revision number, and the JA1/JB1 connector location. Details of
the VTCC diagnostics are in Chapter 8, Troubleshooting & Diagnostics.
Calibration
The thermocouple inputs and cold junction inputs are automatically calibrated using
the filtered calibration reference and zero voltages.

Table 9-5. Typical VTCC Specification
Item Specification
Number of Channels 24 channels per termination board & I/O board
Thermocouple types E, J, K, T thermocouples, and mV inputs
Span -8 mV to +45 mV
Converter Resolution 16-bit A/D converter with better than 14 bit resolution
Cold junction compensation Reference junction temperature measured at two locations
on each TC termination board
Cold junction temperature error Cold junction accuracy 2 F
Conformity error Maximum software error 0.25 F
Measurement accuracy 53 microvolts (excluding cold junction reading)
Example: 3 F, type K, at 1000 F, including cold junction
contribution (RSS)
Common mode rejection AC common mode rejection 110 dB @ 50/60 Hz, for
balanced impedance input
Common mode voltage +/- 5 Volts
Normal mode rejection Rejection of 250 mV Rms is 80 dB @ 50/60 Hz
Scan time All inputs are sampled at 120 times per second for 60 Hz
operation; for 50 Hz operation it is 100 times per second .
Fault detection High/low (hardware) limit check
High/low system (software) limit check
Input Configuration Overview

Like all I/O boards, the thermocouple board is configured using the Control System
Toolbox. This software usually runs on a data-highway connected CIMPLICITY
station or workstation. The table below summarizes configuration choices and
defaults. For details refer to GEH-6403 Control System Toolbox for Configuring the
Mark VI Controller.

Table 9-6. Thermocouple Board Configuration

SysFreq System Frequency (used for noise rejection) 50 or 60 Hz
SystemLimits Enables or Disables All System Limit Checking Enable, Disable
Auto Reset Automatic Restoring of Thermocouples removed from scan Enable, Disable
J3J4:I200TBTCG1A
ThermCpl1 First of 24 thermocouples Point Edit
ThermoCpl Type Thermocouples supported by VTCC; unused inputs are Unused, mV, T,K,J,E
removed from scanning, mV inputs are primarily for
maintenance.
SysLim1 Enabl Enables or disables a temperature limit which can be used Enable, disable
to create an alarm.
SysLim1 Latch Determines whether the limit condition will latch or unlatch; Latch, unlatch
reset used to unlatch.
SysLim1 Type Limit occurs when the temperature is greater than or equal Greater than or equal,
(>=), or less than or equal to (<=) a preset value. Less than or equal
SysLimit 1 Enter the desired value. Engineering Units
SysLim2 Enabled Enables or disables a temperature limit which can be used Enable, disable
to create an alarm.
SysLim2 Latch Determines whether the limit condition will latch or unlatch; Latch, unlatch
reset used to unlatch.
SysLim2 Type Limit occurs when the temperature is greater than or equal Greater than or equal,
(>=), or less than or equal to (<=) a preset value. Less than or equal
SysLimit 2 Enter the desired value. Engineering Units
TMR Diff Limt Limit condition occurs if 3 temperatures in R,S,T differ by -60 to 2,000
more than a preset value (deg F); this creates a voting
alarm condition.
ColdJunc1 First Cold Junction Reference (similar configuration as for As above
thermocouples).
ColdJunc2 Second Cold Junction Reference (similar configuration as As above
for thermocouples).
Diagnostics
Each thermocouple type has Hardware Limit Checking based on preset (non-
configurable) high and low levels set near the ends of the operating range. If this
limit is exceeded a logic signal is set and the input is no longer scanned. If any one of
the 24 inputs hardware limits is set it creates a composite diagnostic alarm,
L3DIAG_VTCC, referring to the entire board. Details of the individual diagnostics
are available from the toolbox. The diagnostic signals can be individually latched,
and then reset with the RESET_DIA signal.
Each thermocouple input has System Limit Checking based on configurable high and
low levels. These limits can be used to generate alarms, and can be configured for
enable/disable, and as latching/nonlatching. RESET_SYS resets the out of limit
signals. In TMR, Systems Limit logic signals are voted and the resulting composite
diagnostic is present in each controller. VTCC diagnostics are described in Chapter
8, Troubleshooting & Diagnostics.

Installation
Thermocouples are wired directly to two I/O terminal blocks. These blocks are
mounted on the termination board and held down with two screws as shown in
Figure 9-9. Each block has 24 terminals accepting 12 AWG wires. A shield
termination strip attached to chassis ground is located immediately to the left of each
terminal block.
Thermocouple Termination Board TBTC
x
x 1 Input 1 (+)
Input 1 (-) x 2
x 3 Input 2 (+)
Input 2 (-) x 4
Input 3 (-)
x 5 Input 3 (+)
x 6
Input 4 (-)
x 7 Input 4 (+)
x 8
x 9 Input 5 (+)
Input 5 (-) x 10
x 11 Input 6 (+)
Input 6 (-) x 12
Input 7 (-)
x 13 Input 7 (+)
x 14
x 15 Input 8 (+) JA1
Input 8 (-) x 16
x 17 Input 9 (+)
Input 9 (-) x 18
x 19 Input 10(+)
Input 10(-) x 20
Input 11(-)
x 21 Input 11(+)
x 22
Input 12(-)
x 23 Input 12(+)
x 24
x
x
x 25 Input 13(+)
Input 13(-) x 26
28
x 27 Input 14(+)
Input 14(-) x
x 29 Input 15(+) JB1 Cable to I/O
Input 15(-) x 30
Input 16(-) x 32
x 31 Input 16(+) Rack J3
Input 17(-)
x 33 Input 17(+)
x 34
Input 18(-) x 36
x 35 Input 18(+)
Input 19(-)
x 37 Input 19(+)
x 38
Input 20(-) x 40
x 39 Input 20(+)
Input 21(-)
x 41 Input 21(+)
x 42
x 43 Input 22(+)
Input 22(-) x 44
Input 23(-) x 46
x 45 Input 23(+)
Input 24(-) x 48
x 47 Input 24(+)
x
I/O Terminal Blocks with Barrier Terminals Cable to I/O

Rack J4
Terminal Blocks can be unplugged from
terminal board for maintenance
Up to two #12 AWG wires per point with

300 volt insulation
Figure 9-9. TBTC Wiring and Cabling

RTD Inputs TRTD
The VME Resistance Temperature Device (VRTD) board accepts 16, three-wire
RTD inputs. These inputs are wired to two barrier type blocks on the RTD
termination board (TRTD). Noise suppression circuitry to protect against surge and
high frequency noise is also mounted on the board. Cables with molded fittings
connect the termination board to the VME rack where the VRTD processor board is
located. The VRTD converts the inputs to digital temperature values and transfers
them over the VME backplane to the VCMI, and then to the controller.
Two versions of TRTD are available, the type shown below in Figure 9-10, and a
TMR type that fans out the signals to three VRTD boards
TRTD Termination Board VRTD VME Board
x
x
x 2
x 1 TRTD capacity for RUN
x 4
x 3 FAIL
8 RTD x 5 16 RTD inputs STAT
x 6
Inputs x 8
x 7
x 10
x 9
x 12
x 14
x 16
x 15
x 18
x 17
x 20
x 19 JA1 37-pin "D" shell
x 22
x 21
x 23 type connectors
x 24 with latching
x
fasteners
x
x 26
x 25
x 28
x 27
8 RTD x 30
x 29
Inputs x 32
x 31
x 33 JB1
x 34
x 36
x 35
x 38
x 37 Cables to
x 40
x 39 VME Rack
VRTD
x 42
x 41 x
x 44
x 43
x 46
x 45 Connectors on J3
x 48
x 47 VME Rack
x
x
Shield
Bar
J4
from board for
maintenance
Figure 9-10. RTD Input Termination Board, I/O Board, & Cabling

RTD Board Operation
The termination board supplies a 10 mA dc multiplexed (not continuous) excitation
current to each RTD, which can be grounded or ungrounded. The 16 RTDs can be
located up to 300 meters (984 feet) from the turbine control cabinet with a maximum
two-way cable resistance of 15 ohms. The RTD inputs and signal processing are
shown in Figure 9-11.
The VCO type A/D converter in the VRTD board uses voltage to frequency
converters and sampling counters. The converter samples each signal and the
excitation current four times per second for normal mode scanning, and 25 times per
second for fast mode scanning, using a time sample interval related to the power
system frequency. Linearization for the selection of 15 RTD types is performed in
software by the digital signal processor.
RTD open and short circuits are detected by out of range values. An RTD which is
determined to be out of hardware limits is removed from the scanned inputs in order
to prevent adverse affects on other input channels. Repaired channels are reinstated
automatically in 20 seconds, or can be manually reinstated.
<R> or <S> or <T> Control Rack
Termination RTD Input Board VRTD

Board TRTD
J3 Excit.
JA1
Excitation
RTD Noise
Signal Suppression
Return
Grounded or (8) RTDs
ungrounded Connectors
at I/O Core
bottom of A/D Processor VMEbus
VME Bus
VME rack TMS320C32
JB1 J4 Excit.
Excitation
RTD Noise
Signal Suppression
VCO Type A/D
Return Converter
Grounded or (8) RTDs
ungrounded
Figure 9-11. RTD Inputs & Signal Processing

VRTD Features
RTD Limits
RTD inputs are supported over a full-scale input range of 0.3532 to 4.054 volts. The
following table shows the types of RTD used and the temperature ranges.
Table 9-7. RTD Types and Ranges
RTD Type Name/Standard Range degree C Range degree F
10 ohm copper MINCO_CA -51 to +260 -60 to +500

GE 10 Ohm Copper
100 ohm platinum SAMA 100 -51 to +593 -60 to +1100
MINCO_PC
100 ohm platinum DIN 43760 -51 to +700 -60 to +1292
IEC-751
MINCO_PD
MINCO_PE
PT100_DIN
100 ohm platinum MINCO_PA -51 to +700 -60 to +1292
IPTS-68
PT100_PURE
100 ohm platinum MINCO_PB -51 to +700 -60 to +1292
Rosemount 104
PT100_USIND
120 ohm nickel MINCO_NA -51 to +249 -60 to +480
N 120
200 ohm platinum PT 200 -51 to +204 -60 to +400
Calibration
RTD inputs are automatically calibrated using the filtered calibration source and null
voltages.
Front panel
Three LEDs at the top of the VRTD front panel provide status information. The
normal RUN condition is a flashing green, FAIL is a solid red. The third LED is
board.
Each termination board has its own ID device which is interrogated by the I/O board.
The board ID is coded into a read-only chip containing the termination board serial
number, board type, revision number, and the JA1/JB1 connector location.

Table 9-8. VRTD Specification
Item Specification
Number of Channels 16 channels per termination board
16 channels per VRTD board

RTD types 10, 100, and 200 ohm platinum
10 ohm copper
120 ohm nickel
Span 0.3532 to 4.054 volts
A/D Converter Resolution 14-bit resolution
Scan Time Normal scan 250 ms (4 Hz)

Fast scan 40 ms (25 Hz)
Power consumption Less than 12 watts
Measurement accuracy See Table 9-10
Common mode rejection AC common mode rejection 60 dB @ 50/60 Hz,

with up to +/-5 volt common mode voltage
Common mode voltage range +/- 5 Volts
Normal mode rejection Rejection of up to 250 mV Rms is 60 dB @ 50/60

Hz system frequency for normal scan
Maximum lead resistance 15 ohms maximum two way cable resistance
Fault Detection High/low (hardware) limit check

High/low (software) system limit check
Table 9-9. RTD Accuracy
RTD Type Group Gain Accuracy

120 ohm Nickel Normal_ 1.0 2 F
200 ohm Platinum
100 ohm Platinum Normal_ 1.0 4 F
100 ohm Platinum Gai_ 2.0 2 F
(-60 F to 400 F)
10 ohm Copper 10 ohm Cu_10 10 F

Like all I/O boards, the RTD board is configured using the Control System Toolbox.
This software usually runs on a data-highway connected CIMPLICITY station or
workstation. The table below summarizes configuration choices and defaults. For
Turbine Controller.

Table 9-10. Typical VRTD Configuration
Module Parameter Description Choices
System Limits Enable or disable all system limit checking Enable, disable
Auto Reset Enable or disable restoring of RTDs removed Enable, disable

from scan
Group A Rate Sampling rate and system frequency filter for 4 Hz, 50 Hz filter
first group of 8 inputs 4 Hz, 60 Hz filter
25 Hz
Group A Gain Gain 2.0 is for higher accuracy if ohms<190, Normal_1.0
first group of 8 inputs Gain_2.0
10 ohm Cu_10.0
Group B Rate Sampling rate and system frequency filter for 4 Hz, 50 Hz filter
second group of 8 inputs 4 Hz, 60 Hz filter
25 Hz
Group B Gain Gain 2.0 is for higher accuracy if ohms<190, Normal_1.0
second group of 8 inputs Gain_2.0
10 ohm Cu_10.0
J3J4:IS200TRTDG1A
RTD Type RTDs linearizations supported by VRTD; select Unused

RTD or Ohms Input (unused inputs are CU10 MINCO_CA
removed from scanning) PT100_DIN MINCO_PD
PT100_PURE MINCO_PA
PT100_USIND MINCO_PB
N120 MINCO_NA
MINCO_PIA PT100_SAMA
MINCO_PC PT200
MINCO_PK Ohms
SysLim1 Enabl Enables or disables a temperature limit for Enable, disable
each RTD, can be used to create an alarm
SysLim1 Latch Determines whether the limit condition will latch Latch, unlatch
or unlatch for each RTD; reset used to unlatch.
SysLim1 Type Limit occurs when the temperature is greater Greater than or equal,
than or equal (>=), or less than or equal to Less than or equal
(<=) a preset value.
System Limit 1 Enter the desired value of the limit temperature, -60 to 1,300
Deg F or Ohms
SysLim2 Enabled Enables or disables a temperature limit which Enable, disable

can be used to create an alarm
SysLim2 Latch Determines whether the limit condition will latch Latch, unlatch
or unlatch; reset used to unlatch.
SysLim2 Type Limit occurs when the temperature is greater Greater than or equal,
than or equal (>=), or less than or equal to Less than or equal
(<=) a preset value.
System Limit 2 Enter the desired value of the limit temperature, -60 to 1,300
Deg F or Ohms
TMR Diff Limt Limit condition occurs if 3 temperatures in -60 to 1,300

R,S,T differ by more than a preset value; this
creates a voting alarm condition.

Diagnostics
Two types of diagnostic checking are applied to all inputs, Hardware Limit Checking
and System Limit Checking.
Each RTD type has Hardware Limit Checking based on preset (non-configurable)
high and low levels set near the ends of the operating range. If this limit is exceeded
a logic signal is set and the input is no longer scanned. If any one of the 16 input’s
hardware limits is set it creates a composite diagnostic alarm, L3DIAG_VRTD,
referring to the entire board. Details of the individual diagnostics are available from
the toolbox. The diagnostic signals can be individually latched, and then reset with
the RESET_DIA signal.
Each RTD input has System Limit Checking based on configurable high and low
levels. These limits can be used to generate alarms, and can be configured for
enable/disable, and as latching/nonlatching. RESET_SYS resets the out of limit
signals. In TMR systems limit logic signals are voted and the resulting composite
diagnostic is present in each controller. Descriptions of the VRTD diagnostics are in

Installation
The sixteen RTDs are wired directly to two I/O terminal blocks mounted on the
termination board. Each block is held down with two screws and has 24 terminals
accepting 12 AWG wires, as shown in Figure 9-12. A shield termination strip
attached to chassis ground is located immediately to the left of each terminal block.
RTD Termination Board TRTD
Input 1 (Sig)
x 1 Input 1 (Exc)
x 2
x 3 Input 1 (Ret)
Input 2 (Exc) x 4
x 5 Input 2 (Sig)
Input 2 (Ret) x 6
x 7 Input 3 (Exc)
Input 3 (Sig) x 8
Input 4 (Exc)
x 9 Input 3 (Ret)
x 10
x 11 Input 4 (Sig)
Input 4 (Ret) x 12
x 13 Input 5 (Exc)
Input 5 (Sig) x 14
Input 6 (Exc)
x 15 Input 5 (Ret) JA1
x 16
Input 6 (Ret)
x 17 Input 6 (Sig)
x 18
x 19 Input 7 (Exc)
Input 7 (Sig) x 20
x 21 Input 7 (Ret)
Input 8 (Exc) x 22
Input 8 (Ret)
x 23 Input 8 (Sig)
x 24
x
x
x 25 Input 9 (Exc)
Input 9 (Sig) x 26
x 27 Input 9 (Ret) Cable to I/O
Input 10 (Exc) x 28
Input 10 (Ret)
x 29 Input 10 (Sig) Rack, J3
x 30
Input 11 (Sig)
x 31 Input 11 (Exc)
x 32
x 33 Input 11 (Ret) JB1
Input 12 (Exc) x 34
x 35 Input 12 (Sig)
Input 12 (Ret) x 36
Input 13 (Sig)
x 37 Input 13 (Exc)
x 38
Input 14 (Exc)
x 39 Input 13 (Ret)
x 40
x 41 Input 14 (Sig)
Input 14 (Ret) x 42
x 43 Input 15 (Exc)
Input 15 (Sig) x 44
Input 16 (Exc)
x 45 Input 15 (Ret)
x 46
Input 16 (Ret)
x 47 Input 16 (Sig)
x 48
x
Cable to I/O
Terminal Blocks can be unplugged from Rack, J4
Up to two #12 AWG wires per

point with 300 volt insulation
Figure 9-12. RTD Termination Board Wiring

Analog Inputs TBAI
The VME Analog Input Board (VAIC) accepts 20 analog inputs and controls four
analog outputs. Ten inputs and two outputs are wired to two barrier type blocks on
each Analog Input Termination Board (TBAI). Noise suppression circuitry to protect
against surge and high frequency noise is also mounted on the board. Cables connect
the termination board to the VME rack where the VAIC processor board is located,
as shown in Figure 9-13. The VAIC converts the inputs to digital values and
transfers these over the VME backplane to the VCMI, and then to the controller.
Input signals are fanned out to three VME board racks R, S, and T for TMR
applications. The VAIC requires two termination boards to monitor 20 inputs.
TBAI Termination Board TBAI Termination Board VAIC VME Board
x
x x
x
x JT1 JT1
x 2
x 1 x 2
x 1 37-pin "D" shell RUN
x 3 4
x 3 type connectors FAIL
x 4 x
STAT
x 5 6
x 5
x 6 x
7
with latching
x 8
x 7 x 8
x
x 9 x 9 fasteners
x 10 x 10
x 11 12
x 11
x 12 x
x 13 14
x 13
x 14 x
x 15 16
x 15
x 16 x
x 17 18
x 18 x
x 19 JS1 20
x 19 JS1
x 20 x Communication
x 21 22
x 21
x 22 x
Board
x 23 To 24
x 23
x 24 x
x Rack x
T
x x
x 25 26
x 25 Cable to VME
x 26 x
x 27 28
x 27
x 28 x
29
Rack T
x 29 30
x
x 30 To x
31
32
x 31 x 32
x
x
x 33 JR1 Rack x 33 JR1 Cable to VME
x 34 x 34
x 35 S 36
x 35 Rack S
x 36 x
x 37 38
x 37
x 38 x
x 39 40
x 39 VAIC
x 40 x
x 41 42
x 41 x
x 42 x
x 43 44
x 43
x 44 x
x 45 46
x 45 Connectors on
x 46 x J3
x 47 48
x 47 VME Rack
x 48 x
x x
x x
Shield
Bar
J4
Blocks can be unplugged Cables to VME
from board for maintenance Rack R
Figure 9-13. Analog Input Termination Boards, I/O Board, & Cabling (TMR System)

Analog Input Board Operation
The termination board accepts 10 analog inputs and controls two analog outputs. 24
V dc power is available on the termination board for all the transducers. The VAIC
board in the VME rack accepts 20 analog inputs and controls four analog outputs.
VAIC contains signal conditioning, an analog MUX, A/D converter, and D/A
converter, as shown in Figure 9-14.
One of the two analog output circuits is a 4-20 mA output, and the other can be
configured using jumpers for 4-20 mA or 0-200 mA.
Termination Board TBAI <R> Control Module
Controller
Application Software
8 Circuits per Term. Board
Noise
Suppr
.
P28V
+24Vdc Current Limit
vdc J#A Analog Input

+/-5,10Vdc Board VAIC
20 ma
4-20 ma
250 ohms A/D D/A
Return
J#B
Open Return
PCOM
Connectors
at
2 Circuits per Term. Board bottom of
VME rack
Noise
Suppr. P28V
+24vdc Current Limit Excit.
1 ma J#A JR1 J3/4
+/-1 ma
20 ma
4-20 ma 250
ohm 5k ohms
Return
J#B
Open Return
Current
Regulator/
Two Output Circuits Power Supply
#2 Circuit is 4-20 ma 200 ma JO
only Noise
Signal Suppr. 20 ma
Maximum Load
4-20 ma, 500 ohms
0-200 ma, 50 ohms
Return
Figure 9-14. Analog Input Processing, SMX

In a TMR system, analog inputs fanout to the three control racks from JR1, JS1, and
JT1. The 24 V dc power to the transducers comes from all three VAIC and is diode
shared on the termination board. Each analog current output is fed by currents from
all three VAIC, as shown in Figure 9-15. The actual output current is measured with
a series resistor, which feeds a voltage back to each control rack.
Termination Board TBAI <R> Control Module
Controller
8 Circuits per Term. Board Application Software
Noise
P28V<T>
Suppr. P28VR P28V<S>
+24vdc Current Limit
J#A Analog Input

+/-5,10vdc vdc
Board VAIC
20 ma
4-20 ma
250 ohms A/D D/A
Return
J#B
Open Return
Connectors
at
2 Circuits per Term. Board bottom of
Noise VME rack
Suppr P28VR
+24vdc . Current Limit
Excit.
1 ma J#A
+/-1 ma JR1 J3/4
20 ma Filter 2 Pole
4-20 ma
250
ohm 5k ohms
Return
J#B
Open Return
Current
S Regulator/
Two Output Circuits T Power Supply
#2 Circuit is 4-20 200 JO

ma only Noise
Signal Suppr. 20
Maximum Load
S
4-20 ma, 500 ohms T JS1
0-200 ma, 50 ohms
Return
JT1
To Rack<S>
To Rack<T>
Figure 9-15. Analog Input Processing, TMR

VAIC Features
The VAIC analog input/output capacity, using two TBAI termination boards, is as
follows:
Table 9-11. Quantity and Types of Analog Inputs and Outputs
Qty Analog Input Types Qty Analog Output Types
16 +/- 10 Vdc, or +/- 5 Vdc, or 4-20 mA 2 4-20 mA

4 4-20 mA, or +/- 1 mA 2 0-20 mA, or 0-200 mA
Transmitter/transducers can be powered by the 24 V dc source in the control system,

or can be independently powered. Termination board jumpers J#A, J#B, and JO set
up the type of voltage and current inputs, and select the type of current output. Each
output is monitored by diagnostics, and a suicide relay disconnects the corresponding
output if a fault cannot be cleared by a command from the processor.
Noise Filtering
Hardware filters on the termination board suppress high frequency noise. Additional
software filters on VAIC provide configurable low pass filtering. With the above
noise suppression and filtering, the AC common mode rejection (CMR) is 60 dB,
and DC CMR is 80 dB.
Front panel
Three LEDs at the top of the VAIC front panel provide status information. The
normal RUN condition is a flashing green, and FAIL is a solid red. The third LED is
normally off but displays a steady orange if a diagnostic alarm condition exists in the
board.
Each termination board has its own ID device, which is interrogated by the I/O
board. The board ID is coded into a read-only chip containing the termination board
serial number, board type, revision number, and the JR, JS, JT connector location.

Table 9-12. VAIC Specification
Item Specification
Number of Channels 12 channels per termination board (10 AI, 2 AO )
24 channels per VAIC board (20 AI, 4 AO )

Input Span 1 – 5 V dc
Input Converter Resolution 16-bit A/D converter with 14-bit resolution
Scan Time Normal scan 10 ms (100 Hz)

Inputs 1 through 4 available for scan at 200 Hz
Measurement accuracy Better than 0.1% full scale
Output Converter 12-bit D/A converter with 0.5% accuracy
Output Load 500 ohms for 4-20 mA output
50 ohms for 200 mA output
Power consumption Less than 31 watts
Noise Suppression The first ten circuits (J3) have a hardware filter
with single pole down break at 500 radians/sec.
The second ten circuits (J4) have a two pole down
break at 72 and 500 radians/sec.
A software filter, using a two pole low pass filter, is
configurable for: 0, 1.5 Hz, 3 Hz, 6 Hz, 12 Hz
Common mode rejection AC common mode rejection 60 dB @ 50/60 Hz,

with up to +/-5 volt common mode voltage.
DC common mode rejection 80 dB with up to +/- 5

Volt common mode voltage.
Common mode voltage range +/- 5 Volts (+/- 1 Volt for the +/- 10 Volt inputs)
Maximum lead resistance 15 ohms maximum two-way cable resistance,

cable length up to 300m (984 ft)
Fault detection High/low (hardware) limit check

High/low system (software) limit check
Diagnostics
Each analog input has Hardware Limit Checking based on preset (non-configurable)
high and low levels set near the ends of the operating range. If this limit is exceeded
a logic signal is set and the input is no longer scanned. If any one of the 16 input’s
hardware limits is set, it creates a composite diagnostic alarm, L3DIAG_VAIC,
which refers to the entire board. Details of the individual diagnostics are available
from the toolbox. The diagnostic signals can be individually latched, and then reset
with the RESET_DIA signal.
Each input has System Limit Checking based on configurable high and low levels.
These limits can be used to generate alarms, and can be configured for
enable/disable, and as latching/nonlatching. RESET_SYS resets the out of limits.
Details of the diagnostics are in Chapter 8, Troubleshooting & Diagnostics.

The table below summarizes configuration choices and defaults. For details refer to
GEH-6403 Control System Toolbox for Configuring the Mark VI Turbine Controller.
Table 9-13. Typical VAIC Configuration
System Limits Enable or disable system limits Enable, disable

Output Voting Select type of output voting Simplex, TMR
Min_ MA_Input Select minimum current for healthy 4-20 mA 0 to 21 mA
input
Max_ MA_Input Select maximum current for healthy 4-20 mA 0 to 21 mA
input
J3:IS200TBAIG1A Termination board connected to VAIC via J3 Connected, not connected
J4:IS200TBAIG1A Termination board connected to VAIC via J4 Connected, not connected
AnalogIn1 First of 10 Analog Inputs Point Edit
Input Type Current or voltage input type Unused, 4-20ma, +/-5V, +/-10V
Low_Input Value of current at the low end of scale -10 to +20
Low_Value Value of input in engineering units at low end -3.4082e+038 to 3.4028e+038
of scale
High_Input Value of current at the high end of scale -10 to +20
High_Value Value of input in engineering units at high -3.4082e+038 to 3.4028e+038
end of scale
Input _Filter Bandwidth of input signal filter 1.5 Hz, 3 Hz, 6 Hz, 12 Hz
TMR Diff Limit Difference limit for voted inputs in % of high- 0 to 100
low values
Sys Lim 1 Enabl Input fault check Enable, disable
Less than or equal
Sys Lim 1 Input limit in Engineering Units -3.4082e+038 to 3.4028e+038
Sys Lim 2 Enabl Input fault check Enable, disable
Less than or equal
Sys Lim 2 Input limit in Engineering Units -3.4082e+038 to 3.4028e+038
AnalogOut1 First of two analog outputs Point Edit
Output_MA Type of output current Unused, 0-20 mA, 0-200 mA
Low_MA Output mA at low value 0 to 200 mA
Low_Value Output in Engineering Units at low mA -3.4082e+038 to 3.4028e+038
High_MA Output mA at high value 0 to 200 mA
High_Value Output value in Engineering Units at high mA -3.4082e+038 to 3.4028e+038
TMR Suicide Suicide for faulty output current, TMR only Enable, disable
Diff Limit Current difference for suicide, TMR only 0 to 200 mA
D/A Err Limit Difference between D/A reference and 0 to 100 %
output, in % for suicide, TMR only

Installation
The 10 inputs and two outputs are wired directly to two I/O terminal blocks mounted
on the termination board. Each block is held down with two screws and has 24
terminals accepting 12 AWG wires. A shield termination strip attached to chassis
ground is located immediately to the left of each terminal block. The types of analog
inputs and outputs are selected with jumpers, as shown in Figure 9-16.
Analog Input Termination Board TBAI Board Jumpers JT1

Circuit Jumpers
20ma VDC OPEN RET

x
x 1 Input 1 (24V) Input 1 J1A J1B
Input 1 (20ma) x 2
x 3 Input 1 (Vdc)
Input 1 (Ret) x 4
Input 2 (20ma) x 6
Input 2 (Ret)
x 7 Input 2 (Vdc)
x 8
Input 3 (20ma)
x 10
x 11 Input 3 (Vdc) To I/O
Input 3 (Ret) x 12
x 13 Input 4 (24V) Input 4 J4A J4B Rack T
Input 4 (20ma) x 14
Input 4 (Ret)
x 15 Input 4 (Vdc)
x 16
x 17 Input 5 (24V) Input 5 J5A J5B JS1
Input 5 (20ma) x 18
x 19 Input 5 (Vdc)
Input 5 (Ret) x 20
Input 6 (20ma) x 22
Input 6 (Ret)
x 23 Input 6 (Vdc)
x 24
Input 7 J7A J7B
x
Input 8 J8A J8B

x
x 25 Input 7 (24V) 20ma 1 ma OPEN RET
Input 7 (20ma) x 26
x 27 Input 7 (Vdc) To I/O
Input 7 (Ret) x 28
Input 8 (20ma)
x 29 Input 8 (24V) Rack S
x 30 Input 9 J9A J9B
Input 8 (Ret)
x 31 Input 8 (Vdc)
x 32
x 33 Input 9 (24V) JR1
Input 9 (20ma) x 34 Input 10 J10A J10B
x 35 Input 9 (Vdc)
Input 9 (Ret) x 36
Input 10 (20ma)
x 37 Input 10 (24V)
x 38
Input 10 (Ret)
x 39 Input 10 (Vdc)
x 40 Output 1 J0
x 41
x 42
x 43
x 44 Output 2 No jumper
Output 1 (Ret)
x 45 Output 1 (Sig)
x 46
Output 2 (Ret)
x 47 Output 2 (Sig)
x 48
x
To I/O
Rack R
Figure 9-16. TBAI Termination Board Wiring

Analog Outputs TBAO
The VME Analog Output Board (VAOC) controls 16 analog 4-20 mA outputs.
These outputs are wired to two barrier type blocks on the Analog Output
Termination Board (TBAO). Noise suppression circuitry to protect against surge and
high frequency noise is mounted on the termination board. Cables with molded plugs
connect the termination board to the VME rack where the VAOC processor board is
located. The VAOC receives digital values from the controller over the VME
backplane from the VCMI, and converts these to analog output currents.
Note that for TMR applications control signals are fanned into the termination board
from three VME board racks R, S, and T, as shown in Figure 9-17. Six cables are
required to support all 16 outputs with TMR.
TBAO Termination Board 37-pin "D" VAOC VME Board

shell type
x connectors x
x
x 1 JT1 JT2 with latching
x 2 RUN
x 4 x 3 fasteners FAIL
8 Analog x 5 STAT
x 6
Outputs x 8 x 7
x 10 x 9
x 12 x 11 VME Bus to VCMI
x 14
x 16 x 15
x 18 x 17
20 x 19 JS1 JS2
x
x 21 Cables to VME
x 22 Rack T
x 24 x 23
x
x
x 26 x 25
28 x 27 Cables to VME
8 Analog x
x 29
x 30 Rack S
Outputs x 32 x 31
x 33 JR1 JR2
x 34
x 36 x 35
x 38 x 37
x 40 x 39 VAOC
x 42 x 41 x
x 44 x 43
46 x 45 Connectors on
x
x 47 J3
x 48 VME Rack R
x
x
Shield
Bar
J4
Barrier Type Terminal

Figure 9-17. Analog Output Termination Board, I/O Board, and Cabling

Analog Output Board Operation
The termination board supports 16 analog outputs. Driven devices have a maximum
resistance of 500 ohms and can be located up to 300 meters (984 feet) from the
turbine control cabinet. The VAOC board in the VME rack contains the D/A
converter which generates the controlled currents, as shown in Figure 9-18.
Diagnostics perform a high and low (hardware) limit check on the outputs, and a
high/low system (software) limit check.
<R> Module
Analog Output Board VAOC TBAO Termination

Board Maximum Load
Suicide
D/A Current Noise 4-20 ma, 500
100 Relay J3 JR1 Suppr
Regulator/ ohms . 01 ohms
Signal
From Power Driver 50 ohms
Controller 02 Return Circuit #1
Sensing
03 Signal
04 Return Circuit #2
Sensing 05 Signal
07 Signal
First group of 8 analog 4-20 ma outputs Group 1 09 Signal
11 Signal
13 Signal
15 Signal
Suicide
D/A Current 16 Return Circuit #8
100 Relay J4 JR2
Regulator/ ohms 17 Signal
From Power Driver 50 ohms 18 Return Circuit #9
Controller 19 Signal
Sensing
21 Signal
Sensing 22 Return Circuit #11

23 Signal
25 Signal
Second group of 8 analog 4-20 ma outputs Group 2 26 Circuit #13
Return
27 Signal
29 Signal
31 Signal
Connectors at bottom 32 Return Circuit #16

of VME rack
Figure 9-18. Analog Output Processing, SMX

In a TMR system, each analog current output is fed by the sum of the currents from
the three VAOCs, as shown in Figure 9-19. The total output current is measured with
a series resistor which feeds a voltage back to each control rack and VAOC. If one
VAOC fails the other two pickup the current to the correct value. If one output fails
high it is disconnected by the suicide relay.
VME Racks <R>

<S>
<T>
Current Output Board VAOC Termination Board -
TBAO
Suicide Maximum Load
D/A Current 100 Relay
Noise
J3 JR1 Suppr 500 ohms
Regulator/ ohms
. 01
From Signal
Power Driver 50 ohms
Controller Circuit #1
02 Return
Sensing
03 Signal
Sensing 05 Signal
07 Signal
J3 JS1 09 Signal
Group 1 10 Circuit #5
Return
First group of (8) Same for
<S> 11 Signal
4-20ma outputs
J3 JT1 13 Signal
Same for 15 Signal
<T> Circuit #8
16 Return
17 Signal
J4 JR2
Same for
<R> 19 Signal
21 Signal
Same for J4 JS2 22 Circuit #11
Second group of Return
<S> 23
(8) 4-20ma outputs Signal
Group 2 25 Signal
Same for J4 JT2 26 Return Circuit #13

<T> 27 Signal
29 Signal
31 Signal
Circuit
32 Return
#16
Figure 9-19. Analog Output Processing, TMR

VAOC Features
Each output is monitored by diagnostics. Voltage drops across the local and outer
loop current sense resistors, at the control reference, D/A outputs, and at the suicide
relay contacts are sampled and digitized. In the event of a malfunction that cannot be
cleared by a command from the processor, the circuit is disconnected by opening the
suicide relay contacts. This isolation function is only operational when configured
for TMR operation.
Each cable on the termination board has its own ID device which is interrogated by
the I/O board. The ID device is a read-only chip coded with the termination board
Noise Filtering
Filters reduce high frequency noise and suppress surge on each output near the point
of signal exit.
Front panel
Three LEDs at the top of the VAOC front panel provide status information. The
normally off but displays a steady orange if a diagnostic alarm condition exists in the
board.
Table 9-14. VAOC Specification
Item Specification
Number of Channels 16 current output channels, single ended (one side

connected to common)
Analog Outputs 4-20 mA, up to 500 ohm burden
Response better than 50 rad/sec
D/A Converter Resolution/Accuracy 12-bit resolution with 0.5% accuracy
Frame Rate 200 Hz on first four outputs, 100 Hz on other 12 outputs

Fault detection Local current
Outer (TMR) current
D/A converter output
Suicide relay operation
Configuration Overview
Like all I/O boards, the VAOC board is configured using the Control System
station or workstation. The table below summarizes the configuration choices. Refer
to GEH-6403 Control System Toolbox for Configuring the Mark VI Turbine
Controller.

Table 9-15. Typical VAOC Configuration
Output Voting Select type of output voting Simplex, TMR

J3:IS200TBAOG1A Termination board connected to VAOC via J3 Connected, not connected
J4:IS200TBAOG1A Termination board connected to VAOC via J4 Connected, not connected
AnalogOut1 First Analog Output Point Edit
Output_MA Type of output current Unused, 0-20 mA
Low_MA Output MA at Low Value 0 to 20 mA
Low_Value Output in Engineering Units at Low MA -3.4028e+038 to
3.4028e+038
High_MA Output MA at High Value 0 to 20 mA
High_Value Output Value in Engineering Units at High MA -3.4028e+038 to
3.4028e+038
TMR_ Suicide Enable Suicide for faulty output current, TMR Enable, disable
only
TMR_Diff Limit Current difference in MA for suicide, TMR only 0 to 20 mA
D/A_Err Limit Difference between D/A reference and output, in 0 to 100 %
% for suicide, TMR only
Diagnostics
Standard diagnostic information is available on the inputs and outputs, including
high and low limit checks, and high and low system limit checks (configurable). If
any one of the 16 outputs goes unhealthy a composite diagnostic alarm,
L3DIAG_VAOC, occurs. Details of the individual diagnostics are available from the
toolbox. The diagnostic signals can be individually latched, and then reset with the
RESET_DIA signal if they go healthy. Refer to Chapter 8, Troubleshooting &
Diagnostics.

Installation
The 16 analog outputs are wired directly to two I/O terminal blocks mounted on the
termination board, as shown in Figure 9-20. Each block is held down with two
screws and has 24 terminals accepting 12 AWG wires. A shield termination strip
attached to chassis ground is located immediately to the left of each terminal block.
Analog Output Termination Board TBAO

JT1 JT2
Output 1 (Ret)
x 1 Output 1 (Sig)
x 2
x 3 Output 2 (Sig)
Output 2 (Ret) x 4
x 5 Output 3 (Sig)
Output 3 (Ret) x 6
Output 4 (Ret)
x 7 Output 4 (Sig)
x 8
Output 5 (Ret)
x 9 Output 5 (Sig) To I/O
x 10
x 11 Output 6 (Sig) Rack T
Output 6 (Ret) x 12
x 13 Output 7 (Sig) J4
Output 7 (Ret) x 14
Output 8 (Ret)
x 15 Output 8 (Sig)
x 16
x 17 Output 9 (Sig) JS1 JS2
Output 9 (Ret) x 18 To I/O
x 19 Output 10(Sig)
Output 10(Ret) x 20 Rack T
x 21 Output 11(Sig)
Output 11(Ret) x 22 J3
Output 12(Ret)
x 23 Output 12(Sig)
x 24
x
x
Output 13 (Sig) To I/O
x 25
Output 13 (Ret) x 26 Rack S
x 27 Output 14 (Sig)
Output 14 (Ret) x 28 J4
Output 15 (Ret)
x 30
Output 16 (Ret)
x 32 JR1 JR2 To I/O
x 33
x 34 Rack S
x 35
x 36 J3
x 37
x 38
x 39
x 40
x 41
x 42
x 43
x 44
x 45
x 46 To I/O
x 47
x 48 Rack R
x J4
To I/O
Rack R
J3
I/O Terminal Block with Barrier Terminals
Up to two #12 AWG wires per point with 300

volt insulation
Figure 9-20. TBAO Termination Board Wiring

Contact Inputs TBCI
The VME Contact Input/Relay Output Board (VCCC) accepts 48 discrete inputs and,
with its associated daughter board, controls 24 relay outputs. VCCC is a double
width module and connects to two sets of J3/J4 plugs via the VME backplane as
shown in the Figure 9-21 below. The Contact Input Termination Board (TBCI)
accepts 24 dry contact inputs, and two boards are required to support 48 inputs. The
Relay Output Termination Board (TRLY) controls 12 relays and is described in the
next section.
VME Rack
J1
VCCC
VCCC Daughter Board
Board
J2 J2
Backplane Cable Connectors Backplane Wiring

J3 J3
J4 J4
Termination Boards
TB3 JF1 JF2 TB3 JF1 JF2 JE1 JE2 JE1 JE2
Power Plugs Power Plugs Power Plugs Power Plugs
TRLY JT1 TRLY JT1 TBCI JT1 TBCI JT1

Relay/ Relay/ Contact Contact
Sol Sol Inputs JS1 Inputs JS1
Outputs JS1 Outputs JS1 24 per 24 per
12 per 12 per board board
board board
JA1 JA1 JR JR
Power Power
1 1
JG1 JG1
Plug Plug
Figure 9-21. Boards & Cabling for Contact Inputs and Relay Outputs, SMX

The first 24 dry contact inputs are wired to two barrier type blocks on the TBCI, and
a second termination board is required for inputs 25-48. DC power for the contacts
and noise suppression circuitry to protect against surge and high frequency noise is
mounted on the termination board. Cables with molded plugs connect the
termination board to the VME rack where the VCCC processor board is located, as
TBCI Contact Input Termination Board VCCC VME Board
x
x
x 37-pin "D" shell
x 1
JT1 type connectors
x 2 RUN
x 4
x 3 with latching FAIL
x 6
x 5 fasteners STAT
12 Contact x 7 JE1 JE2
x 8
Inputs x 10
x 9
x 12
x 14
x 13
x 16
x 15
x 18
x 17
x 20
x 19 JS1
x 21 Cable to VME
x 22
x 24
x 23 Rack T
x
x
x 25 Cable to VME
x 26
x 28
x 27 Rack S
x 29
12 Contact x 30
x 32
x 31
Inputs x 33 JR1
x 34
x 36
x 35
x 38
x 37
x 40
x 39 Cable to VME VCCC
x 42
x 41 Rack R x
x 44
x 43
x 46
x 45
x 47 Connectors on J3 J3
x 48
x VME Rack R
x
Shield
Bar
J4 J4

from board for maintenance
To Relay
Output Boards
Cable from
Second TBCI
Figure 9-22. Contact Input Termination Board, I/O Board, & Cabling

Contact Input Board Operation
The VCCC passes the input voltages through optical isolators and transfers the
signals over the VME backplane to the VCMI. The VCMI then sends them to the
Mark VI controller. The contact input processing is shown in Figure 9-23.
The dry contact inputs can be powered from either a floating 125 V dc (100-145 V
dc) supply or an optional floating 24 V dc (16-32 V dc) supply from the turbine
control. The latter is a low voltage form of TBCI. The supply is created from power
converters which convert the 115/230 V ac and/or 125 V dc power sources to a
redundant, internal 125 V dc bus to power the electronics. The 125 V dc bus is
current limited in the Power Distribution Module prior to feeding each contact input.
Optional power converter(s) can be supplied to convert the 125 V dc bus to a floating
24 V dc bus for feeding field contacts.
Termination Board TBCI <R> Rack
Contact Input Board VCCC

JE1
(+) Floating
From Power (-)
Distribution
Gate
Module <PDM> JE2
24 Vdc or
(+) Gate
125 Vdc Total of 48 circuits
(-) P5
Power Source J3
JR1 Gate
Sup.
(+) Gate
(-) Ref.
Gate
Field Contact Sup.
(+)
Gate
(-) Optical Isolation
Field Contact Gate
(+) Sup. J4
(-)
Field Contact Sup.
(+)
(-)
Field Contact
Sup.
(+)
(-)
Field Contact
Sup.
(+)
(-)
Contact Inputs from Second
TBCI Termination Board
Field Contact
24 Contact Inputs per
Termination Board
Figure 9-23. Contact Input Processing, SMX

A pair of termination points is provided for each input with one point (screw)
providing the positive dc source and the second point providing the return (input) to
the board. The current loading is 2.5 mA per point for 21 of the inputs on each
termination board, and the other three have a 10 mA load to support interface with
remote solid-state output electronics. Each input is optically isolated and sampled at
frame rate for control functions, and at 1ms for sequence of events (SOE) reporting.
A 4 ms hardware filter is used, and noise rejection is 60 V rms at 125 V dc
excitation. Contact input circuitry is designed for NEMA Class G creepage and
clearance.
For TMR applications contact input voltages are fanned out to three VME board
racks R, S, and T via plugs JR1, JS1, and JT1, as shown in Figure 9-24. The signals
are processed by the three VCCC and the results voted by the VCMI board in each
controller rack.
<T> VME Racks

Termination Board TBCI <S>
<R>
Contact Input Board VCCC
JE1
From Power (+) Floating
Distribution (-) Shown for <R>
Module Gate
<PDM> JE2
24 Vdc or (+) Gate
125 Vdc (-) Total of 48 circuits
P5
Power Source JR1 J3 Gate
(+) Sup.
Gate
(-) Ref.
Gate
Field Contact Sup. JS1 J3
(+)
Gate
(-)
Optical Isolation
Field Contact Gate
(+) Sup.
JT1 J3
(-) J4
Field Contact From Second TBCI
(+) Sup.
(-)
Field Contact
(+) Sup.
(-) Each contact input
Field Contact terminates on one (1)
Sup. point and is fanned to
(+)
<R> <S> <T>
(-)
Field Contact 24 Contact Inputs per
Termination Board
Figure 9-24. Contact Input Processing, TMR

VCCC Features
Sequence of Events
High speed scanning and recording at 1 ms rate is available for inputs monitoring
important turbine variables. The sequence of events recorder reports all contact
openings and closures with a time resolution of 1 ms. Contact chatter and pulse
widths down to 6 ms are reported.
Noise Filtering
Filters reduce high frequency noise and suppress surge on each input near the point
of signal exit. Noise and contact bounce is filtered with a 4 ms filter. AC voltage
rejection (50/60 Hz) is 60 V rms with 125 V dc excitation, and 12 V rms with 24 V
dc excitation.
Front panel
Three LEDs at the top of the VCCC front panel provide status information. The
board.
Diagnostics
The dry (isolated) external contacts are monitored, and also the excitation voltage. If
the excitation drops to below 40% of the nominal voltage, a diagnostic alarm is set
and latched. All inputs associated with this TB are forced to the open contact (fail
safe) state. Any input that fails the diagnostic test is forced to the failsafe state.
If any one of the 48 inputs goes unhealthy a composite diagnostic alarm,
L3DIAG_VCCC occurs. Details of the individual diagnostics are available from the
Diagnostics

Table 9-16. VCCC Specification
Item Specification
Number of Channels 48 dry contact voltage input channels

(24 per termination board)
Excitation Voltage a: Nominal 125 V dc, floating, ranging from 100 to 145 Vdc
b: Nominal 24 V dc, floating, ranging from 16 to 32 V dc
Input Current a: For 125 V dc applications:

First 21 circuits draw 2.5 mA (50 kohms)
Last three circuits draw 10 mA (12.5 kohms)
b: For 24 V dc applications;
First 21 circuits draw 2.5 mA
Last three circuits draw 10 mA
Isolation Optical Isolation to 1500 Volts on all inputs
Input Filter Hardware filter, 4 ms
AC Voltage Rejection 60 V rms @ 50/60 Hz at 125 Vdc excitation
12 V rms @ 50/60 Hz at 24 V dc excitation
Frame Rate System dependent scan rate for control purposes
1,000 Hz scan rate for Sequence of Events monitoring
Power consumption 20.6 watts on the termination board
NA watts in the VCCC board
Fault detection Loss of contact input excitation voltage

Non-responding contact input in test mode
Unplugged cable

Like all I/O boards, the VCCC is configured using the toolbox. This software usually
runs on a data-highway connected CIMPLICITY station or workstation. The table
below summarizes configuration choices and defaults. Refer to GEH-6403 Control
System Toolbox for Configuring the Mark VI Turbine Controller.
Table 9-17. Typical VCCC Configuration
VCCC System Limits Select System Limits Enable, disable

J3A:IS200TBCIG1A Terminal board connected to VCCC from J3 Connected, not connected
J4A:IS200TBCIG1A Terminal board connected to VCCC from J4 Connected, not connected
Contact N: Contact Input Select contact input Used, Unused
Contact N: Signal Invert Select input logical inversion Normal, Invert
Contact N: Sequence of Events Select input for sequence of events scanning Enable, disable

Installation
The 24 dry contact inputs are wired directly to two I/O terminal blocks mounted on
the termination board. Each block is held down with two screws and has 24 terminals
accepting 12 AWG wires. A shield termination strip attached to chassis ground is
located immediately to the left of each terminal block. The 125 V dc excitation
voltage is cabled in through plugs JE1 and JE2, as shown in Figure 9-25.
Contact Input Termination Board TBCI 1 1

JT1
x
3 3
Input 1 (Ret)
x 1 Input 1 (Pos) JE1 JE2
x 2
x 3 Input 2 (Pos)
Input 2 (Ret) x 4 Contact Excitation
x 5 Input 3 (Pos)
Input 3 (Ret) x 6 Source, 125 Vdc
x 7 Input 4 (Pos)
Input 4 (Ret) x 8
Input 5 (Ret)
x 9 Input 5 (Pos)
x 10
x 11 Input 6 (Pos)
Input 6 (Ret) x 12
x 13 Input 7 (Pos) To Rack T
Input 7 (Ret) x 14
Input 8 (Ret)
x 15 Input 8 (Pos)
x 16
Input 9 (Ret)
x 17 Input 9 (Pos)
x 18 JS1
x 19 Input 10 (Pos)
Input 10 (Ret) x 20
x 21 Input 11 (Pos)
Input 11 (Ret) x 22
Input 12 (Ret) x 23 Input 12 (Pos)
x 24
x
x
x 25 Input 13 (Pos)
Input 13 (Ret) x 26
x 27 Input 14 (Pos)
Input 14 (Ret) x 28
Input 15 (Ret)
x 29 Input 15 (Pos) To Rack S
x 30
Input 16 (Ret)
x 31 Input 16 (Pos)
x 32 JR1
x 33 Input 17 (Pos)
Input 17 (Ret) x 34
x 35 Input 18 (Pos)
Input 18 (Ret) x 36
x 37 Input 19 (Pos)
Input 19 (Ret) x 38
Input 20 (Ret)
x 39 Input 20 (Pos)
x 40
x 41 Input 21 (Pos)
Input 21 (Ret) x 42
x 43 Input 22 (Pos)
Input 22 (Ret) x 44 Inputs 22, 23,
Input 23 (Ret)
x 45 Input 23 (Pos)
x 46 24 are 10 ma
Input 24 (Ret)
x 47 Input 24 (Pos)
x 48
x
To Rack R
Terminal Blocks can be unplugged

from terminal board for maintenance
Up to two #12 AWG wires per

point with 300 volt insulation
Figure 9-25. TBCI Termination Board Wiring

Isolated Digital Inputs TICI
The Isolated Digital Input termination board (TICI) is a new board which works with
VCCC (and VCRC) in a similar way to TBCI. TICI provides voltage detection
circuits to detect a range of voltages across relay contacts, fuses, and switches.
Features
The TICI is similar to the TBCI, except for the following items:
• TICI input voltage ranges are:
- 16-32 V dc, nominal 24 V dc
- 90-132 V rms, nominal 15 V rms, 47-63 Hz
- 190-264 V rms, nominal 230 V rms, 47-63 Hz
• Input hardware filtering is provided using time delays of 10 msec, nominal. In
addition, the contact input state is software filtered using configurable time
delays.
Refer to the section Contact Inputs TBCI for information on the VCCC board.

Relay Outputs TRLY
The VME Contact Input/Relay Output Board (VCCC) with its associated daughter
board controls 24 relay/solenoid outputs. VCCC is a double width module and
connects to two sets of J3/J4 plugs via the VME backplane as shown in Figure 9-26
below. The main board controls 12 relays via the Relay Output Termination Board
(TRLY). Two TRLY boards are required for a total of 24 relays.
VME Rack
J1
VCCC
VCCC Daughter Board
Board
J2 J2
Backplane Cable Connectors Backplane Wiring

J3 J3
J4 J4
Termination Boards
TB3 JF1 JF2 TB3 JF1 JF2 JE1 JE2 JE1 JE2
Power Plugs Power Plugs Power Plugs Power Plugs
TRLY JT1 TRLY JT1 TBCI JT1 TBCI JT1

Relay/ Relay/ Contact Contact
Sol Sol Inputs JS1 Inputs JS1
Outputs JS1 Outputs JS1 24 per 24 per
12 per 12 per board board
board board
JA1 JA1 JR JR
Power Power
1 1
JG1 JG1
Plug Plug
Figure 9-26. Cabling for Contact Inputs and Relay Outputs, SMX

TRLY holds twelve plug-in magnetic relays. A second board is required for output
relays 13-24. Cables with molded fittings connect the termination board to the VME
rack where the VCCC processor board is located, as shown in Figure 9-27. Plug JA1
is used for simplex systems, plugs JR1, JS1, and JT1 are for TMR systems.
Relay Output Termination Board TRLY VME Board VCCC

Solenoid
Power
TB3 X x
x JT1
x 2
x 1 RUN
JF1 JF2
x 4
x 3 FAIL
STAT
x 6
x 5 Cable to VME
x 8
x 7 Rack T
x 10
x 9
x 12
x 11
x 14
x 15 Fuses
x 16
x 18
x 17
x 20
x 19 JS1
x 22
x 21
x 24
x 23
x
Cable to VME
x Rack S
x 26
x 25 Output
28
x 27 Daughter
x
x 29
Relays
x 30 Board
x 32
x 31
x 33 JA1 JR1
x 34
x 36
x 35
x 38
x 37 Cable to VME
x 40
x 39 Rack R VCCC
x 42
x 41 x
x 44
x 43
46
x 45
x Connectors on J3 J3
x 48
x 47
VME Rack R
x x
Solenoid
Shield Power
Bar Cables to Relay J4 J4
Output Terminal
Boards
from board for maintenance To Second
TRLY
To Contact Input Board
Figure 9-27. Relay Output Termination Board, I/O Board, & Cabling

Relay Output Board Operation
Cables carry control signals from VCCC to TRLY through JA1, plus feedback
voltages from the monitor circuits. Relay drivers, fuses, and jumpers are mounted on
the relay board. The first six relay circuits can be jumper configured for either dry,
Form-C contact outputs, or to drive external solenoids. A standard 125 V dc or 115
V ac source, or an optional 24 V dc source, with on-board suppression can be
provided for solenoid power. This comes in on TB3, as shown in Figure 9-28. The
next five relays (7-11) are unpowered isolated Form-C contacts. Output 12 is an
isolated Form-C contact, used for ignition transformers, for example.
<R> Rack Relay Termination Board - TRLY

K# K# NO
VCCC
Relay Dry
Com
Output Contacts
Form-C
K#
NC
J3/4 JA1 P28V "5" of these circuits
Coil
K1
RD
Monitor
"12" of the above
circuits
Connectors Monitor
at bottom
of VME
Rack P125/24 Vdc FUX JPX K# K#
NO
TB3 Com
1 24 V dc or +
125 V dc or Field
Power 2 K#
115 V ac NC Solenoid -
Source 3 240 V ac
(20 Amp) 4
N125/24 Vdc FUY Sol
JF1 "6" of the above circuits
1 3.2 Amp
K# K# NO
Alternate slow-blow
3
Power
Source JF2 Com Special
1
(7Amp) Circuit
3 K#
NC
Available for
JG1
GT Ignition 1
Transformers Sol
3
(6 Amp at 120 Vac
"1" of the above circuit
3 Amp at 240 Vac)
Figure 9-28. Relay Output Processing, SMX

For TMR applications, relay control signals are fanned into TRLY from the three
VME board racks R, S, and T through plugs JR1, JS1, and JT1. These signals are
voted and the result controls the corresponding relay driver. Power for the solenoids
comes in from all three racks and is diode shared, as shown in Figure 9-29.
<T>
<S> Relay Termination Board - TRLY
<R>
K# K# NO
VCCC
Relay
Output Com Dry
Contact,
JA1 Form-C
K# NC
Shown for JR1
J3/4 P28V
<R> "5" of these circuits
JA1
Coil K1
J3/4 JS1 RD
Same for
<S>
Monitor
J3/4 JT1 "12" of the above circuits
Same for Monitor
<T>
FUX JPX K# K#
P125/24 V dc NO
TB3 Com
24 V dc or +
1
125 V dc or
Power 2 Field
115 V ac K#
NC Solenoid -
Source 3 240 V ac
(20 Amp) 4 FUY
N125/24 Vdc Sol
JF1 1 3.2 Amp "6" of the above circuits
K# K#
slow-blow NO
Alternate 3
Power
Source JF2 Com Special
1
(7Amp) Circuit
3 K#
NC
Available for
JG1
GT Ignition 1
Transformers 3 Sol
(6 Amp at 120 Vac "1" of these circuits
3 Amp at 240 Vac)
Figure 9-29. Relay Output Processing, TMR

VCCC-Relay Features
Relays are driven at the frame rate. For system powered solenoids, the excitation
voltage is monitored and an alarm is latched if this voltage drops below 12 V dc.
Each relay coil current is also monitored and if it does not agree with the control
signal an alarm is latched.
Relay Characteristics
Relays have a 3.0 Amp rating. The rated contact to contact voltage is 500 V ac for
one minute, and the rated coil to contact voltage is 1,500 V ac for one minute. The
typical time to operate is 10 ms.
Failsafe Outputs
The relay outputs have failsafe features so that when a cable is unplugged, the inputs
vote to de-energize the corresponding relays. Similarly, if communication with the
associated VME board is lost, the relays de-energize.
Front panel
Three LEDs at the top of the VCCC front panel provide status information. The
board.
serial number, board type, revision number, and the JA, JR, JS, JT plug location.
Diagnostics
The output of each relay (coil current) is monitored and checked against the
command, at the frame rate. If there is no agreement for two consecutive checks, an
alarm is latched. The solenoid excitation voltage is monitored downstream of the
fuses and an alarm is latched if it falls below 12 Volts (AC or DC).
If any one of the 12 outputs goes unhealthy a composite diagnostic alarm,

L3DIAG_VCCC occurs. Details of the individual diagnostics are available from the
Diagnostics.

Table 9-18. VCCC Relay Output Specification
Item Specification
Number of Relay Channels on 12 relays: 6 relays with optional solenoid driver voltages
one TRLY board 5 relays with dry contacts only
1 relay with 7 Amp rating
VCCC total is 24 relays on two TRLY boards
Rated Voltage on Relays a: Nominal 125 V dc or 24 V dc
b: Nominal 120 V ac or 240 V ac
Max Load Current a: 0.6 Amp for 125 V dc operation

b: 3.0 Amp for 24 V dc operation;
c: 3.0 Amp for 120/240 V ac, 50/60 Hz operation
Response Time On 10 ms typical
Response Time Off 10 ms typical
Contact Material Silver cad-oxide
Contact Life Electrical operations: 100,000

Mechanical operations: 10,000,000
Fault detection Loss of excitation current or relay coil current
Unplugged cable or loss of communication with VME
board

Like all I/O boards, the VCCC module is configured using the Control System
station or workstation. The table below summarizes the configuration choices and
defaults. Refer to GEH-6403 Control System Toolbox for Configuring the Mark VI
Turbine Controller.
Table 9-19. Typical VCCC Relay Configuration
VCCC System Limits Select System Limits Enable, disable

L3DIAG_VCCC Select Board Diagnostic Used, unused
J3:IC200TRLYG1A Termination Board 1 connected to VCCC via J3 Connected, not connected
J4:IC200TRLYG1A Termination Board 2 connected to VCCC via J4 Connected, not connected
Relay N: Select Relay Output (for relays 1-12) Used, Unused
Relay Output Select Relay N Used, Unused

Installation
The customer’s 12 solenoids are wired directly to two I/O terminal blocks mounted
on the termination board. Each block is held down with two screws and has 24
terminals accepting 12 AWG wires. A shield termination strip attached to chassis
ground is located immediately to the left of each terminal block. Solenoid power for
outputs 1-6 is wired to TB3, or alternatively to plugs JF1 or JF2, as shown in Figure
9-30. JG1 provides power to customer’s special solenoid, Output 12.
Solenoid Power Alternate Power

Customer Solenoid Return Power to Return from
Power to Solenoids Solenoids Solenoids
TB3 JF1 JF2

x x x x 1 1
Relay Output Termination Board TRLY
1 2 3 4
3 3
x
x 1 Output 01 (NC) Out 01
Output 01 (COM) x 2
x 3 Output 01 (NO) FU1 FU7 JP1
Output 01 (SOL) x 4
x 5 Output 02 (NC) Out 02
Output 02 (COM) x 6
x 7 Output 02 (NO)
Output 02 (SOL) x 8 FU2 FU8
x 9 Output 03 (NC) JP2 To Connectors
Powered, Output 03 (COM) x 10
Output 03 (SOL) x 11 Output 03 (NO) Out 03 JA1, JR1, JS1,
Fused x 12
Output 04 (COM) 14
x 13 Output 04 (NC) FU3 FU9 JP3 JT1
Solenoids x
Output 04 (SOL) 16
x 15 Output 04 (NO) Out 04
Form-C x
Output 05 (COM) x 17 Output 05 (NC) FU4 FU10 JP4
x 18
Output 05 (SOL) x 19 Output 05 (NO)
x 20 Out 05
Output 06 (COM) x 21 Output 06 (NC)
x 22
x 23 Output 06 (NO) FU5 FU11 JP5
Output 06 (SOL) x 24
x Out 06
FU6 FU12 JP6 Jumper
Fuses Jumpers Choices:
x Power (JPx) or
Output 07 (COM) x 25 Output 07 (NC) Dry Contact
x 26
x 27 Output 07 (NO) (Dry)
x 28
Dry Output 08 (COM) x 30
x 29 Output 08 (NC)
Contacts x 31 Output 08 (NO) To Connectors JA1, JR1, JS1, JT1
x 32
Form-C Output 09 (COM) x 33 Output 09 (NC)
x 34
x 36
x 35 Output 09 (NO)
Output 10 (COM) x 37 Output 10 (NC) JG1 Power to Circuit 12
x 38
x 40
x 39 Output 10 (NO)
x 41 Output 11 (NC) 1 Customer Power
Output 11 (COM) x 42
to Solenoid
Special x 43 Output 11 (NO) 2
x 44
Circuit, Output 12 (COM) x 45 Output 12 (NC)
x 46 3 Customer Return
Form-C, Output 12 (SOL)
x 47 Output 12 (NO)
x 48 from Solenoid
Ign. Xfmr. x 4
JF1, JF2, and JG1 are Power Plugs
Figure 9-30. TRLY Termination Board Wiring

Contact Input/Relay Output Board VCRC
The VCRC board has the same functionality as the VCCC board but takes up only
one VME slot. The VCCC daughter board is not required, and two front panel
connectors, J33 and J44, accommodate the contact inputs from the TBCI boards.
Relay outputs on TRLY use the J3 and J4 ports on the VME rack, as shown in Figure
9-31.
P1
VCRC
Single Width
Front Panel
P2
J33 37
J44 37
VME
J3 backplane
wiring
J4
Termination
Boards
JT1 JT1 JT1 JT1

TBCI TBCI TRLY TRLY
Contact Contact Relay/Sol Relay/Sol
Inputs Inputs Outputs Outputs
24 per JS1 24 per JS1 12 per JS1 12 per JS1
board board board board
JR1 JR1 JA1 JA1
Figure 9-31. VCRC with Boards and Cabling to Contact Inputs & Relay Outputs

The VCRC firmware, configuration, and specifications are the same as for the
VCCC board. Cabling to TBCI is shown in Figure 9-32.
TBCI Contact Input Termination Board VCRC VME Board
x
x
x
x 1 JT1
x 2 RUN
x 3 FAIL
x 4 STAT
x 6
x 5
12 Contact x 7 JE1 JE2
x 8
Inputs x 10
x 9 VME Bus to VCMI
x 12
x 11
x 14
x 13
x 16
x 15
x 18
x 17
x 20
x 19 JS1 Cable to VME J33
x 22
x 21
x 23 Rack T
x 24
x
x
x 25 Cable to VME
x 26 J44
x 28
x 27 Rack S
x 29
12Contact x 30
x 32
x 31
Inputs x 33 JR1
x 34
x 36
x 35 VCRC
x 38
x 37 x
x 40
x 39
x 41 Cable to VME
x 42 J3
x 44
x 43 Rack R
x 46
x 45
x 48
x 47
Connectors
x
x on VME
Rack R
J4
Shield Bar
Cable from Second TBCI
To Relay Output Boards
Figure 9-32. VCRC with Contact Input Board and Cabling

Servo/LVDT TSVO
The Servo Board (VSVO) controls four electrohydraulic servo-valves that actuate
the steam/fuel valves. These four channels are divided between two termination
boards, TSVO. Valve position is measured with linear variable differential
transformers (LVDT). Three cables to VSVO use the J5 plug on the front of the
board and the J3/4 connectors on the VME rack, as shown in Figure 9-33. TSVO
provides simplex signals via the JR1 connectors, and fans out TMR signals to the JR,
JS, and JT connectors. Plugs JD1 or JD2 are for an external trip from the protection
module.
TSVO Termination Board VSVO VME Board

External
trip
x
x
x
x 1 JT1
x 2 37-pin "D" shell RUN
x 4 x 3 FAIL
x 5 JD1 type connectors STAT
x 6
x 8 x 7 with latching
x 10 x 9 JD2 fasteners
x 12 x 11
x 14 x 13
x 16
x 18 x 17
x 20 x 19 JT5 JS1 Cables to VME
x 22 x 21 Rack T
x 24 x 23
x
x
x 26 x 25 JS5
x 28 x 27 Cables to VME
x 30 x 29 Rack S
x 32 x 31
x 34 x 33 JR1
x 36 x 35
x 38 x 37 JR5
x 40 x 39 VSVO
x 42 x 41 x
x 44 x 43
x 46 x 45
x 47 J3
x 48
x
x
Shield Connectors on
Bar VME Rack R J4

From Second TSVO
Figure 9-33. Servo/LVDT Termination Board, Processor Board, and Cabling

Servo Board Operation
The servo board provides four channels each consisting of bi-directional current
outputs to drive the servo coils, LVDT position feedback, LVDT excitation, and
active pulse rate flow inputs. The TSVO provides excitation for, and accepts inputs
from, up to six LVDT valve position inputs. This provides a choice of either one,
two, three, or four LVDTs for each servo control loop. If three inputs are used they
are voted in a median selector. Two pulse rate inputs are available for gas turbine
flow measuring applications, and these signals connect directly to the VSVO board
front at J5. These inputs are shown in Figure 9-34, and the outputs in Figure 9-35.
Each servo output is equipped with an individual suicide relay under firmware
control that will short the VSVO output to signal common when de-energized, and
recover to nominal limits after a manual reset command is issued. Diagnostics
monitor the output status of each servo voltage, current, and suicide relay.
<R> Control Module

Capacity
6 LV D T / R i n p ut s (4 d u a l s e c o n d a ry Controller
windings), and 2 active magnetic pickups Application Software
on each of 2 Termination Boards
Termination Servo Board

Board TSVO VSVO
LVDT 1 JR1 J3
A/D Regulator
3.2k Hz, 7 V rms
Excitation Source 6 Ckts.
Connector at
2 bottom of D/A
VME rack
or LVDR Servo Driver P28V J3
Voltage
Limit
Suicide
Current P28V Relay
P24V 41 Limit
Configurable
Gain To Servo
42
Pulse Rate Outputs
JR5 J5 3.2KHz
Inputs 43
Pulse Excitation To TSVO
Active Probes PR Rate
44
0 - 12 k Hz To
P24V 45 CL Connector
Second
Only available on on front of
TSVO
1 of 2 TSVOs 46 VSVO board
47
Pulse Rate
Inputs PR 48
Active Probes Noise Suppr.
0 - 12 k Hz
Figure 9-34. LVDT and Pulse Rate Inputs, SMX

Each of the servo output channels can drive either one or two-coil servos in Simplex
applications, or two or three-coil servos in TMR applications. The two-coil TMR
applications are for 200# oil gear systems where each of two control modules drive
one coil each, and the third control module has no servo coil interface. Servo cable
lengths up to 300 meters (984 feet) are supported with a maximum two-way cable
resistance of 15 ohms. Since there are many types of servo coils, a variety of bi-
directional current sources are jumper selectable, as shown in Figure 9-35.
The primary and emergency Another trip override relay K1 is provided on each termination board which is driven
overspeed systems will trip from the Protection Module. If an emergency overspeed condition is detected in
the hydraulic solenoids the Protection Module, the K1 relay will energize and disconnect the VSVO servo
independent of this circuit output from the terminal block and apply a bias to drive the control valve closed.
This is only used on Simplex applications to protect against the servo amplifier
failing high, and is functional only with respect to the servo coils driven from <R>.
<R>
Controller
Servo Board Termination Board

VSVO TSVO
Range
10,20,40,80,120 ma
K1 JD1
P28VR Trip input
A/D Regulator 1 from 
2
From Module(J1)
LVDT JD2
D/A JP1
TSVO 120B
1 Servo coil
Servo Driver 120 2 driven from
J3 P28V JR1 80
25
Voltage 40 <R>
Limit 20
10 31
S
Suicide
U 22 ohms
P 1k
P28V Relay 2 Ckts. 89 ohms
ohm
26 1k ohm
Configurable
Gain
17 3.2KHz,
J5 3.2KHz JR5 7V rms
S
Pulse Excitation 2 Ckts. U Excitation
Rate P 18
Source
To for
Connector on
Second LVDTs
front of VSVO TSVO
Figure 9-35. Servo Coil and LVDT Outputs, SMX

Only two pulse rate probes on In TMR applications the LVDT signals on TSVO fan out to three racks via JR1, JS1,
one TSVO are used and JT1, as shown in Figure 9-36. These connectors also bring power into TSVO.
Here the three voltages are diode high-selected and current limited to supply 24 V dc
to the pulse rate active probes.
<R>
<S>
<T>
Controller
Termination Servo Board

Board TSVO VSVO
LVDT 1 JR1 J3
3.2k Hz, A/D Regulator
7 V rms
6 Ckts.
Excitation
2 JS1 J3
Source P28V D/A
Same for <S>
Servo Driver To Servo
Voltage
JT1 J3 Limit Outputs
P28V on TSVO
Same for <T>
Diode Select
P24V 41 CL Connector on Configurable
front of VSVO Gain
42 card in <R>
Pulse Rate JR5 J5 To TSVO
Inputs 43 3.2KHz
Pulse Excitation
Active Probes PR 44 Rate
0 - 12 k Hz
P24V 45 CL JS5 J5 in <S>
Only available
on 1 of 2 46
TSVOs JT5
47 J5 in <T>
Pulse Rate PR 48
Inputs
Active Probes
0 - 12 k Hz
Noise Suppr.
Figure 9-36. LVDT and Pulse Rate Inputs, TMR

For TMR systems, each servo channel has connections to three output coils with a
range of current ratings up to 120 mA, selected by jumper, as shown in Figure 9-37.
<R>
<S>
<T>
Controller
Termination Board
Servo Board TSVO
VSVO Servo Current Range
10,20,40,80,120 ma
JD1
A/D Regulator P28VR Trip input from
1
JS1 2 Not Used for
From Suicide JT1 TMR
TSVO JD2
D/A Relay JP1
LVDT 120B
1
Servo Driver P28V JR1 120 2 Servo coil driven

J3 80
Voltage 40
25 from <R>
Limit 20
10 31
S
U 22 ohms
P
P28V 2 Ckts. 89 ohms
26 1k ohm
Configurable
Gain
J5 17 3.2KHz,
3.2KHz JR5
Pulse
S 7V rms
Excitation 2 Ckts. U
Excitation
Rate P 18
Source
Connector on J3 JS1 JP2 For LVDTs
front of VSVO 120B
120 Servo coil driven
card 80
40
27 from <S>
20
10 S
U
P
2 Ckts. 28
21 3.2KHz,
S 7V rms
1 Ckt. U
Excitation
P 22
Source
J3 JT1 JP3 For LVDTs
120B
120 Servo coil driven
80
40
29 from <T>
20
10 S
U
P
2 Ckts. 30
23
3.2KHz,
S
1 Ckt. U 7V rms
P 24 Excitation
Source
For LVDTs
.
Figure 9-37. Servo Coil Outputs and LVDT Excitation, TMR

In the following four drawings, the first two examples use LVDT sensors, and the
third uses flow sensing (pulses); note the different regulator types. The monitor
circuit allows the LVDTs to be viewed online, for example on the toolbox screen.
Mark VI VSVO Servo Regulator with LVDT Feedback

VSVO
Insert Regulator (IO Config) Software Hardware
RegNumber Reg3 (exam) 200 hz, 4 Regulators per card TSVO #1
EnableCurSuic
Suicide
I/O EnableFdbkSuic Function
Config RegType 3_LVposMID (exam)
SuicideForce
DitherAmpl Servo
RegNullBias RD JR1 coil;
Suicide
RegGain Current JS1 positive
Regn_GainMod not used Gain Driver P2 J3 JT1 current to
D shutdown
++
Regn_Ref I D/A Ref1 +
+- X + D/A
+ T Dedicated
Regn_Error H total connection
Regn_NullCor of 4 R
ccts 2 ccts per S
CalibEnabn T
Calib TB per
function Servo_MA_Out
Controller
Regn_suicide L Suicide
o LVDT
g
ServoOutputn i Fan
Signal c Connection
Space
SuicideForce
6 ccts per
TB
JR5
JS5
JT5
LVDT1input Not used,

A/D
Regn_Fdbk Mid LVDT2input Fan VSVO has
LVDT1 Connection
Sel LVDT3input only one P5
+ X
-+ LVDT2 connector
PilotFdbkn not used +
LVDT3
2 ccts per
LVDT4
MinPosvalue TB
Gain LVDT5
MaxPosvalue LVDT6
LVDT TSVO #2
MnLVDT3_Vrms LVDT7 total
I/O Scaling Offset
MxLVDT3_Vrms LVDT8 of 12
Config Function
LVDT9 LVDT
LVDT10 ccts
LVDT_Margin LVDT11
Diag, Suicide
LVDT12 Servo
Servo_MA_Out coil;
JR1
JS1 positive
LVDT1input LVDT2, (exam) J4 JT1 current to
shutdown
LVDT +
LVDT2input LVDT5 Dedicated
input
selections connection
LVDT3input LVDT6 R
2 ccts per S
T
TB per
Controller
I/O PRType
Config LVDT
PRScale
Fan
Signal FlowRate1 flow hz PR/D Connection
Space
6 ccts per
I/O PRType TB
Config JR5
PRScale
JS5
P5 JT5
Signal FlowRate2 flow hz PR/D Pulse Rate
Space Pickup
Fan
Connection
second PR cct 2 ccts per

TB
Notes:
1: where "n" in signal space has values 1 to 4 (i.e. four regulators)
Figure 9-38. Servo Regulator with LVDT feedback

VSVO
Insert Regulator (IO Config) Software Hardware
EnableCurSuic Suicide
Suicide
Config RegType 2_LV_LM_ACT (exam) SuicideForce
DitherAmpl Servo
CurClpNg, CurClpPs coil;
Tau1, Tau2 RD Suicide JR1 positive
RegNullBias Current JS1
C current to
RegGain Driver P2 J3 JT1
L D shutdown
CurBreak
+ + Ld A I D/A Ref1 +
Lg D/A
CurSlope1,CurSlope2 M T Dedicated
Regn_GainMod not used Gain P H total connection
Regn_Ref of 4 R
+- x + ccts 2 ccts per S
Regn_Error + T
TB per
Regn_NullCor Servo_MA_Out
Controller
Gain
CalibEnabn Calib
L Suicide
function LVDT
Regn_suicide o
g
ServoOutputn i Fan
Signal Connection
SuicideForce Position sel (avg, min,max) c
Space
SelectMnMx
6 ccts
DefltValue JR5 per TB
Regn_Fdbk posit’n
JS5
select
JT5
PilotFdbkn not used Posa LVDT1input
MasterReset, VCMI LVDT2input Not used,
A/D VSVO
PosaFail Posb LVDT3input Fan
A-B A LVDT1 has only
PosbFail + X
-+ A+B B LVDT4input
Connection
+ LVDT2 one P5
LVDT3 connector
PosDiffEnab 2 ccts
LVDT4
PosDiffFail1 per TB
LVDT5
PosDiffFail2 LVDT6
LVDT7 total TSVO #2
Gain Posa
MinPosvalue LVDT8 of 12
Posb LVDT
MaxPosvalue LVDT9
LVDT PosDiffCmp1 LVDT10 ccts
MnLVDT3_Vrms PosDiffTime1 LVDT11
Scaling Offset
MxLVDT3_Vrms Function LVDT12 Servo
PosDiffCmp2
MnLVDT4_Vrms coil;
PosDiffTime2 JR1
MxLVDT4_Vrms Diag positive
JS1 current to
Learned Suicide J4 JT1
LVDT_Margin shutdown
limit Position sel
LVDTVsumMarg +
I/O checks
PosaFail Dedicated
Config PosSelect with PosbFail connection
latching PosDiffFail1 R
MasterReset PosDiffFail2 2 ccts per S
Servo_MA_Out T
PosDefltEnab TB per
PosDiffEnab Controller
LVDT1input LVDT5, (exam)
LVDT2input LVDT6 PosSelect
LVDT
LVDT3input LVDT7 LVDT
LVDT4input LVDT8 input Fan
SelectMnMx selections Connection
DefltValue
PosDefltEnab 6 ccts
PosDiffCmp1 per TB
PosDiffTime1
PosDiffCmp2
PosDiffTime2
PRType JR5
I/O JS5
Config PRScale
P5 JT5 Pulse
Rate
Signal FlowRate1 flow hz PR/D PR condit’n cct Pickup
Space
Fan
Connection
PRType
I/O
Config PRScale
2 ccts
Signal FlowRate2 flow hz PR/D
per TB
Space second PR cct
Notes:
Figure 9-39. Servo Regulator with LVDT Feedback

Mark VI VSVO Servo Regulator with PR Feedback
VSVO
Insert Regulator (IO Config) Software Hareware
EnableCurSuic
Suicide
Config RegType 2_PulseRateMax(exam)
SuicideForce
DitherAmpl Servo
RegNullBias RD JR1 coil;
Suicide
RegGain Current JS1 positive
Regn_GainMod not used Gain Driver P2 J3 JT1 current to
D shutdown
++
Regn_Ref I D/A Ref1 +
+- X + D/A
+ T Dedicated
Regn_Error H total connection
Regn_NullCor of 4 R
ccts 2 ccts per S
CalibEnabn T
Calib TB per
function Servo_MA_Out
Controller
Regn_suicide L Suicide
o LVDT
g
ServoOutputn i Fan
Signal c Connection
Space
SuicideForce
6 ccts per
TB
JR5
JS5
JT5
PRateinput1 A/D Not used,

Regn_Fdbk Max Fan VSVO has
PRateinput2 LVDT1
Sel Connection only one P5
LVDT2 connector
PilotFdbkn not used
LVDT3
2 ccts per
LVDT4
TB
LVDT5
LVDT6
LVDT7 total TSVO #2
LVDT8 of 12
Servo_MA_Out LVDT9 LVDT
LVDT10 ccts
LVDT11
LVDT12 Servo
JR1 coil;
JS1 positive
PRateinput1 PR1 (exam) J4 JT1 current to
shutdown
I/O PR +
Config PRateInput2 PR2 Dedicated
input
R
2 ccts per S
T
TB per
Controller
PRType
LVDT
PRScale
Fan
Signal FlowRate1 flow hz PR/D PR1 Connection
Space
6 ccts per
I/O PRType TB
Config JR5
PRScale
JS5
P5 JT5
Signal FlowRate2 flow hz PR/D PR2 Pulse Rate
Space Pickup
Fan
Connection

TB
Notes:
Figure 9-40. Servo Regulator with Pulse Rate Feedback

Mark VI VSVO Monitor
Software Hardware
TSVO #1
VSVO
Servo
RD JR1 coil;
Suicide
Current JS1 positive
Driver P2 J3 JT1 current to
shutdown
D/A
+
Dedicated
total connection
of 4 R
ccts 2 ccts per S
T
TB per
Controller
Insert Monitor (IO Config)
100 hz,up to 16 Monitors per card L Suicide
o LVDT
g
i Fan
I/O MonitorType 3_LVposMID (exam) c Connection
Config
6 ccts per
JR5 TB
JS5
JT5
LVDT1input Not used,

A/D
Signal Monn Mid LVDT2input Fan VSVO has
Space LVDT1 Connection
Sel LVDT3input only one P5
+ X
-+ LVDT2 connector
+
LVDT3
2 ccts per
LVDT4
MinPosvalue TB
Gain LVDT5
MaxPosvalue LVDT6
LVDT TSVO #2
MnLVDT3_Vrms LVDT7 total
I/O Scaling Offset
MxLVDT3_Vrms LVDT8 of 12
Config Function
LVDT9 LVDT
LVDT10 ccts
LVDT_Margin LVDT11
Diag, Suicide
LVDT12 Servo
JR1 coil;
JS1 positive
LVDT1input LVDT2, (exam) J4 JT1 current to
shutdown
LVDT +
LVDT2input LVDT5 Dedicated
input
LVDT3input LVDT6 R
2 ccts per S
T
TB per
Controller
PRType
LVDT
PRScale
Fan
FlowRate1 flow hz PR/D Connection
6 ccts per
PRType TB
JR5
PRScale JS5
P5 JT5
FlowRate2 flow hz PR/D Pulse Rate
Pickup
Fan
Connection

TB
Notes:
1: where "n" in signal space has values 1 to 16 (i.e. up to 16 monitors)
Figure 9-41. Servo Monitor

VSVO Features
The range of servo coil ratings that can be jumper selected are as follows:
Table 9-20. Servo Coil Ratings
Coil Type Nominal Current Coil resistance Application
1 +/- 10 mA 1,000 ohms Simplex & TMR

2 +/- 20 mA 125 ohms Simplex
3 +/- 40 mA 62 mA Simplex
4 +/- 40 mA 89 ohms TMR
5 +/- 80 mA 22 ohms TMR
6 +/- 120 mA (A) 40 ohms Simplex
7 +/- 120 mA (B) 75 ohms TMR
Regulation of the output current is within 2% of the nominal full scale, when
properly configured and loaded for the coil resistance specified in the previous table.
Resolution over the full scale range is 12 bits. Servo coil inductance is not a
specified parameter, but it is nominally less than 5 Henries.
Control Valve Position Feedback
Valve position is sensed with either a four wire LVDT or a three-wire linear variable
differential reluctance (LVDR). Redundancy implementations for the feedback
devices is determined by the application software to allow the maximum flexibility.
LVDT/Rs can be mounted up to 300 meters (984 feet) from the turbine control with
a maximum two-way cable resistance of 15 ohms.
Two LVDT/R excitation sources are located on each termination board for Simplex
applications and another two for TMR applications. Excitation voltage is 7 V rms
and the frequency is 3.2 kHz with a total harmonic distortion of less than 1% when
loaded. The excitation source is isolated from signal common (floating), and is
capable of operation at common mode voltages up to 35 Vdc, or 25 Vrms, 50/60 Hz.
A typical LVDT/R has an output of 0.7 V rms as the zero stroke position of the valve
stem, and an output of 3.5 V rms at the designed maximum stroke position (some
applications have these reversed). The LVDT/R input is converted to dc and
conditioned with a low pass filter. Diagnostics perform a high/low (hardware) limit
check on the input signal and a high/low system (software) limit check. The software
limit check is adjustable in the field.
Pulse Rate Inputs

Two pulse rate inputs are cabled to a single J5 connector on the VSVO board front.
This is a dedicated connection to minimize noise sensitivity on the pulse rate inputs.
Inputs support both passive magnetic pickups and active pulse rate transducers (TTL
type) interchangeably without configuration. Normally, these inputs are not used on
steam turbine applications, but usually for monitoring flow divider feedback in some
gas turbine applications with liquid fuel. Pulse rate inputs can be located up to 300
meters (984 feet) from the turbine control cabinet; this assumes shielded-pair cable is
used with typically 70 nF single-ended or 35 nF differential capacitance and 15 ohms
resistance.
A frequency range of 2 to 12 kHz can be monitored at a normal sampling rate of
either 10 or 20 ms.

Magnetic pickups typically have an output resistance of 200 ohms and an inductance
of 85 mH excluding cable characteristics. The transducer is a high impedance source,
generating energy levels insufficient to cause a spark. The maximum short circuit
current is approximately 100 mA with a maximum power output of 1 watt.
LVDT Auto Calibration

A semi-automatic procedure can be used to calibrate the valve mounted LVDTs. A
series of commands are made from the LVDT/R Calibration dialog box in the
toolbox. This is shown below, and is found in the Outline View under the
appropriate VSVO board. Right click Regulator N, select Modify, and go Online.
View Position
Gain & Offset
Force Actuator to Constants for
Minimum End Position each LVDT
(positive current,
shutdown) Calibrate; the
System Learns
the Voltage
Force Actuator to Ranges for
Maximum End future use
Position (negative
current, maximum Save the
capacity) Measured Values
to Controller
Fix; take the Flash Memory
Measured Values
Verify
Performance by
Actual Values for all
Stroking the
Regulators
Actuator under
Manual Control,
Position
Regulator 1 Reference (Setpt.)
Ramping,
Regulator 1 Feedback (LVDT)
or Step Current
Servo 1 Output Current (ma)
Regulator 1 Null Error
Regulator 1 Null Correction Manual Entry of
Actuator Position
Figure 9-42. LVDT Auto Calibration Screen on the Toolbox
Calibrate Sequence. The Min End Position command is sent to the VSVO board,
which checks the permissive logic, then manipulates the valve current reference to
the servo valve. The servo valve drives the actuator to its end stop where the LVDT
voltage is read. Clicking the Max End Position button causes the actuator to be
driven to the other end stop where the LVDT voltage is read again. The difference
represents a known stroke. These voltage fixes are used in conjunction with the I/O
configuration definition of the end stops to map the LVDT voltages into the actuator
stroke, in engineering units. The normal voltage range is learned during the
calibration, a margin is added, and the result is used for suicide and diagnostic limits.

By selecting Calibration Mode-On, a full-screen real time trend of current and valve
position displays. This is used to verify the LVDT calibration and the performance of
the actuator.
Verification. There are three ways provided to verify servo performance through
stroking the actuator. They are manual, position ramping, and step current. In manual
mode the desired value is entered numerically and the performance monitored on the
trend display. Selecting Verify Position applies a ramp to the actuator, and selecting
Verify Current applies a step input to the actuator. The trend display shows any
abnormalities in the actuator stroke.
Front panel
Three LEDs at the top of the VSVO front panel provide status information. The
normally off but displays a steady orange if an alarm condition exists in the board.
Connectors JR1, JS1, JT1 on the termination board have their own ID device which
is interrogated by the I/O board. The ID device is a read-only chip coded with the
terminal board serial number, board type, revision number, and the plug location.
Table 9-21. TSVO Specification
Item Specification
Number of Inputs (per TSVO) 6 LVDT windings

2 Pulse Rate signals (total of 2 per VSVO)
External trip signal
Number of Outputs (per TSVO) 2 Servo Valves, (total of 4 per VSVO board)
4 Excitation Sources for LVDTs
2 Excitation Sources for Pulse Rate transducers
Power Supply Voltage Nominal 24 V dc
LVDT Accuracy 1 % with 14-bit resolution
LVDT Input Filter Low pass filter with 3 down breaks at 50 rad/sec (80 Hz)
LVDT Input Noise Rejection AC common mode rejection (CMR) is 60 dB at 50/60 Hz
DC common mode rejection (CMR) is 80 dB
Pulse Rate Accuracy 0.05% of reading with 16-bit resolution
Noise of acceleration measurement is less than ± 50
Hz/sec for a 10,000 Hz signal being read at 10 ms
Pulse Rate Input Minimum signal for proper measurement at 2 Hz is
33 mVpk, and at 12 kKz is 827 mVpk.
Magnetic PR Pickup Signal Generates 150 V p-p into 60 K ohms
Active PR Pickup Signal Generates 5 to 27 V p-p into 60 K ohms
Servo Valve Output Accuracy 2% with 12-bit resolution
LVDT Excitation Output Frequency of 3.2 +/- 0.2 kHz
Voltage of 7.00 +/- 0.07 V rms
Fault detection Suicide servo outputs initiated by:
a: Servo Current out of limits or not responding
b: Regulator Feedback signal out of limits

Diagnostics
Servo diagnostics cover items such as out of range LVDT voltage, servo suicide,
servo current open circuit, and short circuit. If any one of the signals goes unhealthy
a composite diagnostic alarm, L3DIAG_VSVO occurs. Details of the individual
diagnostics are available from the toolbox. The diagnostic signals can be individually
latched, and then reset with the RESET_DIA signal if they go healthy. Refer to

Like all I/O boards, the VSVO module is configured using the toolbox. This software
usually runs on a data-highway connected CIMPLICITY station or workstation.
Table 9-23 summarizes the configuration choices and defaults. For details refer to
GEH-6403 Control System Toolbox for Configuring the Mark VI Turbine Controller.

Table 9-22. Typical VSVO Configuration
VSVO System Limits Select System Limits Enable, disable

Regulator 1 Online LVDT calibration
RegType Algorithm used in the regulator Unused, 1_PulseRate
2_PlsRateMAX, 1_LVPosition
2_LV_PosMIN, 2_LV_PosMID
2_LvpilotCyl, 4_LVp/cylMAX
2_LV_LM_ACT, 2_LV_LM_FMV
2_LV_LM-LFP 2_LV_posMAX
RegGain Position Loop Gain in (%Current/%position) -100 to 100
RegNullBias Null Bias in % current, Balances Servo -100 to 100
Spring Force
Dither Dither in % Current (minimizes hysteresis) Dither Amp: 0 to 10
Monitor 1
Monitor Type Monitor Algorithm Unused,
1_LVposition
2_LVposMIN, 2_LVposMAX
3_LVposMID,
1_LVposRatio
2_LVposRatio
J3 Terminal Board 1 connected to VSVO via J3 Connected, not connected
J4 Terminal Board 2 connected to VSVO via J4 Connected, not connected
Servo Output N Servo current output wired to valve Point Edit
Reg Number Identify Regulator Number Unused, Reg1, Reg2, Reg3, Reg4
Servo_MA_Out Select current output for coil windings 10, 20, 40, 80, 120 mA
EnableCurSuic Select Suicide function based on current Enable, Disable
Curr_Suicide Percent current error to initiate suicide 0 to 100% (output current error)
EnablFbkSuic Select Suicide function based on feedback Enable, Disable
Fdbk_Suicide Percent position error to initiate suicide 0 to 100% (actuator position error)
J5:I200TSVOG1A Pulse Rate inputs cabled to J5 connector Connected, Not connected
FlowRateN Pulse rate input selected Point edit
PRType Select Speed or Flow type signal Unused, Speed, or Flow
PRScale Convert Hz to Engineering Units 0 to 1,000
SysLim1Enabl Select System Limit Enable, Disable
SysLim1Latch Select whether alarm will latch Latch, Not Latch
SysLim1Type Select type of alarm initiation >= or <=
SysLimit Select alarm level in GPM or RPM 0 to 12,000
TMR_DiffLimt Difference Limit for voted pulse inputs (EU) 0 to 12,000

Installation
Sensors and servovalves are wired directly to two I/O terminal blocks mounted on
the termination board. Each block is held down with two screws and has 24 terminals
accepting 12 AWG wires. A shield termination strip attached to chassis ground is
located immediately to the left of each terminal block. External trip wiring is
plugged into either JD1 or JD2. The position choices for the servo current jumpers
are as shown in Figure 9-43.
Servo/LVDT Termination Board TSVO

1 External Trip from 
2 GND
x
x 1 LVDT 01 (H)
LVDT 01 (L) x 2 JD1 1 External Trip
x 3 LVDT 02 (H)
LVDT 02 (L) x 4
LVDT 03 (L) x 6
x 5 LVDT 03 (H) 2 GND
LVDT 04 (L) x 8
x 7 LVDT 04 (H)
x 9 LVDT 05 (H) JD2
LVDT 05 (L) x 10
LVDT 06 (L) x 12
x 11 LVDT 06 (H)
x 13
x 14
x 15
x 16 To Connectors
Exc R1 (L) x 17 Exc R1 (H)
x 18 JR5, JS5, JT5,
Exc R2 (L) x 19 Exc R2 (H)
x 20 JR1, JS1, JT1
Exc S (L) x 21 Exc S (H)
x 22
Exc T (L) x 24
x 23 Exc T (H)
x JP1 Servo 01 R
JP2 Servo 01 S
x
Servo 01 (RL) x 25 Servo 01 (RH) JP3 Servo 01 T

x 26
Servo 01 (SL) x 27 Servo 01 (SH)
x 28
Servo 01 (TL) x 30
x 29 Servo 01 (TH)
x 31 Servo 01 (SMXH) JP4 Servo 02 R
Servo 02(SMXH) x 32
Servo 02 (RL) x 34
x 33 Servo 02 (RH)
x 35 Servo 02 (SH) JP5 Servo 02 S
Servo 02 (SL) x 36
x 37 Servo 02 (TH)
Servo 02 (TL) x 38
x 39
x 40 JP6 Servo 02 T
Pulse 01 (24R) x 42
x 41 Pulse 01 (24V)
Jumper Choices:
x 43 Pulse 01 (H)
Pulse 01 (L) x 44 120B +/-120 ma (75 ohm coil)
x 45 Pulse 02 (24V)
Pulse 02 (24R) x 46 120A +/-120 ma (40 ohm coil)
Pulse 02 (L) x 47 Pulse 02 (H)
x 48 80 +/- 80 ma
x 40 +/- 40 ma
20 +/- 20 ma
10 +/- 10 ma
Up to two #12 AWG wires per Terminal Blocks can be unplugged

point with 300 volt insulation from terminal board for maintenance
Figure 9-43. Servo/LVDT Termination Board Wiring

Turbine Control TTUR
The VME Turbine Control Board (VTUR) controls the primary overspeed trip
solenoid and automatic synchronizing. It also interfaces to four pulse rate devices
(passive or active), and monitors shaft voltage and current. The speed signal cable to
VTUR uses the J5 plug on the front of the board, and the other signals use J3
connector on the VME rack. Termination board TTUR provides simplex signals
through the JR connector, and fans out TMR signals to the JR, JS, and JT connectors.
J4 on the VME rack connects to the TRPG termination board described in the
Primary Trip section. The cable connections are shown in Figure 9-44.
TTUR Termination Board VTUR VME Board
x
x 37-pin "D" shell
x
x 1 JT1 type connectors
x 2 RUN
x 4 x 3 with latching FAIL
x 6 x 5 fasteners STAT
x 8 x 7
x 10 x 9
x 12 x 11
x 14 x 13
x 16 x 15
x 20 x 19 JT5 JS1 Rack T
x 22 x 21
24 x 23
x VME Bus to VCMI
x
x
x 25 JS5
x 26
x 30 x 29 Rack S J
x 32 x 31 5
x 34 x 33 JR1
x 36 x 35
x 38 x 37 JR5
x 40 x 39 VTUR
x 42 x 41 x
x 44 x 43
x 46 x 45
x 47 J3
x 48
x
x
Shield Connectors on
Bar VME Rack R J4
Cable to TRPG
Figure 9-44. Turbine Control Termination Board, Processor Board, and Cabling

Turbine Board Operation
Three primary magnetic speed inputs are used for speed control and for the
overspeed trip signal. Pulse rate circuits and median selector are on the VTUR board.
Generator and bus voltages are brought into VTUR for automatic synchronizing in
conjunction with the turbine controller and GE excitation system. TTUR has
permissive generator synchronizing relays and controls the main breaker relay coil
52G. Shaft voltage is picked up with brushes and monitored along with the current to
the machine case. VTUR alarms high voltages and also provides ac and dc test
voltages to test the integrity and continuity of the external monitoring circuitry.
Generator Breaker 52G

<R> Control Rack
Feedback
a
Termination Board TTUR Turbine Termination Board TTUR 02 01
Board (continued)
JR1 J3 VTUR
17 28Vdc
J3 JR1 JP1
Gen. Volts Noise f()
TMR
120 V ac SMX K25P Synch. perm.
18 Suppr Pr/D Equival. 52Z
from PT MUX RD
A/D TMR JP2
AC&DC SMX K25 Close gener.
19 breaker
Line shaft RD
Volts Noise test
120 Vac 20 Suppr K25A Synch. check
from PT Equival. GXS
To
TPRO
21 Mon
Noise
175V 22 Suppr J5
08 06,7 05 04 03
MAN
AUTO
BKRH
Shaft
J4
23
Noise
14V P125Gen
Suppr To
24 Connectors
TRPG 52G
at bottom of
b
Machine Case JR5 VME rack
41 Bkr Coil
#1 Primary Filter
Magnetic Suppr. Clamp
42 AC
N125Gen
Speed PU Coupling
43
#2 Primary Filter
Magnetic Suppr. Clamp
44 AC
Speed PU Coupling Note: Signal to K25A
comes from TREG
#3 Primary 45 Filter through TRPG & VTUR
Clamp
Magnetic 46
Suppr.
AC
Speed PU Coupling
#4 Primary 47 Filter
Clamp
Magnetic Suppr.
AC
48
Speed PU Coupling
Figure 9-45. Turbine Control Inputs, Synchronizing, and Primary Trip Interface, SMX

In TMR applications all inputs fan out to the three control racks. Control signals
coming into TTUR from R, S, and T are voted before they actuate permissive relays
K25 and K25P. Relay K25A is controlled by the VPRO and TREG boards. All three
relays have two normally open contacts in series with the breaker coil. The TMR
arrangement is shown in Figure 9-46.
52G
Generator Breaker a
<T>
<S> Feedback
<R> Termination Board
02 01
Termination Board TTUR Turbine TTUR (continued)
Board
JR1 J3 VTUR
17 28Vdc
J3 JR1 JP1
Gen. Volts Noise f()
TMR
120 vac Suppr
SMX K25P Synch. perm.
18 Pr/D 2 Equival. 52Z
from PT MUX RD
J3 JS1 3
A/D TMR JP2
SMX K25 Close gener.
AC&DC 2
19 breaker
Line JS1 shaft RD
J3 JT1 3
Volts Noise test
120 vac 20 Suppr K25A Synch. check
from PT Equival. GXS
J5
To
TPRO
21 Mon
Noise JT1
175V 22 Suppr
08 06,7 05 04 03
J4
BKRH
MAN
AUTO
Shaft
23
To 52G
Noise Connectors
14V TRPG b P125Gen
Suppr at bottom of
24
VME rack Bkr Coil
Machine Case JR5 N125Gen
41
#1 Primary Filter
Clamp
Magnetic Suppr.
AC
42 Coupling
Speed PU
4 Circuits
JS5 Note: Signal to K25A
33
#2 Primary Filter
comes fromTREG
Magnetic Clamp via TRPG and VTUR
Suppr.
AC To Rack S
Speed PU 34 Coupling
4 Circuits
JT5
25
#3 Primary Filter
Clamp
Magnetic Suppr.
AC
To Rack T
26
Speed PU Coupling
4 Circuits
Figure 9-46. Turbine Control Inputs, Synchronizing, and Primary Trip Interface, TMR

Turbine Control Features
Speed Pickups
An interface is provided for four passive, magnetic speed inputs with a frequency
range of 2 to 14,000 Hz. The median speed signal is used for speed control and for
the primary overspeed trip signal. Using passive pickups on a sixty tooth wheel,
circuit sensitivity allows detection of 2 rpm turning gear speed to determine if the
turbine is stopped (zero speed). If automatic turning gear engagement is provided in
the turbine control, this signal initiates turning gear operation.
Shaft Voltage & Current Monitor

Bearings can be damaged by the flow of electrical current from the shaft to the case.
This current can occur for several reasons.
• A static voltage can be caused by droplets of water being thrown off the last
stage buckets in a steam turbine. This voltage will build up until a discharge
occurs through the bearing oil film.
• An ac ripple on the dc generator field can produce an ac voltage on the shaft
with respect to ground through the capacitance of the field winding and
insulation. Note that both of these sources are weak, so high impedance
instrumentation is used to measure these voltages with respect to ground.
• A voltage may be generated between the ends of the generator shaft due to
dis-symmetries in the generator magnetic circuits. If the insulated bearings
on the generator shaft break down, the current will flow from one end of the
shaft through the bearings and frame to the other end. Brushes can be used
to discharge damaging voltage buildup, and a shunt should be used to
monitor the current flow.
The turbine control continuously monitors the shaft to ground voltage and current,
and alarms excessive levels. There is an ac test mode and a dc test mode. The ac test
applies an ac voltage to test the integrity of the measuring circuit. The dc test checks
the continuity of the external circuit, including the brushes, turbine shaft, and the
interconnecting wire.
Primary Trip Solenoid Interface

VTUR sends a trip command to the TRPG termination board which contains
magnetic relays for interface with the Electrical Trip Devices (ETDs). The TRPG
works in conjunction with the TREG to form the Primary and Emergency sides of
the interface to the ETDs. Usually this applies to turbines which do not have a
mechanical overspeed bolt and require a separate emergency overspeed (EOS)
system. Three ETDs can be driven from each TRPG/TREG combination with the
positive side of each solenoid connected to the TREG and the negative side
connected to the TRPG. A metal oxide varister (MOV) and a current limiting resistor
are used in each circuit. Two different versions of the TRPG are available with
version “1” used for triple redundant (TMR) control systems and version “2” used
for Simplex control systems. The only difference is that the TMR version has three
voting relays per ETD circuit and the Simplex version has one relay per circuit. The
VTUR board monitors the current flowing in its relay driver control line to determine
its energize or de-energize vote/status of the relay coil. A normally closed contact
from each relay on the TRPG board is monitored by the diagnostics to determine its
proper operation.

Table 9-23. VTUR Specification
Item Specification
Number of Inputs TTUR: 12 Passive Speed Pickups

1 Shaft Voltage and 1 Shaft Current Measurement
1 Generator and 1 Bus Voltage
Generator Breaker Status contact
VTUR: 4 Passive Speed Pickups
1 Shaft Voltage and 1 Current Measurement
Generator Breaker Status
8 Flame Detectors from first TRPG
8 Flame Detectors from second TRPG via daughter
board and J4A connector
Number of Outputs TTUR: Generator Breaker Coil
VTUR: Automatic Synchronizing
Primary Trip Solenoid Interface
Trip Solenoids Solenoids draw up to 1 A at 125 V dc and have a time constant of

L/R= 0.1 sec.
Power Supply Voltage TTUR: Nominal 125 V dc to breaker coil
MPU Pulse Rate Range 2 Hz to 14 kHz
MPU Pulse Rate Accuracy 0.05% of reading
MPU Input Circuit Sensitivity 27 mV pk (detects 2 rpm speed)
Shaft Voltage Monitor Monitors frequencies between 5 and 3,200 Hz, and generates a
DC signal with less than 1% ripple at 60 Hz.
Voltage signal is +/- 5 V dc pulses from 0 to 2,000 Hz
Shaft Voltage wiring Up to 300 m (984 ft), with maximum two-way cable resistance of
15 ohms
Shaft Voltage DC Test Applies a 6 V (max) source producing 300 mA (max); circuit reads
a differential resistance between 0 and 150 ohms within ± 5 ohms.
Readings above 50 ohms indicate a fault. Returned signal has 40
dB of noise attenuation at 60 Hz.
Shaft Voltage AC Test Applies a test voltage of 1 kHz to the input of the VTUR shaft
voltage circuit (R module only).
Generator and Bus Voltage Two Single Phase Potential Transformers, with fused (10 A max.)
Sensors secondary output supplying a nominal 115 V rms.
Each PT is magnetically isolated with a 1,500 V rms barrier
Cable length can be up to 1,000 ft. of 18 AWG wiring
Synchronizing measurements Frequency Accuracy 0.05% over 45 to 66 Hz range

Zero crossing of the inputs is monitored on the rising slope
Phase Difference Measurement is better than 1 degree
Generator Synchronizing External circuits should have a voltage range within 70 to 140 V dc
Circuits with an external 20 A fuse.
Circuits are rated for NEMA class E creepage and clearance.
250 V dc applications require interposing relays.
Contact Voltage Sensing 20 V dc indicates high and 6 V dc indicates low. Each cicuit is
optically isolated and filtered for 4 ms.

Table 9-24. Typical VTUR Configuration

VTUR System Limits Select System Limits Enable, disable
SMredundancy Select Simplex or Redundant system Simplex or TMR
J3J5 TTUR connected to VTUR via J3 and J5 Connected, Not connected
PulseRate Point Edit
PRType Select Speed or Flow type input Unused, Speed, Flow
PRScale Select Pulses per Revolution 0 to 1,000
SysLimit1 Select alarm level in GPM or RPM 0 to 20,000
TMRDiffLimit Difference Limit for voted Pulse Rate 0 to 20,000
inputs EU
ShVoltMon Shaft Voltage Monitor Point Edit
SysLimit1 Select alarm level in frequency 0 to 100
ShCurrMon Shaft Current Monitor Point Edit
ShuntOhms Shunt resistance 0 to 100
Shunt Limit Shunt maximum ohms 0 to 100
Brush Lim Shaft Brush maximum ohms 0 to 100
SysLim1Enable Select System Limit Enable, Disable
SysLimit1 Select alarm level in Amps 0 to 100
GenPT_KVolts Generator Potential Transformer Point Edit
PT_Input PT input in kVrms for PT output 0 to 1,000
PT_Output PT output in Vrms, nominal 115 Vrms 0 to 150
SysLim1 Select alarm level in kVrms 0 to 1,000
BusPT_Kvolts Bus Potential Transformer Point Edit
Ckt_Bkr Circuit Breaker Point Edit
System Frequency Select frequency in Hz 50 or 60
CB1CloseTime Breaker 1 Closing Time, ms 0 to 1,000
CB1 AdaptLimit Breaker 1 Self Adaptive Limit, ms 0 to 1,000
CB1 AdaptEnabl Select Breaker 1 Self Adaptive Limit Enable, Disable
CB1FreqDiff Breaker 1 special window Frequency 0 to 10
Difference, Hz
CB1PhaseDiff Breaker 1 special window Phase 0 to 30
Difference, degrees
J4:IS200TRPGG1A TRPG Terminal Board with 8 Flame (see TRPG)
Detectors

Like all I/O boards, the VTUR module is configured using the toolbox. Table 9-25
summarizes the configuration choices and defaults. For details refer to GEH-6403
Control System Toolbox for Configuring the Mark VI Turbine Controller.
Diagnostics
Diagnostic information includes feedback from the solenoid relay driver and contact,
high flame detector voltage, slow synch check relay, slow auto synch relay, and
locked up K25 relay.
If any one of the signals goes unhealthy a composite diagnostic alarm,

L3DIAG_VTUR occurs. Details of the individual diagnostics are available from the
RESET_DIA signal if they go healthy.
A list of the VTUR diagnostics is in Chapter 8, Troubleshooting & Diagnostics.
Automatic Synchronizing
All synchronizing connections are located on the TTUR termination board. The
generator and bus voltages are supplied by two, single phase, potential transformers
(PTs) with a fused secondary output supplying a nominal 115 V rms. Measurement
accuracy between the zero crossing for the bus and generator voltage circuits is 1
degree.
Turbine speed is matched against the bus frequency, and the generator and bus
voltages are matched by adjusting the generator field excitation voltage from
commands sent between the turbine controller and the EX2000 over the Unit Data
Highway (UDH). A command is given to close the breaker when all permissives are
satisfied, and the breaker is predicted to close within the calculated phase/slip
window. An external synch check relay is connected in series with the internal K25P
synch permissive relay and the K25 auto synch relay through TB points 05 and 06 on
the TTUR termination board. Feedback of the actual breaker closing time is provided
by a 52G/a contact from the generator breaker (not an auxiliary relay) to update the
data base. An internal K25A synch check relay is provided on the TTUR; however,
the backup phase/slip calculation for this relay is performed in the Protection
Module. Diagnostics monitor the current flowing through each relay coil to
determine if the relay properly energizes or de-energizes upon command.
Synchronizing Modes
There are three basic synchronizing modes. Traditionally, these modes are selected
from a generator panel mounted selector switch:
• Off The breaker will not be closed by the Mark VI control. The check relay will
not pickup.
• Manual The operator initiates breaker close, which is still subject to the K25A
Synch Check contacts driven by VPRO. The manual close is initiated from an
external contact on the generator panel, normally connected in series with a
Synch Mode in Manual contact.

• Auto The system will automatically match voltage and speed, and then close
the breaker at the right time to hit top dead center on the synchroscope. All three
of the following functions must agree for this closure to occur:
- K25A - synch check relay, checks the allowable slip/phase window
- K25 - auto synch relay, provides precision synchronization
- K25P - synch sequence permissive, checks the turbine sequence status.
Details of the various checks are discussed in the following sections.
Synch Check
The K25A synch check function is based on phase lock loop techniques. It performs
limit checks against adjustable constants as follows:
• Generator undervoltage
• Bus undervoltage
• Voltage error
• Frequency error (slip), with a maximum value of 0.33 Hz, typically set to
0.27 Hz.
• Phase error with a maximum value of 30 degrees, typically set to 10 degrees.
In addition, synch check arms logic to enable the function, and provides bypass logic
for deadbus closure. The synch window in Figure 9-47 is based on typical settings:
SLIP
+0.27 Hz
PHASE
-10 +10 Degrees
-0.27 Hz
Figure 9-47. Typical Synch Window
Auto Synch
The Auto Synch K25 function uses zero voltage crossing techniques. It compensates
for the breaker time delay which is defined by two adjustable constants with logic
selection between the two ( for two breaker applications). The calculations include
phase, slip, acceleration, and anticipated time lead for the breaker delay. Based on
the measured breaker close time, the time delay parameter is adjusted, up to certain
limits.
In addition, auto synch arms logic to enable the function, and bypasses logic to
provide for deadbus or manual closure. The auto synch projected synch window is

SLIP
* * 0.3 Hz
**
**
* * 0.12 Hz
PHASE
* ** Degrees
* *
Gen Lag ** 10 Gen Lead
Figure 9-48. Auto Synch Window
The projected window is based on current phase, current slip, and current
acceleration. The generator must currently be lagging and have been lagging for the
last 10 consecutive cycles. Auto synch will not allow the breaker to close with
negative slip; speed matching typically aims at around +0.12 Hz slip.
Synchronization Display
A special synchronization screen is available on the HMI with a graphical phase
display and control pushbuttons. The display provides the real time items listed in
Table 9-26.

Table 9-25. Synchronizing Display Items
Synch Display Description
Dynamic Parameters Voltages: Generator, Bus, Difference

Frequencies: Generator, Bus, Slip (difference)
Phase: Difference angle, degrees
Status Indication Mode: Synch OFF, MANUAL, AUTO
Synch Monitor : OFF, ON
Dead Bus
Breaker: Open/close
Second Breaker if applicable: Open/close
Synch Permissive: K25P
Auto Synch enabled
Speed Adjust: Raise/lower
Voltage Adjust: Raise/lower
Synch Permissives Gen Voltage: OK/not OK
Bus Voltage: OK/not OK
Gen Frequency: OK/not OK
Bus Frequency: OK/not OK
Difference Volts: OK/not OK
Difference Frequ: OK/not OK
Phase: K25, OK/not OK
K25A, OK/not OK
Limit Constants Upper and Lower Limits for the above permissives
Breaker Performance Diagnostics: Slow check relay
Synch relay lockup
Breaker #1 close time out of limits
Breaker #2 close time out of limits
Relay K25P trouble
Breaker closing voltage (125 V dc) missing
Control Pushbuttons Synch Monitor: ON, OFF
Speed Adjust: RAISE, LOWER
Voltage Adjust: RAISE, LOWER

Installation
Magnetic pick ups, shaft pick ups, potential transformers, and breaker relays are
wired to two I/O terminal blocks mounted on the TTUR termination board. Each
block is held down with two screws and has 24 terminals accepting 12 AWG wires.
A shield termination strip attached to chassis ground is located immediately to the
left of each terminal block. Jumpers JP1 and JP2 select either SMX or TMR for relay
drivers K25 and K25P. The wiring connections are shown in Figure 9-49.
Turbine Termination Board TTUR

JP1 JP2
K1
x
TMR SMX TMR SMX
x 1 52G (H)
52G (L) x 2
x 3 P125GEN
AUTO x 4 K3
BKRH x 6
x 5 MAN
N125GEN x 8
x 7 BKRH
x 9
x 10
x 11
x 12 K2
x 13
x 14
x 15
x 16
x 17 Gen (H)
Gen (L) x 18
Bus (L) x 19 Bus (H)
x 20
x 21 ShaftV (H)
ShaftV (L) x 22
x 23 ShaftC (H)
ShaftC (L) x 24
x
To Connectors
x
JR5, JS5, JT5,
x 25 MPU 1T (H)
MPU 1T (L) x 26 JR1, JS1, JT1
MPU 2T (L) x 28
x 27 MPU 2T (H)
MPU 3T (L) x 30
x 29 MPU 3T (H)
MPU 4T (L) x 32
x 31 MPU 4T (H)
x 33 MPU 1S (H)
MPU 1S (L) x 34
MPU 2S (L) x 36
x 35 MPU 2S (H)
MPU 3S (L) x 38
x 37 MPU 3S (H)
x 39 MPU 4S (H)
MPU 4S (L) x 40
x 41 MPU 1R (H) Terminal Blocks can be unplugged
MPU 1R (L) x 42
MPU 2R (L) x 44
x 43 MPU 2R (H) from terminal board for maintenance
MPU 3R (L) x 46
x 45 MPU 3R (H)
x 47 MPU 4R (H) Up to two #12 AWG wires per
MPU 4R (L) x 48
x point with 300 volt insulation
Figure 9-49. TTUR Termination Board

Primary Trip TRPG1
The TRPG termination board contains nine magnetic relays to interface with three
trip solenoids, known as the Electrical Trip Devices (ETD). The TRPG works in
conjunction with the TREG to form the Primary and Emergency sides of the
interface to the ETDs. Shown in Figure 9-50 is the TRPG1 version for TMR
applications, which has three voting relays per trip solenoid. The TRPG2 version is
for simplex applications and has one relay per trip solenoid. TRPG also
accommodates eight Geiger Mueller flame detectors.
An optional VTUR daughter board provides an interface to a second TRPG board.
TRPG Termination Board VTUR VME Board

ETD Power
from PDM
x
x
x
x 1 JT1 37-pin "D" shell
x 2 J1 RUN
x 4 x 3 type connectors FAIL
x 6 x 5 STAT
x 7 with latching
x 8
x 10 x 9 fasteners
x 12 x 11
x 14 x 13
x 16 x 15
x 20 x 19 JS1 Rack T
x 22 x 21
x 24 x 23
x VME Bus to VCMI
x
x 26 x 25
x 30 x 29 Rack S J
x 32 x 31 5
x 34 x 33 JR1
x 36 x 35
x 38 x 37
x 40 x 39 VTUR
x 42 x 41 J2 x
x 44 x 43
x 45 J4
x 46 J5 J3
x 48
x 47
J3
x
x Cable to TTUR
Connectors on
Shield Bar VME Card Rack R
J4
335 V from
Rack Power Cable to Cable to TTUR
Supplies TREG
R, S, T
Cable to VME Rack R
Figure 9-50. TRPG Termination Board, I/O Board & Cabling

Primary Trip Operation
VTUR controls the relays on TRPG which trip the main protection solenoids. In the
TMR case the three inputs are voted in hardware using a relay ladder logic two-out-
of-three voting circuit. Relay coil currents, contact status, and supply voltages are
monitored for diagnostic purposes, as shown in Figure 9-51.
<PDM> 125vdc + - Monitoring Outputs

Termination Board J1 01 03 05 09 10
Termination
TRPG1 (TMR), G2 (Simplex) Trip Board TREG
JR1 "PTR 1/4" Solenoid
<R>
VTUR RD KR1 KR1 KS1 1 or 4 KE1
02 - + 01
J4
RD KR2 KS1 KT1
J2 J2
RD KR3 Mon
KT1 KR1 04
28 Vdc
Optional 03
Mon Economizing Trip
"PTR 2/5" Resistor Solenoid
KR1,2,3
KR2 KS2 04 2 or 5 05
KE2
- +
<S> JS1 These relays in TMR systems

KS2 KT2 J2 J2
VTUR RD KS1
J4 Mon
KT2 KR2 08
RD KS2
07
RD KS3
Trip
28 Vdc "PTR 3/6" Solenoid
KR3 KS3 3 or 6 KE3
Mon 06 - + 09
<T> KS1,2,3 KS3 KT3

J2 J2
VTUR JT1
J4 Mon
RD KT1 KT3 KR3 12
11
RD KT2
02
To JR1,
RD KT3 JS1, JT1 Solenoid Pwr 06
28 Vdc Monitor 10
Mon J2 J2
N125 Vdc -
KT1,2,3 +
8 Signals to 3 Monitor
JR1,JS1,JT1 Signals to J3
Voltage Sply
JR1,JS1,JT1 and Monitor 335 Vdc from R
33 J4
NS Voltage Sply
34 and Monitor 335 Vdc from S
NS
Voltage Sply J5
Supply 8 and Monitor 335 Vdc from T
Eight Flame
Detectors
Detector Circuits
Figure 9-51. TRPG and Trip Solenoids

TRPG Features
VTUR controls the main breaker via TTUR, and three trip solenoids via TRPG. With
a second TRPG, six trip solenoids can be controlled. In addition, VTUR handles
shaft speed, generator voltage, and bus voltage inputs from TTUR, plus up to 16
flame detector inputs from one or two TRPG boards.
Control of Trip Solenoids

Both TRPG and TREG control the trip solenoids so that either one can remove
power and close the steam or fuel valves. TRPG holds nine relays in three voting
groups of three, one group for each trip solenoid. Voltage for the relay coils is
supplied from the R, S, and T rack backplane. The trip solenoids are supplied with
power through plug J1. A metal oxide varistor (MOV) for current suppression is on
TREG, and an optional economizing current limiting resistor can be wired to the
TREG terminals.
In Simplex systems TRPG2 is used. This board has one relay per ETD circuit instead
of three and is controlled by only one VTUR board.
Flame Detectors
Up to eight flame detectors can be used for gas turbine applications. The detectors
are supplied with 335 V dc, 0.5 mA through plugs J3, J4, and J5.
With no flame present the detector charges up to the supply voltage, but presence of
the flame causes the detector to charge to a level and then discharge through the
TRPG board. As the flame intensity increases the discharge frequency increases.
When the detector discharges, VTUR and TRPG convert the discharged energy into
a voltage pulse. The pulse rate varies from 0 to 1,000 pulses/sec. These voltage
pulses are fanned out to all three modules. Voltage pulses above 2.5 volts generate a
logic high, and the pulse rate over a 40 ms time period is measured in a counter.
Table 9-26. TRPG Specification
Item Specification
Trip Solenoids 3 Solenoids per TRPG (total of 6 per VTUR)

Solenoid Rated Voltage/Current 125 V dc standard with up to 1 Amp draw
24 V dc is alternate with up to 3 Amp draw
Solenoid Response Time L/R time constant is 0.1 sec

Current Suppression Metal oxide varister (MOV) on TREG
Current Economizer Terminals for optional 10 ohm, 70 watt
economizing resistor
Control Relay Coil Voltage Supply Relays supplied with 28 V dc from R, S, and T
racks
Flame Detectors 8 detectors per TRPG
Detector Supply Voltage/Current 335 V dc with 0.5 mA per detector

Like all I/O boards, the TRPG board is configured using the toolbox. This software
usually runs on a data-highway connected CIMPLICITY station or workstation. The
table below summarizes the configuration choices, for details refer to GEH-6403
Control System Toolbox for Configuring the Mark VI Turbine Controller.
Table 9-27. Typical TRPG Configuration
J4:IS200TRPGG1A First TRPG Termination Board

FlameInd1 Flame detector (Indicator) Number 1 Point edit
FlmDetTime Flame Detector Time Interval 0.04, 0.08, 0.16 sec
FlameLimitHI Flame Threshold Limit HI (HI detection cnts means LOW 0 to 160
sensitivity)
FlameLimitLO Flame Threshold Limit LO (LOW detection cnts means HI 0 to 160
sensitivity)
Flame_Det Flame Detector selected Used, Unused
FlameIndN Flame Detectors 2 through 8 as above
J4A:IS200TRPGG1A Second TRPG Board with Flame Detectors 9 through 16
Diagnostics
Descriptions of the TRPG diagnostics are listed under VTUR. The diagnostics
include feedback from the trip solenoid relay driver and contact, solenoid power loss,
and the flame detector excitation voltage too low or too high.
The VTUR diagnostics are in Chapter 8, Troubleshooting & Diagnostics.

Installation
The three trip solenoids are wired directly to the first I/O terminal block, and the
flame detectors (if used) to the second terminal block. Power to the flame detectors is
wired to J3, J4, and J5. These connections are shown in Figure 9-52.
Turbine Primary Trip Termination Board TRPG

125 V dc
J1
2
x 1 125 Vdc (P)
Trip Solenoid 1 or 4 x
4
x 3 125 Vdc (P)
6
x 5 125 Vdc (P)
x 7
x 8
x 9 125 Vdc (N)
125 Vdc (N) x 10
x 11
x 12 To Connectors
x 13
x 14 JR1, JS1, JT1
x 15
x 16
x 17
x 18
x 19
x 20
x 21
x 22
x 23
x 24
x
To Connectors
x JR1, JS1, JT1
x 25
x 26
x 27
x 28
x 30
x 29 J2
x 31
x 32
Flame 1 (L) x 33 Flame 1 (H) Cable to TREG
x 34
x 35 Flame 2 (H)
Flame 2 (L) x 36
x 37 Flame 3 (H)
Flame 3 (L) x 38
x 39 Flame 4 (H) 335 Vdc
Flame 4 (L) x 40 J4
Flame 5 (L) x 42
x 41 Flame 5 (H)
Flame 6 (L) x 44 J5
Flame 7 (L) x 46
x 47 Flame 8 (H) J3
Flame 8 (L) x 48
x

Figure 9-52. TRPG Termination Board Wiring

Turbine Emergency Trip TREG
Up to three trip solenoids can be connected between the TREG and TRPG
termination boards. TREG provides the positive side of the 125 V dc to the solenoids
and TRPG provides the negative side. The VPRO board in the Protection Module
 provides emergency overspeed protection and controls the 12 relays on TREG.
Nine of these relays form three groups of three to vote inputs controlling the three
trip solenoids. A second TREG board may be driven from VPRO through J4.
VPRO also connects to the TPRO termination board and has an Ethernet connection
for IONet communications with the control modules. These connections are shown
in Figure 9-53. Details of the TREG board are shown in Figure 9-54.
TREG Termination Board VPRO Module - X

P125 Vdc Ethernet
To TRPG
JH1 J1 IONet x x x
x
x
x 2 x 1 J2 RUN
I
4 x 3 JZ1 O FAIL
x
x 5 To TSVO N STAT
x 6 Termination E
x 8 x 7 T
8 X
4 Y
x 10 x 9 Boards (SMX) T 2 Z
x 12 x 11 R 1
x 13 C
x 14
x 16 x 15 S
x 18 x 17 E
x 19 Cable to VPRO-Z R J
x 20 JY1
x 22 x 21 6
x 23 J P5
x 24 COM
x 5 P28A
P28B
To TPRO E
x T
x 26 x 25 H
x 28 x 27 R
x 30 x 29 To TPRO J J P
x 31 3 4 P
x 32 JX1 A
x 34 x 33 R O
x 35 Cable to VPRO-Y A W
x 36
x 38 x 37 F N L
E
x 40 x 39 VPRO R
x 42 x 41 x x x
x 44 x 43
x 46 x 45
x 48
x 47
x
x Cable to VPRO-X
To Second TREG
(optional)
Shield 37-pin "D" shell
Bar type connectors
with latching
BarrierType Terminal fasteners
Blocks can be
unplugged
from board for
maintenance
Figure 9-53. Trip Emergency Termination Board, VPRO Board, and Cabling

Emergency Trip Operation
Trip
Termination Termination Board TREG 
Solenoid JX1
Board TRPG VPRO
1 or 4 KE1 KX1 KY1 KX1 RD
02 - + 01 Section X
J3
KY1 KZ1 KX2 RD
J2 J2
Mon KX3 RD
04
KZ1 KX1
Optional P28X1 Mon
Economizing 03
Resistor, Trip K4X KX1,2,3
28vdc
100 ohm, Solenoid
70W 04 2 or 5 05
KE2 KX2 KY2 JY1 
- +
VPRO
KY1 RD
KY2 KZ2 Section Y
J2 J2 J3
KY2 RD
Mon
08
KZ2 KX2
KY3 RD
07
Trip P28Y1 Mon
Solenoid K4Y KY1,2,3
28vdc
3 or 6 KE3 KX3 KY3
06 - + 09
JZ1 
KY3 KZ3 KZ1 VPRO
J2 J2 RD
Section Z
Mon J3
KZ3 KX3 KZ2 RD
12
11 KZ3 RD
02
P28Z1 Mon
06
Sol Pwr Monitor K4Z KZ1,2,3
10 JX1 28vdc
Mon JY1
J2 J2 JZ1 KE1,2,3 JX1
- N125V
+ P125V
P28VV RD 2 JY1
3 JZ1
Three Economizing Relay Circuits
To TSVO K4CL JX1 Trip Interlock
P28VV RD 2 JY1 To P125X
Boards on J1 3 35 seven circuits
SMX Systems JZ1 JX1 NS
K4CL K4CL 36
JY1 NS
JZ1
Servo Clamp Mon 13,14
P28VV CL
To Relay
15 E-Stop
K25A on J2 J2 K4X
JX1
TTUR 16
RD 2 JY1 K4Y
3 JZ1
Mon K4Z 17
JH1
P125X
JX1 P28X1 18
N125X
JY1 Mon P28Y1
JZ1 P28Z1
Figure 9-54. TREG Board, Trip Interlocks, and Trip Solenoids

TREG Features
TREG is entirely controlled by VPRO, and the only connections to the control
modules are the J2 power cable and the trip solenoids. In Simplex systems a third
cable carries a trip signal from J1 to the TSVO terminal board.
Control of Trip Solenoids

Both TRPG and TREG control the trip solenoids so that either one can remove
power and actuate the hydraulics to close the steam or fuel valves. The nine trip relay
coils on TREG are supplied with 28 V dc from VPRO boards in X, Y, and Z. The
trip solenoids are supplied with 125 V dc via plug J2, and draw 1 Amp with a 0.1
second L/R time constant. The solenoid circuit has a metal oxide varistor (MOV) for
current suppression and a 10 ohm, 70 watt current limiting resistor.
A separately fused 125 V dc feeder is provided from the turbine control for the
solenoids which energize in the run mode and de-energize in the trip mode.
Diagnostics monitor each 125 V dc feeder from the Power Distribution Module at its
point of entry on the terminal board to verify the fuse integrity and the cable
connection.
Two series contacts from each emergency trip relay (ETR1,2,3) are connected to the
positive 125 V dc feeder for each solenoid, and two series contacts from each
primary trip relay (PTR1,2,3 in TRPG) are connected to the negative 125 V dc
feeder for each solenoid. An economizing relay (KE1,2,3) is supplied for each
solenoid with a normally closed contact in parallel with the current limiting resistor.
These relays are used to reduce the current load after the solenoids are energized.
The ETR, PTR, and KE relay coils are powered from a 28 V dc source from the
VPRO boards. Each VPRO board in each of the X, Y, and Z sections supplies an
independent 28 V dc source which is diode Or’ed (high selected), and the resulting
redundant 28 V dc source powers the relays. A normally closed contact from each
relay is used to sense the relay status for diagnostics.
The 28 V dc bus is current limited and used for power to an external manual
emergency trip contact, shown as E-Stop. Three master trip relays (K4X, K4Y, K4Z)
disconnect the redundant 28 V dc bus from the ETR, PTR, and KE relay coils if a
manual emergency trip occurs. Any trip which originates in either the Protection
Module (such as EOS) or the TREG (such as a manual trip) will cause each of the
three Protection Module sections to transmit a trip command over the IONet to the
control module along with a distinctive message identifying the source of the trip.
In addition, the K4CL servo clamp relay will energize and send a contact feedback
directly from the TREG termination board to the TSVO servo termination board.
TSVO disconnects the servo current source from the terminal block and applies a
bias to drive the control valve closed. This is only used on Simplex applications to
protect against the servo amplifier failing high. Note that the primary and emergency
overspeed systems will trip the hydraulic trip solenoids independent of this circuit.

Solenoid Trip Tests
Application software in the control module is used to initiate tests of the trip
solenoids. Online tests allow each of the trip solenoids to be manually tripped one at
a time either through the PTR relays from the control module(s) or through the ETR
relays from the Protection Module. A contact from each solenoid circuit is wired
back as a contact input to give a positive indication that the solenoid has tripped.
Primary and emergency off-line overspeed tests are provided too for verification of
actual trips due to software simulated trip overspeed conditions.
Table 9-28. TREG Specification
Item Specification
Number of Trip Solenoids (TREG) 3 Solenoids per TREG (total of 6 per VPRO)
Trip Solenoid Rated 125 V dc standard with 1 Amp draw
Voltage/Current 24 V dc is alternate with 3 Amp draw
Trip Solenoid Circuits Circuits rated for NEMA class E creepage and clearance.
Circuits can clear a 20 A fuse with all circuits fully loaded.
Solenoid Response Time Solenoid L/R time constant is 0.1 sec.
Relay outputs 3 Economizer relay outputs, 2 second delay to energize
Breaker relay K25A on TTUR
Solenoid Control Relay Contacts Contacts are rated to interrupt inductive solenoid loads at
125 V dc, 1 A
Bus voltage can vary from 70 to 145 V dc
Trip Inputs 7 trip interlocks to VPRO protection module
1 Emergency Stop hardwired trip interlock

Like all I/O boards, TREG is configured using the toolbox. This software usually
runs on a data-highway connected CIMPLICITY station or workstation. The table
below summarizes the configuration choices and defaults. For details refer to GEH-
6403 Control System Toolbox for Configuring the Mark VI Turbine Controller.

Table 9-29. Typical TREG Configuration
J3:IS200TREGG1A First TREG Board

KESTOP1_Fdbk1 Emergency Stop Point edit
Contact1 Trip Interlock 1 (first of 7) Point Edit
ContactInput Trip Interlock 1 used Used, Unused
TripEnable Trip Interlock active Enable, Disable
TrpTimeDelay Time delay before Tripping Turbine after Contact 0 to 10
Opens (sec)
SeqOfEvents Record Contact Transitions in Sequence of Events Enable, Disable
K1_Fdbk Relay feedback (first of 3) Point Edit
RelayOutput Relay feedback used Used, Unused
KE1_Fdbk Economizer Relay Feedback (first of 3) Point Edit
RelayOutput Economizer Relay Feedback Used Used, Unused
K4CL_Fdbk Servo Valve Clamp Point Edit
Relay Output Servo Valve Clamp used Used, Unused
K25A Synchronizing Relay on TTUR Point Edit
SynchCheck Synch Check Relay K25A Used Used, Unused
SystemFreq System Frequency in Hz 50 or 60
ReferFreq Select Generator Frequency Reference for PLL, PR Std or Sg Space
standard PR input or from Signal Space
TurbRPM Rated Load Turbine RPM 0 to 20,000
VoltageDiff Maximum Voltage Difference in kV rms for 0 to1,000
Synchronizing
FreqDiff Maximum Frequency Difference in Hz for 0 to 0.5
Synchronizing
PhaseDiff Maximum Phase Difference in Degrees for 0 to 30
Synchronizing
GenVoltage Minimum Generator Voltage in kVolts rms for 1 to 1,000
Synchronizing
BusVoltage Minimum Bus Voltage in kVolts rms for Synchronizing 1 to 1,000
J4A:IS200TREGG1A Second TREG Board
Diagnostics
Descriptions of the TREG diagnostics are contained in the VPRO section. The
diagnostics cover the trip relay driver and contact feedbacks, solenoid voltage,
economizer relay driver and contact feedbacks, K25A relay driver and coil, servo
clamp relay driver and contact feedback, and the solenoid voltage source.
A list of the VPRO diagnostics is in Chapter 8, Troubleshooting & Diagnostics.

Installation
The three trip solenoids, economizing resistors, and the emergency stop are wired
directly to the first I/O terminal block. Up to seven trip interlocks can be wired to the
second terminal block. The wiring connections are shown in Figure 9-55.
Power 125 V dc To TSVO

To TRPG, 12 wires boards on
SMX
system
Turbine Emergency Trip J1

J2
Termination Board TREG JH1
x
JZ1
2
x 1 SOL 1 or 4
PWR_N1 x
x 3 RES 1A
RES 1B x 4
6
x 5 SOL 2 or 5
PWR_N2 x
RES 2B x 8
x 7 RES 2A
x 9 SOL 3 or 6
PWR_N3 x 10
12
x 11 RES 3A
RES 3B x
14
x 13 E-TRP 1 (H)
E-TRP 2 (H) x
x 15 TRP 3
TRP 4 x 16
E-TRP 6 (L) x 18
x 17 E-TRP 5 (L)
x 20
x 19 JY1
x 21
x 22
x 23
x 24
x
x
x 25
x 26
x 27
x 28
PWR_P2 (for probe) x 29
x 30 JX1
x 31 PWR_P1 (for probe)
x 32
x 33
x 34
x 35 TRP 1 (H)
TRP 1 (L) x 36
x 37 TRP 2 (H)
TRP 2 (L) x 38
x 39 TRP 3 (H)
TRP 3 (L) x 40
x 41 TRP 4 (H)
TRP 4 (L) x 42
x 43 TRP 5 (H)
TRP 5 (L) x 44
TRP 6 (L) x 46
x 45 TRP 6 (H)
x 47 TRP 7 (H)
TRP 7 (L) x 48
x

Figure 9-55. TREG Termination Board

Turbine Protection TPRO & VPRO
The Turbine Protection Module (VPRO) and associated termination board (TPRO)
provide an independent emergency overspeed protection system. The protection
system consists of triple redundant VPRO boards in a module separate from the
turbine control system, controlling the trip solenoids through TREG. Figure 9-56
shows the cabling to VPRO from the termination boards.
TPRO Termination Board VPRO- X

Ethernet
x IONet x x x
x
x 1 JZ1
x 2 I RUN
x 4 x 3 O FAIL
x 6 x 5 N STAT
x 7 E 8 X
x 8 T 4 Y
x 10 x 9 T 2 Z
x 12 x 11 R 1
x 13 C
x 14
x 16 x 15 JZ5 S
x 18 x 17 E
x 20 x 19 JY1 R J
x 22 x 21 Cables to VPRO-Z 6
x 23 J P5
x 24 COM
x 5 P28A
P28B
JY5 E
x T
x 26 x 25 H
x 28 x 27 R
x 29 J J
x 30 P
x 32 x 31 3 4 A P
x 33 JX1 Cables to VPRO-Y R O
x 34
x 36 x 35 JX5 A W
x 37 F N L
x 38 E
x 40 x 39 VPRO
x 41 R
x 42 x x x
x 44 x 43
x 46 x 45 Cables to VPRO-X
x 48
x 47
x
x
To TREG
To Second TREG
(optional)
Shield 37-pin "D" shell
Bar type connectors
with latching
BarrierType Terminal fasteners
Figure 9-56. Turbine Protection Termination Board, VPRO Board, and Cabling
Figure 9-57 shows how the VTUR and VPRO processor boards share in the turbine
protection scheme. Either one can independently trip the turbine via the relays on
TRPG or TREG. Figure 9-58 provides details of the TPRO termination board.

VTUR Special speed cable
JR5 TTUR
JS5
JT5
J5
Two
JR1
xfrs
JS1
Optional 3 Relays
JT1
Daughter Gen Synch
Board
335 V dc from <Q>
J3 J4 J5
JR1
TRPG
JS1
J3
JT1
To second
TRPG board 9 Relays
J4 J4 (optional) (3 x 3 PTR’s)
J1
J2
125 VDC
Cable Trip Solenoids,

three circuits
J2 J1
TREG Trip signal to
JX1
TSVO TB’s
JY1
VPRO
JZ1
J3
To second 12 Relays
J4 TREG Board
(9 ETR’s,
(optional)
J5 3 Econ Relays)
JH1
J6
P125 V dc from <PDM>
NEMA class F
Special speed cable

JX5 TPRO
JY5
J7
JZ5
JX1 Two
xfrs
JY1
125 VDC JZ1
Figure 9-57. Turbine Control & Protection Boards

Termination Board TPRO VPRO X VPRO Y VPRO Z
Protection Protection Protection
1 JX1
Gen. Volts Noise
120 V ac 2 Suppr
from PT
Line J6 J6 J6
3
Volts JY1
Noise
120 Vac 4 Suppr
from PT
To TREG
TCX1H NS Overspeed Overspeed Overspeed
Three TC ccts to X Em Stop Em Stop Em Stop
TCX1L NS Sync Check Sync Check Sync Check
JZ1 Overtemp Overtemp Overtemp
TCY1H NS
Three TC ccts to Y
TCY1L NS
TCZ1H NS
Three TC ccts to Z J5 J5 J5
TCZ1L NS
P28VV
P28V,X
P24Vx Current P28V,Y J3 J3 J3
Limiter P28V,Z
VDC VDC
JPA1
20mAx 20 ma
To X,Y, Z J4 J4 J4
250 ohms
mAret
One of the above ccts
Open Ret
JPB1
Current P28VV
P28Vx To TREG and
Limiter
Trip Solenoids
20 mAx
250
To X, Y, Z
ohms
Two of the above ccts
#1 JX5
Emergency 31
Magnetic Filter
Clamp
Speed Suppr.
AC
32
PU Coupling
3 Circuits
#2 JY5
Emergency 37
Filter
Magnetic Clamp
Suppr. AC
Speed 38 Coupling
PU
3 Circuits
#3 JZ5
Emergency 43
Filter
Magnetic Clamp
Speed Suppr.
AC
44 Coupling
PU
3 Circuits
Figure 9-58. TMR Protection System

Protection System Operation
The main purpose of the Protection Module is emergency overspeed (EOS)
protection for the turbine. In addition, the module has backup synchronization check
protection, three analog current inputs, and nine thermocouple inputs, primarily
intended for exhaust over temperature protection on gas turbines.
The Protection Module is always triple redundant with three completely separate and
independent sections named X, Y, and Z. Any one of these sections can be powered
down and replaced while the turbine is running without jeopardizing the protection
system. Each section contains its own I/O interface, processor, power supply, and
Ethernet communications (IONet) to the control modules. The communications
allow initiation of test commands from the control module to the Protection Module
and the monitoring of EOS system diagnostics in the control module and on the
operator interface. Communications are resident on the VPRO board which is the
heart of the system. The VPRO board has a VME interface to allow programming
and testing in a VME rack; however, the back-plane is neutralized when plugged into
the Protection Module to eliminate any continuity between the three independent
sections.
VPRO Features
Speed Control and Overspeed Protection
Speed control and overspeed protection is implemented with six passive, magnetic
speed pickups. The first three are monitored by the control module(s) which use the
median signal for speed control and the primary overspeed protection. The second
three are separately connected to the X, Y, and Z sections of the Protection Module.
Provision is made for nine passive magnetic speed pickups or active pulse rate
transducers (TTL type) on the TPRO termination board with three being monitored
by each of the X, Y, and Z sections. This capability is not used for industrial steam
turbine applications. Separate overspeed trip settings are programmed into the
application software for the primary and emergency overspeed trip limits, and a
second emergency overspeed trip limit must be programmed into the I/O
configurator to confirm the EOS trip point.
The speed is calculated by counting passing teeth on the wheel and measuring the
time involved. Another protection feature is the calculation of the rate of change of
speed which is compared with 100%/sec and transmitted to the control module to trip
the unit if it is detected after the turbine reaches a predetermined steady-state speed.
This steady-state speed limit is a tuning constant located in the controller’s
application software. Another speed threshold which is monitored by the EOS
system is 10% speed. This is transmitted to the control module to verify that there is
no gross disagreement between the first set of three speed pickups being monitored
by the controller (for speed control and the primary overspeed protection) and the
second set of three speed pickups being monitored by the EOS system.
Interface To Trip Solenoids

The trip system combines the Primary Trip Interface from the control module(s) with
the EOS Trip Interface from the Protection Module. Three separate, triple redundant
trip solenoids (also called Electrical Trip Devices - ETDs) are used to interface with
the hydraulics. The ETDs are connected between the TRPG and TREG termination
boards. A separately fused 125 V dc feeder is provided from the turbine control for
each solenoid which energize in the run mode and de-energize in the trip mode.

Backup Synch Check Protection
Backup synch check protection is provided in the Protection Module. The
generator and bus voltages are supplied from two, single phase, potential
transformers (PTs) with a fused (10 A max.) secondary output supplying a nominal
115 V rms. The maximum cable length between the PTs and the turbine control is
100 meters of 18 AWG twisted, shielded wire. Each PT is magnetically isolated with
a 1,500 V rms rated barrier and a circuit load less than 3 VA. The synch algorithms
are based on phase lock loop techniques. Phase error between the generator and bus
voltages is less than +/-1 degree at nominal voltage and 50/60 Hz. A frequency range
of 45 to 66 Hz is supported with the measured frequency within 0.05% of the input
frequency. Measurement accuracy between the zero crossing for the bus and
generator voltage circuits is 1 degree with 0.03 degrees resolution.
Each PT input is internally connected in parallel to the X, Y, and Z sections of the
Protection Module. The triple redundant phase slip windows result in a voted logical
output on the TREG termination board which drives the K25A relay. This relay’s
contacts are connected in series with the synch permissive relay (K25P) and the auto
synch relay (K25) to insure that no false command is issued to close the generator
breaker. Similarly, contacts from the K25A contact are connected in series with the
contacts from remote, manual synchronizing equipment to insure no false
commands.
Thermocouple and Analog Inputs

Thermocouple and analog inputs are available in the Protection Module, primarily
for gas turbine applications. Nine thermocouple inputs are monitored with three
connected to each section of the Protection Module. These are generally used for
backup exhaust over-temperature protection. Also, one +/-5,10 V dc, 4-20 mA
(selectable) input, and two 4-20 mA inputs can be connected to the TPRO
termination board which feeds the inputs in parallel to the three sections of the
Protection Module.

Table 9-30. VPRO Specification
Item Specification
Number of Inputs TPRO: 9 Passive Speed Pickups

9 Thermocouples
1 4-20 mA current or voltage
2 4-20 mA current
VPRO: 3 Passive Speed Pickups
3 Thermocouples
1 4-20 mA current or voltage
2 4-20 mA current
7 Trip interlocks
1 Emergency Stop
Number of Outputs TREG: 3 Trip Solenoids per TREG (6 total)

3 Economizer relays
1 Breaker relay command, K25A on TTUR
1 Servo clamp relay contact, to TSVO boards
VPRO: 6 Trip Solenoids

3 Economizer relays
1 Breaker relay command, K25A on TTUR
1 Servo clamp relay contact, to TSVO boards
Power Supply Voltage TPRO: 28 V dc from X, Y, and Z boards, voted
VPRO: 5 V dc and 28 V dc
MPU Characteristics Output resistance 200 ohms with inductance of 85 mH.

Output generates 150 V p-p into 60 K ohms at the TPRO
terminal block, with insufficient energy for a spark. The
maximum short circuit current is approximately 100 mA.
The system applies up to 400 ohm normal mode load to
the input signal to reduce the voltage at the terminals.
MPU Cable Sensors can be up to 300 m (984 ft) from the cabinet,
assuming that shielded pair cable is used, with typical
70 nF single ended or 35 nF differential capacitance, and
15 ohms resistance.
MPU Pulse Rate Range 2 Hz to 14 kHz
MPU Pulse Rate Accuracy 0.05% of reading.

Noise of the acceleration measurement is less than
± 50 Hz/sec for a 10,000 Hz signal being read at 10 ms.
MPU Input Circuit Sensitivity Minimum signal is 27 mV pk at 2 Hz
Minimum signal is 450 mV pk at 14 kHz
Generator and Bus Voltage Two Single-Phase Potential Transformers, 115 V rms
Sensors secondary
Frequency Accuracy 0.05%
Phase Difference Measurement better than 1 degree

Table 9-31. Typical VPRO Configuration
Slot 1 VPRO
Turbine_Type Define the type of turbine from selection of ten Two gas turbine
types Two LM, Two large steam
One medium steam
One small steam
Two Stag GT
OT_Trip_Enbl Enable Overtemperature Trip Enable, Disable
OvrTemp_Trip Iso-thermal Overtemperature Trip Setting for -60 to 2,000
Exhaust Thermocouples in Degree F
CPD_Corner Overtemperature Trip Compressor Discharge 0 to 450
Pressure in psi at which CDP Bias Starts
CPD_Slope Overtemperature Trip Compressor Discharge -10 to 0
Pressure Bias Slope in Degree F/psi
Auto Reset Automatic Restoring of Thermocouples removed Enable, Disable
from scan
Min_MA_Input Minimum MA for Healthy 4-20 mA Input 0 to 21
Max_MA_Input Maximum MA for Healthy 4-20 mA Input 0 to 21
L3DIAG_VPRO Point Edit
J5:IS200TPROG1A J5 cable section of TPRO board
PulseRate1 First of three speed inputs Point Edit
PRType Selects Gearing (Resolution) Unused, PR<6,000 Hz,
PR>6,000 Hz
PRScale Pulses per revolution (output RPM) 0 to 1,000
OS_Setpoint Overspeed Trip Setpoint in RPM 0 to 20,000
OS_Tst_Delta Offline Overspeed Test Setpoint Delta in RPM -2,000 to 2,000
Zero_Speed Zero Speed for this Shaft in RPM 0 to 20,000
Min_Speed Minimum Speed for this Shaft in RPM 0 to 20,000
Accel_Trip Enable Acceleration trip Enable, Disable
Acc-Setpoint Accelerate Trip Setpoint in RPM/second 0 to 20,000
TMR_DiffLimt Difference Limit for Voted Pulse Rate Inputs in 0 to 20,000
Engineering Units
J6:IS200TPROG1A J6 Cable section of TPRO board
BusPT_KVolts Bus Potential Transformer Point edit
PT_Input PT input in kilovolts rms for PT_Output 0 to 1,000
PT_Output PT output in Volts rms for PT_Input-typically 115 60 to 150
TMR_DiffLimt Difference Limit for Voted PT Inputs in Per Cent 0 to 100
GenPT_KVolts Generator PT, configuration similar to Bus PT Point Edit
TC1X Thermocouple 1, for X module (three TC per Point Edit
module)
ThermCplType Select Thermocouple Type or mV Input Unused, mV, T, K, J, E
Cold Junction Cold Junction for Thermocouples Point Edit
TMR_DiffLimt Difference Limit for Voted TMR Cold Junction -60 to 2,000
Inputs in Deg F
AnalogIn1 First of Three Analog Inputs Point Edit

Input Type Type of Analog Input Unused, 4-20 mA,
+/- 10 volts
Low_Input Input MA at Low Value -10 to 20
Low_Value Input Value in Engineering Units at Low Value -3.402e+38 to 3.402e+38
High_Input Input MA at High Value -10 to 20
High_Value Input Value in Engineering Units at High MA -3.402e+38 to 3.402e+38
InputFilter Filter Bandwidth in Hz Unused, 12 Hz, 6 Hz, 3Hz,
1.5 Hz, 0.75 Hz
Trip_Enable Enable Trip for this MA Input Enable, Disable
TripSetpoint Trip Setpoint in Engineering Units -3.402e+38 to 3.402e+38
TripTimeDelay Time Delay before Tripping Turbine after Signal 0 to 10
exceeds Setpoint in seconds
TMR_DiffLimt Difference Limit for Voted TMR Inputs in Per Cent 0 to 100
of (High_Value-Low_Value)
J3:IS200TREGG1A First TREG board (see TREG section for
configuration)
J4:IS200TREGG1A Second TREG board (optional) Connected, Not Connected
Diagnostics
The diagnostics cover the thermocouple limits, reference voltage, cold junction,
analog input health, and contact input test failure. Relay diagnostics cover the trip
relay driver and contact feedbacks, solenoid voltage, economizer relay driver and
contact feedbacks, K25A relay driver and coil, and the servo clamp relay driver and
contact feedback. Voltage diagnostics cover the solenoid power bus, and the voltage
to the solenoids.
Descriptions of the VPRO diagnostics are contained in Chapter 8, Troubleshooting
& Diagnostics.
Protection Logic
The following Figures 9-59 through 9-69 define the protection algorithms coded in
the VPRO firmware. These algorithms are configurable from the toolbox. A
configurable parameter is illustrated with the abbreviation CFG(xx) where xx
indicates where the configuration is located. Some parameters/variables are followed
with a SS indicating they are outputs from Signal Space (meaning they are driven
from the CSDBase); other variables are followed with IO indicating they are
hardware I/O points.

L5ESTOP1
KESTOP1_Fdbk, IO
Estop1
Trip
L5ESTOP1 L86MR, SS
L5ESTOP2
KESTOP2_Fdbk, IO
Estop2
Trip
L5ESTOP2 L86MR, SS
Cont1_TrEnab
Used Enable
ContactInput, CFG (J3, Contact1)
TripEnable, CFG (J3, Contact1)
L5Cont1_Trip
Contact1, IO Cont1_TrEnab
Contact
TDPU Trip
TrpTimeDelay (sec), CFG (J3, Contact1)
L5Cont1_Trip L86MR, SS
Repeated seven times for Contact 1 thru Contact 7
Figure 9-59. VPRO Protection Logic - Contact Inputs

OS1_Setpoint , SS
A
|A| A
RPM
A-B A OS1_SP_CfgEr
OS_Setpoint, CFG A>B
B 1 RPM System Alarm, if the two
(J5, PulseRate1) RPM B
setpoints don’t agree
A
MIN
B
OS_Setpoint_PR1
OS_Stpt_PR1
A A
MULT A A+B zero

0.04
B MIN B
OS_Tst_Delta,
B
CFG (J5, PulseRate1) RPM
OfflineOS1test, SS
OnlineOS1test, SS
PulseRate1, IO
A
A>=B OS1
OS_Setpoint_PR1
B
OS1_Trip
OS1
Overspeed Trip
OS1_Trip L86MR, SS
Figure 9-60. VPRO Protection Logic - Overspeed Trip

PulseRate1, IO
A
PR1_Zero
AB
Min_Speed, CFG (J5, PulseRate1)
B
S PR1_Accel
(Der) A
PR1_Dec
AB
Acc_Setpoint, CFG (J5,PulseRate1)
B
Dec1_Trip
PR1_DEC
Decel Trip
Dec1_Trip L86MR,SS
Acc_Trip, CFG (J5, PulseRate1)
Enable Acc1_Trip
PR1_ACC Acc1_TrEnab
Accel Trip
Acc1_Trip L86MR,SS
*Note: where 100% is defined as the

configured value of OS_Stpt_PR1
Figure 9-61. VPRO Protection Logic - Overspeed Trip, continued

OS1_SP_CfgEr L5CFG1_Trip
PR1_Zero
HP
Config Trip
L5CFG1_Trip L86MR,SS
PR_Max_Rst PR1_Max_Rst
PR1_Zero_Old PR1_Zero
PR1_Zero
0.00
PR1_Max_Rst PR1_Max
Max
PulseRate1
PR1_Zero PR1_Zero_Old
Figure 9-62. VPRO Protection Logic - Overspeed Trip, continued

TC1
TC1 M TC_MED
E
TC1 D
Overtemp_Trip, CFG (VPRO)

A
OT_Setpoint
CPD, SS A+B
A A
M B
A-B A*B I
CPD_Corner, CFG (VPRO) N
B B
CPD_Slope, CFG (VPRO)
Neg number Zero
TC_MED
A
L26T
A>=B
OT_Setpoint
B
OT_Trip_Enbl, CFG (VPRO)
Enable OT_Trip
L26T OT_TrEnab Over
Temp Trip
OT_Trip L86MR, SS
Figure 9-63. VPRO Protection Logic - Overtemperature Trip

L5Cont_Trip
L5Cont1_Trip
Contact
Trip
L5Cont2_Trip
L5Cont3_Trip
L5Cont4_Trip
L5Cont5_Trip
L5Cont6_Trip
L5Cont7_Trip
Turbine_Type, CFG (VPRO) Configured

Steam Turbine
SteamTurb Only only, not
LargeSteam1
including Stag
LargeSteam2
MediumSteam
SmallSteam
Figure 9-64. VPRO Protection Logic - Turbine Trip

OS1_Trip ComposTrip1 Composite
Trip 1
Dec1_Trip
L5CFG1_Trip
L5Cont_Trip
Acc1_Trip
Cross_Trip, SS
OT_Trip SteamTurbOnly
HPZeroSpdByp, SS PR1__Zero
Turbine_Type, CFG (VPRO)
ComposTrip2
ComposTrip1 Stag_GT_1Sh Composite
Trip 2
Stag_GT_1Sh
OS1_Trip
Dec1_Trip
L5CFG1_Trip
L5Cont_Trip
Acc1_Trip
Cross_Trip, SS
Figure 9-65. VPRO Protection Logic - Turbine Trip, continued

RelayOutput, CFG( J3,K1_Fdbk)
Trip Relay,
used ETR1 Energize to Run,
ComposTrip1 ETR1_Enab L5ESTOP1 KX1, J3
KY1, J3
KZ1, J3
ETR1 SOL1_Vfdbk KE1_Enab KE1

TDPU Economizing Relay,
used Energize to Econ,
KE1, J3
RelayOutput, CFG( J3,KE1_Vfdbk)
2 sec

Trip Relay,
ComposTrip1 used ETR2 Energize to Run,
L5ESTOP1
ETR2_Enab KX2, J3
KY2, J3
KZ2, J3
Energize to Econ,
used
KE2, J3
RelayOutput, CFG(J3,KE2_Vfdbk)
2 sec

Trip Relay,
used ETR3
ComposTrip1 L5ESTOP1 Energize to Run,
ETR3_Enab
KX3, J3
KY3, J3
KZ3, J3
TDPU
Economizing Relay,
RelayOutput, CFG(J3,KE1_Vfdbk) KE3, J3
2 sec
Figure 9-66. VPRO Protection Logic - Trip & Economizing Relays ( J3, TREG)

Trip Relay,
used ETR1 Energize to Run,
ComposTrip1 ETR1_Enab L5ESTOP1 KX1, J3
KY1, J3
KZ1, J3

KE1, J3
RelayOutput, CFG( J3,KE1_Vfdbk)
2 sec

Trip Relay,
ComposTrip1 used ETR2 Energize to Run,
L5ESTOP1
ETR2_Enab KX2, J3
KY2, J3
KZ2, J3
Energize to Econ,
used
KE2, J3
RelayOutput, CFG(J3,KE2_Vfdbk)
2 sec

Trip Relay,
used ETR3
ComposTrip1 L5ESTOP1 Energize to Run,
ETR3_Enab
KX3, J3
KY3, J3
KZ3, J3
TDPU
Economizing Relay,
RelayOutput, CFG(J3,KE1_Vfdbk) KE3, J3
2 sec
Figure 9-67. VPRO Protection Logic - Trip & Economizing Relays (J4, TREG)

K4CL
ComposTrip1 K4CL_Enab Servo Clamp
Relay, Energize to
Clamp, K4CL
Used
RelayOutput, CFG
(J3,K4CL_Fdbk)
L25A_Cmd K25A_Enab K25A
Used Synch Check Relay,

Energize to Close
Breaker, K25A
SynchCheck, CFG on TTUR via TREG
(J3,K25A_Fdbk)
Figure 9-68. VPRO Protection Logic - Servo Clamp & Synch Check Relays (J3,
TREG)

CFG(J3, K25K_Fdbk)
SynchCheck(Used, Unused)
VoltageDiff
SystemFreq(50,60)
TurbRPM
ReferFreq
FreqDiff
PhaseDiff
GenVoltage
BusVoltage
SynCk_Perm, SS GenFreq, SS
SynCk_ByPass, SS BusFreq, SS
Synch Check Function
GenVolts, SS
BusVolts, SS
GenFreqDiff, SS
Slip
DriveFreq GenPhaseDiff, SS
GenVoltsDiff, SS
Phase
Synch
Window
GenPT_KVolts, IO
BusPT_KVolts, IO
L25A_Cmd, IO
Figure 9-69. VPRO Protection Logic - Synchronization Check

Installation
The generator and bus potential transformers are wired to the first TPRO terminal
block, and the magnetic speed pickups to the second block. Jumpers JP1A and JP1B
are set to give either a 4-20 mA or voltage input on the first of the three analog
inputs. The wiring connections are shown on Figure 9-70.
Turbine Protection
Termination Board TPRO ma VOLTS
x JP1A
x 1 Gen (H)
Gen (L) x 2
Bus (L) x 4
x 3 Bus (H) OPEN RETURN
x 5 P24 (1)
20mA (1) x 6
mA ret x 8
x 7 VDC
x 9 P24V (2) JP1B
20mA (2) x 10
20mA (3) x 12
x 11 P24V (3)
TC1X (L) x 14
x 13 TC1X (H)
x 15 TC2X (H)
TC2X (L) x 16
x 17 TC3X (H)
TC3X (L) x 18
x 19 TC1Y (H)
TC1Y (L) x 20
TC2Y (L) x 22
x 21 TC2Y (H)
24
x 23 TC3Y (H)
TC2Y (L) x
x To Connectors
JX5, JY5, JZ5,
JX1, JY1, JZ1
x
x 25 TC1Z (H)
TC1Z (L) x 26
x 27 TC2Z (H)
TC2Z (L) x 28
TC3Z (L) x 30
x 29 TC3Z (H)
MX1 (L) x 32
x 31 MX1 (H)
x 33 MX2 (H)
MX2 (L) x 34
MX3 (L) x 36
x 35 MX3 (H)
MY1 (L) x 38
x 37 MY1 (H)
x 39 MY2 (H)
MY2 (L) x 40
x 41 MY3 (H)
MY3 (L) x 42
MZ1 (L) x 44
x 43 MZ1 (H)
MZ2 (L) x 46
x 45 MZ2 (H)
x 47 MZ3 (H)
MZ3 (L) x 48
x
Up to two #12 AWG wires per Terminal Blocks can be

point with 300 volt insulation unplugged from terminal board
for maintenance
Figure 9-70. Termination Board TPRO

Vibration/Position TVIB
The Mark VI system uses Bently Nevada probes for shaft vibration monitoring. Up
to 14 probes connect to the TVIB termination board, two of which can be cabled to
the VVIB board. The signals are processed by the VVIB board, and the digitized
displacement and velocity signals are sent over the VME bus to the controller. If
desired a Bently Nevada 3500 monitoring system can be cabled into the termination
board to permanently monitor turbine vibration. Also the type 2 termination board
(TVIBH2A) has BNC connectors allowing portable vibration data gathering
equipment to be plugged in for predictive maintenance purposes. These connectors
are shown in Figure 9-71, and details of the TVIB board are shown in Figure 9-72.
TVIB Termination Board VVIB VME Board
x
x
x 37-pin "D" shell
x 1 ...JA1
... JT1 type connectors
x 2 ...
. RUN
x 4 x 3 ... with latching FAIL
...
6 x 5 . STAT
x
x 7
...
... fasteners
Vibration x 8 .
...
x 10 x 9 ...
.
Signals x 11 ...
x 12 ...
. JB1
x 14 x 13 ...
...
.
x 16 x 15
x 17
...
...
.
Cable to VME
x 18
x 20 x 19 ...
...
. JS1 Rack T
x 22 x 21
24 x 23 JC1
x VME Bus to VCMI
x
x
x 26 x 25
x 28 x 27 Cable to VME
x 29 JD1 Rack S
Vibration x 30
x 32 x 31
Signals x 33 JR1
x 34 P2 P1
x 36 x 35
x 38 x 37
x 40 x 39 P6 P5 P4 P3 VVIB
x 42 x 41 x
x 44 x 43
x 46 x 45 P10 P9 P8 P7 J3
x 47 Connectors on
x 48
x 14 13 12 P11 VME Rack R
x
Shield Bar
To Portable Bentley- J4
Cable to VME
Nevada Data Gathering &
Rack R
Monitoring Equipment
To Fixed Bentley-Nevada Cable to second TVIB

3500 Vibration Monitoring
System
Figure 9-71. Vibration Termination Board, Processor Board, and Cabling

Vibration Board Operation
<R>
<S>
<T>
Vibration Board
Termination Board TVIB VVIB
JR1 J3 To
N28V 28Vdc Contr
-oller
<S>
<T> Amp A/D
N28VR
Sampling type A/D
1 N24V
S CL Converter(16 bit)
P V 2 PR01H
S JS1 J3
R s V 3mA
S
N28V
O JP1A
3 PR01L P,A
X S Same as <S>
Vib. or Pos. PCOM
Eight of the
Prox. (P), or above ccts.
P,V,A
Seismic (S), TMR
or Accel., or N28V Applications
Velomiter(V) JT1 J3
S
N28V
CL JP1B
Negative Same as
25 N24V Volt Ref <T>
S
P 26 PR09H
R S JA1
O 27 PR09L
S
X 4 of the
above ccts. Buffer
Position DB25
Amplifier JB1 J4
Prox PCOM
N28V
DB25
Buffer P1-P8 JC1 J4
CL
Amplifier
37 N24V
S
P 38 PR13H DB25
R S
O 39 PR13L P9-P12
S BNC JD1
X J4
Buffer Connectors DB9
Reference Amplifier
or PCOM
Keyphasor
Prox. One of the above ccts for Mark VI.
Two of the above ccts for B/N interface
P13-P14
Four cables to Bentley
Nevada 3500 System
Figure 9-72. TVIB Board, Vibration Probes, and Bentley Nevada Interface

TVIB supports Proximitor, Seismic, Accelerometer, and Velomitor probes of the
type supplied by Bently Nevada. Power for the vibration probes comes from the
VVIB boards, in either Simplex or TMR mode. The probe signals return to VVIB
where they are A/D converted and sent over the VME bus to the controller.
Vibration, eccentricity, and axial position alarms and trip logic are generated in the
controller.
A –28 V dc source is supplied from the VME board to the termination board for
Proximitor power. In TMR systems, a diode high-select circuit selects the highest –
28 V dc bus for redundancy. Probe inputs are sampled at high speed over discrete
time periods. The maximum and minimum values are accumulated, the difference is
taken (max-min) for vibration, and the results are filtered. The resulting peak to peak
voltage is scaled to yield mils (peak to peak) displacement, or velocity.
VVIB Features
Vibration Functions
Vibration probe inputs are normally used for four protective functions in turbine
applications as follows:
Vibration: Proximity probes monitor the peak-to-peak radial displacement of the
shaft (the shaft motion in the journal bearing) in two radial directions. This system
uses non-contacting probes and Proximitors, and results in alarm, trip, and fault
detection.
Rotor Axial Position: A probe is mounted in a bracket assembly off the thrust
bearing casing to observe the motion of the thrust collar on the turbine rotor. This
system uses non-contacting probes and Proximitors, and results in thrust bearing
wear alarm, trip, and fault detection.
Differential Expansion: This application uses non-contacting probe(s) and
Proximitor(s) and results in alarm, trip, and fault detection for excessive expansion
differential between the rotor and the turbine casing.
Rotor Eccentricity: A probe is mounted adjacent to the shaft to continuously sense
the surface and update the turbine control. The calculation of eccentricity is made
once per revolution while the turbine is on turning gear. Alarm and fault indications
are provided.
Probes
The eight vibration inputs on each termination board can be applied as either
proximitor, accelerometer, seismic (velocity), or velomitor inputs. Jumpers on the
termination board are used to assign a specific vibration sensor type to each input
point with the seismic type assigned to point (S), the velomitor type assigned to point
(V), and the proximitor and accelerometer types sharing point (P/A). A proximitor
reads a shaft keyway to generate a once per revolution KeyPhasor input for phase
angle reference.
Alarms & Trips

Diagnostics perform a high/low (hardware) limit check on the input signal and a
high/low system (software) limit check. The software limit check is adjustable in the
field. A probe fault, alarm, or trip condition will occur if either of a X or Y probe
pair exceeds its limits. In addition, the application software will inhibit a vibration
trip (the AC component) if a probe fault is detected based on the DC component.

Position inputs for thrust wear protection, differential expansion, and eccentricity are
monitored similar to the vibration inputs except only the DC component is used for a
position indication. A 16-bit sampling type A/D converter is used with 14-bit
resolution and overall circuit accuracy of 1% of full scale.
Vibration Monitoring and Analysis

Each input is actively isolated and the signals made available through four plugs for
direct cabling to a Bently Nevada 3500 monitor. This configuration provides the
maximum reliability by having a direct interface from the proximitors to the turbine
control for trip protection and still retain the real-time data access to the Bently
Nevada system for static and dynamic vibration monitoring. Note that the Mark VI
displays the total vibration, the 1X vibration component and the 1X vibration phase
angle, but it is not intended as a vibration analysis system. Fourteen BNC connectors
on TVIB provide buffered signals to portable data gathering equipment for predictive
maintenance purposes. Buffered outputs have unity gain and can drive loads up to
1500 ohms.
Table 9-32. VVIB Specification
Item Specification
Number of Channels TVIB: 13 probes:

8 Vibration, 4 Position, 1 Key Phasor
VVIB: 26 probes with two TVIB boards
Vibration Measurement Range Accuracy Frequency
Proximity Displacement 0 to 4.5 V pp ± .030 V pp 5 to 200 Hz

Displacement 0 to 4.5 V pp ± .150 V pp 200 to 500 Hz
Seismic Velocity 0 to 2.25 V p Max [2% reading,±.008 Vp] 5 to 200 Hz

Velocity 0 to 2.25 V p Max [5% reading,±.008 Vp] 200 to 500 Hz
Velomitor Velocity 0 to 2.25 V p Max [2% reading,±.008 Vp] 5 to 200 Hz

Velocity 0 to 2.25 V p Max [5% reading,±.008 Vp] 200 to 500 Hz
Accelerometer Velocity (tracking filter) 0 to 2.25 V p ± .015 Vp 10 to 233 Hz
Position Position -.5 to -20 V dc ± 0.2 V dc Air Gap (average)
Phase Degrees 0 to 360 degrees ± 2 degrees up to 14,000 RPM

(1X vibration component with respect to key slot)
Probe Power -24 V dc from the –28 V dc bus; each probe supply is current limited.
Probe Signal Sampling 16-bit A/D converter with 14-bit resolution on the VVIB
Sampling rate is 4,600 samples per second in fast scan mode (4,000 to 17,500 rpm)
Sampling rate is 2,586 samples per second for nine or more probes.
All inputs are simultaneously sampled in time windows of 160 ms.

Table 9-33. VVIB Configuration
System Limits Enable system limits Enable, Disable

Vib_PP_Fltr First order filter time constant (sec) 0.01 to 2
L3DIAG_VVIB Diagnostic for all board points Point Edit
SysLim1GAP1-26 Two system limit diagnostics for all 26 board points Point Edits
J3:IS200TVIBG1A Vibration Termination Board Connected , Not Connected

GAP1_VIB1 First vibration probe Point Edit
VIB_Type Type of vibration probe Unused, PosProx, VibProx,
VibProx-KPH1, VibProx-
KPH2, VibLMAccel,
VibVelomitor, KeyPhasor
VIB_Scale Volts/mil or Volts/ips 0 to 2
SysLim1Enabl Enable System Limit 1 Enable, Disable
SysLim1Latch Latch the alarm Latch, Not Latch
SysLim1Type System Limit 1 Check Type >= or <=
SysLimit1 System Limit 1 – GAP in negative volts (for Vel) or -100 to +100
positive mils (Prox)
SysLim2Enabl Enable System Limit 2 (same configuration as Enable, Disable
above)
TMR_DiffLimt Difference Limit for Voted TMR Inputs in Volts or -100 to +100
Mils
GAP2_VIB2 Second Vibration Probe of 8 As above
GAP9_POS1 First Position Probe of 4 As above
GAP13_KPH1 Key Phasor Probe As above
J4:IS200TVIBG1A Second Vibration Termination Board Connected, Not Connected

GAP14_VIB9 First Vibration Probe of 8 As above
GAP22_POS5 First Position Probe of 4 As above
GAP26_KPH2 Key Phasor Probe As above

Installation
Fourteen vibration probes are wired to the two terminal blocks, three wires per
probe. Jumpers JP1 through JP8 select the type of the first eight probes. These are
shown in Figure 9-73. The Bently Nevada 3500 system is optional, so cables to JA1,
JB1, JC1, and JD1 may not be required. BNCs P1 through 14 are for temporary
connection to portable data gathering equipment.
S P,V,A
Vibration Termination B/N Buffer Jumper
Board TVIB Sensor Input Positions
V P,A
S
JP1B Probe
x JP1A Selection
x 1 N24V (01) JP2B Jumpers
PR01 (H) x 2
N24V (02) x 4
x 3 PR01 (L) JP2A
x 5 PR02 (H) JP3B
PR02 (L) x 6
x 7 N24V (03) JP3A
PR03 (H) x 8 JP4B
x 9 PR03 (L)
N24V (04) x 10 JP4A
x 11 PR04 (H) JP5B
PR04 (L) x 12
14
x 13 N24V (05) JP5A
PR05 (H) x
x 15 PR05 (L) JP6B
N24V (06) x 16
PR06 (L) x 18
x 17 PR06 (H) JP6A
PR07 (H)
x 19 N24V (07) JP7B
x 20
N24V (08) x 21 PR07 (L) JP7A
x 22
x 23 PR08 (H) JP8B
PR08 (L) x 24
JP8A
x
Connectors JR1, JS1, JT1, to VME Racks
Connectors JA1,JB1, JC1, JD1 to Bentley

x Nevada 3500 system
PR09 (H) x 26
x 25 N24V (09)
N24V (10) x 28
x 27 PR09 (L)
x 29 PR10 (H)
PR10 (L) x 30 BNC
x 31 N24V (11) P2 P1
PR11 (H) x 32 connectors
x 33 PR11 (L)
N24V (12) x 34 for portable
x 35 PR12 (H)
PR12 (L) x 36 data
x 37 N24V (13) P6 P5 P4 P3
PR13 (H) x 38 gathering
N24V (14) 40
x 39 PR13 (L)
x equipment
PR14 (L) x 42
x 41 PR14 (H)
x 43 P10 P9 P8 P7
x 44
x 45
x 46
x 47 P14 P13 P12 P11 P1 is PR01
x 48
x P2 is PR02
and so on.
Up to two #12 AWG wires
JumperJPXA: S = Seismic
per point with 300 volt
V = Velomitor
insulation
P = Proximitor
Terminal Blocks can be
or Accelerometer
unplugged from terminal
board for maintenance JumperJPXB: S = Seismic
V = Velomitor
or Proximitor
or Accelerometer
Figure 9-73. Termination Board TVIB

Generator TGEN
The generator board VGEN and its termination board TGEN monitor the generator
three-phase voltage and currents, and calculate three-phase power and power factor.
The boards and cabling is shown in Figure 9-74. For large steam turbine
applications, VGEN provides the Power Load Unbalance (PLU) and Early Valve
Actuation (EVA) functions, using fast acting solenoids located on the TRLY
termination board.
TGEN Termination Board VGEN VME Board
TB1 x
x 37-pin "D" shell
x JT1
x 2 x 1 type connectors
RUN
x 4 x 3 with latching FAIL
Current x 6 x 5
fasteners STAT
Inputs & x 8 x 7
x 10 x 9
Gen PT x 11
x 12
Signals x 14 x 13
x 16 x 15
x 18 x 17 Cable to VME
x 20 x 19 JS1 Rack T
x 22 x 21
x 24 x 23
VME Bus to VCMI
x
TB2
Cable to VME
Rack S
Gen CT TB3 JR1
Signals
VGEN
x
TB4
Connectors on J3
VME Rack R
x
Cable to VME
Shield Bar Rack R
J4
Cable to Optional TRLY,

for Fast Acting Solenoids
Figure 9-74. Generator Termination Board, Processor Board, and Cabling

Generator Monitor Operation
VGEN monitors two, three-phase potential transformer (PT) inputs, and three, one-
phase current transformer (CT) inputs. Also on TGEN there are four analog inputs
which can be configured for 4-20 mA or +/-5, 10 V dc. Signal conversion and
calculations of power, power factor and frequency take place on the VGEN board.
Details of the termination board are shown in Figure 9-75.
<R>
<S>
<T>
Termination Board TGEN Controller
4 Circuits per Term. Board
TB1 Noise
Suppr. Generator
+24Vdc Current Limit
Board
vdc JP1 VGEN
+/-5,10Vdc
20 ma
4-20 ma
250 ohms
Return
JP2 Shown
for <R>
Open Return
JR1 J3 +28 Vdc
PCOM
17
115 Vrms yields
TB1
18 PCOM 1.5333 Vrms A/D
A 19 TP-GA
Generator To TRLY
3-Phase B 20
TP-GB from
Volts <R>
TP-GC JS1 J3 Buffer <S>
(115VAC) C 21
<T>
TP-BA Same for
A 22
Bus <S>
3-Phase TP-BB
B 23
Volts TP-BC
(115VAC) C 24
TB2 JT1 J3
TP-IA1
H1 01 1:2000
Current - 100
H2 02
Phase A TP-IA2 ohms Same for
L1 03
(115VAC) <T>
L2 04
TB3 TP-IB1
H1 01 1:2000
Current - H2 02 100
Phase B L1 03
TP-IB2 ohms
(115VAC) L2 04
TP-IC1 Connectors at bottom
H1 01 1:2000
100 of VME Racks
Current - H2 02
Phase C L1 03
TP-IC2 ohms
(115VAC) L2 04 5 amps yields 0.25 Vrms (l-n)
TB4 Noise Suppr. or 0.433 Vrms (l-l)
Figure 9-75. TGEN Board showing Potential & Current Transformer Inputs

Generator Board Features
VGEN monitors generator three-phase power and supplies the Power Load
Unbalance (PLU) and Early Valve Actuation (EVA) functions for large steam
turbines.
Power Monitoring
The generator and bus PT inputs are three-wire, open delta, voltage measurements
which are used to calculate all three line-to-line voltages. They are not used for
automatic synchronizing which requires two separate single-phase PT inputs. Each
PT input is nominally 115 V rms, and the PTs are magnetically isolated.
Three single-phase CT inputs are provided with a normal current range of 0 to 5 A
continuous. The CTs are magnetically isolated on TGEN. Terminations for the CTs
are on non-pluggable terminal blocks with captive lugs acepting are up to 10 AWG.
Test points are provided for all PT and CT inputs to verify the phase in the field. The
following parameters are calculated from these inputs:
• Total MWatts
• Total MVars
• Total MVA
• Power Factor
• Bus Frequency (5 to 66 Hz)
The four analog inputs can accept 4-20 mA inputs or +/-5,10 V dc inputs. A +24 V
dc source is available for all four circuits with individual current limits for each
circuit. The 4-20 mA transducer can be connected to use the +24 V dc source from
the turbine control or as a self-powered source. A jumper is located on the
termination board to select between current and voltage inputs for each circuit. High
frequency and 50/60 Hz noise is reduced with an analog hardware filter
Power Load Unbalance

The purpose of the rate sensitive Power/Load Unbalance (PLU) feature is to initiate
Control Valve (CV) and Intercept Valve (IV) fast closing action under load rejection
conditions that might lead to rapid acceleration, over speed and consequent tripping
of the turbine. The system avoids actuating the valves under stable fault conditions
which are self-clearing.
Valve action will occur when the difference between turbine power and generator
load is approximately 40% of the rated load or greater, and the load is lost at a rate
equivalent to going from rated to zero load in approximately 35 ms or less.
The turbine mechanical power (PM) is measured by a pressure signal from the reheat
steam pressure. The generator load is measured by a signal derived from the three
phase currents, thereby discriminating between load loss and faults which would not
be the case if a watt signal were used
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 causes closing of the Intercept Valves (IV) 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.

Diagnostics
Diagnostics perform a high/low (hardware) limit check on the input signal and a
high/low system (software) limit check. The software limit check is adjustable in the
field. Open wire detection is provided for voltage inputs.
Descriptions of the VGEN diagnostics are contained in Chapter 8, Troubleshooting
& Diagnostics.
Table 9-34. VGEN Specification
Item Specification
Inputs to TGEN and VGEN 2 Three-phase Generator and Bus PTs

3 One-phase Generator CTs
4 Analog Inputs (4-20 mA, +/- 5,10 V dc)
Outputs from VGEN via TRLY 12 Relay Outputs
Generator and Bus Voltages Nominal 115 V rms with range of interest of 10 to 120%
Nominal frequency 50/60 Hz with range of interest 25 to 66 Hz
Magnetic isolation to 1,500 V rms and loading less than 3 VA
Input measurement has a resolution of 0.1%
Input accuracy is 0.5% of rated V rms from 45 to 66 Hz
Input accuracy is 1.0% of rated V rms from 25 to 45 Hz
Generator Current Inputs Normal current range is 0 to 5 A with overange to 10 A
Nominal frequency 50/60 Hz with range of interest 45 to 66 Hz
Magnetic isolation to 1,500 V rms
Input accuracy 0.5% of full scale (5A) with resolution of 0.1% FS
Analog Inputs Current Inputs: 4-20 mA
Voltage Inputs: +/- 5 V dc or +/- 10 V dc
Transducers can be up to 300 m (984 ft) from the control cabinet
with a two-way cable resistance of 15 ohms.
Input burden resistor on TGEN is 250 ohms.
Jumper selection of single ended or self powered inputs
Jumper selection of voltage or current inputs
High Frequency Analog Filter: Breaks at 72 and 500 radians/sec
AC Common Mode Rejection (CMR) 60 dB
DC Common Mode Rejection (CMR) 80 dB
Conversion Accuracy Sampling type 16-bit A/D Converter, 14 bit resolution
Accuracy 0.1% overall
Calculated values Total MWatts and MVars have an accuracy of 1% FS, and 0.5%
for totalizing.
Total MVA and Power Factor have an accuracy of 1% full scale.
Bus frequency (5 to 66 Hz) has an accuracy of ± 0.1%.

Table 9-35. Typical VGEN Configuration

PLU_Enab Enable PLU function Enable, Disable
PLU_Del_Enab Enable PLU delay Enable, Disable
MechPwrInput Mech. Power via TMR (first 3 MA ccts), Dual Xducer TMR_1 thru 3, Dual 1 & 2,
(Max), Single Xducer, or Signal Space SMX_1, SMX_2, Signal Space
PLU_Rate Select PLU threshold rate ME, LO, HI
PLU_Unbal PLU Unbalance threshold % 20 to 80
PLU_Delay PLU delay, secs 0 to 10
Press Ratg Reheat press equiv. to 100% Mech. Power 50 to 600
Current Ratg Generator Current equivalent to 100% Elect Power 1,000 to 60,000
EVA_Enab Enable EVA function Enable, Disable
EVA_ExtEnab Enable external EVA function Enable, Disable
EVA_Rate Select EVA threshold rate LO, ME, HI
EVA_Unbal EVA unbalance threshold % 20 to 80
EVA_Delay EVA drop out time, seconds 0 to 10
MW_Ratg Generator MW equivalent to 100 % Electrical Power 10 to 1,500
IVT_Enab Enable IVT function Enable, Disable
Min_MA_Input Minimum MA for Healthy 4-20 mA Input 0 to 21
MAx_MA_Input Maximum MA for Healthy 4-20 mA Input 0 to 21
SystemFreq System Frequency in Hz 50 or 60
J3:IS200TGENG1A
AnalogIn1 First Analog Input (of four) Point Edit
Input Type Type of analog input Unused, 4-20ma,
+/-5 V, +/-10 V
Low Input Input MA at low value -10 to 20
Low Value Input value in Engineering Units at low MA -3.4028e+038 to
3.4028e+038
System Limits Standard System Limits (see TBAI configuration)
GenPT_Vab_KV Generator Potential Transformer Input "ab", (first of 3) Point Edit
PT_Input PT Input in KiloVolts rms for PT_output 1 to 1,000
PT_Output PT Output in Volts rms for PT_Input-typically 115 60 to 150
Phase Shift Compensating Phase Shift, applied to PT signals Zero, Plus 30, Plus 60, Minus
30, Minus 60
System Limits Standard System Limits (similar to Analog Inputs)
BusPT_Vab_KV Bus Potential Transformer Input "ab", (first of three) Point Edit
GenCT_A Generator Current Transformer A (first of three) Point Edit
CT_Input CT Input in Amperes rms for rated CT_Output 100 to 50,000
CT_Output Rated CT Output in Amperes rms, typically 5 1 to 5
Standard configuration inputs
J4:IS200TRLYG1A
Relay01 First of 12 relays Point Edit
Relay Output Configurable Item: Slot N Unused, CV, Tst Only, CV EVA

Installation
The analog current and PT inputs are wired to terminal block 1. The CTs are wired to
special terminal blocks TB2, 3, and 4, which cannot be unplugged. This protects
against an open CT circuit. Jumpers J1A,B through J4A,B set the desired input
current or voltage on analog inputs 1 through 4. The wiring connections are shown
in Figure 9-76.
Generator Termination Board TGEN
TB1 20ma VDC RET OPEN

x
J1A J1B
20 mA (1) x 2
x 1 P24V (1)
RET (1) x 4
x 3 VDC (1)
x 5 P24V (2) J2A J2B
20mA (2) x 6
RET (2) x 8
x 7 VDC (2)
x 9 P24V (3)
20mA (3) x 10 J3A J3B
x 11 VDC (3)
RET (3) x 12
x 13 P24V (4)
20mA (4) x 14
x 15 VDC (4)
RET (4) x 16 J4A J4B
x 17 PCOM
PCOM x 18
GenB x 20
x 19 GenA
BusA x 22
x 21 GenC
24
x 23 BusB
BusC x
x
CurAH1 1
CurAH2 2
CurAL1 TB2
3
CurAL2 4
To Connectors
CurBH1 1 JR1, JS1, JT1
CurBH2 2
TB3
CurBL1 3
CurBL2 4
CurCH1 1
CurCH2 2
TB4
CurCL1 3
CurCL2 4
Terminal Block 1 can be

unplugged from terminal
board for maintenance. TB2,
TB3, TB4 are not pluggable.
Figure 9-76. Termination Board TGEN and Wiring

Pyrometer Board – TPYR
The Optical Pyrometer Board (VPYR) provides a dynamic temperature profile of the
rotating turbine blades, and computes temperature conditions which lead to a trip.
The Pyrometer termination board (TPYR) is wired to two infrared TBTMS
thermometers, known as Pyrometers, and to two KeyPhasor Proximitor probes for
shaft reference. Dedicated analog to digital converters on VPYR provide sampling
rates up to 200,000 samples per second for burst data from two of the temperature
channels. Fast temperature data is made available for display and off-line evaluation.
The termination board has Simplex and TMR capability, as shown in Figure 9-77.
TPYR Termination Board VPYR VME Board
37-pin "D" shell type x

x connectors with
x JT1
x 2
x 1 latching fasteners RUN
x 4
x 3 FAIL
STAT
x 6
x 5
Pyrometer x 8
x 7
x 10
x 9
Wiring x 11
x 12
x 14
x 16
x 15
x 18
x 17
x 20
x 19 JS1
x 22
x 21 Cables to VME
x 24
x 23 Racks S and T
x
x
x 26
x 25
x 28
x 27
x 30
x 29
KeyPhasor x 31
x 32 JR1
Wiring x 34
x 33
x 36
x 35
x 38
x 37
x 40
x 39 Cable to VME VPYR
x 42
x 41 Rack R x
44
x 43
x
45
Connectors on
x 46
x J3
x 47 VME Rack
x 48
x
x
Shield Bar
J4
Figure 9-77. Pyrometer Termination Board, Processor, and Cabling

Pyrometer Board Operation
Analog signals from the termination board, shown in Figure 9-78, are cabled to the
VPYR processor board where signal sampling and conversion take place. VPYR
calculates the temperature profiles and runs turbine protection algorithms using both
pyrometer signals. If a trip is indicated and the signals are validated, VPYR issues
the trip signal.
<T>
Chan A TPYR Termination Board <S>
<R>
1 P24A Current P28VX VPYR Pyrometer Board

2 PCOM Limiter
JR1 J3
3 N24A Current N28VX Chan A Fast
4 PCOM Limiter Fan Fast A/D sampling
Distrib P28VR
5 20mA A1 -ution
P 6 Avg N28VR Chan B
RetA1 Fast
y Fast
r A/D sampling
o 7 100 ohms
m 8 Pk
e All
t 9 others
e 10 Avg-Pk Mux A/D
r
11
12 Fast
Chan B JS1 J3
13 P24B Current P28VX
14 PCOM Limiter Same for
P28VS <S>
15 N24B Current N28VX
16 PCOM Limiter N28VS
P 17
y 18 Avg
r
o
m 19
e 20 Pk
t
e 21
r 22 Avg-Pk
23 JT1 J3
24 Fast
Same for<T>
30 N24Pr1 Current N28VX P28VT
Limiter
31 PrH1 N28VT
32 PrL1
P28VR
KeyPhasor#1
P28VX P28VS
33 N24Pr2 Current N28VX P28VT
Limiter
34 PrH2 N28VR
35 PrL2
N28VX N28VS
KeyPhasor#2 N28VT
Noise Suppression on all
Inputs & Power Outputs
Figure 9-78. TPYR Termination Board and Processor Board

VPYR Features
Optical Pyrometer Measurements
Two infrared pyrometers dynamically measure the temperature profile of the rotating
turbine blades. Each pyrometer is powered by a +24 V dc and a –24 V dc source on
the termination board, diode selected from the voltages from the three VPYR boards.
Four 4-20 mA signals are returned from each pyrometer, representing the following
blade measurements:
• The average temperature
• The maximum peak temperature
• The average peak temperature
• A fast dynamic profile, with 30 kHz bandpass, providing the full signature.
Each 4-20 mA input generates a voltage across a resistor which is sent to the VPYR
board where it is multiplexed and converted. A dedicated A/D converter is used to
sample input 4 at up to 200,000 samples per second. VPYR can be configured for
different numbers of turbine buckets, with up to 30 temperature samples per bucket.
KeyPhasor Inputs
Two keyphasors are used for shaft position reference, one as a backup. These
keyphasor probes and associated circuitry are identical to those used with
TVIB/VVIB. They sense a shaft keyway or pedestal to provide a time stamp.
Turbine Protection Algorithm

Fast burst data is used for the protection algorithms. One peak temperature per
bucket is isolated and the highest for that revolution is selected. The delta
temperature compared to the previous revolution is calculated (the rate of change)
and compared to a calculated value which uses configurable parameters. Three of
these are computed using different parameters. Similarly a distance variable is
computed by taking the difference between the revolution peak and a peak taken y
samples ago, where y is configurable. This delta is also compared to a configurable
value. Finally the three rate signals and one distance signal are logically combined
with permissives and the other channel trip condition to produce the trip signal.

Table 9-36. VPYR Specification
Item Specification
Number of Inputs 2 Pyrometers, each with 4 analog 4-20 mA current signals

(TPYR & VPYR) 2 Key Phasor probes, each with –0.5 to –20 V dc inputs
Current Inputs from Pyrometers 4-20 mA across a 100 ohm resistor

Common Mode Rejection: DC up to +/- 5 Vdc, CMRR of 80 dB
AC up to +/-5 Volt peak, CMRR of 60 dB
Measurement accuracy of +/- 0.1 % full scale, 14-bit resolution
Bandwidth of 0 to 100 Hz on 6 slow inputs using multiplexed A/D converter
Sampling at 200,000 per sec. on 2 fast inputs using dedicated A/D converters
Keyphasor Inputs Input voltage range of –0.5 to –20 V dc
Common Mode Rejection: CMR of 5 Volt, CMRR of 60 dB at 50/60 Hz
Accuracy 1 % of full scale (0.2 V dc)
DC level detection typically 0.2 V/mil sensitivity
Speed measurement 2 to 5,610 RPM with accuracy of 0.1 % of reading
Device Excitation Pyrometers have individual power supplies, current limited:
P24V source is diode selected, +22 to +30 V dc, 0.175 Amp
N24V source is diode selected, -22 to -30 V dc, 0.175 Amp
Measurement Parameters Rated RPM up to 5,100 RPM
Number of Buckets per stage, up to 92
Number of samples per bucket, up to 30
Fast inputs sampled in bursts covering three revolutions, at twice per second.
Diagnostics
VPYR provides system limit checking on the KeyPhasor gap signals. The two
pyrometer inputs are compared against configuration limits to determine if they are
tracking, and the fast data is compared with other inputs to check validity.
Descriptions of the VPYR diagnostics are contained in Chapter 8, Troubleshooting
& Diagnostics.

Like all I/O boards, VPYR is configured using the Control System Toolbox. This
software usually runs on a data-highway connected CIMPLICITY station or
workstation. The table below summarizes the configuration choices and defaults. For
Turbine Controller.
Table 9-37. Typical VPYR Configuration
Module Parameter Description Choices

System Limits Enables or Disables all System Limit Checking Enable, Disable
L3DIAG_VPYR Diagnostic for all Board Points Used, Not used
Min_MA_Input Min MA for healthy 4/20 mA Input 0 to 21
Max_MA_Input Max MA for healthy 4/20 mA Input 0 to 21
RPMrated Rated turbine RPM 0 to 10,000

BuckSamples Minimum samples per bucket at 110 percent 10 to 30
speed
BuckOffset_A Offset from key to the first bucket, % bucket, 0 to 50
Pyr A
SetptR1_A Setpoint, Rate 1, Pyr A 0 to 30
SetptR1B_A Setpoint, Rate 1, Bias, Avg temp, Pyr A -1 to 1
SetptD_A Setpoint distance, Pyr A 0 to 30
SetptDB_A Setpoint distance. Bias, Avg Temperature, -1 to 1
Pyr A
SetptDDepth_A Setpoint, Depth of the Distance measurement, 0 to 30
Pyr A
Rate2Enab_A Enable, Temperature rate 2, Pyr A Enable, Disable
Rate3Enab_A Enable, Temperature rate 3, Pyr A Enable, Disable
DistEnab_A Enable Temperature rate 3, Pyr A Enable, Disable
Same Configuration for B
J3:IS200TPYRG1A Termination Board 1 connected to VPYR via J3 Connected, Not connected
SlowAvg_A Slow, Average temperature, Pyr A Point Edit
Input Use Is this point used? Used, Unused
Low_Input Input MA at Low Value 0 to 21
Low_Value Input value in Engineering Units at Low MA -3.4e+038 to 3.4e+038
High_Input Input MA at High Value 0 to 21
High_Value Input Value in Engineering Units at High MA -3.4e+038 to 3.4e+038
TMR_Diff Difference Limit for Voted TMR Inputs in % of 0 to 100
(High Value-Low Value)
SlowMXPk_A Same Configuration as above Point Edit
SlowAvgPk_A Same Configuration Point Edit
FastAvg_A Same Configuration Point Edit
SlowAvg_B Same Configuration Point Edit
SlowMXPk_B Same Configuration Point Edit
SlowAvgPk_B Same Configuration Point Edit
FastAvg_B Same Configuration Point Edit
GAP_KPH1 Keyphasor Gap Point Edit
VIB-Type Configurable Item Used, Not used
VIB_Scale Volts/mil 0 to 2
KPH_Thrshld Voltage difference from gap voltage where 1 to 5
Keyphasor Trigger
KPH_Type Type of Pulse Generator Slot, Pedestal
SysLim System Limits 1 and 2, and TMR Standard Choices
GAP_KPH2 Same Configuration as for KPH1 Point Edit

Installation
The two optical pyrometers are wired to the first terminal block on TPYR, and the
two KeyPhasor probes are wired to the second terminal block. There are no probe
jumpers as on the TVIB board. The wiring connections are shown in Figure 9-79.
TPYR Termination Board JR1
PCOM1 (A) x 2
x 1 P24 (A)
x 3 N24 (A)
PCOM2 (A) x 4
x 5 20ma (A1)
Ret (A1) x 6
x 7 20ma (A2)
Ret (A2) x 8
x 9 20ma (A3)
Ret (A3) x 10
x 11 20ma (A4) Cable to <R>
Ret (A4) x 12
14
x 13 P24 (B)
PCOM1 (B) x
x 15 N24 (B)
PCOM2 (B) x 16
x 17 20ma (B1) JS1
Ret (B1) x 18
20
x 19 20ma (B2)
Ret (B2) x
Ret (B3) x 22
x 21 20ma (B3)
Ret (B4) x 24
x 23 20ma (B4)
x
x
x 25 Cable to <S>
x 26
x 27
x 28
x 29
N24 Pr (1) x 30
PrL (1) x 32
x 31 PrH (1) JT1
PrH (2) x 34
x 33 N24Pr (2)
x 35 PrL (2)
x 36
x 37
x 38
x 39
x 40
x 41
x 42
x 43
x 44
x 45
x 46
x 47
x 48 Cable to <T>
x

Figure 9-79. Termination Board TPYR and Wiring

VME Rack Power Supply
The VME rack power supply mounts on the side of the VME control and interface
modules, as shown in Figure 9-80, and supplies +5, +/-12, +/-15, and +/-28 V dc to
the VME backplane. The power supply runs off 125 V dc cabled in from the Power
Distribution Module (PDM). A special 335 V dc output is provided for powering
flame detectors connected to TRPG. Note that a different power supply is used on
the small control rack, which only powers the Mark VI controller, VDSK, and
VCMI, and not the I/O boards, as required for the control and interface modules.
Cable Harness
to VME Rack Side View
PSA PSB
POWER
SUPPLY
Pull to Toggle
On
Off
Normal
Fault
Availabl
Front View Heat Sink Cooling Fins
PS28A PS28B PS28C PS335 PS125

Bottom
View
125 Vdc
28 V dc 335 from
(special) V dc PDM
Figure 9-80. VME Rack Power Supply, Front, Side & Bottom Views

Power Supply Operation
The power supply contains no user serviceable parts and the cover must not be
removed. The power supply contains three circuit boards, an input board with
control, monitoring and auxiliary functions, a module board with power supply
modules, and an output board with four more power modules and output filtering.
Twelve power modules, shown in Figure 9-81, are mounted to the inside surface of
the heat sink under these boards:
• Five +28 V dc supplies
• Two combined +5 V dc supplies
• One –28 V dc supply
• One +12 V dc supply
• One +15 V dc supply
The input board holds the control and monitoring circuits, plus a 335 V dc power
supply circuit along with an auxiliary 24 V dc power supply for the control logic.
Schematics of the power supply are shown in Figures 9-82 and 9-83.
Connectors for Cable Harness
Output Filtering
Power Supply Modules Mounted under the
M-100 M-101 M-102 M-103 Circuit Boards on the Heat Sink
+5V +5V +28V +28V
Output Board
Heat Sink with Fins on Back of Assembly

M-300 M-301 M-302 M-303
-28V +28V +28V +28V
Module Board
M-304 M-305 M-306 M-307
+12V -12V +15V -15V
Control & Auxiliary 335 Volt Latching Power On-Off Switch

Monitoring 24 V Supply
Circuits Supply
10 A Fuse
Input Board
125 V dc
Power Input
Figure 9-81. Inside View of VME Power Supply showing Power Modules

Power Input
125 VDC IS2020RKPSG1AC 400 W Power Supply
PS125 suppression startup relay
fuse Continued on next page
P125 2
N125 1 Green-- Normal
3 On/Off
NC Red----- Fault
4 switch
Yellow-- Avail
enable
P335V
1.68 W
PS335 + Ret
P335VDC P28V P28V P28V P28V P28V
1
2 50/100 W 50/100 W 50/100 W 50/100 W 50/100 W
+ Ret + Ret + Ret + Ret + Ret 3 PS28A
3 2
1
3 PS28B
2
1
3 PS28C
2
1
PSA 24 22 20 18 16 14 12 10 8 6
*PS28C
"Normal"
To Safety Ground
*PS28C
"Isolation"
I/O 21- Slot VME

P12Vdc Rack
Fan 1
2 N12Vdc
Power
PL1
1
*PS28C 2
PL2
"Normal" 3
4
1
*PS28C 2 PL3
"Isolation" 3
s
4 P28A P28B s P28C s s P28D s P28E
s s s s s
PCOM
PCOM
SCOM
Slots 1 thru 5 Slots 6 thru 9 Slots 10 thru 13 Slots 14 thru 17 Slots 18 thru 21
PS28C Configuration: The Power Supply PS28C may be

isolated from the I/O Rack for external use. One plug, two
The represents a pi
positions "Normal", "Isolation", for selection; Plug is located on
symbol, s suppression
left side of Rack (from the front).
filter: scom
P28A and P28B are for internal cabinet use only, not to go
outside of the cabinet.
Figure 9-82. VME I/O Rack Power Supply & Cables

IS2020RKPSG1AC 400 W Power Supply
Continued from previous page
P125 (power)
enable
N28V N15V P15V N12V P12V P5V

25/100 W 50/100 W 50/100 W 25 W 50 W 150 W
- Ret - Ret + Ret - Ret + Ret + Ret
V sensing
28 26 3220 30
18 8 6 12 10 16 14 24,28,32 22,26,30 20 18
PSA PSB
21 Slot VME Rack s s

P5V
DCOM s s
P15V s P12V s
s s s s
ACOM
ACOM
s s N12V
N15V
s PCOM
PCOM SCOM
s
N28V
*SCOM
Above Distribution for All Slots
Note: SCOM must be connected to ground

The s represents a pi via the Rack mounting hardware, metal to
symbol, suppression filter: metal conductivity, to the mounting base and
scom hence to ground.
Figure 9-83. VME I/O Rack Power Supply & Cables, continued

Table 9-38. Power Supply Specification
Item Description
Input Voltage 70 to 145 V dc floating supply

Up to 10 V pp ripple
Under voltage shutdown on input voltage, latching, cycle shutdown switch to recover
Isolation True isolation from Input to Output, 1500 Volts
Output Voltages Output Voltage Voltage Regulation Capacity Current Over Voltage Shutdown
P5 5 V dc Less than +/- 3 % 150 Watts 30 Amps 20 % +/- 5 %
P15 15 V dc Less than +/- 3 % 50 Watts 3.33 Amps 20 % +/- 5 %
N15 -15 V dc Less than +/- 3 % 50 Watts 3.33 Amps 20 % +/- 5 %
P335 335 V dc Less than +/- 5 % 1.68 Watts 0.005 Amps 10 % to 20 %
Total Output Maximum of 400 Watts
Short Circuit Short circuit protection on all power supplies, with self recovery
Temperature Ambient Air Convection Cooling 0 to 75 degree C
Indicating Lights Green: Normal -Status is OK
Red: Fault -Power is applied but supply is shutdown due to:
Trouble with the supply, latched off
Low input voltage, latched off
Yellow: Available -Power is applied, but switch is "off"
Power The 5 V dc supply comes up first, then all the others
Sequencing
Diagnostics
Incoming and outgoing voltages and currents are monitored for control and
protection purposes. The following protective actions can occur:
• An input 110 V dc undervoltage condition sets the fault latch, shuts off all
power supplies, and lights the Red LED. Upon recovery, the fault can be reset
with the on/off switch.
• Any power supply output overvoltage fault turns off the bad power supply and
lights the Red LED. Reset by turning off the power supply.
• Undervoltage on the +5 Volt supply (output less than 4.7 Volts) cuts off all the
power supplies until the 5 Volts comes back. The red LED is lit.
• The 335 V dc supply has an overvoltage circuit that lights the Red LED and
shuts down the 335 Volts and other supplies. The output has current limiting.
Test points for all these voltages are located at the left hand side of the VME rack
(refer to the diagram in Chapter 6, Installation for the test point location).

Installation
The power supply is mounted to the right hand side of the VME rack on a sheet
metal bracket, as shown in Figure 9-84. The 125 V dc input, 28 V dc output, and 335
V dc output connections are at the bottom. Two connectors, PSA and PSB, at the top
of the assembly mate with a cable harness carrying power to the VME rack.
Power cables to
VME Chassis
5 slots - A 4 slots - B 4 slots - C 4 slots - D 4 slots - E
Fan
+/- 12 Volts x x x x x x x x x x x x x x x x x x x PSA
to Fan, used PSB
with Controller Power
Supply
Plug Position
P28 Normal
Plug Position
P28 Isolated
VME Chassis,
21 slots for I/O
and Control, or x x x x x x x x x x x x x x x x x x x x x
for just I/O
J301
Power Supply
Test Points
GND
Rack Ethernet
ID Plug 125
Vdc
Input
from
P28C Power to External PDM
Peripheral Device (Move
Cable from
Plug from Normal to 335 V dc
PDM Monitor
Isolated Position)
Figure 9-84. Power Supply, VME Chassis, & Cabling to External Devices
Each of the five 28 Volt power modules supplies a section of the VME rack. These
sections are labeled A, B, C, D, E, and F in Figure 9-84. The P28C output at the
bottom of the power supply can be used to power an external peripheral device. To
do this the jumper plug shown on the bracket to the left of the rack must be moved
from the Normal position to the Isolated position below. This allows Module D to
supply rack sections D and E, and Module E to supply the external load via P28C.
Note that the 28 Volt power modules A, B, C, are not related to P28A, B, C; also
note that normally only P28C is used.
The fan, only used when the controller is mounted in the rack, is powered by +/- 12
Volts from the top connector on the same bracket on the left side of the rack.

Power Distribution Module
The Power Distribution Module (PDM) provides 125 V dc and 115 V ac (or 230 V
ac) to the Mark VI system, including all racks and termination boards. The PDM
arrangement is shown in Figure 9-85. There is a second version of the PDM for the
control cabinet in those systems using remote I/O cabinets.
Diagnostics to
VCMI via J301
in <R> Rack
Power Cables to
Interface Modules
125 V dc, 115/230 V ac
DIN rail
Termination
Output Power Board
Connectors
Power Distribution Module

(for Interface Modules)
TB2 TB1
Power
TB3 Input Filters
Terminals Filtered DC
and AC power
to PDM
JTX1 AC/DC
115 V Converter
Cable to
Cable to PDM JZ2
Transformer or JZ3
inside AC/DC JTX2
JZ
Converter 230 V
TB1
Customer’s Power TB2

Cables, 125 Vdc
One or two converters and 115/230 Vac
Figure 9-85. Power Distribution Module, AC to DC Converter, & Diagnostic Cabling

PDM Operation
The customer’s 125 V dc and 115/230 V ac power is brought through power filters
into the PDM. The AC power is cabled out to one or two AC/DC converters which
produce 125 V dc. This DC voltage is then cabled back into the PDM and diode
coupled to the main DC power, forming a redundant power source, as shown in
Figure 9-86. This power is distributed to the VME racks and termination boards.
Either 115 V ac or 230 V ac can be handled by the AC/DC converters. The
transformer cable must be plugged into either JTX1 for 115 V ac, or JTX2 for
230 V ac operation.
Diagnostic information is collected in the PDM and wired out to a DIN rail mounted
termination board. A cable then runs to the VCMI in rack <R> via J301. Diagnostic
information in the control cabinet is handled slightly differently, refer to Figure 9-88.
PDM for Interface Cabinet

AC feeders, J17-20, are fused and cabled out to the relay termination boards. 125 V
dc feeders are fused and cabled to the interface cabinets, protection modules, TRPG,
TREG, and TRLY. To ensure a noise free supply to the boards, the PDM is supplied
through a Control Power Filter (CPF) which suppresses EMI noise. The CPF rack
holds either two or three Corcom 30 A filter modules as shown in Figure 9-86
Power to the contact inputs first passes through resistors R3 and R4, through TB2,
before being fused and cabled to the TBCI. Contact inputs normally operate with 125
V dc excitation, but can be converted to an external 24 V dc supply if desired. This
24 V dc is wired to TB2.
PDM for Control Cabinet

Power requirements for the control cabinet are less than for the interface cabinet. The
PDM has the same layout but different fuse ratings, since only the control racks and
relay output boards require power.

125 VDC AC1 AC2
+ P125 - N125 115/230 VAC 115/230 VAC
TB2 5 6 3 4 1 2
DCF1 ACF1 ACF2 Power Filter Board

TB1 5 6 3 4 1 2
TB1 1 2 3 4 5 6 7 8 9 10 11 12
Chassis Chassis
DS2020PDMAG6 DS200TCPD
DCLO AC1N AC
DCHI AC2H AC2N Fuse Feeders
AC1H
J17
JZ4 J18
For Bus P125V J19
JZ5 J20
Monitoring 125 VDC
BJS To TREG,
TB3 ACSHI JH1,
P125 VR JZ2 DACA#1
1 Contact
P125S Inputs
2 332k
(+1.82V)
JZ3 DACA#2 +
3
10k -
Chassis 4
5 TB3
6
10k DC 12 11 10
N125 S 7 feeders
8 332k Fuse Switch J1R J1T
(-1.82V) J2R J2T
9 J1S J1C
N125 VR J2S J1D
R1 1 R2 1
Fuse 22 22
J8A ohm ohm
J8B 70 70
J8C W 2W 2
JZ1 J8D
1
10
TB2 9
Door
6
1 2 3 4 Fuse Switch
J7X
P125 VR J7Y
N125 VR
4 J7Z
7
11 J7A
12
R3 R4
1 1 1 J7W P125 V
Fuse 2 N125 V
22 22 Door
J12A
ohm 2ohm 2 J12B
70 W 70 W 3 J12C
2
+ P125 V J16
3
2
R5, 50 ohm,* 70 W Fuse 1
Fuse
3.2
1 2
3.2 Amp J15
Amp 1
2
R6, 50 ohm,* 70 W 3
1 2
Diagnostic Info JPD
*Note: Field configurable
Figure 9-86. Power Distribution Module for I/O Cabinet

Diagnostic Monitoring
As shown in Figure 9-87, the 125 V dc is reduced by a resistance divider network to
signal level for monitoring. Other items monitored include the fuses in the feeders to
the relay output boards. In the interface cabinet this diagnostic data is monitored by
the VCMI; in the control cabinet it is cabled to the VDSK board and then to the
VCMI. This is shown on the PDM diagram of Figure 9-88.
DS2020PDMAGx Din Rail Transition

Termination Board
TB3
P125 VR
1 37-pin
332k P125S (+1.82V) connector
2
+28 Analog In 1
3
10k Chassis 29 P125_Grd
4
5 27 Analog In 2
6 10k
+26 N125_Grd
7 37-wire cable
N125 S (-1.82V) +7
N125 VR 8 332k Analog In 3
9 8 Spare01
One to one
+5 Analog In 4 compatability Connect to VCMI
6 Spare02 between via J301, in <Rx>
screw (TB) I/O Rack
and 37-pin
connector
numbers.
10 P5V
9 DCOM
JPD
35 DIN1, Logic_In_1
P5V 7 34 DIN2, Logic_In_2
DCOM 8
33 DIN3, Logic_In_3
BAT 1
AC1 2 32 DIN4, Logic_In_4
AC2 3
31 DIN5, Logic_In_5
Spare 4
J19 Fuse31 5 30 DIN6, Logic_In_6
J17 Fuse29 9
Figure 9-87. PDM Diagnostic Monitoring in I/O Cabinet
Control Cabinet PDM

For additional noise filtering for the controllers, Corcom power filters are added to
the PDM. The controller PDM, shown in Figure 9-88, only supplies the controllers
and the relay output boards.

AC1 AC2 To Safety
125 VDC Ground
115/230 115/230
Vac Vac
+P125 - N125 AC1H AC1N AC2H AC2N IS2020CCPD
TB1 1 2 3 4 5 6
Chassis
MOV Suppression
In+ Gnd In- In+ Gnd In- In+ Gnd In-
DCF1 ACF1 ACF2
120/250 V, 30 Amp 120/250 V, 30 Amp 120/250 V, 30 Amp Power Filters
Out+ Out- Out+ Out- Out+ Out-
DS200TCPD AC Feeders to
AC1H AC1N
DCHI DCLO AC2H AC2N Fuse TRLY Boards
J17
JZ4 J18
P125V J19
JZ5 J20
BJS
ACSHI DACA#1
DACA#2
JZ2
JZ3
Fuse Switch
J1R DC Feeders to
J1S
J1T Controller Racks
<R0>,<S0>,<T0>
Din Rail Transition Term. Board
+ 28 Analog In 1 37- pin
P125 V TB2 P125S (+1.82V)
29 P125_Grd connector
1
332k
2 27 Analog In 2
3
10k N125 S + 26 N125_Grd
4
(-1.82V) + 7 Analog In 3 Cable to VCMI
5
10k 8 Spare 01 via VDSK on
6 Chassis
+ 5 Analog In 4 front of <R0>
7
8 332k
One to one Control Rack.
6 Spare 02 compatability
9 between screw
N125 V 10 P5V (TB) and 37-pin
connector
9 DCOM numbers.
Diagnostic Information JPD 35 DIN1, Logic_In_1
P5V 7 34 DIN2, Logic_In_2
DCOM 8 33 DIN3, Logic_In_3
BAT 1
Spare 4
J17 Fuse29 9
Figure 9-88. PDM for Controller Cabinet

Installation
Figure 9-89 shows the PDM cabling and wiring connections, and fuse locations.
PDM Cable Destination
JPD Diagnostic Term. Bd.

JZ2 AC/DC Convert #1
JZ3 AC/DC Convert #2
JZ1 Cable to Door Resis.
J1R <R> Power Supply

J2R <R> Power Supply
J1S <S> Power Supply
J2S <S> Power Supply
J1T <T> Power Supply
J2T <T> Power Supply
J1C Spare
J1D Spare
J7X <X> Power Supply

J7Y <Y> Power Supply
J7Z <Z> Power Supply
J7A TRPG#1
J7W TREG
J8A TRLY
J8B TRLY
JZ1
J8C TRLY
J8D TRLY
J12A TBCI
Ground reference J12B TBCI
Jumper BJS J12C TBCI
J15 Miscellaneous
J16 Miscellaneous
J17 TRLY
J18 TRLY
J19 TRLY
J20 TRLY
TB2 Power Connection Points

125 Vac: with jumpers as shown.
Note : When connecting AC power
125 V dc Supply 24 V dc: Remove jumpers &
to the power distribution (TB1), verify
connect as follows:-
that JTX connector on both AC
120 V ac Supply #1 +24 V dc Input
source selectors (see AC/DC
#2 Open
Converter) are plugged into JTX1 for
Auxiliary 120 #3 -24 V dc Input
115 V ac, or JTX2 for 230 V ac.
V ac Supply #4 Open
Figure 9-89. PDM Circuit Board showing Terminals, Fuses, Switches, & Lights

Fuses in Interface and Controller Cabinet PDM
Values of the fuses for the PDM (DS2020PDMAG6) in the interface cabinet are
shown in Table 9-40.
Table 9-39. I/O Cabinet PDM Fuse Ratings
PDM Fuse No. J Connector Current Rating Vendor Catalog No.

/Voltage Rating
FU1-FU6 J1R,S,T 15 Amps/125 V Bussman GMA-15A
FU7-FU10 J1C,D 5 Amps/125 V Bussman GMA-5A
FU13-FU20 J8A,B,C,D 15 Amps/125 V Bussman GMA-15A
FU21-FU26 J12A,B,C 1.5 Amps/250 V Bussman GMC-1.5A
FU27-FU28 J15,16 3.2 Amps/250 V Bussman MDL-3.2A
FU29 J17 15 Amps/250 V Bussman ABC-15A
FU30 J18 5 Amps/250 V Bussman ABC-5A
FU31-FU32 J19,20 15 Amps/250 V Bussman ABC-15A
FU34-FU39 J7X,Y,Z 5 Amps/125 V Bussman GMA-5A
The short circuit rating for FU21-FU26 is 100 Amps

The short circuit rating for FU27-FU28 is 70 Amps
All fuses are ferrule type 5 mm x 20 mm, except for FU27-FU32 which are
.25" x 1.25 ".
Values for the fuses in the PDM (IS2020CCPD) for the controller cabinet are
similar, except the rating for fuses FU1-FU6 is 5 Amps instead of 15 Amps.
Ground Reference Jumper

Jumper BJS is supplied for isolation of ground reference on systems with an external
ground reference. The ground reference bridge across the 125 V dc power has two
resistances, one on each side, and BJS connects the center to ground.
Note: When more than one PDM is supplied from a common 125 V dc source,
remove all the BJS connections except one.

Glossary of Terms
ADL
Asynchronous Device Language, an application layer protocol used for I/O
communication on IONet.
application code
Software that controls the machines or processes, specific to the application.
ARCNET
Attached Resource Computer Network. A LAN communications protocol developed
by Datapoint Corporation. The physical (coax and chip) and datalink (token ring and
board interface) layer of a 2.5 MHz communication network which serves as the
basis for DLAN+. See DLAN+.
ASCII
American Standard Code for Information Interchange. An 8-bit code used for data.
attributes
Information, such as location, visibility, and type of data that sets something apart
from others. In signals, an attribute can be a field within a record.
Balance of Plant (BOP)

Plant equipment other than the turbine that needs to be controlled.
baud
A unit of data transmission. Baud rate is the number of bits per second transmitted.
Bently Nevada
A manufacturer of shaft vibration monitoring equipment.
bind
A toolbox command in the Device menu used to obtain information from the SDB..
GEH-6421 Mark VI System Guide Glossary of Terms • 1

BIOS
Basic input/output system. 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.
bit
Binary Digit. The smallest unit of memory used to store only one piece of
information with two states, such as One/Zero or On/Off. Data requiring more than
two states, such as numerical values 000 to 999, requires multiple bits (see Word).
block
Instruction blocks contain basic control functions, which are connected together
during configuration to form the required machine or process control. Blocks can
perform math computations, sequencing, or continuous control. The toolbox receives
a description of the blocks from the block libraries.
board
Printed wiring board.
Boolean
Digital statement that expresses a condition that is either True or False. In the
toolbox, it is a data type for logical signals.
bus
An electrical path for transmitting and receiving data.
bumpless
No disruption to the control when downloading.
byte
A group of binary digits (bits); a measure of data flow when bytes per second.
CIMPLICITY
Operator interface software configurable for a wide variety of control applications.
CMOS
Complementary metal-oxide semiconductor.
COM port
Serial controller communication ports (two). COM1 is reserved for diagnostic
information and the Serial Loader. COM2 is used for I/O communication
configure
To select specific options, either by setting the location of hardware jumpers or
loading software parameters into memory.
2 • Glossary of Terms GEH-6421 Mark VI System Guide

CRC
Cyclic Redundancy Check, used to detect errors in Ethernet and other transmissions.
CT
Current Transformer, used to measure current in an ac power cable.
datagrams
Messages sent from the controller to I/O blocks over the Genius network.
Data Server
A PC which gathers control data from input networks and makes the data available
to PCs on output networks.
DCS (Distributed Control System)

Control system, usually applied to control of boilers and other process equipment.
dead band
A range of values in which the incoming signal can be altered without changing the
output response.
device
A configurable component of a process control system.
DLAN+
GE Industrial System’s LAN protocol, using an ARCNET controller chip with
modified ARCNET drivers. A communications link between exciters, drives, and
controllers, featuring a maximum of 255 drops with transmissions at 2.5 MBPS.
DRAM
Dynamic Random Access Memory, used in microprocessor-based equipment.
gateway
A device that connects two dissimilar LANs or connects a LAN to a wide-area
network (WAN), PC, or a mainframe. A gateway can perform protocol and
bandwidth conversion.
EGD
Ethernet Global Data is a control network and protocol for the controller. Devices
share data through EGD exchanges (pages).
EMI
Electro-magnetic interference; this can affect an electronic control system

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.
event
A property of Status_S signals that causes a task to execute when the value of the
signal changes.
EX2000 (Exciter)
GE generator exciter control; regulates the generator field current to control the
generator output voltage.
Fanned Input
An input to the termination board which is connected to all three TMR I/O boards.
fault code
A message from the controller to the HMI indicating a controller warning or failure.
Finder
A subsystem of the toolbox for searching and determining the usage of a particular
item in a configuration.
firmware
The set of executable software that is stored in memory chips that hold their content
without electrical power, such as EEPROM.
flash
A non-volatile programmable memory device.
forcing
Setting a live signal to a particular value, regardless of the value blockware or I/O is
writing to that signal.
frame rate
Basic scheduling period of the controller encompassing one complete
input-compute-output cycle for the controller. It is the system dependent scan rate.
function
The highest level of the blockware hierarchy, and the entity that corresponds to a
single .tre file.
gateway
A device that connects two dissimilar LAN or connects a LAN to a wide-area
network (WAN), PC, or a mainframe. A gateway can perform protocol and
bandwidth conversion.

Genius bus
GE Fanuc’s distributed network of intelligent I/O blocks.
Genius global data

Data that is automatically and repeatedly broadcast by a bus controller. All other bus
controllers on the same bus are capable of receiving the data, although some bus
controllers can choose not to. The controller can broadcast global data and receive
global data from certain devices, such as the Series 90-70 PLC and other controllers.
Graphic Window
A subsystem of the toolbox for viewing and setting the value of live signals.
health
A term that defines whether a signal is functioning as expected.
Heartbeat
A signal emitted at regular intervals by software to demonstrate that it is still active.
hexadecimal (hex)
Base 16 numbering system using the digits 0-9 and letters A-F to represent the
decimal numbers 0-15. Two hex digits represent 1 byte.
HMI
Human Machine Interface, usually a PC running CIMPLICITY software.
HRSG
Heat Recovery Steam Generator using exhaust from a gas turbine.
ICS
Integrated Control System. ICS combines various power plant controls into a single
system.
IEEE
Institute of Electrical and Electronic Engineers. A United States-based society that
develops standards.
initialize
To set values (addresses, counters, registers, and such) to a beginning value prior to
the rest of processing.
Innovation Series Controller

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

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.
IONet
The Mark VI I/O Ethernet communication network; controlled by the VCMIs.
insert
Adding an item either below or next to another item in a configuration, as it is
viewed in the hierarchy of the Outline View of the toolbox.
instance
Update an item with a new definition.
item
A line of the hierarchy of the Outline View of the toolbox, which can be inserted,
configured, and edited (such as Function or System Data).
IP Address
The address assigned to a device on an Ethernet communication network.
LCI Static Starter

This runs the generator as a motor to bring a gas turbine up to starting speed.
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 version of the Innovation Series controller hosted in one or more VME 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.
MTBFO
Mean Time Between Forced Outage, a measure of overall system reliability.
µGENI controller board

IC660ELB912_. An optional board for the controller that provides an interface to an
additional Genius I/O bus.
NEMA
National Electrical Manufacturers Association; a U.S. standards organization.
non-volatile
The memory specially designed to store information even when the power is off.
online
Online mode provides full CPU communications, allowing data to be both read and
written. It is the state of the toolbox when it is communicating with the system for
which it holds the configuration. Also, a download mode where the device is not
stopped and then restarted.
pcode
A binary set of records created by the toolbox, which contain the controller
application configuration code for a device. Pcode is stored in RAM and Flash
memory.
Power Distribution Module (PDM)

The PDM distributes 125 V dc and 115 V ac to the VME racks and I/O termination
boards.
period
The time between execution scans for a Module or Task. Also a property of a
Module that is the base period of all of the Tasks in the Module.
pin
Block, macro, or module parameter that creates a signal used to make
interconnections.

Plant Data Highway (PDH)
Ethernet communication network between the HMI Servers and the HMI Viewers
and workstations
PLC
Programmable Logic Controller. Designed for discrete (logic) control of machinery.
It also computes math (analog) function and performs regulatory control.
product code (runtime)

Software stored in the controller’s Flash memory that converts application code
(pcode) to executable code.
Proximitor
Bently Nevada's proximity probes used for sensing shaft vibration.
PT
Potential Transformer, used for measuring voltage in a power cable.
QNX
A real time operating system used in the controller.
realtime
Immediate response, referring to process control and embedded control systems that
must respond instantly to changing conditions.
reboot
To restart the controller or toolbox.
RFI
Radio Frequency Interference; this is high frequency electromagnetic energy which
can affect the system.
register page
A form of shared memory that is updated over a network. Register pages can be
created and instanced in the controller and posted to the SDB.
relay ladder diagram (RLD)

A ladder diagram represents a relay circuit. Power is considered to flow from the left
rail through contacts to the coil connected at the right.
Resources
Also known as groups. Resources are systems (devices, machines, or work stations
where work is performed) or areas where several tasks are carried out. Resource
configuration plays an important role in the CIMPLICITY system by routing alarms
to specific users and filtering the data users receive.

RTD
Resistance Temperature Device, used for measuring temperature.
runtime
See product code.
runtime errors
Controller problems indicated on the front panel by coded flashing LEDS, and also
in the Log View of the toolbox.
sampling rate
The rate at which process signal samples are obtained, measured in samples/second.
Serial Loader
Connects the controller to the toolbox PC using the RS-232C COM ports. The Serial
Loader initializes the controller flash file system and sets its TCP/IP address to allow
it to communicate with the toolbox over Ethernet.
Server
A PC which gathers data over Ethernet from plant devices, and makes the data
available to PC-based operator interfaces known as Viewers.
SIFT
Software Implemented Fault Tolerance, a technique for voting the three incoming
I/O data sets to find and inhibit errors. Note that Mark VI also uses output hardware
voting.
signal
The basic unit for variable information in the controller.
Simplex
Operation that requires only one set of control and I/O, and generally uses only one
channel. The entire Mark VI control system can operate in Simplex mode, or
individual VME boards in an otherwise TMR system can operate in Simplex mode.
simulation
Running a system without all of the configured I/O devices by modeling the behavior
of the machine and the devices in software.
Status_S
GE proprietary communications protocol that provides a way of commanding and
presenting the necessary control, configuration, and feedback data for a device. The
protocol over DLAN+ is Status_S. It can send directed, group, or broadcast
messages.
SOE
Sequence of Events, a high speed record of contact closures taken during a plant
upset to allow detailed analysis of the event.

Static Starter
See LCI.
Status_S pages
Devices share data through Status_S pages. They make the addresses of the points on
the pages known to other devices through the system database.
symbols
Created by the toolbox and stored in the controller, the symbol table contains signal
names and descriptions for diagnostic messages.
task
A group of blocks and macros scheduled for execution by the user.
TCP/IP
Communications protocols developed to inter-network dissimilar systems. It is a
de facto UNIX standard, but is supported on almost all systems. TCP controls data
transfer and IP provides the routing for functions, such as file transfer and e-mail.
time slice
Division of the total module scheduling period. There are eight slices per single
execution period. These slices provide a means for scheduling modules and tasks to
begin execution at different times.
TMR
Triple Modular Redundancy. An operation that uses three identical sets of control
and I/O (channels R, S, and T) and votes the results.
token passing network

The token is a message which gives a station permission to transmit on a network;
this token is passed from station to station so all can transmit in turn.
toolbox
A Windows-based software package used to configure the Mark VI controllers, also
exciters and drives.
trend
A time-based plot to show the history of values, similar to a recorder, available in the
Historian and the toolbox.
UCVB
A version of the Mark VI controller.
Unit Data Highway (UDH)

Connects the Mark VI controllers, LCI, EX2000, 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.
VCMI
The Mark VI VME communication board which links the I/O with the controllers.
VME board
All the Mark VI boards are hosted in Versa Module Eurocard (VME) racks.
VPRO
Mark VI Turbine Protection Module, arranged in a self contained TMR subsystem.
Windows NT
Advanced 32-bit operating system from Microsoft for 386-based PCs and above.
word
A unit of information composed of characters, bits, or bytes, that is treated as an
entity and can be stored in one location. Also, a measurement of memory length,
usually 4, 8, or 16-bits long.

Notes

fiber optic, 2-2, 2-3, 3-5–3-8, 3-10, 3-16, 3-21–3-26, 6-
Index 29
Frame, 2-4, 2-7, 2-17, 2-18, 2-23, 2-25, 3-2, 3-11, 3-19,
7-4, 7-26, 8-2, 8-3, 9-2, 9-9–9-11, 9-37, 9-43, 9-
45, 9-52–9-53
A
ADL, 2-9, 3-4, 3-10 G
Availability, 2-29–2-30, 3-20
gas turbine, 2-1, 2-4, 2-11, 3-9, 4-2–4-3, 6-10, 9-58, 9-
66, 9-83, 9-85, 9-98, 9-100
B GE Fanuc 90-70 PLC, 2-13
Balance of Plant, 1-2, 2-2, 2-13, 6-10, 7-24 generator excitation, 2-1
BBL, 9-1–9-2 generator protection, 2-1, 2-4, 4-3
Big Block Library, 2-7, 9-1 Generator Protection Panel, 2-4
generator synchronization, 1-1, 2-11
Genius Bus, 2-1, 2-7, 3-12–3-15, 6-35, 9-1, 9-4
C Genius I/O, 2-4, 2-7, 3-1, 6-35, 9-1, 9-3
CIMPLICITY, 1-3–1-4, 1-3–1-4, 2-3, 2-12, 3-6, 3-8, 3- GSM, 2-31, 3-1, 3-5, 3-20
10, 7-1, 7-6–7-7, 9-3–9-4, 9-17, 9-23, 9-37, 9-45,
9-53, 9-69, 9-86, 9-91, 9-129 H
communication boards, 1-4, 2-4
console, 2-3, 6-8 Heat Recovery Steam Generator, 1-2, 2-1, 6-10
Control, 1-1, 1-2, 2-1, 2-4, 2-7, 2-13–2-14, 2-16, 2-18, Historian, 1-4, 3-1, 3-9, 7-1, 7-24–7-26
2-25, 2-27, 2-29–2-30, 2-27, 3-4, 3-7, 3-11, 3-19, HMI, 1-3–1-4, 2-2–2-4, 2-3–2-4, 2-15, 2-31, 3-1, 3-4,
4-1–4-2, 6-42, 7-2, 8-7, 9-2, 9-7, 9-9–9-10, 9-32, 3-8, 3-14, 3-16–3-17, 3-20, 3-26, 6-8, 6-29, 7-1, 7-
9-38, 9-49, 9-57, 9-59, 9-66, 9-72, 9-75–9-77, 9- 6–7-8, 7-24–7-25, 8-2–8-3, 9-3, 9-80
83, 9-85, 9-90, 9-116, 9-126 Human Machine Interface, 1-3–1-4, 2-3, 3-14, 7-6
control blocks, 1-1, 7-4–7-5, 7-4–7-5
CT, 6-23, 8-12, 9-121–9-122, 9-124, 9-121–9-122 I
Current Transformer, 9-121, 9-124
I/O cabinet, 2-1, 4-2, 6-11, 9-140–9-141
IEEE 802.3, 2-9, 6-33
D Innovation Series™ controller, 2-4
data highways, 1-3, 2-3, 6-10, 6-29, 6-33 IONet port, 2-6, 2-8, 9-2, 9-7
Data Server, 2-2, 2-3, 3-4
DCS, 2-3, 2-31, 3-1, 3-16–3-17, 3-20, 7-8, 8-3, 9-1, 9-3 L
designated processor, 2-2
diagnostic alarms, 1-4, 8-1–8-2, 8-3–8-5, 8-17–8-18 LAN, 3-1, 3-12, 3-25, 6-33, 9-1
digital signal processor, 2-9, 9-8, 9-11, 9-21 LCI, 1-2, 2-4
LCI Static Starter, 2-4
distributed control system, 1-2, 2-3, 2-31, 3-1, 3-16, 9-3
E M
EGD, 2-2, 2-18, 3-2, 3-6, 3-8 magnetic pickups, 2-10, 2-29, 9-66–9-67
engineering work stations, 2-1, 2-12 master time clock, 2-17
Mean Time Between Forced Outages, 2-30
Ethernet, 1-2, 2-1, 2-3–2-4, 2-7–2-8, 2-31, 3-2, 3-4–3-9,
3-10, 3-23–3-26, 4-1, 6-22, 6-29, 6-33–6-34, 6-37, mean time to repair, 2-30
6-40, 7-1, 7-6, 9-1, 9-3, 9-8, 9-9, 9-11, 9-13, 9-88, Median Value, 2-24
9-97 Median values, 2-22
EX2000, 2-4, 3-9, 9-73, 9-78 MTBFO, 2-30
MTTR, 2-30
Exciter, 1-2, 2-2, 2-4, 2-25, 6-23
exhaust overtemperature, 2-11
O
F On-line Repair, 2-29
Failure Handling, 2-26 operator stations, 2-1, 2-3, 2-12, 2-15, 3-4
GEH-6421 Mark VI System Guide Index • 1

Output voting, 2-13, 2-27, 9-32, 9-38 TGEN, 2-10, 8-12, 9-120–9-121, 9-123
overspeed, 1-1, 2-11, 2-23, 2-28–2-29, 2-28, 9-59, 9- Toolbox, 1-3–1-4, 1-3–1-4, 2-3, 2-9, 2-12, 3-8, 6-37, 7-
72–9-73, 9-75, 9-88, 9-90–9-91, 9-94, 9-97, 9- 1, 7-4–7-5, 8-1–8-3, 8-16–8-18, 9-3–9-4, 9-17–9-
100, 9-103–9-105 18, 9-23, 9-25, 9-31, 9-37, 9-45, 9-53, 9-62, 9-67–
9-69, 9-77–9-78, 9-86, 9-91, 9-101, 9-129
P TPRO, 2-10–2-11, 2-29, 8-10, 9-88, 9-94, 9-97–9-100
TPYR, 2-10, 9-126, 9-128–9-129
PDH, 2-1–2-2, 2-3, 3-4–3-7, 3-9, 3-23, 6-22, 7-6 TREG, 2-10–2-11, 2-29, 8-10, 9-74, 9-75, 9-83, 9-85,
PDM, 2-5, 6-39, 8-18, 9-13, 9-132, 9-138–9-139, 9- 9-88–9-89, 9-94, 9-97–9-99, 9-101, 9-109–9-111,
141–9-143 9-139
peer-to-peer, 2-1, 3-6 trip solenoids, 2-11, 2-29, 8-11, 9-83, 9-85, 9-87, 9-88,
permissive relay, 2-11, 9-78, 9-98 9-89–9-91, 9-93–9-94, 9-97–9-99
Plant Data Highway, 2-1, 2-3, 3-2, 3-4, 7-1 Triple Modular Redundant, 1-1, 1-2, 2-16
programmable logic controllers, 1-2, 7-8 TRLY, 2-10, 8-7, 8-12, 9-40, 9-48–9-53, 9-120, 9-123,
PT, 8-12, 9-22, 9-77–9-78, 9-98, 9-100, 9-121–9-122, 9-139
9-124–9-125, 9-121–9-122 TRPG, 2-10, 2-28–2-29, 6-10, 6-14, 8-10–8-11, 9-72,
9-75, 9-77, 9-83–9-86, 9-88, 9-90, 9-94, 9-97, 9-
Q 132, 9-139
TRTD, 2-10, 9-20
QNX, 2-12, 9-1, 9-3 TSVO, 2-10, 2-29, 9-57–9-58, 9-60, 9-90, 9-99
TTUR, 2-10, 2-28, 8-10–8-12, 9-72–9-74, 9-76, 9-77–
R 9-78, 9-82, 9-85, 9-91–9-92, 9-99
turbine control console, 2-3, 6-8
redundant transceiver, 2-3 Turbine Protection Module, 2-11–2-12, 9-94
Resistance Temperature Device, 2-10, 9-20 TVIB, 2-10, 8-13, 9-114, 9-115–9-117, 9-128, 9-131
RTD, 2-9–2-10, 8-2, 8-6, 9-20–9-22, 9-23–9-25
U
S
UDH, 2-1, 2-3–2-4, 2-7–2-8, 2-17, 2-25, 2-27, 3-6–3-7,
Sequence of Events, 1-2, 2-3, 2-9, 2-31, 3-20, 7-27, 9- 3-9, 3-23, 3-26, 4-1, 6-22, 6-29, 6-40, 7-6, 8-2, 8-
10, 9-43–9-45, 9-92 3, 9-78
servo actuator, 2-20 Unit Data Highway, 2-1–2-2, 3-2–3-6, 3-7, 3-26–3-27,
SIFT, 2-8, 2-14, 2-17, 2-23–2-25, 2-27 7-24, 9-78
Simplex, 1-1, 2-1–2-2, 2-4, 2-7–2-8, 2-13–2-14, 2-18,
2-25, 2-27, 2-29–2-30, 2-27, 3-4, 3-7, 3-11, 3-19,
4-1–4-2, 6-42, 7-2, 8-7, 9-2, 9-7, 9-9–9-10, 9-32, V
9-38, 9-49, 9-57, 9-59, 9-66, 9-72, 9-75–9-77, 9- VAIC, 2-10, 8-6, 9-27–9-32, 9-38
83, 9-85, 9-90, 9-116, 9-126 VAOC, 2-10, 8-7, 9-34–9-37
SOE, 1-2, 2-9, 2-17, 3-20–3-21, 7-25–7-27, 9-10, 9-43 VCCC, 2-9–2-10, 8-7, 9-40–9-45, 9-47, 9-48–9-50, 9-
SOF, 2-17 52–9-53
Software Implemented Fault Tolerant, 2-8, 2-14 VCRC, 2-9–2-10, 8-7, 9-47
Static Starter, 1-2, 2-1–2-2, 2-4, 3-9 VDSK, 2-4–2-6, 2-5–2-6, 9-4, 9-13, 9-132, 9-141
steam turbine, 1-1, 2-1, 3-9, 4-2, 6-10, 7-7, 9-66, 9-75, VGEN, 2-10, 8-12, 9-120–9-123
9-97, 9-120 voting, 1-1–1-2, 2-8, 2-11, 2-13, 2-17–2-25, 2-19–2-25,
suicide relay, 2-20, 8-7, 9-30, 9-36–9-37, 9-58 2-27–2-29, 2-28–2-29, 3-11, 3-13, 8-4, 9-9–9-10,
synchronization, 1-1, 2-11, 2-17, 3-2, 3-26, 7-24, 7-26, 9-9–9-10, 9-18, 9-24, 9-32, 9-38, 9-75, 9-83–9-85
8-12, 9-2, 9-79–9-80, 9-97, 9-112, 9-122 VPRO, 2-10–2-11, 2-29, 6-40–6-42, 8-5, 8-8–8-10, 9-
System reliability, 2-13, 2-29 74, 9-78, 9-88, 9-90–9-92, 9-94, 9-97
VPYR, 2-10, 8-13, 9-126–9-127, 9-128–9-129
T VRTD, 2-10, 8-6, 9-20–9-22
VSVO, 2-10, 8-8, 9-57–9-59, 9-66–9-70
TBAI, 2-10, 9-27, 9-30, 9-124 VTCC, 2-10, 8-5, 9-14, 9-16–9-18
TBAO, 2-10, 9-34 VTUR, 2-10, 2-28, 8-10–8-11, 9-72–9-73, 9-77–9-78,
TBCI, 2-10, 8-7, 9-40–9-42, 9-47, 9-139 9-83–9-86, 9-94
TBTC, 2-10, 9-14–9-15 VVIB, 2-10, 8-13, 9-114, 9-116–9-117, 9-128
termination cabinet, 2-1
2 • Index GEH-6421 Mark VI System Guide

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GEH-6421

Printed in the United States of America.

ARCNET is a registered trademark of Datapoint Corporation.

Indicates a procedure or condition that, if not

Indicates a procedure or condition that, if not

Indicates a procedure or condition that should be

Note Indicates an essential or important procedure, condition, or statement.

The example and setup screens in this manual do

Symbol Publication Description

IEC 417, No. 5031 Direct Current

IEC 417, No. 5032 Alternating Current

IEC 417, No. 5033 Both direct and alternating current

3 IEC 617-2, Three-phase alternating current

IEC 417, No. 5017 Earth (CCOM signal ground) Terminal

IEC 417, No. 5019 Protective Conductor Terminal

IEC 417, No. 5020 Frame or Chassis Terminal

IEC 417, No. 5021 Equipotentiality

IEC 417, No. 5007 On (Supply)

IEC 417, No. 5008 Off (Supply)

IEC 417, No. 5172 Equipment protected throughout by

ISO 3864, No. B.3.6 Caution, risk of electric shock

ISO 3864, No. B.3.1 Caution

R Remotely Mounted Bus Aux Compt Device

1 2 Mounted on Door 1, 2, and so on G Generator Terminal Enclosure

OS Mounted in Main Operator Station PEECC MCC

E Equipment Exists in place SS Static Starter

EX EX2000 Exciter LCI

Generator Control Panel ISO Isolation Transformer

Turbine Control Generator Excitation Compartment

Jumper Ground Bus

Relay Coil Signal Ground

Solenoid Coil Contact Actually Shown Elsewhere

Flame Detector Customer Connection

Twisted Pair Wire

1. For wire runs internal to the controller, twisted

2. For wire runs external to the controller (and

3. All shield drain wires should be terminated on

Wye 4. None of the shield drain wires should ever

H High Level Wiring

Chapter 2 System Architecture 2-1

GEH-6421 Mark VI System Guide Contents • 1

Chapter 3 Networks 3-1

Chapter 4 Packaging 4-1

Chapter 5 Codes & Standards 5-1

2 • Contents GEH-6421 Mark VI System Guide

Chapter 7 Tools 7-1

GEH-6421 Mark VI System Guide Contents • 3

Chapter 8 Troubleshooting & Diagnostics 8-1

Chapter 9 I/O Description 9-1

4 • Contents GEH-6421 Mark VI System Guide

Glossary of Terms G-1

GEH-6421 Mark VI System Guide Contents • 5

6 • Contents GEH-6421 Mark VI System Guide

GEH-6421 Mark VI System Guide List of Figures • 1

2 • List of Figures GEH-6421 Mark VI System Guide

GEH-6421 Mark VI System Guide List of Figures • 3

4 • List of Figures GEH-6421 Mark VI System Guide

2 • List of Tables GEH-6421 Mark VI System Guide

GEH-6421 Mark VI System Guide List of Tables • 3