SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the
Service Bulletin. All questions should be directed to your Solar Field Service Representative. Solar, Saturn,
Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated.
Cat and Caterpillar are trademarks of Caterpillar Inc. Specifications subject to change without notice.

NUMBER: 5.13.1/101A
ISSUED: December 2000
REVISED: March 2001
PRODUCT: All
MODEL(S): All
Specifics: PLC Based Control Systems Utilizing an STI Instruction or Model
5/20 Series C Revision G or earlier PLC’s

SUBJECT: LOSS OF COMMUNICATION UPDATES DUE TO

PLC INTERRUPT ERROR

PRODUCT SAFETY

—REVISION NOTICE—
This revision replaces Service Bulletin 5.13.1/101. The previous
bulletin must be removed and discarded. With this revision Type
of Change is now "Safety" and Recommended Compliance is now
"Immediate".

Type of Change: Safety

Recommended
Compliance: Immediate

Purpose:
This Service Bulletin is to alert users of a potential safety issue existing with PLC 5/20 series C
Revision G or earlier processors. This Service Bulletin contains additional program instructions
to be implemented in the ladder logic to detect a communications error due to a selectable timed
interrupt failure. This Service Bulletin also contains details about a program to upgrade specific
versions of Allen Bradley model 5/20 PLC’s.

SERVICE BULLETIN Page 1 of 12

NUMBER: 5.13.1/101A
 FAILURE TO TAKE CORRECTIVE ACTION COULD RESULT IN DAM-
AGE TO PROPERTY AND SERIOUS BODILY INJURY OR DEATH.

GENERAL INFORMATION:
Allen-Bradley Programmable Logic Controller (PLC) based control systems supplied by Solar Tur-
bines Incorporated utilize either a 1771-QRC module or a 1771-CFM module to process the mag-
netic speed pickup signals from the gas turbine. Figure 1 shows the front panel of both the QRC
and CFM modules. The PLC requests data from the QRC or CFM module and updates the PLC
data table with frequency data proportional to gas turbine speed. This data is used as feedback in
the speed control loop, controlling gas turbine speed.

Figure 1

In systems where a QRC module is used, the PLC must utilize a Selectable Timed Interrupt (STI) to
request data from the QRC module. CFM modules can be configured to different operating modes,
one of which is to emulate a QRC module. When a CFM module is configured to emulate a QRC
module, the PLC must utilize an STI to request data from the module.

Page 2 of 12 SERVICE BULLETIN

NUMBER: 5.13.1/101A
Should the STI instruction not execute, the turbine speed data will not update in the PLC. The speed
data in the PLC data table will be from the last successful STI (old data). This will result in the gas
turbine speed control system not responding to actual speed fluctuations. Currently, there is no
annunciation generated when the STI instruction does not execute. Under certain circumstances, a
failure involving the STI could result in an engine overspeed condition, which in conjunction with
other system failures could result in an uncontained engine failure and potential safety implications.
The Action Required section of this Service Bulletin, provides details about the implementation of
a STI loop counter which will shutdown the gas turbine when the STI instruction does not execute.
Table 1 summarizes the PLC control systems which are to have the STI loop counter implemented
in the software.

All PLC based control systems rely on an independent backup speed control system which is not
affected by the problem outlined in this bulletin.

The problem of an STI instruction not executing is installation dependant and not predictable. Fac-
tors such as EMI/RFI noise, number of communication channels used, amount and frequency of
communications on these channels all contribute to the possibility of this problem occurring in the
PLC.

The PLC interrupt service routine processes interrupt requests of communications tasks and vari-
ous other system tasks. Due to the factors described above, it is possible that the interrupt service
routine may not properly execute, resulting in communication errors with other hardware including
a second control rack or the data highway.

The PLC models 5/20, 5/30 and 5/40 series C revision G and earlier may be susceptible to this
problem. Due to design differences between the PLC 5/20 and the PLC 5/30 and 5/40, the PLC
5/30 and 5/40 are far less susceptible to this problem. In the model 5/20 PLC, all the interrupt
service requests are handled by a single processor. Both the model 5/30 and 5/40 PLC’s utilize
several processors to handle the various interrupt requests. With a lower number of interrupts being
handled by each processor, the possibility of an interrupt service routine not executing correctly is
reduced. To date there have been no reported incidents with control systems using the PLC 5/30 or
5/40.

The PLC models 5/15 and 5/25 are not susceptible to this problem. The susceptibility to this prob-
lem was corrected in the PLC 5/20, 5/30 and 5/40 series C revision H and later.

The Action Required section of this Service Bulletin describes a program to upgrade the affected
PLC’s. Table 1 provides a summary of the PLC’s which are included in the upgrade program

SERVICE BULLETIN Page 3 of 12

NUMBER: 5.13.1/101A
 Table 1 Summary of Hardware & Software Affected
Software Upgrade
Service Bulletin Does Not
Service Bulletin May Apply Applicability Determination
Apply
PLC’s shipped prior to June PLC’s shipped June 1995 or Factory ship date
1995 later
All 1771-QRC modules CFM modules which do not STI instruction present in
or emulate QRC modules ladder logic: Software Update
1771-CFM modules Applies
which emulate a QRC module

PLC Hardware Upgrade

Configurations to be
upgraded due to interrupt
problem
Model 5/20 Series C
Revision G & earlier
Configurations with low
probability of interrupt
problem
Model 5/30 Series C
Revision G & earlier
Model 5/40 Series C
Revision G & earlier
Configurations not
susceptible to interrupt
problem
Model 5/15
Model 5/25
Model 5/20 Series C
Revision H & later
Model 5/30 Series C
Revision H & later
Model 5/40 Series C
Revision H & later

ACTION REQUIRED:
Confirm that you have the affected PLC 5 processor installed or in inventory. See Table 1 Summary
of Hardware and Software affected. Modify software and upgraded hardware as detailed below.

Software Modification: (Required for ALL control systems utilizing a STI )

1. An STI is utilized by all control systems which have a QRC module and systems which
have a CFM module configured to emulate a QRC module. To determine if the standard
STI QRC program file is used in a control system, connect a PLC programming terminal
to the operating PLC and on the Program Directory screen check to see if there is a
program file 13, named QRC_STIxx_. An example of a Program Directory with the STI
file is shown in Figure 2. Other STI configurations can be found by viewing the processor
status screen. It will show "Select timed inter." program file number and the scheduled
interrupt time in milliseconds. If present, a STI is used and the software update is to be
installed.

Page 4 of 12 SERVICE BULLETIN

NUMBER: 5.13.1/101A
 2. If the control system utilizes an STI, install the additional PLC ladder logic shown in
Figures 3 - 8. Figure 9 shows the INF file with a spare discrete which is changed in
Figure 10 to annunciate a STI error. This logic will detect, annunciate and shutdown the
gas turbine in the event the STI fails to execute. The modifications described are typical.
Before beginning the changes, the actual program must be reviewed to insure that unused
addresses are used for program implementation.

NOTE
For assistance in determining if a control system utilizes an STI or imple-
mentation of the additional ladder logic, contact your local Solar District Field
Service office.

Figure 2

SERVICE BULLETIN Page 5 of 12

NUMBER: 5.13.1/101A
 Figure 3

Figure 4

Page 6 of 12 SERVICE BULLETIN

NUMBER: 5.13.1/101A
 Figure 5

Figure 6

SERVICE BULLETIN Page 7 of 12

NUMBER: 5.13.1/101A
 Figure 7

Page 8 of 12 SERVICE BULLETIN

NUMBER: 5.13.1/101A
 Figure 8

SERVICE BULLETIN Page 9 of 12

NUMBER: 5.13.1/101A
 Figure 9

Page 10 of 12 SERVICE BULLETIN

NUMBER: 5.13.1/101A
 Figure 10

Hardware Upgrade:

Model 5/20 PLC

1. Determine if the control system utilizes a model 5/20 PLC included in the upgrade
program. This is accomplished by either visually inspecting the nameplate located on
the side of the PLC for the model, series and revision information or by going online
with the PLC programming terminal. When online the PLC model, series and revision
information is located at the bottom of the display above the menu buttons (Figure 11).

SERVICE BULLETIN Page 11 of 12

NUMBER: 5.13.1/101A
 Figure 11

2. If the PLC is a model 5/20 series C revision G or earlier contact Solar. Solar will supply
a PLC 5/20 series C revision H or later, at no charge, if a serviceable core is returned.
If no serviceable core is returned to Solar there will be a charge for the upgraded PLC.
The upgraded PLC is Solar P/N 186896-61.
Model 5/30 and 5/40 PLC’s
1. In the unlikely event a STI fail shutdown occurs, confirm that the PLC is a series C
revision G or earlier and contact Solar. Solar will supply a PLC model 5/30 or 5/40 series
C revision H or later, at no charge, if a serviceable core is returned. If no serviceable core
is returned to Solar there will be a charge for the upgraded PLC. The upgraded PLC’s
are Solar P/N 1014211-4 (model 5/30) and 1014211-5 (model 5/40).

NOTE
Should a STI fail shutdown occur on a system with a model 5/20, 5/30 or
5/40 PLC, the gas turbine may be restarted, however arrangements should
be made to install an upgraded PLC as soon as possible.

For assistance in determining the model, series and revision of a PLC or for assistance in trou-
bleshooting the controls system, contact your local Solar District Field office.

Page 12 of 12 SERVICE BULLETIN

NUMBER: 5.13.1/101A