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SPEEDTRONIC™ Mark VI Turbine Control
Multicustomer Training Loveland, Colorado
2002
All rights reserved by the General Electric Company. No copies permitted without the prior written consent of the General Electric Company. The text and the classroom instruction offered with it are designed to acquaint students with generally accepted good practice for the operation or maintenance of equipment and/or systems. They do not purport to be complete nor are they intended to be specific for the products of any manufacturer, including those of the General Electric Company; and the Company will not accept any liability whatsoever for the work undertaken on the basis of the text or classroom instruction. The manufacturer’s operating and maintenance specifications are the only reliable guide in any specific instance; and where they are not complete, the manufacturer should be consulted. © 2002 General Electric Company
GE Power Systems
SPEEDTRONIC™ Mark VI Turbine Control Multicustomer Training Loveland, Colorado 2002 Tab 1 Fundamentals of SPEEDTRONIC™ Mark VI Control
Fund_Mk_VI
Tab 2 Introduction to SPEEDTRONIC™ Mark VI SPEEDTRONIC™ Mark VI Control System Tab 3 Windows NT© Introduction
mk_VI_intro R1 GER 4193A 95_NT_INTRO_2
Tab 4 System Manual for SPEEDTRONIC™ Mark VI Turbine Control Volume 1
GEH 6421D
Tab 5 System Manual for SPEEDTRONIC™ Mark VI Turbine Control
GEH 6421D
Volume 2 Tab 6 Control System Toolbox for Configuring a Mark VI Controller
GEH 6403F
Tab 7 Turbine Library Standard Block Help Library Turbine Help Library
GEH 6409 TBLIB
Tab 8 Unit Controller 2000/VME Operation and Maintenance
GEH 6371
Tab 9 Control System Toolbox Trending
GEH 6408C
Tab 10 I/O Report (Example)
io_rpt_samp
Tab 11 Panel Layout Drawings (Example)
panel_layout_ex
Tab 12 Network Layout (Example)
352B4435C
Tab 13 Mark VI I/O Definition
MKVI_IO2
Tab 14 Mark VI Protection Configuration SPEEDTRONIC™ Mark VI Turbine Control Multicustomer Training Loveland, Colorado
Prot_A3 1
GE Power Systems Tab 15 Alarm Troubleshooting Tab 16 CIMPLICITY® HMI Base System User’s Manual ®
alm_trbl_mk6 GFK 1180K
Tab 17 CIMPLICITY CimEdit Operation Manual
GFK 1396F
Tab 18 Reference Drawings Device Summary Servovalve Overview Lubrication Oil ppg Schematic Trip Oil ppg Schematic Fuel Gas ppg Schematic Cooling and Sealing Air ppg Schematic
363A5932G MOOG2 114E5966F 115E2525 115E2577 355B5850
Tab 19 Signal Data Base (SDB) Browser
GEI 100506
Tab 20 Control Specifications Tab 21 Documentation ANSI Device Nomenclature Acronyms Signal List
SPEEDTRONIC™ Mark VI Turbine Control Multicustomer Training Loveland, Colorado
586A2603 A00029B acronym_class.pdf signal_name_class.pdf
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GE Power Systems
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM SPEEDTRONIC Mark VI Control contains a number of control, protection and sequencing systems designed for reliable and safe operation of the gas turbine. It is the objective of this chapter to describe how the gas turbine control requirements are met, using simplified block diagrams and one–line diagrams of the SPEEDTRONIC Mark VI control, protection, and sequencing systems. A generator drive gas turbine is used as the reference.
celeration, speed, temperature, shutdown, and manual control functions illustrated in Figure 1. Sensors monitor turbine speed, exhaust temperature, compressor discharge pressure, and other parameters to determine the operating conditions of the unit. When it is necessary to alter the turbine operating conditions because of changes in load or ambient conditions, the control modulates the flow of fuel to the gas turbine. For example, if the exhaust temperature tends to exceed its allowable value for a given operating condition, the temperature control system reduces the fuel supplied to the turbine and thereby limits the exhaust temperature.
CONTROL SYSTEM Basic Design Control of the gas turbine is done by the startup, acTO CRT DISPLAY
FUEL TEMPERATURE
TO CRT DISPLAY FSR MINIMUM VALUE SELECT LOGIC
SPEED
ACCELERATION RATE
FUEL SYSTEM
TO TURBINE TO CRT DISPLAY
START UP SHUT DOWN MANUAL
id0043
Figure 1 Simplified Control Schematic
Operating conditions of the turbine are sensed and utilized as feedback signals to the SPEEDTRONIC control system. There are three major control loops – startup, speed, and temperature – which may be in control during turbine operation. The output of these control loops is connected to a minimum value gate circuit as shown in Figure 1. The secondary control Fund_Mk_VI
modes of acceleration, manual FSR, and shutdown operate in a similar manner. Fuel Stroke Reference (FSR) is the command signal for fuel flow. The minimum value select gate connects the output signals of the six control modes to the FSR controller; the lowest FSR output of the six 1
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems
LOGIC
FSRSU
CQTC
FSR LOGIC
TNHAR
FSRACC
ACCELERATION CONTROL
FSRMAN
MANUAL FSR
TNH
TNH
START-UP CONTROL
TNHAR FSRMIN
LOGIC
FSR
FSRSU FSRACC
FSRC
FSRMAN FSRSD
MIN GATE
FSRN
FSR
FSRT
LOGIC TNHCOR
FSRSD
FSRC
FSRMIN
FSR
CQTC
SHUTDOWN CONTROL
FSRMIN
SPEED CONTROL TTUR VTUR PR/D
77NH
LOGIC
TNR
LOGIC
TNRI
LOGIC TNH FSRN
TNR
TNRI
ISOCHRONOUS ONLY
TEMPERATURE CONTROL LOGIC
96CD
TBAI VAIC A/D
TTRX TTRX
FSR
FSRT LOGIC
TBTC VTCC TTXD
TTXM
TTXD
A/D
FSR
TTXM
MEDIAN
id0038V
Figure 2 Block Diagram – Control Schematic
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
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GE Power Systems control loops is allowed to pass through the gate to the fuel control system as the controlling FSR. The controlling FSR will establish the fuel input to the turbine at the rate required by the system which is in control. Only one control loop will be in control at any particular time and the control loop which is controlling FSR will be displayed on the .
The following speed detectors and speed relays are typically used: –L14HR Zero–Speed (approx. 0% speed) –L14HM speed)
–L14HA Accelerating Speed (approx. 50% speed)
Figure 2 shows a more detailed schematic of the control loops. This can be referenced during the explanation of each loop to show the interfacing.
–L14HS speed)
Operating Speed (approx. 95%
The zero–speed detector, L14HR, provides the signal when the turbine shaft starts or stops rotating. When the shaft speed is below 14HR, or at zero– speed, L14HR picks–up (fail safe) and the permissive logic initiates turning gear or slow–roll operation during the automatic start–up sequence of the turbine.
Start–up/Shutdown Sequence and Control Start–up control brings the gas turbine from zero speed up to operating speed safely by providing proper fuel to establish flame, accelerate the turbine, and to do it in such a manner as to minimize the low cycle fatigue of the hot gas path parts during the sequence. This involves proper sequencing of command signals to the accessories, starting device and fuel control system. Since a safe and successful start–up depends on proper functioning of the gas turbine equipment, it is important to verify the state of selected devices in the sequence. Much of the control logic circuitry is associated not only with actuating control devices, but enabling protective circuits and obtaining permissive conditions before proceeding.
The minimum speed detector L14HM indicates that the turbine has reached the minimum firing speed and initiates the purge cycle prior to the introduction of fuel and ignition. The dropout of the L14HM minimum speed relay provides several permissive functions in the restarting of the gas turbine after shutdown. The accelerating speed relay L14HA pickup indicates when the turbine has reached approximately 50 percent speed; this indicates that turbine start–up is progressing and keys certain protective features.
The gas turbine uses a static start system whereby the generator serves as a starting motor. A turning gear is used for rotor breakaway.
The high–speed sensor L14HS pickup indicates when the turbine is at speed and that the accelerating sequence is almost complete. This signal provides the logic for various control sequences such as stopping auxiliary lube oil pumps and starting turbine shell/exhaust frame blowers.
General values for control settings are given in this description to help in the understanding of the operating system. Actual values for control settings are given in the Control Specifications for a particular machine.
Should the turbine and generator slow during an underfrequency situation, L14HS will drop out at the under–frequency speed setting. After L14HS drops out the generator breaker will trip open and the Turbine Speed Reference (TNR) will be reset to 100.3%. As the turbine accelerates, L14HS will again pick up; the turbine will then require another start signal before the generator will attempt to auto– synchronize to the system again.
Speed Detectors An important part of the start–up/shutdown sequence control of the gas turbine is proper speed sensing. Turbine speed is measured by magnetic pickups and will be discussed under speed control. Fund_Mk_VI
Minimum Speed (approx. 16%
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FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems The actual settings of the speed relays are listed in the Control Specification and are programmed in the processors as EEPROM control constants.
OR LOWER” allows manual adjustment of FSR setting between FSRMIN and FSRMAX. While the turbine is at rest, electronic checks are made of the fuel system stop and control valves, the accessories, and the voltage supplies. At this time, “SHUTDOWN STATUS” will be displayed on the . Activating the Master Operation Switch (L43) from “OFF” to an operating mode will activate the ready circuit. If all protective circuits and trip latches are reset, the “STARTUP STATUS” and “READY TO START” messages will be displayed, indicating that the turbine will accept a start signal. Clicking on the “START” Master Control Switch (L1S) and “EXECUTE” will introduce the start signal to the logic sequence.
START–UP CONTROL The start–up control operates as an open loop control using preset levels of the fuel command signal FSR. The levels are: “ZERO”, “FIRE”, “WARM– UP”, “ACCELERATE” and “MAX”. The Control Specifications provide proper settings calculated for the fuel anticipated at the site. The FSR levels are set as Control Constants in the SPEEDTRONIC Mark VI start–up control.
The start signal energizes the Master Control and Protection circuit (the “L4” circuit) and starts the necessary auxiliary equipment. The “L4” circuit permits pressurization of the trip oil system. With the “L4” circuit permissive and starting clutch automatically engaged, the starting device starts turning. Startup status message “STARTING” will be displayed on the . See point “A” on the Typical Start–up Curve Figure 3.
Start–up control FSR signals operate through the minimum value gate to ensure that other control functions can limit FSR as required. The fuel command signals are generated by the SPEEDTRONIC control start–up software. In addition to the three active start–up levels, the software sets maximum and minimum FSR and provides for manual control of FSR. Clicking on the targets for “MAN FSR CONTROL” and “FSR GAG RAISE
SPEED – % 100
80 ACCELERATE IGNITION & CROSSFIRE 60
WARMUP IGV – DEGREES
1 MIN
START AUXILIARIES & DIESEL WARMUP
Tx – °F/10
PURGE COAST
40
DOWN
20
FSR – % C
0 A
B
APPROXIMATE TIME – MINUTES
D
id0093
Figure 3 Mark VI Start-up Curve
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
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GE Power Systems The starting clutch is a positive tooth type overrunning clutch which is self–engagifng in the breakaway mode and overruns whenever the turbine rotor exceeds the turning gear speed.
eration. This is done by programming a slow rise in FSR. See point “C” on Figure 3. As fuel is increased, the turbine begins the acceleration phase of start–up. The clutch is held in as long as the turning gear provides torque to the gas turbine. When the turbine overruns the turning gear, the clutch will disengage, shutting down the turning gear. Speed relay L14HA indicates the turbine is accelerating.
When the turbine ‘breaks away’ the turning gear will rotate the turbine rotor from 5 to 7 rpm. As the static starter begins it’s sequence, and accelerates the rotor the starting clutch will automatically disengage the turning gear from the turbine rotor. The turbine speed relay L14HM indicates that the turbine is turning at the speed required for proper purging and ignition in the combustors. Gas fired units that have exhaust configurations which can trap gas leakage (i.e., boilers) have a purge timer, L2TV, which is initiated with the L14HM signal. The purge time is set to allow three to four changes of air through the unit to ensure that any combustible mixture has been purged from the system. The starting means will hold speed until L2TV has completed its cycle. Units which do not have extensive exhaust systems may not have a purge timer, but rely on the starting cycle and natural draft to purge the system.
The start–up phase ends when the unit attains full– speed–no–load (see point “D” on Figure 3). FSR is then controlled by the speed loop and the auxiliary systems are automatically shut down. The start–up control software establishes the maximum allowable levels of FSR signals during start– up. As stated before, other control circuits are able to reduce and modulate FSR to perform their control functions. In the acceleration phase of the start–up, FSR control usually passes to acceleration control, which monitors the rate of rotor acceleration. It is possible, but not normal, to reach the temperature control limit. The display will show which parameter is limiting or controlling FSR.
The L14HM signal or completion of the purge cycle (L2TVX) ‘enables’ fuel flow, ignition, sets firing level FSR, and initiates the firing timer L2F. See point “B” on Figure 3. When the flame detector output signals indicate flame has been established in the combustors (L28FD), the warm–up timer L2W starts and the fuel command signal is reduced to the “WARM–UP” FSR level. The warm–up time is provided to minimize the thermal stresses of the hot gas path parts during the initial part of the start–up.
Fired Shutdown A normal shutdown is initiated by clicking on the “STOP” target (L1STOP) and “EXECUTE”; this will produce the L94X signal. If the generator breaker is closed when the stop signal is initiated, the Turbine Speed Reference (TNR) counts down to reduce load at the normal loading rate until the reverse power relay operates to open the generator breaker; TNR then continues to count down to reduce speed. When the STOP signal is given, shutdown Fuel Stroke Reference FSRSD is set equal to FSR.
If flame is not established by the time the L2F timer times out, typically 60 seconds, fuel flow is halted. The unit can be given another start signal, but firing will be delayed by the L2TV timer to avoid fuel accumulation in successive attempts. This sequence occurs even on units not requiring initial L2TV purge.
When the generator breaker opens, FSRSD ramps from existing FSR down to a value equal to FSRMIN, the minimum fuel required to keep the turbine fired. FSRSD latches onto FSRMIN and decreases with corrected speed. When turbine speed drops below a defined threshold (Control Constant K60RB) FSRSD ramps to a blowout of one flame detector. The sequencing logic remembers which flame detectors were functional when the breaker opened. When any of the functional flame detectors
At the completion of the warm–up period (L2WX), the start–up control ramps FSR at a predetermined rate to the setting for “ACCELERATE LIMIT”. The start–up cycle has been designed to moderate the highest firing temperature produced during accelFund_Mk_VI
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FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems Speed/Load Reference
senses a loss of flame, FSRMIN/FSRSD decreases at a higher rate until flame–out occurs, after which fuel flow is stopped.
The speed control software will change FSR in proportion to the difference between the actual turbine– generator speed (TNH) and the called–for speed reference (TNR).
Fired shut down is an improvement over the former fuel shut off at L14HS drop out. By maintaining flame down to a lower speed there is significant reduction in the strain developed on the hot gas path parts at the time of fuel shut off.
The called–for–speed, TNR, determines the load of the turbine. The range for generator drive turbines is normally from 95% (min.) to 107% (max.) speed. The start–up speed reference is 100.3% and is preset when a “START” signal is given.
SPEED CONTROL The Speed Control System controls the speed and load of the gas turbine generator in response to the actual turbine speed signal and the called–for speed reference. While on speed control the control mode message “SPEED CTRL”will be displayed.
TNR MAX. 107
HIGH SPEED STOP
104
“FSNL”
95 TNR MIN.
LOW SPEED STOP
MAX FSR
RATED FSR
100
MINIMUM FSR
Three magnetic sensors are used to measure the speed of the turbine. These magnetic pickup sensors (77NH–1,–2,–3) are high output devices consisting of a permanent magnet surrounded by a hermetically sealed case. The pickups are mounted in a ring around a 60–toothed wheel on the gas turbine compressor rotor. With the 60–tooth wheel, the frequency of the voltage output in Hertz is exactly equal to the speed of the turbine in revolutions per minute.
FULL SPEED NO LOAD FSR
SPEED REFERENCE % (TNR)
Speed Signal
FUEL STROKE REFERENCE (LOAD) (FSR) id0044
The voltage output is affected by the clearance between the teeth of the wheel and the tip of the magnetic pickup. Clearance between the outside diameter of the toothed wheel and the tip of the magnetic pickup should be kept within the limits specified in the Control Specifications (approx. 0.05 inch or 1.27 mm). If the clearance is not maintained within the specified limits, the pulse signal can be distorted. Turbine speed control would then operate in response to the incorrect speed feedback signal.
Figure 4 Droop Control Curve
The turbine follows to 100.3% TNH for synchronization. At this point the operator can raise or lower TNR, in turn raising or lowering TNH, via the 70R4CS switch on the generator control panel or by clicking on the targets on the , if required. Refer to Figure 4. Once the generator breaker is closed onto the power grid, the speed is held constant by the grid frequency. Fuel flow in excess of that necessary to maintain full speed no load will result in increased power produced by the generator. Thus the speed control loop becomes a load control loop and the speed reference is a convenient control
The signal from the magnetic pickups is brought into the Mark VI panel, one mag pickup to each controller , where it is monitored by the speed control software. FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
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GE Power Systems of the desired amount of load to be applied to the turbine–generator unit.
units have the same droop, all will share a load increase equally. Load sharing and system stability are the main advantages of this method of speed control.
Droop speed control is a proportional control, changing FSR in proportion to the difference between actual turbine speed and the speed reference. Any change in actual speed (grid frequency) will cause a proportional change in unit load. This proportionality is adjustable to the desired regulation or “Droop”. The speed vs. FSR relationship is shown on Figure 4.
Normally 4% droop is selected and the setpoint is calibrated such that 104% setpoint will generate a speed reference which will produce an FSR resulting in base load at design ambient temperature. When operating on droop control, the full–speed– no–load FSR setting calls for a fuel flow which is sufficient to maintain full speed with no generator load. By closing the generator breaker and raising TNR via raise/lower, the error between speed and reference is increased. This error is multiplied by a
If the entire grid system tends to be overloaded, grid frequency (or speed) will decrease and cause an FSR increase in proportion to the droop setting. If all
SPEED CONTROL FSNL TNR SPEED REFERENCE + –
+
ERROR SIGNAL
+
FSRN
TNH SPEED DROOP
SPEED CHANGER LOAD SET POINT
MAX. LIMIT L83SD RATE MEDIAN SELECT
L70R RAISE L70L LOWER
TNR
L83PRES PRESET LOGIC
SPEED REFERENCE
PRESET OPERATING MIN.
L83TNROP MIN. SELECT LOGIC START-UP OR SHUTDOWN
id0040
Figure 5 Speed Control Schematic Fund_Mk_VI
7
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems gain constant dependent on the desired droop setting and added to the FSNL FSR setting to produce the required FSR to take more load and thus assist in holding the system frequency. Refer to Figures 4 and 5.
Synchronizing
The minimum FSR limit (FSRMIN) in the SPEEDTRONIC Mark VI system prevents the speed control circuits from driving the FSR below the value which would cause flameout during a transient condition. For example, with a sudden rejection of load on the turbine, the speed control system loop would want to drive the FSR signal to zero, but the minimum FSR setting establishes the minimum fuel level that prevents a flameout. Temperature and/or
Automatic synchronizing is accomplished using synchronizing algorithms programmed into and software. Bus and generator voltage signals are input to the core which contains isolation transformers, and are then paralleled to . software drives the synch check and synch permissive relays, while provides the actual breaker close command. See Figure 6.
start–up control can drive FSR to zero and are not influenced by FSRMIN.
AUTO SYNCH AUTO SYNCH PERMISSIVE CALCULATED PHASE WITHIN LIMITS GEN VOLTS REF
LINE VOLTS REF
A A>B B
CALCULATED SLIP WITHIN LIMITS AND
L83AS AUTO SYNCH PERMISSIVE
A A>B B
CALCULATED ACCELERATION
AND
L25 BREAKER CLOSE
CALCULATED BREAKER LEAD TIME
id0048V
Figure 6 Synchronizing Control Schematic
There are three basic synchronizing modes. These may be selected from external contacts, i.e., generator panel selector switch, or from the SPEEDTRONIC Mark VI .
For synchronizing, the unit is brought to 100.3% speed to keep the generator “faster” than the grid, assuring load pick–up upon breaker closure. If the system frequency has varied enough to cause an unacceptable slip frequency (difference between generator frequency and grid frequency), the speed matching circuit adjusts TNR to maintain turbine speed 0.20% to 0.40% faster than the grid to assure the correct slip frequency and permit synchronizing.
1. OFF – Breaker will not be closed by SPEEDTRONIC Mark VI control 2. MANUAL – Operator initiated breaker closure when permissive synch check relay 25X is satisfied
For added protection a synchronizing check relay is provided in the generator panel. It is used in series with both the auto synchronizing relay and the manual breaker close switch to prevent large out– of–phase breaker closures.
3. AUTO – System will automatically match voltage and speed and then close the breaker at the appropriate time to hit top dead center on the synchroscope FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
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GE Power Systems turbine occurs in the flame zone of the combustion chambers. The combustion gas in that zone is diluted by cooling air and flows into the turbine section through the first stage nozzle. The temperature of that gas as it exits the first stage nozzle is known as the “firing temperature” of the gas turbine; it is this temperature that must be limited by the control system. From thermodynamic relationships, gas turbine cycle performance calculations, and known site conditions, firing temperature can be determined as a function of exhaust temperature and the pressure ratio across the turbine; the latter is determined from the measured compressor discharge pressure (CPD). The temperature control system is designed to measure and control turbine exhaust temperature rather than firing temperature because it is impractical to measure temperatures directly in the combustion chambers or at the turbine inlet. This indirect control of turbine firing temperature is made practical by utilizing known gas turbine aero– and thermo–dynamic characteristics and using those to bias the exhaust temperature signal, since the exhaust temperature alone is not a true indication of firing temperature.
ACCELERATION CONTROL Acceleration control compares the present value of the speed signal with the value at the last sample time. The difference between these two numbers is a measure of the acceleration. If the actual acceleration is greater than the acceleration reference, FSRACC is reduced, which will reduce FSR, and consequently the fuel to the gas turbine. During start–up the acceleration reference is a function of turbine speed; acceleration control usually takes over from speed control shortly after the warm–up period and brings the unit to speed. At “Complete Sequence”, which is normally 14HS pick–up, the acceleration reference is a Control Constant, normally 1% speed/second. After the unit has reached 100% TNH, acceleration control usually serves only to contain the unit’s speed if the generator breaker should open while under load.
EXHASUT TEMPERATURE (Tx)
ISOTHERMAL
Firing temperature can also be approximated as a function of exhaust temperature and fuel flow (FSR) and as a function of exhaust temperature and generator output (DWATT). Either FSR or megawatt exhaust temperature control curves are used as back–up to the primary CPD–biased temperature control curve.
COMPRESSOR DISCHARGE PRESSURE (CPD)
These relationships are shown on Figures 7 and 8. The lines of constant firing temperature are used in the control system to limit gas turbine operating temperatures, while the constant exhaust temperature limit protects the exhaust system during start– up.
id0045
Figure 7 Exhaust Temperature vs. Compressor Discharge Pressure
Exhaust Temperature Control Hardware
TEMPERATURE CONTROL Chromel–Alumel exhaust temperature thermocouples are used and, typically 27 in number. These thermocouples circumferentially inside the exhaust diffuser. They have individual radiation shields that allow the radial outward diffuser flow to pass over
The Temperature Control System will limit fuel flow to the gas turbine to maintain internal operating temperatures within design limitations of turbine hot gas path parts. The highest temperature in the gas Fund_Mk_VI
9
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems tive exhaust temperature value, compares this value with the setpoint, and then generates a fuel command signal to the analog control system to limit exhaust temperature. ISOTHERMAL EXHASUT TEMPERATURE (Tx)
Temperature Control Command Program The temperature control command program compares the exhaust temperature control setpoint with the measured gas turbine exhaust temperature as obtained from the thermocouples mounted in the exhaust plenum; these thermocouples are scanned and cold junction corrected by programs described later. These signals are accessed by . The temperature control command program in (Figure 9) reads the exhaust thermocouple temperature values and sorts them from the highest to the lowest. This array (TTXD2) is used in the combustion monitor program as well as in the Temperature Control Program. In the Temperature Control Program all exhaust thermocouple inputs are monitored and if any are reading too low as compared to a constant, they will be rejected. The highest and lowest values are then rejected and the remaining values are averaged, that average being the TTXM signal.
FUEL STROKE REFERENCE (FSR) id0046
Figure 8 Exhaust Temperature vs. Fuel Control Command Signal
these 1/16” diameter (1.6mm) stainless steel sheathed thermocouples at high velocity, minimizing the cooling effect of the longer time constant, cooler plenum walls. The signals from these individual, ungrounded detectors are sent to the SPEEDTRONIC Mark VI control panel through shielded thermocouple cables and are divided amongst controllers .
If a Controller should fail, this program will ignore the readings from the failed Controller. The TTXM signal will be based on the remaining Controllers’ thermocouples and an alarm will be generated.
Exhaust Temperature Control Software
The TTXM value is used as the feedback for the exhaust temperature comparator because the value is not affected by extremes that may be the result of faulty instrumentation. The temperature–control– command program in compares the exhaust temperature control setpoint (calculated in the temperature–control–bias program and stored in the computer memory) TTRXB to the TTXM value to determine the temperature error. The software program converts the temperature error to a fuel stroke reference signal, FSRT.
The software contains a series of application programs written to perform the exhaust temperature control and monitoring functions such as digital and analog input scan. A major function is the exhaust temperature control, which consists of the following programs: 1. Temperature control command 2. Temperature control bias calculations 3. Temperature reference selection
Temperature Control Bias Program
The temperature control software determines the cold junction compensated thermocouple readings, selects the temperature control setpoint, calculates the control setpoint value, calculates the representaFUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
Gas turbine firing temperature is determined by the measured parameters of exhaust temperature and 10
Fund_Mk_VI
GE Power Systems
. TO COMBUSTION MONITOR
TTXD2
TTXDR SORT HIGHEST TO LOWEST
TTXDS TTXDT
REJECT LOW TC’s
QUANTITY
REJECT HIGH AND LOW
TTXM
AVERAGE REMAINING
OF TC’s USED
CORNER
TEMPERATURE CONTROL REFERENCE
TEMPERATURE CONTROL FSRMIN
CPD FSRMAX SLOPE
SLOPE
TTRXB MEDIAN SELECT
MIN SELECT
FSRT
TTXM + FSR
+
GAIN CORNER FSR ISOTHERMAL id0032V
Figure 9 Temperature Control Schematic
compressor discharge pressure (CPD) or exhaust temperature and fuel consumption (proportional to FSR). In the computer, firing temperature is limited by a linearized function of exhaust temperature and CPD backed up by a linearized function of exhaust temperature and FSR (See Figure 8). The temperature control bias program (Figure 10) calculates the exhaust temperature control setpoint TTRXB based on the CPD data stored in computer memory and constants from the selected temperature–reference table. The program calculates another setpoint based on FSR and constants from another temperature– reference table.
DIGITAL INPUT DATA
SELECTED TEMPERATURE REFERENCE TABLE
COMPUTER MEMORY
TEMPERATURE CONTROL BIAS PROGRAM
COMPUTER MEMORY
CONSTANT STORAGE id0023
Figure 10 Temperature Control Bias
perature setpoint. The constants TTKn_K (FSR bias corner) and TTKn_M (FSR bias slope) are used with the FSR data to determine the FSR bias exhaust temperature setpoint. The values for these constants are
Figure 11 is a graphical illustration of the control setpoints. The constants TTKn_C (CPD bias corner) and TTKn_S (CPD bias slope) are used with the CPD data to determine the CPD bias exhaust temFund_Mk_VI
11
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems Temperature Reference Select Program
EXHAUST TEMPERATURE
given in the Control Specifications–Control System Settings drawing. The temperature–control–bias program also selects the isothermal setpoint TTKn_I. The program selects the minimum of the three setpoints, CPD bias, FSR bias, or isothermal for the final exhaust temperature control reference. During normal operation with gas or light distillate fuels, this selection results in a CPD bias control with an isothermal limit, as shown by the heavy lines on Figure 11. The CPD bias setpoint is compared with the FSR bias setpoint by the program and an alarm occurs when the CPD setpoint is higher. For units operating with heavy fuel, FSR bias control will be selected to minimize the effect of turbine nozzle plugging on firing temperature. The FSR bias setpoint will then be compared with the CPD bias setpoint and an alarm will occur when the FSR setpoint exceeds the CPD setpoint. A ramp function is provided in the program to limit the rate at which the setpoint can change. The maximum and minimum change in ramp rates (slope) are programmed in constants TTKRXR1 and TTKRXR2. Consult the Control Sequence Program (CSP) and the Control Specifications drawing for the block diagram illustration of this function and the value of the constants. Typical rate change limit is 1.5°F per second. The output of the ramp function is the exhaust temperature control setpoint which is stored in the computer memory.
TTKn_K
TTKn_I
The exhaust temperature control function selects control setpoints to allow gas turbine operation at various firing temperatures. The temperature–reference–select program (Figure 12) determines the operational level for control setpoints based on digital input information representing temperature control requirements. Three digital input signals are decoded to select one set of constants which define the control setpoints necessary to meet those requirements. A typical digital signal is “BASE SELECT”, selected by clicking on the appropriate target on the operator interface .
FUEL CONTROL SYSTEM The gas turbine fuel control system will change fuel flow to the combustors in response to the fuel stroke reference signal (FSR). FSR actually consists of two separate signals added together, FSR1 being the called–for liquid fuel flow and FSR2 being the called–for gas fuel flow; normally, FSR1 + FSR2 = FSR. Standard fuel systems are designed for operation with liquid fuel and/or gas fuel. This chapter will describe a dual fuel system. It starts with the servo drive system, where the setpoint is compared with the feedback signal and converted to a valve position. It will describe liquid, gas and dual fuel operation and how the FSR from the control systems previously described is conditioned and sent as a set point to the servo system.
ISOTHERMAL
TTKn_C
DIGITAL INPUT DATA
CPD FSR
TEMPERATURE REFERENCE SELECT
SELECTED TEMPERATURE REFERENCE TABLE
CONSTANT STORAGE id0054 id0106
Figure 11 Exhaust Temperature Control Setpoints
Figure 12 Temperature Reference Select Program
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
12
Fund_Mk_VI
GE Power Systems Servo Drive System
actuator. If the hydraulic actuator has spring return, hydraulic oil will be ported to one side of the cylinder and the other to drain. A feedback signal provided by a linear variable differential transformer (LVDT, Figure 13) will tell the control whether or not it is in the required position. The LVDT outputs an AC voltage which is proportional to the position of the core of the LVDT. This core in turn is connected to the valve whose position is being controlled; as the valve moves, the feedback voltage changes. The LVDT requires an exciter voltage which is provided by the VSVO card.
The heart of the fuel system is a three coil electro– hydraulic servovalve (servo) as shown in Figure 13. The servovalve is the interface between the electrical and mechanical systems and controls the direction and rate of motion of a hydraulic actuator based on the input current to the servo. 3-COIL TORQUE MOTOR TORQUE MOTOR ARMATURE
TORQUE MOTOR N
N
Figure 14 shows the major components of the servo positioning loops. The digital (microprocessor signal) to analog conversion is done on the VSVO card; this represents called–for fuel flow. The called–for fuel flow signal is then compared to a feedback representing actual fuel flow. The difference is amplified on the VSVO card and sent through the TSVO card to the servo. This output to the servos is monitored and there will be an alarm on loss of any one of the three signals from .
JET TUBE FORCE FEEDBACK SPRING
S
S
FAIL SAFE BIAS SPRING
P
R 1
P 2
Â
SPOOL VALVE
FILTER DRAIN
PS
Liquid Fuel Control
1350 PSI
The liquid fuel system consists of fuel handling components and electrical control components. Some of the fuel handling components are: primary fuel oil filter, fuel oil stop valve, three fuel pumps, fuel bypass valve, fuel pump pressure relief valve, flow divider, combined selector valve/pressure gauge assembly, false start drain valve, fuel lines, and fuel nozzles. The electrical control components are: liquid fuel pressure switch (upstream) 63FL–2, fuel oil stop valve limit switch 33FL, liquid fuel pump bypass valve servovalve 65FP, flow divider magnetic speed pickups 77FD–1, –2, –3 and SPEEDTRONIC control cards TSVO and VSVO. A diagram of the system showing major components is shown in Figure 15.
HYDRAULIC ACTUATOR
TO
LVDT
ABEX Servovalve
id0029
Figure 13 Electrohydraulic Servovalve
The servovalve contains three electrically isolated coils on the torque motor. Each coil is connected to one of the three Controllers . This provides redundancy should one of the Controllers or coils fail. There is a null–bias spring which positions the servo so that the actuator will go to the fail safe position should ALL power and/or control signals be lost. If the hydraulic actuator is a double–action piston, the control signal positions the servovalve so that it ports high–pressure oil to either side of the hydraulic
Fund_Mk_VI
The fuel bypass valve is a hydraulically actuated valve with a linear flow characteristic. Located
13
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
TSVO
LVDT
TSVO
VSVO REF
14
Figure 14 Servo Positioning Loops
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
POSTION FEEDBACK 3.2KHZ
EXCITATION
D/A
FUEL
REF
SERVO VALVE
3.2KHZ
VSVO D/A
TORQUE MOTOR HYDRAULIC ACTUATOR
HIGH PRESSURE OIL
VSVO REF
3.2KHZ
EXCITATION
D/A
LVDT
Fund_Mk_VI id0026
GE Power Systems
POSTION FEEDBACK
GE Power Systems between the inlet (low pressure) and discharge (high pressure) sides of the fuel pump, this valve bypasses excess fuel delivered by the fuel pump back to the fuel pump inlet, delivering to the flow divider the
fuel necessary to meet the control system fuel demand. It is positioned by servo valve 65FP, which receives its signal from the controllers.
FQ1
FSR1
TSVO
FQROUT TNH L4 L20FLX
VSVO PR/A
BY-PASS VALVE ASM. P R
40µ
63FL-2
65FP DIFFERENTIAL PRESSURE GUAGE
FLOW DIVIDER
TYPICAL FUEL NOZZLES
77FD-1
OH HYDRAULIC SUPPLY
COMBUSTION CHAMBER OFV
FUEL STOP VALVE
VR4 AD
OF FUEL PUMP (QTY 3)
M
33FL FALSE START DRAIN VALVE CHAMBER OFD
OLTCONTROL OIL
77FD-2 TO DRAIN 77FD-3 id0031V
Figure 15 Liquid Fuel Control Schematic
The flow divider divides the single stream of fuel from the pump into several streams, one for each combustor. It consists of a number of matched high volumetric efficiency positive displacement gear pumps, again one per combustor. The flow divider is driven by the small pressure differential between the inlet and outlet. The gear pumps are mechanically connected so that they all run at the same speed, making the discharge flow from each pump equal. Fuel flow is represented by the output from the flow divider magnetic pickups (77FD–1, –2 & –3). These are non–contacting magnetic pickups, giving a pulse signal frequency proportional to flow divider speed, which is proportional to the fuel flow delivered to the combustion chambers.
VSVO card modulates servovalve 65FP based on inputs of turbine speed, FSR1 (called–for liquid fuel flow), and flow divider speed (FQ1). Fuel Oil Control – Software When the turbine is run on liquid fuel oil, the control system checks the permissives L4 and L20FLX and does not allow FSR1 to close the bypass valve unless they are ‘true’ (closing the bypass valve sends fuel to the combustors). The L4 permissive comes from the Master Protective System (to be discussed later) and L20FLX becomes ‘true’ after the turbine vent timer times out. These signals control the opening and closing of the fuel oil stop valve. The FSR signal from the controlling system goes through the fuel splitter where the liquid fuel requirement becomes FSR1. The FSR1 signal is multiplied by TNH, so fuel flow becomes a function of
The TSVO card receives the pulse rate signals from 77FD–1, –2, and –3 and outputs an analog signal which is proportional to the pulse rate input. The Fund_Mk_VI
15
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems Gas Fuel Control
speed – an important feature, particularly while the unit is starting. This enables the system to have better resolution at the lower, more critical speeds where air flow is very low. This produces the FQROUT signal, which is the digital liquid fuel flow command. At full speed TNH does not change, therefore FQROUT is directly proportional to FSR.
The dry low NOx II (DLN–2) control system regulates the distribution of gas fuel to a multi–nozzle combustor arrangement. The fuel flow distribution to each fuel nozzle assembly is a function of combustion reference temperature (TTRF1) and IGV temperature control mode. By a combination of fuel staging and shifting of combustion modes from diffusion at ignition through premix at higher loads, low nitrous oxide (NOx) emissions are achieved.
FQROUT then goes to the VSVO card where it is changed to an analog signal to be compared to the feedback signal from the flow divider. As the fuel flows into the turbine, speed sensors 77FD–1, –2, and –3 send a signal to the TSVO card, which in turn outputs the fuel flow rate signal (FQ1) to the VSVO card. When the fuel flow rate is equal to the called– for rate (FQ1 = FSR1), the servovalve 65FP is moved to the null position and the bypass valve remains “stationary” until some input to the system changes. If the feedback is in error with FQROUT, the operational amplifier on the VSVO card will change the signal to servovalve 65FP to drive the bypass valve in a direction to decrease the error.
Fuel gas is controlled by the gas stop/speed ratio valve (SRV), the primary, secondary and quaternary gas control valves (GCV) , and the premix splitter valve (PMSV). The premix splitter valve controls the split between secondary and tertiary gas flow. All valves are servo controlled by signals from the SPEEDTRONIC control panel (Figure 16). It is the gas control valve which controls the desired gas fuel flow in response to the command signal FSR. To enable it to do this in a predictable manner, the speed ratio valve is designed to maintain a predetermined pressure (P2) at the inlet of the gas control valve as a function of gas turbine speed.
The flow divider feedback signal is also used for system checks. This analog signal is converted to digital counts and is used in the controller’s software to compare to certain limits as well as to display fuel flow on the . The checks made are as follows:
There are three main DLN–2 combustion modes: Primary, Lean–Lean, and Premix. Primary mode exists from light off to 81% corrected speed, fuel flow to primary nozzles only. Lean– Lean is from 81% corrected speed to a preselected combustion reference temperature, with fuel to the primary and tertiary nozzles. In Premix operation fuel is directed to secondary, tertiary and quaternary nozzles. Minimum load for this operation is set by combustion reference temperature and IGV position.
L60FFLH:Excessive fuel flow on start–up L3LFLT1:Loss of LVDT position feedback L3LFBSQ:Bypass valve is not fully open when the stop valve is closed. L3LFBSC:Servo current is detected when the stop valve is closed.
The fuel gas control system consists primarily of the following components: gas strainer, gas supply pressure switch 63FG, stop/speed ratio valve assembly, fuel gas pressure transducer(s) 96FG, gas fuel vent solenoid valve 20VG, control valve assembly, LVDT’s 96GC–1, –2, –3, –4, –5, –6, 96SR–1, –2, 96 PS–1, –2, electro–hydraulic servovalves 90SR, 65GC and 65PS, dump valve(s) VH–5, three pressure gauges, gas manifold with ‘pigtails’ to respec-
L3LFT:Loss of flow divider feedback If L60FFLH is true for a specified time period (nominally 2 seconds), the unit will trip; if L3LFLT1 through L3LFT are true, these faults will trip the unit during start–up and require manual reset. FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
16
Fund_Mk_VI
GE Power Systems tive fuel nozzles, and SPEEDTRONIC control cards TBQB and TCQC. The components are shown schematically in Figure 17. A functional explana-
tion is graphs.
contained
in
subsequent
para-
DLN–2 GAS FUEL SYSTEM T
SGCV
SRV PGCV
PMSV
S
SINGLE BURNING ZONE
P QGCV
5 BURNERS
* Q
GAS SKID
TURBINE COMPARTMENT
SRV SPEED/RATIO VALVE
T TERTIARY MANIFOLD, 1 NOZ. PREMIX ONLY
PGCV GAS CONTROL, PRIMARY
S SECONDARY MANIFOLD, 4 NOZ. PREMIX INJ.
SGCV GAS CONTROL, SECONDARY
P PRIMARY MANIFOLD, 4 NOZ. DIFFUSION INJ.
QGCV GAS CONTROL, QUATERNARY
Q QUAT MANIFOLD, CASING. PREMIX ONLY
PMSV PREMIX SPLITTER VALVE
*
PURGE AIR (PCD AIR SUPPLY)
Figure 16 DLN–2 Gas Fuel System
Fund_Mk_VI
17
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems
VSVO TSVO
POS1
SPEED RATIO VALVE CONTROL
FSR2
FPRG POS2
VSVO
TSVO GAS CONTROL VALVE POSITION FEEDBACK
GAS CONTROL VALVE SERVO
FPG
TBAI VAIC
TSVO
96FG-2A 96FG-2B 20VG
96FG-2C TRANSDUCERS
VENT
COMBUSTION CHAMBER 63FG-3 STOP/ RATIO VALVE
GAS CONTROL VALVE
GAS P2
Electrical Connection LVDT’S 96GC-1,2
LVDT’S 96SR-1,2
Hydraulic Piping
GAS MANIFOLD
Gas Piping VH5-1 DUMP RELAY TRIP
90SR SERVO
65GC SERVO
HYDRAULIC SUPPLY
id0059V
Figure 17 Gas Fuel Control System
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
18
Fund_Mk_VI
GE Power Systems Gas Control Valves
then output to the servo valve through the TSVO card. The gas control valve stem position is sensed by the output of a linear variable differential transformer (LVDT) and fed back through the TSVO card to an operational amplifier on the VSVO card where it is compared to the FSROUT input signal at a summing junction. There are two LVDTs providing feedback ; two of the three controllers are dedicated to one LVDT each, while the third selects the highest feedback through a high–select diode gate. If the feedback is in error with FSROUT, the operational amplifier on the VSVO card will change the signal to the hydraulic servovalve to drive the gas control valve in a direction to decrease the error. In this way the desired relationship between position and FSR2 is maintained and the control valve correctly meters the gas fuel. See Figure 18.
The position of the gas control valve plug is intended to be proportional to FSR2 which represents called– for gas fuel flow. Actuation of the spring–loaded gas control valve is by a hydraulic cylinder controlled by an electro–hydraulic servovalve. When the turbine is to run on gas fuel the permissives L4, L20FGX and L2TVX (turbine purge complete) must be ‘true’, similar to the liquid system. This allows the Gas Control Valve to open. The stroke of the valve will be proportional to FSR. FSR goes through the fuel splitter (to be discussed in the dual fuel section) where the gas fuel requirement becomes FSR2, which is then conditioned for offset and gain. This signal, FSROUT, goes to the VSVO card where it is converted to an analog signal and OFFSET GAIN
FSR2
+
+
HIGH SELECT
L4
TBQC
L3GCV FSROUT ANALOG I/O
GAS CONTROL VALVE
ELECTRICAL CONNECTION GAS PIPING HYDRAULIC PIPING
ÎÎ ÎÎ ÎÎ
GAS CONTROL VALVE POSITION LOOP CALIBRATION
LVDT’S 96GC-1, -2
SERVO VALVE
POSITION LVDT
GAS P2
FSR id0027V
Figure 18 Gas Control Valve Control Schematic Fund_Mk_VI
19
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems
TNH GAIN VSVO
OFFSET
+
FPRG
+
D A
L4
FPG
L3GRV HIGH POS2 SELECT
96FG-2A 96FG-2B 96FG-2C SPEED RATIO VALVE GAS
ÎÎÎ ÎÎÎ ÎÎÎ
VAIC
96SR-1,2 LVDT’S
OPERATING CYLINDER PISTON TRIP OIL
TBAI
DUMP RELAY TSVO
SERVO VALVE LEGEND ELECTRICAL CONNECTION
HYDRAULIC OIL
GAS PIPING HYDRAULIC PIPING
P2 or PRESSURE CONTROL VOLTAGE
DIGITAL
TNH Speed Ratio Valve Pressure Calibration id0058V
Figure 19 Stop/Speed Ratio Valve Control Schematic
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
20
Fund_Mk_VI
GE Power Systems The plug in the gas control valve is contoured to provide the proper flow area in relation to valve stroke. The gas control valve uses a skirted valve disc and venturi seat to obtain adequate pressure recovery. High pressure recovery occurs at overall valve pressure ratios substantially less than the critical pressure ratio. The net result is that flow through the control valve is independent of valve pressure drop. Gas flow then is a function of valve inlet pressure P2 and valve area only.
The stop/speed ratio valve provides a positive stop to fuel gas flow when required by a normal shut– down, emergency trip, or a no–run condition. Hydraulic trip dump valve VH–5 is located between the electro–hydraulic servovalve 90SR and the hydraulic actuating cylinder. This dump valve is operated by the low pressure control oil trip system. If permissives L4 and L3GRV are ‘true’ the trip oil (OLT) is at normal pressure and the dump valve is maintained in a position that allows servovalve 90SR to control the cylinder position. When the trip oil pressure is low (as in the case of normal or emergency shutdown), the dump valve spring shifts a spool valve to a position which dumps the high pressure hydraulic oil (OH) in the speed ratio/stop valve actuating cylinder to the lube oil reservoir. The closing spring atop the valve plug instantly shuts the valve, thereby shutting off fuel flow to the combustors.
As before, an open or a short circuit in one of the servo coils or in the signal to one coil does not cause a trip. Each GCV has two LVDTs and can run correctly on one. Stop/Speed Ratio Valve
In addition to being displayed, the feedback signals and the control signals of both valves are compared to normal operating limits, and if they go outside of these limits there will be an alarm. The following are typical alarms:
The speed ratio/stop valve is a dual function valve. It serves as a pressure regulating valve to hold a desired fuel gas pressure ahead of the gas control valve and it also serves as a stop valve. As a stop valve it is an integral part of the protection system. Any emergency trip or normal shutdown will move the valve to its closed position shutting off gas fuel flow to the turbine. This is done either by dumping hydraulic oil from the Stop/Speed Ratio Valve VH–5 hydraulic trip relay or driving the position control closed electrically.
L60FSGH: Excessive fuel flow on start–up L3GRVFB: Loss of LVDT feedback on the SRV L3GRVO: SRV open prior to permissive to open L3GRVSC: Servo current to SRV detected prior to permissive to open L3GCVFB: Loss of LVDT feedback on the GCV
The stop/speed ratio valve has two control loops. There is a position loop similar to that for the gas control valve and there is a pressure control loop. See Figure 19. Fuel gas pressure P2 at the inlet to the gas control valve is controlled by the pressure loop as a function of turbine speed. This is done by proportioning it to turbine speed signal TNH, with an offset and gain, which then becomes Gas Fuel Pressure Reference FPRG. FPRG then goes to the VSVO card to be converted to an analog signal. P2 pressure is measured by 96FG which outputs a voltage proportional to P2 pressure. This P2 signal (FPG) is compared to the FPRG and the error signal (if any) is in turn compared with the 96SR LVDT feedback to reposition the valve as in the GCV loop. Fund_Mk_VI
L3GCVO: GCV open prior to permissive to open L3GCVSC: Servo current to GCV detected prior to permissive to open L3GFIVP: Intervalve (P2) pressure low The servovalves are furnished with a mechanical null offset bias to cause the gas control valve or speed ratio valve to go to the zero stroke position (fail safe condition) should the servovalve signals or power be lost. During a trip or no–run condition, a positive voltage bias is placed on the servo coils holding them in the ‘valve closed’ position. 21
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems Premix Splitter Valve
FUEL SPLITTER A=B
The Premix splitter valve (PMSV) regulates the split of secondary/tertiary gas fuel flow between the secondary and tertiary gas fuel manifolds. The valve is referenced to the secondary fuel passages, i.e. 0% valve stroke corresponds to 0% secondary fuel flow. Unlike the SRV and GCV’s the flow through the splitter valve is not linear with valve position.The control system linearizes the fuel split setpoint and the resulting valve position command FSRXPOUT is used as the position reference.
A=B MAX. LIMIT
L84TG TOTAL GAS L84TL TOTAL LIQUID
MIN. LIMIT L83FZ PERMISSIVES
MEDIAN SELECT
RAMP RATE L83FG GAS SELECT L83FL LIQUID SELECT FSR
FSR1 LIQUID REF. FSR2 GAS REF. id0034
Dual Fuel Control
Figure 20 Fuel Splitter Schematic
Turbines that are designed to operate on both liquid and gaseous fuel are equipped with controls to provide the following features:
Fuel Transfer – Liquid to Gas If the unit is running on liquid fuel (FSR1) and the “GAS” target on the screen is selected the following sequence of events will take place, providing the transfer and fuel gas permissives are true (refer to Figure 21):
1.Transfer from one fuel to the other on command. 2. Allow time for filling the lines with the type of fuel to which turbine operation is being transferred.
FSR1 will remain at its initial value, but FSR2 will step to a value slightly greater than zero, usually 0.5%. This will open the gas control valve slightly to bleed down the intervalve volume. This is done in case a high pressure has been entrained. The presence of a higher pressure than that required by the speed/ratio controller would cause slow response in initiating gas flow.
3. Operation of liquid fuel nozzle purge when operating totally on gas fuel. 4. Operation of gas fuel nozzle purge when operating totally on liquid fuel. The software diagram for the fuel splitter is shown in Figure 20.
After a typical time delay of thirty seconds to bleed down the P2 pressure and fill the gas supply line, the software program ramps the fuel commands, FSR2 to increase and FSR1 to decrease, at a programmed rate through the median select gate. This is complete in thirty seconds.
Fuel Splitter As stated before FSR is divided into two signals, FSR1 and FSR2, to provide dual fuel operation. See Figure 20.
When the transfer is complete logic signal L84TG (Total Gas) will de–energize the liquid fuel forwarding pump, close the fuel oil stop valve by de–energizing the liquid fuel dump valve 20FL, and initiate the purge sequence.
FSR is multiplied by the liquid fuel fraction FX1 to produce the FSR1 signal. FSR1 is then subtracted from the FSR signal resulting in FSR2, the control signal for the secondary fuel. FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
22
Fund_Mk_VI
GE Power Systems Fuel Transfer – Gas to Liquid Transfer from Full Gas to Full Distillate
Transfer from gas to liquid is essentially the same sequence as previously described, except that gas and liquid fuel command signals are interchanged. For instance, at the beginning of a transfer, FSR2 remains at its initial value, but FSR1 steps to a value slightly greater than zero. This will command a small liquid fuel flow. If there has been any fuel leakage out past the check valves, this will fill the liquid fuel piping and avoid any delay in delivery at the beginning of the FSR1 increase.
UNITS
FSR2
FSR1 PURGE
TIME
SELECT DISTILLATE
Transfer from Full Distillate to Full Gas
UNITS
FSR1
FSR2 PURGE
The rest of the sequence is the same as liquid–to– gas, except that there is usually no purging sequence.
TIME
SELECT GAS
Transfer from Full Distillate to Mixture
Gas Fuel Purge
UNITS
FSR1
Primary gas fuel purge is required during premix steady state and liquid fuel operation. This system involves a double block and bleed arrangement, wherby two purge valves (VA13–1, –2) are shut when primary gas is flowing and intervalve vent solenoid (20VG–2) is open to bleed any leakage across the valves. The purge valves are air operated through solenoid valves 20PG–1, –2. When there is no primary gas flow, the purge valves open and allow compressor discharge air to flow through the primary fuel nozzle passages. Secondary purge is required for the secondary and tertiary nozzles when secondary and tertiary fuel flow is reduced to zero and when operating on liquid fuel. This is a block and bleed arrangement similar to the primary purge with two purge valves (VA13–3, –4), intervalve vent solenoid (20VG–3), and solenoid valves 20PG–3, –4.
FSR2 PURGE SELECT GAS
TIME SELECT MIX id0033
Figure 21 Fuel Transfer
Liquid Fuel Purge To prevent coking of the liquid fuel nozzles while operating on gas fuel, some atomizing air is diverted through the liquid fuel nozzles. The following sequence of events occurs when transfer from liquid to gas is complete. Air from the atomizing air system flows through a cooler (HX4–1), through the fuel oil purge valve (VA19–3) and through check valve VCK2 to each fuel nozzle.
MODULATED INLET GUIDE VANE SYSTEM
The fuel oil purge valve is controlled by the position of a solenoid valve 20PL–2 . When this valve is energized , actuating air pressure opens the purge oil check valve, allowing air flow to the fuel oil nozzle purge check valves.
Fund_Mk_VI
The Inlet Guide Vanes (IGVs) modulate during the acceleration of the gas turbine to rated speed, loading and unloading of the generator, and deceleration of the gas turbine. This IGV modulation maintains proper flows and pressures, and thus stresses, in the 23
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems compressor, maintains a minimum pressure drop across the fuel nozzles, and, when used in a com-
bined cycle application, maintains high exhaust temperatures at low loads.
CSRGV VSVO IGV REF
CSRGV
CSRGVOUT
D/A HIGH SELECT
TSVO
CLOSE HM3-1 HYD. SUPPLY IN
R
P
2
1
OPEN
FH6 OUT –1
90TV-1 A
96TV-1,2
OLT-1 TRIP OIL C1
VH3-1 D
C2 ORIFICES (2)
OD
id0030
Figure 23 Modulating Inlet Guide Vane Control Schematic
Guide Vane Actuation
Operation
The modulated inlet guide vane actuating system is comprised of the following components: servovalve 90TV, LVDT position sensors 96TV–1 and 96TV–2, and, in some instances, solenoid valve 20TV and hydraulic dump valve VH3. Control of 90TV will port hydraulic pressure to operate the variable inlet guide vane actuator. If used, 20TV and VH3 can prevent hydraulic oil pressure from flowing to 90TV. See Figure 23.
During start–up, the inlet guide vanes are held fully closed, a nominal 27 degree angle, from zero to 83.5% corrected speed. Turbine speed is corrected to reflect air conditions at 27° C (80° F); this compensates for changes in air density as ambient conditions change. At ambient temperatures greater than 80° F, corrected speed TNHCOR is less than actual speed TNH; at ambients less than 27° C (80° F), TNHCOR is greater than TNH. After attaining a speed of approximately 83.5%, the guide vanes will
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
24
Fund_Mk_VI
GE Power Systems modulate open at about 6.7 degrees per percent increase in corrected speed. When the guide vanes reach the minimum full speed angle, nominally 54°, they stop opening; this is usually at approximately 91% TNH. By not allowing the guide vanes to close to an angle less than the minimum full speed angle at 100% TNH, a minimum pressure drop is maintained across the fuel nozzles, thereby lessening combustion system resonance. Solenoid valve 20CB is usually opened when the generator breaker is closed; this in turn closes the compressor bleed valves.
IGV ANGLE – DEGREES (CSRGV)
FULL OPEN (MAX ANGLE)
SIMPLE CYCLE (CSKGVSSR)
MINIMUM FULL SPEED ANGLE ROTATING STALL REGION
0
REGION OF NEGATIVE 5TH STAGE EXTRACTION PRESSURE
100 CORRECTED SPEED–% (TNHCOR) 0 FSNL
100
LOAD–% EXHAUST TEMPERATURE
BASE LOAD id0037
Figure 24 Variable Inlet Guide Vane Schedule
PROTECTION SYSTEMS The gas turbine protection system is comprised of a number of sub–systems, several of which operate during each normal start–up and shutdown. The other systems and components function strictly during emergency and abnormal operating conditions. The most common kind of failure on a gas turbine is the failure of a sensor or sensor wiring; the protection systems are set up to detect and alarm such a failure. If the condition is serious enough to disable the protection completely, the turbine will be tripped.
During a normal shutdown, as the exhaust temperature decreases the IGVs move to the minimum full speed angle; as the turbine decelerates from 100% TNH, the inlet guide vanes are modulated to the fully closed position. When the generator breaker opens, the compressor bleed valves will be opened.
Protective systems respond to the simple trip signals such as pressure switches used for low lube oil pressure, high gas compressor discharge pressure, or similar indications. They also respond to more complex parameters such as overspeed, overtemperature, high vibration, combustion monitor, and loss of flame. To do this, some of these protection systems and their components operate through the master control and protection circuit in the SPEEDTRONIC control system, while other totally mechanical systems operate directly on the components of the turbine. In each case there are two essentially independent paths for stopping fuel flow, making use of both the fuel control valve (FCV) and the fuel stop valve (FSV). Each protective system is designed independent of the control system to avoid the possi-
In the event of a turbine trip, the compressor bleed valves are opened and the inlet guide vanes go to the fully closed position. The inlet guide vanes remain fully closed as the turbine continues to coast down. For underspeed operation, if TNHCOR decreases below approximately 91%, the inlet guide vanes modulate closed at 6.7 degrees per percent decrease in corrected speed. In most cases, if the actual speed decreases below 95% TNH, the generator breaker will open and the turbine speed setpoint will be reset to 100.3%. The IGVs will then go to the minimum full speed angle. See Figure 24. Fund_Mk_VI
STARTUP PROGRAM
FULL CLOSED (MIN ANGLE)
As the unit is loaded and exhaust temperature increases, the inlet guide vanes will go to the full open position when the exhaust temperature reaches one of two points, depending on the operation mode selected. For simple cycle operation, the IGVs move to the full open position at a pre–selected exhaust temperature, usually 371° C (700° F). For combined cycle operation, the IGVs begin to move to the full open position as exhaust temperature approaches the temperature control reference temperature; normally, the IGVs begin to open when exhaust temperature is within 17° C (30° F) of the temperature control reference.
COMBINED CYCLE (TTRX)
25
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems bility of a control system failure disabling the protective devices. See Figure 25.
PRIMARY OVERSPEED
MASTER PROTECTION CIRCUIT
GCV SERVOVALVE
GAS FUEL CONTROL VALVE
SRV SERVOVALVE
GAS FUEL SPEED RATIO/ STOP VALVE
OVERTEMP
VIBRATION
COMBUSTION MONITOR RELAY VOTING MODULE
LOSS of FLAME
SECONDARY OVERSPEED
MASTER PROTECTION CIRCUIT
20FG
BYPASS VALVE SERVOVALVE
RELAY VOTING MODULE
20FL
FUEL PUMP
LIQUID FUEL STOP VALVE id0036V
Figure 25 Protective Systems Schematic
Trip Oil
Inlet Orifice
A hydraulic trip system called Trip Oil is the primary protection interface between the turbine control and protection system and the components on the turbine which admit, or shut–off, fuel. The system contains devices which are electrically operated by SPEEDTRONIC control signals as well as some totally mechanical devices.
An orifice is located in the line running from the bearing header supply to the trip oil system. This orifice is sized to limit the flow of oil from the lube oil system into the trip oil system. It must ensure adequate capacity for all tripping devices, yet prevent reduction of lube oil flow to the gas turbine and other equipment when the trip system is in the tripped state. Dump Valve
Besides the tripping functions, trip oil also provides a hydraulic signal to the fuel stop valves for normal start–up and shutdown sequences. On gas turbines equipped for dual fuel (gas and oil) operation the system is used to selectively isolate the fuel system not required.
Each individual fuel branch in the trip oil system has a solenoid dump valve (20FL for liquid, 20FG for gas). This device is a solenoid–operated spring–return spool valve which will relieve trip oil pressure only in the branch that it controls. These valves are normally energized–to–run, deenergized–to–trip. This philosophy protects the turbine during all nor-
Significant components of the Hydraulic Trip Circuit are described below. FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
26
Fund_Mk_VI
GE Power Systems mal situations as well as that time when loss of dc power occurs.
PROTECTIVE SIGNALS
MASTER PROTECTION L4 CIRCUITS
LIQUID FUEL LIQUID FUEL STOP VALVE 20FG
20FL
ORIFICE AND CHECK VALVE NETWORK 63HL
INLET ORIFICE GAS FUEL SPEED RATIO/ STOP VALVE
GAS FUEL
63HG
WIRING PIPING
GAS FUEL DUMP RELAY VALVE OH
id0056
Figure 26 Trip Oil Schematic – Dual Fuel
Check Valve & Orifice Network
dividual fuel stop valve may be selectively closed by dumping the flow of trip oil going to it. Solenoid valve 20FL can cause the trip valve on the liquid fuel stop valve to go to the trip state, which permits closure of the liquid fuel stop valve by its spring return mechanism. Solenoid valve 20FG can cause the trip valve on the gas fuel speed ratio/stop valve to go to the trip state, permitting its spring–returned closure. The orifice in the check valve and orifice network permits independent dumping of each fuel branch of the trip oil system without affecting the other branch. Tripping all devices other than the individual dump valves will result in dumping the total trip oil system, which will shut the unit down.
At the inlet of each individual fuel branch is a check valve and orifice network which limits flow out of that branch. This network limits flow into each branch, thus allowing individual fuel control without total system pressure decay. However, when one of the trip devices located in the main artery of the system, e.g., the overspeed trip, is actuated, the check valve will open and result in decay of all trip pressures. Pressure Switches Each individual fuel branch contains pressure switches (63HL–1,–2,–3 for liquid, 63HG–1,–2,–3 for gas) which will ensure tripping of the turbine if the trip oil pressure becomes too low for reliable operation while operating on that fuel.
During start–up or fuel transfer, the SPEEDTRONIC control system will close the appropriate dump valve to activate the desired fuel system(s). Both dump valves will be closed only during fuel transfer or mixed fuel operation.
Operation The dump valves are de–energized on a “2–out– of–3 voted” trip signal from the relay module. This helps prevent trips caused by faulty sensors or the failure of one controller.
The tripping devices which cause unit shutdown or selective fuel system shutdown do so by dumping the low pressure trip oil (OLT). See Figure 26. An inFund_Mk_VI
27
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems The signal to the fuel system servovalves will also be a “close” command should a trip occur. This is done by clamping FSR to zero. Should one controller fail, the FSR from that controller will be zero. The output of the other two controllers is sufficient to continue to control the servovalve.
HIGH PRESSURE OVERSPEED TRIP HP SPEED
TNH
TRIP SETPOINT TNKHOS TNKHOST
By pushing the Emergency Trip Button, 5E P/B, the P28 vdc power supply is cut off to the relays controlling solenoid valves 20FL and 20FG, thus de–energizing the dump valves.
A A>B B
L12H SET AND LATCH
TO MASTER PROTECTION AND ALARM MESSAGE
TEST
LH3HOST
TEST PERMISSIVE
L86MR1
MASTER RESET
RESET
SAMPLING RATE = 0.25 SEC id0060
Figure 27 Electronic Overspeed Trip
Overtemperature Protection
Overspeed Protection
The overtemperature system protects the gas turbine against possible damage caused by overfiring. It is a backup system, operating only after the failure of the temperature control system.
The SPEEDTRONIC Mark VI overspeed system is designed to protect the gas turbine against possible damage caused by overspeeding the turbine rotor. Under normal operation, the speed of the rotor is controlled by speed control. The overspeed system would not be called on except after the failure of other systems.
TTKOT1
EXH TEMP
The overspeed protection system consists of a primary and secondary electronic overspeed system. The primary electronic overspeed protection system resides in the controllers. The secondary electronic overspeed protection system resides in the controllers (in ). Both systems consist of magnetic pickups to sense turbine speed, speed detection software, and associated logic circuits and are set to trip the unit at 110% rated speed.
TRIP
TTRX TRIP MARGIN TTKOT2 ALARM MARGIN TTKOT3 CPD/FSR id0053
Figure 29 Overtemperature Protection
Electronic Overspeed Protection System
Under normal operating conditions, the exhaust temperature control system acts to control fuel flow when the firing temperature limit is reached. In certain failure modes however, exhaust temperature and fuel flow can exceed control limits. Under such circumstances the overtemperature protection system provides an overtemperature alarm about 14° C (25° F) above the temperature control reference. To avoid further temperature increase, it starts unloading the gas turbine. If the temperature should increase further to a point about 22° C (40° F) above the temperature control reference, the gas turbine is tripped. For the actual alarm and trip overtempera-
The electronic overspeed protection function is performed in both and as shown in Figure 27. The turbine speed signal (TNH) derived from the magnetic pickup sensors (77NH–1,–2, and –3) is compared to an overspeed setpoint (TNKHOS). When TNH exceeds the setpoint, the overspeed trip signal (L12H) is transmitted to the master protective circuit to trip the turbine and the “OVERSPEED TRIP” message will be displayed on the . This trip will latch and must be reset by the master reset signal L86MR. FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
28
Fund_Mk_VI
GE Power Systems ture setpoints refer to the Control Specifications. See Figure 29.
will be tripped through the master protection circuit. The trip function will be latched in and the master reset signal L86MR1 must be true to reset and unlatch the trip.
Overtemperature trip and alarm setpoints are determined from the temperature control setpoints derived by the Exhaust Temperature Control software. See Figure 30.
Flame Detection and Protection System The SPEEDTRONIC Mark VI flame detectors perform two functions, one in the sequencing system and the other in the protective system. During a normal start–up the flame detectors indicate when a flame has been established in the combustion chambers and allow the start–up sequence to continue. Most units have four flame detectors, some have two, and a very few have eight. Generally speaking, if half of the flame detectors indicate flame and half (or less) indicate no–flame, there will be an alarm but the unit will continue to run. If more than half indicate loss–of–flame, the unit will trip on “LOSS OF FLAME.” This avoids possible accumulation of an explosive mixture in the turbine and any exhaust heat recovery equipment which may be installed. The flame detector system used with the SPEEDTRONIC Mark VI system detects flame by sensing ultraviolet (UV) radiation. Such radiation results from the combustion of hydrocarbon fuels and is more reliably detected than visible light, which varies in color and intensity.
OVERTEMPERATURE TRIP AND ALARM TTXM
A ALARM
TTKOT3
TTRXB
L30TXA
A>B
ALARM
B
TO ALARM MESSAGE AND SPEED SETPOINT LOWER
A A>B B
TTKOT2
OR A TRIP ISOTHERMAL
TTKOT1
A>B B
L86MR1
SET AND LATCH
L86TXT TRIP
TO MASTER PROTECTION AND ALARM MESSAGE
RESET SAMPLING RATE: 0.25 SEC.
id0055
Figure 30 Overtemperature Trip and Alarm
Overtemperature Protection Software Overtemperature Alarm (L30TXA) The representative value of the exhaust temperature thermocouples (TTXM) is compared with alarm and trip temperature setpoints. The “EXHAUST TEMPERATURE HIGH” alarm message will be displayed when the exhaust temperature (TTXM) exceeds the temperature control reference (TTRXB) plus the alarm margin (TTKOT3) programmed as a Control Constant in the software. The alarm will automatically reset if the temperature decreases below the setpoint.
The flame sensor is a copper cathode detector designed to detect the presence of ultraviolet radiation. The SPEEDTRONIC control will furnish +24Vdc to drive the ultraviolet detector tube. In the presence of ultraviolet radiation, the gas in the detector tube ionizes and conducts current. The strength of the current feedback (4 – 20 mA) to the panel is a proportional indication of the strength of the ultraviolet radiation present. If the feedback current exceeds a threshold value the SPEEDTRONIC generates a logic signal to indicate ”FLAME DETECTED” by the sensor.
Overtemperature Trip (L86TXT) An overtemperature trip will occur if the exhaust temperature (TTXM) exceeds the temperature control reference (TTRXB) plus the trip margin (TTKOT2), or if it exceeds the isothermal trip setpoint (TTKOT1). The overtemperature trip will latch, the “EXHAUST OVERTEMPERATURE TRIP” message will be displayed, and the turbine Fund_Mk_VI
The flame detector system is similar to other protective systems, in that it is self–monitoring. For example, when the gas turbine is below L14HM all channels must indicate “NO FLAME.” If this condition is not met, the condition is annunciated as a 29
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems “FLAME DETECTOR TROUBLE” alarm and the turbine cannot be started. After firing speed has been reached and fuel introduced to the machine, if at least half the flame detectors see flame the starting sequence is allowed to proceed. A failure of one detector will be annunciated as “FLAME DETECTOR TROUBLE” when complete sequence is reached
and the turbine will continue to run. More than half the flame detectors must indicate “NO FLAME” in order to trip the turbine. Note that a short–circuited or open–circuited detector tube will result in a “NO FLAME” signal.
SPEEDTRONIC Mk VI Flame Detection Turbine Protection Logic
28FD UV Scanner 28FD UV Scanner 28FD UV Scanner
Analog I/O
Flame Detection Logic
Display
TBAI VAIC
28FD UV Scanner
Turbine Control Logic
NOTE: Excitation for the sensors and signal processing is performed by SPEEDTRONIC Mk VI circuits
Figure 31 SPEEDTRONIC Mk VI Flame Detection
ido115
Vibration Protection
ceeded, the vibration protection system trips the turbine and annunciates to indicate the cause of the trip.
The vibration protection system of a gas turbine unit is composed of several independent vibration channels. Each channel detects excessive vibration by means of a seismic pickup mounted on a bearing housing or similar location of the gas turbine and the driven load. If a predetermined vibration level is ex-
Each channel includes one vibration pickup (velocity type) and a SPEEDTRONIC Mark VI amplifier circuit. The vibration detectors generate a relatively low voltage by the relative motion of a permanent magnet suspended in a coil and therefore no excitation is necessary. A twisted–pair shielded cable is
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
30
Fund_Mk_VI
GE Power Systems used to connect the detector to the analog input/output module.
Combustion Monitoring
The pickup signal from the analog I/O module is inputted to the computer software where it is compared with the alarm and trip levels programmed as Control Constants. See Figure 32. When the vibration amplitude reaches the programmed trip set point, the channel will trigger a trip signal, the circuit will latch, and a “HIGH VIBRATION TRIP” message will be displayed. Removal of the latched trip condition can be accomplished only by depressing the master reset button (L86MR1) when vibration is not excessive.
The primary function of the combustion monitor is to reduce the likelihood of extensive damage to the gas turbine if the combustion system deteriorates. The monitor does this by examining the exhaust temperature thermocouples and compressor discharge temperature thermocouples. From changes that may occur in the pattern of the thermocouple readings, warning and protective signals are generated by the combustion monitor software to alarm and/or trip the gas turbine. This means of detecting abnormalities in the combustion system is effective only when there is incomplete mixing as the gases pass through the turbine; an uneven turbine inlet pattern will cause an uneven exhaust pattern. The uneven inlet pattern could be caused by loss of fuel or flame in a combustor, a rupture in a transition piece, or some other combustion malfunction.
L39TEST 39V OR A AB ALARM
ALARM L39VA
VA
B
A A>B TRIP
VT
AND
TRIP L39VT
SET AND LATCH
The usefulness and reliability of the combustion monitor depends on the condition of the exhaust thermocouples. It is important that each of the thermocouples is in good working condition.
TRIP
B RESET
Combustion Monitoring Software
AUTO OR MANUAL RESET L86AMR
id0057
The controllers contain a series of programs written to perform the monitoring tasks (See Combustion Monitoring Schematic Figure 33). The main monitor program is written to analyze the thermocouple readings and make appropriate decisions. Several different algorithms have been developed for this depending on the turbine model series and the type of thermocouples used. The significant program constants used with each algorithm are specified in the Control Specification for each unit.
Figure 32 Vibration Protection
When the “VIBRATION TRANSDUCER FAULT” message is displayed and machine operation is not interrupted, either an open or shorted condition may be the cause. This message indicates that maintenance or replacement action is required. With the display, it is possible to monitor vibration levels of each channel while the turbine is running without interrupting operation.
Fund_Mk_VI
31
FUNDAMENTALS OF SPEEDTRONIC MARK VI CONTROL SYSTEM
GE Power Systems COMBUSTION MONITOR ALGORITHM
CTDA MAX
TTKSPL1
MIN
TTKSPL2
MEDIAN SELECT CALCULATE ALLOWABLE SPREAD
TTXM
MAX
TTKSPL5
MIN
TTKSPL7
MEDIAN SELECT
TTXSPL
A
L60SP1
CONSTANTS
A>B B
TTXD2
A
CALCULATE ACTUAL SPREADS
A>B
L60SP2
B A A +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.
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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 bidirectional). 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 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.
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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 (1 ms). 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 1 ms time stamp, thus eliminating the initial cost and long term maintenance of a separate SOE system. The HMI server has the turbine data to support GSM messages.
An Ethernet link is available using TCP/IP to transmit data with the local time tags to the plant level control. The link supports all the alarms, events, and SOEs in the Mark VI panel. 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 (see Figure 3-13).
HMI View Node PLANT DISTRIBUTED CONTROL SYSTEM (DCS)
Redundant Switch Ethernet GSM
Ethernet Modbus
PLANT DATA HIGHWAY PLANT DATA HIGHWAY
HMI Server Node
HMI Server Node
Modbus Communication
From UDH
From UDH
Figure 3-13. 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.
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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, 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.
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PROFIBUS Communications PROFIBUS is an open fieldbus communication standard.
PROFIBUS is used in wide variety of industrial applications. It is defined in PROFIBUS Standard EN 50170 and in other ancillary guideline specifications. PROFIBUS devices are distinguished as Masters or slaves. Masters control the bus and initiate data communication. They decide bus access by a token passing protocol. Slaves, not having bus access rights, only respond to messages received from Masters. Slaves are peripherals such as I/O devices, transducers, valves, and such devices.
PROFIBUS functionality is only available in simplex, non-TMR Mark VI’s only.
At the physical layer, PROFIBUS supports three transmission mediums: RS-485 for universal applications; IEC 1158-2 for process automation; and optical fibers for special noise immunity and distance requirements. The Mark VI PROFIBUS controller provides opto-isolated RS-485 interfaces routed to 9-pin D-sub connectors. Termination resistors are not included in the interface and must therefore be provided by external connectors. Various bus speeds ranging from 9.6 kbit/s to 12 Mbit/s are supported, although maximum bus lengths decrease as bus speeds increase.
The Mark VI operates as a PROFIBUS-DP Class 1 Master exchanging information (generally I/O data) with slave devices each frame.
To meet an extensive range of industrial requirements, PROFIBUS consists of three variations: PROFIBUS-DP, PROFIBUS-FMS, and PROFIBUS-PA. Optimized for speed and efficiency, PROFIBUS-DP is utilized in approximately 90% of PROFIBUS slave applications. The Mark VI PROFIBUS implementation provides PROFIBUS-DP Master functionality. PROFIBUS-DP Masters are divided into Class 1 and Class 2 types. Class 1 Masters cyclically exchange information with slaves in defined message cycles, and Class 2 Masters provide configuration, monitoring, and maintenance functionality. Mark VI UCVE controller versions are available providing one to three PROFIBUSDP Masters. Each may operate as the single bus Master or may have several Masters on the same bus. Without repeaters, up to 32 stations (Masters and slaves) may be configured per bus segment. With repeaters, up to 126 stations may exist on a bus. Note More information on PROFIBUS can be obtained at www.profibus.com.
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Features Table 3-11. PROFIBUS Features PROFIBUS Feature
Description
Type of Communication
PROFIBUS-DP Class 1 Master/slave arrangement with slaves responding to Masters once per frame; a standardized application based on the ISO/OSI model layers 1 and 2
Network Topology
Linear bus, terminated at both ends with stubs possible
Speed
9.6 kbit/s, 19.2 kbit/s, 93.75 kbit/s, 187.5 kbit/s, 500 kbit/s, 1.5 Mbit/s, 12 Mbit/s
Media
Shielded twisted pair cable
Number of Stations
Up to 32 stations per line segment; extendable to 126 stations with up to 4 repeaters
Connector
9-pin D-sub connector
Number of Masters
From 1−3 Masters per UCVE
Table 3-12. PROFIBUS Bus Length kb/s
Maximum Bus Length in Meters
9.6
1200
19.2
1200
93.75
1200
187.5
1000
500
400
1500
200
12000
100
Configuration GSD files define the properties of all PROFIBUS devices.
The properties of all PROFIBUS Master and slave devices are defined in electronic device data sheets called GSD files (for example, SOFTB203.GSD). PROFIBUS can be configured with configuration tools such as Softing AG’s PROFI-KON-DP. These tools enable the configuration of PROFIBUS networks comprised of devices from different suppliers based on information imported from corresponding GSD files. The third party tool is used rather than the toolbox to identify the devices making up PROFIBUS networks as well as specifying bus parameters and device options (also called parameters). The toolbox downloads the PROFIBUS configurations to Mark VI permanent storage along with the normal application code files. Note Although the Softing AG’s PROFI-KON-DP tool is provided as the PROFIBUS configurator, any such tool will suffice as long as the binary configuration file produced is in the Softing format. For additional information on Mark VI PROFIBUS communications, refer to document, GEI-100536, PROFIBUS Communications.
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I/O and Diagnostics PROFIBUS I/O transfer is done by application blocks.
PROFIBUS I/O transfer with slave devices is driven at the Mark VI application level by a set of standard block library blocks. Pairs of blocks read and write analog, Boolean, and byte-oriented data types. The analog blocks read 2, 4, 8 bytes, depending on associated signal data types, and handle the proper byte swapping. The Boolean blocks automatically pack and unpack bit-packed I/O data. The byteoriented blocks access PROFIBUS I/O as single bytes without byte swapping or bit packing. To facilitate reading and writing unsigned short integer-oriented PROFIBUS I/O (needed since unsigned short signals are not available), a pair of analog-to-word/word-to-analog blocks work in tandem with the PROFIBUS analog I/O blocks as needed. Data transfers initiated by multiple blocks operating during a frame are fully coherent since data exchange with slave devices takes place at the end of each frame.
PROFIBUS diagnostics can be monitored by the toolbox and the Mark VI application.
PROFIBUS defines three types of diagnostic messages generated by slave devices: •
Station-related diagnostics provide general station status.
•
Module-related diagnostics indicate certain modules having diagnostics pending.
•
Channel-related diagnostics specify fault causes at the channel (point) level.
Presence of any of these diagnostics can be monitored by the toolbox as well as in Mark VI applications by a PROFIBUS diagnostic block included in the standard block library.
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Fiber-Optic Cables Fiber-optic cable is an effective substitute for copper coaxial cable, especially when longer distances are required, or electrical disturbances are a serious problem. The main advantages of fiber-optic transmission in the power plant environment are:
Fiber-optics is a good choice for high bandwidth transmission over longer distances.
•
Fiber-optic segments can be longer than copper because the signal attenuation per foot is less.
•
In high lightning areas, copper cable can pick up currents, which can damage the communications electronics. Since the glass fiber does not conduct electricity, the use of fiber-optic segments avoids pickup and reduces lightning caused outages.
•
Grounding problems are avoided with fiber-optic 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 fiber-optic 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 are: •
Fiber-optic links require powered hubs with a reliable source of ac power. Power failure to the hub on either end of the fiber-optic 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-optic segment is 1.25 times the electrical cable distance.
•
The extra equipment required for fiber-optic 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.
Cable Contruction Two connectors are required for duplex operation of each fiber-optic link.
Each fiber-optic link consists of two fibers, one outgoing and the other incoming, to form a duplex channel. A light emitting diode drives the outgoing fiber 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 fiber-optic 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.
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Connectors for a power plant need to be fastened to a reasonably robust cable with its own buffering. The SC type connector is recommended. This connector is widely used for local area networks, and is readily available.
Cable Ratings 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, and so on. This ray travels further but goes faster because it spends most of its 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. 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 fiber-optic cable failure. If this is a problem in the 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 (OTDR). 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. Cables with two fibers are available for indoor use.
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Fiber-optic Converter The Mark VI communication system may require an Ethernet Media Converter to convert selected UDH and PDH electrical signals to fiber-optic signals. The typical media converter makes a two-way conversion of one or more Ethernet 10BaseT signals to Ethernet 100BaseFX signals (10 or 100 Mb/s). The media converter mounts adjacent to the Ethernet switch. The fiber-optic cable plugs into two SC ports on the front as shown in Figure 3-14. The diagnostic display consists of four LEDs providing visual status monitoring of the fiber-optic link.
100BaseFX Port TX
RX
10/100BaseTX Port
Pwr
Fiber
UTP/STP
Dimensions:
Power:
Data:
Width: 3.0 (76 mm) Height: 1.0 (25 mm) Depth: 4.75 (119 mm)
120 V ac, 60 Hz
100 Mbps, fiber optic
Figure 3-14. Media Converter, Ethernet Electric to Ethernet Fiber-optic
Connectors The 100BaseFX fiber-optic cables for indoor use in Mark VI have SC type connectors. The connector, shown in Figure 3-15, is a keyed, snap-in connector that automatically aligns the center strand of the fiber with the transmission or reception points of the network device. An integral spring helps to keep the SC connectors from being crushed together, to avoid damaging the fiber. The two plugs can be held together as shown, or they can be separate.
.
Locating Key Fiber
. Solid Glass Center Snap-in connnectors Figure 3-15. SC Connector for Fiber-optic Cables
The process of attaching the fiber-optic 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.
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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 switches, and 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-optic 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 switches, 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.
•
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-optic LAN installation experience.
•
The fiber-optic switches and converters need reliable power, and should be placed in a location that minimizes the amount of movement they must endure, yet keep them accessible for maintenance.
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Chapter 3 Networks • 3-33
Component Sources The following are typical sources for fiber-optic cable, connectors, converters, and switches. Fiber-Optic Cable: Optical Cable Corporation 5290 Concourse Drive Roanoke, VA 24019 Phone: (540) 265-0690 Siecor Corporation PO Box 489 Hickory, NC 28603-0489 Phone: (800) 743-2673 Fiber-Optic Connectors: 3M - Connectors and Installation kit Thomas & Betts - Connectors and Assembly polishing kit Amphenol – Connectors and Terminal kit Ethernet Media Converters and Switches: Cisco Systems West Tasman Drive San Jose, CA www.cisco.com Transition Networks Minneapolis, MN 55344 3COM Corporation 5400 Bayfront Plaza Santa Clara, CA 95052 www.3com.com Lancast 12 Murphy Drive Nashua, NH 03062 www.lancast.com
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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. Sequence of Events data requires accurate time tags for event analysis.
A time/frequency processor board, either the BC620AT or BC627AT, 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 through 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 is 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 through unicast mode or broadcast mode. Local time is used for display of real-time data by adding a local time correction to UTC. A node’s internal time clock is normally 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 or BC627AT 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.
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Chapter 3 Networks • 3-35
Selection of Time Sources The BC620AT and BC627AT boards support 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:
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•
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 or BC627AT board - Flywheel mode as the sole time source for the plant
Mark VI System Guide GEH-6421D, Vol. I
Chapter 4
Codes and Standards
Introduction This chapter describes the codes, standards, and environmental guidelines used for the design of all printed circuits, modules, cores, panels, and cabinet line-ups in the Mark VI. Requirements for harsh environments, such as marine applications, are not covered here. Section
Page
Safety Standards .......................................................................................................4-1 Electrical...................................................................................................................4-2 Environmental ..........................................................................................................4-4 Packaging .................................................................................................................4-5 UL Class 1 Division 2 Listed Boards .......................................................................4-6
Safety Standards UL 508A CAN/CSA 22.2 No. 1010.1-92 ANSI/ISA S82.01 1999
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Safety Standard Industrial Control Equipment Industrial Control Equipment Industrial Control Equipment
Chapter 4 Codes and Standards • 4-1
Electrical Printed Circuit Board Assemblies UL 796 ANSI IPC guidelines ANSI IPC/EIA guidelines
Printed Circuit Boards
Electromagnetic Compatibility (EMC) EN 55081-2 EN 50082-2:1994 EN 55011 IEC 61000-4-2:1995 IEC 61000-4-3:1997 IEC 61000-4-4:1995 IEC 61000-4-5:1995 IEC 61000-4-6:1995 IEC 61000-4-11:1994 ANS/IEEE C37.90.1
General Emission Standard Generic Immunity Industrial Environment Radiated and Conducted Emissions Electrostatic Discharge Susceptibility Radiated RF Immunity Electrical Fast Transient Susceptibility Surge Immunity Conducted RF immunity Voltage variation, dips, and interruptions Surge
Low Voltage Directive EN 61010-1 IEC 529
Safety of Electrical Equipment, Industrial Machines Intrusion Protection Codes/NEMA 1/IP 20
Supply Voltage Line Variations Ac Supplies – Operating line variations of ±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.
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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 harmonic 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% when operating from ac supplies (20 Hz/sec slew rate) This exceeds IEC 204-1 1996.
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.
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Chapter 4 Codes and Standards • 4-3
Environmental Temperature Ranges Ambient temperature ranges for the Mark VI equipment are as follows: Operating I/O processor and terminal boards 0 to 50 °C Operating controller with forced air cooling 0 to 45 °C −40 to 80 °C
Shipping and storage
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) Note A guideline for system behavior as a function of altitude is that for altitudes above 3300 feet, the maximum ambient rating of the equipment decreases linearly to a derating of 5 °C at 10000 feet. The extended operation and shipping specifications exceed EN50178, 1994.
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 10 ppb Chlorine (Cl2) 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).
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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.
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Chapter 4 Codes and Standards • 4-5
UL Class 1 Division 2 Listed Boards Certain boards used in the Mark VI are UL listed (E207685) for Class 1 Division 2, Groups A, B, C, and D, Hazardous Locations, Temperature Class T4 using UL-1604. Division 2 is described by NFPA 70 NEC 1999 Article 500 (NFPA - National Fire Protection Assocation, NEC - National Electrical Code). The Mark VI boards/board combinations that are listed may be found under file number E207685 at the UL website and currently include: •
IS200VCMIH1B, H2B
•
IS200DTCCH1A, IS200VTCCH1C
•
IS200DRTDH1A, IS200VRTDH1C
•
IS200DTAIH1A, IS200VAICH1C
•
IS200DTAOH1A, IS200VAOCH1B
•
IS200DTCIH1A, IS200VCRCH1B
•
IS200DRLYH1B
•
IS200DTURH1A, IS200VTURH1B
•
IS200DTRTH1A
•
IS200DSVOH2B, IS200VSVOH1B
•
IS200DVIBH1B, IS200VVIBH1C
•
IS200DSCBH1A, IS200VSCAH2A
•
IS215UCVEH2A, M01A, M03A, M04A, M05A
•
IS215UCVDH2A
•
IS2020LVPSG1A
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Chapter 5
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. The chapter is organized as follows: Section
Page
Installation Support ..................................................................................................5-3 Early Planning ...................................................................................................5-3 GE Installation Documents................................................................................5-3 Technical Advisory Options..............................................................................5-3 Equipment Receiving, Handling, and Storage..........................................................5-5 Receiving and Handling ....................................................................................5-5 Storage...............................................................................................................5-5 Operating Environment .....................................................................................5-6 Weights and Dimensions ..........................................................................................5-8 Cabinets.............................................................................................................5-8 Control Console (Example).............................................................................5-12 Power Requirements...............................................................................................5-13 Installation Support Drawings ................................................................................5-14 Grounding...............................................................................................................5-19 Equipment Grounding .....................................................................................5-19 Building Grounding System ............................................................................5-20 Signal Reference Structure (SRS) ...................................................................5-20 Cable Separation and Routing ................................................................................5-26 Signal/Power Level Definitions ......................................................................5-26 Cableway Spacing Guidelines.........................................................................5-28 Cable Routing Guidelines ...............................................................................5-31 Cable Specifications ...............................................................................................5-32 Wire Sizes .......................................................................................................5-32 Low Voltage Shielded Cable...........................................................................5-33 Connecting the System ...........................................................................................5-36 I/O Wiring .......................................................................................................5-38 Terminal Block Features .................................................................................5-39 Power System..................................................................................................5-39 Installing Ethernet ...........................................................................................5-39
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Startup Checks........................................................................................................5-41 Board Inspections ............................................................................................5-41 Wiring and Circuit Checks ..............................................................................5-44 Startup.....................................................................................................................5-45 Topology and Application Code Download ....................................................5-46 I/O Wiring and Checkout ................................................................................5-46 Maintenance............................................................................................................5-47 Modules and Boards ........................................................................................5-47 Component Replacement........................................................................................5-48 Replacing a Controller.....................................................................................5-48 Replacing a VCMI...........................................................................................5-48 Replacing an I/O Board in an Interface Module..............................................5-49 Replacing a Terminal Board............................................................................5-49 Cable Replacement..........................................................................................5-50 Note Before installation, consult and study all furnished drawings. These should include panel and layout drawings, connection diagrams, and a summary of the equipment.
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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
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 Industrial Systems offers the optional technical advisory services of field engineers for: • Review of customer’s installation plan • Installation support
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These services are not normally included as installation support or in basic startup and commissioning services shown in Figure 5-1. GE presents installation support options to the customer during the contract negotiation phase.
Installation Support Startup
Begin Installation
Complete Installation
Commissioning
Product Support - On going
Begin Formal Testing
System Acceptance
Figure 5-1. Startup and Commissioning Services Cycle
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, 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 terminal practice for each shielded cable (refer to section, Connecting the System).
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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 Post Sales Service 1501 Roanoke Blvd. Salem, VA 24153-6492 Phone: +1 888 GE4 SERV (888 434 7378, United States) +1 540 378 3280 (International) Fax: +1 540 387 8606 (All)
"+" indicates the international access code required when calling from outside of the USA.
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.
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•
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 four hour period, and with smaller temperature variations at higher humidity. If the storage room temperature varies in such a way, install a reliable heating system that keeps the equipment temperature slightly above that of the ambient air. This can include space heaters or 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 cabinet 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): Relative humidity:
20 °C (68 °F) to 30 °C (87 °F) 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.
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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 cabinet should be mounted where the floor surface allows for attachment in one plane (a flat, level, and continuous surface). The customer provides the mounting hardware. Lifting lugs are provided and if used, the lifting cables must not exceed 45° from the vertical plane. Finally, the cabinet is equipped with a door handle, which can be locked for security. Interconnecting cables can be brought into the cabinet from the top or the bottom through removable access plates. Convection cooling of the cabinet requires that conduits be sealed to the access plates. Also, air passing through the conduit must be within the acceptable temperature range as listed previously. This applies to both top and bottom access plates.
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Chapter 5 Installation • 5-7
Weights and 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
Window
400
lbs
Cabinet Depth
610.0 mm (24 in)
Cable Entry Space for wire entry in base of cabinet 1842 mm (72.5)
A A
Total Weight
Air Intake
Equipment Access Front and rear access doors, no side access. Front door has clear plastic window. Service Conditions NEMA1 enclosure for standard indoor use.
610 mm (24)
610 (24.0)
Six 16 mm (0.635 inch) dia holes in base for customers mounting studs or bolts.
236.5 (9.31) 236.5 (9.31)
View of base looking down in direction "A" 475 (18.6875)
Figure 5-2. Controller Cabinet
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The one door cabinet shown in Figure 5-3 is for small gas turbine systems (Simplex only). It contains control, I/O, and power supplies, and weighs 1,367lbs complete.
One Panel Lineup (one door)
609.6 (24.0)
151.64 (5.97)
Notes: 1. All dimensions are in mm and (inches) unless noted. 2. Door swing clearance required at front as shown. Doors open 105 degrees max. and are removable by removing hinge pins. 3. All doors have provisions for pad locking. 4. Suggested mounting is 10 mm (0.375) expansion anchors. Length must allow for 71.1 (2.8) case sill. 5. Cross hatching indicates conduit entry with removable covers. 6. Lift angles should remain in place to meet seismic UBC zone 4 requirements. 7. No mechanical clearance required at back or ends. 8. Service conditions - indoor use at -5 C minimum to =40 C maximum ambient temperature. 9. Approx. weight is 1367 lbs.
View of top looking down in direction of arrow "A"
254.0 (10.0) 317.25 (12.49)
114.3 (4.5)
38.1 (1.5) 2400.3 (94.5) 57.9 (2.28)
A
865.63 (34.08)
906.53 (35.69)
184.15 (7.25)
348.49 (13.72)
925.58 (36.44)
Approx. Door Swing (See Note 2)
387.6 (15.26)
62.74 (2.47)
6 holes, 16 mm (0.635 inch) dia, in base for customers mounting studs or bolts.
387.6 (15.26)
69.09 (2.72)
775.97 (30.55)
61.47 (2.42)
View of base looking down in direction of arrow "A"
Figure 5-3. Controller Cabinet
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The two-door cabinet shown in Figure 5-4 is for small gas turbine systems. It contains control, I/O, and power supplies, and weighs 1,590 lbs complete. A 1600 mm wide version of this cabinet is available, and weighs 2,010 lbs complete. Lift Angles with two 30.2 (1.18) holes, should be left in place for Seismic Zone 4, if removed, fill bolt holes.
Two Panel Lineup (two doors) Total Weight
1,590 lbs
Cabinet Depth
903.9 mm (35.59 in)
Cable Entry Removable covers top and bottom. 2324.3 mm (91.5)
Front Equipment Access doors only, no rear or side access. Door swing clearance 977.9 mm (38.5). Mounting Holes in Base Six 16 mm (0.635 in) dia holes in base of the cabinet for customers mounting studs or bolts, for details see GE dwgs.
A
1350 mm (53.15)
Service Conditions Standard NEMA1 enclosure for indoor use.
387.5 (15.26) 387.5 15.26)
6 holes, 16 mm (0.635 inch) dia, in base for customers mounting studs or bolts. 1225.0 (48.23)
62.5 (2.46)
62.5 (2.46) View of base looking down in direction of arrow "A" Figure 5-4. Controller Cabinet
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A typical lineup for a complete Mark VI system is shown in Figure 5-5. These cabinets contain controllers, I/O, and terminal boards, or they can contain just the remote I/O and terminal boards. Lift Angles front and back, should be left in place for Seismic Zone 4, if removed, fill bolt holes.
I/O
Three Cabinet Lineup Li (five doors)
I/O
Control
I/O
1600 mm (62.99)
237.5 (9.35) 237.5 (9.35)
1475.0 (58.07) 62.5 (2.46)
875.0 (34.45)
125.0 (4.92)
Equipment Access Front doors only, no rear or side access. Door swing clearance 977.9 mm (38.5).
18 holes, 16 mm (0.635 inch) dia, in base for customers mounting studs or bolts.
1475.0 (58.07)
125.0 (4.92)
602 mm (23.7 in)
Service Conditions Standard NEMA1 enclosure for indoor use.
4200 mm (165.35)
62.5 (2.46)
Cabinet Depth
Mounting Holes in Base Six 16 mm (0.635 in) dia holes in base of each of the three cabinets for customers mounting studs or bolts, for details see GE dwgs.
A
1000mm (39.37)
3,900 lbs
Cable Entry Removable covers top and bottom.
Power 2324.3 mm (91.5)
1600 mm (62.99)
Total Weight
62.5 (2.46)
View of base looking down in direction of arrow "A"
Figure 5-5. Typical Mark VI Cabinet Lineup
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Chapter 5 Installation • 5-11
Control Console (Example) The turbine control HMI pcs can be tabletop mounted, or installed in the optional control console shown in Figure 5-6. 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 Monit e ul d o M
Main Module M M onit od or ule
Modular Desktop
Printer
Phone
Monitor
Phone
Monitor
Printer Pedestal
2233.61 mm (7 '- 3 15/16")
Monitor
Monitor 1181.1mm (46.5 ")
Undercounter Keyboards
Figure 5-6. Turbine Control Console with Dimensions
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Power Requirements The Mark VI control panel can accept power from multiple power sources. Each power input source (such as the dc and two ac sources) should feed through its own external 30 A two-pole thermal magnetic circuit breaker before entering the Mark VI enclosure. The breaker ratings are 250 V and 30 A with a minimum withstand of 10,000 A. 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 containing controllers, I/O, and terminal boards are shown in the table below. The power shown is the heat generated in the cabinet, which must be dissipated. For the total current draw, add the current supplied to external solenoids as shown in the notes below the table. These external solenoids do not generate heat inside the cabinet. Heat Loss in a typical 4200 mm TMR panel is 1500 W fully loaded. For a single control cabinet containing three controllers and VCMIs only (no I/O), Table 5-1 shows the nominal power requirements. This power generates heat inside the control cabinet. Heat Loss in a typical TMR controller cabinet is 300 W. The current draw number in Table 5-1 is assuming a single voltage source; if two or three sources are used, they share the load. The actual current draw from each source cannot be predicted because of differences in the ac/dc converters. For further details on the panel power distribution system, refer to Chapter 9, I/O Descriptions (GEH6421D, Vol. II Mark VI System Guide). Table 5-1. Power Requirements for Panels Panel Nominal 4200 mm Panel
Controller Cabinet
Voltage Tolerance
Frequency Nominal Tolerance
Current Draw (from one source at nom. 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 and 4)
240 V ac
200 to 264 V ac
50/60 Hz
± 3 Hz
8.8 Amps rms
(see Notes 3 and 4)
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 and 4)
240 V ac
200 to 264 V ac
50/60 Hz
± 3 Hz
1.9 Amps rms
(see Notes 3 and 4)
Notes on Table 5-1 (these are external and do not create cabinet heat load). 1. Add 0.5 A dc continuous for each 125 V dc external solenoid powered. 2. Add 6.0 A rms for a continuously powered ignition transformer (2 maximum). 3. Add 3.5 A rms for a continuously powered ignition transformer (2 maximum). 4. Add 2.0 A rms continuous for each 120 V ac external solenoid powered (inrush 10 A). 5. Supply voltage ripple is not to exceed 10 V peak-to-peak. 6. Supply voltage Total Harmonic Distortion is not to exceed 5.0%.
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Chapter 5 Installation • 5-13
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 include: •
System Topology
•
I/O Cabinets
•
Panel Layout Diagram
•
I/O Panel Layout Diagram
•
Circuit Diagram
In addition to the installation drawings, site personnel will need the following: •
Control Sequence Program with cross references (CSP with XREF)
•
Alarm Database (Alarm.dat)
•
I/O Assignments (IO Report)
Figure 5-7. Typical System Topology showing Interfaces to Heat Recovery Steam Generator and B.O.P.
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Figure 5-8. Typical I/O Cabinet Drawing showing Dimensions, Cable Access, Lifting Angles, and Mounting
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Figure 5-9. Panel Layout with Protection Module
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Figure 5-10. I/O Panel with Terminal Boards and Power Supplies
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Chapter 5 Installation • 5-17
Figure 5-11. Typical Circuit Diagram showing TRPG Terminal Board
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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 11001992 IEEE Recommended Practice for Powering and Grounding Sensitive Electronic Equipment provide guidance in the design and implementation of the system. Chapter 9 I/O Descriptions (GEH-6421D, Vol. II, Mark VI System Guide), 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.
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Chapter 5 Installation • 5-19
•
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.
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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.
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 5-12 call for the equipment grounding conductor to be 120 mm2 (AWG 4/0) gauge wire, connected to the building ground system. The Control Common (CCOM) is bonded at one point to the chassis safety ground using two 25 mm2 (4 AWG) green/yellow bonding jumpers.
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Chapter 5 Installation • 5-21
Control & I/O Electronics Panel Mark VI Cabinet
Control Common (CCOM) Equipment grounding conductor, Identified 120 mm sq. (4/0 AWG), Insulated Wire, short a distance as possible
Two 25 mm sq. (4 AWG) Green/Yellow insulated bonding jumpers
Protective Conductor Terminal (Chassis Safety Ground Plate) PE
Building Ground System
Figure 5-12. 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 5-13. 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. 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 through 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.
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I/O Panel
Control Electronics Panel
I/O Panel
Panel Grounding Connection Plates
Control Common (CCOM)
Equipment grounding conductor, Identified 120 mm sq. (4/0 AWG), insulated wire, short a distance as possible
Two 25 mm sq. 4AWG Green/Yellow Bonding Jumper wires
Protective Conductor Terminal (Chassis Safety Ground plate)
PE
Building Ground System Figure 5-13. Grounding Recommendations for Mark VI Cabinet Lineup
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.
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Chapter 5 Installation • 5-23
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 must be 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 trays provides a low impedance path at high frequencies. Metal framing channel - Metal framing channel cable support systems 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. Conduit terminal at cable trays - To provide the best shielding, conduits containing level L cables (see Leveling channels) should be terminated to the tray's side rails (steel solid bottom) with two locknuts and a bushing. Conduit should be terminated to ladder tray side rails with approved clamps. Where it is not possible to connect conduit directly to tray (such as with large conduit banks), conduit must be terminated with bonding bushings and bonded to tray with short bonding jumpers. Leveling channels - If the enclosure is mounted on leveling channels, bond the channels to the woven wire mesh with solid-steel wire jumpers of approximately the same gauge as the woven wire mesh. Bolt the enclosure to leveling steel, front and rear. Signal and power levels - See section, Cable Separation and Routing for guidelines. Solid-bottom tray - Use steel solid bottom cable trays with steel covers for lowlevel signals most susceptible to noise.
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Level P
Level L Solid Bottom Tray
Enclosure
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).
Bolt Leveling Channels Wire Mesh
Bolt the enclosure to the leveling steel, front and rear. See site specific GE Equipment Outline dwgs. Refer to Section 6 for examples.
Figure 5-14. Enclosure and Cable Tray Installation Guidelines
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Chapter 5 Installation • 5-25
Cable Separation and 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, B B
L3GenVolts
A L3BusVolts A>B AND B A A=B B
3
Trip_Mode1, CFG
Contact1, IO
ESTOP1 TRIP
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip1_En_Dir
Trip1_En_Cond
Trip1_En_Dir
Trip1_En_Cond
Trip1_Inhbt, SS L3SS_Comm
L5Cont1_Trip, (SS) CONTACT1 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact1) L5Cont1_Trip
L86MR, SS
Trip1_Inhbt, SS
Inhbt_T1_Fdbk, (SS)
Figure 7-12. VPRO Protection Logic - Contact Inputs
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CONTACT INPUT TRIPS (CONT.): Trip_Mode2, CFG
Contact2, IO
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip2_En_Dir
Trip2_En_Cond
Trip2_En_Dir
Trip2_En_Cond
Trip2_Inhbt, SS L3SS_Comm
L5Cont2_Trip, (SS) CONTACT2 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact2) L5Cont2_Trip
L86MR, SS
Trip2_Inhbt, SS
Inhbt_T2_Fdbk, (SS)
Trip_Mode3, CFG
Contact3, IO
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip3_En_Dir
Trip3_En_Cond
Trip3_En_Dir
Trip3_En_Cond
Trip3_Inhbt, SS L3SS_Comm
L5Cont3_Trip, (SS) CONTACT3 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact3) L5Cont3_Trip
L86MR, SS
Trip3_Inhbt, SS
Inhbt_T3_Fdbk, (SS)
Figure 7-13. VPRO Protection Logic - Contact Inputs (continued)
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Chapter 7 Applications • 7-23
CONTACT INPUT TRIPS (CONT.): Trip_Mode4, CFG
Contact4, IO
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip4_En_Dir
Trip4_En_Cond
Trip4_En_Dir
Trip4_En_Cond
Trip4_Inhibit, SS L3SS_Comm
L5Cont4_Trip, (SS) CONTACT4 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact4) L5Cont4_Trip
L86MR, SS
Trip4_Inhbt, SS
Inhbt_T4_Fdbk, (SS)
Trip_Mode5, CFG
Contact5, IO
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip5_En_Dir
Trip5_En_Cond
Trip5_En_Dir
Trip5_En_Cond
Trip5_Inhibit, SS L3SS_Comm
L5Cont5_Trip, (SS) CONTACT5 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact5) L5Cont5_Trip
L86MR, SS
Trip5_Inhbt, SS
Inhbt_T5_Fdbk, (SS)
Figure 7-14. VPRO Protection Logic - Contact Inputs (continued)
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CONTACT INPUT TRIPS (CONT.): Trip_Mode6, CFG
Contact6, IO
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip6_En_Dir
Trip6_En_Cond
Trip6_En_Dir
Trip6_En_Cond
Trip6_Inhibit, SS L3SS_Comm
L5Cont6_Trip, (SS) CONTACT6 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact4) L5Cont6_Trip
L86MR, SS
Trip6_Inhbt, SS
Inhbt_T6_Fdbk, (SS)
Trip_Mode7, CFG
Contact7, IO
Direct, CNST
A A=B B
Conditional, CNST
A A=B B
Trip7_En_Dir
Trip7_En_Cond
Trip7_En_Dir
Trip7_En_Cond
Trip7_Inhibit, SS L3SS_Comm
L5Cont7_Trip, (SS) CONTACT7 TRIP
TDPU
TrpTimeDelay (sec.), CFG (J3, Contact5) L5Cont7_Trip
L86MR, SS
Trip7_Inhbt, SS
Inhbt_T7_Fdbk, (SS)
Figure 7-15. VPRO Protection Logic - Contact Inputs (continued)
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Chapter 7 Applications • 7-25
OnLineOS1
OnlineOS1Tst, SS
Online OverSpeed Test
OnlineOS1X, SS
OnlineOS1X, SS A TDPU 1.5 sec B
OnlineOS1x, SS
L97EOST_ONLZ
L97EOST_ONLZ
L97EOST_RE Reset pulse
L86MRX
L86MR, SS
L97EOST_RE
OnLineOS1X, SS L97EOST_ONLZ
L97EOST_RE, Reset Pulse
1.5 sec
Figure 7-16. VPRO Protection Logic - Online Overspeed Test
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OS1_Setpoint , SS RPM OS_Setpoint, CFG (J5, PulseRate1)
RPM
A A-B
|A|
A
A
B
A>B 1 RPM
OS1_SP_CfgEr System Alarm, if the two setpoints don't agree
B
A Min B OS_Setpoint_PR1
OS_Stpt_PR1 A Mult
0.04
B OS_Tst_Delta CFG(J5, PulseRate1) RPM
A A
A+B
Min
B
zero
B
OfflineOS1test, SS OnlineOS1
PulseRate1, IO
A A>=B
OS_Setpoint_PR1
B
OS1_Trip
OS1
OS1_Trip
OS1
Overspeed Trip L86MRX
Figure 7-17. VPRO Protection Logic - Overspeed Trip, HP
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Chapter 7 Applications • 7-27
PR_Zero 1 0
PulseRate1, IO
CFG
A
RPM
PR1_Zero
AB B A
PR1_Dec
AB B
Dec1_Trip
PR1_DEC
Decel Trip Dec1_Trip
L86MR,SS
Acc_Trip, CFG (J5, PulseRate1) Enable
PR1_ACC
Acc1_TrEnab
Acc1_Trip Accel Trip
Acc1_Trip
L86MR,SS
*Note: where 100% is defined as the configured value of OS_Stpt_PR1
Figure 7-18. VPRO Protection Logic - Overspeed Trip, HP (continued)
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OS1_SP_CfgEr L5CFG1_Trip
L5CFG1_Trip
PR1_Zero
HP Config Trip
L86MR,SS PR1_Max_Rst
PR_Max_Rst PR1_Zero_Old
PR1_Zero
PR1_Zero
0.00 PR1_Max_Rst PulseRate1
PR1_Zero
Max
PR1_Max
PR1_Zero_Old
Figure 7-19. VPRO Protection Logic - Overspeed Trip, HP (continued)
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Chapter 7 Applications • 7-29
OS2_Setpoint , SS
A
RPM
A-B
OS_Setpoint, CFG
|A|
B
(J5, PulseRate2) RPM
A
A
OS2_SP_CfgEr
A>B 1 RPM
System Alarm, if the two setpoints don't agree
B
A Min B OS_Setpoint_PR2
OS_Stpt_PR2 A 0.04 OS_Tst_Delta CFG(J5, PulseRate2)
A
Mult
A
A+B
B
Min
B
RPM
zero
B
OfflineOS2test, SS OnlineOS2
PulseRate2, IO
A A>=B
OS_Setpoint_PR2
OS2
B
OS2_Trip
OS2
Overspeed Trip OS2_Trip
L86MR,SS
Figure 7-20. VPRO Protection Logic - Overspeed LP
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PulseRate2, IO
A
PR2_Zero
AB B A
PR2_Dec
AB B
Dec2_Trip
PR2_DEC
Decel Trip LP
Dec2_Trip
L86MR,SS
Acc_Trip, CFG (J5, PulseRate2) PR2_ACC
PR2_MIN
Acc2_Trip
Enable Acc2_TrEnab
Acc2_Trip Accel Trip LP
L86MR,SS
*Note: where 100% is defined as the configured value of OS_Stpt_PR2
Figure 7-21. VPRO Protection Logic - Overspeed LP (continued)
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Chapter 7 Applications • 7-31
OS2_SP_CfgEr
L5CFG2_Trip
PR2_Zero
LP Config Trip
L5CFG2_Trip L86MR,SS
PR2_Max_Rst
PR_Max_Rst PR2_Zero
PR2_Zero_Old
PR2_Zero
0.00 PR2_Max_Rst
Max
PR2_Max
PulseRate2 PR2_Zero_Old
PR2_Zero
PR1_MIN LPShaftLocked
PR2_Zero
LockRotorByp
LPShaftLocked
L86MR, SS
Figure 7-22. VPRO Protection Logic - Overspeed LP (continued)
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OS3_Setpoint , SS
A
RPM
A-B
OS_Setpoint, CFG (J5, PulseRate3)
|A|
B
RPM
A
A
OS3_SP_CfgEr
A>B 1 RPM
B
System Alarm, if the two setpoints don't agree
A Min B OS_Stpt_PR3 A
OS_Tst_Delta CFG(J5, PulseRate3)
A
Mult
A
B
Min
0.04
OS_Setpoint_PR3
zero
A+B B
B
RPM
OfflineOS3tst, SS OnlineOS3tst, SS
PulseRate3, IO
A A>=B
OS_Setpoint_PR3
OS3
B
OS3_Trip
OS3
Overspeed Trip
OS3_Trip
L86MRX
Figure 7-23. VPRO Protection Logic - Overspeed IP
GEH-6421D, Vol. I Mark VI System Guide
Chapter 7 Applications • 7-33
PulseRate3, IO
A
PR3_Zero
AB B
A
PR3_Dec
AB Acc_Setpoint, CFG (J5,PulseRate3)
B
Dec3_Trip
PR3_DEC
Decel Trip IP Dec3_Trip
L86MR,SS
Acc_Trip, CFG (J5, PulseRate3) PR3_ACC Acc3_Trip
PR3_MIN
Enable Acc3_TrEnab
Acc3_Trip Accel Trip IP
L86MR,SS
*Note: where 100% is defined as the configured value of OS_Stpt_PR2
Figure 7-24. VPRO Protection Logic - Overspeed IP (continued)
7-34 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
OS3_SP_CfgEr L5CFG3_Trip
L5CFG3_Trip
PR3_Zero L86MR,SS
PR3_Max_Rst
PR_Max_Rst PR3_Zero_Old
IP Config Trip
PR3_Zero
PR3_Zero
0.00 PR3_Max_Rst PulseRate3
PR3_Zero
Max
PR3_Max
PR3_Zero_Old
Figure 7-25. VPRO Protection Logic - Overspeed IP (continued)
GEH-6421D, Vol. I Mark VI System Guide
Chapter 7 Applications • 7-35
Notes: == VPRO config data == from signal space == to signal space
,CFG ,SS (SS)
TC1 (SS) TC2 (SS)
TC_MED(SS)
MED
TC3 (SS) Zero OTSPBias(SS)
MAX
OTBias,SS L3SS_Comm OTBias_RampP,CFG OTBias_RampN,CFG OTBias_Dflt,CFG
MED
A A+B
A
B
A-B B
-1
Z
TC_MED
A
Overtemp_Trip,CFG
OTSPBias
A
A>=B
A-B
B
B
L26T
OTSetpoint(SS)
OT_Trip_Enable,CFG OT_Trip (SS)
L26T
OT_Trip
L86MR,SS
Figure 7-26. VPRO Protection Logic - Over-temperature
7-36 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
RatedRPM_TA, CFG (VPRO, Config)
RPM_94% RPM_103.5% RPM_106% RPM_116% RPM_1%
Calc Trip Anticipate Speed references
RPM_116% OS1_TATrpSp,SS RPM
A AB B
S
PulseRate2 A A>B B
S
R
AccBSetpoint
FastOS2Trip
R
PulseRate3 A A>B B PulseRate4 A A>B B
S R
FastOS3Trip
S
FastOS4Trip
R
Accel1 Accel2 Input Accel3 cct. Accel4 select
AccelA
Accel1 Accel2 Input Accel3 cct. Accel4 select
AccelB
AccelAEnab AccelAPerm InForChanB
FastOS1Trip
A A>B B
R
A A>B B
R
S
AccATrip
S
AccBTrip
AccelBEnab AccelBPerm ResetSys, VCMI, Mstr
PTR1 PTR1_Output PTR2 PTR2_Output PTR3 PTR3_Output PTR4 PTR4_Output PTR5 PTR5_Output PTR6 PTR6_Output
OR Primary Trip Relay, normal Path, True= Run Primary Trip Relay, normal Path, True= Run
AND
Fast Trip Path False = Run
True = Run
Output, J4,PTR1
AND True = Run Output, J4,PTR2
-------------Total of six circuits -----
True = Run
Output, J4,PTR3
True = Run
Output, J4A,PTR4
True = Run
Output, J4A,PTR5
True = Run
Output, J4A,PTR6
Figure 7-39. Fast Overspeed Algorithm, PR-Single
7-52 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
Input Config. Input, PR1 param. PR1Type, 2 PR1Scale
Scaling
VTUR, Firmware PulseRate1
PulseRate2
RPM
Accel1 Accel2 Accel3 Accel4
PulseRate3 PulseRate4 FastTripType PR_Max
RPM/sec RPM RPM/sec RPM RPM/sec RPM RPM/sec
d dt ------ Four Pulse Rate Circuits -------
Signal Space inputs PulseRate1 Accel1 PulseRate2 Accel2 PulseRate3 Accel3 PulseRate4 Accel4
Fast Overspeed Protection
DecelPerm DecelEnab DecelStpt InForChanA InForChanB Accel1 Accel2 Accel3 Accel4
PulseRate1 PulseRate2 PulseRate3 PulseRate4
Input cct. Select for AccelA and AccelB
AccelA AccelB
Neg
PulseRateA A PulseRateB A>B B
PulseRate1 FastOS1Stpt FastOS1Enab FastOS1Perm
A AB B
S
FastOS1Trip
R PR3/4Max PulseRate3
FastOS2Stpt FastOS2Enab FastOS2Perm
PR1/2Max DiffSetpoint
MAX
PulseRate4
PR3/4Max
A |A-B| B
A A>B B
S
FastOS2Trip
R
N/C N/C A A>B B
DiffEnab DiffPerm
S
FastDiffTrip
R
ResetSys, VCMI, Mstr
PTR1
OR
Primary Trip Relay, normal Path, True= Run
AND
Primary Trip Relay, normal Path, True= Run
AND
PTR1_Output PTR2 PTR2_Output PTR3 PTR3_Output PTR4 PTR5 PTR5_Output PTR6 PTR6_Output
FastOS3Trip FastOS4Trip
-------------Total of six circuits ---------
Fast Trip Path False = Run True = Run Output, J4,PTR1
True = Run
Output, J4,PTR2
True = Run
Output, J4,PTR3
True = Run
Output, J4A,PTR4
True = Run
Output, J4A,PTR5
True = Run
Output, J4A,PTR6
Figure 7-40. Fast Overspeed Algorithm, PR-Max
GEH-6421D, Vol. I Mark VI System Guide
Chapter 7 Applications • 7-53
Compressor Stall Detection Gas turbine compressor stall detection is included with the VAIC firmware and is executed at a rate of 200 Hz. There is a choice of two stall algorithms and both use the first four analog inputs, scanned at 200 Hz. One algorithm is for small LM gas turbines and uses two pressure transducers, refer to Figure 7-41. The other algorithm is for heavy-duty gas turbines and uses three pressure transducers, refer to Figure 7-42. Real-time inputs are separated from the configured parameters for clarity. The parameter CompStalType selects the type of algorithm required, either two transducers or three. PS3 is the compressor discharge pressure, and a drop in this pressure (PS3 drop) is an indication of a possible compressor stall. In addition to the drop in pressure, the algorithm calculates the rate of change of discharge pressure, dPS3dt, and compares these values with configured stall parameters (KPS3 constants). Refer to Figure 7-43. The compressor stall trip is initiated by VAIC, and the signal is sent to the controller where it is used to initiate a shutdown. The shutdown signal can be used to set all the fuel shut-off valves (FSOV) through the VCRC and TRLY or DRLY board.
7-54 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
Input Config param.
Input, cctx* Low_Input, Low_Value, High_Input, High Value SysLim1Enabl, Enabl SysLim1Latch, Latch SysLim1Type, >= SysLimit1, xxxx ResetSys, VCMI, Mstr
VAIC, 200 Hz scan rate
*Note: where x, y, represent any two of the input circuits 1 thru 4.
AnalogInx*
Scaling 4
Sys Lim Chk #1
SysLimit1_x*
4
Sys Lim Chk #2 4
SysLimit2_x*
SysLim2Enabl, Enabl SysLim2Latch, Latch SysLim2Type, B
stall_timeout X A
MIN
B
-DPS3DTSel A A>B AND PS3i_Hold B
-DPS3DTSel
-1 PS3_Fail
A+B
KPS3_Delta_I KPS3_Delta_Mx
d DPS3DTSel __ dt PressRateSel
B
B
PS3i
PressSel
PS3Sel
TD
-DPS3DTSel
z-1
CompStalPerm
PS3_Fail
DeltaFault
Max
KPS3_Drop_Mx KPS3_Drop_Mn KPS3_Drop_I KPS3_Drop_S
PS3B_Fail PS3B
PS3A_Fail
A A>B B
PS3Sel
OR
PS3A
PS3A
KPS3_Drop_L
Signal Space Inputs
delta_ref A
delta A= SysLimit1, xxxx ResetSys, VCMI, Mstr
*Note: where x, y, z, represent any three of the input circuits 1 thru 4.
Signal Space inputs AnalogInx*
Sys Lim Chk #1
SysLimit1_x*
Sys Lim Chk #2
SysLimit2_x*
4 SysLim2Enabl, Enabl SysLim2Latch, Latch SysLim2Type, B
A+B
X
-DPS3DTSel
X
B
B
z-1
PS3Sel
PS3i
KPS3_Delta_S
stall_timeout X
stall_set A
A+B
KPS3_Delta_I
B
KPS3_Delta_Mx
MIN
delta_ref A
delta AB B
AND
A
PS3i_Hold PS3Sel
A-B B
stall_permissive
MasterReset, VCMI, Mstr
Figure 7-42. Heavy Duty Gas Turbine Compressor Stall Detection Algorithm
7-56 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
Rate of Change of Pressure- dPS3dt, psia/sec
180 0 A. B. C. D.
140 0
B. Delta PS3 drop (PS3 initial - PS3 actual) , DPS3, psid
200 0 25 0
D
KPS3_Drop_S KPS3_Drop_I KPS3_Drop_Mn KPS3_Drop_Mx
20 0 A
120 0 100 0
15 0
80 0 60 0
10 0
G
40 0
E
20 C 0
5 0 E. KPS3_Delta_S F. KPS3_Delta_I G. KPS3_Delta_Mx
B 0 F -200 0
100
200
300
400
500
0 700
600
Initial Compressor Discharge Pressure PS3 Figure 7-43. Configurable Compressor Stall Detection Parameters
The variables used by the stall detection algorithm are defined as follows: PS3 Compressor discharge pressure PS3I Initial PS3 KPS3_Drop_S Slope of line for PS3I versus dPS3dt KPS3_Drop_I Intercept of line for PS3I versus dPS3dt KPS3_Drop_Mn Minimum value for PS3I versus dPS3dt KPS3_Drop_Mx Maximum value for PS3I versus dPS3dt KPS3_Delta_S Slope of line for PS3I versus Delta PS3 drop KPS3_Delta_I Intercept of line for PS3I versus Delta PS3 drop KPS3_Delta_Mx Maximum value for PS3I versus Delta PS3 drop
GEH-6421D, Vol. I Mark VI System Guide
Chapter 7 Applications • 7-57
Vibration Sampling Speed and Accuracy Vibration inputs on Mark VI may be driven from Proximitor®, Velomiter, or Seismic transducers. The first three vibration channels may also be configured for Accelerometers, where speed-tracking filters are used, but this is not included in this discussion. Inputs are fast sampled at 2586 or 4600 Hz, depending on the number of inputs configured as vibration type inputs. For eight or less vibration inputs (that is vibration inputs on TB1, J3), the sample rate is 4600 Hz; otherwise (any input on J4 configure for vibration), the sample rate is 2586 Hz. All inputs are simultaneously sampled for discrete 160 ms periods (time windows). The software accumulates the maximum and minimum values (a new set of values for each window), takes the difference for vibration (maximum − minimum), and filters the results with a low-pass one-pole filter with a configurable time constant. The resulting peak-to-peak voltage is then scaled with the configurable sensitivity (typically 0.2 volts/mil for Proximitors, 0.150 volts/ips for Seismic transducers), yielding mils (pk-pk) displacement, or ips (pk) velocity. The basic accuracy is ±1% of signal, or 0.016 Vpp whichever is larger. In addition, it is theoretically possible to search out a number of subharmonic frequencies where the vibration signal is exactly synchronized with the sample rate, and attenuated an additional amount per Figure 7-44.
1.1000
Attenuation
1.0000 8 or less vibration channels enabled
0.9000
0.8000
9 or more vibration channels enabled
0.7000
0.6000
0.5000 0.0
100.0
200.0
300.0 Frequency, Hz
400.0
500.0
600.0
Figure 7-44. Vibration Signal Attenuation versus Frequency
7-58 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
The significance of the frequency response with respect to the machine speed (RPM) is shown in Figure 7-45 in terms of 0.5X, 1X, 2X and 3X, where X represents the fundamental machine speed frequency. 700
Vibration Frequency
600
500
0.5X hz 1X hz 2X hz 3X hz
400
300
200
100
0 0
2000
4000
6000
8000 10000 Machine RPM
12000
14000
Figure 7-45. Vibration Frequency versus RPM
GEH-6421D, Vol. I Mark VI System Guide
Chapter 7 Applications • 7-59
Ground Fault Detection Sensitivity Ground fault detection on the floating 125 V dc power bus is based upon monitoring the voltage between the bus and the ground. The bus voltages with respect to ground are normally balanced (in magnitude), that is the positive bus to ground is equal to the negative bus to ground. The bus is forced to the balanced condition by the bridging resistors, Rb, refer to Figure 7-46. Bus leakage (or ground fault) from one side will cause the bus voltages with respect to ground to be unbalanced.
Ground fault detection is performed by the VCMI using signals from the PDM. Refer to Chapter 9 I/O Descriptions (GEH-6421D, Vol. II Mark VI System Guide).
Power Distribution Module P125 Vdc Vout,Pos Monitor1
Rf
Rb
Grd Fault
Jumper Grd
Vout,Neg Monitor2
Rb N125 Vdc
Electrical Circuit Model Rb/2 Vbus/2
Rf
Vout, Bus Volts wrt Ground
Figure 7-46. Ground Fault on Floating 125 Vdc power Bus
There is a relationship between the bridge resistors, the fault resistance, the bus voltage, and the bus to ground voltage (Vout) as follows: (see Figure 7-47) Vout = Vbus*Rf / [2*(Rf + Rb/2)] Therefore the threshold sensitivity to ground fault resistance is as follows: Rf = Vout*Rb / (Vbus – 2*Vout). The ground fault threshold voltage is typically set at 30 V, that is Vout = 30 V. The bridging resistors are 82 K each. Therefore, from the formula above, the sensitivity of the control panel to ground faults, assuming it is on one side only, is as shown in Table 7-6. Note On Mark V, the bridging resistors are 33 K each so different Vout values
result.
7-60 • Chapter 7 Applications
Mark VI System Guide GEH-6421D, Vol. I
Table 7-6. Sensitivity to Ground Faults Vbus Bus voltage
Vout - Measured Bus to ground voltage (threshold)
Rb (Kohms) bridge resistors (balancing)
Rf (Kohms) fault resistor
Control System
105
30
82
55
Mark VI
125
30
82
38
Mark VI
140
30
82
31
Mark VI
105
19
82
23
Mark VI
125
19
82
18
Mark VI
140
19
82
15
Mark VI
105
10
82
10
Mark VI
125
10
82
8
Mark VI
140
10
82
7
Mark VI
105
30
33
22
Mark V
125
30
33
15
Mark V
140
30
33
12
Mark V
The results for the case of 125 V dc bus voltage with various fault resistor values is shown in Figure 7-47.
Fault, Rf
40.0 Fault Resistance (Rf) Vs Threshold Voltage (Vout) at 125 V dc on Mark VI
30.0 20.0 10.0 0.0 0
10
20
30
Voltage, Vout Figure 7-47. Threshold Voltage as Function of Fault Resistance
Analysis of Results On Mark VI, when the voltage threshold is configured to 30 V and the voltage bus is 125 V dc, the fault threshold is 38 Kohms. When the voltage threshold is configured to 17 V and the voltage bus is 125 V dc, the fault threshold is 15 Kohms. The sensitivity of the ground fault detection is configurable. Balanced bus leakage decreases the sensitivity of the detector.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 7 Applications • 7-61
Chapter 8
Troubleshooting and Diagnostics
Introduction This chapter discusses troubleshooting and alarm handling in the Mark VI system. The configuration of process alarms and events is described, and also the creation and handling of diagnostic alarms caused by control system equipment failures. This chapter is organized as follows: Section
Page
Overview ..................................................................................................................8-2 Process Alarms .........................................................................................................8-3 Process (and Hold) Alarm Data Flow................................................................8-3 Diagnostic Alarms ....................................................................................................8-5 Voter Disagreement Diagnostics.......................................................................8-6 I/O Board Alarms ..............................................................................................8-7 Controller Runtime Errors...............................................................................8-33 Totalizers................................................................................................................8-35 Troubleshooting......................................................................................................8-36 I/O Board LEDs ..............................................................................................8-36 Controller Failures...........................................................................................8-38 Power Distribution Module Failure.................................................................8-38
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-1
Overview Three types of alarms are generated by the Mark VI system, as follows:
Figure 8-1 shows the routings.
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 interlocks in the application program. Hold list alarms are similar to process alarms with the additional feature that the scanner drives a specified signal True whenever any hold list signal is in the alarm state (hold present). This signal is used to disable automatic turbine startup logic at various stages in the sequencing. Operators may override a hold list signal so that the sequencing can proceed even if the hold condition has not cleared. Diagnostic alarms are caused by 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.
HMI
Alarm Display
HMI
Toolbox
Diagnostic Display
UDH
Process and Hold List Controller Alarms
I/O
Controller
Controller
Diagnostic Alarms
I/O
I/O
Diagnostic Alarm Bits
Figure 8-1. Three Types of Alarms generated by Mark VI
8-2 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
Process Alarms Process Alarms are generated by the transition of Boolean signals configured by the toolbox with the alarm attribute. The signals may be driven by sequencing or they may be tied to input points to map values directly from I/O boards. Process alarm signals are scanned each frame after the sequencing is run. In TMR systems process signals are voted and the resulting composite diagnostic is present in each controller. A useful application for process alarms is the annunciation of system limit checking. Limit checking takes place in the I/O boards at the frame rate, and the resulting Boolean status information is transferred to the controller and mapped to process alarm signals. Two system limits are available for each process input, including thermocouple, RTD, current, voltage, and pulse rate inputs. System limit 1 can be the high or low alarm setting, and system limit 2 can be a second high or low alarm setting. These limits are configured from the toolbox in engineering units. There are several choices when configuring system limits. Limits can be configured as enabled or disabled, latched or unlatched, and greater than or less than the preset value. System out of limits can be reset with the RESET_SYS signal.
Process (and Hold) Alarm Data Flow The operator or the controller can take action based on process alarms.
Process and Hold alarms are time stamped and stored in a local queue in the controller. 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 HMIs. Here the alarms are again queued and prepared for operator display by the alarm viewer. Operator commands from the HMI, such as alarm Acknowledge, Reset, Lock, and Unlock, are sent back over the UDH to the alarm queue where they change the status of the appropriate alarms. An alarm entry is removed from the controller queue when its state has returned to normal and it has been acknowledged and reset by an operator. Refer to Figure 8-2. Hold alarms are managed in the same fashion but are stored on a separate queue. Additionally, hold alarms cannot be locked but may be overridden.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-3
Mark VI Controller
Input
Signal 1
. . .
. . .
Input
Signal n
UDH
Alarm Receiver
Alarm Report
Alarm Scanner
Alarm Comm -and
Alarm Viewer
Alarm Queue Operator Commands - Ack - Reset - Lock - Unlock - Override for hold lists
Alarm Queue including Time
Alarm Logic variable
Mark VI HMI
Alarm ID Figure 8-2. Generating Process Alarms
To configure the alarm scanner on the controller, refer to GEH-6403 Control System Toolbox for Mark VI Controller. To configure the controller to send alarms to all HMIs, use the UDH broadcast address in the alarm IP address area.
8-4 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
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 (nonconfigurable) 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_xxxx, where xxxx is the board name. This signal can be used to trigger a process alarm. Each board has three L3DIAG_ signals, L3DIAG_xxxx1, 2, and 3. Simplex boards only use L3DIAG_xxxx1. TMR boards use all three with the first assigned to the board in , the second assigned to the same board in , and the third assigned to the same board in .
•
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 its own diagnostics. The VCMI and 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 are set as follows: •
VCMI communication board
150 ms
•
I/O boards
150 ms
If an I/O board times out, the outputs go to a fail-safe condition which is zero (or open contacts) and the input data is put in the default condition, which is zero. The 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 and FAIL is a solid red. The third LED is normally off but shows a steady orange if a diagnostic alarm condition exists in the board. The controller has extensive self-diagnostics, most of which are available directly at the toolbox. In addition, UCVB and UCVD runtime diagnostics, which may occur during a program download, are displayed on LEDs on the controller front panel. Each terminal board has its own ID device, which is interrogated by the I/O board. The board ID is coded into a read-only chip containing the terminal board serial number, board type, revision number, and the J type connector location.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-5
Voter Disagreement Diagnostics Each I/O board produces diagnostic alarms when it is configured as TMR and any of its inputs disagree with the voted value of that input by more than a configured amount. This feature allows the user to find and fix potential problems that would otherwise be masked by the redundancy of the control system. The user can view these diagnostics the same way one views any other diagnostic alarms. The VCMI triggers these diagnostic alarms when an individual input disagrees with the voted value for a number of consecutive frames. The diagnostic clears when the disagreement clears for a number of frames. The user configures voter disagreement diagnostics for each signal. Boolean signals are all enabled or disabled by setting the DiagVoteEnab signal to enable under the configuration section for each input. Analog signals are configured using the TMR_DiffLimit signal under configuration for each point. This difference limit is defined in one of two ways. It is implemented as a fixed engineering units value for certain inputs and as a percent of configured span for other signals. For example, if a point is configured as a 4−20 ma input scaled as 0−40 Engineering units, its TMR_DiffLimit is defined as a percent of (40−0). The type of limit checking used is spelled out in the dialog box for the TMR_DiffLimit signal for each card type and is summarized in Table 8-1. Table 8-1. Type of TMR Limit Checking I/O Processor Board
Type of I/O
VAIC
Delta Method % of Configured Span
VGEN
Analogs PT, CT
% of Configured Span Engineering Units
VPRO
Pulse rates Thermocouples Analogs PT, CT
Engineering Units Engineering Units % of Configured Span Engineering Units
VPYR
mA Gap
% of Configured Span Engineering Units
VRTD
--------
Engineering Units
VSVO
Pulse rates POS mA
Engineering Units Engineering Units % of Configured Span
VTCC
--------
Engineering Units
VTURH1/H2
Pulse rates PT Flame Shaft monitor
Engineering Units Engineering Units Engineering Units Engineering Units
VVIB
Vibration signals
Engineering Units
For TMR input configuration, refer to GEH-6403 Control System Toolbox for a Mark VI Controller. All unused signals will have the voter disagreement checking disabled to prevent nuisance diagnostics.
Viewing Diagnostic Alarms Mark VI troubleshooting is simplified using the extensive system diagnostics.
Diagnostic alarms can be viewed from the toolbox by selecting the desired board, clicking the right mouse button to display the drop down menu, and selecting display diagnostics. A list of the diagnostic alarms for any I/O board can be displayed and may be reset from the toolbox.
8-6 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
I/O Board Alarms The I/O boards, VCMI, VPRO, and the (UCVx) controllers generate the following diagnostic alarms. They are viewed in the toolbox. Table 8-2. I/O Board Diagnostic Alarms Board
Fault
Fault Description
Possible Cause
UCVx
31
I/O Compatibility Code Mismatch
Outdated configuration in the VCMI
32
Diagnostic Queue Overflow
Too many diagnostics are occurring simultaneously
33
Foreground Process
Outdated runtime version
34
Background Process
Outdated runtime version
37
Idle Process
Outdated runtime version
38
Ambient Air Overtemperature Warning. The rack is beginning to overheat.
The rack fan has failed or the filters are clogged.
39
CPU Overtemperature Fault. The controller CPU has overheated and may fail at any time.
The rack fan has failed or the filters are clogged.
40
Genius I/O Driver Process
Outdated runtime version
41
Register I/O Process
Outdated runtime version
42
Modbus Driver Process
Outdated runtime version
43
Ser Process
Outdated runtime version
44
Rcvr Process
Outdated runtime version
45
Trans Process
Outdated runtime version
46
Mapper Process
Outdated runtime version
47
SRTP Process
Outdated runtime version
48
Heartbeat Process
Outdated runtime version
49
Alarm Process
Outdated runtime version
50
Queue Manager Process
Outdated runtime version
51
EGD Driver Process
Outdated runtime version
52
ADL Dispatcher Process
Outdated runtime version
53
ADL Queue Process
Outdated runtime version
54
DPM Manager Process
Outdated runtime version
68
Genius IOCHRDY Hangup
Outdated runtime version
70
Genius Lock Retry
Outdated runtime version
71
Genius
Outdated runtime version
72
Application Code Online Load Failure
Application code error
74
Application Code Startup Load Failure
Application code error
75
Application Code Expansion Failure
Application code error
76
ADL/BMS Communication Failure with the VCMI
The VCMI firmware version is too old to work with this controller runtime version.
77
NTP Process
Outdated runtime version
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-7
78
Outdated Controller Topology
Download application code and reboot
79
Outdated VCMI Topology
Download configuration to VCMI and reboot
80
No VCMI Topology
Old VCMI firmware doesn’t support controller/VCMI topology checking. Upgrade VCMI firmware.
81
Platform Process
Outdated runtime version
82
Hardware Configuration Error
The controller hardware doesn’t match the configuration specified by the toolbox. Use the toolbox to view the errors in the controller trace buffer (for example: View → General → Dump the trace buffer).
83
Register I/O Write/Command Limit Exceeded
Verify that the total command rate of all Modbus interfaces does not exceed the maximum.
84
State Exchange Voter Packet Mismatch
Verify that all three controllers are executing the same application code.
85
Maximum Number of Boolean State Variables Exceeded
The application code is using too many Boolean variables. Move some functions to other controllers.
86
Too Many EGD Producers Configured for Fault Tolerant Support
The controller can redirect data over the IONET from a maximum of 16 EGD producers. Data from subsequent producers will be lost in the event of an Ethernet failure.
87
Too Many EGD Points Configured for Fault Tolerant Support
The controller can redirect a maximum of 1400 bytes of data over the IONET. Subsequent EGD points will be lost in the event of an Ethernet failure.
88
Producing Fault Tolerant EGD Data
The controller is redirecting data from the Ethernet to another controller over the IONET.
89
Requesting Fault Tolerant EGD Data
The controller is requesting that Ethernet data be redirected to it over the IONET from another controller.
90
Process Alarm Queue Is Full
Subsequent process alarms will be lost unless the current alarms are acknowledged and cleared by the operator.
91
Hold List Queue Is Full
Subsequent hold alarms will be lost unless the current alarms are acknowledged and cleared by the operator.
92
Data Initialization Failure
Verify that all controllers are executing the same application code. If no VCMI is used (simulation mode), verify that the clock source is set to internal. If a VCMI is used, verify that the clock source is set to external.
93
Pcode mismatech between TMR controllers
Download the same application code to all three controllers
8-8 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
VAIC
94
Unable to start up Dynamic Data Recorder
Outdated runtime version - download runtime and restart.
95
Dynamic Data Recorder Configuration Fault
Revalidate the application code and then select the Update Dynamic Data Recorder button from the toolbox toolbar
96
Dynamic Data Recorder Process
Outdated runtime version - download runtime and restart
2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC failure override is Active
Board firmware programming error (board is allowed to go online)
16
System Limit Checking is Disabled
System checking was disabled by configuration
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J3A ID Failure
Failed ID chip on connector J3A, or cable problem
23
J4A ID Failure
Failed ID chip on connector J4A, or cable problem
24
Firmware/Hardware Incompatibility. The firmware on this board cannot handle the terminal board it is connected to
Invalid terminal board connected to VME I/O board- check the connectors and call the factory
30
ConfigCompatCode mismatch. Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
31
IOCompatCode mismatch. Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
32-65
Analog Input # Unhealthy
Excitation to transducer, bad transducer, open or short-circuit
66-69
Output # Individual Current Too High Relative to Total Current. An individual current is N mA more than half the total current, where N is the configurable TMR_Diff Limit
Board failure
70-73
Output # total Current Varies from Reference Current. Total current is N mA different than the reference current, where N is the configurable TMR_Diff Limit
Board failure or open circuit
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-9
VOAC
74-77
Output # Reference Current Error. The difference between the output reference and the input feedback of the output reference is greater than the configured DA_Err Limit measured in percent
Board failure (D/A converter)
78-81
Output # Individual Current Unhealthy. Simplex mode only alarm if current out of bounds
Board failure
82-85
Output # Suicide Relay Non-Functional. The shutdown relay is not responding to commands
Board failure (relay or driver)
86-89
Output # 20/200 mA Selection Non-Functional. Feedback from the relay indicates incorrect 20/200 mA relay selection (not berg jumper selection)
Configured output type does not match the jumper selection, or VAIC board failure (relay).
90-93
Output # 20/20 mA Suicide Active. One output of the three has suicided, the other two boards have picked up current
Board failure
128-223
Logic Signal # Voting mismatch. The identified signal from A problem with the input. This could this board disagrees with the voted value be the device, the wire to the terminal board, the terminal board, or the cable.
224-249
Input Signal # Voting mismatch, Local #, Voted #. The specified input signal varies from the voted value of the signal by more than the TMR Diff Limit
A problem with the input. This could be the device, the wire to the terminal board, the terminal board, or the cable.
2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC failure override is Active
Board firmware programming error (board is allowed to go online)
16
System Limit Checking is Disabled
System checking was disabled by configuration
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J3A ID Failure
Failed ID chip on connector J3A, or cable problem
23
J4A ID Failure
Failed ID chip on connector J4A, or cable problem
24
Firmware/Hardware Incompatibility
Invalid terminal board connected to VME I/O board
30
ConfigCompatCode mismatch; Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
8-10 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
31
IOCompatCode mismatch; Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
82-97
Output # Total Current Too High Relative to Total Current. Board failure An individual current is N mA more than half the total current, where N is the configurable TMR_Diff Limit
98-113
Output # Total Current Varies from Reference Current. Total current is N mA different than the reference current, where N is the configurable TMR_Diff Limit
Board failure or open circuit
114-129
Output # Reference Current Error. The difference between the output reference and the input feedback of the output reference is greater than the configured DA_Err Limit measured in percent
Board failure (D/A converter)
130-145
Output # Individual Current Unhealthy. Simplex mode alarm indicating current is too high or too low
Board failure
146-161
Output # Suicide Relay Non-Functional. The suicide relay is not responding to commands
Board failure (relay or driver)
162-177
Output # Suicide Active. One output of three has suicided, Board failure the other two boards have picked up the current
VCCC/ 1 VCRC
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
SOE Overrun. Sequence of Events data overrun
Communication problem on IONet
2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC failure override is Active
Board firmware programming error (board is allowed to go online)
16
System Limit Checking is Disabled. System limit checking System checking was disabled by has been disabled configuration
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J33/J3A ID Failure
Failed ID chip on connector J33 or J3A, or cable problem
23
J44/J4A ID Failure
Failed ID chip on connector J44 or J4A, or cable problem
24
Firmware/Hardware Incompatibility. The firmware on this board cannot handle the terminal board it is connected to
Invalid terminal board connected to VME I/O board. Check the connections and call the factory.
30
ConfigCompatCode mismatch; Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-11
VCMI
31
IOCompatCode mismatch; Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
33-56/ 65-88
TBCI J33/J3A/J44/J4A Contact Input # Not Responding to Normally a VCCC problem, or the Test 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 terminal board, or a bad cable.
129-140/ 145-156
TRLY J3/J4 Relay Output Coil # Does Not Match Requested State. A relay coil monitor shows that current is flowing or not flowing in the relay coil, so the relay is not responding to VCCC commands
The relay terminal board may not exist, or there may be a problem with this relay, or, if TMR, one VCCC may have been out-voted by the other two VCCC boards.
161-172/ 177-188
TRLY J3/J4 Relay Driver # Does Not Match Requested State. The relay is not responding to VCCC commands
The relay terminal board may not exist and the relay is still configured as used, or there may be a problem with this relay driver.
97-102/ 113-118
TRLY J3/J4 Fuse # Blown. The fuse monitor requires the The relay terminal board may not jumpers to be set and to drive a load, or it will not respond exist, or the jumpers are not set and correctly there is no load, or the fuse is blown.
240/241
TBCI J3/J4 Excitation Voltage Not Valid, TBCI J33/J3A/J44/J4A Contact Inputs Not Valid. The VCCC monitors the excitation on all TBCI and DTCI boards, and the contact input requires this voltage to operate properly
The contact input terminal board may not exist, or the contact excitation may not be on, or be unplugged, or the excitation may be below the 125 V level.
256-415
Logic Signal Voting Mismatch. The identified signal from this board disagrees with the voted value
A problem with the input. This could be the device, the wire to the terminal board, the terminal board, or the cable.
1
SOE Overrun. Sequence of Events data overrun
Communication problem on IONet
2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC Failure Override is Active
Board firmware programming error (board is allowed to go online)
16
System Limit Checking is Disabled
System checking was disabled by configuration
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J3A ID Failure
Failed ID chip on connector J3A, or cable problem
23
J4A ID Failure
Failed ID chip on connector J4A, or cable problem
8-12 • Chapter 8 Troubleshooting and Diagnostics
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
Mark VI System Guide GEH-6421D, Vol. I
24
Firmware/Hardware Incompatibility
Invalid terminal board connected to VME I/O board
25
Board inputs disagree with the voted value
A problem with the input. This could be the device, the wire to the terminal board, the terminal board, or the cable.
30
ConfigCompatCode mismatch; Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
31
IOCompatCode mismatch; Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
32
P5=###.## Volts is Outside of Limits. The P5 power supply is out of the specified operating limits
A VME rack backplane wiring problem and/or power supply problem
33
P15=###.## Volts is Outside of Limits. The P15 power supply is out of the specified operating limits
If "Remote Control", disable diagnostic and ignore; otherwise probably a back plane wiring or VME power supply problem.
34
N15=###.## Volts is Outside of Limits. The N15 power supply is out of the specified operating limits
If "Remote Control", disable diagnostic and ignore; otherwise probably a VME backplane wiring and/or power supply problem.
35
P12=###.## Volts is Outside of Limits. The P12 power supply is out of the specified operating limits
If "Remote I/O", disable diagnostic and ignore; otherwise probably a VME backplane wiring and/or power supply problem.
36
N12=###.## Volts is Outside of Limits. The N12 power supply is out of the specified operating limits
If "Remote I/O", disable diagnostic and ignore; otherwise probably a VME backplane wiring and/or power supply problem.
37
P28A=###.## Volts is Outside of Limits. The P28A power supply is out of the specified operating limits
If "Remote Control", disable diagnostic and ignore; otherwise probably a VME backplane wiring and/or power supply problem.
38
P28B=###.## Volts is Outside of Limits. The P28B power supply is out of the specified operating limits
If "Remote Control", disable diagnostic and ignore; otherwise probably a VME backplane wiring and/or power supply problem.
39
P28C=###.## Volts is Outside of Limits. The P28C power supply is out of the specified operating limits
If "Remote Control" disable diagnostic. Disable diagnostic if not used; otherwise probably a backplane wiring and/or power supply problem.
40
P28D=###.## Volts is Outside of Limits. The P28D power supply is out of the specified operating limits
If "Remote Control" disable diagnostic. Disable diagnostic if not used; otherwise probably a backplane wiring and/or power supply problem.
41
P28E=###.## Volts is Outside of Limits. The P28E power supply is out of the specified operating limits
If "Remote Control" disable diagnostic. Disable diagnostic if not used; otherwise probably a backplane wiring and/or power supply problem.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-13
42
N28=###.## Volts is Outside of Limits. The N28 power supply is out of the specified operating limits
If "Remote Control" disable diagnostic. Disable diagnostic if not used; otherwise probably a backplane wiring and/or power supply problem.
43
125 Volt Bus=###.## Volts is Outside of Limits. The 125Volt bus voltage is out of the specified operating limits
A source voltage or cabling problem; disable 125 V monitoring if not applicable.
44
125 Volt Bus Ground =###.## Volts is Outside of Limits. The 125-Volt bus voltage ground is out of the specified operating limits
Leakage or a fault to ground causing an unbalance on the 125 V bus; disable 125 V monitoring if not applicable.
45
IONet-1 Communications Failure. Loss of communication on IONet1
Loose cable, rack power, or VCMI problem
46
IONet-2 Communications Failure. Loss of communication on IONet2
Loose cable, rack power, or VCMI problem
47
IONet-3 Communications Failure. Loss of communication on IONet3
Loose cable, rack power, or VCMI problem
48
VME Bus Error Detected (Total of ### Errors). The VCMI has detected errors on the VME bus
The sum of errors 60 through 66 Contact the factory.
49
Using Default Input Data, Rack R.#. The VCMI is not getting data from the specified rack
IONet communications failure - Check the VCMI and/or IONet cables.
50
Using Default Input Data, Rack S.#. The VCMI is not getting data from the specified rack
IONet communications failure - Check the VCMI and/or IONet cables.
51
Using Default Input Data, Rack T.#. The VCMI is not getting data from the specified rack
IONet communications failure - Check the VCMI and/or IONet cables.
52
Missed Time Match Interrupt (## uSec). The VCMI has detected a missed interrupt
Possible VCMI hardware failure
53
VCMI Scheduler Task Overrun. The VCMI did not complete running all its code before the end of the frame
Possibly too many I/O
54
Auto Slot ID Failure (Perm. VME Interrupt). The VCMI cannot perform its AUTOSLOT ID function
I/O board or backplane problem
55
Card ID/Auto Slot ID Mismatch. The VCMI cannot read the identity of a card that it has found in the rack
Board ID chip failed
56
Topology File/Board ID Mismatch. The VCMI has detected a mismatch between the configuration file and what it actually detects in the rack
ID chip mismatch - Check your configuration
57
Controller Sequencing Overrun
Too much application code used in controller. Reduce the code size.
58
Controller PCODE Version Mismatch between R,S,and T. Error during controller download R, S, and T have different software versions revalidate, build, and download all 3 controllers.
59
IONet Communications Failure. Loss of communications on the slave VCMI IONet
60-66
VME Error Bit # (Total ## Errors). The VCMI has detected VME backplane errors - Contact errors on the VME bus factory.
67
Controller Board is Offline. The VCMI cannot communicate with the controller
8-14 • Chapter 8 Troubleshooting and Diagnostics
Loose cable, rack power, or VCMI problem (VCMI slave only)
Controller failed or is powered down.
Mark VI System Guide GEH-6421D, Vol. I
68-87
I/O Board in Slot # is Offline. The VCMI cannot communicate with the specified board
I/O board is failed or removed. You must replace the board, or reconfigure the system and redownload to the VCMI, and reboot.
88
U17 Sectors 0-5 are not write protected
Sectors not write protected in manufacturing. Contact the factory.
89
SRAM resources exceeded. Topology/config too large
The size of the configured system is too large for the VCMI. You must reduce the size of the system.
VCRC VGEN
See VCCC 2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC failure override is Active
Board firmware programming error (board is allowed to go online)
16
System Limit Checking is Disabled
System checking was disabled by configuration
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J3A ID Failure
Failed ID chip on connector J3A, or cable problem
23
J4A ID Failure
Failed ID chip on connector J4A, or cable problem
24
Firmware/Hardware Incompatibility
Invalid terminal board connected to VME I/O board
30
ConfigCompatCode mismatch; Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
31
IOCompatCode mismatch; Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
32-43
Relay Driver # does not Match Requested State. There is a mismatch between the relay driver command and the state of the output to the relay as sensed by VGEN
The relay terminal board may not exist and the relay is configured a used, or there may be a faulty relay driver circuit or drive sensors on VGEN.
44-55
Relay Output Coil # does not Match Requested State. There is a mismatch between the relay driver command and the state of the current sensed on the relay coil on the relay terminal board
Relay is defective, or the connector cable J4 to the relay terminal board J1 is disconnected, or the relay terminal board does not exist.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-15
VPRO
56-59
Analog Input # Unhealthy. Analog Input 4−20 mA ## has exceeded the A/D converter's limits
60-65
Fuse # and/or # Blown. The fuse monitor requires the One or both of the listed fuses is jumpers to be set and to drive a load, or it will not respond blown, or there is a loss of power on correctly TB3, or the terminal board does not exist, or the jumpers are not set.
66-69
Analog 4−20 mA Auto Calibration Faulty. One of the analog 4−20 mA auto calibration signals has failed. Auto calibration or 4-20 mA inputs are invalid
70-73
PT Auto Calibration Faulty. One of the PT auto calibration Precision reference voltage or null signals has gone bad. Auto calibration of PT input signals reference is defective on VGEN, or is invalid, PT inputs are invalid multiplexer or A/D converter circuit on VGEN is defective.
74-79
CT Auto Calibration Faulty. One of the CT auto calibration Precision reference voltage or null signals has gone bad. Auto calibration of CT input signals reference is defective on VGEN, or is invalid, CT inputs are invalid multiplexer or A/D converter circuit on VGEN is defective.
96-223
Logic Signal # Voting mismatch. The identified signal from A problem with the input. This could this board disagrees with the voted value be the device, the wire to the terminal board, the terminal board, or the cable.
224-241
Input Signal # Voting mismatch, Local #, Voted #. The specified input signal varies from the voted value of the signal by more than the TMR Diff Limit
A problem with the input. This could be the device, the wire to the terminal board, the terminal board, or the cable.
2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC failure override is active
Board firmware programming error (board is allowed to go online)
16
System Limit Checking is Disabled
System checking was disabled by configuration.
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J3A ID Failure
Failed ID chip on connector J3A, or cable problem
23
J4A ID Failure
Failed ID chip on connector J4A, or cable problem
24
Firmware/Hardware Incompatibility
Invalid terminal board connected to VME I/O board
8-16 • Chapter 8 Troubleshooting and Diagnostics
Analog input is too large, TGEN jumper (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.
3 Volt or 9 Volt precision reference or null reference on VGEN is defective, or multiplexer or A/D converter circuit on VGEN is defective.
Mark VI System Guide GEH-6421D, Vol. I
30
ConfigCompatCode mismatch; Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
31
IOCompatCode mismatch; Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
32-38
Contact Input # Not Responding to Test Mode. Trip interlock number # is not reliable
Contact input circuit failure on VPRO or TREG board.
39-40
Contact Excitation Voltage Test Failure. Contact excitation voltage has failed, trip interlock monitoring voltage is lost
Loss of P125 voltage caused by disconnection of JH1 to TREG, or disconnect of JX1, JY1, JZ1 on TREG to J3 on VPRO.
41-43
Thermocouple ## Raw Counts High. The ## thermocouple input to the analog to digital converter exceeded the converter limits and will be removed from scan
A condition such as stray voltage or noise caused the input to exceed +63 millivolts.
44-46
Thermocouple ## Raw Counts Low. The ## thermocouple The board detected a thermocouple input to the analog to digital converter exceeded the open and applied a bias to the circuit converter limits and will be removed from scan driving it to a large negative number, or the TC is not connected, or a condition such as stray voltage or noise caused the input to exceed −63 millivolts.
47
Cold Junction Raw Counts High. Cold junction device input to the A/D converter has exceeded 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
The cold junction device on the terminal board has failed.
48
Cold Junction Raw Counts Low. Cold junction device input to the A/D converter has exceeded the limits of the converter
The cold junction device on the terminal board has failed.
49
Calibration Reference # Raw Counts High. Calibration reference # input to the A/D converter 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
The precision reference voltage on the board has failed.
50
Calibration Reference Raw Counts Low. The precision reference voltage on the Calibration reference input to the A/D converter exceeded board has failed. the converter limits
51
Null Reference Raw Counts High. The null (zero) reference input to the A/D converter has exceeded the converter limits
The null reference voltage signal on the board has failed.
52
Null Reference Raw Counts Low. The null (zero) reference input to the A/D converter has exceeded the converter limits
The null reference voltage signal on the board has failed.
53-55
Thermocouple ## Linearization Table High. The thermocouple input has exceeded the range of the linearization (lookup) table for this type. The temperature will be set to the table's maximum value
The thermocouple has been configured as the wrong type, or a stray voltage has biased the TC outside of its normal range, or the cold junction compensation is wrong.
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-17
56-58
Thermocouple ## Linearization Table Low. The thermo couple input has exceeded the range of the linearization (lookup) table for this type. The temperature will be set to the table's minimum value
The thermocouple has been configured as the wrong type, or a stray voltage has biased the TC outside of its normal range, or the cold junction compensation is wrong.
59-61
Analog Input # Unhealthy. The number # analog input to the A/D converter has exceeded the converter limits
The input has exceeded 4−20 mA 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.
63
P15=####.## Volts is Outside of Limits. The P15 power supply is out of the specified +12.75 to +17.25 V operating limits
Analog ±15 V power supply on VPRO board has failed.
64
N15=####.## Volts is Outside of Limits. The N15 power supply is out of the specified –17.25 to –12.75 V operating limits
Analog ±15 V power supply on VPRO board has failed.
67
P28A=####.## Volts is Outside of Limits. The P28A power supply is out of the specified 23.8 to 31.0 V operating limits
The P28A power supply on VPWR board has failed, test P28A at VPRO front panel, otherwise there may be a bad connection at J9, the VPWR to VPRO interconnect.
68
P28B=####.## Volts is Outside of Limits. The P28B power supply is out of the specified 23.8 to 31.0 V operating limits
The P28B power supply on VPWR board has failed, test P28B at VPRO front panel, otherwise there may be a bad connection at J9, the VPWR to VPRO interconnect.
69-71
Trip Relay (ETR) Driver # Mismatch Requested State. The state of the command to the Emergency Trip Relay (ETR) does not match the state of the relay driver feedback signal; the ETR cannot be reliably driven until corrected
The ETR # relay driver or relay driver feedback monitor on the TREG terminal board has failed, or the cabling between VPRO and TREG is incorrect.
75
Servo Clamp Relay Driver Mismatch Requested State. The state of the command to the servo clamp relay does not match the state of the servo clamp relay driver feedback signal; cannot reliably drive the servo clamp relay until corrected
The servo clamp relay driver or relay driver feedback monitor on the TREG board has failed, or the cabling between VPRO and TREG is incorrect.
76
K25A Relay (Synch Check) Driver Mismatch Requested State. The state of the command to the K25A relay does not match the state of the K25A relay driver feedback signal; cannot reliably drive the K25A relay until corrected
K25A relay driver or relay driver feedback on the TREG board has failed, or the cabling between VPRO and TREG is incorrect.
83-85
Trip Relay (ETR) Contact # Mismatch Requested State. The state of the command to the ETR does not match the state of the ETR contact feedback signal; the ETR cannot be reliably driven until corrected
The relay driver on TREG may have failed, or the ETR on the TREG board has failed, or the cabling between the VPRO and TREG is incorrect.
99-104
TREG Solenoid Voltage # Mismatch Requested State. The state of the trip solenoid # does not match the command logic of the voted ETR # on TREG, and the voted primary trip relay (PTR) # on TRPG, the ETR cannot be reliably driven until corrected
The trip solenoid # voltage monitor on TREG has failed or ETR # driver failed, or PTR # driver failed. There may be a loss of 125 V dc via the J2 connector from TRPG, which has a diagnostic.
72-74
Econ Relay Driver # Mismatch Requested State. The state of the command to the economizing relay does not match the state of the economizing relay driver feedback signal; cannot reliably drive the economizing relay until corrected
Economizing relay driver # or relay driver feedback monitor on TREG board has failed, or the cabling between VPRO and TREG is incorrect.
77-79
91-93
80-82
8-18 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
86-88
Econ Relay Contact # Mismatch Requested State. The state of the command to the economizing relay does not match the state of the economizing relay contact feedback signal; cannot reliably drive the economizing relay until corrected
Economizing relay driver # on TREG board has failed, or the economizing relay on TREG has failed, or the cabling between VPRO and TREG is incorrect.
90
K25A Relay (Synch Check) Coil Trouble, Cabling to P28V on TTUR. The state of the command to the K25A relay does not match the state of the K25A relay contact feedback signal; cannot reliably drive the K25A relay until the problem is corrected. The signal path is from VPRO to TREG to TRPG to VTUR to TTUR
The K25A relay driver or relay driver feedback on the TREG board has failed, or the K25A relay on TTUR has failed, or the cabling between VPRO and TTUR is incorrect.
89
Servo Clamp Relay Contact Mismatch Requested State. The state of the command to the servo clamp relay does not match the state of the servo clamp relay contact feedback signal; cannot reliably drive the servo clamp relay until corrected
The servo clamp relay driver or the servo clamp relay on the TREG board has failed, or the cabling between VPRO and TREG is incorrect.
97
TREG J3 Solenoid Power Source is Missing. The P125 V dc source for driving the trip solenoids is not detected; cannot reliably drive the trip solenoids
The power detection monitor on the TREG1 board has failed, or there is a 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.
98
TREG J4 Solenoid Power Source is Missing. The P125 V dc source for driving the trip solenoids is not detected; cannot reliably drive the trip solenoids K4-K6
The power detection monitor on the TREG2 board has failed, or there is a 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.
105
TREL/S, J3, Solenoid Power, Bus A, Absent. The voltage source for driving the solenoids is not detected on Bus A; cannot reliably drive these solenoids
Loss of power bus A through J2 connector from TRPL/S
106
TREL/S, J3, Solenoid Power, Bus B, Absent. The voltage source for driving the solenoids is not detected on Bus B; cannot reliably drive these solenoids
Loss of power bus B through J2 connector from TRPL/S
107
TREL/S, J3, Solenoid Power, Bus C, Absent. The voltage source for driving the solenoids is not detected on Bus C; cannot reliably drive these solenoids
Loss of Power Bus C through J2 connector from TRPL/S
128-319
Logic Signal # Voting mismatch. The identified signal from A problem with the input. This could this board disagrees with the voted value be the device, the wire to the terminal board, the terminal board, or the cable.
320-339
Input Signal # Voting mismatch, Local #, Voted #. The specified input signal varies from the voted value of the signal by more than the TMR Diff Limit
A problem with the input. This could be the device, the wire to the terminal board, the terminal board, or the cable.
2
Flash Memory CRC Failure
Board firmware programming error (board will not go online)
3
CRC failure override is Active
Board firmware programming error (board is allowed to go online)
94-96
VPYR
GEH-6421D, Vol. I Mark VI System Guide
Chapter 8 Troubleshooting and Diagnostic • 8-19
16
System Limit Checking is Disabled
System checking was disabled by configuration.
17
Board ID Failure
Failed ID chip on the VME I/O board
18
J3 ID Failure
Failed ID chip on connector J3, or cable problem
19
J4 ID Failure
Failed ID chip on connector J4, or cable problem
20
J5 ID Failure
Failed ID chip on connector J5, or cable problem
21
J6 ID Failure
Failed ID chip on connector J6, or cable problem
22
J3A ID Failure
Failed ID chip on connector J3A, or cable problem
23
J4A ID Failure
Failed ID chip on connector J4A, or cable problem
24
Firmware/Hardware Incompatibility
Invalid terminal board connected to VME I/O board
30
ConfigCompatCode mismatch; Firmware: #; Tre: # The configuration compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
31
IOCompatCode mismatch; Firmware: #; Tre: # The I/O compatibility code that the firmware is expecting is different than what is in the tre file for this board
A tre file has been installed that is incompatible with the firmware on the I/O board. Either the tre file or firmware must change. Contact the factory.
32&38
Milliamp input associated with the slow average temperature is unhealthy. Pyro## SLOW AVG TEMP unhealthy
Specified pyrometer's average output is faulty, or VPYR or TPYR is faulty.
33&39
Pyro## Slow Max Pk Temp unhealthy. Milliamp input associated with the slow maximum peak temperature is unhealthy
Specified pyrometer's maximum output is faulty, or VPYR or TPYR is faulty.
34&40
Pyro## Slow Average Peak Temp. Milliamp input associated with the slow average peak temperature is unhealthy
Specified pyrometer's peak output is faulty, or VPYR or TPYR is faulty.
35&41
Pyro##Fast Temp Unhealthy. Milliamp input associated with the fast temperature is unhealthy
Specified pyrometer's fast output is faulty, or VPYR or TPYR is faulty.
36&42
Pyro## Fast Cal Reference out of limits. The fast calibration reference is out of limits
VPYR is faulty
37&43
Pyro## Fast Cal Null out of limits. The fast calibration null is out of limits
VPYR is faulty
44
Slow Cal Reference out of limits. The slow calibration reference is out of limits
VPYR is faulty
45
Slow Cal Null out of limits. The slow calibration null is out of limits
VPYR is faulty
128-191
Logic Signal # Voting mismatch. The identified signal from A problem with the input. This could this board disagrees with the voted value be the device, the wire to the terminal board, the terminal board, or the cable.
8-20 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
VAMA
224-247
Input Signal # Voting mismatch, Local #, Voted #. The specified input signal varies from the voted value of the signal by more than the TMR Diff Limit
A problem with the input. This could be the device, the wire to the terminal board, the terminal board, or the cable.
M040
ASIG Open Wire Detection V dc
Terminal board or cable problem
M041
ARET Open Wire Detection V dc
Terminal board or cable problem
M042
BSIG Open Wire Detection V dc
Terminal board or cable problem
M043
BRET Open Wire Detection V dc
Terminal board or cable problem
M044
Chan A DAC Bias V dc
Board failure
M045
Chan B DAC Bias V dc
Board failure
M046
Chan A Diff Amp Out V dc
Board failure
M047
Chan B Diff Amp Out V dc
Board failure
M048
Chan A FFT Filtered Null Counts
Board failure
M049
Chan B FFT Filtered Null Counts
Board failure
M050
Chan A FFT Filtered Reference Counts
Board failure
M051
Chan B FFT Filtered Reference Counts
Board failure
M052
Chan A (Slow) Filtered RMS Null Counts
Board failure
M053
Chan B (Slow) Filtered RMS Null Counts
Board failure
M054
Chan A (Slow) Filtered RMS Reference Counts
Board failure
M055
Chan B (Slow) Filtered RMS Reference Counts
Board failure
M072
Chan A FFT Null
Board failure
M073
Chan B FFT Null Counts
Board failure
M074
Chan A FFT Reference Counts
Board failure
M075
Chan B FFT Reference Counts
Board failure
M076
Chan A (Slow) RMS Null Counts
Board failure
M077
Chan B (Slow) RMS Null Counts
Board failure
M078
Chan A (Slow) RMS Reference Counts
Board failure
M079
Chan B (Slow) RMS Reference Counts
Board failure
M080
Ch A FFT AC Gain Corr LPF=600Hz Gain=4.5 Freq=300
Board failure
M081
Board failure
M082
Ch B FFT AC Gain Corr LPF=600Hz Gain=4.5 Freq=300 Ch A FFT AC Gain Corr LPF=1kHz Gain=4.5 Freq=600
M083
Ch B FFT AC Gain Corr LPF=1kHz Gain=4.5 Freq=600
Board failure
M084
Ch A FFT AC Gain Corr LPF=3.6kHz Gain=4.5 Freq=2160
Board failure
M085
Ch B FFT AC Gain Corr LPF=3.6kHz Gain=4.5 Freq=2160
Board failure
M086
Ch A FFT AC Gain Corr 260_970Hz Gain=2.25 Freq=600
Board failure
Config. Dep.
VAMA Startup
GEH-6421D, Vol. I Mark VI System Guide
Board failure
Chapter 8 Troubleshooting and Diagnostic • 8-21
M087
Ch B FFT AC Gain Corr 260_970Hz Gain=2.25 Freq=600
Board failure
M088
Slow Ch A RMS Gain Corr 270_970Hz Gain=4.5 Freq=600
Board failure
M089
Slow Ch B RMS Gain Corr 270_970Hz Gain=4.5 Freq=600
Board failure
M090
CHAN A FFT LPF=3.6kHz Gain=4.5 Freq=0
Board failure
M091
CHAN B FFT LPF=3.6kHz Gain=4.5 Freq=0
Board failure
M092
CHAN A FFT LPF=600Hz Gain=1.0 Freq=300
Board failure
M093
CHAN B FFT LPF=600Hz Gain=1.0 Freq=300
Board failure
M094
CHAN A FFT LPF=600Hz Gain=2.25 Freq=300
Board failure
M095
CHAN B FFT LPF=600Hz Gain=2.25 Freq=300
Board failure
M096
CHAN A FFT LPF=600Hz Gain=4.5 Freq=300
Board failure
M097
CHAN B FFT LPF=600Hz Gain=4.5 Freq=300
Board failure
M098
CHAN A FFT LPF=1kHz Gain=4.5 Freq=600
Board failure
M099
CHAN B FFT LPF=1kHz Gain=4.5 Freq=600
Board failure
M100
CHAN A FFT LPF=3.6kHz Gain=4.5 Freq=2160
Board failure
M101
CHAN B FFT LPF=3.6kHz Gain=4.5 Freq=2160
Board failure
M102
CHAN A FFT LPF=3.6kHz Gain=4.5 Freq=600
Board failure
M103
CHAN B FFT LPF=3.6kHz Gain=4.5 Freq=600
Board failure
M104
CHAN A FFT LPF=600Hz Gain=4.5 Freq=706 –12db
Board failure
M105
CHAN B FFT LPF=600Hz Gain=4.5 Freq=706 –12db
Board failure
M106
CHAN A FFT LPF=1kHz Gain=4.5 Freq=1192 –12db
Board failure
M107
CHAN B FFT LPF=1kHz Gain=4.5 Freq=1192 –12db
Board failure
M108
CHAN A FFT LPF=3.6kHz Gain=4.5 Freq=3854 –6db
Board failure
M109
CHAN B FFT LPF=3.6kHz Gain=4.5 Freq=3854 –6db
Board failure
M110
CHAN A FFT LPF=600Hz Gain=4.5 Freq=5 –3db
Board failure
M111
CHAN B FFT LPF=600Hz Gain=4.5 Freq=5 –3db
Board failure
M112
CHAN A FFT LPF=600Hz Gain=2.25 Freq=600 –3db
Board failure
M113
CHAN B FFT LPF=600Hz Gain=2.25 Freq=600 –3db
Board failure
M114
CHAN A FFT LPF=1kHz Gain=2.25 Freq=1000 –3db
Board failure
M115
CHAN B FFT LPF=1kHz Gain=2.25 Freq=1000 –3db
Board failure
M116
CHAN A FFT LPF=3.6kHz Gain=2.25 Freq=3600 –3db
Board failure
M117
CHAN B FFT LPF=3.6kHz Gain=2.25 Freq=3600 –3db
Board failure
M118
CHAN A FFT 260-970Hz Gain=2.25 Freq=400
Board failure
M119
CHAN A RMS 260-970Hz Gain=2.25 Freq=400
Board failure
M120
CHAN B FFT 260-970Hz Gain=2.25 Freq=400
Board failure
M121
CHAN B RMS 260-970Hz Gain=2.25 Freq=400
Board failure
M122
CHAN A FFT 260-970Hz Gain=2.25 Freq=600
Board failure
M123
CHAN A RMS 260-970Hz Gain=2.25 Freq=600
Board failure
8-22 • Chapter 8 Troubleshooting and Diagnostics
Mark VI System Guide GEH-6421D, Vol. I
M124
CHAN B FFT 260-970Hz Gain=2.25 Freq=600
Board failure
M125
Board failure
M126
CHAN B RMS 260-970Hz Gain=2.25 Freq=600 CHAN A FFT 260-970Hz Gain=2.25 Freq=235 –3db
M127
CHAN A RMS 260-970Hz Gain=2.25 Freq=235 –3db
Board failure
M128
CHAN B FFT 260-970Hz Gain=2.25 Freq=235 –3db
Board failure
M129
CHAN B RMS 260-970Hz Gain=2.25 Freq=235 –3db
Board failure
M130
CHAN A FFT 260-970Hz Gain=2.25 Freq=220 –9db
Board failure
M131
CHAN A RMS 260-970Hz Gain=2.25 Freq=220 –9db
Board failure
M132
CHAN B FFT 260-970Hz Gain=2.25 Freq=220 –9db
Board failure
M133
Board failure
M134
CHAN B RMS 260-970Hz Gain=2.25 Freq=220 –9db CHAN A FFT 260-970Hz Gain=2.25 Freq=205 –15db
M135
CHAN A RMS 260-970Hz Gain=2.25 Freq=205 –15db
Board failure
M136
CHAN B FFT 260-970Hz Gain=2.25 Freq=205 –15db
Board failure
M137
CHAN B RMS 260-970Hz Gain=2.25 Freq=205 –15db
Board failure
M138
CHAN A FFT 260-970Hz Gain=2.25 Freq=1065 –3db
Board failure
M139
CHAN A RMS 260-970Hz Gain=2.25 Freq=1065 –3db
Board failure
M140
CHAN B FFT 260-970Hz Gain=2.25 Freq=1065 –3db
Board failure
M141
CHAN B RMS 260-970Hz Gain=2.25 Freq=1065 –3db
Board failure
M142
CHAN A FFT 260-970Hz Gain=2.25 Freq=1150 –9db
Board failure
M143
CHAN A RMS 260-970Hz Gain=2.25 Freq=1150 –9db
Board failure
M144
CHAN B FFT 260-970Hz Gain=2.25 Freq=1150 –9db
Board failure
M145
CHAN B RMS 260-970Hz Gain=2.25 Freq=1150 –9db
Board failure
M146
CHAN A FFT 260-970Hz Gain=2.25 Freq=1235 –15db
Board failure
M147
CHAN A RMS 260-970Hz Gain=2.25 Freq=1235 –15db
Board failure
M148
CHAN B FFT 260-970Hz Gain=2.25 Freq=1235 –15db
Board failure
M149
CHAN B RMS 260-970Hz Gain=2.25 Freq=1235 –15db
Board failure
M150
CHAN A FFT 260-970Hz Gain=2.25 Freq=130 :" 6% & "
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