System Manual GEK-114902 Version No.2.0
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. The information is supplied for informational purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced herein. GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not provide any license whatsoever to any of these patents. All license inquiries should be directed to the address below. If further information is desired, or if particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to: GE Energy Control Solutions 1800 Nelson Road Longmont, CO 80501 [email protected]
http://www.ge-energy.com/oc Phone: + 1 (800) 835-5182, United State) + 1 (970) 461-5201 (International) (“+” indicates the international access code required when calling from outside the USA) This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy. GE provides the following document and the information included therein as is and without warranty of any kind, express or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose. © 2012 General Electric Company, USA. All rights reserved.
Safety Symbols Indicates a procedure or condition that, if not strictly observed, could result in personal injury or death.
Indicates a procedure or condition that, if not strictly observed, could result in damage or destruction of equipment.
Indicates a procedure, condition, or statement that should be strictly followed in order to optimize these applications.
Note Indicates an essential or important procedure or statement.
Tip Provides essential information that is not normally defined in regular use but from an experienced user.
Contents Chapter 1 OC 6000e System Introduction
1.1 OC 6000e overview ············································································································································ 1 1.2 OC 6000e System Architecture ···················································································································· 3 1.3 System feature or specification···················································································································· 4 1.4 Hardware Summary ·········································································································································· 5 1.4.1 OC 6000e IO Module Summary ··············································································································· 7 1.4.2 OC 6000e Communication Module Summary················································································· 9 1.4.3 Controller ························································································································································· 11 1.4.4 HMI ······································································································································································ 11 1.4.5 Printer ································································································································································ 12 1.4.6 IONet Switch ··················································································································································· 12 1.4.7 UDH Switch ····················································································································································· 13 1.4.8 Console······························································································································································ 13 1.5 Software ······························································································································································· 13 1.5.1 OS ········································································································································································· 14 1.5.2 Platform Software ······································································································································· 14 1.5.3 Application Software ································································································································· 14 1.6 Certification and standards ························································································································ 14
Chapter 2 System configuration via requirement
2.1 Hardware configuration calculation ······································································································ 15 2.1.1 Controllers ······················································································································································· 15 2.1.2 I/O modules ···················································································································································· 15 2.1.3 Communication modules ························································································································ 15 2.1.4 Cabinets and accessories ······················································································································· 15 2.2 HMI ·········································································································································································· 16 2.3 UDH Network switches ································································································································· 16 2.4 Other equipment ·············································································································································· 16
Chapter 3 Engineering Design: hardware
3.1 System arrangement ····································································································································· 17 3.2 Signal assignment ··········································································································································· 17 3.3 Cabinet assembly············································································································································· 17 3.4 IO Network switch arrangement ·············································································································· 19 3.5 System Network Topology ·························································································································· 20 3.6 Power Distribution in cabinet····················································································································· 20 3.7 System Power distribution ·························································································································· 22 3.8 Power Distribution Cabinet ························································································································· 22 3.9 Grounding ···························································································································································· 23 3.9.1 Cabinet Grounding ······································································································································ 23 3.9.2 Signal grounding ·········································································································································· 24 3.9.3 System grounding ······································································································································· 25 3.10 Field Signal Cable and wiring ·················································································································· 26 3.11 Interface ····························································································································································· 29 3.11.1 Information communication ··············································································································· 29 3.11.2 Control signal connection ···················································································································· 29 3.11.3 Signals between subsystem ··············································································································· 29
Chapter 4 Engineering Design: IP address assignment
4.1 Node number ····················································································································································· 30 4.2 Node IP Address················································································································································ 30 GEK-114902 OC6000e System Manual
4.3 IP address setup··············································································································································· 30
Chapter 5 Engineering Design: Naming
5.1 Signal Tag ···························································································································································· 32 5.2 System Device Tag ·········································································································································· 32
Chapter 6 Engineering Design: HMI graphic 6.1 6.2 6.3 6.4
HMI Graphic Layout ········································································································································ 34 Menu······································································································································································· 35 Default Color Definition ································································································································· 35 System Objects ·················································································································································· 37
Chapter 7 Controller Software design
7.1 Page and block definition ···························································································································· 38 7.2 Cycle time····························································································································································· 38 7.3 Page logic and algorithm ····························································································································· 38
Chapter 8 Alarm
Chapter 9 Safety Design
9.1 Fail-Safe ································································································································································ 40 9.2 Project design and commission ················································································································ 40 9.3 Password ····························································································································································· 40
Chapter 10 Installation
10.1 Standard Cabinet Dimension ·················································································································· 41 10.2 Installation conditions································································································································· 41
GEK-114902 OC 6000e System Manual
Chapter 1 OC 6000e System Introduction 1.1 OC 6000e overview OC 6000e is a new generation of Distributed Control System by GE Energy, which is based on OC 4000 and Mark VIe systems and combines with years of XinHua DCS engineering experience. GE Energy has more than 100 years of experience in the area of electricity. Since 1884 GE Energy provided the first turbine generator, GE Energy constantly develops new technology; the product line covers steam turbine, gas turbine, generator, wind generator, water turbine and so on. At the same time, GE Energy provides auxiliary control systems for main equipment including Mark series controllers, Woodward controller, Bently conditioning monitor equipment, and EX2100 excitation controller, etc. The OC 6000e system is an integrated control platform with high-performance and highly reliability. It highlights the following technical features in the system design: 1) The Brand new controller and I/O module design Adopting high performance 667 MHz controller - UCSA, the controller's software platform adopts the QNX real-time operating system and achieves high-speed logic operation and the millisecond clock timing function. 2) High-efficiency network communication and time synchronization function OC 6000e control network and I/O network are 100 M high-speed Ethernet. Controller and the I/O modules communicate directly via Ethernet to reduce the number of intermediaries and time delay. At the same time the I/O network is based on IEC1588 protocol, which achieves 0.1ms accuracy of time synchronization between all I/O modules. 3) Various communication interfaces to other systems The MCI communication modules provide interfaces between OC6000e and other system, including RS-232C, RS-485, RS-422 and Ethernet. General communication protocols are supported, such as Modbus and IEC60870-5-104. 4) Compact system layout The new I/O module and terminal board interfaces with a whole set of components, the filed signal cables connect directly to the terminals of I/0 components. A reduction in the number of cabinets lowers the space requirements of the central control room, thus reducing the total cost of customer installation. 5) Reliable system design In order to improve the reliability of the system, reliable design and relevant experimental verification are widely used in the system development and the manufacturing process. Prior to system design each module undergoes a rigorous test of the HALT (highly accelerated life test) to ensure quality and reliability of the module design. System design and manufacture complies with CE, CSA certification and other related requirements.
GEK-114902 OC6000e System Manual
6) Compatible integration platform OC 6000e is compatible with GE Energy Control Products integration solutions. This includes both the integration and integration features. First, the control network adopts the GE standard EGD protocol. GE Energy’s different control products can have unified communication protocol to allow exchange of data. Second, OC 6000e software integrates with optimization interface, which allows it to connect with optimization software at plant-level and unit-level. Third, IONet and IO module are fully hot swappable. Fourth, OC 6000e software is compatible with Mark Vie IO and OC 6000e IO. OC 6000e system architecture is divided into three levels: human-machine interface level, process control level and the process of input/output (I/O) level.
Human-machine interface level
Human-machine interface refers to the ability to monitor and control using a Windowsbased platform, including operator station, engineer station, historical data station and process optimization station. All human-machine interface stations are backups to each other; users can modify the software settings and user privileges to change the humanmachine interface functions. The human-machine interface level and the control level communicate through the redundant process real-time control network. This is called the UDH network. All nodes on the network use NTP protocol. A NTP server is connected on the UDH and usually connected to a GPS receiver.
Process control level
The process control level is the redundant controller based on the QNX platform, which effectively integrates main existing products of GE Energy in a public platform and offers solutions for the integration of the entire plant.
Process input/output (I/O) level
The I/O level uses distributed modules via high-speed Ethernet to connect to the process control. Distributed architecture enables users to place the I/O modules anywhere in the factory based on the physical location of the equipment, thus minimizing signal cable requirements, reducing installation costs, and effectively reducing the electromagnetic interference that can exist in long-distance signal transmission. All I/O modules adopt a no-jumper design concept, and module configuration is determined by specialized software, which improves the reliability and user-friendliness. The OC 6000e and Mark VIe system use the same controller. The I/O modules on the I/O network level are fully compatible between these two systems, making them capable of swapping. (Physical size and appearance are different however) Users can choose Mark VIe triple redundant modules to control the critical components to result in triple redundant control of high priority installations. An original system installed with Mark VIe, OC 6000e may be easily upgraded. Communication: supporting Modbus, IEC60870-5-104 or OPC communication through special module or HMI. OC 6000e software includes OC 4000 system software’s features of being intuitive and easy-to-use. The unified system software achieves continuity of the system and logic 2
GEK-114902 OC 6000e System Manual
configuration. Users will use a single software system to complete the tasks of network configuration, user management, controller configuration, I/O module parameters and controller programming, and many other functions. The real-time database is capable of detailed name and description of the control points. The controller generates all the data recorded and users can directly read from the controller and modify the process data and information. OC 6000e software widely adopts the design of the ActiveX control technology. Users are able to easily integrate the functions of various systems to the Web environment, to view the remote access process data.
1.2 OC 6000e System Architecture OC 6000e system architecture is shown below. This configuration is for one unit.
Figure 1.2-1 OC6000e Architecture
GEK-114902 OC6000e System Manual
Different nodes on the system are listed below:
OPU: Operator unit. For process monitoring and control.
ENG: Engineer unit. For configuration and system maintenance.
HSU: Historical unit. For historical recording.
Process control level and Process input/output (I/O) level:
MAI10: Analog Input, mA/V type, 16 channels
MAI20: Analog Input, TC/RTD type, 16 channels
MAO10: Analog Output, mA/V type, 8 channels
MDI10: Digital Input, 16 channels
MDO10: Digital Output, 16 channels
MCI12: Serial communication, isolated 7 port RS-485 and 1 port RS-485/RS422 MCI20: Serial and Ethernet communication, 2 port Ethernet and 3 port RS-232 Industrial Ethernet switch
MCI11: Serial communication, isolated 3 port RS-485 and 1 port RS-485/RS422
MCI10: Serial communication, 7 port RS-485 and 1 port RS-485/RS-422
Industrial Ethernet switch
24VDC power supply
1.3 System feature or specification Table 1.3-1 System feature or specification Item Specification System ambient temperature 0 to 60ºC System ambient humidity 10 to 95% Non-Condensing Total points in one system no more than 64,000 Total control drops in one system no more than 160 Total HMI in one system no more than 80 SOE 1ms Controller 667MHz, 13.55W Real time operating system QNX Power rating for each cabinet 110-240V~, 50Hz/60Hz,