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GE Mark VIe, System Manual

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1.6.1.3

Triple Modular Redundant (TMR) Controllers

The TMR control architecture contains three controllers, three IONets, and singular or fanned TMR I/O Modules.

Reliability

and availability

are much better with TMR controllers than with dual controllers due to increased fault detection capability. In

addition to all of the dual redundant features, the TMR controller provides three independent outputs to all TMR I/O modules
and the state variables between controllers are voted.

I/O Modules

Switches

Controllers

R

S

T

IONet <T>

IONet <S>

IONet <R>

Legend

UDH

TMR Mark VIe Control System

Note

The level of I/O reliability can be varied to meet the application needs because I/O redundancy can be simplex, dual, or

TMR.

In a TMR control system, all three controllers receive inputs from the I/O modules on all networks and transmit outputs on
their respective IONet continuously. If a controller or network component fails, the system does not require fault detection or
failover time to continue operating. All controllers transmit their copy of the state variables after the output packet has been
transmitted. Each controller takes the three sets of state variables and votes the data to get the values for the next run cycle.

40

GEH-6721_Vol_I_BP

GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I

Public Information

Summary of Contents for Mark VIe

Page 1: ...GEH 6721_Vol_I_BP Mark VIe and Mark VIeS Control Systems Volume I System Guide June 2020 Public Information ...

Page 2: ...t matter in this document The furnishing of this document does not provide any license whatsoever to any of these patents Public Information This document contains non sensitive information approved for public disclosure GE provides the following document and the information included therein as is and without warranty of any kind expressed or implied including but not limited to any implied statut...

Page 3: ...G3A and IS200JPDDG4A remove FU from GE Part column BJ Introduction Added Attention statement that users application may not be licensed to access full system capability and I O types described in this document Modbus Protocol Changes made for clarification including Removed the note referencing GSM 3 0 documentation which is not related to Modbus Added a note below the Mark VIe Controller Modbus C...

Page 4: ...d Wiring New table for wire limitations BPPC based I O Pack Migration New sections BPPC based Mark VIeS Safety I O Packs Available Mark VIe BPPC based I O Packs Mark VIe BPPC I O Migration Guidelines Equip Mark VIe System for Migration BB Communication Protocols Added PROFINET to the list of Fieldbus Network Protocols Component Part Numbers New section Troubleshooting Added some helpful tables and...

Page 5: ... Data UDH Unit Data Highway EMC Electromagnetic Capability UDP User Datagram Protocol EMI Electromagnetic Interference UTC Coordinated Universal Time ERA Electrical Riser Angle UTP Unshielded Twisted Pair cabling FE Functional Earth VLAN Virtual Local Area Network GPS Global Position System WAN Wide Area Network GSM GE Standard Messaging GTS Global Time Source HMI Human machine Interface HRSG Heat...

Page 6: ...IeS Functional Safety System Equipment in Hazardous Locations HazLoc Instruction Guide GEH 6741 Sequential Function Chart Application Guide GEH 6742 Mark VIe and Mark VIeS Virtual Controller User Guide GEH 6757 WorkstationST GSM 3 0 User Guide GEH 6760 WorkstationST GSM 3 0 Application Guide GEH 6761 Mark VIe Control FOUNDATION Fieldbus Interface Application Guide GEH 6812 Mark Controllers Shared ...

Page 7: ...personal injury or death Caution Indicates a procedure or condition that if not strictly observed could result in damage to or destruction of equipment Attention Indicates a procedure or condition that should be strictly followed to improve these applications GEH 6721_Vol_I_BP System Guide 7 Public Information ...

Page 8: ...quipment cannot be grounded to the equipment under test the test equipment s case must be shielded to prevent contact by personnel To minimize hazard of electrical shock or burn approved grounding practices and procedures must be strictly followed Warning To prevent personal injury or equipment damage caused by equipment malfunction only adequately trained personnel should modify any programmable ...

Page 9: ...ring Supervisory and Unit Control Layers 94 3 8 Third party Communication Links 98 4 Communication Protocols 99 4 1 OPC Protocols 101 4 2 WorkstationST GSM Protocol 104 4 3 Modbus Protocol 106 4 4 Ethernet Global Data EGD 109 4 5 System Data Interface SDI Protocol 111 4 6 Network Time Protocol NTP 112 4 7 Fieldbus Communications 115 5 Technical Regulations Standards and Environment 117 5 1 Safety ...

Page 10: ...ion Flow 174 8 Troubleshooting 175 8 1 Controller I O Pack IONet Switch Not Powering On 175 8 2 Unable to Download to Controller 178 8 3 Controller Not in Controlling State 179 8 4 Unable to Download to I O Modules 184 8 5 Unable to Communicate with I O Module 185 8 6 Unable to Download to Controller or I O Module 186 8 7 Communication Loss Between Controller and I O Module 187 8 8 Boot Log Collec...

Page 11: ...e the YUAA module is the companion module that is used in the Mark VIeS Safety control system The UIO control cabinet is a lower cost smaller footprint alternative to the standard Mark control cabinet The control cabinet is installed at sites when there are I O power and or space limitations in the existing Mark VI Mark VIe or Mark VIeS control cabinet This is especially required for upgrades when...

Page 12: ...ions in this manual also apply to the UIO control cabinet Typical Architecture for Large Industrial Control Systems 12 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 13: ...s The control system provides more options for redundancy better maintainability and greater capability for locating I O modules closer to the controlled equipment It provides quality time coherent data at controller and plant level for effectively managing control system equipment ControlST which include the ToolboxST and WorkstationST applications is used for programming configuration trending a...

Page 14: ...Component Hardware Editor 14 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 15: ...er the I O networks IONet IONet data includes process inputs outputs to the I O packs In a dual system IONet data also includes Internal state values and initialization information from the designated controller Status and synchronization information from both controllers In a triple module redundant TMR system IONet data also includes Internal state values for voting and status and synchronizatio...

Page 16: ...e for General purpose Applications GEH 6721_Vol_II the chapter Unmanaged Ethetnet Swtiches 1 4 Distributed I O Modules TMR I O Module The I O modules contain three basic parts terminal board terminal block and I O pack The terminal board mounts to the cabinet and comes in two basic types S and T The I O pack mounts to the terminal board J port connector Both terminal board types provide the follow...

Page 17: ...re catalog number and the firmware version The I O packs have a temperature sensor that is accurate to within 2 C 3 6 F Every I O pack temperature is available in the database and can be used to generate an alarm 1 4 2 Terminal Boards Signal flow begins with a sensor connected to a terminal block on a board Wide and narrow terminal boards are arranged in vertical columns of high and low level wiri...

Page 18: ...ring type lugs In addition captive clamps are provided for terminating bare wires Screw spacing is 9 53 mm 0 375 in minimum and center to center Note Some application specific TMR terminal boards do not fan inputs or vote the outputs Barrier type Terminal Blocks These terminal blocks have the following features Black in color with white number labels Terminal rating is 300 V 10 A UL recognized Rec...

Page 19: ...pe terminal blocks Some boards are available as either removable or fixed terminal block versions S type board terminal blocks accept one 2 05 mm 0 08 in 12 AWG wire or two 1 63 mm 0 06 in 14 AWG wires each with 300 V insulation per point Screw spacing is 5 08 mm 0 2 in minimum and center to center Box type Terminal Blocks These terminal blocks have the following features Green in color with numbe...

Page 20: ... V dc group isolated SOE Box Yes PDIAH1A 1 PDIAH1B 1 STCIH4A 24 DI 48 V dc group isolated SOE Box Yes PDIAH1A 1 PDIAH1B 1 STCIH6A 24 DI 125 V dc group isolated SOE Box Yes PDIAH1A 1 PDIAH1B 1 STCIH8A 24 DI 24 V dc group isolated SOE Box Yes PDIIH1A 1 PDIIH1B 1 SDIIH1A 16 DI 24 48 125 250 V dc 115 230 V ac point isolated line break detection SOE Box Yes SDIIH2A Same as H1A but is also enhanced to p...

Page 21: ...Yes PDOAH1A 1 3 PDOAH1B 1 3 TRLYH2C 12 type C mechanical relays with 6 solenoids voltage diagnostics 24 V dc SOE for relay outputs Barrier Yes PDOAH1A 1 3 PDOAH1B 1 3 TRLYH1D 6 type A mechanical relays for solenoids solenoid impedance diagnostics 24 125 V dc SOE for relay outputs Barrier Yes PDOAH1A 1 PDOAH1B 1 SRLYH1A 12 type C mechanical relays 115 230 V ac 24 48 125 V dc SOE for relay outputs B...

Page 22: ...1 PAICH1B 1 STAIH2A 10 AI V I inputs group isolated and 2 AO 0 20 mA outputs group isolated Box Yes PAICH2A 1 PAICH2B 1 STAIH2A 10 AI V I inputs group isolated and 2 AO 0 20 0 200 mA outputs group isolated Box Yes PAICH1A 1 PAICH1B 1 SAIIH1A 10 AI V I inputs point isolated and 2 AO 0 20 mA outputs group isolated Box No PAICH2A 1 PAICH2B 1 SAIIH1A 10 AI V I inputs point isolated and 2 AO 0 20 0 200...

Page 23: ... EPRI compliance Barrier Yes PTCCH1A 1 PTCCH1B 1 STTCH1A 12 Thermocouples Box No PTCCH2A 1 PTCCH2B 1 STTCH1A 12 Thermocouples with extended range for EPRI compliance Box No PTCCH1A 1 PTCCH1B 1 STTCH2A 12 Thermocouples Box Yes PTCCH2A 1 PTCCH2B 1 STTCH2A 12 Thermocouples with extended range for EPRI compliance Box Yes PRTDH1A 1 2 PRTDH1B 1 2 TRTDH1D 16 RTDs 3 wires RTD 8 per I O pack Barrier Yes PR...

Page 24: ...Box Yes PCNOH1A 1 PCNOH1B 1 SPIDG1A CANopen Master Gateway N A N A PPRFH1A 1 PPRFH1B 1 PROFIBUS DP V0 Class 1 Master Communications PROFIBUS DP V1 Class 1 Master Communications PPRFH1B only N A N A PPNGH1A N A PROFINET RT Version 2 2 I O gateway module maps I O from PROFINETslave devices to the Mark VIe controller on the IONet N A N A PFFAH1A 1 N A FOUNDATION Fieldbus H1 TO HSE Linking Device N A ...

Page 25: ... Box 3 TCATH2A PEFVH1A 1 2 or 3 TEFVH1A Electric Fuel Valve Gateway to Woodward DVP N A PGENH1A 1 or 3 TGNAH1A Used for Power Load Unbalance PLU and has three 1 phase PTs three V I inputs Analog inputs are box type and removable Current transformer CT inputs are barrier type and not removable PVIBH1A PVIBH1B 1 or 3 TVBAH1A TVBAH2A TVBAH1B TVBAH2B Refer to GEH 6721_Vol_II for a complete listing of ...

Page 26: ...e Protection 48 points TPRO_1A Removable Barrier TPRO_2A Removable Box PPROS1B PPROH1A 3 TPROH C 1 SPROH A Backup Turbine Protection 24 points SPROH1A Removable Barrier SPROH2A Removable Box 3 TREAH A Aero derivative Turbine Emergency Trip 48 points H1A H2A Removable Barrier H3A H4A Removable Box These modules have IEC 61508 safety certified functions 26 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe a...

Page 27: ...UCSA used as I O pack controller to interface with dedicated Mark V turbine I O application boards Box No H1A Yes H2A No G1A No G1B PMVD 1 3 DTBA DTBB DTBC DTBD TCRA 96 contact inputs 60 relay contact outputs Box No H1A Yes H2A No G1A No G1B PMVP 3 PTBAG1A PTBAG2A Expansion board TCEB and trip boards TCTE TCTG TCTL TCTS 2 magnetic p u speed inputs 8 flame detector pulse inputs Trip solenoid interf...

Page 28: ...0 20 mA All I O HARTenabled Box No Yes YTCCS1A 1 2 1 2 1 1 TBTCS1B TBTCS1C STTCS1A STTCS2A 12 thermocouple inputs Box Yes Yes No Yes YVIBS1A YVIBS1B 1 3 TVBAS1A TVBAS2A TVBAS2B Refer to GEH 6721_Vol_II for a complete listing of supported inputs TVBAS2A and TVBAS2B include buffered outputs and BNC connectors Box Yes YPROS1A 3 3 3 3 3 3 1 TREAS1A TREAS2A TREAS3A TREAS4A TREGS1B TREGS2B SPROS1A Backu...

Page 29: ...A 12 type C mechanical relays 115 230 V ac 24 48 125 V dc SOE for relay outputs Box No YDOAS1A YDOAS1B 1 SRLYS2A 12 type C mechanical relays 115 230 V ac 24 48 125 V dc Refer to Option Boards Note1 2 and 3 SOE for relay outputs Box Yes YDOAS1A YDOAS1B 1 SRSAS1A SRSAS3A 10 relay outputs Box None Yes No YDOAS1A YDOAS1B 3 TRLYS1F 36 mechanical relays 12 voted type A normally open NO outputs 115 V ac ...

Page 30: ...1 incremental encoder input 1 analog output 20 discrete inputs 2 discrete outputs 9 relay outputs 2 RS 485 interfaces 2 PWM control outputs WEPAH1B AEPAH1B BPPC WPCI WEPAH2A AEPAH1B BPPB WEPAH2B AEPAH1B BPPC WETAH1A WETAH1A BPPB Wind Energy Top Box board A special purpose in 1 5 MW ESS turbine 69 digital inputs 8 are pulse rate counter inputs 18 analog PT100 temperature sensor inputs 2 analog ther...

Page 31: ...utputs 3 solid state relay outputs WEMAH2B WEMA BPPC WECAH1A MACC BPPB Wind power converter interface for the power converter 27 digital inputs 9 relay contact outputs 3 solid state relay outputs SECAH1A MACC BPPB Solar power converter interface for the solar inverter 27 digital inputs 9 relay contact outputs 3 solid state relay outputs Control System Overview GEH 6721_Vol_I_BP System Guide 31 Pub...

Page 32: ...FU6 FU7 FU8 FU9 FU10 FU11 FU12 64G5005 011 FUSE 3 15A 500VAC 400VDC LITTELFUSE 04773 15MXP IS200TRLYS1D FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FU12 64G5005 011 FUSE 3 15A 500VAC 400VDC LITTELFUSE 04773 15MXP IS200WROBH1A FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FU12 64G5005 011 FUSE 3 15A 500VAC 400VDC LITTELFUSE 04773 15MXP IS200WROFH1A FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FU...

Page 33: ... FU6 FU7 FU8 323A2396P250 FUSE 10A 250V SLOW BLOW LITTELFUSE 326010 COOPER BUSSMANN MDA 10 IS200JPDCG1A FU71 FU72 FU73 FU74 FU75 FU76 FU1R FU1S FU1T FU2R FU2S FU2T 64G5005 010 FUSE 10A 500VAC 400VDC TIME LAG SLO BLOW LITTELFUSE 0477010 MXP FU81 FU82 FU83 FU84 FU85 FU86 44A725207 011 FUSE 3 15A 250V FAST ACTING LITTELFUSE 217 3 15 FUAC1 FUAC2 342A4908ABP21 FUSE 10A 250V TIME LAG SLO BLOW LITTELFUSE...

Page 34: ...USE 314015P COOPER BUSSMANN ABC 15 IS200JPDGH2A FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 323A2396P250 FUSE 10A 250V SLOW BLOW LITTELFUSE 326010 COOPER BUSSMANN MDA 10 FU10 FU11 FU12 FU13 FU14 FU15 FU16 FU17 FU18 FU19 FU20 FU21 FU22 FU23 323A2396P96 FUSE 15A 3AB ABC FAST ACTING LITTELFUSE 314015P COOPER BUSSMANN ABC 15 IS200JPDMG1A FU1 FU2 FU3 FU4 FU5 FU6 FU7 FU8 FU9 FU10 FU11 FU12 323A2396P250 FUSE 10A 250...

Page 35: ...ELFUSE 021806 3MXP FU6 342A4908ABP24 FUSE 1 0A 250V 5X20MM COOPER BUSSMANN BK S506 1 R LITTELFUSE 218001 218001MXP 218001P WEMAH1A FU1 342A4908ABP22 FUSE0 315A 250V 5X20MM LITTELFUSE 218 315 218 315H 218 315HXP FU2 FU3 259A9266P16 FUSE SLO B 3 15A 5X20MM 250V COOPER BUSSMANN GDC 3 15A LITTELFUSE 218 3 15 FU6 342A4908ABP24 FUSE 1 0A 250V 5X20MM COOPER BUSSMANN BK S506 1 R LITTELFUSE 218001 218001MX...

Page 36: ...distribution board allows for the optional attachment of a PPDA I O pack for system feedback The PDM can be divided into two substantially different categories the core distribution system and the branch circuit elements They serve as the primary power management for a cabinet or series of cabinets The branch circuit elements take the core output and fan it into individual circuits for consumption...

Page 37: ...t controllers TMR 1 6 1 1 Simplex Controller The simplex control architecture contains one controller connected to an Ethernet interface through the Ethernet network IONet No redundancy is provided and no online repair of critical functions is available Online replacement of non critical I O that where the loss of the I O does not stop the process is possible Each I O pack delivers an input packet...

Page 38: ...en the I O pack will use that packet Note With dual controllers the level of I O reliability can be varied to meet the application needs because not all I O has to be dual redundant The Mark VIe controllers listen for the data on both networks at power on The channel that delivers the first valid packet becomes the preferred network As long as the data arrives on that channel the controller uses t...

Page 39: ...eing re calculated is an internal state variable This principle can be displayed in the following two equations A B C C 3 x D Assume B and D are inputs and A and C are intermediate values Since C is used prior to being calculated the value of C during the previous scan retains some state information Therefore C is a state variable that must be updated in the non designated controller if both contr...

Page 40: ...rk VIe Control System Note The level of I O reliability can be varied to meet the application needs because I O redundancy can be simplex dual or TMR In a TMR control system all three controllers receive inputs from the I O modules on all networks and transmit outputs on their respective IONet continuously If a controller or network component fails the system does not require fault detection or fa...

Page 41: ...rollers at the end of the frame 1 6 2 2 Two Single Pack Single Network 2SPSN I O Modules This configuration is typically used for inputs where there are multiple sensors monitoring the same process points Two sensors are connected to two independent I O modules Redundant sensors Redundant data acquisition Redundant network Online repair Each I O pack delivers input data on a separate network at th...

Page 42: ...from active module are used in the controller Redundant data acquisition Redundant network Online repair The two I O packs are both connected to both networks but only communicates to the controller and the gateway network If a failure occurs on the active I O pack the backup I O pack becomes the active I O pack thus maintaining communication with the connected devices 1 6 2 6 Triple Pack Triple N...

Page 43: ...rk VIe Controller Redundancy Available IONet Topology Simplex One I O pack with one IONet The number of IONets in a system equals the number of controllers Dual One I O pack with two IONets Two I O packs with one IONet per pack Three I O packs with R one IONet to controller R S one IONet to controller S and T two IONets with one to controller R and one to controller S TMR Fanned three packs one IO...

Page 44: ...at is responsible for transmitting outputs all controllers see all IONets The result is that for a simplex input the data is not only seen by the output owner of the IONet it is seen in parallel by any other controllers The benefit of this is that loss of a controller associated with a simplex input does NOT result in the loss of that data The simplex data continues to arrive at other controllers ...

Page 45: ...vide the individual sensor values to the application Median values can be selected in the controller if required This configuration displayed in the following figure is used for special applications only Three Independent Sensors with Common Input Not Voted Control System Overview GEH 6721_Vol_I_BP System Guide 45 Public Information ...

Page 46: ... are brought in as dedicated inputs and SIFT voted The following figure displays this configuration Inputs such as speed control and overspeed are not fanned so there is a complete separation of inputs with no hardware cross coupling which could propagate a failure RTDs thermocouples contact inputs and 0 20 mA inputs can also be configured this way Three Sensors with Dedicated Inputs Software Vote...

Page 47: ...s single ended non redundant outputs from individual I O networks Outputs exist on all three I O networks and are merged into a single output by the hardware Outputs exist on all three I O networks and are output separately to the controlled process This process may contain external voting hardware For normal relays the three outputs feed a voting relay driver which operates a single relay per cha...

Page 48: ...mbined through a 2 3 current sharing circuit that allows the three outputs to be voted to one Failure of a 0 20 mA output is sensed and a deactivating relay contact is opened TMR Circuits for Voted 0 20 mA Outputs 48 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 49: ...vides contingency options for those weak links to obtain higher reliability Users can access the MTBF ratings for their Mark VIeS Safety control system from the Exida exSilentia tool To access Mark VIeS Safety Controls IEC 61508 certificates and assessment reports 1 Go to the Exida website at http www exida com and select Safety Automation Equipment List from the top tool bar 2 Type vies in the Se...

Page 50: ...using two out of three voting are always able to select a valid value when presented with any single failure Depending on the equipment the time required to detect the fault and switch to the new component may be hours minutes seconds milliseconds In the case of fuel flow control to a turbine this is required to be done in milliseconds When a redundant control bypasses a failure it is required tha...

Page 51: ...utput 0 20 mA use a small current sense resistor on the output terminal board This output is read back through a separate A D converter and compared to the commanded value A difference between the commanded and actual value exceeding an acceptable level results in the output being declared in bad health Discrete input opto isolators are periodically forced to an on condition then forced off This i...

Page 52: ...fer to the requisition specific system application documentation control specification if available for redundancy testing procedures Forced Outage Probability versus Time Conventional TMR Forced Outage Probability versus Time Mark VIe TMR 52 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 53: ...the pack declares the communication as being lost Upon loss of communication the pack action is configurable The pack can continue to hold the last commanded value indefinitely or it can be commanded to go to a specified output state The default action is to go to a power down state the same as if the power were removed from the pack Note Refer to specific I O pack documentation in Mark VIe and Ma...

Page 54: ...reement between the prevote logical signals generates an alarm Failure of one of the three voted input circuits has no effect on the controlled process since the fault is masked by SIFT Without a disagreement detector a failure could go unnoticed until a second failure occurs For analog signals comparisons are made between the voted value and each of the three prevote values The delta for each val...

Page 55: ...ating unit 1 7 11 Peer I O In addition to the data from the I O modules there is a class of data coming from other controllers in other cabinets connected through the UDH network For integrated systems this network provides a data path between multiple turbine controllers and possibly the controls for the generator the exciter or the HRSG boiler Selected signals from the controller database can be...

Page 56: ...ed with a gray rectangle Activities that span multiple subsystems identified with a dashed TMR IONet TMR Mark VIe Control I O Start of frame Transmission of outputs from controllers to I O packs Input and state variables copied into variable space in prep for execution of control logic application code Control Logic Time to execute based on quantity and complexity of control blocks Synchronization...

Page 57: ...e full part number that is used to identify the function of the part An example of a board type is Pack Discrete Input A PDIA Part Number The Part Number is the ANSI EIA 649 A National Consensus Standard for Configuration Management Product Identifier that represents a specific version of a printed wiring assembly PWA and consists of all applicable fields specified in the table Product Identifier ...

Page 58: ...s 20 1 or more PCBAs in an enclosure 21 1 or more PCBAs in an enclosure and all PCBAs are coated 5 30 One or more PWAs on a base 31 One or more PWAs on a base and all PCBAs are coated 5 IV Board or Module Type 4 letter mnemonic that describes the function of the PWA V Technology code G Lead through hole components only no surface mount technology H Contains surface mount technology components S Fu...

Page 59: ...SG1A IS210AEPSG B were originally released as un coated IS200 and coated IS210 parts but the un coated parts were never used in the host product As these designs evolve the IS200 level parts are being abandoned and the IS210 level parts are being maintained using the level 00 rules 7 Each functional safety system PWA is certified to meet IEC 61508 and is equivalent in form fit and function to any ...

Page 60: ...UCPA part number Example UCPA Controller Label 60 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 61: ...Example UCSx Controller Label Control System Overview GEH 6721_Vol_I_BP System Guide 61 Public Information ...

Page 62: ...rs can use the ENOVIA PLM tool to search for parts The following Power Generation PLM web portal is available to assist with account registration and training on how to use the tool to search for parts http colab ge com dashboard canvas v 518d03b3bf1d408e570001c9 home 62 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 63: ...uring locations Y Year code one character Refer to the table Year Codes for permitted values M Month code one character Refer to the table Month Codes for permitted values D Day of month code one character Refer to the table Day of Month Codes for permitted values S2S1S0 Serial number count code three characters The total count of unique serial numbers generated for a component is reset to zero ea...

Page 64: ... C 2016 D 2017 E 2018 F 2019 G 2020 H 2021 J 2022 K 2023 L 2024 M 2025 N 2026 P 2027 R 2028 S 2029 T 2030 U 2031 V 2032 W 2033 X 2034 Y 2035 Z Month Codes Month Code January 0 February 1 March 2 April 3 May 4 June 5 July 6 August 7 September 9 October A November C December D 64 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 65: ...th Code 1 0 2 1 3 2 4 3 5 4 6 5 7 6 8 7 9 9 10 A 11 C 12 D 13 E 14 F 15 G 16 H 17 J 18 K 19 L 20 M 21 N 22 P 23 R 24 S 25 T 26 U 27 V 28 W 29 X 30 Y 31 Z Control System Overview GEH 6721_Vol_I_BP System Guide 65 Public Information ...

Page 66: ...Notes 66 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 67: ... is a differentiator in the market because of its significant flexibility easy of control logic development and redundancy capabilities Its safety I O is very flexible in application for example both analog inputs and outputs are available The Mark VIeS Safety control is an engineered solution designed for the customers that work on our systems to help simplify and reduce maintenance costs GE has ...

Page 68: ...e restricted and only used when validated by the SIL application logic The Mark VIeS Safety control was designed and certified to meet functional safety standards according to IEC 61508 Parts 1 through 3 It is certified for use in both high and low demand applications uses redundant architecture configurations and a hardware fault tolerance HFT of 1 to achieve safety integrity level SIL 3 The high...

Page 69: ...sk Reduction Increasing Risk Residual Risk Tolerable Risk Inherent Process Risk Necessary Risk Reduction Actual Risk Reduction To achieve functional safety it is necessary to analyze the potential hazards to personnel and property including any environmental impact that could occur when the control of equipment is lost Requirements for safety function and integrity must be met to achieve functiona...

Page 70: ...tely 104 hours in a year IEC 61508 defines a scale of four distinct levels of risk reduction referred to as the Safety Integrity Level SIL SIL PFDavg Low Demand Mode PFH High Demand Mode RRF 1 10 2 to 10 1 10 6 to 10 5 10 to 100 2 10 3 to 10 2 10 7 to 10 6 100 to 1 000 3 10 4 to 10 3 10 8 to 10 7 1 000 to 10 000 The SIL applies to all elements in the safety loop sensors logic solver and final elem...

Page 71: ...ated controller the common terminal board then performs 2oo3 voting on the outputs and controls the discrete actuator 2oo3 Voting in Actuator TMR Outputs Voted in Actuator Three independent output modules receive the output command from their associated controller then command the actuator 2oo3 voting performed in the actuator TMR Controllers Three Mark VIeS controllers work as a set synchronizing...

Page 72: ...p in Output Modules Two independent output modules receive the output command from designated controller combination of two creates 1oo2 de energize to trip function across the two modules Dual Controllers Dual Mark VIeS controllers work as a controller set synchronizing data every frame sweep Each controller receives inputs on both I O networks and sends output commands on designated I O network ...

Page 73: ...rface options OPC DA server OPC UA server Modbus master Third Party Control System Embedded Controller Gateway Embedded controller for communication interface options OPC UA server Modbus slave Single Sensor Single sensor wired to a single input module with a simplex I O network to controller Sensor A Sensor A1 Sensor A2 Dual Sensor Dual sensors wired to independent input modules with a simplex I ...

Page 74: ...Notes 74 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 75: ...control of the process to the HMIs and out to facility wide monitoring and external networks industrial internet Each network layer uses industry standard components and protocols to simplify integration between different platforms and improve overall reliability and maintenance These layers are designated as IONet Unit Control Supervisory and Enterprise in the following figure which displays a si...

Page 76: ...ctronic Security Perimeter ESP Mark Stat Wind Power Converter Mark VIe Controller R S T TMR I O Modules Simplex I O Modules SIL 3 Functional Safety Monitoring Data Highway Monitoring Layer On Site Monitor OSM Remote Services Gateway RSG Mark VIe HMI Mark VIe Historian SecurityST Cyber Security Management System Printer Customer Network Simplified Network Hierarchy switches not shown 76 GEH 6721_Vo...

Page 77: ...tional layer 3 security hardware infrastructure Network traffic is then regulated by an additional series of routers switches and firewalls The SecurityST appliance can be installed to allow for tighter network security with or without the additional layer 3 security hardware by providing white listing and restricted access to network devices Various options for existing sites are available to imp...

Page 78: ...de Plant Facility GE Demilitarized Zone DMZ To Remote Services Gateway RSG Onsite Monitor OSM Bently etc Layer 3 Security Video Terminal KVM DC2 VH1 DC1 AP1 AP2 AP3 Catalyst 2960 S Series 25 26 27 2 8 M G M T B A S E T CONSOL E STCK SPED D PLX STAT MSTR R PS SYST M OD E 13X 14X 23X 24X 13 14 1 5 1 6 17 18 19 20 21 22 23 2 4 1 2 3 4 5 6 7 8 9 10 11 1 2 1X 2X 11X 12X Catalyst 2960 S Series 25 26 27 ...

Page 79: ...ble located rear Mark VIe HMIs Historians Legend Catal yst 2960 SSer i es 25 26 27 28 M G M T B A S E T CO N SO LE STC K SPED DPLX STA T M STR R PS SYST M O DE 13 X 14 X 23 X 24 X 1314 1516 17181920 2122 2324 12 34 56 78 910 1112 1 X 2 X 11 X 12 X Catal yst 2960 SSer i es 25 26 27 28 M G M T B A S E T CO N SO LE STC K SPED DPLX STA T M STR R PS SYST M O DE 13 X 14 X 23 X 24 X 1314 1516 17181920 21...

Page 80: ...ion Controller Redundancy for more information The IONet provides direct communication between controllers and I O modules IONet EGD protocol which is different than UDH EDG protocol is used The I O modules send their inputs to the controllers and the controllers send their outputs to the I O modules each frame as displayed in the section Rate of Response Examples of IONet traffic are as follows S...

Page 81: ...r 100m 328 ft IONet Maximum Distances Item IONet Specification IEEE specification 802 3u Wire speed 100 Mbps Cable types 100Base TX UTP Cat 5e 100Base FX MMF or SMF Maximum taps per segment 2 Maximum packets per network 199 Maximum number of switches 5 Topology Star For the control system IONet topologies the following rules apply for deploying SMF systems No more than five switches can be placed ...

Page 82: ... 2 ports 100BASE FX LC type connection IS420ESWAH3A 8 ports 10 100BASE TX IS420ESWAH4A 8 ports 10 100BASE TX 1 port 100BASE LX10 LC type connection IS420ESWAH5A 8 ports 10 100BASE TX 2 ports 100BASE LX10 LC type connection IS420ESWBH1A 16 ports 10 100BASE TX 1 port 100BASE FX LC type connection IS420ESWBH2A 16 ports 10 100BASE TX 2 ports 100BASE FX LC type connection IS420ESWBH3A 16 ports 10 100BA...

Page 83: ...ata Mark VIe Controller IONet Switch Communication path between I O packs and controller IONet switches A B A B C D E Communication path between I O packs and controller IONet switches A B C Communication path between I O packs and controller IONet switches A B C D Communication path between I O packs and controller IONet switches A B C D E Note Maximum of 5 IONet switches that Ethernet packets pa...

Page 84: ...d the user must associate the new Host ID to the configured device The ToolboxST application presents a list of unrecognized devices that have requested IP addresses to simplify this process IONets are Class C networks Each is an independent network with different subnet addresses The IONet IP host addresses for the controllers are fixed The IP addresses of the I O packs are assigned by the Toolbo...

Page 85: ...ty loop field devices One TMR redundant IONet Shared IONet Example The owner controller allows for the configuration of the owned I O modules writes outputs reads SOEs and provides diagnostic information Owned I O modules are attached to their owner controller that can configure and write to them and obtain their IP addresses from their owner controller Outputs from controllers are received by the...

Page 86: ... to the controller over the UDH Alarms and capture buffer uploads that feed trip logs are also through the SDI protocol Note Current controls systems network architecture has UDH PDH and MDH connections on a common set of network switches and media trunks The UDH connections to the controllers and HMIs are unshielded twisted pair UTP Cat 5e from edge switches This redundant mesh architecture allow...

Page 87: ...ir category 5e EIA TIA 568 A B Distance is up to 100 m Ethernet 100Base FX with fiber optic cable optional for distances up to 2 km 1 24 mi Number of Nodes At least 25 nodes given a 25 Hz data rate Other configurations may be available Type of Nodes Supported Controllers PLCs operator interfaces and engineering workstations Protocol EGD based on UDP IP Message Integrity 32 bit CRC appended to each...

Page 88: ...ark Stat controller contains specialized firmware and application to control a GE multi megawatt wind turbine power conversion system 3 3 3 2 Human machine Interface The Human machine Interface HMI is the main operator interface to the Mark VIe control system Current Mark VIe HMIs are desktop computers running the Windows 7 operating system with multiple communication drivers for the redundant dat...

Page 89: ...t Ethernet Communication known as the Control Data Highway CDH allows two separate controllers to communicate with each other The second CDH Ethernet can be added to a control system currently using the other UDH Ethernet port The following table displays requirements for hardware setup Note To configure a CDH refer to ToolboxST User Guide for Mark Controls Platform GEH 6700 or GEH 6703 the sectio...

Page 90: ...naged Switch Field Device Output C atalyst2960 S Series 25 26 27 28 M G M T B A S E T CONSOL E STCK SPE D DPLX STAT MSTR R PS SYS T M O DE 13X 14X 23 X 24 X 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 1 0 11 12 1X 2X 11X 12X C atalyst2960 S Series 25 26 27 28 M G M T B A S E T CONSOL E STCK SPE D DPLX STAT MSTR R PS SYS T M O DE 13X 14X 23 X 24 X 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3...

Page 91: ...les from HMI to HMI for example CIMPLICITY projects PDH uses redundant cables to form one single logical network and the mesh architecture is identical to the UDH The hardware consists of edge Ethernet switches with single mode fiber optic trunks connected to root switches then standard Cat 5e outputs to HMIs and other devices Redundant Ethernet switches and cables prevent complete network failure...

Page 92: ...lity completely free of electromagnetic interference EMI and radio frequency interference RFI Large point to point distances are possible and since the cable does not carry electrical charges ground potential problems are eliminated 3 5 Monitoring Layer The monitoring data highway MDH is used to further partition the flow of data to individual assets and can include connection to GE Monitoring and...

Page 93: ...grity and security of the control system establishing a DMZ that terminates the outside networks and then only allows specific authenticated traffic to flow from the DMZ to specific hosts behind the DMZ is recommended GE demilitarized zone DMZ Customer Enterprise Network GE Wide Area Network WAN to ADH Firewall Outside Plant Facility Virtual local area networks VLANs Mark VIe Integrated Control Sy...

Page 94: ...e required runs and simplify the installation Fiber optic connections normally have higher signal levels and decreased chances of packet discard from noise corruption Typical differences in error rate is 10000 lower for fiber optic cables The cost per connection for fiber may now be less than copper cables Large multifiber trunk cables contain many fibers so cost per foot for each connection may a...

Page 95: ...cations Note Refer to the section Mesh Architecture for more information The small form factor pluggable SFP or Mini GBIC is a compact hot pluggable transceiver used in network switch applications It interfaces the network switch to a fiber optic or copper networking cable It is a popular industry format supported by many network component vendors The switches used in the current Mark VIe control ...

Page 96: ...ielded Twisted Pair UTP Copper Cables 3 7 2 1 Cat 5e Cables for PDH UDH MDH These copper cables are used for data highways connections from edge switches to HMIs and controllers High quality category 5e UTP cable for 10 100Base TX Ethernet Four pairs of twisted 22 AWG or 24 AWG wire Protective plastic jacket Impedance 75 165 Ω Connector RJ 45 UTP connector for solid wire 3 7 2 2 Cat 6 Cables for L...

Page 97: ...t the GE field engineer can do any changes to MMF sites Also it is not recommended to use a converter from MMF SC connector to single SMF LC connector as this can cause network latency or introduce an additional failure point Note Refer to the figure in the section SMF and Trunks that displays the LC connector and SFP The options for supporting the new network switch architecture are as follows Re...

Page 98: ...rs to have access to real time data and provides for discrete and analog commands to be passed to the Mark VIe controller The Mark VIe control system can be linked to third parties in several different ways OPC UA direct from the Mark VIe controller UCSC OPC UA DA AE from the WorkstationST server Serial or Ethernet Modbus Slave link from the WorkstationST server Ethernet Modbus Slave direct from t...

Page 99: ...her third party equipment This allows some protocols to be sent directly to the Mark VIe controllers while others must first communicate with the I O module that then interfaces with the controller Other protocols use an HMI with WorkstationST application as a gateway Communication Protocol Across Mark VIe Controls Networks Communication Protocols GEH 6721_Vol_I_BP System Guide 99 Public Informati...

Page 100: ...nST PCs and a master time source NTP operates on both the UDH and IONet networks System Data Interface SDI ToolboxSTconfiguration and monitoring with controllers I O packs and WorkstationST PCs Real time alarm annunciation and management between controllers and WorkstationST Alarm Server Transmission of trip log data from controllers to WorkstationST Alarm Server OPC UA Server Mark VIe controller ...

Page 101: ...OPC UA Server Instruction Guide GEI 100828 ToolboxST User Guide for Mark Controls Platform GEH 6703 for OPC UA configuration from the Mark VIe controller and Mark VIe for OPC DA AE HDA and UA configuration from the WorkstationST server ControlST Software Suite How to Guides GEH 6808 chapters How to Interface to Third Parties Using and How to Configure OPC AE Capability 4 1 1 WorkstationST OPC DA S...

Page 102: ...kstationST OPC AE OPC Alarm and Event AE protocol enables third party OPC AE clients to obtain live alarm and event notifications The server complies with the OPC AE 1 1 specification and has an internal client that can be configured to receive external alarm and event data from external OPC AE servers The following figure illustrates the data flow for a common application WorkstationST OPC AE Ser...

Page 103: ...tems there are multiple historians that are logging the same variable at different frequencies And depending on the situation an OPC HDA client will prefer one historian versus another The HDA server client is designed to support this scenario The following figure illustrates the data flow for an example system around the WorkstationST OPC UA supported functions WorkstationST OPC UA Server Example...

Page 104: ...des the GSM server with the following Periodic reading of variables from Mark controllers Writing of variables to Mark controllers The WorkstationST Alarm server provides the GSM server with the following Alarm and event data from Mark controllers with time resolution equal to the controller frame rate Path for alarm commands from DCS to Mark controllers GSM Server Example 104 GEH 6721_Vol_I_BP GE...

Page 105: ...s initiated or clears Process event occurs Sequence of Event SOE contact input opens or closes Periodic Data consists of variable sets transmitted from the GSM server to DCS either once or periodically rates up to once per second This data is typically used to refresh DCS process display screens Command Requests fall into two classes Process alarm command requests Process command requests either a...

Page 106: ... to the Master upon request In the Mark control systems Modbus is supported in both the controllers and WorkstationST For the Mark VIeS Safety controller only Ethernet Modbus and the Modbus Read command from the Modbus Master is supported Serial Modbus and the Write command is not supported Note Modbus protocol does not provide security against unauthorized commands or interception of data A separ...

Page 107: ... TCP IP stream sockets Note A subset of the Modbus function codes are supported Mark VIe Controller Modbus Communication Protocols Note These diagrams are for informational purposes only to illustrate where Modbus is implemented They do not illustrate how to connect Modbus to your application Communication Protocols GEH 6721_Vol_I_BP System Guide 107 Public Information ...

Page 108: ...Mark VIeS Safety Controller Modbus Communication Protocols 108 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 109: ...ture which displays the revision number of the exchange configuration If the consumer receives data with an unknown configuration signature it makes that data unhealthy If a transmission is interrupted the receiver waits three periods for the EGD message after which it times out and the data is considered unhealthy EGD Communications Features Feature Description Example types of communication Supe...

Page 110: ...vel of Ethernet fault tolerance to the control system Note There are many features that make the Mark VIe control system fault tolerant including the network configuration Unit Data Highway EGD TMR Configuration Similarly with dual redundant controllers each controller receives UDH EGD data independently from a direct Ethernet connection If the connection is broken a controller may request the mis...

Page 111: ...re a separate SDI connection from the controller to each HMI In addition sites with multiple HMIs should limit requests for controller trip logs to be made from only a few HMIs as to not overburden the Mark VIe controller Because EGD does not create a connection per HMI EGD is typically used for live data transfer and to fan data out from controllers to a large number of HMIs SDI is used for live ...

Page 112: ...tions are allowed to local time Historical data is stored with global time to minimize discontinuities 4 6 2 Clock Stratum Note This stratum is different from the clock strata used in telecommunication systems The term Stratum defines the levels in the hierarchy of clocks that makeup NTP Each level is assigned a layer number starting with zero at the top The stratum level defines its distance from...

Page 113: ...n of the response packet is t3 t0 The time the server waited before sending the answer is t2 t1 The offset t1 t0 t2 t3 2 The NTP synchronization is correct when both the incoming and outgoing routes between the client and the server have a symmetrical nominal delay If the routes do not have a common nominal delay the synchronization has a systematic bias of half the difference between the forward ...

Page 114: ...id overshooting the time with large time adjustments NTP uses a system where large adjustments occur quickly and small adjustments occur over time For small time differences less than 128 ms NTP uses a gradual adjustment This is called slewing For larger time differences the adjustment is immediate This is called stepping If the accuracy of the clock becomes too insufficient off by more than 17 mi...

Page 115: ...Guide GEI 100758 Mark VIe Control FF Block Library Instruction Guide CANopen Master Gateway Yes No GEH 6721 Vol II Mark VIe Control CANopen Master Gateway PCNO HART Enabled Analog I O Yes Yes GEH 6721 Vol II Mark VIe HART Enabled Analog Input Output PHRA YHRA GEI 100662 HART Message Server GEH 6821 Device Manager User Guide GEI 100757 WorkstationST Device Manager Gateway Instruction Guide Serial C...

Page 116: ...Notes 116 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 117: ...r Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements CAN CSA 22 2 No 61010 1 12 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements UL 61010 1 3rd Edition Safety Standard for Electrical and Electronic Test Measuring Controlling and Related Equipment General Requirements IEC 60529 Intrusion Prot...

Page 118: ...nameplate examples The customer shall provide an easily accessible external disconnect device for each of the mains supplies near the control cabinet The customer shall provide external 30 A two pole circuit breaker protection for each 120 Vac and 125 V dc mains and 15 A two pole circuit breaker protection for each 240 Vac and 220 V dc mains Circuit breaker can serve as the Disconnect Device if mo...

Page 119: ...al equipment for measurement control and laboratory use EMC requirements IEC 61000 4 2 Electrostatic Discharge Susceptibility IEC 61000 4 3 Radiated RF Immunity IEC 61000 4 4 Electrical Fast Transient Susceptibility IEC 61000 4 5 Surge Immunity IEC 61000 4 6 Conducted RF Immunity IEC 61000 4 11 Voltage Variation Dips and Interruptions 5 3 2 Low Voltage Directive 2014 35 EU Under the conditions spe...

Page 120: ...e Less than 10 of total rms voltages between live conductors for 2nd through 5th harmonic Additional 2 of total rms voltages between live conductors for sum of 6th through 30th harmonic This meets IEC 60204 1 2005 Current The system specification is not per individual equipment Less than 15 of maximum demand load current for harmonics less than 11 Less than 7 of maximum demand load current for har...

Page 121: ... used 5 4 2 Enclosures It is recommended that enclosures not be placed in direct sunlight and locations near heat generating equipment need to be evaluated Since the internal temperature increases from the bottom to the top of the enclosure limiting the temperature at the top is a key design objective Temperature Considerations in Packaging Electronics When selecting an enclosure system for Mark V...

Page 122: ...ed for control equipment and are suitable in many cases for providing sufficient cooling air to internal equipment The application of filters to the air vents is also a common practice and can provide similar Ingress Protection IP rating to a solid door It should be noted however that a filtered cabinet with clogged filters will function like a solid door enclosure and can result in over temperatu...

Page 123: ...ssive temperatures can however limit the life of the equipment With the latest version of BPPC based processor firmware the diagnostic alarm for excessive heating is set at 90 C The equipment should be arranged by following normal wiring practices for separation of high and low levels but in a few cases heat should be considered Some components dissipate more heat than others If there is a signifi...

Page 124: ...ntroduced 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 Note Enclosures can be custom engineered for other locations if desired The preferred location for the control system cabinet would be in an environmentally contr...

Page 125: ...5 C 149 F at 1000 m 3280 8 ft will be rated for 62 6 C 144 7 F at 2000 m 6562 ft 5 4 8 Contaminants The control equipment withstands the following concentrations of corrosive gases at 50 relative humidity and 40 C 104 F Note This meets EN50178 Section A 6 1 4 Table A 2 m Corrosive Gas Concentration Sulfur dioxide SO2 30 ppb Hydrogen sulfide H2S 10 ppb Nitrous fumes NO 30 ppb Chlorine Cl2 10 ppb Hy...

Page 126: ...plications are rated only for operation within an enclosure with ambient temperatures from 30 to 65 C 22 to 158 F With the latest version of firmware the excessive heat diagnostic alarm for BPPC based I O packs is set at 90 C 194 F 5 4 11 Applications in Harsh Environments The Mark VIe control product line is suitable for use in G3 harsh environments as defined in ANSI ISA 71 04 2013 Environmental...

Page 127: ...tional 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 6 1 1 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 mana...

Page 128: ...imarily of elementary diagrams revised to incorporate any revisions or changes made during manufacture and test These are issued when the equipment is ready to ship Revisions made after the equipment ships but before start of installation are sent as Field Changes with the changes circled and dated 6 1 3 Technical Advisory Options To assist the customer GE offers the optional technical advisory se...

Page 129: ... Customer s Conduit and Cable Schedule The customer s finished conduit and cable schedule should include Interconnection wire list optional Level definitions Shield terminations The cable and conduit schedule should define signal levels and classes of wiring refer to the section Cable Separation and Routing This information should be listed in a separate column to help prevent installation errors ...

Page 130: ...mber and case number when identifying the missing or damaged part Attention 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 al...

Page 131: ...corrosive elements such as salt spray or chemical and electrically conductive contaminants Ambient relative humidity from 5 to 95 with provisions to prevent condensation No rodents snakes birds or insects No temperature variations that cause moisture condensation Attention Moisture on certain internal parts can cause electrical failure Condensation occurs with temperature drops of 15 C 59 F at 50 ...

Page 132: ...corporations who receive such information shall be deemed by the act of their receiving the same to have agreed to make no duplication or other disclosure or use whatsoever for any or all such information except as expressly authorized in writing by the General Electric Company GE Energy USA LLC and or its affiliates GE CLASS II INTERNAL CRITICAL GENERAL ELECTRIC COMPANY GE Energy SALEM VA GE PROP...

Page 133: ... I O modules IONet switches power supplies and external loading Power Requirements for Control Cabinets Cabinet Voltage Frequency Current Requirements Large four cabinet turbine control 125 V dc 120 V ac 240 V ac 10 10 10 N A 50 60 Hz 50 60 Hz N A 3 Hz 3 Hz 15 0 A dc Note 1 20 0 A rms Notes 2 4 10 0 A rms Notes 3 4 1 Add 0 5 A dc continuous for each 125 V dc external solenoid powered 2 Add 6 0 A r...

Page 134: ...der test the test equipment s case must be shielded to prevent contact by personnel Be sure to follow the site LOTO and safety practices 6 5 1 Equipment Grounding Equipment grounding and signal referencing have two distinct purposes Equipment grounding protects personnel from risk of serious or fatal electrical shock burn fire and or other damage to equipment caused by ground faults or lightning S...

Page 135: ...per 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...

Page 136: ...er control rooms Bolted grid stringers for cellular raised floors Steel floor decking or grating on line mounted equipment Galvanized steel culvert stock Ferrous metallic cable tray systems Raceway cableway and raceway support systems Embedded steel floor channels Connection of the Protective Earth PE terminal to the installation ground system must first comply with code requirements and second pr...

Page 137: ... armored cables the armor is an additional current carrying braid that surrounds the internal conductors This type cable can be used to carry control signals between buildings The armor carries secondary lightning induced earth currents bypassing the control wiring thus avoiding damage or disturbance to the control system At the cable ends and at any strategic places between the armor is grounded ...

Page 138: ...Grounding Recommendations for Control Cabinet Lineup 138 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 139: ...pers 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 section Cable Separation and Routing This serves as a signal reference structure between remotely connected pieces of equip...

Page 140: ... enclosure to leveling channel front and rear Signal and power levels Refer to section Cable Separation and Routing for guidelines Solid bottom tray Use steel solid bottom cable trays with steel covers for low level signals most susceptible to noise Enclosure and Cable Tray Installation Guidelines 140 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Informati...

Page 141: ...lt in each cabinet bottom providing a separate parallel path for grounding This may require opening ground path jumpers on the power distribution boards and disconnecting wiring at the bottom of the adjacent cabinets By temporarily opening the connection from Functional Earth FE to the building grounding system the installer can confirm if adjacent cabinet connections to ground still exist Once te...

Page 142: ...net this jumper was removed from both of the JPDF power distribution boards Unit specific Grounding Example 2 of 2 142 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 143: ...6 6 1 Signal and Power Level Definitions Signal and power carrying cables are categorized into four defining levels low medium high and power Each level can include classes 6 6 1 1 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 60 mA Digital logic level signals less than 28 V dc 4 to 20 mA current loops Ac signals ...

Page 144: ...ng are specific examples of level H signals used in cabling Contact inputs Relay outputs Solenoid outputs Potential transformer PT and current transformer CT circuits Note Flame detector GM type signals 335 V dc and Ultraviolet detectors are a special category Level HS Special low capacitance twisted shielded pair wiring is required 6 6 1 4 Power Level P Power wiring is designated as level P This ...

Page 145: ...way cables conduit and trays in a way that clearly identify their signal power levels This helps ensure correct level separation for proper installation It can also be useful during equipment maintenance Cables can be marked by any means that makes the level easy to recognize for example coding or numbering Conduit and trays should be marked at junction points or at periodic intervals 6 6 2 Cablew...

Page 146: ...trays are impractical levels L and M can be combined in a common tray if a grounded steel barrier separates levels This practice is not as effective as tray separation and may require some rerouting at system startup If levels L and M are run side by side a 50 mm 1 97 in minimum spacing is recommended Locate levels L and M trays and conduit closest to the control cabinets Trays containing level L ...

Page 147: ...e recommended distances between metal trays and metal conduit carrying cables with various signal levels and the cable to cable distance of conduit and trays Cable Tray and Conduit Spacing Installation Guidelines GEH 6721_Vol_I_BP System Guide 147 Public Information ...

Page 148: ...around high control or level P conduit or trays 6 6 3 4 Conduit Around and Through Machinery Housing Care should be taken to plan level spacing on both embedded and exposed conduit in and around machinery Runs containing mixed levels should be minimized to 1 5 m 5 ft or less overall Conduit running through and attached to machinery housing should follow level spacing recommendations This should be...

Page 149: ...imits are defined by the standard GEH 6721_Vol_II provides and a table with baud rate to maximum distances PFFA Foundation Fieldbus standards for cabling apply SHRA 15 Ω maximum two way cable resistance cable length up to 300 m 984 ft PPRF GEH 6721_Vol_II provides a summary of Profibus cable requirements including a bus length vs data rate table PRTD The eight RTDs can be located up to 300 meters ...

Page 150: ...18 16 18 1 1 974 19 1 31 2 585 22 16 1 5 2 960 24 2 08 4 105 29 14 2 5 4 934 32 3 31 6 532 37 12 4 7 894 42 5 26 10 381 50 10 6 11 841 54 8 36 16 499 65 8 10 19 735 73 13 3 26 248 87 6 16 31 576 98 21 15 41 740 116 4 25 49 338 129 33 6 66 310 154 2 35 69 073 158 42 4 83 677 178 1 50 98 676 198 53 5 105 584 206 1 0 67 4 133 016 239 2 0 70 138 147 245 85 167 750 273 3 0 95 187 485 292 107 211 167 31...

Page 151: ...ated per cable with minimum 85 to 100 coverage shield Protective insulating cover for shield Wire rating 300 V minimum Mutual capacitance between conductors with shield grounded 394 pF m 120 pF ft maximum Capacitance between one conductor and all other conductors and grounded shield 213 pF m 65 pF ft 6 7 4 3 Shielded Twisted Pair STP Cable Rated 300 V Two 18 AWG minimum stranded conductors individ...

Page 152: ...xceed 5 cm 2 in to reduce the high frequency impedance of the shield ground Reducing the length of the pigtail should take precedence over reducing the length of exposed wire within the cabinet Pigtails should not be connected except at the grounding bars provided to avoid loops and maintain a radial grounding system Shields should be insulated up to the pigtail In most instances shields should no...

Page 153: ...trol power circuit breaker s Before handling or connecting any conductors to the equipment use proper safety precautions to ensure all power is turned off Inspect the cabinet components for any damage possibly occurring during shipping Check for loose cables wires connections or loose components such as relays or retainer clips Report all damage that occurred during shipping to GE Product Service ...

Page 154: ... if necessary 5 Check that incoming power 125 V dc 115 Vac 230 Vac is the correct voltage and frequency and is clean and free of noise Make sure the DACA converters if used are set to the correct voltage by selecting the JTX1 115 Vac or JTX2 230 Vac jumper positions on the top of the converter 6 If the installation includes more than one JPDF on an interconnected 125 V dc system the BJS jumper mus...

Page 155: ...F positions as expected 5 Verify that the control power supplies are properly configured 6 If present verify that the DACA is properly configured Check that the power connector is attached for the correct input voltage level 7 Verify that Cat 5e cables for IONet are connected properly from switches ESWA or ESWB to the controllers I O packs and PPDA if present 8 Verify that the Cat 5e cables for UD...

Page 156: ...ming network cable has network traffic I O pack s ATTN LED is on when beginning to boot Once booted the pack will begin to show other indicators I O Packs 156 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 157: ... Controller s Boot LED indicates if the Network IP address has been properly configured Boot LED Installation Guidelines GEH 6721_Vol_I_BP System Guide 157 Public Information ...

Page 158: ...ased I O packs continue to have firmware updates and can be upgraded to the latest version BPPB based safety packs are not supported in firmware version 5 00 or later Firmware versions 5 00 and later are only supporting the BPPC based safety packs Do NOT upgrade BPPB based safety I O packs beyond their compatible firmware versions as listed in GEH 6721 Volumes II and III 6 10 1 BPPC based Mark VIe...

Page 159: ...olboxST application WorkstationST features WorkstationST Alarm Viewer Mark VIe controller firmware PDIA I O pack firmware PDOA I O pack firmware Note A Mark VIe system requires ControlST V04 04 or later to introduce a BPPC based I O pack Refer to the ControlST Software Suite Upgrade Instruction Guide GEI 100694 for detailed instructions on the system upgrade procedure The minimum firmware for a pa...

Page 160: ...4C RTD Input PSCAH1A PSCAH1B V04 07 00C Serial Communication PCNOH1A PCNOH1B V04 06 04C CANopen Master Gateway PPRFH1A PPRFH1B V04 07 01C PROFIBUS Master Gateway PHRAH1A PHRAH1B V04 07 00C HART Analog I O PCAAH1A PCAAH1B V04 07 01C Core Analog I O PCLAH1A PCLAH1B V04 06 04C Core Analog I O Aero PSVOH1A PSVOH1B V04 09 01C Servo Control PTURH1A PTURH1B V04 07 03C Turbine Specific Primary Trip PPRAH1...

Page 161: ...ST Alarm Viewer Mark VIe controller firmware PDIA I O pack firmware PDOA I O pack firmware Note A Mark VIe system requires ControlST V04 04 or later to introduce a BPPC based I O pack Refer to the ControlST Software Suite Upgrade Instruction Guide GEI 100694 for detailed instructions on the system upgrade procedure TMR I O Module Guidelines BPPB based I O packs BPPC based I O pack In a Triple Modu...

Page 162: ...packs the following items are required ControlST V04 04 or later must be installed across the Mark VIe system The correct BPPC based I O pack firmware must be installed on the HMI Auto Reconfiguration feature must be enabled on each Mark VIe controller with associated I O packs Note There are three Mark VIe BPPB BPPC migrations not supported by Auto Reconfiguration The following modules must be ma...

Page 163: ...Guide GEI 100694 Equip system for BPPB to BPPC I O pack migration Is system ControlST version at V04 04 or later Upgrade ControlST version across system to V04 04 or later Has BPPC I O upgrade V05 01 xx been installed Upgrade I O firmware packs across the system Install BPPC I O upgrade V05 01 x across system Yes No No Yes Brings Mark VIe I O pack firmware to a level across system to support BPPC ...

Page 164: ...Notes 164 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 165: ...ral networks and supervisory equipment Should a network malfunction occur local alarm logic time tags and messages are retained in the local controller and are available to operator stations upon restoration of the network In normal operation each unit control communicates its alarm messages and local high resolution time tags to operator stations where they are combined into the overall plant ala...

Page 166: ...m State Transition Messages Composite Alarm Queue constructed from alarm state transition messages Alarm Horn I O Pack I O Pack FF Linking Device FF Device I O Net Ethernet Switch FF Device Switch Foundation Fieldbus I O I O Pack I O Pack Control Network UDH Alarm Queue Application Code Creates Alarms In Alarm Queue Example of the Alarm System Showing Multiple Alarm Display Mechanisms 166 GEH 6721...

Page 167: ...time stamps from third party servers with native Mark VIe alarm data The OPC Alarm and Events AE has typically been used for this purpose but now with ControlST V05 03 or later the newer OPC Unified Architecture UA protocol can be used OPC UA combines the features of OPC DA AE and HDA with the flexibility to include some or all of these features An operator needs to be able to see and react to ala...

Page 168: ...ing a transition in the internal queue A constant load of 100 alarm transitions per second are supported without missing a transition in the internal queue 7 3 Controller Alarm Subsystem The Mark VIe and VIeS controllers contain an embedded alarm subsystem that can handle the following data types Boolean Alarms Analog Alarms not available with Mark VIeS controller Boolean Events Boolean Holds Begi...

Page 169: ... board has its own diagnostics The I O boards have a processor stall timer which generates the signal SYSFAIL This signal lights the red LED on the front panel and queues and alarm The watchdog timers are set at 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 7 4 1 Controller Di...

Page 170: ...status It displays the I O pack s known time stamp which is the time of the first occurrence of the diagnostic Each time the user refreshes the viewer the pack s time stamp is obtained Refer to GEH 6700 ToolboxST User Guide for Mark VIe Control the section I O Diagnostic Viewer 7 4 4 Voter Disagreement Diagnostics Detection VDDD Each I O pack produces diagnostic alarms when it is configured as TMR...

Page 171: ...f Configured Span Engineering Units PPRA Pulse rates Engineering Units PPRO Pulse rates Thermocouples Analogs PT PT CTCT Engineering Units Engineering Units of Configured Span Engineering Units PPYR mA Gap of Configured Span Engineering Units PSVO Pulse rates POS mA Engineering Units Engineering Units of Configured Span PTCC Thermocouples Engineering Units PTUR Pulse rates PT Flame Shaft monitor E...

Page 172: ...ormation analog alarms also have additional information attached to the alarm state relating to those threshold limits such as if the process value is below the LO threshold or above the HI threshold 7 5 2 Process Alarm Development Process Alarms are typically developed in the Mark VIe controller by using the ToolboxST application An application engineer creates Mark VIe application code in Relay ...

Page 173: ...set for Auto Acknowledge The operator can acknowledge the alarm the alarmed Boolean can change to False and the operator can reset the alarm The acknowledge and reset may be accomplished in single keystroke if the auto acknowledge feature is enabled Events and Holds can be created in a fashion that is very similar to that of process alarms Sequence of Events SOEs are created by setting a similar p...

Page 174: ...ion is lost or if there is any question that the client has the correct state the process must be repeated This is the nature of all change detect protocols including those used by OPC the client must first learn the current state before change of state notifications are useful Configuration information about variables including alarmed variables is preloaded into the WorkstationST device by using...

Page 175: ...ot Powering On The following figure provides a decision making flow to aid in troubleshooting power loss to controllers I O packs or IONet switches Warning Follow all site safety requirements and precautions including PPE to diagnose the issue while maintaining power to the enclosure Troubleshooting GEH 6721_Vol_I_BP System Guide 175 Public Information ...

Page 176: ...witches in the OFF position Turn switch to ON Yes No Is there incoming power at the input cable Yes No Is the power distribution board fed incoming power from a power supply No Is there input power from the cable leading to prior distribution board Yes Replace the power distribution board that is directly connected to the I O pack Ethernet switch or controller No No Replace the board Is there powe...

Page 177: ...O pack power connector I O pack failure Some other I O packs on same terminal board have power LED lit or simplex board I O pack power connector I O pack failure Terminal board failure No other I O packs on same terminal board have power LEDs lit Terminal board power Terminal board failure Troubleshooting GEH 6721_Vol_I_BP System Guide 177 Public Information ...

Page 178: ...d to Controller Note Before downloading the controller IP address must be setup Refer to GEH 6808 for more information 178 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 179: ... configured as required should be able to communicate with the controllers Note The Mark VIe control system may not reach a controlling state due to faults in either the I O module the IONet switch or the controller itself A single faulty controller can prevent the other two controllers from reaching a controlling state Perform the following procedures if the controller is not attaining a controll...

Page 180: ...DATA_INITIALIZATION d3 INPUTS_ENABLED d5 EXCH_INITIALIZATION d6 EXCHANGING d7 SEQUENCING d8 STANDBY dA CONTROLLING Perform the following procedures if the controller is stalled at Master Installation state 180 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 181: ...Perform the following procedures if the controller is stalled at DC determination state Troubleshooting GEH 6721_Vol_I_BP System Guide 181 Public Information ...

Page 182: ...ler is stalled at Input Enabled state The following diagram displays the possible causes if the controller is not reaching the controlling state 182 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 183: ... State Designated Controller Determination state If the controller halts before d0 MASTER_INITIALIZATION at power on state the problem could be with the controller If the controller halts at d0 MASTER_INITIALIZATION state the controller may have lost its IP address If the controllers halt at the d1 dc_DETERMINATION state one of the controllers may be unable to communicate to either IONet 1 2 or 3 ...

Page 184: ...le to Download to I O Modules Perform the following procedures if you are unable to download to I O packs 184 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 185: ... the Component Editor select the Hardware tab and right click on the I O pack with a red X 3 Select View Diagnostics Note In TMR I O modules the diagnostic displays for the faulty module only I O Pack Communication Troubleshooting Condition Potential Problem Other I O packs on same IONet switch still communicating I O pack power Ethernet cable from I O pack Incomplete downloads to pack or controll...

Page 186: ... the controllers and the I O packs Firmware download to the controllers could be interrupted due to issues related to incorrect library references The Model Predictive Control MPC block libraries are not supported by the UCSA UCSB UCSC controller Therefore if the application is configured for the UCSA UCSB UCSC controller and the MPCBlockLib is used as a reference library the firmware download is ...

Page 187: ...the module Communication Troubleshooting Condition Potential Problem No other I O packs on same IONet switch are losing communication I O pack power I O pack communication diagnostic Incomplete downloads Improper ToolboxSTconfiguration I O pack failure Some other I O packs on same IONet switch are losing communication I O pack power I O pack communication diagnostic Incomplete downloads Improper T...

Page 188: ...Accessories Communications and HyperTerminal Note HyperTerminal is not included in Windows 7 Note The serial cable between the computer COM port and the controller COM port must be connected 188 GEH 6721_Vol_I_BP GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 189: ...olve Communication Errors Download Errors Active Diagnostics Mismatched Revision Note If one I O pack has different diagnostics than the other two in a TMR set it is typically due to an incomplete download or mismatched revision If neither of these issues can be resolved try replacing the I O pack with a new one of the same hardware form as the other two in the TMR set Troubleshooting GEH 6721_Vol...

Page 190: ... Diagnostics Verify that the terminal board bar code configured in the ToolboxST configuration matches the actual hardware Verify that the terminal board type including HW Form in the ToolboxST configuration matches the terminal board in the actual I O module Verify that the network cables and switches to the I O module are plugged in correctly and that the Link and Activity LEDs are active To vie...

Page 191: ...T configuration and the hardware form of the actual I O module To correct a hardware form mismatch between the I O module and the ToolboxST configuration 1 From the Mark VIe Component Editor Hardware tab right click the affected I O module and select Modify Troubleshooting GEH 6721_Vol_I_BP System Guide 191 Public Information ...

Page 192: ... perform the download again When the download has completed successfully open the Download wizard and verify that all I O modules are equal display green Check the InfoView log and resolve any Communication Errors 8 9 3 Active Diagnostics If the Warning symbol displays on an I O module I O module has active diagnostic alarms Firmware and or application revisions in the I O module do not match the ...

Page 193: ...ad to the I O module When the Download is complete wait for the I O module to go online and verify that all revisions are equal Attention If the configuration being downloaded contains I O modules with different module IDs than the configuration currently running the download may install incorrect firmware to some I O modules If this occurs make sure the controller is running the new configuration...

Page 194: ...f control power Green LED labeled LINK is provided for each Ethernet port to indicate that a valid Ethernet connection is present Yellow LED labeled TxRx is provided for each Ethernet port to indicate when the pack is transmitting or receiving data over the port Red LED labeled ATTN indicates pack status with the following conditions LED off no detectable problems with the pack LED solid on a crit...

Page 195: ...re of data flow when bytes per second CIMPLICITY Operator interface software configurable for a wide variety of control applications Configure To select specific options either by setting the location of hardware jumpers or loading software parameters into memory Control Data Highway CDH Redundant Ethernet communication network allows two separate controllers to communicate with each other Cyclic ...

Page 196: ...d to perform part of an application program Macros can be saved and reused Modbus A serial communication protocol developed by Modicon for use between PLCs and other computers Module A collection of tasks that have a defined scheduling period in the controller Multicast The delivery of a message or Information to a group of destination computers simultaneously in a single transmission from the sou...

Page 197: ...bit errors Note that control also uses output hardware voting TCP IP Communication protocols developed to inter network dissimilar systems It is a de facto UNIX standard but is supported on almost all systems TCP controls data transfer and IP provides the routing for functions such as file transfer and e mail ToolboxST A Windows based software package used to configure the control systems exciters...

Page 198: ...Notes 198 GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

Page 199: ...ility Directive EMC 119 Elevation 125 Environment 119 Operating 124 Ethernet Global Data EGD 109 F Forcing 55 Frequency Variations 120 G Grounding 134 Notes 139 System 135 Guidelines Cableway Spacing 145 H Harmonic Distortion 120 Historian 89 Human machine Interface HMI 88 I I O Peer 55 Wiring 152 Installation 127 Support Drawings 134 L Line Variations 120 Low Voltage Directive 119 M Median Value ...

Page 200: ...Voltage 120 T Terminal Board 17 Two Out of Three Logic 54 V Vibration 125 Voltage Unbalance 120 Voting 53 W Wire Sizes 150 200 GEH 6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information ...

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