GEH-6721_Vol_III_BJ
Mark* VIe and Mark VIeS Control Systems
Volume III: For GE Industrial Applications
Dec 2018
Non-Public Information
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.
Non-Public Information – This document contains proprietary information that belongs to the General Electric Company
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 or the information it contains shall not be copied or reproduced in whole or in part or
disclosed to any third party without the express written consent of GE.
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 statutory warranty of merchantability or fitness for
particular purpose.
For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales
Representative.
Revised: Dec 2018
Issued: March 2009
© 2009 – 2018 General Electric Company.
___________________________________
* Indicates a trademark of General Electric Company and/or its subsidiaries.
All other trademarks are the property of their respective owners.
We would appreciate your feedback about our documentation.
Please send comments or suggestions to controls.doc@ge.com
Non-Public Information
Document Updates
Revision
Location
Description
Acoustic Monitoring Input PAMC
processor updates, new Compatibility section, new parameters, new Phase Delta
Updates to incorporate BAPB by replacing instances of BAPA with BAPx, UCSA
Calculation, Specifications table updates, and SAMB configuration, signal, and
Module
parameter modifications
Updates to incorporate BAPB by replacing instances of BAPA with BAPx
BJ
PAMC Acoustic Monitoring Input
Updated all alarm numbers for 3000 range
Module PAMC Specific Alarms
Added new alarm 3037
Removed deprecated alarms 3216–3222
Corrections made to the TREASS1A and TREAS3A Output Contacts 125 V dc and
PPRO Compatibility
24 V dc Trip Board Compatibility values
PSVO Servos Configuration
Added an Attention statement notifying users to not run the coil ohm calculation for
PSVP Configuration
Inlet Guide Vane or Variable Stator Vane servo loops
Added content in the following sections for the Rate-based Overspeed (RBOS)
feature:
•
Protective Functions: new section with available protective functions for YSIL
(references to PPRO chapter for details)
•
YSIL Configuration Parameters: added RBOS parameters
•
YSIL Configuration RBOS Parameter Restrictions: new section with restrictions
•
YSIL Configuration Variables Vars_Speed: added RBOS variables
YSIL Core Safety Protection Module
BH
PPRA, PPRO, and YPRO Shaft
Speed Accel, Decel, and Zero
Contacts (used on TREG, TRES,
Correction to Zero_Speed logic in the drawing Speed State Boolean Values
Updated the available selections in the Choices column for the TripMode parameter
TREL)
YSIL, WCSA 4–20 ma Inputs
Added a Caution statement that connecting AIx_P24V to AIx_20MA could damage
the circuit
Added content in the following sections for the Rate-based Overspeed (RBOS)
feature:
•
PPRO
BG
Firmware Overspeed Trip: replaced the diagram Firmware Overspeed, and
added functionality
•
Rate-based Overspeed Trip (RBOS): new section with functional description
•
Configuration Parameters: added RBOS parameters
•
RBOS Parameter Restrictions: new section with restrictions
•
Variables Vars-Speed: added RBOS variables
•
Alarm 132: RBOS detection not supported alarm
•
Shaft Speed Accel, Decel, and Zero: added acceleration calculation
Updated content in the Thermocouple Inputs table for Cold Junction temperature
reading accuracy, including the following sections to accompany the table
specifications:
•
Cold Junction Accuracy Scenarios provides details on three scenarios for SCSA
I/O configuration
•
Cold Junction Internal or Remote Configuration informs the user of the option to
use either the internal Cold Junction sensor with the accuracy specification or
read the Cold Junction temperature from the controller using the System Output
variables, CJRemote_R,S,T
YSIL Thermocouple Inputs
System Guide
GEH-6721_Vol_III_BJ
Non-Public Information
3
Revision
BG
Location
Description
YSIL TCSA + WCSA Core Protection
Updated the TCSA Contact Input Specifications V dc values from 32 to 140 V dc in
Terminal Board TCSA Contact Inputs
the section
YSIL Speed Repeater Outputs
YSIL
BF
YPRO
TTURH#C, S1C TMR Primary
Turbine Protection Terminal Board,
Specifications
BE
Corrected the Shipping and Storage temperature to -40 to 85°C (-40 to 185 °F) in the
YSIL I/O Pack Specifications table
Corrected the Storage temperature to -40 to 85°C (-40 to 185 °F) in the YPRO
Specifications table
Updated the TTUR Specification table, the Number of Outputs specification, to
include close and open values
YSIL
Added Output Bits
PPRO, YPRO, PPRA
Updated the description for the LedDiags parameter.
UCSA
Moved the information about this Mark VIe controller platform into GEH-6721_Vol_II
PCMI
Moved the information about this Mark VI VME rack gateway to the Mark VIe
controls into GEH-6830
YSIL
Added the missing TripMode Parameter to the TCSA Contracts configuration.
PAMC
Dual configuration can use either IONet port
PPRA, PPRO, YPRO
Updated the section, Hardware Overspeed Trip to include the Speed Pulse Counter
YSIL Specific Alarms
Updated the solutions for Alarm IDs 2458-2473, 2490 with instructions to unlatch
PTUR
Updated the specification for Speed sensor accuracy
PCAA
Updated the following regulator diagrams: Liquid Fuel, Position, Speed Ratio, and
Liquid Fuel with Position
PPRA, PPRO, and YPRO
Updated the figure Steam Turbine Trip Signals
TRES
Updated the figure TRES Terminal Board, Trip Interlocks, and Trip Solenoids
YPRO
BC
Corrected the configurations listed as supported speed repeater outputs for TB2 of
WCSA
Updated figure YPRO Speed Difference Detection, the parameter description for
OS_Diff, and the figure YPRO Contract Input E-Stop
PPRO and PPRA
Updated the figure Speed Difference Detection
YSIL Core Safety Protection Module
New chapter added to provide details for the YSIL module
TREA_#A
Updated the figure TREA_1A Trip Relays (PPRO, YPRO)
PPRA
Updated the figure in the section Trip Input
PPRO
Cycle-power after a hardware overspeed trip is no longer required
The following component’s specification was expanded to be -40 to 70°C for ambient
Various
temperate rating: PCAAH1B, PCLAH1B, PPRAH1B, PPROH1B, PSVOH1B, and
PTURH1B
4
TPRO
Updated the figure TPRO_#C Board Layout
PAMC
Updated the figure Dual Acoustic Monitoring
PPRO and YPRO
Updated the figure in the section K25 Relay Algorithm
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Safety Symbol Legend
Indicates a procedure or condition that, if not strictly observed, could result in
personal injury or death.
Warning
Indicates a procedure or condition that, if not strictly observed, could result in damage
to or destruction of equipment.
Caution
Indicates a procedure or condition that should be strictly followed to improve these
applications.
Attention
GEH-6721_Vol_III_BJ System Guide 5
Non-Public Information
Control System Warnings
To prevent personal injury or damage to equipment, follow all equipment safety
procedures, Lockout Tagout (LOTO), and site safety procedures as indicated by
Employee Health and Safety (EHS) guidelines.
Warning
This equipment contains a potential hazard of electric shock, burn, or death. Only
personnel who are adequately trained and thoroughly familiar with the equipment
and the instructions should install, operate, or maintain this equipment.
Warning
Isolation of test equipment from the equipment under test presents potential electrical
hazards. If the test equipment cannot be grounded to the equipment under test, the
test equipment’s case must be shielded to prevent contact by personnel.
Warning
To minimize hazard of electrical shock or burn, approved grounding practices and
procedures must be strictly followed.
To prevent personal injury or equipment damage caused by equipment malfunction,
only adequately trained personnel should modify any programmable machine.
Warning
Warning
6
GEH-6721_Vol_III_BJ
Always ensure that applicable standards and regulations are followed and only
properly certified equipment is used as a critical component of a safety system. Never
assume that the Human-machine Interface (HMI) or the operator will close a safety
critical control loop.
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Contents
1 PAMC Acoustic Monitoring Input Module .................................................................................. 9
1.1 Acoustic Monitoring Input (PAMC) Module .................................................................................................9
1.2 PAMC Specific Alarms........................................................................................................................... 29
1.3 SAMB and BAPx Acoustic Monitoring Input.............................................................................................. 33
2 PCAA Core Analog Module.......................................................................................................... 39
2.1 PCAA Core Analog I/O Pack ................................................................................................................... 39
2.2 PCAA Specific Alarms ........................................................................................................................... 85
2.3 TCAT Core Analog Terminal Board .......................................................................................................... 97
2.4 JGPA Ground and Power Board...............................................................................................................104
3 PCLA Core Analog Module — Aero .........................................................................................107
3.1 PCLA Core Analog I/O for Aero .............................................................................................................107
3.2 PCLA Specific Alarms ..........................................................................................................................128
3.3 SCLS Core Analog Terminal Board..........................................................................................................136
3.4 SCLT Core Analog Terminal Board..........................................................................................................148
4 PEFV Electric Fuel Valve Gateway...........................................................................................157
4.1 PEFV Electric Fuel Valve Gateway Pack...................................................................................................157
4.2 PEFV Specific Alarms...........................................................................................................................160
4.3 TEFV Electric Fuel Valve Terminal Board.................................................................................................161
5 PGEN Turbine Generator Monitor ............................................................................................163
5.1 PGEN Turbine-Generator Monitor I/O Pack...............................................................................................163
5.2 PGEN Specific Alarms ..........................................................................................................................173
5.3 TGNA Turbine-Generator Monitor Terminal Board .....................................................................................176
6 PPRA Emergency Turbine Protection.....................................................................................183
6.1 PPRA Emergency Turbine Protection I/O Pack...........................................................................................183
6.2 PPRA Specific Alarms...........................................................................................................................217
6.3 TREA and WREA Turbine Emergency Trip ...............................................................................................232
7 PPRO, YPRO Backup Turbine Protection ..............................................................................245
7.1 Mark VIe PPRO Backup Turbine Protection I/O Pack..................................................................................245
7.2 PPRO Specific Alarms...........................................................................................................................291
7.3 Mark VIeS YPRO Backup Turbine Protection I/O Pack ...............................................................................302
7.4 YPRO Specific Alarms ..........................................................................................................................339
7.5 TPRO_#C TMR Backup Protection Terminal Board....................................................................................347
7.6 SPROH#A, S1A Simplex Backup Protection Terminal Board........................................................................354
7.7 TREAH#A, S#A Aeroderivative Turbine Trip Board ...................................................................................359
7.8 TREGH#B, S#B Gas Turbine Trip Board ..................................................................................................369
7.9 TREL Large Steam Turbine Trip Board ....................................................................................................376
7.10 TRES Small Steam Turbine Trip Board.....................................................................................................381
8 PSCH Specialized Serial Communication..............................................................................387
8.1 PSCH Specialized Serial Communication I/O Pack .....................................................................................387
8.2 PSCH Specific Alarms...........................................................................................................................393
8.3 Simplex Serial Communication Input/Output (SSCA)..................................................................................397
9 PSVO Servo Control Module .....................................................................................................399
9.1 PSVO Servo Control I/O Pack.................................................................................................................399
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9.2 PSVO Specific Alarms ..........................................................................................................................417
9.3 TSVC Servo Input/Output Terminal Board ................................................................................................431
10 PSVP Servo Control – Steam ..................................................................................................441
10.1 PSVP Servo Control I/O Pack for Steam ...................................................................................................441
10.2 PSVP Specific Alarms ...........................................................................................................................491
10.3 SSVP Servo Input/Output Terminal Board.................................................................................................503
11 PTUR, YTUR Turbine Specific Primary Trip.........................................................................513
11.1 Mark VIe PTUR Primary Turbine Protection I/O Pack .................................................................................513
11.2 PTUR Specific Alarms ..........................................................................................................................541
11.3 Mark VIeS YTUR Primary Turbine Protection I/O Pack...............................................................................548
11.4 YTUR Specific Alarms..........................................................................................................................573
11.5 TTURH#C, S1C TMR Primary Turbine Protection Terminal Board................................................................579
11.6 STURH#A Simplex Primary Turbine Protection Terminal Board ...................................................................586
11.7 TRPA_#A Aeroderivative Turbine Primary Trip Board ................................................................................596
11.8 TRPG_#B Gas Turbine Primary Trip Board ...............................................................................................609
11.9 TRPL Large Steam Turbine Primary Trip Board .........................................................................................615
11.10TRPS Small Steam Turbine Primary Trip Board ........................................................................................620
12 YSIL Core Safety Protection Module.....................................................................................625
12.1 YSIL Overview ....................................................................................................................................625
12.2 Mark VIeS YSIL Core Protection I/O Pack................................................................................................629
12.3 YSIL Specific Alarms ...........................................................................................................................649
12.4 TCSA + WCSA Core Protection Terminal Board ........................................................................................666
12.5 SCSA I/O Expansion Board....................................................................................................................689
13 Application-specific Functions ..............................................................................................699
13.1 Mark VIeS Safety Controller Black Channel ..............................................................................................699
13.2 Mark VIe PAIC Compressor Stall Detection ..............................................................................................699
13.3 PIOA ARCNET Interface Module ...........................................................................................................703
14 Remote Services ........................................................................................................................705
14.1 On-Site Monitor (OSM) .........................................................................................................................705
14.2 OnSite Support* Remote Services Gateway (RSG) .....................................................................................705
15 Legacy Equipment .....................................................................................................................707
15.1 UCCx Controllers .................................................................................................................................707
15.2 IONet Switches and SMF .......................................................................................................................725
15.3 PAMB Acoustic Monitoring ...................................................................................................................726
16 Replacement ...............................................................................................................................727
16.1 Replacement Procedures ........................................................................................................................727
16.2 Ordering Parts......................................................................................................................................735
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1 PAMC Acoustic Monitoring Input
Module
1.1 Acoustic Monitoring Input (PAMC) Module
The Acoustic Monitoring Input (PAMC) module supports combustion dynamics for heavy-duty gas turbines. The PAMC is
the Analog Processor board (BAPA or BAPB) and the Acoustic Monitoring terminal board (SAMB) grouped together as an
application sub-assembly, with the UCSAH1A controller.
The UCSA controller is a processor that mounts as a stand-alone LAN module and serves as the PAMC processing engine.
The UCSA controller was selected for acoustic monitoring because it provides the additional processing capacity required for
the fast Fourier transform (FFT) analysis, frequency search function, and sensor diagnostics. The BAPx receives dynamic
pressure data from the SAMB. The analog signal is conditioned to remove dc bias and amplify ac content (to maximize
resolution) before it is digitized by an analog-to-digital (A/D) converter. A field programmable gate array (FPGA) sequences,
digitizes, and filters the dynamic pressure signals and controls the high-speed serial link (HSSL) protocol for the Ethernet link
between the BAPx and the UCSA controller.
Note References to BAPx can indicate either BAPA or BAPB.
Two versions of the PAMC module are available: Simplex and Dual.
PAMC Acoustic Monitoring Input Module
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Dual PAMC Configuration
The SAMB terminal board fans all 18 inputs to each BAPx. The BAPx 1 (left processor) communicates with the UCSA
controller through the IONet R connection. The BAPx 2 (right processor) communicates with the UCSA through the IONet S
connection. Either IONet port (ENET1 or ENET2) can provide IONet as long as it is configured correctly in the ToolboxST
application. The controller’s application code votes which PAMC data to use, based on the signal health.
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Simplex PAMC Configuration
Controller application code is not required to vote signals from the PAMC. The PAMC connects to either the PCB-based
charge amplifiers or an Encore-based Charge Converter Signal Amplifier (CCSA).
1.1.1 Compatibility
The PAMC is comprised of the UCSAH1A controller, which executes the firmware, and one of two supported Analog
Processor boards.
Analog Processor Compatibility
Analog Processor Board
Minimum Firmware Version
Minimum ControlST Version
IS210BAPAH1A
IS410BAPBH1A
V04.06
V05.06
V04.06
V07.04
The PAMC also supports the Acoustic Monitoring terminal board (SAMB) with Simplex or Dual redundancy.
Acoustic Monitoring Terminal Board Compatibility
Terminal Board
Description
SAMBH1A
Terminal board that supports 18–channel CCSA or PCB charge amplifier inputs.
Fans signals to one or two BAPx Analog Processor boards for Simplex or Dual
redundancy.
1.1.2 Installation
Only a qualified GE technician should install the PAMC signal space inputs. For the ToolboxST procedures to add the PAMC
I/O module and configure the IP address, refer to the ToolboxST User Guide for Mark Controls Platform (GEH-6700), the
chapter Special I/O Functions.
PAMC Acoustic Monitoring Input Module
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1.1.3 Operation
The PAMC provides the following features:
•
Signal conditioning for up to 18 combustion dynamic pressure inputs:
GE Encore-based Charge Converter Signal Amplifier (CCSA) or PCB Piezotronics® charge amplifier for heavy-duty
turbines are supported
− Differential inputs and adjustable gains
− Fast synchronous-sampled A/D with 16x over-sampling
− FPGA pre-processor with finite impulse response (FIR) filters
− Configurable high pass filter prior to FFT stage to eliminate dc bias
− Open wire detection
Analysis capability per channel:
−
•
−
−
−
−
−
−
−
−
−
Windowed FFT analysis
Rolling average per bin
50/60 Hz rejection filters
Frequency band search function providing maximum peak detection for six different frequency bands
Maximum peak detect for each frequency band
Average channel peak-to-peak amplitudes per frequency band
Alarm detection if peak-to-peak amplitude exceeds configurable level for each frequency band
List capture for all 18 channels if alarm is detected or user requests capture
Phase delta calculation is performed on adjacent channels by showing relative phase difference channel to channel
1.1.3.1
UCSA Controller
The UCSAH1A controller provides the following features:
•
•
•
High-speed processor with random access memory (RAM) and flash memory
Two fully-independent 10/100 Ethernet ports with connectors Enet1 and Enet2 for connecting to the main controllers'
IONet ports.
Three fully-independent high-speed serial link ports with connectors R/SL1, S/SL2, T/SL3.
Note Only R/SL1 is used in the PAMC for connecting to a BAPx Analog Processor board.
•
•
•
•
•
One universal asynchronous receiver-transmitter (UART) type serial port with RJ-45 connector
Hardware watchdog timer and reset circuit
Status-indication LEDs
Electronic ID
CompactFlash® support
The UCSA controller connects to the BAPx through the R/SL1 high-speed serial link (HSSL) interface. The PAMC is
designed so that the UCSA and the BAPx can be located in different locations (up to 100 m, 328.08 ft of HSSL cable length).
Each module can be powered independently. At power up, the BAPx waits for the UCSA to initiate communications. After
communication is established, the application FPGA is programmed.
The processor application code contains the logic to allow a UCSA to operate on one or two IONet inputs. When using two
IONet inputs, both network paths are active at all times. A failure of either network does not disturb I/O pack operation and is
indicated through the working network connection. This arrangement is more tolerant of faults than a classic hot-backup
system in which the second port is only used after a primary port failure is detected. The Ethernet ports on the UCSA
auto-negotiate between 10 and 100 mbps speed, and between half-duplex and full-duplex operation.
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Mark VIe and VIeS Control Systems for GE Industrial Applications
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1.1.3.2
Auto-Reconfiguration
For details, refer to GEH-6721_Vol_II, the chapter Common Module Content, the section Auto-Reconfiguration.
Attention
1.1.3.3
When replacing a PAMC or PMVE, the Auto-Reconfiguration process will not
function properly unless the existing CompactFlash® board from the UCSA being
replaced is removed and installed into the new UCSA. If a new or blank
CompactFlash board is used, complete the procedure to setup the PAMC for IONet
communication. Refer to the ToolboxST User Guide for Mark Controls Platform
(GEH-6700), the chapter Special I/O Functions.
Acoustic Monitoring Firmware
The acoustic monitoring firmware supports 18 input channels. The main features are:
•
RMS Broadband Calculation – Calculates the broadband root-mean-square (RMS) energy of the time-domain sampled
data in the frequency range of 0 to 5000 Hz. The output is the input of the RMS Scan Average.
RMS Scan Average – Average multiple scans of broadband RMS values. A scan is defined by the amount of
time-domain sampled combustion data to calculate a windowed FFT of some defined length. The output is the system
input, SIGx (where x is the channel number), passed to the controller.
High Pass Filter – A configurable high pass filter is run on the time-domain data to filter out any dc component of the
signal prior to the FFT.
Windowed FFT – Calculates the frequency domain peak-to-peak magnitude and bin frequency, based on time-domain
sampled combustion input data. The configuration defines the type of FFT window function used, the FFT length
(amount of input data collected for the calculation), and the sample frequency. The output feeds the Peak-to-Peak Scan
Average.
Peak-to-Peak Scan Average – Provides a frequency domain peak-to-peak magnitude average per frequency bin, over
multiple scans. The configuration defines the number of scans used in the rolling average calculation. The output is the
input for the Six-Band Sort function.
•
•
•
•
•
Six-Band Frequency Search – Average frequency domain peak-to-peak data is divided into six separate frequency
bands (refer to the following table).
Frequency Bands
Frequency Band Number
Configuration Band Name
1
Low (Low)
2
Middle (Mid)
3
High (High)
4
Low Low (LoLo)
5
Trans (Trns)
6
Screech (Scrch)
PAMC Acoustic Monitoring Input Module
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The maximum of the average peak-to-peak magnitudes from each frequency band and its corresponding frequency bin are
selected and output as system inputs for the controller.
•
•
•
•
Band n Average – Calculates the average peak-to-peak magnitude over all enabled healthy input channels, based on the
output of the Six-Band frequency search.
Band n Maximum – Calculates the maximum peak-to-peak magnitude over all input channels enabled, based on the
Six-Band frequency search. The six frequency band maximums are output for use by the controller.
Band n Limit Check – A frequency band limit check based on the Band n Maximum output data.
Phase Delta Calculation – Calculates the difference in phase between two adjacent channels at the selected peak
frequency. Up to three frequency bands may be selected for the phase delta calculation across all enabled channels.
Acoustic Monitoring Block Diagram
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Mark VIe and VIeS Control Systems for GE Industrial Applications
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1.1.3.4
Acoustic Monitoring Parameters
Can Overlap?
Bands that Can Be
Overlapped
LowLow_EndPt
Yes
Low
LowMid_BrkPt
No
N/A
LowMid_BrkPt
MidHi_Brkpt
No
N/A
MidHi_Brkpt
HiScrchBrkPt
Scrch_EndPt
No
N/A
No
Scrch_EndPt
Yes
N/A
Low, Mid, High
Trns_EndPt
Yes
Low, Mid, High, Screech
Band Name
Start Frequency
End Frequency
Low-Low
LowLowStrtPt
Low_StrtPt
Low
Mid
High
Screech
HiScrchBrkPt
Scrch_StrtPt
Transverse
Trns_StrtPt
All bands may be placed contiguously, as displayed in the following figure.
The Transverse band may have a frequency range that overlaps with the Low, Mid, High, or Screech band range by placing its
endpoints within the range of those bands. When Transverse overlaps another band, a keep out area of T_FilWidth Hz is
employed on both sides of the frequency at which Transverse has discovered its peak amplitude, preventing the overlapped
band from discovering the same peak amplitude. When the parameter Trns_Bnd_Enb is disabled and the Transverse band is
overlapping another band, Transverse’s frequency search will not take place. If the Transverse band is not overlapping, Trns_
Bnd_Enb is ignored.
When contiguous, the Screech band’s endpoint is HiScrchBrkPt. When Screech_Overlap_Enb is set to Enable, the
configuration parameter Scrch_StrtPt becomes the new start frequency value and allows for the Screech band to be placed
within the Low, Mid, or High band. When Screech overlaps another band, a keep out area of T_FilWidth Hz is employed on
both sides of the Screech band peak, preventing the frequency search from finding the same peak in the overlapped band.
Note Both Transverse band and Screech band can overlap another frequency band at the same time.
PAMC Acoustic Monitoring Input Module
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The Low-Low band’s independent endpoints allow it to have a frequency range that overlaps with the Low band’s. The
Low-Low band end frequency may not exceed the Low band’s and it must have a start frequency that is less than or equal to
the Low Band’s. The Low-Low band does not employ a keep out area around the combustion peak when overlapping the Low
band
1.1.3.5
A/D Compensation
The A/D compensation function eliminates any gain or offset error due to initial component inconsistency. An
auto-calibration function runs each time the module is reset. The auto-calibration function compares each of the 18 analog
channels against a standard A/D channel. This A/D channel is calibrated using a standard high-precision voltage reference
and the A/D common.
1.1.3.6
Dynamic Pressure Probe to PAMC Signal Scaling
The signal flow from the dynamic pressure probe to the signal-space inputs involves the following three steps:
1.
Probe converts the combustion dynamic pressure in psi to a charge output in pico-coulombs (pC).
2.
Either the CCSA or the PCB charge amplifier converts the charge output of the probe to a voltage in millivolts.
Note The CCSA signal (InputUse is set to CCSA) is 0 V dc and 0 V ac when the dynamic pressure is 0 psi. The PCB charge
amplifier signal (InputUse is set to PCB) is 12 V dc and 0 V ac when the dynamic pressure is 0 psi.
3.
The PAMC removes the dc bias portion of the signal (as specified by the input type) before the digitization of the
dynamic pressure signal. PAMC offers an internal gain feature to improve the A/D resolution of the signal. Additionally,
a high pass filter (enabled by setting HPF_Enable to Enable) will eliminate any residual dc component of the signal.
The configuration parameter, InputUse, determines the scaling method used to convert the voltage input to useful Engineering
Units, for example psi.
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Scaling CCSA and Custom Inputs
When InputUse is set to CCSA, Custom, and File, the configuration parameters used for input scaling are as follows:
•
•
Low_Input and High_Input (mVpk-pk)
Low_Value and High_Value (Engineering units [psipk-pk])
Given that 0 V= 0 psi, and a 5 psipk input with a Probe Sensitivity of pC/psi and a Charge Amp Sensitivity of mV/pC, the
voltage output from the CCSA can be calculated as follows:
PAMC Input Voltage(mVpk-pk) = Dynamic Pressure(psipk-pk) x ProbeSensitivity(pC/psi) x ChargeAmpSensitivity
(mV/pC)
PAMC Input Voltage(mVpk-pk) = 10 psipk-pk x 17 pC/psi x 10 mV/pC = 1700 mVpk-pk
Assign the configuration parameters as follows:
•
•
Low_Input = 0 mVpk-pk and Low_Value = 0 psipk-pk
High_Input = 1700 mVpk-pk and High_Value = 10 psipk-pk
Attention
The CCSA signal generator or the portable signal generator used to test the CCSA
charge inputs only provides a single-ended output and no differential output.
Therefore, when the test signal is applied to the CCSA, the charge amplifier outputs
half the output voltage as compared to the output when the probe’s differential signal
is connected to the charge amplifier input.
Scaling PCB Inputs
When InputUse is set to PCB, the configuration parameters used are PCB_Probe_Gn and PCB_Amp_Gn.
For example, assign the following values:
PCB_Probe_Gn = 17 pC /psi
and
PCB_Amp_Gn = 10 mV/pC
The PAMC will scale the inputs, SIGx, in Vrms and FFT outputs, FrqBx_PkAmpy in psipk-pk, where x in the variable FrqBx_
PkAmpy is the frequency band number 1 – 6 and y is the input channel number 1 – 18.
PAMC Acoustic Monitoring Input Module
GEH-6721_Vol_III_BJ System Guide 17
Non-Public Information
1.1.3.7
A/D Gain Adjust
The configuration parameter, Gain, controls the channel gain in the hardware. This parameter is defined for each channel. The
gain allows low-level signals to be amplified to provide better resolution in the A/D conversion hardware. The gain options
are 1x and 2x. The channel control writes the gain setup to the FPGA input amplifier control registers. The PAMC firmware
scales the input signal appropriately to result in a net gain of 1 for the signal regardless of the gain factor used. The maximum
expected signal level should not exceed 10 V (saturation) after the gain is applied as indicated in the following table.
Rules for Selecting Gain Value
Gainx
Maximum Magnitude of Input Signal after DC Bias Removal (Volts)
1
2
10
5
If the configuration parameter InputUse is set to PCB, Gain must be equal to 1.
Attention
The PAMC signal-conditioning gain is determined using the following calculation:
PAMC A/D VoltageMAX = Pressure PeakMAX(psipk) x ProbeSensitivityMAX(pC/psi) x
ChargeAmplifierSensitivityMAX(mVpk/pC) x Gain(mV/mV) ≤ 8000 mVpk
where:
•
•
•
•
ProbeSensitivityMAX is the nominal sensitivity plus worst case variation.
ChargeAmplifierSensitivityMAX is the nominal charge amplifier gain with worst case variation added to the nominal.
Gain is the internal signal-conditioning gain previously described.
8000 mVpk is the 80% limit for the ±10 Vpk range for A/D.
Example:
PAMC A/D VoltageMAX = 12.5 psipk x 1.2 x 17 pC/psi x 1.05 x 11.75 mV/pC x 2 x 0.001 V/mV = 6.29 Vpk
PAMC A/D VoltageMAX < 8000 mVpk. Therefore, this configuration is OK to use.
Note The value 1.2 is the ±20% range in the factory calibrated probe sensitivity and the value 1.05 is the 5% range in the
factory calibrated charge amp sensitivity from nominal.
1.1.3.8
RMS Calculation and Rolling Average
The RMS calculation function performs an RMS calculation on the ac acoustic information sampled for a given scan.
The rolling average function provides smoothing to the signal.
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1.1.3.9
Capture Buffers
Two capture buffers are available: Trip Capture Buffers and User Capture Buffers.
Trip Capture Buffers
This function provides capture buffers that input internally calculated data, which is selected based on a configuration
parameter. The capture buffers can be configured (parameter NumEventScans) to capture up to 32 scans of information for
each of 18 channels. Parameter EventListSel can be used to configure the trip capture buffer to collect any one of the
following internal data:
•
•
•
•
•
Time-domain sampled input data (in volts)
Frequency-domain FFT peak-to-peak magnitude (in volts)
FFT output data with transducer compensation (in volts)
FFT output data with transducer compensation (in EU)
Scan-averaged FFT output data with transducer compensation (in EU) (default)
Trip Capture Buffers are pre-triggered; meaning for a 32 scan FFT average, data is scanned 32 times before the triggered
event and none after the event. The triggered event is activated by the signal space input, TripCapReq. Running on the HMI
or OSM computer, AM Gateway software uploads the captured buffers to the computer on which the Gateway is running.
PAMC Acoustic Monitoring Diagnostic Support
User Capture Buffers
This function provides capture buffers that are only one scan in length (compared to the trip capture with up to 32 scans). The
user capture buffers can be configured using parameter OpListSel to collect any of the internal data listed above for trip
capture buffers. The AM Gateway software can upload these buffers. User capture buffers are activated through the AM
Gateway or other compatible applications. The diagram displayed above for trip capture buffers is the same for user capture
buffers except for the trigger source.
PAMC Acoustic Monitoring Input Module
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1.1.3.10
Phase Delta Calculation
FrqBX_PhDelta_Sel, FrqBY_PhDelta_Sel, and FrqBZ_PhDelta_Sel are configuration parameters that allow the user to select
frequency bands for which to perform phase delta calculations across all enabled and healthy channels.
Each phase delta calculation is performed by taking the difference of the phases of two adjacent channels, where phase values
are calculated from the maximum amplitude and corresponding frequency found within a selected band's frequency range.
PhaseDelta(X) = Phase(X) – Phase(X-1), where X is a channel number. For X=1, adjacent channel is the maximum enabled
channel number.
For example, with all channels enabled, channel 1's adjacent channel is channel 18. If channels 16-18 are disabled, channel 1's
adjacent channel becomes channel 15.
Note Channel corresponds to the signal number, not the Can_Id index.
Note If either of the two channels being used for a phase delta calculation go unhealthy, the resulting phase delta value is 0.
Bands X and Y display all 18 phase deltas in ToolboxST, while band Z only displays phase deltas 1 – 17.
A moving average of stored FFT scans is maintained for each channel, with the parameter ScanPrAvgPhDelta specifying the
number of scans to average. Once a maximum amplitude has been identified for each band of a channel, the average FFT
output for the corresponding FFT bin for that channel is compared against the average FFT output for the same bin of the
adjacent channel.
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Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
1.1.4 Specifications
Item
Specification
Input channels
18 dynamic pressure inputs
Output channels
18 buffered outputs
Supported frame rates
10 ms, 20 ms, 40 ms, 80 ms, 160 ms
Gain adjustment options
1x and 2x
Bias - minimum adjust
-13.5 ± 0.25 V dc
Bias - maximum adjust
+13.5 ± 0.25 V dc
Input accuracy from terminal point to inputs, SIGx (RMS
calc) for passband = 0 to 5 kHz
≤ 2.0 % of full scale = 10 V dc for Gain = 1x
≤ 2.0 % of full scale = 5 V dc for Gain = 2x
Input accuracy (dc + ac) from terminal point to
≤ 0.5 % of full scale = 10 V dc for Gain = 1x
peak-peak signal -space values through FFT analysis for
≤ 0.5 % of full scale = 5 V dc for Gain = 2x
passband = 0 to 3.2 kHz
Input accuracy (dc + ac) from terminal point to
≤ 2.0 % of full scale = 10 V dc for Gain = 1x
peak-peak signal -space values through FFT analysis for
≤ 2.0 % of full scale = 5 V dc for Gain = 2x
passband = 3.2 kHz to 5 kHz
Input passband frequency
0 to 5 kHz
† Ambient rating for enclosure design
0 to 65°C (32 to 149 °F)
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
Note Gain adjustment options 4x and 8x have been removed due to circuit limitations in the BAPB hardware. In accordance
with the ± 0.25 psi accuracy requirement from GEPS Combustion, the signal resolution is 167 counts per 0.25 psi for the PCB
configuration and 334 counts per 0.25 psi for the CCSA option.
1.1.5 Diagnostics
The I/O module performs the following self-diagnostic tests:
•
•
•
•
A power-up self test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board ID to confirm
that the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
Each input has sensor limit checking, open circuit detection, excessive dc bias detection, and hardware saturation
detection. Diagnostic alarms are generated for these conditions.
Note If the Continuous_Scan variable is False, the excessive dc bias detection is disabled. For more details on the
Continuous_Scan variable, refer to the section SAMB Signal Definitions.
Details of the individual diagnostics are available in the ToolboxST application. I/O block SYS_OUTPUTS, input RSTDIAG
can be used to direct all I/O modules to clear from the alarm queue all diagnostics in the normal healthy state.
PAMC Acoustic Monitoring Input Module
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1.1.5.1
•
•
•
•
•
•
•
•
UCSA LEDs
Power displays solid green when the internal 5 V supply is up and regulating. The PAMC converts the incoming 28 V dc
to 5 V dc. All other internal supplies are derived from the 5 V.
Online displays solid green when the PAMC is online and running application code.
Flash flashes amber when any flash device is being accessed. DC is not used in the PAMC application.
Diag flashes red when the PAMC has a diagnostic available. The diagnostic can be viewed and cleared using the
ToolboxST application.
Link displays solid green if the Ethernet hardware interface on the PAMC has established a link with an Ethernet port.
Act indicates packet traffic on an Ethernet interface. If traffic is low, this LED may flash but in most systems, it is on
solid.
On displays solid green when the USB is active.
Boot displays solid red or flashing red during the boot process.
The boot LED is lit continuously during the boot process unless an error is detected. If an error is detected, the LED flashes at
a 1 Hz frequency. While flashing, the LED is on for 500 ms and off for 500 ms. The number of flashes indicates the failed
state. After the flashing section, the LED turns off for three seconds. These are flashing codes:
1.
Failed Serial Presence Detect (SPD) EEPROM
2.
Failed to initialize DRAM or DRAM tests failed
3.
Failed NOR flash file system check
4.
Failed to load FPGA or PCI failed
5.
CompactFlash device not found
6.
Failed to start IDE driver
7.
CompactFlash image not valid
If the CompactFlash image is valid but the runtime firmware has not been loaded, the boot LED flashes continuously at a 1
Hz rate. Once the firmware is loaded, the boot LED turns off.
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1.1.6 Configuration
1.1.6.1
SAMB Level Configuration
Parameter
Description (SAMB Level Configuration)
Choices
BinReject
Number of side bins to reject from the peak search in adjacent bands
when a peak is detected near the band boundary. This prevents the
same peak from being detect in two adjacent bands. Zero = no bins
rejected.
0 to 6 (default: 3)
Config_Mode
Defines the source of the currently active configuration. ToolboxST allows
only mode Toolbox as a selection. The remote gateway configurator
Toolbox
forces mode to tuning configurator without user control.
Defines the sample site for the event capture list:
EventLstSel
•
Disable: list not used
•
FFT_Out: FFT output scaled in volts
•
TC_Out: FFT output after transducer compensation
•
PSI_Out: FFT outputs scaled in psi
•
Avg_Out: PSI_Out after averaging filter
•
Raw_Input: Input time domain data
Avg_Out, Disable,
FFT_Out, PSI_Out, Raw_
Input, TC_Out
(default: Avg_Out)
FFT_Length
1024, 2048, 4096, 8192,
Length of the FFT Buffer. Defines the number of samples that are used in
16384, 32768
FFT calculation.
(default: 8192)
FFT_TF_SelA
All Channels Source Select. Selects an internal test file as the input to all
acoustic monitoring channels for the actual analog input signals.
HW_Input or File
(default: HW_Input)
FrqBX_PhDelta_Sel
Selects frequency band X for phase delta calculation
Low-Low, Low, Mid, High,
Screech, Transverse, None
(default: Transverse)
FrqBY_PhDelta_Sel
Selects frequency band Y for phase delta calculation
Low-Low, Low, Mid, High,
Screech, Transverse, None
(default: None)
FrqBZ_PhDelta_Sel
Selects frequency band Z for phase delta calculation
Low-Low, Low, Mid, High,
Screech, Transverse, None
(default: None)
HPF_Enable
Enable High pass filter on acoustic inputs
Enable, Disable
(default: Enable)
HPF_Cutoff_Freq
High pass filter cutoff frequency
5 to 30 Hz (default: 5)
HiB_Limit
Defines the limit for the max peak-peak amplitude signal in the High
frequency band
0 to 50 psi (default: 50)
HiScrchBrkPt
Defines the frequency boundary between the High and Screech
frequency bands. When Screech_Overlap_Enb is set to Enable, this
value serves only as the upper frequency boundary for the High band.
0 to 5000 Hz (default: 500)
LoLoB_Limit
Defines the limit for the max peak-peak amplitude signal in the low-low
frequency band
0 to 50 psi (default: 50)
LowB_Limit
Defines the limit for the max peak-peak amplitude signal in the low
frequency band
0 to 50 psi (default: 50)
LowLow_EndPt
Defines the ending frequency of the Low-Low band. The Low-Low band
can be placed contiguously, with a gap between itself and any
neighboring band, or with a frequency range that overlaps with the Low
0 to 5000 Hz (default: 30)
band's. Additionally, this value is bounded by the ending frequency of the
Low band (LowMidBrkPt).
PAMC Acoustic Monitoring Input Module
GEH-6721_Vol_III_BJ System Guide 23
Non-Public Information
Parameter
Description (SAMB Level Configuration)
Choices
LowLowStrtPt
Defines the starting frequency of the low-low frequency band. This value
is bounded by the starting frequency of the Low band (Low_StrtPt).
LowLowStrtPt may not be larger than Low_StrtPt.
0 to 5000 Hz (default: 10)
LowMid_BrkPt
Defines the frequency boundary between low and mid frequency bands
0 to 5000 Hz (default: 120)
Low_StrtPt
Defines the starting frequency of the low band. Refer to the parameter
definition for LowLow_EndPt.
0 to 5000 Hz (default: 30)
MaxVoltCCSA
Max sensor volts for a CCSA type sensor
-30 to 30 V (default: 8.568)
MaxVoltCustm
Max sensor volts for a custom type sensor
-30 to 30 V (default: 5.25)
MaxVoltPCB
Max sensor volts for a PCB type sensor
-30 to 30 V (default: 20)
MidB_Limit
Defines the limit for the max peak-peak amplitude signal in the mid
frequency band
0 to 50 psi (default: 50)
MidHi_Brkpt
Defines the frequency boundary between mid and high frequency bands
0 to 5000 Hz (default: 240)
MinVoltCCSA
Minimum sensor volts for a CCSA type sensor
-30 to 30 V (default: -8.568)
MinVoltCustm
Minimum sensor volts for a custom type sensor
-30 to 30 V (default: -5.25)
MinVoltPCB
Minimum sensor volts for a PCB type sensor
-30 to 30 V (default: 3.5)
Defines the number of scans an event buffer contains.
1 to 100 scans (default: 32)
NumEventScns
If the sample location is Raw_Input the max scan allowed is 1.
Defines sample site for spectrum on demand capture or diagnostic list:
OpLstSel
•
Disable: list not used
•
Raw_Input: input time domain data
•
FFT_Out: FFT output scaled in volts
•
TC_Out: FFT output after transducer compensation
•
PSI_Out: FFT outputs scaled in psi
•
Avg_Out: PSI_Out after averaging filter
Avg_Out, Disable,
FFT_Out, PSI_Out, Raw_
Input,
TC_Out (default: Avg_Out)
PL_Fil_Freq
Defines the power line frequency that the notch filter removes from the
spectral content of the FFT output
50_Hz, 60_Hz
(default: 60_Hz)
PL_Fil_Tol
This is the power line frequency notch filter tolerance in per unit, for
example 0.1=10%. A higher number de-sensitizes the filter so other
energy peaks near the power line frequency are also rejected.
0 to 1.0 (default: 0.1)
PL_Fil_Width
Defines the bandwidth of the power line notch filter. The bandwidth is ±
value centered about the configured power line frequency.
0 to 100 Hz (default: 0.5)
SampleRate
Defines the FFT sample rate for all the acoustic monitoring channels
12,887 Hz only
ScanPrAvgFFT
Number of scans per average in acoustic monitoring filtered FFT output
1 to 100 scans (default: 32)
ScanPrAvgRMS
Number of scans per average in the RMS calculation
1 to 32 scans (default: 1)
ScanPrAvgPhDelta
Number of scans per average in the phase delta calculation
1 to 64 scans (default: 1)
SearchInAvg(1) –
SearchInAvg(6)
Selects whether the sort function for pk-pk amplitudes uses the present
scan or an average value
No_Average, Average
(default: Average)
Session_Time
Scheduled time for temporary configuration mode. This time is forced to
zero in the ToolboxST entry. This value is set to the user-selected time in
the temporary gateway remote configurator.
0 only
ScrchB_Limit
Defines the limit level for the maximum peak-peak amplitude signal in the
0 to 50 psi (default: 50)
screech frequency band
Screech_Overlap_
Enb
When enabled, allows the Screech band to have a frequency range that
overlaps another band’s frequency band
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Enable, Disable
(default: Disable)
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Parameter
Description (SAMB Level Configuration)
Choices
Scrch_StrtPt
Defines the starting frequency of the screech frequency band when
Screech_Overlap_Enb is set to Enable. When enabled, this parameter
becomes available and allows for the Screech band to overlap the Low,
Mid, or High band.
0 to 5000 Hz (default:
2000)
Scrch_EndPt
Defines the ending frequency of the screech frequency band. When
Screech_Overlap_Enb is set to Enable, the Screech band may overlap
the Low, Mid, or High band.
0 to 5000 Hz (default:
3000)
T_FilWidth
Defines the width (± Hz) of the keep out area around the
Transverse/Screech band peak frequency that is ignored by an
0 to 100 Hz (default: 40)
overlapped band’s frequency search. In the case of Transverse band, it is
used only if Trns_Bnd_Enb is set to Enable.
TMC_Gain(1) –
TMC_Gain(30)
Transducer mounting compensation gain to response
0 to 30 (default: 1)
TMC_Freq(1) –TMC_
Frequency corresponding to the gain value entered
Freq(30)
0 to 5000 Hz (default:
n*100)
TrnsB_Limit
Defines the limit for the max peak-peak amplitude signal in the
Transverse frequency band
Trns_Bnd_Enb
Determines whether to perform the frequency search in Transverse
Disable, Enable
band’s range when it is overlapping another band. If the Transverse band
(default: Enable)
is not overlapping another band, this parameter value is ignored.
Trns_EndPt
Defines the ending frequency of the Transverse frequency band. The
Transverse frequency band’s independent endpoints allow it to overlap
the Low, Mid, High, or Screech band range.
0 to 5000 Hz (default: 1150)
Trns_StrtPt
Defines the starting frequency of the Transverse frequency band. The
Transverse frequency band’s independent endpoints allow it to overlap
the Low, Mid, High, or Screech band range.
0 to 5000 Hz (default: 950)
Selects window function for sampled data for each channel
Rectangular
Hamming
Hanning
Triangular
Blackman
Blackman-Har(ris)
Flat Top
(default: Hanning)
WindowSelect
PAMC Acoustic Monitoring Input Module
0 to 50 psi (default: 50)
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1.1.6.2
SAMB Variable Definitions and Configuration
SIGx
Where x = 1 – 18
Analog Input x – Card Point
Point Edit (Input FLOAT)
Gain
Analog input resolution adjustment to amplify signal before digital
conversion. Gain factor x (maximum signal peak voltage) must be less
than 10 V to prevent saturation.
1x, 2x (default: 1x)
Bias
DC bias voltage subtracted from the analog signal input for dc bias
compensation. Only used when InputUse is Custom or File.
-13.5 to 13.5 (default: 0)
Bias_Range
Allowable deviation of dc bias used for dc bias diagnostics. Only used
when InputUse is Custom or File.
0 to 10 (default: 1)
Can_Id
Combustor can be wired to this terminal board signal. This normally
corresponds to the signal number to avoid confusion; wire terminal
board signal 1 to can 1.
1 to 18 (default: 1)
High_Input
Defines point 2 X-axis value in mV for SAMB terminal point that is used
-10000 to 10000 (default: 170)
to calculate gain and offset for conversion to EU
High_Value
Defines point 2 Y-axis value in EU for SAMB terminal point that is used
Any positive real (default: 1)
to calculate gain and offset for conversion from mV to EU
Selects the sensor type used on the signal
InputUse
Unused, CCSA, PCB,
Custom, File
(default: Unused)
If the CCSA in JB1000 is used, set InputUse and the
terminal board jumpers to CCSA regardless of the
transducer manufacturer. Damage to the CCSA may
occur if the PCB jumper setting is used on the terminal
board.
Caution
Low_Input
Defines point 1 X-axis value in mV for SAMB terminal point that is used
-10000 to 10000 (default: 0)
to calculate gain and offset for conversion to EU
Low_Value
Defines point 1 Y-axis value in EU for SAMB terminal point that is used
Any positive real (default: 0)
to calculate gain and offset for the conversion from mV to EU
PCB_Probe_Gn
PCB probe gain, pC per psi
Used only if InputUse = PCB
5 to 40 (default: 17)
PCB_AmpGain
PCB amplifier gain, milli-volts per pC
Used only if InputUse = PCB
1 to 20 (default: 10)
PL_Fil_En
Enables the power line notch filter
Disable, Enable
(default: Disable)
DiagHighEnab
Enables high input sensor limit diagnostics
Disable, Enable
(default: Enable)
DiagLowEnab
Enables low input sensor limit diagnostics
Disable, Enable
(default: Enable)
DiagOCChk
Enables open sensor error diagnostic
Disable, Enable
(default: Enable)
DiagBiasNull
Enables excessive dc bias diagnostic
Disable, Enable
(default: Enable)
DiagSigSat
Enables signal HW saturation diagnostic
Disable, Enable
(default: Enable)
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1.1.6.3
SAMB Signal Definitions
Signal
Description – Point Edit (Enter Signal Connection)
Direction
Type
L3DIAG_SAMB_R(S or T)
Board Diagnostic active (non-voted signal)
Input
BIT
LINK_OK_SAMB_R(S or T)
High-speed serial link SL1 is communicating with BAPx
Input
BIT
ATTN_SAMB
SAMB has an active alarm
Indicates that PAMC can scan and process all the time domain
data prior to beginning the next scan. For FFT_Length of 1024 or
2048, this signal may be False if enough channels are enabled.
When False, this signal indicates that there will be a gap in the
time domain data between scans. The excessive dc bias
detection is disabled if Continuous_Scan is False.
Input
BIT
Input
BIT
BIT
Continuous_Scan
Test_Config
PAMC is temporarily remotely configured
Input
Test_Mode
Signals are from internal test sources, not from terminal board
Input
BIT
TripCapList
A capture buffer triggered by TripCapReq is available
Input
BIT
UserCapList
A capture buffer manually requested by a user is available
Input
BIT
Num_Of_Scans
Scan (block of FFT data) number of this data (1 – 100)
Input
INTEGER
Num_Avg_Scns
Number of scans (block of FFT data) averaged (1 – 100)
Input
INTEGER
Session_Tmr
Time remaining for remote tuning session
Input
INTEGER
TripCapReq
Request for trip capture buffer collection
Output
BIT
FrqBX_PhDelta1
↓
FrqBX_PhDelta18
(FrqBX_PhDeltam, m=1-18)
Phase Delta value for band X between channel m and its
adjacent channel
Input
FLOAT
FrqBY_PhDelta1
↓
FrqBY_PhDelta18
(FrqBY_PhDeltam, m=1-18)
Phase Delta value for band Y between channel m and its
adjacent channel
Input
FLOAT
Input
FLOAT
BIT
↓
FrqBZ_PhDelta1
↓
FrqBZ_PhDelta17
(FrqBZ_PhDeltam, m=1-17)
Phase Delta value for band Z between channel m and its
adjacent channel
Can1_Health
Combustor can 1 signal health
Input
↓
↓
↓
Only 17 Phase Delta values are displayed for FrqBZ.
Can18_Health
Combustor can 18 signal health
Input
BIT
FrqB1_LmtSet
All cans, Low Band, Peak amplitude exceeds LowB_Limit
Input
BIT
FrqB2_LmtSet
All cans, Mid Band, Peak amplitude exceeds MidB_Limit
Input
BIT
FrqB3_LmtSet
All cans, High Band, Peak amplitude exceeds HiB_Limit
Input
BIT
BIT
FrqB4_LmtSet
All cans, LoLo Band, Peak amplitude exceeds LoLoB_Limit
Input
FrqB5_LmtSet
All cans, Transverse Band, Peak amplitude exceeds TrnsB_Limit
Input
BIT
FrqB6_LmtSet
All cans, Screech Band, Peak amplitude exceeds ScrchB_Limit
Input
BIT
FrqBn_PkAmpm
FrqBn_PkHzm
Peak amplitude detected in band n can m (psi)
Where m=1-18 can number
n=1 for low band
n=2 for mid band
Input
n=3 for high band
n=4 for lolo band
n=5 for transverse band
n=6 for screech band
Peak frequency for the peak amplitude FrqBn_PkAmpm in can m
Input
band n (Hz)
PAMC Acoustic Monitoring Input Module
FLOAT
FLOAT
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Signal
FrqBn_AmpMx
FrqBn_HzMx
Description – Point Edit (Enter Signal Connection)
Peak Amplitude detected in all cans in band n (psi)
Where
n=1 for low band
n=2 for mid band
n=3 for hi band
n=4 for lolo band
n=5 for transverse band
n=6 for screech band
Peak frequency for the peak amplitude FrqBn_PkAmpMx
detected in all cans band n (Hz)
Direction
Type
Input
FLOAT
Input
FLOAT
FrqBn_AmpAvg
Can number for the peak amplitude FrqBn_PkAmpMx detected in
Input
all cans band n
Average peak amplitude in all cans band n (psi)
Input
FLOAT
BAPA_Temptur
BAPx module (plugged into terminal board) temperature (deg C)
Input
FLOAT
LowLowStrtPt
Starting frequency of Low-Low band (Hz)
Input
FLOAT
LowLow_EndPt
Ending frequency of Low-Low band (Hz)
Input
FLOAT
Low_StrtPt
Starting frequency of Low band (Hz)
Input
FLOAT
FrqBn_ChMx
FLOAT
LowMid_BrkPt
Breakpoint frequency between Low band and Mid band (Hz)
Input
FLOAT
MidHi_BrkPt
Breakpoint frequency between Mid band and High band (Hz)
Input
FLOAT
HiScrchBrkPt
Breakpoint between High and Screech band (Hz)
Input
FLOAT
Trns_StrtPt
Starting frequency of Transverse band (Hz)
Input
FLOAT
Trns_EndPt
Ending frequency of Transverse band (Hz)
Input
FLOAT
FLOAT
Scrch_EndPt
Ending frequency of Screech band (Hz)
Input
FFT_Length
Length of the FFT Buffer (samples)
Input
FLOAT
Sample_Rate
FFT Sample Rate (Hz)
Input
FLOAT
ScanPrAvgFFT
Number of Scans Per Average in the FFT output
Input
FLOAT
28
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1.2 PAMC Specific Alarms
The following alarms are specific for the PAMC.
3037
Description Frequency Band Configuration Error on Band [ ], Error Code: [ ]
Possible Cause The frequency band configuration is invalid. Refer to error code descriptions and decoded band indices
for details.
Band Index:
•
•
•
•
•
•
1 - Low Band
2 - Mid Band
3 - High Band
4 - Low Low Band
5 - Trans Band
6 - Screech Band
Band Configuration Error Codes:
•
•
•
•
•
1 - Multiple Overlap: The band has two other bands who end within its frequency range. Only 1 overlapping band is
allowed.
2 - Overlapping Disallowed Band: Trans or Screech band is overlapping a disallowed band. Trans can overlap all but
LowLow. Screech can overlap Low, Mid, High. LowLow can overlap Low.
3 - Overlap Overrun: The band is overlapping into the subsequent band (may or may not already be within a band).
4 - Ordering: The band is out of place.
5 - Non-Positive Range: The band has a non-positive frequency range.
Solution Fix band ranges to comply with configuration rules. Use the error code and involved band to help diagnose the
issue.
3038
Description Flash disk error: Unable to revert to flash configuration after remote access
Possible Cause The permanent configuration data on PAMC is corrupted.
Solution
•
•
Build and download the firmware and configuration to the PAMC.
Replace the PAMC UCSA.
PAMC Acoustic Monitoring Input Module
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3041-3058
Description SIG[ ]: Open Circuit Failure (or PCB Charge Amp Output Shorted)
Possible Cause
•
•
An open circuit for a specified terminal board signal has been detected.
For PCB type charge amps, the terminal board signal could be shorted.
Solution
•
•
•
Check the wiring and sensor.
Replace the BAPx.
Replace the terminal board.
3061-3078
Description SIG[ ]: Excessive DC Bias
Possible Cause
•
•
The configuration does not match the sensor type.
The DC bias (DC offset) designated for the sensor type is outside the range detected for the sensor.
Solution
•
•
Check the sensor type in the configuration parameter InputUse.
Check the dc voltage on the signal. Refer to the PAMC documentation.
3081-3098
Description SIG[ ]: Input Signal Exceeds HW Limit
Possible Cause The peak input voltage exceeds the HW limit for the input.
Solution
•
•
Decrease the configuration parameter Gain for the designated signal.
Check the sensor for issues.
3101-3118
Description SIG[ ]: Sensor Limit Exceeded
Possible Cause The peak input voltage exceeds the limit for the selected sensor type.
Solution
•
•
•
Check the sensor type in the configuration parameter InputUse.
Check the MaxVolt and MinVolt settings for selected sensor type for proper sensor range.
Check the sensor for issues.
30
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3120
Description BAPx ADC Reference Input Calibration Failure
Possible Cause The BAPx failed the calibration test when powered on.
Solution Replace the BAPx.
3121-3138
Description BAPx Chan [ ]: ADC Calibration Failure
Possible Cause The BAPx failed the calibration test when powered on.
Solution Replace the BAPx.
3139-3156
Description BAPx Chan [ ]: DAC Calibration Failure
Possible Cause The BAPx failed the calibration test when powered on.
Solution Replace the BAPx.
3157-3174
Description BAPx Chan [ ]: DC Test Failure
Possible Cause The BAPx failed the DC test during the manually invoked self-test.
Solution Replace the BAPx.
3175-3192
Description BAPx Chan [ ]: Analog Gain Test Failure
Possible Cause The BAPx failed the gain test during the manually invoked self-test.
Solution Replace the BAPx.
3193-3210
Description BAPx Chan [ ]: AC FFT Test Failure
Possible Cause The BAPx failed the AC FFT test during the manually invoked self-test.
Solution Replace the BAPx.
PAMC Acoustic Monitoring Input Module
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3212
Description HSSL Comm link [ ] Communication Failure, Code [ ]
Possible Cause The PAMC/UCSA cannot communicate with the remote acquisition hardware (terminal board and
BAPx) through the High-speed Serial Link (HSSL) cable. The code indicates a specific failure type.
Common Codes:
•
•
•
•
•
•
51xxxxxx: Remote acquisition target returning bad ID
52xxxxxx: Download to BAPx failed
53xxxxxx: Link loss detected
54xxxxxx: Receive packet error detected
55xxxxxx: Transmit packet error (excessive naks)
57xxxxxx: No data received from BAPx in 5 seconds
Solution
•
•
•
•
Verify that the BAPx is connected to the SL1 connector on the PAMC UCSA.
Check the HSSL cables. If problem persists, replace the PAMC UCSA module.
Check the power on the BAPx.
Replace the BAPx.
3213
Description HSSL Comm link [ ] Initialization Failure
Possible Cause The PAMC UCSA cannot properly initialize the BAPx through the HSSL.
Solution
•
•
•
•
Verify that the BAPx is connected to the appropriate HSSL connector on the PAMC UCSA.
Check the HSSL cables. If the problem persists, replace the PAMC UCSA module.
Check the power on the BAPx.
Replace the BAPx.
3214
Description HSSL Comm link [ ] Configuration Failure, Code [ ]
Possible Cause The PAMC UCSA interface to the HSSL failed to initialize properly.
Solution Replace the PAMC UCSA.
3215
Description BAPx Plugged into Wrong SAMB Connector on HSSL [ ]
Possible Cause The SAMB connector that the BAPx is plugged into does not agree with the HSSL connector configured
in the ToolboxST application.
Solution
•
•
•
Verify that the HSSL cable is plugged into the PAMC UCSA SL1 connector.
Verify that the HSSL cable is plugged into the correct BAPx.
Verify that the SAMB TB connector setting in the ToolboxST application matches the BAPx connection to the terminal
board.
32
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3230-3247
Description BAPx Chan [ ]: Anti-alias Rolloff Test Failure
Possible Cause The BAPx failed the anti-alias test during the manually invoked self-test.
Solution Replace the BAPx.
1.3 SAMB and BAPx Acoustic Monitoring Input
The Mark VIe Acoustic Monitoring terminal board (SAMB) provides Dual fanned connections for 18 inputs for the Acoustic
Monitoring system. The SAMB provides two terminal points per input channel for a maximum of 18 channels on 36
terminals. It also provides an additional 18 buffered outputs on 36 terminals to connect external instrumentation for
monitoring the ac voltage signal that represents the dynamic pressure signals from the combustor. The SAMB includes
passive electromagnetic interference (EMI) filters to protect against very high frequency noise generated by external sources.
The SAMB provides the following features:
•
•
•
•
•
•
•
Eighteen signal interface channels for acoustic monitoring, supporting Dual configuration
Channels 1 – 18 can be configured to support PCB Piezotronics charge amplifiers or Charge Converter Signal Amplifier
(CCSA) outputs. Sensor power for the PCB sensors is independent for channels 1 – 9 and 10 – 18.
Eighteen buffered outputs providing ac signal content of the dynamic pressure signals without dc bias voltage
Thirty-six Euro style box-type terminal blocks for the customer inputs
Thirty-six Euro style box-type terminal blocks for the buffered outputs
EMI protection for all inputs
EMI filtered inputs fanned to the A and B slots
Note The BAPAH1A or BAPBH1A Analog Processor board (BAPx) and the SAMB terminal board are grouped together as
application sub-assemblies.
1.3.1 Installation
Note Only a qualified GE field service technician should install the PAMC module.
The following figure displays the functionality of one of the 18 channels supported by the SAMB and the PAMC. The CCSA
voltage output or the PCB constant-current charge amplifiers and the buffered outputs are connected to the terminal blocks.
Refer to the SAMB Configuration section.
PAMC Acoustic Monitoring Input Module
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SAMB Acoustic Monitoring Terminal Board
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1.3.2 Operation
The SAMB inputs an ac voltage signal from the CCSA proportional to the dynamic pressure sensed by either an Endevco® or
PCB probe. SAMB also inputs the dynamic pressure directly from a PCB constant-current charge amplifier connected to a
PCB probe as an ac voltage proportional to the combustion dynamics riding on a dc bias voltage.
Each channel provides a 3.6 mA constant-current source that can be connected to SIGx (where x is the channel number) for
the PCB charge amplifiers. The jumper JPx (where x equals the channel number) is a two-pole jumper that controls the
constant-current power supply and whether RETx is tied to the power ground, PCOM. When JPx is in the CCSA position, the
constant-current is disabled and RETx is not tied to PCOM. When JPx is in the PCB position, the constant-current is
connected to SIGx, providing approximately 3.6 mA of current to power the PCB charge amplifier. The RETx line is tied to
PCOM to provide a return path for the constant-current.
1.3.2.1
BAPx Analog Processor
The BAPx Analog Processor boards provide the following features:
•
Eighteen analog signal-conditioning channels
•
− Differential inputs
− Adjustable gains of 1x and 2x
− DC bias nulling
− Multiplexer to bypass signal input and apply test signal
− Anti-alias filters
FPGA
•
− A/D converter control
− D/A converter control
− Eighteen channels of FIR filtering
− Configuration registers
− HSSL over Ethernet
Power supplies
−
−
−
−
P28 input
P15 and N15 outputs
P5 output
3.3 V, 2.5 V, and 1.2 V outputs
1.3.2.2
BAPx LEDs
The BAPx has the following LEDs:
•
•
•
•
PWR displays solid green when 28 volt power is present.
ATTN will display solid red for about a half second on power applied and will then go dark. If a valid serial link has been
established with the host UCSA, configuration will be downloaded to the BAPx and then the LED will display solid
green.
Link displays solid green if the HSSL interface on the BAPx has established a proper link with a UCSA serial port.
Tx/Rx indicates packet traffic on the HSSL. This LED will flash green when this traffic is present.
PAMC Acoustic Monitoring Input Module
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1.3.3 Specifications
Item
SAMB Specification
Input channels
18 dynamic pressure inputs
Output channels
18 buffered outputs
Power inputs
2 P28 inputs, each with a 2-pin connector
Bias circuit
DC output gain
1 ±0.5%
Allowable offset on outputs
30 mV ±10%
Output impedance
40 Ω ±50%
Test points
2 with > ±10 V dc range, < 0.5% error tolerance, and = 2.5 mV/count resolution
Size
14.3 cm high x 23.1 cm wide (5.625 x 9.1 in)
Cooling
Free air convection
Humidity
5 to 95% non-condensing
P28 on each channel with < 0.2 % dc error
1.3.4 Diagnostics
The SAMB terminal board has its own ID device, which is interrogated by the PAMC. The board ID is coded into a read-only
chip containing the terminal board serial number, board type, revision number, and the JA4 or JB4 connector location. This
ID is checked as part of the power-up diagnostics.
1.3.5 Configuration
1.3.5.1
Terminal Points
Use JP1-18 to select the interface configuration for the SAMB terminal point inputs. Use JPx = CCSA to connect weak pull
up resistors to the SIGx and RETx lines. This configuration allows for an out of range voltage detection if an open-wire
occurs between the CCSA and SAMB. JPx = PCB is used when the PCB charge amplifier is connected to the SAMB. The
PCB configuration provides a 3.6 mA constant-current source to the PCB charge amplifier. The PCB charge amplifier
generates a nominal 12 V dc bias voltage with a maximum ac peak of approximately ±5 Vpk riding on top of the dc bias
voltage. Open-wire detection or PCB charge amplifier hardware issues are detected by monitoring the bias voltage.
Terminal
Point
Vendor Model
Vendor I/O
Connection
1– 18
CCSA: Disables constant
GE Charge Converter
current and does not tie RETx
Signal Amp
to PCOM
CCSA
OUT+
OUT-
1 – 18
PCB: Enables constant
current and ties RETx to
PCOM
682M57 Charge Amp
Signal
Ground
Channels
JPx Position (Two-pole)
SIGx
RETx
SIGx
RETx
36
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PCB Piezotronics
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1.3.5.2
Terminal Variables
Ch. # Variable
Signal
Description
Variable
Signal
Description
1
1
3
BUFOUT1
BUFRET1
Buffered output, signal
Buffered output, return
2
4
SIG1
RET1
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
2
5
7
BUFOUT2
BUFRET2
Buffered output, signal
Buffered output, return
6
8
SIG2
RET2
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
3
9
11
BUFOUT3
BUFRET3
Buffered output, signal
Buffered output, return
10
12
SIG3
RET3
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
4
13
15
BUFOUT4
BUFRET4
Buffered output, signal
Buffered output, return
14
16
SIG4
RET4
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
5
17
19
BUFOUT5
BUFRET5
Buffered output, signal
Buffered output, return
18
20
SIG5
RET5
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
6
21
23
BUFOUT6
BUFRET6
Buffered output, signal
Buffered output, return
22
24
SIG6
RET6
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
7
25
27
BUFOUT7
BUFRET7
Buffered output, signal
Buffered output, return
26
28
SIG7
RET7
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
8
29
31
BUFOUT8
BUFRET8
Buffered output, signal
Buffered output, return
30
32
SIG8
RET8
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
9
33
35
BUFOUT9
BUFRET9
Buffered output, signal
Buffered output, return
34
36
SIG9
RET9
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
10
37
39
BUFOUT10
BUFRET10
Buffered output, signal
Buffered output, return
38
40
SIG10
RET10
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
11
41
43
BUFOUT11
BUFRET11
Buffered output, signal
Buffered output, return
42
44
SIG11
RET11
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
12
45
47
BUFOUT12
BUFRET12
Buffered output, signal
Buffered output, return
46
48
SIG12
RET12
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
13
49
51
BUFOUT13
BUFRET13
Buffered output, signal
Buffered output, return
50
52
SIG13
RET13
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
14
53
55
BUFOUT14
BUFRET14
Buffered output, signal
Buffered output, return
54
56
SIG14
RET14
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
15
57
59
BUFOUT15
BUFRET15
Buffered output, signal
Buffered output, return
58
60
SIG15
RET15
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
16
61
63
BUFOUT16
BUFRET16
Buffered output, signal
Buffered output, return
62
64
SIG16
RET16
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
17
65
67
BUFOUT17
BUFRET17
Buffered output, signal
Buffered output, return
66
68
SIG17
RET17
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
18
69
71
BUFOUT18
BUFRET18
Buffered output, signal
Buffered output, return
70
72
SIG18
RET18
Dynamic pressure voltage, signal
Dynamic pressure voltage, return
PAMC Acoustic Monitoring Input Module
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Notes
38
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2
PCAA Core Analog Module
2.1 PCAA Core Analog I/O Pack
The Core Analog PCAA and optional Core Analog TCAT terminal board provide a
large portion of the analog signal I/O required to operate a gas turbine. The PCAA and
TCAT provide thermocouple inputs, 4-20 mA current loop I/O, seismic inputs, Linear
Variable Differential Transformer (LVDT) excitation and inputs, pulse rate inputs, and
servo coil outputs. The PCAA can be applied in simplex, and TMR systems. A single
TCAT terminal board fans signal inputs to one or three connected PCAA modules. The
shield ground and 24 V field power terminals on an adjacent JGPA board supplement
the terminals on the PCAA and TCAT.
The PCAA contains a BPPx processor board, two application I/O boards, and a TCAS
terminal board. The complete module is regarded as the least replaceable unit. There is
no support provided to diagnose or replace the individual boards making up the module.
Input to the module is through dual RJ-45 Ethernet connectors and 28 V dc power
connector P5. Field device I/O is through 120 Euro style box-type terminal blocks on
the module edge. Power for a JGPA board is through connector P4. Module connection
to TCAT is through two 68-pin cables on connectors P1 and P2.
2.1.1 Compatibility
The PCAA includes one of the following compatible processor boards:
•
•
The PCAAH1A contains a BPPB processor board.
The PCAAH1B contains a functionally compatible BPPC that is supported with ControlST* software suite V04.04 and
later.
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 39
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The following table defines the redundancy, hardware form, number of IONet connections, maximum frame rate, and TCAT
terminal board configurations that are permissible for the PCAA.
PCAA
Quantity
Hardware
Form
IONet
Connections
Frame
Rate
TCAT
Connections
Comments
Simplex
H1A
Two
40 ms
Zero or One
TCAT Optional on Simplex applications
Simplex
H1A
One
10 ms
Zero or One
Only one IONet at 10 ms frame rates for H1A
Simplex
H1B
One or Two
10 ms
Zero or One
PCAAH1B supports 10 ms and dual networks
TMR
H1A
Two
40 ms
One
** If configured as TMR pack dual network
(TPDN), PCAAH1A is limited to 40 ms.
TMR
H1A
One
10 ms
One
At 10 ms, PCAAH1A supports only 1 network
connection for TMR configurations.
TMR
H1B
One or Two
10 ms
One
** If configured as TMR pack dual network
(TPDN) at 10 ms, all three modules must be
H1B.
** Normal TMR configurations (TPTN) will have one network per PCAA. TMR pack Dual network (TPDN) configurations will
have dual networks connected on the T PCAA. Refer to GEH-6271 Volume I, Chapter 2 System Architecture, the section
Redundancy Options, for more information.
2.1.1.1
Signals
The signals on the PCAA are separated into two groups. Signal inputs that can be fanned from a single input into a simplex or
TMR PCAA modules are routed through the TCAT terminal board. Signals that are dedicated to a single PCAA module are
wired to the terminals on PCAA. This creates the signal split displayed in the following table. It is possible to use PCAA
without TCAT if the fanned inputs are not required.
PCAA Terminals
TCAT Terminals
# Signals
Signal Type
Screws/Signal
# Signals
Signal Type
Screws/Signal
25
Thermocouples
2
12
Fanned seismic inputs
2
10
Analog 4-20 mA inputs
2
24
Fanned analog 4-20 mA inputs
2
2
Analog 4-20 mA or ±10 V in
2
12
24 V output power at 25 mA
1
2
Analog 4-20 mA outputs
2
3
Voting 4-20 mA outputs
2
1
±12 V power output
2
12
Fanned LVDT Feedback
2
6
LVDT Excitation outputs
2
2
Fanned Mag. Pulse Rate Inputs
(servo flow meter)
2
6
Servo coil driver outputs
3
1
Common connection
1
1
Servo suicide relay input
2
2
TTL pulse inputs+power
4
40
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PCAA Core Analog
PCAA-TCAT Connection Diagram - Simplex (PCAA cover omitted to display board relationship)
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 41
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PCAA-TCAT Connection Diagram - TMR (PCAA cover omitted to display board relationship)
2.1.2 Installation
➢ To install the PCAA module
1.
Securely mount the PCAA module.
2.
Connect the JGPA power connection to the P4 connector on PCAA.
3.
Connect the PCAA module to an optional associated TCAT terminal board using two 68-pin cables on connectors P1 and
P2. Connectors on TCAT are paired by a network connection. PR1 and PR2 go to a PCAA connected to the R controller
network, PS1 and PS2 go to a PCAA connected to the S controller, and PT1 and PT2 go to a PCAA connected to the T
controller. It is important to fully seat the cable mounting screws, finger-tight only, into PCAA and TCAT to ensure
proper cable grounding. Failure to secure the cables may result in an inability of PCAA to read the electronic ID on
TCAT and may reduce the quality of other signals.
Note When removing 68-pin cables, ensure that the hex posts in the board-mounted connectors do not turn when backing
out the cable thumbscrews.
4.
Plug in one or two Ethernet cables depending on the system configuration. When a single IONet connection is used, the
module operates correctly over either port. If dual connections are used, standard practice is to hook ENET1 to the
network associated with the R controller. However, the PCAA is not sensitive to Ethernet connections, and negotiates
proper operation over either port. If TMR PCAA modules are present, the network connection should match with the
connection made to TCAT. For example, the PCAA module with R IONet connection should have cables that go to the
TCAT PR1 and PR2 connectors.
42
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5.
Check grounding of the JGPA shield wire terminals. In most applications, JGPA shield ground terminals are electrically
tied to the sheet metal the board is mounted on. The mounting then supplies the ground path for the terminals. In some
applications, it is required to define a shield ground that is independent of the mounting sheet metal. For these
applications, the JGPA is mounted using hardware that isolates the board from the sheet metal. In these applications, it is
important to provide a suitable ground wire between one or more JGPA terminals and the required shield ground
potential.
6.
Apply power to the module through the P5 connector and check the power and Ethernet status indicator lights.
7.
Use the ToolboxST* application to configure the PCAA as necessary. For more information, refer to GEH-6700,
ToolboxST User Guide for Mark VIe Control.
2.1.2.1
•
•
•
•
•
Connectors
Connectors P1 and P2 provide cable connections to a TCAT terminal board.
An RJ-45 Ethernet connector named ENET1 on the module side is the primary system interface.
A second RJ-45 Ethernet connector named ENET2 on the module side is the redundant or secondary system interface.
A 3-pin power connector P5 on the module is the input point for 28 V dc power for the module and terminal boards.
A power connector P4 on the module provides 28 V dc power to a JGPA board located for wire shield termination.
Note The module operates from a power source that is applied directly to the module P5 connector, not through the normal
power connector located on the processor board.
2.1.2.2
Wiring
The PCAA module features 120 pluggable Euro style box-type terminal blocks. A JGPA board mounts adjacent to the PCAA
module and uses Euro style box-type terminal blocks to provide forty-eight shield termination points (green) plus twelve 24 V
dc output terminals (orange) for 4-20 mA transmitters. The Euro-style box terminals on TCAT accept conductors with the
following characteristics:
TCAT Conductors
Conductor Type
Minimum
Maximum
Conductor cross section solid
0.2 mm²
2.5 mm²
Conductor cross section stranded
0.2 mm²
2.5 mm²
Conductor cross section stranded, with ferrule without plastic sleeve
0.25 mm²
2.mm²
Conductor cross section stranded, with ferrule with plastic sleeve
0.25 mm²
2.5 mm²
Conductor cross section AWG/kcmil
24 AWG
12 AWG
2 conductors with same cross section, solid
0.2 mm²
1 mm²
2 conductors with same cross section, stranded
0.2 mm²
1.5 mm²
2 conductors with same cross section, stranded, ferrules without plastic sleeve
0.25 mm²
1 mm²
2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve
0.5 mm²
1.5 mm²
PCAA Core Analog Module
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TCAS Screw Terminal Assignments
Name
Function
Name
Function
1
TC1H
Thermocouple1
3
TC2H
Thermocouple2
2
TC1L
4
TC2L
5
TC3H
7
TC4H
6
TC3L
8
TC4L
9
TC5H
11
TC6H
10
TC5L
12
TC6L
13
TC7H
15
TC8H
14
TC7L
16
TC8L
17
TC9H
19
TC10H
18
TC9L
20
TC10L
21
TC11H
23
TC12H
22
TC11L
24
TC12L
25
TC13H
27
TC14H
26
TC13L
28
TC14L
29
TC15H
31
TC16H
30
TC15L
32
TC16L
33
TC17H
35
TC18H
34
TC17L
36
TC18L
37
TC19H
39
TC20H
38
TC19L
40
TC20L
41
TC21H
43
TC22H
42
TC21L
44
TC22L
45
TC23H
47
TC24H
46
TC23L
48
TC24L
49
TC25H
51
TFH1
50
TC25L
52
TFL1
55
TFH2
53
TFPWR1
56
TFL2
54
TFL1
57
TFPWR2
59
ASIH1
58
TFL2
60
ASIL1
61
ASIH2
63
ASIH3
62
ASIL2
64
ASIL3
65
ASIH4
67
ASIH5
66
ASIL4
68
ASIL5
69
ASIH6
71
APWRP12
70
ASIL6
72
APWRN12
44
Thermocouple3
Thermocouple5
Thermocouple7
Thermocouple9
Thermocouple11
Thermocouple13
Thermocouple15
Thermocouple17
Thermocouple19
Thermocouple21
Thermocouple23
Thermocouple25
TTLpulserate input #2
Analog 4-20 mA input #2
Analog 4-20 mA input #4
Analog 4-20 mA input #6
GEH-6721_Vol_III_BJ
Thermocouple4
Thermocouple6
Thermocouple8
Thermocouple10
Thermocouple12
Thermocouple14
Thermocouple16
Thermocouple18
Thermocouple20
Thermocouple22
Thermocouple24
TTLpulserate input #1
Analog 4-20 mA input #1
Analog 4-20 mA input #3
Analog 4-20 mA input #5
±12 V power output
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Non-Public Information
TCAS Screw Terminal Assignments
Name
Function
Name
Function
73
ASIH7
Analog 4-20 mA input #7
75
ASIH8
Analog 4-20 mA input #8
74
ASIL7
76
ASIL8
77
ASIH9
79
ASIH10
78
ASIL9
80
ASIL10
81
ASIH11
83
ASIH12
84
ASIL12
Analog 4-20 mA ±10 V input #12
Note Odd-Even Terminal Grouping
82
ASIL11
85
ASOH1
87
ASOH2
Analog 4-20 mA Output #2
86
ASOL1
88
ASOL2
89
SVO1L
95
SVO3L
90
SVO2L
96
SVO4L
91
SVO1H
97
SVO3H
92
SVO2H
98
SVO4H
93
SVO1X
99
SVO3X
94
SVO2X
100
SVO4X
101
SVO5L
107
SVRL1
102
SVO6L
108
SVRL2
103
SVO5H
109
LVDTEXH1
104
SVO6H
110
LVDTEXL1
105
SVO5X
111
LVDTEXH2
106
SVO6X
112
LVDTEXL2
113
LVDTEXH3
115
LVDTEXH4
114
LVDTEXL3
116
LVDTEXL4
117
LVDTEXH5
119
LVDTEXH6
Analog 4-20 mA input #9
Analog 4-20 mA ±10 V input #11
Analog 4-20 mA Output #1
Servo Output #1 and #2.
Note Odd-Even Terminal Grouping
Servo Output #5 and #6.
Note Odd-Even Terminal Grouping 1
LVDT Excitation Output #3
LVDT Excitation Output #5
Analog 4-20 mA input #10
Servo Output #3 and #4.
Note Odd-Even Terminal Grouping
Servo Suicide Relay Input
LVDT Excitation Output #1
LVDT Excitation Output #2
LVDT Excitation Output #4
LVDT Excitation Output #6
2.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
Note Auto-Reconfiguration is not available with the PCAA module.
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2.1.3.1
•
•
•
•
•
Connectors
Connectors P1 and P2 provide cable connections to a TCAT terminal board.
An RJ-45 Ethernet connector named ENET1 on the module side is the primary system interface.
A second RJ-45 Ethernet connector named ENET2 on the module side is the redundant or secondary system interface.
A 3-pin power connector P5 on the module is the input point for 28 V dc power for the module and terminal boards.
A power connector P4 on the module provides 28 V dc power to a JGPA board located for wire shield termination.
Note The module operates from a power source that is applied directly to the module P5 connector, not through the normal
power connector located on the processor board.
2.1.3.2
Module Design
The PCAA module consists of four separate circuit boards in a single physical assembly. The module is regarded as the least
replaceable unit because of the difficulty of isolating a failure to a single board. The module is not designed for replacement
of individual boards.
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PCAA Board Relationship Diagram
PCAA Core Analog Module
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2.1.3.3
BCAA and BCAB Analog Application Boards
The BCAA is the main printed circuit board in the PCAA module. This board provides the main ±15 V power and the
majority of the digital and analog interface to the processor board. In addition, this board provides the signal conditioning
required to interface 12 LVDT sensors, five 4-20 mA and six servo outputs, and two TTL flow sensors to the processor board.
The BCAB interface board provides the signal conditioning required to interface the thermocouples, 4-20 mA inputs, pulse
rate flow sensors and vibration inputs to the control electronics.
Note Inside the module cover the BCAA and BCAB boards provide power, analog signal conditioning, and analog/digital
conversion.
BCAA Block Diagram
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BCAB Block Diagram
2.1.3.4
TCAS Terminal Board
The IS200TCAS terminal board provides the customer terminals and signal routing into the BCAA and BCAB boards. TCAS
accepts bulk 28 V control power through the P5 connector. It then provides the power through connector P4 to a JGPA board
in the input cable shield termination location. TCAS provides the P1 and P2 68 pin connectors for IS200TCAT terminal board
cables. Internal to the module the TCAS terminal board routes signals to connectors for the BCAA and BCAB analog
processing boards.
Note Refer to the table, TCAS Screw Terminal Assignments for more information.
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2.1.3.5
Signal Response
For each signal type an accuracy specification is listed that includes all effects such as aging, temperature, power supply input
variation, and product variation. For each signal type a typical accuracy at 25ºC with mean and standard deviation is also
listed. This typical accuracy is similar to the accuracy that can be expected in normal operation while the specified accuracy is
an absolute worst case limit on the signal accuracy.
2.1.3.6
Thermocouples
PCAA supports the following thermocouple types and temperature ranges:
Type
Range °F
Range °C
E
-60 to 1150
-51 to 621
J
-60 to 1500
-51 to 816
K
-60 to 2000
-51 to 1093
T
-60 to 750
-51 to 399
S
0 to 3200
-17.78 to 1760
Note The units (°C or °F) are based on the ThermCplUnit settings. Refer to the Configuration, ThermCplUnit Parameter
section.
A single cold junction is provided with each PCAA module. The module accepts a controller backup cold junction value,
CJBackup, in the event a problem is detected with the local sensor. The PCAA may be configured to use a controller provided
remote cold junction value, CJRemote. All thermocouple inputs are biased with a dc voltage that will drive the temperature
signal full scale negative if an open wire occurs. Accuracy exceeds ±0.1% of full scale over the full specified operating
temperature of PCAA. Typical measured mean accuracy at 25ºC is ±0.01% with a standard deviation of 0.016%. Primary
source of temperature drift for thermocouple inputs is a precision calibration reference rated at 0.0008%/ºC worst case.
2.1.3.7
4-20 mA Inputs
PCAA meets the specification of ±0.25% for 4-20 mA inputs, ±0.5% for voltage inputs over the full PCAA operating
temperature range. Typical measured mean current input accuracy at 25ºC is ±0.05% with a standard deviation of 0.016%.
Primary source of temperature drift for analog inputs is a precision calibration reference rated at 0.0008%/ºC worst case.
Note Analog inputs 11 and 12 may also be configured as voltage inputs. In support of sensors on legacy systems a single
±12 V power supply output is provided on PCAA with rating of 50 mA.
All inputs have a jumper to select grounded or floating measurements. When the Open/GND jumper is in the Open position
the input accepts a maximum of 7 volts common mode relative to the PCAA ground. As a group, it is possible to specify an
upper and lower current level for a valid input. Each input may then be individually configured to produce a diagnostic when
current is outside the specified limits. Analog Inputs 11 and 12 are typically used as P2 pressure inputs for the Speed Ratio
Valve.
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2.1.3.8
4-20 mA Outputs
Typical measured mean accuracy at 25ºC is ±0.1% with standard deviation of 0.11%. The two outputs on PCAA behave as
typical simplex analog outputs. The three outputs on TCAT, when driven from triple PCAA modules, exhibit full fault
tolerance. An output failure on one of the three PCAA modules results in a very short disturbance to the output with full
recovery to the commanded value. All five analog outputs are provided with independent read-back of the output current and
an output relay. If incorrect operation of the output is detected, the relay is automatically opened to protect the connected
device against excessive output current. All analog output circuits have greater than 18 V output drive capability.
2.1.3.9
Seismic Inputs
TCAT seismic inputs are biased with a small dc current for open wire detection. Inputs go through a high-pass filter at 4 Hz
and low pass filter at 600 Hz. The filtered signal goes through an RMS conversion followed by a 1 Hz filter. The result is
sampled and used to perform a calculation to determine inches per second peak vibration. In parallel with the primary signal
path, the inputs are monitored for the presence of dc voltage to drive the annunciation of a failed or open sensor. PCAA meets
accuracy of ±2% over the full PCAA operating temperature range. Typical measured mean seismic input accuracy at 25ºC is
±0.02% with standard deviation of 0.25%.
2.1.3.10
LVDT
Each of six excitation outputs provides a 7 V rms, 3.2 kHz sine wave and is capable of driving 60 mA. Input sampling takes
place at 100 Hz. PCAA meets LVDT input voltage accuracy of ±1% over the full range of operating temperature and load
impedances. Typical measured mean accuracy at 25ºC is ±0.07% with standard deviation of 0.05%. Position feedback
accuracy in the PCAA is dominated by initial calibration quality and any drift experienced in the circuits after calibration. In
PCAA, drift is determined by the precision voltage reference used for internal circuit calibration, rated for 0.0008%/ºC worst
case temperature drift and almost no measurable aging.
LVDT signal conditioning on the PCAA uses the measured value of excitation voltage to correct for excitation changes. One
PCAA module may be providing excitation on an LVDT that is being read by all three PCAA modules in a TMR set.
Application blockware must be provided to pass the excitation voltage monitor inputs, ServoExcitMonitor_R,
ServoExcitMonitor_S, ServoExcitMonitor_T to the ExcMon_fromR and ExcMon_fromS and ExcMon_fromT outputs
through the Move block function.
2.1.3.11 Pulse Inputs
The Mark VIe control system uses shaft speed inputs on the PTUR and the PPRO, and flow inputs on the PSVO. The PCAA
is intended for use with the PTUR and the PPRO, so it does not include shaft speed inputs. The PCAA includes two TTL (5v
active) pulse rate inputs with output power. The TCAT has two fanned magnetic pulse rate inputs. All inputs are for flow
measurements associated with servo regulation and work up to 20,000 Hz.
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2.1.3.12
Servo Outputs
Servo output features in the PCAA module include:
•
•
•
•
Six output drivers capable of full scale output of 10 mA.
Regulators run at 100 Hz
Servo output accuracy ±3.5%
Two of the six outputs can be tied to an output signal from a PPRO or PTUR, which removes output drivers and biases
the output closed if a trip occurs.
PCAA implements four regulator types. The Speed Ratio Valve (SRV) regulator in the PCAA is an enhanced version of the
SRV control in the Mark VI product. The PCAA provides support for both the outer P2 pressure loop and the inner position
loop. The PCAA can run both loops at 100 Hz compared to 200 Hz for the PSVO’s inner position loop and 25 Hz for the
controller’s outer P2 loop.
Output current range is fixed at 10 mA. PCAA meets a servo output accuracy of ±3.5% of full scale over the full range of
operating temperature and load impedance. Typical measured mean accuracy at 25ºC is ±0.5% with standard deviation of
0.07%.
To allow continuous movement of the servo system to avoid sticking, PCAA features adjustable amplitude dither with
frequency selected to be 50 Hz, 25 Hz, 16.67 Hz, 12.5 Hz, and 8.13 Hz.
The first two servo outputs are equipped with an output shut down relay. Terminals 107 and 108 must be disconnected for
servo 1 and 2 to be enabled. If terminals 107 and 108 are shorted together, the servo driver is disconnected from the output
terminals and a passive circuit biases the servo closed. This feature is used when it is required to include servo action in a
control protective response. The TREG K4CL relay is often used for this purpose in simplex systems. If protective action is
not needed on these servos, leave terminals 107 and 108 open. Servos three through six are not affected by the shutdown relay
action.
2.1.3.13
Calibrate Valve Function
The calibration of LVDTs associated with PSVO, PSVP, PCAA, or PMVE (MVRA or MVRF) servos is required when a new
terminal board is used on a system. The controller saves the barcode of the terminal board and compares it to the current
terminal board during reconfiguration load time. Any time a recalibration is saved, it updates the barcode name to the current
board.
Note Refer to the ToolboxST User Guide for Mark Controls Platform (GEH-6700), the chapter Special I/O Functions. the
section Calibrate Valve Function.
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2.1.4 PCAA Specifications
Item
PCAA Specification
Number of Inputs
25 thermocouple inputs
Ten 4-20 mA inputs
Two 4-20 mA or ±10 V configurable inputs
Two active pulse rate inputs
One servo coil suicide relay input – first two servo outputs
Number of Outputs
PCAA I/O pack
Six servo coil driver outputs
Two 4-20 mA outputs
One ±12 V dc power output
Six LVDT excitation outputs
JGPA board
Twelve 24 V power outputs for 4-20 mA transmitters
Power supply input voltage
28 V dc ±5%
Size
33.02 cm high x 17.8 cm wide (13 in x 7 in)
Technology
Surface-mount
† Ambient rating for enclosure design
PCAAH1B is rated from -40 to 70ºC (-40 to 158 ºF)
PCAAH1A is rated from -30 to 65ºC (-22 to 149 ºF)
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
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Signal Accuracy
Thermocouple inputs
Type E, J, K, S and T are supported
PCAA
±0.10% including all sources of error for a full scale range of
-13.8 to +45.5 mV
±0.06% typical at 25ºC
Analog 4-20 mA inputs
PCAA and TCAT
±0.25% including all sources of error
±0.10% typical at 25ºC
Analog 0-10 V dc inputs
PCAA
±0.50% including all sources of error
±0.20% typical at 25ºC
Pulse rate inputs
TCAS
2-20 khz with accuracy of .05% of reading
Flow rate inputs
TCAS
2-20 khz with accuracy of .05% of reading
Seismic inputs with a range of ± 1.5 V
peak
TCAT
±2.00% including all sources of error
±0.90% typical at 25ºC
LVDT 0-7.07 V rms input
TCAT
±1.00% including all sources of error
±0.25% typical at 25ºC
LVDT 0-7.07 V rms excitation monitor
input
PCAA
±1.00% including all sources of error
±0.55% typical at 25ºC
LVDT excitation output
PCAA
7 V ac RMS ±5.00% including all error sources, ±3.00% typical
at 25ºC
3.2 kHz output sine wave frequency.
60 mA output drive current capability.
Servo driver output, range of ± 10 mA
PCAA
±3.50% including all sources of error
±0.70% typical at 25ºC
Analog 4-20 mA output
PCAA and TCAT
±0.75% including all sources of error
±0.43% typical at 25ºC
24 V Power output
JGPA and TCAT
24 V dc ±0.5% over current ranges of 0 to 25 mA.
LVDT position calculation uses monitor
value, not excitation output
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2.1.5 Diagnostics
The module performs the following self-diagnostic tests:
•
•
•
•
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set
As a group, the 4-20 mA analog inputs have a specified high and low current range for a valid signal. If a signal falls
outside the specified range, the signal health is declared to be bad.
The analog input hardware includes precision reference voltages in each scan. Measured values are compared against
expected values, and are used to confirm the health of the analog to digital converter circuits. If the reference value does
not fall within a defined range, an alarm is generated to indicate a potential problem with signal accuracy.
Analog output current is sensed on the terminal board using a small burden resistor. The pack conditions this signal and
compares it to the commanded current to confirm the health of the digital to analog converter circuits.
The analog output suicide relay is continuously monitored for agreement between commanded state and feedback
indication.
Thermocouple circuits are biased with a small dc current. If a thermocouple circuit opens, the temperature signal goes to
a full-scale negative reading.
Seismic input circuits are biased with a small dc current. If a seismic sensor circuit opens, an alarm is generated and the
signal health is set to indicate a problem.
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RESET_DIA signal if they go healthy.
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2.1.6 Configuration
2.1.6.1
Analog Input
The PCAA is able to interface to several different types of 4-20 mA transmitters. Each input has a jumper next to the
terminals that is used to determine if the return terminal is grounded or floating. The default position of the jumper is floating
or open. The JGPA board provides twelve 24 V dc terminals, one for each 4-20 mA transmitter input.
The last two 4-20 mA inputs on PCAA feature an additional jumper that removes the 250 Ω burden resistor for ±10 V dc
input applications. When the jumper is in the MA position, the input behaves the same as the first ten inputs. When the
jumper is in the VOLT position the burden resistor is removed and the input acts as a voltage input.
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Analog Input Jumper Summary
Jumper
Pos 1-2
Pos 2-3
Notes
JP1
OPEN
GND
Analog In 1
JP2
OPEN
GND
Analog In 2
JP3
OPEN
GND
Analog In 3
JP4
OPEN
GND
Analog In 4
JP5
OPEN
GND
Analog In 5
JP6
OPEN
GND
Analog In 6
JP7
OPEN
GND
Analog In 7
JP8
OPEN
GND
Analog In 8
JP9
OPEN
GND
Analog In 9
JP10
OPEN
GND
Analog In 10
JP11
OPEN
GND
Analog In 11
JP12
OPEN
GND
Analog In 12
JP13
MA
VOLT
Analog In 11
JP14
MA
VOLT
Analog In 12
2.1.6.2
Servo Output
Correct position selection for servo configuration jumpers are listed under each servo regulator type.
Jumper
Pos 1-2
Pos 2-3
Notes
JP15
TMR
Simplex
Servo1 output select
JP16
TMR
Simplex
Servo2 output select
JP17
TMR
Simplex
Servo3 output select
JP18
TMR
Simplex
Servo4 output select
JP19
TMR
Simplex
Servo5 output select
JP20
TMR
Simplex
Servo6 output select
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2.1.6.3
ThermCplUnit Parameter
The ThermCplUnit parameter affects the native units of the controller application variable. It is only indirectly related to the
tray icon and associated unit switching capability of the HMI. This parameter should not be used to switch the display units of
the HMI.
Caution
2.1.6.4
Do not change the ThermCplUnit parameter in the ToolboxST application because
these changes will require corresponding changes to application code and to the
Format Specification or units of the connected variable. This parameter modifies the
actual value sent to the controller as seen by application code. Application code that is
written to expect degrees Fahrenheit will not work correctly if this setting is changed.
External devices, such as HMIs and Historians, may also be affected by changes to this
parameter.
Position Valve Servo System
The Position Valve Servo system is used to control the Gas Control Valves (GCV) on the fuel skids of heavy-duty gas
turbines and the Inlet Guide Vanes (IGV) on the compressor of the heavy-duties. Refer to the diagram Position Valve Servo
System.
GCV or guide vane position is fed back to the digital position regulator in the PCAA using LVDT sensors. The TCAS
terminal board provides the six LVDT excitation signal pairs: LVDTEXH1_R/LVDTEXL1_R through LVDTEXH6_
R/LVDTEXL6_R. These excitation outputs are connected to the primary-side of the LVDT position sensor. The primary-side
signal is a 3.2 kHz sine wave excitation with a 7.07 V RMS amplitude. The LVDT secondary-side signal amplitude is
proportional to the position change in the valve. The LVDT secondary-side is connected to one of the twelve TCAT terminal
board LVDT input signal pairs: LVDT1H/LVDT1L through LVDT12H/LVDT12L. The TCAT terminal board is used to fan
the LVDT signal pair to the TMR PCAA set: PCAA (R), PCAA (S) and PCAA (T) through cabling. The BCAA acquisition
board provides signal conditioning to convert the RMS voltage from the secondary-side of the LVDT to a dc equivalent signal
read by the processor through analog-to-digital (A/D) converters.
The PCAA firmware can run up to six independent digital servo regulators. Each loop is performed at a 100 Hz sample rate.
Details of the Position digital regulator are covered in the next section. The digital regulator output, ServoCurrentRef is
written to a digital-to-analog (D/A) converter. The negated output of the D/A is the current command for the analog current
regulator.
The BCAA acquisition board has six analog current regulators, one per digital servo regulator. All six analog current
regulators are rated for 10 mA only. Each current output provides an internal suicide protection relay controlled by the PCAA
firmware. Each of the six servo outputs supports either three-coil servos or two-coil servos and each provides a jumper on the
TCAS terminal board to configure the output.
The jumper is placed in the TMR position for the 3-coil servo and placed in the opposite position for the 2-coil servo. For
example, for the 3-coil servo using Servo output 1:
•
•
•
TCAS SVO1H_R/SVO1L_R outputs are connected to coil 1. TCAS-R J15 is placed in the 1-2_TMR position.
TCAS SVO1H_S/SVO1L_S outputs are connected to coil 2. TCAS-S JP15 is placed the 1-2_TMR position.
TCAS SVO1H_T/SVO1L_T outputs are connected to coil 3. TCAS-T JP15 is placed in the 1-2_TMR position.
For the simplex 2-coil servo connection, TCAS SVO1H_R/SVO1L_R outputs are connected to coil 1 and SVO1X_
R/SVO1L_R outputs are connected to coil 2. TCAS-R JP15 is placed in the 2-3_Simplex position.
Servo outputs 1 and 2 also provide a means to externally suicide the outputs through the TCAS inputs SVRL1/2. For the
Mark VIe, the PPRO provides an external contact connected across SVRL1 and SVRL2. If the contact closes, the K1 relay is
energized and the servo output is isolated from the digital regulator control, providing a direct connection through a current
limiting resistor (15 mA fixed output), as long as the K1 relay is energized.
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Position Valve Servo System
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2.1.6.5
Digital Servo Regulator_Position
The digital Position regulator is a proportional regulator generating a servo current command proportional to the error signal,
the difference between the position reference from the controller and the valve position feedback. Refer to the diagram Digital
Servo Regulator_Position.
Three feedback options are supported: Single position feedback, dual position feedbacks or three position feedbacks.
•
•
•
Setting PositionInput1 equal to one of the twelve LVDT inputs can configure the single position feedback option.
The dual feedback option is selected when the configuration parameters, PositionInput1 and PositionInput2 are assigned
to different LVDT inputs.
The three feedback option is enabled by setting each of the following configuration parameters to a unique LVDT input:
PositionInput1, PositionInput2 and PositionInput3.
Each of the enabled position inputs run through a Position Calculation function that converts the dc volts signal representing
RMS volts to a valve position in percent where 0% represents fully closed and 100% represents a fully open valve.
The Position Limit function’s input is the following based on the configuration:
•
•
•
Equal to the Position Calculation output for a single position feedback.
Equal to the maximum select from two Position Calculation outputs for the dual position input configuration.
Equal to the median select for the three position input configuration. The Position Limit function checks the feedback
range of Reg#_Fdbk. The range defined in percent over nominal is configurable using the parameter, Fdbk_Suicide. The
suicide only works if it is enabled by EnabPosFbkSuic.
In the next figure, the proportional regulator error, is equal to the position reference command from the controller, Reg#Ref
minus the position feedback, Reg#_Fdbk. Proportional regulator error is multiplied by a composite gain defined by the
multiplication of the configuration parameter, RegGain and the controller output, Reg#_GainAdj. The product of the gain and
position error defines a current in percent. The amount of current required to negate the spring force used to close the valve if
the servo fails is compensated by the configuration parameter, RegNullBias. The controller system output, Reg#_NullCor is
used to correct the null bias value when one of the TMR servos is suicided. The resultant output from the proportional
position regulator is a current command in percent with the Monitor variable name, CurrentOutputCmd.
After the initial configuration setting is made for the position loop, the user calibrates the position valve feedbacks. This is
done by using ToolboxST to select the LVDT calibration mode and setting the controller output CalibEnab# equal to TRUE.
In the calibration mode, the user can use the servo output in the open-loop mode to force the valve to the fully closed position
and also to the fully open position. During the calibration mode, the PCAA assigns the RMS voltage that represents the open
and closed position to the configuration parameters for each LVDT that is used: MinVrms and MaxVrms. The user selects
Calibrate and Save to store the LVDT Excitation output voltage in the LVDT configurable parameter ExcitMonCal. The
excitation voltage is used to compensate for excitation voltage changes during runtime. The user must also verify that the
LVDT parameter ExcitSelect comes from the proper Excitation voltage source (R, S, or T).
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I/O Configuration
PositionInput1
Reg_GainAdj_Enab
PositionInput 2
RegType
PositionInput3
LVDT1
LVDT2
LVDT3
LVDT4
LVDT5
LVDT6
LVDT7
LVDT8
LVDT9
LVDT10
LVDT11
LVDT12
Select 1 if PositionInput 1 only used.
Select 2 if PositionInput 1 & PositionInput 2 used.
Select 3 if PositionInput 1, PositionInput 2 & PositionInput 3 used.
Position1(%)
Position1 Calc
(volts to %)
M
U
X
RegNullBias
RegGain
Reg#_GainAdj
(%/%) (so)
1
1
Reg#_Error (%)
(si)
CalibEnab#(so)
Reg#_Ref (%)
(sso)
+
+
RegOutput
Cmd(%)
+
LVDT1
M
U
X
Position
Maximum
Select
Position2 Calc
(volts to %)
Position
Limit
Check
2
M
U
X
LVDT12
Position2(%)
LVDT1
M
U
X
Position3 Calc
(volts to %)
Median
Select
+
-
Reg#_NullCor(%)
(so)
Note: Positive
RegOutputCmd (%)
generates negative current ,
neg . ServoOutput (%)
opening the servo valve .
Reg#_Fdbk(%)
(si)
3
Position3(%)
Calibrate
Function
LVDT12
MinVrms(cfg)
MaxVrms(cfg)
Note: Calculated for
all three LVDTs
RegCalMode (si)
ExcitMonCal (cfg)
Note : Calculated for all
three LVDTs
CalibEnab# (so)
Param_Name (cfg) - Servo config parameter (Toolbox view )
Signal_Name - signal from A/D in (no Toolbox view )
Variable_Name
- internal vars to Servo (no Toolbox view )
* - indicates a detailed drawing with title per block name .
Input _Name (si) - Input to controller from Servo (Toolbox view )
MaxPosValue
PositionMargin
Output _Name (so)- Output from controller to Servo (Toolbox view )
VarName
MinPosValue
- Name of Monitor Variable (Toolbox view )
I/O Configuration
# = 1 to 6 (Regulator Number)
Digital Servo Regulator - Position
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 61
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2.1.6.6
Speed Ratio Valve Servo System
The Speed Ratio Valve Servo system is used to control the main fuel-feed Speed Ratio Valve (SRV) whose output feeds the
GCVs on the fuel skids of the heavy-duty gas turbines. The SRV control is a multi-loop servo. The P2 pressure provides the
outer loop feedback and the valve position provides the inner loop control. Refer to the diagram Speed Ratio Valve Servo
System.
The outer loop SRV pressure is fed back to the digital pressure loop in the PCAA using pressure sensors. These pressure
sensors have 4-20 mA outputs that connect to the dedicated TCAS SRV analog inputs: ASIH11/ASIL11 and/or
ASIH12/ASIL12.
Note The pressure inputs are not fanned, and redundant pressure inputs are connected to separate PCAA modules when the
SRV is configured as TMR.
The inner loop P2 valve position is fed back to the digital position loop in the PCAA using LVDT sensors. The LVDT
secondary-side is connected to one of the twelve TCAT terminal board LVDT input signal pairs: LVDT1H/LVDT1L through
LVDT12H/LVDT12L. The TCAT terminal board is used to fan the LVDT signal pair to the TMR PCAA set: PCAA (R),
PCAA (S) and PCAA (T) through cabling. The BCAA acquisition board provides signal conditioning to convert the RMS
voltage from the secondary-side of the LVDT to a dc equivalent signal read by the processor through analog-to-digital (A/D)
converters.
The PCAA firmware uses one of the six independent digital servo regulators. The SRV loop is run at a 100 Hz sample rate.
Details of the Speed Ratio Valve digital regulator are covered in the next section. The digital regulator output
CurrentOutputCmd is written to a digital-to-analog (D/A) converter. The output of the D/A is the current command for the
analog current regulator.
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Speed Ratio Valve Servo System
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 63
Non-Public Information
2.1.6.7
Digital Servo Regulator – Speed Ratio
The digital Speed Ratio Valve regulator is a proportional plus integral (PI) outer regulator with an inner proportional position
regulator generating a servo current command. The SRV output is based on a multi-loop control using the P2 pressure
feedback for the outer loop and the valve position for the inner loop feedback. Refer to the diagram Digital Servo Regulator Speed Ratio.
The outer P2 pressure loop derives its pressure feedback from either a single pressure input or the maximum select of two
pressure inputs. For a single pressure input, the configuration parameter PressureInput1 is assigned to either AnalogInput11
or 12. For a dual pressure input, PressureInput1 is assigned to AnalogInput11 or 12 and PressureInput2 is assigned to
AnalogInput11 or 12. The Pressure Limit Check checks the range of the maximum select or the single feedback depending on
the configuration. If the pressure feedback, Reg#_Pressure is less than PresFdbkLoLim or Reg#_Pressure is greater than
PresFdbkHiLim then the pressure loop is assumed to be open loop and the SRV servo out will suicide if the
EnabPressureFbkSuic parameter is set to Enable.
The SRV pressure error, Reg#Ref minus Reg#Pressure has an integrator convergence error added to it. The objective of the
convergence error is to keep the PI controller between PCAA (R), PCAA (S) and PCAA (T) together. The PI output for (R, S
and T), Reg#_IntOut is read by the controller. The average error, Reg#_IntConv is calculated from the three inputs. Each SRV
regulator for R, S and T takes the average, subtracts its own PI output value from this, multiplies it by a gain value, K_Conv_
OuterReg to come up with the convergence error to move the integrator for PI R, S and T together. The PI proportional gain,
K_OuterReg and the integral time constant, Tau_OuterReg provide the PI adjustments. The clamping is controlled by the
parameters: HiLim_OuterReg and LowLim_OuterReg. The PI outer loop output, Reg#_IntOut is the position command for the
inner position loop.
The inner position loop supports two feedback options: Single position feedback and the maximum select of two position
feedbacks. Setting PositionInput1 equal to one of the twelve LVDT inputs can configure the single position feedback option.
The maximum select of two position feedbacks is selected when the configuration parameters, PositionInput1 and
PositionInput2 are assigned to different LVDT inputs.
Each of the position inputs enabled run through a Position Calculation function that converts the dc volts signal representing
RMS volts to a valve position in percent where 0% represents fully closed and 100% represents a fully open valve.
The Position Limit function’s input is the following based on the configuration: equal to the Position Calculation output for a
single position feedback or equal to the maximum select from two Position Calculation outputs for the dual position input
configuration. The Position Limit function checks the feedback range of Reg#_Fdbk. The range defined in percent over
nominal is configurable using the parameter, Fdbk_Suicide.
The proportional regulator error, Reg#_Error is equal to the position reference command from the controller, Reg#Ref minus
the position feedback, Reg#_Fdbk. Reg#_Error is multiplied by a composite gain defined by the multiplication of the
configuration parameter, RegGain and the controller output, Reg#_GainAdj. The product of the gain and position error
defines a current in percent. The amount of current required to negate the spring force used to close the valve if the servo fails
is compensated by the configuration parameter, RegNullBias. The controller system output, Reg#_NullCor is used to correct
the null bias value when one of the TMR servos suicides for some reason. The resultant output from the proportional position
regulator is a current command in percent with the Monitor variable name, CurrentOutputCmd.
After the initial configuration setting is made for the position loop, the user calibrates the position valve feedbacks. This is
done by using ToolboxST to select the LVDT calibration mode and setting the controller output CalibEnab# equal to TRUE.
In the calibration mode, the user can use the servo output in the open-loop mode to force the valve to the fully closed position
and also to the fully open position. During the calibration mode, the PCAA assigns the RMS voltage that represents the open
and closed position to the configuration parameters: MinVrms and MaxVrms. The user selects Calibrate and Save to store the
LVDT Excitation output voltage in the LVDT configurable parameter ExcitMonCal. The excitation voltage is used to
compensate for excitation voltage changes during runtime. The user must also verify that the LVDT parameter ExcitSelect
comes from the proper Excitation voltage source (R, S, or T).
64
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I/O Configuration
LowLim _OuterReg
HiLim_OuterReg
Tau_OuterReg
K_OuterReg
Reg_Kadj_Enab
PressureInput 2
K_Conv_OuterReg
PressureInput 1
AnalogInput11
1
-
+
-
+
Reg#_ByPass
(so)
OuterReg
Err (%)
1
k = proportional gain,
T = Time constant of up-break
Pressure Max .
Select
Pressure 2(%)
1
M
2U
X
3
LVDT1
Position1 Calc
Reg#_PosBiasFF
(%) (so)
+
-
RegOutput
Cmd(%)
+
Note: Positive
RegOutput
Cmd(%)
generates
negative
current , neg.
ServoOutpu t
(%) opening
the servo
valve.
Reg#_NullCor
(%) (so)
Reg#_Fdbk(%)
(si)
Position1(%)
a
M
bU
X
Position(%)
Position
Limit
Check
MinVrms(cfg)
MaxVrms(cfg)
Note : Calculated for
both LVDTs
c
Position2 (%)
Sel a if PositionInput 1 only.
Sel b if PositionInput 1 and PositionInput 2 used.
Sel c if PositionInput 2 only.
M
U
X
+
Select 1 if PressureInput 1 only used .
Select 2 if PressureInput 1 & PressureInput 2.
Select 3 if PressureInput 2 only used .
Position2 Calc
LVDT1
+
Reg#_Pressure (%)
(si)
Pressure
Limit
Check
Position
Maximum
Select
LVDT12
Reg#_Error
(%) (si)
k(1+sT)
s
Pressure 1(%)
M
U
X
M
U
X
Reg#_GainAdj
(%/%) (so)
CalibEnab# (so)
+
M
U
X
AnalogInput12
RegNullBias
+
OuterLoop
Err (%)
Reg#_Ref
(so)
Reg_GainAdj_Enab
RegGain
Reg#_IntOut (%)
(si)
Reg#_Kadj
(%/%) (so)
Reg#_IntConv
(%) (so)
RegType
Calibrate
Function
ExcitMonCal (cfg)
Note : Calculated for
both LVDTs
LVDT12
RegCalMode (si)
CalibEnab# (so)
PositionInput1
PositionInput2
I/O Configuration
Param_Name(cfg) - Servo config parameter(Toolbox view)
Signal_Name - signal from A/D in (no Toolbox view)
Variable _Name
- internal vars to Servo (no Toolbox view)
* - indicates a detailed drawing with title per block name
.
Input_Name (si) - Input to controller from Servo(Toolbox view)
Output_ Name (so)- Output from controller to Servo(Toolbox view)
- Name of Monitor Variable(Toolbox view)
VarName
MaxPosValue PositionMargin
MinPosValue
I/O Configuration
# = 1 to 6 (Regulator number)
Speed Ratio Valve Servo System
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 65
Non-Public Information
2.1.6.8
Liquid Fuel Valve Servo System
The Liquid Fuel Servo system is used with gas turbines using the liquid fuel option. Refer to the diagram Liquid Fuel Valve
Servo System.
The flow rate is fed back to the digital flow rate regulator in the PCAA using Liquid Fuel flow meter with magnetic pickup
outputs. The flow meter output is connected to one of the two TCAT terminal board magnetic flow sensor input signal pairs:
MFI1H/MFI1L through MFI2H/MFI2L or two TCAS terminal board TTL flow sensor input signals: TFH1/L1 through
TFH2/L2. The TCAT terminal board is used to fan the magnetic input signal pair to the TMR PCAA set: PCAA (R), PCAA
(S) and PCAA (T) through cabling. The BCAA acquisition card provides signal conditioning to convert the variable
frequency, variable amplitude input to a digital pulse. The digital pulse from the magnetic flow sensor signal conditioning or
the TTL sensor conditioning feeds a counter used to determine the frequency of the pulse train from the flow meter.
The processor board uses one of the six independent digital servo regulators. The Liquid Fuel servo regulator is sampled at a
100 Hz rate. Details of the Liquid Fuel digital regulator are covered in the next section. The digital regulator output,
ServoCurrentRef is written to a digital-to-analog (D/A) converter. The output of the D/A is the current command for the
analog current regulator.
The BCAA acquisition board has six analog current regulators, one per digital servo regulator. All six analog current
regulators are rated for 10 mA only. Each current output provides an internal suicide protection relay controlled by the
processor board software. Each of the six servo outputs supports either three-coil servos or two-coil servos and each provides
a jumper on the TCAS terminal board to configure the output. The jumper is placed in the TMR position for the 3-coil servo
and placed in the Open position for the 2-coil servo. For the 3-coil servo using Servo output 1, TCAS SVO1H_R/SVO1L_R
outputs are connected to coil 1, TCAS SVO1H_S/SVO1L_S outputs are connected to coil 2, and TCAS SVO1H_T/SVO1L_
T outputs are connected to coil 3. For the simplex 2-coil servo connection, TCAS SVO1H_R/SVO1L_R outputs are
connected to coil 1 and TCAS SVO1X_R/SVO1L_R outputs are connected to coil 2.
Servo outputs 1 and 2 also provide a means to externally suicide the outputs through the TCAS inputs SVRL1/2. For the
Mark VIe control, the PPRO provides an external contact connected across SVRL1 and SVRL2. If the contact closes, the K1
relay is energized and the servo output is isolated from the digital regulator control, providing a direct connection through a
current limiting resistor (15 mA fixed output), as long as the K1 relay is energized.
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Liquid Fuel Valve Servo System
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 67
Non-Public Information
2.1.6.9
Digital Servo Regulator - Liquid Fuel
The Digital Liquid Fuel regulator is a proportional regulator generating a servo current command proportional to the error
signal, the difference between the Liquid Fuel flow rate reference from the controller and the flow rate feedback. Refer to the
diagram Digital Servo Regulator - Liquid Fuel.
Two flow rate feedback options are supported: Single flow rate feedback or the dual flow rate option. Setting FlowInput1
equal to one of the four flow rate inputs configures the single flow rate option. The dual feedback option is selected when the
configuration parameters, FlowInput1 and FlowInput2 are assigned to different flow inputs. Unlike the LVDT calibration
available for the position inputs, there is no ToolboxST calibration function for the flow inputs.
Each of the enabled flow rate inputs runs through a Flow Rate Calculation function that converts the revolutions per minute
frequency to a flow rate percentage where 0% represents no flow and 100% represents a rated flow.
The Flow Rate Limit Check’s input is the following based on the configuration: equal to the flow rate output for a single
feedback or equal to the maximum select from two flow rates. The Flow Rate Limit Check looks for the flow rate feedback,
Reg#_Fdbk to be out of range. The range is defined using configurable minimum and maximum flow limits in percent of
nominal. There is also a configurable delay that must be exceeded before a diagnostic alarm is generated. If the flow feedback
exceeds either flow limit for the defined delay the servo will suicide, if enabled.
The proportional regulator error, Reg#_Error is equal to the flow rate reference command from the controller, Reg#Ref minus
the flow rate feedback, Reg#_Fdbk. Reg#_Error is multiplied by the composite gain defined by the multiplication of the
configuration parameter, RegGain and the controller output, Reg#_GainAdj. The product of the gain and flow rate error
defines a current in percent. The amount of current required to negate the spring force used to close the valve if the servo fails
is compensated by the configuration parameter, RegNullBias. The controller system output, Reg#_NullCor is used to correct
the null bias value when one of the TMR servos suicides for some reason. The resultant output from the proportional position
regulator is a current command in percent with the Monitor variable name, CurrentOutputCmd.
68
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Digital Servo Regulator - LiquidFuel
PRScale
I/O Configuration
Reg_GainAdj_Enab
FlowInput1
FlowInput2
RegType
RegGain
RegNullBias
Reg#_GainAdj
(%/%) (so)
FlowRate3 (si)
1
FlowRate1 (si)
PR1
PR3
Flow Calc
(rpm to %)
M
U
X
Flow Calc
(rpm to %)
Flow1(%)
1
Maximum
Select
PR2
Flow Calc
(rpm to %)
PR4
Flow Calc
(rpm to %)
M
U
X
Flow2(%)
M
2U
X
Note: Positive
RegOutputCmd (%)
generates negative
current , neg .
ServoOutput(%)
opening the servo
valve.
Reg#_Ref(%)
(so)
Reg#_Error(%)
(si)
+
RegOutput
Cmd(%)
+
+
-
+
Reg#_Fdbk(%) (si)
Reg#_NullCor(%) (so)
Flow Rate
Limit
Check
3
Select 1 if FlowInput 1 only used .
Select 2 if FlowInput 1 and FlowInput 2 used .
Select 3 if FlowInput 2 only used .
Param_Name(cfg) - Servo config parameter(ToolboxST view)
Signal_Name - signal from A/D in (no ToolboxST view)
Variable _Name
- internal vars to Servo (no ToolboxST view)
* - indicates a detailed drawing with title per block name
.
FlowRate2 (si)
Input_Name (si)- Input to controller from Servo(ToolboxST view)
FlowRate4 (si)
Output_Name (so)- Output from controller to Servo(ToolboxST view)
VarName - Name of Monitor Variable(ToolboxST view)
# = 1 to 6 (Regulator number)
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 69
Non-Public Information
2.1.6.10
Liquid Fuel Valve with Position Feedback Servo System
The Liquid Fuel Valve with Position Feedback Servo system is used with gas turbines using the liquid fuel option. The Liquid
Fuel Valve with Position Feedback is the multi-loop control system. The fuel flow rate is the feedback for the outer loop and
the valve position is the inner loop feedback. Refer to the diagram Liquid Fuel Valve with Position Feedback Servo System.
The flow rate is fed back to the digital flow rate regulator in the PCAA using Liquid Fuel flow meter with magnetic pickup
outputs. The flow meter output is connected to one of the two TCAT terminal board magnetic flow sensor input signal pairs:
MFI1H/MFI1L through MFI2H/MFI2L or one of the PCAA TTL flow sensor input signal pairs. The TCAT terminal board is
used to fan the magnetic input signal pair to the TMR PCAA set: PCAA (R), PCAA (S) and PCAA (T) through cabling. The
BCAA acquisition card provides signal conditioning to convert the variable frequency, variable amplitude input to a digital
pulse. The digital pulse feeds a counter used to determine the frequency of the pulse train from the flow meter.
The inner loop valve position is fed back to the digital position loop in the PCAA using Linear Variable Differential
Transformer (LVDT) sensors. The TCAS terminal board provides the six LVDT excitation signal pairs: LVDTEXH1_
R/LVDTEXL1_R through LVDTEXH6_R/LVDTL6_R. The primary-side signal is a 3.2 kHz sine wave excitation with a 7.07
V RMS amplitude. The LVDT secondary-side is connected to one of the twelve TCAT terminal board LVDT input signal
pairs: LVDT1H/LSVT1L through LVDT12H/LVDT12L. The TCAT terminal board is used to fan the LVDT signal pair to the
TMR PCAA set: PCAA (R), PCAA (S) and PCAA (T) through cabling. The BCAA acquisition board provides signal
conditioning to convert the RMS voltage from the secondary-side of the LVDT to a dc equivalent signal read by the processor
through analog-to-digital (A/D) converters.
The processor board will use one of the six independent digital servo regulators. The Liquid Fuel Valve with Position
Feedback servo regulator is sampled at a 100 Hz rate. Details of the Liquid Fuel Valve with Position Feedback digital
regulator are covered in the next section. The digital regulator output, ServoCurrentRef is written to a digital-to-analog (D/A)
converter. The output of the D/A is the current command for the analog current regulator.
The BCAA acquisition board has six analog current regulators with a 10 mA rating. Each current output provides an internal
suicide protection relay controlled by the PCAA firmware. Each of the six servo outputs supports either three-coil servos or
two-coil servos and each provides a jumper on the TCAS terminal board to configure the output. The jumper is placed in the
TMR position for the 3-coil servo and placed in the Open position for the 2-coil servo.
Servo outputs 1 and 2 also provide a means to externally suicide the outputs the TCAS inputs SVRL1/2. In the Mark VIe
control system, the PPRO provides an external contact connected across SVRL1 and SVRL2. If the contact closes, the K1
relay is energized and the servo output is isolated from the digital regulator control, providing a direct connection through a
current limiting resistor (15 mA fixed output), as long as the K1 relay is energized.
70
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Mark VIe and VIeS Control Systems for GE Industrial Applications
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Liquid Fuel Valve with Position Feedback Servo System
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 71
Non-Public Information
2.1.6.11 Digital Servo Regulator – Liquid Fuel with Position
The Digital Liquid Fuel with Position regulator is a proportional plus integral (PI) outer flow rate regulator with an inner
proportional position regulator generating a servo current command. The Liquid Fuel with Position output is based on a
multi-loop control using the liquid fuel flow rate feedback for the outer loop and the valve position for the inner loop
feedback. Refer to the diagram Digital Servo Regulator - Liquid Fuel with Position.
The outer flow rate loop derives its feedback from either a single flow rate input or the maximum select of two flow rate
inputs. For a single flow rate input, the configuration parameter FlowInput1 is assigned to FlowRate1 through FlowRate4. For
the maximum select of two flow rates, the configuration parameter, FlowInput1 is equal to one of four flow rate feedbacks
and FlowInput2 is equal to a different one of the four flow feedbacks. The Flow Rate Limit Check checks the range of the
maximum select or the single feedback depending on the configuration. If the flow rate feedback, Reg#_FlowFdbk is less
than FlowFdbkLoLim or Reg#_PressureFlowFdbk is greater than FlowFdbkHiLim then the flow loop is assumed to be open
loop and the SRV servo out will suicide.
The flow rate error, Reg#Ref minus Reg#FlowFdbk has an integrator convergence error added to it. The objective of the
convergence error is to keep the PI controller between PCAA (R), PCAA (S) and PCAA (T) together. The PI output for (R, S
and T), Reg#_IntOut is read by the controller. The median selected value, Reg#_IntConv is calculated from the three inputs.
Each LFBV regulator for R, S, and T takes the average, subtracts its own PI output value from this, multiplies it by a gain
value, K_Conv_OuterReg to come up with the convergence error to move the integrator for PI R, S, and T together. The PI
proportional gain, K_OuterReg and the integral time constant, Tau_OuterReg provide the PI adjustments. The clamping is
controlled by the parameters: HiLim_OuterReg and LowLim_OuterReg. The PI outer loop output, Reg#_IntOut is the position
command for the inner position loop.
The inner position loop supports two feedback options: Single position feedback and the maximum select of two position
feedbacks. Setting PositionInput1 equal to one of the twelve LVDT inputs can configure the single position feedback option.
The maximum select of two position feedbacks is selected when the configuration parameters, PositionInput1 and
PositionInput2 are assigned to different LVDT inputs.
Each of the enabled position inputs run through a Position Calculation function that converts the dc volts signal representing
RMS volts to a valve position in percent where 0% represents fully closed and 100% represents a fully open valve. The valve
percent representation can also be configured for the opposite where 100% is equivalent to fully closed.
The Position Limit function’s input is the following based on the configuration: equal to the Position Calculation output for a
single position feedback or equal to the maximum select from two Position Calculation outputs for the dual position input
configuration. The Position Limit function checks the feedback range of Reg#_Fdbk. The range defined in percent over
nominal is configurable using the parameter, Fdbk_Suicide; if enabled.
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The proportional regulator error, Reg#_Error is equal to the position reference command from the controller, Reg#Ref minus
the position feedback, Reg#_Fdbk. Reg#_Error is multiplied by a composite gain defined by the multiplication of the
configuration parameter, RegGain and the controller output, Reg#_GainAdj. The product of the gain and position error
defines a current in percent. The amount of current required to negate the spring force used to close the valve if the servo fails
is compensated by the configuration parameter, RegNullBias. The controller system output, Reg#_NullCor is used to correct
the null bias value when one of the TMR servos suicides for some reason. The resultant output from the proportional position
regulator is a current command in percent with the Monitor variable name, CurrentOutputCmd.
After the initial configuration setting is made for the position loop, the user calibrates the position valve feedbacks. This is
done by using ToolboxST to select the LVDT calibration mode and setting the controller output CalibEnab# equal to TRUE.
In the calibration mode, the user can use the servo output in the open-loop mode to force the valve to the fully closed position
and also to the fully open position. During the calibration mode, the PCAA assigns the RMS voltage that represents the open
and closed position to the configuration parameters: MinVrms and MaxVrms. The user selects Calibrate and Save to store the
LVDT Excitation output voltage in the LVDT configurable parameter ExcitMonCal. The excitation voltage is used to
compensate for excitation voltage changes during run time. The user must also verify that the LVDT parameter ExcitSelect
comes from the proper Excitation voltage source (R, S, or T).
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 73
Non-Public Information
Reg_Kadj_Enab
K_Conv_OuterReg
LowLim_OuterReg
HiLim_OuterReg
Tau_OuterReg
Reg#_GainAdj
(%/%) (so)
1
OuterLoop
Err (%)
Reg#_Ref(%) (so)
Reg#_IntOut
(%) (si )
+
-
+
+
-
+
RegNullBias
Reg_GainAdj_Enab
K_OuterReg
Reg#_KAdj
(so)
Reg#_IntConv
(%) (so)
RegGain
RegType
OuterReg
Err (%)
Reg#_ByPass
(so)
CalibEnab# (so)
1
k(1+sT)
sT
k = proportional gain,
T = Time constant of up-break
Reg#_PosBiasFF
(%) (so)
+
+
Reg#_Error (%)
(si)
+
-
+
Reg#_FlowFdbk
(%) (si)
FlowRate1 (si)
M
U
X
FlowRate2 (si)
FlowRate3 (si)
Flow1(%)
FlowRate4 (si)
Max
Select
M
U
X
LVDT1
Flow2(%)
Reg#_NullCor(%)
(so)
Reg#_Fdbk(%)
(si)
1
FlowRate
Limit
Check
M
2 U
X
MinVrms(cfg)
MaxVrms(cfg)
Note: calculated for all
three LVDTs
RegCalMode (si)
Calibrate
Function
Position1(%)
LVDT12
Position1 Calc
Position (%)
Position
Maximum
Select
LVDT1
Position2(%)
M
U
X
Note:
Positive
RegOutputCmd
(%) generates
negative current ,
neg.
ServoOutput (%)
opening the servo
valve.
3
Select 1 if FlowInput 1 only used .
Select 2 if FlowInput 1 and FlowInput 2 used.
Select 3 if FlowInput 2 only used .
M
U
X
RegOutput
Cmd(%)
+
CalibEnab#
(so)
Position
Limit
Check
ExcitMonCal (cfg)
Note : Calculated for all
LVDTs
Position2 Calc
LVDT12
PositionInput1
Param_Name(cfg) - Servo config parameter(Toolbox view)
Signal_Name - signal from A/D in (no Toolbox view)
Variable _Name
- internal vars to Servo(no Toolbox view)
* - indicates a detailed drawing with title per block name
.
Input_Name (si) - Input to controller from Servo(Toolbox view)
Output_ Name (so) - Output from controller to Servo(Toolbox view)
FlowInput1
FlowInput2
VarName
PositionInput 2
I/O Configuration
- Name of Monitor Variable(Toolbox view)
# = 1 to 6 (Regulator number)
MaxPosValue
PositionMargin
MinPosValue
I/O Configuration
Digital Servo Regulator - LiqFuel_wPos
74
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2.1.6.12
Parameters
Parameter
Description
Choices
Max_MA_Input
Maximum MA for Healthy 4/20 ma Input
0 to 21.5 mA
Min_MA_Input
Minimum MA for Healthy 4/20 ma Input
0 to 21.5 mA
LVDT_TMR_DiffLim
TMR Input vote difference in % of range.If any of the TMR
LVDTs are greater than or less than this difference from
the median value in percent, a diagnostic is generated on
the errant PCAA.
0 to 200%
2.1.6.13
TCAS Analog Inputs
Input
Description
Choices
AnalogInput01_R,S,T
First of 10 Simplex Analog inputs on the TCAS board board variable
Variable edit (Input FLOAT)
InputType
Type of Analog Input
Unused, 4-20ma
Low_Input
Input MA at Low Value
-10 to 20
Low_Value
Input Value in Engineering Units at Low MA
-3.4082 e +38 to 3.4028 e +38
High_Input
Input MA at High Value
-10 to 20
High_Value
Input Value in Engineering Units at High MA
-3.4082 e +38 to 3.4028 e +38
DiagHighEnab
Enable High Input Limit Diagnostic as specified in
Parameters tab
Enable Low Input Limit Diagnostic as specified in
Parameters tab
Analog inputs 11, 12 Can be used as pressure inputs to
the servo Speed Ratio regulator
Enable, Disable
DiagLowEnab
AnalogInput11_R,S,T
Enable, Disable
Variable edit (Input FLOAT)
InputType
Type of Analog Input
Unused, 4-20ma, +/-10V, +/-5V
Low_Input
Input MA (or Volts) at Low Value
-10 to 20
Low_Value
Input Value in Engineering Units at Low MA (or Volts)
-3.4082 e +38 to 3.4028 e +38
High_Input
Input MA (or Volts) at High Value
-10 to 20
High_Value
Input Value in Engineering Units at High MA (or Volts)
-3.4082 e +38 to 3.4028 e +38
DiagHighEnab
Enable High Input Limit Diagnostic as specified in
Parameters tab
Enable Low Input Limit Diagnostic as specified in
Parameters tab
Enable, Disable
DiagLowEnab
PCAA Core Analog Module
Enable, Disable
GEH-6721_Vol_III_BJ System Guide 75
Non-Public Information
2.1.6.14
TCAT Analog Inputs
Input
Description
Choices
AnalogInput13
First of 24 TMR (13-36) Analog inputs on the TCAT board
Variable edit (Input FLOAT)
InputType
Type of Analog Input
Unused, 4-20 ma
Low_Input
Input MA at Low Value
-10 to 20
Low_Value
Input Value in Engineering Units at Low MA
-3.4082 e +38 to 3.4028 e +38
High_Input
Input MA at High Value
-10 to 20
High_Value
Input Value in Engineering Units at High MA
-3.4082 e +38 to 3.4028 e +38
DiagHighEnab
Enable High Input Limit Diagnostic as specified in
Enable, Disable
Parameters tab
Enable Low Input Limit Diagnostic as specified in
Enable, Disable
Parameters tab
Diag Limit,TMR Input Vote Difference, in Percent of (High_ 0 to 200
Value - Low_Value)
DiagLowEnab
TMR_DiffLimit
2.1.6.15
Thermocouples
Input
Description
Choices
Thermocouple01_R,S,T
First of 10 Simplex Analog inputs on the TCAS board board variable
Select thermocouples type or mV input. mV inputs are
primarily for maintenance, but can also be used for
custom remote CJ compensation. Standard remote CJ
compensation also available.
Variable edit (Input FLOAT)
ThermCplType
ThermCplUnit
76
GEH-6721_Vol_III_BJ
Unused, mV, E, J, K, S, T
The ThermCplUnit parameter affects the native units of Deg_F, Deg_C
the controller application variable. It is only indirectly
related to the tray icon and associated unit switching
capability of the HMI. This parameter should not be used
to switch the display units of the HMI. Caution Do not
change the ThermCplUnit parameter in the ToolboxST
application because these changes will require
corresponding changes to application code and to the
Format Specifications or units of the connected variable.
This parameter modifies the actual value sent to the
controller as seen by application code. Application code
that is written to expect degrees Fahrenheit will not work
correctly if this setting is changed. External devices,
such as HMIs and Historians, may also be affected by
changes to this parameter.
Mark VIe and VIeS Control Systems for GE Industrial Applications
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2.1.6.16
Cold Junctions
Input
Description
Choices
ColdJunction_R,S,T
Cold junction for TC 1-25
Variable edit (Input FLOAT)
ColdJuncType
Select CJ Type
Local, Remote
ColdJuncUnit
Select CJ Display Unit
Deg_F, Deg_C
2.1.6.17
Analog Outputs
Input
Description
Choices
AnalogOutput01_R,S,T
Variable edit (Output FLOAT)
Output_MA
First of 2 simplex Analog outputs on the TCAS terminal
board
First of 3 TMR (3-5) Analog outputs on the TCAT
terminal board
Type of output current, mA selection
Unused, 0-20ma
Suicide_Enab
Enable suicide for faulty output current (TMR only)
Enable, Disable
Low_MA
Output MA at Low Value
0 to 20 mA
Low_Value
Output Value in Engineering Units at Low MA
-3.4082 e +38 to 3.4028 e +38
High_MA
Output MA at High Value
0 to 20 mA
-3.4082 e +38 to 3.4028 e +38
AnalogOutput03
Variable edit (Output FLOAT)
High_Value
Output Value in Engineering Units at High MA
TMR_SuicLimit
0 to 20 mA
This is the load sharing Margin for Suicide Threshold
(mA), for TMR operation. It is the reference difference
for simplex operation.
If any of the three individual analog outputs exceeds
50% of the mA output plus this margin, the mA output is
allowed to suicide. Additionally, if reference command
and total current feedback are mismatching by this
threshold, a diagnostic will be generated.
OutputState
Sets the mA output to a known value when the PCAA is PwrDownMode, HoldLastValue,
Output_Value
offline. PwrDownMode sets analog output to 0.0 mA.
HoldLastVal holds the analog output at the last value in
engineering units received before the PCAA went
offline. Output_Value allows the user to specify the
offline value in engineering units.
Output_Value
Pre-determined value for the outputs when OutputState Engineering Units
is set to Output_Value
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 77
Non-Public Information
2.1.6.18
Pulse Rates
Input
Description
Choices
FlowRate1
Variable edit (Input FLOAT)
PR_Enable
1 of two (1-2) magnetic pickup pulse inputs on the TCAT
terminal board
1 of two (3-4) TTL pulse inputs on the TCAS terminal
board
Enables pulse rate input
PRScale
Scaling pulses/sec to Engineering units
0 to 1000
TMR_DiffLimit
Diag Limit, TMR Input Vote Difference, in Engineering
units
0 to 20000
Input
Description
Choices
LVDT01
1 of 12 LVDT inputs on the TCAT terminal board
Variable edit (Input FLOAT)
Enable
LVDT Enable
Enable, Disable
MinVrms
Vrms at Min End Stop – Normally set by Auto-Calibrate
0 to 7.1
MinVrms
Vrms at Max End Stop – Normally set by Auto-Calibrate
0 to 7.1
MinPosValue
Position at Min End Stop in Eng Units
-15 to 150
MaxPosValue
Position at Max End Stop in Eng Units
-15 to 150
PositionMargin
Allowable range exceed error of position in percentage. If 1 to 10
the position exceeds the MaxPosValue or MinPosValue by
this percentage, an unhealthy status and a diagnostic is
generated.
ExcitSelect
Excitation monitor selection. Select the Excitation monitor Unused, Excit_fromR, Excit_fromS,
signal conditioning command that is used by the LVDT.
Excit_fromT
For instance, if the LVDT excitation comes from the S
TCAS, the setting would be Excit_FromS. If set to Unused,
the LVDT uses the local ServoExcitMonitor for signal
condition. To receive Excitation signal conditioning from
another (TMR) pack, the application blockware must be
provided to pass the excitation voltage monitor inputs
ServoExcitMonitor_R,S,T to the ExcMon_fromR,S,T
outputs through a Move block function.
ExcitMonCal
Excitation monitor calculated value in Vrms. This is
normally populated during Auto-Calibrate and helps to
condition the LVDT signals against fluctuations in
Excitation voltage
FlowRate3
2.1.6.19
78
Variable edit (Input FLOAT)
Enable, Disable
LVDTs
GEH-6721_Vol_III_BJ
1 to 10
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2.1.6.20
Vibration
Input
Description
Choices
VibrationFbk01
Variable edit (Input FLOAT)
SensorEnab
1 of 12 Vibration feedback inputs on the TCAT terminal
board
VibrationFbk Enable
Vib_Gain
Vibration Gain in Vpk/Vipspk
0.04 to 0.5
SensorRes
Sensor resistance ohms This resistance is used to
calculate a specific minimum voltage working range. If the
sensor exceeds this limit, it is declared faulted. Generates
diagnostic and unhealthy.
100 to 2000
2.1.6.21
Enable, Disable
Regulators
Input
Description
Choices
RegType
Servo regulator algorithm type
Unused, Position, SpeedRatio,
LiquidFuel, LiquidFuel_wPosition
RegGain
Position loop gain in (% Current/Eng Unit). This adjusts
the regulator loop gain response. The higher this value,
the faster the servo valve responds. This rate is limited by
the valve slew rate.
Position loop Null Bias in %Current – Balances Servo
Spring Force. This force closes or opens the valve if the
power is lost. This parameter compensates to this force.
-200 to 200 (FLOAT)
RegNullBias
-100 to 100 (FLOAT)
EnabCurSuic
Current Suicide Enable If the Current Feedback Suicide is
enabled and the following are True, the servo performs a
suicide. a) The difference between the commanded
current and the individual current feedback exceeds the
Curr_Suicide limit. b) for a period greater than ½ second.
Disable, Enable
EnabPosFbkSuic
Position Feedback Suicide Enable If the Position
Feedback Suicide is enabled and the following are True,
the servo performs a suicide. a) the position feedback
exceeds the position limits of either: MinPosValue - Fdbk_
Suicide MaxPosValue + Fdbk_Suicide b) for a period of
PosFailDelay in milliseconds.
Disable, Enable
EnabPressureFbkSuic
Disable, Enable
Pressure Feedback Suicide Enable If the Pressure
Feedback Suicide is enabled and the following is True, the
servo performs a suicide. a) the pressure feedback
exceeds the pressure limits of either: PresFbkLowLim
PresFbkHighLim b) for a period of PressureFailDelay in
ms
Flow feedback suicide enable If the flow feedback suicide Disable, Enable
is enabled and all the below is True, the servo performs a
suicide. a) the flow feedback exceeds the flow limits of
either: FlowFbkLowLim FlowFbkHighLim b) for a period of
FlowFailDelay in ms
EnabFlowFbkSuic
Curr_Suicide
Short servo output if current error exceeds this amount in
percentage
0 to 100 % (FLOAT)
Fdbk_Suicide
Short servo output if position feedback error exceeds this
amount in percentage
0 to 10 % (FLOAT)
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 79
Non-Public Information
Input
Description
TMR_DiffLimit
-15 to 150% (FLOAT)
Diag limit, TMR input vote Difference, servo current in
engineering units The controller calculates the median
value of the three servo currents values. If any of the three
servo currents are greater than or less than this difference
in percent, a diagnostic is generated. This notifies the user
of a possible fault of that servo output.
DitherAmpl
Dither in % current. Amplitude of the dither moves a valve
from a fixed position and back again. This dithering is to
reduce breakaway torque if the valve sits in a fixed
position for an extended time.
DitherFreq
Dither rate in Hertz. Rate at which dithering moves a valve Unused, 8_33 Hz, 12_5 Hz, 16_67 Hz,
from a fixed position and back again. This dithering is to
25 Hz, 50 Hz
reduce breakaway torque if the valve sits in a fixed
position for an extended time.
PositionInput1
Position input 1 selection Selected LVDT converted from
VRMS to a position by using the LVDT configuration. This
selection is valid for the following regulator types: Position,
SpeedRatio, LiquidFuel_wPosition.
LVDT01, LVDT02, LVDT03, LVDT04,
LVDT05, LVDT06, LVDT07, LVDT08,
LVDT09, LVDT11, LVDT10, LVDT11,
LVDT12, Unused
PositionInput2
Position input 2 selection Selected LVDT converted from
VRMS to a position by using the LVDT configuration. This
selection is valid for the following regulator types: Position,
SpeedRatio, LiquidFuel_wPosition.
LVDT01, LVDT02, LVDT03, LVDT04,
LVDT05, LVDT06, LVDT07, LVDT08,
LVDT09, LVDT11, LVDT10, LVDT11,
LVDT12, Unused
PositionInput3
Position input 3 selection Selected LVDT converted from
VRMS to a position by using the LVDT configuration. This
selection is valid for the following regulator types: Position,
SpeedRatio, LiquidFuel_wPosition.
LVDT01, LVDT02, LVDT03, LVDT04,
LVDT05, LVDT06, LVDT07, LVDT08,
LVDT09, LVDT11, LVDT10, LVDT11,
LVDT12, Unused
PressureInput1
Pressure input 1 selection Selected pressure input
converted from mA to a position by the analog input
configuration. This selection is valid for the SpeedRatio
regulator type
Unused, AnalogInput11, AnalogInput12
PressureInput2
Pressure input 2 selection Selected pressure input
converted from mA to a position by the analog input
configuration. This selection is valid for the SpeedRatio
regulator type
Unused, AnalogInput11, AnalogInput12
FlowInput1
Flow rate input 1 selection Selected pulse input converted
from a flow rate to a position using the pulse rate
configuration. This selection is valid for following regulator
types: LiquidFuel, LiquidFuel_wPosition
Unused, FlowRate1, FlowRate2,
FlowRate3, FlowRate4
FlowInput2
Flow rate input 2 selection Selected pulse input converted
from a flow rate to a position using the pulse rate
configuration. This selection is valid for following regulator
types: LiquidFuel, LiquidFuel_wPosition
Unused, FlowRate1, FlowRate2,
FlowRate3, FlowRate4
K_OuterReg
Outer Regulator Gain
-200 to 200 (FLOAT)
Choices
0 to 10 % (FLOAT)
K_Conv_OuterReg
Outer Regulator K_Conv
-200 to 200 (FLOAT)
Tau_OuterReg
Tau for Outer Regulator
0 to 10 (FLOAT)
LowLim_OuterReg
Outer regulator low limit clamp
-200 to 200 (FLOAT)
HiLim_OuterReg
Outer regulator high limit clamp
-200 to 200 (FLOAT)
PresFbkLowLim
Pressure Feedback Low Limit If pressure feedback is
lower than this limit, a diagnostic is generated. The servo
is suicided, if the EnabPressureFbkSuic is enabled.
-150 to 5000 (FLOAT)
80
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Input
Description
Choices
PresFbkHiLim
Pressure Feedback High Limit If pressure feedback is
higher than this limit a diagnostic is generated. The servo
is suicided, if the EnabPressureFbkSuic is enabled.
-150 to 5000 (FLOAT)
FlowFbkLowLim
Flow Feedback Low Limit If Flow feedback is lower than
this limit, a diagnostic is generated. The servo is suicided,
if the EnabFlowFbkSuic is enabled.
Flow Feedback High Limit If flow feedback is higher than
this limit, a diagnostic is generated. The servo is suicided,
if the EnabFlowFbkSuic is enabled.
Time delay (msec) before position feedback suicide is
generated on a fault. This time delay keeps the firmware
from generating a suicide based on a transient condition.
-150 to 5000 (FLOAT)
FlowFbkHiLim
PosFailDelay
-150 to 5000 (FLOAT)
0 to 10000 ms (FLOAT)
PressFailDelay
Time delay (msec) before pressure feedback suicide is
generated on a fault This time delay keeps the firmware
from generating a suicide based on a transient condition.
0 to 10000 ms (FLOAT)
FlowFailDelay
Time delay (msec) before flow feedback suicide is
generated on a fault. This time delay keeps the firmware
from generating a suicide based on a transient condition.
0 to 10000 ms (FLOAT)
EnabRegGainAdj
If enabled, RegGain will be adjusted according to the
Reg_GainAdj setting in the Regulator Variables Tab. If
disabled, Reg_GainAdj is ignored and a value of 1 for
Reg_GainAdj will leave RegGain as entered in the
Regulators Tab.
Enable, Disable
EnabRegKAdj
If enabled, K_OuterReg will be adjusted according to the
Reg_KAdj setting in the Regulator Variables Tab. If
disabled, Reg_KAdj is ignored and a value of 1 for Reg_
KAdj will leave K_OuterReg as entered in the Regulators
Tab.
Enable, Disable
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 81
Non-Public Information
2.1.6.22
Monitors
Input
Description
Choices
RegType
Monitor regulator type selection. Allows monitoring of the
regulator’s control feedback in percentage. The monitor
type must match the regulator type.
Unused, Position, SpeedRatio,
LiquidFuel, LiquidFuel_wPosition
ServoNum
Servo number used Select the servo feedback to be
monitored. Based upon the selected monitor RegType,
only one of the MonVxx parameters is visible or
selectable.
Monitor variable selection for position regulator. Select
one of these to be monitored in percentage.
Servo01, Servo02, Servo03, Servo04,
Servo05, Servo06
Unused, Position1, Position2, Position3,
RegOutputCmd, CurrentOutputCmd
MonVarLiqFuel
Monitor variable selection for liquid fuel regulator. Select
one of these to be monitored in percentage.
Unused, Flow1, Flow2, RegOutputCmd,
CurrentOutputCmd
MonVarSpdRat
Monitor variable selection for speed ratio regulator. Select
one of these to be monitored in percentage.
Unused, Pressure1, Pressure2,
Position, Position2, Position1,
OuterRegErr, OuterLoopErr,
RegOutputCmd, CurrentOutputCmd
MonVarLiqFuelPos
Monitor variable selection for liquid fuel with position
regulator. Select one of these to be monitored in
percentage.
Unused, Position, Position1, Position2,
Flow1, Flow2, OuterRegErr,
OuterLoopErr, RegOutputCmd,
CurrentOutputCmd
MonVarPos
2.1.6.23
Variables
Variable
Description
Direction
Type
L3DIAG_PCAA
I/O diagnostic indication
Input
BIT
LINK_OK_PCAA
I/O link okay indication
Input
BIT
ATTN_PCAA
I/O Attention Indication
Input
BIT
PS18V_PCAA
I/O 18 V Power Supply Indication
Input
BIT
PS28V_PCAA
I/O 28 V Power Supply Indication
Input
BIT
IOPackTmpr
I/O pack temperature
Input
FLOAT
RegCalMode
Regulator calibration mode active
Input
BIT
CalibEnab1
Servo 1 Regulator Calibration Enable
Output
BIT
CalibEnab2
Servo 2 Regulator Calibration Enable
Output
BIT
CalibEnab3
Servo 3 Regulator Calibration Enable
Output
BIT
CalibEnab4
Servo 4 Regulator Calibration Enable
Output
BIT
CalibEnab5
Servo 5 Regulator Calibration Enable
Output
BIT
CalibEnab6
Servo 6 Regulator Calibration Enable
Output
BIT
Monitor1
Servo monitor 1
Input
FLOAT
Monitor2
Servo monitor 2
Input
FLOAT
CJRemote
Cold Junction Remote value (deg F)
Output
FLOAT
CJBackup
Cold Junction Backup value (deg F)
Output
FLOAT
ActivateCalibCmd
Internally generated calibration signal. DO NOT connect variable
to this signal.
Output
BIT
82
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2.1.6.24
AO Feedbacks
Feedback
Description
Direction
Type
AOutSuicide1_R,S,T
Status of Suicide Relay for Output 1
Input
FLOAT
AOutSuicide2_R,S,T
Status of Suicide Relay for Output 2
Input
FLOAT
AOutSuicide3
Status of Suicide Relay for Output 3
Input
FLOAT
AOutSuicide4
Status of Suicide Relay for Output 4
Input
FLOAT
AOutSuicide5
Status of Suicide Relay for Output 5
Input
FLOAT
AOut1MA_R,S,T
Feedback, Output Current, mA
Input
FLOAT
AOut2MA_R,S,T
Feedback, Output Current, mA
Input
FLOAT
AOut3MA
Total feedback, Output Current, mA
Input
FLOAT
AOut4MA
Total feedback, Output Current, mA
Input
FLOAT
AOut5MA
Total feedback, Output Current, mA
Input
FLOAT
2.1.6.25
Excitation Variables
Variable
Description
Direction
Type
Excit_Mon1_R,S,T
Excitation Ground Health
Input
BIT
Excit_Mon2_R,S,T
Excitation Ground Health
Input
BIT
Excit_Mon3_R,S,T
Excitation Ground Health
Input
BIT
Excit_Mon4_R,S,T
Excitation Ground Health
Input
BIT
Excit_Mon5_R,S,T
Excitation Ground Health
Input
BIT
Excit_Mon6_R,S,T
Excitation Ground Health
Input
BIT
ServoExcitMonitor_R,S,T
Servo Excitation Monitor (Vrms)
Input
FLOAT
ExcMon_fromR
Excitation Monitor signal from R PCAA. For TMR applications,
application code must be added to attach this signal to the
corresponding ServoExcitMonitor_R value through a Move block.
Output
FLOAT
ExcMon_fromS
Excitation Monitor signal from S PCAA. For TMR applications,
application code must be added to attach this signal to the
corresponding ServoExcitMonitor_R value through a Move block.
Output
FLOAT
ExcMon_fromT
Excitation Monitor signal from T PCAA. For TMR applications,
application code must be added to attach this signal to the
corresponding ServoExcitMonitor_R value through a Move block.
Output
FLOAT
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 83
Non-Public Information
2.1.6.26
Regulator Variables
Variable
Description
Direction
Type
Reg#_Calibrated_R,S,T
Regulator has been calibrated status
Input
BIT
Reg#_Suicide_R,S,T
Regulator suicide status
Input
BIT
Reg#_SuicForce
Regulator Suicide Force
Output
BIT
Reg#_ByPass
Bypass Outer Regulator (SpeedRatio, LiqFuel_wPos)
Output
BIT
Reg#_Error
Regulator Error
Input
FLOAT
Reg#_Fdbk
Regulator Feedback
Input
FLOAT
Reg#_IntOut
Outer Regulator Integrator Output (SpeedRatio, LiqFuel_wPos)
Input
FLOAT
Reg#_Pressure
Regulator pressure feedback (SpeedRatio)
Input
FLOAT
Reg#_FlowFdbk
Regulator flow feedback (LiqFuel_wPos)
Input
FLOAT
Reg#_Ref
Regulator Reference
Output
FLOAT
Reg#_GainAdj
Regulator Gain Adjust
Output
FLOAT
Reg#_NullCor
Regulator Null Correction
Output
FLOAT
Reg#_Kadj
Outer Regulator Gain Adjust (SpeedRatio, LiqFuel_wPos)
Output
FLOAT
Reg#_IntConv
Outer Regulator Integrator Convergence (for TMR) (SpeedRatio,
LiqFuel_wPos)
Output
FLOAT
Reg#_PosBiasFF
Position Bias Feedforward (SpeedRatio, LiqFuel_wPos)
Output
FLOAT
2.1.6.27
Servo Outputs
Outputs
Description
Direction
Type
ServoOutput1
Servo Output Feedback (% current)
Input
FLOAT
ServoOutput2
Servo Output Feedback (% current)
Input
FLOAT
ServoOutput3
Servo Output Feedback (% current)
Input
FLOAT
ServoOutput4
Servo Output Feedback (% current)
Input
FLOAT
ServoOutput5
Servo Output Feedback (% current)
Input
FLOAT
ServoOutput6
Servo Output Feedback (% current)
Input
FLOAT
84
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2.2 PCAA Specific Alarms
The following alarms are specific to the PCAA I/O pack.
32
Description Unallowed VarIOCompatCode Change: Old - [ ]; New - [ ]
Possible Cause A .dll file (ToolboxST support file) has been installed that is incompatible with the firmware loaded on
the I/O processor.
Solution
•
•
Confirm the correct installation of the ToolboxST application.
Rebuild the application and download firmware, and the application code to the affected I/O pack.
33-67
Description Thermocouple [ ] Unhealthy
Possible Cause
•
•
•
•
Thermocouple millivolt input on terminal board has exceeded the thermocouple range or hardware limit. Refer to the
PCAA help documentation for specified thermocouple ranges.
The thermocouple is configured as the wrong type.
The board has detected a thermocouple open, and has applied a bias to the circuit driving it to a large negative number, or
the TC is not connected, or a condition such as stray voltage or noise caused the input to exceed -63 mV.
Stray voltage or noise has caused the input to exceed -63 mV.
Solution
•
•
•
•
Check the field wiring, including shields. Check the installation of the PCAA on terminal board. The problem is usually
not a PCAA or terminal board failure if other thermocouples are working correctly.
Check the thermocouple for an open circuit.
Measure the incoming millivolt signal to verify that it does not exceed -63 mV.
Verify that the thermocouple type matches the configuration.
PCAA Core Analog Module
GEH-6721_Vol_III_BJ System Guide 85
Non-Public Information
68
Description Cold Junction Unhealthy, Using Backup
Possible Cause The local cold junction signal from the TCAS terminal board is out of range. The normal range is -50 to
85°C (-58 to 185 °F).
Solution If the hardware is in the normal temperature range, a possible hardware failure of the cold junction sensor on the
TCAS board may have occurred. Replace the PCAA module.
69-80
Description Analog Input (TCAS) [ ] unhealthy
Possible Cause
•
•
•
•
•
The excitation to the transducer is wrong or missing.
The transducer may be faulty.
The terminal board jumper settings do not match the ToolboxST configuration.
The analog input current/voltage input is beyond the specified range.
There may be an open or short-circuit on the input.
Solution
•
•
•
•
Check the field wiring and connections to the indicated analog input channel.
Check the field device for failure.
Check the PCAA ground select jumper for the input.
Verify that the inputs are in the operable range (3.0-21.5 mA,+/-5.25 V,+/-10.5 V).
81-104
Description Analog Input (TCAT) [ ] unhealthy
Possible Cause
•
•
•
•
•
The excitation to the transducer is wrong or missing.
The transducer may be faulty.
The terminal board jumper settings do not match the ToolboxST configuration.
The analog input current input is beyond the specified range.
There may be an open or short-circuit on the input.
Solution
•
•
•
•
•
Check the field wiring and the connections to the indicated analog input channel.
Check the field device for failure.
Check the PCAA ground select jumper for the input.
Verify that the TCAT - PCAA cables are fully seated in connectors.
Verify that the inputs are in the operable range (3.0-21.5 mA)
86
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105-116
Description Vibration Input for Seismic (Velocity) Sensor [ ] unhealthy
Possible Cause
•
•
•
The transducer may be faulty.
There may be an open circuit.
The configuration for sensor resistance (Ohms) is incorrect.
Solution
•
•
Check the field wiring, including the shields. The problem is usually not a PCAA or terminal board failure if other
vibration inputs are working correctly.
Verify that the sensor resistance matches the configured sensor resistance.
117-122
Description LVDT Excitation [ ] Failed
Possible Cause
•
•
•
There may be an excitation ground fault.
There may be a field wiring issue or an LVDT sensor failure.
There may be an internal hardware failure.
Solution
•
•
•
Check the field wiring, including shields, for LVDT excitation output. The problem is usually not a PCAA or terminal
board failure if other LVDT excitation outputs are working correctly.
Check the LVDT sensor.
If the problem is a hardware failure, replace the PCAA.
123-134
Description LVDT [ ] Excitation voltage out of range
Possible Cause ExcitMonCal is set during servo regulator calibration, and is a nominal excitation value. If actual LVDT
excitation goes out of range (+/- 10% of ExcitMonCal), this alarm is generated.
•
There may be a terminal board failure.
Solution
•
•
•
•
Measure the excitation voltage, and verify against the configuration parameter.
Check the LVDT sensor.
Recalibrate the servo.
Replace the PCAA.
PCAA Core Analog Module
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135-146
Description LVDT [ ] Position Out of Limit
Possible Cause
•
•
•
There may be an issue with excitation to the LVDT, a faulty transducer, or an open or short-circuit.
The LVDT input is out of range.
The LVDT has not been calibrated.
Solution
•
•
•
•
•
•
Check the field wiring, including the shields and the LVDT excitation. The problem is usually not a PCAA or terminal
board failure if other LVDT inputs are working correctly.
Check the LVDT sensor.
Calibrate the servo regulator with the proper LVDT.
Verify the configuration limits: MinVrms and MaxVrms.
Verify that the LVDT excitation terminal board connections match the configured excitation source specified in
ExcitSelect.
Verify that PositionMargin is set to the proper value.
147-148
Description Invalid Monitor [ ] Configuration
Possible Cause
•
The configuration for the selected servo and regulator type is invalid.
Solution
•
•
Verify that the monitor regulator type matches the regulator type of the selected servo.
Rebuild and download the configuration.
149
Description More than One Servo Requested for Calibration
Possible Cause
•
The user has requested more than one servo calibration (only one servo can be calibrated at a given time).
Solution
•
Check the variables in the Variables tab to verify that only one CalibEnab# for only one servo is set to True at a given
time.
88
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150
Description Calibration : Selected LVDT Max / Min Pos Limit Out of Range
Possible Cause Used to ensure that all selected LVDTs are scaled to the same units.
•
The parameter MaxPosValue or MinPosValue for the selected LVDT configured in the regulator configuration is out of
range (+/-50%, encountered during calibration).
Solution
•
•
•
•
Check the regulator configuration for the parameter PositionInput#1 for the particular servo.
Check the parameters MaxPosValue and MinPosValue for the LVDT# selected input in PositionInput#1.
The parameter MaxPosValue for LVDT input should be between 50% to 150%.
The parameter MinPosValue for LVDT input should be between -50% to 50%.
151-154
Description FlowRate [ ] Input unhealthy
Possible Cause
•
•
There may be a broken wire on the flow rate input.
There may be a faulty sensor.
Solution
•
•
•
•
Verify the field wiring, including shields. The problem is usually not a PCAA or terminal board failure if other flow rate
inputs are working correctly.
Check the gap for the magnetic pickup sensor.
For the TTL sensor, verify the power to the sensor and the gap.
Replace the hardware.
PCAA Core Analog Module
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155-160
Description Servo [ ] Disabled: Configuration error
Possible Cause
•
•
•
•
•
•
The servo position input is connected to an unused LVDT.
The configuration for the position input is incorrect.
The servo flow input is connected to an unused PR.
The configuration for the flow input is incorrect.
The servo pressure input is connected to an unused analog input.
The configuration for the pressure input is incorrect.
Solution
•
•
•
Check and correct, if necessary, the configuration parameters relating to the list of possible causes.
Verify that the regulator inputs are connected to ENABLED sensor inputs in configuration.
In the ToolboxST configuration, right-click the PCAA, then select the parameter Troubleshooting->Advanced
Diagnostics. Navigate through the PCAA Commands to the parameter Servos->Servo Cfg Error. Send the command to
the PCAA for a list of configuration errors that were detected in the servo regulator settings.
161-166
Description Servo [ ] Output Suicide Active
Possible Cause
•
•
•
•
•
•
•
•
The servo position input is connected to an unused LVDT.
The configuration for the position input is incorrect.
The servo flow input is connected to an unused PR.
The configuration for the flow input is incorrect.
The servo pressure input is connected to an unused analog input.
The configuration for the pressure input is incorrect.
The regulator feedback is out of range.
The servo current feedback differs from the servo current command.
Solution
•
•
•
•
•
•
Check and correct, if necessary, the configuration parameters relating to the list of possible causes.
Verify that the inputs are connected to used sensor inputs in the configuration.
It is a LVDT feedback issue; check the position sensor connections.
Verify the position sensor mechanical integrity to the valve.
Check the wiring of the servo output loop for an open or short circuit.
Check for a short or open servo coil.
90
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167-173
Description Pack internal reference voltage out of limits ([ ])
Possible Cause The calibration reference voltage is more than +/-5% from the expected value, which indicates a
hardware failure.
Solution
•
•
Cycle power on the PCAA.
Replace the PCAA.
174-180
Description Pack internal null voltage out of limits ([ ])
Possible Cause The null voltage is more than +/- 5% from the expected value which indicates a hardware failure.
Solution
•
•
Cycle power on the PCAA.
Replace the PCAA.
181-183
Description Analog Output [ ] Individual current fdbk unhealthy
Possible Cause
•
•
•
•
•
•
The commanded output is beyond the range of the output.
There may be a field wiring problem.
There may be a field device problem.
There is an open loop or too much resistance in the loop.
There may be an I/O pack failure.
There may be a terminal board failure.
Solution
•
•
•
•
Verify that the commanded output is within the range of the output.
Confirm the correct I/O pack 28 V input power.
Check the field wiring and the device. The problem is usually not a PCAA or terminal board failure if other analog
outputs are working correctly.
Replace the I/O pack.
PCAA Core Analog Module
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184-188
Description Analog Output [ ] Total current fdbk unhealthy
Possible Cause
•
•
•
•
The commanded output is beyond the range of the output.
There may be a field wiring problem.
There may be a field device problem.
There may be an open loop or too much resistance in the loop.
Solution
•
•
•
•
•
Verify that the commanded output is within the range of the output.
Confirm the correct I/O pack 28 V input power.
Check the field wiring and the device.
Check the PCAA- TCAT cables. The problem is usually not a PCAA or terminal board failure if other analog Inputs are
working correctly.
Replace the I/O pack.
189-190
Description Analog Output (TCAS) [ ] 20 mA suicide active
Possible Cause
•
•
•
There may be a field wiring problem.
The connected device may have problems that are interfering with the current.
There may be a hardware failure.
Solution
•
•
Check the field wiring and the status of the connected device.
If there is a hardware failure, replace the PCAA.
92
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191-193
Description Analog Output (TCAT) [ ] 20 mA suicide active
Possible Cause
•
•
•
•
•
Review any additional diagnostics for possible causes.
The TMR_SuicLimit parameter is set too low.
There may be a field wiring problem.
The command is beyond the range of the output.
There may be a terminal board failure.
Solution
•
•
•
•
•
•
•
Check the field wiring and the status of the connected device.
Verify that the TCAT-PCAA cables are fully seated in the connectors.
Verify that the value of the parameter TMR_SuicLimit is set correctly.
Verify the field wiring connections.
Verify that the commanded output is within output range.
Replace the PCAA module.
Replace the TCAT terminal board.
194-195
Description Analog Output (TCAS) [ ] Suicide relay non-functional
Possible Cause The analog output suicide relay command does not match the feedback.
•
•
There may be a relay failure on the acquisition board.
There may be a hardware failure.
Solution If there is a hardware failure, replace the PCAA.
196-198
Description Analog Output (TCAT) [ ] Suicide relay non-functional
Possible Cause The analog output suicide relay command does not match the feedback.
•
•
There may be a relay failure on the acquisition board.
There may be a hardware failure.
Solution If there is a hardware failure, replace the PCAA.
PCAA Core Analog Module
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199-204
Description Servo [ ] Position Feedback out of range
Possible Cause
•
The LVDT position feedback is outside the specified range.
Solution
•
•
•
•
•
•
Check the LVDT configuration settings.
Calibrate the affected regulator.
Check the field wiring.
Check for a shorted or open-position sensor coil.
Verify the mechanical integrity of the position sensor.
Verify that the TCAT-PCAA cables are fully seated.
205-210
Description Servo [ ] Pressure Feedback out of range
Possible Cause
•
The pressure feedback used in a servo regulator is outside the specified range.
Solution
•
•
Check the source of the pressure signal, including the sensor, field wiring, and configuration.
Verify the terminal board jumper settings for the analog inputs.
211-216
Description Servo [ ] Flow Feedback out of range
Possible Cause
•
The flow feedback used in a servo regulator is outside the specified range.
Solution
•
•
If the out-of-range flow input is connected to the parameter FlowRate3 or FlowRate4 (TTL Pulse input), check the
power to device, the field wiring, the sensor, and the configuration.
If the out-of-range flow input is connected to the parameter FlowRate1 or FlowRate2 (Magnetic pickup), check the
device, the field wiring, the input configuration, and the TCAT-PCAA cables.
Check the gap between the sensor and the flow wheel.
94
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217
Description TCAT Configuration and Hardware Mismatch
Possible Cause This diagnostic is only generated on power-up.
•
•
The TCAT is configured in the ToolboxST application, but the terminal board is not connected.
The TCAT is not configured in the ToolboxST application, but the terminal board is connected.
Solution
•
•
•
•
Verify that the TCAT selection in the ToolboxST configuration matches the actual hardware.
Verify that the P1 and P2 cable connections are not swapped.
Verify the the TCAT terminal board P1 and P2 cable connections are screwed down, and all terminal boards are properly
grounded.
Perform a power-down reset to clear.
218
Description TCAT Connector P1 and P2 Types Mismatch
Possible Cause The Type ( for example, R/R or S/S or T/T) of P1 and P2 connections between the TCAT and the TCAS
do not match. The Valid combinations are:
•
•
•
P1(TCAS)-PR1(TCAT) & P2(TCAS)-PR2(TCAT)
P1(TCAS)-PS1(TCAT), P2(TCAS)-PS2(TCAT)
P1(TCAS)-PT1(TCAT), P2(TCAS)-PT2(TCAT)
Solution
•
•
Check the ToolboxST configuration, as well as the TCAT terminal board P1 and P2 cable connections between the TCAS
and the TCAT.
Verify that there is no Type (R/R,S/S,T/T) mismatch.
221
Description Calibration Mode Enabled
Possible Cause
•
One of the CalibEnab# outputs is set to True.
Solution
•
•
This alarm is active to annunciate that the board is in a special mode (the servo suicide protection has been disabled, and
the user needs to take special precautions).
Set CalibEnab# to False.
PCAA Core Analog Module
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1050-1145
Description Logic Signal [ ] Voting Mismatch
Possible Cause N/A
Solution N/A
1146-1238
Description Input Signal [ ] Voting Mismatch, Local [ ], Voted [ ].
Possible Cause
•
A voter disagreement was detected between the R, S and T controllers.
Solution Adjust the specified parameter below for each input type:
•
•
•
•
If the input variable is AnalogInput[ ], adjust the TMR_DiffLimit.
If the input variable is PulseInput[ ], adjust the TMR_DiffLimit.
If the input signal is LVDT[ ], adjust the LVDT_TMR_DiffLimit on the Parameters tab.
If the input variable is ServoOutput[ ]:
−
−
−
96
Adjust the TMR_DiffLimit on the Regulators tab.
Also check for a mismatch in the coil resistance between the R, S and T servo coils.
Reg#_Gain is set too high for specified TMR_DiffLimit value.
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2.3 TCAT Core Analog Terminal Board
2.3.1 Functional Description
The Core Analog (TCAT) terminal board provides additional I/O terminals for the PCAA module. It handles input signals that
are fanned to one or three PCAA modules. Inputs include twelve seismic, twelve LVDT, twenty four 4-20 mA, and two
magnetic pulse rate inputs. An individual 24 V dc power source is included for all twenty four 4-20 mA inputs with half on
TCAT and half on an adjacent JGPA board. TCAT outputs consist of three 4-20 mA voted signals.
Field wire terminal points are provided by 120 pluggable Euro style box-type terminal blocks. Terminal grouping is a set of
48 terminals, a set of 24, and a second set of 48. A JGPA board adjacent to the TCAT field terminals provides twelve
additional 24 V dc outputs for 4-20 mA devices as well as shield wire terminals. Power to JGPA is supplied by TCAT
connector P3 or P4 and is the diode-or of power from the connected PCAA modules.
Pairs of 68 pin cables provide connection between TCAT and one or more PCAA modules. PR1 and PR2 go to a PCAA
connected to the R IONet. PS1 and PS2 go to a PCAA connected to the S IONet. PT1 and PT2 go to a PCAA connected to
the T IONet. TCAT provides an electronic ID on each cable connection. Cables are always used in pairs and PCAA uses the
electronic ID to confirm that correct TCAT cables are in place.
PCAA Core Analog Module
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TCAT Terminal Board
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2.3.2 Installation
TCAT with an underlying insulating plastic carrier mounts to a metal back base. Screws are located at the top and bottom of
the field terminals with a third screw approximately in the center of the board.
2.3.2.1
Wiring
The TCAT terminal board features 120 pluggable Euro style box-type terminal blocks. A JGPA board mounts adjacent to the
TCAT terminal board and uses Euro style box-type terminal blocks to provide forty-eight shield termination points plus
twelve 24 V dc output terminals for 4-20 mA transmitters. The Euro style box-type terminal blocks on TCAT accept
conductors with the following characteristics:
TCAT Terminal Conductor Size Range
Conductor Type
Minimum
Maximum
Conductor cross section solid
0.2 mm²
2.5 mm²
Conductor cross section stranded
0.2 mm²
2.5 mm²
Conductor cross section stranded, with ferrule without plastic sleeve
0.25 mm²
2.5 mm²
Conductor cross section stranded, with ferrule with plastic sleeve
0.25 mm²
2.5 mm²
Conductor cross section AWG/kcmil
24 AWG
12 AWG
2 conductors with same cross section, solid
0.2 mm²
1 mm²
2 conductors with same cross section, stranded
0.2 mm²
1.5 mm²
2 conductors with same cross section, stranded, ferrules without plastic sleeve
0.25 mm²
1 mm²
2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve
0.5 mm²
1.5 mm²
PCAA Core Analog Module
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TCAT Screw Terminal Assignments
#
Name
Function
#
Name
Function
1
AFT1H
Analog Fanned #1
3
AFT2H
Analog Fanned #2
2
AFT1L
4
AFT2L
5
AFT3H
7
AFT4H
6
AFT3L
8
AFT4L
9
AFT5H
11
AFT6H
10
AFT5L
12
AFT6L
13
AFT7H
15
AFT8H
14
AFT7L
16
AFT8L
17
AFT9H
19
AFT10H
18
AFT9L
20
AFT10L
21
AFT11H
23
AFT12H
22
AFT11L
24
AFT12L
25
APWR13
24 V power
39
AFT13H
no connect
40
AFT13L
26
Analog Fanned # 3
Analog Fanned # 5
Analog Fanned # 7
Analog Fanned # 9
Analog Fanned # 11
27
APWR14
41
AFT14H
28
APWR15
42
AFT14L
29
APWR16
43
AFT15H
30
APWR17
44
AFT15L
31
APWR18
45
AFT16H
32
APWR19
46
AFT16L
33
APWR20
47
AFT17H
34
APWR21
48
AFT17L
35
APWR22
49
AFT18H
36
APWR23
50
AFT18L
37
APWR24
51
AFT19H
38
PCOM
Common
52
AFT19L
53
AFT20H
Analog Fanned # 20
55
AFT21H
54
AFT20L
56
AFT21L
57
AFT22H
59
AFT23H
58
AFT22L
60
AFT23L
61
AFT24H
63
VFI1H
62
AFT24L
64
VFI1L
65
VFI2H
67
VFI3H
66
VFI2L
68
VFI3L
69
VFI4H
71
VFI5H
70
VFI4L
72
VFI5L
73
VFI6H
75
VFI7H
100
24 V power output for 4-20 mA
input devices
Analog Fanned # 22
Analog Fanned # 24
Seismic Input # 2
Seismic Input # 4
Seismic Input # 6
GEH-6721_Vol_III_BJ
Analog Fanned # 4
Analog Fanned # 6
Analog Fanned # 8
Analog Fanned # 10
Analog Fanned # 12
Analog Fanned # 13
Analog Fanned # 14
Analog Fanned # 15
Analog Fanned # 16
Analog Fanned # 17
Analog Fanned # 18
Analog Fanned # 19
Analog Fanned # 21
Analog Fanned # 23
Seismic Input # 1
Seismic Input # 3
Seismic Input # 5
Seismic Input # 7
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
TCAT Screw Terminal Assignments (continued)
#
Name
74
VFI6L
77
VFI8H
78
VFI8L
81
VFI10H
82
VFI10L
85
VFI12H
86
VFI12L
89
MFI2H
90
MFI2L
93
LVDTH2
94
LVDTL2
97
LVDTH4
98
LVDTL4
101
LVDTH6
102
LVDTL6
105
LVDTH8
106
LVDTL8
109
LVDTH10
110
LVDTL10
113
LVDTH12
114
LVDTL12
117
ATOH4
118
ATOL4
Function
Seismic Input # 8
Seismic Input # 10
Seismic Input # 12
Mag pickup flow input
LVDT Input # 2
LVDT Input # 4
LVDT Input # 6
LVDT Input # 8
LVDT Input # 10
LVDT Input # 12
TMR 4-20 mA
#
Name
Function
76
VFI7L
79
VFI9H
80
VFI9L
83
VFI11H
84
VFI11L
87
MFI1H
88
MFI1L
91
LVDTH1
92
LVDTL1
95
LVDTH3
96
LVDTL3
99
LVDTH5
100
LVDTL5
103
LVDTH7
104
LVDTL7
107
LVDTH9
108
LVDTL9
111
LVDTH11
112
LVDTL11
115
ATOH3
116
ATOL3
119
ATOH5
120
ATOL5
Seismic Input # 9
Seismic Input # 11
Mag pickup flow input
LVDT Input # 1
LVDT Input # 3
LVDT Input # 5
LVDT Input # 7
LVDT Input # 9
LVDT Input # 11
TMR 4-20 mA
TMR 4-20 mA
2.3.3 Operation
TCAT provides fanning of input signals to one or more PCAA modules. This is done with high reliability passive circuits to
ensure reliability in redundant applications.
TCAT accepts 28 V dc power from connected PCAA modules. It then does a diode-or of the power sources to obtain
redundant power input for the 24 V dc outputs. Each 24 V output on TCAT is provided with an individual voltage regulator
that includes thermal shutdown for branch circuit protection.
Note An over current condition on one 24 V dc output will result in only that output being shut down. When the overload is
removed the terminal will return to 24 V dc.
TCAT accepts ±15 V dc power from connected PCAA modules. It then does a diode-or of the power sources to obtain
redundant power. The ±15 V dc power is then used internally to voltage bias the seismic inputs.
PCAA Core Analog Module
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2.3.4 Specifications
For details of the signals on TCAT, refer to the PCAA section, Specifications.
Item
TCAT Specification
Number of inputs
Twenty-four 4-20 mA signals.
Twelve seismic signals.
Twelve LVDT windings.
Two magnetic pulse rate flow signals.
Number of outputs
Three 4-20 mA hardware voted analog outputs.
Twelve 24 V dc outputs with 25 mA capability.
Twelve 24 V dc additional outputs on JGPA with 25 mA capability.
Power supply voltage
28 V dc ±5% from one or more PCAA modules.
±15 V dc from one or more PCAA modules.
(both supplies routed through the cabling between PCAA and TCAT).
Pulse rate input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 66 mV p-p
12 kHz requires 1664 mV p-p
20 kHz requires 3200 mV p-p
Size
33.02 cm high x 17.8 cm wide (13 in x 7 in)
Technology
Surface-mount
102
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2.3.5 Configuration
2.3.5.1
Analog Input
The TCAT is able to interface with several different types of 4-20 mA transmitters. Each input has a jumper next to the
terminals that is used to determine if the return terminal is grounded or floating. The default position of the jumper is floating
or open. The combination of TCAT + JGPA provides twenty-four 24 V dc terminals, one for each 4-20 mA transmitter input.
PCAA Core Analog Module
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2.4 JGPA Ground and Power Board
2.4.1 Functional Description
The PCAA core analog module and TCAT terminal board each provide twelve 4-20 mA inputs that are not provided with 24
V power for field devices. The Ground and Power (JGPA) board is a long narrow board that mounts adjacent to PCAA where
shield wires are terminated. JGPA provides shield wire terminal points that may be tied directly to the underlying functional
earth sheet metal or wired to a preferred grounding point. In this respect it is very similar to the JGND board offered as an
option with other Mark VIe terminal boards. JGPA also provides twelve individually regulated and protected 24 V field
device power outputs. Each output is sufficient to power a single 4-20 mA field device.
JGPA receives power from PCAA or TCAT through a 28 V power feed on connector P1. Power passes through twelve
regulators and is available on TB3 screws 1-12. TB3 uses terminals colored orange to set them apart from the terminals
provided for shield wire termination. Shield terminals are on TB1 and TB2 using twenty-four conventional green Euro style
box-type terminal blocks for each.
JGPA Terminal Board
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2.4.2 Installation
JGPA is installed adjacent to the terminals on PCAA and TCAT. Power is provided to JGPA through a cable from P1 to
PCAA or TCAT. JGPA mounts on a sheet metal bracket that is at ground potential. When mounted with conductive hardware
the ground path for JGPA shield wires is through the mounting bracket. If alternate shield wire grounding is desired the JGPA
may be mounted with non-conductive washers and hardware. With isolated mounting, ground is defined by one or more wires
from JGPA shield ground terminals to the desired ground location.
The terminals on JGPA have the following conductor capacities.
Conductor Type
Minimum
Maximum
Conductor cross section solid
0.2 mm²
2.5 mm²
Conductor cross section stranded
0.2 mm²
2.5 mm²
Conductor cross section stranded, with ferrule without plastic sleeve
0.25 mm²
2.5 mm²
Conductor cross section stranded, with ferrule with plastic sleeve
0.25 mm²
2.5 mm²
Conductor cross section AWG/kcmil
24 AWG
12 AWG
2 conductors with same cross section, solid
0.2 mm²
1 mm²
2 conductors with same cross section, stranded
0.2 mm²
1.5 mm²
2 conductors with same cross section, stranded, ferrules without plastic sleeve
0.25 mm²
1 mm²
2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve
0.5 mm²
1.5 mm²
2.4.3 Operation
JGPA provides regulated 24 V dc power to the twelve terminals of TB3. An over current condition on one 24 V dc output
results in only that output being shut down. When the overload is removed, the terminal returns to 24 V dc.
2.4.4 Specifications
Item
JGPA Specification
Number of ground points
24 terminals on TB1 and 24 terminals on TB2. Ground points use green terminal housings.
Outputs
12 outputs at 24 V dc ±5%, 30 mA capability on TB3. Power outputs use orange terminal
housings.
Size
33 cm high x 3.2 cm wide (13 in x 1.25 in)
Technology
Through hole
PCAA Core Analog Module
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Notes
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3
PCLA Core Analog Module — Aero
3.1 PCLA Core Analog I/O for Aero
The Core Analog I/O for aeroderivative gas turbines (PCLA) and associated Core
Analog (SCLS and SCLT) terminal boards provide a large portion of the analog signal
I/O required to operate an engine. PCLA and SCLT provide thermocouple inputs, RTD
inputs, voltage inputs, and 4-20 mA current loop inputs and outputs. PCLA can be
applied in simplex controller simplex I/O, dual controller simplex I/O, dual controller
TMR I/O and TMR controller TMR I/O control systems. A single SCLT terminal board
fans signal inputs to one or three connected PCLA(s).
PCLA provides the electrical interface between one or two Ethernet I/O networks and
the terminal board. Inside the PCLA module is a BCLA acquisition board and a BPPx
processor board. Input to the PCLA module is through dual RJ-45 Ethernet connectors
and a 28 V dc power connector P1.
Field device I/O is connected through 72 Euro style box-type terminal blocks on the
SCLS edge and is connected through 48 Euro style box-type terminal blocks on the
SCLT edge. Connection to SCLS is through 96-pin J3 and 48-pin J4 connectors on
SCLS. The connection between SCLS and SCLT is through one 68-pin cable on the J2
connector on SCLS, and the JR/JS/JT connector on SCLT.
3.1.1 Compatibility
The PCLA includes one of the following compatible processor boards.
•
•
The PCLAH1A contains a BPPB processor board.
The PCLAH1B contains a functionally compatible BPPC that is supported with ControlST* software suite V04.03 and
higher.
The PCLA module is fully compatible with other Mark VIe control system I/O packs and controllers. The PCLA module is
designed to run at frame rates of 10, 20, 40, 80, 160, 320 ms. PCLA supports frame rates, redundancy, and networking as
indicated in the following table.
PCLA
Quantity
IONet
Connections
SCLT
Connections
Comments
Simplex
0 or 1
SCLT optional on simplex configurations. One or two IONets supported.
TMR
1
Normal TMR configurations (TPTN) will have one network per PCLA.
TMR pack Dual network (TPDN) configurations will have dual networks
connected on the T PCLA. Refer to GEH-6271, Mark VIe Control,
Volume I System Guide, Chapter 2 System Architecture, the section,
Redundancy Options.
1 or 2
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3.1.1.1
Hardware Options
The signals on TMR PCLAs are separated into two groups. Signal inputs that can be fanned from a single input into a TMR
PCLA are routed through the SCLT terminal board. Signals that are dedicated to a single TMR PCLA are wired to the
terminals on SCLS. This creates the signal split as indicated in the following table.
Note It is possible to use TMR PCLAs without SCLT if the fanned inputs are not required.It is possible to use TMR PCLAs
without SCLT if the fanned inputs are not required.
SCLS Terminals
#
Signal Type
Signals
SCLT Terminals
Screws/
#
Signal
Signals
Signal Type
Screws/ Signal
8
Thermocouples
2
8
Fanned Thermocouples
2
4
Analog 4-20 mA inputs or ±10
4
4
Fanned Analog 4-20 mA inputs or
4
V inputs or ±5 V inputs
8
RTD
±10 V inputs or ±5 V inputs
3
6
TMR (Triple Modular Redundant)
2
Analog 4-20 mA outputs
1
Analog 4-20 mA outputs
2
1
Common connection
6
NC (Not Connected) Screws
8
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PCLA Core Analog Module
28 V dc
power input
Ethernet
Connectors
Terminals for
field devices
SCLT
Connectors
PCLA Module fitting
screws
SCLS Base screws
4 corners
SCLS Plates
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Magnified View of Connectors
BCLA is the acquisition board. The processor board resides on BCLA. SCLS is the simplex terminal board.
PCLA Simplex with SCLS
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SCLT is the terminal board, which can be used either for simplex Input/Outputs or for fanned inputs, redundant outputs.
When the SCLT is used with a simplex PCLA module, the concept of fanning does not apply. Instead, the SCLT serves as a
simplex I/O expansion board as displayed in the following figure.
PCLA Simplex with SCLT for More I/O Channels
PCLA TMR with SCLT
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3.1.2 Installation
➢ To install the PCLA module
1.
Securely mount the SCLS board with the help of four mounting holes at the four corners.
2.
Directly plug the PCLA into the terminal board connectors J3 and J4.
3.
Mechanically secure the pack using two-side mounting holes.
4.
If SCLT is the part of configuration then the SCLT and a plastic insulator mount on a sheet metal carrier that then mounts
on a DIN-rail. Optionally, the SCLT and plastic insulator mounts on a sheet metal assembly and then bolts directly to a
cabinet.
Note Refer to the PCLA Core Analog figure in the section, Hardware Options.
5.
Connect the SCLS to an optional associated SCLT terminal board using one 68-pin cable. The connection between SCLS
and SCLT is through one 68-pin cable on the J2 connector on SCLS and the JR/JS/JT connector on SCLT.
6.
If using a simplex configuration, connect the JR connector on SCLT to the J2 connector on SCLS through the 68-pin
cable. If using a TMR configuration, connectors on SCLT are paired by a network connection. For example, JR1 connects
to the SCLS-PCLA through the R controller network, JS connects to the SCLS-PCLA through the S controller, and JT
connects to the SCLS-PCLA through the T controller. It is important to fully seat the cable mounting screws, finger-tight
only, into PCLA and SCLT to ensure proper cable grounding. Failure to secure the cables may result in an inability of
PCLA to read the electronic ID on SCLT and may reduce the quality of other signals.
Note When removing 68-pin cables, ensure that the hex posts in the board-mounted connectors do not turn when backing
out the cable thumbscrews.
7.
Plug in one or two Ethernet cables depending on the system configuration. When a single IONet connection is used, the
module operates correctly over either port. If dual connections are used, standard practice is to hook ENET1 to the
network associated with the R controller. However, the PCLA is not sensitive to Ethernet connections, and negotiates
proper operation over either port. If TMR PCLA modules are present, the network connection should match with the
connection made to the SCLT. For example, the PCLA module with R IONet connection should have cables that go to the
SCLT JR connector.
8.
Check grounding of the SCLS/SCLT shield wire terminals. In most applications, shield ground terminals are electrically
tied to the sheet metal the board is mounted on. The mounting then supplies the ground path for the terminals.
9.
Apply power to the module through the P1 connector on PCLA and check the power and Ethernet status indicator lights.
10. Use the ToolboxST* application to configure the PCLA as necessary. Refer to GEH-6700, ToolboxST User Guide for
Mark VIe Control, for more information.
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3.1.3 Operation
The following features are common to the distributed I/O modules:
•
•
•
•
•
•
Auto-Reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
Note Refer to GEH-6721_Vol_II, the chapter Common I/O Module Functionality.
3.1.3.1
•
•
•
•
PCLA Connectors
ENET1 is an RJ-45 Ethernet connector located on the side of PCLA, and used for IONet.
ENET2 is a second RJ-45 Ethernet connector located on the side of PCLA, and used for IONet.
P1 is a 3-pin power connector on PCLA for 28 V dc input power for the module and terminal boards.
J2 is a connector on SCLS that provides cable connections to the SCLT terminal board.
3.1.3.2
Module Overview
The PCLA module consists of two separate circuit boards in a single physical assembly: a BCLA acquisition board and a
BPPx processor board. The BCLA is interfaced with an SCLS and an optional SCLT in simplex configuration. In TMR, one
SCLT is connected to three (SCLS-PCLA) sets. Typical block diagram of the PCLA along with the terminal boards is
displayed in the following figure.
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PCLA-SCLS-SCLT Block Diagram
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3.1.3.3
BCLA Analog Processing Board
Inside the module cover the BCLA board provides power, analog signal conditioning, and analog/digital conversion. BCLA is
the main printed circuit board in the PCLA module. This board provides the main ±15 V power and the majority of the digital
and analog interface to the processor board. In addition, this board provides the signal conditioning required to interface the
thermocouples, analog inputs, RTDs and the analog outputs.
3.1.3.4
Thermocouples
The PCLA supports E, J, K, S, and T types of thermocouples. Simplex inputs from field are terminated on SCLS. There are
eight simplex thermocouple inputs. TMR inputs from field are terminated on SCLT and then fanned out to three PCLA
modules. There are eight fanned (TMR) thermocouple inputs.
The PCLA input board accepts 16 (8 each from SCLS and SCLT) signals at mV levels from the thermocouples wired to the
terminal board. The thermocouple input section consists of differential multiplexers, amplifier gain stages, a main multiplexer,
and a 16-bit analog to digital converter that sends the digital data to the adjacent processor board. Each input has hardware
filters, and the converter samples at up to 120 Hz.
Thermocouples can be grounded or ungrounded. Thermocouples can be located up to 300 meters (984 feet) from the turbine
I/O cabinet with a maximum two-way cable resistance of 450 Ω. Linearization for individual thermocouple types is
performed by the PCLA.
PCLA TC Section
A single cold junction is provided with each SCLS board. Three cold junctions, one for each PCLA, are provided on SCLT.
The module accepts a controller backup cold junction value, CJBackup, in the event a problem is detected with the local
sensor. The PCLA may be configured to use a controller-provided remote cold junction value, CJRemote.
All thermocouple inputs are biased with a dc voltage that will drive the temperature signal full scale negative if an open wire
occurs. There is a configuration to report an open thermocouple as fail cold or fail hot. Measurement accuracy for
thermocouple is 0.1% full scale, or 53 uV excluding the cold junction reading.
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3.1.3.5
Thermocouple Limits
Thermocouple inputs support a full-scale input range of -16.0 mV to + 63.0 mV. The following table demonstrates typical
input voltages for different thermocouple types versus the minimum and maximum temperature range. The cold junction
temperature is assumed to range from -50 to 85°C (-58 to 185 °F).
Note The units (°C or °F) are based on the ThermCplUnit settings. Refer to the section, Configuration.
Thermocouple Type
E
J
K
S
T
Low range, °F
-60
-60
-60
0
-60
-51
-51
-51
-17.78
-51
mV at low range with reference at 70°C (158 °F)
-7.174
-6.132
-4.779
-0.524
-4.764
High range, °F
1100
1400
2000
3200
750
593
760
1093
1760
399
44.547
42.922
44.856
18.612
20.801
°C
°C
mV at high range with reference at 0°C (32 °F)
3.1.3.6
Analog Voltage or Current Inputs
±10 V voltage inputs
±5 V voltage inputs
4-20 mA current inputs
The inputs can be configured as current or voltage inputs using jumpers (JP#A) on SCLS or SCLT. The PCLA accepts input
voltage signals from the terminal board, four input channels from SCLS and four input channels form SCLT. The analog input
section consists of analog multiplexer blocks, several gain and scaling selections, and a 16-bit analog-to-digital converter.
PCLA Analog Input Section
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The inputs can be individually configured as ±5 V or ±10 V scale signals or 4-20 mA, depending on the input configuration.
The terminal board provides a 250 Ω burden resistor when configured for current inputs yielding a 5 V signal at 20 mA.
These analog input signals are first passed through a passive, low-pass filter network with a pole at 75.15 Hz. The
measurement accuracy offered by PCLA is 0.1% of the full scale over the operating temperature range.
The inputs can be configured as current or voltage inputs using jumpers (JP#A) on the terminal boards SCLA/SCLT. The
JP#A jumper removes the 250 Ω burden resistor for voltage input applications. Each input has one more jumper (JP#B) on the
board that is used to determine if the return terminal is grounded or floating.
3.1.3.7
RTD Inputs
The terminal board supplies a 1 mA dc multiplexed (not continuous) excitation current to each RTD. The eight RTDs can be
located up to 300 m (984 ft) from the turbine control cabinet with a maximum two-way cable resistance of 15 Ω. The
on-board noise suppression is provided on SCLS. The first two RTD channels (1 and 2) can be configured for either fast or
normal mode scanning. Channels 3 to 8 are only normal mode scan channels. Fast RTDs are scanned 25 times per second and
slow RTD channels are scanned four times per second using a time sample interval related to the power system frequency.
The processor performs linearization for the selection of RTD types. PCLA RTD signals are as follows.
RTD Signals on PCLA
Note The PCLA accepts eight 3-wire RTD inputs from the SCLS terminal board.
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The following table indicates the types of RTD used and the temperature ranges.
RTD Type
Name/Standard
Configuration
Name **
Range °C
Range °F
100 Ω platinum
SAMA 100
PT100_SAMA
-51 to 593
-60 to 1100
DIN 43760
PT100_DIN
-51 to 852
-60 to 1566
MINCO_PA
-51 to 630
-60 to 1167
MINCO_PB
-51 to 630
-60 to 1166
Rosemount 104
Rosemount 104
-51 to 630
-60 to 1166
MINCO_NA
MINCO_NA
-51 to 259
-60 to 499
PT 200
MINCO_PK
-51 to 629
-60 to 1164
MINCO_PN
MINCO_PN
-51 to 629
-60 to 1164
IEC-751
MINCO_PD
MINCO_PE
PT100_DIN
MINCO_PA
IPTS-68
PT100_PURE
MINCO_PB
PT100_USIND
120 Ω nickel
N 120
200 Ω platinum
** PCLA does not support the MINCO_CA and CU10 RTD types.
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3.1.3.8
Analog Current Outputs (0-20 mA)
The PCLA 0-20 mA analog outputs are capable of 18 V compliance voltages. A 14-bit Digital to Analog converter commands
a current reference to the current regulator loop in the PCLA that senses current both in the PCLA and on the terminal board.
In TMR mode, the three current regulators in each PCLA share the commanded current loads among themselves. Analog
output status feedbacks for each output include:
•
•
•
Current reference voltage
Individual current (output current sourced from within the PCLA)
Total current (as sensed from the terminal board, summed current in TMR mode)
Note PCLA supports one simplex 0-20 mA output through SCLS and six 0-20 mA simplex/ TMR (voted) configurable set
of outputs through SCLT.
Analog Current Outputs
Each analog output circuit also includes a normally open mechanical relay to enable or disable operation of the output. The
relay is used to remove a failed output from a TMR system allowing the remaining two PCLAs to create the correct output
without interference from the failed circuit. When the output enable relay is de-activated, the output opens through the relay,
open-circuiting that PCLA's analog output from the customer load that is connected to the terminal board.
The mechanical relay’s second normally open contact is used as a status to indicate position of the relay to the control and
includes an LED. One amber LED per channel indicates the output enable relay status for each analog output. When the
enabled output of a particular channel is normal, the LED is turned on. If incorrect operation of the output is detected, the
relay is automatically opened to protect the connected device against excessive output current and the LED is turned off.
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3.1.3.9
Conditions for Operating the Output Enable Relay to De-energized State
The analog output enable relay is enabled only under the following conditions:
Condition 1:
•
•
•
PCLA configuration must be TMR
SuicEnable must be set to True from configuration
Individual current feedback is greater than half of total current feedback plus TMR_DiffLimit set from the ToolboxST
application
Condition 2:
•
•
•
PCLA configuration must be TMR
SuicEnable must be set to True from configuration
Percentage Difference in commanded AnalogOut value and Reference feedback by Full-scale Analog Output is greater
than D/A_ErrLimit set from the ToolboxST application.
The accuracy of the output is 0.5% of full scale and the maximum output load supported is 800 Ω.
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3.1.4 Specifications
The following table provides information specific to the PCLA module with the SCLS and SCLT terminal boards included.
Item
PCLA Specification
Number of channels Simplex
SCLS has 8 thermocouples, 4 analog inputs, 8 RTDs, 1 current output
SCLT (Simplex configuration) has 8 thermocouples, 4 analog inputs, 6 current outputs
Number of channels TMR
SCLT (TMR configuration) has 8 thermocouples, 4 analog inputs, 6 current outputs
Power Supply Input voltage
28 V dc ±5% through P1 on PCLA
Power consumption
19.8 W maximum
Boards
BCLA, SCLS, SCLT (optional), processor board
Fault detection
Incorrect ID chip on each board
† Ambient rating for enclosure design
PCLAH1B is rated from -40 to 70ºC (-40 to 158 ºF)
PCLAH1A is rated from -30 to 65 ºC (-22 to 149 ºF)
† Refer to GEH-6721_Vol_I, the chapter Technical Regulations, Standards, and Environments.
Technology
Surface mount for all boards
Thermocouple
Number of channels
8 channels on SCLS, 8 channels on SCLT
Thermocouple types
E, J, K, S, T thermocouples, and mV inputs
Span
-16.0 mV to +63.0 mV
A/D converter resolution
16-bit A/D converter
Cold junction compensation
Reference junction temperature measured
Cold junction temperature accuracy
Over the Celsius operating range: 1.1°C
Over the Fahrenheit operating range: 2 °F
Measurement accuracy
53 µV (excluding cold junction reading). ±0.1% FS for simplex thermocouple inputs
Example: For type K, at 1000 °F, including cold junction contribution,
RSS error= 3 °F
74.2 µV (excluding cold junction reading). ±0.14% FS for fanned thermocouple inputs
Common mode rejection
Ac common mode rejection 110 dB at 50/60 Hz, for balanced impedance input. Both hardware and
firmware filtering
Common mode voltage
±5 Volts
Normal mode rejection
Rejection of 250 mV rms at 50/60 Hz, ±5%,
Both hardware and firmware filtering provides a total of 80 dB NMRR
Scan time
All inputs are sampled at up to 120 times per second per input
Maximum lead resistance
450 Ω maximum two-way cable resistance, cable length up to 300 m (984 ft)
Fault detection
High/low (hardware) limit check
Monitor readings from all thermocouples, cold junctions, calibration voltages, and calibration zero
readings
Analog Inputs
Number of channels
4 channels on SCLS, 4 channels on SCLT
Input span
±5 V dc, ±10 V dc, or 0-20 mA
Input span, transmitters
1 - 5 V dc across a precision resistor (usually 250 Ω)
A/D converter resolution
16-bit A/D converter
Scan time
8.33 ms for 60 Hz line frequency, 10 ms for 50 Hz line frequency
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Item
PCLA Specification
Measurement accuracy
0.1% of full scale over the full operating temperature range
Noise suppression on inputs
A hardware filter with cut off frequency at 76 Hz, single pole down break at 500 rad/sec. A software
filter, using a two-pole, low-pass filter, is configurable for: 0 Hz, .75 Hz, 1.5 Hz, 3 Hz, 6 Hz, 12 Hz
Common mode rejection
Ac common mode rejection 60 dB at 60 Hz, with up to ±5 V common mode voltage.
Dc common mode rejection 80 dB with from -5 to +7 peak V common mode voltage
Common mode voltage range
±5 V (±2 V CMR for the ±10 V inputs)
Maximum lead resistance
15 W maximum two-way cable resistance, cable length up to 300 m (984 ft).
Outputs
24 V dc outputs rated at 21 mA each
RTD Inputs
Number of channels
8 simplex channels of 3-wire RTDs on SCLS
RTD types
100, and 200 Ω platinum
120 Ω nickel
Scan time
Normal scan 250 ms (4 Hz)
Fast scan 40 ms (25 Hz)
Measurement accuracy
0.1% of full scale
Common mode rejection
Ac common mode rejection 60 dB at 50/60 Hz,
Dc common mode rejection 80 dB
Common mode voltage range
±5 Volts
Normal mode rejection
Rejection of up to 250 mV rms is 60 dB at 50/60 Hz system frequency for normal scan
Maximum lead resistance
15 Ω maximum two-way cable resistance
Fault detection
High/low (hardware) limit check
Analog Outputs
Number of channels
1 simplex channel on SCLS, 6 simplex / TMR channels on SCLT
Accuracy
0.5% full scale with respect to the command
Load on output currents
800 Ω burden for 4-20 mA output
Compliance Voltage
18 V dc (based on output load value)
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3.1.5 Diagnostics
The PCLA performs the following self-diagnostic tests:
•
•
•
•
•
•
•
A power up self test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware.
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
As a group, the 4-20 mA analog inputs have a specified high and low current range for a valid signal. If a signal falls
outside the specified range, the signal health is declared to be bad.
The analog input hardware includes precision reference voltages in each scan. Measured values are compared against
expected values, and are used to confirm the health of the analog to digital converter circuits. If the reference value does
not fall within a defined range, an alarm is generated to indicate a potential problem with signal accuracy.
Analog output current is sensed on the terminal board using a small burden resistor. PCLA conditions this signal and
compares it to the commanded current to confirm the health of the digital to analog converter circuits.
The analog output enable relay is continuously monitored for agreement between commanded state and feedback
indication.
Thermocouple circuits are biased with a small dc current. If a thermocouple circuit opens, the temperature signal goes to a
full-scale negative reading. There is a configuration to report an open thermocouple as fail cold or fail hot.
•
•
Each RTD type has hardware limit checking based on preset (non-configurable) high and low levels set near the ends of
the operating range. If this limit is exceeded, an alarm is generated to indicate a potential problem with the signal.
The resistance of each RTD is checked and compared with the correct value. If the resistance is high or low, a fault is
created.
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RESET_DIA signal if they go healthy. Additional diagnostic information may be found in the
PCLA Diagnostic Alarms section.
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3.1.6 Configuration
3.1.6.1
Parameters
Parameter
Description
Choices
Min_MA_Input
Minimum mA for Healthy 4-20 mA Input
0 to 21 mA
Max_MA_Input
Maximum mA for Healthy 4-20 mA Input
0 to 21 mA
RTDRate
Select Scan Rate For RTD 1 and 2
Fast, Slow
SysFreq
System Frequency (used for noise rejection)
60 Hz, 50 Hz
3.1.6.2
SCLS Analog Inputs
Input
Description
Choices
AnalogIn1
First of 10 Analog Inputs – board variable. Variable edit
(Input FLOAT)
Input Type
Current or voltage input type
Unused, 4-20 mA, ±5 V,
±10 V
Low_Input
Value of current at the low end of scale
-10 to 20
Low_Value
Value of input in engineering units at low end of scale
-3.4082 e + 038 to 3.4028
e + 038
High_Input
Value of current at the high end of scale
-10 to 20
High_Value
Value of input in engineering units at high end of scale
-3.4082 e + 038 to 3.4028
e + 038
Input _Filter
Bandwidth of input signal filter
Unused, 0.75, 1.5 Hz, 3
Hz, 6 Hz, 12 Hz
DiagHighEnab
Enable high input limit
Enable, disable
DiagLowEnab
Enable low input limit
Enable, disable
3.1.6.3
SCLT Analog Inputs
Input
Description
Choices
AnalogIn1
First of 10 Analog Inputs – board variable. Variable edit
(Input FLOAT)
Input Type
Current or voltage input type
Unused, 4-20 mA, ±5 V, ±10 V
Low_Input
Value of current at the low end of scale
-10 to 10
Low_Value
Value of input in engineering units at low end of scale
-3.4082 e + 038 to 3.4028 e + 038
High_Input
Value of current at the high end of scale
-10 to 10
High_Value
Value of input in engineering units at high end of scale
-3.4082 e + 038 to 3.4028 e + 038
Input _Filter
Bandwidth of input signal filter
TMR Diff Limit
Difference limit for voted inputs in % of high-low values
Unused, 0.75, 1.5 Hz, 3 Hz, 6 Hz,
12 Hz
0 to 100
DiagHighEnab
Enable high input limit
Enable, disable
DiagLowEnab
Enable low input limit
Enable, disable
124
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3.1.6.4
TC Inputs
Input
Description
Choices
ThermocoupleX_(R, S, or First of 8 thermocouples, point signal
T)
where X = 01 to 08
ThermoCpl Type
Select thermocouples type or mV input
mV inputs are primarily for maintenance, but can also be used for
custom remote CJ compensation. Standard remote CJ
compensation also available.
Variable Edit (Input FLOAT)
ThermCplHot
Select Open TC to be reported Failed Hot
Disable, Enable
ThermCplUnit
The ThermCplUnit parameter affects the native units of the
controller application variable. It is only indirectly related to the tray
icon and associated unit switching capability of the HMI. This
parameter should not be used to switch the display units of the HMI.
deg_F, deg_C
Caution
3.1.6.5
Unused, mV, E, J, K, S, T
Do not change the ThermCplUnit parameter in the
ToolboxST application because these changes will
require corresponding changes to application code
and to the Format Specifications or units of the
connected variable. This parameter modifies the
actual value sent to the controller as seen by
application code. Application code that is written to
expect degrees Fahrenheit will not work correctly if
this setting is changed. External devices, such as
HMIs and Historians, may also be affected by
changes to this parameter.
RTD Inputs
Input
Description
Choices
RTD Inputs
8 RTD’s, point signal
Variable Edit (Input FLOAT)
RTD Type
Select RTD type or ohms input
RTD linearization supported by RTD
Unused,
PT100_DIN, MINCO_PA,
MINCO_PB, MINCO_PK,
MINCO_PA, MINCO_NA, MINCO_
PN
OHMS, PT100_SAMA,
ROSEMONT_104
RTDUnit
Select RTD Display Unit Deg °C or °F
deg_F, deg_C
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3.1.6.6
CJ Inputs
Input
Description
Choices
ColdJunction_(R, S, or T)
Cold junction for TC 1- 8
Variable Edit (Input FLOAT)
ColdJuncType
Select CJ Type
Local, Remote
ColdJuncUnit
Select CJ Display Unit Deg °C or °F
This value needs to match units of attached variable.
Diag Limit, TMR Input Vote Difference, in Eng Units
deg_F, deg_C
TMR_DiffLimt
0 to 100
(SCLT only)
3.1.6.7
Analog Outputs
Output
Description
AnalogOut01_(R, S, or T)
First of 7 analog outputs is simplex only - board variable
Variable edit (Output FLOAT)
Output_MA
Type of output current, mA selection
Unused, 0-20 mA
Output_State
State of the outputs when offline
PwrDownMode
Hold Last Value
Output_Value
Choices
Output_Value
Pre-determined value for the outputs
Low_MA
Output mA at low value
0 to 20 mA
Low_Value
Output in Engineering Units at low mA
-3.4082 e + 038 to 3.4028 e + 038
High_MA
Output mA at high value
0 to 20 mA
High_Value
Output value in Engineering Units at high mA
-3.4082 e + 038 to 3.4028 e + 038
Suicide_Enab
Suicide for faulty output current, TMR only
Enable, disable
TMR SuicLimit
Suicide threshold for TMR operation
0 to 20 mA
D/A Err Limit
Difference between D/A reference and output, in % for
suicide, TMR only
0 to 100%
3.1.6.8
Variables
Variable
Description-Variable Edit (Enter
Signal Connection)
Direction
Type
L3DIAG_PCLA
I/O diagnostic indication
Input
BIT
LINK_OK_PCLA
I/O link okay indication
Input
BIT
ATTN_PCLA
I/O Attention Indication
Input
BIT
PS18V_PCLA
I/O 18 V Power Supply Indication
Input
BIT
PS28V_PCLA
I/O 28 V Power Supply Indication
Input
BIT
I/O packTmpr
I/O pack temperature
Input
FLOAT
CJRemote1
SCLS CJ Remote value (deg °F)
Output
FLOAT
CJBackup1
SCLS CJ Backup value (deg °F)
Output
FLOAT
CJRemote2
SCLT CJ Remote value (deg °F)
Output
FLOAT
CJBackup2
SCLT CJ Backup value (deg °F)
Output
FLOAT
126
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3.1.6.9
AO Feedbacks
Feedback
Description-Variable Edit (Enter
Signal Connection)
Direction
Type
AOutSuicide1_R
Status of Suicide Relay for Output 1
Input
FLOAT
AoutSuicide2
Status of Suicide Relay for Output 2
Input
FLOAT
AoutSuicide3
Status of Suicide Relay for Output 3
Input
FLOAT
AoutSuicide4
Status of Suicide Relay for Output 4
Input
FLOAT
AoutSuicide5
Status of Suicide Relay for Output 5
Input
FLOAT
AoutSuicide6
Status of Suicide Relay for Output 6
Input
FLOAT
AoutSuicide7
Status of Suicide Relay for Output 7
Input
FLOAT
AOutFbk1_R
Feedback, Output Current, mA
Input
FLOAT
AoutFbk2
Total feedback, Output Current, mA
Input
FLOAT
AoutFbk3
Total feedback, Output Current, mA
Input
FLOAT
AoutFbk4
Total feedback, Output Current, mA
Input
FLOAT
AoutFbk5
Total feedback, Output Current, mA
Input
FLOAT
AoutFbk6
Total feedback, Output Current, mA
Input
FLOAT
AoutFbk7
Total feedback, Output Current, mA
Input
FLOAT
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3.2 PCLA Specific Alarms
The following alarms are specific to the PCLA Core Analog Module - Aero
32
Note This alarm is obsolete.
Description Unallowed VarIOCompatCode Change: Old - [ ]; New - [ ]
Possible Cause There is a .dll file (ToolboxST support file) installed that is incompatible with the firmware loaded on the
PCLA.
Solution
•
•
Confirm the correct installation of the ToolboxST application.
Rebuild the application, then download the firmware and application code to the affected PCLA.
33-36
Description Analog Input (Simplex) [ ] unhealthy
Possible Cause
•
•
•
•
•
Excitation to transducer wrong or missing
Transducer faulty
Terminal board jumper settings do not match ToolboxST configuration
Analog input current/voltage input beyond specified range
Open or short-circuit on input
Solution
•
•
•
•
•
128
Check the field wiring and the connections to the indicated analog input channel.
Check the field device for failure.
Check the ground select jumper for the input.
Verify that the inputs are in operable range (3.0-21.5 mA, ±5.25 V, ±10.5 V).
Verify that the configuration matches the terminal board jumper settings for the indicated analog input channel.
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37-40
Description Analog Input (SCLT) [ ] unhealthy
Possible Cause
•
•
•
•
•
Excitation to transducer wrong or missing
Transducer faulty
Analog input current/voltage input beyond specified range
Terminal board jumper settings do not match ToolboxST configuration
Open or short-circuit on input
Solution
•
•
•
•
•
•
•
Check the field wiring and connections to the indicated analog input channel.
Check the field device for failure.
Check the ground select jumper for the input.
Verify that the cable between the SCLT - PCLA module is fully seated in the connector.
Verify that the inputs are in operable range (3.0-21.5 mA, ±5.25 V, ±10.5 V).
Verify that the configuration matches the terminal board jumper settings for the indicated analog input channel.
Replace the SCLT - PCLA cable.
41-46
Description Analog Output [ ] Individual current feedback unhealthy
Possible Cause
•
•
•
•
•
Commanded output beyond range of output
Field wiring problem
Field device problem
I/O pack or module failure
Terminal board failure
Solution
•
•
•
•
Verify that the commanded output is within the range of the output.
Confirm the correct I/O pack or module 28 V input power.
Check the field wiring and the device.
Replace the I/O pack or module.
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47-53
Description Analog Output [ ] Total current feedback unhealthy
Possible Cause
•
•
•
•
Commanded output beyond range of output
Field wiring problem
Field device problem
Open loop or too much resistance in the loop
Solution
•
•
•
•
•
Verify that the commanded output is within the range of the output.
Confirm the correct I/O pack or module 28 V input power.
Check the field wiring and the device.
For the analog outputs 2 through 7, check the cable between the PCLA module and the SCLT.
Replace the I/O pack or module.
54-60
Description Analog Output [ ] Internal reference current unhealthy
Possible Cause
•
I/O pack or module failure
Solution
•
•
130
Confirm the correct I/O pack or module 28 V input power.
Replace the PCLA module.
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61
Description Analog Output (Simplex) [ ] 20 mA suicide active
Possible Cause
•
•
•
•
•
•
Suicide parameter enabled on analog output
Review any additional diagnostics for possible causes.
Analog output current feedback too high (30 mA)
Parameter TMR_SuicLimit set too low
Field wiring problem
Command is beyond range of output
Solution
•
•
•
Verify that the value of the parameter TMR_SuicLimit is set correctly.
Verify that the value of the parameter D/A_ErrLimit is set correctly.
Verify that the commanded output is within output range.
62-67
Description Analog Output (SCLT) [ ] 20 mA suicide active
Possible Cause
•
•
•
•
•
•
Suicide parameter enabled on analog output
Review any additional diagnostics for possible causes.
Analog output current feedback too high (30 mA)
Parameter TMR_SuicLimit set too low
Field wiring problem
Command beyond range of output
Solution
•
•
•
Verify that the value of the parameter TMR_SuicLimit is set correctly.
Verify that the value of the parameter D/A_ErrLimit is set correctly.
Verify that the commanded output is within output range.
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68
Description Analog Output (Simplex) [ ] Suicide relay non-functional
Possible Cause
•
•
•
Analog output suicide relay command does not match feedback
Relay failure on acquisition board
There is a hardware failure.
Solution Replace the PCLA.
69-74
Description Analog Output (SCLT) [ ] Suicide relay non-functional
Possible Cause
•
•
•
Analog output suicide relay command does not match feedback
Relay failure on acquisition board
Hardware failure
Solution Replace the PCLA.
75
Description I/O module internal reference voltage out of limits [ ]
Possible Cause
•
Internal calibration of inputs uses internal reference voltage. This reference voltage is more than ±5% from the expected
value, and indicates a hardware failure.
Solution
•
•
•
Check the ground quality through the mounting bolts.
Cycle power on the PCLA.
Replace the PCLA.
104
Description I/O module internal null voltage out of limits [ ]
Possible Cause
•
Internal calibration of inputs uses internal null voltage. This null voltage is more than ±5% from the expected value,
which indicates a hardware failure.
Solution
•
•
•
132
Check the ground quality through the mounting bolts.
Cycle power on the PCLA.
Replace the PCLA module.
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133-140
Description Thermocouple (Simplex) [ ] Unhealthy
Possible Cause
•
•
•
Thermocouple millivolt input on terminal board exceeded thermocouple range or hardware limit. Refer to the PCLA
module help documentation for specified thermocouple ranges.
Thermocouple configured as wrong type.
Board detected thermocouple open and applied bias to circuit driving it to large negative number, or TC not connected, or
condition such as stray voltage or noise caused input to exceed -63 mV.
Solution
•
•
•
•
Check field wiring including shields. Check installation of PCLA module on terminal board. Problem is usually not a
PCLA module or terminal board failure, if other thermocouples are working correctly.
Check thermocouple for open circuit.
Measure incoming millivolt signal and verify that it doesn't exceed -63 mV.
Verify that the thermocouple type matches the configuration.
141-148
Description Thermocouple (SCLT) [ ] Unhealthy
Possible Cause
•
•
•
Thermocouple millivolt input on terminal board exceeded thermocouple range or hardware limit. Refer to PCLA module
help documentation for specified thermocouple ranges.
Thermocouple configured as wrong type
Board detected thermocouple open and applied bias to circuit driving it to large negative number, or TC not connected, or
condition such as stray voltage or noise caused input to exceed -63 mV.
Solution
•
•
•
•
•
Ensure cable between SCLT - PCLA module is fully seated in connector.
Check field wiring including shields. Check installation of PCLA on terminal board. Problem is usually not a PCLA or
terminal board failure if other thermocouples are working correctly.
Check thermocouple for open circuit.
Measure incoming millivolt signal and verify that it doesn't exceed -63 mV.
Verify that the thermocouple type matches the configuration.
149
Description Cold Junction (SCLS) Unhealthy, Using Backup
Possible Cause
•
•
Local cold junction signal from SCLS terminal board out of range. The normal range is -50 to 85°C (-58 to 185 °F).
Hardware failure of cold junction sensor
Solution
•
•
If hardware is in the normal temperature range, replace the SCLS terminal board.
Replace PCLA.
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150
Description Cold Junction (SCLT) Unhealthy, Using Backup
Possible Cause
•
•
Local cold junction signal from SCLT terminal board out of range. The normal range is -50 to 85°C (-58 to 185 °F).
Hardware failure of cold junction sensor
Solution
•
•
Verify that the cable between the SCLT and PCLA is fully seated in the connector.
If hardware is in the normal temperature range, replace the SCLT terminal board.
151-158
Description RTD [ ] Unhealthy
Possible Cause
•
•
•
•
•
•
•
RTD wiring/cabling open or high impedance
Open on connections to the terminal board
RTD device failed
PCLA module internal hardware problem
Current source on PCLA for RTD faulty or measurement device failed
Wrong type of RTD configured or selected by default
High-resistance values created by high voltage and/or low current
Solution
•
•
•
•
•
Check the field wiring for open circuit or high impedance.
Verify the proper connections to the terminal board.
Check the RTD for proper operation.
Verify that the RTD type configuration matches the attached device type.
Replace the PCLA.
159
Description SCLT Configuration & Hardware Mismatch
Possible Cause
•
•
•
SCLT terminal board connected in hardware but not configured in ToolboxST application.
In ToolboxST application, the PCLA configured with a SCLT terminal board, but SCLT not physically connected.
Faulty cable between SCLT - PCLA module
Solution
•
•
•
•
•
134
Verify that the PCLA configuration matches the hardware connected.
Replace the cable.
Replace the SCLT terminal board.
Replace the SCLS terminal board.
Replace the PCLA.
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160-191
Description Logic Signal [ ] Voting Mismatch
Possible Cause N/A
Solution N/A
192-211
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause Voter disagreement between R, S and T I/O packs or modules.
Solution Adjust the TMR threshold limit for the inputs causing the diagnostic or correct the cause of the difference.
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3.3 SCLS Core Analog Terminal Board
The Core Analog (SCLS) terminal board provides the terminal and signal routing into the BCLA board. Inputs include eight
thermocouple inputs, four analog inputs and eight RTD inputs. An individual 24 V dc power source is included for all four
4-20 mA inputs on SCLS. SCLS output channel consist of one 4-20 mA simplex output signal. Seventy-two pluggable Euro
style box-type terminal blocks provide field wire terminal points. Terminal grouping is three sets of 24 terminals each. SCLS
provides the J2 68 pin connectors for IS200SCLT terminal board cable.
Note PCLA supports one simplex 0-20 mA output through SCLS and six 0-20 mA simplex/ TMR (voted) configurable set
of outputs through SCLT.
136
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SCLS Terminal Board
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3.3.1 Installation
An I/O cable shield terminal is provided adjacent to the terminal blocks. Terminals 23, 24, 43, 44, 45, 46, 47, and 48 are NOT
Connected terminal points. Field device I/O is through 72 Euro style box-type terminal blocks on the SCLS edge and is
through 48 Euro style box-type terminal blocks on the SCLT edge. SCLS and SCLT accept conductors with the following
characteristics:
SCLS Terminal Conductor Size Range
Conductor type
Minimum
Maximum
Conductor cross section solid
0.2 mm2
2.5 mm2
Conductor cross section stranded
0.2 mm2
2.5 mm2
Conductor cross section stranded, with ferrule without plastic sleeve
0.25 mm2
2.5 mm2
Conductor cross section stranded, with ferrule with plastic sleeve
0.25 mm2
2.5 mm2
Conductor cross section AWG/kcmil
24 AWG
12 AWG
2 conductors with same cross section, solid
0.2 mm2
1 mm2
2 conductors with same cross section, stranded
0.2 mm2
1.5 mm2
2 conductors with same cross section, stranded, ferrules without plastic sleeve
0.25 mm2
1 mm2
2 conductors with same cross section, stranded, TWIN ferrules with plastic sleeve
0.5 mm2
1.5 mm2
Note Refer to the PCLA Core Analog Module - Aero, Installation section for more information.
SCLS Screw Terminal Assignments
Terminal number
Signal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
P24V1
20mA1
VDC1
RET1
P24V2
20mA2
VDC2
RET2
P24V3
20mA3
VDC3
RET3
P24V4
20mA4
VDC4
RET4
PCOM
PCOM
PCOM
PCOM
OP1
OR1
NC
NC
TC 1H
TC 1L
138
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Function
Analog Input 1
Analog Input 2
Analog Input 3
Analog Input 4
Common points
4-20 mA output 1
No Connect
Thermocouple 1
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SCLS Screw Terminal Assignments (continued)
Terminal number
Signal
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
TC 2H
TC 2L
TC 3H
TC 3L
TC 4H
TC 4L
TC 5H
TC 5L
TC 6H
TC 6L
TC 7H
TC 7L
TC 8H
TC 8L
PCOM
PCOM
NC
NC
NC
NC
NC
NC
RTD EXC1
RTD SIG1
RTD RET1
RTD EXC2
RTD SIG2
RTD RET2
RTD EXC3
RTD SIG3
RTD RET3
RTD EXC4
RTD SIG4
RTD RET4
RTD EXC5
RTD SIG5
RTD RET5
RTD EXC6
RTD SIG6
RTD RET6
RTD EXC7
RTD SIG7
RTD RET7
RTD EXC8
RTD SIG8
RTD RET8
PCLA Core Analog Module — Aero
Function
Thermocouple 2
Thermocouple 3
Thermocouple 4
Thermocouple 5
Thermocouple 6
Thermocouple 7
Thermocouple 8
Common points
Not connected
RTD 1
RTD 2
RTD 3
RTD 4
RTD 5
RTD 6
RTD 7
RTD 8
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3.3.2 Operation
The SCLS terminal board provides the customer terminals and signal routing into the BCLA board. SCLS provides the J2 68
pin connectors for IS200SCLT terminal board cable. Internal to the module the SCLS terminal board routes signals to
connectors for the BCLA analog processing board. Seventy-two pluggable Euro style box-type terminal blocks provide Field
wire terminal points. Terminal grouping is 3 sets of 24 terminals each.
SCLS Terminals
# Signals
Signal Type
Screws/Signal
8
Thermocouples
2
4
Analog 4-20 mA inputs or ±10 V Inputs or ±5 V inputs
4
8
RTD
3
1
Analog 4-20 mA outputs
2
1
Common connection
6
NC (Not Connected) Screws
8
3.3.2.1
Thermocouples
The PCLA supports E, J, K, S, and T types of thermocouples and mV inputs. Simplex inputs from field are terminated on
SCLS. There are eight simplex thermocouple inputs. Connect the thermocouple wires directly to the thermocouple I/O
terminal blocks as described in the table. These removable blocks are mounted on the terminal board and held down with two
screws.
The eight-thermocouple inputs can be grounded or ungrounded. They can be located up to 300 m (984 ft) from the turbine
control cabinet with a maximum two-way cable resistance of 450 Ω. SCLS terminal boards feature high-frequency noise
suppression and one cold junction reference device. The I/O processor performs the analog-to-digital conversion and the
linearization for individual thermocouple types.
Thermocouple Inputs and I/O Processor, Simplex
140
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3.3.2.2
Analog Voltage or Current Inputs
SCLS can accommodate four simplex analog voltage or current inputs. They can be located up to 300 m (984 ft) from the
turbine control cabinet with a maximum two-way cable resistance of 15 Ω. Connect the input and output wires directly to two
I/O terminal blocks mounted on the terminal board. Each block is held down with two screws. A shield terminal attachment
point is located adjacent to each terminal block.
SCLS can accommodate the following analog I/O types:
•
•
•
•
•
Analog input, two-wire transmitter
Analog input, three-wire transmitter
Analog input, four-wire transmitter
Analog input, externally powered transmitter
Analog input, voltage ±5 V dc, ±10 V dc, current 4-20 mA
Analog Inputs
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3.3.2.3
Analog Voltage or Current Inputs Configurations
The SCLS is able to interface to several different types of 4-20 mA transmitters. SCLS board provides four 24 V dc terminals,
one for each 4-20 mA transmitter input. The inputs can be configured as current or voltage inputs using jumpers (JP#A). The
JP#A jumper removes the 250 Ω burden resistor for voltage input applications. The following configurations are supported:
Analog Input Configurations
Each input has a jumper (JP#B) on the board that is used to determine if the return terminal is grounded or floating. The
default position of the jumper is floating or open. With the noise suppression and filtering, the input ac CMR is 60 dB, and the
dc CMR is 80 dB.
Analog Input Jumper Summary
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 1
JP1A
mA
VDC
Analog In 2
JP2A
mA
VDC
Analog In 3
JP3A
mA
VDC
Analog In 4
JP4A
mA
VDC
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 1
JP1B
GND
OPEN
Analog In 2
JP2B
GND
OPEN
Analog In 3
JP3B
GND
OPEN
Analog In 4
JP4B
GND
OPEN
142
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3.3.2.4
RTD Inputs
SCLS can accommodate eight simplex 3-wire RTD inputs. The eight inputs feature group isolation from the grounding
system. Connect the wires for the eight RTDs directly to the terminal blocks on the SCLS board. A shield terminal strip
attached to chassis ground is located immediately to the left of each terminal block.
Note Refer to the PCLA Operation section, RTD Inputs.
For CE mark applications, double-shielded wire must be used. All shields must be
terminated at the shield terminal strip. Do not terminate shields located at the end
device.
Caution
The terminal board supplies a 1 mA dc multiplexed (not continuous) excitation current to each RTD. The eight RTDs can be
located up to 300 m (984 ft) from the turbine control cabinet with a maximum two-way cable resistance of 15 Ω. The
on-board noise suppression is provided on SCLS. The first two RTD channels (1 and 2) can be configured for either fast or
normal mode scanning. Channels 3 to 8 are only normal mode scan channels. Fast RTDs are scanned 25 times per second and
slow RTD channels are scanned 4 times in a second using a time sample interval related to the power system frequency.
Note RTD open and short circuits are detected by out-of-range values.
The processor performs linearization for the selection of RTD types. RTD open and short circuits are detected by out-of-range
values. RTD inputs are automatically calibrated using the filtered calibration source and null voltages. The RTD inputs and
signal processing are illustrated in the following figure.
SCLS RTD Section and Input Processor Board BCLA RTD Section
RTD Accuracy
RTD Type
Accuracy at 400 ºF
120 Ω nickel
2 ºF
200 Ω platinum
2 ºF
100 Ω platinum
4 ºF
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3.3.2.5
Analog Output
SCLS supports one simplex analog (0-20 mA) output capable of 18 V compliance voltage. It can be located up to 300 m (984
ft) from the turbine control cabinet. Maximum load resistance supported is 800 Ω. Connect output wires directly to two I/O
terminal blocks mounted on the terminal board. Each block is held down with two screws. The output channel has noise
suppression circuitry to protect against surge and high frequency noise.
Analog Outputs
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3.3.3 Specifications
Item
SCLS Specification
Number of channels
8 Thermocouples, 4 Analog inputs, 8 RTDs, 1 Current Output
Supply Input P28
Through P1 on PCLA
Interface
With SCLT and BCLA
Fault detection
Incorrect ID chip
Size
5.625 inch x 9.1 inch
Technology
Surface mount
Thermocouple
Number of channels
8 channels on SCLS
Thermocouple types
E, J, K, S, T thermocouples, and mV inputs
Span
-16.0 mV to 63.0 mV
Cold junction compensation
Reference junction temperature measured
Cold junction temperature
accuracy
Over the Celsius operating range: 1.1°C
Over the Fahrenheit operating range: 2 °F
Fault detection
High/low (hardware) limit check
Monitor readings from all thermocouples, cold junctions, calibration voltages, and calibration
zero readings
Analog Inputs
Number of channels
4 Channels
Input span, transmitters
1 - 5 V dc across a precision resistor (usually 250 Ω)
Maximum lead resistance
15 Ω maximum two-way cable resistance, cable length up to 300 m (984 ft).
Outputs
24 V dc outputs rated at 21 mA each
RTD Inputs
Number of channels
8 Channels of 3-wire RTDs
RTD types
100, and 200 Ω platinum
120 Ω nickel
Maximum lead resistance
15 Ω maximum two-way cable resistance
Fault detection
High/low (hardware) limit check
Analog Output
Number of channels
1 Channel
Load on output currents
800 Ω burden for 4-20 mA output
Compliance Voltage
18 V dc
PCLA Core Analog Module — Aero
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3.3.4 Diagnostics
Each terminal board connector has its own ID device that is interrogated by the I/O board. The board ID is coded into a
read-only chip containing the terminal board serial number, board type, revision number. If a mismatch is encountered, a
hardware incompatibility fault is created.
3.3.4.1
Thermocouples
Thermocouple circuits are biased with a small dc current. If a thermocouple circuit opens, the temperature signal goes to a
full-scale negative reading. There is a configuration to report an open thermocouple as fail cold or fail hot.
•
•
Each RTD type has hardware limit checking based on preset (non-configurable) high and low levels set near the ends of
the operating range. If this limit is exceeded, an alarm is generated to indicate a potential problem with the signal.
The resistance of each RTD is checked and compared with the correct value. If the resistance is high or low, a fault is
created.
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RESET_DIA signal if they go healthy. Additional diagnostic information may be found in the
PCLA Diagnostic Alarms section.
3.3.4.2
Analog Outputs
The board provides the voltage drop across a series resistor to indicate the output current. The I/O processor creates a
diagnostic alarm (fault) if the output goes unhealthy.
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3.3.5 Configuration
The SCLS is able to interface to several different types of 4-20 mA transmitters. SCLS board provides four 24 V dc terminals,
one for each 4-20 mA transmitter input. The inputs can be configured as current or voltage inputs using jumpers (JP#A). The
JP#A jumper removes the 250 Ω burden resistor for voltage input applications. The following configurations are supported:
Analog Input Configurations
Each input has a jumper (JP#B) on the board that is used to determine if the return terminal is grounded or floating. The
default position of the jumper is floating or open.
Analog Input Jumper Summary
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 1
JP1A
mA
VDC
Analog In 2
JP2A
mA
VDC
Analog In 3
JP3A
mA
VDC
Analog In 4
JP4A
mA
VDC
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 1
JP1B
GND
OPEN
Analog In 2
JP2B
GND
OPEN
Analog In 3
JP3B
GND
OPEN
Analog In 4
JP4B
GND
OPEN
PCLA Core Analog Module — Aero
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3.4 SCLT Core Analog Terminal Board
3.4.1 Functional Description
The Core Analog (SCLT) terminal board provides additional I/O terminals for the PCLA module. It handles input signals that
are fanned to one or three PCLA modules and also handles the voted output signals. Inputs include eight thermocouple inputs,
four analog voltage or current inputs, and six 4-20 mA outputs. An individual 24 V dc power source is included for all four
4-20 mA inputs on SCLT. Forty-eight pluggable Euro style box-type terminal blocks provide field wire terminal points. The
following table lists I/O supported by SCLT:
SCLT Terminals
# Signals
Signal Type
Screws/Signal
8
Fanned Thermocouples
2
4
Fanned Analog 4-20 mA inputs or ±10 V Inputs or ±5 V inputs
4
6
TMR (triple Modular Redundant) Analog 4-20 mA outputs
2
1
Common connection
4
SCLT supports simplex or TMR configurations. The connection diagrams for both the configurations are given below.
PCLA Diagram - Simplex board (PCLA cover omitted to display board relationship)
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PCLA-SCLT Connection Diagram - TMR Controller TMR I/O Configuration (PCLA Cover Omitted to Display Board
Relationship)
SCLT Terminal Board
PCLA Core Analog Module — Aero
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3.4.2 Installation
An I/O cable shield terminal is provided adjacent to the terminal blocks. Field device I/O is through 72 Euro style box-type
terminal blocks on the SCLS side and is through 48 Euro -style box terminals on the SCLT side. SCLS and SCLT accept
conductors with the following characteristics:
SCLT Terminal Conductor Size Range
Conductor type
Minimum
Maximum
Conductor cross section solid
0.2 mm2
2.5 mm2
Conductor cross section stranded
0.2 mm2
2.5 mm2
Conductor cross section stranded, with ferrule without plastic sleeve
0.25 mm2
2.5 mm2
Conductor cross section stranded, with ferrule with plastic sleeve
0.25 mm2
2.5 mm2
Conductor cross section AWG/kcmil
24 AWG
12 AWG
2 conductors with same cross section, solid
0.2 mm2
1 mm2
2 conductors with same cross section, stranded
0.2 mm2
1.5 mm2
2 conductors with same cross section, stranded, ferrules without plastic
0.25 mm2
1 mm2
0.5 mm2
1.5 mm2
sleeve
2 conductors with same cross section, stranded, TWIN ferrules with plastic
sleeve
Note Refer to the PCLA Core Analog Module - Aero Installation section for more information.
SCLT Screw Terminal Assignments
Terminal #
Signal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
TC 9H
TC 9L
TC 10H
TC 10L
TC 11H
TC 11L
TC 12H
TC 12L
TC 13H
TC 13L
TC 14H
TC 14L
TC 15H
TC 15L
TC 16H
TC 16L
PCOM
PCOM
P24V5
20mA5
VDC5
RET5
P24V6
20mA6
VDC6
RET6
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Function
Thermocouple 9
Thermocouple 10
Thermocouple 11
Thermocouple 12
Thermocouple 13
Thermocouple 14
Thermocouple 15
Thermocouple 16
Common Points
Analog Input 5
Analog Input 6
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SCLT Screw Terminal Assignments (continued)
Terminal #
Signal
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
P24V7
20mA7
VDC7
RET7
P24V8
20mA8
VDC8
RET8
PCOM
PCOM
OP2
OR2
OP3
OR3
OP4
OR4
OP5
OR5
OP6
OR6
OP7
OR7
Function
Analog Input 7
Analog Input 8
Common points
4-20 mA output 2
4-20 mA output 3
4-20 mA output 4
4-20 mA output 5
4-20 mA output 6
4-20 mA output 7
PCLA Core Analog Module — Aero
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3.4.3 Operation
SCLT provides fanning of input signals to one or more PCLA modules. This is done with high reliability passive circuits to
ensure reliability in redundant applications. SCLT accepts 28 V dc power from connected PCLA modules. The power supplies
from all PCLAs are connected through diodes (Diode-OR) to obtain redundant power input for the 24 V dc outputs. Each 24
V output on SCLT is provided with an individual voltage regulator that includes thermal shutdown for branch circuit
protection. The SCLT terminal board provides the customer terminals and 68 pin connectors for SCLS terminal board cable.
Forty-eight pluggable Euro style box-type terminal blocks provide Field wire terminal points.
Note An over current condition on one 24 V dc output will result in only that output being shut down. When the overload is
removed the terminal will return to 24 V dc.
3.4.3.1
Thermocouples
The PCLA supports E, J, K, S, and T types of thermocouples and mV inputs. Simplex/TMR inputs from field are ended on
SCLT based on the configuration. There are eight simplex thermocouple inputs. Connect the thermocouple wires directly to
the thermocouple I/O terminal blocks as described in the table. These removable blocks are mounted on the terminal board
and held down with two screws.
The 8-thermocouple inputs can be grounded or ungrounded. They can be located up to 300 m (984 ft) from the turbine control
cabinet with a maximum two-way cable resistance of 450 Ω. SCLT-SCLS terminal boards feature high-frequency noise
suppression and one cold junction reference device. The I/O processor performs the analog-to-digital conversion and the
linearization for individual thermocouple types.
3.4.3.2
Analog Voltage or Current Inputs
SCLT can accommodate four simplex / Fanned analog voltage or current inputs. They can be located up to 300 m (984 ft)
from the turbine control cabinet with a maximum two-way cable resistance of 15 Ω. Connect the input and output wires
directly to two I/O terminal blocks mounted on the terminal board. Each block is held down with two screws. A shield
terminal attachment point is located adjacent to each terminal block.
SCLT can accommodate the following analog I/O types:
•
•
•
•
•
152
Analog input, two-wire transmitter
Analog input, three-wire transmitter
Analog input, four-wire transmitter
Analog input, externally powered transmitter
Analog input, voltage ±5 V dc, ±10 V dc, current 4-20 mA
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3.4.3.3
Analog Voltage or Current Inputs Configurations
The SCLT is able to interface to several different types of 4-20 mA transmitters. SCLT board provides four 24 V dc terminals,
one for each 4-20 mA transmitter input. The inputs can be configured as current or voltage inputs using jumpers (JP#A). The
JP#A jumper removes the 250 Ω burden resistor for voltage input applications. The following configurations are supported:
Analog Input Configurations
Each input has a jumper (JP#B) on the board that is used to determine if the return terminal is grounded or floating. The
default position of the jumper is floating or open. With the noise suppression and filtering, the input ac CMR is 60 dB, and the
dc CMR is 80 dB.
Analog Input Jumper Summary
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 5
JP5A
mA
VDC
Analog In 6
JP6A
mA
VDC
Analog In 7
JP7A
mA
VDC
Analog In 8
JP8A
mA
VDC
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 5
JP5B
GND
OPEN
Analog In 6
JP6B
GND
OPEN
Analog In 7
JP7B
GND
OPEN
Analog In 8
JP8B
GND
OPEN
PCLA Core Analog Module — Aero
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3.4.3.4
Analog Outputs
SCLT supports six simplex or voted analog (0-20 mA) outputs capable of 18 V compliance voltage. It can be located up to
300 m (984 ft) from the turbine control cabinet. Maximum load resistance supported is 800 Ω. Connect output wires directly
to two I/O terminal blocks mounted on the terminal board. Each block is held down with two screws. The output channels
have noise suppression circuitry to protect against surge and high frequency noise.
3.4.4 Specifications
Please refer to the signal specifications listed in the PCLA documentation for details of the signals on SCLT.
Item
SCLT Specification
Number of channels
8 Thermocouples, 4 Analog inputs, 6 Current Outputs
Interface
With SCLS and field wires
Fault detection
Incorrect ID chip
Power supply voltage
28 V dc ±5% from one or more PCLA modules
Size
6.25 inch x 7 .00 inch
Technology
Surface mount
Thermocouple
Number of channels
8 simplex or fanned channels on SCLT based on the configuration
Thermocouple types
E, J, K, S, T thermocouples, and mV inputs
Span
-16.0 mV to 63.0 mV
Cold junction compensation
Reference junction temperature measured
Cold junction temperature accuracy
Over the Celsius operating range: 1.1°C
Over the Fahrenheit operating range: 2 °F
Analog Inputs
Number of channels
4 simplex or fanned channels based on the configuration
Input span, transmitters
1 - 5 V dc across a precision resistor (usually 250 Ω)
Maximum lead resistance
15 Ω maximum two-way cable resistance, cable length up to 300 m (984 ft)
Outputs
24 V dc outputs rated at 21 mA each
Analog Outputs
Number of channels
6 simplex or voted channels based on the configuration
Load on output currents
800 Ω burden for 0-20 mA output
Compliance Voltage
18 V dc
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3.4.5 Diagnostics
Each cable connector on the terminal board has its own ID device that is interrogated by the I/O controller. The ID device is a
read-only chip coded with the terminal board serial number, board type, revision number, and the JR, JS, JT connector
location. A hardware incompatibility fault is created when the I/O controller reads this chip and a mismatch is encountered.
3.4.5.1
Thermocouples
Thermocouple circuits are biased with a small dc current. If a thermocouple circuit opens, the temperature signal goes to a
full-scale negative reading. There is a configuration to report an open thermocouple as fail cold or fail hot.
Each RTD type has hardware limit checking based on preset (non-configurable) high and low levels set near the ends of the
operating range. If this limit is exceeded, an alarm is generated to indicate a potential problem with the signal. The resistance
of each RTD is checked and compared with the correct value. If the resistance is high or low, a fault is created.
3.4.5.2
Analog Outputs
The board provides the voltage drop across a series resistor to indicate the output current. The I/O processor creates a
diagnostic alarm (fault) if any of the outputs go unhealthy.
The analog output enable relay is enabled only under following conditions:
Condition 1:
•
•
•
PCLA configuration must be TMR.
SuicEnable must be set to True from configuration.
Individual current feedback is greater than half of total current feedback plus TMR_DiffLimit set from The ToolboxST
application.
Condition 2:
•
•
•
PCLA configuration must be TMR.
SuicEnable must be set to True from configuration.
Percentage Difference in commanded Analogout value and Reference feedback by Full-scale Analog Output is greater
than D/A_ErrLimit set from The ToolboxST application.
The accuracy of the output is 0.5% of full scale and the maximum output load supported is 800 Ω.
PCLA Core Analog Module — Aero
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3.4.5.3
Analog Voltage or Current Inputs Configurations
The SCLT is able to interface to several different types of 4-20 mA transmitters. SCLT board provides four 24 V dc terminals,
one for each 4-20 mA transmitter input. The inputs can be configured as current or voltage inputs using jumpers (JP#A). The
JP#A jumper removes the 250 Ω burden resistor for voltage input applications. Following configurations are supported.
Each input has a jumper (JP#B) on the board that is used to determine if the return terminal is grounded or floating. The
default position of the jumper is floating or open.
Analog Input Jumper Summary
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 5
JP5A
ma
VDC
Analog In 6
JP6A
ma
VDC
Analog In 7
JP7A
ma
VDC
Analog In 8
JP8A
ma
VDC
Channel
Jumper
Pos 1-2
Pos 2-3
Analog In 5
JP5B
GND
OPEN
Analog In 6
JP6B
GND
OPEN
Analog In 7
JP7B
GND
OPEN
Analog In 8
JP8B
GND
OPEN
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4
PEFV Electric Fuel Valve Gateway
4.1 PEFV Electric Fuel Valve Gateway Pack
4.1.1 Functional Description
The Electric Fuel Valve Gateway (PEFV) is an Ethernet gateway between the Mark* VIe
control I/O Ethernet network and an electric fuel valve interface module. The module
communicates through the Ethernet Global Data (EGD). The fuel valve interface module
is called a Digital Valve Positioner (DVP). It is made by Woodward® Controls.
The PEFV contains a processor board common to the distributed I/O packs. One of the
dual RJ-45 Ethernet connectors connects to the I/O Ethernet network. The other RJ-45
Ethernet connector connects directly to the DVP. A 3-pin connector supplies power to
the I/O pack.
Infrared Port Not Used
PEFV Simplified Diagram
4.1.1.1
Compatibility
Terminal Board
TEFVH1A
Control mode
Simplex-yes
Dual-yes
TMR-yes
Note The PEFV can be configured as simplex, dual, or TMR. By design, the PEFV works specifically with the Woodward
Controls DVP. The DVP has three Ethernet connections and must use all three to function properly.
Control mode refers to the number of I/O packs used in a signal path:
•
•
•
Simplex uses one I/O pack with one network connection on each pack.
Dual uses two I/O packs with one network connections on each pack.
TMR uses three I/O packs with one network connection on each pack.
PEFV Electric Fuel Valve Gateway
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4.1.2 Installation
➢ To install the PEFV I/O pack
1.
Securely mount the TEFVH1A terminal board.
2.
Directly plug three PEFVs, for triple modular redundancy (TMR), into the terminal board connectors.
3.
Mechanically secure the I/O pack(s) using the threaded inserts adjacent to the Ethernet ports. The inserts connect to a
mounting bracket specific to the terminal board type. The bracket should be adjusted so there is no right angle force
applied to the DC-37 pin connector between the I/O pack and the terminal board. This adjustment is required once during
the service life of the product.
4.
Plug one Ethernet cable into the I/O Ethernet network. Connect the other Ethernet cable to the corresponding network
connector on the Woodward DVP. The pack will operate with connections made to either port. The pack must reboot if
the connections are modified. Standard practice is to connect ENET1 to the network associated with the I/O Ethernet
network.
5.
Power is applied to the connector on the side of the pack. It is not necessary to insert the connector with power removed
from the cable. PEFV has inherent soft-start capability that controls current inrush on power application.
6.
Use the ToolboxST* application to configure the I/O pack as necessary. Refer to GEH-6700 for more information.
4.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
4.1.3.1
Electric Fuel Valve Gateway Hardware
The PEFV links the Woodward DVP to the Mark VIe through the two network connections on the processor board. The
associated terminal board provides a unique board ID identifying PEFV to the Mark VIe control system. The terminal board
is not used for any I/O connections. Data from the Mark VIe controller goes to the PEFV through the Ethernet connection to
the I/O Ethernet network. Next, the data is passed to the DVP through the other Ethernet connection to the DVP. The IP
addresses for these networks must be configured correctly for the communication link to be valid.
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4.1.4 Specifications
Item
PEFV Specification
Transmit time
Data from Mark VIe is transmitted once per frame, up to 100 times per second.
Receive time
Data from DVP is received asynchronously from the Woodward DVP at a rate up to 100 times
per second. This data is transmitted to the Mark VIe synchronous to the frame at the frame rate.
The PEFV will timeout in 50 ms.
Fault detection
Ethernet link ok to/from DVP
Data link ok to and from DVP
EGD Packet diagnostics
IP configuration error
Size
8.26 cm high x 4.19 cm wide x 12.1 cm deep (3.25 in x 1.65 in x 4.78 in)
Technology
Surface mount
† Ambient rating for
Operating: -30 to 65ºC (-22 to 149 ºF)
enclosure design
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
4.1.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
4.1.6 Configuration
Parameter
Description
Selections
WGC_IP_Addr
Valve Driver (DVP) IP addresses on TMR networks
should identify defaults.
Note: IP address of R network given. For S and T networks, the
subnet is incremented by 1 and 2 respectively.
For example, the default R value is 192.168.128.20.
The S IP address is 192.168.129.20.
The T IP address is 192.168.130.20.
192.168.128.20 (Default)
Specify IP address
WGC_Subnet
DVP network subnet mask
255.255.255.0 (Default)
Specify subnet mask.
Gateway_IP_Addr
Gateway IP addresses on TMR should identify defaults (PEFV
non-IONet IP address).
Follows the same conventions as WGC_IP_Addr for the S and T
network IP addresses
192.168.128.1 (Default)
Specify IP address
PEFV Electric Fuel Valve Gateway
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4.2 PEFV Specific Alarms
The following alarms are specific to the PEFV I/O pack.
32
Description No Ethernet ports could be setup for WGC valve driver
Possible Cause
•
•
Both Ethernet ports on the PEFV pack have already received an IP address through DHCP so the IP address for the
Woodward® Governor Controls DVP (WGC) driver network could not be assigned.
Both ports may be connected to the IONET-EGD network.
Solution
•
•
Verify that network connections are correct.
Verify that no DHCP server exists on the network connected to the WGC driver.
33
Description Problem with the WGC valve driver Ethernet port
Possible Cause PEFV could not properly configure the Ethernet port.
Solution
•
•
Re-download the base load and firmware to the I/O pack.
Replace the I/O pack.
34
Description WGC valve driver communication error - packet mismatch
Possible Cause The received Ethernet Global data is incorrect.
Solution
•
•
•
160
Verify that network addresses are configured correctly.
Verify that the WGC_IP_Addr is set to the IP address of the DVP.
Verify that the Gateway_IP_Addr is set to the IP address of the PEFV gateway port.
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35
Description Experiencing delay in reception of data from WGC valve driver
Possible Cause The PEFV has not received data from the Woodward Governor Controls DVP for five frames (50 ms).
Solution
•
•
Verify that network connections between the PEFV and the Woodward DVP are correct.
Check for faulty or loose network cables.
38
Description No communication with WGC valve driver
Possible Cause The PEFV has not received data from the Woodward Governor Controls DVP for three seconds.
Solution
•
•
•
Verify that network connections between the PEFV and the Woodward DVP are correct.
Verify that Woodward DVP power is on.
Verify that Woodward DVP is sending data correctly.
39
Description Config Error - WGC and Gateway IP address subnet mismatch
Possible Cause The subnet of configured IP addresses WGC_IP_Addr and Gateway_IP_Addr do not match.
Solution
•
•
Verify that the configured IP addresses WGC_IP_Addr and Gateway_IP_Addr are on the same subnet.
Verify that WGC_Subnet is set correctly.
4.3 TEFV Electric Fuel Valve Terminal Board
The Electric Fuel Valve Terminal board (TEFVH1A), in this configuration, is used to mount the PEFV only. The connections
on the board are for electronic ID only. It uses no other connections. Visual diagnostics are provided through indicator LEDs
on the PEFV.
PEFV Electric Fuel Valve Gateway
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Notes
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5
PGEN Turbine Generator Monitor
5.1 PGEN Turbine-Generator Monitor I/O Pack
The Mark* VIe control Turbine-Generator Monitor (PGEN) provides the electrical
interface between one I/O Ethernet network and the TGNA turbine-generator. The pack
contains a processor board common to the distributed I/O packs and an acquisition
board. The pack uses 3 analog channels to monitor turbine mechanical power from
voltage or 4-20 mA sensors. Each phase of generator armature current is monitored
using a current transformer input. The PGEN performs the power load unbalance (PLU)
function but it does not include the power calculations (kW, kVARS, KVA) or early
valve actuation logic.
Input to the I/O pack is through dual RJ-45 Ethernet connectors and a 3-pin power input.
The PGEN supports single Ethernet networks for simplex or TMR applications. Output
is through a DC-37 pin connector that connects directly with the associated terminal
board connector. Visual diagnostics are provided through indicator LEDs.
Infrared Port Not Used
PGEN Turbine Generator Monitor
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5.1.1 Compatibility
PGENH1A is compatible with the turbine-generator Terminal Board (TGNA). The following table describes the
compatibility:
Terminal Board
TGNA
Control mode
Simplex-yes
Dual-no
TMR-yes
Control mode refers to the number of I/O packs used in a signal path:
•
•
Simplex uses one I/O pack with one network connection only
TMR uses three I/O packs with one network connection on each I/O pack
5.1.2 Installation
➢ To install the PGEN I/O pack
1.
Securely mount the desired terminal board.
2.
Directly plug one PGEN I/O pack for simplex or three PGEN I/O packs for TMR into the terminal board connectors.
3.
Mechanically secure the I/O pack(s) using the threaded studs adjacent to the Ethernet ports. The studs slide into a
mounting bracket specific to the terminal board type. The bracket location should be adjusted such that there is no right
angle force applied to the DC-37 pin connector between the I/O pack and the terminal board. The adjustment should only
be required once in the service life of the product.
Note The PGEN mounts directly to a Mark VIe control terminal board. TMR-capable terminal boards have three DC-37 pin
connectors, and can also be used in simplex mode if only one PGEN is installed. The PGEN directly supports all of these
connections.
4.
Plug in one Ethernet cable only. The I/O pack operates over either port.
Note The ToolboxST* configuration of the PGEN does not allow the I/O pack to operate redundantly from the two Ethernet
inputs.
5.
Apply power by plugging in the connector on the side of the I/O pack. It is not necessary to remove power from the cable
before plugging it in because the I/O pack has inherent soft-start capability that controls current inrush on power
application.
6.
Use the ToolboxST* application to configure the I/O pack as necessary. Refer to GEH-6700 for more information.
5.1.2.1
Connectors
The PGEN contains the following connectors:
•
•
A DC-37 pin connector on the underside of the I/O pack connects directly to the turbine generator terminal board. The
connector contains six input signals and an ID signal.
An RJ-45 Ethernet connector named ENET1 on the side of the I/O pack is the primary system interface.
•
A second RJ-45 Ethernet connector named ENET2 on the side of the I/O pack can be used as an alternate to ENET1.
Note The ToolboxST configuration does not allow the PGEN to operate from two Ethernet inputs simultaneously.
•
164
A 3-pin power connector on the side of the I/O pack is for 28 V dc power to the PGEN module.
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5.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
5.1.3.1
Turbine-Generator Monitoring Hardware
The PGEN application-specific hardware consists of an analog filter acquisition board (BPAIH3). The analog filter
acquisition board provides the signal conditioning to center and amplify the signal to improve analog-to-digital resolution.
The PGEN accepts analog input signals from the terminal board for three mechanical power sensors and three CT currents.
The analog input section consists of an analog multiplexer block, several gain and scaling sections, and a 16-bit,
analog-to-digital converter (ADC).
The three analog mechanical power inputs can be individually configured as ±5 V, ±10 V, or 4-20 mA scaled signals,
depending on the input configuration. If configured as 4-20 mA signals, the three current inputs are brought through 250 Ω
burden resistors on the terminal board. This resistance generates a 5 V signal at 20 mA. The terminal board provides a 250 Ω
burden resistor when configured for current inputs yielding a 5 V signal at 20 mA. These analog input signals are first passed
through a passive, low pass filter network with a pole at 75.15 Hz. Voltage signal feedbacks from calibration voltages are also
sensed by the PGEN input section.
5.1.3.2
Power Load Unbalance Overspeed Control
The Power Load Unbalance (PLU) function monitors the difference between the per unit steam turbine power based on steam
pressure and the per unit generator power based on the generator current. A PLU event occurs when turbine per unit power is
40% greater than the generator power and the difference meets both a specified rate of change and a specified duration. When
a PLU event is sensed, the steam turbine control valves (CVs) and Intercept valves (IVs) are closed to reduce the power.
The PLU monitoring is performed by the PGEN I/O pack and the TGNA terminal board. The PLU function supports either a
TMR or Simplex configuration. The Mark VIe Digital Output PDOA I/O pack and the TRLY terminal board controls the
steam turbine CV and IV valves. The PGEN commands the state of the relays on the PDOA. The control of the relays in the
PDOA is enhanced by a peer-to-peer multicast packet that provides a fast communication path. The fast communication path
is in parallel with the normal pack-to-pack communication that is routed through the signal space using the controller to
transfer relay commands. The multicast path is only used for the initiating command to the relays.
PLU events that are detected in firmware generate logic signals PLU_IV_Event to energize IV relays and PLU_CV_Event to
energize CV relays. An additional relay communication paths is provided through PGEN signal space to allow controller
application code to control the CV and IV relays. Each relay has a configurable dropout time so that relays can be dropped out
in a staggered sequence. The actual dropout time may vary + one IONet frame time (typically 40 ms) due to the asynchronous
interaction of the IONet communications and PGEN PLU processing. The following Control Valve and Intercept Valve
Control Logic diagram depicts this logic.
Note When relays are configured as Test Only, the relay state can only be changed by the corresponding signal space out
logical RelayxTest, where x = relay number.
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Sample Logic for intercept Valves
PLU IV Event
[C]
PLU_Test_Active
IV_Trgr (SSO)
RelayUse =
TstOnly
Dropout
Delay
IV Permissive
To PDOA
To PDOA Intercept
Valve1 Solenoid
Control
IVT_ Enb (config)
RelayDropTim1 (config )
Ext_IV_ Trgr (SSO)
Ext_ IVT_Enb (config)
Relay01_ Tst (SSO)
RelayUse =
TstOnly
Sample Logic for Control Valves
CV Permissive
To PDOA
PLU CV Event PLU_Test_Active
[D]
Dropout
CV_Trgr (SSO)
RelayUse =
TstOnly
Delay
To PDOA Control
Valve5 Solenoid
Control
CVT_Enb (config)
Relay Drop Tim5 (config)
Relay05 _Tst(SSO)
RelayUse =
TstOnly
Attention
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Relay activation is blocked when signal space output PLU_Test is True, so the signal
space logicals PLU_Event and PLU_IV_Event can be forced True without activating
relays. This is a test mode designed for commissioning tests if needed and should not
be used during normal operation.
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5.1.4 Specifications
Item
PGEN Specification
Input converter resolution
16-bit analog-to-digital converter
Common mode voltage range
±5 V (±2 V CMR for the ±10 V inputs)
Size
8.26 cm high x 4.19 cm wide x 12.1 cm deep (3.25 in x 1.65 in x 4.78 in)
† Ambient rating for enclosure
-30 to 65ºC (-22 to 149 ºF)
design
Technology
Surface mount
Number of channels
TGNA: 6 inputs total consisting of
3 pressure inputs and 3 CT current inputs
Measurement
Range (V dc + V ac)
Noise Suppression
Accuracy
76 Hz single pole low
pass
0.1% of full scale
507 Hz single pole
low pass
0.1% of full scale
Analog Inputs
(channels 1-3)
Pressure
±5 V dc
±10 V dc
4-20 mA
All with 5% over range
Current Inputs
(CT channels 1-3)
Current
0 to 1 A rms
0 to 5 A rms
All with 100% over
range
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
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5.1.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
Each analog or current input has hardware limit checking based on preset (configurable) high and low levels near the end
of the operating range. If this limit is exceeded, a logic signal is set to Unhealthy in signal space, then the unhealthy
signal is forced to zero volts or mA. The signal state returns to Healthy if the signal returns to its limits. If any signal is
unhealthy, logic signal L3DIAG-PGEN is set.
Each input has system limit checking based on configurable high and low levels. These limits can be used to generate
alarms, to enable and disable, and as latching and non-latching.
The analog input hardware includes precision reference voltages in each scan. Measured values are compared against
expected values and are used to confirm health of the analog to digital circuits.
Details of the individual diagnostics are available from the ToolboxST application. I/O block SYS_OUTPUTS, input
RSTDIAG can be used to direct all I/O modules to clear from the alarm queue all diagnostics in the normal healthy state.
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5.1.6 Configuration
The following information is extracted from the ToolboxST application represents a sample of the configuration information
for this board. Refer to the actual configuration file within the ToolboxST application for specific information.
Parameter
Description
Sections
PLU_Del_Enab
Enable the PLU delay
Enable, disable (default Enable)
IVT_Enab
Enable the turbine control-driven IV trigger function
Enable, disable (default Enable)
PLU_DiagEnab
Enable voting disagreement diagnostic for PLU_Event
Enable, disable (default Enable)
Ext_IVT_Enb
Enable customer-driven IV trigger function
Enable, disable (default Disable)
MechPwrInput
Mech power through: TMR (median of 3), dual (max of
first two), single Xducer, or signal space
DualXducer, Signal Space, TMRXducer,
Xducer1, Xducer2
PLU_Unbal
PLU unbalance threshold, percent
20 to 80 (default 40)
PLU_Delay
PLU delay, seconds
0 to 0.5 (default 0)
PressRatg
Reheat pressure equivalent to 100 % mech power
(engineering units)
5 to 1500 (default 200)
CurrentRatg
Generator current equivalent to 100 % elect power (amps
RMS)
1 to 2E6 (default 20000)
PowerScale
Scale factor that multiplies time per unit current to equate
generator power to per unit mechanical power
0 to 2 (default 1.0)
Min_MA_Input
Minimum MA for healthy 4/20 mA Input
0 to 22.5 (default 4)
Max_MA_Input
Maximum MA for healthy 4/20 mA Input
0 to 22.5 (default 20.40)
SystemFreq
System frequency in Hz
60 Hz, 50 Hz (default 60 Hz)
CT_Primary
Generator CT primary in amperes RMS
1 to 1.2E+06 Arms (default 20000)
CT_Secondary
Generator CT secondary in amperes RMS (TGNA CT
input)
1 to 5 Arms
0 to 1 Arms (default: 0 to 5 Arms)
CVT_Enab
Enable the turbine control-driven CV trigger function
Enable, disable (default Disable)
SystemLimits
Allows user to temporarily disable all system limit checks
for testing purposes. Setting this parameter to Disable will
cause a diagnostic alarm to occur.
Enable, Disable (default Enable)
Note All other I/O configuration parameters are defined under the specific I/O pack or terminal board variables in the
following sections.
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5.1.6.1
PGEN Variable Definitions
Name
Description
Direction/Type
L3DIAG_PGEN
PGEN diagnostics
(Input non-voted Boolean-3 bits)
Cap1_Ready
Capture buffer 1 ready for upload-not used
(Input non-voted Boolean-3 bits)
Cap2_Ready
Capture buffer 2 ready for upload-not used
(Input non-voted Boolean-3 bits)
SysLim2analogInx
where x = 1 to 3
Boolean set TRUE if System Limit 1 exceeded for analog input x
(Vgen has only 3, 4th TBD)
(Input Boolean)
SysLim2AnalogInx
Boolean set TRUE if system limit 2 exceeded for analog input x
(Input Boolean)
Boolean set TRUE if system limit 1 exceeded for phase A
generator current
(Input Boolean)
SysLim1GenCTb
Boolean set TRUE if system limit 1 exceeded for phase B
generator current
(Input Boolean)
SysLim1GenCTc
Boolean set TRUE if system limit 1 exceeded for phase C
generator current
(Input Boolean)
SysLim2GenCTa
Boolean set TRUE if system limit 2 exceeded for phase A
generator current
(Input Boolean)
SysLim2GenCTb
Boolean set TRUE if system limit 2 exceeded for phase B
generator current
(Input Boolean)
SysLim2GenCTc
Boolean set TRUE if system limit 2 exceeded for phase C
generator current
(Input Boolean)
PLU_Diff_Value
Equal to the steam turbine per unit power based on the reheat
pressure minus the generator per unit power (corrected by power
scale) based on generator current.
(Input FLOAT)
PLU_Event
Boolean set TRUE if a PLU has occurred.
(Input Boolean)
PLU_IV_Event
Boolean set TRUE if a PLU intercept valve event has occurred.
(Input Boolean)
PLU_Current
Generator current (amps rms) scaled by power scale
(Input Float)
SteamPressure
Steam pressure (EUs)
(Input Float)
CVPermissive
Boolean set TRUE to leave CV relays de-energized
(Input Boolean)
IVPermissive
Boolean set TRUE to leave IV relays de-energized
(Input Boolean)
Relay01Test to
Relay12Test
Solenoid 1 test
(Output Boolean)
where x = 1 to 3
SysLim1GenCTa
PLUTst
Boolean to command PLU test.
(Output Boolean)
IV_Trgr
Turbine control-driven IV trigger
(Output Boolean)
Ext_IV_Trgr
Customer-driven IV trigger
(Output Boolean)
MechPower
Mechanical power (percent) when configured through signal
space
(Output Float)
CV_Trgr
Control valve trigger
(Output Boolean)
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5.1.6.2
IS200TGNA Variable Definitions
Analog input x - Board Point
AnalogInputOx
where x = 1 through
3
Point Edit (Input FLOAT)
InputUse
Defines analog input as either as ±10 V, ±5 V, 4-20
mA or unused.
±5 V ±10 V 4-20 mA unused (Default
unused)
Low_Input
Defines point 1 x-axis value in volts or mA for the
TGNA terminal point used in calculating the gain and
offset for the conversion to engineering units.
0 to 10 volts or -10 to 20 mA (Default 4.0)
High_Input
Defines point 2 x-axis value in volts or mA for the
TGNA terminal point used in calculating the gain and
offset for the conversion to engineering units.
0 to 10 V or -10 to 20 mA (Default 20.0)
Low_Value
±3.402820 E+38 EUs (Default 0.0)
InputFilter
Defines point 1 Y-axis value in engineering units for
the TGNA terminal point used in calculating the gain
and offset for the conversion from volts to EUs
Defines point 2 Y-axis value in engineering units for
the TGNA terminal point used in calculating the gain
and offset for the conversion from volts to EUs
Filter bandwidth in Hz (pressure inputs)
SysLim1Enabl
Enable system Limit 1 fault check
Enable, disable (Default disable)
SysLim1Latch
Latch system Limit 1 fault
Latch, Not Latch (Default Latch)
SysLim1Type
System Limit 1 check type
≥ or ≤ (Default ≤)
High_Value
±3.402820 E+38 EUs (Default 100.0)
0.75 Hz, 1.5 Hz, 3 Hz, 6 Hz, 2 Hz or unused
(Default 12 Hz)
SysLimit1
System Limit 1 – EUs
±3.402820 E+38 EUs (Default 0.0)
SysLim2Enabl
Enable system Limit 2 (same configuration as for
Limit 1)
Enable, disable (Default disable)
SysLim2Latch
Latch system Limit 2 fault
Latch, Not Latch (Default Latch)
SysLim2Type
System Limit 2 check type
≥ or ≤ (Default ≤)
SysLimit2
System Limit 2 – EUs
±3.402820 E+38 EUs (Default 0.0)
TMR_DiffLmt
Difference limit for voted TMR inputs in percent
0 to 100 percent (Default 5)
DiagHighEnab
Enable high input limit diag
Enable, Disable (Default Enable)
DiagLowEnab
Enable low input limit diag
Enable, Disable (Default Enable)
GenCTInputOx
where x = 1, 2, or 3
Total generator line current x to neutral
(amps rms) - Card Point
Point Edit (Input FLOAT)
SysLim1Enabl
Enable system limit 1 fault check
Enable, Disable (Default Disable)
SysLim1Latch
Latch system Limit 1 Fault
Latch, Not Latch (Default Latch)
SysLim1Type
System limit 1 check type
≥ or ≤ (Default ≥)
SysLimit1
System limit 1 – EUs
±3.402820 E+38 EUs (Default 0.0)
SysLim2Enabl
Enable system limit 2 (same configuration as for limit
1)
Enable, Disable (Default Disable)
SysLim2Latch
Latch system limit 2 fault
Latch, Not Latch (Default Latch)
SysLim2Type
System limit 2 check Type
≥ or ≤ (Default ≤)
SysLimit2
System limit 2 – EUs
±3.402820 E+38 Eus (Default 0.0)
TMR_DiffLmt
This is the difference limit for voted TMR inputs in
EUs. It is a unit specific, calculated setting.
±3.402820 E+38 EUs (Default 100)
This should be set to the recommended minimum of
10% of generator rated phase current in engineering
units.
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Relayx
Solenoid x state - board point
where x = 1 through
12
Boolean
RelayUse
Defines relay type
CV_FASV_Type (1-4): control valve
IV_FASV_Type (5-10): intercept valve
TstOnly : test driven
Unused
Spare CV_Fas_Type(11 only)
Spare IV_Fas_Type(12 only)
(Default Relay1 – CV 1)
(Default Relay2 – CV 2)
(Default Relay3 – CV 3)
(Default Relay4 – CV 4)
(Default Relay5 – IV 1)
(Default Relay6 – IV 2)
(Default Relay7 – IV 3)
(Default Relay8 – IV 4)
(Default Relay9 – IV 5)
(Default Relay10 – IV 6)
(Default Relay11 – Spare CV)
(Default Relay12 – Spare IV)
RelayDropTim
Relay dropout time — actual dropout time can vary +
1 IONet frame time (typically 40 ms) due to the
asynchronous interaction of the IONet
communications and PGEN PLU processing
0.0 to 5.0 seconds
(Default Relay1 – 1.10)
(Default Relay2 – 2.00)
(Default Relay3 – 3.00)
(Default Relay4 – 4.00)
(Default Relay5 – 0.35)
(Default Relay6 – 0.50)
(Default Relay7 – 0.75)
(Default Relay8 – 0.35)
(Default Relay9 – 0.75)
(Default Relay10 – 0.50)
(Default Relay11 – 0.00)
(Default Relay12 – 0.00)
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5.2 PGEN Specific Alarms
The following alarms are specific to the PGEN I/O pack.
32
Description Unallowed VarIOCompatCode Change: Old - [ ]; New - [ ]
Possible Cause The .dll for the installed PGEN is incompatible with the firmware loaded on the I/O processor.
Solution
•
•
Confirm the correct installation of the PGEN distributed I/O pack.
Rebuild the application, then download the firmware and the application code to the affected I/O pack.
33-35
Description Analog Input [ ] Unhealthy
Possible Cause The analog input 1-3 signal strength is outside the limits for the sensor type.
Solution
•
•
•
•
For 4-20 mA analog inputs: Check the configuration parameters MaxMAInput and MinMAInput for proper values.
For voltage analog inputs: the inputs voltage magnitude is greater than 9.24 V.
Check the analog inputs 1-3 at the terminal points for in-range values.
Replace the PGEN I/O pack or the TGNA terminal board if inputs are in range.
36-39
Description Generator Current Input [ ] Unhealthy
Possible Cause The CT input current exceeds the configured CT input by 200%.
Solution
•
•
•
•
Check the configuration parameter CT_Secondary for the correct setting.
Check the compatibility of the generator CT secondary output to the TGNA 1 or the 5 A connections.
Check the CT input currents for currents exceeding 200% of the configured (5 or 1 A).
Replace the PGEN I/O pack or the TGNA terminal board if the inputs are in range.
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40-46
Description Channel [ ] ADC Conversion Error
Possible Cause The analog-to-digital conversion for the specified input failed to complete.
Solution Replace the PGEN I/O pack.
47
Description ADC Conversion Not Completed
Possible Cause The analog-to-digital conversion of the terminal board signals failed to complete before the next
conversion cycle was scheduled to start.
Solution Replace the PGEN I/O pack.
51
Description Pack internal reference voltage out of limits
Possible Cause The calibration reference voltage is more than +/-5% from the expected value, which indicates a
hardware failure.
Solution
•
•
•
Check the terminal board grounding for noise or poor connections.
Cycle power on the I/O pack.
Replace the I/O pack if the grounding is okay, and if the condition persists through a power cycle.
52
Description Pack internal null voltage out of limits
Possible Cause The null calibration voltage exceeds 150 mV, which indicates a hardware failure.
Solution
•
•
•
174
Check terminal board grounding for noise or poor connections.
Cycle power on the I/O pack.
Replace the I/O pack if grounding OK and condition persists through a power cycle.
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53
Description Peer to Peer communication initialization failure
Possible Cause The peer-to-peer communication link between the PGEN and the PDOA failed to initialize.
Solution Replace the PGEN I/O pack.
54
Description FPGA Interrupt Time Out
Possible Cause Interrupt to read terminal board signals failed to occur at the designated time.
Solution Replace the PGEN I/O pack.
55
Description Logic Signal [ ] Voting Mismatch
Possible Cause N/A
Solution N/A
56-64
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause
•
•
There is a voter disagreement between the R, S, and T I/O packs.
The I/O pack is not seated on the terminal board correctly.
Solution
•
•
•
Adjust the parameter TMR_DiffLimt or correct the cause of the difference.
Re-seat the I/O pack to the terminal board.
Replace the PGEN I/O pack.
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5.3 TGNA Turbine-Generator Monitor Terminal Board
The Turbine-Generator terminal board (TGNA) acts as a signal interface board for the PGEN I/O pack. The TGNA provides a
direct interface to three analog inputs for sensing turbine steam pressure and three current transformer (CT) feedbacks for
sensing generator current. The signals are passed on to the PGEN(s) through 37-pin connectors. The TGNA can be used for
either simplex or TMR applications. TMR applications fan the signal to three PGEN(s).
The three analog inputs are configurable to be 4-20 mA, ±5 V, or ±10 V inputs. There are two jumpers for each analog input.
One jumper is used to select either current (4-20 mA) or voltage feedback. The other jumper can optionally ground the return
path for the inputs.
The three CT inputs can be fed from 1 A or 5 A rated CT outputs. A separate terminal board point is provided for the two
different amp rated inputs. Configuration parameter CT_Secondary designates which terminal board points are used.
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Analog
Inputs
P 24 Vn
P28 V,<R >
TGNA
TB1
Current
Limiter
P 28 V
P28V ,<S>
JR 1
P28V ,<T>
ID
VDCn
P28 V
Voltage I/P
JPx
IDCn
4 -20 mA Cur I/P
250ohms
Retn
JPy
Open
Three of the above circuits
( n = 1,2,3 )(x=1, 3, 5) (y=2,4, 6)
Ret
CT current
JS1
ID
Inputs
Cur_ A_5H 1
TB2
5 A:0. 0025 A
Cur_ A_5 L 2
Phase A
Cur_ A_1H 3
P 28 V
IA 1
TP2
IA 2
TP1
500 ohms
0.01%
Cur_ A_1 L 4
1A:0. 0025 A
JT 1
ID
Cur_B_ 5H 1
TB3
5 A:0. 0025 A
Cur_ B_5L 2
Phase B
Cur_B_ 1H 3
P28V
IB1
TP4
IB2
TP3
500 ohms
0.01%
Cur_ B_1L 4
1A:0. 0025 A
Cur_C_ 5 H 1
TB4
5 A:0. 0025 A
Cur_C_5 L 2
Cur_C_ 1H 3
Phase C
IC1
TP6
IC2
TP5
500 ohms
0.01%
Cur_C_1L 4
1A:0. 0025 A
TGNA Circuits
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5.3.1 Installation
The TGNA accepts three analog inputs (voltage or current) and three CT inputs.
Analog input channels 1 through 3:
•
•
•
•
Supports voltage or 4-20 mA current turbine pressure inputs
Current-limited 24 V power supply per channel
JP1 (3, 5) jumper for selecting current or voltage inputs
JP2 (4, 6) configures the return as Open for true differential input or connects return to PCOM for a 24 V return.
Connect the analog pressure sensors to the variables identified in the table, Terminal Variable Definitions.
Voltage-output sensors should use VDCx and Retx as signal connection points. Jumper JP1 (3, 5) should be in the voltage I/P
position. JP2 (4, 6) should be in differential input position for differential feedback and in the Return to GND position for
sensors supplied with the 24 V output. Configuration parameter InputUse for the analog inputs should be set according to the
type of sensor being used, ±10 V, ±5 V, or 4-20 mA.
Current-based sensors should use IDCx and Retx as signal connection points. Jumper JP1 (3, 5) should be in the 4-20 mA I/P
position. JP2 (4, 6) should be in differential input position.
CT current Phase A, B, C
•
•
Supports 0 to 1 A or 0 to 5 A CT secondary currents
Separate terminal points for 0 to 1 A or 0 to 5 A CT secondary currents
Connect the secondary of the generator current CT sensors to the points identified in the table, Terminal Variable Definitions.
The CT sensors should use the pair of signal points corresponding to the secondary rating of the CT sensors, 1 A or 5 A. The
configuration parameter CT_Secondary should be set to the rating of the CT secondary.
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Generator Terminal Board TGNA
TB1
x
P24 V(2)
PCOM
VDC(2)
RET (2)
IDC(2)
RET (2)
NC
NC
NC
NC
NC
NC
x 2
x 4
x 6
x 8
x 10
x 12
x 14
x 16
x 18
x 20
x 22
x 24
x
JT1
Analog Input Jumpers
x 1 P24V (1)
x 3 PCOM
x 5 VDC (1)
x 7 RET(1)
x 9 IDC (1)
x 11 RET(1)
x 13 P24V (3)
x 15 PCOM
x 17 VDC (3)
x 19 RET(3)
x 21 IDC (3)
x 23 RET(3)
JP1
4-20 mA CUR I/P
VOLTAGE I/ P
JP2
RETURN TO GND
DIFFERENTIAL IN
JP3
4-20 mA CUR I/P
VOLTAGE I/P
JP4
RETURN TO GND
DIFFERENTIAL IN
JP5
4-20 mA CUR I/P
JS1
VOLTAGE I/P
JP6
Cur_ A_5 H
x 1
Cur_A_5L
x 2
Cur_ A_1 H
Cur_A_1L
x 3
x 4
Cur_ B_5 H
x 1
Cur_ B_5L
x 2
Cur_ B_1 H
x 3
Cur_ B_1L
x 4
Cur_ C_5 H
x 1
Cur_C_5L
Cur_ C_1 H
x 2
Cur_C_1L
x 4
x 3
RETURN TO GND
DIFFERENTIAL IN
TB 2
Cur A Test
points
TB 3
TB 4
JR1
Cur B Test
points
Cur C Test
points
Terminal block 1 can be unplugged from terminal board for maintenance .
TB2, TB3 , TB4 are not removeable.
PGEN Turbine Generator Monitor
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Terminal Variable Definitions
CH #
Point
Signal
Description
Analog 1
TB1-1
P24V1
+24 V output feed for pressure sensor
TB1-3
PCOM1
Power supply return for the P24 V
TB1-5
VDC1
Turbine pressure voltage, signal
TB1-7
Ret1
Turbine pressure voltage/current, return
TB1-9
IDC1
Turbine pressure 4-20 mA, signal
TB1-2
P24V2
+24 V output feed for pressure sensor
TB1-4
PCOM2
Power supply return for the P24 V
TB1-6
VDC2
Turbine pressure voltage, signal
TB1-8
Ret2
Turbine pressure voltage/current, return
TB1-10
IDC2
Turbine pressure 4-20 mA, signal
TB1-13
P24V3
+24 V output feed for pressure sensor
TB1-15
PCOM3
Power supply return for the P24 V
TB1-17
VDC3
Turbine pressure voltage, signal
TB1-19
Ret3
Turbine pressure voltage/current, return
TB1-21
IDC3
Turbine pressure 4-20 mA, signal
TB2-1
CUR_A_5H
5 A CT current, high
TB2-2
CUR_A_5L
5 A CT current, low
TB2-3
CUR_A_1H
1 A CT current, high
TB2-4
CUR_A_1L
1 A CT current, low
TB3-1
CUR_B_5H
5 A CT current, high
TB3-2
CUR_B_5L
5 A CT current, low
TB3-3
CUR_B_1H
1 A CT current, high
TB3-4
CUR_B_1L
1 A CT current, low
TB4-1
CUR_C_5H
5 A CT current, high
TB4-2
CUR_C_5L
5 A CT current, low
TB4-3
CUR_C_1H
1 A CT current, high
TB4-4
CUR_C_1L
1 A CT current, low
Analog 2
Analog 3
Phase A current
Phase B current
Phase C current
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5.3.2 Operation
The PGEN monitors generator 3-phase current and turbine mechanical power to provide the PLU over-speed control for large
steam turbines. Test points are provided for all CT inputs to verify the phase in the field.
Three single-phase CT inputs are provided with a normal current range of 0 to 5 A continuous or 0 to 1 A continuous. The
CTs are magnetically isolated on TGNA. CTs connect to non-pluggable terminal blocks with captive lugs accepting up to #10
AWG wires. The total generator current is calculated from these inputs.
The three analog inputs accept 4-20 mA inputs or ±5, ±10 V dc inputs. A +24 V dc source is available for all three circuits
with individual current limits for each circuit. The 4-20 mA transducers can use the +24 V dc source from the turbine control
or a self-powered source. A jumper on TGNA selects between current and voltage inputs for each circuit. In a TMR system,
analog inputs fan out to the three I/O packs (PGEN). The 24 V dc power to the transducers comes from all three PGEN packs,
and is diode-shared on the TGNA.
Note High frequency and 50/60 Hz noise is reduced with an analog hardware filter.
5.3.3 Specifications
Item
Specification
Inputs to TGNA and PGEN
3 one-phase generator CTs
3 analog inputs (4-20 mA, ±5, ±10 V dc)
Generator current inputs
Normal current range is 0 to 5 A with over-range to 10 A or
0 to 1 A with over-range to 2 A
Nominal frequency 50/60 Hz with range of interest 45 to 66 Hz
Magnetic isolation to 1,500 V rms
Input accuracy 0.5% of full scale (5 A or 1 A) with resolution of 0.1% FS
Input burden less than 0.5 Ω per circuit
Analog inputs
Current inputs: 4-20 mA
Voltage inputs: ±5 V dc or ±10 V dc
Transducers can be up to 300 m (984 ft) from the control cabinet with a two-way cable
resistance of 15 Ω.
Input burden resistor on TGNA is 250 Ω.
Jumper selection of single ended or self powered inputs
Jumper selection of voltage or current inputs
Analog Input Filter: Breaks at 72 and 500 rad/sec
Ac common mode rejection (CMR) 60 dB
Dc common mode rejection (CMR) 80 dB
Conversion accuracy
Sampling type 16-bit A/D converter, 14 bit resolution
Accuracy 0.1% overall
Frame rate
720 or 600 Hz
Calculated values
Total current
Mechanical power
Size
33.02 cm high x 10.16 cm wide (13 in x 4 in)
PGEN Turbine Generator Monitor
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5.3.4 Diagnostics
Diagnostic tests are made on the terminal board as follows:
•
•
The TGNA provides out of sensor limits checks for each Turbine-Generator input. The PGEN creates a diagnostic alarm
(fault) if any one of the inputs has an out-of-range voltage/current.
Each cable connector on the terminal board has its own ID device that is interrogated by the PGEN. The ID device is a
read-only chip coded with the terminal board serial number, board type, revision number, and the JR, JS, JT connector
location. When this chip is read by the PGEN and a mismatch is encountered, a hardware incompatibility fault is created.
5.3.5 Configuration
The terminal board is configured with jumpers. For location of these jumpers, refer to the installation diagram. The jumper
choices are as follows:
•
•
Jumpers JP1, JP3, and JP5 select either current (4-20 mA) input or voltage input
Jumpers JP2, JP4, and JP6 select whether the return is connected to common (Return to GND) or is left open (differential
input)
The following diagrams illustrate connections for common analog inputs.
All other configuration for PGEN is done from the ToolboxST. For the location of these jumpers, refer to the installation
diagram.
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6
PPRA Emergency Turbine Protection
6.1 PPRA Emergency Turbine Protection I/O Pack
The Emergency Turbine Protection I/O packs (PPRA) and associated TREA terminal
board provide an independent backup overspeed protection system. They also provide
an independent watchdog function for the primary control and isolated trip contact
inputs. A protection system consists of three triple modular redundant (TMR) PPRA I/O
packs mounted to a TREA terminal board that has a WREA.
The PPRA supports six speed inputs fanned to three protection I/O packs in the
following two configurations:
•
•
Two speed sensors on each of three shafts
Three speed sensors on each of two shafts.
The PPRAS1B is the only version that supports different grouping of speed inputs. The
PPRA accepts six speed signals (configured as three sets of two speed inputs, or two
sets of three speed inputs) for firmware overspeed, acceleration, deceleration, and a
hardware implemented overspeed protection. It monitors the operation of the primary
control. The PPRA monitors the status and operation of the TREA trip board through a
comprehensive set of feedback signals. If a problem is detected, the PPRA will trip the
backup trip relays on the TREA board and activate a trip on the primary control.
The Mark VIe control is designed with a primary and backup trip protection systems
that interact at the trip terminal board level. Primary protection is provided with the
Turbine Primary I/O pack (PTUR) operating a primary trip board (typically TRPA)
when paired with PPRA/TREA. Backup protection is provided with PPRA mounted on
a TREA terminal board. The PPRA is fully independent of and unaffected by the
turbine primary protection.
6.1.1 Compatibility
There are currently three versions of the PPRA I/O pack and each contain a functionally compatible BPPx processor board:
•
•
•
The PPRAH1A contains a BPPB processor board.
The PPRAS1A contains a BPPB processor board.
The PPRAS1B contains a functionally compatible BPPC processor board that is supported in the ControlST* software
suite V04.07 and later. Refer to GEI-100709, Mark VIe Control PPROS1B and PPRAS1x Functional Safety Instruction
Guide for proper safety loop operation and restrictions.
The PPRAS1A and S1B are IEC 61508 certified versions for use in IEC 61511 certified safety loops. The PPRAS1A or S1B
with TREAS#A and WREAS1A are the safety certified versions.
The PPRA mounts directly on TREA, and with TREA it is required to have the WREA option board mounted on the PPRA
application specific circuit board Option Header connector. The PPRA mounted on TREA with WREA will only function
correctly with three PPRA I/O packs. Single and dual pack operation is not possible.
PPRA Emergency Turbine Protection
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TREA
JZ1
DC-62
PPRA
PPRA
DC-62
JY1
Trip relays,
Estop,
Overspeed
DC-62
JX1
WR EA
PPRA
Only PPRAS1A and PPRAS1B I/O packs mounted on TREAS1A terminal boards can
be configured for SIL applications.
Attention
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6.1.2 Installation
➢ To install the PPRA I/O pack
1.
Securely mount the TREA terminal board.
2.
Directly plug three PPRA I/O packs into the TREA.
3.
Slide the threaded posts on PPRA, located on each side of the Ethernet ports, into the slots on the terminal board
mounting-bracket. Adjust the bracket location so the DC-62 pin connector on PPRA and the terminal board fit together
securely. Tighten the mounting bracket. The adjustment should only be required once in the service life of the product.
Securely tighten the nuts on the threaded posts locking PPRA in place.
4.
Plug in one or two Ethernet cables depending on the controller and network redundancy. PPRA is not sensitive to
Ethernet connections and selects the proper operation over either port.
5.
Apply power by plugging in the power connector on the side of the module. The I/O module has inherent soft-start
capability that controls current levels upon application.
6.
Use the ToolboxST* application to configure the module as necessary.
6.1.2.1
Controller and Network Redundancy
In systems with a single controller, the controller R network should be connected to the PPRA on the JX1 connector, the S
network should be connected to PPRA on the JY1 connector, and the T network should be connected to the PPRA on the JZ1
connector. All three networks are coming from the single controller. PPRA applications do not support dual network
connections for all three PPRAs. In a redundant system there is no additional system reliability gained by adding network
connections to the first two PPRAs with dual controllers or any of the three PPRAs with TMR controllers.
In systems with dual controllers, the controller R network should be connected to the PPRA on the JX1 connector, the S
network should be connected to PPRA on the JY1 connector, and both the R and S networks should be connected to the
PPRA on the JZ1 connector.
In systems with three controllers, the R network should be connected to the PPRA on the JX1 connector, the S network
should be connected to PPRA on the JY1 connector, and the T network should be connected to the PPRA on the JZ1
connector.
6.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
PPRA Emergency Turbine Protection
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6.1.3.1
•
•
•
•
Connectors
A DC-62 pin connector on the underside of the PPRA I/O pack connects directly to the terminal board. The connector
contains the signals needed to sense inputs and operate a trip terminal board.
An RJ-45 Ethernet connector named ENET1 on the side of the pack is the primary IONET-EGD connection.
A second RJ-45 Ethernet connector named ENET2 on the side of the pack is the redundant or IONET-EGD connection
used on dual network configurations.
A 3-pin power connector on the side of the pack is for 28 V dc power for the pack and terminal board.
Note The TREA trip terminal board plus WREA features contact trip inputs. The power for those contacts is provided
through a separate terminal board connector, not from the 28 V dc power source.
6.1.3.2
Application Hardware
The PPRA I/O pack has an internal application specific circuit board that contains the hardware needed for the emergency trip
function. The application board connects between the processor and the TREA terminal board and is common between PPRA
and PPRO I/O packs. The application board has an option card header that connects to a PPRA-specific option card. The
following diagram displays the functions of the application board.
To Processor
Board
To Processor
Board
PPRA Application Specific Circuit Board
In the PPRA not all of the signal conditioning is used. The option card connected to the internal header adds support for three
additional pulse rate input channels and support for the speed pulse rate repeater outputs.
All boards within the pack contain electronic ID parts that are read during power application. A similar part located with each
terminal board connector allows the processor to confirm correct matching of the I/O pack to the terminal board and to report
board revision status to the system level control.
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6.1.3.3
Protective Functions
The PPRA performs the following protective functions in a mix of hardware, programmable logic, and firmware. In the
following diagram, standard symbols for time delay contacts have been used:
In the following diagrams, a standard has been used to indicate signal origin and flow.
•
•
•
•
•
•
•
Signal names that end with (SS) are created within PPRA and the data flow is out to the controller through signal space.
Signal names that end with SS are created in the controller and the data flow is into PPRA through signal space.
Signal names that end with (IO) are created within PPRA and the data flow is out to the hardware.
Signal names that end with IO indicate the signal is a hardware input into PPRA.
Signal names that end with anything containing CFG are part of the PPRA configuration. In this case an attempt has been
made to indicate what area of the PPRA configuration contains the variable.
When J3 is referenced in a CFG, it refers to the connection point for the trip relay board, TREA, and the corresponding
configuration values.
The combination IO (SS) indicates a signal that comes from the hardware inputs to PPRA, and is then sent out to the
controller as part of signal space.
If there is no special ending on a signal name, then the signal is used internal to PPRA and is not part of the hardware or
signal-space data movement. This signal is not available or visible to applications, but it is needed to adequately describe the
I/O pack's operation.
PPRA Emergency Turbine Protection
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6.1.3.4
Direct/Conditional Discrete Input Trip
PPRA supports the four isolated discrete contact input trip signals provided on the TREA+WREA board. In the following
figure, the direct / conditional determination is implemented in firmware while Contact # and L5Cont #_Trip are in hardware
logic. When configured for direct trip, the firmware is not in the trip path. When configured for conditional trip, the firmware
determines the communication health (displayed as network_keepalive) and populates the programmable logic with the
conditional signal from signal space. If the controller communication is lost, the default will permit any conditional trip.
Note The contact inputs include an 8 ms contact de-bounce filter to protect against false trips.
A
Network_ keepalive
L3SS_Comm, (SS)
Inhbt #_Fdbk , (SS)
Trip_Mode, CFG (J3,Contact #)
Direct , CNST
Conditional, CNST
Contact #, (IO)
Cont #_ TrEnab
Trip #_EnCon
L5Cont #_Trip, (SS)
L3SS_ Comm, (SS)
B
3
Trip #_Inhbt, SS
A >= B
A
A=B
B
A
A =B
B
Cont #_ TrEnab,(SS)
Trip #_EnCon,(SS)
L5 Cont #_Trip, (SS)
Inhbt #_Fdbk, SS
CONTACT #
TRIP
L86MR, SS
Note: The contact circuit in this diagram is duplicated4 times. To obtain the correct signal name,
replace the symbol # with the numbers 1-4. Signal names without# appear only once for all 4
circuits (L3SS_COMM, L86MR).
PPRA Contact Input Trips
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The resulting contact trip signals are combined into a single contact trip summary, L5Cont_Trip.
Contact Input Trip Signal Concentration
6.1.3.5
Trip Input
PPRA monitors a trip input signal that is present on the TREA board and uses it to cross trip the main control in the event the
trip input is activated. It is also used within the pack logic as part of the trip relay output command. The relays are not
required to close if the trip input signal is present. The main control counterpart is also present. If the main control votes to
trip, it can also cross-trip the corresponding PPRA.
HwTripin, IO
J3 = TREA
EstopEnab , CFG
J3 = TREA
KESTOP1_Fdbk , (SS)
KESTOP1_Fdbk , (SS)
EstopEnab , CFG L5ESTOP1, (SS)
TRIP
L5ESTOP1, (SS)
L86MR, SS
Contact Input Trip Input
Note There are several inversions in the hardware signal path, but the end result is that KESTOP#_Fdbk is only a 1 when
E-Stop is energized. Therefore, 1 = OK.
PPRA Emergency Turbine Protection
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6.1.3.6
PPRA Speed Input High Select
When PRGrouping is set to ThreeGroups, PPRA speed inputs are expected to be in pairs on each shaft with up to three shafts
possible (other combinations of speed inputs are not permitted). The following table displays the TREA input screw pairs for
the primary (PulseRate_A) and secondary (PulseRate_B) speed signals, signal space (SS).
TREA Input Screw Pair (TB#)
Speed Variable
High-selected value
PR1H_X (43) – PR1L_X (44)
PR1_Spd (SS)
PulseRate1 (SS) (Shaft 1)
PR4H (25) – PR4L (26)
PR4_Spd (SS)
PR2H_X (45) – PR2L_X (46)
PR2_Spd (SS)
PR5H (27) – PR5L (28)
PR5_Spd (SS)
PR3H_X (47) – PR3L_X (48)
PR3_Spd (SS)
PR6H (29) – PR6L (30)
PR6_Spd (SS)
PulseRate2 (SS) (Shaft 2)
PulseRate3 (SS) (Shaft 3)
Configuration of the speed inputs is done at the PulseRate1-3 level. PPRA then applies the PulseRate1 configuration values to
both PR1_Spd and PR4_Spd. This ensures that the two inputs that go through a high select are configured the same.
Paired speed inputs should be the same value during normal operation. Protection for excessive difference between the two
inputs is provided. The difference is calculated and compared to a configurable threshold, Dual_DiffLimit (default 25 rpm). If
the difference exceeds the threshold a diagnostic alarm is created, Dual speed sensors mismatch.
PR1_Spd, IO (SS)
A
|A -B|
PR4_Spd, IO (SS)
B
A
Dual_DiffLimit1,
CFG (PulseRate1)
A>B
Latched AlarmDual speed sensor mismatch
B
A
High
Select
PulseRate1, IO (SS)
B
Shaft Speed High Select, Difference Alarm
The high select diagram displays the overspeed names used for the first of three pulse rate inputs. The same figure is repeated
for PulseRate2 and 3. For all variables where the number 1 displays, simply substitute a 2 or 3 for the 1 to get the signal
name.
Note Speed inputs are sensitive to the mV level. To avoid speed difference diagnostics, unused speed input screw pairs
should be electrically tied together.
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6.1.3.7
PPRA Speed Input Median Select
When PRGrouping is set to TwoGroups, PPRA speed inputs are expected to be in groups of three with up to two shafts
possible (other combinations of speed inputs are not permitted). The following table displays the TREA input screw sets for
the speed signals, signal space (SS).
TREA Input Screw Pair (TB#)
Speed Variable
Mid-Select value
PR1H_X(43) - PR1L_X(44)
PR1_Spd (SS)
PulseRate1(SS) (Shaft 1)
PR2H_X(45) - PR2L_X(46)
PR2_Spd (SS)
PR4H(25) - PR4L(26)
PR4_Spd (SS)
PR3H_X(47) - PR3L_X(48)
PR3_Spd (SS)
PR5H(27) - PR5L(28)
PR5_Spd (SS)
PR6H(29) - PR6L(30)
PR6_Spd (SS)
N/A
N/A
PulseRate2(SS) (Shaft 2)
PulseRate3(SS)
Configuration of the speed inputs is done at the PulseRate1-2 level. PPRA then applies the PulseRate1 configuration values to
PR1_Spd, PR2_Spd, and PR4_Spd. This ensures that the three inputs that go through the median select are configured the
same.
Grouped speed inputs should be the same value during normal operation. Protection for excessive difference between any two
inputs in a group is provided. The difference is calculated and compared to a configurable threshold, Dual_DiffLimit (default
25 rpm). If the difference of any one speed in a group from the voted median value exceeds the threshold, a diagnostic alarm
is generated (Dual speed sensors mismatch).
A
| A- B|
PR1_Spd, IO (SS) B
PR1_Spd, IO (SS)
A
Dual_ DiffLimit1,
CFG (PulseRate1)
|A- B|
PR4_Spd, IO (SS)
B
A
A
PR2_Spd, IO (SS) Median
B Select
A >B
Latched AlarmDual speed sensor mismatch PR1_Spd
PR2_Spd, IO (SS) B
A
Dual_DiffLimit1,
CFG (PulseRate1)
AB
Latched AlarmDual speed sensor mismatch PR2_Spd
B
A
C
|A-B |
PR4_Spd, IO (SS) B
A
Dual_DiffLimit1,
CFG (PulseRate1)
AB
B
Latched AlarmDual speed sensor mismatch PR4_Spd
PulseRate1, IO (SS)
Shaft Speed Median Select, Difference Alarm
PPRA Emergency Turbine Protection
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6.1.3.8
Firmware Overspeed Trip
Firmware overspeed protection is performed on the three values that come out of the high speed select. Although the
established standard for naming these three inputs is HP, IP, and LP, the three inputs are free to be applied as needed in a
system design. The following pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3
for IP.
OS1_ Setpoint,SS
RPM
OS _ Setpoint, CFG (J5,PulseRate #)
RPM
A
A-B
|A|
A
B
A
A>B
1 RPM
B
OS1_SP_ CfgEr
System Alarm, if the two setpoints
do not agree
A
MIN
B
OS _Stpt_PR #
A
A
MULT
A
A+B
B
MIN
B
0.04
OS_Tst_Delta, CFG (J5,PulseRate #)
RPM
OS _Setpoint_ PR #
zero
B
OfflineOS # tst, SS
OnlineOS # tst, SS
PulseRate #, IO
A
OS_ Setpoint _ PR #
OS#_SP_CfgEr
OS1
A>=B
B
L5 CFG #_ Trip
PR #_Zero
OS# HW_ SP_ CfgEr
L5 CFG #_Trip
L86 MR, SS
OS1_ Trip
OS1
OS1_Trip
Overspeed
Trip
L86MR,SS
Firmware Overspeed Trip
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Firmware Overspeed Trip functions include:
•
•
•
•
Fault on overspeed threshold match failure between config and signal space values when speed is zero
Pick the lower threshold from config or signal space
Provide a mechanism to zero the threshold for online overspeed test
Provide a mechanism to modify the threshold for offline overspeed test, bounded to limit increases to the threshold to
104%
Note Use a negative OS_Tst_Delta value to reduce the threshold during testing.
•
Compare the threshold to the calculated speed and latch overspeed
6.1.3.9
PPRA Hardware Overspeed Trip
The following figure displays the overspeed names used for the first of three pulse rate input groupings. The configuration,
alarms, and latched trip are performed for the pair of inputs: PR1_Spd and PR4_Spd. A detected overspeed on either PR1_
Spd or PR4_Spd will latch as OS1HW_Trip. The same groupings are repeated for pairs PR2_Spd, PR5_Spd, and PR3_Spd,
PR6_Spd. The pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP.
OSHW_ Setpoint #, SS
A
|A- B|
Generate an alarm if the hardware is
different than the firmware trip
A
OSHW _ Setpoint ,CFG
OS # HW_ SP_ CfgEr ( SS)
B
A> B
(PulseRate #)
1RPM
OS_ Setpoint
HW Value
B
Generate an alarm if the hardware
setpoint changes after power - on
OS # HW_ SP_ Pend ( SS)
A
| A- B|
B
PulseRate #,
HWIO
A
A> =B
OS # HW
B
Hardware
OS# HW
OS # HW _Trip
Overspeed
Trip
( SS )
OS # HW _Trip, ( SS)
L 86MRX
Speed#Updating
Hardware Overspeed Trip, HP Shaft
Note Refer to the section, Shaft Speed Accel, Decel, and Zero for the definition of Speed#Updating
PPRA Emergency Turbine Protection
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Hardware Overspeed Trip functions include:
•
•
•
•
•
•
•
Load the independent hardware overspeed set point only when the PPRA pack re-boots or has power cycled
Generate an alarm when the hardware config set point is >1 Hz different from the value passed through signal space from
the application configuration
Generate an alarm and signal space Boolean logic change when the setpoint in config fails to match the value stored in
the hardware
Implement speed calculation and the trip logic entirely inside programmable logic
Overspeed response time will be < 20 ms at trip speed
Hardware overspeed response in less than three rotations of the shaft (typically less than 60 ms at normal operating
speeds)
Hardware overspeed is implemented for each of the six speed inputs. The configuration and trip indication is done using
the same groupings identified for firmware overspeed
For a PRGrouping of TwoGroups, the configuration, alarms, and latched trip are performed for the group of inputs: PR1_Spd,
PR2_Spd, and PR4_Spd. A detected overspeed on either PR1_Spd, PR2_Spd, or PR4_Spd will latch as OS1HW_Trip. The
same figure is repeated for the second grouping of PR3_Spd, PR5_Spd, and PR6_Spd. In the signal name for all variables, the
number 1 can replaced by a 2, as applicable.
Note There is no separate enable or disable signal for this Overspeed protection. The disable signal is created by setting a
high overspeed point value. The calculated speed will never reach the value needed to trigger OS1HW.
The actual hardware implementation depends on two configuration items:
•
•
OSHW_Setpoint specifies the overspeed trip level in RPM
PRScale determines the number of speed sensor pulses per revolution used to convert pulse rate into RPM for both
hardware and firmware overspeed value
The hardware implementation requires two adjacent revolutions exceeding the OSHW _Setpoint to trip the system. When a
trip is present, the setting of OSHW _Setpoint is reduced by a small amount in the hardware to provide a clean trip signal.
Because there are set limits to the time integration used in the hardware detector, the minimum RPM setting for the OSHW
_Setpoint is approximately four RPM.
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6.1.3.10
LP Shaft Locked Detection
There is another protection function in addition to the overspeed protection displayed on the preceding page. It generates a
signal in the event the first pulse rate signal is above minimum speed, and the second pulse rate signal is still at zero.
PR1_MIN
PR2_Zero, (SS)
LockRotorByp , SS
LPShaftLock , (SS)
LPShaftLock , (SS)
L86MR, SS
6.1.3.11 E-Stop
The I/O pack monitors the E-Stop trip signal that is present on the TREG or TREA terminal boards and uses it to cross trip
the main control in the event E-Stop is invoked. It is also used within the pack logic as part of the trip relay output command.
The relays are not required to close if the E-Stop signal is present. The main control counterpart is also present. If the main
control votes to trip, it can also cross-trip the corresponding I/O pack.
J3= TREA TRIPENAB, CFG
KESTOP1_ Fdbk , ( SS)
Hw Estop1 , IO
J3= TREG
L5 ESTOP1 , (SS)
KESTOP1_ Fdbk , ( SS)
ESTOP1
TRIP
L5 ESTOP1 , (SS)
L86MR , SS
Contact Input E-Stop
Note There are several inversions in the hardware signal path, but the end result is that KESTOP#_Fdbk is only a 1 when
E-Stop is energized. Therefore, 1 = OK. The TREL and TRES terminal boards do not have E-Stop capability because it is on
the primary trip boards TRPL and TRPS.
PPRA Emergency Turbine Protection
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6.1.3.12
Speed Difference Detection
There should never be a reason why the speed calculated by the I/O pack is significantly different from the speed calculated
by the main control. Speed difference detection looks at the difference in magnitude between pulse rate 1 from both the pack
and the main control. If the difference is greater than the set threshold for three successive samples, a SpeedDifTrip is latched.
If the main control recovers for 60 seconds, the trip is removed. This allows the main control to recover with subsequent
re-arming of the backup protection.
IO Frame Rate
Speed 1 , SS
PulseRate1
(RPM) , IO
A
|A - B |
B
-0
Z
A
-1
Z
B (A & B & C)
-2
Z
C
A
A >B
OS_Diff, CFG (%) Rated RPM_TA,
*
B
CFG (RPM)
100
Speed 1_ Diff
PulseRate 1 ( Hz) , IO
A
Shaft Turning
A >B
75 Hz
B
1 Second Delay
SpeedDifEn , Card CFG
SpeedDiff _ Trip
Speed 1_ Diff
SpeedDiff _ Trip
Enable
Enable
L 86 MR , SS
Speed 1_ Diff
Close immediately , 60 sec delay on opening
Speed
Difference
Trip
When configured for dual controller, additional logic is added so that separate speed inputs from the two controllers come into
the I/O pack. This trip logic acts as if both controllers have a speed error, but continues to run if one controller has a valid
speed signal.
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6.1.3.13
Maximum Speed Hold
The I/O pack provides a maximum speed hold function that resets when:
•
•
Using the command PR_Max_RST (from signal space)
PR1_Zero changes to false when the shaft first starts turning
Output values are PR1_Max, PR2_Max, and PR3_Max. These signals are used to determine the maximum speed obtained
while running or after stopping a turbine.
6.1.3.14
Overspeed Test Logic, Steam Turbine
The signal OnLineOS1Tst is used for PulseRate1, OnLineOS2Tst is used for PulseRate2, and OnLineOS3Tst is used for
PulseRate3. In the following figure, there is another signal, Online OS1X, which initiates an online overspeed test for
PulseRate1. This signal also creates a 1.5 second reset pulse when removed.
Online Overspeed Test Logic
6.1.3.15
Speed State Boolean Values
The I/O pack has detection for zero speed from a set point with 1 RPM hysteresis. The I/O pack calculates a minimum speed
signal from a set point. The rate of change of speed from a set point is calculated resulting in a selectable acceleration trip. A
deceleration trip is then determined from a fixed 100% / second rate.
PPRA Emergency Turbine Protection
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6.1.3.16
Shaft Speed Accel, Decel and Zero
The I/O pack has detection for zero speed from a set point with 1 RPM hysteresis. The I/O pack calculates a minimum speed
signal from a set point. The rate of change of speed from a set point is calculated, resulting in a selectable acceleration trip. A
deceleration trip is then determined from a fixed 100% / second rate.
The acceleration for a given pulse rate (PR#_Accel) is calculated by computing two adjacent shaft speeds over a period of
AccelCalType ms each by computing change in pulse counts, and then computing the difference in these speeds divided by
AccelCalType ms to get the acceleration of the shaft.
In the following figures, pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP.
This figure is the same for PulseRate1, 2, and 3. Simply replace the 1 with a 2 or 3 to get the signal name. The contact, PR#_
Min, in the Acc1_Trip is only present for PR2 (PR2_Min) and PR3 (PR3_Min). It is not used for PR1.
Speed State Boolean Values
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The pulse rate inputs have special detection for loss of signal, and special filtering to remove input noise from nearly
stationary shaft speeds.
PulseRate #, IO
Speed Wheel Pulse
Detected Window
Inactive Counter
Based on last speed
(Maximum 24
seconds )
(Pulse Rates in Hz )
Speed #Updating
Shaft # Turning
A
Allow Accel /
Decel Trip
A > B
75 Hz
Speed
Updating
Normally
B
1 Second Delay
1 **
Speed # Updating
†
Shaft # Turning
Decel #Trip
Decel #Trip
Loss of
Pulse Rate
†
can only be reset when
Speed #Updating becomes True
(pulses are able to be seen ) or
after the I/O pack is rebooted
** 1 = Normal Operation
Pulse Rate Conditioning
PPRA Emergency Turbine Protection
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Decel#Trip
PulseRate#
(RPM)
PR#_DEC
A
(From GearSpeed)
A
B
A<B
-100%/SEC**
S
(Der)
0 %/Sec
OR
Speed#Updating
B
Shaft#Turning
%/Sec
PR#_ACC
A
AND
A
B
A>B
Acc_Setpoint, CFG (J5, PulseRate#)
B
Dec#_Trip, (SS)
PR#_DEC
Dec#_Trip
L86MR,SS
Acc_Trip, CFG (J5, PulseRate#)
PR#_ACC
PR#_MIN **
Acc#_Trip
L86MR,SS
Enable
Acc#_TrEnab
Acc#_Trip, (SS)
HP, IP and LP Shaft Accel Decel Trip Logic
Note: PR#_MIN is not used on ACC1_Trip.
PR2_Min is used on ACC2_Trip and
PR3_Min is used on ACC3_Trip.
**Note: Where 100% is defined as the OS Setpoint.
Shaft Speed Accel, Decel and Zero
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6.1.3.17
Trip Anticipate Function
Steam turbine applications provide a speed trip that uses a live set point from signal space. This overspeed trip is vigorously
changed as a function of turbine load. This function does the following:
•
•
•
•
•
Input set point is OS1_TATrpSp from signal space. Input rated RPM is specified by RatedRPM_TA as part of the I/O
pack configuration. Function test request input is TrpAntcptTst from signal space.
If (OS1_TATrpSP is < 103.5% OR > 116% of RatedRPM_TA) then TA_Spd_Sp (the local set point value) = 106% of
RatedRPM_TA and TA_StptLoss (Signal space) is true and alarm L30TA is declared. Otherwise, TA_Spd_Sp = OS1_
TATrpSP.
If TrpAntcptTst is true, decrease the current value of TA_Spd_Sp by 1RPM / second. Set the minimum value of
RatedRPM_TA to 94%. If TrpAntcptTst is false, the value of TA_Spd_Sp from above is immediately used.
If PulseRate1 (Speed input 1 from the pulse rate input) > TA_Spd_Sp the internal value Trp_Anticptr is set properly.
If the I/O pack is configured for steam turbine application (internal value SteamTurbOnly), then TA_Trip (signal space)
equals the value of Trp_Anticptr.
Note The I/O pack mounted on a TREA does not toggle the relays for trip anticipate function.
PPRA Emergency Turbine Protection
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6.1.3.18
Solenoid Voltage / Power Sense
The I/O pack provides three comparator voltage inputs used to monitor solenoid power or solenoid voltage depending on the
trip card that is connected. SOL1_Vfdbk (SS), SOL2_Vfdbk (SS), and SOL3_Vfdbk (SS) are generated from the input
signals.
6.1.3.19
Main Control Watchdog
A standard control watchdog function is provided by the I/O pack. In this function, a value from a Device Heartbeat
(DEVICE_HB) block is passed from the main controller to the I/O pack each data frame. If the I/O pack stops detecting the
value from the main controller, a counter is incremented and, after five data frames, leads to a trip. If the main controller
recovers for 60 seconds, the trip is removed, allowing for the recovery of the main controller with subsequent re-arming of the
backup protection. The recovery function is provided for typical activities such as cycling power on a controller to perform
maintenance.
While the controller is offline, the I/O pack associated with that controller will vote to trip. When the controller returns to
operation, the I/O pack will remove the vote to trip. The watchdog offers monitoring of two main controllers in the event both
Ethernet ports are connected. When configured for two controllers, having one controller active is sufficient to prevent a trip.
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6.1.3.20
Stale Speed Detection
The I/O pack provides an additional main control watchdog function that is based on a live speed signal. The protection works
as follows: If the pack PulseRate1 is determined to be zero speed the protection is turned off. If above zero speed, the pack
looks at the value of Speed1 from the main control. If the most recent Speed1 value exactly matches the Speed1 value from
the last data frame then a counter is incremented. If the counter reaches a threshold then a stale speed trip is declared and
latched. If speeds are different the counter is cleared.
Although Speed_1, SS is available as a connected variable, it should not be forced. It
can cause the protection to trip the system if enabled.
Attention
This protection is based on the knowledge that a live speed signal always dithers or moves some small amount. If the speed
values being read by PPRO from the controller are not changing (dithering), there is loss of speed signal integrity from the
controller. If the main control recovers for 60 seconds, the trip is removed allowing for the recovery of the main control with
subsequent re-arming of the backup protection. The protection offers monitoring of two main controls in the event both
Ethernet ports are connected. When configured for two controls, having one control satisfy the test is sufficient to prevent a
trip.
PPRA Emergency Turbine Protection
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6.1.3.21
Main Control Ethernet Monitor
The main control provides time synchronization across the distributed control elements. The time synchronization is tied
tightly into the time at which traffic occurs on a given controller's IONet. The I/O pack provides monitoring of this service to
ensure it is working correctly. Gross errors in time synchronization are detected by the pack through a number of different
means, and if problems persist, the I/O pack will vote to trip. Once the trip is latched, if the problem goes away for 60 seconds
the trip shall be reset (this assumes the control recovers from the problem and is back on line). The monitor will offer
monitoring of two main controls in the event both Ethernet ports are connected. When configured for two controls, having
one control sequencing correctly is sufficient to prevent a trip.
In the following diagram, the detection has been simplified to display monitoring of an Ethernet frame number as the means
for determining a problem is present.
Sync Frame Count Monitor
6.1.3.22
Trip Signal Logic
The different trip signals are combined into a composite signal that is used in the relay output logic. The following figure
specifies how the signals are combined. This function is partitioned between firmware and programmable logic. The path to
trip through hardware overspeed is done completely in hardware so that a firmware malfunction cannot defeat the protection.
The same is true of the contact input trip signals when they are configured for direct trip.
There are differences between steam turbine protection and other protection. A composite signal SteamTurbOnly is created
for ease of use:
LargeSteam **
MediumSteam **
SmallSteam **
** A number of contacts depend on
the value of Turbine _Type, CFG.
SteamTurbOnly
Steam Turbine Trip Signals
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Dec1_Trip
OS1_Trip
PulseRate1
Trips
Acc1_Trip
L5CFG1_Trip
Dec2_Trip
OS2_Trip
1
GT_2Shaft
PulseRate2
Trips
Acc2_Trip
L5CFG2_Trip
LM_2Shaft1
1
LPShaftLock
LM_3Shaft
ComposTrip1,
(SS)
Dec3_Trip
OS3_Trip
PulseRate3
Trips
1
LM_3Shaftf
Acc3_Trip
L5CFG3_Trip
L5Cont_Trip
SpeedDiff_Trip
System
Trips
Cross_Trip, SS
StaleSpdTrip
ContWdogTrip
FrameSyncTrip
Sil_Diag_Trip
2
1
LM_2Shaft
1
LM_3Shaft
LMTripZEnable, CFG
PR1_Zero
HPZeroSpdByp
SS
1
SteamTurbOnly
Zero
Speed
Special
Case
L3Z
Hardware
Overspeed
OS1HW_Trip
OS2HW_Trip
OS3HW_Trip
1
Notes: CFG values.
2
This trip is generated if a PulseRate signal is broken (such as in the case of no
signal) and SilMode is set to enabled, or if a hardware issue is detected
regardless of SilMode. There will be an accompanying diagnostic generated to
designate the actual cause of the trip.
Trip Combine - All Signals (SS) unless Marked
PPRA Emergency Turbine Protection
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6.1.3.23
Watchdog Trip Function
Hardware in the I/O pack monitors local firmware operation, providing a watchdog trip function if the firmware malfunctions.
The operation of this watchdog does not display in the normal sequencing figures. The I/O pack hardware is designed to be in
a fail-safe or trip mode if it is not properly configured and operating. This means that with power off, while starting up, when
in a hardware reset, or otherwise not online, the I/O pack will vote to trip. If the I/O pack watchdog acts, it resets the hardware
thereby generating a vote to trip.
The processor board used inside the I/O pack has hardware features that allow it to differentiate between a reset caused by the
watchdog hardware and a reset caused by cycling of power. This information is available from the pack after it restarts. In the
event that an I/O pack votes to trip due to a reset, it is then possible to determine if a watchdog reset or a cycling of control
power caused the event.
6.1.3.24
Trip Relay Outputs
PPRA provides drivers for three emergency trip relay commands, and provides monitoring for three status feedback signals.
Trip is a combination of firmware trip and direct trip implemented in programmable logic.
In
FPGA
TestETR 1
SS
ComposTrip1 ETR1_Enab L5ESTOP1(SS)
(SS)
CFG, K1_Fdbk
ETR1 (IO)
Trip Relay,
Energize to Run,
TA_TRIP_ENABL1**
CFG (PPRA)
In
FPGA
TestETR 2
SS
ComposTrip1 ETR2_Enab L5ESTOP1(SS)
(SS)
CFG, K2_Fdbk
ETR2 (IO)
Trip Relay,
Energize to Run,
TA_TRIP_ENABL2**
CFG (PPRA)
L97EOST_ONLZ
In
FPGA
ComposTrip1
(SS)
TestETR 3
ETR3_Enab L5ESTOP1(SS)
SS
CFG, K3_Fdbk
ETR3 (IO)
Trip Relay,
Energize to Run,
TA_TRIP_ENABL3**
CFG (PPRA)
Note ** Parameter set to Disable and is not configurable.
Trip and Economizing Relay Outputs
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6.1.4 Specifications
Item
PPRA Specification
Speed input quantity
Six input signals provided
Speed input range
Pulse rate frequency range 2 Hz to 20 kHz
Speed input accuracy
Pulse rate accuracy 0.05% of reading
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 28 mV p-p
20 kHz requires 300 mV p-p
Speed input sensitivity is such that turning gear
speed may be observed on a typical turbine
application.
Frame Rate
100 Hz maximum
Size
8.26 cm High x 4.19 cm Wide x 12.1 cm Deep (3.25 in x 1.65 in x 4.78 in)
Technology
Surface-mount
† Ambient rating for enclosure design
PPRAS1B is rated from -40 to 70ºC (-40 to 158 ºF)
PPRAS1A and PPRAH1A are rated from -30 to 65ºC (-22 to 149 ºF)
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
6.1.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the analog feedback currents
A comparison between the commanded state of each relay drive and the feedback from the commanded output circuit
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
A failed power-up self-test is indicated by solid red lighting of the power and attention LEDs. Failure to verify the electronic
ID will result in a communication failure. Failures of the other tests will result in a generated diagnostic alarm.
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RSTDIAG if they become inactive.
PPRA Emergency Turbine Protection
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6.1.5.1
PPRA Trip Status
Six additional LEDs located on the left side of the faceplate are used for trip status. All six LEDs stay off until all hardware
application is complete. The LEDs indicate trip status of the PPRA as follows:
RUN is green any time the I/O pack has energized the emergency trip relays. RUN turns red any time the I/O pack has
removed power from the emergency trip relays, voting to trip.
ESTP is green when the E-STOP input (if applicable) is in the run state. ESTP turns red any time E-STOP is invoked to
prevent pick up of the emergency trip relays. If the chosen trip terminal board doesn't support E-STOP then the LED defaults
to green.
OSPD turns red any time the I/O pack votes to trip in response to a detected overspeed condition on any of the three speed
inputs. OSPD is green when an overspeed condition is not present or latched.
WDOG turns red when any of the following PPRA trip functions are enabled and active:
•
•
•
•
Control Watch dog
Speed Difference Detection
Stale Speed Detection
Frame Sync Monitor
WDOG turns green to indicate that the trip status of any of these features has been cleared.
SIL is green when configured for SIL 2 or SIL 3 safety functionality. When configured for SIL 3 if an internal fault is
detected, it turns red. PPRAS1A and S1B with TREAS1A and WREAS1A are required for SIL functionality.
Note The SIL and KREA LEDs are only labeled on the PPRAS1A, but are also present on the H1A version.
KREA is green when power is detected on the KREA sub-module in the I/O pack.
During normal PPRA operation, all six application LEDs display green. An additional feature, rotating LEDs, can be
configured for the PPRA. Using this feature, only one LED is turned on at a time and walked up and down the six LEDs
creating a synchronized motion. The walking is regulated by the controller IONet and synchronized across a set of three I/O
packs. This provides a quick visual indication of the system time synchronization status.
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6.1.6 Configuration
The following subsections (Parameters, Pulse Rate, Contacts, E-Stop, ETR Relays, Variables, and so forth) define the choices
within the tabs of the ToolboxST configuration.
6.1.6.1
Parameters
Parameter
Description
Choices
TurbineType
Turbine Type and Trip Solenoid Configuration
Unused, GT_1Shaft, LM_
3Shaft, MediumSteam,
SmallSteam,GT_2Shaft, Stag_
GT_1Sh,Stag_GT_2Sh, LM_
2Shaft
LMTripZEnabl
On LM machine, when no PR on Z,Enable a vote for Trip
Disable, Enable
SpeedDifEn
Enable Trip on Speed Difference between Controller and
PPRA
Disable, Enable
StaleSpdEn
Enable Trip on Speed from Controller Freezing
Disable, Enable
RotateLeds
Rotate the Status LEDs if all status are OK
Disable, Enable
LedDiags
Disable, Enable
LedDiags is
Disabled by
default.
Attention
When enabled, generates a diagnostic alarm when Trip
LEDs are lit. Refer to the section, Diagnostics, PPRA Trip
Status for more information on LED operation.
SilMode
Perform additional SIL diagnostic and trip checks
Not_SIL, SIL_2,SIL_3
PRGrouping
Whether the six speed inputs are grouped as 3 groups of
two (three shafts) or 2 groups of three (two shafts)
ThreeGroups, TwoGroups
RatedRPM_TA
Rated RPM, used for Trip Anticipater and for Speed Diff
Protection
0 to 20,000
AccelCalTime
Select Acceleration Calculation Time (milliseconds)
10 to 100
OS_Diff
Absolute Speed Difference in Percent For Trip Threshold
0 to 10
HwSpdDiff Sensitivity
How quickly a trip is caused when the speed differs within
a group
Normal, High, Low
PPRA Emergency Turbine Protection
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6.1.6.2
Pulse Rate
Parameter
Description
Choices
PRType
Selects the type of Pulse Rate Input, (For Proper Resolution)
Unused, Speed, Flow,
Speed_LM, Speed_High
PRScale
Pulses per Revolution (outputs RPM)
0 to 1,000
OSHW_Setpoint
Hardware Overspeed Trip Setpoint in RPM
0 to 20,000
OS_Setpoint
Overspeed Trip Setpoint in RPM
0 to 20,000
OS_Tst_Delta
Off Line Overspeed Test Setpoint Delta in RPM
-2,000 to 2,000
Zero_Speed
Zero Speed for this Shaft in RPM (1 RPM hysteresis), 0 RPM
sets PR#_Zero always false
0 to 20,000
Min_Speed
Min Speed for this Shaft in RPM
0 to 20,000
Accel_Trip
Enable Acceleration Trip
Disable, Enable
Acc_Setpoint
Acceleration Trip Setpoint in RPM / Sec
0 to 20,000
TMR_DiffLimt
Diag Limit,TMR Input Vote Difference, in Eng Units
0 to 20,000
Dual_DiffLimit
Diag Limit,Dual speed sensor, in Eng Units
0 to 20,000
6.1.6.3
Contacts
Parameter
Description
Choices
ContactInput
ContactInput
Used, Unused
SeqOfEvents
Record Contact transitions in Sequence of Events
Enable, Disable
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
TripMode
TripMode
Enable, Disable
6.1.6.4
E-Stop (Used on TREA)
Parameter
Description
Choices
EstopEnab
Enable E-Stop Detection on TREA
Enable, Disable
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
Parameter
Description
Choices
RelayOutput
Relay Signal
Used, Unused
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
DiagSolEnab
Enable Solenoid Voltage Diagnostic
Enable, Disable
6.1.6.5
210
ETR Relays
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6.1.6.6
Variables PPRA
Variable
Description
Direction
Type
L3DIAG_PPRA_R,_S, and _T
I/O Diagnostic Indication
Input
BOOL
LINK_OK_PPRA_R,_S, and _T
I/O Link Okay Indication
Input
BOOL
ATTN_PPRA_R,_S, and _T
I/O Attention Indication
Input
BOOL
PS18V_PPRA_R,_S, and _T
I/O 18 V Power Supply Indication
Input
BOOL
PS28V_PPRA_R,_S, and _T
I/O 28 V Power Supply Indication
Input
BOOL
IOPackTmpr_R,_S, and _T
I/O Pack Temperature (deg °F)
AnalogInput
REAL
K1FLT
K1 Shorted Contact Fault
Input
BOOL
K2FLT
K2 Shorted Contact Fault
Input
BOOL
K3FLT
K3 Shorted Contact Fault
Input
BOOL
Repeater_flt1
RS-232 Speed repeater fault for PR4_Spd
Input
BOOL
Repeater_flt2
RS-232 Speed repeater fault for PR5_Spd
Input
BOOL
Repeater_flt3
RS-232 Speed repeater fault for PR6_Spd
Input
BOOL
SilModErr
Sil Mode Configuration modification after going On
Line
Input
BOOL
EstopModErr
E-Stop Configuration modification after going On Line
Input
BOOL
TA_StptLoss
L30TA
Input
BOOL
GT_1Shaft
Config – Gas Turb,1 Shaft Enabled
Input
BOOL
GT_2Shaft
Config – Gas Turb,2 Shaft Enabled
Input
BOOL
LM_2Shaft
Config – LM Turb,2 Shaft Enabled
Input
BOOL
LM_3Shaft
Config – LM Turb,3 Shaft Enabled
Input
BOOL
MediumSteam
Config – Medium Steam Enabled
Input
BOOL
SmallSteam
Config – Small Steam Enabled
Input
BOOL
Stag_GT_1Sh
Config – Stag 1 Shaft, Enabled
Input
BOOL
Stag_GT_2Sh
Config – Stag 2 Shaft, Enabled
Input
BOOL
L3SS_Comm
Communication Status - OK = True
Input
BOOL
LokdRotorByp
LL97LR_BYP - Locked Rotor Bypass
Output
BOOL
HPZeroSpdByp
L97ZSC_BYP - HP Zero Speed Check Bypass
Output
BOOL
Speed1
Shaft Speed 1 in RPM
AnalogOutput
REAL
ContWdog
Controller Watchdog Counter
Output
DINT
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 211
Non-Public Information
6.1.6.7
Variables Contacts
Variable
Contact Variable Description
Direction
Type
Contact1
Contact Input 1
Input
BOOL
Contact2
Contact Input 2
Input
BOOL
Contact3
Contact Input 3
Input
BOOL
Contact4
Contact Input 4
Input
BOOL
6.1.6.8
Variables E-Stop
Variable
Description
Direction
Type
KESTOP1_Fdbk
ESTOP1,inverse sense,True = Run
Input
BOOL
6.1.6.9
Variables ETR Relays
Variable
Description
Direction
Type
K1_Fdbk
L4ETR1_FB, Trip Relay 1 Feedback
Input
BOOL
K2_Fdbk
L4ETR2_FB, Trip Relay 2 Feedback
Input
BOOL
K3_Fdbk
L4ETR3_FB, Trip Relay 3 Feedback
Input
BOOL
6.1.6.10
Variables Fanned-PR
Variable
Description
Direction
Type
Fan_Spd_Fbk
Fanned Speed Signal Feedback: Fanned = Jumpers
Closed
Input
BOOL
6.1.6.11 Variables Pulse Rate
Variable
Description
Direction
Type
PulseRate1
HP speed
AnalogInput
REAL
PulseRate2
LP speed
AnalogInput
REAL
PulseRate3
IP speed
AnalogInput
REAL
212
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6.1.6.12
Variables Vars-CI
Variable
Description
Direction
Type
Cont1_TrEnab
Config – Contact 1 Trip Enabled – Direct
Input
BOOL
Cont2_TrEnab
Config – Contact 2 Trip Enabled – Direct
Input
BOOL
Cont3_TrEnab
Config – Contact 3 Trip Enabled – Direct
Input
BOOL
Cont4_TrEnab
Config – Contact 4 Trip Enabled – Direct
Input
BOOL
Inhbt1_Fdbk
Trip Inhibit Signal Feedback for Contact 1
Input
BOOL
Inhbt2_Fdbk
Trip Inhibit Signal Feedback for Contact 2
Input
BOOL
Inhbt3_Fdbk
Trip Inhibit Signal Feedback for Contact 3
Input
BOOL
Inhbt4_Fdbk
Trip Inhibit Signal Feedback for Contact 4
Input
BOOL
Trip1_EnCon
Contact 1 Trip Enabled – Conditional
Input
BOOL
Trip2_EnCon
Contact 2 Trip Enabled – Conditional
Input
BOOL
Trip3_EnCon
Contact 3 Trip Enabled – Conditional
Input
BOOL
Trip4_EnCon
Contact 4 Trip Enabled – Conditional
Input
BOOL
Trip1_Inhbt
Contact 1 Trip Inhibit
Output
BOOL
Trip2_Inhbt
Contact 2 Trip Inhibit
Output
BOOL
Trip3_Inhbt
Contact 3 Trip Inhibit
Output
BOOL
Trip4_Inhbt
Contact 4 Trip Inhibit
Output
BOOL
6.1.6.13
Variables Vars-Relay
Variable
Description
Direction
Type
K1_FdbkNV_R, S, T
Non Voted L4ETR1_FB, Trip Relay 1 Feedback
Input
BOOL
K2_FdbkNV_R, S, T
Non Voted L4ETR2_FB, Trip Relay 2 Feedback
Input
BOOL
K3_FdbkNV_R, S, T
Non Voted L4ETR3_FB, Trip Relay 3 Feedback
Input
BOOL
ETR1_Enab
Config – ETR1 Relay Enabled
Input
BOOL
ETR2_Enab
Config – ETR2 Relay Enabled
Input
BOOL
ETR3_Enab
Config – ETR3 Relay Enabled
Input
BOOL
PTR1
L20PTR1 - Primary Trip Relay CMD versus Voltage - a
Mismatch Diagnostic Monitor
Output
BOOL
PTR2
L20PTR2 - Primary Trip Relay CMD versus Voltage - a
Mismatch Diagnostic Monitor
Output
BOOL
PTR3
L20PTR3 - Primary Trip Relay CMD versus Voltage - a
Mismatch Diagnostic Monitor
Output
BOOL
TestETR1
L97ETR1 - ETR1 test, True de-energizes relay
Output
BOOL
TestETR2
L97ETR2 - ETR2 test, True de-energizes relay
Output
BOOL
TestETR3
L97ETR3 - ETR3 test, True de-energizes relay
Output
BOOL
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 213
Non-Public Information
6.1.6.14
Variables Vars-Speed
Variable
Vars-Speed Variable Description
Direction
Type
Acc1_TrEnab
Config – Accel 1 Trip Enabled
Input
BOOL
Acc2_TrEnab
Config – Accel 2 Trip Enabled
Input
BOOL
Acc3_TrEnab
Config – Accel 3 Trip Enabled
Input
BOOL
OS1HW_SP_Pend
Hardware HP overspeed setpoint changed after power
up
Input
BOOL
OS2HW_SP_Pend
Hardware LP overspeed setpoint changed after power
up
Input
BOOL
OS3HW_SP_Pend
Hardware IP overspeed setpoint changed after power
up
Input
BOOL
OS1HW_SP_CfgErr
Hardware HP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS2HW_SP_CfgErr
Hardware LP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS3HW_SP_CfgErr
Hardware IP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS1_SP_CfgEr
HP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS2_SP_CfgEr
LP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS3_SP_CfgEr
IP Overspd Setpoint Config Mismatch Error
Input
BOOL
PR1_Accel
HP Accel in RPM/SEC
AnalogInput
REAL
PR2_Accel
LP Accel in RPM/SEC
AnalogInput
REAL
PR3_Accel
IP Accel in RPM/SEC
AnalogInput
REAL
PR1_Max
HP Max Speed since last Zero Speed in RPM
AnalogInput
REAL
PR2_Max
LP Max Speed since last Zero Speed in RPM
AnalogInput
REAL
PR3_Max
IP Max Speed since last Zero Speed in RPM
AnalogInput
REAL
PR1_Spd
PR1 - Speed sensor 1 (1A if three or two groups, see
PRGrouping parameter)
AnalogInput
REAL
PR2_Spd
PR2 - Speed sensor 2 (2A if three groups, 1B if two
groups, see PRGrouping parameter)
AnalogInput
REAL
PR3_Spd
PR3 - Speed sensor 3 (3A if three groups, 2A if two
groups, see PRGrouping parameter)
AnalogInput
REAL
PR4_Spd
PR4 - Speed sensor 4 (1B if three groups, 1C if two
groups, see PRGrouping parameter)
AnalogInput
REAL
PR5_Spd
PR5 - Speed sensor 5 (2B if three or two groups, see
PRGrouping parameter)
AnalogInput
REAL
PR6_Spd
PR6 - Speed sensor 6 (3B if three groups, 2C if two
groups, see PRGrouping parameter)
AnalogInput
REAL
OnLineOS1Tst
L97HP_TST1 - On Line HP Overspeed Test
Output
BOOL
OnLineOS2Tst
L97LP_TST1 - On Line LP Overspeed Test
Output
BOOL
OnLineOS3Tst
L97IP_TST1 - On Line IP Overspeed Test
Output
BOOL
OffLineOS1Tst
L97HP_TST2 - Off Line HP Overspeed Test
Output
BOOL
OffLineOS2Tst
L97LP_TST2 - Off Line LP Overspeed Test
Output
BOOL
214
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Variable
Vars-Speed Variable Description
Direction
Type
OffLineOS3Tst
L97IP_TST2 - Off Line IP Overspeed Test
Output
BOOL
PR_Max_Rst
Max Speed Reset
Output
BOOL
OnLineOS1X
L43EOST_ONL - On Line HP Overspeed Test,with auto
reset
Output
BOOL
OS1_Setpoint
HP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS2_Setpoint
LP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS3_Setpoint
IP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS1_TATrpSp
PR1 Overspeed Trip Setpoint in RPM for Trip Anticipate
Fn
AnalogOutput
REAL
OSHW_Setpoint1
HP Overspeed Setpoint in RPM
AnalogOutput
REAL
OSHW_Setpoint2
LP Overspeed Setpoint in RPM
AnalogOutput
REAL
OSHW_Setpoint3
IP Overspeed Setpoint in RPM
AnalogOutput
REAL
6.1.6.15
Variables Vars-Trip
Variable
Vars-Trip Variable Description
Direction
Type
ComposTrip1
Composite Trip 1
Input
BOOL
WatchDog_Trip
Enhanced diag - Watch Dog trip
Input
BOOL
StaleSpeed_Trip
Enhanced diag - Stale Speed trip
Input
BOOL
SpeedDiff_Trip
Enhanced diag - Speed Difference trip
Input
BOOL
FrameMon_Flt
Enhanced diag - Frame Monitor Fault
Input
BOOL
Sil_Diag_Trip
SIL Diagnostic Trip
Input
BOOL
PR1_Zero
L14HP_ZE - HP shaft at zero speed
Input
BOOL
PR2_Zero
L14LP_ZE - LP shaft at zero speed
Input
BOOL
PR3_Zero
L14IP_ZE - IP shaft at zero speed
Input
BOOL
OS1_Trip
L12HP_TP - HP overspeed trip
Input
BOOL
OS2_Trip
L12LP_TP - LP overspeed trip
Input
BOOL
OS3_Trip
L12IP_TP - IP overspeed trip
Input
BOOL
Dec1_Trip
L12HP_DEC - HP de-acceleration trip
Input
BOOL
Input
BOOL
Input
BOOL
Input
BOOL
Can only be reset when pulses are able to be seen on
speed input or after the I/O pack is rebooted.
Dec2_Trip
L12LP_DEC - LP de-acceleration trip
Can only be reset when pulses are able to be seen on
speed input or after the I/O pack is rebooted.
Dec3_Trip
L12IP_DEC - IP de-acceleration trip
Can only be reset when pulses are able to be seen on
speed input or after the I/O pack is rebooted.
Acc1_Trip
L12HP_ACC - HP acceleration trip
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 215
Non-Public Information
Variable
Vars-Trip Variable Description
Direction
Type
Acc2_Trip
L12LP_ACC - LP acceleration trip
Input
BOOL
Acc3_Trip
L12IP_ACC - IP acceleration trip
Input
BOOL
DualCfgErr
Dual sensor cfg mismatch - SIL 3 will trip in 1 hour
Input
BOOL
OS1HW_Trip
L12HP_HTP - HP Hardware detected overspeed trip
Input
BOOL
OS2HW_Trip
L12LP_HTP - LP Hardware detected overspeed trip
Input
BOOL
OS3HW_Trip
L12IP_HTP - IP Hardware detected overspeed trip
Input
BOOL
HW_Spd1_diff
HW speed diff PR1 detected - SIL 3 will trip in 1 hour
Input
BOOL
HW_Spd2_diff
HW speed diff PR2 detected - SIL 3 will trip in 1 hour
Input
BOOL
HW_Spd3_diff
HW speed diff PR3 detected - SIL 3 will trip in 1 hour
Input
BOOL
L5CFG1_Trip
HP Config Trip
Input
BOOL
L5CFG2_Trip
LP Config Trip
Input
BOOL
L5CFG3_Trip
IP Config Trip
Input
BOOL
L5CFG3_Trip
E-STOP1 Trip
Input
BOOL
L5Cont1_Trip
Contact 1 Trip
Input
BOOL
L5Cont2_Trip
Contact 2 Trip
Input
BOOL
L5Cont3_Trip
Contact 3 Trip
Input
BOOL
L5Cont4_Trip
Contact 4 Trip
Input
BOOL
LPShaftLock
LP Shaft Locked
Input
BOOL
Cross_Trip
L4Z_XTRP - Control Cross Trip
Output
BOOL
6.1.6.16
Variables VSen
Variable
Description
Direction
Type
VSen1
Voltage Sensor 1 Feedback
Input
BOOL
VSen2
Voltage Sensor 2 Feedback
Input
BOOL
VSen3
Voltage Sensor 3 - Power Monitor Feedback
Input
BOOL
216
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6.2 PPRA Specific Alarms
The following alarms are specific to the PPRA I/O pack.
40
Description Contact Excitation Voltage Test Failure
Possible Cause Voltage for the contact inputs on the trip board is not within published limits.
Solution Check source of contact excitation voltage applied to trip board.
50
Description Main Terminal Board Mismatch
Possible Cause
•
•
The terminal board that was selected in the ToolboxST configuration does not match the actual board found by the PPRA.
The WREA daughterboard has not been attached to the TREA.
Solution
•
•
•
Change the ToolboxST configuration to use the correct board.
Replace the terminal board to match the board selected in the ToolboxST configuration.
Verify that the WREA is seated correctly on the TREA.
51
Description TREA board mismatch - remain offline
Possible Cause The TREA hardware grouping is not compatible with the Sil Capable IS200PPRAS1A I/O pack. The
PPRA will not go online in this state.
Solution
•
•
Verify that you are using a IS220PPRAS1A module attached to a TREA SxA/WREA SxA terminal board.
Either use a SIL capable terminal board or replace the PPRA with an IS200PPRAH1A.
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 217
Non-Public Information
52
Description Grouped speed inputs require fanned speed input jumpers to be in place
Possible Cause The JP1 and JP2 jumpers are not set to fan the speed signals to all three packs. This is required for
grouped speed inputs.
Solution Remove the WREA daughterboard, and set the jumpers to the correct position.
53
Description WREA - Repeater status fault 1/4
Possible Cause The speed repeater output does not match the input speed signal.
•
•
•
One of the speed sensors is not connected.
The pins on the cable are shorted.
The RS-232/RS-485 chip is not functioning.
Solution
•
•
•
Verify the pins and connections on the cable.
Verify the connection of both speed sensors.
Replace the WREA daughterboard.
54
Description WREA - Repeater status fault 2/5
Possible Cause The speed repeater output does not match the input speed signal.
•
•
•
One of the speed sensors is not connected.
The pins on the cable are shorted.
The RS-232/RS-485 chip is not functioning.
Solution
•
•
•
218
Verify the pins and connections on the cable.
Verify the connection of both speed sensors.
Replace the WREA daughterboard.
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55
Description WREA - Repeater status fault 3/6
Possible Cause The speed repeater output does not match the input speed signal.
•
•
•
One of the speed sensors is not connected.
The pins on the cable are shorted.
The RS-232/RS-485 chip is not functioning.
Solution
•
•
•
Verify the pins and connections on the cable.
Verify the connection of both speed sensors.
Replace the WREA daughterboard.
56
Description Dual speed sensors mismatch: PR 1=[ ], PR 4=[ ]
Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit
value.
Solution
•
•
Verify that the Dual_DiffLimit value is set correctly. Note that the value is given in engineering units.
Verify the connection and correct operation of the speed sensors.
57
Description Dual speed sensors mismatch: PR 2=[ ], PR 5=[ ]
Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit
value.
Solution
•
•
Verify that the Dual_DiffLimit value is set correctly. Note that the value is given in engineering units.
Verify the connection and correct operation of the speed sensors.
58
Description Dual speed sensors mismatch: PR 3=[ ], PR 6=[ ]
Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit
value.
Solution
•
•
Verify that the Dual_DiffLimit value is set correctly. Note that the value is given in engineering units.
Verify the connection and correct operation of the speed sensors.
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 219
Non-Public Information
59
Description Internal power supply failure - P5 power for WREA
Possible Cause The PPRA internal 5 V power supply is unhealthy, causing either a faulty PPRA or TREA+WREA
terminal board.
Solution
•
•
If all three PPRAs are reporting the problem, replace the TREA+WREA terminal board.
If only one pack is reporting the problem, replace the PPRA.
60
Description Internal power supply failure - P15 power for WREA
Possible Cause The PPRA internal 15 V power supply is unhealthy, causing either a faulty PPRA or TREA+WREA
terminal board.
Solution
•
•
If all three PPRAs are reporting the problem, replace the TREA+WREA terminal board.
If only one pack is reporting the problem, replace the PPRA.
61
Description Internal power supply failure - N15 power for WREA
Possible Cause The PPRA internal -15 V power supply is unhealthy causing either a faulty PPRA or TREA+WREA
terminal board.
Solution
•
•
If all three PPRAs are reporting the problem, replace the TREA+WREA terminal board.
If only one pack is reporting the problem, replace the PPRA.
62-64
Description Hardware speed mismatch: PR[ ], PR[ ]
Possible Cause
The FPGA detected differences between speed sensors. SIL3 systems will be tripped in one hour.
Solution
•
•
220
SIL 3 systems will trip the emergency trip relays one hour after this condition has been detected.
Check the connection and correct the operation of the speed sensors.
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65
Description Configuration changed after power up - running with old configuration
Possible Cause The following configuration parameters may not change after going online:
•
•
•
•
•
•
•
EstopEnab
SILMode
PRType cannot go from/to Unused
PRScale
Contact Input TripMode/Used/Unused
PRGrouping
SpdDiffSensitivity
Note This restriction is in place even if SilMode is set to Not_Sil due to hardware restrictions in the PPRA.
Solution
•
•
•
Check if the listed parameters have been changed inadvertently. Refer to the error log. From the ToolboxST application,
right-click IOPack and select Troubleshooting, Advanced Diagnostics, and Error Log.
Set the parameters to their original state and download them to the PPRA if they have been changed inadvertently.
Remove power from the I/O pack to get the hardware to accept the new values if changes are required.
66
Description PPRA is not SIL compatible - remain offline
Possible Cause One or more of the PPRA(s) are not SIL compatible. The PPRA module will not go online in this
condition.
Solution
•
•
Verify that the BPPB or BPPC, BPRO, KREA, TREA, and WREA are all S board revision types. Replace all H board
revisions with their S board revisions.
Change the SilMode parameter to Not_SIL.
69-71
Description Trip Relay (ETR) Driver [ ] does not match commanded state
Possible Cause The driver output of the I/O pack for Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not
match the commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector
into the expected terminating impedance on the trip board.
Solution
•
•
•
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating (if not TREA) and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 221
Non-Public Information
72-74
Description Econ Relay Driver [ ] does not match commanded state
Possible Cause The driver output of the I/O pack for Economizing Relay KE1, KE2, or KE3 does not match the
commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector into the
expected terminating impedance on the trip board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
75
Description Servo Clamp Relay Driver does not match commanded state
Possible Cause The driver output of I/O pack for K4CL does not match the commanded state. This indicates that I/O
pack does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip
board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
76
Description K25A Relay (synch check) Driver does not match commanded state
Possible Cause The driver output of I/O pack for K25A does not match the commanded state. This indicates that I/O
pack does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip
board.
Solution
•
•
•
222
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting
the I/O pack, and the I/O pack.
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83-85
Description Trip Relay (ETR) Contact [ ] does not match commanded state
Possible Cause
•
•
Relay feedback from Emergency Trip Relay ETR1 (K1), ETR2 (K2), or ETR3 (K3) does not match the commanded
state. This indicates that the relay feedback from the trip board does not agree with the commanded state.
Solenoid power is not applied to the trip board.
Solution
•
•
Check the trip board relays, as well as the cable from trip board to main terminal board (if not TREA).
Check that solenoid power is applied to the terminal board.
86-88
Description Econ Relay Contact [ ] does not match commanded state
Possible Cause The relay feedback from Economizing Relay 1 (KE1), KE2, or KE3 does not match the commanded
state. This indicates that the relay feedback from the trip board does not agree with the commanded state.
Solution Check the trip board relays, as well as the cable from trip board to main terminal board.
89
Description Servo Clamp Relay Contact does not match commanded state
Possible Cause The relay feedback from K4CL does not match the commanded state. This indicates that the relay
feedback from the trip board does not agree with the commanded state.
Solution
•
•
•
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
PPRA Emergency Turbine Protection
GEH-6721_Vol_III_BJ System Guide 223
Non-Public Information
90
Description K25A Relay Coil Feedback does not match commanded state
Possible Cause The relay feedback from K25A does not match the commanded state. This indicates that the relay
feedback from the trip board does not agree with the commanded state. Relay feedback is taken after hardware command
voting on the trip terminal board has occurred; therefore, a probable cause is that one I/O pack is not commanding the same
state as the other two I/O packs.
Solution
•
•
•
•
Confirm that the TMR packs are commanding the same state for K25A.
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating and the cable integrity.
One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting
the I/O pack, and the I/O pack.
97
Description Solenoid Power Source is missing
Possible Cause Solenoid power monitoring provided by the trip board indicates the absence of power.
Solution
•
•
Check the source of solenoid power.
Confirm that the wiring between the trip boards is correct.
99-101
Description Solenoid Voltage [ ] does not match commanded state
Possible Cause
•
•
•
•
The solenoid voltage associated with K1-K3 does not match the commanded state.
K1-K3 are closed, but no voltage is detected on the solenoid.
Solenoid voltage was removed through another means while the I/O pack expects to detect its presence.
The ETR state associated with this PPRA is being out voted by the other two PPRAs.
Solution
•
•
•
224
Review the system-level trip circuit wiring and confirm the voltage should be present if the I/O pack energizes the
associated trip relay.
From the ToolboxST application, verify that the variables (typically L20PTR#) which drive the Primary Trip Relays
(PTRs) in the PTUR are correctly assigned to the PPRO or PPRA Variables tab (PTR1, PTR2, and PTR3).
Check the pre-voted values for ComposTrip1 under the Vars-Trip tab to verify that all three PPRAs have the same status.
If the current PPRA differs from the others, check the pre-vote status of other variables under this tab to determine the
exact cause of the composite trip, and correct the condition.
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105
Description TREL/S, Solenoid Power, Bus A, Absent
Possible Cause TRES/TREL solenoid power A is absent. Solenoid power does not match the solenoid state for longer
than 40 milliseconds.
Solution
•
•
•
•
Check power applied to the trip board.
Check the field wiring.
Check the solenoid.
Replace the terminal board.
106
Description TREL/S, Solenoid Power, Bus B, Absent
Possible Cause TRES/TREL solenoid power B is absent. The solenoid power does not match the solenoid state for
longer than 40 milliseconds.
Solution
•
•
•
•
Check power applied to the trip board.
Check the field wiring.
Check the solenoid.
Replace the terminal board.
107
Description TREL/S, Solenoid Power, Bus C, Absent
Possible Cause TRES/TREL solenoid power C is absent. The solenoid power does not match The solenoid state for
longer than 40 milliseconds.
Solution
•
•
•
•
Check power applied to the trip board.
Check the field wiring.
Check the solenoid.
Replace the terminal board.
PPRA Emergency Turbine Protection
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6.2.1 108
Description Control Watchdog Protection Activated
Possible Cause An alarm indicates that the ContWdog variable has not changed for five consecutive frames. The alarm
clears if changes are seen for 60 seconds.
Solution
•
•
Verify that the ContWdog is connected to the output of a device_hb block and that the block is located in a task which is
run at frame rate.
Verify that the output signal from the block is changing at least once a frame.
6.2.2 109
Description Speed Difference Protection Activated
Possible Cause This alarm only occurs if the parameter SpeedDifEnable has been enabled. An alarm indicates that the
difference between the output signal Speed1 and the first I/O pack pulse rate speed is larger than the percentage OS_DIFF for
more than three consecutive frames. The percentage is based off of the parameter RatedRPM_TA. The alarm clears if the
difference is within limits for 60 seconds for more than three consecutive frames.
Solution Verify that the Speed1 signal is set up correctly in the ToolboxST and that the source of the signal reflects the
primary (PTUR/YTUR) pulse rate speed.
6.2.3 110
Description Stale Speed Protection Activated
Possible Cause The speed trip protection may be stale. This alarm can only occur if the parameter StaleSpdEn has been
enabled. An alarm indicates that the variable Speed1 has not changed for 100 consecutive frames. The alarm clears if the
speed dithers for 60 seconds.
Solution Verify that the Speed1 signal is set up correctly in the ToolboxST configuration, and that the source of the signal
reflects the primary (PTUR/YTUR) pulse rate speed.
6.2.4 111
Description Frame Sync Monitor Protection Activated
Possible Cause This alarm indicates that the communication with the controller was lost for at least five consecutive
frames after the I/O pack was online. The alarm clears if the frame synch is established for at least 60 seconds.
Solution Verify that the IONet is healthy. This indicates that the I/O pack is not synchronized with the Mark VIe
start-of-frame signal.
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112-114
Description Overspeed [ ] firmware setpoint configuration error
Possible Cause There is a firmware overspeed limit mismatch between IO signal space limit and the configuration.
The current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signal
OS[ ]_Setpoint.
Solution Change the output signal designated in OS[ ] _Setpoint (Vars-Speed tab) to match the configuration value OS_
Setpoint (Pulse Rate tab).
115-117
Description Overspeed [ ] hardware setpoint configuration error
Possible Cause There is a hardware over-speed limit mismatch between IO signal space limit and the configuration. The
current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signal
OSHW_Setpoint[ ].
Solution Change the output signal designated in OSHW_ Setpoint [ ] (Vars-Speed tab) to match the configuration value
in OSHW_Setpoint (Pulse Rate tab).
118-120
Description Overspeed [ ] hardware setpoint changed after power up
Possible Cause
•
•
This alarm always occurs when Pulse Rate [ ] HWOS_Setpoint is changed and downloaded to the I/O pack after the
turbine has started.
It can also change if PRScale is changed to a decimal value and downloaded to the I/O pack after the turbine has started.
Solution
•
•
Confirm that the limit or scale change is correct.
Restart the I/O pack to force the hardware overspeed to re-initialize the limit.
121
Description TREA - K1 solid state relay shorted
Possible Cause The TREA provides voltage-based detection of relays that remain in the energized position in the six
voting contacts used to provide K1. Zero voltage has been detected on one or more contacts of K1 when voltage should be
present.
Solution Replace the TREA.
122
Description TREA - K2 solid state relay shorted
Possible Cause TREA provides voltage based detection of relays that remain in the energized position in the six voting
contacts used to provide K2. Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.
Solution Replace the TREA.
PPRA Emergency Turbine Protection
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123
Description LED - Turbine RUN Permissives Lost
Possible Cause The RUN LED is lit red on the I/O pack because one of the RUN permissives for the turbine has been
lost. The LedDiags parameter must be set to Enable to get this alarm.
Solution
•
•
•
Verify the configuration of the LedDiag parameter.
From the Vars-Trip tab, identify the condition that caused the trip.
The condition leading to a trip condition must be cleared, and a master reset issued.
124
Description LED - Overspeed fault detected
Possible Cause The Overspeed LED is lit on the pack because of a detected Trip condition. The LedDiag parameter
must be set to True to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
The condition leading to a trip condition must be cleared, and a master reset issued.
125
Description LED - Estop detected
Possible Cause The E-Stop LED is lit on the pack because of a detected E-Stop signal. The LedDiag parameter must be
set to True to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
Remove the E-Stop condition and issue a master reset.
126
Description LED - SIL3 trip pending
Possible Cause The SIL trip pending LED is lit on the I/O pack because a hardware speed difference has been detected
between two redundant sensors. The emergency trip relays (ETR) will fire one hour after the condition has been detected.
Solution
•
•
SIL 3 systems will fire the ETR one hour after this condition has been detected. After resolving the issue, cycle power to
the I/O pack to reset this alarm.
Power down the I/O pack and determine the source of the sensor discrepancy.
127
Description WREA - K3 solid state relay shorted
Possible Cause WREA provides voltage based detection of "stuck-on" relays in the six voting contacts used to provide
K3. Zero voltage has been deleted on one or more contacts of K3 when voltage should be present.
Solution Replace the WREA.
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128
Description Tripped - Missing pulse rate signal
Note This diagnostic is generated from hardware detection that is only available on BPPC-based I/O packs. BPPB-based I/O
packs will not detect this condition the same way.
Possible Cause No speed input detected on a speed sensor due to the following reasons:
•
•
•
Broken wire
Sensor malfunction
Signal conditioning malfunction
Solution
•
•
Check the terminal connections for the speed sensor.
Check the speed sensor gap.
129
Description Processor hardware error detected (Error Code:[ ])
Possible Cause Hardware error detected by the FPGA due to the following reasons:
•
•
Error code 1: FPGA program changed during runtime, possibly one-time event
Error code 2: clock oscillator error
Note These conditions cause a trip that can only be cleared with a power cycle.
Solution
•
•
•
Restart the I/O pack.
Download the firmware of the I/O pack.
If the problem persists, replace the I/O pack.
130
Description Invalid configuration detected
Possible Cause The configuration is not supported due to the following reasons:
•
•
•
•
TREA not selected
TRES/L is selected
QC Mode enabled
Configured as a Large Steam turbine
Note These conditions cause a trip that can only be cleared by changing the configuration and restarting the I/O pack.
Solution Change the configuration to be valid.
PPRA Emergency Turbine Protection
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131-136
Description Speed sensor mismatch for PulseRate [ ]: PR[ ]_Spd [ ]
Possible Cause A speed sensor is reporting speeds that differ by more than the configured Dual_DiffLimit value from
the voted PulseRate value.
Solution
•
•
Verify that the Dual_DiffLimit value is set correctly (value is given in engineering units).
Check the connection and correct the operation of the speed sensors.
137-143
Description Hardware speed sensor mismatch PR[ ], PR[ ]
Possible Cause The FPGA detected an excessive difference between speed sensors, and the SilMode parameter is set to
SIL2 or SIL3. If SilMode is set to SIL3, then the system will trip in 1 hour.
Solution
•
•
•
SIL 3 systems will trip the emergency trip relays one hour after this condition has been detected.
Verify the connection and correct the operation of the speed sensors.
If speed sensors appear to match but diagnostic is still active, reduce speed to less than 50% of the HW_OS_Setpoint
to reset the diagnostic and trip condition.
144
Description PRGrouping of two groups is not supported by this module
Possible Cause The configuration has PRGrouping set to TwoGroups and is trying to run on an H1A/S1A. This
configuration is not supported.
Solution Change PRGrouping to ThreeGroups or change the H1A/S1A module to an H1B/S1B module.
145
Description HwSpdDiffSensitivity setting invalid for this module
Possible Cause HwSpdDiffSensitivity is either Low or High. Only Normal is supported for H1A/S1A modules.
Solution Either change HwSpdDiffSensitivity to Normal or change the H1A/S1A module to an H1B/S1B module.
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224-239
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:
•
•
•
Device
Connections to the terminal board
Terminal board
Solution
•
•
•
•
•
•
•
Adjust the TMR threshold limit or correct the cause of the difference.
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and the networking.
Check the I/O pack mounting on terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
1064-1255
Description Logic Signal [ ] Voting Mismatch
Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:
•
•
•
Device
Connections to the terminal board
Terminal board
Solution
•
•
•
•
•
•
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and the networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
PPRA Emergency Turbine Protection
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6.3 TREA and WREA Turbine Emergency Trip
6.3.1 Functional Description
The Aeroderivative Turbine Emergency Trip (TREA) terminal board combined with the WREA is used with PPRA I/O packs
as part of the Mark* VIe control system. The inputs and outputs are as follows:
•
•
•
•
•
•
Customer input terminals provided through two 24-point pluggable barrier terminal blocks (H1A or S1A) or 48 pluggable
Euro style box-type terminal blocks (H3A or S3A).
Six fanned passive pulse rate devices (up to three shafts with two sensors each) sensing a toothed wheel to measure the
turbine speed.
Three 24 V dc TMR voted solid-state output contacts to trip the system:
− TREAH1A or H3A plus WREAH1A
− TREAS1A or S3A plus WREAS1A
Four 24-125 V dc voltage detection circuits for monitoring trip string.
Four 24 V dc WREAH1A or WREAS1A contact inputs provide additional hardware or conditional trip inputs. Wetting
power is supplied through the JH1 connector on WREA.
One speed repeater output for each of the six speed inputs reproduces the speed pulse rate signals using an RS–232 or
RS–422 transmitter.
TREA plus WREA requires three PPRA I/O packs for correct operation.
In 240 V ac applications, do not inadvertently cross-connect the 240 V ac and the dc
voltages. The peak voltage will exceed the Transorb rating, resulting in a failure.
Caution
232
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Most ac supplies operate with a grounded neutral, and if an inadvertent connection
between the 125 V dc and the ac voltage is created, the sum of the ac peak voltage and
the 125 V dc is applied to Transorbs connected between dc and ground. However, in
120 V ac applications, the Transorb rating can withstand the peak voltage without
causing a failure.
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TREA Aeroderivative Turbine Terminal Board
PPRA Emergency Turbine Protection
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WREA
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6.3.2 Installation
The WREA is factory installed and mounted to the TREA terminal board. Should the board have to be removed to service the
TREA fanning jumpers, perform the following procedure to replace the WREA.
➢ To install the WREA
1.
Align the two connectors on the WREA with those on the TREA. When viewing the WREA the bottom of the board is
considered to be the end with the row of configuration jumpers. The connectors are keyed such that they will only mate
when aligned properly.
2.
Once the two boards are aligned, seat the connection by firmly pressing on the four screw heads that surround the
connector. The WREA is considered fully mounted when it cannot be pushed any farther.
6.3.2.1
TREA/WREA Terminal Board Wiring
For H1 and S1 board variants, voltage detection, trip contact inputs, and relay outputs are wired to the I/O terminal blocks
TB1. Passive pulse rate pick-ups are wired to TB2. Each block is held down with two screws and has 24 terminals accepting
up to #12 AWG wires. A shield termination strip attached to chassis ground is located immediately to the left of each terminal
block.
For H3 and S3 board variants, voltage detection, trip contact inputs, and relay outputs are wired to the I/O box terminals at the
top of the board. Passive pulse rate pick-ups are wired to the lower terminals. All terminals plug into a header on the TREA
board and accept up to a single #12 AWG wire.
When used with WREA, the TREA must be configured for fanning of the X section
pulse rate pickups to the Y and Z PPRAs. This is done by placing the jumpers on the
P1 and P2 pin pairs.
Caution
PPRA Emergency Turbine Protection
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In the following table, the speed inputs called PR1_Y through PR3_Z are grayed out. While the signal paths are present as
documented for use with PPRO I/O packs they are not used and should not be connected when PPRA I/O packs are used.
TREA/WREA Terminal Board Wiring
Pin
Signal Name
Pin
Signal Name
1
K1_PDC
2
K1_NDC
3
K2_PDC
4
K2_NDC
5
SOL1_A
6
SOL1_B
7
SOL2_A
8
SOL2_B
9
PWR_A
10
PWR_B
11
TRP_A
12
TRP_B
13
K3_PDC
14
K3_NDC
15
PWET
16
TRP1L
17
PWET
18
TRP2L
19
PCOM
20
PCOM
21
PWET
22
TRP3L
23
PWET
24
TRP4L
25
PR4H
26
PR4L
27
PR5H
28
PR5L
29
PR6H
30
PR6L
31
PR1H_Z
32
PR1L_Z
33
PR2H_Z
34
PR2L_Z
35
PR3H_Z
36
PR3L_Z
37
PR1H_Y
38
PR1L_Y
39
PR2H_Y
40
PR2L_Y
41
PR3H_Y
42
PR3L_Y
43
PR1H_X
44
PR1L_X
45
PR2H_X
46
PR2L_X
47
PR3H_X
48
PR3L_X
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6.3.2.2
Contact Outputs
The contact outputs are polarity sensitive. Wire the circuit carefully to avoid
damaging the relays. There is no contact or solenoid suppression, user must add
external solenoid suppression to avoid damaging the relays and their contacts.
Caution
A voltage detection circuit is included on TREA and WREA that is able to detect a shorted relay when voltage is present
across the open contact set.
Connection to TREA Contact Output
6.3.2.3
•
•
•
•
The Trip input is configurable in PPRA to either be required or bypass the signal. When enabled the Trip input works
through a hardware path on PPRA and does not act through PPRA firmware. When enabled the Trip input must be
powered for the trip relays to close.
The Trip input must be connected to a CLEAN dc source battery or filtered (< 5% ripple) rectified ac.
There must be a minimum of 18 V dc at the Trip inputs for proper operation. The current required was kept low to
minimize drop on long cable runs.
As the Trip input is very fast < 5 ms and the output relay contacts are also fast (< 1 ms), best wiring practices should be
utilized to avoid misoperation. Use twisted-pair cable when possible and avoid running with ac wiring.
6.3.2.4
•
•
Trip Input
Contact Inputs
Wetting power is supplied through the JH1 connector on WREA with the following pin connections: Pin 1 is positive
wetting voltage, Pin 2 is ground, and Pin 3 is negative or return wetting voltage.
Each contact input has two associated screw terminals on TREA. Odd numbered terminals identified as PWET are
directly connected to the JH1 pin 1 input power. Even numbered terminals identified as TRP1L through TRP4L lead to
individual voltage detectors that share a return path to JH1 Pin 3. Because all PWET terminals are connected together it
is permissible to use a single wire from PWET to a set of remote contacts and then use individual return wires to the
TRP_L inputs.
PPRA Emergency Turbine Protection
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6.3.2.5
Speed Repeater Outputs
Each speed repeater output may be configured to provide either RS–232 or RS–485 signal levels. RS–232 provides a bipolar
signal that crosses through zero as is required by many speed inputs. It is recommended that RS–232 repeater outputs be
limited in wiring length to 10 meters and go to equipment that is grounded at the same potential as TREA / WREA. RS–485
provides a balanced differential signal that is more suitable for long distance transmissions. It is recommended that RS–485
repeater outputs be limited in wiring length to 500 meters. Wire type and termination should comply with published RS–485
standards.
The repeater outputs are grouped together on the J3 connector located on WREA. The outputs are arranged to provide a signal
ground and chassis ground pin pair between each active signal pair. This makes it possible to ground the individual shields of
twisted shielded pair cable and reduces any chance of signal cross talk. The diagram indicates the J3 pin assignments when
looking into the connector.
13
NO CONNECT
12
CHASSIS Shield
11
SPD6 _P Black
10
CHASSIS Shield
9
SPD5 _P Black
8
CHASSIS Shield
7
SPD4_P Black
6
CHASSIS Shield
5
SPD3_P Black
4
CHASSIS Shield
3
SPD2_P Black
2
CHASSIS Shield
1
SPD1_P Black
25
Yellow SPD6_N
24
23
Brown SPD5_N
22
21
Blue SPD4_N
20
19
Green SPD3_N
18
17
White SPD2_N
16
15
RED SPD1_N
14
WREA-J3 Connector
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Speed repeater outputs from the WREA-J3 connector are wired to a transition module ALH#5747.2 through a special 25 pin
cable, 259B2434AEPxx, where xx is the cable length in feet. It transmits the six sets of speed signals through six sets of
individually shielded, twisted pair wires. The six sets of signals connect pin to pin as displayed in the WREA-J3 connector
pin assignment drawing.
The shields from each wire pair also connect the chassis connections pin to pin, from the WREA-J3 Sub-D connector to the
transition module connector. Signal and chassis connection point numbers carry through from the transition module Sub-D
connector to the corresponding points on the box type terminal board. The cable also has an overall shield terminated on the
Sub-D connector shells at each end the cable. That shield ties to the chassis ground on the WREA board.
The shield wires at the final connection point for the cables should be left un-terminated and properly protected/sheathed to
prevent shorting.
6.3.3 Operation
The TREA board is designed to use three PPRA I/O packs mounted directly on it. The TREA / WREA / PPRA assembly then
forms a self-contained emergency trip function. TREAH1A, S1A, H3A, and S3A plus WREA will only function correctly
with three PPRA I/O packs. Single and dual pack operation is not possible. The Trip Anticipate test function does not toggle
the ETR relays on the TREA.
PPRA Emergency Turbine Protection
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6.3.3.1
Speed Inputs
Speed inputs are associated with specific shafts. The PRGrouping parameter allows the user to select between two speed
inputs in three groups (three shafts) or three speed inputs in two groups (two shafts). For three groups, the PR1_X and PR4
speed inputs must be wired to the two speed sensors on the first shaft. The PR2_X and PR5 speed inputs must be wired to the
two speed sensors on the second shaft, if present. The PR3_X and PR6 speed inputs must be wired to the two speed sensors
on the third shaft, if present. If two groups are selected for PRGrouping, PR1_X, PR2_X, and PR4 must be wired to the three
speed sensors on the first shaft and PR3_X, PR5, and PR6 must be wired to the three speed sensors on the second shaft.
PulseRate3 must remain unused.
JP1 and JP2 must be placed on the TREA to take the first three speed inputs (those for the X pack) and fan them to the Y and
Z packs. When JP1 and JP2 are in place, the terminal board points for Y and Z speed inputs become no-connects and should
not be used. As a check, a jumper position feedback signal is provided by TREA. If the jumpers are not in place, a PPRA
alarm will be generated.
6.3.3.2
Trip Input
The TREA includes a Trip input function. This consists of an optically isolated input circuit designed for a dc input in the
range of 24 V to 125 V nominal. When energized, the circuit enables coil drive power in the X, Y, and Z relay circuits through
independent hardware paths.
The response time of this circuit of less than five ms plus the response time of the trip relays of less than one ms yields very
fast response. Trip input status is monitored by PPRA firmware, but the action to remove trip relay coil power is a hardware
path in PPRA. It is possible to configure PPRA to turn off the Trip input function.
6.3.3.3
Direct/Conditional Discrete Input Trip
TREA / WREA provides four discrete group isolated contact input trip signals to the PPRA I/O packs. The transition
threshold of the contacts tracks 50% of the applied wetting voltage. Approximately 1% voltage hysteresis is applied to
transitions. A filter with nominal 4 ms delay, max 5 ms is present. PPRA monitors wetting voltage on JH1 and generates an
alarm at voltages below approximately 40% of nominal voltage.
6.3.3.4
Voltage Monitors
The trip relays on TREA may be freely located anywhere in a trip string. Because the trip string circuit is not fixed, there are
three general-purpose isolated voltage sensor inputs on TREA. These can be used to monitor any points in the trip system and
drive the voltage status into the system controller where action can be taken. Typical use of these inputs may be to sense the
power supply voltage for the two trip strings (PWR) and to sense the solenoid voltage of the device being driven by the relays
(SOL1, SOL2). This set of applications is used in the wording of the board symbol, but the sensors may be freely applied to
best serve the application.
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6.3.3.5
Speed Repeaters
There are six speed repeater circuits on WREA. Each repeater is associated with a specific speed input signal and may be
configured for RS–232 or RS–485 signal levels on the output. The speed repeater is driven by an internal signal after speed
input pulse detection has taken place. While the speed sensor input signal may span a wide range of amplitude as speed is
changed the repeater output maintains constant output amplitude through all pulse rates.
The speed repeaters do add some latency to the speed signal. In addition to copper transmission latencies, the repeater
circuitry will add between 1.5 and 2.0 usecs of edge to edge latency. The variation is due to pulse rate input channel (pulse
rate 1-3 vs. 4-6) and repeater configuration (RS–232 vs RS–485).
6.3.3.6
Trip Relays
The trip relays are made using sets of six individual form A devices arranged in a voting pattern. Any two controllers that
vote to close will establish a conduction path through the set. Because detection of a shorted relay is important to preserve
tripping reliability, there is a sensing circuit applied to each of the sets of relays.
When the relays are commanded to open, and voltage is present across the relays, the circuit will detect if one or more relays
are shorted. This signal goes to the PPRA I/O pack to create an alarm. The TREA sensing circuit uses the relay commands
from all three packs to avoid a false indication in the event that one PPRA I/O pack votes to close the relay while the other
two PPRA I/O packs vote to open. The voting arrangement is displayed in the following TREA diagram.
Contacts are polarity-sensitive. External voltage suppression must be used.
Caution
PPRA Emergency Turbine Protection
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TREA and WREA Trip Boards
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6.3.4 Specifications
Item
TREA Specification
Number of inputs
6 passive (magnetic) speed pickups
3 voltage detection circuits
1 E-STOP/TRP input
4 contact inputs
Number of outputs
3 trip contacts
6 speed repeater drivers
Contact ratings
NEMA class F.
IS200TREAH1A, H3A, SIA, S3A
Voltage: 28 V dc max
plus WREAH1A, SIA
Max. Current 10 A dc at 40ºC (104 ºF) maximum (Trip Relays 1 and 2)
de-rate current linearly to 7 A dc at 65ºC (149 ºF) maximum.
Max. Current 5 A dc at 40ºC (104 ºF) maximum (Trip Relay 3)
No de-rating necessary at 65°C (149 ºF) as traces are limiting factor.
Voltage detection inputs
Min/max input voltage rating: 16/140 V dc max pk
Current Loading (Max leakage): 3 mA
Detection delay (max): 60 ms
Voltage isolation: Optically isolated: 2500 V rms isolation, for one min.
Surge/Spike rating: 1000 V pk for 8.3 ms
ESTOP/TRP detection
Input Voltage: 24-125 V dc ±10% (18/140 V pk Min/Max)
Loading (max): 12 mA (5 typical)
Delay (max): 5 ms (<1 typical)
Contact input voltage
WREAH1A, S1A – nominal 24 V dc input
Contact input threshold
Tracks 50% of wetting voltage applied to JH1 connector. Hysteresis of 1% applied
to transitions. Filter delay of 4 ms nominal, 5 ms maximum.
MPU pulse rate range
2 Hz to 20 kHz
MPU pulse rate accuracy
0.05% of reading
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 28 mV p-p
20 kHz requires 300 mV p-p
Speed input sensitivity is such that turning
gear speed may be observed on a typical
turbine application.
Size
33.0 cm high x 17.8 cm, wide (13 in x 7 in)
Technology
Surface mount
PPRA Emergency Turbine Protection
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6.3.5 Diagnostics
Diagnostic tests are made on the terminal board:
•
•
•
•
•
•
Feedback from the shorted contact detector is checked, if a shorted relay is detected an alarm will be created.
Feedback from speed pickup fanning jumpers is checked; if there is a mismatch between intention and actual position, an
alarm is created.
Each speed repeater output has a receiver circuit that monitors the output. If the output signal does not closely match the
required speed signal an alarm is generated. This diagnostic protects against shorted repeater outputs or repeater output
drive failure.
If any one of the above signals goes unhealthy, a composite diagnostic alarm xxDIAG_PPRA occurs. The diagnostic
signals can be individually latched and then reset with the RESET_DIA signal if they go healthy.
Terminal board connectors have their own ID device that is interrogated by the I/O pack. The ID device is a read-only
chip coded with the terminal board serial number, board type, revision number, and plug location. When the chip is read
by PPRA and a mismatch is encountered, a hardware incompatibility fault is created.
Wetting power presence.
6.3.6 Configuration
TREA jumpers P1 and P2 select the fanning of the X channel speed inputs to the Y and Z PPRA I/O packs. PPRA operation
with TREA and WREA requires that these jumpers be in place.
WREA jumpers JP1 through JP12 are used to configure output behavior of the six speed repeater output circuits. The jumpers
are located at the bottom of WREA in the same order as displayed in the following diagram.
Jumpers JP1 through JP6 are used to select between RS–232 signal level (default) and RS–485 signal level on the repeater
output. JP1 through JP6 configure the repeater outputs for PR1 through PR6.
Jumpers JP7 through JP12 default to the PR1 through PR6 positions and should remain in these positions when used with
PPRA.
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7 PPRO, YPRO Backup Turbine
Protection
7.1 Mark VIe PPRO Backup Turbine Protection I/O Pack
The Backup Turbine Protection (PPRO) I/O pack and associated terminal boards provide
an independent backup overspeed protection system with a backup check for generator
synchronization to a utility bus. They also provide an independent watchdog function for
the primary control. A typical protection system consists of three triple modular
redundant (TMR) PPRO I/O packs mounted to a separate simplex protection (SPRO)
terminal board or three PPROs mounted on a TMR TPROH#C terminal board. A cable,
with DC-37 pin connectors on each end, connects each SPRO or TPROH#C to the
designated emergency trip board:
•
•
•
TREG: Gas Turbine Emergency Trip Terminal Board
TREL: Large Steam Turbine Emergency Trip Terminal Board
TRES: Small/Medium Steam Turbine Emergency Trip Terminal Board
An alternate arrangement puts three PPRO I/O packs directly on TREA for a single-board
TMR protection system. The PPRO has an Ethernet connection for IONet
communications with the control modules.
The Mark* VIe control is designed with a primary and backup trip system that interacts at
the trip terminal board level. Primary protection is provided with the Turbine Primary I/O
pack (PTUR) operating a primary trip board (TRPG, TRPL, TRPS, TRPA). Backup
protection is provided with the PPRO I/O pack operating a backup trip board (TREG,
TREL, TRES, TREA).
The PPRO accepts three speed signals for overspeed protection functions, including basic
overspeed, acceleration, deceleration, and a hardware implemented overspeed. The I/O
pack monitors the operation of the primary control and can monitor the primary speed as
a sign of normal operation. The PPRO monitors the status and operation of the selected
trip board through a comprehensive set of feedback signals. If a problem is detected, the
PPRO activates the backup trip relays on the trip board and activates a trip on the primary
control. The I/O pack is fully independent of and unaffected by the primary control
operation.
A maximum of three trip solenoids can be connected between the primary and emergency
trip terminal boards. Connecting a solenoid between the boards isolates the power on both
sides of the solenoid as well as visibility of solenoid voltage as a system feedback. The
primary/emergency trip boards TRPG/TREG, TRPL/TREL, and TRPS/TRES are
designed to operate as a pair and use cabling between the boards for system connections.
The TRPA and TREA are designed with no pairing required and can be used
independently of each other. When TRPA and TREA are paired, they function the same
as other board pairs.
PPRO, YPRO Backup Turbine Protection
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7.1.1 Compatibility
The PPRO I/O pack includes one of the following compatible BPPx processor boards:
•
•
The PPROH1A contains a BPPB processor board.
The PPROS1B contains a functionally compatible BPPC processor board that is supported in the ControlST* software
suite V04.07 and later.
The PPROS1B is an IEC 61508 certified version for use in IEC 61511 certified safety loops. The safety-certified I/O pack,
trip board, and terminal board combinations are as follows:
•
•
•
•
•
PPROS1B, TPROS#C, TREGS1B, 125 V dc
PPROS1B, TPROS#C, TREGS2B, 24 V dc
PPROS1B, TPROS#C, TREGS3B, 125 V dc, TMR, special 28 V power JX1
PPROS1B, TPROS#C, TREGS4B, 125 V dc , TMR, special 28 V Power JY1
PPROS1B, TPROS#C, TREGS4B, 125 V dc , TMR, special 28 V Power JZ1
Note Refer to the Mark VIe Control PPROS1B and PPRAS1x Functional Safety Instruction Guide (GEI-100709).
The PPRO I/O pack mounts directly to the SPRO, TPROS#C, TPROH#C, or TREA. When mounted on the SPRO or TPRO,
it is cable-compatible to the TREG, TREL, or TRES trip board.
Trip Board Compatibility
Board1
TMR
Simplex
Output
Contacts,
125 V dc
Output
Contacts,
24 V dc
E-Stop
Input
Contacts,
125 V dc
Input
Contacts,
24 V dc
Economy
Resistor
TREG_1B
Yes
No
Yes
Yes
Yes
Yes
No
Yes
TREG_2B
Yes
No
Yes
Yes
Yes
No
Yes
Yes
TREG_3B2
Yes
No
Yes
Yes
Yes
Yes
No
Yes
TREG_4B2
Yes
No
Yes
Yes
Yes
Yes
No
Yes
TREG_5B2
Yes
No
Yes
Yes
Yes
Yes
No
Yes
TRELH1A
Yes
No
Yes
Yes
No
Yes
No
TRELH2A
Yes
No
Yes
Yes
No
No
Yes
TRESH1A
Yes
Yes
Yes
Yes
No
Yes
No
TRESH2A
Yes
Yes
Yes
Yes
No
No
Yes
TREAH1A
Yes
No
No
Yes
Yes
No
No
TREAH2A
Yes
No
Yes
No
Yes
No
No
No
No
Yes
Yes
No
No
TREAH3A3 Yes
TREAH4A3 Yes
No
Yes
No
Yes
No
No
No
No
Yes
Yes
No
No
TREAS1A3 Yes
3
Yes
No
Yes
No
Yes
No
No
TREAS2A
No
No
Yes
Yes
No
No
TREAS3A3 Yes
No
Yes
No
Yes
No
No
TREAS4A3 Yes
1 Underscore ( _ ) indicates the TREG board version may be H or S.
2 The TREG_3A, 4A, and 5A versions are the same as the 1A except that power is provided by JX1, JY1, or JZ1.
3 TREA_#A and _#A are the same as _1A and _2A only Euro versions.
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No
No
No
No
No
No
No
No
No
No
No
No
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7.1.1.1
Simplex Main Control
Simplex backup protection is supported by the Mark VIe control trip board TRES. One PPRO network port resides on the
controller IONet.
TMR backup protection is supported by all Mark VIe control backup trip boards, TREG, TREL, TREA, and TRES. In this
configuration, each I/O pack is connected to a separate (R,S,T) controller network.
7.1.1.2
Dual Main Control
Simplex backup protection is supported by the Mark VIe control trip board TRES. When used in this configuration, the first
network connection is to the R controller. The second network connection is to the S controller. The PPRO is then responsible
for monitoring the operation of both controllers. The PPRO supports two options: the pack trips if either controller
malfunctions or if both controllers malfunction.
TMR backup protection is supported by all Mark VIe control backup trip boards, TREG, TREL, TREA, and TRES. This
configuration uses the dual controller TMR output standard network connection. The first PPRO has one network port
connected to the R controller network. The second I/O pack has one network port connected to the S controller network. The
third pack has one network port connected to the R controller network and one network port connected to the S controller
network. The third PPRO monitors the operation of both controllers. The I/O pack activates a trips if either controller
malfunctions or both controllers malfunction.
7.1.1.3
Triple Main Control
TMR backup protection is supported when operating with a TMR main control (two out of three running). All Mark VIe
control backup trip boards (TREG, TREL, TREA, and TRES) support this configuration. The normal network configuration
connects the first PPRO I/O pack to the R network, the second PPRO to the S network, and the third PPRO to the T network.
PPRO TMR applications do not support dual network connections for all three PPROs. In a redundant system there is no
additional system reliability gained by adding network connections to the first two PPROs with dual controllers or any of the
three PPROs with TMR controllers. The additional connections simply reduce mean time between failures (MTBF) without
increasing mean time between forced outages (MTBFO).
Note Simplex backup protection is not supported. One PPRO cannot monitor the health of all three main controls and trip on
loss of a single main control. Therefore, one of the fundamental protection features cannot be met with a single I/O pack.
PPRO, YPRO Backup Turbine Protection
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7.1.2 Installation
The PPRO I/O pack mounts directly to the SPRO, TPROS#C, TPROH#C, or TREA. When mounted on the SPRO or
TPROH#C, cables with DC-37 pin connectors on both ends are required between the SPRO or TPROH#C and the selected
trip terminal board.
➢ To install the PPRO I/O pack
1.
Securely mount the SPRO, TPROH#C, or TREA terminal board. Mount the selected trip terminal board if SPRO or
TPRO is used.
2.
Connect the cable with DC-37 pin connectors on each end between the SPRO or TPRO and the selected trip terminal
board (if TREA is not used).
3.
Directly plug one PPRO into each SPRO, or three PPROs into the TREA or TPRO.
4.
Slide the threaded posts on PPRO, located on each side of the Ethernet ports, into the slots on the terminal board
mounting bracket. Adjust the bracket location so the DC-62 pin connector on PPRO and the terminal board fit together
securely. Tighten the mounting bracket. The adjustment should only be required once in the service life of the product.
Securely tighten the nuts on the threaded posts locking PPRO in place.
5.
Plug in one or two Ethernet cables depending on the system configuration. The PPRO module is not sensitive to Ethernet
connections and selects the proper operation over either port.
6.
Apply power to the module by plugging in the power connector on the side of the module. The I/O module has inherent
soft-start capability that controls current levels upon application.
7.
Use the ToolboxST* application to configure the module as necessary. For more information, refer to GEH-6700,
ToolboxST User Guide for Mark VIe Control.
7.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
7.1.3.1
Overspeed Protection
Turbine overspeed protection is available in three levels; control, primary, and emergency. Control protection comes through
closed loop speed control using the fuel/steam valves. Primary overspeed protection is provided by the controller. The TTUR
terminal board and PTUR I/O pack bring in a shaft speed signal to each controller where the median signal is selected. If the
controller determines a trip condition, it sends the trip signal to the TRPG terminal board through the PTUR I/O board. The
three PTUR outputs are 2/3 voted in three relay voting circuits (one for each trip solenoid) and power is removed from the
solenoids. The following figure displays the primary and emergency levels of protection.
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Primary and Emergency Overspeed Protection
Emergency overspeed protection is provided by the independent triple redundant PPRO protection system displayed in the
preceding figure. This uses three shaft speed signals from magnetic pickups (MPU), one for each protection module. These
are brought into SPRO, a terminal board dedicated to the protection system.
Each PPRO independently determines when to trip, and the signals are passed to the TREG terminal board. TREG operates in
a similar way to TRPG, voting the three trip signals in relay circuits and removing power from the trip solenoids. This system
contains no software voting, making the three PPRO modules completely independent. The only link between PPRO and the
other parts of the control system is the IONet cable, which transmits status information.
Additional protection for simplex systems is provided by the protection module through the Servo Terminal Board, TSVC.
Plug J1 on TREG is wired to plug JD1 on TSVC, and if this is energized, relay K1 disconnects the servo output current and
applies a bias to force the control valve closed.
PPRO, YPRO Backup Turbine Protection
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7.1.3.2
Application-specific Hardware
DC - 6 2
To I / O Pack
The I/O pack has an internal, application-specific circuit board (BPRO) that contains the hardware needed for the turbine
backup trip function. The application board connects between the processor and either the SPRO, TPRO, or TREA terminal
board. The application board has provisions for additional hardware expansion options that can be added through a dedicated
header.
3 Pulse Rate
Input
Conditioning
ID Chip
2 PT Input
Processor
12 Digital Signal
Inputs, E-Stop
7 Isolated
Contact Inputs
8 Relay
Command
Outputs
Pass Through to
Option
Processor
Local Power
Supplies
Option Header
BPRO Application Board
7.1.3.3
Protective Functions
The I/O pack performs the following protective functions in a mix of hardware, programmable logic, and firmware. In the
following diagram, standard symbols for time delay contacts have been used:
In the following diagrams, a standard has been used to indicate signal origin and flow.
•
•
•
•
•
•
•
Signal names that end with (SS) are created within the I/O pack and the data flow is out to the controller through signal
space.
Signal names that end with SS are created in the controller and the data flow is into the I/O pack through signal space.
Signal names that end with (IO) are created within the I/O pack and the data flow is out to the hardware.
Signal names that end with IO indicate the signal is a hardware input into the I/O pack.
Signal names that end with anything containing CFG are part of the I/O pack configuration. In this case an attempt has
been made to indicate what area of the I/O pack configuration contains the variable.
When J3 is referenced in a CFG, it refers to the connection point for the turbine backup trip relay board, and the
corresponding configuration values.
The combination IO (SS) indicates a signal that comes from the hardware inputs to the I/O pack, and is then sent out to
the controller as part of signal space.
If there is no special ending on a signal name, then the signal is used internal to the I/O pack and is not part of the hardware or
signal-space data movement. This signal is not available or visible to applications, but it is needed to adequately describe the
I/O pack’s operation.
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7.1.3.4
Direct/Conditional Discrete Input Trip
The I/O pack supports the seven isolated discrete contact input trip signals provided on the backup turbine trip board. In the
following figure, the direct / conditional determination is implemented in firmware while Contact#, and L5Cont#_Trip are in
hardware logic. When configured for direct trip, the firmware is not in the trip path. When configured for conditional trip, the
firmware determines the communication health (displayed as network_keepalive) and populates the programmable logic with
the conditional signal from signal space. If the controller communication is lost, the default will permit any conditional trip.
Note The contact inputs include an 8 ms contact de-bounce filter to protect against false trips.
A
network _keepalive
L3SS_Comm, (SS)
B
3
Trip#_Inhbt , SS
A>=B
L3SS_Comm, (SS)
Inhbt#_Fdbk , (SS)
A
Trip_Mode , CFG (J3, Contact #)
A=B
Direct, CNST
B
Cont#_TrEnab , (SS)
A
A=B
Conditional , CNST
Contact #, (IO)
Includes 8 mSec
digital filter on close ,
no delay on open
Cont#_TrEnab
Trip#_EnCon
L5Cont#_Trip , (SS)
B
Trip#_EnCon, (SS)
L5Cont#_Trip, (SS)
Inhbt#_Fdbk , SS
CONTACT#
TRIP
L86MR, SS
Note: The contact circuit in this diagram is duplicated 7 times. To obtain the correct signal name,
replace the symbol # with the numbers 1-7. Signal names without # appear only once for all 7
circuits (L3SS_COMM, L86MR).
Contact Input Trips
PPRO, YPRO Backup Turbine Protection
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The resulting contact trip signals are combined into a single contact trip summary, L5Cont_Trip.
Contact Input Trip Signal Concentration
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7.1.3.5
Firmware Overspeed Trip
Firmware overspeed protection is performed on the three values that come out of the high speed select. Although the
established standard for naming these three inputs is HP, IP, and LP, the three inputs are free to be applied as needed in a
system design.
Note The following pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP.
Firmware Overspeed
Firmware Overspeed Trip functions include:
•
•
•
•
•
Fault on overspeed threshold match failure between config and signal space values when speed is zero
Pick the lower threshold from config or signal space
Provide a mechanism to zero the threshold for online overspeed test
Provide a mechanism to modify the threshold for offline overspeed test, bounded to limit increases to the threshold to
104%
Provide a mechanism to modify the threshold based upon current computed acceleration (Rate-based Overspeed feature).
Refer to the section Rate-Based Overspeed Trip (RBOS).
Note Use a negative OS_Tst_Delta value to reduce the threshold during testing.
PPRO, YPRO Backup Turbine Protection
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•
•
Compare the threshold to the calculated speed and latch overspeed
Active firmware overspeed setpoint (OS_Setpoint_PR#) is available as an input signal
Rate-based Overspeed Trip (RBOS)
Note Rate-based Overspeed is only supported on PPROS1B. RBOS cannot be enabled if a PPROH1A I/O pack is
configured.
The Rate-based Overspeed (RBOS) function is an optional feature that is implemented for each shaft independently. It enables
the PPRO to modify the firmware overspeed threshold trip setpoint in real-time based upon the current acceleration of the
shaft. The purpose of the RBOS feature is to specify an overspeed setpoint profile that lowers the firmware overspeed setpoint
dynamically as the shaft acceleration increases. The user has the ability to enable or disable the RBOS feature on a per-shaft
basis, and can specify the response curve per shaft. There is also a Test mode that allows the user to insert a test acceleration
input to the function.
The core of the RBOS feature is a user-specified overspeed setpoint profile composed of five acceleration and overspeed
setpoint breakpoints. These breakpoints define a response curve, with the X-axis as acceleration in RPM/s, and the Y-axis as
Overspeed setpoint in RPM. The RBOS feature interpolates between these breakpoints to provide an RBOS-driven overspeed
setpoint given an input acceleration. The following diagram illustrates this overspeed setpoint profile.
RBOS Overspeed Setpoint Profile
As shown in the Firmware Overspeed diagram, some simple logic chooses which acceleration to use in the RBOS feature. If
the RBOS#_TestEnable is True, then the RBOS#_Accel_Test is used as Accel input for RBOS, unless the actual acceleration
(PR#_Accel) is greater.
The chosen acceleration is fed into the overspeed setpoint profile and a calculated RBOS#_Setpoint is provided. If the
acceleration is less than RBOS#_AccelSetpt1 or greater than RBOS#_AccelSetpt5, the RBOS#_Setpoint is clamped to be
equal to RBOS#_OSSetpt1 or RBOS#_OSSetpt5 respectively. Thus, the overspeed setpoint profile does not extrapolate past
the setpoint range, but instead clamps the output.
Once the RBOS overspeed setpoint profile has calculated a RBOS#_Setpoint, the result is minimum-selected against the
firmware overspeed output from the rest of the firmware overspeed logic if the RBOS feature is enabled (RBOS#_Enab). This
final selected overspeed setpoint (OS_Setpoint_PR#) is compared against the PulseRate# shaft speed to drive an overspeed
trip. It is also available to the user in signal space as OS#_Setpoint_Fbk.
Note Refer to the section Parameters for details on configuration parameters for the RBOS feature, and the section
Variables Vars-Speed for details on RBOS I/O signals.
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7.1.3.6
Hardware Overspeed Trip
The following pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP. OSHW_
Setpoint only goes into the hardware at I/O pack startup.
OSHW_ Setpoint #, SS
A
|A- B|
Generate an alarm if the hardware is
different than the firmware trip
A
OSHW _ Setpoint ,CFG
OS # HW_ SP_ CfgEr ( SS)
B
A> B
(PulseRate #)
1RPM
OS_ Setpoint
HW Value
B
Generate an alarm if the hardware
setpoint changes after power - on
OS # HW_ SP_ Pend ( SS)
A
| A- B|
B
PulseRate #,
HWIO
A
A> =B
OS # HW
B
Hardware
OS# HW
OS # HW _Trip
Overspeed
Trip
( SS )
OS # HW _Trip, ( SS)
L 86MRX
Speed#Updating
Hardware Overspeed Trip, HP Shaft
Note Refer to the section Shaft Speed Accel, Decel, and Zero for the definition of Speed#Updating.
PPRO, YPRO Backup Turbine Protection
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Hardware Overspeed Trip functions include:
•
•
Load the independent hardware overspeed set point only when the I/O pack restarts or is power cycled
Generate an alarm when the hardware configuration set point is >1 Hz different from the value passed through signal
space from the application configuration
Note Hardware overspeed detection involves two rotations of the shaft to determine an overspeed condition.
•
Generate an alarm and signal space Boolean when the set point in configuration fails to match the value stored in the
hardware
•
•
Implement speed calculation and the trip logic entirely inside programmable logic
Overspeed trip response typically less than 60 ms at normal operating speeds
Note There is no separate enable or disable signal for this overspeed protection. The disable signal is created by setting a
high overspeed point value. The calculated speed will never reach the value needed to trigger OS1HW.
The actual hardware implementation depends on two configuration items:
•
•
OSHW_Setpoint specifies the overspeed trip level in RPM.
PRScale determines the number of speed sensor pulses per revolution used to convert pulse rate into RPM for both
hardware and firmware overspeed value.
The hardware implementation requires two adjacent revolutions exceeding the OSHW_Setpoint to trip the system. When a
trip is present, the setting of OSHW_Setpoint is reduced by a small amount in the hardware to provide a clean trip signal. Due
to this reduction, speed must be reduced well below the overspeed threshold before a reset may take place. Because there are
set limits to the time integration used in the hardware detector, the minimum RPM setting for the OSHW_Setpoint is
approximately four RPM.
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7.1.3.7
LP Shaft Locked Detection
This is another protection function that is in addition to the overspeed protection. LP Shaft Locked Detection generates a
signal if the first pulse rate signal is above minimum speed, and the second pulse rate signal is still at zero.
PR1_MIN
PR2_Zero, (SS)
LockRotorByp, SS
LPShaftLock, (SS)
LPShaftLock, (SS)
L86MR, SS
LP Shaft Locked Detection
7.1.3.8
E-Stop
The I/O pack monitors the E-Stop trip signal that is present on the TREG or TREA terminal boards and uses it to cross trip
the main control in the event E-Stop is invoked. It is also used within the pack logic as part of the trip relay output command.
The relays are not required to close if the E-Stop signal is present. The main control counterpart is also present. If the main
control votes to trip, it can also cross-trip the corresponding I/O pack.
J3= TREA TRIPENAB, CFG
KESTOP1_ Fdbk , ( SS)
Hw Estop1 , IO
J3= TREG
L5 ESTOP1 , (SS)
KESTOP1_ Fdbk , ( SS)
ESTOP1
TRIP
L5 ESTOP1 , (SS)
L86MR , SS
Contact Input E-Stop
Note There are several inversions in the hardware signal path, but the end result is that KESTOP#_Fdbk is only a 1 when
E-Stop is energized. Therefore, 1 = OK. The TREL and TRES terminal boards do not have E-Stop capability because it is on
the primary trip boards TRPL and TRPS.
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7.1.3.9
Speed Difference Detection
There should never be a reason why the speed calculated by the I/O pack is significantly different from the speed calculated
by the main control. Speed difference detection looks at the difference in magnitude between pulse rate 1 from both the pack
and the main control. If the difference is greater than the set threshold for three successive samples, a SpeedDifTrip is latched.
If the main control recovers for 60 seconds, the trip is removed. This allows the main control to recover with subsequent
re-arming of the backup protection.
IO Frame Rate
Speed 1 , SS
PulseRate1
(RPM) , IO
A
|A - B |
B
-0
Z
A
-1
Z
B (A & B & C)
-2
Z
C
A
A >B
OS_Diff, CFG (%) Rated RPM_TA,
*
B
CFG (RPM)
100
Speed 1_ Diff
PulseRate 1 ( Hz) , IO
A
Shaft Turning
A >B
75 Hz
B
1 Second Delay
SpeedDifEn , Card CFG
SpeedDiff _ Trip
Speed 1_ Diff
SpeedDiff _ Trip
Enable
Enable
L 86 MR , SS
Speed 1_ Diff
Close immediately , 60 sec delay on opening
Speed
Difference
Trip
When configured for dual controller, additional logic is added so that separate speed inputs from the two controllers come into
the I/O pack. This trip logic acts as if both controllers have a speed error, but continues to run if one controller has a valid
speed signal.
7.1.3.10
Maximum Speed Hold
The I/O pack provides a maximum speed hold function that resets when:
•
•
Using the command PR_Max_RST (from signal space)
PR1_Zero changes to false when the shaft first starts turning
Output values are PR1_Max, PR2_Max, and PR3_Max. These signals are used to determine the maximum speed obtained
while running or after stopping a turbine.
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7.1.3.11 Overspeed Test Logic, Steam Turbine
The signal OnLineOS1Tst is used for PulseRate1, OnLineOS2Tst is used for PulseRate2, and OnLineOS3Tst is used for
PulseRate3. In the following figure, there is another signal, Online OS1X, which initiates an online overspeed test for
PulseRate1. This signal also creates a 1.5 second reset pulse when removed.
Online Overspeed Test Logic
Note If the K4CL relay is enabled during an online Overspeed test, use the OnlineOS1X option and not the OnlineOS1Tst.
This will avoid an unwanted K4CL activation.
7.1.3.12
Speed State Boolean Values
The I/O pack has detection for zero speed from a set point with 1 RPM hysteresis. The I/O pack calculates a minimum speed
signal from a set point. The rate of change of speed from a set point is calculated resulting in a selectable acceleration trip. A
deceleration trip is then determined from a fixed 100% / second rate.
PPRO, YPRO Backup Turbine Protection
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7.1.3.13
Shaft Speed Accel, Decel and Zero
The I/O pack has detection for zero speed from a set point with 1 RPM hysteresis. The I/O pack calculates a minimum speed
signal from a set point. The rate of change of speed from a set point is calculated, resulting in a selectable acceleration trip. A
deceleration trip is then determined from a fixed 100% / second rate.
The acceleration for a given pulse rate (PR#_Accel) is calculated by computing two adjacent shaft speeds over a period of
AccelCalType ms each by computing change in pulse counts, and then computing the difference in these speeds divided by
AccelCalType ms to get the acceleration of the shaft.
In the following figures, pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP.
This figure is the same for PulseRate1, 2, and 3. Simply replace the 1 with a 2 or 3 to get the signal name. The contact, PR#_
Min, in the Acc1_Trip is only present for PR2 (PR2_Min) and PR3 (PR3_Min). It is not used for PR1.
Speed State Boolean Values
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The pulse rate inputs have special detection for loss of signal, and special filtering to remove input noise from nearly
stationary shaft speeds.
PulseRate #, IO
Speed Wheel Pulse
Detected Window
Inactive Counter
Based on last speed
(Maximum 24
seconds )
(Pulse Rates in Hz )
Speed #Updating
Shaft # Turning
A
Allow Accel /
Decel Trip
A > B
75 Hz
Speed
Updating
Normally
B
1 Second Delay
1 **
Speed # Updating
†
Shaft # Turning
Decel #Trip
Decel #Trip
Loss of
Pulse Rate
†
can only be reset when
Speed #Updating becomes True
(pulses are able to be seen ) or
after the I/O pack is rebooted
** 1 = Normal Operation
Pulse Rate Conditioning
PPRO, YPRO Backup Turbine Protection
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Decel#Trip
PulseRate#
(RPM)
PR#_DEC
A
(From GearSpeed)
A
B
A<B
-100%/SEC**
S
(Der)
0 %/Sec
OR
Speed#Updating
B
Shaft#Turning
%/Sec
PR#_ACC
A
AND
A
B
A>B
Acc_Setpoint, CFG (J5, PulseRate#)
B
Dec#_Trip, (SS)
PR#_DEC
Dec#_Trip
L86MR,SS
Acc_Trip, CFG (J5, PulseRate#)
PR#_ACC
PR#_MIN **
Acc#_Trip
L86MR,SS
Enable
Acc#_TrEnab
Acc#_Trip, (SS)
HP, IP and LP Shaft Accel Decel Trip Logic
Note: PR#_MIN is not used on ACC1_Trip.
PR2_Min is used on ACC2_Trip and
PR3_Min is used on ACC3_Trip.
**Note: Where 100% is defined as the OS Setpoint.
Shaft Speed Accel, Decel and Zero
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7.1.3.14
Trip Anticipate Function
Steam turbine applications provide a speed trip that uses a live set point from signal space. This overspeed trip is vigorously
changed as a function of turbine load. This function does the following:
•
•
•
•
•
Input set point is OS1_TATrpSp from signal space. Input rated RPM is specified by RatedRPM_TA as part of the I/O
pack configuration. Function test request input is TrpAntcptTst from signal space.
If (OS1_TATrpSP is < 103.5% OR > 116% of RatedRPM_TA) then TA_Spd_Sp (the local set point value) = 106% of
RatedRPM_TA and TA_StptLoss (Signal space) is true and alarm L30TA is declared. Otherwise, TA_Spd_Sp = OS1_
TATrpSP.
If TrpAntcptTst is true, decrease the current value of TA_Spd_Sp by 1RPM / second. Set the minimum value of
RatedRPM_TA to 94%. If TrpAntcptTst is false, the value of TA_Spd_Sp from above is immediately used.
If PulseRate1 (Speed input 1 from the pulse rate input) > TA_Spd_Sp the internal value Trp_Anticptr is set properly.
If the I/O pack is configured for steam turbine application (internal value SteamTurbOnly), then TA_Trip (signal space)
equals the value of Trp_Anticptr.
Note The I/O pack mounted on a TREA does not toggle the relays for trip anticipate function.
PPRO, YPRO Backup Turbine Protection
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7.1.3.15
Solenoid Voltage / Power Sense
The I/O pack provides three comparator voltage inputs used to monitor solenoid power or solenoid voltage depending on the
trip card that is connected. SOL1_Vfdbk (SS), SOL2_Vfdbk (SS), and SOL3_Vfdbk (SS) are generated from the input
signals.
7.1.3.16
Main Control Watchdog
A standard control watchdog function is provided by the I/O pack. In this function, a value from a Device Heartbeat
(DEVICE_HB) block is passed from the main controller to the I/O pack each data frame. If the I/O pack stops detecting the
value from the main controller, a counter is incremented and, after five data frames, leads to a trip. If the main controller
recovers for 60 seconds, the trip is removed, allowing for the recovery of the main controller with subsequent re-arming of the
backup protection. The recovery function is provided for typical activities such as cycling power on a controller to perform
maintenance.
While the controller is offline, the I/O pack associated with that controller will vote to trip. When the controller returns to
operation, the I/O pack will remove the vote to trip. The watchdog offers monitoring of two main controllers in the event both
Ethernet ports are connected. When configured for two controllers, having one controller active is sufficient to prevent a trip.
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7.1.3.17
Stale Speed Detection
The I/O pack provides an additional main control watchdog function that is based on a live speed signal. The protection works
as follows: If the pack PulseRate1 is determined to be zero speed the protection is turned off. If above zero speed, the pack
looks at the value of Speed1 from the main control. If the most recent Speed1 value exactly matches the Speed1 value from
the last data frame then a counter is incremented. If the counter reaches a threshold then a stale speed trip is declared and
latched. If speeds are different the counter is cleared.
Although Speed_1, SS is available as a connected variable, it should not be forced. It
can cause the protection to trip the system if enabled.
Attention
This protection is based on the knowledge that a live speed signal always dithers or moves some small amount. If the speed
values being read by PPRO from the controller are not changing (dithering), there is loss of speed signal integrity from the
controller. If the main control recovers for 60 seconds, the trip is removed allowing for the recovery of the main control with
subsequent re-arming of the backup protection. The protection offers monitoring of two main controls in the event both
Ethernet ports are connected. When configured for two controls, having one control satisfy the test is sufficient to prevent a
trip.
PPRO, YPRO Backup Turbine Protection
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7.1.3.18
Main Control Ethernet Monitor
The main control provides time synchronization across the distributed control elements. The time synchronization is tied
tightly into the time at which traffic occurs on a given controller's IONet. The I/O pack provides monitoring of this service to
ensure it is working correctly. Gross errors in time synchronization are detected by the pack through a number of different
means, and if problems persist, the I/O pack will vote to trip. Once the trip is latched, if the problem goes away for 60 seconds
the trip shall be reset (this assumes the control recovers from the problem and is back on line). The monitor will offer
monitoring of two main controls in the event both Ethernet ports are connected. When configured for two controls, having
one control sequencing correctly is sufficient to prevent a trip.
In the following diagram, the detection has been simplified to display monitoring of an Ethernet frame number as the means
for determining a problem is present.
Sync Frame Count Monitor
7.1.3.19
Trip Signal Logic
The different trip signals are combined into a composite signal that is used in the relay output logic. The following figure
specifies how the signals are combined. This function is partitioned between firmware and programmable logic. The path to
trip through hardware overspeed is done completely in hardware so that a firmware malfunction cannot defeat the protection.
The same is true of the contact input trip signals when they are configured for direct trip.
There are differences between steam turbine protection and other protection. A composite signal SteamTurbOnly is created
for ease of use:
LargeSteam **
MediumSteam **
SmallSteam **
** A number of contacts depend on
the value of Turbine _Type, CFG.
SteamTurbOnly
Steam Turbine Trip Signals
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Dec1_Trip
OS1_Trip
PulseRate1
Trips
Acc1_Trip
L5CFG1_Trip
Dec2_Trip
OS2_Trip
1
GT_2Shaft
PulseRate2
Trips
Acc2_Trip
L5CFG2_Trip
LM_2Shaft1
1
LPShaftLock
LM_3Shaft
ComposTrip1,
(SS)
Dec3_Trip
OS3_Trip
PulseRate3
Trips
1
LM_3Shaftf
Acc3_Trip
L5CFG3_Trip
L5Cont_Trip
SpeedDiff_Trip
System
Trips
Cross_Trip, SS
StaleSpdTrip
ContWdogTrip
FrameSyncTrip
Sil_Diag_Trip
2
1
LM_2Shaft
1
LM_3Shaft
LMTripZEnable, CFG
PR1_Zero
HPZeroSpdByp
SS
1
SteamTurbOnly
Zero
Speed
Special
Case
L3Z
Hardware
Overspeed
OS1HW_Trip
OS2HW_Trip
OS3HW_Trip
1
Notes: CFG values.
2
This trip is generated if a PulseRate signal is broken (such as in the case of no
signal) and SilMode is set to enabled, or if a hardware issue is detected
regardless of SilMode. There will be an accompanying diagnostic generated to
designate the actual cause of the trip.
Trip Combine - All Signals (SS) unless Marked
PPRO, YPRO Backup Turbine Protection
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7.1.3.20
Watchdog Trip Function
Hardware in the I/O pack monitors local firmware operation, providing a watchdog trip function if the firmware malfunctions.
The operation of this watchdog does not display in the normal sequencing figures. The I/O pack hardware is designed to be in
a fail-safe or trip mode if it is not properly configured and operating. This means that with power off, while starting up, when
in a hardware reset, or otherwise not online, the I/O pack will vote to trip. If the I/O pack watchdog acts, it resets the hardware
thereby generating a vote to trip.
The processor board used inside the I/O pack has hardware features that allow it to differentiate between a reset caused by the
watchdog hardware and a reset caused by cycling of power. This information is available from the pack after it restarts. In the
event that an I/O pack votes to trip due to a reset, it is then possible to determine if a watchdog reset or a cycling of control
power caused the event.
7.1.3.21
Backup Synchronizing Check
The Mark VIeS YPRO or Mark VIe PPRO provides two PT inputs and performs a backup synchronizing check. The TPRO
has fanned PT inputs. The SPRO does not use fanned PT inputs because there are three direct PT paths.
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Generator Synchronizing with TPRO
TTUR Cont’d
TTURH 1C
Generator,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 Hz
R PTUR
17
P3
PR 3
(0.1 Hz)
Fan out
connection
PS3
to S
19
20
Phase
+10 Deg
Gen lag
Gen lead
PT3
to T
2/3
RD
(0.25 Hz)
+0.12 Hz
18
Bus,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 V Hz
Slip
P3
+0.3 Hz Cont’d
PR3
Cont’d
Auto Synch
Algorithm
S PTUR
P28
K25P
01
K25
T
2/3
RD S
K25A
P125/24 V dc
From JR 4
03
K25P
02
L52Ga
JT4
CB_ Volts_OK
04
K25
CB_K25P_PU
L52G
05
K25A
CB_K25_PU
52Gb
07
T PTUR
JS4
06
CB_K25A_PU
08
Breaker
Close
Coil
JR4
N125 /24 V dc
JT1
Generator,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 Hz
1
JS1
2
Bus,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 V Hz
TRPG / TRPL / TRPS
JR1
Fan out
connection
3
J2
4
J2
TREG / TREL / TRES
R PPRO
Sync Check
Slip Algorithm
2/3
RD
TPRO
TPROH1C
JR1
JX1
JX1
JS1
JY1
JY1
JT1
JZ1
JZ1
K25A
Relay
Driver
+0.3 Hz
-10 Deg +10 Deg Phase
-0.3 Hz
S
T
PPRO
PPRO
PPRO, YPRO Backup Turbine Protection
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Generator Synchronizing with SPRO
TTUR
Generator
PT secondary
Nomin . 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
nomin. 115 V ac
( 75 to 130 V ac)
45 to 66 Hz
R YTUR
17
PR3
18
19
Fan out
connection
PS3
to S
20
P3
Cont’d
+0.3 Hz
Slip
(0.25Hz)
P3
+0. 12 Hz
(0.1Hz)
Phase
+ 10 Deg
Gen lag
Gen lead
Auto Synch
Algorithm
PT 3
to T
S Y TUR
T Y TUR
PR3
Cont’d
01
TTUR
P28 Cont’d
K 25 P
K25
T
2 /3 2/ 3
RD
RD S
JT 4
JS 4
P125 /24 V dc
From JR 4
Volt
02 CB_ s _OK
L 52 Ga
K25 A
CB_K25P_PU
L52 G
CB_K25_PU
03
K 25P
04
K 25
K 25 A
05
06
07
CB_K25A_PU
08
JR4
52 Gb
Breaker
Close
Coil
N 125 /24 V dc
JT1
JS1
TRPG
JR1
J2
J2
JA 3
JX1
2/3
RD
Generator
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
Nomin .115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Generator
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Generator
PT secondary
Nomin . 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
270
R
K25 A
Relay
Driver
SPRO
1
R
2
Sync Check
Slip
Algorithm
+0.3 Hz
Fan out
3 connection
YPRO
JA1
-10 Deg +10 Deg
-0.3 Hz
4
Phase
TREG
JY 1
1
S
JA3
SPRO
2
Fan out
3 connection
S
4
1
YPRO
JA1
T
JZ 1
JA 3
SPRO
2
Fan out
3 connection
T
4
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7.1.3.22
K25A Sync Check Function
The K25A sync check function is based on phase lock loop techniques. The PPRO or YPRO performs the calculations for this
function with interfaces to the breaker close circuit located on the TTUR board (not TPRO or SPRO). Its basic function is to
monitor two Potential Transformer (PT) inputs, and to calculate generator and bus voltage amplitudes and frequencies, phase,
and slip.
When it is armed (enabled) from the application code, and when the calculations determine that the input variables are within
the requirements, the relay K25A will be energized. The above limits are configurable. The algorithm uses the phase lock loop
technique to derive the above input variables, and has a bypass function to provide dead bus closures. The window in this
algorithm is the current window, not the projected window (as used on the auto sync function), therefore it does not include
anticipation. Limit checks are performed against adjustable constants as follows:
•
•
•
•
•
Generator under-voltage
Bus under-voltage
Voltage error
Frequency error (slip), with a maximum recommended value of 0.5 Hz, typically set to 0.27 Hz
Phase error with a maximum rotational value of 30°, typically set to 10°.
PPRO, YPRO Backup Turbine Protection
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The sync check arms logic to enable the function and provides bypass logic for dead bus closure. The following sync window
is based on typical settings.
Typical Sync Window
The PPRO or YPRO provides a command to monitor feedback for the K25A sync relay and K25A coil. The feedback is
named K25A_Fdbk, (SS).
Sync Check and K25A Sync Relay Command
The Sync Check will allow the breaker to close with negative slip. The window is configurable for phase and slip.
The following diagnostics relating to the auto sync function are generated by the PPRO or YPRO:
•
•
272
K25A Relay (sync check) Driver mismatch requested state. This means the PPRO or YPRO cannot establish a current
path to the TREx terminal board.
K25A Relay (sync check) Coil trouble, cabling to P28 V on TTUR. This means the K25A relay is not functional; it could
be due to an open circuit between the TREx and the TTUR terminal boards or to a missing P28 V source on the TTUR
terminal board.
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7.1.3.23
K25A Relay Algorithm
The following figure displays the logic for K25A Relay from the Mark VIeS YPRO, which is the same as from the Mark VIe
PPRO.
Signal Space, Outputs;
Algorithm Inputs
YPRO Config
SynchCheck
SystemFreq
FreqDiff
TurbRPM
PhaseDiff
* ReferFreq
used/ unused
L3_Window
Slip
PR_Std
+0. 3 Hz
+ 10 Deg
Phase
PR1/PR2
SPRO
Gen Lag
Signal Space, inputs;
Algorithm Outputs
Gen Lead
DriveFreq
center freq
1
Generator,
PT secondary 2
BusFreq
GenFreq
GenVoltsDiff
GenFreqDiff
GenPhaseDiff
Phase Lock Loop
Phase, Slip, Freq,
Amplitude
Calculations
3
Bus,
PT secondary 4
L25A_Command
GenVoltsDiff
VoltageDiff
GenVoltage
2.8
GenVolts
6.9
BusVolts
BusVoltage
6.9
A
A
|A|<B
B
OR
B
A
A> B
B
L3_GenVolts
A
A> B
B
L3_BusVolts
SynCk_Perm
SynCk_ByPass
AND
C
D
L3_GenVolts
L3_BusVolts
A
B
A
B
C
AND
D
E
Dead Bus
NOT
A
OR
L25A _ Command
B
TREG
TRPG
Y TUR
RD
TTUR
K25A
Note *ReferFreq is a configuration parameter, used to make a selection of the variable that is used to establish the center
frequency of the Phase Lock Loop. It allows a choice between:
•
PR_Std
– Using PulseRate1 speed input on a single shaft applications
– Using PulseRate2 on all multiple shaft applications
• SgSpace uses DriveFreq (the generator frequency in Hz) from signal space
PR_Std is not applicable.
(application code). SgSpace is used when
PPRO, YPRO Backup Turbine Protection
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7.1.3.24
Servo Suicide Relay Command
The I/O pack provides a command to a servo suicide relay, and provides coil-monitoring feedback named K4CL_Fdbk, (SS).
This signal is typically used in a simplex control of a gas turbine system where it is highly desirable for the pack emergency
protection to have a hardware path to close the fuel valves. It is also used in simplex steam turbines to close the steam valves.
Servo Suicide Relay Command
Note If the K4CL relay is enabled during an online Overspeed test, use the OnlineOS1X option and not the OnlineOS1Tst.
This will avoid an unwanted K4CL activation.
7.1.3.25
Trip and Economizing Relay Outputs
The I/O pack provides drivers for three emergency trip relay commands, and provides monitoring for three status feedback
signals. Trip is a combination of firmware trip and direct trip implemented in programmable logic. The pack contains drivers
for three economizing relay commands and monitoring for three status feedback signals. Economizing relays are used when it
is desirable to introduce some series resistance in a solenoid coil path to reduce current once the solenoid is picked up.
Note YPROs or PPROs mounted on TREA terminal boards have TA_Trip_Enab# set by default to Disable and this
parameter is not configurable.
The reset signal applied to this function is not edge triggered. A continuously applied reset can result in output cycling in the
presence of an intermittent trip signal. The duration of the reset should only be sufficient to allow the reset to complete and
should not be maintained. Logic for the economizing relay drivers is a time-delayed copy of the emergency trip relays as
displayed in the following figure.
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In
FPGA
TA_Trip, (SS)
TestETR1 ComposTrip1 ETR1_Enab
SS
(SS)
CFG, K1_Fdbk
L5ESTOP1(SS)
TA_Trip_Enabl1
CFG (PPRO)
ETR1 (IO)
Trip Relay,
Energize to Run
TRES, TREL Used
In
Firmware
ETR1
SOL1_Vfdbk
KE1_Enab
IO (SS)
CFG, KE1_Fdbk
TD_KE1
In
Firmware
2 Second Delay on
Pickup
KE1 (IO)
Economizing Relay,
Energize to Econ
TD_KE1
In
FPGA
TA_Trip(SS)
TestETR2 ComposTrip1 ETR2_Enab
SS
(SS)
CFG, K2_Fdbk
TA_Trip_Enabl2
CFG (PPRO)
L5ESTOP1(SS)
ETR2 (IO)
Trip Relay,
Energize to Run
TRES, TREL Used
In
Firmware
ETR2
SOL2_Vfdbk
KE2_Enab
IO (SS)
CFG, KE2_Fdbk
TD_KE2
In
Firmware
2 Second Delay on
Pickup
KE2 (IO)
TD_KE2
Economizing Relay,
Energize to Econ
L97EOST_ONLZ
Large Steam
CFG
In
FPGA
TA_Trip(SS)
ComposTrip1 TestETR 3
(SS)
SS
TA_Trip_Enabl3
CFG (PPRO)
ETR3_Enab
CFG, K3_Fdbk
L5ESTOP1(SS)
ETR3 (IO)
Trip Relay,
Energize to Run
TRES, TREL Used
In
Firmware
ETR3
SOL3_Vfdbk
KE3_Enab
IO (SS)
CFG, KE3_Fdbk
2 Second Delay on
Pickup
TD_KE3
In
Firmware
KE3 (IO)
Economizing Relay,
Energize to Econ,
TD_KE3
Note: TREL and TRES do not have economizing relays so the KE1, KE2, and KE3 drivers are
not used when those boards are configured. Estop is only on TREG so it is bypassed when
driving ETR1-3 with TREL and TRES.
Trip and Economizing Relay Outputs
PPRO, YPRO Backup Turbine Protection
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7.1.4 Specifications
Item
PPRO Specification
Speed Input Quantity
Three input signals provided
Speed input Range
Pulse rate frequency range 2 Hz to 20 kHz
Speed Input Accuracy
Pulse rate accuracy 0.05% of reading
Speed Input Sensitivity
Speed input sensitivity is such that
turning gear speed may be observed on
a typical turbine application.
Generator and Bus Voltage Inputs
Frame Rate
Pulse Duration Limitation
Size
Technology
† Ambient rating for enclosure design
Seismic
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 27 mV p-p (TREA, SPRO, TPRO)
20 kHz requires 294 mV p-p (TREA)
20 kHz requires 276 mV p-p (SPRO, TPRO)
Input voltage range 75 to 127 V rms. Loading less than 3 VA.
Frequency accuracy 0.05% over 45 to 66 Hz range.
100 Hz maximum
Trip contact input can only be detected if the pulse contact is greater than 8 ms.
8.26 cm high x 4.19 cm wide (3.25 in x 1.65 in x 4.78 in)
Surface-mount
PPROS1B is rated from -40 to 70ºC (-40 to 158 ºF)
PPROH1A is rated from -30 to 65ºC (-22 to 149 ºF)
† Refer to GEH-6721_Vol_I, the chapter Technical Regulations, Standards, and
Environments.
Vibration
Universal Building Code (UBC) – Seismic Code section 2312 Zone 4 with operation
without trip
Shipping (by road)
Bellcore GR-63-CORE Issue 1, 1995 0.5 g, 5-100 Hz, 10 min. per octave, 1
sweep/axis x 3 axes, ~ 42 min./axis
3 shocks of 15 g, 2 ms impulse each repeated for all axes
Operating at site
1.0 g horizontal. 0.5 g vertical at 15 to 120 Hz
IEC 60721-3-2
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Agency Approvals
Type
Standards
Safety
UL 508A Safety Standard Industrial Control Equipment
CSA 22.2 No. 14 Industrial Control Equipment
EN 61010-1 Safety of Electrical Equipment, Industrial Machines (Low Voltage
Directive)
Printed Wire Board Assemblies
UL 796 Printed Circuit Boards
UL recognized Board manufacturer
ANSI IPC guidelines
ANSI IPC/EIA guidelines
Electromagnetic Compatibility (EMC)
EN 61000-4-2 Electrostatic Discharge Susceptibility
EN 6100 4-3 (ENV 50140) Radiated RF Immunity
EN 61000-6-2 Generic Immunity Industrial Environment
EN 61000-4-4 Electrical Fast Transient Susceptibility
EN 61000-4-5 Surge Immunity
EN 61000-4-6 Conducted RF Immunity
EN 55011 Radiated and Conducted RF Emissions
ANSI/IEEE C37.90.1 Surge
7.1.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the analog feedback currents
A comparison between the commanded state of each relay drive and the feedback from the commanded output circuit
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RESET_DIA signal if they go health.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 277
Non-Public Information
7.1.5.1
PPRO Trip Status
During normal I/O pack operation, all six trip application LEDs display green. An additional feature, rotating LEDs, can be
configured for the I/O pack. Using this feature, only one LED is turned on at a time, and walked up and down the six LEDs
creating a synchronized motion. The walking is regulated by the controller IONet, and synchronized across a set of three I/O
packs. This provides a quick visual indication of the system time synchronization status. There are six LEDs on the front left
side of the I/O pack to indicate trip status. All six LEDs stay off until the I/O pack is completely online.
RUN is green any time the I/O pack has energized the emergency trip relays. RUN turns red any time the I/O pack has
removed power from the emergency trip relays, voting to trip.
ESTP is green when the ESTOP input (if applicable) is in the run state. ESTP turns red any time ESTOP is invoked to
prevent pick up of the emergency trip relays. If the selected trip terminal board does not support ESTOP, then the LED
defaults to green.
OSPD turns red any time the I/O pack votes to trip in response to a detected overspeed condition on any of the three speed
inputs. OSPD is green when an overspeed condition is not present or latched.
Note WDOG turns green to indicate that the trip status of any of these features has been cleared.
WDOG turns red when any of the following I/O pack trip functions are enabled and active:
•
•
•
•
Control Watchdog
Speed Difference Detection
Stale Speed Detection
Frame Sync Monitor
SYNC is green when generator and bus voltage is synchronized and matched in amplitude. SYNC turns red when the I/O
pack determines that ac bus and generator bus voltage does not satisfy the synchronization requirements, and synchronization
has been requested by the system.
OPT is reserved for options that expand the capabilities of the I/O pack. The default display is green.
278
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7.1.6 Configuration
The following subsections (Parameters, Pulse Rate, PT, K25A, and so forth) define the choices within the tabs of the
ToolboxST configuration.
7.1.6.1
Parameters
Description
Choices
TurbineType
Turbine Type and Trip Solenoid configuration
Unused, GT_1Shaft, LM_3Shaft,
MediumSteam, SmallSteam,GT_2Shaft,
Stag_GT_1Sh,Stag_GT_2Sh,
LargeSteam, LM_2Shaft
LMTripZEnabl
On LM machine, when no PR on Z,Enable a vote for
trip
Disable, Enable
TA_Trp_Enab1
Steam, enable trip anticipate on ETR1
† Disable, Enable
TA_Trp_Enab2
Steam, enable trip anticipate on ETR2
† Disable, Enable
TA_Trp_Enab3
Steam, enable trip anticipate on ETR3
† Disable, Enable
StaleSpdEn
Enable trip on speed from controller freezing
Disable, Enable
Parameter
SpeedDifEn
DiagSolPwrA
DiagSolPwrB
DiagSolPwrC
RotateLeds
Enable trip on speed difference between controller
Disable, Enable
and PPRO
When using TREL/TRES, sol power, bus A, diagnostic
Disable, Enable
enable
When using TREL/TRES, sol power, bus B, diagnostic
Disable, Enable
enable
When using TREL/TRES, sol power, bus C, diagnostic
Disable, Enable
enable
Disable, Enable
Rotate the status LEDs if all status are OK
LedDiags is
disabled by
default.
LedDiags
Attention
Disable, Enable
When enabled, generates a diagnostic alarm when
Trip LEDs are lit. Refer to the section, Diagnostics,
PPRO Trip Status for more information on LED
operation.
SilMode
Perform additional SIL diagnostic and trip checks
RatedRPM_TA
Rated RPM, used for trip anticipater and for speed diff
0 to 20,000
protection
Disable, Enable
AccelCalType
Select acceleration calculation time (milliseconds)
10 to 100
OS_Diff
Absolute speed difference in percent for trip threshold
0 to 10
RBOS1_Enab
HP Rate-based Overspeed enable
Disable, Enable
‡ RBOS1_AccelSetptn,
HP Rate-based Overspeed acceleration setpoint n,
RPM/s
0 to 20,000
HP Rate-based Overspeed setpoint n, RPM
0 to 20,000
LP Rate-based Overspeed enable
Disable, Enable
LP Rate-based Overspeed acceleration setpoint n,
RPM/s
0 to 20,000
n=1-5
‡ RBOS1_OSSetptn, n=
1-5
RBOS2_Enab
‡ RBOS2_AccelSetptn,
n=1-5
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 279
Non-Public Information
Parameter
‡ RBOS2_OSSetptn, n=
1-5
RBOS3_Enab
Description
Choices
LP Rate-based Overspeed setpoint n, RPM
0 to 20,000
IP Rate-based Overspeed enable
Disable, Enable
‡ RBOS3_AccelSetptn,
IP Rate-based Overspeed acceleration setpoint n,
0 to 20,000
n=1-5
RPM/s
‡ RBOS3_OSSetptn, n=
IP Rate-based Overspeed setpoint n, RPM
0 to 20,000
1-5
† PPROs mounted on TREA terminal boards have TA_Trp_Enab# set by default to Disable and this parameter is not
configurable.
‡ RBOS setpoints have restrictions in their relative values. Refer to the section RBOS Parameter Restrictions for further
details.
7.1.6.2
RBOS Parameter Restrictions
The following restrictions apply to the relative values of RBOS setpoints (within a given shaft):
1.
RBOS#_AccelSetpts must increase in value by at least 0.1 RPM/s (RBOS1_AccelSetpt2 must be 0.1 RPM/s or greater
than RBOS1_AccelSetpt1). This prevents an infinite slope calculation in the overspeed setpoint profile.
2.
RBOS#_OSSetpts must be either equal to or less than the previous entry (RBOS1_OSSetpt2 must be less than or equal to
RBOS1_OSSetpt1). This ensures the functionality of the RBOS feature in that as Acceleration increases the RBOS
overspeed setpoint either stays the same or decreases, but never increases.
These restrictions are enforced by the build in ToolboxST, with errors that provide help to the user to identify the issues in
their configuration.
7.1.6.3
Pulse Rate (used on SPRO, TPRO, TREA)
Parameter
Pulse Rate Description
Choices
PRType
Selects the type of Pulse Rate Input, (For Proper
Resolution)
Unused,Speed,Flow,Speed_LM,Speed_
High
PRScale
Pulses per Revolution (outputs RPM)
0 to 1,000
OSHW_Setpoint
Hardware Overspeed Trip Setpoint in RPM
0 to 20,000
OS_Setpoint
Overspeed Trip Setpoint in RPM
0 to 20,000
OS_Tst_Delta
Off Line Overspeed Test Setpoint Delta in RPM
-2,000 to 2,000
Zero_Speed
Zero Speed for this Shaft in RPM (1 RPM hysteresis), 0 to 20,000
0 RPM sets PR#_Zero always false
Min_Speed
Min Speed for this Shaft in RPM
0 to 20,000
Accel_Trip
Enable Acceleration Trip
Disable, Enable
Acc_Setpoint
Acceleration Trip Setpoint in RPM / Sec
0 to 20,000
TMR_DiffLimt
Diag Limit,TMR Input Vote Difference, in Eng Units
0 to 20,000
7.1.6.4
PT (used on TPRO, SPRO)
Parameter
Description
PT_Input
PT primary in Eng Units (kv or percent) for PT_Output 1 to 1000
Choices
PT_Output
PT Output in Volts rms for PT_Input - typically 115
0 to 150
TMR_DiffLimt
Diag Limit,TMR Input Vote Difference, in Eng Units
1 to 1000
280
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7.1.6.5
K25A (used on TREG, TRES, TREL)
Parameter
K25A Description
Choices
SynchCheck
Synch Check Relay K25A Used
Used, Unused
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
SystemFreq
System Frequency in hz
50 Hz, 60 Hz
ReferFreq
Select Freq Refer for PLL, PR_Std input (If single
shaft PR1, otherwise PR2) or from Signal Space
PR_Std or SgSpace
TurbRPM
Rated RPM, Load Turbine
0 to 20,000
VoltageDiff
Maximum Voltage Diff in Eng Units (kv or percent) for
Synchronizing
1 to 1000
FreqDiff
Maximum Frequency Difference in hz for
Synchronizing
0 to 0.5
PhaseDiff
Maximum Phase Difference in degrees for
Synchronizing
0 to 30
GenVoltage
Allowable Minimum Gen Voltage,Eng Units (kv or
percent) for Synchronizing. Typically 50% of rated
1 to 1000
BusVoltage
Allowable Minimum Bus Voltage,Eng Units (kv or
percent) for Synchronizing. Typically 50% of rated
1 to 1000
7.1.6.6
Contacts (used on TREG, TRES, TREL)
Parameter
Description
Choices
ContactInput
ContactInput
Used, Unused
SeqOfEvents
Record Contact transitions in Sequence of Events
Enable, Disable
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
TripMode
TripMode
Disable, Direct, Conditional
7.1.6.7
E-Stop (used on TREG)
Parameter
Description
Choices
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
7.1.6.8
E-Stop (used on TREA)
Parameter
Description
Choices
EstopEnab
Enable E-Stop Detection on TREA card
Enable, Disable
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
7.1.6.9
Econ Relays (used on TREG)
Parameter
Description
Choices
Signal
Relay Signal
Used, Unused
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 281
Non-Public Information
7.1.6.10
K4CL (used on TREG, TRES, TREL)
Parameter
Description
Choices
Signal
Relay Signal
Used, Unused
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
7.1.6.11 ETR Relays (used on TREA, TREG, TRES, TREL)
Parameter
Description
Choices
RelayOutput
Relay Signal
Used, Unused
DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
DiagSolEnab
Enable Solenoid Voltage Diagnostic
Enable, Disable
7.1.6.12
Variables PPRO
Variable
PPRO Variable Description
Direction
Type
L3DIAG_PPRO_R,S,T
I/O Diagnostic Indication
Input
BOOL
LINK_OK_PPRO_R,S,T
I/O Link Okay Indication
Input
BOOL
ATTN_PPRO_R,_S, and _T
I/O Attention Indication
Input
BOOL
PS18V_PPRO_R,_S, and _T
I/O 18 V Power Supply Indication Input
BOOL
PS28V_PPRO_R,_S, and _T
I/O 28 V Power Supply Indication Input
BOOL
IOPackTmpr_R,_S, and _T
I/O Pack Temperature (deg °F)
REAL
AnalogInput
K1FLT
K1 Shorted Contact Fault
Input
BOOL
K2FLT
K2 Shorted Contact Fault
Input
BOOL
SilModErr
Sil Mode Configuration
modification after going On Line
Input
BOOL
EstopModErr
E-Stop Configuration
modification after going On Line
Input
BOOL
TA_StptLoss
L30TA
Input
BOOL
GT_1Shaft
Input
BOOL
Input
BOOL
Input
BOOL
Input
BOOL
LargeSteam
Config – Gas Turb,1 Shaft
Enabled
Config – Gas Turb,2 Shaft
Enabled
Config – LM Turb,2 Shaft
Enabled
Config – LM Turb,3 Shaft
Enabled
Config – Large Steam 1, Enabled
Input
BOOL
MediumSteam
Config – Medium Steam Enabled Input
BOOL
SmallSteam
Config – Small Steam Enabled
Input
BOOL
Stag_GT_1Sh
Config – Stag 1 Shaft, Enabled
Input
BOOL
Stag_GT_2Sh
Config – Stag 2 Shaft, Enabled
Input
BOOL
L3SS_Comm
Communication Status - OK =
True
LL97LR_BYP - Locked Rotor
Bypass
Input
BOOL
Output
BOOL
L97ZSC_BYP - HP Zero Speed
Check Bypass
Output
BOOL
GT_2Shaft
LM_2Shaft
LM_3Shaft
LokdRotorByp
HPZeroSpdByp
282
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Variable
PPRO Variable Description
DriveFreq
Type
Terminal Boards
RefrFreq - Drive (Gen) Freq (Hz), AnalogOutput
used for non standard drive
config
REAL
TPRO, SPRO
Speed1
Shaft Speed 1 in RPM
AnalogOutput
REAL
ContWdog
Controller Watchdog Counter
Output
DINT
7.1.6.13
Direction
All
Variables Contacts
Variable
Contact Variable
Description
Direction
Type
Terminal Boards
Contact1
Contact Input 1
Input
BOOL
TREG, TRES, TREL
Contact2
Contact Input 2
Input
BOOL
TREG, TRES, TREL
Contact3
Contact Input 3
Input
BOOL
TREG, TRES, TREL
Contact4
Contact Input 4
Input
BOOL
TREG, TRES, TREL
Contact5
Contact Input 5
Input
BOOL
TREG, TRES, TREL
Contact6
Contact Input 6
Input
BOOL
TREG, TRES, TREL
Contact7
Contact Input 7
Input
BOOL
TREG, TRES, TREL
7.1.6.14
Variables Econ Relays
Variable
Econ Relay Variable
Description
Direction
Type
Terminal Boards
KE1_Fdbk
Current Economizing Relay for
Trip Solenoid 1
Input
BOOL
TREG
KE2_Fdbk
Current Economizing Relay for
Trip Solenoid 2
Input
BOOL
TREG
KE3_Fdbk
Current Economizing Relay for
Trip Solenoid 3
Input
BOOL
TREG
Type
Terminal Boards
Input
BOOL
TREG
Input
BOOL
TREA
7.1.6.15
Variables E-Stop
Variable
E-Stop Variable Description Direction
ESTOP1,inverse sense,K4 relay,
True = Run
KESTOP1_Fdbk
A SOE is generated for this
variable, requiring the attachment
of an application variable to this
signal. Otherwise, a build warning
is generated.
ESTOP1,inverse sense,True =
Run
KESTOP1_Fdbk
A SOE is generated for this
variable, requiring the attachment
of an application variable to this
signal. Otherwise, a build warning
is generated.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 283
Non-Public Information
7.1.6.16
Variables ETR Relays
Variable
ETR Relay Variable
Description
Direction
Type
Terminal Boards
K1_Fdbk
L4ETR1_FB, Trip Relay 1
Feedback
L4ETR2_FB, Trip Relay 2
Feedback
L4ETR3_FB, Trip Relay 3
Feedback
Input
BOOL
Input
BOOL
Input
BOOL
TREA, TREG, TRES,
TREL
TREA, TREG, TRES,
TREL
TREG, TRES, TREL
K2_Fdbk
K3_Fdbk
7.1.6.17
Variables Fanned-PR
Variable
Description
Direction
Type
Terminal Boards
Fan_Spd_Fbk
Fanned Speed Signal Feedback
:- Fanned = Jumpers Closed
Input
BOOL
TREA
7.1.6.18
Variables K25A
Variable
Description
Direction
Type
Terminal Boards
K25A_Fdbk
Synch Check Relay
Input
BOOL
TREG, TRES, TREL
When this is set to False, the
generator and bus potential
transformer (PT) live values are
disabled.
7.1.6.19
Variables K4CL
Variable
Description
Direction
Type
Terminal Boards
K4CL_Fdbk
Drive Control Valve Servos
Closed
Input
BOOL
TREG, TREL, TRES
Variable
Description
Direction
Type
Terminal Boards
BusPT_KVolts
Kilo-Volts RMS (Active only if
K25A is Enabled)
AnalogInput
REAL
TPRO, SPRO
GenPT_KVolts
Kilo-Volts RMS (Active only if
K25A is Enabled)
AnalogInput
REAL
TPRO, SPRO
7.1.6.20
7.1.6.21
Variables PT
Variables Pulse Rate
Variable
Description
Direction
Type
Terminal Boards
PulseRate1
HP speed
AnalogInput
REAL
TPRO, SPRO,TREA
PulseRate2
LP speed
AnalogInput
REAL
TPRO, SPRO,TREA
PulseRate3
IP speed
AnalogInput
REAL
TPRO, SPRO,TREA
284
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7.1.6.22
Variables Vars-CI
Variable
Vars-CI Variable Description Direction
Type
Terminal Boards
Cont1_TrEnab
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
BOOL
TREG, TRES, TREL
Trip1_Inhbt
Config – Contact 1 Trip Enabled – Input
Direct
Config – Contact 2 Trip Enabled – Input
Direct
Config – Contact 3 Trip Enabled – Input
Direct
Config – Contact 4 Trip Enabled – Input
Direct
Config – Contact 5 Trip Enabled – Input
Direct
Config – Contact 6 Trip Enabled – Input
Direct
Config – Contact 7 Trip Enabled – Input
Direct
Input
Trip Inhibit Signal Feedback for
Contact 1
Input
Trip Inhibit Signal Feedback for
Contact 2
Input
Trip Inhibit Signal Feedback for
Contact 3
Trip Inhibit Signal Feedback for
Input
Contact 4
Trip Inhibit Signal Feedback for
Input
Contact 5
Input
Trip Inhibit Signal Feedback for
Contact 6
Trip Inhibit Signal Feedback for
Input
Contact 7
Input
Contact 1 Trip Enabled –
Conditional
Input
Contact 2 Trip Enabled –
Conditional
Input
Contact 3 Trip Enabled –
Conditional
Input
Contact 4 Trip Enabled –
Conditional
Input
Contact 5 Trip Enabled –
Conditional
Input
Contact 6 Trip Enabled –
Conditional
Input
Contact 7 Trip Enabled –
Conditional
Contact 1 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Trip2_Inhbt
Contact 2 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Trip3_Inhbt
Contact 3 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Trip4_Inhbt
Contact 4 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Trip5_Inhbt
Contact 5 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Trip6_Inhbt
Contact 6 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Trip7_Inhbt
Contact 7 Trip Inhibit
Output
BOOL
TREG, TRES, TREL
Cont2_TrEnab
Cont3_TrEnab
Cont4_TrEnab
Cont5_TrEnab
Cont6_TrEnab
Cont7_TrEnab
Inhbt1_Fdbk
Inhbt2_Fdbk
Inhbt3_Fdbk
Inhbt4_Fdbk
Inhbt5_Fdbk
Inhbt6_Fdbk
Inhbt7_Fdbk
Trip1_EnCon
Trip2_EnCon
Trip3_EnCon
Trip4_EnCon
Trip5_EnCon
Trip6_EnCon
Trip7_EnCon
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 285
Non-Public Information
7.1.6.23
Variables Vars-Relay
Variable
Vars-Relay Variable
Description
Direction
Type
K1_FdbkNV_R,S,T
Non Voted L4ETR1_FB, Trip
Relay 1 Feedback
Input
BOOL
K2_FdbkNV_R,S,T
Non Voted L4ETR2_FB, Trip
Relay 2 Feedback
Input
BOOL
K3_FdbkNV_R,S,T
Non Voted L4ETR3_FB, Trip
Relay 3 Feedback
Input
BOOL
TREG, TRES, TREL
SOL1_Vfdbk
When TREG,Trip Solenoid 1
Voltage
Input
BOOL
TREG
SOL2_Vfdbk
When TREG,Trip Solenoid 2
Voltage
Input
BOOL
TREG
SOL3_Vfdbk
When TREG,Trip Solenoid 3
Voltage
Input
BOOL
TREG
ETR1_Enab
Config – ETR1 Relay Enabled
Input
BOOL
ETR2_Enab
Config – ETR2 Relay Enabled
Input
BOOL
ETR3_Enab
Config – ETR3 Relay Enabled
Input
BOOL
TREG, TRES, TREL
KE1_Enab
Config – Economizing Relay 1
Enabled
Config – Economizing Relay 2
Enabled
Config – Economizing Relay 3
Enabled
Config – Servo Clamp Relay
Enabled
Config – Synch Check Relay
Enabled
L20PTR1 - Primary Trip Relay
CMD vs. Voltage - a Mismatch
Diagnostic Monitor
Input
BOOL
TREG
Input
BOOL
TREG
Input
BOOL
TREG
Input
BOOL
TREG, TRES, TREL
Input
BOOL
TREG, TRES, TREL
Output
BOOL
PTR2
L20PTR2 - Primary Trip Relay
CMD vs. Voltage - a Mismatch
Diagnostic Monitor
Output
BOOL
PTR3
L20PTR3 - Primary Trip Relay
CMD vs. Voltage - a Mismatch
Diagnostic Monitor
Output
BOOL
TestETR1
L97ETR1 - ETR1 test, True
deenergizes relay
Output
BOOL
TestETR2
L97ETR2 - ETR2 test, True
deenergizes relay
Output
BOOL
TestETR3
L97ETR3 - ETR3 test, True
deenergizes relay
Output
BOOL
KE2_Enab
KE3_Enab
K4CL_Enab
K25A_Enab
PTR1
286
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All
All
TREG, TRES, TREL
All
TREG, TRES, TREL
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Non-Public Information
7.1.6.24
Variables Vars-Speed
Variable
Vars-Speed Variable
Description
Direction
Acc1_TrEnab
Config – Accel 1 Trip Enabled
Input
BOOL
Acc2_TrEnab
Config – Accel 2 Trip Enabled
Input
BOOL
Acc3_TrEnab
Config – Accel 3 Trip Enabled
Input
BOOL
OS1HW_SP_Pend
Hardware HP overspeed setpoint
Input
changed after power up
BOOL
OS2HW_SP_Pend
Hardware LP overspeed setpoint
changed after power up
Input
BOOL
OS3HW_SP_Pend
Hardware IP overspeed setpoint
changed after power up
Input
BOOL
OS1HW_SP_CfgErr
Hardware HP Overspd Setpoint
Config Mismatch Error
Input
BOOL
OS2HW_SP_CfgErr
Hardware LP Overspd Setpoint
Config Mismatch Error
Input
BOOL
OS3HW_SP_CfgErr
Hardware IP Overspd Setpoint
Config Mismatch Error
Input
BOOL
Input
BOOL
Input
BOOL
Input
BOOL
Type
PR1_Accel
HP Overspd Setpoint Config
Mismatch Error
LP Overspd Setpoint Config
Mismatch Error
IP Overspd Setpoint Config
Mismatch Error
HP Accel in RPM/SEC
AnalogInput
REAL
PR2_Accel
LP Accel in RPM/SEC
AnalogInput
REAL
PR3_Accel
IP Accel in RPM/SEC
HP Max Speed since last Zero
Speed in RPM
AnalogInput
REAL
AnalogInput
REAL
OS1_SP_CfgEr
OS2_SP_CfgEr
OS3_SP_CfgEr
PR1_Max
PR2_Max
LP Max Speed since last Zero
Speed in RPM
AnalogInput
REAL
PR3_Max
IP Max Speed since last Zero
Speed in RPM
AnalogInput
REAL
OS1_Setpoint_Fbk
Current firmware overspeed
setpoint for HP shaft in RPM
AnalogInput
REAL
OS2_Setpoint_Fbk
Current firmware overspeed
setpoint for LP shaft in RPM
AnalogInput
REAL
OS3_Setpoint_Fbk
Current firmware overspeed
setpoint for IP shaft in RPM
AnalogInput
REAL
OnLineOS1Tst
L97HP_TST1 - On Line HP
Overspeed Test
Output
BOOL
OnLineOS2Tst
L97LP_TST1 - On Line LP
Overspeed Test
Output
BOOL
OnLineOS3Tst
L97IP_TST1 - On Line IP
Overspeed Test
Output
BOOL
OffLineOS1Tst
L97HP_TST2 - Off Line HP
Overspeed Test
Output
BOOL
OffLineOS2Tst
L97LP_TST2 - Off Line LP
Overspeed Test
Output
BOOL
OffLineOS3Tst
L97IP_TST2 - Off Line IP
Overspeed Test
Output
BOOL
PPRO, YPRO Backup Turbine Protection
Terminal Boards
All
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Variable
Vars-Speed Variable
Description
TrpAntcptTst
PR_Max_Rst
OnLineOS1X
Direction
Type
L97A_TST - Trip Anticipate Test
Output
BOOL
Max Speed Reset
Output
BOOL
L43EOST_ONL - Online HP
Overspeed Test,with auto reset
Output
BOOL
OS1_Setpoint
Enable Test Mode for RBOS
feature for HP. RBOS1_Accel_
Output
Test will be used as Accel input to
RBOS.
Enable Test Mode for RBOS
feature for LP. RBOS2_Accel_
Output
Test will be used as Accel input to
RBOS.
Enable Test Mode for RBOS
feature for IP. RBOS3_Accel_Test
Output
will be used as Accel input to
RBOS.
HP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS2_Setpoint
LP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS3_Setpoint
IP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS1_TATrpSp
PR1 Overspeed Trip Setpoint in
RPM for Trip Anticipate Fn
AnalogOutput
REAL
OSHW_Setpoint1
HP Overspeed Setpoint in RPM
AnalogOutput
REAL
RBOS1_TestEnable
RBOS2_TestEnable
RBOS3_TestEnable
TREG, TRES, TREL
BOOL
BOOL
BOOL
OSHW_Setpoint2
LP Overspeed Setpoint in RPM
AnalogOutput
REAL
OSHW_Setpoint3
IP Overspeed Setpoint in RPM
AnalogOutput
REAL
RBOS1_Accel_Test
Test Accel signal for RBOS
feature for HP shaft, RPM/s
AnalogOutput
REAL
RBOS2_Accel_Test
Test Accel signal for RBOS
feature for LP shaft, RPM/s
AnalogOutput
REAL
RBOS3_Accel_Test
Test Accel signal for RBOS
feature for IP shaft, RPM/s
AnalogOutput
REAL
7.1.6.25
Terminal Boards
All
Variables Vars-Sync
Variable
Vars-Sync Variable
Description
Direction
Type
Terminal Boards
L25A_Cmd
L25A Breaker Close Pulse
Input
BOOL
TPRO, SPRO
BusFreq
SFL2 hz
AnalogInput
REAL
TPRO, SPRO
GenFreq
DF2 hz
AnalogInput
REAL
TPRO, SPRO
GenVoltsDiff
DV_ERR KiloVolts rms - Gen Low AnalogInput
is Negative
REAL
TPRO, SPRO
GenFreqDiff
SFDIFF2 Slip hz - Gen Slow is
Negative
AnalogInput
REAL
TPRO, SPRO
GenPhaseDiff
SSDIFF2 Phase degrees - Gen
Lag is Negative
AnalogInput
REAL
TPRO, SPRO
SynCk_Perm
L25A_PERM - Sync Check
Permissive
L25A_BYPASS - Sync Check
ByPass
Output
BOOL
TPRO, SPRO
Output
BOOL
TPRO, SPRO
SynCk_ByPass
288
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7.1.6.26
Variables Vars-Trip
Variable
Vars-Trip Variable
Description
Direction
Type
ComposTrip1
Composite Trip 1
Input
BOOL
WatchDog_Trip
Enhanced diag - Watch Dog trip
Input
BOOL
StaleSpeed_Trip
Enhanced diag - Stale Speed trip
Input
BOOL
SpeedDiff_Trip
Enhanced diag - Speed
Difference trip
Input
BOOL
FrameMon_Flt
Enhanced diag - Frame Monitor
Fault
SIL Diagnostic Trip
Input
BOOL
Input
BOOL
Sil_Diag_Trip
PR1_Zero
L14HP_ZE - HP shaft at zero
speed
Input
BOOL
PR2_Zero
L14LP_ZE - LP shaft at zero
speed
Input
BOOL
PR3_Zero
L14IP_ZE - IP shaft at zero speed Input
BOOL
OS1_Trip
L12HP_TP - HP overspeed trip
BOOL
Input
OS2_Trip
L12LP_TP - LP overspeed trip
Input
BOOL
OS3_Trip
L12IP_TP - IP overspeed trip
Input
BOOL
Dec1_Trip
L12HP_DEC - HP
de-acceleration trip
Input
BOOL
Terminal Boards
All
Can only be reset when pulses are
able to be seen on speed input or
after the I/O pack is rebooted.
Dec2_Trip
L12LP_DEC - LP de-acceleration Input
trip
BOOL
Can only be reset when pulses are
able to be seen on speed input or
after the I/O pack is rebooted.
Dec3_Trip
L12IP_DEC - IP de-acceleration
trip
Input
BOOL
Input
BOOL
Can only be reset when pulses are
able to be seen on speed input or
after the I/O pack is rebooted.
Acc1_Trip
L12HP_ACC - HP acceleration
trip
Acc2_Trip
L12LP_ACC - LP acceleration trip Input
BOOL
Acc3_Trip
L12IP_ACC - IP acceleration trip
Input
BOOL
TA_Trip
Trip Anticipate Trip,L12TA_TP
Input
BOOL
PPRO, YPRO Backup Turbine Protection
TREG, TRES, TREL
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Variable
Vars-Trip Variable
Description
Direction
Type
OS1HW_Trip
L12HP_HTP - HP Hardware
detected overspeed trip
Input
BOOL
OS2HW_Trip
L12LP_HTP - LP Hardware
detected overspeed trip
Input
BOOL
OS3HW_Trip
L12IP_HTP - IP Hardware
detected overspeed trip
Input
BOOL
L5CFG1_Trip
HP Config Trip
Input
BOOL
L5CFG2_Trip
LP Config Trip
Input
BOOL
L5CFG3_Trip
IP Config Trip
Input
BOOL
L5ESTOP1
ESTOP1 Trip
Input
BOOL
Terminal Boards
All
TREG, TREA
L5Cont1_Trip
Contact 1 Trip
Input
BOOL
TREG, TRES, TREL
L5Cont2_Trip
Contact 2 Trip
Input
BOOL
TREG, TRES, TREL
L5Cont3_Trip
Contact 3 Trip
Input
BOOL
TREG, TRES, TREL
L5Cont4_Trip
Contact 4 Trip
Input
BOOL
TREG, TRES, TREL
L5Cont5_Trip
Contact 5 Trip
Input
BOOL
TREG, TRES, TREL
L5Cont6_Trip
Contact 6 Trip
Input
BOOL
TREG, TRES, TREL
L5Cont7_Trip
Contact 7 Trip
Input
BOOL
TREG, TRES, TREL
LPShaftLock
LP Shaft Locked
Input
BOOL
Cross_Trip
L4Z_XTRP - Control Cross Trip
Output
BOOL
7.1.6.27
All
Variables VSen
Variable
VSen Variable Description
Direction
Type
Terminal Boards
VSen1
Voltage Sensor 1 Feedback
Input
BOOL
TREA
VSen2
Voltage Sensor 2 Feedback
Input
BOOL
TREA
VSen3
Voltage Sensor 3 - Power Monitor Input
Feedback
BOOL
TREA
290
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7.2 PPRO Specific Alarms
The following alarms are specific to the PPRO I/O pack.
40
Description Contact Excitation Voltage Test Failure
Possible Cause Voltage for the contact inputs on the trip board is not within published limits.
Solution Check source of contact excitation voltage applied to trip board.
50
Description Main Terminal Board Mismatch
Possible Cause The terminal board configured in the ToolboxST application does not match the actual hardware.
Solution Verify that the ToolboxST configuration matches the actual hardware. Build and download the configuration to
the I/O pack.
51
Description Trip Board Mismatch
Possible Cause The trip board configured in the ToolboxST application does not match the actual trip board hardware.
Solution Verify that the ToolboxST configuration matches the actual hardware. Build and download the configuration to
the I/O pack.
69-71
Description Trip Relay (ETR) Driver [ ] does not match commanded state
Possible Cause The driver output of the I/O pack for Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not
match the commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector
into the expected terminating impedance on the trip board.
Solution
•
•
•
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating (if not TREA) and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
72-74
Description Econ Relay Driver [ ] does not match commanded state
Possible Cause The driver output of the I/O pack for Economizing Relay KE1, KE2, or KE3 does not match the
commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector into the
expected terminating impedance on the trip board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
PPRO, YPRO Backup Turbine Protection
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75
Description Servo Clamp Relay Driver does not match commanded state
Possible Cause The driver output of I/O pack for K4CL does not match the commanded state. This indicates that I/O
pack does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip
board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
76
Description K25A Relay (synch check) Driver does not match commanded state
Possible Cause The driver output of I/O pack for K25A does not match the commanded state. This indicates that I/O
pack does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip
board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting
the I/O pack, and the I/O pack.
83-85
Description Trip Relay (ETR) Contact [ ] does not match commanded state
Possible Cause
•
•
Relay feedback from Emergency Trip Relay ETR1 (K1), ETR2 (K2), or ETR3 (K3) does not match the commanded
state. This indicates that the relay feedback from the trip board does not agree with the commanded state.
Solenoid power is not applied to the trip board.
Solution
•
•
Check the trip board relays, as well as the cable from trip board to main terminal board (if not TREA).
Check that solenoid power is applied to the terminal board.
86-88
Description Econ Relay Contact [ ] does not match commanded state
Possible Cause The relay feedback from Economizing Relay 1 (KE1), KE2, or KE3 does not match the commanded
state. This indicates that the relay feedback from the trip board does not agree with the commanded state.
Solution Check the trip board relays, as well as the cable from trip board to main terminal board.
292
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89
Description Servo Clamp Relay Contact does not match commanded state
Possible Cause The relay feedback from K4CL does not match the commanded state. This indicates that the relay
feedback from the trip board does not agree with the commanded state.
Solution
•
•
•
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
90
Description K25A Relay Coil Feedback does not match commanded state
Possible Cause The relay feedback from K25A does not match the commanded state. This indicates that the relay
feedback from the trip board does not agree with the commanded state. Relay feedback is taken after hardware command
voting on the trip terminal board has occurred; therefore, a probable cause is that one I/O pack is not commanding the same
state as the other two I/O packs.
Solution
•
•
•
•
•
Verify that the K25A Relay is supported on the paired PTUR terminal board.
Confirm that the TMR packs are commanding the same state for K25A.
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating and the cable integrity.
One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting
the I/O pack, and the I/O pack.
97
Description Solenoid Power Source is missing
Possible Cause Solenoid power monitoring provided by the trip board indicates the absence of power.
Solution
•
•
Check the source of solenoid power.
Confirm that the wiring between the trip boards is correct.
PPRO, YPRO Backup Turbine Protection
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99-101
Description Solenoid Voltage [ ] does not match commanded state
Possible Cause
•
•
•
•
The solenoid voltage associated with K1-K3 does not match the commanded state.
K1-K3 are closed, but no voltage is detected on the solenoid.
Solenoid voltage was removed through another means while the I/O pack expects to detect its presence.
The ETR state associated with this PPRO is being out voted by the other two PPROs.
Solution
•
•
•
•
This may be due to removal of solenoid voltage through another means when the I/O pack expects to see it.
Review the system-level trip circuit wiring and confirm the voltage should be present if the I/O pack energizes the
associated trip relay.
From the ToolboxST application, verify that the variables (typically L20PTR#) which drive the Primary Trip Relays
(PTRs) in the PTUR are correctly assigned to the PPRO Variables tab (PTR1, PTR2, and PTR3).
Check the pre-voted values for ComposTrip1 under the Vars-Trip tab to verify that all three PPROs have the same status.
If the current PPRO differs from the others, check the pre-vote status of other variables under this tab to determine the
exact cause of the composite trip and correct the condition.
105
Description TREL/S, Solenoid Power, Bus A, Absent
Possible Cause TRES/TREL solenoid power A is absent. Solenoid power does not match the solenoid state for longer
than 40 ms.
Note This diagnostic alarm can be turned off if required. From the PPRO Parameters tab, change the value of
DiagSolPwrA to Disable.
Solution
•
•
•
•
294
Check power applied to the trip board.
Check the field wiring.
Check the solenoid.
Replace the terminal board.
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106
Description TREL/S, Solenoid Power, Bus B, Absent
Possible Cause TRES/TREL solenoid power B is absent. The solenoid power does not match the solenoid state for
longer than 40 ms.
Note This diagnostic alarm can be turned off if required. From the PPRO Parameters tab, change the value of
DiagSolPwrB to Disable.
Solution
•
•
•
•
Check power applied to the trip board.
Check the field wiring.
Check the solenoid.
Replace the terminal board.
107
Description TREL/S, Solenoid Power, Bus C, Absent
Possible Cause TRES/TREL solenoid power C is absent. The solenoid power does not match The solenoid state for
longer than 40 ms.
Note This diagnostic alarm can be turned off if required. From the PPRO Parameters tab, change the value of
DiagSolPwrC to Disable.
Solution
•
•
•
•
Check power applied to the trip board.
Check the field wiring.
Check the solenoid.
Replace the terminal board.
108
Description Control Watchdog Protection Activated
Possible Cause An alarm indicates that the ContWdog variable has not changed for five consecutive frames. The alarm
clears if changes are seen for 60 seconds.
Solution
•
•
Verify that the ContWdog is connected to the output of a DEVICE_HB block and that the block is located in a task which
is run at frame rate.
Verify that the output signal from the block is changing at least once a frame.
PPRO, YPRO Backup Turbine Protection
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109
Description Speed Difference Protection Activated
Possible Cause This alarm only occurs if the parameter SpeedDifEnable has been enabled. An alarm indicates that the
difference between the output signal Speed1 and the first I/O pack pulse rate speed is larger than the percentage OS_DIFF for
more than three consecutive frames. The percentage is based off of the parameter RatedRPM_TA. The alarm clears if the
difference is within limits for 60 seconds for more than three consecutive frames.
Solution Verify that the Speed1 signal is set up correctly in the ToolboxST and that the source of the signal reflects the
primary (PTUR/YTUR) pulse rate speed.
110
Description Stale Speed Protection Activated
Possible Cause The speed trip protection may be stale. This alarm can only occur if the parameter StaleSpdEn has been
enabled. An alarm indicates that the variable Speed1 has not changed for 100 consecutive frames. The alarm clears if the
speed dithers for 60 seconds.
Solution Verify that the Speed1 signal is set up correctly in the ToolboxST configuration, and that the source of the signal
reflects the primary (PTUR/YTUR) pulse rate speed.
111
Description Frame Sync Monitor Protection Activated
Possible Cause This alarm indicates that the communication with the controller was lost for at least five consecutive
frames after the I/O pack was online. The alarm clears if the frame synch is established for at least 60 seconds.
Solution Verify that the IONet is healthy. This indicates that the I/O pack is not synchronized with the Mark VIe
start-of-frame signal.
112-114
Description Overspeed [ ] firmware setpoint configuration error
Possible Cause There is a firmware over-speed limit mismatch between IO signal space limit and the configuration. The
current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signal
OS[]_Setpoint.
Solution Change the output signal designated in OS[]_Setpoint (Vars-Speed tab) to match the configuration value
OS[]_Setpoint (Pulse Rate tab).
115-117
Description Overspeed [ ] hardware setpoint configuration error
Possible Cause There is a hardware over-speed limit mismatch between IO signal space limit and the configuration. The
current configuration file downloaded from the ToolboxST application has a different over-speed limit than the IO signal
OSHW_Setpoint[ ].
Solution Change the output signal designated in OSHW Setpoint [ ] (Vars-Speed tab) to match the configuration value in
OSHW_Setpoint (Pulse Rate tab).
296
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118-120
Description Overspeed [ ] hardware setpoint changed after power up
Possible Cause This alarm always occurs when PulseRate[ ] parameter OSHW_Setpoint is changed and downloaded to
the I/O pack after the turbine has started. It can also change if PRScale is changed to a decimal value and downloaded to the
I/O pack after the turbine has started.
Solution Confirm that the limit or scale change is correct. Restart the I/O pack to force the hardware overspeed to
re-initialize the limit.
121
Description TREA - K1 solid state relay shorted
Possible Cause The TREA provides voltage-based detection of relays that remain in the energized position in the six
voting contacts used to provide K1. Zero voltage has been detected on one or more contacts of K1 when voltage should be
present.
Solution Replace the TREA.
122
Description TREA - K2 solid state relay shorted
Possible Cause TREA provides voltage based detection of relays that remain in the energized position in the six voting
contacts used to provide K2. Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.
Solution Replace the TREA.
123
Description LED - Turbine RUN permissives lost
Possible Cause The RUN LED is lit red on the I/O pack because one of the RUN permissives for the turbine has been
lost. The LedDiags parameter must be set to Enable to get this alarm.
Solution
•
•
•
Verify the configuration of the LedDiag parameter.
From the Vars-Trip tab, identify the condition that caused the trip.
The condition leading to a trip condition must be cleared, and a master reset issued.
124
Description LED - Overspeed fault detected
Possible Cause The Overspeed LED is lit on the I/O pack because of a detected Trip condition. The LedDiag parameter
must be set to Enable to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
The condition leading to a trip condition must be cleared, and a master reset issued.
PPRO, YPRO Backup Turbine Protection
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125
Description LED - Estop detected
Possible Cause The Estop LED is lit on the I/O pack because of a detected Estop signal. The LedDiag parameter must
be set to Enable to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
Remove the Estop condition, and issue a master reset.
126
Description LED - Synch fault detected
Possible Cause
•
•
The Synch LED is lit on the I/O pack because of a failure to synchronize. The LedDiag parameter must be set to Enable
to get this alarm.
The K25A Relay is not enabled to support synchronization
Solution
•
•
•
Verify the configuration of the LedDiag parameter.
Verify that the K25A Relay is enabled.
Issue a master reset to clear the alarm until the next failed attempt to synchronize.
127
Description Configuration changed after power up - running with old configuration
Possible Cause SIL related configuration parameters have changed after going online. The following parameters may not
change after going online while SilMode is enabled:
•
•
•
•
•
SILMode
PRType cannot go from/to Unused
Contact Input TripMode/Used/Unused
TurbineType
EstopEnab (TREA only)
Note PRScale may not change regardless of SilMode.
Solution
•
•
•
298
From the Parameters tab, verify that SilMode is set correctly. Set the parameters to their original state and download
them to the PPRO if they have been changed inadvertently.
Refer to the error log to determine which parameter may have changed. From the ToolboxST application, right-click
IOPack and select Troubleshooting, Advanced Diagnostics, and Error log.
Remove power from the I/O pack to get the hardware to accept the new values if changes are required.
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128
Description PPRO module is not SIL compatible - remain offline
Possible Cause One or more of the boards in the PPRO module is not SIL compatible. The PPRO will not go online in
this condition.
Solution
•
•
Verify that the I/O pack(s), trip board(s), and terminal board(s) are all S-board revision types. Replace all H-board
revisions with their compatible S-board revisions. Refer to the PPRO help file, the section, Compatibility.
If SIL is not required, change the SilMode parameter to Disable.
129
Description Tripped - Missing pulse rate signal
Note This diagnostic is generated from hardware detection that is only available on PPRO_1B I/O packs. PPROH1A I/O
packs will not detect this condition the same way.
Possible Cause No speed input detected on a speed sensor due to the following reasons:
•
•
•
Broken wire
Sensor malfunction
Signal conditioning malfunction
Note This condition will cause a trip on SIL3 systems.
Solution
•
•
•
Examine the PreVote values for the PulseRate signals to determine which PulseRate is affected.
Check the terminal connections for the failed speed sensor.
Check the speed sensor gap.
130
Description Processor hardware error detected (Error Code) [ ]
Possible Cause Hardware error detected by the FPGA as follows:
•
•
Error code 1: FPGA program changed during runtime, possibly one-time event
Error code 2: clock oscillator error
Note These conditions cause a trip that can only be cleared with a power cycle.
Solution
•
•
•
Restart the I/O pack.
Download firmware of the I/O pack.
Replace the I/O pack.
PPRO, YPRO Backup Turbine Protection
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131
Description The configuration is not supported for SIL mode
Possible Cause SilMode is Enable and one of the following conditions is true:
•
•
•
•
TREA is used
TRES/L is selected
QC Mode enabled
Configured as a LargeSteam turbine
Note This condition causes a trip that can only be cleared by changing the configuration and restarting the I/O pack.
Solution
•
•
Correct the configuration to be valid.
Change SilMode to Disable.
132
Description Rate-based Overspeed detection not supported on this hardware
Possible Cause The Rate-based Overspeed (RBOS) detection feature is not enabled on this module because it is not
supported on the PPROH1A. This is likely caused by installing a PPROH1A in place of a PPROS1B without updating the
ToolboxST configuration.
Note If this diagnostic alarm is active, the RBOS protection feature is not running on the specified I/O module.
Solution
•
•
Install the PPROS1B module.
Disable the RBOS feature for all shafts.
224-239
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause Within the TMR I/O pack set, one of the same input signals does not match the other two of the same
input signals.
Solution
•
•
•
•
•
•
•
300
Adjust the TMR threshold limit or correct the cause of the difference.
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and the networking.
Check the I/O pack mounting on terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
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1064-1255
Description Logic Signal [ ] Voting Mismatch
Possible Cause Within the TMR I/O pack set, one of the same logic signals does not match the other two of the same
logic signals.
Solution
•
•
•
•
•
•
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and the networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
PPRO, YPRO Backup Turbine Protection
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7.3 Mark VIeS YPRO Backup Turbine Protection I/O Pack
The Backup Turbine Protection (YPRO) I/O pack and associated terminal boards
provide an independent backup overspeed protection system with a backup check for
generator synchronization to a utility bus. They also provide an independent watchdog
function for the primary control. The YPRO has Ethernet connections for IONet
communications with the control modules.
A typical protection system consists of three TMR YPRO I/O packs mounted to
separate simplex protection (SPRO) terminal boards or three TMR YPROs mounted to
one TPROS#C terminal board. A cable, with DC-37 pin connectors on each end,
connects each terminal board to the designated TREG trip board. An alternate
arrangement puts three YPRO I/O packs directly on the TREA for an aeroderivative
TMR protection system.
The Mark VIeS Safety control is designed with primary and backup trip protection that
interacts at the trip terminal board level. Primary protection is provided with the YTUR
I/O pack, which operates a primary trip board (TRPG, TRPA). Backup protection is
provided with the YPRO I/O pack operating a backup trip board (TREG, TREA).
Infrared Port Not Used
YPRO accepts three speed signals. It monitors the operation of the primary control and
can monitor the primary speed as a sign of normal operation. YPRO monitors the status
and operation of the selected trip board through a comprehensive set of feedback
signals. If a problem is detected, YPRO will trip the backup trip relays on the trip board
and activate a trip on the primary control. The I/O pack is fully independent of and
unaffected by the primary control operation.
A maximum of three trip solenoids can be connected between the primary and backup
trip terminal boards. Connecting a solenoid between the boards isolates the power on
both sides of the solenoid and provides visibility of solenoid voltage as a system
feedback. The primary/backup trip boards TRPG/TREG are designed to operate as a
pair and use cabling between the boards for system connections. TRPA and TREA are
designed with no pairing required and can be used independently of each other. When
TRPA and TREA are paired, they function the same as other board pairs.
In following figure, the YTUR and YPRO I/O packs share in the turbine protection scheme. Either one can independently trip
the turbine using the relays on TRPG or TREG.
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Mark VIeS Safety Control Turbine Protection Boards
PPRO, YPRO Backup Turbine Protection
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7.3.1 Compatibility
The YPROS1A I/O pack mounts directly onto the SPRO, TPROS#C, or TREA terminal board. When mounted onto the
SPRO or TPROS#C, it is cable-compatible with the TREG. The following table lists all compatible boards.
Board
TMR Simplex
Output
Contacts,
125 V dc
Output
Contacts,
24 V dc
ESTOP
Input
Contacts, 125
V dc
Input
Contacts, 24
V dc
TPROS#C
Yes
No
Yes
SPROS1A
Yes1
1 with three SPROs
TREGS1B
Yes
No
Yes
Yes
Yes
Yes
No
TREGS2B
Yes
No
No
Yes
Yes
No
Yes
No
TREGS3B **
JX1 28 V dc
Yes
No
Yes
No
TREGS4B **
JY1 28 V dc
Yes
No
Yes
No
TREGS5B **
JZ1 28 V dc
** TREG S3, S4, and S5 versions are the same as the S1 except that power is provided by JX1, JY1, or JZ1.
TREAS1A
Yes
No
No
Yes
Yes
TREAS2A
Yes
No
TREAS3A ***
No
Yes
TREAS4A ***
Yes
No
*** TREA S3 and S4 are the same as S1 and S2, only euro versions.
No
No
Economy
Resistor
Yes
No
Simplex Main Control with TMR backup protection is supported by all Mark VIeS backup trip boards. In this
configuration, one port on each of three YPRO I/O packs hooks into the controller IONet.
Dual Main Control with TMR backup protection is supported by all Mark VIeS backup trip boards (TREG and TREA).
This configuration uses the dual controller TMR output standard network connection. The first YPRO pack has one network
port connected to the R controller network. The second pack has one network port connected to the S controller network. The
third pack has one network port connected to the R controller network and one network port connected to the S controller
network. The third YPRO monitors the operation of both controllers. The pack trips if either controller malfunctions or both
controllers malfunction.
Triple Main Control with TMR Backup protection is supported when operating with a TMR main control, two out of three
(2oo3). All Mark VIeS backup trip boards support this configuration. The normal network configuration connects the first
YPRO I/O pack to the R network, the second to the S network, and the third to the T network.
Note YPRO TMR applications do not support dual network connections for all three YPROs. In a redundant system there is
no additional system reliability gained by adding network connections to the first two YPROs with dual controllers or any of
the three YPROs with TMR controllers. The additional connections simply reduce mean time between failures (MTBF)
without increasing mean time between forced outages (MTBFO).
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7.3.2 Installation
The YPRO mounts directly on the SPROS1A, TPROS#C, or TREAS#A terminal board. When mounted on the SPRO or
TPRO, cables with DC-37 pin connectors on both ends are required between the terminal board and the selected TREG trip
board. The TREG terminal board connects to the SPRO or TPRO terminal board.
➢ To install the YPRO I/O pack
1.
Securely mount the SPRO, TPRO, or TREA terminal board.
2.
If SPRO or TPRO is used, mount the desired TREG trip terminal board and connect the DC-37 cable between the trip
board and terminal board.
3.
Depending on terminal boards used, directly plug all three YPRO I/O packs as follows.
a.
Plug one YPRO I/O pack into each of the three SPROs.
b.
Plug all three YPRO I/O packs into one TREA.
c.
Plug all three YPRO I/O packs into one TPRO.
4.
Slide the threaded posts on YPRO, located on each side of the Ethernet ports, into the slots on the terminal
board-mounting bracket.
5.
Adjust the bracket location so the DC-62 pin connector on YPRO and the terminal board fit together securely. Tighten the
mounting bracket. The adjustment should only be required once in the life of the product.
6.
Securely tighten the nuts on the threaded posts locking YPRO in place.
7.
Plug in one or two Ethernet cables depending on the system configuration. The YPRO is not sensitive to Ethernet
connections and selects the proper operation over either port.
8.
Apply power by plugging in the power connector on the side of the I/O pack. It has inherent soft-start capability that
controls current levels upon application.
9.
Use the ToolboxST* application to configure the I/O pack as necessary. Refer to GEH-6705, ToolboxST User Guide for
Mark VIeS Safety Control for more information.
7.3.2.1
•
•
•
•
Connectors
A DC-62 pin connector on the underside of the I/O pack connects directly to the terminal board. The connector contains
the signals needed to sense inputs and operate a trip terminal board.
An RJ-45 Ethernet connector named ENET1 on the side of the pack is the primary system interface.
A second RJ-45 Ethernet connector named ENET2 on the side of the I/O pack is the redundant or secondary system
interface.
A 3-pin power connector on the side of the I/O pack is for 28 V dc power for the I/O pack and terminal board.
Note If the trip terminal board features contact trip inputs, the power for those contacts is provided through a separate
terminal board connector, not from the 28 V dc power source.
PPRO, YPRO Backup Turbine Protection
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7.3.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Safety Module Alarms
7.3.3.1
Application-specific Hardware
DC - 6 2
To I / O Pack
The I/O pack has an internal, application-specific circuit board (BPRO) that contains the hardware needed for the turbine
backup trip function. The application board connects between the processor and either the SPRO, TPRO, or TREA terminal
board. The application board has provisions for additional hardware expansion options that can be added through a dedicated
header.
3 Pulse Rate
Input
Conditioning
ID Chip
2 PT Input
Processor
12 Digital Signal
Inputs, E-Stop
7 Isolated
Contact Inputs
8 Relay
Command
Outputs
Pass Through to
Option
Processor
Local Power
Supplies
Option Header
BPRO Application Board
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7.3.3.2
Protective Functions
The I/O pack performs the following protective functions in a mix of hardware, programmable logic, and firmware. In the
following diagram, standard symbols for time delay contacts have been used:
In the following diagrams, a standard has been used to indicate signal origin and flow.
•
•
•
•
•
•
•
Signal names that end with (SS) are created within the I/O pack and the data flow is out to the controller through signal
space.
Signal names that end with SS are created in the controller and the data flow is into the I/O pack through signal space.
Signal names that end with (IO) are created within the I/O pack and the data flow is out to the hardware.
Signal names that end with IO indicate the signal is a hardware input into the I/O pack.
Signal names that end with anything containing CFG are part of the I/O pack configuration. In this case an attempt has
been made to indicate what area of the I/O pack configuration contains the variable.
When J3 is referenced in a CFG, it refers to the connection point for the turbine backup trip relay board, and the
corresponding configuration values.
The combination IO (SS) indicates a signal that comes from the hardware inputs to the I/O pack, and is then sent out to
the controller as part of signal space.
If there is no special ending on a signal name, then the signal is used internal to the I/O pack and is not part of the hardware or
signal-space data movement. This signal is not available or visible to applications, but it is needed to adequately describe the
I/O pack’s operation.
PPRO, YPRO Backup Turbine Protection
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7.3.3.3
Direct/Conditional Discrete Input Trip
The I/O pack supports the seven isolated discrete contact input trip signals provided on the backup turbine trip board. In the
following figure, the direct / conditional determination is implemented in firmware while Contact#, and L5Cont#_Trip are in
hardware logic. When configured for direct trip, the firmware is not in the trip path. When configured for conditional trip, the
firmware determines the communication health (displayed as network_keepalive) and populates the programmable logic with
the conditional signal from signal space. If the controller communication is lost, the default will permit any conditional trip.
Note The contact inputs include an 8 ms contact de-bounce filter to protect against false trips.
A
network _keepalive
L3SS_Comm, (SS)
B
3
Trip#_Inhbt , SS
A>=B
L3SS_Comm, (SS)
Inhbt#_Fdbk , (SS)
A
Trip_Mode , CFG (J3, Contact #)
A=B
Direct, CNST
B
Cont#_TrEnab , (SS)
A
A=B
Conditional , CNST
Contact #, (IO)
Includes 8 mSec
digital filter on close ,
no delay on open
L5Cont#_Trip , (SS)
Cont#_TrEnab
Trip#_EnCon
B
Trip#_EnCon, (SS)
L5Cont#_Trip, (SS)
Inhbt#_Fdbk , SS
CONTACT#
TRIP
L86MR, SS
Note: The contact circuit in this diagram is duplicated 7 times. To obtain the correct signal name,
replace the symbol # with the numbers 1-7. Signal names without # appear only once for all 7
circuits (L3SS_COMM, L86MR).
Contact Input Trips
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The resulting contact trip signals are combined into a single contact trip summary, L5Cont_Trip.
Contact Input Trip Signal Concentration
PPRO, YPRO Backup Turbine Protection
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7.3.3.4
Firmware Overspeed Trip
Firmware overspeed protection is performed on the three values that come out of the high speed select. Although the
established standard for naming these three inputs is HP, IP, and LP, the three inputs are free to be applied as needed in a
system design.
Note The following pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP.
OS1_ Setpoint,SS
RPM
OS _ Setpoint, CFG (J5,PulseRate #)
RPM
A
A-B
|A|
A
B
A
A>B
1 RPM
B
OS1_SP_ CfgEr
System Alarm, if the two setpoints
do not agree
A
MIN
B
OS _Stpt_PR #
A
A
MULT
A
A+B
B
MIN
B
0.04
OS_Tst_Delta, CFG (J5,PulseRate #)
RPM
OS _Setpoint_ PR #
zero
B
OfflineOS # tst, SS
OnlineOS # tst, SS
PulseRate #, IO
A
OS_ Setpoint _ PR #
OS#_SP_CfgEr
OS1
A>=B
B
L5 CFG #_ Trip
PR #_Zero
OS# HW_ SP_ CfgEr
L5 CFG #_Trip
L86 MR, SS
OS1_ Trip
OS1
OS1_Trip
Overspeed
Trip
L86MR,SS
Firmware Overspeed
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Firmware Overspeed Trip functions include:
•
•
•
•
Fault on overspeed threshold match failure between config and signal space values when speed is zero
Pick the lower threshold from config or signal space
Provide a mechanism to zero the threshold for online overspeed test
Provide a mechanism to modify the threshold for offline overspeed test, bounded to limit increases to the threshold to
104%
Note Use a negative OS_Tst_Delta value to reduce the threshold during testing.
•
Compare the threshold to the calculated speed and latch overspeed
7.3.3.5
Hardware Overspeed Trip
The following pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP. OSHW_
Setpoint only goes into the hardware at I/O pack startup.
OSHW_ Setpoint #, SS
A
|A- B|
Generate an alarm if the hardware is
different than the firmware trip
A
OSHW _ Setpoint ,CFG
OS # HW_ SP_ CfgEr ( SS)
B
A> B
(PulseRate #)
1RPM
OS_ Setpoint
HW Value
B
Generate an alarm if the hardware
setpoint changes after power - on
OS # HW_ SP_ Pend ( SS)
A
| A- B|
B
PulseRate #,
HWIO
A
A> =B
OS # HW
B
Hardware
OS# HW
OS # HW _Trip
Overspeed
Trip
( SS )
OS # HW _Trip, ( SS)
L 86MRX
Speed#Updating
Hardware Overspeed Trip, HP Shaft
Note Refer to the section Shaft Speed Accel, Decel, and Zero for the definition of Speed#Updating.
PPRO, YPRO Backup Turbine Protection
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Hardware Overspeed Trip functions include:
•
•
Load the independent hardware overspeed set point only when the I/O pack restarts or is power cycled
Generate an alarm when the hardware configuration set point is >1 Hz different from the value passed through signal
space from the application configuration
Note Hardware overspeed detection involves two rotations of the shaft to determine an overspeed condition.
•
Generate an alarm and signal space Boolean when the set point in configuration fails to match the value stored in the
hardware
•
•
Implement speed calculation and the trip logic entirely inside programmable logic
Overspeed trip response typically less than 60 ms at normal operating speeds
Note There is no separate enable or disable signal for this overspeed protection. The disable signal is created by setting a
high overspeed point value. The calculated speed will never reach the value needed to trigger OS1HW.
The actual hardware implementation depends on two configuration items:
•
•
OSHW_Setpoint specifies the overspeed trip level in RPM.
PRScale determines the number of speed sensor pulses per revolution used to convert pulse rate into RPM for both
hardware and firmware overspeed value.
The hardware implementation requires two adjacent revolutions exceeding the OSHW_Setpoint to trip the system. When a
trip is present, the setting of OSHW_Setpoint is reduced by a small amount in the hardware to provide a clean trip signal. Due
to this reduction, speed must be reduced well below the overspeed threshold before a reset may take place. Because there are
set limits to the time integration used in the hardware detector, the minimum RPM setting for the OSHW_Setpoint is
approximately four RPM.
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7.3.3.6
LP Shaft Locked Detection
This is another protection function that is in addition to the overspeed protection. LP Shaft Locked Detection generates a
signal if the first pulse rate signal is above minimum speed, and the second pulse rate signal is still at zero.
PR1_MIN
PR2_Zero, (SS)
LockRotorByp, SS
LPShaftLock, (SS)
LPShaftLock, (SS)
L86MR, SS
LP Shaft Locked Detection
7.3.3.7
YPRO E-Stop
The I/O pack monitors the E-Stop trip signal that is present on the TREG or TREA terminal boards and uses it to cross trip
the main control in the event E-Stop is invoked. It is also used within the pack logic as part of the trip relay output command.
The relays are not required to close if the E-Stop signal is present. The main control counterpart is also present. If the main
control votes to trip, it can also cross-trip the corresponding I/O pack.
HwEstop1 , IO
J 3 = TREA
EstopEnab, CFG
KESTOP 1_Fdbk , (SS )
J3 = TREG
J3 = TREA
KESTOP1_Fdbk , (SS)
EstopEnab, CFG
J3 = TREG
L5ESTOP1 , ( SS )
L5ESTOP1 , ( SS )
ESTOP 1
TRIP
L86MR , SS
YPRO Contact Input E-Stop
Note There are several inversions in the hardware signal path, but the end result is that KESTOP#_Fdbk is only a 1 when
E-Stop is energized. Therefore, 1 = OK. The TREL and TRES terminal boards do not have E-Stop capability because it is on
the primary trip boards TRPL and TRPS.
PPRO, YPRO Backup Turbine Protection
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7.3.3.8
YPRO Speed Difference Detection
There should never be a reason why the speed calculated by the I/O pack is significantly different from the speed calculated
by the main control. Speed difference detection looks at the difference in magnitude between pulse rate 1 from both the pack
and the main control. If the difference is greater than the set threshold for three successive samples, a SpeedDifTrip is latched.
If the main control recovers for 60 seconds, the trip is removed. This allows the main control to recover with subsequent
re-arming of the backup protection.
Speed 1, SS
PulseRate1
(RPM), IO
A
A
|A-B|
B
OS_Diff, CFG (%)
100
Rated RPM_TA,
A
A>B
B
CFG (RPM)
B (A&B&C)
Speed1_Diff
C
SpeedDifEn , Card CFG
Speed1_Diff
Enable
L86 MR, SS
Speed_Diff_Trip
Speed
Difference
Tip
Speed1_Diff Close
immediately , 60 second
delay on opening
Speed_Diff_Trip
YPRO Speed Difference Detection
When configured for dual controller, additional logic is added so that separate speed inputs from the two controllers come into
the I/O pack. This trip logic acts as if both controllers have a speed error, but continues to run if one controller has a valid
speed signal.
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7.3.3.9
Maximum Speed Hold
The I/O pack provides a maximum speed hold function that resets when:
•
•
Using the command PR_Max_RST (from signal space)
PR1_Zero changes to false when the shaft first starts turning
Output values are PR1_Max, PR2_Max, and PR3_Max. These signals are used to determine the maximum speed obtained
while running or after stopping a turbine.
7.3.3.10
Overspeed Test Logic, Steam Turbine
The signal OnLineOS1Tst is used for PulseRate1, OnLineOS2Tst is used for PulseRate2, and OnLineOS3Tst is used for
PulseRate3. In the following figure, there is another signal, Online OS1X, which initiates an online overspeed test for
PulseRate1. This signal also creates a 1.5 second reset pulse when removed.
Online Overspeed Test Logic
Note If the K4CL relay is enabled during an online Overspeed test, use the OnlineOS1X option and not the OnlineOS1Tst.
This will avoid an unwanted K4CL activation.
7.3.3.11 Speed State Boolean Values
The I/O pack has detection for zero speed from a set point with 1 RPM hysteresis. The I/O pack calculates a minimum speed
signal from a set point. The rate of change of speed from a set point is calculated resulting in a selectable acceleration trip. A
deceleration trip is then determined from a fixed 100% / second rate.
PPRO, YPRO Backup Turbine Protection
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7.3.3.12
Shaft Speed Accel, Decel and Zero
The I/O pack has detection for zero speed from a set point with 1 RPM hysteresis. The I/O pack calculates a minimum speed
signal from a set point. The rate of change of speed from a set point is calculated, resulting in a selectable acceleration trip. A
deceleration trip is then determined from a fixed 100% / second rate.
The acceleration for a given pulse rate (PR#_Accel) is calculated by computing two adjacent shaft speeds over a period of
AccelCalType ms each by computing change in pulse counts, and then computing the difference in these speeds divided by
AccelCalType ms to get the acceleration of the shaft.
In the following figures, pulse rate variables are displayed using a # symbol. Replace the # with 1 for HP, 2 for LP, or 3 for IP.
This figure is the same for PulseRate1, 2, and 3. Simply replace the 1 with a 2 or 3 to get the signal name. The contact, PR#_
Min, in the Acc1_Trip is only present for PR2 (PR2_Min) and PR3 (PR3_Min). It is not used for PR1.
Speed State Boolean Values
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The pulse rate inputs have special detection for loss of signal, and special filtering to remove input noise from nearly
stationary shaft speeds.
PulseRate #, IO
Speed Wheel Pulse
Detected Window
Inactive Counter
Based on last speed
(Maximum 24
seconds )
(Pulse Rates in Hz )
Speed #Updating
Shaft # Turning
A
Allow Accel /
Decel Trip
A > B
75 Hz
Speed
Updating
Normally
B
1 Second Delay
1 **
Speed # Updating
†
Shaft # Turning
Decel #Trip
Decel #Trip
Loss of
Pulse Rate
†
can only be reset when
Speed #Updating becomes True
(pulses are able to be seen ) or
after the I/O pack is rebooted
** 1 = Normal Operation
Pulse Rate Conditioning
PPRO, YPRO Backup Turbine Protection
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Decel#Trip
PulseRate#
(RPM)
PR#_DEC
A
(From GearSpeed)
A
B
A<B
-100%/SEC**
S
(Der)
0 %/Sec
OR
Speed#Updating
B
Shaft#Turning
%/Sec
PR#_ACC
A
AND
A
B
A>B
Acc_Setpoint, CFG (J5, PulseRate#)
B
Dec#_Trip, (SS)
PR#_DEC
Dec#_Trip
L86MR,SS
Acc_Trip, CFG (J5, PulseRate#)
PR#_ACC
PR#_MIN **
Acc#_Trip
L86MR,SS
Enable
Acc#_TrEnab
Acc#_Trip, (SS)
HP, IP and LP Shaft Accel Decel Trip Logic
Note: PR#_MIN is not used on ACC1_Trip.
PR2_Min is used on ACC2_Trip and
PR3_Min is used on ACC3_Trip.
**Note: Where 100% is defined as the OS Setpoint.
Shaft Speed Accel, Decel and Zero
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7.3.3.13
Trip Anticipate Function
Steam turbine applications provide a speed trip that uses a live set point from signal space. This overspeed trip is vigorously
changed as a function of turbine load. This function does the following:
•
•
•
•
•
Input set point is OS1_TATrpSp from signal space. Input rated RPM is specified by RatedRPM_TA as part of the I/O
pack configuration. Function test request input is TrpAntcptTst from signal space.
If (OS1_TATrpSP is < 103.5% OR > 116% of RatedRPM_TA) then TA_Spd_Sp (the local set point value) = 106% of
RatedRPM_TA and TA_StptLoss (Signal space) is true and alarm L30TA is declared. Otherwise, TA_Spd_Sp = OS1_
TATrpSP.
If TrpAntcptTst is true, decrease the current value of TA_Spd_Sp by 1RPM / second. Set the minimum value of
RatedRPM_TA to 94%. If TrpAntcptTst is false, the value of TA_Spd_Sp from above is immediately used.
If PulseRate1 (Speed input 1 from the pulse rate input) > TA_Spd_Sp the internal value Trp_Anticptr is set properly.
If the I/O pack is configured for steam turbine application (internal value SteamTurbOnly), then TA_Trip (signal space)
equals the value of Trp_Anticptr.
Note The I/O pack mounted on a TREA does not toggle the relays for trip anticipate function.
PPRO, YPRO Backup Turbine Protection
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7.3.3.14
Solenoid Voltage / Power Sense
The I/O pack provides three comparator voltage inputs used to monitor solenoid power or solenoid voltage depending on the
trip card that is connected. SOL1_Vfdbk (SS), SOL2_Vfdbk (SS), and SOL3_Vfdbk (SS) are generated from the input
signals.
7.3.3.15
Main Control Watchdog
A standard control watchdog function is provided by the I/O pack. In this function, a value from a Device Heartbeat
(DEVICE_HB) block is passed from the main controller to the I/O pack each data frame. If the I/O pack stops detecting the
value from the main controller, a counter is incremented and, after five data frames, leads to a trip. If the main controller
recovers for 60 seconds, the trip is removed, allowing for the recovery of the main controller with subsequent re-arming of the
backup protection. The recovery function is provided for typical activities such as cycling power on a controller to perform
maintenance.
While the controller is offline, the I/O pack associated with that controller will vote to trip. When the controller returns to
operation, the I/O pack will remove the vote to trip. The watchdog offers monitoring of two main controllers in the event both
Ethernet ports are connected. When configured for two controllers, having one controller active is sufficient to prevent a trip.
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7.3.3.16
Stale Speed Detection
The I/O pack provides an additional main control watchdog function that is based on a live speed signal. The protection works
as follows: If the pack PulseRate1 is determined to be zero speed the protection is turned off. If above zero speed, the pack
looks at the value of Speed1 from the main control. If the most recent Speed1 value exactly matches the Speed1 value from
the last data frame then a counter is incremented. If the counter reaches a threshold then a stale speed trip is declared and
latched. If speeds are different the counter is cleared.
Although Speed_1, SS is available as a connected variable, it should not be forced. It
can cause the protection to trip the system if enabled.
Attention
This protection is based on the knowledge that a live speed signal always dithers or moves some small amount. If the speed
values being read by PPRO from the controller are not changing (dithering), there is loss of speed signal integrity from the
controller. If the main control recovers for 60 seconds, the trip is removed allowing for the recovery of the main control with
subsequent re-arming of the backup protection. The protection offers monitoring of two main controls in the event both
Ethernet ports are connected. When configured for two controls, having one control satisfy the test is sufficient to prevent a
trip.
PPRO, YPRO Backup Turbine Protection
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7.3.3.17
Main Control Ethernet Monitor
The main control provides time synchronization across the distributed control elements. The time synchronization is tied
tightly into the time at which traffic occurs on a given controller's IONet. The I/O pack provides monitoring of this service to
ensure it is working correctly. Gross errors in time synchronization are detected by the pack through a number of different
means, and if problems persist, the I/O pack will vote to trip. Once the trip is latched, if the problem goes away for 60 seconds
the trip shall be reset (this assumes the control recovers from the problem and is back on line). The monitor will offer
monitoring of two main controls in the event both Ethernet ports are connected. When configured for two controls, having
one control sequencing correctly is sufficient to prevent a trip.
In the following diagram, the detection has been simplified to display monitoring of an Ethernet frame number as the means
for determining a problem is present.
Sync Frame Count Monitor
7.3.3.18
Trip Signal Logic
The different trip signals are combined into a composite signal that is used in the relay output logic. The following figure
specifies how the signals are combined. This function is partitioned between firmware and programmable logic. The path to
trip through hardware overspeed is done completely in hardware so that a firmware malfunction cannot defeat the protection.
The same is true of the contact input trip signals when they are configured for direct trip.
There are differences between steam turbine protection and other protection. A composite signal SteamTurbOnly is created
for ease of use:
LargeSteam **
MediumSteam **
SmallSteam **
** A number of contacts depend on
the value of Turbine _Type, CFG.
SteamTurbOnly
Steam Turbine Trip Signals
322
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Dec1_Trip
OS1_Trip
PulseRate1
Trips
Acc1_Trip
L5CFG1_Trip
Dec2_Trip
OS2_Trip
1
GT_2Shaft
PulseRate2
Trips
Acc2_Trip
L5CFG2_Trip
LM_2Shaft1
1
LPShaftLock
LM_3Shaft
ComposTrip1,
(SS)
Dec3_Trip
OS3_Trip
PulseRate3
Trips
1
LM_3Shaftf
Acc3_Trip
L5CFG3_Trip
L5Cont_Trip
SpeedDiff_Trip
System
Trips
Cross_Trip, SS
StaleSpdTrip
ContWdogTrip
FrameSyncTrip
Sil_Diag_Trip
2
1
LM_2Shaft
1
LM_3Shaft
LMTripZEnable, CFG
PR1_Zero
HPZeroSpdByp
SS
1
SteamTurbOnly
Zero
Speed
Special
Case
L3Z
Hardware
Overspeed
OS1HW_Trip
OS2HW_Trip
OS3HW_Trip
1
Notes: CFG values.
2
This trip is generated if a PulseRate signal is broken (such as in the case of no
signal) and SilMode is set to enabled, or if a hardware issue is detected
regardless of SilMode. There will be an accompanying diagnostic generated to
designate the actual cause of the trip.
Trip Combine - All Signals (SS) unless Marked
PPRO, YPRO Backup Turbine Protection
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7.3.3.19
Watchdog Trip Function
Hardware in the I/O pack monitors local firmware operation, providing a watchdog trip function if the firmware malfunctions.
The operation of this watchdog does not display in the normal sequencing figures. The I/O pack hardware is designed to be in
a fail-safe or trip mode if it is not properly configured and operating. This means that with power off, while starting up, when
in a hardware reset, or otherwise not online, the I/O pack will vote to trip. If the I/O pack watchdog acts, it resets the hardware
thereby generating a vote to trip.
The processor board used inside the I/O pack has hardware features that allow it to differentiate between a reset caused by the
watchdog hardware and a reset caused by cycling of power. This information is available from the pack after it restarts. In the
event that an I/O pack votes to trip due to a reset, it is then possible to determine if a watchdog reset or a cycling of control
power caused the event.
7.3.3.20
Servo Suicide Relay Command
The I/O pack provides a command to a servo suicide relay, and provides coil-monitoring feedback named K4CL_Fdbk, (SS).
This signal is typically used in a simplex control of a gas turbine system where it is highly desirable for the pack emergency
protection to have a hardware path to close the fuel valves. It is also used in simplex steam turbines to close the steam valves.
Servo Suicide Relay Command
Note If the K4CL relay is enabled during an online Overspeed test, use the OnlineOS1X option and not the OnlineOS1Tst.
This will avoid an unwanted K4CL activation.
7.3.3.21
Trip and Economizing Relay Outputs
The I/O pack provides drivers for three emergency trip relay commands, and provides monitoring for three status feedback
signals. Trip is a combination of firmware trip and direct trip implemented in programmable logic. The pack contains drivers
for three economizing relay commands and monitoring for three status feedback signals. Economizing relays are used when it
is desirable to introduce some series resistance in a solenoid coil path to reduce current once the solenoid is picked up.
Note YPROs or PPROs mounted on TREA terminal boards have TA_Trip_Enab# set by default to Disable and this
parameter is not configurable.
The reset signal applied to this function is not edge triggered. A continuously applied reset can result in output cycling in the
presence of an intermittent trip signal. The duration of the reset should only be sufficient to allow the reset to complete and
should not be maintained. Logic for the economizing relay drivers is a time-delayed copy of the emergency trip relays as
displayed in the following figure.
324
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Non-Public Information
In
FPGA
TA_Trip, (SS)
TestETR1 ComposTrip1 ETR1_Enab
SS
(SS)
CFG, K1_Fdbk
L5ESTOP1(SS)
TA_Trip_Enabl1
CFG (PPRO)
ETR1 (IO)
Trip Relay,
Energize to Run
TRES, TREL Used
In
Firmware
ETR1
SOL1_Vfdbk
KE1_Enab
IO (SS)
CFG, KE1_Fdbk
TD_KE1
In
Firmware
2 Second Delay on
Pickup
KE1 (IO)
Economizing Relay,
Energize to Econ
TD_KE1
In
FPGA
TA_Trip(SS)
TestETR2 ComposTrip1 ETR2_Enab
SS
(SS)
CFG, K2_Fdbk
TA_Trip_Enabl2
CFG (PPRO)
L5ESTOP1(SS)
ETR2 (IO)
Trip Relay,
Energize to Run
TRES, TREL Used
In
Firmware
ETR2
SOL2_Vfdbk
KE2_Enab
IO (SS)
CFG, KE2_Fdbk
TD_KE2
In
Firmware
2 Second Delay on
Pickup
KE2 (IO)
TD_KE2
Economizing Relay,
Energize to Econ
L97EOST_ONLZ
Large Steam
CFG
In
FPGA
TA_Trip(SS)
ComposTrip1 TestETR 3
(SS)
SS
TA_Trip_Enabl3
CFG (PPRO)
ETR3_Enab
CFG, K3_Fdbk
L5ESTOP1(SS)
ETR3 (IO)
Trip Relay,
Energize to Run
TRES, TREL Used
In
Firmware
ETR3
SOL3_Vfdbk
KE3_Enab
IO (SS)
CFG, KE3_Fdbk
2 Second Delay on
Pickup
TD_KE3
In
Firmware
KE3 (IO)
Economizing Relay,
Energize to Econ,
TD_KE3
Note: TREL and TRES do not have economizing relays so the KE1, KE2, and KE3 drivers are
not used when those boards are configured. Estop is only on TREG so it is bypassed when
driving ETR1-3 with TREL and TRES.
Trip and Economizing Relay Outputs
PPRO, YPRO Backup Turbine Protection
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7.3.3.22
Backup Synchronizing Check
The Mark VIeS YPRO or Mark VIe PPRO provides two PT inputs and performs a backup synchronizing check. The TPRO
has fanned PT inputs. The SPRO does not use fanned PT inputs because there are three direct PT paths.
Generator Synchronizing with TPRO
TTUR Cont’d
TTURH 1C
Generator,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 Hz
R PTUR
17
P3
PR 3
(0.1 Hz)
Fan out
connection
PS3
to S
19
20
Phase
+10 Deg
Gen lag
Gen lead
PT3
to T
2/3
RD
(0.25 Hz)
+0.12 Hz
18
Bus,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 V Hz
Slip
P3
+0.3 Hz Cont’d
PR3
Cont’d
Auto Synch
Algorithm
S PTUR
P28
K25P
01
K25
T
2/3
S
RD
K25A
P125/24 V dc
From JR 4
03
K25P
02
L52Ga
JT4
CB_ Volts_OK
04
K25
CB_K25P_PU
L52G
05
K25A
CB_K25_PU
52Gb
07
T PTUR
JS4
06
CB_K25A_PU
08
Breaker
Close
Coil
JR4
N125 /24 V dc
JT1
Generator,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 Hz
Bus,
PT secondary,
nomin. 115 V ac
(75 to 130 V ac),
45 to 66 V Hz
1
JS1
2
JR1
Fan out
connection
3
TRPG / TRPL / TRPS
J2
4
J2
TREG / TREL / TRES
R PPRO
Sync Check
Slip Algorithm
2/3
RD
TPRO
TPROH1C
JR1
JX1
JX1
JS1
JY1
JY1
JT1
JZ1
JZ1
K25A
Relay
Driver
+0.3 Hz
-10 Deg +10 Deg Phase
-0.3 Hz
S
T
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PPRO
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Generator Synchronizing with SPRO
TTUR
Generator
PT secondary
Nomin . 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
nomin. 115 V ac
( 75 to 130 V ac)
45 to 66 Hz
R YTUR
17
PR3
18
19
Fan out
connection
PS3
to S
20
P3
Cont’d
+0.3 Hz
Slip
(0.25Hz)
P3
+0. 12 Hz
(0.1Hz)
Phase
+ 10 Deg
Gen lag
Gen lead
Auto Synch
Algorithm
PT 3
to T
S Y TUR
T Y TUR
PR3
Cont’d
01
TTUR
P28 Cont’d
K 25 P
K25
T
2 /3 2/ 3
RD
RD S
JT 4
JS 4
P125 /24 V dc
From JR 4
Volt
02 CB_ s _OK
L 52 Ga
K25 A
CB_K25P_PU
L52 G
CB_K25_PU
03
K 25P
04
K 25
K 25 A
05
06
07
CB_K25A_PU
08
JR4
52 Gb
Breaker
Close
Coil
N 125 /24 V dc
JT1
JS1
TRPG
JR1
J2
J2
JA 3
JX1
2/3
RD
Generator
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
Nomin .115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Generator
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Generator
PT secondary
Nomin . 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
Bus
PT secondary
Nomin. 115 V ac
( 75 to 130 V ac )
45 to 66 Hz
R
K25 A
Relay
Driver
SPRO
1
R
2
Sync Check
Slip
Algorithm
+0.3 Hz
Fan out
3 connection
YPRO
JA1
-10 Deg +10 Deg
-0.3 Hz
4
Phase
TREG
JY 1
1
S
JA3
SPRO
2
Fan out
3 connection
S
4
1
YPRO
JA1
T
JZ 1
JA 3
SPRO
2
Fan out
3 connection
T
4
YPRO
JA1
PPRO, YPRO Backup Turbine Protection
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7.3.3.23
K25A Sync Check Function
The K25A sync check function is based on phase lock loop techniques. The PPRO or YPRO performs the calculations for this
function with interfaces to the breaker close circuit located on the TTUR board (not TPRO or SPRO). Its basic function is to
monitor two Potential Transformer (PT) inputs, and to calculate generator and bus voltage amplitudes and frequencies, phase,
and slip.
When it is armed (enabled) from the application code, and when the calculations determine that the input variables are within
the requirements, the relay K25A will be energized. The above limits are configurable. The algorithm uses the phase lock loop
technique to derive the above input variables, and has a bypass function to provide dead bus closures. The window in this
algorithm is the current window, not the projected window (as used on the auto sync function), therefore it does not include
anticipation. Limit checks are performed against adjustable constants as follows:
•
•
•
•
•
328
Generator under-voltage
Bus under-voltage
Voltage error
Frequency error (slip), with a maximum recommended value of 0.5 Hz, typically set to 0.27 Hz
Phase error with a maximum rotational value of 30°, typically set to 10°.
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The sync check arms logic to enable the function and provides bypass logic for dead bus closure. The following sync window
is based on typical settings.
Typical Sync Window
The PPRO or YPRO provides a command to monitor feedback for the K25A sync relay and K25A coil. The feedback is
named K25A_Fdbk, (SS).
Sync Check and K25A Sync Relay Command
The Sync Check will allow the breaker to close with negative slip. The window is configurable for phase and slip.
The following diagnostics relating to the auto sync function are generated by the PPRO or YPRO:
•
•
K25A Relay (sync check) Driver mismatch requested state. This means the PPRO or YPRO cannot establish a current
path to the TREx terminal board.
K25A Relay (sync check) Coil trouble, cabling to P28 V on TTUR. This means the K25A relay is not functional; it could
be due to an open circuit between the TREx and the TTUR terminal boards or to a missing P28 V source on the TTUR
terminal board.
PPRO, YPRO Backup Turbine Protection
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7.3.3.24
K25A Relay Algorithm
The following figure displays the logic for K25A Relay from the Mark VIeS YPRO, which is the same as from the Mark VIe
PPRO.
Signal Space, Outputs;
Algorithm Inputs
YPRO Config
SynchCheck
SystemFreq
FreqDiff
TurbRPM
PhaseDiff
* ReferFreq
used/ unused
L3_Window
Slip
PR_Std
+0. 3 Hz
+ 10 Deg
Phase
PR1/PR2
SPRO
Gen Lag
Signal Space, inputs;
Algorithm Outputs
Gen Lead
DriveFreq
center freq
1
Generator,
PT secondary 2
BusFreq
GenFreq
GenVoltsDiff
GenFreqDiff
GenPhaseDiff
Phase Lock Loop
Phase, Slip, Freq,
Amplitude
Calculations
3
Bus,
PT secondary 4
L25A_Command
GenVoltsDiff
VoltageDiff
GenVoltage
2.8
GenVolts
6.9
BusVolts
BusVoltage
6.9
A
A
|A|<B
B
OR
B
A
A> B
B
L3_GenVolts
A
A> B
B
L3_BusVolts
SynCk_Perm
SynCk_ByPass
A
B
AND
C
D
L3_GenVolts
L3_BusVolts
A
B
C
AND
D
E
Dead Bus
NOT
A
OR
L25A _ Command
B
TREG
TRPG
Y TUR
RD
TTUR
K25A
Note *ReferFreq is a configuration parameter, used to make a selection of the variable that is used to establish the center
frequency of the Phase Lock Loop. It allows a choice between:
•
PR_Std
– Using PulseRate1 speed input on a single shaft applications
– Using PulseRate2 on all multiple shaft applications
• SgSpace uses DriveFreq (the generator frequency in Hz) from signal space
PR_Std is not applicable.
330
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(application code). SgSpace is used when
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
7.3.4 Specifications
Item
YPRO Description
Speed Input Quantity
Three input signals provided
Speed input Range
Pulse rate frequency range 2 Hz to 20 kHz
Speed Input Accuracy
Pulse rate accuracy 0.05% of reading
Speed Input Sensitivity
Required peak-peak voltage rises as a function of frequency:
2 Hz requires 24 mV p-p (TREA, SPRO, TPRO)
20 kHz requires 294 mV p-p (TREA)
20 kHz requires 276 mV p-p (SPRO, TPRO)
Generator and Bus Voltage
Inputs
Input voltage range 75 to 127 V rms. Loading less than 3 VA. Frequency accuracy 0.05%
over 45 to 66 Hz range.
Frame Rate
Size
25 Hz maximum
8.26 cm High x 4.19 cm Wide x 12.1 cm Deep (3.25 in. x 1.65 in. x 4.78 in.)
Technology
Surface-mount
† Ambient rating for enclosure
-30 to 65ºC (-22 to 149 ºF)
design
Shipping and Storage
Temperature
-40 to 85ºC (-40 to 185 ºF)
Humidity
5 to 95% non-condensing
Air Quality
Pollution Degree 2, free convection at the module
Seismic
Vibration
Universal Building Code (UBC) – Seismic Code section 2312 Zone 4 with operation without
trip
Shipping (by road)
Bellcore GR-63-CORE Issue 1, 1995 0.5 g, 5-100 Hz, 10 min. per octave,
1 sweep/axis x 3 axes, ~ 42 min./axis
3 shocks of 15 g, 2 ms impulse each repeated for all axes
Operating at site
1.0 g horizontal. 0.5 g vertical at 15 to 120 Hz, IEC 60721-3-2
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
PPRO, YPRO Backup Turbine Protection
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YPRO Agency Approvals
Safety Standards
UL 508 A Safety Standard Industrial Control Equipment
CSA 22.2 No. 14 Industrial Control Equipment
EN 61010-1 Safety of Electrical Equipment, Industrial Machines (Low Voltage Directive)
Printed Wire Board Assemblies
UL 796 Printed Circuit Boards
UL recognized Board manufacturer
ANSI IPC guidelines
ANSI IPC/EIA guidelines
Electromagnetic Compatibility
(EMC)
EN 61000-4-2 Electrostatic Discharge Susceptibility
EN 61000-4-3 (ENV 50140) Radiated RF Immunity
EN 61000-6-2 Generic Immunity Industrial Environment
EN 61000-4-4 Electrical Fast Transient Susceptibility
EN 61000-4-5 Surge Immunity
EN 61000-4-6 Conducted RF Immunity
EN 55011 Radiated and Conducted RF Emissions
ANSI/IEEE C37.90.1 Surge
7.3.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the analog feedback currents
A comparison between the commanded state of each relay drive and the feedback from the commanded output circuit
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set
Note Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be
individually latched, and then reset with the RESET_DIA signal if they go healthy.
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7.3.5.1
YPRO Status LEDs
During normal I/O pack operation, all six trip application LEDs display green. An additional feature, rotating LEDs, can be
configured for the I/O pack. Using this feature, only one LED is turned on at a time, and walked up and down the six LEDs
creating a synchronized motion. The walking is regulated by the controller IONet, and synchronized across a set of three I/O
packs. This provides a quick visual indication of the system time synchronization status. There are six LEDs on the front left
side of the I/O pack to indicate trip status. All six LEDs stay off until the I/O pack is completely online.
RUN is green any time the I/O pack has energized the emergency trip relays. RUN turns red any time the I/O pack has
removed power from the emergency trip relays, voting to trip.
ESTP is green when the ESTOP input (if applicable) is in the run state. ESTP turns red any time ESTOP is invoked to
prevent pick up of the emergency trip relays. If the selected trip terminal board does not support ESTOP, then the LED
defaults to green.
OSPD turns red any time the I/O pack votes to trip in response to a detected overspeed condition on any of the three speed
inputs. OSPD is green when an overspeed condition is not present or latched.
Note WDOG turns green to indicate that the trip status of any of these features has been cleared.
WDOG turns red when any of the following I/O pack trip functions are enabled and active:
•
•
•
•
Control Watchdog
Speed Difference Detection
Stale Speed Detection
Frame Sync Monitor
SYNC is green when generator and bus voltage is synchronized and matched in amplitude. SYNC turns red when the I/O
pack determines that ac bus and generator bus voltage does not satisfy the synchronization requirements, and synchronization
has been requested by the system.
OPT is reserved for options that expand the capabilities of the I/O pack. The default display is green.
PPRO, YPRO Backup Turbine Protection
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7.3.6 Configuration
Note The information in this section is extracted from the ToolboxST application and represents a sample of the
configuration information for this board. Refer to the actual configuration file within the ToolboxST application for specific
information.
7.3.6.1
Parameters
Parameter
TurbineType
Description
Choices
Turbine Type and Trip Solenoid Configuration
Unused, GT_1Shaft, LM_
3Shaft, MediumSteam,
SmallSteam,
GT_2Shaft, Stag_GT_1Sh,
Stag_GT_2Sh, LargeSteam,
LM_2Shaft
LMTripZEnabl
On LM machine, when no PR on Z, Enable a vote for Trip
Disable, Enable
TA_Trp_Enab1
Steam, Enable Trip Anticipate on ETR1
Disable, Enable
TA_Trp_Enab2
Steam, Enable Trip Anticipate on ETR2
Disable, Enable
TA_Trp_Enab3
Steam, Enable Trip Anticipate on ETR3
Disable, Enable
SpeedDifEn
Enable Trip on Speed Difference between Controller and YPRO
Disable, Enable
StaleSpdEn
Enable Trip on Speed from Controller Freezing
Disable, Enable
Rotate the Status LEDs if all status are OK
Disable, Enable
RotateLeds
LedDiags is Disabled by
default.
LedDiags
Disable, Enable
Attention
When enabled, generates a diagnostic alarm when Trip LEDs are
lit. Refer to the section, Diagnostics, YPRO Trip Status for more
information on LED operation.
RatedRPM_TA
Rated RPM, used for Trip Anticipator and for Speed Diff Protection
0 to 20,000
AccelCalType
Select Acceleration Calculation Time (milliseconds)
10 to 100
OS_Diff
Absolute Speed Difference in Percent For Trip Threshold
0 to 10
7.3.6.2
Terminal Board SPRO or TPRO
Variable
Description
Direction
Type
PulseRate1
HP speed
AnalogInput
REAL
PulseRate2
LP speed
AnalogInput
REAL
PulseRate3
IP speed
AnalogInput
REAL
BusPT_KVolts
Kilo-Volts rms
AnalogInput
REAL
GenPT_KVolts
Kilo-Volts rms
AnalogInput
REAL
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7.3.6.3
Terminal Board TREA
Variable
Description
Direction
Type
PulseRate1
HP speed
AnalogInput
REAL
PulseRate2
LP speed
AnalogInput
REAL
PulseRate3
IP speed
AnalogInput
REAL
Fan_Spd_Fbk
Fanned Speed Signal Feedback: - Fanned = Jumpers Closed
Input
BOOL
KESTOP1_Fdbk
ESTOP1, inverse sense, True = Run
Input
BOOL
The SOE generated for this variable requires the attachment of
an application variable to this signal. Otherwise, a build warning
is generated.
K1_Fdbk
L4ETR1_FB, Trip Relay 1 Feedback
Input
BOOL
K2_Fdbk
L4ETR2_FB, Trip Relay 2 Feedback
Input
BOOL
VSen1
Voltage Sensor 1 Feedback
Input
BOOL
VSen2
Voltage Sensor 2 Feedback
Input
BOOL
VSen3
Voltage Sensor 3 - Power Monitor Feedback
Input
BOOL
7.3.6.4
Terminal Board TREG
Variable
Description
Direction
Type
KESTOP1_Fdbk
ESTOP1, inverse sense, K4 relay, True = Run
Input
BOOL
The SOE generated for this variable requires the attachment of
an application variable to this signal. Otherwise, a build warning
is generated.
Contact1 through 7
Contact Input 1 through 7
Input
BOOL
K1_Fdbk
L4ETR1_FB, Trip Relay 1 Feedback
Input
BOOL
K2_Fdbk
L4ETR2_FB, Trip Relay 2 Feedback
Input
BOOL
K3_Fdbk
L4ETR3_FB, Trip Relay 3 Feedback
Input
BOOL
KE1_Fdbk
Current Economizing Relay for Trip Solenoid 1
Input
BOOL
KE2_Fdbk
Current Economizing Relay for Trip Solenoid 2
Input
BOOL
KE3_Fdbk
Current Economizing Relay for Trip Solenoid 3
Input
BOOL
K4CL_Fdbk
Drive Control Valve Servos Closed.
Input
BOOL
K25A_Fdbk
Synch Check Relay
Input
BOOL
PPRO, YPRO Backup Turbine Protection
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Non-Public Information
7.3.6.5
YPRO Signals
Board Points (Signals)
Description – Point Edit (Enter Signal Connection)
Direction
Type
L3DIAG_YPRO_R, _S, _T
I/O Diagnostic Indication
Input
BOOL
LINK_OK_YPRO_R, _S, _T
I/O Link Okay Indication
Input
BOOL
ATTN_YPRO_R, _S, _T
I/O Attention Indication
Input
BOOL
PS18V_YPRO_R, _S, _T
I/O 18 V Power Supply Indication
Input
BOOL
PS28V_YPRO_R, _S, _T
I/O 28 V Power Supply Indication
Input
BOOL
IOPackTmpr_R, _S, _T
I/O pack Temperature (deg °F)
AnalogInput
REAL
K1_FdbkNV_R, _S, _T
Non Voted L4ETR1_FB, Trip Relay 1 Feedback
Input
BOOL
K2_FdbkNV_R, _S, _T
Non Voted L4ETR2_FB, Trip Relay 2 Feedback
Input
BOOL
K3_FdbkNV_R, _S, _T
Non Voted L4ETR3_FB, Trip Relay 3 Feedback
Input
BOOL
K1FLT
K1 Shorted Contact Fault
Input
BOOL
K2FLT
K2 Shorted Contact Fault
Input
BOOL
PR1_Zero
L14HP_ZE
Input
BOOL
PR2_Zero
L14HP_ZE
Input
BOOL
PR3_Zero
L14HP_ZE
Input
BOOL
OS1_Trip
L12HP_TP
Input
BOOL
OS2_Trip
L12HP_TP
Input
BOOL
OS3_Trip
L12HP_TP
Input
BOOL
Dec1_Trip
L12HP_DEC
Input
BOOL
Dec2_Trip
L12HP_DEC
Input
BOOL
Dec3_Trip
L12HP_DEC
Input
BOOL
Acc1_Trip
L12HP_ACC
Input
BOOL
Acc2_Trip
L12HP_ACC
Input
BOOL
Acc3_Trip
L12HP_ACC
Input
BOOL
TA_Trip
Trip Anticipate Trip, L12TA_TP
Input
BOOL
TA_StptLoss
L30TA
Input
BOOL
OS1HW_Trip
L12HP_TP
Input
BOOL
OS2HW_Trip
L12HP_TP
Input
BOOL
OS3HW_Trip
L12HP_TP
Input
BOOL
SOL1_Vfdbk
When TREG, Trip Solenoid 1 Voltage
Input
BOOL
SOL2_Vfdbk
When TREG, Trip Solenoid 2 Voltage
Input
BOOL
SOL3_Vfdbk
When TREG, Trip Solenoid 3 Voltage
Input
BOOL
L25A_Cmd
L25A Breaker Close Pulse
Input
BOOL
Cont1_TrEnab through 7
Config – Contact 1 Trip Enabled through 7
Input
BOOL
Acc1_TrEnab through 3
Config – Accel 1 Trip Enabled through 3
Input
BOOL
GT_1Shaft
Config – Gas Turb, 1 Shaft Enabled
Input
BOOL
GT_2Shaft
Config – Gas Turb, 2 Shaft Enabled
Input
BOOL
LM_2Shaft
Config – LM Turb, 2 Shaft Enabled
Input
BOOL
LM_3Shaft
Config – LM Turb, 3 Shaft Enabled
Input
BOOL
LargeSteam
Config – Large Steam 1, Enabled
Input
BOOL
MediumSteam
Config – Medium Steam, Enabled
Input
BOOL
336
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Board Points (Signals)
Description – Point Edit (Enter Signal Connection)
Direction
Type
SmallSteam
Config – Small Steam, Enabled
Input
BOOL
Stag_GT_1Sh
Config – Stag 1 Shaft, Enabled
Input
BOOL
Stag_GT_2Sh
Config – Stag 2 Shaft, Enabled
Input
BOOL
ETR1_Enab
Config – ETR1 Relay Enabled
Input
BOOL
ETR2_Enab
Config – ETR2 Relay Enabled
Input
BOOL
ETR3_Enab
Config – ETR3 Relay Enabled
Input
BOOL
OS1HW_SP_Pend
Hardware HP overspeed setpoint changed after power up
Input
BOOL
OS2HW_SP_Pend
Hardware LP overspeed setpoint changed after power up
Input
BOOL
OS3HW_SP_Pend
Hardware IP overspeed setpoint changed after power up
Input
BOOL
KE1_Enab
Config – Economizing Relay 1 Enabled
Input
BOOL
KE2_Enab
Config – Economizing Relay 2 Enabled
Input
BOOL
KE3_Enab
Config – Economizing Relay 3 Enabled
Input
BOOL
OS1HW_SP_CfgErr
Hardware HP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS2HW_SP_CfgErr
Hardware LP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS3HW_SP_CfgErr
Hardware IP Overspd Setpoint Config Mismatch Error
Input
BOOL
K4CL_Enab
Config – Servo Clamp Relay Enabled
Input
BOOL
K25A_Enab
Config – Synch Check Relay Enabled
Input
BOOL
L5CFG1_Trip
HP Config Trip
Input
BOOL
L5CFG2_Trip
LP Config Trip
Input
BOOL
L5CFG3_Trip
IP Config Trip
Input
BOOL
OS1_SP_CfgEr
HP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS2_SP_CfgEr
LP Overspd Setpoint Config Mismatch Error
Input
BOOL
OS3_SP_CfgEr
IP Overspd Setpoint Config Mismatch Error
Input
BOOL
ComposTrip1
Composite Trip 1
Input
BOOL
ComposTrip2
Composite Trip 2
Input
BOOL
ComposTrip3
Composite Trip 3
Input
BOOL
L5ESTOP1
ESTOP1 Trip
Input
BOOL
L5Cont1_Trip through 7
Contact 1 Trip 7
Input
BOOL
LPShaftLock
LP Shaft Locked
Input
BOOL
Inhbt1_Fdbk through 7
Trip Inhibit Signal Feedback for Contact 1 through 7
Input
BOOL
L3SS_Comm
Communication Fault
Input
BOOL
Trip1_EnCon through 7
Contact 1 Trip Enabled through 7 – Conditional
Input
BOOL
BusFreq
SFL2 Hz
AnalogInput
REAL
GenFreq
DF2 Hz
AnalogInput
REAL
GenVoltsDiff
DV_ERR KiloVolts rms - Gen Low is Negative
AnalogInput
REAL
GenFreqDiff
SFDIFF2 Slip Hz - Gen Slow is Negative
AnalogInput
REAL
GenPhaseDiff
SSDIFF2 Phase degrees - Gen Lag is Negative
AnalogInput
REAL
PR1_Accel
HP Accel in RPM/SEC
AnalogInput
REAL
PR2_Accel
LP Accel in RPM/SEC
AnalogInput
REAL
PR3_Accel
IP Accel in RPM/SEC
AnalogInput
REAL
PR1_Max
HP Max Speed since last Zero Speed in RPM
AnalogInput
REAL
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 337
Non-Public Information
Board Points (Signals)
Description – Point Edit (Enter Signal Connection)
Direction
Type
PR2_Max
LP Max Speed since last Zero Speed in RPM
AnalogInput
REAL
PR3_Max
IP Max Speed since last Zero Speed in RPM
AnalogInput
REAL
SynCk_Perm
L25A_PERM - Sync Check Permissive
Output
BOOL
SynCk_ByPass
L25A_BYPASS - Sync Check ByPass
Output
BOOL
Cross_Trip
L4Z_XTRP - Control Cross Trip
Output
BOOL
OnLineOS1Tst
L97HP_TST1 - On Line HP Overspeed Test
Output
BOOL
OnLineOS2Tst
L97LP_TST1 - On Line LP Overspeed Test
Output
BOOL
OnLineOS3Tst
L97IP_TST1 - On Line IP Overspeed Test
Output
BOOL
OffLineOS1Tst
L97HP_TST2 - Off Line HP Overspeed Test
Output
BOOL
OffLineOS2Tst
L97LP_TST2 - Off Line LP Overspeed Test
Output
BOOL
OffLineOS3Tst
L97IP_TST2 - Off Line IP Overspeed Test
Output
BOOL
TrpAntcptTst
L97A_TST - Trip Anticipate Test
Output
BOOL
LokdRotorByp
LL97LR_BYP - Locked Rotor Bypass
Output
BOOL
HPZeroSpdByp
L97ZSC_BYP - HP Zero Speed Check Bypass
Output
BOOL
PTR1
L20PTR1 - Primary Trip Relay CMD, for Diagnostic only
Output
BOOL
PTR2
L20PTR2 - Primary Trip Relay CMD, for Diagnostic only
Output
BOOL
PTR3
L20PTR3 - Primary Trip Relay CMD, for Diagnostic only
Output
BOOL
PR_Max_Rst
Max Speed Reset
Output
BOOL
OnLineOS1X
L43EOST_ONL - On Line HP Overspeed Test,with auto reset
Output
BOOL
TestETR1
L97ETR1 - ETR1 test, True de-energizes relay
Output
BOOL
TestETR2
L97ETR2 - ETR2 test, True de-energizes relay
Output
BOOL
TestETR3
L97ETR3 - ETR3 test, True de-energizes relay
Output
BOOL
Trip1_Inhbt through 7
Contact 1 Trip Inhibit through 7
Output
BOOL
OS1_Setpoint
HP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS2_Setpoint
LP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS3_Setpoint
IP Overspeed Setpoint in RPM
AnalogOutput
REAL
OS1_TATrpSp
PR1 Overspeed Trip Setpoint in RPM for Trip Anticipate Fn
AnalogOutput
REAL
DriveFreq
Drive (Gen) Freq (Hz), used for non standard drive config
AnalogOutput
REAL
Speed1
Shaft Speed 1 in RPM
AnalogOutput
REAL
OSHW_Setpoint1
HP Overspeed Setpoint in RPM
AnalogOutput
REAL
OSHW_Setpoint2
LP Overspeed Setpoint in RPM
AnalogOutput
REAL
OSHW_Setpoint3
IP Overspeed Setpoint in RPM
AnalogOutput
REAL
ContWdog
Controller Watchdog Counter
Output
DINT
338
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
7.4 YPRO Specific Alarms
17
Description Main Terminal Board Mismatch
Possible Cause The terminal board configured in the ToolboxST application does not match the actual hardware.
Solution
•
•
Verify that the ToolboxST configuration matches the actual hardware.
Perform the Build and Download commands to configure the I/O pack.
18
Description Trip Board Mismatch
Possible Cause The trip board configured in the ToolboxST application does not match the actual trip board hardware.
Solution
•
•
Verify that the ToolboxST configuration matches the actual hardware.
Perform the Build and Download commands to configure the I/O pack.
40
Description Contact Excitation Voltage Test Failure
Has Health Bit
Yes
Possible Cause Voltage for the contact inputs on the trip board is not within published limits.
Solution Check source of contact excitation voltage applied to trip board.
50
Description Main Terminal Board Mismatch
Possible Cause The terminal board configured in the ToolboxST application does not match the actual hardware.
Solution
•
•
Verify that the ToolboxST configuration matches the actual hardware.
Perform the Build and Download commands to configure the I/O pack.
51
Description Trip Board Mismatch
Possible Cause The trip board configured in the ToolboxST application does not match the actual trip board hardware.
Solution
•
•
Verify that the ToolboxST configuration matches the actual hardware.
Perform the Build and Download commands to configure the I/O pack.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 339
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69–71
Description Trip relay (ETR) driver [ ] does not match commanded state
Has Health Bit
No
Possible Cause The driver output of the I/O pack for Emergency Trip Relay 1 (K1), ETR2 (K2), or ETR3 (K3) does not
match the commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector
into the expected terminating impedance on the trip board.
Solution
•
•
•
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating (if not TREA) and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
72–74
Description Econ Relay Driver [ ] does not match commanded state
Has Health Bit
No
Possible Cause The driver output of the I/O pack for Economizing Relay KE1, KE2, or KE3 does not match the
commanded state. This indicates that the I/O pack does not see the relay command going out the DC-62 connector into the
expected terminating impedance on the trip board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
75
Description Servo Clamp Relay Driver does not match commanded state
Has Health Bit
No
Possible Cause The driver output of I/O pack for K4CL does not match the commanded state. This indicates that I/O
pack does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip
board.
Solution
•
•
•
340
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
Replace the cable, the trip board, the main terminal board, and the I/O pack.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
76
Description K25A relay (synch check) driver does not match commanded state
Has Health Bit
No
Possible Cause The driver output of I/O pack for K25A does not match the commanded state. This indicates that I/O
pack does not see the relay command going out the DC-62 connector into the expected terminating impedance on the trip
board.
Solution
•
•
•
Check the I/O pack connector seating on terminal board.
Check the trip board cable seating and the cable integrity.
One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting
the I/O pack, and the I/O pack.
83–85
Description Trip relay (ETR) contact [ ] does not match commanded state
Has Health Bit
No
Possible Cause
•
•
Relay feedback from Emergency Trip Relay ETR1 (K1), ETR2 (K2), or ETR3 (K3) does not match the commanded
state. This indicates that the relay feedback from the trip board does not agree with the commanded state.
Solenoid power is not applied to the trip board.
Solution
•
•
Check the trip board relays, as well as the cable from trip board to main terminal board (if not TREA).
Check that solenoid power is applied to the terminal board.
86–88
Description Econ relay contact [ ] does not match commanded state
Has Health Bit
No
Possible Cause The relay feedback fromEconomizing Relay 1 (KE1), KE2, or KE3 does not match the commanded
state. This indicates that the relay feedback from the trip board does not agree with the commanded state.
Solution Check the trip board relays, as well as the cable from trip board to main terminal board.
89
Description Servo clamp relay contact does not match commanded state
Has Health Bit
No
Possible Cause Check the I/O pack connector seating on the terminal board. Check the trip board cable seating and the
cable integrity. Replace the cable, the trip board, the main terminal board, and the I/O pack.
Solution Servo Clamp Relay Contactmismatch requested state
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 341
Non-Public Information
90
Description K25A relay (synch check) coil trouble, cabling to P28 V on TTUR
Has Health Bit
No
Possible Cause
•
•
•
•
Confirm that the TMR packs are commanding the same state for K25A.
Check the I/O pack connector seating on the terminal board.
Check the trip board cable seating and the cable integrity.
One at a time, replace the following: the emergency trip board cable, the trip terminal board, the terminal board hosting
the I/O pack, and the I/O pack.
Solution K25A Relay (synch check) Coil trouble, cabling to/P28 V on TTUR
97
Description Solenoid power source is missing
Has Health Bit
No
Possible Cause
•
•
Check the source of solenoid power.
Confirm that the wiring between the trip boards is correct.
Solution Solenoid Power Source is missing
99–101
Description Solenoid voltage [ ] does not match commanded state
Has Health Bit
No
Possible Cause
•
•
•
•
•
Solenoid voltage associated with K1-K3 does not match the commanded state
Removal of solenoid voltage through another means when the I/O pack expects to see it
K1-K3 are closed, but no voltage is detected on the solenoid
Solenoid voltage was removed through another means while the I/O pack expects to detect its presence
ETR state associated with this YPRO is being out voted by the other two YPROs
Solution
•
•
•
342
Review the system-level trip circuit wiring and confirm the voltage that should be present if the I/O pack energizes the
associated trip relay.
From the ToolboxST application, verify that the variables (typically L20PTR#) which drive the Primary Trip Relays
(PTRs) in the YTUR are correctly assigned to the YPRO Variables tab (PTR1, PTR2, and PTR3).
Check the pre-voted values for ComposTrip1 under the Vars-Trip tab to verify that all three YPROs have the same status.
If the current YPRO differs from the others, check the pre-vote status of other variables under this tab to determine the
exact cause of the composite trip and correct the condition.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
108
Description Control Watchdog Protection Activated
Has Health Bit
No
Possible Cause An alarm indicates that the ContWdog signal has not changed for five consecutive frames. The alarm
clears if changes are detected for 60 seconds.
Solution
•
•
Verify that the ContWdog is connected to the output of a DEVICE_HB block and that the block is located in a task which
is run at frame rate.
Verify that the output signal from the block is changing at least once a frame.
109
Description Speed Difference Protection Activated
Has Health Bit
No
Possible Cause This alarm only occurs if the SpeedDifEnable parameter has been enabled. An alarm indicates that the
difference between the Speed1 output signal and the first I/O pack pulse rate speed is larger than the OS_DIFF percentage for
more than three consecutive frames. The percentage is based off of the RatedRPM_TA parameter. The alarm clears if the
difference is within limits for 60 seconds for more than three consecutive frames.
Solution Verify that the Speed1 signal is set up correctly in the ToolboxST application, and that the source of the signal
reflects the primary YTUR pulse rate speed.
110
Description Stale Speed Protection Activated
Has Health Bit
No
Possible Cause The speed trip protection may be stale. This alarm can only occur if the StaleSpdEn parameter has been
enabled. An alarm indicates that the Speed1 variable has not changed for 100 consecutive frames. The alarm clears if the
speed dithers for 60 seconds.
Solution
•
•
•
Verify that the source of the Speed1 signal reflects the YTUR primary pulse rate speed.
Verify that Speed1 is not set to a static (fixed) value.
Verify that Speed1 is not filtered.
111
Description Frame Sync Monitor Protection Activated
Has Health Bit
No
Possible Cause This alarm indicates that the communication with the controller was lost for at least five consecutive
frames after the I/O pack was online. The alarm clears if the frame synch is established for at least 60 seconds.
Solution Verify that the IONet is healthy. This indicates that the I/O pack is not synchronized with the Mark VIe controller
start-of-frame signal.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 343
Non-Public Information
112–114
Description Overspeed [ ] firmware setpoint configuration error
Has Health Bit
No
Possible Cause There is a firmware over-speed limit mismatch between the OS[ ]_Setpoint I/O signal space limit and the
current configuration file downloaded from the ToolboxST application. This causes the OS[ ]_Setpoint output signal to not
match the configuration value of OS_Setpoint.
Solution From the Vars Speed tab, change the output signal designated in OS[ ]_Setpoint to match the configuration
value of OS_Setpoint (found in the Pulse Rate tab).
115–117
Description Overspeed [ ] hardware setpoint configuration error
Has Health Bit
No
Possible Cause There is a hardware over-speed limit mismatch between the OSHW_Setpoint[ ] I/O signal space limit
and the current configuration file downloaded from the ToolboxST application. This causes the OSHW_Setpoint[ ] output
signal to not match the configuration value of OSHW_Setpoint.
Solution From the Var-Speed tab, change the output signal designated in OSHW_Setpoint[ ] to match the configuration
value of OSHW_Setpoint (found in the Pulse Rate tab).
118–120
Description Overspeed [ ] hardware setpoint changed after power up
Has Health Bit
No
Possible Cause This alarm always occurs when PulseRate[ ] OSHW_Setpoint is changed and downloaded to the I/O
pack after the turbine has started.
Solution Confirm that the limit change is correct. Restart the I/O pack to force the hardware overspeed to re-initialize the
limit.
121
Description TREA - K1 solid state relay shorted
Has Health Bit
No
Possible Cause The TREA provides voltage-based detection of relays that remain in the energized position in the six
voting contacts used to provide K1. Zero voltage has been detected on one or more contacts of K1 when voltage should be
present.
Solution Replace the TREA.
122
Description TREA - K2 solid state relay shorted
Has Health Bit
No
Possible Cause TREA provides voltage based detection of relays that remain in the energized position in the six voting
contacts used to provide K2. Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.
Solution Replace the TREA.
344
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
123
Description LED - Turbine RUN permissives lost
Has Health Bit
No
Possible Cause The RUN LED is lit red on the I/O pack because one of the RUN permissives for the turbine has been
lost. The LedDiag parameter must be set to Enable to get this alarm.
Solution
•
•
•
Verify the configuration of the LedDiag parameter.
From the ToolboxST application Vars Trip tab, identify the condition that caused the trip.
The condition leading to a trip condition must be cleared, and a master reset issued.
124
Description LED - Overspeed fault detected
Has Health Bit
No
Possible Cause The Overspeed LED is lit on the I/O pack because of a detected Trip condition. The LedDiag parameter
must be set to Enable to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
The condition leading to a trip condition must be cleared, and a master reset issued.
125
Description LED - Estop detected
Has Health Bit
No
Possible Cause The Estop LED is lit on the I/O pack because of a detected Estop signal. The LedDiag parameter must be
set to Enable to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
Remove the Estop condition, and issue a master reset.
126
Description LED - Synch fault detected
Has Health Bit
No
Possible Cause The Synch LED is lit on the I/O pack because of a failure to synchronize. The LedDiag parameter must
be set to Enable to get this alarm.
Solution
•
•
Verify the configuration of the LedDiag parameter.
Issue a master reset to clear the alarm until the next failed attempt to synchronize.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 345
Non-Public Information
224–239
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Has Health Bit
No
Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:
•
•
•
The device
The connections to the terminal board
The terminal board
Solution
•
•
•
•
•
•
•
Adjust the TMR threshold limit or correct the cause of the difference.
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and the networking.
Check the I/O pack mounting on terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
1064–1255
Description Logic Signal [ ] Voting Mismatch
Has Health Bit
No
Possible Cause A problem exists with a status input between the R, S, and T I/O packs and one of the following:
•
•
•
The device
The connections to the terminal board
The terminal board
Solution
•
•
•
•
•
•
346
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and the networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
7.5 TPRO_#C TMR Backup Protection Terminal Board
The TMR Backup Protection (TPROH#C, TPROS#C) terminal board conditions speed signal inputs and contains a pair of
potential transformers (PTs) for bus and generator voltage input. It has three DC-37 pin connectors, each adjacent to the I/O
pack connectors. Each DC-37 accepts a cable leading to a trip relay terminal board. The TPRO has two 24-point terminal
blocks (48 points).
Compatibility
I/O Packs
Three Mark VIe PPROs
Three Mark VIeS YPROs †
or
Three Mark VIe PPROS1Bs †
TPRO Version
Terminal Block Type
TPROH1C
Barrier, removable
TPROH2C
Euro Box, removable
TPROS1C
Barrier, removable
TPROS2C
Euro Box, removable
Available Trip Boards
TREG, TREL, TRES
TREGS#B
† This combination is IEC 61508 safety certified
7.5.1 TPRO _#C Installation
The TPRO and a plastic insulator mount on a sheet metal carrier, which mounts on a DIN-rail. Optionally, the TPRO and
insulator mount on a sheet metal assembly, which bolts directly in a panel. Speed signals and PT inputs are wired directly to
the terminal block using typical #18 AWG wires.
The R, S and T I/O packs mount on TPRO connectors JR1, JS1 and JT1, respectively. Three DC-37 pin conductor cables plug
into TPRO connectors JX1, JY1 and JZ1 with the other ends attached to the turbine backup trip board.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 347
Non-Public Information
Transformers
(T1 and T 2)
Cold junctions
(only three
used at a time )
Magnetic
pickup
TPRO_#C Board Layout
348
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
7.5.1.1
Primary and Backup Turbine Protection
In the following figure, the TPRO and three I/O packs (Mark VIe PPROs or Mark VIeS YPROs) are connected to a trip relay
board for backup turbine trip protection. Three Mark VIe PTURs or Mark VIeS YTURs, the TTUR terminal board, and a
primary trip relay board provide turbine-specific primary trip protection.
PPRO, YPRO Backup Turbine Protection
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YTUR
YTUR
YTUR
TPROS#C
YPRO
YPRO
YPRO
Primary and Backup Turbine Protection
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7.5.2 Operation
In the following drawing, the PT inputs to TPRO are displayed on terminals 1-4.
TPRO Signal Inputs
PPRO, YPRO Backup Turbine Protection
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Nine speed inputs are displayed on terminals 31-48. Terminals 5, 9, and 11 offer P24 output for the customer. Terminal 8
(MARET) acts as the return path for the P24 output. The P24 output is derived by ORing the 28 V power supply of I/O packs
R, S, and T. If any of the I/O pack are switched off, P24 V output can still be sourced. If speed inputs are TTL-based, then
TB3 terminals are used along with even-numbered terminals 32-48, as displayed in the following table.
Input
Signal
TBConnector
Terminal
Number
Description
PulseRate1
MAG1TTL_R
TB3
1
For TTL input High
MX1L
TB2
32
Return for TTL input
MAG1TTL_S
TB3
4
For TTL input High
MY1L
TB2
38
Return for TTL input
MAG1TTL_T
TB3
7
For TTL input High
MZ1L
TB2
44
Return for TTL input
P24V1
TB1
5
For TTL input Sensor Power
MARET
TB1
8
For TTL input Sensor Power
Return
PulseRate2
MAG2TTL_R
TB3
2
For TTL input High
MX2L
TB2
34
Return for TTL input
MAG2TTL_S
TB3
5
For TTL input High
MY2L
TB2
40
Return for TTL input
MAG2TTL_T
TB3
8
For TTL input High
MZ2L
TB2
46
Return for TTL input
P24V2
TB1
9
For TTL input Sensor Power
MARET
TB1
8
For TTL input Sensor Power
Return
PulseRate3
MAG3TTL_R
TB3
3
For TTL input High
MX3L
TB2
36
Return for TTL input
MAG3TTL_S
TB3
6
For TTL input High
MY3L
TB2
42
Return for TTL input
MAG3TTL_T
TB3
9
For TTL input High
MZ3L
TB2
48
Return for TTL input
P24V3
TB1
11
For TTL input Sensor Power
MARET
TB1
8
For TTL input Sensor Power
Return
Note For terminal 8 (MARET) to act as the return path for 24 V output and 4-20 mA input, ensure that JP1B is at position
(1-2).
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7.5.3 Specification
Item
TPRO Specification
Generator and bus voltage sensors
If K25A_Enab = False, the generator and bus potential
transformer (PT) live values are disabled.
Two single-phase potential transformers, with secondary output
supplying a nominal 115 V rms
Each input has less than 3 VA of loading.
Allowable voltage range for synch is 75 to 130 V rms
Each PT input is magnetically isolated with a 1,500 V rms barrier.
Cable length can be up to 1,000 ft. of 18 AWG wiring.
Magnetic speed pickup pulse rate range
2 Hz to 20,000 Hz
Magnetic speed pickup pulse rate accuracy
0.05% of reading
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
20 kHz requires 276 mV p-p
Speed input sensitivity is such that turning gear
speed may be observed on a typical turbine
application.
Size
33.02 cm high x 17.8 cm wide (13 in x 7 in)
Technology
Surface-mount
P24V1
P24V2
P24V3
There are three 24 V outputs for customer (not voted), with each
supporting a max current output of 25 mA.
7.5.4 Diagnostics
The TPRO board and backup trip relay terminal board contain electronic ID parts that are read during power initialization.
This information is used by the I/O pack to confirm a valid hardware arrangement prior to starting normal operation.
PPRO, YPRO Backup Turbine Protection
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7.6 SPROH#A, S1A Simplex Backup Protection Terminal
Board
The Simplex Backup Protection (SPRO) terminal board conditions speed signal inputs for the I/O pack and contains a pair of
potential transformers (PTs) for bus and generator voltage input. It has a DC-37 pin connector adjacent to the I/O pack
connector that accepts a cable leading to a backup trip relay terminal board.
Compatibility
I/O Packs
Board
Revision
Available Trip Boards
24 removable, barrier
SPROH1A
One Mark VIe PPRO
One Mark VIeS YPRO †
Terminal Block
TREG, TREL, TRES
SPROH2A
SPROS1A
24 removable, Euro style box-type
TREGS#B
24 removable, barrier
† IEC 61508 safety certified with YPRO (not PPROS1B)
7.6.1 Installation
The SPRO and a plastic insulator mount on a sheet metal carrier, which mounts on a DIN-rail. Optionally, the SPRO and
insulator mount on a sheet metal assembly, which bolts directly in a panel. Speed signals and PT inputs are wired directly to
the terminal block using typical #18 AWG wires.
The I/O pack mounts directly on connector JA1 of the SPRO. A DC-37 pin conductor cable plugs into connector JA3 of
SPRO with the other end attached to a backup trip terminal board.
7.6.1.1
Primary and Backup Turbine Protection
The following figure displays the primary and backup trip protection system. Turbine-specific primary trip protection is
provided by the Mark VIe PTUR or Mark VIeS YTUR, the TTUR terminal board, and a primary trip relay board. Backup
protection is provided by the Mark VIeS YPRO or Mark VIe PPRO, the SPRO, and a backup trip relay board.
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Primary and Backup Turbine Protection
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 355
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7.6.2 Operation
In the following drawing, the PT inputs to SPRO are displayed on terminals 1-4. Three speed inputs are displayed on
terminals 19-24. Terminals 7-15 are reserved for future control feature expansion and are routed to the JA1 I/O pack
connector. Terminals 5-6 and 16-18 have no board connection. The JA1 and JA3 connectors provide locations for the I/O
pack and the trip terminal board cables.
SPRO Signal Inputs
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SPRO Inputs
Terminal
Signal Name
Variable Name
Description
1
GENH
GenPT_KVolts
Generator PT input high.
2
GENL
3
BUSH
4
BUSL
Generator PT input low
BusPT_KVolts
Bus PT input high
Bus PT input low
5
Not connected
6
Not connected
7
KPRO1
Unused, left for future control feature expansion.
8
KPRO2
Unused, left for future control feature expansion.
9
KPRO3
Unused, left for future control feature expansion.
10
KPRO4
Unused, left for future control feature expansion.
11
KPRO5
Unused, left for future control feature expansion.
12
KPRO6
Unused, left for future control feature expansion.
13
KPRO7
Unused, left for future control feature expansion.
14
KPRO8
Unused, left for future control feature expansion.
15
KPRO9
Unused, left for future control feature expansion.
16
Not connected
17
Not connected
18
Not connected
19
MAG1H
20
MAG1L
21
MAG2H
22
MAG2L
23
MAG3H
24
MAG3L
PulseRate1
Magnetic pickup-1 high input
Magnetic pickup-1 low input
PulseRate2
Magnetic pickup-2 high input
Magnetic pickup-2 low input
PulseRate3
Magnetic pickup-3 high input
Magnetic pickup-3 low input
PPRO, YPRO Backup Turbine Protection
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7.6.3 Specifications
Item
SPRO Specification
Generator and bus voltage sensors
If K25A_Enab = False, the generator
and bus potential transformer (PT) live
values are disabled.
Two single-phase potential transformers, with secondary output supplying a
nominal 115 V rms
Each input has less than 3 VA of loading.
Allowable voltage range for synch is 75 to 130 V rms
Each PT input is magnetically isolated with a 1,500 V rms barrier.
Cable length can be up to 1,000 ft. of 18 AWG wiring.
Magnetic speed pickup pulse rate range
2 Hz to 20,000 Hz
Magnetic speed pickup pulse rate
accuracy
0.05% of reading
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
20 kHz requires 276 mV p-p
Turning gear speed may be observed
on a typical turbine application.
Size
15.9 cm high x 17.8 cm wide (6.25 in x 7.0 in)
Technology
Surface-mount
7.6.4 Diagnostics
The SPRO board and backup trip relay terminal board contain electronic ID parts that are read during power initialization.
This information is used by the I/O pack to confirm a valid hardware arrangement prior to starting normal operation.
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7.7 TREAH#A, S#A Aeroderivative Turbine Trip Board
The Aeroderivative Turbine Emergency Trip (TREA) terminal board inputs and outputs are as follows:
•
•
•
•
•
•
Customer input terminals provided through two 24-point terminal blocks (48 points)
Nine passive pulse rate devices (three per X/Y/Z section) sensing a toothed wheel to measure the turbine speed.
Jumper blocks that enable fanning of one set of three speed inputs to all three I/O packs.
Two TMR-voted output contacts to trip the system.
Four 24–125 V dc voltage detection circuits for monitoring trip string.
Signals fan out to the three I/O packs through JX1, JY1, and JZ1 DC-62 connectors.
Compatibility
Board Revision
Mark VIe control
IS220PPRO
TREAH1A
TREAH2A
TREAH3A
TREAH4A
TREAS1A
TREAS2A
Mark VIeS Safety control
IS200YPRO
24 V dc with barrier terminal blocks
125 V dc with barrier terminal blocks
24 V dc with Euro box terminal blocks
125 V dc with Euro box terminal blocks
24 V dc, barrier, IEC 61508 safety certified with
YPRO (not PPROS1B)
No
Yes
TREAS3A
Features
125 V dc, barrier, IEC 61508 safety certified with
YPRO (not PPROS1B)
Yes
24 V dc, Euro box, IEC 61508 safety certified
with YPRO (not PPROS1B)
TREAS4A
125 V dc, Euro box, IEC 61508 safety certified
with YPRO (not PPROS1B)
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 359
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TREA_1A Turbine Terminal Board
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7.7.1 Installation
In 240 V ac applications, do not inadvertently cross-connect the 240 V ac and the dc
voltages. The peak voltage will exceed the Transorb rating, resulting in a failure.
Caution
Most ac supplies operate with a grounded neutral, and if an inadvertent connection
between the 125 V dc and the ac voltage is created, the sum of the ac peak voltage and
the 125 V dc is applied to Transorbs connected between dc and ground. However, in
120 V ac applications, the Transorb rating can withstand the peak voltage without
causing a failure.
For H1 / S1 and H2 / S2 board versions, voltage detection and the breaker relay are wired to the I/O terminal blocks TB1.
Passive pulse rate pick-ups are wired to TB2. Each block is held down with two screws and has 24 terminals accepting up to
#12 AWG wires. A shield termination strip attached to chassis ground is located immediately to the left of each terminal
block.
For H3 / S3 and H4 / S4 board versions, voltage detection and the breaker relay are wired to the I/O box terminals at the top
of the board. Passive pulse rate pick-ups are wired to the lower terminals. All terminals plug into a header on the TREA board
and accept up to a single #12 AWG wire.
The TREA must be configured for the desired speed input connections using the
following table. Jumpers P1 and P2 select fanning of the <R> section pulse rate
pickups to the <S> and <T> I/O packs.
Attention
Speed Input Connections
Wiring
Function
Jumper
Wire to all 9 pulse inputs:
PR1_X – PR3_Z
Each set of three pulse inputs goes to its own
dedicated I/O pack
Cannot use jumper: place in
STORE position.
Wire to bottom 3 pulse inputs only:
PR1_X – PR3_X
NO wiring to PR1_Y-PR3_Z
The same set of signals are fanned to all the I/O
packs
Use jumper: place over pin pairs.
PPRO, YPRO Backup Turbine Protection
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7.7.1.1
TREA Terminal Board Wiring
Screw terminal connections are listed in the following table. Terminal names starting with DBRD are reserved for the addition
of an optional daughterboard.
Pin
Signal Name
Pin
Signal Name
1
K1_PDC
2
K1_NDC
3
K2_PDC
4
K2_NDC
5
SOL1_A
6
SOL1_B
7
SOL2_A
8
SOL2_B
9
PWR_A
10
PWR_B
11
TRP_A
12
TRP_B
13
K4_PDC
14
K4_NDC
15
K5_PDC
16
K5_NDC
17
K6_PDC
18
K6_NDC
19
DBRD1_A
20
DBRD1_B
21
DBRD2_A
22
DBRD2_B
23
DBRD3_A
24
DBRD3_B
25
DBRD4_A
26
DBRD4_B
27
DBRD5_A
28
DBRD5_B
29
DBRD6_A
30
DBRD6_B
31
PR1H_Z
32
PR1L_Z
33
PR2H_Z
34
PR2L_Z
35
PR3H_Z
36
PR3L_Z
37
PR1H_Y
38
PR1L_Y
39
PR2H_Y
40
PR2L_Y
41
PR3H_Y
42
PR3L_Y
43
PR1H_X
44
PR1L_X
45
PR2H_X
46
PR2L_X
47
PR3H_X
48
PR3L_X
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7.7.1.2
Contact Outputs
The contact outputs are polarity sensitive. Wire the circuit carefully to avoid
damaging the relays. There is no contact or solenoid suppression, user must add
external solenoid suppression to avoid damaging the relays and their contacts.
Caution
A voltage detection circuit is included on TREA that is able to detect a shorted relay when voltage is present across the open
contact set.
Connection to TREA contact output
7.7.1.3
•
•
•
•
E-Stop/TRP Input
The TRP input is configurable in the I/O pack to either be required or bypass the signal. When enabled, the TRP input
works through a hardware path on the I/O pack and does not act through the I/O pack firmware. When enabled, TRP
must be powered for the trip relays to close.
The E-Stop must be connected to a CLEAN dc source battery or filtered (< 5% ripple) rectified ac.
There must be a minimum of 18 V dc at the TRP inputs for proper operation. The current required was kept low to
minimize drop on long cable runs.
As the TRP is very fast < 5 ms and the output relay contacts are also fast (< 15 ms), best wiring practices should be
utilized to avoid disoperation. Use twisted-pair cable when possible and avoid running with ac wiring.
PPRO, YPRO Backup Turbine Protection
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7.7.2 Operation
The TREA is designed for three I/O packs to be mounted directly onto it. This module assembly forms a self-contained
emergency trip function. TREA_1A, 2A, 3A, and 4A only functions correctly with three I/O packs. Simplex operation is not
possible.
Note The Trip Anticipate test function does not toggle the ETR relays on the TREA.
7.7.2.1
Speed Inputs
With the three I/O packs mounted directly on the TREA, the speed inputs provide two options. Each I/O pack can receive a
dedicated set of three speed inputs from their respective TREA terminal points. As an option, jumpers P1 and P2 can be
placed on the TREA to take the first three speed inputs from the <X> I/O pack and fan them to the <Y> and <Z> I/O packs.
When this is selected, the terminal board points for the Y and Z speed inputs become no-connects and should not be used. As
a check, when the I/O pack is configured for either fanned or direct speed input, a feedback signal is provided by TREA. If
there is a mismatch between the jumper position and I/O pack configuration, an alarm will be generated.
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7.7.2.2
E-Stop
The TREA includes an E-Stop function. This consists of an optically isolated input circuit designed for a dc input in the range
of 24 V to 125 V nominal. When energized, the circuit enables coil drive power in the X, Y, and Z relay circuits through
independent hardware paths. The response time of this circuit of less than five milliseconds plus the response time of the trip
relays of less than one millisecond yields very fast E-Stop response. E-Stop is monitored by I/O pack firmware, but the action
to remove trip relay coil power is a hardware path in the I/O pack. It is possible to configure the I/O pack to turn off the
E-Stop function.
7.7.2.3
Voltage Monitors
The trip relays on TREA may be freely located anywhere in a trip string. Because the trip string circuit is not fixed, there are
three general-purpose isolated voltage sensor inputs on TREA. These can be used to monitor any points in the trip system and
drive the voltage status into the system controller where action can be taken. Typical use of these inputs may be to sense the
power supply voltage for the two trip strings (PWR) and to sense the solenoid voltage of the device being driven by the relays
(SOL1, SOL2). This set of applications is used in the wording of the board symbol, but the sensors can be freely applied to
best serve the application.
7.7.2.4
Trip Relays
The trip relays are made using sets of six individual form devices arranged in a voting pattern. Any two controllers that vote
to close will establish a conduction path through the set. Because detection of a shorted relay is important to preserve tripping
reliability, there is a sensing circuit applied to each of the sets of relays. When the relays are commanded to open, and voltage
is present across the relays, the circuit will detect if one or more relays are shorted. This signal goes to the I/O pack to create
an alarm. The TREA sensing circuit uses the relay commands from all three I/O packs to avoid a false indication, in the event
that one I/O pack votes to close the relay while the other two I/O packs vote to open. The voting arrangement is displayed in
the following TREA symbol.
Contacts are polarity-sensitive, external voltage suppression MUST be used.
Caution
Note Many circuit paths in the following drawing have been omitted for clarity.
PPRO, YPRO Backup Turbine Protection
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Trip Relays
K1_PDC
KX1 KY1
JZ1
Relay V Monitor
KY1
KZ1
JX1
JY1
JZ1
KZ1 KX1
K1_NDC
K2_PDC
KX2 KY2
Relay V Monitor
KY2
KZ2
Relay Drivers
P28X
KZ2 KX2
JX1
K2_NDC
SOLn_A
SOLn_B
TRP_A
TRP_B
PWR_A
PWR_B
Trip Voltage
Monitor
2 Circuits
Estop Monitor
1 Circuit
TMR Output
JX1
JY1
JZ1
JX1
JY1
JZ1
P28Y
KX1
R
D
KX2
R
D
KY1
R
D
KY2
R
D
KZ1
R
D
KZ2
R
D
JY1
P28Z
ID
JZ1
Solenoid Power
Monitor
1 Circuits
JX1
JY1
JZ1
JY1
Alternate Sol Input
on WTEA
X Channel Speed
Inputs (3 circuits)
MP
U
PRnH_X
JX1
Suppression
PRnL_X
Y Channel Speed
Optional Speed
Fanning Jumper
P1
JX1
JY1
JZ1
Speed Fan
Sense
ID
Inputs (3 circuits)
MP
U
PRnH_Y
JY1
Suppression
JX1
PRnL_Y
Z Channel Speed
Optional Speed
Fanning Jumper
P2
Inputs (3 circuits)
MP
U
PRnH_Z
JZ1
Suppression
PRnL_Z
ID
TREA_1A Trip Relays (PPRO, YPRO)
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7.7.3 Specifications
Item
TREA Specification
Number of inputs
3 x 3 passive (magnetic) speed pickups
3 voltage detection circuits
1 E-STOP/TRP input
Number of outputs
2 trip contacts
Contact ratings
NEMA class F. Minimum operations: 100,000
IS200TREA_1A, 3A
Voltage: 28 V dc max
Max. Current 10 A dc 40ºC (104 ºF) maximum
de-rate current linearly to 7 A dc 65ºC (149 ºF) maximum
Leakage: 2.21 mA max
IS200TREA_2A, 4A
Voltage: 140 V dc max
Max. Current 3 A dc 40ºC (104 ºF) maximum
de-rate current linearly to 2 A dc 65ºC (149 ºF) maximum
Leakage: 3.31 mA max
Voltage detection inputs
Min/max input voltage rating: 16/140 V dc max pk
Current Loading (Max leakage): 3 mA
Detection delay (max): 60 ms
Voltage isolation: Optically isolated: 2500 V rms isolation, for one min.
Surge/Spike rating: 1000 V pk for 8.3 ms
ESTOP/TRP detection
Input Voltage: 24-125 V dc ±10% (18/140 V pk Min/Max)
Loading (max): 12 mA (5 typical)
Delay (max): 5 ms (<1 typical)
MPU pulse rate range
2 Hz to 20 kHz
MPU pulse rate accuracy
0.05% of reading
MPU input circuit sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
20 kHz requires 294 mV p-p
Size
33.0 cm high x 17.8 cm, wide (13 in x 7 in)
Technology
Surface mount
PPRO, YPRO Backup Turbine Protection
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7.7.4 Diagnostics
Diagnostic tests are made on the terminal board:
•
•
•
•
Feedback from the shorted contact detector is checked, if a shorted relay is detected an alarm will be created.
Feedback from speed pickup fanning jumpers is checked; if there is a mismatch between intention and actual position, an
alarm is created.
If any one of the above signals goes unhealthy, a composite diagnostic alarm occurs. The diagnostic signals can be
individually latched and then reset with the RESET_DIA signal if they go healthy.
Terminal board connectors have their own ID device that is interrogated by the I/O pack. The ID device is a read-only
chip coded with the terminal board serial number, board type, revision number, and plug location. When the chip is read
by the I/O pack and a mismatch is encountered, a hardware incompatibility fault is created.
7.7.5 Configuration
Jumpers JP1 and JP2 select the fanning of the 3 X section passive speed pickups to the S and T section I/O packs. Place the
jumper over the pin pairs if you want to fan the 3 R speed input to the other two TMR sections.
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7.8 TREGH#B, S#B Gas Turbine Trip Board
The Gas Turbine Backup Trip (TREG) terminal board provides power to three emergency trip solenoids and is controlled by
the Mark VIe PPRO or Mark VIeS YPRO. Up to three trip solenoids can be connected between the TREG and TRPG
terminal boards. The TREG provides the positive side of the dc power to the solenoids and TRPG provides the negative side.
The PPRO or YPRO provides emergency overspeed protection, emergency stop functions, and controls the 12 relays on
TREG, nine of which form three groups of three to vote inputs controlling the three trip solenoids.
TREG Terminal Board
P125 V dc
JH1
x
x
x
x
x
x
x
x
x
x
x
x
1
3
5
7
9
11
13
15
17
19
21
23
x
26
28
30
32
34
36
38
40
42
44
46
48
x
x
x
x
x
x
x
x
x
x
x
x
x
25
27
29
31
33
35
37
39
41
43
45
47
x
x
x
x
x
x
x
x
x
x
x
x
To TRPG
J1
x
x
x 2
x 4
x 6
x 8
x 10
x 12
x 14
x 16
x 18
x 20
x 22
x 24
x
J2
TREG terminal board
Shield bar
JZ1
To TSVC
terminal boards
Cable
to SPRO
TPRO
Cable to
or SPRO
JY1
JX1
x
YPRO I/O
pack mounted
the SPRO
TPRO
on the
or SPRO
CabletotoSPRO
TPRO
Cable
or SPRO
Cable
to TPRO
or SPRO
Cable
to SPRO
37-pin D shell type
connectors with
latching fasteners
Barrier type terminal
blocks can be
unplugged from board for
maintenance
PPRO, YPRO Backup Turbine Protection
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7.8.1 Compatibility
The TREG trip board connects to the SPRO or TPRO terminal board. Control power from the JX1, JY1, and JZ1 connectors
are diode combined to create redundant power on the board for status feedback circuits and powering the economizing relays.
Power separation is maintained for the trip relay circuits. The following table lists all compatible versions.
Board
TMR
Simplex Output
Output
Contacts, Contacts,
125 V dc 24 V dc
E-Stop
Input
Contacts,
125 V dc
Input
Contacts,
24 V dc
Economy
Resistor
No
Yes
Yes
Yes
Yes
No
Yes
TREGH1B, S1B‡ Yes
No
Yes
Yes
Yes
No
Yes
Yes
TREGH2B, S2B‡ Yes
†TREGH3B, S3B‡ Yes
No
Yes
Yes
Yes
Yes
No
Yes
JX1 28 V dc
†TREGH4B, S4B‡ Yes
No
Yes
Yes
Yes
Yes
No
Yes
JY1 28 V dc
†TREGH5B, S5B‡ Yes
No
Yes
Yes
Yes
Yes
No
Yes
JZ1 28 V dc
† TREGH3/S3, H4/S4, and H4/S5 versions are the same as the H1/S1 except that power is provided by JX1, JY1, or JZ1.
‡ S#B versions are IEC 67508 safety certified with Mark VIeS YPRO (SPRO or TPRO) or with Mark VIe PPROS1B (only
TPRO)
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7.8.2 Installation
The three trip solenoids, economizing resistors, and the emergency stop are wired directly to the first I/O terminal block. Up
to seven trip interlocks can be wired to the second terminal block. The wiring connections are displayed in the following
figure.
To TRPG, 12 wires
Power 125 V dc
Turbine Emergency Trip
Terminal Board TREG
J1
J2
JH1
JZ1
x
PWR_N1
RES 1B
PWR_N2
RES 2B
PWR _N3
RES 3B
E-TRP (H)
E-TRP (L)
x
x
x
x
x
x
x
x
x
x
x
x
2
4
6
8
10
12
14
16
18
20
22
24
To servo
terminal
boards on
simplex
systems
x
x
x
x
x
x
x
x
x
x
x
x
1
3
5
7
9
11
13
15
17
19
21
23
SOL 1 or 4
RES 1A
SOL 2 or 5
RES 2A
SOL 3 or 6
RES 3A
E-TRP (H)
JUMPER
JY1
TPRO or SPRO
SPRO
with
YPRO I/O
pack
JX1
TPRO or SPRO
SPRO
with
YPRO I/O
pack
x
x
x
x
PWR_P2 (for probe)
x
x
x
Contact TRP1 (L)
Contact TRP2 (L)
Contact TRP3 (L)
Contact TRP4 (L)
Contact TRP5 (L)
Contact TRP6 (L)
Contact TRP7 (L)
x
x
x
x
x
x
x
26
28
30
32
34
36
38
40
42
44
46
48
x
x
x
x
x
x
x
x
x
x
x
x
25
27
29
31
33
35
37
39
41
43
45
47
PWR_P1 (for probe)
Contact TRP1 (H)
Contact TRP2 (H)
Contact TRP3 (H)
Contact TRP4 (H)
Contact TRP5 (H)
Contact TRP6 (H)
Contact TRP7 (H)
x
Up to two #12 AWG wires per
point with 300 volt insulation
Terminal blocks can be unplugged
from terminal board for maintenance
TPRO or SPRO
SPRO
with
YPRO I/O
pack
TREG Terminal Board Wiring
Note TREG_2B is a 24 V dc version of the terminal board.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 371
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7.8.3 Operation
The TREG is entirely controlled by the I/O pack. The connections to the control modules are the J2 power cable and trip
solenoids. In simplex systems, a third cable carries a trip signal from J1 to the servo terminal board, which provides a servo
valve clamp function upon turbine trip.
7.8.3.1
Control of Trip Solenoids
Both TRPG and TREG control the trip solenoids so that either one can remove power and actuate the hydraulics to close the
steam or fuel valves. The nine trip relay coils on TREG are supplied with 28 V dc from the I/O pack. The trip solenoids are
supplied with 125 V dc through plug J2, and draw up to 1 A with a 0.1 second L/R time constant.
Note The solenoid circuit has a metal oxide varistor (MOV) for current suppression and an optional 100 Ω, 70 W
economizing resistor.
A separately fused 125 V dc feeder is provided from the turbine control for the solenoids, which energize in the run mode and
de-energize in the trip mode. Diagnostics monitor each 125 V dc feeder from the power distribution module at its point of
entry on the terminal board to verify the fuse integrity and the cable connection.
Two series contacts from each emergency trip relay (ETR1, 2, 3) are connected to the positive 125 V dc feeder for each
solenoid, and two series contacts from each primary trip relay (PTR1, 2, 3 in TRPG) are connected to the negative 125 V dc
feeder for each solenoid. An economizing relay (KE1, 2, 3) is supplied for each solenoid with a normally closed contact in
parallel with the current limiting resistor. These relays are used to reduce the current load after the solenoids are energized.
The ETR and KE relay coils are powered from the I/O pack in each of the R, S, and T sections, which supply an independent
28 V dc source.
The 28 V dc bus is current limited and used for power to an external manual emergency trip contact, displayed as E-Stop.
Three master trip relays (KX4, KY4, KZ4) disconnect the 28 V dc bus from the ETR, and KE relay coils if a manual
emergency trip occurs. Any trip that originates in either the protection module (such as EOS) or the TREG (such as a manual
trip) will cause each of the three protection module sections to transmit a trip command over the IONet to the control module,
and may be used to identify the source of the trip.
In addition, with the Mark VIe PSVO, the K4CL servo clamp relay will energize and send a contact feedback directly from
the TREG terminal board to the TSVC servo terminal board. The servo terminal board disconnects the servo current source
from the terminal block and applies a bias to drive the control valve closed. This is only used on simplex applications to
protect against the servo amplifier failing high.
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TREG Board, Trip Interlocks, and Trip Solenoids
Note ** The KCL4 relay is referred to as K4CL within ladder logic, signal names, and descriptions in this document.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 373
Non-Public Information
7.8.3.2
Solenoid Trip Tests
The Mark VIe or Mark VIeS controller is used to initiate tests of the trip solenoids. Online tests allow each of the trip
solenoids to be manually tripped one at a time, either through the PTR relays from the controller, or through the ETR relays
from the protection module. A contact from each solenoid circuit is wired back as a contact input to give a positive indication
that the solenoid has tripped. Primary and emergency offline overspeed tests are provided too for verification of actual trips
due to software simulated trip overspeed conditions.
7.8.4 Specifications
Item
TREG Specification
Number of trip solenoids
Three solenoids per TREG (total of six per I/O pack)
Trip solenoid rating
H1 and S1 are 125 V dc standard with 1 A draw
H2 and S2 are 24 V dc alternate with 1 A draw
Trip solenoid circuits
Circuits rated for NEMA class E creepage and clearance
Circuits can clear a 15 A fuse with all circuits fully loaded
Solenoid inductance
Solenoid maximum L/R time constant is 0.1 second
Suppression
MOV across the solenoid
Relay outputs
Three economizer relay outputs, two second delay to energize
Driver to breaker relay K25A on TTUR
Servo clamp relay on the servo terminal board
Solenoid control relay contacts
Contacts are rated to interrupt inductive solenoid loads at 125 V dc, 1 A
Bus voltage can vary from 70 to 140 V dc
Trip inputs
Seven trip interlocks to the I/O pack, 125/24 V dc
One emergency stop hard wired trip interlock, 24 V dc
Trip interlock excitation
H1 and S1 are nominal 125 V dc, floating, ranging from 100 to 140 V dc
H2 and S2 are nominal 24 V dc, floating, ranging from 18.5 to 32 V dc
Trip interlock current
H1 and S1 for 125 V dc applications:
Circuits draw 2.5 mA (50 Ω)
H2 and S2 for 24 V dc applications:
Circuits draw 2.5 mA (10 Ω)
Trip interlock isolation
Optical isolation to 1500 V on all inputs
Trip interlock filter
Hardware filter, 4 ms
Trip interlock ac voltage rejection
60 V rms 50/60 Hz at 125 V dc excitation
Size
17.8 cm wide x 33.02 cm, high (7.0 in x 13.0 in)
7.8.5 Diagnostics
The I/O pack runs diagnostics on the TREG board and connected devices. The diagnostics cover the trip relay driver and
contact feedbacks, solenoid voltage, economizer relay driver and contact feedbacks, K25A relay driver and coil, servo clamp
relay driver and contact feedback, and the solenoid voltage source. If any of these do not agree with the desired value, a fault
is created.
TREG connectors JX1, JY1, and JZ1 have their own ID device that is interrogated by the I/O pack. The ID device is a
read-only chip coded with the terminal board serial number, board type, revision number, and the plug location. When the
chip is read by the I/O pack and a mismatch is encountered, a hardware incompatibility fault is created.
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7.8.6 Configuration
A jumper must be placed across terminals 15 and 17 if the second emergency stop input is not required. There are no switches
on the terminal board.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 375
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7.9 TREL Large Steam Turbine Trip Board
7.9.1 Functional Description
The Large Steam Turbine Emergency Trip (TREL) terminal board is used for the emergency overspeed protection for large
steam turbines. The TREL is controlled by the PPRO I/O pack in the protection module. It provides power to three emergency
trip solenoids, which can be connected between the TREL and TRPL terminal boards. The TREL provides the positive side of
the 125 V dc (or 24 V dc) to the solenoids and TRPL provides the negative side. The PPRO I/O pack provides emergency
overspeed protection, emergency stop functions, and controls the nine relays on TREL, which form three groups of three to
vote inputs controlling the three trip solenoids. The three groups are called ETR (emergency trip) 1, 2, and 3. The following
also applies to the TREL:
•
•
•
376
TREL is only available in TMR form.
TREL has no economizing relay as with TREG.
TREL has no E-Stop function as with TREG.
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7.9.2 Installation
The three trip solenoids are wired to the first I/O terminal block. Up to seven trip interlocks are wired to the second terminal
block. The wiring connections are displayed in the following figure. Connector J2 carries three power buses from TRPL, and
JH1 carries the excitation voltage for the seven trip interlocks.
TREL Terminal Board Wiring
PPRO, YPRO Backup Turbine Protection
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7.9.3 Operation
The TREL is entirely controlled by the PPRO I/O pack. The only connections to the turbine control are the J2 power cable
and the trip solenoids. In simplex systems, a third cable carries a trip signal from J1 to the servo terminal board, providing a
servo valve clamp function upon turbine trip.
7.9.3.1
Control of Trip Solenoids
Both TRPL and TREL control the trip solenoids 1 and 2 so that either one can remove power and actuate the hydraulics to
close the steam or fuel valves. ETR3 is set up to supply power to trip solenoid #3. The nine trip relay coils on TREL are
supplied with 28 V dc from the PPRO . The trip solenoids are supplied with 125 or 24 V dc through plug J2, and draw up to 1
A with a 0.1 second L/R time constant. The solenoid circuit has a MOV for current suppression on TRPL.
A separately fused 125 or 24 V dc feeder is provided from the PDM to the solenoids. Diagnostics monitor each dc feeder
from the PDM at its point of entry on the terminal board to verify the fuse integrity and the cable connection.
Note A normally closed contact from each relay is used to sense the relay status for diagnostics.
Two series contacts from each of the emergency trip relays (ETR1, 2, 3) are connected to the positive 125 or 24 V dc feeder
for each solenoid, and two series contacts from each of the primary trip relays are connected to the negative dc feeder for each
solenoid. The ETR relay coils are powered from a 28 V dc source from the PPRO . Each PPRO in each of the R, S, and T
sections supplies an independent 28 V dc source.
The K4CL servo clamp relay will energize and send a contact feedback directly from the TREL terminal board to the servo
terminal board. The servo terminal board disconnects the servo current source from the terminal block and applies a bias to
drive the control valve closed. This is only used on simplex applications to protect against the servo amplifier failing high.
The primary and emergency overspeed systems will trip the hydraulic trip solenoids independent of this circuit.
7.9.3.2
Solenoid Trip Tests
Software in the Mark VIe controller is used to initiate tests of the trip solenoids. Online tests allow each of the trip solenoids
to be manually tripped one at a time, either through the PTR relays from the controller, or through the ETR relays from the
protection module. A contact from each solenoid circuit is wired back as a contact input to give a positive indication that the
solenoid has tripped. Primary and emergency offline overspeed tests are provided too for verification of actual trips due to
software simulated trip overspeed conditions.
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TREL Terminal Board, Trip, Interlocks, and Trip Solenoids
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 379
Non-Public Information
7.9.4 Specifications
Item
TREL Specification
Number of trip solenoids
Three solenoids per TREL (total of six per PPRO I/O pack)
Trip solenoid rating
125 V dc standard with 1 A draw
24 V dc is alternate with 3 A draw or 125 V dc standard with 1 A draw
Trip solenoid circuits
Circuits rated for NEMA class E creepage and clearance
Circuits can clear a 15 A fuse with all circuits fully loaded
Solenoid inductance
Solenoid maximum L/R time constant is 0.1 sec
Suppression
MOV on TRPL across the solenoid
Relay Outputs
Driver to breaker relay K25A on TTUR.
Servo clamp relay on the servo terminal board.
Solenoid control relay contacts
Contacts are rated to interrupt inductive solenoid loads at 125 V dc, 1 A.
Bus voltage can vary from 70 to 140 V dc
Trip inputs
Seven trip interlocks to the PPRO protection module, 125/24 V dc
Trip interlock excitation
H1 - Nominal 125 V dc, floating, ranging from 100 to 140 V dc
H2 - Nominal 24 V dc, floating, ranging from 18.5 to 32 V dc
Trip interlock current
H1 for 125 V dc applications:
Circuits draw 2.5 mA (50 Ω)
H2 for 24 V dc applications:
Circuits draw 2.5 mA (10 Ω)
Trip interlock isolation
Optical isolation to 1500 V on all inputs
Trip interlock filter
Hardware filter, 4 ms
Trip interlock ac voltage rejection
60 V rms at 50/60 Hz at 125 V dc excitation
Size
17.8 cm wide x 33.02 cm high (7.0 in x 13.0 in)
7.9.5 Diagnostics
The PPRO protection module runs diagnostics on the TREL board and connected devices. The diagnostics cover the trip relay
driver and contact feedbacks, solenoid voltage, K25A relay driver and coil, servo clamp relay driver and contact feedback,
and the solenoid voltage source. If any of these do not agree with the desired value, a fault is created.
TREL connectors JX1, JY1, and JZ1 have their own ID device that is interrogated by the PPRO. The ID device is a read-only
chip coded with the terminal board serial number, board type, revision number, and the plug location. When the chip is read
by the PPRO
I/O pack and a mismatch is encountered, a hardware incompatibility fault is created.
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7.10
TRES Small Steam Turbine Trip Board
7.10.1
Functional Description
The Small Steam Turbine Emergency Trip (TRES) terminal board is used for the emergency overspeed protection for
small/medium size steam turbines. The TRES is controlled by the PPRO I/O pack. The TRES provides power to three
emergency trip solenoids, which can be connected between the TRES and TRPS terminal boards. TRES provides the positive
side of the 125/24 V dc to the solenoids and TRPS provides the negative side. The PPRO I/O pack provides emergency
overspeed protection, emergency stop functions, and controls the three relays on TRES, which control the three trip solenoids.
The following also applies to the TRES:
•
•
•
•
TRES has both simplex and TMR form.
There are seven dry contact inputs for trip interlocks.
TRES has no economizing relays.
There are no emergency stop inputs.
In the TRES, the seven dry contact inputs excitation and signal are monitored and fanned to the protection module. The board
includes the synch check relay driver, K25A, and associated monitoring, the same as on TREG, and the servo clamp relay
driver, K4CL, and its associated monitoring. A second TRES board cannot be driven from the protection module.
PPRO, YPRO Backup Turbine Protection
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7.10.2
Installation
The three trip solenoids are wired to the first I/O terminal block. Up to seven trip interlocks are wired to the second terminal
block. The wiring connections are displayed in the following figure.
Connector J2 carries three power buses from TRPS, and JH1 carries the excitation voltage for the seven trip interlocks.
TRES Terminal Board Wiring
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7.10.3
Operation
7.10.3.1
Control of Trip Solenoids
Both TRPS and TRES control the trip solenoids 1 and 2 so that either one can remove power and actuate the hydraulics to
close the steam or fuel valves. ETR3 is set up to supply power to trip solenoid #3. The nine trip relay coils on TRES are
supplied with 28 V dc from the PPRO I/O pack. The trip solenoids are supplied with 125 or 24 V dc through plug J2, and
draw up to 1 A with a 0.1 second L/R time constant. In simplex systems, a third cable carries a trip signal from J1 to the servo
terminal board, providing a servo valve clamp function upon turbine trip.
A separately fused 125 or 24 V dc feeder is provided from the PDM for the solenoids. Diagnostics monitor each 125 or 24 V
dc feeder from the PDM at its point of entry on the terminal board to verify the fuse integrity and the cable connection. The
solenoid circuit has a MOV for current suppression on TREL.
Note A normally closed contact from each relay is used to sense the relay status for diagnostics
Two series contacts from each of the emergency trip relays (ETR1, 2, 3) are connected to the positive 125 or 24 V dc feeder
for each solenoid, and two series contacts from each of the primary trip relays are connected to the negative 125 or 24 V dc
feeder for each solenoid. The ETR relay coils are powered from PPROs in each of the R, S, and T sections, which supply an
independent 28 V dc source.
The K4CL servo clamp relay will energize and send a contact feedback directly from the TRES terminal board to the servo
terminal board. The servo terminal board disconnects the servo current source from the terminal block and applies a bias to
drive the control valve closed. This is only used on simplex applications to protect against the servo amplifier failing high.
The primary and emergency overspeed systems will trip the hydraulic trip solenoids independent of this circuit.
Note To enable solenoid voltage feedbacks on the TRPS board, install jumpers between SUS#A and either SOL#A or
SOL#B. Connect SUS#A to the solenoid in the chosen configuration. The solenoids may be connected to the NO or NC
contacts of the ETR, and the SUS#A pin should be connected to the same contact to enable the voltage monitoring input. For
jumper configurations needed to enable solenoid voltage feedback, refer to GEI-100575, Mark VIe Control Turbine Specific
Primary Trip (PTUR) Module Description, the section, TRPS Turbine Primary Trip.
7.10.3.2
Solenoid Trip Tests
Software in the Mark VIe controller is used to initiate tests of the trip solenoids. Online tests allow each of the trip solenoids
to be manually tripped one at a time, either through the PTR relays from the controller, or through the ETR relays from the
protection module. A contact from each solenoid circuit is wired back as a contact input to give a positive indication that the
solenoid has tripped. Primary and emergency offline overspeed tests are provided too for verification of actual trips due to
software simulated trip overspeed conditions.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 383
Non-Public Information
JA 1
Simplex
system
uses JA 1
J 2 , power
buses from
TRPS
Terminal Board TRES
PwrA_ N
P 28 A
P 28 X
PwrB_N
PwrA_P
Terminal
Board
TRPS
PwrC_N
PwrB_ P
PwrC_P
P 28 Y
P 28
P 28 Z
Sol .
To JX1, Power
JY1, JZ1, Monitor
JA1
ID
JX1
I/O
Controller
2
3
RD
ETR 1
PwrA_P
To X , Y, Z, A
Mon
ETR 1
ID
P 28
RD
2
3
SUS1A
01
SUS1B
ETR1
SOL1A
Trip
solenoid
03 +
-
ETR1
SOL1B
04
02
Several terminals
positions for
different
applications
PwrA_P 08
PwrA_N 09
PwrA_N
JY1
I /O
Controller
J2
J2
ETR 2
J2
J2
To X, Y, Z, A
Mon
ETR 2
PwrB_P
SUS2A
11
SUS2B
12
ID
P 28
ETR2
SOL 2A
ETR2
SOL2B
14
PwrB_P
18
JZ1
PwrB_ N
I /O
Controller
RD
2
3
PwrB_N
ETR 3
Mon
ETR 3
PwrC_P
ID
ETR3
P 28 VV
ETR3
K4 CL
J1
To TTURH 1B
To relay K 25 A
on TTUR
PDM
JX1
JY1
JZ1
JA1
J2
PwrC_N
SUS3A
21
SUS3B
22
SOL3A
Trip
solenoid
23 +
-
SOL 3B
24
PwrC_P
28
PwrC_N
29
To JX 1, JY 1 ,
JZ 1, JA1
Mon
K4 CL
J 25
Exc _ P
2
RD 3
J2
JH 1
From
2
RD 3
K4 CL
Servo Clamp
19
J2
To X , Y, Z, A
To the servo
terminal board
on simplex
systems
Trip
solenoid
13 +
-
Excit_ P
Mon
JX1
JY1
JZ1
JA1
Excitation
volts
7
Excitation _ N
BCOM
35
TRP1A
36
TRP1B
NS
NS
.
.
.
Trip interlock
7 circuits as above
TRES Terminal Board, Trip Interlocks, and Trip Solenoids
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7.10.4
Specifications
Item
TRES Specification
Number of trip solenoids
Three solenoids per TRES
Trip solenoid rating
125 V dc standard with 1 A draw
24 V dc is alternate with 3 A draw
Trip solenoid circuits
Circuits rated for NEMA class E creepage and clearance
Circuits can clear a 15 A fuse with all circuits fully loaded
Solenoid inductance
Solenoid maximum L/R time constant is 0.1 sec
Suppression
MOV on TRPS across the solenoid
Relay Outputs
Driver to breaker relay K25A on TTUR
Servo clamp relay on the servo terminal board.
Solenoid control relay contacts
Contacts are rated to interrupt inductive solenoid loads at 125 V dc, 1 A.
Bus voltage can vary from 70 to 140 V dc.
Trip inputs
Seven trip interlocks to the PPRO I/O pack
Trip interlock excitation
H1 - Nominal 125 V dc, floating, ranging from 100 to 140 V dc
H2 - Nominal 24 V dc, floating, ranging from 18.5 to 32 V dc
Trip interlock current
H1 for 125 V dc applications:
Circuits draw 2.5 mA (50 Ω)
H2 for 24 V dc applications:
Circuits draw 2.5 mA (10 Ω)
Trip interlock isolation
Optical isolation to 1500 V on all inputs
Trip interlock filter
Hardware filter, 4 ms
Trip interlock ac voltage rejection
60 V rms at 50/60 Hz at 125 V dc excitation
Size
17.8 cm wide x 33.02 cm high (7.0 in x 13.0 in)
7.10.5
Diagnostics
The PPRO runs diagnostics on the TRES board and connected devices. The diagnostics cover the trip relay driver and contact
feedbacks, solenoid voltage, K25A relay driver and coil, servo clamp relay driver and contact feedback, and the solenoid
voltage source. If any of these do not agree with the desired value, a fault is created.
TRES connectors JA1, JX1, JY1, and JZ1 have their own ID device that is interrogated by the PPRO. The ID device is a
read-only chip coded with the terminal board serial number, board type, revision number, and the plug location. When the
chip is read by the PPRO and a mismatch is encountered, a hardware incompatibility fault is created.
PPRO, YPRO Backup Turbine Protection
GEH-6721_Vol_III_BJ System Guide 385
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Notes
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8 PSCH Specialized Serial
Communication
8.1 PSCH Specialized Serial Communication I/O Pack
The Serial Communication Input/Output (PSCH) pack provides specialized
communication support for GE Drilling equipment, including the blowout preventer
(BOP). The PSCH can have one or two I/O Ethernet networks and mounts to the serial
communications terminal board (SSCA). Several unique communication devices
(protocols) can be configured to manage I/O points during scans.
The PSCH I/O pack contains a processor board used with most distributed I/O modules
and a serial communications board (BSCA). The BSCA contains six serial transceiver
channels, each of which can be individually configured to comply with RS-232C, RS-422,
or RS-485 half-duplex standards. Input to the I/O pack is through dual RJ-45 Ethernet
connectors and a 3-pin power input. Output is through a DC-62 pin connector that
connects directly with the associated terminal board connector. Visual diagnostics are
provided through indicator LEDs.
The PSCH does not support frame periods less than 40 ms.
For configuration of I/O
points, refer to GEH-6763,
Mark* VIe Control PSCH
Specialized Serial
Communication Module
Instruction Guide.
PSCH Specialized Serial Communication
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8.1.1 Installation
➢ To install the PSCH I/O pack
1.
Securely mount the SSCA terminal board inside the distributed I/O cabinet. Refer to GEH-6721_Vol_II, the chapter
PSCA Serial Communication Module, the section SSCA Simplex Serial Communication Terminal Board.
2.
Directly plug one PSCH I/O pack into the SSCA terminal board connector.
3.
Mechanically secure the I/O pack using the threaded inserts adjacent to the Ethernet ports. The inserts connect with the
mounting bracket specific to the terminal board type (H1 or H2). The bracket location should be adjusted such that there
is no right angle force applied to the DC-62 pin connector between the PSCH I/O pack and the terminal board. This
adjustment should only be required once in the service life of the PSCH.
4.
Plug in one or two Ethernet cables depending on the system configuration. The PSCH operates over either port. If dual
connections are used, standard practice is to attach ENET1 to the network associated with the R controller. However, the
PSCH is not sensitive to Ethernet connections, and will operate correctly over either port.
5.
Apply power to the PSCH by plugging in the connector on the side of the I/O pack. It is not necessary to remove power
from the cable before plugging it in because the PSCH has inherent soft-start capability that controls current inrush on
power application.
6.
From the ToolboxST* application, add the PSCH I/O module and communication devices. Refer to GEH-6700, the
chapter Special I/O Functions.
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8.1.1.1
Rules and Restrictions
A summary of device restrictions and configuration rules for the PSCH is as follows:
•
•
•
•
•
•
•
•
Maximum number of subsea POD serial channels per PSCH is 1
Maximum number of surface test POD serial channels per PSCH is 2
No other device types or serial protocols may be used with a POD device
Every POD in the system must have a unique POD with Subsea Electronics Module (SEM) configuration setting
Maximum number of GPS serial channels per PSCH is 1
No other device types or serial protocols may be used with a GPS device
Maximum number of other BOP serial channels per PSCH is 4
PSCH is limited to 4 input exchange buffers and 3 output exchange buffers. Refer to the following table for the number
of input and output exchanges used per I/O device.
Number of Exchanges Required
I/O Device
Output Exchange
Ethernet Buffers
Input Exchange
Ethernet Buffers
FTI (Panametrics)
1
1
ASK
1
–
FTD (OTEK display)
1
–
ERA
–
1
UPS
–
1
The following are examples of valid configurations:
•
•
•
•
•
PSCH with one ERA, one ASK, and two UPS
PSCH with two FTIs and one FTD
PSCH with one subsea POD
PSCH with two surface test PODs
PSCH with one GPS
Redundancy
Protocol
Simplex
HotBackup
FTI, FTD, and GPS
Yes
No
POD, ASK, ERA, and UPS
Yes
Yes
PSCH Specialized Serial Communication
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8.1.2 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
•
•
•
•
•
•
8.1.2.1
Serial Channels
The BSCA board in the pack contains six independently configurable serial channels. The processor board configures the
channels with one of three mode inputs as follows:
Mode
Transceiver
0
RS-232C
1
RS-422
2
RS-485 half duplex only
3
Default/resent state (fail safe)
Jumpers on the SSCA terminal board are used to set up the terminal scheme for the selected communication mode.
8.1.2.2
Data Flow
For most applications, the system is normally configured to use dual Mark VIe controllers and PSCHs with redundancy
configured as HotBackup. The following specialized communication devices provide data flow between equipment, PSCHs,
and Mark VIe controllers:
•
•
Automatic Station Keeping (ASK)
Electronic Riser Angle (ERA)
•
Flow Totalizer Display (FTD)
•
•
Flow Totalizer Input (FTI)
Global Positioning System (GPS)
Note FTD, FTI, and GPS communication devices do not support HotBackup redundancy.
•
•
POD
Universal Power Supply (UPS)
Note Refer to GEH-6763, Mark VIe Control PSCH Specialized Serial Communication Module Instruction Guide for more
information on these communication devices.
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8.1.2.3
•
•
•
Connectors
DC-62 located on the underside of the I/O pack connects directly to a discrete output terminal board.
RJ-45 Ethernet connector – ENET1 located on the I/O pack side is the primary system interface.
RJ-45 Ethernet connector – ENET2 located on the I/O pack side is the redundant or secondary system interface.
Note The terminal board provides fused power output from a power source that is applied directly to the terminal board, not
through the I/O pack connector.
8.1.3 Specifications
Item
PSCH Specification
Channels
Six independently configurable serial channels
One Ethernet Modbus Channel (simplex network)
Communication choices
RS-232C Mode
RS-422 Mode
RS-485 Mode half duplex only
Ethernet Modbus Mode
RS-232C Mode
Cable distance: 50 ft (15.24 m)
Communication Rate: 115.2 kbps maximum
RS-422 Mode
Cable distance: 1000 ft (304.8 m)
Communication Rate: 375 kbps maximum
Number of Drops: 8
RS-485 Mode
Cable distance: 1000 ft (304.8 m)
Communication Rate: 115.2 kbps maximum
Number of drops: 8
Size
8.26 cm high x 4.19 cm wide x 12.1 cm deep (3.25 in x 1.65 in x 4.78 in)
Technology
Surface-mount
† Ambient rating for enclosure design
Operating: -30 to 65ºC (-22 to 149 ºF)
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
PSCH Specialized Serial Communication
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8.1.4 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RESET_DIA signal if they go healthy.
8.1.5 Configuration
For configuration of I/O points, refer to GEH-6763, Mark VIe Control PSCH Specialized Serial Communication Module
Instruction Guide.
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8.2 PSCH Specific Alarms
The following alarms are specific to the PSCH.
32-67
Description Comm Port #[ ] Device/Station #[ ] Communication Failure - No Response
Possible Cause
•
•
A command was sent to a field device, but no response was received.
The connected device is powered-off or rebooting.
Solution
•
•
•
•
•
•
Verify that the serial or Ethernet cable is connected to the field device.
Verify that the device is powered-on and configured for the correct station ID.
For serial connections, verify that the baud rate and parity are set correctly.
For Ethernet connections, verify that the IP address is set correctly.
Cycle power on the field device.
Troubleshoot the field device for internal errors, referring to its manual. If the problem persists, replace the field device.
72-107
Description Comm Port #[ ] Device/Station #[ ] Communication Failure - Bad Data
Possible Cause
The field device responded, but could not provide data for one or more points.
Solution
•
•
•
•
For serial connections, verify that the baud rate and parity are set correctly.
Cycle power on the field device.
Troubleshoot the field device for internal errors, referring to its manual. If the problem persists, replace the field device.
Verify that the slave device is the one expected to be communicating with.
108-113
Description Configuration Problem Port #[ ]
Possible Cause
The configuration file downloaded from the Toolbox ST application contained an error.
Solution
•
•
•
Verify that the I/O and configuration compatibility codes agree between the ToolboxST configuration and the PSCH.
Build and download the firmware and the configuration to the PSCH.
If diagnostic persists, restart the PSCH.
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120-125
Description Communication Device Failure Port #[ ]
Possible Cause
Failed to create a task to support the configured communication device
Solution
•
•
•
Verify that the I/O and configuration compatibility codes agree between the ToolboxST configuration and the PSCH.
Build and download the firmware and the configuration to the PSCH.
If diagnostic persists, restart the PSCH.
126-131
Description FTI Port #[ ] - Register Set Mismatch
Possible Cause
•
•
The Modbus port is connected to a device other than an Ultrasonic Flow Meter.
Register 508 is not reporting the correct baud rate.
Solution
•
•
•
Verify that the serial port is connected to an Ultrasonic Flow Meter.
Verify that register 508 is returning the baud rate index for the device.
If the diagnostic persists, restart the PSCH.
132-137
Description Simplex Communication Device on Port #[ ] used in a HotBackup PSCH
Possible Cause A simplex protocol (GPS, FTI, FTD) was defined in a PSCH that was configured as a HotBackup. This
protocol does not support HotBackup.
Solution From the ToolboxST application, either remove the communication device from the port specified, or configure
the PSCH as simplex.
138-143
Description POD Port #[ ] Communication Device Major Revision Mismatch. PSCH: [ ], POD: [ ]
Possible Cause As part of the communications between the PSCH and the POD, certain revision information is
exchanged to ensure compatibility. This alarm indicates that there is a mismatch between the PSCH major revision and the
major revision currently loaded in the POD. From the ToolboxST application, the PSCH major revision MasterMajorRev
displays in the Parameters tab (show advanced rows).
Solution The major revisions of the PSCH and POD must match for communication to occur. Perform one of the
following:
•
•
394
Upgrade the POD software to match the major/minor revision implemented in the PSCH.
Re-add the PSCH to the system definition, using a firmware revision that implements the major/minor revision of the
communication device that matches the current version in the POD.
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144-149
Description POD Port #[ ] Communication Device Minor Revision Mismatch. PSCH: [ ], POD: [ ]
Possible Cause As part of the communications between the PSCH and the POD, certain revision information is
exchanged to ensure compatibility. This alarm indicates that there is a mismatch between the PSCH minor revision and the
minor revision currently loaded in the POD. From the ToolboxST application, the PSCH minor revision MasterMinorRev
displays in the Parameters tab (show advanced rows).
Solution The minor revisions of the PSCH and POD must match for communication to occur. Perform one of the
following:
•
•
Upgrade the POD software to match the major/minor revision implemented in the PSCH.
Re-add the PSCH to the system definition, using a firmware revision that implements the major/minor revision of the
communication device that matches the current version in the POD.
150-155
Description ASK Port #[ ] Prefix string requires '$' then 5 characters
Possible Cause For the ASK communication device on the PSCH, the port is configured with three prefix code strings
for serial communications. These three strings must be six characters in length with the first character being a dollar sign ($).
Solution Correct the three prefix code strings and re-download.
➢ To display and correct these strings
1.
From the Component Editor Tree View, select the PSCH.
2.
Expand and select the ASK port.
3.
From the Summary View, select the Parameters tab.
4.
Click the lightening bolt (advanced view) icon.
5.
Verify that all names beginning with Prefix are six characters in length and start with a $.
Defaults: PrefixYellow="$HYRIY", PrefixBlue="$HYRIB", PrefixSurfaceRiser="$HYRIT"
156-161
Description Port #[ ]: Scan period, [ ] millisecond, too small for specified baud rate
Possible Cause Based on the number of characters to be transmitted and received on the serial port and the associated
baud rate, the specified scan period is too small.
Solution Do one of the following:
•
•
•
Increase the scan period.
Increase the baud rate.
Configure the PSCH for less data to be transmitted or received.
162-167
Description Port #[ ]: GPS - Satellite signals are too weak
Possible Cause
available.
Fewer than three satellite signals have been detected by the GPS unit. No position or time information is
Solution Verify that the GPS antenna is positioned correctly and is connected to the GPS receiver.
PSCH Specialized Serial Communication
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168-173
Description Comm Port #[ ]: Communication Failure - Insufficient Data
Possible Cause
The field device responded, but did not provide enough data for a complete response.
Solution
•
•
•
•
Verify that the serial or Ethernet cable is connected to the field device.
Verify that the device is powered-on and configured for the correct station ID.
For serial connections, verify that the baud rate and parity are set correctly.
For Ethernet connections, verify that the IP address is set correctly.
174-179
Description Comm Port #[ ]: Communication Failure - Excess Data
Possible Cause
The field device responded, but provided more data than required for a complete response.
Solution
•
•
•
Verify that the serial cable is connected to the correct field device.
Verify that the device is configured for the correct station ID.
For Ethernet connections, verify that the IP address is set correctly.
180-185
Description Configuration Problem Port #[ ]: - incorrect scaling values
Possible Cause
Scaling data was entered incorrectly.
Solution
•
•
•
Fix Raw Min to be less than the Raw Max value.
Fix Eng Min to be less than the Eng Max value.
To disable scaling, set all four entries (Raw Min, Raw Max, Eng Min, Eng Max) to 0.
186-191
Description Comm Port #[ ]: No HotBackup Primary Detected
Possible Cause
No HotBackup Primary was detected for over five seconds.
Solution
•
•
•
396
Verify that the primary control bits are being used in the class one variable definition.
Verify that the R and S primary control are not both set to true for over five seconds.
Verify that the R and S primary control are not both set to false for over five seconds.
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192-197
Description Comm Port #[ ]: GPS Receiver Configuration Failed
Possible Cause
Unable to configure the GPS Receiver
Solution
•
•
•
Verify the connection to the GPS Receiver is correct.
Verify the baud rate is 1200, 4800, 9600 or 19200. The auto baud only attempts these values.
Verify that the Yellow and Blue Panel Baud rates are the same. The Blue panel does not auto-baud and relies on the
Yellow Panel GPS to set the baud rate on the GPS Receiver.
198-203
Description Comm Port #[ ]: - Value exceeds the display's ability, [ ]
Possible Cause
Solution
Trying to display too large a value
Change the DigitsAfterPt parameter to a value between 0 and 7.
204-209
Description Comm Port #[ ]: Communication Failure - Incorrect Message
Possible Cause
The field device responded, but did not provide the correct response.
Solution
•
•
•
•
Verify that the serial or Ethernet cable is connected to the correct field device.
Verify that the device is powered on and configured for the correct station ID.
For serial connections, verify that the baud rate and parity are set correctly.
For Ethernet connections, verify that the IP address is set correctly.
210
Description NTP is not currently running - No time sync available
Possible Cause
The NTP process is not currently active, which means that UTC clock synchronization is not occurring.
Solution Verify that the GPS signals are not weak, and that the GPS device is providing an accurate time source to the
PSCH.
8.3 Simplex Serial Communication Input/Output (SSCA)
Refer GEH-6721_Vol_II, the chapter PSCA Serial Communication I/O Module, the section, Simplex Serial Communication
Input/Output (SSCA).
PSCH Specialized Serial Communication
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Notes
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9
PSVO Servo Control Module
9.1 PSVO Servo Control I/O Pack
The Servo Control (PSVO) I/O pack provides the electrical interface between one or
two I/O Ethernet networks and a TSVC servo terminal board. The I/O pack contains
common processor board and an application board specific to the servo function. The
PSVO uses the adjacent WSVO servo driver module to handle two servo valve position
loops, with a selection of five servo valve output currents from 10-120 mA dc. The I/O
pack supplies LVDT excitation, and accepts eight LVDT feedbacks and two pulse rate
inputs from fuel flow meters.
Input to the I/O pack is through dual RJ-45 Ethernet connectors, and 28 V dc power is
supplied from the terminal board. Output is through a DC-62 pin connector that
connects directly with the associated terminal board connector. Visual diagnostics are
provided through indicator LEDs.
BSVOH1 A
board
TSVCH1A
Servo
Terminal
Board
PSVO
I/O Pack
Processor
board
Ethernet
connections
ENET1
WSVO
Servo
driver
Servo coil outputs
LVDT excitation
LVDT inputs
Pulse rate inputs
ENET2
ENET1
ENET2
WSVO
ENET1
WSVO
PSVO Servo Control Module
ENET2
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9.1.1 Compatibility
The PSVO I/O pack includes one of the following BPPx processor boards.
•
•
The PSVOH1A contains a BPPB processor.
The PSVOH1B contains a BPPC processor, and requires firmware V04.09 or later.
Terminal
Board
Option for T1
through T4
Module
Redundancy
Network Redundancy
TSVCH1A
With isolation
Simplex, 1 I/O pack
1 I/O network with 1 controller
TSVCH2A
transformers
2 I/O networks with 2 or 3 controllers
Excludes isolation
TMR, 3 I/O packs
transformers
TMR controllers: 3 I/O network per pack (R, S, T)
Dual controllers: 2 I/O networks with T pack having both networks
9.1.2 Installation
➢ To install the PSVO I/O pack
1.
Securely mount the desired terminal board (TSVCH1A or H2A).
2.
Directly plug one (simplex) or three I/O packs (for TMR) into the terminal board connectors.
3.
Mechanically secure the I/O pack(s) using the threaded inserts adjacent to the Ethernet ports. The inserts connect with a
mounting bracket specific to the terminal board type. The bracket location should be adjusted such that there is no right
angle force applied to the DC-62 pin connector between the I/O pack and the terminal board. The adjustment should only
be required once in the service life of the product.
4.
Plug the WSVO servo driver assemblies into the J2 48-pin connectors and secure with the four screws.
5.
Plug in one or two Ethernet cables depending on the system configuration. The I/O pack operates over either port. If dual
connections are used, standard practice is to hook ENET1 to the network associated with the R controller, however, the
PSVO is not sensitive to Ethernet connections and negotiates proper operation over either port.
6.
Apply power to the I/O packs and drivers using the power switches on TSVC. Use SW3 for R, SW2 for S, and SW1 for
T, and check the indicator lights.
Caution
7.
400
For simplex applications that have a connection to the TSVC JD1 or JD2 (the K1 relay
is being used) verify that SW1 is in the ON position, and verify that the green DS1
LED is lit. This indicates that the necessary P28T power is available. If the DS1 LED
is not lit, then the K1 trip override relay will not provide the intended protection.
Use the ToolboxST* application to configure the I/O packs as necessary.
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9.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
9.1.3.1
•
•
•
Connectors
The DC 62-pin connector on the underside of the I/O pack connects directly to a discrete output terminal board.
The RJ-45 Ethernet connector (ENET1) on the I/O pack side is the primary system interface.
The second RJ-45 Ethernet connector (ENET2) on the I/O pack side is the redundant or secondary system interface.
Note The terminal board provides fused power output from a power source that is applied directly to the terminal board, not
through the I/O pack connector.
9.1.3.2
Calibrate Valve Function
The calibration of LVDTs associated with PSVO, PSVP, PCAA, or PMVE (MVRA or MVRF) servos is required when a new
terminal board is used on a system. The controller saves the barcode of the terminal board and compares it to the current
terminal board during reconfiguration load time. Any time a recalibration is saved, it updates the barcode name to the current
board.
Note Refer to the ToolboxST User Guide for Mark Controls Platform (GEH-6700), the chapter Special I/O Functions. the
section Calibrate Valve Function.
PSVO Servo Control Module
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9.1.3.3
BSVO Servo Board
The BSVO board multiplexes 24 analog channels into a 16-bit A/D converter. The 100 kHz A/D has a ±10 V dc range, and
handles the servo current regulator signals, the LVDT inputs, and power supply monitoring. The current references for the
analog current regulators on WSVO are generated on the BSVO by a 14-bit D/A converter. Excitation for the LVDTs uses a
digital to analog converter, which outputs a sine wave with a frequency of 3.2 kHz. This is filtered and passed to the WSVO.
The board provides signal conditioning for two pulse rate channels and passes the signals to the processor board to determine
the pulse rate.
9.1.3.4
WSVO Servo Driver Assembly
The servo driver assembly has a power supply that converts the P28 voltage input to a positive 15 V and negative 15 V output
for the servo current regulator circuits. There are two servo current regulators working off the current references from the
servo I/O pack. The servo driver circuit has a selection of five configurable gains, and the assembly contains the servo suicide
relays and excitation output driver circuits.
9.1.3.5
Flow Rate / Speed Pickups
An interface is provided for two passive magnetic speed inputs or two TTL active sensor inputs with a frequency range of 2 to
12,000 Hz. The PSVO signal-conditioning circuit is optimized for flow divider sensors, whereas the PTUR circuit is
optimized for primary speed inputs.
Pulse rate inputs can be configured for a variety of applications. Flow types are used for flow divider fuel flow measurements.
Speed type is used for normal single shaft turbines. Speed high type provides extended speed range above the standard speed
type. Speed LM type is designed for LM applications. Speed_HSNG type is used for applications where compensation for
inconsistent tooth spacing on the speed wheel is desired. This pulse rate type will map the spacing of the teeth on the speed
wheel to remove this periodic variation from speed measurements. Mapping locked status bits (HSNGn_Stat) are in signal
space so that the mapping status of the algorithm can be observed. If the status indicator for a pulse rate input is false then the
mapping algorithm sees too much variation in the tooth-tooth measurements to lock onto the tooth geometry.
The Lock_Limit parameter can be adjusted in 1% increments to allow for more tooth-to-tooth variation per revolution.
Increasing the Lock_Limit value will allow the next generation speed algorithm to stay locked with increased variation. The
following are reasons why this parameter may need to be adjusted:
•
•
•
•
Magnetized speed wheel
Two-piece speed wheel
Electro-magnetic interference from outside sources
Improper wiring or shielding practices
The cost for opening the Lock_Limit is that it will allow for more speed variation. If
the speed variation is too high when opening up the Lock_Limit, go to the source of
the problem as listed above and correct the issue there.
Attention
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9.1.3.6
Regulators
Type
Description
no_fdk
Regx_Ref is directly the Servo mA command. Regn_fdbk is not used and set to 0. This regulator type
may be used when the actual servo position regulator is performed in application logic.
1 LV position
Position regulator used with a single LVDT Input.
1_PulseRate
Pulse rate regulator used with a single pulse rate feedback.
2_LVpilotCyl
Pilot Cylinder regulator with two LVDT position feedbacks: LVDT1 (main) and LVDT2 (pilot).
2_LVposMAX
Position regulator using the maximum select from 2 LVDT inputs for feedback.
2_LVposMIN
Position Regulator using the minimum select from 2 LVDT inputs for feedback.
2_PlsRateMAX
Pulse Rate Regulator using the maximum select from two pulse rate feedbacks.
3_LV_LMX
Position Regulator using the median select from 3 LVDT inputs for feedback. Originally designed for the
LMX100 gas turbine.
3_LVposMID
Position Regulator using the median select from 3 LVDT inputs for feedback. Originally designed for
heavy-duty gas turbines.
4_LV_LM
Position Regulator selecting one of two ratio-metric LVDT pairs for the position feedback. Originally
designed for the LM1600, LM2500, and LM6000 gas turbines.
4_LV_LMX
Position Regulator selecting from 2 LVDT ratio-metric pairs for feedback.
4_LVp/cylMAX
Pilot Cylinder Regulator with four LVDT position feedbacks: LVDT1 (main), LVDT2 (main), LVDT3 (pilot),
and LVDT4 (pilot).
PSVO Servo Control Module
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9.1.4 Specifications
Item
PSVO Specification
Number of inputs
Eight LVDT windings
Two pulse rate signals
Number of outputs
Two servo valve currents
Two excitation sources for LVDTs
Two excitation sources for pulse rate transducers
Power supply voltage
Nominal 28 V dc
LVDT accuracy
1% with 14-bit resolution
LVDT input filter
Low pass filter with 3 down breaks at 50 rad/sec ±15%
LVDT common mode rejection
CMR is 1 V, 60 dB at 50/60 Hz
LVDT excitation output
Frequency of 3.2 ±0.2 kHz
Voltage of 7.00 ±0.14 V rms
Pulse rate accuracy
0.05% of speed value calculated from 2hz to 12khz with 16-bit resolution at 50 Hz frame rate
Noise of acceleration measurement is less than ±50 Hz/sec for a 10,000 Hz signal being read at 10
ms
Pulse rate input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 72 mV p-p
12 kHz requires 1486 mV p-p
Magnetic PR pickup signal
< 150 V p-p into 60 kΩ
Active PR Pickup Signal
5 to 27 V p-p into 60 kΩ
Servo valve output accuracy
2% with 12-bit resolution
Dither amplitude and frequency adjustable
Fault detection
Servo current out of limits or not responding
Regulator feedback signal out of limits
Servo suicided
Calibration voltage range fault
The LVDT excitation is out of range
The input signal varies from the voted value by more than the TMR differential limit
Failed ID chip
Size
8.26 cm high x 4.19 cm wide x 12.1 cm deep (3.25 in x 1.65 in x 4.78 in)
Technology
Surface-mount
† Ambient rating for enclosure design
PSVOH1B is rated from -40 to 70ºC (-40 to 158 ºF)
PSVOH1A is rated from -30 to 65ºC (-22 to 149 ºF)
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
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9.1.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set
Each input has system limit checking based on configurable high and low levels. These limits can be used to generate
alarms, to enable and disable, and as latching and non-latching. RSTSYS resets the out of limits.
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually
latched, and then reset with the RSTDIAG signal if they go healthy.
9.1.5.1
Servo Application LEDs
The ENA1 and ENA2 LEDs indicate that a given servo output is driving current. If a servo is suicided, the corresponding
LED will be off.
PSVO Servo Control Module
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9.1.6 Configuration
9.1.6.1
Parameters
Parameter
Description
Choices
SystemLimits
Allows the user to temporarily disable all system limit checks for
testing purposes. Setting this parameter to Disable will cause a
diagnostic alarm to occur.
Enable (default), Disable
9.1.6.2
Variables
Name where
(p = R, S, or T),
(x = 1 or 2)
Variable Description
Type
L3DIAG_PSVO_p
PSVO I/O Diagnostic indication
Input non-voted Boolean-3 bits
LINK_OK_PSVO_p
PSVO I/O Link OK indication
Input non-voted Boolean-3 bits
ATTN_PSVO_p
PSVO I/O Attention indication
Input non-voted Boolean-3 bits
PS18V_PSVO_p
PSVO I/O 18 V Power Supply indication
Input non-voted Boolean-3 bits
PS28V_PSVO_p
PSVO I/O 28 V Power Supply indication
Input non-voted Boolean-3 bits
IOPack_Tmpr_p
PSVO I/O Pack Temperature (deg °F)
Analog Input non-voted -3 real
Sx_SuicideNV_p
ServoOutputx Suicide relay status
Input non-voted Boolean-6 bits
Servox_Suicide
ServoOutput x Suicide relay status
Input voted Boolean-2 bits
HSNGx_STAT
Pulse rate x high speed next generation stability status
(TRUE for tooth – tooth distance inside Lock_Limit for
tooth geometry compensation)
Input voted Boolean
RegCalMode
Regulator under Calibration
Input voted Boolean
Accelx
Acceleration value of the board point FlowRatex
Analog Input voted REAL
Mon#
Value assigned to Monx based on configuration
parameters found in the Monitor Tab, where # = 1 to 8
Analog Input voted REAL
Excit_Monx
Excitation Monitor x (V rms)
Analog Input voted REAL
ServoOutxNV
Servo Output x measured current (%)
Analog Input non-voted Real
ServoxMonitorNV
Servo x AvSelection Monitor
Analog Input non-voted Real
SysLimxPRx
Process Alarm
Input Boolean
ActiveCalibCMd
Internally generated calibration signal, do Not connect
variable to this signal
Output Boolean
9.1.6.3
Regx Variables
Name
where x = 1 or 2
Regx Variable Description
Type
Regx_CalibratedNV_p
Regulator has been calibrated status
Input non-voted Boolean-6 bits
RegxFbkFail
Regulator x feedback fault status
Input non-voted Boolean-6 bits
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Name
where x = 1 or 2
Regx Variable Description
Type
RegxSensorSpreadAlm
Regulator x Sensor Spread Alarm status
Input voted Boolean-2 bits
Regx_PosAFlt
Regulator x, LM machine only, Position A failure
Input voted Boolean
Regx_PosBFlt
Regulator x, LM machine only, Position B failure
Input voted Boolean
Regx_PosDif1
For LM machines, Position Difference 1 failure
For 4LVLMX, PosDif1 is ratio-metric pair A position out of limits
Input voted Boolean
Regx_PosDif2
For LM machines, Position Difference 2 failure
For 4LVLMX, PosDif2 is ratio-metric pair B position out of limits
Input voted Boolean
RegxSenAFlt
Regulator x Sensor A fault, LMX machines only
Input voted Boolean
RegxSenBFlt
Regulator x Sensor B fault, LMX machines only
Input voted Boolean
RegxSenCFlt
Regulator x Sensor C fault, 3LVLMX only
Input voted Boolean
RegCalMode
Regulator under Calibration
Input voted Boolean
RegxSenA2LVSumFlt
Regulator x Sensor A 2LV Summation Fault, 4_LV_LMX only
Input voted Boolean
RegxSenB2LVSumFlt
Regulator x Sensor B 2LV Summation Fault, 4_LV_LMX only
Input voted Boolean
Regx_Fdbk
Regulator x position feedback
Analog Input voted REAL
MiscFdbkxa
Regulator x Position A when 2_LVpilotCyl, 4_LV_LM, 4_LV_
LMX, and 4LVp/cylMAX regs
Analog Input voted REAL
MiscFdbkxb
Regulator x Position B when 4_LV_LM, and 4_LV_LMX regs
Analog Input voted REAL
Regx_Error
Position error for the Regulator x position loops and pulse rate
error for the Pulse Rate reg
Analog Input voted REAL
RegxFdbkSelState
3LVLMX or 4LVLMX Tri-select State
State = 3 indicates MidSelect from 3 Sensors
State = 5 indicates Use single Sensor
State = 4 indicates Average 2 Sensors
State = 6 indicates Min/Max Select of 2 Sensors
State = 7 indicates No Sensor Available
Input DINT
CalibEnabx
Enable Calibration Regulator x
Output Boolean
SuicidForcex
Force Suicide on Reg x
Output Boolean
PosDiffEnabx
Position Difference Enable for Regulator x when configured as
4_LV_LM
Output Boolean
RegxSenAFReq
RegxSenBFReq
RegxSenCFReq
Force a Sensor fault on Regulator x configured as 3 or 4_LV_
LMX
Output Boolean
RSuicRegx
SSuicRegx
TSuicRegx
R, S, or T I/O pack Force Suicide for Regulator x
Used with LV_LMX regs only
Output Boolean
Regx_Ref
Regulator x Position reference (%) where x = 1 or 2
Output Boolean
Regx_NullCor
Regulator x Null Bias Correction (%) where x = 1 or 2
Output Boolean
PSVO Servo Control Module
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9.1.6.4
Servos
It is not recommended to run the coil ohm calculation for Inlet Guide Vane or
Variable Stator Vane servo loops. The higher gain servo loops introduce an AC
component to the coil voltage and current. The calculated coil ohm results will be in
error due to the out-of- phase AC portions of the coil voltage and current. To disable
the coil ohm calculation, set the following parameters to Disable:
• OpenCoilSuic
Attention
• OpenCoildiag
• ShrtCoilSuic
• ShrtCoildiag
Servo
Parameter
Description
Choices
ServoOutput#
where # = 1 or 2
Servo Output X measured current in percent.
Point Edit (Input Real)
RegNumber
Maps a specific regulator to a given servo output.
Unused, Reg1, Reg2
(default is Unused)
Servo_MA_Out
Nominal servo current rating in milliamperes.
10 mA, 20 mA, 40 mA, 80 mA,
120 mA
(default is 10 mA)
EnablCurSuic
Enable Current Suicide Function
Enable, Disable
(default is Disable)
EnablFbkSuic
Enable Position Feedback Suicide Function
Enable, Disable
(default is Disable)
EnblAutoGain
Enable Auto Gain function is approved for 4_LV_LM, 3_LVLMX and
4_LVLMX regulator configurations. The Auto_Gain function modifies
the regulator output based on the suicide state of the other two
PSVOs. If the total system gain is applied to the configuration
parameter, Reg_Gain, then enabling Auto Gain adjusts the gain in
each of the three PSVOs to provide 100% of the system gain. For
example, G=0.33 for each PSVO if all PSVOs are not suicided, and
G=0.5 for each PSVO if only one of the PSVOs is suicided. The
objective is to maintain a constant gain and null bias under the
condition of a single PSVO output failure.
Enable, Disable
(default is Disable)
Coil_RS_Only
Configuration parameter is enabled when the PSVO is driving a 2-coil
servo. For 2-coil servo, no load is connected to the SxTH/L where x =
1or 2 terminal screws.
Enable, Disable
(default is Disable)
AV_Selector
Configuration selector to map one of the specified variables to the
PSVO variable, ServoxMonitorNV where x = 1 or 2.
Coil_OHMs = Servo coil resistance (ohms)
Compliance_Voltage = Servo driver output voltage (V)
LM_Auto_Gain = Gain determined by Auto_Gain function (%/%)
MA_CMD_PC = Servo mA command (%).
Coil_OHMs,
Compliance_Voltage
LM_Auto_Gain
MA_CMD_PCT
(default is
Compliance_Voltage)
Curr_Suicide
Current command is compared to the actual feedback current. If the
error exceeds the configuration limit, Curr_Suicide (%), then the
Servo output will suicide.
0 to 100
(default is 5)
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Servo
Parameter
Description
Choices
Fdbk_Suicide
The position feedback, Regx_Fdbk (%) is compared against the
value, 100% + Fdbk_Suicide (%). If Regx_Fdbk (%) where x = 1 or 2
exceeds that value, the regulator assumes the feedback has gone
open loop and the servo must be suicided if this condition and the
EnablFbkSuic = Enable.
0 to 10
(default is 5)
OpenCoilSuic
If configuration parameter, OpenCoilSuic = Enable, then the servo coil
open detection function will suicide the servo if the function detects an
open ckt.
Enable, Disable
(default is Disable)
Set this parameter to Enable to receive a diagnostic message as to why
the servo suicide occurred.
Set this parameter to Disable to disable the coil ohm calculation. Refer to
the Attention statement at the beginning of this section for further
details.
OpenCoildiag
If enabled, a specific diagnostic message is generated for why the
servo suicide occurred; for example, Servo x Suicide due to Open
servo coil.
Enable, Disable
(default is Disable)
Set this parameter to Disable to disable the coil ohm calculation. Refer to
the Attention statement at the beginning of this section for further
details.
ShrtCoilSuic
If configuration parameter, ShrtCoilSuic = Enable, then the servo coil
short ckt. detection function will suicide the servo if the function
detects a short ckt.
Enable, Disable
(default is Disable)
Set this parameter to Enable to receive a diagnostic message as to why
the servo suicide occurred.
Use of dither with shorted
coil detection enabled is not
recommended.
Attention
Set this parameter to Disable to disable the coil ohm calculation. Refer to
the Attention statement at the beginning of this section for further
details.
ShrtCoildiag
If enabled, a specific diagnostic message is generated for why the
servo suicide occurred; for example, Servo x Suicide due to Short
circuit of servo coil.
Enable, Disable
(default is Disable)
Use of dither with shorted
coil detection enabled is not
recommended.
Attention
Set this parameter to Disable to disable the coil ohm calculation. Refer to
the Attention statement at the beginning of this section for further
details.
PSVO Servo Control Module
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Servo
Parameter
Description
Choices
TBmAJmpPos
TSVC terminal board mA jumper position selection. This should
match the jumper selection on the TSVC to allow the open / short
circuit servo coil detection to work correctly.
10 mA, 20 mA, 40 mA, 80 mA,
120 mA_A, 120 mA_B
(default is 10 mA)
RopenTimeLim
Time in seconds required for the open circuit condition of the servo
coil to be in effect before a diagnostic and / or suicide of the servo (if
enabled) occurs.
0 to 100
(default is 1)
RShrtTimeLim
Time in seconds required for the short circuit condition of the servo
coil to be in effect before a diagnostic and / or suicide of the servo (if
enabled) occurs.
0 to 100
(default is 1)
RcoilOpen
This defines the initial value for the open circuit resistance in ohms.
After the LVDT calibration, the value for RcoilOpen = 2 * (Servo
Compliance Voltage / Servo Current) measured during the calibration
mode.
0 to 10000000000
(default is 1000000 simplex or
1000000,1000000,1000000
TMR)
There is one value for simplex I/O packs and three values for R, S, and T
on TMR systems.
RcoilShort
This defines the initial value for the short circuit resistance in ohms.
After the LVDT calibration, the value for RcoilShort = 0.5 * (Servo
Compliance Voltage / Servo Current) measured during the calibration
mode.
0 to 10000000000
(default is 0 simplex or 0,0,0
TMR)
There is one value for simplex I/O packs and three values for R, S, and T
on TMR systems.
TMR_DiffLimt
9.1.6.5
Diagnostic limit, TMR Input Vote difference in %
0 to 110
(default is 25)
Pulse Rates
Pulse Rates
Parameter
Description
Choices
FlowRatex
where x = 1 or 2
Bipolar input = PRxH – PRxL,
Unipolar = TTLx - PRxL
Point Edit (Input Real)
PRType
Define the pulse rate feedback type or basic speed range. See
section Speed Pickups for description of types.
Flow, Speed, Speed_High,
Speed_HSNG, Speed_LM,
Unused
PRScale
Scaling: multiplier to convert pulses per second into desired EU for
feedback
0 to 1000 EU/pulse
SysLim1Enabl
If enabled, System Limit 1 is active.
Enable, Disable
(default is Disable)
SysLim1Latch
If enabled, the System Limit 1 function will latch its state if the
FlowRate exceeds the limit function defined by SysLim1Type and
SysLimit1.
Latch, NotLatch
(default is Latch)
SysLim1Type
Defines the compare function used in the Limit1 expression.
≤ or ≥
(default is ≥)
SysLimit1
Defines Limit1 value to be used for the input, FlowRate.
0 to 20,000 EU
(default is 0)
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Pulse Rates
Parameter
Description
Choices
SysLim2Enabl
If enabled, System Limit 2 is active.
Enable, Disable
(default is Disable)
SysLim2Latch
If enabled, the System Limit 2 function will latch its state if the
FlowRate exceeds the limit function defined by SysLim2Type and
SysLimit2.
Latch, NotLatch
(default is Latch)
SysLim2Type
Defines the compare function used in Limit 2’s expression.
≤ or ≥
(default is ≥)
SysLimit2
Defines Limit2 value to be used for the input, FlowRate.
0 to 20,000 EU
(default is 0)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in EU
0 to 20,000 EU
(default is 5)
TeethPerRev
(Speed_HSNG
only)
Number of teeth on speed wheel (per revolution)
1 to 512
Calculation rate of speed in milliseconds. Speed is calculated at this
rate and averaged over the previous time interval specified by this
period.
5 to 1000
Speed_x_ms
(Speed_HSNG
only)
Using a value other than an integer multiple of the
application frame period can have adverse impact on use of
this control.
Attention
Accel_x_ms
(Speed_HSNG
only)
This is the averaging period for acceleration calculation in
milliseconds. The acceleration is calculated every Accel_X_ms. It is
based on the difference between two speed samples divided by the
sample period. Each acceleration calculation is the average of
acceleration over the period specified by this parameter. For example,
if Accel_x_ms is 40 then acceleration will be the average acceleration
over the previous 80 ms.
10 to 1000
Using a value other than an integer multiple of the
application frame period can have adverse impact on use of
this control.
Attention
Lock_Limit
(Speed_HSNG
only)
HSNG speed type locking limit for teeth mapping (percent). Refer to
section Speed Pickups for description of Lock_Limit function.
PSVO Servo Control Module
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9.1.6.6
Regulators
Regulators
Parameter
Description
Certain parameters are only available with certain regulator types.
Choices
Regulator 1
Regulator 2
Select and enable the regulators
Enable checkbox
Reg_Type
Regulator Algorithm Type
Unused, no_fbk, 1_
LVposition, 1_
PulseRate, 2_
LVpilotCyl, 2_
LVposMAX, 2_
LVposMIN, 2_
PlsRateMAX, 3_LV_
LMX, 3_LVposMID, 4_
LV_LM, 4_LV_LMX, 4_
LVp/cylMAX
Regulator 1, 2 must be enabled before the configuration parameter, Reg_
Type can be selected.
Refer to the section Operations, Regulators for more information.
Dither rate in hertz.
12_5 Hz, 25 Hz, 33_33
Hz, 50 Hz, 100 Hz,
Unused
(default is Unused)
Dither_Freq
Use of dither with shorted coil detection enabled is not
recommended.
Attention
DitherAmpl
Dither in % current
0 to 10
(default is 2)
Dither magnitudes greater than 2 percent could interfere with the proper
operation of the coil ohm calculation. If dither magnitude is a priority, disable
the coil ohm calculation.
LVDT_Margin
Defines the over range in % for the LVDT input. A diagnostic is generated if
this value is exceeded.
1 to 100
(default is 2)
LVDT1input
This is the LVDT input selection.
With 2_LVpilotCyl selected, LVDT1 is main and LVDT2 is pilot.
With 4_LVp/cylMAX selected, LVDT1 is main, LVDT2 is main, LVDT3 is pilot,
and LVDT4 is pilot.
LVDT1, LVDT2, LVDT3,
LVDT4, LVDT5, LVDT6,
LVDT7, LVDT8, Unused
(default is Unused)
RegGain
Position loop Gain in % current / Eng Units or usually % current / % position.
-200 to 200
(default is 1)
RegNullBias
Regulator Null Bias provides a fixed current command in percent to cancel or
null the spring force of the valve which will close the valve if the servo suicides
or shuts down.
-100 to 100
(default is 0)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
-15 to 150
(default is 5)
MaxPOSvalue
Position in Eng. units (usually %) at the maximum end stop of the valve.
-15 to 150 (default is
100)
MinPOSvalue
Position in Eng. Units (usually %) at the minimum end stop of the valve.
-15 to 150 (default is 0)
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Regulators
Parameter
Description
Certain parameters are only available with certain regulator types.
Choices
MnLVDTx_Vrms
This is the value of LVDTx V rms at the minimum end stop of the valve. These
values are normally set by the Auto-Calibrate function. For TMR, the first
value is from PSVO-R perspective, the second from PSVO-S, and the last
from PSVO-T
0 to 7.1
(default is 1 simplex or
1,1,1 TMR)
There is one value for simplex I/O packs and three values for R, S, and T on TMR
systems.
MxLVDTx_Vrms
This is the value of LVDTx V rms at the maximum end stop of the valve. These
values are normally set by the Auto-Calibrate function. For TMR, the first
value is from PSVO-R perspective, the second from PSVO-S, and the last
from PSVO-T
0 to 7.1
(default is 5 simplex or
5,5,5 TMR)
There is one value for simplex I/O packs and three values for R, S, and T on TMR
systems.
PRateInputx
Pulse Rate input selection
PR1, PR2, Unused
(default is Unused)
PilotGain
Pilot loop gain in % current / Eng. unit
-200 to 200
(default is 1)
CurBreak
Current break for nonlinear servo current
-100 to 100
(default is 0)
CurClpNg
Servo Current Clamp (%) Negative
-300 to 300
(default is -100)
CurClpPs
Servo Current Clamp (%) Positive
-300 to 300
(default is 100)
CurSlope1
Slope current gain modifier for low position error values
0 to 10
(default is 1)
Position regulator requires CurSlope1 and CurSlope2 equal to a nonzero value for
feedback to follow position command.
CurSlope2
0 to 10
(default is 1)
Slope current gain modifier for position error > CurBreak limit
Position regulator requires CurSlope1 and CurSlope2 equal to a nonzero value for
feedback to follow position command.
DefltValue
If all position sensors or LVDTs are bad, the regulator feedback is assigned to
this value in percent.
-1 to 110
(default is 100)
LagTau
Position loop Lag Breakpoint (seconds), zero to disable
0 to 10
(default is 0)
LeadTau
Position loop Lead Breakpoint (seconds), zero to disable
0 to 10
(default is 0)
SelectMinMax
With regulator type 3 or 4_LV_LMX, If 2 of the 3 LVDTs are healthy, this
parameter determines whether a minimum select or maximum select is made
for the remaining two sensors.
Max, Min
(default is Max)
With regulator type 4_LV_LM, Select the Min or the Max of PositionA or
PositionB when the difference between the two is excessive. Used in
conjunction with PosDiffcmp1 and PosDifftime1.
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Regulators
Parameter
Description
Certain parameters are only available with certain regulator types.
Choices
SensorOofRTD
Sensor Out of Range Time Delay (seconds)
0 to 2000
(default is 10)
SenSpreadMx
Sensor Spread Maximum (%)
-2000 to 2000
(default is 1000)
SensoSpreadTD
Sensor Spread Time Delay (seconds)
0 to 2000
(default is 10)
LVDTVsumMarg
Allowable rang exceed error (%) for ratio-metric sum
1 to 100
(default is 2)
PosDefltEnab
Position Default Enable / Disable
Enable, Disable
(default is Enable)
PosDiffcmp1
Position Difference Limit1 (%)
-1 to 110
(default is 2)
PosDiffcmp2
Position Difference Limit2 (%)
-1 to 110
(default is 3)
PosDifftime1
Position Difference Limit1 Timeout (seconds)
0 to 10
(default is 0.5)
PosDifftime2
Position Difference Limit2 Timeout (seconds)
0 to 10
(default is 0.5)
PosSelect
Position Selection Mode
Avg, Max, Min
(default is Avg)
SenSumChkTD
Volts RMS Sum Check Out of Range Time Delay (seconds)
0 to 2000
(default is 10)
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9.1.6.7
Monitors
Monitors
Parameter
Description
Certain parameters are only available with certain monitor types.
Choices
MonType
Monx will equal sensor position expressed in percent assigned in the
3LVLMX regulator where x = 1 to 8
1_LMposition
Monx will equal sensor position expressed in V rms assigned in the 4_LV_
LMX, 3_LV_LMX, or 4_LV_LM regulator where x = 1 to 8
1_LMVRMS
Monx will equal the scaled value from the LVDT assigned through LVDT1
input where x = 1 to 8
1_LVposition
Monx will equal the maximum selected scaled value from two LVDTs
assigned through LVDTyinput where x = 1 to 8 and y = 1 to 2.
2_LVposMAX
Monx will equal the minimum selected scaled value from two LVDTs
assigned through LVDTyinput where x = 1 to 8 and y = 1 to 2.
2_LVposMIN
Monx will equal the median selected scaled value from three LVDTs
assigned through LVDTyinput where x = 1 to 8 and y = 1 to 3.
3_LVposMID
LMPOSin
LMX Position Input Selector
Reg1SenAPos,
Reg1SenBPos,
Reg1SenCPos,
Reg1SenDPos (not used),
Reg2SenAPos,
Reg2SenBPos,
Reg2SenCPos,
Reg2SenDPos (not used),
Unused (default)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
-15 to 150
(default is 5)
LVRMSin
LMX VRMS Input Selection
Reg1SenAVrms,
Reg1SenBVrms,
Reg1SenCVrms,
Reg1SenDVrms (4LVLMX
only),
Reg2SenAVrms,
Reg2SenBVrms,
Reg2SenCVrms,
Reg2SenDVrms (4LVLMX
only),
Unused (default)
LVDT_Margin
Defines the over range in % for the LVDT input. A diagnostic is generated
if this value is exceeded.
1 to 100
(default is 2)
LVDTxinput
LVDTx input selection
LVDT1, LVDT2, LVDT3,
LVDT4, LVDT5, LVDT6,
LVDT7, LVDT8, Unused
(default)
MaxPOSvalue
Position in Eng. units (usually %) at the maximum end stop of the valve.
-15 to 150
(default is 100)
MinPOSvalue
Position in Eng. Units (usually %) at the minimum end stop of the valve.
-15 to 150
(default is 0)
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Monitors
Parameter
Description
Certain parameters are only available with certain monitor types.
Choices
MnLVDTx_
Vrms
This is the value of LVDTx V rms at the minimum end stop of the valve.
These values are normally set by the Auto-Calibrate function, and must be
manually entered. For TMR, the first value is from PSVO-R perspective,
the second from PSVO-S, and the last from PSVO-T perspective.
0 to 7.1
(default is 1 simplex or 1,1,1
TMR)
There is one value for simplex I/O packs and three values for R, S, and T on
TMR systems.
MxLVDTx_
Vrms
This is the value of LVDTx V rms at the maximum end stop of the valve.
These values are normally set by the Auto-Calibrate function, and must be
manually entered. For TMR, the first value is from PSVO-R perspective,
the second from PSVO-S, and the last from PSVO-T perspective.
0 to 7.1
(default is 5 simplex or 5,5,5
TMR)
There is one value for simplex I/O packs and three values for R, S, and T on
TMR systems.
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9.2 PSVO Specific Alarms
The following alarms are specific to the PSVO I/O pack.
33-40
Description LVDT #[ ] RMS voltage for Regulator [ ] out of limits
Possible Cause
•
•
•
Excitation to LVDT, faulty transducer, or open or short-circuit
LVDT [ ] input to the analog to digital converter exceeded the converter limits
LVDT scaling configuration (MnLVDT[ ]_Vrms, MxLVDT[ ]_Vrms) has not been calibrated.
Solution
•
•
•
•
•
•
•
Check the field wiring between the TSVC excitation output and the LVDT including shields.
Check for approximately 7 V rms at the TSVC Excitation screws.
Check the feedback wire between LVDT and TSVC LVDT Input connections (including shields).
Check the LVDT for mechanical integrity.
Calibrate the regulator with the proper LVDTs.
Verify the configuration limits, MnLVDT[ ]_Vrms and MxLVDT[ ]_Vrms for the affected regulator.
Problem is usually not a PSVO or terminal board failure if other LVDT inputs are working correctly.
45
Description Calibration Mode Enabled
Possible Cause
•
Variable CalibEnab# set to True and user has selected the Calibration Mode button in the Calibrate Valve dialog.
Solution
•
•
This alarm is active to annunciate that the I/O pack is in a special mode where servo suicide protection has been disabled,
the user needs to take special precautions in this mode.
Exit calibration mode and set CalibEnab# to False.
PSVO Servo Control Module
GEH-6721_Vol_III_BJ System Guide 417
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46
Description PSVO not online, Servos suicided
Possible Cause Servo outputs suicided because I/O pack offline
Solution
•
•
Verify that the controller is online.
Verify that network connections to the I/O pack are okay.
47-48
Description Servo current #[ ] disagrees w/ ref, suicided
Possible Cause
•
•
•
•
•
Possible open circuit in servo current loop
Servo current feedback does not match servo current command within specified (Cur_Suicide) percentage and
EnablCurSuic is enabled.
Jumper configuration set incorrectly
Open circuit to servo coil
I/O pack hardware failure
Solution
•
•
•
•
•
418
Check the field wiring for an open loop
Check for servo open coil.
Verify the proper settings of TSVC hardware jumpers.
Verify the proper setting of configuration parameters and tuning of servo.
Replace the PSVO and WSVO.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
52-53
Description Servo current #[ ] short circuit
Possible Cause
•
•
•
Servo short circuit detection enabled (ShrtCoildiag) and low resistance measured
Possible shorted servo coil
Shorted coil threshold (RcoilShort) or shorted coil time limit (RShrtTimeLim) set incorrectly.
Solution
•
•
•
•
•
•
Verify the proper servo ohm value.
Set AV_Selector to the value Coil_OHMS (build/download), and view the measured coil resistance displayed in
Servo#MonitorNV_R,S,T.
Verify that the measured resistance matches the actual coil resistance, and is above RcoilShort value.
Verify that the RcoilShort is set to the proper value. Re-calibrate to update measured resistance values.
Verify the proper setting on the Servo_MA_Out parameter.
Verify that the terminal board jumpers match the configuration.
57-58
Description Servo current #[ ] open circuit
Possible Cause
•
•
•
Servo short circuit detection enabled (OpenCoildiag) and low resistance measured
Possible open servo coil
Open coil threshold (RcoilOpen) or open coil time limit (RopenTimeLim) set incorrectly
Solution
•
•
•
•
•
Check field wiring for possible open circuit. Verify the proper servo ohm value.
Set AV_Selector to value Coil_OHMS (build/download) and view the measured coil resistance displayed in
Servo#MonitorNV_R,S,T.
Verify that the measured resistance matches actual coil resistance, and is below value.
Verify that the RcoilOpen is set to the proper value. Re-calibrate to update measured resistance values.
Verify that the terminal board jumpers match the configuration.
PSVO Servo Control Module
GEH-6721_Vol_III_BJ System Guide 419
Non-Public Information
62-63
Description Servo posititon #[ ] fdbk out of range, suicided
Possible Cause
•
•
LVDT position feedback outside specified range
LVDT inputs not calibrated or V rms limits incorrect
Solution
•
•
•
•
Check field wiring including shields and LVDT excitation. Problem is usually not a PSVO or terminal board failure if
other LVDT inputs are working correctly.
Check the LVDT sensor.
Calibrate the servo regulator with the proper LVDT.
Verify that LVDT_Margin is set to the proper value.
67-68
Description Regulator #[ ] configuration error
Possible Cause
•
•
•
•
•
•
Regulator LVDTInput connected to unused LVDT
LVDT selected by two or more LVDTInputs
MnVrms and MxVrms values are equal for LVDTInput
Regulator selected by Servo but not enabled
Not enough Pulse Rates selected for a regulator
For Pilot Cylinder regulators, Servo CurrentRange parameters not equal
Solution
•
•
•
•
•
Use Advanced Diagnostics command, Servo Regulator Config Error to display decoded fault code.
Verify the regulator configuration settings.
Verify the servo configuration settings.
Verify that the LVDT input setup (Max/Min limits) matches the regulator configuration.
Verify that the configured regulators are used by the proper servos.
72
Description Internal calibration reference voltage range fault
Possible Cause Internal voltage reference values out of range.
Solution Replace I/O pack hardware.
420
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
73-74
Description Lvdt excitation #[ ] voltage out of range
Possible Cause
•
•
Possible short in excitation voltage.
Excitation voltage too low.
Solution
•
•
•
Disconnect LVDT excitation from terminals and check that excitation voltage at TSVC screws is approximately 7 V rms.
If proper voltage is verified, check field wiring from terminal board to the LVDT sensor and LVDT electrical integrity for
shorted coil.
If improper voltage at screws, replace PSVO and WSVO, then TSVC.
77
Description Servo Output Assignment Mismatch
Possible Cause
•
Regulator types 2_LVpilotCyl and 4_LVp/cylMAX require two servos assigned to regulator. These servos must match in
configured parameters.
Solution
•
•
Verify that both servos specify the configured regulator.
Verify that servo configuration parameters (Servo_MA_Out) are both set to the same value.
90-96
Description Power supply [ ] V is out of range, voltage = [ ]
Possible Cause
•
Specified internal power supply voltage incorrect.
Solution
•
•
Replace the WSVO.
If the problem still exists, replace the PSVO.
97
Description Pack internal null voltage out of limits, voltage = ([ ])V
Possible Cause The null voltage is more than +/- 5% from the expected value which indicates a hardware failure.
Solution
•
•
Cycle power on the PSVO.
Replace the PSVO.
PSVO Servo Control Module
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108-109
Description LVDT configuration error on Regulator #[ ]
Possible Cause
•
For regulators 4_LV_LM and 4_LV_LMX, the configured LVDT V rms limits configured incorrectly for ratiometric
LVDTs.
Solution
•
Verify that ratiometric LVDT pairs have opposite V rms values in the Min/Max limits.
110-111
Description Servo Coil #[ ] not within resistance limits, resulting in Servo Coil Open and Short Detection functions being
disabled
Possible Cause During calibration, the measured servo coil resistance was out of range.
Note As a result of this alarm condition, RCoilShort and RCoilOpen values were not saved during calibration.
Solution
•
•
•
Verify that Servo_MA_Out setting matches the terminal board jumpers.
Verify servo coil resistance.
Verify field wiring.
112-119
Description Regulator #[ ] Sensor #[ ] out of range
Possible Cause
•
•
LVDT position feedback is outside the specified range.
LVDT inputs have not been calibrated or V rms limits are incorrect.
Solution
•
•
•
•
422
Check field wiring including shields and LVDT excitation. Problem is usually not a PSVO or terminal board failure if
other LVDT inputs are working correctly.
Check the LVDT sensor.
Calibrate the servo regulator with the proper LVDT.
Verify that LVDT_Margin is set to the proper value.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
120-121
Description Servo #[ ] Suicided
Possible Cause
•
•
•
•
Servo suicided.
Regulator feedback out of range.
Servo Current feedback differs from Servo Current command.
Open or shorted coil detected.
Solution
•
•
•
•
LVDT feedback issue: Check LVDT connections.
Check LVDT mechanical integrity to the valve.
Check for wiring of servo output loop for open or short circuit.
Check for a short or an open servo coil.
128
Description Logic Signal [ ] Voting Mismatch
Possible Cause N/A
Solution N/A
192-215
Description LVDT #[ ] RMS voltage for Monitor [ ] out of limits
Possible Cause
•
•
•
•
After a PSVO calibration, the Min/Max V rms saved values for the LVDTs were not manually copied to the Monitors.
Excitation to LVDT, faulty transducer, or open or short-circuit.
LVDT [ ] input to analog-to-digital converter exceeded converter limits.
LVDT scaling configuration (MnLVDT[ ]_Vrms, MxLVDT[ ]_Vrms) not calibrated.
Solution
•
•
•
•
•
•
•
After calibration, manually copy the saved LVDT Min/Max V rms values from the Regulator tab to the Monitors.
Check field wiring between the TSVC excitation output and LVDT, including shields.
Check for approximately seven V rms at the TSVC excitation screws.
Check the feedback wire between the LVDT and TSVC LVDT input connections, including shields.
Check the LVDT for mechanical integrity.
Verify the configuration limits, MnLVDT[ ]_Vrms and MxLVDT[ ]_Vrms for the affected regulator.
Problem is usually not a PSVO or terminal board failure if other LVDT inputs are working correctly.
PSVO Servo Control Module
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224-247
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause Voter disagreement between R, S, and T I/O packs.
Solution Adjust the specified parameter below for each input type:
•
•
•
•
•
•
If input variable is FlowRate[ ], adjust the TMR_DiffLimt.
If input signal is Reg[ ]_Fdbk, adjust the TMR_DiffLimt on the Regulators tab.
If input variable is Mon[ ], adjust the TMR_DiffLimt on the Monitors tab.
If input variable is ServoOutput[ ], adjust the TMR_DiffLimt.
Check for a mismatch in the coil resistance.
Reg[ ]_Gain is set too high for the specified TMR_DiffLimt value.
1050
Description R Detects S ComFailure on channels 1+2
Possible Cause
•
•
•
S I/O pack serial communication to R I/O pack failed
S I/O pack rebooted
S I/O pack not connected properly
Solution
•
•
•
•
Verify that the S PSVO is seated correctly on the terminal board.
Check the S I/O pack for other diagnostics to determine the cause of the reboot.
Replace the S I/O pack.
Replace the terminal board.
1051 - 1052
Description R Detects S ComError on channel [ ]
Possible Cause
•
•
•
S I/O pack serial communication to R I/O pack failed
S I/O pack rebooted
S I/O pack not connected properly
Solution
•
•
•
•
424
Verify that the S PSVO is seated correctly on the terminal board.
Check S I/O pack for other diagnostics to determine cause of reboot.
Replace the S I/O pack.
Replace the terminal board.
GEH-6721_Vol_III_BJ
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1053
Description R Detects T ComFailure on channels 1+2
Possible Cause
•
•
•
T I/O pack serial communication to R I/O pack failed
T I/O pack rebooted
T I/O pack not connected properly
Solution
•
•
•
•
Verify that the T PSVO is seated correctly on the terminal board.
Check the T I/O pack for other diagnostics to determine the cause of the reboot.
Replace the T I/O pack.
Replace the terminal board.
1054 - 1055
Description R Detects T ComError on channel [ ]
Possible Cause
•
•
•
T I/O pack serial communication to R I/O pack failed
T I/O pack rebooted
T I/O pack not connected properly
Solution
•
•
•
•
Verify that the T PSVO is seated correctly on the terminal board.
Check the T I/O pack for other diagnostics to determine the cause of the reboot.
Replace the T I/O pack.
Replace the terminal board.
1056
Description R Detects R ComFailure on channels 1+2
Possible Cause R I/O Pack serial communication failure on R feedback indicates internal hardware failure.
Solution
•
•
•
Verify that the R PSVO is seated correctly on the terminal board.
Replace the R I/O pack.
Replace the terminal board.
PSVO Servo Control Module
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1057 - 1058
Description R Detects R ComError on channel [ ]
Possible Cause R I/O Pack serial communication failure on R feedback indicates an internal hardware failure
Solution
•
•
•
•
Verify that the R PSVO is seated correctly on the terminal board.
Check R I/O pack for other diagnostics to determine cause of reboot.
Replace the R I/O pack.
Replace the terminal board.
1059
Description S Detects R ComFailure on channels 1+2
Possible Cause
•
•
•
R I/O pack serial communication to S I/O pack failed
R I/O pack rebooted
R I/O pack not connected properly
Solution
•
•
•
•
Verify that the R PSVO is seated correctly on the terminal board.
Check the R I/O pack for other diagnostics to determine the cause of the reboot.
Replace the R I/O pack.
Replace the terminal board.
1060 - 1061
Description S Detects R ComError on channel [ ]
Possible Cause
•
•
•
R I/O pack serial communication to S I/O pack failed
R I/O pack rebooted
R I/O pack not connected properly
Solution
•
•
•
•
426
Verify that the R PSVO is seated correctly on the terminal board.
Check the R I/O pack for other diagnostics to determine the cause of the reboot.
Replace the R I/O pack.
Replace terminal board.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
1062
Description S Detects T ComFailure on channels 1+2
Possible Cause
•
•
•
T I/O pack serial communication to S I/O pack failed
T I/O pack has rebooted
T I/O pack is not connected properly
Solution
•
•
•
•
Verify that the T PSVO is seated correctly on the terminal board.
Check the T I/O pack for other diagnostics to determine the cause of the reboot.
Replace the T I/O pack.
Replace the terminal board.
1063 - 1064
Description S Detects T ComError on channel [ ]
Possible Cause
•
•
•
T I/O pack serial communication to S I/O pack failed
T I/O pack rebooted
T I/O pack not connected properly
Solution
•
•
•
Verify that the T PSVO is seated correctly on the terminal board.
Replace the T I/O pack.
Replace the terminal board.
1065
Description S Detects S ComFailure on channels 1+2
Possible Cause S I/O Pack serial communication failure on S feedback indicates internal hardware failure
Solution
•
•
•
Verify that the S PSVO is seated correctly on the terminal board.
Replace the S I/O pack.
Replace the terminal board.
PSVO Servo Control Module
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1066 - 1067
Description S Detects S ComError on channel [ ]
Possible Cause S I/O Pack serial communication failure on S feedback indicates internal hardware failure
Solution
•
•
•
Verify that the S PSVO is seated correctly on the terminal board.
Replace the S I/O pack.
Replace the terminal board.
1068
Description T Detects R ComFailure on channels 1+2
Possible Cause
•
•
•
R I/O pack serial communication to T I/O pack failed
R I/O pack rebooted
R I/O pack not connected properly
Solution
•
•
•
•
Verify that the R PSVO is seated correctly on the terminal board.
Check the R I/O pack for other diagnostics to determine the cause of the reboot.
Replace the R I/O pack.
Replace the terminal board.
1069 - 1070
Description T Detects R ComError on channel [ ]
Possible Cause
•
•
•
R I/O pack serial communication to T I/O pack failed
R I/O pack rebooted
R I/O pack not connected properly
Solution
•
•
•
•
428
Verify that the R PSVO is seated correctly on the terminal board.
Check the R I/O pack for other diagnostics to determine the cause of the reboot.
Replace the R I/O pack.
Replace the terminal board.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
1071
Description T Detects S ComFailure on channels 1+2
Possible Cause
•
•
•
S I/O pack serial communication to T I/O pack failed
S I/O pack rebooted
S I/O pack not connected properly
Solution
•
•
•
•
Verify that the S PSVO is seated correctly on the terminal board.
Check the S I/O pack for other diagnostics to determine the cause of the reboot.
Replace the S I/O pack.
Replace the terminal board.
1072 - 1073
Description T Detects S ComError on channel [ ]
Possible Cause
•
•
•
S I/O pack serial communication to T I/O pack failed
S I/O pack rebooted
S I/O pack not connected properly
Solution
•
•
•
•
Verify that the S PSVO is seated correctly on the terminal board.
Check the S I/O pack for other diagnostics to determine the cause of the reboot.
Replace the S I/O pack.
Replace terminal board.
1074
Description T Detects T ComFailure on channels 1+2
Possible Cause T I/O Pack serial communication failure on T feedback indicates internal hardware failure.
Solution
•
•
•
Verify that the T PSVO is seated correctly on the terminal board.
Replace the T I/O pack.
Replace the terminal board.
PSVO Servo Control Module
GEH-6721_Vol_III_BJ System Guide 429
Non-Public Information
1075 - 1076
Description T Detects T ComError on channel [ ]
Possible Cause T I/O Pack serial communication failure on T feedback indicates internal hardware failure
Solution
•
•
•
430
Verify that the T PSVO is seated correctly on the terminal board.
Replace the T I/O pack.
Replace the terminal board.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
9.3 TSVC Servo Input/Output Terminal Board
9.3.1 Functional Description
The Servo Input/Output (TSVC) terminal board interfaces to two electro-hydraulic servo valves that actuate the steam/fuel
valves. Valve position is measured with linear variable differential transformers (LVDT). TSVC is designed specifically for
the PSVO I/O pack and the WSVO servo driver. The terminal board supports simplex and TMR configurations. Three 28 V
dc supplies come in through plug J28. Plugs JD1 or JD2 are for an external trip from the protection module.
TSVC Servo Terminal Board
TSVCH1 T1 through T4 isolation transformers provide galvanic isolation between the WSVO's excitation output driver and
the primary-side of the LVDT/R position sensor.
TSVCH2 excludes the isolation transformers T1 through T4 resulting in no galvanic isolation between the WSVO excitation
driver output and the LVDT/R position sensor.
PSVO Servo Control Module
GEH-6721_Vol_III_BJ System Guide 431
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9.3.2 Installation
Sensors and servo valves are wired directly to two I/O terminal blocks. Each block is held down with two screws and has 24
terminals accepting up to #12 AWG wiring. A shield terminal strip attached to chassis ground is located immediately to the
left of each terminal block. External trip wiring is plugged into either JD1 or JD2.
Each servo output can have three coils in TMR configuration. The size of each coil current is jumper selected using JP1, 3, 5
for Servo 1, and JP2, 4, 6 for servo 2.
Three 28 V dc power supplies for the R, S, and T board functions are connected to J28. Two non-isolated LVDT excitation
sources for S and T are wired to terminal block TB3 and TB4.
Servo/LVDT Terminal Board Wiring
432
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Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
The three J1 connectors for the PSVO I/O packs are R, S, and T. These plug into the DC-37 pin connector with latching
fasteners, and bolt to a side bracket holding the I/O packs in place. The three J2 connectors for the WSVO servo drivers are R,
S, and T. Each WSVO is held down with four screws. The WSVO servo driver and PSVO I/O pack are ordered as a set and
should be replaced if diagnostics indicate a servo problem.
The PSVO I/O pack and WSVO driver can be replaced with the unit running by removing power from the failed channel with
the corresponding manual enable switch, SW1, or SW2, or SW3. Power to each channel is indicated with LEDs on the board
and LEDs on each power switch.
9.3.3 Operation
The TSVC servo terminal board provides two channels consisting of bi-directional servo current outputs, LVDT position
feedback, LVDT excitation, and pulse rate flow inputs. It provides excitation for, and accepts inputs from, up to eight LVDT
valve position inputs. There is a choice of one, two, three, or four LVDTs for each servo control loop. The two pulse rate
inputs are used for gas turbine liquid fuel flow feedback measurement. Each servo output is equipped with an individual
suicide relay under firmware control that shorts the PSVO output signal to signal common when de-energized, and recovers to
nominal limits after a manual reset command is issued. Diagnostics monitor the output status of each servo voltage, current,
and suicide relay.
Each of the servo output channels can drive either one or two-coil servos in simplex applications, or two or three-coil servos
in TMR applications. The two-coil TMR applications are for 200# oil gear systems where each of two control PSVOs drive
one coil each, and the third PSVO has no servo coil interface. Servo cable lengths up to 300 m (984 ft) are supported with a
maximum two-way cable resistance of 15 Ω. Since there are many types of servo coils, a variety of bi-directional current
sources are jumper selectable.
Note The primary and emergency overspeed systems will trip the hydraulic solenoids independent of this circuit.
For simplex applications, a trip override relay K1 is provided on the terminal board, which is controlled from the PPRO
protection module. If an emergency overspeed condition is detected in the protection module, the K1 relay will energize,
disconnect the servo output, and apply a bias to drive the control valve closed. This is only used on simplex applications to
protect against the servo amplifier failing high, and is functional only with respect to the servo coils driven from <R>.
For Simplex applications that require this backup protection relay, verify that the JPDM or JPDS wiring includes jumpers
between the PR, PS, and PT connectors on either TB1 or TB2 to energize the T bus, and that the TSVC SW1 is in the ON
position. The TSVC green DS1 LED (indicating that P28T is available) should be lit if power is being supplied for the K1
relay. Illumination of the DS1 LED is sufficient to demonstrate that power to energize the K1 relay is available.
Caution
9.3.3.1
For simplex applications that have a connection to the TSVC JD1 or JD2 (the K1 relay
is being used) verify that SW1 is in the ON position, and verify that the green DS1
LED is lit. This indicates that the necessary P28T power is available. If the DS1 LED
is not lit, then the K1 trip override relay will not provide the intended protection.
LVDT Excitation
In TMR applications, the LVDT signals fan out to three I/O packs through JR1, JS1, and JT1. A single 5-pin connector brings
power into the TSVC where the three voltages are diode high-selected and current limited to supply 24 V dc to the pulse rate
active probes.
Note Only two pulse rate probes on one TSVC are used.
PSVO Servo Control Module
GEH-6721_Vol_III_BJ System Guide 433
Non-Public Information
LVDT and Pulse Rate Inputs
LVDT ( or LVDR )
LVDT1 H
3.2 kHz ,
7 V rms
excitation
source
Mark VIe Controller
Application Logic
Servo Terminal Board
TSVCH1 A
Input Portion
JR 1
1 8 Ckts .
Servo Pack <R >
PSVO
A / D converter
A/ D
LVDT1 L
2
Servo Driver < R >
WSVO
Regulator
P28VR
SCOM
J 28
1
4
2
5
3
28 V dc for R
28 V dc return
28 V dc for S
28 V dc return
28 V dc for T
Digital
servo
regulator
JS1
D/ A
D/ A
converter
P28VS
JT1
P 28 V
Servo driver
voltage
limit
To servo
outputs
on TSVC
E n a b l e swi tch,
fu se , a n d l i g h t
P28VT
P28 V
P1 TTL 39
P1H 43
TTL
P1L
To TSVC
excitation
Pulse
Rate
(
PR
3. 2 k Hz
JR1
continued
PCOM 42
Pulse rate
inputs
active probes
2 Hz - 12 kHz
Configurable
Gain
CL
P24 V1 41
44
JS1
continued
P24 V2
CL
45
PSVO Servo Pack <S >
WSVO Driver < S>
PSVO Servo Pack <T>
WSVO Driver <T>
46
2 Hz - 12 kHz
JT1
continued
(
Pulse rate
inputs ,
magnetic
pickups
PCOM
40
P2 TTL
P2 H 47
PR
P2L 48
MPU
Noise
suppression
TSVC continued
434
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
For TMR systems, each servo channel has connections to three output coils with a range of current ratings up to 120 mA,
selected by jumper.
TSVC Servo Coil Outputs and LVDT Excitation
PSVO Servo Control Module
GEH-6721_Vol_III_BJ System Guide 435
Non-Public Information
9.3.3.2
Pilot Cylinder Servo Control
The pilot cylinder regulator types are used on low-pressure hydraulic systems with an inner pilot position loop. Both servo
outputs must be assigned to the same regulator. Each servo output is configured for ±120 mA current, yielding a total current
of ±240 mA. The following figure displays approved wiring options and jumper settings.
Mark VIe Controller
Application logic
Servo Terminal Board TSVCH 1A (continued )
Servo Pack R
PSVO
Digital
Servo
Regulator
Servo Driver R
WSVO
JD1
P28V
A/D converter
A/D
1
2
Regulator
Trip input from
PPRO not used
for TMR
JD2
Suicide relay
D/A
D/A
Converter
Servo
Driver (s)
JR1
P 28 V
J P1
120B
120
80
40
20
10
JR2
Pulse
Rate
Configurable
Gain
JS1
WSVO Driver S
JS2
JP 2
120B
120
80
40
20
10
J P3
120 B
120
80
40
20
10
J P4
120B
120
80
40
20
10
JT1/2
PSVO Servo Pack T
436
GEH-6721_Vol_III_BJ
25 S1RH
Parallel Servos for
Pilot / Cylinder App .
( 240 mA max .) for
Servo coil from R
31
26 S1RL
Configurable
Gain
PSVO Servo Pack S
1
2
P 28 V
WSVO Driver T
J P3
120B
120
80
40
20
10
2 Ckts.
33 S2RH
34 S2 RL
27 S1SH
The resistance
calculation will
measure only half
of the current
through the coil
resistance , so the
reported resistance
is twice the actual
coil resistance of
the actuator .
Parallel Servos for
Pilot / Cylinder App.
( 240 mA max .) for
Servo coil from S
28 S1SL
35 S2 SH
36 S2SL
29
30
Pilot / Cylinder App.
using PSVO does
not use Servo Outs
from T (user does
not have to put a
S 1TL resistor load on T )
S 1TH
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
9.3.3.3
Servo Coil Resistance
The following table defines the standard servo coil resistance and their associated internal resistance, selected with the
terminal board jumpers displayed in the previous figures. In addition to these standard servo coils, it is possible to drive
non-standard coils by using a non-standard jumper setting. For example, an 80 mA, 125 Ω coil could be driven by using a
jumper setting 120B.
Note The excitation source is isolated from signal common (floating) and is capable of operation at common mode voltages
up to 35 V dc, or 35 V rms, 50/60 Hz.
Servo Coil Resistance and Associated Internal Resistance
Jumper Label Coil
Type
Nominal Current
Coil Resistance
(Ohms)
Internal
Resistance (Ohms)
Application
101
±10 mA
1000
180
Simplex and TMR
202
±20 mA
125
442
Simplex
403
±40 mA
62
195
Simplex
404
±40 mA
89
195
TMR
805
±80 mA
22
115
TMR
120A
±120 mA (A)
40
28
Simplex
120B
±120 mA (B)
75
10
TMR
This table does not apply when the servo outputs are paralleled.
The governing equation for determining if the user needs to select a non-standard terminal board jumper position is
R ILIM_Calculated = (12,000 / Servo_MA_OUT) — RCOIL / Coil_Parallel - 10
where:
R ILIM_CALCULATED is the maximum terminal board current-limiting resistance in ohms the WSVO servo driver can
withstand to push 100% Servo_MA_OUT current through the coil. A negative value implies an unreal resistance highlighting
an incorrect value for RCOIL, Servo_MA_OUT, and so forth.
Servo_MA_OUT is the configuration parameter in the ToolboxST Servo Component Editor, Hardware tab, PSVO or
PSVP, Servo tab. The value in milli-amperes defines the servo actuator nominal current.
RCOIL is the servo actuator resistance per coil in ohms.
Coil_Parallel
value equals 1 for a single coil and equals 2 for two coils paralleled.
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If the following inequality is True,
Jumper Setting Internal Resistance (from table above) > R ILIM_CALCULATED
then the WSVO will not have the capability to drive 100% current. Select the next lowest terminal board current-limiting
resistance from the Internal Resistance column in the Servo Coil Resistance and Associated Internal Resistance table.
If the new Internal Resistance value meets the condition
Jumper Setting Internal Resistance ≤ R ILIM_CALCULATED
then use this terminal board current-limiting resistor jumper setting.
The following is an example of this formula:
R ILIM_Calculated = (12,000 / 80) - 125 / 1 - 10 = 15 ohms
where only one single servo driver output used, the servo actuator resistance is 125 ohms per coil, the nominal current is 80
mA and the servo actuator coils are not paralleled. Based on this calculation, Jumper 120B is selected with the ToolboxST
application PSVO or PSVP configuration parameters defined as given in the equation above.
9.3.3.4
Valve Position
Control valve position is sensed with either a four-wire LVDT or a three-wire linear variable differential reluctance (LVDR)
transducer. Redundancy implementations for the feedback devices are determined by the application software to allow the
maximum flexibility. LVDT/Rs can be mounted up to 300 m (984 ft) from the turbine control with a maximum two-way cable
resistance of 15 Ω.
Two LVDT/R transformer isolated excitation sources are located on the terminal board for simplex applications and another
two transformer isolated excitation sources for TMR applications. A fifth and sixth non-isolated excitation source are
provided for the customer’s use. Excitation voltage is 7 V rms and the frequency is 3.2 kHz with a total harmonic distortion of
less than 1% when loaded.
A typical LVDT/R has an output of 0.7 V rms at the zero stroke position of the valve stem, and an output of 3.5 V rms at the
designed maximum stroke position (some applications have these reversed). The LVDT/R input is converted to dc and
conditioned with a low pass filter. Diagnostics perform a high/low (hardware) limit check on the input signal and a high/low
system (software) limit check.
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9.3.3.5
Pulse Rate
Pulse rate inputs support both passive magnetic pickups and active pulse rate transducers (TTL type) interchangeable without
configuration. Normally, these inputs are not used on steam turbine applications, but are usually for liquid fuel flow
measurement, and monitoring flow divider feedback in gas turbine applications. Pulse rate inputs can be located up to 300 m
(984 ft) from the turbine control cabinet. This assumes shielded-pair cable is used with typically 70 nF single ended or 35 nF
differential capacitance and 15 Ω resistance.
A frequency range of 2 Hz to 12 kHz can be monitored at a normal sampling rate of either 10 or 20 ms. Magnetic pickups
typically have an output resistance of 200 Ω and an inductance of 85 MHz excluding cable characteristics. The transducer is a
high-impedance source, generating energy levels insufficient to cause a spark.
9.3.4 Specifications
Item
TSVC Specification
Number of inputs
Eight LVDT windings
Two pulse rate signals, magnetic or TTL
External trip signal to shut off servo outputs
Number of outputs
Two servo valves, three coils each, ±(10, 20, 40, 80, 120) mA
Four excitation sources for LVDTs (transformer isolation)
Two excitation sources for LVDTs (no transformer isolation)
Two 24 V dc excitation sources for pulse rate transducers
TSVCH2 has 6 sources with no isolation
Power supply voltage
Nominal 24 V dc from three supplies P28R, P28S, P28T
Power supply current
5 A dc (Poly-Fuse or current limit rating for each input is 1 A dc)
LVDT excitation output
Frequency of 3.2 ±0.2 kHz
Voltage of 7.00 ±0.14 V rms
Pulse rate input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 72 mV p-p
12 kHz requires 1486 mV p-p
Magnetic PR pickup signal
< 150 V p-p into 60 Ω
Active PR pickup signal
5 to 27 V p-p into 60 Ω
Fault detection
Servo current out of limits or not responding
Regulator feedback signal out of limits
Failed ID chip
Size
33.02 cm high x 17.8 cm wide (13 in x 7 in)
Technology
Surface-mount
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9.3.5 Diagnostics
PSVO makes diagnostic checks on the terminal board components as follows:
•
•
•
•
The output servo current is out of limits or not responding, creating a fault.
The regulator feedback (LVDT) signal is out of limits, creating a fault. If the associated regulator has two sensors, the bad
sensor is removed from the feedback calculation and the good sensor is used.
If any one of the above signals go unhealthy a composite diagnostic alarm, L#DIAG_PSVO occurs. Details of the
individual diagnostics are available from the ToolboxST* application. The diagnostic signals can be individually latched,
and reset with the RESET_DIA signal if they go healthy.
Each cable connector on the terminal board has its own ID device that is interrogated by the I/O processor. The ID device
is a read-only chip coded with the terminal board serial number, board type, revision number, and the J connector
location. When this chip is read by the I/O processor and a mismatch is encountered, a hardware incompatibility fault is
created.
9.3.6 Configuration
In a simplex system, servo 1 is configured for the correct coil current with jumper JP1, and servo 2 is configured with jumper
JP2. In a TMR system, each servo output can have three coils. In this case, each coil current is jumper selected using JP1, JP3,
and JP5 for servo 1, and JP2, JP4, and JP6 for servo 2. All other servo board configuration is done from the ToolboxST
application.
Power must be applied to the three channels, so check that all three switches SW1, SW2, and SW3 are ON, and the power
indicators for P28 R, S, and T are lit.
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10
PSVP Servo Control – Steam
10.1
PSVP Servo Control I/O Pack for Steam
The PSVP servo I/O pack, WSVO servo driver and the SSVP terminal board provide an
electro-hydraulic control for both new and retrofit steam turbine applications. The
following are salient features for this product:
•
•
•
•
Six position sensor input channels
Two servo outputs with a parallel feature allowing isolation of a failure in
electronics
Two excitation outputs with a hot-backup redundancy feature for single position
sensor valves
A pulse rate input optimized for turbine speed feedback similar to the PTUR and
PPRO pulse rate inputs
The product firmware supports single, minimum-select or maximum-select dual, and
mid-select triple position sensor input position regulators. The single and
maximum-select dual pilot cylinder position regulators are available. The product does
not support the flowrate regulators for liquid-fuel control or any of the position
regulators supporting the land and marine (LM) gas turbines.
Infrared Port Not Used
Input to the PSVP is through dual RJ-45 Ethernet connectors, and 28 V dc power is
supplied from the terminal board. The output is through a 62-pin connector that connects
directly with the associated terminal board connector. Visual diagnostics are provided
through indicator light emitting diodes (LEDs).
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10.1.1
Compatibility
PSVPH1A is only compatible with the DIN-rail mounted servo terminal board SSVP.
Terminal Board
Control Mode
SSVPHxx
Simplex, Dual, TMR
TSVOHxx
Not compatible
TSVCHxx
Not compatible
Note The PSVP is designed in particular for retrofit steam turbine applications.
Control mode refers to the number of I/O packs used in a signal path.
•
•
•
442
Simplex uses one PSVP, WSVO, and SSVP set with one or two network connections on each I/O pack.
Dual uses two PSVP, WSVO, and SSVP sets with one network connection on each I/O pack.
TMR uses three PSVP, WSVO, and SSVP sets with one network connection on each I/O pack.
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10.1.2
Installation
➢ To install the PSVP I/O pack
1.
Securely mount the terminal board.
Note The PSVP along with its associated WSVO servo driver assembly mounts directly to SSVP terminal board.
2.
Directly plug one PSVP I/O pack into the terminal board connector.
3.
Mechanically secure the I/O pack using the threaded inserts adjacent to the Ethernet ports. The inserts connect with a
mounting bracket specific to the terminal board type. The bracket location should be adjusted such that there is no right
angle force applied to the 62-pin connector between the I/O pack and the terminal board. The adjustment should only be
required once in the service life of the product.
4.
Plug the WSVO servo driver assembly into the J2 48-pin connector and secure it with the four screws.
5.
Plug in one or two Ethernet cables depending on the system configuration. The pack operates over either port. If dual
connections are used, standard practice is to hook ENET1 to the network associated with the R controller; however, the
PSVP is not sensitive to Ethernet connections and negotiates proper operation over either port.
6.
Plug the 28 V power into the SSVP P28IN 2-pin connector. Be sure the high is connected to pin 1 and the low is
connected to pin 2.
7.
If PSVP redundancy is simplex, insert the plug for suicide protection from the protection module.
8.
If PSVP redundancy is dual, plug the RJ-45 connector from SSVP_R JLA to SSVP_S JUA, and from SSVP_R JLB to
SSVP_S JUB.
9.
Apply power to the PSVP subassembly using the SW1 power switch on the SSVP. Check the indicator lights on the
PSVP.
10. Use the ToolboxST* application to configure the I/O pack as necessary. Refer to GEH-6700 for more information.
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10.1.3
Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
10.1.3.1
•
•
•
Connectors
The DC 62-pin connector on the underside of the I/O pack connects directly to a discrete output terminal board.
The RJ-45 Ethernet connector (ENET1) on the I/O pack side is the primary system interface.
The second RJ-45 Ethernet connector (ENET2) on the I/O pack side is the redundant or secondary system interface.
Note The terminal board provides fused power output from a power source that is applied directly to the terminal board, not
through the I/O pack connector.
10.1.3.2
PSVP Circuitry
The PSVP has a BSVP application board that provides six rms to V dc converters for position feedback. The rms to V dc
converters accept a maximum of 7.07 V rms sine wave input. They change the ac input signal into a 10 V dc input, read by
the 16-bit analog-to-digital converter. The digitized position information is used in the valve position control loop in the
PSVP firmware. The output of the position regulator is written to an analog-to-digital converter located on the BSVP. This
analog output feeds the WSVO current regulator.
The PSVP also controls the servo suicide relay on the WSVO and the isolation relay on the SSVP. It inputs the servo driver
output voltage and the servo current. Coil ohms are calculated in firmware by using the servo current feedback and the
voltage monitored at the SSVP servo terminal points.
The excitation source for the LVDT/R position sensor is generated using the processor board’s field programmable gate array
(FPGA) to control a digital-to-analog converter. The converter’s 3.2 kHz sine wave is outputted to the SSVP terminal board
where the excitation driver is located. The excitation redundancy control is performed by a micro-controller located on the
BSVP.
The decision to switch from one excitation source to the hot backup is determined by the excitation current feedback and
excitation voltage feedback from the SSVP terminal board. If the excitation current and/or voltage is outside its prescribed
operating window, the micro-controller will send a command to de-energize the KE1 or KE2 switchover relay on one SSVP
and energize the KE1 or KE2 switchover relay on the SSVP that has the redundant excitation source. The state information
for this switchover control is passed to the other PSVP through a Private Serial Network (PSN). The PSN is a RS-422 based
serial network that works in concert with a FPGA / micro-controller excitation switchover function.
Note The PSN has a faster response time than what can be achieved through IONet / PSVP firmware.
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10.1.3.3
Pulse Rate Input
The PSVP module has one pulse rate input designed for turbine speed, but not for flow rate feedback used for liquid-fuel
control. The pulse rate input circuit in the PSVP enhances the turbine speed signal. The 28 V dc input on the BPPB is not
used to power the PSVP I/O module. The 28 V dc source is connected to the P28IN connector on the SSVP to power the
PSVP, WSVO servo driver and the SSVP terminal board.
Note The PSVP pulse rate input is similar to the PTUR and PPRO pulse rate inputs.
An interface is provided for one passive magnetic speed input. There is no provision for active pulse rate sensors or TTL
input. A frequency range of 2 to 20,000 Hz is supported. The pulse rate input is not designed for flow divider sensors and the
corresponding liquid fuel regulators are not included.
Note The PSVP signal-conditioning circuit is designed for the primary speed input, the same as the PTUR or PPRO.
Pulse rate inputs can be configured for a variety of applications. Speed type is the default setting normally used with turbine
control. Speed_high type provides an extended speed range above the standard speed type. Speed_HSNG type is an improved
pulse rate detection method that eliminates discontinuities due to hardware and software gearing, and eliminates alias speed
values associated with non-uniform pulse rate. Speed_HSNG should be used for all turbine applications unless otherwise
specified.
The Speed_HSNG type will map the spacing of the teeth on the speed wheel to remove periodic variation from speed
measurements. HSNGn_Stat mapping locked status bits are in signal space so the mapping status of the algorithm can be
observed. If the status indicator for a pulse rate input is false, then the mapping algorithm detects too much variation in the
tooth-tooth measurements to lock onto the tooth geometry. The Lock_Limit parameter can be adjusted in 1% increments.
Increasing the Lock_Limit value will allow the next generation speed algorithm to stay locked with increased variation. This
allows greater tooth-to-tooth variation per revolution, which can be caused by some of the following issues:
•
•
•
A Magnetized speed wheel
Electro-magnetic interference from outside sources
Improper wiring or shielding practices
The impact of opening the Lock_Limit is increased speed variation. If the speed
variation becomes excessive after increasing the Lock_Limit, identify the source of the
problem (listed above) and correct the issue.
Caution
10.1.3.4
WSVO
The WSVO servo driver is used for both the PSVP and PSVO applications. The WSVO has two servo current regulators to
drive the servo outputs on the SSVP terminal board. It provides the dc-to-dc converter (28 V dc to +15 / -15 V dc) to power
the analog circuitry. It also has two excitation voltage drivers that are not used by the PSVP. The excitation drivers for the
PSVP are located on the SSVP to optimize the excitation output for load steps in the excitation switchover scheme used in
this module.
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10.1.3.5
Position Feedback
The PSVP / SSVP has six Linear Variable Differential Transformer (LVDT) or Linear Variable Differential Reluctance
(LVDR) sensor inputs, each of which includes:
•
•
SSVP Open-wire detection circuit and load
BSVP rms to V dc converter
Note Although there are six LVDT signal inputs, there are only two excitation outputs. Each excitation output can only
support two LVDTs, effectively limiting the number of LVDTs that a PSVP can support to four for certain applications.
The SSVP open-wire circuitry provides weak pull-up and pull-down resistors to the appropriate power rails, adding
approximately one mA of dc current into the feedback windings of the LVDT or LVDR. If the circuit on the feedback side of
the position transducer opens, the PSVP detects the absence of this additional dc current. It flags the controller that a position
sensor connection has opened using the Out of Range detection logic in the PSVP firmware. The SSVP provides a 20
kilo-ohm resistive load for the feedback winding of the LVDT or LVDR.
Note For dual and TMR PSVP redundancy, the position sensor feedbacks must be fanned external to the SSVP.
The BSVP rms to V dc converter has a high impedance differential amplifier, providing common mode voltage protection.
The rectifier and low-pass filtering is designed to scale the dc signal output where 10 V dc is equivalent to 7.07 V rms at the
input. The rms to V dc converter outputs are multiplexed into a single 16-bit analog-to-digital converter. Each converter
output is sampled every five ms or at a 200 Hz rate.
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10.1.3.6
Position Sensor Types
Most LVDTs used for sensing valve positions are three-wire with bias winding as displayed in the following figure.
LVDT with Bias Winding
The LVDT with bias winding has a primary excitation winding defined by the red and blue wire connections. The red wire
connects to SSVP EXnH, and the blue wire connects to EXnL where n = 1-2. The two secondary windings are connected in
series, providing a position output between the yellow and blue wires. The yellow wire is connected to SSVP LVxH where x
= 1-6 and the blue wire is connected to SSVP LVxL. A bias winding has also been added to aid in the detection of sensor
failures.
A sliding magnetic core or armature is located within the LVDT, coupling the primary and secondary windings. The
secondary windings are connected in series, aiding each other electrically. The output voltage is above zero when the core is
positioned equally between the two secondary windings. Moving the core from the center position will create a voltage
proportional to the distance from the null position. The steam turbine product line normally uses LVDRs.
The LVDR is a linear variable differential reluctance transducer, having a single coil and a center tapped with a movable
magnetic core or armature. Normally, the excitation source is applied across the entire winding through the black and red
wires. The valve position feedback is extracted from the center-tapped point on the coil (white wire) and the low side (red
wire) of the excitation.
LVDR Position Sensor
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10.1.3.7
Recommended Wiring Practices
The excitation black wire is connected to the SSVP EXnH screw. The excitation red wire is connected to the SSVP EXnL
screw where n = 1 –2. The position sensing high-side white wire is connected to SSVP LVxH. the red wire is connected to
SSVP LVxL where x = 1-6.
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10.1.3.8
Servo Outputs
The PSVP module has two servo channels. The servo loop is comprised of the following:
•
•
•
•
•
•
Firmware position regulator
Digital-to-analog converter
Current regulator
Current limiting resistors
Simplex protection
Parallel option with failure isolation
The PSVP processor runs the firmware position regulator for Servo 1 and Servo 2 every five ms or at a 200 Hz rate. The
position reference command is a system output from the controller and the position feedback is the digitized and scaled value
from the BSVP / SSVP circuitry.
The regulator output is written to a digital-to-analog converter. The converter output is the analog current command for the
WSVO analog current regulator. The fixed-gain proportional-plus-integral current regulator provides a voltage-controlled
current source output with discrete nominal current ratings of 10, 20, 40, 80, and 120 mA.
When the configuration for the PSVP is properly set, a suicide relay on the WSVO limits the current regulator output if the
coil ohms calculation function detects any of the following:
•
•
•
A coil open or coil short condition
A current regulator control loss
An open or out-of-range position feedback
The SSVP current limiting resistors reduce the power dissipation of the current driver to prevent a shorted output. Berg
Jumpers on the SSVP are provided to select the proper nominal current rating for the coil driver application.
For simplex controller application of the PSVP module, an externally controlled relay is provided on the SSVP (controlled by
the PPRO) to disable the WSVO servo driver and select a positive biased current to drive the valve closed. The PSVO /
WSVO / TSVC and the PSVP / WSVO / SSVP servo outputs can be paralleled, but only the PSVP module can isolate a
failure of the WSVO. The isolation circuitry is controlled by the PSVP through the KS1 and KS2 relays on the SSVP terminal
board.
10.1.3.9
Calibrate Valve Function
The calibration of LVDTs associated with PSVO, PSVP, PCAA, or PMVE (MVRA or MVRF) servos is required when a new
terminal board is used on a system. The controller saves the barcode of the terminal board and compares it to the current
terminal board during reconfiguration load time. Any time a recalibration is saved, it updates the barcode name to the current
board.
Note Refer to the ToolboxST User Guide for Mark Controls Platform (GEH-6700), the chapter Special I/O Functions. the
section Calibrate Valve Function.
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10.1.4
Specifications
The following table provides information specific to the PSVP I/O pack and WSVO driver.
Item
PSVP Specification
Number of inputs
Six LVDT / R windings**
Single pulse rate input
** Although there are six LVDT signal inputs, there are only two excitation outputs. Each excitation output can only support two
LVDTs, effectively limiting the number of LVDTs that a PSVP can support to four for certain applications.
Number of outputs
Two servo valve currents
Two excitation sources with redundant control capability for LVDT / Rs.
Power supply voltage
Nominal 28 V dc
LVDT accuracy
1% with 16-bit resolution
LVDT input filter
Low pass filter with 3 down breaks at 50 rad/sec ±15%
LVDT common mode range
CMR is 15 V dc, 10 V rms
at 50/60 Hz
LVDT excitation output
Frequency of 3.2 ±0.2 kHz
Voltage of 7.07 ±0.14 V rms
Pulse rate accuracy
0.05% of reading with 16-bit resolution at 50 Hz frame rate
Noise of acceleration measurement is less than ±50 Hz/sec for a 10,000 Hz signal being read
at 10 ms
Pulse rate input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 28 mV p-p
20 kHz requires 320 mV p-p
Magnetic PR pickup signal
Generates 150 V p-p into 60 kΩ
Servo valve output accuracy
2% with 12-bit resolution
Fault detection
Servo current out of limits or not responding
Regulator feedback signal out of limits
Servo suicide
Calibration voltage range fault
The LVDT excitation is out of range
The input signal varies from the voted value by more than the TMR differential limit
Failed ID chip
Size
8.26 cm high x 4.19 cm wide x 12.1 cm deep (3.25 in x 1.65 in x 4.78 in)
Technology
Surface-mount
† Ambient rating for
Operating: -30 to 65ºC (-22 to 149 ºF)
enclosure design
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
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10.1.5
Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware.
Continuous monitoring of the internal power supplies for correct operation.
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
Each analog input has hardware limit checking based on preset (non-configurable) high and low levels near the end of the
operating range. If this limit is exceeded, a logic signal is set and the input is no longer scanned. The L3DIAG_xxxx logic
signal refers to the entire board.
The pulse rate input has system limit checking based on configurable high and low levels. These limits can be used to
generate alarms, to enable/disable, and as latching/non-latching. RSTSYS in the SYS_OUTPUTS blocks resets the out of
limits. Refer to GEI-100682, Mark VIe Controller Standard Block Library, the section, System Outputs (SYS_OUTPUTS)
for more information.
The analog input hardware includes precision reference voltages in each scan. Measured values are compared against
expected values and are used to confirm health of the analog to digital converter circuits.
Analog output current is sensed on the terminal board using a small burden resistor. The pack conditions this signal and
compares it to the commanded current to confirm health of the digital to analog converter circuits.
The analog output suicide relay is continuously monitored for agreement between commanded state and feedback
indication.
Servo coil resistance is calculated based on servo terminal point voltage and current. The calculated resistance is
compared against configurable limits to generate open and/or shorted coil alarms.
•
•
•
•
•
•
•
•
Details of the individual diagnostics are available from the ToolboxST application. The diagnostic alarms can be individually
latched and then reset with the RSTDIAG parameter in the SYS_OUTPUTS block when the diagnostic condition becomes
inactive. Suicide alarms require a RSTSUIC before the servo relays will un-suicide. Excitation alarms require a RSTDIAG to
rearm excitation switchover when excitation sharing is used.
10.1.5.1
PSVP LEDs
PSVP LEDs
LED
Label
Description
Green
SV1
Servo #1 is able to output current and not suicided.
Green
SV2
Servo #2 is able to output current and not suicided.
Green
EX1
Excitation Output #1 is active and connected to position sensor.
Green
EX2
Excitation Output #2 is active and connected to position sensor.
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10.1.6
Configuration
Note Only the configurations provided in this document have been approved for use.
It is not recommended to run the coil ohm calculation for Inlet Guide Vane or
Variable Stator Vane servo loops. The higher gain servo loops introduce an AC
component to the coil voltage and current. The calculated coil ohm results will be in
error due to the out-of- phase AC portions of the coil voltage and current. To disable
the coil ohm calculation, set the following parameters to Disable:
• OpenCoilSuic
Attention
• OpenCoildiag
• ShrtCoilSuic
• ShrtCoildiag
Parameter
Description
Choices
ServoOutput#
Where # = 1 or
2
Servo Output X measured current in percent.
Point Edit (Input Real)
RegNumber
Maps a specific regulator to a given servo output
Unused, Reg1, Reg2
(Default-Unused)
Servo_MA_Out
Nominal servo current rating in mA
10 mA (default), 20 mA,
40 mA, 80 mA, 120 mA
EnablCurSuic
Enable Current Suicide Function
Enable, Disable (default)
EnablFbkSuic
Enable Position Feedback Suicide Function
Enable, Disable (default)
AV_Selector
Configuration selector to map one of the specified variables to the
PSVP variable, ServoxMonitorNV where x = 1 or 2.
Coil_Ohms, Compliance_Voltage,
Excitation_Current, mA_cmd_pct,
mA_cmd_pct_limit,
RCoilLocalOhms, Servo_Screw_
Voltage
Curr_Suicide
Current command is compared to the actual feedback current. If the
error exceeds the configuration limit, Curr_Suicide (%), then the
Servo output will suicide.
0 to 100 (default 5)
Fdbk_Suicide
The position feedback, Regx_Fdbk(%), where x = 1 or 2, is
compared against the values, 100% + Fdbk_Suicide(%) and 0% Fdbk_Suicide(%). If Regx_Fdbk(%) is greater than the positive value
or less than the negative value, the Servo output will suicide.
0 to 10 (default 5)
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Parameter
Description
Choices
OpenCoilSuic
If configuration parameter, OpenCoilSuic = Enable, then the servo
coil open detection function will suicide the servo if the function
detects an open ckt. Set OpenCoildiag = Enable to receive a
diagnostic message as to why the servo suicide occurred.
Enable, Disable (default)
If the Coil_Parallel parameter is set to Coils_Parallel, set
OpenCoilSuic to Disable. This allows the servo to keep generating
current if one of the two servo coils fails to open.
If one coil fails and remains open, the calculated coil resistance
value doubles to a value that is at the nominal open circuit threshold.
Set the OpenCoilDiag parameter to Enable so the open coil failure is
annunciated for this case.
Set this parameter to Disable to disable the coil ohm calculation. Refer
to the Attention statement at the beginning of this section for further
details.
ShrtCoilSuic
If configuration parameter ShrtCoilSuic = Enable, then the servo coil
short ckt. Detection function will suicide the servo if the function
detects a short ckt. Set ShrtCoildiag = Enable to receive a diagnostic
message as to why the servo suicide occurred.
Enable, Disable (default)
Set this parameter to Disable to disable the coil ohm calculation. Refer
to the Attention statement at the beginning of this section for further
details.
OpenCoildiag
If enabled, a specific diagnostic message is generated to explain
why the servo suicide occurred, such as Servo x Suicide due to
Open servo coil.
Enable, Disable (default)
Set this parameter to Disable to disable the coil ohm calculation. Refer
to the Attention statement at the beginning of this section for further
details.
ShrtCoildiag
If enabled, a specific diagnostic message is generated to explain
why the servo suicide occurred, such as Servo x Suicide due to
Short circuit of servo coil.
Enable, Disable (default)
Set this parameter to Disable to disable the coil ohm calculation. Refer
to the Attention statement at the beginning of this section for further
details.
Coil_Parallel
If set to Coils_Parallel then the servo is connected to 2 servo coils
wired in parallel. The coil resistance calculation determines the
resistance of a single coil for use with the short and open circuit coil
protection. If set to Coils_not_parallel, then the servo is connected to
a single servo coil.
Coils_parallel,
Coils_not_parallel (default)
TBmAJmpPos
This is the SSVP terminal board mA jumper position selection. It
should match the jumper selection on the SSVP
10 mA (default), 20 mA, 40 mA,
80 mA, 120 mA A, 120 mA B
RopenTimeLim
This is the time in seconds required for the open circuit condition of
the servo coil to be in effect before a diagnostic and / or suicide of
the servo (if enabled) occurs.
0 to 100 (default 1)
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Parameter
Description
Choices
RShrtTimeLim
This is the time in seconds required for the short circuit condition of
the servo coil to be in effect before a diagnostic and / or suicide of
the servo (if enabled) occurs.
0 to 100 (default 1)
RcoilOpen
This defines the initial value for the open circuit resistance in ohms.
After the LVDT calibration, the value for RcoilOpen is 2 * (Servo_
Screw_Volts / Servo Current) measured during the calibration mode.
1 to 10E+09 (default 1000000)
RcoilShort
This defines the initial value for the short circuit resistance in ohms.
After the LVDT calibration, the value for RcoilShort is 0.5 * (Servo_
Screw_Volts / Servo Current) measured during the calibration mode.
1 to 10E+09 (default 0)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
0 to 110 (default 25)
Pulse Rates
Bipolar input = PRH – PRL
Point Edit (Input Real)
PRType
This defines the speed algorithm used for the pulse rate input.
Speed, Speed_High, Speed_
HSNG, Unused
PRScale
Scaling: pulses per revolution (outputs RPM)
0 to 1000
TeethPerRev
Number of teeth on speed wheel (per revolution)
1 to 512
This is the calculation rate of speed in milliseconds. Speed is
calculated at this rate and averaged over the previous time interval
specified by this period.
5 to 1000
Speed_x_ms
Using a value other than an integer multiple of the associated
application frame rate can have an adverse impact on use of
this in control.
Attention
Accel_x_ms
This is the averaging period for acceleration calculation in
milliseconds. The acceleration is calculated every Accel_X_ms. It is
based on the difference between two speed samples divided by the
sample period. Each acceleration calculation is the average of
acceleration over the period specified by this parameter. For
example, if Accel_x_ms is 40 then acceleration is the average
acceleration over the previous 80 ms.
10 to 1000
Using a value other than
an integer multiple of the
associated application
frame rate can have an
adverse impact on use of
this in control.
Attention
Lock_Limit
This is the HSNG speed type-locking limit for teeth mapping
(percent).
1 to 100 (must be a positive
integer)
SysLim1Enabl
If enabled, System Limit 1 is active.
Enable, Disable (default)
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Parameter
Description
Choices
SysLim1Latch
If enabled, the System Limit 1 function will latch its state if the
PulseRate exceeds the limit function defined by SysLim1Type and
SysLimit1.
Latch (default), NotLatch
SysLim1Type
Defines the compare function used in the Limit1 expression.
≥ (default), ≤
SysLimit1
Defines Limit1 value to be used for the input, PulseRate.
0 to 20,000 (default 0)
SysLim2Enabl
If enabled, System Limit 2 is active.
Enable, Disable (default)
SysLim2Latch
If enabled, the System Limit 2 function will latch its state if the
PulseRate exceeds the limit function defined by SysLim2Type and
SysLimit2.
Latch (default), NotLatch
SysLim2Type
Defines the compare function used in Limit 2’s expression
≥ (default), ≤
SysLimit2
Defines Limit2 value to be used for the input, PulseRate
0 to 20,000 (default 0)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
0 to 20,000 (default 5)
Excitation
PSVP supports 2 LVDT excitation channels. An individual set of
configuration parameters are supplied for each Excitation x
where x = 1 through 2.
StandAloneDiag
Non-shared diagnostic enable, diagnostics cannot be disabled for
excitation outputs that have been configured as shared by the Exc_
Sharing parameter
Common
The following parameters are common for all regulators
RegType
Regulator Algorithm Type
Unused, no_fbk, 1_LVposition,
2_LVpilotCyl,
2_LVposMAX, 2_LVposMIN,
3_LVposMID,
4_LVp/cylMAX
RegGain
Position loop Gain in % current / Eng Units or usually % current / %
position
-200 to 200 (default 1)
RegNullBias
Regulator Null Bias provides a fixed current command in percent to
cancel or null the spring force of the valve which will close the valve if
the servo suicides or shuts down.
-100 to 100 (default 0)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
0 to 150 (default 5)
LVDT
Parameters
PSVP supports six LVDT input channels. An individual set of
configuration parameters as listed below are supplied for each
LVDTx where x = 1 through 6.
Enable
Selects this LVDT to be used by the PSVP monitor or position
regulator for servo control use
Enable or Disable (default)
LVDT_Margin
This defines the over range in % for the LVDT input. A diagnostic is
generated if this value is exceeded.
0 to 100 (default 2)
MinVrms
LVDT1 V rms is at the minimum end stop of the valve. These values
are normally set by the Auto-Calibrate function.
0 to 7.1 (default 1)
MaxVrms
LVDT1 V rms is at the maximum end stop of the valve. These values
are normally set by the Auto-Calibrate function.
0 to 7.1 (default 1)
MaxPOSvalue
Position in Eng. units (usually %) at the maximum end stop of the
valve
-15 to 150 (default 100)
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Parameter
Description
Choices
MinPOSvalue
Position in Eng. units (usually %) at the minimum end stop of the
valve
-15 to 150 (default 0)
TMR_DiffLimt
Diagnostic limit, TMR Input vote difference in %
0 to 150 (default 5)
RegType
Position regulator used with a single LVDT Input
= 1 LV position
LVDT1input
Defines which LVDT input from the SSVP will be used by the position
regulator for input 1
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
RegType
Pilot cylinder regulator with two LVDT position feedbacks
= 2_LVpilotCyl
PilotGain
Pilot loop gain in % current / Eng. unit
-200 to 200 (default 1)
LVDT1input
Defines which LVDT input from the SSVP will be used for the cylinder
feedback mapped into Regx_Fdbk where x = 1 or 2
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT2input
Defines which LVDT input from the SSVP will be used for the pilot
feedback mapped into PilotFdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
RegType
Position regulator using the maximum select from 2 LVDT
inputs for feedback
= 2_LVposMAX
LVDT1input
Defines which LVDT input from the SSVP the position regulator will
use for input 1.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT2input
Defines which LVDT input from the SSVP the position regulator will
use for input 2.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
RegType
Position regulator using the minimum select from 2 LVDT inputs
for feedback
= 2_LVposMIN
LVDT1input
Defines which LVDT input from the SSVP the position regulator will
use for input 1
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT2input
Defines which LVDT input from the SSVP the position regulator will
use for input 2
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
RegType
This is the position regulator using the median select from 3
LVDT inputs for feedback. It was originally designed for
heavy-duty gas turbines.
= 3_LVposMID
LVDT1input
Defines which LVDT input from the SSVP the position regulator will
use for input 1
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT2input
Defines which LVDT input from the SSVP the position regulator will
use for input 2
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT3input
Defines which LVDT input from the SSVP the position regulator will
use for input 3
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
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Parameter
Description
Choices
RegType
Four LVDT pilot cylinder with maximum select of two LVDTs for
cylinder feedback and maximum select of two LVDTs for the
pilot feedback
=4_LVp/cylMAX
PilotGain
Pilot loop gain in % current / Eng. unit
-200 to 200 (default 1)
LVDT1input
Defines which LVDT input from the SSVP will be used for the first
input into the maximum select of the cylinder feedback mapped into
Reg_fdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT2input
Defines which LVDT input from the SSVP will be used for the second
input into the maximum select of the cylinder feedback mapped into
Reg_fdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT3input
Defines which LVDT input from the SSVP will be used for the first
input into the maximum select of the pilot feedback, PilotFdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT4input
Defines which LVDT input from the SSVP will be used for the second
input into the maximum select of the pilot feedback, PilotFdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
RegType
Six LVDT pilot cylinder with median select of three LVDT/Rs for
cylinder feedback and median select of three LVDT/Rs for the
pilot feedback.
=6_LVp/cylMID
PilotGain
Pilot loop gain in % current / Eng. unit
-200 to 200 (default 1)
LVDT1input
Defines which LVDT/R input from the SSVP will be used for the first
input into the median select of the cylinder feedback mapped into
Reg_fdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT2input
Defines which LVDT/R input from the SSVP will be used for the
second input into the median select of the cylinder feedback mapped
into Reg_fdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT3input
Defines which LVDT/R input from the SSVP will be used for the third
input into the median select of the cylinder feedback, Reg_fdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT4input
Defines which LVDT/R input from the SSVP will be used for the first
input into the median select of the pilot feedback, PilotFdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT5input
Defines which LVDT/R input from the SSVP will be used for the
second input into the median select of the pilot feedback, PilotFdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
LVDT6input
Defines which LVDT/R input from the SSVP will be used for the third
input into the median select of the pilot feedback, PilotFdbk.
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, or Unused
(default)
MonType
Monx equals the scaled value from the LVDT assigned through
LVDT1input where x = 1 to 6
= 1_LVposition
LVDTxinput
where x = 1
LVDTx input selection
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, Unused (default)
MonType
Monx equals the maximum selected scaled value from two
LVDTs assigned through LVDTyinput where x = 1 to 6 and y = 1
to 2.
= 2_LVposMAX
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Parameter
Description
Choices
LVDTxinput
where x = 1 to 2
LVDTx input selection
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, Unused (default)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
-10 to 150 (default 5)
MonType
Monx equals the minimum selected scaled value from two
LVDTs assigned through LVDTyinput where x = 1 to 6 and y = 1
to 2.
= 2_LVposMIN
LVDTxinput
where x = 1 to 2
LVDTx input selection
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, Unused (default)
TMR_DiffLimt
Diagnostic limit, TMR Input Vote difference in %
-10 to 150 (default 5)
MonType
Monx equals the median selected scaled value from three
LVDTs assigned through LVDTyinput where x = 1 to 6 and y = 1
to 3.
= 3_LVposMID
LVDTxinput
where x = 1 to 3
LVDTx input selection
LVDT1, LVDT2, LVDT3, LVDT4,
LVDT5, LVDT6, Unused (default)
TMR_DiffLimit
Diagnostic limit, TMR Input Vote difference in %
-10 to 150 (default 5)
10.1.6.1
Valid Servo Configurations with TMR I/O (non Pilot / Cylinder)
Servo #1 Configuration
Option 1
* Coil_Parallel (cfg)
Coils_not_parallel
RegType (cfg)
3_LVposMID
Servo #2 Configuration
Option 1
* Coil_Parallel (cfg)
Coils_not_parallel
RegType (cfg)
3_LVposMID
* The parameter Coil_Parallel is not visible in ToolboxST for a TMR PSVP. It is forced by the firmware to Coils_not_parallel.
Note LVDT or LVDR position sensors can be used. 1_LVposition, 2_LVposMIN or 2_LVposMAX are supported but are not
normally used.
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Option One: TMR LVDR and Triple Coil Servo
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10.1.6.2 Valid Servo Configurations with Dual LVDR and Dual Coil Servo, Coils Not
Paralleled
If PSVP-S powers on before PSVP-R, the controller selects the PSVP-S signal-space inputs as the voted data to be used.
LVDT or LVDR position sensors can be used. 2_LVposMIN, 2_LVposMAX or 3_LVposMID are supported for two or three
sensors per servo but are not normally used.
Servo #1
Configuration
Option 2
Option 2 with fanned
inputs
Option 3
Option 4
Coil_Parallel (cfg)
Coils_not_parallel
Coils_not_parallel
Coils_not_parallel
Coils_not_parallel
RegType (cfg)
1_LVposition
2_LVposMAX
1_LVposition
1_LVposition
Servo #2
Configuration
Option 2
Option 2
Option 2
Option 2
Coil_Parallel (cfg)
Coils_not_parallel
Coils_not_parallel
Coils_not_parallel
Coils_not_parallel
RegType (cfg)
1_LVposition
1_LVposition
1_LVposition
1_LVposition
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Option Two: Dual LVDR and Dual Coil Servo
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10.1.6.3 Valid Servo Configurations with Simplex LVDR and Dual Coil Servo, Coils Not
Paralleled
If PSVP-S powers on before PSVP-R, the controller selects the PSVP-S signal-space inputs as the voted data to be used.
LVDT or LVDR position sensors can be used. 2_LVposMIN, 2_LVposMAX or 3_LVposMID are supported for two or three
sensors per servo but are not normally used.
Servo #1 Configuration
Option 3
Option 4
Coil_Parallel (cfg)
Coils_not_parallel
Coil_parallel
RegType (cfg)
1_LVposition
1_LVposition
Servo #2 Configuration
Option 3
Option 3
Coil_Parallel (cfg)
Coils_not_parallel
Coils_not_parallel
RegType (cfg)
1_LVposition
1_LVposition
Option Three: Simplex LVDR and Dual Coil Servo with Coils not Paralleled
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10.1.6.4 Valid Servo Configuration with Simplex LVDR and Dual Coil Servo, Coils
Paralleled
Servo #1 Configuration
Option 4
Option 5
Coil_Parallel (cfg)
Coil_parallel
Coil_parallel
RegType (cfg)
1_LVposition
1_LVposition
Servo #2 Configuration
Option 4
Option 4
Coil_Parallel (cfg)
Coil_parallel
Coil_parallel
RegType (cfg)
1_LVposition
1_LVposition
Option Four: Simplex LVDR and Dual Coil Servo with Coils Paralleled
If PSVP-S powers on before PSVP-R, the controller selects the PSVP-S signal-space inputs as the voted data to be used.
LVDT or LVDR position sensors can be used. 2_LVposMIN, 2_LVposMAX or 3_LVposMID are supported for two or three
sensors per servo but are not normally used.
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10.1.6.5
Controller Software Support for Dual PSVP I/O Configurations
In the dual I/O redundancy configuration, the controller(s) use the I/O pack health to determine which I/O pack inputs to use.
For example, assume the controller(s) voted or selected PSVP(R) for system inputs. Also assume that LVDT1 input on PSVP
(R) is out of range, resulting in an unhealthy LVDT1 input, and LVDT1 from PSVP(S) is healthy. Because PSVP(R) is the
voted I/O pack for system inputs, the controller software is constrained due to the unhealthy LVDT1 input.
The dual I/O redundancy configuration can be enhanced by using the Pre-Vote block on PSVP(R) and PSVP(S) system
inputs. The Pre-Vote block frees the controller software to determine whether the PSVP(R) or PSVP(S) input should be used.
Recommended Controller Software Selection Logic for Pre-Vote Outputs
Voted Source
<R> Healthy
<S> Healthy
Vote Mismatch
Pre-Vote Output to
Use
<R> or <S>
NO
NO
NO or YES
Default to Safe Value
<R> or <S>
NO
YES
NO or YES
<S>
<R> or <S>
YES
NO
NO or YES
<R>
<R>
YES
YES
NO
<R>
<S>
YES
YES
NO
<S>
<R> or <S>
YES
YES
YES
** Application Dependent
** The application determines whether to use either PSVP(R) system input or PSVP(S) system input.
Voted Source
PSVP(R) or PSVP(S) system inputs are selected for use by controller
<R> Healthy
PSVP(R) pack is healthy
<S> Healthy
PSVP(S) pack is healthy
Vote Mismatch
PSVP(R) system input – PSVP(S) system input > TMR Diff Limit
Pre-Vote Output to Use
Result of controller software selection logic
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10.1.6.6 Valid Servo Configuration with Simplex LVDR and Dual Coil Servo, Coils
Paralleled
Servo #1 Configuration
Option 5
Coil_Parallel (cfg)
Coil_parallel **
RegType (cfg)
1_LVposition
Servo #2 Configuration
Option 5
Coil_Parallel (cfg)
Coil_parallel **
RegType (cfg)
1_LVposition
** This parameter is forced to Coils_Parallel internal to a Simplex PSVP for all regulator types except Pilot/Cylinder.
Note LVDT or LVDR position sensors can be used. 2_LVposMIN, 2_LVposMAX, or 3_LVposMID are supported for two or
three sensors per servo but are not normally used.
Option Five: Simplex LVDR and Dual Coil Servo with Coils Paralleled
Note Dual IONet is permissible for frame rates of 25 and 50 Hz. The 100 Hz frame rate is not permissible due to firmware
execution limitations.
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10.1.6.7
Simplex PSVP: Pilot / Cylinder Configuration
The Pilot / Cylinder regulator types are used on low-pressure hydraulic systems with an inner pilot position loop. For pilot /
cylinder regulator types, both servo outputs should be assigned to the same regulator. Each servo output is configured for
±120 mA current, yielding a total current of ±240 mA.
The 2_LVpilotCyl regulator type configuration uses one position sensor for the outer cylinder valve and one position sensor
for the inner pilot cylinder loop. Independent excitation outputs are provided on the SSVP to supply 7.07 V rms at 3.2 kHz to
the LVDT or LVDR sensor input.
The 4_LVp/cylMAX selects the maximum from two position inputs from both the outer cylinder position loop and the inner
pilot position loop. The PSVP / WSVO / SSVP provides two excitation outputs. Each excitation output is designed to support
two LVDT/R position sensors assuming the total current does not exceed 60 mA.
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Servo with Paralleled Coils
For a servo with parallel coils, Servo drive #1 and Servo drive #2 are paralleled. Set the Servo Tab configuration parameter,
Coil_Parallel to Coils_Parallel for both servos. With this new configuration, the PSVP module allows the suicide to remain
enabled for protection. The servos have an isolation contact provided for each servo circuit located on the SSVP. If Servo
drive #1 hardware fails, the WSVO suicides Servo drive #1 output. Simultaneously, the SSVP opens the isolation contact
controlled by the KS1 relay. The relay isolates Servo drive #1 from Servo drive #2, allowing Servo drive #2 to continue to
run. This results in half the rated current of ±120 mA being supplied to the servo valve. Set the Regulator Tab configuration
parameter, RegType to 4_LVp/cylMAX.
Note Dual IONet is permissible for frame rates of 25 and 50 Hz. The 100 Hz frame rate is not permissible due to firmware
execution limitations.
Simplex PSVP: Dual Pilot / Dual Cylinder Valves with Dual Coil Servo (coils paralleled)
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For the Simplex PSVP with single pilot and single cylinder and dual coil servo, set the Regulator Tab configuration
parameter, RegType to 2_LVpilotCyl.
Simplex PSVP: Single Pilot / Single Cylinder Valves with Dual Coil Servo (coils paralleled)
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Servo with Non-paralleled Coils
If the pilot cylinder servo coils have separate coil connections, set the PSVP Servo Tab configuration parameter, Coil_
Parallel to Coils_not_parallel. For this case, the isolation contacts are always closed and the suicide contacts work like all
other servo products. Set the Regulator Tab configuration parameter, RegType to 4_LVp/cylMAX.
Note Dual IONet is permissible for frame rates of 25 and 50 Hz. The 100 Hz frame rate is not permissible due to firmware
execution limitations.
Simplex PSVP: Dual Pilot / Dual Cylinder Valves with Dual Coil Servo (not paralleled)
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For the Simplex PSVP with single pilot and single cylinder and dual coil servos not paralleled, set the Regulator Tab
configuration parameter, RegType to 2_LVpilotCyl.
Simplex PSVP: Single Pilot / Single Cylinder Valves with Dual Coil Servo (not paralleled)
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10.1.6.8
Dual PSVP: Pilot / Cylinder Configuration
The Dual PSVP redundancy configuration provides paralleled servo outputs per PSVP, and each PSVP drives a single servo
coil. The dual PSVP configuration provides redundancy for both of the following:
•
•
Servo driver failure on the PSVP, maintaining 100% forcing for the servo coil
Servo coil failure with reduced forcing dependent on the overdrive capability of the servo coil
The 2_LVpilotCyl regulator type configuration uses one position sensor for the outer cylinder valve and one position sensor
for the inner pilot cylinder loop. Independent excitation outputs are provided on the SSVP to supply 7.07 V rms at 3.2 KHz to
the LVDT or LVDR sensor input.
The 4_LVp/cylMAX selects the maximum from two position inputs from both the outer cylinder position loop and the inner
pilot position loop. The PSVP / WSVO / SSVP provides two excitation outputs. Each excitation output is designed to support
two LVDT/R position sensors assuming the total current does not exceed 60 mA.
The 6_LVp/cylMID selects the median of the three position inputs from both the outer cylinder position loop and the inner
pilot position loop. In this configuration, the Excitation Switchover function allows one of the two PSVPs to be powered off
while the other still maintains control of the pilot cylinder loop.
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The configuration parameter(s) for the following figure are:
Coil_Parallel = Coils_not_parallel
RegType = 4_LVp/cylMAX
Dual PSVP: Dual Pilot / Dual Cylinder Valves with Dual Coil Servo
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Servo with Non-paralleled Coils
The pilot / cylinder servo with individual coil connections and servo outputs paralleled is supported. In this configuration, the
PSVP Servo Tab configuration parameter, Coil_Parallel entry is not used. The PSVP firmware overrides this selection,
forcing the PSVP servo outputs to be paralleled per PSVP.
Note The paralleled servo coils configuration is not supported.
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The configuration parameter(s) for the following figure are:
RegType = 2_LVpilotCyl
Dual PSVP: Single Pilot / Single Cylinder Valves with Dual Coil Servo
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The configuration parameter(s) for the following figure are:
RegType = 6_LVp/cylMID
Dual PSVP: Triple Pilot / Triple Cylinder LVDRs with Dual Coil Servo
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10.1.6.9
TMR PSVP: Pilot / Cylinder Configuration
The TMR PSVP redundancy for Pilot / Cylinder configuration provides three fully independent sets of PSVP electronics.
Each PSVP has its regulator configured as RegType = 2_LVpilotCyl, inputting a single independent position feedback for
both the pilot and operating cylinder valves. The 2_LVpilotCyl position regulator output generates a servo current command
for Servo drive #1 and Servo drive #2. PSVP <R>, PSVP <S> and PSVP <T> Servo drive #1 outputs are paralleled together
to control the current to Coil #1. Likewise, Servo drive #2 outputs are paralleled to drive Coil #2. The maximum current
applied to each coil is limited depending upon the number of operating Servo drives paralleled.
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The configuration parameter(s) for the following figure are:
RegType = 2_LVpilotCyl
TMR PSVP: Single Pilot / Single Cylinder Valves with Dual Coil Servo
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10.1.6.10 PSVP Position Regulators
The following seven servo position regulators are supported by the PSVP:
•
•
•
•
•
•
•
Single LVDT/R position feedback, RegType = 1_LVposition
Dual LVDT/R feedback minimum select, RegType = 2_LVposMIN
Dual LVDT/R feedback maximum select, RegType = 2_LVposMAX
Triple LVDT/R position feedback middle select, RegType = 3_LVposMID
Single LVDT/R pilot cylinder, RegType = 2_LVpilotCyl
Dual LVDT/R pilot cylinder maximum select, RegType = 4_LVp/cylMAX
Triple LVDT/R pilot cylinder middle select, RegType = 6_LVp/cylMID
There is an eighth position regulator option, RegType = no_fbk. With this option, a position regulator runs in the control
software, and the PSVP provides the position feedback through the system input variable, Regn_fdbk where n = 1 or 2. The
controller’s position regulator output can be assigned to the System output, Regn_Ref where the PSVP maps this value to the
current regulator command.
Each of the position regulator types are comprised of the following blocks:
•
•
•
Feedback Conditioning
Proportional Regulator
Calibration section
The configuration parameter RegType determines the number of feedback position sensors. In addition, it determines the
initial position feedback selection. Before the selection process takes place, the Reg_Calc_Position block scales the position
sensor feedback from V rms to percent, where usually 100% is defined as a fully open valve. An out-of-range check is
performed on the V rms position value before the scaling takes place. The out-of-range limit is defined by the configuration
parameter LVDT_Margin in units of percent. An out-of-range is declared if the V rms value is less than –LVDT_Margin(%) or
greater than LVDT_Margin(%) + 100% of the feedback range.
RegType
No. of Position Sensors
Selection Criteria
1_LVposition
1
No selection required.
2_LVposMIN
2
Select the minimum of the two position sensors.
2_LVposMAX
2
Select the maximum of the two position sensors.
3_LVposMID
3
Select the middle value from the three position values.
2_LVpilotCyl
1 pilot sensor
1 cylinder sensor
No selection required.
4_LVp/cylMAX
2 pilot sensors
2 cylinder sensors
Select the maximum from the two pilot sensor values, and
select the maximum from the two cylinder sensor values.
6_LVp/cylMID
3 pilot sensors
3 cylinder sensors
Select the median from the three pilot sensor values, and select
the median from the three cylinder sensor values.
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After the selection of the sensor feedback is complete, the selected position feedback runs through a limit check function. The
limits are defined by the configuration parameter Fdbk_Suicide. The value is units of percent of feedback. A value of 5%
would declare an exceeded limit if the selected position feedback is greater than 105% or less than –5% where 100% is
usually defined as a fully open valve. For the 2_LVpilotCyl, the 4_LVp/cylMAX, and the 6_LVp/cylMID regulator types, the
position feedback PilotFdbkn is used for the limit check. If the configuration parameter EnabFbkSuic = TRUE and the Fdbk_
Suicide limit is exceeded, the servo output will suicide (zero current). This condition implies that the feedback has gone open
loop due to either a damaged sensor or a sensor excitation / feedback wiring open or short.
The proportional regulator error Regn_Error is equal to the reference command from the controller Regn_Ref minus the
resultant position sensor feedback Regn_Fdbk where n is the regulator number 1 or 2. The position regulator output is defined
as:
Servo_mA_refs(%) = Regn_Error(%) * RegGain(%servo current / % valve position) +
(RegNullBias(% current) + Regn_NullCor(% current))
where
Servo_mA_refs is the analog current regulator command in percent of servo current nominal of 10, 20, 40, 80, or 120 mA
•
•
•
RegGain is the configuration parameter defining the gain from percent position to percent servo current.
RegNullBias is the portion of current required to null the spring force of the servo actuator. For 3-coil servos, the null bias
will be ⅓ of the total. For 2-coil individual, the null bias will be ½ of the total. For 2-coil paralleled or single coil servos,
the null bias is assigned 100% of the total current needed to balance the spring force.
Regn_NullCor is used by the controller to correct a null bias imbalance if one of the PSVPs in a dual or TMR redundancy
configuration goes offline or the servo output suicides.
At startup or when a new PSVP is installed on site, a servo valve calibration should be performed. During the calibration
procedure, the servo is used to push the valve to the maximum open-end point and the maximum closed-end point. At these
end points, the LVDT/R feedback voltage is read and stored. The PSVP uses this value for scaling purposes when the Reg_
Calc_Position function runs.
Note Servo regulator configuration settings (RegGain, and so forth) are application and site specific. Consult the equipment
specific Controls Setting Specification or equivalent document for proper configuration.
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10.1.6.11 Module Level Parameters
Parameter
Description
Choices
Exc_Sharing
Connections for sharing excitation of LVDT (for dual configuration only)
For example: R1_S1 and R2_S2 means
Excitation output 1 of R PSVP and output 1 of S PSVP connected to
the same LVDT coil
Excitation output 2 of R PSVP and output 2 of S PSVP connected to
the same LVDT coil
Unused
R1_S1_only,
R2_S2_only,
R1_S1_and_R2_S2
Serial_Links
These are the serial link cable connections where upper refers to the
serial connectors at the top of the SSVP and lower refers to the serial
connectors at the bottom of the SSVP. All connections from A labeled
connectors must go to A connectors on other SSVPs. All connections
from B connectors must go to B connectors on other SSVPs. Upper
connectors can only be connected to lower connectors.
For dual systems, only R and S can be used with connections R_
Upper_to_S_Lower or R_Lower_to_S_Upper.
Unused
R_upper_to_S_lower
R_lower_to_S_upper
For TMR systems, there are only two available combinations of
connections. They are uniquely identified by one connection pair
selected from the option list.
R_Upper_to_S_Lower option configures:
R upper connected to S lower
S upper connected to T lower
T upper connected to R lower
R_Lower_to_S_Upper option configures:
R upper connected to T lower
S upper connected to R lower
T upper connected to S lower
AccelCalTime
This is the acceleration calculation time for speed algorithms Speed
and Speed_High. Use integer multiples of controller frame period.
0 to 100 ms (default is 100)
SystemLimits
Allows user to temporarily disable all system limit checks for testing
purposes. Setting this parameter to Disable will cause a diagnostic
alarm to occur.
Enable (default), Disable
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10.1.6.12 PSVP Variable Definitions
Name
Description
Description Type
L3DIAG_PSVP
PSVP I/O diagnostic indication
Input non-voted Boolean 3 bits
LINK_OK_PSVP
PSVP I/O Link OK indication
Input non-voted Boolean 3 bits
ATTN_PSVP
PSVP I/O attention indication
Input non-voted Boolean 3 bits
PS18V_PSVP
PSVP I/O 18 V power supply indication
Input non-voted Boolean 3 bits
PS28V_PSVP
PSVP I/O 28 V power supply indication
Input non-voted Boolean 3 bits
IOPackTmpr
PSVP I/O pack temperature in degrees °F
Analog input non-voted Real
Rx_SuicideNV
ServoOutputx suicide relay status where x = 1 or 2
Input non-voted Boolean 3 bits
Regx_CalibratedNV
Regulator x (x=1 or 2) has been calibrated.
Input non-voted Boolean 3 bits
Reg1_Suicide
ServoOutput1 suicide relay status
Input voted Boolean
Reg2_Suicide
ServoOutput2 suicide relay status
Input voted Boolean
HSNG_Stat
Pulse rate high speed next generation stability status (TRUE
for tooth to tooth distance inside Lock_Limit for tooth
geometry compensation)
Input voted Boolean
RegCalMode
Regulator under calibration
Input voted Boolean
Reg1_Fdbk
Regulator 1 position feedback
Analog input voted REAL
Reg2_Fdbk
Regulator 2 position feedback
Analog input voted REAL
PilotFdbk1
Regulator 1 pilot feedback when 2_LvpilotCyl or 4_
LVp/cylMax
Analog input voted REAL
PilotFdbk2
Regulator 2 pilot feedback when 2_LvpilotCyl or 4_
LVp/cylMax
Analog input voted REAL
Reg1_Error
Position error for the regulator 1 position loops
Analog input voted REAL
Reg2_Error
Position error for the regulator 2 position loops
Analog input voted REAL
Accel
Acceleration value of the variable PulseRate
Analog input voted REAL
Monx where x = 1 to 6
Value assigned to Monx based on configuration parameters
found in the Monitor tab
Analog input voted REAL
Exn_ActiveNV
Excitation #n active(on) where n = 1 or 2
Input non-voted Boolean 3 bits
Excit_Monx
Excitation monitor x (V rms) where x = 1 or 2
Analog input voted REAL
ServoOutx
Servo output x measured current (%) where x = 1 or 2
Analog input non-voted Real
ServoxMonitorNV
Servo x AvSelection monitor where x = 1 or 2
Analog input non-voted Real
CalibEnab1
Enable calibration regulator 1
Output Boolean
CalibEnab2
Enable calibration regulator 2
Output Boolean
SuicidForcex
Force suicide on servo x where x = 1 or 2
Output Boolean
Regx_Ref
Regulator x position reference (%) where x = 1 or 2
Output Boolean
Regx_NullCor
Regulator x null bias correction (%) where x = 1 or 2
Output Boolean
SysLimxPR
System limit for pulse rate input X, where x=1 or 2
Input Boolean
ActivateCalibCmd
Activate calibration command
Inputed voted Boolean
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10.2
PSVP Specific Alarms
The following alarms are specific to the PSVP I/O pack
45
Description Calibration Mode Enabled
Possible Cause
•
The variable CalibEnab# has been set to True and the user has selected the Calibration Mode button in the Calibrate
Valve dialog.
Solution
•
•
This alarm is active to annunciate that the pack is in a special mode where servo suicide protection has been disabled, and
the user needs to take special precautions in this mode.
Exit calibration mode and set CalibEnab# to False.
46
Description PSVP not online, servos suicided
Possible Cause Servo outputs suicided because I/O pack was offline. This alarm is not visible until the pack goes back
online, so it should be inactive when visible. If the reason for the offline state is unknown, proceed to the solutions.
Solution
•
•
Verify that the controller is online.
Verify that network connections to the pack are okay.
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47-48
Description Servo current #[ ] disagrees w/ ref, suicided
Possible Cause
•
•
•
•
•
Possible open circuit in servo current loop
Servo current feedback does not match servo current command within specified Cur_Suicide percentage and
EnablCurSuic is enabled.
Jumper configuration set incorrectly
Open or shorted servo coil
I/O pack hardware failure
Solution
•
•
•
•
•
Check the field wiring for an open loop.
Check for servo open coil.
Verify the proper settings of SSVP hardware jumpers.
Verify the proper setting of configuration parameters and tuning of servo.
Replace the PSVP and WSVO.
52-53
Description Servo current #[ ] short circuit
Possible Cause
•
•
•
Servo short circuit detection enabled (ShrtCoildiag) and low resistance measured
Possible shorted servo coil
Shorted coil threshold (RcoilShort) or shorted coil time limit (RShrtTimeLim) set incorrectly
Solution
•
•
•
Verify the proper servo ohm value.
Set AV_Selector to the value Coil_OHMS (build/download), and view the measured coil resistance displayed in
Servo#MonitorNV_R,S,T.
Verify that the measured resistance matches the actual coil resistance, and it is above RcoilShort value.
Note For pilot/cylinder regulator types it may be necessary to lower the value of RcoilShort (calculated by the
calibration) if the measured value of Coil_Ohms is noisy enough to cause a short circuit alarm at low currents.
•
•
•
492
Verify that the RcoilShort is set to the proper value. Re-calibrate to update measured resistance values.
Verify the proper setting on the Servo_MA_Out parameter.
Verify that the terminal board jumpers match the configuration.
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57-58
Description Servo current #[ ] open circuit
Possible Cause
•
•
•
•
Servo open circuit detection enabled (OpenCoildiag) and low resistance measured
Possible open servo coil
Open coil threshold (RcoilOpen) or open coil time limit (RopenTimeLim) set incorrectly
PPRO K4CL relay activated.
Solution
•
•
•
Check field wiring for possible open circuit. Verify the proper servo ohm value.
Set AV_Selector to value Coil_OHMS (build/download) and view the measured coil resistance displayed in
Servo#MonitorNV_R,S,T.
Verify that the measured resistance matches actual coil resistance, and is below value.
Note For pilot/cylinder regulator types, it may be necessary to raise the value of RcoilOpen (calculated by the
calibration) if the measured value of Coil_Ohms is noisy enough to cause an open circuit alarm at low currents.
•
•
•
Verify that the RcoilOpen is set to the proper value. Re-calibrate to update measured resistance values.
Verify that the terminal board jumpers match the configuration.
Check state of K4Cl relay.
62-63
Description Servo position #[ ] fdbk out of range, suicided
Possible Cause
•
•
LVDT position feedback outside specified range
LVDT inputs not calibrated or V rms limits incorrect
Solution
•
•
•
•
Check field wiring including shields and LVDT excitation. The problem is usually not a PSVP or terminal board failure if
other LVDT inputs are working correctly.
Check the LVDT sensor.
Calibrate the servo regulator with the proper LVDT.
Verify that LVDT_Margin is set to the proper value.
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67-68
Description Regulator #[ ] configuration error-Error Category [ ]
Possible Cause Configuration settings incorrect for specified regulator type:
•
•
•
•
•
•
•
Category 0 error = inactive alarm
Category 1 error = servo used but no regulator type is assigned to the designated regulator
Category 2 error = servo does not have a valid regulator assigned to it
Category 3 error = LVDT sensors required for the designated regulator type are unused
Category 4 error = LVDT min and max V rms are configured the same
Category 5 error = Coil_Parallel parameter value not supported for selected PSVP redundancy
Category 6 error = LVDT required for regulator is not enabled
Solution
•
•
•
•
Check the regulator configuration settings.
Verify that the LVDT input setup (Max/Min limits) matches the regulator configuration.
Verify that the configured regulators are used by the proper servos.
Verify that the LVDTs used are enabled.
69
Description Dual Ethernets not supported with 10 msec frame rate
Possible Cause The second Ethernet port is connected, but not supported for a 10 ms frame rate.
Solution Remove the second Ethernet connection to the I/O pack.
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73-74
Description
Lvdt excitation #[ ] voltage or current out of range-Error Category [ ]
Possible Cause
•
•
•
•
Possible short or open inexcitation voltage
Excitation diagnostics for unused excitation outputs have not been disabled.
Excitation voltage or current too low
Loss of serial communications between PSVP modules if excitation sharing is enabled.
Solution
•
•
•
•
•
•
•
•
•
Check that excitation voltage at SSVP screws is approximately 7 V rms
If serial link faults are indicated, correct serial link problems first. Serial link faults may cause shared excitation sources
to energize simultaneously.
Set parameter StandAloneDiag to 0 for unused excitation outputs.
If excitation is shared with another PSVP that has no excitation faults then replace PSVP and WSVO, then replace SSVP.
A diagnostic reset is required to reset the fault for shared excitation, and to enable the backup excitation source to be
re-armed for excitation switchover.
If proper voltage is verified, check field wiring from terminal board to the LVDT sensor and LVDT electrical integrity for
shorted or open coil.
If improper voltage at screws is detected, replace PSVP and WSVO, then replace SSVP.
Category 1 failure = voltage low
Category 2 failure = current low
Category 3 failure = detection logic failure (replace PSVP)
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77
Description
Servo Output Assignment Mismatch
Possible Cause
•
•
•
Regulator types 2_LVpilotCyl, 4_LVp/cylMAX, and 6_LVp/cylMID require two servos assigned to a single regulator.
Only one regulator should be enabled.
Servos must have matching parameter (RegNumber) values, as well as matching parameter values for Servo_MA_Out and
TBmAJmpPos.
Solution
•
•
•
Verify that both servos specify the configured regulator.
Verify that only one regulator is enabled.
Verify that the configuration parameters (RegNumber, Servo_MA_Out , and TBmAJmpPos) are the same for both servos.
80-85
Description LVDT [ ] Position Out of Limit
Possible Cause
•
•
•
Excitation to LVDT, bad transducer, or open or short-circuit.
LVDT input is out of range.
LVDT has not been calibrated.
Solution
•
•
•
•
•
Check field wiring including shields and LVDT excitation. The problem is usually not a PSVP/SSVP failure if other
LVDT inputs are working correctly.
Check LVDT sensor.
Calibrate servo regulator with the proper LVDT.
Verify the configuration limits, MinVrms and MaxVrms.
Verify that LVDT_Margin is set to the proper value.
90-97
Description Power supply [ ]V out of range, voltage = [ ]V
Possible Cause
•
Specified internal power supply voltage is incorrect.
Solution
•
•
496
Replace the WSVO.
If the problem still exists, replace the PSVP.
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98
Description Pack internal reference voltage out of limits, voltage = ([ ])V
Possible Cause The calibration reference voltage is more than ±5% from the expected value, indicating a hardware
failure.
Solution
•
•
Cycle power on the PSVP.
Replace the PSVP.
99
Description Pack internal null voltage out of limits, voltage = ([ ])V
Possible Cause The null voltage is more than ±5% from the expected value, indicating a hardware failure.
Solution
•
•
Cycle power on the PSVP.
Replace the PSVP.
100-101
Description Lvdt backup excitation #[ ] not available
Possible Cause
•
•
Possible short in excitation voltage
Excitation voltage too low
Solution This diagnostic is only generated for shared excitation where the standby excitation source has failed internally to
the PSVP I/O module. Replace the PSVP and WSVO, then replace the SSVP.
110-111
Description Servo Coil #[ ] not within resistance limits
Possible Cause
•
During calibration, the measured servo coil resistance was out of range.
Note As a result of this alarm condition, RCoilShort and RCoilOpen values were not saved during calibration, resulting in
Servo Coil Open and Short Detection functions being disabled.
Solution
•
•
•
Verify that Servo_MA_Out setting matches the terminal board jumpers.
Verify servo coil resistance.
Verify field wiring.
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120-121
Description Servo #[ ] Suicided
Possible Cause
•
•
•
•
Servo suicided
Regulator feedback out of range
Servo Current feedback differs from Servo Current command
Open or shorted coil detected
Solution
•
•
•
•
LVDT feedback issue: Check LVDT connections.
Check LVDT mechanical integrity to the valve.
Check for wiring of servo output loop for open or short circuit.
Check for a short or an open servo coil.
122
Description SSVP Serial Communications Cabling Error: Board Network Ports (#[ ] connected to each other
Possible Cause
•
•
#1 - Direct cable connection between upper and lower left serial connectors [Connector JUA cabled to connector JLA] on
the same terminal board
#2 - Direct cable connection between upper and lower right serial connectors [Connector JUB cabled to connector JLB]
on the same terminal board
Solution
•
•
•
•
498
Remove extraneous cables.
Connect private serial network cables to adjacent SSVP board.
Adjust configuration data to agree with corrected cable connections.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
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123
Description SSVP Serial Communications Cabling Error: Redundant Cables on Network "A" (Left side)
Possible Cause
•
Private Serial "A" upper and lower connectors are both connected to the same SSVP board.
Solution
•
•
•
Remove the extra cable connection.
Adjust the configuration data to agree with the remaining single connection.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
124
Description SSVP Serial Communications Cabling Error: Redundant Cables on Network "B" (Right side)
Possible Cause
•
Private Serial "B" upper and lower connectors are both connected to the same SSVP board.
Solution
•
•
•
Remove extra cable connection.
Adjust configuration data to agree with remaining single connection.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
125
Description SSVP Serial Communications Failure: Upper Left ("A") Network
Possible Cause
•
•
•
•
Adjacent SSVP connected to upper left "A" network has rebooted
Cable not connected properly
Communications driver failure on SSVP
"A" (Left side) and "B" (Right side) networks are cross connected to each other.
Solution
•
•
•
•
•
•
Verify that adjacent PSVP pack is operational.
Verify cable connection.
Replace the adyacent PSVP pack and/or SSVP terminal board.
Replace the local PSVP pack and/or SSVP terminal board.
Remove left-to-right network cross connections.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
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126
Description SSVP Serial Communications Failure: Upper Right ("B") Network
Possible Cause
•
•
•
•
Adjacent SSVP connected to upper left "B" network has rebooted.
Cable not connected properly.
Communications driver failure on SSVP.
"A" (Left side) and "B" (Right side) networks are cross connected to each other.
Solution
•
•
•
•
•
•
Verify that adjacent PSVP pack is operational.
Verify cable connection.
Replace the adjacent PSVP pack and/or SSVP terminal board.
Replace the local PSVP pack and/or SSVP terminal board.
Remove left-to-right network cross connections.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
127
Description SSVP Serial Communications Failure: Lower Left ("A") Network
Possible Cause
•
•
•
•
Adjacent SSVP connected to lower left "A" network has rebooted.
Cable not connected properly.
Communications driver failure on SSVP.
"A" (Left side) and "B" (Right side) networks are cross connected to each other.
Solution
•
•
•
•
•
•
500
Verify that adjacent PSVP pack is operational.
Verify cable connection.
Replace the adjacent PSVP pack and/or SSVP terminal board.
Replace the local PSVP pack and/or SSVP terminal board.
Remove left-to-right network cross connections.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
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128
Description SSVP Serial Communications Failure: Lower Right ("B") Network
Possible Cause
•
•
•
•
Adjacent SSVP connected to lower left "B" network has rebooted.
Cable not connected properly
Communications driver failure on SSVP
"A" (Left side) and "B" (Right side) networks are cross connected to each other.
Solution
•
•
•
•
•
•
Verify that adjacent PSVP pack is operational.
Verify cable connection.
Replace the adjacent PSVP pack and/or SSVP terminal board.
Replace the local PSVP pack and/or SSVP terminal board.
Remove left-to-right network cross connections.
Refer to diagrams in the PSVP Servo Control, Configuration section for proper serial connections between PSVP
assemblies.
129
Description SSVP Serial Communications Configuration or Wiring Error: Error Category = [ ]
Possible Cause
•
•
•
•
•
•
•
•
•
•
Category #1: excitation sharing defined, but serial comm is Not Used
Category #2: unexpected data received on upper left ("A") network, unused port
Category #3: unexpected data received on upper right ("B") network, unused port
Category #4: unexpected data received on lower left ("A") network, unused port
Category #5: unexpected data received on lower right ("B") network, unused port
Category #6: unexpected data received on upper left ("A") network, wrong pack sending data
Category #7: unexpected data received on upper right ("B") network, wrong pack sending data
Category #8: unexpected data received on lower left ("A") network, wrong pack sending data
Category #9: unexpected data received on lower right ("B") network, wrong pack sending data
Category #10: Regulator Type 2_LVpilotCyl in TMR topology, but serial comm is Not Used
Solution
•
Category #1:
•
− For Simplex or TMR: from the Parameters tab, set Exc_Sharing to Unused.
− For Dual: from the Parameters tab, set Serial_Links to a selection other than Unused.
Category #2-9: change Serial_Links from R_Lower_to_S_Upper to R_Upper_to_S_Lower or the other way around as
appropriate. Check the cabling between the packs. Ensure that the serial ports are connected in agreement with the
Serial_Links setting.
Category #10: Set Serial_Links to a selection other than Unused when the TMR 2_LVpilotCyl application is used.
•
130
Description
Calibration mode permissive cleared because multiple SSVP serial links are faulted
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Possible Cause
•
•
LVDT excitation configured for sharing and both SSVP serial links are faulted
TMR 2_LVpilotCyl application is used, and multiple SSVP serial links are faulted
Solution
•
•
•
•
•
•
•
Verify that the adjacent PSVP is operational.
Check all serial cable connections. Clear alarms 125-128 as appropriate.
Replace the adjacent PSVP I/O pack and/or the SSVP terminal board.
Replace the local PSVP I/O pack and/or the SSVP terminal board.
Remove left-to-right network cross connections.
Refer to the section, PSVP Servo Control - Steam, Configuration for proper serial connections between PSVP assemblies.
Set the Exc_Sharing parameter to Unused if in TMR configuration for PSVP.
144
Description Logic Signal [ ] Voting Mismatch
Possible Cause N/A
Solution N/A
224-247
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause
•
•
•
Voter disagreement between R, S and T packs
Mismatch in the coil resistance
Reg[ ]_Gain is set too high for the specified TMR_DiffLimt value
Solution
•
Adjust the parameters for each input type as follows:
•
•
− If input variable is PulseRate[ ], adjust TMR_DiffLimt on the Pulse Rates tab.
− If input parameter is Reg[ ]_Fdbk, adjust TMR_DiffLimt on the Regulators tab.
− If input variable is Mon[ ], adjust TMR_DiffLimt on the Monitors tab.
− If the input parameter is LVDT[ ], adjust the TMR_DiffLimit on the LVDTs tab.
− If input variable is ServoOutput[ ], adjust TMR_DiffLimt on the Regulators tab.
Check for a mismatch in the coil resistance.
Check parameter Reg[ ]_Gain settings and adjust TMR_DiffLimt.
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10.3
SSVP Servo Input/Output Terminal Board
10.3.1
Functional Description
The Servo I/O (SSVP) terminal board connects to two electro-hydraulic servo valves that actuate the steam valves. Valve
position is measured with linear variable differential transformers (LVDT) or linear variable differential reluctance
transformers (LVDR). SSVP is designed specifically for the PSVP I/O pack and the WSVO servo driver. It does not work
with the VSVO board or the PSVO pack. The SSVP is a simplex terminal board. Dual redundancy is supported by using two
SSVPs and fanning the inputs externally. Likewise, for TMR redundancy, use three SSVPs and fan the LVDT inputs
externally by using jumpers to send the signal from one SSVP to another SSVP. A single 28 V dc supply comes in through
plug P28IN. Plugs JD1 or JD2 are for an external trip from the protection module.
Note T1 through T2 isolation transformers provide galvanic isolation between the SSVP’s excitation output driver and the
primary-side of the LVDT/R position sensor.
SSVP Terminal Board
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10.3.1.1
Terminal Board Options
The SSVP accepts direct mounting of the PSVPH1A I/O pack and the WSVOH1A servo driver module. There are four
options for the SSVP terminal board:
•
•
•
•
SSVPH1A provides the 24-point barrier style input connector.
SSVPH2A provides the Euro style box-type terminal blocks.
IS230SSVPH1A barrier style with subassembly
IS230SSVPH2A Euro style box-type terminal blocks with subassembly
The IS230SSVPHxx is a subassembly comprised of the PSVP I/O pack, the WSVO servo driver, the SSVP terminal board,
and the DIN-rail mechanical assembly.
Subassembly
PSVP
WSVO
SSVP
Description
IS230SSVPH1A
H1A
H1A
H1A
DIN-rail subassembly with a SSVP providing a 24-point
barrier-strip type customer connector
IS230SSVPH2A
H1A
H1A
H2A
DIN-rail subassembly with a SSVP providing a Euro style
box-type terminal blocks
10.3.2
Installation
Sensors and servo valves are wired directly to the TB1 I/O terminal block. The block is held down with two screws and has
24 terminals accepting up to #12 AWG wiring. A shield terminal strip attached to chassis ground is located immediately to the
left of the terminal block. External trip wiring is plugged into either JD1 or JD2.
Note The SSVP can only be used with the PSVP I/O pack.
Each SSVP servo output can support one coil of a three-coil electro-hydraulic servo-actuator or paralleled-coils from a
two-coil servo. Based on the rated coil current, the user selects the current limiting resistor value to limit thermal stress on the
current driver in case of a shorted output. Jumper, JP1 selects the resistor value for Servo 1 and JP2 is for Servo 2.
The P28 power input for the PSVP and WSVO comes into the servo through the SSVP connector labeled P28IN. Switch,
SW1 is used to enable the P28 bus that feeds the PSVP pack and the WSVO servo driver module. The LED labeled P28IN
lights if 28 V dc has been applied to the SSVP. The P28ON LED will remain OFF until the user turns SW1 to the P28ON
position. The RED LED on SSVP labeled PSVP_ONLY will light if a PSVO instead of a PSVP I/O pack is accidently
plugged into the JA1 connector.
10.3.2.1
Connecting to the PSVP
The SSVP simplex terminal board has one DC-62 pin connector, JA1 to accommodate the PSVP pack. The JA1 inputs LVDT
and the pulse rate signals from the SSVP input circuits. It outputs current command signals to the WSVO and receives
feedback status information from the WSVO. It outputs excitation reference to the excitation drivers on the SSVP. It supports
I/O from the RS-422 drivers to support the Private Serial Network used to control the excitation switchover and the isolation
protection for servos paralleled.
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10.3.2.2
Connecting to the WSVO
The JA2 connector is for the WSVO servo driver module. The WSVO module is held down with four screws. If a diagnostic
indicates a servo problem, it is recommended to replace both the PSVP pack and the WSVO servo driver module.
Turn the SSVP input power switch, SW1 to OFF before removing the PSVP, WSVO,
TB1, P28 connector, and serial connectors.
Attention
10.3.3
Operation
The SSVP servo terminal board provides two channels consisting of bi-directional servo current outputs, six channels of
LVDT/R position feedback, two channels of LVDT/R excitation, and one pulse rate input. There is a choice of one, two, or
three LVDT/Rs for each servo control loop. The single pulse rate input is used for the steam turbine primary speed and is not
designed for a flow-type pulse-rate input.
Each servo output is equipped with an individual suicide relay under firmware control that shorts the current output to
common when de-energized, and recovers to nominal limits after a manual reset command is issued. Each servo output also
includes an isolation relay on the SSVP to isolate a short from other servos that are connected in parallel to the suicided servo.
Diagnostics monitor the output status of each servo voltage, current, and suicide relay.
Each of the servo output channels are designed to drive a single coil or parallel coils. The servo outputs are also designed to
be paralleled as shown in the PSVP configuration section. Servo cable lengths up to 300 m (984 ft) are supported with a
maximum two-way cable resistance of 15 Ω. Since there are many types of servo coils, a variety of bi-directional current
sources are jumper selectable.
A trip override relay K1 is provided on the terminal board, which is driven from the PPRO protection I/O pack. If an
emergency overspeed condition is detected in the protection module, the K1 relay energizes, disconnects the servo output, and
applies a bias to drive the control valve closed. This is only used on simplex applications to protect against the servo amplifier
failing high, and is functional only with respect to the servo coils driven from <R>.
Note The primary and emergency overspeed systems will trip the hydraulic solenoids independent of this circuit.
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SSVP Operational Flow 1 of 2
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SSVP Operational Flow 2 of 2
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10.3.3.1
TMR
For Option One: TMR LVDR and Triple Coil Servo (refer to the figure, Option One: TMR LVDR and Triple Coil Servo), the
LVDT/R signals are fanned externally through customer wiring to LVDT inputs SSVP_R, SSVP_S, and SSVP_T. For 3-coil
servos, SSVP_R servo output connects to coil one, SSVP_S connects to coil two, and SSVP_T connects to the third coil of the
3-coil servo actuator. Redundant power for the TMR configuration is handled by independent 28 V dc sources for each SSVP.
The PSVP also provides TMR support for the Pilot/Cylinder configuration. A TMR PSVP: Single Pilot/Single Cylinder
Valves with Dual Coil Servos allows for three independent PSVPs, each inputting one Pilot position feedback and one
Cylinder position feedback running the 2LVpilotCyl position regulator. Each PSVP provides one servo driver output for Coil
#1 and the other servo driver output for Coil #2. This configuration allows Coil #1 servo drivers from PSVP <R>, <S> and
<T> to be paralleled; likewise, for Coil #2 servo drivers.
10.3.3.2
Servo Coils
The following table defines the standard servo coil resistance and their associated internal resistance, selected with the
terminal board jumpers. In addition to these standard servo coils, it is possible to drive non-standard coils by using a
non-standard jumper setting. For example, an 80 mA, 125 Ω coil could be driven by using a jumper setting 120B. The
excitation source is isolated from signal common (floating) and is capable of operation at common mode voltages up to 15 V
dc, or 10 V rms, 50/60 Hz.
Note Servo configuration settings (RegGain, jumpers, and so forth) are application and site specific. Consult the equipment
specific Controls Setting Specification or equivalent document for proper configuration.
Servo Coil Resistance and Associated Internal Resistance
Current Rating
Current
Coil Resistance
(Ohms)
Internal Resistance (Ohms)
10
±10 mA
1000
170 ±10%
20
±20 mA
125
432 ±10%
40
±40 mA
62 - 89
185 ±10%
80
±80 mA
22
105 ±10%
120A
±120 mA (A)
40
18 ±10%
120B
±120 mA (B)
75
0
Note This table does not apply when servo driver outputs are paralleled.
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The governing equation for determining if the user needs to select a non-standard terminal board jumper position is
R ILIM_Calculated = (12,000 / Servo_MA_OUT) — RCOIL / Coil_Parallel - 10
where:
R ILIM_CALCULATED is the maximum terminal board current-limiting resistance in ohms the WSVO servo driver can
withstand to push 100% Servo_MA_OUT current through the coil. A negative value implies an unreal resistance highlighting
an incorrect value for RCOIL, Servo_MA_OUT, and so forth.
Servo_MA_OUT is the configuration parameter in the ToolboxST Servo Component Editor, Hardware tab, PSVO or
PSVP, Servo tab. The value in milli-amperes defines the servo actuator nominal current.
RCOIL is the servo actuator resistance per coil in ohms.
Coil_Parallel is the configuration parameter found in the ToolboxST Component Editor, Hardware tab, PSVO or PSVP,
Servo tab. The value equals 1 for a single coil and equals 2 for two coils paralleled. If the inequality
Jumper Setting Internal Resistance (from table above) > R ILIM_CALCULATED
is True, then the WSVO will not have the capability to drive 100% current. Select the next lowest terminal board
current-limiting resistance from the Internal Resistance column in the Servo Coil Resistance and Associated Internal
Resistance table.
If the new Internal Resistance value meets the condition
Jumper Setting Internal Resistance ≤ R ILIM_CALCULATED
The following is an example of this formula:
R ILIM_Calculated = (12,000 / 80) - 125 / 1 - 10 = 15 ohms
where only one single servo driver output used, the servo actuator resistance is 125 ohms per coil, the nominal current is 80
mA and the servo actuator coils are not paralleled. Based on this calculation, Jumper 120B is selected with the ToolboxST
application PSVO or PSVP configuration parameters defined as given in the equation above.
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10.3.3.3
Valve Position
Control valve position is sensed with either a three or four-wire LVDT, or a three-wire linear variable differential reluctance
(LVDR) transducer. Redundancy implementations for the feedback devices are determined by the application software to
allow the maximum flexibility. LVDT/Rs can be mounted up to 300 m (984 ft) from the turbine control with a maximum
two-way cable resistance of 15 Ω.
Note Refer to the section, PSVP Servo Control, Operation, Recommended Wiring Practices.
Two LVDT/R transformer-isolated excitation sources are located on the terminal board. Excitation voltage is 7.07 V rms, and
the frequency is 3.2 kHz with a total harmonic distortion of less than 1%. A typical LVDT/R has an output of 0.7 V rms at the
zero stroke position of the valve stem, and an output of 3.5 V rms at the designed maximum stoke position (some applications
have these reversed). The LVDT/R input is converted to dc and conditioned with a low pass filter. Diagnostics perform a
high/low (hardware) limit check on the input signal and a high/low system (software) limit check.
The pulse rate input supports a single passive magnetic pickup only. The TTL type active pulse rate transducer is not
supported. The MPU can be located up to 300 m (984 ft) from the turbine control cabinet. This assumes shielded-pair cable is
used with typically 70 nF single ended or 35 nF differential capacitance, and 15 Ω resistance.
A frequency range of 2 to 20 kHz can be monitored. Magnetic pickups typically have an output resistance of 200 Ω and an
inductance of 85 mH excluding cable characteristics. The transducer is a high-impedance source, generating energy levels
insufficient to cause a spark.
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10.3.4
Specifications
Item
SSVP Specification
Number of inputs
Six LVDT windings
One pulse rate signal, magnetic pickup sensor only
External trip signal to shut off servo outputs
Number of outputs
Two servo valves, ±(10, 20, 40, 80, 120) mA
Two excitation sources for LVDT / Rs (transformer isolation)
Power supply voltage
Nominal 28 V dc from single supply, P28
Pin 1 is Hi
Pin 2 is Lo
Power supply current
1.5 A dc (Poly-Fuse or current limit rating for each input is 1 A dc)
LVDT excitation output
Frequency of 3.2 ±0.2 kHz
Voltage of 7.07 ±0.14 V rms
Pulse rate input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 28 mV p-p
20 kHz requires 320 mV p-p
Magnetic PR pickup signal
Generates 150 V p-p into 60 Ω
Fault detection
Servo current out of limits or not responding
Regulator feedback signal out of limits
Failed ID chip
Size
15.875 cm high x 20.32 cm wide (6.25 in x 8 in)
Technology
Surface-mount
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10.3.5
Diagnostics
PSVP makes diagnostic checks on the terminal board components as follows:
•
•
•
The output servo current is out of limits or not responding, creating a fault.
The regulator feedback (LVDT) signal is out of limits, creating a fault. If the associated regulator has two sensors, the bad
sensor is removed from the feedback calculation and the good sensor is used.
If any one of the above signals goes unhealthy a composite diagnostic alarm, L3DIAG_PSVP occurs. Details of the
individual diagnostics are available from the ToolboxST application. The diagnostic signals can be individually latched
and reset with the RESET_DIA signal if they go healthy.
10.3.6
Configuration
In a simplex system, servo 1 is configured for the correct coil current with jumper JP1. Servo 2 is configured with jumper JP2.
In a TMR non-pilot/cylinder system, one servo from three different SSVPs provides the drivers needed for three coils. In this
case, the LVDT inputs are fanned externally to all three SSVPs. All other servo board configuration is done from the
ToolboxST application.
Note Power must be applied to P28IN connector. Verify that the P28IN LED is lit, the SW1 switch is ON, and the P28ON
power indicator is lit.
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11 PTUR, YTUR Turbine Specific
Primary Trip
11.1
Mark VIe PTUR Primary Turbine Protection I/O Pack
The Turbine Specific Primary Trip (PTUR) I/O pack provides the electrical interface
between one or two I/O Ethernet networks and a turbine control terminal board. The
PTUR contains a processor board common to the distributed I/O packs, a board specific
to the turbine control function, and an analog acquisition daughterboard. The I/O pack
plugs into the TTURH1C terminal board and handles four speed sensor inputs, bus and
generator voltage inputs, shaft voltage and current signals, eight flame sensors, and
outputs to the main breaker. Input to the pack is through dual RJ-45 Ethernet connectors
and a three-pin power input. Output is through a DC-62 pin connector that connects
directly with the associated terminal board connector. Visual diagnostics are provided
through indicator LEDs.
As an alternative to TTURH1C, three PTUR I/O packs can be plugged directly into a
TRPAH1A terminal board. This arrangement handles four speed inputs per PTUR, or
alternately fans the first four inputs into all three PTURs. Two solid-state primary trip
relays are provided by the TRPA. This arrangement does not support bus and generator
voltage inputs, shaft voltage or current signals, flame sensors, or main breaker output.
For simplex applications, the STUR terminal boards can be used.
KTURH1A
board
BTURH1A
board
TTURH1C Turbine
Terminal Board
Processor board
Single or dual
Ethernet cables
ENET1
ENET2
K25 and K25P output
Speed Sensor inputs
Shaft Voltage
Bus & Gen. Voltages
External 28 V dc
power supply
ENET1
ENET2
28 V dc
3 PTUR packs for
TMR operation
ENET1
1 PTUR pack for
Simplex operation
ENET2
28 V dc
Trip signals, 8
flame detectors,
to TRPx
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11.1.1 Compatibility
The PTUR I/O pack includes one of the following compatible BPPx processor boards:
•
•
The PTURH1A contains a BPPB processor board.
The PTURH1B contains a functionally compatible BPPC processor board that is supported in the ControlST* software
suite V04.07 and later.
TMR Compatible Trip and Terminal Boards
Terminal Board
Trip Board
TTUR H1C
TRPA H1A
TRPA H2A
No Trip Board
X
X
X
TRPA H1A
TRPA H2A
TRPG H1B
TRPG H3B
TRPL H1A
TRPS H1A
X
X
X
X
X
X
Simplex Compatible Trip and Terminal Boards
Terminal Board
Trip Board
TTUR H1C
No Trip Board
TRPG H2B
TRPS H1A
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X
X
STUR H1A
STUR H2A
STUR H3A
X
X
X
X
X
STUR H4A
X
X
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11.1.2 Installation
In 240 V ac applications, do not inadvertently cross-connect the 240 V ac and the dc
voltages. The peak voltage will exceed the Transorb rating, resulting in a failure.
Caution
Most ac supplies operate with a grounded neutral, and if an inadvertent connection
between the 125 V dc and the ac voltage is created, the sum of the ac peak voltage and
the 125 V dc is applied to Transorbs connected between dc and ground. However, in
120 V ac applications, the Transorb rating can withstand the peak voltage without
causing a failure.
➢ To install the PTUR I/O pack
1.
Securely mount the desired terminal board.
2.
Directly plug the PTUR I/O pack into the terminal board connectors.
3.
Mechanically secure the I/O pack(s) using the threaded studs adjacent to the Ethernet ports. The studs slide into a
mounting bracket specific to the terminal board type. The bracket location should be adjusted such that there is no
right-angle force applied to the DC-62 pin connector between the I/O pack and the terminal board. The adjustment should
only be required once in the service life of the product.
Note The PTUR mounts directly to a TTUR, STUR, or TRPA terminal board. The TMR TTUR and TRPA have three DC-62
pin connectors for I/O packs. For simplex, either STUR or TTUR can be used.
4.
Plug in one or two Ethernet cables depending on the system configuration. The I/O pack will operate over either port. If
dual connections are used, the standard practice is to connect ENET1 to the network associated with the R controller.
5.
Apply power to the I/O pack by plugging in the connector on the side of the I/O pack. It is not necessary to remove
power from the cable before plugging it in because the I/O pack has inherent soft-start capability that controls current
inrush on power application.
6.
Use the ToolboxST* application to configure the I/O pack as necessary. Refer to GEH-6700, ToolboxST User Guide for
Mark VIe Control, for more information.
11.1.2.1
•
•
•
Connectors
The DC 62-pin connector on the underside of the I/O pack connects directly to a discrete output terminal board.
The RJ-45 Ethernet connector (ENET1) on the I/O pack side is the primary system interface.
The second RJ-45 Ethernet connector (ENET2) on the I/O pack side is the redundant or secondary system interface.
Note The terminal board provides fused power output from a power source that is applied directly to the terminal board, not
through the I/O pack connector.
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11.1.3 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
•
Auto-reconfiguration
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Module Alarms
11.1.3.1
Analog Input Hardware
In simplex applications, up to four pulse rate signals may be used to measure turbine speed. The PTUR I/O pack contains
circuits to convert pulse rate inputs to digital speed. Generator and bus voltages are brought into PTUR for automatic
synchronizing in conjunction with the turbine controller and GE excitation system. TTUR has permissive generator
synchronizing relays and controls the main breaker relay coil 52G. Shaft voltage is picked up with brushes and monitored
along with the current to the machine case. PTUR alarms high voltages and tests the integrity and continuity of the circuitry.
In TMR applications there are separate sets of four speed inputs for each PTUR, R, S, and T. All other inputs fan to the three
PTUR I/O packs. Control signals from R, S, and T are voted before they actuate permissive relays K25 and K25P. Relay
K25A is controlled by the PPRO. All three relays have two normally open contacts in series with the breaker close coil.
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PTUR with TTURH1C Terminal Board, Simplex System
PTUR, YTUR Turbine Specific Primary Trip
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11.1.3.2
Speed Pickups
An interface is provided for four passive, magnetic speed inputs with a frequency range of 2 to 20,000 Hz. Using passive
pickups on a sixty-tooth wheel, circuit sensitivity allows detection of 2-RPM turning gear speed to determine if the turbine is
stopped (zero speed). If automatic turning gear engagement is provided in the turbine control, this signal initiates turning gear
operation.
Note The median speed signal is used for speed control and for the primary overspeed trip signal.
Pulse rate inputs can be configured for a variety of applications. When using the configuration parameter PRType, flow type is
used for flow divider fuel flow measurements. Speed type is used for normal single shaft turbines. Speed_High type provides
extended speed range above the standard speed type. Speed_LM type is designed for LM applications. Speed_HSNG type is
used for applications where compensation for inconsistent tooth spacing on the speed wheel is desired. This pulse rate type
will map the spacing of the teeth on the speed wheel to remove this periodic variation from speed measurements. Mapping
locked status bits (HSNGn_Stat) are in signal space so that the mapping status of the algorithm can be observed. If the status
indicator for a pulse rate input is false, then the mapping algorithm sees too much variation in the tooth-tooth measurements
to lock onto the tooth geometry.
Note The primary overspeed trip calculations are performed in the controller using algorithms similar to (but not the same
as) those in the PPRO. The optional fast overspeed trip for gas turbines runs in the PTUR.
The Lock_Limit parameter can be adjusted in 1% increments to allow for more tooth-to-tooth variation per revolution caused
by some of the following issues:
•
•
•
Magnetized speed wheel
Electro-magnetic interference from outside sources
Improper wiring or shielding practices
Increasing the Lock_Limit value will allow the HSNG speed algorithm to stay locked with increased variation.
The cost for opening the Lock_Limit is that it will allow for more speed variation. If
the speed variation is too high when opening up the Lock_Limit, go to the source of
the problem as listed above and correct the issue there.
Attention
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PTUR I/O Packs with TTURH1C Terminal Board, TMR System
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 519
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11.1.3.3
Primary Trip Solenoid Interface
The normal primary overspeed trip is calculated in the controller and passed to the PTUR and then to the chosen primary trip
terminal board. TRPx contains relays for interface with the electrical trip devices (ETD). TRPx typically works in conjunction
with an emergency trip board (TREx) to form the primary and emergency sides of the interface to the ETDs. The PTUR
supports up to three ETDs driven from each TRPx/TREx combination.
There are a number of different trip boards supported by the PTUR:
•
•
•
•
TRPG is targeted at gas turbine applications and works in conjunction with TREG for emergency trip.
TRPS is used for small and medium size steam turbine systems and is controlled by the PTUR I/O pack.
TRPL is intended for large steam turbine systems and is controlled by the PTUR I/O pack for emergency trip.
TRPA and TREA are used for Aero applications.
In support of the trip board operation, the PTUR provides a number of discrete inputs used to monitor signals, such as trip
relay position, synchronizing relay coil drive, and ETD power status.
11.1.3.4
Synchronizing System
The synchronizing system interfaces to the breaker close coil through the TTURH1C terminal board. Three Mark VIe control
relays must be picked up, plus external permissions must be true, before a breaker can be closed. Both sides of the breaker
close coil power bus must be connected to the TTUR board. This provides diagnostic information and measures the breaker
closure time, through the normally open breaker auxiliary contact, for optimization. The breaker close circuit is rated to make
(close) 10 A at 125 V dc, but to open only 0.6 A. A normally open auxiliary contact on the breaker is required to interrupt
the closing coil current.
The K25P relay is directly driven from the controller application code. In a TMR system, it is driven from R, S, and T, using 2
out of 3 logic voting. For a simplex system, it may be configured by jumper to be driven from R only.
The K25 relay is driven from the PTUR auto sync algorithm, which is managed by the controller application code. In a TMR
system, it is driven from R, S, and T, using 2 out of 3 logic voting. For a simplex system, it may be configured by jumper to
be driven from R only.
The K25A relay is located on TTUR, but is driven from the PPRO sync check algorithm, which is managed by the controller
application code. The relay is driven from the PPRO, using 2 out of 3 logic voting in TREG/L/S. The sync check relay driver
(located on TREG/L/S) is connected to the K25A relay coil (located on TTUR) through cabling from the J2 connector to
TRPG/L/S. It then goes through JR1 (and JS1, JT1) to JR4 (and JS4, JT4) on TTUR.
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11.1.3.5
Synchronizing Modes
There are four basic synchronizing modes: Off, Manual, Auto, and Monitor:
Off The breaker cannot be closed by the controller. The K25A check relay will not pick up.
Manual The operator initiates breaker close, which is still subject to the K25A Sync Check contacts driven by the PPRO or
YPRO. The manual close is initiated from an external contact on the generator panel, normally connected in series with a
sync mode in manual contact.
Auto The system automatically matches voltage and speed, and then closes the breaker at the right time to hit top dead
center on the synchroscope. All three of the following functions must agree for this closure to occur:
•
•
•
K25A - sync check relay, checks the allowable slip or phase window, from the PPRO or YPRO
K25 - auto sync relay, provides precision synchronization, from the PTUR or YTUR
K25P - sync sequence permissive, checks the turbine sequence status, from the PTUR or YTUR
The K25A relay should close before the K25 or else the sync check function will interfere with the auto sync optimizing. If
this sequence does not run, a diagnostic alarm occurs, a lockout signal is set to True. The application code may prevent any
further attempts to synchronize until a reset is issued and the correct coordination is set up.
Monitor The monitor mode is identical to the auto sync mode except it blocks the actual closure of the K25 relay contacts.
The intended K25 breaker closure command can be monitored using the parameter L25_Command. Monitor mode is used to
verify that the performance of the system is correct; it is used as a confidence builder.
11.1.3.6
Automatic Synchronizing
All synchronizing connections are located on the TTUR terminal board. The generator and bus voltages are provided by two,
single phase, potential transformers (PTs) with a fused secondary output supplying a nominal 115 V rms. The PTs are external
to the TTUR, and it is the secondary output of these PTs that ties to the PT inputs of the TTUR. Measurement accuracy
between the zero crossing for the bus and generator voltage circuits is 1 degree.
Turbine speed is matched against the bus frequency. The generator and bus voltages are matched by adjusting the generator
field excitation voltage from commands sent between the turbine controller and the excitation controller over the Unit Data
Highway (UDH). A command is given to close the breaker when all permissions are satisfied. The breaker is predicted to
close within the calculated phase or slip window. Feedback of the actual breaker closing time is provided by a 52G/a contact
from the generator breaker (not an auxiliary relay) to update the database.
An internal K25A sync check relay is provided on the TTUR. The independent backup phase or slip calculation for this relay
is performed in the PPRO or YPRO. Diagnostics monitor the relay coil and contact closures to determine if the relay properly
energizes or de-energizes upon command.
PTUR, YTUR Turbine Specific Primary Trip
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11.1.3.7
Auto Sync Application Code
The application code must sequence the turbine and bring it to a state where it is ready for the generator to synchronize with
the system bus. For automatic synchronization, the code must:
•
•
•
•
•
Match speeds
Match voltages
Energize the sync permissive relay, K25P
Arm (grant permission to) the sync check function (PPRO, K25A)
Arm (grant permission to) the auto sync function (PTUR, K25)
The following illustrations represent positive slip (Gen) and negative phase (Gen).
11.1.3.8
Automatic Synchronizing Algorithm
The PTUR or YTUR runs the auto sync algorithm. Its basic function is to monitor two Potential Transformer (PT) inputs,
generator and bus, to calculate phase and slip difference, and when armed (enabled) from the application code, and when the
calculations anticipate top center, to attempt a breaker closure by energizing relay K25. The algorithm uses the zero voltage
crossing technique to calculate phase, slip, and acceleration. It compensates for breaker closure time delay (configurable),
with self-adaptive control when enabled, with configurable limits. It is interrupt driven and must have generator voltage to
function. The configuration can manage the timing on two separate breakers.
The algorithm has a bypass function, two signals for redundancy, to provide dead bus and Manual Breaker Closures. It
anticipates top dead center; therefore, it uses a projected window, based on current phase, slip, acceleration, and breaker
closure time. To pickup K25, the generator must be currently lagging, have been lagging for the last 10 consecutive cycles,
and projected (anticipated) to be leading when the breaker actually reaches closure. Auto sync will not allow the breaker to
close with negative slip. In this fashion, assuming the correct breaker closure time has been acquired, and the sync check relay
is not interfering, breaker closures with less than 1 degree error can be obtained.
Slip is the difference frequency (Hz), positive when the generator is faster than the bus. Positive phase means the generator is
leading the bus; the generator is ahead in time, or the right hand side on the synchroscope. The standard window is fixed and
is not configurable. However, a special window has been provided for synchronous condenser applications where a more
permissive window is needed. It is selectable with a signal space Boolean and has a configurable slip parameter.
The algorithm validates both PT inputs with a requirement of 50% nominal amplitude or greater; that is, they must exceed
approximately 60 V rms before they are accepted as legitimate signals. This is to guard against cross talk under open circuit
conditions. The monitor mode is used to verify that the performance of the system is correct and to block the actual closure of
the K25 relay contacts. It is used as a confidence builder. The signal space Input Gen_Sync_Lo will become true if the K25
contacts are closed when they should not be closed, or if the Sync Check K25A is not picked up before the Auto Sync K25. It
is latched and can be reset with Sync_Reset.
The algorithm compensates for breaker closure time delay, with a nominal breaker close time, provided in the configuration in
milliseconds. This compensation is adjusted with self-adaptive control, based upon the measured breaker close time. The
adjustment is made in increments of one cycle (16.6/20 ms) per breaker closure and is limited in authority to a configurable
parameter. If the adjustment reaches the limit, a diagnostic alarm, Breaker Slower/Faster Than Limits Allows is posted.
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The Auto Sync K25 function uses zero voltage crossing techniques. It compensates for the breaker time delay, which is
defined by two adjustable constants with logic selection between the two (for two breaker applications). The calculations,
which are done on the PTUR or YTUR I/O pack, include phase, slip, acceleration, and anticipated time lead for the breaker
delay. Based on the measured breaker close time, the time delay parameter is adjusted, up to certain limits.
In addition, auto sync arms logic to enable the function, and bypasses logic to provide for deadbus or manual closure. The
auto sync projected sync window is displayed below, where positive slip indicates that the generator frequency is higher than
the bus frequency.
Auto Sync Projected Window
The projected window is based on current phase, current slip, and current acceleration. The generator must currently be
lagging and have been lagging for the last 10 consecutive cycles, and projected (anticipated) to be leading when the breaker
actually reaches closure. Auto sync will not allow the breaker to close with negative slip; speed matching typically aims at
around + 0.12 Hz slip.
PTUR, YTUR Turbine Specific Primary Trip
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Automatic Synchronizing Algorithm
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11.1.3.9
Synchronization Testing
The hardware interface may be verified by forcing the three synchronizing relays, individually or in combination. If the
breaker close coil is connected to the TTUR terminal board, then the breaker must be disabled so as not to actually connect
the generator to the system bus.
➢ To verify the hardware interface
1.
Operate the K25P relay by forcing output signal Sync Perm found under PTUR, card points. Verify that the K25P relay is
functional by probing TTUR screws 3 and 4. The application code has direct control of this relay.
2.
Simulate generator voltage on TTUR screws 17 and 18. Operate the K25 relay by forcing TTUR, card point output
signals Sync_Bypass1 =1, and Sync_Bypass0 = 0. Verify that the K25 relay is functional by probing screws 4 and 5 on
TTUR.
3.
Simulate generator voltage on SPRO screws 1 and 2. Operate the K25A relay by forcing SPRO, card point output signals
SynCK_Bypass =1, and SynCk_Perm 1. The bus voltage must be zero (dead bus) for this test to be functional. Verify that
the K25A relay is functional by probing screws 5 and 6 on TTUR.
➢ To simulate a synchronization
1.
Disable the breaker.
2.
Establish the center frequency of the PPRO I/O pack PLL. From the Hardware tab Tree View, select the PPRO.
3.
Select the K25A tab and locate the signal, K25A_Fdbk, ReferFreq.
a.
If ReferFreq is configured PR_Std, and the PPRO is configured for a single shaft machine, apply rated speed
(frequency) to input PulseRate1.
Terminal Board
Screw Pairs
TPRO
31/32
37/38
43/44
SPRO
19/20
b. If ReferFreq is configured PR_Std, and the PPRO is configured for a multiple shaft machine, apply rated speed
(frequency) to input PulseRate 2.
Terminal Board
Screw Pairs
TPRO
33/34
39/40
45/46
SPRO
21/22
c.
4.
If ReferFreq is configured SgSpace, force the PPRO signal space output DriveRef to 50 or 60 (Hz), depending on the
system frequency.
Apply the bus voltage, a nominal 115 V ac, 50/60 Hz, to TTUR screws 19 and 20, and to SPRO screws 3 and 4.
PTUR, YTUR Turbine Specific Primary Trip
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5.
Apply the generator voltage, a nominal 115 V ac, adjustable frequency, to TTUR screws 17 and 18 and to SPRO screws 1
and 2. Adjust the frequency to a value giving positive slip, that is PTUR signal GenFreqDiff of 0.1 to 0.2 Hz. (10 to 5 sec
scope).
6.
Force the following signals to the TRUE state:
−
−
−
PTUR, Sync_Perm, then K25P should pick up
PTUR, Sync_Perm_AS, then K25 should pulse when the voltages are in phase
PPRO, SynCK_Perm, then K25A should pulse when the voltages are in phase
7.
Verify that the TTUR breaker close interface circuit, screws 3 to 7, is being made (contacts closed) when the voltages are
in phase.
8.
Run a trend chart on the following signals:
−
−
9.
PPRO: GenFreqDiff, GenPhaseDiff, L25A_Command, K25A_Fdbk
PTUR: GenFreqDiff, GenPhaseDiff, L25_Command, CB_K25_PU, CB_K25A_PU
Use an oscilloscope, voltmeter, synchroscope, or a light to verify that the relays are pulsing at approximately the correct
time.
10. Examine the trend chart and verify that the correlation between the phase and the close commands is correct.
11. Increase the slip frequency to 0.5 Hz and verify that K25 and K25A stop pulsing and are open.
12. Return the slip frequency to 0.1 to 0.2 Hz, and verify that K25 and K25A are pulsing.
13. Reduce the generator voltage to 40 V ac and verify that K25 and K25A stop pulsing and are open.
11.1.3.10
Fast Overspeed Trip
In special cases where a fast overspeed trip system is required, the PTUR Fast Overspeed Trip algorithms can be enabled. The
system employs a speed measurement algorithm using a calculation for a predetermined tooth wheel. The fast trips are linked
to the output trip relays with an OR-gate. The PTUR computes the overspeed trip instead of the controller, so the trip is very
fast. The time from the overspeed input to the completed relay dropout is 30 ms or less. The following two overspeed
algorithms are available:
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PR_Single uses two redundant PTURs by splitting up the two redundant PR transducers, one to each board. PR_Single
provides redundancy and is the preferred algorithm for LM gas turbines.
Signal Space
Outputs
Input
Config.
param.
Signal Space
Inputs
PTUR I/O Pack Firmware
Scaling
RPM
Input, PR1
PR 1Type,
PR 1Scale
2
PulseRate2
PulseRate3
PulseRate4
AccelCal Type
d
RPM/sec
dt
RPM
------ Four Pulse Rate Circuits ------RPM/sec
Accel1
Accel2
RPM
Accel3
RPM/sec
Accel4
RPM
RPM/sec
PulseRate1
Accel1
PulseRate2
Accel2
PulseRate3
Accel3
PulseRate4
Accel4
Fast Overspeed Protection
FastTripType
PR_Single
PR1Setpoint
PR1TrEnable
PR1TrPerm
PR2Setpoint
PR2TrEnable
PR2TrPerm
PR3Setpoint
PR3TrEnable
PR3TrPerm
PR4Setpoint
PR4TrEnable
PR4TrPerm
InForChanA
PulseRate1 A
A >B
B
S
FastOS1Trip
R
PulseRate2 A
A >B
B
S
FastOS2Trip
R
PulseRate3 A
A >B
B
S
FastOS3Trip
R
PulseRate4 A
A >B
B
S
FastOS4Trip
R
Accel1
Accel2 Input
Accel3 cct.
Accel4 select
AccelA
AccASetpoint
A
A>B
B
S
AccATrip
R
AccelAEnab
AccelAPerm
InForChanB
Accel1
Accel2 Input
Accel3 cct.
Accel4 select
AccBSetpoint
AccelB
A
A>B
B
S
AccBTrip
R
AccelBEnab
AccelBPerm
Master Reset
(MRESET) MarkVIe,
SYS_OUTPUT block
Kq1
PTR1_Output
Kq2
OR
Fast Trip
Path
False = Run
True = Run
Primary Trip Relay, normal Path, True= Run
AND
Primary Trip Relay, normal Path, True= Run
AND
True = Run
Primary Trip Relay, normal Path, True= Run
AND
True = Run
Output, J4,PTR 1
Output, J4,PTR 2
PTR 2_Output
Kq3
Output, J4,PTR 3
PTR 3_Output
PTUR, YTUR Turbine Specific Primary Trip
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PR_Max uses one PTUR connected to the two redundant PR transducers. PR_Max allows broken shaft and deceleration
protection without the risk of a nuisance trip if one transducer is lost.
Signal Space
Outputs
Input, PR1
PR1Type,
PR1Scale
2
RPM
_d
dt
PulseRate2
Accel1
Accel2
Accel3
Accel4
PulseRate3
PulseRate4
AccelCalType
FastTripType
Signal Space
Inputs
Input Config.
PTUR I /O Pack Firmware
Scaling
Param.
PulseRate1
PR_Max
Four Pulse
Rate Circuits
RPM/sec
RPM
RPM/sec
RPM
RPM/sec
RPM
RPM/sec
PulseRate1
Accel1
PulseRate2
Accel2
PulseRate3
Accel3
PulseRate4
Accel4
Fast Overspeed Protection
DecelPerm
DecelEnab
DecelStpt
InForChanA
InForChanB
Accel1
Accel2
Accel3
Accel4
PulseRate1
PulseRate2
PulseRate3
PulseRate4
AccelA
Input
cct .
Select
for
AccelA
and
AccelB
A
A<B
B
Neg
AccelB
Neg
PulseRateA
PulseRateB
PulseRate1
PulseRate2
MAX
FastOS1Stpt
FastOS1Enab
FastOS1Perm
S
DecelTrip
R
A
A> B
B
PR1/2Max
A
A>B
B
S
FastOS 1Trip
R
PR3/4Max
PulseRate3
PulseRate4
MAX
A
A>B
B
FastOS2Stpt
FastOS2Enab
FastOS2Perm
S
FastOS 2Trip
R
N/C
PR1/2Max
PR3/4Max
DiffSetpoint
DiffEnab
DiffPerm
Master Reset
(MRESET )
MarkVIe,
SYS_OUTPUT
block
Kq1
PTR 1_Output
Kq2
PTR 2_Output
Kq3
PTR 3_Output
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N/C
A
|A-B|
B
A
A>B
B
FastOS 3Trip
FastOS 4Trip
S
FastDiffTrip
R
OR
Primary Trip Relay , normal Path, True=Run
AND
Primary Trip Relay , normal Path, True=Run
AND
Primary Trip Relay , normal Path, True=Run
AND
Fast Trip
Path
False = Run
True=Run
True=Run
True=Run
Output, J4, PTR 1
Output, J4, PTR2
Output, J4, PTR3
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11.1.3.11
Shaft Voltage and Current Monitor
Bearings can be damaged by the flow of electrical current from the shaft to the case. This current can occur for several
reasons:
•
•
•
A static voltage can be caused by droplets of water being thrown off the last stage buckets in a steam turbine. This
voltage builds up until a discharge occurs through the bearing oil film.
An ac ripple on the dc generator field can produce an ac voltage on the shaft with respect to ground through the
capacitance of the field winding and insulation. Note that both of these sources are weak, so high impedance
instrumentation is used to measure these voltages with respect to ground.
A voltage can be generated between the ends of the generator shaft due to dissymmetries in the generator magnetic
circuits. If the insulated bearings on the generator shaft break down, the current flows from one end of the shaft through
the bearings and frame to the other end. Brushes can be used to discharge damaging voltage buildup, and a shunt should
be used to monitor the current flow.
Note The dc test is driven from the R controller only. If the R controller is down, this test cannot be run successfully.
The turbine control continuously monitors the shaft to ground voltage and current, and alarms excessive levels. There is an ac
test mode and a dc test mode. The ac test applies an ac voltage to test the integrity of the measuring circuit. The dc test checks
the continuity of the external circuit, including the brushes, turbine shaft, and the interconnecting wire.
11.1.3.12
Flame Detectors
With the TRPG primary trip terminal board, the primary protection system monitors signals from eight flame detectors. With
no flame present the detector charges up to the supply voltage. The presence of flame causes the detector to charge to a level
and then discharge through the TRPG. As the flame intensity increases, the discharge frequency increases. When the detector
discharges, the primary protection system converts the discharged energy into a voltage pulse. The pulse rate varies from 0 to
1,000 pulses/sec. These voltage pulses are fanned out to all three modules. Voltage pulses above 2.5 V generate a logic high.
Pulses are counted over a 40 ms period in a counter to generate the flame detector pulse rate.
Note Refer to GEH-6721_Vol_II, the chapter Power Distribution Modules, the section, PSFD Flame Detector Power Supply.
11.1.4 Specifications
Item
PTUR Specification
Number of inputs
4 Passive speed pickups
1 Shaft voltage and 1 current measurement
1 Generator and 1 bus voltage
Generator breaker status
Eight flame detectors from TRPG
Number of outputs
Automatic synchronizing control to main breaker
Primary trip solenoid interface, 3 outputs to TRPG
Speed sensor range
MPU pulse rate range 2 Hz to 20 kHz
Speed sensor accuracy
MPU pulse rate accuracy 0.05% of reading from 2 Hz to 20 kHz
The voted speed from the TMR-configured PTUR I/O packs meets the UCTE OH – Policy 1,
±10 mHz accuracy requirement for a frequency in the range of 2000 to 5600 hertz.
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
Turning gear speed may be observed on
a typical turbine application.
20 kHz requires 276 mV p-p
PTUR, YTUR Turbine Specific Primary Trip
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Item
PTUR Specification
Shaft voltage monitor
Signal is frequency of ±5 V dc (0 – 1 MHz) pulses from 0 to 2,000 Hz
Shaft voltage dc test
Applies a 5 V dc source to test integrity of the circuit. Circuit reads a differential resistance
between 0 and 150 Ω within ±5 Ω. Readings above the BrushLimit ohms setting indicate a
fault. Returned signal is filtered to provide 40 dB of noise attenuation at 60 Hz.
Shaft voltage ac test
Applies a test voltage of 2 kHz to the input of the PTUR shaft voltage circuit.
Shaft current input
Measures shaft current in amps ac (shunt voltage up to 0.1 V pp)
Generator and bus voltage sensors
Two single phase potential transformers, with secondary output supplying a nominal 115 V
rms. These PTs are external to the TTUR, and it is the secondary output of these PTs that ties
to the PT inputs of the TTUR.
Each PT input on the TTUR has less than 3 VA of loading. Allowable voltage range for sync is
75 to 130 V rms with an accuracy of ±0.5% (of the measurement range).
Synchronizing measurements
Frequency accuracy 0.05% over 45 to 66 Hz range.
Zero crossing of the inputs is monitored on the rising slope.
Phase difference measurement is better than ±1°.
Contact voltage sensing
20 V dc indicates high and 6 V dc indicates low. Each circuit is optically isolated and filtered for
4 ms.
Size
8.26 cm High x 4.19 cm Wide x 12.1 cm Deep (3.25 in x 1.65 in x 4.78 in)
† Ambient rating for enclosure design
PTURH1B is rated from -40 to 70ºC (-40 to 158 ºF)
PTURH1A is rated from -30 to 65ºC (-22 to 149 ºF)
Technology
Surface mount
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
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11.1.5 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
•
•
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware.
Continuous monitoring of the internal power supplies for correct operation.
L3BKR_GXS – the Sync Check Relay on TTUR is Slow.
Breaker #1 Slower than Adjustment Limit Allows.
Breaker #2 Slower than Adjustment Limit Allows.
Synchronization Trouble – the K25 Relay on TTUR Locked Up.
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
Diagnostic information includes status of the solenoid relay driver, contact, high and low flame detector voltage, and the
sync relays. If any one of the signals goes unhealthy a composite diagnostic alarm, L3DIAG_PTUR occurs.
The diagnostic signals can be individually latched, and then reset with the RESET_DIA signal if they go healthy. Details of
the individual diagnostics are available from the ToolboxST application.
11.1.5.1
PTUR Application LEDs
LED
Label
Description
Yellow
K25
Indicates the presence of a command to energize the primary synchronizing relay.
Yellow
K25P
Indicates the presence of a command to energize the synchronizing permissive relay.
Yellow
DCT
Indicates the presence of a command to enable the DC Test of shaft voltage and
current monitoring.
Yellow
K1, K2, and K3
Indicates a command to energize the corresponding relay.
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11.1.6 PTUR ToolboxST Configuration
11.1.6.1
Parameters
Parameter Name
Parameter Description
Choices
SystemLimits
Allows user to temporarily disable all system limit checks for
testing purposes. Setting this parameter to Disable will cause a
diagnostic alarm to occur.
Enable, Disable
ResetShuntTest
Reset shunt test OK status on SysLimit Reset (TTUR only)
Enable, Disable
No_T_PS_Req
No flame detect power supply required for T (TRPG only)
Enable, Disable
AccelCalType
Select acceleration calculation time (milliseconds)
10 to 100
TripType
Select fast trip algorithm
Unused, PR_Single, PR_Max
DecelStpt
Deceleration setpoint, rpm/sec (TripType = PR_Max)
0 to 1500
DecelEnab
Deceleration enable (TripType = PR_Max)
Disable, Enable
FastOS1Stpt
Fast Overspeed trip #1 setpoint, Max (PR1, PR2), rpm (TripType
= PR_Max)
0 to 20000
FastOS1Enabl
Fast Overspeed trip #1 enable (TripType = PR_Max)
Disable, Enable
FastOS2Stpt
Fast Overspeed trip #2 setpoint, Max (PR3, PR4), rpm (TripType
= PR_Max)
0 to 20000
FastOS2Enabl
Fast Overspeed trip #2 enable (TripType = PR_Max)
Disable, Enable
DiffSetpoint
Difference Speed trip setpoint, rpm (TripType = PR_Max)
0 to 20000
DiffEnable
Difference Speed trip, enable (TripType = PR_Max)
Disable, Enable
PR1Setpoint
Fast Overspeed trip #1, setpoint, PR1, rpm (TripType = PR_
Single)
0 to 20000
PR1TrEnable
Fast Overspeed trip #1, enable (TripType = PR_Single)
Disable, Enable
PR2Setpoint
Fast Overspeed Trip #2, setput, PR2, rpm (TripType = PR_
Single)
0 to 20000
PR2TrEnable
Fast Overspeed trip #2, enable (TripType = PR_Single)
Disable, Enable
PR3Setpoint
Fast Overspeed Trip #3, setput, PR3, rpm (TripType = PR_
Single)
0 to 20000
PR3TrEnable
Fast Overspeed trip #3, enable (TripType = PR_Single)
Disable, Enable
PR4Setpoint
Fast Overspeed Trip #4, setput, PR4, rpm (TripType = PR_
Single)
0 to 20000
PR4TrEnable
Fast Overspeed trip #3, enable (TripType = PR_Single)
Disable, Enable
AccASetpoint
Acceleration trip setpoint, Chan A, rpm/sec (TripType = PR_
Single)
0 to 1500
AccBSetpoint
Acceleration trip setpoint, Chan B, rpm/sec (TripType = PR_
Single)
0 to 1500
AccAEnable
Acceleration Trip Enable, Chan A (TripType = PR_Single)
Disable, Enable
AccBEnable
Acceleration Trip Enable, Chan B (TripType = PR_Single)
Disable, Enable
InForChanA
Input change selection for Accel/Decel trip (TripType = PR_Max
or PR_Single)
Accel, Accel2, Accel3, Accel4
532
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Parameter Name
Parameter Description
Choices
InForChanB
Input change selection for Accel/Decel trip (TripType = PR_Max
or PR_Single)
Accel, Accel2, Accel3, Accel4
DiagSolPwrA
When using TRPL/S, Sol Power, Bus A, Diagnostic enable.
Enable, Disable
DiagSolPwrB
When using TRPL/S, Sol Power, Bus B, Diagnostic enable
Enable, Disable
DiagSolPwrC
When using TRPL/S, Sol Power, Bus C, Diagnostic enable
Enable, Disable
11.1.6.2
Pulse Rate
Pulse Rate Name
Pulse Rate Description
Choices
PRType
Define the pulse rate feedback type or basic speed range (for
proper resolution). Refer to section, Speed Pickups for
description of types.
Flow, Speed, Speed_High,
Speed_HSNG, Speed_LM,
Unused
PRScale
Pulses per revolution (outputs rpm)
0 to 1,000
TeethPerRev
Number of teeth on speed wheel (per revolution)
1 to 512
Speed_x_ms
Calculation rate of speed in milliseconds. Speed is calculated at
this rate and averaged over the previous time interval specified by
this period.
10 to 1000
Attention
Accel_x_ms
Using a value other
than an integer multiple
of the application frame
period can have adverse
impact on use of this
control.
This is the averaging period for acceleration calculation in
milliseconds. The acceleration is calculated every Accel_X_ms. It
is based on the difference between two speed samples divided by
the sample period. Each acceleration calculation is the average
of acceleration over the period specified by this parameter. For
example, if Accel_x_ms is 40 then acceleration will be the
average acceleration over the previous 80 ms.
Attention
20 to 1000
Using a value other
than an integer multiple
of the application frame
period can have adverse
impact on use of this
control.
Lock_Limit
HSNG speed type locking limit for teeth mapping (percent). Refer
to the section, Speed Pickups for description of Lock_Limit
function.
1 to 100
TMRDiffLimit
Diag Limit, TMR input vote difference, in Eng units
0 to 20,000
SysLim1Enable
Enable System Limit 1 Fault Check
Enable, Disable
SysLim1Latch
Latch System Limit 1 Fault
Latch, NotLatch
SysLim1Type
System Limit 1 Check Type
>=, <=
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 533
Non-Public Information
Pulse Rate Name
Pulse Rate Description
Choices
SysLimit1
System Limit 1 – RPM
0 to 20,000
SysLim2Enable
Enable System Limit 2 Fault Check
Enable, Disable
SysLim2Latch
Latch System Limit 2 Fault
Latch, NotLatch
SysLim2Type
System Limit 2 Check Type
>=, <=
SysLimit2
System Limit 2 – RPM
0 to 20,000
11.1.6.3
Shaft Volt Mon
Parameter
Description
Choices
TMRDiffLimt
Diag limit, TMR input vote difference, in Hertz
0 to 100
11.1.6.4
Shaft Curr Mon
Parameter
Description
Choices
ShuntOhms
Shunt ohms
0 to 100
ShuntLimit
Shunt maximum test ohms
0 to 100
BrushLimit
Shaft (Brush + Shunt) maximum ohms
0 to 100
SysLim1Enable
Enable System Limit 1 Fault Check
Enable, Disable
SysLim1Latch
Latch System Limit 1 Fault
Latch, NotLatch
SysLim1Type
System Limit 1 Check Type
>=, <=
SysLimit1
System Limit 1 – Amps
0 to 100
SysLim2Enable
Enable System Limit 2 Fault Check
Enable, Disable
SysLim2Latch
Latch System Limit 2 Fault
Latch, NotLatch
SysLim2Type
System Limit 2 Check Type
>=, <=
SysLimit2
System Limit 2 – Amps
0 to 100
TMR_DiffLimt
Diag Limit, TMR Input Vote Difference, in Eng Units
0 to 100
11.1.6.5
Potential Transformer
Parameter
Description
Choices
PT_Input
PT primary in Eng units (kV or percent) for PT_Output
0 to 1,000
PT_Output
PT output in volts rms, for PT_Input - typically 115
0 to 150
TMR_DiffLimt
Diag Limit, TMR Input Vote Difference, in Eng Units
1 to 1000
534
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Non-Public Information
11.1.6.6
Circuit Breaker
Parameter
Description
Choices
System Frequency
Select frequency in Hz
50 or 60
CB1CloseTime
Breaker 1 closing time in milliseconds
0 to 1,000
CB1 AdaptLimit
Breaker 1 self adaptive limit in milliseconds
0 to 1,000
CB1 AdaptEnabl
Enable breaker 1 self adaptive adjustment
Enable, Disable
CB1FreqDiff
Breaker 1 special window frequency difference, Hz
0.15 to 0.66
CB1PhaseDiff
Breaker 1 special window phase Diff, degrees
0 to 20
CB1DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
CB2CloseTime
Breaker 2 closing time in milliseconds (as above)
0 to 1,000
CB2 AdaptLimit
Breaker 2 self adaptive limit in milliseconds
0 to 1,000
CB2 AdaptEnabl
Enable breaker 2 self adaptive adjustment
Enable, Disable
CB2FreqDiff
Breaker 2 special window frequency difference, Hz
0.15 to 0.66
CB2PhaseDiff
Breaker 2 special window phase Diff, degrees
0 to 20
CB2DiagVoteEnab
Enable Voting Disagreement Diagnostic
Enable, Disable
Parameter
Description
Choices
FlmDetTime
Flame detector time interval
0.160, 0.080, 0.040 sec
FlameLimitHI
Flame threshold Limit HI (HI detection counts means LOW
sensitivity)
0 to 160
FlameLimitLOW
Flame threshold Limit Low (Low detection counts means HIGH
sensitivity)
0 to 160
Flame_Det
Flame detector used/unused
Used, Unused
TMR_DiffLimt
Diag Limit, TMR Input Vote Difference, in Hz
1 to 160
Parameter
Description
Choices
PTR_Output
Primary protection relay used/unused
Unused, used
DiagVoteEnab
Enable voting disagreement diagnostic
Enable, Disable
Parameter
Description
Choices
DiagVoteEnab
Enable voting disagreement diagnostic
Enable, Disable
11.1.6.7
11.1.6.8
11.1.6.9
Flame
Relays
E-Stop
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 535
Non-Public Information
11.1.6.10
Variables PTUR
Variable Name
Variable Description
Direction
Type
L3DIAG_PTUR_R,S,T
I/O Diagnostic Indication
Input
BOOL
LINK_OK_PTUR_R,S,T
I/O Link Okay Indication
Input
BOOL
ATTN_PTUR_R,S,T
I/O Attention Indication
Input
BOOL
PS18V_PTUR_R,S,T
I/O 18 V Power Supply Indication
Input
BOOL
PS28V_PTUR_R,S,T
I/O 28 V Power Supply Indication
Input
BOOL
IOPackTmpr_R,S,T
I/O Pack Temperature (deg °F)
AnalogInput
REAL
Kq1_StatNV_R,S,T
Non voted Primary Trip Relay 1 Feedback
Input
BOOL
Kq2_StatNV_R,S,T
Non voted Primary Trip Relay 2 Feedback
Input
BOOL
ShShntTst_OK
Shaft voltage monitor shunt test OK
Input
BOOL
ShBrshTst_OK
Shaft voltage brush + shunt test OK
Input
BOOL
Estop_Signal
Raw Estop Signal (unlatched)
Input
BOOL
K1FLT
K1 Shorted Contact Fault
Input
BOOL
K2FLT
K2 Shorted Contact Fault
Input
BOOL
PR1_HSNGstat
Pulse rate 1 HSNG stability status (TRUE for tooth
– tooth distance inside Lock_Limit for tooth
geometry compensation)
Input
BOOL
PR2_HSNGstat
Pulse rate 2 HSNG stability status
Input
BOOL
PR3_HSNGstat
Pulse rate 3 HSNG stability status
Input
BOOL
PR4_HSNGstat
Pulse rate 4 HSNG stability status
Input
BOOL
Sol1_Vfdbk
When TRPL/S, Trip Solenoid #1 Voltage
Input
BOOL
Sol2_Vfdbk
When TRPL/S, Trip Solenoid #2 Voltage
Input
BOOL
Sol3_Vfdbk
When TRPL/S, Trip Solenoid #3 Voltage
Input
BOOL
ShTestAC
L97SHAFT_AC SVM_AC_TEST
Output
BOOL
ShTestDC
L97SHAFT_DC SVM_DC_TEST
Output
BOOL
ETR1_Fdbk
ETR1 feedback, for TREL/S diag checking
Output
BOOL
ETR2_Fdbk
ETR2 feedback, for TREL/S diag checking
Output
BOOL
ETR3_Fdbk
ETR3 feedback, for TREL/S diag checking
Output
BOOL
Kq1_Status
Primary Trip Relay1 Feedback
Input
BOOL
Kq2_Status
Primary Trip Relay2 Feedback
Input
BOOL
Kq3_Status
Primary Trip Relay3 Feedback
Input
BOOL
SysLim1PR1
Pulse Rate 1 System Limit 1 Fault
Input
BOOL
↓
↓
↓
↓
SysLim1PR4
Pulse Rate 4 System Limit 1 Fault
Input
BOOL
SysLim1SHV
AC Shaft Voltage Frequency High L30TSVH
Input
BOOL
SysLim1SHC
AC Shaft Current High L30TSCH
Input
BOOL
536
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Variable Name
Variable Description
Direction
Type
SysLim1GEN
Gen Voltage System Limit 1 Fault
Input
BOOL
SysLim1BUS
Bus Voltage System Limit 1 Fault
Input
BOOL
SysLim2PR1
Pulse Rate 1 System Limit 2 Fault
Input
BOOL
↓
↓
↓
↓
SysLim2PR4
Pulse Rate 4 System Limit 2 Fault
Input
BOOL
SysLim2SHV
AC Shaft Voltage System Limit 2 Fault
Input
BOOL
SysLim2SHC
AC Shaft Current System Limit 2 Fault
Input
BOOL
SysLim2GEN
Gen Voltage System Limit 2 Fault
Input
BOOL
SysLim2BUS
Bus Voltage System Limit 2 Fault
Input
BOOL
11.1.6.11
Variables Vars_Sync
Variable
Vars_Sync Variable Description
Direction
Type
CB_Volts_OK
Breaker Closing Coil Voltage is present (L3BKR_
VLT). Used in diagnostics.
Input
BOOL
CB_K25P_PU
Breaker Closing Coil Voltage is present downstream
of the K25P relay contacts. L3BKR_PRM Sync
Permissive Relay Picked Up. Used in diagnostics.
Input
BOOL
CB_K25_PU
Breaker Closing Coil Voltage is present downstream
of the K25 relay contacts. L3BKR_GES Auto Sync
Relay Picked Up. Used in diagnostics.
Input
BOOL
CB_K25A_PU
Breaker Closing Coil Voltage is present downstream
of the K25A relay contacts. L3BKR_GEX Sync
Check Breaker Closed. Used in diagnostics.
Input
BOOL
Gen_Sync_LO
Generator Synch Lock out. Traditionally known as
L30AS1 or L30AS2; it is a latched signal requiring a
reset to clear (Sync_Reset). It detects a K25 relay
problem (picked up when it should be dropped out)
or a slow Sync Check (relay K25A) function.
Input
BOOL
L25_Command
Breaker Close Command to the K25 relay.
Traditionally known as L25.
Input
BOOL
GenFreq
Generator frequency, Hz.
AnalogInput
REAL
BusFreq
Hz frequency
AnalogInput
REAL
GenVoltsDiff
KiloVolts rms-Gen Low is negative
AnalogInput
REAL
Gen Freq Diff
Slip Hz-Gen Slow is negative
AnalogInput
REAL
Gen Phase Diff
Phase Degrees-Gen Lag is negative
AnalogInput
REAL
CB1CloseTime
Breaker #1 close time in milliseconds
AnalogInput
REAL
CB2CloseTime
Breaker #2 close time in milliseconds
AnalogInput
REAL
Sync_Perm_AS
Auto sync permissive. Traditionally known as
L83AS.
Output
BOOL
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 537
Non-Public Information
Variable
Vars_Sync Variable Description
Direction
Type
Sync_Perm
Sync permissive mode, L25P. Traditionally known
as L25P; interface to control the K25P relay.
Output
BOOL
Sync_Monitor
Auto Sync monitor mode. Traditionally known as
L83S_MTR; enables the Auto Sync function, except
it blocks the K25 relays from picking up.
Output
BOOL
Sync_Bypass1
Auto Sync bypass. Traditionally known as L25_
BYPASS; to pickup L25 for Dead Bus or Manual
Sync.
Output
BOOL
Sync_Bypass0
Auto Sync bypass. Traditionally known as L25_
BYPASSZ; to pickup L25 for Dead Bus or Manual
Sync.
Output
BOOL
CB2_Selected
#2 Breaker is selected. Traditionally known as
L43SAUTO2; to use the breaker close time
associated with Breaker #2
Output
BOOL
AS_Win_Sel
Special Auto Sync window. New function, used on
synchronous condenser applications to give a more
permissive window.
Output
BOOL
Synch_Reset
Auto Sync reset. Traditionally known as L86MR_
TCEA; to reset the Sync Lockout function.
Output
BOOL
11.1.6.12
Variables Vars-Flame
Variable
Vars-Flame Variable Description
Direction
Type
FD1_Flame
Flame Detect 1 present
Input
BOOL
↓
↓
↓
↓
FD8_Flame
Flame Detect 8 present
Input
BOOL
FD1_Level
1=High Detection Counts Level
Output
BOOL
↓
↓
↓
↓
FD8_Level
1=High Detection Counts Level
Output
BOOL
11.1.6.13
Variables Vars-Speed
Variable
Vars-Speed Variable Description
Direction
Type
DecelTrip
Deceleration Trip (Accel1, Accel2)
Input
BOOL
FastDiffTrip
Fast Difference Trip
Input
BOOL
FastOS1Trip
Fast Overspeed Trip #1
Input
BOOL
↓
↓
↓
↓
FastOS4Trip
Fast Overspeed Trip #4
Input
BOOL
AccATrip
Acceleration Trip ChanA
Input
BOOL
AccBTrip
Acceleration Trip ChanB
Input
BOOL
Accel1
rpm/sec
AnalogInput
REAL
538
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Variable
Vars-Speed Variable Description
Direction
Type
↓
↓
↓
↓
Accel4
rpm/sec
AnalogInput
REAL
PR1_PulseCnt_R,S,T
Pulse Rate 1 – Pulses in the last frame
AnalogInput
REAL
↓
↓
↓
↓
PR4_PulseCnt_R,S,T
Pulse Rate 4 – Pulses in the last frame
AnalogInput
REAL
FlmDetPwr1
335 V dc
AnalogInput
REAL
DecelPerm
Permissive – Deceleration Trip
Output
BOOL
FastOS1Perm
Permissive – Fast Overspeed Trip #1, from Max
(PR1, PR2)
Output
BOOL
FastOS2Perm
Permissive – Fast Overspeed Trip #2, from Max
(PR3, PR4)
Output
BOOL
DiffPerm
Permissive – Fast Difference Speed Trip
Output
BOOL
PR1TrPerm
Permissive – Fast Overspeed Trip #1, from PR1
Output
BOOL
↓
↓
↓
↓
PR4TrPerm
Permissive – Fast Overspeed Trip #4, from PR4
Output
BOOL
AccelAPerm
Permissive – Acceleration Trip, Chan A
Output
BOOL
AccelBPerm
Permissive – Acceleration Trip, Chan B
Output
BOOL
11.1.6.14
Variables Pulse Rate
Variable
Pulse Rate Variable Description
Direction
Type
PulseRate1
Pulse rate input, PTUR Connector J#5
AnalogInput
REAL
PulseRate2
Pulse rate input, PTUR Connector J#5
AnalogInput
REAL
PulseRate3
Pulse rate input, PTUR Connector J#5
AnalogInput
REAL
PulseRate4
Pulse rate input, PTUR Connector J#5
AnalogInput
REAL
11.1.6.15
Variables Shaft Volt Mon
Variable
Description
Direction
Type
ShVoltMon
Shaft voltage monitor, frequency (Hz)
AnalogInput
REAL
11.1.6.16
Variables Shaft Curr Mon
Variable
Description
Direction
Type
ShCurrMon
Shaft current monitor, Current (Amps)
AnalogInput
REAL
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 539
Non-Public Information
11.1.6.17
Variables Potential Transformer
Variable
Description
Direction
Type
GenPT_KVolts
Kilo-Volts RMS
AnalogInput
REAL
BusPT_KVolts
Kilo-Volts RMS
AnalogInput
REAL
11.1.6.18
Variables Circuit Breaker
Variable
Description
Direction
Type
Ckt_Bkr
Circuit breaker Closed – L52G Contact Feedback
Input
BOOL
11.1.6.19
Variables E-Stop
Variable
Description
Direction
Type
KESTOP1_Fdbk
When TPRL/S, ESTOP, inverse sense, K4 relay,
True = Run
Input
BOOL
11.1.6.20
Variables Flame
Variable
Description
Direction
Type
FlameInd1
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd2
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd3
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd4
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd5
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd6
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd7
When TRPG, Intensity (Hz)
AnalogInput
REAL
FlameInd8
When TRPG, Intensity (Hz)
AnalogInput
REAL
11.1.6.21
Variables Relays
Variable
Description
Direction
Type
Kq1
L20PTR1 – Primary Trip Relay
Output
BOOL
Kq2
L20PTR2 – Primary Trip Relay
Output
BOOL
Kq3
L20PTR3 – Primary Trip Relay
Output
BOOL
540
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.2
PTUR Specific Alarms
The following alarms are specific to the PTUR I/O pack.
32-34
Description Solenoid #[ ] Relay driver Feedback Incorrect
Possible Cause The I/O pack monitors the relay command for the correct state and termination into the expected trip
board impedance. The I/O pack internal feedback of relay command output does not match the desired state.
Solution
•
•
•
•
Check the mounting of the I/O pack on the terminal board.
Check the cable from the TTUR to the trip board, if used.
Replace the I/O pack.
Replace the TRPx trip board.
38-40
Description Solenoid #[ ] Contact Feedback Incorrect
Possible Cause The contact state feedback from the trip board does not match the relay command.
Solution
•
•
•
Check the mounting of the I/O pack on the terminal board.
Check the cable from the TTUR to the TRPx.
Check the operation of the relay.
44
Description Trip Board Solenoid Power Absent
Possible Cause
•
•
The I/O pack has detected the absence of solenoid power as indicated by the connected TRPx board.
The issue could be with the power source applied in TRPx terminal boards.
Solution
•
•
•
•
•
•
Verify the TRPx on the J1 connector is receiving power.
Verify that the voltage at the J1 cable is at an acceptable range. If it is out of range, there could be a problem with the
source or the cable connected between source and the terminal board.
Check the cabling to the TRPx.
If the voltage source is good, change the cable between the power source and TRPx boards.
If the problem persists, replace the cable between the TRPx and the TTUR or STUR board.
If the problem persists, replace the TRPx board.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 541
Non-Public Information
46
Description TRPG Flame Detector Volts Lower than 314.9 V
Possible Cause The voltage is less than 314.9 V dc and any flame detector is configured as Used.
Note The 335 V dc power required for the Honeywell flame detector is provided by the Flame Detector Power Supply
(PSFD). This nominal 335 V power enters the TRPG through the J3, J4, and J5 connectors.
Solution
•
•
•
•
•
If no flame detector is being used, verify that all the Flame_Det parameters are set to Unused.
If only two PSFDs are being used, set the No_T_PS_Req parameter to True. This disables the check for power on TRPG
J5.
If the PSFD voltage is less than 314.9 V dc, replace the PSFD.
Check the voltage at the TRPG side (J3, J4, and J5). If the voltage is above 314.9 V dc, replace TRPG.
If the voltage reading at TRPG side (J3, J4, and J5) is below 314.9 V dc and the voltage at PSFD is nominal, replace the
cable connected between the TRPG and the PSFD.
47
Description TRPG Flame Detector Volts Higher than 355.1 V
Possible Cause This power comes into the TRPG through the J3, J4, and J5 connectors. If the voltage is greater than
355.1 V dc, this fault is declared.
Solution
•
•
If the voltage is higher than 355.1 V dc, check the power supply.
Check the voltage on the TRPG. If the voltage is above 355 V, the monitoring circuitry on the TRPG or the cabling to the
TRPG may be the problem.
50
Description L3BKRGXS - Sync Check Relay Is Slow
Possible Cause
•
•
•
The K25 (auto sync) has picked up but the Sync check relay L3BKRGXS, known as K25A, on the TTUR has not picked
up.
There is no breaker closing voltage source.
The K25A relay is not enabled on the PPRO I/O module.
Solution
•
•
•
•
542
Attempt to perform a Sync Reset (set Synch_Reset to True).
Check the breaker to verify closure.
Verify that the K25A relay is enabled on the PPRO I/O module.
Replace the TTUR.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
51
Note This alarm is obsolete.
Description L3BKRGES - Auto Sync Relay Is Slow
Possible Cause
•
•
•
The Auto Sync relay L3BKRGES, also known as K25, on the TTUR has not picked up when it should have.
The K25P is not picked up.
There is no breaker closing voltage source.
Solution
•
•
•
Attempt to perform a Sync Reset (set Synch_Reset to True).
Check the breaker to verify closure.
Replace the TTUR.
52-53
Description Breaker #[ ] Slower Than Adjustment Limit Allows
Possible Cause
•
•
The self-adaptive function adjustment of the Breaker Close Time has reached the allowable limit and cannot make further
adjustments to correct the Breaker Close Time.
The breaker is experiencing a problem, or the operator should consider changing the configuration. Both the nominal
close time and the self-adaptive limit in milliseconds can be configured.
Solution
•
•
•
•
Increase the limit setting of CBxCloseTime for the breaker in question.
Review breaker feedback timing to verify that it meets the documented specifications.
Verify that there are no interposing relays causing a delay.
Replace the terminal board.
54
Description Synchronization Trouble - K25 Relay Locked Up
Possible Cause
•
•
The K25 relay is picked up when it should not be.
K25 on TTUR is most likely stuck closed, or the contacts are welded together.
Solution
•
•
•
Attempt to perform a Sync Reset (set Synch_Reset to True).
Isolate which relay (K25A or K25) is causing a problem by checking the diagnostics and correcting the source of the
issue.
Replace TTUR.
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55
Description Trip Board required by Main Terminal Board
Possible Cause When the PTUR is used with a TTUR, STURH3, or STURH4 terminal board, an auxiliary trip board is
required. However, the PTUR does not detect that a required trip board has been connected.
Solution
•
•
Verify that the proper terminal board and trip board has been configured in the ToolboxST application. Rebuild the
application, then download the firmware and application code to the affected I/O pack.
Verify the trip board cable connections at both ends.
57
Description Hardware and Configuration Incompatibility - Main Terminal Board
Possible Cause The PTUR configuration does not match the actual terminal board hardware.
Solution
•
•
•
•
Verify that the ToolboxST configuration matches the actual hardware.
Rebuild the application, then download the firmware and application code to the affected I/O pack.
Verify that the PTUR is fully seated on the terminal board.
Verify that the installed ToolboxST version supports the configured hardware.
58
Description Hardware and Configuration Incompatibility - Trip Board
Possible Cause The configuration does not match the connected trip board.
Solution
•
•
•
•
•
•
•
Review the hardware compatibility information and correct, if necessary.
Check the I/O pack configuration to verify that the TTUR board hardware form matches the installed terminal board.
Rebuild the application, then download the firmware and application code to the affected I/O pack.
If the configuration is correct, rebuild the device and download the firmware and parameters to the affected I/O pack.
Verify the trip board cable connections at both ends.
Verify that the cable between the TTUR/STUR board and the TRPx terminal board is properly seated.
Verify that the installed ToolboxST version supports the configured hardware.
61
Description TRPL/S Solenoid Power on Bus A is absent
Possible Cause No solenoid power is detected on the TRPL/S bus A.
Solution
•
•
•
544
Verify that power is applied to the terminal board.
Verify that the DC-37 cable is fully seated.
Replace the terminal board.
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62
Description TRPL/S Solenoid Power on Bus B is absent
Possible Cause No solenoid power is detected on TRPL/S bus B.
Solution
•
•
•
Verify that power is applied to the terminal board.
Verify that the DC-37 cable is fully seated.
Replace the terminal board.
63
Description TRPL/S Solenoid Power on Bus C is absent
Possible Cause No solenoid power is detected on TRPL/S bus C.
Solution
•
•
•
Verify that power is applied to the terminal board.
Verify that the DC-37 cable is fully seated.
Replace the terminal board.
64-66
Description TRPL/S Solenoid #[ ] Voltage Mismatch
Possible Cause Power is applied to the solenoid, but the voltage feedback is not detected.
Solution
•
•
•
Verify that the J2 connector is fully seated between the primary and emergency trip boards.
Replace the J2 cable.
Replace the TTUR.
67
Description Speed Trip
Possible Cause
•
•
•
•
•
•
I/O pack has detected that a speed input has exceeded the overspeed threshold
Acceleration threshold has been exceeded
De-acceleration speed has been exceeded
Overspeed configuration is set too low
Acceleration limit has been enabled and is set too low
Noisy pulse input signal
Solution
•
•
•
•
Verify that the overspeed configuration is correct.
Verify that the acceleration configuration is correct.
Check the speed sensor.
Determine the cause of the overspeed condition; for example, input signal, configuration, or noise.
PTUR, YTUR Turbine Specific Primary Trip
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68
Description TRPA - K1 solid state relay shorted
Possible Cause TRPA provides voltage-based detection of stuck-on relays in the six voting contacts used to provide K1.
Zero voltage has been detected on one or more contacts of K1 when voltage should be present.
Solution Replace the TRPA.
69
Description TRPA - K2 solid state relay shorted
Possible Cause TRPA provides voltage-based detection of stuck-on relays in the six voting contacts used to provide K2.
Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.
Solution Replace the TRPA.
70
Description Pack internal reference voltage out of limits
Possible Cause The calibration reference voltage is beyond the expected value, indicating a hardware failure.
Solution
•
•
Cycle power on the I/O pack.
Replace the I/O pack.
71
Description Pack internal null voltage out of limits
Possible Cause The calibration null voltage is beyond the expected value, indicating a hardware failure.
Solution
•
•
Cycle power on the I/O pack.
Replace the I/O pack.
128-223
Description Logic Signal [ ] Voting Mismatch
Possible Cause A problem exists with a status input between the R, S, and T I/O packs. This could be the device, the
wire to the terminal board, or the terminal board.
Solution
•
•
•
•
•
•
546
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
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224-252
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause A problem exists with a status input between the R, S, and T I/O packs. This could be the device, the
wire to the terminal board, or the terminal board.
Solution
•
•
•
•
•
•
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
PTUR, YTUR Turbine Specific Primary Trip
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11.3
Mark VIeS YTUR Primary Turbine Protection I/O Pack
The Primary Turbine Protection (YTUR) I/O pack provides the electrical interface
between one or two I/O Ethernet networks and a turbine control terminal board. The
YTUR contains a processor board common to the distributed I/O packs, a board specific
to the turbine control function, and an analog acquisition daughterboard. The I/O pack
plugs into the TTUR terminal board and handles four speed sensor inputs, bus and
generator voltage inputs, shaft voltage and current signals, eight flame sensors, and
outputs to the main breaker.
Infrared Port Not Used
As an alternative to TTUR, three YTUR I/O packs can be plugged directly into a TRPA terminal board. This arrangement
handles four speed inputs per YTUR, or alternately fans the first four inputs into all three YTURs. Two solid-state primary
trip relays are provided by TRPA. This arrangement does not support bus and generator voltage inputs, shaft voltage or
current signals, flame sensors, or main breaker output.
Note Refer to the Turbine Primary Trip TRPA section for more information.
Input to the I/O pack is through dual RJ-45 Ethernet connectors and a three-pin power input. Output is through a DC-62 pin
connector that connects directly with the associated terminal board connector. Visual diagnostics are provided through
indicator LEDs.
Compatibility
548
Teminal Board
# of I/O Packs
Additional Trip Board
TTURS1C
1 or 3
TRPAS#A or TRPGS#B
TRPAS#A
3
none
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11.3.1 Installation
➢ To install the YTUR I/O pack
1.
Securely mount the desired terminal board.
2.
Directly plug one YTUR I/O pack for simplex or three YTUR I/O packs for TMR into the terminal board connectors.
3.
Mechanically secure the packs using the threaded studs adjacent to the Ethernet ports. The studs slide into a mounting
bracket specific to the terminal board type. The bracket location should be adjusted such that there is no right-angle force
applied to the DC62 connector between the pack and the terminal board. The adjustment should only be required once in
the life of the product.
4.
Plug in one or two Ethernet cables depending on the system configuration. The pack will operate over either port. If dual
connections are used, the standard practice is to connect ENET1 to the network associated with the R controller.
5.
Apply power to the pack by plugging in the connector on the side of the I/O pack. It is not necessary to insert this
connector with the power removed from the cable as the I/O pack has inherent soft-start capability that controls current
inrush on power application.
6.
Use the ToolboxST application to configure the I/O pack as necessary. Refer to GEH-6705 for more information.
Note Three YTURs mounts directly to a Mark VIeS Safety control TTUR or TRPA terminal board, which has three DC-62
pin connectors for TMR I/O packs. The TTUR can also be used in simplex mode if only one YTUR is installed. The YTUR
directly supports all of these connections.
PTUR, YTUR Turbine Specific Primary Trip
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11.3.2 Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Safety Module Alarms
11.3.2.1
Analog Input Hardware
Circuits to convert pulse rate to digital speed are in the YTUR I/O pack. Generator and bus voltages are brought into YTUR
for automatic synchronizing in conjunction with the turbine controller and GE excitation system. TTUR has permissive
generator synchronizing relays and controls the main breaker relay coil 52G. Shaft voltage is picked up with brushes and
monitored along with the current to the machine case. YTUR alarms high voltages and tests the integrity and continuity of the
circuitry.
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In TMR applications there are separate sets of four speed inputs for each YTUR, R, S, and T. All other l inputs fan to the three
YTURs. Control signals from R, S, and T are voted before they actuate permissive relays K25 and K25P. Relay K25A is
controlled by the I/O controller and TREG boards. All three relays have two normally open contacts in series with the breaker
close coil.
YTUR I/O Packs with TTURS1C Terminal Board, TMR
PTUR, YTUR Turbine Specific Primary Trip
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In the simplex application, up to four pulse rate signals may be used to measure turbine speed.
YTUR I/O Pack with TTURS1C Terminal Board, Simplex
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11.3.2.2
Speed Pickups
An interface is provided for four passive, magnetic speed inputs with a frequency range of 2 to 20,000 Hz. Using passive
pickups on a sixty- tooth wheel, circuit sensitivity allows detection of 2-RPM turning gear speed to determine if the turbine is
stopped (zero speed). If automatic turning gear engagement is provided in the turbine control, this signal initiates turning gear
operation.
Note The median speed signal is used for speed control and for the primary overspeed trip signal.
The primary overspeed trip calculations are performed in the controller using algorithms similar to (but not the same as) those
in the YPRO protection I/O pack. The fast trip option used on gas turbines runs in YTUR.
11.3.2.3
Primary Trip Solenoid Interface
The normal primary overspeed trip is calculated in the controller and passed to the YTUR and then to the chosen primary trip
terminal board. TRPx contains relays for interface with the electrical trip devices (ETD). TRPx typically works in conjunction
with an emergency trip board (TREG) to form the primary and emergency sides of the interface to the ETDs. YTUR supports
up to three ETDs driven from each TRPx/TREx combination. TRPG is targeted at gas turbine applications and works in
conjunction with TREG for emergency trip.
In support of the trip board operation, YTUR provides a number of discrete inputs used to monitor signals such as trip relay
position, synchronizing relay coil drive, and ETD power status.
Note The reset signal applied to this function is not edge triggered. A continuously applied reset may result in output cycling
in the presence of an intermittent trip signal. The duration of the reset should only be sufficient to allow the reset to complete
and should not be maintained.
11.3.2.4
Automatic Synchronizing
All synchronizing connections are located on the TTUR terminal board. The generator and bus voltages are supplied by two,
single phase, potential transformers (PTs) with a fused secondary output supplying a nominal 115 V rms. Measurement
accuracy between the zero crossing for the bus and generator voltage circuits is 1 degree.
Turbine speed is matched against the bus frequency, and the generator and bus voltages are matched by adjusting the
generator field excitation voltage from commands sent between the turbine controller and the excitation controller over the
UDH. A command is given to close the breaker when all permissions are satisfied, and the breaker is predicted to close within
the calculated phase/slip window. Feedback of the actual breaker closing time is provided by a 52G/a contact from the
generator breaker (not an auxiliary relay) to update the database. An internal K25A sync check relay is provided on the
TTUR; the independent backup phase/slip calculation for this relay is performed in the <P> protection module. Diagnostics
monitor the relay coil and contact closures to determine if the relay properly energizes or de-energizes upon command.
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11.3.2.5
Synchronizing Modes
There are three basic synchronizing modes.
•
•
•
Off The breaker will not be closed. The check relay will not pickup.
Manual The operator initiates breaker close, which is still subject to the K25A Sync Check contacts driven by the I/O
controller. The manual close is initiated from an external contact on the generator panel, normally connected in series
with a sync mode in manual contact.
Auto The system will automatically match voltage and speed, and then close the breaker at the right time to hit top dead
center on the synchroscope. All three of the following functions must agree for this closure to occur:
−
−
−
K25A sync check relay, checks the allowable slip/phase window, from YPRO.
K25 auto sync relay, provides precision synchronization, from YTUR.
K25P sync sequence permissive, checks the turbine sequence status, from YTUR.
Note These modes are selected from an HMI screen or a generator panel mounted switch.
The K25A relay should close before the K25 otherwise the sync check function will interfere with the auto sync optimizing. If
this sequence is not executed, a diagnostic alarm will be posted, a lockout signal will be set true in signal space, and the
application code may prevent any further attempts to synchronize until a reset is issued and the correct coordination is set up.
Details of the various checks are discussed in the following sections.
11.3.2.6
Synchronizing Hardware
The synchronizing system interfaces to the breaker close coil through the TTURS1C terminal board. Three TTURS1C relays
must be picked up, plus external permissions must be true before a breaker can be closed.
The K25P relay is directly driven from the controller application code. In a TMR system, it is driven from R, S, and T, using 2
out of 3 logic voting. For a simplex system, it may be configured by jumper to be driven from R only.
The K25 relay is driven from the YTUR auto sync algorithm, which is managed by the controller application code. In a TMR
system, it is driven from R, S, and T, using 2 out of 3 logic voting. Again for a simplex system, it may be configured by
jumper to be driven from R only.
The K25A relay is located on TTUR, but is driven from the YPRO sync check algorithm, which is managed by the controller
application code. The relay is driven from YPRO, R8, S8, and T8, using 2 out of 3 logic voting in TREG/L/S.
The sync check relay driver (located on TRPG, TRPL, or TRPS) is connected to the K25A relay coil (located on TTUR)
through cabling through the J2 connector to TRPG, TRPL, or TRPS. It then goes through JR1 (and JS1, JT1) to JR4 (and JS4,
JT4) on TTUR.
Both sides of the breaker close coil power bus must be connected to the TTUR board. This provides diagnostic information
and measures the breaker closure time, through the normally open breaker auxiliary contact, for optimization.
The breaker close circuit is rated to make (close) 10 A at 125 V dc, but to open only 0.6 A. The externally supplied normally
open auxiliary contact on the breaker is required to interrupt the closing coil current.
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11.3.2.7
Synchronization Display
A special synchronization screen is available on the HMI with a real-time graphical phase display and control pushbutton.
The display items are listed in table.
Sync Display
Description
Dynamic Parameters
Voltages: Generator, Bus, Difference
Frequencies: Generator, Bus, Slip (difference)
Phase: Difference angle, degrees
Status Indication
Mode: Sync OFF, MANUAL, AUTO
Sync Monitor: OFF, ON
Dead bus breaker: Open/close
Second breaker if applicable: Open/close
Sync permissive: K25P
Auto sync enabled
Speed adjust: Raise/lower
Voltage adjust: Raise/lower
Sync Permissive
Gen voltage: OK/not OK
Bus voltage: OK/not OK
Gen frequency: OK/not OK
Bus frequency: OK/not OK
Difference volts: OK/not OK
Difference frequ: OK/not OK
Phase: K25, OK/not OK
K25A, OK/not OK
Limit Constants
Upper and lower limits for the above permissive
Breaker Performance
Diagnostics: Slow check relay
Sync relay lockup
Breaker #1 close time out of limits
Breaker #2 close time out of limits
Relay K25P trouble
Breaker closing voltage (125 V dc) missing
Control Pushbuttons
Sync monitor: ON, OFF
Speed adjust: RAISE, LOWER
Voltage adjust: RAISE, LOWER
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11.3.2.8
Auto Sync Application Code
The application code must sequence the turbine and bring it to a state where it is ready for the generator to synchronize with
the system bus. For automatic synchronization, the code must:
•
•
•
•
•
Match speeds
Match voltages
Energize the sync permissive relay, K25P
Arm (grant permission to) the sync check function (YPRO, K25A)
Arm (grant permission to) the auto sync function (YTUR, K25)
The following illustrations represent positive slip (Gen) and negative phase (Gen).
Generator Synchronizing System
11.3.2.9
Automatic Synchronization Control in YTUR (K25)
The YTUR runs the auto sync algorithm. Its basic function is to monitor two Potential Transformer (PT) inputs, generator and
bus, to calculate phase and slip difference, and when armed (enabled) from the application code, and when the calculations
anticipate top center, to attempt a breaker closure by energizing relay K25. The algorithm uses the zero voltage crossing
technique to calculate phase, slip, and acceleration. It compensates for breaker closure time delay (configurable), with
self-adaptive control when enabled, with configurable limits. It is interrupt driven and must have generator voltage to
function. The configuration can manage the timing on two separate breakers. For details, refer to the figure.
The algorithm has a bypass function, two signals for redundancy, to provide dead bus and Manual Breaker Closures. It
anticipates top dead center; therefore, it uses a projected window, based on current phase, slip, acceleration, and breaker
closure time. To pickup K25, the generator must be currently lagging, have been lagging for the last 10 consecutive cycles,
and projected (anticipated) to be leading when the breaker actually reaches closure. Auto sync will not allow the breaker to
close with negative slip. In this fashion, assuming the correct breaker closure time has been acquired, and the sync check relay
is not interfering, breaker closures with less than 1 degree error can be obtained.
Slip is the difference frequency (Hz), positive when the generator is faster than the bus. Positive phase means the generator is
leading the bus; the generator is ahead in time, or the right hand side on the synchroscope. The standard window is fixed and
is not configurable.
A special window has been provided for synchronous condenser applications where a more permissive window is needed.
The special window is selected when the signal space Boolean AS_Win_Sel is true. When selected, the window will be
expanded from the standard window to a new window that is defined by configuration parameters CB#FreqDiff and
CB#PhaseDiff, where # is 1 or 2.
The algorithm validates both PT inputs with a requirement of 50% nominal amplitude or greater; that is, they must exceed
approximately 60 V rms before they are accepted as legitimate signals. This is to guard against cross talk under open circuit
conditions. The monitor mode is used to verify that the performance of the system is correct, and to block the actual closure
of the K25 relay contacts; it is used as a confidence builder. The signal space Input Gen_Sync_Lo will become true if the K25
contacts are closed when they should not be closed, or if the Sync Check K25A is not picked up before the Auto Sync K25. It
is latched and can be reset with Sync_Reset.
PTUR, YTUR Turbine Specific Primary Trip
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The algorithm compensates for breaker closure time delay, with a nominal breaker close time, provided in the configuration in
milliseconds. This compensation is adjusted with self-adaptive control, based upon the measured breaker close time. The
adjustment is made in increments of one cycle (16.6/20 ms) per breaker closure and is limited in authority to a configurable
parameter. If the adjustment reaches the limit, a diagnostic alarm Breaker Slower/Faster than limits allows is posted.
The Auto Sync K25 function uses zero voltage crossing techniques. It compensates for the breaker time delay, which is
defined by two adjustable constants with logic selection between the two (for two breaker applications). The calculations,
which are done on the PTUR or YTUR I/O pack, include phase, slip, acceleration, and anticipated time lead for the breaker
delay. Based on the measured breaker close time, the time delay parameter is adjusted, up to certain limits.
In addition, auto sync arms logic to enable the function, and bypasses logic to provide for deadbus or manual closure. The
auto sync projected sync window is displayed below, where positive slip indicates that the generator frequency is higher than
the bus frequency.
Auto Sync Projected Window
The projected window is based on current phase, current slip, and current acceleration. The generator must currently be
lagging and have been lagging for the last 10 consecutive cycles, and projected (anticipated) to be leading when the breaker
actually reaches closure. Auto sync will not allow the breaker to close with negative slip; speed matching typically aims at
around + 0.12 Hz slip.
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Automatic Synchronizing Algorithm
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11.3.2.10
K25A Sync Check Function
Refer to the chapter, YPRO Emergency Turbine Protection, the section, K25A Sync Check Function.
11.3.2.11
Synchronization Simulation
➢ To simulate a synchronization
1.
Disable the breaker
2.
Establish the center frequency of the YPRO PLL; this depends on the YPRO configuration, under the YPRO K25A tab,
signal K25A_Fdbk, parameter ReferFreq.
−
−
−
If ReferFreq is configured PR_Std, and YPRO is configured for a single shaft machine, then apply rated speed
(frequency) to input PulseRate1; that is SPRO screw pairs 19/20.
If ReferFreq is configured PR_Std and YPRO is configured for a multiple shaft machine, then apply rated speed
(frequency) to input PulseRate 2, that is SPRO screw pairs 21/22.
If ReferFreq is configured SgSpace, force YPRO signal space output DriveRef to 50 or 60 (Hz), depending on
the system frequency.
3.
Apply the bus voltage, a nominal 115 V ac, 50/60 Hz, to TTUR screws 19 and 20, and to SPRO screws 3 and 4.
4.
Apply the nominal 115 V ac generator voltage, adjustable frequency, to TTUR screws 17 and 18 and SPRO screws 1 and
2. Adjust frequency to value giving positive slip, YTUR signal GenFreqDiff of 0.1 to 0.2 Hz. (10 to 5 sec scope).
5.
Force the following signals to the TRUE state:
−
−
−
YTUR, Sync_Perm, then K25P should pick up
YTUR, Sync_Perm_AS, then K25 should pulse when voltages are in phase
YPRO, SynCK_Perm, then K25A should pulse when voltages are in phase
6.
Verify that the TTUR breaker close interface circuit, screws 3 to 7, is being made (contacts closed) when the voltages are
in phase.
7.
Run a trend chart on the following signals:
−
−
YPRO: GenFreqDiff, GenPhaseDiff, L25A_Command, K25A_Fdbk
YTUR: GenFreqDiff, GenPhaseDiff, L25_Command, CB_K25_PU, CB_K25A_PU
8.
Use an oscilloscope, voltmeter, synchroscope, or a light to verify that the relays are pulsing at approximately the correct
time.
9.
Examine the trend chart and verify that the correlation between the phase and the close commands is correct.
10. Increase the slip frequency to 0.5 Hz and verify that K25 and K25A stop pulsing and are open.
Return the slip frequency to 0.1 to 0.2 Hz, and verify that K25 and K25A are pulsing. Reduce the generator voltage to 40 V ac
and verify that K25 and K25A stop pulsing and are open.
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11.3.2.12
Sync Hardware Verification
The hardware interface can be verified by forcing the three synchronizing relays, individually or in combination. If the
breaker close coil is connected to the TTUR terminal board, then the breaker must be disabled to disconnect the generator
from the system bus.
➢ To perform sync hardware verification
1.
Operate the K25P relay by forcing output signal Sync Perm found under YTUR, board points. Verify that the K25P relay
is functional by probing TTUR screws 3 and 4. The application code has direct control of this relay.
2.
Simulate generator voltage on TTUR screws 17 and 18. Operate the K25 relay by forcing TTUR, board point output
signals Sync_Bypass1 =1, and Sync_Bypass0 = 0. Verify that the K25 relay is functional by probing screws 4 and 5 on
TTUR.
3.
Simulate generator voltage on SPRO screws 1 and 2. Operate the K25A relay by forcing SPRO board point output
signals SynCK_Bypass =1, and SynCk_Perm 1. The bus voltage must be zero (dead bus) for this test to be functional.
Verify that the K25A relay is functional by probing screws 5 and 6 on TTUR.
11.3.2.13
Fast Overspeed Trip
In special cases where a faster overspeed trip system is required, the YTUR Fast Overspeed Trip algorithms may be enabled.
The system employs a speed measurement algorithm using a calculation for a predetermined tooth wheel. Two overspeed
algorithms are available as follows:
•
•
PR_Single. This uses two redundant YTURs by splitting up the two redundant PR transducers, one to each board. PR_
Single provides redundancy and is the preferred algorithm for LM gas turbines.
PR_Max. This uses one YTUR I/O pack connected to the two redundant PR transducers. PR_Max allows broken shaft
and deceleration protection without the risk of a nuisance trip if one transducer is lost.
The fast trips are linked to the output trip relays with an OR-gate. YTUR computes the overspeed trip, not the controller, so
the trip is very fast. The time from the overspeed input to the completed relay dropout is 30 ms or less.
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Input , PR1
Input
Config.
param.
PR1Type,
PR1Scale
Signal Space
Inputs
YTUR I/O Pack Firmware
Scaling
RPM
2
PulseRate2
PulseRate3
PulseRate4
AccelCal Type
d
RPM/sec
dt
RPM
------ Four Pulse Rate Circuits ------RPM/sec
Accel1
RPM
Accel2
RPM/sec
Accel3
RPM
Accel4
RPM/sec
PulseRate1
Accel1
PulseRate2
Accel2
PulseRate3
Accel3
PulseRate4
Accel4
Fast Overspeed Protection
FastTripType
PR_Single
PR1Setpoint
PR1TrEnable
PR1TrPerm
PR2Setpoint
PR2TrEnable
PR2TrPerm
PR3Setpoint
PR3TrEnable
PR3TrPerm
PR4Setpoint
PR4TrEnable
PR4TrPerm
InForChanA
AccASetpoint
PulseRate1 A
A>B
B
FastOS1Trip
S
R
PulseRate2 A
A>B
B
S
FastOS2Trip
R
PulseRate3 A
A>B
B
FastOS3Trip
S
R
PulseRate4 A
A>B
B
S
FastOS4Trip
R
Accel1
Accel2 Input
Accel3 cct.
Accel4 select
AccelA
A
A>B
B
S
AccATrip
R
AccelAEnab
AccelAPerm
InForChanB
AccBSetpoint
Accel1
Accel2 Input
Accel3 cct.
Accel4 select
AccelB
A
A>B
B
S
AccBTrip
R
AccelBEnab
AccelBPerm
Master Reset
(MRESET ) MarkVIeS,
SYS_OUTPUT block
OR
PTR1
PTR1_Output
Primary Trip Relay, normal Path, True= Run
AND
PTR2
PTR2_Output
Primary Trip Relay, normal Path , True= Run
AND
PTR3
PTR3_Output
PTR4
PTR4_Output
PTR5
PTR5_Output
PTR6
PTR6_Output
-------------Total of six circuits -----
Fast Trip
Path
False = Run
True = Run
Output, J4,PTR1
True = Run
Output, J4,PTR2
True = Run
Output, J4,PTR3
True = Run
Output, J4A,PTR4
True = Run
Output, J4A,PTR5
True = Run
Output, J4A,PTR6
Fast Overspeed Algorithm, PR-Single
562
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Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Input, PR1
PR1Type,
PR1Scale
Input Config .
PTUR I/O Pack Firmware
Scaling
Param.
PulseRate1
2
d
_
dt
PulseRate2
Accel1
Accel2
Accel3
Accel4
PulseRate3
PulseRate4
AccelCalType
FastTripType
RPM
PR_Max
Four Pulse
Rate Circuits
RPM/sec
RPM/sec
RPM
Signal Space
Inputs
PulseRate1
Accel1
PulseRate2
Accel2
PulseRate3
Accel3
PulseRate4
Accel4
RPM/sec RPM
RPM/sec RPM
Fast Overspeed Protection
DecelPerm
DecelEnab
DecelStpt
InForChanA
InForChanB
Accel 1
Accel 2
Accel3
Accel 4
PulseRate1
PulseRate2
PulseRate3
PulseRate4
AccelA
A
A<B
B
Neg
Input
cct.
Select
for
AccelA
and
AccelB
AccelB
Neg
PulseRateA
PulseRateB
PulseRate1
PulseRate2
MAX
S
DecelTrip
R
A
A>B
B
PR 1/2Max
A
A>B
B
FastOS1Trip
S
FastOS1Stpt
FastOS1Enab
FastOS1Perm
R
PR3/4Max
PulseRate3
PulseRate4
MAX
A
A>B
B
S
FastOS2Stpt
FastOS2Enab
FastOS2Perm
FastOS2Trip
R
N/C
PR1/2Max
PR3/4Max
DiffSetpoint
DiffEnab
DiffPerm
Master Reset
(MRESET )
MarkVIeS,
SYS _OUTPUT
block
PTR1
PTR1_Output
PTR2
PTR2_Output
N/C
A
|A-B|
B
A
A>B
B
S
FastOS3Trip
FastOS4Trip
FastDiffTrip
R
OR
Primary Trip Relay, normal Path, True=Run
AND
Primary Trip Relay, normal Path, True=Run
PTR3
PTR3_Output
PTR4
PTR5
PTR5_Output
PTR6
PTR6_Output
Fast Trip
Path
False = Run
True=Run
Output, J4, PTR1
True=Run
Output, J4, PTR2
AND
Total of six circuits
True=Run
Output, J4, PTR3
True=Run
Output, J4, PTR4
True=Run
Output, J4, PTR5
True=Run
Output, J4, PTR6
Fast Overspeed Algorithm, PR-Max
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 563
Non-Public Information
11.3.2.14
Shaft Voltage and Current Monitor
Bearings can be damaged by the flow of electrical current from the shaft to the case. This current can occur for several
reasons:
•
•
•
A static voltage can be caused by droplets of water being thrown off the last stage buckets in a steam turbine. This
voltage builds up until a discharge occurs through the bearing oil film.
An ac ripple on the dc generator field can produce an ac voltage on the shaft with respect to ground through the
capacitance of the field winding and insulation. Note that both of these sources are weak, so high impedance
instrumentation is used to measure these voltages with respect to ground.
A voltage can be generated between the ends of the generator shaft due to dissymmetries in the generator magnetic
circuits. If the insulated bearings on the generator shaft break down, the current flows from one end of the shaft through
the bearings and frame to the other end. Brushes can be used to discharge damaging voltage buildup, and a shunt should
be used to monitor the current flow.
Note The dc test is driven from the R controller only. If the R controller is down, this test cannot be run successfully.
The turbine control continuously monitors the shaft to ground voltage and current, and alarms excessive levels. There is an ac
test mode and a dc test mode. The ac test applies an ac voltage to test the integrity of the measuring circuit. The dc test checks
the continuity of the external circuit, including the brushes, turbine shaft, and the interconnecting wire.
11.3.2.15
Flame Detectors
With the TRPG primary trip terminal board, the primary protection system monitors signals from eight flame detectors. With
no flame present the detector charges up to the supply voltage. The presence of flame causes the detector to charge to a level
and then discharge through the TRPG. As the flame intensity increases, the discharge frequency increases. When the detector
discharges, the primary protection system converts the discharged energy into a voltage pulse. The pulse rate varies from 0 to
1,000 pulses/sec. These voltage pulses are fanned out to all three modules. Voltage pulses above 2.5 V generate a logic high.
Pulses are counted over a 40 ms period in a counter to generate the flame detector pulse rate.
Note Refer to GEH-6721_Vol_II, the chapter Power Distribution Modules, the section, PSFD Flame Detector Power Supply.
11.3.2.16
•
•
•
•
Connectors
A DC-62 pin connector on the underside of the YTUR I/O pack connects directly to a discrete output terminal board.
An RJ-45 Ethernet connector named ENET1 on the I/O pack side is the primary system interface.
A second RJ-45 Ethernet connector named ENET2 on the I/O pack side is the redundant or secondary system interface.
A 3-pin power connector on the pack side is the input point for 28 V dc power for the I/O pack and terminal board.
Note The terminal board provides fused power output from a power source that is applied directly to the terminal board, not
through this I/O pack connector.
564
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11.3.3 Specifications
Item
YTUR Specification
Number of inputs
Passive speed pickups: 4 TRPG, 3 TRPA
3 voltage detection circuits from TRPA
Estop from TRPA
1 Shaft voltage and 1 current measurement from TRPG
1 Generator and 1 bus voltage from TRPG
Generator breaker status from TRPG
Eight flame detectors from TRPG
Number of outputs
Automatic synchronizing control to main breaker
Primary trip solenoid interface: 3 outputs to TRPG, 2 trip contact outputs from
TREA
Speed sensor range
MPU pulse rate range 2 Hz to 20 kHz
Speed sensor accuracy
MPU pulse rate accuracy 0.05% of reading
Speed sensor circuit sensitivity
Required peak-peak voltage rises as a function of frequency:
0 to 2 kHz requires 27 mV
2 to 6 kHz requires 50 mV
6 to 10 kHz requires 100 mV
10 to 15 kHz requires 160 mV
Above 15 kHz requires 250 mV
Shaft voltage monitor
Voltage signal is ±5 V dc pulses from 0 to 2,000 Hz
Shaft voltage dc test
This applies a 5 V dc source to test integrity of the circuit. The circuit reads a
differential resistance between 0 and 150 Ω within ±5 Ω. Readings above the
BrushLimit ohms setting indicate a fault. The returned signal is filtered to
provide 40 dB of noise attenuation at 60 Hz.
Shaft voltage ac test
Applies a test voltage of 2 kHz to YTUR shaft voltage circuit input.
Shaft current input
Measures shaft current in amps ac (shunt voltage up to 0.1 V pp)
Generator and bus voltage sensors
2 single phase PTs, with secondary output supplying a nominal 115 V rms.
Less than 3 VA loading on inputs. Allowable voltage range for sync is 75 to
130 V rms.
Synchronizing measurements
Frequency accuracy 0.05% over 45 to 66 Hz range.
Zero crossing of the inputs is monitored on the rising slope.
Phase difference measurement is better than ±1 degree.
Contact voltage sensing
20 V dc indicates high and 6 V dc indicates low. Each circuit is optically
isolated and filtered for 4 ms.
Size
8.26 cm High x 4.19 cm Wide x 12.1 cm Deep (3.25 in. x 1.65 in. x 4.78 in.)
† Ambient rating for enclosure design
-30 to 65ºC (-22 to 149 ºF)
Technology
Surface mount
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 565
Non-Public Information
11.3.4 Diagnostics
The I/O pack performs the following self-diagnostic tests:
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware.
Continuous monitoring of the internal power supplies for correct operation.
L3BKR_GXS - the Sync Check Relay on TTUR is Slow
L3BKR_GES - the Auto Sync Relay on TTUR is Slow
Breaker #1 Slower than Adjustment Limit Allows
Breaker #2 Slower than Adjustment Limit Allows
Synchronization Trouble - the K25 Relay on TTUR Locked Up.
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set.
Diagnostic information includes status of the solenoid relay driver, contact, high and low flame detector voltage, and the
sync relays. If any one of the signals goes unhealthy a composite diagnostic alarm, L3DIAG_YTUR occurs.
•
•
•
•
•
•
•
•
The diagnostic signals can be individually latched, and then reset with the RESET_DIA signal if they go healthy. Details of
the individual diagnostics are available from the toolbox.
11.3.4.1
YTUR Application LEDs
LED
Label
Description
Yellow
K25
Indicates the presence of a command to energize the primary synchronizing relay.
Yellow
K25P
Indicates the presence of a command to energize the synchronizing permissive relay.
Yellow
DCT
Indicates the presence of a command to enable the DC Test of shaft voltage and
current monitoring.
Yellow
K1, K2, and K3
Indicates a command to energize the corresponding relay.
566
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11.3.5 Configuration
Note The following information is extracted from the ToolboxST application and represents a sample of the configuration
information for this board. Refer to the actual configuration file within the ToolboxST application for specific information.
Parameter
Description
Choices
System Limits
Enable or disable all system limit checking
Enable, disable
AccelCalType
Select acceleration calculation type
Slow, Medium, Fast
TripType
Select fast trip algorithm
Unused, PR_Single, PR_Max
Deceleration enable
Disable, Enable
YTUR_Mod_Cfg
Trip Type (PR_Max)
DecelEnab
DecelStpt
Deceleration setpoint, RPM/sec
0 … 1500
FastOS1Stpt
Fast Overspeed trip #1 setpoint, Max (PR1, PR2), RPM
0 ... 20000
FastOS1Enabl
Fast Overspeed trip #1 enable
Disable, Enable
FastOS2Stpt
Fast Overspeed trip #2 setpoint, Max (PR3, PR4), RPM
0 ... 20000
FastOS2Enabl
Fast Overspeed trip #2 enable
Disable, Enable
DiffSetpoint
Difference Speed trip setpoint, RPM
0 ... 20000
DiffEnable
Difference Speed trip, enable
Disable, Enable
PR1Setpoint
Fast Overspeed trip #1, setpoint, PR1, RPM
0 ... 20000
PR1TrEnable
Fast Overspeed trip #1, enable
Disable, Enable
AccASetpoint
Acceleration trip setpoint, Change A, RPM/sec
0 ... 1500
InForChanA
.
DiagSo1PwrA
.
Input change selection for Accel/Decel trip
.
When using TRPL/S, Sol Power, Bus A, Diagnostic enable.
.
Accel, Accel2, Accel3, Accel4.
.
Enable, Disable
.
Parameter
Description
Choices
Selects the type of pulse rate input, n (for proper
resolution)
Unused, Speed, Flow, Speed_LM
Trip Type (PR_Single)
YTUR_PR_Cfg
PRType
PRScale
Pulses per revolution (outputs RPM)
0 to 1,000
SysLim1Enabl
Enable system limit 1 fault check
Enable, Disable
SysLim1Latch
Latch system limit 1 fault
SysLim1Type
System limit 1 check type (= or <=)
Latch, Not Latch
= or <=
SysLimit1
System limit 1 - RPM
0 to 20,000
SysLim2Enabl
.
TMRDiffLimit
Enable system limit 2 fault check (as above)
.
Diag Limit, TMR input vote difference, in Eng units
Enable, Disable
.
0 to 20,000
YTUR_ShV_Cfg
Shaft voltage monitor
SysLim1Enabl
Enable system limit 1
Enable, Disable
SysLim1Latch
Latch system limit 1 fault
SysLim1Type
System limit 1 check type (= or <=)
Latch, Not Latch
= or <=
SysLimit1
Select alarm level in frequency Hz
0 to 100
SysLim2Enabl
Select system limit 2 (as above)
Enable, Disable
TMRDiffLimt
Diag limit, TMR input vote difference, in Hertz
0 to 100
YTURShC_Cfg
Shaft current monitor
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 567
Non-Public Information
Parameter
Description
Choices
ShuntOhms
ShuntLimit
BrushLimit
Shunt ohms
Shunt maximum test ohms
Shaft (Brush + Shunt) maximum ohms
0 to 100
0 to 100
0 to 100
SysLim1Enable
Select system limit 1
Enable, Disable
SysLim1Latch
Select whether alarm will latch
SysLim1Type
Select type of alarm initiation
Latch, Not Latch
= or <=
SysLimit1
Current Amps, select alarm level in Amps
0 to 100
SysLim2Enable
.
YTUR_PT_Cfg
Select system limit 2
.
Generator potential transform
Enable, Disable
.
PT_Input
PT primary in Eng units (kv or percent) for PT_Output
0 to 1,000
PT_Output
PT output in volts rms, for PT_Input - typically 115
0 to 150
SysLim1
Select alarm level in k volts rms
0 to 1,000
SysLim2
Select alarm level in k volts rms
0 to 1,000
YTUR_CB_Cfg
Circuit Breaker
System Frequency
Select frequency in Hz
50 or 60
CB1CloseTime
Breaker 1 closing time, ms
0 to 1,000
CB1 AdaptLimit
Breaker 1 self adaptive limit, ms
0 to 1,000
CB1 AdaptEnabl
Enable breaker 1 self adaptive adjustment
Enable, Disable
CB1FreqDiff
Breaker 1 special window frequency difference, Hz
0.15 ... 0.66
CB1PhaseDiff
Breaker 1 special window phase Diff, degrees
0 to 20
CB2CloseTime
.
YTUR_Flm_Cfg
Breaker 2 closing time, ms (as above)
.
0 to 1,000
.
0.160, 0.080, 0.040 sec
FlmDetTime
Flame detector time interval
FlameLimitHI
Flame threshold LimitHI with higher detection counter
provides lower sensitivity.
FlameLimitLOW
Flame threshold LimitLOW with lower detection counter
provides higher sensitivity.
Flame_Det
Flame detector used or unused
Used, Unused
PTR_Output
Primary protection relay used or unused
Unused, used
DiagVoteEnab
Enable voting disagreement diagnostic
Enable, Disable
Enable voting disagreement diagnostic
Enable, Disable
1 … 160
YTUR_Rly1_Cfg
YTUR_Estop_Cfg
DiagVoteEnab
568
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Mark VIe and VIeS Control Systems for GE Industrial Applications
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11.3.5.1
YTUR Signal Space Outputs
Output
Description
Function
Sync_Perm_AS
Auto sync permissive
Traditionally known as L83AS
Sync_Perm
Sync permissive mode, L25P
Traditionally known as L25P; interface to control the K25P
relay
Sync_Monitor
Auto Sync monitor mode
Traditionally known as L83S_MTR; enables the Auto Sync
function, except it blocks the K25 relays from picking up
Sync_Bypass1
Auto Sync bypass
Traditionally known as L25_BYPASS; to pickup L25 for
Dead Bus or Manual Sync
Sync_Bypass0
Auto Sync bypass
Traditionally known as L25_BYPASSZ; to pickup L25 for
Dead Bus or Manual Sync
CB2 Selected
#2 Breaker is selected
AS_WIN_SEL
Special Auto Sync window
Traditionally known as L43SAUTO2; to use the breaker
close time associated with Breaker #2
New function, used on Synchronous condenser
applications to give a more permissive window
When true, selects the special auto sync window
Sync_Reset
Auto Sync reset
Traditionally known as L86MR_TCEA; to reset the Sync
Lockout function
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 569
Non-Public Information
11.3.5.2
YTUR Signal Space Inputs
Input
Description
Function
Ckt_BKR
Breaker State (feedback)
Traditionally known as L52B_SEL
CB_Volts_OK
Breaker Closing Coil Voltage is
present
Used in diagnostics
CB_K25P_PU
Breaker Closing Coil Voltage is
present downstream of the K25P
relay contacts
Used in diagnostics
CB_K25_PU
Breaker Closing Coil Voltage is
present downstream of the K25
relay contacts
Used in diagnostics
CB_K25A_PU
Breaker Closing Coil Voltage is
present downstream of the K25A
relay contacts
Used in diagnostics
Gen_Sync_LO
Sync Lock out
Traditionally known as L30AS1 or L30AS2; it is a latched
signal requiring a reset to clear (Sync_Reset). It detects a
K25 relay problem (picked up when it should be dropped
out) or a slow Sync Check (relay K25A) function
L25_Comand
Breaker Close Command to the K25 Traditionally known as L25
relay
GenFreq
Generator frequency
Hz
BusFreq
Bus frequency
Hz
GenVoltsDiff
Engineering units, kV or percent
CB1CloseTime
CB2CloseTime
GenPT_Kvolts
Difference Voltage between the
Generator and the Bus
Difference Frequency between the
Generator and the Bus
Difference Phase between the
Generator and the Bus
Breaker #1 measured close time
Breaker #2 measured close time
Generator Voltage
BusPT_Kvolts
Bus Voltage
Engineering units, kV or percent
J4:IS200TRPGS1A
TRPG terminal board, 8 flame
detectors
Connected, not connected
GenFreqDiff
GenPhaseDiff
570
GEH-6721_Vol_III_BJ
Hz
Degrees
ms
ms
Engineering units, kV or percent
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.3.5.3
Board Point Signals
Board Points Signals
Description - Point Edit
Direction
Type
L3DIAG_YTUR
I/O Diagnostic Indication
Input
BIT
LINK_OK_YTUR
I/O Link Okay Indication
Input
BIT
ATTN_YTUR
I/O Attention Indication
Input
BIT
ShShntTst_OK
Shaft voltage monitor shunt test OK
Input
BIT
ShBrshTst_OK
Shaft voltage brush + shunt test OK
Input
BIT
CB_Volts_OK
L3BKR_VLT circuit breaker coil voltage available
Input
BIT
CB_K25P_PU
L3BKR_PERM sync permissive relay picked up
Input
BIT
CB_K25_PU
L3KBR_GES auto sync relay picked up
Input
BIT
CB_K25A_PU
L3KBR_GEX sync check relay picked up
Input
BIT
Gen_Sync_LO
Generator sync trouble (lockout)
Input
BIT
L25_Command
——————
Input
BIT
Kq1_Status
——————
Input
BIT
:
:
Input
BIT
Kq6_Status
——————
Input
BIT
FD1_Flame
——————
Input
BIT
:
:
Input
BIT
FD16_Flame
——————
Input
BIT
SysLim1PR1
——————
Input
BIT
:
:
Input
BIT
SysLim1PR4
——————
Input
BIT
SysLim1SHV
Ac shaft voltage frequency high L30TSVH
Input
BIT
SysLim1SHC
Ac shaft current high L30TSCH
Input
BIT
SysLim1GEN
——————
Input
BIT
SysLim1BUS
——————
Input
BIT
SysLim2PR1
(same set as for Limit1 above)
Input
BIT
GenFreq
Hz frequency
Input
FLOAT
BusFreq
Hz frequency
Input
FLOAT
GenVoltsDiff
KiloVolts rms-Gen Low is negative
Input
FLOAT
Gen Freq Diff
Slip Hz-Gen Slow is negative
Input
FLOAT
Gen Phase Diff
Phase Degrees-Gen Lag is negative
Input
FLOAT
CB1CloseTime
Breaker #1 close time in milliseconds
Input
FLOAT
CB2CloseTime
Breaker #2 close time in milliseconds
Input
FLOAT
Accel1
RPM/SEC
Input
FLOAT
:
:
Input
FLOAT
Accel4
RPM/SEC
Input
FLOAT
FlmDetPwr1
335 V dc
Input
FLOAT
ShTestAC
L97SHAFT_AC SVM_AC_TEST
Output
BIT
ShTestDC
L97SHAFT_DC SVM_DC_TEST
Output
BIT
FD1_Level
1 = high detection counts level
Output
BIT
:
:
Output
BIT
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 571
Non-Public Information
Board Points Signals
Description - Point Edit
Direction
Type
FD16_Level
1 = high detection counts level
Output
BIT
Sync_Perm_AS
L83AS - auto sync permissive
Output
BIT
Sync_Perm
L25P - sequencing sync permissive
Output
BIT
Sync_Monitor
L83S_MTR - monitor mode
Output
BIT
Sync_Bypass1
L25_BYP-1 = auto aync bypass
Output
BIT
Sync_Bypass0
L25_BYPZ-0 = auto sync permissive
Output
BIT
CB2_Selected
L43SAUT2 - 2nd breaker selected
Output
BIT
AS_Win_Sel
L43AS_WIN - special window selected
Output
BIT
Sync_Reset
L86MR_SYNC - sync trouble reset
Output
BIT
Kq1
L20PTR1 - primary trip relay
Output
BIT
:
:
Output
BIT
Kq6
L20PTR6 - primary trip relay
Output
BIT
572
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Mark VIe and VIeS Control Systems for GE Industrial Applications
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11.4
YTUR Specific Alarms
32–34
Description
Solenoid #[ ] Relay driver Feedback Incorrect
Possible Cause The I/O pack monitors the relay command for the correct state and termination into the expected trip
board impedance. The I/O pack internal feedback of relay command output does not match the desired state.
Solution
•
•
•
•
Check the mounting of the I/O pack on the terminal board.
Check the cable from the TTUR to the trip board, if used.
Replace the I/O pack.
Replace the TRPx trip board.
38–40
Description
Solenoid #[ ] Contact Feedback Incorrect
Possible Cause The contact state feedback from the trip board does not match the relay command.
Solution
•
•
•
Check the mounting of the I/O pack on the terminal board.
Check the cable from the TTUR to the TRPx.
Check the operation of the relay.
44
Description Trip Board Solenoid Power Absent
Possible Cause
•
•
The I/O pack has detected the absence of solenoid power as indicated by the connected TRPx board.
The issue could be with the power source applied in the TRPx terminal boards.
Solution
•
•
•
•
•
•
Verify that the TRPx on the J1 connector is receiving power.
Verify that the voltage at the J1 cable is at an acceptable range. If it is out of range, there could be a problem with the
source or the cable connected between source and the terminal board.
Check the cabling to the TRPx.
If the voltage source is good, change the cable between the power source and TRPx boards.
If the problem persists, replace the cable between the TRPx and the TTUR or STUR board.
If the problem persists, replace the TRPx board.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 573
Non-Public Information
46
Description TRPG Flame Detector Volts Lower than 314.9 V
Possible Cause The voltage is less than 314.9 V dc and any flame detector is configured as Used.
Note The 335 V dc power required for the Honeywell flame detector is provided by the Flame Detector Power Supply
(PSFD). This nominal 335 V power enters the TRPG through the J3, J4, and J5 connectors.
Solution
•
•
•
•
•
If no flame detector is being used, verify that all the Flame_Det parameters are set to Unused.
If only two PSFDs are being used, set the No_T_PS_Req parameter to True. This disables the check for power on TRPG
J5.
If the PSFD voltage is less than 314.9 V dc, replace the PSFD.
Check the voltage at the TRPG side (J3, J4, and J5). If the voltage is above 314.9 V dc, replace TRPG.
If the voltage reading at TRPG side (J3, J4, and J5) is below 314.9 V dc and the voltage at PSFD is nominal, replace the
cable connected between the TRPG and the PSFD.
47
Description TRPG Flame Detector Volts Higher than 355.1 V
Possible Cause This power comes into the TRPG through the J3, J4, and J5 connectors. If the voltage is greater than
355.1 V dc, this fault is declared.
Solution
•
•
If the voltage is higher than 355.1 V dc, check the power supply.
Check the voltage on the TRPG. If the voltage is above 355 V, the monitoring circuitry on the TRPG or the cabling to the
TRPG may be the problem.
50
Description
L3BKRGXS - Sync Check Relay Is Slow
Possible Cause
•
•
•
The K25 (auto sync) has picked up but the Sync check relay L3BKRGXS, known as K25A, on the TTUR has not picked
up.
There is no breaker closing voltage source.
The K25A relay is not enabled on the YPRO I/O module.
Solution
•
•
•
•
574
Attempt to perform a Sync Reset (set Synch_Reset to True).
Check the breaker to verify closure.
Verify that the K25A relay is enabled on the YPRO I/O module.
Replace the TTUR.
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51
Description L3BKRGES - Auto Sync Relay Is Slow
Possible Cause
•
•
•
The Auto Sync relay L3BKRGES, also known as K25, on the TTUR has not picked up when it should have.
The K25P is not picked up.
There is no breaker closing voltage source.
Solution
•
•
•
Attempt to perform a Sync Reset (set Synch_Reset to True).
Check the breaker to verify closure.
Replace the TTUR.
52–53
Description Breaker #[ ] Slower Than Adjustment Limit Allows
Possible Cause
•
•
The self-adaptive function adjustment of the Breaker Close Time has reached the allowable limit and cannot make further
adjustments to correct the Breaker Close Time.
The breaker is experiencing a problem, or the operator should consider changing the configuration. Both the nominal
close time and the self-adaptive limit in milliseconds can be configured.
Solution
•
•
•
•
Increase the limit setting of CBxCloseTime for the breaker in question.
Review breaker feedback timing to verify that it meets the documented specifications.
Verify that there are no interposing relays causing a delay.
Replace the terminal board.
54
Description Synchronization Trouble - K25 Relay Locked Up
Possible Cause
•
•
The K25 relay is picked up when it should not be.
K25 on TTUR is most likely stuck closed, or the contacts are welded together.
Solution
•
•
•
Attempt to perform a Sync Reset (set Synch_Reset to True).
Isolate which relay (K25A or K25) is causing a problem by checking the diagnostics and correcting the source of the
issue.
Replace TTUR.
PTUR, YTUR Turbine Specific Primary Trip
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55
Description Trip Board required by Main Terminal Board
Possible Cause When the YTUR is used with a TTUR, STURH3, or STURH4 terminal board, an auxilliary trip board is
required. However, the YTUR does not detect that a required trip board has been connected.
Solution
•
•
Verify that the proper terminal board and trip board has been configured in the ToolboxST application. Rebuild the
application, then download the firmware and application code to the affected I/O pack.
Verify the trip board cable connections at both ends.
57
Description Hardware and Configuration Incompatibility - Main Terminal Board
Possible Cause The YTUR configuration does not match the actual terminal board hardware.
Solution
•
•
•
•
Verify that the ToolboxST configuration matches the actual hardware.
Rebuild the application, then download the firmware and application code to the affected I/O pack.
Verify that the YTUR is fully seated on the terminal board.
Verify that the installed ToolboxST version supports the configured hardware.
58
Description Hardware and Configuration Incompatibility - Trip Board
Possible Cause The configuration does not match the connected trip board.
Solution
•
•
•
•
•
•
•
576
Review the hardware compatibility information and correct, if necessary.
Check the I/O pack configuration to verify that the TTUR board hardware form matches the installed terminal board.
Rebuild the application, then download the firmware and application code to the affected I/O pack.
If the configuration is correct, rebuild the device and download the firmware and parameters to the affected I/O pack.
Verify the trip board cable connections at both ends.
Verify that the cable between the TTUR/STUR board and the TRPx terminal board is properly seated.
Verify that the installed ToolboxST version supports the configured hardware.
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67
Description Speed Trip
Possible Cause
•
•
•
•
•
•
I/O pack has detected that a speed input has exceeded the overspeed threshold
Acceleration threshold has been exceeded
De-acceleration speed has been exceeded
Overspeed configuration is set too low
Acceleration limit has been enabled and is set too low
Noisy pulse input signal
Solution
•
•
•
•
Verify that the overspeed configuration is correct.
Verify that the acceleration configuration is correct.
Check the speed sensor.
Determine the cause of the overspeed condition; for example, input signal, configuration, or noise.
68
Description TRPA - K1 solid state relay shorted
Possible Cause TRPA provides voltage-based detection of stuck-on relays in the six voting contacts used to provide K1.
Zero voltage has been detected on one or more contacts of K1 when voltage should be present.
Solution Replace the TRPA.
69
Description TRPA - K2 solid state relay shorted
Possible Cause TRPA provides voltage-based detection of stuck-on relays in the six voting contacts used to provide K2.
Zero voltage has been deleted on one or more contacts of K2 when voltage should be present.
Solution Replace the TRPA.
70
Description Pack internal reference voltage out of limits
Possible Cause The calibration reference voltage is beyond the expected value, indicating a hardware failure.
Solution
•
•
Cycle power on the I/O pack.
Replace the I/O pack.
PTUR, YTUR Turbine Specific Primary Trip
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71
Description Pack internal null voltage out of limits
Possible Cause The calibration null voltage is beyond the expected value, indicating a hardware failure.
Solution
•
•
Cycle power on the I/O pack.
Replace the I/O pack.
128–223
Description Logic Signal [ ] Voting Mismatch
Possible Cause A problem exists with a status input between the R, S, and T I/O packs. This could be the device, the
wire to the terminal board, or the terminal board.
Solution
•
•
•
•
•
•
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
Replace the I/O pack.
224–252
Description Input Signal [ ] Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause A problem exists with a status input between the R, S, and T I/O packs. This could be the device, the
wire to the terminal board, or the terminal board.
Solution
•
•
•
•
•
578
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and networking.
Check the I/O pack mounting on the terminal board.
Verify the operation of the device generating the specified signal.
Verify the terminal board wiring and connections.
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11.5 TTURH#C, S1C TMR Primary Turbine Protection
Terminal Board
The Primary Turbine Protection (TTUR) terminal board inputs and outputs are as follows:
•
•
•
•
•
•
12 pulse rate devices sensing a toothed wheel to measure the turbine speed
Generator voltage and bus voltage signals taken from external potential transformers
125 V dc output to the main breaker coil for automatic generator synchronizing
Inputs from shaft voltage and current sensors to measure induced shaft voltage and current
Three overspeed trip signals to the trip board
Additional I/O signals from the trip board
TTUR has three relays, K25, K25P, and K25A, that all have to close to provide 125 V dc power to close the main breaker
52G. The signals to the I/O pack use the PR3 and JR4 connector for simplex systems. For TMR systems, signals fan out to the
PR3, PS3, PT3, JR4, JS4, and JT4 connectors.
TTUR Primary Turbine Protection
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 579
Non-Public Information
Compatibility
Board Revision
Mark VIe Control
IS220PTUR
Mark VIeS Safety Control
IS200YTUR
TTURH1C
Comments
Supports connection of TRPG, TRPS, TRPL, or
TRPA
No
TTURH2C
Contains altered internal power distribution for
special applications and is not interchangeable with
Yes
a TTURH1C
TTURS1C
Yes
Supports connection of TRPGS, TRPAS, and is IEC
61508 safety certified with YTUR
11.5.1 Installation
Pulse rate pick ups, shaft pick ups, potential transformers, and the breaker relay are wired to the two terminal blocks TB1 and
TB2. Each block is held down with two screws and has 24 terminals accepting up to #12 AWG wires. A shield terminal strip
attached to chassis ground is located immediately to the left of each terminal block.
In 240 V ac applications, do not inadvertently cross-connect the 240 V ac and the dc
voltages. The peak voltage will exceed the Transorb rating, resulting in a failure.
Caution
Most ac supplies operate with a grounded neutral, and if an inadvertent connection
between the 125 V dc and the ac voltage is created, the sum of the ac peak voltage and
the 125 V dc is applied to Transorbs connected between dc and ground. However, in
120 V ac applications, the Transorb rating can withstand the peak voltage without
causing a failure.
Jumpers JP1 and JP2 select either simplex or TMR for relay drivers K25 and K25P. Removing wire jumper WJ1 isolates the
K25A control line to the J8 connector on the terminal board. TB3 is for optional TTL connections to active speed pickups;
these devices require an external power supply. Simplex systems use connectors PR3 and JR4. TMR systems use all six
connectors.
Note Passive or active Pulse rate devices can be used.
The I/O pack plugs into the TTUR as displayed in the following figure. Either one or three I/O packs can be used. The turbine
primary trip board connects to the J4 connectors.
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TTUR Terminal Board Wiring
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 581
Non-Public Information
11.5.2 Operation
In simplex applications, up to four pulse rate signals can be used to measure turbine speed. Generator and bus voltages are
brought into TTUR for automatic synchronizing in conjunction with the PTUR or YTUR, the turbine controller, and the
excitation system. The TTUR has permissive generator synchronizing relays and controls the main breaker relay coil 52G. All
three relays have two normally open contacts in series with the breaker close coil.
In TMR applications, all inputs, except speed, fan to the three PTURs or YTURs. Control signals coming into TTUR from R,
S, and T are voted before they actuate permissive relays K25 and K25P. The sync check relay driver (located on TREG,
TREL, or TRES) is connected to the K25A relay coil (located on TTUR) through cabling from the J2 connector to TRPG,
TREL, or TRES. It then goes through JR1 (and JS1, JT1) to JR4 (and JS4, JT4) on TTUR. This is the primary path. An
optional path is through J8 on TREG. Relay K25A is controlled by the PPRO or YPRO.
Note The Mark VIeS YTUR does not support the TREL or TRES.
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TTUR and I/O Packs, TMR system
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 583
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11.5.3 Specifications
Item
TTUR Specification
Number of inputs
12 passive speed pickups
1 shaft voltage and 1 shaft current measurement
1 generator and 1 bus voltage. Generator breaker status contact.
Signal to K25A relay from Mark VIe PPRO or Mark VIeS YPRO
Number of outputs
Generator breaker coil, make (close) 10 A at 125 V dc,
break (open) 0.6 A at 125 V dc
Power supply voltage
Nominal 125 V dc to breaker coil
MPU pulse rate range
2 Hz to 20 kHz
MPU pulse rate accuracy
0.05% of reading
Speed input sensitivity
Turning gear speed can be observed
on a typical turbine application.
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
20 kHz requires 276 mV p-p
Shaft voltage monitor
Signal is frequency of ±5 V dc (0 – 1 MHz) pulses from 0 to 2,000 Hz
Shaft voltage wiring
Up to 300 m (984 ft), with maximum two-way cable resistance of 15 Ω
Shaft voltage dc test
This applies a 5 V dc source to test integrity of the circuit. The circuit reads a
differential resistance between 0 and 150 Ω within ±5 Ω. Readings above the
BrushLimit ohms setting indicate a fault. The returned signal is filtered to provide 40
dB of noise attenuation at 60 Hz.
Shaft voltage ac test
Applies a test voltage of 2 kHz to the input of the Mark VIe PTUR or Mark VIeS
YTUR shaft voltage circuit.
Shaft current input
Measures shaft current in amps ac (shunt voltage up to 0.1 V pp)
Generator and bus voltage sensors
Two single phase potential transformers, with secondary output supply a nominal
115 V rms. These PTs are external to the TTUR.
Each PT input on the TTUR has less than 3 VA of loading.
Each PT input on the TTUR is magnetically isolated with a 1,500 V rms barrier.
Cable length can be up to 1,000 ft. of 18 AWG wiring.
Generator breaker circuits
(synchronizing)
External circuits should have a voltage range within 20 to 140 V dc. The external
circuit must include a NC breaker auxiliary contact to interrupt the current. Circuits
are rated for NEMA class E creepage and clearance. 250 V dc applications require
interposing relays.
Contact voltage sensing
20 V dc indicates high and 6 V dc indicates low. Each circuit is optically isolated and
filtered for 4 ms.
Size
33.0 cm high x 17.8 cm wide (13 in x 7 in)
Technology
Surface mount
584
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11.5.4 Diagnostics
Diagnostic tests are made on the terminal board as follows:
•
•
•
•
•
•
Feedback from the solenoid relay drivers is checked; if there is a problem with the control signal a fault is created.
Feedback from the relay contacts; if there is a problem with the control signal a fault is created.
Loss of solenoid power creates a fault.
Slow sync check relay, slow breaker, and locked up K25 relay; all of these create a fault.
If any one of the above signals goes unhealthy, a composite diagnostic alarm occurs. The diagnostic signals can be
individually latched and then reset with the RESET_DIA signal if they go healthy.
Terminal board connectors have their own ID device that is interrogated by the I/O pack. The ID device is a read-only
chip coded with the terminal board serial number, board type, revision number, and plug location. When the chip is read
by the I/O pack and a mismatch is encountered, a hardware incompatibility fault is created.
11.5.5 Configuration
Jumpers JP1 and JP2 select either simplex (SMX) or TMR for relay drivers K25 and K25P. Wire jumper WJ1 is installed;
removing this will isolate the K25A control line to the J8 connector on the TTUR board. There are no switches on the board.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 585
Non-Public Information
11.6 STURH#A Simplex Primary Turbine Protection
Terminal Board
The Simplex Primary Turbine Protection Input (STUR) terminal board is a simplex S-type terminal board version of the
turbine terminal board (TTUR). It provides a connection for the turbine specific primary trip (PTUR), speed and
synchronizing inputs, and trip relay outputs or a cable to drive a primary trip board.
Note The STUR terminal board is not compatible with the Mark VIeS YTUR I/O pack.
STUR is used for the following:
•
•
•
Mechanical drives requiring overspeed protection but no synchronizing function.
Generator drive systems requiring overspeed and primary synchronization.
Other applications requiring the four pulse input circuits of PTUR.
This terminal board has the same physical size, customer terminal locations, and I/O pack mounting as other S-type terminal
boards. There will be no components higher than an attached PTUR I/O pack permitting double stacking of terminal boards.
There are four groups:
•
•
•
•
IS200STURH1 omits synchronizing hardware and includes trip relays.
IS200STURH2 includes synchronizing hardware and trip relays.
IS200STURH3 omits synchronizing hardware and includes a DC-37 pin connector for a cable leading to a trip terminal
board.
IS200STURH4 includes synchronizing hardware and includes a DC-37 pin connector for a cable leading to a trip
terminal board.
Note Boards revisions prior to version STURH3ADB and STURH4ADB do not support the third trip relay.
STUR provides the following major functions:
•
•
•
•
•
•
•
Provides a DC-62 pin connector for mounting a single PTUR I/O pack.
Accepts up to four speed input signals.
A 48 terminal Euro style box-type terminal blocks for customer connection points is supplied on the board.
Provides two trip solenoid outputs, K1 and K2, with each composed of a safety relay (H1, H2).
Provides a DC-37 pin connector for connecting a TPRG or TPRS primary trip relay (H3, H4).
Accepts two PT inputs supporting primary synchronization (H2, H4). They accept generator voltage and bus voltage
signals taken from potential transformers.
Provides two relay outputs supporting primary synchronization (H2, H4). Two relays, K25 and K25P, have to close to
provide 125 V dc power needed to close the main breaker 52G.
Note STUR contains no provisions for an E-stop circuit.
11.6.1 Installation
STUR and a plastic insulator mount on a sheet metal carrier. The carrier is then mounted to a cabinet by screws.
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Customer Terminal Assignments
Terminal
Description
Signal Name
STURH1A
STURH2A
STURH3A
STURH4A
1
K1_NO1_In
K1_NO1_In
Parallel connection to terminal 2.
2
K1_NO1_In
K1_NO1_In
Relay K1 Normally Open contact #1
3
K1_Centertap
K1_Centertap
Relay K1 Common
4
K1_NC_Out
K1_NC_Out
Relay K1 Normally Closed
5
K1_NO2_In
K1_NO2_In
Relay K1 Normally Open Contact #2 in
6
K1_NO2_Out
K1_NO2_Out
Relay K1 Normally Open Contact #2 ret.
7
K1_NO2_Out
K1_NO2_Out
Parallel connection to terminal 6
8
K2_NO1_In
K2_NO1_In
Parallel connection to terminal 9
9
K2_NO1_In
K2_NO1_In
Relay K2 Normally Open contact #1
10
K2_Centertap
K2_Centertap
Relay K2 Common
11
K2_NC_Out
K2_NC_Out
Relay K2 Normally Closed
12
K2_NO2_In
K2_NO2_In
Relay K2 Normally Open Contact #2 in
13
K2_NO2_Out
K2_NO2_Out
Relay K2 Normally Open Contact #2 ret.
14
K2_NO2_Out
K2_NO2_Out
Parallel connection to terminal 13
15
SOL1_In
SOL1_In
Solenoid 1 voltage sensor + input
16
SOL1_Ret
SOL1_Ret
Solenoid 1 voltage sensor - input
PTUR, YTUR Turbine Specific Primary Trip
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Customer Terminal Assignments (continued)
Terminal
Signal Name
Description
17
SOL2_In
SOL2_In
Solenoid 2 voltage sensor + input
18
SOL2_Ret
SOL2_Ret
Solenoid 2 voltage sensor - input
19
no connect
20
no connect
21
GENH
GENH
Generator PT input high
22
GENL
GENL
Generator PT input low
23
BUSH
BUSH
Bus PT input high
24
BUSL
BUSL
Bus PT input low
25
B52GH
B52GH
Output (PGEN) to B52G feedback contact
26
B52GL
B52GL
Return side of B52G feedback contact
27
PGEN
PGEN
Positive breaker coil power input
28
AUTO
AUTO
Output of K25P contact closure
29
MAN
MAN
Output of K25 contact closure
30
BKRH
BKRH
52G Breaker Coil positive output.
31
BKRH
BKRH
Parallel connection to terminal 30
32
NGEN
NGEN
Negative breaker coil power connection
33
no connect
34
no connect
35
no connect
36
no connect
37
TTL1
TTL1
TTL1
TTL1
Active speed pickup input 1
38
PR1_H
PR1_H
PR1_H
PR1_H
Passive speed pickup input 1
39
PR1_L
PR1_L
PR1_L
PR1_L
Speed pickup 1 return (active and passive)
40
TTL2
TTL2
TTL2
TTL2
Active speed pickup input 2
41
PR2_H
PR2_H
PR2_H
PR2_H
Passive speed pickup input 2
42
PR2_L
PR2_L
PR2_L
PR2_L
Speed pickup 2 return (active and passive)
43
TTL3
TTL3
TTL3
TTL3
Active speed pickup input 3
44
PR3_H
PR3_H
PR3_H
PR3_H
Passive speed pickup input 3
45
PR3_L
PR3_L
PR3_L
PR3_L
Speed pickup 3 return (active and passive)
46
TTL4
TTL4
TTL4
TTL4
Active speed pickup input 4
47
PR4_H
PR4_H
PR4_H
PR4_H
Passive speed pickup input 4
48
PR4_L
PR4_L
PR4_L
PR4_L
Speed pickup 4 return (active and passive)
588
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11.6.2 Operation
11.6.2.1
Board Groups
STUR is available in four distinct configurations. STUR is not available with fixed box terminals. It uses pluggable type
terminals. Two groups offer on-board trip relays and two groups offer DC-37 pin connectors for using an external trip board.
Components supporting generator applications will be omitted from two groups used for mechanical applications and added
for groups used for generator applications.
STUR Board Variations
Board Version
Generator
Application
Trip
Connections
Application
STURH1A
No
Trip relays
Mechanical drive turbines
STURH2A
Yes
Trip relays
Generator drive turbines
STURH3A**
No
DC-37 pin connector
Pulse inputs only, mechanical drive requiring
features provided by a separate primary trip board.
STURH4A**
Yes
DC-37 pin connector
Generator drive turbines requiring features
provided by a separate primary trip board.
** Boards revisions prior to version STURH3ADB and STURH4ADB do not support the third trip relay.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 589
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STUR Schematic
11.6.2.2
Speed Input
STUR provides four speed input circuits that accept passive speed sensors or active speed sensors. When passive sensors are
used the signal is applied between terminals PR#_H and PR#_L where # is 1 through 4. Sensitivity of the passive sensor input
is such that the PTUR I/O pack is able to sense speeds as low as 2RPM. When active speed sensors are used the signal is
applied between terminals TTL# and PR#_L.
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11.6.2.3
Trip Relays
STUR version H1 and H2 provides two trip solenoid outputs, K1 and K2, with each composed of a safety relay that uses
forcibly guided contacts. Relay position feedback is provided to PTUR using one of the contact pairs in the relay.
Note The ControlST* software suite V03.01 or later is required for the K1 and K2 trip function.
11.6.2.4
Primary Synchronizing
STURH2 and STURH4 used with PTUR provides support for synchronized closure of a 52G primary breaker. Two PT inputs
are provided for Bus and Generator voltage on terminals 21 through 24. Breaker positive power at 24, 48, or 125 V dc is
applied to terminal 27 (PGEN) and the return is applied to terminal 32 (NGEN). The presence of this voltage is indicated by
the BKRVLT signal. Positive power passes through a permissive relay K25P to terminal 28 (AUTO) with power indicated by
the BKRPRM signal. Power then passes through the synchronizing pilot relay K25 to terminal 29 (MAN) as indicated by the
BKRGES signal.
Note All voltage based feedback of synchronizing relay status is based on a voltage return path through terminal 32.
If a backup sync-check relay is used it is to be wired between terminals 29 and 30 (BKRH) with closure indicated by signal
BKRGXS. If a backup sync-check is not used a jumper between terminals 29 and 30 is used to complete the circuit and
BKRGXS and BKRGES both indicate that power is applied to the breaker coil. The breaker coil or a pilot relay is to be wired
between terminals 31(BKRH) and 32 (NGEN).
Note Refer to the PTUR Operation section, Synchronizing System.
PTUR, YTUR Turbine Specific Primary Trip
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11.6.2.5
Feedback Signals
Feedback signals are dependent on the group of STUR. Possible signals include the following:
•
•
•
Relay position feedback from STUR K1 and K2 trip relays.
Solenoid voltage feedback associated with K1 and K2.
Five voltage feedbacks associated with the sync function. The following signals are formed by testing the voltage
between the desired signal and the return side of the power bus or N125GEN.
−
−
BKRVLT – Voltage status of the power bus used to close the breaker.
L52G – Voltage feedback from an auxiliary contact on the 52G breaker. A separate set of customer screw terminals
provides input.
− BKRPRM – Voltage status of the breaker close permissive relay contact, K25P.
− BKRGES – Voltage status of the combination of the K25P contacts wired in series with the K25 contacts.
− BKRGXS – Voltage status of the series combination of K25P, K25, and an auxiliary backup sync check relay
(K25A) which equals the voltage applied to the breaker coil or a pilot relay.
Two sync relay coil drive feedback signals.
Feedback signals provided by a trip card wired to J2
•
•
Relationship between Feedback and STUR Group
STUR
Group
Relay Position
Solenoid Volts
STURH1
Yes
Yes
STURH2
Yes
Yes
Sync Circuit
Volts
Sync Relay
Coils
Yes
Yes
STURH3
Yes
STURH4
11.6.2.6
Trip Card
Feedback
Yes
Yes
Yes
Failure Detection
An external test signal is required for speed input testing. Normal running speed signal failure detection is achieved through
redundant signals applied to STUR. PT inputs require external test signals for proper feedback. Trip relays, depending on
which STUR version is being tested, use forcibly guided contacts ensuring a feedback contact accurately represents the power
contact position. Breaker closure relay contact logic includes voltage based status feedback announcing any unexpected
behavior.
592
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11.6.2.7
Trip Board Comparison
The following table compares existing primary trip boards to STUR.
Board
TMR/Simplex
Output
Contacts 125
V
Output
Contacts 24 V
E-Stop
Sync Support
Trip Output
Count
TRPGH1B
TMR
1A
No
No
Yes
3
TRPGH2B
Simplex
1A
3A
No
Yes
3
TRPLH1A
TMR
1A
3A
Yes
Yes
3
TRPSH1A
TMR/Simplex
1A
3A
Yes
Yes
3
TRPAH1A
TMR
No
5A
Yes
No
2
TRPAH2A
TMR
1A
No
Yes
No
2
STURH1A
Simplex
0.5A
5A
No
No
2
STURH2A
Simplex
0.5A
5A
No
Yes
2
STURH3A**
Simplex
(TRPx)
(TRPx)
No
No
(TRPx)
STURH4A**
Simplex
(TRPx)
(TRPx)
No
Yes
(TRPx)
** Boards revisions prior to version STURH3ADB and STURH4ADB do not support the third trip relay.
11.6.2.8
Simplex Turbine Applications
In simplex applications STUR accepts up to four pulse rate signals used to measure turbine speed. The PT signals provide
voltage input from both sides of a 52G circuit breaker permitting automatic synchronization to be performed. The on-board
trip relays provided by the H1 and H2 groups of STUR create a self-contained overspeed and synchronizing function. It is
also possible to use the H3 or H4 group of STUR in a simplex application with a simplex trip terminal board cabled into
STUR using the DC-37 pin connection.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 593
Non-Public Information
11.6.3 Specifications
Item
STUR Specification
Number of inputs
4 passive or active speed pickups
1 generator and 1 bus voltage potential transformer (H2, H4)
1 generator breaker status contact. (H2, H4)
Number of outputs
2 Primary trip relays (H1, H2)
2 Synchronizing relays (H2, H4)
1 DC-37 connector for primary trip terminal board (H3, H4)
MPU pulse rate range
2 Hz to 20 kHz
MPU pulse rate accuracy
0.05% of reading
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
20 kHz requires 276 mV p-p
Speed input sensitivity is such that turning
gear speed may be observed on a typical
turbine application.
Generator and bus voltage sensors
Two single phase 115 V ac rms potential transformer inputs. Each input has
less than 3 VA of loading.
Each PT input is magnetically isolated with a 1,500 V rms barrier.
Cable length can be up to 1,000 ft. of 18 AWG wiring.
Generator breaker circuits (synchronizing,
K25, K25p)
External circuits should have a voltage range within 20 to 140 V dc. Circuits are
rated for NEMA class E225 creepage and clearance. 250 V dc applications
require interposing relays.
Contact rating 3.15 A at 24 V dc, 1.2 A at 48 V dc, 0.4 A at 125 V dc, resistive.
Contact voltage sensing
20 V dc indicates high and 6 V dc indicates low. Each circuit is optically isolated
and filtered for 4 ms. Circuits will accept up to 140 V dc input.
Trip Relays (K1, K2)
Contact Rating: 4 A at 24 V dc, 4 A at 48 V dc, 2 A at 125 V dc for normally
open contacts resistive. 4 A at 24 V dc, 4 A at 48 V dc, 0.3 A at 125 V dc for
normally closed contacts resistive.
Minimum contact load >50 mW.
Maximum Switching Rate: 3 operations/minute at rated load, 60
operations/minute at minimum load
Associated printed circuit board designed for minimum of 20 A surge rating for
10 ms.
Size
15.9 cm high x 17.8 cm, wide (6.25 in x 7 in)
Technology
Surface mount
594
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.6.4 Diagnostics
Diagnostic tests are made on the STUR as follows:
•
•
•
•
•
•
Feedback from the solenoid relay drivers is checked; if there is a problem with the control signal a fault is created.
Feedback from the relay contact position is checked; if there is a problem with the control signal a fault is created.
Loss of solenoid power creates a fault.
Slow synch check relay, slow breaker, and locked up K25 relay; all of these create a fault.
If any one of the above signals goes unhealthy, a composite diagnostic alarm L3DIAG_PTUR occurs. The diagnostic
signals can be individually latched and then reset with the RESET_DIA signal if they go healthy.
Terminal board connectors have their own ID device that is interrogated by the I/O pack. The ID device is a read-only
chip coded with the terminal board serial number, board type, revision number, and plug location. When the chip is read
by PTUR and a mismatch is encountered, a hardware incompatibility fault is created.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 595
Non-Public Information
11.7
TRPA_#A Aeroderivative Turbine Primary Trip Board
The Aeroderivative Turbine Primary Trip (TRPA) terminal board inputs and outputs are as follows:
•
Twelve passive pulse rate devices (four per R/S/T section) sensing a toothed wheel to measure the turbine speed. Or, six
active pulse rate inputs (two per TMR section)
Two 24 V dc (H1A) or 125 V dc (H2A) TMR voted output contacts to the main breaker coil for trip coil.
Four 24-125 V dc voltage detection circuits for monitoring trip string.
One 24-125 V dc ‘Fail-safe’ ESTOP input for removing power from trip relays.
•
•
•
With three I/O packs, signals fan out to the PR3, PS3, PT3, JR4, JS4, and JT4 connectors.
Compatibility
Board Revision
Mark VIe control
IS220PTUR
Mark VIeS Safety control
IS200YTUR
TRPAH1A
24 V dc output contact rating
No
TRPAH2A
TRPAS1A
GEH-6721_Vol_III_BJ
125 V dc output contact rating
24 V dc output contact rating, IEC 61508
safety certified with YTUR
Yes
TRPAS2A
596
Comments
Yes
125 V dc output contact rating, IEC 61508
safety certified with YTUR
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.7.1 Installation
In 240 V ac applications, do not inadvertently cross-connect the 240 V ac and the dc
voltages. The peak voltage will exceed the Transorb rating, resulting in a failure.
Caution
Most ac supplies operate with a grounded neutral, and if an inadvertent connection
between the 125 V dc and the ac voltage is created, the sum of the ac peak voltage and
the 125 V dc is applied to Transorbs connected between dc and ground. However, in
120 V ac applications, the Transorb rating can withstand the peak voltage without
causing a failure.
TTL pulse rate pick ups, voltage detection, E-Stop, and the breaker relay are wired to the I/O terminal blocks TB1. Passive
pulse rate pick-ups are wired to TB2. Each block is held down with two screws and has 24 terminals accepting up to #12
AWG wires. A shield termination strip attached to chassis ground is located immediately to the left of each terminal block.
The TRPA must be configured for the desired speed input connections using the following table. Jumpers JP1 and JP2 select
fanning of the R section pulse rate pickups to the S and T I/O packs.
Speed Input Connections
Function
Jumper
Wire to all 12 pulse inputs:
PR1_R – PR4_T
Each set of (4) pulse inputs goes to its own
dedicated I/O pack.
Cannot use jumper:
Place in STORE position
Wire to TTL pulse inputs:
TTL1_R – TTL2_T
Each set of (2) pulse inputs goes to its own
dedicated I/O pack.
Cannot use jumper:
Place in STORE position
Wire to bottom 4 pulse inputs only:
PR1_R – PR4_R
NO wiring to TTL1_R-TTL2_T or
PR1_S-PR4_T
The same set of signals are fanned to all the
I/O packs.
Use jumper:
Place over pin pairs
Wire to bottom 2 pulse inputs:
TTL1_R – TTL2-R
Cannot fan the TTL signals. Only the R I/O
pack will receive data.
Cannot use jumper:
Place in STORE position
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 597
Non-Public Information
TRPA Terminal Board Wiring
598
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.7.1.1
•
•
Contact Outputs
The contact outputs are polarity sensitive. Wire the circuit carefully to avoid damaging the relays.
There is no contact or solenoid suppression, user must add external solenoid suppression to avoid damaging the relays
and their contacts.
Connection to TRPA contact output
11.7.1.2
•
•
•
•
E-Stop/TRP Input
The TRP inputs must be powered for the relays to operate. If the user does not need or use an ESTOP, then jumper the
local TRP power source (P24O and P24R) to the respective TRP inputs at the terminal board.
The ESTOP must be connected to a CLEAN dc source – battery or filtered (< 5% ripple) rectified ac.
There must be a minimum of 18 V dc at the TRP inputs for proper operation. The current required was kept low to
minimize drop on long cable runs.
As the TRP is very fast < 5 ms and the output relay contacts are also fast (< 15 ms), best wiring practices should be
utilized to avoid misoperation. Use twisted-pair cable when possible and avoid running with ac wiring and so on.
Attention
The E-Stop signal that is reported in the ToolboxST E-Stop Tab is latched by firmware
and needs a Master Reset to clear that status. A true indicates a completed E-Stop
circuit. A false indicates a loss of the E-Stop since the last Master Reset, not the
current state of the E-Stop circuit.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 599
Non-Public Information
Typical E-Stop connection options
600
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.7.2 Operation
11.7.2.1
System Design
The TRPA board is designed for application in two different ways. When a TTUR terminal board is used to hold three I/O
packs, the TRPA terminal board may be connected using three cables with DC-37 pin connectors on each end. In this mode of
operation the TRPA provides two contact voted trip relay outputs, ESTOP, and four voltage sensors. TTUR provides the
normal set of features described for that board. The TRPA speed inputs are not active and should not be connected with this
board arrangement.
The TRPA board can also be used with three I/O packs mounted directly to it. In this mode of operation the speed inputs to
TRPA become active paths into the I/O pack, allowing for a single terminal board primary trip solution. Simplex operation is
not possible.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 601
Non-Public Information
11.7.2.2
Speed Inputs
When used with I/O packs mounted directly on the TRPA, the speed inputs provide two options. Each I/O pack can receive a
dedicated set of four speed inputs from their respective TRPA terminal points as is done on TTUR. As an option, jumpers P1
and P2 can be placed on the TRPA to take the first four speed inputs (those for the R pack) and fan them to the S and T packs.
When this is selected the terminal board points for S and T speed input become no-connects and should not be used.
11.7.2.3
Voltage Monitors
The trip relays on TRPA can be freely located anywhere in a trip string. Because the trip string circuit is not fixed, there are
four general-purpose isolated voltage sensor inputs on TRPA. These can be used to monitor any points in the trip system and
drive the voltage status into the system controller where action can be taken. Typical use of these inputs may be to sense the
power supply voltage for the two trip strings and to sense the solenoid voltage of the device being driven by the relays. This
set of applications is used in the wording of the board symbol, but the sensors can be freely applied to best serve the
application.
602
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11.7.2.4
E-Stop
The TRPA includes an E-Stop function. This consists of an optically isolated input circuit designed for a dc input in the range
of 24 V to 125 V nominal. When energized the circuit enables coil drive power in the R, S, and T relay circuits through
independent hardware paths. The response time of this circuit (less than five milliseconds) plus the response time of the trip
relays (less than one millisecond) yields a very fast E-Stop response. E-Stop is monitored by the I/O pack, but the action to
remove trip relay coil power is entirely in the hardware of TRPA.
Attention
The E-Stop signal that is reported in the ToolboxST E-Stop Tab is latched by firmware
and needs a Master Reset to clear that status. A true indicates a completed E-Stop
circuit. A false indicates a loss of the E-Stop since the last Master Reset, not the
current state of the E-Stop circuit.
TRPA E-Stop Function
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 603
Non-Public Information
11.7.2.5
TRPA Trip Relays
The trip relays are made using sets of six individual form A devices arranged in a voting pattern. Any two controllers that
vote to close will establish a conduction path through the set. Because detection of a shorted relay is important to preserve
tripping reliability there is a sensing circuit applied to each of the sets of relays. When the relays are commanded to open and
voltage is present across the relays the circuit will detect if one or more relays are shorted. This signal goes to the I/O pack to
create an alarm. The TRPA sensing circuit uses the relay commands from all three packs to avoid a false indication in the
event that one I/O pack votes to close the relay while the other two I/O packs vote to open.
TRPA and I/O Pack, TMR System
The following figure is simplified with many circuit paths omitted for clarity. Refer to the sections, E-Stop/TRP Input and
E-Stop.
604
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TTLn _ T
TRPA
Pulse Rate Inputs
P3T
MnTH
MPU
8
S
MnTL
TTLn _S
ID
P3S
MnSH
8
S
MnSL
Four of above
circuits to S ,
except for TTL ,
see Table.
TTLn _R
ID
MnRH
MnR
L
K1DCN
Pin 9
P3 R
8
S
Four of above
circuits to R ,
except for TTL,
see Table .
Relay V Monitor
KR 1 KS1
Circuit duplicated
for S and T
K4 R
KS 1 KT1
KR 1
RD
KR2
RD
ID
KT 1 KR 1
JR 4
KR 2 KS2
Relay V Monitor
KS 2 KT2
KT 2 KR 2
ID
JS4
Refer to the figure ,
TRPA E- Stop
Function.
ID
JT4
P 28 R 1
P 28 S1
P 28 T1
g o h ere
Primary
E - STOP
T T U R
K2DCP
Pin 14
C a bl e s t o
K1DCP
Pin 10
K2DCN
Pin 13
I/ O p a c k s g o h er e
Four of above
circuits to T,
except for TTL,
see Table .
Monitor
Monitor
Monitor
Solenoid
Voltage
Monitor x 2
ID
Monitors go to TTUR and I /O pack
< R >, <S >, < T > connectors
Power
Voltage
Monitor x 2
TRPA Typical Voted Contact Configuration
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 605
Non-Public Information
11.7.2.6
TRPA Terminal Board Connectors
Pin #
Signal Name
Pin #
Signal Name
1
VSEN1_A
2
VSEN1_B
3
VSEN2_A
4
VSEN2_B
5
VSEN3_A
6
VSEN3_B
7
VSEN4_A
8
VSEN4_B
9
K1DCN
10
K1DCP
11
No connection
12
No connection
13
K2DCN
14
K2DCP
15
E-TRP
16
E-TRPR
17
P24O
18
P24R
19
TTL2_T
20
TTL1_T
21
TTL2_S
22
TTL1_S
23
TTL2_R
24
TTL1_R
25
PR1_TH
26
PR1_TL
27
PR2_TH
28
PR2_TL
29
PR3_TH
30
PR3_TL
31
PR4_TH
32
PR4_TL
33
PR1_SH
34
PR1_SL
35
PR2_SH
36
PR2_SL
37
PR3_SH
38
PR3_SL
39
PR4_SH
40
PR4_SL
41
PR1_RH
42
PR1_RL
43
PR2_RH
44
PR2_RL
45
PR3_RH
46
PR3_RL
47
PR4_RH
48
PR4_RL
606
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
11.7.3 Specifications
Item
TRPA Specification
Number of inputs
3x4 passive (magnetic) speed pickups or 3x2 active (TTL) speed pickups.
4 voltage detection circuits
1 ESTOP/TRP input
Number of outputs
2 trip contacts:
1 ESTOP/TRP power source.
Contact ratings
NEMA class F. Minimum operations: 100,000
IS200TRPA_1A
Voltage: 24 V dc nominal
5 A dc resistive
3 A dc with L/R = 7 ms and no suppression
3 A dc with L/R = 100 ms with suppression
Active Voltage Clamp Limiting max. voltage ≤60 V dc
IS200TRPA_2A
Voltage: 125 V dc nominal
1 A dc resistive
1 A dc with L/R = 7 ms and no suppression
1 A dc with L/R = 100 ms with suppression
Active Voltage Clamp Limiting max. voltage ≤ 200 V dc
Voltage detection inputs
Min/max input voltage rating: 16/140 V dc max pk
Current Loading (Max leakage): 3 mA
Detection delay (max): 60 ms
Voltage isolation: Optically isolated: 2500 V rms isolation, for one min
Surge/Spike rating: 1000 V pk for 8.3 ms
ESTOP/TRP voltage source
24 V dc no-load, 0.3 to 1K source impedance
ESTOP/TRP detection
Input Voltage: 24-125 V dc ±10% (18/140 V pk Min/Max)
Loading (max): 12 mA (5 typical)
Delay (max): 5 ms (<1 typical)
MPU pulse rate range
2 to 20 kHz
MPU pulse rate accuracy
0.05% of reading
Speed input sensitivity
Required peak-peak (p-p) voltage rises as a function of frequency:
2 Hz requires 24 mV p-p
20 kHz requires 276 mV p-p
Turning gear speed can be observed on
a typical turbine application.
Size
33.0 cm high x 17.8 cm, wide (13 in x 7 in)
Technology
Surface mount
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 607
Non-Public Information
11.7.4 Diagnostics
Diagnostic tests are made on the terminal board:
•
•
•
•
•
Feedback from the shorted contact detector checked; if there is a problem with the control signal an alarm should be
created.
Feedback from the ESTOP/TRP input is checked; if there is a problem with the signal a fault should be created.
Feedback from speed pickup fanning jumpers is checked; if there is a mismatch between intention and actual position, an
alarm should be created.
If any one of the above signals goes unhealthy, a composite diagnostic alarm occurs. The diagnostic signals can be
individually latched and then reset with the RESET_DIA signal if they go healthy.
Terminal board connectors have their own ID device that is interrogated by the I/O pack. The ID device is a read-only
chip coded with the terminal board serial number, board type, revision number, and plug location. When the chip is read
by the I/O pack and a mismatch is encountered, a hardware incompatibility fault is created.
11.7.5 Configuration
Jumpers JP1 and JP2 select the fanning of the 4 R section passive speed pickups to the S and T section I/O packs. Place the
jumper over the pin pairs to fan the 4 R speed input to the other two TMR sections.
608
GEH-6721_Vol_III_BJ
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11.8
TRPG_#B Gas Turbine Primary Trip Board
The Gas Turbine Primary Trip (TRPG) terminal board is controlled by Primary Turbine Protection PTUR or YTUR I/O packs
that are mounted on the TTUR terminal board, which is cabled to TRPG. The TRPG contains nine magnetic relays in three
voting circuits to interface with three trip solenoids (ETDs). The TRPG works in conjunction with the TREG to form the
primary and backup sides of the interface to the ETDs. The TRPG also accommodates inputs from eight flame detectors for
gas turbine applications.
TRPG Terminal Board and Cabling
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 609
Non-Public Information
11.8.1 Compatibility
Board Revision
Mark VIe control
IS220PTUR
Mark VIeS Safety
control IS200YTUR
Comments
TRPGH1B
TRPGH3B
Yes
No
TMR applications, has three voting
relays per trip solenoid
TRPGH2B
Yes
No
Simplex applications
TRPGS1B
Yes
Yes
IEC 61508 safety certified TMR
application with YTUR and
TTURS1C, has three voting relays
per trip solenoid
TRPGS2B
Yes
Yes
IEC 61508 safety certified simplex
applications with YTUR and
TTURS1C, has one relay per trip
solenoid
Version Difference
Board
TMR
Simplex
Output contact,
125 V dc, 1 A
Output contact,
24 V dc, 3 A
28 V Power use
TRPGH1B
TRPGS1B
Yes
No
Yes
Yes
Normal
TRPGH2B
TRPGS2B
No
Yes
Yes
Yes
Normal
TRPGH3B **
Yes
No
Yes
Yes
Special
** TRPGH3B features special handling of 28 V control power and is otherwise identical to a TRPGH1B.
610
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11.8.2 Installation
➢ To install the TRPG board
1.
Connect the wires for the three trip solenoids directly to the first I/O terminal block.
2.
Connect the wires for the flame detectors (if used) to the second terminal block. Connect the power for the flame
detectors (if used) to the J3, J4, and J5 plug.
3.
Connect the 125 V dc power for the trip solenoids to the J1 plug.
4.
Transfer power to the TREG board using the J2 plug.
Turbine Primary Trip Terminal Board TRPG
125V dc
J1
JT1
x
x
x
x
x
125 V dc (N) x
x
x
x
x
x
x
x
Trip Solenoid1 or 4
Trip Solenoid 2 or 5
Trip Solenoid 3 or 6
2
4
6
8
10
12
14
16
18
20
22
24
x
x
x
x
x
x
x
x
x
x
x
x
x
1 125 V dc (P)
3 125 V dc (P)
5 125 V dc (P)
7
9 125 V dc (N)
11
13
15
17
19
21
23
J Port Connections
JS1
Cables to TTUR
JR1
Flame1 (L)
Flame2 (L)
Flame3 (L)
Flame4 (L)
Flame5 (L)
Flame6 (L)
Flame7 (L)
Flame8 (L)
x
x
x
x
x
x
x
x
x
x
x
x
x
26
28
30
32
34
36
38
40
42
44
46
48
x
x
x
x
x
x
x
x
x
x
x
x
x
25
27
29
31
33
35
37
39
41
43
45
47
J2
Flame1 (H)
Flame2 (H)
Flame3 (H)
Flame4 (H)
Flame5 (H)
Flame6 (H)
Flame7 (H)
Flame8 (H)
Up to two #12 AWG wires per
point with 300 V insulation
PTUR, YTUR Turbine Specific Primary Trip
Cable to TREG
J4
J5
J3
335 V dc
is provided
from PSFD
PSVP
power supply
Terminal blocks can be unplugged
from terminal board for maintenance
GEH-6721_Vol_III_BJ System Guide 611
Non-Public Information
11.8.3 Operation
The I/O pack provides the primary trip function by controlling the relays on TRPG, which trip the main protection solenoids.
In TMR applications, the three inputs are voted in hardware using a relay ladder logic two-out-of-three voting circuit. The I/O
pack monitors the current flow in its relay driver control line to determine its energize or de-energize, vote or status of the
relay coil contact status. Supply voltages are monitored for diagnostic purposes. A normally closed contact from each relay on
TRPG is monitored by the diagnostics to determine its proper operation.
Note A metal oxide varister (MOV) and a current limiting resistor are used for noise suppression in each ETD circuit.
612
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The primary overspeed trip comes from the controller and is passed to the PTUR or YTUR, and then to TRPG. TRPG works
in conjunction with the TREG board, which is controlled by the PPRO or YPRO backup overspeed function. This
TRPG/TREG combination can drive three ETDs.
PTUR, YTUR Turbine Specific Primary Trip
GEH-6721_Vol_III_BJ System Guide 613
Non-Public Information
11.8.3.1
Flame Detectors
With the TRPG primary trip terminal board, the primary protection system monitors signals from eight flame detectors. With
no flame present the detector charges up to the supply voltage. The presence of flame causes the detector to charge to a level
and then discharge through the TRPG. As the flame intensity increases, the discharge frequency increases. When the detector
discharges, the primary protection system converts the discharged energy into a voltage pulse. The pulse rate varies from 0 to
1,000 pulses/sec. These voltage pulses are fanned out to all three modules. Voltage pulses above 2.5 V generate a logic high.
Pulses are counted over a 40 ms period in a counter to generate the flame detector pulse rate.
Note Refer to GEH-6721_Vol_II, the chapter Power Distribution Modules, the section, PSFD Flame Detector Power Supply.
11.8.4 Specifications
Item
TRPG Specification
Trip solenoids
3 solenoids per TRPG
Solenoid rated voltage/current
125 V dc standard with up to 1 A draw
24 V dc is alternate with up to 3 A draw
Solenoid response time
L/R time constant is 0.1 sec
Current suppression
MOV on TREG
Current economizer
Terminals for optional 100 Ω, 70 W economizing resistor on TREG
Control relay coil voltage supply
Relays are supplied with 28 V dc from JR1, JS1, and JT1
Flame detectors
8 detectors per TRPG
Flame detector supply voltage/current
335 V dc with 0.5 mA per detector
11.8.5 Diagnostics
The I/O pack runs the TRPG diagnostics. These include feedback from the trip solenoid relay driver and contact, solenoid
power bus, and the flame detector excitation voltage too low or too high. A diagnostic alarm is created if any one of the
signals go unhealthy (beyond limits). Connectors JR1, JS1, and JT1 on the terminal board have their own ID device, which is
interrogated by the I/O pack, and if a mismatch is encountered, a hardware incompatibility fault is created. The ID device is a
read-only chip coded with the terminal board serial number, board type, revision number, and the plug location.
614
GEH-6721_Vol_III_BJ
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11.9
TRPL Large Steam Turbine Primary Trip Board
The Large Steam Turbine Primary Trip (TRPL) terminal board is used for the primary overspeed protection of large steam
turbines. TRPL is controlled by the Primary Turbine Protection PTUR, and contains nine magnetic relays in three voting
circuits to interface with three trip solenoids (ETDs). TRPL works in conjunction with the TREL terminal board to form the
primary and emergency sides of the interface to the ETDs. These two terminal boards are used in a similar way as TRPG and
TREG are used on gas turbine applications.
Note The TRPL is not compatible with the Mark VIeS YTUR.
Up to three trip solenoids can be connected between the TREL and TRPL terminal boards. TREL provides the positive side of
the 125/24 V dc to the solenoids and TRPL provides the negative side. In addition, two manual emergency stop functions can
be connected.
11.9.1 Installation
The TRPL is controlled by PTUR I/O packs on the TTURH1C, and it only supports TMR applications. The I/O packs plug
into the D-type connectors on TTURH1C, which is cabled to TRPL.
➢ To install the TRPL board
1.
Connect the wires for the three trip solenoids directly to the first I/O terminal block.
2.
Connect the wires for the primary emergency stop and optional secondary emergency stop to the second terminal block.
3.
Connect the trip solenoid power to plugs JP1, JP2, and JP3.
4.
Install a jumper across terminals 9 and 11 for the PTR3 trip.
5.
If a second emergency stop is required, remove the jumper from terminals 46 and 47 and connect the wires there.
PTUR, YTUR Turbine Specific Primary Trip
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TRPL Terminal Board Wiring
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11.9.2 Operation
TRPL is used for TMR applications only. Three separate power buses, PwrA, PwrB, and PwrC for solenoid power, are
brought in through connectors JP1, JP2, and JP3, and then distributed to TREL through connector J2.
The power buses have a nominal voltage of 125 V dc (70 to 140 V dc) or 24 V dc (18 to 32 V dc). The board includes power
bus monitoring (three buses). The maximum current per bus is 3 A.
Each of the three trip solenoids is controlled by three relays using 2 out of 3 contact voting. The relay output rating (for
100,000 operations) is as follows:
•
•
At 24 V dc, 3 A, L/R = 100 ms, with suppression
At 125 V dc, 1.0 A, L/R = 100 ms, with suppression
The trip circuits include solenoid suppression, associated solenoid voltage monitoring, and trip relay contact monitoring. In
the TRPL, the hardwired trip (E-Stop) and associated monitoring provides approximately 6.6 V dc to the PTUR when the K4
relays are picked up.
Attention
The E-Stop signal that is reported in the ToolboxST E-Stop Tab is latched by firmware
and needs a Master Reset to clear that status. A true indicates a completed E-Stop
circuit. A false indicates a loss of the E-Stop since the last Master Reset, not the
current state of the E-Stop circuit.
PTUR, YTUR Turbine Specific Primary Trip
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TRPL Terminal Board
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11.9.3 Specifications
Item
TRPL Specification
Trip solenoids
3 solenoids per TRPL
Solenoid rated voltage/current
125 V dc standard with up to 1 A draw
24 V dc is alternate with up to 3 A draw
Solenoid response time
L/R time constant is 0.1 sec with suppression
Current suppression
MOVs
Control relay coil voltage supply
Relays are supplied with 28 V dc from JR1, JS1, and JT1
Primary Emergency Stop, manual
One with optional secondary E-Stop
11.9.4 Diagnostics
The PTUR runs the TRPL diagnostics. These include feedback from the trip solenoid relay driver and contact, solenoid
voltage, and solenoid power bus. A diagnostic alarm is created if any one of the signals goes unhealthy (beyond limits). The
Jx1 connectors on the terminal board have their own ID device, which is interrogated by the PTUR, and if a mismatch is
encountered, a hardware incompatibility fault is created.
Note The ID device is a read-only chip coded with the terminal board serial number, board type, revision number, and the
plug location.
11.9.5 Configuration
There are no switches or hardware settings on the terminal board. Terminals 9 and 11 must use a jumper to include the PTR 3
trip. Terminals 46 and 47 must use a jumper if only one manual emergency stop is required.
PTUR, YTUR Turbine Specific Primary Trip
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11.10
TRPS Small Steam Turbine Primary Trip Board
The Small Steam Turbine Primary Trip (TRPS) terminal board is used for the primary overspeed protection of small and
medium size steam turbines. The TRPS is controlled by the Primary Turbine Protection (PTUR) I/O pack, and it contains
three magnetic relays to interface with three trip solenoids (ETDs). The TRPS works in conjunction with the TRES terminal
board to form the primary and emergency sides of the interface to the ETDs. These two terminal boards are used in a similar
way as TRPG and TREG are used on gas turbine applications, except with the following differences:
•
•
•
•
Two-out-of-three voting is done in the relay drivers and not using relay contacts as with TRPG and TRPL.
In a simplex application, the voting is bypassed and the relay drivers are controlled by a single signal from JA1.
There are no economizing relays.
There are no flame detector inputs.
Note The TRPS is not compatible with the Mark VIeS YTUR.
Up to three trip solenoids can be connected between the TRES and TRPS terminal boards. TRES provides the positive side of
the 125/24 V dc to the solenoids and TRPS provides the negative side. In addition, two manual emergency stop functions can
be connected.
11.10.1
Installation
The TRPS is controlled by PTUR I/O packs on the TTURH1C, and it supports simplex and TMR applications. The I/O packs
plug into the D-type connectors on TTURH1C, which is cabled to the TRPS.
➢ To install the TRPS board
1.
Connect the wires for the three trip solenoids to the first I/O terminal block.
2.
Connect the wires for the primary emergency stop and optional secondary emergency stop to the second terminal block.
3.
Connect the trip solenoid power to plugs JP1, JP2, and JP3.
4.
If a second emergency stop is required, remove the jumper from terminals 46 and 47, and connect the wires there.
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TRPS Terminal Board Wiring
PTUR, YTUR Turbine Specific Primary Trip
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11.10.2
Operation
The TRPS is used for TMR and simplex applications. Three separate power buses, PwrA, PwrB, and PwrC for solenoid
power, are brought in through connectors JP1, JP2, and JP3, and then distributed to TRES through connector J2.
The power buses have a nominal voltage of 125 V dc (70 to 140 V dc) or 24 V dc (18 to 32 V dc). The board includes power
bus monitoring (three buses). The maximum current per bus is 3 A.
Each of the three trip solenoids is controlled by a relay driver. The relay output rating (for 100,000 operations) is as follows:
•
•
At 24 V dc, 3 A, L/R = 100 ms, with suppression
At 125 V dc, 1.0 A, L/R = 100 ms, with suppression
The trip circuits include solenoid suppression, associated solenoid voltage monitoring, and trip relay contact monitoring. In
the TRPS, the hardwired trip (E-Stop) and associated monitoring provides approximately 6.6 V dc to the I/O board when the
K4 relays are picked up.
Attention
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The E-Stop signal that is reported in the ToolboxST E-Stop Tab is latched by firmware
and needs a Master Reset to clear that status. A true indicates a completed E-Stop
circuit. A false indicates a loss of the E-Stop since the last Master Reset, not the
current state of the E-Stop circuit.
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
TRPS Terminal Board
PTUR, YTUR Turbine Specific Primary Trip
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11.10.3
Specifications
Item
TRPS Specification
Trip solenoids
3 solenoids per TRPS
Solenoid rated voltage/current
125 V dc standard with up to 1 A draw
24 V dc is alternate with up to 3 A draw
Solenoid response time
L/R time constant is 0.1 sec with suppression
Current suppression
MOVs
Control relay coil voltage supply
Relays are supplied with 28 V dc from JR1, JS1, and JT1
Primary Emergency Stop, manual
One with optional secondary E-Stop
11.10.4
Diagnostics
The PTUR runs the TRPx diagnostics. These include feedback from the trip solenoid relay driver and contact, solenoid
voltage, and solenoid power bus. A diagnostic alarm is created if any one of the signals goes unhealthy (beyond limits).
The Jx1 connectors on the terminal board have their own ID device, which is interrogated by the PTUR, and if a mismatch is
encountered, a hardware incompatibility fault is created.
Note The ID device is a read-only chip coded with the terminal board serial number, board type, revision number, and the
plug location.
11.10.5
Configuration
There are no switches or hardware settings on the terminal board. Terminals 46 and 47 must use a jumper if only one manual
emergency stop is required; remove jumper if secondary E-Stop is used.
To enable the solenoid voltage feedback inputs in the ToolboxST application, connect the SUS#A and SUS#B pins on the
TRPS terminal board. If you are not using a TRES for emergency protection, connect a jumper between SUS1A and PwrA_
P1, SUS2A and PwrB_P1, and SUS3A and PwrC_P1. This connection is normally supplied through the J2 connector to the
TRES terminal board. SUS#B should be connected to the solenoid in the configuration. The solenoids may be connected to
the NO or NC contacts of the PTR, and the SUS#B pin should be connected to the same contact to enable the voltage
monitoring input.
Note For jumper configurations needed to enable solenoid voltage feedback, refer to GEI-100596 Mark VIe Control Backup
Turbine Protection (PPRO) Module Description, the section, TRES Turbine Emergency Trip.
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12
YSIL Core Safety Protection Module
12.1
YSIL Overview
The Mark VIeS Safety controller is used in a wide range of process control and turbo-machinery applications. When applied
as a control, protection, and monitoring system for heavy duty and aero-derivative gas turbines, it is configured with primary
and backup protection systems for tripping reliability. The YSIL module requires ControlST V5.04 or later.
The YSIL backup protection is a triple redundant SIL 3 capable system that will trip the turbine independent of the primary
protection system. Although it is independent, YSIL monitors each of the primary controllers for speed differential detection,
watchdog diagnostics, and to provide cross-tripping capability. In addition, all diagnostics are communicated to the main
controllers on the I/O network (IONet), which also facilitates operator-initiated tests such as online and offline overspeed
tests.
Turbine trips are generated from each of the three YSIL sections, which feed voted relay drivers and trip relays on the TCSA
board, and separate hydraulic trip solenoids in the trip manifold. Each trip solenoid is connected between one-out-of-three
primary trip sections on the TRPG or TRPA primary trip board and one-out-of-three backup trip sections on the TCSA
backup trip board. Therefore, each trip solenoid will de-energize to trip if either its primary trip relay or backup trip relay
de-energizes. Then, the turbine will trip if two-out-of-three trip solenoids de-energize. Due to the wide voltage range allowed,
external suppression should be provided at the solenoid coil.
The backup protection system consists of the following:
•
•
•
•
TCSA is the main terminal board for the backup protection system.
YSIL I/O packs (three total) with local processors and data acquisition boards mount on the TCSA board.
WCSA is the required daughter board on the TCSA board.
SCSAs are I/O extension boards (three are required) that connect to the WCSA by serial bus.
The YSIL module can only be used to control the positive side of the solenoids. YSIL is always used with either a
YTUR/TRPx or a PTUR/TRPx primary trip module for control of both sides of the solenoid. This is displayed in the
following figure.
YSIL Core Safety Protection Module
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†
YTUR
TTUR
†
I/O
PTUR I /O packs
can be used with
a Shared IONet
system.
IONet
Primary
Protection
System
TRPG or TRPA
I/O
-V dc
Three Trip Solenoids
Backup Sync
Check Protection
+V dc
TCSA
YSIL
<T>
WCSA
I/O
IONet
< S>
I/O
<R>
Backup
Protection
System
Serial Buses
<T>
SCSA
I/O
< S>
SCSA
I/O
<R>
I/O
SCSA
Turbine Protection with YSIL and YTUR or PTUR
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The backup protection system monitors up to nine (9) passive magnetic speed pickups, which enable inputs for up to three (3)
sets of three (3) redundant speed sensors from HP, IP, and LP shafts. It also supports interface for up to ten (10) Rueter-Stokes
flame detectors with 4-20 mA inputs or eight (8) inputs from Honeywell flame detectors with 335 V dc wetting.
Backup trip protection I/O includes:
•
•
•
One E-Stop input (TCSA)
Nine trip solenoid outputs (TCSA)
Two TMR-voted drive contact outputs (TCSA)
For synchronizing, YSIL monitors two (2) single-phase PT inputs for the generator and line busses, and performs phase-lock
loop calculations for the K25A backup synch check function. Since the tuning constants are adjustable, limit checks are
provided to verify:
•
•
•
•
•
Generator under-voltage
Bus under-voltage
Voltage error
Frequency error (slip)
Phase error
The synch check arms logic to enable the function, and provides bypass logic for dead-bus breaker closure scenarios.
Calculations for the primary phase-slip window are performed in the YTUR I/O packs and are independent of the backup
protection with separate PT inputs and a different methodology (zero voltage crossing to calculate phase, slip, and
acceleration). Different methodologies provide a more robust backup protection system to the primary synchronizing
calculations.
Additional inputs are available for general-purpose use including:
•
•
•
24, 48, 125 V dc contact inputs with optical isolation (TCSA and SCSA)
− Sequence of Events (SOEs), 1 ms time stamps
4-20 mA inputs for loop powered differential inputs and single-end inputs with +24 V dc sensor power provided. Support
for HART® communications is provided (SCSA).
Thermocouple inputs (SCSA)
YSIL Core Safety Protection Module
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YSIL I/O Types
† Configuration
Board
I/O Type
Quantity
TCSA
E-Stop Input
1
Fanned
TCSA
Solenoid Contact Outputs
9
3 Fanned
6 Discrete
TCSA
Voted Contact Outputs
2
Fanned
TCSA
PT Inputs
2
Fanned
TCSA + WCSA
Contact Inputs
20
Fanned
TCSA
Speed Inputs
9
Discrete
TCSA
Honeywell Flame Detectors
8
Fanned
WCSA
GE Flame Detectors
or
Analog Inputs
10
Fanned
WCSA
Speed Repeater Outputs
6
Discrete
SCSA
Contact Inputs
3 / SCSA
Discrete
SCSA
Contact Outputs
2 / SCSA
Discrete
SCSA
Externally Powered Analog Inputs
6 / SCSA
Discrete
SCSA
Loop Powered Analog Inputs
10 / SCSA
Discrete
SCSA
Thermocouple Inputs
3 / SCSA
Discrete
† Fanned Inputs: a field device signal is distributed in parallel to the three protection sections.
Fanned Outputs: output signals from the three protection sections are voted to create a singular field output.
Discrete Inputs: each signal from three field devices is connected to each of three protection sections.
Discrete Outputs: each signal from three protection sections is connected to each of three field devices.
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12.2
Mark VIeS YSIL Core Protection I/O Pack
The Core Safety Protection YSIL I/O pack and associated terminal boards provide an
independent backup overspeed protection system with a backup check for generator
synchronization to a utility bus. They also provide an independent watchdog function
for the primary control. The YSIL has Ethernet connections for IONet communications
with the control modules. This backup protection system consists of three TMR YSIL
I/O packs mounted to one TCSA terminal board with serial cables from the WCSA
connected to the three SCSA I/O expansion boards.
The YSIL I/O pack accepts three speed signals. It monitors the operation of the primary
control, and can monitor the primary speed as a sign of normal operation. The I/O pack
monitors the status and operation of the trip board through a comprehensive set of
feedback signals. If a problem is detected, YSIL activates the backup trip relays on the
trip board and activates a trip on the primary control. YSIL can drop out power to the
backup side of the trip relays. It can also send a cross trip signal to the primary
protection system.
The following redundancy options are supported:
•
•
Triple Main Control with TMR backup protection, two out of three (2oo3), is
supported. Connect the first YSIL I/O pack to the R IONet, the second to the S
IONet, and the third to the T IONet.
Dual Main Control with TMR backup protection is supported. Connect the first
YSIL I/O pack to the R IONet, the second to the S IONet, and the third to the R and
S IONets.
S CS
A I/
TCSA Main Board
+
WCSA Daughter Board
OE
xpa
nsio
n Bo
ar d
s
YSIL Backup Protection System
YSIL Core Safety Protection Module
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12.2.1
Installation
Three YSIL I/O packs mount directly on the TCSA terminal board. Connect the WCSA to the three SCSA I/O expansion
boards with shielded Cat 6 patch cords plugged into the RJ-45 jacks.
➢ To install the YSIL module
1.
Securely mount the TCSA terminal board.
2.
Mount the three SCSA boards, and connect the shielded Cat 6 patch cords between them and the WCSA daughter board.
For the serial cables, use shielded Cat 6 with a length not more than 2 meters.
3.
Directly plug all three I/O packs into the J-ports on the TCSA.
4.
Slide the threaded posts on the I/O packs (located on each side of the Ethernet ports) into the slots on the terminal
board-mounting bracket.
5.
Securely tighten the nuts on the threaded posts locking the I/O pack in place.
6.
Connect each YSIL I/O pack Ethernet port to the IONet with shielded Cat 6 patch cords based on network redundancy.
7.
Refer to the TCSA and SCSA installation sections of this document for field wiring instructions.
8.
Connect P1 on each YSIL I/O pack and SCSA module to the appropriate 28 V dc power supply and apply power. Each
one has inherent soft-start capability that permits plugging into a live 28 V dc power supply without affecting the rest of
the system.
9.
Use the ToolboxST* application to configure the I/O pack as necessary.
12.2.2
Operation
Refer to the following sections in the GEH-6721_Vol_II, the chapter, Common Module Content:
•
•
•
•
•
630
BPPx Processor
Processor LEDs
Power Management
ID Line
Common Safety Module Alarms
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12.2.2.1
Application-specific Hardware
The YSIL I/O pack has an internal, application-specific circuit board (BPRO) that contains hardware needed for the backup
trip function. This application board connects to the BPPC processor.
Pulse Rate
Input
Conditioning
ID Chip
PT Input
BPPC
Processor
Digital Signal
Inputs, E-Stop
Isolated
Contact Inputs
Connect
to TCSA
Relay
Command
Outputs
BPPC
Processor
Local Power
Supplies
Pass Through to
Option
Option Header
BPRO Application Board
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12.2.2.2
Protective Functions
The YSIL contains several protective functions that are similar or identical to the PPRO Backup Turbine Protection I/O pack.
Refer to the section Mark VIe PPRO Backup Turbine Protection I/O Pack for details about the following protective functions:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Direct/Conditional Discrete Input Trip
Firmware Overspeed Trip (including Rate Based Overspeed)
Hardware Overspeed Trip
LP Shaft Locked Detection
E-Stop
Speed Difference Detection
Maximum Speed Hold
Overspeed Test Logic
Shaft Speed Accel, Decel, and Zero
Trip Anticipate Function
Main Control Watchdog
Stale Speed Detection
Main Control Ethernet Monitor
Trip Signal Logic
Watchdog Trip Function
Backup Synchronizing Check
K25A Sync Check Function
12.2.2.3
•
•
•
•
Connectors
A DC-62 pin connector on the YSIL I/O pack connects directly to the TCSA terminal board.
An RJ-45 Ethernet connector named ENET1 on the side of the I/O pack is the primary IONet interface port.
The second RJ-45 Ethernet connector named ENET2 on the side of the I/O pack only used to interface a second
redundant IONet for Dual Main Control configurations.
The 3-pin P1 power connector on the side of the I/O pack is for supplying power to the I/O pack and TCSA and WCSA
terminal boards. Each YSIL module requires a power supply of 28 V dc, 1 A.
Note Solenoid output and contact input circuits are powered through a separate terminal board connector, not from the I/O
pack 28 V dc power source.
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12.2.3
YSIL I/O Pack Specifications
Feature
Description
Speed Input Quantity
Three input signals provided
Speed Input Range
Pulse rate frequency range 2 Hz to 20 kHz
Speed Input Accuracy
Pulse rate accuracy 0.05% of reading
Speed Input Sensitivity
2 to 2000 Hz, 25 mV pk
20 kHz, 300 mV pk
Scan rate
1200 Hz
Size
8.26 cm High x 4.19 cm Wide x 12.1 cm x Deep (3.25 in. x 1.65 in. x 4.78 in.)
Relative humidity
5 to 95% non-condensing
Micro-environment
Pollution Degree 2
†Rated local ambient operating
-30 to 65ºC (-22 to 149 ºF)
temperature (for enclosure design)
Shipping and Storage Temperature
-40 to 85ºC (-40 to 185 ºF)
Vibration, seismic
Universal Building Code (UBC) – Seismic Code section 2312 Zone 4 with operation without trip
Vibration, shipping
Bellcore GR-63-CORE Issue 1, 1995 0.5 g, 5-100 Hz, 10 min. per octave,
1 sweep/axis x 3 axes, ~ 42 min./axis
3 shocks of 15 g, 2 ms impulse each repeated for all axes
Vibration, operating
1.0 g horizontal. 0.5 g vertical at 15 to 120 Hz, IEC 60721-3-2
Power supply
28 V dc, 1 A dc
Safety standards
UL 508 Safety Standard Industrial Control Equipment
CSA 22.2 No. 14 Industrial Control Equipment
EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use
IEC 61508:2010 parts 1-7 Functional Safety of Electrical/Electronic/Programmable Electronic
Safety-Related Systems
Printed Wire Board Assemblies
UL 796 PWB Components Recognition
ANSI/IPC/EIA guidelines
Electromagnetic Compatibility (EMC)
EN 61000-4-2 Electrostatic Discharge Susceptibility
EN 61000-4-3 (ENV 50140) Radiated RF Immunity
EN 61000-6-2 Generic Immunity Industrial Environment
EN 61000-4-4 Electrical Fast Transient Susceptibility
EN 61000-4-5 Surge Immunity
EN 61000-4-6 Conducted RF Immunity
EN 55011 Radiated and Conducted RF Emissions
ANSI/IEEE C37.90.1 Surge
Note † For further details, refer to the Mark VIe and Mark VIeS Control Systems System Guide, Volume I (GEH-6721_Vol_
I), the chapter Technical Regulations, Standards, and Environments.
YSIL Core Safety Protection Module
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12.2.4
Diagnostics
The YSIL module performs the following self-diagnostic tests:
•
•
•
•
•
A power-up self-test that includes checks of RAM, flash memory, Ethernet ports, and most of the processor board
hardware
Continuous monitoring of the internal power supplies for correct operation
A check of the analog feedback currents
A comparison between the commanded state of each relay drive and the feedback from the commanded output circuit
A check of the electronic ID information from the terminal board, acquisition board, and processor board to confirm that
the hardware set matches, followed by a check that the application code loaded from flash memory is correct for the
hardware set
Note Details of the individual diagnostics are available from the ToolboxST application. The diagnostic signals can be
individually latched, and then reset with the RESET_DIA signal if they go healthy.
Trip Status LEDs
During normal I/O pack operation, all six trip application LEDs display green. An additional feature, rotating LEDs, can be
configured for the I/O pack. Using this feature, only one LED is turned on at a time, and walked up and down the six LEDs
creating a synchronized motion. The walking is regulated by the controller IONet, and synchronized across a set of three I/O
packs. This provides a quick visual indication of the system time synchronization status. There are six LEDs on the front left
side of the I/O pack to indicate trip status. All six LEDs stay off until the I/O pack is completely online.
RUN is green any time the I/O pack has energized the emergency trip relays. RUN turns red any time the I/O pack has
removed power from the emergency trip relays, voting to trip.
ESTP is green when the ESTOP input (if applicable) is in the run state. ESTP turns red any time ESTOP is invoked to
prevent pick up of the emergency trip relays. If the selected trip terminal board does not support ESTOP, then the LED
defaults to green.
OSPD turns red any time the I/O pack votes to trip in response to a detected overspeed condition on any of the three speed
inputs. OSPD is green when an overspeed condition is not present or latched.
WDOG is green when the trip status of all features is cleared. WDOG turns red when any of the following I/O pack trip
functions are enabled and active:
•
•
•
•
Control Watchdog
Speed Difference Detection
Stale Speed Detection
Frame Sync Monitor
SYNC is green when generator and bus voltage is synchronized and matched in amplitude. SYNC turns red when the I/O
pack determines that ac bus and generator bus voltage does not satisfy the synchronization requirements, and synchronization
has been requested by the system.
OPT is used for Composite Analog Trip status. If an SCSA Analog Trip is asserted, this LED will be red. When the trip is
reset, this LED will be green.
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12.2.5
YSIL Configuration
12.2.5.1
Parameters
Default values are in blue.
Name
Value
2Shafts_3Sensors
PRGrouping
3Shafts_2Sensors
3Shafts_3Sensors
LMTripZEnabl
TA_Trp_Enab1
TA_Trp_Enab2
TA_Trp_Enab3
SpeedDifEn
StaleSpdEn
No_T_PS_Req
RotateLeds
LedDiags
TemperatureUnits
SystemFreq
Enable
Disable
Enable
Disable
Enable
Disable
Enable
Disable
Enable
Disable
Enable
Disable
Enable
Disable
Enable
Disable
Enable
Disable
°C
°F
50Hz
60Hz
Description
Select grouping of speed inputs: 2 Shafts (3 speed sensors/shaft), 3 shafts (2
speed sensors/shaft), 3 shafts (3 speed sensors/shaft)
On LM machine, when no PR on Z, Enable a vote for Trip
Steam, Enable Trip Anticipate on ETR1
Steam, Enable Trip Anticipate on ETR2
Steam, Enable Trip Anticipate on ETR3
Enable Trip on Speed Difference between Controller & YSIL
Enable Trip on Speed from Controller Freezing
No Flame Detect Power Supply required for T
Rotate the Status LEDs if all status are OK
Generate diag alarm when LED status lit
Used for SCSA Thermocouples and Cold Junctions
System frequency in Hz
Unused
GT_1Shaft
GT_2Shaft
LargeSteam
TurbineType
LM_2Shaft
LM_3Shaft
Turbine Type and Trip Solenoid Configuration
MediumSteam
SmallSteam
Stag_GT_1Sh
Stag_GT_2Sh
RatedRPM_TA
3600 is default
AccelCalType
70 is default
Select Acceleration Calculation Time (msec)
5.0 is default
Absolute Speed Difference in Percent For Trip Threshold
OS_Diff
AMS_Mux_Scans_Permitted
Enable
Disable
Rated RPM, used for Trip Anticipater and for Speed Diff Protection
AMS mulitplexer scans for command 1 and 2 are allowed (command 3 always
allowed). Refer to the section Asset Management System Tunnel Command for
Min_MA_Input
3.8 is default
more information.
Minimum mA for Healthy 4–20 mA Input
Max_MA_Input
20.5 is default
Maximum mA for Healthy 4–20 mA Input
125V
Excitation_Volt
24V
48V
RBOS1_Enab
Disable, Enable
Contact Input Excitation (wetting) Voltage (SCSA and TCSA must use the same
voltage level)
HP Rate-based Overspeed enable
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 635
Non-Public Information
Name
† RBOS1_AccelSetptn, n=1-5
Value
Description
0 to 20,000
HP Rate-based Overspeed acceleration setpoint n, RPM/s
† RBOS1_OSSetptn, n=1-5
0 to 20,000
HP Rate-based Overspeed setpoint n, RPM
RBOS2_Enab
Disable, Enable
LP Rate-based Overspeed enable
† RBOS2_AccelSetptn, n=1-5
0 to 20,000
LP Rate-based Overspeed acceleration setpoint n, RPM/s
† RBOS2_OSSetptn, n=1-5
0 to 20,000
LP Rate-based Overspeed setpoint n, RPM
RBOS3_Enab
Disable, Enable
IP Rate-based Overspeed enable
† RBOS3_AccelSetptn, n=1-5
0 to 20,000
IP Rate-based Overspeed acceleration setpoint n, RPM/s
† RBOS3_OSSetptn, n=1-5
0 to 20,000
IP Rate-based Overspeed setpoint n, RPM
† RBOS setpoints have restrictions in their relative values. Refer to the section RBOS Parameter Restrictions for further details.
12.2.5.2
RBOS Parameter Restrictions
The following restrictions apply to the relative values of RBOS setpoints (within a given shaft):
1.
RBOS#_AccelSetpts must increase in value by at least 0.1 RPM/s (RBOS1_AccelSetpt2 must be 0.1 RPM/s or greater
than RBOS1_AccelSetpt1). This prevents an infinite slope calculation in the overspeed setpoint profile.
2.
RBOS#_OSSetpts must be either equal to or less than the previous entry (RBOS1_OSSetpt2 must be less than or equal to
RBOS1_OSSetpt1). This ensures the functionality of the RBOS feature in that as Acceleration increases the RBOS
overspeed setpoint either stays the same or decreases, but never increases.
These restrictions are enforced by the build in ToolboxST, with errors that provide help to the user to identify the issues in
their configuration.
636
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12.2.5.3
Variables
Name
Direction
Data Type
Variable Description
L3DIAG_YSIL_R, S, or T
Input
BOOL
I/O Diagnostic Indication
LINK_OK_YSIL_R, S, or T
Input
BOOL
I/O Link Okay Indication
ATTN_YSIL_R, S, or T
Input
BOOL
I/O Attention Indication
PS18V_YSIL_R, S, or T
Input
BOOL
I/O 18V Power Supply Indication
PS28V_YSIL_R, S, or T
Input
BOOL
I/O 28V Power Supply Indication
SCSA_Comm_Status_R, S, or T
Input
BOOL
SCSA Serial Communication Status
L3SS_Comm
Input
BOOL
Controller Communication Status
GT_1Shaft
Input
BOOL
Config – Gas Turb,1 Shaft Enabled
GT_2Shaft
Input
BOOL
Config – Gas Turb,2 Shaft Enabled
LM_2Shaft
Input
BOOL
Config – LM Turb,2 Shaft Enabled
LM_3Shaft
Input
BOOL
Config – LM Turb,3 Shaft Enabled
LargeSteam
Input
BOOL
Config – Large Steam, Enabled
MediumSteam
Input
BOOL
Config – Medium Steam Enabled
SmallSteam
Input
BOOL
Config – Small Steam Enabled
Stage_GT_1Sh
Input
BOOL
Config – Stage 1 Shaft, Enabled
Stage_GT_2Sh
Input
BOOL
Config – Stage 2 Shaft, Enabled
IOPackTmpr_R, S, or T
AnalogInput
REAL
IO Pack Temperature (deg F)
LockedRotorByp
Output
BOOL
LL97LR_BYP - Locked Rotor Bypass
HPZeroSpdByp
Output
BOOL
L97ZSC_BYP - HP Zero Speed Check Bypass
DriveFreq
AnalogOutput
REAL
RefrFreq - Drive (Gen) Freq (Hz), used for non standard drive
config
Can be used for zero speed logic in Dead Bus Closure of breaker
Speed1
AnalogOutput
REAL
Shaft Speed 1 in RPM
ControllerWdog
Output
DINT
Controller Watchdog Counter
CJBackup_R, S, or T
AnalogOutput
REAL
CJ Backup Value °C/°F Based on configured TemperatureUnits
CJRemote_R, S, or T
AnalogOutput
REAL
CJ Remote Value °C/°F Based on configured TemperatureUnits
TA_StptLoss
Input
BOOL
(L30TA) True if Trip Anticipate overspeed setpoint from TR_Spd_
Sp is too far from rated RPM RatedRPM_TA
12.2.5.4
Vars-Al Trip
Name
Direction
Data Type
Vars-Al Description
AnalogInput01_Trip_R, S, or T
Input
BOOL
SCSA Analog Input Trip Status
Input
BOOL
SCSA Analog Input Trip Status
↓
AnalogInput16_Trip_R, S, or T
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 637
Non-Public Information
12.2.5.5
Vars-Trip
Name
Direction
Data Type
Vars-Trip Description
WatchDog_Trip
Input
BOOL
Enhanced diag - Watch Dog trip
StaleSpeed_Trip
Input
BOOL
Enhanced diag - Stale Speed trip
SpeedDiff_Trip
Input
BOOL
Enhanced diag - Speed Difference trip
FrameMon_Flt
Input
BOOL
Enhanced diag - Frame Monitor Fault
OverSpd1_Trip
Input
BOOL
L12HP_TP - HP overspeed trip
OverSpd2_Trip
Input
BOOL
L12LP_TP - LP overspeed trip
OverSpd3_Trip
Input
BOOL
L12IP_TP - IP overspeed trip
Decel1_Trip
Input
BOOL
L12HP_DEC - HP de-acceleration trip
Decel2_Trip
Input
BOOL
L12LP_DEC - LP de-acceleration trip
Decel3_Trip
Input
BOOL
L12IP_DEC - IP de-acceleration trip
Accel1_Trip
Input
BOOL
L12HP_ACC - HP acceleration trip
Accel2_Trip
Input
BOOL
L12LP_ACC - LP acceleration trip
Accel3_Trip
Input
BOOL
L12IP_ACC - IP acceleration trip
HW_OverSpd1_Trip
Input
BOOL
L12HP_HTP - HP Hardware detected overspeed trip
HW_OverSpd2_Trip
Input
BOOL
L12LP_HTP - LP Hardware detected overspeed trip
HW_OverSpd3_Trip
Input
BOOL
L12IP_HTP - IP Hardware detected overspeed trip
TA_Trip
Input
BOOL
Trip Anticipate Trip,L12TA_TP
TSCA_Contact01_Trip
Input
BOOL
Contact Trip (L5Cont01_Trip)
TSCA_Contact20_Trip
Input
BOOL
Contact Trip (L5Cont20_Trip)
LPShaftLock
Input
BOOL
LP Shaft Locked
PR1_Zero
Input
BOOL
L14HP_ZE - HP shaft at zero speed
PR2_Zero
Input
BOOL
L14LP_ZE - LP shaft at zero speed
PR3_Zero
Input
BOOL
L14IP_ZE - IP shaft at zero speed
CompositeAnalog_Trip
Input
BOOL
Composite Analog Trip Status
CompositeTrip
Input
BOOL
Composite Trip Status
Estop_Trip
Input
BOOL
ESTOP Trip (L5ESTOP1)
Config1_Trip
Input
BOOL
HP Config Trip(L5CFG1_Trip)
Config2_Trip
Input
BOOL
LP Config Trip(L5CFG2_Trip)
Config3_Trip
Input
BOOL
IP Config Trip(L5CFG3_Trip)
Cross_Trip
Output
BOOL
L4Z_XTRP - Control Cross Trip
↓
638
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12.2.5.6
Vars-Flame
Name
Direction
Data Type
Vars-Flame Description
FlameDetPwrStat
Input
BOOL
335 V dc status
FD1_Flame
Input
BOOL
Flame Detect present
FD8_Flame
Input
BOOL
Flame Detect present
FD1_Level
Output
BOOL
1 = High Detection Cnts Level
Output
BOOL
1 = High Detection Cnts Level
↓
↓
FD8_Level
12.2.5.7
Vars-Contacts
Name
Direction
Data Type
Description
Input
BOOL
Config – Contact Trip Enabled – Direct
TCSA_Contact01_TripEnab
↓
TCSA_Contact20_TripEnab
12.2.5.8
Vars-Speed
Name
Direction
Data Type
Vars-Speed Description
Accel1_TrEnab
Input
BOOL
Config – Accel 1 Trip Enabled
Accel2_TrEnab
Input
BOOL
Config – Accel 2 Trip Enabled
Accel3_TrEnab
Input
BOOL
Config – Accel 3 Trip Enabled
HW_OverSpd1_Setpt_Pend
Input
BOOL
Hardware HP overspeed setpoint changed after power up
HW_OverSpd2_Setpt_Pend
Input
BOOL
Hardware LP overspeed setpoint changed after power up
HW_OverSpd3_Setpt_Pend
Input
BOOL
Hardware IP overspeed setpoint changed after power up
HW_OverSpd1_Setpt_CfgErr
Input
BOOL
Hardware HP Overspd Setpoint Config Mismatch Error
HW_OverSpd2_Setpt_CfgErr
Input
BOOL
Hardware LP Overspd Setpoint Config Mismatch Error
HW_OverSpd3_Setpt_CfgErr
Input
BOOL
Hardware IP Overspd Setpoint Config Mismatch Error
OverSpd1_Setpt_CfgErr
Input
BOOL
HP Overspd Setpoint Config Mismatch Error
OverSpd2_Setpt_CfgErr
Input
BOOL
LP Overspd Setpoint Config Mismatch Error
OverSpd3_Setpt_CfgErr
Input
BOOL
IP Overspd Setpoint Config Mismatch Error
RBOS1_TestEnable
Output
BOOL
Enable Test Mode for RBOS feature for HP.
RBOS1_Accel_Test will be used as Accel input to RBOS.
RBOS2_TestEnable
Output
BOOL
Enable Test Mode for RBOS feature for LP.
RBOS2_Accel_Test will be used as Accel input to RBOS.
RBOS3_TestEnable
Output
BOOL
Enable Test Mode for RBOS feature for IP.
RBOS3_Accel_Test will be used as Accel input to RBOS.
PR1_Accel
AnalogInput
REAL
HP Accel in RPM/SEC
PR2_Accel
AnalogInput
REAL
LP Accel in RPM/SEC
PR3_Accel
AnalogInput
REAL
PR1_Max
AnalogInput
REAL
IP Accel in RPM/SEC
HP Max Speed since last Zero Speed in RPM
PR2_Max
AnalogInput
REAL
LP Max Speed since last Zero Speed in RPM
PR3_Max
AnalogInput
REAL
IP Max Speed since last Zero Speed in RPM
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 639
Non-Public Information
Name
Direction
Data Type
Vars-Speed Description
PR1_Spd
AnalogInput
REAL
PR1 - Speed sensor 1 (1A if three or two groups, see
PRGrouping parameter)
PR2_Spd
AnalogInput
REAL
PR2 - Speed sensor 2 (2A if three groups, 1B if two groups,
see PRGrouping parameter)
PR3_Spd
AnalogInput
REAL
PR3 - Speed sensor 3 (3A if three groups, 2A if two groups,
see PRGrouping parameter)
PR4_Spd
AnalogInput
REAL
PR4 - Speed sensor 4 (1B if three groups, 1C if two groups,
see PRGrouping parameter)
PR5_Spd
AnalogInput
REAL
PR5 - Speed sensor 5 (2B if three or two groups, see
PRGrouping parameter)
PR6_Spd
AnalogInput
REAL
PR6 - Speed sensor 6 (3B if three groups, 2C if two groups,
see PRGrouping parameter)
OS1_Setpoint_Fbk
AnalogInput
REAL
Current firmware overspeed setpoint for HP shaft in RPM
OS2_Setpoint_Fbk
AnalogInput
REAL
Current firmware overspeed setpoint for LP shaft in RPM
OS3_Setpoint_Fbk
AnalogInput
REAL
Current firmware overspeed setpoint for IP shaft in RPM
OverSpd1_Test_OnLine
Output
BOOL
L97HP_TST1 - OnLine HP Overspeed Test
OverSpd2_Test_OnLine
Output
BOOL
L97LP_TST1 - OnLine LP Overspeed Test
OverSpd3_Test_OnLine
Output
BOOL
L97IP_TST1 - OnLine IP Overspeed Test
OverSpd1_Test_OffLine
Output
BOOL
L97HP_TST2 - OffLine HP Overspeed Test
OverSpd2_Test_OffLine
Output
BOOL
L97LP_TST2 - OffLine LP Overspeed Test
OverSpd3_Test_OffLine
Output
BOOL
L97IP_TST2 - OffLine IP Overspeed Test
TripAnticipateTest
Output
BOOL
L97A_TST - Trip Anticipate Test
PR_Max_Reset
Output
BOOL
Max Speed Reset
OnLineOverSpd1X
Output
BOOL
OverSpd1_Setpt
AnalogOutput
REAL
L43EOST_ONL - On Line HP Overspeed Test,with auto
reset
HP Overspeed Setpoint in RPM
OverSpd2_Setpt
AnalogOutput
REAL
LP Overspeed Setpoint in RPM
OverSpd3_Setpt
AnalogOutput
REAL
IP Overspeed Setpoint in RPM
OverSpd1_TATrip_Setpt
AnalogOutput
REAL
PR1 Overspeed Trip Setpoint in RPM for Trip Anticipate Fn
HWOverSpd_Setpt1
AnalogOutput
REAL
HP Hardware Overspeed Setpoint in RPM
HWOverSpd_Setpt2
AnalogOutput
REAL
LP Hardware Overspeed Setpoint in RPM
HWOverSpd_Setpt3
AnalogOutput
REAL
IP Hardware Overspeed Setpoint in RPM
RBOS1_Accel_Test
AnalogOutput
REAL
Test Accel signal for RBOS feature for HP shaft, RPM/s
RBOS2_Accel_Test
AnalogOutput
REAL
Test Accel signal for RBOS feature for LP shaft, RPM/s
RBOS3_Accel_Test
AnalogOutput
REAL
Test Accel signal for RBOS feature for IP shaft, RPM/s
Repeater1
Input
BOOL
Speed Repeater Fault Status
Input
BOOL
Speed Repeater Fault Status
↓
Repeater6
640
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12.2.5.9
Vars-Relay
The following are the contact feedbacks for the electromechanical safety relays. They must be closed (feedback True) for
current to flow in the ETRs.
Contact Feedbacks
Name
Direction
Data Type
Description
Mech1_Fdbk
Input
BOOL
Mechanical relay feedback, controls group 1 (K1–3)
Mech2_Fdbk
Input
BOOL
Mechanical relay feedback, controls group 2 (K4–6)
Mech3_Fdbk
Input
BOOL
Mechanical relay feedback, controls group 3 (K7–9)
The following are the Output Bits, which can be used to open ETR Relays. They are only available when the ETRs are
configured as Used and TripMode configuration as Enable (from the ETR Relay tab).
Output Bits
Name
Direction
Data Type
Description
ETR1_Open
Output
BOOL
ETR1 Open Command, True de-energizes relay
ETR2_Open
Output
BOOL
ETR2 Open Command, True de-energizes relay
ETR3_Open
Output
BOOL
ETR3 Open Command, True de-energizes relay
ETR4_Open
Output
BOOL
ETR4 Open Command, True de-energizes relay
ETR5_Open
Output
BOOL
ETR5 Open Command, True de-energizes relay
ETR6_Open
Output
BOOL
ETR6 Open Command, True de-energizes relay
ETR7_Open
Output
BOOL
ETR7 Open Command, True de-energizes relay
ETR8_Open
Output
BOOL
ETR8 Open Command, True de-energizes relay
ETR9_Open
Output
BOOL
ETR9 Open Command, True de-energizes relay
Note When the relay outputs are configured as TripMode Disable, the associated mechanical relay will pick up when any
of the three solid state relays pick up within that group, and drops when all the solid state relays are False in that group.
12.2.5.10 Vars-Sync
Name
Direction
Data Type
Vars-Sync Description
GenFreq
AnalogInput
REAL
DF2 hz
BusFreq
AnalogInput
REAL
SFL2 hz
GenVoltsDiff
AnalogInput
REAL
DV_ERR KiloVolts rms - Gen Low is Negative
GenFreqDiff
AnalogInput
REAL
SFDIFF2 Slip hz - Gen Slow is Negative
GenPhaseDiff
AnalogInput
REAL
SSDIFF2 Phase degrees - Gen Lag is Negative
SyncCheck_Enab
Output
BOOL
L25A_PERM - Sync Check Permissive
SyncCheck_ByPass
Output
BOOL
L25A_BYPASS - Sync Check ByPass
Used for dead bus breaker closure feature
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 641
Non-Public Information
12.2.5.11 TSCA Contacts
Default values are in blue.
Name
Direction
Data Type
TCSA_Contact01
↓
Description
ContactInput
SeqOfEvents
DiagVoteEnab
TripMode
Used
Enable
Enable
Disable
Unused
Disable
Disable
Enable
Contact Input 1
Input
BOOL
TCSA_Contact20
↓
Contact Input 20
12.2.5.12 EStop
Default values are in blue.
Name
Direction
Data Type
Description
DiagVoteEnab
ESTOP_Fdbk
Input
BOOL
ESTOP, inverse sense, True = Run
Enable
Disable
12.2.5.13 ETR Relay
Default values are in blue.
Name
Direction
Data Type
Description
RelayOutput
TripMode
†
K4
Output
BOOL
K4 Relay Ouput, Emergency Trip Relay when Trip
Mode Enabled
Enable
Disable ‡
K5
Output
BOOL
K5 Relay Ouput, Emergency Trip Relay when K4
Trip Mode Enabled
N/A
K6
Output
BOOL
K6 Relay Ouput, Emergency Trip Relay when K4
Trip Mode Enabled
N/A
K7
Output
BOOL
K7 Relay Ouput, Emergency Trip Relay when Trip
Mode Enabled
K8
Output
BOOL
K8 Relay Ouput, Emergency Trip Relay when K7
Trip Mode Enabled
N/A
K9
Output
BOOL
K9 Relay Ouput, Emergency Trip Relay when K7
Trip Mode Enabled
N/A
Used
Unused
Enable
Disable ‡
Note † TripMode on ETR Relay can only be selected in groups. K4-K6 are in one group, and K7-K9 are in another group.
Note ‡ When the relay outputs are configured as TripMode Disable, the associated mechanical relay will pick up when any
of the three solid state relays pick up within that group, and drops when all the solid state relays are False in that group.
642
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12.2.5.14 ETR Fdbk
Default values are in blue.
Name
Direction
Data Type
Description
K1_Fdbk
Input
BOOL
Trip Relay Feedback
K2_Fdbk
Input
BOOL
Trip Relay Feedback
K3_Fdbk
Input
BOOL
Trip Relay Feedback
K4_Fdbk
Input
BOOL
Normal / Trip Relay Feedback
K5_Fdbk
Input
BOOL
Normal / Trip Relay Feedback
K6_Fdbk
Input
BOOL
Normal / Trip Relay Feedback
K7_Fdbk
Input
BOOL
Normal / Trip Relay Feedback
K8_Fdbk
Input
BOOL
Normal / Trip Relay Feedback
K9_Fdbk
Input
BOOL
Normal / Trip Relay Feedback
SeqOfEvents
DiagVoteEnab
Enable
Disable
Enable
Disable
12.2.5.15 TSCA Relay
Default values are in blue.
Name
Direction
Data
Type
Description
TCSA_Relay01
Output
BOOL
Under control of SyncCheck if
RelayOutput
Output_State
Output_Value
SyncCheck is configured for
Relay01
TCSA_Relay02
Output
BOOL
HoldLastVal
Used
Under control of SyncCheck if
Output_Value
Unused
PwrDownMode
On
Off
SyncCheck is configured for
Relay02
12.2.5.16 TCSA Relay Fdbk
Default values are in blue.
Name
Direction
Data
Type
Description
SeqOfEvents
DiagVoteEnab
TCSA_Relay01Fdbk
Input
BOOL
Relay Feedback
Enable
Enable
TCSA_Relay02Fdbk
Input
BOOL
Relay Feedback
Disable
Disable
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 643
Non-Public Information
12.2.5.17 K25A
Default values are in blue.
Name
Direction
Data Type
Description
SynchCheck
DiagVoteEnab
K25A_Cmd_Status
Input
BOOL
Synch Check Relay
Relay01
Disable
Relay02
Enable
Unused
GenFreqSource
TurbRPM
VoltageDiff
FreqDiff
PhaseDiff
GenVoltage
BusVoltage
PR_Std
Default is
Default is 2.8
Default is
Default is
Default is 6.9
Default is 6.9
SgSpace
3600
0.30
10.0
Description
PRType
PRScale
Unused
12.2.5.18 Pulse Rate
Default values are in blue.
Name
Direction
Data
HwOverSpd_Setpt
OverSpd_Setpt
Default is 0
Default is 0
Type
PulseRate1
AnalogInput
REAL
HP speed
PulseRate2
AnalogInput
REAL
LP speed
PulseRate3
AnalogInput
REAL
IP speed
Speed
Default is
Speed_High
60
Speed_LM
OverSpd_Test_Delta
Zero_Speed
Min_Speed
Default is 0
Default is 0
Default is 0
Accel_Trip
Enable
Disable
Accel_Setpt
TMR_DiffLimt
Default is 0
Default is 5
Dual_DiffLimit
Default is 25
12.2.5.19 PT Inputs
The following PT inputs on the TCSA are fanned, single phase (75 to 130 V rms).
Name
Direction
Data
Type
Description
GenPT_KVolts
AnalogInput
REAL
Kilo-Volts RMS (Active only if
PT_Input
PT_Output
TMR_DiffLimt
Default is 13.8
Default is 115
Default is 1
K25A is Enabled)
BusPT_KVolts
AnalogInput
REAL
Kilo-Volts RMS (Active only if
K25A is Enabled)
644
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12.2.5.20 TCSA Analog Inputs
Default values are in blue.
Name
Direction
Data Type
Description
Input
Low_Input
Low_Value
AnalogInput
REAL
Flame Analog Input
Used
Unused
Default is 4
Default is 0
High_Input
High_Value
InputFilter
DiagHighEnab
DiagLowEnab
TMR_DiffLimt
Default is 20
Default is 100
Used
Unused
Enable
Disable
Enable
Disable
Default is 5
FlameAnalogInput01
↓
FlameAnalogInput10
12.2.5.21 Flame
Name
Direction
Data Type
Description
FlmDetTime
REAL
Flame Intensity
(Hz)
0.040sec
0.080sec
0.160sec
FlameInd1
↓
AnalogInput
FlameInd8
FlameLimitHi
FlameLimitLow
Flame_Det
TMR_DiffLimt
Default is 5
Default is 3
Used
Unused
Default is 5
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 645
Non-Public Information
12.2.5.22 SCSA Analog Inputs
Default values are in blue.
Name
Data Type
Description
AnalogInput01_
REAL
4–20 mA
Input
Low_Input
Low_Value
High_Input
High_Value
InputFilter
Default is 4
Default is 0
Default is 20
Default is 100
0.75hz
R, S, or T
1.5hz
4–20ma
↓
3hz
Unused
AnalogInput16_
REAL
4–20 mA
6hz
Default is 4
Default is 0
Default is 20
R, S, or T
646
12hz
Unused
DiagHighEnab
DiagLowEnab
TripEnab
TripSetPoint
TripDelay
HART_Enable
Enable
Enable
Default is 0
Default is 100
Enable
Disable
Disable
(milliseconds)
Disable
GEH-6721_Vol_III_BJ
Default is 100
HART_MfglD
HART_DevType
HART_DevID
Default is 0
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12.2.5.23 SCSA Thermocouple Inputs
Default values are in blue.
Name
Type
Thermocouple01_R, S, or T
Unused
Thermocouple02_R, S, or T
Thermocouple03_R, S, or T
ReportOpenTC
Type_J
Fail_Hot
Type_K
Fail_Cold
Type_S
ReportOpenTC sets the failed state of an open
Type_T
thermocouple to either hot (high) or cold (low). This does
Type_E
not apply when Type = mV.
mV
12.2.5.24 SCSA Cold Junction
Default values are in blue.
Name
Direction
Data
Type
Description
ColdJuncType
ColdJunction_R, S, or T
AnalogInput
REAL
Cold Junction for TCs 1 to 3
Local
Remote
12.2.5.25 SCSA Relay
Default values are in blue.
Name
Direction
Data Type
SCSA_Relay01_
R, S, or T
Output
BOOL
SCSA_Relay02_
R, S, or T
Output
BOOL
RelayOutput
Output_State
Output_Value
Used
Unused
HoldLastVal
Output_Value
PwrDownMode
On
Off
12.2.5.26 SCSA Relay Fdbk
Name
Direction
Data Type
Description
SCSA_Relay01Fdbk_R, S, or T
Input
BOOL
Relay Feedback
SCSA_Relay02Fdbk_R, S, or T
Input
BOOL
Relay Feedback
12.2.5.27 SCSA Contacts
Default values are in blue.
Name
Direction
Data Type
Description
SCSA_Contact01_
R, S, or T
Input
BOOL
Contact Input
Used
Unused
↓
SCSA_Contact03_
R, S, or T
ContactInput
Input
BOOL
Contact Input
YSIL Core Safety Protection Module
SignalInvert
SignalFilter
Invert
Normal
100ms
10ms
20ms
50ms
Unfiltered
GEH-6721_Vol_III_BJ System Guide 647
Non-Public Information
12.2.6
Asset Management System Tunnel Command
The Asset Management System (AMS) scans the HART-enabled field devices to determine health. This scan command
decision is made in the AMS (not the I/O pack). The AMS can send scan commands over channels 1, 2, or 3. The YSIL I/O
pack (or if using PHRA/YHRA) can be configured to either only allow for the scan command to occur on the default channel
3 or it can allow these scan commands to occur on any of the three channels (as determined by the AMS). By changing the
parameter, AMS_Mux_Scans_Permitted to Enable (it is disabled by default), the I/O pack will accept a change from channel
3 (which is the default channel).
From the perspective of the AMS, the multiplexer is the I/O pack (YSIL, YHRA, or PHRA). † In electronics, a multiplexer (or
mux) is a device that selects one of several analog or digital input signals and forwards the selected input into a single line.
Note † Retrieved Nov 13, 2014 from http://en.wikipedia.org/wiki/Multiplexer
HMI
Asset Management
System (AMS)
WorkstationST
Application
UDH
YSIL
TCSA
IONet
WCSA
Serial B us
TMR Mark VIeS
Controller Set
SCSA
HART
Field
Device
SCSA
S CSA
Tunnel command sent from AMS to
I/O pack, then I /O pack sends status
of HART field devices to AMS
Example of YSIL HART Communications
648
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12.3
YSIL Specific Alarms
The following diagnostic alarms are specific to the YSIL I/O pack.
32
Description Control Watchdog Protection Activated
Possible Cause
An alarm indicates that the variable ContWdog has not changed for five consecutive frames. The alarm clears if changes are
detected for 60 seconds.
Solution
•
•
Verify that the ContWdog is connected to the output of a DEVICE_HB block and that the block is located in a task which
is run at frame rate.
Verify that the output signal from the block is changing at least once a frame.
33
Description Speed Difference Protection Activated
Possible Cause
This alarm only occurs if the parameter SpeedDifEn has been enabled. An alarm indicates that the difference between the
output signal Speed1 and the first I/O pack pulse rate speed is larger than the percentage of parameter Os_Diff for more than
three consecutive frames. The percentage is based off of the parameter RatedRPM_TA. The alarm clears if the difference is
within limits for 60 seconds for more than three consecutive frames.
Solution
Verify that the Speed1 signal is set up correctly in the ToolboxST Component Editor and that the source of the signal reflects
the primary (PTUR/YTUR) pulse rate speed.
34
Description Stale Speed Protection Activated
Possible Cause
The speed trip protection may be stale. This alarm can only occur if the parameter StaleSpdEn has been enabled. An alarm
indicates that the variable Speed1 has not changed for 100 consecutive frames. The alarm clears if the speed dithers for 60
seconds.
Solution
Verify that the Speed1 signal is set up correctly in the ToolboxST configuration, and that the source of the signal reflects the
primary (PTUR/YTUR) pulse rate speed.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 649
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35
Description Frame Sync Monitor Protection Activated
Possible Cause
This alarm indicates that the communication with the controller was lost for at least five consecutive frames after the I/O pack
was online. The alarm clears if the frame synch is established for at least 60 seconds. This indicates that the I/O pack is not
synchronized with the Mark VIeS controller start-of-frame signal.
Solution
Verify that the IONet is healthy.
36
Description Configuration changed after power up - running with old configuration
Possible Cause
SIL related configuration parameters have changed after going online. The following parameters must not change after going
online:
•
•
•
Pulse Rate tab, PRType
Pulse Rate tab, PRScale
TCSA Contacts tab, TripMode
Solution
•
•
Set the parameters to their original state and download them to the YSIL if they have been changed inadvertently.
If changes are required, cycle power from the I/O pack to get the hardware to accept the new values.
Note View the error log to determine which parameter may have changed. From the ToolboxST Component Editor Tree
View, right-click the I/O pack and select Troubleshooting–>Advanced Diagnostics–>Error log. Expand the tree menu and
double-click the error log.
37
Description [ ] SCSA Power supply unhealthy
Possible Cause The SCSA power monitor circuit detected a drop in voltage or a failed power supply.
Solution
•
•
•
650
If the PPDA is available to monitor control cabinet power, check the PPDA for active alarms.
Troubleshoot the power within the control cabinet. Begin with the power supplies and work towards the affected YSIL
module.
Replace the SCSA.
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2400-2415
Description SCSA Analog Input [ ] Unhealthy
Possible Cause
•
•
•
•
•
wetting to the transducer is wrong or missing.
The transducer may be faulty.
The analog input, current input is beyond the specified range.
There may be an open or short-circuit on the input.
Serial link to the SCSA is faulty.
Solution
•
•
•
Check the field wiring and connections to the indicated analog input channel.
Check the field device for failure.
Check the serial link connection to the SCSA.
2416-2425
Description TCSA Analog Input [ ] Unhealthy
Possible Cause
•
•
•
•
•
wetting to the transducer is wrong or missing.
The transducer may be faulty.
The current input is beyond the specified range.
There may be an open or short-circuit on the input.
WCSA daughter board is not seated properly.
Solution
•
•
•
Check the field wiring and connections to the indicated analog input channel.
Check the field device for failure.
Verify that the WCSA daughter board is seated properly.
2426-2441
Description HART Input [ ] Not Initialized
Possible Cause An enabled HART input channel does not respond.
Solution
•
•
Verify that the field device is attached to the correct I/O point.
Using a HART handheld communicator, confirm that the field device is operating correctly and communicating.
2442-2457
Description HART Input [ ] Address Mismatch
Possible Cause The device ID in the ToolboxST configuration does not match the field device.
Solution
•
•
Verify that the correct field device is connected to the I/O point.
If so, either set the three ID fields to zero, or upload the device ID from the field device.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 651
Non-Public Information
2458-2473
Description HART Input [ ] Field Device Modified
Possible Cause The configuration of the HART field device was externally modified with either an Asset Management
System (AMS) or a HART handheld communicator.
Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change and
clear the fault.
➢ To unlatch this diagnostic
1.
From the ToolboxST application, Component Editor, Software tab, navigate to the SYS_OUTPUTS block (this block
is part of the Standard or SIL block library depending on controller type).
2.
Set the RSTDIAG input BOOL to TRUE.
3.
Wait for the I/O pack diagnostics to become inactive, and then set the RSTDIAG to FALSE.
4.
From the Diagnostics tab, click Reset Alarms (as usual) to clear the alarm.
2474-2489
Description HART Input [ ] - field device not write protected in locked mode
Possible Cause The field device for this channel is not in a write-protected or secured mode while the controller is in
locked mode.
Solution Refer to the field device manual to determine how to place the device in the write-protected mode. All devices
used in a safety-protected system must be able to be placed in a read-only mode.
2490
Description HART Module Modified
Possible Cause The configuration of the HART multiplexer on the I/O pack was externally modified with either an Asset
Management System (AMS) or a HART handheld communicator.
Solution Determine what change was made and if OK, issue a system diagnostic reset to acknowledge the change and
clear the fault.
➢ To unlatch this diagnostic
1.
From the ToolboxST application, Component Editor, Software tab, navigate to the SYS_OUTPUTS block (this block
is part of the Standard or SIL block library depending on controller type).
2.
Set the RSTDIAG input BOOL to TRUE.
3.
Wait for the I/O pack diagnostics to become inactive, and then set the RSTDIAG to FALSE.
4.
From the Diagnostics tab, click Reset Alarms (as usual) to clear the alarm.
652
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2491
Description Flame Detector 335 V dc Voltage Supply Is Low
Possible Cause
•
•
The 335 V dc voltage is low, (FlameDetPwrStat is False) and any flame detector is configured as Used.
The WCSA daughter board is not seated properly.
Note The 335 V dc power required for the Honeywell flame detector is provided by the Flame Detector Power Supply
(PSFD). Refer to the ExtraCircuits tab for proper 335 V screw connections.
Solution
•
•
•
•
•
•
If no flame detector is being used, verify that all the Flame_Det parameters are set to Unused.
If only two PSFDs are being used, set the No_T_PS_Req parameter to Enable. This disables the check for power on the
HV335T connection (ExtraCircuits tab).
If the PSFD voltage is low, replace the PSFD.
Check the connections from the PSFD to the TCSA terminal board.
Check the voltage at the TCSA side. If the voltage is reading proper value, replace TCSA.
Verify that the WCSA daughter board is seated properly.
2492-2494
Description Overspeed [ ] firmware setpoint configuration error
Possible Cause There is a firmware overspeed limit mismatch between IO signal space limit and the configuration. The
current configuration file downloaded from the ToolboxST application has a different overspeed limit than the IO signal
OverSpd[ ]_Setpt.
Solution From the ToolboxST Component Editor, change the output signal designated in Vars-Speed tab,
OverSpd[ ]_Setpt to match the configuration value in Pulse Rate tab, OverSpd_Setpt.
2495-2497
Description Overspeed [ ] hardware setpoint configuration error
Possible Cause There is a hardware overspeed limit mismatch between IO signal space limit and the configuration. The
current configuration file downloaded from the ToolboxST application has a different overspeed limit than the IO signal
HWOverSpd_Setpt[ ].
Solution From the ToolboxST Component Editor, change the output signal designated in HWOverSpd_Setpt[ ] to
match the configuration value in Pulse Rate tab, HwOverSpd_Setpt.
2498-2500
Description Overspeed [ ] hardware setpoint changed after power up
Possible Cause This alarm always occurs when PulseRate[ ] HwOverSpd_Setpt is changed and downloaded to the I/O
pack after the turbine has started. It can also change if PRScale is changed to a decimal value and downloaded to the I/O
pack after the turbine has started.
Solution Confirm that the limit or scale change is correct. Restart the I/O pack to force the hardware overspeed to
re-initialize the limit.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 653
Non-Public Information
2501-2503
Description ETR [ ] local driver from hardware does not match commanded state
Possible Cause The driver output of the I/O pack for ETR relay does not match the commanded state. This indicates that
the I/O pack does not detect the relay driver feedback from the hardware.
Solution
•
•
Reboot the I/O pack.
Replace the I/O pack that has the diagnostic.
2510-2518
Description ETR [ ] voted relay driver feedback does not match commanded state
Possible Cause
•
•
Feedback from the voted ETR relay driver feedback does not match the commanded state. This indicates that the
feedback from the TCSA (for ETRs 1-3) and WSCA hardware (for ETRs 4-9) does not agree with the commanded state
sent to the hardware.
For ETR 4-9, the serial communications to WSCA could be faulty.
Solution
•
•
•
•
•
Verify I/O packs are seated properly.
Verify the WSCA is seated properly on the TSCA terminal board.
Verify that the serial cables from SCSA to WCSA are properly connected.
Replace the I/O pack that has the diagnostic.
Replace the TSCA/WSCA terminal board set.
2529
Description LED - Turbine RUN Permissives Lost
Possible Cause The RUN LED is lit red on the I/O pack because one of the RUN permissives for the turbine has been
lost. The LedDiags parameter must be set to Enable to get this alarm.
Solution
•
•
•
Verify the configuration of the LedDiags parameter.
From the Vars-Trip tab, identify the condition that caused the trip.
The trip condition must be cleared, and a master reset issued.
2530
Description LED - Overspeed Fault Detected
Possible Cause The Overspeed LED is lit on the I/O pack because of a detected Trip condition. The LedDiags
parameter must be set to Enable to get this alarm.
Solution
•
•
654
Verify the configuration of the LedDiags parameter.
The trip condition must be cleared, and a master reset issued.
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2531
Description LED - ESTOP Detected
Possible Cause The ESTOP LED is lit on the I/O pack because of a detected E-Stop signal. The LedDiags parameter
must be set to Enable to get this alarm.
Solution
•
•
Verify the configuration of the LedDiags parameter.
Remove the E-Stop condition, and issue a master reset.
2532
Description LED - Synch Fault Detected
Possible Cause The Synch LED is lit on the I/O pack because of a failure to synchronize. The LedDiags parameter
must be set to Enable to get this alarm. The K25A Relay must be enabled to support synchronization.
Solution
•
•
•
Verify the configuration of the LedDiags parameter.
Verify the K25A Relay is enabled.
Issue a master reset to clear the alarm until the next failed attempt to synchronize.
2533-2534
Description SCSA Relay [ ] Driver does not match commanded state
Possible Cause SCSA Relay driver output does not match commanded state.
Solution
•
•
Check for a serial communication problem (another diagnostic).
Replace the SCSA terminal board.
2535-2536
Description TCSA Relay [ ] Driver does not match commanded state
Possible Cause TCSA Relay driver output does not match commanded state.
Solution
•
•
•
Verify that the I/O pack is seated properly.
Check the I/O pack configuration.
Replace the I/O pack.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 655
Non-Public Information
2537-2538
Description SCSA Relay Contact [ ] Failure
Possible Cause SCSA relay contact feedback does not match the commanded state.
Solution
•
•
•
Check the serial cable between WCSA and SCSA.
Replace the I/O pack.
Replace the SCSA.
2539-2540
Description TCSA relay [ ] command does not match voted output command
Possible Cause TCSA relay command does not match voted output command.
Solution
•
•
•
Verify that the I/O pack is seated properly.
Replace the I/O pack.
Replace the TCSA terminal board.
2541
Description SCSA Wetting Voltage Not Valid, SCSA Contact Inputs Not Valid
Possible Cause
•
•
•
The contact wetting voltage may not be connected to the SCSA through JE1 connector.
The contact wetting voltage does not match the Excitation_Volt parameter.
The contact wetting voltage applied to the SCSA is not within the acceptable range for the board.
Solution
•
•
•
Check the contact wetting voltage connections to the SCSA.
Verify the applied contact wetting voltage matches the Excitation_Volt parameter setting.
Check the power distribution and wiring to ensure that correct wetting voltage is applied to the SCSA.
2542
Description TCSA Wetting Voltage Not Valid, TCSA Contact Inputs Not Valid
Possible Cause
•
•
•
The contact wetting voltage may not be connected to the TCSA through J1 connector.
The contact wetting voltage does not match the Excitation_Volt parameter.
The contact wetting voltage applied to the TCSA is not within the acceptable range for the board.
Solution
•
•
•
656
Check the contact wetting voltage connections to the TCSA.
Verify the applied contact wetting voltage matches the Excitation_Volt parameter setting.
Check the power distribution and wiring to ensure that correct wetting voltage is applied to the TCSA.
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2543-2545
Description SCSA Contact Input [ ] Unhealthy
Possible Cause The digital input self-test has failed on the SCSA.
•
•
Serial link issue.
Internal hardware issue.
Solution
•
•
Check for other diagnostics related to serial links and resolve.
Replace the SCSA.
2546-2565
Description TCSA Contact Input [ ] Unhealthy
Possible Cause The digital input self-test has failed.
•
•
Serial link issue with the WCSA (for Contact inputs 8-20)
Internal hardware issue.
Solution
•
•
•
•
Check for other diagnostics related to serial links and resolve.
Verify that the WCSA is seated properly on the TCSA.
Replace the I/O pack.
Replace the TCSA/WCSA board.
2566
Description LED - Composite Analog Trip
Possible Cause The Composite Analog Trip LED is lit on the I/O pack because an Analog Trip is detected. The
LedDiags parameter must be set to Enable to get this alarm.
Solution
•
•
•
Verify that the LedDiags parameter should be set to Enable or Disable.
From the Vars-AI Trip tab, examine the analog input that has tripped.
Remove the Analog Trip condition, and issue a master reset.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 657
Non-Public Information
2594
Description SCSA Communication Failure
Possible Cause
•
•
•
SCSA is not connected
Serial link cable is faulty or too long
Hardware failure on SCSA terminal board
Solution
Note To clear this diagnostic alarm, first correct the issue that is causing the serial communication failure and then reboot
the I/O pack.
•
•
•
•
Verify that power is applied to the SCSA.
Verify that the proper serial cable type and length are being used.
Replace the serial cable.
Replace the SCSA.
2595
Description WCSA Communication Failure
Possible Cause
•
•
•
WCSA is not properly seated on the TCSA terminal board
Serial link cable between WCSA and SCSA is faulty
Hardware failure on WCSA daughter board
Solution
Note To clear this diagnostic alarm, first correct the issue that is causing the serial communication failure and then reboot
the I/O pack.
•
•
•
•
•
658
Check for and resolve other diagnostics.
Verify that the WCSA is properly seated on the TCSA.
Verify that proper serial cable type and length are being used.
Replace the serial cable.
Replace the TCSA/WCSA terminal board.
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2596-2601
Description Speed Repeater [ ] Unhealthy
Possible Cause
•
•
Speed repeater output is shorted.
Hardware failure on WCSA daughter board
Solution
•
•
•
Check the speed repeater wiring connections.
Verify that the proper speed repeater jumper settings are being used.
Replace the TCSA/WCSA terminal board.
2602
Description SCSA not connected on power up
Possible Cause
•
•
The SCSA is not physically connected when the I/O pack powers on.
Serial link cable between SCSA and WCSA is faulty
Solution
•
•
•
•
•
Verify that the SCSA is connected to the WCSA in the correct serial link connector for R, S, or T.
Verify that power is applied to the SCSA.
Replace the serial link cable.
Replace the SCSA terminal board.
Replace the TCSA/WCSA terminal board.
2603
Description SCSA Barcode Mismatch
Possible Cause
•
•
Bar code of the connected SCSA terminal board does not match the configuration in the ToolboxST application
Failure in the electronic ID on SCSA
Solution
•
•
•
•
Verify that the bar code configuration matches the hardware connected.
Verify that the SCSA is connected to the WCSA in the correct serial link connector for R, S, or T.
Replace the serial cable.
Replace the SCSA terminal board.
2604
Description WCSA not connected on power up
Possible Cause WCSA daughter board is not properly seated on TCSA terminal board
Solution
•
•
Verify that the WCSA is properly seated on the TCSA terminal board.
Replace the TCSA/WCSA terminal board.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 659
Non-Public Information
2605–2606
Description SynchCheck is enabled with TCSA relay [ ], TCSA relay [ ] needs to be configured as Used
Possible Cause Synch Check is enabled and has selected one of the TCSA relays for driving K25A relay. The selected
TCSA relay is configured as Unused.
Solution Enable the respective TCSA relay as Used.
2607
Description Dual speed sensors mismatch: PR 1=[ ], PR 4=[ ]
Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit
value.
Solution
•
Verify that the Dual_DiffLimit value is set correctly.
Note The value is given in engineering units.
•
Verify the connection and correct operation of the speed sensors.
2608
Description Dual speed sensors mismatch: PR 2=[ ], PR 5=[ ]
Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit
value.
Solution
•
Verify that the Dual_DiffLimit value is set correctly.
Note The value is given in engineering units.
•
Verify the connection and correct operation of the speed sensors.
2609
Description Dual speed sensors mismatch: PR 3=[ ], PR 6=[ ]
Possible Cause The dual speed sensors are reporting speeds that differ by more than the configured Dual_DiffLimit
value.
Solution
•
Verify that the Dual_DiffLimit value is set correctly.
Note The value is given in engineering units.
•
660
Verify the connection and correct operation of the speed sensors.
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2610-2615
Description Speed sensor mismatch for PulseRate[ ]: Voted= [ ], PR{2:F0}_Spd= [ ]
Possible Cause A speed sensor is reporting speeds that differ by more than the configured Dual_DiffLimit value from
the voted PulseRate value.
Solution
•
Verify that the Dual_DiffLimit value is set correctly.
Note The value is given in engineering units.
•
Verify the connection and correct operation of the speed sensors.
2616-2618
Description Mechanical Relay [ ] driver feedback does not match commanded state
Possible Cause The driver output feedback for mechanical relay does not match the commanded state.
Solution
•
•
•
•
Verify that the I/O pack is seated properly.
Verify that the WCSA is properly seated on the TCSA.
Replace the I/O pack.
Replace the TCSA/WCSA terminal board.
2619-2621
Description Mechanical Relay [ ] contact feedback does not match commanded state
Possible Cause Feedback from mechanical relay contacts does not match the commanded state.
Solution
•
•
•
Verify that the I/O pack is seated properly.
Replace the I/O pack.
Replace the TCSA/WCSA terminal board.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 661
Non-Public Information
2622
Description Invalid TCSA Analog Input Calibration, using defaults. Error [ ]
Possible Cause
Note Error number is for factory use only.
•
•
•
Calculated constants are out of range of full scale analog value.
Calculated constants are corrupted or not found on board.
Cannot retrieve constants from board, board disconnected
Solution
•
•
•
Check the hardware connections and reboot the I/O pack.
Replace the TCSA/WCSA terminal board.
Replace the I/O pack.
2623
Description Invalid SCSA Analog Input Calibration, Using Defaults - Error [ ]
Possible Cause
Note Error number is for factory use only.
•
•
•
Calculated constants are out of range of full scale analog value.
Calculated constants are corrupted or not found on board
Cannot retrieve constants from board, board disconnected
Solution
•
•
•
662
Check the hardware connections and reboot the I/O pack.
Replace the SCSA terminal board.
Replace the I/O pack.
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2624-2626
Description Thermocouple [ ] Unhealthy
Possible Cause
•
•
•
•
Thermocouple mV input on terminal board exceeded thermocouple range or hardware limit.
Thermocouple is configured as wrong type.
Thermocouple is not connected or broken wire.
Serial link to the SCSA is faulty.
Solution
•
•
•
Verify that the thermocouple type matches the configuration.
Check the field wiring, including shields.
Verify that the I/O pack is seated properly.
Note The problem is usually not an I/O pack or terminal board failure if other thermocouples are working correctly.
•
•
•
Check the thermocouple for an open circuit.
Measure incoming mV signal and verify that it is not less than -63 mV.
Check for serial communication problem (another diagnostic).
2627
Description Cold Junction Unhealthy, using backup
Possible Cause Local cold junction signal from SCSA is out of range. The normal range is -50 to 85 °C (-58 to 185 °F).
•
•
If hardware is in the normal temperature range, then possible hardware failure of cold junction sensor on the SCSA
board.
Serial link to the SCSA is faulty.
Solution
•
•
Check for serial communication problem (another diagnostic).
Replace the SCSA.
2628
Description Cold Junction [ ] value beyond specified temperature range
Possible Cause Cold junction temperature exceeded range of linearization (lookup) table. Refer to documentation for
specified cold junction ranges.
Solution
•
•
Reboot the I/O pack.
Replace the SCSA terminal board.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 663
Non-Public Information
2629
Description Could not load programmable logic on TCSA: Error [ ]
Possible Cause
•
•
•
Corrupted firmware download
Corrupted programmable hardware image
Hardware failure
Solution
•
•
•
•
Download the firmware and application files.
Reboot the I/O pack.
Cycle power to all three I/O packs at the same time.
Replace the TCSA/WCSA terminal board.
2630
Description Could not load programmable logic on SCSA: Error [ ]
Possible Cause
•
•
•
Corrupted firmware download
Corrupted programmable hardware image
Hardware failure
Solution
•
•
•
Download the firmware and application files.
Reboot the I/O pack.
Replace the SCSA.
2631-2686
Description Input Signal $V Voting Mismatch, Local=[ ], Voted=[ ]
Possible Cause Within the TMR I/O pack set, one of the same input signals does not match the other two of the same
input signals.
Solution
•
•
•
•
•
•
•
•
664
Adjust the TMR threshold limit or correct the cause of the difference.
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and network connections.
Verify that the I/O pack is seated properly.
Verify the operation of the device generating the specified signal.
Verify the TCSA wiring and connections.
Replace the I/O pack.
Replace the TCSA terminal board.
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
2687-2978
Description Logic Signal $V Voting Mismatch
Possible Cause
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•
Within the TMR I/O pack set, one of the same logic signals does not match the other two of the same logic signals.
A mismatch in ETR relay feedbacks could be due to a failure of the mechanical relay.
Solution
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•
•
•
•
•
•
•
Verify that the R, S, and T I/O pack configurations are equal to the ToolboxST configuration.
Check the I/O pack power and network connections.
Verify that the I/O pack is seated properly.
Verify the operation of the device generating the specified signal.
If mismatch in ETR relay feedback, verify proper operation of the mechanical relay.
Check the TCSA wiring and connections.
Replace the I/O pack.
Replace the TCSA terminal board.
YSIL Core Safety Protection Module
GEH-6721_Vol_III_BJ System Guide 665
Non-Public Information
12.4
TCSA + WCSA Core Protection Terminal Board
The Mark VIeS Core Protection TCSA main terminal board hosts three YSIL I/O packs, includes a WCSA daughter board
that has serial links to the SCSA I/O expansion boards, and provides the inputs and outputs as listed in the table, YSIL I/O
Types.
12.4.1
Installation
The TCSA accepts three I/O packs that are mounted directly onto it. This module assembly forms a self-contained backup trip
function. The WCSA daughter board comes assembled to TCSA, and is therefore not installed or replaced as a separate part.
The WCSA provides serial links to the three SCSAs. Attach a good common ground to the TCSA board. Refer to GEH-6721_
Vol_I for grounding practices.
666
GEH-6721_Vol_III_BJ
Mark VIe and VIeS Control Systems for GE Industrial Applications
Non-Public Information
Connectors