GE Mark VIe System Manual
Read Online
Read the GE Mark VIe System Manual online using the built-in PDF viewer.
Text of the manual
Mark* VIe and Mark VIeS Control Systems
Volume I: System Guide
June 2020
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.
Public Information – This document contains non-sensitive information approved for public disclosure.
GE provides the following document and the information included therein as is and without warranty of any kind,
expressed or implied, including but not limited to any implied 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: June 2020
Issued: Jan 2004
© 2004 - 2020 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 [email protected]
Public Information
Corrected the GE industrial Ethernet 10/100 IONet switch operating
temperature
BPPC-based I/O Pack Migration
Removed “although this is not recommended” from table entry on mixing BPPB
and BPPC I/O packs
Intrinsic Variables and Totalizers
Updated totalizer support by ControlST version
BN
Turbine I/O Types
Added the compatible terminal boards TVBAH1B and TVBAH2B for the
PVIBH1 I/O pack
Mark VIeS Safety I/O Types
Added the compatible terminal board TVBAS2B for the YVIBS1 I/O pack
BM
Signal Reference Structure
Updated the last paragraph for clarification
Terminal Board Fuse Details
Updated IS200TRLYH1C and 2C to include 5 X 20MM TIME-LAG in the table
Power Distribution, Terminal Board Fuses
BL
Terminal Board Fuse Details
Corrected IS200JPDDG2A to 3A in the table Power Distribution, Terminal
Board Fuses
IONet Switches
Incorporated content from the removed section Approved IONet Switches
section into this section and added Approved IONet Switches as the table
heading for the list of approved IONet switches
BK
Serial Number/Barcode Convention
New section that provides the logic of the GE serial number/barcode
convention
Terminal Board Fuse Details
Added the following terminal boards to the table Power Distribution, Terminal
Board Fuses: IS200JPDDG2A, IS200JPDDG3A, and IS200JPDDG4A; remove
+FU# from GE Part # column
BJ
Introduction
Added Attention statement that users application may not be licensed to
access full system capability and I/O types described in this document
Modbus Protocol
Changes made for clarification, including:
•
Removed the note referencing GSM 3.0 documentation, which is not
related to Modbus
•
Added a note below the Mark VIe Controller Modbus Communication
Protocols diagrams in the section Controller Modbus to state that the
diagram is not meant to show how to connect Modbus to an application; it
is to give the reader a point of reference as to how Modbus is
implemented.
•
Controller was removed from the Mark VIe Controller Modbus
Communication Protocols diagram to limit confusion because it does not
add value; it was only a point of reference
BH
Introduction
Added content for the Universal I/O (UIO) Mark VIe control cabinet
BG
IONet Switches
Corrected the redundant input voltage range from 10–30 to 18–36 v dc
Approved IONet Switches
Updated the list of approved IONet ESWx switches
Modbus Protocol
Added Modbus Slave support for Mark VIeS Safety controller
Electromagnetic Compatibility Directive (EMC)
2014/30/EU
Updated the EU directive number from 2004/108/EC to 2014/30/EU
Added the Code and Description details in the table of fulfilled requirements for
EU directive EN/IEC 61326-1
Low Voltage Directive 2014/35/EU
Updated the EU directive number from 2006/95/EC to 2014/35/EU
Humidity
Removed EN50178 statement
System Guide
GEH-6721_Vol_I_BP
3
Public Information
Shipping and Storage Temperature
Added a table providing equipment shipping and storage temperature range
Alarm Types
Added content providing the alarm system requirements for maximum number
of new alarms that can be processed
BE
Mark VIe BPPC I/O Migration Guidelines
Removed mention of BPPC I/O Upgrade V05.01.xx or Later DVD and added
note about Auto-Reconfiguration not available with the Mark VIeS Safety
controller.
Mean Time Between Failure (MTBF)
Added procedure for accessing Exida
Applications in Harsh Environments
New section
Software Tools
Moved this content to ControlST Software Suite Installation, Upgrade, and
Compatibility Guide (GEI-100694)
BD
BPPC-based I/O Packs Migration
Updates to installation guideslines
I/O Module Types
Added PVIBH1B, YVIBH1B
Diagnostic Alarms Reset
New section
Unit-specific Grounding Examples
New section
I/O Types
New PUAAH1A Universal Analog I/O Module
BC
I/O Module Types
Added SDIIH2A, YDIAS1B, and YAICS1B
Power and I/O Field Wiring
New table for wire limitations
BPPC-based I/O Pack Migration
New sections
BPPC-based Mark VIeS Safety I/O Packs
Available Mark VIe BPPC-based I/O Packs
Mark VIe BPPC I/O Migration Guidelines
Equip Mark VIe System for Migration
BB
Communication Protocols
Added PROFINET to the list of Fieldbus Network Protocols
Component Part Numbers
New section
Troubleshooting
Added some helpful tables and notes
Dual Controllers
Updated description to better explain differences between dual controllers and
dual I/O pack functions.
Functional Safety
Updated table to include YSIL, SRSA, YDOAS1B, and STAIS3A
Localization - Translation to Native Languages
New section
Environment
Updated information to include components with expanded ambient
temperature ratings
Controller Alarm Subsystem
New section
Ethernet Networks
Removed subsection on Wind Plant Architecture
Less specific switch definitions used, with reference to related document for
details
Added the ESWA to the section Approved IONet Switches
I/O Packs
Fixed the accuracy rating for temperature sensor
Terminal Board Fuse Details
New section
4
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Acronyms and Abbreviations
Acronym
Definition
Acronym
Definition
AWG
American Wire Gauge
PDM
Power Distribution Module
BoP
Balance of Plant
PE
Protective Earth
CDH
Control Data Highway
PLC
Programmable Logic Controller
CMOS
Complementary Metal-Oxide Semiconductor
RLD
Relay Ladder Diagram
CRC
Cyclic Redundancy Code/Check
RTD
Resistance Temperature Device
DAC
Digital-to-Analog Converter
RTU
Remote Terminal Unit
DCE
Data Communication Equipment
SDI
System Data Interface Protocol
DCS
Distributed Control System
SIFT
Software Implemented Fault Tolerance
DHCP
Dynamic Host Configuration Protocol
TMR
Triple Modular Redundancy
DMZ
Demilitarized Zone
TTL
Transistor-transistor Logic
EGD
Ethernet Global Data
UDH
Unit Data Highway
EMC
Electromagnetic Capability
UDP
User Datagram Protocol
EMI
Electromagnetic Interference
UTC
Coordinated Universal Time
ERA
Electrical Riser Angle
UTP
Unshielded Twisted Pair (cabling)
FE
Functional Earth
VLAN
Virtual Local Area Network
GPS
Global Position System
WAN
Wide Area Network
GSM
GE Standard Messaging
GTS
Global Time Source
HMI
Human-machine Interface
HRSG
Heat Recovery Steam Generator
IEC
International Electrotechnical Commission
IEEE
Institute of Electrical and Electronics
Engineers
KP
Keyphasor*
LAN
Local Area Network
MPU
Magnetic Pickup
MDH
Monitoring Data Highway
MTBF
Mean Time Between Failures
MTBFO
Mean Time Between Forced Outage
MTTR
Mean Time To Repair
NEMA®
National Electrical Manufacturer’s
Association
NFPA
National Fire Protection Association
NTP
Network Time Protocol
PDH
Plant Data Highway
System Guide
GEH-6721_Vol_I_BP
5
Public Information
Mark VIeS Control Functional Safety Manual
GEH-6725
Mark VIe and Mark VIeS Control Systems Equipment in Hazardous Locations (HazLoc)
Instruction Guide
GEH-6700 or GEH-6703
ToolboxST User Guide for Mark Controls Platform
GEH-6721_Vol_II
Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose
Applications
GEH-6855_Vol_I
Mark VIeS Functional Safety Systems for General Market Volume I: System Guide
GEH-6855_Vol_II
Mark VIeS Functional Safety Systems for General Market Volume I: System Guide for
General-purpose Applications
GEH-6860
Mark VIeS Control General Market Functional Safety Manual
GEH-6861
Mark VIeS Functional Safety System Equipment in Hazardous Locations (HazLoc) Instruction
Guide
GEH-6741
Sequential Function Chart Application Guide
GEH-6742
Mark VIe and Mark VIeS Virtual Controller User Guide
GEH-6757
WorkstationST GSM 3.0 User Guide
GEH-6760
WorkstationST GSM 3.0 Application Guide
GEH-6761
Mark VIe Control FOUNDATION Fieldbus™Interface Application Guide
GEH-6812
Mark Controllers Shared IONet User Guide
GEI-100679
Mark VIe Distributed Control System (DCS) Block Library
GEI-100682
Mark VIe Control Standard Block Library
GEI-100681
Mark VIe Control Legacy Block Library
GEI-100694
ControlST Software Suite Installation, Upgrade, and Compatibility Guide
GEI-100795
Trender Instruction Guide
GEI-100620
WorkstationST Alarm Viewer Instruction Guide
6
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Safety Symbol Legend
Warning
Indicates a procedure or condition that, if not strictly observed, could result in
personal injury or death.
Caution
Indicates a procedure or condition that, if not strictly observed, could result in damage
to or destruction of equipment.
Attention
Indicates a procedure or condition that should be strictly followed to improve these
applications.
GEH-6721_Vol_I_BP System Guide 7
Public Information
Control System Warnings
Warning
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.
To minimize hazard of electrical shock or burn, approved grounding practices and
procedures must be strictly followed.
Warning
To prevent personal injury or equipment damage caused by equipment malfunction,
only adequately trained personnel should modify any programmable machine.
Warning
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.
8
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Control System Overview............................................................................................................. 11
1.1 Introduction.......................................................................................................................................... 11
1.2 Controllers ........................................................................................................................................... 15
1.3 IONet Switches ..................................................................................................................................... 16
1.4 Distributed I/O Modules.......................................................................................................................... 16
1.5 Power Distribution................................................................................................................................. 36
1.6 Redundancy Options .............................................................................................................................. 37
1.7 Reliability and Availability ...................................................................................................................... 49
1.8 Component Part Numbers and Serial Numbers/Barcodes............................................................................... 57
2
Functional Safety............................................................................................................................67
2.1 Safety Instrumented System (SIF)............................................................................................................. 68
2.2 Risk Reduction...................................................................................................................................... 69
2.3 Safety System Redundancy Options .......................................................................................................... 70
3
Ethernet Networks..........................................................................................................................75
3.1 Introduction.......................................................................................................................................... 75
3.2 IONet Layer ......................................................................................................................................... 80
3.3 Unit Control Layer................................................................................................................................. 86
3.4 Supervisory Layer.................................................................................................................................. 91
3.5 Monitoring Layer................................................................................................................................... 92
3.6 Enterprise Layer.................................................................................................................................... 93
3.7 Ethernet Cabling for Monitoring, Supervisory, and Unit Control Layers ........................................................... 94
3.8 Third-party Communication Links ............................................................................................................ 98
4
Communication Protocols ...........................................................................................................99
4.1 OPC Protocols .....................................................................................................................................101
4.2 WorkstationST GSM Protocol.................................................................................................................104
4.3 Modbus Protocol ..................................................................................................................................106
4.4 Ethernet Global Data (EGD) ...................................................................................................................109
4.5 System Data Interface (SDI) Protocol .......................................................................................................111
4.6 Network Time Protocol (NTP) ................................................................................................................112
4.7 Fieldbus Communications ......................................................................................................................115
5
Technical Regulations, Standards, and Environment ........................................................ 117
5.1 Safety Standards...................................................................................................................................117
5.2 Conditions for Compliance .....................................................................................................................118
5.3 Electrical.............................................................................................................................................119
5.4 Environment........................................................................................................................................121
6
Installation Guidelines ................................................................................................................127
6.1 Installation Support...............................................................................................................................127
6.2 Equipment Receiving and Handling .........................................................................................................130
6.3 Power Requirements .............................................................................................................................132
6.4 Installation Support Drawings .................................................................................................................134
6.5 Grounding...........................................................................................................................................134
6.6 Cable Separation and Routing .................................................................................................................143
6.7 Power and I/O Field Wiring....................................................................................................................149
GEH-6721_Vol_I_BP System Guide 9
Public Information
6.8 System Power Connection......................................................................................................................152
6.9 Startup Checks .....................................................................................................................................153
6.10 BPPC-based I/O Pack Migration..............................................................................................................158
6.11 Available Mark VIe BPPC-based I/O Packs ...............................................................................................160
6.12 Mark VIe BPPC I/O Migration Guidelines.................................................................................................161
6.13 Equip Mark VIe System for Migration......................................................................................................163
7
Alarm Overview.............................................................................................................................165
7.1 Alarm System Architecture.....................................................................................................................165
7.2 Alarm Types ........................................................................................................................................168
7.3 Controller Alarm Subsystem...................................................................................................................168
7.4 Diagnostic Alarms ................................................................................................................................169
7.5 Process Alarms ....................................................................................................................................172
7.6 Alarm Communication Flow...................................................................................................................174
8
Troubleshooting ...........................................................................................................................175
8.1 Controller, I/O Pack, IONet Switch Not Powering On..................................................................................175
8.2 Unable to Download to Controller............................................................................................................178
8.3 Controller Not in Controlling State...........................................................................................................179
8.4 Unable to Download to I/O Modules ........................................................................................................184
8.5 Unable to Communicate with I/O Module .................................................................................................185
8.6 Unable to Download to Controller or I/O Module .......................................................................................186
8.7 Communication Loss Between Controller and I/O Module............................................................................187
8.8 Boot Log Collection..............................................................................................................................188
8.9 I/O Module Replacement or Upgrade Issues...............................................................................................189
8.10 LED Indicators.....................................................................................................................................194
Glossary of Terms ..............................................................................................................................195
Index.......................................................................................................................................................199
10
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Control System Overview
1.1
Introduction
The Mark* VIe control system is a flexible platform used in multiple applications. Its architecture enables unique engineered
solutions for a variety of large industrial applications. It features high-speed, networked input/output (I/O) for Simplex, Dual,
and Triple Modular Redundant (TMR) systems. Industry-standard Ethernet communications are used for I/O, controllers, and
supervisory interface to operator and maintenance stations, as well as third-party systems.
The Mark VIeS Safety controller and I/O can operate independently or integrated with the rest of the Mark VIe controllers for
safety-critical applications that conform to IEC® 61508.
The ControlST* Software Suite, which contains the ToolboxST* application software, is used or programming, configuration,
trending, and analyzing diagnostics for Mark controls and related systems. It provides quality, time-coherent data at controller
and plant level for effectively managing control system equipment. ControlST simplifies maintenance while retaining a
unique set of certified hardware and software blocks. ToolboxST provides a means to lock or unlock the Mark VIeS Safety
controller for configuration and Safety Instrumented Function (SIF) programming
The Universal I/O (UIO) control cabinet provides a platform for an independent, miniature version of the Mark VIe or Mark
VIeS Safety control. The PUAA module is the standard Mark VIe compatible module, while the YUAA module is the
companion module that is used in the Mark VIeS Safety control system. The UIO control cabinet is a lower cost, smaller
footprint alternative to the standard Mark control cabinet. The control cabinet is installed at sites when there are I/O, power,
and/or space limitations in the existing Mark VI, Mark VIe, or Mark VIeS control cabinet. This is especially required for
upgrades when there are space restrictions. This unit may also be used as an independent Mark VIe or Mark VIeS control
system, communicating directly with the Unit Data Highway (UDH) or Plant Data Highway (PDH), regardless of the existing
controller at the site. The UIO control system supports specific I/O. For a list of supported I/O, refer to the Mark VIe and
Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II). ToolboxST is
used to set up, configure, and download to the UIO Mark VIe controller.
Attention
The information in this document applies to the overall Mark* VIe control system or
Mark VIeS Functional Safety System control products; however, your application may
not be licensed to access full system capability and I/O packs as described in this
document. For example, the Mark VIeS Functional Safety System for General
Markets only utilizes the following I/O packs:
••
Analog I/O (YAIC)
••
Universal Analog (YUAA)
••
Vibration Input Monitor (YVIB)
••
Relay Output (YDOA)
••
Discrete Contact Input (YDIA)
••
Power Distribution System Diagnostics (PPDA)
••
Serial Modbus Communication (PSCA)
••
Mark VIeS Safety Controller (UCSCS2x)
••
Mark VIe Controller for Gateway (UCSCH1x)
Control System Overview
GEH-6721_Vol_I_BP System Guide 11
Public Information
Note All instructions in this manual also apply to the UIO control cabinet.
Typical Architecture for Large Industrial Control Systems
12
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Mark VIe and Mark VIeS control systems are used in a wide range of process control and protection applications, including steam, gas, and wind turbines, power
generation balance of plant (BoP), deep sea drilling, desalinization, gas compression, and other facility-wide equipment management systems. The control system
primarily consists of three hardware components: controller(s), I/O network (IONet) switches, and I/O modules. The control system provides more options for redundancy,
better maintainability, and greater capability for locating I/O modules closer to the controlled equipment. It provides quality, time-coherent data at controller and plant
level for effectively managing control system equipment. ControlST, which include the ToolboxST and WorkstationST applications, is used for programming,
configuration, trending, and troubleshooting the Mark control product line. The following are two commonly used ToolboxST configuration screens.
Software Block Editor
Control System Overview
GEH-6721_Vol_I_BP System Guide 13
Public Information
Component Hardware Editor
14
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Mark VIe controller is a stand-alone, single-board controller with scalable
processing power. It includes built-in power supplies and requires no batteries or
jumper settings. Controllers run the ControlST* Software Suite, providing a common
software environment for turbine and generator excitation controls in the power island
and balance of plant equipment to simplify operations and maintenance.
The Mark VIeS Safety controller is IEC 61508 certified to SIL 3.
Controllers are loaded with software specific to its application, such as steam, gas,
land-marine (LM), Balance of Plant (BoP), offshore drilling, desalination, CS, and
Wind Power Conversion. It can run Relay Ladder Diagrams (RLD) or blocks. The
IEEE® 1588 protocol is used through the R, S, and T I/O networks (IONet) to
synchronize the clock of the I/O modules and controllers to within ±100 microseconds.
Data is transferred to and from the control system database in the controller over the
I/O networks (IONet). IONet data includes process inputs/outputs to the I/O packs.
In a dual system, IONet data also includes:
•
Internal state values and initialization information from the designated controller
•
Status and synchronization information from both controllers
In a triple module redundant (TMR) system, IONet data also includes:
•
Internal state values for voting and status and synchronization information from all
three controllers
•
Initialization information from the designated controller
Note For more information on the Mark VIe controller, refer to the Mark VIe and Mark VIeS Control Systems Volume II:
System Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter Controllers. More more information on the
Mark VIeS Safety controller, refer to the Mark VIeS Control Functional Safety Manual (GEH-6723).
For a list of controllers that are available for each control system, including the supported and unsupported features the
controllers offer for that control system, refer to the ToolboxST User Guide for Mark Controls Platform (GEH-6700 or
GEH-6703).
Control System Overview
GEH-6721_Vol_I_BP System Guide 15
Public Information
GE’s Industrial Ethernet 10/100 switches (ESWA and ESWB) provide the performance and features needed in today’s
real-time industrial control systems. Use 8-port ESWA or 16-port ESWB Ethernet switches in all control system I/O networks
to maintain the reliability needed for I/O module reception of controller outputs.
Note For more information on the IONet switches, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System
Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter Unmanaged Ethetnet Swtiches.
1.4
Distributed I/O Modules
TMR I/O Module
The I/O modules contain three basic parts: terminal board, terminal block, and I/O pack.
The terminal board mounts to the cabinet and comes in two basic types: S and T. The I/O
pack mounts to the terminal board J-port connector. Both terminal board types provide the
following features:
•
Terminal blocks for I/O wiring
•
Mounting hardware
•
Input isolation and protection
•
I/O pack connectors
•
Unique electronic ID
Simplex I/O Module
16
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
I/O packs have a common processor board and a data acquisition board that is unique
to the type of connected device. I/O packs on each terminal board digitize the I/O
variables, perform algorithms, and communicate with the controller.
The I/O pack provides fault detection through a combination of special circuitry in the
data acquisition board and software running in the Central Processing Unit (CPU)
board. The fault status is transmitted to and used by the controllers. The I/O pack
transmits inputs and receives outputs on both network interfaces if connected.
Each I/O pack also sends an identification message (ID packet) to the main controller
when requested. The packet contains, the hardware catalog number of the I/O board,
the hardware revision, the board barcode serial number, the firmware catalog number,
and the firmware version. The I/O packs have a temperature sensor that is accurate to
within ±2°C (±3.6 °F). Every I/O pack temperature is available in the database and can
be used to generate an alarm.
1.4.2
Terminal Boards
Signal flow begins with a sensor connected to a terminal block on a board. Wide and narrow terminal boards are arranged in
vertical columns of high and low-level wiring. An example of a wide board is a board that contains magnetic relays with
fused circuits for solenoid drivers. A shield strip is provided to the left of each terminal block. It can be connected to a metal
base for immediate grounding or floated to allow individual ground wires from each board to be wired to a centralized,
cabinet ground strip.
Input
Screws
I/O Pack
Connector
Output
Screws
Simplex Terminal Board
Input
Screws
I/O Pack
Connector
I/O Pack
Connector
I/O Pack
Connector
Output
Screws
Vote /
Select
TMR Terminal Board
Control System Overview
GEH-6721_Vol_I_BP System Guide 17
Public Information
T-type terminal boards typically fan the sensor inputs to three separate I/O packs. Usually, the TMR board hardware votes the
outputs from the three I/O packs. T-type boards contain two, 24-point, barrier-type, removable, terminal blocks. Each point
can accept two 3.0 mm (0.12 in) (#12AWG) wires with 300 V insulation per point with either spade or ring-type lugs. In
addition, captive clamps are provided for terminating bare wires. Screw spacing is 9.53 mm (0.375 in) minimum and
center-to-center.
Note Some application-specific TMR terminal boards do not fan inputs or vote the outputs.
Barrier-type Terminal Blocks
These terminal blocks have the following features:
•
Black in color with white number labels
•
Terminal rating is 300 V, 10 A
•
UL recognized
•
Recommended screw tightening torque is 7 lb-in (0.8 Nm).
18
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
S-type boards provide a single set of screws for each I/O point and allow a single I/O pack to condition and digitize the I/O.
They are half the size of T-type boards and are standard base mounted but can also be DIN-rail mounted. These boards can be
used for simplex, dual, or dedicated triple redundant sensors by using one, two, or three modules.
S-type boards have Euro-style, box type terminal blocks. Some boards are available as either removable or fixed terminal
block versions. S-type board terminal blocks accept one 2.05 mm (0.08 in) (#12 AWG) wire or two 1.63 mm (0.06 in) (#14
AWG) wires, each with 300 V insulation per point. Screw spacing is 5.08 mm (0.2 in) minimum and center-to-center.
Box-type Terminal Blocks
These terminal blocks have the following features:
•
Green in color with number labels.
•
Terminal rating is 300 V, 10 A
•
UL and CSA recognized
•
Recommended screw tightening torque is 5 lb-in (0.5 - 0.6 Nm)
Control System Overview
GEH-6721_Vol_I_BP System Guide 19
Public Information
I/O Module Types
1.4.3.1
General Purpose I/O Types
Discrete I/O Types
I/O Pack/
# per Board
Board
Discrete I/O Types
Type
Removable
PDIAH1A/1, 2, 3
PDIAH1B/1, 2, 3
TBCIH1C
24 discrete inputs (DI) (125 V dc, group isolated) sequence of events (SOE)
Barrier
Yes
PDIAH1A/1, 2, 3
PDIAH1B/1, 2, 3
TBCIH2C
24 DI (24 V dc, group isolated) SOE
Barrier
Yes
PDIAH1A/1, 2, 3
PDIAH1B/1, 2, 3
TBCIH3C
24 DI (48 V dc, group isolated) SOE
Barrier
Yes
PDIAH1A/1, 2, 3
PDIAH1B/1, 2, 3
TBCIH4C
24 DI (24 V dc, group isolated) SOE
Barrier
Yes
PDIAH1A/, 2, 3
PDIAH1B/1, 2, 3
TICIH1A
24 DI (115/230 V ac, 125 V dc point isolated) SOE
Barrier
Yes
PDIAH1A/1, 2, 3
PDIAH1B/1, 2, 3
TICIH2A
24 DI (24 V dc, point isolated) SOE
Barrier
Yes
PDIAH1A/1
PDIAH1B/1
STCIH1A
24 DI (24 V dc, group isolated) SOE
Box
No
PDIAH1A/1
PDIAH1B/1
STCIH2A
24 DI (24 V dc, group isolated) SOE
Box
Yes
PDIAH1A/1
PDIAH1B/1
STCIH4A
24 DI (48 V dc, group isolated) SOE
Box
Yes
PDIAH1A/1
PDIAH1B/1
STCIH6A
24 DI (125 V dc, group isolated) SOE
Box
Yes
PDIAH1A/1
PDIAH1B/1
STCIH8A
24 DI (24 V dc, group isolated) SOE
Box
Yes
PDIIH1A/1
PDIIH1B/1
SDIIH1A
16 DI (24, 48, 125, 250 V dc, 115, 230 V ac point isolated, line-break detection) SOE
Box
Yes
SDIIH2A
Same as H1A but is also enhanced to provide more vibration protection for use in some GE Drilling
applications. The purchase price is higher for this version, which includes RTV and stabilizer bar.
WDIIH1A
WDIIH2A
WDIIH3A
Add 24 V dc, 115/230 V ac wetting voltage
Add 48 V dc wetting voltage
Add 125 V dc wetting voltage (group isolation)
Daughter boards
PDIOH1A/1
PDIOH1B/1
TDBSH2A
24 DI and 12 type C mechanical relays (24 V dc group isolated) SOE
(Refer to Option Boards Note 1, 2, and 3), SOE for relay outputs
Box
Yes
20
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Discrete I/O Types (continued)
I/O Pack/
# per Board
Board
Discrete I/O Types
Type
Removable
PDIOH1A/1
PDIOH1B/1
TDBSH4A
24 DI and 12 type C mechanical relays (48 V dc group isolated) SOE (Refer to Option Boards Note
1, 2, and 3), SOE for relay outputs
Box
Yes
PDIOH1A/1
PDIOH1B/1
TDBSH6A
24 DI and 12 type C mechanical relays (125 V dc group isolated) SOE (Refer to Option Boards
Note 1, 2, and 3), SOE for relay outputs
Box
Yes
PDIOH1A/3
PDIOH1B/3
TDBTH2A
24 DI and 12 type C mechanical relays (24 V dc group isolated) SOE (Refer to Option Boards Note
1), SOE for relay outputs
Box
Yes
PDIOH1A/3
PDIOH1B/3
TDBTH4A
24 DI and 12 type C mechanical relays (48 V dc group isolated) SOE (Refer to Option Boards Note
1), SOE for relay outputs
Box
Yes
PDIOH1A/3
PDIOH1B/3
TDBTH6A
24 DI and 12 type C mechanical relays (125 V dc group isolated) SOE (Refer to Option Boards
Note 1), SOE for relay outputs
Box
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH1B
12 type C mechanical relays with 6 solenoids, coil diagnostics (115/230 V ac, 24/48/125 V dc), SOE
for relay outputs
Barrier
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH1C
12 type C mechanical relays with 6 solenoids, voltage diagnostics (115/230 V ac, 125 V dc), SOE
for relay outputs
Barrier
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH2C
12 type C mechanical relays with 6 solenoids, voltage diagnostics (24 V dc), SOE for relay outputs
Barrier
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH1D
6 type A mechanical relays for solenoids, solenoid impedance diagnostics (24/125 V dc), SOE for
relay outputs
Barrier
Yes
PDOAH1A/1
PDOAH1B/1
SRLYH1A
12 type C mechanical relays (115/230 V ac, 24/48/125 V dc), SOE for relay outputs
Box
No
PDOAH1A/1
PDOAH1B/1
SRLYH2A
12 type C mechanical relays (115/230 V ac, 24/48/125 V dc) (Refer to Option Boards Note1, 2, and
3), SOE for relay outputs
Box
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH1E
12 type A solid-state relays (115/230 V ac), voltage diagnostics, SOE for relay outputs
Barrier
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH2E
12 type A solid-state relays (125 V dc), voltage diagnostics, SOE for relay outputs
Barrier
Yes
PDOAH1A/1, 3
PDOAH1B/1, 3
TRLYH3E
12 type A solid-state relays (24 V dc), voltage diagnostics, SOE for relay outputs
Barrier
Yes
PDOAH1A/3
PDOAH1B/3
TRLYH1F
36 mechanical relays, 12 voted type A normally open (NO) outputs (115 V ac, 24/48/125 V dc)
(Refer to Option Boards Note 4 and 5), SOE for relay outputs
Barrier
Yes
PDOAH1A/3
PDOAH1B/3
TRLYH2F
36 mechanical relays, 12 voted type B normally closed (NC) outputs (115 V ac, 24/48/125 V dc)
(Refer to Option Boards Note 4 and 5), SOE for relay outputs
Barrier
Yes
Control System Overview
GEH-6721_Vol_I_BP System Guide 21
Public Information
Note 1: Add solenoid interface to first 6 relay circuits
WROFH1A
Note 2: Add fuse in COM leg of all 12 relay circuits
WROGH1A
Note 3: Add fuse power distribution in COM leg of all 12 relay circuits
WPDFH1A
Note 4: Fuses for solenoid power in (+) and (-) legs
WPDFH2A
Note 5: Fuses for field solenoid power in top side only for common neutral AC solenoids
Analog I/O Types
I/O Pack/
# per Board
Board
Analog I/O Types
Type
Removable
PAICH1A/1, 3
PAICH1B/1, 3
TBAIH1C
10 analog inputs (AI) voltage over current (V/I) inputs, group isolated and 2
analog outputs (AO) (0-20 mA outputs, group isolated)
Barrier
Yes
PAICH2A/1, 3
PAICH2B/1, 3
TBAIH1C
10 AI (V/I inputs, group isolated) and 2 AO (0-20/0-200 mA outputs, group
isolated)
Barrier
Yes
PAICH1A/1
PAICH1B/1
STAIH1A
10 AI (V/I inputs, group isolated) and 2 AO (0-20 mA outputs, group
isolated)
Box
No
PAICH2A/1
PAICH2B/1
STAIH1A
10 AI (V/I inputs, group isolated) and 2 AO (0-20/0-200 mA outputs, group
isolated)
Box
No
PAICH1A/1
PAICH1B/1
STAIH2A
10 AI (V/I inputs, group isolated) and 2 AO (0-20 mA outputs, group
isolated)
Box
Yes
PAICH2A/1
PAICH2B /1
STAIH2A
10 AI (V/I inputs, group isolated) and 2 AO (0-20/0-200 mA outputs, group
isolated)
Box
Yes
PAICH1A/1
PAICH1B/1
SAIIH1A
10 AI (V/I inputs, point isolated) and 2 AO (0-20 mA outputs, group
isolated)
Box
No
PAICH2A/1
PAICH2B/1
SAIIH1A
10 AI (V/I inputs, point isolated) and 2 AO (0-20/0-200 mA outputs, group
isolated)
Box
No
PAICH1A/1
PAICH1B/1
SAIIH2A
10 AI (V/I inputs, point isolated) and 2 AO (0-20 mA outputs, group
isolated)
Box
Yes
PAICH2A/1
PAICH2B/1
SAIIH2A
10 AI (V/I inputs, point isolated) and 2 AO (0-20/0-200 mA outputs, group
isolated)
Box
Yes
PAOCH1A/1, 2
PAOCH1B/1, 2
TBAOH1C
16 AO (0-20 mA outputs) 8 per I/O pack
Barrier
Yes
PAOCH1A/1
PAOCH1B/1
STAOH1A
8 AO (0-20 mA outputs)
Box
No
PAOCH1A/1
PAOCH1B/1
STAOH2A
8 AO (0-20 mA outputs)
Box
Yes
PHRAH1A/1
PHRAH1B/1
SHRAH1A
10 AI (V/I inputs) and 2 AO (0-20 mA outputs) with HARTcommunications
Box
No
PHRAH1A/1
PHRAH1B/1
SHRAH2A
10 AI (V/I inputs) and 2 AO (0-20 mA outputs) with HARTcommunications
Box
Yes
22
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Analog I/O Types (continued)
I/O Pack/
# per Board
Board
Analog I/O Types
Type
Removable
PPDAH1A/1
PPDAH1B/1
JPDS
JPDM
JPDG
JPDC
Power Distribution System Feedback
N/A
NA
PTCCH1A/1, 2, 3
PTCCH1B/1, 2, 3
TBTCH1B
12 Thermocouples
Barrier
Yes
PTCCH2A/1, 2, 3
PTCCH2B/1, 2, 3
TBTCH1B
12 Thermocouples with extended range for EPRI compliance
Barrier
Yes
PTCCH1A/1, 2
PTCCH1B/1, 2
TBTCH1C
24 Thermocouples (12 per I/O pack)
Barrier
Yes
PTCCH2A/1, 2
PTCCH2B/1, 2
TBTCH1C
24 Thermocouples (12 per I/O pack) with extended range for EPRI
compliance
Barrier
Yes
PTCCH1A/1
PTCCH1B/1
STTCH1A
12 Thermocouples
Box
No
PTCCH2A/1
PTCCH2B/1
STTCH1A
12 Thermocouples with extended range for EPRI compliance
Box
No
PTCCH1A/1
PTCCH1B/1
STTCH2A
12 Thermocouples
Box
Yes
PTCCH2A/1
PTCCH2B/1
STTCH2A
12 Thermocouples with extended range for EPRI compliance
Box
Yes
PRTDH1A/1, 2
PRTDH1B/1, 2
TRTDH1D
16 RTDs 3 wires /RTD (8 per I/O pack)
Barrier
Yes
PRTDH1A/1, 2
PRTDH1B/1, 2
TRTDH2D
16 RTDs 3 wires /RTD (8 per I/O pack) supports fast scan rate
Barrier
Yes
PUAAH1A / 1
SUAAH1A
The Universal Analog I/O Pack supports a variety of I/O types. Refer to
GEH-6721_Vol_II for details.
Box
Yes
Control System Overview
GEH-6721_Vol_I_BP System Guide 23
Public Information
Fieldbus I/O Types
I/O Pack/
Qty per Board
Board
Communications Types
Type
Removable
PSCHHIA/1, 2
SSCAH1A
SSCAH2A
6 serial
6 serial
Box
Box
No
Yes
PSCAH1A/1
PSCAH1B/1
SSCAH1A
6 MODBUS Master serial or 1 Modbus Ethernet
Box
No
PSCAH1A/1
PSCAH1B/1
SSCAH2A
6 MODBUS Master serial or 1 Modbus Ethernet
Box
Yes
PCNOH1A/1
PCNOH1B/1
SPIDG1A
CANopen Master Gateway
N/A
N/A
PPRFH1A/1
PPRFH1B/1
PROFIBUS - DP-V0, Class 1 Master Communications
PROFIBUS - DP-V1 Class 1 Master Communications
(PPRFH1B only)
N/A
N/A
PPNGH1A
N/A
PROFINET RT Version 2.2 I/O gateway module maps
I/O from PROFINETslave devices to the Mark VIe
controller on the IONet
N/A
N/A
PFFAH1A/1
N/A
FOUNDATION Fieldbus H1 TO HSE Linking Device
N/A
N/A
24
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Turbine I/O Types
Turbine specific I/O modules provide direct interface to unique turbine field devices, which reduces or eliminates a substantial amount of interposing instrumentation. As a
result, many potential single-point failures are eliminated for improved running reliability and reduced long-term maintenance. Direct interface also enables the diagnostics
to directly monitor field devices. This provides more precise messages to minimize maintenance time.
Pack
# packs
Terminal Board
Turbine Applications
Terminal Block Type
PAMCH1A
1 or 2
SAMBH1A
Acoustic Monitor for MS 6, 7, 9 gas turbines: 18 inputs and buffered outputs
UCSA used as I/O pack to interface with BAPA for acoustic monitoring function
Removable, Box
PCLAH1A
PCLAH1B
1
SCLSH2A
Core Analog I/O for aero-derivative turbines
Removable, Box
3
SCLTH2A
PCAAH1A
PCAAH1B
1
TCASH2A
Core Analog I/O for heavy duty gas turbines
Removable, Box
3
TCATH2A
PEFVH1A
1, 2, or 3
TEFVH1A
Electric Fuel Valve Gateway to Woodward™DVP
N/A
PGENH1A
1 or 3
TGNAH1A
Used for Power Load Unbalance (PLU) and has three 1-phase PTs, three V/I inputs. Analog inputs are box-type and
removable. Current transformer (CT) inputs are barrier-type and not removable.
PVIBH1A
PVIBH1B
1 or 3
TVBAH1A
TVBAH2A
TVBAH1B
TVBAH2B
Refer to GEH-6721_Vol_II for a complete listing of supported inputs.
TVBAH2A and TBVAH2B include buffered outputs and BNC connectors.
Removable, Barrier
PSVOH1A
PSVOH1B
1 or 3
TSVCH1
TSVCH2A
Servos: 2 channels, 2-coil outputs, 8 LVDTs and excitation, 2 pulse rate inputs (heavy
duty & Aero-derivative gas & steam)
Removable, Barrier
PSVPH1A
1
SSVPH1A
SSVPH2A
Steam servo applications: 2 channels, 2-coil outputs, 6 LVDTs and 2 excitation, 1
pulse rate input for speed feedback
Removable, Barrier
Removable, Box
PTURH1B
PTURH1A
1, 3
TTURH#C
Turbine Specific Primary Trip, 48 points
Removable, Barrier
1
STURH#A
Removable, Box
3
TRPAH#A
Aeroderivative Turbine Primary Trip, 48 points
Removable, Barrier
Control System Overview
GEH-6721_Vol_I_BP System Guide 25
Public Information
Terminal Block Type
PPRAS1B††
PPRAS1A††
3
TREAS#A +
WREAS1A
Aero-derivative Turbine Emergency Trip, 48
points
TREA_1A: Removable, Barrier
TREA_3A: Removable, Box
PPRAH1A
3
TREAH#A +
WREAH1A
PPROS1B††
3
TPROS#C
Backup Turbine Protection, 48 points
TPRO_1A: Removable, Barrier
TPRO_2A: Removable, Box
PPROS1B
PPROH1A
3
TPROH#C
1
SPROH#A
Backup Turbine Protection, 24 points
SPROH1A: Removable, Barrier
SPROH2A: Removable, Box
3
TREAH#A
Aero-derivative Turbine Emergency Trip, 48
points
H1A, H2A: Removable, Barrier
H3A, H4A: Removable, Box
††These modules have IEC 61508 safety-certified functions
26
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Migration I/O Types
The following table provides a list of I/O modules approved for use with Mark V, Mark V LM, and Mark VI migration to the Mark VIe control
Mark V, Mark V LM, and Mark VI Migration to Mark VIe Control
I/O Pack/Qty
per Board
Terminal
Board
Interface
Board
Migration I/O Types
Type
Removable
PIOAH1A/1
N/A
JPDV
Mark V ARCNET I/O (for excitation control)
N/A
N/A
PMVE/1, 3
QTBA
TBQA
TBQB
TBQC
TBQF
TBQD
TBQG
CTBA
TBCA
TBCB
TCQC
MVRA
MVRB
MVRC
MVRF
UCSA used as I/O pack controller to interface with
dedicated Mark V turbine I/O application boards.
Box
No – H1A,
Yes - H2A,
No - G1A,
No - G1B
PMVD/1, 3
DTBA
DTBB
DTBC
DTBD
TCRA
96 contact inputs,
60 relay contact outputs
Box
No – H1A,
Yes – H2A,
No –G1A,
No – G1B
PMVP/3
PTBAG1A
PTBAG2A
Expansion
board TCEB
and trip
boards TCTE,
TCTG, TCTL,
TCTS,
2 magnetic p.u. speed inputs,
8 flame detector pulse inputs,
Trip solenoid interface relays,
Generator breaker synchronizing circuits
E-Stop
Barrier
No
PCMI
VRID
Any existing
Mark VI VME
board except
VPYR, VSCA,
VPRO, or
VAMB
Migration from Mark VI Master Interface
N/A
N/A
Control System Overview
GEH-6721_Vol_I_BP System Guide 27
Public Information
Mark VIeS Safety I/O Types
The following table lists the Mark VIeS Safety specific I/O modules.
I/O Pack
# of
packs
Terminal Board
Mark VIeS Safety I/O Types
Connector Type
Removable
YAICS1A
YAICS1B
1, 3
1
1
1
TBAIS1C
STAIS1A
STAIS2A
STAIS3A
10 analog inputs (voltage, 0-20 mA)
2 analog outputs (0-20 mA)
Box
Box
Box
None
Yes
No
Yes
No
YDIAS1A
YDIAS1B
1, 2, 3
1, 2, 3
1, 2, 3
1
1
1
1
TBCIS1
TBCIS2
TBCIS3
STCIS1A
STCIS2A
STCIS4A
STCIS6A
24 discrete inputs w/ group isolation
(24 V dc, 48 V dc, or 125 V dc)
Box
Yes
Yes
Yes
No
Yes
Yes
Yes
YHRAS1A
1
SHRAS1A
SHRAS2A
10 analog inputs (0-20 mA),
2 analog outputs (0-20 mA)
(All I/O HARTenabled)
Box
No
Yes
YTCCS1A
1 , 2
1 , 2
1
1
TBTCS1B
TBTCS1C
STTCS1A
STTCS2A
12 thermocouple inputs
Box
Yes
Yes
No
Yes
YVIBS1A
YVIBS1B
1, 3
TVBAS1A
TVBAS2A
TVBAS2B
Refer to GEH-6721_Vol_II for a complete listing of supported inputs.
TVBAS2A and TVBAS2B include buffered outputs and BNC connectors.
Box
Yes
YPROS1A
3
3
3
3
3
3
1
TREAS1A
TREAS2A
TREAS3A
TREAS4A
TREGS1B
TREGS2B
SPROS1A
Backup/emergency protection
3 speed inputs
7 contact inputs
3 monitored trip relay outputs
1 E-Stop
Barrier
Barrier
Box
Box
Box
Box
Barrier
Yes
YTURS1A
3
TTURS1C
TRPAS1A
TRPAS2A
TRPGS1B
TRPGS2B
Primary turbine protection
4 speed inputs
8 flame inputs
3 monitored trip relay outputs
1 E-Stop
Box
Yes
28
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Mark VIeS Safety I/O Types
Connector Type
Removable
YSILS1B
3
one TCSAS1A
and three
SCSAS1A
I/O types are detailed in GEH-6721_Vol_III for GE Industrial Applications (if available)
Box
Yes
YDOAS1A
YDOAS1B
1, 3
TRLYS1B
12 type C mechanical relays with 6 solenoids, coil diagnostics (115/230 V ac, 24/48/125 V dc), SOE for
relay outputs
Barrier
Yes
YDOAS1A
YDOAS1B
1, 3
TRLYS1D
6 type A mechanical relays for solenoids, solenoid impedance diagnostics (24/125 V dc), SOE for relay
outputs
Barrier
Yes
YDOAS1A
YDOAS1B
1, 3
SRLYS1A
12 type C mechanical relays (115/230 V ac, 24/48/125 V dc), SOE for relay outputs
Box
No
YDOAS1A
YDOAS1B
1
SRLYS2A
12 type C mechanical relays (115/230 V ac, 24/48/125 V dc) (Refer to Option Boards Note1, 2, and 3),
SOE for relay outputs
Box
Yes
YDOAS1A
YDOAS1B
1
SRSAS1A
SRSAS3A
10 relay outputs
Box
None
Yes
No
YDOAS1A
YDOAS1B
3
TRLYS1F
36 mechanical relays, 12 voted type A normally open (NO) outputs (115 V ac, 24/48/125 V dc) (Refer
to Option Boards Note 4 and 5), SOE for relay outputs
Barrier
Yes
YDOAS1A
YDOAS1B
3
TRLYS2F
36 mechanical relays, 12 voted type B normally closed (NC) outputs (115 V ac, 24/48/125 V dc) (Refer
to Option Boards Note 4 and 5), SOE for relay outputs
Barrier
Yes
Control System Overview
GEH-6721_Vol_I_BP System Guide 29
Public Information
Renewable Energy I/O Types
The following table lists the Renewable Energy I/O types.
Assembly
Individual Boards
Renewable I/O Types
AEPAH1A
AEPAH1A
BPPB
Alternative Energy Pitch Axis, special-purpose in 1.5 MW wind pitch control: 8 analog inputs, 1 incremental encoder input, 1 absolute
encoder input, 1 analog output, 20 discrete inputs, 1 discrete output, 8 relay outputs, 2 RS-485 interfaces, 1 brake control output
AEPAH1C
AEPAH1A
BPPC
AEPCH1A
AEPCH1A
BPPB
Alternative Energy Pitch Center module in 20, 30, and 40 Newton Meters (Nm) wind pitch control: 1 24 V dc, 8 A power input, 1 RS-422
interface
AEPCH1B
AEPCH1B
BPPB
AEPCH1C
AEPCH1C
BPPB
AEPCH1D
AEPCH1A
BPPC
WEMDH4
AEPCH1E
AEPCH1B
BPPC
WEMDH5
AEPCH1F
AEPCH1C
BPPC
WEPAH1A
AEPAH1B
BPPB
WPCI
Wind Energy Pitch Axis special-purpose in 30 and 40 Nm wind pitch control: 8 analog inputs, 1 incremental encoder input, 1 analog
output, 20 discrete inputs, 2 discrete outputs, 9 relay outputs, 2 RS-485 interfaces, 2 PWM control outputs
WEPAH1B
AEPAH1B
BPPC
WPCI
WEPAH2A
AEPAH1B
BPPB
WEPAH2B
AEPAH1B
BPPC
WETAH1A
WETAH1A
BPPB
Wind Energy Top Box board A, special-purpose in 1.5 MW ESS turbine: 69 digital inputs; 8 are pulse-rate counter inputs, 18 analog PT100
temperature sensor inputs, 2 analog thermistor temperature sensor inputs, 12 analog 4 to 20 mA current inputs, 25 relay contact outputs
19 solid-state relay outputs, 1 RS-485 interface
WETAH1B
WETAH1B
BPPC
WCBMH1A
WCBMH1A
Wind Condition Top Box Monitor condition-based monitoring for wind turbines, measures vibration on main bearing, gearbox, and
generator bearings
WEMAH1A
WEMA
BPPB
Wind Energy Main converter control for ESS wind turbine: 27 digital inputs, 2 analog thermistor temperature sensor inputs, 9 relay contact
outputs, 3 solid-state relay outputs
WEMAH1B
WEMA
BPPC
30
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Renewable I/O Types
WEMAH2A
WEMA
BPPB
Wind Energy Main converter control for Brilliance Solar PV inverter: 27 digital inputs, 2 analog thermistor temperature sensor inputs, 9
relay contact outputs, 3 solid-state relay outputs
WEMAH2B
WEMA
BPPC
WECAH1A
MACC
BPPB
Wind power converter interface for the power converter: 27 digital inputs, 9 relay contact outputs, 3 solid-state relay outputs
SECAH1A
MACC
BPPB
Solar power converter interface for the solar inverter: 27 digital inputs, 9 relay contact outputs, 3 solid-state relay outputs
Control System Overview
GEH-6721_Vol_I_BP System Guide 31
Public Information
Terminal Board Fuse Details
The following tables are provided to assist in inventory management of the replaceable fuses used on some terminal boards.
Discrete I/O, Terminal Board Fuses
Board
Fuse Designator
GE Part #
Fuse Rating
MFR #
IS200TRLYH1B
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200TRLYS1B
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200TRLYH1C
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC, 5 X
20MM TIME-LAG
LITTELFUSE 04773.15MXP
IS200TRLYH2C
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC, 5 X
20MM TIME-LAG
LITTELFUSE 04773.15MXP
IS200TRLYH1D
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200TRLYS1D
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200WROBH1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200WROFH1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200WROGH1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5005-011
FUSE, 3.15A,
500VAC/400VDC
LITTELFUSE 04773.15MXP
IS200WDIIH1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12, FU13,
FU14, FU15, FU16
342A4908AFP1
FUSE 0.2A 250V TM
LAG TR5
LITTELFUSE 3720200041,
37202000411
IS200WDIIH2A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12, FU13,
FU14, FU15, FU16
342A4908AFP1
FUSE 0.2A 250V TM
LAG TR5
LITTELFUSE 3720200041,
37202000411
32
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Discrete I/O, Terminal Board Fuses (continued)
Board
Fuse Designator
GE Part #
Fuse Rating
MFR #
IS200WPDFH1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12, FU13,
FU14, FU15, FU16, FU17,
FU18, FU19, FU20, FU21,
FU22, FU23, FU24
259A9266P16
FUSE(SLO-B) 3.15A
250V
LITTELFUSE 218 3.15
COOPER BUSSMANN GDC-3.15A
IS200WPDFH2A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12, FU13,
FU14, FU15, FU16, FU17,
FU18, FU19, FU20, FU21,
FU22, FU23, FU24
259A9266P16
FUSE(SLO-B) 3.15A
250V
LITTELFUSE 218 3.15
COOPER BUSSMANN GDC-3.15A
Power Distribution, Terminal Board Fuses
Board
Fuse Designator
GE Part #
Fuse Rating
MFR #
IS200JPDAG1A
FU1, FU2, FU3, FU4
323A2396P96
FUSE 15A
LITTELFUSE 314015P
COOPER BUSSMANN ABC-15
IS200JPDBG1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
IS200JPDBG2A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
IS200JPDCG1A
FU71, FU72, FU73, FU74,
FU75, FU76,FU1R,FU1S,
FU1T,FU2R,FU2S,FU2T
64G5005-010
FUSE, 10A,
500VAC/400VDC,
TIME-LAG
(SLO-BLOW)
LITTELFUSE 0477010.MXP
FU81, FU82, FU83, FU84,
FU85, FU86
44A725207-011
FUSE, 3.15A,250V,
FAST ACTING
LITTELFUSE 217 3.15
FUAC1, FUAC2
342A4908ABP21
FUSE, 10A, 250V,
TIME-LAG
(SLO-BLOW)
LITTELFUSE 218 010, 218010.
HXP, 218010H
IS200JPDDG1A
FU1N, FU1P, FU2N, FU2P,
FU3N, FU3P, FU4N, FU4P,
FU5N, FU5P, FU6N, FU6P
323A2396P96
FUSE 15A
LITTELFUSE 314015P
COOPER BUSSMANN ABC-15
IS200JPDDG2A
N/A
FUSE 15A,
250VAC/125VDC,
FAST ACTING
N/A
IS200JPDDG3A
N/A
FUSE 15A
N/A
IS200JPDDG4A
323A2396P68
FUSE 0.5A,
250VAC/125VDC,
FAST ACTING
LITTELFUSE 0314.500MXP
COOPER BUSSMANN ABC-1/2
IS200JPDEG1A
FU11, FU12, FU21, FU22,
FU31, FU32
323A2396P20
FUSE 7 A
LITTELFUSE 312007P
COOPER BUSSMANN AGC-7
FUA1, FUA2, FUB1,
FUB2, FUC1, FUC2
323A2396P96
FUSE 15A
LITTELFUSE 314015P
COOPER BUSSMANN ABC-15
Control System Overview
GEH-6721_Vol_I_BP System Guide 33
Public Information
Power Distribution, Terminal Board Fuses (continued)
Board
Fuse Designator
GE Part #
Fuse Rating
MFR #
IS200JPDFG1A
FU1R, FU1S, FU1T, FU2R,
FU2S, FU2T
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
FU71, FU72, FU73, FU74,
FU75, FU76
323A2396P94
FUSE 5A
LITTELFUSE 314005
COOPER BUSSMANN ABC-5
FU12, FU13
323A2396P98
FUSE 3A 250V ABC
LITTELFUSE 314003
COOPER BUSSMANN ABC-3
FU81, FU82, FU83, FU84
323A2396P91
FUSE 12A 250V ABC
LITTELFUSE 314012
COOPER BUSSMANN ABC-12
IS200JPDFG2A
FU71, FU72, FU73, FU74,
FU75, FU76, FU1R, FU1S,
FU1T, FU2R, FU2S, FU2T
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
FU81, FU82, FU83, FU84
323A2396P91
FUSE 12A 250V ABC
LITTELFUSE 314012
COOPER BUSSMANN ABC-12
FU12, FU13
323A2396P98
FUSE 3A 250V ABC
LITTELFUSE 314003
COOPER BUSSMANN ABC-3
IS200JPDGH1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
FU10, FU11, FU12, FU13,
FU14, FU15, FU16, FU17,
FU18, FU19, FU20, FU21,
FU22, FU23
323A2396P96
FUSE 15A 3AB ABC
FAST ACTING
LITTELFUSE 314015P
COOPER BUSSMANN ABC-15
IS200JPDGH2A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
FU10, FU11, FU12, FU13,
FU14, FU15, FU16, FU17,
FU18, FU19, FU20, FU21,
FU22, FU23
323A2396P96
FUSE 15A 3AB ABC
FAST ACTING
LITTELFUSE 314015P
COOPER BUSSMANN ABC-15
IS200JPDMG1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
323A2396P250
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 326010
COOPER BUSSMANN MDA-10
IS400JPDMG1A
FU1, FU2, FU3, FU4, FU5,
FU6, FU7, FU8, FU9,
FU10, FU11, FU12
64G5002-001
FUSE 10A 250V
SLOW BLOW
LITTELFUSE 0326010.MXP,
326010HP
COOPER BUSSMANN MDA-10-R,
MDA-10BK-R
IS200JPDAG2A
FU1, FU2, FU3, FU4
EMPTY FUSE HOLDERS WITH BLACK CAPS ACCEPTING 5 X 20 mm (0.20 X 0.79
in) FUSES
IS200JPDAG3A
FU1, FU2, FU3, FU4
EMPTY FUSE HOLDERS WITH GREY CAPS ACCEPTING 31.75 X 6.35 mm (1.25 X
0.25 in) FUSES
IS200JPDDG2A
FU1N, FU1P, FU2N, FU2P,
FU3N, FU3P, FU4N, FU4P,
FU5N, FU5P, FU6N, FU6P
EMPTY FUSE HOLDERS WITH BLACK CAPS ACCEPTING 5 X 20 mm (0.20 X 0.79
in) FUSES
IS200JPDDG3A
FU1N, FU1P, FU2N, FU2P,
FU3N, FU3P, FU4N, FU4P,
FU5N, FU5P, FU6N, FU6P
EMPTY FUSE HOLDERS WITH GREY CAPS ACCEPTING 31.75 X 6.35 mm (1.25 X
0.25 in) FUSES
34
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Renewable Energy I/O, Terminal Board Fuses
Board
Fuse Designator
GE Part #
Fuse Rating
MFR #
AEPCH1A
FU1, FU2, FU3
323A2396P59
FUSE 4A 250V SLOW BLOW
COOPER BUSSMANN MDL-4A
LITTELFUSE 313004P
AEPCH1B
FU1, FU2, FU3
323A2396P59
FUSE 4A 250V SLOW BLOW
COOPER BUSSMANN MDL-4A
LITTELFUSE 313004P
WETAH1A
FU2
259A9266P16
FUSE(SLO-B) 3.15A 5X20MM
250V
COOPER BUSSMANN GDC-3.15A
LITTELFUSE 218 3.15
FU3, FU4,FU7, FU8
342A4908ABP21
FUSE 10.0A 250V 5X20MM
LITTELFUSE 218 010, 218010.HXP,
218010H
FU5
64G5005-009
FUSE, 6.3A, 250V, 5 X 20MM
TIME-LAG (SLO-BLOW)
COOPER BUSSMANN S506-6.3-R
LITTELFUSE 021806.3MXP
FU6
342A4908ABP24
FUSE 1.0A 250V 5X20MM
COOPER BUSSMANN BK/S506-1-R
LITTELFUSE 218001, 218001MXP,
218001P
WEMAH1A
FU1
342A4908ABP22
FUSE0.315A 250V 5X20MM
LITTELFUSE 218.315, 218.315H,
218.315HXP
FU2, FU3
259A9266P16
FUSE(SLO-B) 3.15A 5X20MM
250V
COOPER BUSSMANN GDC-3.15A,
LITTELFUSE 218 3.15
FU6
342A4908ABP24
FUSE 1.0A 250V 5X20MM
COOPER BUSSMANN BK/S506-1-R
LITTELFUSE 218001, 218001MXP,
218001P
WEMAH2A
FU1
342A4908ABP22
FUSE0.315A 250V 5X20MM
LITTELFUSE 218.315, 218.315H,
218.315HXP
FU2, FU3
259A9266P16
FUSE(SLO-B) 3.15A 5X20MM
250V
COOPER BUSSMANN GDC-3.15A,
218 3.15
FU6
342A4908ABP24
FUSE 1.0A 250V 5X20MM
COOPER BUSSMANN BK/S506-1-R
LITTELFUSE 218001, 218001MXP,
218001P
Control System Overview
GEH-6721_Vol_I_BP System Guide 35
Public Information
The Mark VIe and Mark VIeS control systems are designed to operate on a flexible, modular selection of power sources. The
power distribution modules (PDM) support 115/230 Vac, 24 and 125 V dc power sources in many redundant combinations.
The power applied is converted to 28 V dc for operation of the I/O packs, controllers, and switches.
Note Refer to For more information on the IONet switches, refer to the Mark VIe and Mark VIeS Control Systems Volume
II: System Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter PDM Power Distribution Modules. The
JPDS, JPDM, JPDG, or JPDC core power distribution board allows for the optional attachment of a PPDA I/O pack for
system feedback.
The PDM can be divided into two substantially different categories, the core distribution system, and the branch circuit
elements. They serve as the primary power management for a cabinet or series of cabinets. The branch circuit elements take
the core output and fan it into individual circuits for consumption in the cabinets. Branch circuits provide their own feedback
mechanisms, which are not part of the feedback provided by the PPDA I/O pack. The wide variety of power distribution
components available for use with the Mark VIe and Mark VIeS control systems allow for a flexible and scalable power
distribution solution.
36
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Mark control platform provides scaleable levels of redundancy. The basic system is a single (simplex) controller with
simplex I/O and one network. The dual system has two controllers, singular or fanned TMR I/O and dual networks, which
provides added reliability and online repair options. The TMR system has three controllers, singular or fanned TMR I/O, three
networks, and state voting between controllers providing the maximum fault detection and availability.
1.6.1
Controller Redundancy
Controller redundancy consists of the following:
•
Simplex controller
•
Dual controllers
•
Triple redundant controllers (TMR)
1.6.1.1
Simplex Controller
The simplex control architecture contains one controller connected to an Ethernet interface through the Ethernet network
(IONet). No redundancy is provided and no online repair of critical functions is available. Online replacement of non-critical
I/O (that where the loss of the I/O does not stop the process) is possible.
Each I/O pack delivers an input packet at the beginning of the frame on its primary network. The controller sees the inputs
from the I/O modules, performs application code, and then delivers an output packet(s) for all I/O modules. The following
diagram displays typical simplex controller architecture.
Switch
Controller
R
UDH
I/O Modules
IONet
Simplex Mark VIe Control System
Control System Overview
GEH-6721_Vol_I_BP System Guide 37
Public Information
The dual control architecture contains two controllers, two IONets, and singular or fanned TMR I/O modules. The following
diagram displays a Mark VIe control system with a Dual redundancy configuration.
Switches
Controllers
R
S
I/O Modules
IONet
IONet
Legend
UDH
Dual Mark VIe Control System
The dual control Mark VIe architecture reliability can be significantly better than the single controller. The network and
controller components are redundant and can be repaired online. The I/O reliability can be mixed and matched to meet
varying requirements.
In a dual Mark VIe control system, both controllers receive inputs from the I/O modules on both networks and transmit
outputs on their respective IONet continuously. When a controller or network component fails, the system continues
operating. I/O packs receive inputs from both controllers, but prefer the designated controller. If the only packet received is
from a non-designated controller, then the I/O pack will use that packet.
Note With dual controllers, the level of I/O reliability can be varied to meet the application needs because not all I/O has to
be dual redundant.
The Mark VIe controllers listen for the data on both networks at power on. The channel that delivers the first valid packet
becomes the preferred network. As long as the data arrives on that channel the controller uses this data. When the preferred
channel does not deliver the data in a frame, the other channel becomes the preferred channel as long as valid data is supplied.
This prevents a given controller from bouncing back and forth between two sources of data. This does mean that different
controllers may have separate preferred sources of data but this can also happen if any component fails.
The I/O modules listen for the data on both networks at power on. If the packet from the designated controller is received, that
one is the preferred network. When the designated controller packet does not arrive in a given frame, the other channel is used
as long as valid data is supplied.
38
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
In a dual control system, the application logic in each controller tries to produce the same results. After many iterations of
running the application, it is possible for the internal data values to differ due to mathematical round off, and different past
history (power-up). To converge this data, the internal data (state) variables are taken from the designated controller and
transmitted to the non-designated controller for its use. This is known as state exchange.
State variables are any internal variables not immediately derived from input or control constants. Any variable that is used
prior to being re-calculated is an internal state variable.
This principle can be displayed in the following two equations:
A = B+C
C = 3 x D
Assume B and D are inputs and A and C are intermediate values. Since C is used prior to being calculated, the value of C
during the previous scan retains some state information. Therefore, C is a state variable that must be updated in the
non-designated controller if both controllers are to remain synchronized.
In the Mark VIe controller, Boolean state variables are updated on every control frame. The analog state variable updates are
multiplexed. A subset of analog state variables is updated every control frame. The controller rolls through each subset until
all state variables are transmitted.
Control System Overview
GEH-6721_Vol_I_BP System Guide 39
Public Information
Triple Modular Redundant (TMR) Controllers
The TMR control architecture contains three controllers, three IONets, and singular or fanned TMR I/O Modules. Reliability
and availability are much better with TMR controllers than with dual controllers due to increased fault detection capability. In
addition to all of the dual redundant features, the TMR controller provides three independent outputs to all TMR I/O modules
and the state variables between controllers are voted.
I/O Modules
Switches
Controllers
R
S
T
IONet
IONet
IONet
Legend
UDH
TMR Mark VIe Control System
Note The level of I/O reliability can be varied to meet the application needs because I/O redundancy can be simplex, dual, or
TMR.
In a TMR control system, all three controllers receive inputs from the I/O modules on all networks and transmit outputs on
their respective IONet continuously. If a controller or network component fails, the system does not require fault detection or
failover time to continue operating. All controllers transmit their copy of the state variables after the output packet has been
transmitted. Each controller takes the three sets of state variables and votes the data to get the values for the next run cycle.
40
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
There are various options available for single and multiple packs and single and dual networks for I/O redundancy. The
following are options for TMR I/O modules:
•
Single Pack Dual Network I/O Module (SPDN)
•
Two Single Pack, Single Network (2SPSN) I/O Modules
•
Dual Pack, Dual Network (DPDN) I/O Module
•
Triple Pack, Dual Network (TPDN) I/O Module
•
Hot Backup I/O Module
1.6.2.1
Single Pack Dual Network I/O Module (SPDN)
This configuration is typically used for non-critical single sensor I/O. A single sensor connects to a single set of acquisition
electronics which is then connected to two networks.
•
Single data acquisition
•
Redundant network
The I/O pack delivers input data on both networks at the beginning of the frame and receives output data from both
controllers at the end of the frame.
1.6.2.2
Two Single Pack, Single Network (2SPSN) I/O Modules
This configuration is typically used for inputs where there are multiple sensors monitoring the same process points. Two
sensors are connected to two independent I/O modules.
•
Redundant sensors
•
Redundant data acquisition
•
Redundant network
•
Online repair
Each I/O pack delivers input data on a separate network at the beginning of the frame and receives output data from separate
controllers at the end of the frame.
1.6.2.3
Dual Pack, Dual Network (DPDN) I/O Module
This is a special case for inputs only, using a dual pack, dual network module. A fanned input terminal board can be populated
with two packs providing redundant data acquisition for a set of inputs.
•
Redundant data acquisition
•
Redundant network
•
Online repair
Each I/O pack delivers input data on a separate network at the beginning of the frame.
Control System Overview
GEH-6721_Vol_I_BP System Guide 41
Public Information
Triple Pack, Dual Network (TPDN) I/O Module
This is a special case mainly intended for outputs, but also applies to inputs. The special output voting/driving features of the
TMR I/O modules can be used in a dual control system. The inputs from these modules are voted in the controller.
•
Redundant data acquisition
•
Output voting in hardware
•
Redundant network
•
Online repair
Two of the I/O packs are connected to separate networks delivering input data and receiving output data from separate
controllers. The third I/O pack is connected to both networks. This pack delivers inputs on both networks and receives outputs
from both controllers.
1.6.2.5
Hot Backup I/O Module
This is a special case mainly intended for a small set of I/O packs used as a gateway to another network. In this configuration,
there are dual I/O packs, dual network but only one I/O pack is communicating to the gateway network at one time, the other
I/O pack operates in a backup mode. The inputs from active module are used in the controller.
•
Redundant data acquisition
•
Redundant network
•
Online repair
The two I/O packs are both connected to both networks, but only communicates to the controller and the gateway network. If
a failure occurs on the active I/O pack, the backup I/O pack becomes the active I/O pack, thus maintaining communication
with the connected devices.
1.6.2.6
Triple Pack, Triple Network (TPTN) I/O Module
For medium integrity applications with medium to high reliability sensors, one sensor can be fanned to three I/O packs. The
special output voting/driving features of the TMR I/O modules can be used in a TMR control system. The inputs from these
modules are voted in the controllers. A fanned input terminal board can be populated with three packs providing redundant
data acquisition for a set of inputs.
•
Redundant data acquisition
•
Output voting in hardware
•
Redundant networks, packs, and controllers
•
Online repair
Each of the I/O packs are connected to separate networks delivering input data and receiving output data from separate
controllers.
42
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
All inputs are available to all three controllers, but there are several ways that the input data is handled. For inputs existing in
only one I/O module, all three controllers use the same value as common input without voting, as displayed in the table
below. Inputs that appear in all three I/O channels may be voted to create a single input value. The triple inputs may come
from three independent sensors. They can also be created from a single sensor by hardware fanning at the terminal board.
Mark VIe Controller Redundancy
Available IONet Topology
Simplex
One I/O pack with one IONet
The number of IONets in a system equals the number of controllers.
Dual
One I/O pack with two IONets
Two I/O packs with one IONet per pack
Three I/O packs with one IONet to controller , one IONet to controller
, and two IONets with one to controller and one to controller
TMR
Fanned – three packs, one IONet/pack with one terminal board
Dedicated – three packs, one IONet/pack with three separate S-type terminal boards
Simplex – One I/O pack, One IONet
Dual – One I/O pack, Two IONets
Dual – Two I/O Packs, One IONet
Dual – Three I/O Packs with 1, 1, 2 IONets
Control System Overview
GEH-6721_Vol_I_BP System Guide 43
Public Information
TMR Fanned – Three I/O Packs with One IONet per I/O Pack
TMR Dedicated – Three simplex I/O modules with One IONet per I/O Pack
For any of the above input configurations, multiple inputs can be used to provide application redundancy. For example, three
Simplex inputs can be used and selected in application code to provide sensor redundancy.
The Mark VIe control provides configuration capability for input selection and voting using a simple, highly reliable and
efficient selection/voting/fault detection algorithm to reduce application configuration effort. This maximizes the reliability
options for a given set of sensor inputs and provides output voting hardware compatibility. All applicable subsets of reliability
options are available on a per terminal board basis for any given Mark VIe topology. For example, in a TMR controller, all
simplex and dual option capabilities are also provided.
While each IONet is associated with a specific controller that is responsible for transmitting outputs, all controllers see all
IONets. The result is that for a simplex input the data is not only seen by the output owner of the IONet, it is seen in parallel
by any other controllers. The benefit of this is that loss of a controller associated with a simplex input does NOT result in the
loss of that data. The simplex data continues to arrive at other controllers in the system.
A single input can be brought to the three controllers without any voting. This is used for non-critical, generic I/O, such as
monitoring 0-20 mA inputs, contacts, thermocouples, and resistance temperature devices (RTD). This interconnection can
also include the following gateway devices: CANbus, FOUNDATION Fieldbus®, Profibus, and Modbus.
Single Input to Three Controllers, Not Voted
One sensor can be fanned to three I/O boards as above for medium-integrity applications. This is used for sensors with
medium-to-high reliability. Three such circuits are needed for three sensors. Typical inputs are 0-20 mA inputs, contacts,
thermocouples, and RTDs.
44
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
One Sensor with Fanned Input and Software Voting
Three independent sensors can be brought into the controllers without voting to provide the individual sensor values to the
application. Median values can be selected in the controller if required. This configuration, displayed in the following figure,
is used for special applications only.
Three Independent Sensors with Common Input, Not Voted
Control System Overview
GEH-6721_Vol_I_BP System Guide 45
Public Information
The following figure displays three sensors, each one fanned and then software implemented fault tolerance (SIFT) voted.
This provides a high reliability system for current and contact inputs, and temperature sensors.
Three Sensors, Each One Fanned and Voted, for Medium-to-High Reliability Applications
Highly reliable speed input applications are brought in as dedicated inputs and SIFT voted. The following figure displays this
configuration. Inputs such as speed control and overspeed are not fanned so there is a complete separation of inputs with no
hardware cross coupling which could propagate a failure. RTDs, thermocouples, contact inputs, and 0-20 mA inputs can also
be configured this way.
Three Sensors with Dedicated Inputs, Software Voted for High Reliability Applications
46
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The system outputs are the portion of the calculated data transferred to the external hardware interfaces and then to the
various actuators controlling the process. TMR outputs are voted in the output voting hardware. Any system can output
individual data through simplex hardware.
The three voting controllers calculate TMR system outputs independently. Each controller sends the output to its associated
I/O hardware (for example, the R controller sends output to the R I/O). The three independent outputs are then combined into
a single output by a voting mechanism. Different data types require different methods of establishing the voted value.
The outputs from the three controllers fall into three groups:
•
Outputs are driven as single ended non-redundant outputs from individual I/O networks
•
Outputs exist on all three I/O networks and are merged into a single output by the hardware
•
Outputs exist on all three I/O networks and are output separately to the controlled process. This process may contain
external voting hardware.
For normal relays, the three outputs feed a voting relay driver, which operates a single relay per channel. For critical
protective signals, the three outputs drive three independent relays, with the relay contacts connected in the typical six-contact
voting configuration.
Relay Output Circuits for Protection
For servo outputs, the three independent currents drive a three-coil servo actuator, which adds them by magnetic flux
summation, as displayed in the following figure. Failure of a servo driver is sensed and a deactivating relay contact is closed
to short the servo coil.
Control System Overview
GEH-6721_Vol_I_BP System Guide 47
Public Information
TMR Circuit to Combine Three Analog Currents into a Single Output
The following figure displays 0-20 mA outputs combined through a 2/3 current sharing circuit that allows the three outputs to
be voted to one. Failure of a 0-20 mA output is sensed and a deactivating relay contact is opened.
TMR Circuits for Voted 0-20 mA Outputs
48
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Reliability and Availability
1.7.1
Mean Time Between Failure (MTBF)
MTBF is a basic measure of reliability for systems. It is the average failure free operating time, during a particular
measurement period under stated conditions. A failure may or may not result in a problem with the overall system depending
on any redundancy employed. MTBF is usually specified for each replaceable system component.
MTBF roll up of the system components gives the equipment owner the knowledge needed to determine how long the
equipment can be expected to operate without failure under given conditions. If it is essential that the equipment does not fail
during operation, the owner can use this data to schedule maintenance/replacement of the equipment prior to failure.
Alternately, redundant applications could be used preventing system problems when a failure occurs. MTBF data is also used
to determine the weak links in a system. The system engineer provides contingency options for those weak links to obtain
higher reliability.
Users can access the MTBF ratings for their Mark VIeS Safety control system from the Exida, exSilentia tool.
➢➢
To access Mark VIeS Safety Controls IEC 61508 certificates and assessment reports
1.
Go to the Exida website at http://www.exida.com/ and select Safety Automation Equipment List from the top tool
bar.
2.
Type vies in the Search field, and click Submit.
3.
Select the company name, General Electric.
4.
At the bottom of the page the user may select to view the following:
•
IEC 61508 certificate
•
Assessment Report
Note A customer can contact Exida to order a copy of the exSILentia Integrated Safety Lifecycle Tool – Standard version.
All versions of the Exida tool include the SILver module, Safety Integrity Level Verification, IEC 61508 compliant
calculation engine. The SIL verification phase tool, SILver, is an analysis tool that uses Markov model calculation technique
during all analyses. Purchasing the Exida tool gives the user access to the Exida Safety Equipment Reliability Handbook
database.
Control System Overview
GEH-6721_Vol_I_BP System Guide 49
Public Information
Mean Time Between Forced Outage (MTBFO)
MTBFO is a measure of system availability, which includes the effects of any fault tolerance that may exist. This average
time between failures causes the loss of system functions.
The engineer must be very aware of MTBF and MTBFO when designing a reliable continuous system. To maximize the
MTBFO, Mark VIe control systems undergo evaluation of all system component MTBF values. The effects of failures and
contingency operation are then analyzed to maximizing MTBFO.
To continue operation after a critical system component has failed, a control must have one or more backups in place
(redundancy) to improve the MTBFO significantly above that of a simplex control. The simplest method is adding a second
component that takes over the critical function when a fault is detected.
The redundancy in the system can be either active or standby. The Mark VIe control uses active redundancy and has all
components operating simultaneously. Standby redundancy activates backup systems after a failure is detected.
Realizing the full benefits of redundancy, a system failure must be detectable for the control to bypass it. In a dual control,
gross failures are readily detectable while subtle failures are more difficult to detect. TMR controls, using two out of three
voting, are always able to select a valid value when presented with any single failure.
Depending on the equipment, the time required to detect the fault and switch to the new component may be
hours/minutes/seconds/milliseconds. In the case of fuel-flow control to a turbine, this is required to be done in milliseconds.
When a redundant control bypasses a failure, it is required that the system annunciate the presence of the failure and that
repairs be completed in a timely fashion. The term, mean time to repair (MTTR), refers to the time it takes to identify and
repair a given failure. The Mark VIe control is designed to support a MTTR of four hours. This preserves the MTBFO
benefits of redundancy resulting in unequaled system reliability. A control is used to run the system as well as detect system
failures. In a dual control, configured for one out of two to run, it is often necessary to add dedicated tripping controls for
each critical trip system. This is done to yield running reliability while maintaining required tripping reliability.
ATMR control normally configures the control for two out of three selection. This yields high running and tripping reliability
from the primary control. Additional dedicated tripping controls can be used to achieve even higher tripping reliability, but
they must also be TMR to preserve running reliability.
50
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
A system offering redundancy can be less reliable than a non-redundant system. The system must be able to detect and
annunciate faults so it can be repaired before a forced outage occurs. Fault detection is needed to ensure a component or group
of components are operating properly. Fault detection is achieved through one or more of the following methods.
•
Operator inspection of the process
•
Operator inspection of the equipment.
•
Special hardware circuits to monitor operation
•
Hardware and software watchdogs
•
Software logic
•
Software heartbeats
Complex control systems have many potential failure points. This can be very costly and time consuming to create foolproof
fault detection. Failure to control the outputs of a system is the most damaging. Fault detection must be determined as close to
the output as possible to achieve the highest level of reliability. With the Mark VIe control configured using triple redundant
controllers and I/O modules, a high level of detection and fault masking is provided by voting the outputs of all three
controllers and monitoring discrepancies.
All Mark VIe control systems benefit from the fault detection design of the I/O packs. Every pack includes function-specific
fault detection methods attempting to confirm correct operation. This is made possible by the powerful local processing that is
present in each input and output pack. Some examples of this include:
•
Analog to digital (A/D) converters are compared to a reference standard each conversion cycle. If the converted
calibration input falls outside of acceptable ranges, the pack declares bad health.
•
Analog output 0-20 mA use a small current-sense resistor on the output terminal board. This output is read back through
a separate A/D converter and compared to the commanded value. A difference between the commanded and actual value
exceeding an acceptable level results in the output being declared in bad health.
•
Discrete input opto-isolators are periodically forced to an on condition, then forced off. This is done independently of the
actual input and is fast enough not to interfere with the sequence of events (SOE) time capture. If any signal path is stuck
and does not respond to the test command, the signal is declared in bad health.
1.7.4
Online Repair
When a component failure is detected and healed in the control system on a critical path, a potential failure has been avoided.
Subsequent actions can include:
Option 1- Continue running until the backup component fails.
Option 2 - Continue running until the system is brought down in a controlled manner to replace the failed component.
Option 3 - Replace the component online.
Option 1 is not recommended. A redundant system, where the MTTR is infinite can have a lower total reliability than a
simplex system.
Option 2 is a valid procedure for some processes needing predictable mission times. Many controlled processes cannot be
easily scheduled for a shut down.
Note As MTTR increases from the expected four hours to infinite, the system reliability can decline from significantly
greater down to less than a simplex system reliability. Repair should be accomplished as soon as possible.
Option 3 is required to get the maximum benefit from redundant systems with long mission times. In dual or triple redundant
Mark VIe controller applications, the controllers and redundant I/O packs can be replaced online.
Control System Overview
GEH-6721_Vol_I_BP System Guide 51
Public Information
To ensure online repair capability, control systems must have their redundancy tested after installation and after any system
modifications. Refer to the requisition specific system application documentation/control specification (if available) for
redundancy testing procedures.
Forced Outage Probability versus Time (Conventional TMR)
Forced Outage Probability versus Time (Mark VIe TMR)
52
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Although three controllers, R, S, and T, contain identical hardware and software, some of the functions performed are unique.
A single designated controller can perform the following functions:
•
Supply initialization data to the other two controllers at start-up
•
Keep the master time clock
•
Supply variable state information to the other controllers if one fails
For the purposes of deciding which controller is to be the designated controller, each controller nominates itself on a
weighting algorithm. The nominating values are voted among the controllers and the majority value is used. If there is a tie, or
no majority, the priority is R, then S, and then T. If a designated controller is powered down and later powered up, the
designated controller will move and not come back if all controllers are equal. This ensures that a toggling designated
controller is not automatically reselected.
Designated controller selection is based on:
•
Control state
•
UDH connectivity
•
IONet connectivity
•
NVRAM health
1.7.6
Communication Loss
Each output pack monitors the IONet for valid commands from one or two controllers. In the event that a valid command is
not received within an expected time the pack declares the communication as being lost. Upon loss of communication the
pack action is configurable. The pack can continue to hold the last commanded value indefinitely or it can be commanded to
go to a specified output state. The default action is to go to a power-down state, the same as if the power were removed from
the pack.
Note Refer to specific I/O pack documentation in Mark VIe and Mark VIeS Control Systems Volume II: System Guide for
General-purpose Applications (GEH-6721_Vol_II).
For critical loops, the default action is the only acceptable choice. The other options are provided for non-critical loops, where
running liability may be enhanced by an alternate output.
1.7.7
State Exchange
To keep multiple controllers in synchronization, the Mark VIe control efficiently exchanges the necessary state information
through the IONet. State information includes calculated values such as timers, counters, integrators, and logic signals such as
bi-stable relays, momentary logic with seal-in, and cross-linked relay circuits. State information is voted in TMR controllers
and follows the designated controller in dual or faulted TMR systems.
1.7.8
Voting
Voting in the Mark VIe control is separated into analog and logic voting. Additionally, fault detection mechanisms directly
choose owned inputs and designated states.
Control System Overview
GEH-6721_Vol_I_BP System Guide 53
Public Information
Median Value Analog Voting
The analog signals are converted to a floating-point format by the I/O pack. The voting operation occurs in each of the three
controller modules (R, S, and T). Each controller receives a copy of the data from the other two channels. For each voted data
point, the controller has three values including its own. The median value voter selects the middle value of the three as the
voter output. This is the most likely of the three values to be closest to the true value.
Median Value Voting Examples with Normal and Bad Inputs
1.7.8.2
Two Out of Three Logic Voter
Each of the controllers has three copies of the data for the logic voter. Voting is a simple logic process, inputting the three
values and finding the two values that agree.
1.7.8.3
Disagreement Detector
A disagreement detector continuously scans the input prevote input data sets and produces an alarm bit if a disagreement is
detected between the three values. Any disagreement between the prevote logical signals generates an alarm. Failure of one of
the three voted input circuits has no effect on the controlled process since the fault is masked by SIFT. Without a
disagreement detector, a failure could go unnoticed until a second failure occurs.
For analog signals, comparisons are made between the voted value and each of the three prevote values. The delta for each
value is compared with a user programmable limit value. The limit can be set as required to avoid nuisance alarms, but give
indication that one of the prevote values has moved out of normal range. Each controller is required to compare only its
prevote value with the voted value; for example, R compares only the R prevote value with the voted value. Nominal, analog
voting limits are set at a 5% adjustment range, but can be configured to any number for each analog input.
1.7.9
UDH Fault Tolerance — Command Action
Using IONet connectivity, the controller copies command traffic from the UDH across all controllers. This provides fault
tolerance for dual UDH networks.
54
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The controller has a feature called Forced Variables. This allows the maintenance technician using application software to set
analog or logical variables to forced values. Variables remain at the forced value until unforced. Both compute and input
processing respect forcing. Any applied forcing is preserved through power down or restart of the controller.
Warning
Logic Forcing is for offline software checkout and troubleshooting and should only be
used in conjunction with proper lockout/tag out procedures. Forcing of protective
functions is never permissible for an operating unit.
1.7.11
Peer I/O
In addition to the data from the I/O modules, there is a class of data coming from other controllers in other cabinets connected
through the UDH network. For integrated systems, this network provides a data path between multiple turbine controllers and
possibly the controls for the generator, the exciter, or the HRSG/boiler.
Selected signals from the controller database can be mapped into pages of peer outputs that are broadcast periodically on the
UDH I/O to peer controllers. For TMR systems, the UDH communicator performs this action using the data from its internal
database. In the event of a redundant UDH network failure, the controller will request data over the remaining network, the
IONet.
Control System Overview
GEH-6721_Vol_I_BP System Guide 55
Public Information
Rate of Response
Mark VIe and Mark VIeS controllers can run at a variety of frame rates to meet the application needs of the industrial control solution. Control systems are tuned
accordingly, based on a variety of factors including: complexity of controller application logic, processor type, and number of I/O and other interfaces used. The following
diagram provides an example of typical processes that occur during a single controller frame in sequence.
Time
TMR set of
Mark VIe Controllers
Notes
Assumes a Triple Modular Redundant (TMR) configuration, versus dual, or simplex
Subsystem activities identified with a gray rectangle
Activities that span multiple subsystems identified with a dashed
TMR IONet
TMR Mark VIe
Control I/O
Start of frame
Transmission of
outputs from
controllers to I/O
packs
Input and state variables copied into variable space in
prep for execution of control logic (application code)
Control Logic
Time to execute based on quantity and complexity of
control blocks
Synchronization of data between R,
S, and T controllers using IONet
Fresh state of outputs
applied to terminal block
screws, latency is
dependent on circuit type
I/O packs sample inputs,
latency is dependent on
circuit type
Transmission of
inputs from I/O
packs to
controllers
End of frame
Mark VIe Subsystem
brown rectangle
56
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Component Part Numbers and Serial
Numbers/Barcodes
1.8.1
Common Terminology
The following terms are used to identify Mark controls components:
Backward Compatible
A part is backward compatible when it can directly replace an earlier version of the part in all
specified end-use applications without requiring any changes to the host system.
Base Part Number
The part number that is used to uniquely identify a part as a component in a higher-level assembly or
to order a backward compatible replacement part. The base part number remains unchanged for all backward-compatible
versions of the part. An example of a base part number is IS220PDIAH1B.
Hardware Form
The three characters following the module or board type in the part number that together with the Type
uniquely defines a module or board in the ToolboxST* configuration tool. An example hardware form is H1B.
Module or Board Type
The four letter mnemonic taken from characters 6 – 9 of the full part number that is used to
identify the function of the part. An example of a board type is Pack Discrete Input A (PDIA).
Part Number
The Part Number is the ANSI/EIA-649-A National Consensus Standard for Configuration Management,
Product Identifier, that represents a specific version of a printed wiring assembly (PWA) and consists of all applicable fields
specified in the table Product Identifier Fields Example. The Part Number identifies the baseline design of a product and is
changed each time the design is changed. An example part number is IS220PDIAH1BA.
Printed Circuit Board Assembly (PCBA)
Indicates a single board.
Printed Wiring Assembly (PWA)
The ANSI/EIA-649-A National Consensus Standard for Configuration Management,
Product Identifier, that indicates one or more PCBAs.
Printed Wiring Board (PWB)
The PC-T-50 Terms and Definitions for Interconnecting and Packaging Electronic
Circuits that indicates a circuit board without any parts added.
Serial Number/Barcode
A unique number assigned to a component that indicates the date of manufacture and the supply
vendor.
Control System Overview
GEH-6721_Vol_I_BP System Guide 57
Public Information
Part Number Convention
A part number consists of up to nine fields of information defined in the following tables.
Product Identifier Fields Example
Part Number
Part Number Fields
I
II
III
IV
V
VI
VII
VIII
IX
IS200ABCDG1AAA
IS
2
00
ABCD
G
1
A
A
A
Part Number Field Definitions
Field
Field Name
Code
Definition
I
Issuing organization code
IS
GE Energy Connections, Salem, Virginia, USA
DS
GE Drive Systems, Salem, Virginia, USA
II
Hazardous substance code
2
Not RoHS [3] compliant
4
RoHS [3] Compliant
III
Assembly level code [4]
00
PCBA
01
Coated PCBA [5]
05
PCBA designed as a component to be soldered into another PCBA
10
PCBA with an added manufacturing or assembly process step [6]
11
Coated PCBA with an added manufacturing or assembly process step [6]
15
PCBA with added application firmware and/or daughter-board(s)
20
1 or more PCBAs in an enclosure
21
1 or more PCBAs in an enclosure and all PCBAs are coated [5]
30
One or more PWAs on a base
31
One or more PWAs on a base and all PCBAs are coated [5]
IV
Board or Module Type
4 letter mnemonic that describes the function of the PWA
V
Technology code
G
Lead-through hole components only, no surface-mount technology
H
Contains surface-mount technology components
S
Functional safety system component [7]
VI
Assembly variant
1 numeric character, excluding 0
VII
Backward compatibility version
1 alpha character, excluding: I, O, Q
VIII
PWA version
Breadboard: BR + 1 numeric character, excluding 0
Prototype: PR + 1 numeric character, excluding 0
Production: 1 alpha character, excluding: I, O, Q
IX
Optional character
Breadboard: Not used
Prototype: Not used
Production
PWB version (assembly levels 00, 05 only): 1 alpha character, excluding: I, O,
Q
Marked for use in hazardous (classified) locations [8]: X
58
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Part Number Field Definitions (continued)
Field
Field Name
Code
Definition
Notes
[3] Directive 2011/65/EU Restriction of Hazardous Substances in Electrical and Electronic Equipment
[4] There are some legacy part numbers with assembly level code “020”. These identify assemblies of one or more PCBAs, and may
not follow the current version rules.
[5] Coated PWAs with assembly level codes 01, 21, and 31 are approved for use in environments where the overall corrosion
potential due to airborne contaminants does not exceed severity level G3, as defined in ANSI/ISA-71.04-2013 Environmental
Conditions for Process Measurement and Control Systems: Airborne Contaminants.
[6] Certain legacy boards: IS210AEAAH*B, IS210AEABH*A, IS210AEACH1A, IS210AEBIH*B, IS210AEDBH*A, IS210AEPSG1A,
IS210AEPSG*B were originally released as un-coated IS200 and coated IS210 parts, but the un-coated parts were never used in
the host product. As these designs evolve, the IS200 level parts are being abandoned and the IS210 level parts are being
maintained using the level 00 rules.
[7] Each functional safety system PWA is certified to meet IEC 61508 and is equivalent in form, fit, and function to any PWA with a
part number that differs only in the Technology Code (field 5). For example: IS400UCSBS1ABB is equivalent in form, fit, and
function to IS400UCSBH1ABB, but is also certified to meet IEC 61508 Functional Safety of Electrical/Electronic/Programmable
Electronic Safety-Related Systems.
[8] NFPA 70 National Electrical Code, Article 500 Hazardous (Classified) Locations
The following figures are examples of component labels identifying the part number.
Example IONet Switch Label
Control System Overview
GEH-6721_Vol_I_BP System Guide 59
Public Information
UCPA part number
Example UCPA Controller Label
60
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Example UCSx Controller Label
Control System Overview
GEH-6721_Vol_I_BP System Guide 61
Public Information
On the replacement, the revision letter
will be the same or a higher letter.
Part
number
Example I/O Pack Label
Internal GE employees and certain third-party parts suppliers can use the ENOVIA PLM tool to search for parts. The
following Power Generation PLM web portal is available to assist with account registration and training on how to use the
tool to search for parts:
http://colab.ge.com/dashboard/canvas/v/518d03b3bf1d408e570001c9/home
62
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Serial Number/Barcode Convention
The serial number/barcode consists of seven characters composed from the following 31 permitted characters:
0 1 2 3 4 5 6 7 9 A C D E F G H J K L M N P R S T U V W X Y Z.
It is composed of five coded groups that represent the component’s supply vendor, date of manufacture, and component count
in the following format: VYMDS2S1S0. The following table describes what these group codes represent.
Group Code
Description
V
Vendor code (one-character)
Contact your GE representative or GE Technical Support for further information on vendors and
manufacturing locations.
Y
Year code (one character)
Refer to the table Year Codes for permitted values.
M
Month code (one character)
Refer to the table Month Codes for permitted values.
D
Day-of-month code (one character)
Refer to the table Day-of-Month Codes for permitted values.
S2S1S0
Serial number count code (three characters)
The total count of unique serial numbers generated for a component is reset to zero each day at 12:00 AM,
and then incremented by one for each unique serial number generated thereafter. This code limits the
number of unique serial numbers to 313 (29,791) per day. Contact your GE representative or GE Technical
Support for more information on this code.
Serial Number
Example Serial Number/Barcode
Control System Overview
GEH-6721_Vol_I_BP System Guide 63
Public Information
The following tables define the groups and characters in a serial number/barcode.
Year Codes
Year
Code
2005
0
2006
1
2007
2
2008
3
2009
4
2010
5
2011
6
2012
7
2013
9
2014
A
2015
C
2016
D
2017
E
2018
F
2019
G
2020
H
2021
J
2022
K
2023
L
2024
M
2025
N
2026
P
2027
R
2028
S
2029
T
2030
U
2031
V
2032
W
2033
X
2034
Y
2035
Z
Month Codes
Month
Code
January
0
February
1
March
2
April
3
May
4
June
5
July
6
August
7
September
9
October
A
November
C
December
D
64
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Control System Overview
GEH-6721_Vol_I_BP System Guide 65
Public Information
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
This chapter provides an introduction to the Mark VIeS Safety control, which is used
for functional safety loops to achieve SIL 2 and 3 capabilities. The Mark VIeS Safety
control is used by operators knowledgeable in safety-instrumented system (SIS)
applications to reduce risk in critical safety functions. Safety controllers and distributed
I/O modules are programmed specifically for safety control use, and this specific
control hardware has been IEC 61508 certified.
Functional safety is concerned about the speed of the control system’s reaction to trip
the system (energize to trip) or to provide an emergency shut-down (de-energize to trip)
when a safety-critical event occurs. With this in mind, safety equipment is rated to meet
safety integrity levels (SIL), which are achieved by analyzing probability of failure on
demand.
The Mark VIeS Safety control is a differentiator in the market because of its significant
flexibility, easy of control logic development, and redundancy capabilities. Its safety
I/O is very flexible in application, for example both analog inputs and outputs are
available. The Mark VIeS Safety control is an engineered solution designed for the
customers that work on our systems to help simplify and reduce maintenance costs.
GE has engineered specific solutions for their internal turbine power plant applications,
meeting high standards for reliability of function, and continues to invest in new SIL
capabilities, for example GE Oil & Gas YSIL applications. The Mark VIeS control has
just recently been made available for integration into other safety-critical applications
outside of GE, for example emergency shutdown, burner management, and fire and
gas-critical control applications. This solution reflects the experience of three plus
decades, four generations, and over ten thousand installed triple-redundant digital
turbine controls.
Functional Safety
GEH-6721_Vol_I_BP System Guide 67
Public Information
Safety Instrumented System (SIF)
While the Safety controller performs the logic solving tasks for the system, it also interfaces with the ToolboxST application
for configuration, diagnostics, and changes to controller application logic (blocks). The ToolboxST application provides a
means to lock or unlock the Safety controller for configuration and safety-instrumented function (SIF) programming. This
allows the user to install a safety function, test it, and place the controller in Locked mode to perform safety control.
Sensors
Safety Controller
Logic Solver
Final Elements
Safety Instrumented System
Third-party
devices
WorkstationST OPC Server
Locked/Unlocked mode
Interfaces to Mark VIeS Safety controller must be strictly regulated to avoid interference with the operation of the system.
Data exchange to the safety control must be restricted and only used when validated by the SIL application logic.
The Mark VIeS Safety control was designed and certified to meet functional safety standards according to IEC 61508 Parts 1
through 3. It is certified for use in both high-and low-demand applications, uses redundant architecture configurations, and a
hardware fault tolerance (HFT) of 1 to achieve safety integrity level (SIL) 3. The highest achievable SIL with an HFT of 0 is
SIL 2.
IEC 61508-4 definitions are as follows:
Safety
Freedom from unacceptable risk.
Risk
Combination of the probability of occurrence of harm and the
severity of that harm.
Functional Safety
Part of the overall safety relating to the equipment under control
(EUC) and the EUC control system that depends on the correct
functioning of the Electrical/electronic/programmable electronic
(E/E/PE) safety-related systems, other technology safety-related
systems, and external risk reduction facilities.
68
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Functional safety relates to proper equipment operation, as well as other risk reduction facilities. Layers of protection (LOP)
concepts are as follows:
Control and Monitoring
Prevention
Mitigation
Plant Emergency Response
BPCS
Process Alarms
Operator Supervision
Mechanical Protection
Alarms with Operator Action
Safety Instrumented Systems
Plant Evacuation Procedures
Relief Valve
Barrier
Process
The LOP around a process can be used to introduce risk reduction. Failure to carefully analyze the available LOP and the
likelihood-consequence relationship of the risks involved with process control failure can lead to an expensive over-design of
the system. The goal is to reduce the risk to a level that is as low as reasonably practicable (ALARP).
Residual
Risk
Tolerable
Risk
Inherent
Process
Risk
Necessary Risk Reduction
Actual Risk Reduction
Increasing Risk
Residual
Risk
Tolerable
Risk
Inherent
Process
Risk
Necessary Risk Reduction
Actual Risk Reduction
To achieve functional safety, it is necessary to analyze the potential hazards to personnel and property, including any
environmental impact, that could occur when the control of equipment is lost.
Requirements for safety function and integrity must be met to achieve functional safety. Safety function requirements describe
what the safety function does and is derived from the hazard analysis. The safety integrity requirement is a quantitative
measure of the likelihood that a safety function will perform its assigned task adequately. For safety functions to be
effectively identified and implemented, the system as a whole must be considered.
A primary parameter used in determining the risk reduction in a safety controller is the Average Probability of Failure on
Demand (PFDavg). The inverse of the PFDavg is the Risk Reduction Factor (RRF).
RR-
F =
1
PFDavg
Functional Safety
GEH-6721_Vol_I_BP System Guide 69
Public Information
Modes of Operation
A demand mode is a mode of operation in which the safety function is called upon only on demand. IEC 61508-4 clause
3.5.12 defines two demand modes of operation:
•
Low demand mode
•
High demand or continuous mode
Low demand describes the mode in which safety function demand occurs no greater than once per year. In high demand
mode, the frequency of demand is greater than once per year. Continuous mode is regarded as very high demand and is
associated with the safety function operating to keep the EUC within its normal safe state.
The mode of operation is relevant when determining the target failure measure of a safety function. Low demand mode relates
to the PFDavg whereas high demand or continuous demand mode relates to measuring the probability of failure per hour
(PFH) (there are approximately 104 hours in a year). IEC 61508 defines a scale of four distinct levels of risk reduction
referred to as the Safety Integrity Level (SIL).
SIL
PFDavg Low Demand Mode
PFH High Demand Mode
RRF
1
≥10-2 to < 10-1
≥10-6 to < 10-5
> 10 to ≤100
2
≥10-3 to < 10-2
≥10-7 to < 10-6
> 100 to ≤1,000
3
≥10-4 to < 10-3
≥10-8 to < 10-7
> 1,000 to ≤10,000
The SIL applies to all elements in the safety loop (sensors, logic solver, and final element) and their architecture. The loop
must be considered in its entirety.
2.3
Safety System Redundancy Options
Redundancy is a key feature in safety control system design that can enable on-line repair without interrupting the process.
The unique Ethernet back-bone of the Mark VIeS Safety system enables several options for redundancy to achieve required
SIL. This provides the safety control engineer unparalleled flexibility to meet the safety SIL requirements for each application
in the most cost effective manner.
70
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Triple Modular Redundant (TMR)
The Mark VIeS Triple Modular Redundant (TMR) Control Modes can provide:
•
Two out of three (2oo3) voting
−
SIL 3 high/low demand for de-energize-to-trip
or
−
SIL 2 low demand for energize-to-trip
•
Hardware fault tolerance (HFT): 1
•
Degradation sequence: [2oo3] > [1oo2] > [Fail Safe]
TMR Fanned Input
Single discrete/
analog sensor is
fanned through a
common terminal
board to three
independent input
packs, 2oo3 voting
is done in the
controller set.
TMR Dedicated
Input
Three redundant
discrete/analog
sensors are wired to
three independent
input modules, 2oo3
voting is done in the
controller set.
Sensor
A
Sensor
A1
Sensor
A2
Sensor
A3
Actuator
TMR Outputs Voted
on Terminal Board
The three packs
receive output
commands from their
associated controller,
the common terminal
board then performs
2oo3 voting on the
outputs and controls
the discrete actuator.
2oo3 Voting in Actuator
TMR Outputs Voted in
Actuator
Three independent output
modules receive the output
command from their
associated controller, then
command the actuator, 2oo3
voting performed in the
actuator.
TMR Controllers
Three Mark VIeS controllers work as a
set synchronizing data every frame
(sweep). Each controller receives inputs
on all 3 I/O networks, and sends output
commands on designated I/O network.
TMR I/O Network
Ethernet based TMR I/O network
supports both centralized and
distributed I/O modules.
R
S
T
Embedded Controller Gateway
Embedded controller for
communication interface,
options:
- OPC-UA server
- Modbus slave
Third Party
Control
System
PC Based Gateway
PC based communication interface, options :
- OPC-DA server
- OPC-UA server
- Modbus master
Functional Safety
GEH-6721_Vol_I_BP System Guide 71
Public Information
The Mark VIeS Dual Control Modes can provide:
•
One out of two (1oo2) voting, SIL 3 high/low demand for de-energize-to-trip
•
Two out of two (2oo2) voting, SIL 2 low demand for energize and de-energize-to-trip
•
Hardware fault tolerance (HFT): 1
TMR Fanned
Input
Single sensor is
fanned through a
common terminal
board to three
independent input
packs, 2oo3
voting done in the
controller set.
Single
Sensor
Single sensor
wired to a
single input
module with
dual I/O
network to
controller set.
Sensor
A
Sensor
A
Sensor
A1
Sensor
A2
Actuator
TMR Outputs
Voted on Terminal
Board
The three output
packs receive an
output command
from designated
controller, the
common terminal
board then
performs 2oo3
voting and controls
the actuator.
Acutator
1oo2 De-energize
to Trip in Output
Modules
Two independent
output modules
receive the output
command from
designated
controller,
combination of two
creates 1oo2 de-
energize to trip
function across the
two modules.
Dual Controllers
Dual Mark VIeS controllers work as a
controller set synchronizing data every frame
(sweep). Each controller receives inputs on
both I/O networks, and sends output
commands on designated I/O network.
Dual I/O Network
Ethernet based dual I/O network
supports both centralized and
distributed I/O modules.
Dual Sensor
Dual sensors
wired to
independent
input modules
with independent
I/O networks to
controller set.
Third Party
Control
System
R
S
PC Based Gateway
PC based communication interface,
options:
- OPC-DA server
- OPC-UA server
- Modbus master
Embedded Controller Gateway
Embedded controller for
communication interface,
options:
- OPC-UA server
- Modbus slave
72
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Mark VIeS Simplex Control Mode is used for one out of one (1oo1), SIL 2 low demand for de-energize to trip
applications.
R
Simplex Controller
Simplex Mark VIeS controller
receives inputs and sends
outputs on the one I/O network.
I/O Network
Ethernet based I/O network
supports both centralized and
distributed I/O modules.
PC Based Gateway
PC based communication interface,
options:
- OPC-DA server
- OPC-UA server
- Modbus master
Third Party
Control
System
Embedded Controller Gateway
Embedded controller for
communication interface,
options:
- OPC-UA server
- Modbus slave
Single Sensor
Single sensor
wired to a single
input module
with a simplex I/
O network to
controller.
Sensor
A
Sensor
A1
Sensor
A2
Dual Sensor
Dual sensors
wired to
independent input
modules with a
simplex I/O
network to
controller.
Actuator
Simplex Output
One output pack
receives an output
command from the
controller.
Functional Safety
GEH-6721_Vol_I_BP System Guide 73
Public Information
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The integrated control system is based on a hierarchy of Ethernet networks, used to interconnect individual nodes or zones.
These networks separate the different communication traffic into layers according to their individual functions. This hierarchy
extends from the I/O modules and controllers (providing real-time control of the process) to the HMIs, and out to
facility-wide monitoring and external networks (industrial internet).
Each network layer uses industry standard components and protocols to simplify integration between different platforms and
improve overall reliability and maintenance. These layers are designated as IONet, Unit Control, Supervisory, and Enterprise
in the following figure, which displays a simplified network hierarchy and is not representative of any specific installation.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 75
Public Information
Unit Control Layer
Supervisory Layer
Mark VIeS
Controller
IONet Layer
EX2100e
Excitation
Control
LS2100e Static
Starter Control
Mark VIe
Controller
Mark VIe
Controller
Plant Data Highway (PDH)
Unit Data Highway (UDH)
Enterprise Layer
GE Demilitarized Zone (DMZ)
Electronic Security Perimeter (ESP)
Mark Stat
Wind Power
Converter
Mark VIe
Controller
R
S
T
TMR I /O Modules
Simplex I/O Modules
SIL 3
Functional
Safety
Monitoring Data Highway
Monitoring Layer
On-Site Monitor (OSM)
Remote Services
Gateway (RSG)
Mark VIe
HMI
Mark VIe
Historian
SecurityST
Cyber
Security
Management
System
Printer
Customer Network
Simplified Network Hierarchy (switches not shown)
76
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
GE Large Industrial Plant Network Architecture
The current networking architecture for GE large industrial plants uses a mesh architecture design (also known as hub and
spoke) with redundant network switches. This design enables flexibility for implementation of cyber security offerings,
allowing secure access to unit control data from external customer and monitoring networks. Trunks from the root or hub
switches to the edge or spoke switches shall be single-mode fiber for all new site installations. These trunks are configured to
provide the UDH, PDH, Monitoring Data Highway (MDH), and can also provide other optional networks to further partition
network access to specified unit control equipment and data.
Network security can be implemented by adding an additional layer 3 security hardware infrastructure. Network traffic is then
regulated by an additional series of routers, switches, and firewalls. The SecurityST* appliance can be installed to allow for
tighter network security with or without the additional layer 3 security hardware by providing white listing and restricted
access to network devices. Various options for existing sites are available to improve network security without having to
relocate equipment or cable runs.
In the following figure, both cyber security offerings (the layer 3 hardware and the SecurityST server) are displayed as a
simplified example that is not representative of any specific installation. This industrial plant network architecture provides
flexibility to cost for sites with various security compliance requirements. A qualified GE networking engineer can determine
best fit options for particular customer facilities.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 77
Public Information
Catalyst 2960-S Series
25
26
27
28
M
G
MT
B
AS
E
T
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
AS
ET
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Root Switch
MODE
Catalyst 3750 -X Series
BLAN K
MODULE
F N
SYST
CONS OLE
XPS
STAT
SPEED
DUPLX
S-PWR
M AST
STACK
Catalyst 3750-X Series
1
2
3
4
5
6
7
8
9
10
11
12
MODE
Catalyst 3750 -X Series
BLAN K
MODULE
F N
SYST
CONS OLE
XPS
STAT
SPEED
DUPLX
S-PWR
M AST
STACK
Catalyst 3750-X Series
1
2
3
4
5
6
7
8
9
10
11
12
ControlST
Software
Mark VIe TMR
Controller Set
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
A
S
E
T
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13 X
14 X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
1 1X
1 2X
XDH Switch
Customer Enterprise Network
GE Wide Area Network (WAN)
Firewall
Outside Plant Facility
GE Demilitarized Zone (DMZ)
To Remote Services Gateway (RSG),
Onsite Monitor (OSM), Bently, etc.
Layer 3 Security
Video Terminal
KVM
DC2
VH1
DC1
AP1
AP2
AP3
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
AS
E
T
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
AS
ET
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Edge Switch
Edge Switch
Router
Router
Switch Connector Cable
Plant Data Highway (PDH)
Cable: Cat 5e
Legend
Unit Data Highway (UDH)
Cable: Cat 5e
Trunk
Cable: Single Mode Fiber
To additional security HW
Cable: Cat 6
WorkstationST
Historian
HMI (hardened)
NIDS
SecurityST monitoring
Cable: Cat 5e
Monitoring Data Highway
(MDH)
Cable: Cat 5e
Printer
Remote Services
Gateway (RSG)
On-Site Monitor
(OSM)
HMI (hardened)
Simplified Industrial Plant Network Architecture
Note 1. Considerations for network upgrades are discussed the section, Network Retrofit Guidelines.
2. GE Wind Farms use a different network architecture.
3. GE M&C supplies the SecurityST appliance.
78
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
Mesh Architecture for UDH, PDH, MDH
The large industrial plant network architecture involves the use of root switches that communicate the Integrated Control
System (ICS) virtual local area networks (VLANs) over Single Mode Fiber (SMF) trunks to edge switches. For redundancy,
two or more identical switches are cabled together, enabling them to act as one switch with the port capacity of the combined
switches. These cables are connected through special ports or plug sockets in the rear of the switches.
Note Refer to NetworkST for Mark VIe Controls Application Guide (GEH-6840).
Redundant switch cabling offers the following advantages:
•
Built-in failover and recovery (failback) in the event one of the switches fails.
•
An unconfigured switch can be used to replace a failed switch in pair. It will automatically upload the running
configuration from the other switch in the group.
•
Enhanced network storm control protection
•
Network redundancy
•
Gigabyte uplink speeds (with SMF)
•
Enhanced Quality of Service (QoS) – ensures UDH (controller traffic) always has priority over PDH network traffic.
•
Cisco switches are 802.1x compliant.
The current large industrial plant network topology uses pairs of edge switches and pairs of root switches to achieve
redundancy. Devices with redundant communications (HMIs, controllers) have a network connection to each of the two
switches in the pair. For Triple Modular Redundant (TMR) controllers, the R controller is connected to the first switch, and
the S and T controllers are connected to the second switch.
MODE
Catalyst
3750
-X Ser ies
BLANK
MODULE
FNSYST
CONSOLEXPSSTATSPEED
DUPLX
S-PWR
MASTSTACK
Catalyst
3750
-X Ser ies
1
2
3
4
5
6
7
8
9
10
11
12
MODE
Catalyst
3750
-X Ser ies
BLANK
MODULE
FNSYST
CONSOLEXPSSTATSPEED
DUPLX
S-PWR
MASTSTACK
Catalyst
3750
-X Ser ies
1
2
3
4
5
6
7
8
9
10
11
12
Root Switches
Edge Switches
Switch connector
cable located rear
Mark VIe HMIs,
Historians
Legend
Catalyst
2960
-S Ser ies
25
26
27
28
M
GM
TBASET
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13
X
14
X
23X
24X
13 14 15 16 17 1819 20 21 22 23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11
X
12
X
Catalyst
2960
-S Ser ies
25
26
27
28
M
GM
TBASET
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13
X
14
X
23X
24X
13 14 15 16 17 1819 20 21 22 23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11
X
12
X
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
AS
E
T
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
A
SE
T
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Edge Switches
Mark VIe
Controller
Set
Cat alyst
2960
-S Series
25
26
27
28
M
GMT
BASET
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13
X
14
X
23
X
24
X
13 1415 16 17 18 19 2021 22 23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11
X
12
X
Cat alyst
2960
-S Series
25
26
27
28
M
GMT
BASET
CONSOLE
STCK
SPED
DPLX
STAT
MSTR
RPS
SYST
MODE
13
X
14
X
23
X
24
X
13 1415 16 17 18 19 2021 22 23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11
X
12
X
Edge Switches
Trunk provides all VLANs
Cable: Single Mode Fiber
Plant Data Highway (PDH)
Cable: Cat5e
Unit Data Highway (UDH)
Cable: Cat5e
Monitoring Data Highway (MDH)
connects to an OSM or RSG
Cable: Cat5e
R
S
T
Mesh Root and Edges
The Root bridge switch is at the top of the network spanning tree. The edge switches (Ethernet connections) are then
connected below the root switch. The most important element to this spanning tree is the root bridge placement. It should be
the most centralized switch on the network (typically located in the control room). All data flow across the network is from
the perspective of this switch. Root switches are configured to provide the control system VLANs and other optional
networks over trunks to the edge switches.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 79
Public Information
Note Root and edge switches are not interchangeable.
Each edge switch connects back to a corresponding root bridge switch through the trunks. There is only one root bridge
switch group in the system. Special configuration files define which switch acts as the root or edge. In addition, the edge
switch ports are specially configured to provide the PDH, UDH, or MDH. Typically, ports 1–10 are PDH, ports 11–22 are
UDH, and 23–24 are MDH (refer to the label on the switch itself for specific port details).
Depending on specific site network requirements, the Cisco 2960S can be supplied as a root bridge switch on jobs with up to
four units. Cisco 3750X switches serve as the root bridge at sites with more than four units.
3.2
IONet Layer
IONet communication is internal between the controller(s) and the I/O modules through an unmanaged IONet switch. IONet
redundancy can be one, two, or three networks, and is equal to the controller redundancy. The following cable color-coding
for RJ-45 hoods is used to reduce the chance for cross connecting:
Note On the UCSx controller from top to bottom, the networks are T, S, R.
•
Blue for IONet 3 (T network)
•
Black for IONet 2 (S network)
•
Red for IONet 1 (R network)
Note Refer to the section Controller Redundancy for more information.
The IONet provides direct communication between controllers and I/O modules. IONet EGD protocol (which is different than
UDH EDG protocol) is used. The I/O modules send their inputs to the controllers and the controllers send their outputs to the
I/O modules each frame, as displayed in the section Rate of Response. Examples of IONet traffic are as follows:
•
Status of control system input data from the I/O packs to the controller set
•
Status of control system output data from the controller set to the I/O packs
•
I/O pack configuration data from the ToolboxST application to the controller to the I/O packs
•
I/O pack health status data from the packs to the controller
•
Field device input data from the I/O pack to the controller
Note The ESWx switch is used for IONet communication.
The sharing of input data between two control sets (Shared IONet) on a single IONet is available for the following controllers:
•
One Mark VIeS Safety controller set and one Mark VIe controller set
•
One Mark Stat controller set and one Mark VIe controller set
•
Two Mark VIe controller sets
Note A control set is the group of controllers (based on redundancy) with the set of owned I/O modules. From the
ToolboxST System Editor Summary View, a control set displays as a single controller.
80
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
IONets are IEEE 802.3 100 Megabits full duplex Ethernet networks. All traffic on each IONet is deterministic UDP/IP based
packets. Each network (red, blue, black) is an independent IP subnet. The IEEE 1588 standard for precision clock
synchronization protocol is used to synchronize frame and time between the controllers, and the I/O modules on the IONet.
This synchronization provides a high level of traffic flow control on the networks.
The following figure display maximum IONet cable lengths.
100FX Fiber
Multi mode (MMF): 2000 m (6600 ft)
Single mode (SMF): 15km (9.32 miles)
Controller
Cat 5e (copper)
100m (328 ft)
Cat 5e (copper )
100m (328 ft)
Copper or Fiber depending
on distance required
field wiring
Field device
Cat 5e (copper)
100m (328 ft)
IONet Maximum Distances
Item
IONet Specification
IEEE specification
802.3u
Wire speed
100 Mbps
Cable types
100Base-TX: UTP Cat 5e
100Base-FX: MMF or SMF
Maximum taps per segment
2
Maximum packets per network
199
Maximum number of switches
5
Topology
Star
For the control system IONet topologies, the following rules apply for deploying SMF systems:
•
No more than five switches can be placed in series between controller and remote I/O module.
•
The topology should be kept as flat and balanced as possible (star topology).
•
Use the GE ESWA or ESWB switch with additional IR SFP single-mode transceiver for SFP1 and SFP2.
−
GE part # 65G2100-009 for single-mode fiber distances up to 2 km
−
GE part # 65G2100-008 for single-mode fiber distances up to 15 km
Caution
Use of any other switch in this application may cause miss operation and/or damage to
the associated equipment.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 81
Public Information
IONet switches are unmanaged, fully switched, and full-duplex to prevent collisions. They provide data buffering and flow
control during the critical input scan. Only industrial grade switches that meet the codes, standards, performance, and
environmental criteria for industrial applications are used for the IONet. GE industrial Ethernet 10/100 IONet switches
(ESWA and ESWB) have an operating temperature of -40 to 70 °C (-40 to 158 °F), have provisions for redundant 18 to 36 V
dc power sources (200/400 mA), and can be DIN-rail mounted. The switches also provide LEDs to indicate the status of the
IONet link, speed, activity, and duplex.
16-port ESWB IONet Switch
Caution
Use only GE-approved Ethernet switches in all control system I/O networks.
Unsupported switches can prevent I/O modules from receiving controller outputs.
Approved IONet Switches
Part #
Description
IS420ESWAH1A
8 ports 10/100BASE-TX + 1 port 100BASE-FX LC-type connection
IS420ESWAH2A
8 ports 10/100BASE-TX + 2 ports 100BASE-FX LC-type connection
IS420ESWAH3A
8 ports 10/100BASE-TX
IS420ESWAH4A
8 ports 10/100BASE-TX + 1 port 100BASE-LX10 LC-type connection
IS420ESWAH5A
8 ports 10/100BASE-TX + 2 ports 100BASE-LX10 LC-type connection
IS420ESWBH1A
16 ports 10/100BASE-TX + 1 port 100BASE-FX LC-type connection
IS420ESWBH2A
16 ports 10/100BASE-TX + 2 ports 100BASE-FX LC-type connection
IS420ESWBH3A
16 ports 10/100BASE-TX
IS420ESWBH4A
16 ports 10/100BASE-TX + 1 port 100BASE-LX10 LC-type connection
IS420ESWBH5A
16 ports 10/100BASE-TX + 2 ports 100BASE-LX10 LC-type connection
Part #
Description
336A4940DNP508TX
8 copper ports
336A4940DNP516TX
16 copper ports
336A4940DNP509FX
8 copper ports and 1 fiber port
336A4940DNP517FX
16 copper ports and 1 fiber port
336A4940DNP508FXE2
6 copper ports and 2 fiber ports (single mode)
336A4940JEP001
Installed within the 1.x ESS wind turbine hub
336A4940JEP002
Installed within the 1.x wind turbine top box
336A4940JEP003
Installed within the 1.x wind turbine Down Tower Assembly (DTA)
336A4940JEP004
Installed within the 2.x and 1.x non-ESS wind turbine hub
82
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
IONet Switch Guidelines
IONet is presently recommended to pass through a maximum of five switches in series when traveling from an I/O pack to a
main controller for the following reasons:
•
IONet switches are not managed switches.
•
Every Ethernet switch introduces latency into the transmission of Ethernet packets.
•
Each controller frame allocates a period of time to service I/O data.
Mark VIe Controller
IONet Switch
Communication path
between I /O packs
and controller, IONet
switches A-B
A
B
C
D
E
Communication path
between I /O packs
and controller, IONet
switches A-B-C
Communication path
between I /O packs
and controller, IONet
switches A-B-C-D
Communication path
between I /O packs
and controller, IONet
switches A-B-C-D-E
Note: Maximum of 5 IONet
switches that Ethernet packets
pass through between I/O pack and
controller
Five Maximum IONet Switches in Series Between Controller and I/O Pack
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 83
Public Information
I/O Pack Ethernet Addressing
On the IONet, I/O packs are assigned IP addresses through the DHCP servers in the controllers. The Host ID presented to the
DHCP server is based on the board type and serial number information stored on a serial EEPROM located on the terminal
board. Since the Host ID is part of the terminal board, the I/O pack can be replaced without having to update the ToolboxST
application or controller communication IDs.
Note When a terminal board is replaced, the user must associate the new Host ID to the configured device. The ToolboxST
application presents a list of unrecognized devices that have requested IP addresses to simplify this process.
IONets are Class C networks. Each is an independent network with different subnet addresses. The IONet IP host addresses
for the controllers are fixed. The IP addresses of the I/O packs are assigned by the ToolboxST application, and the controller
automatically distributes the addresses to the I/O packs through a standard Dynamic Host Configuration Protocol (DHCP)
server in the controllers.
84
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Shared IONet function (with ControlST* V04.06 or higher) enables the sharing of Mark VIeS Safety inputs or Mark Stat
Wind Converter inputs with another basic process Mark VIe controller set, saving the cost of redundant sensors and I/O.
Specific configurations supported include:
•
One Mark VIeS Safety controller set and one Mark VIe controller set
•
Two Mark VIe controller sets
•
One Mark Stat Wind power conversion controller set and one Mark VIe controller set
Note The Mark VIe UCPA controller platform does not support Shared IONet.
R
S
T
R
S
T
Safety Inputs
Field devices for
functional safety loop
Mark VIeS
controller set
owns the safety
I/O modules (for
SIL rating,
configuration,
and diagnostic
reporting).
Safety I/O modules
Basic process I/O modules
Mark VIe
controller set
receives the
inputs from safety
I/O modules (data
from safety loop
field devices).
One TMR
redundant IONet
Shared IONet Example
The owner controller allows for the configuration of the owned I/O modules, writes outputs, reads SOEs, and provides
diagnostic information. Owned I/O modules are attached to their owner controller that can configure and write to them, and
obtain their IP addresses from their owner controller. Outputs from controllers are received by their owned I/O modules (not
shared I/O modules).
Note Refer to Mark Controllers Shared IONet User Guide (GEH-6812) for more information.
A shared I/O module sends field device inputs to both its owner controller and to the consumer controller. The consumer
controller receives the field device inputs from the shared I/O modules that are owned by the other owner controller.
Configuration of the control sets is managed with the ToolboxST application. The computer with the ToolboxST application
communicates with the I/O devices through a software gateway function residing in the controllers.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 85
Public Information
Unit Control Layer
The Unit Control layer or Unit Data Highway (UDH) provides the network connections that support continuous operation of
the process equipment, including controller sets (general-purpose, safety loops, turbine-specific, static starter, exciter) and
HMIs. The UDH is an Ethernet-based network that provides direct or broadcast peer-to-peer communications between a
controller set and an operator/maintenance interface. The controllers operate at a fundamental rate called the frame rate,
which is configurable, and is dependant on the controller processor type, the amount of application code being run, and other
loads.
Mark VIe controllers and HMIs use the EGD protocol to exchange real-time data, which on the UDH is based on UDP/IP (for
data exchange) and HTTP (for configuration of pages). In addition, SDI protocol is used by the ToolboxST application to
download to the controller over the UDH. Alarms and capture buffer uploads (that feed trip logs) are also through the SDI
protocol.
Note Current controls systems network architecture has UDH, PDH, and MDH connections on a common set of network
switches and media trunks.
The UDH connections to the controllers and HMIs are unshielded twisted pair (UTP) Cat 5e from edge switches. This
redundant mesh architecture allows network connectivity even if one cable or switch is faulty. Redundant networks still
comprise one logical network.
The following figure displays the UDH network with connections to the controllers and HMIs.
Mark VIe
Controller
Set
Mark VIeS
Controller
EX2100e
Excitation
Control
LS2100e
Static Starter
Control
Mark VIe
Controller
Mark VIe
Controller
Unit Data Highway (UDH)
Mark Stat
Wind Power
Converter
Mark VIe
Controller
R
S
T
SIL 3
Functional
Safety
SecurityST
Cyber
Security
Management
System
PDH
PDH
PDH
Mark VIe
HMI
Mark VIe
Historian
Unit Data Highway Example
86
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
UDH Communicator in a Redundant Controller Set
In dual or TMR Mark VIe controller sets, a single controller is designated to transmit real-time and alarm data for the set; this
is the UDH Communicator. This data includes both control signals (EGD) and alarms (SDI). Since each controller has an
independent, physical connection to the UDH, if a UDH network fault occurs where one controller becomes isolated from its
companion controllers, the isolated controllers assumes the role of UDH communicator for that network fragment. For this
reason, a controller set has only one designated controller, while there could be multiple UDH communicators. The
designated controller is always a UDH communicator.
Note UDH command data is replicated to redundant controllers by the UDH Communicator, allowing for synchronization
across the redundant controller set.
When a controller does not receive external EGD data from its UDH connection, it may request that the data be forwarded
across the IONet from another UDH communicator. One or more communicators supply the data, and the requesting
controller uses the last data set received. Only the external EGD data used in sequencing by the controllers is forwarded in
this manner.
3.3.2
UDH Network Specifications
Item
Description
Type of Network
Ethernet, full duplex, in a single or redundant star configuration
Media and Distance
Ethernet 100Base-TX for switch to controller/device connections. The cable is 22 to 26 AWG
unshielded twisted pair; category 5e EIA/TIA 568 A/B. Distance is up to 100 m. Ethernet
100Base-FX with fiber-optic cable optional for distances up to 2 km (1.24 mi).
Number of Nodes
At least 25 nodes, given a 25 Hz data rate. Other configurations may be available.
Type of Nodes Supported
Controllers, PLCs, operator interfaces, and engineering workstations
Protocol
EGD, based on UDP/IP
Message Integrity
32-bit CRC appended to each Ethernet packet plus integrity checks built into UDP and EGD
Time Sync. Methods
Network time protocol (NTP), accuracy ±1 ms.
3.3.3
Control System Devices on the UDH
3.3.3.1
Mark VIe Controllers
The Mark VIe controllers are applied in a wide variety of industrial control applications. The Mark VIeS Safety controller is
used for safety-critical SIL applications. The Mark VIe UCPA platform is a lower cost, smaller footprint controller with
integral I/O and limited expansion I/O capability. The same ToolboxST application is used for configuration of the Mark VIe
controller product line. For more information, refer to Mark VIe and Mark VIeS Control Systems Volume II: System Guide for
General-purpose Applications (GEH-6721_Vol_II), the chapter Controllers.
The EX2100e excitation controller supplies dc power to the field of the synchronous generator, and controls the generator ac
terminal voltage and/or the reactive volt-amperes by means of the field current. The excitation control system is supplied in
NEMA 1 freestanding floor-mounted indoor type metal cabinets. The cabinet lineup consists of several cabinets bolted
together.
Note Refer to EX2100e Excitation Control User Guide (GEH-6781) for further details.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 87
Public Information
The LS2100e Static Starter controller is used to start a gas turbine by running the generator as a starting motor. The Static
Starter control, the Mark VIe control, and the excitation control system form an integrated static start system. The Mark VIe
control supplies the run, torque, and speed setpoint signals to the Static Starter control, which operates in a closed loop control
mode to supply variable frequency power to the generator stator. The excitation control system is controlled by the Static
Starter control to regulate the field current during startup.
Note The Static Starter control cabinet is a ventilated NEMA 1 freestanding enclosure made of 12-gauge sheet steel on a
rigid steel frame designed for indoor mounting.
The LS2100e Static Starter control is an adjustable speed ac drive system specifically designed to start a gas turbine generator
set. By operating the generator as a synchronous motor, the static starter accelerates the turbine set according to a specific
speed profile that provides optimum starting conditions for the gas turbine. The LS2100e control eliminates the need for
separate starting hardware, such as an electric motor or diesel engine, torque converters, and associated auxiliary equipment,
thus opening up critical space around the turbine base.
Note Refer to LS2100e Static Starter Control User Guide (GEH-6798).
The Mark Stat controller contains specialized firmware and application to control a GE multi-megawatt wind turbine power
conversion system.
3.3.3.2
Human-machine Interface
The Human-machine Interface (HMI) is the main operator interface to the Mark VIe control system. Current Mark VIe HMIs
are desktop computers running the Windows® 7 operating system with multiple communication drivers for the redundant data
highways, WorkstationST* and ToolboxST applications, and the CIMPLICITYAdvanced Viewer for the Graphical User
Interface (GUI). The operator initiates commands from the real-time graphic displays, and views real-time process data and
alarms. Detailed I/O diagnostics and system configuration is accomplished from the ToolboxST applications.
Note HMIs typically connect to both PDH and UDH networks.
The WorkstationST server is the hub of the system, channeling data between the UDH and the PDH, and providing data
support and system management. The server also has the responsibility for device communication for both internal and
external data interchanges. WorkstationST servers collect data on the UDH, and use the PDH to communicate with HMI
viewers. Configuration servers, Historian servers, and Alarm servers are used for large system scaling. Multiple servers can
be used to provide redundancy so that communication with the viewers continues even if one server fails.
Note The HMI can be configured as a server or viewer, containing tools and utility programs.
88
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Mark VIe Historian computer runs ControlST software including Historian reports, the WorkstationST application, and
Trender, and can be configured for PI or Proficy data exchange to an external database server. The Historian is a data archival
system based on client-server technology, used for data collection, storage, and display of process data. Flexible tools enable
the operator to quickly generate custom trends and reports from the archived process data. The Historian combines
high-resolution digital event data from the Mark VIe controllers with process analog data, creating a sophisticated tool for
investigating cause-effect relationships.
The Historian receives data from the controllers over the UDH. The HMIs and other operator interface devices communicate
to the Historian through the PDH. Network technology provided by the Windows operating system allows interaction from
network computers, including query and view capabilities, using the Historian Client Tool Set. The interface options include
the ability to export data into spreadsheet applications.
3.3.3.4
Power Conversion Controllers
GE Brilliance* solar inverter and legacy wind power conversion controllers can reside on the integrated control system UDH,
and are configured with a common ToolboxST application.
3.3.4
Control Data Highway (CDH)
A second UDH or redundant Ethernet Communication known as the Control Data Highway (CDH) allows two separate
controllers to communicate with each other. The second CDH Ethernet can be added to a control system currently using the
other UDH Ethernet port. The following table displays requirements for hardware setup.
Note To configure a CDH, refer to ToolboxST User Guide for Mark Controls Platform (GEH-6700 or GEH-6703), the
section Networks.
CDH Hardware Setup
First
Controller
Second
Controller
Ethernet Connection
Simplex
Simplex
Each controller connects though the second Ethernet port using a single cross-over
category 5 network cable.
Simplex
Dual
The simplex controller connects to the second Ethernet ports of both the and
controllers of the dual system using a category 5 network cable through a network
switch.
Simplex
TMR
The simplex controller connects to the second Ethernet ports of , , and
controllers of the TMR system using a category 5 network cable through a network
switch.
Dual
Dual
The and controllers of each system connect using a category 5 network
cable through a network switch.
Dual
TMR
The and controllers of the dual system connect to the , , and
controllers of the TMR system using a category 5 network cable through a network
switch.
TMR
TMR
The , , and controllers of each system connect using a category 5
network cable through a network switch.
With the TMR and TMR configuration, the customer does not have to use the network
if all EGD exchanges run at frame rate.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 89
Public Information
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
A
S
ET
CONSOLE
S TCK
S PE D
D PLX
S TAT
MSTR
R PS
S YS T
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
BA
S
E
T
CONSOLE
S TCK
S PE D
D PLX
S TAT
MSTR
R PS
S YS T
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Controller R
Controller S
Controller T
2960S
Switch
Control Panel 1
Control Panel 2
PAIC
PSVO
ENET2
GE
Unmanaged
Switch
Field
Device
Output
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
B
A
S
ET
CONSOLE
STCK
SPE D
DPLX
STAT
MSTR
R PS
SYS T
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Catalyst 2960-S Series
25
26
27
28
M
G
M
T
BA
S
E
T
CONSOLE
STCK
SPE D
DPLX
STAT
MSTR
R PS
SYS T
MODE
13X
14X
23X
24X
13 14
15 16
17 18
19 20
21 22
23 24
1 2
3 4
5 6
7 8
9 10
11 12
1X
2X
11X
12X
Controller R
Controller S
Controller T
Input
2960S
Switch
CDH Application Example
Control Data Highway (CDH)
Cable: Cat 5e UTP
Legend
Unit Data Highway (UDH)
Cable: Cat 5e UTP
IONet
Cables: Cat 5e UTP
IONet
Cable: SMF or MMF
Field
Device
GE
Unmanaged
Switch
90
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Supervisory layer contains the Plant Data Highway (PDH), which connects to WorkstationST servers, Alarm Viewers,
printers, historians, and other HMIs. Additional cyber security management equipment can also reside on the PDH. The PDH
has no direct connection to the Mark VIe controllers, which communicate over the UDH.
The PDH network is used to further partition equipment and to restrict access or prevent disruptions to the Mark VIe
controllers (which are busy broadcasting data across the UDH). The PDH should be used to copy or transfer large files from
HMI to HMI (for example, CIMPLICITY projects).
PDH uses redundant cables to form one single logical network, and the mesh architecture is identical to the UDH. The
hardware consists of edge Ethernet switches with single-mode fiber-optic trunks connected to root switches, then standard Cat
5e outputs to HMIs and other devices. Redundant Ethernet switches and cables prevent complete network failure if a single
component fails. The PDH and the UDH are physically the same network of switches, but use different ports for the particular
data highway.
Plant Data Highway (PDH)
UDH
UDH
UDH
SecurityST
Cyber
Security
Management
System
Printer
Mark VIe
HMI
Mark VIe
Historian
Supervisory Layer Example
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 91
Public Information
PDH Network Features
Feature
Description
Type of Network
IEEE 802.3 Ethernet in a mesh topology
Speed
100 megabit per second or with 1000 megabit per second trunks interconnecting switches
Media and Distance
Ethernet 100Base-TX is used for switch to controller/device connections. Cable is CAT 5e
compliant. Distance is up to 100 m (328 ft). * Fiber-optic connections, Ethernet 100FX, 1000SX,
1000 LX are used for distances of 2 km (1.24 mi), 550 m (1804.46 ft), and 5 km (3.11 mi),
respectively.
Number of Nodes
Up to 1024 nodes supported
Protocols
Ethernet-compatible protocol, typically TCP/IP-based. Use GSM, OPC UA, or Modbus over
Ethernet for external communications.
Message Integrity
32-bit cyclic redundancy code (CRC) appended to each Ethernet packet plus additional checks in
protocol used.
External Interfaces
Various third-party interfaces are available; GSM, OPC UA, and Modbus are the most common.
* Fiber-optic cable provides the best signal quality, completely free of electromagnetic interference (EMI) and radio frequency
interference (RFI). Large point-to-point distances are possible, and since the cable does not carry electrical charges, ground
potential problems are eliminated.
3.5
Monitoring Layer
The monitoring data highway (MDH) is used to further partition the flow of data to individual assets, and can include
connection to GE Monitoring and Diagnostic (M&D) equipment: the On-Site Monitor (OSM) or Remote Services Gateway
(RSG). The data that is allowed to travel over the MDH is managed by two specially configured Cisco 2901 routers. The
same mesh architecture and trunks provide the MDH from the root to edge switches, then from special configured ports on the
edge switches to the OSM or RSG. Other devices may also be included on the MDH to meet customer requirements.
Connectivity to the RSG and OSM is designed during the plant requisition phase, so the MDH is not the only available
implementation of GE M&D equipment.
Note Refer to the figure Simplified Network Hierarchy.
92
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Enterprise layer allows access to specific control system data or communication sources for facility-wide or group asset
management systems. The Enterprise layer can include the following features:
•
Additional firewalls, routers, and security features
•
Interface to customer network
•
GE Demilitarized Zone (DMZ) for hosting GE assets to be accessed external from customer site facility
•
Interface to other GE Wide Area Network (WAN), Atlanta Data Higway (ADH) for GE Monitoring and Diagnostics
(M&D) services
The Industrial Internet Gateway (IIG) option consists of a firewall appliance that is inserted as a barrier between the ICS
VLAN and any other external devices. The firewall establishes security regions, or zones, as defined in the IEC standard
62443 or ISA 99. Equipment is allocated to each zone based on their function and relative security risk to the Mark VIe
control system. For diagnostic or analysis purposes, access to specifically tagged control system data or communications can
be allowed from outside the plant. Since any outside communications represent a significant risk to the integrity and security
of the control system, establishing a DMZ that terminates the outside networks and then only allows specific authenticated
traffic to flow from the DMZ to specific hosts behind the DMZ is recommended.
GE demilitarized zone (DMZ)
Customer Enterprise Network
GE Wide Area Network (WAN) to ADH
Firewall
Outside Plant Facility
Virtual local area networks (VLANs)
Mark VIe Integrated Control System (ICS)
Enterprise Layer Example (does not represent an actual installation)
The IIG establishes four interfaces to connect from the firewall: Customer, ADH, DMZ, and ICS VLAN. The Customer
interface typically connects to an additional upstream router or firewall provided by the customer. The ADH is used by GE
M&D to provide remote services for the customer, for example analytics or troubleshooting. The DMZ has a rule set or policy
that is implemented by GE to enable remote access to key resources. These resources are able to collect specifically
configured control system data or perform specifically configured control system functions. The ICS VLAN connects from
the IIG firewall to a switch that terminates at two routers and then into the root switch and on to the edge switch. Refer to the
section Mesh Architecture for more information.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 93
Public Information
Ethernet Cabling for Monitoring, Supervisory, and
Unit Control Layers
3.7.1
Single-mode Fiber
Note Trunks tie edge switches to the root switch.
For new sites, single-mode fiber-optic (SMF) cables are installed for all trunks. The main advantages of fiber-optic
transmission are as follows:
Note
For more information, refer to Fiber-optic Cable and Patch Panel Selection (GHT-200001).
•
Fiber segments can be longer than copper because the signal attenuation per foot is less.
•
In high-lightning areas, copper cable can pick up currents, which can damage the communications electronics. Since the
glass fiber does not conduct electricity, the use of fiber-optic segments avoids pickup and reduces lightning-caused
outages.
•
Grounding problems are avoided with optical cable. The ground potential can rise when there is a ground fault on
transmission lines, caused by currents coming back to the generator neutral point, or lightning.
•
Optical cable can be routed through a switchyard or other electrically noisy area and not pick up any interference. This
can shorten the required runs and simplify the installation.
•
Fiber-optic connections normally have higher signal levels and decreased chances of packet discard from noise
corruption. Typical differences in error rate is 10000 lower for fiber-optic cables.
•
The cost per connection for fiber may now be less than copper cables. Large, multifiber trunk cables contain many fibers,
so cost per foot for each connection may actually cost less than multiple copper cables.
•
Fiber-optic cable with proper jacket materials can be run buried in trays or in conduit.
•
High-quality fiber-cable is light, tough, and easily pulled. With careful installation, it can last the life of the plant.
3.7.1.1
SMF Specifications
•
Single-mode fiber-optic cables are connected from the root switch group to the edge switch group, providing redundancy.
Refer to the figure, Mesh Root and Edges.
•
SMF cable lengths are less than or equal to 15 km (9.32 mi).
•
SMF cables must be terminated and/or spliced by a certified fiber-optic cable installer. SMF cables cannot be terminated
and/or spliced by requisition or field engineers.
•
SMF cables are 8.3/125 µm Core/Cladding diameter with a numeric aperture of 0.13.
94
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
SMF and Trunks
Use the following rules for installing SMF cables:
•
SMF cable lengths cannot exceed 15 km (9.32 mi).
•
SMF cables must be terminated and/or spliced by a certified fiber-optic cable installer, not by installation engineers.
•
SMF is used for new unit installations because the new network switches used have Gbit speeds. SMF has greater
distance capability than multi-mode fiber (MMF) in Gbit applications.
Note Refer to the section Mesh Architecture for more information.
The small form-factor pluggable (SFP) or Mini-GBIC is a compact, hot-pluggable transceiver used in network switch
applications. It interfaces the network switch to a fiber optic or copper networking cable. It is a popular industry format
supported by many network component vendors.
The switches used in the current Mark VIe
control system networking design use SFPs
with LC Connectors to connect to single mode
fiber-optic cable for new installations.
LC Connectors
SFP
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 95
Public Information
SMF Component Sources
The following are typical sources for single-mode fiber-optic cables and connectors.
Fiber-optic Cable:
Optical Cable Corporation
5290 Concourse Drive
Roanoke, VA 24019
Phone: +1-540-265-0690
Part Numbers (from OCC)
Each of these cables are SMF 8.3/125 um Core/Cladding diameter with a numeric aperture of 0.13.
OC041214-01 4 Fiber Zero Halogen Riser Rated Cable.
OC041214-02 4 Fiber Zero Halogen with CST Armor.
OC041214-03 4 Fiber with Flame Retardant Polyurethane.
OC041214-04 4 Fiber with Flame Retardant Polyurethane with CST Armor
Corning Cable Systems
PO Box 489
Hickory, NC 28603-0489
Phone: +1-800-743-2671
Fiber-optic Connectors:
3M® - Connectors and Installation kit
Thomas and Betts - Connectors and Assembly polishing kit
Amphenol - Connectors and Termination kit
3.7.2
Un-shielded Twisted Pair (UTP) Copper Cables
3.7.2.1
Cat 5e Cables for PDH, UDH, MDH
These copper cables are used for data highways connections from edge switches to HMIs and controllers.
•
High-quality, category 5e UTP cable, for 10/100Base-TX Ethernet
•
Four pairs of twisted 22 AWG or 24 AWG wire
•
Protective plastic jacket
•
Impedance: 75 – 165 Ω
•
Connector: RJ-45 UTP connector for solid wire
3.7.2.2
Cat 6 Cables for Layer 3 Security Hardware
These copper cables are used for the additional layer 3 security offering, and provide connections from root switches to an
additional series of routers, switches, and firewalls.
•
High-quality, category 6 UTP cable, for 10/100Base-TX Ethernet
•
Four pairs of twisted 22 AWG or 24 AWG wire
•
More stringent specifications for crosstalk and system noise
•
Protective plastic jacket
•
Connector: RJ-45 UTP connector for solid wire
•
Backward compatible with the Category 5/5e cable standards
96
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The data highways use a number of 100Base-TX segments and some fiber-optic segments. These guidelines comply with
IEEE 802.3 standards for Ethernet. For details on individual Ethernet LAN component installation, refer to the instructions
supplied by the manufacturer of that equipment. For more information, refer to the section Cable Separation and Routing.
Note If the connection within a building and the sites share a common ground, it is acceptable to use 100Base-TX
connections. If connecting between buildings, or there are differences in ground potential within a building, or distances
exceed 100 m (328 ft), then 100Base-FX fiber is required.
3.7.4
Network Retrofit Guidelines
Existing sites should upgrade from Allied Telesis to Cisco switches, and use single-mode fiber (SMF) for all ICS VLAN
trunks. These required Cisco network switches can use SFPs with LC connectors to connect to multi-mode fiber (MMF),
however this is not recommended because it downgrades them to only 100 Mb speed (with SMF, the switches function at Gb
speeds).
Note GE recommends replacing MMF with SMF. If not, the network is downgraded to only run at 100 MB speed.
The GE requisition engineer needs to understand the ramifications if existing sites have MMF runs and the options for
retermination of Ethernet cables, changes to junction boxes, and so forth. Only a certified cable installer (not the GE field
engineer) can do any changes to MMF sites. Also, it is not recommended to use a converter from MMF SC connector to
single SMF LC connector as this can cause network latency or introduce an additional failure point.
Note Refer to the figure in the section SMF and Trunks that displays the LC connector and SFP.
The options for supporting the new network switch architecture are as follows:
•
Re-terminate existing MMF with LC connectors to connect to the SFPs. This downgrades to 100 Mb speed, and requires
a certified cable technician.
•
Use SC to LC conversion part (323A4747CSP1G). This is not recommended as it can introduce network latency and
another possible point of failure. In addition, it still downgrades network to 100 Mb speed.
•
Run new SMF cables and use new Cisco switches to full capabilities of Gbit speeds (preferred solution).
3.7.4.1
MMF Cable, Outdoor Use (Data Highways)
Warning
Never look directly into a fiber because some longer links use lasers, which can cause
permanent eye damage. Most fiber links use LEDs, which cannot damage the eyes.
The following MMF cables are approved for use:
•
Multi-mode fiber, 62.5/125 µ core/cladding, 850 nm infrared light
•
Four sub-cables with elastomeric jackets and aramid strength members, and plastic outer jacket
•
Cable construction: flame retardant pressure extruded polyurethane. Cable diameter: 8.0 mm (0.31 in). Cable weight: 65
Kg/km
•
Optical Cable Corporation part number: RK920929-A
The following sections provide more details on existing site MMF cabling specifications.
Ethernet Networks
GEH-6721_Vol_I_BP System Guide 97
Public Information
MMF Cable, Heavy Duty Outdoor Use
•
Multi-mode fiber, 62.5/125 µ core/cladding, 850 nm infrared light
•
Four sub-cables with elastomeric jackets and aramid strength members, and armored outer jacket
•
Cable construction: flame retardant pressure extruded polyurethane. Armored with 0.155 mm (0.01 in) steel tape, wound
with 2 mm (0.08 in) overlap, and covered with polyethylene outer jacket, 1 to 1.5 mm (0.04 to 0.06 in) thick. Cable
diameter: 13 mm (0.51 in). Cable weight: 174 Kg/km
•
Optical Cable Corporation part number: RK920929-A-CST
3.7.4.3
MMF Cable, Indoor Use (Data Highways)
•
Multi-mode fiber, 62.5/125 µ core/cladding, 850 nm infrared light
•
Twin plastic jacketed cables (Zipcord) for indoor use
•
Cable construction: tight-buffered fibers surrounded by aramid strength members with a flexible flame retardant jacket.
Cable dimensions: 2.9 mm (0.11 in) diameter x 5.8 mm (0.23 in) width. Cable weight: 15 Kg/km
•
Corning Cable Systems part number: 002K58-31141–24
3.8
Third-party Communication Links
External communication links are available to interface with third-party plant controls or devices. This allows operators to
have access to real-time data, and provides for discrete and analog commands to be passed to the Mark VIe controller. The
Mark VIe control system can be linked to third-parties in several different ways:
•
OPC UA direct from the Mark VIe controller (UCSC)
•
OPC UA, DA, AE from the WorkstationST server
•
Serial or Ethernet Modbus® Slave link from the WorkstationST server
•
Ethernet Modbus Slave direct from the Mark VIe controller to the third-party device (Ethernet to serial converter device
may be used)
•
GSM from the WorkstationST server to the DCS.
GEDS Standard Messages (GSM) is a proprietary 100 mbps Ethernet link using TCP/IP. It supports turbine control
commands, Mark VIe control data and alarms, the alarm silence function, logical events, and contact input sequence of events
records with 1 ms resolution. Ethernet GSM has the advantage of tighter system integration.
Attention
When connecting to third-party devices, the security of the networks and the overall
network architecture need to be considered and engineered accordingly. Third-party
links are best connected through a firewall where one is available. Consideration must
be given to redundancy and availability of communication paths.
98
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information
The Mark VIe control system uses a variety of communication protocols to interface both internally between control system
equipment and out to specialized field devices and other third-party equipment. This allows some protocols to be sent directly
to the Mark VIe controllers, while others must first communicate with the I/O module that then interfaces with the controller.
Other protocols use an HMI with WorkstationST application as a gateway.
Communication Protocol Across Mark VIe Controls Networks
Communication Protocols
GEH-6721_Vol_I_BP System Guide 99
Public Information
External Interface Protocols
External interface protocols support transmitting and receiving data with third-party control, monitoring, and supervisory
systems through the Plant Data Highway (PDH). Communication is important but normally not critical to control and
equipment protection. The protocol types include:
•
Variable feedback and commands to and from a third-party Distributed Control System (DCS)
•
Alarm annunciation and management interface with third-party systems
•
Interface with third-party industrial protocol gateways
Equipment Control and Configuration Protocols
The Unit Data Highway (UDH) and IONet networks use several different protocols for equipment control and configuration,
as described in the following table.
Equipment Control and Configuration
Protocols
Functions
Ethernet Global Data (EGD)
•
Feedback and commands between HMI and Mark VIe controllers on UDH
•
Control data between Mark VIe controllers on UDH
•
Real time data between I/O modules and Mark VIe controllers on IONet
•
Redundant controller data synchronization
Network Time Protocol (NTP)
Clock synchronization between Mark VIe controllers, I/O packs, WorkstationST
PCs, and a master time source. NTP operates on both the UDH and IONet
networks.
System Data Interface (SDI)
•
ToolboxSTconfiguration and monitoring with controllers, I/O packs, and
WorkstationST PCs
•
Real time alarm annunciation and management between controllers and
WorkstationST Alarm Server
•
Transmission of trip log data from controllers to WorkstationST Alarm
Server
OPC-UA Server
Mark VIe controller interfaces with OPC-UA client functions on UDH network
Precision Time Protocol IEEE 1588
IEEE 1588 is designed for local systems requiring high precision that cannot
afford the a GPS receiver at each node. The standards describe a hierarchical
master-slave architecture for clock distribution.
FOUNDATION Fieldbus HSE
Mark VIe implementation of HSE is used to couple the controller with the linking
device (gateway between IONet and H1).
Fieldbus Network Protocols
Fieldbus protocols network field devices (sensor and actuators) with the control system, enabling diagnostic and configuration
functions along with traditional real time control. The Mark VIe system supports the following protocols:
•
FOUNDATION Fieldbus
•
PROFIBUS -DP
•
HART communications
•
CANopen communications
•
Modbus Master RS-232, 422, 485
•
Modbus Master Ethernet
•
PROFINET
100
GEH-6721_Vol_I_BP
GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I
Public Information