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SPEEDTRONIC
Mark V
Turbine Control
Maintenance Manual
SPEEDTRONIC
Mark V
Turbine Control
Maintenance Manual
GEH-5980E
Issue Date: June 25, 1993
Revision A: July 21, 1993
Revision B: September 16, 1993
Revision C: June 1994
Revision D: July 1996
Revision E: February 1998
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. If further information is desired or if particular
problems arise that are not covered sufficiently for the purchasers purpose, the matter should be referred to GE
Industrial Control Systems.
This document contains proprietary information of General Electric Company, USA and is furnished to its cu stomer
solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This
document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the
written approval of GE Industrial Control Systems.
WARNING
Indicates a procedure, practice, condition, or statement that, if not strictly o bserved, could result in
personal injury or death.
CAUTION
Indicates a procedure, practice, condition, or statement which, if not strictly o bserved, could result in
damage to or destruction of equipment.
NOTE
Indicates an essential operation or important procedure, practice, condition, or statement.
WARNING
This equipment contains a potential hazard of electric shock or burn. Only personnel who are
adequately trained and thoroughly familiar with the equipment and the instructions should install,
operate, or maintain this equipment.
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 equipments 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 device.
Notes:
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GEH-5980E
TABLE OF CONTENTS
Section/Subject
Page
CHAPTER 1
INTRODUCTION
1-1. ORGANIZATION OF DOCUMENTATION..................................................................................................................1-1
1-1.1. Requisition Specific Drawings ................................................................................................................................1-1
1-1.2. Instruction Books.....................................................................................................................................................1-1
1-1.2.1. USERS MANUAL. .....................................................................................................................................1-2
1-1.2.2. MAINTENANCE MANUAL. .....................................................................................................................1-2
1-1.2.3. APPLICATION MANUAL .........................................................................................................................1-2
1-2. MARK V TURBINE CONTROL PRODUCT OVERVIEW ..........................................................................................1-2
1-2.1. Primary Operator Interface, <I>...............................................................................................................................1-3
1-2.2. Backup Operator Interface Panel - <BOI> .............................................................................................................1-4
1-2.3. Control Panel Configurations ...................................................................................................................................1-4
1-2.4. Location of Turbine Control..................................................................................................................................1-5
CHAPTER 2
CONTROL SYSTEM HARDWARE
2-1. MARK V DATA COMMUNICATION NETWORKS ...................................................................................................2-1
2-2. STAGE LINK ....................................................................................................................................................................2-2
2-3. DATA EXCHANGE NETWORK....................................................................................................................................2-3
2-4. IONET................................................................................................................................................................................2-5
2-5. THE ARCNET INTERFACE BOARD ............................................................................................................................2-6
2-5.1. Hardware Configuration ..........................................................................................................................................2-7
2.6. ALERT BOX FUNCTION................................................................................................................................................2-7
2-6.1. Adding an Alert Box to the <I> Processor..............................................................................................................2-8
2-6.2. Modifications To F:\IO_PORTS.DAT ...................................................................................................................2-8
2-6.3. Using the Alert Box .................................................................................................................................................2-9
CHAPTER 3
<I> SOFTWARE STRUCTURE
3-1. INTRODUCTION .............................................................................................................................................................3-1
3-2. IDOSTHE <I>'s COMPUTER OPERATING SYSTEM.............................................................................................3-2
3-2.1. Root Directory .........................................................................................................................................................3-2
3-2.1.1. DRIVE F: FILES ..........................................................................................................................................3-3
3-2.1.2. DRIVE F: SUBDIRECTORIES ..................................................................................................................3-3
3-2.1.3. DRIVE G: SUBDIRECTORIES..................................................................................................................3-4
3-3. <I> HARD DISK BACK-UP ............................................................................................................................................3-4
CHAPTER 4
SOFTWARE TOOLS
4-1. INTRODUCTION .............................................................................................................................................................4-1
4-2. DYNAMIC RUNG DISPLAY..........................................................................................................................................4-1
4-2.1. BBL (Sequencing/Non-sequencing)........................................................................................................................4-1
4-2.1.1. PRIMITIVE ..................................................................................................................................................4-3
4-2.1.2. PARAMETERS -PASSED/AUTOMATIC.................................................................................................4-3
4-2.1.3. PARAMETERS -ANALOG/LOGIC...........................................................................................................4-3
4-2.1.4. LOGIC STATES ..........................................................................................................................................4-3
4-2.2. Position Indicator.....................................................................................................................................................4-4
4-2.3. User Status Box .......................................................................................................................................................4-5
4-2.4. Positioning Targets ..................................................................................................................................................4-5
4-2.5. Parameter/Picture Targets .......................................................................................................................................4-6
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4-2.6. Executing/Exiting Dynamic Rung Display .............................................................................................................4-6
4-2.6.1. FINDING BBL .............................................................................................................................................4-6
4-2.6.2. SELECTING AUTO ....................................................................................................................................4-7
4-2.6.3. SELECTING MORE....................................................................................................................................4-8
4-2.6.4. SELECTING PAR........................................................................................................................................4-8
4-2.7. Segments, Rungs, and Sub-rungs ............................................................................................................................4-9
4-2.7.1. SEGMENTS ...............................................................................................................................................4-10
4-2.7.2. RUNGS.......................................................................................................................................................4-11
4-2.7.3. SUB-RUNGS..............................................................................................................................................4-11
4-2.7.4. SELECTING SRC IN A SEQUENCING BBL. ......................................................................................4-11
4-2.7.5. PIC FILE IN A NON-SEQUENCING BBL .............................................................................................4-14
4-2.7.6. TEXT MESSAGE ......................................................................................................................................4-18
4-2.7.7. RLD RUNG ................................................................................................................................................4-19
4-2.8. Using "Find All" to Find Parameters ....................................................................................................................4-21
4-2.9. Files Used by the Dynamic Rung Display.............................................................................................................4-27
4-3. DIAGNOSTIC DATA DISPLAY (DIAGC) ..................................................................................................................4-27
4-3.1. Executing DIAGC .................................................................................................................................................4-27
4-3.2. Menus ...................................................................................................................................................................4-28
4-3.2.1. SUB-MENUS .............................................................................................................................................4-29
4-3.2.2. POSITIONING TARGETS. .....................................................................................................................4-30
4-3.2.3. SELECTING A DISPLAY ........................................................................................................................4-31
4-3.3. Associated Files .....................................................................................................................................................4-33
4-4. EEPROM DOWNLOADER ...........................................................................................................................................4-33
4-4.1. Executing EEPROM Downloader.........................................................................................................................4-33
4-4.2. EEPROM Downloader Command <option> ........................................................................................................4-34
4-4.3. EEPROM Downloader Command <sections>......................................................................................................4-39
4-5. REVERSE TABLE COMPILER ....................................................................................................................................4-41
4-5.1. Executing Reverse Table Compiler.......................................................................................................................4-41
4-6. MK5MAKE.BAT ............................................................................................................................................................4-42
4-6.1. OPERATION ........................................................................................................................................................4-42
4-6.2. MK5MAKE.LOG File ..........................................................................................................................................4-44
4-7. Alarm Help.......................................................................................................................................................................4-44
4-8. CONTROL CONSTANT ADJUSTMENT ....................................................................................................................4-45
4-8.1. Modifying A Control Constant..............................................................................................................................4-47
4-8.1.1. CHANGING THE NEW VALUE.............................................................................................................4-47
4-8.1.2. CHANGING THE RAM VALUE .............................................................................................................4-47
4-8.2. Saving Control Constant Modifications ................................................................................................................4-48
4-9. LOGIC FORCING...........................................................................................................................................................4-50
4-9.1. Executing Logic Forcing ......................................................................................................................................4-50
4-9.2. Unforcing A Logic Pointname ..............................................................................................................................4-51
4-10. PREVOTE DATA ........................................................................................................................................................4-51
4-10.1. Executing Prevote Data .......................................................................................................................................4-52
4-11. COMMAND TARGETS...............................................................................................................................................4-53
4-11.1. Executing Command Targets ..............................................................................................................................4-53
4-11.2 Edit Form Screen ..................................................................................................................................................4-54
4-11.2.1. COMMAND POINTNAME FIELDS. ....................................................................................................4-55
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4-11.2.2. VALUE FIELDS ......................................................................................................................................4-55
4-11.2.3. FEEDBACK SIGNAL FIELDS...............................................................................................................4-55
4-11.2.4. TARGET TYPE FIELD...........................................................................................................................4-56
4-11.2.5. TARGET NAME......................................................................................................................................4-56
4-11.3. Command Target Additions, Modifications, Deletions ......................................................................................4-56
4-11.3.1. COMMAND TYPE POINTNAMES ......................................................................................................4-57
4-11.3.2. COMMAND TARGET SELECTION GUIDELINES ...........................................................................4-57
4-12. LAN CONTROL CARD (LCC)....................................................................................................................................4-58
4-13. TERMINAL INTERFACE MONITOR (TIMN) .........................................................................................................4-58
4-13.1. Set-up/Operation..................................................................................................................................................4-59
4-13.2. TIMN Commands................................................................................................................................................4-59
4-13.2.1. I/O STATUS.............................................................................................................................................4-60
4-13.2.2. PROFILER ...............................................................................................................................................4-61
4-13.2.3. UPDATE COMMAND............................................................................................................................4-62
4-13.2.4. ZERO COUNTERS..................................................................................................................................4-62
4-13.2.5. DUAL PORTED MEMORY (DPM) ......................................................................................................4-62
4-13.2.6. ERROR .....................................................................................................................................................4-63
4-13.2.7. FACTORY USE ONLY COMMANDS..................................................................................................4-63
4-14. HOLD LIST ...................................................................................................................................................................4-63
4-14.1. Points ...................................................................................................................................................................4-64
4-14.2. Programs ..............................................................................................................................................................4-64
4-14-.3. Conditions...........................................................................................................................................................4-64
4-14-4. Display Targets....................................................................................................................................................4-65
CHAPTER 5
INSTALLATION AND INITIAL STARTUP
5-1. INTRODUCTION .............................................................................................................................................................5-1
5-1.1. Receiving & Handling .............................................................................................................................................5-1
5-1.2. Unpacking & Storage ..............................................................................................................................................5-2
5-2. <I> INSTALLATION AND STARTUP ..........................................................................................................................5-2
5-2.1. Equipment Overview...............................................................................................................................................5-2
5-2.2. Installation and Initial Startup .................................................................................................................................5-3
5-2.2.1. HARDWARE CONFIGURATION.............................................................................................................5-3
5-2.2.2. STARTUP.....................................................................................................................................................5-4
5-2.2.3. SET CLOCK/DATE.....................................................................................................................................5-5
5-2.2.4. CALIBRATE TOUCH SCREEN ................................................................................................................5-5
5-2.2.5. CONFIGURE DOT MATRIX PRINTER...................................................................................................5-5
5-2.3. Load Requisition and Product Specific Software ..................................................................................................5-5
5-2.4. Get Configuration Information................................................................................................................................5-6
5-3. CONTROL PANEL INSTALLATION AND STARTUP ...............................................................................................5-6
5-3.1. Control Panel Inspection .........................................................................................................................................5-7
5-3.1.1. CARD INSPECTIONS ................................................................................................................................5-7
5-3.1.2. CONTROL PANEL INITIAL ENERGIZATION ......................................................................................5-7
5-3.2. Control Processor Startup........................................................................................................................................5-8
5-3.2.1. VERIFY VOTER ID ....................................................................................................................................5-8
5-3.2.2. VERIFY STAGE LINK ID..........................................................................................................................5-8
5-3.3. Establish ARCNET Communications ...................................................................................................................5-10
5-3.4. Download Configuration Files to the Mark V.......................................................................................................5-11
5-3.5. Set Control Panel Date and Time ..........................................................................................................................5-11
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5-4. AUXILIARY COMPONENT CONNECTIONS ...........................................................................................................5-11
5-4.1 Operator Interface Auxiliaries ................................................................................................................................5-11
5-4.2. Backup Operator Interface (<BOI>) .....................................................................................................................5-12
5-5. FORMAT DISK AS SYSTEM DISK.............................................................................................................................5-12
5-6. MAKE A BACKUP OF THE <I>S HARD DISK.........................................................................................................5-13
5-7. SERVO-VALVE AUTOMATIC CALIBRATION........................................................................................................5-13
5-7.1. AUTOCAL Display...............................................................................................................................................5-14
5-7.2. Operation ...............................................................................................................................................................5-15
5-7.2.1. AUTOCAL TARGETS..............................................................................................................................5-15
5-7.3. Precautions/Preliminary Steps ..............................................................................................................................5-16
5-7.4. Executing AUTOCAL...........................................................................................................................................5-18
CHAPTER 6
DATA DISPLAY TOOLS
6-1. INTRODUCTION .............................................................................................................................................................6-1
6-2. DATA COLLECTION PROGRAMS...............................................................................................................................6-1
6-2.1. VIEW1.EXE............................................................................................................................................................6-1
6-2.1.1. VIEW1.EXE OPTIONS. ............................................................................................................................6-2
6-2.2. VIEW2.EXE............................................................................................................................................................6-6
6-2.2.1. VIEW2.EXE OPTIONS. .............................................................................................................................6-6
6-2.2.2. VIEW2ASC - VIEW TO ASCII FILE CONVERSION UTILITY. ..........................................................6-7
6-2.2.3. VIEW2T - VIEW HIGH SPEED TRIGGERED MARK V DATA. ..........................................................6-7
6-2.2.4. VIEWPV - VIEW PREVOTE DATA. .......................................................................................................6-9
6-2.2.5. VIEWQ - VIEW <Q> DATA. .................................................................................................................6-10
6-2.2.6. VIEW_LIM - VIEW FILE LIMITS ANALYSIS. ...................................................................................6-10
6-2.2.7. VIEW_SD - ANALYZE VIEW OUTPUT FOR STANDARD DEVIATION. ......................................6-11
6-2.2.8. VIEWHD - VIEW HISTORICAL DATA.................................................................................................6-11
6-2.2.9. VIEWST - VIEW DATA IN THE SHORT-TERM TREND QUEUES..................................................6-11
6-3. SHORT-TERM TRENDING ..........................................................................................................................................6-12
6-3.1. Theory of Operation ...............................................................................................................................................6-12
6-3.2. Adding Short-Term Trending................................................................................................................................6-12
6-4. REAL TIME PLOT .........................................................................................................................................................6-14
6-4.1 Format.....................................................................................................................................................................6-14
6-4.2. Notes and Considerations ......................................................................................................................................6-14
6-4.3. Loading of PreSaved Forms into the Real Time Plot ...........................................................................................6-15
6-4.3.1. THEORY OF OPERATION. ....................................................................................................................6-15
6-4.3.2. FORMAT. ..................................................................................................................................................6-15
6-4.3.3. USE OF THE PRESAVED FORM IN THE MAIN MENU. ..................................................................6-16
6-5. TRIGGERED PLOT........................................................................................................................................................6-16
6-5.1. Defining The Display ............................................................................................................................................6-17
6-5.2. Program Operation ................................................................................................................................................6-19
6-6. SCALING DISPLAYED DATA.....................................................................................................................................6-19
6-7. PERFORMANCE MONITOR........................................................................................................................................6-20
6-7.1. Method of Operation .............................................................................................................................................6-20
6-7.2. Simulation Feature.................................................................................................................................................6-20
6-7.3. Adding the Performance Monitor to a Mark V.....................................................................................................6-21
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Section/Subject
Page
6-7.3.1. LOW DRIFT SENSOR PACKAGE..........................................................................................................6-21
6-7.3.2. PERFORMANCE MONITOR DATA FILES. ........................................................................................6-21
6-7.3.3. ENABLE THE <I> PERFORMANCE MONITOR PACKAGE. ...........................................................6-21
6-7.3.4. ADD TO MAIN MENU. ...........................................................................................................................6-21
6-7.4. Performance Monitor Operation ............................................................................................................................6-24
6-7.4.1. MAIN SCREEN .........................................................................................................................................6-24
6-7.4.2 MAKING A PERFORMANCE OR BASELINE RUN. ..........................................................................6-25
6-7.4.3. REQUIRED TURBINE CONDITIONS ...................................................................................................6-25
6-7.4.4. COMPLETING THE CALCULATIONS .................................................................................................6-25
6-7.4.5. FAILED RUNS. ........................................................................................................................................6-26
6-7.4.6. PERFORMANCE SIMULATION. ..........................................................................................................6-26
6-7.4.7. COMPLETING SIMULATED CALCULATIONS..................................................................................6-28
6-7.4.8. FAILED SIMULATION RUNS. ..............................................................................................................6-28
6-7.5. Performance Monitor Output and Interpretation...................................................................................................6-28
6-7.5.1. RELATIVE DATA PRESENTED. ..........................................................................................................6-28
6-7.5.2. INTERPRETATION OF RESULTS .........................................................................................................6-28
6-7.5.3. EXPECTED GENERATOR OUTPUT - POWER BALANCE. .............................................................6-29
6-7.5.4. INLET AND EXHAUST DROP DEVIATIONS .....................................................................................6-29
6-7.5.5. HEAT RATE DEVIATION.......................................................................................................................6-29
6-7.5.6. COMPRESSOR EFFICIENCY DEVIATION & COMPRESSOR FLOW DEVIATION. ....................6-29
6-7.5.7. EFFECTIVE NOZZLE AREA DEVIATION. .........................................................................................6-30
6-7.5.8. TURBINE EFFICIENCY DEVIATION. .................................................................................................6-30
6-8. SYNONYMS ...................................................................................................................................................................6-30
6-8.1. The SYNONYM.DAT File...................................................................................................................................6-30
6-8.2. Adding, Modifying, or Deleting Synonyms ..........................................................................................................6-30
6-9. CUSTOMIZING THE TRIP LOG DISPLAY ...............................................................................................................6-31
6-9.1 The HIST_B.SRC File ..........................................................................................................................................6-31
6-10. EPA DATA DISPLAY..................................................................................................................................................6-32
6-10.1. Defining EPA Data Points....................................................................................................................................6-32
CHAPTER 7 FUSE RATINGS
7-1. Power Distribution - TCPD ............................................................................................................................................71
7-2. Power Supply - TCPS .....................................................................................................................................................72
7-3 Power Supply - TCEA .....................................................................................................................................................73
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CHAPTER 1
INTRODUCTION
1-1. ORGANIZATION OF DOCUMENTATION
Documentation for the SpeedtronicTM Mark V turbine control system consists of two types: unit-specific drawings and product
manuals. A unique set of requisition-specific documentation is supplied with each control system (see Section 1-1.1) and three
instruction books are available for the specific needs of each user (see Section 1-1.2).
I/O Report contains the unit-specific assignment of I/O terminations in the Mark V control panel. This report also has
I/O related information such as the signal names, scale type, cabling information, termination points, and device
nomenclature.
Control Sequence Program Printout is a unit-specific printout that shows a functional representation of the Big
Blocks and sequencing of a particular requisition. Software on the operator interface allows editing and printing of this
document from any location.
Outline Drawings provide an external view of the control panel and primary operator interface. The drawings furnish
information needed for handling and installing the equipment.
Case Layout Drawing supplies an internal view of the control panel. The primary purpose of this drawing is to furnish
information needed to route interconnect cables.
Case Wiring Drawing defines the factory cabling internal to the control panel case. The drawing's primary purpose is
to document the internal wiring for maintenance use.
Core Drawings provide an isometric drawing of the core depicting the cards and their respective locations within the
core. For each card, the physical location and identification of removable parts, such as connectors and hardware
jumpers, is highlighted. The core drawing is placed in a pocket on the inside of the core door.
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1-1.2.1. USERS MANUAL. The users manual provides information needed by a turbine operator to understand both the
primary and back-up Mark V operator interfaces. Topics in the manual include:
1-1.2.2. MAINTENANCE MANUAL. The maintenance manual provides information needed by control system maintenance
personnel for installation, calibration, and troubleshooting the Mark V control system. Topics in the manual include:
LCC Operation
Terminal Interface Monitor Operation
DIAGC Display Operation
VIEW Tools
1-1.2.3. APPLICATION MANUAL. The application manual is an engineer's reference for the Mark V control system. Topics
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(IONETs). Each processor accepts what it believes the value of the logic signal to be (the pre-voted value) then communicates
that value to the other two processors over a single data exchange communication network (DENET). Each processor then
performs a two-out-of-three "vote" of the digital inputs logic signal value and uses the voted value in its control and
protection algorithms/sequencing. Therefore, a failure does not result in a turbine trip signal being generated by that
processor. (The condition described above is reported as a voting mis match Diagnostic Alarm.)
The SIFT voting technique will tolerate multiple failures without initiating a turbine trip. For example, one control processor
might determine that a turbine trip should be initiated as the result of a low lube oil pressure switch input and a second control
processor might determine that the turbine should be tripped on a high exhaust temperature based on a faulty thermocouple
input. Without SIFT, the two control processors initiate a turbine trip generated by two different input devices. However,
using SIFT, the control processors use the voted values of the inputs and do not initiate a turbine trip.
Another feature, Control Lockout, places the primary operator interface into a view only mode (unless control capability is
turned on with the correct password).
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<I>
1
Mk V
Turbine/Driven Device - A
A
<I>
2
Mk V
<I>
3
Turbine/Driven Device - B
B
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<S>
<R>
<C>
<R>
<C>
<T>
<P>
<PD>
<P>
<PD>
<QD1>
<CD>
<QD1>
<CD>
<C>
- Communicator Core
<R>
<S>
<T>
<P>
- Protective Core
Figure 1-2. Typical Control Panel Layouts for TMR and Simplex Control Panel Components (Cores)
The TMR control panel employs three identical control processors, <R>, <S>, and <T> (collective ly referred to as
<Q>), to monitor, control, and protect the unit. The three control processors each perform identical operations. The
majority of the inputs to the three control processors are voted, as are the majority of the outputs.
The Simplex control panel consists of a single control processor, <R>. As such, it does not employ SIFT technology
nor is it capable of controlling or protecting a turbine while its single control processor is taken out of service for
repairs.
Other cores which make up a typical Mark V control panel include a communicator processor, <C>; a protective
core, <P>; a power distribution core, <PD>; a communicator processor digital I/O core, <CD>; and a control
processor digital I/O core, <QD1>. Optional cores that are available are a backup communicator processor, <D>,
and additional digital I/O core(s), <QD2> .
1-2.4.
The <I> can be remotely located from the turbine (up to a maximum of 6000 meters in some cases). Additionally,
through an <I>, a unit(s) can be controlled from a separate control system . For example, a distributed control system (DCS) using MODBUS protocol over a serial communication link or a TCP/IP protocol over an Ethernet
communication link.
The Mark V control panel may be located near the unit or in a control room close to the unit (the distance limitation
is defined by the amount of wire and cable needed to interconnect the control panel and unit).
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CHAPTER 2
CONTROL SYSTEM HARDWARE
2-1. MARK V DATA COMMUNICATION NETWORKS
Information is communicated, shared, and acted upon in the Mark V Control System via three separate networks. The one
external network, the Stage Link, is the primary means of communication between the Operator Interface (<I>) and the
common data processor (<C>) of the control panel. This link is of the ARCNET configuration.
The data exchange network (DENET) is an ARCNET type communication network internal to the Mark V control panel. The
function of the DENET is to provide a communication link between the internal processors of the control panel. In a TMR
panel, it is the foundation for the voting process which takes place on control signals.
Stage Link
R
DENET
IONET
Stage
Link
R = termination resistor
<I>
* = optional components
DENET
<C>
<R>
<S>
<T>
IONET
Digital I/O
<CD>
Protection
(TCEA)
Protection
(TCEA)
Protection
(TCEA)
Digital I/O
<QD1>
Digital I/O
<QD1>
Digital I/O
<QD1>
Digital I/O
<QD2> *
Digital I/O
<QD2> *
Digital I/O
<QD2> *
Power Load
Unbalance
<PLU> *
Power Load
Unbalance
<PLU> *
Power Load
Unbalance
<PLU> *
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The third internal network is known as the I/O network (IONET). The IONET is a serial communications network that is
connected in a daisy chain configuration. Its function is to communicate I/O signals between the control processor (DCCA),
the protection core (<P>), and digital I/O core (<QD1>). The IONET is identical in all processors with the exception of <C>.
The <C> core has no direct link to the <P>, therefore, the IONET communicates only between <C> and the digital I/O
board. With this configuration, a TMR panel has four independent IONETs (<R>, <S>, <T>, and <C>) while the Simplex
panel has two (<R>, and <C>).
Stage Link
Stage Link
Port
Port
Processor
Figure 2-2. Three Port Active Repeater
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The Stage Link connection on the <C> core is an active three port repeater (see Figure 2-2). This device consists of three
ports (two external and one internal). The internal port communicates from the processor to the external ports. Either external
port receives a signal, amplifies it, and then passes it to the <C> core and the other external port. Similarly, a signal
originating in the core is amplified and sent out both external ports. In the event of interrupted power to the repeater, a bypass
relay provides continuation of the Stage Link.
In the event of a loss of power to <C>, the turbine continues to operate as critical turbine functions are handled by <R>, <S>,
and <T> (cumulatively known as <Q>). However, loss of the <C> core results in a loss of communication between the control
panel and the affected <I>s on the Stage Link. Due to the three port repeater design of <C>, the Stage Link continues to
operate between other devices, but is not able to communicate with the affected control panel.
A TMR panel may contain a redundant common data processor, <D>. This backup core provides continued Stage Link
communication if there is a failure in <C>. The <D> core is identical to that of <C>, except that it is not capable of
monitoring <C> I/O (non-critical I/O). The turbine can continue to operate with the temporary loss of non-critical I/O.
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TCQA
DCCA
TCDA
TCEA
LCCB
DENET
IONET
3PL Cable
TCQC
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DENET
LCCB
<C>
DCC
DENET
DENET
DENET
TCQC
TCQC
TCQC
LCCB
<R>
LCCB
<S>
LCCB
<T>
To DCC
<R>
To DCC
<S>
LCCB
<D>
DCC
To DCC
<T>
TCC
TCC
DENET
Stage Link
Stage Link
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DCCA
TCQC
TCEA
TCDA
IONET
HJ
Hardware Jumper
Terminal Board
Terminal Board
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DCCA
TCQC
TCEA
TCEA
TCEA
TCDA
IONET
HJ
Hardware Jumper
Terminal Board
Terminal Board
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An <I> processor can support more than one Alert Box. All Alert Boxes are treated identically; particular units can not be
assigned to particular Alert Boxes. No filters are available in the <I> to mask particular alarms from generating alert pulses;
however, process alarms that are locked out will not generate alert pulses as they do not meet the criteria of being a new alarm
that is unacknowledged. The Alert Box supports inputs from up to eight <I> processors. These inputs are in parallel, so that
simultaneous alarms from multiple <I> processors will create a single pulse which ends one second after the last alarm input.
3.
Choose an unused RS-232 port, probably a DigiBoard port. Connect the selected port from the first < I> to port A on
the Alert Box. Subsequent <I>s may be added to remaining ports.
Edit the F:\IO_PORTS.DAT file to:
a) Define the <I>s unused serial ports BASE-PORT address.
b) Assign the <I>s unused serial port as an ALERT port.
Restart the <I> using either RUN_IDP or Ctrl/Alt/Delete to make the changes made in IO_PORTS.DAT take effect.
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;
;
Section 1 - SERIAL PORT DEFINITIONS
;
P1 IRQ 7 BASE_PORT 0378
;
DIGIBOARD STATUS_PORT 0140 IRQ 9
D1 BASE_PORT 0100 BAUD 9600
D2 BASE_PORT 0108 BAUD 9600 PARITY NONE MODBUS
D3 BASE_PORT 0110
D4 BASE_PORT 0118
D5 BASE_PORT 0120
D6 BASE_PORT 0128
D7 BASE_PORT 0130
D8 BASE_PORT 0138
;
;
; LOGICAL PRINTER ASSIGNMENTS
;
ASSIGN SYS$PRINT
P1
ASSIGN DOS$PRINT
P1
ASSIGN EPA$PRINT
P1
;
ASSIGN DOT_MATRIX P1
ASSIGN HPLASERJET D1
;
ASSIGN ALM$ALERT
D3
;
; DEFINE MODBUS PARAMETERS
;
MODBUS PORT D2 SLAVE 1 UNIT T1 MODE NATIVE
MODBUS PORT D2 SLAVE 2 UNIT T2 MODE NATIVE
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CHAPTER 3
<I> SOFTWARE STRUCTURE
3-1. INTRODUCTION
Software that allows a properly configured 386 or 486 IBM TM compatible personal computer to be used as an <I> runs under
a proprietary disk-operating system known as IDOS. The software is stored in two groups on the <I>s hard disk drive. The
two groups, product-specific software and site-specific software, are divided on pseudo or substitute drives. The F: drive
contains the site-specific software in various subdirectories. The software common to all turbine control panels is stored in
subdirectories on drive G:.
The hard drive for a typical factory-configured <I> computer is partitioned to be one logical drive, C:. The following shows a
directory tree for C: of a typical <I> computer:
C:
DOS
IDP
CONFIG
RUNTIME
UNIT1
PROM
USER
DATA
EXEC
LOG
UTILITY
CUSTOM
The following shows a directory tree for the pseudo drive F:
F:
RUNTIME
UNIT1
PROM
USER
The following shows a directory tree for the pseudo drive G:
G:
CONFIG
DATA
EXEC
LOG
As shown in the directory trees, drives F: and G: are actually subdirectories of the IDP directory of the C: drive. The pseudo
drives are established by commands in the AUTOEXEC.BAT file which is executed when <I> is started. Programs running
under IDOS require the above pseudo drive and directory structure for proper operation of the <I> and the transmission of
data to and from the unit control panel(s).
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CAUTION
The use of RAM disks, memory managers, and programs requiring expanded or extended memory may cause
memory resource allocation problems when run under IDOS and is not recommended. Installation of
software not supplied or authorized by GEDS may adversely affect system performance.
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3-2.1.1. DRIVE F: FILES. The top level of the pseudo drive F: contains the following site-specific configuration files:
CONFIG.DAT is the master site configuration file. It specifies items such as how many units exist on the site and the
unit names and subdirectory names containing all the unit specific information. It also contains network information
about what communication links exist out of the <I> and which units can be reached on those links.
ARCNET.DAT contains information necessary for configuring/enabling the ARCNET card for communication with the
Mark V through the Stage Link.
IO_PORTS.DAT contains information about the configuration of the parallel and serial ports of the <I> for communicating
with printers and MODBUS communication links.
DYNAMIC.BIN contains dynamic system settings such as logging, passwords, etc.
3-2.1.2. DRIVE F: SUBDIRECTORIES. Subdirectories on the drive F: contain the following information/files:
\RUNTIME contains all the runtime data files created by programs running under IDOS. Programs check this directory for
display-related data files (User Defined Displays, Main Menu, Logic Forcing recall points, Trip History data, etc.).
Configuration files in the F:\RUNTIME subdirectory include:
*.A0, A1, A2,...A8 contain specific code defining the animated displays.
A0
A1
A2
A8
Generic
Unit 1
Unit 2
Unit 8
MENU.DAT contains information defining the layout and the displays available from the Main Menu.
DEMANDnn.BIN contains user-defined Display Menu definitions
\USER is the default subdirectory specified in the AUTOEXEC.BAT file run during start-up of the <I>. Some programs
create data files in the current default directory such as screen copy programs. If the current default directory has not changed,
the data files output by these programs could be found here.
\UNITn is created for each unit being controlled by an <I>, where n is equal to the unit designator number (up to a maximum
of eight units/subdirectories). Files which make up the Data Dictionary and EEPROM images for a unit are stored in its unitspecific directory and should always be kept there.
The files in each unit-specific subdirectory which comprise the Data Dictionary for each unit are as follows:
SCLEDATA.DAT contains the pointname scaling data information used to convert signal data from raw binary units to
engineering units for display on the <I>.
UNITDATA.DAT contains basic information about each signal (logic or real) of the unit, including its name, memory
location, point type, scale code, command information, and internal point number.
ENUMDATA.DAT contains the enumerated data strings for the enumerated data types. Enumerated data is used to
"describe" the operational state of the unit such as OFF, SYNCHRONIZING, LOADING, COOLDOWN ON, etc.
ALARM.DAT contains the text messages for each Process Alarm drop and for each Diagnostic Alarm drop.
\UNITn\PROM are Mark V Control Panel processor PROM-related files. They are used by IDOS programs such as the I/O
Configurator, the CSP Documenter, the Control Sequence Editor, the Control Sequence Compiler, and others. The files in
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this sub-directory must match the BBL and memory location information stored in the processor PROMs for proper
configuration and operation of the Mark V Control Panel.
3-2.1.3. DRIVE G: SUBDIRECTORIES. Subdirectories on drive G: contain the following information/files:
\EXEC contains all the executable files/programs that form the basic <I> and any batch files used during start-up or
execution.
\DATA contains any data files which programs require that are not site-specific. It also contains any generic data files
which might be used before any site-specific data files are created. Programs using data files look for and use any files
found in site-specific directories on drive F: first. They only use the generic data files if no site-specific files can be
found.
\LOG contains the output from various programs which might be important for debugging or troubleshooting purposes.
Error log files and normal start-up files are stored here.
\CONFIG contains the site and unit configuration files. See Section 3.2.1.1.
Complete hard disk drive. Backup all of the C: drive after installation is complete and if changes are made to the
operating system with disks supplied from GEDS. Since the F: and G: drives are pseudo drives assigned as a
subdirectory of C:, the data in these directories is saved at the same time. This back-up could be used to rebuild the
system after a catastrophic loss of the hard disk.
F:\UNITn Unit configuration files on the F: pseudo drive. This directory (or directories) should be backed-up
after any configuration or sequencing changes, such as new I/O points added, Control Sequence Editor changes, or a
control constant change.
F:\RUNTIME and F:\USER should be routinely backed-up for display modifications and any screen images that
were saved.
CAUTION
During the back-up or restoration of a hard disk, that specific <I> cannot be controlling the turbine(s). If it is
necessary to run the turbine(s) during this time, other control systems such as other <I>s or <BOI>s must be
utilized.
It is necessary to exit the IDOS operating system to perform any back-up. To exit IDOS, type IDOSEXIT at the DOS
prompt. Once the back-up is complete, type RUN_IDP to return to the IDOS system or turn off the <I> momentarily.
Before backing up the hard disk, it is recommended that a system disk is made. This disk can be made by typing
SYS A: at the DOS prompt with a new floppy disk in the A: drive. The system disk should include the following files:
COMMAND.COM, IO.SYS, MSDOS.SYS - these should be copied by the SYS command
AUTOEXEC.BAT, CONFIG.SYS, MSMOUSE.COM - these files are needed to initialize the <I>
MSBACKUP*.* - with DOS version 6 or later (or BACKUP.* and RESTORE.* with versions less than 6) are the
programs necessary to restore the hard disk
MSAV*.* - anti-virus software to protect the system from computer viruses (DOS version 6 or later)
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Various methods are available to back-up the hard disk drive. For computers using versions of DOS before 6.0, the DOS
BACKUP command is available in the C:\DOS subdirectory. Consult the DOS documentation for details or type BACKUP
/? at the DOS prompt.
The DOS RESTORE command is the complement to the BACKUP command; RESTORE rebuilds the C: drive to the
configuration that was saved using the BACKUP command. Consult the DOS documentation or type RESTORE /?
at the DOS prompt.
For computers using DOS version 6.0 or later, the equivalent command is MSBACKUP, which is available in the C:\DOS
subdirectory. For details, consult the DOS 6.0 documentation or type MSBACKUP at the DOS prompt.
The DOS backup utilities will not work with puesdo or substituted drives (F: or G:); remove the substitutations before
doing a backup. The substitutions can be removed by entering SUBST /D at the C:> prompt.
File compression software reduces the size of some of the files and therefore, the number of disks needed to back-up the hard
disk. See the manufacturers directions.
Although other methods, such as removable hard disk drives, magnetic tape units, and commercially available back-up
software may also be used, none are supported by GEDS.
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CHAPTER 4
SOFTWARE TOOLS
4-1. INTRODUCTION
The operator interface uses software (program) to troubleshoot and set up the Mark V control system. This Chapter describes
several of these software "tools." They are not arranged in any particular order, because different situations may require the
use of one or more of these tools in a different sequence.
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L30TF
L30TFX
L63TFH1
Primitive: TMV
L63TH1H_ALM
K63TF1H_ALM
T63TF1H_ALM
0.0 sec
0.0 sec
PIC
L30RHFLT
L30RHFLTX
L26CTH
L26CTH_ALM
L26BT1H
L26BT1H_ALM
L27MC1N
Primitive: TMV
L27MC1N_ALM
K27MC1N_ALM
T27MC1N_ALM
0.0 sec
0.0 sec
PIC
L49X
L27BLN
L49X_ALM
L27MC1N
Primitive: TMV
L27BLN_ALM
K27BLN_ALM
K27BLN_ALM
0.0 sec
0.0 sec
PIC
L64D_P
L64D
L41FY
L64D_N
L27DZ
L27DZ_ALM
Primitive: TMV
0.0 sec
0.0 sec
PIC
L4
L64F
LSC1
Primitive: CMP
L49X
TNH
TNL
0.00%
0.00%
PIC
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NOTE
Non-sequencing BBLs have F:\UNITn\PROM\*.PIC files that permit viewing picture files. These PIC files are
available for printout.
FSRMAX
>A
L60FSRG
cur_seg_time
A>B-<
>
FSKRMAN1
max
>clmp
-1
min
x
_
/ +
MED
FSRMAN
FSRMAN_CMD + _/ OSEL//<
>O
+ 0
-1
pup-init
FSRMAX
L43FSRS
>(
FSR
> (/
simple algorithms such as Add, Subtract, Multiply, Time Delay (TMV), Compare (A>B), and such. Primitives are used as
"modules" within BBLs and RLDs to simplify the programming process.
4-2.1.2. PARAMETERS -PASSED/AUTOMATIC. Parameters are signal point names that can be either passed or automatic
parameters. Both are used in BBLs (sequencing and non-sequencing) and Primitives.
Passed Parameters are signal points that are passed to and from BBLs and Primitives. They are user-definable in the Control
Sequence Editor and are shown by the Dynamic Rung Display as merely parameters (parameters = passed parameters). They
are accessed by selecting the PAR target.
Automatic Parameters are not user-definable and are configured by GEDS. These signal points are shown by the Dynamic
Rung Display as automatics (Automatics = automatic parameters). They can be accessed by selecting the AUTO target.
4-2.1.3. PARAMETERS -ANALOG/LOGIC. Analog parameters (passed or automatic) are signal point definitions having
values other than zero or one. The range can vary and is determined by its scaling. Logic parameters (passed or automatic)
can have values of one or zero only. They are typically used to define logic states such as ON and OFF.
4-2.1.4. LOGIC STATES. A parameter that is a software "logic" can have several different states other than "picked up" or
"dropped out." The Dynamic Rung Display only displays the value of the logical parameter as it relates to the value in <C>.
It does not matter what value the parameter has in <R>, <S>, and <T>. The following are descriptions of all the possible
states a logic can be in as well as the Dynamic Rung Displays representation of each of these states.
A white on black contact or coil indicates no power flow in the normal state.
A solid green box or circle indicates power flow through any contact or coil.
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A solid green box or circle with an "F" (or ">") in the middle indicates Forced power flow through the contact or coil.
An empty yellow box or circle with an "F" (or ">") in the middle indicates no power flow due to a Force.
A "?" indicates that the logical name is not defined in the database.
An inverted coil is shown as a coil with a "/" through it. An inverted coil with a <C> value of "0" is considered to be
picked up and therefore is shown as a solid green coil with a "/" through it.
A contact from an inverted coil is shown as normal. For example, if an inverted coil has a <C> value of "0" then a
normally open contact would appear to be open (no green), and a normally closed contact would appear closed (with a
green identifier).
NOTE
The Dynamic Rung Display only shows the logic states of parameters as they relate to their current value in <C>.
The position of the current rung within its segment. For example, the caption
Segment 2 of 3
SEQU_XX: 2 of 5
reveals that the BBL currently being viewed is in the second segment (2 of 3), and that it is the second of five rungs (see
Figure 4-6).
The position of the current sub-rung within the sequencing rung (BBL). For example, selecting SRC while viewing the
main display of BBL: ALARMS_MISC_L1 would show a position indicator
Sequencing BBL
ALARMSL1.SRC : 1 of 12
indicating that the sub-rungs in the sequencing BBL: ALARMSL1.SPC are being viewed and this sub-rung is one of 12
sub-rungs.
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To exit the Dynamic Rung Display, press F1 or the Esc key, or click on EXIT, MAIN DISPLAY, or ALARM DISPLAY.
The following sections show how targets affect the Dynamic Rung Display. The screens represent actual Dynamic Rung
Displays, however, the data shown such as BBLs, Primitives, RLDs, parameters, comments, and such is furnished as an
example only.
4-2.6.1. FINDING BBL. To reach the main display of non-sequencing BBL: L39VV5 perform the following steps.
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4-4. When viewing the Automatics, PAR can be selected to view the "passed" parameters. Likewise, when viewing "passed"
parameters , AUTO can be selected to view the Automatics. Both parameters and Automatics cannot be viewed
simultaneously with the Dynamic Rung Display.
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4-5. The Dynamic Rung Display shows only 57 parameters. If a BBL has more than 57 parameters such as BBL: L39VV5
with 109 Automatics (see Figure 4-5), a MORE target appears that allows the user to view Automatics 58 to 114. The
MORE target appears for both passed and automatic parameters as needed.
4-2.6.4. SELECTING PAR. From the screen shown in Figure 4-5, select MORE. This reveals the screen in Figure 4-3.
Selecting AUTO then PAR merely toggles the viewing area between the two displays.
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SEG#
---1.
Segments
--------
2.
Maintenance Manual
Rung# Rungs
----- -----
Sub-Rung#
---------
Sub-Rungs
---------
SEQ_Q
1TITLE
2RLD
3sequencing BBL
1TITLE
2RLD
3RLD W/ Primitive
11TITLE
4RLD
SEQ_XX
1non-sequencing BBL
2non-sequencing BBL
3RLD
4sequencing BBL
1TITLE
2RLD
8TITLE
5TITLE
3.
SEQU_B
1TITLE
2non-sequencing BBL
3TITLE
The file that defines and determines which Segments are used and the order they are executed in the Dynamic Rung Display is
F:\UNITn\MSTR_SEQ.CFG. Part of the MSTR_SEQ.CFG file is as follows:
F:\UNITn\MSTR_SEQ.CFG
#Segment
#Segment
#Segment
SEQU_Q
SEQU_XX
SEQU_B
The following numerical assignments show how the Dynamic Rung Display orders the Segments being used.
SEQU_Q is Segment 1 of 3
SEQU_XX is Segment 2 of 3
SEQU_B is Segment 3 of 3
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A RLD consisting of contacts, coils, and possibly Primitives, see section 4-2.7.7.
A sequencing BBL_Rung can consist of "passed" parameters, automatics, or both. Also, a sequencing BBL consists of SubRungs. The Sub-Rungs contain the dynamic "pictures" of the RLDs and show the actual arrangement of the contacts and coils
as well as the current state of each. The Sub-rungs are accessed selecting the SRC target.
When SRC is selected, the Dynamic Rung Display no longer looks at a Rung to Segment positioning indicator. The
Dynamic Rung Display now looks at a Sub-rung to Rung positioning indicator. In order to return to the Rung to Segment
positioning it is necessary to select Return Main (see Figure 4-9). Section 4-2.7.4 is an example using BBL:
L43_AUX_LOGIC to show the effect of selecting SRC from the Main Display.
4-2.7.3. SUB-RUNGS. Sequencing BBLs is the only type of Rung that has Sub-rungs associated with it. Sub-rungs are
accessed by selecting the SRC target when viewing a sequencing BBL. The Sub-rungs are then ordered from beginning to end
with the current position being displayed by the position indicator. Select Goto Main to exit Rungs.
4-2.7.4. SELECTING SRC IN A SEQUENCING BBL. From the screen shown in Figure 4-3, perform the following steps to
retrieve BBL: L43_AUX_LOGIC, shown in Figure 4-7.
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Rung Display provides no SRC target. However, non-sequencing BBLs have related PIC files that are accessible by selecting
the PIC target. Once the user selects PIC,the picture file is displayed along with two to seven additional targets. The two
targets that are always displayed after selecting PIC are Rung Display and Show Value.
NOTE
The following section shows how targets affect the Dynamic Rung Display. The screens represent actual Dynamic
Rung Displays; however, the data shown such as BBLs, Primitives, RLDs, parameters, comments, and such is
furnished as an example only.
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Since BBL: L43_AUX_LOGIC is Rung 6 of 11 in Segment 1 of 3 (see Figure 4-7) and BBL: CMDSTATE is Rung 5 of the
same segment, select Prev Rung to reach the Main Display of non-sequencing BBL: CMDSTATE. Figure 4-10 is
revealed.
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4-2.7.6. TEXT MESSAGE. If a Text Message Rung is defined by the sequence editor as a "text message" or "comment", it is
displayed by the Dynamic Rung Display in exactly the same manner as it was defined in the Sequence Editor. There are no
additional parameter/picture targets (AUTO, PAR, SRC, or PIC). Only the positioning targets are shown (see Figure 4-13).
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4-2.7.7. RLD RUNG. If an RLD Rung contains contacts, coils, and possibly Primitives, it is displayed by the Dynamic Rung
Display as shown in Figures 4-14 and 4-15. Although this type of BBL Rung looks similar to the Sub-rung structure, it is not
considered a Sub-rung since it is not contained within a sequencing BBL. Therefore, it is not necessary to select SRC to view
these type of Rungs. However, if the RLD contains a Primitive, the Primitives PIC file can be accessed by selecting the PIC
target as shown in Figure 4-14. For an explanation of the "F"s shown in the contacts see section 4-2.1.4. From the screen in
Figure 4-13, perform the following steps to reach RLD Rung.
1. Select EXIT or type F8,
2. Restart the Dynamic Rung Display (see section 4-2.6).
3. Select Goto Jump
4. Type 7 and press Enter. Figure 4-14 is revealed.
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at Rung 1 of Segment 1 there are no Prev Rung, Prev Seg, or Page Up targets (conditions do not exist)
at the last Rung of the last Segment there are no Next Rung, Next Seg, or Page Down targets (conditions do not exist)
The User Display, Alarm Display, and Function targets are always displayed in the same manner regardless of what type of
Rung is being viewed.
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Although all the previous examples used Find All to find specific BBLs or Primitives, the example in this section uses
Find All to find a specific Parameter. This "chases" a particular Parameter and determines what is causing the Parameter
to be the value or state it is. It also enables the user to find what effect this Parameter is having on other parameters.
NOTE
When selecting Find All and/or Find Coil the Dynamic Rung Display searches from the current position to the
end of the file. Therefore, select Goto Top, before selecting Find All or Find Coil, to ensure that all points are
found during the search.
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\UNITn\USER.A
\UNITn\MSTR_SEQ.CFG
\UNITn\*.SRC
(from MSTR_SEQ.CFG)
\UNITn\Rung_TMP.A
\UNITn\Rung.ERR
(created by the Dynamic Rung Display. All errors are logged to this file.)
\UNITn\PIC_TMP.A
\UNITn\PROM\BIGBLOCK.DEF
\UNITn\PROM\PRIMITIVE.DEF
\UNITn\PROM\*.PIC
\UNITn\PROM\*.SPC
DIAGC.
When first executed, the DIAGC program displays the following message reminding the user that only qualified individuals
should access the software:
"DIAGC "is a diagnostic tool for firmware designers and field personnel only. Its purpose is to assist firmware
designers in the performance evaluation of the EPROM based programming and to assist field personnel in problem
diagnosis. While the program is a "display only" program that poses no threat to the operation of the turbine
control, it does not provide Turbine Operation information and should be run by authorized personnel only.
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The Main Menu shows the list of cards that are predefined as active cards for this display. Some of these cards have PROM
revisions defined in the title such as TCQAG1A (F1AEA v5.1) Diagnostics. If this list shows an incorrect revision of PROM
to that identified by the PROM labels, contact the factory for a new data file. PROM revision information is displayed in the
Main Menu. Cards are defined in this list by the lowest common revision for which the display works. The display is only
correctly defined for the DS200TCQAG1A board with PROM firmware labelled DS200TCQAF1AEA (see Figure 4-22).
This means version 5.1 of the TCQA firmware. Another of the menu picks may be for Drive Control Card (DCC)
diagnostics. This means that the display is correct for all revisions of the DS200DCCx board and associated firmware.
4-3.2.1. SUB-MENUS. Selecting a card from the menu produces a second level menu or Submenu. Submenus show the
individual data displays available for that particular card (see Figure 4-22). Available displays at this level are predefined by
the structure of the data that the card has been preprogrammed to send back to the <I>. Therefore, they vary considerably
from card to card.
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I/O data read in by the data acquisition portion of the I/O card software such as the LVDT data for the TCQA board.
performance information gathering software for advanced troubleshooting use only, such as the LCC ARCNET counter
display. Consult Product Service Engineering for details.
GE Industrial Control Systems
Product Service Engineering, Rm. 191
1501 Roanoke Blvd.
Salem, VA 24153-6592 USA
(540) 387-7595
4-3.2.2. POSITIONING TARGETS. Some positioning targets are standard throughout the <I> operating system. Standard
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in question and ask for the PROM previously defined data associated with this display. The top right of a display shows the
processor that is currently communicating with <I> (in Figure 4-23, it is the <R> processor). The next line shows the number
of replies received from the processor. This number increments approximately once per-second as the replies come back from
the linked processor or card. This counter returns to zero when 256 replies have been received. If the communication link is
not established or the I/O card or communication link fails, the Reply received section turns red to indicate that the data is
either stale or invalid. The Reply received section also turns red if the data received is invalid. Contact GEDS Product Service
Engineering for assistance.
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NOTE
For modifications downloaded with the EEPROM Downloader to take effect, the processor(s) must be restarted
in order for the new information on the EEPROM chip to be transferred to RAM for use by the processor in
controlling and/or monitoring the unit.
Upon accessing the EEPROM Downloader from the Main Menu, the user is out of the <I> menu system. EEPROM is an
executable file run as an IDOS task.
CAUTION
When running EEPROM Downloader, the <I> is not controlling the turbine. However, the turbine continues
to operate at the last setpoint and all Mark V protective functions are operational.
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GEH-5980E
EEPROM
DOWNLOADER
Processor
EEPROM
Chip
All information
transferred to
RAM on power-up
or re-boot of
processor
Control Constants
and Totalizer Data
ONLY stored on
EEPROM by commands
EEPROM
Update
Processor
RAM
Operator-initiated
command
Automatic
command
CONTROL
CONSTANT
Adjust
Totalizer Data
gathered from
and acted on in RAM
TOTALIZER
Control Constants
modified in RAM
CONTROL
LOGGING
MONITORING
PROTECTION
11
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CBLR_*.SRC
TOTT_*.SRC
BIO_Q*.SRC
CHNG_*.SRC
EVENT_*.SRC
MAOUT_*.SRC
EPA_*.SRC
QSEG_0n.SRC
HIST_*.SRC
BSEG_0n.SRC
CONST_*.SRC
CONTROL
SEQUENCE
COMPILER
SEQ_B.DAT
SEQ_Q.DAT
TABLE
COMPILER
CONST_*.DAT
HIST_*.DAT
EPA_*.DAT
MAOUT_*.DAT
T
EVENT_*.DAT
CHNG_*.DAT
BIO_Q*.DAT
TOTT_*.DAT
CBLR_*.DAT
UBBL_*.DAT
TOTD_*.DAT
FORMAT_*.DAT
* B or Q
EEPROM
DOWNLOADER
Processor
EEPROM
Chip
Figure 4-27. EEPROM Downloader
4-36
CFG.DAT
IO_CFG.DAT
I/O
CONFIGURATOR
IOCFG_D.DAT
IOCFG_CDAT
IOCFG_Q.DAT
Maintenance Manual
GEH-5980E
DOWN downloads or transfers point lists and data which are to be stored in the EEPROM chip from <I> to the
EEPROM chip in the desired processor. Data may be downloaded to the EEPROM chip on the DCC card after the
EEPROM chip or the DCC card is replaced, after modification and compilation of the point lists or data, to initialize a
new EEPROM chip being installed on a DCC card, or to reinitialize an existing EEPROM, when necessary.
NOTE
Prior to downloading, data must be compiled to convert the information to a hexadecimal format. Failure to
compile the modified files results in the downloading of old information to the EEPROM rather than the
modified point lists or data files.
DIR provides a list including the date when each EEPROM section file was compiled. This option lists the information
for all sections as follows.
DIR T1 S
DIRECTORY OF UNIT T1 PROCESSOR S:
Partition offset size --------date-------SEQ
4000
07F2 18-OCT-1991 14:33:20
CONST
1000
07DC 01-JAN-1980 00:00:00
IOCFG
2000
031A 22-OCT-1991 09:21:00
UBBL
0000
0000 01-JAN-1980 00:00:00
HIST
0000
0000 01-JAN-1980 00:00:00
EPA
0000
0000 01-JAN-1980 00:00:00
MAOUT
0000
0000 01-JAN-1980 00:00:00
EVENT
0000
0000 01-JAN-1980 00:00:00
CHNG
0000
0000 01-JAN-1980 00:00:00
BOI
0900
0002 01-JAN-1980 00:00:00
TOTT
0D00
0016 01-JAN-1980 00:00:00
TOTD
3000
0FE8 01-JAN-1980 00:00:00
CBLR
0E00
0006 01-JAN-1980 00:00:00
22 -OCT-1991 10:00:19
cksum
-id50F1
SEQ
0A33
CNST
CACC
IO
0000
UBL
0000
HIST
0000
EPA
0000
4-20
0000
EVNT
0000
CHNG
CAFE
BOI
0385
TOTT
CAFE
TOTD
0000
CBLR
CHECK performs a checksum comparison of all of the EEPROM section files and lists the results.
This option lists the information for all of the sections as follows:
CHECK T1 S
CHECKSUM TEST
Partition
SEQ
CONST
IOCFG
UBBL
HIST
EPA
MAOUT
EVENT
CHNG
BOI
TOTT
TOTD
CBLR
OF UNIT
offset
4000
1000
2000
0000
0000
0000
0000
0000
0000
0900
0D00
3000
0E00
T1 PROCESSOR S:
size --------date-------07F2 18-OCT-1991 14:33:20
07DC 01-JAN-1980 00:00:00
031A 22-OCT-1991 09:21:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0002 01-JAN-1980 00:00:00
0016 01-JAN-1980 00:00:00
0FE8 01-JAN-1980 00:00:00
0006 01-JAN-1980 00:00:00
22 -OCT-1991 10:00:51
cksum
-id- -status50F1
SEQ
OK
0A33
CNST OK
CACC
IO
OK
0000
UBL
<NO DATA>
0000
HIST <NO DATA>
0000
EPA
<NO DATA>
0000
4-20 <NO DATA>
0000
EVNT <NO DATA>
0000
CHNG <NO DATA>
CAFE
BOI
OK
0385
TOTT OK
CAFE
TOTD OK
CAFE
CBLR OK
NOCHECK disables a checksum comparison of the defined section. For example, type the following command after the
prompt EEPROM Download>
NOCHECK T1 S CBLR
The following message would appear on the screen:
CBLR
OK
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GEH-5980E
Maintenance Manual
and a subsequent command to perform a checksum comparison gives the following display:
CHECKSUM TEST
Partition
SEQ
CONST
IOCFG
UBBL
HIST
EPA
MAOUT
EVENT
CHNG
BOI
TOTT
TOTD
CBLR
OF UNIT
offset
4000
1000
2000
0000
0000
0000
0000
0000
0000
0900
0D00
3000
0E00
T1 PROCESSOR S:
size --------date-------07F2 18-OCT-1991 14:33:20
07DC 01-JAN-1980 00:00:00
031A 22-OCT-1991 09:21:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0000 01-JAN-1980 00:00:00
0002 01-JAN-1980 00:00:00
0016 01-JAN-1980 00:00:00
0FE8 01-JAN-1980 00:00:00
0006 01-JAN-1980 00:00:00
22 -OCT-1991 10:00:51
cksum
-id- -status50F1
SEQ
OK
0A33
CNST OK
CACC
IO
OK
0000
UBL
<NO DATA>
0000
HIST <NO DATA>
0000
EPA
<NO DATA>
0000
4-20 <NO DATA>
0000
EVNT <NO DATA>
0000
CHNG <NO DATA>
CAFE
BOI
OK
0385
TOTT OK
CAFE
TOTD OK
CAFE
CBLR <NO CHKSM>
To re-enable the checksum comparison download the section information using the DOWN option. This option has no effect
on turbine operation or control and may be useful only in certain troubleshooting situations.
EEPROM UNIT NAME must be specified for each application. Unit name(s) are found in the file CONFIG.DAT on
the F: drive. The section of the CONFIG.DAT file that defines the unit names/numbers is shown as follows (the site is a
single unit steam turbine installation, and the unit name assigned to the steam turbine is S1):
;
;-----------------------------------------------------------------------------;
; This section defines the unit numbers, unit names, and the path to the
; directory that contains the unit information. Each line contains the
; unit number (decimal), the unit name (2 char max), and the path to the
; unit configuration data (64 char max). The unit numbers should be in
; order, and if a unit number is repeated, the last entry wins.
;
;
UNIT
UNIT
PATH TO
;
NUMBER
NAME
CONFIG DATA
;
--------------------------------UNIT_DATA
1
S1
F:\UNIT1
;
;----------------------------------------------------------------------------;
EEPROM DOWNLOADER PROCESSOR NAME specifies the processor for information to be
uploaded, downloaded, or otherwise acted on each time a command is executed using EEPROM.
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CONST
HIST
EPA
MAOUT
EVENT
CHNG
BOI
TOTT
CBLR
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FORMAT
UBBL
TOTD
When an EEPROM chip is formatted, all existing data is lost and the related processor can no longer be used to
control a turbine. It is imperative that the EEPROM DOWN command be executed successfully before it is
possible to return the processor to service.
To simplify and modernize the downloading process, two special commands were developed.
ALL is specified to download or upload, ALL the sections in the unit name specified. Steps that occur include,
EPROM chips are formatted and all files are transferred to and from <I>. This section is especially useful in performing
EEPROM back-ups to the <I>s hard-disk files.
USER is specified in the section command to download or upload all of the above sections (with the exception of
FORMAT and TOTD). It is similar to the ALL command, except it does not format the EEPROM chip or overwrite the
totalizer data. This section is useful in downloading the "user" modifiable files at unit start-up or when changes to
multiple sections have been performed.
The following are examples in using the <section> commands.
To download Control Constants to <S> processor of unit named S1, type the following command after the prompt EEPROM
Downloader> DOWN S1 S CONST
where DOWN is the direction of the flow of information (from <I> to the EEPROM), S1 is the Unit Name (from the file
CONFIG.DAT), S is the processor location, and CONST is the operation the user is performing.
Modified Control Constants can be backed-up from the processor to <I> using the UP option. For example, to back-up
Control Constants modified in <C> of unit name T2, type the following command after the prompt EEPROM
Downloader> UP T2 C CONST
To format the EEPROM chip on <C> with unit name T1, type the following after the prompt EEPROM Downloader>
DOWN T1 C FORMAT. To download the historical log point list or the <C> processor of the unit named S1, type the
following command after the prompt EEPROM Downloader> DOWN S1 C HIST Historical log point list(s) may be
backed-up to <I> using the UP option.
To download I/O Configuration information/changes to <T> processor of unit name T3, type the following command after
the prompt EEPROM Downloader> DOWN T3 T IOCFG.
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<table>
<table>
V1.1
REVX_TAB
WARNING:
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Inserting a scale command in the REVX_TAB command line that has no corresponding scale file (*.SCA) causes the
following error message:
<filename>
ERROR:
4-6. MK5MAKE.BAT
Any time changes are made to any of the assignment files, the source Table Files, or the CSP segment source files, the
changes must be incorporated into the files which will ultimately be downloaded to the Mark V control panel. Several
programs must usually be manually executed in a specific order from the DOS command line of the unit-specific directory.
Some have the names of files or options specified on the command line in order for the changes to become effective.
MK5MAKE.BAT is a batch file which automatically executes those programs in succession with the proper filenames and
options.
MK5MAKE.BAT must be executed in the unit-specific directory as it uses and creates files in the unit-specific directory, and
uses files in the unit-specific PROM subdirectory. The flow-chart in Figure 4-30 illustrates the programs executed by
MK5MAKE.BAT.
4-6.1. OPERATION
When run from the DOS command line of the unit-specific directory, MK5MAKE.BAT first executes the program
DDLOCATE.EXE and specifies four assignment files to be used by DDLOCATE; IO.ASG, FACTORY.ASG,
ALLOCSSP.ASG, and SITE.ASG. DDLOCATE uses the specified assignment files, the ENGLISH.SCA scale code
file, and accesses three files in the PROM subdirectory in order to create a new unsorted, un-validity-checked
UNITDATA.DAT file. Any messages generated by DDLOCATE are reported to the screen and written to a log file,
MK5MAKE.LOG. This log file, which contains any messages generated by the programs executed by MK5MAKE.BAT can be
viewed using any ASCII text editor and printed, if necesssary.
Next, MK5MAKE.BAT executes the program DDUTIL.EXE with the sort option specified. DDUTIL sorts the
UNITDATA.DAT file and validity-checks it to determine if the same CDB pointname has been used for more than one CDB
memory location/point. It writes the results of the sorting into a new UNITDATA.DAT file. Any error or warning messages
generated as a result of the sorting and validity-checking are reported to the screen and written to MK5MAKE.LOG.
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MK5MAKE.BAT
ENGLISH.SCA
DDLOCATE
IO.ASG
FACTORY.ASG
ALLOCSSP.ASG
SITE.ASG
PROM\UNITDATA.TPL
PROM\UNITFREE.TPL
PROM\UNITMAP.TPL
Creates unsorted,
un-validity-checked
UNITDATA.DAT
DDUTIL SORT
Creates sorted,
validity-checked
UNITDATA.DAT
TABLE_C ALL
Compiles all
source Table Files
ALARM_L
Creates Alarm Cross-Reference
file ALARM.LST
No response
in 30 seconds?
Compile
Control Sequence
Program?
NO
YES
COMP_SEQ
Program messages
written to
MK5MAKE.LOG
GEH-5980E
Maintenance Manual
MK5MAKE.BAT then executes the Table Compiler program, TABLE_C.EXE with the ALL option specified on the
command line. The ALL option directs the Table Compiler to compile (convert from ASCII text hexadecimal) all the source
Table Files (BOI_?.SRC, CBLR_?.SRC, CHNG_?.SRC, CONST_?.SRC, EPA_?.SRC, EVENT_?.SRC,
HIST_?.SRC, MAOUT_?.SRC, TOTT_?.SRC). Any messages generated as a result of compiling the Table files are
reported to the screen, and also written to the log file, MK5MAKE.LOG.
Next, MK5MAKE.BAT executes ALARM_L.EXE. This program generates the Alarm Cross-Reference List, ALARM.LST,
from the UNITDATA.DAT and the alarm text message file, ALARM.DAT. Any messages generated as a result of running
ALARM_L is reported to the screen and written to MK5MAKE.LOG.
Finally, MK5MAKE.BAT asks the user if he/she wishes to compile the Control Sequence Program segment source files. The
user has thirty seconds to respond. If no response is detected within thirty seconds MK5MAKE executes the CSP Compiler. If
the user responds affirmatively to the prompt within thirty seconds by pressing " Y ", MK5MAKE executes the CSP Compiler
and creates the downloadable hex format CSP files from the source CSP segment files. Any messages generated as a result of
compiling the CSP is reported to the screen and written to MK5MAKE.LOG. If the user responds negatively to the prompt
within thirty seconds by pressing " N ", MK5MAKE does not execute the CSP. If the user responds negatively, a message is
reported to the screen and written to the log file indicating that the user elected not to compile the CSP. If no response is
detected in thirty seconds, MK5MAKE executes the CSP Compiler, and a message indicating the CSP Compiler was
automatically executed along with any messages generated as a result of running the compiler is written to MK5MAKE.LOG.
It is also reported to the screen.
4-6.2.
MK5MAKE.LOG File
The log file, MK5MAKE.LOG, is created each time MK5MAKE.BAT is executed. As detailed in section 4-6.1, any messages
generated by the programs executed when MK5MAKE is executed, are reported to the screen and written to the log file for
later viewing and/or printing. This file can be very useful in troubleshooting and resolving warning or error messages
generated by the execution of programs by MK5MAKE. It can be viewed using any ASCII text editor and printed the same as
any ASCII text file.
HELP_QP.DAT
HELP_BP.DAT
HELP_QD.DAT
HELP_BD.DAT
The process alarm files (HELP_QP.DAT and HELP_BP.DAT) can be edited and printed for a specific application using any
ASCII text editor. The diagnostic alarm files (HELP_QD.DAT and HELP_BD.DAT) are created by GEDS and should not be
edited.
The Mark V can provide help text on any alarm that is active on the ALARM or DIAGNOSTIC ALARM display by selecting
an alarm and clicking on the "EXPLAIN" target on the bottom of the screen. If the alarm drop number is in the ASCII text
file listed above, the help explanation will be copied from the file to the screen. If the drop number is not in the file, a default
message will be displayed.
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NOTE
Control Constant modifications are not automatically backed-up. They must be uploaded to the <I>s hard-disk
files using EEPROM to make permanent.
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2.
Select NEXT PAGE or PREV PAGE (or press F4 or F5) to scroll through the Master List Displays.
3.
Select the desired Control Constant. The screen changes to the Control Constants Adjust Point Display for that Control
Constant (refer to Figure 4-35).
The processor(s) use the RAM value(s) of the Control Constant to control, monitor, or protect the unit. The steps involved in
changing the RAM value are as follows:
1.
Change the NEW VALUE to the desired value of the Control Constant.
2.
Change the RAM VALUE by either stepping or ramping to equal the NEW VALUE
4-8.1.1. CHANGING THE NEW VALUE. To change the NEW VALUE of the Control Constant, select ENTER VALUE.
The background color changes to light blue and the text changes to VALUE. Type the new value of the Control Constant,
within five seconds, and press ENTER, or the target background reverts to white and the action is terminated. The new value
appears in the NEW VALUE field of the Control Constant Adjust Point Display (see Figure 4-35).
The NEW VALUE field can also be changed by selecting any of the RAISE/LOWER targets on the Adjust Point Display.
Selecting the RAISE or LOWER target causes the NEW VALUE to increment or decrement by one unit corresponding to the
least significant digit of the Control Constants value. Selecting on the RAISE 10X or LOWER 10X targets causes the NEW
VALUE to increment or decrement by ten times one unit of the least significant digit of the Control Constants value.
Selecting RAISE 100X or LOWER 100X causes the NEW VALUE to change by 100 times one unit of the least significant
digit of the value. For example, in Figure 4-35, the least significant digit of the Control Constant CAKCPD is 0.1, or tenths.
Selecting RAISE increments the NEW VALUE by 0.1 psi. Selecting RAISE 10X increments the NEW VALUE by 1.0 psi
and selecting LOWER 100X decrements the NEW VALUE by 10.0 psi.
4-8.1.2. CHANGING THE RAM VALUE. After entering the NEW VALUE for the Control Constant to be modified, change
the RAM VALUE(s) to equal the NEW VALUE to change unit operation. You may either step (instantly change) or ramp
the RAM VALUE to the NEW VALUE.
To step the RAM VALUE(s) to the NEW VALUE, select STEP CHANGE. This turns the target background to light blue,
indicating the step change action is armed. Then select EXECUTE, or press F6. This changes both target backgrounds to
purple, indicating the step change action was sent to the Control Panel. They then revert to normal colors. The RAM values
for the Control Constant changes instantly to equal the new value and the controllers (<Q>) use the new RAM VALUE for
control, protection and/or monitoring. STEP CHANGE is enabled only when the turbine is off-line.
Another method of changing Control Constants is the ramp change, where the RAM values are incremented or decremented
slowly to equal the New Value instead of instantly. Ramp change is the only method of changing Control Constants when the
turbine is on-line, but can be used when the turbine is off-line also.
WARNING
Changing Control Constants while the turbine is running could interrupt turbine operation and should only
be done by authorized personnel knowledgeable in turbine control and protection.
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To ramp the RAM VALUE to equal the NEW VALUE, select START RAMP. This changes the targets background to
light blue to arm the action. Then select EXECUTE COMMAND or press F6. This changes both targets backgrounds to
purple indicating the action was sent to the Control Panel. The RAM values begin to increase or decrease at the rate of
approximately one unit of the least significant digit of the Control Constants value per second until the RAM values equals
the NEW VALUE.
The ramp change can be stopped at any point, by selecting STOP RAMP, which aborts the ramp change at that value. It can
be restarted in the normal manner. The ramp change is aborted also if the Adjust Point Display is left to view any other
display except the Alarm Display. Therefore, it is recommended that while making Control Constant changes, particularly
while the turbine is on-line, the technician not change displays until the RAM values equal the NEW VALUE to ensure the
change action is completed fully. During the ramp change, the text of the START RAMP target changes to yellow to indicate
that a change is in progress and reverts to its original color when the ramp is complete.
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Start
Use NEXT PAGE or PREV PAGE to locate, then click on desired Control Constant
Is the turbine
running?
No
Yes
Click on START RAMP to slowly change the
RAM value tothe new value
Execute Control
Adjust?
No
Yes
Step
Ramp
Ramp chang may be interrupted by clicking on STOP RAMP target
and re-started by clicking on START RAMP & EXECUTE
Click on EXECUTE
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CAUTION
Only qualified personnel knowledgeable about turbine control and protection should use the Logic Forcing
functions. Improper use may adversely affect the control and protective features of the control system.
If the EXECUTE command target is selected before the command target background reverts to green, both target
backgrounds change to purple indicating that the action was executed and sent to the Control Panel. The <RST> logic values
of the pointname is preceded by a " >", indicating the logic data point is forced. Refer to Figure 4-37.
When a logic data point is forced (to either a logic " 1 " or " 0 "), it remains forced even when another display is accessed
such as Main Display or Alarm Display. It reappears on the Logic Forcing Display when reaccessed. While performing a
forcing action, other pointnames (including real data pointnames) may be added to the Logic Forcing Display for viewing.
However, when the Logic Forcing Display is left to view another display, only logic data points which are forced
automatically reappear when the Logic Forcing Display is reaccessed.
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When the heading of the <Q> columns (<R>VAL, <S>VAL, <T>VAL) appears in white text, this indicates that the
processor(s) is communicating with the voter network and participating in the voting process. If the heading of any of the
three processor columns appears in blue text, the processor is not participating in the voting process, typically caused by
failure of communication with the voter network (DENET).
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CAUTION
Only qualified personnel knowledgeable about turbine control and protection should add, modify, or
delete command targets.
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Command Pointname
Value
Target Type
Target Name
The cyan fields are used to enter information for each command target. To enter information select the desired field. The
field background changes to white, and information may be typed in from the keyboard. Press ENTER or select another field
to complete the action. To correct, change, or delete information in a selected field, use the backspace key to erase one
character at a time beginning with the last character on the line, or press CTRL U to erase the entire field.
In the Edit Form screen, select DATA DISPLAY or press F3, to return to the current User Defined Display. Select CHECK
FORM or press F4, to check changes to the edit form for accuracy. (Modifications errors are in yellow.)
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4-11.2.1. COMMAND POINTNAME FIELDS. The two fields in this group indicate the unit name (in a multi-unit application)
and the pointname of the logic signal which receives the command in the unit control panel. The unit name field is only filled
in if there are commands which need to be sent to a different unit/location than the currently selected unit in a multi-unit
installation. For example, on a multi-unit installation being controlled by one <I> in a central location, it may be necessary to
have a breaker control signal acting on a breaker in a central highyard on a particular User Defined Display for each unit.
Signal pointnames that are valid and receive command targets, are found in the UNITDATA.DAT file. To verify a signal
pointname, select CHECK FORM or press F4. If the command pointname is valid, one of the following four messages
appears directly beneath the field:
Pushbutton
Logic state
Analog setpoint
Enumerated state
When the signal pointname is invalid, it either displays with a yellow background or the error message, Not a
command. If the pointname is displayed with a yellow background, it could not be found in the Data Dictionary. If the
pointname was found in the Data Dictionary but is not a valid signal pointname, the above error message is displayed.
4-11.2.2. VALUE FIELDS . Two fields are used to specify the type of value and the actual value to send to the current unit
control panel. Therefore, these fields are only applicable when predetermined values or setpoint changes are sent to the unit
when a command target is selected or executed.
For logic state, analog setpoint, and enumerated state command pointnames this value type tells the <I> computer to read
the current value of the command pointname from the unit control panel into its memory, replace it with value from the
value field to the right, and send the new value to the unit control panel to be acted upon. When the command pointname
is a pushbutton, this value type tells the <I> computer to set and hold the command pointname equal to a logic " 1 " for
the number of scans in the value field to the right. By default, when the command pointname is a pushbutton, the value
type is set to " = " and the value field is set to " 4 ", meaning that the pushbutton command pointname is set for four scans
of the unit control panel.
This value type can only be used with analog setpoint command and tells the <I> computer to read the current value of
the command pointname from the unit control panel into its memory, add the value from the value field to the right, and
send the new value to the unit control panel to be acted upon.
This value type can only be used with analog setpoint command and tells the <I> computer to read the current value of
the command pointname from the unit control panel into its memory, subtract the value from the value field to the right,
and send the new value to the unit control panel to be acted upon.
Values entered and shown in the value field are HEX values. Once a value is entered into this field, the line directly below
the field contains the engineering units conversion of the HEX value. This conversion is only done if a valid command
pointname is entered into the command pointname field.
4-11.2.3. FEEDBACK SIGNAL FIELDS. This option changes the color of the command target text to yellow based on the
logic state of the command pointname. For example, the text of ARM/EXECUTE targets, used to select or change the
operating state of a turbine, change to yellow as an extra indication of the current operating state. This is the most common
usage of this option. The three fields in this option are feedback sense of the signal pointname such as " 0 " or " 1 ", unit
number/designation (the two character designator for the desired unit), and the signal pointname whose feedback sense is used
to set the color of the text of the command target.
If logic " 1 " is selected as the feedback sense, when the feedback
signal pointname is a logic " 1 " the text of the target is displayed in yellow.
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4-11.2.4. TARGET TYPE FIELD . This field is used to specify the type of target and the background color (see section 4-11).
The following values are used in this single character field to specify the type of target on this line:
?
4-11.2.5. TARGET NAME. The target name is the text appearing in the target on the display and can have a maximum of two
lines of eight characters per line. However, to allow for the outline around the target, the first character in each line should be
a blank space, permitting only seven characters per line. The main function of the target or the most descriptive term is placed
on the upper line of the target. Setpoint command targets, which prompt the operator for a value, use the lower line of the
target for the entry.
selecting the appropriate command type pointname from the UNITDATA.DAT file (pushbutton, logic state,
analog setpoint, or enumerated state command)
using the Edit Form screen of the User Defined Display where the new command target is to be added and
entering the appropriate information in the various group fields
performing an UPDATE DISPLAY action followed by a SAVE FILE action to make the changes to the display
permanent, by saving them to the <I> computer's hard-disk files.
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4-11.3.1. COMMAND TYPE POINTNAMES. Command target additions must be made from the available command type
pointnames found in the UNITDATA.DAT file (see Figure 4-37). Using your ASCII text editor to view the file, the rightmost character of the seventh column of the file, Flags (Hex), contains the code which identifies the pointname command
type. The codes for the command types are as follows:
2
3
4
5
6
7
A
B
For example, in Figure 4-37, the signal CA43ISL (Cable Remote Isochronous Setpoint Lower) is a pushbutton command in
<Q>. The right-most character/least significant bit of the Flags column value for the pointname is " 3 ". Pointname
CSRGVAUT is an invalid point for use as a command target. Its Flag code is a " 1 ". Only Flag codes appearing in the table
above are valid command pointnames.
;
;
Name
No.
;
<>
<-->
#unit_data GT
1
;
#point_data
;
;
Memory Offset (Hex) ------------------------------------+
;
Memory Segment (Hex) -----------------------------+
|
;
Flags (Hex) --------------------------------+
|
|
;
High/low limits type -----------------+
|
|
|
;
Plotting limits type -----------+
|
|
|
|
;
Scale code type ----------+
|
|
|
|
|
;
Point type ---------+
|
|
|
|
|
|
;
Point Number -+
|
|
|
|
|
|
|
;
Name
|
|
|
|
|
|
|
|
<---------->
<---> <->
<--> <--> <--> <--> <--> <-->
CA43ISL
CSRGV
CSRGVAUT
L43BW_CMD
SC43
480
4363
4788
535
4354
001
002
002
001
009
0002
0011
0011
0002
0002
0000
0000
0000
0000
0000
0000
0000
0000
0000
0000
0003
0007
0001
0005
000B
0 060
0060
0060
0060
0060
01E0
1216
1568
0217
1204
4-11.3.2. COMMAND TARGET SELECTION GUIDELINES. The following are guidelines for adding or modifying command
targets:
Use Arm/Execute command targets for the majority of commands to prevent false or unintended commands from being
issued (see section 4-11.1).
Setpoint command targets should only be used with analog setpoint command pointnames.
Use Immediate action command targets for commands which do not cause an unintended process disturbance when
issued (such as issuing a Raise Speed/Load Setpoint Command).
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initializes its half of the dual ported memory, if successful go to state A4.
failure in the 80196 processor, when it loses synchronization with the 80186
processor. The 80186 ignores all signals being sent from the 80196. The 80196
should re-initialize and return to state A4.
failure in the 80186 processor when it loses synchronization with the 80196
processor. The 80196 ignores all signals being sent from the 80186. The 80186
should re-initialize and return to state A4.
checks all I/O configuration, current revision, and dual ported memory.
A6 Agent Synchronization
synchronization of the voter network. All cards need to reach state A6 before any can
reach A7. Once all cards have reached state A6 and voting is synchronized, all cards
go to state A7. If a card loses state A7, the other cards remain at state A7 while the
suspect card re-initializes and attempts to return to state A7.
This is the normal sequence of sequencer power-up, with all cards reaching state A7. A failure during the power-up sequence
or during operation causes the processor to return to states A2 or A3. A failure of the 80196 initiates a return to state A2 and a
failure of the 80186 returns to state A3.
Additional states indicating a failure:
A8 I/O card initialization failure
A9 I/O card not used
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4-13.1. Set-up/Operation
Gaining access to TIMN requires a connection between the serial port of a computer (or terminalequipped with a
telecommunications software package) and the 9-pin connector of the processor core(s) in the control panel. A "straightthrough" serial cable will require a null modem for proper communication. A specially made cable with two DB-9 connectors
(assuming the computer/terminal has a DB-9 RS-232 serial port) would require only three connections: pin 2 to pin 3, pin 3 to
pin 2, and pin 5 to pin 5. This type of cable eliminates the need for a null modem.
NOTE
Only one CPU unit can be connected to an individual panel circuit board at a time; multiple
connections are not possible.
9-Pin
Connector
(Computer/
Terminal)
TXD
RXD
GND
2
3
5
9-Pin
Connector
(Mark V
Processor)
3
2
5
RXD
TXD
GND
Figure 4-38. Pinout Connections for DB-9 to DB-9 TIMN Interface Cable
A communications software package or computer terminal using the above communications configuration can access the
TIMN program. The link requires no parity, eight data bits, and one stop bit. The BAUD rate may be set from 300 to 9600
through the on-line Help menu screen.
To activate the TIMN editor, from the DOS prompt, press CTRL+Z. The screen displays the program version, the core
which the connection was made, the time/dates of the PROM set and the BBL library. The current time and date is also
displayed.
To access the on-line Help menu, press
To access the Status display, press S. Once in the status display, press H to obtain an additional Status Help menu.
To exit TIMN, press CTRL+Z, or X+Enter, or Q+Enter.
4-13.2. TIMN Commands
The following is the Status Command menu pick in the TIMN Help menu. Each command may be executed once by selecting
the appropriate letter and press Enter. For continuous monitoring of a specific process, press U+ the letter of the
function.
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Status> H
Enter
B :=
C :=
D :=
E :=
I :=
L :=
M :=
P :=
Q :=
R :=
S :=
U :=
V :=
X :=
Z :=
selection:
BMS qst entries
counters
Dpm
system errors
I/O status
voter error log
memory tables
rtos profiler
quit/exit
BMS LST summary
BMS sockets
update command
voter status
quit/exit
zero counters
4-13.2.1. I/O STATUS . Each card has a micro-processor controlling the I/O of that card. The Card name column lists the
state of that card. (****, indicates that the card is listed in the configuration file but not responding over the link). The DCC
card is an exception, the 80186 micro-processor handles all I/O functions. (see I/O configuration and I/O states below)
Status> I
obj card maj min I/O cfg qst cfg cfg eep rsp msg
ID
name rev rev stat stat ID
flgs tics ofst type seq
-----------------------------------------------------------1
**** 00
00
A1
00
22
80
0011 00
00
0000
4
**** 00
00
A2
00
21
00
0000 00
00
0000
8
LCCq 00
02
A7
D0
20
01
3D01 275 05
0005
12
DCCq 01
01
A7
D0
27
01
0001 2B3 05
0002
13
IOMA 01
01
A7
D0
21
05
0020 00
04
0000
15
TCE1 01
01
A7
D0
21
05
0040 00
04
0000
0xC0
0xC1
0xC2
0xC3
0xC4
0xC5
0xC6
0xC7
0xC8
0xC9
0xCA
0xD0
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0xA0
0xA1
0xA2
0xA3
0xA4
0xA5
0xA6
0xA7
0xA8
0xA9
0xAA
:::::::::::-
GEH-5980E
I/O states
----------186 started cold start init
196 started cold start init
196 not responding - warm start requested
186 not responding - warm start requested
BMS/DPM is being initialized
196 card is being configured via BMS msgs
I/O card is doing only inputs
I/O card is doing normal I/O operations
Error detected in cold start init
I/O card not included in EEPROM cfg
I/O card in QC test mode
4-13.2.2. PROFILER. Execution distribution of tasks in percentages, identified by priority, lower number tasks have higher
priority.
Status> P
--- RTOS profiler --... gathering samples ...
--> Total Samples: 5121
task( 45) - 3785 hits 74% ||*************************************
voter
- 327 hits 6% ||***
seg ( 1) - 316 hits 6% ||***
kernel
- 186 hits 4% ||**
task( 10) - 132 hits 3% ||*
task( 33) 89 hits 2% ||*
task( 20) 72 hits 1% ||
task( 8) 70 hits 1% ||
task( 44) 49 hits 1% ||
task( 25) 29 hits 1% ||
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4-13.2.3. UPDATE COMMAND. When the update command is typed before any of the commands with a space, it
periodically updates that display. For example, u v, periodically updates the voter display.
Status> U V
Agent:
DCC voter:
LCC voter:
I/O state: A7
I/O ready: yes
Frame Rate: 16 Hz
State: 0430
State: 0440
Conforming: 03
Agent rdy: yes
Voting Mode: TMR
Status: 0
Status: 2
Active: 2
BMS OK: 0
VDP: R
TDP: C
Present: R:3F
S:1F
Time stats: Status: 00
OK cntr:
328
Vote stats: Status: 04
OK cntr:
328
Voter buffs: Current: 5
Total:
1645
T:1F - C:DF
D:00
missed cntr:
0
missed cntr:
0
Bad type:
0
Misc counters:
DCC OK:
329
DCC aborted:
0
LCC degenerate votes:
0
DCC stand alone passes: 0
LCC sequence error: 0
LCC lost time sync: 0
DCC frame_overrun: 0
4-13.2.4. ZERO COUNTERS. Sets all diagnostic counters to 0. Counting resumes immediately.
Status> Z
8 system errors cleared
4-13.2.5. DUAL PORTED MEMORY (DPM). Shows shared memory information on the card indicated and the 80186 micro-
processor. I/O state refers to the state of the I/O card as seen by the 80186. The BMS Mask column is a hex code indicating
the amount of dpm available. A value of " 00 " is an indication of a memory problem.
Status> D
card I/O cfg BMS rset Hmsg Hmsg Hsig Hsig Imsg Imsg Isig pend pend int int
name stat stat mask cnt sema cnt sema cnt sema cnt sema 186 196 186 196
-----------------------------------------------------------------------------IOMA A7
D0
7F
0 00
0 00
19 00
0 00
00
00
00
00
LCCq A7
D0
07
1 00
113 00
0 00
236 00
00
00
00
00
**** A1
00
00
0 00
0 00
42 00
0 00
00
02
00
02
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4-13.2.6. ERROR. Continuous count of diagnostic errors that occur on the 80186 micro-processor. Look to diagnostic
alarm page for more detailed explanation of alarms
Status> E
---- System error counters ---System error cntr 7:
1
System error cntr 17:
2
System error cntr 19:
2
System error cntr 33:
1
::::-
4-13.2.7. FACTORY USE ONLY COMMANDS. The following commands are for factory use only or under the direction of
GEDS personnel. They can be viewed on the Help screen.
Command
Description
Lists the queue server IDs of messages waiting to be sent out to the networks
of the control panel. No "que entries" indicates that all messages were
successfully sent to the appointed destination. A large queue may indicate a
data communication problem.
Counters
Cumulative count of BMS messages sent and received. Counters roll over to
0 after it reaches 65,535.
A log of events and/or errors that occur during the voting cycle
Memory Tables
BMS Sockets
Listing of process IDs and socket IDs supported by the core that is being
looked at. Gives indication of what the current process can support.
Voter Status
Lists features on voting status such as, frame rate of DCC voter, designated
voting processor, time designator, processor with time functions and
miscellaneous counters.
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4-14.1. Points
The points for the Hold List are listed in the <I> processor F:\UNITn\TOTT_B.SCR file. The list can hold a maximum of
64 points. The points are either Alarms or Events and appear on the Alarm Event logger. This file must be compiled by the
table compiler, G:EXEC\TABLE_C.EXE.
The point list is then downloaded to <C> and <D> processors with the EEPROM downloader, G:\EXEC\EEPROM.EXE.
Select TOTT for the section to download. Reboot the processors to make any list change active.
4-14.2. Programs
The Hold List is maintained in the <C> and <D> processors by programs in PROM. To activate the Hold List in the <I>, it
must contain the following.
In F:\CONFIG.DAT, under OPTIONS
HOLD_LIST
=YES
In G:\EXEC\RUN_IDP.BAT,
4-14-.3. Conditions
A Hold List is maintained as follows:
A point that picks up and drops out remains in the Hold List until it is reset by an operator command.
Hold List entries must be acknowledged. Unacknowledged entries have a * character next to its status.
The Hold List has the time of the initial pickup, unit, current state and override status, and the short and long name of
each point.
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ACK
ALL
RESET
ALL
MORE
OPTIONS
SAVE
REPORT
PRINT
REPORT
TRACK
LATEST
ALARM
DISPLAY
MAIN
DISPLAY
PRINT
IMAGE
ALARM
DISPLAY
MAIN
DISPLAY
EXIT
SAVE
IMAGE
ACK
HOLD
RESET
HOLD
TRACK
LATEST
ALARM
DISPLAY
MAIN
DISPLAY
MORE
OPTIONS
OVERRIDE
HOLD
CANCEL
OVERRIDE
TRACK
LATEST
ALARM
DISPLAY
MAIN
DISPLAY
MORE
OPTIONS
PREV
PAGE
NEXT
PAGE
FIRST
HOLD
TRACK
LATEST
ALARM
DISPLAY
MAIN
DISPLAY
MORE
OPTIONS
SAVE
REPORT
PRINT
REPORT
SAVE
IMAGE
PRINT
IMAGE
ALARM
DISPLAY
MAIN
DISPLAY
EXIT
EXIT
EXIT
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EXIT
MORE OPTIONS
TRACK LATEST
displays the global targets and shows the newest list entries.
ALARM DISPLAY
MAIN DISPLAY
SAVE REPORT
PRINT REPORT
SAVE IMAGE
PRINT IMAGE
ACK ALL
RESET ALL
reset all list entries that have been acknowledged and have a zero state (dropped out).
ACK HOLD
RESET HOLD
reset the selected list entry that has been acknowledged and has a zero state (dropped out).
OVERRIDE HOLD
overrides the selected list entry if it is picked up. If this was the only active entry, ATS is free to
continue. Overridden points display a "V" as their status.
CANCEL HOLD
PREV PAGE
NEXT PAGE
FIRST HOLD
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CHAPTER 5
INSTALLATION AND INITIAL STARTUP
5-1. INTRODUCTION
This Chapter is a general guide to the installation of a Mark V Control system. As a guide, it does not purport to cover all the
details of every start-up. Each installation is different and requires a thorough system knowledge to successfully startup.
WARNING
Danger of shock, burn or other trauma exists if necessary safety precautions are not taken. These startup
procedures should be done only by personnel knowledgeable in the Mark V control system and the turbine
control philosophies. This Chapter does not cover every detail of all start -ups.
CAUTION
Immediately upon receiving the system, place it under adequate cover to protect it from ad verse conditions.
Packing cases are not suitable for outdoor or unprotected storage.
Shock caused by rough handling can damage electrical equipment. To prevent such damage when moving
the equipment, observe normal precautions along with all handling instructions printed on the case.
GE carefully inspects and packs all equipment before shipping it from the factory. A packing list, which itemizes the contents
of each package, is attached to the side of each case of the equipment.
Upon receipt, carefully examine the contents of each shipment and check them with the packing list. Immediately report any
shortage, damage, or visual indication of rough handling to the carrier. Then notify both the transportation company and GE
Industrial Control Systems. Be sure to include the serial number, part (model) number, drive code, GE requisition number,
and case number when identifying the missing or damaged part.
If assistance is needed, contact:
GE Industrial Control Systems
Product Service Engineering, Rm. 191
1501 Roanoke Blvd.
Salem, Virginia 24153-6592 USA
(540) 387-7595
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NOTE
The auxiliary components of an <I> such as printer(s), LDDS(s), and Ethernet card(s) may not be the same for
all <I>s on a particular site.
4.
CAUTION
Check the dot matrix printers nameplate for ac power frequency and voltage. Verify that the printer
supplied is designed to operate on the sites ac power frequency and voltage. Obtain a replacement from
GEDS Product Service if it is not.
5-2.2.1. HARDWARE CONFIGURATION. Some of the <I>s main components have small switches and/or hardware jumpers
that must be set to function properly. Most of these switches are preset before shipping. Verify the switch settings prior to
applying power to the <I>.
CAUTION
Failure to check and properly set the switches on the components prior to energization can result in
damage to the equipment.
5.
6.
7.
8.
Monitor must be set to enable the proper video input. Consult the monitor manufacturers instructions concerning the
positions of the switches for the particular application.
CPU switches and/or jumpers have been preset before shipping. If problems are encountered later in the start-up, it may
be necessary to verify them. If so, details will be given then.
Note the manufacturer, model number, and serial number of the ARCNET interface card.
ARCNET Interface Card is factory preset and should not need to be changed.
Each node on a Stage Link must have its own unique Stage Link ID. Mark V gas turbine control panel <C> and <D>
processor(s), Mark V steam turbine control panel <C> and D processor(s), and <I> CPU(s) have ranges which their Stage
Link IDs must be chosen. Stage Link IDs are expressed in hexadecimal format. <I> CPU Stage Link IDs are in the range
5-3
GEH-5980E
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from 01 hexadecimal to 2F hexadecimal, beginning with 2F for the first <I>, 2E for the second <I>, 2D for the third <I>, and
so on.
For example, the first <I> CPU in a Stage Link would be assigned a Stage Link ID of 2F. To set the switches to an ID of 2F to
a CPU, convert 2F from hexadecimal to decimal (2F hexadecimal = 47 decimal). Then move the switches so that the sum of
the switch values equals 47 decimal. There are eight numbered switches on the edge of the card. The switches each have the
values as follows:
DIP Switch
Value
1
1
2
2
3
4
4
8
5
16
6
32
7
64
8
128
To enable a switchs value (to add that switchs value to the total value), move the switch to the UP position. Using the Stage
Link ID example above of 2F hexadecimal (47 decimal = 32+8+4+2+1), switches 1, 2, 3, 4, and 6 should be moved to the
" 1 " position and switches 5, 7, and 8 should be in the " 0 " position.
Set the Stage Link ID for the first <I> to be 2F (hexadecimal), 2E for the second, and so on by moving the switches on the
ARCNET interface card to settings/values which equal the desired Stage Link ID value. Refer to the ARCNET interface card
manufacturers instructions for more information.
9.
If an Ethernet interface card is provided, it has jumpers which are preset. These should only be checked when
troubleshooting the Ethernet communication network.
NOTE
For more specific information about ARCNET and Ethernet interface cards and the settings of their switches
and/or hardware jumpers, new <I>s shipped after approximately September 1994 will be shipped with a
separate floppy disk labelled "IDP_CARD". An ASCII text file located on the disk will provide information
about their configuration, as well as serial port expander cards, and any other auxiliary cards which might be
provided with an <I> CPU.
5-2.2.2. STARTUP.
10.
Connect the <I> components to site AC power and turn them on. The monitor should display a series of DOS commands
and stop at a normal DOS prompt. (for example, C:\> )
CAUTION
If an operating system change or error occurs the computer might automatically invoke the Configuration
Utility program. DO NOT shut off the system, or restart using Ctrl+Alt+Del or by pressing the
RESET button. Restarting the CPU by any action while in the Configuration Utility program could cause
all information in the program to be lost or erased. To exit, press ESC or F10. If the program information
is lost or erased, it must be manually re-entered. A printout of the Configuration Utility program is
included with the CPU instructions.
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Generic software, (DOS, trackball or mouse, touch screen, etc.) are pre-loaded and it should not be necessary to re-load them.
The floppy disks are included with the computer and should be kept with the other software in a safe place.
Product and Requisition Specific software is not usually loaded onto the hard disk, or, if it is loaded, it might be a previous revision.
It is recommended that they be reloaded at this time.
15.
16.
Place the first Product Specific software floppy disk in the A: drive.
15.1. At the C: prompt, type A:INSTALL and press ENTER.
15.2. Repeat previous step for all Product Specific floppy disks.
Place the Requisition Specific software floppy disk in the A: drive.
16.1. At the C: prompt, type A:INSTALL and press ENTER.
The software is automatically installed and over-writes any necessary existing software on the <I> hard disk.
17. The CHECKCRC batch file is available to verify that the <I> Product Code disk files are all present, are the correct version,
and have not been corrupted. To run this check, type CHECKCRC at the DOS prompt.
18. Restart the computer by pressing the RESET button next to the A: drive.
At the completion of the AUTOEXEC.BAT file, the units MAIN DISPLAY should be shown on the monitor.
19.
Check cursor operation while in the MAIN DISPLAY. Using the CPD, select a display target. Selecting should initiate the
targets function. If there is difficulty with the operation of the trackball or mouse, refer to the manufacturers documentation
for further troubleshooting instructions.
19.1. If the monitor is a touch screen model, select a display with the fingertip. The function initiates when the fingertip is
withdrawn from the screen. Refer to the manufacturers documentation for troubleshooting instructions.
NOTE
After loading software onto the hard disk, write-protect the disk(s) and store in a secure location. The disks may be
necessary in the event of a catastrophic loss of the hard disk. Refer to Chapter 3, for more information on performing
a hard disk backup to the <I>.
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From the Main Menu of the <I>, exit to DOS. (It may be necessary to enable Maintenance Password Level or above
from the Password Administration Display of the Main Menu in order to exit to DOS.)
Change to the root directory of the F: drive.
Open the file F:\ARCNET.DAT with an ASCII text editor and scroll to the bottom of the file. Any lines in the file which
begin with a semicolon are comments and are ignored by the operating system.
Verify that the lines which do not start with a semicolon are for the ARCNET interface card supplied in the <I> CPU.
The configuration information for older ARCNET cards should match the table below.
Parameter Name
pcARC-AT/20
CN190SBT
PCA-CXS
CONTROLLER
90C198
90C98
90C198
IRQ
15
15
15
IO_BASE
2B0
2A0
2B0
MEMORY_BASE
D000
D000
D000
MEMORY_SIZE
4K
8K
8K
DIAGNOSTICS
OFF
OFF
ON
23.1 If the file does not contain information for the card supplied, check the README.TXT file on the IDP_CARD
floppy disk. This README.TXT file contains information about all the supported ARCNET cards and sample
data files which can be copied into the F:\ARCNET.DAT file.
23.2 Check the G:\DATA\ARCNET.DAT file for additional comments and data files. This file can be copied to
F:\ARCNET.DAT for the most recent data files, but semicolons will need to be added to "comment out" incorrect
setup lines.
24. Close the F:\ARCNET.DAT file, saving the changes.
25. Open the F:\CONFIG.DAT file with a text editor.
25.1 Note the value of the variable called "LUN" (Logical Unit Number) which is the same as the Stage Link ID. This
value will be needed in future steps.
26. Close the F:\CONFIG.DAT file. No changes should have been done, so saving it is not necessary.
27. Open the F:\IO_PORTS.DAT file with a text editor.
27.1 Copy down or print the contents of this file for later use.
28. If modifications were made to the F:\ARCNET.DAT file, press the RESET button next to the A: floppy drive in order
for the changes to take effect.
Before any more start-up functions can be done on the <I>, the Mark V control panel must be energized.
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WARNING
This equipment contains a potential hazard of electrical shock or burn. Power is provided by the Mark V to
various input and output devices. External sources of power may be present in the Mark V panel that are
NOT switched by the control power circuit breaker(s). Before handling or connecting any conductors to the
equipment, use proper safety precautions to insure all power is turned off.
30.
Inspect the control panel components for any damage which might have occurred during shipping. Check for loose
cables or wires, connections or loose components such as relays or retainer clips. Report any damage that may have
occurred during shipping to GEDS Product Service.
The ground lug in the bottom of the Mark V control panel must be connected to a suitable ground point, preferably
plant ground grid. For more information see the Installation Guidance Service Manual, GEH-6011.
31.
32.
33.
Inspect the printed circuit cards in each core checking for loose or damaged components. Verify all plug in relays are
firmly connected into their sockets.
Check to see that each card is held firmly.
Check ribbon cables and wire harnesses. Verify all ribbon cables are securely connected.
33.1 If it is necessary to unplug the connector, use the pull tabs on each ribbon cable to remove them. DO NOT
pull directly on the ribbon cables or wires.
33.2 Note the orientation of the ribbon cable or wire harness "trace". (Trace is the colored wire on the edge of the
ribbon cable, or the "odd"-colored wire on the edge of the wire harness.)
33.3 Check each wire harness power cable for proper location, checking the cable ID tag against the connector ID
printed on the card and the drawings.
CAUTION
Ribbon cables and wire harnesses are always oriented with the trace connected to pin 1 of the receptacle.
Refer to the core drawings for more information. Incorrect connection could damage card(s).
Many ribbon cable connectors are not keyed. Use caution when connecting them. The connectors which do
not fit into a receptacle must be aligned properly leaving no pins exposed.
34.
Verify that the card hardware jumpers match the drawings supplied with the Mark V and move the jumper(s) if
necessary. The jumpers in the digital output circuits can provide power to an external device from the Mark V (solenoid
output) or they can be configured as "dry" contacts, i.e: power provided by an external source. Verify each digital
output has only one source of power. If any questions arise, contact GEDS Product Service.
35. Use appropriate caution while replacing each card carrier when the core inspection is complete. Avoid binding,
pinching, or chafing the ribbon cables and wire harnesses. Prior to closing the core door, push in the two silver retaining
clips at the lower front corners of the core to lock the card carriers in place.
5-3.1.2. CONTROL PANEL INITIAL ENERGIZATION
36.
37.
5-7
GEH-5980E
38.
Maintenance Manual
resolve any extra grounds before continuing. Be sure the ground reference jumper in the <PD> core is in the correct
position.
Reconnect the ground braided conductor and capacitor.
CAUTION
Failure to check and resolve grounds on field-connected wiring and cabling can cause damage to either
Mark V Turbine Control System components or field devices, or both.
Do not connect the output of a battery charger directly to the Mark V turbine control panel without the
battery being connected to the charger; serious damage can result to the Mark V power supplies.
39.
40.
41.
Verify polarity and voltage of dc and/or ac supplies. If the battery system is referenced to ground, verify in accordance
with plant drawings.
Apply power to the control panel cores one at a time while monitoring source voltage. (Turn one on, check voltages,
turn it off. Turn on next one, etc.) If a ground exists, resolve before continuing.
Verify LEDs and fuses in the <PD> core. See Appendix E of the Application Manual, GEH-6195.
Energize the processors (<R>, <S>, <T>, <C>, and/or <D>). The LCC display should indicate state A4, A5, A6, or A7
and possibly displays several error messages. See Chapter 4 for additional information on the LCC display.
If desired or necessary, the voltages of the individual power supplies can be checked using Table 5-1.
44.
Using the LCC display and the drawings supplied with the panel, match the Voter IDs of each processor.
44.1 Press NORM button on the LCC keypad. If the Voter IDs match the prints in every processor, continue with
panel initialization procedure.
44.2 If any processors Voter ID does not agree with the core drawings, change Voter ID using the following steps:
44.2.1 Press DCC on the LCC keypad.
44.2.2 Press INC until VOTER ID is displayed.
44.2.3 Press ENTER. The current Voter ID is shown on the display.
44.2.4 To change the Voter ID, press and hold SHIFT while pressing the appropriate Voter ID character. If
a valid Voter ID is entered, the message OK FINE is shown.
44.2.5 If an invalid key sequence is entered, repeat the last four steps.
44.2.6 Turn off the core,then restart. (Newer panels have switches in the <PD> core for each core. Older
cards need to be unplugged or turned off at the control power circuit breaker.)
45.
5-8
Using the LCC display and the drawings supplied with the panel, match the Stage Link ID(s) of each communication
processor. To verify the Stage Link ID of <C> (and <D>, if equipped):
45.1 Press DCC on the LCC keypad. "186 MONITOR" appears on the display.
45.2 Press INC until STAGE LINK ID is displayed.
45.3 Press ENTER. The current Stage Link ID is shown on the display.
45.4 If the Stage Link ID conforms to the proper address range described above and matches the variable called
"LUN" (Lan Unit Number) in F:\CONFIG.DAT, press NORMAL and continue with panel initialization
procedure. If the Stage Link ID does not match the "LUN" variable in the F:\CONFIG.DAT file, perform the
following steps.
Maintenance Manual
GEH-5980E
45.4.1 To change the Stage Link ID, press and hold SHIFT while pressing the appropriate Stage Link ID
character. If a valid Stage Link ID is entered, the message OK FINE is shown.
45.4.2 If an invalid key sequence is entered, repeat the last 4 steps.
45.4.3 Turn off the core, then restart. (Newer panels have switches in the <PD> core for each core. Older
cards need to be unplugged or turned off at the control power circuit breaker.)
Although the LCC displays of the <Q> control processors have a menu selection for Stage Link ID, it is not necessary to set
the Stage Link IDs for them. The control processors do not communicate directly with <I>s, but with <C> and/or <D> which
in turn communicate with the <I>s.
5-9
GEH-5980E
Core
Card
PD
Maintenance Manual
AC
or
DC
Nominal
Positive or
"Hot"
Negative or
Neutral
Regulated?
Yes
or
No
Acceptable
Range
Fuse number, if
applicable
or other
comments
DC
125
ST-DCHI
ST-DCLOW
No
100-144
User supplied
AC
120/240
ST-AC1H
ST-AC1N
No
108-132/
216/264
User supplied
AC
120/240
ST-AC2H
ST-AC2N
No
108-132/
216/264
User supplied
DC
+15
TP-P15
TP-DCOM
Yes
12.75 - 17.25
S,
DC
-15
TP-N15
TP-DCOM
Yes
-17.25 - -12.75
T,
DC
+24
TP-+24V
TP-DCOM
No
21.6 - 32
FU1 - 5A
C,
DC
+5
TP-+5V
TP-DCOM
Yes
4.85 - 5.25
FU3 - 8A
DC
-24
TP--24V
TP--24V
No
-32 - -21.6
FU2 - 1.5A
DC
+5
TP-P5
TP-DCOM
Yes
4.8 - 5.5
R,
TCPS
DCCA
developed on the
DC
+15
TP-P15
TP-DCOM
Yes
12.75 - 17.25
DC
-15
TP-N15
TP-DCOM
Yes
-17.25 - -12.75
PLU
TCPA
DC
+5
TP-P5
TP-DCOM
Yes
4.85 - 5.25
TCEA
DC
-15
TP-N15
TP-COM
Yes
-17.25 - -12.75
DC
+15
TP-P15
TP-COM
Yes
12.75 - 17.25
DC
+5
TP-P5
TP-COM
Yes
4.85 - 5.25
DC
+24
TP-P24
TP-COM
No
21.6 - 32
DC
+24
TP-P24A
TP-N24A
No
21.6 - 32
DC
+335
PL-JW1
PL-JW2
No
300 - 400
47.
5-10
Connect the Stage Link cable to <C> and <I>. Connect one end to the JAI OR JAJ connector of the CTBA card in
location six of the <C> core and the other to the tee adapter on the ARCNET interface card on the back of the
computer. If the control panel is equipped with a <D>, only connect the Stage Link cable to <C> at this time.
Verify a termination resistor is present at the end of the Stage Link.
Maintenance Manual
48.
49.
GEH-5980E
Verify Stage Link communications. On the <I>s Main Display, the time shown in the upper right corner is
incrementing and is shown in white numbers on a black background.
48.1 If the time displays in red or the message NO VALID DATA is displayed, the ARCNET communication has
failed or has not been established. Verify the following are correct:
48.1.1 Cable and connector integrity
48.1.2 Tee adapter and 93 ohm termination resistor are installed correctly.
48.1.3 Stage Link ID and LUN match.
48.1.4 Topologies are as defined in Application Manual, Chapter 9.
48.1.5 Verify the switches and jumpers on the ARCNET interface card are correct; see step 8..
48.1.6 If problems persist, execute the stand-alone utility program I_ARCWHO. (At the DOS prompt, type
G:\SA\I_ARCWHO and press ENTER.) The Stage Link ID of the <I> is displayed, with the Stage
Link IDs of any other node(s) on the Stage Link. Additionally, if the Stage Link network is
experiencing problems, a message similar "The network is unstable." to is displayed.
If a <D> processor is provided, repeat the previous steps for it with the <C> Stage Link disconnected to ensure
communication with <D>. Be sure the <D> Stage Link ID is different from the <C> Stage Link ID.
Set the Mark V Control Panels time and date to that of the <I> CPU.
From the MAIN MENU, select TIMESET. The IDOS date and time is transmitted to the control panel processors.
To verify, view the LCC monitor of any processor in the Mark V control panel.
55.1 Press the NORMAL button. The time displayed should be the same as that on the <I>s MAIN DISPLAY.
56.
57.
Using the F:\IO_PORTS.DAT information (see step 0), connect dot matrix printer(s), laser printer(s), color printers,
LDDS(s) and modems, using the RS-232 serial cable(s) provided. The file IO_PORTS.DAT also specifies baud rate,
parity, and other serial port configuration information. These must agree with the desired parameters of the device
being connected.
Consult the manufacturers instructions for the auxiliary component for required serial communication configuration
parameters and ensure that the information in F:\IO_PORTS.DAT and the configuration of the device agree.
5-11
GEH-5980E
58.
Maintenance Manual
Modems and/or LDDS(s) are necessary to communicate with the plant DCS system. (LDDSs are necessary if the total
distance from the CPU to the plant distributed control system (DCS) exceeds 50 feet.) One Modem or LDDS is
connected to a serial port of the CPU and the other is connected to the plant DCS computer. See Application Manual,
GEH-6195, Chapter 10, for additional information.
The <BOI> must be configured before initial operation. The BOI vendor default factory configuration (RS-232) will
not work. The sequence is simple but requires power to be cycled on the <BOI>. With power OFF, press ESC and
hold while power is applied and until the display reads "LCD VIEWING ANGLE".
59.1 Each configurable feature is displayed sequentially on the LCD display. The options are selected by pressing
"." or "9". The features are scrolled by pressing "ENTER". To return the option to its current default press
"CLEAR". To exit the setup routine press "SCROLL UP".
FEATURE
LCD viewing angle
Serial Mode
Baud rate
Parity
Data/stop bits
Handshaking
Turn around
Op mode
Line terminator
Local echo
Delayed LF
Tab width
Cursor
Keyboard
Lower case
Key click
Local setup
Setup correct?
Save the setup?
OPTION
1
RS-485
9600
None
8/1
XON/XOFF
No delay
Interactive
CRLF
Disabled
Disabled
1 space
Underline
Enabled
Enabled
Enabled
Enabled
YES/NO Select YES if correct, NO if additional change is necessary.
YES/NO Select YES to save the setup and return to normal
operation, select NO to exit without saving.
5-12
Maintenance Manual
61.
62.
GEH-5980E
It is not necessary to use AUTOCAL to recalibrate the feedback signal(s) of the LVDT/R(s) whose faulty servo-valve has
been replaced, unless the servo-valve itself has a LVDT/R(s) attached (as on some medium steam turbine applications).
5-13
GEH-5980E
Maintenance Manual
5-14
Maintenance Manual
GEH-5980E
Configuration Constant values must be written down or printed from the AUTOCAL display, entered into the I/O
Configurator, and downloaded to EEPROM in the processor(s) in the Mark V control panel. This is the only method of
making the EEPROM and RAM values equal.
5-7.2. Operation
The AUTOCAL Display starts by reading ACALIB.DAT for the current unit. (The current unit is the unit selected from the
main menu. The data file defines all the SVOs that require calibration and presents a menu of the defined SVO. Once the
desired SVO is selected, information is displayed on the screen. However, no commands can be sent to the unit until the
permissive logic signal is met. If the Mark V does not respond or the AUTOCAL function is being used by another <I>, the
data fields remain blank.
The data file can define a logic PERMISSIVE signal that must be in a required state before calibration commands can be sent
to the Mark V. If the data file defines a signal name that does not exist for this unit, the display issues an error message about
an invalid PERMISSIVE signal name and refuses to enable commands. To enable commands the data file must add the
PERMISSIVE signal and the logic that drives it to the Mark V. If the user has the required privilege and the permissive
signal is found to be valid, a warning message is displayed.
5-7.2.1. AUTOCAL TARGETS. When AUTOCAL is enabled the following seven targets appear.
START CALIBRATE sends the command to the Mark V to start AUTOCAL. This executes the position calibrate function
and reports the resulting information on the display. When all required permissives are met and hydraulic operation of the
valve is possible, AUTOCAL controls the servo-valve output current(s) to the servo-valve device to position the actuator or
device. The Mark V then measures the feedback voltages and calculates I/O Configuration Constants. The currents
determined during the AUTOCAL procedure are stored in TCQA RAM.
VERIFY POSITION starts the "verify under position" control function. This function ramps the actuator from actuator
mechanical minimum travel to mechanical maximum travel then ramps back again at a constant rate (for example, constant
inches per minute). While verifying under position control, AUTOCAL causes the servo-valve output current to increase or
decrease as necessary to maintain the fixed rate of travel as indicated by the LVDT/R feedback signal(s). Servo current data
is collected at 128 Hz rate and is placed in the Mark Vs buffer. If the servo-valve, the actuator, or device is not mechanically
binding or sticking, the amount of current required to maintain the fixed rate of travel should be constant. Such mechanical
binding could be caused by such things as valve packing, a scored hydraulic actuator cylinder, or a damaged valve stem. The
results of verifying under position control can be plotted on the <I> and printed for further analysis.
VERIFY CURRENT starts the "verify under current" control function. This function causes AUTOCAL to output a fixed
servo-valve output current that causes the device to move at a constant rate of approximately 30% travel-per-second from
actuator minimum mechanical to maximum mechanical travel and back. If the processor is re-booted or another valve
calibrated, the current values from the most recent AUTOCAL procedure are lost. If no values exist in TCQA RAM for
moving the device at the 30% per second rate, a message is displayed indicating that the device must be calibrated before the
operation can occur. The current for each direction is different because of the null bias current required to overcome the failsafe spring bias in the servo-valve
MANUAL SETPOINT defines the position reference if manual control is enabled. Manual control is used to check the
accuracy of calibration or to hold the device in some position for mechanical inspection or maintenance. The desired position
is entered, ENABLE MANUAL is selected, then the valve is driven to the setpoint position. Changing the MANUAL
SETPOINT when manual control is enabled ramps the device at a fixed 30% stroke-per-second rate to the new setpoint.
IDLE halts any calibration, verify, or manual control and clears any status or error condition from a previous command.
VIEW VERIFY is used to collect and plot data in the capture buffer.
5-15
GEH-5980E
Maintenance Manual
WARNING
Personnel should keep clear of the area during an automatic calibration sequence or when one of the
automatic calibration options is executed. The hydraulic actuator is moving the device from mechanical
stop to mechanical stop at rates as quick as approximately 4 seconds using full hydraulic pressure.
63.
64.
Safety concerns and precautions. To enable AUTOCAL, high-pressure shaft turbine speed must be below 28%,
meaning the unit must be off-line, shut down, or on crank in certain applications.
Insure LVDT is in the linear region and that the minimum travel is set (see Figure 5-2). LVDT/Rs are usually specified
so that the linear range of output voltage is slightly greater than the mechanical range of travel of the actuator or device.
Since the output voltages of LVDT/Rs are non-linear at the extreme ends of travel, it is important to mechanically
adjust the LVDT/Rs so that at its minimum travel, such as at one of the mechanical stops of the actuator or devicer, the
output voltage is in the linear range. See documentation for minimum travel voltage.
LVDT/R
Range of
Travel
Actuator/
Device
Range of
Travel
Effective
Stroke
LVDT/R
Output
Voltage
Range of Travel
5-16
Verify pretravel. Pretravel dimensions are defined and explained in the turbine manual.
Understand difference between LVDT range of travel, Actuator range of travel, and actual mechanical range of travel.
The following information must be known before AUTOCAL can calibrate LVDT/R position feedback signal(s) from a
device: (see Figure 5-3)
Maintenance Manual
1
2
3
4
5
GEH-5980E
6
7
8
9
----------------------|
1
|
2
| |
3 4
---------------------|
5
|
6
|
7
|
8
69.
70.
5-17
GEH-5980E
Maintenance Manual
the device, the CDB pointname and the required state of the logic signal can be viewed in the unit-specific
ACALIB.DAT file. Most applications use the CDB logic signal L3ADJ for the AUTOCAL permissive and require it to
be a logic " 1 ". By reviewing the units Control Sequence Program, the conditions which make L3ADJ (or the
particular specified CDB logic signal point) a logic " 1 " can be determined.
WARNING
Confirm that all personnel and mechanical obstructions are clear of the valve area. The Mark V will move
the valve quickly from actuator mechanical minimum travel to actuator mechanical maximum travel. Also,
sudden loss of oil pressure could result in rapid movement.
6.
7.
8.
9.
5-18
Maintenance Manual
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
or
or
GEH-5980E
Click on MANUAL SETPOINT, enter the value for maximum valve position in the same units used for
POSITION_POS_SAT. (For example, if percent was used before, use 100 here. If inches were used before, use the
value in inches for maximum valve position.) Click on OK.
Measure and Record the LVDT feedback AC voltage using the DIAGC utility. See Chapter 4 for details..
Click on IDLE. The AUTOCAL testing is finished.
Return system to normal.
29.1. Remove any logic forcing installed to execute test.
29.2. Return hydraulic system to normal.
Test is now complete. If the new values are to be made permanent, continue; if not stop here.
Edit the I/O Configurator, TCQA card, for the regulator just tested. Enter the median values of <R>, <S>, and <T>
from the print out and the 0% and 100% position AC voltage readings.
Click on VERIFY SCREEN, then EXIT CARD DEF.
Click on SAVE CHANGES. This will save the new values on THIS <I>.
Click on EEPROM DOWNLOADER and follow the directions in Chapter 4 to save the new values to EEPROM in each
processor.
Reset (push white reset button on DCC card) the processors to update the RAM with the EEPROM values.
If there is more than one <I> on the system that could be used for future maintenance, this same information should be
stored on the other <I>s hard disk(s). This can be done one of three ways:
36.1. Execute steps 33, 34 and 35 for each <I>. It is not necessary to download to EEPROMs again (step 36).
36.4. Copy the file IOCFG_.DAT from the <I> used for the test onto a floppy disk and then copy the file from the
floppy disk to the other <I>s hard disk(s).
36.5. Use the EEPROM UP feature. See Chapter 4 for details. Remember that the EEPROM uploader will not save
any comments in the files.
5-19
GEH-5980E
Maintenance Manual
WARNING
Confirm all personnel and mechanical obstructions are clear of the valve area. The Mark V will move the
valve quickly from actuator mechanical minimum travel to actuator mechanical maximum travel. Also,
sudden loss of oil pressure could result in rapid movement.,
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
5-20
Maintenance Manual
GEH-5980E
CHAPTER 6
DATA DISPLAY TOOLS
6-1. INTRODUCTION
The <I> gathers data from the CDB of the control processor, scales it, and displays it with the correct units. This chapter will
describe the programs that the <I> uses to gather data, scale it in English, metric, or custom units, and display the data in
several different ways, including triggered and real-time plots. Some of these features are cost options however, and may not
be available on all operator interfaces.
6-2.1.
VIEW1.EXE
VIEW1.EXE is executed from the DOS command line of an <I> while IDOS is running. While VIEW1.EXE program is
collecting data, the <I> is dedicated to this task. If necessary, control commands may be issued froma ntoher <I> or <BOI>.
The program is manually initiated, not by an event or predetermined time. (See VIEW2T.) VIEW1.EXE can collects data at
a once-per-second rate (1 Hz).
To view the startup screen, type VIEW1.EXE at the DOS prompt and press Enter. This reveals the information shown in
Figure 6-1.
When executing VIEW1.EXE on a multi-unit <I>, it collects data from the currently selected <I> unit unless a unit name
prefix is supplied. To collect data from units other than the currently selected unit, use the unit name followed by a colon as a
prefix to the CDB pointname. For example, to collect data for CDB pointname L4 for unit T2, enter the pointname at the
prompt or in the pointlist file as T2:L4.
6-1
GEH-5980E
Maintenance Manual
The following list of CDB pointnames could be used by VIEW1.EXE to gather data from multiple units (in this example T1
is the currently selected unit when the file is executed.)
TNH
FSR
CPD
T3:L3STCK
T2:L4
This is regardless of the drive/directory from which the program was executed. The currently selected unit is the one whose
Main Menu was switched to or was being viewed at the time the user exited to DOS. A sample of data collected by running
VIEW1.EXE with three data points specified is shown in Fig. 6-2.
Scale
----%
%
psi
83.20
83.17
87.96
79.45
78.76
82.38
84.78
The time for each data sample in Figure 6-2 is the time in the <I>, used to execute VIEW1.EXE. It is not the time in the
Mark V Control Panel(s) from which the data was collected.
6-2.1.1.
output.
VIEW1.EXE OPTIONS. The options available give two ways to enter the pointnames and two ways to direct the
VIEW1 [output_file] [@pointlist]
Entering pointnames:
If no options are specified, the program prompts the user to enter the pointnames.
Use a pointlist file, (@pointlist) where pointlist is the name of the ASCII text file containing the pointnames for the
data to be gathered. Pointnames used by VIEW1.EXE are listed in an ASCII text file created prior to executing
VIEW1.EXE.
Directing the output:
6-2
Maintenance Manual
GEH-5980E
The data collected is displayed to the <I> CRT and written to the output filename specified when VIEW1.EXE is
executed. If a file has the same name as the output file when VIEW1.EXE is executed, it is overwritten. Data that is
collected by VIEW1.EXE and written to disk can be viewed and printed using an ASCII text editor. Vendors have other
programs available that are able to import ASCII text data in order to convert it to a chart, graphs, or other readable
formats.
If desired, an ASCII text file can be specified which defines a list of CDB pointnames to collect data from when
VIEW1.EXE is executed. The file must exist prior to executing VIEW1.EXE. A maximum of 29 CDB pointnames can
be listed in the file. However, only eight can be displayed on the screen at a time. The data for the first eight CDB
pointnames can be displayed on the <I> CRT. The file which lists CDB pointnames to be used by VIEW1.EXE should
be created with one pointname per line. When VIEW1.EXE is being executed, the CDB pointlist filename must be
preceded with the "@" symbol.
Execute VIEW1.EXE in the USER directory on the F: drive, particularly if collected data is saved to a file on the <I>
hard disk. Since data files created by VIEW1.EXE could be very large and are only used in troubleshooting, it is not
recommended that VIEW1.EXE data files be created or stored in unit-specific directories. Archiving such files is
unnecessary and consumes a lot of disk space. Additionally, once they have served their purpose VIEW1.EXE data
files can easily be deleted from F:\USER without the possibility of accidentally deleting unit-specific files.
Press any key to stop VIEW1.EXE. Do not leave VIEW1.EXE running unattended for long periods of time if collected
data is being written to the hard disk and <I> hard disk space is limited. The flowchart (displayed in Figures 6-3 and 6-4)
details the steps involved in executing VIEW1.EXE.
6-3
GEH-5980E
Maintenance Manual
START
Data Collection using
VIEW1.EXE
NO
Is access
to DOS
enabled?
YES
If <I> is multi-unit,
change to unit from
which data is
primarily collected
Exit to DOS
command line
output_file
Determine name
of file where
Is collected
data written to
an output file?
YES
collected data
is written
Will a
pointlist file
specify CDB
pointnames?
NO
NO
YES
Will a
pointlist file
specify CDB
pointnames?
YES
NO
filename
Use an ASCII
text editor to
create
pointlist file
of CDB
pointnames
filename
Use an ASCII
text editor to
create
pointlist file
of CDB
pointnames
See Note 1
A
6-4
See Note 1
B
VIEW1.EXE (Sheet 1 of 2)
Maintenance Manual
GEH-5980E
VIEW1 @filename
VIEW1 output_file
VIEW1
See Note 1
See Note 1
NOTE 1
On multi-unit <I>s, CDB pointnames
from units other than currently
selected unit must be preceded with
the two-character unitname and a
colon; e.g., T3:
VIEW1.EXE (Sheet 2 of 2)
6-5
GEH-5980E
6-2.2.
Maintenance Manual
VIEW2.EXE
The program VIEW2.EXE can also be a very useful data-collecting tool for troubleshooting purposes. It is very similar to
VIEW1.EXE (see the previous section) except VIEW2.EXE has different options, it must output to a file, and it stops
differently. VIEW2.EXE can collect data for a specified period or be left to continue until the <I>s RAM is full. When full,
the program terminates and writes the data from RAM to a file. The programs execution can be terminated at any time by
pressing any key. All data collected until that time is written to an ASCII text file.
The command line format/syntax for VIEW2.EXE and its options are shown in the Help screen in Figure 6-5.
output_file
[Default is C]
[Default is 1 for 32 Hz]
[Default is all memory]
VIEW2.EXE OPTIONS. The various options that can be specified when running VIEW2.EXE are detailed as
follows: (VIEW2.EXE uses default values for any options not specified.)
6-2.2.1.
/PROC instructs VIEW2.EXE to collect data for the specified CDB pointnames from a particular processor in the Mark V
control panel. If no processor is specified when VIEW2.EXE is executed, it collects data from its default processor, <C>. In
a TMR Mark V control panel, data is usually collected from the <S> or <T> processors rather than from <C> or <R> because
all the information in <C>s control signal database is not updated as quickly as that in the <Q>, and it is desirable to keep the
<R>s processing load as light as possible. Choosing <S> or <T> results in "fresher" data and does not increase the processing
load on <R>. In a Simplex Mark V control panel, data is collected from <R>, if possible. There are instances, however, when
data is collected from <C>, such as when there are troubleshooting problems with the <C> I/O.
/SCAN is the "scan rate," or rate at which data is collected by VIEW2. It is defined by specifying a value for this option.
The actual rate of data collection is usually defined in Hz or the number of times-per-second that data is gathered and stored.
The corresponding "scan rate" of data collection is calculated using the formula:
scan rate = (32 / Hz)
For example, if data is collected at an 8 Hz rate (8 times-per-second), the scan rate value to be specified when executing
VIEW2.EXE would be 4. If no scan rate is specified when VIEW2.EXE is executed, it collects data at the default scan rate
of 1 (32 Hz).
/SAMPLES defines the number of times (samples) data is collected by VIEW2. This option can define the length of time (in
seconds) the data is collected using the following formula:
time = samples / (32 / scan rate)
Solving for samples, the above formula becomes:
samples = time * (32 / scan rate)
For example, if data were to be collected at a scan rate of 4 (8 Hz rate), for 2 minutes (120 seconds), the value of samples to
be specified when executing VIEW2.EXE would be 9600. If no number of samples is specified when VIEW2.EXE is
executed, it collects data until the available memory in the first 640K of <I> RAM is full, writes the data to a file on the hard
disk, and terminates itself.
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The command for executing VIEW2.EXE to collect data from the <S> processor of a TMR Mark V control panel at an 8 Hz
rate for a period of 2 minutes using the CDB point(s) listed in the file VIEW2.LST and stored in the file VIEW2.DAT is:
VIEW2.EXE /PROC=S /SCAN=4 /SAMPLES=9600 @VIEW2.LST VIEW2.DAT
The ASCII text file which defines the list of CDB pointnames may be specified when VIEW2.EXE is executed. The file
must exist prior to executing VIEW2.EXE. A maximum of 29 CDB pointnames can be listed in the file. The list is created
with one pointname per line. If the Synonym Feature is enabled, pointname synonyms can be used instead of CDB
pointnames. When specifying the CDB pointlist filename, it must be preceded with the " @ " symbol.
The data collected by VIEW2.EXE is written to a specific file by supplying a filename when VIEW2.EXE is executed. If a
file with the same name as the output file already exists when VIEW2.EXE is executed, it is overwritten. A flowchart
detailing the steps involved in executing VIEW2.EXE is shown in Figures 6-6 and 6-7.
VIEW2ASC - VIEW TO ASCII FILE CONVERSION UTILITY. This utility will take the results of a VIEW1 or a
VIEW2.EXE data file and format it so that the data can be imported into most spreadsheet or database programs. The time is
converted into a raw number of seconds. The data is left untouched. Many spreadsheets can not accept as many numbers as
are in the data file because of memory limitations. Therefore, the user must specify which points are to be included in the
output file. Type VIEW2ASC with no parameters and the following help screen will appear:
6-2.2.2.
Mark V and save it in a circular memory buffer. When the first logic point specified makes a transition, VIEW2T will collect
a user-defined number of post-trigger records and write that data into a file for analysis. It can collect data at up to 32 Hz from
any processor. Type VIEW2T with no parameters and the following help screen will appear:
VIEW2T
where:
Options are:
/PROC=c
where "c" is { R | S | T | C | D }
[Default is C]
/SCAN=n
where n is CPU ticks, (1..65535)
[Default is 1 for 32 Hz]
/SAMPLES=n where n is maximum number of samples [Default is all memory]
/POST=n
where n is number of samples after trigger [Default = 1]
/TRIG=0
Trigger upon dropout of the first signal
/TRIG=1
Trigger upon pickup of the first signal
[Default = 1]
@pointlist_file is the file with the list of points to collect data from
output_file is the file to which the data will be written to
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START
Data collection using
VIEW2.EXE
NO
Is access
to DOS
enabled?
YES
If <I> is multi-unit, change to unit from
which data is gathered
Exit to DOS command line
pointlist_file
YES
NO
Will data
NO
be collected for a
specific period of time?
(i.e. number of
samples)
YES
Will data
be collected for a
specific period of time?
(i.e. number of
samples)
YES
NO
Determine the time in seconds,
for which data is gathered,
then calculate the number
of samples collected.
/SAMPLES =
time * (32/scan)
/SAMPLES =
time * (32/scan)
A
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GEH-5980E
Is Mark V
YES
NO
control panel
TMR?
Is Mark V
YES
NO
control panel
TMR?
See Note 1
See Note 1
See Note 1
YES
Is Mark V
NO
control panel
TMR?
YES
Is Mark V
See Note 1
NO
control panel
TMR?
Collected data is
written to file
after specified
number of samples
have been collected
Data-collection using
VIEW2
COMPLETE
Collected data is
written to file
after specified
number of samples
have been collected
Data-collection using
VIEW2
COMPLETE
NOTE 1
Depending on the
circumstances it may be
advantageous to choose
<C> as processor from
which data is gathered
ASCII data file for analysis. In other words, this program will take input before it is voted upon by the processors and write it
to a file for analysis. It can collect data at up to 32 Hz. Type VIEWPV with no parameters and the following help screen will
appear:
VIEWPV [options] [@pointlist_file] output_file
where:
Options are:
/PROC=c where "c" is { B | C | D }
[Default is
/SCAN=n
where n is CPU ticks, (1..65535)
[ Default is
/SAMPLES=n where n is maximum number of samples [ Default is
/[NO]SEP
[NOT] show separators in output file [ Default is
@pointlist_file is the file with the list of points to collect
output_file is the file to which the data will be written to
B]
1 for 32 Hz]
all memory]
/SEP]
data from
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See Section 6-2.2.1 for an explanation of /PROC, /SCAN, and /SAMPLES. The @ is necessary before the pointlist name.
Help is available on-line by typing VIEWPV at the DOS prompt.
6-2.2.5.
VIEWQ - VIEW <Q> DATA. This program will collect selected points from the CDB from each of the <Q>
processors and write the data to a file for analysis. It can collect data at up to 32 Hz. Type VIEWQ with no parameters and
the following help screen will appear:
VIEW_LIM filename
The resulting report is written to standard output. To transfer the report to a file, use the standard redirectioning commands in
DOS, for example, VIEW_LIM filename > report_filename. Help is available on-line by typing VIEW_LIM at
the DOS prompt.
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6-2.2.7. VIEW_SD - ANALYZE VIEW OUTPUT FOR STANDARD DEVIATION. This program will take the output from
VIEW1.EXE or VIEW2.EXE and for each point will determine the mean value and standard deviation. The format of the
command is:
VIEW_SD filename
The resulting report is written to standard output. To transfer the report to a file, use the standard redirectioning commands in
DOS (for example, VIEW_SD filename > report_filename). Help is available on-line by typing VIEW_SD at the
DOS prompt.
6-2.2.8. VIEWHD - VIEW HISTORICAL DATA. This program polls a Historian for historical data and displays the data on a
point by point basis, with a time and value for each historical record. The format for this command is:
VIEWHD [\CALL] [filename]
where:
\CALL uses the call level interface to the Historian and
filename is the name of an output file to write the historical data to.
Both the filename and \CALL are optional. \CALL sends the data one value at a time rather than in a large batch. There is a
danger of losing communications with this method. When the command is entered, it will ask for a start time and an end time
(both in the format DD-MM-YYYY HH:MM:SS) and then it will ask for a unit and its pointname. The data will then be
displayed in a list format. On-line help is available by typing VIEWHD /? at the DOS prompt.
6-2.2.9. VIEWST - VIEW DATA IN THE SHORT-TERM TREND QUEUES. This program writes the contents of the Short-
Term Trend circular queues to a data file (VIEWST.OUT). Output is on a point by point basis, giving a time and a value for
each short-term trend data record. The format is as follows:
VIEWST [/REAL]
where:
/REAL includes the Real Time Plot points in the data file
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If a queue has a period of 1, and a depth of 600, it will hold one point sample per second for 10 minutes.
If a queue has a period of 60, and a depth of 180, it will hold one point sample per minute for 3 hours.
The STTREND task reads a data file which defines the points, periods, and depths of the queues. STTREND creates the
global section to hold this data and proceeds to collect and store the desired data. When a point is plotted on a Real Time
Plot, the plotting program will look into the global section to see if the point was saved in short-term trending. If it was, the
plot will show the values leading up to the current reading.
6-3.2. Adding Short-Term Trending
The first step is to enable the Short-Term Trending Option. The F:\CONFIG.DAT file defines what options are enabled at
each site. Edit this file's options section to include the line:
ST_TREND = Yes
If this line is not included, a reduced size section of memory is reserved to hold just the information for the six points
currently being displayed on the Real Time Plot. The second step is to reserve memory for holding the short-term trending
queues. By default the <I> will reserve 1 MByte of memory for short-term trend data queues. Always use the default first,
and only change the size if there is an insufficient memory error. If the <I> does not have 1 MByte of memory available, the
size of the global section can be reduced by adding the option line:
ST_TREND_SIZE = 512
The size given is the number of KBytes of memory to reserve for the short-term trend data. The default value (used if this
line does not appear) is 1024, which reserves 1 MByte of memory. Next, the points to be included in the short-term queues
need to be defined. The Short-Term Trend package uses the file F:\RUNTIME\ST_TREND.DAT to define which points
are to be included in the short-term data queues; up to 64 points can be included. The total size of all the data collected must
fit within the memory allocated for the short-term trend data. Figure 6-8 contains a sample point definition file.
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Once this file has been edited, a report can be generated on the points in the ST_TREND.DAT file. This report is generated
by the trending administration (TADMIN) program; to generate a report, enter the command:
F:\RUNTIME> TADMIN /LIST
TADMIN will read the system options from F:\CONFIG.DAT and the point list definition from the
F:\RUNTIME\ST_TREND.DAT file and prepare a report similar to Figure 6-9.
If all the desired information has been received, the size of the reserved memory may be reduced as shown above. This will
free up some memory for other IDOS functions.
NOTE
The six points available on the Real Time Plot program are NOT included in the count of the number of points
used, but ARE included in the percent of the global section used. Even if a file is reduced to zero points, about 8
percent of the global section will be used.
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6-4.1 Format
RTPLOT uses a data entry form similar to the forms used elsewhere in the <I> processor to specify plotting parameters. The
parameters for the real time plot are as follows:
Elapsed time: Enter the desired elapsed time on the plot in hours and minutes. The minimum time is 2 minutes. The
plot allows for a range of up to 99 hours, but typically the range will not be more than one hour. (See the short term
trending option in Section 6-3.)
Unit Names and Point Names: Enter the unit name and point name for each point (up to six) to be plotted. If the unit
name is left off, the current selected unit will be used. Unit names must be specified in order to see information from
more than one unit at once. (Example: MW and MVAR output from multiple turbines.)
Low and High Plotting limits: Enter the engineering units values for the low and high plotting limits for each point.
The graphs will be drawn with the axis labeled according to these low and high plotting limits.
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The real time plot program can also start with the data plot instead of the form displayed by having the parameter "/GO"
added to the menu data file. The program will check the form, and if all entries are valid it will present the plot instead of the
form. If any entry is invalid, the program will highlight the field and remain in the form.
The resulting menu file would be as follows:
"
"g:\exec\rtplot.exe"
"/GO"
The PreSaved Form file for the Real Time Plot program is an ASCII file (F:\RUNTIME\RTPLOT.PSF). This file should be
edited using an ASCII editor to define the PreSaved Forms desired for each site. There is no limit to the number of PreSaved
Forms that can be put in this file. Each PreSaved Form is given an OPTION name, which is used as the command line
parameter to the Real Time Plot program.
6-4.3.2. FORMAT. The F:\RUNTIME\RTPLOT.PSF file contains a set of PreSaved Forms in an ASCII format. Each
PreSaved Form is started with an OPTION line which specifies the name of this PreSaved Form. The OPTION line starts
with the keyword OPTION in column one (1). The name of the option follows inside a set of quotes. (Quoted strings are
used because the option can include embedded spaces.)
OPTION
"Option name"
Each OPTION has a set of parameter lines that follow to define the various parameters used to fill in the form. These lines
must be indented by at least one space under the OPTION line. The parameter lines include:
TITLE
"<title>"
The TITLE line defines the title centered at the top of the screen. It is a quoted string that can be up to 32 characters long.
ELAPSED
"<delta time>"
The ELAPSED line defines the elapsed time of the plot. The <delta time> parameter is a normal delta time
string. It is enclosed in quotes since delta times do include a space. The format of a delta time is: DDDD HH:MM:SS.CC.
The delta times for real time plots usually range from 2 to 60 minutes.
POINT
"<unit>"
"<signal>"
<low_counts>
<high_counts>
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The POINT line defines a trace to be included on the plot. The definition of the point matches the fields of the
form. One POINT line is included for each trace on the plot.
The <unit> parameter is the name of the desired unit. If this is not included, then the point will be displayed from the
currently selected unit. This is a quoted string since the unit name can be blank.
The <signal> parameter is the name of the signal to plot. This must be the Mark V signal name; it cannot be a synonym.
(The synonym name, however, is what the user will see on the screen.)
The <low_counts> and <high_counts> parameters are the raw counts for the range of the Y axis. These are
specified in raw counts so that the values are valid no matter what engineering units the user has selected.
Figure 6-10 is a sample PreSaved Form data file (F:\RUNTIME\RTPLOT.PSF) that defines a plot of the Plant Output to be
the MW and MVAR traces of the two units over a half-hour period. Lines that start with a semicolon are taken to be comment
lines and are ignored.
; This file holds the PreSaved Forms for the Real Time Plot
; program.
OPTION "Plant Output"
TITLE
"Plant Output"
ELAPSED
"0000 00:30:00.0"
POINT
"T1" "MW"
-1280 12800 ; -10..100 MW
POINT
"T2" "MW"
-1280 12800
POINT
"T1" "MVAR"
-3840
7680 ; -30..60 MVAR
POINT
"T2" "MVAR"
-3840
7680
6-4.3.3. USE OF THE PRESAVED FORM IN THE MAIN MENU. To create a main menu option that includes the use of a
PreSaved Form, include the name of the PreSaved Form as a parameter to the Real Time Plot (RTPLOT) program. The
PreSaved Form name is not case sensitive, so that upper, lower, or mixed case can be used.
For example, to create a main menu option for the Plant Output sample in Figure 6-10, the following addition to the main
menu data file (F:\RUNTIME\MENU.DAT) would be made:
"
"g:\exec\rtplot.exe"
"Plant Output"
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GEH-5980E
PLOT
display titles
plot point name(s)
plot point range(s)
plot point position(s) on the graph (left or right axis)
elapsed time
status point names (0-8 status points)
push button definitions (0-2 push buttons)
trigger signal name and value
reference line information
One data file per unit is kept in the units configuration directory. Figure 6-11 shows a data file that defines one triggered data
plot display. Each data file may contain up to 40 display definitions. Each new plot is started by a PLOT line starting in
column one. Each item included in the definition of that plot starts indented by one or more spaces or tabs. Lines that start
with a semicolon are comment lines. Figure 6-12 shows a sample data file containing the display specifications and
explanations.
The user can save or print a copy of the screen image using the PRINT SCREEN key, the SAVE IMAGE target, or the
PRINT IMAGE target. If a copy of the raw data used to produce the plot is desired, it can be printed using the PRINT
REPORT target, or saved into an ASCII text file using the SAVE REPORT target. The SAVE REPORT and PRINT
REPORT targets become active only when the plotting has completed.
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6-18
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"g:\exec\tplot.exe"
When the program is run a display select menu will be presented. Clicking on the desired display choice will start the
program. Point plotting begins as soon as the trigger condition is met. The plot start time is defined as the time when the
trigger condition was first met; the elapsed time will be added to determine the end plot time. The display select menu can be
bypassed by passing the name of the desired display to the program as a command line option. This allows access to a
specific display directly from the main menu. Example: To access the "Control test #1"-triggered plot directly from
the Main Menu, add the following line to the main menu data file (F:\RUNTIME\MENU.DAT):
"
"g:\exec\tplot.exe"
The push-buttons are active at all times but do not directly start or stop the plotting. Once plotting begins it will continue until
the elapsed time has passed. Plotting may be stopped at any time by exiting to the MENU or MAIN DISPLAY or by normal
EXIT. The SAVE REPORT and PRINT REPORT targets become active only after all data for the plot is collected and the
plotting has completed.
Exiting to the ALARM DISPLAY will not stop the plot but will cause gaps in the plot graph.
NOTE
Plot Data is NOT collected while in the alarm display.
"g:\exec\scaleset.exe"
"g:\exec\scaleset.exe"
"english"
"metric"
CAUTION
Make sure the scale set that is specified has been defined for each unit in a multi-unit <I>.
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included.
6-7.3.2. PERFORMANCE MONITOR DATA FILES. The Performance Monitor requires three special data files that hold
information about the actual turbine. These include the names of the sensors used to collect data, constants specific to each
turbine/generator set, and default values for the simulation mode. These files will be supplied by the turbine vendor.
Examples of these files can be seen in Figures 6-13, 6-14, and 6-15. (These are only examples, and should not be used at any
actual site.)
F:\UNITn\PERF1.DAT - Lists signals used in calculations
F:\UNITn\PERF2.DAT - Lists turbine-specific constants
F:\UNITn\PERF3.DAT - Lists simulation initial values
NOTE
The Performance Monitor also produces a binary output file ( F:\RUNTIME\PERF.Bn) in which the baseline
run, last performance run, and last simulation form values are stored. It is extremely important not to lose this
file, as it contains the only record of the units baseline run. Without maintaining the same baseline run,
performance results would be useless.
6-7.3.3. ENABLE THE <I> PERFORMANCE MONITOR PACKAGE. This is done via an OPTION in the <I> main
configuration file. Edit the OPTIONS section in the F:\CONFIG.DAT file to include the line:
OPTIONS
PERFORMANCE = Yes
6-7.3.4. ADD TO MAIN MENU. The Performance Monitor program should be added to the main menu by adding the
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GEH-5980E
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;
Mark V Performance Monitor data file
;
; +--- Performance program label DO NOT CHANGE except to add/delete ;
; |
+--- MARK V unit, optional, use if sensor is from another unit
; |
| +--- MARK V Point name
; |
| |
+--- semicolon for comment
; |
| |
|
; V
V V
V
;CTD
FE:CTD
; Point name for compressor discharge temperature.deg F
TC
;
;
***** MEASURED POINTS *****
;
;
The Mark V controller must contain the following data
;
points for the Performance Monitor.
;
;SYM
Point
Description
EngU
MK5 Scal
;-------------------------------------------------- -------CTIM
CTIM ; Point name for compressor inlet temperature.
deg F
TC
CTD
CTD
; Point name for compressor dischg. temperature. deg F
TC
TTXM
TTXM ; Point name for Exhaust temperature.
deg F
TC
CPD
CPD
; Point name for compressor discharge pressure.
psi(g) PRESS
AFPAP
AFPAP ; Point name for Barometric pressure.
in Hg
DP_HG
AFPEP
AFPEP ; Point name for Exhaust Duct drop.
psi
AFPCS
AFPCS ; Point name for Inlet drop.
psi
AFPBD
AFPBD ; Point name for Compressor throat drop.
inH2O
DPH2O
DWATT
DWATT ; Point name for Generator Power.
MW
MWATT
FQG
GAS_FLOW ; Point name for Fuel Flow.
lb/s
;LHV
GAS_BTU_LB ; Point name for Lower Heating Value.
BTU/lb BTU_#
;
;RATIO ---- ; Point name for Atoms of H/ Atoms of C.
(Ratio H/C)
WQJ
WQJ
; Point name for Steam Nox flow.
(Lb/s )
SPSJ
SPSJ ; Point name for Steam Nox pressure.
(PsiA )
STSJ
STSJ ; Point name for Steam Nox temperature.
(Deg F)
;WQJA
WQJA ; Point name for Steam Augmentation flow.
(Lb/s )
;SPAJ
SPAJ ; Point name for Steam Augmentation pressure.
(PsiA )
;STAJ
STAJ ; Point name for Steam Augmentation temperature. (Deg F)
;WIF
---- ; Point name for Water Injection Flow.
(Lb/s )
;WIT
---- ; Point name for Water Injection Temperature.
(Deg F)
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;
PERF2.DAT
Mark V Performance Monitor data file
;
;
The following represent turbine and compressor
;
constants that must be supplied by Gas Turbine for
;
the performance program to make its calculations.
;
;
+--- Performance program internal label
;
|
+--- Constant value
;
|
|
+--- semicolon for comment
;
|
|
|
+-- Constant description
;
V
V
V
V
;COMPCOEF1
0.2739370
; COMPCOEF1.
;
;
Generator_Type
=
7H2
DEFEXHDRP
0.0
; Default value for Exhaust Duct Drop.
BELLMOUTH
2689.0
; Inlet Annulus flow constant K.
y
NCC
0.9880
; Ncc constant.
K8
3.1500E-06
; K8 constant.
KB
9.6000
; Kb constant.
;
COMPCOEF1
0.2739370
; COMPCOEF1.
COMPCOEF2
2.7851590E-03
; COMPCOEF2.
COMPCOEF3
-5.1460185E-05
; COMPCOEF3.
COMPCOEF4
-0.3147956
; COMPCOEF4.
COMPCOEF5
-2.5918689E-06
; COMPCOEF5.
COMPCOEF6
8.2511512E-08
; COMPCOEF6.
COMPCOEF7
5.0612923E-04
; COMPCOEF7.
TURBCOEF1
1.404470
; TURBCOEF1.
TURBCOEF2
-1.1544063E-04
; TURBCOEF2.
TURBCOEF3
-2.7475037E-04
; TURBCOEF3.
TURBCOEF4
-0.8814492
; TURBCOEF4.
TURBCOEF5
-6.2203992E-07
; TURBCOEF5.
TURBCOEF6
3.9133459E-07
; TURBCOEF6.
TURBCOEF7
1.2844708E-03
; TURBCOEF7.
CFLOWCOEF1
0.1955100
; CFLOWCOEF1.
CFLOWCOEF2
1.880579
; CFLOWCOEF2.
CFLOWCOEF3
-1.023240
; CFLOWCOEF3.
CFLOWCOEF4
-4.3079383E-03
; CFLOWCOEF4.
LOSSCOEF1
945947.6
; LOSSCOEF1.
LOSSCOEF2
8.9997863E-03
; LOSSCOEF2.
LOSSCOEF3
5.5138370E-11
; LOSSCOEF3.
;
;;;;;;;;;;;;;;;;;;;;;;;; E N D O F S A M P L E ;;;;;;;;;;;;;;;;;;;;;;;;;;;
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;
Mark V Performance Monitor data file
;
***** SIMULATION VALUES *****
;
The following "ideal" performance data must be provided
;
by turbine to support the simulation portion of the program.
; Warning : Eng units must match those of data dictionary points displayed
;
INLET_TEMP
59.0
deg f
; deg F Compressor Inlet Temperature
DSCHG_TEMP
674.8 deg f
; deg F Compressor Discharge Temperature
EXH_TEMP
987.3 deg f
; deg F Turbine Exhaust Temperature
DSCHG_PRES
173.4 psi
; PSIG Compressor Discharge Pressure
ATM_PRES
29.92 in hg
; in Hg Barometric Pressure
EXH_DROP
0.144 in h20 ; 0.144 PSI - 3.99 in-h20 Exhaust Duct Drop
INLET_DROP
0.72
in h20 ; 0.072 PSI - 1.99 in-h20
Inlet Drop
THROAT_DROP
59.43 in h20
; 2.147 PSI - 59.43 in-h20 Compressor Throat Drop
MEGA_WATTS
90.885 mw
; Mw
Generator Power
HEAT_VALUE
21515.0 btu/lb ; B/LB Lower Heating Value
COMPOSITION
4.000
; Ratio Atoms of H / Atoms of C
FUEL_FLOW
11.839 lb/s
; 11.839 lb/s Fuel Flow
NOX_FLOW
14.97 lb/s
; Lb/s Nox Steam Flow
NOX_PRESS
565.0 psi
; PSIA Nox Steam Pressure
NOX_TEMP
522.0 deg f
; DEG F Nox Steam Temperature
AUG_FLOW
0.0
lb/s
; LB/S Augmentation Steam Flow
AUG_PRESS
565.0 psi
; PSIA Augmentation Steam Pressure
AUG_TEMP
750.0 deg f
; DEG F Augmentation Steam Temperature
WATER_FLOW
0.0
lb/s
; LB/S Water Flow
WATER_TEMP
0.0
deg f
; DEG F Water Temperature
;;
;;;;;;;;;;;;;;;;;;;;;;;; E N D O F S A M P L E ;;;;;;;;;;;;;;;;;;;;;;;;;;;
EXIT
MORE OPTIONS
SIMULATE RUN
DO PERF RUN
ALARM DISPLAY
MAIN DISPLAY
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GEH-5980E
6-7.4.2 MAKING A PERFORMANCE OR BASELINE RUN. The user should select DO PERF RUN on the performance
monitor main screen to start a baseline run or performance run. The Fuel Data Form is presented. Use the keyboard to input
the current fuel properties. The following options will be available from the current screen:
EXIT
ABORT RUN
BASELINE RUN
DO PERF RUN
ALARM DISPLAY
MAIN DISPLAY
Selecting baseline run or performance run uses the real time measurements from an operating gas turbine and fuel data values
to calculate the baseline or deviation parameters descriptive of the condition of the gas path of the turbine.
6-7.4.3. REQUIRED TURBINE CONDITIONS. To do a baseline or performance run, the turbine being measured must be
operating at sufficient load to have the exhaust temperature above 850F. The IGV must be completely open (that is, 84
degrees on 7001E). For combined cycle machines with IGV temperature control, this means the turbine is essentially on
temperature control. For proper comparisons the gas turbine heat soak must be completed. One good measure of heat soak is
the wheelspace temperatures; have they come to a steady-state temperature for the load being generated?
6-7.4.4. COMPLETING THE CALCULATIONS. When a successful baseline or performance run is complete, the calculated
performance deviations and turbine operating conditions will be presented in tabular form on the screen. Performance
deviations are not displayed for a baseline run. The following options will be available:
EXIT
MORE OPTIONS
SAVE RESULTS
NEW RUN
ALARM DISPLAY
MAIN DISPLAY
For a baseline run, SAVE RESULTS will save the baseline run. If there is an existing baseline, it will be replaced by the
new one. MORE OPTIONS allows the user to save or print a text report or save or print a screen copy. Successful
performance runs should be printed and saved to disk under MORE OPTIONS on the results screen. There is no automatic
historical storage or archiving of performance run results. The latest successful baseline and performance run will
automatically be available for recall under MORE OPTIONS on the performance monitor main screen. Example Baseline
and Performance runs can be seen in Figures 6-16 and 6-17.
NOTE
A baseline run should be run and saved only when the machine is new or upgraded. Maintaining the same
baseline is the ONLY way to assure meaningful data from performance runs.
6-25
GEH-5980E
Maintenance Manual
GE_TEST
UNIT T1
PERFORMANCE MONITOR
10-AUG-1993 11:30:47
GAS TURBINE DATA AND PERFORMANCE CALCULATIONS
BASELINE RUN
Barometric Pressure
29.9
in Hg
Compressor
Inlet Temperature
Discharge Temperature
Inlet Pressure
Discharge Pressure
Pressure Ratio
Air Flow
59
675
14.6
173.4
12.87
607
deg F
deg F
psi
psi
Turbine
Exhaust Pressure
Exhaust Temperature
Effective Nozzle Area
14.8
987
316
psi
deg F
in2
Fuel Flow
Lower Heating Value
Fuel Composition
Generator Power
Heat Rate (Uncorrected)
11.84
21515
4.000
90.9
10089
Nox Steam
Flow
Pressure
Temperature
14.97
565.0
522
#/sec
psi
deg F
lb/sec
#/sec
BTU/LB
RATIO
MW
BTU/KWH
The actual abort message will yield more information about the nature of the failure. A review of input data and subsequent
trials on the performance simulation may yield insight into failed thermodynamic calculations. The user may select his
options from the following:
EXIT
NEW RUN
ALARM DISPLAY
MAIN DISPLAY
6-7.4.6. PERFORMANCE SIMULATION. The performance program has the ability to let the user do a baseline and
performance run with "test" inputs. To begin the simulation, choose the SIMULATE RUN option from the main
performance screen. The user is presented with a form to enter data for the performance calculation. Any and all values on
the form may be modified. It is important to enter sets of data that are consistent. For example, if the data for compressor
discharge pressure were increased, it is likely that in a real turbine this would be accompanied by changes in other parameters
such as the compressor discharge temperature increase, fuel flow increase, and others. One measure of consistency is the
value of expected generator output (power balance). Proper sets of data should maintain a very low Expected Generator
Output (power balance) deviation, generally five percent or less. The user has the following choices:
6-26
Maintenance Manual
GEH-5980E
GE_TEST
UNIT T1
PERFORMANCE MONITOR
14-SEP-1993 11:49:14
GAS TURBINE DATA AND PERFORMANCE CALCULATIONS
PERFORMANCE RUN
Barometric Pressure
29.9
in Hg
Compressor
Inlet Temperature
Discharge Temperature
Inlet Pressure
Discharge Pressure
Pressure Ratio
Air Flow
70
679
14.6
175.2
12.99
601
deg F
deg F
psi
psi
Turbine
Exhaust Pressure
Exhaust Temperature
Effective Nozzle Area
14.8
990
310
psi
deg F
in2
Fuel Flow
Lower Heating Value
Fuel Composition
Generator Power
Heat Rate (Uncorrected)
11.89
21515
4.000
90.2
10210
Nox Steam
Flow
Pressure
Temperature
14.97
565.0
522
#/sec
psi
deg F
lb/sec
#/sec
BTU/LB
RATIO
MW
BTU/KWH
EXIT
MORE OPTIONS
CHECK FORM
LEAVE SIMULATE
SIMULATE BASELINE
SIMULATE RUN
ALARM DISPLAY
MAIN DISPLAY
Normally the user will want to do a simulated performance run against the actual baseline run. If no actual baseline run
exists, or if the user wishes to use a "what if" baseline, then a simulated baseline can be created. The user may then do a
simulated performance run against the simulated baseline run. Simulated baseline runs are lost when the user returns to the
performance monitor main screen or exits the program.
6-27
GEH-5980E
Maintenance Manual
6-7.4.7. COMPLETING SIMULATED CALCULATIONS. For simulation runs, the data from the form is used in the
performance calculation. When a successful simulated baseline or performance run is complete, the calculated performance
deviations and turbine operating conditions will be presented in tabular form on the screen. Performance deviations are not
displayed for a simulated baseline run. The simulation results are available for review on the screen, but cannot be saved or
printed. The results screen offers the following choices:
EXIT
LEAVE SIMULATE
NEW SIM RUN
ALARM DISPLAY
MAIN DISPLAY
6-7.4.8. FAILED SIMULATION RUNS. An unsuccessful simulation run will result in an error message appearing on the
screen. Calculations may be aborted for a number of reasons such as any of the following:
measurement uses the gas turbines' uncalibrated inlet bell mouth as the measuring orifice. By calculating deviations from the
base line, useful results are obtained if the sensors are sufficiently stable and quite independent of the absolute accuracy of
measurements. The performance monitor compares current performance against a baseline run which must have been
previously made for each turbine in the plant. Results are given in percent deviation from the baseline run. When a baseline
run is completed it is saved, and future performance runs will be compared to this base. If something is wrong with the
baseline run, it can be done over; only the latest base line run is saved.
6-7.5.2. INTERPRETATION OF RESULTS. The programs used to calculate the deviations are complex, making use of
proprietary information about the internal design of specific General Electric gas turbines. Over the range of operation, the
calculations are generally accurate to 1 percent with occasional instances of 2 percent error where operation is far from
design point. For this reason output deviations are rounded to 1 percent. The accuracy of the results is the combination of
this calculation inaccuracy and that introduced by the drifting of sensors over the comparison period. Sensor drift can be
controlled by an effective sensor calibration program. Program output gives the deviations from the baseline run for the
following parameters:
heat rate
inlet drop
compressor efficiency
effective nozzle area
compressor flow
exhaust drop
turbine efficiency
6-28
Maintenance Manual
GEH-5980E
calculated by two different methods from sensor data and directly compared; the deviation of this power balance is presented.
The power balance deviation is a measure of the validity and accuracy of the sensor data used in the calculations. High
Expected Generator Output (power balance) deviation is often a result of miscalibrated sensors. If a problem exists or is
suspected, the operator can apply some common-sense procedures to obtain additional information. For instance, if it exceeds
5 percent deviation, some of the data input values can be changed by using the simulator. Make the changes one at a time to
see what effect it has on the calculation output. In this way, the operator can determine which transducers might need
recalibration. Inputs with a significant influence on Expected Generator Output (power balance) deviation include inlet
temperature, exhaust temperature, barometric pressure, bell mouth pressure drop, output power, fuel flow, lower heating
value, and injection steam flows. The Expected Generator Output (power balance) should be 5 percent or less.
6-7.5.4. INLET AND EXHAUST DROP DEVIATIONS. Two of the deviations are direct measurements and do not involve
calculation other than scaling and comparison with the base line: the performance inlet drop deviation and performance
exhaust drop deviation. Inlet drop is an indication of the state of the inlet filtration, or other obstruction to inlet flow such as
icing. Exhaust pressure drop is a measure of pressure drop in the waste heat recovery system. Turbines without waste heat
recovery will not have the exhaust pressure transducer.
Thus the values of deviation mean different things for different categories. A difference of 2 percent from the new and clean
condition for the inlet pressure drop and exhaust pressure drop is of little consequence. A deviation of 50 percent might
mean it is time to consider cleaning the appropriate section, although letting this go to 100 percent is not unreasonable since
the only effect is a loss in output capability provided absolute limits of pressure drop are not exceeded. A deviation of 100
percent means the pressure drop has doubled.
6-7.5.5. HEAT RATE DEVIATION. In the remaining deviations, a consistent deviation of 0.05 is cause for concern while a
deviation of 0.10 is cause for action. If the calculation for power balance is high, or other deviations have shown up positive,
transducer and other input data should be checked. Heat rate deviation is a measure of overall turbine performance which is
broken down into some of its contributing causes by the other parameters presented. A significant
deviation (like 0.05) that shows up consistently in heat rate indicates that the turbine is sick, and the compressor and turbine
efficiency deviations show why.
6-7.5.6. COMPRESSOR EFFICIENCY DEVIATION & COMPRESSOR FLOW DEVIATION. Compressor efficiency deviation
is a measure of the compressor performance. A negative deviation in compressor flow or efficiency usually is a result of
compressor fouling and is an indication that cleaning is needed. If cleaning does not improve the situation, a search for
foreign object damage is indicated. Low flow might also be caused by incorrect inlet guide vane position, very severe
plugging of the inlet filters, or significant icing.
6-29
GEH-5980E
Maintenance Manual
6-7.5.7. EFFECTIVE NOZZLE AREA DEVIATION. The effective nozzle area deviation is another indicator. On heavy fuel
machines, nozzle plugging can cause this parameter to decrease. Some machines are equipped to wash the turbine, which
reduces this plugging. Erosion can cause it to increase.
6-7.5.8. TURBINE EFFICIENCY DEVIATION. The turbine efficiency is also influenced by plugging; a negative deviation of
turbine efficiency might be caused by deposits and indicates a need for cleaning.
6-8. SYNONYMS
The use of synonyms is described in the Users Manual (GEH-5979). This section will explain how to edit synonyms.
6-30
Maintenance Manual
GEH-5980E
NOTE
Synonyms can only be assigned to one pointname, and a pointname can have only one synonym.
If the SYNONYM.DAT file is large, use the search function of the text editor to check that the signal pointname
does not already have a synonym defined and that the synonym has not already been assigned to another signal
pointname.
To change or modify an existing synonym, use an ASCII text editor to locate the signal pointname/synonym in the
SYNONYM.DAT file and then change the synonym entry to the desired synonym. Save the change(s) to the file when exiting
the ASCII text editor, then re-boot the <I> for the change(s) to become effective.
To delete a synonym, use an ASCII text editor to search the SYNONYM.DAT file for the appropriate synonym text. When the
desired synonym is found, delete the line with the signal pointname and its synonym from the file or insert a semi-colon at the
beginning of the line. Inserting a semicolon will cause the Data Dictionary Loader to ignore the line when loading the
synonyms into the <I>s RAM. Save the change(s) to the file before exiting the ASCII text editor and then reboot the <I> for
the change(s) to become effective.
Synonyms can also consist of foreign language characters from a foreign language character set. The DOS commands
KEYB.SYS or KEYB.COM must be understood and followed.
6-31
GEH-5980E
Maintenance Manual
New points defined in HIST_B.SRC will be implemented only after the file is compiled, downloaded to the <C> processor,
and the <C> processor rebooted. For additional details, see Chapter 4 of this manual, and Chapter 3 of the application manual
(GEH-6195).
NOTE
Use of the table compiler prohibits the use of synonyms; therefore, synonyms are not permitted in HIST_B.SRC,
but the synonym name will be on the display.
; ----------------------------EPA_B.SRC------------------------; Note that the TIME column header does not have to be defined in this file.
: The header is automatically created when the program is run.
;
;
SIGNAL NAME
;
----------DWATT
CTIM
TTXM
WXJ
WXC
FQG
FQL
CMHUM
;END OF FILE
NOTE
Although any valid Mark V data point may be defined for the EPA Display, it is required that both WXJ
(ACTUAL FUEL/WATER-STEAM RATIO) and WXC (required FUEL/WATER-STEAM RATIO) control data
points be included in all EPA displays. In addition, it is required that the points WXJ and WXC be defined for the
FOURTH and FIFTH positions (from the left) of the display respectively. Therefore, they must be in the fourth
and fifth positions from the top in EPA_B.SRC.
Once the correct points have been added to the EPA_B.SRC file, the file must be compiled and downloaded to the <C>
processor. For more details on compiling and downloading, see Chapter 4 of this manual and Chapter 3 of the application
manual (GEH-6195).
6-32
Maintenance Manual
GEH-5980E
CHAPTER 7
FUSE RATINGS
CURRENT
RATING
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
15 Amps
15 Amps
15 Amps
15 Amps
15 Amps
15 Amps
15 Amps
15 Amps
1.5 Amps
1.5 Amps
1.5 Amps
1.5 Amps
1.5 Amps
1.5 Amps
3.2 Amps
3.2 Amps
15 Amps
5 Amps
15 Amps
15 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
5 Amps
CHARACTERISTIC
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Time Lag
Time Lag
Time Lag
Time Lag
Time Lag
Time Lag
Time Delay
Time Delay
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
Fast Acting
VOLTAGE
RATING
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
250 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
125 Volts
7-1
GEH-5980E
Maintenance Manual
CURRENT
RATING
5 Amps
1.5 Amps
8 Amps
1.5 Amps
CHARACTERISTIC
Fast Acting
Fast Acting
Fast Acting
Fast Acting
VOLTAGE
RATING
125 Volts
250 Volts
250 Volts
250 Volts
7-2
CURRENT
RATING
1.5 Amps
1.5 Amps
1.5 Amps
CHARACTERISTIC
Time Lag
Time Lag
Time Lag
VOLTAGE
RATING
125 Volts
250 Volts
250 Volts
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1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
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