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, 1993Revision 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 purchaser’s 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.
Printed in the United States of America. Print date February 20, 1998
ARCNET is a registered trademark of Datapoint Corporation. Ethernet is a trademark of Xerox Corporation.
HP is a trademark of Hewlett Packard Company. IBM is a trademark of International Business Machines. MODBUS is a trademark of Gould Inc.
Indicates a procedure, practice, condition, or statement that, if not strictly o bserved, could result in personal injury or death.
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.
CAUTION
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 equipment’s case must be shielded to prevent contact by personnel.
To minimize hazard of electrical shock or burn, approved grounding practices and procedures must be strictly followed.
To prevent personal injury or equipment damage caused by equipment malfunction, only adequately trained personnel should modify any programmable device.
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. USER’S 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. IDOS—THE <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
TABLE OF CONTENTS - continued
Section/Subject Page
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
TABLE OF CONTENTS - continued
Section/Subject Page
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
TABLE OF CONTENTS - continued
Section/Subject Page
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
TABLE OF CONTENTS - continued
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
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).
1-1.1. Requisition Specific Drawings
Requisition or unit specific drawings are provided by various sources with each Mark V Turbine Control System. General Electric Drive Systems (GEDS) Turbine Products Division provides drawings to describe the hardware and software configuration for each requisition, including:
• 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.
Additional documentation is provided by the turbine manufacturer directly to the customer.
1-1.2. Product Manuals
The three manuals provided by GEDS for the Mark V Turbine Control System are designed to meet the special needs of operators, maintenance personnel, and application engineers.
• For the operator, SpeedtronicTM Mark V User’s Manual (GEH-5979)
• For the maintenance technician, SpeedtronicTM Mark V Maintenance Manual (GEH-5980)
1-1.2.1. USER’S MANUAL. The user’s 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:
• Main Menu and Display • Trip Log Display
• PASSWORD Administration • EPA Display
• Synonyms • Back-up Operator Interface Operation
• Alarm Management • Printer Functions
• User-Defined Displays • Multi-Unit Operator Interfaces
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:
• Control System Installation • LCC Operation
• Control Constant Adjustment • Terminal Interface Monitor Operation
• Dynamic Rung Display • DIAGC Display Operation
• Logic Forcing • VIEW Tools
• Pre-voted Data Display
1-1.2.3. APPLICATION MANUAL. The application manual is an engineer's reference for the Mark V control system. Topics in the manual include:
• Introduction To Mark V Controls • Stage Link Application Rules
• Specifications & I/O Capacities • MODBUS Configuration Instructions
• The Screen Builder • The I/O Configurator
• The Control Sequence Editor • Signal Flow Diagrams
• I/O Application Examples • Hardware Jumper Application Notes
• Regulator Descriptions & Diagrams • Big Block Reference
1-2. MARK V TURBINE CONTROL PRODUCT OVERVIEW
Turbine Control Systems have been produced for several decades and have enjoyed widespread acceptance in both new unit and retrofit applications. The Mark V represents the latest in a line of microprocessor-based turbine control systems designed specifically for controlling turbines. The Mark V can be used on medium or large steam turbines, heavy duty gas turbines (single or two shaft), and aircraft derivative gas turbines.
Unit control and protection is accomplished by using the Mark V in combination with sensors and devices mounted on the unit and its auxiliaries. Unit reliability is improved by using redundant sensors and devices for feedback, control, and protection of critical functions. Should one of the redundant devices fail, operation is not adversely affected. The connection of redundant devices to the control panel and their regulation by the control software were considered to be crucial factors in designing the Mark V. This fail-safe approach results in a highly reliable control and protection system for the turbine. In its most common configuration, the Mark V further improves unit reliability by using three redundant control processors. This triple modular redundant (TMR) design is capable of safely operating, controlling, and protecting a unit in the event of the failure of one of its control processors or control processor components. The TMR design permits a single control processor to be shutdown and repaired without shutting the turbine down.
Another attribute of the Mark V TMR control system is its use of software-implemented fault tolerance (SIFT) technology. Each control processor in a TMR control panel makes its own determination of control and protection functions based on separate inputs. The control processors individually vote the inputs used to make these determinations. Should one control processor fail to read an input correctly, its erroneous value would be "out-voted."
(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 input’s 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).
1-2.1. Primary Operator Interface, <I>
The Mark V Turbine Control System’s primary operator interface <I> consists of an IBM-compatible personal computer (PC), color CRT, keyboard, cursor positioning device (CPD), either touchscreen CRT and/or trackball or mouse, and a printer. The <I> is used to issue commands to start/stop the unit, load/unload the unit, manage and log alarms, and monitor unit operation. With the exception of the Plant Load Control option, no control or protection of the unit is accomplished by the <I>. It is simply an operator’s/technician’s interface to the Mark V control panel(s) with which it communicates.
<I>s are connected to a Mark V turbine control panel(s) with coaxial cable using ARCNET LAN (Local Area Network) com-munication-style interface. This connection between <I>s and Mark V control panels is called the Stage Link. In some cases, the Stage Link may include fiber optic cables and repeaters in order to accommodate long distances between the <I> computer(s) and the turbine control panel. Figure 1-1 shows an installation in which three <I>s are used to control two tur-bines and their driven devices.
An <I> can also be used to configure or modify the control, protection, monitoring, and logging functions of the Mark V Turbine Control System using programs supplied on the <I> computer. The ability to modify or configure these Mark V functions is password protected. Options available for the <I> include color printers and laser printers.
The Mark V control system has powerful features for customizing control strategy for each site. For example, one <I> can interface with up to eight gas or steam turbines (or any combination thereof). In addition, more than one <I> can be used (each interfacing with up to eight turbines or a subset of the eight, if desired). A hierarchy of control can be programmed on-site when multiple <I>s are used.
Figure 1-1. Multi-Unit Installation Employing Three <I>s
1-2.2. Backup Operator Interface Panel - <BOI>
The Mark V System also provides a secondary means of monitoring/controlling the turbine functions. This ancillary device is known as the Backup Operator Interface or <BOI>. The <BOI> has its own communications link which is directly connected to the three control processors <R>, <S>, and<T>.
An LCD panel with a keypad, this device is usually mounted on the control panel. It also can be used to start and stop the unit, load or unload it, silence acknowledge alarms, reset process alarms, and monitor unit operation.
1-2.3. Control Panel Configurations
The Mark V control panel is supplied in one of two configurations: triple modular redundant (TMR) or single modular (Sim-plex). Refer to Figure 1-2.
New gas turbine units almost always use a TMR control panel, while most existing gas turbine control system retrofit applications can be equipped with either a TMR or a Simplex control panel. New steam turbine units can be equipped with either a TMR or Simplex control panel. Existing steam turbines can also be retrofitted with either TMR or Simplex control panels.
Printed circuit cards and terminal boards in a Mark V control panel are contained in or are mounted on cores. Cores are sheetmetal housings that can have stationary and movable printed circuit card holders called card carriers. The cores have a maximum of five printed circuit cards mounted on the card carriers. In addition, up to four I/O terminal boards (printed circuit cards with high-density terminal boards) can be mounted on a single core.
<I>
<I>
<I>
1
2
3
Mk V
Mk V
A
B
Turbine/Driven Device - A
Turbine/Driven Device - B
Stage Link Cable
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. Location of Turbine Control
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 sys-tem (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).
<S> <R> <C>
<R> <C>
<T> <P> <PD>
<P> <PD>
<QD1> <CD> <QD1> <CD>
Mark V TMR Control Panel Mark V SIMPLEX Control Panel
<C> - Communicator Core
<S> - Redundant Control Processor Core <P> - Protective Core
<QD1>- Digital I/O Core for Control Processor(s)
<R> - (Redundant) Control Processor Core <T> - Redundant Control Processor Core <PD> - Power Distribution Core <CD> - Communicator Digital I/O Core
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.
* = optional components Protection (TCEA) Power Load Unbalance <PLU> * Digital I/O <QD2> * Digital I/O <QD1> Power Load Unbalance <PLU> * Digital I/O <QD2> * Digital I/O <QD1> Protection (TCEA) R = termination resistor IONET IONET DENET DENET Stage Link Stage Link Power Load Unbalance <PLU> * Digital I/O <QD2> * Digital I/O <QD1> Protection (TCEA) Digital I/O <CD> < T > < S > < R > < C > < I > R
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 (DCC), 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>).
2-2. STAGE LINK
The Stage Link consists of a coax cable that is terminated at both ends with BNC connectors. It runs from the ARCNET interface card in the <I> to <C> in the Control Panel. The ARCNET interface card is a high impedance source that enables the <I> to communicate on the Stage Link. Connection to the Stage Link hardware requires the use of a "T" type BNC connector. This device also permits the Stage Link to continue to further processors on the network. Due to design parameters, it is necessary to terminate the cable of the last <I> on the link with a 93 ohm termination resistor on the open connection of the "T" type BNC connector.
Stage Link
Stage Link
Port
Port
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.
2-3. DATA EXCHANGE NETWORK
Within a TMR control panel, each of the <Q> cores independently read inputs from the driven device. A critical input, such as turbine speed, is read from three independent sensors. Less critical signals are obtained through a single sensor connected to all three processors. Logic signals are received by the DCC card, which in turn acts as a data manager and storage area for all I/O signals (see Figure 2-3). Signals are then sent from the DCC card to the LCCB card, and onto the DENET. Once the information is on the DENET, each processor retrieves all three values (one from <R>, <S> and <T> respectively) and performs a two out of three software vote. Each core performs the voting task individually on the LCCB card. The voted values are stored on the DCC card of each processor where they can be applied for use in unit operation. This configuration ensures that all three cores use the same values for internal calculations on current data. Information on the DENET is also read by the <C> core, which independently performs a two out of three vote. The DENET pre-vote data from <Q> is made available to the DCC card in <C>. Voting mismatches in any of the cores are picked up by the DCC card in <C>. As a result, a diagnostic alarm is annunciated.
The process described above compares to the manner in which analog signals are handled in the panel. Values for <Q> are read into all three cores where the median value is selected. The median value is stored on the DCC card and made available for use in performing calculations critical to turbine operation. Voting mismatches in any of the cores are noted by the DCC card in <C>. As a result, a diagnostic alarm is annunciated.
This control scheme, Software Implemented Fault Tolerance (SIFT), ensures that all values used in turbine control
calculations are consistent within all three processors. For example, a sensor input failure to <S> does not cause the processor to incorporate the faulty value into its calculations as it is effectively masked by the software vote. Instead <S> uses the voted value of the three processors and proceeds with the calculation. Therefore, different pre-vote turbine trip signals in multiple processors do not cause a turbine trip.
The configuration of the Mark V control panel allows on-line maintenance or replacement of any board in a core while the unit is running. The DENET cabling is connected to the TCQC cards of <Q> and to the LCCB card of <C> and <D>. The TCQC cards are a passive connection point which forms the hub of a six port passive bridge.
NOTE
If a TCQC card is removed for service or troubleshooting from <R>, the DENET does not communicate to <S> and <T>. Without this communication link the Mark V continues to operate, but commands issued from the <I> will not be passed to <S> or <T>. For this reason, it is recommended that a TCQC card removed for
troubleshooting be replaced immediately. Commands may be issued from the <BOI> without the TCQC card as it does not use the DENET.
3PL Cable
IONET
DENET
TCEA
TCDA
TCQA
TCQC
LCCB
DCC
2-4. IONET
The I/O Network (IONET) is a communication network internal to the Mark V panel that permits data exchange between the I/O Master (DCC) and the TCDA and TCEA cards. This network allows the control to perform I/O (TCDA) and protection (TCEA) related functions. Information transmitted over the network is address-specific. As a result, data is sent to either the TCDA or TCEA cards according to their hardware jumper address settings. On start-up of the control panel, the DCC card downloads unit parameters to the TCDA and TCEA cards for I/O configuration and internal diagnostics. During operation, operating parameters from these cards are sequentially exchanged with the DCC over the IONET for unit control.
The configuration explained above allows TCEA and TCDA cards to be added to the network as necessary. Termination of the IONET is accomplished by setting the hardware jumpers on the last TCDA card of the network. See the Application Manual, GEH-6195, Appendix A for hardware jumper setting information). Each card must have a specific network address, also set by hardware jumpers, that matches a software description. If a board needs to be removed for service, the network connection is broken at that point. This does not cause a problem in a TMR panel because the IONET continually serves each processor and the unit continues to operate with one processor shut down).
In both TMR and Simplex control panels, three TCEA cards (known as X, Y, and Z) are required in the <P> core. The TMR panel has a TCEA card for each of the <Q> cores. These cards communicate with the individual DCC card of their
respective cores. The Simplex control panel also has three TCEA cards mounted in <P> which are linked in a daisy chain configuration. All of these cards operate on the same IONET and all communicate with the <R> core.
DENET DENET DENET Stage Link Stage Link To DCC <T> To DCC <S> To DCC <R> TCC TCC DCC LCCB <D> LCCB <T> LCCB <S> LCCB <R> DCC LCCB <C> TCQC TCQC TCQC DENET DENET
2-5. THE ARCNET INTERFACE BOARD
The ARCNET interface board is a device that allows the <I> to communicate with the Mark V control panel via the Stage Link network. Located in a spare 16-bit slot in the PC, the board passes signals onto the network through a "T" type BNC connector (this latter device is located at the back of the PC). The last connection on the Stage Link requires a 93 ohm termination resistor on the open end of the "T" type connector. All supported ARCNET interface boards (several ARCNET boards are supported) are high impedance "BUS" type cards. (For installation, see Chapter 5 of this manual).
HJ
HJ
Hardware Jumper
IONET
Terminal Board
Terminal Board
< P > Core
< Q > Core
TCDA
TCEA
TCQC
DCC
< QD1 > Core
2-5.1. Hardware Configuration
Supported ARCNET controller boards may implement hardware jumpers or switches for hardware configuration. Each of these boards retains the ability to configure the dual-ported memory base address, the I/O base address, the PC’s ARCNET address, and the interrupt request level (IRQ). Other selectable features are card specific.
Information regarding configuration of specific cards is provided by the IDP_CARD diskette. This information is supplied with each <I> processor and replacement I/O card ordered through GE. The IDP_CARD diskette contains a README.TXT file that describes supported I/O cards and references the card-specific hardware setup. Refer to the files on IDP_CARD for further information on hardware setup.
2.6. ALERT BOX FUNCTION
The ALERT BOX is an optional process alarm annunciator box that will provide a set of contacts and generate a tone
whenever a new unacknowledged alarm is added to the <I> process alarm queue. The Alert Box generates a one second pulse (contacts and tone) as its alert. The <I> creates an alert whenever a new unacknowledged alarm is added to the process alarm queue in order to inform operators to look at the process alarm screen. The contacts may be fed to a DCS to allow it to annunciate a change to the <I> alarm queue as well.
NOTE
The <I> being used to control the Alert Box must be using IDP version 3.5 or later in order to operate.
The alert pulses do not stack up and can not be used to count additions into the alarm queue. If multiple alarms are added to the queue at the same time a one second alert pulse will be generated. If already in the alert state, the one second pulse is stretched each time a new alarm is added to the process alarm queue - if 2 alarms are added, 1/2 second apart, the alert pulse would be seen as a 1 1/2 second pulse.
< QD1 > Core < P > Core < Q > Core HJ TCDA TCEA TCEA TCEA TCQC DCC HJ Hardware Jumper IONET Terminal Board Terminal Board
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.
2-6.1. Adding an Alert Box to the <I> Processor
The three steps for adding an Alert box to an <I> processor are:
1. 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.
2. Edit the F:\IO_PORTS.DAT file to:
a) Define the <I>‘s unused serial port’s BASE-PORT address. b) Assign the <I>‘s unused serial port as an ALERT port.
3. Restart the <I> using either RUN_IDP or Ctrl/Alt/Delete to make the changes made in IO_PORTS.DAT take effect.
2-6.2. Modifications To F:\IO_PORTS.DAT
In the section that defines which ports that IDOS is to use, the port(s) that the alert box(es) use must be included. If this is the only port used on a DigiBoard, make sure that IDOS has been told to take over the DigiBoard. Do this by uncommenting the DigiBoard port definition in IO_PORTS.DAT. The baud rate and parity of the alert box port are not important for the ALERT functions.
In the section that defines LOGICAL PRINTERS, a logical name must be created to point to each Alert Box that is to be used. Multiple Alert Box ports are allowed, but more than one logical printer should not be pointed to the same port. The name of the logical printers can be of the form ALM$ALERT (used for the primary or single alert box) or ALM$ALERTn, with n being a digit from 0 to 9. Contained in Figure 2-7 is a sample F:\IO_PORTS.DAT (using D1 for a second printer,
2-6.3. Using the Alert Box
After the <I> is connected to the alert box, connect the power source to the box and turn on the unit with the power switch. The green power LED should light. The green/red LEDs associated with each port are for diagnostic purposes and do not indicate that the alert box is on, since they are powered through the communication port.
During normal operation, the port LED for each port in use will be green. When an ALERT is received on that port, the LED will turn red for the duration of the alert. During the ALERT time, the audible alarm and the red alarm LED will pulse and the external normally open contact will be closed. Rebooting an <I> or entering RUN_IDP on the <I> will only create an ALERT if there is an unacknowledged alarm in the alarm queue. If there are unacknowledged alarms, one ALERT will be generated.
; ; 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
CHAPTER 3
<I> SOFTWARE STRUCTURE
3-1. INTRODUCTION
Software that allows a properly configured 386 or 486 IBMTM 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).
CAUTION
3-2. IDOS—THE <I>'s COMPUTER OPERATING SYSTEMIDOS schedules the <I>’s microprocessor tasks in order to support the operation, control and protection of the turbine and driven device. IDOS is priority-based and interrupt-driven with preemptive scheduling. Tasks are scheduled with a priority code of 0 to 15, with priority 0 as the lowest and priority 15 the highest. Because of its interrupt-driven, preemptive nature, an interrupt with a higher priority code takes precedence over other tasks being executed at the time the interrupt is received. MS-DOS, which runs under IDOS on the <I>, has a priority code of 4. Optimum priority scheduling is done by GEDS and cannot be configured by the user.
When invoked during the start-up (via the AUTOEXEC.BAT file), IDOS becomes the top-level operating system. Its main purpose is to enable real-time communications with the control panel(s), particularly for alarm annunciation purposes. Several precautions should be taken when loading and running other DOS-based programs on the <I>. The use of RAM disks is not recommended as the amount of extended memory available on a typical factory-configured <I> does not accommodate RAM disks. <I> operation is not increased by expanded or extended memory managers and they are not recommended.
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.
3-2.1. Root Directory
The top level or root directory of the <I> system’s C: drive contains the following minimum files:
AUTOEXEC.BAT is the batch file executed automatically upon start-up to run the IDOS operating system and enable the menu and display system of <I>.
COMMAND.COM is the command processor that reads, analyzes and performs computer instructions entered from the keyboard at the DOS prompt ( > ).
MSMOUSE.COM is used to enable the mouse or trackball. CONFIG.SYS contains PC configuration commands.
NOTE
Modifying the AUTOEXEC.BAT file, the CONFIG.SYS file, or deleting, renaming or moving files or directories provided with the <I> without the consent of GEDS is not recommended.
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 Generic
A1 Unit 1
A2 Unit 2
A8 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 unit-specific 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
CAUTION
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.
3-3. <I> HARD DISK BACK-UP
To prevent permanent loss of valuable data and work, backup the <I> hard disk drive routinely. There are three levels of back-up that are recommended:
• 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.
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
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 manufacturer’s 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.
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.
4-2. DYNAMIC RUNG DISPLAY
The Dynamic Rung Display locates and monitors the values of all parameters ("passed" or "automatic" / "logic" or "analog") that are used on any specific block of Big Block Language (BBL) code. BBL consists of primitive, generic and application specific big blocks. A big block is a section or sub-routine of software that performs a specific function. Therefore, the Dynamic Rung Display is an excellent tool for stepping through the control programming of a Mark V. The following sections describe how to use the program. For additional information on BBLs, see Chapter 5 (Control Sequence Editor) and Appendix C of the Turbine Control Application Manual, GEH-6195. Unlike the Control Sequence Editor, the Dynamic Rung Display is used for monitoring purposes only. The unit’s control sequence program cannot be altered using this program. The following sections define the operation of the Dynamic Rung Display.
4-2.1. BBL (Sequencing/Non-sequencing)
BBL is a programming language that uses blocks of standardized control functions consisting of parameters ("passed" and/or "automatic"), and/or Primitives. BBLs are used for a specific application or function and can be defined as either sequencing or non-sequencing.
Sequencing BBLs consist entirely of Relay Ladder Diagrams (RLDs). These diagrams may be used in conjunction with
Primitives. They are the only BBLs that have sub-rungs associated with them. Selecting the source code (SRC) target changes the display currently shown to a dynamic "picture" of the logic used within the sub-rung. This picture is derived from the SRC or source/picture code (SPC) files and are accessed by the dynamic rung display. Since the BBL: ALARMS_MISC_L1 shown in Figure 4-1 consists entirely of RLDs and Primitives, it is considered a sequencing BBL.
NOTE
Non-sequencing BBLs are used to perform "analog" type calculations. Non-sequencing BBLs usually consist of several
parameters (passed and/or automatic) that are manipulated by one or more Primitives. The BBL: FSRMANV2 in Figure 4-2, uses various inputs and Primitives such as clamps and multipliers to calculate desired outputs. Non-sequencing BBLs do not have sub-rungs associated with them. Instead, they have PIC files that can be accessed by clicking on the PIC target.
K63TF1H_ALM T63TF1H_ALM Primitive: TMV K27MC1N_ALM T27MC1N_ALM Primitive: TMV K27BLN_ALM Primitive: TMV Primitive: CMP TNH L30TF L63TFH1 L30RHFLT L26CTH L26BT1H L27MC1N L49X L27BLN L27MC1N L64D_P L64D_N L41FY L27DZ Primitive: TMV PIC PIC PIC PIC L30TFX L27BLN_ALM L64D L27DZ_ALM LSC1 L63TH1H_ALM L4 L64F L49X K27BLN_ALM PIC L30RHFLTX L27MC1N_ALM L49X_ALM L26CTH_ALM L26BT1H_ALM TNL 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.0 sec 0.00% 0.00%
NOTE
Non-sequencing BBLs have F:\UNITn\PROM\*.PIC files that permit viewing picture files. These PIC files are available for printout.
±µµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµ£ ¢ FSRMANV2 - MANUAL FUEL STROKE REFERENCE ¢ ¢ ¢ ¢FSRMAX ¬¬¬¬§ ¢ >¬¬¿¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬ª¬¬¬¬¬¬¬¬¬¬¬¬¬A L60FSRG¢ ¢cur_seg_time A>B«¬¬¬¬¬¬¬-¿¬¬< >¬¬¿¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬§ ¬B ¢ ¢FSKRMAN1 max¬¬©¬§ ¨¬¬¬¬Á ¢ >¬¬¿¬¬¬¬ª¬¬¬¬¬¬¬¬¬clmp ¢ ¢ -1©§ min ¬¬¬§ ¨¬¬¬¬¬¬§ ¢ ¢ ¬¬x«¬¬¬¬¬¬¬¬ _ ¨¬ ¢ ¢ ¨¬Á / + MED FSRMAN¢ ¢FSRMAN_CMD + _/ «¬¬O¬¬¬¬SEL«¬ª¬¬/«¬ª/«¬¬¬¬¬¬¬¬¿¬¬< >¬¬¿¬¬¬¬¬ª¬¬¬¬¬¬O¬ + 0 â â ¢ ¢ - ¨¬¬¬¬Á ¬¬ â â ¢ ¢ ¨¬¬¬Á â â ¢ ¢ ¬¬¬§ â â ¢ ¢ -1«¬¬Á â â ¢ ¢ ¨¬¬¬¬¬¬¬¬¬©¬¬¬Z â â ¢ ¢ ¨¬¬¬¬¬¬¬¬¬¬¬¬§ ¨¬¬¬Á â â ¢ ¢ pup-init â â ¢ ¢ ¬¬¬¬¬¬¬¬¬¬¬ªââââââââââââââââââââÁ â ¢ ¢ FSRMAX â â ¢ ¢ ¬¬¬¬¬¬¬ª¬¬ «¬ â ¢ ¢L43FSRS â â ¢ >¬¬¿¬¬¬¬¬¬¬ªââââââ(ââââââââââââââââââââââââÁ ¢ ¢FSR â â ¢ >¬¬¿¬¬¬ª¬¬ «¬¬(¬¬/«¬Á ¢ ¢ â â ¢ ¢ â ¨¬¬ «¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬Á ¢ ¢ â â ¢ ¢ ¨¬¬ «¬¬¬¬¬/«¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬¬Á ¢ ¢ ¢ °µµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµµ¤ Figure 4-2. BBL: FSRMANV2
4-2.1.1. PRIMITIVE. Primitive is a software construction that consists of parameters (passed and/or automatic), and relatively 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 Display’s 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.
• 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>.
4-2.2. Position Indicator
The position indicator is the area under the User-defined Display that refers to either: • 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.
4-2.3. User Status Box
The User Status Box available in the Dynamic Rung Display is the rectangular area in Figure 4-3 that contains TNH, FSR, TTXM, CPD, CSGV and their respective values. It is shown in all Rungs and Sub-rungs, except when viewing PIC files. The User Status Box is user programmable utilizing the format as described in Chapter 5 of the Applications Manual, GEH-6195. The User Status Box can contain any of the supported animator items, text or graphics. The file F:\RUNTIME\USER.A
defines what is displayed in the User Status Box. Improper use of the F:\RUNTIME\USER.A file causes unpredictable displays such as overwriting of variables and graphics.
4-2.4. Positioning Targets
Positioning targets locate and view specific segments, rungs, BBLs, Primitives, or parameters. The Dynamic Rung Display’s positioning targets are as follows:
Goto Jump jumps the display to the specified rung number. If the number is greater than the number of rungs in the
current segment, the next segment is used. If the number is preceded by a plus or minus (+ or -), the number is used as a relative value, for example, +5 = 5. Press Enter (not Execute), for the Dynamic Rung Display to accept a Goto Jump command. If this target is not selected within five seconds of Goto Jump, the process is aborted.
Search Name: enters the name to be searched. All letters (A-Z and a-z) and numbers (0-9) are valid entries. In
addition, wild card characters are permitted (*/?). For example, both L30* or K?8 are both valid entries. Press Enter (not Execute), to accept Search Name:. If this target is not selected within five seconds of an entry, the process is aborted. Once a valid Search Name is entered, select Find Coil or Find All to carry out the search. The
Execute function key must then be used to Find Coil or Find All.
Find Coil searches for coils only. When selected, this target instructs the Dynamic Rung Display to search for the name
of the coil entered in Search Name:. Find Coil is used only to find a coil of an RLD. It is not used to find where a Parameter is written to. If Find Coil is used while viewing rungs, only the coils in the RLD rungs are found. To find where a Parameter is written to, the user must click on the Find All target repeatedly, and then click on either the PIC or SRC targets to look at the particular Parameter (see section 4-2.8). The Find Coil function can only be effectively used when looking for coils in RLD rungs or after selecting SRC, thereby looking at the RLD sub-rungs.
Find All searches for the next occurrence of the name entered into the Search Name: field. The search includes all segments downward from the display’s current position. If the name is found, the rung is displayed and the name highlighted. BBL, Primitives, and parameters can be searched. Comments cannot be searched. Press any key, except ESC, F1, F8, or a non-target, to abort a search.
Goto Top returns the display to the first rung of the first segment (the top of the file). Prev Rung displays the previous rung, same as the Page Up function.
Next Rung displays the next rung, same as the Page Down function. Prev Seg moves the display to the first rung in the previous segment. Next Seg moves the display to the first rung in the next segment.
Return Main is displayed after selecting the SRC target. It returns user to the main BBL Display of the sequencing BBL. Rung Display is displayed after the PIC target is selected. It returns to the rung display from a PIC display.
Show Value shows the values of all passed parameters.
If a picture is too large to show on the screen, the following four targets enable viewing of the entire PIC file. They are displayed only after the PIC target is selected.
• Scroll Right moves to the right on the PIC display. • Scroll Left moves to the left on the PIC display.
• Scroll Up moves upward on the PIC display.
• Scroll Down moves downward on the PIC display.
4-2.5. Parameter/Picture Targets
Parameter/Picture targets are located in the lower right-hand corner of the display just above the position indicator.
AUTO displays the automatics of the algorithm.
MORE views more parameters (passed or automatic) of the current BBL when it contains more than 57. Continually
clicking on the MORE target while viewing a particular BBL results in a scrolling through of all the parameters (passed or automatic) of that BBL.
PAR displays the passed parameters of a particular BBL. PIC displays the respective *.PIC file.
SRC displays either the source file (*.SRC) or source/picture file (*.SPC) depending on which one exists.
4-2.6. Executing/Exiting Dynamic Rung Display
To start the Dynamic Rung Display, select RUNG DISPLAY from the main menu, or type Anim Rung at the DOS prompt.
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. 1. Start the Dynamic Rung Display (see section 4-2.6).
2. Click on Search Name: and type L39VV* or L39VV5 and press Enter.
3. Click on Find All then EXECUTE COMMAND.
This reveals the screen in Figure 4-3. For other methods on finding BBLs, Primitives, and parameters using the Dynamic Rung Display see section 4-2.13.
4-2.6.2. SELECTING AUTO. From the screen shown in Figure 4-3, select AUTO. This reveals the screen shown in Figure 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.
4-2.6.3. SELECTING MORE. From the screen shown in Figure 4-4, select MORE. This reveals the screen shown in Figure 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.
Figure 4-5. More Automatics of Non-sequencing BBL: L39W5
4-2.7. Segments, Rungs, and Sub-rungs
Protecting and controlling a turbine requires using BBLs (sequencing and non-sequencing). Understanding how BBLs are defined, arranged, and ordered is imperative for effective use of the Dynamic Rung Display. Further, since the Dynamic Rung Display is primarily used for monitoring and locating BBLs and their corresponding parameters, the user must understand how to move from one BBL to another in relation to both Segments and Sub-Rungs.
BBLs are arranged and ordered in the Dynamic Rung Display much like a "tree" structure in DOS. However, instead of directories, files, and contents, the Dynamic Rung Display uses segments, rungs, and sub-rungs respectively. Figure 4-6 shows the layout of several BBLs and their relationship to the various segments and sub-rungs. It is for demonstration purposes only and is not related to any job’s specific Segments, Rungs, and Sub-Rungs.
