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GE Mark VIe System Manual

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GEH-6721_Vol_I_BP
Mark* VIe and Mark VIeS Control Systems
Volume I: System Guide
June 2020
Public Information

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  • Page 1 GEH-6721_Vol_I_BP Mark* VIe and Mark VIeS Control Systems Volume I: System Guide June 2020 Public Information...
  • Page 2 It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced herein.
  • Page 3 Communication Protocols diagram to limit confusion because it does not add value; it was only a point of reference Added content for the Universal I/O (UIO) Mark VIe control cabinet Introduction Corrected the redundant input voltage range from 10–30 to 18–36 v dc...
  • Page 4 Ethernet Networks details Added the ESWA to the section Approved IONet Switches Fixed the accuracy rating for temperature sensor I/O Packs Terminal Board Fuse Details New section GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 5 Electrical Riser Angle Unshielded Twisted Pair (cabling) Functional Earth VLAN Virtual Local Area Network Global Position System Wide Area Network GE Standard Messaging Global Time Source Human-machine Interface HRSG Heat Recovery Steam Generator International Electrotechnical Commission IEEE Institute of Electrical and Electronics...
  • Page 6 Instruction Guide GEH-6700 or GEH-6703 ToolboxST User Guide for Mark Controls Platform GEH-6721_Vol_II Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications GEH-6855_Vol_I Mark VIeS Functional Safety Systems for General Market Volume I: System Guide...
  • Page 7 Safety Symbol Legend Indicates a procedure or condition that, if not strictly observed, could result in personal injury or death. Warning Indicates a procedure or condition that, if not strictly observed, could result in damage to or destruction of equipment. Caution Indicates a procedure or condition that should be strictly followed to improve these applications.
  • Page 8 Never assume that the Human-machine Interface (HMI) or the operator will close a safety critical control loop. Warning GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 9: Table Of Contents

    Contents 1 Control System Overview......................11 1.1 Introduction............................11 1.2 Controllers ............................15 1.3 IONet Switches ............................. 16 1.4 Distributed I/O Modules.......................... 16 1.5 Power Distribution..........................36 1.6 Redundancy Options ..........................37 1.7 Reliability and Availability ........................49 1.8 Component Part Numbers and Serial Numbers/Barcodes ................57 2 Functional Safety..........................
  • Page 10 8.7 Communication Loss Between Controller and I/O Module................187 8.8 Boot Log Collection ..........................188 8.9 I/O Module Replacement or Upgrade Issues....................189 8.10 LED Indicators.............................194 Glossary of Terms ..........................195 Index...............................199 GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 11: Control System Overview

    Unit Data Highway (UDH) or Plant Data Highway (PDH), regardless of the existing controller at the site. The UIO control system supports specific I/O. For a list of supported I/O, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II).
  • Page 12 Note All instructions in this manual also apply to the UIO control cabinet. Typical Architecture for Large Industrial Control Systems GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 13 The Mark VIe and Mark VIeS control systems are used in a wide range of process control and protection applications, including steam, gas, and wind turbines, power generation balance of plant (BoP), deep sea drilling, desalinization, gas compression, and other facility-wide equipment management systems. The control system primarily consists of three hardware components: controller(s), I/O network (IONet) switches, and I/O modules.
  • Page 14 Component Hardware Editor GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 15: Controllers

    Initialization information from the designated controller Note For more information on the Mark VIe controller, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter Controllers. More more information on the Mark VIeS Safety controller, refer to the Mark VIeS Control Functional Safety Manual (GEH-6723).
  • Page 16: Ionet Switches

    I/O module reception of controller outputs. Note For more information on the IONet switches, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter Unmanaged Ethetnet Swtiches.
  • Page 17 1.4.1 I/O Packs I/O packs have a common processor board and a data acquisition board that is unique to the type of connected device. I/O packs on each terminal board digitize the I/O variables, perform algorithms, and communicate with the controller. The I/O pack provides fault detection through a combination of special circuitry in the data acquisition board and software running in the Central Processing Unit (CPU) board.
  • Page 18 Black in color with white number labels • Terminal rating is 300 V, 10 A • UL recognized • Recommended screw tightening torque is 7 lb-in (0.8 Nm). GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 19 1.4.2.2 S-type S-type boards provide a single set of screws for each I/O point and allow a single I/O pack to condition and digitize the I/O. They are half the size of T-type boards and are standard base mounted but can also be DIN-rail mounted. These boards can be used for simplex, dual, or dedicated triple redundant sensors by using one, two, or three modules.
  • Page 20 16 DI (24, 48, 125, 250 V dc, 115, 230 V ac point isolated, line-break detection) SOE PDIIH1B/1 SDIIH2A Same as H1A but is also enhanced to provide more vibration protection for use in some GE Drilling applications. The purchase price is higher for this version, which includes RTV and stabilizer bar. WDIIH1A...
  • Page 21 Discrete I/O Types (continued) I/O Pack/ Board Discrete I/O Types Type Removable # per Board PDIOH1A/1 TDBSH4A 24 DI and 12 type C mechanical relays (48 V dc group isolated) SOE (Refer to Option Boards Note PDIOH1B/1 1, 2, and 3), SOE for relay outputs PDIOH1A/1 TDBSH6A 24 DI and 12 type C mechanical relays (125 V dc group isolated) SOE (Refer to...
  • Page 22 10 AI (V/I inputs) and 2 AO (0-20 mA outputs) with HART communications Box PHRAH1B/1 PHRAH1A/1 SHRAH2A 10 AI (V/I inputs) and 2 AO (0-20 mA outputs) with HART communications Box PHRAH1B/1 GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 23 Analog I/O Types (continued) I/O Pack/ Board Analog I/O Types Type Removable # per Board PPDAH1A/1 JPDS Power Distribution System Feedback PPDAH1B/1 JPDM JPDG JPDC PTCCH1A/1, 2, 3 TBTCH1B 12 Thermocouples Barrier PTCCH1B/1, 2, 3 PTCCH2A/1, 2, 3 TBTCH1B 12 Thermocouples with extended range for EPRI compliance Barrier PTCCH2B/1, 2, 3 PTCCH1A/1, 2...
  • Page 24 PROFINET RT Version 2.2 I/O gateway module maps I/O from PROFINET slave devices to the Mark VIe controller on the IONet PFFAH1A/1 Fieldbus H1 TO HSE Linking Device OUNDATION GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 25 1.4.3.3 Turbine I/O Types Turbine specific I/O modules provide direct interface to unique turbine field devices, which reduces or eliminates a substantial amount of interposing instrumentation. As a result, many potential single-point failures are eliminated for improved running reliability and reduced long-term maintenance. Direct interface also enables the diagnostics to directly monitor field devices.
  • Page 26 SPROH2A: Removable, Box PPROH1A Aero-derivative Turbine Emergency Trip, 48 H1A, H2A: Removable, Barrier TREAH#A points H3A, H4A: Removable, Box †† These modules have IEC 61508 safety-certified functions GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 27 1.4.3.4 Migration I/O Types The following table provides a list of I/O modules approved for use with Mark V, Mark V LM, and Mark VI migration to the Mark VIe control Mark V, Mark V LM, and Mark VI Migration to Mark VIe Control...
  • Page 28 1 E-Stop TREGS2B SPROS1A Barrier Primary turbine protection TTURS1C 4 speed inputs TRPAS1A 8 flame inputs YTURS1A TRPAS2A 3 monitored trip relay outputs TRPGS1B 1 E-Stop TRPGS2B GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 29 Terminal Board Removable packs one TCSAS1A I/O types are detailed in GEH-6721_Vol_III for GE Industrial Applications (if available) YSILS1B and three SCSAS1A 12 type C mechanical relays with 6 solenoids, coil diagnostics (115/230 V ac, 24/48/125 V dc), SOE for...
  • Page 30 Wind Energy Main converter control for ESS wind turbine: 27 digital inputs, 2 analog thermistor temperature sensor inputs, 9 relay contact BPPB WEMA outputs, 3 solid-state relay outputs WEMAH1B BPPC GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 31 Assembly Renewable I/O Types Individual Boards WEMA WEMAH2A Wind Energy Main converter control for Brilliance Solar PV inverter: 27 digital inputs, 2 analog thermistor temperature sensor inputs, 9 BPPB WEMA relay contact outputs, 3 solid-state relay outputs WEMAH2B BPPC MACC Wind power converter interface for the power converter: 27 digital inputs, 9 relay contact outputs, 3 solid-state relay outputs WECAH1A BPPB...
  • Page 32 FU1, FU2, FU3, FU4, FU5, FU6, FU7, FU8, FU9, FUSE 0.2A 250V TM LITTELFUSE 3720200041, IS200WDIIH2A 342A4908AFP1 FU10, FU11, FU12, FU13, LAG TR5 37202000411 FU14, FU15, FU16 GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 33 Discrete I/O, Terminal Board Fuses (continued) Fuse Designator Fuse Rating Board GE Part # MFR # FU1, FU2, FU3, FU4, FU5, FU6, FU7, FU8, FU9, FU10, FU11, FU12, FU13, FUSE(SLO-B) 3.15A LITTELFUSE 218 3.15 IS200WPDFH1A 259A9266P16 FU14, FU15, FU16, FU17, 250V COOPER BUSSMANN GDC-3.15A...
  • Page 34 FU1N, FU1P, FU2N, FU2P, EMPTY FUSE HOLDERS WITH GREY CAPS ACCEPTING 31.75 X 6.35 mm (1.25 X FU3N, FU3P, FU4N, FU4P, IS200JPDDG3A 0.25 in) FUSES FU5N, FU5P, FU6N, FU6P GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 35 Renewable Energy I/O, Terminal Board Fuses Fuse Designator Fuse Rating Board GE Part # MFR # COOPER BUSSMANN MDL-4A FU1, FU2, FU3 AEPCH1A 323A2396P59 FUSE 4A 250V SLOW BLOW LITTELFUSE 313004P COOPER BUSSMANN MDL-4A FU1, FU2, FU3 AEPCH1B 323A2396P59 FUSE 4A 250V SLOW BLOW LITTELFUSE 313004P FUSE(SLO-B) 3.15A 5X20MM...
  • Page 36: Power Distribution

    1.5 Power Distribution The Mark VIe and Mark VIeS control systems are designed to operate on a flexible, modular selection of power sources. The power distribution modules (PDM) support 115/230 V ac, 24 and 125 V dc power sources in many redundant combinations.
  • Page 37: Redundancy Options

    I/O modules, performs application code, and then delivers an output packet(s) for all I/O modules. The following diagram displays typical simplex controller architecture. Controller IONet Switch I/O Modules Simplex Mark VIe Control System Control System Overview GEH-6721_Vol_I_BP System Guide 37 Public Information...
  • Page 38 The Mark VIe controllers listen for the data on both networks at power on. The channel that delivers the first valid packet becomes the preferred network. As long as the data arrives on that channel the controller uses this data. When the preferred channel does not deliver the data in a frame, the other channel becomes the preferred channel as long as valid data is supplied.
  • Page 39 In the Mark VIe controller, Boolean state variables are updated on every control frame. The analog state variable updates are multiplexed. A subset of analog state variables is updated every control frame. The controller rolls through each subset until all state variables are transmitted.
  • Page 40 All controllers transmit their copy of the state variables after the output packet has been transmitted. Each controller takes the three sets of state variables and votes the data to get the values for the next run cycle. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 41 1.6.2 I/O Redundancy There are various options available for single and multiple packs and single and dual networks for I/O redundancy. The following are options for TMR I/O modules: • Single Pack Dual Network I/O Module (SPDN) • Two Single Pack, Single Network (2SPSN) I/O Modules •...
  • Page 42 Redundant networks, packs, and controllers • Online repair Each of the I/O packs are connected to separate networks delivering input data and receiving output data from separate controllers. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 43 Inputs that appear in all three I/O channels may be voted to create a single input value. The triple inputs may come from three independent sensors. They can also be created from a single sensor by hardware fanning at the terminal board. Mark VIe Controller Redundancy Available IONet Topology One I/O pack with one IONet Simplex The number of IONets in a system equals the number of controllers.
  • Page 44 All applicable subsets of reliability options are available on a per terminal board basis for any given Mark VIe topology. For example, in a TMR controller, all simplex and dual option capabilities are also provided.
  • Page 45 One Sensor with Fanned Input and Software Voting Three independent sensors can be brought into the controllers without voting to provide the individual sensor values to the application. Median values can be selected in the controller if required. This configuration, displayed in the following figure, is used for special applications only.
  • Page 46 RTDs, thermocouples, contact inputs, and 0-20 mA inputs can also be configured this way. Three Sensors with Dedicated Inputs, Software Voted for High Reliability Applications GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 47 1.6.4 Output Processing The system outputs are the portion of the calculated data transferred to the external hardware interfaces and then to the various actuators controlling the process. TMR outputs are voted in the output voting hardware. Any system can output individual data through simplex hardware.
  • Page 48 The following figure displays 0-20 mA outputs combined through a 2/3 current sharing circuit that allows the three outputs to be voted to one. Failure of a 0-20 mA output is sensed and a deactivating relay contact is opened. TMR Circuits for Voted 0-20 mA Outputs GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 49: Reliability And Availability

    1.7 Reliability and Availability 1.7.1 Mean Time Between Failure (MTBF) MTBF is a basic measure of reliability for systems. It is the average failure free operating time, during a particular measurement period under stated conditions. A failure may or may not result in a problem with the overall system depending on any redundancy employed.
  • Page 50 The redundancy in the system can be either active or standby. The Mark VIe control uses active redundancy and has all components operating simultaneously. Standby redundancy activates backup systems after a failure is detected.
  • Page 51 Failure to control the outputs of a system is the most damaging. Fault detection must be determined as close to the output as possible to achieve the highest level of reliability. With the Mark VIe control configured using triple redundant controllers and I/O modules, a high level of detection and fault masking is provided by voting the outputs of all three controllers and monitoring discrepancies.
  • Page 52 Refer to the requisition specific system application documentation/control specification (if available) for redundancy testing procedures. Forced Outage Probability versus Time (Conventional TMR) Forced Outage Probability versus Time (Mark VIe TMR) GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 53 The default action is to go to a power-down state, the same as if the power were removed from the pack. Note Refer to specific I/O pack documentation in Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II).
  • Page 54 1.7.9 UDH Fault Tolerance — Command Action Using IONet connectivity, the controller copies command traffic from the UDH across all controllers. This provides fault tolerance for dual UDH networks. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 55 1.7.10 Forced Variables The controller has a feature called Forced Variables. This allows the maintenance technician using application software to set analog or logical variables to forced values. Variables remain at the forced value until unforced. Both compute and input processing respect forcing.
  • Page 56 1.7.12 Rate of Response Mark VIe and Mark VIeS controllers can run at a variety of frame rates to meet the application needs of the industrial control solution. Control systems are tuned accordingly, based on a variety of factors including: complexity of controller application logic, processor type, and number of I/O and other interfaces used. The following diagram provides an example of typical processes that occur during a single controller frame in sequence.
  • Page 57: Component Part Numbers And Serial Numbers/Barcodes

    1.8 Component Part Numbers and Serial Numbers/Barcodes 1.8.1 Common Terminology The following terms are used to identify Mark controls components: Backward Compatible A part is backward compatible when it can directly replace an earlier version of the part in all specified end-use applications without requiring any changes to the host system.
  • Page 58 Breadboard: Not used Prototype: Not used Optional character PWB version (assembly levels 00, 05 only): 1 alpha character, excluding: I, O, Production Marked for use in hazardous (classified) locations GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 59 Part Number Field Definitions (continued) Field Field Name Code Definition Directive 2011/65/EU Restriction of Hazardous Substances in Electrical and Electronic Equipment There are some legacy part numbers with assembly level code “020”. These identify assemblies of one or more PCBAs, and may not follow the current version rules.
  • Page 60 UCPA part number Example UCPA Controller Label GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 61 Example UCSx Controller Label Control System Overview GEH-6721_Vol_I_BP System Guide 61 Public Information...
  • Page 62 Example I/O Pack Label Internal GE employees and certain third-party parts suppliers can use the ENOVIA PLM tool to search for parts. The following Power Generation PLM web portal is available to assist with account registration and training on how to use the tool to search for parts: http://colab.ge.com/dashboard/canvas/v/518d03b3bf1d408e570001c9/home...
  • Page 63 This code limits the number of unique serial numbers to 313 (29,791) per day. Contact your GE representative or GE Technical Support for more information on this code.
  • Page 64 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 Month Codes Month Code January February March April June July August September October November December GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 65 Day-of-Month Codes Day-of-Month Code Control System Overview GEH-6721_Vol_I_BP System Guide 65 Public Information...
  • Page 66 Notes GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 67: Functional Safety

    GE has engineered specific solutions for their internal turbine power plant applications, meeting high standards for reliability of function, and continues to invest in new SIL capabilities, for example GE Oil & Gas YSIL applications. The Mark VIeS control has just recently been made available for integration into other safety-critical applications outside of GE, for example emergency shutdown, burner management, and fire and gas-critical control applications.
  • Page 68: Safety Instrumented System (Sif)

    (EUC) and the EUC control system that depends on the correct functioning of the Electrical/electronic/programmable electronic (E/E/PE) safety-related systems, other technology safety-related systems, and external risk reduction facilities. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 69: Risk Reduction

    2.2 Risk Reduction Functional safety relates to proper equipment operation, as well as other risk reduction facilities. Layers of protection (LOP) concepts are as follows: Plant Evacuation Procedures Barrier Relief Valve Mechanical Protection Alarms with Operator Action Safety Instrumented Systems BPCS Process Alarms Operator Supervision...
  • Page 70: Safety System Redundancy Options

    The unique Ethernet back-bone of the Mark VIeS Safety system enables several options for redundancy to achieve required SIL. This provides the safety control engineer unparalleled flexibility to meet the safety SIL requirements for each application in the most cost effective manner. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 71 2.3.1 Triple Modular Redundant (TMR) The Mark VIeS Triple Modular Redundant (TMR) Control Modes can provide: • Two out of three (2oo3) voting − SIL 3 high/low demand for de-energize-to-trip − SIL 2 low demand for energize-to-trip • Hardware fault tolerance (HFT): 1 •...
  • Page 72 2oo 3 creates 1 oo2 de - voting and controls energize to trip the actuator. function across the two modules. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 73 2.3.3 Simplex The Mark VIeS Simplex Control Mode is used for one out of one (1oo1), SIL 2 low demand for de-energize to trip applications. PC Based Gateway PC based communication interface, options: - OPC-DA server - OPC-UA server - Modbus master Simplex Controller Simplex Mark VIeS controller receives inputs and sends...
  • Page 74 Notes GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 75: Ethernet Networks

    Ethernet Networks 3.1 Introduction The integrated control system is based on a hierarchy of Ethernet networks, used to interconnect individual nodes or zones. These networks separate the different communication traffic into layers according to their individual functions. This hierarchy extends from the I/O modules and controllers (providing real-time control of the process) to the HMIs, and out to facility-wide monitoring and external networks (industrial internet).
  • Page 76 SIL 3 LS2100e Static Wind Power Excitation Functional Starter Control Converter Safety Control IONet Layer Simplex I/O Modules TMR I /O Modules Simplified Network Hierarchy (switches not shown) GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 77 This industrial plant network architecture provides flexibility to cost for sites with various security compliance requirements. A qualified GE networking engineer can determine best fit options for particular customer facilities.
  • Page 78 Note 1. Considerations for network upgrades are discussed the section, Network Retrofit Guidelines. GE Wind Farms use a different network architecture. 3. GE M&C supplies the SecurityST appliance. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 79 These cables are connected through special ports or plug sockets in the rear of the switches. Note Refer to NetworkST for Mark VIe Controls Application Guide (GEH-6840). Redundant switch cabling offers the following advantages: •...
  • Page 80: Ionet Layer

    The sharing of input data between two control sets (Shared IONet) on a single IONet is available for the following controllers: • One Mark VIeS Safety controller set and one Mark VIe controller set • One Mark Stat controller set and one Mark VIe controller set •...
  • Page 81 Use the GE ESWA or ESWB switch with additional IR single-mode transceiver for SFP1 and SFP2. − GE part # 65G2100-009 for single-mode fiber distances up to 2 km − GE part # 65G2100-008 for single-mode fiber distances up to 15 km Use of any other switch in this application may cause miss operation and/or damage to the associated equipment.
  • Page 82 Only industrial grade switches that meet the codes, standards, performance, and environmental criteria for industrial applications are used for the IONet. GE industrial Ethernet 10/100 IONet switches (ESWA and ESWB) have an operating temperature of -40 to 70 °C (-40 to 158 °F), have provisions for redundant 18 to 36 V dc power sources (200/400 mA), and can be DIN-rail mounted.
  • Page 83 IONet switches are not managed switches. • Every Ethernet switch introduces latency into the transmission of Ethernet packets. • Each controller frame allocates a period of time to service I/O data. Mark VIe Controller Communication path Communication path Communication path between I /O packs...
  • Page 84 The IP addresses of the I/O packs are assigned by the ToolboxST application, and the controller automatically distributes the addresses to the I/O packs through a standard Dynamic Host Configuration Protocol (DHCP) server in the controllers. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 85 The Shared IONet function (with ControlST* V04.06 or higher) enables the sharing of Mark VIeS Safety inputs or Mark Stat Wind Converter inputs with another basic process Mark VIe controller set, saving the cost of redundant sensors and I/O. Specific configurations supported include: •...
  • Page 86: Unit Control Layer

    Controller Controller Mark VIe Controller Mark Stat SIL 3 LS2100 e EX2100 e Wind Power Functional Static Starter Excitation Converter Safety Control Control Unit Data Highway Example GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 87 3.3.1 UDH Communicator in a Redundant Controller Set In dual or TMR Mark VIe controller sets, a single controller is designated to transmit real-time and alarm data for the set; this is the UDH Communicator. This data includes both control signals (EGD) and alarms (SDI). Since each controller has an independent, physical connection to the UDH, if a UDH network fault occurs where one controller becomes isolated from its companion controllers, the isolated controllers assumes the role of UDH communicator for that network fragment.
  • Page 88 The LS2100e Static Starter controller is used to start a gas turbine by running the generator as a starting motor. The Static Starter control, the Mark VIe control, and the excitation control system form an integrated static start system. The Mark VIe control supplies the run, torque, and speed setpoint signals to the Static Starter control, which operates in a closed loop control mode to supply variable frequency power to the generator stator.
  • Page 89 Flexible tools enable the operator to quickly generate custom trends and reports from the archived process data. The Historian combines high-resolution digital event data from the Mark VIe controllers with process analog data, creating a sophisticated tool for investigating cause-effect relationships.
  • Page 90 Cable: Cat 5e UTP ENET2 Cable: SMF or MMF ENET2 Unit Data Highway (UDH) IONet Cable: Cat 5e UTP Cables : Cat 5e UTP CDH Application Example GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 91: Supervisory Layer

    Mark VIe controllers, which communicate over the UDH. The PDH network is used to further partition equipment and to restrict access or prevent disruptions to the Mark VIe controllers (which are busy broadcasting data across the UDH). The PDH should be used to copy or transfer large files from HMI to HMI (for example, CIMPLICITY projects).
  • Page 92: Monitoring Layer

    The monitoring data highway (MDH) is used to further partition the flow of data to individual assets, and can include connection to GE Monitoring and Diagnostic (M&D) equipment: the On-Site Monitor (OSM) or Remote Services Gateway (RSG). The data that is allowed to travel over the MDH is managed by two specially configured Cisco 2901 routers. The same mesh architecture and trunks provide the MDH from the root to edge switches, then from special configured ports on the edge switches to the OSM or RSG.
  • Page 93: Enterprise Layer

    VLAN and any other external devices. The firewall establishes security regions, or zones, as defined in the IEC standard 62443 or ISA 99. Equipment is allocated to each zone based on their function and relative security risk to the Mark VIe control system.
  • Page 94: Ethernet Cabling For Monitoring, Supervisory, And Unit Control Layers

    SMF cables must be terminated and/or spliced by a certified fiber-optic cable installer. SMF cables cannot be terminated and/or spliced by requisition or field engineers. • SMF cables are 8.3/125 µm Core/Cladding diameter with a numeric aperture of 0.13. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 95 It interfaces the network switch to a fiber optic or copper networking cable. It is a popular industry format supported by many network component vendors. The switches used in the current Mark VIe LC Connectors control system networking design use SFPs with LC Connectors to connect to single mode fiber-optic cable for new installations.
  • Page 96 More stringent specifications for crosstalk and system noise • Protective plastic jacket • Connector: RJ-45 UTP connector for solid wire • Backward compatible with the Category 5/5e cable standards GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 97 Note GE recommends replacing MMF with SMF. If not, the network is downgraded to only run at 100 MB speed. The GE requisition engineer needs to understand the ramifications if existing sites have MMF runs and the options for retermination of Ethernet cables, changes to junction boxes, and so forth.
  • Page 98: Third-Party Communication Links

    External communication links are available to interface with third-party plant controls or devices. This allows operators to have access to real-time data, and provides for discrete and analog commands to be passed to the Mark VIe controller. The Mark VIe control system can be linked to third-parties in several different ways: •...
  • Page 99: Communication Protocols

    This allows some protocols to be sent directly to the Mark VIe controllers, while others must first communicate with the I/O module that then interfaces with the controller. Other protocols use an HMI with WorkstationST application as a gateway.
  • Page 100 (gateway between IONet and H1). Fieldbus Network Protocols Fieldbus protocols network field devices (sensor and actuators) with the control system, enabling diagnostic and configuration functions along with traditional real time control. The Mark VIe system supports the following protocols: • Fieldbus OUNDATION •...
  • Page 101: Opc Protocols

    WorkstationST OPC UA Server Instruction Guide (GEI-100828) • ToolboxST User Guide for Mark Controls Platform (GEH-6703) for OPC UA configuration from the Mark VIe controller and Mark VIe for OPC DA, AE, HDA, and UA configuration from the WorkstationST server •...
  • Page 102 An OPC UA server enables the real-time exchange of variables with an OPC UA client. Beginning with ControlST V05.01, it is available in the Mark VIe UCSB/UCSC controller (not available with the UCPA or for the Mark VIeS UCSBS1A). Mark VIe Control OPC UA Server Example 4.1.3 WorkstationST OPC AE...
  • Page 103 4.1.4 WorkstationST OPC UA Server The OPC UA specification combines OPC Data Access (DA), OPC Alarms and Events (AE), and OPC Historical Data Access (HDA), into one interface. The WorkstationST OPC UA server supports: • OPC Data Access (DA) • Historical Alarm and Event access (HDA) In large systems, there are multiple historians that are logging the same variable at different frequencies.
  • Page 104: Workstationst Gsm Protocol

    4.2 WorkstationST GSM Protocol The WorkstationST-based GSM Server (GE Standard Messaging) is typically used for the exchange of unit-level control and alarm data between Mark Controls equipment and a plant-level Distributed Control System (DCS). The WorkstationST OPC DA server provides the GSM server with the following: •...
  • Page 105 There are four types of GSM messages: • Administrative • Event-driven data • Periodic data • Command Administration Messages are not associated with given Mark controller. These requests are messages from the DCS to the GSM server to interrogate its capabilities. Event Driven Messages are sent from the GSM server to the DCS in reaction to a system alarm or event occurring or clearing.
  • Page 106: Modbus Protocol

    Ethernet or serial communication running simultaneously • Each Modbus page is configured with ToolboxST, enabling virtually any variable in the system to be mapped to a page GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 107 4.3.2 Controller Modbus The Mark VIe and Mark VIeS controllers directly support the Ethernet Modbus Slave interface. The Ethernet Modbus protocol is layered on top of the TCP/IP stream sockets. Note A subset of the Modbus function codes are supported.
  • Page 108 Mark VIeS Safety Controller Modbus Communication Protocols GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 109: Ethernet Global Data (Egd)

    4.4 Ethernet Global Data (EGD) The EGD protocol on the UDH is used for Mark VIe controller to Mark VIe HMI (running WorkstationST application), or for Controller to Controller communications, and is configured using the ToolboxST application for the Mark VIe controller and the WorkstationST application.
  • Page 110 These controllers provide data to each of the segments. These features adds a level of Ethernet fault tolerance to the control system. Note There are many features that make the Mark VIe control system fault tolerant, including the network configuration. Unit Data Highway EGD TMR Configuration Similarly, with dual redundant controllers, each controller receives UDH EGD data independently from a direct Ethernet connection.
  • Page 111: System Data Interface (Sdi) Protocol

    WorkstationST Alarm Server, and to transmit alarm commands to the controllers. Note The Mark VIe control systems can support up to a maximum of 10 supervisory PCs with individual alarm server connections to a unit controller (not including OSM and Historian).
  • Page 112: Network Time Protocol (Ntp)

    Note Refer to GEH-6808, the section How to Configure Time Synchronization in the ToolboxST Application. GE recommends using a dedicated NTP box that is not part of the HMI, but a time/frequency processor board can be placed in the HMI as an alternative. This NTP box or board acquires time from the master time source with a high degree of accuracy.
  • Page 113 However, systems that are starting up need to know the date within no more than 68 years. The Mark VIe control uses a battery powered hardware clock to avoid this problem.
  • Page 114 If the time is within a fraction of a second, the PPS pulses can be used to precisely synchronize to the tick of the second. The method achieves accuracies in the tens of microsecond range. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 115: Fieldbus Communications

    GEH-6721 Vol II, Mark VIe Control PROFIBUS Master Gateway PROFIBUS DP-V0 and V1 (PPRF) Master Gateway GEH-6823, Mark VIe PROFIBUS Interface Application Guide GEH-6721 Vol II, Mark VIe Control FF Linking Device (PFFA) Fieldbus H1 to GEH-6761, Mark VIe Control FF Interface Application Guide OUNDATION HSE Linking Device...
  • Page 116 Notes GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 117: Technical Regulations, Standards, And Environment

    Technical Regulations, Standards, and Environment This chapter describes the technical regulations, standards, and environmental guidelines used for the design of all printed circuit boards, modules, core components, panels, and cabinet line-ups in the control system. 5.1 Safety Standards EN61010-1:2010 (3rd Edition) Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements CAN/CSA...
  • Page 118: Conditions For Compliance

    These OV and EMI filter circuits are built-in to the JPDB and JPDF Power Distribution Modules. If JPDB/JPDF are not used to distribute AC and DC power supply mains to the Mark VIe control, then a separate GE Filter Module 246B8279Gx should be used to filter the mains.
  • Page 119: Electrical

    IEC 61000-4-11 5.3.2 Low Voltage Directive 2014/35/EU Under the conditions specified in this document, the Mark VIe control fulfils the requirements of CAN/CSA-C22.2 No. 61010-1-12, UL Std. No. 61010-1 (3rd Edition), and EN 61010-1 (3rd edition) Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements.
  • Page 120 5.3.3 Supply Voltage 5.3.3.1 Line Variations Mark VIe control equipment meets the requirements for Overvoltage Category II equipment (IEC 60664-1:2007) under the Conditions for Compliance specified in this document. Ac Supplies – Operating line variations of ±10% IEEE STD 141-1993 defines the Equipment Terminal Voltage – Utilization voltage.
  • Page 121: Environment

    Temperature Considerations in Packaging Electronics When selecting an enclosure system for Mark VIe hardware, it is the responsibility of the system designer to select an enclosure which will ensure reliable operation of the enclosed equipment. The designer must ensure that the local temperatures inside the enclosure do not exceed the rating of the equipment.
  • Page 122 For all types of enclosure systems, it is important to highlight the potential effect of changes from the original design. GE designed enclosure systems are engineered to maintain the Mark VIe system components within their specified temperature ratings. Modifying the enclosure or adding additional equipment to the enclosure could potentially compromise the thermal design.
  • Page 123 Enclosure Example For internal enclosure design considerations, many Mark VIe components have an ambient temperature rating of -40 to 70°C (-40 to 158 °F). The following table lists only the components with more restrictive ambient ratings.
  • Page 124 In addition, air passing through the conduit must be within the acceptable temperature range as listed previously. 5.4.6 Humidity The ambient humidity range is 5 to 95% non-condensing. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 125 5.4.7 Elevation Note † Elevation shall not exceed 2000 m for compliance to 61010-1. Equipment elevation is related to the equivalent ambient air pressure: • Normal operation: 0 to 1000 m (0 to 3280.8 ft) at 101.3 to 89.8 kPa •...
  • Page 126 (194 °F). 5.4.11 Applications in Harsh Environments The Mark VIe control product line is suitable for use in G3 harsh environments, as defined in ANSI/ISA-71.04-2013 Environmental Conditions for Process Measurement and Control Systems: Airborne Contaminants. Note For Mark VIe control products, G3 compatibility does not depend on conformal coating, however conformal coating is available for certain Mark VIe products.
  • Page 127: Installation Guidelines

    Warning 6.1 Installation Support GE’s system warranty provisions require both quality installation and that a qualified service engineer be present at the initial equipment startup. To assist the customer, GE offers both standard and optional installation support. Standard support consists of documents that define and detail installation requirements.
  • Page 128 Field Changes, with the changes circled and dated. 6.1.3 Technical Advisory Options To assist the customer, GE offers the optional technical advisory services of field engineers for: • Review of customer’s installation plan •...
  • Page 129 6.1.4 Installation Plan and Support It is recommended that a GE field representative review all installation/construction drawings and the cable and conduit schedule when completed. This optional review service ensures that the drawings meet installation requirements and are complete. Optional installation support is offered: planning, practices, equipment placement, and onsite interpretation of construction and equipment drawings.
  • Page 130: Equipment Receiving And Handling

    6.2 Equipment Receiving and Handling GE inspects and packs all equipment before shipping it from the factory. A packing list, itemizing the contents of each package, is attached to the side of each case. Only personnel who are adequately trained and thoroughly familiar with the equipment and instructions should install, operate, or maintain the equipment.
  • Page 131 Maintain the following environment in the storage enclosure: − Recommended ambient storage temperature limits for the Mark VIe controller are from -40 to 85°C (-40 to 185 °F). − Surrounding air free of dust and corrosive elements, such as salt spray or chemical and electrically conductive contaminants −...
  • Page 132: Power Requirements

    Mark VIe control systems may use up to three mains supplies; two for redundant control power (ac and / or dc) and one auxiliary ac supply for accessories such as cabinet lights and fans. The following are example mains power supply rating (100 [3.94])
  • Page 133 Heat dissipation in a typical TMR turbine control is about 1600 watts. However, power supply mains and heat dissipation requirements must be calculated for each Mark VIe cabinet application based on the number and mix of controllers, I/O modules, IONet switches, power supplies, and external loading.
  • Page 134: Installation Support Drawings

    6.4 Installation Support Drawings GE supplies the customer with site-specific documentation that can include a variety of drawings to display the equipment ® installed at site. Drawings are typically B-size AutoCAD , and can include the following: • System Topology (4108) •...
  • Page 135 250 under the heading Grounding Electrode System. The guidelines below are for metal-framed buildings. For non-metal framed buildings, consult the GE factory. The ground electrode system should be composed of steel reinforcing bars in building column piers bonded to the major building columns.
  • Page 136 Functional Earth (FE) is bonded at one point to the PE ground using two 25 mm (6 AWG or larger) green/yellow bonding jumpers. These grounding recommendations are illustrated in the following figure. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 137 Grounding Recommendations for Single Control Cabinet Note If acceptable by local codes, the bonding jumpers may be removed and a 4/0 AWG identified insulated wire run from FE to the nearest accessible point on the building ground system, or to another ground point as required by the local code. The grounding method for a larger system is displayed in the following figure.
  • Page 138 Grounding Recommendations for Control Cabinet Lineup GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 139 6.5.3.1 Grounding Notes Bonding to building structure - The cable tray support system typically provides many bonding connections to building structural steel. If this is not the case, supplemental bonding connections must be made at frequent intervals from the cable tray system to building steel.
  • Page 140 Routing, for guidelines. Solid-bottom tray - Use steel solid bottom cable trays with steel covers for low-level signals most susceptible to noise. Enclosure and Cable Tray Installation Guidelines GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 141 6.5.3.2 Unit-specific Grounding Examples The Mark VIe control system is applied in a variety of situations, using enclosures that are tailored for the end customer. Field installers need to be well versed in best practices for grounding their equipment for the end customer. Various local guidelines should be followed, as well as the site-specific installation drawings to determine the exact procedures for grounding the unit controls.
  • Page 142 In the first cabinet, this jumper was removed from both of the JPDF power distribution boards . Unit-specific Grounding Example (2 of 2) GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 143: Cable Separation And Routing

    If a situation at the installation site is not covered in this document, or if these guidelines cannot be met, please contact GE before installing the cable. Early planning enables the customer’s representatives to design adequate separation of embedded conduit. On new installations, sufficient space should be allowed to efficiently arrange mechanical and electrical equipment.
  • Page 144 SCR field exciter ac power input and dc output • Static exciters (regulated and unregulated) ac power and dc output • 250 V shop bus • Machine fields GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 145 6.6.1.5 Class Codes Certain conditions can require that specific wires within a level be grouped in the same cable. This is indicated by class codes, defined as follows: S Special handling of specified levels can require special spacing of conduit and trays. Check dimension chart for levels. These wires include: •...
  • Page 146 Where practical for level P and/or P(S) wiring, route the complete power circuit between equipment in the same tray or conduit. This minimizes the possibility of power and control circuits encircling each other. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 147 6.6.2.2 Tray and Conduit Spacing The following tables display the recommended distances between metal trays and metal conduit carrying cables with various signal levels, and the cable-to cable distance of conduit and trays. Cable, Tray, and Conduit Spacing Installation Guidelines GEH-6721_Vol_I_BP System Guide 147 Public Information...
  • Page 148 Unless specifically noted otherwise, suppression (for example, a snubber) is required on all inductive devices controlled by an output. This suppression minimizes noise and prevents damage caused by electrical surges. Standard relay and solenoid output boards have adequate suppression. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 149: Power And I/O Field Wiring

    6.7 Power and I/O Field Wiring 6.7.1 General Requirements • Maximum length (unless specified) 300 m (984.25 ft) • Individual minimum stated wire size is for electrical needs • Clamp-type terminals accept two 14 AWG wires or one 12 AWG wire •...
  • Page 150 49,338 33.6 66,310 69,073 42.4 83,677 98,676 53.5 105,584 67.4 133,016 138,147 167,750 187,485 211,167 236,823 250,000 250 MCM 296,029 365,102 473,646 500,000 500 MCM 592,058 789,410 GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 151 6.7.4 Low-voltage Shielded Power Cables This section defines the minimum requirements for low-voltage shielded cable. These guidelines should be used along with the level practices and routing guidelines provided previously. Note The specifications listed are for sensitive computer-based controls. Cabling for less sensitive controls should be considered on an individual basis.
  • Page 152: System Power Connection

    Shields must continue across junction boxes between the control and the turbine, and should match up with the signal they are shielding. Avoid hard grounding the shield at the junction boxes, but small capacitors to ground at junction boxes may improve immunity. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 153: Startup Checks

    Inspect the cabinet components for any damage possibly occurring during shipping. Check for loose cables, wires, connections, or loose components, such as relays or retainer clips. Report all damage that occurred during shipping to GE Product Service.
  • Page 154 Measure the current from first the P125 V dc, and then the N125 V dc, using a 2000 Ω, 10 W resistor to the protective conductor terminal of the Mark VIe control in series with a dc ammeter. The measured current should be 1.7 to 2.0 mA, (the tolerance will depend on the test resistor and the JPDF tolerances).
  • Page 155 6.9.2 Mark VIe Control Cabinet Hardware Checks Before and after applying power to a Mark VIe control cabinet as supplied by GE Intelligent Platforms, the user is advised to perform the following hardware components checks. Refer to Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II), the chapter PDM Power Distribution Modules for more information on architecture and components.
  • Page 156 IONet switches display network activity only if the incoming network cable has network traffic. • I/O pack’s ATTN LED is on when beginning to boot. Once booted, the pack will begin to show other indicators. I/O Packs GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 157 • Controller’s Boot LED indicates if the Network IP address has been properly configured. Boot LED Installation Guidelines GEH-6721_Vol_I_BP System Guide 157 Public Information...
  • Page 158: Bppc-Based I/O Pack Migration

    6.10 BPPC-based I/O Pack Migration As part of the ongoing support for the Mark VIe and Mark VIeS control platforms, many I/O packs have migrated from a BPPB to a BPPC processor board. This is because the components for BPPB-based processors are end of life, and BPPC processors can offer enhanced capabilities.
  • Page 159 6.10.2 BPPC-based Mark VIe I/O Packs Mark VIe I/O packs typically have a part number that ends with 'H1B'. Refer to the section, I/O Types for a complete listing of available components. There are several guidelines to keep in mind when BPPB-based I/O packs are migrated to BPPC-based I/O packs.
  • Page 160: Available Mark Vie Bppc-Based I/O Packs

    † V04.09.02C † The automated form of migration from BPPB to BPPC using the Mark VIe Auto-Reconfiguration function is not supported. You must manually perform a Download of the new firmware and configuration using the ToolboxST application. †† IS230PCAAH1A, IS230PCAAH1B...
  • Page 161: Mark Vie Bppc I/O Migration Guidelines

    Mark VIe System at ControlST V04.04 or Later ® The ControlST software suite includes Windows -based configuration and monitoring tools coupled with firmware for all Mark VIe controllers and I/O packs. A sample of tools and components follows. • ToolboxST application •...
  • Page 162 Note There are three Mark VIe BPPB-BPPC migrations not supported by Auto-Reconfiguration. The following modules must be manually configured: • PPROH1A to PPROS1B BPPC-based I/O pack • PPRAH1A to PPRAS1B • PCAAH1A to PCAAH1B GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 163: Equip Mark Vie System For Migration

    Refer to ControlST UpgradeInstruction Guide (GEI-100694) Has BPPC I/O Install BPPC I/O upgrade upgrade – V05.01.xx Brings Mark VIe I/O pack firmware to a level V05.01.x across system been installed ? across system to support BPPC I/O packs Refer to the section Installing BPPC I/O Upgrade V05.01.xx...
  • Page 164 Notes GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 165: Alarm Overview

    7.1 Alarm System Architecture Each Mark VIe unit control (such as a turbine control) has its own embedded alarm detection and management system to ensure the integrity of its data. Alarm logic is embedded in the overall unit control logic, and runs at the same frame rate, synchronous with the control logic.
  • Page 166 I/O Pack I/O Pack (Ethernet ) Fieldbus I/O FF Linking FF Device Device Alarm Horn FF Device Example of the Alarm System Showing Multiple Alarm Display Mechanisms GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 167 GE controls and third-party components, using OPC to integrate alarm messages and time stamps from third-party servers with native Mark VIe alarm data. The OPC Alarm and Events (AE) has typically been used for this purpose, but now with ControlST V05.03 or later, the newer OPC Unified Architecture (UA) protocol can be used. OPC UA combines the features of OPC DA, AE, and HDA with the flexibility to include some or all of these features.
  • Page 168: Alarm Types

    To be effective, time synchronized sequence-of-events reporting is needed throughout the plant. In general, ±1 ms resolution is available on native Mark VIe and Mark VIeS discrete input modules for dc contacts and available with less resolution for ac contacts. Time resolution for third-party I/O on fieldbus networks is application-specific.
  • Page 169: Diagnostic Alarms

    7.4 Diagnostic Alarms Controllers and I/O packs generate diagnostic alarms to indicate potential issues with control system equipment or the connections to it (power, networks, and so forth). I/O pack firmware checks raw inputs from hardware and creates alarm bits at frame rate, queueing any resulting alarms.
  • Page 170 I/O pack's known time stamp, which is the time of the first occurrence of the diagnostic. Each time the user refreshes the viewer, the pack's time stamp is obtained. Refer to GEH-6700, ToolboxST User Guide for Mark VIe Control, the section, I/O Diagnostic Viewer.
  • Page 171 TMR Limit Checking Types Type of I/O I/O Processor Board Delta Method Analogs % of Configured Span PAIC Pulse rates % of Configured Span PCAA Analogs Engineering Units % of Configured Span Analogs Engineering Units PCLA Thermocouples Engineering Units Voting Disagreement Contact Input PDIA Diagnostic Enable/Disable...
  • Page 172: Process Alarms

    LO threshold or above the HI threshold. 7.5.2 Process Alarm Development Process Alarms are typically developed in the Mark VIe controller by using the ToolboxST application. An application engineer creates Mark VIe application code in Relay Ladder Diagram (RLD) or Function Block language. Alarms are configured using individual variables in the controller.
  • Page 173 The alarm system collects exactly what the controller logic detects so there are no losses in resolution and there is no resampling. The Mark VIe controller can run frames as fast as once every 10 milliseconds, and uses POSIX timestamps with nanosecond resolution and sub millisecond accuracy.
  • Page 174: Alarm Communication Flow

    One goal of the alarm system communications infrastructure is to replicate each alarm queue at the point of visualization. Each Mark VIe controller has an alarm queue and each Alarm Viewer must have a copy of those alarm queue entries in order to display them.
  • Page 175: Troubleshooting

    Troubleshooting The following sections are provided to aid in common troubleshooting of control system equipment. 8.1 Controller, I/O Pack, IONet Switch Not Powering On The following figure provides a decision making flow to aid in troubleshooting power loss to controllers, I/O packs, or IONet switches.
  • Page 176 (check at the input to circuit breakers, disconnects, the power contactors, and so forth). supply? Troubleshooting Power Loss to Controllers, I/O Packs, or IONet Switches GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 177 8.1.1 I/O Pack Power LED Not Lit I/O Pack Power Troubleshooting Potential Problem Condition All other I/O packs on same terminal board have power I/O pack power connector lights lit I/O pack failure Some other I/O packs on same terminal board have power I/O pack power connector LED lit (or simplex board) I/O pack failure...
  • Page 178: Unable To Download To Controller

    8.2 Unable to Download to Controller Note Before downloading, the controller IP address must be setup. Refer to GEH-6808 for more information. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 179: Controller Not In Controlling State

    All I/O modules (if configured as required) should be able to communicate with the controllers. Note The Mark VIe control system may not reach a controlling state due to faults in either the I/O module, the IONet switch or the controller itself. A single faulty controller can prevent the other two controllers from reaching a controlling state.
  • Page 180 • d2-DATA_INITIALIZATION • d3-INPUTS_ENABLED • d5-EXCH_INITIALIZATION • d6-EXCHANGING • d7-SEQUENCING • d8-STANDBY • dA-CONTROLLING Perform the following procedures if the controller is stalled at Master Installation state. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 181 Perform the following procedures if the controller is stalled at DC determination state. Troubleshooting GEH-6721_Vol_I_BP System Guide 181 Public Information...
  • Page 182 Perform the following procedures if the controller is stalled at Input Enabled state. The following diagram displays the possible causes if the controller is not reaching the controlling state. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 183 • The ToolboxST application may not display any information in the Status tab for the faulty Mark VIe control if it is set in the Power on/d0-MASTER_INITIALIZATION state. The other two controllers are suspended at d1-State Designated Controller Determination state.
  • Page 184: Unable To Download To I/O Modules

    8.4 Unable to Download to I/O Modules Perform the following procedures if you are unable to download to I/O packs. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 185: Unable To Communicate With I/O Module

    ➢ ➢ To view I/O communication failures between an I/O pack and the controller diagnostic From the ToolboxST application, open the Mark VIe control .tcw file. From the Component Editor, select the Hardware tab and right-click on the I/O pack with a red X.
  • Page 186: Unable To Download To Controller Or I/O Module

    The Model Predictive Control (MPC) block libraries are not supported by the UCSA/UCSB/UCSC controller. Therefore, if the application is configured for the UCSA/UCSB/UCSC controller and the MPCBlockLib is used as a reference library, the firmware download is interrupted. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 187: Communication Loss Between Controller And I/O Module

    If there are diagnostic alarms on an I/O module related to .xml files, download the base load, firmware, and parameters to the module. If an I/O module is unable to go online with the controller when powering on a Mark VIe control, cycle power to the module.
  • Page 188: Boot Log Collection

    From the Windows ® Note HyperTerminal is not included in Windows 7. Note The serial cable between the computer COM port and the controller COM port must be connected. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 189: I/O Module Replacement Or Upgrade Issues

    Reboot the controller and save the boot log collected in the HyperTerminal session. 8.9 I/O Module Replacement or Upgrade Issues After upgrading or replacing an I/O module, the following conditions require additional troubleshooting to resolve: • Communication Errors • Download Errors •...
  • Page 190 When firmware and application is downloaded to an I/O module, it can take several minutes to install, restart, and re-establish communication to the Mark VIe controller. If the ATTN LED is red and flashing at 2 Hz 50%, the IP address has not been received from the controller.
  • Page 191 I/O module. ➢ ➢ To correct a hardware form mismatch between the I/O module and the ToolboxST configuration From the Mark VIe Component Editor Hardware tab, right-click the affected I/O module and select Modify. Troubleshooting...
  • Page 192 Select the diagnostic alarm with the red icon and press F1 to display the Help file. Use the possible causes and solutions provided for the specific alarm number to correct the problem. GEH-6721_Vol_I_BP GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 193 8.9.4 Mismatched Revision A revision mismatch is indicated by a ≠ icon on the I/O module Status tab. ➢ ➢ To resolve a revision mismatch From the Component Editor Device menu, select Download and Download Wizard. From the wizard page, select Next and scan the I/O module to verify that all unequal items are selected for download. Perform a Download to the I/O module.
  • Page 194: Led Indicators

    ToolboxST application settings. For further details on BPPx Processor LEDs, refer to the Mark VIe and Mark VIeS Control Systems Volume II: System Guide for General-purpose Applications (GEH-6721_Vol_II), the Common I/O Module Functionality section BPPx Processor LEDs.
  • Page 195: Glossary Of Terms

    Ethernet Global Data (EGD) Control network and protocol for the controller. Devices share data through EGD exchanges (pages). EX2100e Excitation Control Latest version of GE generator exciter control; regulates the generator field current to control the generator output voltage. Fanned input An input to the terminal board that is connected to all three TMR I/O boards.
  • Page 196 IP Address The address assigned to a device on an Ethernet communication network. Logical A statement of a true sense, such as a Boolean. LS2100e Static Starter control GE’s current state-of-the-art control for static starter control systems, used to bring a gas turbine up to starting speed.
  • Page 197 Server A computer that gathers data over the Ethernet from plant devices, and makes the data available to computer-based operator interfaces known as viewers. Simplex Operation that requires only one set of control and I/O, and generally uses only one channel. The entire Mark VIe control system can operate in simplex mode.
  • Page 198 Notes GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 199: Index

    Index Grounding 134 Notes 139 System 135 Guidelines Cableway Spacing 145 Acronyms and Abbreviations 5 alarms process 172 Applications 13 Harmonic Distortion 120 Historian 89 Human-machine Interface (HMI) 88 cable fiber-optic 94 Instrument 151 Routing Guidelines 148 Peer 55 Wiring 152 Separation and Routing 143 Installation 127 shielded 149, 151...
  • Page 200 Supply Voltage 120 Terminal Board 17 Two Out of Three Logic 54 Vibration 125 Voltage Unbalance 120 Voting 53 Wire Sizes 150 GEH-6721_Vol_I Mark VIe and Mark VIeS Control Systems Volume I Public Information...
  • Page 202 Public Information...

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Mark vies