MARK V

Mark V TMR Control Panel

Mark V SIMPLEX Control Panel



- Communicator Core



- (Redundant) Control Processor Core



- Redundant Control Processor Core



- Redundant Control Processor Core

- Protective Core

- Power Distribution Core

- Digital I/O Core f or Control Processor(s)

- Communicator Digital I/O Core

Figure 1-2. Typical Control Panel Layouts for TMR and Simplex Control Panel Components (Cores) The TMR control panel employs three identical control processors, , , and (collective ly referred to as ), 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, . 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, ; a protective core,

; a power distribution core, ; a communicator processor digital I/O core, ; and a control processor digital I/O core, . Optional cores that are available are a backup communicator processor, , and additional digital I/O core(s), .

1-2.4.

Location of Turbine Control

The can be remotely located from the turbine (up to a maximum of 6000 meters in some cases). Additionally, through an , a unit(s) can be controlled from a separate control system . For example, a distributed control system (DCS) using MODBUS protocol over a serial communication link or a TCP/IP protocol over an Ethernet communication link. The Mark V control panel may be located near the unit or in a control room close to the unit (the distance limitation is defined by the amount of wire and cable needed to interconnect the control panel and unit).

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CHAPTER 2 CONTROL SYSTEM HARDWARE 2-1. MARK V DATA COMMUNICATION NETWORKS Information is communicated, shared, and acted upon in the Mark V Control System via three separate networks. The one external network, the Stage Link, is the primary means of communication between the Operator Interface () and the common data processor () of the control panel. This link is of the ARCNET configuration. The data exchange network (DENET) is an ARCNET type communication network internal to the Mark V control panel. The function of the DENET is to provide a communication link between the internal processors of the control panel. In a TMR panel, it is the foundation for the voting process which takes place on control signals.

Stage Link

R

DENET IONET

Stage Link

R = termination resistor



* = optional components DENET









IONET Digital I/O

Protection (TCEA)

Protection (TCEA)

Protection (TCEA)

Digital I/O

Digital I/O

Digital I/O

Digital I/O *

Digital I/O *

Digital I/O *

Power Load Unbalance *

Power Load Unbalance *

Power Load Unbalance *

Figure 2-1. Mark V Network Communications 

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The third internal network is known as the I/O network (IONET). The IONET is a serial communications network that is connected in a daisy chain configuration. Its function is to communicate I/O signals between the control processor (DCCA), the protection core (

), and digital I/O core (). The IONET is identical in all processors with the exception of .  The core has no direct link to the

, therefore, the IONET communicates only between and the digital I/O board. With this configuration, a TMR panel has four independent IONETs (, , , and ) while the Simplex panel has two (, and ).

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 to in the Control Panel. The ARCNET interface card is a high impedance source that enables the 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 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

Processor Figure 2-2. Three Port Active Repeater 

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The Stage Link connection on the 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 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 , the turbine continues to operate as critical turbine functions are handled by , , and (cumulatively known as ). However, loss of the core results in a loss of communication between the control panel and the affected s on the Stage Link. Due to the three port repeater design of , 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, . This backup core provides continued Stage Link  communication if there is a failure in . The core is identical to that of , except that it is not capable of  monitoring 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 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 DCCA 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 DCCA card to the LCCB card, and onto the DENET. Once the information is on the DENET, each processor retrieves all three values (one from , and 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 DCCA 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 core, which independently performs a two out of three vote. The DENET pre-vote data from is made available to the DCCA card in . Voting mismatches in any of the cores are picked up by the DCCA card in . 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 are read into all three cores where the median value is selected. The median value is stored on the DCCA card and made available for use in performing calculations critical to turbine operation. Voting mismatches in any of the cores are noted by the DCCA card in . 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 does not cause the processor to incorporate the faulty value into its calculations as it is effectively masked by the software vote. Instead 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 and to the LCCB card of and . 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 , the DENET does not communicate to and . Without this communication link the Mark V continues to operate, but commands issued from the will not be passed to or . For this reason, it is recommended that a TCQC card removed for troubleshooting be replaced immediately. Commands may be issued from the without the TCQC card as it does not use the DENET.

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TCQA DCCA TCDA

TCEA LCCB DENET IONET 3PL Cable

TCQC

Figure 2-3. Typical Processor Setup 

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DENET

LCCB

DCC

DENET

DENET

DENET

TCQC

TCQC

TCQC

LCCB

LCCB

LCCB

To DCC

To DCC

LCCB

DCC

To DCC

TCC

TCC DENET Stage Link

Stage Link Figure 2-4. Control Processor Internal Communications 

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 (DCCA) 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 DCCA 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 DCCA 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

core. The TMR panel has a TCEA card for each of the cores. These cards communicate with the individual DCCA card of their respective cores. The Simplex control panel also has three TCEA cards mounted in

which are linked in a daisy chain configuration. All of these cards operate on the same IONET and all communicate with the core.

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2-5. THE ARCNET INTERFACE BOARD The ARCNET interface board is a device that allows the 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).

< Q > Core

< P > Core

< QD1 > Core HJ

DCCA

TCQC

TCEA

TCDA

IONET HJ

Hardware Jumper

Terminal Board

Terminal Board

Figure 2-5. TMR IONET Configuration (Typical of , or )

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< Q > Core

< P > Core

< QD1 > Core HJ

DCCA

TCQC

TCEA

TCEA

TCEA

TCDA

IONET HJ

Hardware Jumper

Terminal Board

Terminal Board

Figure 2-6. Simplex IONET Configuration 

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 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 process alarm queue. The Alert Box generates a one second pulse (contacts and tone) as its alert. The 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 alarm queue as well.

NOTE The 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.

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An 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 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 processors. These inputs are in parallel, so that simultaneous alarms from multiple processors will create a single pulse which ends one second after the last alarm input.

2-6.1. Adding an Alert Box to the Processor The three steps for adding an Alert box to an processor are: 1. 2.

3.

Choose an unused RS-232 port, probably a DigiBoard port. Connect the selected port from the first < I> to port ’A’ on the Alert Box. Subsequent s may be added to remaining ports. Edit the F:\IO_PORTS.DAT file to: a) Define the ‘s unused serial port’s BASE-PORT address. b) Assign the ‘s unused serial port as an ALERT port. Restart the 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, D2 for a MODBUS, and  D3 as the ALM$ALERT port.

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; ; Section 1 - SERIAL PORT DEFINITIONS ; P1 IRQ 7 BASE_PORT 0378 ; DIGIBOARD STATUS_PORT 0140 IRQ 9 D1 BASE_PORT 0100 BAUD 9600 D2 BASE_PORT 0108 BAUD 9600 PARITY NONE MODBUS D3 BASE_PORT 0110 D4 BASE_PORT 0118 D5 BASE_PORT 0120 D6 BASE_PORT 0128 D7 BASE_PORT 0130 D8 BASE_PORT 0138 ; ; ; LOGICAL PRINTER ASSIGNMENTS ; ASSIGN SYS$PRINT P1 ASSIGN DOS$PRINT P1 ASSIGN EPA$PRINT P1 ; ASSIGN DOT_MATRIX P1 ASSIGN HPLASERJET D1 ; ASSIGN ALM$ALERT D3 ; ; DEFINE MODBUS PARAMETERS ; MODBUS PORT D2 SLAVE 1 UNIT T1 MODE NATIVE MODBUS PORT D2 SLAVE 2 UNIT T2 MODE NATIVE

Figure 2-7. Sample F:\IO_PORTS.DAT 

2-6.3. Using the Alert Box After the 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 or entering  RUN_IDP on the 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.

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CHAPTER 3 SOFTWARE STRUCTURE 3-1. INTRODUCTION Software that allows a properly configured 386 or 486 IBM TM compatible personal computer to be used as an runs under a proprietary disk-operating system known as IDOS. The software is stored in two groups on the ’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 computer is partitioned to be one logical drive, C:. The following shows a directory tree for C: of a typical 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 is started. Programs running under IDOS require the above pseudo drive and directory structure for proper operation of the and the transmission of  data to and from the unit control panel(s).

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3-2. IDOS —THE 's COMPUTER OPERATING SYSTEM IDOS schedules the ’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 , 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 . The use of RAM disks is not recommended as the amount of extended memory available on a typical factory-configured does not accommodate RAM disks. operation is not increased by expanded or extended memory managers and they are not recommended.

CAUTION The use of RAM disks, memory managers, and programs requiring expanded or extended memory may cause memory resource allocation problems when run under IDOS and is not recommended. Installation of  software not supplied or authorized by GEDS may adversely affect system performance.

3-2.1.

Root Directory

The top level or root directory of the 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 .

 is the command processor that reads, analyzes and performs computer instructions entered from the COMMAND.COM  keyboard at the DOS prompt ( > ).  is used to enable the mouse or trackball.  MSMOUSE.COM  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 without the consent of GEDS is not recommended.

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3-2.1.1. DRIVE F: FILES. The top level of the pseudo drive F: contains the following site-specific configuration files: CONFIG.DAT is the master site configuration file. It specifies items such as how many units exist on the site and the unit names and subdirectory names containing all the unit specific information. It also contains network information about what communication links exist out of the 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 for communicating with printers and MODBUS communication links. DYNAMIC.BIN contains dynamic system settings such as logging, passwords, etc. 3-2.1.2. DRIVE F: SUBDIRECTORIES. Subdirectories on the drive F: contain the following information/files: \RUNTIME  contains all the runtime data files created by programs running under IDOS. Programs check this directory for display-related data files (User Defined Displays, Main Menu, Logic Forcing recall points, Trip History data, etc.).

Configuration files in the F:\RUNTIME  subdirectory include: *.A0, A1, A2,...A8 contain specific code defining the animated displays. A0 A1 A2 A8

Generic Unit 1 Unit 2 Unit 8

 MENU.DAT  contains information defining the layout and the displays available from the Main Menu. DEMANDnn.BIN  contains user-defined Display Menu definitions

 is the default subdirectory specified in the  AUTOEXEC.BAT file run during start-up of the . Some programs \USER  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. \UNIT n is created for each unit being controlled by an , where n is equal to the unit designator number (up to a maximum of eight units/subdirectories). Files which make up the Data Dictionary and EEPROM images for a unit are stored in its unitspecific directory and should always be kept there.

The files in each unit-specific subdirectory which comprise the Data Dictionary for each unit are as follows: SCLEDATA.DAT contains the pointname scaling data information used to convert signal data from raw binary units to engineering units for display on the . UNITDATA.DAT  contains basic information about each signal (logic or real) of the unit, including its name, memory location, point type, scale code, command information, and internal point number. ENUMDATA.DAT contains the enumerated data strings for the enumerated data types. Enumerated data is used to "describe" the operational state of the unit such as OFF, SYNCHRONIZING, LOADING, COOLDOWN ON, etc.  ALARM.DAT  contains the text messages for each Process Alarm drop and for each Diagnostic Alarm drop. \UNITn\PROM are Mark V Control Panel processor PROM-related files. They are used by IDOS programs such as the I/O Configurator, the CSP Documenter, the Control Sequence Editor, the Control Sequence Compiler, and others. The files in

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this sub-directory must match the BBL and memory location information stored in the processor PROMs for proper configuration and operation of the Mark V Control Panel. 3-2.1.3. DRIVE G: SUBDIRECTORIES. Subdirectories on drive G: contain the following information/files: \EXEC  contains all the executable files/programs that form the basic and any batch files used during start-up or execution.

 contains any data files which programs require that are not site-specific. It also contains any generic data files \DATA  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. HARD DISK BACK-UP To prevent permanent loss of valuable data and work, backup the 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.

CAUTION

During the back-up or restoration of a hard disk, that specific cannot be controlling the turbine(s). If it is necessary to run the turbine(s) during this time, other control systems such as other s or 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 momentarily. Before backing up the hard disk, it is recommended that a system disk is made. This disk can be made by typing SYS A: at the DOS prompt with a new floppy disk in the A: drive. The system disk should include the following files: COMMAND.COM, IO.SYS, MSDOS.SYS  - these should be copied by the SYS command AUTOEXEC.BAT, CONFIG.SYS, MSMOUSE.COM  - these files are needed to initialize the MSBACKUP*.*  - with DOS version 6 or later (or  BACKUP.* and RESTORE.* with versions less than 6) are the programs necessary to restore the hard disk  MSAV*.* - anti-virus software to protect the system from computer viruses (DOS version 6 or later)

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Various methods are available to back-up the hard disk drive. For computers using versions of DOS before 6.0, the DOS BACKUP command is available in the  C:\DOS subdirectory. Consult the DOS documentation for details or type   BACKUP /? at the DOS prompt. The DOS RESTORE command is the complement to the  BACKUP command;  RESTORE rebuilds the C: drive to the configuration that was saved using the  BACKUP command. Consult the DOS documentation or type RESTORE /? at the DOS prompt. For computers using DOS version 6.0 or later, the equivalent command is MSBACKUP, which is available in the  C:\DOS subdirectory. For details, consult the DOS 6.0 documentation or type  MSBACKUP at the DOS prompt. The DOS backup utilities will not work with puesdo or substituted drives (F: or G:); remove the substitutations before doing a backup. The substitutions can be removed by entering  SUBST /D at the C:> prompt. File compression software reduces the size of some of the files and therefore, the number of disks needed to back-up the hard disk. See the 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.

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CHAPTER 4 SOFTWARE TOOLS 4-1. INTRODUCTION The operator interface uses software (program) to troubleshoot and set up the Mark V control system. This Chapter describes several of these software "tools." They are not arranged in any particular order, because different situations may require the use of one or more of these tools in a different sequence.

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 To view the "picture" of a sequencing BBL, use the Dynamic Rung Display to access the SRC or SPC file.

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L30TF

L30TFX

L63TFH1

Primitive: TMV L63TH1H_ALM K63TF1H_ALM T63TF1H_ALM

0.0 sec  0.0 sec

PIC L30RHFLT

L30RHFLTX

L26CTH

L26CTH_ALM

L26BT1H

L26BT1H_ALM

L27MC1N

Primitive: TMV L27MC1N_ALM K27MC1N_ALM T27MC1N_ALM

 0.0 sec  0.0 sec

PIC L49X

L27BLN

L49X_ALM

L27MC1N

Primitive: TMV L27BLN_ALM K27BLN_ALM K27BLN_ALM

 0.0 sec  0.0 sec PIC

L64D_P

  L64D

L41FY

L64D_N

L27DZ

L27DZ_ALM

Primitive: TMV  0.0 sec  0.0 sec PIC

L4

L64F

LSC1

Primitive: CMP L49X

TNH TNL

 0.00%  0.00% PIC

Figure 4-1. Sequencing BBL: ALARMS_MISC_L1 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.

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NOTE Non-sequencing BBLs have  F:\UNITn\PROM\*.PIC  files that permit viewing picture files. These PIC files are available for printout.

 

                                                                                                                                                                                                                           

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 . It does not matter what value the parameter has in , , and . 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.

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•

A solid green box or circle with an "F" (or ">") in the middle indicates Forced power flow through the contact or coil.

•

An empty yellow box or circle with an "F" (or ">") in the middle indicates no power flow due to a Force.

•

A "?" indicates that the logical name is not defined in the database.

•

An inverted coil is shown as a coil with a "/" through it. An inverted coil with a 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 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 .

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.

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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 Name shows the names of all passed parameters.

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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.

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Figure 4-3. Non-sequencing BBL:L39VV5  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.

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Figure 4-4. Automatics of Non-sequencing BBL: L39VV5  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.

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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.

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                                 



                            

      

Figure 4-6. Segments, Rungs, and Sub-Rungs  Each BBL corresponds to a certain rung within a segment. All BBLs are considered rungs and are contained within a given segment. However, not all rungs are BBLs. For example, rung 2 of segment 1 is a RLD and therefore is not considered a BBL. Also, depending on whether the BBL is a sequencing BBL or non-sequencing BBL determines whether it has subrungs. The non-sequencing BBL which is Rung 1 of 5 in Segment SEQU_XX (Segment 2 of 3) has no Sub-Rungs. However, the sequencing BBL in Rung 3 of Segment 1 has Sub-Rungs. This method of segments, rungs, and sub-rungs serves only to keep track of all the BBLs in an orderly fashion. 4-2.7.1. SEGMENTS. A segment is a collection of rungs (BBLs, titles, or RLDs) much like a DOS directory is a collection of files. For example, Segment: SEQU_Q may have 9 Rungs and Segment: SEQU_Z may have 130 Rungs much like a DOS directory called C:\DOS may have 69 files stored in it.

The file that defines and determines which Segments are used and the order they are executed in the Dynamic Rung Display is F:\UNITn\MSTR_SEQ.CFG . Part of the  MSTR_SEQ.CFG  file is as follows: F:\UNITn\MSTR_SEQ.CFG

#Segment #Segment #Segment

SEQU_Q SEQU_XX SEQU_B

The following numerical assignments show how the Dynamic Rung Display orders the Segments being used. SEQU_Q is Segment 1 of 3 SEQU_XX is Segment 2 of 3 SEQU_B is Segment 3 of 3

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4-2.7.2. RUNGS. A Rung can be one of four things:

•

A sequencing BBL (with Sub-rungs), see section 4-2.7.4.

•

A non-sequencing BBL (with no Sub-rungs), see section 4-2.7.5.

•

A title, text message, or some kind of "comment", see section 4-2.7.6.

•

A RLD consisting of contacts, coils, and possibly Primitives, see section 4-2.7.7.

A sequencing BBL_Rung can consist of "passed" parameters, automatics, or both. Also, a sequencing BBL consists of SubRungs. The Sub-Rungs contain the dynamic "pictures" of the RLDs and show the actual arrangement of the contacts and coils as well as the current state of each. The Sub-rungs are accessed selecting the SRC target. When SRC is selected, the Dynamic Rung Display no longer looks at a Rung to Segment positioning indicator. The Dynamic Rung Display now looks at a Sub-rung to Rung positioning indicator. In order to return to the Rung to Segment positioning it is necessary to select  Return Main  (see Figure 4-9). Section 4-2.7.4 is an example using BBL: L43_AUX_LOGIC to show the effect of selecting SRC from the Main Display. 4-2.7.3. SUB-RUNGS. Sequencing BBLs is the only type of Rung that has Sub-rungs associated with it. Sub-rungs are accessed by selecting the SRC target when viewing a sequencing BBL. The Sub-rungs are then ordered from beginning to end with the current position being displayed by the position indicator. Select  Goto Main to exit Rungs. 4-2.7.4. SELECTING SRC IN A SEQUENCING BBL. From the screen shown in Figure 4-3, perform the following steps to retrieve BBL: L43_AUX_LOGIC, shown in Figure 4-7.

1. Select Goto Top 2. Select Search Name: 3. Type L43_AU* and press Enter. 4. Select Find All

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Figure 4-7. Main Display of Sequencing BBL: L43_AUX_LOGIC   Select SRC, to reach the screen shown in Figure 4-8.

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Figure 4-8. Text Message (Sub-rung 1 of 11) of File L43AUXL1.SPC  The Next Rung target actually performs a "Next Sub-Rung" operation here because while viewing an SRC or SPC file the Sub-rungs are subsets of the Rung. Normally the Rungs are viewed as subsets of Segments. The following steps reveal subrung 5 of 11, shown in Figure 4-9. 1. Select Goto Jump 2. Type 5 and press  Enter Next Rung, Prev Rung, PAGE UP, and PAGE DOWN are all targets that scroll through the RLD Sub-rungs of a sequencing BBL. While viewing the Sub-rungs within a sequencing BBL the position indicator Sequencing BBL L43AUXL1.SPC: 5 of 11

is referring only to the Sub-rungs within the BBL (not to the BBL’s position within the Segment).

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Figure 4-9. Sub-rung 5 of SRC (L43AUXL1.SPC) File  To return to the main menu where the SRC command was selected , select Return Main.  The screen as shown in Figure 4-7 is retrieved. Return Main moves back one level (going from viewing Sub-rungs to viewing Rungs). 4-2.7.5. PIC FILE IN A NON-SEQUENCING BBL. A non-sequencing BBL has no Sub-rungs and therefore the Dynamic Rung Display provides no SRC target. However, non-sequencing BBLs have related PIC files that are accessible by selecting the PIC target. Once the user selects PIC,the picture file is displayed along with two to seven additional targets. The two targets that are always displayed after selecting PIC are Rung Display and Show Value.

NOTE The following section shows how targets affect the Dynamic Rung Display. The screens represent actual Dynamic Rung Displays; however, the data shown such as BBLs, Primitives, RLDs, parameters, comments, and such is furnished as an example only.

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Since BBL: L43_AUX_LOGIC is Rung 6 of 11 in Segment 1 of 3 (see Figure 4-7) and BBL: CMDSTATE is Rung 5 of the same segment, select Prev Rung to reach the Main Display of non-sequencing BBL: CMDSTATE. Figure 4-10 is revealed.

Figure 4-10. Main Display of Non-sequencing BBL: CMDSTATE  Select PIC, Figure 4-11 the PIC file of Non-sequencing BBL: CMSTATE is revealed.

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Figure 4-11. PIC File of Non-sequencing BBL: CMDSTATE  To show the values of passed parameters, select Show Value  (see Figure 4-12).

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Figure 4-12. Parameters (passed) of Non-sequencing BBL:CMDSTATE  To return to the Main Display, select  Rung Display . Figure 4-10 is revealed.

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4-2.7.6. TEXT MESSAGE. If a Text Message Rung is defined by the sequence editor as a "text message" or "comment", it is displayed by the Dynamic Rung Display in exactly the same manner as it was defined in the Sequence Editor. There are no additional parameter/picture targets (AUTO, PAR, SRC, or PIC). Only the positioning targets are shown (see Figure 4-13).

To reach the Text Message select  Goto Top. This is the first display shown when starting the Dynamic Rung Display (Rung 1 of Segment 1).

Figure 4-13. Dynamic Rung Display Text Message (Rung 1 of Segment 1)

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4-2.7.7. RLD RUNG. If an RLD Rung contains contacts, coils, and possibly Primitives, it is displayed by the Dynamic Rung Display as shown in Figures 4-14 and 4-15. Although this type of BBL Rung looks similar to the Sub-rung structure, it is not considered a Sub-rung since it is not contained within a sequencing BBL. Therefore, it is not necessary to select SRC to view these type of Rungs. However, if the RLD contains a Primitive, the Primitive’s PIC file can be accessed by selecting the PIC target as shown in Figure 4-14. For an explanation of the "F"s shown in the contacts see section 4-2.1.4. From the screen in Figure 4-13, perform the following steps to reach RLD Rung.

1. Select EXIT or type F8, 2. Restart the Dynamic Rung Display (see section 4-2.6). 3. Select Goto Jump 4. Type 7 and press  Enter. Figure 4-14 is revealed.

Figure 4-14. RLD Rung: (Rung 7 of Segment 1). Select PIC, to reach Figure 4-15, the PIC file of Primitive: CMP.

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Figure 4-15. Primitive: CMP in User-Defined "Ladder Logic" Rung  The parameter/picture target displayed by the Dynamic Rung Display depends on the type of category (one of four) to which a particular Rung belongs. However, the same positioning targets are always displayed with the following exceptions: •

at Rung 1 of Segment 1 there are no Prev Rung, Prev Seg, or Page Up targets (conditions do not exist)

•

at the last Rung of the last Segment there are no Next Rung, Next Seg, or Page Down targets (conditions do not exist)

The User Display, Alarm Display, and Function targets are always displayed in the same manner regardless of what type of  Rung is being viewed.

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4-2.8. Using "Find All" to Find Parameters The positioning targets described in sections 4-2.4 and 4-2.5 are extremely useful to search for a given Parameter and determine what is causing that Parameter to be a certain value or state. For example, to find out why L26CTH is currently a logic "1" the following steps are used: 1. Start the Dynamic Rung Display (see section 4-2.6). 2. Select Search Name:  and type L26CTH, press Enter 3. Select

Find All. Figure 4-16 is revealed.

Although all the previous examples used  Find All to find specific BBLs or Primitives, the example in this section uses Find All to find a specific Parameter. This "chases" a particular Parameter and determines what is causing the Parameter to be the value or state it is. It also enables the user to find what effect this Parameter is having on other parameters.

NOTE When selecting Find All and/or Find Coil the Dynamic Rung Display searches from the current position to the end of the file. Therefore, select Goto Top, before selecting Find All or Find Coil, to ensure that all points are found during the search.

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Figure 4-16. Logical Parameter L26CTH  From Figure 4-16, select  SRC, Figure 4-17 is revealed. At this point selecting Find Coil would find the coil of L26CTH only if it existed in the Sub-rungs of Sequencing BBL: ALARMSL1.SPC. Selecting Find All finds every place that either a coil or a contact of L26CTH is used in the Sub-rungs of this BBL.

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Figure 4-17. Sub-rung of Logical Parameter L26CTH  Select Find All to find every place that either a coil or a contact of L26CTH is used in the Sub-rung of this BBL (see Figure 4-17). It also shows what is causing the L26CTH coil to be a "1", only if  its coil is located within this particular BBL: ALARMS_MISC_L1. Select Find All again, Figure 4-18 is revealed.

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Figure 4-18. Use of the Find All command to find a ’coil’  By selecting Find All the coil of L26CTH was found. Since Primitive: CMP (A>B) is enabled by contact LTRUE (always "1"), and since 77 deg F > 0 deg F, L26CTH is picked up (a "1"). The Dynamic Rung Display shows this by filling in the coil with a solid green color. Select Find All again, Figure 4-19 is revealed.

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Figure 4-19. Use of Find All Target  Selecting "Find All" again shows that L26CTH has a normally open contact in series with a coil: L26CTH_ALM. Since L26CTH is a "1", L26CTH_ALM is driven to a "1" (see Figure 4-20). Select Find All again, Figure 4-20 is revealed.

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Figure 4-20. "No More Occurrences" of Finding Logical Parameter L26CTH  After selecting Find All (again), "No more occurrences" appears below the positioning targets. This means that L26CTH is not used between Sub-rung 6 and 12 of Sequencing BBL: ALARMSL1.SPC. It does not mean that L26CTH is not used in another rung below BBL: ALARMS_MISC_L1. To check for this circumstance, the target  Return Main must be selected, followed by successive  Find All selections. Search Name: target can be used to find BBLs, parameters (passed or automatic) and Primitives.

NOTE When searching for BBLs, and Primitives you must use "Find All" instead of "Find Coil". "Find Coil" is only used to find a coil of a RLD. If "Find Coil" is used while viewing Rungs only coils in RLD Rungs are found. If  "Find Coil" is used while viewing Sub-rungs only coils in RLD Sub-rungs are found.

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4-2.9. Files Used by the Dynamic Rung Display  \UNITn\Rung.A

(text file with "Rung" in it used by animator)

 \UNITn\USER.A

(called from Rung.A used by animator)

 \UNITn\MSTR_SEQ.CFG  \UNITn\*.SRC

(from MSTR_SEQ.CFG)

 \UNITn\Rung_TMP.A

(created/deleted by the Dynamic Rung Display)

 \UNITn\Rung.ERR

(created by the Dynamic Rung Display. All errors are logged to this file.)

 \UNITn\PIC_TMP.A

(created/deleted by the Dynamic Rung Display)

 \UNITn\PROM\BIGBLOCK.DEF  \UNITn\PROM\PRIMITIVE.DEF  \UNITn\PROM\*.PIC

(referenced from segment source files)

 \UNITn\PROM\*.SPC

(sequence BBL source files)

4-3. DIAGNOSTIC DATA DISPLAY (DIAGC) The Diagnostic Data Display (DIAGC) is a view-only program used for troubleshooting and/or statistical data gathering purposes. It permits I/O card data not defined in the control signal database (CDB) to be viewed. Not all data is defined in the CDB because data must be processed or scaled before it can be used by the Turbine Control programs or it is data created by the operating or communication systems of the I/O cards for troubleshooting purposes.

4-3.1. Executing DIAGC The DIAGC can be executed from a menu pick on the Main Menu or from the DOS prompt using the command:   DIAGC. DIAGC is located within the product code in the G:\EXEC subdirectory. When first executed, the DIAGC program displays the following message reminding the user that only qualified individuals should access the software: " DIAGC "is a diagnostic tool for firmware designers and field personnel only. Its purpose is to assist firmware designers in the performance evaluation of the EPROM based programming and to assist field personnel in problem diagnosis. While the program is a "display only" program that poses no threat to the operation of the turbine control, it does not provide Turbine Operation information and should be run by authorized personnel only.

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Figure 4-21. Main Display Menu  4-3.2. Menus The DIAGC is organized in two menu levels. The Main Menu level displays a list of cards from which to select. This menu varies for different applications depending on which cards are in the system and which cards have a diagnostic data interface information coded in PROM. Not all cards in a given system may appear here, some I/O cards (such as the TCDA) perform very little data preprocessing. The Main Menu shows the amount of free memory available in the upper right corner of the display (see Figure 4-21). The amount of free memory does not matter unless it falls below the minimum required to run DIAGC. This could be due to other applications still resident in memory. If there is insufficient free memory the program refuses to enter displays, an error message is displayed, and the user is exited to the DOS prompt or the original program.

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The Main Menu shows the list of cards that are predefined predefined as active cards for this display. Some of these cards have PROM revisions defined in the title title such as TCQAG1A (F1AEA v5.1) Diagnostics. If this list shows an incorrect revision revision of PROM to that identified by the PROM labels, contact the factory for a new data file. PROM revision information is displayed in the Main Menu. Cards are defined in this list by the lowest common revision for which the display works. The display is only correctly defined for the DS200TCQAG1A board with PROM firmware labelled DS200TCQAF1AEA (see Figure 4-22). This means version 5.1 of the TCQA firmware. Another of the menu picks may be for Drive Control Card (DCC) diagnostics. This means that the display is correct correct for all revisions of the DS200DCCx board and associated associated firmware. produces a second level menu or Submenu. Submenus show the 4-3.2.1. SUB-MENUS. Selecting a card from the menu produces individual data displays available for that particular card (see Figure 4-22). Available displays at this level are predefined by the structure of the data that the card has been preprogrammed to send back to the . Therefore, they vary considerably from card to card.

Figure 4-22. Submenu 

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There are two types of Submenu picks: • •

I/O data data read in in by the data data acquisi acquisition tion portio portion n of the I/O I/O card softwa software re such as as the LVDT LVDT data for for the TCQA TCQA board. board. performa performance nce informa information tion gather gathering ing softwar softwaree for advanced advanced trouble troubleshoot shooting ing use only, only, such as as the LCC ARCNET ARCNET counter counter display. Consult Product Service Engineering for details. GE Industrial Control Systems Product Service Engineering, Rm. 191 1501 Roanoke Blvd. Salem, VA 24153-6592 USA (540) 387-7595

4-3.2.2. POSITIONING TARGETS. Some positioning targets are standard throughout the operating system. Standard targets used by DIAGC are as follows:

ALARM DISPLAY moves to the alarm display. EXIT moves out of DIAGC to where the program was initiated such as Main Menu or the DOS prompt. MORE OPTIONS shows additional targets to select. MAIN DISPLAY shows list of cards to select. PRINT IMAGE captures a snapshot of the screen and sends it to the printer spooler. SAVE IMAGE stores a copy of the display to the disk. The following targets are defined specifically for DIAGC: MENU ↑ returns to the Main Menu. NEXT sequences through Submenu displays. NEXT PRCESSR selects the next processor such as , , or . SUBMENU ↑ returns to the Submenu of the selected card. SUBMENU ↓ retrieves Submenu of selected card. VIEW ↓ shows next Submenu data. data. At the lower end of the screen is the standard alarm window. Alarms can be silenced by clicking anywhere in the blue area and can be acknowledged by clicking on the alarm status target.

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Figure 4-23. Power Supply Data  particular display causes the to establish a communication communication link to the card 4-3.2.3. SELECTING A DISPLAY. Selecting a particular in question and ask for the PROM previously defined data associated associated with this display. The top right of a display shows the processor that is currently communicating communicating with (in Figure 4-23, it is the processor). The next line shows the number of replies received from the processor. This number increments approximately approximately once per-second as the replies come back from the linked processor or card. This counter returns to zero when 256 replies have been received. If the communication link is not established or the I/O card or communication link fails, the Reply received section turns red to indicate that the data is either stale or invalid. The Reply received section also turns red if the data received is invalid. Contact GEDS Product Service Engineering for assistance.

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Figure 4-24. Milliamp Inputs  The Data shown must be understood before it is assumed valid or invalid. For example, not all power supplies are used in all applications and the P125V and N125V measures these points to ground. In Figure 4-24, not all milliamp inputs are used. Proper interpretation of DIAGC data requires comprehensive system knowledge.

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4-3.3. Associated Files The DIAGC Display is driven by the data file DIAGC.DAT in the PROM subdirectory of the UNITn directory for the given unit. This data file contains all of the screen definitions and the menu structure. For each display, there are text definitions of  each line. Included in these text definitions is the scaling information on how to display the fixed point integers reported back  by the I/O cards as floating point displays. Instructions on how these are formatted are included in the comments in the data file. This file does not need to be edited on-site as the data is PROM firmware dependent and not site-dependent. When new PROMs are installed in the unit, ones that make changes to the data supplied for the Diagnostic Data Display, a new DIAGC.DAT file may also be required.

4-4. EEPROM DOWNLOADER Control Sequence Programs, Control Constants, Totalizer Data, I/O Configuration information, and point lists for various displays, loggers, and options are some of the critical data stored on EEPROM chips in the Mark V Control Panel. Each processor has one EEPROM chip, located on the DCC card, which holds the information needed by that processor. When the processor is started, information from the EEPROM is copied to RAM, where it used to control and monitor the turbine (see Figure 4-26). The EEPROM Downloader program, run from the Main Menu on the , is used to transfer data to and from the Mark V’s EEPROM chip(s). The critical data is stored on the EEPROM chip in hexadecimal format. With the exception of  the I/O configuration information, the data must be compiled to convert from ASCII text to hexadecimal format. Modifications to the Control Sequence Program file(s) must be compiled using the Control Sequence Compiler, while modifications to all the other EEPROM information files are compiled using the Table Compiler  TABLE_C. This section describes the EEPROM information file transfer process.

NOTE For modifications downloaded with the EEPROM Downloader to take effect, the processor(s) must be restarted in order for the new information on the EEPROM chip to be transferred to RAM for use by the processor in controlling and/or monitoring the unit.

Upon accessing the EEPROM Downloader from the Main Menu, the user is out of the menu system. EEPROM is an executable file run as an IDOS task.

CAUTION When running EEPROM Downloader, the is not controlling the turbine. However, the turbine continues to operate at the last setpoint and all Mark V protective functions are operational.

4-4.1. Executing EEPROM Downloader The EEPROM Downloader can be executed from a menu pick of the Main Menu or from the DOS prompt using the command: EEPROM Downloader. Once executed, a Help screen is available at any time by typing HELP at the EEPROM Downloader> prompt. To return to the Main Display from the EEPROM Downloader program, after the  prompt EEPROM Downloader> , type EXIT Once in EEPROM, use the format specified in the Help screen (Figure 4-25) to perform one of the options of EEPROM . Enter the two character unit name of the Control Panel using EEPROM. This information is in the CONFIG.DAT file on F: and also in the EEPROM program by typing the wildcard character " ? " for the unit name and processor name in a command.  For example, to obtain a list of the valid unit names for the , type the following command after the prompt  EEPROM Downloader>

DIR ?? ?

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------------------------------------------------------------------Mark V EEPROM downloader, Version 2.2 EEPROM Where: is one of { UP | DOWN | DIR | CHECK | NOCHECK } is the name of the desired unit. is the processor to talk to, one of { R | S | T | C | D } is ALL or a list of EEPROM partitions, partitions are: FORMAT - Formats (initializes) EEPROM. [Not in USER category] SEQ- Contains sequencing. CONST - Contains control constants. IOCFG - Contains IO configuration. UBBL - Contains User BBL library. HIST - Contains point list for history log. EPA - Contains point list for EPA log. MAOUT - Contains point list for 4-20 Ma outputs. EVENT - Contains point list for events. CHNG - Contains point list for change detection. BOI - Contains point list for backup operator display. TOTT - Contains point list for totalized data. TOTD - Contains totalized data.[Not in USER category] CBLR - Contains point list for cable remote. -------------------------------------------------------------------

Figure 4-25 . HELP Screen  After obtaining the unit name(s), information can be transferred between and the unit Control Panels. For example, to replace the EEPROM chip in of the Control Panel of Unit Name " T1 ", type the following command at the prompt EEPROM Downloader> DOWN T1 C ALL

As in the above example, download all EEPROM information immediately after formatting the EEPROM chip of any processor.

4-4.2. EEPROM Downloader Command The following section describes EEPROM Downloader command options and their uses. UP uploads or transfers point lists and data from the various partitions of the EEPROM chip in the desired processor to the hard-disk files of . Data can be uploaded for back-up purposes, when the EEPROM chip or the DCC card is being replaced, or to prepare the point lists or data for modification, when possible.

NOTE Periodically, the Totalizer Data, point list files, and formatting information should be uploaded to the ’s hard disk using EEPROM Downloader. If a card failure (DCC Card) should occur, this information can be downloaded in order to restore this critical data.

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EEPROM DOWNLOADER

Formats, Sequencing, Control Constants, Data, and Point Lists

Processor EEPROM Chip

Control Constants and Totalizer Data ONLY stored on EEPROM by commands

All information transferred to RAM on power-up or re-boot of processor

EEPROM Update

Processor RAM

Operator-initiated command Automatic command

Totalizer Data gathered from and acted on in RAM

CONTROL CONSTANT Adjust

TOTALIZER

Control Constants modified in RAM

CONTROL

LOGGING

MONITORING

PROTECTION

11

Figure 4-26. Processor EEPROM to RAM Data Transfer and Storage 

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Maintenance Manual CBLR_*.SRC TOTT_*.SRC BIO_Q*.SRC CHNG_*.SRC

QSEG_0n.SRC BSEG_0n.SRC

EVENT_*.SRC MAOUT_*.SRC EPA_*.SRC HIST_*.SRC CONST_*.SRC

CONTROL SEQUENCE COMPILER SEQ_B.DAT SEQ_Q.DAT

CFG.DAT IO_CFG.DAT

I/O

TABLE COMPILER

CONST_*.DAT HIST_*.DAT EPA_*.DAT MAOUT_*.DAT T EVENT_*.DAT CHNG_*.DAT BIO_Q*.DAT TOTT_*.DAT CBLR_*.DAT

CONFIGURATOR

IOCFG_D.DAT IOCFG_CDAT IOCFG_Q.DAT

UBBL_*.DAT

TOTD_*.DAT

FORMAT_*.DAT

* B or Q

EEPROM DOWNLOADER

Processor EEPROM Chip Figure 4-27. EEPROM Downloader 

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DOWN downloads or transfers point lists and data which are to be stored in the EEPROM chip from to the EEPROM chip in the desired processor. Data may be downloaded to the EEPROM chip on the DCC card after the EEPROM chip or the DCC card is replaced, after modification and compilation of the point lists or data, to initialize a new EEPROM chip being installed on a DCC card, or to reinitialize an existing EEPROM, when necessary.

NOTE Prior to downloading, data must be compiled to convert the information to a hexadecimal format. Failure to compile the modified files results in the downloading of old information to the EEPROM rather than the modified point lists or data files. DIR provides a list including the date when each EEPROM section file was compiled. This option lists the information for all sections as follows. DIR T1 S DIRECTORY OF UNIT T1 PROCESSOR S: Partition offset size --------date-------SEQ 4000 07F2 18-OCT-1991 14:33:20 CONST 1000 07DC 01-JAN-1980 00:00:00 IOCFG 2000 031A 22-OCT-1991 09:21:00 UBBL 0000 0000 01-JAN-1980 00:00:00 HIST 0000 0000 01-JAN-1980 00:00:00 EPA 0000 0000 01-JAN-1980 00:00:00 MAOUT 0000 0000 01-JAN-1980 00:00:00 EVENT 0000 0000 01-JAN-1980 00:00:00 CHNG 0000 0000 01-JAN-1980 00:00:00 BOI 0900 0002 01-JAN-1980 00:00:00 TOTT 0D00 0016 01-JAN-1980 00:00:00 TOTD 3000 0FE8 01-JAN-1980 00:00:00 CBLR 0E00 0006 01-JAN-1980 00:00:00

22 -OCT-1991 10:00:19 cksum -id50F1 SEQ 0A33 CNST CACC IO 0000 UBL 0000 HIST 0000 EPA 0000 4-20 0000 EVNT 0000 CHNG CAFE BOI 0385 TOTT CAFE TOTD 0000 CBLR

CHECK performs a checksum comparison of all of the EEPROM section files and lists the results. This option lists the information for all of the sections as follows: CHECK T1 S CHECKSUM TEST Partition SEQ CONST IOCFG UBBL HIST EPA MAOUT EVENT CHNG BOI TOTT TOTD CBLR

OF UNIT offset 4000 1000 2000 0000 0000 0000 0000 0000 0000 0900 0D00 3000 0E00

T1 PROCESSOR S: size --------date-------07F2 18-OCT-1991 14:33:20 07DC 01-JAN-1980 00:00:00 031A 22-OCT-1991 09:21:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0002 01-JAN-1980 00:00:00 0016 01-JAN-1980 00:00:00 0FE8 01-JAN-1980 00:00:00 0006 01-JAN-1980 00:00:00

22 -OCT-1991 10:00:51 cksum -id- -status50F1 SEQ OK 0A33 CNST OK CACC IO OK 0000 UBL 0000 HIST 0000 EPA 0000 4-20 0000 EVNT 0000 CHNG CAFE BOI OK 0385 TOTT OK CAFE TOTD OK CAFE CBLR OK

NOCHECK disables a checksum comparison of the defined section. For example, type the following command after the prompt EEPROM Download> NOCHECK T1 S CBLR

The following message would appear on the screen: CBLR

OK

Checksums will not be done for this partition.

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and a subsequent command to perform a checksum comparison gives the following display: CHECKSUM TEST Partition SEQ CONST IOCFG UBBL HIST EPA MAOUT EVENT CHNG BOI TOTT TOTD CBLR

OF UNIT offset 4000 1000 2000 0000 0000 0000 0000 0000 0000 0900 0D00 3000 0E00

T1 PROCESSOR S: size --------date-------07F2 18-OCT-1991 14:33:20 07DC 01-JAN-1980 00:00:00 031A 22-OCT-1991 09:21:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0000 01-JAN-1980 00:00:00 0002 01-JAN-1980 00:00:00 0016 01-JAN-1980 00:00:00 0FE8 01-JAN-1980 00:00:00 0006 01-JAN-1980 00:00:00

22 -OCT-1991 10:00:51 cksum -id- -status50F1 SEQ OK 0A33 CNST OK CACC IO OK 0000 UBL 0000 HIST 0000 EPA 0000 4 -20 0000 EVNT 0000 CHNG CAFE BOI OK 0385 TOTT OK CAFE TOTD OK CAFE CBLR

To re-enable the checksum comparison download the section information using the DOWN option. This option has no effect on turbine operation or control and may be useful only in certain troubleshooting situations. EEPROM UNIT NAME must be specified for each application. Unit name(s) are found in the file CONFIG.DAT on the F: drive. The section of the CONFIG.DAT file that defines the unit names/numbers is shown as follows (the site is a single unit steam turbine installation, and the unit name assigned to the steam turbine is S1): ; ;-----------------------------------------------------------------------------; ; This section defines the unit numbers, unit names, and the path to the ; directory that contains the unit information. Each line contains the ; unit number (decimal), the unit name (2 char max), and the path to the ; unit configuration data (64 char max). The unit numbers should be in ; order, and if a unit number is repeated, the last entry wins. ; ; UNIT UNIT PATH TO ; NUMBER NAME CONFIG DATA ; --------------------------------UNIT_DATA 1 S1 F:\UNIT1 ; ;----------------------------------------------------------------------------;

EEPROM DOWNLOADER PROCESSOR NAME specifies the processor for information to be  uploaded, downloaded, or otherwise acted on each time a command is executed using EEPROM.

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4-4.3. EEPROM Downloader Command Four types of information are saved to the EEPROM chip by EEPROM Downloader. The following section describes command sections and their uses. For more information see the Application Manual, GEH-6195, Chapter 3. Control Sequence Files SEQ is specified to download or upload the Control Sequence files, SEQ_B.DAT and/or SEQ_Q.DAT. Table Files Table files start as ASCII text files (*.SRC) and are compiled using the table compiler program (TABLE_C). The following commands can be specified to transfer data to and from the using EEPROM. Command

Transfers Data Files

CONST

Control Constants that are used to configure and tune-up. CONST_B.DAT CONST_Q.DAT

HIST

Point list data files for the historical log. HIST_B.DAT HIST_Q.DAT

EPA

Point list data file for emissions monitoring EPA_B.DAT EPA_Q.DAT

MAOUT

User defined 4-20 mA analog output. MAOUT_B.DAT MAOUT_Q.DAT

EVENT

Point list data file for event log. EVENT_B.DAT EVENT_Q.DAT

CHNG

Point list data file for analog change detection. CHNG_B.DAT CHNG_Q.DAT

BOI

User defined modifications to the back-up operator display. BOI_B.DAT BOI_Q.DAT

TOTT

Point list data file for totalizer data information. TOTT_B.DAT TOTT_Q.DAT

CBLR

Point list data files for cable remote. CBLR_B.DAT CBLR_Q.DAT

I/O Configuration Files IOCFG is specified to download I/O Configuration information to the individual processors from using files IOCFG_D.DAT, IOCFG_C.DAT, and/or IOCFG_Q.DAT

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Special Functions and Data Command

Transfers Data Files

FORMAT

Prepare the EEPROM chips to receive data, similar to the DOS command all information on the disk is lost. FORMAT_B.DAT FORMAT_Q.DAT

UBBL

Transfers user specific BBLs from to the Control Panel. UBBL_B.DAT UBBL_Q.DAT

TOTD

Transfers totalizer data such as unit timers, counters, fuel flows, and steam flows. TOTD_B.DAT TOTD_Q.DAT

NOTE When an EEPROM chip is formatted, all existing data is lost and the related processor can no longer be used to control a turbine. It is imperative that the EEPROM DOWN command be executed successfully before it is possible to return the processor to service. To simplify and modernize the downloading process, two special commands were developed. ALL is specified to download or upload, ALL the sections in the unit name specified. Steps that occur include, EPROM chips are formatted and all files are transferred to and from . This section is especially useful in performing EEPROM back-ups to the ’s hard-disk files. USER is specified in the section command to download or upload all of the above sections (with the exception of  FORMAT and TOTD). It is similar to the ALL command, except it does not format the EEPROM chip or overwrite the totalizer data. This section is useful in downloading the "user" modifiable files at unit start-up or when changes to multiple sections have been performed. The following are examples in using the