GEK-114902 OC6000e System Manual - V2.0

GE Energy
OC 6000e
System Manual
GEK-114902
Version No.2.0
These instructions do not purport to cover all details or variations in equipment, nor to
provide for every possible contingency to be met during installation, operation, and
maintenance. The information is supplied for informational purposes only, and GE makes
no warranty as to the accuracy of the information included herein. Changes,
modifications and/or improvements to equipment and specifications are made
periodically and these changes may or may not be reflected herein. It is understood that
GE may make changes, modifications, or improvements to the equipment referenced
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further information is desired, or if particular problems arise that are not covered
sufficiently for the purchasers purpose, the matter should be referred to:
GE Energy
Control Solutions
1800 Nelson Road
Longmont, CO 80501
energy.controlsolutions@ge.com
http://www.ge-energy.com/oc
Phone: + 1 (800) 835-5182, United State)
+ 1 (970) 461-5201 (International)
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Safety Symbols
Indicates a procedure or condition that, if not strictly

observed, could result in personal injury or death.
Indicates a procedure or condition that, if not strictly

observed, could result in damage or destruction of
equipment.
Indicates a procedure, condition, or statement that should

be strictly followed in order to optimize these applications.
Note Indicates an essential or important procedure or statement.
Tip Provides essential information that is not normally defined in regular use
but from an experienced user.
Contents
Chapter 1 OC 6000e System Introduction 1
1.1 OC 6000e overview 1
1.2 OC 6000e System Architecture 3
1.3 System feature or specification 4
1.4 Hardware Summary 5
1.4.1 OC 6000e IO Module Summary 7
1.4.2 OC 6000e Communication Module Summary 9
1.4.3 Controller 11
1.4.4 HMI 11
1.4.5 Printer 12
1.4.6 IONet Switch 12
1.4.7 UDH Switch 13
1.4.8 Console 13
1.5 Software 13
1.5.1 OS 14
1.5.2 Platform Software 14
1.5.3 Application Software 14
1.6 Certification and standards 14
Chapter 2 System configuration via requirement 15
2.1 Hardware configuration calculation 15
2.1.1 Controllers 15
2.1.2 I/O modules 15
2.1.3 Communication modules 15
2.1.4 Cabinets and accessories 15
2.2 HMI 16
2.3 UDH Network switches 16
2.4 Other equipment 16
Chapter 3 Engineering Design: hardware 17
3.1 System arrangement 17
3.2 Signal assignment 17
3.3 Cabinet assembly 17
3.4 IO Network switch arrangement 19
3.5 System Network Topology 20
3.6 Power Distribution in cabinet 20
3.7 System Power distribution 22
3.8 Power Distribution Cabinet 22
3.9 Grounding 23
3.9.1 Cabinet Grounding 23
3.9.2 Signal grounding 24
3.9.3 System grounding 25
3.10 Field Signal Cable and wiring 26
3.11 Interface 29
3.11.1 Information communication 29
3.11.2 Control signal connection 29
3.11.3 Signals between subsystem 29
Chapter 4 Engineering Design: IP address assignment 30
4.1 Node number 30
4.2 Node IP Address 30
GEK-114902 OC6000e System Manual i

4.3 IP address setup 30
Chapter 5 Engineering Design: Naming 32
5.1 Signal Tag 32
5.2 System Device Tag 32
Chapter 6 Engineering Design: HMI graphic 34
6.1 HMI Graphic Layout 34
6.2 Menu 35
6.3 Default Color Definition 35
6.4 System Objects 37
Chapter 7 Controller Software design 38
7.1 Page and block definition 38
7.2 Cycle time 38
7.3 Page logic and algorithm 38
Chapter 8 Alarm 39
Chapter 9 Safety Design 40
9.1 Fail-Safe 40
9.2 Project design and commission 40
9.3 Password 40
Chapter 10 Installation 41
10.1 Standard Cabinet Dimension 41
10.2 Installation conditions 41
ii GEK-114902 OC 6000e System Manual

Chapter 1 OC 6000e System Introduction
1.1 OC 6000e overview

OC 6000e is a new generation of Distributed Control System by GE Energy, which is
based on OC 4000 and Mark VIe systems and combines with years of XinHua DCS
engineering experience.
GE Energy has more than 100 years of experience in the area of electricity. Since 1884
GE Energy provided the first turbine generator, GE Energy constantly develops new
technology; the product line covers steam turbine, gas turbine, generator, wind
generator, water turbine and so on. At the same time, GE Energy provides auxiliary
control systems for main equipment including Mark series controllers, Woodward
controller, Bently conditioning monitor equipment, and EX2100 excitation controller, etc.
The OC 6000e system is an integrated control platform with high-performance and
highly reliability. It highlights the following technical features in the system design:
1) The Brand new controller and I/O module design
Adopting high performance 667 MHz controller - UCSA, the controller's software
platform adopts the QNX real-time operating system and achieves high-speed logic
operation and the millisecond clock timing function.
2) High-efficiency network communication and time synchronization function
OC 6000e control network and I/O network are 100 M high-speed Ethernet. Controller
and the I/O modules communicate directly via Ethernet to reduce the number of
intermediaries and time delay. At the same time the I/O network is based on IEC1588
protocol, which achieves 0.1ms accuracy of time synchronization between all I/O
modules.
3) Various communication interfaces to other systems
The MCI communication modules provide interfaces between OC6000e and other
system, including RS-232C, RS-485, RS-422 and Ethernet. General communication
protocols are supported, such as Modbus and IEC60870-5-104.
4) Compact system layout
The new I/O module and terminal board interfaces with a whole set of components, the
filed signal cables connect directly to the terminals of I/0 components. A reduction in the
number of cabinets lowers the space requirements of the central control room, thus
reducing the total cost of customer installation.
5) Reliable system design
In order to improve the reliability of the system, reliable design and relevant
experimental verification are widely used in the system development and the
manufacturing process. Prior to system design each module undergoes a rigorous test
of the HALT (highly accelerated life test) to ensure quality and reliability of the module
design. System design and manufacture complies with CE, CSA certification and other
related requirements.
GEK-114902 OC6000e System Manual 1

6) Compatible integration platform
OC 6000e is compatible with GE Energy Control Products integration solutions. This
includes both the integration and integration features.
First, the control network adopts the GE standard EGD protocol. GE Energys different
control products can have unified communication protocol to allow exchange of data.
Second, OC 6000e software integrates with optimization interface, which allows it to
connect with optimization software at plant-level and unit-level.
Third, IONet and IO module are fully hot swappable.
Fourth, OC 6000e software is compatible with Mark Vie IO and OC 6000e IO.
OC 6000e system architecture is divided into three levels: human-machine interface
level, process control level and the process of input/output (I/O) level.
Human-machine interface level
Human-machine interface refers to the ability to monitor and control using a Windows-
based platform, including operator station, engineer station, historical data station and
process optimization station. All human-machine interface stations are backups to each
other; users can modify the software settings and user privileges to change the human-
machine interface functions.
The human-machine interface level and the control level communicate through the
redundant process real-time control network. This is called the UDH network.
All nodes on the network use NTP protocol.
A NTP server is connected on the UDH and usually connected to a GPS receiver.
Process control level
The process control level is the redundant controller based on the QNX platform, which
effectively integrates main existing products of GE Energy in a public platform and offers
solutions for the integration of the entire plant.
Process input/output (I/O) level
The I/O level uses distributed modules via high-speed Ethernet to connect to the process
control. Distributed architecture enables users to place the I/O modules anywhere in the
factory based on the physical location of the equipment, thus minimizing signal cable
requirements, reducing installation costs, and effectively reducing the electromagnetic
interference that can exist in long-distance signal transmission. All I/O modules adopt a
no-jumper design concept, and module configuration is determined by specialized
software, which improves the reliability and user-friendliness.
The OC 6000e and Mark VIe system use the same controller. The I/O modules on the I/O
network level are fully compatible between these two systems, making them capable of
swapping. (Physical size and appearance are different however)
Users can choose Mark VIe triple redundant modules to control the critical components
to result in triple redundant control of high priority installations. An original system
installed with Mark VIe, OC 6000e may be easily upgraded.
Communication: supporting Modbus, IEC60870-5-104 or OPC communication through
special module or HMI.
OC 6000e software includes OC 4000 system softwares features of being intuitive and
easy-to-use. The unified system software achieves continuity of the system and logic
2 GEK-114902 OC 6000e System Manual

configuration. Users will use a single software system to complete the tasks of network
configuration, user management, controller configuration, I/O module parameters and
controller programming, and many other functions.
The real-time database is capable of detailed name and description of the control points.
The controller generates all the data recorded and users can directly read from the
controller and modify the process data and information.
OC 6000e software widely adopts the design of the ActiveX control technology. Users
are able to easily integrate the functions of various systems to the Web environment, to
view the remote access process data.
1.2 OC 6000e System Architecture

OC 6000e system architecture is shown below. This configuration is for one unit.
Figure 1.2-1 OC6000e Architecture

Different nodes on the system are listed below:
HMI:
OPU: Operator unit. For process monitoring and control.
ENG: Engineer unit. For configuration and system maintenance.
HSU: Historical unit. For historical recording.
Process control level and Process input/output (I/O) level:
UCSA: Controller
MAI10: Analog Input, mA/V type, 16 channels
MAI20: Analog Input, TC/RTD type, 16 channels
MAO10: Analog Output, mA/V type, 8 channels
MDI10: Digital Input, 16 channels
MDO10: Digital Output, 16 channels
Communication module:
MCI10: Serial communication, 7 port RS-485 and 1 port RS-485/RS-422
MCI11: Serial communication, isolated 3 port RS-485 and 1 port RS-485/RS-
422
MCI12: Serial communication, isolated 7 port RS-485 and 1 port RS-485/RS-
422
MCI20: Serial and Ethernet communication, 2 port Ethernet and 3 port RS-232
UDH Network:
Industrial Ethernet switch
IO network:
Industrial Ethernet switch
Power Supply:
24VDC power supply
1.3 System feature or specification

Table 1.3-1 System feature or specification
Item Specification
System ambient temperature 0 to 60C
System ambient humidity 10 to 95% Non-Condensing
Total points in one system no more than 64,000
Total control drops in one system no more than 160
Total HMI in one system no more than 80
SOE 1ms
Controller 667MHz, 13.55W
Real time operating system QNX
Power rating for each cabinet 110-240V~, 50Hz/60Hz, <500W

1.4 Hardware Summary
The items in this list are validated to sale to customer.
Table 1.4-1 I/O Modules list

Item Model Name PN Specification
1 MAI10 16 mA/V Analog Input Module 369B1841G5001 16 channel mA/V analog input
with individual ADC & DC/DC
2 BAI10 16 AI Base Board 369B1868G5001 Baseboard for MAI10
3 MAI20 16 TC/RTD Analog Input Module 369B1841G5002 16 channel TC/RTD analog input
with individual ADC & DC/DC
4 BAI20 16 TC/RTD Base Board 369B1867G5001 Baseboard for MAI20
5 MAO10 8 Analog Output Module 369B1842G5001 8 channel mA/V analog output
6 BAO10 8 AO Base Board 369B1871G5001 Baseboard for MAO10
7 MDI10 16 Digital Input Module 369B1843G5001 16 channel Digital input
8 BDI10 16 DI Base Board 369B1873G5001 Baseboard for MDI10
9 MDO10 16 Digital Output Module 369B1844G5001 16 channel Digital output
10 BDO10 16 DO Relay Base Board 369B1874G5001 Relay Baseboard 250VAC/5A
11 MSP10 Speed Measure and Protection 369B1851G5001 Up to 20KHz frequency input,
Module 0.1Hz precision
12 BSP10 MSP10 Base Board 369B1879G5001 Baseboard for MSP10
13 MVP10 Valve Position Control Module 369B1848G5001 2 AI, 2 LVDT, 2 +/-40mA Servo
40mA 369B1848G5003 Valve output
369B1848G5005
14 MVP11 Valve Position Control Module 369B1848G5002 2 AI, 2 LVDT, 2 +/-400mA Servo
400mA 369B1848G5004 Valve output
369B1848G5006
15 BVP10 Valve Position Control Base 369B1878G5001 Baseboard for MVP
16 MAI12 16 mA/V Analog Input Module 369B1841G5003 16 channel mA/V analog input
17 BAI11 16 AI Base Board 369B1868G5002 Baseboard for MAI12
18 MAI22 16 TC/RTD Analog Input Module 369B1841G5004 16 channel TC/RTD analog input
19 BAI21 16 TC/RTD Base Board 369B1867G5002 Baseboard for MAI22
20 BAO21 8 AO Base Board 369B1871G5003 Baseboard for MAO10, signal
power supply
21 MDI12 24 Digital Input Module 369B1843G5002 24 channel Digital/Pulse input
22 BDI11 16 DI Base Board 369B1873G5002 Baseboard for MDI12
23 MDO11 16 Digital Output Module 369B1844G5002 16 channel Digital output
24 BDO11 16 DO Base Board 369B1874G5002 Baseboard for MDO11, with relay
extension port
25 BDO12 16 DO Relay Board, AC 369B1874G5003 16 relay output, 1NO/1NC for
each DO, 10A@250VAC
26 BDO20 16 DO Relay Board, DC 369B1874G5004 16 relay output, 1 contact for
each DO, 10A@220VDC
Table 1.4-2 Communication Modules list

1 MCI10 8-port RS-485 communication 369B1860G0020 7-port RS-485 and 1-port RS-
module 485/RS-422

2 MCI11 4-port isolated RS-485 369B1860G0021 3-port isolated RS-485 and 1-
communication module port isolated RS485/RS422
3 MCI12 8-port isolated RS-485 369B1860G0022 7-port isolated RS-485 and 1-
communication module port isolated RS-485/RS-422
4 MCI20 2-port Ethernet communication 369B1860G0023 2-port Ethernet and 3-port RS-
module 232C
5 MDP10 2-port Profibus-DP master module 369B1860G0024 2-port Profibus-DP master
6 MDP11 1-port Profibus-DP master module 369B1860G0025 1-port Profibus-DP master
Table 1.4-3 Outsourced Items list

Item Model Name Specification
1 CAB10 Universal Cabinet (800x600x2000) DCS control cabinet, WxDxH=800x600x2000mm
2 220V AC Power Distribution Box Two 220V AC input switch and distribution
3 PSA30 Power Supply 24V DC Input 100-240VAC; Output 24VDC@20A
4 UCSAH1A UCSA (Controller with QNX 6.3.0 Processor: Freescale 8349, 667MHz; 5 Ethernet;
OS) 128MB DDR RAM; CF 128MB
5 Industrial Ethernet Switch RJ45 Ethernet, Auto-sensing 10/100 Base TX
Table 1.4-4 Parts made by GE Bently

1 ETS-CPU BN3702ETS-CPU BN-177933-01 ETS Controller
2 ETS-DI BN3702ETS-DI BN-177934-01 24 DI and 2 Speed
3 ETS-DO BN3702ETS-DO BN-177935-01 8 DO
4 ETS-BASE BN3702ETS-BASE BN-177936-01 1CPU/2DI/1DO slots
5 Voting- 2oo3 Voting extend relay module BN-178778-01 2oo3 Voting, 4x220V AC/DC@3A
Relay Output
Table 1.4-5 General Peripheral list

Item Name Specification Remark
1 Industrial Ethernet Switch 100Mbps Ethernet switch e.g.
Hirschman/MOXA brand switch
3 Industry Computer General equipment
4 LCD General equipment
5 Serial port server General equipment e.g. Nport 5430i
6 GPS General equipment NTP Server
Table 1.4-6 OS & Software list

Item Name Specification
1 Window XP (English Version) For English User, CD ROM
2 Window XP (Chinese Version) For Chinese User, CD ROM
3 Office 2007 (English version) For English User, CD ROM
4 Office 2007 (Chinese version) For Chinese User, CD ROM
5 OC 6000e HMI software package Multilingual, CD ROM
6 OC 6000e Controller software package Multilingual, CD ROM
7 Hardware Key for OC6000e HMI Hard dog, Parallel Port or USB

1.4.1 OC 6000e IO Module Summary
1.4.1.1 Module assemble
This section gives a brief introduction of hardware. For details, please see GEK-114903
OC6000e Hardware Manual.
Each OC 6000e IO function consists of two parts: one module and one baseboard.
Each module has two Ethernet and one or two 24VDC power supply input.
Ethernet, power connector, wiring terminators are mounted at baseboard.
Module is plugged on the baseboard.
DIN/bolt mounted to baseboard.
Module dimension: 132x66x154mm (HxWxD)
Standard Baseboard Dimension: 127x175x56mm (WxLxH)
Double dimension baseboard: 127x350x56mm (WxLxH)
Figure 1.4-1 OC6000e module

Figure 1.4-2 OC6000e module assembly
1.4.1.2 Module overview

Analog Input for mA and Voltage signals
A MAI10 module and a BAI10 Baseboard (or MAI12 with BAI11) combine in the
mA/Voltage signal I/O module.
Table 1.4-7 mA/V input main specification
Item Specification
MAI10 MAI12
Channel 16
Input type 0-5V/1-5V/5V/10V or 0-20mA/4-20mA
Input converter resolution Individual ADC, 24 bit Group ADC, 16 bit
Measurement accuracy <0.1% full scale
Common Mode Rejection Ratio 120dB at 250VAC common mode voltage
Normal Mode Rejection Ratio 60dB at 50/60Hz with amplitude of half of full scale
Temperature sensor TC/RTD signals input

A MAI20 module and a BAI20 Baseboard (or MAI22 with BAI21) combine in the TC/RTD
I/O module.
Table 1.4-8 Temperature input main specification
Item Specification
MAI20 MAI22
Channel 16
Input type RTD of Pt10/Pt100/Cu100/Cu50 or
TC of T, J, E, K, N, B, R, S
Input converter resolution Individual ADC, 24 bit Group ADC, 24 bit
Measurement accuracy <0.2% full scale
Common Mode Rejection Ratio 120dB at 250VAC common mode voltage
Normal Mode Rejection Ratio 60dB at 50/60Hz with amplitude of half of full scale

Analog Output
A MAO10 module and a BAO10 (or BAO21) baseboard combine in the analog output I/O
module.
Table 1.4-9 MAO10 main specification
Item Specification
Channel 8 independent & isolated channel
Output type 0~5V/0~10V
0-20mA/4-20mA with max load resistor 750ohm
DA converter resolution 12 bit digital to analog converter
Accuracy <0.2% full scale
Digital Input and SOE

A MDI10 module and a BDI10 Baseboard (or MDI12 with BDI11) combine in the digital
input I/O module.
SOE function is executed by DI module. DI module can be used as PI.
Table 1.4-10 Digital input main specification
Item Specification
MDI10 MDI12
Channel 16 24
Input type Dry contact input; sink or source input; 24V DC
SOE 1ms
Pulse input 0~200Hz, min width 2ms 0~5kHz, min width 80us
Digital Output with relay Extension

A MDO 10 module and a BDO 10 Baseboard combine in the digital output I/O module.
Table 1.4-11 MDO10 main specification
Item Specification
Channel 16 independent & isolated channel
Output type 1 NO/NC/C with 250VAC/5A per channel
Alternative selection is using one MDO11 and one BDO11 with extension relay board for
relay output. 2 types of relay board are available, BDO12 for AC circuit with
10A@250VAC load capacity and BDO20 for DC circuit with 10A@220VDC load capacity.
1.4.2 OC 6000e Communication Module Summary

1.4.2.1 Module assemble
This section gives a brief introduction of hardware. For details, please see GEK-114903
OC6000e Hardware Manual.
Each OC 6000e communication module consists of three parts: one processor board,
one or two expansion boards and one terminal board.
Each module has dual Ethernet and dual 24V DC power supply input.

Ethernet, power connector, wiring terminators are mounted at internal terminal board.
DIN -mount is supported.
Module dimension: 165x121x87mm (H x W x D)
Figure 1.4-3 MCI communication module
1.4.2.2 Communication module overview

Serial communication module
Table 1.4-12 MCI10 main specification

Item Specification
Number of COM ports 7 RS-485 ports and 1 RS-422/485 port
Baud rate 9600bps, 19200bps at 3000 points
Protocol to other system Modbus or IEC60870-5-104

Item Specification
Number of COM ports 3 isolated RS-485 ports and 1 isolated RS-422/485 port

Item Specification
Number of COM ports 7 isolated RS-485 ports and 1 isolated RS-422/485 port
Item Specification
Number of Ethernet ports Dual 10M/100M Base-T Ethernet
Number of COM ports 3 RS-232C ports

1.4.3 Controller
Single board including:
Main Processor
Control Network 2 Ethernet
IO Network 3 Ethernet
USB and COM ports
Processor: Freescale 8349, 667MHz, 3.3W
Operating system: QNX
Convenient Din rail or Base mounting
Status LED
Watchdog/diagnostics
Memory
128 MB ECC DDR333 RAM, expandable to 512MB
64MB Configuration Data Flash
32 KB Flash Backed NVRAM
Power consumption: 13.55W
Power supply: 20~28VDC
Fig 1.4-4 OC6000e Controller
1.4.4 HMI
Minimum computer requirement of HMI is listed below.
Table 1.4-16 Computer requirement of HMI
Item OPU HSU ENG INT
CPU 2.0G Hz 2.0G Hz 2.0G Hz 2.0G Hz
RAM 512MB 1GB 512MB 512MB

HDD 40G 120G 40G 40G
Network ports 2 2 2 4
Network card 100Base T 100Base T 100Base T 100Base T
Video RAM 64MB 64MB 64MB 64MB
Media DVD-R DVD-RW DVD-RW DVD-R
Operating system Win XP Win XP Win XP Win XP
Office software N/A Office 2007 N/A N/A
1.4.5 Printer
Any generic printer can be used in the system. A color laser printer is recommended.
1.4.6 IONet Switch

Industrial Ethernet Switch is used for IONet switch. Based on the number of modules in
each side of cabinet, 8 ports or 16 ports could be selected.
Note:
The switch on the front side of the cabinet should be set based on the number of
Ethernet ports counting 2 ports of UCSA for each IP and n ports for each link in addition
to IONet ports. (n is the number of additional switches) Link mode refers to chapter 3.4
IO Network switch arrangement.
For example, N-Tron network switch model is as below.
Table 1.4-17 N-Tron Ethernet switch specification
Model Name Specification
508TX 8 Ports, Ethernet N-Tron 508TX 8 Port RJ45 Ethernet, Auto-sensing 10/100 Base TX
516TX 16 Ports, Ethernet N-Tron 516TX 16 Port RJ45 Ethernet, Auto-sensing 10/100 Base TX
Specification:
Operating Temperature: -40 to 85C
Operating Humidity: 10 to 95% Non-Condensing
Shock: 200g @ 10ms
Vibration / Seismic: 50g, 5-200Hz, Tri-axial
MTBF: > 2M hours
Auto-sensing 10/100 Base TX, Duplex, and MDIX
Up to 2.6Gb/s, High Speed Backplane
Steel Enclosure, Prevents EFI and RFI
DIN-Rail or Rack Mounted
Redundant Power Inputs 10-30Vdc,

Figure 1.4-5 N-Tron 516TX switch
1.4.7 UDH Switch

An Industrial Ethernet Switch should be used for the UDH switch, e.g. Hirschman, D-Link,
3Com, SMC or some other qualified switch.
1.4.8 Console
Operation console is usually a customized design.
We suggest a console pattern as shown in the below picture.
This recommended console item code is: 267B6530G0006
Figure 1.4-6 OC 6000e operation console
1.5 Software
Software should be supplied with system delivery to end user customer.

1.5.1 OS
Each Controller needs one QNX real time operating system. It is associated with the
UCSA controller.
Each HMI computer needs one Windows XP professional operating system.
An MS office package (2007 or better) is needed for each report server or HMI which
needs to configure or communicate with the report server.
1.5.2 Platform Software

The platform software should be supplied for each UDH station Controller &
HMI/Server.
A common platform HMI software package is supplied for all kinds of HMI. The only
difference is when the computer configured as a separate HMI runs the corresponding
function software. ENG can run all functions while OPU runs the higher level function.
Controllers must have the same controller platform software installed.
1.5.3 Application Software

Application Software is designed by the application engineer to address the system
control functions and safety requirements.
It includes two aspects:
HMI Graphics.
Controllers Logic: each redundant controller has a control algorithm and control
logic communicating with their I/O modules and HMI to complete functions.
1.6 Certification and standards

Chapter 2 The product designs abide by international, domestic and industrial
standards and specifications for relevant products.
Chapter 3 FCC and CE certificate has been approved.
Chapter 4 Pollution Degree 2 (as defined in IEC 61010-1).

Chapter 2 System configuration via requirement
To configure specific project hardware, the following steps could be used to roughly
calculate system components. Additional hardware could be included according to
customer requirements based on some special functions.
2.1 Hardware configuration calculation

Controller, its I/O modules and cabinet number are calculated according to the IO
quantity and design limits.
2.1.1 Controllers
Generally, the controllers are always configured as redundant.
2.1.2 I/O modules

Each module is calculated by the formula below. Every module needs the corresponding
Baseboard to match.
AI = (Quantity of mA/V input signals)*(1+spare channel rate)/16
AI_T = (Quantity of TC and RTD signals)*(1+spare channel rate)/16
AO = (Quantity of mA/V output signals)*(1+spare channel rate)/8
DI10 = (Quantity of Digital input signals)*(1+spare channel rate)/16
DI12 = (Quantity of Digital input signals)*(1+spare channel rate)/24
DO = (Quantity of Digital output signals)*(1+spare channel rate)/16
2.1.3 Communication modules

Both the whole communication modules and single communication port can be
configured as redundant.
2.1.4 Cabinets and accessories

Except for the controller that is calculated at the above and not equipped with extension
cabinet, each basic cabinet should have the following equipment and accessories.
Equipment (these are to listed in BOM)
One cabinet framework
Two redundant 24V DC power

Two or four IONet switches (one cabinet side needs two)
Accessories (These are included in the cabinets and not listed in the BOM)
AC power circuit breakers and filters
Grounding bars
IONet cables
DC power distribution terminals and cables
Air filters
Each cabinet can install up to 27 IO modules (DO module occupies 2 positions of
standard modules)
Cabinet quantity is calculated as below:
Cabinets = (AI+AI_T+AO+DI10+DI12+2*DO+BDO20)*(1+spare space rate)/27, here BDO20
is the quantity of DC Relay module
24V DC Power supply= cabinets*2
16 ports IONet switches= Cabinets*4
2.2 HMI
HMI is normally determined by the customer operation requirements. It is
recommended at least one ENG and two OPU per system.
Table 2.2-1 Typical HMI quantity for one 300MW unit power plant
HMI ENG HSU GTW OPU
Quantity 1 1 2 4-5
Note:
1) GTW is a HMI like computer used for communication with other systems. This task
could be done by the other HMI. It is dependent on customer requirements.
2) Each HMI should include not only hardware but also software, such as windows,
office etc. Refer to Chapter 1.5 Software for detail.
2.3 UDH Network switches

Select industrial Ethernet Switch for UDH network switch.
For example, Hirschman switch, type: RS2-1600M, including 16 RJ45 ports and 2 fiber
optic ports. The quantity is calculated as below:
UDH Network Switch = 2*(HMI + UCSA + spare ports) /14
2.4 Other equipment

Other equipment, such as optic transceiver, gateway, and safety barrier are to be
determined by project requirements.

Chapter 3 Engineering Design: hardware
System design must ensure that:

Any hardware and software faults should not endanger human safety or integrity of
power systems.
A fault on any unit anywhere should not cause production equipment to go to an unsafe
mode.
If the equipment is used in a manner not specified by the

manufacturer, the protection provided by the equipment may
be compromised.
3.1 System arrangement

Cabinets controlling the processing related equipment are arranged one after another.
According to location of control equipment, cabinet may be located at different sites.
They should be relatively close and organized as cabinets groups. They must be kept a
clean and air condition environment.
3.2 Signal assignment

Important redundant input signals should be receive their input from different input
modules.
3.3 Cabinet assembly

The standard cabinet dimension is 800x600x2000mm.
There are two kind of basic I/O cabinet:
Control Cabinet: Cabinet with controllers.
I/O Extension Cabinet: Cabinet without controllers.
The only difference is the I/O extension cabinet has no controllers
Basic cabinet assembly layout is shown in the below figure.

Figure 3.3-1 Cabinet assembly layout
The cabinet is described as follows:

A/B Columns are two vertical areas from left to right in the front side while C/D columns
are the same areas in the rear side. From top to bottom, each column is divided as I/II
and row1~7 horizontally.
AI includes AC distribution box including circuit accessory and breakers for the cabinet.
AII is a pair of redundant controllers. For extension cabinet, with no controller installed,
this area remains empty.
BI includes dual-redundant 24V DC power supplies for the cabinet.
BII is two IONet switches for the front panel modules.
CI~DI is DC distribution terminals.
CII is empty normally. Two optical fiber switches are installed here if remote I/O modules
are connected to this controller.
DII is two IONet switches for the rear panel modules.

A1~A6, B1~B7, C1~C7, D1~D7 are all for I/O modules. There is an external cable tray and
grounding bar at the left of an I/O module column. An internal cable tray is installed in
the right of the I/O module column.
A7 is used for power supply input terminals.
Each module needs one standard position except MDO10, which need 2 positions.
Maximum module positions in front side are 13, rear side 14.
DO modules usually drive high voltage device. To separate high/low voltage cables in a
cabinet, MDO10 module should be assigned in one column if possible. If DO modules
must mix with other low level modules in one column, they should be put at the lower
area of the column. In this case, high voltage cables go through the right half of the tray
while the lower signal cables use the left half tray. The tray is separated into left and
right sections by a metal shield plate.
3.4 IO Network switch arrangement

Net switches in rear side cascade connections to the switches in front side.
Controller IO net ports connect to front side switches.
Front side switches in extended cabinet connect to front side switches in controller
cabinet
Three-level switches cascading in series is not recommended for I/O modules where
precision time synchronization is required, for example SOE function.
Figure 3.4-1 IO network switch arrangement

3.5 System Network Topology
For redundant system UDH network with high-speed industrial switches.
Network topology example for one unit and a common system is shown below.
Figure 3.5-1 System network topology
3.6 Power Distribution in cabinet

All components in OC 6000e cabinet use 24VDC power supply. Each cabinet uses two
220VAC power supply inputs, by connecting the following AC distribution Box, the power
supplies then feed the DC modules.
Figure 3.6-1 AC distribution box assembly

The scheme below shows the internal wiring connection.
Figure 3.6-2 AC distribution box connection
The 24VDC power supply distribution is as following diagram.
Figure 3.6-3 24VDC power supply distribution
Two separate AC power supply inputs are connected to two redundant DC power supply
modules and then go from the DC to controllers and IO modules and switches.
All IO modules have two separate DC power supply inputs.

Proper fuse should be installed between DC power supply
module and IO modules. Fuse (20*5, 3A) is recommended for
this purpose.
3.7 System Power distribution

The system is powered with two independent redundant power supplies. The topology is
shown in the following figure.
It is recommended that at least one power supply comes from UPS system.
Figure 3.7-1 System power supply distribution
3.8 Power Distribution Cabinet

The above power distribution system originates from the Power Distribution Cabinet or
Panel. Generally, if a system has more than 10 cabinets, then an independent Power
Distribution cabinet is needed. For small system, the distribution is supplied by the
customer.
The Power Distribution Cabinet requires two independent power inputs from the
customer.
It distributes power to cabinets and equipment such as HMI.
Necessary alarms and circuit protection and switch over must be provided.
A maximum 80 breakers and 40 output loops (redundant outputs) can be supplied.

Figure 3.8-1 Power distribution cabinet
3.9 Grounding
3.9.1 Cabinet Grounding
There are two kinds of grounding in the cabinet.
FE is signal reference ground. This is for module and signal shield grounding.
PE is protection ground. This is for cabinet frame grounding.
In each cabinet, FE and PE must be insulated from each other. They are connected at
one point and then to the total grounding point.
Cabinet internal ground is arranged as in the drawings.

Figure 3.9-1 Cabinet grounding
3.9.2 Signal grounding

OC 6000e IO module uses a direct grounding contacting spring that can establish a solid
connection to the main ground plate.
Signal shield is connected at the grounding bar near I/O module wiring terminals. It is
disconnected at the signal end.

Figure 3.9-2 Signal grounding
3.9.3 System grounding

The grounding system is a kind of single point grounding system. All I/O cabinets should
be connected to the system grounding point by grounding cable.
The system adopts star-type connection to unit grounding point through grounding bar
box.
The grounding resistance between cabinet grounding bar and unit grounding grid must
not be greater than 2.5 Ohm.
Recommended grounding cable must meet the following specifications:
No less than 10mm2 between cabinet.
No less than 20mm2 between cabinet and system grounding bar.
No less than 90mm2 between system grounding bar and plant grounding grid.
Metal Control console and remote control cabinet connect to nearest grounding point.

Figure 3.9-3 System grounding
3.10 Field Signal Cable and wiring

Field cables and wirings are supplied by customer.
It is recommended that:
Analog signal cable should be shielded for every pair of signal wires and a total
shield must be provided for the entire cable.
Any Digital signal cable must have the whole cable shielded.
For AI/TC/RTD/AO/DI signal cable, 1.5 mm2 is proper for distance within 100 meters
or 2.5 mm2 is needed for distances greater than 100 meters.
For DO outputs, usually a high voltage and large current device is connected to. The
cable should be selected within these parameters.
Different field signals are connected to terminals as follows:

mA/V signal (MAI10/MAI12)
Figure 3.10-1 mA/V signal wiring
TC/RTD Signal (MAI20/MAI22)
Figure 3.10-2 TC/RTD signal wiring
AO Signal (MAO10)

Figure 3.10-3 AO signal wiring (BAO10)
Figure 3.10-4 AO signal wiring (BAO21)
DI/PI Signal (MDI10/MDI11)
Figure 3.10-5 DI signal wiring (BDI10)
Figure 3.10-6 DI signal wiring (BDI11)
DO Signals (MDO10)

Figure 3.10-7 DO signal wiring (BDO10/BDO12)
3.11 Interface
3.11.1 Information communication
Information is shared with other system/device.
The standard communication interface could be used for data communication with
other control systems or devices to sharing information among different control
platforms.
It is not recommended to communicate control commands through communication
between different platforms.
When communicating plant information or office automation system, a firewall is a
must. The information can only be sent out from DCS. Receiving from outside to DCS is
not allowed or supported.
3.11.2 Control signal connection

Control signals interfacing to third-party systems or protection systems must use
hardwire connection.
3.11.3 Signals between subsystem

Within the same platform when communicating different control functions, all
information and control instruction should be transferred through UDH networks.
Any protection signal must also be connected through hardwire.

Chapter 4 Engineering Design: IP address
assignment
4.1 Node number

All the Nodes on UDH should be configured with a unique ID number by the engineer.
The ID must follow the rules specified below:
Table 4.1-1 Node number list

Type R S T
Controller 1 ~ 80 101 ~ 180 201 ~ 250
HMI 81 ~ 100, 181 ~ 200 - -
R, S, and T are for redundant controller. 1-50, 101-150, 201-250 are for triple redundant
controllers, for example, 1, 101 and 201 are a triple redundant controller. 51-80, 151-
180 is for a dual redundant controller, and, 51 and 151 are dual redundant controller.
Nodes for triple redundant controller can also be used for dual redundant controller, for
example, 50 and 150 are for dual redundant controller.
Note: DCS and DEH/ETS controller could be assigned a fixed number that is coordinated
by engineers.
4.2 Node IP Address

All node IP addresses must follow the rules specified below:
Table 4.2-1 Node IP address list
Type UDH Net A UDH Net B IO Net A IO Net B IO Net C
Controller 192.168.101.x 192.168.102.x 192.168.1.x 192.168.2.x 192.168.3.x
HMI 192.168.101.x 192.168.102.x - - -
IO Module - - 192.168.1.x 192.168.2.x 192.168.3.x
Note: For HMI and controller, "x" is the node number. For IO module, "x" is a number
starting with 21. IO module IP addresses are automatic configured by UCSA.
4.3 IP address setup

Select network management switch for UDH network. After setting IP address, each
switch can be easily accessed by IE on any HMI.
The UDH network switch IP address can be set by the firmware installed, or by serial
connection as below.

For example, for Hirschman network switches RS2-16MM series, the IP address is set by
the following steps:
1) Prepare a serial communication cable (cable is available from Hirschman dealer).
2) Connect the serial ports of switch and a computer by using the cable.
3) Start hyper terminal from the computer.
4) Set the serial communication parameters as follows:
Port: Com1 (choose the connecting port of computer)
Bits per second: 9600
Data bits: 8
Parity: None
Stop bits: 1
Flow control: None
5) Start the connection, when prompted for a user and password, input "private" as the
password.
6) After login, select "Setting IP address". For the switch for network A it is recommended
to use "192.168.101.x" while network B is "192.168.102.x", where, "x" is recommended to
start from 201.
Save the setting and restart the switch, the IP address should be set and can be
accessed from IE by using the address.

Chapter 5 Engineering Design: Naming
5.1 Signal Tag

Maximum signal tag length is 29 characters (including letter, number, dot and underline)
or 14 Chinese characters (each Chinese character occupies two bytes). Comma, space
or other special ASCII characters such as ~!@#$%^&*+\?/(=)<> are not allowed.
Maximum signal tag description length is 95 characters (including letter, number, dot,
underline and so on). Comma is not allowed.
I/O point tag name and description should be used based on customer specs. Usually
the tag name is the KKS code of the signal that the design specs or customer supplied.
5.2 System Device Tag

Name a device or component in the system so it is convenient to recognize the device
based on its name.
A template is suggested as follows for a fossil steam power plant:
Device name template: ABBCCCDD
The First Group (ABB) Unit Description

A means
U Unit
C Common system
B Boiler Only
T Turbine Only
G Generator Only
BB means series number. For example: 01 means unit 1.
The Second Group (CCCDD) Subsystem Description

CCC means
DAS Data Acquisition System
MCS Modulate Control System
SCS Sequence Control System
BMS Boiler Management System
FSSS Furnace Safeguard Supervisory System

ECS Electric Control System
DEH Digital Electro-Hydraulic Control System
MEH Micro-Electro-Hydraulic Control System
ETS Emergency Trip System
COM Common System
HMI HMI computer
FGD Flue Gas Desulphurization System
SCR Selective Catalytic Reduction System
DD means series number. For example: 01 means cabinet 1.

Chapter 6 Engineering Design: HMI graphic
6.1 HMI Graphic Layout

Two standard base layouts (Length: Height): 16:10 and 4:3, Recommended
resolution for 16:10 is 1680x1050; 4:3 is 1600x1200.
Recommended background color (RGB): 215,215,215
Recommend using default graphic objects.
Main graphic function (4:3)
A: Project name
B: Figure name
C: Menu navigation
D: Toolbar
E: Important signal display
F: Main process graphic
Figure 6.1-1 HMI graphic 43 Layout

Main graphic function (16:10)
A: Project name
B: Figure name
C: Menu navigation
D: Toolbar
E: Important signal display
F: Main process graphic
G: Alarm list
Figure 6.1-2 HMI graphic 1610 Layout
6.2 Menu
Maximum 4 level hierarchies can be defined, generally not to exceed 3.
First level: System Function
Second level: Process Function (Optional)
Third level: Sub Process Function (Optional)
Fourth level: Detailed Process Function (Optional)
Maximum of 32 items in each hierarchy (Items in sub hierarchy depends on the
hierarchy item numbers)
Distinguish each level by different colors.
6.3 Default Color Definition

Recommend using system default color during graphic design.
Recommend medium color

Figure 6.3-1 Recommended medium color
Recommended graphic color
Figure 6.3-2 Recommended graphic color

Recommended dynamic color

Figure 6.3-3 Recommended dynamic color
Recommended Button Design
Figure 6.3-4 Recommended button design
6.4 System Objects

Recommend using system default object library unless not defined.
Recommend using system predefined operation pane
Please see the HMI software object lab for details of above.
The engineer can suggest adding new objects to this lab.
The screens should be reviewed by the principle engineers and updated every
quarter.

Chapter 7 Controller Software design
7.1 Page and block definition

Maximum page number is 999.
Block assignment: done automatically.
Maximum block numbers in one page cannot exceed 300 for concise read.
Recommended capacity should not exceed 30%. This number is shown on upper
part of the control page dynamically as you configure the control algorithm.
7.2 Cycle time

Default I/O cycle time: 40ms.
I/O cycle time can be 20ms, 40ms, 80ms, 160ms. 20ms is for special rapid I/O, such as
turbine speed in turbine control system. 160ms is for slow signals and where load rate
decrease is preferred.
Default page cycle time: 200ms.
The software support cycle times of:
0ms, 10ms, 20ms, 40ms, 80ms, 200ms, 480ms, 1000ms, 2000ms, 5000ms, 10000ms,
60000ms, 600000ms.
80ms is recommended for small scale or when fast response is needed.
For especially fast control object, i.e. turbine control, 40ms is recommended.
Any time slower than 1000ms is not recommended for a control system.
Note: Setting page cycle time to 0ms means this page is not executed.
7.3 Page logic and algorithm

It is recommended that the software control logic for functional related equipment
or subgroup equipment is always configured in one page or consecutive several
pages.
Logic control page is suggested in the front of algorithm page.
Set the equipments control page sequence to be similar to the sequence of the
equipment in the real processing procedure.

Chapter 8 Alarm
The following runtime status items should always be alarmed and shown in HMI graphic.
The priority of these in the Alarm queue should always be the highest level: level 7.
When communication fails, communication will be repeated and an alarm shall be
sent out.
Failure of any AC or DC power supply
Failure of any DPU (Controller)
DPU temperature alarm
Cabinet temperature alarm
Loss of redundancy of Data Net on UDH
Loss of redundancy I/O network
Network cable and device fault
I/O module, terminal board failure
Failure of safety-related I/O modules/signals
Failure of safety-related redundant signals mismatch/deviation
Failure of TC compensation temperature

Chapter 9 Safety Design
9.1 Fail-Safe
In the process, some status of the equipment will have critical importance, depending
on equipment, operators or the whole process. For these processes, the power loop and
control loop must be designed to be "fail-safe" type.
When setting up you must first define what kind of status is "safe", and then ensure that
the design of the various fault conditions defaults to "safe" in case of failure. Various
fault conditions such as: loss of control system commands, loss of power, loss Gas (if the
Executive Cabinet for pneumatic).
9.2 Project design and commission

Establish a "fail-safe" concept; the system may clarify the existing risk. Be familiar
with the system of abnormal operation conditions. Be aware of the risk conditions of
the equipment.
Fully understand the field commissioning safety principles. When forcing the
function blocks or making online changes, it is not recommended to do so unless
the operation is verified as critical and is a relatively simple change. Safety
measures must be taken and the responsible operator and/or the plant engineer
are informed. Function block override cannot be forced for an extended period.
Customer must provide a fail-safe devices list" or GE can provide a list to the user
for them to confirm and sign off on. Equipment must be clearly identified along with
safety status, and any other types of instruction
According to the "fail-safe devices list" provided by customer, sufficient safety
related consideration for DPU power loss, restart, downloading, and any other
abnormal conditions must be taken when designing the software control logic. For
example: the output of DMA function block will be cleared to zero after system
restart, then there will be an opposite logic status, and the method of setting
expected input parameter will help to achieve safety protection.
9.3 Password
The system has 3 levels of security including managing the system, configuring the
system, and only operating the system.
Proper password and user passwords should be assigned at the beginning of the
system configuration to ensure the system can only be modified by authorized
personnel.

Chapter 10 Installation
10.1 Standard Cabinet Dimension

The diagram below shows a standard cabinet without side panels. If side panels are
used, 5mm space for each panel should be added. The specific cabinet for each project
may be different from this one. Please consult the project engineer for details.
Figure 10.1-1 Standard cabinet dimensions
10.2 Installation conditions

Before system cabinet installation, Electric room design must be completed including
wall finishing and ceiling installation. Security, lighting and fire fighting systems must be
in service. Air condition system can be put into service later. All system equipment must
be stored properly after receipt to prevent corrosion, dampness and loss. The customer
must provide a clean, dry storehouse, free of temperature variations, high humidity, and
dust. 24 hours security is strongly suggested after system power-up.

All DCS equipment must be located as shown in System Layout drawing. Ensure that the
cabinet face and door directions are correct.
DCS cabinet size is 800*600*2000(w*d*h). The gross weight is 150kg. The cabinet should
be mounted on the slot ware steel. The fastening bolts are M12*25 inner hex nut.
Check the internal power distribution from DCS power cabinet to control cabinet and
MMI. Ensure the wire cross-section is larger than 1.5 mm2 and use O type connection.
Ensure the UPS power is connected to power input A and security power is connected to
power input B.
DCS grounding is single point grounding system; the system adopts star-type
connection to unit grounding point through system grounding bar box. Ensure the
resistance between cabinet grounding bar and unit grounding point is lower than 2.5
Ohm. All I/O cabinets must be grounded to system grounding box through cable (Wire
cross-section of no less than 20 mm2).
The exterior of the cabinets can be grounded to the nearest grounding point.
All real-time Ethernets and I/O Ethernets must be connected properly before the system
has first power-up.
All 24V power connections must be covered properly before the first system power-up.
All I/O signals must be shielded and grounded at DCS side following the single ground
principle.
A power warning sign must be placed on each cabinet during commissioning. Cabinet
power must be operated by qualified people.
According to commissioning schedule, each module can be installed onto the
baseboard until all terminals related to the module are checked.
Recover as many as possible hardware configuration, including HMI, grounding, power
supply, network, 24V DC power connection and relative peripheral devices during the
first time power supplied to the system.
Keep the devices related to commissioning fully functioning and stop all others while the
system is confirming power-up functionality.
Customer should issue Engineering control room management procedure after
system power up. All operations must be controlled by this procedure.

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GEK-114902 OC6000e System Manual i

ii GEK-114902 OC 6000e System Manual

1.1 OC 6000e overview

GEK-114902 OC6000e System Manual 1

2 GEK-114902 OC 6000e System Manual

1.2 OC 6000e System Architecture

Figure 1.2-1 OC6000e Architecture

GEK-114902 OC6000e System Manual 3

1.3 System feature or specification

4 GEK-114902 OC 6000e System Manual

Table 1.4-1 I/O Modules list

Table 1.4-2 Communication Modules list

GEK-114902 OC6000e System Manual 5

Table 1.4-3 Outsourced Items list

Table 1.4-4 Parts made by GE Bently

Table 1.4-5 General Peripheral list

Table 1.4-6 OS & Software list

6 GEK-114902 OC 6000e System Manual

Figure 1.4-1 OC6000e module

GEK-114902 OC6000e System Manual 7

1.4.1.2 Module overview

Temperature sensor TC/RTD signals input

8 GEK-114902 OC 6000e System Manual

Digital Input and SOE

Digital Output with relay Extension

1.4.2 OC 6000e Communication Module Summary

GEK-114902 OC6000e System Manual 9

Figure 1.4-3 MCI communication module

1.4.2.2 Communication module overview

Table 1.4-12 MCI10 main specification

Table 1.4-13 MCI11 main specification

Table 1.4-14 MCI12 main specification

10 GEK-114902 OC 6000e System Manual

Fig 1.4-4 OC6000e Controller

GEK-114902 OC6000e System Manual 11

1.4.6 IONet Switch

12 GEK-114902 OC 6000e System Manual

1.4.7 UDH Switch

Figure 1.4-6 OC 6000e operation console

GEK-114902 OC6000e System Manual 13

1.5.2 Platform Software

1.5.3 Application Software

1.6 Certification and standards

14 GEK-114902 OC 6000e System Manual

2.1 Hardware configuration calculation

2.1.2 I/O modules

2.1.3 Communication modules

2.1.4 Cabinets and accessories

GEK-114902 OC6000e System Manual 15

2.3 UDH Network switches

2.4 Other equipment

16 GEK-114902 OC 6000e System Manual

System design must ensure that:

If the equipment is used in a manner not specified by the

3.1 System arrangement

3.2 Signal assignment

3.3 Cabinet assembly

GEK-114902 OC6000e System Manual 17