Description

GE IS230TDBTH6A

I. Product Overview

The GE IS230TDBTH6A is a high-performance industrial-grade temperature control and monitoring module launched by General Electric (GE). It belongs to the core I/O component family of GE's Mark VIe Distributed Control System (DCS) and Speedtronic turbine control system. Its core positioning is to achieve precise collection, real-time monitoring, and closed-loop control of multi-channel temperature parameters in industrial production processes. Through high-precision temperature measurement circuits, flexible control algorithms, and strong system compatibility, it realizes temperature management of key equipment such as turbines, boilers, and chemical reactors, providing core data support for the safe, stable operation and process optimization of industrial production.

The application scenarios of this module extensively cover fields with strict requirements for temperature measurement accuracy and control reliability, including power energy (temperature monitoring of turbine casings in thermal power units, temperature collection of boiler tube walls), petroleum and chemical industry (closed-loop temperature control of reactors, temperature monitoring of pipeline media), metallurgy and steel (temperature control of blast furnace hot stoves, temperature monitoring of rolling mill rolls), and heavy machinery (temperature monitoring of engine blocks, oil temperature control of hydraulic systems). As a dedicated module for GE's high-end control systems, it not only has excellent temperature collection performance but also can achieve seamless collaboration with the system, supporting the rapid deployment of complex control logic. It is a key component for building highly reliable industrial temperature control systems.

In terms of hardware architecture and system compatibility, the GE IS230TDBTH6A adopts a standardized modular design, which can be seamlessly integrated into the I/O racks (such as IC695 racks) of GE's Mark VIe control system and Speedtronic turbine control cabinets, occupying one standard I/O module slot. It realizes high-speed data interaction with the system controller through the backplane bus. The module is compatible with GE CIMPLICITY HMI and iFIX monitoring software, supporting configuration of temperature measurement ranges, control algorithm parameters, and alarm thresholds through a graphical interface, enabling system integration without underlying code development. Relying on industrial-grade reinforced design, the module can adapt to industrial on-site environments with high temperature, high humidity, dust, and strong electromagnetic interference, ensuring continuous stability of temperature collection and control.

II. Technical Parameters

Parameter Category	Parameter Name	Specific Parameters	Unit
Basic Parameters	Model	GE IS230TDBTH6A	-
	Product Type	Industrial-grade multi-channel temperature control and monitoring module	-
	System Compatibility	GE Mark VIe Distributed Control System, Speedtronic Turbine Control System	-
	Adaptable Rack	GE Mark VIe IC695 series racks, Speedtronic control cabinets, occupying 1 standard slot	-
	Overall Dimensions (L×W×H)	175×105×230	mm
	Installation Method	I/O rack embedded installation, equipped with mechanical locating pins and anti-loosening buckles	-
Temperature Measurement Parameters	Number of Channels	8 independent temperature measurement channels, supporting simultaneous closed-loop control of 4 channels	pcs
	Supported Sensor Types	Thermocouples (J/K/T/E/R/S/B/N), RTDs (Pt100, Pt1000, Cu50, Cu100)	-
	Measurement Range	Thermocouple: -270℃~1820℃ (varies by model); RTD: -200℃~850℃	℃
	Measurement Accuracy	Thermocouple: ±0.1℃ (-100℃~100℃), ±0.2℃ (100℃~1000℃); RTD: ±0.05℃ (-50℃~200℃)	℃
	Sampling Rate	Maximum single-channel sampling rate: 10Hz; 8-channel synchronous sampling rate: 1.25Hz/channel	Hz
	Resolution	24-bit A/D conversion, temperature resolution: 0.01℃	℃
Control and Output Parameters	Control Algorithms	Standard PID, PID Auto-tuning, Fuzzy PID, Feedforward-Feedback Control	-
	Output Type	4-channel analog output (4~20mA DC), 2-channel relay output (configurable normally open/normally closed)	-
	Analog Output Accuracy	±0.03% FS, load resistance: 0~600Ω	-
	Relay Output Capacity	AC 250V/5A, DC 30V/10A	V/A
	Control Response Time	≤100ms (from measured value deviation to output adjustment)	ms
Reliability and Diagnosis Parameters	Mean Time Between Failures (MTBF)	≥400,000 hours (complying with IEC 61508 standard)	hours
	Redundancy Support	Supports 1:1 module hot redundancy configuration, redundancy switching time: ≤15ms	ms
	Fault Diagnosis Coverage	≥99.5%, supporting diagnosis of channel faults, sensor faults, A/D faults, etc.	%
	Alarm Function	Supports high-temperature alarm, low-temperature alarm, temperature deviation alarm, sensor fault alarm; thresholds configurable	-
	Fault Tolerance	Supports channel-level fault isolation; single-channel fault does not affect the operation of other channels; automatic identification of sensor open/short circuits	-
Electrical and Environmental Parameters	Power Supply Voltage	DC 24V±10% provided by I/O rack, supporting dual redundant power input	V
	Maximum Power Consumption	≤20W (full-load operation, including control output power consumption)	W
	Operating Temperature Range	-20℃~70℃ (standard operating range); -40℃~85℃ (wide-temperature customized version)	℃
	Electromagnetic Interference Resistance	Complies with IEC 61000-4 series standards; ESD ±25kV (air discharge)/±15kV (contact discharge); surge immunity ±4kV	-

III. Functional Features

1. Multi-Channel High-Precision Measurement, Adapting to Diverse Temperature Scenarios

The GE IS230TDBTH6A is equipped with 8 independent temperature measurement channels, supporting the connection of multiple types of sensors including thermocouples (8 types such as J/K/T) and RTDs (4 types such as Pt100). It can adapt to temperature measurement needs of different ranges without additional signal conversion modules, such as simultaneous monitoring of high temperatures of turbine casings (up to over 1000℃) and low temperatures of hydraulic systems (below -50℃). The 24-bit A/D conversion technology enables a temperature resolution of 0.01℃. The RTD measurement accuracy reaches ±0.05℃ within the range of -50℃~200℃, and the thermocouple accuracy reaches ±0.2℃ within 100℃~1000℃, which is much higher than that of ordinary industrial-grade temperature modules. The 8 channels support synchronous sampling, with a maximum single-channel sampling rate of 10Hz, which can capture dynamic temperature changes in real time and provide accurate data support for scenarios with rapid temperature fluctuations (such as the heating stage of chemical reactors).

2. Multi-Algorithm Closed-Loop Control, Excellent Control Accuracy

The module supports simultaneous closed-loop temperature control of 4 channels, with 4 core built-in algorithms: standard PID, PID auto-tuning, fuzzy PID, and feedforward-feedback control, which can be flexibly selected according to different process characteristics. The PID auto-tuning function can automatically identify the dynamic characteristics of the controlled object (such as lag time and gain), intelligently optimize PID parameters, and avoid the complexity and errors of manual debugging. The fuzzy PID algorithm has better control effects for controlled objects with large lag and nonlinearity (such as boiler temperature control), which can effectively suppress overshoot and oscillation. The feedforward-feedback control can adjust the output in advance based on process disturbances (such as changes in feed quantity), improving control accuracy. The control response time is ≤100ms, which can quickly adjust the output when a temperature deviation occurs, stabilizing the temperature within the range of ±0.1℃ of the set value, meeting the needs of high-precision temperature control (such as semiconductor manufacturing and precision chemical engineering).

3. Diverse Outputs and Alarms, Timely Control Response

The module is equipped with 4-channel 4~20mA analog outputs and 2-channel relay outputs, realizing multi-form feedback of temperature control and alarms. The analog output can directly drive actuators such as control valves and heaters, with an output accuracy of ±0.03% FS, ensuring accurate transmission of control signals. The relay output can be configured as temperature over-limit alarm (such as high-temperature triggering shutdown), sensor fault alarm, or control logic linkage (such as low-temperature starting heater), directly driving alarms, indicator lights, or contactors to achieve local rapid response. It supports 4 core alarm types: high-temperature, low-temperature, temperature deviation, and sensor fault. Alarm thresholds can be accurately set through configuration software, and alarm signals are simultaneously uploaded to the controller and upper-level system through the backplane bus, ensuring timely detection and handling of abnormal situations.

4. Redundancy Configuration and Fault Isolation, Stable and Reliable Operation

It supports 1:1 module hot redundancy configuration. The master and standby modules realize real-time data synchronization through a dedicated redundant communication link, including measurement data, control parameters, output status, and fault information, with a synchronization delay of ≤1ms. During normal operation, the master module performs measurement and control functions, while the standby module monitors the status of the master module in real time and synchronizes data. When the master module experiences power failure, channel abnormality, or communication interruption, the standby module can automatically switch without disturbance within 15ms. During the switching process, there is no fluctuation in control output and no temperature deviation, ensuring uninterrupted temperature control of key equipment such as turbines and boilers. The module has channel-level fault isolation capability. When a sensor open/short circuit or measurement abnormality occurs in a single channel, it automatically isolates the faulty channel and triggers an alarm, without affecting the measurement and control of other channels, improving the system's fault tolerance.

5. Full-Dimensional Fault Diagnosis, Efficient and Convenient Operation and Maintenance

It has a fault diagnosis coverage rate of 99.5%, integrating triple diagnosis mechanisms at the sensor level, channel level, and module level. The sensor level can automatically identify open circuits, short circuits, reverse connections, and aging faults (judged by the stability of measured signals). The channel level monitors channel health through signal verification and A/D conversion accuracy detection. The module level monitors hardware status through power supply monitoring and communication link detection. It can accurately identify more than 20 types of faults and generate standardized fault codes (such as sensor open circuit code E01, A/D fault code E08). When a fault occurs, the local LED indicator lights alarm in layers (yellow light flashes for channel faults, red light stays on for module faults), and at the same time, fault information is uploaded to the upper-level system, clearly indicating the fault location, type, and handling suggestions (such as "Channel 3 sensor open circuit, please check the wiring"). It supports online calibration and remote diagnosis. Operation and maintenance personnel can complete calibration and fault troubleshooting through GE CIMPLICITY software without shutting down the system.

6. In-Depth System Compatibility and Flexible Integration, Efficient Deployment

As a dedicated module for GE Mark VIe and Speedtronic systems, the IS230TDBTH6A adopts a standardized interface design, which can be seamlessly integrated into the corresponding system racks. It realizes high-speed data interaction with the controller through the backplane bus, with a data transmission rate of ≥100Mbps, ensuring real-time transmission of measurement data and control commands. It is compatible with GE CIMPLICITY HMI and iFIX monitoring software, supporting configuration of sensor types, selection of control algorithms, parameter setting, and alarm threshold adjustment through a graphical interface. It has built-in common process control templates (such as turbine temperature control template and boiler control template), and the integration and debugging cycle is shortened by more than 60% compared with traditional modules. At the same time, it supports communication with third-party DCS systems through the Modbus TCP protocol and has standard communication interfaces, which can be flexibly integrated into non-GE control systems, improving the flexibility of system integration.

IV. Working Principle

The GE IS230TDBTH6A realizes high-precision temperature measurement and control through the collaboration of hardware circuits and software algorithms, based on the core workflow of "signal collection - data processing - control calculation - output feedback - fault diagnosis". The specific working mechanism is as follows:

1. Temperature Signal Collection and Preprocessing

Signals from on-site temperature sensors (thermocouples/RTDs) are connected through the module's input terminals and first enter the signal conditioning unit. For thermocouple signals, the conditioning unit performs cold-junction compensation (using a high-precision temperature sensor to measure the internal temperature of the module in real time to compensate for the impact of ambient temperature on measurement), filtering and noise reduction, and linearization processing. For RTD signals, the conditioning unit provides constant current excitation (ensuring the excitation current is stable at 1mA or 5mA), collects the voltage across the RTD, and performs linearization correction. The preprocessed signals are sent to the 24-bit A/D conversion unit, converted into digital signals, and stored in the data register. At the same time, the signal monitoring unit monitors the amplitude and stability of the signals in real time, and immediately triggers fault diagnosis if an abnormality (such as open circuit or short circuit) is detected.

2. Control Algorithm Calculation

The data processing unit reads the temperature measurement value from the data register, compares it with the target temperature value set by the upper-level system, and calculates the temperature deviation. According to the preset control algorithm (such as PID auto-tuning), the calculation unit performs calculations based on the deviation value, deviation change rate, and historical data. In the PID auto-tuning mode, it first identifies the characteristics of the controlled object through step testing, then calculates the optimal PID parameters. In the fuzzy PID mode, it converts the deviation and deviation change rate into control quantity adjustment values through fuzzy rules. The control commands generated by the calculation are sent to the output drive unit, and at the same time, the calculation process data (such as deviation value and PID parameters) are stored in the buffer for fault tracing and parameter optimization.

3. Redundancy Synchronization and Switching

In the redundancy configuration mode, the master module sends synchronization data to the standby module 1000 times per second through the redundant communication link, including measurement data, control parameters, output status, and fault information. After receiving the data, the standby module updates its own register data in real time to ensure data consistency between the master and standby modules. The master and standby modules send health status signals to each other: the master module monitors the status of the standby module, and the standby module monitors the status of the master module in real time. When the master module detects its own fault or the loss of the standby module's health signal, it immediately sends a switching request. After the standby module confirms, it takes over the bus control right within 15ms and continues to perform measurement and control functions. During the switching process, the output holding circuit ensures the stable status of the actuator. After the fault of the master module is resolved, it can be manually switched back to the master-standby mode to resume data synchronization.

4. Output Feedback and Fault Handling

The control commands are converted into 4~20mA analog signals or relay switch signals by the output drive unit to drive the actuator to act. The analog output unit uses a high-precision D/A conversion chip to ensure the accuracy of the output signal. The relay output unit has an overcurrent protection function to prevent damage to the module due to load short circuits. The fault diagnosis unit monitors the status of each link in real time, compares the fault signal with the preset threshold, generates a fault code if it exceeds the range, triggers a local alarm, and uploads it to the controller. For sensor open circuit faults, the module automatically switches the control output of the corresponding channel to a safe value (such as power-off of the heater) to avoid the risk of out-of-control.

GE IS230TDBTH6A ​| Mark VI Printed Circuit Board