GE IS200TRPGH1BDD Trip Solenoid Control Board

Description

Technical Parameters

Electrical Parameters

Functional Parameters

Mechanical Parameters

Environmental Parameters

Functional Features

Relay and Trip Control

Multi-Signal Processing

• Accepts input signals from eight Geiger-Müller flame detectors to monitor the combustion status of gas turbines, providing critical flame detection information to the control system.
• Manages voltage supply for relay coils and voltage/current supply for flame detectors, processing and transmitting various signal types to meet the interactive needs of multiple signals in gas turbine control systems.

Interfaces and Compatibility

• In the Mark VI system, it connects to the VTUR board via a cable with a molded plug to the VME rack where the VTUR board is installed.
• In the Mark VIe system, it is controlled by the PTUR component on TTURH1C, which accepts I/O components as inputs via a D-type connector. It supports simplex and triple modular redundancy (TMR) systems, offering strong compatibility with different system architectures and application scenarios.

Working Principle

I. Module Positioning and Core Functions

• Acquires raw signals from rotational speed sensors (e.g., reluctance sensors).
• Filters, amplifies, and digitizes signals to calculate real-time rotational speed values.
• Communicates with other control system modules (e.g., main control modules, protection modules) to transmit speed data or control commands.
• Supports redundant configurations to enhance system reliability (in some models or setups).

II. Detailed Working Principle

1. Signal Acquisition and Preprocessing
• Filtering: Removes high-frequency noise via hardware filters (e.g., RC filter circuits) to avoid interference with speed calculations.
• Amplification and Shaping: Amplifies weak AC signals and converts them into square waves via Schmitt triggers for subsequent digital circuit processing.
• Input Signal Type: Receives AC voltage signals from rotational speed sensors (frequency proportional to speed), such as sinusoidal signals from reluctance sensors. The frequency formula is:$f=\frac{n\times p}{60}$
  (where $n$ = rotational speed, $p$ = number of teeth on the sensor gear).
• Signal Conditioning:
2. Speed Calculation and Digitization
• Measuring a single period $T$, rotational speed $n=\frac{60}{T\times p}$.
• Counting pulses within a fixed time window to calculate frequency.
• Frequency Measurement: Measures the period or frequency of square wave signals using counter chips (e.g., FPGA or specialized timing chips). For example:
• Digitization: Converts calculated speed values into digital signals (e.g., 16-bit binary numbers) and transmits them to the main control module via an internal bus (e.g., VME bus).
3. Control Logic and Protection Functions
• Closed-Loop Control Logic: Adjusts actuator signals (e.g., fuel valves) using preset control strategies (e.g., PID control) based on speed feedback and target values to regulate unit speed.
• Overspeed Protection: Immediately triggers a hardware trip signal via hardwired connections to shut down solenoids when speed exceeds a set threshold (e.g., 110% of rated speed), ensuring safe shutdown independent of software logic ("fail-safe" mechanism).
4. Communication and Redundancy Mechanisms
• Data Communication: Exchanges data with other modules via serial interfaces (e.g., RS-485) or buses (e.g., Ethernet), such as sending real-time speed data to HMIs or receiving control parameters from main control modules.
• Redundancy Design (Partial Configurations): Employs dual-module redundancy, where two modules operate simultaneously and cross-verify data. If the primary module fails, the backup module switches over to control, preventing single-point failures.

III. Key Technical Points

• Anti-Interference Design: Uses isolated power supplies and shielded circuits to reduce EMI effects on signal acquisition. Hardware watchdog circuits prevent program crashes to ensure stable operation.
• High-Precision Measurement: Counter resolution reaches nanosecond levels to ensure speed calculation accuracy (e.g., ±0.1% error). Supports multi-channel inputs (e.g., three speed sensors) with a two-out-of-three voting mechanism for reliability (compliant with SIL safety standards).
• Real-Time Performance and Response Speed: Signal processing cycles are short (typically <10ms) to meet fast adjustment needs of gas turbines. Hardware-triggered overspeed protection signals respond in microseconds for emergency shutdowns.

IV. Coordination with Other System Components

• Sensor Connection: Receives speed sensor signals via a dedicated terminal board with overvoltage protection and signal isolation.
• Actuator Interaction: Outputs analog signals (e.g., 4–20mA) to fuel control systems or digital signals to variable frequency drives (VFDs).
• Integration with Protection Systems: Overspeed signals are also fed into independent protection modules (e.g., GE’s UR6ES module) for dual protection.

V. Typical Application Process

• Startup Phase: Acquires starter motor speed to determine if ignition speed thresholds are met. After ignition, adjusts speed to no-load speed (e.g., 3000rpm) in real time as fuel increases.
• Grid-Connected Operation Phase: Adjusts fuel supply via speed control loops based on grid frequency signals to maintain synchronous speed with the grid.
• Shutdown Phase: Gradually reduces fuel supply after receiving shutdown commands, continuously monitoring speed until the unit stops completely.

Fault Diagnosis and Troubleshooting for IS200TRPGH1BDD Module

I. Preparation for Fault Diagnosis

• Confirm Module Function and System Architecture: Clarify the module’s role (e.g., I/O module, communication module, control module) and refer to official manuals for baseline information such as indicator light statuses, voltage ranges, and communication protocols.
• Safety Precautions: Ensure physical inspections are conducted with power off or isolated to avoid electric shock or equipment damage. Wear anti-static wristbands to prevent electrostatic damage to components.

II. Initial Visual and Hardware Checks

• Visual Inspection:
• Look for physical damage (cracks, burn marks, bulging capacitors) on the module casing.
• Check terminal blocks, cable interfaces, and slots for loose connections, oxidation, corrosion, or poor contact.
• Verify module model, firmware version, and compatibility with the system to determine if an upgrade is needed.
• Power and Voltage Test: Measure the module’s supply voltage (e.g., DC 24V or AC 110V) with a multimeter to ensure it falls within the nominal range (±5% error). If voltage is abnormal, check upstream power modules or supply lines.

III. Indicator Light Status Analysis (Key Diagnostic Tool)

IV. Functional Testing and Signal Verification

• I/O Testing:
• Analog Input (AI): Connect a standard signal source (e.g., 4–20mA or 0–10V) and read values via control system software to compare with actual inputs (allowable error: ±1%). If abnormal, check the signal source, cable shielding, grounding, or replace the channel for testing.
• Analog Output (AO): Send commands via software and measure voltage/current at module output terminals to confirm matching. Abnormal outputs may indicate internal driver circuit faults, requiring module replacement.
• Digital Input/Output (DI/DO): Manually trigger input signals (e.g., pushbuttons) to observe indicator lights or system status changes. For outputs, test relay contact actuation with a multimeter’s continuity function.
• Communication Testing: Use an oscilloscope or specialized tools to detect signal waveforms and levels on the communication bus (e.g., RS-485, Ethernet) for interference or attenuation. Check module address settings, baud rate, and parity bits for consistency with the system, and try replacing communication cables or interface modules.
• Load Testing: If the module drives external devices (e.g., solenoids, motors), check for overloads (current exceeding rated values) causing overheating or protection activation. Measure module surface temperature; if excessively hot (e.g., >60°C), suspect poor heat dissipation or component aging.

V. System-Level Diagnosis and Software Troubleshooting

• Control System Log Analysis: Review fault logs from the host computer or PLC to obtain module-related error codes (e.g., "communication timeout," "channel fault"). Use the codes to locate faults in the manual (e.g., software configuration errors, firmware defects, or compatibility issues).
• Firmware Upgrade and Configuration Reset: Confirm if the module’s firmware is up-to-date and upgrade it via official procedures if known bugs exist. Attempt to restore factory settings (via hardware jumpers or software commands) and retest after reconfiguring parameters.
• Swap Testing: Safely swap the faulty module with a known-good identical module to observe if the fault transfers. If it does, the module is damaged and needs repair/replacement. If not, check slot contact issues, backplane bus faults, or system power problems.

VI. Common Faults and Solutions