GE IS200TRPAH2A Aeroderivative Turbine Primary Trip Board

The IS200TRPAH2A is an Aeroderivative Turbine Primary Trip Board designed by General Electric (GE) for its Mark VIe™ Control System. This board is the version within the TRPA series specifically for the 125 V dc output contact rating, primarily used for emergency protection systems in aeroderivative gas turbines, providing overspeed protection, emergency stop, and trip control functions.

The IS200TRPAH2A board can work with three I/O packs to form a Triple Modular Redundant (TMR) protection system. The board features multiple input and output channels, including speed pickup inputs, voltage detection inputs, E-Stop emergency stop input, and TMR voted trip contact outputs. Jumpers allow flexible configuration of speed input signal distribution to suit different system requirements.

Key features of the IS200TRPAH2A include:

• Dedicated for Aeroderivative Turbines: Suitable for emergency protection systems in aeroderivative gas turbines.

• Triple Modular Redundant (TMR) Support: Works with three I/O packs to achieve highly reliable protection control.

• 125 V dc Output Contacts: Trip contacts rated at 125 V dc, suitable for standard industrial control voltages.

• Multiple Speed Inputs: Supports 12 passive magnetic speed pickups or 6 active TTL speed pickups.

• Voltage Detection Inputs: 4 isolated voltage detection circuits for monitoring voltage status in the trip string.

• E-Stop Emergency Stop Input: 1 fail-safe emergency stop input, 24-125 V dc, with hardware response time <5 ms.

• Fast Trip Response: E-Stop circuit response time <5 ms, plus trip relay response time <1 ms, resulting in extremely fast overall response.

• Short Circuit Detection: Built-in relay contact short circuit detection circuit to ensure trip reliability.

• Configurable Speed Inputs: Jumpers JP1 and JP2 allow selection of speed input signal distribution method.

• ID Chip Identification: Connectors feature read-only ID chips storing board information for verification by I/O packs.

The board measures 33.0 cm high × 17.8 cm wide, utilizes surface-mount technology, and is suitable for industrial control cabinet installation.

II. Main Functions

The primary functions of the IS200TRPAH2A include, but are not limited to, the following:

1. Speed Signal Input

The IS200TRPAH2A board offers multiple speed input configuration options:

• 12 Passive Magnetic Speed Pickups: 4 per TMR section (R, S, T) for measuring turbine speed.

• 6 Active TTL Speed Pickups: 2 per TMR section as an alternative.

Jumpers JP1 and JP2 configure the speed input distribution:

• Each I/O pack receives dedicated 4 speed inputs.

• The 4 speed inputs from the R section are fanned out to the S and T section I/O packs.

Speed input sensitivity is frequency-dependent: 24 mV p-p minimum at 2 Hz, 276 mV p-p minimum at 20 kHz. The pulse rate range is 2 Hz to 20 kHz with an accuracy of 0.05% of reading.

2. TMR Voted Trip Contact Outputs

The IS200TRPAH2A provides two TMR voted trip contact outputs for driving the main breaker coil. Each trip contact is composed of 6 independent Form A devices arranged in a voting pattern. Any two controllers voting to close will establish a conduction path.

Contact Ratings (H2A Version):

• Nominal Voltage: 125 V dc

• Resistive Load: 1 A dc

• Inductive Load (L/R = 7 ms, no suppression): 1 A dc

• Inductive Load (L/R = 100 ms, with suppression): 1 A dc

• Active Voltage Clamp Limiting: Max voltage ≤200 V dc

• Contact Rating: NEMA Class F, minimum operations: 100,000

Important Notes:

• Contact outputs are polarity sensitive. Wire the circuit carefully to avoid damaging the relays.

• There is no contact or solenoid suppression. Users must add external solenoid suppression to avoid damaging the relays and their contacts.

3. Voltage Detection Inputs

The IS200TRPAH2A provides 4 general-purpose isolated voltage sensor inputs. These can be used to monitor any points in the trip system and feed the voltage status into the system controller. Typical applications include monitoring the power supply voltage for the two trip strings and sensing the solenoid voltage of the device being driven by the relays.

Voltage Detection Input Specifications:

• Min/Max Input Voltage Rating: 16/140 V dc max pk

• Max Leakage Current: 3 mA

• Max Detection Delay: 60 ms

• Isolation Voltage: Optically isolated, 2500 V rms for one minute

• Surge/Spike Rating: 1000 V pk for 8.3 ms

4. E-Stop Emergency Stop Input

The IS200TRPAH2A includes an E-Stop function, consisting of an optically isolated input circuit designed for a DC input in the range of 24 to 125 V nominal. When energized, the circuit enables coil drive power in the R, S, and T relay circuits through independent hardware paths.

E-Stop Input Specifications:

• Input Voltage: 24-125 V dc ±10% (18/140 V pk Min/Max)

• Max Loading: 12 mA (5 mA typical)

• Max Delay: 5 ms (<1 ms typical)

Important Characteristics:

• The E-Stop circuit response time is <5 ms. Added to the trip relay response time of <1 ms, this yields a very fast E-Stop response.

• The E-Stop is monitored by the I/O pack, but the action to remove trip relay coil power is entirely in the hardware of the TRPA.

• The E-Stop signal reported in ToolboxST is latched by firmware and needs a Master Reset to clear that status.

• The E-Stop must be connected to a CLEAN dc source – battery or filtered (<5% ripple) rectified ac.

• There must be a minimum of 18 V dc at the TRP inputs for proper operation. The current required was kept low to minimize voltage drop on long cable runs.

5. Shorted Contact Detection

To preserve tripping reliability, the IS200TRPAH2A applies a sensing circuit to each set of relays. When the relays are commanded to open and voltage is present across the relays, the circuit detects if one or more relays are shorted. This signal goes to the I/O pack to create an alarm. The sensing circuit uses the relay commands from all three I/O packs to avoid false indication if one I/O pack votes to close while the other two vote to open.

6. Speed Input Fanout Configuration

Jumpers JP1 and JP2 configure whether the 4 passive speed inputs from the R section are fanned out to the S and T section I/O packs:

• Jumpers not used (stored in STORE position): Each set of 4 pulse inputs goes to its own dedicated I/O pack.

• Jumpers used (placed over pin pairs): The 4 R section speed inputs are fanned out to all I/O packs. The S and T section speed input terminals become no-connects and should not be used.

  
  

III. System Applications

1. Application in Aeroderivative Turbine Protection Systems

The IS200TRPAH2A is the core terminal board for aeroderivative gas turbine protection systems. Working with three I/O packs (PTUR or YTUR), it forms a Triple Modular Redundant (TMR) emergency protection system. Its roles within the system include:

• Overspeed Protection: Monitors turbine speed via speed pickups and triggers a trip when speed exceeds setpoints.

• Emergency Stop: Receives external emergency stop signals via the E-Stop input, rapidly power to the trip relays.

• Trip Control: Drives the main breaker via TMR voted contact outputs to implement emergency shutdown.

• Status Monitoring: Monitors power supply voltage and solenoid voltage in the trip string via voltage detection inputs.

• Fault Diagnosis: Monitors relay contact status via short circuit detection circuits, identifying faults promptly.

2. Differences from the H1A Version

The main difference between the IS200TRPAH2A and the H1A version is the output contact rating:

The H2A version is suitable for industrial applications requiring 125 V dc control voltage, while the H1A is for 24 V dc systems.

3. Safety Certified Versions

The document mentions IS200TRPAS1A and IS200TRPAS2A versions, which are IEC 61508 safety certified for use with YTUR. The IS200TRPAH2A is a standard industrial version, not mentioned as safety certified, but functionally compatible with the safety versions.

4. Typical Application Scenarios

• Aeroderivative Gas Turbines: Emergency protection for LM series and other aeroderivative gas turbines.

• Industrial Gas Turbines: Suitable for industrial gas turbines requiring 125 V dc control voltage.

• Generator Protection: Serves as the trip interface for generator main protection systems.

• Compressor Protection: Used for overspeed protection and emergency stop in large industrial compressors.

  
  

IV. Detailed Interface Description

1. Terminal Block Allocation

Each terminal block can accept up to two #12 AWG wires and is pluggable for easy on-site wiring and maintenance. A shield termination strip attached to chassis ground is located immediately to the left of each terminal block.

2. Jumper Configuration

3. Connector Pin Assignments

V. Operating Principles

1. System Design

The IS200TRPAH2A board has two application methods:

• Used with TTUR: When a TTUR terminal board is used to hold three I/O packs, the TRPA may be connected using three cables with DC-37 pin connectors on each end. In this mode, the TRPA provides two contact voted trip relay outputs, E-Stop, and four voltage sensors. The TRPA speed inputs are not active and should not be connected.

• I/O Packs Mounted Directly: Three I/O packs are mounted directly on the TRPA. In this mode, the TRPA speed inputs become active paths into the I/O pack, allowing for a single terminal board primary trip solution. Simplex operation is not possible.

2. Trip Relay Operating Principle

The trip relays are made using sets of six individual Form A devices arranged in a voting pattern. Any two controllers that vote to close will establish a conduction path through the set. To detect shorted relays, a sensing circuit is applied to each set of relays. When the relays are commanded to open and voltage is present across the relays, the circuit detects if one or more relays are shorted. This signal goes to the I/O pack to create an alarm.

3. E-Stop Operating Principle

The E-Stop function consists of an optically isolated input circuit. When energized, the circuit enables coil drive power in the R, S, and T relay circuits through independent hardware paths. The E-Stop is monitored by the I/O pack, but the action to remove trip relay coil power is entirely in the hardware of the TRPA, ensuring extremely fast response and high reliability.

Important Notes:

• The E-Stop signal reported in ToolboxST is latched by firmware and needs a Master Reset to clear that status. True indicates a completed E-Stop circuit. False indicates a loss of the E-Stop since the last Master Reset, not the current state of the E-Stop circuit.

• If the user does not need or use an E-Stop, then jumper the local TRP power source (P240 and P24R) to the respective TRP inputs at the terminal board.

  
  

VI. Diagnostics and Configuration

1. Diagnostic Functions

The IS200TRPAH2A performs the following diagnostic tests via the I/O packs:

Diagnostic signals can be individually latched and reset with the RESET_DIA signal after returning to normal.

2. Configuration Method

Configuration of the IS200TRPAH2A is primarily done via jumpers JP1 and JP2 to select the speed input fanout method. Other configurations are completed via the I/O packs and ToolboxST software.

VII. Installation and Maintenance

1. Installation Precautions

• 240 V ac Application Warning: In 240 V ac applications, do not inadvertently cross-connect the 240 V ac and the DC voltages. The peak voltage will exceed the Transorb rating, resulting in a failure.

• 120 V ac Applications: In 120 V ac applications, the Transorb rating can withstand the peak voltage without causing a failure.

• E-Stop Wiring: The E-Stop must be connected to a clean DC source. Use twisted-pair cable and avoid running with AC wiring.

• Contact Output Polarity: Contact outputs are polarity sensitive. Wire the circuit carefully to avoid damaging the relays.

2. Maintenance Recommendations

• Periodic Inspection: Check that terminal blocks are securely plugged in and wires are not loose.

• Cleaning: Regularly clean the board to prevent dust accumulation.

• ESD Protection: Wear a grounding strap when handling the board and store it in anti-static bags.

• Spare Parts Management: Maintain a spare TRPAH2A board to reduce downtime in case of failure.