TURBOTRONIC 4

CONTROL SYSTEM

Power Generation
CONTROL SYSTEMS
Introduction
Solar's Turbotronic 4 control system is used for
sequencing, control, and protection of the gas
turbine package, and for providing an extensive
range of options for monitoring and plant control.
The control system is based on a commer-
cially available programmable controller config-
ured to Solar's requirements. It provides an opti-
mum combination of control and display features,
reliability and maintainability, and is configured
specifically for the control of turbomachinery and
associated equipment.
The control system described herein is pro-
vided for Power Generation products and in-
cludes a number of sensors, transducers, and
monitoring devices. Data are collected and sent
i
to the programmable controller for computation
and generation of the required control actions
and indications.
The programmable controller, in conjunction
with the video display unit (VDU), permits a wide
range of features. These include a variety of ad-
vanced software and control options, as well as
condition and trend monitoring and supervisory
control.
The control system provides the operator
with necessary information for operation of the
equipment. It also offers a variety of communica-
tions options for data exchange with the cus-
tomer's supervisory system.
Contents
Introduction................................................................................................................................................... i

Standard Hardware .................................................................................................................................... 1

GENERAL INFORMATION ....................................................................................................................... 1
ONSKID CONTROL CONSOLE................................................................................................................ 1
PROGRAMMABLE CONTROLLER .......................................................................................................... 2
INPUT/OUTPUT MODULES ..................................................................................................................... 3
INTERNAL COMMUNICATION................................................................................................................. 4
POWER SUPPLY SYSTEM ...................................................................................................................... 4
BACKUP SYSTEM .................................................................................................................................... 4
VIBRATION MONITORING SYSTEM....................................................................................................... 5
GOVERNOR.............................................................................................................................................. 5
GENERATOR CONTROL AND PROTECTION........................................................................................ 6
VOLTAGE REGULATION ......................................................................................................................... 7
CONTROL AND PROTECTION................................................................................................................ 7
OPERATOR INTERFACE ......................................................................................................................... 9
Optional Control and Display Features ................................................................................................. 15
ENGINEERING UNITS............................................................................................................................ 15
FIRE DETECTION AND SUPPRESSION SYSTEM ............................................................................... 15
FIELD PROGRAMMING ......................................................................................................................... 15
LANGUAGE............................................................................................................................................. 15
COMMUNICATIONS – TURBINE CONTROL TO SUPERVISORY SYSTEM ....................................... 15
VIDEO DISPLAY OPTIONS .................................................................................................................... 18
Appendix A: Hardware ........................................................................................................................... 20
PHYSICAL HARDWARE......................................................................................................................... 20
ELECTRICAL SPECIFICATION.............................................................................................................. 20
ENVIRONMENTAL SPECIFICATION..................................................................................................... 20
RFI/EMI SUSCEPTIBILITY AND EMISSION ..........................................................................................20
Appendix B: Technical Supplement ..................................................................................................... 21
HARDWARE INFORMATION ................................................................................................................. 21
HARDWARE CERTIFICATION ............................................................................................................... 22
AREA CLASSIFICATION ........................................................................................................................ 22
QUALITY ASSURANCE.......................................................................................................................... 22
CONTROL CONSOLE LAYOUT ............................................................................................................. 22
Appendix C: Control System Information ............................................................................................ 24
TURBOTRONIC DEFINITIONS .............................................................................................................. 24
HUMAN MACHINE INTERFACE DESCRIPTIONS ................................................................................ 24
SYSTEM DESCRIPTIONS...................................................................................................................... 24

Caterpillar is a registered trademark of Caterpillar Inc.

Solar, Centaur, Titan and Turbotronic are trademarks of Solar Turbines Incorporated.
Specifications subject to change without notice. Printed in U.S.A.
©2002 Solar Turbines Incorporated. All rights reserved.
SPTT-PG/802

ii
Standard Hardware
GENERAL INFORMATION
The Turbotronic 4 control system is a highly inte-
grated programmable controller-based control
system with a video display unit (VDU) and op-
erator interface panel (Figure 1).
The control system consists of several dis-
tinct modules: a programmable controller, in-
put/output (I/O) modules (discrete and analog),
VDU, relay backup system, control and monitor-
ing software, onskid control console, and the
package sensing and control elements. The in-
ternal computing capability of the control system
may vary by product line, but each control system
has the same basic internal components, as de-
picted in Figure 2.
The control system requires a source of 24-
Vdc nominal power, which is derived from a
source of 120-Vdc power supplied by a battery
bank with associated battery charger.

ONSKID CONTROL CONSOLE

The control system is provided in two onskid,
NEMA 4 boxes. The control system is designed
to operate in a nonhazardous area. The turbine
control panel and onskid VDU include all neces-
sary switches and indicators for gas turbine op-
eration. Figure 1. Typical Control Console

OPERATOR'S
PROGRAMMABLE
INTERFACE
CONTROLLER

CONTROLNET BRIDGE
DISPLAY
CONTROLNET REDUNDANT MODULE
LINK

CONTROLNET
LINK

FLEX I/O COMBINATION

MODULES GENERATOR
CONTROL MODULE
BACKUP
RELAY
SHUTDOWN

TURBINE GENERATOR

Figure 2. Typical Package Control System

1
 All components within the control console are
factory interconnected and wired to the sensors
and transmitters. Labels are in English, but can
be provided in various other languages (see "Op-
tional Control and Display Features").
PROGRAMMABLE CONTROLLER
The heart of the control system is the program-
mable controller. The programmable controller
performs the following functions in conjunction
with the input and output signal modules:
· Sequencing of gas turbine and auxiliaries
· Control of turbine and driven equipment
during start-up, loading, operation and
shutdown
· Protection of turbine from abnormal
operating conditions
· Protection of driven equipment from
abnormal operating conditions
· Response to commands from operator
· Analog and status outputs for display
and monitoring
Figure 3. Ladder Logic Diagram
2
The programmable controller is programmed
in a language called “relay ladder logic” or in
“function block diagram” programming.
Ladder logic format (Figure 3) is quite fa-
miliar to most operators and engineering person-
nel, since it closely emulates the relay logic used
in the past. It also includes a variety of computa-
tional and file transfer commands useful for data
manipulation, calculation, and communication.
Using an optional programming terminal, the user
can monitor the program online and troubleshoot
a problem or make modifications when required
(see “Programmable Controller Field Program-
ming” option). In addition to viewing the ladder
logic online, a copy of the ladder files may be
printed out.
Function block diagram programming
(Figure 4) allows control algorithms to be pro-
grammed in a graphical format familiar to process
control engineers. This format can program a
complex algorithm on one page that would take
multiple pages of ladder logic to implement. The
compact program is easier to read, troubleshoot,
and understand.
Figure 4. Function Block Diagram Programming

INPUT/OUTPUT MODULES
In order to perform many of its functions, the pro-
grammable controller must gather physical data.
This is accomplished through I/O modules that
are provided as discrete (input, output, or both) or
analog (input, output, or both). Discrete inputs are
typically used for alarms, shutdowns, or status
indications and analog inputs are used for scale-
able functions.
The I/O modules are mounted to terminal
base units (Figure 5). Terminal base units have
two primary functions. First, when they are con-
nected side to side, the bases serve as a back-
plane, allowing data to be transferred from the I/O
module to the programmable controller via Con-
trolNet 1.5. Second, the terminal base acts as the
terminal strip to which the field devices are wired.
Data are transferred to and from the I/O module
via an adapter module. The adapter serves as a
communication hub between each of the at-
tached I/O modules and the programmable con-
troller, providing not only I/O data, but also indi- Figure 5. Typical I/O Module Mounted
vidual module status and health. In addition, the on a Terminal Base Unit
adapter also serves to power the internal logic for
as many as eight I/O modules.

3
Discrete Input Modules. Discrete input modules
receive signals from on/off devices, such as level
switches, pressure switches, push buttons, re-
lays, and protective equipment normally used
during sequencing of the gas turbine. Discrete
signals can be used for alarms, shutdowns or
simply indicators, but are not necessarily dis-
played. The discrete input modules can have a
capacity of up to 16 channels depending on
module type.
Discrete Output Modules. Discrete output mod-
ules are used to drive output devices such as
solenoid valves, relays or motor contactors. The
discrete output module is capable of having either
8 or 16 channels of output data per module.
If “dry” contacts are required, then a set of
interposing relays or a two-amp contact relay
output module may be provided at additional
cost.
Analog Input Modules. Analog input modules
accept analog signals and digitize the data for
transfer to the programmable controller. Modules
can accept either four or eight single-ended in-
puts, with different channels being used for dif-
ferent types of input. Each channel is individually
configured for current or voltage by choosing
where the input is connected on the terminal
base.
Temperature Modules. Temperature modules
serve to condition and transfer temperature data
from package resistance temperature detectors
(RTD), 100-ohm platinum preferred, and thermo-
couples to the programmable controller. The
temperature module has eight input channels.
Speed Modules. Speed modules perform high-
speed frequency algorithms. The frequency in-
puts can accept frequencies up to 32,767 Hz.
The speed module has two input channels, each
of which may accept magnetic pickup signals
from 500 mV to 28 Vac peak.
Analog Output Modules. Analog output mod-
ules are used to send an analog signal, either
repeating one of those supplied by the purchaser
or used in the basic control or display of the con-
trol system. The analog output module is a four-
channel output module.
INTERNAL COMMUNICATION
Communication between the programmable con-
troller and I/O modules is via ControlNet 1.5 (Fig-
ure 2). ControlNet 1.5 is a high speed, determi-
nistic, serial communications link. This can be
4
used with both non-Flex I/O and Flex I/O and can
handle communications over distances of up to
1000 m (3300 ft), or more if repeaters are used,
at a bus speed of 5.0 megabits per second. This
is more than 50 times faster than the widely used
Data Highway Plus (DH+) and the Remote I/O
systems.
The physical layer of ControlNet 1.5 is quad
shielded RG-6U coaxial cable, with a passive tap
used to make a connection.
The most significant features of ControlNet
1.5 are its speed and the fact that it is both de-
terministic and repeatable. Deterministic is the
ability to reliably predict when data will be deliv-
ered, and repeatability ensures that transmit
times are constant and unaffected by devices
connecting to, or leaving, the network. The net-
work update time for a typical turbomachinery
control system is around five milliseconds.
POWER SUPPLY SYSTEM
The power supply system supplies power to the
programmable controller, input/output modules,
video display unit, and relay backup systems. It
consists of independent, voltage converting, dc-
to-dc isolating power supplies. The system re-
ceives 120-Vdc input from the battery system and
converts it into a regulated and filtered 28-Vdc
power at a maximum of 20 amps.
BACKUP SYSTEM
The basic control system is equipped with an in-
dependent relay backup system that serves to
initiate emergency shutdown of the turbomachin-
ery and to control the post-lube cycle. Critical
input signals monitored by the backup system
include the backup power turbine overspeed
monitor, manual emergency stop switches (lo-
cated at the console and turbine skid), the pro-
grammable controller fail “watchdog” timer, and
the fire system relay contacts. When activated by
any of the above faults, the relay backup system
initiates a safe shutdown of the turbine and driven
equipment. The backup control system is a com-
bination of instantaneous and time delay relays.
When a failure of the programmable control-
ler occurs, all discrete outputs are automatically
switched off. The programmable controller fail
relay is re-energized on a fault condition. A fault
is initiated either by the internal programmable
controller “watchdog“ or by failure of the output
module. The programmable controller fail relay
contacts are used in the relay backup system to
initiate an emergency shutdown, to isolate the
driven equipment by transferring block valves or
circuit breakers to their safe position, and to se-
quence operation of the post-lube oil system.
 Once a shutdown is initiated by the backup
system, operation can only be restored manually
by a safety key switch lockout located on the
console front panel when all faults have been
cleared. This action re-energizes the master con-
trol relay and its associated relays and timers are
restored to their normal position.
VIBRATION MONITORING SYSTEM
The vibration monitoring system provides vibra-
tion indication and protection for the gas turbine,
gearbox, and driven equipment. Depending on
the unacceptable vibration level, either a warning
is indicated or a turbine shutdown is initiated.
The gas turbine vibration monitoring instru-
mentation consists of a single proximity probe per
bearing or two velocity transducers per engine for
the Centaur 40 gas turbine. The gearbox is typi-
cally instrumented with an accelerometer. The
generator is typically instrumented with a velocity
transducer per bearing. The proximity probes,
accelerometers, and velocity transducers are
connected to individual transmitters that provide
4-to-20 mA signals to be read by the turbine
package control system.
All data available to the programmable con-
troller are also obtainable via serial link for user
remote monitoring, diagnostics and trending. Di-
rect access to the raw vibration signals is avail-
able via BNC connectors.
GOVERNOR
The "governor system" consists of various hard-
ware and systems integrated together to provide
the governor function. The governor is a speed,
load and temperature control system whose
dominant signal depends on the mode of opera-
tion of the turbine generator set: for example,
starting, stopping, operating in island mode, op-
erating in parallel with other units, or operating in
parallel with a utility source.
The system consists of the turbine speed
transducer (magnetic pickup), the speed monitor,
turbine T5 temperature thermocouples, tempera-
ture input module, electronic fuel valve, and the
programmable controller software files.
The governor system maintains generator
frequency and/or generator load distribution
(when operating in parallel) by controlling turbine
fuel flow. Output current to the fuel actuator pro-
vides the mechanical interface to the electronic
fuel valve. The system includes provisions for
selection of isochronous or speed droop modes
5
of operation. The transfer from droop to isochro-
nous and isochronous to droop is bumpless.
Speed set-point adjustment is by means of speed
increase and speed decrease momentary push
buttons on the turbine control console.
A solid-state combination generator control
module (CGCM) provides load sharing between
multiple units and is specifically designed to in-
terface with the programmable controller to pro-
vide an integrated power generation control solu-
tion. Each generator's load is continuously meas-
ured by the respective CGCM and compared to
other units on the same bus via interconnect cir-
cuits, facilitating equal real and reactive load
sharing between the units.
Turbine engine temperature (T5) is also an
input to the governor control. When turbine tem-
perature exceeds rated levels, fuel flow is then
controlled based on temperature rather than
speed or load inputs. In the case of a generator
paralleled with an infinite bus (utility), the tem-
perature control limits the load-carrying contribu-
tion of the unit to its rated full-load capacity for
the current ambient temperature conditions.
When the generator is not paralleled with the
utility, the temperature control is set to a higher
temperature to allow momentary operation in ex-
cess of rated load during on-load transients.
T5 Temperature Limiter. Limits the real load
(kW) on a unit operating in parallel with a large
power source, such as an electric utility or other
infinite bus system at the maximum unit rating for
any ambient temperature condition. The system
limits the kW load by limiting T5 temperature to a
predetermined factory-set level. When the pre-
determined temperature level is reached, the lim-
iter takes control of the throttle and prevents any
further increase in temperature and, thus, load.
The unit continues to operate at this full site-rated
load for the current ambient temperature. With
changes in ambient temperature (engine air inlet
temperature T1), the limiter adjusts the load to
maintain a constant T5 temperature, thus, auto-
matically maintaining the unit at full site-rated
load at all times.
If the application periodically requires opera-
tion at a specific constant load level, rather than
full site-rated capacity, then the optional kW con-
troller should be used.
The T5 temperature limited system is a part of
the turbine temperature control and indication
system and its set point can be viewed from the
VDU.
GENERATOR CONTROL AND PROTECTION
General. Combining several generator control
components into one powerful package, the
combination generator control module (CGCM)
provides more flexibility and accessibility to spe-
cific generator control options. The CGCM (Fig-
ure 6) combines load share, synchronization,
voltage control, reactive power control, and gen-
erator protection functions into one module. The
CGCM communicates with the programmable
controller via high speed ControlNet 1.5 (Figure
7). The module performs synchronization in com-
bination with the programmable controller soft-
ware program and voltage regulation via the con-
trol of the exciter field current. The module
senses the three-phase voltage and the three-
phase current via PTs and CTs. The module pro-
vides real load-sharing and reactive load sharing.
Reactive load sharing can be reactive droop or
reactive differential (cross-current compensation).

Auto Synchronizing. The control system in-

cludes an auto synchronizer for the closure of the
unit circuit breaker. Upon sending an initiate syn-
chronization discrete signal, the auto synchro- Figure 6. Combination Generator Control
nizer brings the generator into frequency, volt- Module (CGCM)

Figure 7. Typical Generator, Exciter, and Regulator System

6
age, and phase compliance and sends a signal to
close the unit circuit breaker. The error signal for
the voltage and phase comes from the CGCM.
The communication is via ControlNet 1.5.
KW Control (Optional). Controls the real kilowatt
load on a generator operating in parallel with an
infinite bus or other large source. Three types of
kW load control are available:
1. KW Import Control – The kW import
control system controls the real load (kW)
on a unit operating in parallel with a large
source such as a utility. The import control
monitors the load that is being imported
from the utility source and adjusts the tur-
bine generator output to maintain a pre-
set amount of minimum load. The import
control allows the import of unlimited
power while maintaining the minimum
power. This control is for applications
where it is desired to prevent any power
from being exported to the utility.
2. KW Control – The kW control system
controls the real load (kW) on a unit oper-
ating in parallel with a large source. The
control monitors the load carried by the
turbine generator set and adjusts turbine
fuel flow to maintain a constant load under
conditions of varying infinite bus fre-
quency. The turbine T5 limiter system pro-
vides protection against excessive kW
load while in parallel with an infinite
source. The kW control system provides
additional operational flexibility by allowing
unit kW load level to be set at any desired
constant level within the capacity of the
unit. In this mode, the unit may be carrying
the entire load within the plant, while the
remaining unit capacity is being exported
to the utility. In addition, the kW control set
point can be the manipulated variable in
the process control loop. For example, to
modulate steam production in a cogen-
eration application, the steam production
control could modulate the kW control set
point.
3. KW Export Control – The kW export
control limits the amount of power that is
being exported to the utility or large
source. The amount of power that is being
exported is limited to a preselected value.
If the selected value exceeds the turbine
capacity, then the T5 limiting control pro-
tects the turbine against excessive kW
load.
7
VOLTAGE REGULATION
Steady-State Stability
Steady-state voltage regulation is defined as
constant frequency and load. When the generator
is operating steady state at any load, the gen-
erator voltage varies no more than ±0.1%.
No Load to Full-Load Accuracy
At constant frequency and at rate power factor,
the voltage regulation varies no more than
±0.25%.
Automatic Voltage Regulator (AVR)
The voltage adjustment range about the selected
nominal value is ±10%. The resolution of the
voltage is 0.1%. Voltage metering accuracy is
±0.2%.
Field Current Regulator (FCR)
The current regulation mode allows the operator
to adjust the field current manually. This gives the
operator a manual voltage regulator. During the
FCR mode, the automatic voltage regulator is
disabled. It is important to note that the FCR is
not the equivalent of an independent manual
voltage regulator, since it uses some of the same
circuitry as the automatic voltage regulator.
CONTROL AND PROTECTION
Reactive Voltage Droop
Reactive voltage droop is possible through the
use of a single externally provided current trans-
former (CT). The voltage droop is adjustable for a
maximum of 10% droop at 0.8-power factor and
full rated load of the generator. Reactive droop,
cross-current compensation and no droop voltage
control are selectable via ControlNet 1.5.
Cross-Current Compensation
The cross-current compensation method of par-
alleling is possible with other controllers of similar
type. This uses the same CT that is used if reac-
tive voltage droop is selected instead of cross-
current compensation.
KVAR/Power Factor Control (Optional)
This feature maintains a constant reactive load
(kVAR) output or constant power factor (pf) on
the generator set when the unit is operating in
parallel with a large source. Power factor and
kVAR control can be enabled or disabled by the
operator from the VDU. The operator can also
select whether to use kVAR control or power
factor control and set the set points from the
VDU.
Kilowatt Load Sharing
The load-sharing circuitry provides the ability to
communicate with another CGCM, such that two
or more generator sets may equally share load
when running in parallel. Also, the CGCM will
load share with older controls from Solar, such as
the LSM module or Woodward 2301 governor.
The load sharing between generators of unequal
rating is proportional to their rating.
Over-Excitation Limiting
The over-excitation limiter senses field current
and responds in less then three cycles. When
field current exceeds the limits, the limiter func-
tion overrides the action of the CGCM AVR, VAR,
or power factor modes and limits the current to
the preset level.
Under-Excitation Limiting
Under-excitation limiting (UEL) limits the de-
crease in excitation to prevent loss of synchroni-
zation and excessive end-iron heating during
parallel operation.
Line Drop Compensation
Line drop compensation is a function of generator
output current. Both the real and the reactive
component of the current are used. The compen-
sation is based on the magnitude of the line cur-
rent. It is adjustable from 0 to 10% of rated volt-
age.
Voltage Input Signal
The voltage regulator sensing uses three-phase
signals.
Current Input Signal
The CGCM uses 5-amp nominal inputs. The ac-
curacy is ±0.2% of full scale.
Protection
The protection functions are designed to diag-
nose and respond to the following events:
· Over-excitation voltage (59F)
· Generator over voltage (59)
· Generator under voltage (27)
· Loss of sensing (60FL)
8
· Loss of PMG (27)
· Loss of excitation (40Q)
· Over frequency (81O)
· Under frequency (81U)
· Reverse power (32R)
· Phase rotation error (47)
· Over current (51)
· Rotating diode monitor (58)
· Reverse VAR (40)
Over-Excitation Voltage. The over-excitation
voltage protection has a timed over-excitation
trip. The timed over-excitation protects the con-
troller and generator from long-term field forcing
conditions.
Generator Over Voltage. The unit has an over-
voltage monitor adjustable from 100 to 140% of
rated voltage in 1% increments.
Generator Under Voltage. The unit has an un-
der-voltage monitor adjustable from 60 to 100%
of rated voltage, settable in 1% increments.
Loss of Sensing. When the generator voltage
falls below 15% of the rated generator voltage, a
loss of voltage sensing annunciation occurs. The
loss of sensing function is supervised by the loss
of operating power function and does not become
active until operating power reaches its minimum
threshold.
Loss of PMG. A loss of PMG fault is issued
within three cycles (50 msec) if PMG power input
is lost.
Loss of Excitation. A loss of excitation protec-
tion fault is issued in order to protect against a
reverse VAR condition in the event the excitation
current is lost.
Over Frequency. When generator frequency
exceeds rated frequency for a specified amount
of time, an over-frequency fault is annunciated.
Under Frequency. When generator frequency
falls below the rated frequency for a specified
amount of time, a definite time under-frequency
fault is annunciated.
Reverse Power. The reverse power protection
pickup level is settable from 1 to 50% of rated
generator power in increments of 1%. This fea-
ture considers real power only.
Phase Rotation Error. When possible and en-
abled, a phase rotation check is performed prior
to initiation of breaker closure.
Over-Current Protection. Over-current protec-
tion must be provided with a short inverse time
characteristic, Basler Electric Time Characteristic
curve S2, 99-1595. This feature is active if exci-
tation is enabled.
Rotating Diode Protection. The rotating diode
monitor is capable of detecting one or more open
or shorted diodes in the rotating field. If a failed
diode is detected, a fault is issued.
Reverse VAR. When excitation current is lost
and the reverse VAR level exceeds the rated
value for a definite amount of time, a reverse
VAR fault is annunciated.
OPERATOR INTERFACE
The control system operator interface has two
major components: the turbine control panel and
the video display unit.
Turbine Control Panel
The turbine control panel (Figure 8) provides the
essential controls to start or stop the turbine, to
adjust the gas generator speed, and other op-
tional control functions. Some typical gas turbine
controls and indications that appear on the con-
trol panel include the following:
Operation Switches
· Off/Local/Remote (control selector with
lockable positions)
Figure 8. Operator Interface
9
· Emergency Stop (shutdown without
cooldown)
· Normal Stop (shutdown with normal no-
load cooldown)
· Speed Control (increase and decrease)
· Start
· Horn Silence (audible alarm)
· Acknowledge (alarms and shutdowns)
· Backup System (Active/Reset)
Operation Indication Lights
· Starting
· Backup Active
· Stopping
Onskid Video Display Unit
The video display unit is used to present an ex-
tensive selection of the turbomachinery operating
parameters. The display system consists of sev-
eral screens organized by systems and functions
to allow the operator to easily locate and monitor
a given parameter. It also includes a password-
protected screen, which allows the operator to
input or modify certain values such as process
control set points.
The onskid VDU makes use of Solar's
TT4000S display and monitoring system, which
performs several key functions to facilitate opera-
tion of the turbomachinery equipment through a
user-friendly interface. The TT4000S system
monitors the turbine and driven equipment pa-
rameters, annunciates alarms, reports on the
running status of the equipment, and provides a
comprehensive set of analysis tools.
Data storage consists of an alarm / event log
containing the last 5000 events, five trigger logs
containing one-second tag samples surrounding
the last five shutdowns, and an hourly log con-
taining snapshot data for the last 12 months.
The TT4000S display and monitoring system
uses the Embedded Windows NT operating sys-
tem and offers the following industry standard
features:
· Complies with Transmission Control Proto-
col and Internet Protocol (TCP/IP)
· Supports Object Linking and Embedding
for Process Control (OPC)
· Supports ActiveX controls
· Can be integrated as part of a local area
network for sharing of data or remote dis-
play communications
Standard Display Screens
The display screens listed below are for a typical
package and are provided as standard equipment
for all turbine packages:

· Main Menu
· Operation Summary
· Engine Temperature
· Shaft and Bearing
· Lube System
· Generator Summary
· Bus Summary
· Generator Control Modes
· Generator Set Points Figure 10. Typical Operation Screen
· Gas Fuel System
· Liquid Fuel System
generator data, control mode, fuel command
· Enclosure
status, fuel selection, operation mode, shutdown
· Alarm Summary status, and lube pump operation. This screen
· Alarm Log also displays the starting and stopping se-
· Event Log quences.
During the package start sequence, the VDU
· Strip Chart
shows the various logic and timed sequences
· Maintenance Modes involved from initiation of start-up to running con-
· VFD Configuration dition. This feature is a valuable troubleshooting
resource for operations personnel to quickly
Menu Screen. (Figure 9) This screen provides identify the source of the starting problem and,
the operator the ability to view the selectable view thus, reach a faster solution.
screens.
Engine Temperature Display Screen. (Figure
11) This screen displays all the turbine-related
temperatures monitored on the unit. The screen
displays each individual thermocouple tempera-
ture, as well as the calculated averages.

Figure 9. Typical Menu Screen

Operation Summary Screen. (Figure 10) This

screen provides a view of the overall gas turbine Figure 11. Typical Engine Temperature
and driven equipment operating parameters. The Screen
screen displays turbine engine temperatures,

10
Shaft and Bearing Screen. (Figure 12) This
screen shows a bar graph representation of the
vibration levels of the engine and generator as
detected by the vibration monitoring system. The
screen displays the bearing temperatures for
engine and generator.
Figure 12. Typical Shaft and Bearing Screen
Typical Lube System Screen. (Figure 13) This
screen displays all pertinent data for the lube oil,
such as pressure, temperature, and the status of
the pumps, along with the manual “backup pump”
test function.
Figure 13. Typical Lube Oil Screen
Generator Summary Screen. (Figure 14) This
screen is a summary of the real-time generator
operating data provided by the control system,
including operating modes, set points, along with
AC calculated and monitored values.
11
Figure 14. Typical Generator Summary
Screen
Bus Summary Screen. (Figure 15) This screen
is a summary of the real-time generator and
customer bus operating data system provided by
the control system, including Circuit Breaker Trip
and Auto Sync Initiate control.
Figure 15. Typical Bus Summary Screen
Generator Control Screen. (Figure 16) This
screen allows the operator to view the status of
the various generator control modes and to select
the control mode desired through the use of pop-
up screens.
Generator Set-Point Screen. (Figure 17) This
screen allows the operator to change set points
by means of a pop-up screen or the local In-
crease/Decrease switch. The set point and actual
values are viewed from this screen as well.
Figure 16. Typical Generator Control Figure 18. Typical Gas Fuel Screen
Modes Screen

Figure 19. Typical Liquid Fuel Screen

Figure 17. Typical Generator Set-Point
Screen

Gas Fuel Screen. (Figure 18) This screen dis-

plays all of the pertinent data for the gas fuel
system, such as pressure, flow, actuator, and
status of the fuel valves. For a dual fuel system,
the operator can transfer fuels from this screen.

Liquid Fuel Screen. (Figure 19) This screen dis-

plays all of the pertinent data for the liquid fuel
system, such as pressure, flow, actuator, and
status of the fuel valves. For a dual fuel system,
the operator can transfer fuels from this screen.

Enclosure Screen. (Figure 20) This screen dis-

plays information related to the enclosure de-
Figure 20. Enclosure Screen
vices, such as fan, temperature, and gas sensor.

12
Alarms Summary Screen. (Figure 21) This
screen displays all alarm and shutdown annun-
ciations with a time and date stamp. Alarms are
time stamped in the order in which they are re-
ceived from the programmable controller.
On the display, alarms are shown in yellow
and shutdowns in red. Unacknowledged alarms
are shown in reverse video. As the malfunctions
are acknowledged, they stop flashing and are
shown in the corresponding colored text until they
are cleared from the system and the Reset switch
is pressed. The first four malfunctions detected
are displayed at the top of all screens until
cleared.

Figure 22. First Out Alarm Screen

Discrete Event Log. (Figure 23) This feature

Figure 21. Typical Alarm Summary Screen
First Out Alarms Display Screen. (Figure 22)
This screen displays the order in which alarms
occurred. The resolution of the alarm order for
this feature is the time of one programmable
controller scan. These data are obtained by
reading the controller's first out alarm buffer,
starting at the first unacknowledged alarm. The
controller updates this buffer each scan. Only
unacknowledged alarms appear on this screen.
Up to 22 alarms can appear.
monitors and records the changes in status of all
defined discrete (switch or binary) inputs. These
include operator command, alarms and shutdown
annunciations, and key sequencing and status
signals. They are displayed as a chronological,
time-stamped listing of events in the order in
which they occurred. It is possible to have multi-
ple events with the same time stamp due to the
update rate of the display system. Up to 500
events can be stored in the log. Events can be
selected by double clicking on the column head-
ing. Right clicking anywhere on the screen and
selecting the Reports menu can easily create
reports.
This feature provides a historical record of
sequence and status events that changed. It can
be used to audit package operation or to identify
malfunctions that have occurred and areas of the
operation that need attention.

Note: If the First Out Alarms display is to be used

to diagnose a shutdown, the Acknowledge button
on the control panel must not be pressed. Press-
ing the Acknowledge button does not eliminate
unacknowledged alarms from the controller's
alarm buffer, but it changes an alarm index so
that the First Out Alarms display cannot access
them. As long as the Reset button is not pressed,
however, the unchanged contents of the control-
ler alarm buffer can be viewed as described
above.
Figure 23. Typical Discrete Event Log
Display Screen

13
Strip Chart Function. (Figure 24) This function
emulates a 10-pen strip chart recorder. The
screen displays in real-time up to 10 variables
selected by the operator. Parameters are se-
lected by assigning each pen a value; the values
can be analog or binary data available for moni-
toring. Each pen can be assigned different colors,
line weights, and symbols to make each moni-
tored value easily distinguished from one an-
other. The bottom of the strip chart screen dis-
plays the corresponding legend for each pen.
Each of the plots is scaled for the selected
variable and displays the actual numerical value
for each variable. The date range and scaling can
be changed by double clicking on the desired pen
to bring up the configuration pull-down menu. The
Figure 25. Typical Maintenance Screen
time axis on the strip chart can be configured for
each pen by date, hours, minutes, or seconds.
The "zoom" feature allows the user to zero in on
VFD Configuration Screen. (Figure 26) This
the particular area of interest.
screen allows the operator to configure the VFD
motors and monitor the performance of the mo-
tors.

Figure 24. Typical Strip Chart Screen

Figure 26. Typical VFD Configuration Screen

Maintenance Screen. (Figure 25) This screen
allows users to perform routine maintenance on
the turbine and displays information such as en-
gine hours and engine starts.

14
Optional Control and Display Features
Other hardware and software options are avail-
able that provide additional flexibility and capabil-
ity to the basic programmable controller control
system. These software, control and display fea-
tures are described in this section.
ENGINEERING UNITS
The following engineering units are available for
display purposes:
Type Pressure Temp. Length
English psig °F inches
Metric (SI) kPa mm
°C
Metric bar °C mm
2
Metric kg/cm °C mm
FIRE DETECTION AND SUPPRESSION
SYSTEM
A fire detection system is available for installation
in the enclosure. The primary fire detection sys-
tem uses ultraviolet (UV) detectors. The system
includes an automatic optical integrity feature,
which provides a continuous check of the optical
surfaces and detector sensitivity.
The secondary detection system uses rate-
compensated thermal detectors. The two detec-
tion systems act completely independent in de-
tecting a fire.
A fire system supervisory release panel is
furnished whose primary purpose is to supervise
the fire system circuitry. An open circuit, ground
fault condition, or loss of integrity in the electrical
wiring results in a trouble signal.
If a fire is sensed, the detectors transmit an
electrical signal via the fire system controller and
the fire system supervisory panel to activate the
fire suppression system. In receiving this signal,
the explosionproof control heads activate the dis-
charge valves on the primary and extended ex-
tinguishing cylinders, releasing the extinguishing
agent into the enclosure and pressurizing the
trips that close all vent openings. The fire sup-
pression system achieves a static air condition
and then floods the enclosure with the proper
concentration of suppressant to extinguish the
fire.
FIELD PROGRAMMING
One characteristic of the control is that it can be
reprogrammed using optional software with criti-
15
cal logic and constants accessible. Limited secu-
rity to prevent inadvertent programming changes
is built in, but predetermined programming altera-
tions are possible with appropriate software.
Programming Terminal. A computer specifically
configured for programming the programmable
controller control logic and sequences is pro-
vided, along with software and a programming
manual to allow for field programming of the con-
trol system logic within the control system.
Programming Kit. The field programming kit in-
cludes software, programming manual, and a
PMCIA Type II interface card to allow field pro-
gramming of the control system and logic.
LANGUAGE
The turbomachinery package labels, control con-
sole labels, and operator interface screen dis-
plays are available in numerous languages. For
languages available, please contact a Solar Tur-
bines representative.
COMMUNICATIONS – TURBINE CONTROL
TO SUPERVISORY SYSTEM
Communication between the gas turbine control
system and the user's supervisory control and
data acquisition (SCADA), distributed control
system (DCS), or other supervisory system is
available. Turbotronic 4 control systems can be
provided with an interface that allows the super-
visory system to communicate with the program-
mable controller, obtain data, and have the con-
trol capability required.
Data for Transmission
The following information from the turbine pack-
age is available to be accessed by the supervi-
sory system:
1. Analog instrumentation values
2. Discrete status values
3. Discrete alarms and shutdowns
The following information can be sent by the su-
pervisory system:
1. Discrete control commands (start, stop,
acknowledge/reset, and change mode of
operations)
2. Analog operating set points (kW control,
speed, kVAR, pf, and voltage)
 The specific addressing for the data transfer necessary drivers to communicate with all turbine
is provided for each turbine package. package control networks and network devices
(except Modbus) and is required for most appli-
Protocol cations.
The communication language used between pro-
Supervisory Interface Options
grammable controller systems usually follows a
set of rules or format called a “protocol.” The There are many ways to interface with the gas
protocol defines the sequence and organization turbine control system. The most common in-
of the transmitted data. The RSLogix controller clude serial communication (RS232, RS422,
uses an internal proprietary bus protocol called RS485), Ethernet TCP/IP, ControlNet 1.5, and
“control and information protocol” (CIP). Commu- Modbus. See Figure 27 for a typical communica-
nication modules allow different communication tion network layout.
networks to interface with this internal bus. Cer- Each communication network has certain ad-
tain arrays of information inside the controller can vantages and disadvantages that need to be
be configured to mimic PLC-5 data tables that considered when selecting a network for a par-
support the DF1 protocol. The user's supervisory ticular application. Below is a description of each
system must be programmed to handle the CIP, network to help select the optimum interface for
DF1, or Modbus protocols. The Allen-Bradley the user’s application:
communications software RSLinx provides all the

Remote Video
Display Unit Auxiliary Video Display
Unit with CNet1.5 PCIC
Basic Configuration Line Printer
Options

RS232
Ethernet

Modbus
Ethernet TCP/IP RS232

SCADA/DCS KFC15

Onskid Control Box

ControlNet Module

Ethernet Module
Modbus Module

Backup Relay
ControlLogix

Shutdown System

Flex I/O (Normal Input/Output)

Redundant
ControlNet 1.5

Hardwire Interconnect

VFD(s)
ControlNet 1.5
(NAP connection)
Heat
Recovery
System Local Programming
Terminal (for use during
commissioning)

Figure 27. Typical Communication Network Layout

16
ControlNet 1.5
This is an Allen-Bradley developed proprietary
field bus network. Data transmission rates are
high, the communication is deterministic, and all
interface modules can be configured for redun-
dant media.
· Physical media: quad shielded RG-6U
coaxial cable
· Protocol: CIP
· Topology: Trunk line/drop line,
star with repeaters
· Maximum distance (per Rockwell
specifications): 1000 m (3280 ft) with
2 nodes, 250 m (820 ft) with 48 nodes
· Maximum data transmission rate: 5 Mbps
· Maximum number of nodes: 48
Typical Application. This is the control network
used to connect the distributed I/O modules to
the controller for turbine control. Onsite, VDUs
are typically connected directly to this I/O network
via PCC or PCIC cards installed in the computer.
Supervisory interface (RS232C) with the turbine
via ControlNet is allowed only through a serial
link connection module (KFC15) or a separate
ControlNet network that is not directly connected
to the turbine I/O network. The maximum dis-
tance and number of nodes allowed for the net-
work can be increased by adding repeaters
and/or by using optical fiber media. Field pro-
gramming terminals can connect to the network
via the network access port (RJ-type) located on
the interface module or Flex I/O adapters. Cur-
rent ControlNet 1.5 networks and network de-
vices are not compatible with older ControlNet
1.25 networks or network devices.
Ethernet TCP/IP
Data transmission rates are high, the communi-
cation is non-deterministic, and cabling and con-
nectivity is well known throughout most industries
(common office computer network technology).
· Physical media: twisted pair (10BaseT)
· Protocol: CIP over TCP/IP
· Topology: star
· Maximum distance (per Rockwell
specifications): 100 m (328 ft) to hub
· Maximum data transmission rate: 10 Mbps
· Maximum number of nodes: unlimited
(8 to 24 nodes per hub typical)
17
Typical Application. The turbine package
Ethernet module is usually connected to a local
hub that is connected to an Ethernet backbone
for data transfer to a remote supervisory system
over longer distances. 10BaseFL fiber lines sup-
port 2000 m (6560 ft) segments.
Modbus Slave
The Modbus protocol is an open, published and
widely implemented protocol. It is used to transfer
I/O and register data between Modbus control
devices.
· Physical media: shielded twisted
conductors
· Protocol: Modbus RTU
· Topology: point-to-point (RS232/RS422)
or multi-drop (RS485)
· Maximum distance (per Rockwell
specifications): 15 m (50 ft) for RS232,
1219 m (4000 ft) for RS422/RS485
· Maximum data transmission rate:
115.2 kbps
· Maximum number of nodes: 32 (RS485)
Typical Application. The Modbus Interface op-
tion gives the turbine package control system the
ability to communicate with a Modbus master
device through a serial interface (RS232, RS422,
or RS485). The turbine package control system
acts as a Modbus slave device using a subset of
the RTU version of the Modbus protocol. The
user provides the Modbus master device, which
may be a supervisory control system, a data ac-
quisition system, a central or plant control sys-
tem, a remote monitoring system or some other
computer system.
Remote RS232/422/485 Serial Link
Serial link communication allows connectivity of
devices without special communication modules
to communication networks.
· Physical media: shielded twisted
conductors
· Protocol: N/A
· Topology: point-to-point (RS232/RS422)
or multi-drop (RS485)
· Maximum distance (per Rockwell
specifications): 15 m (50 ft) for RS232,
1219 m (4000 ft) for RS422/RS485
 · Maximum data transmission rate: 20 kbps The auxiliary VDU communicates with the
(RS232), 100 kbps @ 4000 ft/10 Mbps onskid controller through ControlNet 1.5. The
@ 40 ft (RS422/RS485) total ControlNet cable run must be no longer than
762 m (2500 ft). Cable run lengths for the auxil-
· Maximum number of nodes: 32 (RS485)
iary VDU vary from project to project depending
upon how close the motor control center is to the
Typical Application. A remote serial link is pro-
gas turbine. Typically, the cable run without the
vided to allow a remote supervisory system to
auxiliary VDU is less than 150 m (500 ft), leaving
send and receive data to and from the ControlNet
610 m (2000 ft) for the auxiliary VDU cable run.
network via an external Allen-Bradley KFC15
Note: these distances are reduced if high flex
communication module (RS232). Supervisory
cable is used.
serial interface through the DH+ network using a
remote KF2 interface module is not advised,
Remote Video Display Unit
since this device can only handle local messag-
ing (communication through other remote net- The remote video display unit (VDU) option con-
works is not allowed). The application software sists of an industrial desktop computer equipped
on the remote supervisory system must handle with TT4000. The remote VDU has all the fea-
either DF1 or CIP communication protocols. tures of the auxiliary VDU with the exception that
some of the operational privileges are limited at
VIDEO DISPLAY OPTIONS the remote VDU. For example, lockout shut-
downs cannot be reset remotely. The auxiliary
Auxiliary Video Display Unit
VDU option is a prerequisite for the remote VDU
The auxiliary video display unit (VDU) consists of option.
an industrial desktop computer and the TT4000 The remote VDU communicates with the
display and monitoring system. The auxiliary auxiliary VDU through Ethernet. The Ethernet
VDU has all the features of the standard skid- interconnect is the responsibility of the customer.
mounted VDU plus the following enhancements: Distance is limited only by the customer’s net-
work. Both the remote VDU and the auxiliary
· Additional Historical Data VDU come with an Ethernet port and modem.
– 2-Minute Log. 1 month of daily files with The viewing of historical data from the remote
data points taken every 2 minutes VDU may be noticeably slower depending upon
– 10-Second Log. Data are read at 10- the speed of the customer-supplied network.
second intervals for the last 14 days. A gas turbine performance map for the pre-
dicted rating of a gas turbine at standard condi-
· Larger Trigger Log. The Trigger Log tions is displayed on the VDU (Figure 28). Algo-
function stores up to 25 triggered files,
each containing 6 minutes of 1-second
data points. (The onskid VDU stores 5
triggered files.)
· Accommodates Additional Options
– Gas turbine performance calculations
and display
– Printer
– Remote VDU
· Higher Resolution Screen
· More Memory, including RAM and
Non-Volatile Storage
· Incorporates Visual Basic for
Application (VBA)
· DVD Reader / CD Writer
Figure 28. Gas Turbine Performance Map

18
rithms convert site data to standard conditions
and the operating point is displayed real time on
the map at the intersection of X and Y cursors.
Digital values for the predicted power, inlet
air temperature, gas turbine temperature, fuel
flow, and compressor discharge pressure are
also displayed on the screen. A key performance
indicator is provided for display by calculating the
differential value (actual minus predicted) of the
digital values. The trend of these parameters pro-
vides a true indication of performance degrada-
tion since the data are standardized for the actual
operating point and not just optimum.
Information gained from this feature can point
to corrective and diagnostic action required, such
as washing the compressor and borescoping the
hot gas path.
Printer/Logger Option
This option is available with the auxiliary VDU. It
includes a printer, cable, and software and pro-
vides for a variety of reports and event logging.
Features provided are:
· Alarm and Shutdown Log – Prints one
event per line with time and date stamp.
· Reports – On demand, prints current
values of standard analog variables and
calculated variables. Standard totalized
variables may be printed also.
· Print Screen – On demand, prints any
screen that is currently being displayed.

19
Appendix A: Hardware
PHYSICAL HARDWARE
· Programmable Controllers Allen-Bradley ControlLogix
· I/O Allen-Bradley Flex Modules
· Voltage Regulator Basler Electric/Allen-Bradley
Combination Generator Control Module (CGCM)
· Onskid Display Allen-Bradley 6181
· Power Supply 120 Vdc to 24 Vdc
· Transducers 4 to 20 mA
· RTDs Platinum 100 Ohms a = 0.00385
· Control Enclosure NEMA 4 or NEMA 4X
· Backup Controls Backup overspeed box
Backup relay shutdown system
· Internal Wiring 20 gauge, typical
22 gauge for low level shielded wire
12 gauge for most power wire
Wire identification, branded every 152 mm (6 in.)
All customer connects are to Flex I/O or terminal blocks on DIN rail

ELECTRICAL SPECIFICATION
· Input Power
· Internal Power
· Input Signals
· Output Signals
· Relay Rating
120 Vdc
24 Vdc
Discrete signals, 24 Vdc
Analog signals, 4 to 20 mA
Low level temperature RTD
High level temperature thermocouple
Speed signal magnetic pick-up
Discrete 24 Vdc, 0.5 amp max.
Discrete 24 Vdc, 2 amps max.
Analog signals, 4 to 20 mA
24 Vdc, 3 to 10 amps
120 Vac,12 amps

ENVIRONMENTAL SPECIFICATION
· Operating Temperature 0 to 60°C
· Storage Temperature -40 to 85°F
· Relative Humidity 5 to 95% non-condensing
· Vibration 1g peak 5 to 20 Hz
· Area Classification Nonhazardous

RFI/EMI SUSCEPTIBILITY AND EMISSION

Similar equipment has been tested to the specification list below and passed the test successfully:

· IEC 801-2 Electrostatic Discharge Level 3

· IEC 801-3 Radiated Immunity Level 3
· IEC 801-4 Fast Transient/Burst Level 3
· IEC 801-5 Electrical Surge Immunity Level 3
· IEC 801-6 Conducted Emission Level 3
· CISPR/B Conducted Emission Class A
· CISPR/B Radiated Emission Class A
20
Appendix B: Technical Supplement
HARDWARE INFORMATION
ControlLogix Processor. The Allen-Bradley Logix5555 processor has 1.5 Mbytes of user memory and
can be connected in a variety of networks for interconnection with computers, distributed processing, and
distributed I/O:

General Specifications
· Processor for Logix5555
· Environmental Conditions
– Operational Temperature
– Storage Temperature
– Relative Humidity
· Vibration – Operating
1756-L55M13
0 to 70°C (32 to 158°F)
-40 to 85°C (-40 to 185°F)
5 to 95% (without condensation)
10 to 500 Hz, 2.0 g maximum peak acceleration

Electrical Specifications
· Operating Voltage 19.2 to 32 Vdc (24 Vdc nominal)
· Integrated Battery Each Logix5555 processor is shipped with a battery installed for
memory backup (part number 1756-BA1).

ControlLogix Power Supply. Used with the 1756 chassis to provide power directly to the chassis back-
plane:

· Model 1756-PB72
· Input Voltage 24 Vdc
· Input Power 97 W
· Backplane Output Current 1.50 A @ 1.2 Vdc
4.00 A @ 3.3 Vdc
10.0 A @ 5.0 Vdc
2.80 A @ 24 Vdc

Discrete Input Modules. These modules receive input from on/off devices such as level switches, pres-
sure switches, push buttons, relays and protective equipment:

· Model 1794-IB16
· Channels 16
· Signal 10 to 32 Vdc

Discrete Output Module. This module drives devices such as solenoid valves and motor contactors.

Current Rating
Model Channels Signal Per Channel Per Module
1794-OB16P 16 10 to 32 Vdc 0.5 8
1794-OB8EP 8 19 to 32 Vdc 2 10

Analog Input Modules. Some modules accept signals from high-level output devices, such as current
transmitters; others accept low-level signals, such as from RTDs.

Model 1794-IE8 Series B

· Channels 8
· Signal Rating 4 to 20 mA, 0 to 20 mA,
± 10 V, 0 to 10 V

21
Model 1794-IJ2
· Channels 2
· Inputs per Channel 2 (frequency and gate)
· Frequency 32,767 Hz max.
· Usage Fast, high resolution speed measurements

Model 1794-IRT8
· Channels 8
· Inputs Ranges -40 to +100 for thermocouples
0 to 325 mVdc for RTDs
0 to 500 ohm for resistance range
· Usage High-speed module used for temperature measurements. Separate
scaling and cold junction compensation is required.

Analog Output Modules. These modules are used for drive-positioning devices such as the fuel throttle
valve and to provide analog signals to other instrumentation.

Model 1794-IE8 Series B

· Channels 4
· Output Current 4 to 20 mA, 0 to 20 mA
· Output Voltage ± 10 V, 0 to 10 V,
± 5 V, 5 V

HARDWARE CERTIFICATION
In general, Allen-Bradley components are SA and ATEX certified for Class I, Division 2, Zone 2, Groups
A, B, C, and D.

AREA CLASSIFICATION
Nonhazardous.

QUALITY ASSURANCE
Complete control systems are put through three test phases at Solar: static test, pre-test, and final test.
Further tests are made during installation and commissioning.

1. Static Test. Verifies the correct console wiring and software was installed, including the standard
options and nonstandard features required for the project.
2. Pre-Test. The controller is mated with the unit it is shipped with and is used to verify correct skid
wiring and certain statically tested functions.
3. Final Test. The unit is operated with its control system, where final package and control tests are
made. The software used for this test is the “as-shipped” software (excluding Titan gas turbines).
4. Commissioning. During commissioning tests onsite, any further software changes that are found
to be necessary are included in the “as installed” software.

CONTROL CONSOLE LAYOUT

The basic arrangement for the programmable controller is to have one seven-slot 1756 I/O chassis and
power supply similar to the one seen in Figure 29. The programmable controller module is in the left-
most slot and all other applicable modules occupy the six remaining slots. This assembly is mounted on a
panel (Figure 30) attached to the back wall of the console.

22
Figure 29. ControlLogix Chassis Configuration

Figure 30. Generator Control Panel and Turbine Control Panel Internal Configuration

23
Appendix C: Control System Information
TURBOTRONIC DEFINITIONS
Control Processor. The central controlling de-
vice. Turbotronic 4 uses the Allen-Bradley Con-
trolLogix processor, which replaces the pro-
grammable logic controller (PLC5) used on ear-
lier systems.
HMI. Human Machine Interface – the generally
accepted industry term for display and monitoring
systems, such as Solar’s TT4000 product.
Onskid. Located on and permanently attached
to the turbomachinery package skid.
Remote. Located someplace other than the tur-
bomachinery area and control room, usually at
some distance away in an unclassified area.
Remote HMI implies a secondary HMI system in
addition to the primary HMI.
TT4000. A Windows 2000 based display and
monitoring system that is available with the Tur-
botronic 4 system.
Turbotronic 4. Solar Turbines new package and
control system.
package skid. It provides only limited data stor-
age capability.
TT4000 Remote. This is the version of TT4000
installed on a “remote” PC (A-B 6155). It mirrors
the functionality of the primary TT4000 system.
Important Note
TT4000 is provided only as a complete system
installed, configured, and tested on computer
hardware supplied by Solar. This hardware must
be dedicated to the TT4000 system and no other
software may be loaded. This is necessary to
protect the integrity of the system and avoid any
potential interaction with other software.
SYSTEM DESCRIPTIONS
Figure 31 shows the various components that
make up the Turbotronic 4 control system.
Auxiliary Desktop PC
The TT4000 display and monitoring system in-
stalled in a desktop PC. This PC must be located
no more than 762 cable m (2500 cable feet) from
the package skid.

VDU. Video Display Unit – a generic term for a Onskid Control System
computerized display device.
The control system is mounted in one or more
panels attached to the package skid. The panels
HUMAN MACHINE INTERFACE
contain the key elements of the system, including
DESCRIPTIONS
the control processor, the I/O modules, the vibra-
TT4000. Solar’s fully featured display and moni- tion monitoring system, and the TT4000S display
toring system consisting of a desktop PC (A-B system. Packages with onskid controls may only
6155) configured with the Windows 2000 operat- be installed in a nonhazardous area.
ing system, the TT4000 application software, and
the specific project software files. It provides ex- Remote Desktop PC
tensive data storage capabilities in addition to
A secondary TT4000 display and monitoring
display, communications, and control capabilities.
system installed in a desktop PC, providing re-
It is designed for operation in a nonhazardous
mote monitoring and control of the turbomachin-
area such as a control room.
ery package. This PC must be linked to the pri-
mary TT4000 system via a network connection.
TT4000S. A version of Solar’s TT4000 software,
The distance between this PC and the primary
which is installed in an onskid VDU (A-B 6183)
TT4000 system is limited only by the capability of
and makes use of the Windows Embedded NT
the network.
operating system. It provides display, communi-
cations, and basic control capabilities at the

24
 TT4000S

ETHERNET
CONTROLNET OR OTHER

TT4000 TT4000
CONTROL
DESKTOP REMOTE
PROCESSOR
AND I/O

Figure 31. Turbotronic 4 Control System Outline

25
FOR MORE INFORMATION
Telephone: (+1) 619-544-5352
Telefax: (+1) 858-694-6715
Internet: www.solarturbines.com

Solar Turbines Incorporated

P.O. Box 85376
San Diego, CA 92186-5376 U.S.A.

SPTT-PG/802