GE DS200TCEAG1BNE DS215TCEAG1BZZ01A is the Emergency Over Speed Board of the GE Speedtronic Mark VIe control system, specially designed for the overspeed safety protection of rotating mechanical equipment such as gas turbines and steam turbines. It can monitor rotor speed in real time and quickly trigger the emergency shutdown interlock when the speed exceeds the safety threshold. As a key core component for ensuring the safe operation of units, it is widely used in the heavy-duty turbomachinery control scenarios of the electric power, petrochemical and other industries.
Core Functions
Overspeed Monitoring and Protection: Continuously collects speed sensor signals and is built with a high-precision speed measurement circuit. It supports configurable multi-stage overspeed thresholds (e.g., alarm value, trip value), meeting the graded overspeed protection requirements of industrial safety standards such as NEMA and ISO.
Fast Trip Response: Adopts hardware-level overspeed detection logic with a response time of ≤10ms, independent of the main controller CPU. This prevents protection failure caused by software malfunctions and ensures millisecond-level trigger of shutdown commands under extreme working conditions.
Signal Redundancy and Diagnosis: Supports 3 channels of speed sensor input (e.g., magnetoelectric, Hall-effect). It features signal validity judgment and fault self-diagnosis functions, capable of detecting abnormalities such as sensor open circuit, short circuit and signal drift, and outputs fault status via LED indicators and communication interfaces.
Safety Interlock Output: Configured with 2-4 channels of independent and redundant emergency shutdown (ESD) relay outputs, with contact ratings meeting the requirements of 125VAC/250VDC industrial loads. It supports interlocking with safety circuits such as unit trip systems, fuel shut-off valves and excitation systems.
On-line Configuration and Monitoring: Compatible with ToolboxST programming software of the Mark VIe system, supporting threshold setting, event log query and real-time status monitoring via Ethernet or serial port. It also supports parameter locking functions associated with the IEC 61508 SIL 3 safety integrity level certification.
Technical Specifications
| Parameter | Specifications |
|---|---|
| Input Channels | 3 speed signal inputs, supporting magnetoresistive sensors (10-1000Hz) or Hall-effect sensors (5-5000Hz) |
| Measurement Range | 0-150% of rated speed, with a measurement accuracy of ±0.1% FS |
| Overspeed Thresholds | Programmable, supporting 3-stage overspeed protection (e.g., 105%, 110%, 115% of rated speed) |
| Output Interfaces | 4 NO/NC relay outputs (contact rating: 5A/250VAC); 2 analog outputs (4-20mA, for speed feedback) |
| Power Requirements | 24VDC (18-32VDC), power consumption ≤15W |
| Operating Environment | Temperature: -40℃~+70℃; Humidity: 5%~95% (non-condensing); Vibration resistance rating: IP30 (board level) |
| Communication Protocols | Supports Modbus RTU and EtherNet/IP, connectable to the FBM (Field Bus Module) network of Mark VIe controllers |
Working Principle
Signal Acquisition: Rotor speed pulse signals are collected by front-end speed sensors (typically configured with 2-out-of-3 redundancy), filtered and amplified by the signal conditioning circuit, and then transmitted to the high-speed counter module.
Speed Calculation: A hardware counter is used to calculate the speed frequency in real time, convert it into a rotational speed value (rpm), and compare it with the preset overspeed threshold in real time.
Protection Logic: When the speed of any channel exceeds the trip threshold for 3 consecutive sampling cycles, the independent hardware trip circuit is activated immediately to drive the emergency shutdown relay to operate, and the event is reported to the main controller via the communication bus at the same time.
Fault Handling: A built-in watchdog timer and signal diagnosis algorithm are featured. If a sensor fault or board hardware abnormality is detected, an audible and visual alarm will be triggered and the system will switch to the redundant channel to ensure the continuous effectiveness of the protection function.
Installation and Adaptation
Physical Installation: This is a standard 3U size board, compatible with the control cabinet slots of the Mark VIe system, and communicates with the controller via the backplane bus. During installation, ensure the ground resistance ≤1Ω to avoid electromagnetic interference.
Sensor Adaptation: Supports passive magnetoelectric sensors (impedance 500-2000Ω) and active Hall-effect sensors (powered by 5-24VDC). The sensor installation gap must comply with GE specifications (typically 0.5-1.5mm).
System Integration: Must be used in conjunction with Mark VIe main processor modules (e.g., IC698CMX) and I/O modules (e.g., IC698CPE). Parameter configuration, logic programming and safety verification are completed via the ToolboxST software.
Application Value
Safety Assurance: As an independent "last line of defense" separate from the main control system, it effectively prevents catastrophic accidents such as blade damage and shafting fracture caused by unit overspeed, reducing equipment maintenance costs and safety risks.
Compliance Fulfillment: It meets the mandatory standards for rotating machinery safety protection in the electric power and petrochemical industries, helping users pass the compliance inspection of safety supervision departments.
Operation and Maintenance Efficiency Improvement: Supporting online fault diagnosis and remote monitoring, it reduces shutdown maintenance time. Combined with the predictive maintenance function of the Mark VIe system, it improves the operational reliability of units.
Cautions
Verify the compatibility of the board model with the unit speed range and sensor type before installation to avoid protective misoperation caused by parameter mismatch.
Calibrate the measurement accuracy of speed sensors and the board regularly; on-site calibration is recommended every 6 months to ensure the accuracy of protection thresholds.
Follow GE safety operation manual, complete the interlock test of the overspeed protection loop before unit startup, and verify the effectiveness of the trip logic.
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