Catalog of GA Control Systems

GA automation technology

product catalog

Contact information

GEBHARDT Automation GmbH

Thüngenfeld 3 D- 58256 Ennepetal Germany

Tel.: +49 2333 7908 - 0 available during working hours, Mo to Fr, from 800 to 1700 (5 pm) central european time (CET, GMT+1). FAX: +49 2333 7908 - 24

Web: www.gebhardt-automation.de

Support [email protected] Information [email protected]

Date: 10/2012

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Contents GA BlueLine Systems ...... 4 Redundancy, fault tolerance and voting...... 5 Machinery Monitoring Systems...... 6 Monitoring Capabilities...... 7 GA TMR/10-S...... 8 GA TMR SMART-S ...... 9 GA DUPLEX/7-S ...... 10 GA DUPLEX SMART-S ...... 11 GA DualCore-S, BASIC/4 ...... 12 GA COMPACT-FS1 ...... 13 Processor cards ...... 14 ICU mod. 2 ...... 14 MPU-M1 ...... 15 I/O cards...... 16 Non-safety I/O cards ...... 16 DIGI32 model 6...... 16 DIGIO model 6...... 17 MCAD model 6...... 18 MCRTD model 6 ...... 19 MCMIO model 6...... 20 SIL3 safety I/O cards...... 21 MCDIN-S model 1...... 21 MCAD-S model 1...... 22 MCDOT-S model 1 ...... 23 MCADA-S model 1...... 24 MPADA-S...... 25 Field I/O components...... 26 TFAB-DIGIO-2oo3...... 26 DFAB-1oo2D...... 27 TFAB-DIGIO...... 28 TFAB-DSPDA...... 29 GA SR-01-42-24-00 ...... 30 GA SCM1/xA...... 31 FLKM-D50/B/R/SO171...... 32 VIP-3/SC/D50SUB/F ...... 32 GA TFAB PIO...... 33 GA FAB PIO MPADA-S ...... 33 GA FAB SI MCAD-S ...... 34 GA FAB SIPO MCADA-S...... 34 System cable, Standard ...... 35 System cable, Frequency...... 35 GA Software...... 36 GA BlueEdit...... 36 GA DataView...... 36 GA DataLogDLx ...... 36 GA DataLogWin ...... 36 GA TurWin...... 36 GA modOPCserver ...... 36 Typical TMC applications ...... 37

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GA BlueLine Systems The GA BlueLine safety and automation Redundant systems can be built using a systems combine functional safety up to single rack. Available rack types are: SIL3 with regular process automation.  COMPACT-FS1: SIL3 CPU card with Even closed-loop automation functions internal redundancy, SIL3 I/O cards may achieve SIL3 safety integrity. either internally redundant or full card redundancy, regular CPU and/or I/O For most projects only a small part of pro- cards non-redundant, power supply cess automation needs to meet functional usually redundant. safety criteria. Most parts use regular con-  DualCore-S: basically like COM- trol without SIL requirements. The Blue- PACT-FS1, but full-sized 19” rack. Line systems allow the combination of  DUPLEX-S: every component fully safety-related and non-safety components redundant. Basically two DualCore-S in a single rack. All non-safety components systems combined in a single rack and are certified to be non-interfering with configured to run in dual-redundant safety functions. mode. Available either as full-scale (DUPLEX/7-S) or as compact (DU- All safety-related components, e.g. SIL3 PLEX SMART-S) version. I/O cards or CPU cards, have internal  TMR-S: every relevant component hardware fault tolerance HFT = 1. Thus triple redundant, power supplies only even a single card easily meets all re- dual redundant. Available either as quirements for functional safety. By com- full-scale (TMR/10-S) or as compact bining multiple units into higher order (TMR SMART-S) version. modular redundant systems, high functional safety becomes compatible with high COMPACT-FS1 or DualCore-S systems process availability. A DUPLEX system – can be configured for distributed redun- dual modular redundant but all components dancy, where up to four single, identical with additional, internal fault tolerance – units are configured for redundant opera- can continue operation even at most hard- tion as DUPLEX, TMR or QMR system. ware failures. The failed component may The necessary signal exchange between be replaced without stopping the DUPLEX units is handled by firmware via Ethernet system or the process. A TMR (triple safety protocol. modular redundant) system will continue operation at any single hardware failure; even multiple failures usually don’t require a shut-down.

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Redundancy, fault tolerance and voting Automation systems for high functional A critical concern with redundant safety safety require fault tolerance. Even if the systems is usually the field output side: system has a dangerous failure it’s still everything else – sensors, transmitters and supposed to either safely handle its job or control system– often is dual or triple re- to shut-down the machine or process. This dundant, but due to operational constraints is achieved by using at least two redundant there is only a single process valve. units that share the job: if one unit misses a The triple redundant output signals from a required shut-down – e.g. pushing the TMR system must be combined into one emergency shut-down button – the other external field signal. unit alone will still shut the machine down. This would be a 1-out-of-2 configuration, All GA BlueLine systems allow two ap- with a hardware fault tolerance of HFT=1. proaches for digital output voting: Basically the two units take a vote “stop or 1. Hardware voting continue”, in case of doubt they will decide on stop. The downside of fault tolerance can be process availability. If one Each digital field output of the redun- of two units has a dant units is connected to a hardware “safe” failure – detecting a shut-down con- voter board, with relay-logic for electro- dition that doesn’t exist – the machine or mechanical voting. process will be stopped anyway. Even if A proven-in-use, low-complexity solu- one unit detects some internal problem, tion for 2oo3 or 1oo2D (1oo2 with di- requiring repair, the system will have to agnostics) architectures. Read-back con- stop, because until the repair is finished tacts and additional signal exchange be- there is no fault tolerance. It may be ac- tween control units and voter board al- ceptable to continue operation during a low the diagnostics for SIL3. previously defined, limited repair time, if 2. Software voting diagnostics can localize the failure.

Adding a third unit to the safety system com- bines safety with avail- With software voting the redundant ability. With 2-out-of-3 processors in every system are pro- voting a single failure can never miss a grammed for the desired output voting: critical condition or cause an unnecessary 1oo2D, 2oo2, 1oo3, 2oo3, 3oo3, 2oo4, shut-down. 3oo4, depending on available hardware. If one unit detects an internal failure it can One unit sets its fault tolerant output via be repaired, while the other two continue external safety relay. The other units are as a 1-o-o-2 system during the repair. available as hot-standby. Read-back and diagnostic signals allow data exchange In GA BlueLine systems each safety-rela- for immediate switch-over. ted component has a built-in fault tolerance. Even in a dual redundant system like Analog field outputs always use software GA DUPLEX-S a failed CPU card can be voting. replaced, while the redundant partner unit continues SIL3-safe operation.

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Machinery Monitoring Systems If your machines require machinery monitoring capabilities, the typical automation solution is:  implement a control system  maybe: implement a safety system  and implement a monitoring system

The newly developed GA MPADA-S analog input and output card (SIL3 approval pending) integrates high-speed data acquisition for monitoring of rotating and reciprocating equipment into GA automation systems.

Typical applications are monitoring of ax- ial thrust, radial vibration, casing and cross GA MPADA-S Features head vibration and keyphasor signals, as  16 analog inputs, high-speed with well as pressures and temperatures. 16-bit resolution per channel  analog frequency band 0 … 20 kHz  4 keyphasor inputs  phase resolved signal sampling supported  HART capability for analog current inputs  compatible to common proximity, field terminal module, with HART capability, supports up to triple redundant systems (TMR) velocity and acceleration transducers The GA machinery monitoring systems  16 analog outputs with 14-bit reso- (MMS) allow flexible combinations of lution machine protection systems (MPS) and/or  configurable limits for warning, condition monitoring systems (CMS). alarm and danger levels  firmware support for dual and triple Existing GA systems may be upgraded redundant systems with monitoring capabilities.  meets SIL3 requirements, SIL3 certification pending

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Monitoring Capabilities Monitoring Features Configurable limits for warning, danger  fully integrated into existing GA and alarm levels are directly applied to safety and control systems high-speed data by the MPADA-S card  stand-alone system architecture itself. This ensures immediate reaction to available (MPS, CMS, MMS) critical signal states.  freely programmable with 80+ SIL3 certified function blocks  programming integrated in GA BlueEdit engineering system, no special tools required  Specialized, easy-to-apply macro programs for machine monitoring will be available with GA BlueEdit engineering tool  time domain and frequency domain data analysis  diagrams available: trend, spectra, orbit, waterfall, etc.  real time data-logging and sequence of events screen-shot of vibration data in HMI

screen-shot with typical diagrams for machinery monitoring

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GA TMR/10-S Technical data triple modular redundant system  19 inch rack, 10U high WxHxD = 483 x 458 x 351 mm  3x DSP data bus, each with 18 slots  1x Tribus/9  redundant power supplies: 2x GA ACE450F, 115/230VAC, or 3x GA DC24-00-02, 24 VDC  3x DSPVCU voltage control cards  3x Four Port RAM cards  3x MPU-M1, MPU-M2 or ICU processor cards  MCxxx-S safety i/o-cards  standard non-safety i/o cards  1x key switch for operating mode

 max. number of i/o approx. 3x 350

 1x front insertable fan (hot swap), with fan monitoring SIL3  1x air filter, removable from rear (hot swap)

 EMC-compatible construction, surface Hardware- output Voting chromated degradation for significant failures:  swing-frame mountable 3-2-0 HFT = 1, ß = 2%, SFF > 99%, DC >99%  operating-temperature range: After the first fault the remaining system is 0° ... +55°C still suitable for SIL3 in accordance to IEC 61508 ! The following system types are available: Software- output Voting  GA TMR/10-S degradation for significant failures:  GA TMR/10 3-2-2-0  GA BASIC/10-S HFT = 2, ß = 2%, SFF > 99%, DC >99%  GA BASIC/10 After the first and second fault the remain- TMR/10 and BASIC/10 systems are suitable for ing system is still suitable for SIL3 in ac- non-safety applications only. cordance to IEC 61508 !

Voting for inputs and internal values Relevant standards Configurable voting and degradation at  IEC 61508 failure is supported by firmware. Typical  EN ISO 13849 configurations are 3oo3D, 2oo3D, 1oo3D  IEC 62061 for voting and failure degradations of 3-2-  IEC 61131 1-0, 3-2-0 or 3-0.  EN 50178

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GA TMR SMART-S Technical data triple modular redundant system  19 inch rack, 4U high WxHxD = 483 x 191 x 351 mm  3x DSP data bus, each with 5 slots  redundant power supplies: 2x GA ACE300F, 115/230VAC, or 2x GA DC24-00-01, 24 VDC  2x DSPVCU voltage control cards  2x Four Port RAM cards  3x MPU-M1, MPU-M2 or ICU processor cards  MCxxx-S safety i/o-cards SIL3  standard non-safety i/o cards

 1x key switch for operating mode

 max. number of i/o approx. 3x 85 Hardware- output Voting degradation for significant failures:  1x front insertable fan (hot swap), with 3-2-0 fan monitoring HFT = 1, ß = 2%, SFF > 99%, DC >99%  1x air filter, removable from rear (hot After the first fault the remaining system is swap) still suitable for SIL3 in accordance to IEC  EMC-compatible construction, surface 61508 ! chromated  swing-frame mountable Software- output Voting degradation for significant failures:  operating-temperature range: 3-2-2-0 0° ... +55°C HFT = 2, ß = 2%, SFF > 99%, DC >99% After the first and second fault the remaining system is still suitable for SIL3 in ac- The following system types are available: cordance to IEC 61508 !  GA TMR SMART-S  GA TMR SMART Voting for inputs and internal values TMR SMART systems are suitable for non-safety Configurable voting and degradation at applications only. failure is supported by firmware. Typical configurations are 3oo3D, 2oo3D, 1oo3D for voting and failure degradations of 3-2- Relevant standards 1-0, 3-2-0 or 3-0.  IEC 61508  EN ISO 13849  IEC 62061  IEC 61131  EN 50178

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GA DUPLEX/7-S Technical data duplex modular redundant system  19 inch rack, 7U high WxHxD = 483 x 324 x 351 mm  2x DSP data bus, each with 18 slots  redundant power supplies: 2x GA ACE450F, 115/230VAC, or 2x GA DC24-00-02, 24 VDC  2x DSPVCU voltage control cards  2x Four Port RAM cards  2x MPU-M1, MPU-M2 or ICU processor cards  MCxxx-S safety i/o-cards  standard non-safety i/o cards  1x key switch for operating mode

 max. number of i/o approx. 2x 350

SIL3  1x front insertable fan (hot swap), with fan monitoring  1x air filter, removable from rear (hot swap)  EMC-compatible construction, surface Hardware- output Voting chromated degradation for significant failures:  swing-frame mountable 2-1-0 HFT = 1, ß = 2%, SFF > 99%, DC >99%  operating-temperature range: After the first fault the remaining system is 0° ... +55°C still suitable for SIL3 in accordance to IEC

61508 !

Software- output Voting The following system types are available: degradation for significant failures:  GA DUPLEX/7-S 2-2-0  GA DUPLEX/7 HFT = 1, ß = 2%, SFF > 99%, DC >99%  GA BASIC/7-S After the fault the remaining system is still  GA BASIC/7 suitable for SIL3 in accordance to IEC DUPLEX/7 and BASIC/7 systems are suitable for non-safety applications only. 61508 !

Voting for inputs and internal values Relevant standards Configurable voting and degradation at  IEC 61508 failure is supported by firmware. Typical  EN ISO 13849 configurations are 1oo2, 1oo2D or 2oo2D  IEC 62061 for voting and failure degradations of 2-1-0 or 2-0.  IEC 61511  IEC 61131  EN 50178

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GA DUPLEX SMART-S Technical data duplex modular redundant system  19 inch rack, 4U high WxHxD = 483 x 191 x 351 mm  2x DSP data bus, each with 5 slots  redundant power supplies: 2x GA ACE300F, 115/230VAC or 2x GA DC24-00-01, 24 VDC  2x DSPVCU voltage control cards

 2x Four Port RAM cards  2x MPU-M1, MPU-M2 or ICU processor cards  MCxxx-S safety i/o-cards SIL3  standard non-safety i/o cards  1x key switch for operating mode

 max. number of i/o approx. 2x 85 Hardware- output Voting degradation for significant failures:  1x front insertable fan (hot swap), with 2-1-0 fan monitoring HFT = 1, ß = 2%, SFF > 99%, DC >99%  1x air filter, removable from rear (hot After the first fault the remaining system is swap) still suitable for SIL3 in accordance to IEC  EMC-compatible construction, surface 61508 ! chromated  swing-frame mountable Software- output Voting degradation for significant failures:  operating-temperature range: 2-2-0 0° ... +55°C HFT = 1, ß = 2%, SFF > 99%, DC >99% After the fault the remaining system is still suitable for SIL3 in accordance to IEC The following system types are available: 61508 !  GA DUPLEX SMART-S  GA DUPLEX SMART Voting for inputs and internal values DUPLEX SMART systems are suitable for non- Configurable voting and degradation at safety applications only. failure is supported by firmware. Typical configurations are 1oo2, 1oo2D or 2oo2D for voting and failure degradations of 2-1-0 Relevant standards or 2-0.  IEC 61508  EN ISO 13849  IEC 62061  IEC 61511  IEC 61131  EN 50178

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GA DualCore-S, BASIC/4 Technical data non-redundant or internally redundant system  19 inch rack, 4U high WxHxD = 483 x 191 x 351 mm  1x DSP data bus, with 18 slots  redundant power supplies 2x GA ACE300F, 115/230VAC or 2x GA DC24-00-01, 24 VDC  2x DSPVCU voltage control cards

 MPU-M1, MPU-M2 or ICU processor card. Hot-standby processor cards are available as option.  MCxxx-S safety i/o-cards SIL3  standard non-safety i/o cards  1x key switch for operating mode

 max. number of i/o approximately: Up to four GA DualCore-S units can be redundant: 2x 175 combined via safe Ethernet communica- non-redundant: 1x 350 tion as multiple redundant, multiple fault tolerant systems. Hardware and software  1x front insertable fan (hot swap), with voting for inputs, outputs and internal val- fan monitoring ues depends on system architecture.  1x air filter, removable from rear (hot swap)  EMC-compatible construction, surface chromated  swing-frame mountable

 operating-temperature range: 0° ... +55°C

The following system types are available:  GA DualCore-S  GA BASIC/4 BASIC/4 systems are suitable for non-safety applications only.

Relevant standards  IEC 61508  EN ISO 13849  IEC 62061 For stand-alone units SIL3 safety is  IEC 61511 achieved with card internal redundancy  IEC 61131 and 1-out-of-2 voting.  EN 50178

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GA COMPACT-FS1 Technical data non-redundant or internally redundant system  9.5 inch rack, 3U high WxHxD = 242 x 143 x 250 mm  1x DSP data bus, with 18 slots  redundant power supplies 2x GA UGS6024-5AR, 24 VDC  MPU-M1, MPU-M2 or ICU processor card.  MCxxx-S safety i/o-cards  standard non-safety i/o cards  1x key switch for operating mode

 number of i/o: typical: 80 maximum: 128 SIL3  EMC-compatible construction, surface chromated  mountable on mounting plate or swing-frame Up to four GA COMPACT-FS1 units can be combined via safe Ethernet communi-  operating temperature range: cation as multiple redundant, multiple fault -20° ... +70°C tolerant systems. Hardware and software  ambient temperature range: voting for inputs, outputs and internal val- -20° ... +55°C ues depends on system architecture.

The following system types are available:  GA COMPACT-FS1  GA COMPACT-FS2, in preparation

Relevant standards  IEC 61508  EN ISO 13849  IEC 62061  IEC 61511  IEC 61131  EN 50178  EN 50155  EN 50156  IEC 61326  EN 54  EN 50130  EN 298 For stand-alone units SIL3 safety is  EN 61373 achieved with card internal redundancy  NFPA 72 and 1-out-of-2 voting.

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Processor cards

ICU mod. 2 Technical data industrial controller unit, high perform-  32Bit Intel processor 1 GHz with ance 512kByte L2 cache memory  Optional: 32Bit Intel Pentium M processor with 1.4 GHz, 1MB L2 cache memory  256 MB DDR RAM memory with ECC error correction code  256 MB Flash memory on board  Compact Flash > 2GB optional  1x 100Base-T Ethernet  1x 1000Base-T Ethernet  1x RS232  2x USB 2.0  1x VGA

 Window Watchdog  Micro-controller for program flow control  temperature- and voltage monitoring The ICU model 2 card is a high-speed  no active fan processor card, with on-board Ethernet  hot replaceable and serial communication ports. Open  multi master capability for master / communication protocols allow easy inte- hot-standby CPU redundancy gration into any control concept.  storage temperature: -40 ... 85°C Software features  operating temperature: -20 ... 65°C  operating system LINUX  relative humidity: 10 ... 90 %,  IEC 61131-3 standard control func- non-condensing tions  shelf life: unlimited  low program execution time, approx. 500µs msec per complex closed-loop control function Relevant standards  all analog control functions with float-  IEC 61508, EN ISO 13849, IEC 62061, ing point, allowing very precise com- IEC 61511, IEC 61131, EN 50178, EN putations with virtually no loss of pre- 50155, EN 50156, IEC 61326, EN 54, EN cision 50130, EN 298, EN 61373, NFPA 72  serial Modbus RTU communication  open communication via Ethernet, UDP and Open Modbus TCP  data logging and alarm management directly on ICU  online changing of control parameters and online reprogramming, without in- terrupting the control process  online hardware & software diagnostics

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MPU-M1 Technical data multi-processor unit: industrial quality redundant CPU card, SIL3 certified  dual redundant 32-Bit processor system, 400MHz, based on newest chip generation  redundant 64MByte SDRAM  redundant 256MByte Flash  redundant Micro-SD cards (> 2GB)  redundant 100Base-T Ethernet  safeTCP: safety related SIL3 Ethernet protocol  OPEN MODBUS TCP, RTU MOD- BUS

 multi-tasking real time operating system GA-RTX

 bool, integer and float operation  digital and analog signal processing  more than 100 SIL3-certified software function blocks

 internal hardware fault tolerance SIL3 HFT = 1

 high diagnostic coverage (DC >99%)  intelligent Watchdog functions  program flow control The MPU-M1 card is a multi-processor safety CPU card. The internally redundant  temperature and voltage monitoring design with two CPUs has a hardware fault tolerance of HFT = 1 and is certified  no active fan for shut down logic and complex control  hot replaceable functions, up to SIL3.  multi master capability for master / hot-standby redundancy Software features  SIL3-certified processor card  operating temperature: -20 ... 85°C  multi-tasking, real time operating sys-  ambient temperature: -20 ... 70°C tem GA-RTX  relative humidity: 10 ... 90 %,  safeTCP SIL3 Ethernet communica- non-condensing tion, for data exchange between inde-  shelf life: unlimited pendent safety systems and for redundant systems over Ethernet Relevant standards  serial Modbus RTU communication  IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178, EN  open communication via Ethernet 50155, EN 50156, IEC 61326, EN 54, EN UDP and Open Modbus TCP 50130, EN 298, EN 61373, NFPA 72  online hardware & software diagnostics

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I/O cards

Non-safety I/O cards Technical data DIGI32 model 6 digital input card, 32 input channels,  32 digital inputs (passive) non-safety  24VDC rating  all input signals with passive filter  operating point defined at 10V +/-1V  galvanical isolation between input- side and backplane interface  in inactive state the inputs show the defined low level  over-voltage protection  automatic card identification in DSP bus  card address configurable by rotary switch

 hot-replaceable  signals connected via DIN 41652 Sub- D multipoint female connector (50- pin), at the face plate  multi-layer PCB design, 4 layers, con- The DIGI32 card is a digital input card for nectors gold plated, both sides fitted non-safety-related digital field signals. It is with SMD components certified not to interfere with safety functions when used in mixed-mode systems.  maximum input voltage: +45VDC, - 9VDC, max. +/- 2 Vpp ripple  current consumption: +5V / 420mA typical  power supply: 4.85V ... 5.25V, max. 80mV Vpp ripple

 operating temperature: 0 ... 70 °C  relative humidity: 10 ... 90% non-condensing  shelf life: unlimited

Relevant standards  IEC 61131-2

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DIGIO model 6 Technical data digital I/O card, 16 in + 16 out channels, non-safety  16 binary inputs (passive)  16 binary outputs (active)  galvanic isolation between all i/o signals and data bus  all input signals with passive filter  inputs and outputs rated at 24 VDC  status of outputs (cable failure, short- cut) can be read back  outputs protected against short-cut and reverse voltage  max. current per output: 0.5 A  total max. current: 4 A  24 V external power for output signals supplied by signal connector on front plate  in the event of CPU failure a card- internal watchdog timer can set a digital output e.g. for alarm annunciation to a PLC and/or either erase or freeze The DIGIO card is a digital input and out- all the other outputs put card for non-safety-related digital field  automatic card identification in DSP signals. It is certified not to interfere with bus safety functions when used in mixed-mode  card address configurable by rotary systems. switch

 3 LEDs to indicate the status of watchdog, board select and external power supply

 hot-replaceable  signals connected via DIN 41652 Sub- D multipoint female connector (50- pin), at the face plate  multi-layer PCB design, 4 layers, connectors gold plated, both sides fitted with SMD components

 operating temperature: 0 ... 70 °C  relative humidity: 10 ... 90%, non-condensing  shelf life: unlimited

 standards: IEC 61131-2

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MCAD model 6 Technical data analog input card, 16 input channels, non-safety  16 differential analog input channels for current: 0 ... 22 mA or 4 individually adjustable voltage ranges: 0 ... 5.478V, 0 ... 2.739V, 0 ... 1.3695V, 0 ... 10.956V  MCU mixed signal micro-controller with integrated 12-bit A/D converter  low pass input filter with cut-off frequency of 1.85 kHz  sampling time for all 16 inputs: approx. 2 ms  analog multiplexer with overvoltage protection up to +/-33V  electrical isolation between input-side and backplane interface  integrated sensor for card temperature measurement  gain and offset programmable by dual The MCAD card is an analog input card for D/A converter non-safety-related current or voltage field  automatic self-calibration during op- signals. It is certified not to interfere with eration safety functions when used in mixed-mode  time-optimized DSP bus interface with systems. dual-ported RAM (DPR)  automatic card identification in DSP bus  card address configurable by rotary switch

 hot-replaceable  signals connected via DIN 41652 Sub- D multipoint female connector (50- pin), at the face plate  multilayer card, 6 layers, both sides fitted with SMD components, all connectors gold plated

 current consumption: +5V/450mA typical, +-15V/80mA typical  power supply: 4.85V ... 5.25V, max. 80mV Vpp ripple

 operating temperature: 0 ... 70 °C  relative humidity: 10 ... 90%, non-condensing  shelf life: unlimited  standards: IEC 61131-2

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MCRTD model 6 Technical data analog input card, 16 RTD temperature input channels, non-safety  16 differential input channels for temperature signals Pt100, Pt200, Pt1000 (others on request)  MCU mixed signal microcontroller with integrated 12-bit A/D converter  four programmable measuring ranges with a dual D/A converter: -30°C ... +70°C, 0°C ... +200°C, 0°C ... +400°C, 0°C ... +800°C  temperature measurement error < 1%  typical sampling time for all 16 inputs: 50ms  low pass input filter for noise- suppression  analog multiplexer with overvoltage protection up to +/-33V  cable failure detection  transmitter support for two- and three- wire technology, 32 constant-current The MCRTD card is an analog input card sources for three-wire technology for non-safety-related RTD (Resistance  electrical isolation between input-side Temperature Detector) field signals. It is and backplane interface certified not to interfere with safety func-  low-drift amplifier with 110 dB com- tions when used in mixed-mode systems. mon mode rejection  integrated sensor for card temperature  automatic self-calibration during operation  time-optimized DSP bus interface with dual-ported RAM (DPR)  automatic card identification in DSP bus  card address configurable by rotary switch

 hot replaceable  signals connected via DIN 41652 Sub- D multipoint female connector (50- pin), at the face plate  multi-layer PCB design, 6 layers, both sides fitted with SMD components, all connectors gold plated

 operating temperature: 0 ... 70 °C  relative humidity: 10 ... 90%, non-condensing  shelf life: unlimited  standards: IEC 61131-2

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MCMIO model 6 Technical data analog input card, 10 current + 2 frequency input channels, non-safety  10 differential input channels for 0 ... 22 mA current (voltages optional)  MCU mixed signal microcontroller with integrated 12-bit A/D converter  sampling time for all 10 inputs: approx. 2.0 ms  2 frequency inputs, 1Hz ... 15 kHz  low pass input filter for noise- suppression  signal failure detection for: cable failure, short-cut, amplitude too low  voltage supply for speed probes  analog multiplexer with overvoltage protection up to +/-33V  electrical isolation between input-side and DSP bus interface  low-drift amplifier with 110 dB common mode rejection  integrated sensor for card tempera- The MCMIO card is an analog input card ture measurement for non-safety-related current (optional  gain and offset programmable by dual voltage) field signals plus frequency sig- D/A converter nals. It is certified not to interfere with safe-  automatic self-calibration ty functions when used in mixed-mode  time-optimized DSP bus interface with systems. dual-ported RAM (DPR)

 automatic card identification in bus  card address configurable by rotary switch

 current consumption: +5V/450mA typical, +-15V/80mA typical  power supply data: 4.85V ... 5.25V, max. 80mV Vpp ripple

 operating temperature: 0 ... 70 °C  relative humidity: 10 ... 90%, non-condensing  shelf life: unlimited  standards: IEC 61131-2

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SIL3 safety I/O cards

MCDIN-S model 1 Technical data safety-related digital input card, 24 input channels  input channels: 1x 24 (simplex) or: 2x 12 (redundant)  3 card types with different input standards: NAMUR, 24VDC active / passive, 24VDC passive

 signal detection: analog, successive approximation with 2x ADC  resolution: 12-Bit  sampling time: 5 msec per channel  precision of current detection: +/- 0,25%  internal analog diagnostic inputs: 20 redundant

NAMUR:  load voltage: 8,2V redundant  internal resistance of power supply NAMUR: 100 Ohm SIL3  signal current, low: 0,05mA ... 1,2mA

 signal current, high: 2,1mA ... 7mA The MCDIN-S card is a digital input card  cable failure detection: < 0,02 mA for safety-related digital field signals. It is  short-cut detection: >7mA certified for use in safety functions up to  inputs NAMUR compatible according SIL3. to EN 60947-5-6 The card has an internally redundant design with hardware fault tolerance HFT=1. 24VDC standard: Digital inputs are handled as analog sig- in accordance to IEC61131-2 nals, to allow extensive signal diagnostics.  electrical isolation between input-side Diagnostic functions with the redundant and backplane interface on-board micro-controllers include:  hot replaceable walking zero, ramp test with 2 D/A converters, temperature monitoring,  4 HE version in preparation voltage monitoring, window watchdog, program flow control, background  storage temperature -25°C ... 85°C memory test, mutual monitoring of  operating temperature -20°C ... 70°C self-tests, ...  ambient temperature: -20°C ... 55°C  relative humidity: 10 ... 90%, Relevant standards: non-condensing IEC 61508, EN ISO 13849, IEC 62061,  shelf life: unlimited IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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MCAD-S model 1 Technical data safety-related analog input card, 24 input channels  current input channels: 1x 24 (simplex) or 2x 12 (redundant) or: 1x 22 / 2x 11 current inputs plus 1 or 2 redundant frequency input  input type: differential current  Delta Sigma A/D converter  digital precision: 14 bit  input current range: 0 ... 25mA  error detection: open, under-range, over-range, short, fault (detected by internal tests)  redundant frequency input for mag- netic-inductive sensor or Hall sensor  redundant power supply for Hall sensor  frequency range: 1Hz ... 15kHz  error detection for frequency: amplitude error, cable failure, short- cut, hall sensor power supply failure, signal fault (detected by internal tests) SIL3 monitoring of operating voltages   electrical isolation between input-side The MCAD-S card is an analog input card and backplane interface for safety-related field signals. It is certified  hot-replaceable for use in safety functions up to SIL3.  signals connected via DIN 41652 Sub- The card has an internally redundant de- D multipoint female connector (50- sign with hardware fault tolerance HFT=1. pin), at the face plate

Diagnostic functions with the redundant  4 HE version in preparation on-board micro-controllers include: monitoring of linearity and cross-talk  storage temperature -25°C ... 85°C by read-back of 12-bit test patterns  operating temperature -20°C ... 70°C with 2x 12 D/A-converters, monitoring  ambient temperature: -20°C ... 55°C of frequency input with redundant fre-  relative humidity: 10 ... 90%, quency signal generators, tempera- non-condensing ture monitoring, voltage monitoring,  shelf life: unlimited window watchdog, program flow control, background memory test, mutual monitoring of self-tests, ...

Relevant standards: IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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MCDOT-S model 1 Technical data safety-related digital output card, 16 output channels  output channels: 1x 16 (simplex) or 2x 8 (redundant)  input channels: 16 (for non-safety)  analog diagnostic inputs  signal detection: analog, successive approximation with 2x ADC  resolution: 12-Bit  precision of detection: +/- 0,2%  output type: high-side switch, i.e. can drive a load against electrical ground  nominal supply voltage: +24V DC  max. supply voltage: +30V DC  max. ripple of supply voltage: +/-2V  electrical isolation between input-side and backplane interface  outputs proof against short-cut (internal limiting of output current)

 supply voltage monitoring  temperature monitoring SIL3  hot-replaceable  signals connected via DIN 41652 Sub- D multipoint female connector (50-pin) The MCDOT-S card is a digital output card for 3 HE version for safety-related field signals. It is certified for use in safety functions up to SIL3.  4 HE version in preparation The card has an internally redundant design with hardware fault tolerance HFT=1.  storage temperature -25°C ... 85°C  operating temperature -20°C ... 70°C Diagnostic functions with the redundant  ambient temperature: -20°C ... 55°C on-board micro-controllers include:  relative humidity: 10 ... 90%, walking change of outputs with read- non-condensing back of card outputs, relay state, sec-  shelf life: unlimited ondary independent shut-down path, temperature monitoring, voltage monitoring, window watchdog, program flow control, background memory test, mutual monitoring of self-tests, ...

Relevant standards: IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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MCADA-S model 1 Technical data safety-related analog input and output card, 8 channels each  2x 4 redundant analog current outputs (0 ... 24mA)  2x 4 redundant analog current inputs (0 ... 25mA) Outputs:  16-Bit resolution and monotonicity for each channel  sigma-delta (SD) DAC technology to achieve 16-bit monotonicity  full-scale settling to 0.1% occurs within 3 ms.  online ramp-test for all outputs in redundancy architecture for each channel  online monitoring of the output current, reverse current and the load by using 3 A/D-channels for each output channel with 15-Bit resolution  on board arbitration for duplex and triplex architecture: fast signal switchover (<3ms) SIL3

Inputs: The MCADA-S card is an analog input and  14-Bit resolution and monotonicity for output card for safety-related field signals. each channel It is certified for use in safety functions up  Delta Sigma A/D converter to SIL3.  error detection: open, under-range, The card has an internally redundant de- over-range, short, fault (determined by sign with hardware fault tolerance HFT=1. internal tests)

Diagnostic functions with the redundant  extensive self-tests during normal on-board micro-controllers include: operation temperature monitoring, voltage moni-  integrated sensor for card tempera- toring, window watchdog, program ture flow control, background memory test,  monitoring of all operating voltages, mutual monitoring of self-tests, ... processor and field  electrical isolation between input-side Relevant standards: and backplane interface IEC 61508, EN ISO 13849, IEC 62061,  hot-replaceable IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54,  4 HE version in preparation EN 50130, EN 298, EN 61373, NFPA 72

 storage temperature -25°C ... 85°C  operating temperature -20°C ... 70°C  ambient temperature: -20°C ... 55°C  relative humidity: 10 ... 90%, non-condensing  shelf life: unlimited

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MPADA-S safety related vibration monitoring card Technical data  2x 8 analog inputs (0…25mA, +/- 20V)  high-speed analog/digital converter - analog frequency band 0 … 20 kHz - 2x 8 synchronous track & hold amplifier - 16-bit resolution per channel  4 keyphasor inputs  phase resolved signal sampling supported  2x 8 analog outputs (+/- 10 V)  high diagnostic coverage through automatic online self-tests for all I/Os  monitoring of all operating voltages, processor and field  galvanic isolation between field and data bus  rf-capable signal termination and ca- bling  isolated power supply for each I/O SIL3 certification pending channel  hot-replaceable The MPADA-S is an analog input and output card for GA safety and control sys- Features tems. It is intended for high-speed data  freely programmable acquisition, especially for machine condi-  easy-to-use vibration monitoring mac- tion monitoring applications and vibration ros monitoring. For SIL3 applications the  time & frequency domain data MPADA-S supports 8 redundant, fault tol-  high-speed, synchronous sampling erant input channels. For monitoring and  compatible to common proximity, ve- control the 16 channels are available for locity and acceleration transducers non-redundant input signals.  stand-alone system architecture pos- Specialized easy-to-apply macros for ma- sible, dual and triple redundant (TMR) chinery monitoring of reciprocating and system architectures supported rotating equipment will be included with  high performance noise-reduced sig- the engineering tool GA BlueEdit. nal processing

 configurable filtering, windowing and conditioning of time-domain data  diagram types: trend, spectra of variable resolution, orbit, waterfall, etc.  configurable warning & alarm levels

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Field I/O components Technical data

TFAB-DIGIO-2oo3  Three forcibly guided safety relays per output are wired in 2-out-of-3 logic. 10 field output module for triple redundant output channels available per TFAB. digital outputs, with hardware 2oo3 vot-  the open-contact of each relay is read ing back for continuous monitoring  the state of both power supply fuses is read back for monitoring

 redundant power supply: 20 ... 29 V  redundant input current at 24 VDC: 1A  max. ripple of power supply: < 150mV

 switching operations DC1 3A 24VDC: 1,000,000 SIL3 DC1 6A 24VDC: 350,000  max. rated switch capacity: 24VDC / 6A The TFAB-DIGIO-2oo3 (Triple redundant 230VAC / 6A Field Assembly Board) is used as hard-  response time typically 15ms ware voter for TMR-S systems.  drop-out time typically 4ms

Each redundant digital output controls one  dimensions (LxWxH): forcibly guided safety relay with multiple 352x128x66 mm contacts. These contacts implement a  weight: 1.6kg hardwired 2-out-of-3 logic. 10 output channels are available per TFAB.  storage temperature -25°C ... 75°C  operating temperature -20°C ... 70°C Diagnostics on the digital output cards  relative humidity: 10 ... 90%, automatically read back the status infor- non-condensing mation.

 shelf life: unlimited Relevant standards: IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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DFAB-1oo2D Technical data field output module for dual redundant digital outputs, with hardware 1oo2D  Four forcibly guided safety relays per voting output are wired in 1-out-of-2 logic with diagnostics. 8 output channels available per DFAB module.  the open-contact of each relay can be read back for continuous monitoring  the state of both power supply fuses can be read back for monitoring

 redundant power supply: 20 ... 29 V  redundant input current SIL3 at 24 VDC: 1 A  max. ripple of power supply: < 150mV The DFAB-1oo2D (Dual redundant Field Assembly Board) is used as hardware  switching operations voter for DUPLEX-S systems. DC1 3A 24VDC: 1,000,000 DC1 6A 24VDC: 350,000 Two redundant digital outputs and their  max. rated switch capacity: corresponding diagnostic outputs each 24VDC / 6A control one forcibly guided safety relay 230VAC / 6A with multiple contacts. These contacts  response time typically: 15ms implement a hardwired 1-out-of-2D logic, with diagnostics that allow continued op-  dimensions (LxWxH): eration even at detected output fault. 352x128x66 mm 8 output channels are available per DFAB.  weight: 1.6kg Diagnostics on the digital output cards automatically read back the status infor-  storage temperature -25°C ... 75°C mation.  operating temperature -20°C ... 70°C  relative humidity: 10 ... 90%, Relevant standards: non-condensing IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178,  shelf life: unlimited EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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TFAB-DIGIO Technical data field input/output module for triple redundant digital inputs and outputs, for  power supply: hot-standby redundancy 20 ... 29 VDC simplex or redundant  input current at 24 VDC: 0.85 A  max. ripple of power supply: < 150 mV  Maximum load capacity of outputs: 24 VDC / 2A The TFAB-DIGIO (Triple redundant Field AC voltage at the outputs only allowed Assembly Board) is used as hardware with extension modules voter for TMR systems. Used in conjunc- tion with DIGIO cards it switches outputs  Max. number of TFAB in a chain with between master unit and hot-standby one master voter: 6 units. One TFAB-DIGIO configured as voting  dimensions (LxW master will switch additional voters for digi- 352x128x80 mm tal and analog outputs in a chain.  weight: 1.3 kg

Switch-over for each output is based on  storage temperature -40°C ... 80°C photo-MOSFET switches.  operating temperature 0°C ... 60°C

 relative humidity: 10 ... 90%, Protection of all digital inputs against short non-condensing circuit with fuses for each input channel.

 shelf life: unlimited The TFAB-DIGIO is suitable for hot- standby redundancy with 16 digital outputs. The following types are available:

 TFAB-DIGIO type Triplex, with voter  TFAB-DIGIO type Triplex, without voter  TFAB-DIGIO type Duplex, with voter  TFAB-DIGIO type Duplex, without voter  TFAB-DIGIO type Simplex  TFAB-DIGIO type PIO, for DIGIO with parallel outputs and inputs

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TFAB-DSPDA Technical data field output module for triple redundant analog outputs, for hot-standby redun-  power supply: dancy 20 ... 29 VDC simplex or redundant  input current at 24 VDC: 0.5 A  max. ripple of power supply: < 150 mV

 Max. number of TFAB in a chain with The TFAB-DSPDA (Triple redundant Field one master voter: 6 Assembly Board) is used as hardware voter for TMR systems. Used in conjunc-  dimensions (LxWxH): tion with DSPDA cards it switches outputs 352x128x80 mm between master unit and hot-standby  weight: 1.2 kg units.  storage temperature -40°C ... 80°C Switch-over for each output is based on  operating temperature 0°C ... 60°C photo-MOSFET switches.  relative humidity: 10 ... 90%,

non-condensing The TFAB-DSPDA is suitable for hot- standby redundancy with 8 digital outputs.  shelf life: unlimited

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GA SR-01-42-24-00 Technical data safety relay module for dual redundant digital outputs, with hardware 1oo2D  Two forcibly guided diversity safety voting relays, by different manufactures  2x4 redundant closing contacts  The closing contacts are wired in 1- out-of-2 logic  the open-contact of each relay can be read back for continuous monitoring  each closing contact circuit is protected by a build in fuse

 The module may be used up to SIL 3 (IEC 61508) as a single device  safety-related data: see manual

 response time typically: 15ms

 dimensions (LxWxH): 114.5x35x99 mm

SIL3  storage temperature -25°C ... 70°C

 operating temperature -25°C ... 70°C

 pollution level 2

 nominal input voltage: 24VAC/DC  max. switching current for NO contacts: 6A The SR-01-42-24-00 safety relay may be  max. switching current used as fault tolerant output relay for safe- for NC contacts: 4A ty-related signals. Each single or redun-  switching voltage range: dant digital output switches four forcibly 15 … 240VDC/AC guided field contacts. Diagnostic contacts allow status read-back  service life, mechanical: 107 cycles for continuous monitoring.  service life, electrical: 105 cycles

In GA systems configured for software voting, see section “Redundancy, fault tolerance and voting” on page 5, it is used as output relay for all system architectures.

Relevant standards: IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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GA SCM1/xA Technical data Two channel safety current to current converter module  Current to current converter

 Two channels galvanically isolated

 Two module types with different inputs ranges: SCM1/1A with 0 … 1A or SCM1/6A with 0 … 6A

 Output ranges: 4 … 20mA

 DC- and AC-current measurement

 Nominal supply voltage 24VDC

 The module may be used up to SIL 3 (IEC 61508) as a single device

 response time typically 100 ms

SIL3  isolation standard EN 50178

 dimensions (LxWxH):

I out1 4..20mA 114.5x22.5x104 mm AC 1 I in1 6+ TRUE U RL RMS I 2 7- I out2 4..20mA AC  storage temperature -40°C ... 70°C I in2 3 8+ TRUE U RL RMS  operating temperature -25°C ... 70°C I 9- 4 open 1 supply group2 open 2  pollution level 2 21+ DC power good 1 24VDC supply group1 DC 22- power good 2 DC

DC 11 Power Power Good Supply 12

The SCM1 converter module is used to convert high-current field signals into standard currents for analog instrumenta- tion. A typical application is read-back of current signals to a solenoid valve or other field device. The high control current is converted to a corresponding 4…20 mA signal and read back as analog value, as safety-related diagnostic.

Relevant standards: IEC 61508, EN ISO 13849, IEC 62061, IEC 61511, IEC 61131-2, EN 50178, EN 50155, EN 50156, IEC 61326, EN 54, EN 50130, EN 298, EN 61373, NFPA 72

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FLKM-D50/B/R/SO171 VIP-3/SC/D50SUB/F field input module for NAMUR compati- simplex field I/O module for all GA I/O ble digital inputs MCDIN-S type 0 cards

Simplex one-to-one field connector module to connect the Sub-D 50-pin connector for the i/o card system cable to screw ter- minals for field signals.

Field connector module to connect NA- Mountable on top hat rail. MUR compatible field signals and non- compatible signals to MCDIN-S type 0 digital input cards. Non-NAMUR signals use the module’s resistors as shown be- low. NAMUR compatible field elements use their internal resistors, allowing cable monitoring for the whole distance from I/O card to field element.

internal MCDIN-S main-cabinet

DC/DC-Converter

8,2V 100R 1k 10k system cable system protection FLKM-D50/B/R/SO171

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GA TFAB PIO GA FAB PIO MPADA-S field I/O module for GA I/O cards field I/O module for MPADA-S

Field connector module for connecting of field signals to MPADA-S cards in single, dual or triple redundant systems. Single field transmitters may be multiplied on- board for redundant signals processing. The module optionally supplies +24 VDC Field connector module for connecting of for 2-wire transmitters or -24 VDC for 3- field signals to GA cards in dual or triple wire proximitors. redundant systems. Single field transmitters may be multiplied on-board for redun- The module optionally works in conjunc- dant signals processing. tion with the GA termination board, for galvanic isolation to Ex-i hazardous area Mountable on top hat rail. signals.

Depending on card type, different module All modules support HART communication types are available. to the field elements. For Ex-i field ele- - GA TFAB PIO DIGI32 ments HART is handled by the termination - GA TFAB PIO MCAD board. - GA TFAB PIO MCDIN-S - GA TFAB PIO MCDOT-S Mountable on top hat rail.

Depending on system architecture, different module options are available. - GA TFAB PIO card duplex - GA TFAB PIO card triplex

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GA FAB SI MCAD-S GA FAB SIPO MCADA-S field I/O module for MCAD-S field I/O module for MCADA-S

Field connector module for connecting of field signals to MCAD-S cards in single, dual or triple redundant systems. Single field transmitters may be multiplied on- board for redundant signals processing. Field connector module for connecting of field signals to MCADA-S cards in single, The module optionally works in conjunc- dual or triple redundant systems. Single tion with the GA termination board, for field transmitters may be multiplied on- galvanic isolation to Ex-i hazardous area board for redundant signals processing. signals. The module optionally works in conjunc- All modules support HART communication tion with the GA termination board, for to the field elements. For Ex-i field ele- galvanic isolation to Ex-i hazardous area ments HART is handled by the termination signals. board. All modules support HART communication Depending on system architecture, differ- to the field elements. For Ex-i field ele- ent module types are available. ments HART is handled by the termination - GA FAB SI MCAD-S simplex board. - GA FAB SI MCAD-S duplex - GA FAB SI MCAD-S triplex Depending on system architecture, differ- - GA FAB PI MCAD-S simplex ent module types are available. - GA FAB PI MCAD-S duplex - GA FAB SIPO MCADA-S simplex - GA FAB PI MCAD-S triplex - GA FAB SIPO MCADA-S duplex - GA FAB SIPO MCADA-S triplex Mountable on top hat rail. - GA FAB PIO MCADA-S simplex - GA FAB PIO MCADA-S duplex - GA FAB PIO MCADA-S triplex - GA FAB SEIPO MCADA-S

Mountable on top hat rail.

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System cable, Standard System cable, Frequency standard system cable for all I/O cards system cable with additional frequency cable, for MCMIO and MCAD-S

50 wire system cable with D-SUB 50-pin connector on both sides. System cable with separate frequency cable for input cards with frequency inputs. Licy 50x 0.14mm², shielded. for MCMIO: System cable: GA-C50-C1-Xm Main cable Licy 36x 0.14mm², shielded. D- SUB 50-pin connector on both sides. Addi- tional frequency cable Pidy 2x 2x0.25mm² with double shielding (one side open ended)

for MCAD-S: Main cable Licy 50x 0.14mm², shielded. D- SUB 50-pin connector on both sides. Addi- tional frequency cable Pidy 2x 2x0.25mm², twisted pairs with double shielding (one side open ended)

Cable with frequency signals: GA-C1-MCAD-S-Typ12-Sm-Fm GA-C1-MCAD-S-Typ34-Sm-Fm

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GA Software

GA BlueEdit GA TurWin Engineering tool for programming and Program for process visualization, data handling of GA BlueLine systems and logging, communication and engineering, components. suitable for GA systems. Also suitable for process simulation.

GA DataView Program for analysis of history data (trends, selection, CSV converter, etc.)

GA modOPCserver

OPC server for GA systems (Data Access, GA DataLogDLx Alarm&Events)

Datalogger module for fast and automatic recording of process data under Linux operating system on the ICU mod.1 or ICU mod.2

GA DataLogWin Datalogger module for fast and automatic recording of process data under Windows operating system on a PC or IPC.

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Typical TMC applications

- anti-surge control - performance control Monitoring of inlet flow versus compressor Capacity control with decoupling and co- head (operating point) and distance to ordinate control of anti-surge controller surge line Additional process limit controller (dis- Surge detection within less 10 ms cycle charge pressure, power consumption) time Bump-less switchover between different High speed event data recorder with ad- control modes (manual, auto) justable time period Ramp functions for compressor start-up / Multi variable algorithm to compensate shut down operations changes on process gas inlet conditions Automatic sequences for start-up / switch- (pressure, temperature, molecular weight) over / shut-down Anti-surge controller with variable and Show operating point within compressor dynamic gain function depending on op- control map eration point Dynamic move of control line into safe - load-sharing control operation range on surge to avoid repeti- Working of multiple machines in parallel tion of surge mode (common header) Remote set point feature without override Working of multiple machines in serial of surge protection mode (multiple stages) Recycle valve position feedback monitor- Load sharing control with feed forward ing with controller anti windup protection and coordinate control of anti-surge controller. - anti-surge protection Featuring low flow and /or low pressure Monitoring of inlet flow and inlet tempera- ratio operation (working on recycle mode) ture for static and dynamic changes Bump-less switchover between different Detection of reverse flow within the com- control modes (suction pressure, discharge pressor pressure, mass flow) and between load Algorithms is working independent of anti- sharing (auto) and stand-alone (manual) surge control operation for each compressor. Surge detection within less 10 ms. cycle Minimize recycle operation, Maximize time efficiency High speed event data coder with adjust- Different control strategies are available: able time period  Common master with separated slave Fast open (de-energize) of anti- surge controller for each compressor train. valves on surge detection  Distributed load sharing control for Multiple surges within an adjustable time each compressor train. window trip the machine. Anti-surge valves functional stroke testing and feedback monitoring Optional: Start up interlock and trip on valve feedback fault

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- blast furnace control - turbine overspeed protection Cold blast flow and pressure control Sensor fault and synchronize speed moni- Bump-less switchover between different toring control modes (pressure, flow, manual) Underspeed, overspeed and speed gradient Freeze control modes, outputs and set- protection points on snort valve operation Overspeed protection within less 10 ms Stove filling operation with feed-forward cycle time control to avoid pressure drop High speed event data recorder with adjustable time period - process control Variable controller for pressure, tempera- - power recovery control ture, mass flow, level and power control Use of compressor blow off / recycle gas etc. for power recovery Bump-less switchover between different Expander inlet pressure control control modes (auto, manual) Expander pressure / temperature protection Expander over speed protection (trip on For example: Gas compressor suction or over speed) discharge pressure or flow control Steam turbine inlet, outlet, admission and / - fluid catalytic cracking or extraction pressure or flow control Use of catalytic strip gas for power recov- Different control strategies available: de- ery coupling and / or feed-forward control Control of difference pressure between reactor and regenerator - turbine speed control Regenerator pressure limit control (after Automatic sequences for start-up with dif- separator) Expander start up sequence / acceleration ferent start up curves (cold, warm, hot) Expander speed / load control Avoidance of working within critical speed Public grid / island mode / frequency con- ranges trol (optional, electrical generator) Additional process limit controller (inlet Expander Inlet Flaps Control pressure, inlet temperature, load) Expander Bypass Flaps Control Selectable priority (power, extraction pressure, back pressure) on multi stage turbines - gas turbine control Turbine speed control with less than 10ms Start-up sequence / acceleration cycle time Gas metering valve control High speed event data recorder with ad- Inlet guide vane control justable time period Gas generator speed control public grid / island mode / frequency con- Power turbine speed control trol (optional, electrical generator) Power turbine limit control last blade protection (trip on inadmissible Temperature limit control operating points)

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