INSTRUCTION MANUAL

TURBINE CONTROL SYSTEMS

CALIBRATOR HANDBOOK

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 Page
Introduction 3
I. Features h

A. Physical 4

B. Signal Sources 4

1. Miflivolt Ii

2. Variable Frequency 5

3. Standard Voltage Source 6

h. current/voltage 6

5. Test Pot and Switches 6

6. Sequence Switches 7

C. Patchbaard 8

TI. Calibration 10

A. General 10

1. Connections 10

2. Instrumentation 10

3. References II

4. TechnIques 12

B. Signal Sources 16

1. Thermocouple Simulation i6

C. Sample Calibration Procedure 17

in. ~ev±sion Variation flefinition is

IV. DEVICE ThEORMATION

A. Calibrator, ICh988A100, Slis. 3.1-3.23

B. IC3EOOEPSS, shs. 3.0-Fl.

IC3EOOSCZA, Shs. 3.0-Fl.

103600SvFA. Shs. 3.0-Fl.

C. ?atchbcard Layout

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 INTRODUCTION

The calibrator provides a convenient method of accessing important variables within an analogue control system and
supplying signals to the panel to simulate the input from sensors external to the panel. The calibrator consists of a
patch board, two connectors which plug between the card rack in the control panel and several cards that are used to
simulate various types of signals.
These include millivolt, variable frequency, current and voltage.

The various cards in the calibrator take power from the panel to which it is connected for the generation of the various
simulated signals.
The patchboard provides a convenient method for reading out and supplying input signals to the control panel.

The calibrator is dedicated to a particular series of analogue control systems.

These instructions describe the various features of the calibrator and how it may be used to calibrate an analogue
turbine control system. The actual procedure for calibrating a particular panel and the appropriate settings are
contained in a separate document that is specific to the panel that is being calibrated.
The appropriate panel drawings are to be used in conjunction with the calibrator and both documents are to be cross
checked to ensure that signals flow to the correct terminations in both items of equipment. In general the
interconnection between the calibrator and the control system is shown on the 42 series of sheets in the panel
drawings.

On the last sheet of this publication is a layout drawing of the patchboard. It shows the locations on the patchboard
from which signals generated within the calibrator can be taken. It also shows typical locations of various common
signals that can be measured or injected at the patchboard.
Within certain limitations described toward the end of this document, this calibrator may be used to calibrate any Mark
I or Mark II analogue control systems

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CALIBRATOR PATCHBOARD, CARDS AND ADJUSTMENTS

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I. FEATURES

A. PHYSICAL

The calibrator is packaged in a carrying case with additional space available for a digital voltmeter and frequency
counter. It is connected to the control panel by means of 2 connector cables, Connector A and Connector B, which
plug into slots “A” and “B” in the calibrator and 2 slots in the control panel designated “CALIBRATOR TEST” and
“AUX TEST” respectively. Each connector cable contains 51 wires.
The calibrator contains 2 patchboards, a 10X10 Matrix and a 5X10 Matrix. Connector A is connected to the 10X10
Matrix and Connector B to the 5X10 Matrix.
Selected power supplies and control system signals from the turbine control panel are allocated to the wires in the
2 interconnecting cables.
Various locations in the patchboards have been allocated to the power supplies and signals that originate in the
turbine control panel. These are connected to the sockets into which the 2 interconnecting cables are inserted.
The calibrator is equipped with various electronic cards that are used to generate various types of signal to support
the calibration of a turbine control system.
These have been allocated to various points in the patchboards and wires in the interconnecting cables and are
thereby available to simulate signals to the turbine control system.
The circuits for power supply, signal sources etc. are built on DIRECTOMATIC* II cards and plugged into the card
slot rack along with the connector cables A and B.
Card Slot C contains SVFA on which the circuits for the 2 variable frequency oscillators are built.
Card Slot D contains SCZA on which the 2 millivolt sources and voltage/current source are built.
Card Slot E contains EPSS on which -50v DC is converted to -I2VDC power supply.

B. SIGNAL SOURCES

1. MilliVolt Sources MV#1 and MV#2

There are 2 milli-volt sources; MV#1 and MV#2; each is designed to simulate low level signals such as turbine
exhaust thermocouples over a range 0 to 50 mV.
These mV sources use the 3.3kHz oscillators in the turbine control panel for the power supply.
Each output has 2 adjustment potentiometers, a course adjustment – approx 0-50 mV, and a ‘Fine” adjustment –
approx 0-3 mV
The respective power is derived each from one of the 3 kHz power oscillators in the control panel.
Outputs are available on the patchboard; mVA at C4 and C5; mVB at C6 and C7.
“SW ” switch can be used to switch each source to either position on the patchboard.
SWITCH DOWN MV#1 AT mVA; MV#2 AT mVB
SWITCH UP MV#1 AT mVB; MV#2 AT mVA
This allows the two sources to be set up at convenient end points, for instance, when calibrating gain and

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 offset on the temperature amplifier.
Circuit details: IC3600SCZA

2. Two Variable Frequency Sources FREQ SOURCE #1 and #2

There are 2variable frequency sources; each is designed to simulate low-level signals such as magnetic speed
pick-ups in the turbine control, liquid fuel control systems and overspeed protection systems.
The signal ranges are over frequency ranges 15 Hz to 12.5 kHz at 10 to 11 v P to P.
The output signals can be varied with 2 potentiometers per signal source:
a. Fine adjustment +- 25 Hz.
b. Coarse adjustment 15 Hz to 12 kHz.
And are available at patchboard points :
FREQ SOURCE #1 at C1 and FREQ SOURCE#2 at C10 with respect to ACOM.

The card that generates these signals is IC3600SVFA.

For operation the card requires power from –12v and + 12 v supplies.
For control systems that include -50v DC power supplies a voltage convertor IC3600EPSS (MINUS 50v to –12 v
DC converter) is used.
For control systems without -50 v DC power supplies the –12v supply is taken directly from the control panel.

3 Standard Voltage Sources

There are 2 accurate regulated standard voltages available; typical uses include calibration checks of digital multi-
meters and oscilloscopes.
Voltages of 6 volts and 20 millivolts are available. The actual values will be recorded on the IC3600SCZA card on
which the terminal ‘banana’ type posts are located. These standard sources may be used to calibrate instruments
such as voltmeter or oscilloscope.

4 Combination Current and Voltage Sources

These sources make available a current and a voltage to simulate pressure transmitters, etc.
a. With 50 volt bus available in the control panel:
current, 0-50ma (500ohm MAX load); voltage 0 – 34 v DC
b With only 12 volt bus available in control:
current, 0-50ma (50 ohm MAX load); voltage 0 – 11 v DC

These sources are adjustable by coarse and fine potentiometers marked “Current” and are available at patchboard
locations:
Voltage source located D2
Current source located C2
To read current with voltmeter connect C2, (positive) to D2 across precision resistor (10 mv/ma).
Circuit details IC3600SCZA

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 5. Sequence Switches
There are 7 single pole single throw switches mounted in the calibrator.
These switches are generally wired to simulate various digital input points that are usually associated with the
start-up mode. Some or all of these switches are wired in a given application if they are needed in order to
calibrate the unit.
Refer to sheet 42 of the control panel drawings to determine which switches have been configured for which
functions.

NOTE: These switches normally must be turned off (down) when starting up or running the turbine with
the calibrator connected. Failure to ensure the switch positions can lead to catastrophic damage to
the turbine and consequent injury to plant personnel.

6 Additional Simulation Features

There are two switches, a resistor potentiometer configuration and a resistor network built into the calibrator.
These can be used to simulate various other calibration functions.

a. SW-9 is a single pole single throw switch with contacts located at F9 and F10 of the patchboard. These
could be connected to +12v, +28v of DCOM to simulate a logic condition or digital input function in the
control system.
b. SW-l0 is a single pole double throw switch that could be used to switch a voltmeter between the two over-
temperature channels to facilitate simultaneous calibration. The poles of the switch are located at
patchboards points J1, J2, and .J3.

c. The Potentiometer and Resistor configuration, available at patchboard points J7 though J10, may be used to
set up a test voltage or with 3 kHz oscillator output to simulate vibration signals or to provide more accurate
control over analogue DC voltage input simulations.

d. The Resistor configuration, available at patchboard points J4 through J6, can be used to simulate vary fast
counter rate by connecting the 10K connected between P12V and “VERY FAST” input of the digital setpoint
counter for calibrating the speed control features of some control panels.

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EPSS1 VOLTAGE CONVERTOR

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C. PATCHBOARD

The patchboard layout is shown on the final sheet of this publication.

Patchboard points are connected to circuitry within the calibrator such as sources, test switches, and components;
or ‘banana’ type jacks along the right side of the calibrator to allow connection of instruments.
The points on the patchboard are wired through the 2 connectors to the Control Panel.

The 10 x 10 section of the patchboard, defined by points A1 by J10, are connected to the turbine control panel
through “Conn A”; the remaining 5 x 10 section, defined by points A11 by J15, are connected to the turbine control
panels by “Conn B”.

On the layout sheet the small numbers in the lower left corner of each block identify the pin numbers to which the
input/output are connected for each connector.
It should be noted that some turbine control panels are equipped with a 3 rd socket to interconnect with a calibrator.
It is common practice for the pins in the control panel to be identified with the corresponding signal name in the
turbine control system.
It is essential to refer to the 42 series of sheets in the turbine control panel drawing to determine which
signals are connected to the interconnecting sockets for the calibrator.

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II.CALIBRATION GUIDELINES

A.GENERAL

These general guidelines assume that the control system is under maintenance or has previously completed all
pre-commissioning activities and has electrical power connected and energized.

1. Reference Documents:
The instruction manuals (Operations and Maintenance manuals) for the project.
The particular Applications Manual that explain the functions and circuit diagrams of the various control cards for
the particular type of control system.
Each turbine control panel is issued with a set of standard documentation that defines the control system.
Although there are few variations between the actual wiring and the locations of the various control cards of
control panels of a given type it is mandatory to use the drawings and other documents that were issued for the
control panel that is being worked on.
The various standard documents include:
a set of drawings that define the locations of cards in the panel and all associated wiring;
a control specification that defines all setpoints in the analogue control system;
a device summary that lists all ‘devices (pressure switches, temperature switches etc) that defines the
setpoints of the devices and a set of ‘mechanical schematics (similar to P&Ids) that illustrate the systems in
which the devices are located.

2. Typical Test Instruments

Digital Multi-meters – 20k ohm/Volt, 0v to 100 v AC and DC 4 digits
Frequency Counters 0 to 20k Hz, 0 to 15v
Oscilloscope
2 calibrated mV sources or Thermocouple Simulators
2 calibrated voltage and current sources – 0 to 35mA, 0 to 10v DC
2 calibrated AC Signal Generators – 0 to 12 kHz, 0 to 12 v

3. Connect The Calibrator to the Control Panel

Connector “A” from the calibrator should be connected to “Calibrate Test Slot” in the control panel.
Connector “B” from the calibrator should be connected to “Aux. Test Card Slot” in the control panel.
Refer to the 42 series of sheets in the turbine control panel drawings to determine the correct locations of these
two card slots.
Plug in the calibrator and check that the power supply levels at the patchboard points A1 through A6.
Verify oscillators outputs at A9 and A10.

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4 Techniques and Procedures
a. Logic Levels
Use a voltmeter to determine logic level of signal.
“0” = 0V to 0.4V (High threshold 0 up to l.5v)
“1” = 4.75V to 12V

b. Definition of Range, Span, Zero, Offset, Gain

Example: Exhaust temperature variation of 300 and 1000 which produces signals of
1.83 mV and 23.41 mV;
Signal span = 23.41 mV - 1.83 1mV = 21.58 mV
Signal range = 1.83 mV to 23.41 mV
Signal zero or offset = 1.83 mV
If this signal is amplified to l.0V and 4.5V;
Output span = 4.5V to 1.0 V = 3.5 V
Output range =1.0V to 4.5V
Output zero or offset = 1.0V
Amplifier gain = Output span/Input span
=3.57V = 0.1624V/mV
21.58mV

c. Adjusting “zero” and “gain” of an amplifier

Theoretically the gain should be adjusted before the zero because, in general, the zero has minimal effect
on the gain. However, since many amplifiers are not perfect the following guide should produce faster
results:
Using the values in the example (b) above:
Apply 1.83 mV to input.
Adjust zero for 1.0 V output.
Apply 23.41 mV to Input.
Adjust gain for 4.5 V output.
Apply 1.83 mV to input.
Note: Because of the gain adjustment, the zero has moved.
Readjust zero for 1.0 V output.
Apply 23.41 mV to Input.
Readjust gain for 4.5 V output.
The amount of readjustment decreased with each adjustment.
Repeat the above cycles until no readjustment is necessary.

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d “Nulling or “Balancing” the summing junction.
Within the stable operating range of an operational amplifier, the sum of all currents to the summing
junction is zero.
Many of the amplifiers used in the analogue control systems use integrating feedback. This means that,
if the net current to the summing junction is negative, the output volts will continue to rise and
conversely, a net positive summing junction current will cause the output volts to continue to decrease.
When the summing junction current is zero, the output will stop integrating, the volts will remain
constant and the operational amplifier is said to be nulled or balanced.
A voltmeter on the output of the amplifier can be used to determine when the Integration stops.
However, an alternative method is to use the function indicating lights in the front of the control panel.

For example, consider the temperature control card STKA with the isothermal base setpoint of 1000
degF.

Input an exhaust T/C signal of 10000F. (4.5 V @ pin 17)

Quickly rotate and counter rotate base reference pot. R95 so that temperature control Indicating light
goes on and off. (Note: Potentiometer movement causes the amplifier to integrate voltage up or down.
The Light Driver is voltage sensitive; above 28V the Light is Out and below 28V the Light is on).
As the potentiometer is rotated and counter-rotated and the light goes on and off, reduce the amount of
excursion until the light just stays on.
Set the potentiometer at the midpoint of this minimum excursion.
The summing Junction Is now “nulled” for this particular setting.

e Inputs and Outputs

The Control Specifications often refer to pin numbers on various cards for monitoring, logic forcing, or
even signal insertion. It is preferred and recommended that the measurements be taken from an
alternative connection within the control panel or at the patchboard of the calibrator.
Several cards include measurement points mounted on the front of the cards.
The locations of alternative points of connection are readily available from the control panel drawings.
Other alternatives include indicating lamps in the front panel or LEDs built into several cards such as
SLEH logic cards and the isolating input isolators.

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 f. Logic Forcing
All logic levels can be forced to zero values by connecting jumpers to DCOM but none can be forced to
‘1’ by connecting to power supplies or to other logic level ‘1’ signals.
To force a signal to logic level ‘1’ it is necessary to insert signals at the input of the card that generates
the signal.
The logic output from the SLEH card can be forced to a “1” or “0” from the test points in the front of the
cards.

g. Signal Sources
The signal source outputs are available on the patchboard to enable interconnection to any other
locations on the patchboard. A selection of jumper leads and miniature plugs are supplied with the
calibrator for this purpose.

h. Millivolt injection for thermocouple simulation may be accomplished in several ways:

Calibrator millivolt sources

Use of T/C reference tables are required. Accurate measurement of the ambient temperature cloe to
the T/C terminations is mandatory. The mV value of this ‘cold junction’ is subtracted from the required
mV values to be used in the calibration process.

Calibrated T/C simulators

These usually have cold junction compensation circuits built into them and automatically subtract the
value of the cold junction from the injected signal. It is imperative that these instruments are correctly
configured for the type of T/C being simulated. T/C compensation wire is used to connect the
instrument to the point of injection.
If the cold junction compensation network is not available the above method will work provided the
ambient temperature is measured and the difference between ambient and 32 deg F (which is the
reference used in the tables) is subtracted from the table value of millivolts for the particular
temperature desired to simulate.
Whichever technique is used it is necessary to reject all T/cs and preferable to inject signals to the
input terminations of the averaging cabinet.

For control panels that have accurate temperature meters installed in the front panel it it usually more
convenient to use the indicated temperature when adjusting temperature control points. However it is
essential that the accuracy of the meter be verified at the beginning of the calibration procedure.

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 i. Speed Signal and Transducer Input Simulation
When simulating speed signals and transducer input signals disconnect the field device wiring at the
termination points in the turbine control panel. Pay particular attention to the wire numbers, termination
points to ensure that the correct polarities are maintained when the devices are reconnected.

SAMPLE CALIBRATION PROCEDURES

Following are brief descriptions of a calibration process when using the calibrator. The values used are common
to several control systems but it is essential that the Turbine Control Specification for a particular panel be used
when performing actual site work.

Before commencing any checks that involve the turbine speed control functions ensure continuous operation of
the lube oil system by switching the control mode of the auxiliary pump to Hand/Manual if appropriate.
Take careful consideration of possible interruptions to cool-down sequences and inadvertent starting and stopping
of other auxiliaries such as cooling water pumps, ventilation fans etc where these are controlled via turbine speed
functions.
Similarly take careful consideration of the interaction between other logic functions and unit auxiliaries that will
occur during a calibration process; eg forcing the logic 4 values when checking speed relay calibrations.

Preliminary Checks
1. Connect the calibrator to the turbine control panel.
2. Connect a multi-meter to the ‘DVM’ Jacks in the calibrator chassis.
3. Connect a frequency meter to the ‘CTR’ (Counter) Jacks in the calibrator chassis.
4. Insert a miniature patchboard jumper between F6 and G6 -- DVM –ve and ACOM.
5. Insert a patchboard lead in E6 and verify the turbine control panel power supplies at patchboard locations
A1 though A6.
6. Verify voltage levels at the test jacks on cards on card IC3600SCZA.
7. Insert a miniature patchboard jumper between F1 and G1 -- CTR –ve and ACOM.
8. Insert a patchboard lead in E1 and verify the frequency of the output from the control panel oscillators is
3.3kHz at patchboard locations A9 and A10.
9. Verify the voltages at A9 and A10 are 8.4v AC with the DVM.
10. Insert a patchboard lead in E1 and verify the frequency source outputs at patchboard points C1 and C10.
11. Verify voltage levels at the C1 and C10 with the DVM.
12. Verify output voltages of mV source #1 at C4 and C5 and mV source #2 at C6 and C7. Do not use the
ACOM jumper for the DVM; measure the voltage levels and ranges of both Coarse and Fine potentiometers
directly with the DVM + and – connections.

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 Verify Analogue Value of NHP – Frame 5001
1. Turn the adjustment potentiometers of all variable source output generators – mV and Frequency – full
counterclockwise.
2. Disconnect the magnetic pick up from the turbine control panel.
3. Connect a patchboard jumper between C1 and B2.
4. Connect a patchboard jumper between C1 and CTR +ve – E1.
5. Connect a miniature jumper between CTR –ve, F1, and ACOM.
6. Connect a Frequency Counter to the CTR Jacks.
7. Connect a miniature jumper between F6 and G6.
8. Connect a jumper between H5 – NHP – and E6 – DVM +ve.
9. Connect a DVM to the DVM Jacks.
10. Slowly increase the output potentiometer of Frequency Source #1 and observe increases in Frequency
Counter and DVM values.
11. Increase the Frequency Input Signal to 5105 RPM and check that NHP – DVM meter value – is 10v +-
0.05v.
12. Adjust potentiometer on Card SS as required.
13. Reduce the frequency input signal to zero -- NOTE that 14HR relay might not drop out for some time.
14. Verify NHP is 0v +- 0.05v.
15. Repeat above but use the 14HR patchboard connection B1.

REVISION VARIATIONS
The calibrator is presently in its 4th revision. Changes have been minor and have been made to make the calibrator
more versatile. The revision number is not on the nameplate, but the revision of any particular calibrator is readily
apparent from the following:
REVISION I: The original form used nomenclature on the switches as illustrated on sheet 3. Also it has seven
test jacks on the right hand side of sheet 3.
REVSION 2: Added two test jacks, AUX (+), (-), wired to patchboard points E2, F2 respectively and spaced all
test jacks to take a standard size of test lead.
REVISION 3: The switch designations were changed from names to switch numbers, eg SW1,2 etc. Note that the
switch numbers on the calibrator drawings were changed to facilitate a left to right flow of switch numbers This
change allows any one switch to be used for different functions from one panel to another, The switch a function Is
defined on sheet 42 of the panel drawing. The switch numberIng is as follows:
SWl SW2 SW3 SW4 SW5 SW6

SW7 SW8 SW SWl0

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In addition to the change in switch nomenclature, 12 additional wire runs from the panel to the patchboard were
added as follows:
connector A: pins 49, 51
connector B: pins 1, 2, 23, 24, 27, 28, 29, 30, 50, 51
These further increase the capability of the calibrator. The calibrator will have these extra runs if it has switch
numbers on the nameplate; it will not have these runs if the switches have names as illustrated on sheet 3.
Any panel may be calibrated with any calibrator with the following reservations limitations
(a) Switch designation may be confusing, but are defined above.
(b) The 12 interconnecting wires defined above will not be on revisions 1 and 2 and may be a problem
when a Mark II Industrial panel is to be calibrated with a revision 1 and 2 calibrator. This limitation may
be identified by referring to the 42 series of sheets of the panel drawings.
A modification kit is available to take care of limitations (a) and (b) where needed.
(c) The voltage/current source on IC3600SCZA, Rev. A is not capable of providing a 50 mA pressure
signal when used on a Mark II panel. If this signal is required for a Mark II panel, a Revision B must be
obtained.

REVISION 4: The “TEST” potentiometer RH1 was changed from a 1 turn 100k ohm to a 10 turn 10K.

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Note: The illustration below is fairly typical for a calibrator patchboard but is not to be taken as a true representation. Before connecting a calibrator to a control panel it is
essential that the drawings of the control panel be used to define the true layout. As an example the patchboard points A12 X B15 suggest that flame detector signals are
brought out. This was true of early flame detection systems which have, in all probability been phased out in favour of the more up to date Honeywell flame detectors.