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GE Measurement & Control

Nexus
System Manual
GEK-118585
Revision 1.4
These instructions do not purport to cover all details or variations in equipment, nor to provide
for every possible contingency to be met during installation, operation, and maintenance. The
information is supplied for informational purposes only, and GE makes no warranty as to the
accuracy of the information included herein. Changes, modifications and/or improvements to
equipment and specifications are made periodically and these changes may or may not be
reflected herein. It is understood that GE may make changes, modifications, or improvements to
the equipment referenced herein or to the document itself at any time. This document is
intended for trained personnel familiar with the GE products referenced herein.
GE may have patents or pending patent applications covering subject matter in this document.
The furnishing of this document does not provide any license whatsoever to any of these
patents. All license inquiries should be directed to the address below. If further information is
desired, or if particular problems arise that are not covered sufficiently for the purchaser’s
purpose, the matter should be referred to:

GE Oil & Gas


Control Solutions
1800 Nelson Road
Longmont, CO 80501
energy.controlsolutions@ge.com
http://www.ge-mcs.com
Phone: + 1 (800) 835-5182 (United State)
+ 1 (970) 461-5201 (International)
(“+” indicates the international access code required when calling from outside the USA)

This document contains proprietary information of General Electric Company, USA and is
furnished to its customer solely to assist that customer in the installation, testing, operation,
and/or maintenance of the equipment described. This document shall not be reproduced in
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GE provides the following document and the information included therein as is and without
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warranty of merchantability or fitness for particular purpose.
©2016 General Electric Company, USA. All rights reserved.

HART is a registered trademark of HART Communication Foundation.


Safety Symbols
Symboles de sécurité

Indicates a procedure or condition that, if not strictly


observed, could result in personal injury or death.

Indique une procédure ou une condition, laquelle, si elle


n'est pas observée, pourrait causer de sérieuses
blessures ou la mort.

Indicates a procedure or condition that, if not strictly


observed, could result in damage or destruction of
equipment.

Indique une procédure ou une condition, laquelle, si


elle n'est pas observée, pourrait causer des dommages
ou la destruction de l'équipement.

Indicates a procedure, condition, or statement that


should be strictly followed in order to optimize these
applications.

Indique une procédure, une condition, ou un énoncé


qui doit être appliqué à la lettre de manière à optimiser
ces applications.

Note Indicates an essential or important procedure or statement.

Tip Provides essential information that is not normally defined in regular use
but from an experienced user.
Contents
Chapter 1 Nexus Overview 1
1.1 Overview ................................................................................................................................................................ 1
1.1.1 Applications ...................................................................................................................................................... 1
1.1.2 Controllers ......................................................................................................................................................... 1
1.1.3 I/O Networks .................................................................................................................................................... 2
1.1.4 I/O Modules....................................................................................................................................................... 2
1.1.5 Related Documents ...................................................................................................................................... 3
1.1.6 How to Get Help ............................................................................................................................................. 3
1.1.7 Acronyms and Abbreviations .................................................................................................................. 4
1.1.8 System Labels for Cabinet ........................................................................................................................ 5
Chapter 2 System Architecture 7
2.1 Overview ................................................................................................................................................................ 7
2.2 System Components ....................................................................................................................................... 7
2.2.1 Controller ........................................................................................................................................................... 7
2.2.2 I/O Networks .................................................................................................................................................... 8
2.2.3 I/O Module ......................................................................................................................................................... 9
2.2.4 Power sources.............................................................................................................................................. 11
2.2.5 Networks ......................................................................................................................................................... 13
2.2.6 Cabinets........................................................................................................................................................... 15
2.2.7 Human Machine Interface (HMI) ........................................................................................................ 17
2.2.8 Remote I/O ..................................................................................................................................................... 18
2.2.9 3rd-party Communication Interface ................................................................................................. 19
2.3 System Features and Specification ...................................................................................................... 21
2.3.1 IO Module Specification .......................................................................................................................... 21
2.3.2 Communication Control Module Specification ........................................................................... 27
2.3.3 HMI summary ............................................................................................................................................... 28
2.4 Software .............................................................................................................................................................. 28
2.4.1 OS ........................................................................................................................................................................ 28
2.4.2 Control Platform Software ..................................................................................................................... 28
2.4.3 Application Software ................................................................................................................................ 28
2.5 Certification and standards ...................................................................................................................... 29
Chapter 3 System Planning 30
3.1 Hardware Calculation .................................................................................................................................. 30
3.1.1 Controller ........................................................................................................................................................ 30
3.1.2 I/O Module ...................................................................................................................................................... 30
3.1.3 iLink Cable ...................................................................................................................................................... 31
3.1.4 Bus & Power Extension Module MCD50 ......................................................................................... 31
3.2 Cabinet................................................................................................................................................................. 31
3.2.1 Control/Extension Cabinet Assemblies ........................................................................................... 31
3.2.2 Control Cabinet ............................................................................................................................................ 32
3.2.3 General Cabinet .......................................................................................................................................... 32
3.3 HMI ......................................................................................................................................................................... 32
3.4 Network switch................................................................................................................................................ 33
3.5 Other equipment ............................................................................................................................................ 33
3.5.1 Communication Module ......................................................................................................................... 33
Chapter 4 Installation and Configuration 34
4.1 System Arrangement ................................................................................................................................... 34
4.2 Signal Segregation ........................................................................................................................................ 34
4.3 Cabinet Assembly .......................................................................................................................................... 34
4.4 System Network Topology ........................................................................................................................ 35
4.5 System Power Distribution ........................................................................................................................ 35
4.6 Power Distribution Cabinet ....................................................................................................................... 36

GEK-118585 Nexus System Manual i


4.7 Grounding .......................................................................................................................................................... 37
4.7.1 Cabinet grounding ..................................................................................................................................... 37
4.7.2 Signal grounding ........................................................................................................................................ 38
4.7.3 System grounding ...................................................................................................................................... 38
4.8 Field Signal Cable and Wiring .................................................................................................................. 39
4.9 Interface .............................................................................................................................................................. 41
4.9.1 Information communication ................................................................................................................ 41
4.9.2 Process control related signal connection ................................................................................... 41
4.9.3 Data transmission between subsystem ......................................................................................... 41
4.10 Node Number ................................................................................................................................................ 42
4.11 Installation conditions............................................................................................................................... 42

ii GEK-118585 Nexus System Manual


Chapter 1 Nexus Overview

1.1 Overview
Nexus control system is designed base on the OC 6000e integrated control platform.
It was designed to serve a wide variety of industrial process control and protection
applications from boiler control and protection, steam turbine control and
protection, to power generation balance of plant (BOP) equipment. The compatibility
design of the Nexus platform and the Nexus I/O series also provides an efficient
system upgrading solution for the legacy OC 4000 DCS user.
Nexus Control System is an advanced, fully configurable solution that improves
overall unit reliability and availability, provides simplified expansion capabilities and
reduces overall installation and training costs.

1.1.1 Applications
The control system consists of three primary components, the Controllers, I/O
Networks, and I/O Modules as shown in the following diagram.

Fig 1.1-1 Nexus System Structure

Note Each pair of redundant controllers can provide max. 4 I/O links. To simplify the diagram, only
one link is shown here.

1.1.2 Controllers
The iDPU series controller is applied in the Nexus system. It is an integrated stand-
alone computer that runs the application code for industrial process control and
data communication. The controller mounts directly in a panel. Real-time I/O data is

GEK-118585 Nexus System Manual 1


transferred to and from the control system over the intelligent I/O buses (iLink)
between the Nexus I/O module and the controller. The Operating System (OS) is
QNX® Neutrino® , a real-time multitasking OS designed for high-speed, high-reliability
industrial applications. The controller is loaded with software specific to its
application, which includes but is not limited to third-party communication, boiler
control, boiler protection, steam turbine control, and balance of plant products. The
function block based programming language complies with IEC1131-3 standards
and offers advantages in graphic configuration and debugging. Time
synchronization of the I/O network is implemented through iLink (R or S bus), and the
synch. accuracy can reach ±100us. Data communication between controllers and
other system nodes is implemented through UDH (Unit Data Highway) A and/or B.
Unlike conventional rack based I/O, there is no active component between Nexus
controllers and I/O modules. Meanwhile, the I/O network is redundant and interfaces
with both redundant controllers (see fig 1.1-1). This hardware architecture along
with corresponding system software design can ensure process control reliability in
the case of single failure occurrence, while also allowing for convenient system
maintenance and troubleshooting.

1.1.3 I/O Networks


Nexus I/O networks are IEEE® RS485 1Mbps half-duplex high-speed serial
communication networks. I/O networks can be redundant configuration, and each
network (white, black) can fulfil bi-direction real-time communication between
controllers and I/O modules.
Nexus I/O networks use a GE self-defined communication protocol, which utilizes an
“inquiry-response” communication mechanism, to ensure no confliction between
network transmissions. Controllers broadcast time synchronization messages to its
I/O modules, which accounts for the time delay caused by data transmission, thus
allowing for a final synch accuracy of ±100us for the I/O network.

1.1.4 I/O Modules


The Nexus I/O modules contain three basic parts, the IO assembly (w/ metal base),
the terminal block, and module cover. The I/O module is directly mounted on cabinet
mounting pillars.
Table 1.1-1 Components of Nexus I/O Module
Parts No. Description
IO Assembly 1 PCBA
2 Base
3 Screw
Module Cover 4 Cover
5 Label
Terminal Block 6 Terminal block
(Pin number and TB quantity are vary from module type)

2 GEK-118585 Nexus System Manual


Fig 1.1-2 Nexus IO Module Structure

Regular types of the Nexus I/O module have the same dimension and installation
mechanism, except the logic protection module MLP/BLP. For discrete output, the
large capacity relay extension module is available for specific applications.
Nexus I/O module provides the following features:
 Redundant 24V dc power supplies
 Module internal working power and I/O power are isolated with system power
 Power management, hot plug and current-limit
 High performance 32 bit embedded processor
 Redundant high-speed serial communication interface
 Full isolated circuit design, input/output isolation and protection
 Self-diagnostic, working power and inner temperature monitoring and alarm
 Removable Euro-style terminal block
 Highly compatible mounting size and I/O wiring definition with legacy OC 4000
terminal board

1.1.5 Related Documents


For additional information, refer to the following documents:
GEK-118586 Nexus Hardware Manual
GEK-118603 Nexus Operation & Maintenance Manual
GEK-118589 OptimumC Operator Software Manual
GEK-118590 OptimumC Engineer Software Manual
GEK-118591 OptimumC Function Block Manual
GEK-118593 OptimumC Hart Message Server

1.1.6 How to Get Help


If technical assistance is required beyond the instructions provided in the
documentation, contact the nearest GE Sales or Service Office or an authorized GE
Sales Representative.

GEK-118585 Nexus System Manual 3


1.1.7 Acronyms and Abbreviations
ADC Analog-to-Digital Converter
AWG American Wire Gauge
BOP Balance of Plant
CCR Central Control Room
CMR Common Mode Rejection
CPU Central Processing Unit
DAC Digital-to-Analog Converter
DCS Distributed Control System
DPU Distributed Process Unit
DHCP Dynamic Host Configuration Protocol
ENG Engineer Unit
EMC Electromagnetic Capability
EU Engineering Units
GPS Global Position System
GTW Gateway
HART Highway Addressable Remote Transducer
HMI Human Machine Interface
HMS HART Message Server
HSU Historical Data Unit
IEC International Electrotechnical Commission
IEEE Institute of Electrical and Electronics Engineers
I/O Input/Output
LAN Local Area Network
MTBF Mean Time Between Failures
MTBFO Mean Time Between Forced Outage
MTTR Mean Time To Repair
NEMA National Electrical Manufacturer’s Association
NFPA National Fire Protection Association
NTP Network Time Protocol
OPC OLE Process Control
OPU Operator Unit
PDH Plant Data Highway
PE Protective Earth
PLC Programmable Logic Controller
RTD Resistance Temperature Device
SIL Safety Integrity Level
SOE Sequence of Events
UART Universal Asynchronous Receiver/Transmitter
TB Terminal Block
UDH Unit Data Highway
UDP User Datagram Protocol
USB Universal Serial Bus
VDPU Virtual DPU
XML Extensible Markup Language

4 GEK-118585 Nexus System Manual


1.1.8 System Labels for Cabinet
•High Voltage Warning

•Electrical Hazard Warning

•Electro-Static discharge

GEK-118585 Nexus System Manual 5


•General Hazard

•Electrical Shock Hazard

6 GEK-118585 Nexus System Manual


Chapter 2 System Architecture

2.1 Overview
This chapter defines the architecture of the Nexus system, including the system
components, communication networks, and remote control/IO station. It also
discusses connectivity between the Nexus system and Third-Party systems.

2.2 System Components


The following sections define the main subsystems making up the control system.
These include the Controllers, I/O Networks, I/O modules, Power Distribution,
Cabinets, Networks and HMI Interfaces.

2.2.1 Controller
The iDPU series controller is applied in the Nexus system. It is an integrated stand-
alone computer that runs the application code for industrial process control and
data communication. The controller mounts directly in a panel. Real-Time I/O data is
transferred to and from the control system over the intelligent I/O buses (iLink)
between the Nexus I/O module and the controller. The Operating System (OS) is
QNX® Neutrino® , a real-time multitasking OS designed for high-speed, high-reliability
industrial applications. The controller is loaded with software specific to its
application, which includes but is not limited to third-party communication, boiler
control, boiler protection, steam turbine control, and balance of plant products. The
function block based programming language complies with IEC1131-3 standards
and offers advantages in graphic configuration and debugging. Time
synchronization of the I/O network is implemented through iLink (R or S bus), and the
synch accuracy can reach ±100us. Data communication between controllers and
other system nodes is implemented through UDH (Unit Data Highway) A and/or B.
In a simplex system, I/O network data includes process inputs/outputs to the I/O
modules.
In a dual system, I/O network data includes:
 Process inputs/outputs to the I/O modules
 Internal state values and initialization information from the designated
controller
 Status and synchronization information from both controllers

iDPU controller is an integrated single-board industrial computer which contains:


 One 1.6GHz Intel® ATOMTM processor
 512MB DDR2 RAM and 2G flash memory
 Two 10/100/1000Mbps Ethernet interfaces for UDH networks
 Two 10/100/1000Mbps Ethernet interfaces as extended connection for other
control equipment
 One 10/100/1000Mbps Ethernet interface for Master/Backup controller tracking

GEK-118585 Nexus System Manual 7


 Four DB-9 intelligent bus interfaces
 One RJ45 RS-232C connection for controller setup
 One USB port for controller base load and firmware downloading
The controller is powered by dual redundant 24V dc.

Redundant 24V dc
Power Supplies

Redundant UDH
Interfaces

Tracking Port for


Redundant Controllers

Intelligent I/O Bus

Fig 2.2-1 Nexus iDPU Series Controller

The iDPU series controller offers the following advantages:


 Integrated design, single-board architecture, industrial-strength protective shell
 Small panel footprint, a smaller installation space is required
 No jumper setting required
 No battery
 Fan-free operation
 On-board non-volatile flash memory, effectively avoid connection problem
caused by transportation/vibration
 Redundant 24V dc power inputs

2.2.2 I/O Networks


The Nexus intelligent I/O network, namely iLink, is a high-speed bus network based
on IEEE® half-duplex RS-485 serial communication, which is used for data
communication between controller and I/O modules and allows for communication
speed up to 1Mbps. Nexus I/O networks use a GE self-defined communication
protocol, which utilizes an “inquiry-response” communication mechanism, to ensure
no confliction between network transmissions. Controllers broadcast time
synchronization messages to its I/O modules, which accounts for the time delay
caused by data transmission, thus allowing for a final synch accuracy of ±100us for
the I/O network.
The iLink cable integrates bus communication and 24V dc power supply for I/O
modules. Each iLink contains one I/O bus and one 24V dc power supply, and can
facilitate bi-directional communication between controllers and I/O modules

8 GEK-118585 Nexus System Manual


independently. Standard Nexus system design applies dual redundant I/O networks
(R net and S net), to meet the requirements of redundant bus communication and
redundant power supply for I/O modules. For non-critical application, or per
customer’s specific requirement, simplex I/O network can also be applied. In such a
case, the I/O system will lose communication and power supply redundancy. The
iLink cable is standardized and I/O networks are different in cable colour, black
represents “Net R” and white represents “Net S”. A DB-9 connector is used to
connect bus and the I/O module, female – bus, male – I/O module. The pin definition
of the connector is as follows:
Table 2.2-1 iLink Connector Pin Definition
Bus connector Network Pin Signal Description
1 R_link+ iLink Net R data+
2 R_24V+ 24V dc A+
3 R_24V+ 24V dc A+
4 GND Ground
iLink
5 GND Ground
R
6 R_link- iLink Net R data-
7 R_24V+ 24V dc A+
iLink connector (female) 8 GND Ground
9 GND Ground
1 S_link+ iLink Net S data+
2 S_24V+ 24V dc B+
3 S_24V+ 24V dc B+
4 GND Ground
iLink
5 GND Ground
S
6 S_link- iLink Net S data-
7 S_24V+ 24V dc B+
I/O module connector (male)
8 GND Ground
9 GND Ground

GE provides the following types of iLink cable:


GE Item Code Name Description
388A2995G2101 iLink12B iLink Cable, w/ connectors for 12 IO Module, Black
388A2995G2102 iLink12W iLink Cable, w/ connectors for 12 IO Module, White
388A2995G2103 iLink6B iLink Cable, w/ connectors for 6 IO Module, Black
388A2995G2104 iLink6W iLink Cable, w/ connectors for 6 IO Module, White
388A2995G2105 iLink3B iLink Cable, w/ connectors for 3 IO Module, Black
388A2995G2106 iLink3W iLink Cable, w/ connectors for 3 IO Module, White

As shown in Fig 1.1-1, integrated I/O networks also include associated I/O bus &
power extension modules, as well as controller iLink extension cables. For a detailed
network connection scheme, please refer to GEK-118586 Nexus Hardware Manual.

2.2.3 I/O Module


The Nexus I/O module is an intelligent I/O module. The module adopts single board
design which contains a processor subsystem and an acquisition circuit, to
complete field process data acquisition, digitalization, control algorithm, control
output and bi-directional real-time communication with the controller.
As a result of the uniquely designed circuit and on-board software (firmware), the
Nexus I/O module can also provide full-level self-diagnostics, from module level to
channel level. These diagnostics cover the processor subsystem, I/O bus
communication, power management and I/O channels. Diagnostic results can be
displayed by the module’s status LEDs while also transmitted to the controller to be
viewed as an alarm displayed on the HMI screen.

GEK-118585 Nexus System Manual 9


Each Nexus I/O module has its unique physical address within each iLink, and it can
be set by the module’s address jumper. Through air heat convection, the module
can work between 0~60 ºC (32~140 ºF) ambient temperature. The module’s
processor contains a temperature sensor which can be used to acquire actual
temperature on the electrical circuit board (measurement accuracy ±5 ºC /±9 ºF).
The acquired data will be transferred to the controller via I/O link by the I/O module.
For detailed information about the I/O module, please refer to GEK-118586 Nexus
Hardware Manual.

Fig 2.2-2 Nexus I/O Module

Field signals are interfaced to the control system via the I/O module terminal blocks
(TB). Each I/O module has several TBs with the actual quantity depending on the
module type. Each TB is a removable single-row Euro-style with 16 pins (or different,
depends on module type) and each pin can hold one 2.05mm (#12AWG) wire, or two
1.63mm (#14AWG) wires. TB pitch is 5.08mm (0.2”) with 2000VAC insulation
withstands voltage.
I/O modules are installed in the cabinet in two columns. The DO module and the
associated extension relay board which are used for large capacity DC control
circuit are mounted adjacently, with modules above relay boards. Front and rear
grounding bars are provided on the bottom of the cabinet and adjacent to the
cabinet entrance of field cables for shield grounding.
Table 2.2-2 Nexus I/O Module
GE Item Code Name Description
369B1841G5006 MAI50 16-Channel mA/V Analog Input Module
369B1841G5007 MAI51 16-Channel TC/RTD Analog Input Module
369B1841G5008 MHT50 8-Channel mA/V Analog Input HART Module
369B1841G5009 MAI52 8-Channel mA/V Analog Input Module
369B1842G5004 MHO50 8-Channel Analog Output HART Module
369B1842G5005 MAO50 8-Channel Analog Output Module
369B1843G5003 MDI50 32-Channel Discrete Input Module, and 4 channels can be
configured for pulse input
369B1843G5005 MDI52 16-Channel Discrete Input Module, and 4 channels can be
configured for pulse input
369B1844G5004 MDO53 16 –Channel Discrete Output Module w/ Relay Output
369B1844G5005 MDO54 16 –Channel Discrete Output Module, extension relay board is
required for application
369B1851G5002 MSP50 Speed Measurement and Overspeed Protection Module
369B1851G5003 MSP51 Speed Measurement and Logic Protection Module
369B1848G5007 MVP50 Valve Position Control Module
369B1852G0007 MLP50 TMR Redundant Logic Control Module
369B1877G0007 BLP50 Programmable Logic Protection Base

10 GEK-118585 Nexus System Manual


2.2.4 Power sources
All Nexus modules use 24V dc power supply. By adopting DC power supply module
and power switch box w/ different voltage input, the system can adapt to various
power sources.
Each Nexus control cabinet has its own power supply system, including power
switch box, 24V dc power supply modules and DC power distribution assembly. DC
power is dual-redundancy configuration. There is no independent power system for
the IO extension cabinet and all power sources are derived from its respective
control cabinet.

Fig 2.2-3 Nexus Standard Control Cabinet Power Distribution

Generally, other equipment added in the control cabinet for process monitoring and
control purpose, such as 3rd-party communication interface module, signal isolator,
should be selected using 24V dc power supply and powered by system DC power. In
such cases, system DC power consumption needs to be calculated and checked,
and the corresponding fuses need to be installed. Those accessories installed in the
cabinet for the control system safety and reliability, or for some special application,
should not use system DC power, e.g. heat dissipation fan, heater, or moisture
eliminator, In principle, power source from switch F3 of power switch box should be
applied, or use separated power supply per actual requirement.
 AC power supply

GEK-118585 Nexus System Manual 11


Fig 2.2-4 Control Cabinet AC Power Switch Box (3D View)

For system w/ AC power supply, the Nexus control cabinet provides two redundant
AC power inputs, connected to the AC power switch box, to provide filtering and
protection for the input power, as well as auxiliary power outlet. The electrical circuit
scheme is shown as follows:

Fig 2.2-5 AC Power Switch Box Electrical Circuit Scheme

Two power inputs are switched by dedicated MCB, then filtered and rectified by
power filters, and connected to two 24V dc power supply modules. The power
supply for the cabinet auxiliaries comes from power input 2 by default, which is
controlled by switch F3, for cabinet heat dissipation fan and other devices.
Maximum current is 2A.
If special power is required for auxiliaries and the default power supply can’t be
used, additional power inputs need to be considered.

If additional power supply is applied for cabinet auxiliaries through power


switch box, make sure short-circuit wire between power input 2&3 is
removed in advance.

12 GEK-118585 Nexus System Manual


Si une source d'alimentation additionnelle est appliquée aux auxiliaires du
cabinet par le biais d'une boîte de commande électrique, assurez-vous que
le fil de court-circuit entre l'entrée d'alimentations 2 et 3 soit
préalablement enlevé.

 DC power supply
Each standard Nexus control cabinet has two redundant DC power supply modules,
and each DC module has a dedicated AC input which comes from the AC power
switch box. DC power is provided for all system modules. All Nexus modules have
redundant DC power input, including iDPU controller, I/O module and
communication control modules.
Two 24V dc outputs from redundant DC modules connect to power distribution
terminal blocks (including circuit fuse), then distribute to the iDPU controller and
MCD50 (I/O bus & power extension module) separately. The DC power for the
extension cabinet also comes from this terminal block.
Looped power supply is applied for I/O modules within each iLink, which is derived
from the same fuse of the power distribution terminal block. Removing or
connecting any module will not affect other module’s respective power supply.
DC power fuse – glass tube fuse, 20x5mm, 4 Amp for each I/O bus.

Proper fuse must be installed for each DC branch, to avoid affecting other
power circuits when short-circuit/overload occurs, and to prevent
equipment damage and avoid consequent safety risks.

Un fusible approprié doit être installé pour chaque branche CC de manière


à éviter de nuire à d'autres circuits d'alimentation lorsqu'un court-circuit
ou une surcharge survient, pour prévenir des dommages à l'équipement et
pour également prévenir des risques en matière de sécurité qui s'en
suivrait.

2.2.5 Networks
Dual-layer communication networks are applied in the Nexus system. The system
topology is shown below. This is for one unit example.

GEK-118585 Nexus System Manual 13


Fig 2.2-6 Nexus Network Architecture

The system backbone network adopts TCP/IP industrial Ethernet and GE standard
EGD communication protocol forms the control system UDH (Unit Data Highway), for
data communication & sharing between controllers and HMIs (Human Machine
Interface).
Between the controller and I/O modules, there is a GE self-defined intelligent serial
communication bus, namely iLink, for real-time communication between I/O
modules and controller.
Per system extension requirement, all HMI’s functionality can be extended for
advanced application. By re-configuring existing HMI station, or setting dedicated
communication interface unit, a high level system network for plant application can
be formed, namely PDH (Plant Data Highway).

14 GEK-118585 Nexus System Manual


Fig 2.2-7 Nexus PDH

2.2.6 Cabinets
The Nexus system contains the following types of cabinet: control cabinet, I/O
extension cabinet, power supply cabinet, network cabinet, etc.
 The control cabinet is the smallest construction unit of the control system.
Normally, an integrated Nexus DCS system is composed by one or several such
control units. Each control cabinet contains dual-redundant (or simplex) iDPU
controllers, dual-redundant (or simplex) iLink buses, I/O modules, power switch
box, dual-redundant (or simplex) DC modules and other system components.
Each control cabinet can hold a maximum of two pairs of redundant I/O buses,
which come from controller’s iLink port #1 and #2.
 The I/O extension cabinet is used to extend I/O capacity of the control cabinet.
Compared with the control cabinet, the extension cabinet normally has no
controller, nor power supply assembly. Module’s power supply comes from the
associated control cabinet’s DC output. Remote I/O cabinet is considered a
special I/O extension cabinet and its own power supply assembly. Each I/O
extension cabinet can hold a maximum two pairs of redundant I/O buses, which
come from controller’s iLink port #3 and #4.
 The power supply cabinet is used for the whole control system’s input power
distribution. Normally, the cabinet contains power indication & alarm assembly,
MCBs and power bus system. The whole system’s grounding bar can also be
installed in this cabinet.
 The whole control system’s UDH/PDH switches are installed in a network
cabinet, as well as all power supplies for these network switches.
All cabinets apply standard framework design. The cabinet dimension is
800x600x2200mm, IP42 protection. Cabinet mounting size is shown below.

GEK-118585 Nexus System Manual 15


Fig 2.2-8 Nexus Standard Cabinet Mounting Size (Bottom View)

 Control cabinet
In consideration of module’s installation characteristics, the inner structure of the
Nexus control cabinet and I/O extension cabinet is separated into two areas: power
& control unit area and I/O area.

I/O bus & power extension module DC distribution TB


Controller

24V dc
module
Power &
Control Unit
Power
Area
switch box

iLink buses

I/O Area

Front View Right View Rear View


Fig 2.2-9 Nexus Control Cabinet Structure
Power & Control Unit Area: The front of this area will be used to install iDPU
controller, power switch box and DC power module; and the rear of this area will be
used to install I/O bus & power extension modules and DC power distribution
assembly (terminal blocks and fuses).

16 GEK-118585 Nexus System Manual


I/O Area: Two pairs of I/O buses are configured on the front/rear of the control
cabinet allowing for a total of 4 columns of I/O modules with a maximum of 6
standard Nexus IO modules for each column. Front - #1 iLink with 12 IO modules;
Rear - #2 iLink with another 12 modules. iLink cables are installed behind I/O
modules, and module’s physical address within the I/O bus is set by its address
jumper.
 Power Supply Cabinet and Network Cabinet
Power supply cabinet & network cabinet adopt a standard 19” rack installation
structure. The mounting pillar is designed to accommodate device/assembly with
different unit height. Typical cabinet structure is shown below.

Power Indication
AC Power
& Alarm Assembly
Switchover
Assembly
MCB
24V dc
Module

UDH
Switch

PDH
Switch

Cabinet Input
Power TB

Fig 2.2-10 Standard Power Supply (Network) Cabinet Structure (Front View)

2.2.7 Human Machine Interface (HMI)


Nexus system contains the following types of HMI, per its functionality:
 Operator Unit (OPU): is the Human-Machine Interface for operator to monitor
and control the whole plant producing process.

GEK-118585 Nexus System Manual 17


 Engineering Station (ENG): is the Human-Machine Interface for I/C engineer to
configure & tune the control logic, and maintain the control system.
 Historian Unit (HSU): is the station used to collect and store process data, alarm
and system log. HSU also can be used to configure and generate reports.
 Communication Interface Unit (CIU): is the station used for 3rd-party
communication. The station uses the same protocol to interface with 3rd-party
device/system for one-way or bi-directional communication.
 Gateway (GTW): is the interface used between different control networks to
share the date and transmit operation commands. Dual redundancy
configuration is also available.

2.2.8 Remote I/O


Remote control station is available in Nexus system. By using twisted pair
communication cable or fibre-optical cable, the system UDH can be extended to the
field and the control cabinet can be located near control devices, thus saving in IO
cables and cable installation cost.
In some applications, Nexus IO can be configured as remote IO, which means the
I/O extension cabinet (no controller) will be installed on site, and connected to the
controller, which is located in the Central Control Room via twisted pair cables or
fibre-optical cables, to fulfil real-time monitoring & control for the field devices.
 Remote IO (copper cable connection)
The following scheme shows the remote IO network connection when using twisted
pair cable.

I/O Bus Terminator


iDPU A iDPU B

MCD50 MCD50
B C

iLink口 R S

iLink
MCD50
A

Control Cabinet Remote I/O

Fig 2.2-11 Nexus Remote IO Network Connection Scheme (Twisted Pair Cable)

MCD50 module should be applied in the central control cabinet for remote IO bus
connection, and connect to redundant iDPU controller via special Y type iLink cable.
Per the application, proper I/O modules and associated two MCD50 modules are
installed in the remote IO cabinet, the I/O network connection is consistent with the
standard iLink connection. When useing remote IO, it is important to ensure the bus
terminator is installed on MCD50 C as seen in the above figure.
Table 2.2-3 Components of Nexus Remote IO

18 GEK-118585 Nexus System Manual


GE Item Code Name Description
388A2995G2003 iLinkEXTR Nexus Controller Remote IO Extension Cable
369B1734P0105 iLinkTerm iLink Terminator

Communication cables between the control cabinet and remote IO cabinet can be
standard twisted pair cable, with a distance normally less than 300m. Typical
communication cables can be selected per the following characteristics:
Parameter Unit Typical value
Maximum Conductor DC Resistance Ω/km 87.6
dielectric strength AC kV/min 1.0
Minimum insulation resistance MΩ/km 500
Characteristic impedance Ω 120
Between conductors ≤ 90;
Capacitance@1kHz pF/m
Conductor – shield ≤ 120

Optional communication baud rate of remote IO can be: 115.2kbps, 230.4kbps,


460.8kbps or 921.6kbps (nominal 1Mbps). The baud rate is determined per actual
distance and amount of communication.
 Remote IO (fiber optical cable connection)
Fibre-optical cable can be used for long distance remote IO, and a RS-485 media
converter must be installed in both sides of the cabinets. Communication distance
depends on the selected FO cable and the communication speed can achieve a
maximum 1Mbps.
Various connection types can be applied to the remote IO, please refer to GEK-
118586 Nexus Hardware Manual, Chapter 2, section 2.1.3 for the detail information.

2.2.9 3rd-party Communication Interface


Nexus provides various ways to interface with 3rd-party devices or systems for one-
way or bi-directional data communication, to monitor and control other industrial
process.
 Communication Interface Unit (CIU)
CIU is a HMI on Nexus UDH dedicated for communication interface. It is loaded
with specific communication software and communicates with 3rd-party
devices/systems through a serial port, Ethernet or special interface hardware.
 Special communication control module
Nexus also provides a special communication control module on the system
UDH, to communicate with 3rd-party device/system through serial port or
Ethernet. In addition, the module also can fulfil relative process control function.
Three series of communication control modules are available in the Nexus
system:
 MPU series, provides RS-485 serial port and Ethernet port, supports Modbus
and other communication protocol
 MCI series, provides RS-232, RS-485 serial ports and Ethernet ports,
supports Modbus and other communication protocols (not recommend,
substituted by MPU module)
 MDP, supports Profibus-DP protocol

GEK-118585 Nexus System Manual 19


For detailed information about communication module, please refer to GEK-118586
Nexus Hardware Manual, GEK-114903 OC6000e Hardware Manual and GEK-
118580 MDP Profibus-DP Communication Module Manual.
Nexus supports the following communication protocols:
Protocol
Modbus Modbus Modbus IEC IEC GE
OPC OPC CDT GE
RTU RTU ASCII 104 104 UDP
Physical Client Server Master GSM
Slave Master Master Slave Master GTW
interface
Ethernet
         
C Port
I
U
Serial port          

Ethernet
         
M port
P
U
Serial port          

Nexus system and 3rd-party device/system connection is shown below:

3rd-party system 3rd-party system 3rd-party system 3rd-party system


(Ethernet) (Serial port) (Special HW) (Ethernet)

PDH
MPU

CIU

TP Cable

Ethernet

Serial port server

Special interface
Ethernet Ethernet

UDH
MDP

3rd-party system
(Profibus-DP)
Fig 2.2-12 Nexus and 3rd-party Device/system Connection

20 GEK-118585 Nexus System Manual


2.3 System Features and Specification
Table 2.3-1 System Features and Specification

Item Specification
System ambient temperature 0~60ºC
System ambient humidity 10 ~ 95% (non-condensing)
Total points in one system < 64,000 points
Number of controllers Max. 160
Number of HMIs Max. 80
SOE accuracy 1ms
Controller 1.66GHz, 15W
Real-time OS QNX®
Power rating for each cabinet 110-240V~, 50Hz/60Hz, < 480W

Table 2.3-2 System OS and SW List


Item Name Note
1 Windows XP/Windows 7 (English version) For English User
2 Windows XP/Windows 7 (Chinese version) For Chinese User
3 Office 2013 (English version) For English User
4 Office 2013 (Chinese version) For Chinese User
5 HMI software OptimumC Multilingual
6 OptimumC Controller software package Controller pre-installed
7 Hardware Key for HMI software HW dongle, Parallel Port or USB

2.3.1 IO Module Specification


Table 2.3-3 Nexus IO Module General Specification

Item Specification
Power supply Dual redundant 24V dc (±10%)
Processor High performance 32bit embedded processor
IO network interface Redundant high-speed serial bus, DB-9 male connector
IO network speed 115.2kbps、230.4kbps、460.8kbps、921.6kbps(nominal 1Mbps)
Controller scan rate Vary from IO network baud rate setting, the fastest 40ms
Terminal block Removable Euro-style terminal block, wiring gauge: two 2.5mm2
Size 209mm x 129.5mm x 51mm (High x Width x Depth)*
Installation Screw mounting
Operating temperature 0 ~ 60 ºC (32 ~ 140 ºF)
Storage temperature -40 ~ 85 ºC (-40 ~ 185 ºF)
Operating relative
humidity 5 ~ 95% (non-condensing)
Vibration 10-500Hz, acceleration < 10m/s2
Contaminants withstand PCBA double-side coating; dust particle size > 0.5uis, < 18,000 parts/L

Note Some type of module has different size, e.g. Logic Protection module.

GEK-118585 Nexus System Manual 21


 mA/V Analog Input Module MAI50/MAI52
Table 2.3-4 mA/V AI Module Specification
Item Specification
MAI50 MAI52
Number of channels 16 8
Input Span ±10V, ±5V, 0(4) - 20mA
A/D resolution 16 bit
Scan time 4 times/second
Accuracy(@25 ºC) 0.1% of full scale range
Temperature drift Max 0.05% of the upper range value over full operating temperature
Interference resistance CMRR ≥ 120dB@250VAC,NMRR ≥ 60dB@50/60Hz
Isolation Channel to channel ≥ 250VAC@50/60Hz
Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Power consumption Typical 2.5W,Max 11W Typical 1.8W,Max 6.5W

Heat dissipation Typical 1W,Max 6.6W Typical 1.8W,Max 4.35W

 16-Channel TC/RTD Analog Input Module MAI51


Table 2.3-5 MAI51 Specification

Item Specification
Number of channels 16
Temperature input types Thermocouples (TC) E/J/K/N/R/S/T/B
Resistance Temperature Device (RTD),
Pt10/Pt100/Cu50/Cu100/BA1/Cu10/Cu53, 3-wire
Input span 0~+128mV or 0~+32mV, acquired by module temperature input type
setting
Cold junction Reference junction temperature measured by one / two channels of RTD
compensation input, and compensated in controller by software
A/D resolution 16 bit
Scan time 2 times/second
Accuracy 0.2% of full scale over the full operating temperature range

Interference resistance CMRR ≥ 120dB@250VAC,NMRR ≥ 60dB@50/60Hz


Isolation Channel to channel ≥ 250VAC@50/60Hz
Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Power consumption Typical 2.1W, Max 2.5W
Heat dissipation Typical 2.1W, Max 2.5W

 8-Channel Analog Output Module MAO50


Table 2.3-6 MAO50 Specification

Item Specification
Number of channels 8
Analog output 0(4)-20mA,0(1)-5V dc(Channel number 07 & 08)
Load capacity (current
output) Max. 1kΩ
Load capacity (voltage Min. 200kΩ
output)
D/A resolution 12 bit
Frame rate Refresh all channels within 1ms;

22 GEK-118585 Nexus System Manual


System dependent scan rate for control purposes
Accuracy 0.2% of full scale over the full operating temperature range
Interference resistance CMRR ≥ 120dB@250VAC
Isolation Channel to channel ≥ 250VAC@50/60Hz
Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Power supply Dual redundant 24V dc (±10%)
Power consumption Typical 1.55W, Max 6.55W
Heat dissipation Typical 1.45W, Max 5.75W

 8-Channel mA/V Analog Input HART Module MHT50


Table 2.3-7 MHT50 Specification
Item Specification
Number of channels 8
Input Span ±10V, ±5V, 0(4) - 20mA
A/D resolution 16 bit
Scan time 4 times/second
Accuracy(@25 ºC) 0.1% of full scale range
Temperature drift Max 0.05% of the upper range value over full operating temperature
HART Support HART protocol V5/V6/V7
All input channels can be configured as HART enabled individually
HART data update time: 5s@8 channels
Interference resistance CMRR ≥ 120dB@250VAC,NMRR ≥ 60dB@50/60Hz
Isolation Channel to channel ≥ 250VAC@50/60Hz
Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Power consumption Typical 1.95W,Max 6.62W

Heat dissipation Typical 1.95W,Max 4.5W

 Discrete Input Module MDI50/MDI52


Table 2.3-8 DI Module Specification
Item Specification
MDI50 MDI52
Number of channels 32, 4 of them (CH #29~#32) also 16, 4 of them (CH #13~#16) also can
can be configured for pulse input be configured for pulse input
Input type Dry contact, current sink type
Input status indication Each channel has one LED for status indication
SOE accuracy 1ms
SOE resolution 0.2ms
Input filter Software filter, 3~50ms tunable, default 24ms
Input wetting voltage 48V dc
Input current 5mA
Pulse input frequency Max. 1.2kHz
Pulse input accuracy 1 pulse
Minimum pulse width High level - 420us; Low level - 410us
Pulse counting range 0-65535
Scan time System dependent scan rate for control purposes
1ms time resolution for SOE input
Isolation Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Power consumption Typical 1.2W, Max 8.5W Typical 1.2W, Max 5W

GEK-118585 Nexus System Manual 23


Heat dissipation Typical 1.2W, Max 8.5W Typical 1.2W, Max 5W

24 GEK-118585 Nexus System Manual


 16 –Channel Discrete Output Module w/ Relay Output MDO53
Table 2.3-9 MDO53 Specification

Item Specification
Number of channels 16
Output type Relay output, dry contact
Max load current Resistive Load - 12A/250VAC; 12A/30VDC
Inductive Load - 7.5A/250VAC; 6A/30VDC
Max response time on 15ms typical
Max response time off 10ms typical
Contact material AgNi
Contact life Electrical operations: 200,000 (AC); 100,000 (DC)
Mechanical operations: 30 x 106 (AC); 50 x 106 (DC)
Frame rate Refresh all channels within 1ms;
System dependent scan rate for control purposes
Isolation Channel to channel ≥ 1000VAC@50/60Hz
Channel to ground ≥2500VAC@50/60Hz
Channel to system ≥3000VAC@50/60Hz
Power consumption Typical 1.3W, Max 11W
Typical 1.3W, Max 27W (including heat dissipation of external control
Heat dissipation loop on relay contact)

 16 –Channel Discrete Output Module MDO54


Table 2.3-10 MDO54 Specification

Item Specification
Number of channels 16
Discrete output capacity Each channel with Max. 100mA@24V dc
Frame rate Refresh all channels within 1ms;
System dependent scan rate for control purposes
Isolation Channel to channel isolation, determined by connected relay board
Channel to ground ≥2500VAC@50/60Hz
Channel to system ≥3000VAC@50/60Hz
Power consumption Typical 1.3W, Max 4W
Heat dissipation Typical 1.3W, Max 4W

 Speed Measurement and Overspeed Protection Module MSP50(MSP51)


Table 2.3-11 MSP50(MSP51) Specification

Item Specification
Number of channels 1
Frequency range 1-20,000Hz
Input Span 50mVrms~40Vrms
Speed
input Signal type sine wave/triangle wave/square wave, or TTL signal
(Frequency) Speed sensor type Magnetic/eddy current/Hall/photoelectric
Accuracy 0.01%, notice that,
speed range 1~3600rpm, < 0.1rpm
speed range 3600~8000rpm, < 0.5rpm
Number of channels 6
Input Span ±10V, 0(4) - 20mA
AI
A/D resolution 16 bit
Accuracy(@25 ºC) 0.1% of full scale range

GEK-118585 Nexus System Manual 25


Temperature drift Max 0.05% of the upper range value over full operating
temperature
Interference resistance CMRR ≥ 120dB@250VAC,NMRR ≥ 60dB@50/60Hz
Isolation Channel to channel ≥ 250VAC@50/60Hz
Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Number of channels 8
Input type Dry contact, current sink type
Input status indication Each channel has one LED for status indication
DI SOE accuracy 1ms
Input filter 1~50ms, default 4ms
Input wetting voltage 24Vdc
Input current <3mA
Number of channels 6
Output type Opto-coupler output
Output status indication Each channel has one LED for status indication
DO SOE accuracy 1ms
Max load current 0.1A@24Vdc
Isolation Channel to channel ≥ 1000VAC@50/60Hz
Channel to ground ≥2500VAC@50/60Hz
Channel to system ≥3000VAC@50/60Hz
Power consumption Typical 2.2W, Max 7.6W
Other
Heat dissipation Typical 1.7W, Max 2.8W

 Valve Position Control Module MVP50


Table 2.3-12 MVP50 Specification

Item Specification
Number of channels 2
Exciting frequency 1~3kHz
LVDT Signal span 3.5Vrms/7.0Vrms
Sensor type 3-wire, 6-wire
Measurement accuracy 0.25%
Number of channels 2
Input span ±10V, ±5V, 0(4) - 20mA
A/D resolution 16 bit
Accuracy(@25 ºC) 0.1% of full scale range
AI Max 0.05% of the upper range value over full operating
Temperature drift
temperature
Interference resistance CMRR ≥ 120dB@250VAC,NMRR ≥ 60dB@50/60Hz
Channel to channel ≥ 250VAC@50/60Hz
Isolation Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Number of channels 6
Input type Dry contact, current sink type
Input status indication Each channel has one LED for status indication
DI
Input filter Software filter, 3~50ms, default 24ms
Input wetting voltage 24V dc
Input current <3mA
Number of channels 2
Servo
output Output capacity -40mA ~ +40mA@120Ω
Or -10V ~ +10V@20mA with Max. load 500Ω

26 GEK-118585 Nexus System Manual


Output accuracy 0.5%
Dither signal Frequency: 1~100Hz
(configurable) Amplitude: 0~10% rated output
Output monitoring Real-time output feedback
Fail-safe output Configurable fail-safe output
Number of channels 2
Output span 0~5V
AO Output capacity Max. load 500Ω
D/A resolution 12 bit
Output accuracy 0.25%
Power consumption Typical 2.5W, Max 11W
Other
Heat dissipation Typical 1W, Max 6.6W

 8-Channel mA/V Analog Output HART Module MHO50


Table 2.3-13 MHO50 Specification

Item Specification
Number of channels 8
Analog output 0(4)-20mA,0(1)-5V dc(Channel number 07 & 08)
Load capacity (current
output) Max. 1kΩ
Load capacity (voltage
output) Min. 200kΩ
D/A resolution 12 bit
Frame rate Refresh all channels within 1ms;
System dependent scan rate for control purposes
Accuracy 0.2% of full scale over the full operating temperature range
HART Support HART protocol V5/V6/V7
All output channels can be configured as HART enabled individually
HART data update time: 5s@8 channels
Interference resistance CMRR ≥ 120dB@250VAC
Isolation Channel to channel ≥ 250VAC@50/60Hz
Channel to ground ≥500VAC@50/60Hz
Channel to system ≥1500VAC@50/60Hz
Power supply Dual redundant 24V dc (±10%)
Power consumption Typical 1.7W, Max 6.7W
Heat dissipation (250Ω
load) Typical 1.6W, Max 5.9W

2.3.2 Communication Control Module Specification


Table 2.3-14 MPU51 Specification
Item Specification
Processor Intel® ATOM™ N450, 1.66 GHz, 512 KB(L2 Cache)
RAM DDR2 667/800MHz, 1GB
Flash 2GB
OS QNX®
Communication interface RJ-45 Ethernet*5 (Two for UDH interface)
Isolated RS-485 serial port*8
Communication speed Ethernet 100Mbps
Baud rate of serial communication (bps): 9600, 14400, 19200, 38400

GEK-118585 Nexus System Manual 27


Communication capacity Modbus protocol, with data refresh rate once per second:
(serial port) Communication speed (bps) Analog points Digital points
9600 384 3072
14400 576 4608
19200 768 6144
38400 1536 12288

Power supply Dual redundant 24V dc (±10%)


Power consumption Max. 15W

2.3.3 HMI summary


Table 2.3-15 Minimum requirements of HMI computer
HMI Type
OPU HSU ENG GTW
Item
Dual-core Dual-core Dual-core Dual-core
CPU
2.6GHz 2.6GHz 2.6GHz 2.6GHz
RAM 512MB 1GB 512MB 512MB
HDD 160GB 160GB 160GB 160GB
Network Interface 2 2 2 4
NIC 100Mbps 100Mbps 100Mbps 100Mbps
Video memory 128MB 128MB 128MB 128MB
OS Windows® 7 Windows® 7 Windows® 7 Windows® 7
Office SW N/A MS Office N/A N/A

2.4 Software
Software is required for all system components (controller, HMI, etc.) normal
operation, including operation software (OS) and Nexus platform software, All
software packages should be supplied to end user along with system hardware.

2.4.1 OS
Each iDPU controller (including communication control module) needs one QNX real-
time operating system.
Each HMI computer needs one Windows 7 professional operating system.
An MS office package (2010 or later version) is required for each report server or HMI
which needs to configure or communicate with the report server.

2.4.2 Control Platform Software


The control platform software is required for each UDH node - Controller &
HMI/Server.
A common HMI software package is supplied for all types of HMI. HMI’s functionality
varies from its software configuration.
All system controllers must have the same control platform software installed. In
addition, the communication module also has related interface software.

2.4.3 Application Software


Control application software is designed by the application engineer to address the
system control functions and safety requirements. It includes:
 HMI Graphics

28 GEK-118585 Nexus System Manual


 Control logic: each controller has a set of control algorithms and control logic
along with its I/O module to fulfil designated control functions
 Communication interface configuration, to communicate with 3rd-party
devices/systems for process monitoring and control

2.5 Certification and standards


Nexus product designed to comply with relevant international, domestic and
industrial standards and specifications.
FCC and CE certificated.
Pollution Degree 2 (as defined in IEC 61010-1).

GEK-118585 Nexus System Manual 29


Chapter 3 System Planning

To plan specific project hardware, the following steps can be used to roughly
calculate system components. The following calculation only considers basic
requirements and the minimum amount of system hardware. Additional hardware
should be included according to the customer’s specific requirements.

3.1 Hardware Calculation


iDPU controller, I/O module and iLink are calculated per actual IO quantity plus a
certain amount of margin.

3.1.1 Controller
Normally, the controllers are dual-redundancy configured.
Each pair of iDPU controller can support up to 4 redundant iLink buses.

3.1.2 I/O Module


Each standard Nexus I/O module occupies same installation space and one node of
redundant iLink bus. Below are notes regarding some special modules.
Module quantities are calculated as follows:
MAI50 = (mA/V inputs) x (1 + channel margin in percentage) / 16
MAI52/MHT50 = (mA/V inputs) x (1 + channel margin in percentage) / 8
MAI51 = (TC inputs) x (1 + channel margin in percentage) / 16 + (RTD inputs) x (1 +
channel margin in percentage) / 16

Note TC and RTD type signals can be configured in one MAI51 module, each type of input occupies
one side of module input (8 channels). Module quantity should be calculated accordingly.

MAO50/MHO50 = (AO points) x (1+ channel margin in percentage) / 8


MDI50 = (DI points) x (1+ channel margin in percentage) / 32
MDI52 = (DI points) x (1+ channel margin in percentage) / 16

Note Pulse input can be calculated together with DI point. Remember one DI module can only
provide 4 PI channels.

MDO53 = (AC or low voltage DC* control circuit DO points) x (1+ channel margin in
percentage) / 16
MDO54 = (DC control circuit DO points) x (1+ channel margin in percentage) / 16

30 GEK-118585 Nexus System Manual


Note 1) MDO53 control circuit voltage class: AC < 220V, DC ≤ 24V. For control circuit DC voltage ≥
28V, MDO54 should be applied, along with extension relay module BDO20 and associated
extension cable.
2) Take module installation space into account when using MDO54 and relay module, BDO20
occupies 2 continuous standard module positions in a column.

BDO20 = MDO54 module number


MSP50/MSP51 = Per actual project requirements
MVP50 = Per actual project requirements

3.1.3 iLink Cable


Nexus has three specifications for iLink cables. Each with 12, 6 or 3 I/O module
interfaces respectively, and the latter two types are used in the remote IO cabinet.
On both ends of the cable, there is a connector to connect the iLink cable and the
MCD50 Bus & Power Extension Module. Normally, iLink is dual-redundancy
configured.
Pair of iLink cable = (I/O modules x (1 + bus connector margin in percentage) + other
reserved module position in cabinet) / 12, the result should not be great than 4.

Note 1) For some special modules, the module number should be calculated per its actual
occupied position, e.g. MDO54 - 3, logical protection module - 2.
2) For remote I/O, the bus number is calculated per actual module number.

3.1.4 Bus & Power Extension Module MCD50


Bus & Power Extension Module MCD50 is used in conjunction with iLink cables. Each
pair of redundant iLink requires two MCD50 modules.

3.2 Cabinet
Nexus recommends 5 standardized control cabinet/extension cabinet designs. For
each standard design, there will be a cabinet layout drawing and BOM for reference.

3.2.1 Control/Extension Cabinet Assemblies


Item Code Name Description
235D2147G4001 1 iDPU 1 iLink Control cabinet, one (or one pair of) controller and
one I/O bus
235D2147G4002 1 iDPU 2 iLink Control cabinet, one (or one pair of) controller and
two I/O buses
235D2147G4003 0 iDPU 1 iLink IO extension cabinet, one I/O bus, no controller
235D2147G4004 0 iDPU 2 iLink IO extension cabinet, two I/O buses, no controller
235D2147G4005 0 iDPU 2 iLink L1R1 IO extension cabinet, two I/O buses pertaining to
different controller, no controller

Cabinet assembly defines a standard cabinet structure which includes all cabinet
components and accessories except I/O modules and cabinet framework.
Control cabinet assembly includes iDPU controller, power switch box, DC module,
iLink cable & bus extension module, DC power distribution terminal block, and other
basic installation accessories.

GEK-118585 Nexus System Manual 31


IO extension cabinet assembly only includes iLink cable & bus extension module, DC
power distribution terminal block and other basic installation accessories. As the
cabinet for I/O extension, it has no controller and power supply assembly.
Project engineers should select specific cabinet framework and proper cabinet
assembly per actual requirements, along with I/O modules, to form their own
cabinet design.

3.2.2 Control Cabinet


Control cabinet & extension cabinet adopt the same cabinet framework. Cabinet
quantities are calculated as follows:
 Calculate cabinet quantity per iLink number derived from 3.1.3 calculation,
maximum 2 (pairs) iLink buses for each cabinet.
 Should follow the cabinet assembly requirements of section 3.2.1
 Per customer’s specific requirements and project needs, configure the proper
number of control cabinets and extension cabinets.

3.2.3 General Cabinet


Other cabinets used for control system related equipment installation, which comply
with the 19” rack mounting requirement, such as power supply cabinet, network
cabinet, MFT relay cabinet, etc., can use a general type cabinet. The cabinet quantity
is considered as follows:
 According to project requirements, if a cabinet needs to be separated per its
function, then a dedicated cabinet should be applied, e.g. power supply cabinet,
or a network cabinet.
 According to project scope of supply, in some applications, certain equipment
can be installed in one cabinet, e.g. a gateway computer can be installed in a
network cabinet.

3.3 HMI
Nexus applies peer-to-peer network architecture where all HMI functions can be
realized on any system computer by configuration, which offers n+1 redundancy for
all HMI stations.
For system security and Intellectual Property protection, Nexus uses a hardware
dongle to protect all HMI applications. Each HMI computer must have a
corresponding dongle and software to ensure the legal use of software.
HMI quantity usually is determined per customer operation requirement. In principle,
one control system should have one engineer station and one historian at minimum.
Operator stations are configured per customer requirement. Other types of stations
should be configured to meet system’s functional extension requirements.
On some small DCS projects, some HMI functions can be integrated into one station
to reduce system’s HMI quantity, e.g. engineer station with historian function.
Basic requirements for HMI computer:
 Industrial PC or brand computer

 CPU:Dual core 2.6GHz or above


 RAM: 1GB DDR or above
 HDD: no specific requirement, recommend 160GB or above

32 GEK-118585 Nexus System Manual


 Network interface: configured per HMI function, at least two RJ45 10/100Mbps
ports

 Display adapter: support 1680x1050 or above resolution, display memory ≥


128M
 Other: support audio output, with spare PCI/PCI-e expansion slot

3.4 Network switch


Nexus real-time data highway is a redundant Ethernet network. Industrial Ethernet
switches are recommended to form the UDH networks.
According to the network topology, certain network switches are selected. For ring
topology, switches must have a network management function, and can set virtual
breakpoints as well. General industrial switches can be chosen for star topology.
RJ 45 twisted-pair cable can be applied for network equipment indoor connection. If
network devices are located in different places with a certain distance, then fibre-
optical connection is recommended.
Different mode FO cable is used per connection distance. Normally, multi-mode FO
cable is used if the distance is less than 2 km; otherwise, single-mode FO cable
should be selected, and the FO-RJ45 media converter should be selected
accordingly.

3.5 Other equipment


3.5.1 Communication Module
Nexus provides the following special communication modules for 3rd-party
device/system communication.
GE Item Code Name Description
369B1860G0028 MPU51 Nexus Communication Control Module,
10/100Mbps*5, RS-485*8, dual 24V dc input
369B1860G0024 MDP10 PROFIBUS-DP Master communication module,
2 DP ports, dual 24V dc input
369B1860G0025 MDP11 PROFIBUS-DP Master communication module,
1 DP port, dual 24V dc input

GEK-118585 Nexus System Manual 33


Chapter 4 Installation and Configuration

Control system design must ensure that:


 Any hardware or software failure should not endanger human safety or integrity
of power systems
 Any fault of control system should not lead production equipment to an unsafe
mode

If the equipment is used in a manner not specified by the manufacturer,


the protection provided by the equipment may be compromised.

Si l'équipement est utilisé d'une façon autre que celle indiquée par le
fabricant, la protection fournie par l'équipement peut être compromise.

4.1 System Arrangement


Process data and related control loops are segregated per industrial process and
control functions. Cabinets are located close to control equipment, but need to be
lined up as several groups and placed in the electronic equipment room with proper
environmental conditions. Remote control cabinet or remote IO cabinet adopt a high
IP grade cabinet and can be located adjacent to field devices and control processes.

4.2 Signal Segregation


Process control loop and associated I/O points are arranged in different controllers
and different I/O modules, according to loop characteristics, control & protection
importance and signal redundancy.

4.3 Cabinet Assembly


The standard cabinet dimension is 800x600x2000mm. The inner structure of the
control the cabinet is shown in Fig 2.2-9 and described as follows:
Power switch box, 24V dc module and iDPU controllers are installed on the top of the
front panel. The AC power supply device is insulated along with the mounting panel.
There are no such components in the I/O extension cabinet.
Cabinet internal 24V dc distribution TB and MCD50 bus & power extension modules
are installed on the top of the rear panel. The 24V dc power is distributed to the iDPU
controller and MCD50 modules separately. 24V dc for the IO extension cabinet is
also derived from here. The MCD50 modules provide iLink connection within its own
cabinet. Additional MCD50 modules are required for the extension cabinet.

34 GEK-118585 Nexus System Manual


I/O modules are installed in the middle of the front/rear panel, with a total of two
pairs of iLink buses, with a maximum 12 modules for each pair of iLink on each side.
iLink buses are installed on the back of I/O modules, and connect with I/O modules
via bus connectors.
On the bottom of the cabinet, there are two dedicated ground bars for field cable
shield grounding. The grounding bars are firmly screwed on the cabinet integrated
welding chassis and provide unique junction to the external grounding system.

4.4 System Network Topology


System redundant UDH networks are composed by high-speed industrial Ethernet
switches. The network topology for one generator unit and common system
connection is shown below.

Fig 4.4-1 Nexus Network Topology

4.5 System Power Distribution


The system is powered with two independent redundant power supplies. The power
distribution is shown as follows.

GEK-118585 Nexus System Manual 35


Fig 4.5-1 Nexus System Power Distribution

At least one of system’s two power supplies should come from plant UPS
system.

Dans les deux fournisseurs d'electrique de systeme, au moins un doit


provenir de I'usine UPS systeme.

4.6 Power Distribution Cabinet


The control system’s power distribution is realized by the power distribution cabinet
or assembly. Generally, if a system has more than 10 cabinets, then a dedicated
power distribution cabinet is required. In some small systems, the power distribution
is supplied by the customer.
Features of the power distribution cabinet:
 Two independent AC power inputs
 Provides power to cabinets and HMIs
 Power voltage indication, circuit protection, power presence monitoring, alarm &
trip output
 Maximum 80 breakers for 40 redundant circuits

36 GEK-118585 Nexus System Manual


Fig 4.6-1 Nexus Power Distribution Cabinet

4.7 Grounding
4.7.1 Cabinet grounding
There are two types of grounding in the Nexus cabinet according to device voltage
class:
 Low voltage device grounding, for devices with 24V dc power supply
 High voltage device grounding, for devices with 220V AC power supply (or
230/240VAC in EU, 115VAC in US)
Each Nexus cabinet has one unique grounding point, which is directly connected to
the cabinet framework.
High voltage devices are installed on a separated power panel which is insulated
with a cabinet mounting plate. The panel then connects to the cabinet grounding
bar through a grounding cable.
The controller mounting plate and IO module mounting pillars are connected by
grounding cables, and connect to the cabinet grounding bars.

GEK-118585 Nexus System Manual 37


FRONT PLATE REAR PLATE

24V dc POWER 24V dc POWER iDPU iDPU


A B

POWER PANEL
AC POWER SWITCH BOX

PILLAR

PILLAR

GROUNDING BAR

CONTROL CABINET

Fig 4.7-1 Nexus Cabinet Inner Grounding

4.7.2 Signal grounding


The Nexus IO module applies direct grounding design - The module is grounded
through mounting screws and cabinet mounting pillars, and finally grounded to the
cabinet grounding bar via grounding cables.
There are two grounding bars on the bottom of the cabinet chassis for field cable
shield grounding.

4.7.3 System grounding


The Nexus grounding system is a single point grounding system. All system cabinets
should be connected to the system single grounding point by grounding cables.
 Star-type grounding connection is applied between system cabinets
 For a large system, cabinets can be separated into several groups per their
location. Star-type grounding is applied within & between groups. Then the
system is grounded to a plant grounding grid through a single grounding point.

38 GEK-118585 Nexus System Manual


 When installing the cabinet, the insulation resistance between the cabinet
chassis and the mounting base should be greater than 2MOhm (500V mega
ohm meter).
 The grounding resistance between the system grounding point and the plant
grounding grid should be less than 2.5 Ohm.
Recommended grounding cable specification:
 The grounding cable within the cabinet shouldn’t be less than AWG14 (or 2mm2);
 The grounding cable between the cabinets, or from cabinet to group grounding
bar shouldn’t be less than AWG8 (or 8mm2);
 The grounding cable from group grounding bar to system grounding junction
box shouldn’t be less than AWG4 (or 20mm2);
 The grounding cable from the system grounding junction box to the plant
grounding grid shouldn’t be less than AWG2/0 (or 70mm2);
 Separately installed equipment, such as metal operator console or remote
cabinet, can be grounded to the nearest grounding point, and the cable gauge
shouldn’t be less than AWG8 (or 8mm2).
Remote Cabinet

Operator Console

AWG8 (or 8mm2)

Local Cabinets Local Cabinets

AWG8 (or 8mm2)

AWG4 (or 20mm2)


System Grounding Bar

AWG2/0 (or 70mm2)

Fig 4.7-2 Nexus System Grounding

4.8 Field Signal Cable and Wiring


Field cables and wirings are supplied by the customer. It is recommended that:
 For analog signal cables, each pair of twisted-pair wires should be shielded
separately, and the entire cable should be shielded as well.
 Individual shielded cables should be provided for each turbine speed input or
turbine valve position signal.
 A shielded cable should be provided for discrete input signals. It’s not necessary
to shield each DI signal individually.
 For AI/TC/RTD/AO/DI signals recommended wire gauge is 1.5 mm2.

GEK-118585 Nexus System Manual 39


 Usually a high voltage and large current device is connected to DO channel. The
cable should be selected accordingly.

The wiring diagrams for different signals are shown as follows:


 mA/V input (MAI50/MAI52/MHT50)
Current Current
Input + Input +
+ Shorted Shorted
+
PS
- 250Ω 250Ω
- Return Return
- + -
-
Open Shorted

+24V dc P +24V dc P
2-wire Transmitter 3-wire Transmitter
External powered Internal Powered
Current Input Shield Current Input Shield
S S

Current Current
Input + Input +

+ Shorted + Open
- 250Ω - 250Ω
Return - Return -

Shorted Open

+24V dc P +24V dc P
2-wire Transmitter 2-wire Transmitter
Internal powered Internal Powered
Current Input Shield Voltage Input Shield
S S

Fig 4.8-1 MAI50/MAI52/MHT50 Wiring

 TC/RTD input (MAI51)


Input + + Input + +

+
TC 3-wire RTD
-
Input - - Input - -

R RTD COM R

Shield S Shield S

Fig 4.8-2 MAI51 Wiring

 AO (MAO50/MHO50)
Output + + CH07 - OUTPUT TYPE SETTING FOR
CHANNEL 07
Load CH08 - OUTPUT TYPE SETTING FOR
Output - - CHANNEL 08

SHORTED - VOLTAGE
OPEN - CURRENT

JUMPER CH07/CH08

Shield S

Fig 4.8-3 MAO50/MHO50 Wiring

40 GEK-118585 Nexus System Manual


 DI (MDI50/52)

Input + + Input + +
48V DC 48V DC

Dry Contact Sink Current


Inupt Input

Input - - Input - -

Fig 4.8-4 MDI50/52 Wiring

 DO (MDO53)

COM COM

Control
Loop
NC NC
Control
Loop
RELAY
NO NO

Fig 4.8-5 MDO53 Wiring

4.9 Interface
4.9.1 Information communication
Process data can be shared between the Nexus system & other device/systems via
communication interface.
 The standard communication protocol can be used for data communication
between different control platforms.
 It is not recommended to transmit real-time control commands through the
communication interface between different control platforms.
 When interfacing with plant MIS/OA system, a firewall is required. The
information can only be sent out from DCS. Receiving from outside to DCS is not
allowed or supported.

4.9.2 Process control related signal connection


Signals used for process control which are derived from other control systems or
protection systems must be hard wire connected.

4.9.3 Data transmission between subsystem


Within the same control platform, all data and control commands are transmitted
via UDH network. Signals used for protection must be hard wired.

GEK-118585 Nexus System Manual 41


4.10 Node Number
All system nodes on the UDH must have a unique ID assigned by the system
engineer. The ID must follow the rules specified below:
Table 4.1-1 UDH Node Number
Type A B
Controller 1 ~ 80 101 ~ 180
HMI 81 ~ 100, 181 ~ 200 -

Type A and B are redundant controllers. Node number 1-80, 101-180 are for dual
redundant controllers, for example, 51 and 151 are a pair of redundant controllers.

Note For management convenience, DCS or DEH/ETS controller can be assigned a fixed ID.

4.11 Installation conditions


 Before system cabinet installation, electronic room construction must be
completed, including wall painting and ceiling installation. Security, lighting and
fire-extinguishing systems must be in service. Air condition system can be put
into service at a later date. All system equipment must be stored properly after
receipt to prevent corrosion, dampness and loss. The customer must provide a
clean & dry warehouse, free of temperature variations, high humidity, and dust.
24-hours security is strongly suggested after system power-up.
 All DCS equipment must be located as shown in the system layout drawing.
Ensure that the cabinet face and door directions are correct.
 The cabinet dimension is 800x600x2200mm (WxDxH). The gross weight is about
150kg. The cabinet should be mounted on the slot ware steel. The fastening
bolts are M12*25 Hexagon nut.
 Check the internal power distribution from the DCS power cabinet to control the
cabinet and HMI. Ensure that the wire gauge is larger than 16AWG (1.32 mm2)
(AC power supply) and use O type connection. Ensure that the UPS power is
connected to power input A and security power is connected to power input B.
 Ground the system per requirements listed in section 4.7.3.
 The UDH networks should be recovered before the first system power-up.
 All 24V dc power connections of extension cabinet must be recovered properly
before the first system power-up.
 All I/O signals must be shielded and grounded at the DCS side following the
single point grounding rules.
 A warning label of electrical safety must be placed on each cabinet during
commissioning. Cabinet power must be operated by qualified person.
 Recover system hardware configuration as much as possible, including HMI,
power supply, network and relative peripheral devices during the first system
power-up.
 Customer should issue “Engineering control room management procedure”
after system power up. All operations must be controlled by this procedure.

42 GEK-118585 Nexus System Manual