GEK-118585 OC 6000e Nexus System Manual V1.3

GE Measurement & Control
OC 6000e Nexus
System Manual
GEK-118585
Revision 1.3
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
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equipment and specifications are made periodically and these changes may or may not be
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HART is a registered trademark of HART Communication Foundation.

OCNEXUS is registered trademarks of Xinhua Control Engineering Co., Ltd.
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 OC 6000e Nexus Overview 1
1.1 Overview .............................................................................................................................................. 1
1.1.1 Applications ..................................................................................................................................... 1
1.1.2 Controllers ........................................................................................................................................ 2
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 ............................................................................................................................. 4
1.1.7 Acronyms and Abbreviations ..................................................................................................... 4
Chapter 2 System Architecture 5
2.1 Overview .............................................................................................................................................. 5
2.2 System Components ........................................................................................................................ 5
2.2.1 Controller .......................................................................................................................................... 5
2.2.2 I/O Networks ................................................................................................................................... 6
2.2.3 I/O Module........................................................................................................................................ 7
2.2.4 Power sources ................................................................................................................................ 9
2.2.5 Networks ........................................................................................................................................ 11
2.2.6 Cabinets .......................................................................................................................................... 13
2.2.7 Human Machine Interface (HMI) ............................................................................................. 15
2.2.8 Remote I/O ..................................................................................................................................... 16
2.2.9 3rd-party Communication Interface ....................................................................................... 17
2.3 System Features and Specification ........................................................................................... 19
2.3.1 IO Module Specification ............................................................................................................. 19
2.3.2 Communication Control Module Specification ................................................................... 24
2.3.3 HMI summary ............................................................................................................................... 25
2.4 Software............................................................................................................................................. 25
2.4.1 OS ..................................................................................................................................................... 25
2.4.2 Control Platform Software ........................................................................................................ 25
2.4.3 Application Software .................................................................................................................. 25
2.5 Certification and standards ......................................................................................................... 26
Chapter 3 System Planning 27
3.1 Hardware Calculation .................................................................................................................... 27
3.1.1 Controller ........................................................................................................................................ 27
3.1.2 I/O Module...................................................................................................................................... 27
3.1.3 iLink Cable ...................................................................................................................................... 28
3.1.4 Bus & Power Extension Module MCD50 ................................................................................ 28
3.2 Cabinet ............................................................................................................................................... 28
3.2.1 Control/Extension Cabinet Assemblies ................................................................................. 28
3.2.2 Control Cabinet............................................................................................................................. 29
3.2.3 General Cabinet ........................................................................................................................... 29
3.3 HMI....................................................................................................................................................... 29
3.4 Network switch ................................................................................................................................ 30
3.5 Other equipment ............................................................................................................................. 30
3.5.1 Communication Module ............................................................................................................ 30
Chapter 4 Installation and Configuration 31
4.1 System Arrangement ..................................................................................................................... 31
4.2 Signal Segregation .......................................................................................................................... 31
4.3 Cabinet Assembly ........................................................................................................................... 31
4.4 System Network Topology ........................................................................................................... 32
4.5 System Power Distribution ........................................................................................................... 32
4.6 Power Distribution Cabinet .......................................................................................................... 33
4.7 Grounding.......................................................................................................................................... 34
GEK-118585 OC 6000e Nexus System Manual i

4.7.1 Cabinet grounding....................................................................................................................... 34
4.7.2 Signal grounding .......................................................................................................................... 35
4.7.3 System grounding ....................................................................................................................... 35
4.8 Field Signal Cable and Wiring ...................................................................................................... 36
4.9 Interface ............................................................................................................................................. 38
4.9.1 Information communication .................................................................................................... 38
4.9.2 Process control related signal connection........................................................................... 38
4.9.3 Data transmission between subsystem ............................................................................... 38
4.10 Node Number ................................................................................................................................ 39
4.11 Installation conditions ................................................................................................................. 39
ii GEK-118585 OC 6000e Nexus System Manual

Chapter 1 OC 6000e Nexus Overview
1.1 Overview
The OC 6000e Nexus series is the I/O system extension based 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 OC 6000e platform and the Nexus I/O
series also provides an efficient system upgrading solution for the legacy OC 4000
DCS user.
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.
UDH A UDH B
A B
Controllers
iDPU iDPU
I/O Link I/O Link
I/O Networks
S Link
R Link
T T T
B B B
I/O Modules
T T T
B B B
Fig 1.1-1 OC 6000e 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.
GEK-118585 OC 6000e Nexus System Manual 1

1.1.2 Controllers
The iDPU series controller is applied in the OC 6000e 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 not limited to third-party communication, boiler
control, boiler protection, steam turbine control, balance of plant products. The
program language is function block based and complies with IEC1131-3 standards
and strengthens in graphic configuration and debugging language. Time
synchronization of the I/O network is implemented through iLink (R or S bus), and the
synch accuracy can reach to ±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 has
interface with both redundant controllers (see fig 1.1-1). This hardware architecture
along with corresponding system software design can ensure process control
reliability in case of single failure occurrence, and make the system convenient for
maintenance and troubleshooting.
1.1.3 I/O Networks

OC 6000e 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 GE self-defined communication protocol, which complies
the “inquiry-response” communication mechanism, to ensure no confliction within
network transmission. Controllers broadcast time synchronization message to its
I/O modules, and the time delay caused by data transmission and processing has
already been considered in the synchronization message, thus making the final
synch accuracy of I/O network able to reach to ±100us.
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 OC 6000e Nexus System Manual

Fig 1.1-2 OC 6000e Nexus IO Module Structure
All 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, plug and play and current-limit
High performance 32bit 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 OC 6000e Nexus Hardware Manual
GEK-118600 OC 6000e Nexus TMR ETS User Manual
GEK-118603 OC 6000e 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.
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

Chapter 2 System Architecture
2.1 Overview
This chapter defines the architecture of the OC 6000e 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 Operator Interfaces.
2.2.1 Controller
The iDPU series controller is applied in the OC 6000e 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 not limited to third-party communication, boiler
control, boiler protection, steam turbine control, balance of plant products. The
program language is function block based and complies with IEC1131-3 standards
and strengthens in graphic configuration and debugging language. Time
synchronization of the I/O network is implemented through iLink (R or S bus), and the
synch accuracy can reach to ±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
1GB 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

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 OC 6000e Nexus iDPU Series Controller
The iDPU series controller offers the following advantages:

Integration 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 OC 6000e 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. The fastest
communication speed can reach to 1Mbps. Nexus I/O networks use GE self-defined
communication protocol, which complies the “inquiry-response” communication
mechanism, to ensure no confliction within network transmission. Controllers
broadcast time synchronization message to its I/O modules, and the time delay
caused by data transmission and processing has already been considered in the
synchronization message, thus making the final synch accuracy of I/O network able
to reach to ±100us.
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

fulfil bi-directional communication between controllers and I/O modules
independently. Standard Nexus system design applies dual redundant I/O network
(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. iLink
cable is standardized and I/O networks are different in cable color, 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
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 OC 6000e Nexus
Hardware Manual.
2.2.3 I/O Module

The OC 6000e 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 controller.
Thanks to a specific 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, covers processor subsystem, I/O bus communication, power management and
I/O channel. Diagnostic results can be displayed by module status LEDs. Meanwhile,

the diagnostic information also transmits to the controller and is alarmed and
displayed on the HMI screen.
Each Nexus I/O module has its unique physical address within one same iLink, and it
can be set by the module’s address jumper. Through air convection, the module can
work on 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 OC
6000e Nexus Hardware Manual.
Fig 2.2-2 OC 6000e Nexus I/O Module
Field signals are interfaced to the control system via the I/O modules terminal blocks.
Each I/O module has several TBs (quantity depends on module type). It is a
removable single-row Euro-style with 16 pins (or different, depends on module type)
for each TB, 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 several columns. The DO module and the
associated extension relay board which are used for large capacity DC control
circuit are mounted adjacently, with module above relay board. 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 OC 6000e Nexus I/O Module

369B1841G5006 MAI50 16-Channel mA/V Analog Input Module
369B1841G5007 MAI51 16-Channel TC/RTD Analog Input Module
369B1841G5009 MAI52 8-Channel mA/V Analog Input Module
369B1841G5008 MHT50 8-Channel mA/V Analog Input HART Module
369B1842G5004 MHO50 8-Channel Analog Output HART Module
369B1842G5003 MAO50 8-Channel Analog Output Module (legacy)
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
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 OC 6000e 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, all power sources are derived from its
associated control cabinet.
Fig 2.2-3 OC 6000e 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 corresponding fuse(s) need to be installed. Those accessories installed the in
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 F31 of power switch box should be
applied, or use separated power supply per actual requirement.
AC power supply

Fig 2.2-4 Control Cabinet AC Power Switch Box (Front/3D View)
For system w/ AC power supply, the OC 6000e Nexus control cabinet provides two
redundant AC power inputs, connect 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 is coming from power input 2 by default, which is
switched by switch F31, for cabinet heat dissipation fan and other device. Maximum
current is 2A.
If special power is required for auxiliaries and can’t use default power supply,
additional power input need to be considered for this purpose.
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.

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 OC 6000e Nexus control cabinet has two redundant DC power supply
modules, and each DC module has its dedicated AC input which comes from the AC
power switch box. DC power is provided for all system modules. All OC 6000e Nexus
modules have redundant DC power input, including iDPU controller, I/O module and
communication control module.
Two 24V dc outputs from redundant DC modules connect to power distribution
terminal block (including circuit fuse), then distribute to 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 one same iLink, which is
derived from the same fuse of the power distribution terminal block. Remove/plug
any module will not affect other module’s power supply.
DC power fuse – glass tube fuse, 20x5mm, 8 Amp for each I/O bus.
Proper fuse must be installed for each DC branch, to avoid affecting other
power circuit when short-circuit/overload occurs, and to prevent
equipment damage and avoid consequent safety risks as well.
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 OC 6000e Nexus system. The
system topology is shown below. This is for one unit.

Fig 2.2-6 OC 6000e 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).

Fig 2.2-7 OC 6000e Nexus PDH
2.2.6 Cabinets
The OC 6000e 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
associated control cabinet DC output. Remote I/O cabinet is some kind of
special I/O extension cabinet. It has a power supply assembly. Each I/O
extension cabinet can hold 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 whole control system 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 network cabinet,
as well as all power supplies for these network switches.
All kinds of cabinets apply standard framework design. The cabinet dimension is
800x600x2200mm, IP42 protection. Cabinet mounting size is shown below.

Fig 2.2-8 OC 6000e Nexus Standard Cabinet Mounting Size (Bottom View)
Control cabinet
In consideration of module’s installation characteristics, the inner structure of the
OC 6000e 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 OC 6000e 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).

I/O Area: Two pairs of I/O buses are configured on the front/rear of control cabinet,
totally 4 columns of I/O modules can be installed with maximum 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 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)

OC 6000e Nexus system contains the following types of HMI, per its functionality：
Operator Unit (OPU): is the Human-Machine Interface for operator to monitor &
control the whole plant producing process.

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 & store process data, alarm
and system log. HSU also can be used to configure & generate report.
Communication Interface Unit (CIU): is the station used for 3rd-party
communication. The station uses same protocol to interface with 3rd-party
device/system, to realize on-way or bi-direction communication.
Gateway (GTW): is the interface used between different control network to
share date and transmit operation command, Dual redundancy configuration is
available.
2.2.8 Remote I/O

Remote control station is available in OC 6000e Nexus system. By using twisted pair
communication cable or fiber-optical cable, the system UDH can be extended to
field and the control cabinet can be located near control devices, thus to save the IO
cables and related cable installation cost.
In some application, OC 6000e Nexus IO can be configure as remote IO, which
means the I/O extension cabinet (no controller) will be installed on site, and connect
to the controller - which is located in the Central Control Room, via twisted pair
cables or fiber-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
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 actual application, proper I/O modules and associated two MCD50 modules are
installed in the remote IO cabinet, the I/O network connection is same as standard
iLink connection. When use remote IO, make sure the bus terminator is installed on
MCD50 C that is shown in above scheme.

Table 2.2-3 Components of OC 6000e Nexus Remote IO
388A2995G2003 iLinkEXTR Nexus Controller Remote IO Extension Cable
369B1734P0105 iLinkTerm iLink Terminator
Communication cable between control cabinet and remote IO cabinet can be

standard twisted pair cable, and normally the distance is less than 300m. Typical
communication cable 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)
Fiber-optical cable can be used for long distance remote IO, and RS-485 media
converter must be installed in both side of cabinets. Communication distance
depends on selected FO cable and the communication speed can reach to
maximum 1Mbps.
Various connection types can be applied to the remote IO, please refer to GEK-
118586 OC 6000e Nexus Hardware Manual, Chapter 2, section 2.1.3 for the detail
information.
2.2.9 3rd-party Communication Interface

OC 6000e Nexus provides various ways to interface with 3rd-party device or system
for data one-way or bi-direction communication, to monitor and control other
industrial process.
Communication Interface Unit (CIU)
CIU is a HMI on OC 6000e Nexus UDH dedicated for communication interface, it
is loaded with specific communication software and communicate with 3rd-
party device/system through serial port, Ethernet or some special interface
hardware.
Special communication control module
OC 6000e Nexus also provides special communication control module on
system UDH, to communicate with 3rd-party device/system through serial port
or Ethernet. Besides that, the module also can fulfil relative process control
function.
Three series of communication control module are available in OC 6000e system:
• MPU series, provide RS-485 serial port and Ethernet port, support Modbus
and other communication protocol
• MCI series, provide RS-232, RS-485 serial port and Ethernet port, support
Modbus and other communication protocol (not recommend, substituted by
MPU module)
• MDP, support Profibus-DP protocol

For detailed information about communication module, please refer to GEK-118586
OC 6000e Nexus Hardware Manual, GEK-114903 OC6000e Hardware Manual and
GEK-118580 MDP Profibus-DP Communication Module Manual.
OC 6000e Nexus supports the following communication protocol:
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
N/A
C Port
I
U
Serial port N/A N/A N/A
Ethernet
N/A
M port
P
U
Serial port N/A N/A N/A N/A
OC 6000e 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)
TP Cable
Serial port server
Special interface
3rd-party system
(Profibus-DP)
Fig 2.2-12 Nexus and 3rd-party Device/system Connection

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 OC 6000e 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.

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
Accuracy 0.2% of full scale over the full operating temperature range
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
Specification
Item
369B1842G5003 (Legacy) 369B1842G5005
Analog output 0(4)－20mA，0(1)－5V dc（Channel number 07 & 08）
Load capacity (current
output) Max. 1kΩ
Load capacity (voltage Min. 500kΩ Min. 200kΩ
output)
D/A resolution 12 bit
Frame rate Refresh all channels within 1ms;
System dependent scan rate for control purposes

Interference resistance CMRR ≥ 120dB@250VAC
Power consumption Typical 1W, Max 6.5W Typical 1.55W, Max 6.55W
Heat dissipation Typical 1W, Max 5.7W Typical 1.45W, Max 5.75W
8-Channel mA/V Analog Input HART Module MHT50

Table 2.3-7 MHT50 Specification
Item Specification
Input Span ±10V, ±5V, 0(4) - 20mA
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
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
Power consumption Typical 1.2W, Max 8.5W Typical 1.2W, Max 5W
Heat dissipation Typical 1.2W, Max 8.5W Typical 1.2W, Max 5W

16 –Channel Discrete Output Module w/ Relay Output MDO53
Table 2.3-9 MDO53 Specification
Item Specification
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 15 ms typical
Max response time off 10 ms typical
Contact material AgNi
Contact life Electrical operations: 200,000 (AC); 100,000 (DC)
Mechanical operations: 30 x 106 (AC); 50 x 106 (DC)
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
Discrete output capacity Each channel with Max. 100mA@24V dc
Isolation Channel to channel isolation, determined by connected relay board
Heat dissipation Typical 1.3W, Max 4W
Speed Measurement and Overspeed Protection Module MSP50(MSP51)

Table 2.3-11 MSP50(MSP51) Specification
Item Specification
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
Input Span ±10V, 0(4) - 20mA
AI A/D resolution 16 bit
Temperature drift Max 0.05% of the upper range value over full operating

temperature
DI SOE accuracy 1ms
Input filter 1~50ms, default 4ms
Input wetting voltage 24Vdc
Input current <3mA
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
Other
Heat dissipation Typical 1.7W, Max 2.8W
Valve Position Control Module MVP50

Table 2.3-12 MVP50 Specification
Item Specification
Exciting frequency 1~3kHz
LVDT Signal span 3.5Vrms/7.0Vrms
Sensor type 3-wire, 6-wire
Measurement accuracy 0.25%
Input span ±10V, ±5V, 0(4) - 20mA
AI Max 0.05% of the upper range value over full operating
Temperature drift
temperature
Channel to channel ≥ 250VAC@50/60Hz
Isolation Channel to ground ≥500VAC@50/60Hz
DI
Input filter Software filter, 3~50ms, default 24ms
Input wetting voltage 24V dc
Input current <3mA
Servo Output capacity -40mA ~ +40mA@120Ω
output Or -10V ~ +10V@20mA with Max. load 500Ω
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
Output span 0~5V
AO Output capacity Max. load 500Ω
Output accuracy 0.25%
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
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
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
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

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 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® XP Windows® XP Windows® XP Windows® XP
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 OC 6000e 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 XP 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 kinds of HMI. HMI’s functionality
varies from its software configuration.
All system controllers must have the same control platform software installed.
Besides that, 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

Control logic: each controller has a set of control algorithm and control logic
along with its I/O module to fulfil designated control function
Communication interface configuration, to communicate with 3rd-party
device/system for process monitoring and control
2.5 Certification and standards

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

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
requirement and minimum amount of system hardware. Additional hardware
should be included according to customer 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. Pay attention to the notes for 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

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

OC 6000e Nexus has three specifications for iLink cable. Each with 12, 6 or 3 I/O
module interfaces separately, 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 - 3.
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 concert with iLink cable. Each pair
of redundant iLink requires two MCD50 modules.
3.2 Cabinet
OC 6000e 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.

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 actual situation, configure
proper number of control cabinet and extension cabinet.
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. Such as 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
OC 6000e Nexus applies peer-to-peer network architecture, 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, OC 6000e Nexus use
hardware dongle to protect all HMI applications. Each HMI computer must have
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 least.
Operator stations are configured per customer requirement. Other types of stations
should be configured to meet system’s function 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

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

OC 6000e Nexus real-time data highway is a redundant Ethernet network. Industrial
Ethernet switches are recommended to form the UDH networks.
According to network topology, certain network switches are selected. For ring
topology, switches must have network management function, and can set virtual
breakpoint as well. General industrial switch can be chose for star topology.
RJ 45 twisted-pair cable can be applied for network equipment indoor connection. If
network devices locate in different places with certain distance, then fiber-optical
connection is recommended.
Different mode FO cable is used per connection distance. Normally, multi-mode FO
cable is used if distance 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
OC 6000e Nexus provides the following special communication modules for 3rd-
party device/system communication.
369B1860G0028 MPU51 OC 6000e 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

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 in anywhere 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
environment 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 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.

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 OC 6000e 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.

Fig 4.5-1 OC 6000e 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 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 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

Fig 4.6-1 OC 6000e Nexus Power Distribution Cabinet
4.7 Grounding
4.7.1 Cabinet grounding
There are two types of grounding in the OC 6000e Nexus cabinet according to
device voltage class:
Low voltage device grounding, for device with 24V dc power supply
High voltage device grounding, for device with 220V AC power supply
Each OC 6000e Nexus cabinet has one unique grounding point, which is directly
connected to 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, IO module mounting pillars are connected by
grounding cables, and connect to the cabinet grounding bars.

Fig 4.7-1 OC 6000e Nexus Cabinet Inner Grounding
4.7.2 Signal grounding

The OC 6000e 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 OC 6000e Nexus grounding system is a kind of 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 plant grounding grid through a single grounding point.
When installing the cabinet, the insulation resistance between the cabinet
chassis and the mounting base should be greater than 2MOhm (500V megaohm
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 AWG8 (or 8mm2)
The grounding cable between the group junction and the system grounding
junction shouldn’t be less than AWG4 (or 20mm2)
The grounding cable between the system grounding junction and 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)
Fig 4.7-2 OC 6000e 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 cable, each pair of twisted-pair wires should be shielded
separately, and the entire cable should be shielded as well.
Individual shielded cable 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 signal, recommended wire gauge is 1.5 mm2.

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)
Fig 4.8-1 MAI50/MAI52/MHT50 Wiring
TC/RTD input (MAI51)
Fig 4.8-2 MAI51 Wiring
AO (MAO50/MHO50)
Fig 4.8-3 MAO50/MHO50 Wiring

DI (MDI50/52)
Fig 4.8-4 MDI50/52 Wiring
DO (MDO53)
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 command through
communication interface between different control platforms.
When interfacing with plant MIS/OA system, a firewall is a must. 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.

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 -
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 fighting systems must be in service. Air condition system can be put into
service later. 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 800*600*2000 (w*d*h). The gross weight is 150kg. The
cabinet should be mounted on the slot ware steel. The fastening bolts are
M12*25 inner hex nut.
Check the internal power distribution from the DCS power cabinet to control
cabinet and MMI. Ensure that the wire gauge is larger than 1.5 mm2 (AC 220V
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 system first 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 many 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.

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Indicates a procedure or condition that, if not strictly

Indique une procédure ou une condition, laquelle, si elle

Indicates a procedure or condition that, if not strictly

Indique une procédure ou une condition, laquelle, si

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Indique une procédure, une condition, ou un énoncé

Note Indicates an essential or important procedure or statement.

GEK-118585 OC 6000e Nexus System Manual i

ii GEK-118585 OC 6000e Nexus System Manual

I/O Link I/O Link

Fig 1.1-1 OC 6000e Nexus System Structure

GEK-118585 OC 6000e Nexus System Manual 1

1.1.3 I/O Networks

1.1.4 I/O Modules

2 GEK-118585 OC 6000e Nexus System Manual

1.1.5 Related Documents

GEK-118585 OC 6000e Nexus System Manual 3

1.1.7 Acronyms and Abbreviations

4 GEK-118585 OC 6000e Nexus System Manual

2.2 System Components

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

GEK-118585 OC 6000e Nexus System Manual 5

Tracking Port for

Intelligent I/O Bus

Fig 2.2-1 OC 6000e Nexus iDPU Series Controller

The iDPU series controller offers the following advantages:

2.2.2 I/O Networks

6 GEK-118585 OC 6000e Nexus System Manual

GE provides the following types of iLink cable:

2.2.3 I/O Module

GEK-118585 OC 6000e Nexus System Manual 7

Fig 2.2-2 OC 6000e Nexus I/O Module

Table 2.2-2 OC 6000e Nexus I/O Module

8 GEK-118585 OC 6000e Nexus System Manual

2.2.4 Power sources

Fig 2.2-3 OC 6000e Nexus Standard Control Cabinet Power Distribution

GEK-118585 OC 6000e Nexus System Manual 9

Fig 2.2-5 AC Power Switch Box Electrical Circuit Scheme

If additional power supply is applied for cabinet auxiliaries through power

10 GEK-118585 OC 6000e Nexus System Manual

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

GEK-118585 OC 6000e Nexus System Manual 11

12 GEK-118585 OC 6000e Nexus System Manual

GEK-118585 OC 6000e Nexus System Manual 13

I/O bus & power extension module DC distribution TB

Front View Right View Rear View

14 GEK-118585 OC 6000e Nexus System Manual

2.2.7 Human Machine Interface (HMI)

GEK-118585 OC 6000e Nexus System Manual 15

2.2.8 Remote I/O

I/O Bus Terminator

16 GEK-118585 OC 6000e Nexus System Manual

Communication cable between control cabinet and remote IO cabinet can be

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

2.2.9 3rd-party Communication Interface

GEK-118585 OC 6000e Nexus System Manual 17

OC 6000e Nexus system and 3rd-party device/system connection is shown below: