CHAPTER 5

Chapter 5 Installation and

Configuration
Introduction
This chapter defines installation requirements for the Mark VI control system.
Specific topics include GE installation support, wiring practices, grounding, typical
equipment weights and dimensions, power dissipation and heat loss, and
environmental requirements.

Installation Support
GE’s system warranty provisions require both quality installation and that a qualified
service engineer be present at the initial equipment startup. To assist the customer,
GE offers both standard and optional installation support. Standard support consists
of documents that define and detail installation requirements. Optional support is
typically the advisory services that the customer may purchase.

Early Planning
To help ensure a fast and accurate exchange of data, a planning meeting with the
customer is recommended early in the project. This meeting should include the
customer’s project management and construction engineering representatives. It
should accomplish the following:

! Familiarize the customer and construction engineers with the equipment

! Set up a direct communication path between GE and the party making the
customer’s installation drawings
! Determine a drawing distribution schedule that meets construction and
installation needs
! Establish working procedures and lines of communication for drawing
distribution

GE Installation Documents
Installation documents consist of both general and requisition-specific information.
The cycle time and the project size determine the quantity and level of
documentation provided to the customer.

General information, such as this document, provides product-specific guidelines for

the equipment. They are intended as supplements to the requisition-specific
information.

Requisition documents, such as outline drawings and elementary diagrams provide

data specific to a custom application. Therefore, they reflect the customer’s specific
installation needs and should be used as the primary data source.

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 As-Shipped drawings consist primarily of elementary diagrams revised to incorporate
any revisions or changes made during manufacture and test. These are issued when
the equipment is ready to ship. Revisions made after the equipment ships, but before
start of installation, are sent as Field Changes, with the changes circled and dated.

Technical Advisory Options

To assist the customer, GE Energy offers the optional technical advisory services of
field engineers for:

! Review of customer’s installation plan

! Installation support
These services are not normally included as installation support or in basic startup
and commissioning services shown below. GE presents installation support options
to the customer during the contract negotiation phase.

Installation
Support

Startup
Begin
Installation
Commissioning
Complete
Installation

Begin Product Support - On going

Formal
Testing
System
Acceptance
Startup and Commissioning Services Cycle

Installation Plan and Support

It is recommended that a GE field representative review all installation/construction

drawings and the cable and conduit schedule when completed. This optional review
service ensures that the drawings meet installation requirements and are complete.

Optional installation support is offered: planning, practices, equipment placement,

and onsite interpretation of construction and equipment drawings. Engineering
services are also offered to develop transition and implementation plans to install and
commission new equipment in both new and existing (revamp) facilities.

Customer’s Conduit and Cable Schedule

The customer’s finished conduit and cable schedule should include:

! Interconnection wire list (optional)

! Level definitions
! Shield terminations
The cable and conduit schedule should define signal levels and classes of wiring
(refer to the section, Cable Separation and Routing). This information should be
listed in a separate column to help prevent installation errors.

The cable and conduit schedule should include the signal level definitions in the
instructions. This provides all level restriction and practice information needed
before installing cables.

5-2 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 The conduit and cable schedule should indicate shield terminal practice for each
shielded cable (refer to the section, Connecting the System).

Equipment Receiving and Handling

Note For information on storing equipment, refer to Chapter 4.

GE inspects and packs all equipment before shipping it from the factory. A packing
list, itemizing the contents of each package, is attached to the side of each case.

Upon receipt, carefully examine the contents of each shipment and check them with
the packing list. Immediately report any shortage, damage, or visual indication of
rough handling to the carrier. Then notify both the transportation company and GE
Energy. Be sure to include the serial number, part (model) number, GE requisition
number, and case number when identifying the missing or damaged part.

Immediately upon receiving the system, place it under adequate

cover to protect it from adverse conditions. Packing cases are not
suitable for outdoor or unprotected storage. Shock caused by
rough handling can damage electrical equipment. To prevent such
damage when moving the equipment, observe normal precautions
along with all handling instructions printed on the case.

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.

Weights and Dimensions

Cabinets
A single Mark VI cabinet is shown below. This can house three controllers used in a
system with all remote I/O. Dimensions, clearance, bolt holes, lifting lugs, and
temperature information is included.

GEH-6421N Mark VI Control System Guide Volume I Chapter 5 Installation and Configuration 5-3
 Lift Bolts with 38 mm (1.5 in) dia
hole, should be left in place after
installation for Seismic Zone 4. If
removed, fill bolt holes.

Single Control Panel

Total Weight 180 kg (400lbs)

Window Cabinet Depth 610.0 mm (24 in)

1842 mm Cable Entry Space for wire entry

(72.5) in base of cabinet

Equipment Access Front and

rear access doors, no side access.
Air Front door has clear plastic
A
A Intake
window.

Service Conditions NEMA1

enclosure for standard indoor use.

610 mm
(24)

Six 16 mm (0.635 inch)

dia holes in base for
236.5
customers mounting
(9.31)
610 studs or bolts
(24.0) 236.5
(9.31)
View of base looking
down in direction "A"
475
(18.6875)
Typical Controller Cabinet

5-4 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 The controller cabinet is for small gas turbine systems (simplex only). It contains
control, I/O, and power supplies, and weighs 620 kg (1,367 lbs) complete.

One Panel Lineup (one door) Notes:

114.3
(4.5)
1. All dimensions are in mm and
(inches) unless noted.
2. Door swing clearance required
at front as shown. Doors open
38.1 105 degrees max. and are
(1.5) removable by removing hinge
pins.
3. All doors have provisions for
2400.3 pad locking.
(94.5) 57.9 4. Suggested mounting is 10 mm
(2.28) (0.375) expansion anchors.
Length must allow for 71.1 mm
A (2.8) case sill.
5. Cross hatching indicates
conduit entry with removable
covers.
865.63 6. Lift angles should remain in
925.58
(34.08) place to meet seismic UBC
(36.44)
906.53 zone 4 requirements.
(35.69) Approx. Door Swing
7. No mechanical clearance
(See Note 2)
required at back or ends.
8. Service conditions - indoor use
rated minimum and
348.49
(13.72) maximum ambient temperature.
184.15
(7.25) 6 holes, 16 mm (0.635 inch)
dia, in base for customers
mounting studs or bolts.
609.6
387.6 151.64 (24.0)
(15.26) (5.97)

(2.47) 387.6
(15.26) View of top looking down
62.74 254.0 in direction of arrow "A"
(10.0)
775.97 61.47
69.09 317.25
(30.55)
(2.72) (2.42) (12.49)

View of base looking down in direction of arrow "A"

Typical Controller Cabinet

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 The two-door cabinet shown in the following figure is for small gas turbine systems.
It contains control, I/O, and power supplies, and weighs approximately 720 kg
(1,590 lbs) complete. A 1600 mm wide version of this cabinet is available, and
weighs approximately 912 kg (2,010 lbs) complete. For installation information,
refer to the requisition specific GE drawings.

Two Panel Lineup (Two Doors)

Lift beams should be left in place.
If removed, fill bolt holes.
912 kg
Total Weight
(2010lbs)
Cabinet Depth 903.9 mm
(35.59 in)

2400 mm Equipment Access Front

(94.5)
doors only, no rear or side
access. Door swing
clearance 977.9 mm (38.5).

Mounting Holes in Base

A Six 16 mm (0.635 in) dia
holes in base of the cabinet
for customers mounting
studs or bolts, for details
see GE dwgs.
1350 mm
(53.15)
Service Conditions
Standard NEMA1 enclosure
for indoor use.

387.5
(15.26)

387.5
(15.26) 6 holes, 16 mm (0.635 inch)
dia, in base for customers
mounting studs or bolts.
1225.0
62.5 (48.23)
(2.46)

62.5
(2.46)
View of base looking down in direction of arrow "A"
Typical Controller Cabinet

A typical lineup for a complete Mark VI system is shown in the following figure.
These cabinets contain controllers, I/O, and terminal boards, or they can contain just
the remote I/O and terminal boards.

5-6 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 Lift Angles front and back, Three Cabinet Lineup (Five Doors)
should be left in place for
Seismic Zone 4, if removed,
fill bolt holes. Total Weight 1770 kg
(3,900 lbs)
Cabinet Depth 602 mm
(23.7 in)

I/O I/O Control I/O Power

2324.3 mm
Equipment Access Front
(91.5)
doors only, no rear or side
access. Door swing
clearance 977.9 mm (38.5 in).

Mounting Holes in Base

A Six 16 mm (0.635 in) dia
holes in base of each of the
three cabinets for customers
mounting studs or bol ts, for
1600 mm 1600 mm
details see GE dwgs.
1000 mm
(62.99) (39.37) (62.99)
Service Conditions
4200 mm
(165.35)
Standard NEMA1 enclosure
for indoor use.

237.5
(9.35)
237.5
(9.35) 18 holes, 16 mm (0.635 in)
dia, in base for
62.5 customers mounting
1475.0 875.0 1475.0
(2.46) (34.45) (58.07) studs or bolts.
(58.07)

62.5 125.0 125.0 62.5

(2.46) (4.92) (4.92) (2.46)

View of base looking down in direction of ar row "A"

Typical Mark VI Cabinet Lineup

Control Console (Example)

The turbine control HMI computers can be table-mounted, or installed in the optional
control console shown in the following figure. The console is modular and
expandable from an 1828.8 mm version with two computers. A 5507 mm version
with four computers is shown. The console rests on feet and is not usually bolted to
the floor.

GEH-6421N Mark VI Control System Guide Volume I Chapter 5 Installation and Configuration 5-7
 Full Console
5507 mm
(18 '- 0 13/16 ")
Short Console
1828.8 mm
(72 ")

itor Main Module

Mon le
d u
Mo
M
M oni t
od o r
ul e 2233.61 mm
Modular Desktop
(7 '- 3 15/16")

Phone Phone
Printer
Monitor Monitor Monitor Monitor

1181.1mm
Printer Undercounter Keyboards (46.5 ")
Pedestal

Turbine Control Console with Dimensions

Power Requirements
The Mark VI control cabinet can accept power from multiple power sources. Each
power input source (such as the dc and two ac sources) should feed through its own
external 30 A two-pole thermal magnetic circuit breaker before entering the Mark VI
enclosure. The breaker should be supplied in accordance with required site codes.

Power sources can be any combination of 125 V dc and 120/240 V ac sources. The
Mark VI power distribution hardware is configured for the required sources, and not
all inputs may be available in a configuration.

Power requirements for a typical three-bay (five-door) 4200 mm cabinet containing

controllers, I/O, and terminal boards are shown in the following table. The power
shown is the heat generated in the cabinet, which must be dissipated. For the total
current draw, add the current supplied to external solenoids as shown in the notes
below the table. These external solenoids generate heat inside the cabinet. Heat Loss
in a typical 4200 mm (165 in) TMR cabinet is 1500 W fully loaded.

For a single control cabinet containing three controllers only (no I/O), the following
table shows the nominal power requirements. This power generates heat inside the
control cabinet. Heat Loss in a typical TMR controller cabinet is 300 W.

5-8 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 The current draw number in the following table assumes a single voltage source, if
two or three sources are used, they share the load. The actual current draw from each
source cannot be predicted because of differences in the ac/dc converters. For further
details on the cabinet power distribution system, refer to Volume II of this System
Guide.
Power Requirements for Cabinets
Cabinet Voltage Frequency Current Draw
4200 mm Cabinet 125 V dc 100 to 144 V dc (see Note 5) N/A N/A 10.0 A dc (see Note 1)
120 V ac 108 to 132 V ac (see Note 6) 50/60 Hz ±3 Hz 17.3 A rms (see Notes 2 and 4)
240 V ac 200 to 264 V ac 50/60 Hz ±3 Hz 8.8 A rms (see Notes 3 and 4)
Controller Cabinet 125 V dc 100 to 144 V dc (see Note 5) N/A N/A 1.7 A dc
120 V ac 108 to 132 V ac (see Note 6) 50/60 Hz ±3 Hz 3.8 A rms
240 V ac 200 to 264 V ac 50/60 Hz ±3 Hz 1.9 A rms

* These are external and do not create cabinet heat load.

1 Add 0.5 A dc* continuous for each 125 V dc external solenoid powered.
2 Add 6.0 A rms* for a continuously powered ignition transformer (2 maximum).
3 Add 3.5 A rms* for a continuously powered ignition transformer (2 maximum).
4 Add 2.0 A rms* continuous for each 120 V ac external solenoid powered (inrush
10 A).
5 Supply voltage ripple is not to exceed 10 V peak-to-peak.
6 Supply voltage total harmonic distortion is not to exceed 5.0%.

Installation Support Drawings

This section describes GE installation support drawings. These drawings are usually
®
B-size AutoCAD drawings covering all hardware aspects of the system. A few
sample drawings include:

! System Topology
! Cabinet Outline
! Cabinet Layout
! Circuit Diagram
In addition to the installation drawings, site personnel will need the I/O Assignments
(IO Report).

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5-10

GPS (ICS)
Chapter 5 Installation and Configuration

Plant Data Highway (GEPS)

Plant
SCADA
Color inkjet Laser Laser
21 '' 21 '' 21'' 21'' Printer Local Local
(ICS) Printer GT GT
ST Interface (ICS) (ICS) (ICS) Server Server
Historian
21 '' 21 '' 21 '' 21 '' 17 " 17 "
21'' 21'' Unit 1 (ICS)
21 ''

HMI Server 2(GEPS ) Supervisor EWS (ICS) OSM

HMI Server 1(GEPS)
(ICS) Work Sta (ICS)
Typical System Topology Showing Interfaces

Operator
IEC608
70
Console Engineering
Printer Alarm printer
-5-104 Alarm printer Office Alarm Printer Alarm Printer
ST OP S t a
(ALSTOM) CEMS

Unit DataHighway

* 350 logic and

150 analog
points.

g g g
g g g g g
GEH-6421N Mark VI Control System Guide Volume I

Gas Turbine Gas Turbine

Centralog Centralog C1 Mark VI TMR Mark VI TMR
S1 HRSG1 HRSG2 BOP 1 X1 MarkVI (ICS)
CVS CVS MarkVI (ICS) MarkVI (ICS) MarkVI (ICS) EX2100 Unit #1 Unit #2
MarkVI (ICS) Air
(ALSTOM) (ALSTOM) Printer ST/BOP H1 H2 by GE PS
Cooled
PEECC #1 PEECC #2
Cond.
Alstom P320
Steam Turbine Electrical Room GEC
Control Unit #3 Modbus

Modbus
Aux Boiler
Gas Chromatograph #1 Data
via Gas Reduction Sta PLC Water g g g g
(ERM) Treatment
Gas Chromatograph #2 (400 PTS)
Serial
EX2100 LS2100 EX2100 LS2100

GT #1 LEC GT #2 LEC
 Typical Cabinet Outline Data

Grounding
This section defines grounding and signal-referencing practices for the Mark VI
control system. This can be used to check for proper grounding and signal reference
structure (SRS) after the equipment is installed. If checking the equipment after the
power cable has been connected or after power has been applied to the cabling, be
sure to follow all safety precautions for working around high voltages.

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 To prevent electric shock, make sure that all power supplies to
the equipment are turned off. Then discharge and ground the
equipment before performing any act requiring physical contact
with the electrical components or wiring. If test equipment
cannot be grounded to the equipment under test, the test
equipment's case must be shielded to prevent contact by
personnel. Be sure to follow the site LOTO and safety practices.

Equipment Grounding
Equipment grounding and signal referencing have two distinct purposes:
! Equipment grounding protects personnel from risk of serious or fatal electrical
shock, burn, fire, and/or other damage to equipment caused by ground faults or
lightning.
! Signal referencing helps protect equipment from the effects of internal and
external electrical noise, such as lightning or switching surges.
Installation practices must simultaneously comply with all codes in effect at the time
and place of installation, and with all practices that improve the immunity of the
installation. In addition to codes, guidance from IEEE Std 142-1991 IEEE
Recommended Practice for Grounding of Industrial and Commercial Power Systems
and IEEE Std 1100-1992 IEEE Recommended Practice for Powering and Grounding
Sensitive Electronic Equipment are provided by the design and implementation of the
system. Code requirements for safety of personnel and equipment must take
precedence in the case of any conflict with noise control practices.

The Mark VI control system has no special or non-standard installation

requirements, if installed in compliance with all of the following:
®
! The NEC or local codes
! With SRS designed to meet IEEE Std 1100
! Interconnected with signal/power-level separation as defined later
This section provides equipment grounding and bonding guidelines for control and
I/O cabinets. These guidelines also apply to motors, transformers, brakes, and
reactors. Each of these devices should have its own grounding conductor going
directly to the building ground grid.

! Ground each cabinet or cabinet lineup to the equipment ground at the source of
power feeding it.
– See NEC Article 250 for sizing and other requirements for the
equipment-grounding conductor.
– For dc circuits only, the NEC allows the equipment-grounding
conductor to be run separate from the circuit conductors.
! With certain restrictions, the NEC allows the metallic raceways or cable trays
containing the circuit conductors to serve as the equipment grounding
conductor:
– This use requires that they form a continuous, low-impedance path
capable of conducting anticipated fault current.
– This use requires bonding across loose-fitting joints and discontinuities.
See NEC Article 250 for specific bonding requirements. This chapter
includes recommendations for high frequency bonding methods.
– If metallic raceways or cable trays are not used as the primary
equipment- grounding conductor, they should be used as a
supplementary equipment grounding conductor. This enhances the
safety of the installation and improves the performance of the SRS.

5-12 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 ! The equipment-grounding connection for the Mark VI control cabinets is plated
copper bus or stub bus. This connection is bonded to the cabinet enclosure using
bolting that keeps the conducting path’s resistance at 1 ohm or less.
! There should be a bonding jumper across the ground bus or floor sill between all
shipping splits. The jumper may be a plated metal plate.
! The non-current carrying metal parts of the equipment covered by this section
should be bonded to the metallic support structure or building structure
supporting this equipment. The equipment mounting method may satisfy this
requirement. If supplementary bonding conductors are required, size them the
same as equipment-grounding conductors.

Building Grounding System

This section provides guidelines for the building grounding system requirements. For
specific requirements, refer to NEC article 250 under the heading Grounding
Electrode System.

The guidelines below are for metal-framed buildings. For non-metal framed
buildings, consult the GE factory.

The ground electrode system should be composed of steel reinforcing bars in

building column piers bonded to the major building columns.
! A buried ground ring should encircle the building. This ring should be
interconnected with the bonding conductor running between the steel reinforcing
bars and the building columns.
! All underground, metal water piping should be bonded to the building system at
the point where the piping crosses the ground ring.
! NEC Article 250 requires that separately derived systems (transformers) be
grounded to the nearest effectively grounded metal building structural member.
! Braze or exothermically weld all electrical joints and connections to the building
structure, where practical. This type of connection keeps the required good
electrical and mechanical properties from deteriorating over time.

Signal Reference Structure (SRS)

On modern equipment communicating at high bandwidths, signals are typically
differential and/or isolated electrically or optically. The modern SRS system replaces
the older single-point grounding system with a much more robust system. The SRS
system is also easier to install and maintain.

The goal of the SRS is to hold the electronics at or near case potential to prevent
unwanted signals from disturbing operation. The following conditions must all be
met by an SRS:

! Bonding connections to the SRS must be less than 1/20 wavelength of the
highest frequency to which the equipment is susceptible. This prevents standing
waves. In modern equipment using high-frequency digital electronics,
frequencies as high as 500 MHz should be considered. This translates to about
30 mm (1 in).
! SRS must be a good high frequency conductor. (Impedance at high frequencies
consists primarily of distributed inductance and capacitance.) Surface area is
more important than cross-sectional area because of skin effect. Conductivity is
less important (steel with large surface area is better than copper with less
surface area).
! SRS must consist of multiple paths. This lowers the impedance and the
probability of wave reflections and resonance

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 In general, a good signal referencing system can be obtained with readily available
components in an industrial site. All of the items listed below can be included in an
SRS:

! Metal building structural members

! Galvanized steel floor decking under concrete floors
! Woven wire steel reinforcing mesh in concrete floors
! Steel floors in pulpits and power control rooms
! Bolted grid stringers for cellular raised floors
! Steel floor decking or grating on line-mounted equipment
! Galvanized steel culvert stock
! Ferrous metallic cable tray systems
! Raceway (cableway) and raceway support systems
! Embedded steel floor channels

Note The provisions covered in this document may not apply to all
installations.

Connection of the protective earth terminal to the installation ground system must
first comply with code requirements and second provide a low-impedance path for
high-frequency currents, including lightning surge currents. This grounding
conductor must not provide, either intentionally or inadvertently, a path for load
current. The system should be designed so that there is no way possible for the
control system to be an attractive path for induced currents from any source. This is
best accomplished by providing a ground plane that is large and low impedance, so
that the entire system remains at the same potential. A metallic system (grid) will
accomplish this much better than a system that relies upon earth for connection. At
the same time all metallic structures in the system should be effectively bonded both
to the grid and to each other, so that bonding conductors rather than control
equipment become the path of choice for noise currents of all types.

In the Mark VI control cabinet, the base is insulated from the chassis and bonded at
one point. The grounding recommendations, shown in the following figure, call for
2
the equipment grounding conductor to be 120 mm (4 AWG) gauge wire, connected
to the building ground system. The Functional Earth (FE) is bonded at one point to
2
the Protective Earth (PE) ground using two 25 mm (4 AWG) green/yellow bonding
jumpers.

5-14 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 Control & I/O
Electronics
Base
Mark VI
Cabinet

Functional
Earth
Two 25 mm sq. (4 AWG)
(FE) Green/Yellow insulated
bonding jumpers
Equipment grounding conductor,
Identified 120 mm sq. (4/0 AWG),
insulated wire, short a distance
as possible Protective Conductor Terminal
Protective Earth (PE)
PE
Building Ground
System
Grounding Recommendations for Single Mark VI Control Cabinet

If acceptable by local codes, the bonding jumpers may be removed and a 4/0 AWG
identified insulated wire run from FE to the nearest accessible point on the building
ground system, or to another ground point as required by the local code. The distance
between the two connections to building ground should be approximately 4.5 m (15
ft), but not less than 3.05 m (10 ft).

The grounding method for a larger system is shown in next figure. Here the FE is
still connected to the control electronics section, but the equipment-grounding
conductor is connected to the center cabinet chassis. Individual control and I/O bases
are connected with bolted plates.

For armored cables, the armor is an additional current carrying braid that surrounds
the internal conductors. This type cable can be used to carry control signals between
buildings. The armor carries secondary lightning-induced earth currents, bypassing
the control wiring, thus avoiding damage or disturbance to the control system. At the
cable ends and at any strategic places between, the armor is grounded to the building
ground through the structure of the building with a 360° mechanical and electrical
fitting. The armor is normally terminated at the entry point to a metal building or
machine. Attention to detail in installing armored cables can significantly reduce
induced lightning surges in control wiring.

GEH-6421N Mark VI Control System Guide Volume I Chapter 5 Installation and Configuration 5-15
 Control
I/O Base Electronics I/O Base
Base

Base Grounding
Connection Plates

Functional
Earth Two 25 mm sq. 4AWG
(FE) Green/Yellow Bonding
Jumper wires

Equipment grounding conductor,

Identified 120 mm sq. (4/0 AWG), Protective Conductor Terminal
insulated wire, short a distance (Chassis Safety Ground plate)
as possible
PE

Building Ground System

Grounding Recommendations for Mark VI Control Cabinet Lineup

Notes on Grounding

Bonding to building structure - The cable tray support system typically

provides many bonding connections to building structural steel. If this is not the case,
supplemental bonding connections must be made at frequent intervals from the cable
tray system to building steel.

Connected equipment - Cable tray installations for connected equipment should

pay special attention to good high frequency bonding between the cable tray and the
equipment.

Cable spacing - Maintain cable spacing between signal levels in cable drops, as
recommended in the section, Cable Separation and Routing.

Conduit sleeves - Where conduit sleeves are used for bottom-entry cables, the
sleeves should be bonded to the floor decking and equipment enclosure with short
bonding jumpers.

Embedded conduits - Bond all embedded conduits to the enclosure with multiple
bonding jumper connections following the shortest possible path.

Galvanized steel sheet floor decking - Floor decking can serve as a high
frequency signal reference plane for equipment located on upper floors. With typical
building construction, there will be a large number of structural connections between
the floor decking and building steel. If this is not the case, then an electrical bonding
connection must be added between the floor decking and building steel. The added
connections need to be as short as possible and of sufficient surface area to be low
impedance at high frequencies.

High frequency bonding jumpers - Jumpers must be short, less than 500 mm
(20 in) and good high frequency conductors. Thin, wide metal strips are best with
length not more than three times width for best performance. Jumpers can be copper,
aluminum, or steel. Steel has the advantage of not creating galvanic half-cells when
bonded to other steel parts.

5-16 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I
 Jumpers must make good electrical contact with both the enclosure and the signal
reference structure. Welding is best. If a mechanical connection is used, each end
should be fastened with two bolts or screws with star washers backed up by large
diameter flat washers.

Each enclosure must have two bonding jumpers of short, random lengths. Random
lengths are used so that parallel bonding paths are of different quarter wavelength
multiples. Do not fold bonding jumpers or make sharp bends.

Metallic cable tray - System must be installed per NEC Article 318 with signal
level spacing per the section, Cable Separation and Routing. This serves as a signal
reference structure between remotely connected pieces of equipment. The large
surface area of cable trays provides a low impedance path at high frequencies.

Metal framing channel - Metal framing channel cable support systems also serve
as parts of the SRS. Make certain that channels are well bonded to the equipment
enclosure, cable tray, and each other, with large surface area connections to provide
low impedance at high frequencies.

Noise-sensitive cables - Try to run noise-sensitive cables tight against a vertical

support to allow this support to serve as a reference plane. Cables that are extremely
susceptible to noise should be run in a metallic conduit, preferably ferrous. Keep
these cables tight against the inside walls of the metallic enclosure, and well away
from higher-level cables.

Power cables - Keep single-conductor power cables from the same circuit tightly
bundled together to minimize interference with nearby signal cables. Keep 3-phase
ac cables in a tight triangular configuration.

Woven wire mesh - Woven wire mesh can serve as a high frequency signal
reference grid for enclosures located on floors not accessible from below. Each
adjoining section of mesh must be welded together at intervals not exceeding 500
mm (20 in) to create a continuous reference grid. The woven wire mesh must be
bonded at frequent intervals to building structural members along the floor
perimeter.

Conduit terminal at cable trays - To provide the best shielding, conduits

containing level L cables (see Leveling channels) should be terminated to the tray's
side rails (steel solid bottom) with two locknuts and a bushing. Conduit should be
terminated to ladder tray side rails with approved clamps.

Where it is not possible to connect conduit directly to tray (such as with large
conduit banks), conduit must be terminated with bonding bushings and bonded to
tray with short bonding jumpers.

Leveling channels - If the enclosure is mounted on leveling channels, bond the

channels to the woven wire mesh with solid-steel wire jumpers of approximately the
same gauge as the woven wire mesh. Bolt the enclosure to leveling channel, front
and rear.

Signal and power levels - See section, Cable Separation and Routing, for
guidelines.

Solid-bottom tray - Use steel solid bottom cable trays with steel covers for low-
level signals most susceptible to noise.

GEH-6421N Mark VI Control System Guide Volume I Chapter 5 Installation and Configuration 5-17
 Level P

Level L

Solid
Bottom
Tray

Bond leveling channels to the

woven wire mesh with solid steel
Enclosure wire jumpers of approximately the
same gage as the wire mesh.

Jumpers must be short, less than

200 mm (8 in). Weld to mesh and
leveling steel at random intervals of
300 - 500 mm (12-20 in).
Bolt
Bolt the enclosure to the leveling
Leveling steel, front and rear. See site
Channels specific GE Equipment Outline
Wire dwgs. Refer to Section 6 for
Mesh examples.

Enclosure and Cable Tray Installation Guidelines

Cable Separation and Routing

This section provides recommended cabling practices to reduce electrical noise.
These practices include signal/power level separation and cable routing guidelines.

Note Electrical noise from cabling of various voltage levels can interfere with
microprocessor-based control systems, causing a malfunction. If a situation at the
installation site is not covered in this document, or if these guidelines cannot be met,
please contact GE before installing the cable.

Early planning enables the customer’s representatives to design adequate separation

of embedded conduit. On new installations, sufficient space should be allowed to
efficiently arrange mechanical and electrical equipment. On revamps, level rules
should be considered during the planning stages to help ensure correct application
and a more trouble-free installation.

Signal and Power Level Definitions

Signal and power carrying cables are categorized into four defining levels; low,
medium, high, and power. Each level can include classes.

Low-Level Signals (Level L)

Low-level signals are designated as level L. In general these consist of:

! Analog signals 0 through ±50 V dc, <60 mA

! Digital (logic-level) signals less than 28 V dc
! 4 – 20 mA current loops
! Ac signals less than 24 V ac

5-18 Chapter 5 Installation and Configuration GEH-6421N Mark VI Control System Guide Volume I