IS220PTCCH1B, REV D - Thermocouple Input Terminal Board

SPECIFICATIONS:

Part Number: IS220PTCCH1B, REV D
Manufacturer: General Electric (GE)
Series: Mark VIe Control Systems
Functional Acronym: PTCC
Product Type: Thermocouple Input Module
Hardware Revision: Rev D
Total Thermocouple Inputs: 12 Channels
Supported Thermocouple Types: Type J, K, E, T, S, R, B, and N
Input Voltage Range: -100 mV to +100 mV DC
Cold Junction Compensation: 2 Channels
A/D Conversion Resolution: 16-bit Analog-to-Digital Resolution
Scan Time / Processing Rate: 10 milliseconds (100 Hz Frame Rate)
Measurement Accuracy: �0.1% of Full Scale (�0.05% Typical)
Network Communication: Dual 10/100BaseTX RJ45 Ethernet Ports
Power Input Requirement: 28.0 V DC Nominal
Power Consumption: 4.5 W Typical, 5.5 W Maximum
Substrate Protection: High-Grade Industrial Conformal Coating
Operating Temperature: -30�C to +65�C (-22�F to +149�F)
Storage Temperature Range: -40�C to +85�C (-40�F to +185�F)
Relative Humidity: 5% to 95% Non-Condensing
Repair / Evaluation Lead Time: 3�5 Business Days
Availability: In Stock
Country of Origin: United States (USA)
Manual Reference: GEH-6721

FUNCTIONAL DESCRIPTION OF IS220PTCCH1B, REV D :

IS220PTCCH1B, REV D is a Thermocouple Input Terminal Board designed and manufactured by General Electric as part of the Mark VIe Series used in GE Distributed Control Systems. The PTCC provides the electrical interface between one or two I/O Ethernet networks and a thermocouple input terminal board. The pack contains a processor board common to all Mark VIe distributed I/O packs and an acquisition board specific to the thermocouple input function. The pack is capable of handling up to 12 thermocouple inputs. Two packs can handle 24 inputs on TBTCH1C. In the TMR configuration with the TBTCH1B terminal board, three packs are used with three cold junctions, but only 12 thermocouples are available. Input to the pack is through dual RJ45 Ethernet connectors and a three-pin power input. Output is through a DC-37 pin connector that mates directly with the associated terminal board connector. Visual diagnostics are provided through indicator LEDs, and local diagnostic serial communications are possible through an infrared port.

INSTALLATION:

• Mount the desired terminal board securely.
• Connect the PTCC I/O pack directly to the terminal board connectors.
• Secure the packs to the threaded studs located near the Ethernet ports. These studs fit into a mounting bracket tailored for the specific terminal board.
• Adjust the bracket position to eliminate right-angle stress on the DC37 connector between the pack and terminal board. This adjustment should be made once during the product�s lifetime.
• Depending on the system configuration, connect one or two Ethernet cables. The pack is compatible with either port, but if using twin connections, it�s standard to link ENET1 to the network associated with the R controller.
• Power the pack by connecting the appropriate connector. There�s no need to switch off the cable power before connection, as the I/O pack features a built-in soft-start mechanism that manages current inrush.
• Configure the I/O pack as needed using the ToolboxST application.

OPERATION:

The processor application code contains all the logic necessary to allow the pack to operate from one or two Ethernet inputs. When operated from two Ethernet inputs, both network paths are active all the time. A failure of either network will not result in any disturbance to the I/O pack operation, and the failure will be indicated through the working network connection. This arrangement is more tolerant of faults than a classic hot-backup system where the second port is only used after a primary port failure is detected. The Ethernet ports on the processor auto-negotiate between 10 MB/s and 100 MB/s speed, and between half-duplex and full-duplex operation. An industry-standard infrared serial communications port is provided on the processor board. Accessible through the pack front, this port provides diagnostic information on the pack status and the ability to program the pack when both Ethernet connections fail. It is possible to communicate with this port using most notebook computers and most hand-held Personal Digital Assistants (PDA).

• High-performance processor with integrated RAM and flash memory
• Two separate 10/100 Ethernet ports with connectors
• Watchdog timer and reset circuitry for hardware reliability
• Onboard local temperature sensor
• Infrared serial communication interface
• LEDs for status indication
• Electronic ID functionality with the ability to read IDs from other boards
• Extensive programmable logic supporting the acquisition board
• Power input connector featuring soft-start and current limiting
• Local power supplies with sequencing and monitoring capabilities

ANALOG INPUT HARDWARE:

The PTCC input board receives 12 millivolt-level signals from the thermocouples connected to the terminal board. The analog input system includes six differential multiplexers, a main multiplexer, and a 16-bit analog-to-digital converter that transmits the digital data to the processor board. Each input is equipped with hardware and firmware filters, and the converter samples at a rate of up to 120 Hz.

POWER MANAGEMENT:

The PTCC includes power management in the 28 V input circuit. The management function provides a soft start to control current inrush during power application. After applying power, the circuit provides a fast current limit function to prevent a pack or terminal board failure from propagating back onto the 28 V power system. When power is present and working properly, the green PWR indicator will light. If the current limit function operates, the indicator will be out until the problem is cleared.
World of Controls specializes in supplying high-quality, warranty-backed OEM replacement parts, including unused surplus and professionally rebuilt components for critical turbine control and industrial automation systems like the General Electric Mark VI and Mark VIe platforms. To minimize customer downtime and ensure original equipment standard compliance, every component undergoes rigorous inspection, testing, and verification in an advanced electronics lab. Beyond parts distribution, the company delivers comprehensive, global support through 24/7 technical assistance, expert troubleshooting, component repair services, and rapid shipping, ensuring optimal efficiency and long-term reliability for critical industrial operations worldwide.

FREQUENTLY ASKED QUESTIONS:

What is the function of a thermocouple input module in a GE Mark VIe control system?

A thermocouple input module provides a reliable interface between thermocouple sensors and the turbine control system. It receives low-level temperature signals, converts analog measurements into digital data, and transfers accurate temperature information to the controller for monitoring and protection functions.

How many thermocouple inputs does this module support?

This module supports up to 12 thermocouple input channels. It is designed to process multiple temperature measurement signals used in gas turbine and industrial control applications.

Which thermocouple types are compatible with this input module?

The module supports multiple standard thermocouple types, including Type J, Type K, Type E, Type T, Type S, Type R, Type B, and Type N, allowing flexibility for different temperature monitoring requirements.

How does cold junction compensation work in thermocouple measurement systems?

Cold junction compensation improves measurement accuracy by correcting temperature variations at the connection point between thermocouple wiring and the input terminal. The module uses dedicated cold junction measurement channels to compensate for these changes.

What communication interfaces are available for integration with the control system?

The module uses dual 10/100BaseTX Ethernet ports for communication with Mark VIe controllers. Both Ethernet paths can operate simultaneously, providing improved network availability and fault tolerance.

What are the common applications of a thermocouple input module?

Thermocouple input modules are commonly used for monitoring turbine exhaust temperatures, bearing temperatures, combustion systems, process heaters, and other industrial applications requiring precise temperature measurement and control.

What diagnostic features are available for troubleshooting?

The module includes LED status indicators, watchdog monitoring, onboard temperature sensing, electronic identification features, and infrared serial communication for local diagnostics and configuration.

Can this module be repaired or refurbished?

Yes. Professional repair and refurbishment services are available for these modules. Each unit should undergo inspection, testing, and functional verification to ensure reliable operation in industrial control environments.

What factors can cause failure of a thermocouple input module?

Common failure causes include electrical surges, power supply issues, environmental stress, wiring faults, excessive temperature exposure, communication errors, and aging electronic components.

How does World of Controls support customers requiring this component?

World of Controls provides OEM replacement solutions, including unused and rebuilt components, repair services, technical support, testing, and worldwide shipping assistance for GE Mark VIe turbine control systems.