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GE IS220UCSAH1A-C

Product Introduction

The IS220UCSAH1A-C is a high-performance Standalone Processor Module (UCSA) engineered by General Electric as a core component of the Mark VIe Speedtronic Control Series, dedicated to delivering centralized control and real-time data processing for industrial automation systems. It serves as a standalone controller running application code, mounting in a panel and communicating with I/O packs through the onboard I/O network (IONet) interfaces, which are private special-purpose Ethernet supporting only I/O modules and controllers. The module is powered by a Freescale PowerPC (Power QUICC II PRO 667 MHz) processor and runs the QNX Neutrino real-time multitasking operating system, designed for high speed, high reliability, and industrial applications.
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Description

Technical Specifications

  • Manufacturer: General Electric (GE) Energy, GE Boards & Turbine Control
  • Product Series: Mark VIe Speedtronic Control System
  • Module Type: Standalone Processor Module (UCSA)
  • Part Number: IS220UCSAH1A-C (Functional Revision C)
  • PCB Coating: Conformal coating for protection against dust, moisture, and corrosion
  • Processor: Freescale PowerPC (Power QUICC II PRO 667 MHz) optimized for real-time control data processing
  • Operating System: QNX Neutrino real-time multitasking operating system
  • Memory: 256 MB DDR SDRAM for data processing, 128 MB hot-swappable compact flash for program storage and data logging
  • Power Supply: 28 V DC (nominal), voltage range 18–32 V DC; typical power consumption 12 W
  • Communication Interfaces: 2 × 100Base‑TX Ethernet ports (RJ‑45) for IONet communication with Mark VIe controllers; 1 × 10/100/1000 Mbps Ethernet port for plant network connection; 1 × RS-232/RS-485 serial port for legacy device integration
  • I/O Expansion: Supports connection to up to 16 I/O packs via IONet, with maximum I/O points up to 1024 points
  • Redundancy Support: Simplex, dual redundant, and triple modular redundancy (TMR) configurations
  • Console Interface: RJ-45 console port for local configuration and diagnostics
  • USB Port: 1 × USB 2.0 port for program download and data transfer
  • Operating Temperature: -40°C to +70°C
  • Storage Temperature: -55°C to +85°C
  • Humidity Range: 5%–95% non‑condensing
  • Vibration Resistance: Compliant with IEC 60068‑2‑6 (10–500 Hz, 10 g peak)
  • Shock Resistance: Compliant with IEC 60068‑2‑27 (50 g, 11 ms duration)
  • Isolation: Channel‑to‑backplane opto‑isolation (2500 Vrms) for noise immunity
  • Certifications: UL/cUL Class I, Div 2 compliant; IEC 61010‑1 safety certified; CE marked for EMC compliance
  • Dimensions: 160 mm × 40 mm × 202 mm (6.30 in × 1.57 in × 7.95 in)
  • Weight: 0.86 kg (1.90 lbs)

Functional Features

  • Standalone Control: Operates as a standalone controller running application code, managing field devices and I/O modules via IONet.
  • Real-Time Processing: Powered by a 667 MHz PowerPC processor and QNX Neutrino OS for fast, reliable control data processing.
  • Dual IONet Redundancy: Two 100Base‑TX Ethernet ports support redundant IONet communication, ensuring uninterrupted data transfer during faults.
  • TMR Support: Compatible with triple modular redundancy configurations for high‑reliability applications requiring fault tolerance.
  • I/O Expansion: Connects to up to 16 I/O packs, supporting up to 1024 I/O points for comprehensive field device integration.
  • Legacy Integration: RS-232/RS-485 serial port enables seamless integration with legacy devices and systems.
  • Diagnostic Monitoring: Built‑in diagnostics for Ethernet link health, power status, and I/O communication, with status LEDs (Attn, Pwr, Link, TxRx) for rapid fault detection.
  • ControlST & ToolboxST Compatibility: Fully integrated with GE ControlST and ToolboxST for configuration, real-time monitoring, and firmware updates.
  • Hot‑Swappable Compact Flash: Supports hot‑swap replacement of compact flash without system shutdown, reducing maintenance downtime.
  • Conformal Coating: Protects against harsh environmental conditions, ensuring reliable performance in power plants and industrial facilities.

Application Scenarios

  • Mark VIe Centralized Control: Standalone processor module in Mark VIe systems for gas/steam turbines, generators, and balance of plant control.
  • Power Generation: Deployed in utility‑scale power plants to provide centralized control for generators, turbines, and auxiliary systems.
  • Oil & Gas Infrastructure: Used in compressor stations, LNG plants, and offshore platforms to control turbine-driven pumps and compressors.
  • Industrial Process Control: Critical component in manufacturing lines for process automation and safety interlock control.
  • TMR Architectures: Essential for TMR systems in nuclear power plants and other high‑risk applications requiring fault tolerance.
  • Retrofit Projects: Compatible with legacy Mark VI systems for upgrade to Mark VIe, enhancing control capabilities and system reliability.
  • Balance of Plant Control: Ideal for managing non-turbine plant systems, including pumps, fans, and heat exchangers.

Compatibility

  • GE Platforms: Mark VIe Speedtronic control systems, compatible with simplex, dual, and TMR architectures
  • I/O Modules: Compatible with all Mark VIe I/O packs, including IS220PDIOH1A, IS220PPRFH1B, IS220PPROS1B, and IS220PVIBH1A
  • Terminal Boards: Interfaces with various terminal boards for field wiring and sensor integration
  • Communication Protocols: 100Base‑TX Ethernet (IONet) for I/O communication; 10/100/1000 Mbps Ethernet for plant network; RS-232/RS-485 for legacy devices
  • Power Supplies: 28 V DC industrial power systems with 18–32 V DC range
  • Software: GE ControlST and ToolboxST for configuration, diagnostics, and firmware updates

Installation Notes

  1. Panel Mounting: Install in a standard equipment panel using rear edge screw mounts; ensure proper air flow through grill openings on three sides.
  2. Power Connection: Supply 28 V DC to power terminals, verify correct polarity to avoid component damage; ensure power supply meets 18–32 V DC range.
  3. IONet Configuration: Connect dual Ethernet ports to Mark VIe IONet network; assign unique IP addresses and enable redundancy mode for high availability.
  4. I/O Pack Integration: Connect to I/O packs via IONet; verify communication and I/O point configuration using ControlST software.
  5. Legacy Device Setup: Wire RS-232/RS-485 serial port to legacy devices; configure communication parameters (baud rate, parity, data bits) in ControlST.
  6. Diagnostic Check: After installation, perform self‑test via ToolboxST to verify Ethernet links, I/O communication, and processor status.
  7. Environmental Protection: Ensure installation enclosure has IP54 or higher rating to complement conformal coating and protect against dust, moisture, and chemical exposure.
  8. Post‑Installation Testing: Conduct redundancy failover tests and I/O data validation to confirm module operation before system commissioning.

Key Advantages

  • Centralized Processing: Freescale PowerPC processor and QNX Neutrino OS deliver high-speed, real-time control for industrial applications.
  • Dual IONet Redundancy: Ensures continuous data transfer for high‑availability applications in critical industries.
  • TMR Support: Provides fault tolerance for mission-critical systems, minimizing the risk of unplanned downtime.
  • I/O Expansion: Supports up to 16 I/O packs and 1024 I/O points, adapting to diverse application needs.
  • Legacy Integration: RS-232/RS-485 serial port enables seamless connection to existing legacy devices.
  • Advanced Diagnostics: Built‑in fault detection and status LEDs enable rapid troubleshooting, reducing maintenance time and costs.
  • ControlST & ToolboxST Integration: Simplifies configuration, monitoring, and maintenance, lowering total cost of ownership.
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