GE IS420UCSBH4A

Technical Specifications

• Manufacturer: General Electric (GE) Energy, GE Boards & Turbine Control
• Product Series: Mark VIe, EX2100e, LS2100e Control Systems
• Module Type: UCSB (Universal Control System Blade) Controller Module
• Part Number: IS420UCSBH4A (Hardware Revision H4A)
• Processor: 1066 MHz Intel EP80579 microprocessor (quad-core architecture)
• Operating System: QNX Neutrino real-time operating system
• Memory: 256 MB DDR2 SDRAM, 512 MB Flash memory
• I/O Connectivity: IONet interface for connecting Mark VIe I/O modules (PDIO, PPRF, PVIB, etc.)
• Local I/O: 2 Hall Effect pulse inputs, 2 analog inputs, 4 digital I/O channels
• Communication Protocols: Modbus, Profinet, Ethernet/IP, VME bus; IEEE 1588 Precision Time Protocol (PTP) for clock synchronization (±1 μs accuracy)
• Power Supply: 24 V DC (nominal), voltage range 18–32 V DC; dual redundant power inputs; typical power consumption 15 W
• PCB Coating: Conformal coating for environmental protection against dust, moisture, and chemical exposure
• 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)
• Certifications: UL E207685 for Class I, Division 2, Groups A–D; IEC 61010-1 safety certified; CE marked for EMC compliance (EN 61326-1); SIL 2/SIL 3 certified (IEC 61508)
• Dimensions: 190 mm × 100 mm × 60 mm (7.48 in × 3.94 in × 2.36 in)
• Weight: 1.1 kg (2.4 lbs)
• Mounting Options: 35 mm DIN-rail mounting or panel mounting
• Diagnostic LEDs: Power A, Power B, Fault, Run, IONet Link/Activity, Local I/O status

Functional Features

• High-Performance Processing: 1066 MHz Intel EP80579 quad-core processor and QNX Neutrino RTOS deliver deterministic control for real-time turbine operations.
• IONet Integration: Seamless connectivity with Mark VIe I/O modules for scalable system expansion (up to 768 I/O points).
• Dual Redundant Power: 24 V DC redundant inputs (18–32 V DC range) prevent power-related downtime in critical applications.
• Hardware Redundancy: Dual controller hot standby with <50 ms switchover time ensures uninterrupted operation in safety-critical systems.
• IEEE 1588 PTP: Precision time synchronization (±1 μs accuracy) for coordinated control across distributed systems.
• Local I/O Channels: 2 pulse inputs, 2 analog inputs, and 4 digital I/O for direct sensor/actuator connection.
• Conformal Coating: Protects against dust, moisture, and chemical exposure in harsh industrial environments.
• ToolboxST Compatibility: Integrated with GE ToolboxST for configuration, real-time monitoring, and diagnostic reporting.
• Modular Design: Compact form factor with DIN-rail/panel mounting options for space-constrained industrial cabinets.
• Safety Certification: SIL 2/SIL 3 certified (IEC 61508) for safety-critical applications (e.g., turbine overspeed protection, safety interlocks).

Application Scenarios

• Mark VIe Control Architecture: Core controller for gas/steam turbine control systems, connecting IONet I/O modules and operator interfaces.
• Power Generation: Deployed in utility power plants for turbine control, generator monitoring, and balance of plant (BOP) systems.
• Oil & Gas Infrastructure: Used in compressor stations and LNG plants to control industrial turbines and monitor remote field devices via IONet.
• Industrial Turbine Control: Critical for real-time control of industrial gas turbines, enabling overspeed protection, safety interlocks, and auxiliary system coordination.
• Redundant Control Systems: Compatible with dual and TMR (Triple Modular Redundancy) Mark VIe architectures for fault-tolerant operation.
• Retrofit Projects: Supports upgrade of legacy Mark VI systems to Mark VIe, enhancing control performance and system integration.
• Process Automation: Used in manufacturing lines and industrial process control systems requiring high-speed, deterministic control and real-time data processing.

Compatibility

• GE Platforms: Mark VIe, EX2100e, LS2100e Control Systems; compatible with simplex, dual, and TMR architectures
• IONet Devices: Mark VIe I/O modules (IS220PDIOH1A, IS220PPRFH1B, IS220PVIBH1A), IONet switches (IS420ESWAH3A, IS420ESWBH2A)
• Power Supplies: 24 V DC industrial power systems (18–32 V DC range) with dual redundant inputs
• Software: GE ToolboxST (v5.0+) for configuration, monitoring, and diagnostics
• Mounting Hardware: 35 mm DIN-rail or panel mounting brackets (GE-approved)
• Communication Networks: IONet (for Mark VIe I/O), Ethernet/IP (for operator interfaces), Modbus (for legacy device integration)

Installation Notes

1. Mounting: Install on 35 mm DIN-rail or panel using GE-approved brackets; ensure 50 mm clearance around the module for airflow and cable management.
2. Power Connection: Connect dual 24 V DC power inputs (18–32 V DC) to redundant power supplies; verify correct polarity to avoid component damage.
3. IONet Configuration: Connect IONet interface to Mark VIe I/O modules; use ToolboxST to configure IONet network parameters (IP address, subnet mask, gateway).
4. Local I/O Wiring: Connect Hall Effect pulse inputs, analog inputs, and digital I/O to sensors/actuators; ensure proper shielding for noise immunity.
5. Redundancy Setup: Configure dual controller hot standby via ToolboxST; test switchover time (<50 ms) to validate redundancy performance.
6. LED Verification: Confirm Power A/B, Run, Fault, and IONet Link/Activity LEDs are active after installation; troubleshoot using diagnostic LEDs (e.g., Fault LED indicates system error).
7. Environmental Protection: Install in an IP54-rated enclosure to complement conformal coating and protect against dust, moisture, and chemical exposure.
8. Post-Installation Testing: Conduct IONet communication checks, redundancy failover tests, and safety interlock validation before system commissioning.

Key Advantages

• High-Performance Processing: 1066 MHz Intel EP80579 processor and QNX RTOS ensure deterministic control for real-time turbine operations.
• IONet Scalability: Supports up to 768 I/O points via IONet, enabling large-scale industrial control system integration.
• Dual Redundant Power & Hardware: Redundant power inputs and hot standby controller minimize downtime in critical applications.
• Safety Certification: SIL 2/SIL 3 compliance (IEC 61508) for safety-critical functions (e.g., turbine overspeed protection).
• ToolboxST Integration: Simplifies configuration, monitoring, and diagnostics for reduced operational complexity.
• Conformal Coating: Extends module lifespan by protecting against harsh industrial environments (dust, moisture, chemicals).
• Local I/O Flexibility: 2 pulse inputs, 2 analog inputs, and 4 digital I/O for direct sensor/actuator connection without additional modules.