GEI-100616B

GE Energy
Mark* VIe Stand-alone Modules
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 accuracy of the information included herein.
Changes, modifications, and/or improvements to equipment and specifications are
made periodically and these changes may or may not be reflected herein. It is
understood that GE may make changes, modifications, or improvements to the
equipment referenced herein or to the document itself at any time. This document is
intended for trained personnel familiar with the GE products referenced herein.
GE may have patents or pending patent applications covering subject matter in this
document. The furnishing of this document does not provide any license whatsoever
to any of these patents.
This document contains proprietary information of General Electric Company, USA
and is furnished to its customer solely to assist that customer in the installation,
testing, operation, and/or maintenance of the equipment described. This document
shall not be reproduced in whole or in part nor shall its contents be disclosed to any
third party without the written approval of GE Energy.
GE provides the following document and the information included therein as is and
without warranty of any kind, expressed or implied, including but not limited to any
implied statutory warranty of merchantability or fitness for particular purpose.
If further assistance or technical information is desired, contact the nearest GE Sales
or Service Office, or an authorized GE Sales Representative.

 2007 General Electric Company, USA. All rights reserved.

Revised: 080201
Issued: 071213

g
* Trademark of General Electric Company
CIMPLICITY is a registered trademark of GE Fanuc Automation North America, Inc.
CompactFlash is a registered trademark of Sandisk Corporation
Modbus is a registered trademark of Schneider Automation.
IEEE is a registered trademark of Institute of Electrical and Electronics Engineers.
QNX is a registered trademarks of QNX Software Systems Ltd (QSSL)
 Safety Symbol Legend

Indicates a procedure, practice, condition, or statement that, if

not strictly observed, could result in personal injury or death.

Indicates a procedure or condition that, if not strictly observed,

could result in damage to or destruction of equipment.

Indicates a procedure, condition, or statement that should be

strictly followed in order to optimize these applications.

Note Indicates an essential or important procedure or statement.

Contents

UCSA Stand-alone Modules 3

Mark* VIe Controller ..................................................................................... 3
Operation ........................................................................................................ 3
Configuration.................................................................................................. 4
Installation ...................................................................................................... 5
Diagnostic Alarms .......................................................................................... 8

2 • UCSA Stand-alone Modules GEI-100616B Mark VIe

 CHAPTER 1

UCSA Stand-alone Modules

Mark* VIe Controller

The Mark* VIe UCSx controllers are a family of stand-alone computers that run the
application code. The controller mounts in a panel, and communicates with the I/O
packs through on-board I/O network interfaces. The controller operating system (OS)
® ®
is QNX Neutrino , a real time, multitasking OS designed for high-speed, high-
reliability industrial applications. Five communication ports provide links to I/O,
operator, and engineering interfaces are as follows:

• Ethernet connection for the Unit Data Highway (UDH) for communication with
HMIs, and other control equipment
• Ethernet connection for the R, S, and T I/O network
• RS-232C connection for setup using the COM1 port

Note The I/O networks are private special-purpose Ethernet that support only the
I/O packs and the controllers.

The stand-alone controllers offer the following advantages over the Compact PCI
and Mark VIe controllers.

• Single module
• Built-in power supply
• No jumper settings required
• No battery
• No fan
• Smaller panel footprint
™
• Easy access to CompactFlash

Operation
Note Application software can be modified online without requiring a restart.

The controller is loaded with software specific to its application, which includes but
is not limited to, steam, gas, wind, hydro, and land-marine aeroderivative (LM), or
®
balance of plant (BoP) products. It can run rungs or blocks. The IEEE 1588 protocol
is used through the R, S, and T IONets to synchronize the clock of the I/O packs and
controllers to within ±100 microseconds.

External data is transferred to and from the control system database in the controller
over the R, S, and T IONets.

GEI-100616B Mark VIe UCSA Stand-alone Modules• 3

 In a simplex system, this includes process inputs/outputs to the I/O packs.

In a dual system:

• Process inputs/outputs to the I/O packs

• Internal state values and initialization information from the designated controller
• Status and synchronization information from both controllers
In a triple modular redundant (TMR) system:

• Process inputs/outputs to the I/O packs

• Internal state values for voting and status, and synchronization information from
all three controllers
• Initialization information from the designated controller

Configuration
The controller must be configured with a TCP/IP address prior to connecting to the
UDH Ethernet. This can be achieved using one of the following methods.
™
• Through the ToolboxST application and the COM1 serial port. See GEH-
6700, ToolboxST Guide for Mark VIe Control for details. A RJ45 to DB9
adapter is required along with an Ethernet cable. The adapter part number is
342A4944P1.
®
• Through the ToolboxST* application and a CompactFlash programmer. See
GEH-6700, ToolboxST Guide for Mark VIe Control for details. The
CompactFlash programmer can be a PCMCIA adapter or a USB device.
The following drawing shows the pin definition of the UCSx RJ45 to the COM port adapter.
Converter
DB 9
RJ45 Female
1 DCD
GND 1 White/Orange 1 Blue
Red 2 RXD
RTS 2 Orange 2
Brown 3 TXD
GND 3 White/Green 3
UCSA TXD/Sout 4 Blue 4
4 DTR
RJ-45 Black 5 GND
NC 5 White Blue 5 Green
6 DSR
CTS 6 Green 6 Yellow 7 RTS
RXD/Sin 7 White/Brown 7 Orange 8 CTS
NC 8 Brown 8 Grey
9 RI

Once the IP address has been assigned, all ToolboxST configuration is through the
Ethernet. See GEH-6700, ToolboxST Guide for Mark VIe Control for further details.

4 • UCSA Stand-alone Modules GEI-100616B Mark VIe

 Installation
The controller is contained in a single module that mounts directly to the panel sheet
metal. The following diagram shows the module envelope and mounting
dimensions.

Module Envelope and Mounting Dimensions

GEI-100616B Mark VIe UCSA Stand-alone Modules• 5

 UCSA Module
The IS220UCSAH1+ Module contains a 667 MHz Power QUICC II Pro Freescale
processor. Two 10/100BaseTX Ethernet ports provide connectivity to the UDH, and
three additional 10/100Base TX Ethernet ports provide connectivity to the IONets.

GE Energy

Link
T/
Act SL3

Link
S/
Act SL2

Link R/
SL1
Act

Power
Boot
OnLine
Flash
DC
Diag

Link
ENET 1
Act

Link
ENET 2
Act

On USB

COM

UCSA Front View

6 • UCSA Stand-alone Modules GEI-100616B Mark VIe

 LEDs
The UCSA module has the following LEDs:

• Link displays solid green if the Ethernet PHY on the UCSA has established a
link with an Ethernet switch port.
• Act indicates packet traffic on an Ethernet interface. This LED may blink if the
traffic is low, but is solid green in most systems.
• Power displays solid Green when the internal 5 V supply is up and regulating.
The UCSA converts the incoming 28 V dc to 5 V dc. All other internal power
planes are derived from the 5 V.
• Boot displays solid red or blinking red during the boot process. The boot blink
codes are described below.
− Online displays solid green when the controller is online and running
application code.
− Flash blinks amber when any flash device is being accessed.
− Dc displays solid green when the controller is the designated controller.
− Diag displays solid red when the controller has a diagnostic available. The
diagnostic can be viewed and cleared using the ToolboxST application.
− On displays solid green when the USB is active.

Boot LED Blink Codes

The boot LED is lit continuously during the boot process unless an error is detected.
If an error is detected, the LED blinks at a 1 Hz frequency. The LED, when blinking,
is on for 500 ms and off for 500 ms. The number of blinks indicates the failed state.
After the blink section, the LED turns off for three seconds.

The blink codes are:

• 1: Failed Serial Presence Detect (SPD) EEPROM.

• 2: Failed to initialize DRAM or DRAM tests failed.
• 3: Failed NOR flash file system check.
• 4: Failed to load FPGA or PCI failed.
• 5: CompactFlash device not found.
• 6: Failed to start IDE driver
• 7: CompactFlash image not valid.
If the CompactFlash image is valid but the runtime firmware has not been loaded, the
boot LED blinks continuously at a 1 Hz rate. Once the firmware is loaded, the boot
LED turns off.

If the controller does not go online, use the ToolboxST application to determine why
the controller is blocked. Once the IP address has been assigned, all the ToolboxST
configuration is through the Ethernet. See GEH-6700, ToolboxST Guide for Mark
VIe Control for further details.

GEI-100616B Mark VIe UCSA Stand-alone Modules• 7

 UCSA Specifications
Item Specification
Microprocessor Freescale Power pc (Power QUICC II PRO 667 MHz)
Memory 256 MB DDR SDRAM
Flash-backed SRAM - 8K allocated as NVRAM for controller functions
CompactFlash size is dependent on the application.
Operating System QNX Neutrino
Programming Control block language with analog and discrete blocks; Boolean logic represented in
relay ladder diagram format. Supported data types include:
Boolean
16-bit signed integer
16-bit unsigned integer
32-bit signed integer
32-bit unsigned integer
32-bit floating point
64-bit long floating point
Primary Ethernet Interface (2) Twisted pair 10BaseT/100BaseTX, RJ-45 connectors:
TCP/IP protocol used for communication between controller and toolbox
TCP/IP protocol used for alarm communication to HMIs
®
EGD protocol for application variable communication with CIMPLICITY HMI and
Series 90-70 PLCs
®
Ethernet Modbus protocol supported for communication between controller and third-
party DCS
IONet Ethernet Interface Twisted pair 10BaseT/100BaseTX, RJ-45 connectors:
(3 ports) TCP/IP protocols used to communicate between controllers and I/O packs
COM ports One accessible through RJ-45 connector on front panel
For cabling use a standard 4-pair UTP cable (for example, Ethernet cable) joined with
a computer null modem connector (GE part #342A4944P1)
Power Requirements +32 V dc to 18 V dc ( 12.5 W (typical preliminary), TBD (maximum))
Environmental Specifications Operating: 0 to +65°C (32 to +149 °F)
Storage: -40 to +85°C (-40 to +185 °F)
Relative humidity: 5% to 95%, no-condensing
Weight 2 lbs

Diagnostic Alarms
The controller detects certain system errors during startup, download, and normal
operation. These diagnostic alarms can be displayed and reset from the ToolboxST
™
application, and are recorded in historical manner on WorkstationST .

Alarm Description Possible Cause Solution

259 [ ] frame overruns have Runtime sequencer malfunction. One or Replace processor module.
occurred more frame overruns, which occur when
frame idle time is 0, detected.
260 [ ] frame number skips Runtime malfunction. Frame number skips Same as above
have occurred have been detected. (Other than during
frame synchronization during startup, the
frame number should monotonically
increase until rollover.)
279 Sys - Could not Incorrect firmware version or hardware Ensure all connectors are aligned
determine platform type malfunction The firmware could not properly and fully seated. Check
from hardware recognize the host hardware type. firmware version for compatibility
with platform; if OK, replace
processor module.

8 • UCSA Stand-alone Modules GEI-100616B Mark VIe

 Alarm Description Possible Cause Solution
280 Sys - Platform hardware The platform type identified in the Fix platform type in the ToolboxST
does not match runtime application configuration does not match application, rebuild and download
application the actual hardware. application.
281 Sys - FPGA not Replace processor module
programmed due to
platform errors
282 Sys - Unable to initialize Runtime malfunction. An application- Reload firmware and application
application independent independent firmware process could not and reboot. For controller, if failure
processes be started successfully. persists remove CompactFlash
module and reprogram boot loader
using the ToolboxST application.
Download Flash Bootloader pick.
After reinstalling the flash module
and rebooting, reload firmware and
application. If this does not work,
replace processor module.
283 Sys - Process Runtime or hardware malfunction. A Same as above
disconnected illegally. runtime process has crashed.

284 Process fault detected. Same as above Same as above

292 A seq client did not Excessive application loading. Check application loading and
respond to an overrun reduce the amount of application
event prior to the next code or frequency of execution.
frame
294 Controller CPU over Fan loss. excessive ambient temperature, Check fan, ambient temperature,
temperature, Temp [ ] hardware malfunction. dust buildup on processor module;
°C, Threshold [ ] °C if OK, replace processor module.
300 Application code load Invalid application configuration, firmware Rebuild and download application
failure or hardware malfunction. to all processors; reload firmware
and application; replace processor
module.
320 Alarm - scan buffers full. Too many alarm variables are changing If possible, reduce the number of
Alarm process can miss state too quickly to transmit all transitions. alarms that can change state at the
alarm transitions Excessive alarms in queue. same time, for example, filter alarm
variables in the application code.
321 Alarm - not scanning. Runtime malfunction. Alarms not being If processor does not reboot,
Application stopped scanned. Processor will likely reboot on a condition was transient. Clear
sending Data S/W watchdog timeout due to a processor alarm and monitor for repeat
overload. occurrences, which may indicate
spurious processor overloads.
Check idle time and reduce
application load, if necessary.
322 EGD configuration >1400 Number of relevant, consumed UDH EGD Reduce amount of relevant,
bytes, may not be variables exceeds fault tolerant EGD consumed UDH EGD data.
supportable by fault limitation. Normal UDH EGD operation is
tolerant EGD not affected; however, in the event of a
UDH EGD failure, some consumed
variables may not be transmitted to
redundant controllers over the IONet.
323 Received request to send Redundant processor unable to receive Check UDH network and verify that
fault tolerant EGD data to UDH EGD inputs and has requested that all redundant processors are
redundant controllers EGD data be transferred over the IONet. receiving all of the expected EGD
An EGD exchange timeout has occurred exchanges. Ensure that all relevant
on the requesting processor. devices are powered up and
producing data on the network.
324 Requested fault tolerant Unable to receive UDH EGD inputs and Same as above
EGD data from the exchange data is being requested
redundant controllers over the IONet.

GEI-100616B Mark VIe UCSA Stand-alone Modules• 9

Alarm Description Possible Cause Solution
326 Communication lost from IONet or hardware malfunction. The S or Verify that the processor is in the
R processor T processor in a redundant system has Controlling state. Check for
lost communication with the R processor. disconnected IONet cables or
malfunctioning switches. Rebuild
and download application.
327 Communication lost from IONet or hardware malfunction. The R or Same as above
S processor T processor in a redundant system has
lost communication with the S processor.
328 Communication lost from IONet or hardware malfunction. The R or Same as above
T processor S processor in a redundant system has
lost communication with the T processor.
329 Data initialization timeout IONet malfunction, controllers have Check IONets; rebuild and
R processor different application revisions, one or more download application, ensure all
controllers are powered down, or controllers are powered up, disable
controller is overloaded by external jabbering command senders (for
command messages. Controller unable to example, Modbus masters) until
complete startup data initialization. controller is online.
330 Data initialization timeout Same as above Same as above
S processor
331 Data initialization timeout Same as above Same as above
T processor
334 Application frame Hardware or IONet malfunction. Frame Check IONet (switches, cables);
number skip number skips detected. Frame number replace processor module.
should monotonically increase until
rollover; alarm occurs following a single
frame number skips in successive frames.
335 Process code segment Hardware memory failure. A modification Replace processor module.
CRC mismatch has occurred in the code segment for one
of the processes.
336 Controller is unlocked Mark VIeS: Leaving Data Init control state Lock the controllers from the
and not locked or the controller is ToolboxST application before
unlocked through the ToolboxST executing safety functions.
application.
337 EGD output exchange IONet malfunction or hardware problem. Check IONet (switches, cables);
disagreement detected For at least one output, a difference was rebuild and download application to
detected between the three controllers in all processors; if this does not help,
a SIS. This alarm remains active until the replace processor module.
controllers agree on all outputs. A
difference for non-Boolean data generally
indicates a deviation of more than 10%
from the median value or no IONet EGD
configuration is present.
347 Running application does Mark VIeS: Application not branded or Reload branded application to
not match the branded different from branded version controller and I/O packs or use the
application ToolboxST application to brand
currently running application.
Note: The purpose of branding is
to label a verified safety application,
and to ensure that it is running.
348 Packet loss on IONet 1 Power cycled on I/O producer (controller Check IONet (switches, cables);
exceeded [ ]% or I/O pack), IONet malfunction, I/O make sure alarm did not occur due
message corruption. Communication to pack reboot, and so on.
errors have occurred on more than 5% of
the data transmissions on IO Net.
349 Packet loss on IONet 2 Same as above Same as above
exceeded[ ]%
350 Packet loss on IONet 3 Same as above Same as above
exceeded [ ]%

10 • UCSA Stand-alone Modules GEI-100616B Mark VIe

 Alarm Description Possible Cause Solution
352 Blockware app static Hardware memory failure. App process Replace processor module.
data CRC mismatch data that should not change after the
controller goes online was modified. This
may indicate a hardware memory
problem.
353 Sys Config Shmem CRC Hardware memory failure. System Same as above
mismatch process data that should not change after
the controller goes online was modified.
354 EGD static data CRC Hardware memory failure. IONet-EGD Same as above
mismatch process data that should not change after
the controller goes online was modified.
355 State Exchange Voter IONet malfunction or hardware problem. Check IONet (switches, cables); if
disagreement detected State Exchange disagreement found. this does not help, replace
processor module.
356 NANs in CALC Block NAN received from I/O interface or Check external devices that may be
detected hardware problem. sending NANs to the controller; if
conditions persists, replace
processor module.
357 Sequencer client out-of- Hardware malfunction. Sequencer critical Replace processor module.
order execution detected clients scheduled out of order. Alarm
occurs following three successive frames
of sequencer critical client out-of-order
execution detections; after five, controller
put in FAILURE control state.
358 Sequencer client Hardware malfunction. Sequencer critical Same as above
execution underrun client underrun detected. Alarm occurs
detected after a sequencer critical client has been
run slower than its nominal rate three
times in a row; after five, controller put in
FAILURE control state.
359 Sequencer client Hardware malfunction. Sequencer critical Same as above
execution overrun client overrun detected. Alarm occurs after
detected a sequencer critical client has been run
faster than its nominal rate three times in
a row; after five, controller put in FAILURE
control state.
360 Sequencer frame period Hardware malfunction. Frame period Same as above
out-of-bounds (±5%) greater than ±5% of nominal. Alarm
detected occurs following frame period out-of-
bounds condition occurring three frames
in a row; after five, controller put in
FAILURE control state.
361 Sequencer frame state Hardware malfunction. Sequencer frame Same as above
timeout out-of-bounds state timeout greater than ±5% of nominal.
(±5%) detected Alarm occurs following a sequencer frame
state timeout being out-of-bounds three
frames in row; after five, controller put in
FAILURE control state.
362 Sequencer frame number Hardware or IONet malfunction. Frame Check IONet (switches, cables);
skip detected number skips detected. Frame number replace processor module.
should monotonically increase until
rollover; alarm occurs following three skips
in a row, after five, controller put in
FAILURE control state.
363 Seq static data CRC Hardware memory failure. Sequencer Replace processor module.
mismatch process data that should not change after
the controller goes online was modified.
364 Too many SEV IONet malfunction or hardware problem. Check IONet (switches, cables); if
disagreements in a single SEV disagreement overflow. Firmware this does not help, replace
packet cannot handle more than 128 processor module.
disagreements at once.

GEI-100616B Mark VIe UCSA Stand-alone Modules• 11

 Note So that input validation alarms can be generated for each I/O pack in a
configuration, the following IONet EGD input validation alarms are numbered
starting from a base of 1000, and are uniquely created based on I/O pack topology.
Four error messages are associated with each alarm number, and are used based on
particular validation types.

Alarm ID convention: R I/O pack in TMR module or Simplex, single-net I/O pack:
1000 + ModuleID; S I/O pack in TMR module: 1256 + ModuleID; T I/O pack in
TMR module or dual-net or dual I/O pack on IONet 1: 1512 + ModuleID; dual-net
or dual I/O pack on IONet 2: 1768 + ModuleID.

Alarm Description Possible Cause Solution

1000-2024 I/O module [ ], R pack: I/O pack comm. malfunction or Check I/O pack health,
exch [ ] timed out, IONet malfunction. (R, S, or T) I/O diagnostics, IONet (cables,
IONet [ ] pack input packet not received switches).
timeout.
1000-2024 I/O module [ ], S pack: Same as above Same as above
exch [ ] timed out,
IONet [ ]
1000-2024 I/O module [ ], S pack: Same as above Same as above
exch [ ] timed out,
IONet [ ]
1000-2024 I/O module [ ]: exch [ ] I/O pack comm. malfunction or Same as above
timed out IONet malfunction. SMX I/O pack
input packet not received timeout.
1000-2024 I/O module [ ]: exch [ ] I/O pack comm. malfunction or Same as above
timed out, IONet [ ] IONet malfunction. SMX I/O pack,
dual network input packet not
received timeout.
1000-2024 I/O module [ ], R pack: Controller, I/O pack application Rebuild application and download.
exch [ ] major sig mismatch. (R, S, or T) I/O pack
mismatch, IONet [ ] input packet major signature
mismatch detected.
1000-2024 I/O module [ ], S pack: Same as above Same as above
exch [ ] major sig
mismatch, IONet [ ]
1000-2024 I/O module [ ], T pack: Same as above Same as above
exch [ ] major sig
mismatch, IONet [ ]
1000-2024 I/O module [ ]: exch y Controller, I/O pack application Same as above
major sig mismatch mismatch. SMX I/O pack input
packet major signature mismatch
detected.
1000-2024 I/O module [ ], R pack: Controller, I/O pack application Same as above
exch [ ] cfg timestamp mismatch. (R, S, or T) I/O pack
mismatch, IONet [ ] input packet configuration
timestamp mismatch detected.
1000-2024 I/O module [ ], S pack: Same as above Same as above
exch [ ] cfg timestamp
mismatch, IONet [ ]
1000-2024 I/O module [ ], T pack: Same as above Same as above
exch [ ] cfg timestamp
mismatch, IONet [ ]
1000-2024 I/O module [ ]: exch [ ] Controller, I/O pack application Same as above
cfg timestamp mismatch mismatch. SMX I/O pack input
packet configuration timestamp
mismatch detected.
1000-2024 I/O module [ ], R pack: Controller, I/O pack application Same as above
exch [ ] received too mismatch. (R, S, or T) I/O pack
short, IONet [ ] input packet received shorter than
expected.

12 • UCSA Stand-alone Modules GEI-100616B Mark VIe

 Alarm Description Possible Cause Solution
1000-2024 I/O module [ ], S pack: Same as above Same as above
exch [ ] received too
short, IONet [ ]
1000-2024 I/O module [ ], T pack: Same as above Same as above
exch [ ] received too
short, IONet [ ]
1000-2024 I/O module [ ]: exch [ ] Controller, I/O pack application Same as above
received too short mismatch. SMX I/O pack input
packet received shorter than
expected.

GEI-100616B Mark VIe UCSA Stand-alone Modules• 13

Notes

14 • UCSA Stand-alone Modules GEI-100616B Mark VIe

g GE Energy
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