GE Mark Vle & VleS Controller Technical Guide: Configuration, Installation, Operation, Debugging and Maintenance

GE Mark Vle & VleS Controller Technical Guide: Configuration, Installation, Operation, Debugging and Maintenance

Chapter 1: Introduction – Controller Platform Overview

GE's Mark Vle and Mark VleS control systems represent the advanced level in the field of industrial control. Their controllers act as the "brain" of the system, responsible for executing complex control logic, processing massive I/O data, ensuring network communication, and maintaining system high availability and functional safety. This guide aims to provide engineers and technicians with a complete technical reference covering the entire lifecycle from initial project configuration to long-term operation and maintenance.

Core Controller Families:

1. UCSC Series: The current mainstream compact, high-performance controllers, and the focus of this document. Their sub-models include:

• UCSCH1x: Quad-core processor, supports Embedded Field Agent (EFA), Embedded PROFINET Gateway (PPNG), or Embedded EtherCAT Master.

• UCSCH2x: Dual-core processor, suitable for Mark Vle and MarkStat power conversion applications.

• UCSCS2x: Designed specifically for the Mark VleS Safety system, IEC 61508 certified, supports SIL 2/3 levels.

• UCECH1x: Controller with a 7-port I/O expansion, suitable for scenarios like excitation that require numerous dedicated I/O connections.

2. UCSB Series: Previous generation mainstream controller, widely deployed in various turbine and Balance of Plant (BoP) controls, also supports Mark VleS safety functions.

3. UCPA Series: Compact controller with integrated basic I/O, suitable for space-constrained, cost-sensitive simplex applications.

4. UCSA/UCCx Series: Older generation controller platforms, currently primarily used for specific retrofit projects or legacy systems.

Documentation Basis: All content in this guide is extracted, integrated, and compiled from the official document *GEH-6721_Vol_II_BN - Mark Vle and Mark VleS Control Systems Volume II*, ensuring accuracy and authority.

Chapter 2: Configuration – System Design and Engineering Preparation

Controller configuration is the cornerstone of the entire system engineering process, primarily completed within the ToolboxST engineering software environment.

2.1 Hardware Configuration

1. Controller Platform Selection:

• In the ToolboxST Component Editor, under the "Hardware" tab, the controller platform (e.g., IS420UCSCH1B, IS420UCSCS2A) must be correctly selected first. This selection determines the available features and performance limits.

• Controller Interoperability: Starting with ControlST V07.04, mixing different platform controllers (e.g., UCSBH1A with UCSCH2A) in a redundant configuration (like Dual or TMR) is supported. During configuration, the correct platform type must be set for the R, S, T controllers separately in the Property Editor.

2. Network Adapter Configuration:

• UDH Network: This is the core network connecting ToolboxST, HMI, and the plant network. A static IP address, subnet mask, and gateway must be assigned to the controller in "Network Adapter 0". This IP address must be on the same subnet as the UDH network card of the engineering station running ToolboxST.

• IONet Network: This is the private network for communication between the controller and distributed I/O modules. Its IP address is managed automatically by the system, but the redundancy mode (Simplex, Dual, TMR) must be correctly configured in the network topology.

3. I/O Module Configuration:

• Analog Inputs: Set range (4-20mA, 0-5V, ±10V, etc.), filter time, engineering unit scaling.

• Discrete Outputs: Set power-up state, output hold mode.

• HART Devices: Configure HART variable mapping.

• Special Functions: Such as filter settings for vibration modules, enabling Sequence of Events (SOE), etc.

• Add the required I/O modules (e.g., YAIC, YDOA, YHRA) to the hardware tree.

• Configure the redundancy mode (Simplex, Dual, TMR) for each module. This mode must match the redundancy mode of the controller and network.

• Configure parameters for each I/O channel in detail, for example:

4. Distributed Network Gateway Configuration:

• Embedded PPNG: Import GSDML files for PROFINET IO devices, configure device update rates (1ms to 512ms), set MRP ring parameters (if used), and assign I/O data to Mark Vle variables.

• Embedded EtherCAT: Use tools like TwinCAT to generate an ENI file and import it into ToolboxST. Configure cable redundancy and frame loss limits.

2.2 Control Logic Configuration

1. Application Development: Use the ToolboxST Block Diagram Editor to build control strategies in the form of function block diagrams. The system provides a rich standard block library covering logic operations, analog processing, motor control, protection loops, etc.

2. Variable Connection: Connect hardware I/O points, network variables to the input and output pins of control logic blocks to establish a complete data flow.

3. System Parameter Configuration:

• Frame Period: Set the basic execution cycle of the controller (e.g., 10ms, 20ms, 40ms). The UCPA controller cannot have a frame period lower than 20ms when using distributed I/O.

• NTP Server: Configure the Network Time Protocol client to synchronize the controller clock with the plant clock.

• Alarms and Events: Configure alarm severity, archiving strategies, and notification methods.

2.3 Security and Access Configuration

1. Password Protection:

• Starting with controller firmware V06.00.00C, setting an 8-character access password for the controller is supported.

• The password is set via ToolboxST to prevent unauthorized configuration downloads and online modifications.

• Important Note: For some I/O terminal boards like TRLY 1D, once a password is set, it cannot be reset to factory defaults and must be kept secure.

2. SecurityST Integration: If SecurityST is deployed in the system, the controller can be placed in "Secure Mode," encrypting and authenticating all communications. Maintenance performed while in this mode requires temporarily exiting Secure Mode.

Chapter 3: Installation – Mechanical and Electrical Implementation

Correct installation is a prerequisite for ensuring the long-term stable operation of the controller.

3.1 Mechanical Installation

1. Location and Environment:

• The control cabinet should be clean, dry, and free of corrosive gases.

• Ensure the installation location is away from strong vibration sources and heat sources.

2. UCSC/UCSB/UCPA Mounting:

• A minimum unobstructed space of 100mm above and below the controller must be maintained for airflow.

• When mounted side-by-side, a minimum 50mm spacing between controllers is required for full 70°C operation. If the spacing is 20mm, the maximum operating temperature is 65°C.

• Use the provided screws to mount it directly to the base plate via the keyhole slots.

• UCSC: Mounted vertically, utilizing its heat sink fins for natural convection cooling.

• UCSB/UCSA: Also vertically mounted, ensuring clear airflow paths.

• UCPA: Base-mounted, using 4 #6-32 or M3.5 screws. Allow approximately 1 inch of space around it for wiring and heat dissipation.

3. UCCx (CPCI) Installation:

• The controller must be inserted into the designated slot of the CPCI chassis (the main controller is usually in Slot 1).

• Before insertion, ensure the top and bottom injector/ejector levers are in the open position.

• Push the board in until the connector mates with the backplane, then simultaneously push the top lever down and pull the bottom lever up until fully seated. Finally, tighten the lever retention screws to provide mechanical security and chassis ground.

• Note: Failure to lock the levers will prevent the controller from booting.

3.2 Electrical Wiring

1. Power Requirements:

• UCSC: 18-30 V dc, nominal 24/28 V dc. Use a 3-pin Phoenix Contact power plug (Pin1: GND, Pin2: -, Pin3: +). Wire gauge: 28-16 AWG.

• UCSB/UCSA: 28 V dc.

• UCPA: 9-16 V dc, nominal 12 V dc. Use the provided 2-pin European-style power plug. Warning: Exceeding 16 V dc can damage the unit. Power wiring length shall not exceed 30 meters.

• UCCx: Powered by the power supply module within the CPCI chassis, providing ±12V, 5V, 3.3V dc.

2. Grounding and Shielding:

• Strictly follow the single-point grounding principle.

• All analog signal cables and communication cables (e.g., Ethernet) must use shielded cables.

• The shield should be connected to the provided shield grounding terminal at the controller end, with the other end left floating and insulated.

• The controller chassis must be reliably connected to the system grounding grid via mounting screws or a dedicated grounding terminal.

3. Network Cabling:

• Use Cat 5e or higher grade Shielded Twisted Pair (STP) cables.

• IONet: Use specific colored cables (e.g., red, black, blue) to distinguish R, S, T networks.

• PROFINET: It is recommended to use green cables to distinguish them from IONet.

• All RJ-45 connectors should be firmly inserted, ensuring good contact between the shield and the connector's metal shell.

Chapter 4: Operation – System Runtime and Monitoring

Once the system is powered up and operational, daily operation and monitoring are key to ensuring production.

4.1 Status Monitoring

1. LED Indicator Interpretation:

• ONL (Green): Solid indicates the controller is online and running the application.

• Diag (Red): Flashing indicates an active diagnostic alarm.

• OT (Yellow): Solid indicates excessively high internal temperature, generating an alarm; if it worsens, the controller will shut down automatically for protection.

• VDC (Green/Amber/Red): Indicates power status. Green indicates full power operation.

• Boot (Red): Solid during the boot process; flashes at specific frequencies upon boot failure, corresponding to different faults (e.g., DRAM failure, firmware load failure).

• FAOK (Green): Indicates the status of the Embedded Field Agent connection to the cloud.

• UCSC Typical LEDs:

• UCSB/UCSA Typical LEDs: Power, OnLine, DC (Designated Controller), Diag.

2. ToolboxST Online Monitoring:

• Component Editor: Graphically displays the real-time status (OK, Attention, Fault) of the controller and all I/O modules.

• Live Values: View and modify variable values in real-time for operation and debugging.

• Alarm Viewer: Centrally view all system diagnostic alarms, including descriptions, timestamps, severity levels, and acknowledgment status.

4.2 Data Communication

1. Communication with HMI/Historian: Via the UDH network, using Modbus TCP, OPC UA, or EGD protocols, to transfer process variables, alarms, and historical data to the upper-level systems.

2. Inter-Controller Communication: In redundant configurations, controllers synchronize status and exchange vote data via IONet and/or CDH networks to achieve bumpless switchover.

3. Cloud Connectivity: Through the Embedded Field Agent (EFA), the controller can securely transmit encrypted time-series data to the GE Predix cloud platform for remote monitoring and data analysis.

4.3 Basic Operations

1. Forcing Variables: During debugging or maintenance, a variable (e.g., DI, DO) can be temporarily forced to a specific value, overriding the logic calculation result. Exercise extreme caution when forcing, maintain proper records, and release forces promptly after use.

2. Download Modes:

• Offline Download: Stops the controller's currently running program to download new configuration and logic. This causes a brief interruption of control tasks.

• Online Download: Allows minor modifications to the control logic to be downloaded without stopping the controller, enabling bumpless updates.

Chapter 5: Debugging – System Verification and Functional Testing

Debugging is the process of verifying that the system configuration is correct and functions meet design requirements.

5.1 Power-Up and Initial Checks

1. Before applying power, double-check all power wiring, network connections, and grounding.

2. During initial power-up, closely observe the controller LED sequence. The Boot LED should be solid and then turn off; the ONL and DC (if applicable) LEDs should turn green.

3. Use ToolboxST to attempt to ping the controller to confirm network connectivity.

5.2 IP Address Assignment and Controller Restore

If the controller is new or unconfigured, a UDH IP address must be assigned.

1. Using a USB Flash Drive (Recommended):

• In ToolboxST, launch the "Controller Setup Wizard" via Device -> Download -> Controller Setup.

• Select a non-encrypted, minimum 4GB capacity USB 2.0 flash drive.

• The wizard writes the network configuration to the flash drive.

• Insert the flash drive into the controller's front USB port.

• For UCSC: Press and hold the PHY PRES button while applying power. Hold for about 15 seconds until the USB On LED lights up, then release. Wait for the LED to turn off, indicating the restore is complete.

• For UCSB: Press and hold the backup/restore button on the bottom while applying power until the USB On LED lights up.

2. Using the COM Port:

• Use a dedicated COM port adapter cable to connect the controller's COM port to the engineering station.

• In the ToolboxST Controller Setup Wizard, select the option to transfer the IP address via the serial port.

5.3 Application Download and Verification

1. Perform a Build on the entire project in ToolboxST to check for configuration errors.

2. Execute Download to Controller. For redundant systems, download to the R, S, T controllers sequentially.

3. After the download is complete, confirm the controller enters the "Controlling" state.

4. I/O Loop Testing:

• Analog Inputs: Apply a known signal (e.g., 4mA, 12mA, 20mA) at the sensor and check if the corresponding variable value in ToolboxST is correct.

• Analog Outputs: Force an output value (e.g., 50%) in ToolboxST and measure the output current or voltage at the terminal board with a multimeter for accuracy.

• Discrete Inputs: Short or open the field contact and observe the variable state change.

• Discrete Outputs: Force the output to True or False, measure the continuity state at the terminal board's output terminals, and verify the feedback signal is correct.

5.4 System Functional Testing

1. Redundancy Switchover Test:

• Manually switch the designated controller (DC) to the backup controller, verifying that control transfer is smooth and bumpless.

• Simulate a fault (e.g., unplug the primary controller's power or network cable) and observe if the system automatically and correctly switches to the backup controller.

2. Alarm and Interlock Testing: Simulate triggering alarm and interlock conditions, verifying that corresponding audible/visual alarms, screen pop-ups, and device actions are executed correctly.

Chapter 6: Maintenance – Preventive and Corrective Actions

Systematic maintenance is the lifeline for ensuring long-term reliability and availability.

6.1 Routine Maintenance

1. Periodic Inspections:

• Visually inspect controller LED status to confirm no abnormal alarms.

• Check the control cabinet ambient temperature, humidity, and cleanliness.

• Check if cooling fans (e.g., for UCSBH3A or CPCI chassis) are operating normally and if filters are clogged.

2. Backups:

• UCSB: Insert a USB flash drive, press and hold the backup/restore button until the On LED lights up, which backs up the controller's NAND Flash content to the USB drive.

• UCSC: Its configuration is stored in the project file; there's no need to separately back up the controller flash, but a system recovery file can be created via USB.

• Project Backup: Regularly use the Archive Project function in ToolboxST to back up the entire engineering configuration.

• Controller Backup:

6.2 Diagnostics and Troubleshooting

1. Using Diagnostic Alarms: Any active fault generates an alarm with a code and description in the ToolboxST Alarm Viewer. For example:

• Communication Alarms: Check network physical connections, switch status, IP configuration.

• I/O Module Faults: Check module power supply, terminal board connections, field wiring.

• Controller Temperature Alarm: Check ambient temperature, whether cooling airflow is blocked, if fans are working.

2. LED Code Analysis: As mentioned earlier, the Boot LED flash pattern is the primary tool for locating boot failures.

3. Log Analysis: The controller and ToolboxST record system events and error logs, which are key to analyzing complex issues.

6.3 Component Replacement

Core Principle: In redundant configurations, faulty components can be replaced while the system is running, enabling maintenance without downtime.

1. Replacing a Controller:

• Note the positions of all cable connections on the faulty controller.

• Disconnect the power connector and all network cables.

• Loosen the mounting screws and remove the faulty controller.

• Install the new controller and connect the cables.

• Do not apply power immediately. First, perform the Controller Restore process (see section 5.2) using the USB flash drive to load the IP address and basic system configuration onto the new controller.

• After the restore is complete, apply power.

• Use ToolboxST to perform an Online Download, downloading the latest application and configuration to the new controller, synchronizing it and bringing it into the redundant group.

• Preparation: Verify the new controller's hardware revision is compatible with the old one. Prepare the recovery USB flash drive.

• Replacement Execution:

• For UCCx: Power down the CPCI chassis, loosen the ejector levers, remove the old board, insert the new board, and lock the levers.

2. Replacing an I/O Module:

• If Auto-Reconfiguration is enabled, the system automatically detects the new module and downloads the required configuration.

• If disabled, or if a terminal board is replaced, a manual download to that module must be initiated from within ToolboxST.

• Note: For S-type (Safety) I/O modules, specific replacement and "Branding" procedures exist; refer to the GEH-6723 Safety Guide.

3. Replacing Power Supplies and Fans:

• CPCI power supplies are hot-swappable. Loosen the screws, press the release lever, and extract the unit. Insert the new power supply, push it back in, and lock it.

• The CPCI cooling fan can be replaced by directly sliding it out of the compartment door at the bottom of the chassis.

6.4 Software and Firmware Updates

1. ToolboxST Software Upgrade: Install new versions of the ControlST software suite as released by GE.

2. Controller and I/O Firmware Upgrade: This is typically done automatically through the ToolboxST download process. When downloading a new project, ToolboxST compares versions and automatically updates the required firmware (Baseload, Firmware) to the controllers and I/O modules.