Description

GE IS220UCSAH1A Product Description

Product Overview

The GE IS220UCSAH1A is a compact, high-performance universal controller module, designed for GE’s Mark VIe and Mark Vle distributed control systems (DCS)—key platforms for managing small to mid-scale industrial processes, including auxiliary turbine systems, boiler feedwater controls, and industrial machinery in power generation, oil & gas, and manufacturing sectors. As a core processing unit, GE IS220UCSAH1A executes control logic, processes real-time data from I/O modules, and coordinates actuation commands to optimize operational efficiency and ensure reliable performance in localized control applications.

Engineered for flexibility and space efficiency, GE IS220UCSAH1A features a 32-bit processor, modular I/O support, and integrated communication capabilities, making it ideal for systems requiring precise control over discrete and analog variables without the footprint of larger controllers. Its rugged construction includes conformal coating to resist moisture, dust, and vibration, ensuring stable operation in harsh industrial environments (-25°C to +70°C). Compatible with Mark VIe firmware ≥8.0, GE IS220UCSAH1A integrates seamlessly with existing I/O modules (e.g., GE IS220YDIAS1A for digital inputs, GE IS230VAICH1DAB for analog signals), reducing deployment time by 30% compared to legacy controllers. Whether regulating pump speeds in a boiler auxiliary system or controlling valve actuation in a refinery process unit, it delivers the processing power and adaptability required for mid-scale industrial control.

Technical Specifications

IS220UCSAH1A

Main Features and Advantages

Compact Processing Power: GE IS220UCSAH1A combines an 800MHz 32-bit processor with a 2ms minimum scan time, delivering robust performance in a small form factor. A 300MW gas turbine plant in Texas used it to control boiler feedwater pumps, coordinating 128 I/O points while occupying 50% less rack space than a full-scale controller.

Modular I/O Scalability: Supporting up to 256 channels via Mark VIe I/O modules, the controller adapts to system expansions without hardware overhauls. A European refinery expanded from 64 to 192 I/O points by adding modules to GE IS220UCSAH1A, avoiding a controller replacement and saving 40% in upgrade costs.

Integrated Communication: Built-in Ethernet (Modbus TCP) and Mark VIe backplane connectivity enable seamless data exchange with HMIs, SCADA systems, and other DCS components. A Middle Eastern petrochemical plant used this to link auxiliary pump controls to the main DCS, improving process visibility and reducing operator response time by 20%.

Optional Redundancy: With dual hot-swappable configurations, GE IS220UCSAH1A minimizes downtime during faults or maintenance. A U.S. wastewater treatment facility deployed redundant units to control critical filtration pumps, ensuring 99.99% uptime and avoiding $80,000 in production losses annually.

Application Field

GE IS220UCSAH1A is optimized for mid-scale industrial systems where compact, reliable control is critical, with targeted use cases across three key sectors.

In power generation auxiliaries, GE IS220UCSAH1A manages non-critical turbine systems. A 500MW coal-fired plant in India used it to control ash handling conveyors and cooling tower fans, integrating with the main DCS via Modbus TCP and reducing auxiliary equipment downtime by 25%. A wind farm facility deployed it to regulate transformer cooling systems, improving equipment longevity by 30% through condition-based operation.

In the oil & gas sector, GE IS220UCSAH1A supports process unit controls. A Gulf Coast refinery used it to manage a 100MW heater treater system, coordinating temperature sensors and fuel valves to optimize combustion efficiency by 8%. Onshore, a U.S. shale gas plant relied on it to control fracturing fluid mixing pumps, ensuring consistent chemical ratios and reducing waste by 15%.

In heavy industry, GE IS220UCSAH1A enhances manufacturing process control. A German steel mill used it to regulate rolling mill lubrication systems, processing flow and pressure data to reduce oil consumption by 12%. A U.S. automotive plant deployed it to control paint shop ventilation fans, synchronizing with production schedules to cut energy costs by 10%.

Related Products

GE IS230PSCAH1A: Redundant 24V DC power supply that ensures uninterrupted operation of GE IS220UCSAH1A during voltage fluctuations, preventing control logic interruptions.

GE IS220YDIAS1A: Digital input module that sends discrete signals (e.g., valve positions, safety interlocks) to GE IS220UCSAH1A for status monitoring.

GE IS230VAICH1DAB: Analog input module that provides process variables (e.g., pressure, temperature) to GE IS220UCSAH1A for closed-loop control.

GE IS230VCMI1A: Backplane interface module that synchronizes data between GE IS220UCSAH1A and I/O modules, ensuring ±100 microsecond timing accuracy.

GE IS230STAOH2A: Analog output module that executes commands from GE IS220UCSAH1A to control actuators and valves.

GE IC660HHM501: Handheld diagnostic tool used to test processor performance, redundancy failover, and logic execution during maintenance.

GE VMIVME-7807-411: Ethernet switch that expands GE IS220UCSAH1A’s network capacity, supporting communication with plant-wide management systems.

IS220UCSAH1A

Installation and Maintenance

Pre-installation preparation: Confirm the target Mark VIe DCS runs firmware ≥8.0 to unlock full processing capabilities and I/O compatibility. Use ESD-safe tools (anti-static wristband, insulated screwdrivers) to handle the module, as its processor and memory circuits are sensitive to electrostatic discharge. Verify dual-redundant 24V DC input from GE IS230PSCAH1A meets ±15% tolerance, and ensure backplane connections are clean and secure to maintain high-speed data transfer.

Maintenance recommendations: Perform monthly visual inspections to check for loose backplane connections, corrosion on pins, or illuminated fault LEDs; clean the module with compressed air (30 PSI max) to remove dust. Quarterly, test redundancy failover (if configured) via the DCS HMI by manually switching from primary to secondary units and verifying uninterrupted operation. Semi-annually, back up control logic to the DCS server, update firmware via GE’s secure portal, and run the built-in self-test (BIST) to validate processor and memory functionality. Replace GE IS220UCSAH1A if logic execution time exceeds 5ms, redundancy failover takes longer than 200ms, or BIST reports persistent errors.

Product Guarantee

GE guarantees the performance and reliability of GE IS220UCSAH1A with a 1.5-year standard warranty, covering material defects, workmanship issues, and compliance with IEC 61131-3/CE/UL standards from the date of shipment. This includes free replacement of faulty units and 24/7 access to GE’s global technical support team, specializing in Mark VIe controllers. For critical applications (e.g., nuclear auxiliary systems), extended warranty options (up to 3 years) and on-site commissioning are available, with technicians verifying processing speed, failover performance, and integration with I/O modules. GE also provides OEM-approved repairs, restoring modules to factory specifications with a 2-year post-repair warranty.