GE Energy Mark V To Mark Ve Control: Steam Retrofit Instruction Guide

GE Energy GEH-6731E
Mark* V to Mark Ve Control

Steam Retrofit
Instruction Guide
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.
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does not provide any license whatsoever to any of these patents.
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shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of
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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
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© 2008 – 2010 General Electric Company, USA. All rights reserved.

Revised: 100908
Issued: 080303
* Trademark of General Electric Company

ARCNET is a registered trademark of Datapoint Corporation.
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strictly observed, could result in personal injury or death.
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strictly observed, could result in damage to or destruction
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Contents
Chapter 1 Overview ................................................................................................................ 1-1
Materials List ...................................................................................................................................1-2
R Core Materials ................................................................................................................................. 1-2
S Core and T Core Materials ................................................................................................................. 1-3
C Core Materials ................................................................................................................................. 1-3
Enclosure Materials ............................................................................................................................. 1-4
Field Service Kit Materials ..................................................................................................................... 1-5
PROM Materials ................................................................................................................................. 1-5
Bar Code Worksheet .......................................................................................................................1-6
Chapter 2 Core Retrofit Procedures ..................................................................................... 2-1
Installation Setup.............................................................................................................................2-1
Disassembling Cores S, R, and T ...................................................................................................2-2
Reassembling Cores R, S, and T....................................................................................................2-8
Disassembling Core C...................................................................................................................2-23
Reassembling Core C ...................................................................................................................2-27
Modifying the TBQC Board ...........................................................................................................2-36
Modifying the TBQD Board ..........................................................................................................2-38
Modifying the Power Distribution Module (PDM)...........................................................................2-40
Upgrading TCEA and TCDA PROMs............................................................................................2-42
Chapter 3 Ethernet Cable Routing ........................................................................................ 3-1
Redundant ARCNET .......................................................................................................................3-1
Single ARCNET...............................................................................................................................3-6
1 Contents Mark* V to Mark Ve Control Steam Retrofit

Chapter 1 Overview
Mark V control is a second-generation microprocessor-based turbine control. A retrofit
package provides a way to upgrade to Mark Ve control without impacting the current
I/O interface. Field-wiring terminations and turbine devices remain intact to minimize
installation and commissioning downtime.
This document provides instruction for retrofitting the following Mark V systems to
Mark Ve systems.
Mark V TMR steam systems:
Single ARCNET® controller
• <R, S, and T> cores with a single analog I/O card (TCQA)
• <R, S, and T> cores with two analog I/O cards (TCQA and TCQB)
• <C> core with single or dual analog I/O cards (TCCA and optional TCCB)
Redundant ARCNET controller
• <R, S, and T> cores with a single analog I/O card (TCQA)
• <R, S, and T> cores with two analog I/O cards (TCQA and TCQB)
Mark V simplex steam systems:
Single ARCNET controller
• <R> cores with a single analog I/O card (TCQA)

• <R> cores with two analog I/O cards (TCQA and TCQB)
Redundant ARCNET controller
• <R> cores with a single analog I/O card (TCQA)

• <R> cores with two analog I/O cards (TCQA and TCQB)
GEH-6731E Chapter 1 Overview Instruction Guide 1-1

Materials List
A set of material for each R, S, T, and C core (S and T are not included for simplex),
PROMs for TCDA and TCEA, as well as one for enclosure level parts, is shipped to the
job site as a package. Verify that all material is available before continuing. The following
table lists materials that are included with TCQB board systems.
R core material 259B2451SMG01 – Redundant ARCNET

259B2451SMG02 – Single ARCNET
S core material 259B2451SNG01
T core material 259B2451SPG01
C core material 259B2451RQG01 – With a CD core
259B2451RQG03 – Without a CD core
Enclosure level 259B2451SRG01 – TMR
material 259B2451SRG01 – SImplex
The following tables provide a materials list for the retrofit. Separate the materials by core
type and verify that all items have been included.
R Core Materials
R core – Redundant ARCNET R core – Single ARCNET
259B2451SMG01 Catalog Number 259B2451SMG02 Catalog Number
Control module 259B2451EVG01 Control module 259B2451EVG02
PWA assembly IS210MVRAH2A PWA assembly IS210MVRAH2A
PWA assembly IS210MVRBH1A PWA assembly IS210MVRBH1A
Power supply 259B2451EZG01 Power supply 259B2451EZG01
Card stop bracket (2) 151X1202LMSP02 Card stop bracket (2) 151X1202LMSP02
2PL cable 336A4940FL G01 2PL cable 336A4940FL G01
19PL cable 336A4940GD G01 19PL cable 336A4940GD G01
JP4 cable 336A4940FN G01 JP4 cable 336A4940FN G01
JP5 cable 336A4940FP G02 JP5 cable 336A4940FP G02
PB1 ground cable 259B2451EU P02 PB1 ground cable 259B2451EU P02
Label, TBQC 336A4940GNP01
1-2 Mark* V to Mark Ve Control Steam Retrofit

S Core and T Core Materials
S core Catalog number T core Catalog number
259B2451SNG01 259B2451SPG01
Control module 259B2451EWG01 Control module 259B2451EXG01
PWA assembly IS210MVRAH2A PWA assembly IS210MVRAH2A
PWA assembly IS210MVRBH1A PWA assembly IS210MVRBH1A
2PL cable 336A4940FL G01 2PL cable 336A4940FL G01
19PL cable 336A4940GD G01 19PL cable 336A4940GD G01
JP4 cable 336A4940FN G01 JP4 cable 336A4940FN G01
JP5 cable 336A4940FP G02 JP5 cable 336A4940FP G02
Label, TBQD 336A4940HLP01
Contact the GE project manager or field engineer

regarding material recovery for any system circuit
boards that are no longer needed due to this retrofit
process. Specific guidance is provided through the Power
Attention Answer Center (PAC).
Verify that the DS200TCQCG# in Location 4 is the

correct revision.
All TCQCG#A boards must be replaced with TCQCG#B

boards. The TCQCG#B must be Revision G or later.
Attention
C Core Materials
C core Catalog number C core 259B2451RQG03 Catalog number
259B2451RQG01
Control module 259B2451EYG01 Control module 259B2451EYG03
PWA assembly IS210MVRCH1A PWA assembly IS210MVRCH1A
2PL cable 336A4940GM G01 2PL cable 336A4940GM G01
JHH cable 336A4940GC G01 JHH cable 336A4940GC G01
JII cable 336A4940GL G01 JII cable 336A4940GL G01

Enclosure Materials
Enclosure Catalog number Enclosure Catalog number
259B2451RRG01 259B2451SRG02
TMR Simplex
Panduit assembly (2) 151X1202LQG01
Panduit assembly 151X1202LQG02 Panduit assembly 151X1202LQG02
Cables (1 bag) 336A4940GB G01 Cables (1 bag) 336A4940GB G04
Door pocket 104X905CA 016 Door pocket 104X905CA 016
BOI plate 151X1202LRG01 BOI plate 151X1236AXG01
R ground cable 336A4940GF G01 R ground cable 336A4940GF G01
S ground cable 336A4940GF G02
T ground cable 336A4940GF G03
C ground cable 336A4940GF G04 C ground cable 336A4940GF G04
Door label 259B2451RHP1 Door label 259B2451RHP1
Extra cables 336A3435DW G01 Extra cables 336A3435DW G01
Extra cables 336A3435AS G01 Extra cables 336A3435AS G01
Extra cables 336A3435DV G01 Extra cables 336A3435DV G01
Extra cables 336A3471BJ G03 Extra cables 336A3435DK G01
Extra cables 336A3460BF G01
Extra cables 336A3460BJ G01
Shield bar spacer 151X1202LTP01 Shield bar spacer 151X1202LTP01
Hardware 336A4940GSG01 Hardware 336A4940GSG01
Label, TCPD 336A4940HBP01 Label, TCPD 336A4940HBP01
FUSES, TCPD 5A 323A2357P25 FUSES, TCPD 5A 323A2357P25
Bracket / label 342SA4909ABG1 Bracket / label 342SA4909ABG1
Field Service Kit 336A4940GWG01 Field Service Kit 336A4940GWG01
Wire ties 218A4335P7 Wire ties 218A4335P7
Cables (1 bag) 336A4940GBG02
Contact the GE project manager or field engineer

regarding material recovery for any system circuit
boards that are no longer needed due to this retrofit
process. Specific guidance is provided through the Power
Attention Answer Center (PAC).

Field Service Kit Materials
Field Service Kit336A4940GWG01 Catalog number
1 - UCSA comm. port adapter 342A4944P1
1 - CompactFlash® drive 336A5199AMP1
1 - 128MB CompactFlash 336A5196AAP8
10 - GMC – 5A DS200TCPD fuse 323A2357P25
10 - S505 4A Mark Ve power supply fuse 342A4908AEP1
1 - NYOGEL Lubricant 10cc syringe tube 336A5116P10
Note The enclosure parts kit for both TMR (catalog number 259B2451SRG01) and
simplex (catalog number 259B2451SRG02) contains a field service kit (catalog number
336A4940GWG01). When the installation is complete, the unused portion of this
kit should be supplied to the customer.
PROM Materials
Mark V Legacy Board PROM Catalog number Quantity
TCDA – A – Site PROM before F1ACE DS200TCDAF1ACE 10
TCDA – A – Site PROM after F1ACE DS200TCDAF1ACN 10
TCDA – B – Site PROM before F1BCE DS200TCDAF1BCE 10
TCDA – B – Site PROM after F1BCE DS200TCDAF1BCN 10
TCEA – A DS200TCEAF1ACM 5
TCEA – B DS200TCEAF1BEC 5
Note One set of PROMs is provided for TCDA and TCEA depending on the original
site configuration (TCEA early/late A/B panel and TCEA A/B panel). All quantities
in the table include spares and reflect the maximum case configuration (TMR, CD,
DD, QD1, QD2).

Bar Code Worksheet
Record the bar codes for your unit in the table below. Boards and cores vary between units.
R Core
R Core control module #
IS220PIOAH - JA
IS220PIOAH - JB
IS200MVRA
IS200MVR (F or B)
S Core (TMR Only)

IS220PIOAH - JB
IS200MVRA
IS200MVR (F or B)
T Core (TMR Only)

IS220PIOAH - JB
IS200MVRA
IS200MVR (F or B)
C Core
C Core control module #
IS220PIOAH - JA
IS220PIOAH - JB
IS200MVRC
D Core
IS220PIOAH - JB
IS200MVRC

Chapter 2 Core Retrofit Procedures
Installation Setup
Follow all GE and local safety Ø To install the BIOA cover plate
procedures before proceeding.
1. Locate the Backup Operator Interface (BOI) on the enclosure front door. Disconnect
wires and remove the BOI module.
2. Replace the BOI module with a cover plate (catalog number 151X1236AXG01) and
attach with provided nuts (catalog number 104X214AA 206)
Ø To install the door label
♦ Place the door label (catalog number 259B2451RHP1) on top of and covering the
existing door label on the left-hand door.
Ø To install the door pocket drawing holder

1. Locate the clear door pocket (catalog number 104X905CA 016) and attach it to the
inside of the left door.
2. Open the <R> core door and remove the door pocket drawings (if present). Repeat
this step for the <S>, <T>, and <C> cores.
3. Place all door pocket drawings into the door pocket installed in step 1.
Note If space is required to work on the enclosure, remove the enclosure front doors.
If removed, re-attach the doors to the enclosure at the end of the retrofit.
GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-1

Disassembling Cores S, R, and T
For TMR, begin the retrofit procedure with the S core located in the upper left corner of
the enclosure, then proceed to the R core, the T core, and the C core, respectively. The
retrofit of the C core is discussed later in this document. For simplex, begin the retrofit
with the R core. Cores S, R, T, and C are to be disassembled and reassembled with new
hardware. Each core is to be disassembled and reassembled before starting the next core.
Ø To disassemble the core panel

1. Remove the hinged doors from each core identified in the following photo.
2. Save the screws. One screw is used in each of the four cores later in the process.
3. Discard the four core doors.

On the TMR panel, cores C, R, and S have nine board locations as displayed in the
following drawing. Core T does not have locations 7, 8 or 9. Cores S and T are not
included for simplex.
Core PWA Locations

No ribbon cable connectors are keyed; therefore,
ribbon cables can be connected backwards during the
reassembly procedure. When the ribbon cables are
reconnected, the red strip on the ribbon cable must be
positioned to the left as viewed from the front of the core.
Caution The red stripe is associated with connector pins 1 or 2.
Refer to the photo below.
All cables that remain in the core must maintain their

routing paths to assure the thermal integrity of the cores.
Caution
Most of the cables in the retrofit procedure are

reconnected to new boards. Do not allow the
disconnected cables to fall into the core.
Caution
Ø To disassemble cores R, S, and T respectively
1. Remove the plastic bezel from the SLCC board and discard. Disconnect cables 3PL,
2PL, and ARCPL from the SDCC board. Remove the four screws holding SLCC
in place and remove the SLCC board.

2. From the SDCC board, disconnect cables 3PL, 7PL, 8PL, 1PL and 2PL (7PL and 1PL
are not included for simplex). Remove the SDCC board from the hinged plastic
frame at location 1.
3. At location 1, pull the right and left release latches forward to allow the plastic board
frames to hinge downward and reveal the TCQA board.
4. Disconnect cables JD, JE, 2PL JG, JF, 3PL, JA, and JB from the TCQA board (JG
is not used for simplex panels containing a TBQD). Cables JD, JE, JG, JF, JA, and
JB are reconnected to a new board in location 2, so secure the cables to keep them
from falling into the core.

5. Remove the location 1-2 hinged plastic frame, including the TCQA board, by
removing the two large hex screws located on the core left and right sheet metal
sides. Save the hex screws for later use.
Note Do not let the hex screws fall into the cores. If lost, additional screws are
provided with the control modules.
Note If the optional TCQB board is not present, skip step 6.
6. From the TCQB board at location 3, disconnect cables 3PL, 2PL, JLL, and JKK.
Remove the TCQB board from the plastic frame.
7. At location 3-4, hinge the board frame downward. This reveals the TCQC board in
location 4, and the TCPS power supply in location 5. Do not remove the TCQC board
from location 4. Refer to the photo on the following page.
Note For ease of the assembly/reassembly process, cables JFF, JGG, JC, JE, JH, and
8PL can be disconnected from the TCQC board; however, they must be reconnected.
Do not allow the cables to drop into the core.

correct revision.

Attention
8. Disconnect and discard cables ARCPL, 1PL, 6PL, and 7PL from the TCQC board.
9. Disconnect cables JBU, CARC, and VARC and tie back out of the way. These cables
will not be reconnected, but cannot be removed from the core since they are tied
within the enclosure cable runs.

10. Disconnect cable 2PL and JX. The JX cable is reconnected later in the process.
11. At location 5, remove the 2PL cable from the TCPS board and discard. Disconnect
the JC, J1, X1, JP1, and JP2 (JP2 is not included for simplex) cables and tie back out
of the way. These cables are reconnected later in the process.
12. Remove the TCPS board from the plastic board frame.

Reassembling Cores R, S, and T
The following instructions are used to reassemble the R, S, and T cores. The power supply
module is the first item to be installed in the core.
Ø To reassemble cores S, R, and T

1. Before placing the power supply (catalog number 259B2451EZG01) in the core,
plug cable 2PL (part number 336A4940FL G01), supplied with core material, into
connector 2PL, located on the MVRP board. The red wire in the 2PL cable must
align with Pin 1 on the board.
Note If there is not enough cable length to allow the connections, connect the cables
after the power supply is seated.
2. Locate connectors JP1 and JP2 on the MVRP board and the NYOGEL 10cc syringe
found in the field service kit.
3. Lubricate JP1 and JP2 by inserting the male pin into the syringe tip opening. There
should be sufficient lubricant in the tip to allow the coating of two pins before the
syringe plunger needs to be depressed slightly. If lubricant is exposed on the outside
of the tip, remove excess by wiping with a clean cloth. Verify that the lubricant does
not extrude out and touch adjoining pins.
Note Lubrication is needed to prevent tin-to-tin fretting corrosion. Refer to TB04931

and GEI–100304 Lubricating Tin/Lead Electrical Connectors Used on Printed Wiring
Boards for further information.

Note To avoid damage, do not push on the heat sinks when installing the power
supply. Refer to the next photo.

4. At location 5, position the power supply at a 30-degree angle in the plastic frame. The
bottom of the power supply must make contact with the three plastic tabs located at
the bottom of the frame.
5. Align the three bottom frame posts with the power supply postholes. While holding
the bottom power supply frame plate in place and maintaining posthole alignment,
gently lower the power supply module until it makes contact with the three upper
tabs. Apply pressure, and allow the supply to rest on upper tabs.
6. While continuing to hold the bottom power supply frame plate, seat the bottom of
the power supply by pushing tab 1, then tab 2 and tab 3. Repeat walking across the
tabs until the power supply is properly seated into the frame. This usually takes
three or four cycles. Use gentle to moderate pressure on the power supply frame to
seat the module easily.
7. Repeat step 4 to seat the top of the power supply module. Verify that it is fully
seated before continuing.
8. Connect cables JP1, JP2, JC, and X1 into the MVRP power board.

9. Connect power cable J1 to the short pigtail connector J1-125VDC located on the lower
right of the power supply. J1 is an existing cable from the disassembly procedure.
The longer pigtail cable with connector JPDV-J28 is connected later in this procedure.
10. Attach the power supply ground wires (green/yellow) from the PS1 connector P1-Gnd
and PS2 connector P1-Gnd to the enclosure (PE) ground bus located in the bottom
right corner of the enclosure. Verify that cables JP1, JP2, 2PL, X1, P1-Gnd (PS1),
and P1-Gnd (PS2) are connected to the power supply.
R, S, T, and C Core Power Supply Ground Wire Paths to PE Ground

Ø To connect the cables from power supply to the TCQC board

correct revision.

Attention
1. At location 4, connect cable 2PL from the power supply to the 2PL connector on the
TCQC board. Refer to the cable connection drawings at the end of this document.
Note All ribbon cables in the R, S, and T cores are positioned with the red strip on
the left side of the cable (viewing the core from the front). This includes the 2PL cable
even though it is not a ribbon cable.
2. Connect cable 19PL, supplied with core material, to the TCQC board. The JX cable
that was connected to the TCQC board is connected to another board later in this
process. Secure the JX cable for later reconnecting. Verify that the cables connected
to the TCQC board are 2PL, JC, JE, 19PL, JFF, JGG, JH, and 8PL.
Verify that 19PL is plugged into the correct location;

7PL and 19PL are located next to each other and look
identical.
Attention
Location 4 – TCQC Board With Cables Attached

Ø To install the MVRB
Note If the optional MVRB board is not present, skip this procedure.
1. At location 3, hinge the location 3-4 plastic frame with the TCQC board into the
upright (closed) position. The TCQC board is on the rear side of the plastic frame.
2. Place the MVRB assembly in location 3. Record the IS200MVRB board bar code.
IS210MVRB in S, R, and T Cores, Location 3

IS210MVRB Diagram
IS210MVRB Board with Cables Connected

3. Connect the purple high-speed serial link HSSL cable (catalog number
336A4940GBPxxx) to BHSLA-J3. Leave the other end free to connect later in the
process.
Cable Material # Color

R Core AHSLA 336A4940GBP012 yellow
R Core BHSLA 336A4940GBP028 purple
S Core AHSLA 336A4940GBP014 yellow
S Core BHSLA 336A4940GBP029 purple
T Core AHSLA 336A4940GBP016 yellow
T Core BHSLA 336A4940GBP030 purple
4. Connect the new cable P5 (part number 336A4940FP G02), supplied with core
material, to MVRB-P5 and leave the other end free to connect later in the process.
5. Reconnect the following cables remaining; JLL and JKK.
6. Verify that the cables connected to the MVRB board are P5, JLL and JKK, and that
the purple HSSL cable is attached to BHSLA-J3.
7. Verify that jumpers JP1 through JP6 (proximity/acceleration) and JP8 through JP11
(20/200 milliamp outputs) are set correctly. The TCQB jumpers J5 through J10
(20mA and S is position 1,2) become MVRB jumpers JP1 through JP6. The TCQB
jumpers J1 through J4 become MVRB jumpers JP8 through JP11.
Ø To install new stop brackets

1. From the inside surface of the core sheet metal sides, remove the single Keps nut that
attaches the slide latch bracket to the core side.
2. Align one stop bracket with the screw and the pop rivet as shown in drawing. Reapply
the Keps nut and tighten.
3. Attach the second stop bracket on the opposite core wall using the same procedure.

Ø To install the S, R, and T control modules
R Core Control Module - Redundant ARCNET
Note The following steps should be completed on S, R, and T respectively before

proceeding to the C core.
Each core has a control module to be assembled in location 1 as follows:
S Core control module (catalog number 259B2451EWG01)

T Core control module (catalog number 259B2451EXG01)
R Core control module, redundant ARCNET (catalog number 259B2451EVG01)
R Core control module, single ARCNET (catalog number 259B2451EVG02)

The control modules are relatively heavy. Take care
when handling and placing in the cores.
Caution
1. Each control module has a plastic board frame attached to the rear of the metal
mounting plate. The rear side of the board frame is vacant. Attach the control module
with the vacant side towards the rear of the core using the two hex screws removed in
step 2 of the disassembly procedure. Insert each hex screw through the slot in the
sheet metal side into the embedded nut contained in the side corners of the frame.
Note It is important that both hex screws be tightened to the point that the shoulder of
the screws are in contact with the plastic frame.
2. Record the catalog number of the installed R core control module. This number is
required for Ethernet Cable routing installation.
Typical Control Module

3. At location 1, with the control module attached, rotate the module downward until it
comes in contact with the stop brackets.
Control Module Hinged Downward

Ø To install the MVRA board
1. Position the MVRA board in the vacant frame. Record the MVRA board bar code.
2. Connect the existing cables JD, JE, JG, JA, JB, JF, and 8PL.
3. Connect the new cable JP4 (part number 336A4940FN G01), supplied with core
material, to the MVRA board. The free end of JP4 is attached later in the procedure.
4. Connect the new 19PL cable (part number 336A4940GD G01), supplied with core
material, from the TCQC board to MVRA-19PL by routing the cable under the plastic
carrier to the MVRA board.
5. Connect the yellow high-speed serial link HSSL cable (catalog number
336A4940GBPxxx) to connector AHSLA-J3. The free end is attached later in the
procedure.
HSSL cables (Catalog Numbers 336A4940GBG01 and 336A4940GBG02)

R Core AHSLA 336A4940GBP012 yellow
R Core BHSLA 336A4940GBP028 purple
S Core AHSLA 336A4940GBP014 yellow
S Core BHSLA 336A4940GBP029 purple
T Core AHSLA 336A4940GBP016 yellow
T Core BHSLA 336A4940GBP030 purple

6. Verify that the cables connected to the MVRA board include JD, JE, JG, JA, JB, JF,
8PL, JP4, 19PL, and the yellow HSSL cable AHSLA.
IS200MVRA Diagram
MVRA Position in Core Location 2

Ø Cable routing to the S, R, and T control modules
1. Route cable JPDV-J28 (pigtail) from the power supply in location 5 under the board
frames to the front of the control module, and attach it to connector JP28 on the
JPDV board.
2. Locate connector JX1A on the JPDV board and the NYOGEL 10cc syringe found
in the field service kit.
3. Lubricate JX1A by inserting the male pin into the syringe tip opening. There should
be sufficient lubricant in the tip to allow coating of two pins before the syringe
plunger needs to be depressed slightly. If lubricant is exposed on the outside of the
tip, remove excess by wiping with a clean cloth. Verify the lubricant does not extrude
out and touch adjoining pins.
4. Route cable JX under the board frames to the front of the control module, and attach
it to connector JX1A on the JPDV board.
5. Route HSSL cables AHSLA (yellow) and BHSLA (purple) under the board frames
to the front of the control module and attach them to the UCSA1-R/SL1 and the
UCSA1-S/SL2, respectively. (BHSLA/UCSA1-S is required only when an MVRB
board is present)
6. Route cables JP4 and P5 from the MVRA board and the MVRB board to the front
of the control module, and attach them to the JPDV board connectors JP4 and JP5.
(JP5 is required only when an MVRB board is present)
Control Module in Location 1

7. Reposition the control module in the closed latched position. Verify that the following
cables are connected: JP4, JP5, JX, JP28, UCSA1-R, and UCSA1-S.
8. Install the ground wire (part number 259B2451EU P02), supplied with core material,
from the JPDV board connector PB1 to the bottom hinge hole where the core door
was removed.

Disassembling Core C
Ø To disassemble core C
1. Remove the plastic bezel from the SLCC board and discard. Disconnect cables 3PL,
2PL, and ARCPL from the SLCC board. Remove the four screws holding SLCC
in place and remove the SLCC board.
2. Disconnect cables 3PL, 6PL, 8PL, and, 2PL from the SDCC board. Remove the
SDCC board from the hinged plastic frame.

3. Locate the CTBA terminal board in the C core. Disconnect cables JEE, 6PL, and
8PL. Discard cable 6PL and 8PL.
4. From location 2, pull the right and left release latches forward to allow the board
frames to hinge downward and reveal the TCCA board. Disconnect cables JAA, JBB,
JCC, JDD, JEE, JAR, JAS, JAT, 2PL, 3PL, and JC. Discard cable JEE.
5. Tie the cables back out of the way so that they can be reconnected to a new board in
location 2. Do not allow the cables to fall into the core.
6. Remove the location 1-2 board frame by removing the two hex screws located on the
outside of the core left and right sheet metal sides. Save the hex screws for use later.
Note TCCB is an optional board. If TCCB is not present, skip steps 7-9, and discard
the cable 3PL disconnected in step 3.

7. From location 3, disconnect cables JMP, JHH, JII, 3PL, and 2PL from the TCCB
board. No cables should be connected to the board. Remove and discard cable 3PL.
Tie JMP back out of the way so that it can be reconnected to a new board later.
8. Remove the TCCB board from the board frame.
9. Hinge the location 3-4 board frame downward. No board should be positioned in
location 4. Do not remove the board frame from the core.
Note Cables JHH, JII, and JMP are optional.

10. The TCPS board should be visible in location 5. Remove and discard the 2PL cable.
Disconnect cables JC, J1, X1, and JP1. Tie these cables out of the way so that they
can be reconnected later. Do not allow the cables to fall into the core.
11. Remove the TCPS board from the plastic board frame.

Reassembling Core C
Use the following instructions to reassemble the C core. The power supply module is
the first item to be installed in the core.
Ø To reassemble core C
1. Before placing the power supply (catalog number 259B2451EZG01) in the core,
plug cable 2PL (part number 336A4940FL G01), supplied with core material, into
connector 2PL, located on the MVRP board. The red wire in the 2PL cable must
align with Pin 1 on the board.
Note If there is not enough cable length to allow the connection, connect the cable
after the power supply is seated.
2. Locate connector JP1 on the MVRP board and the NYOGEL 10cc syringe found
3. Lubricate JP1 by inserting the male pin into the syringe tip opening. There should be
sufficient lubricant in the tip to allow coating of two pins before the syringe plunger
needs to be depressed slightly. If lubricant is exposed on the outside of the tip,
remove excess by wiping with a clean cloth. Verify the lubricant does not extrude
out and touch adjoining pins.
Note Lubrication is required to prevent tin-to-tin fretting corrosion. Refer to TB04931

Technical Bulletin and GEI–100304 Lubricating Tin/Lead Electrical Connectors Used
on Printed Wiring Boards for further information.

4. Position the power supply module in the plastic frame (refer to the section,
Reassembling Cores S, R, and T, Steps 4 through 7). Verify that it is fully seated
before continuing.
Note To avoid damage, do not push on the heat sinks when installing the power
supply. Refer to the photo below. Press only on the module sheet metal to seat it.
5. Connect cables JC, JP1, and X1 to the MVRP board.

6. Attach the J1 power cable to the short pigtail connector J1-125 V dc located on
the lower right of the power supply. J1 is an existing cable from the disassembly
procedure. The longer pigtail cable with the connector labeled JPDV-J28 is attached
later in this procedure.
7. Attach power supply ground wires (green/yellow) from power supply PS1, connector
P1-Gnd and power supply PS2, connector P1-Gnd to the enclosure (PE) ground bus
located in the bottom right corner of the enclosure. Refer to the drawings R, S, T, and
C Core Power Supply Ground Wire Paths to PE Ground.
8. Verify that the cables connected to the power supply are JP1, 2PL, JC, X1, P1-Gnd
(PS1), and P1-Gnd (PS2).
9. Hinge the location 3 and 4 of the frame into the closed position.
Note There should be no boards positioned in location 3 or 4 of the frame.

Ø To install new stop brackets on the C core
1. From the inside surface of the core sheet metal sides, remove the single Keps nut that
attaches the slide latch bracket to the core side.
2. Align one stop bracket with the screw and the pop rivet as shown in the drawing.
Reapply the Keps nut and tighten.
3. Attach the second stop bracket on the opposite core wall using the same process.

Ø To install the C core cables
Note JHH and JII are optional cables. If the Mark V did not contain a TCCB board,
skip this procedure.
1. Since existing cables JHH and JII are too short to reach their new destinations on the
MVRC board, they must be replaced. Disconnect the JHH and JII cables from the
TBCB board in location 7 and discard.
2. Route the new cables JHH (part number 336A4940GC G01) and JII (part number
336A4940GL G01), found with the C core material, using the same paths previously
taken by the JHH and JII cables.
Ø To install the C control modules
C Core Control Module – without D Core Analog I/O or DD Core
The C core has a control module to be assembled in location 1 as follows:
Systems without D core analog I/O or DD core:
• C Core control module (catalog number 259B2451EYG01)
Systems with D core analog I/O and/or DD core:
• C Core control module (catalog number 259B2451EYG02)

The control modules are relatively heavy. Take care
when handling and installing into the cores.
Caution
1. The C core control module has a plastic board frame attached to the rear of the metal
mounting plate. The rear side of the board frame is vacant. Attach the control module
with the vacant side towards the rear of the core using the two hex screws removed in
step 2 of the disassembly procedure. Insert each hex screw through the slot in the
sheet metal side into the embedded nut contained in the side corners of the frame.
Note It is important that both hex screws be tightened to the point that the shoulder of
the screws is in contact with the plastic.
2. Record the catalog number of the installed C core control module. This number is
required for Ethernet cable routing installation, as well as other steps.
3. At location 1, with the control module attached, rotate the module downward until it
comes in contact with the stop brackets.
Control Module Hinged Downward

Ø To install the MVRC board
1. Position the MVRC board in the vacant frame (location 2) in the rear of the control
module. Record the MVRC board bar code.
2. Connect existing cables 2PL and JC from the power supply to the MVRC board.
Connect existing cables JAA, JBB, JCC, JDD, JAR, JAS, JAT, and optional JMP.
Note Align the red wire in the 2PL cable with pin 1 on the 2PL connector of the
MVRC board.
3. Remove the cable JPD from the CTBA connector in location 6, and reconnect to
the JPD connector on the MVRC board.
4. Attach the yellow HSSL cable to the connector CHSLA-J3 located on the MVRC
board. The free end is attached later in the procedure.
HSSL cables (Catalog Number 336A4940GBG01)

C Core CHSLA 336A4940GBP018 yellow
5. Verify that the cables connected to the MVRC board include 2PL, JC, JAA, JBB,
JCC, JDD, JAR, JAS, JAT, JPD, the yellow HSSL cable CHSLA, and optional JHH,
JII, and JMP.
IS210MVRCH1A Board

IS210MVRC Board Positioned in Location 2

IS210MVRC Board

Ø To route cables to the C control module
1. From the power supply module in location 5, route the cable JPDV-J28 pigtail from
the power supply under the board frames in front of it to the front of the control
module, then attach it to connector JP28 on the JPDV.
2. Route HSSL cables CHSLA (yellow Ethernet cable) under the board frames to the
front of the control module, then connect it into the UCSA1-R/SL1, C control module.
Note If the unit does not have a CD core, skip steps 3, 4, and 5.
3. Locate connector JX1A on the JPDV board and the NYOGEL 10cc syringe found
4. Lubricate JX1A by inserting the male pin into the syringe tip opening. There should
be sufficient lubricant in the tip to allow coating of two pins before the syringe
plunger needs to be depressed slightly. If lubricant is exposed on the outside of the
tip, remove excess by wiping with a clean cloth. Verify that the lubricant does not
extrude out and touch adjoining pins.
5. Disconnect cable JX from the CTBA in location 6, and attach it to connector JX1A
on the JPDV.
6. Reposition the control module to the closed latched position. Verify that the JX,
JP28, and UCSA1-R cables are connected.
7. Install ground wire (part number 259B2451EU P02), supplied with core material,
from the JPDV board connector PB1 to the bottom hinge hole where the core door
was removed.

Modifying the TBQC Board
Ø To modify the TBQC board (G1AAA or G1ABB)
1. Remove the Metal Oxide Varistors (MOVs) MV33 and MV34 from the TBQC board
by clipping the leads of each MOV without damaging the surface of the Printed Board
Assembly (PWA) or the components surrounding the MOVs.
There can be up to two TBQC boards, one located in the S and one located in the R cores
in location 9 (for simplex R core only). Each form letter must be changed from G1 to G2.
New labels are supplied with the core material.

2. Apply the new label directly on top of the existing label.
Existing label: DS200TBQCG1AAA

New label: DS200TBQCG2AAA
Or
Existing label: DS200TBQCG1ABB

New label: DS200TBQCG2ABB
Note When the new label is applied, the last three digits of the catalog number on the
label should match the last three digits of the catalog number on the PWA.

Modifying the TBQD Board
There can be a TBQD board located in the S core in location 7 for TMR and in the R
core in location 7 for simplex. Each form letter must be changed from G1 to G2. New
labels are supplied with the core material.
Ø To modify the TBQD board (G1A**)

1. Remove the Metal Oxide Varistors (MOVs) MV46 and MV47 from the TBQD board
by clipping the leads of each MOV without damaging the surface of the Printed Board
Assembly (PWA) or the components surrounding the MOVs.
2. Locate the DS200TBQDG1 catalog number. Depending on the board revision, it is

positioned at the far left or bottom center of the terminal board.

3. Apply the new label directly on top of the existing catalog number. The last three
digits in the existing catalog number must remain visible.
Existing label: DS200TBQDG1A**
New label: DS200TBQDG2
Note When the new label is applied, the last three digits of the catalog number on the
TBQD must be visible.

Modifying the Power Distribution Module (PDM)
The enclosure material includes a bracket/label (catalog number 342A4909ABG1) that
must be added to the PDM.
Ø To modify the PDM

1. Replace the fuses in fuse holders labeled F1 through F10.

2. From the Enclosure Level Material package (catalog number 259B2451SRG01), add
the bracket/label (catalog number 342A4909ABG1) to switches SW1 and SW3.
• Remove the nuts from the SW1 and SW3 switches.

• Remove the metal OFF/ON labels from the SW1 and SW3 switches
• Place the bracket/labels on top of the three switches, then replace the OFF/ON labels
and the nuts. Snug the nuts to the switches at approximately four inch/lbs.
3. Apply the self-adhesive catalog number label (DS200TCPDG4BEC) over the top of
the catalog number (DS200TCPDG1BEC) that is silk-screened on the PWA. The
self-adhesive label is found in the Enclosure Level Material package (catalog number
336A4940HBP01).

Upgrading TCEA and TCDA PROMs
The PROMs on the TCEA and TCDA are upgraded to a PROM revision based on original
site configuration. Refer to the section, PROM Materials. The TCDA cards are located
in the <QD1>, <QD2>, <CD>, and <DD> core. The TCEA cards are located in the
<P> protective core.
Ø To upgrade the TCEA and TCDA PROMs

1. Using the Mark V PROM puller (catalog number PDTL1000CHIPEXT ), remove
the PROM from each TCEA and replace with the new PROM (catalog number
DS200TCEAG1XXX).
2. Using the Mark V PROM puller (catalog number PDTL1000CHIPEXT), remove
the PROM from each TCDA and replace with the new PROM (catalog number
DS200TCDAG1XXX).
DS200 TCEA Board

DS200 TCDA Board

Notes

Chapter 3 Ethernet Cable Routing
Redundant ARCNET
This installation has the following control modules.
Redundant EX2000 ARCNET control includes:
• R core control module catalog number – 259B2451EVG01

• C core control module catalog number – 259B2451EYG01
• No D core analog I/O or DD core
Use the following table to run the Ethernet cables from core to core. The cables are in the
enclosure material container (catalog number 259B2451SRG01).
TMR
Cable Catalog Number From Point To Point
336A4940GBP001 R-SW-5 C-UCSA1-E1
336A4940GBP002 R-SW-6 S-UCSA2-R
336A4940GBP003 R-SW-7 T-UCSA2-R
336A4940GBP004 S-SW-4 C-JA1-E1
336A4940GBP005 S-SW-5 C-JB1-E1
336A4940GBP006 S-SW-6 R-UCSA2-S
336A4940GBP007 S-SW-7 T-UCSA2-S
336A4940GBP008 T-SW-4 C-JB1-E2
336A4940GBP009 T-SW-5 C-UCSA1-E2
336A4940GBP010 T-SW-6 S-UCSA2-T
336A4940GBP011 T-SW-7 R-UCSA2-T
Simplex
336A4949FZP001 R-SW-1 R-UCSA1-E1
336A4949FZP002 R-SW-2 R-JB1-E1
336A4949FZP003 R-SW-3 R-UCSA2
336A4949FZP004 R-SW-4 R-JA1-E1
336A4940GBP031 R-SW-6 C-JA1-E1
GEH-6731E Chapter 3 Ethernet Cable Routing Instruction Guide 3-1

From Point (example: R-SW-5)
• R is the R core
• SW is the Ethernet switch
• 5 is the port number on the switch
To Point (example: C-UCSA1-E1)
• C is the C core
• UCSA1 is the PMVE processor
• E1 is the first Ethernet port on the UCSA
The Ethernet cableway supports provide two functions: routing Ethernet cables from
core to core, and providing a routing path to the space between location 7 and location
8 for holding the excess Ethernet cable.

Ø To route the Ethernet cable
1. Remove the shield tie bars in the three locations as shown in the drawing below (A,
B, and C, for simplex C only). A total of six bars are removed. Do not disconnect
the shield wires from the bars.
2. Mount the Ethernet cable supports in the locations shown using the existing hardware
that holds the sheet metal for board location 7.
Note Remove the cord ties that provide the hinge function for location 7 and 9 if they
interfere with the mounting of the Panduit cable supports.
Control Panel Ethernet Cable Routing

3. The Ethernet cables routed to all UCSA controller modules should be dressed to
prevent them from touching the inside of the enclosure doors.
4. After all Ethernet cables are routed and dressed, snap on the cable covers and reattach
the six shield tie bars. If the screws that attach the shield wire to the shield tie bar
are too long and interfere with the cableway cover, use the metal spacer bars (catalog
number 151X1202LTP01) between the bar and the mounting surface.
5. Remove or print the cable connection drawings for redundant ARCNET and place in
the door pocket that was installed in the section Installation Setup.
Note Refer to the site-specific cable connection drawings.

Single ARCNET
Note If the C Core control module catalog number is 259B2451EYG03, the unit does
not have a CD core. The following cables are not required: 336A4940GBP005 and
336A4940GBP008. Cables display in bold in the table below.
This installation has the following control modules.
Single EX2000 ARCNET control includes:
• R Core control module catalog number – 259B2451EVG02
Use the following table to run the Ethernet cables from core to core. The cables are in the
enclosure material container (catalog number 259B2451SRG01).
TMR
336A4940GBP002 R-SW-6 S-UCSA2-R
336A4940GBP003 R-SW-7 T-UCSA2-R
336A4940GBP004 S-SW-4 C-JA1-E1
336A4940GBP027 R-SW-4 C-JA1-E2
336A4940GBP005 S-SW-5 C-JB1-E1
336A4940GBP006 S-SW-6 R-UCSA2-S
336A4940GBP007 S-SW-7 T-UCSA2-S
336A4940GBP008 T-SW-4 C-JB1-E2
336A4940GBP009 T-SW-5 C-UCSA1-E2
336A4940GBP010 T-SW-6 S-UCSA2-T
336A4940GBP011 T-SW-7 R-UCSA2-T
Simplex
336A4949FZP001 R-SW-1 R-UCSA1-E1
336A4949FZP002 R-SW-2 R-JB1-E1
336A4949FZP003 R-SW-3 R-UCSA2
336A4940GBP027 R-SW-4 R-JA1-E2
336A4940GBP031 R-SW-6 C-JB1-E1

From Point (for example: R-SW-5)
• R is the R core
• SW is the Ethernet switch
• 5 is the port number on the switch
To Point (example: C-UCSA1-E1)
• C is the C core
• UCSA1 is the PMVE UCSA
• E1 is the first Ethernet port on the UCSA
The Ethernet cableway supports provide two functions: routing Ethernet cables from
core to core, and providing a routing path to the space between location 7 and location
8 for holding the excess Ethernet cable.

Ø To route the Ethernet cable
1. Remove the shield tie bars in the three locations as shown in the drawing below (A,
B, and C, for simplex C only). A total of six bars are removed. Do not disconnect
the shield wires from the bars.
2. Mount the Ethernet cable supports in the locations shown in the drawing below (A, B,
and C) using the existing hardware that holds the sheet metal for board location 7.
Note Remove the cord ties that provide the hinge function for location 7 and 9 if they
interfere with the mounting of the Panduit cable supports.
Control Panel Ethernet Cable Routing

3. The Ethernet cables routed to all UCSA controller modules should be dressed to
prevent them from touching the inside of the enclosure doors.
4. After all Ethernet cables are routed and dressed, snap on the cable covers and reattach
the six shield tie bars. If the screws that attach the shield wire to the shield tie bar
are too long and interfere with the cableway cover, use the metal spacer bars (catalog
number 151X1202LTP01) between the bar and the mounting surface.
5. Remove or print the cable connection drawings for redundant ARCNET and place in
the door pocket that was installed in the section Installation Setup.
Note Refer to the site-specific cable connection drawings.

GE Energy
1501 Roanoke Blvd.
1 540 387 7000

www.geenergy.com

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GE Energy GEH-6731E

Mark* V to Mark Ve Control

© 2008 – 2010 General Electric Company, USA. All rights reserved.

* Trademark of General Electric Company

We welcome comments and suggestions to make this publication more useful.

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........................................................................................Fold here first........................................................................................

Indicates a procedure, condition, or statement that, if not

Indicates a procedure, condition, or statement that, if not

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Note Indicates an essential or important procedure, condition, or statement.

A margin note is used to

1 Contents Mark* V to Mark Ve Control Steam Retrofit

Mark V TMR steam systems:

Single ARCNET® controller

Redundant ARCNET controller

Mark V simplex steam systems:

Single ARCNET controller

• <R> cores with a single analog I/O card (TCQA)

Redundant ARCNET controller

• <R> cores with a single analog I/O card (TCQA)

GEH-6731E Chapter 1 Overview Instruction Guide 1-1

R core material 259B2451SMG01 – Redundant ARCNET

1-2 Mark* V to Mark Ve Control Steam Retrofit

Contact the GE project manager or field engineer

Verify that the DS200TCQCG# in Location 4 is the

All TCQCG#A boards must be replaced with TCQCG#B

GEH-6731E Chapter 1 Overview Instruction Guide 1-3

Contact the GE project manager or field engineer

1-4 Mark* V to Mark Ve Control Steam Retrofit

GEH-6731E Chapter 1 Overview Instruction Guide 1-5

S Core (TMR Only)

T Core (TMR Only)

1-6 Mark* V to Mark Ve Control Steam Retrofit

Ø To install the door label

Ø To install the door pocket drawing holder

GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-1

Ø To disassemble the core panel

2-2 Mark* V to Mark Ve Control Steam Retrofit

Core PWA Locations

GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-3

All cables that remain in the core must maintain their

Most of the cables in the retrofit procedure are

2-4 Mark* V to Mark Ve Control Steam Retrofit

GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-5

Note If the optional TCQB board is not present, skip step 6.

Verify that the DS200TCQCG# in Location 4 is the

All TCQCG#A boards must be replaced with TCQCG#B

2-6 Mark* V to Mark Ve Control Steam Retrofit

GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-7

Ø To reassemble cores S, R, and T

Note Lubrication is needed to prevent tin-to-tin fretting corrosion. Refer to TB04931

2-8 Mark* V to Mark Ve Control Steam Retrofit

GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-9

2-10 Mark* V to Mark Ve Control Steam Retrofit

R, S, T, and C Core Power Supply Ground Wire Paths to PE Ground

GEH-6731E Chapter 2 Core Retrofit Procedures Instruction Guide 2-11

Verify that the DS200TCQCG# in Location 4 is the

All TCQCG#A boards must be replaced with TCQCG#B

Verify that 19PL is plugged into the correct location;

Location 4 – TCQC Board With Cables Attached

2-12 Mark* V to Mark Ve Control Steam Retrofit