Geh-6730 e

GE Energy GEH-6730E
Mark* V to Mark Ve Control

Gas 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.
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 – 2010 General Electric Company, USA. All rights reserved.

Revised: 100830
Issued: 070515
* Trademark of General Electric Company

ARCNET is a registered trademark of Datapoint Corporation.
To:
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Safety Symbol Legend
Indicates a procedure, condition, or statement that, if not strictly

observed, could result in personal injury or death.
Warning
Indicates a procedure, condition, or statement that, if not strictly

observed, could result in damage to or destruction of equipment.
Caution
Indicates a procedure, condition, or statement that should be

strictly followed in order to optimize these applications.
Attention
Contents
Chapter 1 Overview ................................................................................................................ 1-1
Materials List .......................................................................................................................................... 1-2
R Core Materials ............................................................................................................................... 1-3
S Core and T Core Materials................................................................................................................ 1-4
C Core and D Core Materials ............................................................................................................... 1-5
Enclosure Materials ........................................................................................................................... 1-6
Field Service Kit Materials .................................................................................................................. 1-7
PROM Materials ............................................................................................................................... 1-7
Bar Code Worksheet ................................................................................................................................. 1-8
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 ............................................................................................................................. 2-26
Reassembling Core C.............................................................................................................................. 2-30
Disassembling Core D............................................................................................................................. 2-39
Reassembling Core D.............................................................................................................................. 2-39
Modifying the TBQC Board ..................................................................................................................... 2-48
Modifying the TBQD Board .................................................................................................................... 2-50
Modifying the TBQG Board..................................................................................................................... 2-52
Modifying the Power Distribution Module (PDM) ........................................................................................ 2-53
Upgrading TCEA and TCDA PROMs ........................................................................................................ 2-55
Chapter 3 Ethernet Cable Routing ........................................................................................ 3-1
Ethernet Cable Routing – Installation 1......................................................................................................... 3-2
Ethernet Cable Routing Installation 2 ........................................................................................................... 3-7
Ethernet Cable Routing Installation 3 ......................................................................................................... 3-12
Ethernet Cable Routing Installation 4 ......................................................................................................... 3-17
1 Contents Mark* V to Mark Ve Control Gas Retrofit

Chapter 1 Overview
Follow all GE and local safety Mark V control is a second-generation microprocessor-based turbine control. A retrofit
procedures before proceeding. 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 control systems to Mark Ve control systems.
The following are Mark V TMR control systems that do not use <D> core analog I/O
or <DD> core:
• 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 TCQF)
− <C> core with single or dual analog I/O cards (TCCA and or TCCB)
• Redundant ARCNET controller
The following are Mark V TMR control systems that require <D> core analog I/O and
or <DD> core:
• Single ARCNET controller

The following are Mark V simplex control systems that do not use <D> core analog
I/O or <DD> core:
• Single ARCNET controller

− <R> core with a single analog I/O card (TCQA)
− <R> core with two analog I/O cards (TCQA and TCQF)
− <R> core with a single analog I/O card (TCQA)
− <R> core with two analog I/O cards (TCQA and TCQF)
GEH-6730E Chapter 1 Overview Instruction Guide 1-1

Materials List
A set of material for each R, S, T, C, and optional D 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.
Control systems with a TCQF board include the following:
R core material 259B2451RMG01 – Redundant ARCNET

259B2451RMG02 – Single ARCNET
S core material 259B2451RNG01
T core material 259B2451RPG01
C core material 259B2451RQG01 – Without D core analog I/O
and/or DD core
Enclosure level material 259B2451RRG01 – TMR
259B2451RRG02 – Simplex
Control systems that include a D core analog I/O and/or DD core are supplied with the
following C and D core material:
C core material 259B2451RQG02

D core material 259B2451RYG01 – Without D core analog I/O
259B2451RYG02 – With D core analog I/O
Control systems without a TCQF board include the following:
R core material 259B2451RMG03 – Redundant ARCNET

259B2451RMG04 – Single ARCNET
S core material 259B2451RNG02
T core material 259B2451RPG02
C core material 259B2451RQG01 – Without D core analog I/O
and/or DD core
Enclosure level material 259B2451RRG01 – TMR
259B2451RRG02 – Simplex
Control systems that include a D core analog I/O and/or DD core are supplied with the
following C and D core material:
C core material 259B2451RQG02

D core material 259B2451RYG01 – Without D core analog I/O
259B2451RYG02 – With D core analog I/O
1-2 Mark* V to Mark Ve Control Gas Retrofit

The following tables lists materials needed to perform the retrofit. Separate the materials
by core type and verify that all items have been included.
R Core Materials
R core Catalog number R core Catalog number
259B2451RMG01 259B2451RMG03
Control module 259B2451EVG01 Control module 259B2451EVG01
PWA assembly IS210MVRAH1A PWA assembly IS210MVRAH1A
PWA assembly IS210MVRFH1A / 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 G01
PB1 ground cable 259B2451EU P02 PB1 ground cable 259B2451EU P02
Label, TBQC 336A4940GNP01 Label, TBQC 336A4940GNP01
R core Catalog number R core Catalog number
259B2451RMG02 259B2451RMG04
Control module 259B2451EVG02 Control module 259B2451EVG02
PWA assembly IS210MVRFH1A / IS210MVRBH1A
JP5 cable 336A4940FP G01
Label, TBQC 336A4940GNP01 Label, TBQC 336A4940GNP01
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 Answer Center (PAC).
Attention

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
S Core and T Core Materials

S core Catalog number T core Catalog number
259B2451RNG01 259B2451RPG01
Control module 259B2451EWG01 Control module 259B2451EXG01
PWA assembly IS210MVRAH1A / IS210MVRBH1A PWA assembly IS210MVRAH1A / IS210MVRBH1A
PWA assembly IS210MVRFH1A PWA assembly IS210MVRFH1A
JP5 cable 336A4940FP G01 JP5 cable 336A4940FP G01
Label, TBQC 336A4940GNP01
Label, TBQG 336A4940GPP01
S core Catalog number T core Catalog number
259B2451RNG02 259B2451RPG02
Control module 259B2451EWG01 Control module 259B2451EXG01

2PL cable 336A4940FLG01 2PL cable 336A4940FL G01
19PL cable 336A4940GDG01 19PL cable 336A4940GD G01
JP4 cable 336A4940FNG01 JP4 cable 336A4940FN G01
PB1 ground cable 259B2451EUP02 PB1 ground cable 259B2451EU P02

Label, TBQC 336A4940GNP01
Label, TBQG 336A4940GPP01
Label, TBQD 336A4940HLP01

Attention

revision.

Attention
C Core and D Core Materials

C core Catalog number D core Catalog number
259B2451RQG01 259B2451RYG01
Control module 259B2451EYG01 Control module 259B2451RXG01
PWA assembly IS210MVRCH1A
2PL cable 336A4940GM G01 Power Supply cables 336A4940GF G05
JHH cable 336A4940GC G01
JII cable 336A4940GL G01 PB1 ground cable 259B2451EU P02
PB1 ground cable 259B2451EU P02 ENET cable kit 336A4940GB G03
C core Catalog number D core 259B2451RYG02 Catalog number
259B2451RQG02
Control module 259B2451EYG02 Control module 259B2451RXG02
PWA assembly IS210MVRCH1A PWA assembly IS210MVRCH1A
2PL cable 336A4940GM G01 Power Supply cables 336A4940GF G05
JHH cable 336A4940GC G01 2PL cable 336A4940GM G01
JII cable 336A4940GL G01 PB1 ground cable 259B2451EU P02
PB1 ground cable 259B2451EU P02 ENET cable kit 336A4940GB G03

Attention

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

Attention

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  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)
 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.
 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-6730E 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.
 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.
Core S Core R Core C
Core T

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

 To disassemble cores R, S, and T respectively
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. The red stripe is associated with connector
Caution 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
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.
Location 1
Bezel
Red strip on
ribbon cable

2. From the SDCC board, disconnect cables 3PL, 7PL, 8PL, 1PL, and 2PL. Remove the
SDCC board from the hinged plastic frame at location 1.
Location 1
SLCC board
SDCC
board
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.
Location 1
Plastic board
frame
Release
Release latch
latch
4. Disconnect cables JD, JE, 2PL JG, JF, 3PL, JA, and JB from the TCQA board. 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 TCQF board is not present, skip step 6.
6. From the TCQF board at location 3, disconnect cables JA, JB, JF, 3PL, 2PL, and
JUU. Remove the TCQF board from the plastic frame.
Location 3
TCQF
board
Location 2
TCQA
board
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.

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.
Location 4
TCQC
board
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.
Location 5
TCPS
board
Location 4
TCQC
board,
with cables
connected

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.
 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.
Location 5
MVRP Mark Ve power supply module
Do not press on the heat sinks when seating the MVRP board
and power supply. Press on the module edges only.
Bottom frame posts
Bottom frame tabs

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.
Plastic tabs
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.
Do not apply pressure to heat sinks
Tab 1 Tab 2 Tab 3

Frame Properly aligned frame post and bottom
power supply postholes.
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.
To connect ground
cables to the PE bus, use
the hardware identified
by catalog number
336A4940GSG01.
R, S, T, and C Core Power Supply Ground Wire Paths to PE Ground

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

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 (part number 336A4940GD G01), 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
19 PL
Location 4 – TCQC Board With Cables Attached

 To install the MVRF / MVRB
Note Some applications require a MVRB board in place of the MVRF board. The
following procedure is also applicable for MVRB.
Note If the optional MVRF / 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.
Location 3
2. Place the MVRF assembly in location 3. Record the board serial number, if required.
IS210MVRF in S, R, and T Cores, Location 3

IS210MVRF Diagram

IS210MVRF Board with Cables Connected

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

R Core AHSLA 336A4940GBP012 yellow
R Core FHSLA 336A4940GBP013 purple
S Core AHSLA 336A4940GBP014 yellow
S Core FHSLA 336A4940GBP015 purple
T Core AHSLA 336A4940GBP016 yellow
T Core FHSLA 336A4940GBP017 purple
4. Connect the new cable JP5 (part number 336A4940FP G01), supplied with core
material, to MVRF-JP5 / MVRV-JP5 and leave the other end free to connect later
in the process.
5. Reconnect the following cables remaining; JUU, JA, JB, and JF.
6. Verify that the cables connected to the MVRF board are JP5, JUU, JA, JB, JF, and
that the purple HSSL cable is attached to FHSLA-J3.
Note The MVRF is location 3. Ribbon cable labels will be one of the two styles
pictured below. Ribbon cables labeled JA, JB and JF are located on the MVRF and
MVRA.

 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.
Stop bracket
151X1202LMSP02

 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.
Optional PIOA pack for ARCNET

communications to EX2000
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

 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.
Location 2
MVRA board connected to the
back side of control module.
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.

R Core AHSLA 336A4940GBP012 yellow
R Core FHSLA 336A4940GBP013 purple
S Core AHSLA 336A4940GBP014 yellow
S Core FHSLA 336A4940GBP015 purple
T Core AHSLA 336A4940GBP016 yellow
T Core FHSLA 336A4940GBP017 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.
PB1
IS200MVRA Diagram

MVRA Position in Core Location 2

 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 FHSLA (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. (FHSLA/UCSA1-S is required only when an MVRF /
MVRB board is present)
6. Route cables JP4 and JP5 from the MVRA board and the MVRF /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 MVRF / 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.
Door hinge mounting hole PB1 Terminal
Ground wire

Disassembling Core C
 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.
Location 1
Bezel
2. Disconnect cables 3PL, 6PL, 8PL, and, 2PL from the SDCC board. Remove the
SDCC board from the hinged plastic frame.
Location 1
SLCC
board
SDCC
board

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.
Location 2
TCCA
board
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.
Location 3
TCCB board
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.
TCPS board
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.
 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.
supply. Refer to the photo below. Press only on the module sheet metal to seat it.
Location 5
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.

 To install new stop brackets on the C core
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.
Stop bracket
151X1202LMSP02

 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.
 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
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.

 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

 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.
Ground wire

Disassembling Core D
Note Skip all D core instructions if:
– the Mark V control does not contain an optional D core
– the D core is used for redundant ARCNET only
– the installed C core control module catalog number is 259B2451EYG01
 To disassemble core D
♦ Refer to the section Disassembling Core C; the procedure is identical.
Reassembling Core D
The power supply module is the first item to be placed in the core. For accessibility,
certain cables should be connected to the power supply before it is seated in the core.
 To reassemble core D
Note Verify the supplied D core control module catalog number. If 259B2451RXG01
is supplied, the D core does not have analog I/O. The following cables are not required:
2PL, JC, JAA, JBB, JCC, JDD, JAR, JAS, JAT, JMP, JHH, and JII.
Remove and discard cables
1. The MVRP board is mounted with the new power supply (part number
259B2451EZG01). Attach cable 2PL (part number 336A4940GM G01), supplied
with core material, to connector 2PL located on the MVRP board. Also, attach cables
JP1, JP2 (if required), and X1 from the disassembly procedure.
Note If there is not enough cable length to allow the connections before seating the
power supply, attach the cables after the power supply is seated.
2. Position the power supply in the plastic frame, then press only on the module sheet
metal to seat it. Verify that it is fully seated before continuing. Depress each of
the six mounting tabs to allow full seating

supply. Refer to the next photo.
Location 5
3. Connect cable JC to the MVRP board. Connect cables JP1 and X1 to the MVRP
board if they were not inserted in Step 2.
4. Attach the J1 power cable from the disassembly procedure to the short pigtail
connector J1-125VDC located on the lower right of the power supply. The longer
pigtail cable with the connector labeled JPDV-J28 is attached later in this procedure.
5. 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 Main Control enclosure. Refer to the drawing
R, S, T, and C Core Power Supply Ground Wire Paths to PE Ground.
6. Verify that the cables connected to the power supply are JP1, 2PL, JC, X1, P1-Gnd
(PS1), and P1-Gnd (PS2).
7. Hinge the location 3 and 4 of the frame into the closed position.

There should be no boards positioned in location 3 or 4 of the
frame.
Attention
 To install new stop brackets on the D core

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.
Stop bracket
151X1202LMSP02
 To install the D core cables
Note JHH and JII are optional cables. If the Mark V did not contain a D core TCCB
board, skip this step.
• Route the existing JHH and JII cables from the TBCB board in location 7 to location 2
(MVRC is installed in a later step) using the same paths previously taken by the cables.
Note If the JHH and JII cables already installed are not long enough for the modified
D core, order new cables JHH - part number 336A4940GC G01 and JII - part number
336A4940GLG01.

 To install the D control module
D Core control module – With DD core only
The D core has a control module to be assembled in location 1 as follows:
With DD core only:
• D Core control module (catalog number 259B2451RXG01)
With D core analog I/O and DD core:
• D Core control module (catalog number 259B2451RXG02)
The control modules are relatively heavy. Be careful when

handling and installing into the cores.
Caution
1. The D core control module has a plastic board frame attached to the rear of the metal
the screws are in contact with the plastic.
2. Record the catalog number of the installed D core control module. This number is
required for Ethernet cable routing installation.

 To install the MVRC board
Note If the Mark V did not use D core analog I/O, skip this procedure.
Note If the installed D core control module catalog number is 259B2451RXG01,

skip this procedure.
1. Position the MVRC board in the vacant frame (location 2) in the rear of the control
module. Record the MVRC board serial number, if required.
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.
The free end is attached later in the procedure.
HSSL Cables (Catalog Number 336A4940GBG01)

D Core CHSLA 336A4940GBP026 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

 To route cables to the D 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. Disconnect cable JX from the CTBA in location 6, then attach it to connector JX1A
on the JPDV.
3. Reposition the control module to the closed latched position.
4. Verify that the JX and JP28 cables are connected.
5. Install ground wire from the JPDV board connector PB1 to the bottom hinge hole
where the core door was removed.
Note If the D core does not contain a MVRC board, skip steps 6 and 7.
6. Route HSSL cable CHSLA (yellow Ethernet cable) under the board frames to the
front of the control module, then connect it into the UCSA1 – R/SL1 control module.
7. Verify that the CHSLA cable is connected.
Ground wire

Modifying the TBQC Board
 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.
MV34 MV33 TBQC board
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.
 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.
MV46 MV47
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.
Catalog number

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
TBQD must be visible.
Catalog number with

properly placed label
Last three digits
Catalog number Last three digits

properly placed

Modifying the TBQG Board
 To modify the TBQG board (G1AAA or G1ABB)
1. Remove the MOVs MV25, MV26, M27, and M28 from the TBQG board by clipping
the leads of each MOV without damaging the surface of the Printed Board Assembly
(PWA) or the components surrounding the MOVs.
MV25 MV26 MV27 MV28
2. Re-label the TBQG boards (located in the S core in location 7 for TMR and in the R
core in location 7 for simplex).
Each board form letter must be changed from G1 to G2. New labels are supplied with the
core material. Apply the new label directly on top of the existing label.
Existing label: DS200TBQGG1AAA

New label: DS200TBQGG2AAA
Or
Existing label: DS200TBQGG1ABB

New label: DS200TBQGG2ABB
label should match the last three digits of the catalog number on the PWA.

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

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

remove the fuses labeled Bussman GMA-5A
then replace with the fuses labeled Bussman
GMC -5A .
The fuse package , part number 323A2357P25, is
located with the enclosure level material , catalog
number 259B 2451SRG01.

2. From the Enclosure Level Material package (catalog number 259B2451SRG01), add
the bracket/label (catalog number 342A4909ABG1) to switches SW1 and SW3.
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).
Silk-screened Self-adhesive
catalog number catalog number label

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.
 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

Chapter 3 Ethernet Cable Routing
The Mark Ve upgrade has four different variations to the core-to-core Ethernet cable
routing. The following information, which should have been recorded during the
installation of the R, C and optional D cores, determines the routing instructions to select.
• R Core Control Module Catalog number – 259B2451_ _ _ _ _

• C Core Control Module Catalog number – 259B2451_ _ _ _ _
Optional D Core
• D Core Control Module Catalog number – 259B2451_ _ _ _ _
Using the numbers recorded above, follow the flow chart to determine the proper
installation instructions.
<R> Core Yes <C> Core Ethernet Cable

Yes
Start 259B2451 259B2451 Routing
EVG01 EYG01 Installation 1
No No
Ethernet Cable <C> Core <D> Core Ethernet Cable

Yes Yes
Routing 259B2451 259B2451 Routing
Installation 4 EYG01 RXG01 Installation 2
No No
Ethernet Cable
Ethernet Cable Routing
Yes <D> Core
Routing Installation 3
259B2451
Installation 2 RXG01
No Core of interest
Ethernet Cable
<R> Core
Routing
Installation 3 259B2451
EVG01
Control Module Catalog number
GEH-6730E Chapter 3 Ethernet Cable Routing Instruction Guide 3-1

Ethernet Cable Routing – Installation 1
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 TMR 259B2451SRG01/ Simplex
259B2451RRG02).
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

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 UCSA
• E1 is the first Ethernet port on the UCSA
JA1
UCSA2 - Controller
UCSA1 - PMVE
PIOA
Ethernet
Switch
JPDV
JB1
PIOA
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.

 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.

Ethernet Cable Routing Installation 2
This installation has the following control modules:
• R Core control module catalog number – 259B2451EVG01
or
Single EX2000 ARCNET control includes:

• C Core control module catalog number – 259B2451EYG02
No D core analog I/O, only DD core:
• D Core control module catalog number – 259B2451RXG01
Use the following table to run the Ethernet cables from core to core. The cables are in the
enclosure material container (catalog number 259B2451RRG01).

336A4940GBP019 S-SW-4 D-SW-8
336A4940GBP020 T-SW-4 C-SW-8
336A4940GBP021 C-SW-6 D-JB1-E2
336A4940GBP022 C-JB1-E2 D-SW-4
336A4940GBP023 C-JA1-E2 D-SW-6
336A4940GBP024 C-UCSA1-E2 D-SW-7

• R is the R core
To Point (example: S-UCSA2-R)
• S is the S core
• UCSA2 is the controller
• R is the Ethernet port on the controller
JA1
UCSA2 - Controller
UCSA1 - PMVE
PIOA
Ethernet
Switch
JPDV
JB1
PIOA

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.

4. Route all Ethernet cables between the R, S, T, and C cores.
5. Route the Ethernet cables between the control panel (R, S, T, and C cores) and the
auxiliary panel (D and DD cores).
Note The D and DD cores are mounted in an auxiliary cabinet, with its physical
location being requisition-dependent. The routing of the D core retrofit cables from the
auxiliary cabinet into the main control panel is determined onsite. When routing these
wires inside the main control panel, follow the same paths outlined in steps 1 through 4.


or

D core analog I/O and DD core includes:
• D Core control module catalog number – 259B2451RXG02

336A4940GBP019 S-SW-4 D-SW-8
336A4940GBP020 T-SW-4 C-SW-8
336A4940GBP021 C-SW-6 D-JB1-E2
336A4940GBP022 C-JB1-E2 D-SW-4
336A4940GBP023 C-JA1-E2 D-SW-6
336A4940GBP024 C-UCSA1-E2 D-SW-7
336A4940GBP025 C-SW-7 D-UCSA1-E2

• R is the R core
To Point (example: S-UCSA2-R)
• S is the S core
• UCSA2 is the controller
• R is the Ethernet port on the controller
JA1
UCSA2 - Controller
UCSA1 - PMVE
PIOA
Ethernet
Switch
JPDV
JB1
PIOA


4. Route all Ethernet cables between the R, S, T, and C cores.
5. Route the Ethernet cables between the control panel (R, S, T, and C cores) and the
auxiliary panel (D and DD cores).
Note The D and DD cores are mounted in an auxiliary cabinet, with its physical
location being requisition-dependent. The routing of the D core retrofit cables from the
auxiliary cabinet into the main control panel is determined onsite. When routing these
wires inside the main control panel, follow the same paths outlined in steps 1 through 4.



• No D core analog I/O or DD core
TMR
336A4940GBP001 R-SW-5 C-UCSA1-E1
336A4940GBP004 S-SW-4 C-JA1-E1
336A4940GBP027 R-SW-4 C-JA1-E2
336A4940GBP005 S-SW-5 C-JB1-E1
336A4940GBP008 T-SW-4 C-JB1-E2
336A4940GBP009 T-SW-5 C-UCSA1-E2
Simplex
336A4949FZP001 R-SW-1 R-UCSA1-E1
336A4949FZP002 R-SW-2 R-JB1-E1
336A4949FZP003 R-SW-3 R-UCSA2
336A4940GBP033 R-SW-6 C-JA1-E2

• R is the R core
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
JA1
UCSA2 - Controller
UCSA1 - PMVE
PIOA
Ethernet
Switch
JPDV
JB1
PIOA



Notes

GE Energy
1501 Roanoke Blvd.
1 540 387 7000

www.geenergy.com

Geh-6730 e

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GE Energy GEH-6730E

Mark* V to Mark Ve Control

© 2007 – 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 strictly

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

Indicates a procedure, condition, or statement that should be

1 Contents Mark* V to Mark Ve Control Gas Retrofit

• Single ARCNET® controller

• Single ARCNET controller

• Single ARCNET controller

GEH-6730E Chapter 1 Overview Instruction Guide 1-1

Control systems with a TCQF board include the following:

R core material 259B2451RMG01 – Redundant ARCNET

C core material 259B2451RQG02

Control systems without a TCQF board include the following:

R core material 259B2451RMG03 – Redundant ARCNET

C core material 259B2451RQG02

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

Contact the GE project manager or field engineer regarding

GEH-6730E Chapter 1 Overview Instruction Guide 1-3

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

S Core and T Core Materials

Power supply 259B2451EZG01 Power supply 259B2451EZG01

PB1 ground cable 259B2451EUP02 PB1 ground cable 259B2451EU P02

Contact the GE project manager or field engineer regarding

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

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

C Core and D Core Materials

Contact the GE project manager or field engineer regarding

GEH-6730E Chapter 1 Overview Instruction Guide 1-5

Contact the GE project manager or field engineer regarding

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

GEH-6730E Chapter 1 Overview Instruction Guide 1-7

S Core (TMR Only)

T Core (TMR Only)

1-8 Mark* V to Mark Ve Control Gas Retrofit

 To install the door label

 To install the door pocket drawing holder

GEH-6730E Chapter 2 Core Retrofit Procedures Instruction Guide 2-1

 To disassemble the core panel

Core S Core R Core C

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

Core PWA Locations

GEH-6730E Chapter 2 Core Retrofit Procedures Instruction Guide 2-3

No ribbon cable connectors are keyed; therefore, ribbon cables

Most of the cables in the retrofit procedure are reconnected to

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

GEH-6730E Chapter 2 Core Retrofit Procedures Instruction Guide 2-5

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

Verify that the DS200TCQCG# in Location 4 is the correct

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

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

GEH-6730E Chapter 2 Core Retrofit Procedures Instruction Guide 2-7

 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 Gas Retrofit

Bottom frame posts

Bottom frame tabs