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GE Energy

Retrofitting Mark V to
Mark Ve Control
GEH-6730 – Preliminary copy

g
Contents

Retrofitting Mark V to Mark Ve Control 3


Introduction .................................................................................................................................................. 3
Disassembling Cores R, S, and T ................................................................................................................. 5
Reassembling Cores R, S, and T ................................................................................................................ 12
Installing the R, S, and T Control Module ................................................................................................. 18
Disassembling Core C ................................................................................................................................ 23
Reassembling Core C ................................................................................................................................. 27
Installing the C Control Module................................................................................................................. 29
Modifying the TBQC ................................................................................................................................. 37
Modifying the TBQG ................................................................................................................................. 37
Retrofitting Mark V to Mark Ve Control

Introduction
Note Follow all GE and local safety procedures before proceeding.

The material for each core has been shipped to the job site as a package. Determine
that all material is available before continuing. There should be five sets of material,
each marked with the catalog number assigned to each core, plus one for the
enclosure level parts. The sets are as follows:
• R core material 259B2451RMG01
• S core material 259B2451RNG01
• T core material 259B2451RPG01
• C core material 259B2451RQG01
• Enclosure level material 259B2451RRG01
The table on the following page lists materials needed to perform the retrofit.
Separate the materials by core type and verify that all the material has been included.

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Quantity Part number
R core 259B2451RMG01 Control module 1 259B2451EVG01
PWA assembly 1 IS210MVRAH1AA
PWA assembly 1 IS210MVRFH1AA
Power Supply 1 259B2451EZG01
Card stop bracket 2 151X1202LMSP02
2PL cable 1 336A4940FLG01
19PL cable 1 336A4940GDG01
JP4 cable 1 336A4940FNG01
JP5 cable 1 336A4940FPG01
S core 259B2451RNG01 Control module 1 259B2451EWG01
PWA assembly 1 IS210MVRAH1AA
PWA assembly 1 IS210MVRFH1AA
Power supply 1 259B2451EZG01
Card stop bracket 2 151X1202LMSP02
2PL cable 1 336A4940FLG01
19PL cable 1 336A4940GDG01
JP4 cable 1 336A4940FNG01
JP5 cable 1 336A4940FPG01
T core 259B2451RPG01 Control module 1 259B2451EXG01
PWA assembly 1 IS210MVRAH1AA
PWA assembly 1 IS210MVRFH1AA
Power supply 1 259B2451EZG01
Card stop bracket 2 151X1202LMSP02
2PL cable 1 336A4940FLG01
19PL cable 1 336A4940GDG01
JP4 cable 1 336A4940FNG01
JP5 cable 1 336A4940FPG01
C core 259B2451RQ Control module 1 259B2451EYG01
PWA assembly 1 IS210MVRCH1AA
Power supply 1 259B2451EZG01
Card stop bracket 2 151X1202LMSP02
2PL cable 1 336A4940GMG01
JHH cable 1 336A4940GCG01
JII cable 1 336A4940GLG01
Enclosure Panduit assembly 2 151X1202LQG01
259B2451RRG01 Panduit assembly 1 151X1202LQG02
Cables 1 bag 336A4940GBG01
Door pocket 1 104X905CA016
BOI plate 1 151X1202LRG01
R ground cable 1 336A4940GFG01
S ground cable 1 336A4940GFG02
T ground cable 1 336A4940GFG03
C ground cable 1 336A4940GFG04
Door label 1 259B2451RHP1

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Disassembling Cores R, S, and T
Start the following procedure with the core S 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.

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
process. Place door label (259B2451RHP1) on top of and covering the existing door
label on the LH door.

Cores R, S, 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.
¾ To disassemble the core
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

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All four cores have nine board locations as shown in the following drawing:

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Note 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.

¾ 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, and remove the SLCC from the SDCC.
2 From the SDCC, disconnect cables 3PL, 7PL, 8PL, 1PL and 2Pl. Remove the
SDCC from the hinged plastic frame at Location 1. All removed parts can be
discarded.

Location 1, Bezel

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SDCC

Location 1, SLCC

3 At Location 2, pull the right and left release latches forward to allow the plastic
board frames to hinge downward and reveal the TCQA. Disconnect cables JD,
JE, 2PL JG, JF, 3PL, JA, and JB from the TCQA. Cables JD, JE, JG, JF, JA and
JB will be reconnected to a new board in Location 2, so secure the cables to keep
them from falling into the core.
4 Remove the location 1-2 hinged plastic frame, including the TCQA, by
removing the two hex screws located on the core left and right sheet metal sides.
Save the hex screws for later use. Discard the plastic board frame and the
TCQA.

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Location 1
Plastic board
frame

Release latch

Location 3
TCQF

Location 2
TCQA

5 From the TCQF at location 3, disconnect cables JA, JB, JF, 3PL, 2PL, and JUU.
Remove the TCQF from the plastic frame.

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Location 3
TCQF

6 At Location 3-4 , hinge the board frame downward. This reveals the TCQC in
Location 4, and the TCPS power supply in Location 5. Do not remove TCQC
from the core.

Note For ease of assembly/reassembly process, cables JFF, JGG, JC, JE, JH, 8PL
may be disconnected from the TCQC; however, they must be reconnected. Do not
allow the cables to drop into the core.

7 Disconnect and discard cables ARCPL, 1PL, 6PL, and 7PL.


8 Disconnect cables JBU and VARC and tie back out of the way. JBU and VARC
will not be reconnected, but cannot be removed from the core since they are tied
within the enclosure cable runs.
9 Disconnect cable JX. It is reconnected later in the reassembly procedure.

Location 4
TCQC

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10 At Location 5, from the TCPS, remove the 2PL cable and discard. Disconnect
the JC, J1, X1, JP1, and JP2 cables and tie back out of the way. These cables are
reconnected later.
11 Remove the TCPS from the plastic board frame and discard.

Location 5
TCPS

Location 4
TCQC, with
cables connected

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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. However, it may be easier
to connect some cables to the power supply before seating it in Location 5 within the
core.
¾ To reassemble cores S, R, and T
1 Before placing the power supply (259B2451EZG01) in the core, from the
MVRP board, plug cable 2PL into connector 2PL. Also connect cables JP1, JP2
and X1, which exist from the disassembly procedure. If there is not enough cable
length to allow the connections, connect the cables after the power supply is
seated.
2 At Location 5, position the power supply in the plastic frame. Make sure it is
fully seated before proceeding. If they were not previously connected, plug in
cables JP1, JP2 and X1 into MVPR.
3 Plug in cable J1 power cable 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 pig-tail cable with connector (JPDV-J28) is
connected later in this procedure.
4 Attach power supply ground wires (green/yellow) from 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 cables connected to power supply
are JP1, JP2, 2PL, X1, P1-Gnd, and P1-Gnd.

Location 5
Mark Ve
Power Supply

Mark Ve Power Supply

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

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¾ To connect cables from power supply to TCQC
1 At Location 4, plug in the 2PL cable from the power supply into 2PL connector
on the TCQC.

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 ever though it is not a ribbon cable.

2 Connect cable 19PL to the TCQC. The 19PL cable is supplied with the core
material. The JX cable that was connected to TCQC is connected to another
board later in this reassembly process. Secure the JX cable for later
reconnecting. Verify that the cables connected to TCQC are 2PL, JC, JE, 19PL,
JFF, JGG, JH, and 8PL.

Location 4
TCQC with
cables attached

3 At Location 3, hinge the Location 3-4 plastic frame with TCQC into the upright
(closed) position. The TCQC will be on the rear side of the plastic frame.
4 Place the MVRF assembly in Location 3.
5 Connect the purple high-speed serial link (HSSL) cable (336A4940GBPxxx)
supplied with enclosure material (259B2451RRG01) to FHSLA-J3. Leave the
other end free to connect later in the reassembly procedure.
HSSL cables (336A4940GBG01)

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

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6 Connect new cable (336A4940FP G01) JP5, supplied with core material, to
MVRF-JP5 and leave the other end free to connect later in the assembly
process.
7 Reconnect the following cables remaining in the core; JUU, JA, JB, and JF.
8 Verify cables connected to MVRF are JP5, JUU, JA, JB, JF, and that the
purple HSSL cable is attached to FHSLA-J3.

Location 3

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IS210MVRF Diagram

IS210MVRF with Cables Connected

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JA JB
JP5

JF

F HSL A
JUU
PB1

IS210MVRF in S, R, and T cores, Location 3


9 Two stop brackets are attached to the inside surface of the core sheet metal
sides. Remove the single Keps nut that attaches the slide latch bracket to the core
side. Align one stop bracket with the screw and the pop rivet as shown in
drawing. Reapply the Keps nut and tighten. Attach the second stop bracket on
the opposite core wall using the same process.

S to p bra cke t
1 5 1X 12 0 2L M S P 0 2

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Installing the R, S, and T Control Module

Note All of 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 4-5 as follows:


• R Core control module 259B2451EVGO1
• S Core control module 259B2451EWGO1
• T Core control module 259B2451EXGO1

The control modules are relatively heavy. Be careful when


handling and installing into the cores.

¾ To install the control modules for S, R, and T

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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 tightend to the point that the shoulder
of the screws be in contact with the plastic frame.

Typical Control Module


2 At Location 1, with the control module attached, rotate the module
downward until it comes in contact with the stop brackets. Position the
MVRA in the vacant frame. Connect the existing cables JD, JE, JG, JA, JB,
JF, and 8PL. Connect cable JP4. The free end of JP4 is attached later in the
procedure.
3 Connect the 19PL cable from the TCQC to MVRA-19PL by routing the
cable under the plastic carrier to the MVRA.
4 Connect the yellow HSSL cable AHSLA-J3. The free end is attached later
in the procedure.
5 Verify that the cables connected to the MVRA include JD, JE, JG, JA, JB,
JF, 8PL, JP4, 19PL, and the yellow HSSL cable AHSLA.

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Control Module Hinged Downward

Location 2
MVRA connected
to rear side of
control module.

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IS200MRVA Diagram
JB1

IS210MVRA
(SIDE VIEW)

Cabling from Core to Control Module

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6 From Location 5, route cable JPDV-J28 (pigtail) from the power supply
under the board frames to the front of the control module, and plug it into
connector JB28 on the JPDV.
7 Route cable JX under the board frames to the front of the control module,
and plug it into connector JX1A on the JPDV.
8 Route HSSL cables AHSLA (yellow) and FHSLA (purple) under the board
frames to the front of the control module and plug them into the UCSA1-R
and the UCSA1-S, respectively.
9 Route cables JP4 and JP5 from the MVRA and the MVRF to the front of
the control module, and connect to the JPDV connectors JP4 and JP5.

Control Module in Location 1


10 Reposition the control module in the closed latched position. Verify that the
following cables are connected: JP4, JP5, JX1A, JP28, UCSA1-R, and
UCSA1-S.

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Disassembling Core C
¾ To disassemble core C
1 From Location 1, remove the plastic bezel from the SLCC and discard.
Disconnect cables 3PL, 2PL, and ARCPL from the SLCC. Remove the SLCC
from the SDCC.

Location 1
Bezel

2 Disconnect cables 3PL, 6PL, 8PL and 2PL from the SDCC PWA. Remove the
SDCC from the hinged plastic frame. All parts removed can be discarded.

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SDCC

Location 1, SLCC

3 From Location 2, pull the right and left release latches forward to allow the
board frames to hinge downward and reveal the TCCA. Disconnect cables
JAA, JBB, JCC, JDD, JEE, JAR, JAS, JAT, 2PL, 3PL, and JC.
4 Tie the cables back out of the way so that they can be reconnected to a new
board in Location 2.
5 Remove the JEE cable from both the CTBA and the C core. The cable can
be discarded.
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. Discard the board frame and the TCCA.

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Location 2
TCCA

7 From Location 3, disconnect cables JMP, JHH, JII, 3PL, and 2PL from the
TCCB. No cables should be plugged into the board. Remove it from the
frame. Cable 3PL can be removed and discarded. Tie JMP back out of the
way so that it can be reconnected to a new board later.
8 Remove the TCCB from the board frame and discard.
9 Hinge the Location 3-4 board frame downward. No boards should be
located on Location 4. Do not remove the board frame from the core.

Location 3
TCCB

10 The TCPS is exposed. Remove and discard the 2PL cable. Disconnect
cables JC, J1, X1 and JP1. Tie these cables out of the way so that they canl
be reconnected later.

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TCPS

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Reassembling Core C
The power supply module is the first item to be placed in the core. However, before
seating it in the core, connect certain cables to the power supply.
¾ To reassemble core C
1 On the MVRP on the new power supply (259B2451EZG01), plug cable 2PL
into connector 2PL. Also connect cables JP1, JP2 and X1 from the disassembly
procedure.

Note If there is not enough cable length to allow the connections, connect the cables
after the power supply is seated.

2 Position the power supply in the plastic frame. Be sure that it is fully seated
before proceeding.
3 If they were not previously connected, plug cables JP1, JP2 and X1 into the
MVPR.
4 Plug in cable J1 power cable 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.
5 Attach power supply ground wires (green/yellow) from PS1, connector P1-Gnd
and PS2, connector P1-Gnd to the enclosure (PE) ground bus located in the
bottom right corner of the enclosure.
6 Verify that the cables connected to the power supply are JP1, JP2, 2PL, X1, P1-
Gnd, and P1-Gnd.

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Location 5
Mark Ve
Power Supply

7 Hinge the frame into the closed position.

Note There should be no boards positioned in Location 3 or 4 of the board frame.

8 Two stop brackets are attached to the inside surface of the core sheet metal
sides. Remove the single Keps nut that attaches the slide latch bracket to the
core side. Align one stop bracket with the screw and the pop rivet as follows.
Reapply the Keps nut and tighten. Attach the second stop bracket on the
opposite core wall using the same process.

Stop bracket
151X1202LMSP02

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Installing the C Control Module

The control modules are relatively heavy so be careful when


handling and positioning in the cores.

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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.
¾ To install the C core
1 Position the control module in the core with the vacant side towards the rear
using the two hex screws removed in step 2 of the disassembly procedure.
2 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 Its important that both hex screws be tightened to the point that the shoulder
of the screws are in contact with the plastic.

3 From Location 4, with the control module attached, rotate the module downward
until the it comes in contact with the stop brackets. Position the MVRC in the
vacant frame at the rear of the control module. Connect existing cables 2PL and
JC from the power supply to the MVRC. Connect existing cables JAA, JBB,
JCC, JDD, JAR, JAS, JAT, and JMP.
4 Remove the cable JPD from the CTBA connector, and reconnect to the JPD
connector on the MVRC.
5 Since cables JHH and JII are too short to reach their new destinations on the
MVRC, they must be replaced. Disconnect the new JHH and JII cables from the
TBCB in Location 7 and discard.
6 Route the new cables JHH (336A4940GCG01) and JII (336A4940GLG01),
found with the C core materials, in the same paths.
7 Connect the yellow HSSL cable CHSLA-J3. The free end is attached later in the
procedure.
8 Verify that the cables connected to MVRC include 2PL, JC, JAA, JBB, JCC,
JDD, JAR, JAS, JAT, JPD, JHH, JII, and JMP, as well as the yellow HSSL
cable CHSLA.

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IS210MVRCH1A

IS210MVRC Positioned in Location 2

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IS210MVRC

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9 From Location 5, route cable JPDV-J28 (pigtail) from the power supply under
the board frames in front of it to the front of the control module, then plug it into
connector JB28 on the JPDV.
10 Route HSSL cables CHSLA (yellow Ethernet cable) under the board frames to
the front of the control module, then connect it into UCSA1 –R.
11 Disconnect cable JX from the CTBA in Location 6, then plug it into connector
JX1A on the JPDV.
12 Reposition the control module to the closed latched position.
13 Verify that the JX, JP28, and CHSLA cables are connected.

Ethernet Cable Routing


¾ To route the Ethernet cable
1 Remove the shield tie bars in the three locations as follows. A total of six bars
will be removed. Do not disconnect the shield wires from the bars. 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 function of hinges for the Location 7, if
they interfere with the mounting of the Panduit cable supports.

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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.

The red line indicates the routing paths for the Ethernet cables running core to core.
The right-hand view indicates an area within S and R cores that allows for excess
cable storage. The three Ethernet cableways are attached to the cores as shown using
existing screws. All Ethernet cables are routed through the cableways. The Ethernet
cables routed to all UCSA controller modules should be dressed to prevent them
from touching the inside of the enclosure doors. After the cables have been routed,
replace the shield tie bars removed in the earlier step.

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2 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 between the bar and the mounting surface.

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3 Use the following table to run the Ethernet cables from core to core. The cables
are in the enclosure material container (259B2451RRG01).
Ethernet Cable Routing
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
From Point:
• R is the R core
• SW is the Ethernet switch
• 5 is the port number on the switch
To Point:
• C is the C core
• UCSA1 is the controller
• E1 is the Ethernet port on the controller

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Modifying the TBQC
¾ To modify the TBQC (either G1AAA or G1ABB)
1 Remove the Metal Oxide Varistors (MOVs) MV33 and MV34 from the TBQC
by clipping the leads of each MOV without damaging the surface of the Printed
Board Assembly (PWA) or the components surrounding the MOVs.
2 There can be up to two TBQCs , located in the S and R cores in Location 9. R is
standard and S is optional. Each TBQC 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: IS200TBQCG1AAA
New label: IS200TBQCG2AAA
Or
Existing label: IS200TBQCG1ABB
New label: IS200TBQCG2ABB

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.

MV33

MV34

TBQC

Modifying the TBQG


¾ To modify the TBQG (either G1AAA or G1ABB)
1 Remove the MOVs MV25, MV26, M27, and M28 from the TBQG by clipping
the leads of each MOV without damaging the surface of the Printed Board
Assembly (PWA) or the components surrounding the MOVs.

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2 Re-label the TBQG (located in the S core in Location 7). Each TBQG 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: IS200TBQGG1AAA
New label: IS200TBQGG2AAA
Or
Existing label: IS200TBQGG1ABB
New label: IS200TBQGG2ABB

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.

MV25 MV26 MV27 MV28

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Preliminary - GEH-672230 Retrofitting Mark V to Mark Ve Control • 41
C CORE

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R Core Cable Crossover

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S Core Cable Crossover

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T Core Cable Crossover

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C Core Cable Crossover

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Preliminary - GEH-672230 Retrofitting Mark V to Mark Ve Control • 47
GE Energy
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA

+1 540 387 7000


www.geenergy.com

GEH-6730
Preliminary
Issued 070319

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