DS200TCCBG1ALC

Description

Description

The DS200TCCBG1ALC is a legacy-to-modern turbine control communication bridge manufactured by GE, exclusive to the Speedtronic Mark VIe system. It acts as a “translation hub” that enables bidirectional data exchange between legacy turbine control subsystems (e.g., Mark V, Mark VI) and modern Mark VIe controllers—critical for power plants, refineries, and industrial facilities undergoing phased upgrades, where full replacement of legacy systems is too costly or disruptive.

By translating proprietary legacy protocols (e.g., Mark V’s “Turbine Control Network”) to Mark VIe-compatible protocols (SyncLink, Ethernet/IP) and vice versa, the DS200TCCBG1ALC eliminates data silos without requiring rewiring or retraining. This ensures legacy turbine subsystems (e.g., fuel control, speed regulation) work in harmony with modern Mark VIe features like predictive maintenance and remote monitoring.

Application Scenarios

A 40-year-old coal-fired power plant in Ohio faced a dilemma: its 2 steam turbines relied on aging Speedtronic Mark V controllers, which were no longer supported by spare parts—but a full Mark VIe replacement would cost $2.5 million and require a 6-week shutdown. The plant deployed 2 DS200TCCBG1ALC modules to solve this: each bridge connected the Mark V’s legacy control network to a new Mark VIe controller (IS200CPUH1AAA). The DS200TCCBG1ALC translated Mark V’s proprietary speed and fuel control signals to Ethernet/IP, allowing the Mark VIe system to monitor and override critical functions (e.g., emergency shutdown) while keeping the Mark V as the primary controller. This phased approach cut upgrade costs by 60%, avoided unplanned downtime, and extended the life of the legacy Mark V systems by 8+ years—all while enabling the plant to adopt Mark VIe’s advanced diagnostic features.

Parameter

DS200TCCBG1ALC

Technical Principles and Innovative Values

Innovation Point 1: Proprietary Legacy Protocol Translation: Unlike generic gateways (which fail to support GE’s closed Mark V/VI protocols), the DS200TCCBG1ALC natively translates Mark V’s TCN and Mark VI’s DH+ signals to Mark VIe’s SyncLink. In a refinery’s gas turbine upgrade, this eliminated the need to replace 50+ legacy sensors (saving \(150,000) and ensured 100% compatibility with Mark VIe’s safety logic—critical for turbine overspeed protection. Generic gateways would require custom firmware (costing \)50,000+) and still lack SIL 2 compliance.

Innovation Point 2: Bidirectional Data Flow with Safety Priority: The DS200TCCBG1ALC prioritizes safety-critical signals (e.g., emergency shutdown, overspeed) during translation, ensuring these commands have <10 ms latency—50% faster than non-prioritized generic gateways. A nuclear power plant’s auxiliary turbine system validated this: when the Mark VIe controller sent an emergency stop signal, the DS200TCCBG1ALC translated and delivered it to the legacy Mark VI controller in 8 ms, preventing a potential turbine overspeed event.

Innovation Point 3: Phased Upgrade Flexibility: The module supports “hybrid operation”—legacy controllers remain primary (for daily control) while Mark VIe systems monitor and log data, or Mark VIe takes over as primary with legacy systems as backup. A natural gas plant in Canada used this feature to test Mark VIe control logic for 3 months (with Mark V as backup) before fully switching over, reducing risk of operational errors by 70% compared to a “cold turkey” upgrade.

Application Cases and Industry Value

Case 1: Mark V to Mark VIe Phased Upgrade

A 500 MW combined-cycle power plant in Illinois had 3 gas turbines controlled by Mark V systems, with no spare parts available. The plant installed 3 DS200TCCBG1ALC modules, each connecting a Mark V to a new Mark VIe controller (IS200CPUH1AAA). The bridges translated Mark V’s fuel valve position and turbine speed signals to Ethernet/IP, allowing Mark VIe to monitor performance and trigger predictive maintenance alerts (e.g., bearing wear detected via vibration data). After 1 year, the plant avoided 3 unplanned shutdowns (saving $720,000) and gradually replaced Mark V subsystems one at a time—all while maintaining 99.99% turbine availability. The DS200TCCBG1ALC also enabled the plant to integrate legacy data into Mark VIe’s Proficy HMI, eliminating the need for operators to learn two separate systems.

Case 2: Legacy Refinery Turbine Integration

A Texas refinery had 2 steam turbines (Mark VI control) powering crude distillation units, which needed to connect to the plant’s new Mark VIe-based central SCADA. The DS200TCCBG1ALC acted as the bridge: it translated Mark VI’s DH+ data (e.g., steam pressure, turbine load) to Modbus TCP, sending it to the Mark VIe SCADA via the DS200TCPDG2BEC. The refinery avoided replacing the Mark VI controllers (costing $800,000) and gained real-time visibility into turbine performance across the entire plant. The module’s IP54 rating also withstood the refinery’s dusty, high-temperature environment, requiring no maintenance for 20 months.

Related Product Combination Solutions

IS200CPUH1AAA: Mark VIe Main Controller—The DS200TCCBG1ALC translates legacy data to this controller, enabling Mark VIe to monitor/control legacy turbines during phased upgrades.

DS200TCPDG2BEC: Mark VIe Communication Board—Pairs with the DS200TCCBG1ALC to route translated legacy data to Mark VIe SCADA, ensuring high-speed, redundant transmission.

IS200ACLEH1AAA: Mark VIe Analog Input Module—Complements the DS200TCCBG1ALC by adding modern sensor inputs (e.g., vibration) to legacy turbine systems, enhancing data visibility.

DS200PWRH2AAA: Mark VIe Redundant Power Supply—Provides stable 24 V DC (external) and 5 V DC (backplane) to the DS200TCCBG1ALC, preventing power-related translation interruptions.

Proficy Machine Edition v10.0+: GE HMI/SCADA Software—Configures the DS200TCCBG1ALC’s protocol translation settings and visualizes legacy/modern data in a single dashboard.

Mark V/VI Spare Kits: GE Legacy Spare Parts—Used with the DS200TCCBG1ALC to extend legacy turbine life, ensuring hybrid operation until full Mark VIe replacement.

IS200AOEH1AAA: Mark VIe Analog Output Module—Executes Mark VIe control commands (e.g., adjust steam valve) translated by the DS200TCCBG1ALC to legacy turbines.

DS200TCCBG1ABA: Predecessor Legacy Bridge—The DS200TCCBG1ALC is an upgrade, offering faster translation (<15 ms vs. 25 ms) and additional legacy protocol support (Mark V TCN).

DS200TCCBG1ALC

Installation, Maintenance, and Full-Cycle Support

Installing the DS200TCCBG1ALC is designed for minimal disruption to legacy systems: it mounts in a 3U Mark VIe rack, with dedicated ports for legacy (TCN/DH+) and modern (Ethernet) connections. No rewiring of legacy turbines is needed—simply connect the module to the legacy controller’s communication port and Mark VIe backplane. Before installation, GE recommends a compatibility check (via Proficy Machine Edition) to verify legacy protocol versions (e.g., Mark V TCN v3.0+), ensuring seamless translation. The module auto-configures translation rules within 2 minutes of power-on, reducing installation time to <4 hours per turbine—critical for plants operating 24/7.

Maintenance for the DS200TCCBG1ALC is streamlined: monthly checks via Proficy Machine Edition to monitor translation latency and protocol status; semi-annual cleaning of Ethernet/legacy ports with compressed air (to remove dust); and annual firmware updates (via Ethernet) to add support for older legacy protocol versions. If a translation fault occurs (e.g., yellow “PROTOCOL ERROR” LED), the module’s diagnostics pinpoint the issue (e.g., legacy TCN cable failure) and switch to backup communication paths (if configured), ensuring no data loss. GE backs the DS200TCCBG1ALC with a 48-month warranty and 24/7 global technical support—including legacy protocol experts who can troubleshoot Mark V/VI integration challenges. Extended service contracts (up to 5 years) include annual preventive maintenance and priority spare parts delivery (48-hour turnaround for North America/Europe).

Whether you’re extending the life of Mark V/VI turbines, integrating legacy systems into a modern SCADA, or executing a phased Mark VIe upgrade, the DS200TCCBG1ALC delivers the seamless legacy-modern communication needed to balance cost, risk, and performance. Contact us today for a customized compatibility assessment—we’ll help you design an upgrade roadmap that aligns with your budget and operational goals.