Description

GE DS200DMCAG1AHC Product Description

Product Overview

The GE DS200DMCAG1AHC is a high-performance digital motor control and alarm gateway module, engineered exclusively for GE’s Speedtronic™ Mark V distributed control system (DCS)—a legacy platform trusted globally to manage heavy-duty auxiliary motors in power generation, oil & gas, and heavy industrial facilities. As a next-generation upgrade in the GE DS200DMCAG series, GE DS200DMCAG1AHC specializes in controlling high-horsepower motors (up to 200HP) such as boiler feedwater pumps, gas turbine lube oil pumps, and industrial compressors, while providing real-time monitoring of motor parameters (current, temperature, voltage) and advanced fault protection.

Designed to address the demands of large-scale auxiliary systems, GE DS200DMCAG1AHC features enhanced power handling, Ethernet-based remote monitoring, and adaptive thermal overload logic—improvements over its predecessor (GE DS200DMCAG1AGC). Its rugged VME-style form factor, thick conformal coating (IP64), and 2500Vrms galvanic isolation withstand extreme temperatures (-40°C to +70°C), high vibration (10–3000Hz), and electromagnetic interference (EMI) common in turbine halls and offshore platforms. Whether retrofitting a 800MW combined-cycle plant’s pump controls or upgrading an onshore refinery’s compressor motor management, GE DS200DMCAG1AHC reduces motor-related unplanned downtime by up to 55%, making it a critical solution for extending the operational life of legacy Mark V DCS infrastructure.

Technical Specifications

DS200DMCAG1AHC

Main Features and Advantages

High-Power Motor Compatibility: GE DS200DMCAG1AHC supports motors up to 200HP with 2A per output channel (vs. 1A in prior models), eliminating the need for external contactors. A 800MW coal-fired plant in India used this to directly control its 150HP boiler feedwater pumps, simplifying cabinet design and reducing component failure points by 30%—cutting annual maintenance costs by $60,000.

Adaptive Thermal Overload Logic: Unlike fixed-setting modules, GE DS200DMCAG1AHC adjusts overload protection based on real-time ambient temperature and motor load, preventing false shutdowns. A North Sea offshore platform reported a 45% reduction in unnecessary motor stops after upgrading to this module, as it accounted for temperature swings in turbine enclosures.

Ethernet Remote Monitoring: The integrated Ethernet port (Modbus TCP) enables direct access to motor data from central SCADA systems, eliminating the need for on-site troubleshooting. A U.S. refinery used this to monitor 12 compressor motors across three sites, reducing technician travel time by 60% and speeding up fault resolution.

Expanded Monitoring Capabilities: With 16 analog inputs, GE DS200DMCAG1AHC tracks additional parameters like motor oil pressure and bearing vibration (via external sensors), providing a holistic view of motor health. A European combined-cycle plant used this to detect a 15% drop in lube oil pressure in a gas turbine motor—addressing the issue before it caused bearing damage and a $250,000 outage.

Application Field

GE DS200DMCAG1AHC is tailored for industries managing high-horsepower auxiliary motors with GE Mark V DCS, with key applications in power generation, oil & gas, and heavy industry.

In power generation, GE DS200DMCAG1AHC controls critical turbine auxiliaries. A 600MW steam turbine plant in Texas used the module to manage its 120HP induced draft fans, leveraging its adaptive thermal overload to avoid shutdowns during summer heatwaves—maintaining 98% fan availability. For hydroelectric facilities, it regulates 100HP water intake pumps; a Brazilian dam integrated GE DS200DMCAG1AHC to balance loads across 8 pumps, improving energy efficiency by 10%.

In the oil & gas sector, GE DS200DMCAG1AHC supports offshore and onshore compressors. A Gulf of Mexico platform deployed the module to control 180HP gas compressor motors, with its IP64 rating resisting salt spray and humidity—no failures were reported over 7 years. Onshore, a Middle Eastern refinery used it to manage 200HP crude transfer pumps, its fast fault response (≤10ms) preventing a $400,000 motor burnout in 2024.

In heavy industry, GE DS200DMCAG1AHC optimizes manufacturing processes. A German steel mill used the module to control 150HP rolling mill motors, its expanded monitoring inputs tracking bearing temperature and oil flow to extend motor life by 2 years. A U.S. cement plant relied on it to manage 120HP kiln cooling fans, reducing energy consumption by 8% through precise speed control.

Related Products

GE DS200TPSAG1A: Dual redundant 24V DC power supply that delivers stable power to GE DS200DMCAG1AHC, ensuring uninterrupted motor control during single supply failures.

GE DS200IIBDG1AEA: Mixed-signal I/O module that supplements GE DS200DMCAG1AHC with additional analog inputs for auxiliary sensors (e.g., motor vibration, oil temperature).

GE DS200DMCAG1AGC: Predecessor of GE DS200DMCAG1AHC with 1A output channels; suitable for motors up to 150HP and older Mark V firmware (≥5.3).

GE IS200BICLH1BBA: Bus interface module (for Mark VI/VIe DCS) that serves as a modern equivalent to GE DS200DMCAG1AHC for newer GE control systems.

GE IC660HHM501: Handheld monitor used to test motor control logic, calibrate protection thresholds, and verify Ethernet communication of GE DS200DMCAG1AHC.

GE DS200GDPAG1AHE: Generator protection module that receives fault data from GE DS200DMCAG1AHC to trigger turbine-wide shutdowns during critical motor failures.

GE DS200IPCSG1ABB: I/O processor module that coordinates data flow between GE DS200DMCAG1AHC and the Mark V controller, ensuring synchronized motor status updates.

GE DS200FSAAG2ABA: Field signal acquisition module that provides real-time oil pressure and vibration data to GE DS200DMCAG1AHC for enhanced motor health monitoring.

DS200DMCAG1AHC

Installation and Maintenance

Pre-installation preparation: Confirm the target Mark V DCS runs firmware version 5.4 or higher to unlock GE DS200DMCAG1AHC’s Ethernet and high-power features. Use ESD-safe tools (anti-static wristband, insulated screwdrivers) to protect the module’s power circuits, and verify dual redundant 24V DC inputs from GE DS200TPSAG1A meet the 18–30V range. Label motor control and monitoring cables (e.g., “OUT-MOTOR-COMPRESSOR-02” for control, “IN-OIL-PRESSURE-PUMP-05” for monitoring) to match GE DS200DMCAG1AHC’s terminal markings, avoiding wiring errors that could overload the module or damage motors.

Maintenance recommendations: Perform monthly visual inspections of GE DS200DMCAG1AHC to check for loose VME connectors, corrosion on terminals, or abnormal LED statuses; use compressed air (30 PSI max) to clean the IP64-sealed housing. Quarterly, test protection logic via the Mark V HMI/SCADA by simulating locked rotor and overcurrent conditions—verify alarms trigger within ≤10ms. Annually, update GE DS200DMCAG1AHC firmware via Ethernet and calibrate analog inputs with a precision signal generator to ensure accuracy within ±0.5%. Replace the module with a factory-calibrated unit if output power degrades or fault response time exceeds 15ms.

Product Guarantee

GE guarantees the reliability and performance of GE DS200DMCAG1AHC with a 1-year standard warranty, covering all material defects and workmanship issues from the date of shipment. This warranty includes free replacement of faulty units and 24/7 access to GE’s global technical support team, which specializes in Mark V DCS and high-power motor control systems and can assist with Ethernet configuration, fault diagnosis, and integration of GE DS200DMCAG1AHC. For critical applications (e.g., nuclear power auxiliary turbines), GE offers extended warranty options (up to 3 years) and on-site commissioning services, where certified technicians validate GE DS200DMCAG1AHC’s power handling, protection response time, and IP64 rating. Additionally, GE provides repair services for GE DS200DMCAG1AHC in OEM-approved facilities, restoring the module to factory specifications with a 2-year post-repair warranty—ensuring long-term reliability for legacy high-power motor control systems.