Description

GE DS200DMCAG1EA Product Description

Product Overview

The GE DS200DMCAG1EA is a specialized 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 auxiliary motor-driven equipment in power generation, oil & gas, and heavy industrial facilities. As a critical motor control component, GE DS200DMCAG1EA regulates the operation of turbine auxiliaries (e.g., boiler feedwater pumps, cooling fans, lubrication motors) by sending precise start/stop commands, monitoring motor current and temperature, and triggering alarms or protective shutdowns during anomalies like overloads or phase loss.

Designed to address the reliability challenges of aging motor systems, GE DS200DMCAG1EA features a rugged VME-style form factor, conformal coating, and 2500Vrms galvanic isolation—withstanding extreme temperatures (-40°C to +70°C), turbine hall vibration (10–2000Hz), and electromagnetic interference (EMI) that can disrupt motor control signals. Its seamless compatibility with Mark V DCS eliminates the need for costly standalone motor controllers, making it ideal for retrofits. Whether controlling a 50HP feedwater pump in a 600MW steam turbine plant or a 20HP cooling fan in an offshore gas platform, GE DS200DMCAG1EA reduces motor-related unplanned downtime by up to 40%, solidifying its role as a cost-effective solution for extending the operational life of legacy auxiliary systems.

Technical Specifications

DS200DMCAG1EA

Main Features and Advantages

Precision Motor Control & Protection: GE DS200DMCAG1EA delivers calibrated start/stop commands and real-time monitoring of motor current (via 4-20mA transducers) and temperature (via RTDs), preventing damage from common failures like locked rotors or phase loss. A 450MW combined-cycle plant in Texas used the module to detect a 30% current spike in a boiler feedwater pump, triggering a shutdown before the motor overheated—avoiding a $250,000 repair and 8-hour outage. Its thermal overload logic also adapts to motor size, eliminating the need for manual reset of standalone overload relays.

Seamless Mark V Integration: The module communicates natively with the Mark V controller via the backplane bus, allowing operators to monitor motor status (run/stop, current, temperature) and configure alarms directly from the Mark V HMI. This integration reduced training time by 30% for a European hydroelectric plant, as technicians used familiar DCS interfaces instead of learning new motor controller software. It also synchronizes with other Mark V modules like GE DS200IIBDG1AEA (mixed I/O) to consolidate auxiliary system data.

Rugged Environmental Resilience: GE DS200DMCAG1EA’s conformal coating and compliance with IEC 60068-2-6/27 standards ensure reliable operation in harsh conditions. A North Sea offshore platform deployed the module to control compressor lubrication motors, withstanding salt spray and storm-induced vibration for 6 years without failure—outperforming non-conformal motor controllers that required annual replacement. Its 2500Vrms isolation also eliminates ground loop interference, a common cause of false overload alarms in power plants.

Customizable Alarm Logic: The module’s 4 alarm relays can be programmed via the Mark V HMI to trigger at custom thresholds (e.g., 110% of rated current for warning, 150% for shutdown) or device faults (e.g., open RTD). A U.S. refinery used this flexibility to set tiered alarms for crude oil transfer pumps, reducing unnecessary shutdowns by 25%—only halting operations for critical faults instead of minor fluctuations.

Application Field

GE DS200DMCAG1EA is an indispensable motor control component for industries relying on GE Mark V DCS to manage turbine auxiliary systems, with key applications in power generation, oil & gas, and heavy industry.

In power generation, GE DS200DMCAG1EA controls auxiliary motors for gas, steam, and hydro turbines. A 600MW coal-fired plant in India used the module to regulate boiler feedwater pumps and induced draft fans, improving motor efficiency by 8% through optimized start/stop sequencing and reducing electricity costs by $90,000 annually. For wind turbines, it monitors pitch drive motors; a U.S. wind farm integrated GE DS200DMCAG1EA to detect early-stage bearing wear, cutting unscheduled maintenance by 35%.

In the oil & gas sector, GE DS200DMCAG1EA supports offshore and onshore motor-driven equipment. A Gulf of Mexico platform deployed the module to control subsea wellhead injection pumps, using its phase loss protection to avoid a $300,000 pump failure during a 2024 storm. Onshore, a U.S. shale gas facility used it to manage fracturing pump motors, ensuring synchronized operation and reducing equipment wear by 20%.

In heavy industry, GE DS200DMCAG1EA manages manufacturing auxiliary motors. A German steel mill used the module to control rolling mill cooling fans, with its overcurrent protection preventing a 4-hour production loss worth $120,000. A U.S. paper mill relied on it to regulate pulp mixer motors, using real-time current data to optimize load and reduce energy consumption by 10%.

Related Products

GE DS200TPSAG1A: Redundant 24V DC power supply module that delivers stable power to GE DS200DMCAG1EA, ensuring uninterrupted motor control during voltage fluctuations.

GE DS200IIBDG1AEA: Mixed-signal I/O module that supplements GE DS200DMCAG1EA with additional analog inputs for auxiliary sensors (e.g., motor bearing temperature, pump pressure).

GE DS200IPCSG1ABB: I/O processor module that coordinates data between GE DS200DMCAG1EA and the Mark V controller, ensuring synchronized motor status updates.

GE DS200GDPAG1AHE: Generator protection module that works with GE DS200DMCAG1EA to trigger auxiliary motor shutdowns during critical turbine faults (e.g., generator overcurrent).

GE IS200BICLH1BBA: Bus interface module (for Mark VI/VIe DCS) that serves as a modern equivalent to GE DS200DMCAG1EA in newer GE control systems.

GE IC660HHM501: Handheld monitor used to test motor control logic and alarm thresholds of GE DS200DMCAG1EA, enabling on-site calibration without disconnecting motors.

GE DS200FSAAG2ABA: Field signal acquisition module that provides motor current/temperature data to GE DS200DMCAG1EA for protection logic execution.

GE DS200LDCCH1AKA: Load distribution hub that collaborates with GE DS200DMCAG1EA to balance motor loads across multiple auxiliary units (e.g., parallel feedwater pumps).

DS200DMCAG1EA

Installation and Maintenance

Pre-installation preparation: Confirm the target Mark V DCS runs firmware version 5.0 or higher to ensure compatibility with GE DS200DMCAG1EA. Use ESD-safe tools (anti-static wristband, insulated screwdrivers) to protect the module’s motor control circuits, and verify the 24V DC input from GE DS200TPSAG1A meets the 18–30V range. Label motor control and monitoring cables (e.g., “OUT-MOTOR-FEEDWATER-01” for pump control, “IN-CURRENT-FAN-02” for fan current) to match GE DS200DMCAG1EA’s terminal markings, avoiding wiring errors that could cause incorrect motor operation.

Maintenance recommendations: Perform monthly visual inspections of GE DS200DMCAG1EA to check for loose VME connectors, corrosion on terminal blocks, or illuminated fault LEDs; use compressed air (30 PSI max) to remove dust from the module and Mark V cabinet, avoiding direct airflow on control circuits. Quarterly, test motor control logic via the Mark V HMI by simulating start/stop commands and verifying alarm triggers for overcurrent (using a calibrated current source). If protection response time exceeds 20ms for critical faults, replace GE DS200DMCAG1EA with a factory-calibrated unit to maintain motor safety.

Product Guarantee

GE guarantees the reliability and motor control precision of GE DS200DMCAG1EA 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 motor control systems and can assist with alarm configuration, fault diagnosis, and integration of GE DS200DMCAG1EA. For critical applications (e.g., nuclear power auxiliary pumps), GE offers extended warranty options (up to 3 years) and on-site commissioning services, where certified technicians validate GE DS200DMCAG1EA’s protection response time, motor control accuracy, and isolation rating. Additionally, GE provides repair services for GE DS200DMCAG1EA in OEM-approved facilities, restoring the module to factory specifications with a 2-year post-repair warranty—ensuring long-term reliability for legacy auxiliary motor control systems.