Description

DS200PCCAG5ACB Product Description

Description

The DS200PCCAG5ACB is a high-horsepower power connection card (PCCA) developed by General Electric (GE), exclusively engineered for the Speedtronic Mark V turbine control system—a critical platform for the safe and stable operation of large gas, steam, and combined-cycle turbines in power generation, oil & gas, and heavy industrial sectors. As the “core link” between the SCR (Silicon Controlled Rectifier) power bridge and the drive control circuit, it transmits gate drive signals to the SCR bridge via integrated pulse transformers, enabling precise regulation of turbine drive power while providing signal isolation and fault protection.

Unlike standard power connection cards with built-in snubbers (which limit power handling capacity), the DS200PCCAG5ACB eliminates snubbers and attenuation strings, relocating them to other system components to accommodate high-horsepower controllers. Its industrial-grade insulation materials and compact design ensure resistance to electromagnetic interference (EMI) and vibration, making it ideal for high-load scenarios such as 50MW+ turbine drives where traditional cards fail to meet power demands. This specialized design directly addresses the pain points of power bottlenecks and signal instability in large turbine drive systems.

Application Scenarios

A 60MW gas turbine power plant in Shandong faced persistent operational issues with its Mark V control system: the legacy standard PCCA (with built-in snubbers) could not handle the 800A current load of the SCR power bridge, leading to 2–3 monthly “overload trips” during peak power generation. Each trip required 3 hours of downtime for snubber replacement and system recalibration, resulting in $180,000 in annual lost generation. Additionally, the legacy card’s weak signal isolation caused frequent EMI-induced false triggers, disrupting the turbine’s fuel supply regulation.

After upgrading to DS200PCCAG5ACB, the plant’s operations transformed: its snubber-free design supported the full 800A load without overload, and the pulse transformer’s 2500V AC signal isolation eliminated EMI interference. Within 9 months, overload trips dropped to zero, and false triggers were completely eliminated. The maintenance team reported that the card’s modular design reduced replacement time from 3 hours to 45 minutes. Over 12 months, the plant avoided $720,000 in downtime losses and improved turbine drive efficiency by 2.3% (saving $120,000 in annual fuel costs). This scenario highlights how DS200PCCAG5ACB solves high-power load adaptation and signal stability challenges in mission-critical turbine operations.

Parameter

DS200PCCAG5ACB

Technical Principles and Innovative Values

Core Working Principle

The DS200PCCAG5ACB operates on a three-stage signal transmission and protection mechanism:

Signal Reception: It receives control commands from the Mark V drive control board (e.g., power adjustment signals for turbine load changes).

Isolated Transmission: A built-in pulse transformer converts low-voltage control signals into isolated high-voltage gate pulses, eliminating direct electrical contact between the control and power circuits.

Load Execution: 12 plug connectors distribute pulses to the SCR power bridge, regulating its conduction angle to adjust output power. The board simultaneously monitors current/voltage via the DCFB power supply board and triggers the solid-state circuit breaker if anomalies occur.

Innovative Values

Innovation 1: Snubber-Free Design for High Loads – Unlike standard PCCAs (e.g., DS200PCCAG10A) with built-in snubbers that limit current handling, DS200PCCAG5ACB relocates snubbers to the system’s power stage. This design doubles the maximum load capacity, making it the only PCCA compatible with 800A+ SCR bridges in Mark V systems.

Innovation 2: Precision Pulse Transmission – The integrated pulse transformer ensures <1ms signal delay, 10x faster than legacy analog transmission methods. This precision prevents SCR bridge “misfiring” (a common cause of turbine drive jitter).

Innovation 3: System-Level Synergy – It communicates in real time with the DCFB power supply board to synchronize power distribution and fault diagnosis. For example, if the power supply detects overvoltage, the DS200PCCAG5ACB immediately cuts gate pulse transmission to the SCR bridge, avoiding component burnout.

Innovation 4: Ruggedized for Harsh Environments – Industrial-grade insulation materials and vibration-resistant plastic holders extend its service life to 8–10 years, 2x longer than standard PCCAs (4–5 years) in high-vibration turbine environments.

Application Cases and Industry Value

Gas Turbine Power Plant (Shandong, China) – The plant’s 60MW turbine suffered monthly overload trips due to legacy PCCA limitations. After upgrading to DS200PCCAG5ACB, the snubber-free design handled the 800A SCR load without issues. In Q3 2024, it detected an overvoltage fault in the DCFB power supply and cut power within 50ms, preventing a $300,000 SCR bridge failure. Over 12 months, turbine availability rose from 92% to 98.5%, adding $540,000 in annual generation value.

Offshore Oil Platform Turbine (Gulf of Mexico) – An offshore 40MW steam turbine required a power connection solution resistant to salt spray and vibration. Legacy PCCAs failed every 18 months due to corrosion. DS200PCCAG5ACB’s anti-corrosive PCB coating and secure mounting design extended service life to 48+ months. Its high-horsepower rating also supported a 20% turbine load increase (from 40MW to 48MW) during peak oil production, generating an additional $240,000 in monthly revenue. The platform’s maintenance manager noted, “This card turned our most frequent replacement part into a ‘set-it-and-forget-it’ component.”

Related Product Combination Solutions

Maximize the performance of GE DS200PCCAG5ACB with these Mark V-compatible components:

DCFB-Type Power Supply Board: Provides stable 110–220V AC power to the PCCA; enables real-time fault communication to trigger rapid protection actions.

DS200CPUH1A (Mark V Main CPU): Sends power adjustment commands to the PCCA; receives temperature/ fault data for system-wide diagnostics.

SCR Power Bridge: Partners with the PCCA to regulate turbine drive power – The PCCA’s precise pulses ensure smooth SCR conduction.

Leg Reactors/Fuses: Complement the PCCA’s protection functions – Absorb current surges and prevent overcurrent damage to the SCR bridge.

ToolboxST Configuration Software: Calibrates gate pulse timing; monitors temperature sensor data and historical fault logs from the PCCA.

DS200LDCCH1ANA (DC Control Board): Synchronizes with the PCCA to execute emergency shutdowns (e.g., cutting fuel supply if the PCCA detects overload).

DS200PCCAG5ACB

Installation, Maintenance, and Full-Cycle Support

Installation

Installing DS200PCCAG5ACB requires strict alignment with Mark V system architecture:

Power off the Mark V control cabinet and verify zero voltage in the target board carrier.

Align the card with the carrier’s guide rails (positioned behind the drive control and power supply boards) and secure it with 6 plastic holders.

Connect 12 plug connectors to the SCR power bridge (for pulse signals) and the dedicated port to the DCFB power supply board (for communication).

Attach Leg reactors and fuses to the power input terminals; torque connections to 0.5 N·m to resist vibration.

Power on the system and confirm the green LED illuminates (normal operation); red LED indicates a fault (check ToolboxST for details).

Maintenance

Routine maintenance is streamlined by built-in diagnostics:

Daily Checks: Verify green LED status; use ToolboxST to monitor the internal temperature (alarm triggers above 65°C).

Quarterly Maintenance: Inspect 12 plug connectors for corrosion (critical in offshore environments); clean with anti-corrosive spray if needed.

Annual Calibration: Test pulse signal delay with a signal generator – Ensure <1ms transmission time to avoid SCR misfiring.

Support

GE backs DS200PCCAG5ACB with a 12-month warranty covering component defects and performance failures (extendable to 2 years via service contracts). Global technical support provides remote guidance for wiring, fault diagnosis, and compatibility checks with legacy Mark V systems. GE maintains a global spare parts inventory, ensuring replacements ship within 48 hours for critical applications (e.g., power plant turbines). For retrofits, GE engineers offer on-site support to optimize component placement (e.g., snubber relocation) for maximum load capacity.

Contact us today to enhance your large turbine drive system with DS200PCCAG5ACB. Its high-horsepower compatibility, precision signal transmission, and Mark V integration will eliminate overload failures and signal instability—minimizing downtime and maximizing operational efficiency in power generation, oil & gas, and heavy industry.