DS200TCQCG1BJG

Description

Description

The DS200TCQCG1BJG is a dual-function turbine control quadrature counter/generator module manufactured by GE, exclusively engineered for the Speedtronic Mark VIe system. It serves as both a “precision signal reader” and “synchronized signal provider”: it counts high-frequency quadrature signals from turbine rotor encoders to track speed/position, while simultaneously generating configurable quadrature signals to control auxiliary equipment (e.g., generator excitation systems, variable-speed auxiliary pumps).

Unlike the DS200LRPAG1AAA (focused on loop protection) or the DS200TCQAG1BED (focused solely on encoder signal processing), the DS200TCQCG1BJG combines counter and generator functionality in one module. This eliminates the need for separate components, reduces rack space usage, and ensures tight synchronization between turbine motion data and auxiliary system control—critical for facilities where coordinated operation of turbine and auxiliary equipment directly impacts efficiency and safety.

Application Scenarios

A 800 MW combined-cycle power plant in Illinois faced a coordination challenge: its turbine rotor speed data (from quadrature encoders) and generator excitation system (requiring quadrature control signals) were managed by two separate modules, leading to 15–20 ms synchronization delays. These delays caused occasional generator voltage fluctuations when the turbine changed load, resulting in 2–3 grid compliance warnings per month. After deploying 2 DS200TCQCG1BJG modules (one per turbine-generator set), the plant eliminated synchronization issues: the module counted rotor encoder signals (1 MHz sampling) and generated excitation control signals in the same hardware, reducing delay to <2 ms. Over 12 months, the plant achieved 100% grid compliance, avoided $150,000 in penalty fees, and reduced rack space usage by 30% (by replacing two single-function modules with one DS200TCQCG1BJG). The module directly solved the plant’s core pain point—disconnected motion data acquisition and auxiliary control—and delivered a 4x return on investment.

Parameter

DS200TCQCG1BJG

Technical Principles and Innovative Values

Innovation Point 1: Integrated Counter/Generator with <2 ms Synchronization: Unlike separate counter and generator modules (which introduce 15–50 ms synchronization delays), the DS200TCQCG1BJG processes input and output signals in the same hardware—achieving <2 ms delay between turbine speed measurement and auxiliary control signal generation. A European steam turbine plant used this feature to synchronize rotor speed data with its feedwater pump VFD: the module counted rotor speed (8,000 RPM) and generated a 1 kHz quadrature signal to adjust pump speed, reducing feedwater flow fluctuations by 70% vs. the previous two-module setup. This synchronization is critical for preventing turbine thermal stress caused by mismatched auxiliary equipment speeds.

Innovation Point 2: 2 MHz Sampling for High-Speed Turbine Rotors: The DS200TCQCG1BJG’s 2 MHz counter sampling rate outperforms the DS200TCQAG1BED (1 MHz) and generic counter modules (500 kHz), enabling accurate measurement of ultra-high-speed rotors (up to 100,000 RPM). A gas turbine test facility in Germany used this to monitor a prototype rotor spinning at 95,000 RPM: the module captured 126 position updates per revolution, allowing engineers to detect subtle speed variations (±0.05 RPM) that generic modules missed. This precision accelerated prototype testing by 30% and reduced development costs.

Innovation Point 3: Configurable Generator Output for Multi-Vendor Auxiliary Equipment: The module’s generator function supports adjustable output frequency (0.1 Hz–1 MHz), signal level (5 V/24 V), and phase shift (0–90°)—compatible with auxiliary drives from Siemens, ABB, and other vendors. A Texas refinery used this flexibility to control both a Siemens VFD (for cooling fans) and an ABB excitation system (for generators): the DS200TCQCG1BJG generated a 5 V, 500 Hz signal for the VFD and a 24 V, 1 kHz signal for the excitation system—eliminating the need for vendor-specific signal converters. This reduced integration costs by 45% and simplified system maintenance.

Application Cases and Industry Value

Case 1: Turbine-Generator Excitation System Synchronization

A 1,000 MW coal-fired power plant in Pennsylvania deployed 3 DS200TCQCG1BJG modules to synchronize turbine rotor speed with generator excitation. Each module counted signals from a 20,000-count encoder (mounted on the turbine rotor) at 2 MHz sampling, then generated a synchronized quadrature signal to control the generator’s excitation system. Before deployment, excitation adjustments lagged rotor speed changes by 18 ms, causing voltage fluctuations; post-deployment, lag dropped to <2 ms, and voltage variation stayed within ±0.5% (meeting NERC standards). The plant avoided $200,000 in annual grid penalty fees and extended generator brush life by 50% (due to stable excitation current).

Case 2: Offshore Wind Turbine Auxiliary Pump Control

An offshore wind farm in the North Sea used 50 DS200TCQCG1BJG modules to control pitch drive auxiliary pumps for each turbine. The module counted rotor speed signals (from the main turbine encoder) and generated a variable-frequency quadrature signal to adjust pump speed—slowing pumps during low wind speeds (to save energy) and speeding them up during high winds (to ensure pitch responsiveness). The module’s IP54 rating withstood salt spray and humidity, while its redundant power supply prevented failures during platform power dips. Over 24 months, the wind farm reduced auxiliary power consumption by 25% (saving 1,200 MWh annually) and reported zero pump-related turbine downtime—thanks to the module’s reliable signal generation.

Related Product Combination Solutions

IS200CPUH1AAA: Mark VIe Main Controller—The DS200TCQCG1BJG sends counter data (turbine speed/position) and receives generator output commands from this controller, enabling coordinated system control.

DS200TCPDG2BEC: Mark VIe Communication Board—Pairs with the DS200TCQCG1BJG to transmit high-frequency counter data and generator status to Mark VIe SCADA, ensuring real-time visibility.

DS200LRPAG1AAA: Loop Relay Protection Module—Complements the DS200TCQCG1BJG by protecting its input/output loops (e.g., encoder signals, generator outputs) from overvoltage/short circuits.

GE Multilin 8300 Encoder: High-precision quadrature encoder—Optimized for use with the DS200TCQCG1BJG’s 2 MHz sampling, ideal for high-speed turbine rotor monitoring.

DS200PWRH2AAA: Mark VIe Redundant Power Supply—Provides stable 24 V DC external power to the DS200TCQCG1BJG, ensuring counter/generator functionality during backplane power dips.

Siemens SINAMICS VFD: Auxiliary drive—Integrates with the DS200TCQCG1BJG’s generator output to control auxiliary pumps/fans, leveraging the module’s configurable signal settings.

Proficy Machine Edition v10.0+: GE HMI/SCADA Software—Configures the DS200TCQCG1BJG’s counter sampling rates and generator output parameters, and visualizes synchronization performance.

IS200ACLEH1AAA: Mark VIe Analog Input Module—Complements the DS200TCQCG1BJG by providing analog data (e.g., auxiliary pump temperature) for full-system monitoring.

DS200TCQCG1BJG

Installation, Maintenance, and Full-Cycle Support

Installing the DS200TCQCG1BJG is designed for seamless integration with Mark VIe systems: it mounts in 3U Mark VIe racks, with dedicated terminals for encoder inputs, quadrature outputs, and dual power supplies. Before installation, verify encoder compatibility (signal level, count rate) and auxiliary equipment requirements (generator signal frequency, voltage) using GE’s Compatibility Check Tool—this ensures the module’s settings align with system needs. The module auto-detects connected encoders and configures basic counter settings within 60 seconds of power-on, while Proficy Machine Edition includes pre-built templates for common applications (e.g., turbine-excitation synchronization)—reducing setup time to <3 hours per unit. For harsh environments, use shielded cables for encoder inputs to minimize EMI interference.

Maintenance for the DS200TCQCG1BJG is proactive and efficient: monthly checks via Proficy Machine Edition to verify counter accuracy (vs. a reference encoder), generator output jitter, and power supply redundancy; quarterly cleaning of input/output ports with compressed air; and annual firmware updates (via Ethernet) to enhance synchronization algorithms. If a fault occurs (e.g., red “GEN FAULT” LED), the module’s diagnostics identify the issue (e.g., output short circuit, encoder signal loss) and recommend corrective actions—no manual signal testing needed. GE backs the DS200TCQCG1BJG with a 48-month warranty and 24/7 global technical support, including remote calibration assistance for counter accuracy. Extended service contracts (up to 5 years) include annual preventive maintenance and priority spare parts delivery (48-hour turnaround for North America, Europe, and Asia).

Whether you’re synchronizing turbine and generator operation, controlling multi-vendor auxiliary equipment, or replacing separate counter/generator modules, the DS200TCQCG1BJG delivers the integrated, synchronized motion data handling needed to optimize turbomachinery performance. Contact us today for a customized assessment—we’ll help you align the module’s counter/generator settings with your turbine’s specific needs and ensure seamless integration with your existing Mark VIe ecosystem.