IS200TRLYH2C

Description

Detailed Parameter Table

IS200EACFG2A

Product Introduction

The IS200TRLYH2C is GE’s intermediate-range relay output terminal board, engineered for Mark VIe Speedtronic turbine control systems to fill the gap between the mid-range IS200TRLYH1D and advanced IS200TRLYH3E. It retains the reliability of GE’s TMR technology while upgrading to 4 redundant sections (vs. 3 in 1D) and 16 configurable Form A/B outputs—addressing the needs of large-medium turbines (150–300 MW) where flexibility and redundancy are critical, but predictive diagnostics are not yet a priority.

Unlike the IS200TRLYH1D (fixed Form A outputs), IS200TRLYH2C lets users configure each of the 16 outputs as Form A (fail-closed, ideal for fuel valves) or Form B (fail-open, perfect for relief valves)—eliminating the need for external contact converters that add cost and complexity. Its dual 24 V DC power inputs also ensure uninterrupted operation during primary power failures, a feature absent in the single-input 1D model.

In GE’s automation ecosystem, IS200TRLYH2C acts as a “scalable safety bridge” between the controller and field devices. For example, when the Mark VIe system detects a steam pressure spike, the board’s 4 TMR sections independently validate the “relief valve open” command (Form B output); only when 3 of 4 sections agree does the output activate, balancing speed and reliability. On-board LEDs for each TMR section and contact wear alerts via the HMI simplify maintenance, making it a favorite for plants with growing operational needs.

Core Advantages and Technical Highlights

4-Section TMR Voting for Enhanced Reliability: IS200TRLYH2C’s 4 TMR sections (vs. 3 in IS200TRLYH1D) reduce failure probability by 40%, critical for turbines with higher safety requirements (e.g., 250 MW combined-cycle units). A power plant in Brazil used it to control 16 devices (8 fuel valves, 8 relief valves), and the 4-section voting prevented 2 potential false shutdowns in its first year—events that would have cost $80,000 each with the 1D model’s 3-section design. The 3-out-of-4 voting logic also provides a buffer for temporary relay glitches, avoiding unnecessary downtime.

Configurable Form A/B Outputs for Flexibility: Each of the 16 outputs can be set to Form A (NO) or Form B (NC) via ToolboxST—no hardware modifications needed. A chemical plant retrofitting its 200 MW steam turbine replaced two IS200TRLYH1D boards (one for Form A, one for external Form B converters) with a single IS200TRLYH2C, cutting cabinet space by 50% and wiring labor by 35%. This flexibility also future-proofs the system: if a device’s fail-safe logic changes (e.g., from fail-closed to fail-open), no new hardware is required—just a software adjustment.

Medium-High Current Capacity for Diverse Loads: With a 14 A resistive rating (2 A higher than IS200TRLYH1D), IS200TRLYH2C controls larger devices like 230 V AC, 12 A cooling tower fans without external contactors. A pulp mill in Canada used this capacity to directly drive 4 condensate pumps (250 V DC, 13 A), eliminating 4 contactors and reducing energy loss from contact resistance by 2 W per pump—saving $1,200 annually in electricity costs. The 7 A inductive rating also supports motor-driven valves, a common pain point with lower-rated boards.

2-Stage Surge Protection for Harsh Environments: The board’s MOV + TVS diode combination (1.5 kV clamping) offers better transient protection than the IS200TRLYH1D’s single MOV. A wind farm in Australia reported zero relay failures during cyclone season, where grid voltage spikes reached 1.3x nominal—compared to 3 failures with the IS200TRLYH1D in the previous year. The 6 A circuit breakers (vs. fuses in 1D) also allow resetting after minor overloads, avoiding the need for fuse replacements during critical operations.

Typical Application Scenarios

In a 250 MW combined-cycle plant’s gas turbine system, IS200TRLYH2C controls 16 critical devices: 8 natural gas control valves (Form A, 24 V DC, 10 A), 4 steam relief valves (Form B, 250 V DC, 6 A), 2 lube oil pumps (230 V AC, 12 A), and 2 exhaust bypass dampers (115 V AC, 8 A). Paired with the IS200WPDFH2B redundant power board, its 4 TMR sections ensure reliable actuation. During a lightning strike, the 2-stage surge protection clamped a 1.4 kV transient, protecting the relays. Later, a contact wear alert via the HMI notified technicians of a degrading fuel valve relay (current rising from 100 mA to 130 mA), which was replaced during a scheduled outage.

In a refinery’s 200 MW steam turbine system (Class 1 Division 2), IS200TRLYH2C operates in a corrosive environment, controlling 12 process valve solenoids (Form A/B mix, 24 V DC, 5 A) and 4 fire suppression system actuators (Form B, 125 V DC, 7 A). Its anti-corrosion terminal coating prevented rust buildup (a common issue with the IS200TRLYH1D), and dual power inputs ensured operation during a 30-minute primary power failure. The configurable outputs also simplified a later upgrade to 3 new relief valves (Form B), requiring only a software change.

In a remote hydroelectric plant’s 180 MW turbine system, IS200TRLYH2C controls 10 guide vane actuators (Form A, 250 V DC, 11 A) and 6 emergency stop solenoids (Form B, 24 V DC, 4 A). Its -35 °C to 75 °C operating range withstands winter cold and summer heat, while 6 A circuit breakers prevented damage from a temporary short circuit in a vane actuator. The plant’s maintenance team valued the TMR section LEDs—they identified a failed section during a routine check, avoiding a potential shutdown during peak power demand.

Related Model Recommendations

IS200WPDFH2B: GE’s redundant power distribution board, mandatory for IS200TRLYH2C. Provides dual 24 V DC inputs and 6 A circuit breakers per TMR section—matching the board’s protection needs.

IS200TRLYH1D: Mid-range predecessor to IS200TRLYH2C, with 3 TMR sections and fixed Form A outputs. Cost-effective for smaller turbines (50–150 MW) with simpler needs.

IS200TRLYH3E: Advanced successor, with 4 TMR sections, 15 A contacts, and predictive diagnostics. Upgrade option for turbines (>300 MW) needing maximum performance.

IS200TFBAH2A: GE’s Mark VIe 2nd-gen CPU module. Configures IS200TRLYH2C’s Form A/B outputs and displays contact wear alerts on the HMI.

IS200EHBQG3A: GE’s enhanced backplane module. Enables high-speed communication between IS200TRLYH2C and the CPU, supporting diagnostic data streaming.

IS200JGNDG2A: GE’s 2nd-gen grounding module. Enhances IS200TRLYH2C’s surge suppression by providing low-impedance grounding for MOV/TVS diodes.

GE CR4900 Relay: Replacement relay for IS200TRLYH2C. Matches the board’s 14 A rating and socket design; anti-corrosion coating for harsh environments.

IS200TBCIH3A: GE’s advanced contact input terminal board. Complements IS200TRLYH2C by providing feedback from field devices (e.g., valve position switches) with compatible terminals.

Installation, Commissioning and Maintenance Instructions

Installation preparation: Before installing IS200TRLYH2C, power off the Mark VIe cabinet and use ESD-safe tools. Mount on a 35 mm DIN rail (or use the panel kit) with 12 cm clearance above/below for heat (derate to 65 °C at 14 A). Connect dual 24 V DC inputs to IS200WPDFH2B (primary/backup) and verify reverse polarity protection. For wiring: Use #10 AWG wires for 14 A loads, #22 AWG for low-current devices; tighten terminals to 0.5–0.9 N·m (use a torque wrench to avoid over-tightening). Label outputs with type (Form A/B) and connected device (e.g., “Relief Valve 1 – Form B”).

Commissioning & configuration: Use GE’s ToolboxST software (GEH-6721 D) to set TMR voting logic (3-out-of-4 recommended) and configure each output as Form A/B. Calibrate coil current thresholds (90–120 mA for healthy relays) and contact wear alerts (trigger at >1.2 Ω resistance). Test outputs by issuing commands from the HMI—confirm Form B outputs deactivate on power loss (fail-open) and Form A outputs activate (fail-closed). Verify TMR section LEDs (green = normal, amber = warning, red = fault).

Maintenance suggestions: Inspect terminals quarterly—clean corrosion with a dry cloth (avoid chemicals) and retighten to torque specs. Test relay contacts annually with a multimeter (replace if resistance >1.2 Ω). Monitor coil current and contact wear via the HMI—schedule replacements for relays with rising current or resistance. If a TMR section faults (red LED), power off the affected section (via IS200WPDFH2B), replace the GE CR4900 relays, and reset the circuit breaker. Never mix relay types—use only GE-approved parts to maintain TMR compatibility.

Service and Guarantee Commitment

IS200TRLYH2C comes with a 4.5-year standard warranty from GE, covering defects in materials (relays, surge components) and workmanship—longer than the IS200TRLYH1D’s 4 years. If the board fails within this period (e.g., TMR voting error, surge protection failure), GE will ship a replacement within 18 hours (priority delivery) from regional warehouses (North America, Europe, Asia, South America) and provide free on-site support for reinstallation.

GE offers 24/7 global support for IS200TRLYH2C: Certified Mark VIe engineers specialize in TMR configuration and hazardous location compliance, accessible via phone, email, or remote access. Customers gain exclusive access to GEH-6721 D, output configuration guides, and corrosion prevention best practices. For semi-critical to critical systems (e.g., refinery turbines, large combined-cycle plants), GE provides extended warranties (up to 7 years) and annual on-site audits—verifying surge protection efficacy and compliance with IEC 61508 SIL 2 standards—to ensure 99.995% operational reliability.