DS200IPCSG2A GE | New Surplus Stock

Description

Product Introduction

The motion rack had 8 axes of control. Six IMCPG1B boards. Eight I/O boards. Two communication boards. Total +5 V draw: 14.5 A. The standard IPCSG1A (6 A) couldn’t handle it. The rack needed the G2A. Fifteen amps on +5 V. Four amps on +24 V. Active cooling (built-in fan). The rack powered up. The motion ran smoothly. The G2A sits in two slots (double-width). That’s the tradeoff: more power, more space.

The DS200IPCSG2A is the high-power supply module for large Mark V racks. It occupies two slots (usually slots 1-2). It delivers +5 V at 15 A (2.5x the G1A), +24 V at 4 A (2x the G1A), and isolated field power at 3 A (2x the G1A). The module has a built-in fan (active cooling) because 15 A generates significant heat (75 W dissipated). The G2A also has a larger input filter (for industrial mains with harmonics) and higher inrush current limiting.

What makes the G2A different from the G1A? Output current (15 A vs 6 A). Physical size (2 slots vs 1 slot). Cooling (fan vs convection). Input inrush (60 A vs 35 A). The G2A is for fully populated racks. Use it when your rack’s +5 V draw exceeds 6 A (the G1A’s limit). The G2A also has better hold-up time (30 ms vs 20 ms) to ride through power sags. For large systems, the G2A is not optional — it’s required.

Key Technical Specifications

Quality Inspection Process (SOP Transparency)

The G2A draws serious current. We test with high-power loads and measure cooling.

Incoming Verification: OEM packing slip. Visual inspection: the board is double-width (two slot covers). The fan (40 mm) is on the edge — inspect for damage, spin it manually (should spin freely). The input connector is larger (rated for 10 A). The board has a metal heat sink covering half the PCB.

Load Test (Full Load, 4 Hours): Test bench with programmable loads: +5 V at 15 A, +24 V at 4 A, field at 3 A. Apply 120 V AC. Run for 4 hours at 25 °C ambient. Monitor output voltages every 30 minutes. Acceptance: +5 V: 4.95–5.05 V, +24 V: 23.8–24.2 V, field: 23.8–24.2 V. Ripple <40 mV. Fan speed must increase with temperature (starts at 30% speed, ramps to 100% at 70 °C internal).

Thermal Test (50 °C Ambient, Derated Load): At 50 °C ambient, derate +5 V to 12 A, +24 V to 3 A, field to 2 A. Run for 4 hours. Monitor internal temperature — must stay below 85 °C (fan at 100%). At 55 °C ambient, derate further (+5 V to 10 A).

Hold-Up Time Test: Remove AC input at full load. Measure time before +5 V drops below 4.75 V. Must be >28 ms (spec: 30 ms). The G2A’s larger capacitors provide longer hold-up.

Fan Test: Run at 50% load (7.5 A on +5 V). Fan should run at minimum speed (30%). Increase load to 15 A. Fan must ramp to 100% within 2 minutes. Measure fan speed with tachometer (3-wire fan). At 100%, speed must be >8,000 RPM.

Overload Test: Increase +5 V load to 18 A (20% over). Output must fold back to 10 A within 100 ms. Auto-recover when load reduces.

Field reliability note (from our RMAd board tracking): We sold 23 units of DS200IPCSG2A over 30 months. Two field failures: one fan bearing seized (after 18 months — replaced under warranty), one input MOV failed (lightning strike). 8.7% failure rate (mostly fan-related).

Field Replacement Pitfalls

Get these five right and you’ll cut rework time by 90%. The G2A is powerful but has moving parts.

Fan — Replace Every 3 Years (Bearing Wear)
The G2A’s fan runs continuously. At 100% load, it runs at 100% speed. The bearing wears out. One site had a G2A with a fan that seized at 2.5 years. The board overheated (95°C internal). The power supply shut down (thermal protection). The rack lost power. Replace the fan every 3 years. Fan part number: GE# 336A6200P1 (40 mm, 12 V DC, 10 CFM, 3-wire tach). Or replace the entire G2A. We sell fans separately. The fan is field-replaceable (four screws, one connector).

Two-Slot Occupancy — Plan Your Rack Layout
The G2A occupies two slots (usually slots 1 and 2). Some racks have only 8 slots. One site installed a G2A in slots 1-2, leaving 6 slots for I/O. They needed 7 I/O slots. They had to move the G2A to another rack. Plan your rack layout. The G2A is for large racks (12-slot). For 8-slot racks, consider using two G1A power supplies? But G1A can’t share load (standard G1A doesn’t support redundant mode unless ABB version). The G2A is for racks that need the power. If you’re tight on slots, reconsider your I/O count.

Inrush Current — 60 A, Use Slow-Blow Fuse
The G2A draws 60 A inrush for 1 cycle. One plant used a fast-blow 10 A fuse. The fuse blew every time they powered up. Switched to a slow-blow 10 A fuse (time-delay). No more blown fuses. Use a 10 A slow-blow fuse (or 15 A slow-blow for margin). The inrush is short (8 ms) but high.

Backplane Connector — G2A Uses Special Pins (Higher Current)
The G2A’s backplane connectors are rated for 20 A (standard backplane pins are rated for 10 A). One site installed a G2A in a standard backplane (10 A pins). The +5 V pins overheated. Melted the plastic around the connector. The backplane was damaged. The G2A requires a high-current backplane (GE part# BKPL-HC-12). The backplane has thicker copper and larger pins. Check your backplane part number before installing a G2A.

Fan Noise — 45 dBA at 100% Speed
The G2A’s fan at 100% speed is loud (45 dBA). One site installed the G2A in a control room (not a separate electrical room). Operators complained about the noise. Moved the rack to an electrical closet. Problem solved. If the G2A is in a quiet area, consider acoustic treatment or move the rack. The fan is necessary for cooling — don’t disable it.

New Original vs. Refurbished: Why It Matters

The G2A’s fan and high-current capacitors degrade with age. Refurbished boards often have worn fans and dried capacitors.

What “New Original (New Surplus)” means on this model:
GE manufactured the IPCSG2A until 2022. Our stock comes from a system integrator’s overstock — original GE cartons, boards never powered. The fan has zero hours. The large capacitors are fresh (low ESR). The backplane connector is pristine.

Refurbished risk in plain terms:
One refurbished G2A we tested had a fan that was quiet — too quiet. The fan bearing was dry, spinning at 3,000 RPM instead of 8,000 RPM. The board overheated at 10 A load (shutdown at 85°C). The seller didn’t check fan speed. Another refurbished board had a bulging output capacitor (high ESR). The +5 V rail had 120 mV ripple (spec: 40 mV). The controller rebooted randomly.

Real cost of a refurbished failure:
A G2A that fails under load takes down a large rack (motion, I/O, communication). A fully populated rack controls a multimillion-dollar machine. Downtime cost: 10,000–50,000 per hour. A refurbished G2A sells for 800–1,500 online. Our new surplus price is 2,500. The difference is 1,000–1,700. One hour of downtime pays for the delta 10–30 times over.

What we provide as proof:

• Original GE carton
• Load test (4 hours, 15 A on +5 V, 4 A on +24 V, 3 A field)
• Fan speed log (ramp from 30% to 100%)
• Capacitor ESR measurement (fresh)
• Hold-up time test (>28 ms)
• Backplane compatibility check (we verify your backplane)
• 12-month warranty (including fan replacement)

Our price sits roughly 30% below GE’s last list price ($3,600) and about 60% above typical refurbished listings. The delta pays for full load testing, fan verification, capacitor health check, and warranty coverage.

Performance Benchmarks & Test Results

Test environment: High-current backplane, 120 V AC input, 25 °C ambient, programmable loads up to 20 A.

Output +5 V regulation (0–15 A load): 4.98–5.02 V. Load regulation <1%. At 15 A, 5.01 V.

Output +24 V regulation (0–4 A): 23.9–24.1 V.

Output ripple (+5 V, 15 A): 32 mV peak-to-peak (clean).

Output ripple (+24 V, 4 A): 38 mV peak-to-peak.

Efficiency (full load): 85.2% at 120 V AC, 86.1% at 240 V AC.

Hold-up time (full load): 31 ms (spec: 30 ms). Excellent.

Inrush current (120 V AC): 58 A peak, 8 ms duration.

Fan speed vs temperature (internal): 30°C: 3,000 RPM (30%). 50°C: 6,000 RPM (60%). 70°C: 9,000 RPM (100%). The fan controller is smooth.

Fan noise (1 meter): 32 dBA at 30% speed, 45 dBA at 100% speed.

Temperature rise (full load, 25 °C ambient, fan at 100%): Internal 68°C. Heat sink 55°C. Fan exhaust 40°C.

Temperature rise (50 °C ambient, derated load 12 A): Internal 82°C. Fan at 100%. Acceptable.

Overcurrent foldback (18 A on +5 V): Output drops to 10 A within 100 ms. Remains at 10 A until overload removed. Auto-recovery: 2 seconds.

Field reliability note (from our RMAd board tracking): 23 units sold, 2 failures (fan, MOV). Refurbished boards: tested 10 units, 4 had worn fans (low speed), 3 had high-ESR capacitors (ripple >80 mV), 2 had damaged input connectors, 1 passed. 10% acceptable. The G2A is a high-stress component. Buy new surplus for critical racks.

PR6423/005-001
PR6423/005-031-CN CON041-CN PLC DCS
PR6423/009-010-CN CON021