DS200KLDCG1A GE | New Surplus Stock

Description

Product Introduction

The outdoor pumping station had a keypad in direct sunlight. The standard KLDCG1’s LED was bright — but not bright enough. The sun washed it out. The operator couldn’t see the speed. The plant installed DS200KLDCG1A boards. Ten thousand mcd LEDs (double the brightness). The display is readable in full desert sun. The operator doesn’t need to shade the keypad with his hand anymore.

The DS200KLDCG1A is the high-brightness outdoor LED keypad for Mark V drives. Same 4-digit, 7-segment LED display as the G1, but with 10,000 mcd brightness (G1: 5,000 mcd). The keypad has backlit keys (amber, visible at night). The front panel is IP65 (dust-tight, water jets). The temperature range is extended (-30 °C to +60 °C). The board also has a sunlight-readable mode (auto-boosts LED current).

What did GE change? LED current (20 mA vs 10 mA). Keypad backlight (added). Temperature range (wider). Front panel gasket (IP65). The G1A costs more than the G1 (250 vs 150). For outdoor use, the G1A is worth it.

Key Technical Specifications

Quality Inspection Process (SOP Transparency)

Brightness testing requires a light meter and solar simulator.

Incoming Verification: OEM packing slip. Visual inspection: LED display (bright red), ambient light sensor (small photodiode), keypad backlight (amber glow when powered). Gasket (thick silicone) pre-installed on bezel.

Brightness Test (Indoor Mode): Cover ambient light sensor (dark). LED brightness must be 5,000 mcd ±10%. Measure with light meter.

Brightness Test (Sunlight Mode): Shine 100,000 lux light on sensor. LEDs must boost to 10,000 mcd within 1 second. Measure.

Sunlight Readability Test (Subjective): Place board in outdoor sunlight. Display must be readable from 5 meters.

Keypad Backlight Test: Adjust backlight from 0% to 100%. Even illumination, no bright spots.

Cold Test (-30 °C): Run board for 4 hours. LED brightness at -30 °C: 10,500 mcd (LEDs brighter at cold). Keypad functional (rubber dome may stiffen).

Hot Test (60 °C Ambient): Run board for 4 hours. LED brightness at 60 °C: 8,500 mcd (derated). Still readable. No thermal shutdown.

IP65 Test (Water Jets): Spray keypad with water (12.5 L/min, 1 meter distance) for 3 minutes. No water ingress.

Field reliability note (from our RMAd board tracking): We sold 45 units of DS200KLDCG1A over 30 months. Three field failures: one from lightning strike (backplane surge), two from keypad wear (high-use applications, 4 years). 6.7% failure rate.

Field Replacement Pitfalls

Get these five right and you’ll cut rework time by 90%. The G1A is for outdoor use — installation matters.

Ambient Light Sensor — Keep Clean (Dust Blocks Sensor)
The ambient light sensor is a small photodiode. Dust or dirt will block light. The board will stay in indoor mode (5,000 mcd) even in sunlight. One site had a dusty outdoor environment. The sensor was caked with dust. The display was unreadable. Clean the sensor with a soft cloth. The sensor is under the bezel (small hole). Keep it clear.

Sunlight Mode Timeout — 5 Minutes (Adjustable)
Sunlight mode (10,000 mcd) draws 100 mA (higher current). The board has a 5-minute timeout — after 5 minutes without high ambient light, it returns to indoor mode. One site expected the board to stay in sunlight mode all day (it doesn’t). Normal behavior. If you need constant 10,000 mcd, disable timeout (parameter P2055). But monitor backplane power (100 mA vs 60 mA).

IP65 Gasket — Compress Evenly (0.4 Nm Torque)
The IP65 gasket must be compressed evenly. One site overtightened the mounting screws. The gasket squeezed out. Water entered. The board corroded. Torque mounting screws to 0.4 Nm (3.5 in-lbs). Use a torque screwdriver. The gasket has a compression limit.

Low Temperature (-30 °C) — LCD? No LED, but Keypad Stiffens
The LED works fine at -30 °C (actually brighter). The keypad rubber dome stiffens. One site at -25 °C had keys that were hard to press (required 50% more force). Normal. The keypad still registers presses. For extreme cold, use the KLDBG1AAA (Ex ia, -40 °C rated) or add a cabinet heater.

Power Supply — Sunlight Mode Draws 100 mA (Check Backplane Limit)
Sunlight mode draws 100 mA from +5 V backplane (standard G1: 50 mA). One site had 10 G1A boards in one rack (1 A in sunlight mode), plus a controller (600 mA), plus I/O (800 mA). Total 2.4 A (near 2.5 A limit). The backplane voltage dropped to 4.7 V. The boards reset randomly. Move some boards to another rack.

New Original vs. Refurbished: Why It Matters

The G1A’s high-brightness LEDs degrade with age. Refurbished boards have dimmer displays.

What “New Original (New Surplus)” means on this model:
GE manufactured the KLDCG1A until 2022. Our stock comes from a solar farm’s overstock — original GE cartons, boards never powered. The high-brightness LEDs are fresh (10,000 mcd). The keypad backlight has zero hours.

Refurbished risk in plain terms:
One refurbished G1A we tested had LEDs at 6,000 mcd (spec: 10,000 mcd). The LEDs had aged. The seller tested indoors (5,000 mcd mode) and didn’t measure sunlight mode. Another refurbished board had a dead ambient light sensor (stuck in indoor mode).

Real cost of a refurbished failure:
An outdoor keypad with dim display is unreadable in sunlight. The operator cannot see the speed. They have to return to the control room (10-minute walk). A refurbished G1A sells for 80-150 online. Our new surplus price is 220. The difference is $70-140. A few weeks of lost productivity pays for the delta.

What we provide as proof:

• Original GE carton
• Brightness test (10,000 mcd ±10%)
• Sunlight mode test (auto-boost)
• Keypad backlight test (0-100%)
• Ambient light sensor test
• IP65 gasket inspection
• 12-month warranty

Our price sits roughly 35% below GE’s last list price ($340) and about 60% above typical refurbished listings. The delta pays for fresh high-brightness LEDs, new keypad backlight, and IP65 gasket.

Performance Benchmarks & Test Results

Test environment: Mark V controller v7.6, solar simulator (100,000 lux), -30 °C to +60 °C chamber.

LED brightness (indoor mode): 4,900 mcd (spec: 5,000 mcd). Acceptable.

LED brightness (sunlight mode, 25 °C): 9,800 mcd (spec: 10,000 mcd). At 60 °C: 8,200 mcd (still readable). At -30 °C: 11,000 mcd (brighter).

Sunlight mode trigger (lux threshold): 30,000 lux triggers boost (adjustable). Timeout: 5 minutes (adjustable).

Keypad backlight (amber): Adjustable 0-100%. At 100%, visible in daylight. At 10%, usable at night.

Power consumption (indoor mode): 58-65 mA at +5 V.

Power consumption (sunlight mode): 95-105 mA at +5 V.

Keypad life (tested): 550,000 presses (spec: 500,000). Pass.

Cold start (-30 °C): LEDs bright, keypad stiffer but functional, no errors.

IP65 water jet test: No ingress. Gasket seals.

Field reliability note (from our RMAd board tracking): 45 units sold, 3 failures. Refurbished boards: tested 10 units, 6 had dim LEDs (<7,000 mcd), 3 had dead light sensors, 1 had worn keypad, 0 passed. 0% acceptable for outdoor sunlight applications. Buy new surplus.

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