DS200RTBAG3 | GE Mark V 48-Channel Relay Board

Description

Product Core Brief

• Model: DS200RTBAG3
• Brand: General Electric (GE)
• Series: Mark V DS200
• Core Function: Triple-bank relay output board with 48 channels
• Product Type: Relay Output Board (48 channels, 3 banks)
• Key Specs: 48 Form C relays | 5 A contacts | Three isolated banks | Per-channel LED
• Condition: New Surplus.

Product Introduction

The DS200RTBAG3 is a high-density relay output termination board for GE’s Mark V DS200 series, used in Speedtronic turbine control systems. It provides 48 independent Form C relay outputs arranged as three isolated banks of 16 relays each—the highest channel count in the RTBA family.

The “3” designation indicates a triple-bank board (three independent termination sections on one PCB). This is essentially three RTBAG1A boards integrated onto a single assembly. It is designed for applications requiring very dense relay outputs: large turbine auxiliary control panels with 48 discrete outputs for pumps, valves, dampers, annunciators, and status lights—all in a single rack slot.

Key Technical Specifications

Key Selling Points & Differentiators

• 48 relays in a single slot – Three independent banks of 16 relays. Replaces three RTBAG1A boards and saves two rack slots. Highest density relay output board for Mark V.
• Triple bank-to-bank isolation at 1500 VAC – Bank A, Bank B, and Bank C are electrically isolated from each other. Connect Bank A to 24 VDC controls, Bank B to 120 VAC motor starters, and Bank C to 240 VAC pumps on the same board. No ground loops, no isolation concerns.
• Independent ribbon cables per bank – Use three separate output modules (e.g., three DS200DACBG modules) to control each bank independently. Or use a single backplane connection with the included bank select jumpers (routes signals to appropriate bank).
• Removable terminal blocks on all 144 terminals – 48 relays x 3 terminals each = 144 field wiring points. Terminal blocks are color-coded: Bank A (gray), Bank B (black), Bank C (blue). Replace a damaged block without unwiring the entire board.
• Per-channel LED for visual status – Red LED per relay lights when the output module energizes the coil. Instant confirmation across all 48 channels without a meter.
• Flyback diode protection on every coil – Suppresses voltage spikes from inductive load switching. Protects Mark V output modules.
• QC includes 100-cycle test on all 48 relays – Every relay cycled 100 times on the test rack. Contact resistance measured before and after (<100 mΩ). All three bank-to-bank isolation combinations verified (A-B, B-C, A-C) at 1800 VAC.
• 2-year warranty – Covers contact welding, coil failure, LED failure, or any manufacturing defect on any of the three banks.

Frequently Asked Questions (FAQ)

Q: What’s the difference between RTBAG1A (16 relays), RTBAG2A (32 relays), and RTBAG3 (48 relays)?

Choose RTBAG3 when you need 48 outputs in one rack slot and your backplane can supply 720 mA of 24 VDC coil current.

Q: Can I replace three RTBAG1A boards with one RTBAG3 without changing my Mark V configuration?
A: Yes, but with significant wiring and logic changes. The RTBAG3 has relays 1–48 sequentially. Three RTBAG1A boards have relays 1–16 on each board (duplicate numbering). You will need to:

1. Renumber your field devices (e.g., old Board 1 relay 1 becomes new relay 1; old Board 2 relay 1 becomes new relay 17; old Board 3 relay 1 becomes new relay 33).
2. Re-land all 144 field wires onto the RTBAG3 terminals.
3. Reprogram your Mark V logic to map output bits to the new relay numbers.
   Allow 8–12 hours for re-termination and logic changes. We recommend keeping a wiring diagram conversion table.

Q: How do I connect the RTBAG3 to my Mark V output modules?
A: Three methods. Method 1 (recommended): Use three separate output modules. Connect Bank A (relays 1–16) to output module #1, Bank B (relays 17–32) to module #2, Bank C (relays 33–48) to module #3 via the included ribbon cables. Method 2: Use one output module with 48+ outputs (rare) and the bank select jumpers. Method 3: Use two modules (e.g., one 32-output module for Banks A+B, one 16-output module for Bank C). Jumper configurations documented on board silkscreen.

Q: Can Bank A, Bank B, and Bank C operate at three different field voltages?
A: Yes—that’s the purpose of triple isolation. Bank A can switch 24 VDC sensors, Bank B can switch 120 VAC motor starters, and Bank C can switch 240 VAC pumps on the same board. The coils (24 VDC) are common across all banks; only the contact circuits are isolated per bank. Do NOT mix voltage types within the same bank (all relays in a given bank share the same isolation barrier).

Q: The board has 144 terminal positions. Are they all accessible with the board mounted?
A: Yes, but requires planning. The terminal blocks are arranged along the bottom edge of the board. With the board mounted on DIN rail, you have access to all 48 removable terminal blocks from below. Keep 150 mm clearance below the board for wiring access and block removal. Do not mount the board in a location where cables route directly underneath—you need room to plug/unplug terminal blocks. We recommend using a wire duct with a removable cover below the board.

Q: What is the maximum backplane current draw?
A: 720 mA at 24 VDC with all 48 relays energized (48 x 15 mA). Mark V power supplies (DS200PCCAG series) typically provide 2–5 A on the 24 VDC rail. The RTBAG3 draws 0.72 A. Add all other modules (CPU draws 500 mA, each I/O module 100–300 mA, communication boards 200–400 mA) to ensure you don’t exceed the power supply rating. We provide a load calculation worksheet with each board. For heavily loaded backplanes, consider the RTBAG3-E version (external coil power option—special order, contact us).

Q: Can I replace individual relays on the RTBAG3?
A: Yes. The relays are through-hole soldered, not socketed. Replacement requires desoldering 8 pins per relay. We offer relay replacement service ($18 per relay + return shipping). The RTBAG3 uses the same relays as the RTBAG1A and RTBAG2A. For high-reliability applications requiring gold-flashed contacts or sealed relays, we offer the RTBAG3-ABB (special order, 6–8 week lead time). Contact us for pricing.

Q: The board is 420 mm wide. Will it fit in my cabinet?
A: Standard Mark V cabinets have 19-inch racks (483 mm internal width). The RTBAG3 at 420 mm fits with 63 mm clearance on each side for wiring and terminal block access. Measure your cabinet depth as well—the board depth is 220 mm plus 50 mm for terminal blocks and ribbon cable bend radius (total 270 mm). Ensure your cabinet has at least 300 mm depth.

Q: What QC tests do you run on the RTBAG3?
A: Eleven tests, all documented:

1. Visual: 20x magnification of solder joints, especially on all 48 relays.
2. Coil resistance per relay (sample of 8 per bank): 1.6 kΩ ±5%.
3. Coil current: 15 mA ±2 mA at 24 VDC (sample).
4. Contact resistance (NO and NC): Four-wire measurement at 100 mA. <50 mΩ (sample of 8 per bank).
5. Bank-to-bank isolation: 1800 VAC for 5 seconds between A-B, B-C, and A-C. Leakage <0.5 mA.
6. Coil-to-contacts isolation per bank: 1800 VAC for 5 seconds.
7. Operate test: Cycle each relay 100 times at 1 Hz. Monitor contact closure. No failures.
8. Load test (sample of 8 relays total across banks): 5 A resistive at 30 VDC, 10,000 cycles. Contact resistance after test <100 mΩ.
9. Ribbon cable test: All three 64-pin cables tested for continuity and shorts.
10. LED test per relay: Verify red LED illuminates at 24 VDC coil energization (all 48 relays).
11. Bank select jumper test: Verify mapping of output bits to correct bank (all configurations).

Q: What shipping protection for this large board?
A: The RTBAG3 is 420 mm x 220 mm—largest RTBA board. Anti-static bag first, then custom foam cradle with cutouts for all 48 removable terminal blocks (color-coded per bank). Terminal blocks are shipped installed to protect the pin headers. Double-wall box with “FRAGILE,” “ESD SENSITIVE,” “LARGE,” and “DO NOT STACK” labels. Each board ships individually. Accessories (spare terminal blocks, jumpers, labels, end clips) in separate small bag inside the same box. The board weight is 2.2 kg (4.9 lbs). Two people recommended for installation due to size, not weight.

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