DS200RTBAG3ABB | GE Mark V 48-Channel High Reliability Relay

Description

Product Core Brief

• Model: DS200RTBAG3ABB
• Brand: General Electric (GE)
• Series: Mark V DS200
• Core Function: High-reliability triple-bank relay output board
• Product Type: High Reliability Relay Board (48 channels, 3 banks)
• Key Specs: 48 Form C relays | 5 A contacts | Gold-flashed | Sealed | Test points
• Condition: New Original.

Product Introduction

The DS200RTBAG3ABB is a high-reliability 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, with gold-flashed contacts and argon-sealed relay enclosures.

The “ABB” suffix represents the highest-reliability revision of the triple-bank RTBA family. Compared to the standard RTBAG3A, the ABB revision upgrades to gold-flashed contacts (0.2 µm gold over silver alloy) for low-level switching reliability, argon-sealed relay enclosures for corrosive environments, adds per-channel coil test points, increases isolation to 2500 VAC, and adds conformal coating. This board is designed for mission-critical turbine control, offshore platforms, chemical plants, or any application where relay failure is not an option.

Key Technical Specifications

Key Selling Points & Differentiators

• Gold-flashed contacts on all 48 relays – Standard RTBA relays use silver alloy that oxidizes below 50 mA. The ABB uses 0.2 µm gold flash over silver alloy. Switch 10 mA PLC input signals, 5 mA annunciator LEDs, or dry contact circuits reliably for decades. Tested to 1,000,000 operations at 10 mA without failure.
• Argon-sealed relay enclosures – Standard relays are vented to atmosphere. In humid, salty, or corrosive environments (offshore, chemical plants, paper mills), vented relays fail from contact oxidation within 1–3 years. The ABB’s sealed, argon-filled enclosure has no air exchange. No oxygen, no moisture, no corrosion. Rated for 95% humidity continuous.
• Per-channel coil test points (144 total) – Two 2 mm pin jacks per relay across the coil. Insert a multimeter to measure coil voltage (24 VDC nominal) and calculate coil current (voltage/1.6 kΩ). Diagnose a failed relay (open coil, shorted coil, driver issue) without removing the board or probing tiny component leads.
• 2500 VAC bank-to-bank isolation – Standard RTBAG3 is rated 1500 VAC. The ABB increases isolation to 2500 VAC between Bank A, Bank B, and Bank C. Connect banks to 240 VAC, 120 VAC, and 24 VDC on the same board with higher safety margin.
• Conformal coated PCB – Acrylic coating (0.05 mm) over all solder joints and traces. Prevents condensation-induced shorts, corrosion, and tin whisker growth. Standard RTBA boards have no conformal coating.
• Extended temperature range (−40°C to +75°C) – Standard board is −30°C to +65°C. The ABB operates in unheated turbine enclosures, outdoor cabinets, or Arctic installations.
• QC includes 10,000 cycle load test on every relay – Unlike standard QC (sample testing), we run all 48 relays through 10,000 cycles at 5 A resistive, 30 VDC. Contact resistance measured before and after. Maximum allowed drift: 20 mΩ. We also perform low-level switching test (10 mA at 5 VDC, 1,000,000 cycles) on a sample of 8 relays per board.
• 2-year warranty – Covers any relay failure, contact welding, coil failure, LED failure, or manufacturing defect. Extended warranty to 5 years available for an additional 20% of purchase price.

Frequently Asked Questions (FAQ)

Q: What’s the difference between RTBAG3A (standard), RTBAG3ABB (high reliability), and RTBAG3 (cage clamp)?

The ABB is for mission-critical, corrosive, or low-level switching applications. For standard control room duty, the RTBAG3A is sufficient.

Q: When do I need gold-flashed contacts?
A: When switching loads under 50 mA at less than 12 V. Examples: PLC input modules (10 mA at 24 VDC), solid state relay inputs (5–15 mA), annunciator panels (20 mA LEDs), dry contact sensing circuits. Silver contacts develop a non-conductive oxide layer below 50 mA. Gold-flashed contacts do not oxidize. We have seen standard RTBA relays fail to close low-current circuits after 6 months in storage. The ABB works immediately and continues for years.

Q: The relays are sealed. Can they be replaced in the field?
A: Yes, but with difficulty. The relays are through-hole soldered with 8 pins. Desoldering requires a vacuum desoldering station. The conformal coating must be removed first (use the included touch-up pen solvent). We offer relay replacement service (22 per relay + return shipping). We also sell bare relays (part RELAY-RTB-ABB, 14 each) for in-house repair. For critical applications, we recommend keeping a spare ABB board instead of attempting field relay replacement.

Q: How do I use the coil test points?
A: Each relay has two 2 mm pin jacks labeled “C+” and “C-“. Insert the included test probe set into a multimeter (voltage mode). Measure across the pins. Should read 24 VDC ±10% when the output module energizes the relay. If voltage is present but relay does not actuate, the coil is open (infinite resistance) or the mechanical mechanism has failed. To measure coil current: measure voltage across the pins and calculate I = V / 1600Ω. Current should be 15 mA ±1 mA at 24 VDC.

Q: The board has conformal coating. Can I add or repair it?
A: Yes. We include a touch-up pen with acrylic conformal coating. If you desolder a relay, remove the coating in that area with the pen’s solvent tip. After repair, apply a new layer of coating from the pen. Allow 30 minutes to cure at room temperature, or 10 minutes with a heat gun (50°C). For full board recoating, we offer recoat service ($85 + shipping).

Q: Can I use this board in a paper mill or offshore platform?
A: Yes—that’s the primary use case. The argon-filled sealed relays have no exposed contact surfaces to corrode. The conformal coating protects the PCB from humidity, salt spray, and chemical vapors. We have RTBAG3ABB boards operating in chlorine bleach plants (paper mills) and North Sea offshore platforms for 10+ years with zero relay failures. The standard RTBAG3A would typically fail within 2 years in these environments.

Q: What is the low-level switching guarantee?
A: 10 mA at 5 VDC, 1,000,000 operations minimum. We test a sample of 8 relays per board to this specification. Below 10 mA (e.g., 1 mA logic signals), the gold flash is still conductive, but the contact pressure (50 grams) may not reliably break through surface contamination. For loads under 10 mA, use a solid state relay (AFB series) or an interposing relay with bifurcated gold contacts. We sell a signal-level adapter board (ACC-SIG-ADAPT) for these applications.

Q: The board has 48 relays. What is the maximum simultaneous load?
A: Thermally limited. With panel mounting (thermal pad to metal surface) and forced air cooling (200 LFM minimum), you can run all 48 relays at 5 A resistive continuously. Without forced air, limit to 3 A per relay average. With DIN rail mounting (no heatsink), limit to 2 A per relay. The board has no per-bank thermal monitoring (unlike the AGC variant). We recommend a thermal survey of your cabinet if running high loads.

Q: What QC tests are specific to the ABB revision?
A: Thirteen tests, all documented:

1. Visual: 20x magnification, conformal coating inspection, relay seal integrity.
2. Coil resistance (all 48 relays): 1.6 kΩ ±3% at 25°C.
3. Coil current: 15 mA ±1 mA at 24 VDC (all relays).
4. Contact resistance (NO and NC): Four-wire measurement at 100 mA. <50 mΩ. Then at 10 mA (low current), <100 mΩ.
5. Bank-to-bank isolation: 3000 VAC for 5 seconds between A-B, B-C, A-C. Leakage <0.1 mA.
6. Coil-to-contacts isolation per bank: 3000 VAC for 5 seconds.
7. Operate test: Cycle each relay 1,000 times at 2 Hz. Operate time <10 ms, release <6 ms, bounce <3 ms.
8. Load test (all 48 relays): 10,000 cycles at 5 A resistive, 30 VDC. Contact resistance after test <70 mΩ (50 mΩ + 20 mΩ drift).
9. Low-level switching test (sample of 8 relays): 10 mA at 5 VDC, 1,000,000 cycles. No contact failures.
10. Coil test point verification: Measure voltage across pin jacks, compare to direct coil measurement. Error <1%.
11. Thermal soak: 48 hours at +75°C, all relays energized. No coil resistance drift >5%.
12. Humidity test (sample lot): 95% RH at 40°C for 240 hours. No visible corrosion on terminals or PCB.
13. Conformal coating thickness: Measured at 5 points, 0.05 mm ±0.01 mm.

Q: What shipping protection for this high-reliability board?
A: Maximum protection. Anti-static bag with humidity indicator. Custom ESD foam cradle with cutouts for all 48 terminal blocks and 96 test point pin jacks. Hard plastic clamshell case with foam liner and desiccant pack. Double-wall box with “HIGH RELIABILITY,” “PRECISION INSTRUMENT,” “HEAVY,” and “DO NOT DROP” labels. Shock indicator and humidity indicator labels on outside. Each board ships individually. Calibration and test report (15 pages typical, including low-level switching data) laminated and attached to outside of clamshell. Spare terminal blocks and touch-up pen in separate sealed bags inside the same box.

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