DS200RTBAG4A | GE PLC 64 Channel Relay Panel Fast Ship

Description

Product Core Brief

• Model: DS200RTBAG4A
• Brand: General Electric (GE)
• Series: Mark V DS200
• Core Function: Ultra-high-density quad-bank relay output board with 64 channels
• Product Type: Relay Output Board (64 channels, 4 banks)
• Key Specs: 64 Form C relays | 5 A contacts | Four isolated banks | Removable screw terminals
• Condition: New Surplus.

Product Introduction

The DS200RTBAG4A is an ultra-high-density relay output termination board for GE’s Mark V DS200 series, used in Speedtronic turbine control systems. It provides 64 independent Form C relay outputs arranged as four isolated banks of 16 relays each—the highest channel count in the entire RTBA family.

The “4A” designation indicates a quad-bank board (four independent termination sections on one PCB). This is essentially four RTBAG1A boards integrated onto a single assembly. It is designed for applications requiring extremely dense relay outputs: large turbine auxiliary control panels with 64 discrete outputs for pumps, valves, dampers, annunciators, status lights, and interlock circuits—all in a single rack slot. Maximum channel density in the smallest footprint.

Key Technical Specifications

Key Selling Points & Differentiators

• 64 relays in a single slot – Four independent banks of 16 relays. Replaces four RTBAG1A boards and saves three rack slots. Highest density relay output board for Mark V. Maximum channel count in minimum space.
• Quad bank-to-bank isolation at 1500 VAC – Bank A, B, C, and D are electrically isolated from each other. Connect Bank A to 24 VDC controls, Bank B to 48 VDC battery circuits, Bank C to 120 VAC motor starters, and Bank D to 240 VAC pumps on the same board. No ground loops.
• Independent ribbon cables per bank – Use four separate output modules to control each bank independently. Flexible configuration for large systems.
• Removable screw terminal blocks on all 192 terminals – 64 relays x 3 terminals each = 192 field wiring points. Terminal blocks are color-coded: Bank A (gray), Bank B (black), Bank C (blue), Bank D (green). 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 64 channels without a meter.
• Flyback diode protection on every coil – Suppresses voltage spikes from inductive load switching. Protects Mark V output modules.
• Removable terminal blocks for all banks – Unlike higher-power variants (AGC, AEB) that use fixed terminals, the RTBAG4A uses removable blocks for all 192 connections. Easier maintenance and rewiring.
• QC includes 100-cycle test on all 64 relays – Every relay cycled 100 times on the test rack. Contact resistance measured before and after (<100 mΩ). All six bank-to-bank isolation combinations verified (A-B, A-C, A-D, B-C, B-D, C-D) at 1800 VAC.
• 2-year warranty – Covers contact welding, coil failure, LED failure, or any manufacturing defect on any of the four banks.

Frequently Asked Questions (FAQ)

Q: What’s the difference between RTBAG1A (16 relays), RTBAG2A (32 relays), RTBAG3A (48 relays), and RTBAG4A (64 relays)?

Choose RTBAG4A when you need 64 outputs in one rack slot and your backplane can supply 960 mA of 24 VDC coil current.

Q: Can I replace four RTBAG1A boards with one RTBAG4A without changing my Mark V configuration?
A: Yes, but with significant wiring and logic changes. The RTBAG4A has relays 1–64 sequentially. Four RTBAG1A boards have relays 1–16 on each board (duplicate numbering). You will need to:

1. Renumber your field devices (old Board 1 relay 1 → new relay 1; old Board 2 relay 1 → new relay 17; old Board 3 relay 1 → new relay 33; old Board 4 relay 1 → new relay 49).
2. Re-land all 192 field wires onto the RTBAG4A terminals (color-coded per bank).
3. Reprogram your Mark V logic to map output bits to the new relay numbers.
   Allow 12–16 hours for re-termination and logic changes. We provide a wiring diagram conversion table.

Q: How do I connect the RTBAG4A to my Mark V output modules?
A: Four methods. Method 1 (recommended): Use four separate output modules. Connect Bank A (relays 1–16) to output module #1, Bank B (17–32) to module #2, Bank C (33–48) to module #3, Bank D (49–64) to module #4 via the included ribbon cables. Method 2: Use two 32-output modules (special order). Method 3: Use one 64-output module (rare). Method 4: Use backplane bank select jumpers (configurations documented on board silkscreen).

Q: Can Bank A, B, C, and D operate at four different field voltages?
A: Yes—that’s the purpose of quad isolation. Bank A can switch 24 VDC sensors, Bank B 48 VDC battery circuits, Bank C 120 VAC motor starters, and Bank D 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 192 terminal positions. Are they all accessible with the board mounted?
A: Yes, but requires planning. Terminal blocks are arranged along the bottom edge of the board (4 banks × 16 relays × 3 terminals = 192 positions). With the board mounted on DIN rail, you have access to all 64 removable terminal blocks from below. Keep 200 mm clearance below the board for wiring access and block removal. The board is 480 mm wide—ensure your cabinet has at least 500 mm internal width (standard 19-inch rack is 483 mm, so check clearance).

Q: What is the maximum backplane current draw?
A: 960 mA at 24 VDC with all 64 relays energized (64 x 15 mA). Mark V power supplies (DS200PCCAG series) typically provide 2–5 A on the 24 VDC rail. The RTBAG4A draws 0.96 A—significant but manageable. Add all other modules (CPU 500 mA, each I/O module 100–300 mA, communication boards 200–400 mA). If total exceeds 80% of power supply rating, consider using the RTBAG4A-E version (external coil power option—special order, 4–6 week lead time). Contact us for load calculation assistance.

Q: Can I replace individual relays on the RTBAG4A?
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 RTBAG4A uses the same relays as the RTBAG1A, RTBAG2A, and RTBAG3A. For high-reliability applications requiring gold-flashed contacts or sealed relays, we offer the RTBAG4ABB (special order, 8–10 week lead time). Contact us for pricing.

Q: The board is 480 mm wide. Will it fit in a standard 19-inch cabinet?
A: Standard 19-inch rack internal width is 483 mm (19.02 inches). The RTBAG4A at 480 mm fits with 3 mm clearance on each side. However, the removable terminal blocks extend slightly beyond the PCB edges. Measure your cabinet’s usable width carefully. We recommend a minimum 500 mm internal width for comfortable installation and terminal block access. For tight cabinets, consider using two RTBAG2A boards instead (350 mm each, requires 2 slots).

Q: What QC tests do you run on the RTBAG4A?
A: Twelve tests, all documented:

1. Visual: 20x magnification of solder joints on all 64 relays.
2. Coil resistance (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 all 6 bank pairs (A-B, A-C, A-D, B-C, B-D, C-D). 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 12 relays total across banks): 5 A resistive at 30 VDC, 10,000 cycles. Contact resistance after test <100 mΩ.
9. Ribbon cable test: All four 64-pin cables tested for continuity and shorts.
10. LED test per relay: Verify red LED illuminates at 24 VDC coil energization (all 64 relays).
11. Bank select jumper test: Verify mapping of output bits to correct bank (all configurations).
12. Thermal imaging: 64 relays at 3 A average (192 A total theoretical—not possible). Practical test: 2 A on 32 relays, 1 A on 32 relays for 2 hours. Hot spots <80°C.

Q: What shipping protection for this large board?
A: The RTBAG4A is 480 mm x 240 mm—largest RTBA board. Anti-static bag, custom foam cradle with cutouts for all 64 removable terminal blocks (color-coded per bank: gray, black, blue, green). Terminal blocks are shipped installed to protect the pin headers. Double-wall box with “FRAGILE,” “ESD SENSITIVE,” “LARGE,” “EXTRA WIDE,” 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 2.8 kg (6.2 lbs). Two people recommended for installation due to width, not weight.

3300350202010 PLC DCS
3300350202020 PLC DCS
77448-01T PLC DCS
3300/55-01-04-02-02-00-00-05-00 PLC DCS