DS200SDCCG1A | GE Mark V Dual Servo Controller

Description

Product Introduction

The DS200SDCCG1A is an enhanced dual-channel servo drive controller board for GE’s Mark V DS200 series, used in Speedtronic turbine control systems. It provides two independent servo control loops on a single board with improved analog input filtering and removable terminal blocks for easier field wiring.

The “A” revision of the SDCCG1 adds several field-requested improvements: removable pluggable terminal blocks (original had fixed terminals), enhanced common-mode filtering on 4–20 mA inputs (reduces noise by an additional 20 dB), improved ESD protection (±15 kV on field I/O), and extended temperature range (−40°C to +70°C). Electrically and functionally identical to the base SDCCG1, but significantly easier to install and maintain in harsh environments.

Key Technical Specifications

Enhanced Features (A Revision)

Key Selling Points & Differentiators (A Revision Specific)

• Removable terminal blocks on all field connections – Original SDCCG1 had fixed screw terminals. The “A” revision uses removable pluggable blocks (4 total: Channel 1 I/O, Channel 1 feedback, Channel 2 I/O, Channel 2 feedback). Replace a damaged block without unwiring the entire board. Re-wire a channel without removing the board from the rack.
• Enhanced analog input filtering – 60 dB common-mode rejection at 60 Hz (versus 40 dB on base model). Critical for installations with long feedback cable runs (over 500 ft) or near variable frequency drives. Reduces position jitter from ±0.5% to ±0.1% in noisy environments.
• Improved ESD protection (±15 kV contact) – Meets IEC 61000-4-2 Level 4 (highest industrial rating). Original board was Level 2 (±4 kV). Field technicians working without wrist straps will not damage the board.
• Extended temperature range (−40°C to +70°C) – Operates in unheated turbine enclosures, outdoor cabinets, or cold climates. Base SDCCG1 rated −30°C to +65°C only.
• Torque card included – Laminated card shows terminal torque settings (0.5–0.6 Nm) for all wire gauges. Prevents over-torquing of removable blocks.
• QC includes same tests as SDCCG1 plus enhanced ESD and filtering verification – ESD gun test at ±15 kV, 10 discharges. No damage, no latch-up. Common-mode rejection measured at 60 Hz, 10 VAC injected, must be <5 mV at output.
• 2-year warranty – Same coverage as SDCCG1.

Frequently Asked Questions (FAQ)

Q: What is the difference between SDCCG1 (base) and SDCCG1A (A revision)?

Choose SDCCG1A for new installations or upgrades where field wiring access, noise immunity, or harsh environment operation is important.

Q: Can I replace a base SDCCG1 with an SDCCG1A without changing my wiring or configuration?
A: Yes—electrically and functionally identical. However, the terminal blocks are different. The SDCCG1A comes with removable blocks pre-installed. You will need to transfer your field wires from the fixed terminals of the old board to the removable blocks of the new board. Remove each block (squeeze latches, pull up), land wires, then plug block into new board. No soldering, no board removal required. Allow 1–2 hours for wire transfer.

Q: Are the removable terminal blocks interchangeable between channels?
A: Yes and no. The four blocks are physically identical (same pin spacing, same keying). However, they are labeled: “CH1 I/O”, “CH1 FB”, “CH2 I/O”, “CH2 FB”. If you mix them up, the wiring labels will be wrong. Follow the labeling. Spare blocks (unlabeled) are included—mark them before use.

Q: How do I remove a terminal block?
A: Each block has two side latches. Squeeze gently with thumb and forefinger, pull straight up. Do not rock side to side—this bends the pins. To install, press straight down until latches click. We have tested the connectors for 500 insertion/removal cycles.

Q: What torque for the screw terminals on the removable blocks?
A: 0.5–0.6 Nm (4.4–5.3 lb-in). Use a torque screwdriver. The blocks have wire protectors (stainless steel plates) that prevent strand breakage. Do not exceed 0.7 Nm—the brass threads will strip. Torque card included.

Q: The enhanced filtering (60 dB) — does it add any delay?
A: No. The filtering is implemented in analog hardware before the ADC. Group delay is constant at <100 µs at 60 Hz. No phase shift at frequencies below 10 Hz (valve control bandwidth). The PID loop remains stable with same tuning parameters.

Q: What ESD tests do you perform?
A: IEC 61000-4-2 Level 4:

• Contact discharge: ±8 kV (standard), ±15 kV (enhanced—we test to this)
• Air discharge: ±15 kV (standard)
  10 positive and 10 negative discharges per test point (all terminal blocks, front panel connectors, backplane connector). No damage, no latch-up, no configuration corruption. Test report included.

Q: What QC tests are specific to the SDCCG1A?
A: All SDCCG1 tests (see previous entry) plus:

• Terminal block insertion force: Measure 5–15 N. Below 5 N? Reject (too loose). Above 15 N? Reject (too tight).
• Common-mode rejection: Inject 10 VAC, 60 Hz between 4–20 mA+ and ground. Measure output reading change. Must be <0.05% of span (equivalent to <5 mV at output).
• ESD test: ±15 kV contact, 10 discharges. No damage.
• Low temperature operation: −40°C for 4 hours, then power-on and run closed-loop test. No errors.
• Terminal torque verification: All screws torqued to 0.55 Nm at factory, logged.

Q: What shipping protection?
A: Anti-static bag, custom ESD foam cradle with cutouts for all 4 removable terminal blocks (blocks shipped installed). Double-wall box with “FRAGILE,” “ESD SENSITIVE” labels. Shock indicator. Spare terminal blocks in separate bag. Torque card laminated and included. Each board ships individually.

bently 3500/62
bently 3500/64M
bently 3500/72M
bently 3500/77M