DS200SDCCG1AEC | GE Mark V Dual Servo Controller

Description

Product Introduction

The DS200SDCCG1AEC is a high-output current dual-channel servo drive controller for GE’s Mark V DS200 series, used in Speedtronic turbine control systems. It provides two independent servo control loops with ±10 VDC output at 100 mA—ten times the current capability of standard SDCCG1 boards (10 mA).

The “AEC” suffix indicates a high-current variant. Standard SDCCG1 outputs are current-limited to 10 mA, sufficient for most electro-hydraulic servo valves (Moog, Vickers, Bosch-Rexroth). However, some direct-drive proportional valves, piezo-actuators, and older torque motor valves require 20–100 mA drive current. The AEC delivers 100 mA per channel with overcurrent protection and thermal limiting. It is designed for retrofit applications where original servo amplifier boards have failed and modern replacements cannot provide sufficient current.

Key Technical Specifications

High Current Features (AEC Revision)

Shared Parameters (Both Channels)

Key Selling Points & Differentiators (AEC Specific)

• 100 mA output per channel – Ten times the current of standard SDCCG1 (10 mA). Drives direct-drive proportional valves, piezo-actuators, and high-impedance torque motors directly. No external current booster required.
• Adjustable current limit (10–120 mA) – Configure via software to match your valve’s requirements. Prevents valve coil burnout. Default: 100 mA.
• Output short-circuit protection – Foldback current limiting reduces output current to 20 mA during short circuit. Auto-recovery when short removed. Standard board outputs would fail permanently.
• Independent overtemperature shutdown per channel – Each channel has its own temperature sensor. If Channel 1 overheats (e.g., driving 150 mA into 50Ω load), only Channel 1 shuts down. Channel 2 continues operating. Fault LED indicates which channel.
• Heatsink included – 2.0°C/W aluminum heatsink attached to board. Required for continuous output >50 mA per channel. For lower currents, heatsink not required but included regardless.
• External heatsinking option – For high ambient temperatures (>50°C) or both channels at 100 mA continuous, attach the included thermal pad to a metal panel for additional heat dissipation.
• QC includes 100 mA continuous burn-in both channels – 24 hours at 100 mA, 50Ω load per channel (resistive). Thermal imaging verifies heatsink temperature <80°C.
• 2-year warranty – Covers output amplifier, current limit circuit, thermal protection, and all I/O.

Frequently Asked Questions (FAQ)

Q: What is the difference between SDCCG1, SDCCG1A, SDCCG1AAA, and SDCCG1AEC?

Choose AEC for valves requiring >10 mA drive current. For standard servo valves (most GE turbines), SDCCG1 is sufficient.

Q: How do I know if my valve requires more than 10 mA?
A: Check valve datasheet for “coil current” or “drive current” specification.

• Moog D63x series: 10–40 mA (depending on model)
• Vickers SM4 series: 15–30 mA
• Bosch-Rexroth 4WRPEH: 50–100 mA
• Direct-drive proportional valves: typically 50–200 mA
• Piezo actuators: 0–100 mA (capacitive load)
  Measure the valve coil resistance. At 10 V, I = 10V / R. If R < 1000Ω, I > 10 mA. Example: 200Ω coil draws 50 mA at 10 V—too high for standard SDCCG1.

Q: Can I use the AEC to drive a 4–20 mA proportional valve (not ±10 VDC)?
A: No. The AEC outputs ±10 VDC, not 4–20 mA. To drive a 4–20 mA valve, add an external voltage-to-current converter (ACC-V2I-HD, rated for 100 mA input). Alternatively, use SDCCF2ANC (4–20 mA output version—special order, 6 weeks).

Q: What is the maximum output current at elevated temperatures?
A: Derating curve:

• At 25°C: 100 mA continuous, 150 mA peak (10 sec)
• At 50°C: 75 mA continuous, 125 mA peak
• At 65°C: 50 mA continuous, 100 mA peak
• At 70°C: shutdown (overtemperature protection)
  Both channels can operate simultaneously at these levels. For continuous high current, provide forced air cooling (200 LFM) or panel mount using thermal pad.

Q: How do I set the current limit?
A: Using GE’s Control System Toolbox (CST) or Toolbox for Mark V software. Navigate to Servo Configuration → Channel X → Output Current Limit. Range: 10–120 mA in 1 mA steps. Default: 100 mA. The current limit is a software setting stored on the board. No potentiometers. We can pre-set current limit before shipping—tell us your valve model.

Q: What happens if I connect a load with resistance lower than 100Ω?
A: Example: 50Ω load at 10 V draws 200 mA. The current limit circuit activates, reducing output voltage to maintain programmed current limit (e.g., 100 mA). Output voltage drops to 5 V (100 mA x 50Ω). The valve may not open fully. If you need to drive very low impedance loads (<100Ω), use an external high-current amplifier (we sell ACC-AMP-1A, 1 A output).

Q: The AEC has a heatsink. Can I remove it for tight spaces?
A: No—the heatsink is required for operation above 50 mA per channel. Without heatsink, the output transistors will overheat and thermal shutdown will activate at much lower currents (approx 25 mA per channel). If space is tight, use the external panel mounting option (remove heatsink, mount board to metal panel with thermal pad). Contact us for panel mounting kit.

Q: What QC tests are specific to the AEC revision?
A: Twelve tests, all documented:
Standard servo tests (output calibration, feedback calibration, PID loop test) plus:

1. Output current capability: Apply 100 mA load (100Ω resistor) to each channel. Verify output voltage >9.9 V at 100 mA.
2. Current limit accuracy: Set limit to 50 mA, 75 mA, 100 mA, 120 mA. Apply load that would draw >limit. Verify output current within ±2 mA of setpoint.
3. Short-circuit test: Short output to ground for 1 minute. Output current must fold back to <20 mA. Remove short, output must recover within 100 ms.
4. Thermal shutdown (Channel 1): Run Channel 1 at 150 mA (overload) until shutdown at 85°C ±5°C. Verify Channel 2 unaffected. Channel 1 fault LED lights. Cool to 70°C, auto-recovery.
5. Thermal shutdown (Channel 2): Repeat for Channel 2.
6. Minimum load test: Apply 100Ω load (100 mA). Measure output ripple <10 mV RMS.
7. Heatsink thermal imaging: Both channels at 100 mA, 25°C ambient, natural convection. Heatsink temperature <80°C.
8. High temperature derating: +65°C ambient, both channels at 50 mA. Must run continuously without thermal shutdown.
9. Output impedance: Measure voltage drop from 0 mA to 100 mA. Impedance <0.5Ω.
10. Isolation (field to backplane): 1800 VAC for 5 seconds. Leakage <0.5 mA.
11. Cross-channel isolation: 1200 VAC for 5 seconds between Channel 1 output and Channel 2 output.
12. Burn-in: 72 hours at +65°C, both channels at 75 mA (derated). No output drift >0.1%, no thermal shutdown.

Q: What shipping protection?
A: Anti-static bag, ESD foam cradle with cutouts for heatsink and terminal blocks. Double-wall box with “HEAVY” (heatsink adds weight), “FRAGILE,” “ESD SENSITIVE” labels. Shock indicator. Heatsink attached securely—do not remove. Thermal pad kit (for optional panel mounting) in separate bag. Each board ships individually. Spare fuses included (4 x 125 mA for external output protection—not installed on board). Configuration service available—ship your old board for parameter extraction.

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