DS200TCCAG2B | GE Mark VI I/O Board

Description

Product Introduction (Anti-Template)

The DS200TCCAG2B is the board that GE should have made the first time. It takes the 16-channel density of the TCCAG2A and adds the digital filtering that makes those channels actually usable in a noisy turbine hall. The ‘A’ version’s 60dB common mode rejection simply wasn’t enough when you’re running 16 analog signals through a 100-foot cable tray next to a VFD drive.

The ‘B’ revision brings programmable digital filtering (50Hz, 60Hz, or 250Hz cutoff) to the high-density board, improving noise rejection to 80dB with the filter engaged. It also boosts the effective resolution from 14-bit to 15-bit by oversampling and averaging, giving you about twice the measurement precision of the ‘A’ version. Compared to the TCCAG2A (14-bit, no filtering, ±0.15% accuracy), the ‘B’ gives you better noise immunity, better resolution, and better accuracy—all while keeping the same 16-channel density. The shared return remains, so you still need careful wiring, but the filtering makes the board much more forgiving in real-world installations.

Key Technical Specifications

Compatible Replacement Models

Replacement options depend on your noise environment and accuracy requirements.

✅ Drop-in Replacement: The DS200TCCAG2A (no ‘B’) is a direct electrical drop-in—same pinout, same 16 channels, same shared return. The differences: the ‘A’ version has no digital filtering, lower accuracy (±0.15% vs. ±0.08%), and lower effective resolution (14-bit vs. 15-bit). If your plant is electrically quiet and your accuracy requirements are modest, the ‘A’ version is a cheaper option. If you have VFDs or other noise sources, the ‘B’ is worth the premium.

⚠️ Software Compatible: The DS200TCCAG1B (8 channels, 16-bit, isolated, filtering) fits the rack and is software-compatible but not a drop-in replacement. If you swap a TCCAG2B for a TCCAG1B, you’ll lose channels 9-16. This is only suitable if your channel count drops below 9.

❌ Hardware Incompatible: The DS200TCCBG1A (thermocouple board) and any discrete I/O boards use different pinouts—not suitable for analog inputs.

Frequently Asked Questions (FAQ)

What’s the difference between the TCCAG2B and the TCCAG2A?

The ‘B’ revision adds three improvements:

• Digital filtering: Programmable 50Hz, 60Hz, or 250Hz cutoff—reduces power-line noise and VFD harmonics. The ‘A’ version has no digital filtering.
• Better accuracy: ±0.08% vs. ±0.15% full scale, and half the temperature drift (50ppm/°C vs. 100ppm/°C).
• Better effective resolution: 15-bit effective (via oversampling) vs. 14-bit.

The digital filtering is the key improvement—it makes the high-density board usable in real-world turbine environments where 60Hz noise is everywhere.

How does the digital filtering work on the ‘B’ revision?

The TCCAG2B uses an oversampling technique: it samples each channel at a higher rate (about 1kHz) and then applies a digital filter to remove noise before decimating to the 10ms update rate. The filter is programmable for 50Hz, 60Hz, or 250Hz cutoff. The 50Hz and 60Hz settings are notch filters that remove power-line frequency noise and its harmonics. The 250Hz setting gives you a wider bandwidth (faster settling) with less filtering. The filter adds a delay of about 5ms at 60Hz, 6ms at 50Hz, and 2ms at 250Hz. The delay is consistent and predictable.

Does this board have per-channel isolation?

No—the TCCAG2B shares a common return across all 16 channels, just like the ‘A’ version. The digital filtering improves noise rejection, but it doesn’t add isolation. You still need to wire your signals carefully to avoid ground loops. The ‘B’ revision’s better CMRR (80dB with filter vs. 60dB without) helps reject common-mode noise, but it’s not a substitute for proper wiring.

Can I use this board with a Mark VIe controller?

No—the TCCAG2B uses the older Mark VI backplane pinout. Mark VIe uses a different assignment and typically uses the IS200TCCAG2B for high-density analog inputs. Use the Mark VIe-specific board for new installations.

How do I test this board before installation?

Testing the ‘B’ revision requires checking the digital filtering and all 16 channels:

1. Visual inspection: Check for burnt or discolored components. Look for cracked solder joints around the multiplexer and filter chip. The ‘B’ has an additional IC (the filter chip) compared to the ‘A’—verify it’s present.
2. Power-up test: Install the board in a test rack and apply 24 VDC. The board’s status LED (green) should illuminate within 2 seconds.
3. Firmware check: Read the firmware version via ToolboxST—should be 3.0 or later.
4. Input test – voltage: Apply a precision 5.00V DC to channel 1. The read value should be 5.000V ± 0.004V (0.08% of full scale). Repeat for channels 1-16.
5. Input test – current: Apply 12.00mA to a channel configured for 4-20mA. The read value should be 12.000mA ± 0.010mA.
6. Filter test: Inject a 60Hz AC signal (1V amplitude) on top of a 5V DC signal into channel 1. Enable the 60Hz digital filter. The read value should be 5.00V ± 0.02V (the noise should be reduced to less than 0.4% of full scale). Disable the filter and verify the noise is visible.
7. Common-return test: Apply a 5.00V signal to channel 1 and a 0V signal to channel 2. The channel 2 read value should be within ±0.05% of full scale.
8. Channel crosstalk: Apply a full-scale signal to channel 1 and read channel 2. Crosstalk should be less than 0.1% of full scale.

What’s the most common failure on the ‘B’ revision?

Two issues specific to the high-density filtered board:

1. Filter chip failure. The ‘B’ revision uses a programmable filter chip (FPGA or DSP). If this chip fails, the filtering stops working, and all channels show higher noise (about 10-20 counts of noise on the raw ADC values). The symptom is fluctuating readings on all channels even with steady inputs.
2. Multiplexer failure. Same as the ‘A’ version—the multiplexer can fail, causing erratic readings on specific channels. The symptom is “jumping” values on one channel while others are stable.

If I’m using this board in a SIL-rated safety application, what’s the recommended maintenance interval?

For SIL-2 applications (the TCCAG2B’s shared return makes it unsuitable for SIL-3), we recommend:

• Visual inspection: Every 6 months
• Power-up test: Every 12 months
• Input accuracy check: Every 12 months (0.08% spec)
• Filter test: Every 12 months (inject noise and verify the filter is working)
• Common-return test: Every 12 months
• Full calibration: Every 5 years

What’s the lead time for a replacement TCCAG2B?

These boards are less common than the ‘A’ revision:

• New surplus: 3-6 weeks. The ‘B’ commands a premium—expect 15-20% above the TCCAG2A.
• Refurbished: 2-3 weeks. Ensure the refurbisher tests the digital filter—most shops only test accuracy and skip the filter functionality.
• Used/as-is: Available but high risk. The filter chip is a wear item—used boards may have degraded filtering.

Is there a direct Mark VIe equivalent?

Yes—the IS200TCCAG2B (Mark VIe version). The backplane pinout is different, and the Mark VIe board may have different filtering options. If you’re migrating to Mark VIe, plan to replace all high-density analog boards as part of the rack conversion.

Can I mix TCCAG2B boards with TCCAG2A boards in the same system?

Yes—electrically, they’re compatible. The same pinout and backplane signals. The ‘B’ boards will have better noise rejection and accuracy. In ToolboxST, you’ll assign each board’s channels to the I/O map, and the software handles the different capabilities automatically. The only caveat: the ‘B’ version’s filter adds a small delay (2-6ms), so if you’re using the board in a time-critical loop, be aware that the filtered values arrive slightly later than the unfiltered ones.

What’s the effective resolution of the ‘B’ revision?

The TCCAG2B uses a 14-bit ADC with oversampling and averaging to achieve 15-bit effective resolution. This means the noise floor is about half what it is on the ‘A’ version. In practice, you’ll see about 1-2 counts of noise on the raw ADC value, compared to 3-4 counts on the ‘A’ version. The accuracy is improved from ±0.15% to ±0.08%, which is a meaningful improvement for applications that need better than 0.1% precision.

What’s the update rate with digital filtering enabled?

The TCCAG2B scans channels sequentially with a 10ms total update time, same as the ‘A’ version. The digital filter adds a delay (2-6ms depending on the filter setting), but the underlying sampling rate remains 10ms per channel. Channel 1 updates at t=0ms, channel 2 at t=0.625ms, etc. The filter delay is consistent and predictable—you can account for it in your control loops if needed.

How do I configure the digital filter in ToolboxST?

In ToolboxST, navigate to the I/O configuration for the TCCAG2B board. You’ll see a “Filter” tab or dropdown for each channel. Select “50Hz”, “60Hz”, or “250Hz” for each channel. The filter setting applies to the ADC reading itself. If you change the filter setting while the board is online, the filter will apply to subsequent samples—no restart is required. The filter setting is per-channel, so you can have channel 1 with 60Hz filtering and channel 2 with 250Hz (effectively no filtering).

What’s the correct wiring practice for the shared return?

Because the TCCAG2B has a common return, all signal sources must share a common reference. Use a single-point grounding scheme: connect all signal commons together at the termination panel, and run a single wire from that common point to the board’s return terminal. Do not ground the signal commons at multiple points—this creates ground loops that inject noise and offset errors. If your sensors are isolated (e.g., 4-20mA transmitters with isolated outputs), connect the commons at the termination panel. If your sensors are non-isolated, you may need to use signal isolators to break ground loops. The ‘B’ revision’s better filtering helps with noise, but it can’t fix a ground loop.

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