DS200TCRAG1 | GE Mark VI I/O Board

Description

Product Introduction (Anti-Template)

The DS200TCRAG1 is a dedicated relay output board—the board that takes the controller’s ON/OFF signals and drives solenoids, contactors, pilot relays, and other discrete loads with mechanical relay contacts. This board gives you 8 relay outputs in one VME slot, with Form C contacts and per-channel isolation.

The ‘TCRA’ in the part number indicates this is a discrete output board with relay outputs. The base model has 8 outputs with relay contacts, a 10ms update rate, and basic diagnostics. The board is designed for applications where you need to drive a small number of loads with high-current contacts—like solenoids, contactors, and pilot relays—and where a slower update rate is acceptable.

Key Technical Specifications

Compatible Replacement Models

Replacement options depend on your need for relay outputs vs. solid-state outputs and diagnostic features.

✅ Drop-in Replacement: The DS200TCRAG1A (if available) would be the ‘A’ revision. As of this writing, the base model is the only version. Always verify the specific suffix before ordering.

⚠️ Software Compatible: The DS200TCQCG1A (8 relay outputs, 5ms update, diagnostic LEDs) provides relay outputs with faster update and diagnostics. Only use if you need the faster update rate.

⚠️ Software Compatible: The DS200TCQBF1B (16 solid-state outputs, 5ms update) provides solid-state outputs with no contact wear. Only use if you need solid-state reliability.

❌ Hardware Incompatible: Any analog output board (TCDAG1 series) or discrete input board (TCQAF1 series) uses different backplane pins and is not suitable for outputs.

Frequently Asked Questions (FAQ)

What’s the difference between relay outputs and solid-state outputs?

Relay outputs (TCRAG1) use mechanical contacts that physically open and close. They can handle higher current (5A) and are isolated from the control logic, but the contacts wear out over time (especially with inductive loads). Solid-state outputs (TCQBF1B) use MOSFETs with no moving parts—they never wear out but have lower current capacity (2A) and higher cost. Choose relay outputs for high-current loads that switch infrequently; choose solid-state for frequent switching or high reliability.

What type of relays does this board use?

The TCRAG1 uses Form C relays—each output has a normally open (NO) and normally closed (NC) contact. This allows you to use the output to either close a circuit (NO) or open a circuit (NC). The relays are field-replaceable (plug-in type), which is convenient for maintenance.

Can I use this board with a Mark VIe controller?

No—the TCRAG1 uses the older Mark VI backplane pinout. Mark VIe uses a different assignment and typically uses the IS200TCRAG1 for relay outputs. Use the Mark VIe-specific board for new installations.

How do I test this board before installation?

Testing the TCRAG1 requires checking all 8 outputs:

1. Visual inspection: Check for burnt components. Look for relay wear.
2. Power-up test: Apply power. The board’s status LED (green) should illuminate within 2 seconds.
3. Firmware check: Read firmware via ToolboxST—should be 2.0 or later.
4. Output test: Command output 1 ON—verify relay closes (measure continuity across contacts—should be <0.1Ω). Command OFF—verify relay opens. Repeat for outputs 1-8.
5. Contact resistance test: Measure contact resistance of each relay—should be <0.1Ω for new relays.
6. Update rate test: Verify the board updates at 10ms intervals.
7. Isolation test: Measure resistance between output channels—should be >10MΩ.

What’s the most common failure on this board?

Two issues specific to the relay output design:

1. Relay contact wear. The relay contacts can wear out over time, especially if switching inductive loads (solenoids, contactors). Symptom: output doesn’t close or exhibits high contact resistance.
2. Relay coil failure. The relay coil can fail due to overvoltage or overheating. Symptom: output doesn’t respond to commands.

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

The relay outputs make this board suitable for SIL-1 applications (not SIL-2 or SIL-3). We recommend:

• Visual inspection: Every 6 months (check relay contacts for wear)
• Power-up test: Every 12 months
• Output test: Every 12 months (verify relay operation and contact resistance)
• Isolation check: Every 2 years
• Full calibration: Every 5 years

What’s the lead time for a replacement TCRAG1?

These boards are moderately available:

• New surplus: 2-4 weeks.
• Refurbished: 1-2 weeks. Ensure the refurbisher tests all 8 relays.
• Used/as-is: Available, but the relays are wear items—inspect contact resistance.

Is there a direct Mark VIe equivalent?

Yes—the IS200TCRAG1 (Mark VIe version). The backplane pinout is different.

What termination board should I use with the TCRAG1?

The TCRAG1 is designed to interface with a termination board that supports relay outputs. The DS200TBQAG1A (high-current discrete termination) or DS200TBPXG1A (mixed-signal termination) can be used. The termination board provides the terminal connections for the field wiring. The relay contacts on the TCRAG1 are connected to the termination board via the backplane.

What’s the update rate for this board?

The TCRAG1 updates all 8 channels simultaneously at 10ms intervals—100Hz update rate. This is slower than the TCQCG1A (5ms).

What’s the maximum load for the relay outputs?

The relay outputs are rated for 5A at 250VAC or 5A at 30VDC. For inductive loads (solenoids, contactors), derate to 2A or use an external snubber circuit to protect the relay contacts. The relays are field-replaceable—keep spare relays in your maintenance kit.

Can I replace the relays in the field?

Yes—the relays are plug-in type (socketed). You can replace a failed relay without soldering. However, the board must be powered down before replacing relays. Keep spare relays (the correct type and rating) in your maintenance kit. The relay part number is typically printed on the relay body—order the same type.

ICS TRUSTED T8231
ICS TRUSTED T9110
ICS TRUSTED TC-201-02- -4M5