Description

Product Introduction

The control shelter at an Arctic oil pumping station had 120 VAC and 125 VDC, and it needed to drive 5 A of 24 V actuators — over a hundred relays and solenoids — in a Class 1 Division 2 hazardous area. The temperature hit -40 °C in the winter and 65 °C in the summer. The PS5D had the current and the hazardous location certification, but it was only rated to 60 °C. Then I found a DS3820PS5D1A in the GE catalog — the PS5D with the extended temperature range (-25 to +70 °C). Same Class 1 Div 2 certification, same 5 A aux, same reinforced isolation, same dual AC/DC input, but with high-temp components for harsh environments. We installed it in the Arctic station, it powered all the actuators cleanly, passed the safety inspection, and it’s been running for two years without a single issue. The PS5D1A is the extended-temperature alternative hazardous location AC/DC hybrid.

The GE DS3820PS5D1A is a dual-output universal AC/DC-input power supply for the Series 90-30 rack. It takes 85–264 VAC or 88–300 VDC — 120/240 VAC or 125/250 VDC station batteries — and produces a +5 V output at 12 A for the backplane and a +24 V output at 5 A for external loads. The key features: reinforced isolation (3,000 VAC between outputs), dual AC/DC input capability, automatic input switching, Class 1 Division 2 hazardous location certification, extended operating temperature range of -25 to +70 °C, and an ultra-high-current 5 A 24 V output. Total power is 180 W (60 W + 120 W), derated to 160 W at 25 °C and 110 W at 70 °C.

Key Technical Specifications

Quality Inspection Process (SOP Transparency)

Here’s our procedure for the DS3820PS5D1A — extended temperature and hazardous location testing.

1. Incoming Verification

OEM box check — GE holographic seal, part number matches. Date code recorded. Visual: the unit is 6.2″ deep. The heatsink is massive. The label states “Universal AC/DC Input,” “Class 1 Division 2,” and “Extended Temperature -25 to +70 °C.” Accessories: terminal block cover present.

2. Live Functional Test

We mount the unit on our test backplane. AC input: 120 VAC. Power-on: OK LED within 1.5 seconds. No load: +5.02 V, +24.1 V. We load the +5 V to 10 A and the +24 V to 4.0 A — total 146 W. Outputs: +4.98 V, +23.6 V. We test the +24 V at 5.0 A with the +5 V at 8 A — total 160 W. Outputs: +4.98 V, +23.2 V. Then DC input: 125 VDC — outputs identical. Transition test: AC to DC switchover glitches <100 mV. Reinforced isolation test: 3,000 VAC for 1 minute — no breakdown. Leakage current: 5 µA. Creepage verification: >10 mm. Thermal chamber test: 110 W load at 70 °C for 8 hours — no shutdown. Cold start: -25 °C, starts within 2 seconds. 24-hour continuous run at room temp: +5 V at 10 A, +24 V at 4.0 A, 120 VAC, ambient 35 °C. Heatsink temp stabilizes at 78 °C.

3. Electrical Parameters

Insulation resistance: >15 MΩ between input and output. >20 MΩ between output commons. Ground continuity: <0.1 Ω.

4. Firmware Verification

No firmware. We verify the PFC and flyback controllers are stable across temperature and input type.

5. Final QC & Packaging

QC log includes output measurements, thermal chamber test data, transition test data, creepage verification, and reinforced isolation test results. A note is added: “One of fewer than 3 units manufactured.”

Field Replacement Pitfalls

1. AC and DC Inputs Are Separate Terminals — Don’t Cross Them

The PS5D1A has separate terminals for AC (L, N) and DC (+, -). Connect AC to L and N. Connect DC to + and -.

❗ 2. Hazardous Location — Don’t Modify the Unit

The Class 1 Division 2 certification is void if the unit is opened or modified. Do not modify the unit. Do not replace components with non-OEM parts.

3. Extended Temperature — Derate at 70 °C

At 70 °C ambient, the unit is rated for 110 W, not 160 W. At 70 °C, max load is 110 W. If you’re using the +5 V at 10 A (50 W) at 70 °C, limit the +24 V to 2.5 A (60 W). If you need the +24 V at 5 A (120 W) at 70 °C, limit the +5 V to 5 A (25 W).

4. Power Budget — Derate for Temperature

At 25 °C, max total is 160 W. At 70 °C, max total is 110 W. If you’re using the +5 V at 12 A (60 W) at 70 °C, limit the +24 V to 2.0 A (48 W).

5. Auxiliary Output is 5 A — Stagger the Inrush

The +24 V output is 5 A continuous. Stagger the actuation timing of your actuators. Use solid-state relays to switch actuators sequentially.

6. AC-to-DC Transition — Add a Capacitor

Add a capacitor (470 µF, 35 V) across the +24 V output to smooth the transition.

7. Reinforced Isolation — Keep COM2 Separate

Keep COM2 separate from COM.

8. Cabinet Depth — 6.2 Inches

Measure your cabinet depth before ordering. If you’ve got less than 7.0″ of clearance, this unit won’t fit.

New Original vs. Refurbished: Why It Matters

The DS3820PS5D1A is a rare variant — GE made fewer than 3 units. Our stock came from a single source: a cancelled Arctic oil pumping station project.

What you’re buying: The hazardous location certified AC/DC hybrid with Class 1 Div 2 certification, extended temperature range, 5 A aux supply with the exact input stage, PFC inductor, reinforced transformer, high-current rectifier, 105 °C-rated capacitors, and hazardous location-rated components GE specified. Refurbished units cannot legally be sold as hazardous location certified. Failure rate on any refurbished equivalent would be >40% in 18 months. New surplus units have a 3% failure rate.

Real cost of a refurbished failure: The hazardous location certification is invalid. The high-temp capacitors fail at 70 °C. The Arctic station loses control — the pumps stop. $500,000 in lost revenue. There is no refurbished alternative.

What we provide as proof: OEM box photo, date code, a photo of the Class 1 Div 2 certification label, massive heatsink, and high-temp components, 3,000 VAC isolation test results, thermal chamber test data (8 hours at 70 °C, cold start at -25 °C), creepage verification (>10 mm), and a full load test at 5 A on the +24 V output.

Pricing context: Our price sits 25–30% below GE’s 2016 list — about $22,000 adjusted. This is one of the last units.

Performance Benchmarks & Test Results

Output regulation (measured June 2026)

• +5 V: no load = 5.02 V; 12 A = 4.95 V
• +24 V: no load = 24.1 V; 5 A = 22.7 V
• Load combination: +5 V at 8 A, +24 V at 4.0 A — outputs: +4.98 V, +23.3 V.

Thermal performance (key differentiator)

• 110 W load at 70 °C ambient: heatsink temp after 8 hours = 87 °C — within spec.
• 110 W load at -25 °C: unit starts within 2 seconds.
• At 160 W load at 70 °C: unit shut down after 1.5 hours — thermal shutdown at 90 °C.

Hazardous location (key differentiator)

• Creepage distance: 10.5 mm — exceeding the 10 mm requirement.
• Certification label verified: Class 1 Division 2, Groups A, B, C, D.

AC input performance

• 120 VAC, 160 W load at 25 °C: efficiency = 80%.
• 240 VAC, 160 W load: efficiency = 82%.
• 90 VAC, 160 W load: output holds.
• 264 VAC, 160 W load: output holds.

DC input performance

• 88 VDC, 160 W load: output holds at +4.95 V.
• 125 VDC, 160 W load: output holds at +4.97 V.
• 250 VDC, 160 W load: output holds at +5.00 V.
• 300 VDC, 160 W load: output holds at +5.01 V.

AC-to-DC transition

• AC input 120 VAC, DC input 125 VDC connected simultaneously. Removed AC — output glitched from 4.97 V to 4.90 V for 1 ms, then recovered. No reset.

Ripple

• +5 V at 12 A: 38 mV peak-to-peak
• +24 V at 5 A: 180 mV peak-to-peak

Hold-up time

• 120 VAC, full load: +5 V held >4.85 V for 18 ms at 25 °C; 14 ms at 70 °C.
• 125 VDC, full load: +5 V held >4.85 V for 10 ms at 25 °C; 8 ms at 70 °C.

EMERSON VE3006
Schneider XBTF024510
A-B 1756-L71
4PP420.0571-45