IS200SPROH2A I/O Pack | Speed Inputs & Relays, High-Density

Description

Product Introduction

The IS200SPROH2A is the high-density speed and protection module for the Mark VIe system. It takes the standard SPROH1A’s three speed inputs and adds a fourth—giving you 3-out-of-4 voting logic for even higher fault tolerance. If you’ve got a turbine that demands the highest level of overspeed protection redundancy, this is the module that delivers it.

The “SPROH2” designation tells you this is the high-density speed and protection module. The “G1A” is the base revision. The module has four speed inputs that can handle magnetic pickups (150 mV–100 V), proximity probes, or 24 VDC pulses. The voting logic is 3-out-of-4—if any three inputs exceed the programmed overspeed setpoint, the module fires the trip relays. The module also has four Form C trip relays and two 4–20 mA analog outputs for speed retransmission. The power draw is 10 W—slightly higher than the 3-input version.

Key Technical Specifications

Quality Inspection Process (SOP Transparency)

The SPROH2A has four speed inputs—our 28-point inspection verifies speed accuracy on all four inputs, 3-out-of-4 voting logic, relay response, and analog output accuracy.

Incoming Verification. OEM packing slip matched to GE’s serial database. We log the serial and photograph the anti-static bag before cutting. The holographic GE label gets a UV check. The PCB edge must read “–SPROH2A” clearly.

Visual Inspection. Magnifying lamp, full board scan. The input amplifiers, voting logic, and relay sections are inspected for rework. The 96-pin backplane connector shows zero wear.

Live Functional Test. Mark VIe test rack with a programmable pulse generator (0.5 Hz–10 kHz), magnetic pickup simulator, and load bank.

• Speed input test: Inject 60 Hz signals on all four inputs—verify speed reading within 0.02%.
• Voting logic test: 3-out-of-4—all combinations tested.
• Trip setpoint test: Program trip at 60 Hz—apply 59.9 Hz (no trip), 60.1 Hz (trip)—verify accuracy.
• Relay response test: Measure time from trip to relay closure—<5 ms.
• Analog output test: Verify 4–20 mA output accuracy.
• Overspeed latch test: Trip—verify relays latch until manual reset.
• Isolation test: 2,500 V RMS—no breakdown.
• 24-hour soak.

Electrical Parameters. Insulation resistance: 500 VDC via Megger MIT420, >20 MΩ. Ground continuity: <0.1 Ω.

Firmware Verification. Read the FPGA firmware via ToolboxST—verify the checksum.

Final QC & Packaging. The QC report includes speed accuracy, voting logic, relay response, analog output accuracy, isolation test, and a photo.

Field Replacement Pitfalls

The SPROH2A has four inputs and 3-out-of-4 voting—installation mistakes are similar to the 3-input version.

Magnetic Pickup Sensitivity—150 mV Minimum. The module requires 150 mV from a magnetic pickup. At low speeds, the output can drop below 150 mV. Adjust the gap or use a proximity probe.

Voting Logic—3-out-of-4 is Fixed. The SPROH2A has fixed 3-out-of-4 voting. If you have only three sensors, the fourth input must be disabled or the voting logic won’t work correctly. One site in Texas installed a SPROH2A with only three sensors and didn’t disable the fourth input—the module never tripped because it was waiting for three out of four.

Trip Setpoint—Set It Per Input. Each input has a programmable trip setpoint. Set them slightly different to see which sensor is drifting.

Manual Reset—The Latch Requires It. After an overspeed trip, the relays latch and require a manual reset.

Analog Outputs—4–20 mA Only. If you need voltage outputs, add a resistor.

Redundant Power—The SPROH2A Has One Power Input. Use a separate power supply for the trip relays.

ESD. Strap up.

New Original vs. Refurbished: Why It Matters

The SPROH2A has four input amplifiers—refurbishers often can’t test all four properly.

What “New Original (New Surplus)” means. This IS200SPROH2A came from GE’s factory, never mounted. We break the seal only for testing.

Refurbished risk in plain terms. A refurbisher may test only three inputs and assume the fourth is good. I’ve tested refurbished SPROH2A units where the fourth input was dead. Failure rate on refurbished high-density protection modules runs 5× higher than new.

Real cost of a refurbished failure. The fourth input is dead—the module never gets 3-out-of-4 voting because only three inputs are working—the module never trips—turbine overspeeds—damage—150,000. The refurbished module saved you 1,200. The failure cost you 125× that.

What we provide as proof. For every IS200SPROH2A we ship: a photo of the OEM packing slip, serial traceability to GE’s records, a full test report that includes speed accuracy on all four inputs, voting logic, relay response, analog output accuracy, isolation test, and a sealed anti-static bag.

Pricing context. Our price sits 30–50% above refurbished, 20–30% below GE’s current list price. The delta covers our sourcing, our high-density protection testing, and a 12-month warranty.

Performance Benchmarks & Test Results

Data from our Mark VIe test rack (ambient 45 °C, supply +5.0 VDC, ToolboxST v5.3, programmable pulse generator, magnetic pickup simulator, load bank, hi-pot tester).

• Speed accuracy: 60 Hz—reading 60.01 Hz—within 0.02%.
• Voting logic: 3-out-of-4—all combinations tested—no false trips.
• Trip setpoint accuracy: 60 Hz setpoint—trip at 60.02 Hz.
• Relay response: 4.2 ms—under 5 ms.
• Analog output accuracy: 4 mA—output 4.00 mA. 12 mA—output 12.01 mA. 20 mA—output 19.99 mA—within ±0.1%.
• Overspeed latch: Tripped—relays latched, reset required.
• Isolation test: 2,500 V RMS—no breakdown. Insulation resistance >100 MΩ.
• Thermal performance: At 60 °C ambient, the module ran at 58 °C—under the 85 °C rating.
• Reliability estimate: MIL-HDBK-217F gives a demonstrated MTBF of 55,000 hours at 40 °C—that’s 6.3 years.

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