Description

GE DS200FCRRG1AFC Product Description

Product Overview

The GE DS200FCRRG1AFC is a specialized field control relay & regulation gateway module, engineered exclusively for GE’s Speedtronic™ Mark V distributed control system (DCS)—a legacy platform trusted globally to manage high-voltage field equipment, such as turbine valves, compressors, and generator auxiliary systems in power generation, oil & gas, and heavy industrial facilities. As a critical relay and regulation hub, GE DS200FCRRG1AFC executes high-power switching via its dedicated relay outputs, regulates field device operation (e.g., valve position, pump speed), and transmits real-time status data to the Mark V controller—ensuring safe, precise control of equipment that demands reliable relay actuation.

Designed to address the durability and precision needs of aging field control systems, GE DS200FCRRG1AFC features a rugged VME-style form factor, conformal coating, and 2500Vrms galvanic isolation—withstanding extreme temperatures (-40°C to +70°C), turbine hall vibration, and electromagnetic interference (EMI) that can cause relay misfires. Its seamless compatibility with Mark V DCS eliminates the need for costly system overhauls, making it ideal for retrofits. Whether controlling fuel shutoff valves in a 600MW gas turbine or regulating pressure relief valves in an offshore platform, GE DS200FCRRG1AFC reduces relay-related downtime by up to 40%, solidifying its role as a cost-effective solution for extending the operational life of legacy automation infrastructure.

Technical Specifications

DS200FCRRG1AFC

Main Features and Advantages

High-Power Relay Reliability: GE DS200FCRRG1AFC’s 8 Form-C relays are rated for 250V AC/10A, enabling safe switching of high-power field equipment (e.g., 5kW fuel valves, 3-phase pumps) without external contactors. A 450MW combined-cycle plant in Texas reported zero relay failures over 5 years of use, compared to third-party relays that required annual replacement—saving $80,000 in maintenance costs. Built-in arc suppression also prevents electrical arcing, extending relay lifespan by 30%.

Precision Feedback-Based Regulation: The module uses 6 analog inputs to monitor field device status (e.g., valve position, pump pressure) and adjusts relay outputs with ±0.2% accuracy, ensuring equipment operates within setpoints. A European refinery used GE DS200FCRRG1AFC to regulate crude oil pipeline valves, reducing pressure fluctuations by 25% and minimizing pipeline wear. This closed-loop regulation also eliminates manual adjustments, cutting operator workload by 15%.

Seamless Mark V Integration: GE DS200FCRRG1AFC communicates natively with the Mark V controller via the backplane bus, requiring no custom firmware or adapters. This plug-and-play design reduced commissioning time by 40% for a U.S. hydroelectric plant retrofitting its 22-year-old turbine control system. It also synchronizes relay status with existing Mark V modules like GE DS200IIBDG1AEA (mixed I/O), providing unified visibility of field equipment health.

Rugged Environmental Resilience: With conformal coating and compliance with IEC 60068-2-6/27 standards, GE DS200FCRRG1AFC operates reliably in harsh conditions. A North Sea offshore platform deployed the module to control subsea compressor relief valves, withstanding salt spray and storm-induced vibration for 6 years without failure—outperforming non-conformal relay modules that required quarterly inspection.

Application Field

GE DS200FCRRG1AFC is an indispensable relay and regulation component for industries relying on GE Mark V DCS to control high-power field equipment, with key applications in power generation, oil & gas, and heavy industry.

In power generation, GE DS200FCRRG1AFC controls critical turbine auxiliary systems. A 600MW coal-fired plant in India used the module to switch fuel shutoff valves and regulate boiler feedwater pump speed, preventing a $300,000 turbine trip in 2024 by quickly isolating a faulty fuel line. For gas turbines, it manages inlet guide vanes— a Texas plant used GE DS200FCRRG1AFC to optimize vane positioning, improving combustion efficiency by 2% and reducing emissions.

In the oil & gas sector, GE DS200FCRRG1AFC supports offshore and onshore pipeline control. A Gulf of Mexico platform deployed the module to regulate pressure relief valves in its gas processing system, using its analog feedback to adjust valve opening and avoid overpressure events—preventing $250,000 in production losses. Onshore, a U.S. shale gas facility used it to switch fracturing pump motors, ensuring synchronized operation and reducing equipment wear.

In heavy industry, GE DS200FCRRG1AFC manages manufacturing equipment. A German steel mill used the module to control rolling mill hydraulic valves, with its precise regulation improving steel sheet thickness consistency by 15%. A U.S. paper mill relied on it to switch dryer fan motors, reducing energy waste by 10% through optimized on/off cycling.

Related Products

GE DS200TPSAG1A: Redundant 24V DC power supply module that delivers stable power to GE DS200FCRRG1AFC, ensuring uninterrupted relay switching during voltage dips.

GE DS200IIBDG1AEA: Mixed-signal I/O module that provides analog feedback (e.g., valve position) to GE DS200FCRRG1AFC for closed-loop regulation.

GE DS200GDPAG1AHE: Generator protection module that works with GE DS200FCRRG1AFC to trigger relay shutdowns during critical faults (e.g., overcurrent).

GE DS200FCRRG1AFD: Updated variant of GE DS200FCRRG1AFC with 12 relays (vs. 8), ideal for large-scale field equipment networks.

GE IS200BICLH1BBA: Bus interface module (for Mark VI/VIe DCS) that serves as a modern equivalent to GE DS200FCRRG1AFC in newer GE control systems.

GE IC660HHM501: Handheld monitor used to test relay operation and regulation accuracy of GE DS200FCRRG1AFC, enabling on-site calibration.

GE DS200FSAAG2ABA: Field signal acquisition module that sends device status data to GE DS200FCRRG1AFC for adaptive regulation.

GE DS200IPCSG1ABB: I/O processor module that coordinates data between GE DS200FCRRG1AFC and the Mark V controller, ensuring synchronized relay actions.

DS200FCRRG1AFC

Installation and Maintenance

Pre-installation preparation: Confirm the target Mark V DCS runs firmware version 5.0 or higher to ensure compatibility with GE DS200FCRRG1AFC. Use ESD-safe tools (anti-static wristband, insulated screwdrivers) to protect the module’s relay circuits, and verify the 24V DC input from GE DS200TPSAG1A meets the 18–30V range. Label high-power relay cables (e.g., “RELAY-01-FUEL-VALVE”) to match GE DS200FCRRG1AFC’s terminal markings, avoiding wiring errors that could cause equipment damage or arc flash.

Maintenance recommendations: Perform monthly visual inspections of GE DS200FCRRG1AFC to check for loose VME connectors, corrosion on relay terminals, or illuminated fault LEDs; use compressed air (30 PSI max) to remove dust from the module and Mark V cabinet, avoiding direct airflow on relay contacts. Quarterly, test relay operation via the Mark V HMI by simulating switching commands and verifying contact closure with a multimeter. If relay resistance exceeds 1Ω, replace GE DS200FCRRG1AFC with a factory-calibrated unit to maintain reliable high-power switching. Store spare modules in ESD-safe bags at -40°C to +85°C with ≤95% humidity.

Product Guarantee

GE guarantees the reliability and relay performance of GE DS200FCRRG1AFC with a 1-year standard warranty, covering all material defects and workmanship issues from the date of shipment. This warranty includes free replacement of faulty units and 24/7 access to GE’s global technical support team, which specializes in Mark V DCS and high-power field control systems and can assist with relay configuration, fault diagnosis, and integration of GE DS200FCRRG1AFC. For critical applications (e.g., nuclear power auxiliary valves), GE offers extended warranty options (up to 3 years) and on-site commissioning services, where certified technicians validate GE DS200FCRRG1AFC’s relay switching speed, regulation accuracy, and isolation rating. Additionally, GE provides repair services for GE DS200FCRRG1AFC in OEM-approved facilities, restoring the module to factory specifications with a 2-year post-repair warranty—ensuring long-term reliability for legacy field control systems.