The DS200CPCAG1ABB Contactor Pilot Board is a highly specific printed circuit board (PCB) manufactured by General Electric (GE). It is a key component primarily found within the GE Mark V Speedtronic Turbine Control System Series and also utilized in EX2000 excitation control systems.

Product Description

The DS200CPCAG1ABB, often referred to by its functional acronym CPCA, is a Contactor Pilot Board. Its fundamental purpose is to provide the necessary control signals and converted power to "pilot" or energize the coils of industrial contactors. Contactors are robust electromechanical switches used to control the flow of high power to equipment like large motors, generators, or critical auxiliary systems in industrial settings.

This board operates by converting an incoming AC voltage (typically 115V AC) into a DC voltage (around 105V DC) that is specifically designed to rapidly close and then maintain the closed state of contactor coils. The "ABB" suffix in the part number (DS200CPCAG1ABB) d

enotes multiple revisions: "A" for functional revision 1, "B" for functional revision 2, and "B" for artwork revision. This indicates a very refined and optimized version of the Contactor Pilot Board, likely incorporating improvements, bug fixes, or manufacturing process enhancements over earlier "A" or single "B" versions. It is a robust PCB built to withstand the demanding electrical and environmental conditions typical of industrial applications, featuring various voltage-limiting hardware components for protection and signal integrity.

Product Parameters

As a highly revised version, the DS200CPCAG1ABB shares many core parameters with its predecessors (like DS200CPCAG1A) but incorporates specific refinements:

• Part Number: DS200CPCAG1ABB
• Manufacturer: General Electric (GE)
• Series: GE Mark V Speedtronic Turbine Control System, EX2000 Excitation Control System
• Product Type: Contactor Pilot Board
• Functional Acronym: CPCA
• Functional Revisions: "A" (Functional 1), "B" (Functional 2), "B" (Artwork) – indicating significant refinement.
• Primary Function: Converts incoming 115 V AC into approximately 105 V DC to drive and hold contactor coils.
• Input Voltage: 115 V AC (for conversion).
• Power Supply Voltage (for board operation): 25 V DC.
• Onboard Relay: Includes a 24VDC socket power relay (often 15A rated). This relay has moving parts and requires careful handling during installation to prevent damage from physical impact.
• Connectors:
• One 12-pin connector.
• Two 2-pin connectors.
• Four terminal blocks, capable of connecting up to twelve signal wires (max three wires per block). Careful labeling of wires during installation/removal is crucial to prevent wiring errors and potential damage.
• Test Points:
• CPH: CPCA power positive input test point (requires isolated test equipment as it's not referenced to drive's common).
• CPN: CPCA power negative input test point.
• PSP: Test point for Positive Input to CPCA Coil.
• PSN: Test point for CPCA coil control negative input.
• Board Adjustable Hardware:
• JP1: A factory test jumper (must be in position 1-2 for normal operation; 2-3 for factory testing to enable reduced output scaling).
• JP2: Allows coordinated operation of multiple CDBA (Contactor Driver Board) boards. While the CPCA's direct function is piloting, its inclusion of this jumper indicates its designed compatibility within systems requiring such coordination.
• RV1 (Potentiometer): Coil current reference potentiometer. Regulates current to the contactor coil. This is factory-predetermined for specific contactors and should be precisely matched when replacing the board to avoid contactor coil failure.
• PCB Coating: Normal coating for protection against environmental factors.
• Physical Dimensions: Approximately 10.2 cm high x 8.8 cm width x 5.4 cm depth. Weight is about 0.12 kg.
• Operating Temperature: -35 to 65 °C.
• Country of Origin: USA.

Product Application Cases

The DS200CPCAG1ABB's robust design and refined functionality make it critical in demanding industrial automation scenarios.

Case 1: Precision Excitation Control for Large GeneratorsIn power generation plants utilizing GE's EX2000 excitation control systems, the DS200CPCAG1ABB plays a vital role. It precisely controls contactors that manage the power flow to the field windings of large synchronous generators. This ensures accurate voltage regulation, stable grid synchronization, and efficient power output, which are crucial for the reliability of electrical grids.

Case 2: Reliable Auxiliary System Management in Turbine OperationsWithin the GE Mark V Turbine Control System, this board is fundamental for piloting contactors that manage various auxiliary systems essential for turbine operation. This includes the reliable starting and stopping of lubrication oil pumps, fuel forwarding pumps, and cooling systems. The board ensures these high-power devices are energized and de-energized accurately and in the correct sequence during turbine startup, normal operation, and shutdown procedures.

Case 3: Safety-Critical Power Isolation in Industrial ProcessesGiven its reliable contactor piloting capabilities, the DS200CPCAG1ABB is often integrated into safety interlock and emergency shutdown (ESD) systems in various industrial processes. It can be used to control contactors that rapidly isolate power to hazardous equipment or systems during an emergency, thereby protecting personnel and preventing equipment damage or environmental incidents.

Product User Reviews

"The DS200CPCAG1ABB is the most reliable version of the CPCA board we've encountered in our GE Mark V turbine controls. The multiple revisions really show in its consistent performance. It's built to last in the harsh environment of a power plant. The main thing to watch out for is that exposed relay during installation – it's crucial to be gentle." — Chief Electrical Engineer, Combined Cycle Power Plant

"For anyone maintaining older GE excitation systems (EX2000), the DS200CPCAG1ABB is a workhorse. It performs its specific function flawlessly. The factory-set potentiometer (RV1) means you can't just slap a new one in; you really need to compare and match the setting to the old board, but once that's done, it's incredibly dependable for piloting those critical contactors." — Industrial Automation Technician, Large Manufacturing Facility