The DS200GDPAG1A is a High Frequency Power Supply Board designed by General Electric (GE) Industrial Control Systems for its AC2000 series drives, Innovation Series drives, and EX2000 excitation systems. Belonging to the GDPA (High Frequency Power Supply Board) series, this board is part of the G1 group and represents revision A. It serves as a core component within GE drive systems, responsible for providing high-frequency power to gate drive circuits.
The primary function of the GDPA High Frequency Power Supply Board is to generate 27 kHz high-frequency AC power, providing the 50 V ac and 120 V dc outputs required for SCR or GTO gate drive circuits. This board features a unique dual-input capability, drawing power from both AC (80-132 V ac) and DC (105-140 V dc) sources simultaneously, ensuring system power redundancy and reliability. The board integrates input rectification and filtering, a buck chopper regulator, a 27 kHz inverter, an output transformer, and various protection circuits, making it a critical power component for reliable gate triggering in drive systems.
The DS200GDPAG1A board embodies GE’s advanced technology in power electronics and features the following characteristics:
Dual Input Power Capability: Simultaneously supports 80-132 V ac and 105-140 V dc inputs, enhancing system redundancy.
High-Frequency Output: Generates 27 kHz, 50 V ac output for driving gate pulse transformers.
Multiple Outputs: Provides four 50 V ac outputs and one 120 V dc output to meet multi-channel gate drive requirements.
Comprehensive Protection Circuits: Integrates inverter overcurrent, regulator overcurrent, P80 bus overvoltage, control voltage undervoltage, and other protection functions.
Status Indicators: Uses LEDs and neon lamps to indicate power status, fault conditions, and fuse status.
Rich Testpoints: Provides multiple testpoints for commissioning and fault diagnostics.
This product is widely used in AC2000 drives, Innovation Series drives, EX2000 excitation systems, and various industrial power electronics applications requiring high-frequency gate drive power.
II. Key Functions
1. Dual Input Power Capability
One of the key advantages of the DS200GDPAG1A board is its dual input power capability, allowing it to draw power from both AC and DC sources simultaneously:
| Input Type | Voltage Range | Description |
| AC Input | 80-132 V ac, 28-66 Hz | Source should be impedance limited |
| DC Input | 105-140 V dc | Inrush limiting and fusing must be supplied externally |
When the input voltage drops below 102 V ac, the board can still operate, but thermal damage may occur under full load. Under reduced loading, the board can operate with input voltages below 95 V dc.
2. High-Frequency Output Power
The core function of the DS200GDPAG1A board is to generate 27 kHz high-frequency AC power, providing the following outputs via output transformer T1:
50 V ac Outputs: Four 50 V ac (27 kHz) outputs are provided via connectors 1GDPL, 2GDPL, 3GDPL, and 4GDPL for driving gate pulse transformers.
120 V dc Output: Provided via the CPTPL connector for external device power.
3. Power Conversion and Regulation
The DS200GDPAG1A board incorporates a complete power conversion chain:
Input Rectification and Filtering: AC input is rectified via a full-wave bridge after passing through an EMI filter.
Buck Chopper Regulator: Reduces the unregulated DC bus voltage to approximately 83 V (P80 bus).
27 kHz Inverter: Converts the P80 bus voltage into 27 kHz high-frequency AC to drive output transformer T1.
4. Protection Circuits
The DS200GDPAG1A board integrates multiple protection circuits to ensure the safety of the board and connected loads:
| Protection Function | Description |
| Inverter Overcurrent | Limits output current by reducing P80 output voltage rather than tripping the inverter when output is shorted or overloaded. |
| Regulator Overcurrent | Shuts down the regulator output when regulator current exceeds the preset reference level. |
| P80 Bus Overvoltage | Shuts down the inverter in the event of output short-circuit failures. |
| Control Voltage Undervoltage | Shuts down the inverter and regulator output during startup until control voltage reaches operational levels. |
| Foldback Characteristic | Overcurrent protection features a foldback characteristic; short-circuit current is just over half the overcurrent level effective at full output voltage. |
5. Status Indicators
The DS200GDPAG1A board provides various status indicators for on-site monitoring and fault diagnostics:
| Indicator | Color | Description |
| CR1/CR2 (PWR IN) | Yellow | AC input: ON when AC voltage is present and F1 is not blown. DC input: ON when high voltage is present, remains ON until voltage drops below 50 V. |
| CR37/CR39 (READY) | Green | ON when voltage is sufficient and board is good; remains ON even if GDPA outputs are zero due to current limit. |
| N1 (HI VOLT SHRT) | Orange | ON when a GDPL connector pin is tied to external voltage greater than 300 V ac/dc, indicating insulation breakdown. |
| N2 (120 V DC FUSE) | Orange | ON when fuse F3 on the 120 V dc output is blown. |
6. Output Voltage Regulation
The DS200GDPAG1A board regulates output voltage by sensing the voltage on windings 10, 11, and 12 of output transformer T1. Output voltage is factory-adjusted to 50 V ac at half load and typically requires no field adjustment.
III. Hardware Architecture
1. Board Structure
The DS200GDPAG1A board uses a standard printed circuit board structure with dimensions compatible with GE drive system mounting requirements. The board includes:
Input Rectification and Filtering Circuits: Process AC and DC inputs.
Buck Chopper Regulator: Reduces unregulated DC to the 83 V bus.
27 kHz Inverter: Generates high-frequency AC to drive the output transformer.
Output Transformer T1: Provides isolation and voltage conversion.
Protection Circuits: Integrated overcurrent, overvoltage, and undervoltage protection.
Indicators: 4 LEDs and 2 neon lamps.
Testpoints: Multiple testpoints (16 for 600 VA version, 26 for 700 VA version).
Connectors: 12 plug connectors and 2 stab-on connectors.
2. Mounting Method
The DS200GDPAG1A board can be mounted on a drive mounting plate or directly inside the drive cabinet, depending on the drive configuration. The board is grounded via three mounting screws (GND1, GND2, GND3).
3. Fuses
| Fuse | Rating | Function Description | GE Part Number |
| F1 | 15 A, 600 V, current limiting | Limits damage during major failures; may blow during continuous full-load operation at AC input below 102 V ac | 104X109AD |
| F2 | 2.25 A, 250 V | Provides control power current limiting; indicates control power regulator failure when blown | 573A392P6 |
| F3 | 1.5 A, 250 V | Protects the T1 output to the 120 V dc power supply | 573A392P12 |
4. Testpoints
The DS200GDPAG1A board provides multiple testpoints. Different versions (600 VA and 700 VA) have different testpoint configurations. Key testpoints include:
| Testpoint | Name | Description |
| TP1 | P160 | Positive 160 V bus voltage |
| TP2 | ACOM | Analog common |
| TP3 | P15 | Positive 15 V control power supply bus voltage |
| TP5 | BUCK | Buck chopper PWM control signal |
| TP8 | OSC1 | Inverter control oscillator signal |
| TP9/TP10 | FG3/FG4 | Inverter MOSFET gate signals |
| TP12 | 0FLT | P80 overvoltage or P15 undervoltage |
| TP13 | INVOC | Inverter overcurrent signal |
| TP14 | BUCKOC | Buck chopper overcurrent signal |
| TP15 | P160F | Positive 160 V bus voltage for control power supply |
| TP16 | NBUS | Negative bus |
IV. Detailed Interface Description
1. 1FAPL and 2FAPL Connectors
Used to connect the fan assembly, providing 115 V ac power:
| Pin | Signal | Description |
| 1 | AC1F | 115 V ac input to fan assembly |
| 2 | AC2 | 115 V ac input to fan assembly |
2. 1GDPL-4GDPL Connectors
Provide 50 V ac (27 kHz) outputs to the control assembly backplane:
| Pin | Signal | Description |
| 1 | HF1 | Input to control assembly backplane (50 V RMS ac bulk) |
| 2 | HFSH | Input to control assembly backplane; grounded for use as shield when jumped at STAB1/STAB2 |
| 3 | HF2 | Input to control assembly backplane (50 V RMS ac bulk) |
Note: Connecting these jumpers voids the double insulated design of the output.
3. ACPL Connector
For AC input connection:
| Pin | Signal | Description |
| 1 | AC1F | 80-132 V ac, 60 Hz input, circuit protection provided by fuse F1 |
| 2 | GND | Ground for use as shield or ground |
| 3 | AC2 | 80-132 V ac input |
4. CPTPL Connector
For external device connection:
| Pin | Signal | Description |
| 1 | CP120 | Positive 120 V for external use |
| 2 | 120SW | 120 V door switch power |
| 3 | CN120 | Negative 120 V for external use |
| 4 | AC1F | AC1F input for external use (see Table 6) |
| 5 | AC2 | AC2 input for external use (see Table 6) |
5. DCPL Connector
For DC input connection:
| Pin | Signal | Description |
| 1 | NBUS | Negative 105-140 V dc input |
| 2 | XCAP | Not connected |
| 3 | PEXT | Positive 105-140 V dc input |
Note: Pins 1, 2, and 3 may be shorted together if the external ride-through capacitor option is chosen.
6. DSPL Connector
For door switch connection:
| Pin | Signal | Description |
| 1 | CP120 | 120 V power to door switch |
| 2 | NC | Not connected |
| 3 | 120SW | 120 V power to door switch |
7. GIPL Connector
For connection to the expander/load source board:
| Pin | Signal | Description |
| 1 | CVOKP | CVOK diagnostic output positive to expander board |
| 2 | CVOKN | CVOK diagnostic output negative to expander board |
| 3 | HFCS | Shield ground to GND3 |
| 4 | HFC1 | 50 V RMS center-tapped AC output to expander board |
| 5 | HFC2 | 50 V RMS center-tapped AC output to expander board |
| 6 | HFC3 | 50 V RMS center-tapped AC output to expander board |
8. GXPL Connector
For connection to the high-voltage source board (normally disconnected on Innovation Series drives):
| Pin | Signal | Description |
| 1 | HFC1 | 50 V RMS center-tapped AC output to high-voltage source board |
| 2 | NC | Not connected |
| 3 | HFCS | Shield ground to GND3 (not connected on Innovation Series drives) |
| 4 | HFC3 | 50 V RMS center-tapped AC output to high-voltage source board |
9. STAB1/STAB2 Stab-On Connectors
For shield grounding:
| Stab-On | Signal | Description |
| STAB1 | GND2 | Shield ground to GND2 |
| STAB2 | HFSH | Input to control assembly backplane; grounded for use as shield when jumped at STAB1/STAB2 |
V. Installation and Maintenance
1. Mounting Location
The DS200GDPAG1A board can be mounted on a drive mounting plate or directly inside the drive cabinet, depending on the drive configuration. The board is grounded via three mounting screws.
2. Installation Steps (Plate Mounting)
Verify Power is Off: Turn off power to the drive, wait several minutes for power supply capacitors to discharge, and test to verify no power exists.
Open Cabinet Door: Access the printed wiring board area.
Disconnect Cables: Identify and disconnect all cables from the board.
Loosen Bottom Bolts: Locate and loosen the two bolts and washers securing the bottom portion of the GDPA board mounting plate.
Remove Top Bolts: Locate and remove the two bolts and washers securing the top portion of the GDPA board mounting plate.
Remove Mounting Plate: Remove the mounting plate and GDPA board by sliding the mounting plate upward until the slotted grooves clear the bottom bolts.
Remove Old Board: Remove the nuts and washers securing the GDPA board to the mounting plate.
Remove Nylon Standoffs: Remove the nylon standoffs from the GDPA board.
Install Nylon Standoffs: Place the nylon standoffs removed from the old GDPA board onto the new board.
Install New Board: Place the new GDPA board onto the mounting plate, ensuring metal standoffs are correctly located, and secure with nuts and washers.
Install Mounting Plate: Install the mounting plate and new board by sliding it downward until it rests fully on the bottom bolts.
Install Top Bolts: Install and tighten the two bolts and washers securing the top portion of the mounting plate.
Tighten Bottom Bolts: Tighten the two bolts and washers securing the bottom portion of the mounting plate.
Reconnect Cables: Identify and reconnect all cables to the new GDPA board.
3. Installation Steps (Direct Mounting)
Verify Power is Off: Turn off power to the drive, wait several minutes for power supply capacitors to discharge, and test to verify no power exists.
Open Cabinet Door: Access the printed wiring board area.
Disconnect Cables: Identify and disconnect all cables from the board.
Remove Fasteners: Remove the nuts and washers securing the GDPA board to the drive standoffs.
Remove Old Board: Remove the GDPA board.
Remove Nylon Standoffs: Remove the nylon standoffs from the GDPA board.
Install Nylon Standoffs: Place the nylon standoffs removed from the old GDPA board onto the new board.
Install New Board: Place the new GDPA board in the drive, ensuring metal standoffs are correctly located, and secure with nuts and washers.
Reconnect Cables: Identify and reconnect all cables to the new GDPA board.
4. Maintenance Recommendations
ESD Precautions: Always wear a grounding strap when handling boards. Store boards in anti-static bags.
Periodic Inspection: Check LED and neon lamp status to ensure normal power operation.
Fuse Inspection: Regularly check fuse status; if blown, investigate the cause promptly.
Spare Parts Management: It is recommended to keep at least one identical GDPA board on-site as a spare to minimize downtime.
VI. Applications
The DS200GDPAG1A High Frequency Power Supply Board is widely used in the following industrial applications:
AC2000 AC Variable Frequency Systems: Provides high-frequency power for IGBT/GTO gate drive circuits.
Innovation Series Drives: Serves as a core component for gate drive power.
EX2000 Excitation Systems: Provides power for SCR gate drives in excitation systems.
High-Power Drive Systems: Provides high-frequency power in high-power drive applications requiring gate drive power.
System Upgrades and Retrofit Projects: Replaces high-frequency power supply boards in older drive systems.
