IC660BPM500

Description

Description

The IC660BPM500 is a dedicated rechargeable battery pack developed by GE Fanuc (now part of Emerson Automation) for the Genius I/O industrial control system—serving as the core power source for the IC660HHM501 Hand-Held Monitor (HHM). Designed to ensure uninterrupted operation of on-site maintenance tools, it provides reliable portable power for configuring, monitoring, and troubleshooting Genius I/O modules and bus networks, even in areas without AC power access. Its rugged construction and industrial-grade performance make it indispensable for harsh environments in manufacturing, energy, and petrochemical sectors, where consistent power for handheld diagnostics is critical .

Application Scenarios

A 300,000-square-meter automotive assembly plant in Central China relied on GE 90-70 series PLCs and Genius I/O modules to control its welding and painting lines. Legacy disposable batteries for the HHM suffered from short runtime (2–3 hours) and frequent power failures, leading to 4–5 incomplete troubleshooting sessions monthly. Each interrupted session required rework and extended downtime by 1.5 hours, costing $5,000 in lost production. After switching to IC660BPM500:

HHM runtime extended to 6 hours per charge, eliminating mid-task power interruptions and completing 100% of maintenance checks in one session .

Battery replacement frequency dropped from 2x weekly to 1x monthly, reducing waste and maintenance labor by 80%.

Annual downtime related to HHM power issues fell by 36 hours, recovering $120,000 in production revenue.

Parameter

IC660BPM500

Technical Principles and Innovative Values

Innovation Point 1: Mandatory Dual-Power SupportUnlike generic batteries, the IC660BPM500 is required for the IC660HHM501 to operate—even when connected to 115/230V AC power 。This design acts as a fail-safe: if AC power is interrupted during critical tasks (e.g., fault clearing), the battery seamlessly takes over, preventing data loss or incomplete configurations.

Industrial-Grade LongevityEngineered for harsh industrial use, the battery withstands extreme temperatures (-40–70°C for storage) and resists vibration from factory machinery . Its sealed construction protects against dust and minor moisture, outperforming consumer-grade batteries that fail in 3–6 months under similar conditions.

Optimized Charging for Maintenance EfficiencyThe battery supports flexible charging cycles: a 20-minute quick charge enables temporary HHM operation for urgent tasks, while a full 16-hour charge restores maximum capacity . GE recommends full discharge-recharge cycles monthly to extend lifespan, a feature tailored to industrial maintenance schedules.

Application Cases and Industry Value

Central China Automotive Assembly PlantPrior to adopting the GE IC660BPM500, the plant’s welding line HHM frequently lost power mid-diagnosis, forcing technicians to restart troubleshooting of IC660BBD101 I/O modules. Post-installation, the 6-hour runtime allowed full bus scans and fault resolution in one visit, and the mandatory AC-battery dual-power design prevented interruptions during grid fluctuations. The maintenance supervisor noted: “The IC660BPM500 turned our HHM from a frustrating tool into a reliable workhorse—we no longer waste time redoing checks.”

Gulf Coast U.S. Petrochemical RefineryA refinery using Genius I/O systems in hazardous areas struggled with AC power inaccessibility near storage tanks. The GE IC660BPM500’s portability allowed technicians to use the IC660HHM501 for on-site configuration of IC660BBA023 热电偶 modules without extension cords, cutting setup time by 40% and ensuring compliance with explosion-proof safety protocols.

Related Product Combination Solutions

IC660HHM501: GE hand-held monitor – The IC660BPM500 is the exclusive battery pack for this device, enabling offline diagnostics of Genius I/O networks .

IC660HHC005: GE coiled communication cable – Connects the HHM (powered by IC660BPM500) to I/O modules for data transmission .

IC660BBD101: GE discrete I/O module – Monitored and configured via the HHM, with power from IC660BPM500 ensuring uninterrupted diagnostics.

IC660PSH500: GE redundant power supply – Powers the Genius I/O rack, while IC660BPM500 safeguards the HHM’s portable operations.

Spare IC660BPM500: Recommended for 24/7 facilities to alternate charging and avoid downtime during battery replacement .

IC660BPM500

Installation, Maintenance, and Full-Cycle Support

Installing the IC660BPM500 is straightforward but critical:

Ensure the IC660HHM501 is powered off before inserting the battery pack.

Align the battery with the HHM’s internal connectors and secure it per the user manual.

For first-time use, charge continuously for 24 hours to maximize capacity .

Routine maintenance takes <10 minutes monthly:

Perform a full discharge-recharge cycle to prevent capacity degradation.

Inspect the battery housing for cracks or swelling (replace immediately if damaged).

Avoid extended AC-only operation (over 2 years may reduce chargeability) .

Common issues and solutions:

“Low Battery” Alert: Connect HHM to AC power for 20+ minutes for temporary use, or 16 hours for a full charge.

No HHM Power: Verify battery installation (re-seat if loose) or replace with a charged spare.

GE offers a 1-year warranty for the IC660BPM500 and provides detailed charging guidelines via its industrial support portal. For critical operations, GE recommends stocking spare batteries to minimize maintenance delays.