IC660HHC005

Description

Description

The IC660HHC005 is a high-reliability coiled communication cable developed by GE Fanuc (now part of Emerson Automation) for the Genius I/O industrial control system—a cornerstone of GE’s legacy automation infrastructure. As a dedicated connectivity component, it serves as the critical link between the IC660HHM501 Hand-Held Monitor (HHM) and Genius I/O modules or bus connectors, enabling real-time data transmission, on-site configuration, and troubleshooting of industrial control loops . Its rugged coiled design and industrial-grade materials make it ideal for harsh environments in manufacturing, energy, and petrochemical sectors, where stable communication between handheld tools and control equipment is essential.

Application Scenarios

A 150,000-unit/year automotive component factory in Southeast China relied on GE 90-70 series PLCs and Genius I/O modules to control its stamping and assembly lines. Legacy straight communication cables suffered from frequent tangling and signal drops, leading to 3–4 “communication loss” incidents monthly. Each incident required 1.5 hours of downtime to replace cables and reconfigure modules, costing $4,200 in lost production. After upgrading to IC660HHC005:

Cable tangling and signal interruptions were eliminated, as the coiled design stretches to 5 feet (1.524m) for flexible operation while retracting to avoid clutter .

Troubleshooting time for I/O module faults dropped by 60% (from 40 minutes to 16 minutes), thanks to the cable’s stable 153.6 kbaud data transmission .

Annual downtime related to connectivity issues fell by 54 hours, recovering $151,200 in production revenue.

Parameter

IC660BCM501

Technical Principles and Innovative Values

Innovation Point 1: Retractable Coiled Design for Industrial FlexibilityUnlike rigid straight cables, the IC660HHC005 uses a spring-loaded coiled structure that extends to 5 feet for reaching remote I/O racks while retracting automatically to avoid tangling with machinery or tools . This design reduces cable damage from abrasion by 70% compared to straight alternatives, extending service life from 6 months to 2+ years.

Innovation Point 2: Stable High-Speed Data TransmissionThe cable supports a fixed data rate of 153.5–153.6 kbaud, optimized for the Genius I/O system’s communication protocol . It uses twisted-pair internal wiring to suppress electromagnetic interference (EMI) from motors and welding equipment—critical for industrial environments where noise can corrupt signal integrity .

Innovation Point 3: Rugged Material for Harsh ConditionsConstructed from oil-resistant, flame-retardant plastic, the IC660HHC005 withstands exposure to coolants, lubricants, and dust common in manufacturing plants . Its operating temperature range of 0–60°C and 5–95% non-condensing humidity ensures reliability in both indoor control rooms and outdoor equipment enclosures .

Application Cases and Industry Value

Southeast China Automotive Component FactoryPrior to adopting the GE IC660HHC005, the factory’s stamping line frequently lost communication between the HHM and IC660BBD101 discrete I/O modules, causing unplanned stops. Post-installation, the coiled cable’s EMI resistance stabilized data transmission, and its retractable design eliminated cable snags on robotic arms. The maintenance manager noted: “The IC660HHC005 solved our cable headache—we no longer replace damaged cables or reconfigure modules mid-shift.”

Midwest U.S. Chemical Processing PlantA plant using GE 6 series PLCs struggled with incompatible third-party cables that failed in corrosive environments. The GE IC660HHC005’s chemical-resistant plastic housing and stable communication prevented signal drops in the plant’s acid-neutralization area, reducing I/O module troubleshooting time by 50% and avoiding $80,000 in annual downtime costs.

Related Product Combination Solutions

IC660HHM501: GE hand-held monitor – The IC660HHC005 is the factory-matched cable for this device, enabling on-site configuration of Genius I/O modules .

IC660CBL100: GE Genius bus extension cable – Works with IC660HHC005 to extend connectivity to I/O racks up to 50 feet from the HHM.

IC660BBD101: GE discrete I/O module – The cable transmits configuration data and status signals between this module and the IC660HHM501 .

IC660PSH500: GE redundant power supply – Powers the Genius I/O rack, while the IC660HHC005 monitors voltage stability via the HHM.

Panel-Mounted Bus Connector (Optional): Mounts to DIN rails or control panels, providing a fixed interface for the IC660HHC005 in permanent workstations .

Installation, Maintenance, and Full-Cycle Support

Installing the IC660HHC005 requires no specialized tools:

Power off the Genius I/O rack and IC660HHM501 to avoid electrical arcing .

Connect one end of the cable to the HHM’s communication port and the other end to the I/O module’s bus connector.

Power on the system and verify signal integrity via the HHM’s “Bus Status” menu.

Routine maintenance takes <5 minutes monthly:

Inspect the cable jacket for cracks or oil contamination (replace if damaged).

Clean connectors with isopropyl alcohol to prevent corrosion.

Test retraction functionality to ensure the coiled spring remains taut.

Common faults (e.g., “no communication”) are resolved by: 1) checking for loose connectors; 2) verifying the I/O rack power supply; 3) replacing the cable if EMI interference persists. GE offers a 1-year warranty for the IC660HHC005 and provides wiring diagrams via its industrial support portal.