GE IC660EPM100J

Product Overview and Introduction

The GE IC660EPM100J is a specialized power and I/O expansion interface module designed for the GE Fanuc Series 90-30 Programmable Logic Controller (PLC) system. This module serves as a critical link, specifically as an Expansion Rack Power Module, that enables the extension of the base PLC rack by providing power, data communication, and physical connectivity to one or more additional I/O racks. The GE IC660EPM100J allows for a distributed I/O architecture, facilitating the placement of I/O modules closer to field devices in larger or more complex machinery and processes.

Detailed Product Parameters and Specifications

This expansion module is defined by its power delivery and communication interface specifications:

• Primary Function: Expansion Rack Power and Communication Module for the Series 90-30 PLC. It mounts in the leftmost slot (Slot 0) of a 5-slot or 10-slot expansion rack.
• Power Supply Function: Provides regulated +5 V DC logic power to all modules in the expansion rack. It does not provide 24 V DC field power; that must be supplied externally to the individual I/O modules.
• Communication Interface: Contains the circuitry to manage data exchange between the CPU in the main rack and the I/O modules in the expansion rack over the proprietary Series 90-30 backplane bus.
• Compatibility: Designed for use with specific Series 90-30 expansion racks (models IC660CHSxxx). The “J” suffix in the part number often indicates a specific region or minor revision.
• Cable Connection: Requires a dedicated expansion cable (e.g., IC660CBLxxxx) to connect its port to the CPU module in the main rack or to another expansion rack’s power module, creating a daisy-chain.
• Maximum Expansion: Supports the connection of multiple expansion racks, up to the system limit of the specific CPU model (typically 2, 3, or 7 racks total, including the main CPU rack).
• Status Indicators: Features LED indicators for power (PWR) and communication (COMM) status to aid in diagnostics.
• Operating Voltage: The module itself is powered via the expansion cable from the main rack; it does not have a separate AC/DC power input.

Key Advantages and Distinctive Features

The GE IC660EPM100J offers essential system expansion capabilities:

• Modular System Scalability: Enables the Series 90-30 system to grow beyond the confines of the main CPU rack, allowing for the addition of dozens or hundreds of I/O points to handle larger applications.
• Distributed I/O Placement: Allows I/O racks to be installed up to the maximum cable length from the CPU (typically 50 feet/15 meters), simplifying wiring by placing digital and analog modules closer to sensors and actuators.
• Cost-Effective Expansion: Provides a modular and economical way to increase I/O capacity without needing a larger, more expensive CPU or a completely separate controller.
• Simplified Power Distribution: By generating the +5V logic bus for the entire expansion rack locally, it ensures stable power for the rack’s electronics and simplifies the overall power design.
• Reliable Communication: Manages the deterministic data transfer between the CPU and remote I/O, a critical function for real-time control. The robust design of the GE IC660EPM100J ensures reliable operation in industrial environments, forming a dependable backbone for system expansion.

Application Scenarios and Case Studies

This module is used in Series 90-30 applications where I/O count or physical layout requires expansion beyond the main rack:

• Machine Tool Control: A main CPU rack controls the core machine logic, while an expansion rack with an IC660EPM100J, located in the machine’s tool changer cabinet, houses I/O for proximity sensors and solenoid valves specific to that subsystem.
• Material Handling Systems: Controlling a long conveyor line where I/O clusters for photo-eyes, motor starters, and diverters are spread out. Expansion racks with power modules are placed at strategic points.
• Packaging Machinery: Separating I/O for different stations (filler, capper, labeler) into individual expansion racks for easier troubleshooting and modular machine design.
• Small Process Skids: Integrating a skid-mounted system (like a small mixer or heater) into a larger plant DCS by using a 90-30 expansion rack as a remote I/O drop.

A typical application case is an automotive parts washer. The main CPU rack houses the master program and analog cards for temperature control. An expansion rack, powered by the GE IC660EPM100J and located inside the wash chamber control panel, houses all the digital I/O for the chamber’s door locks, pump motors, and valve solenoids, keeping high-voltage wiring contained and localized.

Comparison with Competing Products

Compared to expansion interface modules for contemporary PLCs like the Allen-Bradley SLC-500 (1747-AIC), Siemens SIMATIC S7-300 (IM 365/360/361), or Modicon Quantum (CRA/CPS), the GE IC660EPM100J serves an analogous function within its specific platform:

• Platform Specificity: Its sole purpose is to expand the GE Series 90-30 system. Its advantage is guaranteed compatibility and performance within that ecosystem.
• Architecture: The 90-30 uses a daisy-chain expansion model similar to some competitors (SLC-500). Others, like the S7-300, may use a master-slave backplane model. The IC660EPM100J is a key component of this specific architecture.
• Legacy System Role: As a component of the mature Series 90-30, its primary competition today is not other expansion modules, but rather the decision to modernize to a new PLC platform entirely (e.g., GE RX3i, Emerson PACSystems).

Competitors’ modules may offer different maximum distances, support for fiber optic cables, or integrated diagnostics. The choice was historically driven by the selection of the base PLC platform.

Selection Guidelines and Important Considerations

Selecting and installing this module requires attention to system-level details:

1. Verify Complete System Compatibility: Confirm the GE IC660EPM100J is compatible with your specific Series 90-30 CPU model and the expansion rack chassis model (IC660CHSxxx). Not all combinations are supported.
2. Expansion Cable Specification: You must use the correct expansion cable (IC660CBLxxxx) of the appropriate length. The cable connects from the CPU or previous rack’s power module to the EPM100J. Maximum total cable length for the system must not be exceeded.
3. Power Budget Calculation: While the module supplies +5V logic power, you must ensure the external 24V DC field power supply for the I/O modules in the expansion rack is adequately sized for the total load of all connected sensors/actuators.
4. Rack Addressing: The position of the expansion rack in the daisy-chain determines its rack address. This is typically set via DIP switches or rotary switches on the IC660EPM100J or the rack itself and must be configured correctly in the PLC hardware configuration software (VersaPro or Proficy Machine Edition).
5. Physical Installation: The module must be installed in Slot 0 (the leftmost slot) of the expansion rack. Ensure it is fully seated. The expansion cable must be securely connected and routed to avoid damage.
6. Diagnostics and Troubleshooting: Use the PWR and COMM LEDs for initial fault finding. No COMM light typically indicates a cable, addressing, or configuration issue. Always consult the Series 90-30 system manual and the specific sheet for the GE IC660EPM100J, available via the product link, for all installation, addressing, and specification details. Ensure the total system configuration (number of racks, modules) does not exceed the CPU’s maximum I/O capacity.