GE IC800SS1228R02-CE

Description

The GE IC800SS1228R02-CE is a dedicated solid-state relay output module designed for GE’s Series 800 programmable logic controller platform. This 8-channel AC output module provides reliable, high-speed switching of resistive and inductive loads in industrial automation applications requiring silent operation and extended mechanical life. The GE IC800SS1228R02-CE remains an essential component for legacy Series 800 control systems still operating in automotive manufacturing, material handling, and specialty machine applications.

Product Overview and Description

The GE IC800SS1228R02-CE functions as an 8-channel AC solid-state output interface, converting logic-level signals from the Series 800 CPU into switched AC power for field devices including motor contactors, solenoid valves, and indicator lamps. Each channel utilizes zero-voltage crossing triac output technology, minimizing electromagnetic interference and inrush current stress on connected loads. The GE IC800SS1228R02-CE incorporates per-channel LED status indication, group fusing, and RC snubber networks for inductive load suppression. Designed for extended service life in industrial environments, the module features optical isolation, rugged epoxy-encapsulated output devices, and comprehensive transient protection. The “-CE” suffix denotes compliance with European Union EMC and Low Voltage Directives, enabling installation in global equipment deployments. The module communicates via the Series 800 proprietary backplane interface, providing deterministic I/O updates synchronized with the CPU scan.

Key Parameters and Specifications

• Output Channels: 8 AC solid-state relay outputs, zero-voltage switching.
• Output Voltage: 24-280 VAC, 47-63 Hz.
• Output Current: 2 A continuous per channel, 4 A total per module.
• Surge Current: 20 A for 1 cycle, non-repetitive.
• Off-State Leakage: <5 mA at rated voltage.
• On-State Voltage Drop: <1.6 V peak at rated current.
• Response Time: 1/2 cycle maximum turn-on, 1/2 cycle maximum turn-off.
• Isolation: 4000 VAC optical isolation field-to-logic, 1500 VAC channel-to-channel.
• Indicators: 8x red LED per channel output status, 1x green LED power OK.
• Protection: Per-channel 2.5 A fast-acting fuse, internal RC snubber (0.01 µF/47Ω).
• Power Consumption: 200 mA from +5 VDC backplane, 50 mA from +24 VDC field supply.
• Termination: 20-point removable terminal strip, 12-22 AWG.
• Certifications: CE, UL 508, CSA C22.2, RoHS compliant.

Advantages and Functional Benefits

The GE IC800SS1228R02-CE delivers specific advantages for AC load switching applications:

1. Silent Operation: Solid-state switching eliminates audible contactor chatter and coil hum, essential for noise-sensitive environments including medical equipment and cleanrooms.
2. Infinite Mechanical Life: No contacts to wear, pit, or weld; suitable for high-cycle applications exceeding 10 million operations where electromechanical relays require quarterly replacement.
3. Zero-Voltage Switching: Turn-on at AC voltage zero-crossing minimizes inrush current and radiated EMI; turn-off at current zero-crossing eliminates inductive kickback transients.
4. Global Compliance: CE marking facilitates machine export to European Union markets without additional component-level certification.
5. Legacy Compatibility: Direct replacement for IC800SS1228R01 and earlier solid-state output modules without control program modification or cabinet rewiring.

Application Fields and Use Cases

The GE IC800SS1228R02-CE is deployed across industries requiring high-cycle AC load switching:

• Automotive Assembly: Resistance welding control, paint system oven heater contactors, conveyor sortation solenoids.
• Packaging Machinery: Carton eraser solenoid valves, hot-melt adhesive applicators, shrink tunnel heaters.
• Plastics Processing: Injection mold heater bands, extrusion barrel heaters, part ejection solenoids.
• HVAC Systems: Compressor contactors, fan starters, electric duct heaters.
• Food Processing: Oven heating elements, fryer temperature control, packaging seal bars.

Competitor Comparison

When evaluated against alternative AC output solutions, the GE IC800SS1228R02-CE demonstrates specific competitive positioning. Allen-Bradley 1746-OA16 offers 16-channel AC output capacity but requires SLC 500 platform migration and complete system re-engineering. Siemens SM 322 (6ES7322-1FF01-0AA0) provides 8-channel AC output but utilizes triac technology with 1 A per channel rating, limiting direct replacement capability. The GE IC800SS1228R02-CE maintains unique value within the Series 800 installed base, where platform migration costs typically exceed $50,000 per machine. Generic solid-state relay modules require individual socket mounting, separate DC power supplies, and extensive point-to-point wiring versus the GE IC800SS1228R02-CE‘s integrated 8-channel density. While contemporary GE RX3i PAC systems offer enhanced diagnostics, the GE IC800SS1228R02-CE remains the only form-fit-function replacement preserving validated machine configurations for regulated industries.

Selection Recommendations and Precautions

• Compatibility Verification: The GE IC800SS1228R02-CE is specifically designed for Series 800 programmable controllers; confirm rack type and power supply compatibility before ordering. This module is not compatible with Series 90-30, Series 90-70, or RX3i PAC systems without significant I/O scanning modifications.
• Load Current Verification: Confirm connected load current does not exceed 2 A continuous per GE IC800SS1228R02-CE channel. Resistive loads (heaters, lamps) operate within rating; inductive loads (contactors, solenoids) exhibit inrush currents up to 10x steady-state. Derate to 1.5 A for inductive applications.
• Minimum Load Consideration: The GE IC800SS1228R02-CE requires minimum 50 mA load current for proper operation; lower currents may cause output triac misfiring or failure to turn off. Add resistive ballast loads for low-power indicator lamp applications.
• External Suppression: Although internal RC snubbers provide basic transient suppression, severe inductive loads (>50 VA) require additional external MOV suppression (GE part number 44A732301-G01) connected directly at load terminals.
• Fuse Replacement: Use only GE specified 2.5 A fast-acting fuses (part number 207D982G001); substitute fuses with different time-current characteristics may not provide adequate protection and invalidate UL/CSA certification.
• Thermal Management: The GE IC800SS1228R02-CE generates heat proportional to load current; maintain minimum 25mm clearance above and below module. Derate total module current to 3 A for installations above 50°C ambient.
• Wiring Practice: AC output wiring must maintain physical separation from low-level DC control wiring; minimum 50mm separation recommended. The GE IC800SS1228R02-CE‘s zero-voltage switching minimizes but does not eliminate conducted EMI.
• Spare Parts Strategy: The GE IC800SS1228R02-CE is classified as mature product with diminishing manufacturing sources; maintain minimum 20% spares inventory relative to installed count. Current availability requires 6-10 week lead time for factory repair/exchange.
• Off-State Leakage Verification: The GE IC800SS1228R02-CE exhibits <5 mA off-state leakage current; confirm connected load does not “chatter” or illuminate at this current level. Some solid-state contactors and LED indicators require parallel bleeder resistors.

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