GE URRHH dual redundant relay output module for critical safety and shutdown applications

The GE URRHH (official order code IC695URRHH) is a dual-channel, safety-certified electromechanical relay output module designed for the GE VersaMax I/O platform, specifically engineered for Emergency Shutdown (ESD), Fire & Gas (F&G), and critical machine protection applications. Unlike standard relay modules, the URRHH features force-guided (positively driven) contacts and dual independent coils that enable 1oo2 (one-out-of-two) or 2oo2 voting logic—ensuring fail-safe actuation even in the event of a single internal fault.

Description:

The GE URRHH (official order code IC695URRHH) is a dual-channel, safety-certified electromechanical relay output module designed for the GE VersaMax I/O platform, specifically engineered for Emergency Shutdown (ESD), Fire & Gas (F&G), and critical machine protection applications. Unlike standard relay modules, the URRHH features force-guided (positively driven) contacts and dual independent coils that enable 1oo2 (one-out-of-two) or 2oo2 voting logic—ensuring fail-safe actuation even in the event of a single internal fault.

This module delivers certified functional safety, mechanical reliability, and diagnostic transparency in a compact industrial form factor, forming a trusted final control element in high-risk automation systems.

Application Scenarios:

At a North Sea offshore gas compression platform, a turbine overspeed event required immediate fuel valve closure to prevent catastrophic failure. The legacy system used standard relays with no fault detection—risking “dangerous undetected” failures. After upgrading to the GE URRHH, the safety system achieved IEC 61508 SIL 3 compliance. During a proof test six months later, the URRHH’s built-in diagnostics revealed a welded contact on Channel A due to arcing from a previous trip. Because the system used 1oo2 logic, Channel B still functioned correctly, and the fault was flagged before it could compromise safety integrity. This case demonstrates how the URRHH transforms passive relays into intelligent, self-monitoring safety barriers that actively prevent hazardous scenarios.

Parameter:

Main Parameters Value/Description

Product Model URRHH (IC695URRHH)

Manufacturer GE Automation (now part of Emerson)

Product Category Safety-Certified Redundant Relay Output Module

Safety Certification IEC 61508 SIL 2/3 (system dependent), API 670 compliant

Output Channels 2 independent, force-guided (positively driven) relay channels

Contact Configuration 1 NO + 1 NC per channel, mechanically linked (EN 50205 compliant)

Contact Rating 2 A @ 250 VAC / 30 VDC (resistive); suitable for pilot-duty loads

Coil Design Dual independent coils per channel for 1oo2/2oo2 voting

Electrical Isolation >2500 Vrms logic-to-field; >1500 Vrms channel-to-channel

Diagnostic Coverage >90% for dangerous undetected failures (via coil/feedback monitoring)

LED Indication Per-channel green (coil energized) and red (fault/diagnostic) LEDs

Mounting Method DIN rail via VersaMax safety base (e.g., IC200CHSxxx with redundancy support)

Operating Temperature 0°C to +60°C

Approvals UL, cUL, CE, ATEX (for hazardous variants)

Technical Principles and Innovative Values:

Force-Guided Contact Mechanism: In the URRHH, the NO and NC contacts are mechanically linked so they cannot be closed simultaneously—even during contact welding. This ensures true fail-safe behavior and meets EN 50205 standards for safety relays.

Dual-Coil Redundancy Architecture: Each channel has two separate coils controlled independently by the safety logic solver, enabling 1oo2 (higher availability) or 2oo2 (higher safety) configurations without external hardware.

Built-In Diagnostic Feedback: The URRHH provides auxiliary feedback contacts that report actual contact position to the controller, enabling detection of welded, stuck, or failed relays during partial stroke tests or continuous monitoring.

Seamless Integration with GE Safety Systems: Works natively with VersaMax Safety CPUs (e.g., IC695CRU320K) and supports safety networks like Genius Safety, enabling end-to-end certified safety chains.

Application Cases and Industry Value:

In a U.S. Gulf Coast ethylene plant, the GE URRHH was deployed to actuate emergency isolation valves on a high-pressure reactor. During a scheduled proof test, the diagnostic feedback circuit detected a slow-opening fault in one relay due to spring fatigue—long before it would have failed to close during an actual emergency. The plant avoided a potential $ 10M incident by replacing the module proactively. In another application, a hydroelectric dam in Canada used URRHH modules to trigger turbine shutdown solenoids under IEC 61508 SIL 2 architecture. Over five years, zero spurious trips occurred, and all proof tests passed on first attempt—validating the module’s reliability in life-critical infrastructure.

Installation, Maintenance, and Full-Cycle Support:

Installing the GE URRHH requires a safety-rated VersaMax base and adherence to separation rules for safety vs. non-safety wiring. Each channel must be wired with its main output and feedback return to enable diagnostics. Configuration is performed in Proficy Machine Edition Safety with pre-certified function blocks for 1oo2 voting. Routine maintenance includes quarterly proof tests using the controller’s built-in test sequences, which verify both coil activation and contact movement via feedback signals.

Every URRHH we supply is sourced from authorized channels or rigorously reconditioned to OEM specifications—including contact resistance validation (<50 mΩ), dielectric testing, and mechanical life cycle verification. Our engineers hold GE Safety System certification and provide full lifecycle support—from SIL verification documentation to on-site commissioning and FAT/SAT assistance.

Contact us for a customized solution—whether you need a single GE URRHH for a critical valve or a full safety I/O matrix for a new compressor station, we ensure your final elements meet the highest standards of functional safety and operational reliability.