Description
- Model: GE IC660BBD023
- Brand: GE Fanuc (now Emerson/GE Automation)
- Series: Genius I/O
- Core Function: Distributed Discrete I/O block with configurable points
- Product Type: 16-Circuit Discrete I/O Block
- Key Specs: 24/48 V DC Genius Bus Communication Smart Diagnostics
- Number of Circuits: 16
- Voltage Range: 18 to 56 V DC (24 V / 48 V nominal)
- Input/Output Type: Configurable (Each point can be an input or an output)
- Output Current: 2.0 Amps max per circuit
- Genius Bus Speed: 153.6 Kbaud, 76.8 Kbaud, or 38.4 Kbaud
- Diagnostics: Short circuit, overload, open wire, and failed switch detection
- Hand-Held Monitor Support: Compatible with IC660HHM501 for field configuration
- Power Dissipation: Approx. 14 Watts (plus 0.6W per output Amp)
- Enclosure Rating: IP20 / NEMA 1 (Open type)
GE IC660BBD023
Application Scenarios & Pain Points
The IC660BBD023 is part of the legendary Genius I/O family, known for its “distributed” intelligence. Unlike standard I/O, these blocks can make simple decisions and report advanced diagnostics directly to a Series 90-70 or 90-30 controller. The primary pain point today is network integrity. As Genius Bus cables age or terminations loosen, these blocks can “drop” from the network intermittently. Because these blocks often control critical field devices like solenoids or motor starters, a communication loss can halt an entire production line.
Typical Application Scenarios:
- Automotive Stamping: Controlling hydraulic presses where high-speed discrete feedback is required for safety interlocks.
- Conveyor Systems: Distributed I/O across long distances in warehouses, taking advantage of the Genius Bus distance capabilities.
- Oil & Gas Refineries: Managing valves and switches in remote areas where the “smart” diagnostics help identify wire breaks without manual inspection.
- Retrofit Projects: Replacing failed blocks in existing Series 90-70 systems to avoid the high cost of a total system migration to RX3i.
Case Study: The “Invisible” Wire Break
Background: A municipal pumping station used Genius I/O to manage its intake valves. One valve stopped responding, but the SCADA showed no “Module Fault” alarm.
The Problem: The site electrician checked the valve, but couldn’t find the issue. Using a Hand-Held Monitor (HHM) on the IC660BBD023, we pulled the “Internal Diagnostics.” The block specifically reported an “Open Wire” on Circuit 4.
The Solution: We provided a fresh IC660BBD023 for the customer’s maintenance stock. In this specific case, the “Open Wire” diagnostic led the technician to a rodent-chewed cable inside a conduit that was otherwise invisible.
The Result: The repair took 20 minutes once the location was known. Without the “Genius” level diagnostics of the BBD023, the team would have spent hours manually ringing out every wire in the field.
Compatible Replacement Models
| Original Model | Replacement Model | Compatibility | Main Difference | Effort Level |
| IC660BBD023 | IC660BBD022 | ⚠️ Software Compatible | Lower voltage rating (24V only) | Medium (Check voltage) |
| IC660BBD023 | IC660BBD024 | ✅ Direct Replace | Later revision, improved diagnostics | Zero (Plug and Play) |
| IC660BBD023 | IC694MDL660 | ❌ Incompatible | RX3i I/O; requires hardware swap | High (Total Retrofit) |
SOP & Quality Transparency
Genius blocks are “Smart,” so they require a smart testing protocol:
- Bus Address Verification: We use a Hand-Held Monitor to verify the block can be assigned a Bus ID (0-31). If the block can’t hold its address, we reject it.
- Circuit Injection Test: We test all 16 circuits as inputs (sensing voltage) and as outputs (driving a 1A load). This ensures the internal power transistors are not “leaking.”
- Diagnostic Simulation: We intentionally create an “Open Load” and “Short Circuit” condition to verify that the block correctly reports these faults back to the bus controller.
- Serial Port Handshake: We check the HHM port on the front of the block to ensure field technicians can connect their diagnostic tools.
- Physical Gasket Check: We inspect the terminal block for any sign of “arc tracking” or corrosion, ensuring a solid electrical connection for your field wires.
GE IC660BBD023
Troubleshooting Quick Reference
| Symptom | Possible Cause | Relation to BBD023 | Quick Check |
| Unit OK LED: Off | Power Supply Failure | ✅ High | Check DC power at terminals 1 & 2. |
| I/O Enabled LED: Off | No Bus Communication | ⚠️ Medium | Verify the Genius Bus “Shield” is grounded at only one end. |
| Circuit LED: Flashing | Diagnostic Fault | ✅ High | Use an HHM to read the specific fault code (e.g., Short, Open). |
| Total Bus Failure | Termination Missing | ❌ Low | Check for a 75, 100, or 150-ohm resistor at the end of the line. |
Engineer’s Field Tip: ❗ Don’t Forget the Serial Link. If you are replacing an IC660BBD023, you must use a Hand-Held Monitor (HHM) to “Configure” the new block to match the old one’s settings (Input vs. Output, Pulse Test on/off, etc.). Unlike modern I/O, these blocks don’t always “take” their configuration from the PLC automatically—they store it internally.
Additional Inventory Models
Maintaining a GE Genius or Series 90 system? We have these parts in stock:
- GE IC660HHM501 Hand-Held Monitor
- GE IC660BBD110 110V AC Genius Block
- GE IC693BEM331 Genius Bus Controller
- GE IC697BEM731 Series 90-70 Genius Bus Controller
- GE IC660BBA101 Analog Genius Block
- GE IC660BBD023 (This Model)
- GE IC693CPU374 90-30 CPU Module
- GE IC697PWR711 Power Supply Module
For technical support or to request an urgent quote, visit www.newplcdcs.com.
