Description
- Model: GE IC660BBA104 (Sub-assembly: 6231BP10910)
- Brand: GE Fanuc / Emerson
- Series: Genius I/O
- Core Function: Distributed analog interface for Genius Bus networks
- Product Type: Analog Input/Output Block (Configurable)
- Key Specs: 115 VAC / 125 VDC Power, 4 Channels (Configurable as In or Out)
Key Technical Specifications
- Channels: 4 Analog channels, individually configurable
- Signal Ranges:
- Current: 4-20 mA, 0-20 mA
- Voltage: 1-5 VDC, 0-5 VDC, 0-10 VDC, -10 to +10 VDC, -5 to +5 VDC
- Input Power: 115 VAC (47-63 Hz) or 105-145 VDC
- Resolution: 12-bit (Current and Voltage)
- Isolation: 1500V between Genius Bus and field wiring
- Diagnostics: Open wire detection, over-range/under-range, and internal CPU monitoring
- Bus Interface: Serial Genius Bus (Shielded Twisted Pair)
- Physical Construction: Cast aluminum housing for superior heat dissipation
- Mounting: Wall mount or rack mount via integrated base
Installation & Configuration Guide
Phase 1: Pre-Installation (Estimated time: 15 minutes) ⚠️ Safety First:
- Ensure the Genius Bus power is isolated. While Genius blocks are robust, high-voltage spikes during “hot-swapping” can damage the bus controller.
- Serial Address: Every Genius block needs a unique “Serial Bus Address” (SBA). Ensure you know the SBA of the block you are replacing.
- Check the wiring. This block (BBA104) is designed for 115VAC/125VDC power. Connecting it to a 24VDC system will result in a failure to boot.
Phase 2: Removal (Estimated time: 10 minutes)
- Unplug Hand-Held Monitor (HHM): If a monitor is connected to the front port, remove it first.
- Disconnect Terminal Block: Loosen the two screws holding the terminal assembly to the electronic block. Pull the terminal assembly away—this allows you to replace the electronics without re-wiring the field side.
- Remove Electronics: Loosen the four corner screws on the cast iron block and pull it away from the base.
Phase 3: Installation (Estimated time: 15 minutes)
- Match Jumpers: Check for any physical jumpers on the terminal assembly or the block.
- Mount Electronics: Align the new IC660BBA104 electronics with the base and tighten the corner screws.
- Re-attach Terminal Assembly: Push the terminal block back into the connector and tighten the two mounting screws.
- Connect HHM: Plug in a GE Hand-Held Monitor (IC660HHM501) to the front port to begin configuration.
Phase 4: Configuration & Testing (Estimated time: 30 minutes)
- Set SBA: Using the HHM, set the Serial Bus Address to match the old block.
- Configure Channels: Define each of the 4 channels (e.g., Channel 1 = 4-20mA Input, Channel 2 = 0-10V Output).
- Calibrate: Genius blocks allow for software-based calibration. Use the HHM to “Zero” and “Span” each channel against a known reference.
- Bus Communication: Check the “I/O Enabled” LED. It should blink and then go solid green once the PLC (Series 90-30, 90-70, or PACSystems RX3i) recognizes the block.
GE IC660BBA104 6231BP10910
Customer Cases & Industry Applications
Case 1: Water Treatment Plant Legacy Maintenance A municipal water treatment facility used Genius I/O for its chemical dosing pumps. The original IC660BBA104 failed due to moisture ingress. The facility was hesitant to upgrade the entire system to RX3i Ethernet I/O due to budget constraints. We supplied a New Surplus IC660BBA104, allowing them to restore their 4-20mA control loops in a single afternoon for a fraction of the cost of a full system migration.
Case 2: Steel Mill Cooling System Repair A steel mill in Germany experienced an intermittent fault on their cooling tower fan controls. The 6231BP10910 electronics were reporting an internal CPU error during high-heat periods. By replacing the module with our New Surplus stock, the mill eliminated the “ghost faults” and ensured continuous cooling for their blast furnace.
Frequently Asked Questions (FAQ)
Q: Can I use the IC660BBA104 if my old block was an IC660BBA101? A: No. The BBA101 is a 24/48 VDC unit, while the BBA104 is a 115 VAC/125 VDC unit. They are not interchangeable. In my experience, mixing these up is the quickest way to blow a fuse or fry the internal power supply.
Q: Do I need a Hand-Held Monitor (HHM) to set it up? A: Yes. Unlike modern I/O that can be configured via a web server, Genius blocks require an HHM or a PLC-based “Configuration Software” to set the SBA and channel types. If you don’t have an HHM, let us know—we often have them in stock!
Q: What is the “6231BP10910” number? A: That is the sub-assembly or board-level part number often found on the internal PCB or the side label. The official GE catalog number is IC660BBA104. Both confirm you are getting the correct 4-channel analog block.
Q: Why is my “I/O Enabled” LED flashing? A: This typically means the block is powered up and the internal diagnostics are “OK,” but it is not communicating with the Bus Controller. Double-check your Serial Bus Address (SBA) and your baud rate (usually 153.6K or 38.4K).
Q: Is “New Surplus” reliable for a product line that is decades old? A: To be honest, Genius blocks are legendary for their durability. “New Surplus” units have been sitting in a box, meaning they haven’t faced the 24/7 heat and vibration of an industrial plant. We’ve seen these units run for another 20 years after being pulled from surplus stock.
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