GE IC660BBS103
GE IC660BBS103
GE IC660BBS103
GE IC660BBS103
GE IC660BBS103

GE IC660BBS103 | 8-Circuit Isolated I/O Block – Field Maintenance Guide

  • Model: IC660BBS103
  • Alt. P/N: N/A (base model; revisions include -K, -L, etc.)
  • Product Series: GE Genius I/O Platform (now Emerson Automation)
  • Hardware Type: 8-Circuit Isolated Discrete I/O Block
  • Key Feature: Configurable as either 8 inputs or 8 outputs in four isolated groups, with selectable input filtering from 10ms to 100ms and internal electronic short-circuit protection for output circuits
  • Primary Field Use: Interface high-voltage field devices to low-voltage control systems, providing galvanic isolation and fault detection to protect personnel and equipment from hazardous voltages.
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Part number: GE IC660BBS103
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Description

Hard-Numbers: Technical Specifications

  • Nominal Supply Voltage: 115 VAC or 125 VDC
  • Input Voltage Range (field devices):
    • AC: 93–132 VAC, 47–63 Hz
    • DC: 105–132 VDC, max. 10% ripple
  • Number of I/O Circuits: 8 (configurable as all inputs or all outputs)
  • Circuit Grouping: 4 isolated groups, 2 circuits per group
  • Input Filter Time: Selectable from 10ms to 100ms in 10ms increments
  • Input Processing Time:
    • AC: 2ms
    • DC: 0.8ms (both affected by configured filter time)
  • Output Current per Circuit:
    • AC: 2.0 A RMS
    • DC: 2.0 A resistive / 1.0 A inductive
  • Maximum Block Output Current:
    • Peak: 15 Amps
    • 7.5 Amps (35°C / 60°C)
  • Internal Electronic Short-Circuit Trip:
    • AC: 100ms long-time trip
    • DC: 10ms long-time trip
  • Isolation Rating:
    • Between groups or group to ground: 250 VAC/VDC continuous
    • Block-to-block isolation: 1500V
    • Transient rating: 2000V peak for 10 seconds
  • Heat Dissipation:
    • Inputs only: 16.8W max.
    • All outputs energized: 45.6W max. (2A per circuit)
    • Control power only (block): 8W max.
  • Power Supply Dropout Time:
    • AC: 1 cycle (16.67ms at 60Hz)
    • DC: 10ms
  • Mechanical Dimensions:
    • Height: 22.44 cm (8.83 inches)
    • Width: 8.48 cm (3.34 inches)
    • Depth: 9.93 cm (3.91 inches)
    • Weight: 1.8 kg (4 lbs)
  • Environmental Ratings:
    • Operating Temperature: 0–60°C (32–140°F)
    • Storage Temperature: -40°C to +80°C (-40°F to +176°F)
    • Relative Humidity: 5–95% non-condensing
    • Vibration Rating: 5–10Hz with 0.2 inches displacement
  • Field Wiring Specifications:
    • Terminal Acceptance: 1 AWG #12 or 2 AWG #14 wires; min. AWG #22
    • Terminal Torque: 0.678 N·m
    • Ring Terminal Capacity: Up to 0.27 inches diameter
  • LED Indicators: Unit OK, I/O Enabled (block level), individual circuit state indicators
    GE IC660BBS103

    GE IC660BBS103

The Real-World Problem It Solves

This isolated I/O block provides a critical layer of protection between high-voltage field devices (115VAC/125VDC) and low-voltage control systems, preventing hazardous voltage transients from damaging sensitive equipment or endangering personnel. Its configurable filtering and diagnostics enable early fault detection, reducing downtime and improving system reliability.
Where you’ll typically find it:
  • Industrial motor control centers with contactors and overloads
  • Power distribution panels with circuit breakers and relays
  • Process automation systems with valves and actuators
  • Material handling equipment with hydraulic/pneumatic controls
  • Hazardous environments requiring high-voltage isolation
Bottom line: It’s your safety barrier that bridges high-voltage field devices to low-voltage control systems, combining robust electrical isolation with advanced diagnostic capabilities.

GE IC660BBS103

GE IC660BBS103

Field Service Pitfalls: What Rookies Get Wrong

Ignoring required terminal torqueTechs over-tighten terminal screws, stripping threads or distorting terminals, leading to loose connections and overheating.
  • Field Rule: Always tighten terminal screws to the manufacturer-recommended torque of 0.678 N·m (5.99 lbf·in). Use calibrated torque screwdrivers for consistent results.
Insufficient spacing between blocksNew engineers mount blocks with less than two inches of separation, causing overheating due to restricted airflow.
  • Field Rule: Maintain minimum 50mm (2 inches) clear space on all sides for adequate ventilation. Use thermal imaging camera to verify block temperature after installation.
Mismatched power supply configurationRookies power blocks with mismatched voltage, exceeding the 132VAC/VDC rating and damaging internal electronics.
  • Field Rule: Verify line voltage with multimeter before connecting. Use power supply with regulation limits of ±10% nominal voltage.
Incorrect input/output configurationTechs configure the block as inputs when outputs are required, causing control system errors.
  • Field Rule: Use handheld monitor or CPU to verify module configuration before commissioning. Label all terminal blocks clearly (INPUT/OUTPUT) for future service reference.
Overlooking diagnostic featuresTechnicians disable diagnostic checks to simplify troubleshooting, masking potential faults that could lead to catastrophic failures.
  • Field Rule: Enable all diagnostic checks during configuration, including open wire, over-temperature, and power loss detection. Review diagnostic logs regularly to identify developing issues.
Poor grounding practicesImproper grounding increases susceptibility to electrical noise and reduces effectiveness of isolation.
  • Field Rule: Connect block to dedicated grounding bar with maximum 1Ω resistance to earth. Use separate green/yellow earth wire for each block to avoid ground loops.
Please note: The listed price is for reference only and is not binding. Final pricing and terms are subject to negotiation based on current market conditions and availability.

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