ABB IC660BBA104 / 6231BP10910 – 16-Channel Mixed I/O Block for Industrial Automation

Description

Application Scenarios

At a North American paper mill undergoing a phased DCS modernization, engineers needed to retain hundreds of existing 24 VDC field devices while migrating from an old Bailey INFI 90 system to AC 800M. By installing ABB IC660BBA104 baseplates with 6231BP10910 modules in remote I/O cabinets near the machine hall, they preserved all field wiring while connecting seamlessly to the new controller via Genius fiber-optic links. The IC660BBA10910’s clear channel LEDs enabled rapid troubleshooting during commissioning, and its hot-swap capability allowed technicians to replace faulty units without halting production. This hybrid approach saved over $ 1.2M in rewiring costs—proving that smart I/O reuse can accelerate digital transformation without operational risk.

Note: The IC660BBA104 is the mechanical and electrical carrier; the 6231BP10910 provides the actual I/O electronics. Both must be used together.

Technical Principles and Innovative Values

Innovation Point 1: True Modularity – The 6231BP10910 snaps into the IC660BBA104 without tools or screws, enabling rapid field replacement and reducing mean time to repair (MTTR) by up to 70%.

Innovation Point 2: Genius Bus Efficiency – Each IC660BBA104 / 6231BP10910 unit occupies only one Genius node address while delivering 16 I/O points, optimizing network bandwidth and reducing controller load.

Innovation Point 3: Field Wiring Clarity – Screw terminals are clearly labeled and grouped by function, with removable terminal blocks that support pre-wired harnesses—cutting panel assembly time.

Innovation Point 4: Backward Compatibility – Fully interoperable with legacy ABB PLCs (e.g., Advant Master, INFI 90) and modern AC 800M via IM modules (e.g., CI854A), bridging decades of automation investment.

Application Cases and Industry Value

In a Chilean copper concentrator, dust and vibration caused frequent I/O card failures in motor control centers. After standardizing on IC660BBA104 / 6231BP10910 units—selected for their robust terminal design and conformal-coated PCBs—the site reduced I/O-related downtime by 85% over two years. Maintenance teams leveraged the hot-swap feature to perform replacements during scheduled shifts, avoiding costly line stoppages.

Similarly, in a European automotive paint shop, the 6231BP10910’s ability to handle inductive loads (e.g., small relays and valve coils) without external flyback diodes simplified cabinet design and lowered BOM cost by 12%.

Related Product Combination Solutions

ABB IC660BBA100: 16-channel digital input-only baseplate—ideal for high-density sensing.

ABB IC660BBA106: 16-channel digital output-only version for actuator-heavy applications.

ABB 6231BP10911: Alternate module with 16 inputs (no outputs)—used with IC660BBA104 for pure input expansion.

ABB CI854A: AC 800M communication module that interfaces with Genius I/O networks hosting IC660BBA104 units.

ABB IMASI03: INFI 90 I/O interface module that connects IC660BBA104 to legacy Symphony systems.

ABB TB660BBA: Terminal block kit with pre-labeled jumpers for faster wiring of IC660BBA104.

ABB 3BSE013208R1: Legacy backup battery—often used in same cabinets to protect controller memory during outages.

ABB GCOM01: Genius bus repeater/extender for long-distance I/O cabinet deployment (>2 km).

Installation, Maintenance, and Full-Cycle Support

Installation begins with mounting the IC660BBA104 baseplate on a DIN rail, followed by snapping in the 6231BP10910 module until it clicks securely. Field wiring uses standard screw terminals (accepting 0.2–2.5 mm² wires), and the Genius bus connects via shielded twisted-pair cable with daisy-chain topology. Always terminate the bus at both ends with 120 Ω resistors to prevent signal reflections.

For maintenance, the per-channel LEDs provide immediate visual feedback—green for active signals, red for overloads or shorts. If a fault occurs, simply depress the release tab and swap the 6231BP10910 module in under 30 seconds—no system reboot required. We recommend annual inspection of terminal torque and bus connector integrity in high-vibration environments.

We guarantee authentic ABB IC660BBA104 and 6231BP10910 units, fully tested for electrical continuity, Genius communication handshake, and LED functionality. Every shipment includes original packaging, model verification, and compatibility notes for your specific PLC platform. With global inventory and deep expertise in ABB I/O ecosystems, we ensure your field layer remains resilient, scalable, and future-ready.

Contact us for a customized solution—whether you’re replacing a single failed module or deploying a new remote I/O rack across your facility.