Description

The GE IC660BBD022 is a 16-point discrete electromechanical relay output module designed for the VersaMax and Series 90-30 programmable logic controller(PLC)families from GE Automation(now part of Emerson).Each channel features a form-C(SPDT)relay,enabling flexible control of both normally open(NO)and normally closed(NC)circuits—making it ideal for applications requiring fail-safe behavior or bidirectional switching.

Engineered for reliability in demanding industrial settings,the IC660BBD022 delivers robust isolation,visual diagnostics,and direct switching of higher-voltage loads without external interposing relays.It remains a widely deployed solution in legacy automation systems across power,water,manufacturing,and infrastructure sectors.

Application Scenarios

At a municipal wastewater treatment plant in the Midwest,a Series 90-30 PLC used IC660BBD022 modules to control sludge pump contactors,chemical dosing valves,and alarm horns.During a lightning storm,a surge damaged several solid-state output cards on competing systems—but the IC660BBD022’s electromechanical relays and 1500 V isolation protected downstream equipment.One module had been in continuous service for 14 years,cycling over 2 million times,before scheduled replacement during a plant upgrade.The maintenance lead noted:“We trust these relays like we trust circuit breakers—they just work.”

Parameter

Main Parameters Value/Description

Product Model IC660BBD022

Manufacturer GE Automation(now Emerson)

Product Category Discrete Relay Output Module

Channels 16 independent SPDT(form-C)electromechanical relays

Contact Rating 2 A 250 VAC/30 VDC(resistive load);0.5 A 125 VDC(inductive)

Electrical Life>100,000 operations at full load;>10 million at low current

Isolation 1500 Vrms between field side and logic/backplane

Response Time~10 ms(typical relay operate/release time)

LED Indicators One bi-color LED per channel:green=ON,red=OFF/fault(if applicable)

Mounting DIN rail(35 mm)in VersaMax I/O base or Series 90-30 backplane

Wiring Removable screw-terminal blocks(field-wireable)

Operating Temperature 0°C to+60°C

Certifications CE,UL,CSA,RoHS compliant

Technical Principles and Innovative Values

Innovation Point 1:True Load Independence via Electromechanical Relays

Unlike transistor or triac outputs limited to specific voltage types,the IC660BBD022 can switch AC or DC,high or low voltage,inductive or resistive loads—offering unmatched flexibility for mixed-signal panels without external interface hardware.

Innovation Point 2:Fail-Safe Capability with Form-C Contacts

The SPDT configuration allows designers to implement de-energize-to-trip safety logic(e.g.,emergency shutdown valves that close on power loss),meeting basic process safety requirements without a dedicated SIS.

Innovation Point 3:Visual Diagnostics for Rapid Troubleshooting

Each channel’s LED shows real-time coil status—green when energized—enabling technicians to verify PLC command vs.field response instantly,reducing mean time to repair(MTTR)by up to 50%.

Innovation Point 4:Hot-Swappable in Compatible Racks

When installed in a VersaMax system with appropriate base units,the module can be replaced without powering down the entire rack,minimizing production downtime during maintenance.

Application Cases and Industry Value

In a food&beverage bottling line,IC660BBD022 modules controlled reject gates,cap applicators,and labeler clutches.The ability to directly drive 120 VAC solenoid valves eliminated intermediate relays,simplifying panel layout and cutting spare parts inventory by 30%.Over five years,only two modules were replaced—both due to external short circuits,not relay wear.

Similarly,in a hydroelectric dam’s auxiliary system,the IC660BBD022 operated lube oil pump starters and cooling fan contactors.Its tolerance to wide temperature swings and humidity ensured reliable operation in unconditioned turbine pits—where solid-state outputs had previously failed due to condensation-induced leakage currents.

Related Product Combination Solutions

VersaMax CPU(e.g.,IC200CPU001):Central controller that drives IC660BBD022 outputs

Series 90-30 PLC(e.g.,IC693CPU364):Legacy platform fully compatible with this module

IC660BBD020/IC660BBD021:Lower-channel-count variants(8 or 12 points)

IC660BBD122:Solid-state(transistor)output alternative for high-speed applications

Genius Bus Controller(IC693BEM331):Enables remote mounting of IC660BBD022 via Genius I/O network

I/O Base Units(e.g.,IC660BBI001):Required for DIN-rail mounting and terminal connection

Proficy Machine Edition:Programming software for logic that controls IC660BBD022 coils

Surge Suppression Modules(e.g.,IC693ACC307):Recommended for inductive loads to extend relay life

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