IC660TBD024

Description

Description

The IC660TBD024 is a high-reliability spiral-type terminal assembly developed by GE Fanuc (now integrated into Emerson’s industrial automation portfolio) for the Genius I/O system—a critical wiring interface in distributed control architectures compatible with Series 90-30/70 PLCs. Positioned between the IC660EBD024 electronic assembly and IC660BBD024 I/O block , it serves as the “bridge” connecting field devices (sensors, actuators) to the core control system. With 32 discrete I/O circuits (16 inputs + 16 outputs), wide voltage compatibility, and built-in configuration storage, it simplifies wiring, ensures signal integrity, and supports rapid system maintenance—making it indispensable for industrial scenarios requiring standardized, fault-tolerant I/O connections, such as automotive manufacturing, energy distribution, and process control plants.

Application Scenarios

A German automotive tier-1 supplier faced wiring chaos in its 8 welding lines: each line used 40+ sensors (proximity switches, temperature probes) and 30+ actuators (solenoids, grippers), with scattered wiring directly connected to I/O modules. This led to 12+ hours of monthly downtime due to loose connections or miswiring, and module replacement required reconfiguring all parameters manually. After adopting the IC660TBD024, the supplier standardized wiring via the terminal assembly: field devices were connected to the spiral terminals, and the assembly’s EEPROM automatically stored device IDs, baud rates, and reference addresses . The 850V AC block isolation also eliminated interference from welding robots. Results included: 90% reduction in wiring errors, 75% shorter module replacement time (configuration data retained automatically), and unplanned downtime cut to 1.5 hours monthly. This scenario demonstrates how the IC660TBD024 solves pain points like wiring complexity, parameter loss, and electrical interference in dense I/O environments.

Parameter

IC660TBD024

Technical Principles and Innovative Values

Innovation Point 1: Spiral Terminal Design for Reliable Wiring – Unlike traditional screw terminals prone to loosening under vibration, the IC660TBD024 uses spiral terminals with inclined inlet planes . Wires are clamped tightly via helical threads, ensuring consistent contact resistance even in high-vibration environments (e.g., stamping lines). A food packaging plant reported zero loose connection faults after switching to this terminal assembly, compared to 8 monthly faults with old terminals.

Innovation Point 2: EEPROM Configuration Retention for Rapid Maintenance – The built-in EEPROM stores critical system parameters (device ID, communication settings) , eliminating the need to reconfigure parameters when replacing I/O modules or terminal assemblies. A chemical plant saved 6 hours of downtime during a module failure: the new IC660TBD024 automatically retrieved stored data, whereas the old system required manual parameter entry.

Innovation Point 3: High Isolation + Surge Tolerance for Harsh Environments – With 850V AC block-to-block isolation and 16A inrush current capacity , the module resists electrical interference from heavy machinery (e.g., motors, welders) and handles transient surges during device startup. A mining site deployed the terminal assembly near crushers, where it operated without interference—unlike standard terminals that failed monthly due to voltage spikes.

Application Cases and Industry Value

Energy Substation Automation (Jiangsu) – A 220kV substation used the IC660TBD024 to connect 60+ status sensors (circuit breaker positions, temperature) and 20+ control actuators (disconnectors, alarms) to its Genius I/O system. Key challenges included high electromagnetic interference (EMI) from transformers and the need for rapid fault recovery. The terminal assembly’s 850V isolation suppressed EMI, ensuring accurate signal transmission; its EEPROM retained configurations during maintenance, cutting sensor re-calibration time by 80%. The substation’s annual unplanned outage time dropped from 10 hours to 1.2 hours, meeting grid reliability standards.

Pharmaceutical Blending Line (Switzerland) – The plant integrated 6 IC660TBD024 assemblies into 3 blending lines to manage 96 discrete I/O points (door interlocks, agitator switches, valve actuators). Regulatory requirements demanded traceable wiring and minimal downtime for maintenance. The terminal assembly’s standardized spiral terminals simplified wiring documentation (required for FDA audits), while EEPROM data retention allowed module replacement without process interruption. The plant passed its FDA inspection with zero wiring-related findings and reduced maintenance downtime by 65%.

Related Product Combination Solutions

Build a complete, fault-tolerant Genius I/O system with the IC660TBD024 and these compatible modules:

IC660EBD024: Electronic Assembly – Works with the IC660TBD024 to process I/O signals and communicate with the PLC .

IC660BBD024: 32-Channel I/O Block – The core I/O module that pairs with the IC660TBD024 for signal collection/execution .

IC693CPU352: Series 90-30 PLC Controller – Serves as the “brain” to process data from the Genius I/O system .

IC660CMM311: Genius Bus Module – Enables communication between the PLC and the IC660TBD024-based I/O network .

IC660PWR100: 24V DC Power Supply – Delivers stable power to the terminal assembly and connected I/O components, with overcurrent protection .

IC660HHM501: Genius Handheld Monitor – Configures the IC660TBD024’s EEPROM parameters and diagnoses wiring faults on-site .

Installation, Maintenance, and Full-Cycle Support

Installing the IC660TBD024 is optimized for efficiency and safety:

Mounting: Secure the assembly to a DIN rail or control cabinet panel (compatible with standard 35mm rails).

Wiring: Connect field devices to the spiral terminals (labeled “IN 1–16” / “OUT 1–16”); link to the IC660EBD024 via the internal connector .

Configuration: Use a handheld monitor (IC660HHM501) to set parameters (device ID, baud rate), which are stored in the EEPROM .

Verification: Power on and check for steady LED indicators (no flashing = normal communication; flashing = wiring/configuration errors).

Routine maintenance is minimal, thanks to built-in durability and diagnostics:

Daily Checks: Inspect terminal connections for tightness (critical in vibrating environments) and verify LED status.

Troubleshooting: Use the handheld monitor to read EEPROM data and identify misconfigured devices; replace faulty modules without reconfiguring (data retained).

Periodic Service: Clean terminals annually to remove dust (use compressed air) and test isolation resistance (ensure ≥850V AC).

Emerson backs the IC660TBD024 with a 2-year warranty and 24/7 technical support. Spare assemblies ship within 48 hours for critical failures, and on-site training is available to cover wiring best practices and EEPROM configuration.

IC660TBD024

Call to Action

Whether you’re simplifying wiring in dense manufacturing lines, upgrading to interference-resistant terminals in harsh environments, or ensuring regulatory compliance with traceable connections, the IC660TBD024 delivers the reliability, flexibility, and maintainability your automation system demands. Contact us today to design a customized Genius I/O solution—our team will pair the IC660TBD024 with compatible electronics and I/O blocks to reduce downtime, cut wiring costs, and future-proof your control infrastructure.