FANUC Series 90-30 PLC. Installation and Hardware Manual (GFK-0356P)

What if I need to cover more than 700 feet (213 meters) ?

You can cover much greater distances by using Series 90-30 communications option

modules. For example, Genius Bus Controller Modules (GBC) can communicate at

distances up to 7,500 feet (2,286 meters) over a shielded twisted-pair cable, as shown in

Example 1 below. Or, serial communications with Communications Coprocessor

Modules (CMM) using the RS-485 standard can cover up to 4,000 feet (1,219 meters), as

shown in Example 2 below. And virtually unlimited communication distances can be

attained with modems and telephone lines or radio transmitters. Also, there are

numerous networking options available such as Ethernet or WorldFIP.

Example 1 - GBC

Example 2 - CMM

Series 90-30 PLC

CPU

GBC

CPU

CMM

Shielded, Twisted-Pair Cable, 7,500

Serial Cable, 4,000 Feet (1,219

Feet (2,286 Meters) Maximum Length

Meters) Maximum Length

Series 90-30 PLC

CPU

GBC

CPU

CMM

Figure 1-10. Connecting PLCs Using GBC or CMM Modules

GFK-0356P

Chapter 1 Overview of the Series 90-30 PLC

1-9

Chapter

Installation

This chapter discusses installation details only. Other information about the products

such as hardware descriptions and specifications, are covered in the applicable chapter.

- Important Note -

The installation instructions described in this chapter apply to PLC installations

that do not require special procedures for noisy or hazardous environments. For

installations that must conform to more stringent requirements (such as CE

Mark), see GFK-1179, Installation Requirements for Conformance to

Standards. Also see GFK-0867, GE Fanuc Product Agency Approvals,

Standards,GeneralSpecifications.

Receiving your Products - Visual Inspection

When you receive your Series 90-30 PLC system, carefully inspect all shipping containers

for damage that may have occurred during shipping. If any part of the system is

damaged, notify the carrier immediately. The damaged shipping container should be

saved as evidence for inspection by the carrier.

As the consignee, it is your responsibility to register a claim with the carrier for damage

that happened during shipment. However, GE Fanuc will fully cooperate with you if

such action is necessary.

Pre-installation Check

After unpacking Series 90-30 PLC racks, cables, modules, etc., record all serial numbers.

Serial numbers are printed on the module packaging. Serial numbers are required to make a

claim during the warranty period of the equipment. All software product registration cards

should be completed and returned to GE Fanuc. See the “Module Features” section in this

chapter for location of module serial numbers. See the “Common Baseplate Features”

section in the “Baseplates” chapter for location of baseplate serial numbers.

You should verify that all components of the system have been received and that they

agree with your order. If the parts received do not agree with your order, call

Programmable Control Customer Service, toll free, in Charlottesville, VA at

1-800-432-7521. A Customer Service representative will provide further instructions.

If you require assistance with your installation, the GE Fanuc Technical Service Hotline

personnel in Charlottesville, VA are available to help you. North American customers

should call toll-free at 1-800-GE FANUC (1-800-433-2682). International customers

should dial direct: 804-978-6036. The GE Fanuc web site support address is

www.gefanuc.com/support/plc. Chapter 13, “Maintenance and Troubleshooting” has

additional telephone numbers and troubleshooting information.

Warranty Claims

Record the serial number of the defective item and contact your distributor for

instructions.

2-1

GFK-0356P

Working with Series 90-30 Modules

Module Features

IC693CPUXXX

CPU MODULE

25 MHZ

LISTED

xxxxxxx

123456789

1234567

Figure 2-1. Features of Series 90-30 Module

Pivot hook

Circuit board holding tabs (two on each side of module)

Catalog number and description section of label

Certification (UL, CE, etc.) section of label

Module connector - plugs into baseplate backplane connector

Release lever - spring loaded

Ventilation openings in module case (top and bottom)

Front cover holding tabs (two on each side of module)

Front cover (shown) or terminal board (for I/O modules).

10. Front cover faceplate or hinged cover for terminal board.

11. Lens cap (some modules do not have).

12. Lens cap holding tabs (one on each side of module)

13. Module label

14. Serial Number - used to determine module warranty status. Note that on some

modules, the Serial Number may be on a small tag on the back of the module.

2-2

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

Installing a Module

Warning

Do not insert or remove modules with power applied. This could

cause the PLC to stop or malfunction. Injury to personnel and damage

to the module or baseplate may result. Also, attempts to force a

module into an improper slot type will result in damage to the module

and/or the baseplate. Modules will mount in the correct slot type

easily, with a minimum of force.

Use the following instructions as a guide when inserting a module into a baseplate slot.

Check that module catalog number matches slot configuration. Each slot is, or will

be, assigned a particular module type during configuration. A Power Supply

module must be installed in the left end unnumbered slot only, and a CPU module

and some special Option modules can only be installed in Slot 1 of a CPU baseplate.

I/O Modules and most Option modules install in slots numbered 2 and higher.

Grasp the module firmly with terminal board toward you and with rear pivot hook

facing away from you.

Align the module with the desired baseplate slot and connector. Tilt the module

upwards so that top rear pivot hook of the module engages the baseplate’s top

module retainer.

Swing the module downward until the module’s connector engages the baseplate’s

backplane connector, and the release lever on the bottom of the module snaps into

place in the baseplate’s bottom module retainer.

Visually inspect the module to be sure that it it properly seated.

a43055A

PIVOT HOOK

BACKPLANE

CONNECTOR

RELEASE LEVER

BOTTOM RETAINER

Figure 2-2. Installing a Module

GFK-0356P

Chapter 2 Installation

2-3

Removing a Module

Warning

Do not insert or remove modules with power applied. This could

cause the PLC to stop or malfunction. Injury to personnel and damage

to the module or baseplate may result. Also potentially dangerous

voltages from user devices may be present on a module’s screw

terminals even though power to the rack is turned off. Care must be

taken any time that you are handling the module’s removable terminal

board or any wires connected to it.

If the module has wiring, remove the module’s terminal board (NOTE: You do not

have to unwire the terminal board) or cables. The procedure for removing a

terminal board is described later in this section.

Locate the release lever at the bottom of the module and firmly press it up, towards

the module.

While holding the module firmly at its top and fully depressing release lever, swing

(pivot) the module upward (release lever must be free of its retaining slot).

Disengage pivot hook at the top rear of the module by moving the module up and

away from the baseplate.

a43056

PIVOT HOOK

ÎÎ

PRESS

RELEASE LEVER

Figure 2-3. Removing a Module

Note

Modules in expansion or remote baseplates can be added, removed, or

replaced while the PLC is in RUN mode if power is first removed from

the expansion or remote baseplate. I/O data to/from this baseplate will

not be updated while power is removed.

2-4

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

Installing a Module’s Terminal Board

Note: Modules IC693MDL730F (and later) and IC693MDL731F (and later) have special

terminal boards that are equipped with holding screws. For Installation and Removal

instructions, please see the section “Installing and Removing Terminal Boards with

Holding Screws” later in this chapter.

To install a terminal board:

Hook the pivot hook➀, located on the bottom of the terminal board, to the lower

slot on the module.

Push the terminal board towards the module➁ until it snaps into place.

Open the terminal board cover➂ and ensure that the latch on the module is

securely holding the terminal board in place.

Caution

Compare the module catalog number on the label on the back of the hinged

door (see Figure 2-6) and the label on the side of the module (see below) to

ensure that they match. If a wired terminal board is installed on the wrong

module type, damage to the module may occur when the system is powered

up.

a43062

Module

Label

REFER TO TEXT FOR

INSTALLATION PROCEDURE

Figure 2-4. Installing an I/O Module’s Terminal Board

GFK-0356P

Chapter 2 Installation

2-5

I/O Module Terminal Board Posts

Notice that the terminal board has three posts on the left side. The top and bottom posts

hold the terminal board cover in place. The purpose of the middle post is to keep the

terminal board wiring in place. This middle post can be easily snapped off if you do not

require it to hold the wiring in place.

Since minimal force is required to snap off the middle post, you should be careful that

you do not inadvertently snap it off if you are using it to keep your wiring in place.

Installing and Removing Terminal Boards with Holding Screws

Discrete output modules IC693MDL730F (and later) and IC693MDL731F (and later)

have a special terminal board that is equipped with holding screws, shown in the figure

below. These screws prevent the terminal board-to-module connections from

deteriorating in applications where the PLC is subjected to severe vibration .

a43082B

A1 2 3 4 5 6 7 8

B1 2 3 4 5 6 7 8

ÎÎÎÎÎÎ

ÎÎÎÎÎÎÎ

Hinged Cover

ÎÎÎÎÎÎÎ

Holding Screw

ÎÎÎÎA1ÎÎÎ

ÎÎÎÎÎÎÎ

Removeable Terminal Board

ÎÎÎÎÎÎÎ

ÎÎ8ÎÎA3ÎÎÎ

ÎÎ10ÎÎA4Î+ÎÎ

ÎÎÎÎÎ–ÎÎ

ÎÎÎÎÎÎÎ

ÎÎ14ÎÎA6ÎÎÎ

ÎÎ16ÎÎA7ÎÎÎ

Holding Screw

ÎÎÎÎÎÎÎ

ÎÎ20ÎÎÎÎÎ

ÎÎÎÎÎÎÎ

IC693MDL730F

Module Catalog Number

ÎÎÎÎÎÎ

Figure 2-6. Terminal Board with Holding Screws

Removing: To Remove these terminal boards, first loosen the two holding screws on

the front of the terminal board, then follow the standard removal instructions in the

section “Removing an I/O Module’s Terminal Board.” The holding screws are held

captive in the terminal board and do not have to be completely removed.

Installing: To install these terminal boards, follow the standard installation

instructions in the section “Installing an I/O Module’s Terminal Board,” then tighten

the two holding screws to 8 to 10 inch pounds (1 Newton-meter) of torque.

GFK-0356P

Chapter 2 Installation

2-7

Baseplate Mounting

Warning

Be sure to follow baseplate grounding instructions in this chapter.

Failure to properly ground the PLC can result in improper operation,

damage to equipment, and injury to personnel.

Mounting a Baseplate to a Panel

Use four good-quality 8-32 x 1/2 (4 x 12 mm) machine screws, lock washers and flat

washers. Install the screws in four 8-32 tapped holes. The “Baseplates” chapter has

the applicable dimensions and mounting clearances. Alternately, 10-slot baseplates

can be mounted in standard 19-inch racks by using the appropriate adapter. This is

also discussed in the “Baseplates” chapter.

A vertical mounting orientation is preferred for maximum heat dissipation. Other

mounting orientations will require derating the Power Supply current capabilities.

See Chapter 12, “System Design,” for details.

All baseplates must be grounded. The “Baseplate Safety Grounding” section of this

chapter has details.

The Rack Number Selection switch must be set on each Expansion or Remote

baseplate. A CPU baseplate does not require this switch. Rack numbers should be

assigned by the system designer. Failure to set the Rack Number Selection switches

properly will result in system malfunction. See the “Baseplates” chapter for details

on setting these switches.

Mounting a Baseplate to a 19” Rack

Two optional Baseplate Adapter Brackets allow a 10-slot baseplate to be mounted in a 19

inch rack. Each baseplate installation requires only one of the adapter brackets.

IC693ACC308 Front Mount Adapter Bracket. Used to mount a baseplate to the

front face of a 19” rack. Install the adapter bracket by inserting the tabs at the top

and bottom of the adapter bracket into the corresponding slots at the top and

bottom of the plastic baseplate cover. NOTE: Although the figure below shows the

plastic baseplate cover removed, this is for illustration purposes only. It is not

necessary to remove the cover to install the bracket. With the bracket in place, insert

and tighten the two screws (included with the bracket) through the back of the

baseplate holes into the threaded holes in the bracket.

IC693ACC313 Recessed Mount Adapter Bracket. Used to recess mount a baseplate

inside a 19” rack. A baseplate mounts on the rear panel of this adapter bracket using

four 8-32 (4 mm) screws, nuts, lockwashers and flat washers. The Adapter Bracket

bolts through its four slotted holes to the face of the 19” rack using applicable

hardware (lockwashers recommended).

2-8

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

RIGHT SIDE OF

a43726A

BASEPLATE

Insert two screws (1 at top; 1 at bottom)

from back of base unit through base unit

and bracket. Tighten screws to secure

bracket to base unit.

Note: Baseplate is shown with cover removed for illustration purposes. It

is not necessary to remove the baseplate cover to install the bracket.

Figure 2-7. IC693ACC308 Front Mount Adapter Bracket Installation

Dimensions for rack mounting a 10-slot baseplate with the IC693ACC308 Front Mount

Adapter Bracket are shown in the following figure.

a45047

18.89

(480)

18.47

(469)

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

DIMENSIONS IN INCHES (MILLIMETERS IN PARENTHESES)

Figure 2-8. Dimensions for 19

Rack Mounting Using IC693ACC308 Adapter Bracket

GFK-0356P

Chapter 2 Installation

2-9

Grounding Procedures

System Grounding Procedures

Warning

In addition to the following grounding information, we strongly urge

that you follow all applicable codes that apply to your area. For

example, in the United States, most areas have adopted the National

Electrical Code standard and specify that all wiring conform to its

requirements. In other countries, different codes will apply. For

maximum safety to personnel and property you must follow these

codes. Failure to do so can mean injury or death to personnel, damage

to property, or both.

All components of a programmable logic control system and the devices it is controlling

must be properly grounded. This is particularly important for the following reasons.

A low resistance path from all parts of a system to earth minimizes exposure to

shock in the event of short circuits or equipment malfunction.

The Series 90-30 PLC system requires proper grounding for correct operation.

The importance of a proper grounding cannot be over-emphasized.

Ground Conductors

Ground conductors should be connected in a tree fashion with branches routed to a

central earth ground point, shown in the figure below. This ensures that no ground

conductor carries current from any other branch. This method is shown in the

following figure.

Ground conductors should be as short and as large in size as possible. Braided

straps or ground cables (typically green insulation with a yellow tracer - AWG #12

(3.3 mm²) or larger) can be used to minimize resistance. Conductors must always be

large enough to carry the maximum short circuit current of the path being

considered.

a43059

SERIES 90-30

MOTOR DRIVES

MACHINERY

PLC CABINET

AND OTHER

ELECTRICAL

RACK

CONTROL

EQUIPMENT

PROGRAMMING

RACK

DEVICE

NOTE

SIGNAL AND POWER

EARTH

CENTRAL

CONNECTIONS

GROUND

GROUND POINT

ARE NOT SHOWN

Figure 2-10. Recommended System Grounding

GFK-0356P

Chapter 2 Installation

2-11

Series 90-30 PLC Equipment Grounding

Equipment grounding recommendations and procedures are listed below. These

grounding procedures must be properly followed for safe, proper operation of your Series

90-30 PLC system.

Baseplate Safety Grounding

The following recommendations are offered, but applicable safety codes for your area or

equipment type should also be consulted. The baseplate’s metal back must be grounded

using a separate conductor; the baseplate mounting screws are not considered to an

acceptable ground connection by themselves. Use a minimum AWG #12 (3.3 mm²) wire

with a ring terminal and star lock washer under the head of one of the baseplate’s two

lower mounting holes. These two holes have openings to the side to allow connecting a

wire and ring terminal under the head of a mounting screw. Connect the other end of this

ground wire to a tapped hole in the panel that the baseplate is mounted to, using a machine

screw, star lock washer, and flat washer. Alternately, if your panel has a ground stud, it is

recommended you use a nut and star lock washer for each wire on the ground stud to

ensure adequate grounding. Where connections are made to a painted panel, the paint

should be removed so clean, bare metal is exposed at the connection point. Terminals and

hardware used should be rated to work with the aluminum baseplate material.

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

AWG #12 or

VALUES MAY BE

LOST IF POWER

Larger Wire

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

CPU/1

I/O-2

I/O-3

I/O-4

I/O-5

POWER

SUPPLY

Alternate location

for Ground connection

Screw, Star Lock washer,

Flat Washer, Ring Terminal,

installed in tapped hole.

Paint Removed

From Panel Here

Figure 2-11. Baseplate Grounding

Warning

All baseplates must be grounded to minimize electrical shock hazard.

Failure to do so can result in severe personal injury.

2-12

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

All baseplates grouped together in a Series 90-30 PLC system must have a common ground

connection. This is especially important for baseplates that are not mounted in the same

control cabinet.

Grounding 19” Rack-Mounted Baseplates

There are two Adapter Brackets used for mounting a 10-slot Series 90-30 baseplate to a

19” Rack. Regardless of which of the two Adapter Brackets is used, the 19” Rack should

be grounded as per the instructions in “System Grounding Procedures,” including Figure

2-10. (For details on the Adapter Brackets, see the “Mounting a Baseplate to a 19” Rack”

section earlier in this chapter.)

Nineteen-Inch Rack-mounted PLC baseplates should be grounded according to the

guidelines in the “Baseplate Safety Grounding” section, using a separate ground wire

from the PLC baseplate as shown in the previous figure (Fig. 2-11).

If using the Recessed Mount Adapter Bracket (IC693ACC313), the ground wire can

be installed as shown in Figure 2-11 with the ground attached to the Recessed

Mount Adapter Bracket. An additional ground wire connecting the Adapter Bracket

to a solid chassis ground on the 19” Rack should be installed. Use the same or

equivalent hardware and paint removal scheme as shown in Figure 2-11.

If using the Surface Mount Adapter Bracket (IC693ACC308), the ground wire

should be run from the baseplate as shown in Figure 2-11, to a solid chassis ground

on the 19” Rack. Use the same or equivalent hardware and paint removal scheme as

shown in Figure 2-11.

Programmer Grounding

For proper operation, the computer (programmer) running the PLC software must have

a ground connection in common with the CPU baseplate. Normally, this common

ground connection is provided by ensuring that the programmer ’s power cord is

connected to the same power source (with the same ground reference point) as the

baseplate. If it is not possible to ensure this common ground scheme, use a port isolator

(IC690ACC903) between the programmer and PLC serial connection. If the programmer

ground is at a different potential than the PLC ground, a shock hazard could exist. Also,

damage to the ports or converter (if used) could occur when the programmer serial cable

is connected between the two.

Warning

Failure to follow programmer grounding recommendations could

result in personal injury, equipment damage, or both.

GFK-0356P

Chapter 2 Installation

2-13

Module Shield Grounding

In general, the aluminum PLC baseplate is used for module shield grounding. On some

Series 90-30 modules, shield connections to the user terminal connector on the module

are routed to the baseplate through the module’s backplane connector. Other modules,

such as CPUs 351, 352, 363, and 364, require a separate shield ground. These are

discussed in the next several sections.

Shield Grounding Information for CPUs with External Port Connections

CPUs with external port connections, the 351, 352, 363, and 364, must have a separate

shield ground connection which provides shielding for these ports. The design of the

ground connection for the CPU351 and 352 is different from that of the CPU363 and 364,

so each grounding method is discussed in a separate heading.

CPU351 and 352 Shield Grounding

The CPU 351 or 352 module must be connected to frame ground at the slot where it is

installed. Two methods are provided for making this ground connection. Each CPU

comes with an EMC Grounding Kit (44A737591-G01) that contains a ground wire,

grounding bracket, and screws.

The connection from the CPU to frame ground can be made using the ground wire

(part number 44A735970-001R01) that comes with the module in the EMC

Grounding Kit. This wire has a stab-on connector on one end for connection to a

mating terminal on the bottom of the CPU, and a ring terminal on the other end for

connection to a grounded enclosure. Where the ring terminal contacts a painted

enclosure panel, either a star lock washer can be installed between the terminal and

the panel to cut through the paint, or the paint can be scraped away down to clean,

bare metal to ensure a good contact. Note: The star lock washer method is

suitable for a shield ground, but not suitable for a safety ground.

CPU351 or 352

#6 TAPPED HOLE

REMOVE PAINT UNDER

BOTTOM OF

RING TERMINAL OR INSTALL

CPU MODULE

USE 1 #6

STAR LOCK WASHER BETWEEN

MACHINE SCREW

TERMINAL AND PANEL

STAB-ON

CONNECTOR

MOUNT ON

44A735970-001R01

GROUNDED

ENCLOSURE

Figure 2-12. CPU 351 or 352 - Attaching Ground Wire

2-14

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

The second method, which can be used for systems in noisy environments consists

of installing the green ground wire and the optional grounding bracket (part

number 44C715646-001R01). This bracket attaches to the CPU using two #4

thread-rolling screws (part number N666P9004B6) and to the grounded enclosure

using two #6 thread-rolling screws (part number N666P13006B6). Two holes must

be drilled in the enclosure for mounting this bracket. Also, if the bracket will be

attached to a painted surface, the paint should be removed down to bare metal

under the bracket to ensure good contact between the bracket and the surface. See

the next figure.

a45514A

CPU351 or 352

44C715646-001R01

PAINT REMOVED WHERE

BRACKET

BRACKET MOUNTS TO PANEL

MOUNT ON

GROUNDED

ENCLOSURE

USE 2 #4

USE 2 #6

THREAD ROLLING SCREWS

(N666P9004B6)

(N666P13006B6

Figure 2-13. CPU 351 or 352 - Mounting Grounding Bracket

Note: When the grounding bracket is used, pin 1 of the cable connector that plugs into

the Port 2 connector should not be connected. A metal connector shell must be used on

the cable for this port, and the cable shield must be terminated at the metal shell instead

of pin 1 of the connector.

CPU363 and CPU364 Shield Grounding

The CPU363 and CPU364 modules must be connected to frame ground at the slot where

they are installed. Each module comes with a grounding wire for this purpose. These

modules do not support or require the use of a grounding bracket. If the ring terminal

on the grounding wire is to be mounted to a painted surface, remove the paint under

the ring terminal to ensure good contact, or place a star lock washer between the ring

terminal and the painted surface. See the next figure. Note: The star lock washer

method is suitable for a shield ground, but not suitable for a safety ground.

GFK-0356P

Chapter 2 Installation

2-15

CPU363 or 364

STAB-ON

CONNECTOR

#6 TAPPED HOLE

REMOVE PAINT UNDER

BOTTOM

RING TERMINAL OR INSTALL

OF CPU MODULE

STAR LOCK WASHER BETWEEN

USE 1 #6

RING TERMINAL AND PANEL

MACHINE SCREW

MOUNT ON

44A735970-001R01

GROUNDED

ENCLOSURE

Figure 2-14. CPU 363 or CPU364 - Attaching Ground Wire

Additional Modules with Shield Grounding Requirements

Some of the Series 90-30 Option modules, such as the FIP Remote I/O Scanner

(IC693BEM330), and DSM modules (IC693DSM302 and IC693DSM314) also have shield

grounding requirements. These modules come equipped with suitable grounding

hardware. Please refer to each module’s user ’s manual for grounding instructions.

Appendix I contains a product to publication cross-reference to help you identify the

correct manual.

2-16

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

General Wiring Guidelines

Warning

In addition to the following wiring suggestions, we strongly urge that

you follow all wiring and safety codes that apply to your area or your

type of equipment. For example, in the United States, most areas have

adopted the National Electrical Code standard and specify that all

wiring conform to its requirements. In other countries, different codes

will apply. For maximum safety to personnel and property you must

follow these codes. Failure to do so can lead to personal injury or

death, property damage or destruction, or both.

Color Coding Wires

These color codes are commonly used in industrial equipment manufactured in the

United States. They are cited here as a reference. Where they are in conflict with codes

that apply to your area or your type of equipment, you should follow your applicable

codes instead. Besides satisfying code requirements, wire color coding makes testing

and troubleshooting safer, faster, and easier.

Green or green with stripe- Ground

Black - Primary AC

Red - Secondary AC

Blue - DC

White - Common or neutral

Yellow - Secondary power source not controlled by the main disconnect. Alerts

maintenance personnel that there may be power present (from an external

source) even if the equipment is disconnected from its main power source.

Wire Routing

To reduce noise coupling among PLC wires, it is recommended you keep electrically

noisy wiring, such as AC power wiring and Discrete Output Module wiring, physically

separated from low-level signal wiring such as DC and Analog Input module wiring or

communications cables. This can be accomplished by grouping separately, where

practical, the following categories of wiring:

AC power wiring. This includes the AC input to the PLC power supply, as

well as other AC devices in the control cabinet.

Analog Input or Output Module wiring. This should be shielded to further

reduce noise coupling. See the Series 90-30 I/O Module Specifications Manual,

GFK-0898 for details.

Discrete Output Module wiring. These often switch inductive loads that

produce noise spikes when switched off.

DC Input Module wiring. Although suppressed internally, these low-level

inputs should be further protected against noise coupling by observing

these wiring practices.

GFK-0356P

Chapter 2 Installation

2-17

Communications Cables. Wiring such as Genius Bus or serial cables should

be kept away from noise-producing wiring.

Where AC or Output wiring bundles must pass near noise-sensitive signal wiring

bundles, avoid running them beside each other. Route them so that, if they have to

cross, they do so at a right angle. This will minimize coupling between them.

Grouping Modules to Keep Wires Segregated

If practical, grouping similar modules together in the PLC racks can help keep wiring

segregated. For example, one rack could contain only AC modules, and a different rack

only DC modules, with further grouping in each rack by input and output types. For

smaller systems, as an example, the left end of a rack could contain Analog modules, the

middle could contain DC modules, and the right end could contain AC modules.

Discrete I/O Module Connection Methods

For modules with 16 points or less, the standard method is to use the removable

terminal board which comes with these modules. The removable terminal

board makes it easy to prewire field wiring to the user supplied input and

output devices, and to replace modules in the field without disturbing existing

field wiring.

Some discrete 16-point I/O modules can be used with an optional Terminal Block

Quick Connect (TBQC) assembly. This assembly contains a module faceplate,

with built-in connector, that replaces the removeable terminal board. The

assembly also contains a DIN-rail mounted terminal block and a cable to connect

the module to the terminal block. The advantage of this method is that it saves

about two hours of wiring time per module compared with hand wiring from a

module’s removable terminal board to a user-supplied, panel-mounted terminal

block or strip.

Older 32-point I/O modules have one 50-pin connector on the front of the

module that is either connected by a cable with a connector on each end to a

Weidmuller panel-mounted terminal block (Weidmuller catalog no. 912263), or is

connected by a cable with stripped, tinned leads to a user-supplied terminal

block or strip.

Newer 32-point I/O modules have two 24-pin connectors on the front of the

module. These module may be wired in one of three ways. (1) Use a pair of

cables (IC693CBL327/328 - see data sheet in “Cables” chapter) to connect the

module to a user-supplied, panel-mounted terminal block or strip. These cables

have a 24-pin connector on one end, and stripped, tinned leads with wire

markers on the other end. (2) Use a pair of dual-connector cables to connect the

module to a Terminal Block Quick Connect (TBQC) terminal block

(IC693ACC377). See Appendix J for details. (3) Make your own custom cables.

Instructions are found in the IC693CBL327/328 data sheet in Chapter 10.

Connections to I/O Module Terminal Boards

Series 90-30 PLC I/O terminal boards have either 10 or 20 screw terminals that will

accept from two AWG #22 (0.36 mm²) to two AWG #16 (1.3 mm²), or one AWG #14 (2.1

mm²) copper 90 C (194 F) wire(s). Each terminal can accept solid or stranded wires, but

the wires into any given terminal should be the same type (both solid or both stranded)

2-18

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

to ensure a good connection. Wires are routed to and from the terminals out of the

bottom of the terminal board cavity. The suggested torque for the I/O terminal board

connection screws is from 9.6 in-lbs to 11.5 in-lbs (1.1 - 1.3 Newton-meters).

For 24 volt DC input modules, an internal 24 volt power connection is provided on the

terminal board to supply a limited number of input devices. Also, a 24 volt DC output

is available on the power supply module’s terminal board to supply a limited number of

output devices.

Terminal Block Quick Connect Installation for 16-Point Discrete Modules

The Terminal Block Quick Connect (TBQC) Assembly is an option for certain Series 90-30

discrete I/O modules. See Appendix J for more information.

Remove standard terminal board from module.

Install TBQC faceplate (it has a 24-pin connector).

Mount the TBQC terminal block. It has a 24-pin connector and a terminal strip, and

mounts on a standard 35 mm DIN-rail.

Connect a TBQC cable between the TBQC faceplate connector on the module and

the connector on the TBQC terminal block.

Wire I/O devices to the terminal block.

Installation of 32-Point Discrete, 50-Pin Connector Modules

These 50-Pin modules are an older design and are not generally used on new systems,

unless to fulfill standardization requirements. They are mainly used as replacements for

existing installations. For new installations, we recommend the dual 24-pin connector

style because they have additional features not found on the older modules (LED

indicators, TBQC), and it is much easier to fabricate custom-length cables for them.

Installation information is provided here for the convenience of those still using these

modules.

Using Weidmuller

#912263 Terminal Block

Note: The TBQC is not available for these modules, but you may purchase a Weidmuller

#912263 from your electronics distributor for this application.

Mount the Weidmuller#912263 terminal block. It has a 50-pin connector and a

terminal strip, and mounts on a standard 35 mm DIN-rail.

Connect an IC693CBL306/307 cable between the module’s faceplate connector and

the connector on the Weidmuller terminal block. See Chapter 10 for cable data.

Wire I/O devices to the terminal block. See the Series 90-30 PLC I/O Module

Specifications Manual, GFK-0898, for pin-out information.

GFK-0356P

Chapter 2 Installation

2-19

Using Generic Terminal Block or Strip

Mount terminal block/strip to the enclosure panel.

Connect an IC693CBL308 or 309 cable, or a custom made cable, to the module’s

faceplate connector and wire the stripped ends of the cable to the terminal

block/strip. See Chapter 10 for cable data.

Wire I/O devices to the terminalblock/strip.

Direct Method

Connect an IC693CBL308 or 309 cable, or a custom made cable, to the module’s

faceplate connector and wire the stripped ends of the cable directly to the field

devices. See Chapter 10 for cable data. See the Series 90-30 PLC I/O Module

Specifications Manual, GFK-0898, for pin-out information.

Installation of Discrete 32-Point, Dual 24-Pin Connector Modules

Using a TBQC

Mount two TBQC terminal blocks. Each has a 24-pin connector and a terminal strip,

and mounts on a standard 35 mm DIN-rail.

Connect a pair of TBQC cables (IC693CBL329 - 334) between the module’s

faceplate connector and the connectors on the two TBQC terminal blocks. Note that

both a right side and left side cable is required. See Appendix J for a list of cables.

Wire I/O devices to the terminal blocks. See the Series 90-30 PLC I/O Module

Specifications Manual, GFK-0898, for pin-out information.

The Terminal Block Quick Connect (TBQC) Assembly is an option for certain Series 90-30

discrete I/O modules. See Appendix J for more information.

With a Generic Terminal Block/Strip

Mount terminal block/strip to the enclosure panel.

Connect an IC693CBL327/328 cables, or a custom made cables, to the module’s

faceplate connectors, and wire the stripped ends of the cables to the terminal

block/strip. Note that both a right side and left side cable is required. See Appendix

J for a list of cables. See Chapter 10 for cable data sheets.

Wire I/O devices to the terminal block/strip. See the Series 90-30 PLC I/O Module

Specifications Manual, GFK-0898, for pin-out information.

Direct Method

Connect an IC693CBL327/328 cables, or a custom made cables, to the module’s

faceplate connectors, and wire the stripped ends of the cable directly to the field

devices. See Chapter 10 for cable data. See the Series 90-30 PLC I/O Module

Specifications Manual, GFK-0898, for pin-out information.

2-20

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

General Wiring Methods for Analog Modules

Twisted, shielded instrumentation cable is strongly recommended for analog module

input or output signal connections. Proper grounding of the shield is also important.

For maximum electrical noise suppression, the cable shield should only be grounded at

one end of the cable. For Input modules, ground the end that is in the noisiest

environment (which often is at the field device end). For Output modules, ground at the

module end. See GFK-0898, Series 90-30 PLC I/O Module Specifications, for more shield

grounding information.

Analog Input Module Wiring Methods

Correcting electrical noise problems can sometimes be a trial-and-error routine.

However, in general, it is generally best to ground the cable shield as close to the source

of the noise as possible, which is usually at the device end. In troubleshooting noise

problems, sometimes it is beneficial to experiment with the shield grounding point

location. Remember, the cable shield should be grounded at one end only. Also, it is best

to keep the length of stripped cable leads as short as possible to minimize the length of

unshielded conductors that will be exposed to the noisy environment. See the Series

90-30 PLC I/O Module Specifications Manual, GFK-0898 for additional details.

Using Generic Terminal Block or Strip

Mount a terminal strip inside the control enclosure and run a shielded cable from

the terminal strip to each input circuit on the module’s terminal board terminals.

Connect each cable’s shield to the metal panel next to the terminal strip. Do do not

connect the shields at the module end (cut shield off at module end of cable and

insulate with shrink tubing).

Wire the field device to the terminal strip with a shielded cable, grounding the shield

at the device end only (cut shield off at terminal strip end of cable and insulate with

shrink tubing). Also, keep the length of exposed (outside of shield) leads at the

terminal strip and device ends as short as possible.

Direct Method

Run a shielded cable from the field device (transducer, potentiometer, etc.) directly

to the module.

Connect the conductors to the applicable screws on the module’s terminal board.

Ground the shield at the field device end, exposing a minimum amount of

conductor to the noisy environment. Do not connect the shield at the module end

(cut shield off at module end of cable and insulate with shrink tubing).

TBQC

The Terminal Block Quick Connect (TBQC) Assembly is not recommended for use with

analog modules due to cable shielding requirements.

GFK-0356P

Chapter 2 Installation

2-21

Analog Output Module Wiring

General

Each output should be connected using a good quality shielded wire with the cable

shield grounded at the module end. See GFK-0898, Series 90-30 PLC I/O Module

Specifications, for more information.

Using Generic Terminal Block or Strip

Mount a terminal strip inside the control enclosure and run a shielded cable from

the terminal strip to each output circuit on the module’s terminal board terminals.

Ground each cable’s shield at the module end only. Do do not connect the shields at

the terminal strip end (cut shields off at terminal strip end of cables and insulate

with shrink tubing).

Wire the field device to the terminal strip with shielded cables, grounding the

shields at the terminal strip end only (cut shields off at field device end of cables and

insulate with shrink tubing). Also, keep the length of exposed (outside of shield)

leads at the terminal strip and device ends as short as possible.

Direct Method

Run a shielded cable from each field device (transducer, potentiometer, etc.) directly

to the module.

Connect the conductors to the applicable screws on the module’s terminal board.

Ground the shield at the module end only, exposing a minimum amount of

conductor to the noisy environment. Do not connect the shield at the device end

(cut shield off at device end of cable and insulate with shrink tubing).

TBQC

The Terminal Block Quick Connect (TBQC) Assembly is not recommended for use with

analog modules due to cable shielding requirements.

2-22

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

AC Power Source Connections

AC Input Wiring to AC/DC Power Supplies

Warning

If the same AC power source is used to provide AC power to other baseplates

in a Series 90-30 PLC System, ensure that all AC input connections are

identical at each rack. Do not cross Line 1 (L1) and Line 2 (L2). A resulting

difference in potential can injure personnel or cause damage to equipment.

Each baseplate must be connected to a common ground.

Ensure that the protective cover is installed over all terminal boards. During

normal operation with an AC power source either 120 VAC or 240 VAC is

present on the AC Power Supply. The cover protects against accidental

shock hazard which could cause severe or fatal injury to the operator or

maintenance personnel.

Both the Standard (IC693PWR321) and High Capacity (IC693PWR330) AC/DCpower

supplies currently have six terminals for user connections. Early versions of some Series

90-30 power supplies had five terminals (see next figure). The wiring methods for both

five-terminal and six-terminal types is similar, except that step 3 below does not apply to

the five-terminal type.

The power supply terminal boards will accept one AWG #14 (2.1 mm²) or two AWG #16

(1.3 mm²) copper 75 C (167 F) wires. Each terminal can accept solid or stranded wires,

but the wires in any given terminal should be the same type. The suggested torque for

the power supply terminal board is 12 in-lbs (1.36 Newton-meters). Open the door

protecting the terminal board and make the following connections from the AC power

source, and ground connections (system grounding requirements are described in detail

later in this chapter).

These are wide range supplies that can operate from an AC power source within the

nominal range of 100 VAC to 240 VAC at 50/60 Hz. This may vary -15% to +10%

for a total maximum range of 85 VAC to 264 VAC. These are auto-ranging supplies

that do not require jumper or switch settings for selection of power source voltage.

Connect the hot and neutral wires or lines L1 and L2 to the upper two terminals on

the terminal board. Connect the safety ground wire to the ground terminal, which

is the third terminal from the top, and is marked with a ground symbol.

For power supplies with six terminals, the factory jumper between the 3rd and 4th

terminals (see figure below), should be left in place for normal installations.

However, this jumper must be removed and external surge suppressors installed in

installations with a “Floating Neutral” input. Please see the section “Special

Instructions for Floating Neutral (IT) Systems” later in this chapter for details.

After all connections to Power Supply terminal board have been completed, the

protective cover plate should be carefully reinstalled.

GFK-0356P

Chapter 2 Installation

2-23

INPUT

100-240 VAC

50/60HZ 90VA

Input Power

125 VDC, 50W

Input Power

125 VDC, 50W

Factory Jumper

24 VDC Output

24 VDC

OUTPUT

For I/O Modules

0.8A MAX.

24 VDC Output

24 VDC

For I/O Modules

OUTPUT

0.8A MAX.

Six-Terminal Board

Five-Terminal Board

Figure 2-15. Power Supply Terminal Boards

Power Supply Overvoltage Protection Devices

The overvoltage protection devices for this power supply are connected internally to pin 4

on the user terminal board. This pin is normally connected to frame ground (pin 3) with

the supplied jumper strap which is installed at the factory. If overvoltage protection is not

required or is supplied upstream, this feature can be disabled by leaving pin 4 unconnected

by removing the jumper strap. Also, this jumper must be removed and external surge

suppressors installed in installations with a “Floating Neutral” input, please see the

following section “Special Instructions for Floating Neutral (IT) Systems” later in this

chapter.

If you want to Hi-pot test this supply, overvoltage protection must be disabled during the

test by removing the terminal board strap. Re-enable overvoltage protection after

testing by reinstalling the strap.

a47086

Frame Ground

Jumper Strap Connects

Overvoltage Protection

Devices to Frame Ground

Screw Terminals on Terminal Board

Figure 2-16. Overvoltage Protection Devices and Jumper Strap

2-24

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

Special Installation Instructions for Floating Neutral (IT) Systems

When the AC input power supplies listed below are installed in a system where the

Neutral line is not referenced to Protective Earth Ground, these special installation

instructions must be followed to prevent damage to the power supply.

IC693PWR321S (or later version)

IC693PWR330A (or later version)

Definition of Floating Neutral Systems

A Floating Neutral System is a system of power distribution wiring where Neutral and

Protective Earth Ground are not tied together by a negligible impedance. In Europe this is

referred to as an IT system (see IEC950). In a Floating Neutral System, voltages measured

from input terminals to protective earth ground may exceed the 264 Volts AC maximum

input voltage specified in the power supply specifications in Chapter 24in this manual.

Example of Floating Neutral System

This system must be installed using the special installation instructions on the following

page.

Systems in which one leg of the power distribution wiring is tied to Protective Earth or a

tap between two legs of the power distribution wiring is tied to Protective Earth are not

Floating Neutral Systems.

Examples of Non-Floating Neutral System

N/PE

These non-floating neutral systems do not require these special installation instructions.

GFK-0356P

Chapter 2 Installation

2-25

Use These Special Installation Instructions for Floating Neutral Systems

The input power terminals should be wired according to the instructions in the “AC

Power Source Connections” section of this chapter.

The factory installed jumper between terminals 3 and 4 of the Power Supply module

must be removed if using one of the Power Supplies that have this feature. See the

“Overvoltage Protection Devices” section of the “Power Supplies” chapter for details.

Voltage surge protection devices, such as MOVs, MUST be installed between the

following terminals:

From L1 to earth ground

From L2 (Neutral) to earth ground

The voltage surge devices must be rated such that the system is protected from power

line transients that exceed Line voltage + 100V +(N-PE)_MAX.

The expression N-PE refers to the voltage potential between neutral and Protective

Earth (PE) ground.

For example, in a 240 Volt AC system with neutral floating 50V above earth ground, the

transient protection should be rated at:

240V + 100V +50V = 390V

2-26

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

DC Power Source Connections

DC Input Wiring to AC/DC and DC-Only Power Supplies

DC Input power can range from 12 to 30 VDC for the 24 VDC supply, 18 to 56 VDC for

the 24/48 VDC supply or 100 to 150 VDC for the 125 VDC supply. All Series 90-30 power

supplies have DC input capabilities. The following connection information applies to all

of them:

Connect the + and - wires from the power source to the top terminals on the terminal

board (+ to the top terminal, - to the second terminal). Connect the third terminal

from the top to system ground.

+24 VDC Output (All Supplies)

The bottom two terminals are connected to the isolated 24 volt DC output that can be

used to supply power to input circuits (within power limitations of the supply).

Warning

If the same DC input power source is used to provide power to two or

more power supplies in a Series 90-30 PLC System, ensure that

connection polarity is identical at each rack (top terminal + and second

terminal -). Do not cross the Positive (+) and Negative (-) lines. A

resulting difference in potential can injure personnel or cause damage

to equipment. Also, each baseplate must be connected to a common

system ground, described earlier in this chapter.

GFK-0356P

Chapter 2 Installation

2-27

Basic Installation Procedure

The system design, which includes producing the layout and wiring drawings, should be

completed before beginning the installation procedure. This section offers a basic

step-by-step approach to installing a Series 90-30 PLC system. Some steps refer to earlier

sections of this chapter for additional details. An attempt was made to place the steps in

an order that will make the process as efficient as possible. However, due to the wide

variance in system designs, this order may not be the most efficient for your system, so

you may wish modify this procedure to fit your needs.

Gather the schematics, layouts, prints, and other information for the job.

Warning

To avoid the possibility of electrical shock to personnel or damage to

your PLC, we recommend that you shut off all power to the system

before mounting and wiring the PLC. Also, keep all electronic

components away from the area while drilling and tapping to keep

metal chips and filings out of these sensitive components.

From the layout drawing, determine where the baseplate(s) will be mounted. Lay

out the hole locations, either using the dimensions given on your layout drawing or

from the “Baseplates” chapter of this manual.

Mark the hole locations for the baseplate safety ground wire (see “Baseplate Safety

Ground” in this chapter).

Mark the hole locations for module shield ground connections (if any). See “Module

Shield Ground” (and accompanying sections) in this chapter for instructions.

Finish laying (marking hole locations) out the rest of the system. This includes any

terminal blocks you will be using. DIN-rail mounted terminal blocks for some of the

32-point I/O modules are manufactured by Weidmuller. DIN-rail mounted GE

Fanuc Terminal Block Quick Connect (TBQC) assemblies are optional for some of the

16-point and 32-point discrete I/O modules. If using these TBQCs, refer to Appendix

J for data. Also, APM and DSM modules use DIN-rail mounted terminal blocks.

Note

We recommend drilling and tapping all holes before mounting any

components. This will avoid getting chips and filings in the

components.

Drill and tap the marked holes. For baseplate mounting, use 8-32 or 4mm size.

Mount the baseplates. Use good quality 8-32 x 1/2 inch or 4 x 12mm size screws. We

recommend using star lock washers and flat washers under the screw heads (star

lock washer should be located between screw head and flat washer) to ensure a

tight baseplate ground connection, and to keep the screws from loosening. Connect

each baseplate ground wire as shown in the “Baseplate Safety Ground” section of

this chapter.

If you have Expansion or Remote racks, determine the correct rack number for each

one, then set the rack numbers using the Rack Number Selection DIP switch on the

baseplate. Please refer to the “Baseplates” chapter for details on setting these DIP

switches. Rack numbers should be assigned by the system programmer because

they correspond to system configuration settings and program memory addressing.

2-28

Series 90-30 PLC Installation and Hardware Manual - October 1999

GFK-0356P

If you have more than one baseplate (rack), connect the I/O Bus Expansion Cables

between the I/O Bus Expansion Connectors, which are located on the right end of

the baseplates. The cables are connected in a “daisy-chain” arrangement from one

baseplate to the other. This is made possible by the fact that the cables have a dual

connector on one end. Therefore, when the cable is plugged into a baseplate

connector, the second connector on that end of the cable provides a socket for

connecting to the next cable. The data sheet for the I/O Bus Expansion cables

(IC693CBL300 etc.) in the “Cables” chapter has sample wiring figures.

10.

On the last I/O Bus Expansion Connector, plug in an I/O Bus Expansion Terminator,

Catalog Number IC693ACC307 (unless using a cable with built-in terminator

resistors, which would either be GE Fanuc cable IC693CBL302, or your own

custom-built cable).

11.

Install the modules in their correct slots using your system layout drawings. (The

label on the side of each module identifies the module type and catalog number.)

Refer to the section “Installing Modules” if you are not familiar with how to do this.

12.

Connect cables to Option modules. Route cables away from noise-producing wires.

See the ”Wire Routing” section of this chapter.

13.

Be sure to follow the information in the “Wiring Guidelines” section of this chapter

to protect the system from electrical noise. Install the power wires to the Power

Supply and I/O modules:

I/O modules with removeable terminal boards. You can wire the terminal

boards in-place on the modules or remove them from the modules before

wiring. Although removing them may help make wiring easier (a previous

section “Working with Removeable Terminal Boards” shows how to remove a

terminal board), care should be taken to avoid mixing them (each terminal

board has the catalog number of the module printed on it, and the hinged cover

has a wiring diagram for that module type). If you are using wire duct, routing

each module’s wires through the opening in the duct directly under the module

will help to keep each terminal board in its correct position.

I/O Modules with terminal blocks. Some modules use terminal blocks that

mount to the enclosure panel. This includes all 32-point modules and, can

include other I/O modules if they are fitted with the optional Terminal Block

Quick Connect Assembly. Connect the terminal blocks to the connectors on the

modules with the provided cables.

14.

Connect the signal (switches, sensors, solenoids, etc.) wires to the terminal boards, or

terminal blocks/strips. If wiring to terminal boards, these can be removed for ease of

wiring, if desired. See the section “Removing a Module’s Terminal Board.”

15.

When finished wiring the I/O terminal boards (if used and if you removed them for

ease of wiring), re-install them on the modules, being careful to match each one with

the correct module.

GFK-0356P

Chapter 2 Installation

2-29

FANUC Series 90-30 PLC. Installation and Hardware Manual (GFK-0356P) - page 2