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

IC693PRG300 Hand-Held Programmer (HHP)

Some models of the Series 90-30 PLC can be programmed with the GE Fanuc Hand-Held

Programmer (HHP). The HHP uses the Statement List Language. With the HHP, you

can develop, debug, and monitor logic programs, monitor data tables, and configure

PLC and I/O parameters.

Note

The user logic program in Series 90-30 CPU numbers 350 and above

cannot be viewed or edited with the Hand-Held Programmer. You must

use Logicmaster 90-30, Control, or VersaPro programming software with

those CPUs.

The HHP connects to the CPU serial port through a 15-pin D-type connector on the

Series 90-30 PLC power supply in the CPU baseplate. The physical connection is

through a 6-foot (2-meters) long cable (IC693CBL303). This cable also provides power

connections to the HHP, and provides a signal that tells the PLC that an HHP is attached.

The HHP can be connected or disconnected while the PLC is powered-up. The HHP

does not require communications parameter configuration in order to communicate

with a PLC. This makes it useful for troubleshooting a communications problem

between a PC and the PLC.

a43052

GE Fanuc

SERIES 90-30

PROGRAMMABLE

CONTROLLER

HAND HELD PROGRAMMER

OUT

SETM

RSTM

TMR

MODE

OUTM

SET

RST

ONDTR

UPCTR

AND

NOT

BLK

DNCTR

RUN

FUNC

DEL

A I

SRCH

SLOT

WRITE

INS

FOR

MEMORY

READ

CARD

VRFY

HEX

ENT

CLR

DEC

SERIAL PORT CONNECTOR

TO CPU SERIAL PORT

Figure 11-5. Hand-Held Programmer for the Series 90-30 PLC

11-6

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

GFK-0356P

HHP Features

The keypad for the HHP is a sealed type with tactile feedback, and has 42 keys, arranged

in a matrix of six keys across by seven keys down. It has a two-line by 16 character LCD

display screen.

HHP Memory Card (IC693ACC303)

The HHP has a slot for a removable memory card , which provides a means for

non-volatile, off-line program storage and restoration. The memory card can only be

used with CPU numbers 311 through 341. CPU numbers 350 and above do not support

either the HHP or the memory card. The memory card plugs into a connector accessed

through a slot on the lower right side of the HHP (see previous figure).

HHP Modes of Operation

The HHP functionality is basically divided into four modes of operation which are

selected through a key sequence on the keypad. These modes are: program mode,

protection mode, data mode, and configuration mode.

Program Mode:

Allows you to create, change, monitor, and debug Statement List logic. This

mode also allows read, write, and verify functions with the memory card,

EEPROM, or flash memory.

ProtectionMode

Provides a way to control access to (protection of) certain PLC functions,

including program logic, reference data, and configuration information. The

use of this function is optional; however, it is convenient in that it allows you to

protect parts of the PLC system from accidental or deliberate modification.

Protection is provided through four levels of passwords assigned by the user.

DataMode

Allows you to view, and optionally alter values in various reference tables.

Several display formats can be selected in which to view this data: binary,

hexadecimal, signed decimal, and timer/counter.

ConfigurationMode

Allows you to define the types of I/O modules that are installed or will be

installed in the PLC system. You can also assign I/O module addresses to these

modules. This feature is convenient in that it allows you to write and test logic

programs using discrete references assigned to I/O modules that are not yet

installed. In this mode, you can also configure CPU data, such as real-time

clock , coil check, and HHP characteristics, such as keyclick on or off.

Documentation

For detailed information about the Hand-Held Programmer, refer to GFK-0402,

the Series 90-30/20/Micro Hand-Held Programmer User’s Manual.

GFK-0356P

Chapter 11 Programmer Hardware Products

11-7

IC693PIF301/400

Personal Computer Interface (PCIF) Cards

These two Personal Computer Interface cards (PCIF and PCIF2) provide an alternative

method of controlling Series 90-30 I/O. Either card can be used in place of a Series 90-30

PLC CPU. These ISA-compatible cards can be installed in any IBM-PC/AT ISA bus

computer. The cards are implemented using computer language software (for example, C),

or PC control software, such as Total Control Products’ FrameworX Automation Software.

Table 11-1. Personal Computer Interface Card Comparison Table

ITEM

PCIF

PCIF2

Catalog Number

IC693PIF301

IC693PIF400

Amount of I/O controlled

1,280 bytes

25,886 bytes

Number of Series 90-30

Up to four Expansion or

Up to seven Expansion or

racks controlled

Remote racks

Slot requirement

IBM-PC/AT ISA, 8-bit, half

IBM-PC/AT ISA, 16-bit, full

size

Documentation

GFK-0889 (IPI)

GFK-1540 (data sheet)

47016

DOS-BASED

MICROSOFT C/TURBO C

WINDOWS-BASED

SOFTWARE

PROGRAMS

SOFTWARE

C LIBRARY

WINDOWS DLL

DOS TSR ROUTINE

MS-DOS

MS WINDOWS

MS-DOS

I/O EXPANSION CABLE

PCIF or PCIF2

I/O EXPANSION CABLE

SERIES 90-30 I/O

ÎÎÎÎÎÎ

ÎÎÎÎ

ÎÎÎÎÎ

ÎÎÎÎÎÎ

5 OR 10 SLOT

BASEPLATE

Figure 11-6. Example of PCIF Interface to Series 90-30 I/O

Both of these PCIF cards have a 25-pin I/O expansion connector that connects to standard

Series 90-30 Expansion and Remote baseplates (see the “Baseplates” chapter) via I/O

expansion cabling. Remote racks can be located up to 700 feet ( 213 meters) and Expansion

racks up to 50 feet (15 meters) from the personal computer. Several standard prewired I/O

expansion cables are available from GE Fanuc. Alternately, custom length cables can be

built. Please refer to the “Cables” chapter of this manual for information on standard and

custom I/O expansion cables.

11-8

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

GFK-0356P

These cards also provide connections to an internal watchdog-supervised RUN output relay

contact. This contact is closed under normal operating conditions, but opens if the

computer or software application fails, which makes it useful for interfacing with external

safety circuits.

These cards support all Series 90-30 discrete and analog I/O modules (except 16-channel

analog modules). A variety of smart modules from Horner Electric, Inc. are also

supported.

A C Language Interface software product, available from Horner Electric, works with both

Borland Turbo C and Microsoft C. The source code for this interface is available from

Horner Electric (catalog number HE693SRC844).

Documentation

Documentation for these cards is noted in the table above. Additional user ’s

documentation is available from Horner Electric, Inc.

GFK-0356P

Chapter 11 Programmer Hardware Products

11-9

IC655CCM590 Isolated Repeater/Conver ter

This item is no longer available. The information provided in this manual is for the

convenience of those still using this product. This product also went by an earlier

catalog number, IC630CCM390, and is nicknamed, the “Brick.” Details can be found in

Appendix E.

Note

In most applications, the newer IC690ACC903 Port Isolator can be used

in place of the IC655CCM590 Isolated Repeater/Converter.

IC690ACC903 Port Isolator

This product was produced to fill the need created when the IC655CCM590 Isolated

Repeater/Converter became obsolete. It provides 500 volts of isolation between

connected RS-485 ports. It can be used in either single or multi-drop applications, and

has a cable length working distance of 4,000 feet (1,219 meters). It is physically smaller

than the IC655CCM590. For details about this product, please refer to Appendix G.

11-10

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

GFK-0356P

Chapter

System Design

Introduction

This chapter does not pretend to cover every possible aspect of designing a Series 90-30

system, but it does provide you with basic product selection guidelines and with help in

finding the information you need. You will also find the GE Fanuc Automation Solutions

Catalog to be a valuable tool for system design.

Step 1: Planning Your System

Planning is an important part of designing a system. The better you plan the system, the

less trouble you will have installing and implementing it. The following list discusses

some basic things to know or have when planning your system:

Expectations. If a new system, what is it expected to do? If retrofitting an existing

system, what does it do now, and what is it expected to do after it is retrofitted.

Specifications (preferably in writing). These include such things as operating

environment information, speed, accuracy, repeatability, size, conformance to

standards, cost restrictions, time requirements, etc.

Technical documentation. If retrofitting existing equipment, you can refer to its

documentation (layout drawings, schematics, etc.). If the documentation is lost,

perhaps a copy is available from the manufacturer. Additional information may be

gathered from discussions with the equipment operators and maintenance

technicians. For a new design, there are probably mechanical or process drawings of

the equipment.

Step 2: Determining I/O Requirements

This step comes next because other Series 90-30 component choices are dependent on

the number of I/O points required. In particular, the number of modules required, and

their locations, determines what type and how many baseplates are needed and also is a

major factor in CPU selection. Note that there are some restrictions on the maximum

number of certain types of modules (Analog I/O and Option) that can be supported in

one PLC system. See the table “Maximum Number of Modules Per System” for data.

To start, determine how many I/O points, both analog and discrete, are needed for

your system. If retrofitting an existing system, use the schematic diagrams for the

system. If designing a new system, use the mechanical drawings or specifications to

determine what inputs and outputs are needed. List these on a piece of paper (or on

12-1

GFK-0356P

your drawing software screen). Separate them into four type, to correspond to the

four types of modules you will use: Discrete Input, Discrete Output, Analog Input,

Analog Output. If there are any special requirements, such as fast response, etc.,

make a note of them on the page. Also, if parts of your system are physically

separated from other parts, meaning you will probably be using Expansion or

Remote Racks, create a separate list for each location.

When you have finished developing your I/O lists, determine how many I/O

modules of each type you need. Although there is an abbreviated ”I/O Modules”

chapter in this manual, you should refer to publication GFK-0898, Series 90-30 PLC

I/O Module Specifications User’s Manual for complete details. If you are using Remote

Racks, create a separate list for each location.

Additional I/O Module Selection Factors

Voltage/Current Requirements - A wide variety of possible operating voltage and

current requirements can be met with Series 90-30 I/O modules.

Positive or Negative Logic - The applicable type can be selected to match sink or

source signal requirements. See GFK-0898, Series 90-30 PLC I/O Module Specifications

User’s Manual, for details.

Isolation Requirements - Isolated discrete I/O and relay output modules may be

selected to meet isolation requirements.

Hard Contact Requirements - Relay output modules can be applied.

Cost - The selection of certain modules can possibly reduce the number of racks

required in your system. For example, 32-point discrete I/O modules can save rack

space compared to lower density modules.

Standardization - Sometimes a company will standardize on particular types of

modules to simplify training or stocking of spare parts.

Response Time and Noise immunity - I/O modules have different response time

and noise immunity capabilities. These factors should be considered when selecting

I/O modules. In general, higher response speed is usually attained at the sacrifice of

some noise immunity. Therefore, if high response speed is not a requirement, it

would be better to select a slower I/O module that has higher noise immunity.

However, all I/O modules, regardless of their response time rating, have a

reasonable level of noise immunity. Note that the IC693APU305 I/O Processor

Option module, with its 500 us update time, can handle I/O signals that are too fast

for the CPU to handle directly (see GFK-1028, Series 90-30 I/O Processor Module User’s

Manual).

Step 3: Selecting Option Modules

There are several application requirements that determine Option module selection.

However, note that there are some restrictions on the maximum number of certain types

of modules (Analog and Option) that can be supported in one PLC system. See the table

“Maximum Number of Modules Per System” for data.

Interfacing with a Particular Protocol or Standard - CCM, Ethernet, FIP, Genius,

RTU, SNP, etc.

Interfacing with GE Fanuc CNC controls- Use the IC693BEM320 and

IC693BEM321 I/O Link modules.

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

GFK-0356P

Distance - Genius controller modules can communicate at distances up to 7,500

feet (2,286 meters). Serial communications using the RS-485 standard can cover up

to 4,000 feet (1,219 meters). FIP networks are rated for 1,640 feet (500 meters).

Modules with serial ports communicating via modems and telephone lines or

satellite links can cover unlimited distances.

High speed inputs - The IC693APU300 High Speed Counter can be used with

encoders to count high speed pulse trains. The IC693APU305 I/O Processor module

is an intelligent module that can satisfy high speed input and output requirements

independent of the PLC scan.

Motion needs - The IC693APM301/302 and IC693DSM302 (and the future

IC693DSM314) are motion control modules that work with servo motor controllers

and other motion devices. The IC693APU300 High Speed Counter module can count

high speed pulses from encoders for use in measuring motion-related data.

Temperature control - The IC693TCM302 Temperature Control Module (TCM) has

thermocouple inputs and PWM outputs.

Extended features - Where there are two or more Option module choices for a

particular application, often an extended feature requirement determines which one

to choose. For example, there are two Ethernet choices, the IC693CMM321 and the

IC693CPU364, but only the IC693CPU364 has Ethernet Global Data (EGD) capability.

Another example: There are three Genius controller modules, the IC693CMM301

Genius Communications Module (GCM), the IC693CMM302 Enhanced Genius

Communications Module (GCM+), and the IC693BEM331 Genius Bus Controller

module (GBC). While all three are capable of basic Genius communications, only

the Genius Bus Controller module can control Genius Blocks.

Remote or distributed I/O needs - One distributed I/O solution is the use of GE

Fanuc’s Genius Blocks, which can be mounted at the point of use and connected

with a PLC’s Genius Bus Controller (GBC) module via a twisted-pair cable. The

Genius Bus Controller is the only Series 90-30 module that can control Genius

Blocks. Other modules (GCM, GCM+) can read input data broadcast by Genius

Blocks, but cannot send commands to them. By selecting the applicable bus

interface unit (BIU), you can use GE Fanuc Field Control distributed I/O to interface

to Series 90-30 WorldFIP, Profibus, and Genius buses.

State Logic - These products allow “Natural Language programming” as an

alternative to ladder logic. This makes program creation, documenting, and editing

easier for those not trained in ladder logic programming. Industries that are

required by law to thoroughly document any changes to their system find State

Logic to be especially useful.

Cost - Sometimes an Option module choice can be made based on the basis of cost.

This is the case where either of two modules are capable of filling a need. For

example, if you only need the capabilities of the IC693CMM302 Enhanced Genius

Communications Module (GCM), you wouldn’t have to purchase the more capable,

but more expensive, IC693BEM331 Genius Bus Controller module (GBC).

Performance - Higher data transfer rate or amount of data often dictates which

Option module will be used. For example, the IC693CMM302 Enhanced Genius

Communications Module can transmit and receive many times more data than the

IC693CMM301 Genius Communications Module, and it transfers data to the PLC

CPU at a faster rate. A comparison table for these two modules is found in

Appendix A of GFK-0695.

GFK-0356P

Chapter 12 System Design

12-3

Standardization - Sometimes a company will standardize on particular types of

modules to simplify training or stocking of spare parts.

Display requirements - Several options are available for interfacing with GE Fanuc

Human to Machine Interface (HMI) devices.

Third-party solutions - Many automation solutions result from combining GE

Fanuc product with third-party products. There are dozens of third-party modules

and other products that work with GE Fanuc PLC products. Example s of

third-party Series 90-30 modules are Profibus, DeviceNet, SDS, LonWorks,

Interbus-S, RTU/Modbus,ASCII Basic,RTD, and Millivolt/Strain Gauge Input.

Contact your GE Fanuc distributor for further information, or check the GE Fanuc

Web site for third-party product information and links.

Step 4: Selecting a CPU

Once you have determined how many and what type of I/O and Option modules you

require, you can select a CPU. Many of the factors that apply to selecting Option

modules, such as performance, cost, standardization, etc. also apply to selecting a CPU.

Details on CPU capabilities are found in the “CPUs” chapter.

Number of modules required by the system - Embedded CPUs come in 5-slot or

10-slot sizes and they do not support Extension or Remote baseplates. Therefore, if

a system requires only a few modules, these may be an option. If more than 10

modules are required, you must select a Modular CPU. The CPU331-341 CPUs

support up to 5 total baseplates, and the CPU350-364 CPUs support up to 8 total

baseplates. If you need more than 49 total Option and I/O modules, you will need

to use one of the CPU350-364 group of CPUs.

Modules with Quantity Restrictions- Many modules are restricted as to how many

may be used in one system. This number also varies by CPU. For example, in the

case of an 8-channel Analog Output module, the maximum number per system is:

4 if using a 311, 313, or 323 CPU

8 if using a 331, 340,or 341 CPU

79 if using a 360-364 CPU

Please see the section “Maximum Number of Modules Per System” table for data.

Types of Option Modules - The PCM, ADC, CMM, and SLP modules can only work

in a Modular CPU baseplate. Use of these modules would, therefore, rule out the

use of Embedded CPUs (311, 313, 323). See the section “Location of Modules in the

PLC Racks” for more information.

Performance - as shown in the “CPUs” chapter, the CPU350 - 364 CPUs use a more

powerful microprocessor than the lower numbered CPUs. For applications where

higher performance is required, one of these would be a good choice. For

math-intensive applications, the CPU352, with its built-in math coprocessor, would

give the best performance. For Ethernet applications, the CPU364 with its built-in

Ethernet interface, provides faster performance than separate CPU and Ethernet

modules because they have to communicate over the PLC backplane, which is

slower than the CPU364’s internal path. For serial communications, the CPUs 351,

352, and 363 (using Ports 1 and 2) perform faster than an IC693CMM311 module.

Extended features - The IC693CPU364 has a built-in Ethernet interface which

would eliminate the need for a separate Ethernet module. This would save a PLC

12-4

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

GFK-0356P

slot. The CPU351, CPU352, and CPU353 each have two additional built-in serial

ports which eliminate the need for a separate serial communications Option module.

The CPUs 350-364 have extra features and capabilities that the other CPUs do not

have such as, Floating Point Math, Sequential Event Recorder, and Memory Protect

Key Switch. Also, CPUs 351-364 have larger total memory size, as well as

configurable analog and register memory.

Memory requirements - The CPU351-364 CPUs have configurable analog and

modules that require this type of memory and (2) user programs that require larger

amounts of register or analog memory. The CPU360 does not have configurable

memory and has a lower base memory size than the CPU351-364 CPUs. The

CPU360-364 CPUs have standard Flash PROM for user data storage. This is not

available in some of the other CPUs. See the “CPU Firmware and PROM

Configurations” table in the “CPUs” chapter for details.

Expandability and Upgradeability - The Embedded CPUs do not support

Expansion or Remote racks and do not allow changing CPU type. Therefore, they

have limited expandability or upgradeability options. Modular CPUs can be

upgraded to more powerful CPUs. The type of modular CPU determines whether a

system can have a total of 5 or 8 baseplates, which can have a direct bearing on the

future expansion capabilities of a system. For example, if you only need 49 total

Option and I/O Modules, you could use one of the CPU331-341 CPUs. However,

you would be at the maximum module limit and would not be able to add any more

to the system without changing the CPU. If you used, instead, one of the

CPU360-364 CPUs, you could later add up to 30 more modules while keeping the

same CPU. This would simplify expanding the system.

Cost - If some of the other factors such as performance or extended features are

not major issues, one of the lower cost CPUs can be applied. However, sometimes

purchasing a more expensive CPU with extended features can be less costly than

purchasing a lower cost CPU and an additional Option module to cover the feature

needed. Besides the direct cost of the modules, using the single CPU would save a

PLC slot, which could help eliminate the need for, and cost of, an extra Baseplate,

Power Supply, I/O Bus Expansion Cable, etc. Since prices are subject to change, it

would not be practical to give an example of this. Please check with your distributor

for current pricing information.

Display requirements - The CPU351, CPU352, CPU363, and CMM311 have serial

ports that are often used to communicate with Human to Machine Interface (HMI)

or Operator Interface (OI) devices.

Time of day (TOD) clock requirements - The Embedded CPUs do not have one,

the Modular CPUs do.

System size limitation - If you are close to the maximum number of modules

limitation of your system, you can use modules that have dual functions to conserve

rack slots. For example, the CPU364 has CPU and Ethernet communications

capability in one module. The CPUs 351, 352, and 363 have CPU and Serial

Communications capability in one module. There are discrete and analog

combination I/O modules that provide a limited number of both inputs and outputs

in one module. Also, the 32-point discrete I/O modules conserve rack slots

compared with lower density (16-point and less) I/O modules. You may also be able

to use Genius Blocks or Field Control distributed I/O to accommodate the need for

additionalI/O, since these do not require a PLC slot; they communicate with the

GFK-0356P

Chapter 12 System Design

12-5

PLC over a communications bus. Genius Blocks communicate over a Genius Bus,

and Field Control can communicate over Genius, FIP, or Profibus busses.

Protection against unauthorized changes. CPUs 360 - 364 have a keylock switch

that can be locked to protect against unauthorized changes to the PLC. CPUs 311 -

341 do not have a keylock switch. However, all CPUs have the capability of

password protection for the application program.

Step 5: Selecting Baseplates

The requirements determined in the previous steps will largely dictate what baseplates

to select. Please refer to the “Baseplates” chapter for additional details.

Embedded CPU baseplate - If the previous selections dictate the use of an

Embedded CPU, you have three choices. The CPU311 and CPU313 are 5-slot sizes,

and the CPU323 is a 10-slot size. The CPU311 has 6K Bytes of memory and the

CPU313 has 12K Bytes.

Modular CPU Baseplate - If you need a modular CPU, you must use a Modular

CPU baseplate. There can be only one CPU baseplate per system. There are just

two types, 5-slot and 10-slot. If you only need a 5-slot size, you may want to

consider whether the extra slots that a 10-slot size would provide would be

advantageous for possible future expansion. On the other hand, the 5-slot size

requires less space.

Expansion and Remote baseplates - These also come in 5-slot and 10-slot sizes. In

general, it is best to use Expansion baseplates where possible instead of Remote

baseplates because of the better speed performance of the Expansion baseplates.

Where a total cable distance of over 50 feet is required, Remote baseplates must be

used. In cases where you only need a 5-slot size, you may want to consider whether

it would be advantageous to use a 10-slot size in order to have open slots for future

expansion. That factor should be weighed against the fact that the 5-slot size

requires less space and costs less.

Physical size - For locations with size limitations, one or more 5-slot baseplates may

be a good choice. See the “Baseplates” chapter for baseplate dimensions and

clearance requirements.

Number of Modules Required - The number of modules need at each location will

have a bearing on the sizes of racks required. You may choose to use a smaller rack

(5-slot), if possible, to save cost and space. However, as noted below, a larger rack

(10-slot) with unused slots will leave some room for future expansion, if desired.

Expandability - For future expansion, you might wish to leave some unused slots in

certain baseplates.

Step 6: Selecting Power Supplies

The following factors will affect your Power Supply selection decisions. See the “Power

Supplies” chapter for additional details.

Power capacity - All Series 90-30 Power Supplies have three individual outputs:

+5VDC, +24VDC (Relay), and +24VDC (Isolated). Although all of these Power

Supplies are rated at 30 Watts maximum total output, the rating of the +5VDC

output varies from supply to supply, as shown in the following table. For

applications requiring heavy loading of the +5VDC supply, choose one of the “High

Output” power supplies: IC693PWR330 or IC693PWR331.

12-6

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

GFK-0356P

Input voltage - As seen in the next table, nominal input voltage choices are 24VDC,

48VDC, 120VAC, 125VDC, and 240VAC.

Table 12-1. Power Supply Feature Comparison Table

Catalog

Load

Nominal

Number

Capacity

Input

Output Capacities (Voltage/Power

)

IC693PWR321

30 Watts

100 to 240 VAC or

+5 VDC

+24 VDC Isolated

+24 VDC Relay

125 VDC

15 watts

20 watts

15 watts

IC693PWR330

30 Watts

100 to 240 VAC or

+5 VDC

+24 VDC Isolated

+24 VDC Relay

125 VDC

30 watts

20 watts

15 watts

IC693PWR322

30 Watts

24 or 48 VDC

+5 VDC

+24 VDC Isolated

+24 VDC Relay

15 watts

20 watts

15 watts

IC693PWR331

30 Watts

24 VDC

+5 VDC

+24 VDC Isolated

+24 VDC Relay

30 watts

20 watts

15 watts

Total of all outputs combined cannot exceed 30 watts.

Reducing PLC Module Count by Using Other GE Fanuc Products

If system size limitations (more than 79 modules are needed) are a problem in a system

using Remote racks, a possible solution could be the use of GE Fanuc Genius Blocks,

Field Control, or VersaMax products. These distributed I/O devices can be used instead

of Remote racks in remote locations in some cases, and their use would not add to the

Series 90-30 module count.

Genius Blocks

These are intelligent distributed I/O blocks that are panel-mounted at the point of use.

They communicate with a Genius Bus Controller (GBC) module in the PLC via a

shielded, twisted-pair cable. They are not included in the PLC module count, but do

require I/O memory allocation. A single GBC module in a PLC rack can control up to 31

Genius Blocks. Genius Blocks come in discrete and analog I/O, high speed counter, RTD,

and thermocouple interface types. For more information on using Genius Blocks, see

GEK-90486-1, Genius I/O System and Communications User’s Manual, and GEK-90486-2,

Genius I/O Discrete and Analog Blocks User’s Manual.

Field Control

These are intelligent distributed I/O units that mount at the point-of-use on a 35mm x

7.5mm DIN-rail. They can communicate over Genius, FIP, or Profibus buses. They are

not included in the PLC module count, but do require I/O memory allocation. A Field

Control unit consists of a Bus Interface Unit (BIU) that interfaces to the applicable bus,

from one to eight I/O modules, and cabling. I/O modules come in various discrete,

analog, and RTD types. A local logic processor module (MFP) is also available. For

further information on Field Control, see the following:

GFK-0826, Field Control Distributed I/O and Control System I/O Modules User’s Manual

GFK-0825, Field Control Genius Bus Interface Unit User’s Manual

GFK-1175, Field Control FIP Bus Interface Unit User’s Manual

GFK-1291, Field Control Profibus Bus Interface Unit User’s Manual

GFK-0356P

Chapter 12 System Design

12-7

VersaMax

VersaMax I/O modules can be used as distributed I/O, communicating with a Series

90-30 PLC over one of three bus types: Genius, Profibus, or Device Net. This

arrangement would require an Option module for the desired bus type in the Series

90-30 PLC as well as the applicable Network Interface Module in the VersaMax system.

For more information on the VersaMax products, please see GFK-1504, VersaMax Modules,

Power Supplies, and Carriers Manual.

Designing For Safety

A good design should not only function properly and efficiently, but must also protect

personnel and equipment from harm. Although some basic guidelines are found in the

“Installation” chapter of this manual, it is not possible to cover every aspect of safety

because of the diversity of applications. Additionally, it is not practical for this manual to

try to cover all the possible codes and regulations that may apply to your locality or type

of equipment. You have the ultimate responsibility to consult applicable safety codes

for your locality, or that pertain to the particular type of equipment you are designing,

and ensure that your design complies with these standards. In the United States, the

National Electric Code (NEC) has been adopted by many localities. The United States

Occupational Safety and Health Administration (OSHA) regulations also contain many

safety regulations that apply to all industrial equipment in the United States. In the

absence of local regulations, the NEC and OSHA regulations should be followed when

designing your system, in addition to the information contained in this manual. OSHA

regulations can be accessed on-line at www.osha.gov. Some key safety issues are

outlined below:

Protection From Electrical Shock

Proper wiring design, including grounding and circuit protection issues, should be

followed. Personnel should be prevented from accidentally coming in contact with

hazardous voltages. Also, unauthorized personnel should be prevented from gaining

access to high voltage cabinets and panels. Interlock circuits are often used for this

purpose.

Fire Prevention

The guidelines in the NEC and OSHA regulations protect against fires, especially those

caused by faulty electrical design.

Protection From Mechanical Hazards

Personnel should be protected from physical hazards, such as moving mechanisms like

conveyors or index tables or mechanical pinch points. The use of interlocked safety

gates, light curtains, safety mat switches, dual hand buttons, physical barriers (guards),

etc. can be used for this purpose. See the applicable section of the OSHA regulations for

details.

Protection From Electrical Failure

In the event of a system component failure, the design should be an acceptable

“fail-safe” one in which the failure does not cause a safety hazard such as a runaway

12-8

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

GFK-0356P

condition or a disabling of emergency stop circuits. Emergency stop and other safety

circuits should consist of hard-wired components that tend to fail in a harmless manner.

For example, in a Master Control Relay (MCR) circuit, use series-wired, normally closed

Emergency Stop pushbutton switches and interlocks to control an electro-mechanical

Master Control Relay (see next figure). This relay should directly disable motor starters,

PLC output circuits, etc. This type of circuit tends to fail “open,” which disables the

equipment. For example, if a wire breaks or a contact wears out, the circuit opens and

the MCR drops out. If solid state devices fail, they tend to fail “shorted,” which in the

case of PLC output circuits would cause the controlled device to turn on or stay on.

In the circuit below, the MCR is an electro-mechanical relay. It is energized by the

application of power to its solenoid coil which magnetically pulls the contacts to their

energized states. When de-energized, the contacts move to their normal, at rest states

by the pull of a mechanical spring. When the Reset pushbutton is pressed, and if all four

of the E-Stop and Gate switches are closed, the MCR relay will energize and “latch” in

the energized state through its MCR contact in parallel with the Reset pushbutton. Its

other MCR contact applies power to the motor starter and PLC output circuits. If any

one of the E-Stop or Gate switches opens, or if a wire breaks in this circuit, or if the MCR

coil becomes defective, MCR will de-energize and open the circuit to the motor starters

and PLC output circuits.

As shown, the PLC’s main power and input circuits are not controlled by the MCR since

they do not directly control any outputs. Keeping these circuits energized is desirable

because this allows the PLC to continue gathering data, recording fault information, and

controlling communications, even if its Output module outputs are disabled by the

MCR.

If an additional margin of safety were desired, two MCR relays could be used. Their

coils would be wired in parallel, their normally open contacts wired in series, and their

normally closed contacts wired in parallel. This would help guard against the possibility

of a “welded contact” on a single MCR relay.

Master Control

Reset

E-Stop 1

E-Stop 2

Gate 1

Gate 2

Relay (MCR)

MCR

PLC Main Power and

Input Power Circuits

MCR

To Motor Starters, PLC

Output Module Circuits, etc.

Figure 12-1. Hard-Wired MCR Circuit Example

GFK-0356P

Chapter 12 System Design

12-9

Protection From Design Changes or Overrides

Only authorized personnel should be allowed to make changes that could impact the

safe operation of the equipment. Passwords and lockout circuits may be used to

accomplish this. Some Series 90-30 CPUs have keylock switches to protect against

program changes (see “CPUs” chapter for keylock switch details).

Safety Documentation

PLC Program Documentation. Thorough documentation will help you and others

who work on the equipment remember and understand how the safety circuits and

features work. (In some industries, applicable regulations may require this type of

documentation.) The PLC programming software gives you extensive

documentation abilities.

For example, you can create Nicknames such as “PSTOP,” Descriptions such as

“Program Stop Coil,” and Comments such as “This coil is used to stop the program

cycle, but it does not turn off power to the main hydraulic circuit. However, if the

operator opens the safety gate, the Safety Gate Interlock switch will open and shut

off the hydraulic pump.” These Nicknames, Descriptions, and Comments become

part of the PLC program and can be viewed with the applicable software.

As an alternative to ladder logic programming, the State Logic programming

language makes it easier to document PLC program design because it uses “Natural

Language” expressions instead of ladder logic symbols.

Electrical and mechanical prints should contain notations pertaining to safety

issues.

Written operating and maintenance instructions as well as training should be

provided to operators and maintenance personnel. These should address any

applicable safety issues.

Guarding Against Unauthorized Operation

Keylock switches and passwords are frequently used for this purpose.

Labeling, Guarding, and Lighting Issues

Labeling. Operator devices such as pushbuttons, switches, or on-screen (software)

buttons should be clearly labeled as to their function.

Guarding. Operator devices should be guarded, where applicable, to prevent them

from being activated accidentally. Recessed pushbutton designs or pushbuttons

with surrounding guard rings might help prevent the pushbutton from being

depressed if, for example, a tool were dropped or laid upon it. Mounting

pushbutton stations to vertical surfaces also may help avoid this problem.

Lighting. Illumination levels in the working area should be adequate so that all

labels can be clearly seen.

Equipment Accessibility Issues

The equipment should be laid out so as to give operators sufficient room to perform

their tasks safely. Also, sufficient clearance should be provided so that maintenance

personnel have safe access to electrical panels, control boxes, etc. These minimum

clearances are specified in the NEC and OSHA requirements.

12-10

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

GFK-0356P

Number of Modules Per Series 90-30 PLC System

The following table lists the maximum number of each type of I/O and option modules

that can be installed in a Series 90-30 PLC system. The number of modules that can be

installed in a system depends on several factors, including available references for each

CPU model, the current rating for each module to be installed in the system, and other

installed modules. Before installing modules in a baseplate, verify that the total current

rating of all of those modules does not exceed the power rating of the power supply.

Table 12-2. Maximum Number of Modules Per System

CPU

Module Type

Model 311/313/323

Model 331/340/341

Model 350 - 364

Input and Output, Discrete

5 (5-slot baseplate)

(331/340/341)

10 (10-slot baseplate)

Input Module, Analog , 4-Channel

5 (5-slot baseplate)

8 (10-slot baseplate)

Input Module, Analog, 16-Channel

8 (Model 331)

12(Model340/341)

Output Module (Voltage), Analog, 2-Channel

5 (5-slot baseplate)

16 (Model 331)

6 (10-slot baseplate)

30(Model340/341)

Output Module (Current), Analog, 2-Channel

3 (5-slot baseplate)

15 (Model 331)

3 (10-slot baseplate)

15(Model340/341)

Output Module, Analog, 8-Channel

8 (Model 331)

32(Model340/341)

Combination Input/Output Module, Analog

5 (5-slot baseplate)

21 (Mode3 31/40/341)

4-ChIn/2-Ch Out

10 (10-slot baseplate)

Programmable CoprocessorModule

n/a

Alphanumeric Display CoprocessorModule

n/a

Communications Control Module

n/a

State Logic ProcessorModule

n/a

Refer to the State Logic User’s Guide, GFK-0726.

Genius Communications ModulE (1)

Enhanced Genius Communications ModulE (1)

High Speed Counter

4 (5/10-slot baseplate)

8 (Model 331)

32(Model340/341)

I/O Link Interface Module

5(5/10-slotbaseplate)

I/O ProcessorModule

2 (5-slot baseplate)

8 (Model 331)

4 (10-slot baseplate)

16(Model340/341)

Genius Bus Controller (2)

Ethernet Interface Module

Refer to the Series 90-30 TCP/IP Ethernet Communications User’s Manual,

GFK-1084 for details.

Motion Mate APM300 Module

Refer to the Motion Mate APM300 User’s Manuals, GFK-0840 or GFK-0781

for details.

Motion Mate DSM302 Module

Refer to the Motion Mate DSM302 User’s Manual, GFK-1464 , for details.

Motion Mate DSM314 Module

Refer to the Motion Mate DSM314 User’s Manual, GFK-1742 , for details

Temperature Control Module

Refer to the Temperature Control User’s Manual, GFK-1466 for details

Power Transducer Module

Refer to the Power Transducer Module User’s Manual, GFK-1734, for details

(1) The Enhanced Genius Communications Module and the Genius Communications Module cannot be

installed in the same PLC baseplate; however, both modules can be present on the same bus.

(2) Refer to GFK-1034, Series 90-30 Genius Bus Controller User’s Manual fordetails.

GFK-0356P

Chapter 12 System Design

12-11

Calculating Power Supply Loading

The load placed on a power supply in a Series 90-30 PLC baseplate is the sum of the

internal and external loads placed on it by all of the hardware components in the

baseplate (backplane, modules, etc.), as well as external loads connected to the Isolated

+ 24 VDC supply. Use of the Isolated +24 Volt power supply output is optional;

however, this output can be used to drive a limited number of input devices. The

maximum total power output rating of the Power Supplies is 30 watts; however, the

individual +5VDC outputs can be rated for either 15 or 30 Watts, depending on the

Power Supply catalog number. See Table 12-1, “Power Supply Feature Comparison

Table,” for details.

Load Requirements for Hardware Components

The following table shows the DC load required by each module and hardware component.

All ratings are in milliamps (except where noted). Input and Output module current

ratings are with all inputs or outputs on. Three voltages are listed in the table:

+5 VDC provides primary power to operate most internal circuits

+ 24 VDC Relay Power provides power for circuits that drive the relays on Relay

modules

+24 VDC Isolated provides power to operate a number of input circuits (input

modules only), and any external circuits connected to the 24 VDC Output terminals

on the power supply terminal strip.

Note that the figures listed in the following table are maximum (worst case)

requirements , not typical requirements.

12-12

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

GFK-0356P

Table 12-3. Load Requirements (in milliamps)

Catalog

+24 VDC

Number

Description

+5 VDC

Relay Power

Isolated

AD693SLP300

State Logic Processor Module

425

IC693ACC300

Input Simulator, 8/16 Points

120

IC693ACC307

Expansion Bus Termination Plug

IC690ACC900

RS-422/RS-485toRS-232Converter

170

IC690ACC901

RS-422 (SNP) to RS-232, Miniconverter Kit (Version A)

150

(version B, or later )

100

IC693ADC311

Alphanumeric Display Coprocessor Module

400

IC693ALG220

Analog Input, Voltage, 4 Channel

IC693ALG221

Analog Input, Current, 4 Channel

100

IC693ALG222

Analog Input, Voltage, High Density (16 Channel)

112

IC693ALG223

Analog Input, Current, High Density (16 Channel)

120

IC693ALG390

Analog Output, Voltage, 2 Channel

120

IC693ALG391

Analog Output, Current, 2 Channel

215

IC693ALG392

Analog Current/Voltage Output, 8 Channel

110

IC693ALG442

Analog Current/Voltage Combination 4 Ch In/2 Ch Out

129

IC693APU300

High Speed Counter

250

IC693APU301

Motion Mate APM300, 1-Axis

800

IC693APU302

Motion Mate APM300, 2-Axis

800

IC693APU305

I/OProcessor Module

360

IC693BEM320

I/O Link Interface Module (slave)

205

IC693BEM321

I/O Link Interface Master Module (w/o optical adapter)

415

(with Optical Adapter)

615

IC693BEM330

FIP Remote I/O Scanner

609

IC693BEM331

Genius Bus Controller

300

IC693BEM340

FIP Bus Controller

(maximum)

1.2A

(typical)

800

IC693CHS391

10-slot Modular CPU Baseplate

250

IC693CHS392

10-slot Expansion Baseplate

150

IC693CHS393

10-slot Remote Baseplate

460

IC693CHS397

5-slot Modular CPU Baseplate

270

IC693CHS398

5-slot Expansion Baseplate

170

IC693CHS399

5-slot Remote Baseplate

480

IC693CMM301

Genius Communications Module

200

IC693CMM302

Enhanced Genius Communications Module

300

IC693CMM311

Communications Control Module

400

IC693CMM321

Ethernet Interface Module

750

IC693CPU311

Series 90-30 5-Slot Embedded CPU Baseplate

410

IC693CPU313

Series 90-30 5-Slot Embedded CPU Baseplate

430

IC693CPU323

Series 90-30 10-Slot Embedded CPU Baseplate

430

IC693CPU331

CPU (Model 331)

350

IC693CPU340

CPU (Model 340)

490

IC693CPU341

CPU (Model 341)

490

IC693CPU350

CPU (Model 350)

670

IC693CPU351

CPU (Model 351)

890

IC693CPU352

CPU (Model 352)

910

IC693CPU360

CPU (Model 360)

670

IC693CPU363

CPU (Model 363)

890

IC693CPU364

CPU (Model 364)

1.51 A

IC693CSE313

State Logic CPU, 5-slot baseplate

430

IC693CSE323

State Logic CPU, 10-slot baseplate

430

GFK-0356P

Chapter 12 System Design

12-13

Catalog

+24 VDC

Number

Description

+5 VDC

Relay Power

Isolated

IC693CSE340

State Logic CPU Module

490

IC693DSM302/314*

Motion Mate DSM302 or DSM314 Module

1.3A

IC693MAR590

120 VAC Input, relay Output, 8 In/8 Out

IC693MDL230

120 VAC Isolated, 8 Point Input

IC693MDL231

240 VAC Isolated, 8 Point Input

IC693MDL240

120 VAC, 16 Point Input

IC693MDL241

24 VAC/DC Pos/Neg logic, 16 Point

125

IC693MDL310

120 VAC, 0.5A, 12 Point Output

210

IC693MDL330

120/240VAC, 1A, 8 Point Output

160

IC693MDL340

120 VAC, 0.5A, 16 Point Output

315

IC693MDL390

120/240VAC Isolated, 2A, 5 Point Output

110

IC693MDL630

24 VDC Positive Logic, 8 Point Input

2.5

IC693MDL632

125 VDC Pos/Neg Logic, 8 Point Input

IC693MDL633

24 VDC Negative Logic, 8 Point Input

IC693MDL634

24 VDC Pos/Neg Logic, 8 Point Input

125

IC693MDL640

24 VDC Positive Logic, 16 Point Input

120

IC693MDL641

24 VDC Negative Logic, 16 Point Input

120

IC693MDL643

24 VDC Positive Logic, FAST, 16 Point Input

120

IC693MDL644

24 VDC Negative Logic, FAST, 16 Point Input

120

IC693MDL645

24 VDC Pos/Neg Logic, 16 Point Input

125

IC693MDL646

24 VDC Pos/NegLogic,FAST, 16 Point Input

125

IC693MDL652

24 VDC Pos/Neg Logic 32 Point Input

IC693MDL653

24 VDC Pos/NegLogic,FAST, 32 Point Input

IC693MDL654

5/12 VDC (TTL) Pos/Neg Logic, 32 Point

195/440

IC693MDL655

24 VDC Pos/Neg, 32Point Input

195

224

IC693MDL730

12/24VDCPositive Logic, 2A, 8 Point Output

IC693MDL731

12/24 VDC Negative Logic, 2A, 8 Point Output

IC693MDL732

12/24VDCPositive Logic, 0.5A, 8 Point Output

IC693MDL733

12/24 VDC Negative Logic, 0.5A, 8 Point Output

IC693MDL734

125 VDC Pos/Neg Logic, 6 Point Output

IC693MDL740

12/24VDCPositive Logic, 0.5A, 16 Point Output

110

IC693MDL741

12/24 VDC Negative Logic, 0.5A, 16 Point Output

110

IC693MDL742

12/24VDCPos. Logic ESCP, 1A, 16 Point Output

130

IC693MDL750

12/24 VDC Negative Logic, 32 Point Output

IC693MDL751

12/24VDCPositive Logic, 32 Point Output

IC693MDL752

5/24 VDC (TTL) Negative Logic, 0.5A, 32 Point

260

IC693MDL753

12/24VDCPositive Logic, 0.5A, 32 Point Output

260

IC693MDL930

Relay, N.O., 4A Isolated, 8 Point Output

IC693MDL931

Relay, N.C. and Form C, 8A Isolated, 8 Point Out

110

IC693MDL940

Relay, N.O., 2A, 16 Point Output

135

IC693MDR390

24 VDC Input, Relay Output, 8 In/8 Out

IC693PCM300

Programmable Coprocessor Module, 65K

425

IC693PCM301

Programmable Coprocessor Module, 85K

425

IC693PCM311

Programmable Coprocessor Module, 380K

400

IC693PRG300

Hand-Held Programmer

170

IC693PTM100*

Power Transducer Module

400

IC693TCM302

Temperature Control Module

150

Refer to module specifications in GFK-0898, Series 90-30 I/O Module Specifications Manual for more details.

Note that the model 350-364 CPUs do not support the A version (IC690ACC901A) of the Miniconverter.

Note that this is preliminary information. The IC693DSM314 and IC693PTM100 will not be available until late 1999.

12-14

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

GFK-0356P

Power Supply Loading Calculation Examples

Following are examples of calculations for determining the total load placed on a Series

90-30 PLC power supply by the Series 90-30 PLC hardware. All current figures are

expressed in milliamps. Note that although each output is rated at 15 or 20 watts (with the

exception that the +5 VDC output for the High Capacity power supply is rated at 30 watts),

the total combined output can be no more than 30 watts. The power required by external

circuits connected to the 24 VDC OUTPUT terminals on the power supply terminal strip

should be added to the calculation.

Example 1: Series 90-30, Model 323 Embedded CPU (10-slot baseplate)

Component

+5V

+24V Isolated

+24V Relay

IC693CPU323 Embedded CPU

430

Baseplate

IC693PRG300 Hand-Held Pro-

170

grammer

IC693ALG390 Analog Output

120

IC693ALG220 Analog Input

IC693APU300 HS Counter

190

24 VDC Input (16 points)

120

IC693MDL340 Input Module

120

IC693MDL740 Output Module

110

IC693MDL240 Input Module

IC693MDL310 Output Module

210

IC693MDL940 Relay Out. Mod.

135

IC693MDL930 Relay Out. Mod.

Totals (milliamps)

1281

458

205

(Watts)

6.41

10.99

4.92

Total Watts = 22.32

Example 2: Series 90-30, Model 351 Modular CPU (10-slot baseplate)

Component

+5V

+24V Isolated

+24V Relay

IC693CHS391 Modular CPU

250

Baseplate

IC693CPU351 CPU Module

890

IC690ACC901 Miniconverter Kit

100

IC693PCM301 PCM Module

425

IC693ALG390 Analog Output

120

IC693ALG220 Analog Input

IC693APU300 HS Counter

190

IC693MDL340 Input Module

120

IC693MDL740 Output Module

110

IC693MDL240 Input Module

IC693MDL310 Output Module

210

IC693MDL940 Relay Out. Mod.

135

Totals (milliamps)

2336

338

135

(Watts)

11.68

8.11

3.24

Total Watts = 23.03

GFK-0356P

Chapter 12 System Design

12-15

Scan (Sweep) Time Calculation

Scan or Sweep time is the time it takes the PLC CPU to perform all of its tasks one time.

Scan time contribution is the amount of time added to the PLC scan by the software and

hardware components of the system. For systems that may be time-sensitive, this factor

should be made part of the design specification. To help avoid timing issues, the

theoretical scan time should be calculated so that appropriate solutions can be designed

into the system up-front.

Major Design Factors Affecting Scan Time

Size of ladder program

Type of CPU. Some CPUs have faster clock speeds and architecture than others.

Types of instructions used in ladder program

Number of modules

Types of modules. Some modules, such as several of the Option modules, have a

much greater impact than others such as discrete I/O modules.

Location of modules. This refers to the type of rack (CPU, Expansion, or Remote)

that they are installed in.

Connections to other devices such as an HMI, or to other systems via

communications modules or ports.

Cable types. Cable type can have a significant impact on scan time, especially when

connecting Remote racks or communicating over long distances. Propagation time of

data should be minimized to ensure proper system timing and margins. Suggested

cable types for I/O Bus Expansion and communication cables are documented in the

“Cables” chapter. Any deviation in cable types from those recommended may

result in erratic or improper system operation.

Where to Find Scan Time Information

For information on calculating scan time, please refer to the “Sweep Time Calculation”

section of GFK-0467, Series 90-30/20/Micro PLC CPU Instruction Set Reference Manual.

Calculating PLC Heat Dissipation

The amount of heat dissipated by a PLC mounted in an enclosure can be an important

factor in determining the enclosure size needed for the system. This is because the

enclosure must be able to adequately dissipate the heat generated by all of the

components mounted inside so that no components overheat. PLC heat dissipation is

also a factor in determining the need for enclosure cooling options such as fans and air

conditioning. Enclosure manufacturers generally consider enclosure heat dissipation as

a factor in their enclosure selection guidelines. Instructions for calculating Series 90-30

PLC heat dissipation can be found in Appendix H, “Series 90-30 Heat Dissipation.”

12-16

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

GFK-0356P

System Layout Guidelines

Because of the differences from one system to another, it is not practical to try to discuss

every possible layout. Instead, this section offers guidelines and an example to help you

lay out your system.

Benefits of a Good Layout - Safe, Reliable, and Accessible

The layout of your system has a lot to do with how reliably your system will operate,

how easy it will be to install, how well it will look, and how easy and safe it will be to

maintain:

Safety and Maintenance - A good layout helps minimize the chance of electrical

shock to personnel working on the system. It lets maintenance technicians easily

access the unit to make measurements, load software, check indicator lights, remove

and replace modules, etc. It also makes it easier to trace wiring and locate

components while troubleshooting.

Reliability -Proper layout promotes good heat dissipation and helps eliminate

electrical noise from the system. Excess heat and noise are two major causes of

electronic component failure.

Installation Efficiency- A well designed layout allows sufficient room to mount

and wire the unit. This saves time and frustration.

Appearance - A neat and orderly layout gives others a favorable impression of your

system. It lets others know that careful thought went into the design of the system.

PLC Rack Location and Clearance Requirement

The following list provides PLC rack mounting location guidelines. For an example

layout, see the figure “Series 90-30 Example Layout” later in this chapter.

Locate PLC racks away from other components that generate a lot of heat, such as

transformers, power supplies, or power resistors.

Locate PLC racks away from components that generate electrical noise such as

relays and contactors.

Locate PLC racks away from high voltages components and wiring such as circuit

breakers and fusible disconnects, transformers, motor wiring, etc. This not only

reduces electrical noise, but makes it safer for personnel working on the PLC.

Locate PLC racks at a convenient level that allows technicians reasonable access for

maintaining the system.

Route sensitive input wires away from electrically noisy wires such as discrete

output and AC wiring. This can be facilitated by grouping I/O modules to keep

Output modules separated from sensitive Input modules.

The PLC racks each require a 4” clearance space on all four sides (6 inches on the

right end if using I/O Bus Expansion Cables) to ensure adequate ventilation/cooling.

See the “Baseplates” chapter for baseplate size and clearance requirement

information.

GFK-0356P

Chapter 12 System Design

12-17

Location of Modules in the PLC Racks

There are several factors to consider when when laying out your PLC racks.

Location restrictions - Although most modules can be located in any type of

baseplate, a few of the Option modules (PCM, ADC, CMM, SLP) will only work in a

CPU baseplate. The next figure identifies where you can locate the modules in your

system.

Power Supply capacity - Since some modules draw considerably more power than

others, it is possible to overload the power supply by placing many of the modules

requiring higher power in one rack. Therefore, before finalizing your rack layout

you should calculate the power supply loading to ensure that you will not overload

the power supply. See the section “Calculating Power Supply Loading.”

Noise Reduction - Group I/O modules to keep Output modules separated from

sensitive Input modules. This will facilitate keeping noisy wiring separated from

sensitive wiring, as recommended in a previous section.

12-18

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

GFK-0356P

Allowable Module Locations

DISCRETE INPUT/OUTPUT

a43086A

ANALOG INPUT/OUTPUT

ÎÎÎÎÎÎÎ

HIGH SPEED COUNTER

MODEL 311/313

I/O PROCESSOR

ÎÎÎÎÎÎÎ

(5-SLOT)

GENIUS COMMUNICATIONS

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

ÎÎÎÎÎÎÎ

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ÎÎÎÎÎÎÎ

ETHERNET INTERFACE

TEMPERATURE CONTROL

ÎÎÎÎÎ

ÎÎ

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

ÎÎÎÎÎÎÎÎÎÎÎÎ

HIGH SPEED COUNTER

I/O PROCESSOR

MODEL 313

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

GENIUS COMMUNICATIONS

(10-SLOT)

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

ETHERNET INTERFACE

TEMPERATURE CONTROL

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

I/O PROCESSOR

ÎCÎÎÎÎÎ

MODEL 331/340/341

GENIUS COMMUNICATIONS

and 350/351/352/360/

ENHANCED GENIUS COMM.

ÎUÎÎÎÎÎ

363/364 5-Slot CPU

MOTION MATE APM300/DSM302

I/O LINK INTERFACE

PCM / ADC / CMM / SLP

ÎÎÎÎÎÎÎ

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

ÎÎÎÎÎÎÎ

TEMPERATURE CONTROL

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

HIGH SPEED COUNTER

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

MODEL 331/340/341

I/O PROCESSOR

and 350/351/352/360/

GENIUS COMMUNICATIONS

ÎPÎÎÎÎÎÎÎÎÎÎÎ

ENHANCED GENIUS COMM.

363/364 10-Slot CPU

MOTION MATE APM300/DSM302

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ETHERNET INTERFACE

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

TEMPERATURE CONTROL

PCM / ADC / CMM / SLP

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

ÎÎÎÎÎÎÎ

HIGH SPEED COUNTER

I/O PROCESSOR

ÎÎÎÎÎÎÎ

MODEL 331/340/341

GENIUS COMMUNICATIONS

and 350/351/352/360/

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

ÎÎÎÎÎÎÎ

363/364 5-Slot Expansion

I/O LINK INTERFACE

GENIUS BUS CONTROLLER

ÎÎÎÎÎÎÎ

ETHERNET INTERFACE

TEMPERATURE CONTROL

ÎÎÎÎÎÎÎ

DISCRETE INPUT/OUTPUT

ANALOG INPUT/OUTPUT

ÎÎÎÎÎÎÎÎÎÎÎÎ

HIGH SPEED COUNTER

I/O PROCESSOR

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

GENIUS COMMUNICATIONS

MODEL 331/340/341

ENHANCED GENIUS COMM.

MOTION MATE APM300/DSM302

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

and 350/351/352/360/

I/O LINK INTERFACE

363/364 10-Slot Expansion

GENIUS BUS CONTROLLER

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

ETHERNET INTERFACE

TEMPERATURE CONTROL

ÎÎÎÎÎÎÎÎÎÎÎÎÎ

* For location of FIP modules in baseplates, refer to the applicable FIP module user’s manual.

Figure 12-2. Allowable Location of Modules

GFK-0356P

Chapter 12 System Design

12-19

Chapter

Maintenance and Troubleshooting

Troubleshooting Features of Series 90-30 Hardware

Indicator Lights (LEDs) and Terminal Board

The following figure shows how the indicator LEDs correspond to the circuit connection

points on an I/O Module’s terminal board. The terminal board terminals are numbered

from the top, with the top terminal in the left row being number 1 and the top terminal

in the right row being number 2. The numbers alternate between rows with even

numbers on the right and odd numbers on the left, as shown in the circuit diagram on

the back of the hinged cover.

LED A6 corresponds to circuit A6:

A1 2 3 4 5 6 7 8

Fuse Indicator LED

B1 2 3 4 5 6 7 8

ÎÎÎÎÎÎ

OUTPUT

ÎRELAY N.O2 AMPÎ

Î1ÎÎÎÎÎ

Î3ÎA2ÎÎVÎ

Circuit A6 connects

ÎÎÎA3ÎÎÎ

to terminal 8

ÎÎÎÎÎÎ

Î7ÎÎA5ÎÎÎ

Î9ÎÎA7ÎÎÎ

Î10ÎA8ÎÎÎ

Î12ÎÎB1ÎÎÎ

13Î B2 ÎÎV Î

Hinged Cover

15Î B4 ÎÎÎ

Î16ÎÎÎÎÎ

Î18ÎB6ÎÎVÎ

Indicates External

Power Supply

19ÎÎB7ÎÎÎ

ÎÎÎÎÎÎ

44A726782-015

ÎÎFIC693MDL940 Î a43082B

ÎÎÎÎÎÎ

Figure 13-1. Relationship of Indicator Lights to Terminal Board Connections

13-1

GFK-0356P

Module LED Indicators

Input Module LED Indicators

When a discrete input device closes, the corresponding input LED should light to

indicate that the signal reached the module. If the light does not turn ON, a voltage

check can be made on the module’s terminal board or block:

If the correct voltage is present at the terminal, the corresponding input bit can

be checked in the PLC with your programming software. If the software shows

that the input bit is at logic 1, the module’s LED circuit is defective.

If the correct voltage level is not present at the terminal, a check can be made at

the input field device to determine if the device or interconnecting wiring is

defective.

If none of an input module’s inputs are working, it may be that the external (field) input

power supply is defective, is not powered up, or is not connected properly. (As indicated

in the connections diagram in the previous figure, input and output devices are powered

from an external power supply, not from inside the module). Input modules are not

fused, so the Fuse Indicator LED in the previous picture does not apply to them.

Output Module LED Indicators

When a discrete output address (%Q) is turned on in the ladder program, the

corresponding output LED should light to indicate that the signal reached the module.

If the light does not turn ON, the module may be defective or the LED light may

be bad.

If the light turns on but the output device doesn’t operate, a voltage check can

be made on the module’s terminal board or block. If the correct voltage level is

present there, a check could be made of the output device or wiring.

If none of an output module’s outputs are working, it may be that the external (field)

output power supply is defective, is not powered up. or is not connected properly.

(As

indicated in the connection diagram in the previous figure, input and output devices are

powered from an external power supply, not from inside the module). If the output

module is a type that has built-in fuses (some have electronic short circuit protection

instead), the Fuse Indicator LED (labeled “F”), shown in the previous picture, will light if

a fuse blows.

Power Supply LED Indicators

The power supplies have four LED indicators. Their functions are explained in the

“Power Supplies” chapter.

CPU LED Indicators

There are several different LED arrangements on the various CPUs. These are explained

in the “CPUs” chapter.

Option Module LED Indicators

There are numerous LED arrangements on the various option modules. The “Option

Modules” chapter has some information on this subject. It also directs you, for each

module, to further information in the “Documentation” heading for each module. Also,

Appendix I contains a catalog number to documentation cross-reference.

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

GFK-0356P

Troubleshooting Features of Programming Software

Detailed information about the following items are found in GFK-0467, Series

90-30/20/Micro PLC CPU Instruction Set Reference Manual, and GFK-0466, Series

90-30/20/Micro Programming Software User’s Manual.

Ladder Screens

Contacts, connections, and coils displayed on the ladder screens that are ON (passing

power or energized) are displayed in enhance brightness, allowing the tracing of signals

through the program. Addresses that refer to physical input (%I and %AI) and output

signals (%Q and %AQ) can be checked against module status lights, voltages, etc. to

verify that the hardware is working properly.

Configuration Screens

Normally, the following information is obtained from the system documentation.

However, if they are not available, the configuration screens can be used to determine:

If the software configuration matches the actual hardware. Sometimes, while

troubleshooting, a module is installed in an incorrect slot by mistake. This will create

a fault in one of the two fault tables. The correct configuration can be determined

from the Configuration Screens.

The memory addresses that a particular module is using.

Fault Tables

There are two fault tables, the “PLC Fault Table,” and the “I/O Fault Table.” The fault

tables can be viewed using the PLC programming software. These fault tables will not

report such things as a defective limit switch, but will identify system faults such as:

Loss of or Missing Modules, System Configuration Mismatch.

CPU hardware failure, Low Battery

PLC Software Failure, Program Checksum Failure, No User Program, PLC Store

Failures.

System Status References

These discrete references (%S, %SA, %SB, and %SC) can be viewed in the System

Reference (Status) Table, or on-screen if used in the ladder program, for determining the

status of various conditions and faults. For example, the %SC0009 bit turns on if a fault

is logged in either fault table. Another example is that bit %SA0011 will turn on if the

CPU memory backup battery is low. The Series 90-30 PLC CPU Instruction Set Reference

Manual, GFK-0467, includes a “System Status Reference Table.”

Reference Tables

There are two types of reference tables, standard and mixed. These tables show groups

of memory addresses and their status. For discrete addresses, the status of these will be

shown as either logic 1 or logic 0. For analog and register addresses, values will be

displayed. Standard tables display only one type of memory address, such as all of the

%I bits. Mixed reference tables are created by the user, who selects what addresses to

display in the tables. These mixed tables can contain discrete, analog, and register

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Chapter 13 Maintenance and Troubleshooting

13-3

references all in one table. This makes them useful for gathering numerous related

addresses on one screen where they can all be viewed or monitored at the same time.

This saves time compared with searching or scrolling through the ladder logic screens to

find these addresses.

Override feature

This feature must be used with caution to ensure the safety of personnel and

equipment. Normally, the machine should not be cycling, and all conditions should be

such that the output device can be turned on without any harm being done. This

method can be used to check an output circuit from the ladder screen all the way to the

device being controlled. For example, when overriding and toggling a %Q output to an

ON state, the relay, solenoid, or other device being controlled should turn on or pick up.

If it does not, the status light on the output module could be checked, then voltage

checks could be made at the module terminal board, the system terminal strip, the

machinery terminal strip, the solenoid or relay connections, etc. until the source of the

fault is found.

Sequential Event Recorder (SER), DOIO functional instruction

These can be set up to capture the status of specified discrete addresses upon receiving a

trigger signal. They may be used to monitor and capture data about certain portions of

the program, even when unattended. They can be useful for locating the cause of an

intermittent problem. For example, a contact in a string of contacts that maintain power

to a coil may, from time to time, momentarily open and interrupt normal operation.

However, when maintenance personnel attempt to locate the problem, all of these

contacts may test OK. By using the SER or DOIO instruction, the status of all of these

contacts can be captured within milliseconds of the time the fault occurs, and the contact

that opened will show a status of logic 0 at the moment of capture.

Replacing Modules

Modules do not contain configuration switches. The slot in each baseplate (rack) is

configured (using the configuration software) to hold a particular module type (catalog

number). This configuration information is stored in CPU memory. Therefore, when

replacing a module, you do not have to make any hardware settings on the module

itself. You do, however, have to ensure that you install the correct module type in a

particular slot.

Be aware that some “intelligent” modules, such as the CPU, PCM, APM, or DSM302,

may contain application programs that will need to be reloaded after the module is

replaced. For such modules, make sure that up-to-date copies of the application

programs are maintained in case they have to be restored later.

For I/O modules with terminal boards, you do not have to rewire a new terminal board

in order to replace the module. If the old terminal board is not defective, it can be

removed from the old module and reinstalled on the new module without removing

any of the wiring. Procedures for removing and installing modules and terminal boards

are found in Chapter 2.

Series 90-30 Product Repair

The Series 90-30 products are, for the most part, not considered to be field-repairable.

The one major exception are the few modules that have replaceable fuses. The next

section, “Module Fuse List,” identifies these modules and their applicable fuses.

GE Fanuc offers a repair/product warranty service through your local distributor.

Contact you distributor for details.

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

GFK-0356P

FANUC Series 90-30 PLC. Installation and Hardware Manual (GFK-0356P) - page 11