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

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

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Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

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-0356Q

Chapter 2 Installation

2-27

Basic Installation Procedure

Note: Series 90-30 PLCs must be mounted in a protective enclosure. The enclosure should be

capable of properly dissipating the heat produced by all of the devices mounted inside it.

For details on calculating heat dissipation, refer to Appendix F.

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 H 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 dual in-line package (DIP) switch on

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Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

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.

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 removable 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

Removable 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-0356Q

Chapter 2 Installation

2-29

Chapter

Baseplates

Baseplate Types

A baseplate is composed of three main parts: (1) a circuit board mounted to (2) a metal back-plate

with (3) a plastic cover. The circuit board, called the “backplane,” contains sockets for plug-in

modules. The metal back-plate has four holes for mounting the baseplate, and retainers for

mounting the modules. The plastic cover provides protection for the circuit board, slotted holes for

the module connectors and retainers, and printed labels such as the baseplate description, serial

number, and slot number labels. There are three basic types of baseplates discussed in this chapter:

■ CPU

■ Expansion

■ Remote

Common Baseplate Features

The following figure shows the features that are common to all Series 90-30 baseplates. Note that

a modular CPU baseplate is shown.

GFK-0356Q

3-1

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

C PU

1 HOUR

POWER

I/O-2

I/O-3

I/O-4

I/O-5

CPU/1

SUPPLY

Module retainers

Upper mounting holes

Baseplate description

Lower mounting holes. The plastic cover is slotted at these two holes to facilitate a ground

connection. See the “Baseplate Safety Grounding” section of the “Installation” chapter for

ground connection details.

Backplane connector for Power Supply

Serial number label (on bottom edge of baseplate)

Backplane connectors for I/O or Option modules (slots 2-4) . Note that the slot labeled CPU/1

is the backplane connector for a CPU module; however, on Embedded CPU, Expansion, and

Remote baseplates, this would be another I/O or Option module slot.

Slot number labels

Compliance label

10.

Catalog number and certification (UL, CE, etc.) label. On an Embedded CPU baseplate, this

label will be located between Slots 4 and 5.

Figure 3-1. Common Baseplate Features

Two Baseplate Sizes

Series 90-30 baseplates come in two sizes: 5-slot and 10-slot. Be aware that the Power Supply slot

is not numbered, and is not considered to be one of the 5 or 10 slots. A 5-slot baseplate has slots

for a Power Supply and five other modules, and a 10-slot baseplate has slots for a Power Supply

and ten other modules.

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GFK-0356Q

Baseplate Terms

Backplane: Refers to the circuit board in the baseplate. It contains the baseplate circuitry and

sockets for plug-in modules.

Rack: This term applies to an assembly consisting of a baseplate, power supply, and other

modules.

Rack Number: In systems that require more than one rack, each rack is given its own unique

number, which enables the CPU to distinguish one rack from another. The CPU rack always has a

rack number of 0 (zero).

Slot Number: Each module location (called a ”slot”) on a baseplate has a unique number (except

for the unnumbered left slot, which is for the Power Supply). The slot to the right of the Power

Supply slot is always called Slot 1. These slot numbers are marked on the baseplate’s plastic

cover. Each slot has a connector for module connections and top and bottom retainers for holding

the module in place.

Module Location: Since each rack is assigned a unique number, and since each slot in a rack’s

baseplate has a unique slot number, each individual module’s location in a system can be identified

by its rack and slot numbers. For example, a module could be referred to as ”the module in Rack 1,

Slot 4.” This numbering method enables the CPU to correctly read from and write to a particular

module, and report the location of a faulted module.

CPU Baseplate: A baseplate that either has a CPU built-in to its backplane circuit board

(embedded CPU) or one that has a slot for a plug-in CPU module (modular CPU). There can only

be one CPU baseplate in a Series 90-30 PLC system and it will always be called Rack 0 (zero). A

CPU module can only mount in Slot 1 of a modular CPU baseplate. A few special Option

modules, such as the FIP Remote I/O Scanner module (IC693BEM330) can also be used in Slot 1

of a modular CPU baseplate. Power Supply, Input/Output (I/O), and most Option modules cannot

fit in a CPU slot.

Expansion Baseplate: One that does not contain a CPU and that can be mounted up to 50 cable-

feet from the CPU baseplate. An Expansion baseplate cannot operate on its own. It must be used

in a system that has a controlling CPU.

Remote Baseplate: One that does not contain a CPU and that can be mounted up to 700 cable-feet

from the CPU baseplate. A remote baseplate cannot operate on its own. It must be used in a

system that has a controlling CPU.

Power Supply Slot: Each baseplate must contain its own Power Supply module, which must

mount in the Power Supply slot. It is the slot located on the left end of the baseplate, it is not

numbered, and it has a unique size and shape so that only a Power Supply module can mount in it.

Caution

Attempts to force a module into an improper slot type will damage the

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

and with a minimum of force.

GFK-0356Q

Chapter 3 Baseplates

3-3

CPU Baseplates

There are two basic kinds of CPU baseplates, embedded and modular. The embedded types fulfill

the need for a good low cost PLC, but lack the power, expandability, and versatility of the modular

systems.

Embedded CPU Baseplate: This type has CPU and memory integrated circuit chips soldered to

its backplane circuit board. All of its numbered slots, including slot 1, are of the same type, and

they accept only I/O modules and standard options modules.

Modular CPU Baseplate: This type does not have CPU and memory chips on its backplane.

Instead, it has a connector in Slot 1 for a plug-in CPU module, which contains the CPU and

memory chips on an internal circuit board. The slot 1 connector is a special type that only mates

with connectors on CPUs and a few special option modules.

Embedded CPU Baseplates (Figures 3-2 and 3-3)

There are three models of embedded baseplates, the 311, 313, and 323. These model numbers are

based upon the CPU type that each contains. This chapter discusses only the baseplate features of

these products. CPU specifications for the embedded CPU are located in Chapter 4. The

embedded CPU baseplates have the following features:

■ The CPU type cannot be changed.

■ They do not support the use of expansion or remote racks, so these racks do not have an

expansion connector like the modular CPU baseplates do.

■ The models 311 and 313 are 5-slot baseplates, and the model 323 is a 10-slot baseplate.

■ Since they do not require a plug-in CPU module, all numbered slots, including Slot 1, can be

used for I/O or Option modules.

■ The memory back-up battery is located in the Power Supply module; so if the Power Supply is

unplugged from the baseplate, the battery will be disconnected from the memory circuits,

which are located on the backplane circuit board. However, the backplane circuit board

contains a high value capacitor, sometimes called a ”super capacitor,” that can store enough

charge to maintain the memory circuits for about 1 hour if the Power Supply is removed or its

battery is disconnected. Chapter 6 discusses the IC693ACC315 Battery Accessory kit that can

be used to maintain memory contents when the Power Supply is removed from an embedded

CPU baseplate.

■ There are no configuration switches or jumpers on the Model 311, 313, or 323 baseplates.

■ An embedded CPU baseplate is always assigned, by default, Rack Number Zero (0).

3-4

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Replaceable System (firmware) PROM

Socket for Optional Program PROM

SYSTEM

PROGRAM

PROM

PROGRAMMABLE

CONTROLLER

Description Label

BASE 5-SLOT

Says "With CPU"

WITH CPU

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

VALUES MAY BE

Memory Backup

LOST IF POWER

Warning Label

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

POWER

I/O-1

I/O-2

I/O-3

I/O-4

I/O-5

SUPPLY

Figure 3-2. Models IC693CPU311 and IC693CPU313 (5-Slot) Embedded CPU Baseplates

SYSTEM

PROGRAM

PROM

PROGRAMMABLE

CONTROLLER

BASE 10-SLOT

WITH CPU

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR.

POWER

I/O-1

I/O-2

I/O-3

I/O-4

I/O-5

I/O-6

I/O-7

I/O-8

I/O-9

I/O-10

SUPPLY

Figure 3-3. Model IC693CPU323 (10-slot) Embedded CPU Baseplate

GFK-0356Q

Chapter 3 Baseplates

3-5

Modular CPU Baseplates (Figures 3-4 and 3-5)

■ A Power Supply module must be plugged into the left slot (which is not numbered) of these

baseplates. The left slot is a unique size and type that only supports a Power Supply module.

■ A CPU module (or a special Option module) must be installed in Slot 1 of these baseplates.

Slot 1 is a unique size and type that only supports a CPU module or a special Option module

like the FIP Remote I/O Scanner (IC693BEM330). Slot 1 is labeled CPU/1.

■ Slots numbered 2 and above are of a unique size and type that only supports I/O or Option

modules.

■ Expansion and Remote baseplates are supported, so a 25-pin D-type female expansion

connector is located at the right end of the baseplate for connecting to an Expansion or Remote

baseplate.

■ Since the CPU is modular, it can be replaced or changed to a different type if additional

features are desired.

■ Only one CPU baseplate is allowed per system. If more than one baseplate is used in a system,

the additional ones must be either Expansion or Remote types.

■ A modular CPU baseplate is always assigned, by default, Rack Number 0.

PROGRAMMABLE

CONTROLLER

BASE 5-SLOT

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

POWER

CPU/1

I/O-2

I/O-3

I/O-4

I/O-5

SUPPLY

Figure 3-4. IC693CHS397 5-Slot Modular CPU Baseplate

PROGRAMMABLE

CONTROLLER

BASE 10-SLOT

CAUTION

NON-CPU SLOTS

USER PROGRAM

AND REGISTER

VALUES MAY BE

LOST IF POWER

SUPPLY IS

REMOVED FOR

LONGER THAN

1 HOUR

POWER

CPU/1

I/O-2

I/O-3

I/O-4

I/O-5

I/O-6

I/O-7

I/O-8

I/O-9

I/O-10

SUPPLY

Figure 3-5. IC693CHS391 10-Slot Modular CPU Baseplate

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Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Expansion Baseplates (Figures 3-6 and 3-7)

■

There can be no more than a total of 50 feet (15 meters) of cable interconnecting Expansion

baseplates and the CPU baseplate.

■

An Expansion baseplate cannot stand alone. It must be connected to a system that has a CPU.

The CPU can be in a PLC or in a Personal Computer that is equipped with a Personal

Computer Interface Card (see Chapter 11).

■

Maximum number of Expansion baseplates allowed per system depends on the type of CPU

they are used with. For CPUs 331, 340, and 341, the maximum is 4. For CPUs numbered 350

and higher, the maximum is 7.

■

Each Expansion baseplate has a 25-pin female D-type I/O Bus Expansion connector mounted

at its right end for connection to other baseplates.

■

Available in two versions; 5-slot (IC693CHS398) and 10-slot (IC693CHS392)

■

An Expansion backplane does not support the following intelligent option modules: PCM,

ADC, BEM330, and CMM311. These modules must be mounted in a CPU baseplate. All

other I/O and option modules can be mounted in any type of rack.

■

All Expansion baseplates must be connected to a common ground (see the “Installation”

chapter for details).

■

Expansion baseplates are the same physical size, use the same type power supplies, and

support the same I/O and option modules as the Remote baseplates.

■

Each Expansion baseplate has a Rack Number Selection DIP switch.

DIP

EXPANSION RACK #

X X X

PROGRAMMABLE

X X

CONTROLLER

X X X

X = CLOSED

BASE 5-SLOT

EXPANSION

NON-CPU SLOTS

POWER

I/O-1

I/O-2

I/O-3

I/O-4

I/O-5

SUPPLY

Figure 3-6. IC693CHS398 5-Slot Expansion Baseplate

GFK-0356Q

Chapter 3 Baseplates

3-7

DIP

EXPANSION RACK #

X X X

PROGRAMMABLE

X X

CONTROLLER

X X X

X = CLOSED

BASE 10-SLOT

EXPANSION

NON-CPU SLOTS

POWER

I/O-1

I/O-2

I/O-3

I/O-4

I/O-5

I/O-6

I/O-7

I/O-8

I/O-9

I/O-10

SUPPLY

Figure 3-7. IC693CHS392 10-Slot Expansion Baseplate

Remote Baseplates (Figures 3-8 and 3-9)

■

There can be no more than 700 feet of cable connecting all baseplates in a system that uses

Remote baseplates.

■

A Remote baseplate cannot stand alone. It must be connected to a system that has a CPU. The

CPU can be in a PLC or in a Personal Computer that is equipped with a Personal Computer

Interface Card (see Chapter 11).

■

Remote capability is facilitated by the Remote baseplate’s built-in isolation between the +5

volt logic supply used by the I/O modules residing in the Remote baseplate and the supply for

the interface circuit associated with the I/O Bus Expansion Interface. Isolation helps prevent

problems associated with unbalanced ground conditions.

■

Maximum number of Remote baseplates allowed per system depends on the type of CPU they

are used with. For CPUs 331, 340, and 341, the maximum is 4. For CPUs numbered 350 and

higher, the maximum is 7.

■

Each remote baseplate has a 25-pin female D-type Expansion connector mounted at its right

end for connection to other baseplates.

■

Remote baseplates are available in two sizes; 5-slot (IC693CHS398) and 10-slot

(IC693CHS392)

■

A Remote backplane does not support the following intelligent option modules: PCM, ADC,

BEM330, and CMM. These modules must be mounted in a CPU baseplate. All other I/O and

option modules can be mounted in any type of baseplate.

■

Remote baseplates are the same physical size, use the same type power supplies, and support

the same I/O and option modules as the Expansion baseplates.

■

Each Remote baseplate has a Rack Number Selection DIP switch.

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Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

DIP

EXPANSION RACK #

PROGRAMMABLE

X X X

X X

CONTROLLER

X X X

X = CLOSED

BASE 5-SLOT

REMOTE

NON-CPU SLOTS

POWER

I/O-1

I/O-2

I/O-3

I/O-4

I/O-5

SUPPLY

Figure 3-8. IC693CHS399 5-Slot Remote Baseplate

DIP

EXPANSION RACK #

PROGRAMMABLE

X X

CONTROLLER

X X X

X = CLOSED

BASE 10-SLOT

REMOTE

NON-CPU SLOTS

POWER

I/O-1

I/O-2

I/O-3

I/O-4

I/O-5

I/O-6

I/O-7

I/O-8

I/O-9

I/O-10

SUPPLY

Figure 3-9. IC693CHS393 10-Slot Remote Baseplate

GFK-0356Q

Chapter 3 Baseplates

3-9

I/O Bus Expansion Cables

Five prewired I/O Bus Expansion cables are available from GE Fanuc. Catalog numbers and

lengths of these cables are listed in the following figure. You can build custom cables to suit the

needs of your application if cable lengths other than those listed are required. Refer to the “Cables”

chapter for detailed information on cable type and connectors. Note that the same cables can be

used with both Expansion and Remote baseplates, however the cables used in a remote expansion

system must use the cable type described in the “Cables” chapter.

FEMALE

CONNECTOR

Figure A

.5, 3, 6, 26 FOOT

CABLES

MALE

CONNECTOR

Figure B

50 FOOT

CABLE

MALE

CONNECTOR

Catalog Number

Length

Figure

IC693CBL300

3 feet (1 meter), continuous shield

IC693CBL301

6 feet (2 meters), continuous shield

IC693CBL302

50 feet (15 meters), continuous shield with

built in terminator (this is not a Wye cable)

IC693CBL312

0.5 feet (.15 meters), continuous shield

IC693CBL313

25 feet (8 meters), continuous shield

Figure 3-10. I/O Bus Expansion Cables

Note

The 3 foot cable (IC693CBL300) can be used as a Wye adapter between custom-

built cables and Remote baseplates.

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GFK-0356Q

Differences Between Remote and Expansion Racks

Basically, Remote racks provide the same functionality as Expansion racks, but with the longer

distance (700 feet/213 meters verses 50 feet/15 meters for Expansion racks) capability. To

minimize unbalanced ground conditions, Remote baseplates have extra isolation circuitry.

Unbalanced ground conditions can occur when systems are located long distances from each other

and do not share the same ground system. However, distance is not always the problem; even

racks that are mounted near each other can experience problems if the system is not grounded

properly. See Chapter 2 for grounding information.

The use of Remote racks requires a special consideration pertaining to scan time. In order to

operate at long distances, the I/O Bus runs at a lower clock speed (compared to that used for

Expansion racks) when communicating with Remote racks, which will have an impact on

performance. The impact will be relatively small for discrete I/O and slightly more for other

modules, such as the High Speed Counter or Genius Communications Module. The increase in

time needed to communicate with modules in a remote baseplate will usually be small with respect

to the overall scan time. For more detailed information on scan time calculations, refer to Chapter

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

Another important scan time consideration is the cable type used for communicating at longer

distances. Data propagation delay must be minimized to ensure proper system timing and margins.

Any deviation in cable type may result in erratic or improper system operation. Suggested cable

types are specified in the “Cables” chapter in the IC693CBL300/etc. data sheet.

Mixing Expansion and Remote Baseplates in a System

Expansion and remote baseplates can be used in the same system as long as certain requirements

are met:

■ You do not exceed the 50 foot (15 meter) maximum cable distance from the CPU to the last

Expansion baseplate

■ You do not exceed the 700 foot (213 meter) maximum cable distance from the CPU to the last

Remote baseplate.

■ The cable type recommended for use with Remote baseplates must be used throughout the

system. The exception to this requirement is that the prewired 3 foot (1 meter) cable,

IC693CBL300, can be used as a Wye adapter to simplify the custom cable assembly associated

with the “daisy chain” connections between baseplates. Information on building cables for use

with Remote baseplates can be found in the “Cables” chapter in the IC693CBL300/etc. data

sheet..

GFK-0356Q

Chapter 3 Baseplates

3-11

Termination Requirement for Expansion or Remote System

When two or more baseplates are connected via the I/O Bus Expansion System, the I/O Expansion

Bus must be properly terminated. The most common method of terminating the I/O Expansion

Bus is by installing a termination resistor pack (IC693ACC307) on the open connector on the last

(most distant from the CPU) Expansion or Remote baseplate in the system. The resistor pack is

physically mounted inside of a connector. Although a termination resistor pack is shipped with

each baseplate, only the last baseplate in the chain needs to have this termination connector

installed. Unused termination packs can be discarded. The prewired 50 foot (15 meter) cable

(IC693CBL302) has termination resistors wired inside the connector on one end of the cable. This

cable can be used if only one expansion rack is needed in a system and a 50 foot cable link is

required (the IC693ACC307 resistor pack is not needed in this case). Also, a custom-built cable

with built-in resistors would eliminate the need for the IC693ACC307 resistor pack.

Powering Down Individual Expansion or Remote Baseplates

Expansion or Remote baseplates can be powered-down individually without affecting the operation

of other baseplates; however, powering off a baseplate generates a loss of module

(LOSS_OF_MODULE) fault in the PLC Fault Table for each module in the baseplate. When this

fault condition occurs, and until the baseplate is powered back on and all modules recovered, the

lost I/O modules are not scanned. For more information on the power-up and power-down

sequence, see Chapter 2 in the Series 90-30 Programmable Controller Reference Manual,

GFK-0467.

Series 90-30 PLC Backplane

The Series 90-30 PLC backplane (on all three types of baseplates) has a dedicated I/O

communications bus. The signals on the remote baseplate backplane are optically coupled and an

isolated DC-DC power supply converter is provided to isolate the signals from other backplanes.

■ Power bus - connects the power supply outputs to the modules in the baseplate.

■ I/O Communications bus - the CPU communicates with I/O modules over this bus. This bus

is connected to the I/O busses in Expansion and Remote racks via the I/O Bus Expansion

connectors and cables.

■ Special Intelligent Module bus - exists only on a CPU baseplate; therefore, certain special

intelligent option modules, such as the Programmable Coprocessor Module (PCM) ,

Alphanumeric Display Coprocessor (ADC), and CMM (Communications Control Module -

IC693CMM311), only work in a CPU baseplate.

3-12

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Rack Number DIP Switch on Expansion and Remote Baseplates

Each baseplate in a Series 90-30 system is identified with a unique number called a “Rack

Number.” Rack Numbers for Expansion and Remote baseplates are selected by setting a DIP

switch located on each baseplate directly above the connector for Slot 1. Rack number 0 must

always be present and is assigned, by default, to the CPU rack (the CPU baseplate does not have

this DIP switch). Racks do not need to be contiguously numbered, although for consistency and

clarity, it is recommended that rack numbers not be skipped (use 1, 2, 3 - not 1, 3, 5). Rack

numbers must not be duplicated within a system. The following table shows the DIP switch

positions for rack number selection.

Table 3-1. Rack Number Selection Switch Settings

Rack Number

DIP Switch

open

closed

open

closed

open

closed

open

closed

open

closed

open

closed

open

* Rack numbers 5, 6, and 7 only valid for CPUs 350 and higher.

The particular CPU module used determines how may expansion and remote baseplates are

allowed:

■ The 331, 340, and 341 CPUs support a total of four Expansion and/or Remote racks.

■ The 350, 351, 352, 360, 363, 364, and 374 CPUs support a total of seven Expansion and/or

Remote racks.

Each baseplate has a label above the DIP switch that shows the settings for each rack number. The

following figure shows this DIP switch package with an example of rack #2 number selected.

Note

Use a ball-point pen to set the DIP switches. In general, it is best to avoid using a

pencil to set DIP switches since graphite from the pencil can damage the switch.

DIP

EXPANSION RACK

GE F anuc

SERIES 90-30

PROGRAMMABLE

CONTROLLER

= CLOSED

BASE 10-SLOT

EXPANSION

= CLOSED (Switch pushed down on right side)

Figure 3-11. Rack Number Selection Switch (Shown with Rack 2 Selected)

GFK-0356Q

Chapter 3 Baseplates

3-13

Expansion Rack Connection Example

The following example shows a system that includes Expansion baseplates.

PROGRAMMER

CPU BASEPLATE

SERIAL

NOTE

TOTAL MAXIMUM

DISTANCE FROM

CPU BASEPLATE

DISCRETE/ANALOG/OPTION

TO LAST EXPANSION

BASEPLATE IS

EXPANSION BASEPLATE

50 FEET (15 METERS)

I/O EXPANSION CABLES

DISCRETE/ANALOG/OPTION

EXPANSION BASEPLATE

DISCRETE/ANALOG/OPTION

EXPANSION BASEPLATE

*NOTE

Each signal pair on the I/O bus must

be terminated at the end of the I/O

bus with120 ohm resistors. This

meination can be done with the I/O

Bus Terminator Plug (IC693ACC307),

by using the 50 foot (15 meter) cable

DISCRETE/ANALOG/OPTION

(IC693CBL302) with built-in terminat

ing resistors, or by building a

EXPANSION BASEPLATE

I/O BUS

cable

with the resistors installed

TERMINATOR

the connector at the end of the

PLUG (See *NOTE)

bus.

IC693ACC307

DISCRETE/ANALOG/OPTION

Figure 3-12. Example of Connecting Expansion Baseplates

3-14

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Expansion and Remote Baseplates Connection Example

The following example shows cable connections in a system that includes both remote and

expansion baseplates. A system can have a combination of remote and expansion baseplates as

long as the distance and cable requirements are followed.

CPU BASEPLATE

CPU

BASEPLATE

IC693CHS391/397

EXPANSION

BASEPLATE

EXPANSION BASEPLATE

IC693CHS392/398

Maximum Cable Distance

from CPU = 50 Feet

(15 meters)

REMOTE BASEPLATE

REMOTE

BASEPLATE

IC693CHS393/399

REMOTE BASEPLATE

REMOTE

BASEPLATE

IC693CHS393/399

REMOTE

BASEPLATE

IC693CHS393/399

REMOTE BASEPLATE

Maximum Cable Distance

from CPU = 700 Feet

(213 meters)

Standard Wye Cable

Custom Built Point-to-Point Cable

IC693CBL300 Standard Wye Cable, Used as Wye Jumper

IC693ACC307 Bus Terminator

Figure 3-13. Example of Connecting Expansion and Remote Baseplates

GFK-0356Q

Chapter 3 Baseplates

3-15

Baseplate Mounting Dimensions

Note: Series 90-30 PLCs must be mounted in a protective enclosure. The enclosure should be

capable of properly dissipating the heat produced by all of the devices mounted inside it.

For details on calculating heat dissipation, refer to Appendix F.

Series 90-30 PLC baseplates are designed to be panel mounted. Each baseplate has standard

attachment flanges for mounting on an electrical panel. Baseplate dimensions and proper spacing

requirements for installation purposes for both the 5 and 10-slot baseplates with embedded CPU

(Models 311 and Model 313 are 5-slot baseplates; Model 323 is a 10-slot baseplate), and the 5 and

10-slot baseplates for Modular CPUs are shown in figures 3-1 through 3-4.

Note

All

5-slot baseplates have the same mounting dimensions and all

10-slot

baseplates have the same mounting dimensions. Baseplates must be mounted in

the orientation as shown in the following figures for proper cooling.

Embedded CPU (311, 313, and 323) Baseplate Dimensions

Baseplate dimensions and spacing requirements for installation for Models 311, 313, and 323

baseplates are shown below.

4.00

10.43

4.00

DIMENSIONS IN INCHES,

MILLIMETERS ARE IN PARENTHESIS

(102)

(265)

(102)

9.84

4.00

(250)

(102)

8.60

REMOVABLE

I/O

5.59

(218)

TERMINAL

(142)

POWER

BLOCK

SUPPLY

.20 DIA.

3.54

(5.08)

5.12

(90)

(TYPICAL)

(130)

.79

FRONT VIEW

HINGED

SIDE VIEW

(20)

DOOR

4.00

(102)

* ALLOWANCE FOR COOLING

Figure 3-14. Model 311 and 313 5-Slot Baseplate Dimensions and Spacing Requirements

3-16

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Modular CPU, Expansion, and Remote Baseplate Dimensions

Baseplate dimensions and spacing requirements for installation for Modular CPU baseplates are

shown below.

DIMENSIONS IN INCHES,

4.00

10.43

4.00

MILLIMETERS ARE IN PARENTHESIS

* (102)

(265)

(102)

9.84

4.00

(250)

(102)

8.60

REMOVABLE

I/O

5.59

(218)

(142)

POWER

TERMINAL

BLOCK

SUPPLY

SEE

NOTE

.20 DIA.

3.54

(90)

(5.08)

5.12

(TYPICAL)

(130)

.79

FRONT VIEW

HINGED

(20)

SIDE VIEW

4.00

DOOR

NOTE:

If the cable is used, allow about 6 inch horizontal clearance

on the right side of the rack for access to the connector.

* (102)

Allowance for cooling

Figure 3-16. Modular CPU, Expansion, and Remote 5-Slot Baseplate Dimensions and Spacing

Requirements

4.00

17.44

4.00

DIMENSIONS IN INCHES,

MILLIMETERS ARE IN PARENTHESIS

(102)

(443)

(102)

16.85

4.00

(428)

(102)

REMOVABLE

15.60

I/O

5.59

(396)

TERMINAL

(142)

BLOCK

POWER

SEE

SUPPLY

NOTE

.20 DIA.

3.54

(5.08)

5.12

(90)

CONNECTOR

(TYPICAL)

(130)

FOR

EXPANSION

CABLE

.79

NOTE:

FRONT VIEW

HINGED

SIDE VIEW

(20)

IF THE CABLE IS USED, ALLOW ABOUT 6 INCH HORIZONTAL CLEARANCE

DOOR

ON THE RIGHT SIDE OF THE RACK FOR ACCESS TO THE CONNECTOR.

4.00

(102)

ALLOWANCE FOR COOLING

Figure 3-17. Modular CPU, Expansion, and Remote 10-Slot Baseplate Dimensions and Spacing

Requirements

3-18

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Baseplate Adapter Brackets for 19" Rack Mounting

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.

Warning

Be sure to follow grounding instructions in Chapter 2 when using these

adapter brackets. Failure to properly ground the PLC can result in

improper operation, damage to equipment, and injury to personnel.

■ 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

(4mm) screws, nuts, lock washers, and flat washers. The Adapter Bracket bolts through its

four slotted holes to the face of the 19" rack using applicable hardware (lock washers

recommended).

RIGHT SIDE OF

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 3-18. IC693ACC308 Front Mount Adapter Bracket Installation

3-20

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Chapter

Power Supplies

Power Supply Categories

Series 90-30 power supplies are modular types that plug into the left slot of all 90-30 baseplates.

They have been placed into two categories for the purpose of this chapter:

AC/DC Input Power Supplies

■ IC693PWR321, Standard 120/240 VAC or 125 VDC input, 30 watts total output

■ IC693PWR330, High Capacity 120/240 VAC or 125 VDC input, 30 watts total output

DC Input-Only Power Supplies

■ IC693PWR322, 24/48 VDC input, 30 watts total output

■ IC693PWR328 48 VDC input, 30 watts total output

■ IC693PWR331, High Capacity 24 VDC input, 30 watts total output

Power Supply Feature Comparison

The following table lists the features of the Series 90-30 PLC Power Supplies.

Table 4-1. Power Supply Comparison

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

IC693PWR328

30 Watts

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.

GFK-0356Q

4-1

AC/DC Input Power Supplies

IC693PWR321 Standard Power Supply, 120/240 VAC or 125 VDC Input

The IC693PWR321 is a 30 watt supply that can operate from an input voltage source in the range

of 85 to 264 VAC or 100 to 300 VDC. This power supply provides three outputs:

■

+5 VDC output,

■

+24 VDC Relay power output which provides power to circuits on Series 90-30 Output Relay

modules.

■ Isolated +24 VDC, which is used internally by some modules, can also be used to provide

external power for 24 VDC Input modules.

The load capacity for each output of this power supply is shown in the following table.

Table 4-2. IC693PWR321 Power Supply Capacities

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

*Total of all outputs combined cannot exceed 30 watts.

PWR

IC693PWR321

GE Fanuc

SYSTEM

STATUS

SERIES 90-30

RUN

INDICATORS

BATT

STANDARD

POWER SUPPLY

PROGRAMMABLE CONTROLLER

INPUT

100-240 VAC

∼

50/60HZ 90 VA

CONNECTIONS

FOR

125 VDC, 50W

AC/DC POWER

SOURCE

INTERNAL

POWER SOURCE

FOR

24 VDC

MODULES REQUIRING

OUTPUT

24VDC

0.8A MAX.

RS-485

COMPATIBLE

SERIAL PORT

BATTERY

CONNECTORS

LITHIUM

BACK-UP

BATTERY

Figure 4-1. Standard AC/DC Input Power Supply - IC693PWR321

Power supplies must be installed in the leftmost slot in all baseplates.

4-2

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

Table 4-3. Specifications for IC693PWR321 Standard AC/DC Input Power Supply

Nominal Rated Voltage

120/240 VAC or 125 VDC

Input Voltage Range

85 to 264 VAC

100 to 300 VDC

Input Power

90 VA with VAC Input

(Maximum with Full Load)

50 W with VDC Input

Inrush Current

4A peak, 250 milliseconds maximum

Output Power

5 VDC and 24 VDC Relay: 15 watts maximum

24 VDC Relay: 15 watts maximum

24 VDC Isolated: 20 watts maximum

NOTE: 30 watts maximum total (all three outputs)

Output Voltage

5 VDC: 5.0 VDC to 5.2 VDC (5.1 VDC nominal)

Relay 24 VDC: 24 to 28 VDC

Isolated 24 VDC: 21.5 VDC to 28 VDC

Protective Limits

Overvoltage:

5 VDC output: 6.4 to 7 V

Overcurrent:

5 VDC output: 4 A maximum

Holdup Time:

20 milliseconds minimum

GFK-0356Q

Chapter 4 Power Supplies

4-3

IC693PWR330 High Capacity Power Supply, 120/240 VAC/125 VDC Input

The IC693PWR330 High Capacity Power Supply is rated for 30 watts output. For applications

requiring greater +5V current capacity than is available with the standard supply

(IC693PWR321), this supply allows all 30 watts to be consumed from the +5V supply. It can

operate from an input voltage source in the range of 85 to 264 VAC or 100 to 300 VDC. This

power supply provides the following outputs:

■

+5 VDC output.

■

+24 VDC Relay power output which provides power to circuits on Series 90-30 Output Relay

modules.

■ Isolated +24 VDC, which is used internally by some modules, can also be used to provide

external power for 24 VDC Input modules.

The load capacity for each output of this power supply is shown in the following table.

Table 4-4. IC693PWR330 Power Supply Capacities

Catalog

Load

Nominal

Number

Capacity

Input

Output Capacities (Voltage/Power *)

IC693PWR330

30 Watts

100 to 240 VAC or

+5 VDC

+24 VDC Isolated

+24 VDC Relay

125 VDC

30 watts

20 watts

15 watts

* Total of all outputs combined cannot exceed 30 watts.

PWR

IC693PWR330

GE Fanuc

SYSTEM

STATUS

Series 90-30

RUN

INDICATORS

BATT

HIGH CAPACITY

POWER SUPPLY

PROGRAMMABL CONTROLLER

INPUT

100-240 VAC

50/60 HZ 100VA

125VDC, 50W

CONNECTIONS FOR

AC/DC POWER SOURCE

INTERNAL POWER SOURCE FOR

24 VDC

MODULES REQUIRING 24VDC

OUTPUT

0.8A MAX.

RS-485

COMPATIBLE

SERIAL PORT

BATTERY

CONNECTORS

LITHIUM

BACK-UP

BATTERY

Figure 4-2. High Capacity AC/DC Input Power Supply - IC693PWR330

4-4

Series 90-30 PLC Installation and Hardware Manual - August 2002

GFK-0356Q

FANUC Series 90-30 PLC. Installation and Hardware Manual (GFK-0356Q) - page 3